RB Series Water Source Heat Pump, 0.5-6 Ton

INDOOR PACKAGED EQUIPMENT
INSTALLATION, OPERATION, MAINTENANCE
Supersedes: 146.00-NOM7 (514)
RB SERIES
WATER SOURCE HEAT PUMP
0.5 – 6 TON
R-410A
Issue Date:
March 28, 2017
Form 146.07-NOM1 (317)
RB SERIES INSTALLATION MANUAL
Table of Contents
Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Installing Horizontal Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hanger Bracket Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Duct System and Water Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Condensate Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System Cleaning and Flushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Open Loop Ground Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Freeze Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-20
Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24
5-Speed ECM Constant Torque Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-29
Controls - Aurora Base Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
Unit Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operating Parameters and Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Compressor and Thermistor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Refrigerant Circuit Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Heat of Extraction/Rejection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Reference Calculations and Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Startup/Troubleshooting Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44
Revision Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
RB SERIES INSTALLATION MANUAL
Model Nomenclature
1-2
3
4
5-7
8
9
10
11
12
13
14
15
16
17
18
19
20
21 22-23 24
RB
S
V
036
T
L
0
0
0
C
A
N
N
A
5
N
0
0
SS
*
Vintage
V
* - Factory Use Only
ype
Model Type
RB – RB Serie
Series
ess
Non-Standard Options
SS – Standard
Operation
on Rang
Range
ge
e
S – Single
ngle Stag
Stage
g
ge
Drain Pan Option
0 – Composite, No Secondary Connection
1 – Composite, Secondary Connection
2 – Stainless Steel, No Secondary Connection
3 – Stainless Steel, Secondary Connection
Cabinet Configu
Configuration
urat
attion
V – Vertical
rtical
rizontal
H - Horizontal
pacity (M
M TUH)
MBT
T
Unit Capacity
(MBTUH)
9, 012, 01
0
15,
006, 009,
015,
018, 024,
24, 030, 036,
0 6,
03
6
041* (Vertical)
Vertical)
48, 060, 070
0 0
07
042, 048,
Cabinet Option
0 – Unpainted, 1 in MERV 4, Filter Rail
1 – Painted, 1 in MERV 4, Filter Rail
2 – Unpainted, 2 in MERV 13, Filter Rail
3 – Painted, 2 in MERV 13, Filter Rail
4 – Unpainted, 1 in MERV 4, Filter Rack
5 – Painted, 1 in MERV 4, Filter Rack
6 – Unpainted, 2 in MERV 13, Filter Rack
7 – Painted, 2 in MERV 13, Filter Rack
ge Configuration
Conffigu
u
uration
Discharge
p (Vertic
ca
al)
T – Top
(Vertical)
E – End
d (Horiz
(Horizontal)
zo
onttal)
t
S – Side
de (Horiz
(Horizontal)
zo
on
nttal)
Conffigu
u
uration
Return Air Configuration
ft
L – Left
R – Right
ght
Electrical Option
N – No Phase Guard, No Disconnect
D – No Phase Guard, Disconnect
P – Phase Guard, No Disconnect
B – Phase Guard, Disconnect
Voltage
0 – 208-230/60/1
0//1
2 – 265-277/60/1
0//1 (018-036)
3 – 208-230/60/3
0//3 (024-070)
4 – 460/60/3 (024-070)
02
24
4--070)
5 – 575/60/3 (PSC
PSC
C Only 042-070)
00
06
6--012)
9 – 115/60/1 (006-012)
Air Coil Option
5 – All-Aluminum, AlumiSeal TM, Extended Rang
6 – All-Aluminum, AlumiSeal, Standard Range
7 – All-Aluminum, No Coating, Extended Range
8 – All-Aluminum, No Coating, Standard Range
Future Option
0 – None
Blower Options
0 – PSC Blower
e ECM Blower (015-070)
ed
1 – Variable Speed
4 – 5-Speed ECM
M Blower (015-070)
Control Option
A – AuroraTM Base Control (ABC)
Z – AuroraTM with SMART Equipment DDC
Water Coil Option
C – Copper
N – CuproNickel
Water Control Option
N – None
R – Water Flow Regulator (015-070)
V – 2-Way Valve (015-070)
B – 2-Way Valve w/ Water Flow Regulator
(015-070)
Sound Kit Option
A – None
B – Sound Kit (Not Available on H006-012)
Note: Phase Guard Only Available on 208-230/60/3 and 460/60/3
50VA Transformer with Aurora and 75VA Transformer with SMART Equipment
*Some options not available in RBSV041.
Future Option
N – None
All RB Series product is safety listed under UL1995 thru ETL and performance listed with AHRI in
accordance with standard 13256-1.
4
RB SERIES INSTALLATION MANUAL
General Installation Information
Unit Location
Safety Considerations
Locate the unit in an indoor area that allows for easy removal of
the filter and access panels. 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 when units are
located in unconditioned spaces to prevent damage from
frozen water lines and excessive heat that could damage
electrical components.
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.
Installing Vertical Units
Vertical units are available in left or right air return configurations.
Top flow 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.
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.
Vertical Unit Mounting
2 in. PEX Foam
5
RB SERIES INSTALLATION MANUAL
Vertical Dimensional Data
Standard filter rails for
open return applications
Field installed
duct flange
Deluxe filter rack for
ductable return applications
A
A
N
S
R
Air coil
N
Q
P
B
AIR COIL SIDE
AIR COIL SIDE
Q
P
FRONT
ACCESS
PANEL
B
2' (61 cm)
Alternate
Service Access
FRONT
F
M
F
M
Top View - Right Return
Top View - Left Return
2' (61 cm)
Service Access Left Return
(Right Return Opposite Side)
Isometric View - Left Return
T
U
W
Air coil
Air coil
ACCESS
PANEL
ACCESS
PANEL
V
C
C
1.6 in (4.1 cm)
Condensate 3/4 in
PVC glue socket
1.6 in (4.1 cm)
H
E
D
5
6
2
8
1
Water
Connections*
Front View - Right Return
L
J
Power supply
1 in (25.4 mm)
knockout
Condensate
3/4 in PVC
glue socket
Low voltage
1/2" (12.7 mm)
knockout
1.6 in (4.1 cm)
8
7
L
K
Water
Connections*
1.6 in
(4.1 cm)
5
6
2
8
1
E
H
8
7
L
K L
D
Front View - Left Return
NOTE: * Water connections protrude approximately 1.5 in. (3.81cm) from cabinet.
6
J
ACCESS
PANEL
Right View - Right Return (J & L)
Left View - Left Return (K & L)
RB SERIES INSTALLATION MANUAL
Vertical Dimensional Data cont.
Overall Cabinet
Vertical
Models
006-012
015-018
024-030
036
041
042-048
060
070
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
Vertical
Models
006-012
015-018
024-030
036
041
042-048
060
070
1
D
2
E
5
H
Loop
A
B
C
Width
Depth
Height*
In
Out
Condensate
Water FPT
19.2
48.8
22.5
57.2
22.5
57.2
22.5
57.2
21.5
54.6
22.5
57.2
25.5
64.8
25.5
64.8
19.2
48.8
22.2
56.4
22.2
56.4
26.2
66.5
21.5
54.6
26.2
66.5
31.2
79.2
31.2
79.2
24.2
61.5
30.2
76.7
36.2
91.9
40.2
102.1
40.2
102.1
44.2
112.3
44.2
112.3
48.2
122.4
2.6
6.6
2.6
6.6
2.6
6.6
2.6
6.6
2.6
6.6
2.6
6.6
2.6
6.6
2.6
6.6
5.6
14.2
7.6
19.3
7.6
19.3
7.6
19.3
7.6
19.3
7.6
19.3
7.6
19.3
7.6
19.3
8.8
22.4
10.8
27.4
10.8
27.4
10.8
27.4
10.8
27.4
10.8
27.4
10.8
27.4
10.8
27.4
1/2”
12.7 mm
3/4”
19.1 mm
3/4”
19.1 mm
3/4”
19.1 mm
3/4”
19.1 mm
3/4”
19.1 mm
1”
25.4 mm
1”
25.4 mm
N
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
Electrical Knockouts
Water Connections
Discharge Connection
duct flange installed (±0.10 in)
P
Q
R
Supply Width
Supply Depth
10.0
25.4
14.0
35.6
14.0
35.6
14.0
35.6
14.0
35.6
18.0
45.7
18.0
45.7
18.0
45.7
10.0
25.4
14.0
35.6
14.0
35.6
14.0
35.6
14.0
35.6
18.0
45.7
18.0
45.7
18.0
45.7
4.6
11.7
4.1
10.4
4.1
10.4
6.1
15.5
3.8
9.7
4.1
10.4
6.6
16.8
6.6
16.8
S
4.4
11.2
4.3
10.9
4.3
10.9
4.5
11.4
3.5
8.9
2.1
5.3
4.6
11.7
4.6
11.7
7.8
19.8
7.7
19.6
7.7
19.6
7.7
19.6
6.7
17.0
3.9
9.9
6.3
16.0
6.3
16.0
T
6
J
1/2” cond
Low
Voltage
7.4
18.8
9.4
23.9
9.4
23.9
10.1
25.7
9.4
23.9
10.1
25.7
10.1
25.7
10.1
25.7
7
K
1/2” cond
Low
Voltage
3.4
8.6
5.4
13.7
5.4
13.7
6.1
15.5
5.4
13.7
6.1
15.5
6.1
15.5
6.1
15.5
8
L
1” cond
Power Supply
5.4
13.7
7.4
18.8
7.4
18.8
8.1
20.6
7.4
18.8
8.1
20.6
8.1
20.6
8.1
20.6
**Return Connection
using deluxe filter rack (±0.10 in)
U
V
Return Depth
Return Height
14.3
36.3
18.1
46.0
18.1
46.0
22.1
56.1
20.2
51.3
22.1
56.1
28.1
71.4
28.1
71.4
10.1
25.7
14.0
35.6
20.0
50.8
22.1
56.1
28.0
71.1
26.1
66.3
26.0
66.0
30.0
76.2
2.4
6.1
2.1
5.3
2.1
5.3
2.1
5.3
0.6
1.5
2.1
5.3
1.6
4.1
1.6
4.1
M
Filter Rack
Width
2.2
5.6
2.2
5.6
2.2
5.6
2.2
5.6
1.2
3.0
2.2
5.6
2.2
5.6
2.2
5.6
W
2.0
5.1
2.0
5.1
2.0
5.1
2.0
5.1
0.6
1.5
2.0
5.1
2.0
5.1
2.0
5.1
Condensate is 3/4” PVC female glue socket and is switchable from side to front.
10/15/15
*Discharge flange is field installed and extends 1” (25.4 mm) from top of cabinet.
**Vertical units shipped with standard 2” (field adjustable to 1”) open application filter rack extending 2.2” from unit and is not suitable for duct connection.
For ductable return connection applications, order the deluxe 2” (field adjustable to 1”) duct collar/filter rack which extends 3.25
Vertical Disconnect
When using disconnect, do not use dimension L from the standard
vertical dimensional data. Use dimension LL from the vertical
disconnect dimensional data.
Vertical Models
015-018
024-030
036
042-048
060
070
Dimensions in inches [cm]
* Models 006-012 - Externally Mounted Disconnect
**UBV-041 - Disconnect not available
LL
15.8 [40.1]
18.8 [47.8]
15.3 [38.9]
13.8 [35.1]
14.3 [36.3]
14.3 [36.3]
Disconnect Located
on this Side for a
Right Return
Disconnect
Location
Alternative
Power Supply
Power
Supply
LL
7
Vertical Shown in Left
Return Configuration
RB SERIES INSTALLATION MANUAL
Horizontal Dimensional Data
1.7
Standard filter rails
1.7
Standard filter rails
1 in knockout
1/2 in knockout
Front
Right Return
K
CP
Left Return
Front
AP
J
CMP
E
A
AP
D
AP
Right Return Air Front View
CMP
CMP
1.7
1.7
2' (61 cm)
Service Access
2' (61 cm)
Service Access
J
CP
Condensate
"X" PVC size
End Discharge
2
Deluxe filter rack option shown
P
N
2.3
Left Return Air Front View
L
Legend
M C
L
3
BP
A
AP
= Alternate Service Panel
BP
= Blower Service Panel
CP
= Control Access Panel
C
M
BLOWER
OUTLET
CMP = Compressor Service Panel
BP
H
A
Left Return
End Discharge
N
K
AP
M
BLOWER
OUTLET
1/2 in knockout J
1 in knockout
Front
Front
1" knockout
J 1/2 in knockout
CMP
Q
P
BP
BLOWER
OUTLET
M
AP
CMP
K
L
Left Return Side Discharge
Right Return Side Discharge
Air Coil
N
1.5
1.5
L
BP
3
2.1
Right Return
End Discharge
P
Condensate
"X" PVC size
End Discharge
Side Discharge
FILTER RACK
AIR COIL SIDE
FILTER RACK
AIR COIL SIDE
1 in knockout
1
D
BLOWER
OUTLET
2.1
K
CMP
E
Deluxe filter rack option shown
2.3
P
N
H
1/2 in knockout
AP
Side Discharge
T
T
S
S
Air Coil
Q
Deluxe filter
rack option
(shown)
C
FILTER RACK CONNECTION
R
C
R
FILTER RACK CONNECTION
Front
Water Connections*
Front
B
B
Right Return Side View
Left Return Side View
NOTE: * Water connections protrude approximately 1.5 in. from cabinet.
8
Water Connections*
RB SERIES INSTALLATION MANUAL
Horizontal Dimensional Data cont.
Overall Cabinet
Horizontal
Models
006-012**
015-018
024-030
036
042-048
060
070
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
Horizontal
Models
006-012**
015-018
024-030
036
042-048
060
070
A
Width
19.2
48.8
22.5
57.2
22.5
57.2
22.5
57.2
22.5
57.2
25.5
64.8
25.5
64.8
L
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
2.3
5.8
5.7
14.5
5.7
14.5
6.7
17.0
4.2
10.7
4.8
12.2
4.8
12.2
B
Depth
35.0
88.9
35.0
88.9
42.0
106.7
42.0
106.7
45.0
114.3
48.0
121.9
53.0
134.6
C
Height*
12.1
30.7
17.2
43.7
17.2
43.7
19.2
48.8
19.2
48.8
21.2
53.8
21.2
53.8
Discharge Connection
duct flange installed (±0.10 in)
M
N
Supply Width Supply Depth
8.0
10.0
20.3
25.4
10.5
9.4
26.7
23.9
10.5
9.4
26.7
23.9
10.5
9.4
26.7
23.9
13.6
13.2
34.5
33.5
13.6
13.2
34.5
33.5
13.6
13.2
34.5
33.5
Water Connections
2
3
E
H
Out
Condensate
4.8
3.6
12.2
9.1
6.8
0.8
17.3
2.0
6.8
0.8
17.3
2.0
6.8
0.8
17.3
2.0
6.8
0.8
17.3
2.0
6.8
0.8
17.3
2.0
6.8
0.8
17.3
2.0
1
D
In
1.8
4.6
1.8
4.6
1.8
4.6
1.8
4.6
1.8
4.6
1.8
4.6
1.8
4.6
Loop
Water FPT
1/2 in.
12.70 mm
3/4 in.
19.05 mm
3/4 in.
19.05 mm
3/4 in.
19.05 mm
3/4 in.
19.05 mm
1 in.
25.4 mm
1 in.
25.4 mm
Electrical Knockouts
J
K
1/2 in. cond
1 in. cond
Low Voltage Power Supply
7.4
7.5
18.8
19.1
7.1
7.1
18.0
18.0
7.1
7.1
18.0
18.0
9.2
7.1
23.4
18.0
9.2
7.1
23.4
18.0
9.2
9.1
23.4
23.1
9.2
9.1
23.4
23.1
Return Connection
using deluxe filter rack option (±0.10 in)
Q
R
S
Return Depth Return Height
22.5
9.4
2.4
57.2
23.9
6.1
16.4
14.5
2.0
41.7
36.8
5.1
23.4
14.5
2.0
59.4
36.8
5.1
27.4
16.5
2.0
69.6
41.9
5.1
30.4
16.5
2.0
77.2
41.9
5.1
35.4
18.7
2.3
89.9
47.5
5.8
40.4
18.5
2.3
102.6
47.0
5.8
P
2.7
6.9
4.9
12.4
4.9
12.4
4.9
12.4
2.4
6.1
4.6
11.7
4.6
11.7
PVC Size
T
1.4
3.6
1.4
3.6
1.4
3.6
1.4
3.6
1.5
3.8
1.3
3.3
1.4
3.6
Horizontal units shipped with standard 2 in. (field adjustable to 1 in.) open application filter rail extending 2.2 in. from the unit and is not
suitable for duct connection. For ductable return connection applications, order the 2 in. (field adjustable to 1 in.) duct collar/filter rack which
extends to 3.25 in. from the unit and is suitable for duct connections.
X
1/2 in.
1.3
3/4 in.
1.9
3/4 in.
1.9
3/4 in.
1.9
3/4 in.
1.9
3/4 in.
1.9
3/4 in.
1.9
09/26/12
** H006-012 offers a lifted drain pan that allows the trap to be installed without additional ceiling height required.
Horizontal Disconnect
When using disconnect, do not use dimension K from the standard
horizontal dimensional data. Use dimension KK from the horizontal
disconnect dimensional data.
Horizontal Models
KK
015-018
8.2 [20.8]
024-030
8.2 [20.8]
036
9.2 [23.4]
042-048
9.2 [23.4]
060
11.2 [28.4]
070
10.2 [25.9]
Disconnect Located on this
Side for a Left Return
Disconnect
Location
Horizontal Shown
In Right Return
Configuration
KK
Dimensions in inches [cm]
* Models 006-012 - Externally Mounted Disconnect
Power Supply
9
RB SERIES INSTALLATION MANUAL
Installing Horizontal Units
Use only the bolts provided in the kit to attach hanger brackets.
The use of longer bolts could damage internal parts. Some
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. Insulate supply plenum and
use at least one 90° elbow and flexible duct collar to reduce noise.
Installing Horizontal Units
Horizontal units are available with side or end discharge and may
be easily field converted by flipping the blower discharge panel.
Horizontal units are normally suspended from a ceiling by four 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 below. 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.
CAUTION: Do not use rods smaller than 3/8 in.
diameter since they may not be strong enough
to support the unit. The rods must be securely
anchored to the ceiling.
NOTE: The unit should be pitched approximately 1/4 in. towards
the drain in both directions to facilitate the removal of condensate.
Horizontal Unit Mounting
10
RB SERIES INSTALLATION MANUAL
Hanger Bracket Locations
Right
D
Left
F
Compressor
Section
E
G
Air Handler
Section
C
B
Air Handler
Section
E
G
D
Compressor
Section
F
A
3/8”
Threaded Rod
(not supplied)
Vibration Isolator
Washer
Hex Nuts
(not supplied)
Bolt and
Lockwasher
Hanger Dimensions
Hanger Kit
Part Number
Model
006-012
015-018
024-030
036
042-048
060
070
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
in.
cm.
99S500A04
99S500A04
99S500A04
99S500A04
99S500A04
99S500A04
99S500A04
Weight Distribution Table
Unit Hanger Dimensions
A
B
C
35.8
21.8
18.1
90.9
55.4
46.0
35.8
25.1
21.4
90.9
63.8
54.4
42.8
25.1
21.4
108.6
63.8
54.4
42.8
25.1
21.4
108.7
63.8
54.4
45.8
25.1
21.4
116.3
63.8
54.4
48.8
28.1
24.4
124.0
71.4
62.0
53.8
28.1
24.4
136.7
71.4
62.0
Model
006-012
015-018
024
030
036
041
042
09/26/12
048
060
070
lbs
kg
lbs
kg
lbs
kg
lbs
kg
lbs
kg
lbs
kg
lbs
kg
lbs
kg
lbs
kg
lbs
kg
Vertical
Shipping
Weight
Horizontal
Shipping
Weight
111
50
171
78
245
111
245
111
267
121
243
110
305
138
305
138
344
156
357
162
Horizontal Weight Distribution
Front
Back
D
E
F
G
112
51
176
80
242
110
242
110
265
120
44
20
32
15
47
21
47
21
60
27
21
10
67
30
85
39
85
39
95
43
19
9
32
15
45
20
45
20
50
23
28
12
45
20
65
29
65
29
60
27
310
141
310
141
350
159
378
171
68
31
68
31
77
35
80
36
60
27
60
27
68
31
73
33
77
35
77
35
90
41
95
43
N/A
105
48
105
48
115
52
130
59
10/15/2015
11
RB SERIES INSTALLATION MANUAL
Duct System
An air outlet collar is provided on vertical top flow units and all
horizontal units to facilitate a duct connection. 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.
The duct system should be sized 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.
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.
Water Piping
All source water connections on commercial units are fittings that
accept a male pipe thread (MPT). Insert the connectors by hand,
then tighten the fitting with a wrench to provide a leakproof joint.
When connecting to an open loop (groundwater) system, thread
any copper MPT fitting into the connector and tighten in the same
manner as described above.
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.
12
RB SERIES INSTALLATION MANUAL
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
Material
pH
Scaling
Acidity/Alkalinity
Calcium and
Magnesium Carbonate
Hydrogen Sulfide
Corrosion
Iron Fouling
(Biological Growth)
Sulfates
Chlorine
Chlorides
Carbon Dioxide
Ammonia
Ammonia Chloride
Ammonia Nitrate
Ammonia Hydroxide
Ammonia Sulfate
Total Dissolved Solids (TDS)
LSI Index
Iron, FE2+ (Ferrous)
Bacterial Iron Potential
Iron Oxide
Suspended Solids
Erosion
Threshold Velocity
(Fresh Water)
NOTES: Grains = ppm divided by 17
mg/L is equivalent to ppm
that the heat exchanger may require occasional flushing. Failure
to adhere to the guidelines in the water quality table could result in
loss of warranty.
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.
Copper
7-9
(Total Hardness)
less than 350 ppm
Less than 0.5 ppm (rotten egg
smell appears at 0.5 ppm)
Less than 125 ppm
Less than 0.5 ppm
Less than 20 ppm
Less than 50 ppm
Less than 2 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 1000 ppm
+0.5 to -0.5
90/10 Cupronickel
7-9
(Total Hardness)
less than 350 ppm
316 Stainless Steel
7-9
(Total Hardness)
less than 350 ppm
10 - 50 ppm
Less than 1 ppm
Less than 125 ppm
Less than 0.5 ppm
Less than 125 ppm
10 - 50 ppm
Less than 2 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
1000 - 1500 ppm
+0.5 to -0.5
Less than 200 ppm
Less than 0.5 ppm
Less than 300 ppm
10 - 50 ppm
Less than 20 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
Less than 0.5 ppm
1000 - 1500 ppm
+0.5 to -0.5
< 0.2 ppm
< 0.2 ppm
< 0.2 ppm
Less than 1 ppm, above this level
deposition will occur
Less than 10 ppm and filtered for
max. of 600 micron size
Less than 1 ppm, above this level
deposition will occur
Less than 10 ppm and filtered for
max. of 600 micron size
Less than 1 ppm, above this level
deposition will occur
Less than 10 ppm and filtered for
max. of 600 micron size
< 6 ft/sec
< 6 ft/sec
< 6 ft/sec
2/22/12
13
RB SERIES INSTALLATION MANUAL
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 in. 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 or stainless steel tube 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.
Horizontal Drain Connection (Composite Drain Pan)
Unit Pitch for Drain
NOTE: All units equipped with electronic condensate overflow
protection.
Vent (if needed)
PVC coupling
1/2'' Pitch
PVC tube stub
1/8 in. per foot
PVC tube stub
1.5 in.
1.5 in.
Drain
14
RB SERIES INSTALLATION MANUAL
System Cleaning and Flushing
Refill the system with clean water. Test the system water for acidity
and treat as required to leave the water slightly alkaline (pH 7.5 to
8.5). The specified percentage of antifreeze may also be added
at this time. Use commercial grade antifreeze designed for HVAC
systems only. Environol™ brand antifreeze is recommended.
Cleaning and Flushing
Prior to start up of any heat pump, the water circulating system
must be cleaned and flushed of all dirt and debris.
If the system is equipped with water shutoff valves, the supply and
return runouts must be connected together at each unit location
(This will prevent the introduction of dirt into the unit, see Flushing
with Water Shutoff Valve Equipped Systems illustration). The
system should be filled at the water make-up connection with all air
vents open. After filling, vents should be closed.
Once the system has been filled with clean water and antifreeze
(if used), precautions should be taken to protect the system
from dirty water conditions. Dirty water will result in system-wide
degradation of performance, and solids may clog valves, strainers,
flow regulators, etc. Additionally, the heat exchanger may become
clogged which reduces compressor service life and can cause
premature unit failure.
Flushing with Water Shutoff Valve Equipped Systems
In boiler/tower application, set the loop control panel set points
to desired temperatures. Supply power to all motors and start the
circulating pumps. After full flow has been established through all
components including the heat rejector (regardless of season), air
vented and loop temperatures stabilized, each of the units will be
ready for check, test and start up and for air and water balancing.
Return Runout
Supply Runout
Mains
Ground Source Loop System Checkout
Rubber Hose
Once piping is completed between the unit pumping system and
ground loop, final purging and charging of the loop is needed. A
high pressure pump is needed to achieve adequate flow velocity
in the loop to purge air and dirt particles from the loop itself.
Antifreeze solution is used in most areas to prevent freezing. Flush
the system adequately to remove as much air as possible; then
pressurize the loop to a static pressure of 40-50 PSI (summer)
or 50-75 PSI (winter). This is normally adequate for good system
operation. Loop static pressure may decrease soon after initial
installation, due to pipe expansion and loop temperature change.
Running the unit for at least 30 minutes after the system has been
completely purged of air will allow for the “break-in” period. It may
be necessary to adjust static loop pressure (by adding water) after
the unit has run for the first time. Loop static pressure will also
fluctuate with the seasons. Pressures will be higher in the winter
months than during the cooling season. This fluctuation is normal
and should be considered when charging the system initially.
Runouts Initially
Connected Together
The contractor should start the main circulator with the pressure
reducing valve makeup open. Vents should be checked in
sequence to bleed off any trapped air and to verify circulation
through all components of the system.
As water circulates through the system, the contractor should
check and repair any leaks found in the piping system. Drain(s) at
the lowest point(s) in the system should be opened for initial flush
and blowdown, making sure water fill valves are set at the same
rate. Check the pressure gauge at the pump suction and manually
adjust the make-up water valve to hold the same positive pressure
both before and after opening the drain valves. Flushing should
continue for at least two hours, or longer if required, until drain
water is clean and clear.
Ensure the pump provides adequate flow through the unit by
checking pressure drop across the heat exchanger.
Usually 2.25-3.0 gpm of flow per ton of cooling capacity is
recommended in earth loop applications.
The supplemental heater and/or circulator pump, if used, should
be shut off. All drains and vents should be opened to completely
drain the system. Short-circuited supply and return runouts should
now be connected to the unit supply and return connections.
15
RB SERIES INSTALLATION MANUAL
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. Insure 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. Due to only minor differences in flow rate
from low to high, only one solenoid valve should be used. The valve
should be sized for full flow.
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.
Open System - Groundwater Application
Unit Supply
Aux. Heat Supply
Flexible
Duct Collar
Rubber Bladder
Expansion Tank
Flow Control
Valve
(on outlet of
Solenoid Valve)
Solenoid
Valve
Water Out
Water In
Drain
Shut Off Valves
Disconnects
(If Applicable)
Shut Off Valves
(to isolate solenoid
valve while acid flushing)
Strainer
Compressor
Line Voltage
Low Voltage
P/T Plugs
to Thermostat
Vibration
and Valve
Absorbing Pad
Boiler Drains
For HX Flushing
16
RB SERIES INSTALLATION MANUAL
Freeze Detection
For Aurora Base Control, set SW2-1, FP1, on the printed circuit
board for applications using a closed loop antifreeze solution to
15°F [-9.4°C]. On applications using an open loop/ground water
system (or closed loop no antifreeze), set this dip switch to 30°F
[-1.1°C], the factory default setting. (Refer to the Dip Switch Field
Selection table).
Electrical Connections
General
208 Volt Operation
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.
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.
CAUTION: When installing a unit with a Variable
Speed ECM blower motor in 460/60/3 voltage, a
neutral wire is required to allow proper unit operation.
Power Connection
Connect the incoming line voltage wires to L1 and L2 of the
contactor for single-phase unit. Consult the Electrical Data tables
for correct fuse sizes.
Aurora Base Control Box
17
RB SERIES INSTALLATION MANUAL
Electrical Data
PSC Motor
Compressor
LRA
Blower
Motor
FLA
Total
Unit
FLA
Min
Circ
Amp
Max
Fuse/
HACR Breaker
6.1
3.0
2.7
8.0
4.1
4.3
9.5
4.9
4.5
29.0
15.0
11.0
50.0
21.0
22.0
50.0
25.0
22.0
1.5
0.6
0.6
1.5
0.6
0.6
1.5
0.6
0.6
7.6
3.6
3.3
9.5
4.7
4.9
11
5.5
5.1
9.1
4.4
4.0
11.5
5.7
6.0
13.4
6.7
6.2
15
10/15
10/15
15
10/15
10/15
20
10/15
10/15
9.2
5.9
29.0
1.1
7.8
9.5
15
7.8
5.0
28.0
1.0
6.6
8.0
10/15
187/253
238/292
10.4
8.7
6.7
5.6
33.5
28.0
1.1
1.0
7.8
6.6
9.5
8.0
15
10/15
208-230/60/1
265/60/1
208-230/60/3
460/60/3
208-230/60/1
265/60/1
208-230/60/3
460/60/3
187/253
238/292
187/253
414/506
187/253
238/292
187/253
414/506
13.0
12.6
13.0
6.0
17.5
14.0
13.5
6.4
7.4
6.7
5.9
2.9
9.4
8.0
6.6
3.2
43.0
46.0
63.0
30.0
54.0
46.0
63.0
30.0
1.2
1.1
1.2
0.6
1.5
1.5
1.5
1.0
8.6
7.8
7.1
3.5
10.9
9.5
8.1
4.2
10.5
9.5
8.6
4.2
13.3
11.5
9.8
5.0
15
15
10/15
10/15
20
15
15
10/15
036
208-230/60/1
265/60/1
208-230/60/3
460/60/3
187/253
238/292
187/253
414/506
20.5
17.7
13.5
7.1
11.6
9.9
7.4
3.8
74.0
67.0
68.0
34.0
2.2
1.1
2.2
1.1
13.8
11.0
9.6
4.9
16.7
13.5
11.5
5.9
25
20
15
10/15
041
208-230/60/1
208-230/60/3
460/60/3
575/60/3
187/253
187/253
414/506
517/633
25.0
14.5
7.7
6.0
13.0
8.6
4.2
3.5
88.0
68.0
34.0
28.0
3.5
3.5
1.8
1.4
16.5
12.1
6.0
4.9
19.8
14.3
7.1
5.8
30
20
10/15
10/15
042
208-230/60/1
208-230/60/3
460/60/3
575/60/3
187/253
187/253
414/506
517/633
25.0
14.5
7.7
6.0
13.0
8.6
4.2
3.5
88.0
68.0
34.0
28.0
3.5
3.5
1.8
1.4
16.5
12.1
6.0
4.9
19.8
14.3
7.1
5.8
30
20
10/15
10/15
048
208-230/60/1
208-230/60/3
460/60/3
575/60/3
187/253
187/253
414/506
517/633
24.5
17.5
8.0
7.0
15.7
11.0
5.6
4.4
84.0
88.0
44.0
36.0
3.5
3.5
1.8
1.9
19.2
14.5
7.4
5.8
23.1
17.3
8.8
6.9
35
25
10/15
10/15
208-230/60/1
208-230/60/3
460/60/3
575/60/3
208-230/60/1
208-230/60/3
460/60/3
187/253
187/253
414/506
517/633
187/253
187/253
414/506
33.0
22.0
12.0
7.5
36.0
21.1
12.9
6.7
5.1
23.0
105.0
88.0
55.0
36.0
130.0
24.6
11.5
14.3
7.1
110.0
55.0
5.9
5.9
3.0
1.9
5.9
5.9
3.0
27.0
18.8
9.7
7.0
28.9
20.2
10.1
32.3
22.0
11.4
8.3
34.7
23.8
11.9
50
30
15
10/15
50
35
15
575/60/3
517/633
8.7
5.6
43.0
1.9
7.5
8.9
10/15
Model
006
009
012
015
018
024
030
060
070
Rated
Voltage
Voltage
Min/Max
MCC
RLA
115/60/1
208-230/60/1
265/60/1
115/60/1
208-230/60/1
265/60/1
115/60/1
208-230/60/1
265/60/1
104/127
187/253
238/292
104/127
187/253
238/292
104/127
187/253
238/292
9.5
4.7
4.2
12.5
6.4
6.7
14.8
7.7
7.0
208-230/60/1
187/253
265/60/1
238/292
208-230/60/1
265/60/1
HACR circuit breaker in USA only
10/15/15
18
RB SERIES INSTALLATION MANUAL
Electrical Data cont.
5 Speed ECM Motor
Model
015
018
024
030
036
041
042
048
060
070
Compressor
LRA
Blower
Motor
FLA
Total
Unit
FLA
Min
Circ
Amp
Max
Fuse/
HACR Breaker
5.9
5.0
6.7
5.6
7.4
6.7
5.9
2.9
9.4
8.0
6.6
3.2
11.6
9.9
7.4
3.8
13.0
8.6
4.2
13.0
8.6
4.2
15.7
11.0
5.6
21.1
12.9
6.7
23.0
14.3
29.0
28.0
33.5
28.0
43.0
46.0
63.0
30.0
54.0
46.0
63.0
30.0
74.0
67.0
68.0
34.0
88.0
68.0
34.0
88.0
68.0
34.0
84.0
88.0
44.0
105.0
88.0
55.0
130.0
110.0
4.1
3.6
4.1
3.6
4.1
3.6
4.1
2.1
4.1
3.6
4.1
2.1
4.1
3.6
4.1
2.1
4.1
4.1
2.1
7.6
7.6
4.0
7.6
7.6
4.0
7.6
7.6
4.0
7.6
7.6
10.0
8.6
10.8
9.2
11.5
10.3
10.0
5.0
13.5
11.6
10.7
5.3
15.7
13.5
11.5
5.9
17.1
12.7
6.3
20.6
16.2
8.2
23.3
18.6
9.6
28.7
20.5
10.7
30.6
21.9
11.5
9.8
12.5
10.6
13.4
12.0
11.5
5.7
15.9
13.6
12.4
6.1
18.6
16.0
13.4
6.9
20.4
14.9
7.4
23.9
18.4
9.3
27.2
21.4
11.0
34.0
23.7
12.4
36.4
25.5
15
10/15
15
10/15
20
15
15
10/15
25
20
15
10/15
30
25
20
10/15
30
20
10/15
35
25
10/15
40
30
15
50
35
15
50
35
7.1
55.0
4.0
11.1
12.9
20
Rated
Voltage
Voltage
Min/Max
MCC
RLA
208-230/60/1
265/60/1
208-230/60/1
265/60/1
208-230/60/1
265/60/1
208-230/60/3
460/60/3
208-230/60/1
265/60/1
208-230/60/3
460/60/3
208-230/60/1
265/60/1
208-230/60/3
460/60/3
208-230/60/1
208-230/60/3
460/60/3
208-230/60/1
208-230/60/3
460/60/3
208-230/60/1
208-230/60/3
460/60/3
208-230/60/1
208-230/60/3
460/60/3
208-230/60/1
208-230/60/3
187/253
238/292
187/253
238/292
187/253
238/292
187/253
414/506
187/253
238/292
187/253
414/506
187/253
238/292
187/253
414/506
187/253
187/253
414/506
187/253
187/253
414/506
187/253
187/253
414/506
187/253
187/253
414/506
187/253
187/253
9.2
7.8
10.4
8.7
13.0
12.6
13.0
6.0
17.5
14.0
13.5
6.4
20.5
17.7
13.5
7.1
25.0
14.5
7.7
25.0
14.5
7.7
24.5
17.5
8.0
33.0
22.0
12.0
36.0
24.6
460/60/3
414/506
11.5
19
RB SERIES INSTALLATION MANUAL
Electrical Data cont.
Variable Speed ECM Motor
Model
015
018
024
030
036
Compressor
LRA
Blower
Motor
FLA
Total
Unit
FLA
5.9
29.0
4.0
5.0
28.0
4.1
10.4
6.7
33.5
8.7
5.6
28.0
13.0
12.6
13.0
7.4
6.7
5.9
43.0
46.0
63.0
Rated
Voltage
Voltage
Min/Max
MCC
RLA
208-230/60/1
187/253
9.2
265/60/1
238/292
7.8
208-230/60/1
187/253
265/60/1
238/292
208-230/60/1
265/60/1
208-230/60/3
187/253
238/292
187/253
Min
Circ
Amp
Max
Fuse/
HACR Breaker
9.9
11.4
15
9.1
10.3
15
4.0
10.7
12.4
15
4.1
9.7
11.1
15
4.0
4.1
4.0
11.4
10.8
9.9
13.3
12.5
11.4
20
20
15
460/60/3
414/506
6.0
2.9
30.0
4.1
7.0
7.7
10/15
208-230/60/1
265/60/1
208-230/60/3
187/253
238/292
187/253
17.5
14.0
13.5
9.4
8.0
6.6
54.0
46.0
63.0
4.0
4.1
4.0
13.4
12.1
10.6
15.8
14.1
12.3
25
20
20
460/60/3
414/506
6.4
3.2
30.0
4.1
7.3
8.1
10/15
208-230/60/1
265/60/1
208-230/60/3
187/253
238/292
187/253
20.5
17.7
13.5
11.6
9.9
7.4
74.0
67.0
68.0
4.0
4.1
4.0
15.6
14.0
11.4
18.5
16.5
13.3
30
25
20
460/60/3
414/506
7.1
3.8
34.0
4.1
7.9
8.9
15
208-230/60/1
208-230/60/3
187/253
187/253
25.0
14.5
13.0
8.6
88.0
68.0
4.0
4.0
17.0
12.6
20.3
14.8
35
25
460/60/3
414/506
7.7
4.2
34.0
4.1
8.3
9.4
15
042
208-230/60/1
208-230/60/3
187/253
187/253
25.0
14.5
13.0
8.6
88.0
68.0
4.0
4.0
17.0
12.6
20.3
14.8
35
25
460/60/3
414/506
7.7
4.2
34.0
4.1
8.3
9.4
15
048
208-230/60/1
208-230/60/3
187/253
187/253
24.5
17.5
15.7
11.0
84.0
88.0
4.0
4.0
19.7
15.0
23.6
17.8
40
30
460/60/3
414/506
8.0
5.6
44.0
4.1
9.7
11.1
15
060
208-230/60/1
208-230/60/3
187/253
187/253
33.0
22.0
21.1
12.9
105.0
88.0
7.0
7.0
28.1
19.9
33.4
23.1
55
35
460/60/3
414/506
12.0
6.7
55.0
6.9
13.6
15.3
25
070
208-230/60/1
208-230/60/3
187/253
187/253
36.0
24.6
23.0
14.3
130.0
110.0
7.0
7.0
30.0
21.3
35.8
24.9
60
40
460/60/3
414/506
11.5
7.1
55.0
6.9
14.0
15.8
25
041
HACR circuit breaker in USA only
10/15/15
CAUTION: When installing a unit with an variable speed ECM blower motor in 460/60/3 voltage, a neutral wire is required to allow proper
unit operation.
20
RB SERIES INSTALLATION MANUAL
Blower Performance Data
Standard PSC Motor
Model
006
009
012
015
018
024
030
036
041
042
048
060
070
Blower
Blower
Motor
Spd
H
MH
ML*
L
H
MH
ML*
L
H
MH
ML*
L
H
M
L
H
M
L
H
M
L
H
M
L
H
M
L
H
M
L
H
M
L
H
M
L
H
M
L
H
M
L
Size
HP
6x8
1/10
6x8
1/10
6x8
1/10
9x7
1/6
9x7
1/6
9x7
1/5
9x7
1/3
9x7
1/2
9x7
1/3
10x10
1/2
10 x 10
1/2
11 x 10
1
11 x 10
1
Airflow (cfm) at External Static Pressure (in. wg)
0
435
400
365
320
435
400
365
320
435
400
365
320
795
725
620
795
725
620
1035
880
810
1170
1040
825
1320
1180
1045
1140
1025
935
1530
1435
1160
1845
1655
1325
2345
2195
2045
2505
2290
2115
0.05
425
390
355
305
423
388
353
305
423
388
353
305
775
710
610
775
710
610
1015
860
790
1145
1030
820
1295
1155
1035
1115
1000
920
1500
1415
1140
1810
1620
1315
2320
2170
2030
2475
2265
2100
0.10
415
380
345
295
415
380
345
295
415
380
345
295
755
695
600
755
695
600
995
845
775
1130
1020
815
1275
1140
1025
1090
980
905
1475
1395
1130
1775
1585
1310
2305
2150
2020
2450
2250
2085
0.15
405
370
335
280
405
370
335
280
405
370
335
280
735
675
590
735
675
590
970
820
755
1110
1005
810
1240
1125
1015
1060
955
885
1445
1370
1120
1740
1555
1285
2285
2125
1995
2410
2230
2060
0.20
390
355
315
260
390
355
315
260
390
355
315
260
715
660
575
715
660
575
950
805
740
1080
990
805
1210
1100
1005
1030
935
865
1425
1350
1100
1705
1535
1265
2250
2105
1980
2385
2200
2040
0.25
365
335
300
250
370
335
300
250
370
335
300
250
690
640
550
690
640
550
925
785
725
1050
965
795
1185
1075
985
1000
910
845
1380
1325
1070
1660
1500
1245
2205
2075
1950
2365
2170
2020
0.30
340
310
280
235
340
310
280
235
340
310
280
235
670
620
525
670
620
525
900
765
705
1030
945
790
1155
1055
970
975
885
825
1340
1300
1050
1615
1465
1220
2180
2045
1925
2340
2150
2005
0.35
325
295
270
225
325
295
270
225
325
295
270
225
600
560
490
600
560
490
865
740
675
995
915
775
1120
1020
945
940
850
795
1290
1265
1020
1560
1415
1180
2135
2005
1890
2305
2135
1990
0.40
305
280
255
210
305
280
255
210
305
280
255
210
530
495
455
530
495
455
835
720
650
965
890
765
1085
990
920
905
820
770
1240
1235
990
1510
1370
1140
2090
1970
1855
2275
2125
1975
0.45
290
265
240
195
290
265
240
195
290
265
240
195
490
465
395
490
465
395
795
690
620
925
860
735
1045
955
890
865
780
740
1185
1180
950
1455
1330
1115
2060
1940
1825
2250
2105
1950
0.50
275
255
230
180
275
255
230
180
275
255
230
180
455
435
340
455
435
340
760
665
595
890
830
705
1005
920
865
830
745
710
1130
1130
910
1405
1290
1090
2030
1915
1800
2230
2085
1930
0.60
245
210
195
150
245
210
195
150
245
210
195
150
395
375
290
395
375
290
685
590
510
815
760
655
915
840
795
750
670
565
810
1040
831
1275
1170
990
1945
1845
1750
2170
2015
1875
0.70
195
135
195
135
195
135
560
530
700
650
805
725
690
353
475
715
755
632
1080
970
1850
1770
1640
2070
1950
1805
0.80
655
590
630
640
590
1740
1630
1535
1975
1865
1720
Setting Blower Speed - PSC
MEDIUM
LOW
FAN SPEE
DW
IR E
HIGH
21
1.00
1465
1765
1680
1510
10/15/15
Factory settings are in Bold
Airflow values are with dry coil and standard filter
For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [cfm] / Face Area [sq ft]).
CAUTION: Disconnect all power before performing
this operation.
0.90
1600
1500
1395
1880
1785
1655
PSC BLOWER MOTOR BODY
RB SERIES INSTALLATION MANUAL
Blower Performance Data cont.
5- Speed ECM Motor
Model
015
018
024
030
036
041
042
048
060
070
Motor Spd
High
Med High
Med
Med Low
Low
High
Med High
Med
Med Low
Low
High
Med High
Med
Med Low
Low
High
Med High
Med
Med Low
Low
High
Med High
Med
Med Low
Low
High
Med High
Med
Med Low
Low
High
Med High
Med
Med Low
Low
High
Med High
Med
Med Low
Low
High
Med High
Med
Med Low
Low
High
Med High
Med
Med Low
Low
Motor Blower Motor
Tap
Size
HP
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
9x7
1/2
9x7
1/2
9x7
1/2
9x7
1/2
9x7
1/2
9x7
1/2
11 x 10
1
11 x 10
1
11 x 10
1
11 x 10
1
0
915
805
725
695
655
915
805
725
695
655
1000
905
855
790
615
1315
1145
1020
980
795
1405
1275
1180
1125
835
1285
1225
1120
1075
795
1805
1695
1605
1510
1340
2000
1840
1755
1645
1430
2455
2260
2140
2010
1815
2500
2300
2175
2040
1850
0.05
895
785
715
675
600
895
785
715
675
600
983
888
838
773
600
1293
1130
1008
963
778
1380
1265
1163
1115
823
1250
1195
1100
1060
770
1793
1688
1593
1495
1323
1990
1833
1743
1630
1413
2440
2250
2123
1995
1803
2495
2295
2163
2028
1833
0.10
880
765
700
650
550
880
765
700
650
550
965
870
820
755
585
1270
1115
995
945
760
1355
1255
1145
1105
810
1215
1170
1085
1045
750
1780
1680
1580
1480
1305
1980
1825
1730
1615
1395
2425
2240
2105
1980
1790
2490
2290
2150
2015
1815
0.15
865
750
680
630
530
865
750
680
630
530
950
860
800
743
565
1243
1105
978
935
738
1333
1245
1135
1090
793
1180
1140
1070
1025
730
1770
1660
1560
1465
1283
1968
1810
1718
1605
1385
2413
2223
2095
1963
1775
2473
2270
2138
2000
1800
Airflow (cfm) at External Static Pressure (in. wg)
0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.60
850
830
815
805
795
775
750
730
740
725
705
685
665
655
635
605
660
635
615
600
585
560
535
485
610
590
575
550
525
490
455
508
490
475
435
395
350
850
830
815
805
795
775
750
730
740
725
705
685
665
655
635
605
660
635
615
600
585
560
535
485
610
590
575
550
525
490
455
508
490
475
435
395
350
935
923
910
900
890
873
855
800
850
833
815
805
795
775
755
740
780
773
765
745
725
715
705
670
730
710
690
675
660
643
625
570
545
523
500
468
435
408
380
1215 1183 1150 1120 1090 1055 1020 930
1095 1080 1065 1053 1040 1013 985
905
960
950
940
923
905
895
885
850
925
908
890
878
865
848
830
805
715
705
695
678
660
650
640
575
1310 1275 1240 1208 1175 1135 1095 1015
1235 1215 1195 1168 1140 1105 1070 985
1125 1110 1095 1085 1075 1060 1045 975
1075 1065 1055 1040 1025 1008 990
950
775
758
740
723
705
690
675
640
1150 1115 1085 1055 1025 980
940
875
1115 1085 1045 1020 995
955
920
855
1055 1040 1030 995
960
925
890
840
1005 995
985
965
945
905
860
825
710
700
690
665
645
615
585
545
1760 1740 1720 1710 1700 1688 1675 1655
1640 1623 1605 1593 1580 1573 1565 1535
1540 1523 1505 1493 1480 1470 1460 1420
1450 1435 1420 1403 1385 1373 1360 1310
1260 1245 1230 1213 1195 1175 1155 1040
1955 1940 1925 1920 1915 1910 1905 1880
1795 1785 1775 1770 1765 1755 1745 1715
1705 1698 1690 1683 1675 1655 1635 1600
1595 1583 1570 1560 1550 1530 1510 1475
1375 1358 1340 1320 1300 1275 1250 1170
2400 2390 2380 2365 2350 2335 2320 2295
2205 2195 2185 2168 2150 2133 2115 2085
2085 2065 2045 2033 2020 2005 1990 1960
1945 1935 1925 1908 1890 1873 1855 1825
1760 1743 1725 1705 1685 1665 1645 1600
2455 2438 2420 2405 2390 2363 2335 2325
2250 2233 2215 2200 2185 2168 2150 2115
2125 2100 2075 2060 2045 2030 2015 1980
1985 1965 1945 1930 1915 1898 1880 1850
1785 1765 1745 1728 1710 1683 1655 1615
Factory settings are in Bold
Air flow values are with dry coil and standard 1” filter
0.70
695
535
695
535
725
705
580
845
820
795
780
530
895
875
865
855
570
600
585
560
545
510
1635
1505
1380
1250
915
1845
1670
1555
1420
1060
2245
2045
1915
1780
1565
2280
2080
1945
1805
1580
5-Speed ECM Motor Connections
High Voltage
Connections
3/16 in.
C
C - Black
L
G
N
N - Brown
L - Orange
G - Green
G - Blue
Y1 - Red
22
1
2
3
4
Low Voltage
Connections 1/4 in.
5
AUX - Gray
0.80
640
640
735
720
775
770
750
730
510
495
475
465
455
1590
1460
1305
1135
875
1790
1620
1495
1350
995
2175
2005
1870
1745
1515
2215
2040
1905
1760
1530
0.90
1550
1395
1205
1055
1655
1540
1435
1265
930
2085
1975
1835
1690
1470
2120
1990
1860
1725
1475
1.00
1475
1300
1135
1010
1505
1360
1300
1180
875
2015
1930
1790
1645
1410
1995
1915
1820
1685
1300
10/15/15
RB SERIES INSTALLATION MANUAL
Setting Blower Speed - Variable Speed ECM
Variable Speed ECM Motor
Max
Model
ESP
Blower Motor
Size
hp
015
0.50
9x7
1/2
018
0.50
9x7
1/2
024
0.50
9x7
1/2
030
0.50
9x7
1/2
036
0.50
9x7
1/2
041
0.50
9x7
1/2
042
0.50
11 x 10
1/2
048
0.50
11 x 10
1/2
Air Flow Dip Switch Settings
1
2
3
4
5
6
300
400
L
400
L
400
L
400
500
600
M
600
M
600
M
600
700
H
700
H
700
800
300
500
500
400
500
L
500
400
500
500
600
500
600
700
L
700
600
800
700
M
700
600
L
600
700
L
1050
875
875
L
1300
1050
1000
L
600
800
1000
1300
070
0.75 11 x 10
1
L
Factory settings are at recommended L-M-H DIP switch locations
CFM is controlled within ±5% up to the maximum ESP
M-H settings MUST be located within boldface CFM range
060
0.75
11 x 10
1
1500
M
1500
7
8
9
800
H
800
900
1000
1100
900
1100
800
900
M
1050
M
1250
1000
H
1000
10
11
12
800
875
1150
M
1150
1750
1750
M
1250
1950
H
1950
1150
1325
1325
M
2100
2100
H
1100
H
1250
1375
H
1375
1200
1325
H
1475
1475
2200
2300
2200
2300
1375
1550
1550
H
1600
10/15/15
23
RB SERIES INSTALLATION MANUAL
Blower Performance Data cont.
Variable Speed ECM Setup with an AID Tool cont.
Setting Blower Speed - Variable Speed ECM
The ABC board’s Yellow Config LED will flash the current variable
speed ECM blower speed selections for low, med, 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 variable speed ECM blower motor speeds can be field
adjusted with or without using an AID Tool.
Selecting YES will enter variable
speed ECM speed setup, while
selecting NO will return to the previous
screen.
ECM SPEED INFO
LOW SPEED: 3
MED SPEED: 5
HIGH SPEED: 7
Variable Speed ECM Setup without an AID Tool
The blower speeds for Low (G only), Med (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 Variable Speed ECM Configuration Mode
portion of the Aurora ‘Base’ Control System section.
WANT TO CHANGE?
YES
OPTION ◀▶
NO
ENTER ◙
Variable Speed ECM Speed Setup - These screens allow
the technician to select the low, medium, and high blower speed for
the variable speed ECM blower motor. Change the highlighted item
using the ▲ and ▼ buttons. Press the ◙ button to select the speed.
Variable Speed 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 variable
speed ECM settings. It allows the technician to enter the setup
screens to change the variable speed ECM settings. Change the
highlighted item using the ◀ and ▶ buttons and then press the ◙
button to select the item.
ECM SPEED INFO
1
2 <– LOW
3
4
5
6
7
8
9
10
11
12
OPTION ◀▶
ECM SPEED INFO
1
2 LOW
3
4
5
<– MED
6
7
8
9
10
11
12
ENTER ◙
OPTION ◀▶
ECM SPEED INFO
1
2 LOW
3
4
5
MED
6
7
8
9
10
11
12
<– HIGH
ENTER ◙
OPTION ◀▶
After the high speed setting is selected the AID Tool will
automatically transfer back to the ECM Setup screen.
24
ENTER ◙
RB SERIES INSTALLATION MANUAL
5-Speed ECM Constant Torque Motors
Signal Connection - 1/4 in. quick connects - Common to C,
24VAC to Taps #1-5.
The 5-Speed ECM is a ‘Constant Torque’ ECM motor and delivers
airflow similar to a PSC but operates as efficiently as a Variable
Speed ECM motor. Because it’s an ECM motor, the 5-Speed
ECM can ramp slowly up or down like the Variable Speed ECM
motor. There are 5 possible speed taps available on the 5-Speed
ECM motor with #1 being the lowest airflow and #5 being the
highest airflow. These speed selections are preset at the time of
manufacture and are easily changed in the field if necessary.
Applying 24VAC power between any of the motor taps 1-5 (1/4
in. quick connects) and common will signal the motor to run and
regulate torque at the programmed level. The tap input voltage
must be in the range 12-33VAC. The 5-Speed ECM will have less
variation over the operating static pressure range versus a PSC
motor as well as a significant watts reduction due to the high motor
efficiency.
5-Speed ECM Benefits:
- High efficiency
- Soft start
- 5 speeds with up to 4 speeds on-line
- Built in logic allows air flow to change with G, Y1, Y2
and W signals
- Super efficient low airflow continuous blower
setting (G)
Thermal Protection - Motor is electronically protected.
Locked Rotor Amps - If motor speed decreases below a
programmed stall speed, the motor will shut down and after a
delay period, the control will attempt to restart the motor.
The 5-Speed ECM speed tap selections are as follows:
The blue wire should be placed on the speed tap desired for the (G)
continuous blower setting – factory wired to Tap 1.
If more than one tap are energized at the same time, built in logic
gives precedence to the highest tap number and allows air flow
to change with G, Y1, Y2 and W signals. Each of those 5 speeds
has a specific ‘Torque’ value programmed into the motor for each
speed selection. As static pressure increases, airflow decreases
resulting in less torque on the rotor. The motor responds only to
changes in torque and adjusts its speed accordingly.
The red wire should be placed on the speed tap desired during
compressor operation (Y1 signal) – factory wired to Tap 3 or 4.
The gray wire is not factory wired to the motor and is tied to the
wire harness. It is field connected and can be used with 3ht/2cl
thermostats or IntelliZone to deliver the required air flow for the Y2
signal.
The 5-Speed ECM motor is powered by line voltage but the motor
speed is energized by 24VAC.
The tan wire should be placed on the speed tap desired for
auxiliary heat (W signal) – factory wired to Tap 5.
Power Connection - 3/16 in. quick connects - Line 1 (orange wire)
to L, Ground (green wire) to G, Line 2 (for 208V-230V units) to N
(brown wire).
25
RB SERIES INSTALLATION MANUAL
Wiring Schematics
Aurora Base Control 208-230-265/60/1 with PSC
Compressor
S
PSC
Blower
Motor
C
Blue
R
Cap
Grn
Black
Red
Brn Wht
Unit Power Supply
208-230-265/60/1
G
Tan
Cap
P3
3 Airflow
Settings
H
M
T2
T1
CC
L2
L
Note 1
L1
White
Black
1
RB
3
Ground
Neutral
Disconnect
Green (93)
Black
Black (95)
L1
L1
Red (97)
L2
L2
L3
L3
Red
208V
Note 2
Blue
230V
265V
Black
Transformer
24V
Yellow
Black/White
470Ω
Resistor
HP
Black (10)
Black (09)
Blue (08)
CC2 CC2 CC2 P5
HI LO G
Blue (07)
F FG CC CCG
Yellow
R
Yellow
P9
Orange (02)
C
Orange (01)
F
LP
T
RV
CC
Black (15)
CC2
JW2
EH1
Violet (14)
White (12)
3
Black (13)
1
CC
RB
2
Red
(51)
Green
(50)
White
(52)
FD
470Ω
RV
Note 3
Isolation
Valve
REV REV FP1 FP1 FP2 FP2 LPS LPS HPS HPS P4
C
P2
R
K1-RV Relay
K5-Alarm
Relay
K3-CC2 Relay
ALG
K2-CC Relay
LS
ALM
K4-Fan Relay
ES
F1-3A
F
ACC COM
ACC NO
ACC NC
PWM
K6-Acc
Relay
Aurora Base Control
(ABC)
LO
R
SW1
Test Mode
CFM
Status
LED3
G
C
Red (53)
Note 3
Fault
LED1
R
C
O/B
G
FP1 – 15°F/30°F
FP2 – 15°F/30°F
RV – B/O
Acc – Dip 4
Acc – Dip 5
CC – Dual/Single
L Output Type
Future Use
Y1
Y2
W
DH
P1
RS485 NET
R
C
Com2
LED5
G
Com1
LED5
RS485 NET
P8
C
R
-
G
+ P7
Config
LED2
Y
RS485 EXP
C
R
-
+ P6 CO C EH1 C EH2 P3
Green
Brown (23)
Condensate
26
Y1
G
CC
P13
On
1
2
3
4
5
6
7
8
SW2
Off
Black/White
Yellow
RB SERIES INSTALLATION MANUAL
Wiring Schematics cont
Aurora Base Control 208-230-265/60/1 with PSC
97P817-12
01/14/2013
Notes:
1 – Optional, factory installed unit mounted disconnect.
2 – Swap blue and red leads for 208V operation.
3 – Optional, factory installed internal isolation valve.
Legend
Factory Low Voltage Wiring
Factory Line Voltage Wiring
Field Low Voltage Wiring
Field Line Voltage Wiring
Optional Block
DC Voltage PCB Traces
Field Zone Sensor Wiring
Internal Junction
Quick Connect Terminal
Relay Coil
Switch - Condensate Overflow
Switch - High pressure
Switch - Low pressure
Polarized connector
1
3
Field Wiring Lug
2
L1
Thermistor
T
Ground
G
Light Emitting Diode - Green
Capacitor
Y
Light Emitting Diode - Yellow
Fuse
R
Light Emitting Diode - Red
Relay Contacts – N.O., N.C.
CC – Compressor Contactor
CO – Condensate Overflow Sensor
ES – Emergency Shutdown
HP – High Pressure Switch
LP – Low Pressure Switch
FD – Freeze Detection Sensor
F1 – Fuse
Aurora LED Flash Codes
1 second on and 1 second off
100 milliseconds on and 100 milliseconds off
100 milliseconds on and 400 milliseconds off with a 2 second pause before repeating
Random Start Delay
Fast Flash
Status LED (LED1, Green)
Fast Flash
Configuration LED (LED2, Yellow)
Fast Flash
Fault LED (LED3, Red)
Configuration LED (LED2, Yellow)
Fault LED (LED3, Red)
Status LED (LED1, Green)
OFF
No Software Overide
Flash ECM Setting Normal Mode
Normal Mode
ON
Flash Code 1
DIP Switch Overide
Slow Flash
Input Fault Lockout
OFF
Control is Non-Functional
Flash Code 2
Fast Flash
High Pressure Lockout
Test Mode
Slow Flash ECM Configure Mode
Flash Code 3
Off
Low Pressure Lockout
Fast Flash Reset Configure Mode
Lockout Active
Flash Code 4
Low Air Coil Limit Lockout - FP2
Flash Code 2
Dehumidification Mode
Low Water Coil Limit Lockout - FP1 Flash Code 5
Flash Code 3
Reserved
Flash Code 6
Reserved
Flash Code 4
Reserved
Flash Code 7
Condensate Overflow Lockout
Flash Code 5
Load Shed
Flash Code 8
Over/Under Voltage Shutdown
ESD
Flash Code 6
Flash Code 9
Flash Code 7
Reserved
Reserved
Flash Code 10
Reserved
Air/Water Coil Limit Sensor Error
Flash Code 11
SW1 – Push button
SW2 – DIP package 8 position
RB – Blower Relay
RV – Reversing Valve Coil
FP1 – 15oF/30oF
On
1
R
FP2 – 15oF/30oF
2
P13
3
ACC – Dip 4
4
ACC – Dip 5
5
CC – Dual/Single
6
LED3
G
L – Pulse/Continuous
7
Reheat/Normal
8
Status
AURORA BASE
CONTROL™
P5
Factory Use
Com1
Fan – K4
G
Com2
G
Acc – K6
G
P9
P7
(+)
(-)
R
P8
F
CC
(+)
(-)
R
C
C
P11
Alarm – K5
EH2
C
EH1
C
CO
N/A
P6
RS 485
CC Hi – K3
Factory
CC2
CC – K2
G
LO
HI
CCG
CC
FG
F
R
P3
SW2
RV – K1
Accessory Relay
Operation
SW2-4 SW2-5
On
On
Cycle with Blower
Off
Off
Cycle with Compressor
Off
On
Water Valve Slow Open
Off
On
Outdoor Air Damper
EH1
Y
Config
RS485 Exp
SW1 Test
CC2
Y2
C
C
3A-Fuse
W
DH
DH
Y2
W
G
O/B
Y1
Y1
G
C
R
LO
O/B
Field Connections
P1
ACC nc
ACC no
ALG
ACC c
LS
ALM
Field Connections
P2
C
C
Factory Fan Connection
R
LO
Y1
JW2 Alarm
ES
Aurora Timing Events
Test Mode
Normal Mode
Event
5 to 80 seconds
1 second
Random Start Delay
5 seconds
< 1 second
Compressor On Delay
2 minutes
5 seconds
Compressor Minimum On Time
4 minutes
15 seconds
Compressor Short Cycle Delay
30 seconds
2 seconds
Blower Off Delay
Less than 1 second Less than 1 second
Fault Recognition Delay – High Pressure
2 minutes
30 seconds
Start-Up Bypass – Low Pressure
30 seconds
30 seconds
Fault Recognition Delay – Low Pressure
30 seconds
2 minutes
Start-Up Bypass – Low Water/Air Coil Limit
30 seconds
30 seconds
Fault Recognition Delay – Low Water/Air Coil Limit
30 seconds
30 seconds
Fault Recognition Delay – Condensate Overflow
2 seconds
2 seconds
Thermostat Call Recognition Time
5 minutes
20 seconds
Auxiliary Heat Staging Delay
2 minutes
7.5 seconds
Emergency Heat Staging Delay
90 seconds
90 seconds
Water Valve Slow Open Delay
30 seconds
30 seconds
Reheat Delay
RV – B/O
Fault
LED2
Factory
Off
LED1
ECM PWM
RS485 NET
P4
Factory
HP
HP
LP
LP
FP2
FP2
FP1
FP1
REV
REV
C
PWM
CFM
Slow Flash
Fast Flash
Flash Code
R
R
P
27
1
RB SERIES INSTALLATION MANUAL
Wiring Schematics cont.
Aurora Base Control 460/60/3 with ECM Motor
Compressor
T3
T1
Unit Power Supply
460/60/3 w/Neutral
G
T2
Red
Yellow
T3
Phase
Guard
Monitor
(PGM)
L1 L2 L3
Black
T2
T1
CC
L3
L2
Orange
PB3
Bro wn
N
Green (93)
Gray (94)
Black (54)
L1
Black (95)
L1
L1
Blue (55)
L2
Yellow (96)
L2
L2
Red (56)
L3
Red (97)
L3
L3
L1
Ground
Neutral
Disconnect
Black (7)
White (8)
Red (9)
Black (54)
Blue (55)
Red (56)
Blue
460V
Black
Orange
Brown
Green
Transfo rmer
PGM
Y-OUT
24V
Y
Yellow
1
Black/White
2
3
4
5
P11
C
Black/White (92)
ECM2
Fan Mo tor
Dual
Capacity
Units Only
470Ÿ
Resistor
Ultra Tech
Black (10)
Black (09)
Blue (08)
Blue (07)
Yellow
Blue(18)
CC2 CC2 CC2 P5
F FG CC CCG
HI LO G
R
Yellow
C
Orange (02)
F
Orange (01)
CC
HP
T
RV
Black (15)
Violet (14)
CC2
JW2
EH1
12 15 10 16 1 3
LP
RCP
Blue(16)
P9
FD
470Ÿ
RV
CS
CC
Red
(51)
Green
(50)
White
(52)
R
G
PWM
CFM
C1
C2
Yellow (91)
REVREV FP1 FP1 FP2 FP2 LPS LPS HPSHPS P4
C
P2
R
ACC NC
K6-Acc
Relay
K1-RV Relay
ACC NO
K3-CC2 Relay
ALG
ACC COM
K5-Alarm
Relay
K2-CC Rel ay
LS
ALM
K4-Fan Relay
ES
Test Mode
Status
LED3
G
Red (53)
Note 2
FP1 – 15°F/30°F
FP2 – 15°F/30°F
RV – B/O
Acc – Dip 4
Acc – Dip 5
CC – Dual/Single
L Output Type
Future Use
Y1
Y2
W
DH
RS485 NET
R
C
Com1
LED5
Com2
LED5
G
RS485 NET
P8
C
R
-
G
+ P7
Config
LED2
Y
RS485 EXP
C
R
-
+ P6 CO C EH1 C EH2 P3
Green
Bro wn (23)
Condensate
28
Y1
G
CC
PWM
Blue (24)
CFM
Yellow (25)
C
P13
Faul t
LED1
R
O/B
G
P1
Yellow
Violet (42)
F
SW1
Aurora Base Control
(ABC)
LO
R
C
F1-3A
Black/White
On
1
2
3
4
5
6
7
8
SW2
Off
Green/Yellow (28)
P12
RB SERIES INSTALLATION MANUAL
Wiring Schematics cont.
Aurora Base Control 460/60/3 with ECM Motor
Notes:
Legend
1 – Optional, factory installed unit mounted disconnect.
2 – Optional, factory installed internal isolation valve.
3 – Optional, factory installed phase guard
4 – Optional, factory installed phase guard. The yellow transformer wire
shall be connected directly to the CPU board, if this option is not installed.
Factory Low Voltage Wiring
Factory Line Vol tage Wiring
Field Low Voltage Wiring
Fi eld Li ne Voltage Wi ri ng
Optional Block
DC Voltage PCB Traces
Field Zone Sensor Wiring
Internal Ju nction
Qui ck Con nect Terminal
Relay Coi l
Switch - Condensate Overfl ow
Switch - High pressure
Switch - Low pressure
1
3
Field Wiring Lug
2
L1
Thermistor
T
Polarized connector
Ground
Relay Con tacts – N.O., N.C.
Capacitor
Fuse
CC – Compressor Contactor
CO – Condensate Overfl ow Sensor
ES – Emergency Shutdown
HP – High Pressure Switch
LP – Low Pressure Switch
FD – Freeze De tecti on Sensor
F1 – Fuse
G
Light Emitting Diode - Green
Y
Light Emitting Diode - Yellow
R
Light Emitti ng Diode - Red
SW1 – Push button
SW2 – DIP package 8 position
RB – Blower Relay
RV – Reversi ng Valve Coi l
PGM – Phase Guard Moni tor
RH – Reheat Valve Coil
Aurora LED Flash Codes
1 second on and 1 second off
100 milliseconds on and 100 milliseconds off
100 milliseconds on and 400 milliseconds off with a 2 second pause before repe ating
Random Start Delay
Fast Fl ash
Status LED (LED1, Green)
Fast Fl ash
Configuration LED (LED2, Yellow)
Fast Fl ash
Faul t LED (LED3, Red)
Configuration LED (LED2, Yellow)
Fault LED (LED3, Red)
Sta tus LED (LED1, Green)
No Software Overi de
Fl ash ECM Settin g Normal Mode
OFF
ON
Normal Mode
DIP Switch Overide
Slow Flash
Input Fault Lockout
Flash Code 1
Control is Non-Functional
OFF
Slow Flash ECM Configu re Mod e
Fl ash Code 2
Test Mode
Fast Fl ash
High Pressure Lockout
Fast Flash Reset Confi gure Mode
Fl ash Code 3
Off
Low Pressure Locko ut
Lockout Active
Low Air Coil Limit Lockout - FP2
Fl ash Code 4
Fl ash Code 2
Dehumidification Mo de
Low Water Coil Limi t Lockout - FP1 Flash Code 5
Fl ash Code 3
Reserved
Reserved
Fl ash Code 6
Fl ash Code 4
Reserved
Flash Code 5
Condensate Overflow Lockout
Fl ash Code 7
Load Shed
Over/Under Voltage Shutdown
Fl ash Code 8
Fl ash Code 6
ESD
Flash Code 7
Reserved
Fl ash Code 9
Reserved
Fl ash Code 10
Reserved
Fl ash Code 11
Air/Water Coil Limit Sensor Error
On
1
R
FP2 – 15oF/30oF
2
P13
3
ACC – Dip 4
4
ACC – Dip 5
5
CC – Dual/Single
6
Faul t
G
L – Pulse/Continuous
7
Reheat/Normal
8
Status
AURORA BASE
CONTROL™
CC Hi – K3
G
P11
Alarm – K5
P8
F
Com2
Acc – K6
G
(+)
(-)
R
C
RS 485
Fan – K4
CC
EH2
C
EH1
C
CO
N/A
P7
Com1
Factory Use
Factory
CC2
P3
P6
CC2
P5
Config
SW2
RV – K1
G
LO
HI
CCG
CC
FG
F
R
EH1
Y
RS485 Exp
Factory
LED3
SW1 Test
CC – K2
P9
G
Y2
C
C
3A-Fuse
W
DH
DH
Y2
W
G
O/B
Y1
Y1
G
R
LO
O/B
Fi eld Connections
P1
ACC nc
ACC no
ALG
ACC c
LS
ALM
Fi eld Connections
P2
C
C
Factory Fan Connection
R
LO
Y1
JW2 Alarm
ES
Aurora Timing Events
Test Mode
Normal Mode
Event
5 to 80 seconds
1 second
Random Start Delay
5 seconds
< 1 second
Compressor On Delay
2 minutes
5 seconds
Compressor Minimum On Time
4 minutes
15 seconds
Compressor Short Cycl e Delay
30 seconds
2 seconds
Blower Off Delay
Less than 1 second Less than 1 second
Faul t Recogn itio n Delay – High Pressure
2 minutes
30 seconds
Start-Up Bypass – Low Pressure
30 seconds
30 seconds
Fault Recogn itio n Delay – Low Pressure
30 seconds
2 minutes
Start-Up Bypass – Low Water/Air Coil Limit
30 seconds
30 seconds
Faul t Recogn itio n Delay – Low Water/Air Coil Limit
30 seconds
30 seconds
Faul t Recogn itio n Delay – Condensate Overfl ow
2 seconds
2 seconds
Thermostat Call Recognition Time
5 minutes
20 seconds
Auxi liary Heat Stagi ng Del ay
2 minutes
7.5 seconds
Emergency Heat Stagi ng Dela y
90 seconds
90 seconds
Water Valve Slow Open Delay
30 seconds
30 seconds
Reheat Delay
RV – B/O
LED2
Factory
FP1 – 15oF/30oF
RS485 NET
P4
Off
LED1
ECM PWM
C
Accessor y Relay
Operation
SW2-4 SW2-5
On
On
Cycl e with Blower
Off
Off
Cycl e with Compressor
On
Off
Water Valve Slow Open
Off
On
Outdoor Air Damper
HP
HP
LP
LP
FP2
FP2
FP1
FP1
REV
REV
C
PWM
CFM
Slow Flash
Fast Flash
Flash Code
R
R
Page 1
29
RB SERIES INSTALLATION MANUAL
Controls - Aurora Base Control
Aurora ‘Base’ Control
Field Selectable Options via Hardware
DIP Switch (SW1) – Test/Configuration Button (See SW1
Operation Table)
Test Mode
The control is placed in the test mode by holding the push
button switch SW1 for 2 - 5 seconds. In test mode most of
the control timings will be shortened by a factor of sixteen
(16). LED3 (green) will flash at 1 second on and 1 second
off. Additionally, when entering test mode LED1 (red) will
flash the last lockout one time. Test mode will automatically
time out after 30 minutes. Test mode can be exited by
pressing and holding the SW1 button for 2 to 5 seconds or
by cycling the power. NOTE: Test mode will automatically
be exited after 30 minutes.
NOTE: Refer to the Aurora Base Control Application and
Troubleshooting Guide and the Instruction Guide: Aurora
Interface and Diagnostics (AID) Tool for additional information.
Control Features
Software ABC Standard Version 3.0
Single or Dual Capacity Compressors
Variable Speed ECM Configuration Mode
(If Applicable)
Either single or dual capacity compressors can be operated.
The control is placed in the ECM configuration mode by
holding the pushbutton switch SW1 for 5 to 10 seconds, the
high, low, and “G” ECM speeds can be selected by following
the LED display lights. LED2 (yellow) will fast flash when
entering the ECM configuration. When setting “G” speed
LED3 (green) will be continuously lit, for low speed LED1
(red) will be continuously lit, and for high speed both LED3
(green) and LED1 (red) will be continuously lit. During the
ECM configuration mode LED2 (yellow) will flash each of
the 12 possible blower speeds 3 times. When the desired
speed is flashed press SW1, LED2 will fast flash until SW1
is released. “G” speed has now been selected. Next select
low speed, and high speed blower selections following the
same process above. After third selection has been made,
the control will exit the ECM configuration mode. Aux fan
speed will remain at default or current setting and requires
the AID Tool for adjustment.
Variable Speed ECM
Blower Motor Option (If Applicable)
A Variable Speed ECM blower motor can be driven directly
using the onboard PWM output. Four blower speeds are
available based upon the G, Y1, Y2, and W input signals to
the board. The blower speeds can be changed either by the
ECM manual configurations mode method or by using the
Aurora AID Tool directly. All four blower speeds can be set
to the same speed if desired.
5-Speed ECM Blower Motor Option (If Applicable)
A 5-Speed ECM blower motor will be driven directly using
the thermostat connections. Any of the G, Y1, or Y2/W
signals can drive any of the 5 available pre-programmed
blower speeds on the motor. All 5 Series "G" vintage units
will be wired this way at the factory.
Reset Configuration Mode
The control is placed in reset configuration mode by
holding the push button switch SW1 for 50 to 60 seconds.
This will reset all configuration settings and the EEPROM
back to the factory default settings. LED3 (green) will turn
off when entering reset configuration mode. Once LED3
(green) turns off, release SW1 and the control will reset.
Other Control Features
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Random start at power up
Anti-short cycle protection
High and low pressure cutouts
Loss of charge
Water coil freeze detection
Air coil freeze detection
Over/under voltage protection
Condensate overflow sensor
Load shed
Dehumidification (where applicable)
Emergency shutdown
Hot gas reheat operation (where applicable)
Diagnostic LED
Test mode push button switch
Two auxiliary electric heat outputs
Alarm output
Accessory output with N.O. and N.C.
Modbus communication (master)
Modbus communication (slave)
DIP Switch (SW2)
SW2-1
FP1 Selection – Low water coil temperature limit
setting for freeze detection. On = 30°F; Off = 15°F.
SW2-2 FP2 Selection – On = 30°F; Off = N/A
SW2-3 RV – O/B - thermostat type. Heat pump
thermostats with “O” output in cooling or “B”
output in Heating can be selected. On = O; Off = B.
SW2-4 Access Relay Operation (P2)
and 2-5
Access Relay Operation
Cycle with Blower
Cycle with Compressor
Water Valve Slow Opening
Cycle with Comm. T-stat Hum Cmd
30
SW2-4
ON
OFF
ON
OFF
SW2-5
ON
OFF
OFF
ON
RB SERIES INSTALLATION MANUAL
Controls - Aurora Base Control cont.
Cycle with Blower - The accessory relay will cycle with
the blower output.
Lockout – when locked out, the blower will operate
continuously in “G” speed, and PSC blower motor output
will remain on. The Alarm output (ALM) and Lockout output
(L) will be turned on. The fault type identification display
LED1 (Red) shall flash the fault code. To reset lockout
conditions with SW2-8 On, thermostat inputs “Y1”, “Y2”,
and “W” must be removed for at least 3 seconds. To reset
lockout conditions with SW2-8 Off, thermostat inputs “Y1”,
“Y2”, “W”, and “DH” must be removed for at least 3 seconds.
Lockout may also be reset by turning power off for at least
30 seconds or by enabling the emergency shutdown input
for at least 3 seconds.
Cycle with Compressor - The accessory relay will cycle
with the compressor output.
Water Valve Slow Opening - The accessory relay will
cycle and delay both the blower and compressor output
for 90 seconds.
SW2-6 CC Operation – selection of single or dual capacity
compressor. On = Single Stage; Off = Dual Capacity
SW2-7 Lockout and Alarm Outputs (P2) – selection of a
continuous or pulsed output for both the LO and
ALM Outputs. On = Continuous; Off = Pulsed
SW2-8 Future Use
Lockout With Emergency Heat - if the control is locked out
in the heating mode, and a Y2 or W input is received, the
control will operate in the emergency heat mode while the
compressor is locked out. The first emergency heat output will
be energized 10 seconds after the W input is received, and the
blower will shift to high speed. If the control remains locked
out, and the W input is present, additional stage of emergency
heat will stage on after 2 minutes. When the W input is
removed, all of the emergency heat outputs will turn off, and
the ECM blower will shift to “G” speed and PSC blower motor
output will remain on.
Alarm Jumper Clip Selection
From the factory, ALM is connected to 24 VAC via JW2. By
cutting JW2, ALM becomes a dry contact connected to ALG.
Variable Speed ECM Blower Speeds
The blower speeds can be changed either by using the
ECM manual configurations mode method or by using the
Aurora AID Tool directly (see Instruction Guide: Aurora
Interface and Diagnostics (AID) Tool topic).
High Pressure – fault is recognized when the Normally
Closed High Pressure Switch, P4-9/10 opens, no matter
how momentarily. The High Pressure Switch is electrically in
series with the Compressor Contactor and serves as a hardwired limit switch if an overpressure condition should occur.
Field Selectable Options via Software
(Selectable via the Aurora AID Tool)
ECM Blower Speeds
Low Pressure - fault is recognized when the Normally
Closed Low Pressure Switch, P4-7/8 is continuously open
for 30 seconds. Closure of the LPS any time during the 30
second recognition time restarts the 30 second continuous
open requirement. A continuously open LPS shall not be
recognized during the 2 minute startup bypass time.
An ECM blower motor can be driven directly using the
onboard PWM output. Four blower speeds are available,
based upon the “G”, Y1 (low), Y2 (high), and Aux input
signals to the board. The blower speeds can be changed
either by the ECM manual configurations mode method (see
ECM Configuration Mode topic) or by using the Aurora AID
Tool directly. All four blower speeds can be set to the same
speed if desired. Aux blower speed will remain at default or
current setting and requires the AID Tool for adjustment.
Loss of Charge – fault is recognized when the Normally
Closed Low Pressure Switch, P4-7/8 is open prior to the
compressor starting.
Condensate Overflow - fault is recognized when the
impedance between this line and 24 VAC common or chassis
ground drops below 100K ohms for 30 seconds continuously.
Safety Features
The following safety features are provided to protect the
compressor, heat exchangers, wiring and other components
from damage caused by operation outside of design conditions.
Freeze Detection (Coax) - set points shall be either 30°F
or 15°F. When the thermistor temperature drops below
the selected set point, the control shall begin counting
down the 30 seconds delay. If the thermistor value rises
above the selected set point, then the count should reset.
The resistance value must remain below the selected set
point for the entire length of the appropriate delay to be
recognized as a fault. This fault will be ignored for the initial
2 minutes of the compressor run time.
Fuse – a 3 amp automotive type plug-in fuse provides
protection against short circuit or overload conditions.
Anti-Short Cycle Protection – 4 minute anti-short cycle
protection for the compressor.
Random Start – 5 to 80 second random start upon power up.
Fault Retry – in the fault condition, the control will stage off
the outputs and then “try again” to satisfy the thermostat
Y input call. Once the thermostat input calls are satisfied,
the control will continue on as if no fault occurred. If 3
consecutive faults occur without satisfying the thermostat
Y input call, then the control will go to Lockout mode.
Freeze Detection (Air Coil) - uses the FP2 input to protect
against ice formation on the air coil. The FP2 input will
operate exactly like FP1 except that the set point is 30
degrees and is not field adjustable.
31
RB SERIES INSTALLATION MANUAL
Controls - Aurora Base Control cont.
Over/Under Voltage Shutdown - An over/under voltage
condition exists when the control voltage is outside the
range of 18 VAC to 30 VAC. If the over/under voltage
shutdown lasts for 15 minutes, the lockout and alarm relay
will be energized. Over/under voltage shutdown is selfresetting in that if the voltage comes back within range
of 18 VAC to 30 VAC for at least 0.5 seconds, then normal
operation is restored.
Cooling Operation
In all cooling operations, the reversing valve directly tracks
the O input. Thus, anytime the O input is present, the
reversing valve will be energized.
Single Compressor Cooling, 2nd Stage (Y1, Y2, 0)
The compressor will be staged to full capacity 20 seconds
after Y2 input was received. The ECM blower will shift to high
speed 15 seconds after the Y2 input was received.
Operation Description
Dual Compressor Cooling, 2nd Stage (Y1, Y2, O)
In dual compressor operation, two ABC boards used in 24
VAC operation, there will be a Y2 call to the Y1 input on the
second ABC. The compressor will stage to full capacity 30
seconds after Y1 input is received to the second board.
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.
Blower (G) - The blower will start immediately upon
receiving a thermostat G command. If there are no other
commands from the thermostat the ECM will run on “G”
speed until the G command is removed. Regardless of
blower input (G) from the thermostat, the blower will
remain on for 30 seconds at the end of each heating,
cooling, and emergency heat cycle.
Standby In standby mode, Y1, Y2, W, DH, and G are not
active. Input O may be active. The blower and compressor
will be off.
Heating Operation
Single Compressor Heating, 2nd Stage (Y1, Y2)
The compressor will be staged to full capacity 20 seconds
after Y2 input is received. The ECM blower will shift to high
speed seconds after the Y2 input is received.
Dehumidification (Y1, O, DH or Y1, Y2, O, DH) - When a
DH command is received from the thermostat during a
compressor call for cooling the ECM blower speed will be
reduced by 15% to increase dehumidification.
Dual Compressor Heating, 2nd Stage (Y1, Y2)
In dual compressor operation, two ABC boards used in 24
VAC operation, there will be a Y2 call to the Y1 input on the
second ABC. The compressor will stage to full capacity 30
seconds after Y1 input is received to the second board.
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.
Single Compressor Heating, 3rd Stage (Y1, Y2, W)
The hot water pump is de-energized and the first stage of
electric heat is energized 10 seconds after the W command
is received. If the demand continues the second stage of
electric heat will be energized after 5 minutes.
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.
Dual Compressor Heating, 3rd Stage (Y1, Y2, W) The first stage of electric heat is energized 10 seconds
after the W command is received. If the demand continues
the second stage of electric heat will be energized after 5
minutes
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.
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.
Blower (G) - The blower will start immediately upon
receiving a thermostat G command. If there are no other
commands from the thermostat the ECM will run on “G”
speed until the G command is removed. Regardless of
blower input (G) from the thermostat, the blower will
remain on for 30 seconds at the end of each heating cycle.
32
RB SERIES INSTALLATION MANUAL
Controls - Aurora Base Control cont.
Aurora ‘Base’ Control LED Displays
Aurora Interface and Diagnostics (AID) Tool
These three LEDs display the status, configuration, and
fault codes for the control. These can also be read in plain
English via the Aurora AID Tool.
The Aurora Interface and
Diagnostics (AID) Tool is
a device that is a member
of the Aurora network.
The AID Tool is used to
troubleshoot equipment
which uses the Aurora
control via Modbus RTU
communication. The AID
Tool provides diagnostics,
fault management, ECM
setup, and system configuration capabilities to the Aurora
family of controls. An AID Tool is recommended, although
not required, for ECM airflow settings. The AID Tool simply
plugs into the exterior of the cabinet in the AID Tool port.
Status LED (LED3, Green)
Description of Operation
Normal Mode
Control is Non-functional
Test Mode
Lockout Active
Dehumidification Mode
(Future Use)
(Future Use)
Load Shed
ESD
(Future Use)
Fault LED, Green
ON
OFF
Slow Flash
Fast Flash
Flash Code 2
Flash Code 3
Flash Code 4
Flash Code 5
Flash Code 6
Flash Code 7
ABC Control Board Layout
FP2 – 15 F/30 F
2
RV – B/O
3
ACC – Dip 4
4
ACC – Dip 5
5
CC – Dual/Single
6
LED3
G
L – Pulse/Continuous
7
Reheat/Normal
8
Status
G
Factory Use
Com1
Fan – K4
Com2
P9
C
C
Y2
C
3A-Fuse
W
DH
DH
Y2
W
G
Y1
Y1
G
O/B
C
R
LO
O/B
C
Field Connections
P1
ACC nc
ACC c
ACC no
LS
ALG
Field Connections
P2
ES
33
Factory Fan Connection
R
LO
Y1
JW2 Alarm
G
Acc – K6
G
(+)
(-)
R
C
P8
P11
Alarm – K5
F
CC
EH2
C
EH1
C
CO
N/A
P7
CC Hi – K3
Factory
CC2
P3
AURORA BASE
CONTROL™
CC – K2
ABC Basic Faults
Config
P6
CC2
P5
EH1
Y
SW2
RV – K1
G
LO
HI
CCG
CC
FG
F
R
LED2
Factory
C
1
R
o
o
Faul t
SW1 Test
On
FP1 – 15oF/30oF
RS485 Exp
LED Flash
Reset/
Lockout
Code*
Remove
Normal - No Faults
OFF
–
Fault - Input
1
No
Auto
Fault - High Pressure
2
Yes
Hard or Soft
Fault - Low Pressure
3
Yes
Hard or Soft
Fault - Freeze Detection FP2
4
Yes
Hard or Soft
Fault - Freeze Detection FP1
5
Yes
Hard or Soft
Fault - Condensate Overflow
7
Yes
Hard or Soft
Fault - Over/Under Voltage
8
No
Auto
Fault - FP1 & FP2 Sensor Error
11
Yes
Hard or Soft
NOTE: All codes >11 use long flash for tens digit and short flash for the ones
digit. 20, 30, 40, 50, etc. are skipped.
Red Fault LED
P13
Off
LED1
ECM PWM
RS 485
Fault LED (LED1, Red)
P4
RS485 NET
HP
HP
LP
LP
FP2
FP2
FP1
FP1
REV
REV
Factory
Configuration LED, Yellow
Flashing ECM Setting
Slow Flash
Fast Flash
ALM
Description of Operation
No Software Overwritten
DIP Switch was Overwritten
ECM Configuration Mode
PWM
CFM
Configuration LED (LED2, Yellow)
R
R
RB SERIES INSTALLATION MANUAL
Unit Startup
Before Powering Unit, Check The Following:
NOTE: Remove and discard the compressor shipping bolts. The bolts can then be discarded.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
High voltage is correct and matches nameplate.
Fuses, breakers and wire size correct.
Low voltage wiring complete.
Piping completed and water system cleaned and flushed.
Air is purged from closed loop system.
Isolation valves are open, water control valves or loop pumps wired.
Condensate line open and correctly pitched.
Transformer switched to 208V if applicable.
Dip switches are set correctly.
Blower rotates freely – foam shipping support has been removed.
Blower speed correct.
Air filter/cleaner is clean and in position.
Service/access panels are in place.
Return air temperature is between 50-80°F heating and 60-95°F cooling.
Check air coil cleanliness to insure optimum performance. Clean as needed according to maintenance guidelines. To
obtain maximum performance the air coil should be cleaned before startup. A 10-percent solution of dishwasher
detergent and water is recommended for both sides of coil, a thorough water rinse should follow.
Startup Steps
NOTE: Complete the Equipment Start-Up/Commissioning Check Sheet during this procedure. Refer to thermostat operating instructions
and complete the startup procedure.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Initiate a control signal to energize the blower motor. Check blower operation.
Initiate a control signal to place the unit in the cooling mode. Cooling setpoint must be set below room temperature.
Cooling will energize after a time delay. Check for correct rotation of scroll compressors in 3 phase applications. Incorrect rotation will
compressor or contactor to reverse rotation.
Be sure that the compressor and water control valve or loop pump(s) are activated.
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 the pressure drop table.
Check the temperature of both the supply and discharge water (Refer to Operating Parameters tables).
Check for an air temperature drop of 15°F to 25°F across the air coil, depending on the blower speed and entering water temperature.
Decrease the cooling set point several degrees and verify high-speed blower operation (Variable Speed ECM only).
Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop pumps deactivate.
Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature.
Heating will energize after a time delay.
Check the temperature of both the supply and discharge water (Refer to Unit Operating Parameters tables).
Check for an air temperature rise of 20°F to 35°F across the air coil, depending on the blower speed and entering water temperature.
If auxiliary electric heaters are installed, increase the heating setpoint until the electric heat banks are sequenced on. All stages of the
auxiliary heater should be sequenced on when the thermostat is in the Emergency Heat mode. Check amperage of each element.
Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps deactivate.
During all testing, check for excessive vibration, noise or water leaks. Correct or repair as required.
Set system to desired normal operating mode and set temperature to maintain desired comfort level.
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.
34
RB SERIES INSTALLATION MANUAL
Operating Parameters
Entering Water
Temp °F
Water Flow gpm/
ton
1.5
3.0
1.5
3.0
1.5
3.0
1.5
3.0
2.3
3.0
30
50
70
90
110
Entering Water
Temp °F
Water Flow gpm/
ton
30
50
70
90
110
1.5
3.0
1.5
3.0
1.5
3.0
1.5
3.0
2.3
3.0
Cooling
Suction
Pressure psig
100-115
95-110
133 - 148
129 - 144
139 - 154
137 - 152
143 - 158
141 - 156
143 - 158
141 - 156
Discharge
Pressure psig
170-190
150-170
205 - 225
185 - 205
280 - 300
250 - 270
360 - 380
330 - 350
360 - 380
440-460
Suction
Pressure psig
73 - 79
79 - 85
103 - 109
110 - 116
140 - 146
146 - 153
170-177
174-181
Discharge
Pressure psig
279 - 304
285 - 310
308 - 333
315 - 340
330 - 365
340 - 375
425-460
435-470
Superheat
Subcooling
17 - 26
20 - 29
17 - 26
20 - 29
8 - 11
9 - 12
8 - 11
9 - 12
8 - 11
9 - 12
10 - 14
7 - 11
10 - 14
7 - 11
8 -12
7 - 11
9 - 13
8 - 12
9 - 13
8 - 12
Water Temp
Rise °F
18 - 22
8 - 10
18 - 22
8 - 10
18 - 22
8 - 10
18 - 22
8 - 10
18 - 22
8 - 10
Air Temp Drop
°F DB
18 - 22
18 - 22
18 - 22
18 - 22
18 - 22
18 - 22
16 - 20
16 - 20
16 - 20
16 - 20
Water Temp
Drop °F
7 -10
3-6
8 - 11
4-7
11 - 14
7 - 10
8-11
8-11
Air Temp Rise
°F DB
18 - 24
20 - 26
20 - 26
22 - 28
26 - 32
28 - 34
42-50
42-50
Heating
Superheat
Subcooling
7 - 13
8 - 14
8 - 12
9 - 13
10 - 14
10 - 14
14-18
14-18
2-6
2-6
4-8
4-8
7 - 11
7 - 11
12-16
12-16
NOTES: Cooling performance based on entering air temperatures of 80°F DB, 67°F WB.
Heating performance based on entering air temperature of 70°F DB.
5/1/11
Operating Limits
Operating Limits
Air Limits
Min. Ambient Air
Rated Ambient Air
Max. Ambient Air
Min. Entering Air
Rated Entering Air db/wb
Max. Entering Air db/wb
Water Limits
Min. Entering Water
Normal Entering Water
Max. Entering Water
Cooling
Heating
(°F)
(°C)
(°F)
(°C)
45
80
100
50
80.6/66.2
110/83
7.2
26.7
37.8
10.0
27/19
43/28.3
45
70
85
40
68
80
7.2
21.1
29.4
4.4
20.0
26.7
30
50-110
120
-1.1
10-43.3
48.9
20
30-70
90
-6.7
-1.1
32.2
NOTE: Minimum/maximum limits are only for start-up conditions, and are meant
for bringing the space up to occupancy temperature. Units are not designed to
operate at the minimum/maximum conditions on a regular basis. The operating
limits are dependant upon three primary factors: 1) water temperature, 2) return
air temperature, and 3) ambient temperature. When any of the factors are at the
minimum or maximum levels, the other two factors must be at the normal level for
proper and reliable unit operation.
35
RB SERIES INSTALLATION MANUAL
Pressure Drop
Model
006
009
012
015
018
024
030
036
041
042
048
060
070
GPM
1.0
1.5
2.0
2.5
1.5
2.0
3.0
4.0
1.5
2.5
3.5
4.5
2.0
3.0
4.0
5.0
3.0
4.0
5.0
6.0
3.0
4.5
6.0
8.0
4.0
6.0
8.0
10.0
5.0
7.0
9.0
12.0
5.0
8.0
11.0
14.0
5.0
8.0
11.0
14.0
6.0
9.0
12.0
16.0
9.0
12.0
15.0
20.0
12.0
15.0
18.0
24.0
Pressure Drop (psi)
30°F
50°F
70°F
90°F
110°F
1.2
2.2
3.3
4.1
1.9
3.0
6.3
8.1
1.1
2.4
4.2
6.1
1.8
3.3
5.0
7.1
3.3
4.7
6.2
7.7
3.2
6.1
9.0
12.9
2.4
5.1
7.8
10.5
2.0
3.6
5.2
7.5
1.5
3.4
7.9
9.1
2.1
4.8
7.5
10.1
2.7
6.0
9.5
14.2
4.5
6.5
8.6
12.1
5.7
8.9
12.0
17.4
1.2
2.0
3.1
3.8
1.7
2.8
6.3
7.9
1.1
2.3
4.0
5.9
1.7
3.1
4.9
6.7
3.2
4.2
5.2
6.2
3.1
5.5
7.9
10.9
2.3
4.9
7.5
10.1
1.9
3.5
5.1
7.4
1.2
3.1
7.5
8.8
2.0
4.7
7.4
9.9
2.6
5.9
9.3
13.9
4.4
6.3
8.1
11.2
5.6
8.6
11.5
16.9
1.1
1.9
2.9
3.4
1.5
2.6
6.1
7.4
1.0
2.2
3.7
5.2
1.6
2.9
4.8
5.9
3.0
3.9
4.7
5.4
2.9
4.9
6.9
9.5
2.2
4.7
7.1
9.6
1.7
3.3
4.8
7.1
0.9
2.8
7.2
8.5
1.8
4.5
7.0
9.6
2.4
5.4
8.5
12.7
4.2
6.1
7.9
10.8
5.4
8.2
11.0
16.5
1.0
1.8
2.7
3.1
1.3
2.4
5.9
6.8
0.9
2.0
3.4
4.7
1.4
2.6
4.7
5.4
2.8
3.6
4.1
4.6
2.7
4.5
6.3
8.8
2.0
4.5
6.9
9.3
1.5
3.1
4.6
6.9
0.5
2.5
6.9
8.2
1.6
4.4
6.6
8.8
2.2
5.2
8.3
12.3
4.0
5.9
7.7
10.6
5.2
7.7
10.1
15.1
1.0
1.7
2.5
2.9
1.1
2.2
5.7
6.1
0.9
1.9
3.2
4.1
1.2
2.3
4.6
5.1
2.6
3.1
3.5
3.8
2.5
4.2
5.8
7.9
1.8
4.3
6.7
8.9
1.4
2.9
4.4
6.7
0.4
2.1
6.6
7.9
1.4
4.2
6.1
8.1
2.0
5.1
8.1
12.1
3.8
5.7
7.5
10.4
5.0
6.7
8.4
11.8
Valve
GPM
Cv
Pressure
Drop (psi)
Internally mounted 2-position solenoid water valves are not
available on models 006-012
1/2”
1/2”
3/4”
3/4”
3/4”
3.0
4.0
5.0
6.0
3.0
4.0
5.0
6.0
3.0
4.5
6.0
8.0
4.0
6.0
8.0
10.0
5.0
7.0
9.0
12.0
9.9
10.1
10.4
10.6
9.9
10.1
10.4
10.6
9.9
10.2
10.6
11.0
10.1
10.6
11.0
11.5
10.4
10.8
11.2
11.9
0.09
0.16
0.23
0.32
0.09
0.16
0.23
0.32
0.09
0.19
0.32
0.53
0.16
0.32
0.53
0.76
0.23
0.42
0.64
1.02
N/A
3/4”
3/4”
1”
1”
10/15/15
5.0
8.0
11.0
14.0
6.0
9.0
12.0
16.0
9.0
12.0
15.0
20.0
12.0
15.0
18.0
24.0
10.4
11.0
11.7
12.3
10.6
11.2
11.9
12.8
16.8
17.4
18.1
19.2
17.4
18.1
18.7
20.1
0.23
0.53
0.89
1.29
0.32
0.64
1.02
1.57
0.29
0.47
0.69
1.09
0.47
0.69
0.92
1.43
10/15/15
36
RB SERIES INSTALLATION MANUAL
Compressor and Thermistor Resistance
Compressor Resistance
Model
006
009
012
015
018
024
030
036
042
048
060
070
115/60/1
Run
Start
1.25-1.43
2.70-3.10
0.77-0.89
1.79-2.05
Not Available at Time of Publication
208-230/60/1
Run
Start
5.30-6.09
5.12-5.89
3.65-4.19
3.75-4.31
3.35-3.85
2.80-3.22
2.74-3.16
2.60-3.00
2.24-2.58
2.84-3.26
1.36-1.50
2.26-2.50
0.93-1.03
1.64-1.82
0.60-0.66
1.20-1.32
0.49-0.55
1.56-1.73
0.51-0.57
1.58-1.74
0.43-0.48
1.33-1.47
0.35-0.40
1.34-1.54
265/60/1
Run
Start
8.33-9.59
4.25-4.89
3.73-4.27
4.45-5.13
3.73-4.27
4.45-5.13
3.03-3.49
2.39-2.75
3.03-3.49
2.39-2.75
1.33-1.47
2.34-2.58
1.33-1.47
2.34-2.58
0.76-0.84
1.67-1.85
208-230/60/3
460/60/3
1.29-1.43
1.29-1.43
1.09-1.21
1.09-1.21
0.88-0.97
0.88-0.97
0.71-081
5.06-5.6
5.06-5.6
4.38-4.84
4.38-4.84
3.41-3.77
2.78-3.07
2.72-3.13
575/60/4
6.88-7.60
5.39-5.96
5.39-5.96
4.27-4.92
09/26/12
Thermistor Resistance
Thermistor
Temperature (°F)
5
14
23
32
41
50
59
68
77
86
95
104
113
122
131
140
149
Microprocessor
Resistance (Ohms)
72,950
55,330
42,330
32,650
25,390
19,900
15,710
12,490
10,000
8,057
6,530
5,327
4,370
3,603
2,986
2,488
2,083
07/08/15
Refrigerant Circuit Guideline
Symptom
Under Charged System (Possible Leak)
Over Charged System
Low Air Flow Heating
Low Air Flow Cooling
Low Water Flow Heating
Low Water Flow Cooling
High Air Flow Heating
High Air Flow Cooling
High Water Flow Heating
High Water Flow Cooling
Low Indoor Air Temperature Heating
Low Indoor Air Temperature Cooling
High Indoor Air Temperature Heating
High Indoor Air Temperature Cooling
Restricted TXV (Check Service Advisory)
Insufficient Compressor (Possible Bad Valves)
TXV - Bulb Loss of Charge
Scaled Coaxial Heat Exchanger Heating
Scaled Coaxial Heat Exchanger Cooling
Restricted Filter Drier
Head
Pressure
Low
High
High
Low
Low/Normal
High
Low
Low
Normal
Low
Low
Low
High
High
High
Low
Low
Low
High
Suction
Compressor
Air Temp.
Superheat
Subcooling
Pressure
Amp Draw
Differential
Low
Low
High
Low
Low
High
High
Normal
High
Normal/Low
High
High
High/Normal
Low
High
Low
Low
Low/Normal
High
High
Low/Normal
Low
Low
High
Low
High
High
High
Low
Low
Low
Low
Low
High
Low
High
Normal
High
Low
Low
Low
Normal
High
Normal
Normal
Low
Low
Low
High
Normal
Low
Low
Normal
High
Normal
Low
Low
Normal/Low
High
Low
High
High
Normal/High
Normal/Low
Low
High
High
High
Low
Low
Low
Normal/Low
High
High
Low
High
Low
High
Normal/High
Low
Low
Low
High
High
Low
Low
Low
Normal/Low
High
Low
High
High
Normal/Low
Low
Low
Check temperature difference (delta T) across filter drier.
Water Temp.
Differential
Low
Normal
Low
Low
High
High
Low
Normal
Low
Low
Normal/High
Low
Normal
High
Low
Low
Low
Low
Low
7/6/10
37
RB SERIES INSTALLATION MANUAL
Heat of Extraction/Rejection Data
Model
gpm
1.0
006
1.5
2.0
1.5
009
2.0
3.0
1.5
012
2.5
3.5
2.0
015
3.0
4.0
3.0
018
4.0
5.0
3.0
024
4.5
6.0
4.0
030
6.0
8.0
5.0
036
7.0
9.0
5.0
042
8.0
11.0
6.0
048
9.0
12.0
9.0
060
12.0
15.0
12.0
070
15.0
18.0
Values displayed in MBtu/h
Heat Of Extraction (HE)
50°F
70°F
4.6
6.0
4.7
6.1
4.8
6.2
6.2
7.7
6.3
7.9
6.5
8.2
8.0
9.9
8.4
10.4
8.7
10.9
9.2
11.5
9.5
11.8
9.9
12.1
11.4
14.6
11.7
14.7
11.9
14.8
15.9
20.2
16.5
20.5
17.2
20.8
19.9
25.4
20.7
26.5
21.6
27.6
24.8
32.3
25.9
33.4
27.0
34.6
28.1
37.3
29.9
39.0
31.6
40.7
33.7
44.8
35.4
47.3
37.1
49.8
36.7
47.2
38.0
49.9
39.3
52.6
47.7
63.7
48.7
65.4
49.6
67.1
30°F
3.6
3.1
5.0
4.8
6.6
6.4
7.7
7.2
9.2
8.9
13.2
11.9
16.1
14.5
20.0
18.4
22.8
22.1
26.3
25.9
28.8
28.6
36.0
34.5
90°F
7.5
7.7
7.8
10.0
10.2
10.4
13.3
13.5
13.7
13.4
13.6
13.8
16.2
16.5
16.8
22.5
22.9
23.3
31.0
31.5
32.0
38.1
38.7
39.3
47.4
48.2
49.0
58.0
58.9
59.9
60.6
61.6
62.6
78.4
79.7
81.0
Reference Calculations
Heating Calculations:
HE
gpm x 500
LWT = EWT -
LAT = EAT +
HC
cfm x 1.08
SC
cfm x 1.08
LC = TC - SC
S/T =
11.8
11.9
14.6
14.7
19.2
19.3
25.2
25.3
33.1
33.3
39.0
39.2
46.7
46.9
54.7
55.0
63.9
64.2
74.0
74.3
76.1
76.4
Heat of Rejection (HR)
70°F
9.2
9.3
9.3
11.1
11.0
10.9
14.6
14.7
14.8
18.0
18.1
18.2
24.0
23.6
23.3
30.8
31.3
31.7
37.4
37.7
38.1
46.4
46.8
47.1
52.9
53.4
54.0
64.8
65.4
66.0
73.7
74.1
74.4
86.1
86.3
86.5
90°F
13.5
13.3
13.2
10.1
10.1
10.2
13.6
13.6
13.6
17.0
17.1
17.2
22.7
22.7
22.9
28.8
28.8
29.1
34.8
34.8
35.2
43.0
43.1
43.5
68.6
68.7
69.2
59.5
59.6
60.1
68.6
68.7
69.2
79.5
79.6
80.3
ABBREVIATIONS AND DEFINITIONS:
HR
gpm x 500
LAT(DB) = EAT(DB) -
TH = HC + HWC
9.8
9.8
50°F
10.2
10.1
10.1
11.9
11.9
12.0
15.2
15.1
15.0
18.9
19.0
19.1
25.4
25.1
24.9
32.6
33.0
33.4
39.9
40.3
40.7
48.6
48.7
48.8
57.0
57.6
58.1
69.2
69.5
69.7
78.1
78.4
78.6
88.8
87.9
87.1
Legend
Cooling Calculations:
LWT = EWT +
30°F
SC
TC
cfm
EWT
gpm
WPD
EAT
=
=
=
=
=
HC
TC
SC
KW
HR
HE
HWC
EER
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
COP
LWT
LAT
TH
LC
S/T
38
airflow, cubic feet/minute
entering water temperature, Fahrenheit
water flow in gallons/minute
water pressure drop, PSI and feet of water
entering air temperature, Fahrenheit
(dry bulb/wet bulb)
air heating capacity, MBtu/h
total cooling capacity, MBtu/h
sensible cooling capacity, MBtu/h
total power unit input, kilowatts
total heat of rejection, MBtu/h
total heat of extraction, MBtu/h
hot water generator capacity, MBtu/h
Energy Efficient Ratio
BTU output/Watt input
Coefficient of Performance
BTU output/BTU input
leaving water temperature, °F
leaving air temperature, °F
total heating capacity, MBtu/h
latent cooling capacity, MBtu/h
sensible to total cooling ratio
110°F
8.2
8.3
9.3
9.4
11.6
11.7
15.5
15.6
21.7
21.8
26.1
26.3
31.4
31.6
39.3
39.6
44.9
45.3
53.5
53.9
62.2
62.6
72.1
72.6
09/26/12
RB SERIES INSTALLATION MANUAL
Troubleshooting
Should a major problem develop, refer to the following information for possible causes and corrective steps.
If compressor won’t run:
1.
2.
3.
4.
5.
6.
7.
8.
9.
The fuse may be open or the circuit breaker is tripped. Check electrical circuits and motor windings for shorts or grounds. Investigate
for possible overloading. Replace fuse or reset circuit breakers after fault is corrected.
Supply voltage may be too low. Check it with a volt meter.
Control system may be faulty. Check control for correct wiring of thermostat or aquastat and check the 24 volt transformer for
proper voltage.
Wires may be loose or broken. Replace or tighten.
The low pressure switch may have tripped due to one or more of the following:
a) Heating
1) Plugged heat exchanger on source side
2) Water flow source side - (Low)
3) Water too cold source side
4) Low refrigerant
b) Cooling
1) Plugged heat exchanger on load side
2) Water flow load side - (Low)
3) Water too cold load side
4) Low refrigerant
The high pressure switch may have tripped due to one or more of the following:
a) Heating
1) Plugged heat exchanger on load side
2) Low water flow load side
3) Water too warm load side
b) Cooling
1) Plugged heat exchanger on source side
2) Low water flow on source side
3) Water too warm source side
The compressor overload protection may be open.
The internal winding of the compressor motor may be grounded to the compressor shell. If so, replace the compressor.
The compressor winding may be open or shorted. Disconnect power. Check continuity with ohm meter. If the winding is open, replace
the compressor.
If sufficient cooling or heating is not obtained:
1.
2.
3.
4.
Check control for improper location or setting.
Check for restriction in water flow.
Check refrigerant subcooling and superheat for proper refrigerant charge and expansion valve operation.
The reversing valve may be defective and creating a bypass of refrigerant. If the unit will not heat, check the reversing valve coil.
If the unit operation is noisy:
1.
2.
3.
4.
5.
6.
Check compressor for loosened mounting bolts. Make sure compressor is floating free on its isolator mounts. Check for tubing contact
with the compressor or other surfaces. Readjust it by bending slightly.
Check screws on all panels.
Check for chattering or humming in the contactor or relays due to low voltage or a defective holding coil. Replace the component.
Check for proper installation of vibration absorbing material under the unit.
Check for abnormally high discharge pressures.
Compressor rotation incorrect
Refrigerant Systems
To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Compare the change in
temperature on the air side as well as the water side to the Operating Parameters tables. If the unit’s performance is not within the ranges
listed, and the airflow and water flow are known to be correct, gauges should then be installed and superheat and subcooling numbers
calculated. If superheat and subcooling are outside recommended ranges, an adjustment to the refrigerant charge may be necessary.
NOTE: Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit.
39
RB SERIES INSTALLATION MANUAL
Startup and Troubleshooting Form
Company Name: _________________________________
Technician Name: ________________________________
Model No: ______________________________________
Owner’s Name: __________________________________
Installation Address: ______________________________
Company Phone No: ______________________________
Date: __________________________________________
Serial No:_______________________________________
Open or Closed Loop: _____________________________
Installation Date: _________________________________
Check One
❑ Start up/Check-out for new installation
❑ Troubleshooting
Problem:___________________________________
1. FLOW RATE IN GPM (COAXIAL HEAT EXCHANGER)
Water In Pressure:
Water Out Pressure:
Pressure Drop = a - b
Convert Pressure Drop to Flow Rate
(refer to Pressure Drop table)
a.______
b.______
c.______
PSI
PSI
PSI
d.______
GPM
2. TEMPERATURE RISE OR DROP ACROSS COAXIAL HEAT EXCHANGER
Water In Temperature:
Water Out Temperature:
Temperature Difference:
COOLING
e.______ °F
f. ______ °F
g.______ °F
HEATING
e.______
°F
f. ______
°F
g.______
°F
3. TEMPERATURE RISE OR DROP ACROSS AIR COIL
Air In Temperature:
Air Out Temperature:
Temperature Difference:
COOLING
h.______ °F
i. ______ °F
j. ______ °F
HEATING
h.______
°F
i. ______
°F
j. ______
°F
4. HEAT OF REJECTION (HR) / HEAT OF EXTRACTION (HE) CALCULATION
HR or HE = Flow Rate x Temperature Difference x Brine Factor*
d. (above) x g. (above) x 485 for Methanol or Environol, 500 for water*
Heat of Extraction (Heating Mode) =
btu/hr
Heat of Rejection (Cooling Mode) =
btu/hr
Compare results to Capacity Data Tables
Note: Steps 5 through 8 need only be completed if a problem is suspected
5. WATTS
Volts:
Total Amps (Comp. + Fan):
Watts = m. x n. x 0.85
COOLING
VOLTS
m._____
n. _____
AMPS
o. _____
WATTS
HEATING
m.______ VOLTS
n. ______ AMPS
o. ______ WATTS
6. CAPACITY
Cooling Capacity = HR. - (o. x 3.413)
Heating Capacity= HE. + (o. x 3.413)
p. _____
p. _____
btu/hr
btu/hr
7. EFFICIENCY
Cooling EER = p. / o.
Heating COP = p. / (o. x 3.413)
q. _____
q. _____
EER
COP
8. SUPERHEAT (S.H.) / SUBCOOLING (S.C.)
Suction Pressure:
Suction Saturation Temperature:
Suction Line Temperature:
Superheat = t. - s.
COOLING
r. ______ PSI
s. ______ °F
t. ______ °F
u. _____
°F
HEATING
r. ______
PSI
s. ______ °F
t. ______
°F
u. ______ °F
Head Pressure:
High Pressure Saturation Temp.:
Liquid Line Temperature*:
Subcooling = w. - x.
v. ______
w. _____
x. ______
y. ______
v. ______
w. _____
x. ______
y. ______
PSI
°F
°F
°F
* Note: Liquid line is between the coaxial heat exchanger and the expansion valve in the cooling mode;
between the air coil and the expansion valve in the heating mode.
40
PSI
°F
°F
°F
RB SERIES INSTALLATION MANUAL
DEALER:
PHONE #:
DATE:
PROBLEM:
MODEL #:
Startup/Troubleshooting Form
SERIAL #:
COOLING CYCLE ANALYSIS
PSI =
SAT °F
°F
Unit Amp Draw:
°F
AIR
COIL
Loop:
Open
Closed
Line Voltage:
°F
SUCTION
COMPRESSOR
COAX
COAX
EXPANSION
VALVE
LOAD
REVERSING
VALVE
SOURCE
DISCHARGE
Hot Water Generator
°F
°F
LIQUID LINE
°F
°F
°F
°F
PSI
PSI
PSI
PSI
°F
BRINE IN
BRINE IN
BRINE OUT
SAT °F
PSI =
Superheat
°F
Subcooling
BRINE OUT
Water to Water Application
Heat of Extraction/Rejection = GPM x 500 (485 for water/antifreeze) x ∆T
Note: DO NOT hook up pressure gauges unless there appears to be a performance problem.
HEATING CYCLE ANALYSIS
PSI =
SAT °F
°F
Unit Amp Draw:
°F
AIR
COIL
Loop:
Open
Closed
Line Voltage:
°F
SUCTION
COMPRESSOR
COAX
EXPANSION
VALVE
LOAD
REVERSING
VALVE
COAX
SOURCE
DISCHARGE
Hot Water Generator
°F
°F
LIQUID LINE
PSI =
°F
°F
°F
°F
PSI
PSI
PSI
PSI
°F
BRINE IN
BRINE OUT
BRINE IN
Water to Water Application
41
BRINE OUT
°F
SAT °F
Superheat
Subcooling
RB SERIES INSTALLATION MANUAL
Preventive Maintenance
Water Coil Maintenance
1.
2.
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.
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
Filters must be clean to obtain maximum performance. They should be inspected monthly under normal operating conditions and be
replaced when necessary. Units should never be operated without a filter.
Condensate Drain
In areas where airborne bacteria produce a slime in the drain pan, it may be necessary to treat chemically to minimize the problem. 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
Blower motors are equipped with sealed ball bearings and require no periodic oiling.
Air Coil
The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or
vacuum (with a brush attachment) clean. Care must be taken not to damage the aluminum fins while cleaning.
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.
42
RB SERIES INSTALLATION MANUAL
Compressor
Service Parts - Vertical
006
009
012
015
018
024
030
036
042
048
060
070
Compressor 208-230/60/1
34P653-01
34P590-01
34P591-01
34P592-01
34P593-01
34P636-01
34P637-01
34P635-01
34P638-01
34P639-01
34P630-01
34P631-01
265/60/1
34P653-02
34P590-02
34P591-02
34P592-02
34P593-02
34P636-02
34P637-02
34P635-02
230/60/3
Not Available
34P636-03
34P637-03
34P635-03
34P638-03
34P639-03
34P630-03
34P631-03
460/60/3
Not Available
34P636-04
34P637-04
34P635-04
34P638-04
34P639-04
34P630-04
34P631-04
34P638-05
34P639-05
34P630-05
34P631-05
575/60/3
Not Available
115/60/1
34P653-09
Run Capacitor 208-230/60/1
16P002D12 16P002D17 16P002D18
16P002D19
16P002D19
16P002D20 16P002D21 16P002D32
16P002D27
16P002D30
16P002D29
16P002D30
Run Capacitor 265/60/1
Run Capacitor 115/60/1
16P002D21
34P590-09
34P591-09
Not Available
16P002D36
Sound Jacket
92P523-01
Variable Speed ECM
Motor & Blower
PSC Motor & Blower
Not Available
VS ECM Motor 265/60/1
Not Available
5-Speed ECM
Motor & Blower
14P516B01
14P515B03
Not Available
14P515B01
14P516B01
VS ECM Motor 460/60/3
Not Available
14P515B03
14P516B03
VS ECM Blower Housing
Not Available
14P517B01
Not Available
VS ECM Motor 230/60/3
53P512B01
14P517B01
14P517B03
53P515B01
PSC Motor 115/60/1
14P553-03
PSC Motor 208-230/60/1
14P553-02
14P507B01
14P508B01 14P509B01 14P510B01 14P511B01 14P512B01
PSC Motor 265/60/1
14P553-02
14P507B02
14P508B02 14P509B02 14P510B02
Not Available
14P514B01
Not Available
PSC Motor 230/60/3
Not Available
14P508B01 14P509B01 14P510B01 14P511B01 14P512B01
14P514B01
PSC Motor 460/60/3
Not Available
14P508B03 14P509B03 14P510B03 14P511B02 14P512B02
14P514B02
14P511B03 14P512B03
14P514B03
53P517-02
53P515B01
PSC Motor 575/60/3
Not Available
53P512B01
5-Speed ECM Motor
208-230/60/1
Not Available
14S536-18
14S536-01
14S536-02
14S536-03
5-Speed ECM Motor
277/60/1
Not Available
14S536-19
14S536-02
14S536-07
14S536-08
14S537-01
14S537-02
14S537-03
14S537-03
Not Available
5-Speed ECM Motor
230/60/3
Not Available
14P536-01
14S536-02
14S536-03
14S537-01
14S537-02
14S537-03
14S537-03
5-Speed ECM Motor
460/60/3
Not Available
14S536-03
14S536-10
14S536-11
14S537-04
14S537-05
14S537-06
14S537-06
5-Speed ECM Blower
& Housing
Refrigeration Components
36P503B02
14P515B01
PSC Blower & Housing
Not Available
Air Coil
Coax (Copper)
Reversing Valve
53P512B01
61P723-41
62P587-01
62P591-01
33P502-05
33P502-05
TXV
61P704-41
62P586-01
33P605-19
62P586-01
62P586-01
61P705-41
62P572-01
33P605-16
33P502-05
61P711-41
62P566-01
33P605-02
33P505-04
62P568-01
33P605-10
33P506-04
61P706-41
61P715-41
62P573-01
62P574-01
33P608-10
33P605-13
33P503-05
33P526-04
36P500B01
36P500B02
15P008B02
Not Available
Transformer 208-230/60/1
15P501B01
Transformer 265/60/1
15P507B01
Transformer 230/60/3
Not Available
Transformer 460/60/3
Not Available
Transformer 575/60/3
Phase Guard
53P515B01
61P713-41
62P586-01
Filter Drier
Transformer 115/60/1
Controls
92P524-01
Not Available
VS ECM Motor 208-230/60/1
16P002D23
Not Available
Not Available
92P504A01
Discharge Muffler
Sensors &
Safeties
Not Available
Not Available
15P501B01
15P505B01
Not Available
15P506B01
Not Available
19P541A06
High Pressure Switch
35P506B02
Low Pressure Switch
35P506B01
Part numbers subject to change
8/19/13
43
RB SERIES INSTALLATION MANUAL
Compressor
Service Parts - Horizontal
006
009
012
015
018
024
030
036
042
048
060
070
Compressor 208-230/60/1
34P653-01
34P590-01
34P591-01
34P592-01
34P593-01
34P636-01
34P637-01
34P635-01
34P638-01
34P639-01
34P630-01
34P631-01
265/60/1
34P653-02
34P590-02
34P591-02
34P592-02
34P593-02
34P636-02
34P637-02
34P635-02
34P636-03
34P637-03
34P635-03
34P638-03
34P639-03
34P630-03
34P631-03
34P636-04
34P637-04
34P635-04
34P638-04
34P639-04
34P630-04
34P631-04
34P638-05
34P639-05
34P630-05
34P631-05
230/60/3
Not Available
460/60/3
Not Available
575/60/3
Not Available
115/60/1
34P653-09
Run Capacitor 208-230/60/1
16P002D12 16P002D17 16P002D18
16P002D19
16P002D19
16P002D20 16P002D21 16P002D32
16P002D27
16P002D30
16P002D29
16P002D30
Run Capacitor 265/60/1
Run Capacitor 115/60/1
16P002D21
34P590-09
34P591-09
Not Available
16P002D36
Sound Jacket
92P523-01
Variable Speed ECM
Motor & Blower
PSC Motor & Blower
Not Available
14P515B01
VS ECM Motor 265/60/1
Not Available
14P515B03
Not Available
VS ECM Motor 460/60/3
Not Available
VS ECM Blower Housing
Not Available
5-Speed ECM
Motor & Blower
14P516B01
14P517B01
Not Available
14P515B01
14P516B01
14P515B03
14P516B03
53P512B01
14P517B01
14P517B03
53P515B01
PSC Motor 115/60/1
14P553-03
PSC Motor 208-230/60/1
14P553-02
14P507B01
14P508B01 14P509B01 14P510B01 14P511B01 14P512B01
PSC Motor 265/60/1
14P553-02
14P507B02
14P508B02 14P509B02 14P510B02
Not Available
14P514B01
Not Available
PSC Motor 230/60/3
Not Available
14P508B01 14P509B01 14P510B01 14P511B01 14P512B01
14P514B01
PSC Motor 460/60/3
Not Available
14P508B03 14P509B03 14P510B03 14P511B02 14P512B02
14P514B02
14P511B03 14P512B03
14P514B03
53P517-02
53P515B01
PSC Motor 575/60/3
Not Available
53P512B01
5-Speed ECM Motor
208-230/60/1
Not Available
14S536-18
14S536-01
14S536-02
14S536-03
5-Speed ECM Motor
277/60/1
Not Available
14S536-19
14S536-06
14S536-07
14S536-08
14S537-01
14S537-02
14S537-03
14S537-03
Not Available
5-Speed ECM Motor
230/60/3
Not Available
14P536-01
14S536-02
14S536-03
14S537-01
14S537-02
14S537-03
14S537-03
5-Speed ECM Motor
460/60/3
Not Available
14S536-09
14S536-10
14S536-11
14S537-04
14S537-05
14S537-06
14S537-06
5-Speed ECM Blower
& Housing
Refrigeration Components
36P503B02
VS ECM Motor 208-230/60/1
PSC Blower & Housing
Not Available
53P512B01
Air Coil
61P726-41
61P726-41
61P726-41
Coax (Copper)
62P587-01
62P591-01
62P586-01
TXV
Reversing Valve
33P605-19
33P502-05
33P502-05
61P704-41
62P586-01
62P586-01
33P502-05
61P707-41
62P572-01
33P605-16
61P708-41
62P566-01
33P605-02
33P505-04
62P568-01
33P605-10
33P506-04
61P709-41
61P710-41
62P573-01
62P574-01
33P608-10
33P605-13
33P503-05
33P526-04
36P500B01
36P500B02
15P008B02
Not Available
Transformer 208-230/60/1
15P501B01
Transformer 265/60/1
15P507B01
Transformer 230/60/3
Not Available
Transformer 460/60/3
Not Available
Transformer 575/60/3
Phase Guard
53P515B01
61P712-41
62P586-01
Filter Drier
Transformer 115/60/1
Controls
92P524-01
Not Available
VS ECM Motor 230/60/3
16P002D23
Not Available
Not Available
92P504A01
Discharge Muffler
Sensors &
Safeties
Not Available
Not Available
15P501B01
15P505B01
Not Available
15P506B01
Not Available
19P541A06
High Pressure Switch
35P506B02
Low Pressure Switch
35P506B01
Part numbers subject to change.
8/19/13
44
RB SERIES INSTALLATION MANUAL
Revision Guide
Pages:
Date:
By:
Removed FX10, Added Aurora Controls, Updated Wiring Schematics
01 Mar 2017
MA
All
Updated with CuproNickel Water Coil Option
20 May 2014
DS
All
Updated to New All-Aluminum Air Coils
09 Oct 2013
DS
All
Updated Nomenclature to Reflect New Variable Speed ECM Blower
12 Nov 2012
DS
All
Added 006 - 015 Models
30 Oct 2012
DS
51
Added Revision Table
30 Oct 2012
DS
Misc.
Description:
45
P.O. Box 1592, York, Pennsylvania USA 17405-1592
Copyright © by Johnson Controls 2017
Form 146.07-NOM1 (317)
Issue Date: March 28, 2017
Supersedes: 146.00-NOM7 (514)
800-861-1001
www.johnsoncontrols.com
Subject to change without notice. Printed in USA
ALL RIGHTS RESERVED
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