Carrier GW Series User manual

GW Series
Water--to--Water Geothermal Heat Pump
Sizes 024, 036, 048, 060, 072, 120
Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE NO.
SAFETY CONSIDERATIONS 1.....................
INSTALLATION RECOMMENDATIONS 2............
CHECK EQUIPMENT & JOBSITE 2.................
LOCATION / CLEARANCE 2.......................
APPLICATION CONSIDERATIONS 3................
Earth Coupled (Geothermal) Systems 3..............
Well Water Systems 4............................
INSTALLATION 6.................................
MINIMAL SYSTEM VOLUME 6.....................
PIPING 6.........................................
ELECTRICAL 7...................................
SAFETY DEVICES AND UPM CONTROLLER 7.......
SEQUENCE OF OPERATION 9......................
Cooling Mode 9.................................
Heating Mode 9.................................
HEAT RECOVERY PACKAGE 11.....................
INITIAL START--UP 12..............................
SYSTEM CHECKOUT 12............................
UNIT START--UP 12.................................
TROUBLESHOOTING 14............................
Information in these installation instructions pertains only to GW
series units.
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes and
current editions of the National Electrical Code ( NEC ) NFPA 70.
In Canada, refer to current editions of the Canadian electrical code
CSA 22.1.
Recognize safety information. This is the safety--alert symbol !!
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand
these signal words; DANGER, WARNING, and CAUTION. These
words are used with the safety--alert symbol. DANGER identifies
the most serious hazards which will result in severe personal injury
or death. WARNING signifies hazards which could result in
personal injury or death. CAUTION is used to identify unsafe
practices which would result in minor personal injury or product
and property damage. NOTE is used to highlight suggestions
which will result in enhanced installation, reliability, or operation.
!WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position.
There may be more than 1 disconnect switch. Lock out and
tag switch with a suitable warning label.
EXPLOSION HAZARD
Failure to follow this warning could
result in death, serious personal injury,
and/or property damage.
Never use air or gases containing
oxygen for leak testing or operating
refrigerant compressors. Pressurized
mixtures of air or gases containing
oxygen can lead to an explosion.
!WARNING

2
!WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal injury
or equipment damage.
PuronRrefrigerant systems operate at higher pressures than
standard R--22 systems. Do not use R--22 service equipment
or components on PuronRrefrigerant equipment.
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing and gloves when
handling parts.
CAUTION
!
INSTALLATION RECOMMENDATIONS
The GW Water--to--Water Heat Pump is Underwriters Laboratories
(UL) and (cUL) listed for safety. The water--to--water heat pumps
are designed to operate with entering fluid temperature between
25_Fto110_F.
Safety devices are built into each unit to provide the maximum
system protection possible when properly installed and maintained.
IMPORTANT:50_Min. EWT (entering water temperature) for
well water applications with sufficient water flow to prevent
freezing. Antifreeze solution is required for all closed loop
applications. Earth Coupled (Geothermal) applications should have
sufficient antifreeze solution to protect against extreme conditions
and equipment failure. Frozen water coils are not covered under
warranty.
IMPORTANT: This product should not be used for temporarily
heating or cooling during construction. Doing so may effect the
unit’s warranty.
CAUTION
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Discharge air configuration change is not possible on Heat
Pumps equipped with Electric Heat Option.
Check Equipment and Job Site
Moving and Storage
If the equipment is not needed for immediate installation upon its
arrival at the job site, it should be left in its shipping carton and
stored in a clean, dry area. Units must only be stored or moved in
the normal upright position as indicated by the “UP” arrows on
each carton at all times.
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage.
If unit stacking is required for storage, stack units as follows:
Do not stack units larger than 6 tons!
Vertical units: less than 6 tons, no more than two high.
Horizontals units: less than 6 tons, no more than three high.
CAUTION
!
Inspect Equipment
Be certain to inspect all cartons or crates on each unit as received at
the job site before signing the freight bill. Verify that all items have
been received and that there are no visible damages; note any
shortages or damages on all copies of the freight bill. In the event
of damage or shortage, remember that the purchaser is responsible
for filing the necessary claims with the carrier. Concealed damages
not discovered until after removing the units from the packaging
must be reported to the carrier within 24 hours of receipt.
Location / Clearance
Locate the unit in an indoor area that allows easy removal of the
filter and access panels, and has enough room for service personnel
to perform maintenance or repair. Provide sufficient room to make
fluid, electrical, and duct connection(s). If the unit is located in a
confined space such as a closet, provisions must be made for return
air to freely enter the space. On horizontal units, allow adequate
room below the unit for a condensate drain trap and do not locate
the unit above supply piping.
CAUTION
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
These units are not approved for outdoor installation;
therefore, they must be installed inside the structure being
conditioned. Do not locate in areas that are subject to
freezing.
CAUTION
!
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in equipment
damage and/or improper equipment operation.
It is extremely important to take the proper precautions to
insure that the heat pump unit is installed in the proper
location and that measures have been taken to prevent
rupturing the water coil due to freezing conditions.
Frozen water coils are not covered under the limited
product warranty.

3
APPLICATION CONSIDERATIONS
Typical Load Side Applications
There are many load side applications for which the
water--to--water heat pump/ liquid chiller is ideally suited.
Some typical uses are as follows:
Hydronic baseboard heating, hydronic in--slab floor heating, forced
air fan coil heating or cooling, ice and snow melting, heating
potable water, (when allowed by code) heating swimming pool and
spa*, process fluid heating or cooling.
When specifying load side fluid volume it is important to consider
the heat pump output capacities and flow rates. Insufficient load
side fluid volume may cause unstable heat pump operation (short
cycling). Pressure/temperature ports should be used to set flow
rates.
*A water--to--water series Heat Pump/Liquid Chiller can be utilized
for direct pool/spa heating without a secondary heat exchanger. In
this application cupronickel heat exchangers must be used.
Automatic chemical feeders must never be installed upstream of
the unit. An external bypass should be installed to avoid
over--flowing the heat exchanger to prevent coil erosion. The pool
pH levels and chemical balances must be maintained to avoid
possible heat exchanger damage.
Earth Coupled (Geothermal) Systems
Closed loop and pond applications require specialized design
knowledge. No attempt at these installations should be made unless
the dealer has received specialized training.
Anti--freeze solutions are utilized when entering loop temperatures
drop below 50_F or where piping will be routed through areas
subject to freezing. A flow rate between 2.5 to 3.0 gpm per
nominal ton of cooling is recommended for this application. See
Flow Center Curve for sizing information. Refer to the Flow
Center installation manuals for more specific instructions.
1. POLYETHELENE WITH
INSULATION
2. GROUND LOOP PUMPING PACKAGE (GLP)
3. GROUND LOOP CONNECTION KIT
4. P/T PLUGS
5. LOAD SIDE CONNECTIONS*
6. LOW VOLTAGE CONTROL CONNECTION*
7. VIBRATION PAD
8. LINE VOLTAGE DISCONNECT
* NOTE: Water and electrical connection locations vary depending
on model. Connect as required per unit labels.
A14173
Fig. 1 -- Earth Coupled Application

4
Well Water Systems
IMPORTANT: Table 1 must be consulted for water quality
requirements when using open loop systems. A water sample must
be obtained and tested, with the results compared to the table.
Scaling potential should be assessed using the pH/Calcium
hardness method. If the pH is <7.5 and the calcium hardness is
l<100 ppm, the potential for scaling is low. For numbers out of the
range listed, a monitoring plan must be implemented due to
probable scaling.
Other potential issues such as iron fouling, corrosion, erosion and
clogging must be considered. Careful attention to water conditions
must be exercised when considering a well water application.
Failure to perform water testing and/or applying a geothermal heat
pump to a water supply that does not fall within the accepted
quality parameters will be considered a mis--application of the unit
and resulting heat exchanger failures will not be covered under
warranty. Where a geothermal system will be used with adverse
water conditions, a suitable plate--frame heat exchanger MUST be
used to isolate the well water from the geothermal unit.
CAUTION
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Discharge air configuration change is not possible on Heat
Pumps equipped with Electric Heat Option.
Water quantity should be plentiful, between 1.5 and 3.0 gpm per
ton of cooling, and of good quality. To avoid the possibility of
freezing in the heating mode, the well water should be above 50_F.
Water pressure must always be maintained in the heat exchanger by
placing a water control valve on the outlet of the water--to--water
unit. A bladder type expansion tank may be used to maintain
pressure on the system. All solenoid valves should be slow closing
to avoid water hammer.
The discharge water from the water--to--water unit is not
contaminated in any manner and can be disposed of in various
ways depending on the local codes (i.e. discharge well, dry well,
storm sewer, drain field, stream, pond, etc.) Pilot operated or slow
closing valves are recommended to reduce water hammering.
1. PRESSURE TANK
2. BALL VALVES
3. SOLENOID VALVE (SLOW CLOSING)
4. HOSE KIT
5. P/T KIT
6. LOAD SIDE CONNECTIONS*
7. LOW VOLTAGE CONTROL CONNECTION*
8. VIBRATION PAD
9. LINE VOLTAGE DISCONNECT
* NOTE: Water and electrical connection locations vary
depending on model. Connect as required per unit labels.
A14172
Fig. 2 -- Well Water Application

5
Table 1 – Water Quality Requirements for Open--Loop Geothermal Heat Pump System
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 <7.5 and Ca Hardness <100ppm
Index Limits for Probable Scaling Situations - (Operation outside these limits is not recommended)
Scaling indexes should be calculated at 150°F for direct use and HWG applications, and at 90°F for indirect HX use.
A monitoring plan should be implemented.
Ryznar Stability Index All -- 6.0 - 7.5
If > 7.5 minimize steel pipe use
Langelier Saturation Index All --
-0.5 to +0.5
If <-0.5 minimize steel pipe use.
Based upon 150°F HWG and Direct well,
84°F Indirect Well HX
Iron Fouling
Iron Fe² (Ferrous)
(Bacterial Iron Potential) All --
<0.2 ppm (Ferrous)
If Fe²* (ferrous) >0.2 ppm with pH 6-8, O2<5 ppm check
for iron bacteria
Iron Fouling All -- <0.5 ppm of Oxygen
Above this level deposition will occur
Corrosion Prevention
pH All 6-8.5
Monitor/treat as needed
6-8.5
Minimize steel pipe below 7 and no open tanks with pH <8
Hydrogen Sulfide (H2S) All --
At H S>0.2 ppm, avoid use of copper and copper nickel
piping or HXs. Rotten egg smell appears at 0.5 ppm level.
Copper alloy (bronze or brass) cast components are OK
to <0.5 ppm
Ammonia ion as hydroxide,
chloride, nitrate and sulfate
compounds
All -- <0.5 ppm
Maximum Chloride Levels
Maximum Allowable at Maximum Water Temperature
50°F 75°F 100°F
Copper -- <20 ppm NR NR
cupronickel -- <150 ppm NR NR
304 SS -- <400 ppm <250 ppm <150 ppm
316 SS -- <1000 ppm <550 ppm <375 ppm
Titanium -- >1000 ppm >550 ppm >375 ppm
Erosion and Clogging
Particulate Size and
Erosion All
<10 ppm of particles and a
maximum velocity of 1.8 m/s.
Filtered for maximum 841 mi-
cron [0.84 mm 20 mesh] size
<10 ppm (<1 ppm "sandfree" for re-injection) of particles
and a maximum velocity of 1.8 m/s. Filtered for maximum
841 micron [0.84 mm. 20 mesh] size. Any particulate that
is not removed can potentially clog components
NOTES:
SClosed recirculating system is identified by a closed pressurized piping system.
SRecirculating open wells should observe the open recirculating design considerations.
SNR - application not recommended
S"—" No design Maximum

6
INSTALLATION
The Water--to--Water series unit should be mounted level on a
vibration absorbing pad slightly larger than the base to minimize
vibration transmission to the building structure. It is not necessary
to anchor the unit to the floor. See Fig. 3.
VIBRATION PAD
FULL SIZE
A14170
Fig. 3 -- Vibration Absorbing Pad
If the unit is installed on a floor over a crawl space, it should not
rest on long, unsupported floor joists. Vibrations may be created in
the joists with the crawl space acting as an amplifier box resulting
in undesirable noise. A drain pan is recommended where water
released during start--up or maintenance could cause damage below
the unit.
In both cases, a 3/4” drain connected to this secondary pan should
be run to a suitable location. If the unit is located in a crawl space,
the bottom of the unit must be at least 4” above grade to prevent
flooding of the electrical parts due to heavy rains.
MINIMAL SYSTEM VOLUME
The manufacturer recommends that the total fluid volume in the
system be not less than 6 gallons per nominal ton of cooling
capacity on both the load and source sides.
PIPING
Supply and return piping must be as large as the unit connections
on the heat pump (larger on long runs).
CAUTION
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper
equipment operation.
Never use flexible hoses of a smaller inside diameter than
that of the fluid connections on the unit.
GW units are supplied with either a copper or optional cupronickel
condenser. Copper is adequate for ground water that is not high in
mineral content.
NOTE: Proper testing is recommended to assure the well water
quality is suitable for use with water source equipment. When in
doubt, use cupronickel.
In conditions anticipating moderate scale formation or in brackish
water, a cupronickel heat exchanger is recommended.
Both the supply and discharge water lines will sweat if subjected to
low water temperature. These lines should be insulated to prevent
damage from condensation.
All manual flow valves used in the system must be ball valves.
Globe and gate valves must not be used due to high pressure drop
and poor throttling characteristics.
CAUTION
!
EQUIPMENT DAMAGE AND/OR UNIT
OPERATION HAZARD
Failure to follow this caution may result in equipment
damage and/or improper operation.
Never exceed the recommended water flow rates as serious
damage or erosion of the water--to--refrigerant heat
exchanger could occur.
Improper heat exchanger water flow due to piping, valve
arrangement or improper pump operation is hazardous to
the unit and constitutes abuse which will void the heat
exchanger and compressor warranty.
Always check carefully for water leaks and repair appropriately.
Units are equipped with female pipe thread fittings. Consult
Product Data for sizes.
NOTE: Teflon tape sealer should be used when connecting water
piping connections to the units to insure against leaks and possible
heat exchanger fouling.
Flexible hoses should be used between the unit and the rigid
system to avoid possible vibration. Ball valves should be installed
in the supply and return lines for unit isolation and unit water flow
balancing.
No unit should be connected to the supply or return piping until
the water system has been completely cleaned and flushed to
remove any dirt, piping chips or other foreign material. Supply and
return hoses should be connected together during this process to
ensure the entire system is properly flushed. After the cleaning and
flushing has taken place the unit may be connected to the water
loop and should have all valves wide open. Do not over--tighten
connections.

7
ELECTRICAL
!WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position.
There may be more than 1 disconnect switch. Lock out and
tag switch with a suitable warning label.
CAUTION
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment
damage and/or improper operation.
SField wiring must comply with local and national
electrical codes.
SPower to the unit must be within the operating voltage
range indicated on the unit nameplate.
SOn three--phase units, phases must be balanced within
2%.
SOperation of unit on improper line voltage or with
excessive phase imbalance will be hazardous to the unit,
constitutes abuse, and may void the warranty.
Properly sized fuses or HACR circuit breakers must be installed for
branch circuit protection. See unit nameplate for maximum fuse or
breaker size.
The unit is provided with a concentric knock--out for attaching
common trade sizes of conduit, route power supply wiring through
this opening. Flexible wiring and conduit should be used to isolate
vibration and noise from the building structure.
Always connect the ground lead to the grounding lug provided in
the control box and power leads to the line side of compressor
contactor as indicated on the wiring diagrams.
SAFETY DEVICES AND UPM
CONTROLLER
1
2
3
4
5
6
7910
11
1213
17
14
15
16
8
A14120
(1) Board Power Indicator (10) Compressor Contact Output
(2) UPM Status LED Indicator (11) High Pressure Switch Connection
(3) Water Coil Freeze Protection
Temperature Selection [R30]
(12) Call for Compressor Y1
(4) Air Coil Freeze Protection
Temperature Selection
(13) Low Pressure Switch Connection
(5) UPM Board Settings (14) 24VAC Power Common
(6) Water Coil Freeze Connection (15) Condensate Overflow Sensor
(7) Air Coil Freeze Connection (16) Dry Contact
(8) LCD Unit Display Connection (17) UPM Ground Standoff
(9) 24VAC Power Input
Fig. 4 -- Unit Protection Module (UPM)
Each unit is factory provided with a Unit Protection Module
(UPM) that controls the compressor operation and monitors the
safety controls that protect the unit (see Fig. 4).
Safety controls include the following:
SHigh pressure switch located in the refrigerant discharge line and
wired across the HPC terminals on the UPM.
SLow pressure switch located in the unit refrigerant suction line
and wired across terminals LPC1 and LPC2 on the UPM.
NOTE: UPM Board Dry Contacts are normally open (NO)
SWater side freeze protection sensor, mounted close to condensing
water coil, monitors refrigerant temperature between condensing
water coil and thermal expansion valve. If temperature drops
below or remains at freeze limit trip for 30 seconds, the controller
will shut down the compressor and enter into a soft lockout
condition.
The default freeze limit trip is 26_F, however this can be changed
to 15_F by cutting the R30 or Freeze1 resistor located on top of
DIP switch SW1 (Refer to Fig. 4, item (3) for resistor location),
RefertoFig.5forsensorlocation.

8
A14121
Fig. 5 -- Freeze Protection Sensor Location
CAUTION
!
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in unit damage
and/or improper equipment operation.
If unit is employing a fresh water system (no anti--freeze
protection), it is extremely important to have the Freeze1
R30 resistor set to 26_F in order to shut down the unit at
the appropriate leaving water temperature and protect your
heat pump from freezing if a freeze sensor is included.
SEvaporator freeze protection sensor, mounted after the thermal
expansion device and the evaporator, monitors refrigerant
temperature between the evaporator coil and thermal expansion
valve. If temperature drops below or remains at freeze limit trip
for 30 seconds, the controller will shut down the compressor and
enter into a soft lockout condition. The default freeze limit trip is
26_F. See Fig. 6.
A14122
Fig. 6 -- Evaporator Freeze Protection Sensor Location
SThe condensate overflow protection sensor is located in the drain
pan of the unit and connected to the ”COND” terminal on the
UPM board. See Fig. 7.
A14123
Fig. 7 -- Condensate Overflow Protection Sensor Location
UPM Board Factory Default Settings
TEMP 26°F
LOCKOUT 2
RESET Y
ALARM PULSE
TEST NO
UPM DIP SWITCH DEFAULT POSITION
lockout 4
reset RY
alarm Cont
test yes
pulse
no
2
The UPM Board includes the following features:
SANTI--SHORT CYCLE TIMER: 5 minute delay on break
timer to prevent compressor short cycling.
SRANDOM START: Each controller has an unique random start
delay ranging from 270 to 300 seconds on initial power up to
reduce the chance of multiple unit simultaneously starting at the
same time after power up or after a power interruption, thus
avoiding creating large electrical spike.
SLOW PRESSURE BYPASS TIMER: If the compressor is
running and the low pressure switch opens, the controller will
keep the compressor ON for 120 seconds. After 2 minutes if the
low pressure switch remains open, the controllers will shut down
the compressor and enter a soft lockout. The compressor will not
be energized until the low pressure switch closes and the
anti--short cycle time delay expires. If the low pressure switch
opens 2--4 times in 1 hour, the unit will enter a hard lockout. In
order to exit hard lockout power to the unit would need to be reset.
SBROWNOUT / SURGE / POWER INTERRUPTION
PROTECTION: The brownout protection in the UPM board
will shut does the compressor if the incoming power falls below
18 VAC. The compressor will remain OFF until the voltage is
above 18 VAC and ANTI--SHORT CYCLE TIMER (300
seconds) times out. The unit will not go into a hard lockout.

9
SMALFUNCTION OUTPUT: Alarm output is Normally Open
(NO) dry contact. If pulse is selected the alarm output will be
pulsed. The fault output will depend on the dip switch setting for
”ALARM”. If it is set to ”CONST”, a constant signal will be
produced to indicate a fault has occurred and the unit requires
inspection to determine the type of fault. If it is set to ”PULSE”, a
pulse signal is produced and a fault code is detected by a remote
device indicating the fault. See L.E.D Fault Indication below for
blink code explanation. The remote device must have a
malfunction detection capability when the UPM board is set to
”PULSE”.
NOTE: If 24 VAC output is needed, R must be wired to
ALR--COM terminal; 24 VAC will be available o the ALR--OUT
terminal when the unit is in the alarm condition.
SLED FAULT INDICATION-- Two LED Indicators are
provided.
GREEN: Power LED indicates 118--30 VAC presentat the board.
RED: Fault indicator wit blink codes as follows:
— One Blink ---- High pressure lockout
— Two Blinks ---- Low pressure lockout
— Three Blinks ---- Freeze sensor lockout
— Four Blinks ---- Condensate overflow
— Five Blinks ---- Brownout
SDISPLAY OUTPUT: The Display output is a pulse output
connected to the Unit Diagnostic Display (UDD) and it pulses
24VAC when the unit is in an lockout alarm condition.
STEST DIP SWITCH: A test dip switch is provided to reduce all
time delays settings to 10 seconds during troubleshooting or
verification of unit operation.
CAUTION
!
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in unit damage
and/or improper equipment operation.
Operation of unit in test mode can lead to accelerated wear
and premature failure of components. The ”TEST” switch
must be set back to ”NO” after troubleshooting/ servicing.
SFREEZE SENSOR: The default setting for the freeze limit trip is
26_F (sensor number 1); however this can be changed to 15_Fby
cutting the R30 resistor located on top of the DIP switch SW1.
Since freeze sensor 2 is dedicated to monitor the evaporator coil, it
is recommended to leave the factory default setting on the board.
The UPM controller will constantly monitor the refrigerant
temperature with the sensor mounted close to the condensing
water coil between the thermal expansion valve and water coil. If
temperature drops below or remains at the freeze limit trip for 30
seconds, the controller will shut the compressor down and enter
into a soft lockout condition. Both the status LED and the Alarm
contact will be active.
The LED will flash the code associated with this alarm condition
three (3) times. If this alarm occurs 2 times (or 4 if Dip switch is set
to 4) within an hour, the UPM controller will enter into a hard
lockout condition. It will constantly monitor the refrigerant
temperature with the sensor mounted close to the evaporator
between the thermal expansion valve and evaporator coil as
showninFig.6.
If temperature drops below or remains at the freeze limit trip for
30 seconds, the controller will shut the compressor down and
enter into a soft lockout condition. Both the status LED and the
alarm contact will be active. The LED will flash the code
associated with this alarm condition six (6) times. If this alarm
occurs 2 times (or 4 if Dip switch is set to 4) within an hour, the
controller will enter into a hard lockout condition.
CAUTION
!
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in unit damage
and/or improper equipment operation.
Freeze sensor will not guard against the loss of water. A
flow switch is recommended to prevent the unit from
running if water flow is lost or reduced.
SINTELLIGENT RESET: If a fault condition is initiated, the 5
minute delay on break time period is initiated and the unit will
restart after these delays expire. During this period the fault LED
will indicate the cause of the fault. If the fault condition still exists
or occurs 2 or 4 times (depending on 2 or 4 setting for Lockout dip
switch) before 60 minutes, the unit will go into a hard lockout and
requires a manual lockout reset.
A single condensate overflow fault will cause the unit to go into a
hard lockout immediately, and will require a manual lockoutreset.
SLOCKOUT RESET: A hard lockout can be reset by turning the
unit thermostat off and then back on when the “RESET” dip
switch is set to “Y” or by shutting off unit power at the circuit
breaker when the “RESET” dip switch is set to “R”.
NOTES: The blower motor will remain active during a lockout
condition.
SEQUENCE OF OPERATION
Cooling Mode
Energizing the “O” terminal energizes the unit reversing valve thus
placing the unit into cooling mode. The fan motor starts when the
“G” terminal is energized.
When the thermostat calls for cooling (Y), the loop pump or
solenoid valve, if present, is energized and compressor will start.
Once the thermostat is satisfied, the compressor shuts down
accordingly and the fan ramps down to either FAN ONLY mode or
OFF over a span of 30 seconds (ECM Motors).
NOTE: A fault condition initiating a lockout will de--energize the
compressor.
Heating Mode
Heating operates in the same manner as cooling, but with the
reversing valve de--energized. The compressor will run until the
desired setpoint temperature on the thermostat is achieved.
Once the thermostat is satisfied, the compressor shuts down and the
fan ramps down in either FAN ONLY mode or turns off over a
span of 30 seconds.

10
CC
LOCKOUT CAN BE SET
TO 4 VIA DIP SWITCH
BLINK CODE ON STATUS LED
SOFT LOCKOUT
RECORD ALARM
START COUNTER (IF APPLICABLE)
CC OUTPUT = ON
NO
YES
LPC
=CLOSED
FRZ >TEMP
LIMIT
Y1 = ON
TIME > 30
SEC
CON > 0
POWER/ SWITCHES/SENSOR
STATUS CHECK
START
TIMER
NO
YES
NO
YES
NO
YES
T > ASC OR
RS SEC
YES
NO
TIME > 120
SEC
START
TIMER
NO
YES
NO
YES
START
ANTI SHORT CYCLE
INITIAL
POWER UP
YES
NO
START
RANDOM START UP
START
COUNTER
NEEDED?
YES
COUNT = 2
OR
COUNT = 4
BLINK CODE ON STATUS LED
DISPLAY OUTPUT = PULSE
ALR OUTPUT = ON/PULSE
NO
YES
HARD
LOCKOUT?
CC OUTPUT = OFF
V > 18VAC
NO
YES YES
NO
BLINK CODE
ON STATUS LED
NO
RESET ON
Y
CLEAR FAULTS
R = 24VAC
NO
YES NO
YES
NO
YES
HPC =
CLOSED
RESET ON R
A14129
Fig. 8 -- UPM Sequence of Operation (SOO) Flow Chart

11
A14175
Fig. 9 -- Heat Recovery Package
HEAT RECOVERY PACKAGE
The Heat Recovery package is a factory mounted option. It
consists of a forced pumped unit that employs a circulating pump
to move water through a double wall/ vented heat exchanger and
returns the heated water to the water tank. The water is heated by
superheated refrigerant discharge gas from the compressor. This
waste heat of the cooling mode, captured by the heat recovery,
increases the capacity and efficiency of the heat pump unit. If the
air temperature is uncomfortable coming from the air vents in
heating mode the heat recovery may need to be turned off. In
heating mode, the heat recovery captures heat that would normally
be used for space heating.
CAUTION
!
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in unit damage
and/or improper equipment operation.
If heat recovery unit is installed in an area where freezing
may occur, the unit must be drained during winter months
to prevent heat exchanger damage. Heat exchanger
ruptures that occur due to freezing will void the heat
recovery package warranty along with the heat pump
warranty.
Water Tank Preparation
1. Turn off electrical or fuel supply to the water heater.
2. Attach garden hose to water tank drain connection and run
other end of hose out doors or to an open drain.
3. Close cold water inlet valve to water heater tank.
4. Drain tank by opening drain valve on the bottom of the
tank, then open pressure relief valve or hot water faucet.
5. Once drained the tank should be flushed with cold water
until the water leaving the drain hose is clear and free of
sediment.
6. Close all valves and remove the drain hose.
7. Install HR water piping.
HR Water Piping
All hot water piping MUST be a minimum of 3/8” O.D. copper
tube to a maximum distance of 15 feet. For distances beyond 15
feet, but not exceeding 60 feet, use 1/2” copper tube. Separately
insulate all exposed surface of both connecting water lines with
3/8” wall closed cell insulation. Install isolation valves on supply
and return to the heat recovery. (See Fig. 9)
Water Tank Refill
1. Open the cold water supply to the tank.
2. Open a hot water faucet to vent air from the system until
water flows from the faucet, then close.
3. Depress the hot water tank pressure relief valve handle to
ensure there is no air remaining in the tank.
4. Carefully inspect all plumbing for water leaks. Correct as
required.
5. Purge all air from HRP by depressing the Schrader valve on
the HR unit. Allow all air to bleed out until water appears at
the valve.
IMPORTANT: All piping from HRP to domestic water tank
must be copper or any metal of stronger alloy.
6. Before restoring the power or fuel supply to the water
heater, adjust the temperature setting on the tank
thermostat(s) to ensure maximum utilization of heat
available from the refrigeration system and to conserve the
most energy.
On tanks with thermostats and both upper and lower ele-
ments, the lower element should be turned down to 100_F,
while the upper element should be adjusted to 120_F. De-
pending upon the specific needs of the customer, you may
need to adjust the upper element differently.
On tanks with a single thermostat, lower the thermostat
setting to 120_F or the “LOW” position.
7. After thermostat adjustments are completed, replace access
cover and restore electrical or fuel supply to water heater.

12
INITIAL START--UP
CAUTION
!
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in unit damage
and/or improper equipment operation.
Make sure all valves in heat recovery water piping system
are open. NEVER OPERATE HR PUMP DRY.
1. Turn on the heat pump. The HR pump should not run if the
compressor is not running.
2. Turn HR switch to the “ON” position. The pump will
operate if entering water temperature to HR is below 120_F.
3. The temperature difference between the water entering and
leaving the heat recovery should be 5_Fto15_F.
4. Allow the unit to operate for 20 to 30 minutes to ensure it is
functioning properly. The pump should shut off when the
water temperature entering the heat recovery reaches 120_F.
SYSTEM CHECKOUT
After completing the installation, and before energizing the unit,
the following system checks should be made:
1. Verify that the supply voltage to the heat pump is in accor-
dance with the nameplate ratings.
2. Make sure that all electrical connections are tight and se-
cure.
3. Check the electrical fusing and wiring for the correct size.
!WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Ensure cabinet and electrical box are properly grounded
4. Verify that the low voltage wiring between the thermostat
and the unit is correct.
5. Verify that the water piping is complete and correct.
6. Check that the water flow is correct, and adjust if necessary.
7. Check the blower for free rotation, and that it is secured to
the shaft.
8. Verify that vibration isolation has been provided.
9. Verify that the unit is serviceable. Be certain that all access
panels are secured in place.
UNIT START--UP
NOTE: A unit Start--Up checklist is included in the unit packet.
Complete the Checklist and place it in the customer file at your
dealership.
1. Open all water valves to the full open position.
2. Turn on line power to the heat pump.
3. Set the mode on the system control to “HEAT”. Adjust the
aquastat to its lowest setting.
4. Slowly increase the aquastat set temperature until the
compressor turns on.
5. After a few minutes, check for warm delivery temperature
on the load side piping exiting the unit.
6. Verify water flow.
7. Check for leaks.
8. Check for excessive noise and vibration.
9. Check the temperature of EWT and LWT. Compare to
tables in Product Data sheets to confirm unit is meeting
heating specification. If unit is not achieving performance
listed, check refrigerant pressures and compare them to table
on page 13 before proceeding.
10. Once heating performance is verified, place system control
to “COOL” mode. Adjust aquastat to its highest setting.
11. Slowly decrease the aquastat setting until the compressor
turns on.
12. After a few minutes, check for cool delivery temperature on
the load side piping exiting the unit.
13. Check the temperature of EWT and LWT. Compare to
tables in Product Data sheets to confirm unit is meeting
cooling specification. If unit is not achieving performance
listed, check refrigerant pressures and compare them to table
on page 13 before proceeding.
14. If unit fails to operate properly, refer to the Troubleshooting
section beginning on page 14.
15. Once proper cooling and heating performance has been
confirmed, adjust control to desired setting.

13
CHILLER MODE
Cooling Mode Operating Pressures (PSIG) (R --- 410A units --- full load)
Entering Fluid
Te m p ° F
Entering Source Condenser Temperature ° F
75° F 85° F 95° F
Suction
Pressure
Discharge
Pressure Suction Pressure Discharge Pressure Suction Pressure Discharge Pressure
65 99---116 290---320 107---123 325---358 107---123 370---400
55 91---107 265---311 91---107 303---350 99---116 370 ---400
45 76---91 265---311 76---91 295---345 83---99 358 ---390
BOILER MODE
Heating Mode operating Pressures (PSIG) (R --- 410A units --- full load)
Entering Load ° F Entering Source Suction Pressure Discharge Pressure
70
40 68---83 255 ---290
60 99---116 270 ---305
80 130---145 290 ---325
90
40 76---91 350 ---380
60 99---116 358 ---390
80 130---165 370 ---400
110
40 76---91 455 ---480
60 99---116 470 ---500
80 139---165 480 ---575
NOTE: Ratings are based on water flow rates stated in specification sheets. 2.4 GPM/ton on evaporator side and 10° F T on condenser side when in the chiller
mode. Boiler mode conditions are 2.4 GPM/ton on the source side and 10° F T on load side. Values are typical and may vary between models.

14
TROUBLESHOOTING
Problem Possible Cause C hecks and Corrections
Compressor
does not
operate
Power Supply Off Apply power, close disconnect
Blown Fuse Replace fuse or reset circuit breaker. Check for correct fuses
Broken or loose
wires
Replace or tighten the wires. Check for loose or broken wires at compressor,
capacitor, or contactor.
Voltage supply low If voltage is below minimum voltage specified on unit data plate, contact
local power company.
Controller Set controller to “COOL” and lowest temperature setting, the unit should
run in the cooling mode (reversing valve energized). Set unit to “HEAT”
and the highest temperature setting, the unit should run in the heating
mode. If the compressor does not run in all cases, the controller could
be miswired or faulty.To ensure miswired or faulty thermostat verify 24
volts is available on the unit section low voltage terminal strip between
“R” and “C”, “Y” and “C”, and “O” and “C”. Replace the controller if
defective.
Safety controls Reset the controller to “OFF”. After a few minutes turn to “COOL” or
“HEAT”. If the compressor runs, unit was off on one of the safety con
trols. (See problem for possible causes)
Compressor
overload open
If the compressor is cool and the overload will not reset, replace com
pressor.
Compressor motor
grounded
Internal winding grounded to the compressor shell. Replace compressor
burnout, install suction filter dryer.
Compressor
windings open
After compressor has cooled, check continuity of the compressor
windings. If the windings are open, replace the compressor.
Unit off on
high pressure
switch
Discharge pressure
too high
In “COOLING” mode: SOURCE COIL - Lack of or inadequate water flow.
Entering water temperature too warm. Scaled or plugged condenser.
In “HEATING” mode: LOAD COIL - Lack of or inadequate water flow.
Entering water temperature too warm. Scaled or plugged load coil.
Refrigerant charge The unit is overcharged with refrigerant. Reclaim refrigerant, evacuate
and recharge with factory recommended charge.
High pressure
switch
Check for defective or improperly calibrated high pressure switch.
Unit off on low
pressure
switch
Suction pressure
too low
In “COOLING” mode: LOAD COIL - Lack of or inadequate fluid flow.
Entering water temperature too cold. Scaled or plugged load coil.
In “HEATING” mode: SOURCE COIL - Lack of or inadequate fluid flow.
Entering water temperature too cold. Scaled or plugged source coil.
Refrigerant charge The unit is low on refrigerant. Check for refrigerant leak, repair, evacu -
ate and recharge with factory recommended charge.
Low pressure
switch
Check for defective or improperly calibrated low-pressure switch.

15
TROUBLESHOOTING (CONT.)
Unit short
cycles
Unit oversized Recalculate heating and or cooling loads.
Wiring and controls Loose connections in the wiring or a defective compressor contactor.
Fluid Volume
Insufficient
cooling or
heating
Unit undersized Recalculate heating and or cooling loads. If excessive, possibly adding
insulation and shading will rectify the problem. Unit may be short of
refrigerant.
Refrigerant charge Unit may be short on refrigerant charge.
Compressor Check for defective compressor. If discharge is too low and suction
pressure is too high, compressor is not pumping properly. Replace
compressor.
Reversing valve Defective reversing valve creating bypass of refrigerant from discharge
to suction side of compressor. Replace reversing valve.
Operating pres
sures
Compare unit operating pressures to the pressure / temperature chart
for the unit.
TXV Check TXV for possible restriction or defect. Replace if necessary
Moisture, noncon
densables
The refrigerant system may be contaminated with moisture or noncon
densables. Reclaim refrigerant, evacuate and recharge with factory
recommended charge. Note: a liquid line dryer may be required
UPM board
trouble
shooting
Compressor will
not run, no fault
blink code
Is Green
Power LED
light on and
no Red
Blink Code?
Yes
No
Is there
power to
the “Y” Call
(C-Y)?
No
Yes
Check
thermostat
settings and
configurations
for heat
pumps, and
wiring
Is there 24 V
power from
C to CC?
No
Yes UPM Board
is Good
Check for Red
Blink Code.
If Red Blink
Code is not
present, replace
UPM Board
- Check all
power supplies
- Check all
safety switches
Inadequate load side fluid volume.

16
8733927110 (04/14)
Copyright 2014 CAC/BDP Corp. S7310 W. Morris St. SIndianapolis, IN 46231 Edition Date: 04/14
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
C a t a l o g N o : I M --- G W --- 0 1
Replaces: New