Premier Installation Manual Geothermal/Water Source Heat Pumps • 3/4 thru 6 Ton Installation Information Water Piping Connections Desuperheater Connections Electrical Startup Procedures Troubleshooting IM1555 11/06 WFI Preventive Maintenance
PREMIER INSTALLATION MANUAL Model Nomenclature P 040 T L 3 2 0 C A D S S A Vintage A = All Others B = P028(Single Phase), P056(All Voltages) Family P = Premier Unit Capacity MBTUH Non-Standard Option Details Non-Standard Options S = Standard 4 = FX10* 5 = FX10 w/Open N2 Com. Card* 6 = FX10 w/LonWorks Com. Card* 7 = FX10 w/BacNet Com.
PREMIER INSTALLATION MANUAL Table of Contents General Installation Information 4-7 Closed Loop Ground Source Systems 8 Open Loop Ground Water Systems 9 Boiler/Cooling Tower Closed Loop Systems 10 System Cleaning & Flushing 11 Desuperheater Connection & Startup 12-13 Electrical Connections 15 Electronic Thermostat Installation 15 Wiring Schematics 16-27 Fan Performance Data 28-29 Standard Microprocessor Control Operation 30-31 DIP Switch Settings 32-33 FX10 Control Operation 34 Sta
PREMIER INSTALLATION MANUAL General Installation Information WARNING: Before performing service or maintenance operations on a system, turn off main power switches to the indoor unit. If applicable, turn off the accessory heater power switch. Electrical shock could cause personal injury. Safety Considerations Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components.
PREMIER INSTALLATION MANUAL Installing Horizontal Units Horizontal 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 from a ceiling by four or six 3/8-inch diameter threaded rods. The rods are usually attached to the unit by hanger bracket kits furnished with each unit. Lay out the threaded rods per the dimensions in Figure 3.
PREMIER INSTALLATION MANUAL Duct System An air outlet collar is provided on vertical top flow units and all horizontal units to facilitate a duct connection. A flexible connector is recommended for discharge and return air duct connections on metal duct systems. Uninsulated duct should be insulated with a minimum of 1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit’s performance will be adversely affected.
PREMIER INSTALLATION MANUAL Water Quality In 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 qualified service mechanic, as special solutions and pumping equipment are required.
PREMIER INSTALLATION MANUAL Closed Loop Ground Source Systems Note: 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 loop to purge air and dirt particles from the loop itself.
PREMIER INSTALLATION MANUAL Open Loop Ground Water Systems Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation. Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. Ensure proper water flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures in Capacity Tables in the Specification Catalog.
PREMIER INSTALLATION MANUAL Boiler/Cooling Tower Closed Loop Systems Boiler/Cooling Tower The 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 tower with a secondary heat exchanger between the tower and the water loop is recommended.
PREMIER INSTALLATION MANUAL System Cleaning and Flushing Prior to start up of any heat pump, the water circulating system must be cleaned and flushed of all dirt and debris. If the system is equipped with water shutoff valves, the supply and return runouts must be connected together at each unit location to prevent the introduction of dirt into the unit, (see Figure 10). The system should be filled at the water makeup connection with all air vents open. After filling, vents should be closed.
PREMIER INSTALLATION MANUAL Desuperheater Connections Water Tank Preparation Figure 11: Water Heater Connection Kit Electric water heaters are recommended for use with the desuperheater in potable water systems. A tank with a 50-gallon minimum capacity should be installed. Multiple tanks may be piped in series to create larger buffer tanks.
PREMIER INSTALLATION MANUAL Initial Desuperheater Startup Plumbing Installation 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove drain valve and fitting from water heater. Thread the 3/4-inch NPT x 3 1/2-inch brass nipple into the water heater drain port. Attach the center port of the 3/4-inch FPT tee to the opposite end of the brass nipple. Attach the 1/2-inch SWT x 3/4-inch NPT copper adapter to the side of the tee closest to the unit. Install the drain valve on the tee opposite the adapter.
PREMIER INSTALLATION MANUAL Electrical Connections General Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable. Unit Power Connection Connect the incoming line voltage wires to L1 and L2 or L1, L2, and L3 of the contactor as shown in Figures 14 and 15.
PREMIER INSTALLATION MANUAL Electronic Thermostat Installation Position the thermostat subbase against the wall so that it is level and the thermostat wires protrude through the middle of the subbase. Mark the position of the subbase mounting holes and drill holes with a 3/16-inch bit. Install supplied anchors and secure base to the wall. Thermostat wire must be 8-conductor 18 AWG wire.
PREMIER INSTALLATION MANUAL Wiring Schematics P Series/E Series - Single Speed Wiring Schematic - 208-230/60/1, ECM Blower 97P618-19 10/13/05 Compressor Note 11 Note 12 Optional Factory Intstalled Internal Pump 208-230/60/1 S Blu PTCR C R Cap Black Pump Current Switch Blk T2 Unit Power 208-230/60/1 Ext Pump 1/2 hp Total 208-230/60/1 PB1 CS Black Red Tan T1 CC L2 L1 2 Pump D G 1 Blk/Wh 1 G PS1 NOTE 4 2 Pump C Gray/Wh A Blk Blu NOTE 6 Yel DHW Pump Blu 3A FUSE Or Gr
PREMIER INSTALLATION MANUAL With optional ' EA' Series Auxiliary ElectricHeat Typical schematic shown Auxiliary Electric Heat Power 208-230/60/1 L2 L4 G NOTE 5 L1 L2 P9 L1 L3 G F2 1 2 Grn 3 Brn Brn Or Or 5 Brn 4 Or P8 Blu Violet PB2 Blk Pink Yel Pink 4 Pink Yel 3 Yel Blk 2 Blk Gray 1 Gray ER1 Gray Grn Grn NO 1 2 3 4 1 P11 5 2 3 4 5 Gray P11 Gray ER2 P7 ECM2 Fan Motor ECM2 Fan Motor NO P12 3 RPM grnd PWM On/Off RPM C2 15 16 10 8 RPM 3 PWM C2
PREMIER INSTALLATION MANUAL Wiring Schematics P Series - Single Speed Wiring Schematic - 208-230/60/1, PSC Blower 97P619-36 10/13/05 NOTE 10 Compressor P010-013 PSC Fan Motor P019-066 PSC Fan Motor Brn Grn Cap Wh S Blu C Brn Cap Black Red Tan CS Black R Wh Cap Grn Current Switch Blk 3 Air Flow Settings 3 Air Flow Settings H M L C P13 H M L T2 Unit Power 208-230/60/1 Wh P13 T1 CC L2 L1 Wh Ext Pump 1/2 hp Total 208-230/60/1 C Gray/Wh Gray Pump 1 A Wh Yel 1 G
PREMIER INSTALLATION MANUAL With optional ' EA' Series Auxiliary ElectricHeat Typical schematic shown Auxiliary Electric Heat Power 208-230/60/1 L2 G L4 NOTE 5 L1 L1 L2 L3 G F2 Brn Or 5 5 Blu 4 4 Violet 3 3 2 2 Pink 4 Pink 1 1 Yel 3 Yel Blk 2 Blk Gray 1 Gray P8 PB2 Pink Blk ER1 Gray Yel NO Gray Gray ER2 P7 NO ER3 Blk Gray HE1 TS1 1 Yel Blk 2 Blk 3 Yel HE2 TS2 Yel 4 Pink NO HE3 TS3 Pink ER4 P12 P2 1 HE4 Pink TS4 NO 3 15 16 1 P10 10 2 3
PREMIER INSTALLATION MANUAL Wiring Schematics P Series - Single Speed Wiring Schematic - 208-230/60/3, ECM Blower 97P618-20 10/13/05 Compressor T3 T1 CS Black T2 Black Red Blue Current Switch Blk Ext Pump 1/2 hp Total 208-230/60/1 T3 PB1 Unit Power 208-230/60/3 2 CC L3 2 Pump T1 T2 L2 L1 NOTE 4 Pump PS1 1 1 G G D Blk/Wh C Gray/Wh A Blk Yel Or Gray Blk/Wh 208V 240V Brn Transformer Switch NOTE 1 Blu Red 240V 208V 240V L2 Fused L2 Fused L2 Transformer 240V L1 24V F1
PREMIER INSTALLATION MANUAL With optional ' EA' Series Auxiliary ElectricHeat Typical schematic shown Auxiliary Electric Heat Power 208-230/60/3 L1 F2 1 2 Grn PB2 3 Brn Brn Or Or G L3 L2 P9 5 Brn 4 Or P8 Blu 4 Violet 2 3 5 4 P11 2 Blk Gray 1 Gray Gray NO Yel 1 3 ER1 Blk Grn Grn Yel Yel Blk 1 2 4 3 5 Gray P11 Gray ER2 ECM2 Fan Motor NOTE 9 NOTE 9 RPM grnd ER3 15 16 10 8 RPM 3 PWM On/Off P12 NO C2 15 16 10 8 PWM On/Off 3 RPM C2 RPM grnd ECM2
PREMIER INSTALLATION MANUAL Wiring Schematics P Series - Single Speed Wiring Schematic - 208-230/60/3, PSC Blower 97P619-33 10/13/05 Compressor PSC Fan Motor T1 T3 Brn Grn Wh Black Blue Red Current Switch Blk 3 Air Flow Settings T3 H M L Unit Power 208-230/60/3 P13 CS Black T2 Cap T2 T1 CC L3 L2 L1 PS1 NOTE 4 Ext Pump 1/2 hp Total 208-230/60/1 Black PB1 G D Blk/Wh White C 2 Gray/Wh 2 Pump Blk/Wh A Pump 1 Blk 1 G 208V 240V Transformer Switch NOTE 1 Yel Or Gray
PREMIER INSTALLATION MANUAL With optional ' EA' Series Auxiliary ElectricHeat Typical schematic shown Auxiliary Electric Heat Power 208-230/60/3 L1 F2 1 2 Grn Br n O r PB2 3 Brn 5 4 G L3 L2 P9 Or 5 Brn 4 Or P8 3 4 2 Yel 3 1 Blk 2 Blk Gray 1 Gray ER1 Blk Gray NO Yel Gray Gray ER2 P7 NO ER3 Blk Yel Gray HE1 1 2 3 Yel HE2 TS2 Yel 4 HE3 NO TS1 Blk Blk TS3 ER4 P12 1 P2 NO 3 15 16 1 P10 10 2 3 4 5 6 EA Series PCB 17P514A01 8 P10 1 Orange 2 Blue
PREMIER INSTALLATION MANUAL Wiring Schematics P Series - Single Speed Wiring Schematic - 265/60/1, ECM Blower 97P618-15 10/13/05 Compressor Current Switch S Blu C CS Black R Black Cap Red Tan Blk Notes: 1 - Connection of remote unit that does not have a loop pump for slave operation. T2 Unit Power 265/60/1 2 - 24V Accessory relay (see SW2 - 3 for description of operation) 3 - Air Flow Configuration Example: SW1 configured for dip 3 as low, dip 5 as medium, and dip 7 as high speed ECM2 fan.
PREMIER INSTALLATION MANUAL Wiring Schematics P Series - Single Speed Wiring Schematic - 265/60/1, PSC Blower 97P619-21 10/13/05 P010-013 PSC Fan Motor P019-034 PSC Fan Motor Brn Grn Current Switch Compressor NOTE 5 Cap Grn Wh S Blu C Red Tan 3 Air Flow Settings 4 3 2 1 C 4 Air Flow Settings P13 H L P13 Wh T1 5 - Unit may be wired with either example shown. Consult installation manual for blower speed wiring instructions.
PREMIER INSTALLATION MANUAL Wiring Schematics P Series - Single Speed Wiring Schematic - 460/60/3, ECM Blower 97P618-16 10/13/05 Notes: Compressor T3 Red 4 - When using thermostat TA32E12, SW2 -8 should be in the ON position. When using 24VAC thermostats, SW2-8 should be in the OFF position. 5 - When optional electronic air-filter is installed, power for the electronic air-filter is provided by P2-2 and 24 VAC.
PREMIER INSTALLATION MANUAL Wiring Schematics P Series - Single Speed Wiring Schematic - 460-575/60/3, PSC Blower 97P619-22 10/13/05 PSC Fan Motor Green PSC Fan Motor H M Grn Red 3 Air flow Settings H M L LI MI Black Black T2 T1 CC L3 MI LI CS Black Blue T3 Ora Yel White T1 T2 Unit Power 460/60/3 3 Air flow Settings Black T3 Brn Cap Capacitor L Compressor - Low - L1 to white side fo capacitor, L2 to L on motor, Yellow wire to L1 on motor, Orange to M1 on motor.
PREMIER INSTALLATION MANUAL Fan Performance Data ECM2 Motor MODEL MAX ESP P019 0.5 P022 0.5 P028 0.5 P034 0.5 P040 0.5 P046 0.5 P040 w/1hp* 0.75 P046 w/1hp* 0.75 P056 0.75 P066 0.
PREMIER INSTALLATION MANUAL Fan Performance Data PSC Motor MODEL FAN MOTOR SPEED HP 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.60 0.70 0.80 0.90 1.
PREMIER INSTALLATION MANUAL Standard Microprocessor Control Operation The Premier control system is a microprocessor-based printed circuit board conveniently located in the unit control box for easy accessibility. The microprocessor provides control of the entire unit as well as outputs for status modes, faults, and diagnostics. Low voltage terminal strips provide all necessary terminals for field connections.
PREMIER INSTALLATION MANUAL Standard Microprocessor Control Operation Fault Retry All faults (except for low RPM fault with the ECM2 fan motor) are retried twice before finally locking the unit out. The “fault retry” feature is designed to prevent nuisance calls. Diagnostics The Premier control board allows all inputs and outputs to be displayed on the LEDs for fast and simple control board diagnosis (see field selection DIP switches #6 and #7).
PREMIER INSTALLATION MANUAL DIP Switch Settings Field Selection DIP Switches (SW2) An eight-position DIP switch package on the control allows the field selectable options shown in the table below. FIELD SELECTION DIP SWITCHES (SW2) DIP SWITCH NUMBER DESCRIPTION OFF POSITION ON POSITION SW 2- 1 Service Test Mode Allows field selection of “normal” or “test” operational modes. Test mode accelerates most timing functions 16 times to allow faster troubleshooting.
PREMIER INSTALLATION MANUAL DIP Switch Settings Factory Setup DIP Switches (SW3) A five-position DIP switch package on the control allows the field selectable options shown in the table below. FACTORY SETUP DIP SWITCHES (SW3) DIP SWITCH NUMBER DESCRIPTION OFF POSITION ON POSITION SW 3- 1 Single-Speed Configures the control for single-speed compressor operation and should always be left in the “ON” position.
PREMIER INSTALLATION MANUAL FX10 Control Operation (Optional Microprocessor) FX10 Advanced Control The Johnson Controls FX10 board is specifically designed for commercial heat pumps and provides control of the entire unit as well as input ports for Open N2, LonTalk, BacNet communication protocols as well as an input port for a user interface. The user interface is an accessory item that can be used to aid in diagnostics and unit setup.
PREMIER INSTALLATION MANUAL Startup Procedures Before Powering Unit, Check The Following: • • • • • • • • • • • • • • • • High Voltage is correct and matches nameplate. Fuses, breakers and wire size correct. Low voltage wiring complete. Piping completed and water system cleaned and flushed. Air is purged from closed loop system. Isolation valves are open, water control valves or loop pumps wired. Condensate line open and correctly pitched.
PREMIER INSTALLATION MANUAL Description of Unit Operation Note: Fan speed operation below applies only to units equiped with ECM blower motors. Heating Operation Heat, 1st Stage (Y1) The fan motor is started on low speed immediately, the loop pump is energized 5 seconds after the “Y1” input is received, and the compressor is energized on low capacity 10 seconds after the “Y1” input. The fan is switched to medium speed 15 seconds after “Y1” input.
PREMIER INSTALLATION MANUAL Operation Logic HEATING OPERATION LOGIC DATA STG1 STG2 COOLING STG3 EMERG STG1 FAN ON STG2 SL1 - IN ON Compressor On On On Off On On – – ECM2 Normal Med High High High Med High Low – ECM2 Dehumidify Med High High High Low Med Low – PSC Low High High High Low High – – Rev Valve Off Off Off Off On On – – Loop Pump On On On Off On On – On DHW Pump On Off Off Off On On – – Aux Heater Off Off Staged Staged
PREMIER INSTALLATION MANUAL Troubleshooting To check the unit control board for proper operation: 1. Disconnect thermostat wires at the control board. 2. Jumper the desired test input (Y1, Y2, W, O, or G) to the R terminal with the SW2-8 in the “OFF” position to simulate a thermostat signal. 3. If control functions properly: - Check for thermostat and field control wiring (use the diagnostic inputs mode). 4.
PREMIER INSTALLATION MANUAL Preventive Maintenance Water Coil Maintenance 1. Keep all air out of the water. An open loop system should be checked to ensure that the well head is not allowing air to infiltrate the water line. Lines should always be airtight. 2. Keep the system under pressure at all times. It is recommended in open loop systems that the water control valve be placed in the discharge line to prevent loss of pressure during off cycles. Closed loop systems must have positive static pressure.
Manufactured by WFI 9000 Conservation Way Fort Wayne, IN 46809 WFI has a policy of continuous product research and development and reserves the right to change design and specifications without notice. ©2006 WFI.
