FHP EV Series Manual

TABLE OF CONTENTS
Model Nomenclature..................................................................................................1
Initial Inspection .........................................................................................................2
General Description ...................................................................................................2
Moving and Storage...................................................................................................2
Safety Considerations ................................................................................................2
Location.....................................................................................................................2
Installation..................................................................................................................2
Condensate Drain ......................................................................................................3
Duct System ..............................................................................................................3
Electrical ....................................................................................................................3
Thermostat Connections............................................................................................3
Safety Devices And The Lockout Circuit.....................................................................4
Piping ........................................................................................................................4
Well Water Systems...................................................................................................4
Cooling Tower / Boiler Application .............................................................................4
Earth Coupled Systems .............................................................................................7
Electric Heater Package Option .................................................................................7
System Checkout ......................................................................................................7
Unit Start-Up .............................................................................................................7
Maintenance ..............................................................................................................8
Optional Ground Loop Pumping Package..................................................................8
Optional Heat Recovery Package Water Piping..........................................................9
Temperature Pressure Chart....................................................................................10
Trouble Shooting .....................................................................................................11
EV SERIES
EV SERIES
INSTALLATION
INSTALLATION
AND MAINTENANCE MANUAL
MODEL NOMENCLATURE
SERIES:
EV-ENVIRO SERIES
NOMINAL CAPACITY:
VOLTAGE DESIGNATION:
1 - 208/1/60 & 230/1/60
3 - 208/3/60 & 230/3/60
CABINET CONFIGURATION:
VT - VERTICAL
HZ - HORIZONTAL
CF - COUNTERFLOW
HEAT EXCHANGER MATERIAL:
C - COPPER
N - CUPRO-NICKEL
SUPPLY AIR LOCATION:
T - TOP
F - FRONT
R - REAR
S - STRAIGHT THRU
E - END BLOW
B - BOTTOM
RETURN AIR LOCATION:
L - LEFT
R - RIGHT
B - BACK
F - FRONT
WATER CONNECTION
LOCATION
F - FRONT
EV 036 -1 VT C - F L T

INTRODUCTION:
The EV Series uses a scroll compressor and refrigerant R-
410A to achieve high efficiency levels, quiet operation and
reliable performance.
The new refrigerant provides performance similar to that of R-
22 with one major advantage. Refrigerant R-410A is an HFC
so it does not contain any ozone depleting HCFC's or CFC's.
INITIAL INSPECTION:
Be certain to inspect all cartons or crates on each unit as
received at the job site before signing the freight bill. Verify that
all items have been received and that there are no visible
damages; note any shortages or damages on all copies of the
freight bill. In the event of damage or shortage, remember that
the purchaser is responsible for filing the necessary claims
with the carrier. Concealed damages not discovered until after
removing the units from the packaging must be reported to
the carrier within 15 days of receipt.
GENERAL DESCRIPTION:
The EV Water-to-Air Heat Pumps provide the best
combination of performance and efficiency available. Safety
devices are built into each unit to provide the maximum
system protection possible when properly installed and
maintained.
The EV Water-to-Air Heat Pumps are Underwriters
Laboratories (UL) and (cUL) listed for safety. The EV Water-to-
Air Heat Pumps are designed to operate with entering fluid
temperature between 25°F to 75°F in the heating mode and
between 50°F to 110°F in the cooling mode.
NOTE: 50°F Min. EWT for well water applications with
sufficient water flow to prevent freezing. Antifreeze solution is
required for all closed loop applications. Cooling Tower/Boiler
and Earth Coupled (Geo Thermal) applications should have
sufficient antifreeze solution to protect against extreme
conditions and equipment failure. Frozen water coils are not
covered under warranty.
WARNING: This product should not be used for temporarily
heating/cooling during construction. Doing so may effect the
units warranty.
MOVING AND STORAGE:
If the equipment is not needed for immediate installation upon
its arrival at the job site, it should be left in its shipping carton
and stored in a clean, dry area. Units must only be stored or
moved in the normal upright position as indicated by the “UP”
arrows on each carton at all times. If unit stacking is required,
stack units as follows: Vertical units, no more than two high.
Horizontal units, no more than three high.
SAFETY CONSIDERATIONS:
CAUTION: R-410A systems operate at higher pressures than
standard R-22 systems. Do not use R-22 service equipment
or components on R-410A equipment.
Installation and servicing of this equipment can be hazardous
due to system pressure and electrical components. Only
trained and qualified personnel should install, repair, or service
the equipment. Untrained personnel can perform basic
functions of maintenance such as cleaning coils and replacing
filters.
WARNING: Before performing service or maintenance
operations on the system, turn off main power to the unit.
Electrical shock could cause personal injury or death.
When working on equipment, always observe precautions
described in the literature, tags, and labels attached to the
unit. Follow all safety codes. Wear safety glasses and work
gloves. Use a quenching cloth for brazing, and place a fire
extinguisher close to the work area.
LOCATION:
Locate the unit in an indoor area that allows easy removal of
the filter and access panels, and has enough room for service
personnel to perform maintenance or repair. Provide sufficient
room to make fluid, electrical, and duct connection(s). If the
unit is located in a confined space such as a closet, provisions
must be made for return air to freely enter the space. On
horizontal units, allow adequate room below the unit for a
condensate drain trap and do not locate the unit above supply
piping. These units are not approved for outdoor installation;
therefore, they must be installed inside the structure being
conditioned. Do not locate in areas that are subject to
freezing.
INSTALLATION:
WARNING: Remove all shipping blocks under blower
housing. Loosen compressor mounting bolts.
MOUNTING VERTICAL UNITS:
Vertical units up to five tons
are available in left, right,
front, or rear air return
configurations. Vertical units
should be mounted level on
a vibration (Figure #1)
absorbing pad slightly larger
than the base to minimize
vibration transmission to the
building structure. It is not
necessary to anchor the
unit to the floor.
MOUNTING
HORIZONTAL UNITS:
While horizontal units
may be installed on any
level surface strong
enough to hold their
weight, they are
typically suspended
above a ceiling by
threaded rods. The rods
are usually attached to
the unit corners by
hanger Bracket kits (P/N 930-004, or 006). (See Figure #2).
The rods must be securely anchored to the ceiling. Refer to
the hanging bracket assembly and installation instructions for
details. (See unit horizontal detail drawing). Horizontal units
installed above the ceiling must conform to all local codes. An
auxiliary drain pan if required by code, should be at least four
inches larger than the bottom of the heat pump. Plumbing
connected to the heat pump must not come in direct contact
with joists, trusses, walls, etc..
2
EV SERIES
(Figure #1)
(Figure #2)
VIBRATION
PAD
FULL SIZE

Some applications require an attic floor installation of the
horizontal unit. In this case the unit should be set in a full size
secondary drain pan on top of a vibration absorbing mesh.
The secondary drain pan prevents possible condensate
overflow or water leakage damage to the ceiling. The
secondary drain pan is usually placed on a plywood base
isolated from the ceiling joists by additional layers of vibration
absorbing mesh. In both cases, a 3/4” drain connected to this
secondary pan should be run to an eave at a location that will
be noticeable. If the unit is located in a crawl space, the
bottom of the unit must be at least 4” above grade to prevent
flooding of the electrical parts due to heavy rains.
CONDENSATE DRAIN:
A drain line must be connected to the heat pump and pitched
away from the unit a minimum of 1/8” per foot to allow the
condensate to flow away from the unit.
This connection must be in conformance with local plumbing
codes. A trap must be installed in the condensate line to
insure free condensate flow. (Heat Pumps are not internally
trapped). A vertical air vent is sometimes required to avoid air
pockets. (See Figure #3). The length of the trap depends on
the amount of positive or negative pressure on the drain pan.
A second trap must not be included.
The horizontal unit should be pitched approximately 1/4”
towards the drain in both directions, to facilitate condensate
removal. (See Figure #4)
DUCT SYSTEM:
All EV models are provided with a return air duct flange and a
supply air outlet collar to facilitate duct connections. Refer to
the individual data specification sheet for physical dimensions
of the collar and flange.
A flexible connector is recommended for supply and return air
connections on metal duct systems. All metal ducting should
be insulated with a minimum of one inch duct insulation to
avoid heat loss or gain and prevent condensate forming during
the cooling operation. Application of the unit to uninsulated
duct work is not recommended as the unit’s performance will
be adversely affected. Do not connect discharge ducts directly
to the blower outlet. The factory provided air filter must be
removed when using a filter back return air grill.The factory
filter should be left in place on a free return system.
If the unit will be installed in a new installation with new duct
work, the installation should be designed using current
ASHRAE procedures for duct sizing. If the unit will be
connected to an existing duct system, a check should be
made to assure that the duct system has the capacity to
handle the air required for the unit application. If the duct
system is too small, larger duct work must be installed. Be
certain to check for existing leaks and repair.
The duct system and all diffusers should be sized to handle
the designed air flow quietly. To maximize sound attenuation
of the unit blower, the supply and return air plenums should
be insulated. There should be no direct straight air path thru
the return air grille into the heat pump. The return air inlet to
the heat pump must have at least one 90 degree turn away
from the space return air grille. If air noise or excessive air flow
are a problem, the blower speed can be changed to a lower
speed to reduce air flow.
ELECTRICAL:
All field wiring must comply with local and national fire, safety
and electrical codes. Power to the unit must be within the
operating voltage range indicated on the unit’s nameplate. On
three phase units, phases must be balanced within 2%.
Properly sized fuses or HACR circuit breakers must be
installed for branch circuit protection. See equipment rating
plate for maximum size. The unit is supplied with an opening
for attaching conduit. Be certain to connect the ground lead to
the ground lug in the control box. Connect the power leads as
indicated on the unit wiring diagram.
NOTE: Units supplied with internal electric heat require two
(2) separate power supplies. One for the unit compressor
circuit and one for the electric heater elements which also
powers the unit blower motor and control circuit.
Refer to the ELECTRIC HEATER PACKAGE OPTION section
on page 6 and figure #8. for wiring instructions, minimum
circuit ampacities and maximum fuse/breaker sizing.
THERMOSTAT CONNECTIONS:
Thermostat wiring is connected to the 7-position low voltage
terminal block located in the upper portion of the electrical
box. The thermostat connections and their functions are as
follows:
C Transformer 24 VAC Common
O Reversing Valve (energized in cooling)
Y Compressor contactor
R Transformer 24 VAC Hot
W2 Auxiliary Electric Heat (2nd stage heat) runs in
conjunction with the compressor
G Fan
E Emergency heat
3
EV SERIES
(Figure #3)
(Figure #4)

SAFETY DEVICES AND THE LOCKOUT CIRCUIT:
Each EV Series unit is factory provided with a CCMI solid state
controller. The CCMI controller incorporates the standard
functions of electromechanical controls while adding several
useful features commonly needed in water source and
geothermal heat pump applications. In addition to the normal
control functions, the CCMI controller includes the following
features:
•RANDOM START - Each controller features a
random start ranging from 30 - 60 seconds.
•ANTI-SHORT CYCLE TIMER - 5 minute delay on break
timer to prevent compressor short cycling.
•LOW PRESSURE BYPASS TIMER - Bypasses the low
pressure switch for 90 seconds to avoid nuisance
lockouts during cold start up.
•HIGH PRESSURE SWITCH DELAY - One (1) second
delay provides switch stabilization on start up to prevent
nuisance lockouts.
•BROWNOUT/SURGE/POWER INTERRUPTION
PROTECTION - A 20 millisecond window is monitored
for the above condition. After the condition is detected,
the 5-minute delay on break timer is initiated in
conjunction with the random start timer before a restart is
allowed.
•MALFUNCTION OUTPUT - The controller has a set of
N.O. wet contacts for remote fault indication.
•TEST/SERVICE PIN - A jumper pin is provided to reduce
all time delay settings to 6 seconds during
troubleshooting or operation verification.
•L.E.D. INDICATORS - Two L.E.D. INDICATORS are
provided as follows:
GREEN: Power L.E.D. indicates voltage present at the
board.
RED: Fault indicator with blink code as follows:
1 BLINK - HIGH PRESSURE LOCKOUT
2 BLINK - LOW PRESSURE LOCKOUT
•INTELLIGENT RESET - If a fault condition is initiated the
5-minute delay on break period and the random start
timer are initiated and the unit will restart after the delays
expire. If the same fault condition is initiated a second
time . The unit will be locked out and requires lockout
reset.
•LOCKOUT RESET - Power must be removed from the
controller then reapplied for the reset. This can be
achieved by turning the unit thermostat off and then back
on or by shutting off unit power at the unit disconnect.
PIPING:
Supply and return piping must be as large as the unit
connections on the heat pump (larger on long runs). Never use
flexible hoses of a smaller inside diameter than that of the fluid
connections on the unit. EV Units are supplied with either a
copper or optional cupro-nickel condenser. Copper is
adequate for ground water that is not high in mineral content.
Should your well driller express concern regarding the quality
of the well water available or should any known hazards exist
in your area, we recommend proper testing to assure the well
water quality is suitable for use with water source equipment.
In conditions anticipating moderate scale formation or in
brackish water a cupro-nickel heat exchanger is
recommended.
Both the supply and discharge water lines will sweat if subject
to low water temperature. These lines should be insulated to
prevent damage from condensation.
All manual flow valves used in the system must be ball valves.
Globe and gate valves must not be used due to high pressure
drop and poor throttling characteristics. Never exceed the
recommended water flow rates. Serious damage or erosion of
the water to refrigerant heat exchanger could occur.
Always check carefully for water leaks and repair
appropriately. Units are equipped with female pipe thread
fittings. Consult the specification sheets for sizes. Teflon tape
sealer should be used when connecting water piping
connections to the units to insure against leaks and possible
heat exchanger fouling. Do not overtighten the connections.
Flexible hoses should be used between the unit and the rigid
system to avoid possible vibration. Ball valves should be
installed in the supply and return lines for unit isolation and unit
water flow balancing.
Pressure / temperature ports are recommended in both the
supply and return lines for system flow balancing. The water
flow can be accurately set by measuring the water-to-
refrigerant heat exchangers water side pressure drop. See the
unit specification sheets for the water flow and pressure drop
information.
CAUTION: Water piping exposed to extreme, low ambient
temperatures is subject to freezing.
WELL WATER SYSTEMS: (50°F EWT Min.) (Figure #5)
When a water well is used exclusively for supplying water to
the heat pump, the pump should operate only when the heat
pump operates. A 24-volt, double pole single throw (DP/ST)
contactor can be used to operate the well pump with the heat
pump.
When two or more units are supplied from one well, the pump
can be wired to operate independently from either unit. Two
24-volt double pole single throw relays wired in parallel are
required. An upsized VA transformer may be required in either
case.
When using a single water well to supply both domestic water
and water to the heat pump, care must be taken to insure that
the well can provide sufficient flow for both.
In well water applications, water pressure must always be
maintained in the heat exchanger. This can be accomplished
with either a control valve or a bladder type expansion tank.
Also, a slow closing 24-volt solenoid valve must be utilized to
prevent water hammer.
The discharge water from the heat pump is not contaminated
in any manner and can be disposed of in various ways
depending on local codes (i.e. discharge well, dry well, storm
sewer, drain field, stream, pond, etc.)
COOLING TOWER / BOILER APPLICATION: (Figure #6)
To assure adequate cooling and heating performance, the
cooling tower and boiler fluid loop temperature should be
maintained between 50° F to 75° F in the heating mode and
60° to 110° in the cooling mode. In the cooling mode, heat is
rejected from the unit into the water loop. A cooling tower
provides evaporative cooling to the loop fluid; thus,
maintaining a constant supply temperature to the unit.
When utilizing an open cooling tower, chemical water
treatment is mandatory to ensure the water is free of corrosive
materials.
4EV SERIES

5
EV SERIES
(Figure #5)
(Figure #6)
COOLING TOWER/BOILER APPLICATION
1. LINE VOLTAGE DISCONNECT (UNIT)
2. LOW VOLTAGE CONTROL CONNECTION
3. P/T PLUGS (Optional)
4. HOSE KITS (Optional)
5. BALL VALVES
6. SUPPLY AND RETURN LINES OF CENTRAL SYSTEM
7. FLEX DUCT CONNECTION
8. HANGING BRACKETS ASSEMBLY (1/2 - 5 TON MODELS)
9. THREADED ROD
NOTE: SEE FIGURE #3 FOR CONDENSATE DRAIN CONNECTION
WELL WATER APPLICATIONS (50°F EWT MIN.)
1. LINE VOLTAGE DISCONNECT (UNIT)
2. FLEX DUCT CONNECTION
3. LOW VOLTAGE CONTROL CONNECTION
4. LINE VOLTAGE CONNECTION
5. VIBRATION PAD
6. P/T PORTS
7. HOSE KITS (Optional)
8. BALL VALVES
9. SOLENOID VALVE SLOW CLOSING
10. CONDENSATE DRAIN CONNECTION
11. PRESSURE TANK (Optional)
12. LINE VOLTAGE DISCONNECT (ELECTRIC HEATER)
NOTE: SEE FIGURE #3 FOR CONDENSATE DRAIN CONNECTION

TABLE 1 - HP Series Electrical Data
* All 15 and 20 kW heaters can be separated into two individual circuits. The wiring information listed presumes the unit transformer
and blower motor will be wired to the first circuit.
6
EV SERIES
EARTH COUPLED APPLICATION
1. LINE VOLTAGE DISCONNECT (UNIT)
2. FLEX DUCT CONNECTION
3. LOW VOLTAGE CONTROL CONNECTION
4. LINE VOLTAGE CONNECTION (UNIT)
5. P/T PORTS
6. VIBRATION PAD
7. CONDENSATE DRAIN
8. GROUND LOOP CONNECTION KIT (550-016, 017)
9.* GROUND LOOP PUMPING PACKAGE
10. POLYETHELENE WITH INSULATION
11. LINE VOLTAGE DISCONNECT (ELECTRIC HEATER)
NOTE: SEE FIGURE #3 FOR CONDENSATE DRAIN CONNECTION
* Optional Internal Installed
(Figure #7)
208V 240V 208V 240V 208V 240V
❍EV030 thru 042 HP050-1XS 4.8 17.3 20.0 L1/L2 27.1 30.4 30 30 8
❍EV048 thru 060 HP050-1XM 4.8 17.3 20.0 L1/L2 27.1 30.4 30 30 8
❍EV030 thru 042 HP075-1XS 7.2 23.6 30.0 L1/L2 34.9 42.9 40 45 8
❍EV048 thru 060 HP075-1XM 7.2 23.6 30.0 L1/L2 35.7 43.8 40 45 8
❍EV030 thru 042 HP100-1XS 9.6 34.7 40.0 L1/L2 48.8 55.4 50 60 6
❍EV048 thru 060 HP100-1XM 9.6 34.7 40.0 L1/L2 49.5 56.3 50 60 6
❍EV048 thru 060 HP150-1XM 14.4 52.0 60.0 SINGLE 71.2 81.3 80 90 4
HP150-1XM 14.4 34.7 40.0 L1/L2 49.5 56.3 60 60 6
17.3 20.0 L3/L4 21.7 25.0 25 25 10
❍EV048 thru 060 HP200-1XM 19.2 69.3 80.0 L1/L2 92.9 106.3 100 110 2
HP200-1XM 19.2 34.7 40.0 L1/L2 49.5 56.3 50 60 6
34.7 40.0 L3/L4 43.4 50.0 45 50 6
All heaters rated single phase 60hz, and include unit fan load. All fuses type “D” time delay or HACR type breaker or HRC FORM 1 Wire
size based on 60 deg. C copper conductors.
EV HEATER KW HEATER CIRCUIT MCA MAX AWG
MODEL MODEL AMPS FUSE MIN

7
EV SERIES
A secondary heat exchanger (plate frame between the unit
and the open cooling tower) may also be used. It is imperative
that all air is eliminated from the closed loop side of the heat
exchanger to prevent condenser fouling.
In the heating mode, heat is absorbed from the water loop to
the unit. A boiler can be utilized to maintain the loop within the
proper temperature range.
Before final connection to the unit, the supply and return
hoses must be connected together and the system flushed to
remove any dirt, piping chips, or any other foreign material.
EARTH COUPLED SYSTEMS: (Figure #7)
NOTE: Closed loop and pond applications require specialized
design knowledge. No attempt at these installations should be
made unless the dealer has received specialized training.
Utilizing Ground Loop Pumping Package (GLP), makes the
installation easy. Anti-freeze solutions must be utilized when
low evaporating conditions are expected to occur. Refer to the
installation manuals for more specific instructions.
ELECTRIC HEATER PACKAGE OPTION:
CAUTION: The HP series heater package requires its own
electrical service separate from the heat pump’s power
supply. DO NOT attempt to wire the package into the same
circuit as the heat pump.
Factory or field installed internal electric heater packages are
available for all EV Series units with the exception of horizontal
straight through configuration models.
Two power supplies are required when utilizing the heater
package option.
Disconnect all power supplies when servicing or installing
heater packages or heat pumps. Failure to do so could result
in serious injury or even death.
When a heater package is utilized the power supply to the
heater package also powers the heat pumps control
transformer primary and the blower motor. This allows control
circuit and motor operation in case of the heat pumps
compressor or associated power supply failure.
When field installing heater packages (refer to the HP Series
Heater Package Installation Instructions), remove the two
factory jumper wires between the comp. contactor (L1 and L2)
and the power interconnect terminal block. Connect (2) two
#14 gauge wires in conjunction with a #16 gauge wire to the
power interconnect terminal block and the electric heater
power block (L1 and L2). (Figure #8).
The heater package power supply is connected to L1 and L2
in the heater package electrical control box and the heat
pump power supply is connected to L1 and L2 of the
compressor contactor. (See figure #8)
Each EV Series heat pump has specific heater packages
available. Nameplate information for wire sizing and fusing are
shown in the above table. All heater packages are 208/240
volt single phase only. For three phase requirements an inline
duct heater from an independent heater manufacturer is
recommended.
SYSTEM CHECKOUT:
After completing the installation, and before energizing the
unit, the following system checks should be made:
• Verify that the supply voltage to the heat pump is in
accordance with the nameplate ratings.
• Make sure that all electrical connections are tight and
secure.
• Check the electrical fusing and wiring for the correct size.
Verify that the low voltage wiring between the thermostat
and the unit is correct.
• Verify that the water piping is complete and correct.
• Check that the water flow is correct, and adjust if
necessary.
• Check the blower for free rotation, and that it is secured
to the shaft.
• Verify that vibration isolation has been provided.
• Unit is serviceable. Be certain that all access panels are
secured in place.
UNIT START-UP:
1. Set the thermostat to the highest setting.
2. Set the thermostat system switch to “COOL”, and the fan
switch to the “AUTO” position. The reversing valve
solenoid should energize. The compressor and fan should
not run.
3. Reduce the thermostat setting approximately 5 degrees
below the room temperature.
4. Verify the heat pump is operating in the cooling mode.
5. Turn the thermostat system switch to the "OFF" position.
The unit should stop running and the reversing valve
should deenergize.
6. Leave the unit off for approximately five (5) minutes to
allow for system pressure equalization.
7. Turn the thermostat to the lowest setting.
8. Set the thermostat switch to "HEAT".
Add (2) #16
Jumpers for
field installed
Electric Heater
Electric
Heater
Power
Block
Power
Interconnect
Terminal Block
Remove Jumpers
for field installed
electric heat
Comp.
Contactor
(Figure #8)

8EV SERIES
9. Increase the thermostat setting to approximately five (5)
degrees above the room temperature.
10. Verify the heat pump is operating in the heating mode.
11. Set the thermostat to maintain the desired space
temperature.
12. Check for vibrations, leaks, etc…
13. Instruct the homeowner on the unit and thermostat
operation.
IMPORTANT NOTES WHEN SERVICING
AN EV SERIES UNIT:
CAUTION: This system uses refrigerant R-410A which has
higher pressures than R-22 and other refrigerants. No other
refrigerant may be used in this system. Gage set, hoses, and
recovery system must be designed to handle R-410A.
The high pressure switch is set to open at 600 PSI. This is
much higher than the opening pressure in an R-22 unit.
The Compressors used in this product is specifically designed
for R-410A and that refrigerant's higher operating pressures. It
contains a polyolester lubricating oil that is compatible with
the new refrigerant. The required oil is Mobil EAL Arctic 22CC.
The polyolester (POE) oil is very hygroscopic, meaning it
absorbs water readily. POE oils can absorb 15 times as much
water as other oils designed for HCFC and CFC refrigerants.
Take all necessary precautions to avoid exposure of the oil to
the atmosphere.
Preventing moisture from entering the system should be a top
priority when servicing an EV series heat pump. To help do
this: Never leave the refrigerant system open to the
atmosphere for more than 15 minutes.
If the sealed refrigeration circuit must be opened for a service
procedure such as replacing a compressor or any other
refrigerant component, steps must be taken to minimize the
introduction of moisture into the refrigerant circuit.
The following procedure should be followed:
• After recovering the refrigerant from the system, break
the vacuum with dry nitrogen. Use a regulator-equipped
nitrogen cylinder. Never exceed 5 PSI in the sealed
system.
This procedure "floods" the inside of the system with dry
nitrogen. Once the system is flooded, the defective
component can be cut from the system.
Residual nitrogen remaining in the system minimizes moisture
entry.
• After removing the component from the system,
immediately seal the rest of the system with tape to
prevent any further introduction of moisture. Only remove
the tape when ready to install the replacement
component.
NOTE: Always replace the Bi-Flow liquid line filter drier when
opening the refrigerant circuit for servicing. Never install a
suction line drier in the liquid line. The rated working pressure
is not adequate for liquid line applications.
If the system is contaminated with moisture, the moisture
must be removed before putting the system back into
operation. Moisture that has not been absorbed by the POE
oil can only be removed by replacing the liquid-line drier.
Evacuating the system with a vacuum pump WILL NOT
remove moisture from the POE oil.
No special vacuum pump is required for R-410A.
The gauge manifold and hoses must be rated to handle the
higher pressures present with refrigerant R-410A. DO NOT
use a conventional gauge manifold or hoses to service this
product because they are not rated to handle the higher
pressures.
MAINTENANCE:
1. Air Filter changes or cleanings are required at regular
intervals. The time period between filter changes will
depend upon type of environment the equipment is used
in. In a single family home, that is not under construction,
changing or cleaning the filter every 60 days is sufficient.
In other applications such as motels, where daily
vacuuming produces a large amount of lint, filter changes
may need to be as frequent as biweekly.
WARNING: Equipment should never be used during
construction due to likelihood of wall board dust accumulation
in the air coil of the equipment which permanently affects the
performance and may shorten the life of the equipment.
2. A bi-yearly “checkup” is recommended by a licensed
refrigeration mechanic. Recording the performance
measurements of volts, amps, and water temperature
differences (both heating and cooling) is recommended.
This data should be compared to the information on the
unit’s data plate and the data taken at the original startup
of the equipment.
3. Lubrication of the blower motor is not required, however
may be performed on some motors to extend motor life.
Use SAE-20 non-detergent electric motor oil.
4. The condensate drain should be checked annually by
cleaning and flushing to insure proper drainage.
5. Periodic lockouts almost always are caused by air or
water flow problems. The lockout (shutdown) of the unit
is a normal protective measure in the design of the
equipment. If continual lockouts occur call a mechanic
immediately and have them check for: water flow
problems, water temperature problems, air flow problems
or air temperature problems. Use of the pressure and
temperature charts for the unit may be required to
properly determine the cause.
OPTIONAL GROUND LOOP PUMPING PACKAGE:
An optional internally mounted ground loop pumping package
is available for the EV unit (Figure #10).
Before operating the unit it is imperative that the system be
purged of air and foreign material. This is accomplished by
flushing the loop in both directions with a high volume of water
at a high velocity. A flush cart and associated equipment will
be required for this operation. Please follow the steps outlined
below for proper flushing procedures:
1. Connect the flush cart discharge to the LOOP PURGE IN
connection (see Figure #9) and the LOOP PURGE OUT
connection. Close valves BV2 and BV3, and open valves
BV1 and BV4. Liquid must be present in the supply lines
at all times.
2. Flush the loop in both directions to ensure that all air and
foreign matter is eliminated. Allowing the water level to
drop below the pump inlet line on the flush cart will allow
air back into the loop. When air bubbles are no longer

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present in the return line, flow should be reversed. This
procedure should be repeated several times until no air is
present. If air is left in the loop, it will have an immediate
effect on the unit’s coaxial heat exchanger causing
corrosion of it and any associated ferrous metal
components. It is absolutely imperative that the system is
clean and completely free of air.
3. With the flush cart running, close BV1 and BV4.
This will create a positive pressure on the loop and the
flush cart may be shut off. It is important to close the
valve on the outlet side of the loop (BV4) first to obtain
this required positive pressure.
4. The heat pump also requires purging. With all valves open
repeat steps 2 and 3. For normal heat pump operation,
open valves BV2 and BV3, close valves BV1 and BV4.
Replace caps in purge connections.
OPTIONAL HEAT RECOVERY PACKAGE
WATER PIPING:
All hot water piping should be a minimum of 3/8” O.D. copper
tube to a maximum distance of fifteen (15) feet. For distances
beyond fifteen feet but not exceeding 60 feet, use 1/2” copper
tube. Separately insulate all exposed surfaces of both
connecting water lines with 3/8” wall closed cell insulation.
Install isolation valves on supply and return to the HR unit.
IMPORTANT NOTE: The water from the HR unit may be in
excess of 140º F. Local codes may require a mixing valve in
the hot water system to prevent water in excess of 120ºF from
reaching a faucet. This valve is not part of the HR package
and should be installed separately.
HR START UP:
1. Make sure all valves in the heat recovery water piping
system are open. Never operate HR Pump dry.
2. Turn on the heat pump. The HR Pump should not run if
the compressor is not running.
3. Turn the HR switch to the “ON” position. The indicator
light will illuminate indicating pump operation if the
entering water temperature is below 140º F.
4. The temperature difference between the water entering
and leaving the heat recovery unit should be between 5º
to 15º F.
5. Allow the unit to operate for 20 to 30 minutes to ensure it
is functioning properly. The pump should shut off when
the water temperature entering the heat recovery unit
reaches approximately 140º F.
BV3
BV4 LOOP
PURGE OUT
CONDENSER
WATER OUT
BV1 LOOP
PURGE IN
CONDENSER
WATER IN
BV2
PUMP
HEAT
EXCHANGER
(Figure #9)
VALVE POSITION DIAGRAM (Figure #10)
TO PURGE LOOP: BV1 - OPEN
BV2 - CLOSED
BV3 - CLOSED
BV4 - OPEN
TO PURGE HEAT PUMP: ALL VALVES OPEN
TO OPERATE SYSTEM: BV1 - CLOSED
BV2 - OPEN
BV3 - OPEN
BV4 - CLOSED
REPLACE CAP PLUGS AFTER PURGING.
UNITS SHIPPED WITH VALVES SET IN
“LOOP PURGE” POSITION

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Temp ( ºF)
1.0
4.8
8.3
11.6
14.8
17.9
20.8
23.6
26.3
28.9
31.4
33.8
36.2
38.5
40.7
42.8
44.9
47.0
49.0
50.9
52.8
54.7
56.5
58.3
60.0
61.7
63.4
65.0
66.6
68.2
69.8
71.3
72.8
Press (PSIG)
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
Temp ( ºF)
74.2
75.7
77.1
78.5
79.9
81.3
82.6
83.9
86.5
89.0
91.5
93.9
96.3
98.5
100.7
102.9
105.0
107.1
109.1
111.1
113.1
115.0
116.9
120.5
124.1
127.5
130.8
134.0
137.2
140.2
143.2
146.0
148.8
Press (PSIG)
215
220
225
230
235
240
245
250
260
270
280
290
300
310
320
330
340
350
360
370
380
390
400
420
440
460
480
500
520
540
560
580
600
TEMPERATURE PRESSURE CHART
Refrigerant R-410A
(Vapor Pressure)

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11
PROBLEM
ENTIRE UNIT DOES
NOT RUN
BLOWER OPERATES
BUT COMPRESSOR
DOES NOT
UNIT OFF ON
HIGH PRESSURE
CONTROL
UNIT OFF ON
LOW PRESSURE
CONTROL
UNIT SHORT
CYCLES
INSUFFICIENT
COOLING OR
HEATING
POSSIBLE CAUSE
Power supply off
Blown fuse
Broken or loose wires
Voltage supply low
Thermostat
Thermostat
Wiring
Safety controls
Compressor overload open
Compressor motor grounded
Compressor windings open
Discharge pressure too high
Refrigerant charge
High pressure switch
Suction pressure too low
Refrigerant charge
Low pressure switch
Unit oversized
Thermostat
Wiring and controls
Unit undersized
Loss of conditioned air
by leaks
Airflow
Refrigerant charge
Compressor
Reversing valve
Operating pressures
TXV
Moisture, noncondensables
CHECKS AND CORRECTIONS
Apply power, close disconnect.
Replace fuse or reset circuit breaker. Check for correct fuses.
Replace or tighten the wires.
If voltage is below minimum voltage specified on unit data plate, contact local power company.
Set the fan to "ON", the fan should run. Set thermostat to "COOL" and lowest temperature
setting, the unit should run in the cooling mode (reversing valve energized). Set unit to "HEAT" and
the highest temperature setting, the unit should run in the heating mode. If neither the blower or
compressor run in all three cases, the thermostat could be miswired or faulty. To ensure miswired
or faulty thermostat verify 24 volts is available on the condensing section low voltage terminal strip
between "R" and "C", "G" and "C", "Y" and "C", and “O” and “C” (cooling only). Replace the
thermostat if defective.
Check setting, calibration, and wiring.
Check for lose or broken wires at compressor, capacitor, or contactor.
Check CCMI board red fault L.E.D. for blink code (See problem for possible causes)
If the compressor is cool and the overload will not reset, replace compressor *.
Internal winding grounded to the compressor shell. Replace compressor and liquid line
drier. If compressor burnout, install suction drier.
After compressor has cooled, check continuity of the compressor windings. If the
windings are open, replace the compressor and liquid line drier.
In "COOLING" mode: Lack of or inadequate water flow. Entering water temperature too
warm. Scaled or plugged condenser.
In “HEATING” mode: Lack of or inadequate air flow. Entering air temperature too warm.
Blower inoperative, clogged filter, or restrictions in ductwork.
The unit is overcharged with refrigerant. Reclaim refrigerant, evacuate and recharge with
factory recommended charge.
Check for defective or improperly calibrated high-pressure switch.
In "COOLING" mode: Lack of or inadequate air flow. Entering air temperature too cold.
Blower inoperative, clogged filter, or restrictions in ductwork.
In "HEATING" mode: Lack of or inadequate water flow. Entering water temperature too
warm. Scaled or plugged condenser.
The unit is low on refrigerant. Check for refrigerant leak, repair, evacuate and recharge
with factory recommended charge.
Check for defective or improperly calibrated low-pressure switch.
Recalculate heating and or cooling loads.
Thermostat installed near a supply air grill, relocate thermostat. Readjust heat anticipator.
Loose connections in the wiring or a defective compressor contactor.
Recalculate heating and or cooling loads. If excessive, possibly adding insulation and
shading will rectify the problem.
Check for leaks in duct work or introduction of ambient air through doors or windows.
Lack of adequate air flow or improper distribution of air. Replace dirty filter.
Low on refrigerant charge causing inefficient operation.
Check for defective compressor. If discharge is too low and suction pressure is too high,
compressor is not pumping properly. Replace compressor and liquid line drier.
Defective reversing valve creating bypass of refrigerant from discharge to suction side of
compressor. Replace reversing valve and liquid line drier.
Compare unit operating pressures to the pressure / temperature chart for the unit.
Check TXV for possible restriction or defect. If replacement is necessary, replace liquid line
drier as well.
The refrigerant system may be contaminated with moisture or noncondensables. Reclaim
refrigerant, evacuate and recharge with factory recommended charge. Note: a liquid line
drier may require replacement.
TROUBLE SHOOTING

REV. 9/00
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