Chiltrix CX30FC User manual

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DC INVERTER
AIR TO WATER HEAT PUMP
AC series Heating & Cooling series CX30
Installation and Operation Manual
Version 1.7

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Table of Contents
Safety Precautions................................................................................................................... 3
Components ............................................................................................................................ 4
Hydronic piping and design guide ........................................................................................... 5
Heat Pump Installation.......................................................................................................... 14
Electrical Connections and Parts Locator.............................................................................. 16
Valves G1, G2, G3 ................................................................................................................. 22
Master –Slave Wiring ........................................................................................................... 28
2nd AC Switch Funtion............................................................................................................ 29
Second Heat Source or Assistant Electric Heater.................................................................. 30
System Filling ........................................................................................................................ 31
Air Purging ............................................................................................................................ 32
Wired Control Panel .............................................................................................................. 33
Initial Temperature Settings.................................................................................................. 36
Parameter Checking and Setting........................................................................................... 38
Parameter Checking Only...................................................................................................... 41
Controller Communications .................................................................................................. 43
Fuction Selection switch........................................................................................................ 43
Error Codes............................................................................................................................ 44
Commissioning and Initial Test Run ...................................................................................... 49

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Safety Precautions
NOTE: It is required to read the Safety precautions in detail before operation. The
precautions listed below are very important for safety, please follow all safety
precautions.
General
Make sure that the ground wire in the building is securely connected to earth.
Wiring tasks should be carried out by qualified electricians only, in addition, they should check
the safety conditions of power utilization, for example, verify that the line capacity is adequate,
and the power cable isn’t damaged.
Users must not install, repair or relocate the unit. Improper procedures might lead to accidents
e.g. personal injury caused by fire, electrical shock or unit's falling off its base, and water leaking
into the machine. Please contact a professional service department if problems arise.
The unit shall not be installed at a spot with the potential hazard of leaking flammable gas. If
gas is leaking near the machine, there might be the risk of explosion.
Make sure that the foundation of the unit is stable. If the foundation is unstable, the outdoor
unit may come loose from its base and cause injury.
Make sure that the GFCI installed at the service panel is working properly to avoid shock or
fires.
If any abnormity occurs in the unit (such as a burning smell is noticed inside the unit), cut off
the power supply immediately, and contact a professional service department.
Please observe the follow items when cleaning the unit. Before cleaning, shut off the electric
supply of the unit first to avoid injuries caused by the fan operation.
Do not rinse the unit with water because the rinsed unit may cause electric shock.
Make sure to shut off the electric supply before maintaining the unit.
Please do not insert fingers or sticks into air outlet or air inlet.
Transporting and storage
The machine must be transported and stored vertically.

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Components

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Hydronic Piping and Design Guide
Installation Methods Heating and Cooling (Heating Shown)
Note: Primary Secondary Piping is NOT supported on this chiller.
A buffer tank must be used for floor heating.
Installation Notes:
1. Minimum pipe size should be no less than 1”, CPVC or Oxygen Barrier PEX, reverse return piping is
preferable to eliminate balancing valves or pressure regulators. The installer should calculate the
pipe and fitting resistance to determine the head pressure. See the examples on the following pages,
maximum water flow for the CX30 is 6 gpm, design flow is 4.8 gpm. If necessary, a second PWM
pump may be added to the loop and controlled by the CX30. The second water pump connections
can be found in the wiring diagram starting on page 19.
2. The loop example above is designed with wild coils. Water flows through the coil at all times, if there
is a call for heating or cooling the FCU controls will turn the fan on. Optionally, a 2 way valve may be
installed at the input tee to prevent any flow through the coil and the FCU will control it.
3. An air discharge valve should be installed at the top of the circulation system if possible for easy air
discharge. As an alternative an automatic/manual air vent can be used inline before the pumps.
4. Flow meters with restrictor valves, Watts Flow Guard for example, may be used when reverse return
piping is not an option.
5. Always install a water filter or wye strainer on the supply pipe to the chiller to prevent blockage of
the heat exchanger.

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Piping Examples: Stacked Chillers
With a Buffer Tank and Second Non-PWM Pump
A buffer tank should be used when the loop volume is less than 10 gallons to keep the compressor from
cycling.

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Using a Buffer Tank
Primary / secondary piping is not supported, when connecting to a floor heating loop always use a buffer
tank.
The pump in the buffer tank drawing is controlled by the customer’s floor loop controls. To calculate the size
of the buffer tank please use the following formula.
If the heat pump capacity is 8000 watts we use 8000/1.16/30 = 230 L/h. This means that an 8000W heat
pump can increase 230 liters of 30°C water in one hour. 1.16 is the water transfer factor, and 30 is the
temperature rise of the water.
4 is the heat pump hysteresis for water temperature change. It means after the compressor stops, the
buffer tank can keep the returned water temperature change difference within heat pump hysteresis of 4c.
12 is 5 minutes (60/12 minutes). It means after the compressor stops, the buffer tank can keep the returned
water temp change difference within heat pump hysteresis 4c for 5 minutes. This allows the compressor to
stop for 5 minutes and save energy.
This formula is for the minimum size buffer tank. You can always add tank volume.
*Note –Cooling set points refer to the CX30 return water temperature, the system is managed by a 9F ΔT
controller and is measured in C (5C). Default setting for cooling should be 12C, therefore the wired
controller setting would be 17C. This will create a 54F leaving water temperature which is the standard
setting.

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Example of head calculation
To calculate the head pressure for the correct water flow, the pipe length must be measured and all fittings
counted. It is advisable to use flexible red oxygen barrier pex piping to avoid as many elbows as possible. All
fittings have an equivalent length of pipe already calculated, available on the next page under PEX Fittings
Pressure Drops. Add up the equivalent length of pipe for the fittings, 13.8’ + 11.7’ =25.5’. Then, add this to
the actual pipe, 25.5’+115” = 140.5’ of 1” pipe. Once you know the total length of pipe, use a (1” PEX 10%
Glycol, feet of head per 100 feet of tubing chart), to get the head for 1’ of pipe, at 40°F and 4.76 GPM. This
comes to (.0500) feet of head per foot. 140.5 x .0500=7.02 ft. of head. Add up all head calculations, 7.02 +
2.3 + 8.35 + 8.3 = 23.67 ft. of head. Next we will look at the Wilo Pump curve on page 13. Maximum head at
4.76 GPM is 25 ft.
If using the CX30SE (Free Cooling option) the CX30SE’s pressure drop is 4.5 PSI when active.

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Notes:
The example loop above has a volume of 4.5 gallons. The internal thermal expansion tank is 2 liters or .52
Gallons. An additional thermal expansion tank may be required for larger loops. There are many thermal
expansion calculators on the internet, the following is an example. http://westank.com/calculator/
Minimum loop pressure is 14.5 psi, maximum pressure is 43.5 psi, and ideal pressure is 29 psi. The Lowest
temperature is 44°F, the highest temperature is 131°F, the Initial pressure is 14.5 psi, and the final pressure
is 29 psi.
An air scoop should be installed above the expansion tank to remove any air in the circulation loop.
Always install a water filter or wye strainer on the supply pipe to the chiller to prevent blockage of the heat
exchanger.
PEX PIPE VOLUME
WYE STRAINER
PEX Fittings Pressure Drops

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Freeze protection

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NOTE:
When using CPVC piping it is highly recommended that you do not exceed a 25% glycol
to water ratio. Environmental Stress Cracking, also referred to as ESC, is a mechanism by
which an organic chemical (possibly a weak solvent or even a non-solvent) achieves an
extremely localized weakening at the surface of the material which permits propagation
of a crack. Environmental stress cracking generally presents itself as a crack with glossy
fracture surfaces that occur in regions of high mechanical stresses. ESC is dependent on
both the presence of the chemical and a significant level of mechanical stress.
Therefore, it may occur in some installations or certain parts of a system, while the
system performs well in other areas. Many problems can, as a result, be avoided by
proper design and installation. Potential ESC agents for CPVC include natural or
synthetic ester oils, nonionic surfactants, alcohols and glycols.

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Internal CX30 WILO Pump
PWM pcb LED Error Codes (3 digit display)
Normally the 3 digit display shows the pump speed percentage in addition to
temperatures and sensor errors.
E1 is a Th1 sensor error, it is open or shorted.
E2 is a Th2 sensor error, it is open or shorted.

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Pipe Insulation
All loop piping must be insulated per local and national mechanical codes.
For design tips and a thickness calculator please visit http://www.armacell.us/knowledge-center/

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Heat Pump Installation
Installation position
Note: Installation must be carried out by professional personnel.
1. The recommended mounting pad should be 1” to 1 ½” above ground level.
2. A drainage path or other facilities should be arranged around the outdoor unit to avoid
flooding the outdoor unit.
3. To install the unit on a balcony or on top of a building, the installation site must meet the
allowable bearing capacity of the building structure without affecting the structural safety.
4. Ensure the unit is well ventilated; the direction of air exhaust should be kept away from the
windows of neighboring buildings. Adequate service clearance should be kept around the unit.
5. The unit should not be installed in places accompanied with oil, inflammable gases; corrosive
components e.g. sulfur compound, or high-frequency equipment.
6. The unit must be installed upon a reliable machine base or framework. Weight capacity of
framework should be 3 times of the outdoor unit’s body weight, and safeguard measures should be
taken to avoid a malfunction of the fasteners.
7. The unit must have extra precautions taken when it is installed at sites with hurricane/ earthquake
hazards. Consult the appropriate professional to determine the needed requirements
8. Midair or suspended installation should be avoided as much as possible, falling machines may result
in personal injury and property damage.

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Clearances (unit: mm) 200mm = 8” , 350mm =14 “, 400=16”, 500=20”,1000=40”

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Electric connection
General
Note!
Electrical installation and service must be carried out under the supervision of a qualified electrician.
Electrical installation and wiring must be carried out in accordance with the NEC.
The heat pump must not be connected without the permission of the electricity supplier and must be
connected under the supervision of a qualified electrician. Wires, spare parts and materials etc. must
satisfy the relevant standards issued by the host country or region.
The heat pump does not include an AC disconnect or switch on the incoming electrical supply. The power
supply cable must be connected to a circuit-breaker with at least a 3 mm breaking gap. Incoming supply
must comply with the technical requirements, with a frame ground wire (neutral is not used), via a
distribution box with breakers.
Voltage range is 208-240vac
Maximum current draw is 13 amps, minimum wire size is 12 AWG, minimum breaker size is 20 AMP.
Main terminal block inside electronics box

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Electric Connections and Component Locator
Using Internal PWM Pump
System layout with external flow switch

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System Layout with internal flow switch and MODBUS
If the Wilo RS 25/7.5 PWM pump does not have the required pressure at the targeted flow rate, a second
Wilo RS 25/7.5 may be added to increase the total pump pressure. This will double the head pressure at
the targeted flow rate. Wiring details are on the following pages.
Contact us for more information on booster pumps.

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Second PWM Pump Wiring
Use proper splicing connectors to connect the second PWM pump in parallel to the internal PWM pump.

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When adding a second PWM pump (Wilo RS25/7.5), all wiring is done in parallel. Up to 4 PWM pumps can
be wired to the PWM controller. They can be spliced into the wiring harness inside the refrigeration
compartment.