WaterFurnace 7 Series 700A11 Installation manual

700A11

Geothermal Heat Pump

• R-410A Refrigerant

• 3, 4, 5 Ton Variable Speed

Installation Information

Water Piping Connections

Hot Water Generator Connections

Electrical

Startup Procedures

Troubleshooting

Preventive Maintenance

C US

IM2700AN 07/12

7 SERIES 700A11 INSTALLATION MANUAL

Table of Contents

Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Closed Loop Ground Source Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Open Loop Ground Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hot Water Generator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Electronic Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Auxiliary Heat Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Auxiliary Heat Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

The Aurora™ Advanced VS Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Operation Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Unit Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Compressor and Thermistor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Refrigerant Circuit Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Heat of Extraction/Rejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Reference Calculations and Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Preventive Maintenance and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46


Model Nomenclature

1

N

2

V

3

V

4-6

048

7

A

8

1

9

0

10

1

11

C

12

T

13

L

14

0

15

J

16

N

Model Type

N = 7 Series

Future Option

N = None

Compressor Type

V = Variable Speed

Cabinet Configuration

V = Vertical

H = Horizontal

Unit Capacity

036, 048, 060

Vintage

A = Current

Voltage

1 = 208-230/60/1

Hot Water Generation

0 = No Hot Water Generation

1 = Hot Water Generation with

factory installed pump

Blower Options

1 = ECM

2 = High Static ECM (036 only)

Control Option

J = Aurora TM Variable Speed Control

K = Aurora Variable Speed Control with Performance Monitoring

Filter Option

0 = 2 in. MERV 11 Filter

1 = AlpinePure 411 (vertical only)

Return Air Configuration

L = Left

R = Right

Discharge Air Configuration

T = Top (vertical)

B = Bottom (vertical)

R = Rear (vertical)

S = Side (horizontal)

E = End (horizontal)

Water Coil Option

C = Copper

N = Cupronickel

4


General Installation Information

Safety Considerations

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.

when units are located in unconditioned spaces to prevent damage from frozen water lines and excessive heat that could damage electrical components.

Filter Rack Conversion

A 2 in. MERV 11 filter is shipped with the heat pump. To field convert the filter rack to use 1 in. filters, simply insert the provided plastic push pins into the holes located in the filter rack. There are holes on the top and bottom of the rack, underneath the instruction labels, for field conversion to 1 in. filters.

Installing Vertical Units

Prior to setting the unit in place, remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket.

Vertical units are available in left or right air return configurations. Top and rear air discharge vertical units should be mounted level on a vibration absorbing pad slightly larger than the base to provide isolation between the unit and the floor. It is not necessary to anchor the unit to the floor (see below).

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. Horizontal units may be moved and stored per the information on the packaging. Do not stack more than three units in total height. Vertical units may be stored one upon another to a maximum height of two units. Do not attempt to move units while stacked. 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.

Bottomflow units should be mounted level and sealed well to floor to prevent air leakage. Bottomflow units require the supply air opening to be cut at least 1/2 in. larger than the unit’s air outlet. Protect the edges of combustible flooring with sheet metal over-wrap or other noncombustible material.

Figure 1: Vertical Unit Mounting

Unit Location

Locate the unit in an indoor area, minimum ambient of

45°F and maximum ambient of 100°F, that allows for easy removal of the filter and access panels. Attic installations are not approved and could result in loss of warranty.

Installation is not recommended in areas with excessive dirt and debris as this may be drawn into the VS drive causing overheating of the VS drive. Location should have enough space for service personnel to perform maintenance or repair. Provide sufficient room to make water, electrical and duct connection(s). If the unit is located in a confined space, such as a closet, provisions must be made for return air to freely enter the space by means of a louvered door, etc. Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit. On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping. Care should be taken

2 in. Extruded

Polystyrene

5


General Installation Information cont.

Installing Horizontal Units

Remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket prior to setting the unit in place. Horizontal units are available with side or end discharge. Horizontal units are normally suspended from a ceiling by four or six 3/8 in. diameter threaded rods. The rods are usually attached to the unit by hanger bracket kits furnished with each unit.

Lay out the threaded rods per the dimensions in Figure

3. Assemble the hangers to the unit as shown. Securely tighten the brackets to the unit using the weld nuts located on the underside of the bottom panel. When attaching the hanger rods to the bracket, a double nut is required since vibration could loosen a single nut. To allow filter access, one bracket on the filter side should be installed 180° from the position shown in Figure 3. The unit should be pitched approximately 1/4-inch towards the drain in both directions to facilitate the removal of condensate. Use only the bolts provided in the kit to attach hanger brackets. The use of longer bolts could damage internal parts.

Some residential applications require the installation of horizontal units on an attic floor. In this case, the unit should be set in a full size secondary drain pan on top of a vibration absorbing pad. The secondary drain pan prevents possible condensate overflow or water leakage damage to the ceiling. The secondary drain pan is usually placed on a plywood base isolated from the ceiling joists by additional layers of vibration absorbing material.

Figure 2: Horizontal Unit Mounting

Flexible Duct

Collar

Insulate supply plenum and use

O at least one 90 reduce noise

Threaded Rods

Hanging

Brackets

(Included)

Hose

Kits

SPECIAL NOTE: The VS drive is limited to a maximum of

125°F ambient temperature. For this reason the 7 Series is not approved for attic installations. The compressor compartment temperature is also monitored by the

Aurora. This ‘compressor ambient’ temperature is available on the AID Tool for reading. The control will de-rate the compressor when ambient air is above 125°F. Installing this product in an attic could result in loss of warranty.

To

Thermostat

Electrical

Disconnect

Line Voltage

Building Water Loop

Ball Valves

CAUTION: Do not use rods smaller than 3/8-inch diameter since they may not be strong enough to support the unit. The rods must be securely anchored to the ceiling.

Figure 3: Hanger Location and Assembly

F

Right

A

Left

1 3

3/8" Threaded

Rod (by others)

Vibration

Isolator

1 Air Coil

4

B C

2

Air Coil

4

D

Hanger Dimensions

Model

Hanger Kit Part

Number

036

048

060 in. cm.

in. cm.

in. cm.

99S500A03

99S500A03

99S500A03

A

Unit Hanger Dimensions

B C D

77.4

196.6

77.4

27.8

70.6

27.8

24.1

61.2

24.1

29.3

74.4

29.3

196.6

82.4

209.3

70.6

27.8

70.6

61.2

24.1

61.2

74.4

29.3

74.4

6/1/12

Washer

Hex Nuts (2)

(by others)

Bolt and

Lock Washer

2 3

Weight Distribution

Model

Vertical

Shipping

Weight

Horizontal

Shipping

Weight

036

048

060

352

361

385

Weights are listed in lbs. [kg]

387

396

415

Horizontal Weight Distribution

Front Back

1 2 3 4

135

145

83

84

86

84

83

83

120 120 45 130

6/1/12

6



Duct System

An air outlet collar is provided on vertical top and rear air discharge units and all horizontal units to facilitate a duct connection (vertical bottomflow units have no collar). A flexible connector is recommended for discharge and return air duct connections on metal duct systems.

Uninsulated duct should be insulated with a minimum of

1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit’s performance will be adversely affected.

If the unit is connected to existing ductwork, check the duct system to ensure that it has the capacity to accommodate the air required for the unit application. If the duct is too small, as in the replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repaired if necessary.

The duct system should be sized according to the table below to handle the design airflow quietly and efficiently.

To maximize sound attenuation of the unit blower, the supply and return plenums should include an internal duct liner of fiberglass or constructed of ductboard for the first few feet. On systems employing a sheet metal duct system, canvas connectors should be used between the unit and the ductwork. If air noise or excessive airflow is a problem, the blower speed can be changed.

Model

NV036

NV048

NV060

Design Airflow

1500

1800

2100 or compound. Check to ensure that the rubber seal is in the swivel connector prior to attempting any connection.

The rubber seals are shipped attached to the waterline.

To make the connection to a ground loop system, mate the brass connector (supplied in CK4LI connector kit) against the rubber gasket in the swivel connector and thread the female locking ring onto the pipe threads, while maintaining the brass connector in the desired direction.

Tighten the connectors by hand, then gently snug the fitting with pliers to provide a leak-proof joint. When connecting to an open loop (ground water) system, thread any 1-inch MPT fitting (SCH80 PVC or copper) into the swivel connector and tighten in the same manner as noted above. The open and closed loop piping system should include pressure/temperature taps for serviceability.

Never use flexible hoses smaller than 1-inch inside diameter on the unit. Limit hose length to 10 feet per connection.

Check carefully for water leaks.

Figure 4: Swivel Connections

Stainless

Steel

Snap Ring

Gasket

Material

Locking

Ring

Gasket

Support

Sleeve

Water Piping

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.

All source water connections on residential units are swivel piping fittings (see Figure 4) that accept a 1-inch male pipe thread (MPT). The swivel connector has a rubber gasket seal similar to a rubber hose gasket, which when mated to the flush end of any 1-inch threaded pipe provides a leak-free seal without the need for thread sealing tape

7



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. Hot water generator 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. Failure to adhere to the guidelines in the water quality table could result in the loss of warranty.

Material pH

Scaling

Corrosion

Iron Fouling

(Biological Growth)

Acidity/Alkalinity

Calcium and

Magnesium Carbonate

Hydrogen Sulfide

Sulfates

Chlorine

Chlorides

Carbon Dioxide

Ammonia

Ammonia Chloride

Ammonia Nitrate

Ammonia Hydroxide

Ammonia Sulfate

Total Dissolved Solids (TDS)

LSI Index

Iron, FE 2 + (Ferrous)

Bacterial Iron Potential

Iron Oxide

Erosion

Suspended Solids

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

< 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

< 6 ft/sec

90/10 Cupronickel

7 - 9


10 - 50 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

< 0.2 ppm



< 6 ft/sec

316 Stainless Steel

7 - 9


Less than 1 ppm

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



< 6 ft/sec

2/22/12

Low Water Coil Limit

Set the freeze sensing switch SW2-1 on the Aurora Base

Control (ABC) printed circuit board for applications using a closed loop antifreeze solution to “LOOP” (15°F). On applications using an open loop/ground water system (or closed loop no antifreeze), set this dip switch to “WELL”

(30°F), the factory default setting. (Refer to the DIP Switch

Settings table in the Aurora Control section.)

Condensate Drain

On vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the drain pan, a 3/4-inch PVC female adapter and a flexible connecting hose. The female adapter may exit either the front or the side of the cabinet. The adapter should be glued to the field-installed PVC condensate piping. On vertical units, a condensate hose is inside all cabinets as a trapping loop; therefore, an external trap is not necessary.

On horizontal units, a PVC stub is provided for condensate drain piping connection. An external trap is required (see below). If a vent is necessary, an open stand pipe may be applied to a tee in the field-installed condensate piping.

Figure 5: Horizontal Drain Connection

PVC tube stub

PVC coupling

1.5 in.

1.5 in.

NOTE: Check dimensional data for actual PVC sizes.

Figure 6: Unit Pitch for Drain

Vent (if needed)

PVC tube stub

1/8 in. per foot

1/2'' Pitch

Drain

8


Closed Loop Ground Source Systems

NOTE: For closed loop systems with antifreeze protection, set SW2-1 to the “LOOP” (15°F) position. (Refer to the DIP

Switch Settings table in the Aurora Control section.)

Multiple Units on One Flow Center

NOTE: This feature is only available in the Aurora Advanced

Control package (AXB board), NOT the Aurora Base

Control (ABC).

Once piping is completed between the unit, pumps and the ground loop (see figure below), final purging and charging of the loop is required. A flush cart (or a 1.5 HP pump minimum) 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 will 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 initially charging the system.

After pressurization, be sure to turn the venting (burping) screw in the center of the pump two (2) turns open (water will drip out), wait until all air is purged from the pump, then tighten the plug. Variable speed pumps do not have a venting screw. Ensure that the loop pumps provide adequate flow through the unit(s) by checking the pressure drop across the heat exchanger and comparing it to the unit capacity data in this catalog. 2.5 to 3 gpm of flow per ton of cooling capacity is recommended in earth loop applications.

Figure 7: Closed Loop Ground Source Application

When two units are connected to one loop pumping system, pump control is automatically achieved by connecting the

SL terminals on connector P2 in both units with 2-wire thermostat wire. These terminals are polarity dependant (see

Figure 8). The loop pump(s) may be powered from either unit, whichever is more convenient. If either unit calls, the loop pump(s) will automatically start. The use of two units on one flow center is generally limited to a total of 20 gpm capacity.

Variable Speed Pump Setup

When using a variable speed pump flow center (FCV1-GL or

FCV2-GL) the use of an AID Tool will be necessary to adjust minimum and maximum flow rates. The factory default is: minimum=50% and maximum=100% speed levels. See the

7 Series FCV1-GL, FCV2-GL Pump Setup and Modulating

Water Valve Setup instructions within the Unit Startup section which is located in the back of this manual. Always ensure that there is adequate flow for the heat pump. See

Recommended Minimum/Maximum Flow Rates table.

NOTE: When sharing a flow center, the variable speed heat pump should be the primary unit. When two variable speed heat pumps share a flow center, the larger capacity heat pump should be the primary unit.

Unit Supply

Auxiliary Heat

Supply

GeoLink ®

Polyethylene w/

Armaflex ®

Insulation

Flexible Duct

Collar

Auxiliary

Heater

Knockout

Unit Power

Hot Water Generator

Connections

GeoLin k

Flow

Center

®

TO

LOOP

Recommended Minimum/Maximum Flow Rates

Closed Loop Open Loop

Model and Size

NV*036

NV*048

NV*060

Min. Flow Rate Max. Flow Rate Min. Flow Rate Max. Flow Rate gpm gpm gpm gpm

5.0

5.0

5.0

12.0

15.0

18.0

5.0

5.0

5.0

8.0

10.0

12.0

6/7/12

Disconnects

(If Applicable)

Low

Voltage to

Thermostat

P/T Plugs

P/T

Vibration Absorbing Pad

Drain

Insulated piping or hose kit

NOTE: Additional information can be found in Flow

Center installation manual and Flush Cart manual.

Figure 8: Primary/Secondary Hook-up

7 Series to

5 or 7 Series Units

7 Series to

Envision Units

7 Series to

Electromechanical Units

7 Series Unit #1 with AXB Board

Shut

Down

C C

SL1

In

SL1

Out

With pump wired to Unit 1

With pump wired to

Unit 2


Shut

Down

C C SL1

In

SL1

Out

With pump wired to

Unit 1

With pump wired to

Unit 2


Shut

Down

C C

SL1

In

SL1

Out

Shut

Down

C C

SL1

In

SL1

Out

5 or 7 Series Unit #2 with AXB Board

Shut

Down

C C

SL1

In

SL1

Out

Envision Unit #2

C S

To Electromechanical Unit

9


Open Loop Ground Water Systems

Typical open loop piping is shown below. 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.

NOTE: For open loop/groundwater systems or systems that do not contain an antifreeze solution, set SW2-Switch

#1 to the “WELL” (30°F) position. (Refer to the DIP Switch

Settings in the Aurora Control section.) Slow opening/ closing solenoid valves (type VM) or modulating valves are recommended to eliminate water hammer.

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. On VS systems, a modulating valve, as shown in figure 9c is the best choice to limit water consumption.

Modulating Water Valve Setup

When using a modulating water valve (23P529-01) the use of an AID Tool will be necessary to adjust minimum and maximum flow rates. The factory default is: minimum=50% and maximum=100% flow levels. See the 7 Series FCV1-GL,

FCV2-GL Pump Setup and Modulating Water Valve Setup instructions within the Unit Startup section which is located in the back of this manual. See Recommended Minimum and Maximum Flow Rates table. Always ensure that there is adequate flow for the heat pump.

Figure 9a: Open Loop Solenoid Valve Connection Option

Typical quick operating external 24V water solenoid valve

(type PPV100 or BPV100) wiring.

C

R

P1

Figure 9b: Open Loop Solenoid Valve Connection Option

Typical slow operating external 24V water solenoid valve

(type VM) wiring and one (1) quick operating valve.

C

R

SV

Solenoid

Valve

Acc Com

Acc NC

Acc NO

1

2

3

P2

NOTE: SW2-4 and SW2-5 should be “OFF” to cycle with the compressor.

VM Valve

Acc Com

ACC NC

Acc NO

NOTE: SW2-4 should be “OFF” and SW2-5 should be “ON” when using a slow opening (VM) water valve.

Figure 10: Open System - Groundwater Application

Unit Supply

Aux. Heat Supply

Flexible

Duct Collar

Disconnects

(IfApplicable)

Rubber Bladder

Expansion Tank

Auxiliary

Heater

Knockout

Hot Water Generator

Connections

Drain

Flow Control

Valve

(on outlet of

Solenoid Valve)

Solenoid

Valve

Water Out

Water In

Shut Off Valves

Shut Off Valves

(to isolate solenoid valve while acid flushing)

Compressor

Line Voltage

Low Voltage to Thermostat and Valve

P/T Plugs

Vibration

Absorbing Pad

Strainer

Boiler Drains

For HX Flushing

10

Figure 9c: Modulating Water Valve Connection Option

Typical 0-10VDC modulating water valve.

AXB BOARD

GND

24 VAC

0-10DC

1

2

3

C

R

ABC BOARD


Hot Water Generator Connections

To maximize the benefits of the hot water generator a minimum 50-gallon water heater is recommended for higher demand applications, use an 80-gallon water heater or two 50-gallon water heaters connected in a series as shown below. Two tanks plumbed in a series is recommended to maximize the hot water generator capability. Electric water heaters are recommended. Make sure all local electrical and plumbing codes are met for installing a hot water generator. Residential units with hot water generators contain an internal circulator and fittings.

A water softener is recommended with hard water (greater than 10 grains or 170 total hardness).

Figure 11: Typical Hot Water Generator Installation

3/4” x 3/4” x 1/2” tee

Cold

Water In

Hot

Water Out

Venting Waste

Valve or Vent

Coupling

HWG

Water Out

P/T Relief

Valve

In

NOTES: 1) Using a preheat tank, as shown in Figure 12, will maximize hot water generator capabilities. 2) The hot water generator coil is constructed of vented double wall copper suitable for potable water.

HWG

Water In Drain Valve

Figure 12: Hot Water Generator Installation In Preheat Tank

Venting Waste Valve or Vent Coupling

3/4" x 3/4" x 1/2" tee

Cold

Water In

Hot

Water Out

Water Tank Preparation

To install a unit with a hot water generator, follow these installation guidelines.

1. Turn off the power to the water heater.

2. Attach a water hose to the water tank drain connection and run the other end of the hose to an open drain or outdoors.

3. Close the cold water inlet valve to the water heater tank.

4. Drain the tank by opening the valve on the bottom of the tank, then open the pressure relief valve or hot water faucet.

5. Flush the tank by opening the cold water inlet valve to the water heater to free the tank of sediments. Close when draining water is clear.

6. Disconnect the garden hose and remove the drain valve from the water heater.

7. Refer to Plumbing Installation and Hot Water Generator

Startup.

HWG

Water Out

P/T Relief

Valve

In

P/T Relief

Valve

HWG

Water In

Drain Valve Drain Valve

Storage

Tank

Electric Powered

Water Heater

NOTE: This configuration maximizes hot water generator capability.

CAUTION: Elements will burn out if energized dry.

11


Hot Water Generator Connections cont.

Plumbing Installation

1. Inspect the dip tube in the water heater cold inlet for a check valve. If a check valve is present it must be removed or damage to the hot water generator circulator will occur.

2. Remove drain valve and fitting.

3. Thread the 3/4-inch NPT x 3-1/2-inch brass nipple into the water heater drain port.

4. Attach the center port of the 3/4-inch FPT tee to the opposite end of the brass nipple.

5. Attach the 1/2-inch copper to 3/4-inch NPT adaptor to the side of the tee closest to the unit.

6. Install the drain valve on the tee opposite the adaptor.

7. Run interconnecting tubing from the tee to hot water generator water out.

8. Cut the cold water “IN” line going to the water heater.

9. Insert the reducing solder tee in line with cold water “IN” line as shown.

10. Run interconnecting copper tubing between the unit hot water generator water “IN” and the tee (1/2-inch nominal). The recommended maximum distance is 50 feet.

11. To prevent air entrapment in the system, install a vent coupling at the highest point of the interconnecting lines.

12. Insulate all exposed surfaces of both connecting water lines with 3/8-inch wall closed cell insulation.

NOTE: All plumbing and piping connections must comply with local plumbing codes.

Hot Water Generator Switch

The hot water generator switch is taped in the disabled position at the factory.

Hot Water Generator Startup

1. Turn the hot water generator switch to the “ON” position. The hot water generator switch will allow the hot water generator pump to be enabled or disabled by the service technician or homeowner.

2. Close the drain valve to the water heater.

3. Open the cold water supply to the tank.

4. Open a hot water faucet in the building to bleed air from the system. Close when full.

5. Open the pressure relief valve to bleed any remaining air from the tank, then close.

6. If so equipped, turn the venting (burping) screw in the center of the pump two (2) turns open (water will drip out), wait until all air is purged from the pump, then tighten the plug. Use vent couplings to bleed air from the lines.

7. Carefully inspect all plumbing for water leaks and correct as required.

8. Before restoring electrical supply to the water heater, adjust the temperature setting on the tank.

• On tanks with both upper and lower elements, the lower element should be turned down to the lowest setting, approximately 100°F. The upper element should be adjusted to 120°F to

130°F. Depending upon the specific needs of the customer, you may want to adjust the upper element differently.

• On tanks with a single element, lower the thermostat setting to 120°F.

9. After the thermostat(s) is adjusted, replace the access cover and restore electrical supply to the water heater.

10. Make sure that any valves in the hot water generator water circulating circuit are open.

11. Use an AID Tool to enable HWG and select the desired water heating set point. Selectable set points are 100°F

– 140°F in 5°F increments (default 130°F). From the Main

Menu of the AID Tool select Setup, then AXB Setup

12. Turn on the unit to first stage heating..

13. The hot water generator pump should be running. When the pump is first started, turn the venting (burping) screw (if equipped) in the center of the pump two (2) turns open until water dribbles out, then replace. Allow the pump to run for at least five minutes to ensure that water has filled the circulator properly. Be sure the switch for the hot water generator pump is “ON”.

14. Allow the unit to heat water for 15 to 20 minutes to be sure operation is normal.

CAUTION: Never operate the HWG circulating pump while dry. If the unit is placed in operation before the hot water generator piping is connected, be sure that the pump switch is set to the OFF position.

12


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. The compressor has no internal overload. The circuit breaker in the control box is the overload protection for the drive and the compressor. Bypassing the circuit breaker could result in damage to the compressor and voiding the warranty.

Unit Power Connection

Connect the incoming line voltage wires to L1 and L2 of the contactor as shown in Figure 13c for single-phase unit.

Consult the Unit Electrical Data in this manual for correct fuse sizes.

Open lower front access panel. Remove ground fastener from bottom of control box (Figure 13b). Swing open control box (Figure 13a). Insert power wires through knockouts on lower left side of cabinet. Route wires through left side of control box and connect to contactor and ground (Figure 13c). Close control box and replace grounding fastener before unit startup.

CAUTION: Frequent cycling of power to the drive can damage the drive! Wait at least 5 minutes between cycles (connecting and disconnecting power to the drive).

Figure 13a:

Wire access (control box open)

Figure 13b:

Wire access (control box closed)

Accessory Relay

A set of “dry” contacts has been provided to control accessory devices, such as water solenoid valves on open loop installations, electronic air cleaners, humidifiers, etc.

This relay contact should be used only with 24 volt signals and not line voltage power. The relay has both normally open and normally closed contacts and can operate with either the blower or the compressor. Use DIP switch SW2-4 and 5 to cycle the relay with blower, compressor, or control a slow opening water valve. The relay contacts are available on terminals #2 and #3 of P2.

A second configurable accessory relay is provided on the

AXB board. When powering high VA draw components such as electronic air cleaners or VM type open loop water valves, R should be taken ‘pre-fuse’ from the ‘R’ quick connect on the ABC board and not the ‘post-fuse’ ‘R’ terminal on the thermostat connection. If not, blown ABC fuses might result.

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 on terminal strip PS.

Figure 13c:

Line Voltage 208-230/60/1 control box

CB

PB1

L1

L2

L1

L2

Compressor

Drive

Overload

Wire Insert

Location

Ground Fastener must be installed for proper unit ground

13


Electrical Connections cont.

Pump Power Wiring

See Figure 14 for electrical connections from control box to pumps.

FC1/FC2 style flow centers with fixed speed pumps connect to PB1 in the control box. If using a variable speed pump it should be connected to L1 and L2 on the AXB.

Figure 14: Pump Wiring 208-230/60/1

CB

PB1

L1

L2

External Fixed

Speed Loop Pump

(ex. UP26-99)

208-230/60/1

1/2 hp Max

External Variable

Speed Loop Pump

(ex. Magna Geo)

208-230/60/1

Electronic Thermostat Installation

Position the thermostat subbase against the wall so that it is level and the thermostat wires protrude through the middle of the subbase. Mark the position of the subbase mounting holes and drill holes with a 3/16-inch bit. Install supplied anchors and secure base to the wall.

Thermostat wire must be 4-conductor, 20-AWG (minimum) wire. Strip the wires back 1/4-inch (longer strip lengths may cause shorts) and insert the thermostat wires into the connector as shown. Tighten the screws to ensure secure connections. The thermostat has the same type connectors, requiring the same wiring. See instructions enclosed in the thermostat for detailed installation and operation information. The W1 terminal on TPCM32U04 communicating thermostats may be hard wired to provide aux/emergency heat in the event communication is lost between the thermostat and the ABC microprocessor.

Figure 15: Thermostat Wiring (Communicating Style Signals)

C

R

–

+

P7

W

P1

C 24VAC (Common)

R 24VAC (Hot)

B- Communication

A+ Communication

W1 (Optional)

TPCM32U04

Monochrome Thermostats

C

R

–

+

P7

C 24VAC (Common)

R 24VAC (Hot)

DX- Communication

DX+ Communication

TPCC32U01

Color Touchscreen

Thermostat

Thermostat Connection

14


Auxiliary Heat Ratings

Model

EAL(H)10

EAL(H)15

EAL(H)20

208V

7.2

10.8

14.4

kW

230V

9.6

14.4

19.2

Stages

2

3

4

208V

24,600

36,900

49,200

Btu/h

230V

32,700

49,100

65,500

Air flow level for auxiliary heat (Aux) must be above the minimum cfm in this table

Order the “H” part number when installed on horizontal and vertical rear discharge units

Min CFM

1100

1250

1500

036

•

•

Model Compatibility

048

•

•

•

060

•

•

•

6/1/12

Auxiliary Heat Electrical Data

Model

EAL(H)10

EAL(H)15

Supply

Circuit

Single

Single

L1/L2

L3/L4

Single

Heater Amps

208 V 240 V

34.7

40

52.0

34.7

17.3

69.3

60

40

20

80

Min Circuit Amp

208 V 240 V

53.3

60

75

53.3

21.7

96.7

EAL(H)20 L1/L2 34.7

40 53.3

L3/L4 34.7

40 43.3

All heaters rated single phase 60 cycle and include unit fan load

All fuses type “D” time delay (or HACR circuit breaker in USA)

85

60

25

110

60

50

Max Fuse (USA)

208 V 240 V

60 60

80

60

25

90

60

25

100

60

45

110

60

50

Max Fuse (CAN)

208 V 240 V

60 60

80

60

25

90

60

25

100

60

45

110

60

50

Max CKT BRK

208 V 240 V

60 60

70

60

20

100

60

30

100

60

40

100

60

50

6/1/12

Electrical Data

Model

Rated

Voltage

Voltage

Min/Max

036 208-230/60/1 187/253

*036 208-230/60/1 187/253

048 208-230/60/1 187/253

060 208-230/60/1 187/253

*With optional 1 hp ECM Motor

Rated Voltage of 208/230/60/1

HACR circuit breaker in USA only

All fuses Class RK-5

Compressor

LRA CMCC

10.2

10.2

12.0

12.0

18.0

18.0

23.5

30.0

LRA

Drive

Internal

Breaker

22.0

22.0

30.0

30.0

28.0

33.0

35.0

40.0

HWG

Pump

FLA

0.4

0.4

0.4

0.4

Ext Loop

FLA

5.4

5.4

5.4

5.4

Blower

Motor

FLA

Total Unit

FLA

Minimum

Circuit

Amp

Max Fuse

HACR

Breaker

4.0

7.0

7.0

7.0

31.8

34.8

40.8

45.8

37.3

40.3

47.8

54.1

40

45

50

60

3/26/12

15


Blower Performance Data

ECM Blower Motor

Model

036

036 w/1hp*

048

Max

ESP

0.50

0.75

0.75

Speed

1

285

480

475

Speed

2

380

G

565

G

620

G

Speed

3

525

L

665

L

730

L

Speed

4

675

761

850

Speed

5

815

870

1020

Air Flow

Speed

6

980

1000

1140

Speed

7

1100

1100

1270

Speed

8

1220

1200

1400

Speed

9

1330

1300

1520

Speed

10

1440

H

1410

H

1650

H

060 0.75

400 600

G

830

L

1-2

1050 1230 1400 1560 1700 1870 2010

H

**VS Compressor Speed 3-4 5-6 7-8 9-10 11-12

** VS Compressor speed is given for the factory default cfm settings. When the cfm default settings are changed it will change the relationship to the compressor speed that is shown in the table. In cooling mode compressor speeds 10-12 are only available when

SuperBoost mode is selected at the thermostat.

* Optional 1 hp ECM

Factory settings are at recommended G, L , H and Aux positions

“G” may be located anywhere within the airflow table

“L” setting should be located within the boldface cfm range

“H” setting MUST be located within the shaded cfm range

“Aux” setting MUST be equal to or greater than “H” setting

“Aux” setting MUST be equal to or greater than the minimum allowable cfm for the auxiliary heater kit (see auxiliary heat ratings table)

Cfm is controlled within 5% up to the maximum ESP

Max ESP includes allowance for wet coil and standard filter

Speed

11

1540

Aux

1520

Aux

1790

Aux

2140

Aux

Speed

12

1575

1630

1925

2265

6/7/12

Setting Blower Speed - ECM

The ABC board’s Yellow Config LED will flash the current

ECM blower speed selections for G, low, and high continuously with a short pause in between. The speeds can also be confirmed with the AID Tool under the Setup/

ECM Setup screen. The Aux will not be flashed but can be viewed in the AID Tool. The ECM blower motor speeds can be field adjusted with or without using an AID Tool.

ECM Setup without an AID Tool

The blower speeds for G only, Low (Y1), and High (Y2/

Aux) can be adjusted directly at the Aurora ABC board which utilizes the push button (SW1) on the ABC board.

This procedure is outlined in the ECM Configuration Mode portion of the Aurora ‘Base’ Control System section. The

Aux cannot be set manually without an AID Tool.

ECM Setup with an AID Tool

A much easier method utilizes the AID Tool to change the airflow using the procedure below. First navigate to the Setup screen and then select ECM Setup. This screen displays the current ECM settings. It allows the technician to enter the setup screens to change the ECM settings. Change

ECM Speed Info the highlighted item using the ◄ and ► buttons and then press the

◙ button to select the item.

Blower Only Speed 3

Lo Compressor

Hi Compressor

Aux Heat

6

9

10

Selecting YES will enter ECM speed setup, while selecting NO will return to the previous screen.

Want To Change?

Yes

Option ◄►

No

Enter ◙

ECM Speed Setup - These screens allow the technician to select the G, low, high, and auxiliary heat blower speed for the ECM blower motor. Change the highlighted item using the ▲ and ▼ buttons. Press the ◙ button to select the speed.

ECM Speed Info

►

7

8

5

6

3

4

1

2

9

10

11

12

◄ G

ECM Speed Info

►

7

8

5

6

3

4

1

2

9

10

11

12

G

◄ Lo

ECM Speed Info

►

7

8

5

6

3

4

1

2

9

10

11

12

G

Lo

◄ Hi

ECM Speed Info

9

►10

11

12

7

8

5

6

3

4

1

2 G

Lo

Hi

◄ Aux

Option ◄► Enter ◙ Option ◄► Enter ◙ Option ◄► Enter ◙ Option ◄► Enter ◙

After the auxiliary heat speed setting is selected the AID

Tool will automatically transfer back to the ECM Setup screen.

Cooling Airflow Setup - These screens allow the technician to select -15%, -10%, -5%, None or +5% change from the heating airflow. Change the adjustment percentage using the ▲ and ▼ buttons. Press the ◙ button to save the change.

Cooling Airflow Setup Cooling Airflow Setup

--- ECM Only ---

The airflow will be adjusted by the chosen amount in cooling mode.

Adjustment:

-15%

Want To Change?

Yes

Option ◄►

No

Enter ◙

--- ECM Only ---

The airflow will be adjusted by the chosen amount in cooling mode.

Adjustment:

-15%

Change ▼▲ Enter ◙

16


Vertical Dimensional Data

Top Air Discharge

LEFT RETURN

Q

O L M

R N

L

P

RIGHT RETURN

O Q

N R

TOP

T T

TOP

1.9in

[4.8cm]

1.9in

[4.8cm]

S S

C C

I K J

A

FRONT

D E H F G

2 ft [61 cm]

Primary Service Access

B

LEFT SIDE

B

RIGHT SIDE

Overall Cabinet Water Connections

Electrical

Connections

Discharge Connection duct flange installed (±0.10 in)

Vertical Top

Flow Model

036

048

A

Width

B

Depth

C

Height

D

Loop

In in.

25.6

31.6

54.4

2.3

cm.

65.0

80.3

138.2

5.8

in.

25.6

31.6

54.4

2.3

cm.

65.0

80.3

138.2

5.8

E

Loop

Out

F

HWG

In

G

HWG

Out

H

Cond- ensate

Loop

Water

FPT

HWG

Sweat

(I.D.)

I

1/2” cond

Low

Voltage

J

1/2” cond

Ext

Pump

K

3/4” cond

Power

Supply

7.3

15.9

18.9

10.6

18.5

40.4

48.0

26.9

1”

Swivel

1/2” female

14.3

36.3

9.8

24.9

12.3

31.2

7.3

15.9

18.9

10.6

18.5

40.4

48.0

26.9

1”

Swivel

1/2” female

14.3

9.8

12.3

36.3

24.9

31.2

L

6.9

17.5

6.9

17.5

M

1.1

2.8

1.1

2.8

N

Supply

Width

O

Supply

Depth

18.0

18.0

45.7

45.7

18.0

18.0

45.7

45.7

060 in.

25.6

31.6

58.4

2.3

cm.

65.0

80.3

148.3

5.8

7.3

18.5

15.9

40.4

18.9

48.0

10.6

26.9

1”

Swivel

1/2” female

14.3

36.3

9.8

24.9

12.3

31.2

6.9

17.5

1.1

2.8

18.0

45.7

18.0

45.7

Condensate is 3/4” PVC female glue socket and is switchable from side to front

Unit shipped with deluxe 2” (field adjustable to 1”) duct collar/filter rack extending from unit 3.25” and is suitable for duct connection.

Discharge flange is field installed and extends 1” [25.4mm] from cabinet

Decorative molding and/or water connections extend 1.2” [30.5mm] beyond front of cabinet.

Louvered vents in the compressor section right side access panel extend 1/2” [12.7 mm] from side of cabinet. Allow clearance for venting.

P

3.8

9.7

3.8

9.7

3.8

9.7

Return Connection using std deluxe filter rack

(±0.10 in)

Q

1.7

4.3

1.7

4.3

1.7

4.3

R

Return

Depth

S

Return

Height

28.1

71.4

28.1

71.4

28.1

71.4

30.0

76.2

30.0

76.2

34.0

86.4

T

1.7

4.3

1.7

4.3

1.7

4.3

6/29/12

17


Vertical Dimensional Data cont.

Bottom Air Discharge

LEFT RETURN RIGHT RETURN

1.70

(4.3 cm)

C C

4

3

2

1

S S

2 ft [61 cm]


T T

B

LEFT SIDE

R

L

O

M N

LEFT BOTTOM DISCHARGE

FLOOR FOOT PRINT

Q

O

B

RIGHT SIDE

R

N L

RIGHT BOTTOM DISCHARGE

FLOOR FOOT PRINT

Q

P

I

K

J

1.90

(4.7 cm)

5

A

FRONT

D

E

F

G

H

Bottomflow

Models

036-

060

Overall Cabinet

A

Width

B

Depth

C

Height

1

D

In

2

E

Out

Water Connections

3

F

HWG

In

4

G

HWG

Out in.

25.5

31.5

62.5

43.4

48.4

57.0

60.0

cm. 64.8

80.0

158.8

110.2

122.9

144.8

152.4

5

H

Condensate

3.1

7.9

Loop

Water

FPT

1”

Swivel

HWG

Sweat

(I.D.)

1/2” female

Electrical Knockouts

I

1/2” cond

Low

Voltage

51.1

129.8

J

1/2” cond

Ext

Pump

55.6

141.2

K

3/4” cond

Power

Supply

53.6

136.1

Discharge Connection duct flange installed (

L

9.1

23.1

M

4.8

12.2

N

Supply

Width

13.4

34.0

±0.10 in)

O

Supply

Depth

13.6

34.5





P

1.7

4.3


( ±0.10 in)

Q

1.8

4.6

R

Return Return

Depth

S

Height

T

28.1

34.0

5.6

71.4

86.4

14.2

4/30/12

18


Vertical Dimensional Data cont.

Rear Air Discharge

2 ft [61 cm]


O Q

M

L

C

N

C

R

1.90 in. [4.8 cm]

1.90 in.

[4.8 cm]

I K

J

T

A

FRONT

D

E

H

F G

T R

S S

C

Q P

M

N

C

A

REAR VIEW

LEFT RETURN

B

SIDE VIEW

LEFT RETURN

B

SIDE VIEW

RIGHT RETURN

A

REAR VIEW

RIGHT RETURN

Vertical

Rear

Discharge

Model

036

048

Overall Cabinet

A

Width

B

Depth

C

Height in.

25.6

31.6

54.4

cm. 65.0

80.3

138.2

in.

25.6

31.6

54.4

cm. 65.0

80.3

138.2

D

Loop

In

2.3

5.8

2.3

5.8

E

Loop

Out

7.3

18.5

F

HWG

In

15.9

40.4

G

HWG

Out

18.9

48.0

H

Cond- ensate

10.6

26.9

Loop

Water

FPT

1”

Swivel

HWG

Sweat

(I.D.)

I

1/2” cond

Low

Votage

1/2” female

J

1/2” cond

Ext

Pump

14.3

9.8

36.3

24.9

7.3


15.9

18.9

10.6

18.5

40.4

48.0

26.9

1”

Swivel

1/2” female

Electrical

Connections

14.3

9.8

36.3

24.9

K

3/4” cond

Power

Supply

12.3

31.2

12.3

31.2

duct flange installed (

L

Supply

Width

Discharge Connection

M

Supply

Depth

N

±0.10 in)

O P

13.3

13.6

39.4

9.1

8.1

33.8

34.5

100.1

23.1

20.6

13.3

13.6

39.4

9.1

8.1

33.8

34.5

100.1

23.1

20.6

060 in.

25.6

31.6

58.4

2.3

cm. 65.0

80.3

148.3

5.8

7.3

18.5

15.9

40.4

18.9

48.0

10.6

26.9

1”

Swivel

1/2” female

14.3

36.3

9.8

24.9

12.3

31.2

13.3

33.8

13.6

34.5

43.4

110.2

9.1

8.1

23.1

20.6




Decorative molding and water connections extend 1.2” [30.5mm] beyond front of cabinet.



( ±0.10 in)

Q

1.7

4.3

1.7

4.3

1.7

4.3

R

Return Return

Depth

S

Height

28.1

71.4

71.4

28.1

71.4

30.0

76.2

28.1

30.0

76.2

34.0

86.4

T

1.7

4.3

1.7

4.3

1.7

4.3

6/29/12

19


Horizontal Dimensional Data

TOP VIEW

Q

P

2.1in

[5.4cm]

MOUNT (2) HANGER BRACKETS

AS SHOWN TO ALLOW ACCESS

TO FILTER

1.9in

[4.8cm]

I K J

FRONT VIEW

A

S

2 ft [61 cm]


SIDE DISHCARGE VIEW

B

N O

L

M

C

L

END VIEW

O S

R

D

E F G

AS SHOWN LR UNIT (RR UNIT ON OPPOSITE SIDE—SAME DIMENSIONS)

H

Horizontal

Models

036

048

Overall Cabinet

A

Width

B

Depth

C

Height in.

25.6

77.0

21.3

cm.

65.0

195.6

54.1

in.

25.6

77.0

21.3

cm.

65.0

195.6

54.1

D

In

2.3

5.8

2.3

5.8

E

Out

7.3

18.5

7.3

18.5


F

HWG

In

15.9

40.4

48.0

15.9

40.4

G

HWG

Out

18.9

18.9

48.0

H

Cond- ensate

Loop

Water

FPT

0.8

2.0

0.8

2.0

1”

Swivel

1”

Swivel

HWG

Sweat

(I.D.)

Electrical Connections

I

1/2” cond

J

1/2” cond

K

3/4” cond

Discharge Connection duct flange installed ( ±0.10 in)

Low

Voltage

Ext

Pump

Power

Supply

L

M

Supply

Height

N

Supply

Depth

O

1/2” female

1/2” female

14.3

36.3

14.3

36.3

9.8

24.9

9.8

24.9

12.3

31.2

12.3

31.2

SEE

CHART

SEE

CHART

13.6

34.5

13.6

34.5

13.2

33.5

13.2

33.5

SEE

CHART

SEE

CHART

060 in.

25.6

82.0

21.3

cm.

65.0

208.3

54.1

2.3

5.8

7.3

18.5

15.9

40.4

18.9

48.0

0.8

2.0

1”

Swivel

1/2” female

14.3

36.3

9.8

24.9

12.3

31.2

SEE

CHART

13.6

34.5

13.2

33.5






SEE

CHART

2.8

7.1

2.8

7.1

2.8

7.1


( ±0.10 in)

P

Q

Return

Depth

R

Return

Height

40.4

18.9

102.6

48.0

40.4

18.9

102.6

48.0

45.4

18.9

115.3

48.0

S

1.3

3.3

1.3

3.3

1.3

3.3

6/29/12

Units Not Shown Above

Right Return End Discharge

Right Return Side Discharge

Left Return End Discharge

Left Return Side Discharge in cm in cm in cm in cm

L

2.8

7.1

4.9

12.4

4.9

12.4

2.8

7.1

O

4.6

11.8

6.9

17.5

7.6

19.4

6.9

17.5

20


Physical Data

Model

Compressor (1 each)

Factory Charge R-410A, oz [kg] Vertical

Factory Charge R-410A, oz [kg] Horizontal

ECM Blower Motor & Blower

Blower Motor Type/Speeds

Blower Motor- hp [W]

High Static Blower Motor - hp [W]

Blower Wheel Size (Dia x W), in. [mm]

High Static Blower Wheel Size - [Dia. x W], in. [mm]

Coax and Water Piping

Water Connections Size - Swivel - in [mm]

HWG Connection Size - Female Sweat I.D. - in [mm]

Coax & Piping Water Volume - gal [l]

Vertical

Air Coil Dimensions (H x W), in. [mm]

Air Coil Total Face Area, ft 2 [m 2 ]

Air Coil Tube Size, in [mm]

Air Coil Number of rows

Filter Standard - 2 in. [51 mm] Pleated MERV 11 Throwaway, in [mm]

Weight - Operating, lb [kg]

Weight - Packaged, lb [kg]

Horizontal

Air Coil Dimensions (H x W), in. [mm]

Air Coil Total Face Area, ft 2 [m 2 ]

Air Coil Tube Size, in [mm]

Air Coil Number of rows

ECM

ECM

ECM

ECM

ECM

Filter Standard - 2 in. [51 mm] Pleated MERV 11 Throwaway, in [mm]

Weight - Operating, lb [kg]

Weight - Packaged, lb [kg]

036

95 [2.69]

95 [2.69]

1/2 [373]

1 [746]

11 x 10 [279 x 254]

11 x 10 [279 x 254]

1 [25.4]

1/2 [12.7]

1.6 [6.1]

32 x 25 [813 x 635]

5.6 [0.570]

3/8 [9.5]

3

32 x 30 [813 x 762]

352 [160]

372 [169]

Variable Speed

048

Variable Speed Scroll

120 [3.40]

136 [3.85]

Variable Speed

1 [746] n/a

11 x 10 [279 x 254] n/a

1 [25.4]

1/2 [12.7]

1.6 [6.1]

32 x 25 [813 x 635]

5.6 [0.570]

3/8 [9.5]

3

32 x 30 [813 x 762]

361 [164]

381 [173]

060

140 [3.96]

148 [4.19]

1 [746] n/a

11 x 10 [279 x 254] n/a

1 [25.4]

1/2 [12.7]

2.3 [8.7]

36 x 25 [914 x 635]

6.3 [0.641]

3/8 [9.5]

4

36 x 30 [914 x 762]

385 [175]

405 [184]

20 x 40 [508 x 1016]

5.6 [0.570]

3/8 [9.5]

3

1 - 20 x 20 [508 x 508]

1 - 20 x 22 [508 x 559]

387 [176]

417 [189]

20 x 40 [508 x 1016]

5.6 [0.570]

3/8 [9.5]

3

1 - 20 x 20 [508 x 508]

1 - 20 x 22 [508 x 559]

396 [180]

426 [193]

20 x 45 [508 x 1143]

6.3 [0.641]

3/8 [9.5]

4

1 - 20 x 25 [508 x 635]

1 - 20 x 22 [508 x 559]

415 [188]

445 [202]

6/1/12

21


The Aurora™ Advanced VS Control System

Aurora Advanced VS Control

Aurora Advanced VS

Control System is a complete residential and commercial comfort system that brings all aspects of the HVAC system into one cohesive module network. The

Aurora Advanced VS

Control features the

Aurora Base Control

(ABC) and the Aurora

Expansion Board

(AXB). The InfiniSpeed drive communicates to the Aurora Control and provides variable capacity and envelope control. The ABC features microprocessor control and HP, LP, loss of charge, condensate and freeze detection, over/under voltage faults, along with communicating thermostat capability for complete fault detection text at the thermostat. Aurora uses the Modbus communication protocol to communicate between modules. Each module contains the logic to control all features that are connected to the module. The ABC has two Modbus channels. The first channel is configured as a master for connecting to devices such as a communicating thermostat, expansion board, or other slave devices. The second channel is configured as a slave for connecting the

Aurora Interface Diagnostics Tool (AID Tool).

The Aurora AXB expands on the capability of the ABC control board. The additional features include active dehumidification, SuperBoost cooling mode, loop pump slaving, intelligent hot water generator control, variable speed pump capability, and also allows for optional energy, refrigeration, and performance monitoring add-on sensor kits. The AXB also features a second field configurable accessory relay, and two home automation inputs that are AID configurable for different types of alarms from sump pumps to home security. The Smart Grid input is

AID configurable with many options to react to Utility controlled relay operation for On Peak optimization.

The AXB also expands the communication capability for

IntelliZone2 ready operation as well as other expansion with the ClimateTalk protocol.

Aurora Control Features Description

Advanced Microprocessor Features Smart Grid, Home Automation Alarm Inputs, and Accessory2 Relay (HRV/ERV)

Advanced Hot Water Generator

Control

Microprocessor and separate power relay for Hot Water Generator Pump with digital temperature monitoring and multiple HWG setpoint selection.

Advanced Speed Pump Control

Microprocessor and separate power relay for loop pump and inline circuit breakers and loop pump slaving.

Variable Speed Pump Capable of setup, monitoring and controlling a variable speed flow center.

Active Dehumidification

SuperBoost

Smart Grid/Utility Input

Home Automation Alarm Input

HAN/Smart Grid Com

(AWL and Portal) Kit

IntelliZone2 ® Compatibility

Coil temperature is monitored and air flow is reduced for maximum latent moisture removal.

Allow the variable speed compressor to ramp up an extra 30% of cooling capacity if needed. This extra ‘SuperBoost’ will only be available for a 24 hr period and then the unit will revert to normal operation.

Allows simple input to externally enable of occupied/unoccupied mode for basic utility time of use programs.

Allows simple input to signal sump, security, or smoke/CO sensor alarms from other home automation or security systems. The two inputs can be field configured to a number of options and logic.

Allows direct communication of the Aurora to Smart Meters, Home Automation

Network and Internet.

IntelliZone2 communicates to the heat pump via the AXB board. IntelliZone requires traditional thermostat inputs and is not compatible with the 7 Series.

Aurora Advanced VS

•

•

•

•

7 Series Variable

Speed Only

•

Dry Contact x1

Dry Contact x2

Optional AWL

Optional IntelliZone2

Service Device Description Aurora Advanced VS

Aurora Interface and Diagnostics

(AID) Tool

Allows setup, monitoring and troubleshooting of any Aurora Control.

NOTE: Although the ABC has basic compatibility with all Aurora, new product features may not be available on older AID Tools. To simplify the basic compatibility ensure the version of AID is at least the same or greater than the ABC software version.

For Service

(Ver. 2.xx or greater)

22


The Aurora Advanced VS Control System cont.

Add On Control Feature Kits

(field or factory Installed)

Geo Energy Monitoring Kit

Refrigeration Monitoring Kit

Performance Monitoring Kit

Data Logging (AWL) Kit

HAN/Smart Grid Com

(AWL and Portal) Kit

Description

Monitors real time power consumption of compressor, blower, aux heat and pump.

Requires thermostat TPCM32U04 or TPCC32U01.

Monitors real time pressures, temperatures, superheat, and subcooling.

Monitors air and water temperatures, and water flow rate and calculates heat of extraction/rejection.

Allows data logging of up to 12 months. Can also be temporarily installed.

Allows direct communication of the Aurora to Smart Meters, HAN, and internet.

Add On Thermostats and Zoning Description

TPCM32U04 - MonoChrome

Communicating Thermostat

Elite Stat with full English fault codes and alerts, communicating thermostat;

Required for viewing Energy Monitoring

TPCC32U01 - Color Touchscreen

Communicating Thermostat

4.3 in. color touchscreen communicating thermostat with full English fault codes and alerts; Required for viewing Energy Monitoring


Standard

Standard

Optional Sensor Kit

Optional

Optional


Optional

Optional

Includes color main thermostat and up to 6 zones (with variable speed), 4 zones

(with dual capacity), and 2 zones (with single speed). There are 3 thermostat options (MasterStat, SensorStat, ZoneStat).

Optional

IntelliZone2 ® Zoning

NOTES: Monochrome thermostat allows instantaneous energy measurement only. Color thermostat allows instantaneous and 13 month history.

The IntelliZone2 or one of the communicating thermostats shown above must be used to control the variable speed heat pump.

Aurora Advanced VS Control Features

NOTE: Refer to the Aurora Advanced VS Control Application and Troubleshooting Guide and the Instruction Guide: Aurora

Interface and Diagnostics (AID) Tool for additional information.

Control Features

Software ABC VS Version 2.0 Variable Capacity Compressors

• 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

• 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)

Variable Speed ECM Blower Motor

A variable speed ECM blower motor is driven directly using the onboard PWM output. Multiple blower speeds are available based upon requirements of the compressor and electric heat. The blower speeds can be changed either by the variable speed ECM manual configurations mode method or by using the Aurora AID Tool directly.

Advanced Hot Water Generator Control

(Domestic Hot Water Option)

An AID Tool selectable temperature limit and microprocessor control of the process is featured. 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 the set point (130°F default) for

30 continuous seconds. 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

23



cycle or after 15 minutes of continuous compressor operation during 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.

Loop Pump Slaving

This input and output are provided so that two units can be slaved together with a common flow center. When either unit has a call for loop outputs, 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 wired and slaved together in this fashion.

VS Drive and Envelope Control

The VS drive operates the compressor between 20 and

100% capacity. The VS drive communicates any out of refrigerant envelope conditions to the Aurora and will attempt to adjust the compressor speed to keep within the envelope. These conditions are measured using the discharge and suction pressure transducers, discharge temperature, and current sensors of the drive.

Advanced Communication Ports

Communication ports P6 and P8 will provide future expansion via dedicated protocols. These are for future use.

IntelliZone2 Zoning Compatibility

(Optional IntelliZone2 Zoning)

A dedicated input to connect and communicate with the

IntelliZone2 (IZ2) zoning system is provided on P7. There is a dedicated communication port using a proprietary

ModBus protocol. The AXB is standard on variable speed systems. 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.

Smart Grid/On Peak (SG) Input

The 'Smart Grid/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 and provide demand reduction.

With a closed contact signal, this input will limit the operation and thus the power consumption of the unit by disabling the compressor and electric heat as long as the signal is present. Code 7 will flash on the Green LED signifying the 'On Peak' mode. On Peak will also display on communicating thermostats.

Electronic Expansion Valve

The electronic expansion valve is operated by the EEV board and is set to maintain optimal superheat setting for maximum efficiency. All operation parameters are communicated to the VS drive and the Aurora system.

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.

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. 50% 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.

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. 50% and 100% are the default settings respectively.

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

24



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

Special Modes and Applications

Communicating Digital Thermostats

The Aurora VS controls system also requires either the 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.

‘SuperBoost’ Cooling Mode

Occasionally there can be a requirement for a short term

‘boost’ of cooling capacity during a large party etc. The

7 Series allows the user to select ‘SuperBoost’ mode on the thermostat which will allow the 7 Series VS to ramp up an extra 30% of cooling capacity if needed. This extra

‘SuperBoost’ will only be available for a 24 hr period and then the unit will revert to normal operation. The short term boost does not affect ground loop sizing since it is limited in operation. Continuous use of SuperBoost will result in overheating of the ground loop.

Monitoring Sensor Kits

Energy Monitoring

(Standard on all 7 Series units)

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 TPCM32U04 will display instantaneous energy use while the color touchscreen

TPCC32U01 will, in addition, display a 13 month history in graph form.

Refrigerant Monitoring

(Standard on all 7 Series units)

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.

Dehumidification – Active

Active dehumidification will only activate during cooling operation and is based upon the humidity setpoint of the thermostat being at least 5% below the actual relative humidity and being within the temperature parameters described here. The green status LED will flash code 2 when active. The unit can operate a maximum of 2°F below the cooling setpoint. The compressor will ramp up and airflow will begin at a low level. Airflow is then reduced periodically until air coil temperature setpoint is reached. If coil temperature continues to drop, the airflow is increased until air coil setpoint is maintained. After 20 minutes of operation in the Active Dehumidification mode, normal cooling operation will resume for 5 minutes. This cycle continues until the dehumidification setpoint is reached, room temperature is more than 2°F below cooling setpoint, or more than 1°F above cooling setpoint (normal cooling takes over). In IntelliZone2 systems, the main zone will remain open during active dehumidification.

Field Hardware Selectable Options

ABC Field Selectable Options via Button (SW1)

Test/Configuration Button (See SW1 Operation Table)

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.

Test Mode

The control is placed in the test mode by holding the push button switch on the ABC 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.

25



Variable Speed ECM Configuration Mode

The control is placed in the variable speed ECM configuration mode by holding the push-button switch SW1 for 5 to 10 seconds, the high, low, and G variable speed ECM speeds can be selected by following the LED display lights.

LED2 (yellow) will fast flash when entering the variable speed 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 variable speed 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 variable speed ECM configuration mode.

Aux blower speed will remain at default or current setting and requires the AID Tool for adjustment.

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 variable speed ECM manual configurations mode method or by using the Aurora AID Tool directly (see Instruction

Guide: Aurora Interface and Diagnostics (AID) Tool topic).

AXB DIP Switch (SW1)

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.

Reset Configuration Mode

The control is placed in reset configuration mode by holding the push button switch SW1 on the ABC 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.

Position DIP 4

1 ON

2 OFF

3

4

ON

OFF

DIP 5

ON

ON

OFF

OFF

Description

Cycles with blower or ECM (or G)

Cycles with CC1 first stage of compressor or compressor spd 1-12

Cycles with CC2 second stage of compressor or compressor spd 7-12

Cycles with DH input from ABC board

ABC 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 – Low air coil temperature limit setting for freeze detection. On = 30°F; Off = Not Used

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

SW2-4

ON

OFF

ON

OFF

SW2-5

ON

OFF

OFF

ON

SW2-6 CC Operation – selection of single or dual capacity compressor. On = Single Stage; Off = Dual Capacity

NOTE: SW2-6 is not applicable to the 7 Series

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

NOTE: SW2-7 is not applicable to the 7 Series

SW2-8 Future Use

Field Selectable Options via Software

(Selectable via the Aurora AID Tool)

Many options are field selectable and configurable in

Aurora software via the AID Tool. Consult the installation manual or Aurora documentation for further details.

Basic Aurora 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.

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

VS 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

VS call, then the control will go to Lockout mode.

26



Lockout – when locked out, the blower will operate continuously in “G” blower speed setting. 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, the demand call must be removed for at least 30 seconds. To reset lockout conditions with SW2-8 Off, the demand call must be removed for at least 30 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 30 seconds.

CAUTION: Frequent cycling of power to the drive can damage the drive! Wait at least 5 minutes between cycles (connecting and disconnecting power to the drive).

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.

Freeze Detection-Air Coil - Air Coil Freeze Detection will use 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.

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. Lockout With Emergency Heat - if the control is locked out in the heating mode, and a call for emergency heat 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 variable speed ECM blower will shift to low speed.

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.

Other Lockouts and Alarms

Several other lockouts and alarms are shown in the Status

LED1 (LED1, Red) table with the associated codes visible on the thermostat, ABC Fault LED, and in text in the AID Tool.

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 the compressor, pump, and blower motor are not active. The RV may be active. The blower and compressor will be off.

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.

Loss of Charge – fault is recognized when the Normally

Closed Low Pressure Switch, P4-7/8 is open prior to the compressor starting.

Heating Operation - The unit will operate based upon demand as calculated by the room setpoint algorithm. The resulting compressor speed (1-12) will also select an appropriate blower speed for the selected compressor speed. Aux Heat will not be available (on IntelliZone2 Aux Heat is available on compressor speeds 10-12) until after the 12th compressor speed has been operational and still is not satisfying the thermostat, then auxiliary electric heat will be activated.

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.

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. 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

Cooling Operation - The unit will operate based upon demand as calculated by the room setpoint algorithm.

The resulting compressor speed, speeds 1-9, (speeds 10-12 are reserved for SuperBoost mode only) will also select

27



an appropriate blower speed. The blower mode will also have the cooling airflow adjustment applied. 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.

Aurora Advanced VS Control LED Displays

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. See the LED tables for further explanation.

Blower (G) - The blower will start immediately upon receiving a thermostat G command. If there are no other commands from the thermostat the variable speed ECM will run on low speed until the G command is removed.

Regardless of blower input (G) from the thermostat, the blower will remain on low speed for 30 seconds at the end of each heating, cooling, and emergency heat cycle.

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.

Aurora Interface and Diagnostics (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, variable speed ECM setup, and system configuration capabilities to the Aurora family of controls.

An AID Tool is recommended, although not required, for variable speed ECM airflow settings. The AID Tool simply plugs into the exterior of the cabinet in the AID Tool port. 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.

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

Warning! VS Derated

Warning! VS SafeMode

Fault LED, Green

ON

OFF

Slow Flash

Fast Flash

Flash Code 2

Flash Code 5

Flash Code 6

Flash Code 7

Flash Code 8

Flash Code 9

Configuration LED (LED2, Yellow)

Description of Operation

No Software Overwritten

DIP Switch Overwritten

ECM Configuration Mode

Reset Configuration Mode

Configuration LED, Yellow

ECM Setting

Slow Flash

Fast Flash

OFF

28



aults ABC & AXB Basic F Miscellaneous

29 e s VS Driv Danfos oss

EEV2

Ind/Pkg Danf



ABC Control Board Layout AXB Control Board Layout

See Figure 1 for

DHW wiring.

CC2

HP

HP

LP

LP

FP2

FP2

FP1

FP1

REV

REV

P4

P13

ECM PWM

SW1 Test

RV – K1

CC – K2

F

CC

G

Y1

G

LO

HI

CCG

CC

FG

F

R

P5

JW2 - Alarm

P2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

Field Connections

LED 1

FP1 – 15 o F/30 o F

Off

R FP2 – 15 o F/30 o F

RV – B/O

Fault

ACC – Dip 1

LED 3

G

ACC – Dip 2

CC – Dual/Single

L – Pulse/Continuous

Status Reheat/Normal

SW2

5

6

7

8

On

1

2

LED 2

Y

3

4

Config

P6

Aurora

TM

Base

Control

Com1

LED 5

P7

G

EH1

P3 EH2

C

EH1

C

CO

N/A

(+)

(-)

R

C

(+)

(-)

R

C

P11

Com2

LED 4

P8

G

P9 Factory Fan Connection

P1

Field Connections

Status

G

AXB™

(Aurora Expansion Board)

R R

OFF ON

1

4

5

2

3

SW1

Modbus Add. ID

Future Use

Future Use

Acc 2 – Dip 4

Acc 2 – Dip 5

P8 P6 P7 P9

EEV Board Layout

KM4 KM5

1

3

2

4

1

3

2

4

KM7

KM6 KM1

1

3

2

4

1 1

2 2

KM2

KM9

Variable Speed Drive

30


Operation Logic

Heating Mode

When the variable speed controls determine that heating is needed in the space the blower will be turned on, the compressor will be ramped to speed 6 and the loop pump will be started. The compressor will continue to run at speed 6 for 60 seconds for oil circulation. During the 60 second oil circulation the controls will calculate what speed the compressor will need to operate at to maintain the set point in the space. If the compressor is operating at speed

12 and the unit is unable to maintain set point the controls will stage on the electric heat. Electric heat will not operate unless the compressor is already running at speed 12. Every

30 minutes if the compressor has been operating lower than speed 6, the controls will increase the compressor to speed 6 for one minute for oil circulation.

Cooling Mode

When the variable speed controls determine that cooling is needed in the space the blower will be turned on, the reversing valve will be enabled, the compressor will be ramped to speed 6, and the loop pump will be started. The compressor will continue to run at speed 6 for 60 seconds for oil circulation. During the 60 second oil circulation the controls will calculate what speed the compressor will need to operate at to maintain the set point in the space.

The compressor will be limited to a maximum of speed 9 for cooling. If additional capacity is needed SuperBoost mode can be enabled from the thermostat allowing the compressor to run at speeds higher than 9 for a period of

24 hours. Every 30 minutes if the compressor has been operating lower than speed 6, the controls will increase the compressor to speed 6 for one minute for oil circulation.

ECM Blower Motor

The variable speed controls will vary the ECM blower output to maintain optimum air flow at each of the 12 compressor speeds. If dehumidification mode is selected during the cooling operation the airflow will be varied to allow for maximum moisture removal.

Variable Speed Loop Pump

The variable speed controls will operate the variable speed loop pump similar to the way the ECM blower motor operates.

The speed of the pump will be increased as the compressor speed is increased to maintain adequate water flow.

Safe Mode

The system has encountered an unsafe operating condition that prevents automatic speed control, e.g. lost a sensor signal. To avoid damage to the system, the drive is running the compressor at a fixed speed of 2400 rpm awaiting the problem to be solved and eventually returning to normal operation. If the problem cannot be solved the drive stops and issues an alarm. (See fault/alarm table.)

Derating

The VS compressor utilizes ‘envelope control’ to maintain performance within operational limits and improve reliability. To accomplish this, pressure sensors for discharge and suction pressure as well as hot gas temperature sensing are used to monitor the conditions in which the compressor operates. The envelope does vary based upon operating speed (rpm). When operating out of these limits the control will attempt to improve the situation by moderating the compressor speed for a larger envelope. When this occurs it can be observed on the

Aurora control as an ‘E’ code. The control will automatically try to resolve the situation. If the situation progresses, a fault and lockout will be generated by the control.

31

T

Brown

Brown

FLOW METER

GND

OUT

5DC

3

2

4

2

3

4

Green

White

Brown

Gray

Gray

T

T

Purple

Purple

White

White

PERFORMANCE

OPTION

Pump Slave

Input/Output

VARIABLE

SPEED PUMP

LOW VOLTAGE

1 10DC

GND

PWM 3

NA 4

1

2

3

2

4

Brown

Blue

Black

NOTE: 4

Future Use

Smart Grid

Home

Automation


Wiring Schematics

Aurora Variable Speed

Ext Pump

1/2 hp Total

208-230/60/1

Pump

G

Pump

Variable

Speed

Pump

208-230/60/1

VS

Pump G

1

1

2

PB1

2

NOTE 12

Brown(10)

Orange(9)

See Figure 1 for

DHW wiring.

Status

G

AXB™


OFF ON

1

2

3

4

5

SW1

Modbus Add. ID

Future Use

Future Use

Acc 2 – Dip 4

Acc 2 – Dip 5

Violet(8)

Violet(7)

White

White

Black

Black

Orange

Orange

Dehumidification Output

Accessory 2 Output

Analog Output 0-10VDC

Black

Black

Brown

Brown

NOTE: 9

AUXILIARY

HEAT CT

NOTE: 8

BLOWER

CT

Black(3)

Black(2)

L2

Red

T2

CC

T1

L1

Black

Circuit Breaker

Circuit Breaker

Red

Black

L1 and L2 on

VS Drive

NOTE 2

Black/White(5)

Gray/White(4)

2

1

NOTE 1

3

PS

BLOWER MOTOR

(CT)

NOTE: 8

Orange

Brown

NOTE 7

Green

G

Unit Power

208-230/60/1

1 2 3 4 5 P11

Red

208V

Black

Blue

240V

ECM

Blower Motor

12 15 10 16 1 33

P12

Transformer

24V

Yellow

Black/White

RV FP1 FP2 LP HP

AXB BOARD

GND

24 VAC

1

2

0-10DC 3

C

R

ABC BOARD

AID Tool

To Master on

VS Drive

C

A-

B+

1

2

3

Pink

Pink

T

HOT WATER

OPTION

EH1

P2

ES

LS

ALM

ALG

ACC COM

ACC NO

ACC NC

CC2 CC

K5-Alarm

Relay

F

K6-Acc

Relay

P1

LO

R

C

O/B

G

Y1

Y2

W

DH

F1-3A

R

C

P9

RS485 NET

Com2

LED4

G

C

P8

R F FG CC CCG

CC2

HI

CC2

LO

CC2

G

C

RS485 NET

R +

Com1

LED5

G

P7

P5

Aurora Base Control™

C R

(ABC)

RS485 EXP

+

P6

REV REV FP1 FP1 FP2 FP2 LPS LPS HPS HPS

SW1

Test Mode

CO C EH1 C EH2

P3

Status

LED3

G

P4

C

R

F

PWM

CFM

Y1 G CC

Fault

LED1

R

C

P13

Off

FP1 – 15

FP2 – 15

°F/30°F

RV – B/O

Acc – Dip 4

Acc – Dip 5

CC – Dual/Single

L Output Type

Future Use

SW2

Config

LED2

Y

2

3

On

1

7

8

5

6

Violet(42)

Blue(24)

Yellow(25)

Green/Yellow(28)

Green(11)

NOTE 6

Brown(23)

Black(21)

Black(22)

Black(20)

Condensate

To P2 on

Electric Heat

Board

With optional ' EA' Series

Auxiliary ElectricHeat

Typical schematic shown

208-230/60/1

Circuit 2

NOTE 3

G L2 L1

208-230/60/1

Circuit 1

L2 L1 G

Brown

Orange

Blue

Violet

Green

P9

1

2

3

5

4

Brown

Orange

Green

1 2 3 4 5 P11

ECM

Blower Motor

12 15 10 16 1 33

P12

F

3

P13 on ABC Board

P13

Pink

Yellow

Black

Gray

G

G

G

NO

ER3

NO

ER4

EA Series PCB

P2

C 1 2 3 4

G NO

P1

C 1 2 3 4

PB2

ER1

NO

ER2

EA Staging

NOTE 5

Auxiliary Electric Heat Power

Pink

Yellow

Black

Gray

Gray

Black

Yellow

Pink

HE3

HE4

HE1

HE2

Gray

TS1

Black

Yellow

TS2

TS3

Pink

TS4

CSA installed units only

Local codes may require a single source of power supply

Single Disconnect Power

208-230/60/1

Breaker box furnished by installer

L1 L2

Condensate

CO C EH1 C EH2 P3

P3 on ABC Board

L1

Circuit Breakers

L2 L1 L2

Aux Elect Power

208-230/60/1

Unit Power

208-230/60/1

Figure 1:

Hot Water

DHW

Pump

Blue

K6 Relay

COM NO

L2

Blue

Cabinet

HW Switch

1

3

2

Connects to L2 and NO on

AXB Board

Purple

Notes

1 - Switch blue and red wires for 208V operation.

2 - The blk/wh and gray/wh wires are removed when Aux Heat is installed

3 - Use manufacturer ’s part number 19P592-01 (jumper bar assembly)

when single source power is required.

4 - Variable speed pump low voltage harness provided with Variable

Speed Flow Center.

5 - For additional Auxiliary Heat staging place jumpers as shown.

6 - Wires provided for Auxiliary Heat low voltage control. Wires are

secured at blower.

7 - When Auxiliary Heat is field installed the harness will then be connected

to the auxiliary heat unit. The auxiliary heat unit will then power the

blower. Refer to EAS/EAM/EAL Auxiliary Heat kit installation instructions.

8 - Brown blower power wire routed through Current Transducer two times.

9 - Field Connected: Refer to Installation Manual and Auxiliary Heat

Instructions for Current Transformer installation.

10 - Communication cable routed through Ferrite Toroid four times.

11 - Compressor power cable routed through Ferrite Toroid three times.

12 - Variable speed pump power wires to connect the pump to L1 and L2

on the AXB board are provided with Variable Speed Flow Center.

97P842-01A 5/14/12

32

Ext Pump

1/2 hp Total

208-230/60/1

Pump

G

Pump

Variable

Speed

Pump

208-230/60/1

VS

Pump G

1

1

2

PB1

2

NOTE 12

Brown(10)

Orange(9)

See Figure 1 for

DHW wiring.

T

Brown

Brown

FLOW METER

GND

OUT

5DC

3

2

4

3

2

4

Green

White

Brown

Gray

Gray

T

T

Purple

Purple

White

White

PERFORMANCE

OPTION

Pump Slave

Input/Output

VARIABLE

SPEED PUMP

LOW VOLTAGE

1 10DC

GND

PWM 3

NA 4

1

2 2

3

4

Brown

Blue

Black

NOTE: 4

Future Use

Smart Grid

Home

Automation

Status

G

AXB™


OFF ON

1

2

3

4

5

SW1

Modbus Add. ID

Future Use

Future Use

Acc 2 – Dip 4

Acc 2 – Dip 5

AXB BOARD

GND

24 VAC

1

2

0-10DC 3

C

R

ABC BOARD

AID Tool

To Master on

VS Drive

C

A-

B+

1

2

3

Violet(8)

Violet(7)

White

White

Black

Black

Orange

Orange

Dehumidification Output

Accessory 2 Output

Analog Output 0-10VDC

Black

Black

Brown

Brown

NOTE: 9

AUXILIARY

HEAT CT

NOTE: 8

BLOWER

CT

Black(3)

Black(2)

Red

T2

CC

T1

L2 L1

Black

Circuit Breaker

Circuit Breaker

Red

Black

L1 and L2 on

VS Drive

NOTE 2

Black/White(5)

Gray/White(4)

2

1

NOTE 1

3

PS

BLOWER MOTOR

(CT)

NOTE: 8

Orange

Brown

NOTE 7

Green

G

Unit Power

208-230/60/1

1 2 3 4 5 P11

Red

208V

Black

Blue

240V

ECM

Blower Motor

12 15 10 16 1 33

P12

Transformer

24V

Yellow

Black/White

RV FP1 FP2 LP HP

Pink

Pink

T

HOT WATER

OPTION

EH1

P2

ES

LS

ALM

ALG

ACC COM

ACC NO

ACC NC

CC2 CC

K5-Alarm

Relay

F

K6-Acc

Relay

P1

G

Y1

Y2

W

DH

LO

R

C

O/B

F1-3A

R

C

P9

RS485 NET

Com2

LED4

G

C

P8

R F FG CC CCG

CC2

HI

CC2

LO

CC2

G

C

RS485 NET

R +

Com1

LED5

G

P7

P5

Aurora Base Control™

C R

(ABC)

RS485 EXP

+

P6

REV REV FP1 FP1 FP2 FP2 LPS LPS HPS HPS

SW1

Test Mode

CO C EH1 C EH2

P3

Status

Y1

LED3

G

G CC

Fault

LED1

R

P4

C

R

F

PWM

CFM

C

P13

Off

FP1 – 15

FP2 – 15

°F/30°F

RV – B/O

Acc – Dip 4

Acc – Dip 5

CC – Dual/Single

L Output Type

Future Use

SW2

7

8

5

6

Config

LED2

Y

2

3

On

1

Violet(42)

Blue(24)

Yellow(25)

Green/Yellow(28)

Green(11)

NOTE 6

Brown(23)

Black(21)

Black(22)

Black(20)

Condensate

To P2 on

Electric Heat

Board

Wiring Schematics cont.

Aurora Variable Speed cont.

With optional ' EA' Series

Auxiliary ElectricHeat

Typical schematic shown

208-230/60/1

Circuit 2

NOTE 3

G L2 L1

208-230/60/1

Circuit 1

L2 L1 G

Brown

Orange

Blue

Violet

Green

P9

1

2

3

5

4

Brown

Orange

Green

1 2 3 4 5 P11

ECM

Blower Motor

12 15 10 16 1 33

P12

F

3

P13 on ABC Board

P13

Pink

Yellow

Black

Gray

G

G

G

NO

ER3

NO

ER4

EA Series PCB

P2

C 1 2 3 4

G NO

P1

C 1 2 3 4

PB2

ER1

NO

ER2

EA Staging

NOTE 5

Auxiliary Electric Heat Power

Pink

Yellow

Black

Gray

Gray

Black

Yellow

Pink

HE3

HE4

HE1

HE2

Gray

TS1

Black

Yellow

TS2

TS3

Pink

TS4

CSA installed units only

Local codes may require a single source of power supply

Single Disconnect Power

208-230/60/1

Breaker box furnished by installer

L1 L2

Condensate

CO C EH1 C EH2 P3

P3 on ABC Board

L1

Circuit Breakers

L2 L1 L2

Aux Elect Power

208-230/60/1

Unit Power

208-230/60/1

Figure 1:

Hot Water

DHW

Pump

Blue

K6 Relay

COM NO

L2

Blue

Cabinet

HW Switch

1

3

2

Connects to L2 and NO on

AXB Board

Purple

Notes

1 - Switch blue and red wires for 208V operation.

2 - The blk/wh and gray/wh wires are removed when Aux Heat is installed

3 - Use manufacturer ’s part number 19P592-01 (jumper bar assembly)

when single source power is required.

4 - Variable speed pump low voltage harness provided with Variable

Speed Flow Center.

5 - For additional Auxiliary Heat staging place jumpers as shown.

6 - Wires provided for Auxiliary Heat low voltage control. Wires are

secured at blower.

7 - When Auxiliary Heat is field installed the harness will then be connected

to the auxiliary heat unit. The auxiliary heat unit will then power the

blower. Refer to EAS/EAM/EAL Auxiliary Heat kit installation instructions.

8 - Brown blower power wire routed through Current Transducer two times.

9 - Field Connected: Refer to Installation Manual and Auxiliary Heat

Instructions for Current Transformer installation.

10 - Communication cable routed through Ferrite Toroid four times.

11 - Compressor power cable routed through Ferrite Toroid three times.

12 - Variable speed pump power wires to connect the pump to L1 and L2

on the AXB board are provided with Variable Speed Flow Center.

97P842-01A 5/14/12


33



Aurora Variable Speed Drive/EEV Wiring

Unit Power

208-230/60/1

G

Red

Circuit Breaker

Black

Circuit Breaker

Red

Black

Compressor

Ambient

Entering

Water Temp

EWT

Discharge

Line Temp

Suction

Pressure

Variable Speed

Drive

Discharge

Pressure

G

CC2

HP

HP

LP

LP

FP2

FP2

FP1

FP1

REV

REV

P4

P13

ECM PWM

SW1 Test

RV – K1

CC – K2

G

Y1

F

CC

CC

FG

F

R

G

LO

HI

CCG

P5

JW2 - Alarm

P2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

Field Connections

LED1

R

FP1 – 15 o F/30 o F

FP2 – 15 o F/30 o F

RV – B/O

Fault

LED3

ACC – Dip 4

ACC – Dip 5

CC – Dual/Single

G

Status


Reheat/Normal

Off

SW2

6

7

4

5

8

On

1

3

2

LED2

Y

Config

EH1

P3 EH2

C

EH1

C

CO

N/A

P11

AURORA BASE

CONTROL™

P6

(+)

(-)

R

C

Com1

G

P7 (+)

(-)

R

C

P8

Com2

G

P9 Factory Fan Connection

P1

Field Connections

(-)

R

C

Green

White

Red

Black

EEV

COMM

NOT

USED

NOT

USED

SUCTION

TEMP

LAT

RS485 EXP

(+)

(-)

R

C

ABC P6

To Aurora Board

NOTE 10

Ferrite Toroid

EEV

COIL

R R

P4

HA2 HA1 SGI LOOP P3 PWM

RS485

(+)

(-)

R

C

ZONE

(+)

(-)

R

C

ABC

(+)

(-)

R

C

+5

MOTOR

RX

TX

R

C

V+

P17 P18

SCT

P12

SUC P

P10

STEPPER

VS SLO SLI

P2

P1

EWT LWT FLOW LAT

4

P15

CT2

3

CT1

2 1

AXB™


LLT

P16

K3 K2 K1

4

P5

CT2

3

CT1

2 1

ANA SPR DH

P11

DIV

EEV CONTROL BOARD

DISCH

P14

COM

COM

K6

K5

NO

NO

C

R

L1

L1

L2

L2

L1

L2

Power to

VS Drive

VARIABLE SPEED

DRIVE END VIEWS

Power to

Compressor

T3

T2

T1

EEV 1

MASTER

EEV 2

EXT. FAN

S_AMBIENT

S_AUX

S_D

P_O

P_C

RLY 1

ABC

5VAC

C

R

(-)

(+)

AXB P9

To AXB Board

NOTE 11

Ferrite Toroid

Metal

Flexible

Conduit

Black

Green

Red

VS Compressor

T3

T1

Blue

T2

Black

Red Connector (4 Pin)

Suction

Line Temp

Discharge

Air Temp

Bipolar Stepper Motor

EEV

Control

L1

Legend

Factory Low voltage wiring

Factory Line voltage wiring

Field low voltage wiring

Field line voltage wiring

Optional block

DC Voltage PCB traces

Junction

Quick connect terminal

Wire nut

Field wire lug

Ground

Relay Contacts-

N.O., N.C.

Fuse

P

2

T

G

3 1

Thermistor

Light emitting diode - Green

Relay coil

Capacitor w/ bleed resistor

Switch - Condensate overflow

Switch - High pressure

Switch - Low pressure

Polarized connector

Current Transducerer (CT)

CC -

CO -

K5 -

K6 -

CR3 -

CR4 -

CS -

F1 and F2 -

HE -

HP -

ER1 to ER4 -

LP -

Compressor Contactor

Condensate overflow sensor

DHW pump relay

Loop pump relay

PSC Fan Speed Relay

PSC Fan Power Relay

Compressor Solenoid

Fuses

Heater element

High pressure switch

Aux heat stage relays

Low pressure switch

PB1, PB2 -

PS -

RV -

SW1 -

SW1 -

SW2 -

TS -

HWL -

SC -

SR -

WCL -

Power blocks

Power strip

Reversing Valve coil

DIP package 5 position AXB

TEST MODE ABC Board

DIP package 8 position ABC Board

Thermal limit switch

Hot water limit sensor

Start Contactor

Start Relay

Water Coil Limit Sensor

Slow Flash

Fast Flash

Flash Code

Au rr ra LE

1 second on and 1 second offff

100 milliseconds on and 100 milliseconds offff

F

Normal Mode

Input Fault Lockout

High Pressure Lockout

Low Pressure Lockout

Freeze Dete cc itton- FP2

Freeze Dete cc itton - FP1

Reserved

Fault-tt FP1 and FP2 Sensor Error

Alarm - Hot Wa tt r

Fault Variable Speed Pump

Non-Critittcal Communicatitton Error

Fault - Critittcal Communicatitton Error

Alarm - Low Loop Pressure

OFF

Flash Code 1

Flash Code 2

Flash Code 3

Flash Code 4

Flash Code 5

Flash Code 6

Flash Code 7

Flash Code 8

Flash Code 9

Flash Code 10

Flash Code 11

Flash Code 12

Flash Code 13

Flash Code 14

Flash Code 15

Flash Code 16

Flash Code 17

Flash Code 18

Flash Code 19

Flash Code 21

C d

Sta tt s LED (LED1, Green)

Confiffguratitton LED (LED 2, Yellow)

Fault LED (LED 3, Red)

Atern aa ing Co

Fast Flash

Fast Flash

Fast Flash

DIP Switctth Overide

Normal Mode

Test Mode

Load Shed

ESD ee

Dehumidififfcatitton Mode

OFF

Slow Flash

EE 3, Gr ee n)

ON

OFF

Slow Flash

Fast Flash

Flash Code 2

Flash Code 3

Flash Code 4

Flash Code 5

Flash Code 6

Flash Code 7

Fault - EEV Error

Flash Code 23

Flash Code 24

Flash Code 25

Flash Code 41

Flash Code 42

Flash Code 43

Flash Code 44

Flash Code 45

Flash Code 46

Flash Code 47 ff Mode - Ambient Temperatu Flash Code 49

Flash Code 51

Fault - Condensing Pressure Sensor

Flash Code 52

Flash Code 53

Fault - Compressor Out of Envelope

Fault - Over Current

Flash Code 54

Flash Code 55

Flash Code 56

Flash Code 57

Flash Code 58

Fault - Loss of Charge

Flash Code 59

Flash Code 61

Flash Code 71

Flash Code 72

Flash Code 73

Flash Code 74

SW1-4 SW1-5 DESCRIPTION

ON ON Cycles with Blower

OFF

ON

ON

OFF

Cycles with CC first stage compressor or compressor spd 1-12

Cycles with CC2 second stage of compressor or comp spd 7-12

OFF OFF Cycles with DH from ABC board

ABC SW2 Accessory Relay

ESCRIPTION

Cycle with Blower

SW2-4

ON




OFF

ON

OFF

SW2-5

ON

OFF

OFF

ON

97P842-01B 6/6/12

34


Unit Power

208-230/60/1

G

Red

Circuit Breaker

Black

Circuit Breaker

Red

Black

Compressor

Ambient

Entering

Water Temp

EWT

Discharge

Line Temp

Suction

Pressure

Variable Speed

Drive

Discharge

Pressure

G

CC2

HP

HP

LP

LP

FP2

FP2

FP1

FP1

REV

REV

P4

P13

ECM PWM

SW1 Test

RV – K1

CC – K2

G

Y1

F

CC

CC

FG

F

R

G

LO

HI

CCG

P5

JW2 - Alarm

P2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

Field Connections

LED1

R

FP1 – 15 o F/30 o F

FP2 – 15 o F/30 o F

RV – B/O

Fault

LED3

ACC – Dip 4

ACC – Dip 5

CC – Dual/Single

G

Status


Reheat/Normal

Off

SW2

6

7

4

5

8

On

1

3

2

LED2

Y

Config

P9

P1

P11

AURORA BASE

CONTROL™

Factory Fan Connection

Field Connections

P3

P6

EH1

Com1

G

P7 (+)

(-)

R

C

P8

Com2

G

EH2

C

EH1

C

CO

N/A

(+)

(-)

R

C

(-)

R

C

Green

White

Red

Black

EEV

COMM

NOT

USED

NOT

USED

SUCTION

TEMP

LAT

RS485 EXP

(+)

(-)

R

C

ABC P6

To Aurora Board

NOTE 10

Ferrite Toroid

EEV

COIL

R R

P4

HA2 HA1 SGI

RS485

(+)

(-)

R

C

ZONE

(+)

(-)

R

C

ABC

(+)

(-)

R

C

+5

MOTOR

RX

TX

R

C

V+

P17 P18

SCT

LOOP

P12

SUC P

P3 PWM

P10

STEPPER

VS SLO SLI

P2

P1

EWT LWT FLOW LAT

P15

CT2

4 3

CT1

2 1

AXB™


CT2

P5

4 3

CT1

2 1

LLT

P16

K3 K2 K1

ANA SPR DH

P11

DIV

EEV CONTROL BOARD

DISCH

P14

COM

COM

K6

K5

NO

NO

C

R

L1

L1

L2

L2

L1

L2

Power to

VS Drive

VARIABLE SPEED

DRIVE END VIEWS

Power to

Compressor

T3

T2

T1

EEV 1

MASTER

EEV 2

EXT. FAN

S_AMBIENT

S_AUX

S_D

P_O

P_C

RLY 1

ABC

5VAC

C

R

(-)

(+)

AXB P9

To AXB Board


Aurora Variable Speed Drive/EEV Wiring cont.

NOTE 11

Ferrite Toroid

Metal

Flexible

Conduit

Black

Green

Red

VS Compressor

T3

T1

Blue

T2

Black

Red Connector (4 Pin)

Suction

Line Temp

Discharge

Air Temp

Bipolar Stepper Motor

EEV

Control

L1

Legend

Factory Low voltage wiring

Factory Line voltage wiring

Field low voltage wiring

Field line voltage wiring

Optional block

DC Voltage PCB traces

Junction

Quick connect terminal

Wire nut

Field wire lug

Ground

Relay Contacts-

N.O., N.C.

Fuse

P

2

T

G

3 1

Thermistor

Light emitting diode - Green

Relay coil

Capacitor w/ bleed resistor

Switch - Condensate overflow

Switch - High pressure

Switch - Low pressure

Polarized connector

Current Transducerer (CT)

CC -

CO -

K5 -

K6 -

CR3 -

CR4 -

CS -

F1 and F2 -

HE -

HP -

ER1 to ER4 -

LP -

Compressor Contactor

Condensate overflow sensor

DHW pump relay

Loop pump relay

PSC Fan Speed Relay

PSC Fan Power Relay

Compressor Solenoid

Fuses

Heater element

High pressure switch

Aux heat stage relays

Low pressure switch

PB1, PB2 -

PS -

RV -

SW1 -

SW1 -

SW2 -

TS -

HWL -

SC -

SR -

WCL -

Power blocks

Power strip

Reversing Valve coil

DIP package 5 position AXB

TEST MODE ABC Board

DIP package 8 position ABC Board

Thermal limit switch

Hot water limit sensor

Start Contactor

Start Relay

Water Coil Limit Sensor

Slow Flash

Fast Flash

Flash Code

Au rr ra LE

1 second on and 1 second offff

100 milliseconds on and 100 milliseconds offff

F

Normal Mode

Input Fault Lockout

High Pressure Lockout

Low Pressure Lockout

Freeze Dete cc itton- FP2

Freeze Dete cc itton - FP1

Reserved

Fault-tt FP1 and FP2 Sensor Error

Alarm - Hot Wa tt r

Fault Variable Speed Pump

Non-Critittcal Communicatitton Error

Fault - Critittcal Communicatitton Error

Alarm - Low Loop Pressure

OFF

Flash Code 1

Flash Code 2

Flash Code 3

Flash Code 4

Flash Code 5

Flash Code 6

Flash Code 7

Flash Code 8

Flash Code 9

Flash Code 10

Flash Code 11

Flash Code 12

Flash Code 13

Flash Code 14

Flash Code 15

Flash Code 16

Flash Code 17

Flash Code 18

Flash Code 19

Flash Code 21

C d

Sta tt s LED (LED1, Green)

Confiffguratitton LED (LED 2, Yellow)

Fault LED (LED 3, Red)

Atern aa ing Co

Fast Flash

Fast Flash

Fast Flash

DIP Switctth Overide

Normal Mode

Test Mode

Load Shed

ESD ee

Dehumidififfcatitton Mode

OFF

EE 3, Gr ee n)

Slow Flash

ON

OFF

Slow Flash

Fast Flash

Flash Code 2

Flash Code 3

Flash Code 4

Flash Code 5

Flash Code 6

Flash Code 7

Fault - EEV Error

Flash Code 23

Flash Code 24

Flash Code 25

Flash Code 41

Flash Code 42

Flash Code 43

Flash Code 44

Flash Code 45

Flash Code 46

Flash Code 47 ff Mode - Ambient Temperatu Flash Code 49

Flash Code 51

Fault - Condensing Pressure Sensor

Flash Code 52

Flash Code 53

Fault - Compressor Out of Envelope

Fault - Over Current

Flash Code 54

Flash Code 55

Flash Code 56

Flash Code 57

Flash Code 58

Fault - Loss of Charge

Flash Code 59

Flash Code 61

Flash Code 71

Flash Code 72

Flash Code 73

Flash Code 74

SW1-4 SW1-5 DESCRIPTION

ON ON Cycles with Blower

OFF

ON

ON

OFF

Cycles with CC first stage compressor or compressor spd 1-12

Cycles with CC2 second stage of compressor or comp spd 7-12

OFF OFF Cycles with DH from ABC board

ABC SW2 Accessory Relay

ESCRIPTION

Cycle with Blower

SW2-4

ON




OFF

ON

OFF

SW2-5

ON

OFF

OFF

ON

97P842-01B 6/6/12

35


Unit Startup

Before Powering Unit, Check the Following:

NOTE: Remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket.

• 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.

• Black/white and gray/white wires in unit control box have been removed if auxiliary heat has been installed.

• Dip switches are set correctly.

• Hot water generator pump switch is “OFF” unless piping is completed and air has been purged.

• Blower rotates freely.

• Blower speed is correct.

• Air filter/cleaner is clean and in position.

• Variable speed drive filter is clean and in place.

• 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.

Powering The Controls

Initial Configuration of the Unit

Before operating the unit, apply power and complete the following Aurora Startup procedure for the controls configuration. An AID Tool is required for setup, configuration, and troubleshooting on the 7 Series

InfiniSpeed system. AID Tool version 2.01 or greater is preferred.

1. Configure Aurora Screen a. Confirm AXB is added and communicating.

b. Confirm AOC is added and communicating.

c. Confirm MOC is added and communicating.

d. Confirm EEV2 is added and communicating.

e. Confirm IntelliZone2 is added and communicating

if installed. Set zoning system to OFF.

f. Confirm communicating thermostat is added

and communicating if IntelliZone2 is not installed.

Set thermostat mode to OFF.

NOTE: The AOC and MOC are the two boards that comprise the VS drive.

2. Aurora Setup Screen a. ECM Setup for Heating Airflow – select G, low,

high and aux blower speeds as appropriate for the

unit and electric heat.

b. Cooling Airflow % – sets the cooling airflow % from

heating airflow.

c. AXB Setup i. DHW Enable – Ensure air is purged from

HW system before enabling (remember the HW switch on the front cabinet) ii. DHW Setpoint – 130 °F is the default but can be changed from 100 to 140 °F iii. 7 Series FCV1-GL, FCV2-GL Pump Setup and Modulating Water Valve Setup – Can be setup to a range between 5% and

100%. Defaults are 50% and 100%.

- From the Main Menu of the AID Tool go

to AXB Setup and select “Yes” at the

bottom of the screen to Make Changes

- Set VS Pump Control to MIN

- The pump(s) or water valve should

begin to operate and flow rate is visible

on this screen, it may take several

seconds for flow to stabilize. Adjust the

minimum % until the minimum flow rate

is achieved.

- Go back to Set VS Pump Control and

select MAX.

- The pump(s) or water valve should

begin to operate and flow rate is visible

on this screen, it may take several

seconds for flow to stabilize. Adjust the

maximum % until the maximum flow

rate is achieved.

- Press Enter.

d. Sensor Kit Setup i. Brine Selection – for HE/HR capacity calculation ii. Flow Meter – activates the flow meter iii. Select blower energy – PSC or

ECM/5-Speed ECM iv. Activate energy option v. Blower and Aux heat current sensor activation vi. Line Voltage calibration – Voltmeter required to calibrate line voltage during heating or cooling. Refer to Line Voltage

Calibration in this manual for more details.

e. Smart Grid Setup – Select action option for utility

received On Peak signal f. Home Automation 1 and 2 Setup – Select type of

sensor for two home automation inputs.

36


Unit Startup cont.

Configuring the Sensor Kits

Configuring the Sensor kits

The Aurora Advanced Control allows Refrigeration, Energy, and Performance Monitoring sensor kits. These kits can be factory or field installed. The following description is for field activation of a factory installation of the sensor kits.

Energy Monitoring

(Standard Sensor Kit Variable Speed Models)

The Energy Monitoring Kit includes two current transducers

(fan 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 TPCM32U04 will display instantaneous energy use while the color touchscreen

TPCC32U01 will in addition display a 13 month history in graph form. Ensure the Energy Kit has been enabled by accessing the ‘Sensor Kit Setup’ in the AID Tool and complete the following: a. Select ‘Blower Energy’ – PSC or ECM/5-Speed ECM b. Activate ‘Energy Option’ to activate the sensors on

for compressor (2), blower and aux heat current sensor. c. Select ‘Pump’ option of FC1, FC2, FCVS1, FCVS2, or

open loop. This selects the pump watts used in the

calculation. Pump watts are not measured but

estimated.

d. Line Voltage Calibration – Voltmeter required to

calibrate line voltage during heating or cooling. i. Turn on Unit in Heating or Cooling . ii. Use multimeter at L1 and L2 to measure line voltage iii. In the Sensor Kit Setup screen adjust the

‘Base Voltage’ to the nearest value to that is measured iv. Then use the ‘Fine Adjust’ to select the exact voltage being measured at L1 and L2.

v. Exit ‘Sensor Setup’ Screen e. Energy monitoring can be read on any of the

following components: i. AID Tool – instantaneous information only ii. TPCM32U04 Communicating

Thermostat (B/W) - instantaneous information only iii. TPCC32U01 Color Touchscreen

Thermostat – Both Instantaneously and historical (13 months) iv. WaterFurnace Web Portal via AWL device hooked to Aurora (future release)

Refrigerant Monitoring

(Standard on Variable Speed Models)

The 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. Ensure the Refrigerant

Monitoring has been setup by accessing the ‘Sensor Kit

Setup’ in the AID Tool and complete the following:

Once sensors are installed for discharge pressure, suction pressure, suction, liquid line cooling, liquid line heating, and leaving air temperature no further setup is required.

a. Turn on unit in Heating or Cooling. b. Use the AID Tool to view the refrigerant

performance in the ‘Refrigerant Monitor’ screen.

c. Refrigerant monitoring can be read on any of the

following components: i. AID Tool – instantaneous information only ii. WF Web Portal via AWL device hooked to Aurora (future release)

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. Ensure the Performance Kit has been enabled by accessing the ‘Sensor Kit Setup’ in the AID Tool and complete the following: a. Select ‘Brine’ – and then choose Water or

Antifreeze for the proper factor b. Activate ‘Flowmeter’ to activate the flow sensor

select the appropriate 3/4 in., 1 in., or none (1 in. is

standard on variable speed units).

c. Exit ‘Sensor Kit Setup’ screen.

d. Turn on unit in Heating or Cooling. e. Use the AID Tool to view the performance in the

‘Performance Monitor’ screen.

f. Performance monitoring can be read on any of the

following components: i. AID Tool – instantaneous information only ii. WaterFurnace Web Portal via AWL device hooked to Aurora (future release)

Startup Steps

NOTE: Complete the Equipment Startup/Commissioning

Check Sheet during this procedure. Refer to thermostat operating instructions and complete the startup procedure.

Verify that the compressor shipping bolt has been removed.

1. Initiate a control signal to energize the blower motor.

Check blower operation through the AID Tool.

2. Initiate a control signal to place the unit in the cooling mode. Cooling setpoint must be set below room temperature.

37


Unit Startup cont.

3. First stage cooling will energize after a time delay.

4. Be sure that the compressor and water control valve or loop pump(s) are activated.

5. 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 performance data in catalog or view on the AID Tool if Performance Kit is installed.

6. Check the temperature of both the supply and discharge water (see the Unit Operating Parameters tables).

7. Check for an air temperature drop of 15°F to 25°F across the air coil (cooling compressor speed 9), depending on the blower speed and entering water temperature.

8. Decrease the cooling set point several degrees and verify high-speed blower operation.

9. Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop pumps deactivate.

10. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature.

11. First stage heating will energize after a time delay.

12. Check the temperature of both the supply and discharge water (see the Unit Operating Parameters tables).

13. Check for an air temperature rise of 12°F to 35°F across the air coil (heating compressor speed 12), depending on the fan speed and entering water temperature.

14. If auxiliary electric heaters are installed, increase the heating setpoint until the electric heat banks are sequenced on (must get to compressor speed 12 before auxiliary heat enables). All stages of the auxiliary heater should be sequenced on when the thermostat is in the Emergency Heat mode. Check amperage of each element.

15. Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps deactivate.

16. During all testing, check for excessive vibration, noise or water leaks. Correct or repair as required.

17. Set system to desired normal operating mode and set temperature to maintain desired comfort level.

18. 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.

Pressure Drop

Model

36

48

60 gpm

13.5

10.5

7.5

6.0

4.0

17.0

13.5

9.5

7.5

5.0

11.5

9.0

7.0

5.5

4.5

4.60

2.90

1.70

1.20

0.62

6.40

4.10

2.20

1.70

0.68

30° F

3.40

2.70

1.65

1.10

0.68

4.40

2.70

1.60

1.10

0.61

6.00

3.80

2.10

1.60

0.62

Pressure Drop (psi)

50° F 70° 90° F

3.20

3.00

2.80

2.60

1.55

1.00

0.64

2.40

1.45

0.90

0.60

2.20

1.35

0.85

0.55

4.10

2.50

1.50

1.00

0.60

5.60

3.60

2.00

1.50

0.58

3.80

2.30

1.40

0.96

0.58

5.20

3.30

1.80

1.40

0.55

110° F

2.60

2.10

1.25

0.75

0.51

3.50

2.20

1.30

0.91

0.56

4.80

3.10

1.70

1.30

0.53

6/29/12

Compressor Resistance

Model

036

048

060

Compressor Model

No.

VRJ028UKNP6

VRJ035UKNP6

VRJ044UKNP6

Winding Resistance

208-230/60/1

0.255

0.210

0.210

4/23/12

38

Thermistor Resistance

Thermistor Resistance (10k Ohm) for FP1, FP2, HWL, LWT and LLT

(EWT with Performance Option)

Thermistor

Temperature

(°F)

5

14

23

32

41

86

95

104

113

50

59

68

77

122

131

140

149

Thermistor

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

4/24/12

Thermistor Resistance (1k Ohm) for compressor discharge line, suction line, LAT, compressor ambient and EWT

Thermistor

Temperature

(°F)

20

Thermistor

Resistance

(Ohms)

974.4-973.4

25

30

35

40

985.4-984.4

996.1-995.1

1007.0-1006.0

1017.8-1016.8

65

70

75

80

45

50

55

60

1028.6-1027.6

1039.5-1038.5

1050.2-1049.2

1061.2-1060.2

1072.9-1071.9

1082.7-1081.7

1093.4-1092.4

1103.0-1102.0

85

90

95

100

105

110

115

120

125

130

1115.5-1114.5

1126.2-1125.2

1136.6-1135.6

1147.2-1146.2

1158.1-1157.1

1168.8-1167.8

1179.4-1178.4

1190.1-1189.1

1200.3-1199.3

1212.2-1211.2

4/24/12


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 EEV (Check Service Advisory)

Insufficient Compressor (Possible Bad Valves)

Scaled Coaxial Heat Exchanger Heating

Scaled Coaxial Heat Exchanger Cooling

Restricted Filter Drier

Head

Pressure

Low

High

High

Suction

Pressure

Low

High

High

Low Low

Low/Normal Low/Normal

High High

Low

Low

Normal

Low

Low

Low

Low

High

Low

Low

Low

Low

High

High

High

Low

Low

High

Compressor

Amp Draw

Low

High

High

Low

Low

High

Low

Normal

Normal

Low

Low

Low

Superheat

High

Normal

High/Normal

Low/Normal

Low

High

Low

High

High

Low

Normal

Normal/Low

Subcooling

Low

High

Low

High

High

Low

High

Low

Normal

High

High

High

High

High

Low

High

Low

High

High

High

Normal/Low

Low

Low

High

Normal/High Normal/Low

High

High

High

Normal/Low

Normal/Low

Low

High

Normal/High

High

Low

Low

Low

Low

Low

Low

Low

Check temperature difference (delta T) across filter drier.

Air Temp.

Differential

Low

Normal/Low

High

High

Low

Low

Low

Low

Normal

Normal

Normal

Low

Water Temp.

Differential

Low

Normal

Low

Low

High

High

Low

Normal

Low

Low

Normal/High

Low

Normal

High

Low

Low

Low

Low

6/1/12

Heat of Extraction/Rejection

036

048

060

Model

Full Load

Full Load

Full Load gpm

5.5

8.0

11.5

6.5

10.0

13.5

8.5

13.0

17.0

30°F

Heat of Extraction (MBtu/h)

50°F 70°F 90°F

26.4

26.7

36.6

37.7

46.2

47.8

54.5

57.6

27.5

32.4

32.6

38.5

44.6

46.0

49.7

54.9

57.9

58.6

68.6

72.6

33.7

40.3

40.6

42.0

47.0

54.7

56.4

57.6

60.3

70.7

74.2

77.3

73.7

85.9

93.1

94.4

gpm

4.5

7.0

9.0

5.5

8.0

10.5

6.5

10.0

13.5

30°F

42.2

41.9

42.3

56.1

55.7

56.2

75.2

74.7

75.3

Heat of Rejection (MBtu/h)

50°F 70°F 90°F

48.3

48.8

43.1

47.0

42.6

42.5

49.1

63.2

63.1

46.8

56.2

59.3

42.7

53.7

53.5

63.3

77.8

77.6

77.9

59.1

74.4

74.2

73.9

53.7

68.9

68.7

68.8

110°F

40.4

40.2

40.3

52.7

52.6

52.7

64.3

64.0

64.1

6/29/12

39


Operating Parameters

Model 060 - Comp Speed 9 (1800 cfm)

Entering Water

Temp °F

30

50

70

90

110

Water Flow

13.5

13.5

13.5

13.5

13.5

Suction Pressure psig

122-127

138-143

143-148

147-152

149-154

Discharge

Pressure psig

162-172

215-225

280-290

357-367

450-460


Entering Water

Temp °F

30

50

70

90

Water Flow

17.0

17.0

17.0

17.0


80-85

111-116

153-158

188-193

Discharge

Pressure psig

345-355

350-360

395-405

440-450

Cooling -- No Hot Water Generation

Superheat Subcooling

20-24

6-10

6-10

6-10

6-10

5-10

6-11

8-12

11-15

15-19

Heating - No Hot Water Generation


6-10

6-10

6-10

8-12

15-20

10-15

13-18

18-23


Entering Water

Temp °F

30

50

70

90

110

Water Flow

10.5

10.5

10.5

10.5

10.5


123-128

140-145

142-147

143-148

145-150

Discharge

Pressure psig

150-160

190-200

260-270

343-348

440-450


Superheat

17-22

10-14

10-14

10-14

10-14

Subcooling

9-14

4-9

6-11

8-13

10-15


Entering Water

Temp °F

30

50

70

90

Water Flow

13.5

13.5

13.5

13.5


75-80

108-113

145-150

183-188

Discharge

Pressure psig

321-331

345-355

400-410

450-460


Entering Water

Temp °F

30

50

70

90

110

Water Flow

12

12

12

12

12


118-123

147-152

150-155

152-157

157-163

Discharge

Pressure psig

135-145

188-198

250-260

326-336

420-430


Entering Water

Temp °F

30

50

70

90

Water Flow

13

13

13

13


80-85

115-120

158-163

189-194

Discharge

Pressure psig

288-298

315-325

345-355

425-435



6-10

6-10

7-12

11-16

20-25

21-26

22-27

24-29



17-25

5-10

5-10

5-10

5-10

8-13

5-10

5-10

7-12

7-12


Superheat

6-10

6-10

5-9

13-18

Subcooling

6-11

6-11

4-9

5-10

Water Temp

Rise °F

8-12

8-12

8-12

8-12

8-12

Water Temp

Drop °F

4-8

4-8

6-10

8-12

Water Temp

Rise °F

8-13

8-13

8-13

7-12

7-12

Water Temp

Drop °F

4-8

5-9

8-12

9-13

Water Temp

Rise °F

6-10

6-10

6-10

6-10

5-9

Water Temp

Drop °F

3-7

4-9

4-9

7-11

Air Temp Drop

°F DB

19-25

19-25

19-25

17-22

17-22

Air Temp Rise

°F DB

20-26

24-30

32-38

39-45

Air Temp Drop

°F DB

19-25

19-25

18-24

17-23

17-23

Air Temp Rise

°F DB

20-25

28-33

34-39

31-36

Air Temp Drop

°F DB

15-20

20-25

20-25

18-23

16-21

Air Temp Rise

°F DB

17-22

23-28

30-35

35-40

6/5/12

40


Reference Calculations

Heating Calculations:

LWT = EWT -

HE gpm x 500

Cooling Calculations:

LWT = EWT +

HR gpm x 500

LAT = EAT +

HC cfm x 1.08

TH = HC + HW

LAT (DB) = EAT (DB) -

SC cfm x 1.08

LC = TC - SC

S/T =

SC

TC

Legend

Abbreviations and Definitions

cfm = airflow, cubic feet/minute

EWT = entering water temperature, Fahrenheit gpm = water flow in gallons/minute

WPD = water pressure drop, psi and feet of water

EAT = entering air temperature, Fahrenheit (dry bulb/wet bulb)

HC = air heating capacity, MBtu/h

TC = total cooling capacity, MBtu/h

SC = sensible cooling capacity, MBtu/h kW = total power unit input, kilowatts

HR = 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

Troubleshooting

Aurora Control System

NOTE: Refer to the Aurora Base Control Application and

Troubleshooting Guide and the Instruction Guide: Aurora

Interface and Diagnostics (AID) Tool for additional information.

To check the unit control board for proper operation:

1. General Check

• If any new device was installed, or any wiring was changed, check the connections to ensure the wiring is correct, and all the wires are in good condition.

• Verify all the plugs are securely connected and in good condition.

• Check the DIP switch (SW2) positions are correct.

• Measure 24 VAC between R and C. (The actual reading may be from 18 to 30 VAC). Check the incoming power and the power transformer if the R and C voltage reading is not correct.

2. No LEDs are On

• Check 24 VAC on board.

• Check the 3 amp fuse. Replace the fuse if needed.

• Verify transformer circuit breaker has not tripped if no low voltage is present.

• Disconnect the thermostat connection P1.

• Replace the Aurora base control board.

Refrigerant Systems

Refrigerant pressures are monitored by the control system; to maintain sealed circuit integrity, do not install service gauges unless pressure sensor is suspected to be inoperative. 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, make sure the airflow and water flow are correct. Check superheat and subcooling with an AID Tool. If superheat and subcooling are outside recommended ranges, an adjustment to the refrigerant charge may be necessary.

NOTE: Refrigerant tests must be made with hot water generator turned “OFF”. Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit.

41


Troubleshooting cont.

Sensor Locations

FP2 Sensor

Air

Coil

Leaving Water

Thermistor

(Sensor Wire

Wrapped 4

Times Around

Water Line)

Blower

Leaving Air

Thermistor

(

Wire Bundle In

Blower

Compartment)

Performance

Option Only

Entering Water

Thermistor

(Sensor Wire

Wrapped 4

Times Around

Water Line)

Flow

Sensor

Flow Meter

Entering Water

Thermistor

(Sensor Wire

Wrapped 4

Times Around

Water Line)

Performance Option Only

Water Line View of Coax

Line

Thermistor

Pressure

Transducer

Ambient Air

Thermistor

(

Wire Bundle In

Compressor

Compartment)

Rev. Valve

Discharge

Pressure

Transducer

Water OUT

Water

OUT

Coax

Water

IN

Compressor

(

LLT

EEV

FP1 Sensor

Muffler

Discharge

Line

Thermistor

Coax

Water IN

Filter

Dryer

42



DEALER:

PHONE #: DATE:

PROBLEM:

MODEL #:

SERIAL #:

Startup/Troubleshooting Form

COOLING CYCLE ANALYSIS

°F

°F AIR

COIL

PSI =

°F

SAT °F

°F High Speed

Unit Amp Draw:

Line Voltage:

Loop: Open

Closed

°F Low Speed

SUCTION

COAX

LOAD

°F

PSI

BRINE IN

°F

PSI

BRINE OUT

Water to Water Application

ELECTRONIC

EXPANSION

VALVE

°F

LIQUID LINE

High Speed

High Speed

Low Speed

Low Speed

°F

PSI

°F

PSI

BRINE IN

COAX

SOURCE

°F

PSI

°F

PSI

BRINE OUT

REVERSING

VALVE

COMPRESSOR

DISCHARGE

Hot Water

Generator

-

° F

PSI =

°F °F Superheat

Subcooling

Heat of Extraction/Rejection = gpm x 500 (485 for water/antifreeze) x ∆T

Note: DO NOT hook up pressure gauges unless pressure sensors are suspect.

HEATING CYCLE ANALYSIS

°F

PSI =

°F

SAT °F

°F AIR

COIL

°F High Speed

°F Low Speed

Unit Amp Draw:

Line Voltage:

Loop: Open

Closed

COAX

LOAD

ELECTRONIC

EXPANSION

VALVE

COAX

SOURCE

°F

PSI

BRINE IN

°F

PSI

BRINE OUT

Water to Water Application

° F

LIQUID LINE

High Speed

High Speed

Low Speed

Low Speed

°F

PSI

°F

PSI

BRINE IN

°F

PSI

°F

PSI

BRINE OUT

43

SUCTION

REVERSING

VALVE

COMPRESSOR

DISCHARGE

Hot Water

Generator

-

° F

PSI =

°F °F Superheat

Subcooling



Variable Speed Startup/Troubleshooting Form

1. Job Information

Model #

Serial #

2. Flow Rate in gpm

WATER IN Pressure:

WATER OUT Pressure: a. b.

HEATING SPEED 12

Job Name:

Install Date:

SOURCE COAX

HEATING SPEED 4 COOLING SPEED 9

psi a.

psi b.

psi a.

psi b.

Loop: Open / Closed

Hot Water Generator: Y / N

psi a.

psi b.

COOLING SPEED 3

psi

psi

Pressure Drop: a - b c.

Look up flow rate in table: d.

3. Temperature Rise/Drop Across Coaxial Heat Exchanger 1

HEATING SPEED 12

psi c.

gpm d.

WATER IN Pressure:

WATER OUT Pressure:

SUPPLY AIR Temperature:

RETURN AIR Temperature: e. f. h. i.

°F e.

°F f.

Temperature Difference: g.

4. Temperature Rise/Drop Across Air Coil

HEATING SPEED 12

°F g.

°F

°F h. i.

°F j. Temperature Difference: j.

5. Heat of Rejection (HR)/Heat of Extraction (HE)

Brine Factor 2 : k.

HEATING SPEED 4

HEATING SPEED 4

psi

gpm

°F

°F

°F

°F

°F

°F c. d. e. f. g. h. i. j.

gpm

COOLING SPEED 9

COOLING SPEED 9

psi

°F

°F

°F

°F

°F

°F c. d. e. f. g. h. i. j.

COOLING SPEED 3

COOLING SPEED 3

psi

gpm

HR/HE = d x g x k l.

HEATING SPEED 12

Btu/h l.

HEATING SPEED 4

Btu/h l.

COOLING SPEED 9

Btu/h l.

COOLING SPEED 3

STEPS 6-9 NEED ONLY BE COMPLETED IF A PROBLEM IS SUSPECTED. USE HEATING SPEED 12 AND COOLING SPEED 9 FOR STEPS 6-9.

6. Watts ENERGY MONITOR


Btu/h

Volts:

Total Amps (Comp. + Blower) 3

Watts = m x n x 0.85:

7. Capacity

: m. n. o.

Volts

Amps

Watts m. n. o.

Volts

Amps

Watts


Cooling Capacity = l - (o x 3.413):

Heating Capacity = l + (o x 3.413):

8. Efficiency p. Btu/h p. Btu/h


°F

°F

°F

°F

°F

°F

Cooling EER = p / o:

Heating COP = p / (o x 3.413):

9. Superheat (S.H.)/Subcooling (S.C.) q. Btu/h q. Btu/h


Suction Pressure:

Suction Saturation Temperature:

Suction Line Temperature:

S.H. = t - s r. s. t. u.

psi r.

°F s.

°F t.

°F u.

Head Pressure:

High Pressure Saturation Temp: v. w.

psi v.

°F w.

Liquid Line Temperature

S.C. = w - x

4 : x. y.

°F

°F x. y.

NOTES: 1 Steps 3-9 should be conducted with the hot water generator disconnected.

psi

°F

°F

°F

psi

°F

°F

°F

Software Version

ABC:

AXB:

IZ2:

TSTAT: in one hour (60) times the specific heat of the fluid. Water has a specific heat of 1.0.

44


Preventive Maintenance

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.

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

Air filters and variable speed drive filter 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. The VS drive filter is located on the lower left corner of the cabinet. Removing the two screws in the honey comb grill allows access to the filter. Run the filter under warm water and gently rub. Let the filter dry. The, reinstall the filter and cover.

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. The condensate drain can pick up lint and dirt, especially with dirty filters. Inspect twice a year to avoid the possibility of overflow.

Blower Motors

ECM blower motors are equipped with sealed ball bearings and require no periodic oiling.

Hot Water Generator Coil

See Water Coil Maintenance section above.

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.

CAUTION: Fin edges are sharp.

Replacement Procedures

Obtaining Parts

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.

In-Warranty Material Return

Material may not be returned except by permission of authorized warranty personnel. Contact your local distributor for warranty return authorization and assistance.

45


Service Parts List

Parts List

Compressor 208-230/60/1

Sound Jacket

036

Vertical

048 060

34P647-01 34P648-01 34P649-01

92P504A05 92P504A05 92P504A05

Power Harness 11P853-01 11P853-01 11P853-01

ECM Motor 208-230/60/1

ECM Blower Housing

ECM Harness - Low Voltage

ECM Power Harness

14S545-01

53P501B01

11P827-02

11P585B03

14S546-01

53P501B01

11P827-02

11P585B03

14S547-01

53P501B01

11P827-02

11P585B03

2” Air Filter MERV 11 (top flow & rear discharge)

59P509-07 59P509-07 59P509-06

2” Air Filter MERV 11 (bottom flow) 59P509-06 59P509-06 59P509-06

AP411 4” Media Refill RM-AP411-46 RM-AP411-46 RM-AP411-46

AP411 1” Carbon Media Refill

Air Coil

Coax

RM-AP411-46C RM-AP411-46C RM-AP411-46C

61S606-02

62I543A01

61S606-02

62I555-01

61S701-02

62I555-01

EEV

Reversing Valve

Discharge Muffler

Filter Dryer

33P617-01 33P617-01 33P617-01

33P526-05 33P526-05 33P526-05

36P503B02 36P503B02 36P503B02

36P500B01 36P500B02 36P500B02

tor Hot Water Generator 62P516-03 62P516-03 62P516-03

Hot Water Generator Pump 24P501A01 24P501A01 24P501A01

Contactor

Transformer 208-230/60/1

3 Pole Power Block

2 Pole Screw Term. Block

EEV Solenoid Coil

EEV/VS Drive Communication

Cable

ABC/AXB/VS Drive

Communication Cable

Keystone Category 5 Coupler

(AID Port)

Category 5 cable (AID Port to

ABC)

Current Transformer

Rocker Switch - HWG ON/OFF

Pump Circuit Breaker - 5 amp,

250v

Pressure Transmitter DIN Cable

VS Drive Control

Drive Circuit Breaker

EEV Board

13P004A03

15P501B01

11P843-01

11P836-01

12P553-01

11P846-01

12P557-01

13P607A01

19P583-01

13P004A03

15P501B01

11P843-01

11P836-01

12P553-01

11P846-01

12P557-01

13P607A01

19P583-01

13P004A03

15P501B01

12P503-06 12P503-06 12P503-06

12P500A01 12P500A01 12P500A01

33P617-02 33P617-02 33P617-02

11P843-01

11P836-01

12P553-01

11P846-01

12P557-01

13P607A01

19P583-01

11P855-01

17P560-01

19P595-01

17P561-01

17P553-02

17P557-01

11P855-01 11P855-01

17P560-02 17P560-03

19P595-02

17P561-01

19P595-03

17P561-01

17P553-02

17P557-01

17P553-02

17P557-01

ABC Board

AXB Board

Freeze Detection Thermistor-FP1-

Yellow

HWL Thermistor-Pink (AXB P17)

Thermistor FP2

Thermistor - LAT/EWT/Suct Line/

Compr Ambient

Thermistor - Compressor

Discharge Line

Thermistor - Heating Liquid Line

Thermistor - Leaving Water

Temperature

12P505-09

12P555-04

12P550-01

12P556-01

12P556-02

12P555-03

12P555-02

12P505-09

12P555-04

12P550-01

12P556-01

12P556-02

12P555-03

12P555-02

12P505-09

12P555-04

12P550-01

12P556-01

12P556-02

12P555-03

12P555-02

Transmitter, Flow Meter (sensor, clip, harness)

29P535-01 29P535-01 29P535-01

Pressure Transmitter, High Pressure 35P553-04 35P553-04 35P553-04

Pressure Transmitter, Low Pressure 35P553-03 35P553-03 35P553-03

Switch, High Pressure

Switch, Low Pressure

Part numbers subject to change

SKHPE600

SKLPE40

SKHPE600

SKLPE40

SKHPE600

SKLPE40

6/19/12

Parts List

Compressor 208-230/60/1

Sound Jacket

Power Harness

ECM Motor 208-230/60/1

ECM Blower Housing

ECM Harness - Low Voltage

ECM Power Harness

2” Air Filter MERV 11

2” Air Filter MERV 11 (second filter if needed)

Air Coil

Coax

EEV

Reversing Valve

Discharge Muffler

Filter Dryer

tor Hot Water Generator

036

Horizontal

048 060

34P647-01 34P648-01 34P649-01

92P504A05 92P504A05 92P504A05

11P853-01 11P853-01 11P853-01

14S545-01 14S546-01 14S547-01

53P501B01 53P501B01 53P501B01

11P827-01 11P827-01 11P827-01

11P585B04 11P585B04 11P585B04

59P509-02 59P509-02 59P509-03

59P509-11 59P509-11 59P509-11

61S612-02 61S612-02 61S649-02

62I543A01 62I555-01 62I555-01

33P617-01 33P617-01 33P617-01

33P526-05 33P526-05 33P526-05

36P503B02 36P503B02 36P503B02

36P500B01 36P500B02 36P500B02

62P516-03 62P516-03 62P516-03

Hot Water Generator Pump 24P501A01 24P501A01 24P501A01

Contactor

Transformer 208-230/60/1

3 Pole Power Block

2 Pole Screw Term. Block

13P004A03 13P004A03 13P004A03

15P501B01 15P501B01 15P501B01

12P503-06 12P503-06 12P503-06

12P500A01 12P500A01 12P500A01

EEV Solenoid Coil 33P617-02 33P617-02 33P617-02

EEV/VS Drive Communication Cable 11P843-01 11P843-01 11P843-01

ABC/AXB/VS Drive Communication

Cable

Keystone Category 5 Coupler (AID

Port)

11P836-01

12P553-01

11P836-01

12P553-01

11P836-01

12P553-01

Category 5 cable (AID Port to ABC)

Current Transformer

Rocker Switch - HWG ON/OFF

Pump Circuit Breaker - 5 amp, 250v

Pressure Transmitter DIN Cable

VS Drive Control

Drive Circuit Breaker

EEV Board

11P846-01 11P846-01 11P846-01

12P557-01 12P557-01 12P557-01

13P607A01 13P607A01 13P607A01

19P583-01 19P583-01 19P583-01

11P855-01 11P855-01 11P855-01

17P560-01 17P560-02 17P560-03

19P595-01 19P595-02 19P595-03

17P561-01 17P561-01 17P561-01

17P553-02 17P553-02 17P553-02

17P557-01 17P557-01 17P557-01

ABC Board

AXB Board

Freeze Detection Thermistor-FP1-

Yellow

HWL Thermistor-Pink (AXB P17)

Thermistor FP2

Thermistor - LAT/EWT/Suct Line/

Compr Ambient

Thermistor - Compressor Discharge

Line

Thermistor - Heating Liquid Line

Thermistor - Leaving Water

Temperature

12P505-09

12P555-04

12P550-01

12P556-01

12P556-02

12P555-03

12P555-02

12P505-09

12P555-04

12P550-01

12P556-01

12P556-02

12P555-03

12P555-02

12P505-09

12P555-04

12P550-01

12P556-01

12P556-02

12P555-03

12P555-02

Transmitter, Flow Meter (sensor, clip, harness)

Pressure Transmitter, High Pressure

Pressure Transmitter, Low Pressure

Switch, High Pressure

Switch, Low Pressure

Part numbers subject to change

29P535-01 29P535-01 29P535-01

35P553-04 35P553-04 35P553-04

35P553-03

SKLPE40

35P553-03

SKLPE40

35P553-03

SKHPE600 SKHPE600 SKHPE600

SKLPE40

6/19/12

46

Manufactured by

WaterFurnace International, Inc.

9000 Conservation Way

Fort Wayne, IN 46809 www.waterfurnace.com

Product:

Type:

Size:

7 Series 700A11

Geothermal Heat Pump

3-5 Ton Variable Speed

Document: Installation Manual

C US ISO 17025 Accredited

©2012 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy of continual product research and development and reserves the right to change design and specifications without notice. IM2700AN 07/12

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