® Warm Air freewatt Plus System, Models WAJ & WDJ PRODUCT SPECIFICATIONS AND PERFORMANCE GUIDE Information and specifications in the manual were in effect at time of printing of this manual. ECR International reserves the right to discontinue, change specifications or system design at any time without notice and without incurring any obligation, whatsoever. P/N# 240008351, REV D [03/2011] Check our website frequently for updates: www.freewatt.com An ISO 9001-2008 Certified Company www.ecrinternational.
PRODUCT SPECIFICATIONS AND PERFORMANCE GUIDE This guide will present the end-user, designer and installer with a better understanding of the Warm Air freewatt® PLUS System and its product data. A properly designed warm air heating system should provide comfort, efficiency and optimize equipment durability. The Warm Air freewatt® PLUS system has been developed to replace an existing warm air heating system and provide home energy features and benefits to enhance home comfort and security.
FEATURES/BENEFITS GREEN POWER GENERATION • Electronically Commutated Motor (ECM) in furnace’s blower assembly reduces electric power consumption by 20% over conventional blower motors in high heat mode and 80% in low heat mode. • Honda MCHP power generation technology provides reliable, quiet heat and power for the home. This technology integrates an engine control unit to ensure proper operating characteristics.
MODEL NUMBER DECODING WAJ 060 N 00A Model WAJ - Warm Air freewatt® PLUS WDJ - Warm Air freewatt® PLUS w/ Domestic Water Heating Revision Revision Number and Letter Furnace Firing Rate (MBH) 060, 080, 100, 120 Fuel Gas N - Natural Gas, L - LP Gas ( Propane Gas) • WAJ Series models provide space heating and electric power.
PRODUCT DESCRIPTION - MODEL WAJ/WDJ Figure 5 - freewatt® PLUS Furnace and HI Module MODEL WIDTH A DEPTH B HEIGHT VENT C H SUPPLY AIR FxG RETURN AIR DxG OVERHANG J 60 27 29 44 2 15-7/8 x 20 14- /4 x 21-1/4 3-1/2 to 5 80 28-1/2 29 44 2 17-1/2 x 20 14- /4 x 21-1/4 3-1/2 to 5 100 30-1/2 29 44 2 19-1/2 x 20 14- /4 x 21-1/4 3-1/2 to 5 120 33-1/2 29 44 2 22-1/2 x 20 14- /4 x 21-1/4 3-1/2 to 5 Model WAJ/WDJ Major Connections Furnace/HI Module Electrical: 120 VAC, 60 Hz, 1 pha
PRODUCT DESCRIPTION - MODEL WAJ/WDJ Figure 6 - Honda MCHP, Model MCHP1.2D(P), Type UCFJ Concrete Floor Requirements: • Thickness: 3" Minimum • Flatness: 1/2" In 10 Feet Class Cx • Drop-In Anchor: 3/8" Od X 1.75" Long (5/16"-18 Thread) Quantity 4 Honda MCHP Battery Honda MCHP1.2D(P) requires battery to provide power to start the engine in backup power mode.
PRODUCT DESCRIPTION - MODEL WAJ/WDJ Model WAJ/WDJ Figure 7 - freewatt® Transfer Switch Load Balancing Transformer Manufacturer Dimensions Square D ( 2S1F) Length 9.56" Width 8.68" Depth 6.56" Weight 39.1 Lbs. ACME Electric Corp. (T-2-53012-S) Length 12.52" Width 5.40" Depth 5.13" Weight 38.0 Lbs. Jefferson Electric (411-0091-000) Notes: • Weight approximately 19 Lbs. • Specifications subject to change without notice. Length 12.50" Width 6.69" Depth 5.34" Weight 41 Lbs.
PRODUCT DESCRIPTION - MODEL WAJ/WDJ Figure 9 - freewatt® PLUS Thermostat (Model RC1000WH - ECR) Figure 10 - Outdoor Temperature Sensor, Model 070 Figure 11 - Optional - TP1 Condensate Pump 8
SYSTEM DESIGN Warm Air freewatt® PLUS System requires evaluation of many site specific conditions, including • Heat Loss Calculation • Fuel Type & Existing Piping • Existing Gas Appliances • Footprint Available • AC Power & Panel Not Supplied with System Miscellaneous HVAC Components Ductwork • Supply Manifold: Connection to furnace's supply opening • Return Manifold: Connection to furnace's return opening • Existing Heating Appliance A. Asbestos B.
SYSTEM DESIGN Installation Considerations • Installation of APC UTS6H: 0 120 VAC wiring from freewatt® Transfer Switch to APC unit must be 12 gauge if run is longer than 12ft (US-NEC) 0 Pigtail for connection to Main Service Panel is factory installed, mount UTS6H in close proximity to Service Panel. Plywood backing and mounting screws are not provided. 0 Hardwire kit supplied, care should be taken to install per instructions for Model UTS6H.
PERFORMANCE DATA Warm Air freewatt® PLUS System freewatt® PLUS HEATING CAPACITIES - NATURAL GAS & PROPANE Natural Gas Model Honda MCHP Back-Up or Grid Boost Furnace WAJ080N00A WAJ100N00A WAJ120N00A WDJ080N00A WDJ100N00A WDJ120N00A WAJ060L00A WAJ080L00A WAJ100L00A WAJ120L00A WDJ060L00A WDJ080L00A WDJ100L00A WDJ120L00A Input (Btu/hr) 0-3,300’ 18,420 18,420 18,420 18,420 Output (Btu/hr) 0-3,300’ 12,300 12,300 12,300 12,300 Input (Btu/hr) 0-3,300’ 26,000 26,000 26,000 26,000 Outp
PERFORMANCE DATA Honda MCHP, Model MCHP1.2D(P), Type UCFJ Honda MCHP (UCFJ) Heating Capacities – Natural Gas & Propane Natural Gas Model 1.2D Propane Model 1.2DP Input (Btu/hr) 0-3,300’ 18,420 Thermal Output (Btu/hr) 0-3,300’ 12,300 Model Honda MCHP MCHP Mode Power Output (kW) 1.2 Voltage (V) 240 Current (A) 5 Noise Level - dB(A) 1m 47 MCHP Steady State Efficiency 89% Input (Btu/hr) 0-3,300’ 18,500-26,000 Thermal Output (Btu/hr) 0-3,300’ 12,000-17,000 Electrical Output (kW) 0 - 1.
PERFORMANCE DATA Load Balancing Transformer 240/120 VAC BALANCING TRANSFORMER ELECTRICAL SPECIFICATION Manufacturer Schneider Electric Acme Electric Corporation Jefferson Electric Brand Square D Acme Electric Jefferson Electric Catalog No.
PERFORMANCE DATA APC Universal Transfer Switch (UTS6H w/ Hardwire Kit) APC UNIVERSAL TRANSFER SWITCH Model UTS6H Manufacturer American Power Conversion Model No.
SELECTION EXAMPLE 1. Determine cooling and heating requirements at design 4. Load Selection conditions: Site Data: Required Heating Capacity 68,000 Btu/hr (Based on Design temperature = 0°F) Required Cooling Capacity 36,000 Btu/hr Select up to six (6) loads to be placed on APC UTS6H back-up panel. Loads need to be 120 VAC and each load should be less than 15 amps. Sheets on following pages outline circuit plan for back-up panel.
SELECTION EXAMPLE TV and radio circuits be configured to use proper-sized and installed UPS. Please follow instructions in UTS6H manual for UPS’s sizing and installation. 6. Heat Rejection System Heat rejection kit (sold separately) is required for backup mode operation during times when no space heating or water heating is required. • A water cooled heat rejection system is available for installations where there is uninterrupted supply of water during power outage (city water).
UTS WIRING PLAN UTS Wiring Plan Load Description Load Voltage 120V/204V Breaker Number Load Power Watts or Amps UTS Circuits Even Odd NOTES Even Circuits Total: Odd Circuits Total: Total Power: Backup Power Sources Configuration Type Power Make/ Model Overload Delay 1 UPS/Gen/ Other Watts - Seconds Start Relay Stop Relay Start Delay Stop Delay 2 2 2 2 Normally open/closed BACKUP1 BACKUP2 Note 1: Refer to the system Configuration and Setup section in the Operation Manual.
CIRCUIT ASSIGNMENTS Circuit Assignments Tables on this page and previous page are intended to be filled in and taped to inside cover of building circuit breaker panel enclosure. UTS6/UTS6H Circuit No. Load Description 1 2 3 4 5 6 Circuit 1 Circuit 1 includes load attached to Circuit 1 connection plus convenience outlet on front of UTS6H, together must consume less than 15 amps. Recommended to use Circuit 1 to power freewatt® System's low power condensate pump.
TYPICAL CONFIGURATION Warm Air freewatt® PLUS System 5 4 2 1 3 1. 2. 3. 4. 5.
TYPICAL CONFIGURATION Warm Air freewatt® PLUS System - Main Panel Configuration 2 1 1. APC Universal Transfer Switch 2. Main Service Panel Warm Air freewatt® PLUS System - Model WDJ: Domestic Hot Water Loop Double wall brazed plate heat exchanger and 3-way valve included with WDJ models for supplemental domestic hot water production. Not included in WAJ models. Water Cooled Heat Rejection System shown Potable water connections are for two separate and distinct purposes.
COMPATIBLE WATER HEATER TABLE Manufacturer Name Model No. Tank Cap. (gal) Input Rating BTU/hr Energy Factor Ef Energy Star Am. Water Heaters PowerFlex Power Vent PVG62-50T42-NV 50 42,000 0.66 Yes Am. Water Heaters PowerFlex Power Vent PVG62-50T60-NV 50 60,000 0.66 Yes Am. Water Heaters PowerFlex Power Direct Vent PDVG62-50T42-NV 50 42,000 0.66 Yes Am. Water Heaters PowerFlex Power Direct Vent PDVG62-50T60-3NV 50 60,000 0.66 Yes A.O Smith ProMaxSL GPVT-40L 40 40,000 0.
APPLICATION DATA Configuration Operation Outline of Warm Air freewatt® PLUS System’s modes of operation: Warm Air freewatt® PLUS System can be installed in several different configurations as long as installer adheres to appliance clearances. Typical configuration is explained below: Furnace, HI Module and Honda MCHP: Typical system configuration has Honda MCHP next to furnace, MCHP can be located on other side of return ductwork or behind furnace, if required.
APPLICATION DATA MCHP unit will continue to operate in Back-up Mode until freewatt® Transfer Switch senses return of utility power. freewatt® control module will safely command freewatt® Transfer Switch to re-close to utility power after MCHP unit ceases backup mode operation, and system will subsequently return to Normal Mode.
APPLICATION DATA Fifth level involves configuring your system control module for remote access. Level allows your freewatt® PLUS dealer to remotely monitor, troubleshoot and diagnose your system’s operation. Homeowner benefits from level of communication because freewatt® PLUS dealer will be remotely signaled about maintenance requirements, abnormal operating conditions and any system errors before homeowner notices these conditions.
TYPICAL ELECTRICAL SCHEMATICS 240 VAC Warm Air freewatt® PLUS System, WAJ/WDJ 25 5
TYPICAL ELECTRICAL SCHEMATICS 120 VAC Warm Air freewatt® PLUS System, WAJ/WDJ 26 6
TYPICAL ELECTRICAL SCHEMATICS 120 VAC Wiring, Warm Air freewatt® PLUS System, WAJ/WDJ, - Control Module & Controls 27
TYPICAL ELECTRICAL SCHEMATICS Low Voltage Wiring, Warm Air freewatt® PLUS System, WAJ/WDJ 28 8
TYPICAL ELECTRICAL SCHEMATICS Low Voltage Wiring, Warm Air freewatt® PLUS System, WAJ/WDJ - Control Module & Controls 29 9
TYPICAL ELECTRICAL SCHEMATICS Low Voltage Wiring, Warm Air freewatt® PLUS System, WAJ/WDJ, MCHP Unit 30
GUIDE SPECIFICATION Guide Specification – WAJ Model Section 23 54 35 Warm Air Micro-CHP System with Back-Up Power & Grid Boost Capability ECR International 2201 Dwyer Avenue Utica, NY 13501 Phone: (315) 797-1310 Fax: (315) 797-3762 Website: www.freewatt.com PART 1 – GENERAL 1.01 SUMMARY A. Section Includes: Warm Air Micro-CHP System using fuel gas (natural gas or liquid propane) to heat indoor spaces and generate power, while also providing on-demand power for grid boost or back-up power conditions.
GUIDE SPECIFICATION i. ii. 1.E.3 A. System shall optimize power output with power management equipment. Configuration of power management equipment shall allow for pre-selected loads to have delayable, non-delayable, interruptible and non-interruptible settings. B. C. 1.
GUIDE SPECIFICATION ii. iii. iv. v. 1. Triple-pass tubular primary heat exchanger 2. Stainless steel heat recovery coil 3. Silicone nitride hot surface igniter 4. Self diagnostic two stage integrated furnace control 5. Electronically commutated motor (ECM) 6. Energy Star Compliant Hybrid Integration Module 1. Coolant system 2. Air coil heat exchanger 3. High efficiency MERV 8 air filtration 4. Integrated heat rejection capability Micro-combined heat & power (MCHP) unit (UL 2200 & UL 1741): 1.
GUIDE SPECIFICATION 2.02 A. ACCESSORIES Condensate Removal: Supply approved means to remove condensate for the furnace and MCHP. PART 3 – EXECUTION 3.01 MANUFACTURER’S INSTRUCTIONS A. Compliance: Comply with manufacturer’s product data, including product technical bulletins, product catalog installation drawings and instructions. B. Coordination: Coordinate electrical or mechanical requirements for these connections. 3.02 EXAMINATION A.
GUIDE SPECIFICATION Guide Specification – WDJ Model Section 23 54 36 Warm Air Micro-CHP System with Back-Up Power & Grid Boost Capability & Domestic Water Heating ECR International 2201 Dwyer Avenue Utica, NY 13501 Phone: (315) 797-1310 Fax: (315) 797-3762 Website: www.freewatt.com PART 1 – GENERAL 1.01 SUMMARY C.
GUIDE SPECIFICATION v. Grid Interconnection: Provide an MCHP unit that meets or exceeds the performance requirements outlined in UL 1741. c. Power Management i. System shall optimize power output with power management equipment. ii. Configuration of power management equipment shall allow for pre-selected loads to have delayable, non-delayable, interruptible and non-interruptible settings. 1.E.9 1.04 SUBMITTALS E.
GUIDE SPECIFICATION PART 2 – PRODUCTS 2.01 C. D. WARM AIR MICRO-CHP SYSTEM Manufacturer: ECR International a. Contact: 2201 Dwyer Avenue, Utica, NY 13501; phone (315) 797-1310; fax (315) 797-3762; Website: www.ecrinternational.com Warm Air freewatt® PLUS System: a. Models: i. Natural Gas: WDJ060N00A, WDJ080N00A, WDJ100N00A, WDJ120N00A ii. Propane: WDJ060L00A, WDJ080L00A, WDJ100L00A, WDJ120L00A b. System shall include: i. High-efficiency, gas furnace (ANSI Z21.47/CSA 2.3): 1.
GUIDE SPECIFICATION iv. v. System controller 1. Micro-processor based with heating algorithm 2. Internet connector (RJ 45 compatible) 3. Outdoor temperature sensor (10 ohm) with outdoor mounting box Thermostat 1. 24 Volt AC 2. Programmable, communicating-type w/ LCD screen 3. Non-volatile program and setting memory: no batteries required for long-term operation 4. Energy Star compliant 2.02 B. ACCESSORIES Condensate Removal: Supply approved means to remove condensate for the furnace and MCHP.
P.O. Box 4729 Utica, NY 13504-4729 www.freewatt.com www.ecrinternational.
