Full Text Searchable PDF User Manual
Installation, Operation &
Large Commercial Series
Water Source Heat Pumps
TABLE OF CONTENTS
Location and Access
Installation of Supply and Return Piping
Sound Attenuation for Large Commercial Units
Wall Mounted Thermostat Installation
precautions must be taken to avoid physical damage to
the units and contamination by foreign material. Physical
damage and contamination may prevent proper start-up
and may result in costly equipment clean-up.
Examine all pipes, fittings, and valves before installing
any of the system components. Remove any dirt found on
Installation, Operation and Maintenance (IOM)
instructions are provided with each unit. Before unit
start-up, read all manuals and become familiar with the
unit and its operation. Thoroughly check out the system
Prepare Large Commercial Units for installation as
Compare the electrical data on the unit nameplate
with ordering and shipping information to verify that
the correct unit has been shipped.
Keep the unit covered with the shipping carton until
installation is complete and all plastering, painting,
etc. is finished.
Verify that refrigerant tubing is free of kinks or
dents, and that it does not touch other unit
Inspect all electrical connections. Connections must
be clean and tight at the terminals.
To avoid equipment damage, DO NOT use these units
as a source of heating or cooling during the
construction process. The mechanical components
and filters used in these units will quickly become
clogged with construction dirt and debris which may
cause system damage.
To avoid the release of refrigerant into the
atmosphere, the refrigerant circuit of this unit MUST
only be serviced by technicians which meet local, state
and federal proficiency requirements.
All refrigerant discharged from this unit MUST be
recovered without exception. Technicians MUST
follow industry accepted guidelines and all local, state
and federal statutes for the recovery and disposal of
When a compressor is removed from this unit, system
refrigerant circuit oil will remain in the compressor.
To avoid leakage of compressor oil, the refrigerant
lines of the compressor MUST be sealed after it is
Upon receipt of shipment at the job site, carefully check
the shipment against the bill of lading. Make sure all
units have been received. Inspect the carton or crating of
each Large Commercial Unit (LCU) and inspect each
unit for damage. Assure that the carrier makes proper
notation of any shortages or damage on all copies of the
freight bill and that he/she completes a Carrier Inspection
Report. Concealed damage not discovered during
unloading must be reported to the carrier within 15 days
of receipt of shipment. NOTE: It is the responsibility of
the purchaser to file all necessary claims with the
carrier. Notify the ClimateMaster Traffic Department
of all damage within fifteen (15) days of shipment.
This Installation, Operation and Maintenance manual
(IOM) is for ClimateMaster Large Commercial Water
Source Heat Pump Systems (LCU).
ClimateMaster Large Commercial Units are typically
installed in a floor level closet or in a small mechanical room.
The installation site chosen for these units must allow
adequate clearance for maintenance and servicing of the unit.
DO NOT store or install Large Commercial Units in
corrosive environments or in locations subject to
temperature or humidity extremes (e.g., attics,
garages, rooftops, etc.). Corrosive conditions and high
temperature or humidity can significantly reduce
performance, reliability, and service life. Always
move units in an upright position. Tilting units on
their sides may cause equipment damage.
Upon the arrival of equipment at the job site,
immediately store units in their shipping cartons in a
clean, dry area. Store units in an upright position at all
times. Stack unit model numbers 080 through 120 no
more than 2 units high. Do not stack units larger than
120. DO NOT remove equipment from shipping
cartons until equipment is required for installation.
Cover Large Commercial Units on the job site with either
shipping cartons, vinyl film, or an equivalent protective
covering. Cap the open ends of pipes stored on the job
site. In areas where painting, plastering, or the spraying
of fireproof material has not been completed, all due
Figure 1 - LCU Installation
Location and Access
Large Commercial Units are typically installed in a floor
level closet or in a small mechanical room. Refer to
Figure 1 for an illustration of a typical installation. Install
units with adequate clearance to allow maintenance and
servicing. Conform to the following guidelines when
selecting unit location:
Provide adequate clearance for filter replacement
and drain pan cleaning. DO NOT block filter access
with piping, conduit or other materials. Refer to
submittal drawing for Vertical Unit Dimensions.
Installation of Supply and Return Piping
Follow these piping guidelines:
Piping must comply with ALL applicable Codes.
Install a drain valve at the base of each supply and
return riser to facilitate system flushing.
Install shut-off/balancing valves and unions at each
unit to permit unit removal for servicing.
Provide access for fan and fan motor maintenance
and for servicing of the compressor and coils without
removal of the unit.
Provide an unobstructed path to the unit within the
closet or mechanical room to enable removal of the
unit if necessary.
Provide access to water valves and fittings, and
screwdriver access to the unit side panels, discharge
collar and all electrical connections
The installation of Large Commercial Water Source
Heat Pump Units and all associated components, parts
and accessories that make up the installation shall be in
accordance with the regulations of ALL Authorities
having jurisdiction and MUST conform to ALL
applicable Codes. It is the responsibility of the Installing
Contractor to determine and comply with ALL
applicable Codes and Regulations.
24 V Remote
Per Local Codes
Rear Return Front Blow shown
Refer to Product Engineering Catalog
for other arrangements & dimensions
Minimum Bend Radius
Place strainers at the inlet of each system circulating
Select the proper hose length to allow slack between
connection points. Hoses may vary in length by +2%
to -4% under pressure.
Refer to Table 2. DO NOT exceed the minimum
bend radius for the hose selected. Exceeding the
minimum bend radius may cause the hose to collapse
which reduces water flow rate. Install an angle
adapter to avoid sharp bends in the hose when the
radius falls below the required minimum as shown in
Figures 2 and 3.
Hose in Inches
Table 2- Metal Hose Minimum Bend Radii
Insulation is not required on loop water piping except
where the piping runs through unheated areas or outside
the building. Because loop temperature is normally
F and 90
F, piping will not sweat nor suffer
heat loss in normal ambient conditions. For regions
outside of the 60
F range, refer to the job
specification to determine if the use of insulation is
Pipe joint compound is not necessary when Teflon
threaded tape is pre-applied to hose assemblies or when
flared-end connections are used. If pipe joint compound
is preferred, use compound only in small amounts on the
male pipe threads of the fitting adapters. Prevent sealant
from reaching the flared surfaces of the joint.
Maximum allowable torque for brass fittings is 30 foot-
pounds. If a torque wrench is not available, tighten
finger-tight plus one quarter turn. Tighten steel fittings
Ensure that the trap is filled with water before operating the
unit to avoid condensate pan overflow at initial start-up.
DO NOT bend or kink supply lines or hoses.
Optional pressure-rated hose assemblies designed
specifically for use with ClimateMaster units are
available. Supply and return hoses are fitted with swivel-
joint fittings at one end to prevent kinking during
Refer to Figure 4 for an illustration of a Supply/Return
Hose Kit. Male adapters secure hose assemblies to the
unit and risers. Install hose assemblies properly and
check them regularly to avoid system failure, reduced
service life and possible damage to surrounding furniture
Figure 4- Supply/Return Hose Kit
Corrosive system water requires corrosion-resistant
fittings and hoses and may require water treatment.
Units are typically installed directly above each other on
successive floors with condensate drains located near the
Connect the unit condensate drain connection to the
building condensate drain with a 1" drain line.
The horizontal run of a condensate hose is usually too short
to cause drainage problems, however pitch the horizontal
run of the condensate line at least 1 inch for every 10 feet
of run in the direction of flow. Avoid low points and
unpitched piping since dirt collects in low or level areas
and may cause stoppage and overflow.
Install a condensate trap at each unit with the top of the trap
positioned below the unit condensate drain connection.
Figure 5 illustrates a typical trap and vent used with
LCU Heat Pumps. Design the length of the trap (water-
seal) based upon the amount of positive or negative
pressure on the drain pan. As a rule, 1" of trap is
required for each inch of negative pressure on the unit.
(2 Foot Length Standard)
Pitch down to drain
1" Per 10 Feet
RECOMMENDED TRAP DIMENSION
Figure 5 - Condensate Drain
Each unit must be installed with its own individual trap
and connection to the condensate line (main) or riser.
Provide a means to flush or blow-out the condensate
drain line. DO NOT install units with a common trap
Install a vent in the condensate line of any application
which may allow dirt or air to collect in the line. Always
vent when the application requires a long, horizontal run,
when some sagging in the condensate line may be
anticipated (as in a long line of plastic pipe) or when
"double trapping" may occur. Also vent when large
units are working against higher external static pressure
than other units connected to the same condensate main
since this may cause poor drainage for all units on the
line. When a vent is installed in the condensate line, it
must be located after the trap in the direction of
Sound Attenuation for Large Commercial
Sound minimization is achieved by enclosing the unit
within a small mechanical room or a closet. Additional
measures for sound control include the following:
Mount the unit so that the return air inlet is 90
the return air grille. Refer to Figure 2 on facing
page. Install a sound baffle as illustrated to reduce
line-of-sight sound transmitted through return air
Mount the unit on a rubber or neoprene isomode pad
to minimize vibration transmission to the building
structure. Extend the pad beyond all four edges of
To avoid possible injury or death due to electrical
shock, open the power supply disconnect switch and
secure it in an open position during installation.
Use only copper conductors for field installed
electrical wiring. Unit terminals are not designed to
accept other types of conductors.
All field installed wiring, including electrical ground,
must comply with the National Electrical Code (NEC) as
well as all applicable local codes. In addition, all field
wiring must conform to Class II temperature limitations
described in the NEC.
Refer to the unit name plate for fuse sizes and a schematic
of the field connections which must be made by the
installing (or electrical) contractor.
Consult the unit wiring diagram located on the inside of
the compressor access panel to ensure proper electrical
Units rated 208-230 volts that have a 24 volt transformer
must have the transformer connection modified if the
actual power supply is 230 volts. Refer to the unit wiring
diagram for details of this procedure.
All final electrical connections must be made with a
length of flexible conduit to minimize vibration and sound
transmission to the building.
Wall Mounted Thermostat Installation
When the unit has a CXM Series controller, do not use a
heat/ cool pump thermostat. Use a thermostat with Y, G,
O, and W outputs. Refer to unit wiring diagram and CXM
Series AOM for additional information
Vender installation instructions and additional installation
information is shipped with each thermostat.
Maintain zone integrity to assure accurate and
efficient operational control of units or groups of
units. Without adequate zone control, adjacent units
may operate in heating and cooling mode
All wiring must comply with all applicable electrical
codes including NEC and local codes. Refer to the
thermostat submittal to verify actual wiring requirements.
A= Two power wires on single-phase units: three power wires on three-phase units. B= 1 heat /1 cool /Manual or Auto
Change-Over remote 24V thermostat. Note: All customer-supplied wiring to be copper only and must conform to NEC
and local electrical codes. Wiring shown with dashed lines must be field-supplied and field-installed.
DISCONNECT ELECTRICAL POWER
SOURCE TO PREVENT INJURY OR
DEATH FROM ELECTRICAL SHOCK.
USE COPPER CONDUCTORS ONLY
TO PREVENT EQUIPMENT DAMAGE.
Typical Field Installed Wiring
Do not allow the total resistance of all low-voltage wires
used to exceed 1 ohm. Resistance in excess of 1 ohm may
cause high voltage drop which may result in control
malfunction. Refer to the thermostat installation and
operation manual to determine recommended heat
Environment -This unit is designed for indoor
Power Supply - A voltage variation of +/- 10% of
nameplate utilization voltage is acceptable. Three-phase
system imbalance should not be allowed to exceed 2%.
Units start and operate in an ambient of 40
entering air at 40
F, entering water at 40
F and with
both air and water at the stated flow rates of ARI
Standard 320-96 rating test for initial winter start-up.
These are not normal or continuous operating
conditions. It is assumed that winter start-up is to
bring the building space up to occupancy
Voltage utilization range complies with ARI
When using 100% outside air as a source of
ventilation, a 40
F DB minimum and a 78
are acceptable. However, the cabinet may sweat
during hot weather.
Determination of operating limits is dependent
primarily upon 3 factors: 1) return air temperature 2)
water temperature and 3) ambient temperature.
When any one of these factors is at minimum or
maximum levels, the other two factors should be at
normal levels to ensure proper unit operation.
Extreme variations in temperature and humidity, and
corrosive water or air will adversely affect unit
performance, reliability and service life.
Min. Ambient Air
Rated Ambient Air
Max. Ambient Air
Min. Entering Air DB/WB
Rated Entering Air DB/WB
Max Entering Air DB/WB
Min. Entering Water
Normal Entering Water
Max. Entering Water
System Cleaning and Flushing
Cleaning and flushing the unit is the single most impor-
tant step to ensure proper start-up and continued efficient
operation of the system.
Follow the instructions below to properly clean and flush
To prevent injury or death due to electrical shock or
contact with moving parts, open unit disconnect
before servicing unit.
Verify that electrical power to the units is discon-
Install the system with the supply hose connected
directly to the return riser valve. Use a single length
of flexible hose.
Open all air vents. Fill the system with water. DO
NOT allow system to overflow. Bleed all air from
the system. Check the system for leaks and repair
Verify that all strainers are in place. Start the pumps
and systematically check each vent to ensure that all
air is bled from the system.
Verify that make-up water is available. Adjust
make-up water appropriately to replace the air which
was bled from the system. Check and adjust the
water/air level in the expansion tank.
Set the boiler to raise the loop temperature to
F. Open a drain at the lowest
point in the system. Adjust the make-up water
replacement rate to equal the rate of bleed.
Refill the system and add trisodium phosphate in a
proportion of approximately one pound per 150
gallons of water. Reset the boiler to raise the loop
temperature to about 100
To avoid possible damage to piping systems
constructed of plastic piping, DO NOT allow loop
temperature to exceed 110
Circulate the solution for a minimum of 8 to 24
hours. At the end of this period, shut off the
circulating pump and drain the solution. Repeat
system cleaning if necessary.
When the cleaning process is complete, remove the
short-circuited hoses. Re-connect the hoses to the
proper supply and return the connections to each of
the Large Commercial Units. Refill the system and
bleed off all air.
Test the system pH with litmus paper. The system
water should be slightly alkaline (pH 7.5 to 8.5).
Add chemicals as appropriate to maintain acidity
DO NOT use “Stop-Leak” or any similar chemical
agent in this system. Addition of these chemicals to
the loop water will foul the system and will inhibit
10. When the system is successfully cleaned, flushed,
refilled and bled, check the main system panels,
safety cutouts, and alarms. Set the controls to
properly maintain loop temperatures.
Alternate Connections Method:
Use standard coupling (field-supplied)
and hose adapters to join 2 hoses.
9. Freeze Protection for Water System: Verify
that freeze protection is provided for the outdoor
portion of the loop water system. Inadequate
freeze protection can cause system operating
To avoid equipment damage, DO NOT leave system
filled in a building without heat during the winter
unless anti-freeze is added to system water.
Condenser coils never fully drain by themselves and
will freeze unless winterized with anti-freeze.
10. System Water Loop: Verify that all air is bled
from the system. Air in the system impedes unit
operation and causes corrosion in the system
11. Unit Filters: To avoid system damage, ensure
that the unit filter is clean.
12. Unit Fans: Manually rotate fans to assure free
rotation. Ensure that fans are properly secured to
the fan shaft. Do not lubricate fan motors on
start-up since they are lubricated at the factory.
13. System Control Center: To ensure control of
the temperature set-points for operation of the
system’s heat rejector and boiler, examine the
system control and alarm panel for proper
installation and operation.
14. Miscellaneous: Note any questionable aspects of
1. Voltage: Ensure that voltage is within the
utilization range specifications of the unit
compressor and fan motor.
2. System Water Temperature: Ensure that it is
within an acceptable range to facilitate start-up.
(When conducting this check, also verify proper
heating and cooling set points.)
3. System Water pH: Verify system water acidity.
(pH = 7.5 or 8.5) Proper pH promotes the
longevity of hoses and heat exchangers.
4. System Flushing: Properly clean and flush
system periodically. Ensure that all supply and
return hoses are connected end-to-end to facilitate
system flushing and prevent fouling of the heat
exchanger by system water.
Water used in the system must be of potable
quality and clean of dirt, piping slag, and chemi-
cal cleaning agents.
5. Closed-Type Cooling Tower or Open Tower
with Heat Exchanger: Check equipment for
proper temperature set points and operation.
6. Balanced Water Flow Rate to Heat Pump:
Verify the inlet and outlet water temperatures are
recorded as each heat pump unit is started. This
check will eliminate nuisance unit trip-outs
resulting from water velocities which are either
too low or too high; it can also prevent the
occurrence of erosive water flow rates.
7. Standby Pump: Verify that the standby pump is
properly installed and in operating condition.
8. System Controls: To ensure that no catastrophic
system failures occur, verify that system controls
are functioning and that the sequencing is correct.
When the installation is complete and the system is cleaned and flushed, follow the System Check-
out procedure outlined below:
Use the procedure outlined below to initiate proper unit start-up:
When the disconnect switch is closed, high voltage is
present in some areas of the electrical panel. Exercise
caution when working with energized equipment.
Turn all valves to their full open position. Turn on
the line power to all heat pump units.
NOTE: The units with scroll compressors are
tested for matched rotation of fan motor and
scroll compressors. At startup check fan
rotation, if fan rotation is correct all scroll
compressor will automatically have correct
rotation. If fan rotation is incorrect, interchange
any two power supply lead connections at
the disconnect. Scroll compressors with
INCORRECT rotation show following operating
characteristics: 1) High sound level 2)High
suction pressure 3) Low current draw.
Operate each unit in the cooling cycle. Room
temperature should be approximately 70
DB, and 61
F WB. Loop water temperature
entering the heat pumps should be between 70
When the unit is operating in the cooling mode
under ARI conditions, the leaving water temperature
is approximately 10
F warmer than the entering
water temperature at 3 GPM / ton.
Turn the unit thermostat to the cooling position.
If the unit has an optional MCO thermostat, set
the selector switch to COOL. Both the fan and
compressor should run.
For heat pumps with ACO, adjust the cooling
set point to a temperature at least 3
Check for cool air delivery at the system grille
within a few minutes after the unit has begun to
operate. List the identification number of any
machines that do not function.
Check the elevation and cleanliness of the
condensate lines. Dripping may be a sign of a
Operate each heat pump in the heating cycle imme-
diately after checking cooling cycle operation. A
time delay will prevent the compressor from re-
starting for approximately 5 minutes.
NOTE: Large Commercial heat pump units are
designed to start heating at a minimum return air
temperature of 40
F with normal water flow rate
and ambient temperature.
If the unit has an optional MCO thermostat, set
the temperature indicator to the highest setting
and set the selector switch to HEAT. The fan
and the compressor should start.
If the unit has an optional ACO thermostat, set
the temperature indicator to the far right setting
and set the selector switch to AUTO. The fan
and the compressor should start.
Once the unit has begun to run, check for warm
air delivery at the unit grille. List the serial
number of any machines that do not function.
Establish a permanent operating record by logging
the unit operating conditions at initial start-up for
If a unit fails to operate, conduct the following
Check the power supply. It should comply with
the electrical specifications described on the unit
Look for wiring errors. Check for loose terminal
screws where wire connections have been made
on both the line and low-voltage terminal
Check for dirty filters. A clogged filter will
cause safety cutouts to stop unit operation.
Check the supply and return piping. They must
be properly connected to the inlet and outlet
connections on the unit.
Check the fan. If the fan fails to operate, verify
that the fan wheel turns freely and that it is
secured to the shaft. Also verify that the fan
operates in both heating and cooling modes,and
rotates in the proper direction.
If the checks described above fail to reveal the
problem and the unit still will not operate,
contact a trained service technician to ensure
proper diagnosis and repair of the equipment.
NOTE: Refer to Controller AOM provided
with the unit for status light operation and
Perform the maintenance procedures outlined below
periodically as indicated:
To prevent injury or death due to electrical shock or
contact with moving parts, open unit disconnect
switch before servicing unit.
FILTERS: Inspect filters. Establish a regular mainte-
nance schedule. Replace/clean filter frequently depend-
ing upon need.
To remove the filter from a Large Commercial Unit, slide
the filter out of its frame located in the return air open-
ing. When re-installing the filter, use the slide-in rails of
the filter frame to guide the filter into the proper position.
Verify that the airflow arrow found on the top of each
filter points toward the unit. Always replace filters with
the same size and quantity of filters as removed from the
To avoid fouled machinery and extensive unit clean-
up, DO NOT operate units without filters in place.
DO NOT use equipment as a temporary heating or
cooling source during construction.
CONDENSATE PANS: Check condensate drain pans
for algae growth every three (3) months. If algae growth
is apparent, consult a water treatment specialist for
proper chemical treatment. The application of an algae-
cide every three (3) months will typically eliminate algae
problems in most locations.
FAN MOTORS: Lubricate fan motors annually. All
ClimateMaster Large Commercial Units are fully
lubricated at the factory. DO NOT lubricate during
installation. Check all belts and sheaves for wear. Adjust
and replace as needed.
Conduct amperage checks annually. Amperage draw
should not exceed normal full load or rated load amps by
more than 10% of the values noted on the unit nameplate.
Maintain a log of amperage values to detect deterioration
prior to component failure.
UNIT INSPECTION: Visually inspect the unit annu-
ally. Pay special attention to hose assemblies. Repair any
leaks and replace deteriorated hoses immediately.
COMPRESSOR: Conduct amperage checks on the
compressor annually. Amperage draw should not exceed
normal full load or rated load amps by more than 10% of
the values noted on the unit nameplate. Maintain a log of
amperage values to detect deterioration prior to compo-
When replacing the compressor contactor or lockout
relay in a unit with electromechanical controls, use
only ClimateMaster replacement parts. Substitution
of other components may result in an inoperative
safety circuit and may cause a hazardous condition.
HEAT EXCHANGERS: Clean heat exchangers
annually. Inspect heat exchangers regularly and clean
more frequently if the unit is located in a “dirty” environ-
NOTE: If the unit must be reset more than twice,
check the unit for a dirty filter, abnormal entering
water temperature, inadequate or excessive water
flow and internal malfunction. If the unit continues to
cutout, contact a trained service technician.
Controller and Safety Protection
The microprocessor-based controller monitors and
controls unit operation. The controller provides
compressor sequencing, high and low pressure
monitoring, field selectable water and air coil freeze
protection sensing, condensate overflow sensing, over/
under voltage monitoring, and unit performance sentinel.
The control provides a test mode, short cycle protection,
random start-up, a fault LED, fault memory, and
intelligent fault retry. Note the controls operation below
and refer to the controller AOM provided with each unit
for specific controller features, specifications and
Interstage Time Delay On two compressor units, a time
delay between stage I and stage 2 can be set with a dip
switch on compressor 2 controller.
Pressure Switches Pressure switches are normally
losed during normal operating conditions, and open
upon fault. The high pressure switch opens at 375 PSIG
and automatically closes at 3 00 PSIG. The low pressure
witch opens at 10 PSIG and automatically closes at 33
PSIG. The low pressure switch must be open for 30
continuous seconds to cause a fault.
Freeze Protection Thermistors used for freeze
protection, is a NTC (negative temperature coefficient)
type. Freeze protection is set at 30 degrees Fahrenheit for
water systems. If antifreeze is used, the freeze protection
can be set at 10 degrees Fahrenheit by cutting a jumper
on the controller.
ClimateMaster works continually to improve its products. As a result, the design and specifications of each product at the time of order may be changed
without notice and may not be as described herein. Please contact ClimateMaster’s Customer Service Department at 1-405-745-6000 for specific
information on the current design and specifications. Statements and other information contained herein are not express warranties and do not form the
basis of any bargain between the parties, but are merely ClimateMaster’s opinion or commendation of its products.
7300 S.W. 44th Street
Oklahoma City, OK 73179
© ClimateMaster 1997
Condensate Overflow The condensate overflow sensor
will detect a high water level in the air coil drain pan. A
signal will travel from the sensor through the water to a
ground source (the air coil). Grounding the condensate
overflow signal from the controller causes a fault after
30 continuous seconds.
Over/Under Voltage When the controller senses a
voltage over 30Vac or under 19Vac for .5 second the unit
will shutdown. When the voltage returns to a value
between 19Vac and 30Vac, the controller will
automatically reset and restart the unit.
Anti Short Cycle The controller provides 5-minute
anti-short cycle protection for the compressor. The
controller provides a random start upon power up from
LED The status LED on the controller advises the
current status or faults of the controller. The unit
performance sentinel will give a warning when the heat
pump is operating inefficiently. Refer to the wiring
diagram for LED fault codes and unit operating status.
Controller Lockout Controllers can be reset from
lockout mode by cycling the thermostat off and on, or
cycling the disconnect off and on.
Test Mode Test mode can be entered by momentarily
shorting the test pins on the controller. The unit will stay
in test mode for 20 minutes.