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2
ES SPLIT INSTALLATION MANUAL
Model Nomenclature
Family
ES=ESeriesSplit
Unit Capacity
024 MBTUH 048 MBTUH
030 MBTUH 060 MBTUH
036 MBTUH 072 MBTUH
Control Option
S = Standard Controls
Voltage
1 = 208-230/60/1
Loop Pump Options
A = Standard Loop Connections
Coax Options
N = Cupronickel
Sound Kit
A = None
B = Blanket
Non-Standard Option Details
S=Standard
A-R, T-Z Non-standard Options
Vintage
A = 024-030
B = 036-072
ES 036 S 1 A N B SS A
3
ES SPLIT INSTALLATION MANUAL
Table of Contents
General Installation Information 4-5
Water Piping 6-8
Heat Recovery Unit 9
Electrical 10-11
Wiring Schematics 12-13
DIP Switch Settings 14
Refrigeration 15-16
Unit Startup 17
Modes of Operation 18-19
Checking Superheat and Subcooling 20-22
Pressure Drop and Recommended Flow Rates 23
Service 24-25
Pressure/Temperature Conversion Chart 26
Preventive Maintenance 27
Replacement Procedures 27
4
ES SPLIT INSTALLATION MANUAL
Moving and Storage
Move units in the normal “up” orientation. Do not stack more than three units in total height. When the equipment is
received, all items should be carefully checked against the bill of lading to be sure that all crates and cartons have been
received. Examine units from the cartons if necessary. Units in question should also be internally inspected. If any damage
is noted, the carrier should make the proper notation on the delivery receipt, acknowledging the damage.
General Information
The ES split compressor section is designed for applications that are not feasible with packaged units. Common appli-
cations for the ES split are downfl ow, horizontal, attic or crawlspace installations (where there is a need to have water con-
nections and duct work in different locations). Other applications that are easily adapted to the ES split are replacements of
existing air-to-air heat pumps and fossil fuel furnace add-ons.
It is required that the fi nned air coil be installed on the supply side of the fossil fuel furnace to prevent condensation on
the furnace heat exchanger during cooling mode.
The installation of the ES split is similar to packaged units with the addition of refrigeration piping and charging. Refrig-
erant lines are to be limited to 50 feet in length. The ES split is manufactured with an extended range expansion valve for
proper performance on earth coupled loop installations.
ARI ratings are based upon a matched compressor section and blower coil section for each model number. Other
manufacturers’ blower coils or mismatched sets may not produce similar/desired results. Using coils other than that speci-
fi ed in the ARI matched rating may alter unit performance.
Split Unit Location
Locate the split compressor section away from areas that may disturb the customer and in a way that allows easy re-
moval of the access panels and the top of the cabinet. Provide suffi cient room to make water, electrical and refrigerant line
connections and allow space for service personnel to perform maintenance. When installed indoors the unit should always
be mounted on a vibration absorbing pad or mesh to reduce noise. The ES split is also approved for outdoor installation
when properly installed.
Duct System
In applications using galvanized metal ductwork, a fl exible duct connector is recommended on both the supply and
return air plenums to minimize vibration from the blower. To maximize sound attenuation of the unit blower, the supply and
return plenums should include an internal duct liner of 1-inch thick glass fi ber or be constructed of ductboard. Insulation is
usually not installed in the supply branch ducts. Ducts in unconditioned areas should be wrapped with a minimum of 1-inch
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 air handler is connected to existing ductwork, a previous check should have
been made to assure that the duct system has the capacity to handle the air required for the unit application.
If ducting is too small, as in the replacement of heating only systems, larger ductwork should be installed, checked for
leaks and repairs made accordingly. The duct system and diffusers should be sized to handle the design airfl ow quietly. If
air noise or excessive airfl ow is a problem, the blower speed can be changed to a lower speed to reduce airfl ow. This will
reduce the performance of the unit slightly in heating; however, it will increase the temperature rise across the air coil.
Airfl ow must still meet minimum requirements.
WARNING: Before performing service or maintenance operations on a system, turn off main power
switches to both units. Turn off accessory heater power switch if applicable. 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 qualifi ed ser-
vice 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 fi lters. 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
fi re extinguisher available.
Safety Considerations
General Installation Information
5
ES SPLIT INSTALLATION MANUAL
ES MODEL MATCHING VARIABLE SPEED
AIR HANDLER
ES024 FV4ANF003 (3 TON)
ES030 FV4ANF003 (3 TON)
ES036 FV4ANF003 (3 TON)
ES036 FV4ANF005 (4 TON)
ES048 FV4ANF005 (4 TON)
ES048 FV4ANF006 (5 TON)
ES060 FV4ANF005 (4 TON)
ES060 FV4ANF006 (5 TON)
ES072 FV4ANF006 (5 TON)
Notes: Matching equipment model numbers are
Carrier®
Compatible Air Handlers
Condensate Drain
Follow the blower coil manufacturer’s instructions.
Air Handler Installation
Air handlers used with Dual Capacity units must be capable of operating with a minimum of 2 blower speeds. For de-
tails on installing the air handling portion of the system, refer to the manufacturer’s instructions for the blower coil unit. All
blower coil units/air coils must be installed as specifi ed by the manufacturer’s instructions. However, the following recom-
mendations should be considered to minimize noise and service problems:
An air fi lter must be installed upstream of the air coil on the return air side of the air handler or furnace. If there is lim-
ited access to the fi lter rack for normal maintenance, it is suggested that a return air fi lter grille be installed. Be sure that the
return duct is properly installed and free of leaks to prevent dirt and debris from bypassing the fi lter and plugging the air coil.
Notes: Improper installation of equipment may result in undesirable noise levels in the living areas.
Ensure that the line set size is appropriate to the capacity of the unit (refer to page 15). Line sets should be routed as
directly as possible, avoiding unnecessary bends or turns. Seal all wall penetrations properly. Line sets should not directly
contact water pipes, fl oor joists, wall studs, duct work, fl oors, walls and brick. Line sets should not be suspended from joists
or studs with a rigid wire or strap which directly contacts the tubing. Wide hanger strips which conform to the shape of the
tubing are recommended. Isolate hanger straps from line set insulation by using metal sleeves bent to conform to the shape
of insulation. Line set insulation should be pliable, and should completely surround the vapor tube.
Figure 1: Typical Split System Application - Remote Blower Coil
with Electric Auxiliary Heat
General Installation Information (cont.)
Lineset
To Air Handler
Insulated
Suction Line
Return
Duct
Low
Voltage Wire
Disconnect
Remote Air Handler
(Maximum Recommended Distance is
50' Between Units)
Condensate Drain
(must be trapped)
Supply
Duct
Air
Handler
6
ES SPLIT INSTALLATION MANUAL
Figure 2: Indoor Installation Using Closed Loop
Water Piping
Residential ES split units are supplied standard with brass water connections which will connect to optional internal loop
pump(s) or 3-way valves. The 3-way valves can be adapted to threaded, barb, or fusion fi ttings. Flush and fi ll adapters are
available separately.
ES units are supplied standard with pressure/temperature taps for checking pressure drop and fl ow rates.
CAUTION: Never use fl exible hoses smaller than 1-inch inside diameter on the unit and limit
hose length to 10 feet per connection. Check carefully for water leaks.
CAUTION: Water piping exposed to outside temperatures may be subject to freezing.
Closed Loop - Earth Coupled Systems (Indoor Installations)
Once piping is completed between the unit, the fl ow center and the earth loop, fi nal purging and charging of the loop is
needed. A fl ush cart (at least a 1.5 HP pump) is needed to achieve adequate fl ow velocity in the loop to purge air and dirt
particles from the loop itself. An antifreeze solution is used in most areas to prevent freezing. Maintain the pH in the 7.6 to
8.2 range for fi nal charging. Flush the system adequately to remove as much air as possible. Pressurize the loop to a static
pressure of 40 to 60 psi. This is normally adequate for good system operation. Ensure that the circulating system provides
adequate fl ow through the unit by checking pressure drop across the heat exchanger and comparing it to the fi gures shown
in the table on page 23.
Line set
To Air Handler
Insulated
Thermostat Wire
From Air Handler
Disconnect
To Loop
VibrationAbsorbing Pad orAir Pad
with access hole for piping entry
7
ES SPLIT INSTALLATION MANUAL
Closed Loop - Earth coupled Systems (Outdoor Installations)
Locate unit on an air pad with access hole as shown below. When mounting on an existing concrete pad, holes must
be bored through to accommodate 1 1/4-inch P.E. pipe with 1/2-inch insulation.
Loop Circulator
The optional fi eld installed, circulating pump(s) and 3-way valve assemblies should be used for outdoor installations.
Wiring connections are supplied in the rear compartment of the unit.
Connecting To Earth Loop
The earth loop trench should be continued directly under the unit as shown in Figure 3. Make the connections to op-
tional fi ttings from the loop circulator pump(s) and insure proper backfi ll to support the loop pipe during trench settling. All 1
1/4-inch piping should be insulated with a minimum of 1/2-inch closed cell insulation from below the ground surface to the
loop circulator.
IMPORTANT
- A freeze protection thermostat is installed in the unit to automatically start loop
circulator pump if loop temperature drops below 20°F. Loop freeze protection should also be maintained
to the lowest temperature the insulated loop may encounter in the case of power failure.
Closed Loop Valve and Pump Kits
Two kits are available when installing pumps inside the unit. The ES-VPK1 contains one pump and fl ush/fi ll valves. The
ES-VPK2 contains two pumps and fl ush/fi ll valves. To determine whether one or two pumps are required, do pressure drop
calculation. Refer to installation instructions for valve/pump kits included in the kit.
Notes: Typically 3 GPM of fl ow per ton of cooling capacity is recommended in earth loop applications.
Loop Supply
and Return
Piping
Figure 3: Typical Split System Outdoor Installation Using Closed
Loop
Water Piping (cont.)
8
ES SPLIT INSTALLATION MANUAL
Open Loop - Well Water Systems
Open Loop Applications
To provide a copper sweat connection for water line piping, remove the brass connectors from the unit. This can be
done with a tube cutter or torch. Be careful to keep debris and contamination out of the water lines. Clean the connec-
tions and pipe to the water source using standard plumbing practices. Reference well water piping kit instructions for the
WWK2T, WWK3T as needed. Typical open loop piping is shown below. Always maintain water pressure in the heat ex-
changer by placing a water control valve at the outlet of the unit and use a closed bladder pressure tank to minimize mineral
deposits. Ensure proper water fl ow through the unit by checking pressure drop across the heat exchanger and comparing it
to the fi gures in the table on page 23.
Water control valves draw their power directly from a unit’s 24V transformer and can overload and possibly burn out the
transformer. Check total VA draw of the water valve and ensure that it is under 15 VA.
Notes: Normally, about a 2 GPM fl ow rate per ton (1.5 GPM/ton minimum for EWT > 50°F) of cooling capacity is needed in
open loop systems.
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 fi eld, adjacent stream or pond, etc.). Most local codes forbid use
of sanitary sewer for disposal. Consult your local building and zoning department to assure compliance in your area.
Water Quality
In applications where the water quality cannot be held to prescribed limits, the use of a secondary or intermediate heat
exchanger is recommended to separate the unit from the contaminated water. The following table outlines the water quality
guidelines for unit heat exchangers. If these conditions are exceeded, a secondary heat exchanger is recommended.
CAUTION: Although the unit is approved for outdoor installations, the use of this product is
prohibited in open loop applications unless installed indoors.
Water Piping (cont.)
Disconnect
Thermostat Wire
From Air Handler
VibrationAbsorbing Pad orAir Pad
with access hole for piping entry
Line set
To Air Handler
Boiler Drains for
System Flushing
Water Solenoid
Control Valve
Rubber Bladder
Pressure Tank
Flow
Regulator
Shut-Off Valves Water
Out
Water In
From Well
Figure 4: Typical Split System Indoor
Installation Using Well Water Water Quality Guidelines
Iron, Fe2+ (Ferrous)
Bacterial Iron Potential
Material Copper 90/10 Cupro-Nickel
pH Acidity/Alkalinity 7- 9 5 - 9
Scaling Calcium and Magnesium Carbonate (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm
Hydrogen Sulfide Less than .5 ppm
(rotten egg smell appears at 0.5 PPM) 10 - 50 ppm
Sulfates Less than 125 ppm Less than 125 ppm
Chlorine Less than .5 ppm Less than .5 ppm
Chlorides Less than 20 ppm Less than125 ppm
Carbon Dioxide Less than 50 ppm 10 - 50 ppm
Ammonia Less than 2 ppm Less than 2 ppm
Ammonia Chloride Less than .5 ppm Less than .5 ppm
Ammonia Nitrate Less than .5 ppm Less than .5 ppm
Ammonia Hydroxide Less than .5 ppm Less than .5 ppm
Ammonia Sulfate Less than .5 ppm Less than .5 ppm
Total Dissolved Solids (TDS) Less than 1000 ppm 1000-1500 ppm
None None
Iron Oxide Less than 1 ppm. Above this level
deposition will occur. Less than 1 ppm. Above this level
deposition will occur.
Suspended Solids Less than 10 ppm and filtered for max
of 600 micron size Less than 10 ppm and filtered for max
of 600 micron size
Threshold Velocity (Fresh Water) 5-8 ft/sec 8-12 ft/sec
Corrosion
Iron Fouling
(Biological Growth)
Erosion
Note: Grains = PPM divided by 17 • mg/l is equivalent to PPM
9
ES SPLIT INSTALLATION MANUAL
Service valves have been provided inside the unit for connecting the discharge gas line to a water heating heat recov-
ery unit (see fi gure 5). To make the connections, close the service valves inside the unit by turning clockwise. Using a
recovery canister connect to either of the schrader ports on the DSH service valves and recover the small amount of refrig-
erant trapped inside of the U-tube. Prior to brazing ensure that all refrigerant has been removed from U-tube. Once
the refrigerant is removed, it is recommended that the tube be cut at the “U” to remove any excess oil that may be trapped.
(This will also allow for easier removal of the tubing with a torch, since each section can be removed independently). Ser-
vice valves must be protected to prevent overheating. Unbraze the 1/2-inch O.D. U-tube and run tubing from the left
hand service valve to the inlet of the heat recovery unit and from the outlet of the heat recovery unit to the right hand of the
service valve. Typically the one way discharge line length should be limited to 25-30 feet and line size must be increased
depending on unit size and length of run. Follow the instructions supplied with the heat recovery unit for mounting location,
water piping, and start up. A typical installation is shown below.
IMPORTANT - Reopen discharge line service valves before starting up unit, but only after leak checking,
purging, and evacuating new discharge line.
To
Compressor
Heat Recovery
Unit “In”
From
Heat Recovery
Unit “Out” to
Reversing
Valve
Insulated Line set
With UV Paint
To Air handler
Add-on
Hot Water
Generator with
Internal Pump
Cold
Drain Valve Pipe Tee
Hot
Venting
Waste Valve or
Vent Coupling
Line set
To Hot Water
Generator
P/T Relief
Valve
Figure 5: Service Valves for Heat Recovery Unit Connections
Figure 6: Typical Hot Water Piping Layout
SIZE 1/2” OD 5/8” OD 3/4” OD
024 - 036 Up to 9 ft. Up to 25 ft. Up to 30 ft.
048 Up to 5 ft. Up to 13 ft. Up to 30 ft.
060 N/A Up to 9 ft. Up to 25 ft.
072 N/A Up to 6 ft. Up to 20 ft.
Maximum One-Way Line Length
Heat Recovery Unit for Domestic Hot Water
10
ES SPLIT INSTALLATION MANUAL
Electrical
General
Be sure that the available power is the same voltage and phase as shown on the unit serial plate. Line and low volt-
age wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable. See tables
below for fuse or circuit breaker sizing information. Refer to the wiring schematic inside the unit access panel for more
information.
Accessory Pump Operation
Refer to the wiring diagram on the unit’s wiring schematic for instruction on wiring the pumps to the unit.
Notes: Always refer to unit nameplate data prior to installation. HACR circuit breaker in United States only. All fuses are class
RK-5.
MODEL RATED
VOLTAGE VOLTAGE
MIN./MAX.
COMPRESSOR INTERNAL
LOOP PUMP
FLA
TOTAL
UNIT
FLA
MIN.
CIRCUIT
AMP.
RESIDENTIAL
MCC RLA LRA MAX
FUSE MAX. HACR
BRAKER
ES024 208-230/60/1 197/253 13.0 8.3 48.0 1.8 10.1 12.2 20 20
ES030 208-230/60/1 197/253 15.5 9.9 55.0 1.8 11.7 14.2 20 20
ES036 208-230/60/1 197/253 19.5 12.5 66.0 1.8 14.3 17.4 25 25
ES048 208-230/60/1 197/253 28.0 17.9 96.0 1.8 19.7 24.1 40 40
ES060 208-230/60/1 197/253 38.5 24.7 130.0 3.5 28.2 34.1 50 50
ES072 208-230/60/1 197/253 41.0 26.3 130.0 3.5 29.8 36.4 60 60
Notes: Always refer to unit nameplate data prior to installation. ACR circuit breaker in United States only. All
fuses are class RK-5.
MODEL RATED
VOLTAGE VOLTAGE
MIN./MAX.
COMPRESSOR TOTAL
UNIT
FLA
MIN.
CIRCUIT
AMP.
RESIDENTIAL
MCC RLA LRA MAX
FUSE MAX. HACR
BRAKER
ES024 208-230/60/1 197/253 13.0 8.3 48.0 8.3 10.4 15 15
ES030 208-230/60/1 197/253 15.5 9.9 55.0 9.9 12.4 20 20
ES036 208-230/60/1 197/253 19.5 12.5 66.0 12.5 15.6 25 25
ES048 208-230/60/1 197/253 28.0 17.9 96.0 17.9 22.4 40 40
ES060 208-230/60/1 197/253 38.5 24.7 130.0 24.7 30.9 50 50
ES072 208-230/60/1 197/253 41.0 26.3 130.0 26.3 32.9 50 50
Electrical Data With Loop Pump(s)
Electrical Data Without Loop Pump(s)
11
ES SPLIT INSTALLATION MANUAL
Dual Fuel Systems
ES units can be connected to fossil fuel furnaces that include an A-coil or slab coil. Dual fuel installations utilize the
ES heat pump for heating until the point that auxiliary heat is called for on the thermostat. At that point, the furnace will be
enabled and the heat pump will be disabled. The ES heat pump provides air conditioning through the furnace’s refrigerant
coils.
Refer to the furnace manufacturer’s installation manual for the furnace installation, wiring and coil insertion. A fi eld-in-
stalled SPDT auxiliary heat relay is required. See Figure 7 for typical Dual Fuel application. Figure 8 shows the wiring for
Single Speed ES units. Figure 9 shows wiring for Dual Capacity ES units.
Figure 7: Typical Split System Application - Heat Pump Coil Add-On Fossil Fuel Furnace
Fault Signal
Fossil Fuel
Furnace
C
R
L0
Reversing Va lve
Commo n
C
R
G
W
Commo n
24 VA C
Fa n
Auxiliary Heat
1st Stage Compressor
Split
Thermostat
Y1
L
O
Y2
C
W
G
R
Y2
O
2nd Stage Compressor
24 VA C
Auxiliary Heat Relay
Y1
Fault Signal
Fossil Fuel
Furnace
C
R
L0
Reversing Valve
Common
C
R
G
W
Common
24 VAC
Fan
Auxiliary Heat
1st Stage Compressor
ES Split
Thermostat
Y1
L
O
Y2
C
W
G
R
Y2
O
2nd Stage Compressor
24 VA
Emergency Shutdown
Note: Field installed SPST dual fuel relay
(Required for dual fuel installation)
C
Auxiliary Heat Relay
Y1
P1
P2
ES
Figure 8: Single Speed Dual Fuel Wiring Figure 9: Dual Capacity Dual Fuel Wiring
Electrical (cont.)
Lineset
To Air Handler
Insulated Suction
Line
Return
Duct
Low
Voltage Wire
Disconnect
Remote Air Handler
(Maximum Recommended Distance is
50' Between Units)
Supply
Duct
Up-Flow
Fossil Fuel
Furnace
Condensate
Drain
(must be trapped)
"A" or
Slab Coil
Wire To
Thermostat
12
ES SPLIT INSTALLATION MANUAL
Wiring Schematics
97P621-10 10/13/05
ES Series - Dual Capacity Split Wiring Schematic - 208-230/60/1
Fused L2 240V L1
HP
240V L2
P6
LP
Microprocessor
Logic Control
(DC Voltage)
P1
Fused L2
R
C
CC-GND
NO
CR2 COM
NO NC
CR4 COM
F1-10A 240V
Fused L2
NO
CR1 COM
RV
FP
1
2
3
4
5
6
7
8
1
2
3
P4
Not Used
Black
Blue
Orange
Orange
Not Used
Yellow
Yellow
1
2
3C
P2
Down
C
1
2
3
4
5
6
7
Shut
SL1 In
Not
SL1 Out
Used
NOTE 2
Acc Com
Acc NC
Acc NO
1
2
3
P3
123
NO NC
CR3 COM
F1-10A 240V
Field Selection Dips - #1 On, #6 On, #7 On
Not Used
FP thermistor (loop<15°F,well<30°F) Lockout
High Pressure > 600 PSI Lockout
Low Pressure < 40 PSI Lockout
Not Used
Microprocessor malfunction*
Not Used
Not Used
Drain
Water Flow
High Press
Low Press
Air Flow
Status
DHW Limit
DHW off
LED Normal Display Mode
#1 Off, #6 On, #7 On
Not Used
FP thermistor (loop<15°F, well<30°F)
High Pressure > 600 PSI
Low Pressure < 40 PSI
Not Used
Not Used
Not Used
Not Used
Current Fault Status
#6 Off, #7 On
Y1
Y2
O
Not Used
Not Used
SL1
SL2
Inputs
#6 On, #7 Off
Lo Capacity Compressor
RV
FAN
Not Used
Loop Pump 1
Outputs
#6 Off, #7 Off
Not Used
Outputs2
Diagnostic Modes
6
5
4
8
7
P5
12
1
2
9
10
3
4
9
11
2
10
8
1
12
5
3
13
14
15
16
11
G
W
O
R
C
Y1
Y2
LO
OnSW1
1
2
3
4
5
6
7
8
9
10
11
12
OnSW3OnSW2
1
2
3
4
5
6
7
824 VAC / TA32E12
Not Used
Not Used
Fan / Comp
Loop / Well
Test / Norm
Outputs / Norm
Inputs / Norm
Dual/ Single Capacity
Must be OFF
No RPM / RPM
Not Used
Must Be ON
ECM2
Air Flow
Settings
1
2
3
4
5
Status LED PCB
SW4
R
R
R
R
R
G
Y
R
T
Black
Blue
14
13
6
7Thermistor
Light emitting diode - Green
Relay coil
Capacitor w/ bleed resistor
Switch - High pressure
Switch - Low pressure
Polarized connector
Factory Low voltage wiring
Factory Line voltage wiring
Field low voltage wiring
Field line voltage wiring
Optional block
DC Voltage PCB traces
Internal junction
Quick connect terminal
Wire nut
Field wire lug
Ground
Fuse
CC -
CR1 -
CR2-
CR3 -
CR4 -
F1 and F2 -
FP -
HP -
LP -
PS -
RV -
SW1 -
SW2 -
SW3 -
SW4 -
Compressor Contactor
Not Used
Loop pump relay 1
Fuses
Freeze protection sensor
High pressure switch
Low pressure switch
Power strip
Reversing Valve coil
Not Used
DIP package 8 position
DIP package 5 position
Not Used
Legend
Relay Contacts-
N.O., N.C.
G
T
1
3
2
P
L1
Loop Pump relay 2
Not Used
*Green LED not flashing
C
NOTE 1
SL1 In
SL1 Out
Optional
Remote Unit
Without
Loop Pump
L2
L1
Heat
Recovery
Unit
NOT USED
SC
Brown
Brown
Hi Capacity Compressor
Loop Pump 2
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not UsedNot UsedNot Used
Protector
CS
R
Start
Main
BRISTOL DUAL CAPACITY
Black Red
Blue
RUN CAP
Pink 1
2
START
CAPACITOR
Pink
CCL
Unit Power
208-230/60/1
G
L2 L1
CCH
X1
T1
2
5
1
SR
X1
T1
Orange
Tan
Pink
SC
FP
NOT USED
CCLO
CC
CCHI
CCH
CCL
Field Diagnositcs LED Board
White
Red
Black
Blk
Blk/
Wht Blk/
Wht
Black
White
Violet Black
Fused L1
Black
Pump
Loop Pump(s)
1/2 HP 208-230/60/1
G
Pump
2 - 24V Accessory relay (see SW2 - 3 for
description of operation)
3 - Field installed DPST dual fuel relay.
(Required for dual fuel installation)
1 - Connection of remote unit thatdoes not have
a loop pump for slave operation.
Notes
Pink
Tan
Tan
Pink
Red
Red Red
Crankcase Heater
2
1
Tan
Tan
CS
Black
Black
Current Switch
CS
CS - Current Switch
Y1
Y2
O
R
C
L
C
R
Fossil Fuel
Furnace
Thermostat
24 VAC
nommoCnommoC
24 VAC
Fault Signal
Reversing Valve
2nd Stage Compressor
1st Stage Compressor Y1
Y2
O
R
C
LO
ES Split
G
GFan
W
W
Auxiliary Heat Relay
Dual Fuel Wiring Diagram
Note: Field installed DPST dual fuel relay
(Required for dual fuel installation)
Auxiliary Heat Relay
P2
P1
Shut
Auxiliary
Heat Relay
Down
=chassis
13
ES SPLIT INSTALLATION MANUAL
Wiring Schematics (cont.)
97P621-11 06/22/04
ES Single Capacity Series - Wiring Schematic - 208-230/60/1
Unit
Power Supply
208-230/60/1
GL1L2
Relay Contacts-
N.O., N.C.
Thermistor
Relay coil
Switch - High pressure
Switch - Low pressure
Polarized connector
Condensate Overflow
Compressor contactor
Condensate overflow
Freeze protection sensor
Factory low voltage wiring
Factory line voltage wiring
Field low voltage wiring
Field line voltage wiring
Optional block
Internal junction
Quick connect terminal
Wire nut
Field wire lug
Ground
CC -
CO -
FP -
HP -
LP -
RB -
RV -
SW1 -
High pressure switch
Low pressure switch
Blower power relay
Reversing Valve coil
DIP switch #1
L1
Legend
3 - Switch transformer switch for 208V operation.
T
1
3
2
P
Notes:
1 - Requires common connection or 24 VAC for
activation.
2 - Night setback used only with TA32U02
thermostat .
R
C
C
R
CC
CCG
On
Off
Test / Normal
Loop / Well
P2
P1
SW1
Commercial / Normal
Not Used/ E Split
1
2
3
4
5
P3
Not Used/ Single Cap Split
CPu
FP
LP
HP
RV
LSNSESLO
G/Y2
OYCR
Thermostat
24 VAC
Common
Y1
RV
Lockout
Emergency Shutdown
Night Setback
Loadshed
NOTE 1
NOTE 2
Violet
T
Black
Black
Blue
Blue
Orange
Orange
Yellow
Yellow
1
6
2
7
8
3
4
9
5
10
DC voltage PCB traces
CC
PR
NO Com
Loop Pump
1/2 HP 208-230/60/1
G
Black
White
LPR - Single capacity loop pump relay
Black
Pump
Air handler
24 VAC
Common
Y1
O
Emergency Heat
W/W1
G
G
FP
Loop Freeze Protection Switch
Blk/Wht Blk/Wht
CCL
PR
Violet
Violet
Violet
Violet
4 - Field installed DPDT auxiliary heat relay.
Note 4
Compresso
r
Cap
Blk
Violet
Blue C
R
S
Red
PTCR - Positive Temperature Coefficient
Resistor
T2 T1
Y1
O
R
C
L
C
R
Fossil
Fuel
Furnace
Thermostat
Auxillary Heat
24 VAC
Common Common
24 VAC
Fault Signal
Reversing Valve
1st Stage Compressor Y1
O
R
C
LO
Premie
rE
Split
G
GFan
W
W
Auxillary Heat Relay
Fossil Fuel Furnace Connection
Crankcase
Heater
Orange
Orange
5 - Field installed outdoor thermostat (optional).
(Required for dual fuel installation)
Outdoor Air
Temperature
Note 5
L1
L2
Heat
Recovery
Unit
PTCR
Note 6
6 - This terminal is not used in the split
application.
Note 4: Field Installed SPST daul fuel relay.
ES
CS
Current Switch
CS
Black
Black
CS - Current Switch
14
ES SPLIT INSTALLATION MANUAL
DIP Switch Settings
DIP SWITCH
NUMBER DESCRIPTION OFF
POSITION ON
POSITION
Service / Test Mode. Allows control of “normal” or “test” Test Mode Normal Timing
operational modes. Test mode accelerates most timing Operation
1 functions 16 times to allow faster troubleshooting. Test
SW1- mode allows viewing the “current” status of the fault
(Single inputs on the LED.
speed Freeze Protection Setting. Allows selection of freeze Loop Water Well Water
units only*) 2 thermistor fault sensing temperatures for well water or Freeze Protection Freeze Protection
antifreeze- protected earth loops. 15º F 30º F
3 Application Selection. Commercial w/ Night Setback Commercial, Night Normal Residential
using TA32U02 thermostat or “Normal” Residential. Setback w/TA32U02
4Split Operation N/ASplit
5Not Used N/AN/A
Service / Test Mode. Allows control of “normal” or “test” Test Mode Normal Timing
operational modes. Test mode accelerates most timing Operation
1 functions 16 times to allow faster troubleshooting. Test
mode allows viewing the “current” status of the fault
inputs on the LED.
Freeze Protection Setting. Allows selection of freeze Loop Water Well Water
2 thermistor fault sensing temperatures for well water or Freeze Protection Freeze Protection
SW2- antifreeze- protected earth loops. 15º F 30º F
(Dual 3 Accessory Relay. Allows selection of the accessory Accessory tracks Accessory tracks
capacity relay to operate with either the compressor or fan. Fan Compressor
units only) 4Not Used N/AN/A
5Not Used N/AN/A
Diagnostics-Inputs. Allows viewing the inputs from the Diagnostic Normal display
6 control board such as the compressor, reversing valve, Inputs viewed viewed at LED
blower, hot water pump, and loop pump on the LED. at LED
Diagnostics-Outputs. Allows viewing the outputs from the Diagnostic Normal display
7 control board such as the compressor, reversing valve, Outputs viewed viewed at LED
blower, hot water pump, and loop pump on the LED. at LED
8 Thermostat selection 24VAC Thermostat N/A
SW3- 1 Dual Capacity Operation Dual Capacity N/A
(Dual 2Not Used N/AN/A
capacity 3 Split Operation Split N/A
units only) 4Not Used N/AN/A
5Not Used N/AN/A
Notes: * Although Dual Capacity units have SW1 switches, they are not used.
15
ES SPLIT INSTALLATION MANUAL
Refrigeration
The ES split compressor section contains an adequate charge amount for the compressor section and matching nomi-
nal size air handler. See table below for additional charge amount needed for line set and larger or smaller air handler.
Refrigeration piping on the split consists of installing a brazed copper line set between the blower coil unit and the unit’s
split compressor section. To select the proper tube diameters for the installation, refer to the table below. Line sets over 50
feet long are not recommended because of oil return and pressure drop problems. The suction line must always be insulat-
ed. Handle and route the line sets carefully to avoid kinking or bending the tubes. If the line set is kinked or distorted and it
cannot be formed back into its original shape, the bad portion of the pipe should be replaced. A restricted line set will affect
the performance of the system.
Connecting Air Coil
Fasten the copper line set to the blower coil unit as instructed by the coil installation instructions. Install bifl ow fi lter/drier
in liquid line between split unit and air handler. Nitrogen should be bled through the system at 2 to 3 psi to prevent oxidation
inside the refrigerant tubing. Use a low silver phos-copper braze alloy on all brazed connections.
Notes: The air coil should be thoroughly washed with a fi lming agent (automatic dishwashing detergent) to help condensate
drainage. Apply a 20-to-1 solution of detergent and water and spray both sides of coil. Repeat and rinse thoroughly with
water.
Connecting Split Unit
Braze line set to the service valve stubs on the front of the split cabinet. Nitrogen should be bled through the system
at 2 to 3 psi to prevent oxidation contamination. Use a low silver phos-copper braze alloy on all brazed connections. ES
split units are shipped with a factory charge and service valves are not to be opened until the line set has been leak tested,
purged and evacuated. Schrader cores should be removed before brazing. A heat sink should be used on the service
valves to prevent damage caused by excessive heat.
SIZE AIR HANDLER 25’ 50’ FACTORY
CHARGE
TOTAL
CHARGE
NEEDED
SUCTION LIQUID SUCTION LIQUID
ES024 FV4ANF003 (3 TON) 5/8” OD 3/8” OD 5/8” OD 3/8” OD 84 oz. 84 oz.
ES030 FV4ANF003 (3 TON) 5/8” OD 3/8” OD 5/8” OD 3/8” OD 86 oz. 86 oz.
ES036 FV4ANF003 (3 TON) 3/4” OD 3/8” OD 3/4” OD 3/8” OD 90 oz. 90 oz.
ES036 FV4ANF005 (4 TON) 3/4” OD 3/8” OD 3/4” OD 3/8” OD 90 oz. 104 oz.
ES048 FV4ANF005 (4 TON) 3/4” OD 3/8” OD 3/4” OD 3/8” OD 116 oz. 116 oz.
ES048 FV4ANF006 (5 TON) 3/4” OD 3/8” OD 3/4” OD 3/8” OD 116 oz. 116 oz.
ES060 FV4ANF005 (4 TON) 7/8” OD 3/8” OD 7/8” OD 3/8” OD 148 oz. 150 oz.
ES060 FV4ANF006 (5 TON) 7/8” OD 3/8” OD 7/8” OD 3/8” OD 148 oz. 148 oz.
ES072 FV4ANF006 (5 TON) 7/8” OD 3/8” OD 7/8” OD 3/8” OD 140 oz. 140 oz.
Line Set Size and Charge Amount
Notes: Line set installations longer than 50’ are not recommended.
* Total charge needed is for air handler and 25 feet of line set. Add 0.5 oz. for each additional foot of line set
16
ES SPLIT INSTALLATION MANUAL
Leak Testing
The refrigeration line set must be pressurized and checked for leaks
before purging and charging the unit. To pressurize the line set, attach
refrigerant gauges to the service ports and add an inert gas (nitrogen or
dry carbon dioxide) until pressure reaches 60 to 90 PSIG. Never use
oxygen or acetylene to pressure test. Use an electronic leak detector or
a good quality bubble solution to detect leaks on all connections made in
the fi eld. Check the service valve ports and stem for leaks and all connec-
tions made in the fi eld. If a leak is found, repair it and repeat the above
steps. For safety reasons do not pressurize the system above 150
psi. Purge pressure from line set. The system is now ready for evacuat-
ing and charging.
System Evacuation
Ensure that the line set and air coil are evacuated before opening ser-
vice valves to the split unit. The line set must be evacuated to at least 200
microns to remove moisture and air that may still be in the line set and coil.
Evacuate the system through both service ports to prevent false readings
on the gauge because of pressure drop through service ports.
Charging the System
Total Charging Method - See table on page 15 for the factory charge
and total charge of the split units. For line sets, add the specifi ed refriger-
ant to the factory charge for every installed foot of liquid line over 25 feet.
Example: Model ES048 with 29 feet of installed liquid line (3/8-inch
O.D.). The factory charge of an ES048 is 116 oz. plus 4 feet of liquid line x
0.50 oz. per ft. = 2.0 oz. + 116 oz. = 118.0 oz. (Total Charge). The ES048
is shipped from the factory with 116 oz. of refrigerant; the amount to be
added is 118.0 oz. - 116 oz. = 2.0 oz.
Add the required refrigerant so that the total charge calculated for
the unit and line set is now in the system. Fully open the service valves
by turning counterclockwise. Start the unit in heating mode and measure
superheat and subcooling values after at least fi ve minutes of run time.
See page 20 for examples of measuring superheat and subcooling perfor-
mance values. After values are measured, compare to tables on pages 21
and 22 and go to FINAL EVALUATION.
Partial Charge Method - After purging and evacuating the line set,
fully open the service valves counterclockwise. Add R-410A (liquid) into
the liquid line service port until the pressure in the system reaches ap-
proximately 200 PSIG. Never add liquid refrigerant into the suction side
of a compressor. Start the unit and measure superheat and subcooling.
Keep adding refrigerant until the unit meets the superheat and subcooling
values on pages 21 and 22.
Final Evaluation
After the initial check of superheat/subcooling values in the heating mode, shut off the unit and allow it to sit 3 to 5 min-
utes until pressures equalize. Restart the unit in the cooling mode and check the values against those in tables on pages
21 and 22. If the unit performs satisfactorily, charging is complete. If the unit does not perform to specifi cations, the charge
may need to be readjusted until the values are close. Adding refrigerant will increase subcooling. Recovering some of the
refrigerant will decrease subcooling and increase superheat. If the superheat/subcooling values are still not close to the
specifi cations in tables on pages 21 and 22, analyze refrigerant circuit operation.
Service ports for attaching
refrigerant gauges
Braze
Connections Suction Line Liquid Line
Replace caps after
adjusting service valves
Figure 10: Typical Split System Refrigerant
Line Connections
Refrigeration (cont.)
17
ES SPLIT INSTALLATION MANUAL
High voltage is correct and matches nameplate.
Fuses, breakers and wire size correct.
Low voltage wiring complete.
Piping completed and water system cleaned and fl ushed.
Air is purged from closed loop system.
Isolation valves are open, water control valves or loop pumps wired.
Condensate line is open, trapped, and correctly pitched (blower coil unit).
Blower rotates freely (blower coil unit).
Blower speed is correct (blower coil unit).
Air fi lter is clean and in position (blower coil unit).
Service/access panels are in place.
Thermostat is in the “off” position.
Return air temperature is between 65°F and 80°F in heating and 70° to 95°F in cooling.
Service valves are open.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
The unit is equipped with a crankcase heater which operates when the compressor is OFF. Energize crankcase heater
24 hours before starting unit. To energize heater only, set indoor thermostat to OFF position and close power discon-
nect to unit.
Turn thermostat fan to the “ON” position. Blower should operate.
Balance airfl ow at registers and adjust fan speed if necessary.
Set thermostat to highest temperature.
Set thermostat operation switch to “COOL” position. Compressor should NOT come on.
Slowly reduce the thermostat setting until both the compressor and water control valve or loop pumps are activated.
Verify that the compressor is on and that the water fl ow rate is correct by measuring pressure drop through the heat
exchanger (using the P/T plugs and comparing to table on page 23).
Check the temperature of both the supply and discharge water (see tables on pages 21 - 22).
If temperature rise is within range of tables on page 21-22 proceed to step 9. Otherwise check the cooling refrigerant
pressures and compare to tables on pages 21-22.
Check for air temperature drop of 16°F to 25°F across the air coil.
Turn thermostat switch to “OFF” position. A hissing should indicate proper functioning of reversing valve.
Leave unit “OFF” for approximately fi ve (5) minutes to allow pressure to equalize.
Turn thermostat to lowest setting.
Set thermostat switch to “Heat” position.
Turn thermostat operation to higher temperatures until both compressor and water control valve are activated.
If temperature drop through the coaxial heat exchanger is within range of the tables on pages 21-22, proceed to step
16. Otherwise check the heating refrigerant pressures and compare to tables on pages 21-22.
Check for air temperature rise of 20°F to 35°F across the air coil.
Turn the thermostat to a higher setting to make certain that the fi rst stage of auxiliary heat is activated and (if installed
and mode switch set correctly) with the appropriate temperature rise across the heater.
Confi rm that all stages of the auxiliary heat come on when the thermostat is in “EMERGENCY HEAT” mode.
Check for vibrations, noise and water leaks.
Set system to maintain desired comfort level.
Instruct the owner/operator on correct thermostat and system operation.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Notes: Starting the compressor without a minimum of 1-2 hours of crankcase heat prior to initial startup may result in
compressor chattering and possible damage to the compressor.
Startup Steps
Unit Startup
Before Powering Unit, Check The Following:
18
ES SPLIT INSTALLATION MANUAL
Heating Operation
Notes: At fi rst power up, a four-minute time delay is employed before the compressor is energized.
Heat, 1st Stage (Y1)
The compressor and loop pumps are energized 10 seconds after the Y1 input.
Heat, 2nd Stage (Y1, W) Single-Speed Units
The auxiliary heat relay will disconnect the compressor, and the auxiliary heat will operate normally.
Heat, 2nd Stage (Y1, Y2) Dual Capacity Units
The 1st stage compressor and loop pumps are de-energized 10 seconds after the Y2 input. The 2nd stage compressor
and loop pumps are energized 1 minute after the 1st stage compressor is de-energized.
Heat, 3rd Stage (Y1, Y2, W) Dual Capacity Units
The auxiliary heat relay will disconnect the compressor, and the auxiliary heat will operate normally.
Cooling Operation
In all cooling operations, the reversing valve directly tracks the
“O”
input. Thus, anytime the
“O”
input is present, the
reversing valve will be energized.
Cool, 1st Stage (Y1, O)
The compressor and loop pumps are energized 10 seconds after the Y1 input.
Cool, 2nd Stage (Y1, Y2, O) Dual Capacity Units
The 1st stage compressor and loop pumps are de-energized 10 seconds after the Y2 input. The 2nd stage compressor
and loop pumps are energized 1 minute after the 1st stage compressor is de-energized.
Fan Only Operation
The Fan Only mode is controlled directly from the unit thermostat to the unit air handler. No input is given to the micro-
processor to operate the fan function.
Modes of Operation
19
ES SPLIT INSTALLATION MANUAL
OPERATION HEATING COOLING
STG1 STG2 STG1
Compressor On Off On
Fan On On On
Loop Pump On Off On
Reversing Valve Off Off On
T-Stat Signal Y1 W Y1, O
OPERATION HEATING COOLING
STG1 STG2 STG3 STG1 STG2*
Compressor-Low On Off Off On Off
Compressor-Hi Off On Off Off On
Fan On On On On On
Loop Pump On On Off On On
Reversing Valve Off Off Off On On
T-Stat Signal Y1 Y1, Y2 W Y1, O Y1, Y2, O
Single Speed Operation Logic
Dual Capacity Operation Logic
Lockout Conditions
During lockout mode, the appropriate thermostat lockout LEDs (if available) will illuminate. The compressor and loop
pumps are de-energized and if the thermostat calls for third stage heating, emergency heat operation will occur.
Lockout modes of any kind can be reset at the thermostat after a 5-second waiting period, which restores normal
operation.
High Pressure
This lockout mode occurs immediately when the normally closed safety switch is momentarily opened.
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 protection thermistor temperature (located between the TXV and coax) is at
or below the selected freeze protection point (well 30°F or loop 15°F) for 30 continuous seconds.
The unit also contains a secondary freeze protection sensor located on the entering water line of the unit. If the loop
reaches a temperature of 20°F the secondary freeze protection sensor will cycle the loop pumps "on" until the loop tempera-
ture rises to or above 25°F.
Modes of Operation (cont.)
20
ES SPLIT INSTALLATION MANUAL
Checking Superheat and Subcooling
Determining Superheat
Measure the temperature of the suction line at the point where the expansion valve bulb is clamped.
Determine the suction pressure in the suction line by attaching refrigeration gauges to the schrader connection on
the suction side of the compressor.
Convert the pressure obtained in Step 2 to the saturation temperature by using the R-410A Pressure/Temperature
Conversion Chart on page 26.
Subtract the temperature obtained in Step 3 from Step 1. The difference is the amount of superheat for the unit. Refer
to tables on pages 21-22 for superheat ranges at specifi c entering water conditions. The fi gure below illustrates a
typical example of how to measure superheat on the unit using R-410A. The temperature of the suction line at the
sensing bulb is 50°F. The suction pressure at the compressor is 114 PSIG which is equivalent to 38°F saturation
temperature (R-410A Pressure/Temeprature Conversion Chart, page 26).
50°F - 38°F = 12°F Superheat
Determining Subcooling
Measure the temperature of the liquid line on the small refrigerant line (liquid line) just outside the split cabinet. This
location will be adequate for measurement in both modes unless a signifi cant temperature drop in the liquid line is
anticipated.
Measure the liquid line pressure by attaching refrigerant gauges to the schrader connection on the liquid line service
valve.
Convert the pressure obtained in Step 2 to the saturation temperature by using the R-410A Pressure/Temperature
Conversion Chart on page 26.
Subtract the temperature in Step 1 from the temperature in Step 3. The difference will be the subcooling value for
that unit. Refer to tables on pages 21-22 for values at specifi c entering water temperatures. The fi gures below
illustrate a typical example of measuring refrigeration subcooling using R-410A. The temperature of the liquid line
after leaving the condensing coil is 90°. The liquid line pressure at the service valve is 356 PSIG, which is equivalent
to 108°F.
108°F - 90°F = 18°F Subcooling
1.
2.
3.
4.
1.
2.
3.
4.
Expansion
Valve Bulb
114psig=38°F
Suction Line = 50 oF
114 psig (see chart) = -38 oF
Superheating = 12oF
Temperature
at Suction of
Compressor
=50°F
Figure 11: Subcooling Check
Temperature of Liquid Line
Outside the ES Cabinet.
Use in Both Modes.
356 psig
=108°F
Suction Line
Temperature of Liquid
Line = 90°F
Liquid Line
356 psig (see chart) = 108 oF
Liquid Line = -90 oF
Subcooling = 18oF
Figure 12: Superheat Check
/
