Premier Installation Manual - WaterFurnace
Premier Installation ManualGeothermal/Water Source Heat Pumps 3/4 thru 6 TonInstallation InformationWater Piping ConnectionsDesuperheater ConnectionsElectricalStartup ProceduresTroubleshootingIM1555 11/06WFIPreventive Maintenance
PREMIER INSTALLATION MANUALModel NomenclatureP 040 TL 3 2 0 C A D S SAVintageA All OthersB P028(Single Phase),P056(All Voltages)FamilyP PremierUnit CapacityMBTUHNon-Standard Option DetailsNon-Standard OptionsS Standard4 FX10*5 FX10 w/Open N2 Com. Card*6 FX10 w/LonWorks Com. Card*7 FX10 w/BacNet Com. Card*Discharge Air ConfigurationT Top Discharge VerticalE End Discharge HorizontalS Side Discharge HorizontalReturn Air ConfigurationL LeftR RightFilter OptionsD 1" Pleated DisposableVoltage0 208-230/60/1 (Commercial)1 208-230/60/1 (Residential)2 265-277/60/13 208-230/60/34 460/60/3Sound KitA NoneB BlanketCoax OptionsC CopperN CupronickelHot Water Option0 None1 Hot Water GenerationWith Factory Installed Pump (Residential)2 Hot Water GenerationWithout Pump (Commercial 022-066, 230 VAC only)Blower Options0 PSC Blower1 ECM Blower2 Oversized ECM Blower Option(040-046 Only)Note: * FX10 available only on units with PSC blowers without desuperheaters.2
PREMIER INSTALLATION MANUALTable of ContentsGeneral Installation Information4-7Closed Loop Ground Source Systems8Open Loop Ground Water Systems9Boiler/Cooling Tower Closed Loop Systems10System Cleaning & Flushing11Desuperheater Connection & Startup12-13Electrical Connections15Electronic Thermostat Installation15Wiring Schematics16-27Fan Performance Data28-29Standard Microprocessor Control Operation30-31DIP Switch Settings32-33FX10 Control Operation34Startup Procedures35Description of Unit Operation36-37Troubleshooting38Preventive Maintenance39Replacement Procedures403
PREMIER INSTALLATION MANUALGeneral Installation InformationWARNING: Before performing service or maintenance operations on a system, turn off mainpower switches to the indoor unit. If applicable, turn off the accessory heater power switch.Electrical shock could cause personal injury.Safety ConsiderationsInstalling and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service heating and air conditioningequipment.Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing filters. Allother operations should be performed by trained service personnel. When working on heating and air conditioning equipment,observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply.Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations and have afire extinguisher available.Moving and StorageMove units in the normal “up” orientation as indicated by the arrows on each carton. Horizontal units may be moved andstored per the information on the carton. Do not stack more than three units in total height. Vertical units may be stored oneupon another to a maximum height of two units. Do not attempt to move units while stacked.When the equipment is received, all items should be carefully checked against the bill of lading to be sure all crates andcartons have been received. Examine units for shipping damage, removing the units from the cartons if necessary. Unitsin question should also be internally inspected. If any damage is noted, the carrier should make the proper notation on thedelivery receipt, acknowledging the damage. Units are to be stored in clean, dry location to prevent damage.Unit LocationLocate the unit in an indoor area that allows for easy removal of the filter and access panels. Location should haveenough space for service personnel to perform maintenance or repair. Provide sufficient room to make water, electricaland duct connection(s). If the unit is located in a confined space, such as a closet, provisions must be made for return airto freely enter the space by means of a louvered door, etc. Any access panel screws that would be difficult to remove afterthe unit is installed should be removed prior to setting the unit. On horizontal units, allow adequate room below the unit fora condensate drain trap and do not locate the unit above supply piping. Care should be taken when units are located inunconditioned spaces to prevent damage from frozen water lines and excessive heat that could damage electricalcomponents.Installing Vertical UnitsVertical units are available in left or right air return configurations. Verticalunits should be mounted level on a vibration absorbing pad slightly larger thanthe base to provide isolation between the unit and the floor. It is not necessary toanchor the unit to the floor (see right). If access to the left side of the unit will belimited after installation, remove the two mounting screws on the left side of thecontrol box before setting the unit (leave the two front mounting screws intact).This will allow the control box to be removed with only the two front mountingscrews for future service.4Figure 1: Vertical Unit MountingVibrationAbsorbingMeshorAirPad
PREMIER INSTALLATION MANUALInstalling Horizontal UnitsHorizontal units are available with side or end discharge and may be field converted from one to the other by replacing the discharge panel with a new panel which must be ordered separately. Horizontal units are normally suspended froma ceiling by four or six 3/8-inch diameter threaded rods. The rods are usually attached to the unit by hanger bracket kitsfurnished with each unit.Lay out the threaded rods per the dimensions in Figure 3. Assemble the hangers to the unit as shown. Securely tightenthe brackets to the unit using the weld nuts located on the underside of the bottom panel. When attaching the hanger rods tothe bracket, a double nut is required since vibration could loosen a single nut. To allow filter access, one bracket on the filterside should be installed 180 from the position shown in theFigure 2: Typical Horizontal Unit Installationfigure below. The unit should bepitched approximately 1/4-inchtowards the drain in both directions to facilitate the removal ofElectric heat3/8”condensate. Use only the boltsassemblyThreaded rods (6)(optional)provided in the kit. The use ofFlexible Ductlonger bolts could damage interCollarnal parts.Some residential applicationsTo ThermostatInsulaterequire the installation of horiTo Linesupply plenumP/T PlugsPowerand use at leastzontal units on an attic floor. Ina 90 elbow toHose Kitsthis case, the unit should be setreduce noisein a full size secondary drain panon top of a vibration absorbingmesh. The secondary drain panprevents possible condensatesDisconnectsoverflow or water leakage damValveBallLineVoltageage to the ceiling. The secondaryHangingdrain pan is usually placed on aBuilding WaterBracketsLoop(included)plywood base isolated from theCAUTION: Do not use rods smaller than 3/8-inch diameter since they may not be strong enough tosupport the unit. The rods must be securely anchored to the ceiling.Figure 3: Hanger Location and Assembly3/8”Threaded Rod(not supplied)EACCompressorSectionVibration IsolatorWasherAir HandlerSectionHex Nuts(not supplied)Bolt andLockwasherBDP010-034, 4 hangers includedP040-066, 6 hangers includedMODELABCDEP010, 01324.842.522.544.0–P01924.851.522.553.0–P022, 028, 03424.861.522.563.0–P040, 627.880.525.582.029.95
PREMIER INSTALLATION MANUALDuct SystemAn air outlet collar is provided on vertical top flow units and all horizontal units to facilitate a duct connection. A flexibleconnector is recommended for discharge and return air duct connections on metal duct systems. Uninsulated duct shouldbe insulated with a minimum of 1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditionedspace is not recommended as the unit’s performance will be adversely affected.If the unit is connected to existing ductwork, check the duct system to ensure that it has the capacity to accommodatethe air required for the unit application. If the duct is too small, as in the replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repaired if necessary.The duct system should be sized to handle the design airflow quietly and efficiently. To maximize sound attenuation ofthe unit blower, the supply and return plenums should include an internal duct liner of fiberglass or constructed of ductboardfor the first 10 feet. On systems employing a sheet metal duct system, canvas connectors should be used between the unitand the ductwork. If air noise or excessive airflow is a problem, the blower speed can be changed (refer to pages 16-17).CAUTION: Be sure to remove the shipping material from the blower discharge beforeconnecting ductwork.Water PipingThe proper water flow must be provided to each unit whenever the unit operates. To assure proper flow, use pressure/temperature ports to determine the flow rate. These ports should be located adjacent to the supply and return water connections on the unit. The proper flow rate cannot be accurately set without measuring the water pressure drop through therefrigerant-to-water heat exchanger.All source water connections on residential units are swivel fittings that accept a 1-inch male pipe thread (MPT). Theswivel connector has a rubber gasket seal similar to a rubber hose gasket, which when mated to the flush end of any 1-inchthreaded pipe provides a leak-free seal without the need for thread sealing tape or compound. Check to ensure that the rubber seal is in the swivel connector prior to attempting any connection. The rubber seals are shipped attached to the waterline. To make the connection to a ground loop system, mate the brass connector (supplied in CK4L and CK3L connector kit)against the rubber gasket in the swivel connector and thread the female locking ring onto the pipe threads, while maintaining the brass connector in the desired direction. Tighten the connectors by hand, then gently snug the fitting with pliers toprovide a leak-proof joint. When connecting to an open loop (ground water) system, thread any 1-inch MPT fitting (SCH80PVC or copper) into the swivel connector and tighten in the same manner as noted above. The open and closed loop pipingsystem should include pressure/temperature taps for serviceability.All source water connections on commercial units are standard female pipe thread.Never use flexible hoses smaller than 1-inch inside diameter on the unit. Limit hose length to 10 feet per connection.Check carefully for water leaks.Freeze ProtectionSet the freeze protection switch SW2-2 on the printed circuit board for applications using a closed loop antifreeze solution to “LOOP”. On applications using an open loop/groundwater system (or closed loop no antifreeze), set this dip switch to“WELL”, the factory default setting. (Refer to the Dip Switch Field Selection table on page 20.)6
PREMIER INSTALLATION MANUALWater QualityIn ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. The heat exchanger coils in ground water systems may, over a period of time,lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualifiedservice mechanic, as special solutions and pumping equipment are required. Desuperheater coils can likewise becomescaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchangermay require occasional flushing.Units with cupronickel heat exchangers are recommended for open loop applications due to the increased resistance tobuild-up and corrosion, along with reduced wear caused by acid cleaning.MaterialCopper90/10 Cupro-NickelpHAcidity/Alkalinity7- 9ScalingCalcium and Magnesium Carbonate(Total Hardness) less than 350 ppm(Total Hardness) less than 350 ppmHydrogen SulfideLess than .5 ppm(rotten egg smell appears at 0.5 PPM)10 - 50 ppmSulfatesLess than 125 ppmLess than 125 ppmChlorineLess than .5 ppmLess than .5 ppmChloridesLess than 20 ppmLess than125 ppmCarbon DioxideLess than 50 ppm10 - 50 ppmAmmoniaLess than 2 ppmLess than 2 ppmAmmonia ChlorideLess than .5 ppmLess than .5 ppmAmmonia NitrateLess than .5 ppmLess than .5 ppmAmmonia HydroxideLess than .5 ppmLess than .5 ppmAmmonia SulfateLess than .5 ppmLess than .5 ppmTotal Dissolved Solids (TDS)Less than 1000 ppm1000-1500 ppmNoneNoneCorrosion5-92Iron, Fe (Ferrous)Bacterial Iron PotentialIron Fouling(Biological Growth)ErosionIron OxideLess than 1 ppm. Above this leveldeposition will occur.Less than 1 ppm. Above this leveldeposition will occur.Suspended SolidsLess than 10 ppm and filtered for maxof 600 micron sizeLess than 10 ppm and filtered for maxof 600 micron sizeThreshold Velocity (Fresh Water)5-8 ft/sec8-12 ft/secNote: Grains PPM divided by 17 mg/l is equivalent to PPMCondensate DrainOn vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the drain pan, a3/4-inch PVC female adapter and a flexible connecting hose. The female adapter may exit either the front or the side of thecabinet. The adapter should be glued to the field-installed PVC condensate piping. On vertical units, a condensate hose isinside all cabinets as a trapping loop; therefore, an external trap is not necessary.On horizontal units, a copper stub is provided for condensate drain piping connection. An external trap is required (seeFigures 4 and 5 below). If a vent is necessary, an open stand pipe may be applied to a tee in the field-installed condensatepiping.Figure 4: Horizontal Drain ConnectionFigure 5: Unit Pitch for DrainClear PVC hoseVent (if needed)3/4" barb toglue adapter1/4'' Pitch3/4" PVCCopper tube stub1/8" per footPlastic Hose Clamps(Included with unit)1.5"1.5"Drain7
PREMIER INSTALLATION MANUALClosed Loop Ground Source SystemsNote: For closed loop systems with antifreeze protection, set SW2-2 to the “loop” position (see table on page 32).Once piping is completed between the unit, flow center and the ground loop (see figure below), final purging and charging of the loop is required. A flush cart (or a 1.5 HP pump minimum) is needed to achieve adequate flow velocity in the loopto purge air and dirt particles from the loop itself. Antifreeze solution is used in most areas to prevent freezing. Flush thesystem adequately to remove as much air as possible then pressurize the loop to a static pressure of 40-50 PSI (summer)or 50-75 PSI (winter). This is normally adequate for good system operation. Loop static pressure will fluctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This fluctuation is normal and should beconsidered when initially charging the system.After pressurization, be sure to remove the plug in the end of the loop pump motor(s), if applicable, to allow trapped air tobe discharged and to ensure that the motor housing has been flooded. Ensure that the loop flow center provides adequateflow through the unit by checking the pressure drop across the heat exchanger and comparing it to the unit capacity datain the specification catalog. Usually 2.5 to 3 GPM of flow per ton of cooling capacity is recommended in earth loop applications. (See wiring diagram attached to the inside of the unit for pump wiring details.)Figure 6: Closed Loop, Ground Source Application - Single unit with Flow CenterAuxiliary HeatSupplyTOLOOPGeoLink Polyethylene w/Armaflex InsulationUnit SupplyFlexible DuctCollarink GeoLloF wrCenteAuxiliaryHeaterKnockoutUnit PowerDesuperheaterConnectionsDisconnects(If Applicable)DrainExternalPump PowerLowVoltage toThermostatGroundLoop ConnectorKits withArmaflex (CK4S or CK4L)P/T PlugsVibration Absorbing PadMultiple Units on One Flow CenterWhen two units are connected to one loop pumping system, pump control is automatically achieved byconnecting the SL terminals on connector P2 in bothunits with 2-wire thermostat wire. These terminals arepolarity dependant. The loop pump(s) may be poweredfrom either unit, whichever is more convenient. If eitherunit calls, the loop pump(s) will automatically start. Theuse of two units on one flow center is generally limited toa total of 20 GPM capacity.Figure 7: Primary/Secondary Hook-upPremier to PremierMicroprocessor UnitsPremier Unit #1Premier Unit #1ShutDownCCPremier toElectromechanical UnitSL1 SL1 SL2 SL2In Out In OutShutDownCCSL1 SL1 SL2 SL2In Out In OutWith pumpwired to Unit 1With pumpwired toUnit 2ShutDownCCSL1 SL1 SL2 SL2In Out In OutPremier Unit #28CSTo Electromechanical Unit
PREMIER INSTALLATION MANUALOpen Loop Ground Water SystemsAlways maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to preventmineral precipitation. Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. Ensureproper water flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures inCapacity Tables in the Specification Catalog. Normally, about 2 GPM flow rate per ton of cooling capacity (1.5 GPM per tonminimum at 50 F) is needed in open loop systems.Note: For open loop/ground water systems or systems that do not contain an antifreeze solution, set SW2-Switch #2 to the“WELL” position.Figure 8: Open System - Groundwater ApplicationUnit SupplyAux. Heat SupplyFlexibleDuct CollarRubber BladderExpansion sFlow ControlValve(on outlet ofSolenoid Valve)SolenoidValveWater OutWater InDrainShut Off ValvesDisconnects(If Applicable)Shut Off Valves(to isolate solenoidvalve while acid flushing)StrainerCompressorLine VoltageLow VoltageP/T Plugsto ThermostatVibrationand ValveAbsorbing PadDischarge water from the unit is not contaminated in anymanner and can be disposed of in various ways, depending onlocal building codes (e.g. recharge well, storm sewer, drain field,adjacent stream or pond, etc.). Most local codes forbid usingthe sanitary sewer for disposal. Consult your local building andzoning department to assure compliance in your area.The water control solenoid is wired between the common pin#2 connector P1 and pin #3 connector P3, and a jumper wire isconnected between R and pin #1 connector P3 (refer to Figure9). Notice that DIP switch 2-3, located on the PCB, must beswitched to the “Comp” position so the valve will operate with thecompressor.Boiler DrainsFor HX FlushingFigure 9: Typical single-stage external 24V watersolenoid valves (type PPV100 or BPV100) wiringP1SolenoidValveC2R1ACC Com1ACC NC2ACC NO3Note: Switch SW2 - 3 to comp position.9
PREMIER INSTALLATION MANUALBoiler/Cooling Tower Closed Loop SystemsBoiler/Cooling TowerThe water loop is usually maintained between 60 F and 90 F. Premier units allow 25 F to 110 F EWT for proper heating and cooling operation.To reject excess heat from the water loop, the use of a closed circuit evaporative cooler or an open type cooling towerwith a secondary heat exchanger between the tower and the water loop is recommended. If an open type cooling tower isused without a secondary heat, continuous chemical treatment and filtering of the water must be performed to ensure thewater is free from damaging materials.Water Piping ConnectionsUnits should not be connected to the supply and return piping until the water system has been cleaned and flushedcompletely. Supply and return water connections are standard female pipe thread on commercial units (1-inch swivel onresidential units). Never use flexible hoses with an inside pipe diameter that is smaller than the water connections on theunit and limit the hose length to 10 feet or less per conne
Set the freeze protection switch SW2-2 on the printed circuit board for applications using a closed loop antifreeze solu-tion to “LOOP”. On applications using an open loop/groundwater system (or closed loop no antifreeze), set this dip switch to “WELL”, the factory default setting. (Refer to the Dip Switch Field Selection table on page 20.)
WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy of continual product research and development and reserves the right to change design and specifications without notice. 2014 WaterFurnace International Inc
Premier products are performance-certified to ARI ISO 13256-1 standards, are ETL listed, and are ENERGYSTAR qualified. As a leader in the industry, WaterFurnace is dedicated to innovation, quality and customer satisfaction.
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premier manufacturing company Page 6 1-800-255-5387 www.premier-mfg.com Model 370 Coupling INSTALLATION The 370 Coupling is only to be used and maintained with Premier parts listed in the Replacement Part Information section. Any substitution or use of non-Premier parts in a 370 Coupling will VOID ALL PRODUCT WARRANTY.
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