Water Furnace E Series User manual

GIMEKW-E November 2008
Installation Information
Water Piping Connections
Electrical
Startup Procedures
Troubleshooting
Preventive Maintenance
50 hz hydronic heat PumPs
  
  
EKW Installation Manual

2
EKW INSTALLATION MANUAL
Model Nomenclature
EKW Series R-410A Hydronic Heat Pump (06 - 17 kW)
1-3 4-5 6 7 8 9 10-11 12
EKW 06 H 6 0 2 SS B
Family Vintage
EKW = E Series 50 hz B = Current
Hydronic Heat Pump
Non-Standard Options
Unit Capacity S = Standard
06 kW
A-R, T-Z = Nonstandard Options
08 kW
12 kW Control
17 kW 2 = Standard
4 = FX-10 without interface
Operation 5 = FX-10 with N2 card without interface
H = Heating Only 6 = FX-10 with LonWorks card without interface
R = Reversible 7 = FX-10 with BACnet card without interface
8 = FX-10 with MUI
Voltage 9 = FX-10 with N2 card and MUI
6 = 220-240/50/1 0 = FX-10 with LonWorks card and MUI
7 = 380-420/50/3 3 = FX-10 with BACnet card and MUI
A = Standard with IntelliStart *
Desuperheater (Requires accessory pump kit)
B = FX-10 without interface with IntelliStart *
0 = None C = FX-10 with N2 card without interface with IntelliStart *
2 = Hot Water Generation without D = FX-10 with LonWorks card without interface with IntelliStart *
Internally Mounted Pump ** E = FX-10 with BACnet card without interface with IntelliStart *
F = FX-10 with MUI with IntelliStart *
G = FX-10 with N2 card and MUI with IntelliStart *
H = FX-10 with LonWorks card and MUI with IntelliStart *
J = FX-10 with BACnet card and MUI with IntelliStart *
Notes:
* - Single Phase Only
** - Not available on 06

3
EKW INSTALLATION MANUAL
Table of Contents
   
    
     
      
     
        

       
        
       
      
        
  
       
 
       
    
      
     
    


EKW INSTALLATION MANUAL
Safety Advisements
Installation and servicing of heating and air conditioning equipment can be hazardous due to system pressure and elec-
trical components. Only trained and qualied service personnel should install, repair or service heating and air conditioning
equipment.
When working on heating and air conditioning equipment, observe precautions in the literature, tags and labels attached
to the unit as well as other safety precautions that may apply, such as the following safety measures:
Follow all safety codes.•
Wear safety glasses and work gloves.•
Use a quenching cloth for brazing operations.•
Have a re extinguisher available for all brazing operations.•
Moving and Storage
Move units in the normal “up” orientation. Do not stack more than two units in total height. When the equipment is
received, all items should be carefully checked against the bill of lading to be sure that all crates and cartons have been
received. Examine units from the cartons if necessary. Units in question should also be internally inspected. If any damage
is noted, the carrier should make the proper notation on the delivery receipt, acknowledging the damage.
Unit Location
Locate the unit in an indoor area that allows easy removal of the access panels and has enough space for service
personnel to perform maintenance or repair. Provide sufcient room to make water and electrical conditions. Units may be
stacked vertically in small mechanical rooms. These units are not approved for outdoor installation and, therefore, must be
installed inside the structure being conditioned. Do not locate in areas subject to freezing.
Piping
Both source as well as load uid piping must be at least as large as the unit connections on the heat pump (larger on
long runs).
Process Water Applications
For process water applications, it is recommended that a secondary load heat
exchanger be installed to prevent corrosion to the unit’s primary coaxial coil. In
situations where scaling could be heavy or where biological growth such as iron
bacteria will be present, a closed loop system is recommended. Over a period of
time, ground water unit heat exchanger coils may lose heat exchange capability
due to a buildup of mineral deposits. These can be cleaned only by a qualied
service mechanic as special pumping equipment and solutions are required. Never
use exible hoses with a smaller inside diameter than that of water connections.
Mounting Units
Units should be mounted level on a vibration absorbing pad slightly larger than
the base to provide isolation between the unit and the oor. It is not necessary to
anchor the unit to the oor. Allow access to front access panel for servicing com-
pressor.




Vibration
Absorbing
Mesh Pad
Figure 1: Unit Mounting
Safety Considerations
General Installation Information

5
EKW INSTALLATION MANUAL
Accessories and Other Options
Desuperheater (Factory Installed, EKW08 to EKW17 only)
An optional heat reclaiming desuperheater coil constructed of vented double-wall copper construction suitable for
potable water is available. The coil is factory mounted inside the unit.
Load-side Pump Kit (Field Installed)
Load pump kits are available to provide all liquid ow requirements for independent single unit systems. To select the
proper pump, be certain that the system pressure drop is calculated correctly.
If the job requirements are outside the pump curve, an alternate pump will need to be obtained to maintain the
necessary ow.
Flow Rate GPM (L/s)
Feet of Head (kPa)
0 5
(0.32)
40 (119.6)
35 (104.7)
30 (89.7)
20 (59.8)
15 (44.9)
10 (29.9)
25 (74.8)
10
(0.63)
15
(0.95)
20
(1.26)
25
(1.58)
30
(1.89)
35
(2.21)
Flow Rate GPM (L/s)
Feet of Head (kPa)
0 2
(0.126)
20 (59.80)
15 (44.85)
10 (29.90)
5 (14.95)
4
(0.252)
6
(0.378)
8
(0.504)
10
(0.063)
12
(0.756)
14
(0.882)
16
(1.134v)
Figure 2: 24P501 - Pump Curve
Figure 3: EWPK1 - Pump Curve
Note: Never use piping smaller than 28
mm. Limit length of pipe to 16 meters
or less.


EKW INSTALLATION MANUAL
Potable Water Systems
The EKW06 heating only model is designed to provide primary hot water generation. An optional factory-installed
desuperheater coil may be provided with an EKW08, 12 or 17 to assist in the generation of domestic hot water.
With either option, the coaxial heat exchangers provide double-wall construction and are vented to allow installation in
potable water applications. Figures 4 and 5 show how to connect a potable water system.
Figure 4: Suggested Domestic Water Heater Hookup
CO LD W AT E R
IN
H O T W A TE R
OUT
EL EC TR IC W A TE R
HEAT ER
HOT W ATE R
ST O R A G E
EQ U A L T O
A. O . S M I TH
TJ -8 0A
EW 0 2 0
HOT WATER
OUT
SOURCE
OUT
IN
EX PAN SI ON T A N K
IF R E QU IR E D
PUMP
PT PORTS
PT PORTS
*UNIONS
(VALVES)
BOILER DRAIN
BOILER DRAIN
HOT WATER
OUT
PT PORTS
SOURCE
FLOW
CENTER
TO LOOP
FIELD
Unions or valves must be installed so that acid ushing of the heat exchanger is possible.
EKW06


EKW INSTALLATION MANUAL
Figure 5: Alternate Hot Water Installation
Potable Water Systems
 * Unions or valves must be installed at the unit so acid ushing of the heat exchanger is possible.
** Make sure there is not a check valve in the diptube of the tank.
UNIONS *
(VALVES)
PT PORTS
PT PORTS
LOAD
IN
SOURCE
OUT
COLD
WATERIN
HOT
WATER OUT
FLOW
CENTER
ELECTRIC
WATER
H EATER
EKW06
Pump
SOURCE
IN
LOAD
OUT
EXPANSION TANK
IF REQUIRED
DIP TUBE **
P & T RELIEF TO
FLOOR DRAIN
BOILER DRAIN
BOILER
DRAIN
PT PORTS


EKW INSTALLATION MANUAL
Open Loop—Well Water Systems
Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit. Use a
closed bladder type expansion tank to minimize mineral deposits. Ensure proper water ow through the unit by checking
pressure drop across the heat exchanger and comparing it to the gures in the capacity data tables in the specication
catalog. Normally, about 0.042 L/s per kW of cooling capacity is needed in open loop systems, 0.032 L/s per kW minimum
if entering source temperature is above 50°F [10°C].
Some water control valves draw their power directly from the unit’s 24V transformer and can overload and possibly burn
out the transformer. Check total VA draw of the water valve(s) and ensure it is under 40 VA.
Discharge water from a heat pump can be disposed of in various ways depending on local building codes (i.e. recharge
well, storm sewer, drain eld, adjacent stream or pond, etc.). Most local codes restrict the use of sanitary sewer for disposal.
Consult your local building and zoning departments to ensure compliance in your area.
oltageLine V
Disconnect
Vibration Absorbing Mesh
or Air Pad
Load Liquid
Connections
For Flushing
Boiler Drains
HX
P/T Plugs
V
Shut-off
alve
f ValveShut-of
(to isolate solenoid
valve while acid
flushing)
ValveSolenoid
Rubber Bladder
Expansion Tank
Water In
Hayes
Valve
Water Out
Figure 6: Typical Open Loop Installation


EKW INSTALLATION MANUAL
Earth-Coupled Systems with Flow Center
Once piping is completed between the unit, ow center and the earth loop, nal purging and charging of the loop is
needed. A ush cart (at least a 1.5 HP or 1.12 kW pump) is needed to achieve adequate ow velocity in the loop to purge
air and dirt particles from the loop itself. Antifreeze solution is used in most areas to prevent freezing. Maintain the pH in
the 7.6-8.2 range for nal charging.
Flush the system adequately to remove as much air as possible. Then, pressurize the loop to a static pressure of 50-75
psi [345-517 kPa]. This is normally adequate for good system operation. Ensure that the ow center provides adequate
ow through the unit by checking pressure drop across the heat exchanger and by comparing it to the gures shown in
the tables on page 36. Usually, 3 GPM/ton [0.054 L/s/kW] or minimum 2.25 GPM/ton [0.04 L/s/kW] of cooling capacity is
needed in closed loop earth-coupled applications.
Line Voltage
Disconnect
Earth-Coupled Loop
Piping with Insulation
Unit Connector Kits
with Insulation
Vibration Absorbing
Mesh or Air Pad
Load Liquid
Connections
P/T Plugs
Figure 7: Typical Closed Loop Earth-Coupled Installation


EKW INSTALLATION MANUAL
Electrical
 All fuses are type “D” time delay (or HACR circuit breaker in USA).
Source pump amps shown are for up to 1/2 HP pump.
Load pump amps shown are for small circulators.
Unit
Model
Rated
Voltage
Voltage
Min/Max
Compressor Total Unit
FLA
Min Ckt
Amp
Max
Fuse
Max
Ckt Brk
RLA LRA
EKW06 220-240/50/1 198/264 10.9 58.0 10.9 13.6 20 20
380-420/50/3 342/462 4.5 26.0 4.5 5.6 10 10
EKW08 220-240/50/1 198/264 15.4 82.0 15.4 19.3 30 30
380-420/50/3 342/462 5.1 35.0 5.1 6.4 10 10
EKW12 220-240/50/1 198/264 21.1 136.0 21.1 26.4 45 45
380-420/50/3 342/462 7.7 51.0 7.7 9.6 15 15
EK W17 220-240/50/1 216/264 25.0 149.0 25.0 31.3 50 50
380-420/50/3 342/462 10.6 75.0 10.6 13.3 20 20
All fuses type “D” time delay.


EKW INSTALLATION MANUAL
*Test standard condition – BS EN 14511
(ARI 260)
PHYSICAL ELEMENTS
Unit
Model
A
in [mm]
B
in [mm]
C
in [mm]
Load
Liquid
in FPT in
Load
Liquid
out FPT in
Source
Liquid
out FPT in
Source
Liquid
in FPT in
Desuperheater
In FPT in
Desuperheater
Out FPT in
EKW06 25.5 [648] 26.3 [668] 18.0 [457] 0.75 0.75 0.75 0.75 - -
EKW08 32.5 [826] 26.3 [668] 22.0 [559] 1.00 1.00 1.00 1.00 0.50 0.50
EKW12 32.5 [826] 26.3 [668] 22.0 [559] 1.00 1.00 1.00 1.00 0.50 0.50
EKW17 32.5 [826] 26.3 [668] 22.0 [559] 1.00 1.00 1.00 1.00 0.50 0.50
DIMENSIONAL DATA
SOUND DATA
ALTERNATE WIRING
KNOCKOUT
Back View Front View
LOW VOLTAGE
PUMP WIRING
LINE VOLTAGE
SOURCE WATER IN
SOURCE WATER OUT
LOAD WATER IN
ALTERNATE
WIRING KNOCKOUT
LOAD WATER OUT
OPTIONAL
DESUPERHEATER
CONNECTION
TOUCH PAD
CONTROLLER
ALTERNATE WIRING
KNOCKOUT
ALTERNATE WIRING
KNOCKOUTS
ALTERNATE WIRING
KNOCKOUTS
OPTIONAL DESUPERHEATER
CONNECTION
A
C
B
Unit
Model Sound Rating*
EKW06 54 dBA
EKW08 56 dBA
EKW12 57 dBA
EKW17 58 dBA


EKW INSTALLATION MANUAL
Electrical
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 Electric Code, whichever is applicable. Refer to the Unit
Electrical Data on page 10 for wire and fuse or circuit breaker sizing information.
Flow Center Pump Operation
Two fuse internal terminal block connections with 1/4-inch spade connectors are provided; one for the load pump and
one for the source pump. The source pump directly connects to the fuse terminal block for the source pump. The load
pump directly connects to the fuse terminal block for the load pump.
Control Box Relocation
The control box can be installed on the rear of the unit. To relocate the control box, follow the procedures below.
Remove all power sources to the unit.1.
Remove the unit’s top panel.2.
Cut all plastic wire3. ties to the following:
a) High pressure switch (black wires)
b) Low pressure switch (blue wires)
c) Freeze protection (yellow wires)
d) Load temperature sensor (black wires)
e) Compressor wires
Remove the four screws from the control box.4.
Relocate the control box to opposite end of the unit.5.
Using the screws removed in step 4 above, reattach the control box.6.
Secure all wires so they do not come in contact with refrigerant lines.7.
Replace the top of the unit.8.
Replace both access panels.9.
Reapply power sources.10.


EKW INSTALLATION MANUAL
Schematics
For all single-phase units, the circulator wiring is as shown in Figures 8 and 9 below. The internal relay and fusing allow for external pumps
no larger than .5 horsepower. The external loop pump connections mentioned in this manual include a dedicated ow center for each unit as well
as an EKW unit connected to a “PK” or an “EK” series unit containing a microprocessor. Figure 9 illustrates a dedicated ow center.
LOAD
CIRCULAT OR
PUMP
TRANSFORMER
LOW VOLTAG E
TERMINAL STRIP
FUSE
BLOCKS
LOW VOLTAGE
THERMOSTAT
CONNECTIONS
COMPRESSOR
CONTACTOR
T1 T2
L1 L2
CAPACITOR
CONTROL BOX
TRANSFORMER
LOW VOLTAGE
TERMINAL STRIP
FUSE
BLOCKS
LOW VOLTAGE
THERMOSTAT
CONNECTIONS
COMPRESSOR
CONTACTOR
T1 T2
L1 L2
CAPA CITOR
FLOW CENTER
CONTROL BOX
SOURCE
PUMP
Figure 8: Load Circulator Wiring
Figure 9: Dedicated Flow Center Wiring


EKW INSTALLATION MANUAL
TRANSFORMER
LOW VOLTAGE
TERMINAL STRIP
FUSE
BLOCKS
LOW VOLTAGE
THERMOSTAT
CONNECTIONS
COMPRESSOR
CONTACTOR
T1 T2
L1 L2
CAPACITOR
P2
SHUT
DOWN
C
Not
Used
C
P1
G
W
O
R
C
Y1
Y2
LO
EK SERIES
CONTROL
BOX
WFI13P003B RELAY
(FIELD SUPPLIED)
3,).
3,/54
CONTROL BOX
Schematics
Figure 10: Multiple Units on a Single Flow Center Wiring


EKW INSTALLATION MANUAL
External Control
Primary Mode
In dedicated heating/cooling units, the unit is controlled by the internal controller. Compressor output is determined by
the entering load-side water temperature.
The secondary output will be energized if two conditions occur:
The initial temperature is greater than1. IC away from the set point.
The change in temperature in a given period of time2. Pis less than d.
In a reversible unit, the unit is controlled by the internal controller. Compressor output is determined by the entering
load-side water temperature. For reversible units, the jumper wire must be positioned across terminals 6 & 7, (factory de-
fault set to this position). Reversible units do not have a secondary output.
 SL in the conguration menu must be set to 0, (factory default). All parameters should be checked for each applica-
tion on primary unit, (refer to the parameter table on page 21).
Secondary Mode
In dedicated heating/cooling units, secondary mode allows the unit to be controlled by an external source. Compressor
output is determined by the Y1 input only.
The secondary output will be energized after the following condition occurs:
The change in temperature in a given period of time1. Pis less than d.
In reversible units, secondary mode allows the unit to be controlled by an external source. Compressor output is de-
termined by the Y1 input and the reversing valve is determined by the O input. In reversible units, the jumper wire must be
positioned across terminals 5 & 6. Reversible units do not have a secondary input.
 SL in the conguration menu must be set to 1. Pand dmust be setup for each secondary unit.
Y1 = Compressor call
R = 24VAC
C
G
W1
L
X1
Y2
O
Y1
W2
S
X2
R
Control Box
Typical Aquastat
Secondary Unit
(SL=1)
Figure 11: Aquastat Wiring for Dedicated Heating/Cooling Unit
REVERSIBLE UNITS
CANNOT BE STAGED.


EKW INSTALLATION MANUAL
Wiring an Aquastat
Reversible Unit
To create a secondary unit, set SL to 1 in the conguration menu.•
Positon the jumper wire in the control box across terminals 5 & 6.•
Y1 = Compressor call
O = Reversing valve call
R = 24VAC
Note: Jumper wire must be moved to terminals 5 & 6.
Secondary Unit
(SL=1)
C
G
W1
L
X1
Y2
O
Y1
W2
S
X2
R
Typical Aquastat
1
2
3
4
5
6
7
8
9
10
11
12
Jumper
Wire
Control Box
Figure 12: Aquastat Wiring for Reversible Unit


EKW INSTALLATION MANUAL
Staging with Primary/Secondary Mode
Staging is only possible with dedicated heating/cooling units. Reversible units cannot be staged. Staging can
be accomplished with primary/secondary modes or by using an aquastat.
The rst stage must be setup as a primary unit. All other units must be setup as secondary units. The set point is
stored in the primary unit. Once the set point in the primary unit has been satised, all units will immediately shutdown.
Figure 13 shows wiring with primary/secondary mode.

C
G
W1
L
X1
Y2
O
Y1
W2
S
X2
R
C
G
W1
L
X1
Y2
O
Y1
W2
S
X2
R
C
G
W1
L
X1
Y2
O
Y1
W2
S
X2
R
Primary Unit
(SL=0)
Secondary Unit
(SL=1)
First Stage Control Box Second Stage Control Box Third Stage Control Box
Secondary Unit
(SL=1)
Figure 13: Wiring for Primary/Secondary Unit Staging
First Stage Second Stage Third Stage
 X1 = Secondary output
Y1 = Compressor call


EKW INSTALLATION MANUAL
Staging with Aquastat
When staging units using an Aquastat, all units must be setup as secondary units. Figure 14 shows wiring for staging
with an Aquastat.

Secondary Unit
(SL=1)
Second Stage Control BoxFirst Stage Control Box
Secondary Unit
(SL=1)
C
G
W1
L
X1
Y2
O
Y1
W2
S
X2
R
C
G
W1
L
X1
Y2
O
Y1
W2
S
X2
R
Typical Aquastat
Figure 14: Wiring for Dedicated Heating/Cooling Units
First Stage Second Stage
 X1 = Secondary output
Y1 = Compressor call
R = 24 VAC
UNIT STARTUP


Compressors bolts have been loosened.•
High voltage wiring is correct and matches the nameplate.•
Fuses, breakers and wire size are correct.•
Piping is completed and water system has been cleaned and ushed.•
Air is purged from the closed loop system.•
Isolation valves are open and loop water.•


EKW INSTALLATION MANUAL
Converting to a Dedicated Cooling Unit
Procedure to Convert a Heating Only Unit to a Cooling Only Unit
All non-reversible EKW units are built at the factory as dedicated heating units. Follow the procedures below to make
the unit a dedicated cooling unit.
Shut off all power to the unit.1.
Remove the top and access panel.2.
Remove the brass in-well thermistor from the load water-in line.3.
Remove the brass plug from the source water-in line.4.
Place new Teon5. ®tape on the threads of the brass in-well thermistor.
Thread the brass in-well thermistor into the source water-in line.6.
Make sure the thermistor wires do not touch the discharge line.7.
Place new Teon8. ®tape on the threads of the brass plug.
Thread the brass plug into the load water-in line.9.
Refer to the labels on the unit for the location of ports and lines.10.
Connect the “Source Water-In” line to the port marked “Load Water-In”. Then, connect the “Source Water-Out” line to 11.
the port marked “Load Water-Out”.
Connect the “Load Water-In” line to the port marked “Source Water-In”. Then, connect the “Load Water-Out” line to the 12.
port marked “Source Water-Out”.
Open the control box.13.
Find the connection marked “P4” as shown in14.
Figure 15
Move the “P4” jumper from across 1 and 2 to 15.
across 2 and 3.
Close the control box and secure the screws.16.
Replace the top and access panel.17.
Make sure all screws have been re-installed.18.
Turn on the power.19.
Using the touch-pad, press the up arrow.20.
The displays should blink “44” to show set point.21.
Now, the unit should operate as a cooling only unit.
Jumper Pin Location
The location of the jumper pin determines the
controller’s mode of operation. Move the jumper pins
to the correct location for dedicated heating, dedicated
cooling or reversible settings as indicated below.
Dedicated heating - 1 & 2 *
Dedicated cooling - 2 & 3
Reversible - 3 & 4 *
* Indicates factory setting.
Figure 15: Control Board with Jumper
P4

20
EKW INSTALLATION MANUAL
Unit Startup
Before Powering Unit
Check the following:
High voltage wiring is correct and matches the nameplate.•
Fuses, breakers and wire size are correct.•
Piping is completed and water system has been cleaned and ushed.•
Air is purged from the closed loop system.•
Isolation valves are open and loop water control valves or loop pumps are wired.•
Service/access panels are in place.•
Primary Unit Startup
Apply power to the unit. Upon power up, the unit will display the current operation mode. 1.
• H for dedicated heating.
• C for dedicated cooling.
• U for reversible units.
Press the mode button. The LED screen will display the current entering water temperature. The load pump will activate2.
after a 5 minute delay.
Once the load pump has been active for 3 minutes, the controller will sample the temperature of the water system. In 3.
heating mode, when the temperature of the water shown on the display is lower than the set point the compressor will
activate.
By using a pressure gauge and the P/T ports, check the pressure drop through both the load and source coaxes. Com-4.
pare this to the capacity tables in the specification catalog to verify the proper flow rate through the unit.
Verify that the compressor, load side and source side pumps are operating.5.
After determining the flow rates, use a thermometer and the PT ports to determine the change in temperature on both 6.
the load and source side coaxes.
Compute the formula7. 
. To ensure proper operation, compare
these values to the capacity tables in the specification catalog.
Press the down arrow on the keypad to reduce the set point below the incoming load temperature. Compressor should8.
shut off and the load pump should shut off 30 seconds after the compressor.
Wait 7 minutes. The load pump should start to sample load temperature.9.
Compressor and source side circulator should not start.10.
Press the up arrow on the keypad to increase the set point to 5 degrees above the water temperature displayed on the11.
LED screen.
Three minutes after the load pump activates, the compressor and source pump should activate.12.
Secondary Unit Startup
Apply power to the unit.1.
After a three to ve-minute delay, the water temperature shall be sampled. If the controller receives a remote aquastat 2.
signal, the compressor shall activate.
Verify that the compressor and load side, source side pumps are running.3.
By using a pressure gauge and the PT ports, check the pressure drop through both the load and source coaxes, and 4.
compare this to the capacity tables in the specication catalog to verify the proper ow rate through the unit.
After determining the ow rates, use a thermometer and the PT ports to determine the change in temperature on both 5.
the load and source side coaxes.
Compute the formula6. 
To ensure proper operation, compare these values
to the capacity tables in the specification catalog.
Press the down arrow on the control to disrupt the remote aquastat signal. Unit should shut off.7.
Instruct the owner or operator about the correct control and system operation.8.