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Nibe COMPACT TWO-STAGE Series Installation, Operation & Maintenance Manual
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Nibe COMPACT TWO-STAGE Series Installation, Operation & Maintenance Manual

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BY COMPACT TWO-STAGE SERIES
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
Part#: 97B0075N32 | Created: September 24, 2024
Models: BY 024-060
60Hz – R-454B
Supercedes: 14804-NOM1-1221 |
Form: 15803-NOM1-0924

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  • Page 1 BY COMPACT TWO-STAGE SERIES INSTALLATION, OPERATION & MAINTENANCE MANUAL Part#: 97B0075N32 | Created: September 24, 2024 Models: BY 024-060 60Hz – R-454B Supercedes: 14804-NOM1-1221 | Form: 15803-NOM1-0924...
  • Page 2 BY VERSATILE SERIES– IOM Models: Table of Contents 024-060 Model Nomenclature Electrical: DXM2.5 Example Wiring Diagram Attentions, Cautions, and Warnings Electrical: Low Voltage Wiring General Information Electrical: Thermostat Wiring Minimum Installation Area EC Blower Motor Control Refrigerant System Servicing Blower Performance Physical Data Controls: DXM2.5 Horizontal Installation...
  • Page 3 024-060 MODEL STANDARD B = R-454B Refrigerant B = Brand MODEL TYPE BLOWER MOTOR Y = Compact Two-Stage Series V = Constant Volume (CV) EC SUPPLY & RETURN EXTENDED OPTIONS CONFIGURATIONS 0 = None Horizontal Confi guration DRAIN PAN/HEAT EXCHANGER OPTIONS...
  • Page 4 BY VERSATILE SERIES– IOM Models: Attentions, Cautions, and Warnings 024-060 SAFETY WARNING All refrigerant discharged from this unit must be recovered WITHOUT Warnings, cautions, and notices appear EXCEPTION. Technicians must follow industry accepted guidelines and throughout this manual. Read these items carefully all local, state, and federal statutes for the recovery and disposal of refrigerants.
  • Page 5 BY VERSATILE SERIES– IOM Models: Attentions, Cautions, and Warnings 024-060 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 significantly reduce performance, reliability, and service life.
  • Page 6 BY VERSATILE SERIES– IOM Models: General Information 024-060 INSPECTION PRE-INSTALLATION Upon receipt of the equipment, carefully check the Installation, Operation, and Maintenance instructions shipment against the bill of lading. Make sure all units are provided with each unit. Horizontal equipment have been received.
  • Page 7 BY VERSATILE SERIES– IOM Models: General Information 024-060 Work Procedure Checks to the Refrigeration Equipment Work shall be undertaken under a controlled procedure The following checks shall be applied to installations so as to minimise the risk of a flammable gas or vapor using FLAMMABLE REFRIGERANTS: being present while the work is being performed.
  • Page 8 BY VERSATILE SERIES– IOM Models: General Information 024-060 REPAIR TO INTRINSICALLY SAFE COMPONENTS Intrinsically safe components must be replaced. CABLING Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.
  • Page 9 BY VERSATILE SERIES– IOM Models: Minimum Installation Area 024-060 MINIMUM INSTALLATION AREA Minimum area where a blower-equipped unit must be installed, and mechanical/natural ventilation is not required Minimum Installation Minimum area where unit is installed where unit Charge Area ft ) [A Model Configuration...
  • Page 10 BY VERSATILE SERIES– IOM Models: Refrigerant System Servicing 024-060 REFRIGERANT SYSTEM To maintain sealed circuit integrity, do not install The outlet for the vacuum pump shall not service gauges unless unit operation appears be close to any potential ignition sources, abnormal.
  • Page 11 BY VERSATILE SERIES– IOM Models: Refrigerant System Servicing 024-060 Ensure that the detector is not a potential source of Before attempting the procedure, ensure that: Ignition and is suitable for the refrigerant used. Leak Mechanical handling equipment is available, detection equipment shall be set at a percentage if required, for handling refrigerant cylinders.
  • Page 12 BY VERSATILE SERIES– IOM Models: Refrigerant System Servicing 024-060 RECOVERY When removing refrigerant from a system, either for In addition, a set of calibrated weighing scales servicing or decommissioning, it is recommended shall be available and in good working order. good practice that all refrigerants are removed safely.
  • Page 13 BY VERSATILE SERIES– IOM Models: Physical Data 024-060 BY Series Unit Size Compressor (1 Each) Scroll Number of refrigerant circuits Factory Charge (oz) R-454B Refrigerant Leak Detection System Number of Sensors Water Connection Size FPT - All Other (inch) 3/4" 3/4"...
  • Page 14 BY VERSATILE SERIES– IOM Models: Horizontal Installation 024-060 HORIZONTAL UNIT LOCATION The installation of water source heat pump units and all associated components, parts and accessories which Units are not designed for outdoor installation. Locate make up the installation shall be in accordance with the unit in an INDOOR area that allows enough the regulations of ALL authorities having jurisdiction space for service personnel to perform typical...
  • Page 15 BY VERSATILE SERIES– IOM Actual area is 7.25” w x 8.875”h Horizontal Installation: Models: Guides indicate .125” bleed all around Service Access 024-060 Left Return Back Discharge Right Return Back Discharge Supply Supply Air Flow Air Flow Return Return Air Flow Air Flow Front Front...
  • Page 16 BY VERSATILE SERIES– IOM Models: Actual area is 3.5313” w x 8.875”h Horizontal Installation 024-060 Guides indicate .125” bleed all around Figure 2: Horizontal Unit Pitch 1/4” (6.4 mm) pitch toward drain for drainage HORIZONTAL INSTALLATION Drain connection Figure 3: Typical Horizontal Unit Installation Figure 3: Typical Unit Installation 3/8"...
  • Page 17 BY VERSATILE SERIES– IOM Models: Horizontal Installation 024-060 CONDENSATE PIPING POLYMER DRAIN PANS A condensate drain line must be installed and Condensate drain connection is a rubber coupling pitched away for the unit to allow for proper that connects to 3/4-inch schedule 40/80 PVC. Use hose drainage.
  • Page 18 BY VERSATILE SERIES– IOM Models: Duct System Installation 024-060 DUCT SYSTEM INSTALLATION Proper duct sizing and design is critical to the An unventilated area where water source performance of the unit. The duct system should heat pump is installed and surpasses a R-454B be designed to allow adequate and even airflow refrigerant charge of 62 oz (1.76 kg), shall be without through the unit during operation.
  • Page 19 BY VERSATILE SERIES– IOM Models: Actual area is 3.5313” w x 8.875”h Field Conversion of Air Discharge 024-060 Guides indicate .125” bleed all around Figure 5: Left Return – Side-to-Back OVERVIEW Remove Screws Water Horizontal unit blower assembly can be field Connection End converted between side (straight) and back (end) discharge using the instructions below.
  • Page 20 BY VERSATILE SERIES– IOM Models: Vertical Installation 024-060 VERTICAL UNIT LOCATION 6. Provide access to water valves and fittings and screwdriver access to the unit side panels, Units are not designed for outdoor installation. Locate discharge collar and all electrical connections. the unit in an INDOOR area that allows enough space Figure 7: Vertical Unit Mounting for service personnel to perform typical maintenance...
  • Page 21 BY VERSATILE SERIES– IOM Models: Vertical Installation 024-060 SOUND ATTENUATION FOR VERTICAL UNITS Always vent the condensate line when dirt or air can collect in the line or a long horizontal drain line Sound attenuation is achieved by enclosing the unit is required.
  • Page 22 BY VERSATILE SERIES– IOM Actual area is 7.25” w x 8.875”h Models: Vertical Installation: Service Access Guides indicate .125” bleed all around 024-060 Left Return Supply Air Opening Front CCP and BSP Right Return Supply Air Opening Front CCP and BSP = Mandatory Service Access 2-foot (61 cm) Notes: While clear access to all removable panels is not required, installer should...
  • Page 23 BY VERSATILE SERIES– IOM Models: Piping Installation 024-060 INSTALLATION SUPPLY AND RETURN PIPING Follow these piping guidelines: Optional pressure-rated hose assemblies designed specifically for use with units are Install a drain valve at the base of each supply available. Similar hoses can be obtained from and return riser to facilitate system flushing.
  • Page 24 BY VERSATILE SERIES– IOM Models: Water-Loop Heat Pump Applications 024-060 COMMERCIAL WATER LOOP APPLICATIONS Commercial systems typically include a number of The piping system should be flushed to remove units connected to a common piping system. Any dirt, piping chips, and other foreign material unit plumbing maintenance work can introduce prior to operation (see Piping System Cleaning air into the piping system;...
  • Page 25 BY VERSATILE SERIES– IOM Models: Ground-Loop Heat Pump Application 024-060 Test individual horizontal loop circuits before CAUTION backfilling. Test vertical U-bends and pond loop The following instructions represent industry accepted installation assemblies prior to installation. Pressures of at least practices for closed loop earth coupled heat pump systems. Instructions are provided to assist the contractor in installing trouble free ground 100 psi (689 kPa) should be used when testing.
  • Page 26 BY VERSATILE SERIES– IOM Models: Ground-Loop Heat Pump Applications 024-060 Figure 12: Typical Ground-Loop Application with Central Pumping To Thermostat Water Out Water In High and Low Voltage Shut Off Knockouts Ball Valves for Isolation Vibration Isolation Pad Figure 13: Ground Water Heat Pump Applications Typical Open Loop/Well To Thermostat Water Out Pressure...
  • Page 27 BY VERSATILE SERIES– IOM Models: Water Quality Requirements 024-060 Table 4: Water Quality Requirements Clean water is essential to the performance and life span of water source heat pumps. Contaminants, chemicals, and minerals all have the potential to cause damage to the water heat exchanger if not treated properly.
  • Page 28 BY VERSATILE SERIES– IOM Models: Water Quality Requirements 024-060 α The Water Quality Table provides water quality Hydrogen Sulfide has an odor of rotten eggs. requirements for coaxial and brazed-plate If one detects this smell, a test for H S must be heat exchangers.
  • Page 29 BY VERSATILE SERIES– IOM Actual area is 7.25” w x 8.875”h Models: Water Quality Requirements Guides indicate .125” bleed all around 024-060 Measuring Earth Ground Resistance for Ground-Water Applications � 0.02 Building Well Casing Ground Rod Ohm meter Measure the earth ground bond using an Ohm meter between the building’s ground rod and the steel well casing.
  • Page 30 BY VERSATILE SERIES– IOM Actual area is 7.25” w x 8.875”h Models: Water Quality Requirements Guides indicate .125” bleed all around 024-060 Measuring Electrolysis, Voltage, and Current for Ground-Water Applications 300mV Heat Pump Volt Meter Wire Electrode inserted into port for Voltage Measurement Pete’s Port Water in...
  • Page 31 BY VERSATILE SERIES– IOM Electrical Data: CV EC Blower Motor Models: Standard Unit 024-060 Compressor Voltage Min/Max Fan Motor Total Unit Min Circ Max Fuse/ Model Voltage Code Voltage HACR G.J. 208/230-60-1 197/252 10.3 62.0 14.5 17.1 BY024 H.K. 208/230-60-3 197/252 56.0 10.5...
  • Page 32 BY VERSATILE SERIES– IOM Models: Electrical: Power Wiring 024-060 POWER CONNECTION WARNING Disconnect electrical power source to prevent injury or death from Line voltage connection is made by connecting the electrical shock. incoming line voltage wires to the “L” side of the CAUTION contactor.
  • Page 33 BY VERSATILE SERIES– IOM Models: Electrical: DXM2.5 Example Wiring Diagram 024-060 NOTES: Field Use Only: Transformer wiring is voltage-sensitive. Use layout corresponding to the unit voltage. Typical heat-pump thermostat wiring shown. Refer to thermostat IOM for wiring to the unit. Thermostat wiring must be “Class I”...
  • Page 34 BY VERSATILE SERIES– IOM Models: Electrical: Low Voltage Wiring 024-060 THERMOSTAT CONNECTIONS The thermostat should be wired directly to the Therefore, LT1 is sensing refrigerant temperature, DXM2.5 board. See Electrical: Thermostat Wiring not water temperature, which is a better indication for specific terminal connections.
  • Page 35 BY VERSATILE SERIES– IOM Models: Electrical: Low Voltage Wiring 024-060 ACCESSORY CONNECTIONS WATER SOLENOID VALVES A terminal paralleling the compressor contactor coil An external solenoid valve(s) should be used on has been provided on the CXM2/DXM2.5 control. ground water installations to shut off flow to the Terminal “A”...
  • Page 36 BY VERSATILE SERIES– IOM Models: Electrical: Low Voltage Wiring 024-060 Figure 19 illustrates piping for two-stage solenoid valves. Review figures 16-18 for wiring of stage one valve. The stage-two valve should be wired between terminal “Y2” and terminal “C.” NOTE: When EWT is below 50°F (10°C), a minimum 2 GPM per ton (2.6 l/m per kW) is required.
  • Page 37 BY VERSATILE SERIES– IOM Models: Electrical: Low Voltage Wiring 024-060 REFRIGERANT DETECTION SYSTEM (RDS) FIELD-INSTALLED RDS SYSTEM The function, operation, and required servicing If an RDS is optionally being field-installed on non- measures for the Refrigerant Detection System (RDS) ducted horizontal units in sizes 006 to 048, use include the following: the following guidelines to install the refrigerant detection sensor upstream of the unit’s return air inlet:...
  • Page 38 BY VERSATILE SERIES– IOM Models: Electrical: Thermostat Wiring 024-060 THERMOSTAT INSTALLATION The thermostat should be located on an interior Mark the position of the back plate mounting holes wall in a larger room, away from supply duct and drill holes with a 3/16-inch (5 mm) bit. Install drafts.
  • Page 39 BY VERSATILE SERIES– IOM Models: EC Blower Motor Control 024-060 The EC blower motor is controlled directly by the It is highly recommended that the ACDU03J be DXM2.5 control board that converts thermostat used to set dehumidification mode electronically. inputs and CFM settings to signals used by the EC Dehumidification can NOT be selected when blower motor controller.
  • Page 40 BY VERSATILE SERIES– IOM Models: Blower Performance 024-060 CV EC MOTOR ADVANTAGE A major benefit of the CV EC motor over other blower motor types is its ability to adjust airflow directly at the unit with a communicating diagnostic service tool. Airflow levels can be adjusted in increments of 25 CFM from the unit’s minimum and maximum CFM range (see the Blower Performance: CV EC Blower Motor Standard Unit table for details).
  • Page 41 BY VERSATILE SERIES– IOM Models: Controls: DXM2.5 024-060 DXM2.5 Controls For detailed controller information, see the DXM2.5 Application, Operation, and Maintenance (AOM) manual (part # 97B0142N01). To confirm the controller type of your particular unit, refer to digit 9 on the unit model number and the unit nomenclature diagram found on page 3 of this manual.
  • Page 42 BY VERSATILE SERIES– IOM Models: Operating and Commissioning Limits 024-060 OPERATING LIMITS COMMISSIONING CONDITIONS Environment – Units are designed for indoor Starting conditions vary depending upon model and installation only. Never install units in areas subject are based upon the following notes: to freezing or where humidity levels could cause NOTES: cabinet condensation (such as unconditioned...
  • Page 43 BY VERSATILE SERIES– IOM Models: Piping System Cleaning and Flushing 024-060 PIPING SYSTEM CLEANING AND FLUSHING Cleaning and flushing the WLHP piping system is the 8. When the cleaning process is complete, single most important step to ensure proper start-up remove the short-circuited hoses.
  • Page 44 BY VERSATILE SERIES– IOM Models: Unit and System Checkout 024-060 SYSTEM CHECKOUT WARNING Polyolester Oil, commonly known as POE oil, is a synthetic oil used in System water temperature: Check water † many refrigeration systems including those with R-454B refrigerant. temperature for proper range and also verify POE oil, if it ever comes in contact with PVC or CPVC piping, may cause failure of the PVC/CPVC.
  • Page 45 BY VERSATILE SERIES– IOM Models: Unit Startup Procedure 024-060 UNIT STARTUP PROCEDURE Turn the thermostat fan position to “ON”. The Refer to the Typical Unit Operating Pressures blower should start. and Temperatures tables. Check the temperature of both entering and leaving 2.
  • Page 46 BY VERSATILE SERIES– IOM Models: Unit Startup Procedure 024-060 HE (kW) = TD x GPM x 500 NOTE: If performance during any mode appears abnormal, refer to the CXM2/DXM2.5 section or where TD is the temperature difference troubleshooting section of this manual. To obtain between the entering and leaving maximum performance, the air coil should be water, and l/s is the flow rate in U.S.
  • Page 47 BY VERSATILE SERIES– IOM Models: Unit Operating Conditions 024-060 Table 9: BY Coax Water Pressure Drop Pressure Drop (psi) Model 30°F* 50°F 70°F 90°F 110°F 2.20 3.00 BY*024 4.50 6.00 2.80 3.80 BY*030 5.60 7.50 3.40 4.50 BY*036 6.80 9.00 4.25 5.25 BY*042...
  • Page 48 BY VERSATILE SERIES– IOM Models: Unit Operating Conditions 024-060 Operating Pressure/Temperature tables include the following notes: Airflow is at nominal (rated) conditions Entering air is based upon 70°F (21°C) DB in heating and 80/67°F (27/19°C) in cooling Subcooling is based upon head pressure at compressor service port Cooling air and water values can vary greatly with changes in humidity level Table 10: BY Series Typical Unit Operating Pressures and Temperatures BY024...
  • Page 49 BY VERSATILE SERIES– IOM Models: Unit Operating Conditions 024-060 BY036 Full Load Cooling Full Load Heating Water Discharge Suction Water Discharge Suction Water Superheat Subcooling Temp Superheat Subcooling Temp EWT °F Flow Pressure Pressure Temp Pressure Pressure Temp °F °F Drop °F °F °F...
  • Page 50 BY VERSATILE SERIES– IOM Models: Unit Operating Conditions 024-060 BY048 Full Load Cooling Full Load Heating Water Discharge Suction Water Discharge Suction Water Superheat Subcooling Temp Superheat Subcooling Temp EWT °F Flow Pressure Pressure Temp Pressure Pressure Temp °F °F Drop °F °F...
  • Page 51 BY VERSATILE SERIES– IOM Models: Preventive Maintenance 024-060 WATER COIL MAINTENANCE COMPRESSOR (WATER LOOP APPLICATIONS) Conduct annual amperage checks to ensure that amp draw is no more than 10% greater than Generally water coil maintenance is not needed for indicated on the serial dataplate. closed loop systems.
  • Page 52 BY VERSATILE SERIES– IOM Models: Functional Troubleshooting 024-060 Fault Htg Clg Possible Cause Solution Check line voltage circuit breaker and disconnect. Check for line voltage between L1 and L2 on the contactor. Main power problems Green Status LED Off Check for 24VAC between R and C on CXM2/DXM2.5. Check primary/secondary voltage on transformer.
  • Page 53 BY VERSATILE SERIES– IOM Models: Functional Troubleshooting 024-060 Table continued from previous page. Fault Htg Clg Possible Cause Solution Check power supply and 24VAC voltage before and during operation. Check power supply wire size. Under Voltage Check compressor starting. Need hard start kit? Over/Under Voltage Code 7 Check 24VAC and unit transformer.
  • Page 54 BY VERSATILE SERIES– IOM Models: Functional Troubleshooting 024-060 Table continued from previous page. Fault Htg Clg Possible Cause Solution Check G wiring at heat pump. Jumper G and R for fan operation. Thermostat wiring Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode.
  • Page 55 BY VERSATILE SERIES– IOM Actual area is 7.25” w x 8.875”h Models: DXM2.5 Functional Troubleshooting Flow Chart Guides indicate .125” bleed all around 024-060 DXM2.5 Functional Start Troubleshooting Flow Chart Did Unit Check Main Attempt to power (see power Start? problems) Did Unit Check fault code on the...
  • Page 56 BY VERSATILE SERIES– IOM Models: Performance Troubleshooting 024-060 Symptom Htg Clg Possible Cause Solution Dirty filter Replace or clean. Check for dirty air filter and clean or replace. Reduced or no airflow in heating Check fan motor operation and airflow restrictions. Too high of external static? Check static vs.
  • Page 57 BY VERSATILE SERIES– IOM Models: Performance Troubleshooting 024-060 Table continued from previous page. Symptom Htg Clg Possible Cause Solution Too high of airflow Check fan motor speed selection and airflow chart. High humidity Recheck loads & sizing. Check sensible cooling load and heat Unit oversized pump capacity.
  • Page 58 BY VERSATILE SERIES– IOM Models: Startup Log Sheet Startup Log Sheet 024-060 Models: Small Packaged Units TY, TZ 7300 S.W. 44th Street, Oklahoma City, OK 73179 • Phone: 1-800-299-9747 Installer: Complete Unit and System Checkout and follow Unit Startup Procedures in the IOM. Use this form to record unit information, temperatures, and pressures during startup.
  • Page 59 Model Number: ________________________ Serial Number: ________________________ BY VERSATILE SERIES– IOM Date: ________________________ Packaged Unit Refrigeration Schematic Customer: _____________________________________ Antifreeze: ________________________ Models: Functional Troubleshooting Form Model#: ________________________ Serial#: ________________ Loop type: _______________ 024-060 Complaint: ________________________________________________________________________ HEATING CYCLE ANALYSIS - °F SUCTION COIL °F °F...
  • Page 60 BY VERSATILE SERIES– IOM Models: Revision History 024-060 Date Section Description 09/24/24 Created 100 JCI Way York, PA 17406 *97B0075N32* Johnson Controls works continually to improve its products. As a result, the design and specifications of each product at the time of order may be changed without notice and may not be as described herein.

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