Genesis Standard (GR) Series Table of Contents Commercial Horizontal & Vertical Packaged Water-Source Heat Pumps Installation, Operation & Maintenance Instructions 50Hz 97B0076N01 Revised: 9 August, 2011 Model Nomenclature General Information Unit Physical Data Horizontal Installation Field Conversion of Air Discharge Horizontal Installation Duct System Installation Vertical Installation Piping Installation Water Loop Heat Pump Applications Ground Loop Heat Pump Applications Ground Water Heat Pump Applica
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 This Page Intentionally Left Blank 2 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t P u m p s
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Model Nomenclature 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 GR V 0 2 4 A G C 1 0 C L T S Model Type Standard S = Standard GR = Genesis High Efficiency Supply Air & Motor Option See model nomenclature for specific options Return Air L = Left Return R = Right Return Configuration V = Vertical Upflow H = Horizontal Heat Exchanger & Valve Options See model nomenclature for specific options Unit Size, MBtuh Wa
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 General Information Safety Warnings, cautions, and notices appear throughout this manual. Read these items carefully before attempting any installation, service, or troubleshooting of the equipment. DANGER: Indicates an immediate hazardous situation, which if not avoided will result in death or serious injury. DANGER labels on unit access panels must be observed.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Pre-Installation - Installation, Operation, and Maintenance instructions are provided with each unit. Horizontal equipment is designed for installation above false ceiling or in a ceiling plenum. Other unit configurations are typically installed in a mechanical room. The installation site chosen should include adequate service clearance around the unit.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Unit Physical Data Genesis Standard (GR) Series Model 006 009 Compressor (1 Each) Factory Charge R-407c (kg) 50Hz Only 012 015 019 024 Rotary 0.34 0.37 030 036 042 048 Reciprocating 0.37 0.68 0.88 0.91 1.19 1.36 060 Scroll 1.19 1.59 2.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Horizontal Installation Horizontal Unit Location Units are not designed for outdoor installation. Locate the unit in an INDOOR area that allows enough space for service personnel to perform typical maintenance or repairs without removing unit from the ceiling. Horizontal units are typically installed above a false ceiling or in a ceiling plenum.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 HORIZONTAL INSTALLATION Figure 3: Typical Horizontal Unit Installation Figure 3: Typical Horizontal Unit Installation 3/8" [10mm] threaded rods (by others) Return Air Thermostat Wiring Power Wiring Optional Low Pressure Drop Water Control Valve (can be internally mounted on some models) Stainless steel braid hose with integral "J" swivel Supply Air Optional Balancing Valve Unit Power Insulated supply duct with at least
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Field Conversion of Air Discharge Overview - Horizontal units can be field converted between side (straight) and back (end) discharge using the instructions below. Figure 4: Left Return Side to Back Remove Screws Water Connection End Note: It is not possible to field convert return air between left or right return models due to the necessity of refrigeration copper piping changes.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Horizontal Installation Figure 6: Horizontal Condensate Connection Condensate Piping - Horizontal Units - A condensate drain line must be installed and pitched away for the unit to allow for proper drainage. This connection must meet all local plumbing/building codes. Pitch the unit toward the drain as shown in Figure 2 to improve the condensate drainage. On small units (less than 8.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Duct System Installation Duct System Installation - Proper duct sizing and design is critical to the performance of the unit. The duct system should be designed to allow adequate and even airflow through the unit during operation. Air flow through the unit MUST be at or above the minimum stated airflow for the unit to avoid equipment damage. Duct systems should be designed for quiet operation.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Vertical Installation Vertical Unit Location Units are not designed for outdoor installation. Locate the unit in an INDOOR area that allows enough space for service personnel to perform typical maintenance or repairs without removing unit from the mechanical room/closet. Vertical units are typically installed in a mechanical room or closet.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Sound Attenuation for Vertical Units - Sound attenuation is achieved by enclosing the unit within a small mechanical room or a closet. Additional measures for sound control include the following: 1. Mount the unit so that the return air inlet is 90° to the return air grille. Refer to Figure 9. Install a sound baffle as illustrated to reduce line-of sight sound transmitted through return air grilles. 2.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Piping Installation Installation of Supply and Return Piping Follow these piping guidelines. 1. Install a drain valve at the base of each supply and return riser to facilitate system flushing. 2. Install shut-off / balancing valves and unions at each unit to permit unit removal for servicing. 3. Place strainers at the inlet of each system circulating pump. 4.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Water-Loop Heat Pump Applications Commercial Water Loop Applications Commercial systems typically include a number of units connected to a common piping system. Any unit plumbing maintenance work can introduce air into the piping system; therefore air elimination equipment is a major portion of the mechanical room plumbing.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Ground-Loop Heat Pump Applications � CAUTION! � CAUTION! The following instructions represent industry accepted installation practices for closed loop earth coupled heat pump systems. Instructions are provided to assist the contractor in installing trouble free ground loops. These instructions are recommendations only. State/provincial and local codes MUST be followed and installation MUST conform to ALL applicable codes.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 HORIZONTAL INSTALLATION Figure 13: Typical Ground-Loop Application Figure 3: Typical Horizontal Unit Installation 3/8" [10mm] threaded rods (by others) Return Air Thermostat Wiring Power Wiring Supply Air Optional Low Pressure Drop Water Control Valve (can be internally mounted on some models) Stainless steel braid hose with integral "J" swivel Optional Balancing Valve Unit Power Insulated supply duct with at least
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Ground-Water Heat Pump Applications Expansion Tank and Pump Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. The expansion tank should be sized to provide at least one minute continuous run time of the pump using its drawdown capacity rating to prevent pump short cycling.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Water Quality Standards Table 3: Water Quality Standards Water Quality Parameter HX Material Closed Recirculating Open Loop and Recirculating Well Scaling Potential - Primary Measurement Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below pH/Calcium Hardness Method All - pH < 7.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Electrical - Line Voltage Electrical - Line Voltage - All field installed wiring, including electrical ground, must comply with the National Electrical Code as well as all applicable local codes. Refer to the unit electrical data for fuse sizes. Consult wiring diagram for field connections that must be made by the installing (or electrical) contractor.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Table 4n: Genesis Standard (GR) Series Electrical Data All GR Units Model Voltage Code Refrigerant Voltage Min/ Max Voltage QTY RLA LRA Fan Motor FLA Total Unit FLA Min Circuit Amps Max Fuse GRH 006 V R407C 220240/50/1 197/254 1 2.3 15.0 0.4 2.7 3.2 15 GRH/V 009 V R407C 220240/50/1 197/254 1 2.7 18.8 0.7 3.7 4.5 15 GRH/V 012 V R407C 220240/50/1 197/254 1 3.9 22.2 0.7 4.5 5.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Electrical - Power Wiring � WARNING! � WARNING! Disconnect electrical power source to prevent injury or death from electrical shock. � CAUTION! � CAUTION! Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Electrical - Power & Low Voltage Wiring Figure 19: Low Voltage Field Wiring Figure 17: PSC Motor Speed Selection Connect the blue wire to: H for High speed fan M for Medium speed fan L for Low speed fan Medium is factory setting Fan Motor Electrical - Low Voltage Wiring Thermostat Connections The thermostat should be wired directly Conectar el cable azul a:to the CXM or DXM board.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Electrical - Low Voltage Wiring Figure 21: Accessory Wiring Figure 20: FP1 Limit Setting CXM PCB JW3-FP1 jumper should be clipped for low temperature operation JW3 should never be clipped for equipment or systems without antifreeze Accessory Connections A terminal paralleling the compressor contactor coil has been provided on the CXM/DXM control. Terminal “A” is designed to control accessory devices, such as water valves.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Electrical - Thermostat Wiring Figure 22: AMV Valve Wiring Y1 C 2 3 AVM Taco Valve Y1 Heater Switch C 1 Thermostat Installation The thermostat should be located on an interior wall in a larger room, away from supply duct drafts. DO NOT locate the thermostat in areas subject to sunlight, drafts or on external walls.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Typical Wiring Diagram - Units with CXM Board (Single Phase) 26 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t P u m p s
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Typical Wiring Diagram - Units with DXM Board (Single Phase) c l i m a t e m a s t e r.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Typical Wiring Diagram - Units with CXM Board and LON Controller (Three Phase) 28 C l i m a t e M a s t e r W a t e r- S o u r c e H e a t P u m p s
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 CXM Controls CXM Control - For detailed control information, see CXM or DXM Application, Operation and Maintenance (AOM) manual (part # 97B0003N12 or part #97B0003N13). Field Selectable Inputs - Test mode: Test mode allows the service technician to check the operation of the control in a timely manner.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 DXM Controls DXM Control - For detailed control information, see CXM AOM (part # 97B0003N12), DXM AOM (part #97B0003N13), Lon controller AOM (part #97B0013N01) or MPC AOM (part # 97B0031N01).
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 On = Heat Pump. Off = Heat/Cool. 1.4 - Thermostat type (O/B): DIP 1.4 provides selection of thermostat type for reversing valve activation. Heat pump thermostats with “O” output (reversing valve energized for cooling) or “B” output (reversing valve energized for heating) can be selected with DIP 1.4. On = HP stat with “O” output for cooling. Off = HP stat with “B” output for heating. 1.5 - Dehumidification mode: DIP 1.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Safety Features Safety Features – CXM/DXM Control The safety features below are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions. Anti-short cycle protection: The control features a 5 minute anti-short cycle protection for the compressor. Note: The 5 minute anti-short cycle also occurs at power up.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 CXM and DXM Controls Unit Performance Sentinel-UPS (patent pending): The UPS feature indicates when the heat pump is operating inefficiently.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Unit Starting and Operating Conditions Operating Limits Starting Conditions Environment – Units are designed for indoor installation Starting conditions are based upon the following notes: only.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Piping System Cleaning and Flushing Piping System Cleaning and Flushing - Cleaning and flushing the WLHP piping system is the single most important step to ensure proper start-up and continued efficient operation of the system. Follow the instructions below to properly clean and flush the system: 1. Ensure that electrical power to the unit is disconnected. 2.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Unit Starting and Operating Conditions � CAUTION! � SYSTEM CHECKOUT � System water temperature: Check water temperature for proper range and also verify heating and cooling set points for proper operation. � System pH: Check and adjust water pH if necessary to maintain a level between 6 and 8.5. Proper pH Unit and System Checkout promotes longevity of hoses and fittings (see table 3).
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Unit Start-Up Procedure Unit Start-up Procedure 1. Turn the thermostat fan position to “ON”. Blower should start. 2. Balance air flow at registers. 3. Adjust all valves to their full open positions. Turn on the line power to all heat pumps. 4. Room temperature should be within the minimummaximum ranges of table 9. During start-up checks, loop water temperature entering the heat pump should be between 16°C and 35°C. 5.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Figure 28: Test Mode Pins � WARNING! � Short test pins together to enter Test Mode and speed-up timing and delays for 20 minutes. WARNING! When the disconnect switch is closed, high voltage is present in some areas of the electrical panel. Exercise caution when working with energized equipment.
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Preventive Maintenance Water Coil Maintenance (Direct ground water applications only) If the system is installed in an area with a known high mineral content (125 P.P.M. or greater) in the water, it is best to establish a periodic maintenance schedule with the owner so the coil can be checked regularly. Consult the well water applications section of this manual for a more detailed water coil material selection.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Functional Troubleshooting Fault Main power Problems Htg Clg Possible Cause X HP Fault-Code 2 High pressure Solution X Green Status LED Off Check Line Voltage circuit breaker and disconnect Check for line voltage between L1 and L2 on the contactor Check for 24VAC between R and C on CXM/DXM Check primary/secondary voltage on transformer Check pump operation or valve operation/setting Check water flow adjust to proper flow
THE SMART SOLUTION FOR ENERGY EFFICIENCY Genesis GR Series Revised: 9 August, 2011 Only Compressor Runs X X Thermostat wiring Check G wiring at heat pump. Jumper G and R for fan operation. X X Fan motor relay Jumper G and R for fan operation. Check for Line voltage across BR contacts.
Packaged Unit Refrigeration Schematic C L I M A T E M A S T E R W A T E R - S O U R C E H E A Date: T P U________________________ MPS Customer: _____________________________________ Antifreeze: ________________________ Genesis GR Series RModel#: e v i s e d : 9 A________________________ ugust, 2011 Serial#: ________________ Loop type: _______________ Complaint: ________________________________________________________________________ Functional Troubleshooting - S-I Units HEATING CYCLE ANALYSIS - bar
c l i m a t e m a s t e r. c o m Rev.: 10/09 Please refer to the CM Installation, Operation and Maintenance Manual for operating and maintenance instructions. LC079 *LC079* NOTE: Some countries do not allow limitations on how long an implied warranty lasts, or the limitation or exclusions of consequential or incidental damages, so the foregoing exclusions and limitations may not apply to you.
CLIMATEMASTER WATER-SOURCE HEAT PUMPS Genesis GR Series Revised: 9 August, 2011 Revision History Date Item Description 08/09/11 Unit Maximum Working Water Pressure Updated to Reflect New Safeties 08/13/10 Entire Document Removed I-P Unit Measurements 08/13/10 GC, GS Info Removed 07/01/10 Nomenclature Displays GR Product Only 05/01/10 All First Published ISO 9001:2000 Certified BR I HE AT P U M P S R ST AND 3 ARD 1 6 -1 IS O R AI A TO NE WATER TO IFIED TO ARI A RT S C CE NG
