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Installation and Service Manual Freon

1. Page 55 DRAWINGS 000344CDG Typical Heating Only Zone Connection Diagram TF amp FCTF Series Page 9 000484PDG Single Unit Connection to DHW Pre Heat Tank Page 10 000310CDG NCB Laptop Communication Cable Page 13 000606CDG Typical Duct and Condensate Connections Vertical Case Page 16 000533PDG Typical Buffer Tank Configuration Four Port Tank Page 18 000530PDG Typical Zone Types for Hydronic Applications Page 19 000627PDG Single Unit Connection to On Demand DHW Pre Heat Tank Page 20 000769PDG DX Line Set Interconnect Tubing Installation 410 Page 22 000268RCD FCTF Series Refrigeration Circuit Diagram Heating Mode Page 45 000268RCD FCTF Series Refrigeration Circuit Diagram Cooling Mode Page 46 000269RCD FCTF Series Refrigeration Circuit Diagram Hydronic Heating Mode Page 47 000737SCH FCTF HAC P 1T DE Schematic Diagram
2. 113 4 J T Top View Size 2 3 4 Ton 3 REVERSIBLE REMOVABLE FILTER RACK FOR i 28 x 31 5 X 2 AIR FILTER 13 1 2 1 31 1 4 10 3 4 13 7 8 at i i 32 5 5 000744MAN 02 Page 56 25 MAY 2009 APPENDIX ECM Fan Airflow Tables NOMINAL AIRFLOW SETTING MED STAGE 2 STAGE 1 PAN Recirculation a Tons 6 AIRFLOW SETTING LOW STAGE 2 STAGE 1 ONLY Recirculation Cd 45 55 65 75 6 AIRFLOW SETTING HIGH STAGE 2 STAGE 1 Recirculation NN RT Tons 12 AIRFLOW SETTING MAX STAGE 2 STAGE 1 Recirculation RN RN R77 RUN Tons 1 1 ue NOTES Unit sizes 25 45 55 nominal value up to 0 50 2 sizes 65 75 up to 0 70 2 To obtain the REDUCED airflow values use a dry contact to connect AR1 to AR2 on the terminal strip INFORMATION TAKEN FROM DOCUMENT 0005271NF 03 25 MAY 2009 Page 57 000744MAN 02 000744MAN 02 Page 58 25 MAY 2009 25 2009 59 000744MAN 02 LIMITED WARRANTY AMERICAN DREAM Ultra Performance Geothermal warran
3. A A 4 016 L sec 2 100 991 2 100 991 2 100 991 2 100 991 2 100 991 2 100 991 2 100 991 2 100 991 k w N w N Ww A w a o F C 88 0 31 1 89 4 31 9 90 9 32 7 92 5 33 6 95 3 35 2 97 2 36 2 99 2 37 4 101 4 38 5 C 18 0 10 0 19 4 10 8 20 9 11 6 22 5 12 5 25 3 14 1 27 2 15 1 29 2 16 2 31 4 17 4 BTU Hr Watts 40 155 11 765 43 251 12 672 46 560 13 642 50 092 14 677 54 151 15 866 58 198 17 052 62 498 18 312 67 060 19 649 49 7Pa 0 20inH20 Ext Static Cooling Mode Watts 2 3 16529 3 055 3 498 Power Consumption 19 4 Co 18 0 5 27 16 7 4 89 A A R41 Watts EER PSIG COPc 1 761 2 044 0 F BTU Hr e 8 a 0 29 4 35 0 60 Hz 22 375 275 90 76 137 1 899 32 2 22 308 15 5 296 9 75 869 22 229 136 934 138 951 138 951 2 357 40 6 21 756 2 705 46 1 21 533 49 7Pa 0 20inH20 Ext Static N 9 9 99 9 9 9 3 167 5 165 z ew 1751 92 6479 sss 162 AEE A 3 903 N gt 141 80 0 16 2 16 923 4 421 ompressor ZPS51K4
4. Indoor Loop Hydronic Loop 1 Verify that all shutoff valves are fully open and there are no restrictions in the piping from the heat pump to the indoor loop and that full flow is available to the heat pump 2 Verify that the entire system has been flooded and all the air has been purged as much as possible Further purging may be required after the system has been operating for a while 3 Verify that the loop contains the proper mix of antifreeze if used for the intended application Record the type of antifreeze and the mixture value on the startup sheet circle Vol or Weight 4 Record the static loop pressure on the startup sheet Line Sets Inside structure 1 Verify that all line sets are connected to the proper ports on the heat pump 2 Verify that the line sets are completely insulated and securely fastened in place Domestic Hot Water if equipped 1 Verify that all shutoff valves are fully open and there are no restrictions in the piping from the heat pump to the domestic hot water tank 2 Verify that the entire system has been flooded and all the air has been purged as much as possible Further purging may be required after the system has been operating for a while 3 Verify that the brown wire with the insulated terminal is disconnected in the electrical box Refer to the schematic diagram for more information Electrical 1 Ensure the power to the unit is off Ensure the power to the plenum heater i
5. 25 2009 17 000744MAN 02 HEAT PUMP CONNECTIONS HOT OUT NOTE Refer to the heat pump labels for the connection locations INDOOR IN HOT IN Typical Buffer Tank Configuration Four Port Tank OPTIONAL gt must install both 2425 1 PSIG Ball PRV Valve 3 Pressure Indoor Loop Gauge Circulator 1 0 60PSIG UP26 99 Union lt Circulator and Expansion Tank 2 4 USGAL 125 PSIG 4 TANK PRV Aquastat Probe 1 12 Dry Well Heating 35 49 C 95 120 F Cooling 7 10 C 45 50 F Electric Gas Insulated Buffer Tank Circulator and isolation valves Pressure gt Gauge 0 60PSIG Boiler Drain 3 Boiler Drain 4 d isolation valves Refer to diagram 000530PDG for the typical types of zones that may be connected to the supply and return headers Unions or another type of disconnect should be used to connect the heat pump to the loop Circulators should be mounted vertically when possible to reduce the chance of air getting caught in the housing The automatic air vent must be installed upright to function properly If the optional 1 ball valve is installed in the Indoor Out line the PRV must be installed as well to prevent pressure build up should both ball valves be closed Pressure gauges 0 60PSIG are placed on both sides of the circulators for a quick check method to determine that the circulators are pumping Ensure the
6. G L Weyy Yo ARAR 1 Thermostat Connections Connections Low 6 High 6 Med Nom Max 12 Fan Contactor IE Plenum Heat Relay C lt gt 24VAC s GND C lt gt 208 230 24VAC Transformer 100VA Comp Start Cap Compressor Run Capacitor Potential Relay Compressor Contactor Heat Pump Electrical Service Requirements 230VAC Single Phase 60Hz 230 1 60 Min Circuit Min Wire TD Fuse or Model Ampacity Gauge Breaker Size hris Geddes 28 MAY 08 SC NN LIU edde 27 08 hris Geddes 27 MAY 08 54 Low Voltage Wiring 24VAC Two Stage Control Box Wiring Use an 18 7 conductor cable to connect this unit to the Heat Pump Electrical Box Thermostat Terminals in the FCTF Two State Control Box Refer to 000139CDG 03 for more detail C 24VAC Common G Fan Y1 Stage 1 Heat Cool Compressor RH 24VAC Hot L Trouble if available on thermostat W2 Stage 2 Heat Plenum Heater O B W1 Reversing Valve Active in Cooling Y2 Stage 2 Heat Cool Compressor S2 Solenoid Coil Use an 18 3 conductor cable to connect this unit to the Heat Pump Electrical Box FCTF Terminals in the FCTF control box Refer to 000740CDG 01 for more detail FC Fan Contactor E1 Emergency Heat In E2 Emergency Heat Out Airflow Reduction Wiring Use an 18 2 conductor cable to connect Elec
7. DREAM Ultra Performance Installation and Service Manual AMERICAN DREAM Freon Copper Series Triple Function Freon Copper Triple Function Heat Pumps on IBDR inc Email info AmericanDreamGeothermal com 3960 Howard Hughes Parkway Web www AmericanDreamGeothermal com Las Vegas Nevada 89169 Document Number 000744MAN 02 REVISION DATE 25 MAY 2009 SAFETY PRECAUTIONS A WARNING Ensure all access panels are in place and properly secured before applying power to the unit Failure to do so may cause risk of electrical shock WARNING Before performing service or maintenance on the heat pump system ensure all power sources are DISCONNECTED Electrical shock can cause serious personal injury or death WARNING Heat pump systems contain refrigerant under high pressure and as such can be hazardous to work on Only qualified service personnel should install repair or service the heat pump CAUTION Safety glasses and work gloves should be worn at all times whenever a heat pump is serviced A fire extinguisher and proper ventilation should be present whenever brazing is performed CAUTION Venting refrigerant to atmosphere is illegal A proper refrigerant recovery system must be employed whenever repairs require removal of refrigerant from the heat pump MODEL NOMENCLATURE FCTF Size HACW P 1T H L SDETV xx Revision 01 02 etc Series FCTP Freon Copp
8. Systems Gemelli cn 14 Duct Systems Grill Layout 1 4 14 Thermostat 15 Plenum Heater Optional nadaa a 15 Condensate 51212024 14 15 Hydronic Systems General 4 0 nene 15 Hydronic System Connections 1 15 DUCESIZING 17 Freon Copper LOOP CONNECTION AND CHARGING PAGE 21 Line Set Interconnect Tubing 21 Pipe EE 21 Silver Soldering Line Sets 21
9. Readjust the setting to 120 F 140 F if required by local code Dole flow control Valve The Dole flow control is a simple self cleaning device designed to deliver a constant volume of water from any outlet whether the pressure is 15 psig or as high as 125 psi The controlling mechanism consists of a flexible orifice that varies its area inversely with pressure so that a constant flow is maintained Multimeter Voltmeter Digital In line Flowmeter 25 MAY 2009 Page 43 000744MAN 02 REPAIR PROCEDURES PUMP DOWN PROCEDURE Connect the refrigerant recovery unit to the heat pump service ports via a refrigeration charging manifold and to a recovery tank as per the instructions in the recovery unit manual If there was a compressor burn out the refrigerant cannot be reused and must be disposed of according to local codes Ensure all hose connections are properly purged of air Start the refrigerant recovery as per the instructions in the recovery unit manual Allow the recovery unit suction pressure to reach a vacuum Once achieved close the charging manifold valves Shut down purge and disconnect the recovery unit as per the instructions in its manual Ensure the recovery tank valve is closed before disconnecting the hose to it Connect a nitrogen tank to the charging manifold and add nitrogen to the heat pump until a positive pres sure of 5 10PSIG is reached This prevents air
10. 99 NJ N wo oO Cooling Mode CFM L sec 1 400 661 1 400 661 1 400 661 1 400 661 1 400 661 1 400 661 1 400 661 1 400 661 C C 16 7 30 4 9 3 17 9 10 0 19 2 10 7 20 5 11 4 22 8 12 7 24 4 13 6 26 1 14 5 27 8 15 4 86 7 87 9 31 1 89 2 31 8 90 5 32 5 92 8 33 8 94 4 34 7 96 1 35 6 97 8 36 5 BTU Hr Watts 24 840 7 278 26 630 7 803 28 502 8 351 30 479 8 930 33 907 9 935 36 297 10 635 38 733 11 349 41 289 12 098 37 3Pa 0 15inH20 Ext Static Power Consumption Watts Amps N N B 21 gt e 410 PSIG F BTU Hr 37 8 55 COPc 25 3 7 42 1 2 52 879 1 631 26 7 15 493 60 Hz 0 23 2 2 85 52 143 6 79 21 2 1 761 29 4 15 278 275 90 51 401 1 899 32 2 15 060 19 6 296 9 51 042 5 75 18 0 2 044 2 597 392 2 705 35 0 14 955 44 4 14 076 115 47 599 46 1 13 947 37 3Pa 0 15inH20 Ext Static 000744MAN 02 CAPACITY RATINGS continued 108 743 119 819 131 900 Heating Mode Nominal 4 ton Power Consumption R410a 60 Hz 12 2 15 9 4 6 7 3 9 30 1 1 35 1 7 40 4 4 45 7 2 BTU Hr Watts 19 476 5 707 21 698 6 357 24 093 7 059 26 667 7 813 30 965 9 073 34 068 9 982 37 377 10
11. Domestic Dry Well 125psi HOT OUT DHW OUT y PRV 5 to house Me emt 120 240 Valve Valve 1 50 60 Drain t Domestic Tank Water Electric Pre Heat or Gas Tank i NOTE Refer to 1 2 copper lines the heat Insulate with 5 8 pipe insulation pump labels for i OPTIONAL f connection must install both i 125pis 1 2 locations v9 Ball Water Valve Tank Insulated Domestic DHW IN Pressure OPTIONAL Gauge must install both If the circulator Indoor Loop 0 60PSIG Boiler 1 2 idoes not have INDOOR t i Drain icheck then Valve zone valve repaid n ishould be installed check valve an d prevent flow INDOOR OUT due to convection Domestic HEAT PUMP COLD IN CONNECTIONS from well Ball J Ball Valve 4 2 Valve T Union 125psig DHW OUT PRV 1 2 1 2 or mixing Ball Check 120 140 F valve Valve Valve 50 60 C Drain 1Hot Water Indirect Electric 1 Pre Heat or Tank Gas NOTE i Refer to 1 2 copper lines the heat Insulate with 5 8 pipe insulation pump labels for OPTIONAL connection i must install both i 125pisg 1 2 i locations v9 Ba
12. H Eis sss AMERICAN DREAM Geothermal 127221020 AZ 6H4 Drawing Name DX Line Set Interconnect Tubing Installation R410a Approved By MFGYD 2 Eco PL Bv pare 197 oP 000769PDG 02 1 of 1 000744MAN 02 Page 22 25 MAY 2009 Startup Procedure The following steps describe how to perform the startup procedure of the geothermal heat pump The Two Stage R410a Air and Hydronic Startup Records located in this manual are used in conjunction with this startup procedure to provide a detailed record of the installation A completed copy should be left on site a copy kept on file by the installer and a copy should be sent to AMERICAN DREAM Geothermal Check the boxes or fill in the data as each step is completed For data boxes circle the appropriate units Fill in the top section of all three copies or one copy if photocopies can be made after the startup has been completed PRE START INSPECTION Ductwork 1 Verify that all ductwork has been completed and is firmly attached to the unit Verify that any dampers or diverters are properly set for operation of the heat pump Verify that all registers are open and clear of any objects that would restrict the airflow Verify that a new air filter is installed and the cover is secured Verify the condensate drain is connected properly vented and free of debris If a plenum heater has been installed verify that it is securely fastened to the ductwork
13. Heat Pump Stage 1 Compressor stage 1 24VAC Hot Fault 24VAC when fault condition Heat Pump Stage 3 auxiliary heat Emer gency Heat Cooling Mode reversing valve Heat Pump Stage 2 Compressor stage 2 The thermostat signals connect to the geothermal unit Control box as per TABLE 1 AQUASTAT REQUIREMENTS Description 24VAC Common Ground 24VAC Hot Heat Pump Stage 1 Compressor stage 1 Page 6 Heat Pump Stage 2 Compressor stage 2 Refer to 000139CDG included with the Control Box for a complete description of the connections to the aquastat For water mode operation a two stage aquastat is re quired to provide the appropriate control signals The connec tions to the FCTF Control Box are shown in TABLE 2 The aquastat can be placed anywhere within the range of the probe cable The probe should be inserted into a dry well in or near the top of the tank for optimal operation refer to draw ing 000533PDG If a dry well is not available it may be possi ble to fix the probe to the tank inside the insulation 25 MAY 2009 TABLE 3 shows typical settings for the aquastat The settings may be changed as desired however the setpoint TABLE 3 Typical Aquastat Settings Item Setpoint Delta Activation Activation is indirectly set by the Setpoint and Delta values All values must be set identical for both stages should not exceed
14. 1 es 11 11141141 ee 25 minutes 30 minutes Average Indoor In Hot In Indoor Out Hot Out and Delta T In Out F Cooling aquastat setpoint and suction pressure at cycle end F Final Aquastat Heating S1 Setpoint S1 Delta S2 Setpoint S2 Delta tti Settings Cooling 51 Setpoint 51 Delta 52 Setpoint 52 Delta 25 MAY 2009 Page 27 000744MAN 02 Heating Adjustment If it is determined during the start up procedure that one or more of the heating TXV s need to be adjusted the following proce dure and record sheet should be used to ensure that adjustments are recorded and performed in a systematic way TABLE 17 describes what each of the columns in the Heating TXV record sheet table represents TABLE 17 TXV Adjustment Record Column Descriptions Description Time Actual Actual time of the reading Time EL Elapsed time since the first reading Common 5 Suction pressure Common ET Evaporating temperature from suction gauge or P T chart Common D Discharge pressure Loop P Loop TXV position Number of turns in from all the way out Loop V Loop Vapour Line temperature Loop S Loop Superheat Vapour Line temperature Evaporating temperature TXV The that is being adjusted Turns The number of turns the TXV is being adjusted In Out The direction the TXV is being adjusted In clockwise OUT counter clockwise T
15. 3 8 C superheat One or more heating 5 stuck too far closed Adjusting the TXV does not affect the superheat or the suction pressure Adjust the TXV all the way in and out a few times to loosen it Replace TXV if this does not work Faulty Normally Open so lenoid valve stuck closed A click can be heard when the coil is energized but the valve is cold in stead of warm Replace NO valve Filter drier plugged Feel each end of the filter drier it should be the same temperature If there is a temperature difference then itis plugged Also causes low suc tion pressure Replace filter drier Unit is overcharged Heating TXV s adjusted too far closed Heating TXV s adjusted too far closed High sub cooling low delta T across air coil Verify superheat It should be be tween 8 14 F 3 8 C Superheat will be high if TXV is closed too far Adjusting the TXV does not affect the superheat or the suction pressure TXV may be frosting up Remove 1 2lb of refrigerant at a time and verify that the discharge pressure reduces Adjust TXV to obtain 8 14 F 3 8 C superheat Adjust TXV to obtain 8 14 F 3 8 C superheat One or more heating TXV s stuck too far closed Adjusting the TXV does not affect the superheat or the suction pressure Adjust the TXV all the way in and out a few times to loosen it Replace TXV if this does not work Faulty Norm
16. Page 53 000738ELB FCTF HAC P 1T DE Electrical Box Diagram Page 54 25 MAY 2009 Page 5 000744MAN 02 Installation Information UNIT DESCRIPTION Your American Dream Geothermal unit is a high efficiency two stage triple function heat pump with R410a refrigerant It extracts and rejects heat from the earth via direct contact with copper loops eliminating the need for a secondary heat ex changer and associated components The FCTF unit can pro vide air heating air cooling and hydronic heating Freon Copper units require less loop per ton and are more efficient than conventional ground loop systems The re duced thermal resistance between the earth and the refrigerant circuit provides better heat transfer resulting in a higher suction pressure and increased output An electrically commutated ECM fan with several speed options is standard The motor has a soft start function for im proved efficiency and reduced wear The unit has several key features that are described in the specifications document for the particular heat pump Please request a copy if desired or visit www AmericanDreamGeothermal com UNPACKING THE UNIT When the heat pump reaches its destination it should be unpacked to determine if any damage has occurred during shipment Any visible damage should be noted on the carrier s freight bill and a suitable claim filed at once The heat pump is
17. Pool Spa Zone Zone Valve Titanium Heal Exchanger Temperature Probe NOTES 1 Floor zones are heating only Cooling a floor zone will cause condensation in the floor Floor zone valves should be wired through relay that is controlled by the cooling signal that breaks the signal when in cooling mode to ensure that they cannot accidentally be energized There may be multiple floor zones There be multiple fan coil units heating and or cooling zone valve is not required if the unit has a internal valve Domestic Pre Heat Tank is for on demand apllications The tank must have a heat eaxchanger in it or an external one must be used io separate the zone loop from the potable water supply Ensure the floor circulator is adequately sized to accomodate the type and number of zones connected to the system The pool aquastat will operate the Pool Spa Zone Valve m me 3980 ra Hughes as Vegas Chris Geddes SEP 07 e E42 By TENG rawing 2 7 hris Geddes Typical Zone Types for Hydronic Applications Aapmec By FG Ecos mP ey Amb 000530PDG 91 1 of 1 25 MAY 2009 Page 19 000744MAN 02 Single Unit Connection to On Demand Domestic Hot Water Pre Heat Tank Dedicated On Demand System No other zones Domestic HEAT PUMP COLD IN Aquastat CONNECTIONS from well P Probe Ball Ball Valve tinea 12 j
18. causes the LED to come on Replace loop pressure switch Faulty Loop Pressure switch Input Faulty reclaim valve sole noid Shorting S and S does not cause the Loop Switch LED to come on or does not cause a loop change Verify solenoid by removing it from the shaft while energized If there is no click the solenoid is bad Replace the control board Replace reclaim solenoid coil Faulty reclaim valve A click can be heard when the valve is selected but the unit still trips out Replace the reclaim valve Faulty control board out put L1 to L5 Cooling TXV adjusted too far closed or stuck or par tially blocked Loop LED does not come on or there is no 24VAC across the loop output and C of the control board when the loop is selected Continuous loop changing every 7 seconds in two loop mode high suction pressure hot compressor Replace the control board Adjust TXV or replace if faulty Unit overcharged Frequent loop changes Switch to heating mode to confirm Remove refrigerant 1 2 pound at a time in heating mode Loop field saturated Frequent loop changes in two loop mode after some season runtime Install soaker hose Loop field too small Frequent loop changes in two loop mode after some season runtime Page 36 Increase loop size 25 MAY 2009 High Suction Pressure may appear to not be pumping Low Suction Pressure Compressor
19. olalla 5 414 18 99 1 1 w gt N T BTU Hr Watts 17 610 5 160 19 204 5 627 20 790 6 092 22 475 6 585 25 716 7 535 27 900 8 175 30 025 8 797 32 256 9 451 wo N ALATA Compressor ZPS30K4E PFV A x o o N A 10 0 5 10 0 987 10 0 43 5 987 10 3 143 51 987 10 3 c Wats watts 80 0 62 2 26 7 80 0 6 26 7 26 7 6 6 6 1 ompressor ZPS30K4E PFV 25 MAY 2009 61 61 61 661 80 0 661 61 61 61 Watts 1 939 1 996 2 080 2 165 2 220 2 280 2 372 2 467 5 9 2 GET 80 0 16 2 Heating Mode Nominal 3 ton Power Consumption e 5 N Watts 4 121 12 739 rae 3686 12485 2 211 2 259 6 A A a N A gt A A A N 38 966 2 469 3 454 7 963 11 417 1 555 26 643 38 198 2 565 49 1 895 2 118 99 gt 99 N AR
20. 120 F 49 C Exceeding this setpoint limit will cause the heat pump operating pressures to approach the safety control settings possibly causing nuisance shut downs If only floor zones are being heated it is highly rec ommended to drop each of the setpoints by 15 F 8 C for increased efficiency It is recommended that a buffer tank with electric elements be selected to provide auxiliary backup heat The tank ele ment thermostats can be set to a low value of around 60 F 15 C which will prevent the hydronic system from becoming too cold should there be a failure in the heating system Drawing 000344CDG shows how a typical zone system would be setup with the FCTF unit The zone controls and heat pump operate independently there are no connections between the two systems TWO STAGE CONTROL BOX The Two Stage Control Box is the interface between the controls thermostat and aquastat and the heat pump It s main function is to provide the signal manipulation required to operate the fan or the Indoor Loop Circulator as required based on the signals received from the controls It also contains a contactor for power connections to the Indoor Loop Circulator The connections between the control box and the heat pump are shown in TABLE 4 Three documents are shipped with the Control Box 000739SCH 000740CDG and TABLE 4 FCTF Two Stage Control Box to Heat Pump Signals Signal 24 Common Ground G Fan low sp
21. 5 IT 21 Vacuuming the System 1 1 Page 21 Charging the Systemi 21 STARTUP PROCEDURE c Page 23 IAM Let sp I cM LI LER ar iride Er Page 23 Unit Startup Air EA AS 24 Startup Record AIT 24 02018 6 s 25 Unit Startup Hydronic ERR Page 26 startup Record 22 2 dita d Page 27 HEATING TXV ADJUSTMENT aea VE Page 28 Adjustment Procedure 4 1 lt Page 28 Heating Adjustment Record eterne Page 29 GENERAL MAINTENANCE 22 02 00 haere Od In Dey codes cave Rae Deu Ee Lon ne Nro wa E CEU eO Maven PAGE 30 TR
22. 9 e COPc 20 1 1 60 Hz 2 62 721 R410 Pa es 37 8 55 1 631 26 7 18 377 a 0 18 6 2 85 61 937 4 75 14 6 3 97 12 6 11 6 Page 50 1 761 29 4 18 147 275 90 61 638 1 899 32 2 18 060 16 2 296 95 61 302 2 044 35 0 17 961 319 100 58 448 2 196 37 8 17 125 2 357 40 6 17 017 366 110 57 684 2 526 392 2 705 13 5 342 105 58 080 43 3 115 46 1 16 901 56 816 16 647 37 3Pa 0 15 20 Ext Static 25 MAY 2009 CAPACITY RATINGS continued Heating Mode Nominal 5 ton R410a 60 Hz PSIG kPa 62 430 70 484 79 543 88 605 97 672 108 743 119 131 900 BTU Hr Watts 27 054 7 927 29 807 8 733 32 777 9 603 35 969 10 539 39 930 11 699 43 638 12 786 47 592 13 944 51 799 15 177 Compressor ZPS51K4E PFV PSIG Pa 131 900 133 917 133 917 136 934 T gt Nia 9 o 80 0 80 0 2 100 6 80 0 80 0 2 100 26 7 1 9 230 835 ve 9 Power Consumption Watts 3 384 A AR Co e 3 484 mi A 3 584 AR 3 683 A zx 99 a a AR Co 3 712 3 811 3 912 N N A gt
23. 951 40 897 11 983 Watts 2 740 2 813 2 885 2 957 3 072 3 147 3 223 3 300 A gt A wo wo w U L sec 1 700 802 1 700 802 1 700 802 1 700 802 1 700 802 1 700 802 1 700 802 1 700 802 F C 88 1 31 2 89 6 32 0 91 2 32 9 92 9 33 8 95 7 35 4 97 7 36 5 99 9 37 7 102 2 39 0 C 18 1 10 0 19 6 10 9 21 2 11 8 22 9 12 7 25 7 14 3 27 7 15 4 29 9 16 6 32 2 17 9 BTU Hr Watts 29 971 8 781 32 441 9 505 35 083 10 279 37 904 11 106 42 594 12 480 45 951 13 464 49 519 14 509 53 304 15 618 Compressor ZPS40K4E PFV gt gt gt aA ojn 25 ojojo 99 o N N gt e A A 141 969 T Cooling Mode c Wats Wats wans 26 7 802 4 931 80 0 6 422 35 919 52 340 26 7 4 812 10 524 15 336 61 7 18 1 700 3 16 5 2 802 26 7 4 655 14 836 ompressor ZPS40K4E PFV 000744MAN 02 37 3Pa 0 15inH20 Ext Static Power Consumption Watts 2 297 2 447 2 601 2 760 2 889 3 059 3 238 3 427 Amps lt A A N
24. Visually inspect the setting Recommended Action Readjust the setting to 120 F 140 F if required by local code Breaker tripped or fuse blown in electrical supply to hot water tank Check both line and load sides of fuses If switch is open determine why Replace blown fuse or reset breaker Reset button tripped on hot water tank Circulator pump not operating Check voltage at elements with multimeter Visually inspect the pump to see if shaft is turning Use an amprobe to measure current draw Push reset button Replace if faulty Blockage or restriction in the water line or hot water heat exchanger Check water flow and power to pump Check water lines for obstruction Remove obstruction in water lines Acid treat the domestic hot water coil Faulty DHW cutout failed open Check contact operation Should close at 120 F and open at 140 F Replace DHW cutout if faulty Heat pump not running enough hours to make sufficient hot water Faulty DHW cutout failed closed Note the amount of time the heat pump runs in any given hour Check contact operation Should close at 120 F and open at 140 F Temporarily turn up the tank thermostats until colder weather creates longer run cycles Replace DHW cutout if faulty Thermostat on hot water tank set too high Should be set at 120 F 140 F if required by local code Visually inspect the setting
25. at the pre sent time see Electrical Tables The Y2 signal is not used for these units INDOOR LOOP CIRCULATOR WIRING The Indoor Loop circulator provides flow between the heat pump and the buffer tank The Two Stage Control Box has pro visions for connecting the Indoor Circulator so that it will be turned on whenever the heat pump is in water heat mode and the compressor operates Connect line voltage 115 or 230VAC to the terminals marked L1 and L2 of the Indoor Circu lator Contactor Connect the Indoor Loop circulator to the termi nals marked P1 and P2 Ensure that the line voltage and circu lator voltage rating are the same FAN MOTOR The unit is equipped with a direct drive ECM fan motor for maximum efficiency The motor features a soft start which fur ther improves efficiency by eliminating inrush current and pro vides a smooth quiet ramp up to speed The motor will main tain the programmed air flow up to the maximum external static TABLE 6 Airflow Selections LOW 12 MED 6 HIGH MAX Nominal 6 value Refer to the APPENDIX A ECM Fan Airflow Tables The air flow can be set to four different levels by changing the position on the Air Flow board located in the electrical box The four levels are indicated in TABLE 6 The actual air flow 000744MAN 02 values be found in APPENDIX Units are shipped with the MED position selected for nominal air flow The air flow can be further re
26. but trips its internal overload after a few seconds Run capacitor already verified Check with capacitance meter Check for black residue around blowout hole on top of capacitor Attempt to rock compressor free If normal operation cannot be established replace compressor Replace if faulty Remove black residue in electri cal box if any Potential Relay faulty Single phase only Replace with new one and verify compressor starts properly Replace if faulty Compressor is tight due to damaged mechanism Compressor attempts to start but trips its internal overload after a few seconds Run capacitor has been verified already Attempt to rock compressor free If normal operation cannot be established replace compres sor Faulty Stage 2 module Verify if 24VAC is present across Y2 and C of the terminal strip Page 33 Replace module if signal is pre sent Check wiring if signal is not present 000744MAN 02 OPERATION TROUBLESHOOTING HEATING MODE High Discharge Pressure Surging Discharge Pressure Low Suction Pressure 000744MAN 02 Possible Cause Air Flow Verification See Fan Troubleshooting section Recommended Action Correct the problem Heating TXV s adjusted too far closed Verify superheat It should be be tween 8 14 F 3 8 C Superheat will be high if TXV s are closed too far Adjust TXV to obtain 8 14 F
27. frosting up Random Low Pressure trip 25 MAY 2009 AIR OPERATION TROUBLESHOOTING COOLING MODE Possible Cause Cooling TXV adjusted too far open Verification Verify superheat It should be be tween 8 12 F 3 6 C Superheat will be low if TXV is open too far Recommended Action Adjust TXV to obtain 8 12 F 3 6 C superheat Cooling TXV stuck open Adjusting the TXV does not affect the superheat or the suction pres sure Low super heat and dis charge pressure Adjust the TXV all the way in and out a few times to loosen it Replace TXV if this does not work Leaking reversing valve Reversing valve is the same tem perature on both ends of body common suction line is warm com pressor is running hot Replace reversing valve Leaking reclaim valve Scavenger line remains hot where it enters the common suction line See Fan Troubleshooting section Note low airflow will cause the air coil to ice up once the suction drops below 90PSIG Replace reclaim valve Correct the problem Cooling TXV stuck almost closed or partially blocked by foreign object Adjusting the TXV does not affect the superheat or the suction pres sure TXV may be frosting up Adjust the TXV all the way in and out a few times to loosen it Replace TXV if this does not work Low or no refrigerant charge Entering air temperature and air flow are good but suction is low Check static
28. ize Drawing Number E SHEET ECO IMPL BY APVD BY DATE 000270RCD 01 1 of 1 25 MAY 2009 Page 47 000744MAN 02 Model Specific Information This section provides general information particular to each model For complete specifications please see the specifica tions document for the desired model STADARD CAPACITY RATINGS The tables below depict the results of standard capacity rating tests according to ARI 870 2005 Stage 1 values do not apply to single stage units Refer to the Electrical Tables to determine which models are single stage Table 18 Standard Capacity Ratings Heating 60Hz STAGE 1 VAPOUR LINE 41 F 5 C OC STAGE 2 VAPOUR LINE 32 F 0 C 4 57 3 99 4 32 3 78 4 19 3 74 Table 19 Standard Capacity Ratings Cooling 60Hz STAGE 1 LIQUID LINE 68 F 20 C STAGE 2 LIQUID LINE 77 F 25 EAT 80 F 26 7 C Tus wats erum STUN 9 9 28 3 19 3 25 2 17 8 24 2 17 6 VAPOUR LINE 32 F 0 C Indoor Indoor Liquid Flow Pressure Drop Capacity Tons IGAL 586 Ls PSI BTUHL 8 6 9 4 5 31 0 2 87 3 21 3 07 3 12 2 95 10 12 0 5 8 40 0 12 14 4 4 8 33 1 000744MAN 02 Page 48 25 MAY 2009 CAPACITY RATINGS R410a 60 Hz U A N N 1 T
29. on to the unit and the plenum heater if installed Set the thermostat to the final settings 000744MAN 02 Page 24 25 MAY 2009 Startup Record Air 2 5 Two Stage R410a Installation Site Startup Date Installer city T Province Model Check boxes unless asked to record data Circle data units PRE START INSPECTION Ductwork Ductwork is completed dampers diverters are adjusted Registers are open and clear of objects Air filter and end cap are installed Condensate Drain is connected properly vented and free of debris Plenum heater is securely fastened if applicable Connected to proper ports insulated and secured in place Domestic Hot All shut off valves are open Water Lines are full and purged Desuperheater pump wire is disconnected High voltage connections are correct and securely fastened Circuit breaker or fuse size and wire gauge for Heat Pump Circuit breaker or fuse size wire gauge and Plenum Heater size Low voltage connections are correct and securely fastened Unit Charge Refrigerant charge be fore power is turned on STARTUP DATA Preparation Voltage across L1 and L2 L1 and L3 L2 and L3 Final refrigerant charge r o lt 00 lt 0 lt 10 minutes 15 minutes 25 minutes 30 minutes Duct Return Duct Supply and Delta Compres
30. refrigeration pressure of unit for very low value Locate the leak and repair it Spray nine a sniffer and dye are common methods of locating a leak Leaking cooling check valve Unit operates correctly when loop is in use Loop lines get cold when loop not in use instead of warming to ambient compressor frosts up Identify the check valve Try switching modes a few times Re place if problem continues Faulty NO solenoid valve coil Verify solenoid by removing it from the shaft while the unit is running There should be an audible click sound if the solenoid is working Replace solenoid if faulty Faulty NO solenoid valve A click can be heard when the coil is energized Unused loops stay cold instead of gradually warming to ambient Compressor frosts up Replace NO valve Faulty compressor not pumping Pressures change only slightly from static values when compressor is started Replace compressor See Low Suction Pressure in this section TXV stuck almost closed or partially blocked by for eign object Faulty compressor contactor Adjusting the TXV does not affect the superheat or the suction pres sure Points pitted or burned Contactor sometimes sticks causing the com pressor to run without the fan trip ping the low pressure control Adjust the TXV all the way in and out a few times to loosen it Replace TXV if this does not work Replace contactor Inter
31. safety control monitors the compressor discharge pressure and will shut the compressor down if the condensing pressure becomes too high There are 3 main reasons why this control would activate in response to the operating conditions of the unit while operat ing in heating mode 1 Low or no airflow or water flow 2 High return air temperature or water temperature 3 Dirty air coil due to poor filter maintenance Each of the controls are auto reset controls There is also a manual reset high pressure control should the control board be faulty and fail to disengage the compressor It can be reset by pressing the rubber button on the end of it It is electrically located between the Y output of the control board and the com pressor contactor coil The control board see next section monitors the pressure controls and shuts the compressor off immediately for a set pe riod of time adjustable should there be a fault The counter for the safety control in question will be increased by 1 The LED indicator for the control will flash until the control is reset as the 000744MAN 02 Page 8 pressures equalize in the unit The unit may restart after the timer period has expired Should the unit trip on the safety con trol again the compressor will once again shut down and the counter will be incremented by one again Each time this occurs the count is incremented until the counter reaches the max value default is 3 at which poin
32. the room It is always a good idea to place a damper in each grill supply or place adjustable grills so that any imbalances in the heat distribution can be corrected TABLE 13 Heat Pump Size vs Hot Air Grills Size tons of Grills 100cfm 11 14 17 21 Page 14 25 MAY 2009 total number of supply grills available is based on the heat pump nominal airflow TABLE 13 shows the number of grills available per heat pump size Return grills should be mounted on the floor At minimum they should be the same size as the supply grill it is highly recommended that they be 25 to 50 larger than the total supply They should be placed opposite the supply grills when possible to ensure distribution across the room For rooms re quiring more than one supply grill it may be possible to use one larger return grill if it can be centrally positioned opposite of the supply grills however it is preferred to have one return for each supply to maximize heat distribution across the room THERMOSTAT LOCATION Most homes are a single zone with one thermostat The ther mostat should be centrally located within the home typically on the main floor It should be placed away from any supply grills and should not be positioned directly above a return grill Most installations have the thermostat located in a hallway or in the inner wall of the living room It should be noted that most homes do not have any supply ducts in the ha
33. well constructed and every effort has been made to ensure that it will arrive intact however it is in the customer s best interest to examine the unit thoroughly when it arrives OPTIMUM PLACEMENT For air units to achieve the greatest efficiency the heat pump should be centrally located in the home with respect to the conditioned space This design provides the utmost in economy and comfort and usually can be accomplished in harmony with the design of the home A heating system cannot be expected to produce an even warmth throughout the household when it is located at one end of the structure and the warm air is transmitted with uninsulated metal ductwork If possible the access panels should remain clear of obstruction for a distance of two feet to facilitate servicing and general maintenance Raising the heat pump off the floor a few inches is generally a good practice since this will prevent rusting of the bottom panel of the unit We recommend that the heat pump be placed on a piece of 2 thick styrofoam The styrofoam will smooth out any irregularities in the cement floor and deaden any compressor noise emitted from the bottom of the cabinet AMERICAN DREAM Ultra Performance heat pumps have an air filter rack which can be installed with the removable end where the filter is inserted on either side to facilitate changing the filter ELECTRICAL CONNECTIONS The heat pump has a concentric 1 093 0 875 knockout for power su
34. 1 12 1 17 Valve Valve Insulated Domestic Refer to Hot i the heat Domestic Mind pump Cone IN Pre Heat i isi ud from well i OPTIONAL locations must install both 25 1 2 PRV Ball Pow Valve 1 2 copper line Insulate with 5 8 pipe insulation 125psig Domestic Pressure HOT OUT Relief to house Valve or mixing valve 120 140 50 60 Electric or Gas Insulated Domestic Hot Water Tank 4 Domestic 125psig OUT Pressure to house mixing vale 120 140 F 50 60 C Electric or Gas Insulated Domestic Hot Water Tank 960 Howard Hughes pkwy AMERICAN DREAM Ultra Performamce e ise Neise hris Geddes JUN 07 8 pam aq Release 5 c cepoes 11 JUN 07 Approved By 47 6H4 Eee tees Single U T 11 JUN 07 Single Unit Connection to DHW Pre Heat Tank IMPL APVD BY DATE A 000484PDG 01 of 1 000744MAN 02 Page 10 25 MAY 2009 AMERICAN DREAM Geothermal Unit Operation REFRIGERATION Freon Copper operation is essentially the same as any other heat pump The main difference is in the outdoor loop section Freon Copper heat pumps eliminate the intermediate ground loop exchanger and pumping equipment by using cop per loops to interact directly with the earth For each ton
35. 202 15 16 11 8 2 5412 18 45238 458 55 0 4 51585822 6 Electrical Connections cad 6 Thermostat Requirements roce oer docu oe e ev venae een Page 6 Aquastat Requirements kar ce auis aix da p naan a rn hr rar JR uw Ra Page 6 Two stage Control BOX siener ce 7 Airflow Reduction amp Plenum Heater Connections Page 7 Indoor Loop Circulator Wirlng 2 112 7 ld Page 7 Control 8 Satety Gontrols 8 Domestic Hot Water Connections HACW only 2 2 Page 8 UNIT OPERATIONS 11 11 Control 11 SIZING AND DUCTWORK dh ce 14 Heat uilnee3rieIT 14
36. 5 MAY 2009 Tables Diagrams and Drawings TABLES Table 1 Thermostat to Control Box Signals Page 6 Table 2 Aquastat to Control Box Signals 22122 Page 6 Table 3 Typical Aquastat Settings Page 7 Table 4 Two Stage Control Box to Heat Pump Signals Page 7 Table 5 Remaining Signal Descriptions 4 4 2 22 2 22 2 Page 7 Table 6 Airflow Selections 4 4554443 343544444344444444 7 Table 7 Cooling Mode Loop Sequences Page 11 Table 8 Cooling Loop Configuration 115855151111 Page 11 Table 9 RS232 Port Configuration 12 Table 10 Control Board Commands 1115111 Page 12 Table 11 Control Board Default Settings Page 12 Table 12 Heat Pump Size vs Heated Area Page 14 Table 13 Heat Pump
37. ANT that all turns in both the supply trunks and the return trunks be made with TURNING RADII Air act like a fluid and just like water pressure drop is increased when air is forced to change direction rapidly around a sharp or irregular corner It is recommended that flexible collars be used to connect the main trunks to the heat pump This helps prevent any vibrations from travelling down the ductwork If a plenum heater is in stalled the collar should be at least 12 away from the heater elements The first 5 10 feet of the main supply trunks should be insu lated with acoustical duct insulation to further inhibit any noise from the unit from travelling down the ductwork If a plenum heater is installed insulation should not be placed within 12 of the heater elements Drawing 000606CDG shows a typical installation DUCT SYSTEMS GRILL LAYOUT Most forced air heating systems in homes have the floor grills placed around the perimeter of the room to be heated Supply grills should be placed under a window when possible to help prevent condensation on the window As mentioned in the pre vious sub section supply grill leads should be 6 in diameter 28 sq in each to allow 100cfm of air flow In a typical new construction there should be one supply grill for every 100sq ft of area in the room When rooms require more than one grill they should be placed in a manner that pro motes even heat distribution such as one at each end of
38. COM of the aquastat when S1 is indi cated on the aquastat display Aquastat does not indicate S2 on the display Replace aquastat Correct the setup Faulty aquastat to DXTF Control Box wiring 24VAC not present across Stage 2 C and COM of the aquastat Correct or replace wiring Faulty aquastat to DXTF Control Box wiring 24VAC signal present across Stage 2 NO and COM of the aquastat but not present across BA and of the DXTF Control box terminal strip Correct or replace wiring 25 MAY 2009 Faulty aquastat Faulty aquastat No 24VAC between Stage 2 NO and COM of the aquastat when S2 is indi cated on the aquastat display E2 error message Can cause the unit to trip a safety control if the set ting is too high or low Page 39 Replace aquastat Replace aquastat 000744MAN 02 HYDRONIC OPERATION TROUBLESHOOTING Recommended Action Possible Cause High Discharge Pressure Surging Discharge Pressure Low Suction Pressure 000744MAN 02 Aquastat set too high Verification Verify aquastat setting Lower aquastat setting to recom mended value of 115 F 46 C Low or no Indoor loop flow Delta T across the Indoor Loop ports should be between 8 12 F 3 6 or compare pressure drop to the ta bles for the unit Verify contactor is on and pump is working and sized correctly Check for restrictions in the cir cuit ie valve par
39. DUCT SYSTEMS GENERAL Ductwork layout for an AMERICAN DREAM heat pump will differ from traditional hot air furnace design in the number of leads and size of main trunks required Air temperature leaving the heat pump is normally 95 105 F 35 40 C much cooler than that of a conventional warm air furnace To compensate for this larger volumes of lower temperature air must be moved and consequently duct sizing must be able to accommodate the greater air flow without creating a high static pressure or high velocity at the floor diffusers 000744MAN 02 A duct system capable of supplying the required air flow is of utmost importance AMERICAN DREAM Geothermal recommends that the static pressure be kept below 0 2 inches of water total In some instances the number of floor diffusers will actually double when compared to the number that would be used for a hot air oil fired furnace Refer to TABLE 15 at the end of this section 1 Generally allow 100 cfm for each floor grill 2 All leads to the grills should be in diameter 28sq in each 3 The main hot air trunks should be at least 75 of the square surface area of leads being fed at any given point 4 Return air grills should have a minimum of the same total square surface area as the total of the supply grills 5 The square surface area of the return trunks should equal the square surface area of the grills being handled at any given point along the trunk It is VERY IMPORT
40. E PFV eo co G A N o T 25 MAY 2009 Page 51 000744MAN 02 ELECTRICAL TABLES RLA 27 8 40 34 5 50 42 3 60 Models are single stage Models are single stage 14 4 812 4 10 4 Models are single stage 000744MAN 02 Page 52 25 MAY 2009 ELECTRICAL DIAGRAMS 230 1 60 L2 FCTF Series Schematic Diagram Two Stage Scroll ECM Fan 230 1 60 230VAC N 115VAC 115VAC 1 temporarily disconnect the DHW circulator pump remove the brown wire with the insulated terminal marked A from the bottom right terminal of the compressor relay 115 DHW E ump Oo Compressor Hot Water Limit Contactor 11 T1 Air Flow Select Low 6 Med Nom Default High 6 Max 12 eR KD ia AIR FLOW 2 gt m ji Required Connections Compressor Stage 2 Coil 100VA Control Transformer AR1 Reduction 5A Time Compressor Potential Relay Start Cap Fan Contactor NOTE These three terminals connect to the matching three terminals in the DXTF control box FC 1 2 Fan Contactor Coil Compressor Contactor Coil High Pres Manual Reset R410a 650psig R22 410psig R407c 450psig Control Box T stat Wiring 2 Reversing Valve coil Liquid line NO solenoid coil Soaker Hose Solenoid Coil Lo
41. E STEP 2 Preparation 1 2 3 Remove the caps from the service ports and connect a refrigeration manifold set to the unit Turn the power on to the heat pump and set the thermostat to OFF Set up the thermostat as per the instructions provided with it so that it will function properly with the heat pump system set for heat pump not for heating and cooling The O signal should be set to active in cooling mode Measure the following voltages on the compressor contactor and record them on the startup sheet L1 L2 L2 L3 11 13 Air Heating Mode 1 2 Set the thermostat to heating mode and adjust the setpoint to activate Stage 2 The fan should slowly ramp up to speed after the time delay of the thermostat expires if applicable and the compressor will start Check the refrigeration gauges The suction and discharge pressures will depend on the loop temperatures but they should be about 75 95PSIG and 290 365PSIG respectively for a typical start up If the unit was not completely charged add the remaining refrigerant through the suction side only Monitoring the refrigeration gauges while the unit runs Record the following data at the time interval s indicated Numbers 1 to 4 record at 10 15 20 25 30 and then average the values Record numbers 5 to 8 at 30 minutes The average superheat for each line set should be 8 14 F 4 8 C The TXV s are set to four turns in from all the way out at the factory and typically s
42. No YA signal to DXTF Control Box Possible Cause Call for heating or cooling from thermostat Verification Verify thermostat Recommended Action None this is normal operation Blown Primary or Secon dary fuse on transformer Visually inspect Remove fuse and check for continuity if in doubt Replace fuse Blown fuse on control board Visually inspect Remove fuse and check for continuity if in doubt Replace fuse Faulty transformer 230VAC is present across L1 and L3 of the compressor contactor but 24VAC is not present across R and C Replace transformer Faulty wiring between heat pump and aquastats 24VAC is not present across 24V COM at the top of the aquastat Correct the wiring Faulty aquastat Incorrect aquastat setup 24VAC is present across 24Vand COM of the aquastat but there is no display Aquastat does not indicate S1 on the display Replace aquastat Correct the setup Faulty aquastat to DXTF Control Box wiring 24VAC not present across Stage 1 C and COM of the aquastat Correct or replace wiring Faulty aquastat to DXTF Control Box wiring 24VAC signal present across Stage 1 NO and COM of the aquastat but not present across YA and of the DXTF Control Box terminal strip Correct or replace wiring No BA signal to DXTF Control Box Faulty aquastat Incorrect aquastat setup No 24VAC between Stage 1 NO and
43. OUBLESHOOTING GUIDE 5 4 dort rn nna Ran Ra RENE oes PAGE 31 Repair ProcedUres A Page 44 Retrigeration Circuit Diagrams eaae rcr 45 MODEL SPECIFIC INFORMATION nenne 48 Standard Capacity Ratings 48 Capacity Ratings Page 49 Electrical Tables 185 005 2 12 2 5 50 154188 52 Electrical Diagrams 230 1 60 4 511121 53 55 APPENDIX A ECM Fan Airflow qnae cater 45454842 NU ea 57 WARRANTY 25454455 4444 48555455554 4255144245544 60 000744MAN 02 Page 4 2
44. STAT section otherwise proceed to STEP 4 Note that the thermostat should be set to off STEP 4 If the appropriate signal from STEP 3 is not present at the terminal strip in the heat pump proceed to the DXTF TWO STAGE CONTROL BOX TROUBLESHOOTING section otherwise proceed to the STEP 5 STEP 5 If the HI or LOW LEDs flash and the compressor does not attempt to start proceed to the SAFETY CONTROL TROUBLESHOOTING section otherwise proceed to STEP 6 STEP 6 If HI or LOW pressure LED s are not flashing and the compressor does not attempt to start attempts to start but cannot starts hard or starts but does not sound normal proceed to the COMPRESSOR TROUBLESHOOTING section otherwise proceed to STEP 7 STEP 7 If the compressor starts and sounds normal this means the compressor is OK and the problem lies elsewhere Proceed to the AIR OPERATION TROUBLESHOOTING section or the HYDRONIC OPERATION TROUBLESHOOTING section POWER SUPPLY TROUBLESHOOTING Verification No power to the heat pump No display on thermostat 25 MAY 2009 Possible Cause Disconnect switch open if installed Verify disconnect switch is in the ON position Recommended Action Determine why the disconnect switch was opened if all is OK close the switch Fuse blown Breaker Tripped Blown Primary or Secon dary fuse on transformer At heat pump disconnect box voltmeter shows 230VAC on the line side but not on the load side Visuall
45. Size vs Hot Air Grills 0 0 Page 14 Table 14 Plenum Heater Sizing eniro pod diia Ea Page 15 Table 15 Duct Sizing aS Page 17 Table FCTE Charge Chart a a a ei 21 Table 17 Heating Adjustment Record Column Descriptions Page 28 Table 18 Standard Capacity Ratings Heating 60 2 Page 48 Table 19 Standard Capacity Ratings Cooling 60Hz Page 48 Table 20 Standard Capacity Ratings Hydronic Heating 60Hz Page 48 Table 21 Heat Pump Electrical Information 230 1 60 Page 52 Table 22 Heat Pump Electrical Information 208 3 60 Page 52 Table 23 Heat Pump Electrical Information 220 1 50 Page 52 Table 24 Heat Pump Electrical Information 380 3 50 Page 52 DIAGRAMS jrrgn
46. T DIAGRAMS continued FCTF Series Refrigeration Circuit Cooling Mode Air Condenser Heating Check l Valves Filter Drier L1 Cooling TIVATION TABLE 22 ENERGIZED RV 1 NO 1 L1 L5 ONE OR TWO NOTE for NO 1 the valve is OPEN when de energized NOTE Shown for L1 active No Water Flow Water IN Water Loop Condenser Service Port High Pressure Cut out Cut out Loop Optional Switch Desuperheater Compressor Accumulator D B Date 3960 How ard Hughes Pkw Chris Geddes Ed auco AMERICAN DREAM Geothermal 575222 Nevada Chis Geddes 40 AUG 06 E Drawing Name FCTF Series Refrigeration Circuit hris Geddes 30 AUG 06 Di Mod Size Drawing Number REV SHEET 000744 02 46 25 2009 REFRIGERATION CIRCUIT DIAGRAMS continued FCTF Series Refrigeration Circuit Water Heating Mode Air Condenser Port L1 i Cooling ACTIVATION TABLE NO NO 1 1145 NOTE for NO 1 the valve is OPEN when de energized Water IN Water Loop Condenser Service Port Water OUT Optional Desuperheater Compressor Accumulator ID B Dat ow ard Hughes e AMERICAN DREAM Geothermal 22050 06 CE S Fo Drawing FCTF Series Refrigeration Circuit Diagram Water Heating Mode Si ing REV Hi Approved By Date
47. ace the circuit with a voltmeter and replace the faulty component Heating TXV s adjusted too far closed Adjusting the TXV does not affect the superheat or the suction pressure TXV may be frosting up Attempt to adjust the TXV all the way out and all the way in a few times to loosen it Replace TXV if this does not work One or more heating TXV s stuck too far closed Adjusting the TXV does not affect the superheat or the suction pressure Attempt to adjust the TXV all the way out and all the way in a few times to loosen it Replace TXV if this does not work Faulty Normally Open so lenoid valve stuck closed May actually draw a vacuum A click can be heard when the coil is energized but the valve is cold in stead of warm Replace NO valve Filter drier plugged Feel each end of the filter drier it should be the same temperature If there is a temperature difference then itis plugged Also causes low suc tion pressure Replace filter drier Low refrigerant charge Check static refrigeration pressure of the unit for a very low value Low discharge pressure when running Page 40 Locate leak and repair it Spray nine a sniffer and dye are com mon methods of locating a leak 25 MAY 2009 Low Suction Pressure continued High Suction Pressure may appear to not be pumping Compressor frosting up Random high pressure trip does not occur w
48. adjust the TXV all the way out and all the way in a few times to loosen it Replace TXV if this does not work Faulty cooling check valve leaking Also low discharge pressure Switch to cooling mode Unit operates cor rectly when loop is in use Loop lines get cold when loop not in use instead of warming to ambient com pressor frosts up Identify the check valve Try switching modes a few times Replace if problem continues See Low Suction Pressure in this section TXV stuck almost closed or partially blocked by for eign object Intermittent Indoor circula tor Faulty compressor contac tor Adjusting the TXV does not affect the superheat or the suction pres sure Verify wiring is good Points pitted or burned Contactor sometimes sticks causing the com pressor to run without the fan trip ping the high pressure control Page 41 Attempt to adjust the TXV all the way out and all the way in a few times to loosen it Replace TXV if this does not work Correct the wiring or replace the circulator Replace contactor 000744MAN 02 PLENUM HEATER TROUBLE SHOOTING Possible Cause 230 across plenum heater L1 and 12 No W2 signal at Heat pump termi nal strip No 24VAC signal from C to ground at the plenum heater control No 24VAC signal heater control connector 000744MAN 02 Disconnect switch open if installed Verification Verify disconnect
49. aks in the indoor loop system and ensure the area is clean Leave a copy of the Startup Record at the installation site send a copy to AMERICAN DREAM Geothermal and keep the final Turn the power on to the unit Set the aquastats to the final settings and record the values 000744MAN 02 Page 26 25 MAY 2009 Startup Record 2 5 Ton Two Stage R410a Installation Site Installer Province Check boxes unless Model asked to record data Country Circle data units Serial PRE START INSPECTION Indoor Loop All shut off valve are open full flow available Hydroni Pyrania Loop is full and purged of air Antifreeze type Antifreeze concentration Volume Weight Loop static pressure Water Lines are full and purged Desuperheater pump wire is disconnected Line Sets Connected to proper ports insulated and secured in place High voltage connections are correct and securely fastened Circuit breaker or fuse size and wire gauge for Heat Pump Domestic Hot All shut off valves are open Circuit breaker or fuse size wire gauge and Plenum Heater size Low voltage connections are correct and securely fastened Unit Charge Refrigerant charge be fore power is turned on STARTUP DATA Preparation Voltage across L1 and L2 L1 and L3 L2 and L3 Final refrigerant charge 10 minutes V4 15 minutes pq 21111 LJ
50. ally Open so lenoid valve stuck closed May actually draw a vacuum A click can be heard when the coil is energized but the valve is cold in stead of warm Replace NO valve Filter drier plugged Feel each end of the filter drier it should be the same temperature If there is a temperature difference then itis plugged Also causes low suc tion pressure Replace filter drier Low refrigerant charge Check static refrigeration pressure of the unit for a very low value Low discharge pressure when running Locate the leak and repair it Spray nine a sniffer and dye are common methods of locating a leak Faulty compressor not pumping Pressures change only slightly from static values when compressor is started Page 34 Replace compressor 25 MAY 2009 AIR OPERATION TROUBLESHOOTING HEATING MODE Low Suction Pressure continued High Suction Pressure may appear to not be pumping Random high pressure trip Random manual high pressure trip does not occur while on site 25 MAY 2009 Possible Cause Loop piping interchanged ie Loop 1 connected be tween Vapour 1 and Liquid 2 Verification Affected TXV s do not seem to oper ate properly Switch to cooling mode and verify all liquid line tem peratures for each individual loop switch The liquid line for the loop in use should be warmer than the oth ers If loops are interchanged the wrong liq
51. ated area AMERICAN DREAM Geothermal HIGHLY RECOMMENDS THAT A PROPER HEAT LOSS GAIN ANALYSIS BE PER FORMEDE BY A PROFESSIONAL INSTALLER WITH CSA APPROVED SOFTWARE BEFORE SELECTING THE SIZE OF UNIT REQUIRED FOR THE APPLICATION For heating dominant areas we recommend sizing the unit to 100 of the heating design load for maximum long term efficiency with minimal supplementary heat The unit should be in stalled as per CSA 448 2 02 There are many factors to consider when sizing the heat pump Some of these factors include the number of levels the size of the windows the orientation of the home attached ga rage bonus rooms walk in basement coldest outdoor tempera ture etc The heat loss program will take all of these factors into consideration in its calculations An undersized installation will not be as efficient and will require expensive supplementary heat to maintain a comfortable temperature in the home and the cost savings of having a geothermal heat pump are greatly re duced Once the total heat loss has been calculated the unit can be sized using the performance tables from the specifications document in conjunction with the minimum expected entering liquid temperature of the ground loop well water temperature for ground water system The heat pump output must be able to match the total heat loss at the selected entering water tempera ture in order to provide a comfortable environment with minimal auxiliary heat
52. atically restarts after the lockout timer expires CONTROL BOARD heating cooling units contain a control board that monitors the thermostat signals safety controls and loop pres sures It controls the operation of the compressor fan and aux iliary emergency heat It also activates the reversing valve and controls the loop sequencing when in cooling mode Heating only units do not have a control board The number of cooling loops must be configured done at the factory There are two jumpers to the top right of the micro controller The configuration is shown in TABLE 8 There is also a jumper marked DEFAULT that should be left in place The jumper marked IF NO B TERMINAL should be left place as well unless the thermostat used has a B terminal that is constantly powered in heating mode TABLE 8 Cooling Loop Configuration of Loops Left Jumper Right Jumper OFF OFF ON OFF OFF ON ON ON The control board has 4 connectors one for the thermostat connections one for the heat pump component connections one for the loop solenoid connections and one for the safety control and loop pressure switch connections There are also several LEDs to indicate the status of the control board Refer to drawing 000301CDG for the location of the connectors and LEDs The Heart Beat LED flashes once every second This indi cates that the control board is operational An on board COP watchdog timer resets the microprocesso
53. between White pin 3 and the following at the fan con trol signal harness insert probes in connector where wire is inserted do not unplug the connector Circulation Grey pin 15 Stage 1 Yellow 6 Stage 2 Yellow Black pin14 Stage 3 Violet pin 2 Verify that the connector is properly inserted into the fan motor Gently tug on each wire to verify it is prop erly inserted into the connector If proper signal isn t present re place Fan Control Signal Har ness If proper signal is present replace fan motor head Repair any loose connections Faulty Control Signal Har ness or Faulty motor head Measure 24VAC between White pin 3 and the following at the fan con trol signal harness insert probes in connector where wire is inserted do not unplug the connector Circulation Grey pin 15 Stage 1 Yellow 6 Stage 2 Yellow Black pin14 Stage 3 Violet pin 2 If proper signal isn t present re place Fan Control Signal Har ness If proper signal is present replace fan motor head Fan Power Harness faulty or Faulty motor Insert the tips of the voltmeter probes into the back of the connec tor at the fan to measure the voltage across the red and black wires value should be 230VAC Page 38 Replace Power Harness if 230VAC is not present replace motor if 230VAC is present 25 MAY 2009 HYDRONIC TROUBLE SHOOTING AQUASTAT No display on aquastat
54. cho is not required in hyperterminal Once connected press H to display the available commands for the control board coeli BSB cRLOWYBG Default no co oe Serial Port Microprocessor High Low Heart Pres Pres Beat IL o 1166 Female Male IL o ILJ 10 10 LOOPS 2 4 EO o o o o o o 8 55 55 Date AMERICAN DREAM Geothermal 2101 10 01 Drawing Name eee Chris Geddes 19 OCT 06 Checked D OCT 06 EAZ NCB Lap Top Communication Cable JR pproved By c Sue praning Nomber REV SHEET ECO IMPL BY APVD BY DATE pee _ 000301CDG 01 1 of 1 25 MAY 2009 Page 13 000744MAN 02 Sizing and Ductwork HEAT PUMP SIZING TABLE 12 depicts averages WILL VARY WITH ENVELOP EFFICIENCY as a rough guideline to the size of home each heat pump size can handle Area THE TABLE ABOVE IS FOR INFORMATION ONLY IT SHOULD NOT BE USED TO SELECT A UNIT SIZE It simply shows on average what size unit is required for a typical two level home main level and below grade basement with R 20 walls R 40 ceiling and average size and number of windows The Heated Area is the area of the main level The tables ac count for a basement the same size as the he
55. dry for even a short period of time Connect the brown wire with the blue insulated terminal to L1 of the compressor contactor Ensure the power is off when connecting the wire The DHW loop may have to be purged of air several times before good circulation is obtained A temperature difference between the DHW In and DHW Out can be felt by hand when the circulator pump is operating properly For the pre heat tank setup the final tank should be set to 140 F 60 C unless local code requires a higher setting The pre heat tank does not require electric elements This setup takes full advantage of the desuperheater as it is the sole heat provider to the pre heat tank The desuperheater remains active during the compressor runtime until the pre heat tank has been completely heated by the desuperheater alone This setup is more energy efficient than a single tank setup CAUTION If two 2 shut off valves are located on the do mestic hot water ines as shown in the diagram a pressure relief valve must be installed to prevent possible damage to the domestic hot water circulator pump should both valves be closed 25 MAY 2009 Line Typical Heating Only Zone Wiring Voltage 1 Voy 4 External Electrical Box Signal may not be required for certain thermostats 24 Class 2 2 Transformer iValve S Zone Circulator Signal may not be required for certain i thermostats Zo
56. duced by 15 by making dry contact across AR and on the terminal strip This can be used for applications that have multiple zones or retrofits with undersized ductwork to help reduce air flow noise in the ductwork It is recommended that airflow reduction only be used with the High or Max air flow setting Care should be taken to ensure that the unit does not trip a safety control in heating or cooling mode if the 15 reduction is used in conjunc tion with the Med or Low air flow setting CONTROL TRANSFORMER The low voltage controls for all models are powered by a 100VA transformer with primary and secondary fuses for circuit protection Should a fuse blow determine the problem and rec tify it before replacing the fuse SAFETY CONTROLS The heat pump has two built in safety controls which are designed to protect the unit from situations which could damage it should the operation of the refrigeration circuit fall outside the allowable operating range A Low Pressure Control The low pressure control monitors the compressor suction pressure and will shut the compressor down if the refrigerant evaporating pressure becomes too low There only reason this control would activate in response to the operating conditions of the unit in the heating mode would be due to a ruptured loop causing a low refrigerant charge Any other low pressure trips would be due to a fault in the unit B High Pressure Control The high pressure
57. ectioned into several areas called zones Each zone has its own thermostat allowing simple separate temperature control of the individual areas in the home A typical system consists of the heat pump the buffer tank and the zones The sole purpose of the heat pump is to maintain the buffer tank set point Its operation is independent of the zone operation HYDRONIC SYSTEM CONNECTIONS The unit has 1 copper pipe connections for the hydronic sys tem labeled INDOOR IN and INDOOR OUT Flow through the unit is provided by an external circulator powered by the control box NOTE Depending on how the system is connected an ex ternal water valve may be required in the INDOOR OUT line to prevent draw through the water coil while in air heating mode The 24VAC coil of the water valve can be connected across Y1A and CA in the heat pump Drawing 000533PDG shows a typical piping configuration for a single unit with a buffer tank This is a guideline for a simple installation There are many other configurations such as mul tiple units connected to one buffer tank on demand domestic only etc It is recommended that the hydronic system be de signed by a qualified system designer to ensure proper function ality Drawing 000627PDG shows two typical on demand domestic hot water systems dedicated and zoned For a dedicated setup there are no zones and the home is heated solely by air The unit can very easily be switched between air or hyd
58. eed for air circulation Heat Pump Stage 1 Compressor stage 1 Ru 24VAC Hot L Fault 24VAC when fault condition We Heat O B W Cooling Mode reversing valve Heat Pump Stage 2 Compressor stage 2 E1 Fan Auxiliary Emergency Speed Control In E2 Fan Auxiliary Emergency Speed Control Out FC Fan Contactor 25 MAY 2009 Page 7 000741INF They contain all the information required to com plete the Two Stage Control Box connections as well as infor mation on how the control box operates AIR FLOW REDUCTION AND PLENUM HEATER CONNECTIONS TABLE 5 lists the remaining four terminals on the heat pump terminal strip These signals are separate from the Con trol Box The AR and terminals are the airflow reduction signal See the FAN MOTOR section for more information on therm The and 1 terminals are the dry contacts for the plenum TABLE 5 Remaining Signal Descriptions Airflow Reduction Airflow Reduction Plenum Heater dry contact Plenum Heater dry contact Connect AR to with a dry contact to reduce the airflow by 15 Refer to the Fan Motor sub section for more infor mation heater Connect these to the C and 1 terminals of the plenum heater Refer to the electrical box diagram ELB of the heat pump or the diagram on the cover of the plenum heater for more information NOTE Some models are not available in two stage
59. er Triple Function Case Style V Vertical Nominal Size 2 Ton i Fan Discharge on 5 i S Side Functions Fan Motor H Heating AC Active Cooling W Domestic Hot Water E ECM Variable Speed Fan Type Refrigerant D Direct Drive 410 5 Air Coil Voltage Code S Standard 1 230 1 60 VAC 22 2 Indoor Coil 6 220 1 50 VAC Copper 7 380 3 50 VAC Z Cupro Nickel CuNi Compressor Stages 2 Stage 5281 ilabl stage unless unavailable Yes due to voltage code refer to the Electrical Tables 000744MAN 02 Page 2 25 MAY 2009 TABLE BLANK 2 SDETV BLANK or CorZ SDETV H BE B BLANK 5 Ton HACW CorZ SDETV H 7 T This manual applies only to the models and revisions listed in this table 0414 25 2009 3 000744MAN 02 Table of Contents INSTALLATION INFORMATION 5255 0 24444528 4 248 uoa denas ace 6 6 Unpacking uuo eger Page 6 Optimum Placement 22 22 242 2 2 5 2 5 22 5124541 251554 02 514
60. floor circulator is adequately sized to accomodate the type and number of zones connected to the system The aquastat probe should be placed all the way in the dry well and the end of the well where the probe wire is should be well insulated The loop be filled with water or an antifreeze mix If the antifreeze used is flammable ie methanol and there are electric elements the buffer tank ensure there is a method to prevent the electric elements from turning on if the tank is not completely full One method is to use a pressure switch to disable the elements should the pressure in the tank drop below a setpoint such as 5 or 10PSIG Allowing the elements to come on when they are not fully submerged will burn the element out and could cause an explosion PURGING PROCEDURE hris Geddes 10 SEP 07 Ensure the power to the heat pump and any other power supplies connected to the system floor circulator etc are turned off The system can be filled using Boiler Drain 1 Connect the fill hose to the boiler drain and begin filling Open the tank PRV to purge the air out as the system fills Close the tank PRV when water begins to run out of it Open the automatic air vent Connect the purge hose to Boiler Drain 2 Close Ball Valve 1 Open Ball Valve 3 if installed Open Boiler Drain 2 Purge until air is no longer heard leaving the system Open the Tank PRV and let any air out Close Boiler Drain 1 2 and Ball Valve 1 and 3 if i
61. from being sucked into the unit by the vacuum when the hoses are disconnected The heat pump is now ready for repairs Always ensure nitrogen is flowing through the system during any soldering procedures to prevent soot buildup inside the pipes AMERICAN DREAM Geothermal recom mends replacing the liquid line filter drier anytime the refrigeration system has been exposed to the atmos EROSEDURE Release the refrigerant circuit pressure and connect the vacuum pump to the charging manifold Start the vacuum pump and open the charging manifold valves Vacuum until the vacuum gauge remains at less than 500 microns for at least 1 minute with the vacuum pump valve closed STEP 3 Close the charging manifold valves then shut off and disconnect the vacuum pump Place a refrigerant tank with the proper refrigerant on a scale and connect it to the charging manifold Purge the hose to the tank Weigh in the appropriate amount of refrigerant through the low pressure suction service port Refer to the label on the unit or the Charging The system section for the proper charge amount If the unit will not accept the entire charge the remainder can be added through the low pressure service port after the unit has been restarted REPLACMENT PROCEDURE FOR A COMPRESSOR BURN OUT STEP 1 Pump down the unit as per the Pump Down Procedure above STEP 2 Replace the compressor Replace the liquid line filter drier STEP 3 Vacuum the unit until it remain
62. he heating TXV s are set to four turns in from all the way out at the factory This should be sufficient for most installa tions however it is sometimes necessary to make adjustments if the ground conditions vary or if the loop lengths vary The procedure below explains how to properly adjust the TXV s so that the task be completed in the minimum amount of time The goal is to obtain a superheat value of 8 14 F 4 8 C on each evaporator loop It is good practice to average out the last few readings as the TXV s tend to cycle causing the superheat to vary e Adjusting a TXV in clockwise increases the superheat of its evaporator loop Adjusting a TXV out counter clockwise decreases the superheat of its evaporator loop e Adjusting one TXV affects the remaining evaporator loops adjustments must be small and done to only one TXV at a time Adjustments are done every other time interval ie every 10 minutes The next two intervals should be averaged together for the next adjustment Always adjust the TXV that is the furthest out ADJUSTMENT PROCEDURE 1 Fillin the information section at the top of the adjustment record sheet Circle F or C at the top right 2 Record all data for the initial readings elapsed time 0 Adjust the TXV for the loop that is the furthest out Record the num ber of the TXV how much it was adjusted in turns ie 1 4 1 2 1 and in which direction it was adjusted Record the new position
63. hile on site Random manual high pressure trip does not occur while on site 25 MAY 2009 HYDRONIC OPERATION TROUBLESHOOTING Possible Cause Faulty compressor not pumping Verification Pressures change only slightly from static values when compressor is started Recommended Action Replace compressor Loop piping interchanged ie Loop 1 connected be tween Vapour 1 and Liquid 2 Loop field too small Leaking reversing valve Affected TXV s do not seem to oper ate properly Switch to cooling mode and verify all liquid line tem peratures for each individual loop switch The liquid line for the loop in use should be warmer than the oth ers If loops are interchanged the wrong liquid line will be warmer Charge is good superheats are good vapor line temperatures are low Reversing valve is the same tem perature on both ends of body common suction line is warm com pressor is running hot Pump the unit down and swap the interchanged lines Increase loop size Replace reversing valve Heating TXV s adjusted too far open Verify superheat It should be be tween 8 14 F 3 8 C Superheat will be low if TXV s are open too far Adjust TXV to obtain 8 14 F 3 8 C superheat One or more heating TXV s stuck too far open Adjusting the TXV does not affect the superheat of the loop or the suc tion pressure Low super heat low discharge pressure Attempt to
64. hould not require any adjustments Should adjustment be required follow the Heating TXV Adjustment procedure in this manual Proceed to Step 4 once adjustments have been completed 1 Suction pressure 2 Discharge pressure 3 Each loop Vapour Line temperature 4 Each loop superheat Vapour line temperature evaporating temperature from suction gauge 5 Duct Return temperature poke a small hole in the flex collar and insert probe in airstream 6 Duct Supply temperature poke a small hole in the flex collar and insert probe in airstream 7 Duct Delta T should be between 22 32 F 12 18 C 8 Compressor L1 C current black wire place meter between electrical box and compressor Adjust the thermostat setpoint to the desired room temperature and let the unit run through a cycle Record the setpoint and the discharge pressure when the unit shuts off Forunits with a desuperheater turn the power off to the unit Connect the brown wire with the blue insulated terminal to the compressor contactor as shown in the electrical box diagram Turn the power to the unit on Remove the electrical cover from the plenum heater Place a current clamp meter around one of the supply wires Turn on the power to the plenum heater Adjust the thermostat setpoint to 85 F 29 C Verify that the current draw increase as each stage is activated 10kW has 2 stages 15kW has 3 stages and 20kW has 4 stages Verify the DHW IN and DHW OUT temperat
65. ing includ ing inside compressor electrical box Fix any loose connections Re place any damaged wires Faulty compressor contactor Voltage on line side with contactor held closed but no voltage on one or both terminals on the load side Points pitted or burned Or 24VAC across coil but contactor will not engage Replace contactor Thermal overload on compressor tripped Ohmmeter shows reading when placed across R and S terminals and infinity between C amp C amp S A valid resistance reading is present again after the compressor has cooled down Proceed to Operation Trouble shooting to determine the cause of the thermal overload trip Burned out motor open winding Remove wires from compressor Ohmmeter shows infinite resistance between any two terminals Note Be sure compressor overload has had a chance to reset If compressor is hot this may take several hours Replace the compressor Burned out motor shorted windings Remove wires from compressor Resistance between any two termi nals is below the specified value Replace the compressor Motor shorted to ground Remove wires from compressor Check for infinite resistance be tween each terminal and ground If any terminal to ground is not infinite replace the compressor Seized compressor due to locked or damaged mechanism Start capacitor faulty Single phase only Compressor attempts to start
66. lace con trol board if it does not Low Pressure Control Faulty Low pressure con trol open Must be a signal present on Y1 for this test HP pressures must be at static levels Lo LED is flashing Short L to L on the connector at the left of the con trol board and verify whether the LED stops flashing or remains flash ing Replace low pressure control if LED stops flashing replace con trol board if it does not 000744MAN 02 Unit out of refrigerant Check static refrigeration pressure of the unit for a very low value Page 32 Locate the leak and repair it Spray nine a sniffer and dye are common methods of locating a leak 25 MAY 2009 COMPRESSOR TROUBLESHOOTING Possible Cause Compressor will not start Compressor Stage 2 will not activate 25 MAY 2009 Manual High pressure control tripped Verification Press the button on the control it will click when pressed Recommended Action Proceed to Operation Trouble shooting Faulty control board and Low LED s off HB is flashing but Y LED is not on or no 24VAC across Y and C of bottom right con nector Replace control board Faulty run capacitor Single phase only Check value with capacitance meter Should match label on capacitor Compressor will hum while trying to start and then trip its overload Replace if faulty Loose or faulty wiring Check all compressor wir
67. lation for validation of this warranty is the customer s responsibility to supply the proper quantity and quality of water or properly sized ground loop with adequate freeze protection If a geothermal heat pump manufactured by AMERICAN DREAM Ultra Performance Geothermal fails to conform to this warranty AMERICAN DREAM Ultra Performance Geothermal s sole and exclusive liability shall be at its option to replace any part or component which is returned by the customer during the applicable warranty period set forth above provided that 1 AMERICAN DREAM Ultra Performance Geothermal is promptly notified in writing upon discovery by the customer that such part or component fails to conform to this warranty 2 the customer returns such part or component to AMERICAN DREAM Ultra Performance Geothermal shipping charges prepaid within 30 thirty days of failure and 3 AMERICAN DREAM Ultra Performance Geothermal s examination of such component discloses to its satisfaction that such part or component fails to conform to this warranty and the alleged defects were not caused by accident misuse neglect alteration improper installation repair or improper testing AMERICAN DREAM Ultra Performance Geothermal will not be responsible for any consequential damages or labor costs incurred In additional AMERICAN DREAM Ultra Performance Geothermal will not be responsible for the cost of replacement parts purchased from a third party
68. ll Water Valve Insulated Domestic DHW IN 1 copper lines Insulate with NOTE 4 1 1 4 pipe insulation It is assumed that the Zone Buffer tank has a circulator expansion tank Zone Valve Zone Supply Header Drawn Date 3960 Howard Hughes Pkwy Eis AMERICAN DREAM Geothermal ves FEB 08 Hum ESL oda On Demand DHW Tank APVD BY DATE uum see 1 000627PDG 01 1 of 4 000744MAN 02 Page 20 25 MAY 2009 Loop Connection amp Charging LINE SET INTERCONNECT TUBING Once the outside loops have been installed and run into the building the piping to the ports on the unit can be constructed Each line set has a liquid line and a vapour line The vapour line is 1 2 OD and the liquid line is 1 2 OD For horizontal loops both lines are 1 2 OD reduce one of the lines in each line set down to 3 8 OD before running the lines over to the heat pump These reduced lines will be the liquid line for each line set Do a final pressure check on each line set and then remove the pressure and cut the ends off the lines The heat pump has ports labeled Liquid 1 to 5 and Vapour 1 to 5 Run each line set over to the designated ports on the heat pump Refer to Diagram 000769CDG for more information on how to connect to the heat pump The tubing used for this procedure must be refrigerati
69. llway This can lead to a temperature lag at the thermostat if there is very little air movement in the hallway causing the home to be warmer than indicated by the thermostat PLENUM HEATER OPTIONAL For installations that do not already have a backup heat source such as electric baseboard wood stove propane etc it is recommended that a plenum heater be installed This pro vides two functions The first function of the plenum heater is to act as an auxiliary heat source As such it will provide additional heat on extremely cold days if the heat pump is unable to bring the home tempera ture up quickly enough eliminating any discomfort to the home owner The second function of the plenum heater is to provide emer gency heat should a problem occur that causes the heat pump to be locked out This can be engaged by setting the thermostat to emergency heat allowing the plenum heater to function while preventing the heat pump from operating Should the heat pump fail while the home is vacant the auxiliary function of the thermostat will maintain the temperature setting of the thermo stat The plenum heater is powered separately from the heat pump Only two control wires are needed to connect the ple num heater to the heat pump Refer to the label on the plenum heater or the electrical box diagram on the inside of the electri cal box cover of the unit for details on the connections The plenum heater should be mounted in the suppl
70. mittent fan See Fan Troubleshooting section Page 37 Correct the problem 000744MAN 02 FAN TROUBLESHOOTING Recommended Action Low Airflow Fan operating on Fan not operat ing or operating intermittently 000744MAN 02 Possible Cause Dirty air filter Verification Inspect Replace Dirty air coil Inspect Clean Poor Ductwork Measure delta T between supply and return ducts at the unit it in heating mode it should not be above 30 F 17 C The ECM fan will provide proper airflow up to 0 5 2 for 1 2HP motors and 0 7 2 for 1HP motors The ductwork is poorly designed or greatly undersized if the fan motor cannot provide the required airflow Air flow selected on Tap Board is too low Check selection on Air Flow Tap Board Select a higher setting Air flow reduction is en abled Fan Control Signal Har ness is loose 1 and are connected with a dry contact Verify that the connector is properly inserted into the fan motor Gently tug on each wire to verify it is prop erly inserted into the connector Air flow reduction may not be fea sible with poor ductwork and or lower Air Flow selections In crease settings until unit operates properly Repair any loose connections Faulty Control Signal Har ness or faulty motor head Fan Control Signal Har ness and or Fan Power Harness is loose Measure 24VAC
71. ne Heat Cool or E Circulator E Heat only Thermostat NOTES 1 Verify the line voltages are correct for the primary of the transformer and for the floor circulator 2 Ensure that the transformer is sized to handle the load with all zones calling for heat 3 Two pipe fan coils are recommended for fan coil zones 4 Zone N indicates the last zone in the zone type Heat Cool or Heat only Thermostat THERMOSTAT FOR FAN COILL Common Internal Transformer 24VAC Internal Transformer W Zone Valve G Fan Signal connect to G1 Fan Speed 1 G2 Fan Speed 2 if equipped G3 Fan Speed 3 if equipped Select one fan speed AMERICAN DREAM Geothermal Las Vegas Ness Drawing Name Typical Heating Only Zone Wring Size Drawing Number REV SHEET 000344CDG 25 MAY 2009 Page 9 000744MAN 02 Single Unit Connection to Domestic Hot Water Tank Domestic Valve HEAT PUMP COLD IN CONNECTIONS from well 125psig Pressure Relief 12 1 2 Ball Check Boiler Valve Valve Drain Insulated Domestic Hot Water Pre Heat Tank Refer to 1 2 copper lines i the heat Insulate with 5 8 pipe insulation pump labels for connection OPTIONAL locations must install both M25pisg 1 2 PRV i 0 Valve 5 1 2 125psig Insulate with 5 8 pipe insulation Pressure Relief
72. nstalled Zone be purged by moving the fill hose turn it off first from Boiler Drain 1 to Boiler Drain 4 Connect the purge hose to Boiler Drain 3 Close Ball Valve 2 Open Boiler Drains 3 and 4 Purge each zone individually and then open them all at once Zones can be opened using the individual thermostats or most can be opened manually Open the Tank PRV intermittently to purge any air during this process When purging is complete pressurize the system between 15 and 25PSIG Turn the fill hose off Close Boiler Drains 3 and 4 Open Ball Valve 2 Remove the fill turn the hose off first and purge hoses Repeat steps 4 to 6 as necessary if air is still present in the system 3960 Howard Hughes p Las Vegas Nevada Name Typical Buffer Tank Configuration Four Port Tank initial Release c GEDDES GEDDES 10 SEP 07 000744MAN 02 Page 18 MFG Date IMPL BY APVD BY DATE A 000533PDG 01 1 of 1 25 MAY 2009 Typical Zone Types for Hydronic Applications Floor Zone 1 Flacr Zone 1 valve Flaor Zone N Valve Fan Unit 1 Heating and or Cooling Fan Coil 1 Zone Vale Only if Fan Coil does net have a valve Supply duct Fan Cail 1 Zone Valve Only if Fan Cail does zone Zone not have valve Return Supply Header Header Domestic Pre Heal Domeslic Pre Heal Zone Zone Valve Pool Spa
73. of ca pacity the evaporator heating mode consists of one three way valve one heating thermostatic expansion valve a pair of check valves and one outdoor copper loop with one vapour and one liquid connection to the heat pump For each additional ton of capacity there is a parallel evaporator circuit added to the unit In heating mode all loops are used simultaneously to cre ate a large evaporator This allows maximum heat transfer from the loop field Since each loop has it s own TXV its superheat can be individually tailored allowing each loop to obtain the same superheat even it may have different soil conditions The loop select valves default to open in heating mode and as such none of the loop select valve solenoid coils are energized In cooling mode running all loops at the same time would create far too large a condenser and the unit would have very low head pressure causing the suction pressure to fall off until the low pressure safety control was reached To circumvent this problem the direct expansion unit will begin cooling mode by using only Loop 1 Loops are selected by activating the solenoid on the loop select valve for the loop in question The remaining loops are scavenged to the suction line Using one loop greatly reduces the size of the condenser allowing the unit to operate properly As the ground tempera ture warms up rejecting the heat to the ground becomes more difficult causing the head pre
74. of the adjusted TXV in the appropriate P column of the next row Record the remaining TXV positions in their indi vidual P columns in the next row 3 Atthe next time interval record the data in the current row Verify that the superheat of the adjusted TXV has changed in the desired direction Do not adjust the TXV Mark in the TXV Turns and In Out columns 4 Atthe next time interval record all data Adjust the TXV that is the furthest out Record the TXV Turns and In Out values Record the new position of the adjusted TXV in the appropriate P column of the next row Record the remaining TXV posi tions in their individual P columns in the next row 5 Repeat Steps 2 and 3 until all superheat values are within 8 14 F 4 8 C 000744MAN 02 Page 28 25 MAY 2009 29 yno u 9S oa SS SA sa vs va vd tS en amp d zS zd i Hd 13 INaWlsnrav 9 4001 Y dOO1 4001 dOO1 4 1 NOWWOD Auedwoy 191 154 uonejejsuj 1 UO 9 2 jueugsn py AXL 25 2009 02 000744 General Maintenance GENERAL MAINTENANCE SCHEDULE Air Filter Inspect for dirt Replace if necessary Inspect for pitted or burned point
75. on tubing cleaned amp dehydrated suitable for the job Every effort must also be made to insure that the tubing does not become contaminated during installation We recommend that caps be placed on the open ends of tubing immediately after cuts are made and that these caps are only removed after all bends have been made and the pipe fixed in its permanent location ready to make the silver soldered joints It is very important to keep a refrigeration system perfectly clean and dry Removing the caps just prior to silver soldering will ensure minimum exposure to the humidity in the atmosphere PIPE INSULATION All line set piping inside the structure between the structure entry point and the heat pump should be insulated with 3 8 thick closed cell pipe insulation to prevent condensation and dripping onto floors or walls during the heating season It can be slid onto the capped tubing without having to slice it down the side Ensure that any joints in in the line sets are accessible for leak testing Liquid and Vapour ports and any remaining exposed tubing should be insulated with 3 8 thick closed cell pipe insulation once the silver soldering and pressure testing is complete Ensure that all individual pieces of pipe insulation are glued to each other so there are no air gaps SILVER SOLDERING LINE SETS Once all the line sets have been routed insulated and fastened in place the connections to the heat pump ports can be made Remove
76. op 5 Plenum Heater PLENUM HEATER OPERATION amp 1 provides set of dry contacts for operating plenum heater e Fan will run automatically with Thermostat W2 signal AIRFLOW REDUCTION Connect AR amp together with dry contacts to reduce the airflow for zone applications Loop Pres Low Pres R410a 480psig High Pres R410a 565psig ae R410a 35psig hris Geddes 27 08 27 08 IChris Gedde LJ T 3L T EV IMPL BY APVD BY DATE 25 MAY 2009 Page 53 NOTE There may be 3 4 or 5 solenoid valves for cooling changeover depending on the model Solenoid Coils Plenum Heat Rela 3960 howard Hughes Pwky AMERICAN DREAM Geothermal tas vegas Nevada 42 6H4 foe twee oe hris Geddes 27 08 Schematic Diagram Size Drawing Number REV SHEET 000737SCH 000744MAN 02 ELECTRICAL DIAGRAMS 230 17 60 continued FCTF Series Electrical Box Diagram 230 1 60 Two Stage Scroll ECM Fan Field FCTF Control Box Wiring 24VAC Field Wiring 230VAC 115VAC L2 N L1 000143 C GEDDES C GEDDES 25 MAY 09 C GEDDES ECO IMPL BY APVD BY DATE 000744MAN 02 CRLOWYBG m 2E B o i 2 Es Ben Plenum Heat Connections Loop D Airflow Reduction Connections
77. ough a cycle Record the setpoint and the discharge pressure when the unit shuts off 5 Forunits with a desuperheater turn the power off to the unit Connect the brown wire with the blue insulated terminal to the compressor contactor as shown in the electrical box diagram Turn the power to the unit on 6 Verify the DHW IN and DHW OUT temperatures if applicable by hand caution pipes get hot If the DHW OUT line does not become hotter than the DHW IN line the circulator is air locked Bleed the air from the system and check the temperature differential again to ensure there is flow from the circulator Cooling Mode 1 Set the thermostat to cooling mode and adjust the setpoint to activate Stage 1 and Stage 2 2 Monitoring the refrigeration gauges while the unit runs Record the following after 10 minutes of runtime 3 Suction pressure Discharge pressure Indoor Loop In Hot In temperature Indoor Loop Out Hot Out temperature Indoor Delta T Adjust the cooling aquastat setpoints to the desired tank temperature and allow the unit to run through a cycle Record the aquastat setpoint and the suction pressure when the unit shuts off Final Inspection 1 2 gt gt Turn the power off to the unit and remove all test equipment Install the electrical box cover and the access panel on the heat pump Install the service port caps securely to prevent refrigerant loss Do a final check for le
78. p off if low lockout HEAT 5min Comp off if low lockout COOL 30min Comp off if high lockout HEAT 5min Comp off if high lockout COOL 30min Comp off time between heat amp cool 5min Comp delay since being off 2min Min loop time before mode increase 15min Loop pressure testing wait time 7sec Soaker start after comp on time 2hrs Soaker hose run time maintenance 4hrs Soaker hose run time emergency 12hrs System check interval 2sec Low pres lockout counter reduce time 6hrs High pres lockout counter reduce time 6hrs Low pres lock ignore counter 3 times High pres lock ignore counter 3 times Reset mode 1 and loop memory time 2 weeks Maximum mode to be allowed 2 Ignore low pres for 5min Ignore low pres for 05 25 2009 NCB Lap Top Communication Cable NCB Adaptor Cable DB9 PINOUT 2 Rx 3 Tx 5 GND Take a 9 pin serial cable and cut the male end off A 0 100 spacing 4 pin header can be obtained from a floppy drive power cable in an old computer Connect the wires as shown in the diagram above A multimeter set to continuity may be used to find the correct wires fron the 9 pin cable A small paper clip will fit in the 9 pin connector holes Hyperterminal can be used to communicate with the control board The com ports settings are 9600 baud 8 data bits no parity 1 stop bit Xon Xoff control The board echos commands so e
79. pply connection to the electrical box as well as one 000744MAN 02 for connection to the circulator pump module for ground loop applications There are two 1 2 openings with plastic grom mets grommet hole is 3 8 in the upper section of the electrical box one for the thermostat connections and one for the op tional plenum heater connections A schematic diagram and electrical box layout diagram ELB can be found inside the electrical box cover of the unit as well as in the Model Specific section of this manual The Electri cal Tables in the Model Specific section and the ELB diagram contain information about the size of wire for the connections as well as the recommended breaker size A properly qualified electrician should be retained to make the connections to the heat pump and associated controls The connections to the heat pump MUST CONFORM TO LOCAL CODES THERMOSTAT REQUIREMENTS The FCTF Series unit includes a three stage heating and two stage cooling thermostat with relay outputs for proper air mode operation Triac output thermostats are incompatible with the control board in the heat pump The stages are S1 heat pump stage 1 S2 heat pump stage 253 electric aux iliary heating only One can be purchased with the unit or other thermostats with the same number of stages can be used TABLE 1 Thermostat to FCTF Control Box Signals Descriptio 24VAC Common Ground Fan low speed for air circulation
80. r sometimes sticks causing the com pressor to run without the fan trip ping the high pressure control Page 35 Identify the check valve Try switching modes a few times Replace if problem continues Adjust the all the way in and out a few times to loosen it Replace if this does not work Correct the problem Replace contactor 000744MAN 02 Heating instead of cooling High Pressure control trips High Pressure control and man ual high pressure control trips very fast Loop changes 000744MAN 02 AIR OPERATION TROUBLESHOOTING COOLING MODE Possible Cause Verification Recommended Action Thermostat not set up properly Faulty reversing valve so lenoid coil Verify that there is 24VAC across O B W 1 and C of the terminal strip when calling for cooling Verify solenoid by removing it from the shaft while the unit is running There should be a loud whoosh sound when it is removed Dis charge pressure will continue to rise even if there is a loop switch Correct thermostat setup Change to a different thermostat Replace solenoid if faulty Faulty reversing valve A click can be heard when the coil is energized but hot gas is still di rected to the air coil Discharge pressure will continue to rise even if there is a loop switch Replace reversing valve Faulty Loop Pressure switch Loop LED does not come on around 480PSIG Shorting S and S
81. r should anything af fect code execution The high and low pressure control LEDs flash once per second when a control is open They will stay on if there is a permanent lockout The loop switch LED will come on when the loop pressure Switch is activated Note that the loop switch is only for cooling mode it does not affect heating mode operation There is a compressor short cycle timer default 2 minutes and also a mode switch timer default 5 minutes Both are ad justable through the control board communications port 11 000744MAN 02 high pressure low pressure and loop switch are 5VDC signals The low pressure control connects to L and L on the control board The high pressure control connects to H and H The loop switch connects to S and S All other inputs and out puts are 24VAC When the thermostat calls for heat the compressor will start Stage 1 as will the fan after a short delay adjustable The unit will run until the thermostat is satisfied and the unit shuts off the fan will continue to run for an adjustable period or a set period of time elapses default 40 minutes Should the set period elapse the auxiliary heat Stage 2 will be engaged to help the unit on cold days when the load is too large for the unit When the thermostat calls for cooling the compressor will start Stage 1 as will the fan after a short delay adjustable The unit will run until the thermostat is satisfied and the unit sh
82. ronic priority during installation 15 000744MAN 02 Typical Duct and Condensate Connections Vertical Case Hot Air Out d Radii Supply 5 Ducts should be sized as per the Duct Sizing table in this manual Hot Air Out Supply Cold Air In Return Flexible Duct Collar minimum 12 above plenum heater elements if installed Optional Electric Plenum Heater Flexible Duct Collar Air filter Filter Rack Can be mounted to the left or right Condensate Drain 2 4 Accoustic insulation be used inside the ducts near the unit ta 3 4 PVC Socket dampen any air noise that may be present Ensure there is insulation Venting may be within 12 of the plenum heater if required refer to installed local building code 2 thick styrofoam Floor Drain Minimum decline of 1 8 per foot a 12 Chris Geddes 15 JAN 08 AMERICAN DREAM Geothermal veges Chris Geddes 15 JAN 08 7 Approved Ry OE ne Drawing Name Typical Duct and Condensate Chris Geddes 15 JAN 08 Connections Vertical Case Approved By MFG Nurber REV SHEET RE 01 1 of 1 Eco APVD BY 000606CDG 000744MAN 02 Page 16 25 MAY 2009 TABLE 15 Duct Sizing Guide external static 0 20 20 Minimum Blameter Return Air Duct Area Rectangular Equivalents in Diameter 2 25 10 2 25 10 3 25 10 N N
83. s Replace if necessary Condensate Drain Inspect for clogs Remove and clean if necessary Circulator Pumps Inspect for leaks Repair or replace if necessary 000744MAN 02 Page 30 25 MAY 2009 Troubleshooting Guide The following steps are for troubleshooting the geothermal heat pump If the problem is with the domestic hot water or the plenum heater proceed to those sections at the end of the troubleshooting guide Repair procedures and reference refrig eration circuit diagrams can be found at the end of the troubleshooting guide STEP 1 Verify that the display is present on the thermostat If it is not proceed to POWER SUPPLY TROUBLESHOOTING otherwise proceed to STEP 2 STEP 2 Remove the door and electrical box cover and check to see if the or LOW LED s are flashing or on Record The results Turn the power off wait 10 seconds and turn the power back on Set the thermostat to call for heating or cooling depending on the season or set the aquastat to call for heating STEP 3 Air If a 24VAC signal does not appear across Y1 and of the Control Box Thermostat terminal strip within 6 minutes proceed to the THERMOSTAT TROUBLESHOOTING section otherwise proceed to STEP 4 Note that the aquastat should be set so there is no call from it STEP Hydronic If a 24VAC signal does not appear across Y1A and CA of the DXTF Two Stage Control Box Aquastat terminal strip proceed to the HYDRONIC TROUBLESHOOTING AQUA
84. s off if equipped 2 Verify all high voltage connections Ensure that there are no stray wire strands all connections are tight and the ground wire is connected tightly to the ground connector for the heat pump and plenum heater 3 Record the fuse circuit breaker size and wire gauge for the heat pump Record the fuse circuit breaker size wire gauge and size of the plenum heater if installed 4 Verify that the control connections to the thermostat and plenum heater if installed are properly connected and all control signals are off so that the unit will not start up when the power is turned on 5 Ensure all access panels except the lower one that provides access to the electrical box are in place Unit Charge 1 Ensure the unit has been vacuumed and has refrigerant in it If the unit is not fully charged the remainder can be added during the start up procedure Record the current amount of refrigerant in the system 25 MAY 2009 Page 23 000744MAN 02 UNIT STARTUP AIR The unit is now ready to be started The steps below outline the procedure for starting the unit and verifying proper operation of the unit It is recommended that safety glasses be worn during the following procedures COMPRESSOR UNDER VACUUM WILL DESTROY IT INA MATTER OF SECONDS VOIDING THE WARRANTY ENSURE UNIT IS CHARGED WITH REFRIGERANT BEFORE TURNING THE POWER ON STARTING A IF THE UNITIS NOT FULLY CHARGED THE REMAINDER CAN BE ADDED DURING HEATING MOD
85. s under 500 microns for several minutes with the vacuum pump valve closed STEP 4 Charge the unit and operate it for continuously for 2 hours Pump down the unit and replace the filter drier Vacuum the unit until it remains under 500 microns for several minutes with the vacuum pump valve closed STEP 5 Charge the unit refrigerant can be re used and operate it for 2 3 days Pump down the unit and replace the filter drier the filter drier STEP 7 Charge the unit a final time Unit should now be clean and repeated future burn outs can be avoided STEP 6 Charge the unit refrigerant can be re used and operate it for 2 weeks Pump down the unit and replace 000744MAN 02 Page 44 25 MAY 2009 REFRIGERATION CIRCUIT DIAGRAMS FCTF Series Refrigeration Circuit Heating Mode Condenser NOTE for NO 1 the valve is OPEN when de energized No Water Flow NEA b Water IN Water Loop Condenser Service Port Optional Desuperheater Compressor f Diagram Heating Mode 01 initial Release GEDDES AUG 06 L Size Drawing Number IMPLBY pare JaA 000268RCD 01 1 of 1 25 MAY 2009 Accumulator Drawn By Date 3960 Howard Hughes Pkwy AMERICAN DREAM Geothermal tss Vegas Nevada 9 FCTF Series Refrigeration Circuit hris Geddes 30 AUG 06 Page 45 000744MAN 02 REFRIGERATION CIRCUI
86. sor L1 black wire current Domestic Hot Water functioning Thermostat setpoint and discharge pressure at cycle end F Cooling Mode Suction Pressure Discharge Pressure psig kPa Duct Return Indoor Out and Delta T In Out F Thermostat setpoint and suction pressure at cycle end F psig kPa 25 MAY 2009 Page 25 000744MAN 02 UNIT STARTUP HYDRONIC The unit is now ready to be started The steps below outline the procedure for starting the unit and verifying proper operation of the unit It is recommended that safety glasses be worn during the following procedures COMPRESSOR UNDER VACUUM WILL DESTROY IT INA MATTER OF SECONDS VOIDING THE WARRANTY ENSURE UNIT IS CHARGED WITH REFRIGERANT BEFORE TURNING THE POWER ON STARTING A IF THE UNITIS NOT FULLY CHARGED THE REMAINDER CAN BE ADDED DURING HEATING MODE STEP 2 Preparation 1 2 3 Remove the caps from the service ports and connect a refrigeration manifold set to the unit Turn the power on to the heat pump and set the thermostat to OFF Set up the thermostat as per the instructions provided with it so that it will function properly with the heat pump system set for heat pump not for heating and cooling The O signal should be set to active in cooling mode Measure the following voltages on the compressor contactor and record them on the startup sheet L1 L2 L2 L3 11 13 Heating Mode 1 2 Set the hea
87. ssure to increase When the loop is sufficiently hot enough to reach the Loop Switch set point 480psig the unit will switch to Loop 2 This starts the cycle over with a new loop and allows the previous loop time to re cover Heat pump operation will continue switching through the loops as required The time between loop changes is monitored and should it fall below the adjustable threshold default 15 minutes indicat ing that the loops are sufficiently hot the heat pump will begin using two loops at a time and continue cycling If the loop Switch time falls below the threshold on two loop mode the soaker hose will be turned on if installed The soaker hose cools the loops down with water The loop sequences are shown in TABLE 7 TABLE 7 Cooling Mode Loop Seque 2 amp 3 3 amp 4 3 amp 4 25 MAY 2009 Page As the transition from summer to fall begins and the cool ing load is greatly reduced the loops begin to cool down on their own Eventually a point is reached at which the loops are cooled down enough that two loops becomes too large a con denser This may occur naturally or there may be a few heating days and then a warm spell again the loops settings are not affected by a switch to heating mode Two loop operation can no longer be sustained and the unit will trip the low pressure safety control This occurrence will set the heat pump back to one loop mode and allow the unit to run properly when it auto m
88. switch is in the ON position Recommended Action Determine why the disconnect switch was opened if all is OK close the switch Fuse blown Breaker Tripped At plenum heater disconnect box if installed voltmeter shows voltage on the line side but not on the load side Check if breaker is tripped Reset breaker or replace fuse at plenum heater disconnect box Replace fuse with proper size and type Time delay type D Same Line to L1 and L2 No call for auxiliary or emergency heat from ther mostat Measuring L1 to ground and L2 to ground both yield 115VAC but L1 to L2 yields OVAC Verify that the thermostat is indicat ing that auxiliary or emergency heat should be on Correct wiring Set thermostat to engage auxil iary or emergency heat note some thermostats require a jumper between auxiliary and emergency Check the thermo stat manual Faulty thermostat Thermostat doesn t indicate a call for auxiliary or emergency when it should Replace thermostat Faulty thermostat Thermostat indicates auxiliary or emergency but no 24VAC signal present across C and the auxiliary and or emergency pin at the ther mostat Replace thermostat Faulty thermostat wiring Plenum Heater trans former is burned out 24V AC signal is present across and the auxiliary and or emergency pin at the thermostat but no 24 signal is present across W2 and C at the hea
89. t a permanent lockout will occur if this occurred within a set period of time default 6 hours and the compressor cannot be started again until the control board is reset by shorting the reset pins together or turning the power off and on again The lockout count is decreased after a set period of time default 6 hours if there are no more occurrences If the control board enters permanent lockout mode there is a serious problem with the system and it must be rectified if the unit is to maintain good service DOMESTIC HOT WATER CONNECTIONS typical piping diagram for pre heat tank configuration can be found in drawing 000484PDG at the end of this section Be sure to note the position of the check valve and the direction of water flow Other configurations are possi ble and there may be multiple units tied together in larger build ings WARNING USE ONLY COPPER LINES TO CONNECT THE DESUPERHEATER TEMPERATURES COULD REACH 200F SHOULD THE DHW CUTOUT SWITCH FAIL POTENTIALLY RUPTURING PEX PIPING A Ensure the tank is filled with water and under pressure before activating the heat pump Slightly loosen the boiler drain on the DHW Out pipe to allow air to escape from the system before the unit is started This step will make certain that the domestic hot water circulator in the unit is flooded with water when it is started CAUTION the domestic hot water pump is water lubricated damage will occur to the pump if it is run
90. t pump terminal strip Voltmeter does not show 24 across transformer secondary wind ing Correct wiring Replace transformer Plenum heater control board is faulty Faulty wiring Transformer tested OK in previous step 24VAC present across C and ground at the plenum heater but not across ground of the plenum heater of the heat pump terminal strip Replace control board Correct wiring Faulty wiring If previous step tested OK 24VAC is present across ground of the plenum heart and 1 of the heat pump termi nal strip but not across ground of the plenum heater and 1 of the ple num heater Page 42 Correct wiring 25 MAY 2009 PLENUM HEATER TROUBLE SHOOTING No 24VAC signal Possible Cause Faulty Plenum Heater Relay in heat pump Verification 24VAC is present across pin 1 and pin 3 of the relay 24VAC is present from heat pump terminal strip to plenum heater ground but not from heat pump terminal strip 1 to ple num heater ground See Fan Not Operating section Recommended Action Replace relay Correct problem Reset thermal overload Faulty overload Reset thermal overload Replace if faulty DOMESTIC HOT WATER DHW TROUBLE SHOOTING Insufficient hot water Tank Problem Insufficient hot Possible Cause Thermostat on hot water tank set too low Should be set at 120 F 140 F if required by local code Verification
91. t signal does not reach Heat Pump termi nal strip Indoor Loop Cir culator does not have power Fan operates in hydronic heat mode Reversing Valve Activated in hy dronic heat mode Emergency Heat override does not work Possible Cause Faulty Mode Select relay Faulty Circulator pump contactor Faulty Mode Select Relay Faulty Break O relay Faulty Emergency Heat Relay Verification Trace the circuit of the signal using a voltmeter and drawing 000740SCH Measure each point to C gnd along the path until the faulty component is located The Mode Select Relay should be energized for water heat Verify 24VAC across the coil of the contactor Check for appropriate voltage across P1 and P2 24VAC is present across pin 1 of the relay and C of the terminal strip 24VAC signal present across pin 4 and C 24VAC signal present across pin 4 and C Recommended Action Replace the head of the relay Replace contactor Replace the head of the relay Replace the relay Replace the relay SAFETY CONTROLS TROUBLESHOOTING High Pressure Control Possible Cause Faulty High Pressure Con trol open HP pressures must be at static levels Verification Hi LED is flashing Short H to H on the connector at the left of the con trol board and verify whether the LED stops flashing or remains flash ing Recommended Action Replace high pressure control if LED stops flashing rep
92. the manifold and start the vacuum pump Vacuum the system until the reading on an electronic vacuum gauge remains below 500 microns for a period of 5 minutes after the vacuum pump is shut off and the system sealed CHARGING THE SYSTEM Once the system has been vacuumed refrigerant can be added by weighing in 1 3 of the prescribed refrigerant charge into the low side of the system Start the heat pump in the heating mode and continue to add refrigerant as a liquid at a rate of no more than 1 Ib per minute until the prescribed charge is reached Alternately before the machine is started the entire charge can be weighed into the system through the high side of the system TABLE 16 shows the typical charge per unit size This allows for e 20ftof distance 40ft of pipe interconnect tubing from the unit to the wall e 20ftof distance from the wall to the borehole trench astandard loop 100ft borehole or 150ft trench Additional refrigerant is required as per TABLE 16 if the installation exceeds these parameters TABLE 16 Charge Chart UCET 73 9 1 Extra loop borehole 0 5 Extra loop trench 0 7 Extra distance to borehole Extra depth of borehole Extra distance to trench Extra length of trench Extra distance in structure 0 10z per foot 000744MAN 02 Lines be bundled together after pressure testing and insulation for neatness and strength 3 8 OD Co
93. the pressure from the heat pump and cut the ends off of the Liquid and Vapour ports Remove the caps from the line set tubing The line sets can be connected to the ports on the heat pump using couplings or alternately the tubing can be swaged The joints should be silver soldered with 5 silfos AMERICAN DREAM Geothermal absolutely requires that dry nitrogen be bled through the system during all silver soldering procedures so that no oxidation occurs on the inside of the copper tubing The service ports on the unit can be used to connect the nitrogen with a refrigeration manifold If necessary a damp clothe can be wrapped around the each of the ports to prevent melting the grommet when silver 25 MAY 2009 Page 21 soldering Ensure that no water enters any of the ports or tubing PRESSURE TESTING Once all connections are complete the system should be pressure tested to 100PSIG 690kPa with dry nitrogen Check all joints at the unit and any made in the interconnect tubing for leaks using soap suds Spray nine etc It is important not to bypass this step as vacuuming the system with a leak will be impossible and attempting to do so will introduce moisture into the system making the vacuum process take much longer than if the leak had been found and repaired first VACUUMING THE SYSTEM Remove the pressure from the system and connect the vacuum pump to the refrigeration manifold Tighten all hose connections open the valves on
94. tially closed Heating TXV s adjusted too far closed Verify superheat It should be be tween 8 14 F 3 8 C Superheat will be high if TXV s are closed too far Adjust TXV to obtain 8 14 F 3 8 C superheat One or more heating TXV s stuck too far closed Adjusting the TXV does not affect the superheat or the suction pressure Attempt to adjust the TXV all the way out and all the way in a few times to loosen it Replace TXV if this does not work Faulty Normally Open so lenoid valve stuck closed A click can be heard when the coil is energized but the valve is cold in stead of warm Replace NO valve Filter drier plugged Feel each end of the filter drier it should be the same temperature If there is a temperature difference then itis plugged Also causes low suc tion pressure Replace filter drier Unit is overcharged Heating TXV s adjusted too far closed Fan operating when it should be off High sub cooling low delta T across air coil Verify superheat It should be be tween 8 14 F 3 8 C Superheat will be high if TXV s are closed too far Verify OVAC across one or both of the following pairs and C in the DXTF Control Box G1 G2 M1 M2 E1 E2 Remove 1 2lb of refrigerant at time and verify that the discharge pressure reduces Adjust TXV to obtain 8 14 F 3 8 C superheat If 24VAC is across both terminals of any of the pairs and C tr
95. ting aquastat setpoints to activate Stage 2 The compressor will start as well as the indoor circulator pumps Check the refrigeration gauges The suction and discharge pressures will depend on the loop temperatures but they should be about 75 95PSIG and 290 365PSIG respectively for a typical start up If the unit was not completely charged add the remaining refrigerant through the suction side only Monitoring the refrigeration gauges while the unit runs Record the following data at the time interval s indicated Numbers 1 to 4 record at 10 15 20 25 30 and then average the values Record numbers 5 to 8 at 30 minutes The average superheat for each line set should be 8 14 F 4 8 C The TXV s are set to four turns in from all the way out at the factory and typically should not require any adjustments Should adjustment be required follow the Heating TXV Adjustment procedure in this manual Proceed to Step 4 once adjustments have been completed 1 Suction pressure 2 Discharge pressure 3 Each loop Vapour Line temperature 4 Each loop superheat Vapour line temperature evaporating temperature from suction gauge 5 Indoor Loop In Hot In temperature 6 Indoor Loop Out Hot Out temperature 7 Indoor Delta T should be between 8 12 F 4 6 C 8 Compressor L1 C current black wire place meter between electrical box and compressor Adjust the aquastat setpoint to the desired buffer tank temperature and let the unit run thr
96. trical Box to dry contacts Fan speed can be reduced by 15 for zone applications Plenum Heater Wiring Use an 18 2 conductor cable to connect Electrical 1 to Plenum Heater C 1 or I 1 Domestic Hot water Circulator Instructions HACW Note If heat pump is to be operated without the hot water circulator connected to the water tank and flooded with water remove the brown wire with the insulated terminal located here This pump is water lubricated and must not be run dry 230 115VAC CONNECTIONS Colour White AMERICAN DREAM Geothermal 3s vegas Nevada E4Z 6H4 FCTF HAC 1T DE Electrical Box Diagram Drawing Number REV SHEET 01 1 of 1 000738ELB 25 MAY 2009 Drawing Name Size A CASE DETAILS ANER CAN DREAN DOMESTIC HOT WATER IN 5 8 DOMESTIC HOT WATER OUT 5 8 O D HIGH PRESSURE SERVICE PORT LOW PRESSURE SERVICE PORT DX LIQUID LINES 1 5 HOT LOOP OUT 1 1 1 8 0 0 A HOT LOOP IN SIGHT run GLASS FILTER DRYER DX VAPOUR ELECTRICAL BOX 13 1 2 7 5 LINES 1 5 55 SOLENOID CONDENSATE DRAIN Front View Back View CONNECTIONS 3 ACCESS 3 WAY VALVES Left Side View Right Side View 25 MAY 2009 Page 55 000744MAN 02 CASE DETAILS continued REVERSIBLE FILTER RACK FOR 28 31 5 X 2 AIR FILTER x 1 4 I 13 1 2 58
97. ts that its geothermal heat pumps shall be free from defects in materials and workmanship for a period of FIVE 5 YEARS after the date of installation or for a period of FIVE 5 YEARS AND SIXTY 60 DAYS after the date of shipment whichever occurs first This warranty covers all internal components of the heat pump Please see labor allowance schedule for information pertaining to labor coverage AMERICAN DREAM Ultra Performance Geothermal shall at its option replace any part covered by this warranty shipping cost will apply Defective parts shall be returned to AMERICAN DREAM Ultra Performance Geothermal shipping charges apply Replacement or repaired parts and components are warranted only for the remaining portion of the original warranty period This warranty is subject to the following conditions 1 The geothermal heat pump must be properly installed and maintained in accordance with AMERICAN DREAM Ultra Performance Geothermal guidelines The installer must complete the Startup Record and return it to AMERICAN DREAM Ultra Performance Geothermal within 21 days of unit installation For new construction it is the responsibility of the building or general contractor to supply temporary heat to the structure prior to occupancy Geothermal heat pumps are designed to provide heat only to the completely finished and insulated structure Startup of the unit shall not be scheduled prior to completion of construction and final duct instal
98. uid line will be warmer Recommended Action Pump the unit down and swap the interchanged lines Loop field too small Leaking reversing valve Charge is good superheats are good vapor line temperatures are low Reversing valve is the same tem perature on both ends of body common suction line is warm com pressor is running hot Increase loop size Replace reversing valve Heating TXV s adjusted too far open Verify superheat It should be be tween 8 14 F 3 8 C Superheat will be lowh if TXV s are open too far Adjust TXV to obtain 8 14 F 3 8 C superheat One or more heating TXV s stuck too far open Adjusting the TXV does not affect the superheat of the loop or the suc tion pressure Low super heat low discharge pressure Adjust the TXV all the way in and out a few times to loosen it Replace if this does not work Faulty cooling check valve leaking See Low Suction Pressure in this section TXV stuck almost closed or partially blocked by for eign object Intermittent fan Faulty compressor contac tor Also low discharge pressure Switch to cooling mode Unit operates cor rectly when loop is in use Loop lines get cold when loop not in use instead of warming to ambient com pressor frosts up Adjusting the TXV does not affect the superheat or the suction pres sure See Fan Troubleshooting section Points pitted or burned Contacto
99. uplings HEAT PUMP CONNECTIONS Liquid 1 Liquid 2 Liquid 3 Liquid 4 Liquid 5 Vapour 1 Vapour 2 Vapour 3 Vapour 4 Vapour 5 NOTES Sul OD Couplings FC Line Set Interconnect Tubing Installation R410a Floor Joist Copper Tubing 3 8 OD The liquid lines for horizontal loops must be reduced to 3 8 OD once it enters the structure Vertical loops are already 3 8 OD All lines insulated with 3 8 thick pipe insulation e Ensure the line sets are kept in order and routed to the proper ports on the heat pump Holes through the foundation structure should be filled with expanding foam from both sides to prevent leakage e Proper drainage material should be used on the outside of the wall to prevent water buildup e All joints should be soldered with 5 silver solder Pressure test to 100PSIG and check for leaks once all connections are complete All lines inside the structure and through the wall should be insualted with 3 8 to 1 2 thick closed cell pipe insulation Ensure adjoining pipe insulation pieces are glued or tapes together to prevent gaps Tubing should be securely fastened to prevent accidental bending 22 ate Da Checked 2 Checked D Chris Geddes 65 AUG Appro Basement Holes should be 1 larger than tube size Fill the gap between insulation and wall with expanding foam or other sealant suitable for 250 F
100. ures if applicable by hand caution pipes get hot If the DHW OUT line does not become hotter than the DHW IN line the circulator is air locked Bleed the air from the system and check the temperature differential again to ensure there is flow from the circulator Cooling Mode 1 Set the thermostat to cooling mode and adjust the setpoint to activate Stage 1 and Stage 2 2 Monitoring the refrigeration gauges while the unit runs Record the following after 10 minutes of runtime 3 Suction pressure Discharge pressure Duct Return temperature Duct Supply Out temperature Duct Delta T Adjust the thermostat setpoint to the desired room temperature if possible otherwise set it just low enough to allow the unit to run ie 1 F 0 5 C less than room temperature and let the unit run through a cycle Record the thermostat setpoint and the suction pressure when the unit shuts off Final Inspection 1 2 kw Turn the power off to the unit and plenum heater if installed and remove all test equipment Install the electrical box cover and the access panel on the heat pump Install the service port caps securely to prevent refrigerant loss Install the electrical cover on the plenum heater if applicable Do a final check around the heat pump and ensure the area is clean Leave a copy of the Startup Record at the installation site send a copy to Maritime Geothermal Ltd and keep the final copy Turn the power
101. uts off the fan will continue to run for an adjustable period During operation the control board will cycle through the loops as required The control board has an RS 232 communications port on board A simple program such as Hyper Terminal and an adapter cable can be used to communicate with the control board Drawing 000301CDG shows how to build the communi cations cable The port settings are shown in TABLE 9 The commands available are listed in TABLE 10 Note that the COP must be unlocked by command U before using command C to change system settings The list of settings for command C is shown in TABLE 11 It is recommended that the settings be left at the defaults values 9 5232 Configuration Baud 9600 Data Bits 8 Parity None Stop Bits 1 Flow Control TABLE 10 Control Board Commands Help displays the list of commands Lock unlock the COP watchdog Display loop status Display loop history Display system status Display system configuration Change system settings use U first System runtimes Advance system time by 59 minutes Reset loop timers to zero commen H U L M 5 2 000744MAN 02 Page 12 TABLE 11 Control Board Default Settings Command o a Blower wait time after comp start 2sec Blower run time after comp stops 5sec Blower run time after aux heat off 59sec Aux heat on time after comp on 40min Com
102. y duct ina manner that allows all of the airflow to pass through it to prevent any hot spots in the heater elements 14 Plenum Heater Sizing Plenum Heater 23016 60 25 2009 TABLE 14 shows the recommended size plenum heater as well as the wire size and breaker size needed to provide power to the plenum heater CONDENSATE DRAIN The unit comes equipped with a 3 4 PVC socket fitting female labeled Condensate Drain This drain allows the con densate which forms during the air conditioning cycle to be re moved from the unit The drain should be connected as per local codes During high humidity weather there could be as much as 25 gallons of water formed per day Care should be taken in the spring to ensure that this pipe is not plugged with dust that has collected during the winter caus ing the condensate to overflow into the bottom of the heat pump and onto the floor The condensate drain is internally trapped however proper venting is required external to the heat pump Refer to local codes to ensure the installa tion is done properly Drawing 000606CDG shows a typical installation HYDRONIC SYSTEMS GENERAL The most common applications for the hydronic heating are see drawing 000530PDG for typical zone types radiant in floor heating On demand domestic hot water e Swimming pool or spa The radiant in floor areas of the home may be s
103. y inspect Remove fuse and check for continuity if in doubt Reset breaker or replace fuse with proper size and type Time delay type D Replace fuse Blown fuse on control board Faulty transformer Faulty wiring between heat pump and thermostat Faulty Thermostat Visually inspect Remove fuse and check for continuity if in doubt 230VAC is present across H1 and H4 of the transformer but 24VAC is not present across X1 and X4 of the transformer 24VAC is not present across C and R Ru of the thermostat 24VAC is present across C and R Ru of the thermostat but thermo stat has no display Page 31 Replace fuse Replace transformer Correct the wiring Replace thermostat 000744MAN 02 THERMOSTAT TROUBLESHOOTING No Y1 signal to heat pump after 6 minutes Possible Cause Incorrect thermostat setup Verification Thermostat does not indicate a call for heat No 24VAC signal present across C and Stage 1 of the thermo stat Recommended Action Correct the setup Faulty thermostat to heat pump wiring 24VAC signal present across Stage 1 and C of the thermostat but not pre sent across Y1 and C of the terminal strip Correct or replace wiring Faulty thermostat 24VAC between Stage 1 and of the thermostat when a call is indi cated on the thermostat Replace thermostat TWO STAGE CONTROL BOX TROUBLESHOOTING Thermostat or Aquasta

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