WFI EKW FX10 User manual

GIMEKWFX-E November 2008
Installation Information
Water Piping Connections
Electrical
Startup Procedures
Troubleshooting
Preventive Maintenance
FX10 50 HZ HYDRONIC HEAT PUMPS
  
  
EKW FX10 Installation Manual

2
EKW FX10 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 FX10 INSTALLATION MANUAL
Table of Contents
General Installation Information.............................................4
Accessories & Other Options ................................................5
Potable Water Systems ......................................................6-7
Open Loop Systems..............................................................8
Earth Coupled Systems.........................................................9
Electrical..............................................................................10
Dimensional Data, Physical Elements, Sound Data............ 11
Electrical..............................................................................12
Small EKW Setup/Operation ..........................................13-14
1. Application Overview .......................................................15
2. Inputs and Outputs Conguration....................................15
3. Sequence of Operation....................................................16
3.1. Power Fail Restart.................................................16
3.2. Random Start Delay..............................................16
3.3. Compressor Fixed On Delay Time ........................16
3.4. Compressor Minimum On Delay ...........................16
3.5. Compressor Short Cycle Delay Time ....................16
3.6. Pump Sampling.....................................................16
3.7. Heating Cycle...................................................16-17
3.8. Cooling Cycle ........................................................17
3.9. Emergency Shutdown ...........................................17
3.10. Lockout Mode......................................................18
3.11. Entering Load Water Temperature (AI-1).............18
3.12. Leaving Load Water Temperature (AI-2) .............18
3.13. Entering Source Water Temp (AI-3) ....................19
3.14. Source Low Water Coil Temperature Limit (AI-4) .. 19
3.15. Load Low Water Coil Temperature Limit (AI-5) ...19
3.16. Entering Source Water Temp (AI-6) ....................19
3.17. Compressor Proving (BI-1)..................................19
3.18. Emergency Shutdown (BI-2) ...............................19
3.19. Low Pressure Switch (BI-3)................................19
3.20. Source Side Low Water Coil
Temperature Limit Select (BI-4)....................................19
3.21. Source Side Low Water Coil Temperature
Limit Selection (BI-5)....................................................19
3.22. Y1/System Enable Command (BI-7) ...................20
3.23. Source Flow Proving Switch (BI-8)......................20
3.24. Aqua-stat O/Heating-Cooling
Select Command (BI-9)................................................20
3.27. Load Flow Proving Switch (BI-12).......................21
4. Outputs............................................................................21
4.1. Reversing Valve (BO-1).........................................21
4.2. Compressor (BO-2)...............................................21
4.3. Reversing Valve (BO-3).........................................21
4.4. Secondary Unit Enable (BO-4)..............................21
4.5. Secondary Unit S-Plan Comfort Select
Enable (BO-5) ..............................................................21
4.6. Alarm Output (BO-6)..............................................21
4.7. Accessory Output 1/Source Pump
Control (BO-7)..............................................................22
4.8. Accessory Output 2/Load Pump
Control (BO-8)..............................................................22
Unit Startup..........................................................................23
ARI/ISO/BS EN Ratings ......................................................24
Capacity Data.................................................................25-40
Source Flow Rates (L/s)......................................................41
Pressure Drop (kPa)............................................................41
Troubleshooting...................................................................42
Preventive Maintenance......................................................43
Disposal/Recycling Section .................................................44


EKW FX10 INSTALLATION MANUAL
Safety Advisements
Installation and servicing of heating and air conditioning equipment can be hazardous due to system pressure and electri-
cal 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
compressor.
Before performing service or maintenance operations on the system, disconnect all
power sources to unit. Electrical shock could cause personal injury. Before applying power to the
unit, make sure that all panels and screws are in place. Failure to do so could cause risk of electri
cal shock.
Vibration
Absorbing
Mesh Pad
Figure 1: Unit Mounting
Safety Considerations
General Installation Information

5
EKW FX10 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 FX10 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 T R IC W A TE R
HEAT ER
HOT W A TE R
ST O R A G E
EQ U A L T O
A. O . S M IT H
TJ -8 0A
EW 0 2 0
HOT WATER
OUT
SOURCE
OUT
IN
EX PAN SI ON T A N K
IF R EQ UIR 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 FX10 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

8
EKW FX10 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.
Desconexión
de la Tensión
en Línea
Conexiones para
Líquido de Carga
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"ASEDE-ALLAODE!IREPARA!BSORBERLA6IBRACIØN
Figure 6: Typical Open Loop Installation

9
EKW FX10 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

10
EKW FX10 INSTALLATION MANUAL
Electrical
Notes: 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
EKW17 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.