ClimateMaster HE Series Guide

HE/VE Series
Installation, Operation, &
Maintenance Instructions
Horizontal & Vertical Series
Water Source Heat Pumps

Page 2
TABLE OF CONTENTS Page
General Information 3
Inspection 3
Introduction 3
Storage 3
Unit Protection 3
Pre-Installation 3
Horizontal Units Location and Access 4
Vertical Units location and Access 5
Installation 6
Installation of Supply and Return Piping 6
Condensate Piping 6
Hanging and Mounting a Horizontal Unit 7
Sound Attenuation for Horizontal Units 7
Installing a Vertical Unit 8
Sound Attenuation for Vertical Units 8
Electrical Wiring 8
Operating Limits 9
Starting Conditions 9
Closed Loop Earth Coupled Applications 10
Introduction 10
Pre-Installation 10
Horizontal Loop Applications 10
Vertical Loop Applications 10
Building Entry 11
Loop Testing 12
Flushing and Purging 12
Start-Up Preparation 13
System Cleaning & Flushing 13
Optional Hot Water Generator 13
System Checkout 14
Unit Start-Up 15
Maintenance 16

Page 3
Inspection
Upon receipt of shipment at the job site, carefully check
the shipment against the bill of lading. Make sure all units
have been received. Verify that hanger brackets are
located inside the fan compartment of Horizontal Units.
Inspect the carton or crating of each unit and inspect each
unit for damage. Repackage unit after verifying that all
components are included. Assure that the carrier makes
proper notation of any shortages or damage on all copies
of the freight bill and that he completes a Carrier
Inspection Report. Concealed damage not discovered
during unloading must be reported to the carrier within 15
days of receipt of shipment. NOTE: It is the
responsibility of the purchaser to file all necessary
claims with the carrier. Notify the ClimateMaster
Traffic Department of all damage within fifteen (15)
days of shipment.
Introduction
This Installation, Operation, and Maintenance Manual is
for ClimateMaster low temperature extended range
Horizontal and Vertical Heat Pumps (HE,VE),
ClimateMaster Horizontal Water Source Heat Pump (HE)
units are designed for installation above a false ceiling,
ceiling plenum, crawl space, or basement. Vertical (VE)
units are typically installed in a floor level closet or in a
small mechanical room. The installation site chosen for
these units must allow adequate clearance for
maintenance and servicing of the unit without its removal
from the installation location.
Electrical data is provided in the Installation section of
this manual. Refer to project submittal drawings for
specific unit technical data and wiring diagrams.
Storage
Do not store or install Horizontal or Vertical units in
corrosive environments or in locations subject to
temperature or humidity extremes (e.g., attics,
garages, rooftops, etc.). Corrosive conditions and high
temperature or humidity can significantly reduce
performance, reliability and service life. Always move
units in an upright position. Tilting units on their sides
may cause equipment damage.
Upon the arrival of equipment at the job site,
immediately store units in their shipping cartons in a
clean, dry area. Store units in an upright position at all
times. Stack Horizontal units a maximum of 3 units high.
Stack vertical units a maximum of 2 units high. Do not
remove equipment from shipping cartons until
equipment is required for installation.
GENERAL INFORMATION
Unit Protection
Cover Horizontal and Vertical units on the job site with
either shipping cartons, vinyl film, or an equivalent
protective covering. Cap the open ends of pipes stored on
the job site. In areas where painting, plastering, or the
spraying of fireproof material has not been completed, all
due precautions must be taken to avoid physical damage
to the units and contamination by foreign material.
Physical damage and contamination may prevent proper
start-up and may result in costly equipment clean-up.
Examine all pipes, fittings, and valves before installing
any of the system components. Remove any dirt found on
these components.
Pre-Installation
Installation, Operation, and Maintenance instructions are
provided with each unit. Before unit start-up, read all
manuals and become familiar with the unit and its
operation. Thoroughly check out the system before
operation.
Prepare Horizontal and Vertical units for installation as
follows:
1. Compare the electrical data on the unit nameplate
with ordering and shipping information to verify that
the correct unit has been shipped.
2. Keep the unit covered with the shipping carton until
installation is complete and all plastering, painting,
etc. is finished.
3. Verify that refrigerant tubing is free of kinks or dents
and that it does not touch other unit components.
4. Inspect all electrical connections. Connections must
be clean and tight at the terminals.
5. Loosen compressor bolts on units equipped with
external spring vibration isolation until the
compressor rides freely on the springs. Remove
shipping restraints.
To avoid equipment damage, do not use these units as
a source of heating or cooling during the construction
process. The mechanical components and filters used
in these units quickly become clogged with
construction dirt and debris which may cause system
damage.
To avoid the release of refrigerant into the
atmosphere, the refrigerant circuit of this unit must
only be serviced by technicians which meet local, state
and federal proficiency requirements.
▲CAUTION
!

Page 4
All refrigerant discharged from this unit must be
recovered without exception. Technicians must follow
industry accepted guidelines and all local, state and
federal statutes for the recovery and disposal of
refrigerants.
When a compressor is removed from this unit, system
refrigerant circuit oil will remain in the compressor.
To avoid leakage of compressor oil, the refrigerant
lines of the compressor must be sealed after it is
removed.
Horizontal Units Location and Access
Horizontal Units are typically installed above a false
ceiling or in a ceiling plenum. Refer to Figure 1 below
for an illustration of a typical installation. Install units
with adequate clearance to allow maintenance and
servicing without removal of the unit from the ceiling.
Conform to the following guidelines when selecting unit
location.
1. Provide a hinged access door in concealed-spline or
plaster ceilings. Provide removable ceiling tiles in T-
bar or lay-in ceilings. Size the access opening to
accommodate the service technician during the
removal and replacement of the compressor and the
removal and installation of the unit.
2. Provide access to hanger brackets, water valves, and
fittings. Provide screwdriver clearance to access
panels, discharge collars, and all electrical
connections.
Figure 1 - Typical Horizontal Installation
Stop Valves
(By others)
Balance/ Stop Valves
(By others)
Electrical
(By others)
High Pressure
Flexible Hose Kit
(Optional)
Condensate Trap
(By others)
Filters
Bar Joist
Controls
(By others)
Heat Pump
Portable Lifting Jack
with Manual Crank
Ceiling
Access
Panels
System Water In
System Water Out
Figure 2 - Unit supported by Portable Jack
during instllation or replacement

Page 5
3. Provide a duct slot for filter replacement if a return
duct is used.
4. Do not obstruct the space beneath the unit with
piping, electrical cables, and other items.
5. Refer to Figure 2. Use a manual portable jack to lift
the unit and to support the weight of the unit during
installation and servicing.
Vertical Units Location and Access
Vertical units are typically installed in a floor level closet
or in a small mechanical room. Refer to Figure 3 for an
illustration of a typical installation. Install units with
adequate clearance to allow maintenance and servicing.
Conform to the following guidelines when selecting unit
location.
1. Provide adequate clearance for filter replacement
and drain pan cleaning. Do not block filter access
with piping, conduit, or other materials.
2. Provide access for fan and fan motor maintenance
and for servicing the compressors and coils without
removal of the unit.
3. Provide an unobstructed path to the unit within the
closet or mechanical room to enable removal of the
unit if necessary.
4. Provide access to water valves and fittings, and
screwdriver access to the unit side panels, discharge
collar, and all electrical connections.
Figure 3 - Vertical Installation
Note: A minimum of 8"
of clearance must be
provided between unit
and remote filter/grille
when no return air duct
is used
Condensate Trap
(By Others)
Note: Adequate
clearance must be
provided on all
sides of unit when
remote filter/grille
is not used
Balance/Stop
Valve (by others)
Controls
(By others)
Electrical
(By others)
High Pressure Flexible
Hose Kit (Optional)
Condensate
System Water in
Remote Filter/
Grille (by others)
System
Water Out

Page 6
The installation of Horizontal and Vertical Water Source
Heat Pump units and all associated components, parts
and accessories that make up the installation shall be in
accordance with the regulations of ALL Authorities
having jurisdiction and MUST conform to all applicable
Codes. It is the responsibility of the Installing Contractor
to determine and comply with ALL applicable Codes and
Regulations.
Installation of Supply and Return Piping
Follow these piping guidelines.
Piping must comply with all applicable codes.
1. Install a drain valve at the base of each supply and
return riser to facilitate system flushing.
2. Install shut-off / balancing valves and unions at each
unit to permit unit removal for servicing.
3. Place strainers at the inlet of each system circulating
pump.
4. Select the proper hose length to allow slack between
connection points. Hoses may vary in length by +2%
to -4% under pressure.
5. Refer to Table 3. Do not exceed the minimum bend
radius for the hose selected. Exceeding the minimum
bend radius may cause the hose to collapse which
reduces water flow rate. Install an angle adapter to
avoid sharp bends in the hose when the radius falls
below the required minimum.
INSTALLATION
Do not bend or kink supply lines or hoses.
Figure 4- Supply/Return Hose Kit
Minimum Bend Radius
2-1/2
4
5-1/2
6-3/4
Hose in Inches
1/2
3/4
1
1-1/4
Table 1- Metal Hose Minimum Bend Radii
Insulation is not required on loop water piping except
where the piping runs through unheated areas or outside
the building. Insulation is required if loop water
temperature drops below the dew point.
Pipe joint compound is not necessary when Teflon
threaded tape is pre-applied to hose assemblies or when
flared-end connections are used. If pipe joint compound
is preferred, use compound only in small amounts on the
male pipe threads of the fitting adapters. Prevent sealant
from reaching the flared surfaces of the joint.
NOTE: When anti-freeze is used in the loop, assure
that it is compatible with Teflon tape or pipe joint
compound used.
Corrosive system water requires corrosion-resistant
fittings and hoses and may require water treatment.
Condensate Piping
Units are typically installed directly above each other on
successive floors with condensate drains located near the
units.
Connect the unit condensate drain connection to the
building condensate drain with a flexible, non-pressure-
rated 3/4 inch ID plastic hose. Ensure that the hose is
without kinks to maintain an unobstructed flow of
condensate from the unit to the drain.
The horizontal run of a condensate hose is usually too short
to cause drainage problems; however, the horizontal run of
the condensate line should be pitched at least 1 inch for
every 10 feet of run in the direction of flow. Avoid low
points and unpitched piping since dirt collects in low or
level areas and may cause stoppage and overflow.
Install a condensate trap at each unit with the top of the trap
positioned below the unit condensate drain connection.
Ensure that the trap is filled with water before operating the
unit to avoid condensate pan overflow at initial start-up.
Optional pressure-rated hose assemblies designed
specifically for use with ClimateMaster units are
available. Similar hoses can be obtained from alternate
suppliers. Supply and return hoses are fitted with swivel-
joint fittings at one end to prevent kinking during
installation.
Refer to Figure 4 for an illustration of a Supply/Return
Hose Kit. Male adapters secure hose assemblies to the
unit and risers. Install hose assemblies properly and
check them regularly to avoid system failure, reduced
service life, and possible damage to surrounding
furniture and carpets.
Maximum allowable torque for brass fittings is 30 foot-
pounds. If a torque wrench is not available, tighten
finger-tight plus one quarter turn. Tighten steel fittings as
necessary.
Rib Crimped
Length
(2 Foot Length Standard)
Swivel
Brass
Fitting
Brass
Fitting
MPT
▲CAUTION!
▲CAUTION
!

Page 7
Figure 5 illustrates a typical trap and vent used with
HE/VE Heat Pumps. Design the length of the trap
(water-seal) based upon the amount of positive or
Follow clearance guidelines described in the Location
and Access section of this manual. Provide adequate
clearance within the plenum for filter removal in all four
directions. When the unit is installed with a return air
plenum, provide a slot to remove the filter toward the
front of the unit.
To avoid condensate overflow, Horizontal Units must be
hung pitched 1/4" to 1/2" toward the condensate drain
connection to insure proper drainage.
negative pressure on the drain pan. As a rule, 1" of trap is
required for each inch of negative pressure on the unit.
Each unit must be installed with its own, individual trap
and connection to the condensate line (main) or riser.
Provide a means to flush or blow-out the condensate
drain line. Do not install units with a common trap and/
or vent.
Install a vent in the condensate line of any application
which may allow dirt or air to collect in the line. Always
vent when the application requires a long, horizontal run,
when some sagging in the condensate line may be
anticipated (as in a long line of plastic pipe), or when
"double trapping" may occur. Also vent when large units
are working against higher external static pressure that
other units connected to the same condensate main since
this may cause poor drainage for all units on the line.
When a vent is installed in the condensate line, it must be
located after the trap in the direction of condensate flow.
Hanging or Mounting a Horizontal Unit
Horizontal heat pumps are typically suspended above a
ceiling or within a soffit using field-supplied, threaded
rods sized to support the weight of the unit.
A mounting kit including four (4) mounting brackets and
four (4) vibration isolators is shipped inside the blower
compartment of each unit.
Refer to Figure 6. Attach brackets and isolators to the
bottom corners of the unit. Use four (4) field-supplied
threaded rods to suspend the unit. Hang the unit clear of
the floor slab above and support the unit by the mounting
bracket assemblies only. DO NOT attach the unit flush
with the floor slab above.
Figure 5 - Condensate Drain
Figure 6 - Hanger and Vibration Isolation Kit
Sound Attenuation for Horizontal Units
Sound minimization is achieved by correct placement of
the unit. Place the units so that principal sound emission
is ducted outside the occupied, sound sensitive space.
Note: If a fire wall is penetrated, a fire damper may be
required by local codes.
NOTES: 1. Kits shipped unassembled and bulk-packed (4
hanger assemblies per unit) 2. Total head space required
= unit height + 1/2 inch + condensate trapping 3. See
unit dimensional drawings for further information.
PITCH DOWN TO DRAIN
1/4" PER FOOT
2”
1”
VENT
When Necessary
UNIT
RECOMMENDED TRAP DIMENSION
Slot used for
installation of
hangers with 096
and 120 models
only. Screws used
must be 1/2" or less
in length.
38" Threaded
Rod (By Others)
Washer &
3/8" Hex Nut
(By Others)
Hanger
Vibration
Isolator

Page 8
WARNING
Installing a Vertical Unit
Vertical units are typically installed on the floor or on
shelves designed to support the weight of the unit. Install
the unit on a piece of rubber, neoprene or other mounting
pad material for sound isolation. The pad should be at
least 3/8" to 1/2" in thickness. Extend the pad beyond all
four edges of unit.
Sound Attenuation for Vertical Units
Sound minimization is achieved by enclosing the unit
within a small mechanical room or a closet. Additional
measures for sound control include the following:
1. Mount the unit so that the return air inlet is 90°to the
return air grille. Refer to Figure 7. Install a sound
baffle as illustrated to reduce line-of-sight sound
transmitted through return air grilles.
2. Mount the unit on a rubber or neoprene isomode pad
to minimize vibration transmission to the building
structure. Extend the pad beyond all four edges of the
unit.
Electrical Wiring
To avoid possible injury or death due to electrical
shock, open the power supply disconnect switch and
secure it in an open position during installation.
Use only copper conductors for field installed
electrical wiring. Unit terminals are not designed to
accept other types of conductors.
Figure 7 - Vertical Sound Attenuation
Field Supplied
Disconnect Switch
Heat Pump
A
Room Thermostat
B
A= Two power wires on single-phase units: three power wires on three-phase units. B= 1 heat /1 cool /manual or Auto
Change-Over remote 24V thermostat. Note: All customer-supplied wiring to be copper only and must conform to NEC
and local electrical codes. Wiring shown with dashed lines must be field-supplied and field-installed.
DISCONNECT ELECTRICAL POWER
SOURCE TO PREVENT INJURY OR
DEATH FROM ELECTRICAL SHOCK.
CAUTION: USE COPPER
CONDUCTORS ONLY TO PREVENT
EQUIPMENT DAMAGE.
Typical Field Installed Wiring
All field installed wiring, including electrical ground,
must comply with the National Electrical Code (NEC) as
well as all applicable local codes. In addition, all field
wiring must conform to Class II temperature limitations
described in the NEC.
Refer to the unit wiring diagrams included with
submittal drawings for fuse sizes and a schematic of the
field connections which must be made by the installing
(or electrical) contractor.
Consult the unit wiring diagram located on the inside of
the compressor access panel to ensure proper electrical
hookup.
Units rated 208-230 volts that have a 24 volt transformer
must have the transformer connection modified if the
actual power supply is 230 volts. Refer to the unit wiring
diagram for details of this procedure.
All final electrical connections must be made with a
length of flexible conduit to minimize vibration and
sound transmission to the building.
Isolation Pad
Insulated Sound Baffle
(Open Both Ends and Bottom)
Return Air Louver or Grille
WARNING
▲CAUTION!

Page 9
Operating Limits
Environment -This unit is designed for INDOOR
INSTALLATION ONLY.
Power Supply - A voltage variation of +/- 10% of
nameplate utilization voltage is acceptable. Three-phase
system imbalance shall not exceed 2%.
Starting Conditions
All Models - Units start and operate in an ambient of 40°
F with entering air at 40°F with both air and water at the
stated flow rates of ARI Standard 325 rating test for
initial winter start-up.
NOTES
1. These are not normal or continuous operating
conditions. This assumes a winter start-up to bring
the building space up to occupancy temperatures.
2. Voltage utilization range complies with ARI
Standard 110.
Air Limits
Minimum Ambient Air
Rated Ambient Air
Maximum Ambient Air
Minimum Entering Air
Rated Entering Air db/wb
Maximum Entering Air db/wb
Water Limits
Minimum Entering Water
Normal Entering Water
Maximum Entering Water
All Models
Table 2 - Operating Limits
Heating
40°F
70°F
85°F
40°F
70°F
80°F
25°F
70°F
80°F
Cooling
40°F
80°F
100°F
50°F
80/67°F
110/83°F
40°F
85°F
110°F
3. When using 100% outside air as a source of
ventilation, a 40º F DB minimum and a 78°F WB
maximum are acceptable, but the cabinet may sweat
during hot weather.
4. Determination of operating limits is dependent
primarily upon 3 factors: 1) return air temperature,
2) water temperature, and 3) ambient temperature.
When any one of these factors is at minimum or
maximum levels, the other two factors should be at
normal levels to ensure proper unit operation.
5. Extreme variations in temperature and humidity, and
corrosive water or air adversely affect unit
performance, reliability, and service life.

Page 10
Introduction
The following instructions represent industry accepted
installation practices for Closed Loop Earth Coupled
Heat Pump Systems. They are provided to assist the
contractor in installing trouble free ground loops.
These instructions are recommendations only. State
and Local Codes MUST be followed and installations
MUST conform to ALL applicable Codes. It is the
responsibility of the Installing Contractor to
determine and comply with ALL applicable Codes and
Regulations.
Closed Loop Earth Coupled Heat Pump systems are
commonly installed in one of three configurations:
horizontal, vertical, or pond loop. Each configuration
provides the benefit of using the moderate temperature of
the earth as a heat source/heat sink. Piping configurations
can be either series or parallel.
Series piping configurations typically use 1-1/4", 1-1/2",
or 2" pipe. Parallel piping configurations typically use
3/4" or 1" pipe for loops and 1-1/4", 1-1/2", or 2" pipe for
headers and service lines. Parallel configurations require
headers to be either "closed-coupled", short headers, or
reverse return design.
Select the installation configuration which provides the
most cost effective method of installation after
considering all application constraints.
Refer to IGSHPA publication Closed Loop/Ground
Source Heat Pump Systems Installation Guide (Sections
4-6) for complete ground loop design, materials
requirements, and joining information.
Pre-Installation
Prior to installation, locate and mark all existing under-
ground utilities, piping, etc. Install loops for new con-
struction before sidewalks, patios, driveways, and other
construction has begun. During construction, accurately
mark all ground loop piping on the plot plan as an aid in
avoiding potential future damage to the installation.
Horizontal Applications
To install Horizontal earth couplings, dig trenches using
either a chain-type trenching machine or a backhoe. Dig
trenches approximately 5 feet apart. Trenches must be at
least 5 feet from existing utility lines, foundations, and
property lines and at least 10 feet from wells. Trenches
may be curved to avoid obstructions and may be turned
around corners.
When multiple pipes are laid in a trench, space pipes
properly and backfill carefully to avoid disturbing the
spacing of the pipes in the trench.
Vertical Applications
To install Vertical earth couplings, drill boreholes using any
size drilling equipment. Regulations which govern water
well installations also apply to vertical ground loop
installations. Vertical applications typically require multiple
boreholes. Space boreholes a minimum of 10 feet apart.
Unless other requirements are mandated by code, use the
following guideline when locating boreholes:
• 5 feet from foundations and lot lines
• 10 feet from utility lines and drain fields
• 20 feet from non-public wells
• 50 feet from public wells
• 100 feet from cesspools, feedlots, lagoons, seepage pits,
and septic tanks.
The minimum diameter for 3/4" or 1" U-bend well bores is
4". Larger diameter boreholes may be drilled if convenient
unless local code requires an expensive method of
backfilling. Assemble each U-bend assembly, fill with
water, and pressure test prior to insertion into the borehole.
To add weight and prevent the pipe from curving and
digging into the borehole wall during insertion, tape a
length of conduit, pipe, or reinforcing bar to the U-bend
end of the assembly. This technique is particularly useful
when inserting the assembly into a borehole filled with
water or drilling mud solutions, since a water filled U-
bend assembly is somewhat buoyant under these
circumstances. Tape the pipes together approximately
every 10 feet to prevent the assembly from separating
under downward pressure and bowing out against the
borehole wall.
Carefully backfill the boreholes to within 10 feet of the
surface. Follow IGSHPA specifications for backfilling
unless local codes mandate otherwise.
When all U-bends are installed, dig the header trench 4 to
6 feet deep and as close to the boreholes as possible. Use
a spade to break through from ground level to the bottom
of the trench. At the bottom of the trench, dig a relief to
allow the pipe to bend for proper access to the header.
CLOSED LOOP EARTH COUPLEDAPPLICATIONS
▲CAUTION!

Page 11
Building Entry
Seal and protect the entry point of the earth coupling into
the building as shown in Figures 8-11 below.
Slab on Grade Construction
New Construction: When possible, position the pipe in
the proper location prior to pouring the slab. To prevent
wear as the pipe expands and contracts, protect the pipe
with a layer of insulation as shown in Figure 8. When the
slab is poured prior to installation, create a chase through
the slab for the service lines with 4" PVC street elbows
and sleeves. Refer to Section 4 of the IGSHPA manual for
details.
Figure 10
Retrofit Construction: Trench as close as possible to the
footing. Bring the loop pipe up along the outside wall of
the footing until it is higher than the slab. Enter the
building as close to the slab as the construction allows.
Shield and insulate the pipe to protect it from damage and
the elements as shown in Figure 9.
Figure 9
Figure 8
Below Grade Entry
New and Retrofit Construction: Bring the pipe through
the wall as shown in Figure 11. For applications in which
loop temperature may fall below freezing, insulate pipes
at least 4 feet into the trench to prevent ice forming near
the wall.
Pier and Beam (crawl space)
New and Retrofit Construction: Bury the pipe beneath the
footing and between piers to the point that it is directly
below the point of entry into the building. Bring the pipe
up into the building. Shield and insulate piping as shown
in Figure 10 to protect it from damage.
Figure 11
Insulation
Finished Grade
4'-6'
Loop Pipe
Finished Grade
4-6'
Loop Pipe
Insulated
Protective Shield
4'-6'
Masonry
Wall
4" Schedule
40 PVC Pipe
Loop Pipe
4" Compression
Well Seal
Existing Grade
Finished Grade
4'-6'
Loop Pipe
Enter Building As
Soon As Possible
Insulated
Protective Shield

Page 12
Loop Testing
Upon completion of the ground loop piping, pressure test
the loop to assure a leak free system.
Parallel systems: Test Parallel systems as each leg is
completed. Test again prior to the connection of the
headers. Test the system for a final time when the entire
loop is assembled and all legs are attached.
Series Systems: Test individual loops as installed. Test
entire system when all loops are assembled.
Horizontal Systems: Test individual loops as installed.
Test entire system when all loops are assembled.
Vertical U-Bends and Pool Loop systems: Test Vertical
U-bends and pond loop assemblies prior to installation
with a test pressure of at least 100 psi. Either water or air
may be used as the testing medium.
Flushing, Purging, Adding Anti-Freeze, and
Pressurizing the System
Upon completion of system installation and testing, flush
the system to remove all foreign objects and purge to
remove all air.
Refer to Section 7 of the IGSHPA manual for more
information on flushing and purging Closed Loop Earth
Coupled Systems.
Add antifreeze if necessary. Refer to the IGSHPA manual
for the correct type and amount of antifreeze to add.
Refer to the IGSHPA Closed Loop Earth Coupled
Systems Application Manual for complete instructions on
flushing, purging, adding anti-freeze, and pressurizing the
system.
Do not use calcium chloride in ClimateMaster units.
The use of calcium chloride voids the equipment
warranty.

Page 13
the Horizontal and Vertical units. Refill the system
and bleed off all air.
9. Test the system pH with litmus paper. The system
water should be slightly alkaline ( pH 7.5 to 8.5).
Add chemicals as appropriate to maintain acidity
levels.
DO NOT use “Stop-Leak” or any similar chemical
agent in this system. Addition of these chemicals to
the loop water can foul the system and inhibit unit
operation.
10. Check the main system panels, safety cutouts, and
alarms after the system is successfully cleaned,
flushed, refilled and bled. Set the controls to
properly maintain loop temperatures.
Optional Hot Water Generator
When the unit is equipped with an optional hot water
generator it will contain a coaxial tube-in-tube, vented
double-wall heat exchanger.
To avoid equipment damage, DO NOT seal the vents
located at each end of the coaxial coil.
Two (2) FPT connections are located on the front of the
unit labeled "HWG IN" and "HWG OUT" which connect
to the hot water generator.
Connect the heat exchanger as follows:
1) Plumb the unit to the water tank as described in the
ClimateMaster Geo-Thermal Heat Pump Manual
Volume 3.
2) Fill the system with water.
3) Purge the system of air.
4) Connect the blue wire to terminal 5 of the low
voltage terminal board to activate the circulating
pump. The circulating pump cycles with the
compressor when there is a demand for hot water.
To avoid damage to the circulating pump, DO NOT
connect the wire until plumbing is complete and the
system is purged of air and filled with water.
Boiler/Cooling Tower System Cleaning and
Flushing
Cleaning and flushing the unit is the single most
important step to ensure proper start-up and continued
efficient operation of the system.
Follow the instructions below to properly clean and flush
the system:
To prevent injury or death due to electrical shock or
contact with moving parts, open unit disconnect
before servicing unit.
1. Verify that electrical power to the units is disconnected.
2. Install the system with the supply hose connected
directly to the return riser valve. Use a single length
of flexible hose.
3. Open all air vents. Fill the system with water. Do not
allow system to overflow. Bleed all air from the
system. Check the system for leaks and repair
appropriately.
4. Verify that all strainers are in place. Start the pumps
and systematically check each vent to ensure that all
air is bled from the system.
5. Verify that make-up water is available. Adjust make-
up water appropriately to replace the air which was
bled from the system. Check and adjust the water/air
level in the expansion tank.
6. Set the boiler to raise the loop temperature to
approximately 85°F. Open a drain at the lowest
point in the system. Adjust the make-up water
replacement rate to equal the rate of bleed.
7. Refill the system and add trisodium phosphate in a
proportion of approximately one pound per 150
gallons of water. Reset the boiler to raise the loop
temperature to about 100°F.
To avoid possible damage to piping systems
constructed of plastic piping, DO NOT allow loop
temperature to exceed 110°F.
Circulate the solution for a minimum of 8 to 24
hours. At the end of this period, shut off the
circulating pump and drain the solution. Repeat
system cleaning if desired.
8. When the cleaning process is complete, remove the
short-circuited hoses. Re-connect the hoses to the
proper supply and return the connections to each of
START-UP PREPARATION
WARNING
▲CAUTION
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▲CAUTION!
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Page 14
12. Standby Pump: Verify that the standby pump is
properly installed and in operating condition.
13. System Controls: To ensure that no
catastrophic system failures occur, verify that
system controls are functioning and that the
sequencing is correct.
14. Freeze Protection for Water System: Verify
that freeze protection is provided for the outdoor
portion of the loop water system. Inadequate
freeze protection can cause system operating
problems.
15. Site Temperature: DO NOT allow the
construction site to fall below freezing once the
system is installed and tested. Condenser coils
never fully drain by themselves and can freeze
unless winterized with glycol.
16. System Water Loop: Verify that all air is bled
from the system. Air in the system impedes unit
operation and causes corrosion in the system
piping.
17. Unit Filters: To avoid system damage, ensure
that the unit filter is clean and in place.
18. Unit Fans: Manually rotate fans to assure free
rotation. Ensure that fans are properly secured to
the fan shaft. DO NOT oil fan motors on start-
up since they are lubricated at the factory.
19. System Control Center: To ensure control of
the temperature set-points for operation of the
system’s heat rejector and boiler, examine the
system control and alarm panel for proper
installation and operation.
20. Cabinet: Ensure that all cabinet panels are
properly in place.
21. Miscellaneous: Note any questionable aspects
of the installation.
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1. Voltage: Ensure that voltage is within the
utilization range specifications of the unit
compressor and fan motor.
2. Wiring: Ensure that fuses, breakers, and wire
are sized correctly and that low voltage wiring is
complete.
3. Piping: Ensure that piping is complete and
water system is cleaned and flushed and that all
air is purged from the water piping. Ensure that
the condensate line is open, trapped, and
correctly pitched.
4. System Water Temperature: Ensure that it is
within an acceptable range to facilitate start-up.
(When conducting this check, also verify proper
heating and cooling set points.)
5. System Water pH: Verify system water acidity.
(pH = 7.5 or 8.5) Proper pH promotes the
longevity of hoses and heat exchangers.
6. System Flushing: Properly clean and flush
system periodically. Ensure that all supply and
return hoses are connected end-to-end to
facilitate system flushing and prevent fouling of
the heat exchanger by system water.
7. System Water: Water used in the system must
be of potable quality and clean of dirt, piping
slag, and chemical cleaning agents.
8. System Return Air: Ensure that return air
temperature is between 50°-80°F in heating and
60°-95°F in cooling.
9. Closed-Loop Cooling Tower (Open Tower
with Heat Exchanger): Check equipment for
proper temperature set points and operation.
10. Compressor: Ensure that shipping blocks are
removed and that compressor mounting bolts are
loosened to reduce vibration noise.
11. Water Flow: Balance Water Flow Rate to Heat
Pump.
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When the installation is complete and the system is cleaned and flushed, follow the System Checkout procedure outlined below.
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SYSTEM CHECKOUT

Page 15
When the disconnect switch is closed, high voltage is
present in some areas of the electrical panel. Exercise
caution when working with energized equipment.
1. Turn thermostat fan position to "ON". Blower should
start.
2. Balance air flow at registers.
3. Adjust all valves to their full open position. Turn on
the line power to all heat pump units.
4. Operate unit in cooling cycle. Room temperature
should be approximately 70°to 75°F DB, and 61°
to 65°F WB. Loop water temperature entering the
heat pumps should be between 70°F and 110°F.
5. Three factors determine the operating limits of a
Horizontal and Vertical unit: (a) return air
temperature, (b) water temperature, and (c) ambient
temperature. When any one of these factors is at a
minimum or maximum level, the other two factors
must be at normal levels to ensure proper unit
operation.
a. Adjust the unit thermostat to the cooling
position. Slowly reduce thermostat setting until
the water control valve/loop pump(s) activates.
b. Check for cool air delivery at a system grille
within a few minutes after the unit has begun to
operate.
NOTE: Units have a 5 minute time delay in
the control circuit.
c. Verify that compressor is on and that the water
flow rate is correct by measuring pressure drop
thorough the heat exchanger using the Pete's
plugs and comparing to the heat pump
specification sheet.
d. Check the elevation and cleanliness of the
condensate lines. Dripping may be a sign of a
blocked line.
e. Check the temperature of both supply (refer to
Table 4) and discharge water. If temperature
differential (refer to Table 4) is within rage,
proceed with test. If temperature is outside
operating range, check cooling refrigerant
pressures.
f. Check air temperature drop across the coil with
the compressor operating. Air temperature
should drop between 16°F and 20°F.
6. Operate the heat pump in the heating cycle
immediately after checking cooling cycle operation.
Use the procedure outlined below to initiate proper unit start-up:
UNIT START-UP
Allow five (5) minutes between tests for pressure to
equalize.
a. Turn thermostat to lowest setting and set
thermostat switch to "HEAT" position.
b. Slowly turn thermostat to a higher temperature
until water control valve/loop pumps activates.
c. Check for warm air delivery at a system grille
within a few minutes after the unit has begun to
operate.
d. Check the temperature of both supply (refer to
Table 4) and discharge water. If temperature
differential (refer to Table 4) is within range,
proceed with test. If temperature is outside
operating range, check heating
refrigerant pressures.
e. Check air temperature rise across the coil when
both compressors are operating. Air temperature
should rise between 25°F and 35°F.
f. If auxiliary heat is used, turn thermostat to
highest setting. Assure that auxiliary electric heat
activates. Check for proper temperature rise
across the heater.
g. Verify that all stages of auxiliary heat (if used)
activate when the thermostat is set in
"EMERGENCY HEAT" position.
h. Check for vibration, noise, and water leaks.
7. If unit fails to operate, perform System Checkout
(page 14). If the check described fails to reveal the
problem and the unit still does not operate, contact a
trained service technician to ensure proper diagnosis
and repair of the equipment.
8. When testing is complete, set system to maintain
desired comfort level.
4°F - 8°F
4°F - 8°F
Table 4: Water Temperature Change Through Heat Exchanger
* Earth Coupled or Cooler/Boiler System use 3 GPM/ton
** Flow rate adjusted for temperature
Water Flow Rate (GPM) Rise Drop
9°F - 12°F
10°F Max
Closed Loop*
Open Loop**
WARNING

Page 16
the values noted on the unit nameplate. Maintain a log of
amperage values to detect deterioration prior to compo-
nent failure.
When replacing the compressor contactor or lockout
relay in a unit with electromechanical controls, use
only ClimateMaster replacement parts. Substitution
of other components may result in an inoperative
safety circuit and may cause a hazardous condition.
HEAT EXCHANGERS: Clean heat exchangers annually.
Inspect heat exchangers regularly and clean more
frequently if the unit is located in a “dirty” environment.
Safety Control Reset
All ClimateMaster Horizontal and Vertical units are
furnished with High and Low pressure cutouts to prevent
the machine from operating at abnormal or damaging
temperature or water flow conditions.
The contacts of the high-pressure control used on units are
designed to open at 380 psig and automatically close at
300 psig. The contacts of the high temperature switch open
at 200º F and close at 160º F. The contacts of the low-
temperature switch open at 21º F and re-close at 31ºF. The
high level condensate device activates when moist and
deactivates when dry. A lockout circuit, electrically linked
with these cutouts, interrupts unit operation. The unit must
be reset manually.
On units with solid state controllers, the control board
indicates which safety resulted in the lockout. The unit
attempts to restart ten (10) minutes after the first trip.
Note: If the unit must be reset, check the unit for a
dirty filter, abnormal entering water temperature,
inadequate or excessive water flow, and internal
malfunction. If the unit continues to cutout, contact a
trained service technician.
Maintenance Procedures
Perform the maintenance procedures outlined below
periodically as indicated.
To prevent injury or death due to electrical shock or
contact with moving parts, open unit disconnect
switch before servicing unit.
FILTERS: Inspect filters. Establish a regular mainte-
nance schedule. Replace/clean filter frequently depend-
ing upon need.
To remove the filter from a Horizontal and Vertical unit,
slide the filter out of its frame located in the return air
opening at the bottom front of the unit. When re-install-
ing the filter, use the slide-in rails of the filter frame to
guide the filter into the proper position.
CAUTION: To avoid fouled machinery and extensive
unit clean-up, do not operate units without filters in
place. Do not use equipment as a temporary heating
or cooling source during construction.
CONDENSATE PANS: Check condensate drain pans
for algae growth every three months. If algae growth is
apparent, consult a water treatment specialist for proper
chemical treatment. The application of an algaecide
every three months typically eliminates algae problems
in most locations.
FAN MOTORS: All units have fully lubricated fan
motors. DO NOT lubricate.
Conduct amperage checks annually. Amperage draw
should not exceed normal full load or rated load amps by
more than 10% of the values noted on the unit nameplate.
Maintain a log of amperage values to detect deterioration
prior to component failure.
UNIT INSPECTION: Visually inspect the unit annu-
ally. Pay special attention to hose assemblies. Repair any
leaks and replace deteriorated hoses immediately.
COMPRESSOR: Conduct an amperage check on the
compressor annually. Amperage draw should not exceed
normal full load or rated load amps by more than 10% of
MAINTENANCE
ClimateMaster works continually to improve its products. As a result, the design and specifications of each product at the time of order may be changed
without notice and may not be as described herein. Please contact ClimateMaster’s Customer Service Department at 1-405-745-6000 for specific
information on the current design and specifications. Statements and other information contained herein are not express warranties and do not form the
basis of any bargain between the parties, but are merely ClimateMaster’s opinion or commendation of its products.
7300 S.W. 44th Street
Oklahoma City, OK 73179
Phone: [phone]
Fax: [phone]
www.climatemaster.com
*69197308*
Part #69197308
© ClimateMaster 1993 Rev.: 7/99
WARNING
▲CAUTION!