Well-Connect WCVC-16 User manual

1
Well-Connect
Installation Guide
Model WCVC-16
Model WCVC-24

2
Congratulations on your purchase of a Well- Connect
Hybrid Heating System. Your satisfaction is very
important to us.
Read and follow this installation guide as it contains
instructions and best practices when installing your
Well-Connect. Some homeowners do possess the
necessary skills to properly install a Well-Connect.
But, Terra Caloric recommends that a qualified
HVAC or plumbing professional be contacted for the
installation.
The installer should contact the local municipality
to obtain any permits that may be required, and the
installation must comply with applicable state and
local mechanical and electrical codes.
If you have questions, email, write or call us at*:
Terra Caloric, LLC Phone: [phone]
PO Box 307 Email: [e-mail]
Alpena, MI 49707
*Please have the following information available before contacting us.
Model # ______________________________________________
Serial # ______________________________________________
Date of purchase: ______________________________________

3
TABLE OF CONTENTS:
IMPORTANT SAFETY INSTRUCTIONS p. 4
1. Definitions p. 7
2. General Installation Instructions p. 11
3. Stan-Alone Installation p. 17
4. Self-Ducted Installation p. 18
5. Hybrid Installation p. 19
6. Multi-Stage System Operation p. 21
7. Water Discharge Options p. 22
System Start-Up Report p. 25
Notes p. 26

4
IMPORTANT SAFETY
INSTRUCTIONS
WARNING: To reduce the risk of fire, explosion, electric
shock, or personal injury when using your Well-Connect,
follow all basic safety precautions, including but not
limited to the following:
1. Please read all instructions before using your Well-
Connect.
2. As with any piece of equipment that uses electricity and
has moving parts, there are potential hazards. To ensure
the safe operation of this appliance, proper care must be
taken. Therefore, anyone using or installing it must heed
all warnings, precautions and instructions.
3. Never install or operate your Well-Connect in an
explosive, corrosive or otherwise hazardous
environment. Doing so may result in equipment damage,
property damage and personal injury.
4. Install your Well-Connect in a dry indoor environment
ONLY. Do not install or store this appliance where it
will be exposed to the weather. Internal water lines may
burst if exposed to freezing conditions leading to
equipment damage and potential property damage.
5. Only install your Well-Connect on a level floor that
supports the weight.
6. Your Well-Connect must remain in an upright position at
all times. If it is subject to any other orientation, even
temporarily, contact us before attempting to operate it.

5
7. This appliance must be properly grounded. Never plug
the appliance cord into a receptacle that is not grounded
adequately and in accordance with local and national
codes.
8. Connect your Well-Connect to a water source that can
provide a constant flow, at a minimum rate of two (2)
gallons per minute for Model WCVC-16 or four (4)
gallons per minute for Model WCVC-24 at a temperature
of 45°F (7°C) or warmer. Some shallow wells may not
be able to produce the flow volume and/or temperature
needed for proper operation. If you are unsure whether
your well can meet these requirements, consult your
Well-Connect dealer or local water well
professional/supplier.
9. DO NOT install your unit where surrounding clearances
are less than those depicted in Figure 1.
10. DO NOT install or operate the unit where it may be
subject to dusty or dirty conditions, such as during a
construction phase of building or remodeling.
SUBJECTING YOUR WELL-CONNECT TO ANY OF
THE ABOVE UNDESIRABLE CONDITIONS SHALL
VOID ALL WARRANTIES.

6
Top View
Side View
Figure 1

7
1. Definitions
Stand-Alone (or Free-Standing)- A Well-Connect that is installed
in a space for heating and cooling and is not connected to any type
of air delivery system or ductwork. Conditioned air is simply
delivered from louvers incorporated into the front panel of the
Well-Connect and returned to the Well-Connect through the filter
area on the back.
(Stand-Alone system shown with optional wood cabinet cover)

8
Top Discharged (or Ducted)- A top discharged Well-Connect has a
12” diameter duct collar incorporated into the top panel to facilitate
a connection to ductwork. In such a situation conditioned air is
delivered from the top, not from front louvers. The Well-Connect
can be converted between ducted and freestanding configurations
by purchasing the appropriate top panel assembly.

9
Self-Ducted- A Well-Connect that is top discharged and the
conditioned air is delivered to a given space via ductwork separate
from any other ductwork. An example would be a Well-Connect
that is installed in a basement and ducted to the main floor, or to
another room, etc.
(May require return ducting; use industry best practices when
designing self-ducted system.)

10
Hybrid (or Integrated)- A top discharged Well-Connect that is
directly connected into the existing heating and cooling system
ductwork of the structure, allowing conditioned air from the Well-
Connect to be distributed throughout the entire building or home.
A Hybrid Well-Connect is a two-stage heating and cooling system
that is installed in parallel with the existing furnace system. The
Well-Connect becomes the primary heating and cooling system
(stage one) and the existing system then becomes the secondary
heating and/or cooling system (stage two). The wireless Well-
Connect thermostat can control both stages of the system. See
section 6 of this guide for two-stage system installation
instructions.

11
2. General Installation Instructions
a. To ensure proper thermostat operation and calibration, batteries
(supplied with your Well-Connect) must be placed in the Well-
Connect wireless thermostat at the beginning of the installation.
The thermostat must then be temporarily placed near the
existing building thermostat during the rest of the installation to
allow time for the sensor in the wireless thermostat to acclimate
itself to the surroundings. Once the installation is complete,
verify that the temperature displayed on the Well-Connect
thermostat matches the temperature displayed on the existing
thermostat. If there is a difference in the two readings, see item
l. For permanent thermostat locations based on the Well-
Connect installation configuration, see item k.
b. Connect the supply water line ahead of (before) the water
softener (if present), as the Well-Connect does not require
softened water.
c. Insulate all water lines that run through any area of the building
or home where condensation is undesirable.
d. If the water system relies on a conventional pressure tank setup
to maintain household water pressure, Terra Caloric
recommends sufficient tank capacity to allow a minimum 8-10
minute pump cycle rate when the Well-Connect is running in
order to avoid excessive pump cycling. To achieve this, it is
recommended that you have a minimum of 15 gallons of draw
down available from the well system for the WCVC-16 model
and 24 gallons for the WCVC-24 model. Additional pressure
tank capacity may be required to achieve the minimum draw
down volumes. The following chart gives general pressure tank
capacities, dimensions, and draw down volumes. For exact
specifications of a given tank, contact the tank manufacturer.

12
Dimensions (in.)
Draw down
(Gallons)
Tank
Volume
Gallons Diameter
Height 30/50psi
7.6 11 22 2.4
10.3 15 18 3.2
14.0 15 22 4.3
14.0 15 25 4.3
20.0 15 32 6.2
26.0 15 39 8.0
32.0 15 47 9.9
34.0 22 30 10.5
44.0 22 36 13.6
62.0 22 47 19.2
86.0 26 47 26.6
e. Note: Draw down as expressed in gallons is not equal to the
tank capacity expressed in gallons; draw down is less.
Therefore, the need for a larger or additional tank for additional
draw down volume in the system may be necessary.
Be aware: You may encounter “cycle stop” valves on the market,
which some manufacturers imply produce an effect similar to a
Variable Frequency Drive (or “VFD”), but at a far lower cost.
Don’t be fooled, as they are not equal! In fact, a cycle stop valve
will cause the well pump to consume more energy than it
otherwise would. Cycle stop valves are not appropriate for the low
flow rates required by the Well-Connect and should not be used for
this application.

13
f. Connect the water supply line to the “water in” connection and
the discharge water line (drain) to the “water out” connection.
The supply water line must be capable of delivering up to 4gpm
and should be at least 1/2” I.D. (inside diameter). The discharge
water line must be at least ¾” I.D. (inside diameter) to handle
the discharge water volume. Both supply and discharge lines
should terminate at the Well-Connect with flexible hose (See
Figure 2) to facilitate movement of the Well-Connect should it
become necessary (service, maintenance, wall access etc.).
Rubber hoses are not recommended because they may
deteriorate, leak or burst over time. Both hoses should be
reinforced nylon or braided stainless steel pressure rated hoses,
which are available in most home improvement stores.
Figure 2
g. When connecting fittings and/or tightening the two water hoses,
be sure to use a backup wrench to secure the copper fittings
protruding out of the Well-Connect. Allowing them to turn,

14
even slightly, may cause serious damage to internal components
(See Figure 3).
Figure 3
h. Terra Caloric also recommends incorporating shut off valves on
the supply and discharge lines where the hoses connect to the
building plumbing for ease of installation and maintenance (See
Figure 4).
Figure 4

15
i. Follow all applicable state and local codes regarding water
piping materials and practices.
j. Well-Connect is a cord-connected appliance and is equipped
with an NEMA 6-20P-240v plug. This must be used with a
compatible receptacle (See Figure 5), and wired to a single
outlet 20-amp circuit in accordance with all state and local
codes. Contact your local electrical contractor for assistance.
Figure 5

16
k. Thermostat Placement: For Stand-Alone and Self-Ducted Well-
Connect applications, the wireless thermostat may be placed
almost anywhere in the space to be conditioned. However,
avoid locations where it may be subject to temperature changes
from direct sunlight, discharge air from the Well-Connect, or
any other heating or cooling source. For a Hybrid application,
the thermostat should be placed in close proximity to the
existing thermostat in the building or home (Figure 6).
Figure 6
l. Thermostat calibration: In some cases the wireless thermostat
may need to be calibrated to match the existing thermostat. For
calibration procedures reference the thermostat owner’s manual.
m.Thermostat communication: The wireless thermostats used in
the Well-Connect are manufactured and shipped with the house
code set at “32”. It is not necessary to change this code at the
time of installation.

17
3. Free Standing Installation
a. Location: A Stand-Alone Well-Connect is typically used to
condition a given space, usually where people spend a lot of
time (living room, family room, office, etc.). The conditioned
air may migrate throughout other areas in the building or home
as the Well-Connect first satisfies the needs in the area where
installed. Use good judgment when selecting the specific
location, not to interfere with other activities in the area or be
subject to unnecessary abuse.
b. Thermostat: The thermostat should be placed in the area where
the Well-Connect is installed, or close to it.
c. Options: A Stand-Alone Well-Connect can be adapted to supply
conditioned air to a space other than where installed via ducting
(Self-Ducted installation), or incorporated into the existing
heating/cooling system and ductwork (Hybrid installation).
Note: Every Well-Connect is manufactured and shipped with
the ECM blower motor set for the most efficient operation. If
the air discharge is unsatisfactory for a specific application
consult a factory rep for possible solutions.
d. Fine oak cabinetry surrounds are available which encapsulate
the Well-Connect and accent the existing décor of any given
space.

18
4. Self-Ducted Installation
a. Use good judgment and proper industry practices when
designing a ducted air distribution system for the Well-Connect.
Supply air (and return air, if applicable) must be routed through
ductwork suitable for carrying and distributing 600 CFM for the
WCVC-16 and 1000 CFM for the WCVC-24, with no more
than ½” total static pressure.
b. If the return is not ducted, make sure there is a clear,
unobstructed return air path from the household supply registers
back to the Well-Connect. Keep in mind any exposed supply
ductwork may sweat when the Well-Connect is used for air
conditioning. In some cases insulating the ductwork may be
necessary.
c. The Well-Connect has a constant torque ECM blower motor
that is pre-set for the most efficient operation. To a certain
degree, the motor will automatically adjust it’s speed to
maintain proper airflow. However, the ECM motor cannot
compensate for extremes such as poorly designed duct
sizing or extremely dirty air filters. f the steady state air
side heating Δ T is greater than 30°F (17°C) with a new air
filter in place, consult a factory rep for diagnosis and possible
solutions.
Do not change the sealed ECM motor speed taps without
factory authorization.

19
5. Hybrid Installation
Ductwork:
a. Use good judgment and proper industry practices when
designing a duct distribution system for the Well-Connect.
The ductwork must be arranged such that the Well-Connect
is in parallel with, rather than in series with, the fossil fuel
furnace. Supply air (and return air, if applicable) must be
routed through ductwork suitable for carrying and
distributing 600 CFM for Model WCVC-16 or 1000 CFM for
Model WCVC-24 with no more than ½” total static pressure.
deally this can be accommodated even when both the Well-
Connect and fossil fuel furnace are on at the same time. n
rare applications it may be necessary to only run one at a
time, or create a separate return duct for the Well-Connect.
t is up to the installer to determine if this is both possible
and practical based on actual trial and pressure
measurements, as well as installer experience. Some sites
may meet the requirement, while some may require
ductwork modifications, and still others may simply not be a
good fit for this type of Well-Connect application. Installers
MUST run t e Well-Connect along wit t e second stage
systems (in bot eating AND cooling modes, if
applicable), until steady-state operation is ac ieved,
and ensure all system ΔTs remain within acceptable
ranges for the equipment involved.
b. f the return is not ducted, make sure there is a clear,
unobstructed return air path from the discharge point(s)
back to the unit.
c. Keep in mind, any exposed supply ductwork may sweat
when the Well-Connect is used for air conditioning and duct
insulation may be in order.

20
d. To ensure proper airflow, and to prevent “short-cycling”,
back-draft dampers MUST be installed both on the outlet of
the Well-Connect, and on the outlet of the fossil fuel furnace,
upstream of where the Well-Connect supply duct connects
to the main duct. Terra Caloric will provide a twelve inch
(12”) round damper for the outlet of the Well-Connect. The
other damper will need to be custom-sized to the existing
ductwork at each particular site. These can usually be
sourced locally, but if not, call Terra Caloric for assistance.
Controls:
For optimum comfort and efficiency, operate both the Well-
Connect and fossil fuel furnace as one complete multi-stage
system. The wireless thermostat supplied with the Well-
Connect is capable of controlling up to two stages of heating
and two stages of cooling, and can therefore be used to
control both the Well-Connect and one other stage of
heating and/or cooling. Controlling more than two stages of
heat or cooling will require more advanced controls, or use
of the existing thermostat in conjunction with the wireless
Well-Connect thermostat. Detailed instructions for multi-
stage applications are found in Section 6.