P/N 96P557A06 07/02
Dual Capacity, 3 to 6 Tons, R410A
Installation and Maintenance Manual
WARNING:
Before performing service or maintenance operations on a system, turn off main
power switches to the indoor unit. If applicable, turn off the accessory heater power switch.
Electrical shock could cause personal injury.
Installing and servicing heating and air conditioning equipment can be hazardous due to system
pressure and electrical components. Only trained and qualified service personnel should install, repair
or service heating and air conditioning equipment.
Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning
and replacing filters. All other operations should be performed by trained service personnel. When
working on heating and air conditioning equipment, observe precautions in the literature, tags and labels
attached to the unit and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing
operations and have a fire extinguisher available.
Move units in the normal “up” orientation. Horizontal units may be moved and stored per the
information on the carton. Do not stack more than three units in total height. Vertical units may be stored
one upon another to a maximum height of two units. Do not attempt to move units while stacked. When
the equipment is received, all items should be carefully checked against the bill of lading to be sure all
crates and cartons have been received. Examine units for shipping damage, removing the units from the
cartons if necessary. Units in question should also be internally inspected. If any damage is noted, the
carrier should make the proper notation on the delivery receipt, acknowledging the damage.
Moving and
Storage
Model
Nomenclature
Table of
Contents
Model Nomenclature 1
Safety Considerations 1
Moving and Storage 1
Physical Data 2
General Installation Information 2-5
Closed Loop Ground Source Systems 6-7
Open Loop Groundwater Systems 8-9
Desuperheater Connection 10-11
Initial Desuperheater Start Up 12
Electrical Connections 12-13
Wiring Schematic 14-15
Unit Electrical Data 16
Electronic Thermostat 16
Microprocessor Control Operation 16-19
Blower Speed 19
ECM Fan Performance Data 19
Unit Start-Up 20-21
Preventive Maintenance 22
Troubleshooting 22-23
Unit Operating Pressures 23
Replacement Procedures 23
Safety
Considerations
Model Type
Premier - R410A
Unit Capacity
MBTUH
Discharge Air Configuration
T = Top Discharge Vertical
B = Bottom Discharge Vertical
E = End Discharge Horizontal
S = Side Discharge Horizontal
Return Air Configuration
L = Left
R = Right
Voltage
1 = 208-230/60/1
Hot Water Options
0 = None
1 = Hot Water Generation With
Factory Installed Pump
ET048 L 1 0 1 C B D SSA
Vintage
A = Current
Non-Standard Option Details
Non-Standard Options
Filter Options
D =1” Pleated Disposable
Sound Kit
B =Blanket (standard)
Coax Options
C =Copper
N =Cupronickel
Blower Options
1 = ECM Blower
2 = Oversized ECM Blower Option
(048 Only)
E Series
2
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
Physical Data
UNIT LOCATION
Locate the unit in an indoor area that allows for easy removal of the filter and access panels.
Location should have enough space for service personnel to perform maintenance or repair. Provide
sufficient room to make water, electrical and duct connection(s). If the unit is located in a confined
space, such as a closet, provisions must be made for return air to freely enter the space by means of a
louvered door, etc. Any access panel screws that would be difficult to remove after the unit is installed
should be removed prior to setting the unit. On horizontal units, allow adequate room below the unit for
a condensate drain trap and do not locate the unit above supply piping. Care should be taken when
units are located in unconditioned spaces to prevent damage from frozen water lines and
excessive heat that could damage electrical components.
General
Installation
Information
MODEL E036 E048 E060 E072
Fan Wheel 11 X 10 11 X 10 11 X 10 11 X 10
Fan Motor ECM-1/2 ECM-1/2* ECM-1 ECM-1
Compressor
Air Coil:
Dimensions 28 x 25 32 x 25 36 x 25 36 x 25
Area (sq. ft.) 4.9 5.6 6.3 6.3
Rows 3 3 3 3
R410A (oz) 61.0 77.0 100.0 103.0
Weight (lbs) 320.0 336.0 399.0 426.0
Filter - 1"
Disposable
Electrostatic
Electronic
*Optional 1 hp ECM2 fan motor available
Bristol Twin Single
EAC3036
(1) 30 x 36
EAF3036
Horizontal Units
MODEL E036 E048 E060 E072
Fan Wheel 11 X 10 11 X 10 11 X 10 11 X 10
Fan Motor ECM-1/2 ECM-1/2* ECM-1 ECM-1
Compressor
Air Coil:
Dimensions 20 x 30 20 x 35 20 x 40 20 x 45
Area (sq. ft.) 4.9 4.9 5.6 6.3
Rows 3 3 3 3
R410A (oz) 58.0 81.0 97.0 103.0
Weight (lbs) 337.0 339.0 429.0 456.0
Filter-1" (1) 20 X 20
Disposable (1) 20 X 25 (2) 20 X25
Electrostatic EAF2042 EAF2048
Electronic EAC2042 EAC2048
*Optional 1 hp ECM2 fan motor available
Bristol Twin Single
(2) 20 X 20
EAF2037
EAC2037
Vertical Units
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
3
Vibration
Absorbing
Mesh
Air
Pad
Figure 1
– Vertical Unit Mounting
SETTING VERTICAL UNITS
Vertical units are available in left or right air
return configurations. Top flow vertical units should
be mounted level on a vibration absorbing pad
slightly larger than the base to provide isolation
between the unit and the floor. It is not necessary to
anchor the unit to the floor (see Figure 1). Bottom
flow units should be mounted level and sealed well
to floor to prevent air leakage.
NOTE:
If access to the left side of the unit will be limited after installation, remove the two mounting
screws on the left side of the control box before setting the unit (leave the two front mounting screws
intact). This will allow the control box to be removed with only the two front mounting screws for future
service.
SETTING HORIZONTAL UNITS
CAUTION:
Do not use rods smaller than 3/8” diameter since they may not be strong enough to
support the unit. The rods must be securely anchored to the ceiling.
Horizontal units are available with side or end discharge and may be field converted from one to
the other by replacing the discharge panel with a new panel which must be ordered separately.
Horizontal units are normally suspended from a ceiling by six 3/8” diameter threaded rods. The rods
are usually attached to the unit by hanger bracket kits furnished with each unit.
Lay out the threaded rods per the dimensions in Figure 2. Assemble the hangers to the unit as
shown. Securely tighten the brackets to the unit using the weld nuts located on the underside of
the bottom panel. When attaching the hanger rods to the bracket, a double nut is required since
vibration could loosen a single nut. The unit should be pitched approximately 1/4” towards the drain in
both directions to facilitate the removal of condensate. (see Figure 5A on page 6). Use only the bolts
provided in the kit. The use of longer bolts could damage internal parts.
Some residential applications require the installation of horizontal units on an attic floor. In this
case, the unit should be set in a full size secondary drain pan on top of a vibration absorbing mesh.
The secondary drain pan prevents possible condensate overflow or water leakage damage to the
ceiling. The secondary drain pan is usually placed on a plywood base isolated from the ceiling joists
by additional layers of vibration absorbing mesh.
Figure 2– Hanger Location and Assembly
C
B
D
E
Compressor
Section
Air Handler
Section
A
Vibration
Isolator
Washer
Hex Nuts
(not supplied)
Bolt and
Lockwasher
3/8”
Threaded Rod
(not supplied)
MODEL
CB
A
DE
E036, 048
E060
E072
27.8
27.8
27.8
29.9
29.9
29.9
70.5
75.5
80.5
72.0
77.0
82.0
25.5
25.5
25.5
4
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
DUCT SYSTEM
CAUTION:
Be sure to remove the shipping material from the blower discharge before connecting
ductwork.
An air outlet collar is provided on vertical top flow units and all horizontal units to facilitate a duct
connection (vertical bottom flow units have no collar). A flexible connector is recommended for
discharge and return air duct connections on metal duct systems. Uninsulated duct should be insulated
with a minimum of 1" duct insulation. Application of the unit to uninsulated ductwork in an unconditioned
space is not recommended as the unit’s performance will be adversely affected.
If the unit is connected to existing ductwork, check the duct system to ensure that it has the capacity
to accommodate the air required for the unit application. If the duct is too small, as in the replacement
of heating only systems, larger ductwork should be installed. All existing ductwork should be checked
for leaks and repaired if necessary.
The duct system should be sized to handle the design airflow quietly and efficiently. To maximize
sound attenuation of the unit blower, the supply and return plenums should include an internal
duct liner of fiberglass or constructed of ductboard for the first few feet. On systems employing
a sheet metal duct system, canvas connectors should be used between the unit and the
ductwork. If air noise or excessive airflow is a problem, the blower speed can be changed (see the
Blower Speed and Blower Performance sections on page 19).
WATER PIPING
The proper water flow must be provided to each unit whenever the unit operates. To assure proper
flow, use pressure/temperature ports to determine the flow rate. These ports should be located adjacent
to the supply and return water connections on the unit. The proper flow rate cannot be accurately set
without measuring the water pressure drop through the refrigerant-to-water heat exchanger. (See Table
2 on page 21 for water flow and pressure drop information.)
All source water connections are swivel piping fittings that accept a 1" male pipe thread (MPT) (see
Figure 4A). The swivel connector has a rubber gasket seal similar to a rubber hose gasket, which when
mated to the flush end of any 1" threaded pipe provides a leak-free seal without the need for thread
sealing tape or compound. Check to ensure that the rubber seal is in the
swivel connector prior to attempting any connection. The rubber seals are shipped attached to the
waterline.
To make the connection to a ground loop system, mate the brass connector (supplied in CK4L and
CK4S connector kits) against the rubber gasket in the swivel connector and thread the female locking
ring onto the pipe threads, while maintaining the brass connector in the desired direction (see Figure
4B). Tighten the connectors by hand, then gently snug the fitting with pliers to provide a leak-proof joint.
When connecting to an open loop (groundwater) system, thread any 1" MPT fitting (PVC or copper) into
the swivel connector and tighten in the same manner as noted above.
The open and closed loop piping system should include pressure/temperature taps
for serviceability.
Never use flexible hoses smaller than 1" inside diameter on the unit. Limit hose length to
10 ft. per connection. Check carefully for water leaks.
Figure 3– Optional Filter Rack
Door side mountable
on either end
E
C
A
D
B
Horizontal Filter Rack
1" duct connection is provided.
Construction is air tight.
MODEL
CB
A
DEModel No.
37.1
42.1
47.1
5.5
5.5
5.5
DCH2037
DCH2042
DCH2048
20.1
20.1
20.1
0.6
0.6
0.6
2.2
2.2
2.2
E036, 048
E060
E072
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
5
WATER QUALITY
The unit may be ordered with either a copper or a cupronickel coaxial heat exchanger. Copper is
adequate for closed loop and open loop groundwater systems which are not high in mineral content. In
conditions anticipating moderate scale formation or in brackish water, a cupronickel heat exchanger is
recommended. In groundwater situations where scaling
could be heavy or where biological growth such as iron bacteria will be present, a closed loop system
is recommended.
The heat exchanger coils in groundwater systems may, over a period of time, lose heat exchange
capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a
qualified service mechanic, as special solutions and pumping equipment are required. Desuperheater
coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the
owner should be informed that the heat exchanger may require occasional flushing.
FREEZE PROTECTION
Set the freeze protection switch SW2-2 on the printed circuit board for applications using a
closed loop antifreeze solution to "LOOP". On applications using an open loop/groundwater system,
(or closed loop no antifreeze) set this dip switch to "WELL" (the factory setting). (See schematics on
pages 14 and 15.)
CONDENSATE DRAIN
On vertical units, the internal condensate drain assembly consists of a drain tube which is con-
nected to the drain pan, a 3/4" PVC female adapter and a flexible connecting hose. The female adapter
may exit either the front or the side of the cabinet. The adapter should be glued to the field-installed
PVC condensate piping. On vertical units, a condensate hose is inside all cabinets as a trapping loop;
therefore, an external trap is not necessary. On horizontal units, a copper stub is provided for conden-
sate drain piping connection. An external trap is required (see Figure 5B). If a vent is necessary, an
open stand pipe may be applied to a tee in the field-installed condensate piping.
Locking
Ring
Stainless
Steel
Snap Ring
Gasket
Support
Sleeve
Gasket
Material
Figure 4B - The female
locking ring is threaded
onto the pipe threads which
hold the male pipe end
against the gasket and seals
the joint.
Figure 4A
6
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
GROUND SOURCE SYSTEMS
NOTE:
For closed loop systems with antifreeze protection, set SW2-2 to the "LOOP" position.
(See schematics on pages 14 and 15.)
Once piping is completed between the unit, flow center and the ground loop (see Figure 6 on
page 7), final purging and charging of the loop is required. A WaterFurnace flush cart (or a 1.5 HP
pump minimum) is needed to achieve adequate flow velocity in the loop to purge air and dirt particles
from the loop itself. Antifreeze solution is used in most areas to prevent freezing. Flush the system
adequately to remove as much air as possible then pressurize the loop to a static pressure of 40-50 psi
(summer) or 50-75 psi (winter). This is normally adequate for good system operation. Loop static
pressure will fluctuate with the seasons. Pressures will be higher in the winter months than during the
cooling season. This fluctuation is normal and should be considered when initially charging the system.
After pressurization, be sure to remove the plug in the end of the loop pump motor(s) (if applicable)
to allow trapped air to be discharged and to ensure that the motor housing has been flooded. Ensure
that the loop flow center provides adequate flow through the unit by checkingthe pressure drop across
the heat exchanger and comparing it to the figures shown in Table 2 on page 21. Usually 2.5 to 3 gpm
of flow per ton of cooling capacity is recommended in earth loop applications. (See Figure 13 on
page 13 for loop pump power wiring details.)
MULTIPLE UNITS ON ONE FLOW CENTER
When two Premier E units are connected to one loop pumping system, pump control is
automatically achieved by connecting the slave terminals on connector P2 in both units with 2-wire
thermostat wire. These terminals are polarity dependant (see Figure 7 on page 7). The loop pump(s)
may be powered from either Premier unit, whichever is more convenient. If either unit calls, the loop
pump(s) will automatically start. The use of two units on one flow center is generally limited to a total of
20 gpm capacity.
Closed Loop
Ground Source
Systems
Figure 5A - Unit Pitch for Drain
1/4'' Pitch
Drain
Figure 5B - Horizontal Drain Connection
1.5"
1.5"
Vent (if needed)
3/4" PVC
3/4" barb to
glue adapter *
1/8" per foot
Clear PVC hose
Plastic Hose Clamps
Copper tube stub
(Included with unit)
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
7
Figure 6 - Closed Loop: Ground Source Application - Single unit with Flow Center
Flexible Duct
Collar
Vibration Absorbing Pad
P/T Plugs
Drain
TO
LOOP
Desuperheater
Connections
Auxiliary
Heater
Knockout
Low
Voltage to
Thermostat
External
Pump Power
Unit Supply
Auxiliary Heat
Supply
* For complete
Geolink
®
Flow
Center installation
information refer
to WF P/N
96P090A04
GeoLink
®
Flow
Center*
WF Ground Loop Connector
Kits with Armaflex
®
(CK4S or CK4L)
GeoLink
®
Polyethylene w/
Armaflex
®
Insulation
Disconnects
(If Applicable)
Unit Power
Figure 7 - Premier Slave Hook-up
Pump slaving connection for multiple units sharing one flow center
Shut
Down
CC
SL2
In
SL2
Out
Shut
Down
CC
SL1
In
SL1
Out
SL2
In
SL2
Out
SL1
In
SL1
Out
Premier E Unit #1
Premier E Unit #2
With pump
wired to Unit 1
With pump
wired to
Unit 2
Premier E to Premier E
Microprocessor Units
Premier E to
Electromechanical Unit
Shut
Down
CC
SL2
In
SL2
Out
SL1
In
SL1
Out
Premier E Unit #1
To Electromechanical Unit
C
S
8
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
OPEN LOOP SYSTEMS
NOTE:
For open loop/groundwater systems or systems that do not contain an antifreeze solution,
set SW2-Switch #2 to the “WELL” position,
(See schematic on pages 14 and 15).
Typical open loop piping is shown in Figure 8. Always maintain water pressure in the heat
exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation.
Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. Insure
proper water flow through the unit by checking pressure drop across the heat exchanger and
comparing it to the figures in Table 2 on page 21. Usually 1.5-2 gpm of flow per ton of cooling
capacity is recommended in open loop applications. In dual capacity units, stage 1 is half of the total
tonnage. Therefore, on a E048, the stage 1 solenoid should flow 3-6 gpm and stage 1 & 2 together
should flow 6-9 gpm.
Discharge water from the unit is not contaminated in any manner and can be disposed of in
various ways, depending on local building codes, i.e. recharge well, storm sewer, drain field, adjacent
stream or pond, etc. Most local codes forbid the use of sanitary sewer for disposal. Consult your
local building and zoning department to assure compliance in your area.
Open Loop
Groundwater
Systems
Figure 8 - Open System: Groundwater Application
Flexible
Duct Collar
Vibration
Absorbing Pad
P/T Plugs
Drain
Desuperheater
Connections
Auxiliary
Heater
Knockout
Low Voltage
to Thermostat
and Valve
Unit Supply
Auxiliary Heat Supply
Water Out
Water In
Shut Off
Valves
Boiler Drains
For HX Flushing
Solenoid Valve
(two should be used
in parallel.)
Flow
Regulator
Disconnects
(If Applicable)
Unit
Power
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
9
Figure 9 - Open loop solenoid valve connections
Typical two stage external 24V water
valve utilizing one motorized valve
( type VM) and one pilot operated
solenoid valve (BPV100 or PPV100)
1
CC
CCHI
Premier E series
Dual Capacity Logic
Board
CC GND
CCLO
Wh
Red
SV2
Stage 2 BPV100 or
PPV100 solenoid valve
3
CCH
CCL
Blk
Blk
2
Remove
Typical Two Stage external 24V
water solenoid valves (type PPV100
or BPV100) wiring
CC
CCHI
CCH
CCL
Blk
Premier E series
Dual Capacity
Logic Board
CC GND
CCLO
SV1
Wh
Red
Stage 2
solenoid valve
SV2
Blk
Blk
10
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
WATER TANK PREPARATION
A family of four should have a water heater with a minimum 50-gallon capacity. For families of
more than four, use an 80-gallon water heater or two 50-gallon water heaters connected in a series as
shown in Figure 12 on page 11. Electric water heaters are recommended.
CAUTION:
Elements will burn out if energized dry.
1) Turn off the power to the water heater.
2) Attach a water hose to the water tank drain connection and run the other end of the hose to an
open drain or outdoors.
3) Close the cold water inlet valve to the water heater tank.
4) Drain the tank by opening the valve on the bottom of the tank, then open the pressure relief valve
or hot water faucet.
5) Flush the tank by opening the cold water inlet valve to the water heater to free the tank of
sediments. Close when draining water is clear.
6) Disconnect the garden hose and remove the drain valve from the water heater.
Figure 10 - Water Heater Connection Kit
Boiler Drain
Brass Tee
Brass Nipple
Male Adapter
Desuperheater
Connection
12
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
WATER TANK REFILL
1) Close the drain valve to the water heater.
2) Open the cold water supply to the tank.
3) Open the hot water faucet in the house to bleed air from the system. Close when full.
4) Depress the handle on the pressure relief valve to bleed any remaining air from the tank
then close.
5) If so equipped, unscrew the indicator plug on the motor end of the pump (located in the Premier E
unit) until all air is purged from the pump, then tighten the plug. Use vent couplings to bleed air
from the lines.
6) Carefully inspect all plumbing for water leaks and correct as required.
7) Before restoring electrical supply to the water heater, adjust the temperature setting on
the tank.
• On tanks with both upper and lower elements, the lower element should be turned down to
the lowest setting, approximately 100°F. The upper element should be adjusted to 120°F to
130°F. Depending upon the specific needs of the customer, you may want to adjust the
upper element differently.
• On tanks with a single element, lower the thermostat setting to 120°F.
8) After thermostat(s) is adjusted, replace the access cover and restore electrical supply to the water
heater.
DESUPERHEATER START UP
CAUTION:
Never operate the DHW circulating pump while dry.
1) Make sure that any valves in the desuperheater water circulating circuit are open.
2) Turn on the Premier E unit to first stage heating.
3) The DHW pump should be running. Be sure the disable switch for the DHW pump (SW4) is ON.
The DHW OFF LED on the unit should not be illuminated.
4) The temperature difference between the water entering and leaving the desuperheater should be
5°F to 15°F. The water flow should be approximately 0.4 gpm per ton of nominal cooling.
5) Allow the unit to heat water for 15 to 20 minutes to be sure operation is normal.
6) When the pump is first started, open the inspection port (if equipped) until water dribbles out, then
replace. Allow the pump to run for at least five minutes to ensure that water has filled the circula-
tor properly.
DESUPERHEATER NOTE
When servicing a unit’s refrigeration circuit, it is always good practice to disable the desuperheater
pump. This can be accomplished by using the DHW pump disable switch located on the front of the
unit cabinet near the LED annunciator panel. The red DHW OFF LED will illuminate, indicating the
DHW pump is disabled.
NOTE:
Do not run DHW pump while dry. If the unit is placed in operation before the desuperheater
piping is connected, be sure that the pump switch is set to the OFF position.
GENERAL
Be sure the available power is the same voltage and phase as that shown on the unit serial plate.
Line and low voltage wiring must be done in accordance with local codes or the National Electric Code,
whichever is applicable.
Initial
Desuperheater
Start Up
Electrical
Connections
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
13
Figure 13 - Premier E Line Voltage 208-230/60/1 Control Box
ACCESSORY RELAY
A set of "dry" contacts has been provided to control accessory devices, such as water solenoid
valves on open loop installations, electronic air cleaners, humidifiers, etc. This relay contact should
be used only with 24 volt signals and not line voltage power. The relay has both normally open
and normally closed contacts and can operate with either the fan or the compressor. Use DIP switch
SW2-3 to cycle the relay with fan or compressor. The relay contacts are available on terminals #2 and
#3 of P3. (See the wiring schematic on pages 14-15 for details).
208 VOLT OPERATION
All Premier E units are factory wired for 230 volt operation. There is a switch located on the control
box, which allows the installer to select 208 volt unit operation. (Refer to Figure 13 on page 13 for
switch location).
UNIT POWER CONNECTION
Connect the incoming line voltage wires to L1
and L2 of the contactor as shown in Figure 13
below. Consult the Unit Electrical Data section on page 16 for correct fuse size.
EXTERNAL LOOP PUMP POWER CONNECTION
If the unit is to be used with an external loop pump (FC1 or FC2 flow center), the pump(s) will be
connected to the terminals on PB1 in the unit electrical box as shown in Figure 10 below. The pumps
will automatically be cycled as required by the unit or by a slave signal from another Premier E unit
sharing the flow center (see Figure 7 on page 7).
CCL
TRANSFORMER
SWITCH
L2
L1
RUN CAPACITOR
START RELAY
START
CAPACITOR
B
C
1
2
3
1
2
PS
CCH
L2
L1
208-230/60/1
Service with
Ground
External Loop
Pump(s)
208-230/60/1
1/2 HP Max
TRANSFORMER
14
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
Premier E Series Bristol Dual Capacity Wiring Schematic
208-230/60/1 - ECM2 Blower
97P644B01 01/18/01 Part 1 of 2
Transformer
NOTE 1
HWL
240V L1
HP
Thermostat
CO
R
C
Y1
L1
Y2
240V L2
G
LP
Premier E
Microprocessor
Logic Control
(DC Voltage)
Fused L2
R
C
NO
CR2
COM
NO
NC
CR4
COM
F1-10A
240V
Fused L2
NO
CR1
COM
RV
FP
W
Orange
Orange
Yellow
Yellow
Pink
Orange
White
Tan
Blue
Not Used
Not Used
P3
On
SW1
On
SW3
Not Used
Brown
1 Test / Norm
2 Loop / Well
3 Fan / Comp
4 Dehum/Norm
5 No Htg3 / Htg3
6 Inputs / Norm
7 Outputs / Norm
8 24 VAC / TA32E12
Dual Cap/1 Speed
ECM2
Air Flow
Settings
NO
NC
CR3
COM
Tan
Tan
ECM / ECM2
No RPM / RPM
EH (See Note 8)
Future Use
NOTE 9
Red
Black
Blue
Blue
Pink
Pink
Black
P4
123
G
W
O
R
C
Y1
Y2
LO
F1-10A
240V
14
5
13
4
P5
12
1
2
9
10
3
4
9
11
2
10
8
1
12
5
14
13
6
7
7
6
15
11
Fused L1
1
2
3
4
5
6
P10
NOTE 7
Factory
Setup
24V
Not Used
Not Used
16
8
Not Used
Transformer
Switch
NOTE 1
240V
208V
ECM2
Fan Motor
P11
15 101638
On/Off
PWM
RPM
C2
RPM gnd
234
5
1
PS
D
C
A
NOTE 2
Optional
Remote Unit
Without
Loop Pump
NOTE 3
Blk/Wh
Blk
Or
Blu
Red
240V
208V
Orange
Brown
Green
Blk/Wh
Yel
Blu
Yel
Gray
Vio
Black
CCH
Wh
CCL
Blk
Red
Blk
CCHI
CCLO
CC
CC-GND
O
1
2
3
4
5
6
7
8
C
SL1 In
SL1 Out
1
2
3
4
5
6
7
C
P2
Down
C
Shut
SL1 In
SL1 Out
1
2
3
Acc Com
Acc NC
Acc NO
Status LED PCB
17P503A01 Rev A
R
R
R
R
R
G
Y
R
1
2
3
4
5
Black
Violet
Yellow
Blue
Gray
T
T
Brn
Premier E Series
Main Logic PCB
17P513A05
Not
Used
NOTE 6
240V L2
2
3
1
Stage 1
Stage 2
Ext Pump
1/2 hp Total
208-230/60/1
Pump
Pump
G
Blk/Wh
NOTE 4
L1
Gray/Wh
L2
PB
BRISTOL DUAL CAPACITY
HIGH CAPACITY
Violet
Tan
Black
Red
Blue
Tan
COMP
CAPACITOR
T1
CCH
White
2
5
1
SR
1
2
START
CAPACITOR
Tan
LOW
CAPACITY
L1
T1
CCL
Protector
C
S
R
Start
Main
Blue
White
Blue
L1
Unit Power
208-230/60/1
G
DHW
Pump
Pink
3
11
17P547A01
L1
L1
L2
Field Selection Dips - #1 On, #6 On, #7 On
Drain Pan Overflow Lockout
FP Thermistor Loop <15° F Lockout
High Pressure > 600 PSI Lockout
ECM2 RPM < 100 rpm Lockout
Microprocessor Malfunction*
HWL Thermistor > 130° F
DHW Pump Switch Off
Drain
Air Flow
Status
DHW Off
LED Normal Display Mode
#1 Off, #6 On, #7 On
Drain Pan Overflow
Low Pressure <40 PSI Lockout
ECM2 RPM <100 rpm
Not used
HWL Thermistor > 130° F
DHW Pump Switch Off
Current Fault Status
#6 Off, #7 On
Y1
Y2
O
G
W
SL1
SL2
--
Inputs
#6 On, #7 Off
Compressor Low
RV
FAN
Loop Pump 1
Loop Pump 2
--
Outputs #1
#6 Off, #7 Off
Blower LO
Blower Med
Blower Hi
Aux Heat #1
Aux Heat #2
AuxHeat #3
Aux Heat #4
--
Outputs #2
Diagnostic Modes
DHW Limit
Low Press
High Press
Water Flow
High Pressure > 600 PSI lockout
Compressor High
DHW Pump
FP Thermistor (Loop <15° F, well <30° F
Low Pressure < 40 PSI Lockout
On
SW2
1
2
3
4
5
6
7
8
9
10
11
12
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
15
Premier E Series Bristol Dual Capacity Wiring Schematic
208-230/60/1- ECM2 Blower
97P644B01 01/18/01 Part 2 of 2
L1
L2
Single Disconnect Power
208-230/60/1
Aux Elect Power
208-230/60/1
AT Unit Power
208-230/60/1
CSA installed units only
Local codes may require a single
source of power supply
Breaker box
furnished by
installer
L1
L2
L1 L2
Circuit Breakers
Notes:
1 - Place switch in 208V position to
operate the unit at 208V.
2 - Connection of remote unit that does
not have a loop pump for slave
operation.
3 - 24V Accessory relay (see SW2 - 3 for
description of operation).
4 - The blk/wh and gray/wh wires are
removed when Aux Heat is installed
ECM2 Only).
5 - Buss lugs L1 and L2 can be removed
and dual power wire sets connected
directly to box lugs L1, L2, and L3, L4.
6 - DHW pump only in models with hot
water generation option.
7 - Air Flow Configuration Example: SW1
configured for dip 1 as low, dip 3 as
medium, and dip 5 as high speed
ECM2 fan.
8 - SW3-4 should be in the “ON” position
when using Premier E Electric Heat
control 17P514A01, and it should be
in the “OFF” position when using
Premier E Electric Heat control
17P501A01.
9 - When using thermostat TA32E12,
SW2 -8 should be in the "ON"
position.When using 24VAC
thermostats. SW2-8 should be in the
"OFF" position.
Premier E Series Logic Board 17P513A05 Physical Layout
OnOff
SW1
240V - L2
240V - L1
Fused L2
Fused L2
Fused L2
F1
F1
R
R
240V - L2
240V - L1
C
C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
P6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
P5
Fused L2
Fused L1
CC
CC-GND
CCLO
CCHI
OnOff
SW2
OnOff
SW3
N.O.
CR4-
Com
N.O.
CR3-
Com
N.C.
CR2- Loop
Pump
N.O.
CR1- DHW
Pump
N.O.
Microprocessor
17P547A01
P4
12
3
123
P3
ACC
NC
ACC
COM
ACC
NO
P1
12345678
RCY1Y2 GOWL
234 5
P2
671
Shut
Down
C
C
IN Out IN
SL2
Out
SL1
SL1
SL2
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
1
2
3
4
5
Thermistor
Light emitting diode - Green
Relay coil
Capacitor w/ bleed resistor
Switch - Condensate overflow
Switch - High pressure
Switch - Low pressure
Switch -Hot Water On/Off
Polarized connector
Factory Low voltage
Factory Line voltage wiring
Field low voltage wiring
Field line voltage
Optional block
DC Voltage PCB traces
Internal junction
Quick connect terminal
Wire nut
Field wire lug
Ground
Fuse
CC -
CO -
CR1 -
CR2-
CR3 -
CR4 -
F1 and F2 -
FP -
HE -
HP -
LP -
PB1, PB2 -
PS -
RV -
SW2 -
SW3 -
SW4 -
TS -
Compressor Contactor
Condensate overflow sensor
DHW pump relay
Loop pump relay
Fuses
Freeze protection sensor
Heater element
High pressure switch
Low pressure switch
Power blocks
Power strip
Reversing Valve coil
DIP package 12 position
DIP package 8 position
DIP package 5 position
Hot water pump enable switch
Thermal limit switch
Legend
Relay Contacts-
N.O., N.C.
G
T
PSC Fan Speed Relay
PSC Fan Power Relay
ER1 to ER4 -
Aux heat stage relays
HWL - Hot water limit sensor
2 3 1
P
L1
SW1
ECM2
Fan Motor
P11
23451
PB2
Auxiliary Electric Heat Power
208-230/60/1
2
3
HE1
TS1
HE2
TS2
HE3
TS3
HE4
TS4
P7
L4 L2
L2
NOTE 5
Yel
F2
P9
ER1
ER2
ER3
ER4
L1
L1 L3
NO
NO
NO
NO
5
4
On/Off
PWM
RPM
C2
RPM grnd
P12
Premier
EA Series PCB
17P514A01
1
123
P10
456
P2
1
15 101638
G G
4
3
2
1
P8
1
2
3
4
Brn
Grn
Blu
Violet
Or
Or
Brn
Gray
Blk
Yel
Pink
Gray
Blk
Yel
Pink
Gray
Pink
Gray
Blk
Yel
Pink
Gray
Blk
Pink
Blk
Yel
Gray
Blk
Pink
Yel
Grn
Black
Violet
Yellow
Blue
Gray
Orange
Blue
Pink
White
Tan
Red
16
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
Microprocessor
Control Operation
Unit Electrical
Data
INSTALLATION
Position the thermostat subbase against the
wall so that it is level and the thermostat wires
protrude through the middle of the subbase.
Mark the position of the subbase mounting
holes and drill holes with a 3/16" bit. Install
supplied anchors and secure base to the wall.
Thermostat wire must be 8-conductor 18 AWG
wire. Strip the wires back 1/4" (longer strip
lengths may cause shorts) and insert the
thermostat wires into the Premier E connector
as shown in Figure 14. Tighten the screws to
insure tight connections. The thermostat has
the same type connectors, requiring the same wiring. See instructions enclosed in the thermostat for
detailed installation and operation information.
NOTE:
DIP switch SW2-#8 is required to be in the OFF position for the Premier E control to
recognize the 24VAC thermostat inputs. SW2-#8 must be ON when using the TA32E12
thermostat. The second stage compressor wire must be installed between the unit and the thermostat
for proper control operation.
HEATING OPERATION
Heat, 1st Stage (Y1)
The fan motor is started on low speed immediately; the first loop pump is energized 5 seconds
after the “Y1” input is received, and the compressor is energized on low capacity 10 seconds after the
“Y1” input; The fan is switched to medium speed 15 seconds after “Y1” input and the hot water pump
is cycled 30 seconds after the “Y1” input.
Heat, 2nd Stage (Y1,Y2)
The compressor is de-energized immediately; the second loop pump is energized 5 seconds after
the “Y2” input; and the hot water pump is cycled 30 seconds after the “Y2” input. The fan changes to
high speed 45 seconds after the “Y2” input and the compressor is energized on high capacity 60
seconds after the “Y2” input.
Heat, 3rd Stage (Y1,Y2,W)
The hot water pump is de-energized which directs all heat to satisfy the thermostat. The first stage
of resistance heat is energized 10 seconds after “W” input, and with continuous 3rd-stage demand, the
additional stages of resistance heat engage sequentially every 5 minutes.
Electronic
Thermostat
R
Y1
C
W
O
G
L1
24VAC
(Hot)
24VAC
(Common)
Compressor
(1
st
Stage)
Aux. Heat
Reversing
Valve
Blower
Relay
System
Monitor
Microprocessor Controller
Thermostat Connection
Y2
Compressor
(2
nd
Stage)
Figure 14 - Thermostat Wiring
Compressor Fan Total Min. Residential*
Model Rated Voltage Motor Unit Circuit
Max. Max. HACR
Voltage Min./Max. MCC RLA LRA FLA FLA (Res.) Amp.(Res.) Fuse Breaker
E036 208-230/60/1 197/254 19.5 12.5 66.0 4.0 22.3 25.4 35 35
E048 208-230/60/1 197/254 28.0 17.9 96.0 4.0 27.7 32.2 50 50
E048** 208-230/60/1 197/254 28.0 17.9 96.0 7.0 30.7 35.2 50 50
E060 208-230/60/1 197/254 38.5 24.7 130.0 7.0 37.5 43.6 60 60
E072 208-230/60/1 197/254 41.0 26.3 130.0 7.0 39.1 45.7 70 70
*Includes 5.4 amperage allowance for source side loop pump (up to 1/2 H.P.) and 0.4 amperage allowance for
desuperheater circulating pump operation.
Always refer to unit nameplate data prior to installation.
HACR circuit breaker in United States only. All fuses are class RK-5.
**With optional 1 HP ECM2 Motor.
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
17
Emergency Heat (W only)
The fan is started on high speed and the first stage of resistance heat is energized 10 seconds
after the “W” input. Continuing demand will engage the additional stages of resistance heat sequen-
tially every 2 minutes.
COOLING OPERATION
In all cooling operations, the reversing valve directly tracks the “O” input, thus any time the “O”
input is present, the reversing valve will be energized.
Cool, 1st Stage (Y1,O)
The fan motor is started on low speed immediately; the first loop pump is energized 5 seconds
after the “Y1” input is received; and the compressor is energized on low capacity 10 seconds after the
“Y1” input. The fan is switched to medium speed 15 seconds after “Y1” input (85% of medium fan
speed if in dehumidification mode) and the hot water pump is cycled 30 seconds after the “Y1” input.
Cool, 2nd Stage (Y1,Y2,O)
The compressor is de-energized immediately, the second loop pump is energized 5 seconds after
the “Y2” input, and the hot water pump is cycled 30 seconds after the “Y2” input. The fan changes to
high speed (85% of high fan speed if in dehumidification mode) 45 seconds after the “Y2” input and
the compressor is energized on high capacity 60 seconds after the “Y2” input.
FAN (G ONLY)
The fan starts on low speed. Regardless of fan input “G” from thermostat, the fan will remain on
low speed for 30 seconds at the end of each heating, cooling or emergency heat cycle.
LOCKOUT CONDITIONS
During lockout mode, the appropriate unit and thermostat lockout LEDs will illuminate. The
compressor, loop pumps, hot water pump and accessory outputs are de-energized. Unless the
lockout is caused by an ECM2 low RPM fault, the fan will continue to run on low speed, and if the
thermostat calls for heating 2nd or 3rd stage, emergency heat operation will occur.
Lockout modes of any kind can be reset at the thermostat by turning the mode switch “OFF” for
five seconds then back to desired modes, which restores normal operation but keeps the unit lockout
LED illuminated. Interruption of power to the unit will reset a lockout without a waiting period and
clear all lockout LEDs.
High Pressure
This lockout mode occurs when the normally closed safety switch is opened momentarily.
Low Pressure
This lockout mode occurs when the normally closed switch is opened for 30 continuous seconds.
Freeze Protection (Water Flow)
This lockout mode occurs when the freeze thermistor temperature is at or below the selected
freeze protection point (well-30°F or loop-15°F) for 30 continuous seconds.
Condensate Overflow
This lockout mode occurs when the condensate overflow level has been reached for 30 continu-
ous seconds.
Fan RPM
The Premier E control board monitors fan RPM to sense if the fan is not operating. This lockout
mode occurs if the fan RPM falls below the low RPM limit (100 RPM) for 30 continuous seconds.
18
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
AIRFLOW SELECTION DIP SWITCHES (SW1)
See Fan Speed section on page 19.
FIELD SELECTION DIP SWITCHES (SW2)
An “8” position dip switch package on the Premier E control allows the following field
selectable options:
1-Service test mode
This dip switch on the control allows field selection of “normal” or “test” operational modes. The
Test mode accelerates most timing functions 16 times to allow faster troubleshooting.
Test mode also allows viewing the “current” status of the fault inputs on the LED display.
2-Freeze Protection Setting
This dip switch allows field selection of freeze thermistor fault sensing temperatures for well water
or antifreeze-protected earth loops.
3-Accessory Relay
This dip switch allows field selection of the accessory relay to operate with the compressor
or fan.
4-Fan speed control
This DIP switch allows field selection of reduced (85% of selected medium and high speed) for
cooling in the dehumidification mode.
5-Auxiliary Off
This dip switch disables heating 3rd-stage. Full emergency heat would in any event still be
available if needed.
6-Diagnostics-Inputs
This dip switch allows viewing the inputs from the thermostat to the control board such as Y1, Y2,
O, G, W, SL1-In, SL2-In on the LED display.
7-Diagnostics-Outputs
This dip switch allows viewing the outputs from the control board such as compressor speed,
reversing valve, blower, hot water pump, and loop pumps on the LED display.
8-Thermostat Selection
This dip switch allows field selection as to what type of thermostat is being connected to the
Premier E control. If using a TA32E12, the dip switch must be in the “ON” position. The dip switch
should be in the “OFF” position for all 24VAC thermostats.
FACTORY SETUP DIP SWITCHES (SW3)
A “5” position dip switch package on the Premier E control allows the following factory setup
options:
1-Dual Capacity / Single Speed
This dip switch on the control configures the control for Single Speed compressor operation or
Dual Capacity compressor operation.
2-ECM / ECM2
This dip switch configures the control to operate with the ECM2 blower motor.
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
19
3-No RPM / RPM
This dip switch configures the control to monitor the RPM output of an ECM/ECM2 blower motor.
4-AT EH board / Premier EH board
This dip switch configures the control to operate with the Premier Electric Heat control board
(6 position connector) or with the Premier Electric Heat control board (3 position connector).
5-Future Use.
ECM2 fan motors have a 12-speed selector dip switch on the Premier E logic board (SW1)
and are factory set for optimum performance. To change speeds, select the appropriate speeds
on dip switch SW1. Consult the ECM2 fan performance table below for specific airflow and switch
information.
Blower Speed
ECM Fan
Performance
Data
MODEL
MAX AIR FLOW DIP SWITCH SETTINGS
ESP 123456789101112
E036 0.50 600 700 800 900 1000 1100 1200 1300 1400 1500 1550 1600
L MH
E048 0.50 600 700 800 900 1000 1100 1200 1300 1400 1500 1550 1600
L MH
E048 0.75 750 900 1000 1200 1400 1600 1700 1850 2000 2200 2300 2400
w/1 hp* L MH
E060 0.75 750 900 1000 1200 1400 1600 1700 1850 2000 2200 2300 2400
L MH
E072
0.75 750 900 1000 1200 1400 1600 1700 1850 2000 2200 2300 2400
L MH
Factory settings are at recommended L-M-H DIP switch locations CFM is controlled within ± 5% up to the maximum ESP
M-H settings must be located within boldface CFM range Max ESP includes allowance for wet coil and standard filter
* With optional one horsepower fan motor Lowest and highest dip switch setting are assumed to be L and
H speed, respectively
A 12 position DIP switch package on the Premier E control allows the airflow levels to be
set for Low, Medium, and High speed when using the ECM2 blower motor.
Only three of the DIP switches can be in the “ON” position. The first “ON” switch
(the lowest position number) determines the “Low Speed Fan” setting. The second “ON”
switch determines the “Medium Speed Fan” setting, and the third “ON” switch determines
the “High Speed Fan” setting.
The example to the right shows SW1 on the Premier E control board configured for the
following E036 airflow settings:
Low Speed Fan: 600 CFM
Medium Speed Fan: 800 CFM
High Speed Fan: 1200 CFM
1
2
3
4
5
6
7
8
9
10
11
12
SW1 On
20
PREMIER E SERIES DUAL CAPACITY INSTALLATION AND MAINTENANCE MANUAL
BEFORE POWERING UNIT, CHECK THE FOLLOWING:
❏ High voltage is correct and matches nameplate
❏ Fuses, breakers and wire size correct
❏ Low voltage wiring complete
❏ Piping completed and water system cleaned and flushed
❏ Air is purged from closed loop system
❏ Isolation valves are open, water control valves or loop pumps wired
❏ Condensate line open and correctly pitched
❏ Transformer switched to 208V if applicable
❏ Black/white and gray/white wires in unit control box have been removed if auxiliary heat has been
installed
❏ Dip switches set correctly
❏ DHW pump switch off unless piping is completed and air has been purged
❏ Blower rotates freely - foam shipping support has been removed
❏ Blower speed correct (dip switch set correctly)
❏ Air filter cleaner is clean and in position
❏ Service/access panels are in place
❏ Return air temperature is between 50-80°F in heating and 60-95°F in cooling
❏ Check air coil cleanliness to insure optimum performance. Clean as needed according to
maintenance guidelines. To obtain maximum performance the air coil should be cleaned before
start-up. A 10 percent solution of dishwasher detergent and water is recommended
for both sides of coil, a thorough water rinse should follow.
START-UP STEPS:
NOTE:
Complete the Equipment Start-Up/Commissioning Check Sheet (WFS147) during this proce-
dure. Refer to thermostat operating instructions and complete the start-up procedure.
1) Initiate a control signal to energize the blower motor. Check blower operation.
2) Initiate a control signal to place the unit in the cooling mode. Cooling setpoint must be set
below room temperature.
3 First stage cooling will energize after a time delay.
4) Be sure that the compressor and water control valve or loop pumps are activated.
5 Verify that the water flow rate is correct by measuring the pressure drop through the heat
exchanger using the P/T plugs and comparing to water pressure drop found on Table 2
on page 21.
6) Check the temperature of both the supply and discharge water. (Refer to Table 1 on page 21.)
7) Check for an air temperature drop of 15 to 25 degrees Fahrenheit across the air coil,
depending on the fan speed and entering water temperature.
8) Decrease the cooling set point several degrees and verify high-speed blower operation.
Verify that the compressor switches to high-capacity operation after a one-minute time delay.
9) Adjust the cooling setpoint above the room temperature and verify that the compressor and
water valve or loop pumps deactivate.
10) Initiate a control signal to place the unit in the heating mode. Heating setpoint must be set
above room temperature.
11) First stage heating will energize after a time delay.
12) Check the temperature of both the supply and discharge water. (Refer to Table 1 on
page 21.)
13) Check for an air temperature rise of 20 to 35 degrees Fahrenheit across the air coil,
depending on the fan speed and entering water temperature.
14) Increase the heating set point 2-3 degrees above current room temperature and verify that
the compressor switches to high-capacity operation after a one-minute time delay.
Unit Start Up
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Premier E060 Installation and Maintenance Manual
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