Electro industries Warmflo ii Owner's manual

01/10/2008 HI321

WARMFLO II

Dual Heat System

Furnace Interface Controller and Control Voltage Installation

and Operations

Application – Heat Pump Multi-Wire Thermostat

Basic or Single Speed Heat Pump

WF-LGR4

As in previous interface modules, this is the plug-in controller for Electro-Mate EM-WU***** or EM-

WD***** plenum heater. Mechanical installation information is contained within companion installation

manual EI703 or EI707.

Also accompanying each system is a specific control program “chip”. This is typically part of ordering

information and should be listed on packing slip. A listing of these “chip codes” is in the controller setup

sections of this document.

This is an upgraded and improved WF-LGR3. Improvements are the response of field requests.

Thermostat wiring terminal block, pass through

Improved stat emergency heat function, no longer requiring extra relay

Reversing valve detection relay, positive WarmFlo and gas furnace interrupt during

cooling (RV logic pin jumper setup required)

Front panel “cool” light

Equipped for ECM blower motor, direct Y connection

Faster defrost response

Easier single cable plug-in to the upgraded (10-pin connector) WarmFlo II board

Reference Field Service Bulletin 1094 which relates to heat pump units with RV logic high for heating –

this unit identified as “Rev A” and has a control board identifier “WFIH46708A” includes revisions

relating to stat emergency “E” hookup and operation, cool light function, etc. Also study page 7,

determine the need for “stat-B” pin jumper.

Any application – this design assumes the connected room thermostat cannot and does not output an

emergency “E” function during cooling. During any and all cooling operations, this controller board “E WF”

and “E GAS” tab must be at 0 volts.

Drawings: HH340

HD320

HH339 page 1

01/10/2008 HI321

TABLE OF CONTENTS PAGE

INTRODUCTION 1

INSTALLATION REQUIREMENTS 1

MECHANICAL INSTALLATION 2

WF Furnace Interface 2

EM-WU***** Upflow Application 2

EM-WU*****/EM-WD***** Horizontal Application 2

EM-WD***** Downflow Application 3

WIRINGINSTALLATION 4

HighVoltage 4

LowVoltage 4

Outdoor Sensor (OT) 4

Supply Sensor (ST) 4

WF-LGR4 & WF II Wiring & Setup 6

Chip Code:

HPDH 8

HPDF 9

HPEL 10

OPERATION INDICATORS 12

Furnace Interface Module 12

WarmFlo II Controller 12

HANDHELD ANALYZER/LAPTOP SOFTWARE 14

SPECIAL APPLICATION/INSTALLATION 15

For Various Heat Pump, Multi-Speed, Multi-Stage Furnaces, Blower Options, Oil Furnace, etc.

OPTIONAL ACCESSORIES 16

TROUBLESHOOTING 16

Drawings Included: HH340

HD320, HH339 pg 1

01/10/2008 1 HI321

INTRODUCTION

Prior to installation we recommend that the installer verify the product intended application is

applicable to your current installation needs. The system application for this model combination is dual

heat, gas or oil furnace as standby, outdoor heat pump unit, and the heat pump manufacturer’s room

thermostat. If your application does not include dual heat with standby furnace, but electric heat with an

air handler, do not use this WarmFlo II series or this installation manual. Contact factory for other

models (EM-WE series, WF-DH*** kits, etc.).

EM-WU***** – WarmFlo Electro-Mate ranging from 10 kW to 25 kW. Can be installed in upflow

applications only.

EM-WD***** – WarmFlo Electro-Mate ranging from 10 kW to 25 kW. Can be installed in downflow

and horizontal applications.

Caution, Heat Pump Application: Depending upon mechanical positioning and airflow, in all

cases (heat pump) the electric element, Electro-Mate, unit must be on the supply or warm side of

the HP refrigerant coil.

First-time or non-routine user – before attempting installation or setup, suggest studying the last section

of this manual, operational information and terminology definitions. Attached HD320 is also a training

document. Also if you have not attended a WarmFlo training session, call the factory for other

descriptive documents or PowerPoint.

**Installation Notice - Upon installation it is necessary that all the components of the heating system are

in place and functional. This controller is designed to operate the complete heating system - heat pump,

backup furnace (gas or oil), Electro-Mate, room thermostat, WF outdoor sensor, etc. If one of these

components is missing or not initially installed, improper performance of WarmFlo II and the system may

be experienced. In other words, if the gas furnace doesn’t exist, LP tank not yet installed or filled, and the

WarmFlo II is operating on a cold day; do not be disappointed if there is no heat.

Warranty/Checkout – Attached to this manual is a warranty certification and checkout procedure. This

must be completed and returned for warranty coverage.

INSTALLATION REQUIREMENTS

1. All installation work must be performed by trained, qualified contractors or technicians. Electro

Industries, Inc., sponsors installation and service schools to assist the installer. Visit our web site at

electromn.com for upcoming service schools.

2. All electrical wiring must be in accordance with National Electric Code and local electric codes,

ordinances, and regulations.

3. Observe electric polarity and wiring colors. Failure to observe could cause electric shock and/or

damage to the equipment.

4. This unit can only be used for its intended design as described in this manual. Any internal wiring

changes, modifications to the circuit board, modifications or bypass of any controls, or installation

practices not according to the details of this manual will void the product warranty, the ARL

certification label, and manufacturer product liability. Electro Industries, Inc., cannot be held

responsible for field modifications, incorrect installations, and conditions which may bypass or

compromise the built-in safety features and controls.

5. The only approved installation for this Electro-Mate series is upflow and horizontal furnace and

above or downstream from the air conditioning or heat pump A-coil. Any other configuration or

furnace plenum/ducting installation voids warranty and manufacturers product liability.

01/10/2008 2 HI321

MECHANICAL INSTALLATION

WF Furnace Interface, WF-LGR4

The mounting location from this enclosure is flexible to any convenient location were the thermostat

connection is easily accessible. The distance between this controller and WF II is limited only by the

provided 4’ cable.

The housing has also been arranged for easy attachment directly to the right side of the Electro-Mate

cabinet. Depending upon furnace surroundings, you can explore mounting this controller directly to the

Electro-Mate, right cabinet end.

EM-WU***** Electro-Mate Upflow Application

Electro-Mate nameplate or companion installation manual EI703 is required for correct mechanical

installation. If you do not have manual #EI703 do not attempt to do the mechanical installation, contact

the factory for a replacement manual. The primary installation concerns focusing on the existing furnace

and ducting system’s airflow capacity and necessary plenum baffling required by the specific Electro-

Mate for correct installation. It is true that the WarmFlo II modulating control and the supply sensor

adjust the electric heat or element capacity based upon temperature. But if you do not have the required

CFM airflow (example 20 kW, 1400 CFM), you could have a situation where you cannot heat the house.

Another even more serious situation (because of improper airflow) is when all stages are on at colder

temperatures and the unit is cycling on mechanical safety hi-limit. When cycling on the hi-limit probe,

the WarmFlo II supply sensor basically gets confused because at one point it is way up in temperature and

then the elements simply disappear and it dips down, the net result probably is switching over to standby

at premature intervals. There is no substitute for adequate airflow capacity and plenum baffling.

EM-WD***** Electro-Mate Horizontal Application

NOTE: It is not permissible to rotate the WarmFlo Electro-Mate 180°. These instructions apply to only

rotating the Electro-Mate unit 90°.

With WarmFlo, IT IS permissible (and authorized by the manufacturer) to turn the Electro-Mate unit 90°

for horizontal application. However, you must follow the instructions below relating to temperature

sensor positioning, etc.

The reason this practice is acceptable is because the element power and temperature is controllable by the

WarmFlo sensor. When placing the sensor at the top of the duct as stated below, heat rise will keep the

elements off even without the blower.

Installation steps

•Ideally, the WF II Electro-Mate should be inserted on an appropriate duct side so that the circuit

breakers are at the bottom.

•Locate the WF II Electro-Mate as high as possible in the horizontal duct. At the top, the elements

should almost touch the top of the duct.

•If the vertical dimension of the horizontal duct is greater than the WF II Electro-Mate element

area, baffle at the bottom.

•If the horizontal duct is deeper than the electric elements, baffling at the back is required.

•Locate and install the WarmFlo duct sensor approximately 4” down from the duct top and 12”

away from the Electro-Mate elements.

•Checkout and operation should be identical to standard WarmFlo system.

01/10/2008 3 HI321

EM-WD***** Electro-Mate Downflow Application

Electro-Mate nameplate or companion installation manual EI707 is required for correct mechanical

installation. If you do not have manual #EI707 do not attempt to do the mechanical installation, contact