WARMFLO II ® Dual Heat System Furnace Interface Controller and Control Voltage Installation and Operations Application – Heat Pump Multi-Wire Thermostat Basic or Single Speed Heat Pump WF-LGR4 As in previous interface modules, this is the plug-in controller for Electro-Mate EM-WU***** or EMWD***** plenum heater. Mechanical installation information is contained within companion installation manual EI703 or EI707. Also accompanying each system is a specific control program “chip”.
TABLE OF CONTENTS PAGE INTRODUCTION 1 INSTALLATION REQUIREMENTS 1 MECHANICAL INSTALLATION WF Furnace Interface EM-WU***** Upflow Application EM-WU*****/EM-WD***** Horizontal Application EM-WD***** Downflow Application 2 2 2 2 3 WIRING INSTALLATION High Voltage Low Voltage Outdoor Sensor (OT) Supply Sensor (ST) 4 4 4 4 4 WF-LGR4 & WF II Wiring & Setup Chip Code: HPDH HPDF HPEL 6 8 9 10 OPERATION INDICATORS Furnace Interface Module WarmFlo II Controller 12 12 12 HANDHELD ANALYZER/LAPTOP SOFTWARE
INTRODUCTION Prior to installation we recommend that the installer verify the product intended application is applicable to your current installation needs. The system application for this model combination is dual heat, gas or oil furnace as standby, outdoor heat pump unit, and the heat pump manufacturer’s room thermostat. If your application does not include dual heat with standby furnace, but electric heat with an air handler, do not use this WarmFlo II series or this installation manual.
MECHANICAL INSTALLATION WF Furnace Interface, WF-LGR4 The mounting location from this enclosure is flexible to any convenient location were the thermostat connection is easily accessible. The distance between this controller and WF II is limited only by the provided 4’ cable. The housing has also been arranged for easy attachment directly to the right side of the Electro-Mate cabinet.
EM-WD***** Electro-Mate Downflow Application Electro-Mate nameplate or companion installation manual EI707 is required for correct mechanical installation. If you do not have manual #EI707 do not attempt to do the mechanical installation, contact the factory for a replacement manual. The primary installation concerns focusing on the existing furnace and ducting system’s airflow capacity and necessary plenum baffling required by the specific ElectroMate for correct installation.
WIRING INSTALLATION High Voltage Please reference manual EI707 pages 2 and 3. Low Voltage WarmFlo II Sensors Located within each WarmFlo control are two sensing probes, OT (outdoor sensing) and ST (supply sensing) necessary for proper operation and installation of the WarmFlo systems. Without proper installation of these probes the WarmFlo system will not operate correctly. Note : With WF-EMA chip the outdoor sensor(OT) is not required. Installation is optional.
OT & ST Sensor Reconnection 1. A plug-in terminal block is provided for wiring convenience. 2. Both red wires are terminated in the same single screw (+), and both white or green wires are terminated in the single common screw (COM). Each appropriate black wire is terminated in the appropriate OT and ST screw.
WF-LGR4 & WF II WIRING & SETUP WF-LGR4 Application – Standard heat pump room thermostat, heat pump, WF II Electro-Mate, gas/oil furnace. HP manufacturer’s fossil fuel kit is not required. Reference Drawing HH340 1. The provided 10-wire cable includes all connections and functions between WF-LGR4 and the WF II main board within the Electro-Mate unit. a. The 10-pin connector on the main WarmFlo II board originated manufacturing date 0804-04 (ARL 3074).
Caution – 24 volts common grounding – the installer must determine whether the furnace fan center COM screw terminal has a good ground bond (not simply furnace skin). If the fan center COM is not adequately grounded, use the pigtail green wire (WarmFlo board, upper, C tab) for a ground bond to the Electro-Mate cabinet power source ground lug. The upper right circuit board mounting screw is a static ground protection point.
Important - Located on the WF II board is a firmware chip that determines a specific set of defaults (see table below). However, this can be programmed (altered) with optional PC software (ET-SOFT-WF) or a plug-in WarmFlo analyzer (WF-ANZ*). As part of the WF II system this chip represents critical defaults and settings that make your system operate correctly. It is a critical portion of the installation to verify that the chip code sent with your WF II is correct for your intended application.
Temperature (Efficiency Dial) – Located on the front cover of the WF II Electro-Mate, the red center screwdriver adjustment dial has a selection of A through G. These A through G selections represent a supply temperature point at 0° outdoor. The closer the user or installer selection is to A, the flatter the heat loss curve or the higher the operating efficiency. The closer a selected setting is to G, the steeper the heat loss curve or the lower overall heat pump system efficiency.
Temperature (Efficiency Dial) – Located on the front cover of the WF II Electro-Mate, the red center screwdriver adjustment dial has a selection of A through G. These A through G selections represent a supply temperature point at 0° outdoor. The closer the user or installer selection is to A, the flatter the heat loss curve or the higher the operating efficiency. The closer a selected setting is to G, the steeper the heat loss curve or the lower overall heat pump system efficiency.
heat loss curve or the higher the operating efficiency. The closer a selected setting is to G, the steeper the heat loss curve or the lower overall heat pump system efficiency. If knob is turned to “full” the WF II will automatically go to “DT flat”. WF-LGR4 adjustments and settings – The normal/standby switch provides the standard user override function (some power companies request inactivation or deletion of this switch).
OPERATION INDICATORS WF-LGR4 Front Monitor LED’s • Utility, off-peak – utility load management receiver is not interrupting. • HP call – the output “Y” screw terminal is active at 24 volts high. The outdoor unit should be on and running. This LED will be off when the OT sensor is below the setup ODT value. • T-stat call – the room thermostat Y or E is active or 24 volts high. • Cool mode – follows the reversing valve wire, top center pin jumper selects the high logic.
Inside Warmflo Board, Red LED’s - The four red LED’s next to the output connector, indicate Stage 1, 2, 3, and 4 operation (Stage 1 is on the bottom). EM-WU*****/EM-WD***** Inside Relay Board Monitor Light COMMENT: This relay board relates to standard Electro-Mate, if this WF-LGR4 is connected to the new Electro-Mate with a WF+ board, the internal relays and relay driver board are totally different. The following does not apply, see description within the Electro-Mate manual itself.
STAT OVERRIDE TIMER (SOT) This is a field option internal timer which can be field programmed with WF analyzer to select a roomstat cycle run time. If this downloaded run time (typically 90 minutes) is exceeded before the thermostat is satisfied, the system automatically switches to either full electric elements or standby. - SOT S – this is the longer set timer which allows transfer to standby if something might have happened to the electric system unmonitored.
SPECIAL APPLICATION/INSTALLATION For Various Heat Pump, Multi-Speed, Multi-Stage Furnaces, Blower Options, Oil Furnace, etc. Typical Oil Furnace Comment This controller is designed to interface directly with a furnace fan center containing 24-volt transformer (40VA or larger), blower relay, and a “W” function to operate the fossil fuel furnace.
OPTIONAL ACCESSORIES Standby Override – The front switch provides a very effective override switch to fossil fuel furnace capability. This is a hardware override switch and does not depend upon the WarmFlo board, microprocessor, electronics, etc. Typically this takes the place of dual fuel heat pump thermostat “emergency lever” function. Remotely located standby override switch – on the left side of the I/F board is a “SB” tab.
2. The terminal blocks for control wire hook-up are designed for a wire insertion and screw clamp down. If there is no wire connected and the screw is loose, the screw may not necessarily make a good electrical contact to the inside components. Example – if you are jumpering the thermostat terminals without thermostat wire connection or if you are attempting to measure voltage on the screw head, you may get erroneous or unpredictable results if the screw is not tightened down. 3.
WF-DUAL HEAT STD.
Electro-HELPS IV WarmFlo Terminology, Key Terms ST – supply temperature sensor. This is the warm air or duct sensor (boiler – supply outlet water). OT – outdoor temperature sensor. Provides the WarmFlo board with outdoor temperature information. DT – desired temperature to overcome building heat loss, the diagonal line on heat loss curve. The front panel efficiency knob selects one of 8 curves to determine DT at specific real time OT.
- - New 2008 – version 2.38, 10.03, 12.04, 15.03, etc. – once activated, it remains for the completion of the heat call. Thus it only needs to be a temporary jumper (5 seconds or more) to step on all stages. User needs to remember to cycle the roomstat to cancel this E tab function. A potential convenience or secondary usage for this upgraded E tab function is to provide an easy manual means for rapidly bringing up the building or room temperature if the system has been set for non-occupancy.
Note: With an Electro-Mate it is assumed there is always standby or gas furnace. For non-automatic or wood, suggest using EMA and select the desired outlet temperature. ODT dial switch mode – within the program chip default and Analyzer/software programming this function defines the use of the dial switch on the circuit board labeled “ODT”. The dial switch selects the temperature, the setup function selects what the temperature does.
Blower operation – the air handler or fossil fuel furnace blower is operated from its own fan center (G screw). The activation of this “G” input is either directly from a heat pump (total electric system) roomstat “G” screw or in the case of dual heat from the Furnace Interface module (WF-EZ3, LGR4, EM3, etc.). The Interface module and its wiring or association with the room thermostat completely controls the blower.
HANDHELD ANALYZER/LAPTOP SOFTWARE PC software (ET-SOFT-WF) or Handheld (WF-ANZ*) – now has provisions for the following setup or reprogramming functions. Caution – do not attempt to reprogram a forced air (Electro-Mate) chip for boiler application.
When the warm air sensor is calling for more than the heat pump and Stage 1 100% output, Stage 2, etc. turns on. Stage 1 may not necessarily remain at 100%, but can be modulated downward to meet the requirements of the warm air sensor. Also on the next call for heat, the WarmFlo II controller remembers what stages were on and starts at that point. A clamp-on amp meter at the service input can be used to “visualize” the Stage 1 modulation and/or Stages 2, 3, and 4 functions.
Outdoor sensor reference or heating requirement level* – the outdoor digital sensor “tells” the WarmFlo “brain” its desired (DT) value or decision making capability. This is for desired or required supply temperatures greater than the “min. warm air” horizontal line setting. At each internal calculation cycle a DT is determined by reading the outdoor temperature (OT) and then finding the appropriate warm air point on the appropriate or selected diagonal line.
Electro Industries, Inc. Limited Product Warranty Effective February 5, 2009 Electro Industries, Inc. warrants to the original owner, at the original installation site, for a period of two (2) years from date of installation, that the product and product parts manufactured by Electro Industries are free from manufacturing defects in materials and workmanship, when used under normal conditions and when such product has not been modified or changed in any manner after leaving the plant of Electro Industries.
THESE WARRANTIES DO NOT COVER: 1. Costs for labor for removal and reinstallation of an alleged defective product or product parts, transportation to Electro Industries, and any other materials necessary to perform the exchange, except as stated in this warranty. Replacement material will be invoiced to the distributor in the usual manner and will be subject to adjustment upon verification of defect. 2.
