FHP AP025 Installation Manual

AP SERIES 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 Piping................................................................................................................................................3 Electrical...........................................................................................................................................4 Thermostat Connections ...........................................................................................................4 Safety Devices & the UPM Controller....................................................................................5 Electric Heater Package Option...............................................................................................6 Sequence of Operation Single Stage Units.........................................................................7 Sequence of Operation Two-Stage Units............................................................................7 Well Water Systems .....................................................................................................................7 Installation of Pressure Regulating Valves ..........................................................................7 Cooling Tower / Boiler Application........................................................................................7 Earth Coupled Systems...............................................................................................................8 System Checkout..........................................................................................................................8 Unit Start-Up...................................................................................................................................8 Maintenance...................................................................................................................................8 Wiring Diagrams ...........................................................................................................................9 Trouble Shooting .......................................................................................................................13 Unit Check Out............................................................................................................................14 Operating Pressures & Temperatures.................................................................................15 MODEL NOMENCLATURE SERIES: AP-AQUARIUS II NOMINAL CAPACITY: VOLTAGE DESIGNATION: 1 - 208/1/60 & 230/1/60 CABINET CONFIGURATION: VT - VERTICAL HZ - HORIZONTAL CF - COUNTERFLOW HEAT EXCHANGER MATERIAL: C - COPPER N - CUPRO-NICKEL SUPPLY AIR LOCATION: T - TOP (VT ONLY) E - END BLOW (HZ ONLY) B - BOTTOM (CF ONLY) RETURN AIR LOCATION: L - LEFT R - RIGHT B - BACK F - FRONT WATER CONNECTION LOCATION: F - FRONT AP 049 -1 VT C - F L T

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 24 hours of receipt. GENERAL DESCRIPTION: These 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 AP Water-to-Air Heat Pumps are Underwriters Laboratories (UL) and (cUL) listed for safety. The water-to- Air Heat Pumps are designed to operate with entering fluid temperature between 20°F to 80°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. NOTE: 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 less than 6 tons, no more than two high. Horizontal units less than 6 tons, no more than three high. "Do not stack units larger than 6 tons." SAFETY CONSIDERATIONS: 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: NOTE: Remove all shipping blocks under blower housing. Loosen compressor mounting bolts. MOUNTING VERTICAL UNITS: Vertical units up to six tons are available in left, right, front, or rear air return configurations. Vertical units should be mounted level on a vibration 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. (See Figure #1). 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 930-008). (See Figure #2). The rods must be securely anchored to the ceiling and be capable of supporting the unit weight. Refer to the hanging bracket assembly and installation instructions included with the unit for details. 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. 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 970-292 Revised 5-12 AP SERIES (Figure #2) (Figure #1) VIBRATION PAD FULL SIZE 2

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: NOTE: If equipped with float style condensate overflow switch, final adjustment must be made in the field. 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: A supply air outlet collar and return air duct flange are provided on all units to facilitate duct connections. Refer to the FHP individual data specification sheet for physical dimensions of the collar and flange. A flexible connector is recommended for supply and return air duct 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 which includes new duct work, the installation should be designed using current ASHRAE procedures for duct sizing. If the unit is to be connected to existing ductwork, 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 ductwork should be installed. 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. (Refer to ECM motor interface board section in this manual and Figure #7) 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. AP 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 subjected 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 as 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 (Figure #3) (Figure #4) AP SERIES

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. ELECTRICAL: (Refer to electrical component box layout, Figure #5) Field wiring must comply with local and national electric codes. Power to the unit must be within the operating voltage range indicated on the unit nameplate or on the performance data sheet. On three phase units (single stage units only) phases must be balanced within 2%. CAUTION: Operation of unit on improper line voltage or with excessive phase imbalance will be hazardous to the unit, constitutes abuse and may void the warranty. Properly sized fuses or HACR circuit breakers must be installed for branch circuit protection. See unit nameplate for maximum fuse or breaker size. The unit is provided with a concentric knock-out in the front left corner post for attaching common trade sizes of conduit, route power supply wiring through this opening. Always connect the ground lead to the grounding lug provided in the control box and power leads to the power supply terminal block as indicated on the wiring diagram and Figure #5. NOTE: Units supplied with internal electric heat require two (2) separate power supplies: one for the unit compressor and one for the electric heater elements, blower motor and control circuit. Refer to the ELECTRIC HEATER PACKAGE OPTION section and Figure #9 for wiring instructions, minimum circuit ampacities and maximum fuse/breaker sizing. ECM INTERFACE BOARD: THERMOSTAT CONNECTIONS: Thermostat wiring is connected to the 10 pin screw type terminal block on the lower center portion of the ECM Interface Board. In addition to providing a connecting point for thermostat wiring, the interface board also translates thermostat inputs into control commands for the variable speed programmable ECM DC fan motor and displays an LED indication of operating status. The thermostat connections and their functions are as follows: Y2 Second Stage Compressor Operation Y1 First Stage Compressor Operation G Fan O Reversing Valve (energized in cooling) W1 Auxiliary Electric Heat (runs in conjunction with compressor) EM/W2 Emergency Heat (electric heat only) NC Transformer 24 VAC Common (extra connection) C1 Transformer 24 VAC Common (primary connection) R Transformer 24 VAC Hot HUM Dehumidification Mode If the unit is being connected to a thermostat with a malfunction light, this connection is made at the unit malfunction output or relay. (Figure #6) 4 (Figure #5) Electrical Box Component Layout Single & Two Step AP SERIES

NOTE: If the thermostat is provided with a malfunction light powered off of the common (C) side of the transformer, the unit must be provided with a malfunction relay (FHP option # 660-006) to properly energize the light. The relay coil will be wired across the (ALR) and (C) contacts on the unit’s UPM board and the relay’s normally open contacts across (ALR) and the malfunction light connection on the thermostat. If the thermostat is provided with a malfunction light powered off of the hot (R) side of the transformer, then the thermostat malfunction light connection should be connected directly to the (ALR) contact on the unit’s UPM board. To the left of the thermostat connection block are a row of 2 red and 4 green LED’s. These LED’s indicate the operating status of the unit. They are labeled as follows: EM (red) Emergency Heat On W1 (red) Auxiliary Heat On O (green) Reversing Valve Energized, unit is in cooling mode Y2 (green) Second Stage Compressor On Y1 (green) First Stage Compressor On G (green) Fan On Just above the connector block is a single red LED labeled CFM that will blink intermittently when the unit is running and may flicker when the unit is off. This LED indicates the air delivery of the blower at any given time. Each blink of the LED represent 100 CFM of air delivery so if the LED blinks 12 times, pauses, blinks 12 times, etc. the blower is delivering 1200 CFM. Refer to Figure #7 for factory programmed air delivery settings for the ES Series. To the right of the thermostat connection block is a green LED labeled dehumidify. Just above and to the right of the thermostat connection block are four sets of jumper pins labeled ADJ, DELAY, HEAT and COOL. The ADJ set of pins are labeled NORM, (+), (-) and TEST. AP units will all be set on the NORM position from the factory, however, airflow can be increased (+) or decreased (-) by 15% from the pre-programmed setting by relocating the jumper in this section. The TEST position is used to verify proper motor operation. If a motor problem is suspected, move the ADJ jumper to the TEST position and energize G on the thermostat connection block. If the motor ramps up to 100% power, then the motor itself is functioning normally. Always remember to replace the jumper to NORM, (+) or (-) after testing and reset the unit thermostat to restore normal operation. NOTE: Do not set the ADJ jumper to the (-) setting when electric heaters are installed. Doing so may cause the heaters to cycle on their thermal overload switches, potentially shortening the life of the switches. The other three sets of jumper pins are used to select the proper program in the ECM motor for the unit. Refer to Figure #7 for the proper jumper placement. NOTE: Always disconnect power before changing jumper positions on the interface board and reset the unit afterward. To the left of the red and green status LED’s is a row of 1/4” male quick connects. These are used to pass thermostat inputs on to the rest of the control circuit. Remember to always turn off unit power at the circuit breaker before attaching or disconnecting any wiring from these connections to avoid accidental short circuits that can damage unit control components. SAFETY DEVICES AND THE UPM CONTROLLER Each unit is factory provided with a Unit Protection Module (UPM) that controls the compressor operation and monitors the safety controls that protect the unit. Safety controls include the following: • High pressure switch located in the refrigerant discharge line and wired across the HPC terminals on the UPM • Low pressure switch located in the unit refrigerant suction line and wired across terminals LPC1 and LPC2 on the UPM. • Optional freeze protection sensor, mounted close to condensing water coil, monitors refrigerant temperature between condensing water coil and thermal expansion valve. If temperature drops below or remains at freeze limit trip for 30 seconds, the controller will shut down the compressor and enter into a soft lockout condition. The default freeze limit trip is 30°F, however this can be changed to 15°F by cutting the R42 resistor located on top of DIP switch SW1. • The condensate overflow protection sensor is located in the drain pan of the unit and connected to the ‘COND’ terminal on the UPM board. NOTE: If freeze protection sensor is not installed, a jumper between freeze contacts must be installed on the UPM board otherwise unit will not start. The UPM includes the following features: • ANTI-SHORT CYCLE TIME—5 minute delay on break timer to prevent compressor short cycling. • RANDOM START—Each controller has a unique random start delay ranging from 270 to 300 seconds to reduce the chances of multiple units simultaneously starting after initial power up or after a power interruption, creating a large electrical spike. • LOW PRESSURE BYPASS TIMER—If the compressor is running and the low pressure switch opens, then the control will keep the compressor on for 120 seconds. MOTOR PROFILE AIR FLOW TABLE CFM TWO STAGE UNITS FAN Y1 Y2 AUX. EMERG. PLUS MINUS TAP MODEL ONLY COOL/HEAT COOL/HEAT HEAT HEAT ADJ ADJ COOL/HEAT/DELAY AP025 600 750 950 950 950 1090 800 A AP035 900 1000 1200 1200 1200 1400 1000 A AP049 1200 1300 1700 1700 1700 1950 1450 B AP061 1300 1500 2000 2000 2000 2100 1900 A AP071 1300 1500 2100 2100 2100 2300 1900 A (Figure #7)