WATER SOURCE HEAT PUMP
INSTALLATION, OPERATION, MAINTENANCE
Supersedes: 146.00-NOM9 (314)
RCL SERIES
LOW SILL CONSOLE
SINGLE SPEED
0.75 TON - 1.5 TON
R-410A
Issue Date:
March 29, 2017
Form 146.09-NOM1 (317)
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus.
During installation, operation maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
materials under pressure, rotating components, and
both high and low voltage. Each of these items has the
potential, if misused or handled improperly, to cause
bodily injury or death. It is the obligation and responsibility of operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property in
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that these
individuals possess independent training that will enable them to perform their assigned tasks properly and
safely. It is essential that, prior to performing any task
on this equipment, this individual shall have read and
understood this document and any referenced materials. This individual shall also be familiar with and
comply with all applicable governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Identifies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollution if proper care is not taken or instructions and are not followed.
Indicates a potentially hazardous situation which will result in possible injuries
or damage to equipment if proper care is
not taken.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accordance with Johnson Controls’ published specifications and must be performed only by a qualified
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warning will void the manufacturer’s warranty and cause serious damage to property or personal injury.
RCL SERIES INSTALLATION MANUAL
Table of Contents
Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
System Cleaning and Flushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Open Loop Ground Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Unit Startup Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Unit Startup Checklist/Unit Startup Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Compressor and Thermistor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Refrigerant Circuit Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Heat of Extraction/Rejection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Reference Calculations and Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Startup/Troubleshooting Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Revision Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
RCL SERIES INSTALLATION MANUAL
Model Nomenclature
1-3
3
5-6
7
8
9
10
11
12
13
14
15
16-17
18
RCL
S
09
L
0
A
1
C
N
N
B
5
SS
*
Vintage
* - Factory Use Only
Model Type
ype
RCL – RCL Series
S
Non-Standard Options
SS – Standard
Cabinet Conf
Configuration
fig
g
guration
hassiss Only
O
C – Chassis
hassiss with
w Cabinet
W – Chassis
assiss with
w Slope Top
S – Chassis
Air Coil/Insulation Option
5 – AlumiSealTM/Extended Range
6 – AlumiSealTM/Standard Range
7 – No Coating/Extended Range
8 – No Coating/Standard Range
pacity
y
Unit Capacity
09, 12, 15, 18
18
Piping Option
n
L – Left
ft
R – Right
ght
Sound Kit
A – None
B – Blanket
Voltage
0 – 208-230/60/1
0/60/1
2 – 265-277/60/1
7/60/1
1 (09 & 12 Only)
9 – 115/60/1
Future Option
N – None
Future Option
N – None
Unit Control
1 – CCM
A – AuroraTM Base Control (ABC)
Z – AuroraTM with SMART Equipment DDC
Coax Option
C – Copper
N – CuproNickel
Thermostat Control
1 – Unit Mounted Thermostat
2 – Remote Wall-Mount Thermostat
Note: Chassis only available with left piping option
SMART Equipment option is only available with remote wall-mounted thermostat control.
09-12 only available with PSC blower motor.
15-18 only available with 3-Speed ECM motor.
All RCL Series product is Safety listed under UL1995 thru ETL and performance listed with AHRI in
accordance with standard 13256-1.
4
RCL SERIES INSTALLATION MANUAL
General Installation Information
Water Piping
Safety Considerations
The proper water flow must be provided to each unit whenever the
unit operates. To assure proper flow, use pressure/temperature
ports to determine the flow rate. These ports should be located at
the supply and return water connections on the unit. The proper
flow rate cannot be accurately set without measuring the water
pressure drop through the refrigerant-to-water heat exchanger.
WARNING: Before performing service or maintenance
operations on a system, turn off main power switches
to the indoor unit. If applicable, turn off the accessory
heater power switch. Electrical shock could cause
personal injury.
Installing and servicing heating and air conditioning equipment can
be hazardous due to system pressure and electrical components.
Only trained and qualified service personnel should install, repair
or service heating and air conditioning equipment. Untrained
personnel can perform the basic maintenance functions of cleaning
coils and cleaning and replacing filters. All other operations should
be performed by trained service personnel. When working on
heating and air conditioning equipment, observe precautions in
the literature, tags and labels attached to the unit and other safety
precautions that may apply.
All source water connections on commercial units are fittings that
accept a male pipe thread (MPT). Insert the connectors by hand,
then tighten the fitting with a wrench to provide a leakproof joint.
When connecting to an open loop (groundwater) system, thread
any copper MPT fitting into the connector and tighten in the same
manner as described above.
Refrigerant Systems
To maintain sealed circuit integrity, do not install service gauges
unless unit operation appears abnormal. Compare the change in
temperature on the air side as well as the water side to the Unit
Operating Parameters tables. If the unit’s performance is not
within the ranges listed, and the airflow and water flow are known
to be correct, gauges should then be installed and superheat and
subcooling numbers calculated. If superheat and subcooling are
outside recommended ranges, an adjustment to the refrigerant
charge may be necessary.
Follow all safety codes. Wear safety glasses and work gloves.
Use a quenching cloth for brazing operations and have a fire
extinguisher available.
Moving and Storage
Move units in the normal “up” orientation. Do not stack units. When
the equipment is received, all items should be carefully checked
against the bill of lading to be sure all crates and cartons have
been received. Examine units for shipping damage, removing the
units from the packaging if necessary. Units in question should also
be internally inspected. If any damage is noted, the carrier should
make the proper notation on the delivery receipt, acknowledging
the damage.
5
RCL SERIES INSTALLATION MANUAL
Dimensional Data - Flat Top Cabinet
RCLW09-18
Left Hand Cabinet
Right Hand Cabinet
TOP
F
D
E
B
A
G
C
FRONT
SIDE
Right return cabinet shown in dimensional views
Overall Cabinet
A
B
C
D
E
F
Width
Depth
Height
Grille
Lid
Grille
Length
Grille
Width
in.
45.1
10.8
22.5
9.2
35.0
6.1
2.3
cm.
114.6
27.4
57.2
23.4
88.9
15.6
5.8
in.
50.0
12.8
22.5
9.2
35.0
6.1
3.3
cm.
127.0
32.4
57.2
23.4
88.9
15.6
8.3
Flat Top
Configuration
09-12
15-18
Grille
6
G
RCL SERIES INSTALLATION MANUAL
Dimensional Data - Slope Top Cabinet
RCLS09-18
Right Hand Cabinet
Left Hand Cabinet
TOP
F
D
80°
E
B
A
G
C
H
SIDE
FRONT
Right return cabinet shown in dimensional views
Overall Cabinet
A
B
C
D
E
F
Width
Depth
Height
Grille
Lid
Grille
Length
Grille
Width
in.
45.1
10.8
24.0
9.2
35.0
cm.
114.6
27.4
61.0
23.4
in.
50.0
12.8
24.0
9.2
cm.
127.0
32.4
61.0
23.4
88.9
Slope Top
Configuration
09-12
15-18
Grille
G
H
6.1
2.0
22.4
88.9
15.6
5.1
56.9
35.0
6.1
2.0
22.5
15.6
5.1
57.2
7
RCL SERIES INSTALLATION MANUAL
Dimensional Data - Chassis
RCLC09-12
25.4 AIR FLOW
WATER OUT
1/2 in. FPT
38.4
WATER IN
1/2 in. FPT
10.2
12.0
26.3
2.1
2.1
BLOWER ACCESS PANEL
COMPRESSOR
ACCESS PANEL
21.7
2.1
17.6
0.8
1.5
2.1
9.5
8.6
CONDENSATE
DRAIN CONNECTION
RCLC15-18
33.1 AIR FLOW
42.7
33.6
12.1
WATER OUT
1/2 in. FPT
1.5
2.10
WATER IN
1/2 in. FPT
21.7
2.1
17.6
1.0
9.6
1.5
8.6
8
9.1
RCL SERIES INSTALLATION MANUAL
Dimensional Data - Controls Detail: Flat Top Chassis
Left Return
Right Return
Blower Option Switch
Control Panel (Remove For
Access To Control Box)
Control Panel
(Remove For Access
To Control Box)
Blower Option Switch
Wall Mount For Chassis
w/Flat Top Cabinets
Wall Mount For Chassis
w/Flat Top Cabinets
Handy Box
Handy Box
Optional
Fused/
Non-fused
Disconnect
Optional
Fused/
Non-fused
Disconnect
Optional
Ball Valves
Optional
Ball Valves
Optional
Hose Kits
Air Filter
Air Filter
Optional
Hose Kits
Dimensional Data - Controls Detail: Slope Top Chassis
Blower Option Switch
(On Side Panel)
Blower Option Switch
(On Side Panel)
Control Panel (Remove For
Access To Control Box)
Control Panel (Remove For
Access To Control Box)
Wall Mount
Attached to Unit
Wall Mount
Attached to Unit
Optional
Fused/
Non-fused
Disconnect
Optional
Fused/
Non-fused
Disconnect
Air Filter
Air Filter
Handy Box
Handy Box
Optional
Hose Kits
Optional
Ball Valves
Optional
Ball Valves
Optional
Hose Kits
9
RCL SERIES INSTALLATION MANUAL
Physical Data
Console
Model
09
12
Compressor (1 each)
15
18
36 [1.02]
34 [1.0]
Rotary
Factory Charge R-410A, oz [kg]
27 [0.77]
27 [0.77]
Blower Motor & Blower
Blower Motor Type/Speeds
Blower Motor - hp [W]
Blower Wheel Size (Dia x W), in. [mm]
3-Spd
ECM
3-Spd
ECM
3-Spd
ECM
N/A
3 Speeds
N/A
1/4 [186]
1/4 [186]
N/A
6.0 x 6.5
[152 x 165]
6.0 x 6.5
[152 x 165]
Blower Motor Type/Speeds
PSC
Blower Motor - hp [W]
PSC
1/16 [44.7]
1/16 [44.7]
N/A
PSC
5.75 x 5.50
[146 x 140]
5.75 x 5.50
[146 x 140]
N/A
Blower Wheel Size (Dia x W), in. [mm]
2 Speeds
N/A
Coax and Water Piping
Water Connection Size - FPT - in [mm]
1/2 [12.7]
1/2 [12.7]
1/2 [12.7]
1/2 [12.7]
Coax & Piping Water Volume - gal [l]
0.15 [0.6]
0.18 [0.7]
0.15 [0.6]
0.18 [0.7]
Air Coil Dimensions (H x W), in. [mm]
8 x 22
[203 x 559]
8 x 22
[203 x 559]
8 x 30
[203 x 762]
8 x 30
[203 x 762]
Air Coil Total Face Area, ft2 [m2]
1.2 [0.114]
1.2 [0.114]
1.7 [0.16]
1.7 [0.16]
3/8 [9.5]
3/8 [9.5]
3/8 [9.5]
3/8 [9.5]
3
3
4
4
23 x 9.6
[584 x 244]
23 x 9.6
[584 x 244]
32 x 9.6
[813 x 244]
32 x 9.6
[813 x 244]
200 [91]
205 [93]
215 [98]
220 [100]
Air Coil
Air Coil Tube Size, in [mm]
Air Coil Number of Rows
Filter Standard - Throwaway, in [mm]
Weight - Packaged, lb [kg]
12/13/13
10
RCL SERIES INSTALLATION MANUAL
Installation Steps
Step 1: Unpack Equipment and Inspect for Damage
Step 2: Determine Equipment Location
•
•
•
•
•
Choose level flooring surface (Correctable with shims. Do not pitch towards drain.)
Location of wall support and fasteners required to secure chassis backplate.
Easy access for both installation and service.
Consider availability and ease of wiring, water piping and condensate drain.
No obstructions to block airflow in front of the unit.
Step 3: Mark Unit Position
• Ensure that floor is level. If shims are required, make sure that the entire compressor compartment area is uniformly
shimmed and that the backplate mounting height is increased by the thickness of the shims used.
• Position backplate in desired equipment location. To further reduce the operating sound level of the unit, 1/8-inch thick
rubber matting may be placed under the chassis to eliminate vibration on hard flooring surfaces. (Make sure back plate is level).
• Mark and cut floor or wall penetrations for electrical wiring, water and condensate piping.
Optional Electrical Disconnect and Motorized Outside Air Damper
• Mark and cut wall penetrations for field fabricated outside air duct sleeve.
• Align mounting holes with backplate and attach with screws supplied.
Figure 1
Wall Mount for Chassis
w/Flat Top Cabinets
19.0
Centered
w/ Cabinet
Low Sill
Chassis
Water Out
P/T Plugs (Optional)
Fused Electrical
Disconnect (Optional)
Wall Penetration
for Water Connection
Floor Penetration for
Water Connection
Water In
Ball Valves
(Optional)
Optional Hoses
Condensate
Drain Location
11
Low Sill Flat
Top Cabinet
RCL SERIES INSTALLATION MANUAL
Installation Steps cont.
Step 4: Provide Water and Condensate Drain Connections
• A two-pipe reverse return piping configuration is recommended as it equalizes the piping circuit lengths and delivers
even water flow to each unit. A direct return piping configuration may be used, but it may be difficult to achieve and
maintain proper water flow to the units.
• An air vent must be installed in the water distribution system.
• The supply and return water piping should be run through the wall or floor penetration and terminate with a ball valve.
The piping material used must comply with all local codes.
• Refer to: System Cleaning and Flushing procedures.
Pipe Locations
Figure 2
Console Cabinet
Console Chassis
Water Connections
Fused Electrical
Disconnect (Optional
Wall Mounted)
24V Accessory
Electrical
Junction
Box
Target Area for
Wall Penetration
5 in. x 8 in. Area Approx.
1/2 in. from Edge of
Chassis 3 in. from Floor
Cabinet Extends
to this Point
5 in. x 8 in. Area Approx.
1/2 in. from Edge of
Chassis 1 in. from Front
Edge of Cabinet
Condensate
Drain
Location
Target Area
for Floor
Penetration
12
RCL SERIES INSTALLATION MANUAL
Installation Steps cont.
Step 5: Provide Line Voltage Wiring
• Check unit data plate located on control side of chassis for ampacity and fuse size.
• Remove electrical knockouts from chassis backplate.
• Run line voltage wiring through knockout and secure wiring to backplate or disconnect.
Step 6: Chassis Installation
• Level and secure backplate to wall.
• Position the chassis against back plate. Drive (2) screws through holes in lip of backplate into top flange of chassis.
Step 7: Final Electrical Connection
• Install flexible electrical conduit between the backplate or electrical disconnect and the unit mounted junction box.
• Make final wiring connections in disconnect and junction box, taking care to replace all covers when done. Wiring must
conform to NEC and/or all local codes. Refer to Electrical Data.
NOTE: It is necessary to make final wiring connections prior to securing unit chassis to back plate on right-hand piping models
with electrical disconnect.
Step 8: Final Water Connection
• For ease of installation and sound attenuation, high pressure (recommended) flexible hoses with a swivel fitting should
be provided. Apply Teflon® tape or sealant compound to threaded hose fittings.
• Combination shut-off/balancing valves should be installed on both the supply and return water lines of the unit.
• Flow control valves should be installed on the water discharge line.
• It is recommended that P/T ports be installed on the supply and return water lines.
Step 9: Set Unit Controls
• Locate the “continuous fan/cycle fan” switch within the electrical compartment of the chassis and set to desired position.
(Remote wall thermostat units do not use this optional switch.)
• Optional Control SettingsRemote Thermostat - Run low voltage wiring from unit to the desired thermostat location.
Mount and wire thermostat according to manufacturer’s recommendations.
Step 10: Secure the Cabinet Cover
• Position and lower cabinet over unit chassis. Apply pressure to the front of the cabinet to ensure that the back lip of the
cabinet hooks over the tabs provided on the backplate.
• Secure cabinet to chassis with mounting screws provided.
Step 11: Perform Final Unit Check
• Measure the pressure drop across the water coil and monitor water or air temperatures in both heating and cooling
modes. The measured values should fall within the acceptable ranges shown in the Startup Performance table.
13
RCL SERIES INSTALLATION MANUAL
Installation Steps cont.
Field Converting Console
Chassis is normally configured with controls on right end and piping on left end (see Figure 3 top view). In this position panel number 1
would be positioned against wall or back plate. Unit may also be turned 180° against wall or back plate. In this position controls will be
on left end and piping on right end panel number 2 would be positioned against wall or back plate. Chassis must be enclosed with an
approved cabinet enclosure.
6. Replace cabinet by sliding it down over the top of the chassis.
7. Remove tab on leg that extends into return air opening. When
the grille side of the cabinet is flat against chassis there will
be 4 holes that line up in the leg section. Only use 1 hole for
alignment for opposite side of grille. (Note: The tab can be
removed by twisting back and forth until it breaks off.)
8. Remove plastic strip from tab and replace on rough edge that
the tab was removed from.
9. Replace screws in font kick panel to secure cabinet to chassis.
10. Mount filter bracket in designated opening area. (Note: The filter
bracket will only fit in one direction if cabinet is installed properly.)
1. Remove 4 screws from front kick panel on cabinet.
2. Remove cabinet from chassis by lifting and sliding cabinet
straight up.
3. Remove grille assembly from cabinet by removing 4 screws from
brackets located on the bottom of the grille and door assemblies.
4. Replace grille/door assemblies into cabinet repositioning pieces
1, 2, and 3 into the locations directly opposite the original
positions. Secure by replacing mounting brackets. (Note: Be
sure that louvers on the grille assembly are facing the proper
direction when replacing the grille section.)
5. Replace grille/frame assembly into cabinet, and secure by
replacing mounting brackets.
6
7
2
3
5
1
1
4
5
2
3
RN
6
TU
E
TR
7
GH
RI
5
5
4
RN
TU
E
TR
F
LE
14
RCL SERIES INSTALLATION MANUAL
System Cleaning and Flushing
Cleaning and Flushing
Prior to start up of any heat pump, the water circulating system must be cleaned
and flushed of all dirt and debris.
If the system is equipped with water shutoff valves, the supply and return
runouts must be connected together at each unit location (This will prevent the
introduction of dirt into the unit, see Figure 7). The system should be filled at
the water make-up connection with all air vents open. After filling, vents should
be closed.
The contractor should start the main circulator with the pressure reducing valve
makeup open. Vents should be checked in sequence to bleed off any trapped
air and to verify circulation through all components of the system.
Figure 7: Flushing with Water
Shutoff Valve Equipped Systems
Return Runout
Supply Runout
Mains
Rubber Hose
Runouts Initially
Connected Together
As water circulates through the system, the contractor should check and repair
any leaks found in the piping system. Drain(s) at the lowest point(s) in the
system should be opened for initial flush and blowdown, making sure water
fill valves are set at the same rate. Check the pressure gauge at the pump suction and manually adjust the make-up water valve to hold
the same positive pressure both before and after opening the drain valves. Flushing should continue for at least two hours, or longer if
required, until drain water is clean and clear.
The supplemental heater and/or circulator pump, if used, should be shut off. All drains and vents should be opened to completely drain the
system. Short-circuited supply and return runouts should now be connected to the unit supply and return connections.
Refill the system with clean water. Test the system water for acidity and treat as required to leave the water slightly alkaline (pH 7.5 to 8.5).
The specified percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVAC systems only.
Environol™ brand antifreeze is recommended..
Once the system has been filled with clean water and antifreeze (if used), precautions should be taken to protect the system from dirty
water conditions. Dirty water will result in system-wide degradation of performance, and solids may clog valves, strainers, flow regulators,
etc. Additionally, the heat exchanger may become clogged which reduces compressor service life and can cause premature unit failure.
In boiler/tower application, set the loop control panel set points to desired temperatures. Supply power to all motors and start the
circulating pumps. After full flow has been established through all components including the heat rejector (regardless of season), air
vented and loop temperatures stabilized, each of the units will be ready for check, test and start up and for air and water balancing.
Ground Source Loop System Checkout
Once piping is completed between the unit pumping system and ground loop, final purging and charging of the loop is needed. A high
pressure pump is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop itself. Antifreeze
solution is used in most areas to prevent freezing. Flush the system adequately to remove as much air as possible; then pressurize the
loop to a static pressure of 40-50 psi (summer) or 50-75 psi (winter). This is normally adequate for good system operation. Loop static
pressure may decrease soon after initial installation, due to pipe expansion and loop temperature change. Running the unit for at least 30
minutes after the system has been completely purged of air will allow for the “break-in” period. It may be necessary to adjust static loop
pressure (by adding water) after the unit has run for the first time. Loop static pressure will also fluctuate with the seasons. Pressures will
be higher in the winter months than during the cooling season. This fluctuation is normal and should be considered when charging the
system initially.
Ensure the pump provides adequate flow through the unit by checking pressure drop across the heat exchanger.
Usually 2.25-3.0 gpm of flow per ton of cooling capacity is recommended in earth loop applications.
15
RCL SERIES INSTALLATION MANUAL
Open Loop Ground Water Systems
Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral
precipitation. Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. Ensure proper water flow
through the unit by checking pressure drop across the heat exchanger and comparing it to the figures in unit capacity data tables in the
specification catalog. 1.5-2 gpm of flow per ton of cooling capacity is recommended in open loop applications.
Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local codes,
i.e. recharge well, storm sewer, drain field, adjacent stream or pond, etc. Most local codes forbid the use of sanitary sewer for disposal.
Consult your local building and zoning departments to assure compliance in your area.
Note: For open loop/groundwater systems or systems that do not contain an antifreeze solution, set SW1-Switch #2 to the “WELL”
position (Refer to the Dip Switch Field Selection table). Slow opening/closing solenoid valves (type VM) are recommended to eliminate
water hammer.
Water Quality
In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop
system is recommended. The heat exchanger coils in ground water systems may, over a period of time, lose heat exchange capabilities
due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualified service mechanic, as special solutions and
pumping equipment are required. Desuperheater coils can likewise become scaled and possibly plugged. In areas with extremely hard
water, the owner should be informed that the heat exchanger may require occasional flushing.
Units with cupronickel heat exchangers are recommended for open loop applications due to the increased resistance to build-up and
corrosion, along with reduced wear caused by acid cleaning.
Material
pH
Scaling
Acidity/Alkalinity
Calcium and
Magnesium Carbonate
Hydrogen Sulfide
Corrosion
Iron Fouling
(Biological Growth)
Sulfates
Chlorine
Chlorides
Carbon Dioxide
Ammonia
Ammonia Chloride
Ammonia Nitrate
Ammonia Hydroxide
Ammonia Sulfate
Total Dissolved Solids (TDS)
LSI Index
Iron, FE2+ (Ferrous)
Bacterial Iron Potential
Iron Oxide
Suspended Solids
Erosion
Threshold Velocity
(Fresh Water)
NOTES: Grains = ppm divided by 17
mg/L is equivalent to ppm
Copper
7-9
(Total Hardness)
less than 350 ppm
Less than 0.5 ppm (rotten egg
smell appears at 0.5 ppm)
Less than 125 ppm
Less than 0.5 ppm
Less than 20 ppm
Less than 50 ppm
Less than 2 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 1000 ppm
+0.5 to -0.5
90/10 Cupronickel
7-9
(Total Hardness)
less than 350 ppm
316 Stainless Steel
7-9
(Total Hardness)
less than 350 ppm
10 - 50 ppm
Less than 1 ppm
Less than 125 ppm
Less than 0.5 ppm
Less than 125 ppm
10 - 50 ppm
Less than 2 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
1000 - 1500 ppm
+0.5 to -0.5
Less than 200 ppm
Less than 0.5 ppm
Less than 300 ppm
10 - 50 ppm
Less than 20 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
1000 - 1500 ppm
+0.5 to -0.5
< 0.2 ppm
< 0.2 ppm
< 0.2 ppm
Less than 1 ppm, above this level
deposition will occur
Less than 10 ppm and filtered for
max. of 600 micron size
Less than 1 ppm, above this level
deposition will occur
Less than 10 ppm and filtered for
max. of 600 micron size
Less than 1 ppm, above this level
deposition will occur
Less than 10 ppm and filtered for
max. of 600 micron size
< 6 ft/sec
< 6 ft/sec
< 6 ft/sec
2/22/12
16
RCL SERIES INSTALLATION MANUAL
Electrical Connections
General
Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be
done in accordance with local codes or the National Electric Code, whichever is applicable.
208 Volt Operation
All 208/230 units are factory wired for 230 volt operation. For 208 volt operation, the red and blue transformer wires must be switched.
Microprocessor Remote Thermostat Wiring
Figure 5
Field
Connections
TB
Unit
Connections
R
Red
24 VAC
C
Black
COMMON
Y
Yellow
COMPRESSOR
REVERSING
VALVE
O
Orange
G
Green
FAN
Requires common
connection or 24
VAC for activation
LOCKOUT
SIGNAL
L
Brown
S
SHUTDOWN
Blue
X2
X1
W2
17
RCL SERIES INSTALLATION MANUAL
Electrical Data
Model
09
12
LRA
Blower
Motor
FLA
Total
Unit
FLA
Min
Circ
Amp
Max
Fuse/
HACR
50.0
1.5
9.5
11.5
15
4.1
21.0
0.6
4.7
5.7
10/15
4.3
22.0
0.6
4.9
6.0
10/15
Compressor
Rated
Voltage
Voltage
Min/Max
MCC
RLA
115/60/1
104/127
12.5
8.0
208-230/60/1
187/253
6.4
265/60/1
238/292
6.7
115/60/1
104/127
14.8
9.5
50.0
1.5
11.0
13.4
20
208-230/60/1
187/253
7.7
4.9
25.0
0.6
5.5
6.7
10/15
265/60/1
238/292
7.0
4.5
22.0
0.6
5.1
6.2
10/15
208-230/60/1
187/253
9.2
5.9
29.0
2.6
8.5
10.0
15
265/60/1
238/292
7.8
5.0
28.0
2.5
7.5
8.7
10/15
208-230/60/1
187/253
10.4
6.7
33.5
2.6
9.3
11.0
15
265/60/1
238/292
8.7
5.6
28.0
2.5
8.1
9.5
15
15
18
HACR circuit breaker in USA only
6/10/13
Blower Performance Data
Model
CFM
Low Speed
High Speed
09
260
300
12
300
340
15
375
450
18
450
600
Air flow values are with dry coil and standard filter.
For wet coil performance, first calculate the face velocity of the air coil (face
velocity (fpm) = airflow (cfm) / face area (sq ft))
18
RCL SERIES INSTALLATION MANUAL
Wiring Schematics
CCM with Remote Thermostat - 208-230-265/60/1
Compressor
S
Blue
PSC
Blower
Motor
C
Brn
Grn
Red
Wht
Unit
Power Supply
208-230/60/1 or
265-277/60/1
Ground
Lug
R
Handi - Box
Blk
G
Tan (33)
Cap
L
T2
T1
CC
L2
L1
H
Black (31)
White (28)
Black (29)
Red (30)
Black (27)
Red (32)
Brown (26)
Black
Blower Switch
High
Black (25)
Low
4
Blue
230V
265V
2
RB
NOTE 3
Red
24 V Supply for Start/
Stop Signal
Transformer
5
RSR
PB
1
NOTE 3
Red
208V
NOTE 1
4
24V
Yellow
Black/White
5
1
2
NOTE 2
Brown
Black
3
TEST
PIN
Green (00)
Red (2)
R
R
Brown (3)
Black (22)
Violet (4)
Brown
Violet (5)
HP
Pink
White
Orange (21)
Not Used
LP
PB-2
1
Yellow
FS
2
Black (6)
Black (7)
Blue (8)
Blue (9)
Yellow (10)
C
Black/White (1)
Orange
C
Yellow
Y LP LP HP HP CC CG LO
Black
Y LP LP HP HP CC CG LO
Terminal Board
R C Y1 O G L S X2 X1 W1
Red
Green
3
RSR
COMPRESSOR
CONTROL MODULE
Yellow (10)
RV
Orange
1
3
Violet (4)
Green
Violet (5)
RB
CC
Pink
Legend
Legend
Factory low voltage wiring
Factory line voltage wiring
Factory low voltage wiring
Factory line voltage wiring
Quick connect terminal
Wire nut
CC - Compressor Contactor
DT - Damper Terminal Block
FS - Freeze Sensing Device
HP - High Pressure Switch
LP - Low Pressure Switch
PB - Power Block
RB - Blower Relay
RSR – Remote Start/Stop Relay
RV - Reversing Valve Coil
ST - Entering Air Temperature Sensor
L1
Wiring lug
HP
Switch - High Pressure
Ground
LP
Switch - Low Pressure
Relay coil
Relay Contacts N.O., N.C.
Capacitor
T
Notes:
1. Switch Red and Blue wires for 208 volt operation.
2. Terminal C of the 24V PB is used as “L” output for
Brown wire 3 for Lockout.
3. When installed, 24VAC connection for remote
start/stop controller option.
Thermistor
Temperature Switch
97P827-01 6/24/11
19
RCL SERIES INSTALLATION MANUAL
Wiring Schematics cont.
CCM with Unit Mounted Thermostat - 208-230-265/60/1
Compressor
S
Blue
PSC
Blower
Motor
C
Ground
Lug
R
Brn
Grn
Red
Wht
Unit
Power Supply
208-230/60/1 or
265-277/60/1
Handi - Box
Blk
G
Tan (33)
Cap
White (28)
L
T2
T1
CC
L2
L1
H
Brown (26)
Black (31)
Red (32)
White (28)
Black (29)
Red (30)
ůŽǁĞƌ^ǁŝƚĐŚ
Black
High
Blue
230V
265V
4
Black (25)
2
Black (27)
NOTE 1 Red
208V
dƌĂŶƐĨŽƌŵĞƌ
Low
Z
5
Brown (26)
24V
PB
1
Red (19)
Yellow
Black/White
2
DŽĚĞ^ǁŝƚĐŚ
NOTE 2
Black (12)
Red (19)
Black (22)
4
Yellow (13)
3
5
Green (00)
TEST
PIN
Yellow (10)
Red (11)
Ther
mistor
24 V
AC
,ĞĂƚ
T1
T3
T2
T3
T4
T1
LP
Black
Blue (8)
Blue (9)
Yellow (10)
C
COMPRESSOR
CONTROL MODULE
T
Black (12)
Red (17)
&ĂŶDŽĚĞ^ǁ
ŽŶƟŶƵŽƵƐ
Black (22)
White (18)
Red (11)
White (20)
1
Z
3
Red
Cycled
Orange
Overide
Shut down
T2
Yellow (13)
T4
Orange (14)
T6
Blue (T6)
T5
ŽŽů
Black (7)
Red
T5
T6
Black (6)
&^
NOTE 3
ST
Black
R
Violet (5)
HP
Red (17)
IN
PUT
Brown (3)
Violet (4)
CC
White (18)
ůĞĐƚƌŽŶŝĐd,ZDK^dd
Red (2)
R
Fan
3
2
Y LP LP HP HP CC CG LO
ƵƚŽ
Y LP LP HP HP CC CG LO
Black/White (1)
1
C
6
Red (15)
Orange (21)
Zs
Not Used
24VAC
^ŚƵƚĚŽǁŶ
SHUT
J1
DOWN
Red (16)
Yellow (13)
Legend
Factory low voltage wiring
Factory line voltage wiring
Field low voltage wiring
Field line voltage wiring
Quick connect terminal
Field wire lug
L1
Earth Ground
HP
LP
Relay Contacts N.O., N.C.
1
P
3
2
Wire nut
CC - Compressor Contactor
DT - Damper Terminal Block
FS - Freeze Sensing Device
HP - High Pressure Switch
LP - Low Pressure Switch
PB - Power Block
RB - Blower Relay
RV - Reversing Valve Coil
ST - Entering Air Temperature Sensor
Switch - High Pressure Notes:
1. Switch Red and Blue wires for 208 volt operation.
Switch - Low Pressure 2. Terminal C of 24 V PB is used as “L”output for
Brown wire 3 for Lockout.
Relay coil
3. Optional field installed freeze sensing device.
Capacitor
Polarized
Connector
T
Thermistor
Temperature Switch
97P827-02 7/14/11
20
21
B Cool
T6
Not Used
White (18)
Overide
Shut down
J1
Orange (14)
Continuous
Cycled
Fan Mode Switch
Green
Red (19)
DH
W
Y2
Y1
G
O/B
C
LO
R
ACC NC
ACC NO
C
K6-Acc
Relay
K5-Alarm
Relay
RS485 NET
C
F FG CC CCG
Note 2
R
-
RS485 NET
JW2
P8
Com2
LED5
G
R
+ P7
G
Com1
LED5
K4-Fan Relay
R
P1
ALG
ACC COM
P9
CC2 CC2 CC2 P5
HI LO G
C
R
-
RS485 EXP
Green
(00)
Condensate
Brown (23)
LP
HP
SW1
Test Mode
Y1
G
Status
LED3
G
CC
FP1 – 15°F/30°F
FP2 – 15°F/30°F
RV – B/O
Acc – Dip 4
Acc – Dip 5
CC – Dual/Single
L Output Type
Future Use
Fault
LED1
R
Config
LED2
Y
Yellow
On
1
2
3
4
5
6
7
8
SW2
Off
P13
C
CFM
PWM
F
F1-3A
R
C
Black/White
REV REV FP1 FP1 FP2 FP2 LPS LPS HPS HPS P4
+ P6 CO C EH1 C EH2 P3
Aurora Base Control
(ABC)
K3-CC2 Relay
DOWN
Blue (T6)
Red (17)
C
K2-CC Relay
SHUT
Yellow (13)
Orange (14)
F
K1-RV Relay
T5
T6
T4
T2
LS
ALM
CC
Black (15)
Red
CC2
Yellow
Orange
ES
EH1
Orange (01)
T1
P2
Yellow
Fan
Red (19)
Orange (02)
2
Auto
470Ÿ
Resistor
Transformer
Blue (07)
T4
T3
3
1
FD
Red 208V
470Ÿ
T5
T2
Red (11)
RV
Note 1
Black (09)
Red (11)
Black (12)
Yellow
Blue 230V/265V
Black
G
Black (10)
T3
AC
6
5
Red (32)
Black (31)
Ground
Lug
Unit
Power Supply
208-230/60/1 or
265-277/60/1
24V
Blue (08)
T1
A Heat
Red
4
Mode Switch
L1
Violet (14)
White (12)
T
ST
Yellow (13)
T1
CC
Handi - Box
Black (13)
CC
RB
24 V
Black
Black
Black (12)
L2
R
Black
Compressor
T
mistor
Ther
Black (27)
White (28)
T2
Tan (33)
Red
C
RV
IN
PUT
Cap
4 RB 2
White (28)
Low
Red (30)
BlackRed
(25)
High
Black (29)
L
Brn
Brn/Wht
S
24V Emergency
Shutdown
Red
Electronic THERMOSTAT
Fan Speed
Switch
H
Grn
PSC
Fan
Motor
Blue
RCL SERIES INSTALLATION MANUAL
Wiring Schematics cont.
ABC - with PSC Motor and Electronic Stat - 208-230-265/60/1
ES
Red
ES
Yellow
RCL SERIES INSTALLATION MANUAL
Wiring Schematics cont.
ABC - with PSC Motor and Electronic Stat - 208-230-265/60/1
Accessory Relay
Operation
SW2-4 SW2-5
On
On
Cycle with Blower
Off
Off
Cycle with Compressor
Off
On
Water Valve Slow Open
Off
On
Outdoor Air Damper
Aurora Timing Events
Normal Mode
Test Mode
Event
5 to 80 seconds
1 second
Random Start Delay
5 seconds
< 1 second
Compressor On Delay
2 minutes
5 seconds
Compressor Minimum On Time
4 minutes
15 seconds
Compressor Short Cycle Delay
30 seconds
2 seconds
Blower Off Delay
Less than 1 second Less than 1 second
Fault Recognition Delay – High Pressure
2 minutes
30 seconds
Start-Up Bypass – Low Pressure
30 seconds
30 seconds
Fault Recognition Delay – Low Pressure
2 minutes
30 seconds
Start-Up Bypass – Low Water/Air Coil Limit
30 seconds
30 seconds
Fault Recognition Delay – Low Water/Air Coil Limit
30 seconds
30 seconds
Fault Recognition Delay – Condensate Overflow
2 seconds
2 seconds
Thermostat Call Recognition Time
5 minutes
20 seconds
Auxiliary Heat Staging Delay
2 minutes
7.5 seconds
Emergency Heat Staging Delay
90 seconds
90 seconds
Water Valve Slow Open Delay
30 seconds
30 seconds
Reheat Delay
Aurora LED Flash Codes
1 second on and 1 second off
100 milliseconds on and 100 milliseconds off
100 milliseconds on and 400 milliseconds off with a 2 second pause before repeating
Random Start Delay
Fast Flash
Status LED (LED1, Green)
Fast Flash
Configuration LED (LED2, Yellow)
Fast Flash
Fault LED (LED3, Red)
Configuration LED (LED2, Yellow)
Fault LED (LED3, Red)
Status LED (LED1, Green)
OFF
No Software Overide
Flash ECM Setting Normal Mode
Normal Mode
ON
Flash Code 1
DIP Switch Overide
Slow Flash
Input Fault Lockout
OFF
Control is Non-Functional
Fast Flash
High Pressure Lockout
Flash Code 2
Test Mode
Slow Flash ECM Configure Mode
Off
Low Pressure Lockout
Flash Code 3
Fast Flash Reset Configure Mode
Lockout Active
Flash Code 4
Low Air Coil Limit Lockout - FP2
Flash Code 2
Dehumidification Mode
Low Water Coil Limit Lockout - FP1 Flash Code 5
Flash Code 3
Reserved
Reserved
Flash Code 6
Flash Code 4
Reserved
Flash Code 7
Condensate Overflow Lockout
Flash Code 5
Load Shed
Over/Under Voltage Shutdown
Flash Code 8
ESD
Flash Code 6
Flash Code 9
Flash Code 7
Reserved
Reserved
Flash Code 10
Reserved
Flash Code 11
Air/Water Coil Limit Sensor Error
Slow Flash
Fast Flash
Flash Code
G
Light Emitting Diode - Green
Y
Light Emitting Diode - Yellow
CC – Dual/Single
6
L – Pulse/Continuous
7
Reheat/Normal
8
P3
G
(+)
(-)
R
C
Com2
G
Acc – K6
P9
P7
P8
F
G
(+)
(-)
R
C
RS 485
Com1
P11
Alarm – K5
P6
RS485 Exp
AURORA BASE
CONTROL™
EH2
C
EH1
C
CO
N/A
Factory Fan Connection
Y2
C
C
3A-Fuse
W
DH
DH
Y2
W
G
O/B
R
Y1
Y1
G
C
R
LO
ACC nc
ES
22
Field Connections
P1
O/B
Field Connections
P2
ACC c
SW1 – Push button
SW2 – DIP package 8 position
PB – Power Block
RB – Blower Relay
RV – Reversing Valve Coil
LO
Y1
JW2 Alarm
C
C
Light Emitting Diode - Red
Config
Factory
5
EH1
Y
SW2
Fan – K4
ALG
R
4
ACC – Dip 5
LED2
CC Hi – K3
CC
Wire nut
CC – Compressor Contactor
CO – Condensate Overflow Sensor
ES – Emergency Shutdown
HP – High Pressure Switch
LP – Low Pressure Switch
FD – Freeze Detection Sensor
F1 – Fuse
P5
LS
Temperature Switch
ACC – Dip 4
Factory Use
Polarized connector
G
LO
HI
CCG
CC
FG
F
R
Factory
CC2
Switch - Low pressure
ALM
Fuse
3
Status
CC – K2
Switch - High pressure
1
Capacitor
G
CC2
Ground
Relay Contacts – N.O., N.C.
RV – B/O
LED3
SW1 Test
Switch - Condensate Overflow
2
Field Wiring Lug
2
RV – K1
Relay Coil
3
L1
On
1
FP2 – 15oF/30oF
Fault
Thermistor
T
FP1 – 15oF/30oF
R
P13
ACC no
Factory Low Voltage Wiring
Factory Line Voltage Wiring
Field Low Voltage Wiring
Field Line Voltage Wiring
Optional Block
DC Voltage PCB Traces
Field Zone Sensor Wiring
Internal Junction
Quick Connect Terminal
Off
LED1
ECM PWM
RS485 NET
Legend
P4
Factory
HP
HP
LP
LP
FP2
FP2
FP1
FP1
REV
REV
C
PWM
CFM
Notes:
1 – Swap blue and red leads for 208V operation.
2 – Use ALG Output for 24V lockout.
R
R
RCL SERIES INSTALLATION MANUAL
Wiring Schematics cont.
ABC - PSC Motor with Remote Stat - 208-230-265/60/1
Compressor
S
Unit
Power Supply
208-230/60/1 or
265/60/1
C
Blu
Ground
Lug
Blk
Brn/Wht
Brn
T1
T2
CC
Cap
L2
White (28)
L
L1
Black
White (28)
White
Black (29)
Fan Speed
Switch
Black
Blue 230V/265V
Red (30)
High
G
Handi - Box
Tan
Grn
H
R
Red
PSC
Fan
Motor
Low
Note 1
Red 208V
Transformer
BlackRed
(25)
4 RB 2
Black (27)
Yellow
C
Fan
G
Compressor A
Y1
Electric Heat
W
K1-RV Relay
O
K3-CC2 Relay
Reversing Valve
K5-Alarm
Relay
K2-CC Relay
C
R
F1-3A
F
ACC COM
LO1
ACC NC
PWM
K6-Acc
Relay
Aurora Base Control
(ABC)
LO
R
SW1
Test Mode
CFM
Status
LED3
G
O/B
G
FP1 – 15°F/30°F
FP2 – 15°F/30°F
RV – B/O
Acc – Dip 4
Acc – Dip 5
CC – Dual/Single
L Output Type
Future Use
Y1
Y2
W
DH
P1
RS485 NET
R
LO2
C
Com2
LED5
G
Com1
LED5
RS485 NET
P8
C
R
-
G
+ P7
Config
LED2
Y
RS485 EXP
C
R
-
+ P6 CO C EH1 C EH2 P3
Y2
Class 2
Black/
White
Brown (23)
Green
(00)
Black/
White
C
Fault
LED1
R
C
DH
Red
Yellow
Black (09)
Black (10)
Blue (08)
Blue (07)
Yellow
REV REV FP1 FP1 FP2 FP2 LPS LPS HPS HPS P4
Condensate
Note 2
23
Y1
G
CC
P13
On
1
2
3
4
5
6
7
8
SW2
Off
ES
HP
470Ÿ
CC2 CC2 CC2 P5
HI LO G
Orange (02)
F FG CC CCG
Orange (01)
Black (15)
LS
LS
ALM
24VAC Common
Lockout Circuit B
R
K4-Fan Relay
ES
ACC NO
Compressor B
P9
Black (13)
ES
R
Dehumidification
C
LP
P2
ALG
24VAC
F
Yellow
Violet (14)
Load Shed
Lockout Circuit A
CC
FD
T
CC
White (12)
RV
RB
Emerg Shutdown
CC2
JW2
EH1
TB
Red
RV
ES
Black/White
470Ÿ
Resistor
Black (27)
24V Emergency
Shutdown
RCL SERIES INSTALLATION MANUAL
Wiring Schematics cont.
ABC - PSC Motor with Remote Stat - 208-230-265/60/1
Notes:
Aurora Timing Events
Test Mode
Normal Mode
Event
5 to 80 seconds
1 second
Random Start Delay
5 seconds
< 1 second
Compressor On Delay
2 minutes
5 seconds
Compressor Minimum On Time
4 minutes
15 seconds
Compressor Short Cycle Delay
30 seconds
2 seconds
Blower Off Delay
Less than 1 second Less than 1 second
Fault Recognition Delay – High Pressure
2 minutes
30 seconds
Start-Up Bypass – Low Pressure
30 seconds
30 seconds
Fault Recognition Delay – Low Pressure
2 minutes
30 seconds
Start-Up Bypass – Low Water/Air Coil Limit
30 seconds
30 seconds
Fault Recognition Delay – Low Water/Air Coil Limit
30 seconds
30 seconds
Fault Recognition Delay – Condensate Overflow
2 seconds
2 seconds
Thermostat Call Recognition Time
5 minutes
20 seconds
Auxiliary Heat Staging Delay
2 minutes
7.5 seconds
Emergency Heat Staging Delay
90 seconds
90 seconds
Water Valve Slow Open Delay
30 seconds
30 seconds
Reheat Delay
1 – Swap blue and red leads for 208V operation.
2 - When field installed 24VAC motorized valve is used, connect
to C and Y.
Accessory Relay
Operation
SW2-4 SW2-5
On
On
Cycle with Blower
Off
Off
Cycle with Compressor
Off
On
Water Valve Slow Open
Off
On
Outdoor Air Damper
Aurora LED Flash Codes
1 second on and 1 second off
100 milliseconds on and 100 milliseconds off
100 milliseconds on and 400 milliseconds off with a 2 second pause before repeating
Random Start Delay
Fast Flash
Status LED (LED1, Green)
Fast Flash
Configuration LED (LED2, Yellow)
Fast Flash
Fault LED (LED3, Red)
Configuration LED (LED2, Yellow)
Fault LED (LED3, Red)
Status LED (LED1, Green)
No Software Overide
Flash ECM Setting Normal Mode
OFF
Normal Mode
ON
DIP Switch Overide
Slow Flash
Input Fault Lockout
Flash Code 1
OFF
Control is Non-Functional
Flash Code 2
Fast Flash
High Pressure Lockout
Test Mode
Slow Flash ECM Configure Mode
Flash Code 3
Off
Low Pressure Lockout
Fast Flash Reset Configure Mode
Lockout Active
Flash Code 4
Low Air Coil Limit Lockout - FP2
Flash Code 2
Dehumidification Mode
Low Water Coil Limit Lockout - FP1 Flash Code 5
Flash Code 3
Reserved
Flash Code 6
Reserved
Flash Code 4
Reserved
Flash Code 7
Condensate Overflow Lockout
Flash Code 5
Load Shed
Flash Code 8
Over/Under Voltage Shutdown
ESD
Flash Code 6
Flash Code 9
Flash Code 7
Reserved
Reserved
Flash Code 10
Reserved
Flash Code 11
Air/Water Coil Limit Sensor Error
P5
EH1
Y
Config
Factory
P3
Fan – K4
G
Com2
G
Acc – K6
G
P9
(+)
(-)
R
P8
F
CC
P7
C
P11
Alarm – K5
(+)
(-)
R
C
RS 485
Com1
EH2
C
EH1
C
CO
N/A
P6
RS485 Exp
AURORA BASE
CONTROL™
CC Hi – K3
Factory Fan Connection
Y2
C
C
3A-Fuse
W
DH
DH
Y2
W
G
Y1
Y1
G
O/B
Field Connections
P1
ACC nc
ACC c
ACC no
LS
ES
24
ALG
Field Connections
P2
ALM
SW1 – Push button
SW2 – DIP package 8 position
PB – Power Block
RB – Blower Relay
RV – Reversing Valve Coil
LO
Y1
JW2 Alarm
O/B
C
Wire nut
CC – Compressor Contactor
CO – Condensate Overflow Sensor
ES – Emergency Shutdown
HP – High Pressure Switch
LP – Low Pressure Switch
FD – Freeze Detection Sensor
F1 – Fuse
7
8
C
Light Emitting Diode - Red
6
Reheat/Normal
R
Light Emitting Diode - Yellow
CC – Dual/Single
L – Pulse/Continuous
R
Y
5
Factory Use
Light Emitting Diode - Green
G
LO
HI
CCG
CC
FG
F
R
Factory
Polarized connector
R
4
ACC – Dip 5
LED2
SW2
LO
Fuse
Temperature Switch
ACC – Dip 4
Status
CC – K2
CC2
Switch - Low pressure
1
Capacitor
G
SW1 Test
Switch - High pressure
G
3
LED3
CC2
Ground
Relay Contacts – N.O., N.C.
RV – B/O
Fault
Switch - Condensate Overflow
2
Field Wiring Lug
2
RV – K1
Relay Coil
3
L1
On
1
FP2 – 15oF/30oF
P13
Thermistor
T
FP1 – 15oF/30oF
R
C
Factory Low Voltage Wiring
Factory Line Voltage Wiring
Field Low Voltage Wiring
Field Line Voltage Wiring
Optional Block
DC Voltage PCB Traces
Field Zone Sensor Wiring
Internal Junction
Quick Connect Terminal
Off
LED1
ECM PWM
RS485 NET
Legend
P4
Factory
HP
HP
LP
LP
FP2
FP2
FP1
FP1
REV
REV
C
PWM
CFM
Slow Flash
Fast Flash
Flash Code
R
R
High
T5
25
B Cool
T4
T6
Not Used
Shut down
Overide
J1
Orange (14)
Continuous
Cycled
Fan Mode Switch
White (18)
Green
Red (19)
DH
W
Y2
Y1
G
O/B
C
LO
R
ACC NC
ACC NO
C
K6-Acc
Relay
K5-Alarm
Relay
RS485 NET
C
R
-
RS485 NET
JW2
P8
Com2
LED5
G
+ P7
G
Com1
LED5
K4-Fan Relay
R
P1
ALG
ACC COM
F FG CC CCG
CC2 CC2 CC2 P5
HI LO G
C
R
-
RS485 EXP
Note 3
Green
(00)
Condensate
Brown (23)
470Ÿ
Resistor
LP
HP
SW1
Test Mode
Y1
G
Status
LED3
G
CC
Config
LED2
Y
FP1 – 15°F/30°F
FP2 – 15°F/30°F
RV – B/O
Acc – Dip 4
Acc – Dip 5
CC – Dual/Single
L Output Type
Future Use
Fault
LED1
R
R
C
On
1
2
3
4
5
6
7
8
SW2
Off
P13
C
CFM
PWM
F
F1-3A
Black/White
Yellow
REV REV FP1 FP1 FP2 FP2 LPS LPS HPS HPS P4
+ P6 CO C EH1 C EH2 P3
Aurora Base Control
(ABC)
K3-CC2 Relay
DOWN
Blue (T6)
Red (17)
R
K2-CC Relay
SHUT
Yellow (13)
Orange (14)
P9
K1-RV Relay
T5
T6
T4
C
White (12)
Orange
F
Violet (14)
T2
CC
Black (13)
LS
ALM
CC2
Black (15)
Red
ES
EH1
Orange (01)
T1
P2
FD
Yellow
Fan
Red (19)
RV
Red 208V
Yellow
2
Auto
Yellow
NOTE 1
Orange (02)
T3
3
1
5
Blue 230V/265V
Black
Blue (07)
T2
Red (11)
6
4
Mode Switch
Red (32)
Black (31)
G
24V
470Ÿ
Red (11)
Black (12)
Yellow (13)
Black (12)
L1
Ground
Lug
Black (10)
T3
AC
Red
T
ST
Black (27)
T1
CC
Handi - Box
Unit
Power Supply
208-230/60/1 or
265-277/60/1
Black (09)
T1
24 V
Black
Black
Red
RB 2
R
Black
Compressor
Transformer
T
mistor
Ther
4
L2
Red
C
CC
Blue (08)
A Heat
Blue
Low
Black
Red
T2
Tan (33)
S
RB
RV
IN
PUT
White
Black (25)
Yellow
Blue
24V Emergency
Shutdown
Red
Electronic THERMOSTAT
Fan Speed
Switch
Note 3
Green/Yellow
ECM
ECM
Motor
Motor
Module
Module
Motor
ECM
RCL SERIES INSTALLATION MANUAL
Wiring Schematics cont.
ABC - with ECM Motor and Electronic Stat - 208-230-265/60/1
Red
ES
ES
Yellow
RCL SERIES INSTALLATION MANUAL
Wiring Schematics cont.
ABC - with ECM Motor and Electronic Stat - 208-230-265/60/1
Accessory Relay
Operation
SW2-4 SW2-5
On
On
Cycle with Blower
Off
Off
Cycle with Compressor
Off
On
Water Valve Slow Open
Off
On
Outdoor Air Damper
Aurora Timing Events
Normal Mode
Test Mode
Event
5 to 80 seconds
1 second
Random Start Delay
5 seconds
< 1 second
Compressor On Delay
2 minutes
5 seconds
Compressor Minimum On Time
4 minutes
15 seconds
Compressor Short Cycle Delay
30 seconds
2 seconds
Blower Off Delay
Less than 1 second Less than 1 second
Fault Recognition Delay – High Pressure
2 minutes
30 seconds
Start-Up Bypass – Low Pressure
30 seconds
30 seconds
Fault Recognition Delay – Low Pressure
30 seconds
2 minutes
Start-Up Bypass – Low Water/Air Coil Limit
30 seconds
30 seconds
Fault Recognition Delay – Low Water/Air Coil Limit
30 seconds
30 seconds
Fault Recognition Delay – Condensate Overflow
2 seconds
2 seconds
Thermostat Call Recognition Time
5 minutes
20 seconds
Auxiliary Heat Staging Delay
2 minutes
7.5 seconds
Emergency Heat Staging Delay
90 seconds
90 seconds
Water Valve Slow Open Delay
30 seconds
30 seconds
Reheat Delay
Aurora LED Flash Codes
1 second on and 1 second off
100 milliseconds on and 100 milliseconds off
100 milliseconds on and 400 milliseconds off with a 2 second pause before repeating
Random Start Delay
Fast Flash
Status LED (LED1, Green)
Fast Flash
Configuration LED (LED2, Yellow)
Fast Flash
Fault LED (LED3, Red)
Configuration LED (LED2, Yellow)
Fault LED (LED3, Red)
Status LED (LED1, Green)
OFF
No Software Overide
Flash ECM Setting Normal Mode
Normal Mode
ON
Flash Code 1
DIP Switch Overide
Slow Flash
Input Fault Lockout
OFF
Control is Non-Functional
Flash Code 2
Fast Flash
High Pressure Lockout
Test Mode
Slow Flash ECM Configure Mode
Flash Code 3
Off
Low Pressure Lockout
Fast Flash Reset Configure Mode
Lockout Active
Flash Code 4
Flash Code 2
Low Air Coil Limit Lockout - FP2
Dehumidification Mode
Flash Code 3
Low Water Coil Limit Lockout - FP1 Flash Code 5
Reserved
Flash Code 6
Reserved
Flash Code 4
Reserved
Flash Code 7
Flash Code 5
Condensate Overflow Lockout
Load Shed
Flash Code 8
Over/Under Voltage Shutdown
Flash Code 6
ESD
Flash Code 9
Flash Code 7
Reserved
Reserved
Flash Code 10
Reserved
Flash Code 11
Air/Water Coil Limit Sensor Error
Slow Flash
Fast Flash
Flash Code
Blower Settings
High
Low
LC*15
Yellow
White
LC*18
Blue
Yellow
6
7
Reheat/Normal
8
P3
Factory
CC – Dual/Single
L – Pulse/Continuous
Config
G
(+)
(-)
R
P8
Com2
P9
P7
C
P11
G
Acc – K6
G
(+)
(-)
R
C
RS 485
Factory Use
Com1
EH2
C
EH1
C
CO
N/A
P6
RS485 Exp
AURORA BASE
CONTROL™
Alarm – K5
CC
Factory Fan Connection
Y2
Y1
G
C
C
3A-Fuse
W
DH
DH
Y2
W
G
Y1
O/B
R
R
LO
ES
Field Connections
P1
O/B
Field Connections
P2
ALG
SW1 – Push button
SW2 – DIP package 8 position
PB – Power Block
RB – Blower Relay
RV – Reversing Valve Coil
LO
Y1
JW2 Alarm
C
C
Wire nut
CC – Compressor Contactor
CO – Condensate Overflow Sensor
ES – Emergency Shutdown
HP – High Pressure Switch
LP – Low Pressure Switch
FD – Freeze Detection Sensor
F1 – Fuse
5
F
ACC nc
Light Emitting Diode - Red
4
ACC – Dip 5
EH1
Y
SW2
Fan – K4
ACC c
R
ACC – Dip 4
LED2
CC Hi – K3
ACC no
Light Emitting Diode - Yellow
LS
Temperature Switch
Y
P5
ALM
Fuse
G
LO
HI
CCG
CC
FG
F
R
Factory
CC2
Polarized connector
Light Emitting Diode - Green
3
Status
CC – K2
Switch - Low pressure
1
Capacitor
G
Switch - High pressure
G
RV – B/O
LED3
SW1 Test
CC2
Ground
Relay Contacts – N.O., N.C.
2
Fault
Switch - Condensate Overflow
2
Field Wiring Lug
FP2 – 15oF/30oF
RV – K1
Relay Coil
3
L1
R
P13
Thermistor
T
On
1
C
Factory Low Voltage Wiring
Factory Line Voltage Wiring
Field Low Voltage Wiring
Field Line Voltage Wiring
Optional Block
DC Voltage PCB Traces
Field Zone Sensor Wiring
Internal Junction
Quick Connect Terminal
FP1 – 15oF/30oF
RS485 NET
Legend
P4
Off
LED1
ECM PWM
Factory
HP
HP
LP
LP
FP2
FP2
FP1
FP1
REV
REV
C
PWM
CFM
Notes:
1 – Swap blue and red leads for 208V operation.
2 – Use ALG Output for 24V lockout.
3 – Factory wired. Refer to blower table settings.
R
R
Page 1
26
RCL SERIES INSTALLATION MANUAL
Controls
Control
General Description
Application
Display/Interface
CCM Control
The CCM (Compressor control module)
is a more reliable replacement for
electro-mechanical control applications.
It features a small microprocessor
board that handles the lockout function
of the unit. A second microporcessor
handles the unit mounted thermostat for
maintaining accurate room temperature.
Residential and commercial
applications requiring minimal but
reliable controls. Includes Random
Start, High and low pressure switches
and auto changeover capability.
Dial thermostat with Hi and
Low blower speeds, and
auto changeover or cont
blower selection switches.
Protocol
None
Thermostat Options
Unit Mounted Digital
Dial Thermostat
Remote Mounted
Standard Thermostat
If either the low or high pressure safety switches are opened, the
compressor and reversing valve are disabled by the lockout relay.
Unit operation will resume only after the voltage to the unit is
interrupted or the mode switch is placed in the “Off” position.
Standard CCM Control Features
Compressor control module (CCM) controls are standard on the
RCL Series Low Sill Console heat pump. This control features unit
mounted thermostat and switches,
Features of the standard control are:
• Easy to understand color coded thermostat adjustment markings.
• Large, rocker type mode and blower switches.
• Internally mounted blower switch to choose cycled or constant
blower operation.
• High pressure and low pressure safety controls to protect the
unit components.
• Lockout circuit to shut down unit operation upon receipt of a fault
indicator from the safety controls.
• A 24 volt control circuit allows for safe and easy diagnosis.
The user selects either “Heat/Cool” or “Fan Only” on the mode
switch, then either “High” or “Low” at the blower speed switch. The
temperature can be controlled by rotating the thermostat control knob.
Unit Mounted Control
The “Fan Only” setting provides constant blower operation.
In the “Heat” mode, a call for heat by the thermostat closes the
compressor contactor contacts, energizing the compressor, which
will run until the thermostat is satisfied.
In the “Cool” mode, a call for cooling by the
thermostat energizes the reversing valve and closes the
compressor contactor contacts, energizing the compressor, which
will run until the thermostat is satisfied.
27
RCL SERIES INSTALLATION MANUAL
Controls cont.
Aurora ‘Base’ Control
Field Selectable Options via Hardware
DIP Switch (SW1) – Test/Configuration Button (See SW1
Operation Table)
Test Mode
The control is placed in the test mode by holding the push
button switch SW1 for 2 - 5 seconds. In test mode most of
the control timings will be shortened by a factor of sixteen
(16). LED3 (green) will flash at 1 second on and 1 second
off. Additionally, when entering test mode LED1 (red) will
flash the last lockout one time. Test mode will automatically
time out after 30 minutes. Test mode can be exited by
pressing and holding the SW1 button for 2 to 5 seconds or
by cycling the power. NOTE: Test mode will automatically
be exited after 30 minutes.
NOTE: Refer to the Aurora Base Control Application and
Troubleshooting Guide and the Instruction Guide: Aurora
Interface and Diagnostics (AID) Tool for additional information.
Control Features
Software ABC Standard Version 3.0
Single or Dual Capacity Compressors
Variable Speed ECM Configuration Mode
(If Applicable)
Either single or dual capacity compressors can be operated.
The control is placed in the ECM configuration mode by
holding the pushbutton switch SW1 for 5 to 10 seconds, the
high, low, and “G” ECM speeds can be selected by following
the LED display lights. LED2 (yellow) will fast flash when
entering the ECM configuration. When setting “G” speed
LED3 (green) will be continuously lit, for low speed LED1
(red) will be continuously lit, and for high speed both LED3
(green) and LED1 (red) will be continuously lit. During the
ECM configuration mode LED2 (yellow) will flash each of
the 12 possible blower speeds 3 times. When the desired
speed is flashed press SW1, LED2 will fast flash until SW1
is released. “G” speed has now been selected. Next select
low speed, and high speed blower selections following the
same process above. After third selection has been made,
the control will exit the ECM configuration mode. Aux fan
speed will remain at default or current setting and requires
the AID Tool for adjustment.
Variable Speed ECM
Blower Motor Option (If Applicable)
A Variable Speed ECM blower motor can be driven directly
using the onboard PWM output. Four blower speeds are
available based upon the G, Y1, Y2, and W input signals to
the board. The blower speeds can be changed either by the
ECM manual configurations mode method or by using the
Aurora AID Tool directly. All four blower speeds can be set
to the same speed if desired.
5-Speed ECM Blower Motor Option (If Applicable)
A 5-Speed ECM blower motor will be driven directly using
the thermostat connections. Any of the G, Y1, or Y2/W
signals can drive any of the 5 available pre-programmed
blower speeds on the motor. All 5 Series "G" vintage units
will be wired this way at the factory.
Reset Configuration Mode
The control is placed in reset configuration mode by
holding the push button switch SW1 for 50 to 60 seconds.
This will reset all configuration settings and the EEPROM
back to the factory default settings. LED3 (green) will turn
off when entering reset configuration mode. Once LED3
(green) turns off, release SW1 and the control will reset.
Other Control Features
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Random start at power up
Anti-short cycle protection
High and low pressure cutouts
Loss of charge
Water coil freeze detection
Air coil freeze detection
Over/under voltage protection
Condensate overflow sensor
Load shed
Dehumidification (where applicable)
Emergency shutdown
Hot gas reheat operation (where applicable)
Diagnostic LED
Test mode push button switch
Two auxiliary electric heat outputs
Alarm output
Accessory output with N.O. and N.C.
Modbus communication (master)
Modbus communication (slave)
DIP Switch (SW2)
SW2-1
FP1 Selection – Low water coil temperature limit
setting for freeze detection. On = 30°F; Off = 15°F.
SW2-2 FP2 Selection – On = 30°F; Off = N/A
SW2-3 RV – O/B - thermostat type. Heat pump
thermostats with “O” output in cooling or “B”
output in Heating can be selected. On = O; Off = B.
SW2-4 Access Relay Operation (P2)
and 2-5
Access Relay Operation
Cycle with Blower
Cycle with Compressor
Water Valve Slow Opening
Cycle with Comm. T-stat Hum Cmd
28
SW2-4
ON
OFF
ON
OFF
SW2-5
ON
OFF
OFF
ON
RCL SERIES INSTALLATION MANUAL
Controls cont.
Cycle with Blower - The accessory relay will cycle with
the blower output.
Lockout – when locked out, the blower will operate
continuously in “G” speed, and PSC blower motor output
will remain on. The Alarm output (ALM) and Lockout output
(L) will be turned on. The fault type identification display
LED1 (Red) shall flash the fault code. To reset lockout
conditions with SW2-8 On, thermostat inputs “Y1”, “Y2”,
and “W” must be removed for at least 3 seconds. To reset
lockout conditions with SW2-8 Off, thermostat inputs “Y1”,
“Y2”, “W”, and “DH” must be removed for at least 3 seconds.
Lockout may also be reset by turning power off for at least
30 seconds or by enabling the emergency shutdown input
for at least 3 seconds.
Cycle with Compressor - The accessory relay will cycle
with the compressor output.
Water Valve Slow Opening - The accessory relay will
cycle and delay both the blower and compressor output
for 90 seconds.
SW2-6 CC Operation – selection of single or dual capacity
compressor. On = Single Stage; Off = Dual Capacity
SW2-7 Lockout and Alarm Outputs (P2) – selection of a
continuous or pulsed output for both the LO and
ALM Outputs. On = Continuous; Off = Pulsed
SW2-8 Future Use
Lockout With Emergency Heat - if the control is locked out
in the heating mode, and a Y2 or W input is received, the
control will operate in the emergency heat mode while the
compressor is locked out. The first emergency heat output will
be energized 10 seconds after the W input is received, and the
blower will shift to high speed. If the control remains locked
out, and the W input is present, additional stage of emergency
heat will stage on after 2 minutes. When the W input is
removed, all of the emergency heat outputs will turn off, and
the ECM blower will shift to “G” speed and PSC blower motor
output will remain on.
Alarm Jumper Clip Selection
From the factory, ALM is connected to 24 VAC via JW2. By
cutting JW2, ALM becomes a dry contact connected to ALG.
Variable Speed ECM Blower Speeds
The blower speeds can be changed either by using the
ECM manual configurations mode method or by using the
Aurora AID Tool directly (see Instruction Guide: Aurora
Interface and Diagnostics (AID) Tool topic).
High Pressure – fault is recognized when the Normally
Closed High Pressure Switch, P4-9/10 opens, no matter
how momentarily. The High Pressure Switch is electrically in
series with the Compressor Contactor and serves as a hardwired limit switch if an overpressure condition should occur.
Field Selectable Options via Software
(Selectable via the Aurora AID Tool)
ECM Blower Speeds
Low Pressure - fault is recognized when the Normally
Closed Low Pressure Switch, P4-7/8 is continuously open
for 30 seconds. Closure of the LPS any time during the 30
second recognition time restarts the 30 second continuous
open requirement. A continuously open LPS shall not be
recognized during the 2 minute startup bypass time.
An ECM blower motor can be driven directly using the
onboard PWM output. Four blower speeds are available,
based upon the “G”, Y1 (low), Y2 (high), and Aux input
signals to the board. The blower speeds can be changed
either by the ECM manual configurations mode method (see
ECM Configuration Mode topic) or by using the Aurora AID
Tool directly. All four blower speeds can be set to the same
speed if desired. Aux blower speed will remain at default or
current setting and requires the AID Tool for adjustment.
Loss of Charge – fault is recognized when the Normally
Closed Low Pressure Switch, P4-7/8 is open prior to the
compressor starting.
Condensate Overflow - fault is recognized when the
impedance between this line and 24 VAC common or chassis
ground drops below 100K ohms for 30 seconds continuously.
Safety Features
The following safety features are provided to protect the
compressor, heat exchangers, wiring and other components
from damage caused by operation outside of design conditions.
Freeze Detection (Coax) - set points shall be either 30°F
or 15°F. When the thermistor temperature drops below
the selected set point, the control shall begin counting
down the 30 seconds delay. If the thermistor value rises
above the selected set point, then the count should reset.
The resistance value must remain below the selected set
point for the entire length of the appropriate delay to be
recognized as a fault. This fault will be ignored for the initial
2 minutes of the compressor run time.
Fuse – a 3 amp automotive type plug-in fuse provides
protection against short circuit or overload conditions.
Anti-Short Cycle Protection – 4 minute anti-short cycle
protection for the compressor.
Random Start – 5 to 80 second random start upon power up.
Fault Retry – in the fault condition, the control will stage off
the outputs and then “try again” to satisfy the thermostat
Y input call. Once the thermostat input calls are satisfied,
the control will continue on as if no fault occurred. If 3
consecutive faults occur without satisfying the thermostat
Y input call, then the control will go to Lockout mode.
Freeze Detection (Air Coil) - uses the FP2 input to protect
against ice formation on the air coil. The FP2 input will
operate exactly like FP1 except that the set point is 30
degrees and is not field adjustable.
29
RCL SERIES INSTALLATION MANUAL
Controls cont.
Over/Under Voltage Shutdown - An over/under voltage
condition exists when the control voltage is outside the
range of 18 VAC to 30 VAC. If the over/under voltage
shutdown lasts for 15 minutes, the lockout and alarm relay
will be energized. Over/under voltage shutdown is selfresetting in that if the voltage comes back within range
of 18 VAC to 30 VAC for at least 0.5 seconds, then normal
operation is restored.
Operation Description
Power Up - The unit will not operate until all the inputs and
safety controls are checked for normal conditions. The unit
has a 5 to 80 second random start delay at power up. Then
the compressor has a 4 minute anti-short cycle delay after
the random start delay.
Standby In standby mode, Y1, Y2, W, DH, and G are not
active. Input O may be active. The blower and compressor
will be off.
Heating Operation
Single Compressor Heating, 2nd Stage (Y1, Y2)
The compressor will be staged to full capacity 20 seconds
after Y2 input is received. The ECM blower will shift to high
speed seconds after the Y2 input is received.
Dual Compressor Heating, 2nd Stage (Y1, Y2)
In dual compressor operation, two ABC boards used in 24
VAC operation, there will be a Y2 call to the Y1 input on the
second ABC. The compressor will stage to full capacity 30
seconds after Y1 input is received to the second board.
Single Compressor Heating, 3rd Stage (Y1, Y2, W)
The hot water pump is de-energized and the first stage of
electric heat is energized 10 seconds after the W command
is received. If the demand continues the second stage of
electric heat will be energized after 5 minutes.
Dual Compressor Heating, 3rd Stage (Y1, Y2, W) The first stage of electric heat is energized 10 seconds
after the W command is received. If the demand continues
the second stage of electric heat will be energized after 5
minutes
Emergency Heat (W) - The blower will be started on “G”
speed, 10 seconds later the first stage of electric heat will
be turned on. 5 seconds after the first stage of electric
heat is energized the blower will shift to Aux speed. If the
emergency heat demand is not satisfied after 2 minutes the
second electric heat stage will be energized.
Cooling Operation
In all cooling operations, the reversing valve directly tracks
the O input. Thus, anytime the O input is present, the
reversing valve will be energized.
Single Compressor Cooling, 2nd Stage (Y1, Y2, 0)
The compressor will be staged to full capacity 20 seconds
after Y2 input was received. The ECM blower will shift to high
speed 15 seconds after the Y2 input was received.
Dual Compressor Cooling, 2nd Stage (Y1, Y2, O)
In dual compressor operation, two ABC boards used in 24
VAC operation, there will be a Y2 call to the Y1 input on the
second ABC. The compressor will stage to full capacity 30
seconds after Y1 input is received to the second board.
Blower (G) - The blower will start immediately upon
receiving a thermostat G command. If there are no other
commands from the thermostat the ECM will run on “G”
speed until the G command is removed. Regardless of
blower input (G) from the thermostat, the blower will
remain on for 30 seconds at the end of each heating,
cooling, and emergency heat cycle.
Dehumidification (Y1, O, DH or Y1, Y2, O, DH) - When a
DH command is received from the thermostat during a
compressor call for cooling the ECM blower speed will be
reduced by 15% to increase dehumidification.
Emergency Shutdown - Four (4) seconds after a valid ES
input, P2-7 is present, all control outputs will be turned off
and remain off until the emergency shutdown input is no
longer present. The first time that the compressor is started
after the control exits the emergency shutdown mode,
there will be an anti-short cycle delay followed by a random
start delay. Input must be tied to common to activate.
Continuous Blower Operation - The blower output will
be energized any time the control has a G input present,
unless the control has an emergency shutdown input
present. The blower output will be turned off when G input
is removed.
Load Shed - The LS input disables all outputs with the
exception of the blower output. When the LS input has been
cleared, the anti-short cycle timer and random start timer
will be initiated. Input must be tied to common to activate.
Blower (G) - The blower will start immediately upon
receiving a thermostat G command. If there are no other
commands from the thermostat the ECM will run on “G”
speed until the G command is removed. Regardless of
blower input (G) from the thermostat, the blower will
remain on for 30 seconds at the end of each heating cycle.
30
RCL SERIES INSTALLATION MANUAL
Controls cont.
Aurora ‘Base’ Control LED Displays
Aurora Interface and Diagnostics (AID) Tool
These three LEDs display the status, configuration, and
fault codes for the control. These can also be read in plain
English via the Aurora AID Tool.
The Aurora Interface and
Diagnostics (AID) Tool is
a device that is a member
of the Aurora network.
The AID Tool is used to
troubleshoot equipment
which uses the Aurora
control via Modbus RTU
communication. The AID
Tool provides diagnostics,
fault management, ECM
setup, and system configuration capabilities to the Aurora
family of controls. An AID Tool is recommended, although
not required, for ECM airflow settings. The AID Tool simply
plugs into the exterior of the cabinet in the AID Tool port.
Status LED (LED3, Green)
Description of Operation
Normal Mode
Control is Non-functional
Test Mode
Lockout Active
Dehumidification Mode
(Future Use)
(Future Use)
Load Shed
ESD
(Future Use)
Fault LED, Green
ON
OFF
Slow Flash
Fast Flash
Flash Code 2
Flash Code 3
Flash Code 4
Flash Code 5
Flash Code 6
Flash Code 7
ABC Control Board Layout
FP2 – 15 F/30 F
2
RV – B/O
3
ACC – Dip 4
4
ACC – Dip 5
5
CC – Dual/Single
6
LED3
G
L – Pulse/Continuous
7
Reheat/Normal
8
Status
G
Factory Use
Com1
Fan – K4
Com2
P9
C
C
Y2
C
3A-Fuse
W
DH
DH
Y2
W
G
Y1
Y1
G
O/B
C
R
LO
O/B
C
Field Connections
P1
ACC nc
ACC c
ACC no
LS
ALG
Field Connections
P2
ES
31
Factory Fan Connection
R
LO
Y1
JW2 Alarm
G
Acc – K6
G
(+)
(-)
R
C
P8
P11
Alarm – K5
F
CC
EH2
C
EH1
C
CO
N/A
P7
CC Hi – K3
Factory
CC2
P3
AURORA BASE
CONTROL™
CC – K2
ABC Basic Faults
Config
P6
CC2
P5
EH1
Y
SW2
RV – K1
G
LO
HI
CCG
CC
FG
F
R
LED2
Factory
C
1
R
o
o
Faul t
SW1 Test
On
FP1 – 15oF/30oF
RS485 Exp
LED Flash
Reset/
Lockout
Code*
Remove
Normal - No Faults
OFF
–
Fault - Input
1
No
Auto
Fault - High Pressure
2
Yes
Hard or Soft
Fault - Low Pressure
3
Yes
Hard or Soft
Fault - Freeze Detection FP2
4
Yes
Hard or Soft
Fault - Freeze Detection FP1
5
Yes
Hard or Soft
Fault - Condensate Overflow
7
Yes
Hard or Soft
Fault - Over/Under Voltage
8
No
Auto
Fault - FP1 & FP2 Sensor Error
11
Yes
Hard or Soft
NOTE: All codes >11 use long flash for tens digit and short flash for the ones
digit. 20, 30, 40, 50, etc. are skipped.
Red Fault LED
P13
Off
LED1
ECM PWM
RS 485
Fault LED (LED1, Red)
P4
RS485 NET
HP
HP
LP
LP
FP2
FP2
FP1
FP1
REV
REV
Factory
Configuration LED, Yellow
Flashing ECM Setting
Slow Flash
Fast Flash
ALM
Description of Operation
No Software Overwritten
DIP Switch was Overwritten
ECM Configuration Mode
PWM
CFM
Configuration LED (LED2, Yellow)
R
R
RCL SERIES INSTALLATION MANUAL
Controls cont.
the current thermostat demand cycle. Since compressor hot
gas temperature is dependent on loop temperature in cooling
mode, loop temperatures may be too low to allow proper
heating of water. The control will monitor water and refrigerant
temperatures to determine if conditions are satisfactory for
heating water. LED1 (red LED) will flash code 15 when the
DHW limit is reached and when conditions are not favorable
for water heating. Error code 15 will also be displayed on the
AID Tool in the fault screen. This flash code is a noncritical
alert and does not necessarily indicate a problem.
Aurora ‘Advanced’ Control Features
The Aurora ‘Advanced’
Control system expands on
the capability of the Aurora
‘Base’ Control (ABC)
by adding the Aurora
Expansion Board (AXB).
All of the preceding
features of the Aurora
‘Base’ Control are included.
The following control
description is of the
additional features and
capability of the Aurora
advanced control.
Compressor Monitoring
The AXB includes two current transducers to monitor the
compressor current and starting characteristics. Open
circuits or welded contactor faults will be detected. A fault
will produce an E10 code.
It is highly recommended the
installing/servicing contractor obtain
an Aurora Interface and Diagnostic
Tool (AID) and specialized training
before attempting to install or service
an Aurora ‘Advanced’ control system.
IntelliZone2 Zoning Compatibility
(Optional IntelliZone2 Zoning)
A dedicated input to connect and communicate with the
IntelliZone2 (IZ2) zoning system is provided on P7. The is a
dedicated communication port using a proprietary ModBus
protocol. An AXB can be added to other selected ABC-only
systems as well. Then an advanced communicating IntelliZone2
zoning system can be added to ABC-only systems. Consult the
IntelliZone2 literature for more information.
The additional AXB features include the following:
AXB DIP Switch
DIP 1 - ID: This is the AXB ModBus ID and should always
read On.
DIP 2 & 3 - Future Use
DIP 4 & 5 - Accessory Relay2: A second, DIP configurable,
accessory relay is provided that can be cycled with the
compressor 1 or 2 , blower, or the Dehumidifier (DH)
input. This is to complement the Accessory 1 Relay on
the ABC board.
Position
1
DIP 4
ON
DIP 5
ON
2
OFF
ON
3
ON
OFF
4
OFF
OFF
Variable Speed Pump
This input and output are provided to drive and monitor
a variable speed pump. The VS pump output is a PWM
signal to drive the variable speed pump. The minimum and
maximum level are set using the AID Tool. 75% and 100%
are the default settings respectively. The VS data input
allows a separate PWM signal to return from the pump
giving fault and performance information. Fault received
from the variable speed pump will be displayed as E16.
Description
Cycles with Fan or ECM (or G)
Cycles with CC1 first stage of compressor
or compressor spd 6
Cycles with CC2 second stage of
compressor or compressor spd 7-12
Cycles with DH input from ABC board
Modulating Water Valve
This output is provided to drive a modulating water valve.
Through advanced design the 0-10VDC valve can be
driven directly from the VS pump output. The minimum
and maximum level are set in the same way as the VS
pump using the AID Tool. 75% and 100% are the default
settings respectively.
Advanced Hot Water Generator Control
(Domestic Hot Water Option)
In lieu of the ‘Base Hot Water Generator Control’, the
Advanced features an AID Tool selectable temperature limit
and microprocessor control of the process. This will maximize
hot water generation and prevent undesirable energy use. An
alert will occur when the hot water input temperature is at
or above setpoint (100°F - 140°F) for 30 continuous seconds
(130°F is the default setting). This alert will appear as an E15
on the AID Tool and the hot water pump de-energizes. Hot
water pump operations resume on the next compressor cycle
or after 15 minutes of continuous compressor operation during
Loop Pump Linking
This input and output are provided so that two units can be
linked together with a common flow center. When either unit
has a call for loop pump, both unit’s loop pump relays and
variable speed pumps are energized. The flow center then can
simply be wired to either unit. The output from one unit should
be routed to the input of the other. If daisy chained up to 16
heat pumps can be wired and linked together in this fashion.
32
RCL SERIES INSTALLATION MANUAL
Controls cont.
Home Automation 2 – E24 HA2
With a closed dry contact signal, this input will cause an
alarm and Alert Code 24 to indicate on the stat or flash
on ABC. The AID Tool will allow configuration of this input
between the following selections:
• No Action
• Home Automation Fault [no lockout info only]
- Output from home automation system
• Security Alarm [no lockout info only]
- Output from home security
• Sump Alarm Fault [no lockout info only]
- Switch output from sump sensor
• Smoke/CO Alarm Fault [no lockout info only]
- Switch output from Smoke/CO sensor
• Dirty Filter Alarm [no lockout info only]
- Output from dirty filter sensor
Advanced Communication Ports
Communication ports P6 and P8 will provide future
expansion via dedicated protocols. These are for future use.
Smart Grid-On Peak (SG) Input
The 'On Peak' input was designed to allow utilities to
utilize simple radio controlled switches to control the On
Electric Peak behavior of the 5 and 7 Series Geothermal
Heat Pumps. With a closed contact signal, this input will
limit the operation and thus the power consumption of the
unit by one of the below selections. The AID Tool will allow
configuration of this input for the action of:
• No Action
• Disable compressor operation until removed
• Go to On Peak thermostat settings until removed
[Requires Com T-Stat] (Future Release)
• Compressor limited to 50% or low cap until removed
[dual capacity or variable speed only] (Future Release)
• Disable compressor operation for 1/2 hr (can be
removed immediately) (Future Release)
Monitoring Sensor Kits
Energy Monitoring
(Standard Sensor Kit on ‘Advanced’ models)
The Energy Monitoring Kit includes two current transducers
(blower and electric heat) added to the existing two
compressor sensors so that the complete power usage of
the heat pump can be measured. The AID Tool provides
configuration detail for the type of blower motor and a
line voltage calibration procedure to improve the accuracy.
This information can be displayed on the AID Tool or
selected communicating thermostats. The TPCM32U03/04
will display instantaneous energy use while the color
touchscreen TPCC32U01 will in addition display a 13 month
history in graph form.
Then Flash Code 7 on the Green LED for the 'On Peak' mode.
And On Peak will display on communicating thermostats.
Home Automation 1 and 2 Inputs
The Home automation inputs are simple closed contact
inputs that will trigger an AID Tool and thermostat alert
for the homeowner. These would require optional sensors
and or equipment for connection to the AXB board. With
two inputs two different sensors can be selected. The
selected text will then be displayed on the AID Tool and
communicating thermostats. These events will NOT alter
functionality or operation of the heat pump/accessories
and is for homeowner/service notification only.
Refrigerant Monitoring (optional sensor kit)
The optional Refrigerant Monitoring Kit includes two
pressure transducers, and three temperature sensors,
heating liquid line, suction temperature and existing cooling
liquid line (FP1). These sensors allow the measurement
of discharge and suction pressures, suction and liquid line
temperatures as well as superheat and subcooling. This
information will only be displayed on the AID Tool.
Home Automation 1 - E23 HA1
With a closed dry contact signal, this input will cause an
alarm and Alert Code 23 to indicate on the stat or flash
on ABC. The AID Tool will allow configuration of this input
between the following selections:
• No Action
• Home Automation Fault [no lockout info only]
- Output from home automation system
• Security Alarm [no lockout info only]
- Output from home security
• Sump Alarm Fault [no lockout info only]
- Switch output from sump sensor
• Smoke/CO Alarm Fault [no lockout info only]
- Switch output from Smoke/CO sensor
• Dirty Filter Alarm [no lockout info only]
- Output from dirty filter sensor
Performance Monitoring (optional sensor kit)
The optional Performance Monitoring Kit includes three
temperature sensors, entering and leaving water, leaving
air temperature and a water flow rate sensor. With this kit
heat of extraction and rejection will be calculated. This
requires configuration using the AID Tool for selection of
water or antifreeze.
33
RCL SERIES INSTALLATION MANUAL
Controls cont.
Special Modes and Applications
Aurora ‘Advanced’ Control LED Displays
5-Speed ECM Blower Motor
These three LEDs display the status, configuration, and
fault codes for the control. These can also be read in plain
English via the Aurora AID Tool.
Normally the 5-Speed ECM motor can be driven off
of thermostat signals and the ABC connector P9.
Communicating thermostats, however present a special
problem in this application since they operate without 24
VAC thermostat signals. The ABC board is wired to operate
these systems from the alternate relay output signals CC1,
CC2, Fan, and EH1 and should be wired for this.
Status LED (LED3, Green)
Description of Operation
Normal Mode
Control is Non-functional
Test Mode
Lockout Active
Dehumidification Mode
Load Shed
Emergency Shutdown
On Peak Mode
(Future Use)
(Future Use)
Communicating Digital Thermostats
The Aurora controls system also features either monochromatic or color touch screen graphic display
thermostats for user interface. These displays not only
feature easy to use graphical interface but display alerts
and faults in plain English. Many of the features discussed
here may not be applicable without these thermostats.
Fault LED, Green
ON
OFF
Slow Flash
Fast Flash
Flash Code 2
Flash Code 5
Flash Code 6
Flash Code 7
Flash Code 8
Flach Code 9
Configuration LED (LED2, Yellow)
Description of Operation
No Software Overwritten
DIP Switch Overwritten
ECM Configuration Mode
Reset Configuration Mode
Dehumidification – Passive
In passive dehumidification mode, the airflow is reduced
by 15% from the heating airflow setting. If cooling airflow is
set to +5, -5 or -10% of heating airflow it will automatically
be set to -15% of heating airflow whenever the
dehumidification call is present in the communicating stat
or from the thermostat input DH. If the airflow for cooling is
already set to -15% no airflow change will be noticed from
normal cooling. Dehumidification mode will be shown on
the ABC and the communicating thermostats.
Configuration LED, Yellow
ECM Setting
Slow Flash
Fast Flash
OFF
Fault LED (LED1, Red)
ABC & AXB Advanced Faults
ABC Basic Faults
Red Fault LED
Normal - No Faults
Fault-Input
Fault-High Pressure
Fault-Low Pressure
Fault-Freeze Detection FP2
Fault-Freeze Detection FP1
Fault-Condensate Overflow
Fault-Over/Under Voltage
Fault-FP1 Snsr Error
LED Flash
Lockout
Code *
Off
1
No
2
Yes
3
Yes
4
Yes
5
Yes
7
Yes
8
No
11
Yes
Reset/
Remove
Fault Condition Summary
Auto
Hard or Soft
Hard or Soft
Hard or Soft
Hard or Soft
Hard or Soft
Auto
Hard or Soft
Tstat input error. Autoreset upon condition removal.
HP switch has tripped (>600 psi)
Low Pressure Switch has tripped (<40 psi for 30 continuous sec.)
Freeze protection sensor has tripped (<15 or 30 degF for 30 continuous sec.)
Freeze protection sensor has tripped (<15 or 30 degF for 30 continuous sec.)
Condensate switch has shown continuity for 30 continuous sec.
Instantaneous voltage is out of range. **Controls shut down until resolved.
If FP1 Sensor Error
Open Crkt, Run, Start or welded cont
Fault-Compressor Monitor
10
Yes
Hard or Soft
Non-CriticAXBSnsrErr
13
No
Auto
CriticAXBSnsrErr
14
Yes
Hard or Soft
Any Other Sensor Error
Sensor Error for EEV or HW
Alert-HotWtr
15
No
Auto
HW over limit or logic lockout. HW pump deactivated.
Fault-VarSpdPump
16
No
Auto
Alert is read from PWM feedback.
Not Used
17
No
Auto
IZ2 Com Fault. Autoreset upon condition removal.
Non-CritComErr
18
No
Auto
Any non-critical com error
Fault-CritComErr
19
No
Auto
Any critical com error. Auto reset upon condition removal
Alarm - Low Loop Pressure
21
No
Auto
Loop pressure is below 3 psi for more than 3 minutes
Alarm - Home Automation 1
23
No
Auto
Closed contact input is present on Dig 2 input - Text is configurable
Alarm - Home Automation 2
24
No
Auto
Closed contact input is present on Dig 3 input - Text is configurable
NOTES:
*All codes >11 use long flash for tens digit and short flash for the ones digit. 20, 30, 40, 50 etc. are skipped!
Alert’ is a noncritical sensor or function that has failed. Normal operation of the heat pump is maintained but service is desired at some point.
34
RCL SERIES INSTALLATION MANUAL
Unit Startup Notes
Electrical Disconnect
Optional field installed console disconnect provides a permanent
electrical connection to the main electrical supply branch. Wiring
between the disconnect and the unit chassis is field supplied and
allows the electrical power source to the chassis to be interrupted
for unit servicing.
Non-Fused
Constructed of heavy gauge galvanized steel, the rocker style
disconnect switch provides reliable electrical control. Wiring
pigtails, using 12-gauge wires, are factory installed to simplify
field wiring.
Fused
Similar in construction to the non-fused electrical disconnect.
The fused disconnect is available in five models with
equipment rated fuses to provide additional circuit protection.
The fuses are panel mounted to allow easy inspection and
removal without removing the cover on the disconnect.
CFD-10 - 10 amp rated fuse
CFD-12 - 12 amp rated fuse
CFD-15 - 15 amp rated fuse
CFD-20 - 20 amp rated fuse
CFD-25 - 25 amp rated fuse
Hydronic Loop Controller for
Boiler/Tower Installations
The hydronic loop controller is a microprocessor based control panel
for control of water loop heat rejector (tower), heat supplier (boiler),
and/or water well pumps and circulation pumps. Includes audible
and visual alarms, temperature indication, and add-on options of low
switches, remote alarm sensor wells and pump alternator.
35
RCL SERIES INSTALLATION MANUAL
Unit Startup Checklist/Unit Startup Steps
Before Powering Unit, Check The Following:
•
•
•
•
•
•
•
•
•
•
•
•
•
1.
High voltage is correct and matches nameplate.
Fuses, breakers and wire size correct.
Low voltage wiring complete.
Piping completed and water system cleaned and flushed.
Air is purged from closed loop system.
Isolation valves are open, water control valves or loop pumps wired.
Condensate line open and correctly pitched.
Transformer switched to 208V if applicable.
Dip switches are set correctly, if applicable.
Blower rotates freely
Air filter is clean and in position.
Service/access panels are in place.
Return air temperature is between 50-80°F heating and 60-95°F cooling.
Check air coil cleanliness to ensure optimum performance. Clean as needed according to maintenance guidelines. To
obtain maximum performance the air coil should be cleaned before startup. A 10-percent solution of dishwasher
detergent and water is recommended for both sides of coil, a thorough water rinse should follow.
Startup Steps
Note: Complete the Equipment Start-Up/Commissioning Check Sheet during this procedure. Refer to thermostat operating instructions
and complete the startup procedure.
1. Initiate a control signal to energize the blower motor. Check blower operation.
2. Initiate a control signal to place the unit in the cooling mode. Cooling setpoint must be set below room temperature.
3. Be sure that the compressor and water control valve or loop pump(s) are activated.
4. Verify that the water flow rate is correct by measuring the pressure drop through the heat exchanger using the P/T plugs and
comparing to unit capacity data in specification catalog.
5. Check the temperature of both the supply and discharge water (Refer to Unit Operating Parameters tables).
6. Check for an air temperature drop of 15°F to 25°F across the air coil, depending on the fan speed and entering water temperature.
7. Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop pumps deactivate.
8. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature.
9. Check the temperature of both the supply and discharge water (Refer to Unit Operating Parameters tables).
10. Check for an air temperature rise of 20°F to 35°F across the air coil, depending on the fan speed and entering water temperature.
11. Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pump deactivate.
12. During all testing, check for excessive vibration, noise or water leaks. Correct or repair as required.
13. Set system to desired normal operating mode and set temperature to maintain desired comfort level.
14. Instruct the owner/operator in the proper operation of the thermostat and system maintenance.
Note: Be certain to fill out and forward all warranty registration papers.
36
RCL SERIES INSTALLATION MANUAL
Operating Parameters
Entering Water
Temp °F
1.5
3.0
1.5
3.0
1.5
3.0
1.5
3.0
2.3
3.0
30
50
70
90
110
Entering Water
Temp °F
Cooling
Water Flow
gpm/ton
Suction Pressure
psig
100 - 115
115 - 125
133 - 148
129 - 144
139 - 154
137 - 152
143 - 158
141 - 156
143 - 158
141 - 156
Discharge
Pressure psig
170 - 190
150 - 170
225 - 245
185 - 205
300 - 320
250 - 270
360 - 380
330 - 350
360 - 380
440 - 460
Suction Pressure
psig
73 - 79
79 - 85
103 - 109
115 - 130
145 - 155
155 - 165
170 - 185
174 - 190
Discharge
Pressure psig
305 - 330
315 - 345
330 - 370
350 - 380
375 - 410
415 - 435
435 - 470
465 - 500
Superheat
Subcooling
17 - 26
20 - 29
8 - 11
8 - 11
6 - 10
6 - 10
6 - 10
6 - 10
6 - 10
6 - 10
10 - 14
7 - 11
7 - 11
6 - 10
6 - 10
6 - 10
6 - 10
6 - 10
6 - 10
6 - 10
Water Temp Rise
°F
18 - 22
8 - 10
18 - 22
8 - 10
18 - 22
8 - 10
18 - 22
8 - 10
18 - 22
8 - 10
Air Temp Drop
°F DB
20 - 30
20 - 30
20 - 30
20 - 30
18 - 26
18 - 26
18 - 26
18 - 26
18 - 22
18 - 22
Water Temp Drop
°F
7 -10
3-6
8 - 11
4-7
11 - 14
7 - 10
8 - 11
8 - 11
Air Temp Rise
°F DB
20 - 26
20 - 26
22 - 32
22 - 32
28 - 38
35 - 45
42 - 50
42 - 50
Heating
Water Flow
gpm/ton
1.5
3.0
1.5
50
3.0
1.5
70
3.0
1.5
90
3.0
2.3
110
3.0
NOTES: Cooling performance based on entering air temperatures of 80°F DB, 67°F WB.
Heating performance based on entering air temperature of 70°F DB.
30
Superheat
Subcooling
7 - 13
7 - 13
7 - 13
7 - 13
7 - 13
10 - 14
11 - 18
11 - 18
7 - 11
7 - 11
7 - 11
7 - 11
7 - 11
7 - 11
7 - 11
7 - 11
6/20/11
Operating Limits
Operating Limits
Air Limits
Min. Ambient Air
Rated Ambient Air
Max. Ambient Air
Min. Entering Air
Rated Entering Air db/wb
Max. Entering Air db/wb
Water Limits
Min. Entering Water
Normal Entering Water
Max. Entering Water
(°F)
Cooling
(°C)
(°F)
Heating
(°C)
45
80
100
50
80.6/66.2
110/83
7.2
26.7
37.8
10.0
27/19
43/28.3
45
70
85
40
68
80
7.2
21.1
29.4
4.4
20.0
26.7
30
50-110
120
-1.1
10-43.3
48.9
20
30-70
90
-6.7
-1.1
32.2
NOTE: Minimum/maximum limits are only for start-up conditions, and are meant
for bringing the space up to occupancy temperature. Units are not designed to
operate at the minimum/maximum conditions on a regular basis. The operating
limits are dependant upon three primary factors: 1) water temperature, 2) return
air temperature, and 3) ambient temperature. When any of the factors are at the
minimum or maximum levels, the other two factors must be at the normal level for
proper and reliable unit operation.
37
RCL SERIES INSTALLATION MANUAL
Pressure Drop
Model
09
12
15
18
GPM
Pressure Drop (psi)
30°F
50°F
70°F
90°F
110°F
1.2
1.0
0.9
0.8
0.7
0.6
1.8
2.3
2.2
2.0
1.9
1.8
2.5
3.8
3.7
3.5
3.3
3.1
1.5
0.9
0.8
0.7
0.6
0.5
2.3
1.7
1.5
1.4
1.3
1.1
3.5
3.0
2.7
2.5
2.4
2.2
2.0
1.7
1.6
1.5
1.4
1.3
3.0
3.3
3.2
3.0
2.9
2.8
4.5
5.7
5.5
5.3
5.1
4.9
3.0
1.7
1.6
1.5
1.4
1.3
4.0
4.1
4.0
3.9
3.7
3.6
5.5
7.9
7.6
7.4
7.2
6.9
6/10/13
Compressor and Thermistor Resistance
Compressor Resistance
Model
09
12
15
18
115/60/1
Run
Start
0.77 - 0.89
1.79 - 2.05
0.77 - 0.89
1.79 - 2.05
208-230/60/1
Run
Start
3.65 - 4.19
3.75 - 4.31
3.35 - 3.85
2.80 - 3.22
2.74 - 3.16
2.60 - 3.00
2.24 - 2.58
2.84 - 3.26
265/60/1
Run
Start
3.73 - 4.27
4.45 - 5.13
3.73 - 4.27
4.45 - 5.13
3.03 - 3.49
2.39 - 2.75
3.03 - 3.49
2.39 - 2.75
6/10/13
Thermistor Resistance
Thermistor
Temperature (°F)
5
14
23
32
41
50
59
68
77
86
95
104
113
122
131
140
149
Microprocessor
Resistance (Ohms)
75757-70117
57392-53234
43865-40771
33809-31487
26269-24513
20570-19230
16226-15196
12889-12093
10310-9688
8300-7812
6723-6337
5480-5172
4490-4246
3700-3504
3067-2907
2554-2424
2149-2019
FX10
Resistance (Ohms)
746-770
775-803
808-836
841-869
875-903
910-938
946-974
981-1013
1019-1051
1058-1090
1097-1129
1137-1169
1179-1211
1221-1253
1261-1297
1305-1341
1350-1386
7/6/10
38
RCL SERIES INSTALLATION MANUAL
Refrigerant Circuit Guideline
Symptom
Under Charged System (Possible Leak)
Over Charged System
Low Air Flow Heating
Low Air Flow Cooling
Low Water Flow Heating
Low Water Flow Cooling
High Air Flow Heating
High Air Flow Cooling
High Water Flow Heating
High Water Flow Cooling
Low Indoor Air Temperature Heating
Low Indoor Air Temperature Cooling
High Indoor Air Temperature Heating
High Indoor Air Temperature Cooling
Restricted TXV (Check Service Advisory)
Insufficient Compressor (Possible Bad Valves)
TXV - Bulb Loss of Charge
Scaled Coaxial Heat Exchanger Heating
Scaled Coaxial Heat Exchanger Cooling
Restricted Filter Drier
Head
Pressure
Low
High
High
Low
Low/Normal
High
Low
Low
Normal
Low
Low
Low
High
High
High
Low
Low
Low
High
Suction
Compressor
Air Temp.
Superheat
Subcooling
Pressure
Amp Draw
Differential
Low
Low
High
Low
Low
High
High
Normal
High
Normal/Low
High
High
High/Normal
Low
High
Low
Low
Low/Normal
High
High
Low/Normal
Low
Low
High
Low
High
High
High
Low
Low
Low
Low
Low
High
Low
High
Normal
High
Low
Low
Low
Normal
High
Normal
Normal
Low
Low
Low
High
Normal
Low
Low
Normal
High
Normal
Low
Low
Normal/Low
High
Low
High
High
Normal/High
Normal/Low
Low
High
High
High
Low
Low
Low
Normal/Low
High
High
Low
High
Low
High
Normal/High
Low
Low
Low
High
High
Low
Low
Low
Normal/Low
High
Low
High
High
Normal/Low
Low
Low
Check temperature difference (delta T) across filter drier.
Water Temp.
Differential
Low
Normal
Low
Low
High
High
Low
Normal
Low
Low
Normal/High
Low
Normal
High
Low
Low
Low
Low
Low
7/6/10
39
RCL SERIES INSTALLATION MANUAL
Heat of Extraction/Rejection Data
Model
gpm
1.2
09
1.8
2.5
1.5
12
2.3
3.5
2.0
15
3.0
4.5
3.0
18
4.0
5.5
Data provided in MBtu/h
Heat of Extraction (HE)
50°F
70°F
6.2
8.1
6.6
8.5
6.9
9.0
7.8
10.1
8.1
10.4
8.6
10.9
10.3
12.4
10.7
12.9
11.3
13.7
12.0
15.2
12.2
15.5
12.6
16.0
30°F
5.0
5.0
6.3
6.2
8.8
7.4
9.5
8.5
90°F
10.6
10.8
10.9
12.4
12.6
12.8
16.4
16.7
17.0
17.6
17.9
18.2
30°F
13.9
14.0
16.3
16.3
19.4
19.5
23.4
23.5
50°F
12.9
13.1
13.4
15.2
15.4
15.8
19.7
19.8
19.9
23.8
23.9
23.9
Heat of Rejection (HR)
70°F
12.1
12.4
12.6
14.4
14.6
14.9
18.2
18.2
18.2
22.0
21.9
21.9
90°F
11.8
11.7
11.8
13.9
13.9
14.0
19.9
20.0
20.2
20.7
20.7
20.9
Reference Calculations
Heating Calculations:
LWT = EWT -
LAT = EAT +
HE
gpm x 500
HC
cfm x 1.08
Cooling Calculations:
LWT = EWT +
HR
gpm x 500
LAT(DB) = EAT(DB) -
SC
cfm x 1.08
LC = TC - SC
TH = HC + HWC
S/T =
SC
TC
Legend
ABBREVIATIONS AND DEFINITIONS:
cfm
EWT
gpm
WPD
EAT
=
=
=
=
=
HC
TC
SC
KW
HR
=
=
=
=
=
airflow, cubic feet/minute
entering water temperature, Fahrenheit
water flow in gallons/minute
water pressure drop, psi and feet of water
entering air temperature, Fahrenheit
(dry bulb/wet bulb)
air heating capacity, MBtu/h
total cooling capacity, MBtu/h
sensible cooling capacity, MBtu/h
total power unit input, kilowatts
total heat of rejection, MBtu/h
HE
= total heat of extraction, MBtu/h
HWC = hot water generator capacity, MBtu/h
EER = Energy Efficient Ratio
= Btu output/Watt input
COP = Coefficient of Performance
= Btu output/Btu input
LWT = leaving water temperature, °F
LAT = leaving air temperature, °F
TH
= total heating capacity, MBtu/h
LC
= latent cooling capacity, MBtu/h
S/T = sensible to total cooling ratio
40
110°F
10.9
11.0
12.9
13.0
18.7
18.9
19.4
19.5
6/10/13
RCL SERIES INSTALLATION MANUAL
DEALER:
PHONE #:
DATE:
PROBLEM:
MODEL #:
Startup/Troubleshooting Form
SERIAL #:
COOLING CYCLE ANALYSIS
PSI =
SAT °F
°F
Unit Amp Draw:
°F
AIR
COIL
Loop:
Open
Closed
Line Voltage:
°F
SUCTION
COMPRESSOR
REVERSING
VALVE
COAX
EXPANSION
VALVE
SOURCE
DISCHARGE
°F
°F
LIQUID LINE
SAT °F
PSI =
°F
°F
PSI
PSI
Superheat
BRINE IN
Subcooling
BRINE OUT
Heat of Extraction/Rejection = GPM x 500 (485 for water/antifreeze) x ∆T
Note: DO NOT hook up pressure gauges unless there appears to be a performance problem.
HEATING CYCLE ANALYSIS
PSI =
SAT °F
°F
Loop:
Unit Amp Draw:
°F
AIR
COIL
Open
Closed
Line Voltage:
°F
SUCTION
COMPRESSOR
REVERSING
VALVE
COAX
EXPANSION
VALVE
SOURCE
DISCHARGE
°F
°F
LIQUID LINE
PSI =
°F
°F
PSI
PSI
SAT °F
Superheat
BRINE IN
BRINE OUT
41
Subcooling
RCL SERIES INSTALLATION MANUAL
Preventive Maintenance
The condensate drain can pick up lint and dirt, especially with dirty
filters. Inspect twice a year to avoid the possibility of overflow.
Water Coil Maintenance
1. Keep all air out of the water. An open loop system should be
checked to ensure that the well head is not allowing air to
infiltrate the water line. Lines should always be airtight.
2. Keep the system under pressure at all times. It is recommended
in open loop systems that the water control valve be placed in
the discharge line to prevent loss of pressure during off cycles.
Closed loop systems must have positive static pressure.
Blower Motors
Blower motors are equipped with sealed ball bearings and require
no periodic oiling.
Air Coil
The air coil must be cleaned to obtain maximum performance.
Check once a year under normal operating conditions and, if dirty,
brush or vacuum (with a brush attachment) clean. Care must be
taken not to damage the aluminum fins while cleaning.
Note: On open loop systems, if the installation is in an area with a
known high mineral content (125 PPM or greater) in the water, it is
best to establish with the owner a periodic maintenance schedule
so the coil can be checked regularly. Should periodic coil cleaning
be necessary, use standard coil cleaning procedures which are
compatible with either the cupronickel or copper water lines.
Generally, the more water flowing through the unit the less chance
for scaling.
Other Maintenance
Filters
CAUTION: Fin edges are sharp.
Filters must be clean to obtain maximum performance. They should
be inspected monthly under normal operating conditions and be
replaced when necessary. Units should never be operated without
a filter.
Condensate Drain
In areas where airborne bacteria produce a slime in the drain pan,
it may be necessary to treat chemically to minimize the problem.
Replacement Procedures
Obtaining Parts
In-Warranty Material Return
When ordering service or replacement parts, refer to the model
number and serial number of the unit as stamped on the serial
plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and the date of failure, along
with an explanation of the malfunctions and a description of the
replacement parts required.
Material may not be returned except by permission of authorized
warranty personnel. Contact your local distributor for warranty
return authorization and assistance.
42
RCL SERIES INSTALLATION MANUAL
Service Parts List
Low Sill Consoles
Compressor
09
12
34P590-09
34P591-09
N/A
N/A
Compressor 208-230/60/1
34P590-01
34P591-01
34P592-01
34P593-01
Compressor 265/60/1
34P590-02
34P591-02
34P592-02
34P593-02
Run Capacitor 115/60/1
16P002D36
16P002D36
N/A
N/A
Run Capacitor 208-230/60/1
16P002D17
16P002D18
16P002D19
16P002D19
Run Capacitor 265/60/1
16P002D27
16P002D27
16P002D30
16P002D30
PSC Motor & Blower
ECM
Motor &
Blower
92P504A01
PSC Motor 115/60/1
14P553-03
N/A
PSC Motor 208-230/60/1
14P553-02
N/A
PSC Motor 265/60/1
14P553-02
N/A
Blower Housing
53P518-01
N/A
Blower Capacitor 208-230/60/1
16P002D10
N/A
Blower Capacitor 265/60/1
16P002D03
N/A
ECM Motor 208-230/265/60/1
N/A
14P549-01
ECM Motor Module 208-230/265/60/1
N/A
17P576-01
Blower Housing
N/A
53P514B01
Controls
Refrigeration
Components
Air Coil
Transformer
18
Compressor 115/60/1
Sound Jacket
Sensors &
Safeties
15
Coax
61P714-41
62P558-03
TXV
61P724-41
62P559-03
33P605-09
33P605-08
Reversing Valve
33P502-05
Filter Drier
36P500B01
CCM Board
17P535-03
ABC
17P553-02
Contactor
13P004A03
Transformer 208-230/60/1
15P514-01
Transformer 265/60/1
15P515-01
High Pressure Switch
35P506B02
Low Pressure Switch
35P506B01
Part numbers subject to change
62P560-01
9/01/15
43
RCL SERIES INSTALLATION MANUAL
Notes
44
RCL SERIES INSTALLATION MANUAL
Revision Guide
Pages:
Date:
By:
Removed FX10 Control Option, Added Aurora Controls, Updated Wiring Schematics
01 Mar 2017
MA
Updated Wiring Schematic, Updated Service Parts Table
11 May 2015
MA
All
Updated with All-Aluminum Air Coils
06 Mar 2014
DS
All
Added 15 & 18 Models
09 Oct 2013
DS
45
Added Revision Table
09 Oct 2013
DS
Misc.
23-24, 43
Description:
45
P.O. Box 1592, York, Pennsylvania USA 17405-1592
Copyright © by Johnson Controls 2017
Form 146.09-NOM1 (317)
Issue Date: March 29, 2017
Supersedes: 146.00-NOM9 (314)
800-861-1001
www.johnsoncontrols.com
Subject to change without notice. Printed in USA
ALL RIGHTS RESERVED
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