Ecologix W2W 36 Instruction Manual

W2W Series [Water-to-Water]
W2W Models: 36, 52, 72
Geothermal Heat Pumps
Residential Water-to-Water
Installation & Maintenance Manual
Revision: o08
Table of Contents
Table of Contents _______________________________________________________ 1
Safety ________________________________________________________________ 2
General Information _____________________________________________________ 3
PHYSICAL, CONNECTION and ELECTRICAL DATA________________________ 4
Installation_____________________________________________________________ 5
PIPING INSTALLATION ______________________________________________ 5
Installation of Supply and Return Piping _________________________________ 5
Load Plumbing Installation____________________________________________ 5
Applications ___________________________________________________________ 7
COMMERCIAL WATER –LOOP HEAT PUMP APPLICATIONS _____________ 7
GROUND WATER HEAT PUMP SYSTEMS ______________________________ 8
GROUND –LOOP HEAT PUMP APPLICATIONS__________________________ 9
ELECTRICAL – LINE VOLTAGE ______________________________________ 12
ELECTRICAL – LOW VOLTAGE ______________________________________ 12
UNIT STARTING & OPERATING CONDITIONS _________________________ 14
PIPING SYSTEM CLEANING & FLUSHING ____________________________ 14
UNIT START-UP PROCEDURE _______________________________________ 15
Unit & System Checklist ________________________________________________ 16
Preventative Maintenance________________________________________________ 17
Product Warranty ______________________________________________________ 18

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Safety
Warnings, cautions and notices appear
throughout this manual. Read these items
carefully before attempting any installation,
service or troubleshooting of the equipment.
DANGER: Indicates an immediate hazardous
situation, which if not avoided will result in
death or serious injury.
DANGER labels on unit access panels must be
observed.
WARNING: Indicates a potentially hazardous
situation, which if not avoided could result in
death or serious injury.
CAUTION: Indicates a potentially hazardous
situation or an unsafe practice, which if not
avoided could result in minor or moderate injury
or product or property damage.
NOTICE: Notification of installation, operation
or maintenance information, which is important,
but which is nor hazard-related.
WARNING
All refrigerant discharged from this unit must
be recovered. To avoid release of
refrigerant into atmosphere, the refrigerant
circuit of this unit must only be serviced by
technicians who meet all required local and
federal qualifications.
CAUTION
Do not use equipment for construction
heating or cooling. Doing so will introduce
construction dirt and debris, shortening
equipment life and voiding motor and/or
compressor warranty.

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General Information
Inspection
Upon receipt of the equipment, carefully check
the shipment against the bill of lading. Make
sure all the units have been received. Inspect the
carton or crating of each unit, and inspect each
unit for damage. Assure the carrier makes
notation of any shortages or damage on all
copies of the freight bill and completes a
common carrier inspection report. Concealed
damage not discovered during unloading must be
reported to the carrier within 15 days of receipt
of shipment. If not filed within 15 days, the
freight company can deny the claim without
recourse. Note: It is the responsibility f the
purchaser to file all necessary claims with the
carrier. Notify the Traffic Department of all
damage within fifteen (15) days of shipment.
Storage
Equipment should be stored in its original
packaging in a clean, dry area. Store units in an
upright position at all times.
Unit Protection
Use shipping cartons, vinyl film, or an
alternative form of covering that can adequately
protect the unit on the job site. Open ends of
piping should always be capped. Avoid causing
physical damage to areas where painting,
plastering, and/or spraying has not been
completed. Take necessary precautions to avoid
contamination by foreign materials. Physical
damage and contamination may require the
equipment to be cleaned or other costly repairs
as this can prevent proper start-up.
Examine all pipes, fittings, and valves before
installing any of the system components.
Remove any dirt or trash found in or on these
components.
Pre-Installation
Installation, Operation and Maintenance
instructions are provided with each unit. Be sure
to completely read and understand these before
beginning installation. The installation site
chosen should include adequate service clearance
around the unit. Before unit start-up, read all
manuals and become familiar with the unit and is
operation. Check the system thoroughly before
operation.
Prepare the units for installation as follows:
1. Compare the electrical data on the unit
nameplate with the ordering and
shipping information to verify that the
correct unit has been shipped.
2. Keep the cabinet covered with the
shipping carton until the installation,
plastering, painting, etc. is complete.
3. Check the refrigerant tubing. Ensure it is
free of any dents or kinks, and verify
that it is not in contact with any other
parts in the unit.
4. Inspect all electrical connections.
Connections must be clean and tight at
the terminals.
5. Loosen compressor bolts on units
equipped with compressor spring
vibration isolation until the compressor
rides freely on the springs. Remove
shipping restraints.
*NOTICE* Failure to remove shipping
brackets (if installed) from spring-mounted
compressors will cause excessive noise, and
could cause failure due to added vibration.
CAUTION
Do not sore or install units in corrosive
environments or in locations subject to
temperature or humidity extremes (e.g.
attics, garages, rooftops, etc.). Such
conditions can significantly reduce
performance, reliability, and service life of
equipment.
CAUTION
Always move and store units in an upright
position. Tilting units on their sides may
cause equipment damage.
CAUTION
CUT HAZARD! Sheet metal parts may have
sharp edges or burrs. Use care and wear
appropriate protective clothing, safety
glasses, and gloves when handling parts
and servicing heat pumps.

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PHYSICAL, CONNECTION and ELECTRICAL DATA
Model W2W-36 W2W-52 W2W-72
Factory Charge R410A (oz) 45 52 90
LOAD water - copper male sweat (in) 1 1 1 1/4
SOURCE water - copper male sweat (in) 1 1 1 1/4
Desuperheater - copper male sweat (in)
1
½ ½ ½
Cabinet Dimensions (A x B x C) (in) 28 x 34 x 24 28 x 34 x 24 28 x 34 x 24
Electrical Voltage /PH 230/60/1 230/60/1 230/60/1
Total Unit FLA 26 34 35
Compressor LRA 82 134 150
MAX fuse size 60 60 80
Min. circuit Ampacity 32.9 42.5 47.5
Weight – Operating, (lbs) 146 180 230
Weight – Packaged, (lbs) 155 195 250
Notes:
(1) Optional item. May not be present.
(2) Balanced Port Expansion Valve (TXV)
(3) Insulated Source and Load Water Coils
(4) Check rating plate for refrigeration type and correct charge

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Installation
Unit Location
W2W series units are not designed for outdoor
installation. Install the unit in an INDOOR
location that allows enough space for service
personnel to perform typical maintenance or
repairs.
The installation of water source heat pump
units and all 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.
Locate the unit in an indoor area that allows easy
removal of access panels, and has enough space
for service personnel to perform maintenance or
repair. Provide sufficient room to make water
and electrical connections. Any access panel
screws that would be difficult to remove after the
unit is installed should be removed prior to
setting the unit. These units are not approved for
the outdoor installation and, therefore, must be
installed inside the structure being conditioned.
Do not locate in areas where ambient conditions
are not maintained within 40-100ºF and up to
75% relative humidity.
PIPING INSTALLATION
Installation of Supply and Return
Piping
Follow these piping guidelines.
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. Do not exceed 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.
Table 1: Hose Minimum Bend Radii
Hose Diameter Minimum Bend Radius
½” [12.7mm] 2½ ” [63.5mm]
¾” [19.1mm] 4” [101.6mm]
1” [25.4mm] 5½” [139.7mm]
1 & 1/4” [31.8mm] 6¾” [171.5mm]
Insulation is not required on loop water piping
except where the piping runs through unheated
areas or outside the building, or when the loop
water temperatures is below the minimum
expected dew point of the pipe ambient.
Insulation is required where loop water
temperature may drop below the ambient air dew
point.
Note: When anti-freeze is used in the loop,
assure that it is compatible with Teflon tape
or pipe joint compound employed.
Optional hose assemblies designed specifically
for use with W2W-series units area available.
Similar hoses can be obtained from alternate
suppliers.
Refer to Hose kit instructions 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 and reduced
service life.
Load Plumbing Installation
W2W-Series Unit Load Plumbing
The applications are varied and cannot be
described in their entirety in this document.
However, some basic guidelines will be
presented. Much of the discussions on water
loop applications would be valid for the load

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plumbing discussion as well. All plumbing
should conform to local codes and consider the
following:
Wide temperature variation applications,
such as heating/cooling coils:
Employ piping materials that are rated for
the maximum temperature and pressure
combination. This excludes PVC for most
heating applications.
Insure load water flow in high temperature
heating applications is at least 3 gpm per ton
to improve performance and reduce
nuisance high-pressure faults.
Should NOT employ plastic to metal
threaded joints.
Utilize a pressure tank and air separator vent
system to equalize pressure and remove air.
Swimming Pool/Hot tub applications:
Load coax material should always be, at
minimum cupro-nickel in chlorine/bromine fluid
applications.
Potable Water Applications:
Load coax material should always be vented
double walled when used directly in potable
water systems. Alternatively, the domestic water
can be separated from the load water through a
second heat exchanger provided as part of a load
manager or other Ecologix geothermal pumping
module.
Ensure load water flow in high temperature
heating applications is at least 3gpm per ton to
improve performance and reduce nuisance high-
pressure faults.
Pressure Testing:
Pressure testing of all piping connections is
recommended before finishing of interior space
or before access to connections is limited.
Equipment manufacturer is not responsible for
damages from water leaks due to inadequate
testing.
Desuperheater:
The W2W-series heat pumps are equipped with a
desuperheater, which can be used to divert a
portion of the delivered heat to a domestic hot
water tank. This provides hot water at the heat
pump’s COP while operating in heating mode,
and virtually free hot water while operating in
cooling mode. Heat pumps with a desuperheater
also include a circulating pump, so that the only
necessary plumbing is to connect the
desuperheater loop to the domestic tank or
preheat tank. For systems with a gas, oil, or
propane water heater, or with an electric water
heater with only a single center element, a dual
tank system is recommended to ensure that water
enters the desuperheater at a suitable
temperature.
WARNING
Do not connect wiring to the desuperheater
pump until the heat pump is ready to
commission and the desuperheater loop has
been filled and fully purged of air. Running
the pump dry can cause pump failure.

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Applications
COMMERCIAL WATER –LOOP HEAT PUMP APPLICATIONS
Commercial systems typically include a number
of units plumbed to a common piping system.
Any unit plumbing maintenance work can
introduce air into the piping system; therefore air
elimination equipment is a major portion of the
mechanical room plumbing. In piping systems
expected to utilize water temperatures below
50ºF [10ºC], ½” closed cell insulation is required
on all piping surfaces to eliminate condensation.
Metal to plastic threaded joints should never be
employed due to their tendency to leak over
time. All non-distributor class units include a
low temperature-soldered bracket-supported FTP
water connection. Teflon tape thread sealant is
recommended to minimize internal fouling of the
heat exchanger. Do not over tighten connections
and route piping so as not to interfere with
service or maintenance access.
Hose kits are available in different
configurations for connection between the
W2W-Series and the piping system. Hose kits
can include shut off valves; P/T plugs for
performance measurement, high-pressure
stainless steel braid hose, “Y” type strainer with
blow-down valve, or “J” type swivel connection.
Balancing valves to facilitate the balancing of the
system, or an external low pressure drop
solenoid valve for use in variable speed pumping
systems, may also be incorporated into the
design of a system and supplied with the
equipment.
The piping system should be flushed to remove
dirt, piping chips and other foreign material prior
to operation. See Piping System Cleaning and
Flushing Procedures. The flow rate is usually set
between 2.25 and 3gpm per ton of cooling
capacity. The manufacturer recommends 2.5gpm
per ton for most applications of water loop heat
pumps. To ensure proper maintenance and
servicing, P/T ports are imperative for
temperature and flow verification, as well as
performance checks.
Cooling Tower/Boiler Systems typically utilize a
common loop maintained at 60-90ºF [15.6-
32.2ºC]. The use of a closed circuit evaporative
cooling tower with a secondary heat exchanger
between the tower and the water loop in
recommended. If an open-type cooling tower is
used continuously, chemical treatment and
filtering will be necessary.

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GROUND WATER HEAT PUMP SYSTEMS
Shut off valves should be included in case of
servicing. Boiler drains or other valves should be
tee’d into the line to allow acid flushing of just
the heat exchanger. Pressure/temperature plugs
should be used so that flow and temperature can
be measured. Piping materials should be limited
to PVC SCH80 or copper. Due to the pressure
and temperature extremes, PVC SCH40 is not
recommended. Water quantity should be
plentiful and of good quality. The unit can be
ordered with either a copper or cupro-nickel
water heat exchanger. Copper is recommended
for closed loop systems and open loop ground
water systems that are not high in mineral
content or corrosiveness. In conditions
anticipating heavy scale formation or in brackish
water, a cupro-nickel heat exchanger is
recommended. In ground water situations where
scaling could be heavy or where biological
growth such as iron bacteria will be present, a
closed loop system is recommended. Heat
exchanger coils may over time lose heat
exchange capabilities due to a build up of
mineral deposits inside. Only a qualified service
mechanic can clean these exchangers.
Desuperheater coils can likewise become scaled
and possibly plugged. In areas with extremely
hard water, the homeowner should be informed
that the heat exchanger might require occasional
acid flushing.
Expansion Tank and Pump
Use a closed, bladder-type expansion tank to
minimize mineral formation due to air exposure.
The expansion tank should be sized to handle at
least one minute run time of the pump to prevent
premature pump failure using its drawdown
capacity rating. The pump should be sized to the
home’s domestic water load (5-9gpm) plus the
heat pump water load. Discharge water from the
unit is not contaminated in any manner and can
be disposed of in various ways depending on
local building codes; i.e. recharge well, storm
sewer, drain field, adjacent stream or pond, etc.
Most local codes forbid the use of sanitary sewer
for disposal. Consult your local building and
zoning department to assure compliance in your
area. The pump should be sized to handle the
home’s domestic water load (typically 5-9 gpm
[23-41 L/m]) plus the flow rate required for the
heat pump. Pump sizing and expansion tank
must be chosen as complimentary items.
Variable speed pumping applications should be
considered for inherent energy savings and
smaller expansion tank requirements.
Water Control Valve
Note the placement of the water control valve.
Always maintain water pressure in the heat
exchanger by placing water control valves at the
outlet of the unit to prevent mineral precipitation.
Pilot operated or Taco slow closing solenoid
valves are recommended to reduce water
hammer. If water hammer persists, a mini-
expansion tank can be mounted on the piping to
help absorb the excess hammer shock. Ensure
that the unit transformer can supply the total
‘VA’ draw of the valve. For instance the Taco
slow closing valve can draw up to 35VA. This
can overload smaller 40 or 50 VA transformers
depending on the other controls employed. A
typical pilot operated solenoid valve draws
approximately 15VA.
Flow Regulation
Flow regulation can be accomplished by two
methods. First, most water control valves have a
built in flow adjustment. By measuring the
pressure drop through the unit heat exchanger,
flow rate can be determined by referring to the
table below. Since the pressure is constantly
varying, two pressure gauges might be needed.
Simply adjust the water control valve until the
desired flow of 1.5 to 2gpm per ton is achieved.
Secondly, a flow control device may be installed.
The devices are typically an orifice of plastic
material that is designed to allow a specified
flow rate. These are mounted on the outlet of the
water control valve. On occasion, these valves
can produce a velocity noise that can be reduced
by applying some back pressure. This is
accomplished by slightly closing the leaving
isolation valve of the well water setup. Note:
when EWT is below 50oF (10oC), a minimum
of 2 gpm per ton (2.6 L/m per kW) is
required.
Low Temperature Cutout
For units where glycol is not provided, the water
low temperature cutout set-point should be set to
avoid freeze damage. Depending on model of
heat pump a flow switch may be installed in
place of the low temperature cut out. Check
wiring diagram on door of unit to confirm.

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GROUND –LOOP HEAT PUMP APPLICATIONS
Closed Loop Applications
A closed loop system re-circulates the same
water/antifreeze solution through a closed system
of underground high-density polyethylene pipe.
As the solution passes through the pipe it collects
heat (in the heating mode) that is being
transferred from the relatively warm surrounding
soil through the pipe and into the relatively cold
solution. The solution is circulated back to the
heat pump that extracts its heat and then returns
to the ground to absorb more heat from the earth.
The W2W-Series heat pumps are designed to
operate on either vertical or horizontal closed
loop applications. Vertical loops are typically
installed with a well drilling rig up to 200 feet
deep or more. Horizontal systems are typically
installed with excavating or trenching equipment
approximately six to eight feet deep, depending
on geographic location and length of pipe used.
Earth loops must be sized properly for each
particular geographic area and individual
capacity requirements. Contact your local
installer for loop sizing requirements in your
area.
Loop Pump Selection
Select a loop circulation pump based upon the
gpm required and total system pressure drop.
Lake or Pond Loops
Closed loop systems may also be used in lakes or
rivers to supply a heat source to the heat pump.
Typically a loop consisting of geothermal pipe
can be designed and placed in an area not much
deeper than 15ft with some water currents
present. In any lake or pond, municipal and area
by-laws must be observed in regards to a lake or
pond loop. The use of an environmentally
friendly loop fluid like ethanol should be
considered if the loop was ever damaged.
Consult an IGSHPA or CGC certified installer
for proper lake or pond loop design.
Piping Installation
All earth-loop piping materials should meet
CSA-C448. P/T plugs should be used so that
flow can be measured using the pressure drop of
the unit heat exchanger in lieu of other flow
measurement means. Earth loop temperatures
can range between 25-110°F and 2.25 to 3gpm
of flow per ton of cooling capacity is
recommended in these applications. Upon
completion of the ground loop piping, pressure
test the loop to assure a leak-free system.
Horizontal Systems: test individual loops as
installed. Test entire system when all loops are
assembled. Vertical U-Bends and Pond Loop
Systems: test vertical U-bends and pond loop
assemblies with a test pressure of at least 100
psi. Either water or air may be used as the testing
medium.
Table 2: Approximate Fluid Volume
Fluid Volume (gal [liters] per 100’ [30 meters]
Pipe)
Pipe Size Volume (gal)
[liters]
Copper
1” 4.1 [15.3]
1.25” 6.4 [23.8]
2.5” 9.2 [34.3]
Rubber Hose 1” 3.9 [14.6]
Polyethylene
¾” IPS
SDR11
2.8 [10.4]
1” IPS
SDR11
4.5 [16.7]
1.25” IPS
SDR11
8.0 [29.8]
1.5” IPS
SDR11
10.9 [40.7]
2” IPS
SDR11
18.0 [67.0]
1.25” IPS
SCH40
8.3 [30.9]
1.5 “IPS
SCH40
10.9 [40.7]
2” IPS
SCH40
17.0 [63.4]
Unit Heat
Exchanger
Typical 1.0 [3.8]
Flush Cart Tank 10” Dia x 3ft
tall
[254mm x
91.4cm tall]
10 [37.9]
Flushing the Earth Loop
Once piping is completed between the unit, flow
center and the ground loop, final purging and
charging of the loop is needed. A flush cart (at
least a 1.5hp pump) is needed to achieve
adequate flow velocity in the loop to purge air

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and dirt particles from the loop itself. An
antifreeze solution is used in most areas to
prevent freezing. All air and debris must be
removed from the earth loop piping system
before operation. Flush the loop with a high
volume of water at a high velocity (2 fps in all
piping) both directions.
The steps below must be followed for proper
flushing. Fill loop with water from a garden hose
through flush cart before using flush cart pump
to ensure an even fill. Once full, do not allow the
water level in the flush cart tank to drop below
the pump inlet line or air can be pumped back
out to the earth loop. Try to maintain a fluid
level in the tank above the return tee so that air
cannot be continuously mixed back into the
fluid. 50 psi surges can be used to help purge air
pockets by simply shutting off the return valve
going into the flush cart reservoir. This
procedure ‘dead heads’ the pump. To dead head
the pump until maximum pumping pressure is
reached, open the valve back up and a pressure
surge will be sent through the loop to help purge
air pockets from the piping system. Notice the
drop in fluid level in the flush cart tank. If air is
purged from the system, the level will drop
only 1-2 inches in a 10" diameter PVC flush
tank (about a half gallon) since liquids are
incompressible. If the level drops more than
this, flushing should continue since air is still
being compressed in the loop fluid. Do this a
number of times.
When the fluid level drops less than 1-2" in a 10"
diameter tank the flow can be reversed. Finally
the deadhead test should be checked again for an
indication of air in the loop. This fluid level
drop is your only indication of air in the loop.
Flushing & Filling Using 3-Way Valves
Step 1:
Use water and a high volume head circulator
pump to flush air and debris and to fill the loop
system.
- Refer to recommendations provided by
IGSHPA when choosing a pump for the flushing
process.
- It is recommended that pump suction be from
the bottom of a large volume container. Use a
suction line strainer to prevent debris discharged
into the container from being recycled to the
system.
Step 2:
Pump water into the system by connecting the
pump discharge hose to one (not both) of the 1”
NPT water connections located on the sides of
the 3-way flush valve. Connect a return hose to
the opposite side of the valve assembly to
discharge debris and air as water is added to the
loop.
Step 3:
Rotate the 3-way valves to engage the pump cart.
Step 4:
Start the pump. Add anti-freeze (if used) and
water to the container as needed so that no air
enters the system. This will push any air out of
the loop. If flushing assembly is equipped with
valves to reverse flow direction, do so
occasionally to help remove trapped air. When
bubbles cease in the return hose container, the
earth loop has been completely flushed.
Step 5:
Flush the heat pump. To do so, simply rotate the
valves while the pump is running. Flush the heat
pump using the same procedure as used to flush
the earth loop.
Pressurizing the System
Step 6:
After flushing and filling the system, rotate the
3-way valve discharging into the flush container
to pressurize the loop. Then turn the valves.
Step 7:
Turn off the flush cart pump. The system should
remain pressurized. Release excess pressure by
rotating either module valve to allow a small
amount of water to pass through and out of the
system and into the container. Some initial loss
of pressure can be expected and is due to the
expansion of the earth loop pipe under pressure.
The pressure will stabilize if the system has no
leaks.
Step 8:
Flushing, filling and pressurization should be
complete. Start the loop pump module
circulators.
Step 9:
Troubleshoot. If for some reason the circulators
are not operating, power off and diagnose the
problem.

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Step 10:
Using a single water pressure gauge, measure the
pressure drop at the pressure/temperature plugs
across the heat pump heat exchanger. Compare
the measurement with the flow versus the
pressure drop information for your specific
model (found in the tables below) and determine
the actual flow rate. If the flow rate is low,
recheck the selection of the loop pump module
model for sufficient capacity. If the model is
correct, there is likely trapped air or a restriction
in the flow circuit. System pressure should
increase rapidly as the flush pump works to force
more water into the system. Additional flushing
of the loop is needed if the water level in the
loop falls. This shows that there is air in the
system. System operating pressures should be
between 10 to 40PSI.
Table 3: Source/Load Heat Exchanger Water-Side Flow Data
W2W-36 gpm 7 8 9 10 11 12 13
psi 2.7 3.3 4.0 4.8 5.7 6.7 7.7
W2W-52 gpm 5 7 9 11 13 15 17
psi 1.3 1.6 2.1 2.8 3.6 4.6 5.8
W2W-72 gpm 12 14 16 18 20 22 24
psi 2.4 3.1 3.9 4.7 5.7 6.8 8.3
Table 4: Desuperheater Water-Side Flow Data
W2W-36 gpm 0.0 0.5 1.0 1.5 2.0
psi 0.0 0.3 0.5 1.2 1.9
W2W-52,72 gpm 1.0 1.5 2.0 2.5 3.0
psi 0.8 1.6 2.7 4.0 5.5
Table 5: Antifreeze Percentages by Volume
Type Minimum Temperature for Low Temperature Protection
10ºF [-12.2ºC] 15ºF [-9.4ºC] 20ºF [-6.7 ºC] 25ºF [-3.9 ºC]
100% USP Propylene Glycol 38% 25% 22% 15%
Ethanol* 29% 25% 20% 14%
*Must be denatured with any petroleum based product
Antifreeze may be added before, during, or after
the flushing procedure. However, depending
upon which time is chosen, antifreeze could be
wasted when emptying the flush cart tank. See
antifreeze section for more details. Loop static
pressure will fluctuate with the seasons.
Pressures will be higher in the winter months
than during the cooling season. This fluctuation
is normal and should be considered when
charging the system initially. Run the unit in
either heating or cooling for a number of minutes
to condition the loop to a homogenous
temperature. This is a good time for tool cleanup,
piping insulation etc. Then final flush and
pressurize the loop to a static pressure of 40-50
psi (winter) 15-20 psi (summer).
After pressurization, be sure to remove the plug
in the end of the loop pump motor(s) to allow
trapped air to be discharged and to ensure the
motor housing has been flooded. This is step is
only required for Grundfos wet rotor circulators
with end plugs. Ensure the loop flow center
provides adequate flow through the unit by
checking pressure drop across the heat exchanger
and comparing it to the figures shown in the
performance table.
Antifreeze
In areas where minimum entering loop
temperatures drop below 40°F or where piping
will be routed through areas subject to freezing,
antifreeze is needed. Alcohols and glycols are
commonly used as antifreeze. However, your
local territory manager should be consulted for
the antifreeze best suited to your area. Freeze
protection should be maintained to 15°F below
the lowest expected entering loop temperature.
For example, if 30°F is the minimum expected

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entering loop temperature, the leaving loop
temperature would be 25-22°F and freeze
protection should be at 15°F (30°F-15°F=15°F).
All alcohols should be premixed and pumped
from a reservoir outside of the building when
possible or introduced under water level to
prevent fuming. Initially calculate the total
volume of fluid in the piping system using the
Table. Then use the percentage by volume
shown in Table 5 for the amount of antifreeze.
Antifreeze concentration should be checked from
a well-mixed sample using a hydrometer to
measure specific gravity.
ELECTRICAL – LINE VOLTAGE
General Line Voltage Wiring
Be sure the available power is the same voltage
and phase as that shown on the unit serial plate.
Line and low voltage wiring must be done in
accordance with local codes or the National
Electrical Code whichever is applicable.
WARNING
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.
W2W Power Connection
Line voltage connection is made by connecting
the incoming line voltage wires to the “Line”
side of the contactor or the power block as
shown in the wiring diagram located on the
electrical panel door of the unit.
Field Wiring
All field installed wiring, including electrical
ground, must comply with the National
Electrical Code as well as all applicable local
codes.
Refer to the unit wiring diagrams for fuse sizes
and a schematic of the field connections that
must be made by the installing (or electrical)
contractor.
Consult the unit wiring diagram provided with
the equipment or located on the inside of the
compressor access panel to ensure proper
electrical hookup.
All final electrical connections must be made
with a length of flexible conduit to minimize
vibration and sound transmission to the building.
ELECTRICAL – LOW VOLTAGE
Thermostat Connections
The aquastat/thermostat or set point control
should be wired directly to the wire connections
in the unit. Refer to wiring diagrams provided
with the unit or the Ecologix pump module
supplied with the unit.
Water Solenoid Valves
When solenoid valves are used, a slow closing
valve may be required to prevent water hammer.
The valve takes approximately 60 seconds to
open (very little water will flow before 45
seconds) and it activates the compressor only
after the valve is completely opened (by closing
its end switch). Only relay or triac based
electronic thermo-stats should be used with the
AVM valve. When wired as described above, the
valve will operate properly with the following
notations.
1-The valve will remain open during a unit
lockout.
2-The valve will draw approximately 25-35 VA
through the “Y” signal of the thermostat.
Note: This can overheat the anticipators of
electromechanical thermostats. Therefore only
relay or triac based thermostats should be used
when a water solenoid valve is present.

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221 Holiday Inn Drive Cambridge ON ph: 519-658-4330
Figure 1: wiring diagram

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UNIT STARTING & OPERATING CONDITIONS
Operating Limits
Environment – This unit is designed for indoor
installation only.
Power Supply – A voltage variation of +/– 10%
of nameplate utilization voltage is acceptable.
Starting Conditions
W Series Units – Units can start and operate in
an ambient temperature of 45°F with entering
load side at 50°F, entering source side at 30°F,
with both at the stated flow rates of 3gpm per ton
for initial winter start-up.
Notes:
1. These are not normal or continuous
operating conditions. It is assumed that
winter start-up is to bring the building
space up to occupancy temperatures.
2. Voltage utilization range complies with
ARI Standard 110.
Determination of operating limits is dependent
primarily upon three factors:
1. Entering load temperature.
2. Entering source temperature
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.
Extreme variations in temperature and humidity
and corrosive water will adversely affect unit
performance, reliability, and service life.
Table 6: Operating Limits
Source Side Water Limits Cooling Heating
Minimum Entering Water 50ºF [10ºC] 20ºF[-6.6ºC]
Normal Entering Water 85ºF[º29.4C] 60ºF[15.6ºC]
Maximum Entering Water 110ºF[43.3ºC] 70ºF[21.1ºC]
Load Side Water Limits
Minimum Entering Water 50ºF[10ºC] 60ºF[15.6ºC]
Normal Entering Water 60ºF[15.6ºC] 100ºF[37.8ºC]
Maximum Entering Water 90ºF[32.2ºC] 120ºF[48.9ºC]
PIPING SYSTEM CLEANING & FLUSHING
Cleaning and flushing of the piping system is the
single most important step to ensure proper start-
up and continued efficient operation of the
system. Follow the instruction below to properly
clean and flush the system:
1. Verify electrical power to the unit is
disconnected.
2. Using a pump cart and the three-way valve
connections shown in the installation
drawings refill the system with water.
3. Bleed all air from the system as described in
the applications section of this manual.
Pressurize and check the system for leaks
and repair appropriately.
4. Set the back up electric heater or fossil fuel
fired boiler system 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.
5. Drain and refill the system adding tri-
sodium phosphate in a proportion of
approximately one pound per 150 gallons of
water (or other equivalent approved cleaning
agent). Reset the heater to raise the loop
temperature to about 100°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.
6. When the cleaning process is complete refill
the system and bleed off all air.
7. Test the system pH with litmus paper. The
system water should be slightly alkaline (pH

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7.5-8.5). Add chemicals, as appropriate, to
maintain acidity levels.
8. When the system is successfully cleaned,
flushed, refilled and bled, check the main
system panels, safety cutouts and alarms. Set
the controls to properly maintain loop
temperatures.
UNIT START-UP PROCEDURE
1. Adjust all valves to their full open position.
Turn on the line power to all heat pump units.
2. Operate each unit in the cooling cycle. Loop
water temperature entering the heat pumps
should be between 70° F and 110° F
3. Operate each heat pump in the heating cycle
immediately after checking cooling cycle
operation. A time delay will prevent the
compressor from re-starting for approximately
five (5) minutes.
4. Establish a permanent operating record by
logging the unit operating conditions at initial
start-up for each unit.
If a unit fails to operate, conduct the following
checks:
A. Check the voltage and current. They should
comply with the electrical specifications
described on the unit nameplate.
B. Look for wiring errors. Check for loose
terminal screws where wire connections have
been made on both the line and low-voltage
terminal boards.
C. Check the supply and return piping. They
must be properly connected to the inlet and
outlet connections on the unit.
D. If the checks described above fail to reveal
the problem and the unit still will not operate,
contact a trained service technician to ensure
proper diagnosis and repair of the equipment
WARNING
Ensure all water valves and controls are set
correctly to allow water to flow through the
load and source side of the unit prior to
engaging the compressor. Failure to do so
can lead to freezing of the heat exchangers
or water lines, which can permanently
damage the heat pump.
WARNING
Do not leave system filled in a building
without heat during the winter unless
antifreeze is used. Heat exchanger coils
never fully drain by themselves and will
freeze unless properly winterized.
Note: Units have a five-minute time delay in
the control circuit that can be eliminated on
the ICM PCB. See wiring diagram on unit for
wiring details. Jumper is marked “test”
Table 7: Water Temperature Change Through heat Exchanger
Water Flow, gpm Rise, Cooling ºF Drop, Heating ºF
For Closed Loop: Ground source or Closed Loop
Systems at 3gpm per ton 9–12 4–8
For Open Loop: Ground Water Systems at 1.5gpm
per ton 20 – 25 10 – 17

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Unit & System Checklist
**Before powering the system, please check the following**
Item Description Done
UNIT Checklist
1Ensure Voltage is within an acceptable range for the unit and wiring and fuses/breakers are
properly sized. Check low voltage wiring is complete
2Ensure transformer has properly selected control voltage tap. 208-230V units are factory
wired for 230V operation unless specified otherwise.
3Ensure entering water temperatures are within operating limits of Performance Table.
4Verify low water temperature cut-out is properly set. Check flow switch is operating
5Verify inlet and outlet water temperatures on both Load and source are recorded for each
heat pump upon startup. This check can eliminate nuisance trip outs and high velocity
water flows that can erode heat exchangers.
SYSTEM Checklist
1Check load and source water temperature for proper range and also verify heating and
cooling set points for proper operation.
2System water pH is 7.5 - 8.5. Proper pH promotes longevity of hoses and fittings.
3Verify all hoses are connected end to end when flushing to ensure debris bypasses unit
heat exchanger and water valves etc. Water used in the system must be potable quality
initially and clean of dirt, piping slag, and strong chemical cleaning agents. Verify all air
is purged from the system. Air in the system can cause poor operation or system corrosion.
4Verify all hoses are connected end to end when flushing to ensure debris bypasses unit
heat exchanger and water valves etc. Water used in the system must be potable quality
initially and clean of dirt, piping slag, and strong chemical cleaning agents. Verify all air
is purged from the system. Air in the system can cause poor operation or system corrosion.
5Cooling Tower/Boiler: Check equipment for proper set-points and operation.
6Verify the standby pump is properly installed and in operating condition.
7Verify system controls function and operate in the proper sequence.

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Preventative Maintenance
Water Coil Maintenance for attached forced
air heating systems: (Direct Ground Water
Applications Only)
If the installation is performed in an area with a
known high mineral content (125 P.P.M. or
greater) in the water, it is best to establish with
the owner a periodic maintenance schedule so
the coil can be checked regularly.
If periodic coil cleaning is necessary, use
standard coil cleaning procedures that are
compatible with either the heat exchanger
material or copper water lines.
Generally, the more water flowing through the
unit the less chance for scaling therefore 1.5gpm
per ton is recommended as a minimum flow.
Compressor:
Conduct annual amperage checks to ensure amp
draw is no more than 10% greater than that
indicated by serial plate data.
Cabinet:
Do not allow water to stay in contact with the
cabinet for long periods of time to prevent
corrosion of the cabinet sheet metal. Generally
all cabinets are set up from the floor a few inches
on an isolation pad for sound control. The
cabinet can be cleaned using a mild detergent.
Refrigerant System:
To maintain sealed circuit integrity, do not install
service gauges unless unit operation appears
abnormal. Reference the operating chart for
pressure and temperatures. Verify that air and
water flow rates are at proper levels before
servicing the refrigerant circuit.
Water Coil Maintenance for attached forced
air heating systems: (All Other Water Loop
Applications)
Generally water coil maintenance is not needed;
however, if the installation is located in a system
with a known high dirt or debris content, it is
best to establish with the owner a periodic
maintenance schedule so the coil can be checked
regularly. These dirty installations are a result of
the deterioration of iron or galvanized piping or
components in the system or open cooling
towers requiring heavy chemical treatment and
mineral buildup through water use. If periodic
coil cleaning be necessary, use standard coil
cleaning procedures which are compatible with
both the heat exchanger material and copper
water lines. Generally, more water flowing
through the unit lowers the chance for scaling.
However, flow rates over 3gpm per ton can
produce water (or debris) velocities that can
erode the heat exchanger wall and ultimately
produce leaks.