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WFI ES024 Installation Manual Download Page 28

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 specifi cations without notice. 
©2006 WFI.

Product:    

ES Split

Type: 

 

Geothermal/Water Source Heat Pumps

Size:  

 

2 thru 6 Ton

Document Type: 

Installation Manual

Part Number: 

IM1460

Release Date: 

11/06

Supercedes: 

IM1460  (10/05)

Summary of Contents for ES024

Page 1: ...iping Connections Desuperheater Connections Electrical Startup Procedures Troubleshooting Preventive Maintenance ES Split Installation Manual Geothermal Water Source Split Heat Pumps R 410A Refrigerant 2 2 5 Ton Single Speed 3 4 5 6 Ton Dual Capacity ...

Page 2: ...0 MBTUH 060 MBTUH 036 MBTUH 072 MBTUH Control Option S Standard Controls Voltage 1 208 230 60 1 Loop Pump Options A Standard Loop Connections Coax Options N Cupronickel Sound Kit A None B Blanket Non Standard Option Details S Standard A R T Z Non standard Options Vintage A 024 030 B 036 072 ES 036 S 1 A N B SS A ...

Page 3: ...it 9 Electrical 10 11 Wiring Schematics 12 13 DIP Switch Settings 14 Refrigeration 15 16 Unit Startup 17 Modes of Operation 18 19 Checking Superheat and Subcooling 20 22 Pressure Drop and Recommended Flow Rates 23 Service 24 25 Pressure Temperature Conversion Chart 26 Preventive Maintenance 27 Replacement Procedures 27 ...

Page 4: ...when properly installed Duct System In applications using galvanized metal ductwork a flexible duct connector is recommended on both the supply and return air plenums to minimize vibration from the blower To maximize sound attenuation of the unit blower the supply and return plenums should include an internal duct liner of 1 inch thick glass fiber or be constructed of ductboard Insulation is usual...

Page 5: ...e installed Be sure that the return duct is properly installed and free of leaks to prevent dirt and debris from bypassing the filter and plugging the air coil Notes Improper installation of equipment may result in undesirable noise levels in the living areas Ensure that the line set size is appropriate to the capacity of the unit refer to page 15 Line sets should be routed as directly as possible...

Page 6: ...s Indoor Installations Once piping is completed between the unit the flow center and the earth loop final purging and charging of the loop is needed A flush cart at least a 1 5 HP pump is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop itself An antifreeze solution is used in most areas to prevent freezing Maintain the pH in the 7 6 to 8 2 range f...

Page 7: ...e insulated with a minimum of 1 2 inch closed cell insulation from below the ground surface to the loop circulator IMPORTANT A freeze protection thermostat is installed in the unit to automatically start loop circulator pump if loop temperature drops below 20 F Loop freeze protection should also be maintained to the lowest temperature the insulated loop may encounter in the case of power failure C...

Page 8: ...ntaminated water The following table outlines the water quality guidelines for unit heat exchangers If these conditions are exceeded a secondary heat exchanger is recommended CAUTION Although the unit is approved for outdoor installations the use of this product is prohibited in open loop applications unless installed indoors Water Piping cont Disconnect Thermostat Wire From Air Handler Vibration ...

Page 9: ...of the heat recovery unit to the right hand of the service valve Typically the one way discharge line length should be limited to 25 30 feet and line size must be increased depending on unit size and length of run Follow the instructions supplied with the heat recovery unit for mounting location water piping and start up A typical installation is shown below IMPORTANT Reopen discharge line service...

Page 10: ... 208 230 60 1 197 253 13 0 8 3 48 0 1 8 10 1 12 2 20 20 ES030 208 230 60 1 197 253 15 5 9 9 55 0 1 8 11 7 14 2 20 20 ES036 208 230 60 1 197 253 19 5 12 5 66 0 1 8 14 3 17 4 25 25 ES048 208 230 60 1 197 253 28 0 17 9 96 0 1 8 19 7 24 1 40 40 ES060 208 230 60 1 197 253 38 5 24 7 130 0 3 5 28 2 34 1 50 50 ES072 208 230 60 1 197 253 41 0 26 3 130 0 3 5 29 8 36 4 60 60 Notes Always refer to unit namepl...

Page 11: ...plit System Application Heat Pump Coil Add On Fossil Fuel Furnace Fault Signal Fossil Fuel Furnace C R L0 Reversing Va lve Commo n C R G W Commo n 24 VA C Fa n Auxiliary Heat 1st Stage Compressor Split Thermostat Y1 L O Y2 C W G R Y2 O 2nd Stage Compressor 24 VA C Auxiliary Heat Relay Y1 Fault Signal Fossil Fuel Furnace C R L0 Reversing Valve Common C R G W Common 24 VAC Fan Auxiliary Heat 1st Sta...

Page 12: ...ring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block DC Voltage PCB traces Internal junction Quick connect terminal Wire nut Field wire lug Ground Fuse CC CR1 CR2 CR3 CR4 F1 and F2 FP HP LP PS RV SW1 SW2 SW3 SW4 Compressor Contactor Not Used Loop pump relay 1 Fuses Freeze protection sensor High pressure switch Low pressure switch Power strip Reversing ...

Page 13: ...P LP HP RV LS NS ES LO G Y2 O Y C R Thermostat 24 VAC Common Y1 RV Lockout Emergency Shutdown Night Setback Loadshed NOTE 1 NOTE 2 Violet T Black Black Blue Blue Orange Orange Yellow Yellow 1 6 2 7 8 3 4 9 5 10 DC voltage PCB traces CC PR NO Com Loop Pump 1 2 HP 208 230 60 1 G Black White LPR Single capacity loop pump relay Black Pump Air handler 24 VAC Common Y1 O Emergency Heat W W1 G G FP Loop ...

Page 14: ...ode allows viewing the current status of the fault inputs on the LED Freeze Protection Setting Allows selection of freeze Loop Water Well Water 2 thermistor fault sensing temperatures for well water or Freeze Protection Freeze Protection SW2 antifreeze protected earth loops 15º F 30º F Dual 3 Accessory Relay Allows selection of the accessory Accessory tracks Accessory tracks capacity relay to oper...

Page 15: ...matic dishwashing detergent to help condensate drainage Apply a 20 to 1 solution of detergent and water and spray both sides of coil Repeat and rinse thoroughly with water Connecting Split Unit Braze line set to the service valve stubs on the front of the split cabinet Nitrogen should be bled through the system at 2 to 3 psi to prevent oxidation contamination Use a low silver phos copper braze all...

Page 16: ... added is 118 0 oz 116 oz 2 0 oz Add the required refrigerant so that the total charge calculated for the unit and line set is now in the system Fully open the service valves by turning counterclockwise Start the unit in heating mode and measure superheat and subcooling values after at least five minutes of run time See page 20 for examples of measuring superheat and subcooling perfor mance values...

Page 17: ...the supply and discharge water see tables on pages 21 22 If temperature rise is within range of tables on page 21 22 proceed to step 9 Otherwise check the cooling refrigerant pressures and compare to tables on pages 21 22 Check for air temperature drop of 16 F to 25 F across the air coil Turn thermostat switch to OFF position A hissing should indicate proper functioning of reversing valve Leave un...

Page 18: ...age Y1 Y2 W Dual Capacity Units The auxiliary heat relay will disconnect the compressor and the auxiliary heat will operate normally Cooling Operation In all cooling operations the reversing valve directly tracks the O input Thus anytime the O input is present the reversing valve will be energized Cool 1st Stage Y1 O The compressor and loop pumps are energized 10 seconds after the Y1 input Cool 2n...

Page 19: ...t operation will occur Lockout modes of any kind can be reset at the thermostat after a 5 second waiting period which restores normal operation High Pressure This lockout mode occurs immediately when the normally closed safety switch is momentarily opened Low Pressure This lockout mode occurs when the normally closed switch is opened for 30 continuous seconds Freeze Protection Water Flow This lock...

Page 20: ... just outside the split cabinet This location will be adequate for measurement in both modes unless a significant temperature drop in the liquid line is anticipated Measure the liquid line pressure by attaching refrigerant gauges to the schrader connection on the liquid line service valve Convert the pressure obtained in Step 2 to the saturation temperature by using the R 410A Pressure Temperature...

Page 21: ...t Stage Operation ENTERING WATER TEMP F WATER FLOW GPM TON COOLING NO DESUPERHEATER SUCTION PRESSURE PSIG DISCHARGE PRESSURE PSIG SUPERHEAT SUBCOOLING WATER TEMP RISE F AIR TEMP DROP F DB 50 1 5 3 0 126 132 124 130 223 237 198 212 12 16 12 16 10 16 10 16 20 24 10 14 18 22 18 22 70 1 5 3 0 132 139 131 137 285 295 255 275 10 14 10 14 10 16 10 16 19 23 9 13 17 21 17 21 90 1 5 3 0 139 145 137 143 365 ...

Page 22: ... 1 5 3 0 141 149 139 147 360 380 330 350 10 14 10 14 8 14 8 14 18 22 9 12 16 20 16 20 Superheat Subcooling Pressures and Water Air Temperatures cont ENTERING WATER TEMP F WATER FLOW GPM TON HEATING NO DESUPERHEATER SUCTION PRESSURE PSIG DISCHARGE PRESSURE PSIG SUPERHEAT SUBCOOLING WATER TEMP DROP F AIR TEMP RISE F DB 30 1 5 3 0 74 77 78 84 285 310 290 315 8 12 8 12 3 9 3 9 5 7 3 5 12 18 14 20 50 1...

Page 23: ...048 1 4 1 3 1 2 1 2 1 1 3 0 2 1 2 0 2 0 1 9 1 8 6 0 3 7 3 5 3 3 3 3 3 0 9 0 5 9 5 6 5 4 5 2 4 8 12 0 ES060 1 1 1 0 0 9 0 9 0 9 5 0 2 1 2 0 2 0 1 9 1 8 8 0 3 1 2 9 2 8 2 7 2 6 11 0 4 8 4 6 4 4 4 2 3 9 14 0 ES072 1 5 1 4 1 3 1 2 1 1 7 0 2 7 2 6 2 4 2 3 2 2 10 0 4 3 4 1 3 8 3 6 3 4 13 0 6 1 5 8 5 4 5 1 4 8 16 0 FLOW RATE GPM CLOSED LOOP WELL WATER 4 5 6 3 4 6 8 4 5 4 5 Lo cap 3 4 Lo cap 7 9 Hi cap 6 ...

Page 24: ... may be defective Replace the compressor The internal winding of the compressor motor may be grounded to the compressor shell This should cause breaker to trip when voltage is applied If so replace the compressor The compressor winding may be open Check continuity with ohmmeter If the winding is open replace the compres sor Make sure compressor is cool before checking windings Check thermostat set...

Page 25: ...ting and cooling modes COAX HEATING TXV ACTIVE LEFT TO RIGHT Htg TXV Measure suction temperature here at TXV bulb in heating modes Suct PSI____ Suct sat temp____ Suct temp____ Superheat____ Discharge PSI____ Disch sat temp____ Liquid temp____ Subcooling____ Bi flow filter drier Air Coil Suction Discharge Comp Desuper heater Measure suction temperature here at TXV bulb in cooling modes Service cont...

Page 26: ...28 5 586 146 5 108 35 4 228 78 1 348 106 7 468 128 8 588 146 8 110 36 4 230 78 7 350 107 2 470 129 1 590 147 1 112 37 3 232 79 2 352 107 6 472 129 4 592 147 3 114 38 2 234 79 8 354 108 0 474 129 8 594 147 6 116 39 1 236 80 3 356 108 4 476 130 1 596 147 9 118 40 0 238 80 9 358 108 8 478 130 4 598 148 2 120 40 9 240 81 4 360 109 2 480 130 7 600 148 4 122 41 7 242 81 9 362 109 6 482 131 1 602 148 7 1...

Page 27: ...ressure drop and the possibility of copper erosion do not exceed GPM flow rate as shown on the specification sheets for each unit Filter Coil Maintenance Filters must be clean to obtain maximum performance They should be inspected every two to three months under normal operating conditions and be replaced when necessary Units should never be operated without a filter In areas where airborne bacter...

Page 28: ...ous product research and development and reserves the right to change design and specifications without notice 2006 WFI Product ES Split Type Geothermal Water Source Heat Pumps Size 2 thru 6 Ton Document Type Installation Manual Part Number IM1460 Release Date 11 06 Supercedes IM1460 10 05 ...

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