Electro Industries/GaugeTech WarmFlo EM-WU Series Manual

Dual heat system universal furnace interface module specially equipped for 2-speed hp controller portion of electro-mate

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Dual Heat System

Universal Furnace Interface Module

Specially Equipped for 2-Speed HP

Controller Portion of Electro-Mate

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.

WarmFlo/Electro-Mate EM-WU*****/EM-WD***** mechanical information –

companion manual EI703/EI707. Also the WarmFlo control board must be the latest

version with 10-pin connector, chip code version 2.30 or higher, and the latest sensors

with "E" identification band.

Model WF-HP2 – B Must use chip 2.02 or higher.

This universal interface module is equipped to handle two types of room thermostats.

The installation and setup information is significantly different, the page shown can assist

in locating the information relating to the type of thermostat you intend to use.

Manufacturer multi-wire HP room thermostat

Conventional heat/cool, 2H/2C room thermostat

NOTE 1:

With the upgraded revision B product, the conventional 2H/2C roomstat may now be the best

choice – see pages 5, 9, 12, and 19.

NOTE 2:

Also review page 19, Blower Speed Operation. Factory default is now set at "B".

NOTE 3:

This interface does not apply to Bryant Evolution or Carrier Infinity.

NOTE 4:

If there is a less than ideal combination of WF+/EZ-Mate with WF-HP2, see page 20 for setup

procedure.

08/16/2011

ARM

6 - 8

9 - 11

HI210B

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Summary of Contents for Electro Industries/GaugeTech WarmFlo EM-WU Series

Page 1 ® Dual Heat System Universal Furnace Interface Module Specially Equipped for 2-Speed HP Controller Portion of Electro-Mate 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.
Page 2: Table Of Contents
TABLE OF CONTENTS Page INTRODUCTION INSTALLATION REQUIREMENTS MECHANICAL INSTALLATION EM-WU***** Electro-Mate Upflow Application EM-WU***** EM-WD***** Electro-Mate Horizontal Application EM-WD***** Electro-Mate Downflow Application WIRING INSTALLATION High Voltage WarmFlo Sensors Outdoor Sensor (OT) Warm Air Supply Sensor (ST) HP Manufacturers’ Multi-Wire Stat WF-HP2 Setup Conventional 2H/2C Thermostat WF-HP2 Setup...
Page 3: Introduction
INTRODUCTION Prior to installation we recommend that the installer verify the system application represents air source heat pump (probably 2-speed)/Electro-Mate plenum heater/standby or gas furnace. The program code chip for the Electro-Mate WarmFlo controller will be either HPDH or HPDF. If your application does not include this combination, do not use this WF-HP2 interface module or this installation manual.
Page 4: Installation Requirements
INSTALLATION REQUIREMENTS 1. All installation work must be performed by trained, qualified contractors or technicians. Electro Industries sponsors installation and service schools to assist the installer. Visit our web site at electromn.com for upcoming service schools. 2. All electrical wiring must be in accordance with National Electric Code and local electric codes, ordinances, and regulations.
Page 5: Em-Wd***** Electro-Mate Downflow Application
Installation steps  Ideally, the WF unit Electro-Mate should be inserted on an appropriate duct side so that the circuit breakers are at the bottom.  Locate the WF unit Electro-Mate as high as possible in the horizontal duct. At the top, the elements should almost touch the top of the duct.
Page 6: Wiring Installation
WIRING INSTALLATION High Voltage Please reference Electro-Mate manual EI707 or EI703, pages 2 and 3. Low Voltage WarmFlo Sensors Located within the WarmFlo control (with Electro-Mate) 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: Hp Manufacturers' Multi-Wire Stat
HP MANUFACTURERS’ MULTI-WIRE STAT 08/16/2011 HI210B...
Page 9 HP MULTI-WIRE STAT - HOOKUP Note: The installer must be familiar with the manufacturer’s low voltage wiring terminology, screw terminal terminology/colors, etc. This manufacturer’s terminology must be related to Electro Industries’ screw terminal identification within this controller. The intent of this instruction manual is not to train each installer on the terminology related to the specific product you are installing.
Page 10: Wf-Hp2 Setup
If your installation has special application and hookup conditions please see section located in this manual called “Special Application/Installation Instructions”. WF-HP2 SETUP (HP STAT) There are four pin jumpers on this control board (upper left area) which must be set in the correct position in order for this controller to relate to the heat pump manufacturer and/or thermostat control arrangement.
Page 11: Conventional 2H/2C Thermostat
CONVENTIONAL HEAT/COOL (2H/2C) THERMOSTAT* *See page 12 for special information on using 4-wire standard heat/cool stat. 08/16/2011 HI210B...
Page 12 1. Install this unit within the 4-foot cable length of the Electro-Mate/WarmFlo plenum heater. 2. Requirements: a. Room thermostat 6 to 8-wire cable b. Gas furnace wiring board 6-wire cable 40VA or larger transformer c. Outdoor heat pump 6 to 8-wire cable 3.
Page 13: Wf-Hp2 Setup
WF-HP2 SETUP (H/C STAT) There are four pin jumpers on this control board (upper left area) which must be set in the correct position in order for this controller to relate to the heat pump manufacturer and/or thermostat control arrangement. These are factory set in the most common position, but proceed through the following steps and verify they are correct for your hardware combinations and requirements.
Page 14: Standard Heat/Cool (4-Wire) Thermostat
OPTIONAL, CONVENTIONAL H/C, BASIC 4-WIRE, THERMOSTAT Relating back to the previous three pages and connection matrix HH211B, there is a method of using the basic 1H/1C 4-wire stat for this controller and the total heat pump/Electro-Mate/gas furnace system. The only shortcomings in using this approach: ...
Page 15: Warmflo Controller Setup Or Programming
WARMFLO CONTROLLER SETUP OR PROGRAMMING Important - Located on the WF unit board is a firmware chip that determines a specific set of defaults (see table below). However, this can be programmed (altered) with optional PC software (ET-SOFT-WF) or a plug-in WarmFlo analyzer (WF-ANZ*). As part of the WF unit system this chip represents critical defaults and settings that make your system operate correctly.
Page 16 Top right dial switch - Built-in ODT or Low Temperature Switch-Over – The yellow screwdriver adjustment dial can be set to terminate the heat pump or via special programming can terminate heat pump and electric to allow total gas operation below ODT temp. (reference manual WF-ANZ*). The temperature settings related to the “ODT dial”...
Page 17 Top right dial switch - Built-in ODT or Low Temperature Switch-Over – The yellow screwdriver adjustment dial can be set to terminate all electric to allow total gas operation below ODT temp. Electric will stay on until thermostat is satisfied. The only time gas will be used is in utility control (reference manual WF-ANZ* for special programming).
Page 18: Operation Indicators
OPERATION INDICATORS There are eight front panel LED’s represented by the decal. The reaction and/or terminology should be quite self explanatory, with a few further definitions.  HP FAULT – this relates directly to whatever wire or voltage is connected to the HP “L” tab. When there is voltage on the L tab, this LED is on.
Page 19 WarmFlo Controller Strip Heat Disable – To maximize heat pump system energy efficiency and preventing “accidental” unnecessary resistant strip heat when it is not required, this WarmFlo controller disables or locks out strip heat elements based upon outdoor temperature. Depending upon program code chip and information in the colored sections, the strip heat may not activate or operate unless the WF outdoor sensor is below the ODT dial setting.
Page 20: Handheld Analyzer/Laptop Software
HANDHELD ANALYZER/LAPTOP SOFTWARE This test tool and/or software is available for temperature offset, field altering the program chip parameters and setup, and general assistance for troubleshooting. See the enclosed “WarmFlo Information” document (HD320) for functional details. SPECIAL APPLICATION/INSTALLATION For Various Heat Pump, Multi-Speed, Multi-Stage Furnaces, Blower Options, Oil Furnace, etc. Thermostat Emergency, Heating Only (this wire function must always be low during cooling) Based upon thermostat type and brand, there may be an “emergency”...
Page 21: Heat/2 Heat
1 HEAT/2 HEAT – one of the first functional decisions and somewhat controversial issue is whether or not the Electro-Mate/WarmFlo should be activated with roomstat/heat pump stage 1. The first reaction may be that stage 1 should be heat pump only to use higher efficient section of the heat pump. However, since the first stage is approximately one-half heat pump capacity there is an almost 100% possibility of heat pump blowing cool air every time the room thermostat is “waiting”...
Page 22: Warmflo - Stat Override Timer (Sot)
WarmFlo – Stat Override Timer (SOT) Activated with T-stat call and can be programmed for switchover to standby or full electric. SOT S – this is the longer set timer which allows transfer to standby if something might have happened to the electric system unmonitored. To prevent Electro-Mate manual reset possibility of house freeze-ups, SOT S is set at 90 minutes.
Page 23 Zone controller – there are a multitude of zone controllers with various wiring and programming requirements. For best success we suggest keeping the zone controller as simple as possible.  Basic gas/AC type – setup the HP2 as conventional and 4-wire stat, page 9 and following. The HP2 stat hookup will go directly to the “equipment”...
Page 24: Troubleshooting
TROUBLESHOOTING Comment: Also see the “WarmFlo Information” document (HD320) included with this manual. EL Mode LED Pulsing – an error in thermostat type, thermostat hookup, or peg setup jumpers has been detected. Recheck pages 7, 8, 10, and 11. Typical examples causing EL mode LED pulsing condition (lock-up): ...
Page 25: Operational Information
Either test set device can display all temperatures, real time evaluation of WarmFlo functions, provide temperature offsets for assimilating winter conditions, and reprogram the control chip (program stays with the actual controller board). Bad sensor, safety – if the internal logic detects open sensor wire, incorrectly wired sensor, or some bad sensor transmitted value conditions;...
Page 26 Where should I set the efficiency dial? – As you can visualize from the curves above, the lower the setting, the flatter the curve, the less electric resistance is added to the heat pump compressor warm air. 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.
Page 27 Note: There are certain things such as SOT’s, MU time, etc. which are only field programmable. If the item is not shown in the chip code table, that feature or item is default set as disable. 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.
Page 28 HP Stat – Hookup Connection – WF-HP2 I/F Module Carrier 7 Bryant 7 Rudd 4 Trane (Am. Std.) WF-HP2 Stat 5 Stat 5 Stat Stat Thermidistat Thermidistat 2-speed 698B 315A 2 stage variable 355M Stat Y/Y2 Y/Y2 E WF E GAS W GAS Furnace W/W1...
Page 29 HP Stat – Hookup Connection – WF-HP2 I/F Module (continued) York York Frigidaire Lennox WF-HP2 Stat Stat Stat Stat T8511M Twin Single T8511M T8424D FT4 - - FG6T 51M28 G61MPV Stat C & X1 C & X1 E WF E GAS W1 OUT Y2 OUT Y2 OUT...
Page 30 Notes: Direct point from stat W2 to furnace W2. If stat has W2, can use. Other options include jumper W1 and W2 on furnace or setup bit switches on furnace for stage gas as a timed function. High, tells WF-HP2 to condition WF Electro-Mate to all stages on (no temp. monitor or control) and will also condition furnace blower to G and Y2 input. High, tell WF-HP2 to condition standby (SB) or Gas only.
Page 31 CONTROL BOARD SETUP – Four, Peg Jumpers HP-WF/HP-GAS – always HP-WF for WarmFlo active. HP-GAS only relates to special condition and HP unit with Wgas output. RV Logic – HP manufacturer specific, their specification sheet or know your product. C = Reversing valve control wire Hi (24V) during cooling H = Reversing valve control wire Hi (24V) during heating Roomstat Type HP Mfg., match to HP...
Page 32 HP MANUFACTURERS’ MULTI-WIRE STAT MULTI-WIRE ROOMSTAT WF-HP2 HEAT PUMP Furnace SEE HOOKUP CONNECTION MATRIX HH210 HH210 F1 10/23/2006 HH210...
Page 33 Conventional, 2H/2C Stat* – Hookup Connection – WF-HP2 I/F Module Carrier Bryant Rudd 4 Trane (Am. Std.) WF-HP2 Stat Stat Stat Stat 698B 315A 2 stage variable speed 355M Stat E WF E GAS W GAS Furnace W/W1 W/W1 1 W2 1 W2 1 W2 Y/Y2...
Page 34 Conventional, 2H/2C Stat* – Hookup Connection – WF-HP2 I/F Module (continued) York York Frigidaire Lennox WF-HP2 Stat Stat Stat Stat Twin Single FT4 - - FG6T G61MPV Stat E WF E GAS W1 OUT Y2 OUT Y2 OUT W GAS W –...
Page 35 Notes: 1 Jumper W1 and W2 on furnace or setup bit switches on furnace for 2 stage gas as a timed function. 2 and 3 The install manual, pages 11 and 12, suggest several possibilities for adding external switches. However, these include an automatic “timeout” sequence for High Cool.
Page 36 CONTROL BOARD SETUP – Four, Peg Jumpers HP-WF/HP-GAS – always HP-WF for WarmFlo active. HP-GAS only relates to special condition and HP unit with Wgas output. RV Logic – HP manufacturer specific, their specification sheet or know your product. C = Reversing valve control wire Hi (24V) during cooling H = Reversing valve control wire Hi (24V) during heating Roomstat Type HP Mfg., match to HP...
Page 37 CONVENTIONAL HEAT/COOL THERMOSTAT WF-HP2 10/23/2006 HH211B...
Page 38 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 39 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 40 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 41 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 42 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 43 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 44 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 45 Electro Industries Residential Limited Product Warranty Effective November 1, 2009 Electro Industries warrants to the original owner, at the original installation site, for a period of two (2) years from date of original purchase, that the product and product parts manufactured by Electro Industries are free from manufacturing defects in materials and workmanship, when used under normal conditions and when such product has not been modified or changed in any manner after leaving the plant of Electro Industries If any product or product parts manufactured by Electro Industries are found to...
Page 46 CONDITIONS AND LIMITATIONS: This warranty is limited to residential, single family dwelling installations only. Any commercial or multi-unit dwelling installations fall under the Electro Industries Commercial Limited Product Warranty. Electro Industries shall not be liable for performance related issues resulting from improper installation, improper sizing, improper duct or distribution system, or any other installation deficiencies.

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