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Electro Industries WF-EM3 Manual

Dual heat system
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W
ARM
Dual Heat System
Controller Portion of Electro-Mate
WarmFlo Electro-Mate EM-WU*****/EM-WD***** mechanical
information – companion manual EI703/EI707.
Special applications and conditions, see page 23.
When used as a dual heat (backup gas or oil furnace) application, the system
must also include Electro Industries' furnace interface module (sometimes
called fossil fuel kit).
Use the appropriate colored section for the appropriate furnace interface.
WF-EM3 – non-heat pump, standard A/C
WF-EZ3 – single speed HP, 4-wire, standard roomstat
WF-LGR3 – heat pump manufacturer's multi-wire stat
(product discontinued)
Note: For 2-speed heat pump, use WF-HP2 (information not contained
in this manual)
Note: The WF-LGR3 is no longer in production, use WF-LGR4 which
has its own installation manual. In other words, this manual is now only
used for conventional, 4-wire, room thermostat application.
Also accompanying each system is a specific control program "chip". This is typically part of
ordering information and should be listed on packing slip. A listing of these "chip codes" is in the
controller setup or programming sections of this document.
11/01/2007
F
LO
II
®
Yellow
Green
Blue
HI320

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Summary of Contents for Electro Industries WF-EM3

  • Page 1 Special applications and conditions, see page 23. When used as a dual heat (backup gas or oil furnace) application, the system must also include Electro Industries’ furnace interface module (sometimes called fossil fuel kit). Use the appropriate colored section for the appropriate furnace interface.

  • Page 2: Table Of Contents

    EM-WU*****/EM-WD***** Horizontal Application EM-WD***** Downflow Application WIRING INSTALLATION High Voltage Low Voltage Outdoor Sensor (OT) Supply Sensor (ST) WF-EM3 & WF II Wiring & Setup Chip Code: WF-EZ3 & WF II Wiring & Setup Chip Code: HPDH HPDF HPEL WF-LGR3 & WF II Wiring & Setup...

  • Page 3: Introduction

    WF-EZ3 – standard 4-wire thermostat – heat pump, EM-WU, EM-WD, gas/oil system. WF-EM3 – standard 4-wire non-heat pump, with or without standard air conditioning. **Installation Notice - Upon installation it is necessary that all the components of the heating system are in place and functional.

  • Page 4: Mechanical Installation

    MECHANICAL INSTALLATION WF Furnace Interface I/F (WF-EZ3, WF-LGR3, WF-EM3) The mounting location of this enclosure is flexible to any convenient location were the thermostat connection is easily accessible. The distance between the I/F and WF II is limited only by the 4’ cable provided with the I/F.
  • Page 5 EM-WD***** Electro-Mate Downflow Application Electro-Mate nameplate or companion installation manual EI707 is required for correct mechanical installation. If you do not have manual #EI707 do not attempt to do the mechanical installation, contact the factory for a replacement manual. The primary installation concerns focusing on the existing furnace and ducting system’s airflow capacity and necessary plenum baffling required by the specific Electro- Mate for correct installation.

  • Page 6: Wiring Installation

    WIRING INSTALLATION High Voltage Please reference manual EI707 pages 2 and 3. Low Voltage WarmFlo II Sensors Located within each WarmFlo control are two sensing probes, OT (outdoor sensing) and ST (supply sensing) necessary for proper operation and installation of the WarmFlo systems. Without proper installation of these probes the WarmFlo system will not operate correctly.
  • Page 7 OT & ST Sensor Reconnection 1. A plug-in terminal block is provided for wiring convenience. 2. Both red wires are terminated in the same single screw (+), and both white or green wires are terminated in the single common screw (COM). Each appropriate black wire is terminated in the appropriate OT and ST screw.

  • Page 8: Wf-Em3 & Wf Ii Wiring & Setup

    Application – non-heat pump, standard Electro-Mate/fossil fuel furnace/with or without air conditioning. Reference Drawing HH318 1. Attached to the WF-EM3 is a 4’ cable harness that interfaces between the WF II and the WF-EM3. Note: Units produced after 08-04-04 (ARL #3074 and up) have an updated control board. This update increases the size of the interface header from a four place to a ten place.

  • Page 9: Chip Code

    WF II controller. The table below represents the typical WF II chip codes and defaults for use with a WF-EM3. Please use this table as a reference as you setup your WF II. See Operational Information and last section of this manual for further information on these defaults.
  • Page 10 WF II DIAL SETTINGS Lower right dial switch – min. warm air – The lower inside yellow screwdriver adjustment dial sets a “floor” or level minimum operating temperature. The supply temperature will never go below this point independent of outdoor temperature. In other words, this is the flat horizontal line on the warm air versus outdoor temperature curve referenced in this manual “Heat Loss Curve”...
  • Page 11 Ø = Disabled, no ODT switch-over Factory set on #0 = disabled. 1 = -15°F 5 = 10°F 2 = -10°F 6 = 20°F 3 = 0°F 7 = 30°F 4 = 5°F Front control red dial - Temperature (Efficiency Dial) – Located on the front door of the main WF II cabinet.

  • Page 13: Wf-Ez3 & Wf Ii Wiring & Setup

    WF-EZ3 & WF II WIRING & SETUP WF-EZ3 Application – 4-wire thermostat, heat pump, WF II Electro-Mate/fossil fuel furnace. HP manufacturer’s fossil fuel kit not required. Reference Drawing HH317 1. Attached to the WF-EZ3 is a 4’ cable harness that interfaces between the WF II and the WF-EZ3. Note: Units produced after 08-04-04 (ARL #3074 and up) have an updated control board.

  • Page 14: Chip Code

    • Y - The HP compressor relay coil, when the Y terminal goes to 24-volt, the compressor and its internal functions should be on. • RV - Reversing valve, determines outdoor unit heat or cool mode. See below for logic selection.

  • Page 15: Hpdh

    MU Time – Standby or Gas Furnace Operation - Whenever all four stages are full on, and operating at a continuous 100% for a fixed delay (see Chip Code Reference Table, MU Time); the WarmFlo II controller automatically terminates all electric and starts the gas furnace. The gas furnace will be used to complete the heating cycle until room thermostat heat call ends.

  • Page 16: Hpdf

    WF-EZ3 adjustments and settings – only one setting, selection of the reversing valve logic. See page 10, paragraph 7. The normal/standby switch provides the standard user override function (some power companies may request deactivation or deletion of this switch, call factory). Reference “WarmFlo Handheld Analyzer/Laptop Software”...
  • Page 17 Reference “WarmFlo Handheld Analyzer/Laptop Software” section in this manual for changes to your chip functions. HPEL Chip Code – Maximum Electric Gas Only Operates with Utility Control Application: 4-wire Thermostat, WF II Electro-Mate, Heat Pump, and gas/oil furnace. This code will only allow gas/oil on during utility control –...
  • Page 18 2. 24V SOURCE IS FAN CENTER, FUSED WITHIN WF-LGR2, AS SHOWN POWERS ROOM STAT AND HP. 3. N.C. FOR OFF-PEAK. IF OPPOSITE LOGIC, SEE MANUAL. 4. FOR DRAWING CLARITY, THE UNIT CONNECTION DETAILS ARE SHOWN OPPOSITE ACTUAL INSTALLATION POSITION. ELECTRO INDUSTRIES, INC. HH329 MONTICELLO, MN 55362 Rev.B 07-25-07...
  • Page 19 WF-LGR3 & WF II WIRING & SETUP WF-LGR3 Application – Standard heat pump room thermostat, heat pump, WF II Electro-Mate, gas/oil furnace. HP manufacturer’s fossil fuel kit is not required. Reference Drawing HH316 1. Attached to the WF-LGR3 is a cable harness that interfaces between the WF II and the WF-LGR3. Note: Units produced after 08-04-04 (ARL #3074 and up) have an updated control board.
  • Page 20 convenience, you can make these three tie points within this enclosure. Over and above the three tie points mentioned above, simply terminate “Y” and “G” at the upper left terminal block. b. Within the WF-LGR3 is a wire harness that goes from WF-LGR3 to the WF II controller.

  • Page 21: Chip Code

    step up function. Reference manual “Special Installation/Application Instructions” for additional assistance. Gas/oil as emergency – depending upon the action within the HP stat sub-base, the “A1” tab on the main WarmFlo board could be used as an input to cause standby mode. However, even though you apply 24 volts to “A1”...

  • Page 22: Hpdf

    WF II DIAL SETTINGS Lower right dial switch – min. warm air – The yellow screwdriver adjustment dial sets a “floor” or level minimum operating temperature. The supply temperature will never go below this point independent of outdoor temperature. In other words, this is the flat horizontal line on the warm air versus outdoor temperature curve.
  • Page 23 independent of outdoor temperature. In other words, this is the flat horizontal line on the warm air versus outdoor temperature curve. Reference manual “heat loss curve graph”. 0 = 90 4 = 98 Factory set on #3. 1 = 92 5 = 100 2 = 94 6 = 102...
  • Page 24 outdoor temperature. In other words, this is the flat horizontal line on the warm air versus outdoor temperature curve. Reference manual “heat loss curve graph”. 0 = 90 4 = 98 Factory set on #3. 1 = 92 5 = 100 2 = 94 6 = 102 3 = 96...

  • Page 26: Operation Indicators

    OPERATION INDICATORS Furnace Interface Module – WF-EZ3, WF-LGR3, WF-EM3 WF-EZ3, WF-LGR3, and WF-EM3 Front Monitor LED’s • Utility, off-peak – utility load management receiver is not interrupting. • HP or A/C call – the output “Y” screw terminal is active at 24 volts high. The outdoor unit should be on and running.
  • Page 27 Monitor LED’s on WF II Controller Green LED - When illuminated the WarmFlo II controller is receiving 24v power. Under all normal operating modes, this should be solid green. • As a secondary function this green LED provides status of the two remote sensors. If a sensor is inoperative, incorrectly wired, or malfunctioning;...

  • Page 28: Handheld Analyzer/Laptop Software

    STAT OVERRIDE TIMER (SOT) This is a field option internal timer which can be field programmed with WF analyzer to select a roomstat cycle run time. If this downloaded run time (typically 90 minutes) is exceeded before the thermostat is satisfied, the system automatically switches to either full electric elements or standby.

  • Page 29: Special Application/Installation

    SPECIAL APPLICATION/INSTALLATION For Various Heat Pump, Multi-Speed, Multi-Stage Furnaces, Blower Options, Oil Furnace, etc. Furnace Interface Module Interchangeability The WarmFlo II controller can operate with any furnace interface module series (1, 2, 3). The updated I/F module series have additional features and are more convenient for installation, but all I/F module models will work (without new features) with this controller.

  • Page 30: Optional Accessories

    Optional - Multi-speed/variable-speed blower connection - Newer “high tech” gas furnaces, special blower speeds, may require energizing fan center “G” and “Y” during WarmFlo II heating cycle. Provisions are included for an extra blower relay contact for appropriate multi-speed wiring. Added jumper wires Variable speed blower, operate a low speed during low heat requirements –...

  • Page 31: Troubleshooting

    EM-LV104L* – Order EZ-Mate plenum heater with load shed capability – 5 kW firm, 5 kW shed. PI-ØA1DYMO – Sensor CT (1 or 2, ½” donut), 4 wire low voltage connection to standard Electro-Mate or WarmFlo II/ Electro-Mate – drops 1 stage or typical 5 kW (reference drawing PH510).

  • Page 32: Operational Information

    Bad sensor, safety – if the internal logic detects open sensor wire, incorrectly wired sensor, or some bad sensor transmitted value conditions; the green LED reverts to a pulsing mode. Basically the appropriate sensor is set internally to a 0° value and there will be an attempt to cause the electric heat output to go “DT flat”.
  • Page 33 Therefore, the efficiency knob setting is based upon comfort and efficiency. The lower the setting the higher the overall operating annual efficiency, the higher the setting the warmer the air at the register. Heat loss curve* – within the “brain” of the WarmFlo controller is a relationship of supply temperature (ST) to outdoor temperature (OT) measurement.
  • Page 34 Delay, transfer from standby to electric – if the unit was operating in SB for more than 1 minute, the follow-up transfer back to electric engages a 4-minute delay before the HP compressor relay is activated and any of the electric stages are activated. The blower will react to the call for heat, but the elements will stay off for 4 minutes in order for the blower to cool down the furnace heat exchanger.
  • Page 35 OPERATION INDICATORS Furnace Interface Module – WF-EZ3, WF-LGR3, WF-EM3 WF-EZ3, WF-LGR3, and WF-EM3 Front Monitor LED’s • Utility, off-peak – utility load management receiver is not interrupting. • HP or A/C call – the output “Y” screw terminal is active at 24 volts high. The outdoor unit should be on and running.
  • Page 36 Monitor LED’s on WF II Controller Green LED - When illuminated the WarmFlo II controller is receiving 24v power. Under all normal operating modes, this should be solid green. • As a secondary function this green LED provides status of the two remote sensors. If a sensor is inoperative, incorrectly wired, or malfunctioning;...
  • Page 37 STAT OVERRIDE TIMER (SOT) This is a field option internal timer which can be field programmed with WF analyzer to select a roomstat cycle run time. If this downloaded run time (typically 90 minutes) is exceeded before the thermostat is satisfied, the system automatically switches to either full electric elements or standby.
  • Page 38 SPECIAL APPLICATION/INSTALLATION For Various Heat Pump, Multi-Speed, Multi-Stage Furnaces, Blower Options, Oil Furnace, etc. Furnace Interface Module Interchangeability The WarmFlo II controller can operate with any furnace interface module series (1, 2, 3). The updated I/F module series have additional features and are more convenient for installation, but all I/F module models will work (without new features) with this controller.
  • Page 39 Optional - Multi-speed/variable-speed blower connection - Newer “high tech” gas furnaces, special blower speeds, may require energizing fan center “G” and “Y” during WarmFlo II heating cycle. Provisions are included for an extra blower relay contact for appropriate multi-speed wiring. Added jumper wires Variable speed blower, operate a low speed during low heat requirements –...
  • Page 40 EM-LV104L* – Order EZ-Mate plenum heater with load shed capability – 5 kW firm, 5 kW shed. PI-ØA1DYMO – Sensor CT (1 or 2, ½” donut), 4 wire low voltage connection to standard Electro-Mate or WarmFlo II/ Electro-Mate – drops 1 stage or typical 5 kW (reference drawing PH510).
  • Page 41 Bad sensor, safety – if the internal logic detects open sensor wire, incorrectly wired sensor, or some bad sensor transmitted value conditions; the green LED reverts to a pulsing mode. Basically the appropriate sensor is set internally to a 0° value and there will be an attempt to cause the electric heat output to go “DT flat”.
  • Page 42 Therefore, the efficiency knob setting is based upon comfort and efficiency. The lower the setting the higher the overall operating annual efficiency, the higher the setting the warmer the air at the register. Heat loss curve* – within the “brain” of the WarmFlo controller is a relationship of supply temperature (ST) to outdoor temperature (OT) measurement.
  • Page 43 Delay, transfer from standby to electric – if the unit was operating in SB for more than 1 minute, the follow-up transfer back to electric engages a 4-minute delay before the HP compressor relay is activated and any of the electric stages are activated. The blower will react to the call for heat, but the elements will stay off for 4 minutes in order for the blower to cool down the furnace heat exchanger.
  • Page 44 WarmFlo Terminology, Key Terms ST – supply temperature sensor. This is the warm air or duct sensor (boiler – supply outlet water). OT – outdoor temperature sensor. Provides the WarmFlo board with outdoor temperature information. DT – desired temperature to overcome building heat loss, the diagonal line on heat loss curve. The front panel efficiency knob selects one of 8 curves to determine DT at specific real time OT.
  • Page 45 New 2008 – version 2.38, 10.03, 12.04, 15.03, etc. – once activated, it remains for the completion of the heat call. Thus it only needs to be a temporary jumper (5 seconds or more) to step on all stages. User needs to remember to cycle the roomstat to cancel this E tab function.
  • Page 46 Note: With an Electro-Mate it is assumed there is always standby or gas furnace. For non-automatic or wood, suggest using EMA and select the desired outlet temperature. ODT dial switch mode – within the program chip default and Analyzer/software programming this function defines the use of the dial switch on the circuit board labeled “ODT”.
  • Page 47 Blower operation – the air handler or fossil fuel furnace blower is operated from its own fan center (G screw). The activation of this “G” input is either directly from a heat pump (total electric system) roomstat “G” screw or in the case of dual heat from the Furnace Interface module (WF-EZ3, LGR4, EM3, etc.).
  • Page 48 HANDHELD ANALYZER/LAPTOP SOFTWARE PC software (ET-SOFT-WF) or Handheld (WF-ANZ*) – now has provisions for the following setup or reprogramming functions. Caution – do not attempt to reprogram a forced air (Electro-Mate) chip for boiler application. Select proper product application – dial switch on the back MU time, or disable SB RESET –...
  • Page 49 When the warm air sensor is calling for more than the heat pump and Stage 1 100% output, Stage 2, etc. turns on. Stage 1 may not necessarily remain at 100%, but can be modulated downward to meet the requirements of the warm air sensor. Also on the next call for heat, the WarmFlo II controller remembers what stages were on and starts at that point.
  • Page 50 Outdoor sensor reference or heating requirement level* – the outdoor digital sensor “tells” the WarmFlo “brain” its desired (DT) value or decision making capability. This is for desired or required supply temperatures greater than the “min. warm air” horizontal line setting. At each internal calculation cycle a DT is determined by reading the outdoor temperature (OT) and then finding the appropriate warm air point on the appropriate or selected diagonal line.
  • Page 51 TWENTY YEAR (20) LIMITED WARRANTY ON SPIN FIN ELEMENTS Electro Industries, Inc. warrants that the spin fin elements of its products are free from defects in materials and workmanship through the twentieth year following date of installation. If any spin fin elements are found to have a manufacturing defect in materials or workmanship, Electro Industries will replace them.
  • Page 52 ALL IMPLIED WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED WITH RESPECT TO ALL PURCHASERS OR OWNERS. ELECTRO INDUSTRIES, INC. IS NOT BOUND BY PROMISES MADE BY OTHERS BEYOND THE TERMS OF THESE WARRANTIES. FAILURE TO RETURN THE WARRANTY CARD SHALL HAVE NO EFFECT ON THE DISCLAIMER OF THESE IMPLIED WARRANTIES.

This manual is also suitable for:

Warmflo iiWf-ez3Wf-lgr3