ClimateMaster Genesis Standard (GR) Series Guía

Genesis Standard

(GR) Series

Commercial Horizontal &

Vertical Packaged

Water-Source Heat Pumps

Installation, Operation &

Maintenance Instructions

50Hz

97B0076N01

Revised: 9 August, 2011

Table of Contents

Model Nomenclature 3

General Information 4

Unit Physical Data 6

Horizontal Installation 7

Field Conversion of Air Discharge 9

Horizontal Installation 10

Duct System Installation 11

Vertical Installation 12

Piping Installation 14

Water Loop Heat Pump Applications 15

Ground Loop Heat Pump Applications 16

Ground Water Heat Pump Applications 17

GroundWater Heat Pump Applications 18

Water Quality Standards 19

Electrical - Line Voltage 20

Electrical - Power Wiring 22

Electrical - Power & Low Voltage Wiring 23

Electrical - Low Voltage Wiring 24

Typical Wiring Diagram - Units with CXM Board

(Single Phase) 26

Typical Wiring Diagram - Units with DXM Board

(Single Phase) 27

Typical Wiring Diagram - Units with CXM Board

and LON Controller (Three Phase) 28

CXM Controls 29

DXM Controls 30

Safety Features 32

CXM and DXM Controls 33

Unit Starting and Operating Conditions 34

Piping System Cleaning and Flushing 35

Unit Starting and Operating Conditions 36

Unit Start-Up Procedure 37

Unit Operating Conditions 38

Preventive Maintenance 39

Functional Troubleshooting 40

Performance Troubleshooting 41

Functional Troubleshooting - S-I Units 42

International Warranty 43

Revision History 44

CLIMATEMASTER WATER-SOURCE HEAT PUMPS

2ClimateMaster Water-Source Heat Pumps

Genesis GR Series

Revised: 9 August, 2011

This Page Intentionally Left Blank

Genesis GR Series

Revised: 9 August, 2011

THE SMART SOLUTION FOR ENERGY EFFICIENCY

climatemaster.com

Model Nomenclature

NOTE: Above model nomenclature is a general reference. Consult individual engineering guides for

detailed information.

A0 2 4 CG 1 0 C L T

4 5 6 7

91011121314

Unit Size, MBtuh

Return Air

Voltage

Controls

Revision Level

Heat Exchanger & Valve Options

See model nomenclature for specific options

Cabinet Insulation

1 2

Model Type

V = Vertical Upflow

Configuration

See model nomenclature for specific options

L = Left Return

R = Right Return

See model nomenclature for specific options

Water Circuit Options

S = Standard

Standard

H = Horizontal

Supply Air & Motor Option

Rev.: 7/1/10

GR = Genesis High Efficiency

See model nomenclature for specific options

NOTE: Some options/configurations not availaible on all series. Please consult Engineering Guides for model specific options.

CE Mark

CXM DXM

Standard

LON DDC

MPC DDC T U

T = 220-240/50/1 - R407C

S = 380-420/50/3 - R407C

CLIMATEMASTER WATER-SOURCE HEAT PUMPS

4ClimateMaster Water-Source Heat Pumps

Genesis GR Series

Revised: 9 August, 2011

General Information

Inspection - Upon receipt of the equipment, carefully

check the shipment against the bill of lading. Make

sure all units have been received. Inspect the

packaging of each unit, and inspect each unit for

damage. Ensure that the carrier makes proper notation

of any shortages or damage on all copies of the freight

bill and completes a common carrier inspection report.

Concealed damage not discovered during unloading

must be reported to the carrier within 15 days of

receipt of shipment. If not ﬁled within 15 days, the

freight company can deny the claim without recourse.

Note: It is the responsibility of the purchaser to ﬁle

all necessary claims with the carrier. Notify your

equipment supplier of all damage within ﬁfteen (15)

days of shipment.

Storage - Equipment should be stored in its original

packaging in a clean, dry area. Store units in an upright

position at all times. Stack units a maximum of 3 units

high.

Unit Protection - Cover units on the job site with either

the original packaging or an equivalent protective

covering. Cap the open ends of pipes stored on the

job site. In areas where painting, plastering, and/or

spraying has not been completed, all due 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 or

debris found in or on these components.

WARNING! To avoid the release of refrigerant into the

atmosphere, the refrigerant circuit of this unit must be

serviced only by technicians who meet local, state, and

federal prociency requirements.

WARNING! 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

refrigerants. If a compressor is removed from this unit,

refrigerant circuit oil will remain in the compressor. To

avoid leakage of compressor oil, refrigerant lines of the

compressor must be sealed after it is removed.

CAUTION! To avoid equipment damage, DO NOT use

these units as a source of heating or cooling during the

construction process. The mechanical components and

lters will quickly become clogged with construction dirt

and debris, which may cause system damage.

WARNING!

CAUTION!

Safety

Warnings, cautions, and notices appear throughout this

manual. Read these items carefully before attempting

any installation, service, or troubleshooting of the

equipment.

DANGER: Indicates an immediate hazardous situation,

which if not avoided will result in death or serious

injury. DANGER labels on unit access panels must be

observed.

WARNING: Indicates a potentially hazardous situation,

which if not avoided could result in death or serious

injury.

CAUTION: Indicates a potentially hazardous situation

or an unsafe practice, which if not avoided could result

in minor or moderate injury or product or property

damage.

NOTICE: Notiﬁcation of installation, operation, or

maintenance information, which is important, but which

is not hazard-related.

WARNING! The EarthPure®Application and Service

Manual should be read and understood before attempting

to service refrigerant circuits with HFC-410A.

Genesis GR Series

Revised: 9 August, 2011

THE SMART SOLUTION FOR ENERGY EFFICIENCY

climatemaster.com

CAUTION! All three phase scroll compressors must have

direction of rotation veried at start-up. Verication is

achieved by checking compressor Amp draw. Amp draw

will be substantially lower compared to nameplate values.

Additionally, reverse rotation results in an elevated sound

level compared to correct rotation. Reverse rotation will

result in compressor internal overload trip within several

minutes. Verify compressor type before proceeding.

CAUTION! DO NOT store or install 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

signicantly reduce performance, reliability, and service

life. Always move and store units in an upright position.

Tilting units on their sides may cause equipment damage.

NOTICE! Failure to remove shipping brackets from

spring-mounted compressors will cause excessive

noise, and could cause component failure due to

added vibration.

CAUTION!

CAUTION! CUT HAZARD - Failure to follow this caution

may result in personal injury. Sheet metal parts may have

sharp edges or burrs. Use care and wear appropriate

protective clothing, safety glasses and gloves when

handling parts and servicing heat pumps.

Pre-Installation - Installation, Operation, and

Maintenance instructions are provided with each unit.

Horizontal equipment is designed for installation

above false ceiling or in a ceiling plenum. Other unit

conﬁgurations are typically installed in a mechanical

room. The installation site chosen should include

adequate service clearance around the unit. Before unit

start-up, read all manuals and become familiar with the

unit and its operation. Thoroughly check the system

before operation.

Prepare units for installation as follows:

1. Compare the electrical data on the unit nameplate

with ordering and shipping information to verify that

the correct unit has been shipped.

2. Keep the cabinet covered with the original

packaging until installation is complete and all

plastering, painting, etc. is ﬁnished.

3. Verify refrigerant tubing is free of kinks or dents and

that it does not touch other unit components.

4. Inspect all electrical connections. Connections must

be clean and tight at the terminals.

5. Remove any blower support packaging (water-to-air

units only).

6. Loosen compressor bolts on units equipped with

compressor spring vibration isolation until the

compressor rides freely on the springs. Remove

shipping restraints. (No action is required for

compressors with rubber grommets.)

7. Some airﬂow patterns are ﬁeld convertible

(horizontal units only). Locate the airﬂow conversion

section of this IOM.

8. Locate and verify any hot water generator (HWG),

hanger, or other accessory kit located in the

compressor section or blower section.

CLIMATEMASTER WATER-SOURCE HEAT PUMPS

6ClimateMaster Water-Source Heat Pumps

Genesis GR Series

Revised: 9 August, 2011

Unit Physical Data

Genesis Standard (GR) Series

Model 006 009 012 015 019 024 030 036 042 048 060

Compressor (1 Each) Rotary Reciprocating Scroll

Factory Charge R-407c (kg) 50Hz Only

0.34 0.37 0.37 0.68 0.88 0.91 1.19 1.36 1.19 1.59 2.41

PSC Fan Motor & Blower (3 Speeds)

Fan Motor - Watts 30 75 75 124 150 250 373 560 560 560 746

Blower Wheel Size (dia x w) - mm

127 x 127 127 x 127 152 x 127 229 x 178 229 x 178 229 x 178 229 x 178

254 x 254 254 x 254 254 x 254 279 x 254

Water Connection Size

FPT (in) 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1 1

Coax Volume

Volume liters 0.47 0.54 0.63 1.08 1.70 1.70 2.12 2.88 2.88 3.48 3.48

Vertical Upow

Air Coil Dimensions (h x w) - mm N/A

254 x 406 254 x 406 406 x 406 406 x 406 406 x 406

508 x 508 508 x 508

711 x 508 711 x 508 711 x 635

Standard Filter - 25.4mm

Throwaway, qty mm

N/A 254 x 508 254 x 508 406 x 508 406 x 508 406 x 508 508 x 610 508 x 610 711 x 610 711 x 610 711 x 762

Horizontal

Air Coil Dimensions (h x w) - mm

254 x 406 254 x 406 254 x 406 406 x 406 406 x 406 406 x 406 457 x 559 457 x 559 457 x 787 457 x 787 508 x 889

Standard Filter - [25.4mm]

Throwaway, qty mm

254 x 508 254 x 508 254 x 508 406 x 508 406 x 508 406 x 508 457 x 610 457 x 610

457 x 457 457 x 457 1=305 x 508,

1=635 x 508

Weight - Operating, kg 50 51 55 67 77 88 100 104 117 121 147

Weight - Packaged, kg 55 56 60 72 82 93 105 110 124 127 254

FPT - Female Pipe Thread

Condensate Drain Connection - 3/4” FPT

Unit Maximum Water Working Pressure

Options Max Pressure [kPa]

Base Unit 2,068

Internal Motorized Water Valve (MWV)

2,068

Internal Auto Flow Valve

2,068

Use the lowest maximum pressure rating when multiple options are combined.

Genesis GR Series

Revised: 9 August, 2011

THE SMART SOLUTION FOR ENERGY EFFICIENCY

climatemaster.com

Horizontal Installation

Mounting Horizontal Units

Horizontal units have hanger kits pre-installed from the

factory as shown in ﬁgure 1. Figure 3 shows a typical

horizontal unit installation.

Horizontal heat pumps are typically suspended above

a ceiling or within a sofﬁt using ﬁeld supplied, threaded

rods sized to support the weight of the unit.

Use four (4) ﬁeld supplied threaded rods and factory

provided vibration isolators to suspend the unit. Hang

the unit clear of the ﬂoor slab above and support the

unit by the mounting bracket assemblies only. DO NOT

attach the unit ﬂush with the ﬂoor slab above.

Pitch the unit toward the drain as shown in Figure 2

to improve the condensate drainage. On small units

(less than 8.8 kW) ensure that unit pitch does not cause

condensate leaks inside the cabinet.

Figure 1: Hanger Bracket

Figure 2: Horizontal Unit Pitch

10mm Threaded

Rod (by others)

Vibration Isolator

(factory supplied)

Washer

(by others)

Double Hex Nuts

(by others)

Varilla Roscada de 3/8"

(fabricada por terceros)

Arandela

(fabricada por terceros)

Tuercas Hexagonales

Dobles (por terceros)

Instale los Tornillos como

se Indica en el Diagrama

La longitud de este tornillo

debe ser de solamente 1/2” para evitar daños

Aislador de Vibraciones

(para codificación por color y

notas de instalación, consulte

las instrucciones de

instalación del soport

e colgador)

6.4mm pitch

for drainage

Drain

Connection

Horizontal Unit Location

Units are not designed for outdoor installation. Locate

the unit in an INDOOR area that allows enough space

for service personnel to perform typical maintenance or

repairs without removing unit from the ceiling. Horizon-

tal units are typically installed above a false ceiling or in

a ceiling plenum. Never install units in areas subject to

freezing or where humidity levels could cause cabinet

condensation (such as unconditioned spaces subject

to 100% outside air). Consideration should be given to

access for easy removal of the ﬁlter and access panels.

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.

Refer to Figure 3 for an illustration of a typical installation.

Refer to unit submittal data or engineering design guide

for dimensional data.

In limited side access installations, pre-removal of the

control box side mounting screws will allow control box

removal for future servicing.

Conform to the following guidelines when selecting

unit location:

1. Provide a hinged access door in concealed-spline

or plaster ceilings. Provide removable ceiling

tiles in T-bar or lay-in ceilings. Refer to horizontal

unit dimensions for speciﬁc series and model in

unit submittal data. Size the access opening to

accommodate the service technician during the

removal or replacement of the compressor and the

removal or installation of the unit itself.

2. Provide access to hanger brackets, water valves

and ﬁttings. Provide screwdriver clearance to

access panels, discharge collars and all electrical

connections.

3. DO NOT obstruct the space beneath the unit

with piping, electrical cables and other items that

prohibit future removal of components or the unit

itself.

4. Use a manual portable jack/lift to lift and support

the weight of the unit during installation and

servicing.

The installation of water source heat pump units and

all associated components, parts and accessories

which make up the installation shall be in accordance

with the regulations of ALL authorities having jurisdic-

tion and MUST conform to all applicable codes. It is

the responsibility of the installing contractor to deter-

mine and comply with ALL applicable codes and

regulations.

CLIMATEMASTER WATER-SOURCE HEAT PUMPS

8ClimateMaster Water-Source Heat Pumps

Genesis GR Series

Revised: 9 August, 2011

Figure 3: Typical Horizontal Unit Installation

Air Coil - To obtain maximum performance, the air coil

should be cleaned before start-up. A 10% solution of

dishwasher detergent and water is recommended for

both sides of the coil. A thorough water rinse should

follow. UV based anti-bacterial systems may damage

coated air coils.

Notice! Installation Note - Ducted Return: Many

horizontal WSHPs are installed in a return air ceiling

plenum application (above ceiling). Vertical WSHPs

are commonly installed in a mechanical room with free

return (e.g. louvered door). Therefore, ﬁlter rails are the

industry standard and are included on ClimateMaster

commercial heat pumps for the purposes of holding

the ﬁlter only. For ducted return applications, the ﬁlter

rail must be removed and replaced with a duct ﬂange

or ﬁlter rack. Canvas or ﬂexible connectors should also

be used to minimize vibration between the unit and

ductwork.

HORIZONTAL INSTALLATION

(by others)

Cableado

del termostato

Válvula compensadora opcional

Salida de agua

Entrada de agua

Válvula invertida opcional para

control de baja presión de agua

(puede montarse en forma interna)

Válvula a bola con tapón

P/T integrado opcional

Manguera trenzada de

acero inoxidable con accesorio

giratorio en “J”

Circuito

de edificación

Disyuntor de

energía de la unidad

(fabricado por terceros)

Alimentación

de energía de

la unidad

Conducto de alimentación

aislado con un codo (mínimo)

de 90 grados para reducir el

ruido del aire

Retorno de

aire

Aire de alimentación

Cableado de

alimentación

de energía

Varillas Roscadas de 3/8"

(fabricadas por terceros)

Colgador

de la unidad

Thermostat

Wiring

Water In

Water Out

Optional Balancing Valve

Ball Valve with optional

integral P/T plug

Stainless steel braid hose

with integral "J" swivel

Building

Loop

Unit Power

Disconnect

Power Wiring

Insulated supply duct with

at least one 90 deg elbow

to reduce air noise

Return Air

Supply Air

Unit Hanger

3/8" [10mm] threaded rods

Unit Power

Flexible Duct

Connector

Figure 3: Typical Horizontal Unit Installation

Optional Low Pressure Drop Water

Control Valve

(can be internally mounted

on some models)

Genesis GR Series

Revised: 9 August, 2011

THE SMART SOLUTION FOR ENERGY EFFICIENCY

climatemaster.com

Field Conversion of Air Discharge

Water

Connection End

Return Air

Remove Screws

Water

Connection End

Return Air

Rotate

Move to Side

Side Discharge

Return Air

Water

Connection End

Discharge Air

Drain

Back Discharge

Replace Screws

Extremo de Con

Conducto de Alimentación

Retorno de Aire

Extremo de Conexión de Agua

Drenaje

Retorno de Aire

Descarga de Aire

Descarga Lateral

Descarga Posterior

Water

Connection End

Supply Duct

Return Air

Water

Connection End

Drain

Return Air

Discharge Air

Side Discharge

Back Discharge

Overview - Horizontal units can be ﬁeld converted

between side (straight) and back (end) discharge using

the instructions below.

Note: It is not possible to ﬁeld convert return air

between left or right return models due to the

necessity of refrigeration copper piping changes.

Preparation - It is best to ﬁeld convert the unit on the

ground before hanging. If the unit is already hung it

should be taken down for the ﬁeld conversion.

Side to Back Discharge Conversion

1. Place unit in well lit area. Remove the screws as

shown in Figure 4 to free top panel and discharge

panel.

2. Lift out the access panel and set aside. Lift and

rotate the discharge panel to the other position as

shown, being careful with the blower wiring.

3. Check blower wire routing and connections for

tension or contact with sheet metal edges. Re-route

if necessary.

4. Check refrigerant tubing for contact with other

components.

5. Reinstall top panel and screws noting that the

location for some screws will have changed.

6. Manually spin the fan wheel to ensure that the wheel

is not rubbing or obstructed.

7. Replace access panels.

Back to Side Discharge Conversion - If the discharge

is changed from back to side, use above instruction

noting that illustrations will be reversed.

Left vs. Right Return - It is not possible to ﬁeld convert

return air between left or right return models due to

the necessity of refrigeration copper piping changes.

However, the conversion process of side to back or

back to side discharge for either right or left return

conﬁguration is the same. In some cases, it may be

possible to rotate the entire unit 180 degrees if the

return air connection needs to be on the opposite side.

Note that rotating the unit will move the piping to

the other end of the unit.

Figure 5: Right Return Side to Back

Figure 4: Left Return Side to Back

CLIMATEMASTER WATER-SOURCE HEAT PUMPS

10 ClimateMaster Water-Source Heat Pumps

Genesis GR Series

Revised: 9 August, 2011

Horizontal Installation

*3/4" FPT

Trap Depth

38mm

Min

38mm

21mm per m

drain slope

3/4" PVC or

Copper by others

Rev.: 7/30/10

Vent

* Some units include a painted drain

connection. Using a threaded pipe or

similar device to clear any excess paint

accumulated inside this fitting may

ease final drain line installation.

Figure 6: Horizontal Condensate Connection

CAUTION! Ensure condensate line is pitched toward

drain 21mm per m of run.

Condensate Piping - Horizontal Units - A condensate

drain line must be installed and pitched away for the unit

to allow for proper drainage. This connection must meet

all local plumbing/building codes.

Pitch the unit toward the drain as shown in Figure 2 to

improve the condensate drainage. On small units (less

than 8.8 kW), ensure that unit pitch does not cause

condensate leaks inside the cabinet.

Install condensate trap at each unit with the top of

the trap positioned below the unit condensate drain

connection as shown in Figure 6. Design the depth of

the trap (water-seal) based upon the amount of ESP

capability of the blower (where 51mm of ESP capability

requires 51mm of trap depth). As a general rule, 38mm

trap depth is the minimum.

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 line.

DO NOT install units with a common trap and/or vent.

Always vent the condensate line when dirt or air

can collect in the line or a long horizontal drain line

is required. 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 DRAIN LINE, IT MUST BE

LOCATED AFTER THE TRAP IN THE DIRECTION OF

THE CONDENSATE FLOW.

CAUTION! 

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