Premium Variable Speed Forced Air Comfort System Geothermal/Water Source Heat Pumps Installation Information n Water Piping Connectionss Electricall Startup Proceduress Troubleshooting g Preventative Maintenance e TEC-IOM-V_0513v1 INSTALLATION, OPERATION & MAINTENANCE MANUAL • R-410A Refrigerant • 3 - 5 To Ton Variable Speed PREMIUM V INSTALLATION MANUAL Table of Contents Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Closed Loop Ground Source Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Open Loop Ground Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hot Water Generator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electronic Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Auxiliary Heat Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Auxiliary Heat Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 The Aurora™ Advanced VS Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Operation Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Unit Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Compressor and Thermistor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Refrigerant Circuit Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Heat of Extraction/Rejection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Reference Calculations and Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Preventive Maintenance and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Revision Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3 PREMIUM V INSTALLATION MANUAL Model Nomenclature 1-2 3-5 6 7 8 9 10 11 12 13 14 15 16 17-18 19 VI 036 T L 1 1 1 C J 0 5 B L SS A Family VI = Variable Speed Vintage A = Current Unit Capacity (MBTUH) 036, 048, 060 Non-Standard Option SS = Standard Discharge Air Configuration T = Top (Vertical) B = Bottom (Vertical) E = End (Horizontal) S = Side (Horizontal) R = Rear (Vertical) Cabinet Option L = Blue Cabinet Sound Kit B = Sound Kit Filter Option 5 = Electrostatic Return Air Configuration L = Left R = Right Future Option 0 = Standard Voltage 1 = 208-230/60/1 Controls Option J = Aurora Variable Speed Control K = Aurora VS Controls w/ Performance Monitoring Hot Water Option 0 = No Hot Water Generation 1 = Hot Water Generation with Factory Installed Pump Coax Options C = Copper N = Cupronickel Blower Option 1 = ECM Blower 2 = High Static ECM Blower (036) Rev.: 04 Sept 2012D 4 PREMIUM V INSTALLATION MANUAL General Installation Information Safety Considerations Filter Rack Conversion A 1 in. electrostatic filter is shipped with the heat pump. To field convert the filter rack to use 2 in. filters, simply remove the provided plastic push pins from the holes located in the filter rack. These holes are on the top and bottom of the rack, underneath the instruction labels. 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 Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations and have a fire extinguisher available. Bottomflow units should be mounted level and sealed well to floor to prevent air leakage. Bottomflow units require the supply air opening to be cut at least 1/2 in. larger than the unit’s air outlet. Protect the edges of combustible flooring with sheet metal over-wrap or other non-combustible material. Prior to setting the unit in place, remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket. Vertical units are available in left or right air return configurations. Top and rear air discharge vertical units should be mounted level on a vibration absorbing pad slightly larger than the base to provide isolation between the unit and the floor. It is not necessary to anchor the unit to the floor (see below). 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. Figure 1: Vertical Unit Mounting Unit Location Locate the unit in an indoor area, minimum ambient of 45°F and maximum ambient of 100°F, that allows for easy removal of the filter and access panels. Attic installations are not approved and could result in loss of warranty. Installation is not recommended in areas with excessive dirt and debris as this may be drawn into the VS drive causing overheating of the VS drive. Location should have enough space for service personnel to perform maintenance or repair. Provide sufficient room to make water, electrical and duct connection(s). If the unit is located in a confined space, such as a closet, provisions must be made for return air to freely enter the space by means of a louvered door, etc. Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit. On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping. Care should be taken when units are located in unconditioned spaces to prevent damage from frozen water lines and excessive heat that could damage electrical components. 2 in. Extruded Polystyrene 5 PREMIUM V INSTALLATION MANUAL General Installation Information cont. pitched approximately 1/4-inch towards the drain in both directions to facilitate the removal of condensate. Use only the bolts provided in the kit to attach hanger brackets. The use of longer bolts could damage internal parts. Installing Horizontal Units Remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket prior to setting the unit in place. Horizontal units are available with side or end discharge. Horizontal units are normally suspended from a ceiling by four or six 3/8 in. diameter threaded rods. The rods are usually attached to the unit by hanger bracket kits furnished with each unit. Some residential applications require the installation of horizontal units on an attic floor. In this case, the unit should be set in a full size secondary drain pan on top of a vibration absorbing pad. The secondary drain pan prevents possible condensate overflow or water leakage damage to the ceiling. The secondary drain pan is usually placed on a plywood base isolated from the ceiling joists by additional layers of vibration absorbing material. Lay out the threaded rods per the dimensions in Figure 3. Assemble the hangers to the unit as shown. Securely tighten the brackets to the unit using the weld nuts located on the underside of the bottom panel. When attaching the hanger rods to the bracket, a double nut is required since vibration could loosen a single nut. To allow filter access, one bracket on the filter side should be installed 180° from the position shown in Figure 3. The unit should be SPECIAL NOTE: The VS drive is limited to a maximum of 125°F ambient temperature. For this reason, variable speed units are not approved for attic installations. The compressor compartment temperature is also monitored by the Aurora. This ‘compressor ambient’ temperature is available on the AID Tool for reading. The control will de-rate the compressor when ambient air is above 125°F. Installing this product in an attic could result in loss of warranty. Figure 2: Horizontal Unit Mounting CAUTION: Do not use rods smaller than 3/8-inch diameter since they may not be strong enough to support the unit. The rods must be securely anchored to the ceiling. Threaded Rods Flexible Duct Collar Hanging Brackets (Included) Insulate supply plenum and use at least one 90 O elbow to reduce noise To Line Power Hose Kits To Thermostat Electrical Disconnect s Valve Ball Line Voltage Building Water Loop Figure 3: Hanger Location and Assembly @WUVb :STb / 4 !&BV`SORSR @]RPg]bVS`a ! DWP`ObW]\ 7a]ZOb]` /W`1]WZ " 1 0 EOaVS` " /W`1]WZ 0]ZbO\R :]QYEOaVS` 2 Hanger Dimensions Hanger Kit Part Number Model 036 048 060 in. cm. in. cm. in. cm. 99S500A03 99S500A03 99S500A03 ! 6Sf<cba Pg]bVS`a Weight Distribution Unit Hanger Dimensions A B C D 77.4 27.8 24.1 29.3 196.6 70.6 61.2 74.4 Vertical Shipping Weight Horizontal Shipping Weight 036 352 Model Horizontal Weight Distribution Front Back 1 2 3 4 387 135 83 86 83 77.4 27.8 24.1 29.3 048 361 396 145 84 84 83 196.6 70.6 61.2 74.4 060 385 415 120 120 45 130 82.4 27.8 24.1 29.3 209.3 70.6 61.2 74.4 Weights are listed in lbs. [kg] 6/1/12 6 6/1/12 PREMIUM V INSTALLATION MANUAL General Installation Information cont. the swivel connector and thread the female locking ring onto the pipe threads, while maintaining the brass connector in the desired direction. Tighten the connectors by hand, then gently snug the fitting with pliers to provide a leak-proof joint. When connecting to an open loop (ground water) system, thread any 1-inch MPT fitting (SCH80 PVC or copper) into the swivel connector and tighten in the same manner as noted above. The open and closed loop piping system should include pressure/temperature taps for serviceability. Duct System An air outlet collar is provided on vertical top and rear air discharge units and all horizontal units to facilitate a duct connection (vertical bottomflow units have no collar). A flexible connector is recommended for discharge and return air duct connections on metal duct systems. Uninsulated duct should be insulated with a minimum of 1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit’s performance will be adversely affected. Never use flexible hoses smaller than 1-inch inside diameter on the unit. Limit hose length to 10 feet per connection. Check carefully for water leaks. 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. Figure 4: Swivel Connections The duct system should be sized according to the table below to handle the design airflow quietly and efficiently. To maximize sound attenuation of the unit blower, the supply and return plenums should include an internal duct liner of fiberglass or constructed of ductboard for the first few feet. On systems employing a sheet metal duct system, canvas connectors should be used between the unit and the ductwork. If air noise or excessive airflow is a problem, the blower speed can be changed. Model Design Airflow 036 1500 048 1800 060 2100 Stainless Steel Snap Ring Gasket Material Water Piping The proper water flow must be provided to each unit whenever the unit operates. To assure proper flow, use pressure/temperature ports to determine the flow rate. These ports should be located at the supply and return water connections on the unit. The proper flow rate cannot be accurately set without measuring the water pressure drop through the refrigerant-to-water heat exchanger. All source water connections on residential units are swivel piping fittings (see Figure 4) that accept a 1-inch male pipe thread (MPT). The swivel connector has a rubber gasket seal similar to a rubber hose gasket, which when mated to the flush end of any 1-inch threaded pipe provides a leak-free seal without the need for thread sealing tape or compound. Check to ensure that the rubber seal is in the swivel connector prior to attempting any connection. The rubber seals are shipped attached to the waterline. To make the connection to a ground loop system, mate the brass connector (supplied in CK4LI connector kit) against the rubber gasket in 7 Locking Ring Gasket Support Sleeve PREMIUM V INSTALLATION MANUAL General Installation Information cont. generator coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional flushing. 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 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 Units with cupronickel heat exchangers are recommended for open loop applications due to the increased resistance to build-up and corrosion, along with reduced wear caused by acid cleaning. Failure to adhere to the guidelines in the water quality table could result in the loss of warranty. 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 Figure 5: Horizontal Drain Connection Low Water Coil Limit Set the freeze sensing switch SW2-1 on the Aurora Base Control (ABC) printed circuit board for applications using a closed loop antifreeze solution to “LOOP” (15°F). On applications using an open loop/ground water system (or closed loop no antifreeze), set this dip switch to “WELL” (30°F), the factory default setting. (Refer to the DIP Switch Settings table in the Aurora Control section.) Vent (if needed) PVC coupling PVC tube stub 1/8 in. per foot PVC tube stub 1.5 in. 1.5 in. Condensate Drain On vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the drain pan, a 3/4-inch PVC female adapter and a flexible connecting hose. The female adapter may exit either the front or the side of the cabinet. The adapter should be glued to the field-installed PVC condensate piping. On vertical units, a condensate hose is inside all cabinets as a trapping loop; therefore, an external trap is not necessary. NOTE: Check dimensional data for actual PVC sizes. Figure 6: Unit Pitch for Drain On horizontal units, a PVC stub is provided for condensate drain piping connection. An external trap is required (see below). If a vent is necessary, an open stand pipe may be applied to a tee in the field-installed condensate piping. 1/2'' Pitch Drain 8 PREMIUM V INSTALLATION MANUAL Closed Loop Ground Source Systems NOTE: For closed loop systems with antifreeze protection, set SW2-1 to the “LOOP” (15°F) position. (Refer to the DIP Switch Settings table in the Aurora Control section.) Multiple Units on One Flow Center NOTE: This feature is only available in the Aurora Advanced Control package (AXB board), NOT the Aurora Base Control (ABC). Once piping is completed between the unit, pumps and the ground loop (see figure below), final purging and charging of the loop is required. A flush cart (or a 1.5 HP pump minimum) is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop itself. Antifreeze solution is used in most areas to prevent freezing. Flush the system adequately to remove as much air as possible then pressurize the loop to a static pressure of 40-50 psi (summer) or 50-75 psi (winter). This is normally adequate for good system operation. Loop static pressure will fluctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This fluctuation is normal and should be considered when initially charging the system. When two units are connected to one loop pumping system, pump control is automatically achieved by connecting the SL terminals on connector P2 in both units with 2-wire thermostat wire. These terminals are polarity dependant (see Figure 8). The loop pump(s) may be powered from either unit, whichever is more convenient. If either unit calls, the loop pump(s) will automatically start. The use of two units on one flow center is generally limited to a total of 20 gpm capacity. Variable Speed Pump Setup When using a variable speed pump flow center (FCV1-GL, FCV2-GL, FCV1-GLNP, or FCV2-GLNP) the use of an AID Tool will be necessary to adjust minimum and maximum flow rates. The factory default is: minimum=50% and maximum=100% speed levels. See the Variable Speed Pump Setup and Modulating Water Valve Setup instructions within the Unit Startup section which is located in the back of this manual. Always ensure that there is adequate flow for the heat pump. See Recommended Minimum/Maximum Flow Rates table. After pressurization, be sure to turn the venting (burping) screw in the center of the pump two (2) turns open (water will drip out), wait until all air is purged from the pump, then tighten the plug. Variable speed pumps do not have a venting screw. Ensure that the loop pumps provide adequate flow through the unit(s) by checking the pressure drop across the heat exchanger and comparing it to the unit capacity data in this catalog. 2.5 to 3 gpm of flow per ton of cooling capacity is recommended in earth loop applications. NOTE: When sharing a flow center, the variable speed heat pump should be the primary unit. When two variable speed heat pumps share a flow center, the larger capacity heat pump should be the primary unit. Figure 7: Closed Loop Ground Source Application Recommended Minimum/Maximum Flow Rates Auxiliary Heat Supply Unit Supply GeoLink® Polyethylene w/ Armaflex® Insulation Closed Loop Model and Size Min. Flow Rate Max. Flow Rate gpm gpm 036 5.0 12.0 048 5.0 15.0 060 5.0 18.0 TO LOOP Flexible Duct Collar Auxiliary Heater Knockout ink ® GeoL Flow r Cente Open Loop Min. Flow Rate gpm 5.0 5.0 5.0 Max. Flow Rate gpm 8.0 10.0 12.0 6/7/12 Figure 8: Primary/Secondary Hook-up Unit Power Premium V Series to Premium V Series Units Premium V Series to Premium G Series Units Premium V Series Unit #1 with AXB Board SLI SLO VS IN C OUT C Premium V Series Unit #1 with AXB Board SLI SLO VS IN C OUT C Desuperheater Connections Disconnects (If Applicable) Drain Low Voltage to Thermostat P/T P/T Plugs Insulated piping or hose kit Vibration Absorbing Pad With pump wired to Unit 1 NOTE: Additional information can be found in Flow Center installation manual and Flush Cart manual. Premium V Series to Electromechanical Units Premium V Series Unit #1 with AXB Board SLI SLO VS IN C OUT C With pump wired to Unit 2 With pump wired to Unit 1 With pump wired to Unit 2 Shut Down IN C OUT C SLI SLO VS Premium V Series Unit #2 with AXB Board 9 C C SL1 SL1 In Out Premium G Unit #2 C S To Electromechanical Unit PREMIUM V 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. Ensure proper water flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures in unit capacity data tables in the specification catalog. 1.5-2 gpm of flow per ton of cooling capacity is recommended in open loop applications. Figure 9a: Modulating Water Valve Connection Option Typical 0-10VDC modulating water valve. Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local codes, i.e. recharge well, storm sewer, drain field, adjacent stream or pond, etc. Most local codes forbid the use of sanitary sewer for disposal. Consult your local building and zoning departments to assure compliance in your area. On VS systems, a modulating valve, as shown in figure 9a is the best choice to limit water consumption. The WWKVS well water kit with modulating valve is the recommended setup for open loop applications with variable speed products. 0-10DC 3 2 1 VS PUMP AXB BOARD GND 1 24 VAC 2 C R ABC BOARD Figure 9b: Open Loop Solenoid Valve Connection Option Typical slow operating external 24V water solenoid valve (type V) wiring. C NOTE: For open loop/groundwater systems or systems that do not contain an antifreeze solution, set SW2-Switch #1 to the “WELL” (30°F) position. (Refer to the DIP Switch Settings in the Aurora Control section.) Slow opening/closing solenoid valves (type VM or V) or modulating valves are recommended to eliminate water hammer. R C Acc Com W/Y ACC NC Acc NO Modulating Water Valve Setup Figure 9c: Open Loop Solenoid Valve Connection Option Typical slow operating external 24V water solenoid valve (type VM) wiring. When using a modulating water valve (23P529-01) the use of an AID Tool will be necessary to adjust minimum and maximum flow rates. The factory default is: minimum=50% and maximum=100% flow levels. See the Variable Speed Pump Setup and Modulating Water Valve Setup instructions within the Unit Startup section which is located in the back of this manual. See Recommended Minimum and Maximum Flow Rates table. Always ensure that there is adequate flow for the heat pump. A modulating water valve is preferred on variable speed system to conserve water. C R Acc Com VM Valve ACC NC Acc NO Figure 10: Open System - Groundwater Application NOTE: SW2-4 should be “ON” and SW2-5 should be “OFF” when using a slow opening (VM or V) water valve. Unit Supply Figure 9d: Open Loop Solenoid Valve Connection Option Typical quick operating external 24V water solenoid valve (type PPV100 or BPV100) wiring. Aux. Heat Supply Flexible Duct Collar Rubber Bladder Expansion Tank C Auxiliary Heater Knockout Desuperheater Connections Flow Control Valve (on outlet of Solenoid Valve) P1 R Solenoid Valve Acc Com 1 Acc NC 2 Acc NO 3 Water Out Water In Drain SV 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 P2 Solenoid Valve Boiler Drains For HX Flushing NOTE: SW2-4 and SW2-5 should be “OFF” to cycle with the compressor. 10 PREMIUM V INSTALLATION MANUAL Hot Water Generator Connections To maximize the benefits of the hot water generator a minimum 50-gallon water heater is recommended for higher demand applications, use an 80-gallon water heater or two 50-gallon water heaters connected in a series as shown below. Two tanks plumbed in a series is recommended to maximize the hot water generator capability. Electric water heaters are recommended. Make sure all local electrical and plumbing codes are met for installing a hot water generator. Residential units with hot water generators contain an internal circulator and fittings. A water softener is recommended with hard water (greater than 10 grains or 170 total hardness). Figure 11: Typical Hot Water Generator Installation Cold Water In 3/4 x 3/4 x 1/2 tee Hot Water Out Venting Waste Valve or Vent Coupling HWG Water Out NOTES: 1) Using a preheat tank, as shown in Figure 12, will maximize hot water generator capabilities. 2) The hot water generator coil is constructed of vented double wall copper suitable for potable water. P/T Relief Valve In Water Tank Preparation HWG Water In To install a unit with a hot water generator, follow these installation guidelines. Drain Valve Figure 12: Hot Water Generator Installation In Preheat Tank 1. Turn off the power to the water heater. 2. Attach a water hose to the water tank drain connection and run the other end of the hose to an open drain or outdoors. 3. Close the cold water inlet valve to the water heater tank. 4. Drain the tank by opening the valve on the bottom of the tank, then open the pressure relief valve or hot water faucet. 5. Flush the tank by opening the cold water inlet valve to the water heater to free the tank of sediments. Close when draining water is clear. 6. Disconnect the garden hose and remove the drain valve from the water heater. 7. Refer to Plumbing Installation and Hot Water Generator Startup. 3/4 in. x 3/4 in. x 1/2 in. Tee Cold Water In Hot Water Out Ball Valve Vent HWG Water Out P/T Relief Valve Storage Tank P/T Relief Valve Electric Powered Water Heater In CAUTION: Elements will burn out if energized dry. HWG Water In Drain Valve Drain Valve NOTE: This configuration maximizes hot water generator capability. 11 PREMIUM V INSTALLATION MANUAL Hot Water Generator Connections cont. Plumbing Installation Hot Water Generator Startup 1. Inspect the dip tube in the water heater cold inlet for a check valve. If a check valve is present it must be removed or damage to the hot water generator circulator will occur. 2. Remove drain valve and fitting. 3. Thread the 3/4-inch NPT x 3-1/2-inch brass nipple into the water heater drain port. 4. Attach the center port of the 3/4-inch FPT tee to the opposite end of the brass nipple. 5. Attach the 1/2-inch copper to 3/4-inch NPT adaptor to the side of the tee closest to the unit. 6. Install the drain valve on the tee opposite the adaptor. 7. Run interconnecting tubing from the tee to hot water generator water out. 8. Cut the cold water “IN” line going to the water heater. 9. Insert the reducing solder tee in line with cold water “IN” line as shown. 10. Run interconnecting copper tubing between the unit hot water generator water “IN” and the tee (1/2-inch nominal). The recommended maximum distance is 50 feet. 11. To prevent air entrapment in the system, install a vent coupling at the highest point of the interconnecting lines. 12. Insulate all exposed surfaces of both connecting water lines with 3/8-inch wall closed cell insulation. 1. Turn the hot water generator switch to the “ON” position. The hot water generator switch will allow the hot water generator pump to be enabled or disabled by the service technician or homeowner. 2. Close the drain valve to the water heater. 3. Open the cold water supply to the tank. 4. Open a hot water faucet in the building to bleed air from the system. Close when full. 5. Open the pressure relief valve to bleed any remaining air from the tank, then close. 6. If so equipped, turn the venting (burping) screw in the center of the pump two (2) turns open (water will drip out), wait until all air is purged from the pump, then tighten the plug. Use vent couplings to bleed air from the lines. 7. Carefully inspect all plumbing for water leaks and correct as required. 8. Before restoring electrical supply to the water heater, adjust the temperature setting on the tank. • On tanks with both upper and lower elements, the lower element should be turned down to the lowest setting, approximately 100°F. The upper element should be adjusted to 120°F to 130°F. Depending upon the specific needs of the customer, you may want to adjust the upper element differently. • On tanks with a single element, lower the thermostat setting to 120°F. 9. After the thermostat(s) is adjusted, replace the access cover and restore electrical supply to the water heater. 10.Make sure that any valves in the hot water generator water circulating circuit are open. 11. Use an AID Tool to enable HWG and select the desired water heating set point. Selectable set points are 100°F – 140°F in 5°F increments (default 130°F). From the Main Menu of the AID Tool select Setup, then AXB Setup. 12.Turn on the unit to first stage heating.. 13.The hot water generator pump should be running. When the pump is first started, turn the venting (burping) screw (if equipped) in the center of the pump two (2) turns open until water dribbles out, then replace. Allow the pump to run for at least five minutes to ensure that water has filled the circulator properly. Be sure the switch for the hot water generator pump is “ON”. 14.Allow the unit to heat water for 15 to 20 minutes to be sure operation is normal. NOTE: All plumbing and piping connections must comply with local plumbing codes. Hot Water Generator Switch The hot water generator switch is taped in the disabled position at the factory. CAUTION: Never operate the HWG circulating pump while dry. If the unit is placed in operation before the hot water generator piping is connected, be sure that the pump switch is set to the OFF position. 12 PREMIUM V INSTALLATION MANUAL Electrical Connections General Accessory Relay Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable. The compressor has no internal overload. The circuit breaker in the control box is the overload protection for the drive and the compressor. Bypassing the circuit breaker could result in damage to the compressor and voiding the warranty. A set of “dry” contacts has been provided to control accessory devices, such as water solenoid valves on open loop installations, electronic air cleaners, humidifiers, etc. This relay contact should be used only with 24 volt signals and not line voltage power. The relay has both normally open and normally closed contacts and can operate with either the blower or the compressor. Use DIP switch SW2-4 and 5 to cycle the relay with blower, compressor, or control a slow opening water valve. The relay contacts are available on terminals #2 and #3 of P2. Unit Power Connection Connect the incoming line voltage wires to L1 and L2 of the contactor as shown in Figure 13c for single-phase unit. Consult the Unit Electrical Data in this manual for correct fuse sizes. A second configurable accessory relay is provided on the AXB board. When powering high VA draw components such as electronic air cleaners or VM type open loop water valves, R should be taken ‘pre-fuse’ from the ‘R’ quick connect on the ABC board and not the ‘post-fuse’ ‘R’ terminal on the thermostat connection. If not, blown ABC fuses might result. Open lower front access panel. Remove ground fastener from bottom of control box (Figure 13b). Swing open control box (Figure 13a). Insert power wires through knockouts on lower left side of cabinet. Route wires through left side of control box and connect to contactor and ground (Figure 13c). Close control box and replace grounding fastener before unit startup. 208 Volt Operation All 208/230 units are factory wired for 230 volt operation. For 208 volt operation, the red and blue transformer wires must be switched on terminal strip PS. CAUTION: Frequent cycling of power to the drive can damage the drive! Wait at least 5 minutes between cycles (connecting and disconnecting power to the drive). Figure 13a: Wire access (control box open) Figure 13b: Wire access (control box closed) Figure 13c: Line Voltage 208-230/60/1 control box CB PB1 L1 L2 L1 L2 Compressor Drive Overload Wire Insert Location Ground Fastener must be installed for proper unit ground 13 PREMIUM V INSTALLATION MANUAL Electrical Connections cont. Figure 14: Pump Wiring 208-230/60/1 Pump Power Wiring See Figure 14 for electrical connections from control box to pumps. CB PB1 FC1/FC2 style flow centers with fixed speed pumps connect to PB1 in the control box. If using a variable speed pump it should be connected to L1 and L2 on the AXB. L1 L2 External Loop Pump(s) (ex. UP26-99) 208-230/60/1 1/2 hp Max (Optional) External Variable Speed Loop Pump (ex. Magna Geo) 208-230/60/1 Electronic Thermostat Installation Position the thermostat subbase against the wall so that it is level and the thermostat wires protrude through the middle of the subbase. Mark the position of the subbase mounting holes and drill holes with a 3/16-inch bit. Install supplied anchors and secure base to the wall. Thermostat wire must be 4-conductor, 20-AWG (minimum) wire. Strip the wires back 1/4-inch (longer strip lengths may cause shorts) and insert the thermostat wires into the connector as shown. Tighten the screws to ensure secure connections. The thermostat has the same type connectors, requiring the same wiring. See instructions enclosed in the thermostat for detailed installation and operation information. The W1 terminal on TPCM32U04GSM communicating thermostats may be hard wired to provide aux/ emergency heat in the event communication is lost between the thermostat and the ABC microprocessor. Figure 15: Thermostat Wiring (Communicating Style Signals) B- Communication A+ Communication P1 W W1 (Optional) TPCM32U04GSM Monochrome Thermostats 14 C R – + C 24VAC (Common) R 24VAC (Hot) DX- Communication DX+ Communication TPCC32U01GSM Color Touchscreen Thermostat Thermostat Connection R 24VAC (Hot) Microprocessor Controller P7 C 24VAC (Common) Thermostat Connection Microprocessor Controller P7 C R – + PREMIUM V INSTALLATION MANUAL Auxiliary Heat Ratings kW Btu/h Model Model Compatibility Stages 208V Min CFM 230V 208V 230V 036 048 060 EAL(H)10 7.2 9.6 2 24,600 32,700 1100 • • • EAL(H)15 10.8 14.4 3 36,900 49,100 1250 • • • EAL(H)20 14.4 19.2 4 49,200 65,500 1500 • • Air flow level for auxiliary heat (Aux) must be above the minimum cfm in this table Order the “H” part number when installed on horizontal and vertical rear discharge units 6/1/12 Auxiliary Heat Electrical Data Model EAL(H)10 EAL(H)15 EAL(H)20 Heater Amps Min Circuit Amp Max Fuse (USA) Max Fuse (CAN) Max CKT BRK Supply Circuit 208 V 240 V 208 V Single 34.7 40 53.3 60 60 60 60 60 60 60 Single 52.0 60 75 85 80 90 80 90 70 100 L1/L2 34.7 40 53.3 60 60 60 60 60 60 60 L3/L4 17.3 20 21.7 25 25 25 25 25 20 30 Single 69.3 80 96.7 110 100 110 100 110 100 100 L1/L2 34.7 40 53.3 60 60 60 60 60 60 60 L3/L4 34.7 40 43.3 50 45 50 45 50 40 50 240 V 208 V 240 V 208 V 240 V 208 V All heaters rated single phase 60 cycle and include unit fan load All fuses type “D” time delay (or HACR circuit breaker in USA) 240 V 6/1/12 Electrical Data Compressor Model Drive Rated Voltage Voltage Min/Max LRA CMCC LRA Internal Breaker HWG Ext Loop Pump FLA FLA Blower Total Unit Motor FLA FLA Minimum Circuit Amp Max Fuse HACR Breaker 036 208-230/60/1 187/253 10.2 18.0 22.0 30.0 0.4 5.4 4.0 31.8 37.3 40 *036 208-230/60/1 187/253 10.2 18.0 22.0 30.0 0.4 5.4 7.0 34.8 40.3 45 048 208-230/60/1 187/253 12.0 23.5 28.0 35.0 0.4 5.4 7.0 40.8 47.8 50 060 208-230/60/1 187/253 12.0 30.0 33.0 40.0 0.4 5.4 7.0 45.8 54.1 60 *With optional 1 hp ECM Motor Rated Voltage of 208/230/60/1 HACR circuit breaker in USA only All fuses Class RK-5 3/26/12 15 PREMIUM V INSTALLATION MANUAL Blower Performance Data ECM Blower Motor Model Max ESP 036 0.50 036 w/1hp* 0.75 048 0.75 060 0.75 Speed 1 285 Speed 2 380 G Speed 3 525 L Speed 4 675 Speed 5 815 Air Flow Speed 6 980 Speed 7 1100 Speed 8 1220 Speed 9 1330 Speed 10 1440 H Speed 11 1540 Aux Speed 12 1575 480 565 G 665 L 761 870 1000 1100 1200 1300 1410 H 1520 Aux 1630 475 620 G 730 L 850 1020 1140 1270 1400 1520 1650 H 1790 Aux 1925 400 600 G 830 L 1050 1230 1400 1560 1700 1870 2010 H 2140 Aux 2265 1-2 3-4 5-6 7-8 9-10 11-12 **VS Compressor Speed 6/7/12 ** VS Compressor speed is given for the factory default cfm settings. When the cfm default settings are changed it will change the relationship to the compressor speed that is shown in the table. In cooling mode compressor speeds 10-12 are only available when SuperBoost mode is selected at the thermostat. * Optional 1 hp ECM Factory settings are at recommended L , H and Aux positions “G” may be located anywhere within the airflow table “L” setting should be located within the boldface cfm range “H” setting MUST be located within the shaded cfm range “Aux” setting MUST be equal to or greater than “H” setting “Aux” setting MUST be equal to or greater than the minimum allowable cfm for the auxiliary heater kit (see auxiliary heat ratings table) Cfm is controlled within 5% up to the maximum ESP Max ESP includes allowance for wet coil and standard filter ECM Speed Setup - These screens allow the technician to select the G, low, high, and auxiliary heat blower speed for the ECM blower motor. Change the highlighted item using the ▲ and ▼ buttons. Press the ◙ button to select the speed. Setting Blower Speed - ECM The ABC board’s Yellow Config LED will flash the current ECM blower speed selections for G, low, and high continuously with a short pause in between. The speeds can also be confirmed with the AID Tool under the Setup/ECM Setup screen. The Aux will not be flashed but can be viewed in the AID Tool. The ECM blower motor speeds can be field adjusted with or without using an AID Tool. ECM Speed Info 1 3 4 5 6 7 8 9 10 11 12 ECM Setup without an AID Tool The blower speeds for G only, Low (Y1), and High (Y2/Aux) can be adjusted directly at the Aurora ABC board which utilizes the push button (SW1) on the ABC board. This procedure is outlined in the ECM Configuration Mode portion of the Aurora ‘Base’ Control System section. The Aux cannot be set manually without an AID Tool. Option ◀▶ 3 6 9 10 Option ◀▶ Enter ◙ Option ◀▶ ECM Speed Info 1 2G 3 Lo 4 5 6 Hi 7 8 9 ▶10 11 12 Enter ◙ Option ◀▶ Selecting YES will enter ECM speed setup, while selecting NO will return to the previous screen. Cooling Airflow Setup Cooling Airflow Setup --- ECM Only --The airflow will be adjusted by the chosen amount in cooling mode. --- ECM Only --The airflow will be adjusted by the chosen amount in cooling mode. Adjustment: -15% Adjustment: -15% Want To Change? Yes Option ◀▶ Want To Change? Yes Option ◀▶ ◀ Aux Enter ◙ Cooling Airflow Setup - These screens allow the technician to select -15%, -10%, -5%, None or +5% change from the heating airflow. Change the adjustment percentage using the ▲ and ▼ buttons. Press the ◙ button to save the change. A much easier method utilizes the AID Tool to change the airflow using the procedure below. First navigate to the Setup screen and then select ECM Setup. This screen displays the current ECM settings. It allows the technician to enter the setup screens to change the ECM settings. Change the highlighted item using the ◀ and ▶ buttons and then press the ◙ button to select the item. Blower Only Speed Lo Compressor Hi Compressor Aux Heat Enter ◙ ECM Speed Info 1 2G 3 Lo 4 5 ▶6 ◀ Hi 7 8 9 10 11 12 After the auxiliary heat speed setting is selected the AID Tool will automatically transfer back to the ECM Setup screen. ECM Setup with an AID Tool ECM Speed Info ECM Speed Info 1 2G ▶ 3 ◀ Lo 4 5 6 7 8 9 10 11 12 ▶ 2 ◀G No Enter ◙ 16 No Enter ◙ Change ▼▲ Enter ◙ PREMIUM V INSTALLATION MANUAL Vertical Dimensional Data Top Air Discharge LEFT RETURN RIGHT RETURN Q P M O L L N R Q O R N TOP T TOP T 1.9in [4.8cm] 1.9in [4.8cm] S S I KJ C DEHFG A C FRONT 2 ft [61 cm] Primary Service Access B B RIGHT SIDE LEFT SIDE Overall Cabinet Vertical Top Flow Model 036 048 060 Electrical Connections Water Connections D A B C Loop Width Depth Height In E Loop Out F HWG In G H Loop HWG Cond- Water Out ensate FPT in. 25.6 31.6 54.4 2.3 7.3 15.9 18.9 10.6 cm. 65.0 80.3 138.2 5.8 18.5 40.4 48.0 26.9 in. 25.6 31.6 54.4 2.3 7.3 15.9 18.9 10.6 cm. 65.0 80.3 138.2 5.8 18.5 40.4 48.0 26.9 in. 25.6 31.6 58.4 2.3 7.3 15.9 18.9 10.6 cm. 65.0 80.3 148.3 5.8 18.5 40.4 48.0 26.9 HWG FPT I J K 1/2 in. 1/2 in. 3/4 in. cond cond cond Low Ext Power Voltage Pump Supply Return Connection using std deluxe filter rack (±0.10 in) Discharge Connection duct flange installed (±0.10 in) L M N O Supply Supply Width Depth P Q R S Return Return Depth Height T 1 in. 1 in. Swivel Swivel 14.3 9.8 12.3 6.9 1.1 18.0 18.0 3.8 1.7 28.1 30.0 1.7 36.3 24.9 31.2 17.5 2.8 45.7 45.7 9.7 4.3 71.4 76.2 4.3 1 in. 1 in. Swivel Swivel 14.3 9.8 12.3 6.9 1.1 18.0 18.0 3.8 1.7 28.1 30.0 1.7 36.3 24.9 31.2 17.5 2.8 45.7 45.7 9.7 4.3 71.4 76.2 4.3 1 in. 1 in. Swivel Swivel 14.3 9.8 12.3 6.9 1.1 18.0 18.0 3.8 1.7 28.1 34.0 1.7 36.3 24.9 31.2 17.5 2.8 45.7 45.7 9.7 4.3 71.4 86.4 4.3 Condensate is 3/4 in. PVC female glue socket and is switchable from side to front Unit shipped with deluxe 1 in. (field adjustable to 2 in.) duct collar/filter rack extending from unit 3.25 in. and is suitable for duct connection. Discharge flange is field installed and extends 1 in. [25.4mm] from cabinet Decorative molding and/or water connections extend 1.2 in. [30.5mm] beyond front of cabinet. Louvered vents in the compressor section right side access panel extend 1/2 in. [12.7 mm] from side of cabinet. Allow clearance for venting. Top auxiliary electric heat power knockouts are 1.125", 1.375", and 2". 17 6/29/12 PREMIUM V INSTALLATION MANUAL Vertical Dimensional Data cont. Bottom Air Discharge RIGHT RETURN LEFT RETURN 1.70 (4.3 cm) 4 3 C C 2 1 S S I T K G F J E T D B B LEFT SIDE RIGHT SIDE 1.90 (4.7 cm) 5 R Q R Q H A FRONT L N 2 ft [61 cm] Primary Service Access L O O M P N LEFT BOTTOM DISCHARGE FLOOR FOOT PRINT RIGHT BOTTOM DISCHARGE FLOOR FOOT PRINT Water Connections Overall Cabinet Bottomflow Models A B C Width Depth Height 036060 1 2 3 4 5 D In E Out F HWG In G HWG Out H Condensate in. 25.5 31.5 62.5 43.4 48.4 57.0 60.0 3.1 cm. 64.8 80.0 158.8 110.2 122.9 144.8 152.4 7.9 Loop Water FPT HWG FPT Electrical Knockouts I J K 1/2 in. 1/2 in. 3/4 in. cond cond cond Low Ext Power Voltage Pump Supply 51.1 1 in. 1 in. Swivel Swivel 129.8 L M N O Supply Supply Width Depth P Q R S Return Return Depth Height T 55.6 53.6 9.1 4.8 13.4 13.6 1.7 1.8 28.1 34.0 5.6 141.2 136.1 23.1 12.2 34.0 34.5 4.3 4.6 71.4 86.4 14.2 Condensate is 3/4 in. PVC female glue socket and is switchable from side to front Unit shipped with deluxe 1 in. (field adjustable to 2 in.) duct collar/filter rack extending from unit 3.25 in. and is suitable for duct connection. Decorative molding and/or water connections extend 1.2 in. [30.5mm] beyond front of cabinet. Louvered vents in the compressor section right side access panel extend 1/2 in. [12.7 mm] from side of cabinet. Allow clearance for venting. Top auxiliary electric heat power knockouts are 1.125", 1.375", and 2". 18 Return Connection using std deluxe filter rack (±0.10 in) Discharge Connection duct flange installed (±0.10 in) 4/30/12 PREMIUM V INSTALLATION MANUAL Vertical Dimensional Data cont. Rear Air Discharge 1.90 in. [4.8 cm] 1.90 in. [4.8 cm] I K J E F G D A FRONT 2 ft [61 cm] Primary Service Access O H R Q T T Q R P M M S S L C C C C N N B B A SIDE VIEW LEFT RETURN SIDE VIEW RIGHT RETURN REAR VIEW RIGHT RETURN A REAR VIEW LEFT RETURN Overall Cabinet Vertical Rear Discharge Model 036 048 060 Electrical Connections Water Connections D A B C Loop Width Depth Height In E Loop Out F HWG In G H Loop HWG Cond- Water Out ensate FPT in. 25.6 31.6 54.4 2.3 7.3 15.9 18.9 10.6 cm. 65.0 80.3 138.2 5.8 18.5 40.4 48.0 26.9 in. 25.6 31.6 54.4 2.3 7.3 15.9 18.9 10.6 cm. 65.0 80.3 138.2 5.8 18.5 40.4 48.0 26.9 in. 25.6 31.6 58.4 2.3 7.3 15.9 18.9 10.6 cm. 65.0 80.3 148.3 5.8 18.5 40.4 48.0 26.9 HWG FPT Return Connection using std deluxe filter rack (±0.10 in) Discharge Connection duct flange installed (±0.10 in) I J K 3/4 1/2 in. 1/2 in. in. L M cond cond cond Supply Supply Low Ext Power Width Depth Voltage Pump Supply N O P Q R S Return Return Depth Height T 1 in. 1 in. Swivel Swivel 14.3 9.8 12.3 13.3 13.6 39.4 9.1 8.1 1.7 28.1 30.0 1.7 36.3 24.9 31.2 33.8 34.5 100.1 23.1 20.6 4.3 71.4 76.2 4.3 1 in. 1 in. Swivel Swivel 14.3 9.8 12.3 13.3 13.6 39.4 9.1 8.1 1.7 28.1 30.0 1.7 36.3 24.9 31.2 33.8 34.5 100.1 23.1 20.6 4.3 71.4 76.2 4.3 1 in. 1 in. Swivel Swivel 14.3 9.8 12.3 13.3 13.6 43.4 9.1 8.1 1.7 28.1 34.0 1.7 36.3 24.9 31.2 33.8 34.5 110.2 23.1 20.6 4.3 71.4 86.4 4.3 Condensate is 3/4 in. PVC female glue socket and is switchable from side to front Unit shipped with deluxe 1 in. (field adjustable to 2 in.) duct collar/filter rack extending from unit 3.25 in. and is suitable for duct connection. Discharge flange is field installed and extends 1 in. [25.4mm] from cabinet Decorative molding and water connections extend 1.2 in. [30.5mm] beyond front of cabinet. Louvered vents in the compressor section right side access panel extend 1/2 in. [12.7 mm] from side of cabinet. Allow clearance for venting. Top auxiliary electric heat power knockouts are 1.125", 1.375", and 2". 19 6/29/12 PREMIUM V INSTALLATION MANUAL Horizontal Dimensional Data TOP VIEW P Q 2.1in [5.4cm] MOUNT (2) HANGER BRACKETS AS SHOWN TO ALLOW ACCESS TO FILTER 2 ft [61 cm] Primary Service Access FRONT VIEW SIDE DISHCARGE VIEW A B 1.9in [4.8cm] S END VIEW N O M I KJ E F D L L G S O R C H AS SHOWN LR UNIT (RR UNIT ON OPPOSITE SIDE—SAME DIMENSIONS) Overall Cabinet Horizontal Models A Width 036 048 060 Electrical Connections I J K 1/2 in. 1/2 in. 3/4 in. cond cond cond Water Connections B C Depth Height D In E Out G F HWG HWG In Out H Loop Cond- Water ensate FPT in. 25.6 77.0 21.3 2.3 7.3 15.9 18.9 0.8 cm. 65.0 195.6 54.1 5.8 18.5 40.4 48.0 2.0 in. 25.6 77.0 21.3 2.3 7.3 15.9 18.9 0.8 cm. 65.0 195.6 54.1 5.8 18.5 40.4 48.0 2.0 in. 25.6 82.0 21.3 2.3 7.3 15.9 18.9 0.8 cm. 65.0 208.3 54.1 5.8 18.5 40.4 48.0 2.0 HWG FPT Low Voltage Ext Power Pump Supply 1 in. 1 in. Swivel Swivel 14.3 9.8 12.3 36.3 24.9 31.2 1 in. 1 in. Swivel Swivel 14.3 9.8 12.3 36.3 24.9 31.2 1 in. 1 in. Swivel Swivel 14.3 9.8 12.3 36.3 24.9 31.2 Discharge Connection duct flange installed (±0.10 in) L M N Supply Supply Height Depth SEE CHART 13.6 13.2 34.5 33.5 SEE CHART 13.6 13.2 34.5 33.5 SEE CHART 13.6 13.2 34.5 33.5 Condensate is 3/4 in. PVC female glue socket and is switchable from side to front Unit shipped with deluxe 1 in. (field adjustable to 2 in.) duct collar/filter rack extending from unit 3.25 in. and is suitable for duct connection. Discharge flange is field installed and extends 1 in. [25.4mm] from cabinet Decorative molding and/or water connections extend 1.2 in. [30.5mm] beyond front of cabinet. Louvered vents in the compressor section right side access panel extend 1/2 in. [12.7 mm] from side of cabinet. Allow clearance for venting. Units Not Shown Above Right Return End Discharge Right Return Side Discharge Left Return End Discharge Left Return Side Discharge in cm in cm in cm in cm L 2.8 7.1 4.9 12.4 4.9 12.4 2.8 7.1 O 4.6 11.8 6.9 17.5 7.6 19.4 6.9 17.5 20 Return Connection using std deluxe filter rack (±0.10 in) Q R Return Return Depth Height O P S SEE CHART 2.8 40.4 18.9 1.3 7.1 102.6 48.0 3.3 SEE CHART 2.8 40.4 18.9 1.3 7.1 102.6 48.0 3.3 SEE CHART 2.8 45.4 18.9 1.3 7.1 115.3 48.0 3.3 6/29/12 PREMIUM V INSTALLATION MANUAL Physical Data Variable Speed Model 036 Compressor (1 each) 048 060 Variable Speed Scroll Factory Charge R-410A, oz [kg] Vertical 95 [2.69] 120 [3.40] 140 [3.96] Factory Charge R-410A, oz [kg] Horizontal 95 [2.69] 136 [3.85] 148 [4.19] ECM Blower Motor & Blower Blower Motor Type/Speeds ECM Blower Motor- hp [W] ECM Variable Speed 1/2  1  1  High Static Blower Motor - hp [W] ECM 1  n/a n/a Blower Wheel Size (Dia x W), in. [mm] ECM 11 x 10 [279 x 254] 11 x 10 [279 x 254] 11 x 10 [279 x 254] High Static Blower Wheel Size - [Dia. x W], in. [mm] ECM 11 x 10 [279 x 254] n/a n/a Water Connections Size - Swivel - in [mm] 1 [25.4] 1 [25.4] 1 [25.4] HWG Connection Size - Swivel - in [mm] 1 [25.4] 1 [25.4] 1 [25.4] Coax & Piping Water Volume - gal [l] 1.6 [6.1] 1.6 [6.1] 2.3 [8.7] 32 x 25 [813 x 635] 32 x 25 [813 x 635] 36 x 25 [914 x 635] 5.6 [0.570] 5.6 [0.570] 6.3 [0.641] 3/8 [9.5] 3/8 [9.5] 3/8 [9.5] 3 3 4 36 x 30 [914 x 762] Coax and Water Piping Vertical Air Coil Dimensions (H x W), in. [mm] Air Coil Total Face Area, ft2 [m2] Air Coil Tube Size, in [mm] Air Coil Number of rows 32 x 30 [813 x 762] 32 x 30 [813 x 762] Weight - Operating, lb [kg] Filter Standard - 1 in. [25 mm] Electrostatic, in [mm] 352  361  385  Weight - Packaged, lb [kg] 372  381  405  20 x 40 [508 x 1016] 20 x 40 [508 x 1016] 20 x 45 [508 x 1143] 5.6 [0.570] 5.6 [0.570] 6.3 [0.641] 3/8 [9.5] 3/8 [9.5] 3/8 [9.5] 3 3 4 20 x 47 [508 x 1194] Horizontal Air Coil Dimensions (H x W), in. [mm] Air Coil Total Face Area, ft2 [m2] Air Coil Tube Size, in [mm] Air Coil Number of rows 20 x 42 [508 x 1067] 20 x 42 [508 x 1067] Weight - Operating, lb [kg] Filter Standard - 1 in. [25 mm] Electrostatic, in [mm] 387  396  415  Weight - Packaged, lb [kg] 417  426  445  6/1/12 21 PREMIUM V INSTALLATION MANUAL The Aurora™ Advanced VS Control System Each module contains the logic to control all features that are connected to the module. The ABC has two Modbus channels. The first channel is configured as a master for connecting to devices such as a communicating thermostat, expansion board, or other slave devices. The second channel is configured as a slave for connecting the Aurora Interface Diagnostics Tool (AID Tool). Aurora Advanced VS Control Aurora Advanced VS Control System is a complete residential and commercial comfort system that brings all aspects of the HVAC system into one cohesive module network. The Aurora Advanced VS Control features the Aurora Base Control (ABC) and the Aurora Expansion Board (AXB). The variable speed drive communicates to the Aurora Control and provides variable capacity and envelope control. The ABC features microprocessor control and HP, LP, loss of charge, condensate and freeze detection, over/under voltage faults, along with communicating thermostat capability for complete fault detection text at the thermostat. Aurora uses the Modbus communication protocol to communicate between modules. The Aurora AXB expands on the capability of the ABC control board. The additional features include active dehumidification, SuperBoost cooling mode, loop pump slaving, intelligent hot water generator control, variable speed pump capability, and also allows for optional energy, refrigeration, and performance monitoring addon sensor kits. The AXB also features a second field configurable accessory relay, and two home automation inputs that are AID configurable for different types of alarms from sump pumps to home security. The Smart Grid input is AID configurable with many options to react to Utility controlled relay operation for On Peak optimization. The AXB also expands the communication capability for IntelliZone2 ready operation as well as other expansion with the ClimateTalk protocol. Aurora Control Features Description Aurora Advanced VS Smart Grid, Home Automation Alarm Inputs, and Accessory2 Relay (HRV/ERV) • Advanced Hot Water Generator Control Microprocessor and separate power relay for Hot Water Generator Pump with digital temperature monitoring and multiple HWG setpoint selection. • Advanced Speed Pump Control Microprocessor and separate power relay for loop pump and inline circuit breakers and loop pump slaving. • Advanced Microprocessor Features Variable Speed Pump Capable of setup, monitoring and controlling a variable speed flow center. • Active Dehumidification Coil temperature is monitored and air flow is reduced for maximum latent moisture removal. Premium V Variable Speed Only SuperBoost Allow the variable speed compressor to ramp up an extra 30% of cooling capacity if needed. This extra ‘SuperBoost’ will only be available for a 24 hr period and then the unit will revert to normal operation. • Smart Grid/Utility Input Allows simple input to externally enable of occupied/unoccupied mode for basic utility time of use programs. Dry Contact x1 Home Automation Alarm Input Allows simple input to signal sump, security, or smoke/CO sensor alarms from other home automation or security systems. The two inputs can be field configured to a number of options and logic. Dry Contact x2 IntelliZone2® Compatibility IntelliZone2 communicates to the heat pump via the AXB board. IntelliZone requires traditional thermostat inputs and is not compatible with the Premium V Series. Optional IntelliZone2 Service Device Description Aurora Advanced VS Allows setup, monitoring and troubleshooting of any Aurora Control. Aurora Interface and Diagnostics (AID) Tool NOTE: Although the ABC has basic compatibility with all Aurora, new product features may not be available on older AID Tools. To simplify the basic compatibility ensure the version of AID is at least the same or greater than the ABC software version. 22 For Service (Ver. 2.xx or greater) PREMIUM V INSTALLATION MANUAL The Aurora Advanced VS Control System cont. Add On Control Feature Kits (field or factory Installed) Description Aurora Advanced VS Monitors real time power consumption of compressor, blower, aux heat and pump. Requires thermostat TPCM32U04GSM or TPCC32U01GSM. Standard Refrigeration Monitoring Kit Monitors real time pressures, temperatures, superheat, and subcooling. Standard Performance Monitoring Kit Monitors air and water temperatures, and water flow rate and calculates heat of extraction/rejection. Geo Energy Monitoring Kit Add On Thermostats and Zoning Description Optional Sensor Kit Aurora Advanced VS Elite Stat with full English fault codes and alerts, communicating thermostat; Monochrome thermostat allows instantaneous energy measurement only. Optional 4.3 in. color touchscreen communicating thermostat with full English fault codes and alerts; Color thermostat allows instantaneous and 13 month history. Optional Includes color main thermostat and up to 6 zones (with variable speed), 4 zones (with dual capacity), and 2 zones (with single speed). There are 3 thermostat options (MasterStat, SensorStat, ZoneStat). Optional TPCM32U04GSM - MonoChrome Communicating Thermostat TPCC32U01GSM - Color Touchscreen Communicating Thermostat IntelliZone2® Zoning NOTES: The IntelliZone2 or one of the communicating thermostats shown above must be used to control the variable speed heat pump. Aurora Advanced VS Control Features Variable Speed ECM Blower Motor NOTE: Refer to the Aurora Advanced VS Control Application and Troubleshooting Guide and the Instruction Guide: Aurora Interface and Diagnostics (AID) Tool for additional information. A variable speed ECM blower motor is driven directly using the onboard PWM output. Multiple blower speeds are available based upon requirements of the compressor and electric heat. The blower speeds can be changed either by the variable speed ECM manual configurations mode method or by using the Aurora AID Tool directly. Control Features Software ABC VS Version 2.0 Variable Capacity Compressors • Random start at power up • Anti-short cycle protection • High and low pressure cutouts • Loss of charge • Water coil freeze detection • Air coil freeze detection • Over/under voltage protection • Condensate overflow sensor • Load shed • Dehumidification (where applicable) • Emergency shutdown • Diagnostic LED • Test mode push button switch • Two auxiliary electric heat outputs • Alarm output • Accessory output with N.O. and N.C. • Modbus communication (master) • Modbus communication (slave) Advanced Hot Water Generator Control (Domestic Hot Water Option) An AID Tool selectable temperature limit and microprocessor control of the process is featured. This will maximize hot water generation and prevent undesirable energy use. An alert will occur when the hot water input temperature is at or above the set point (130°F default) for 30 continuous seconds. This alert will appear as an E15 on the AID Tool and the hot water pump de-energizes. Hot water pump operations resume on the next compressor cycle or after 15 minutes of continuous compressor operation during the current thermostat demand cycle. Since compressor hot gas temperature is dependent on loop temperature in cooling mode, loop temperatures may be too low to allow proper heating of water. The control will monitor water and refrigerant temperatures to determine if conditions are satisfactory for heating water. 23 PREMIUM V INSTALLATION MANUAL The Aurora Advanced VS Control System cont. VS Drive and Envelope Control Advanced Communication Ports The VS drive operates the compressor between 20 and 100% capacity. The VS drive communicates any out of refrigerant envelope conditions to the Aurora and will attempt to adjust the compressor speed to keep within the envelope. These conditions are measured using the discharge and suction pressure transducers, discharge temperature, and current sensors of the drive. Communication ports P6 and P8 will provide future expansion via dedicated protocols. These are for future use. Smart Grid/On Peak (SG) Input The 'Smart Grid/On Peak' input was designed to allow utilities to utilize simple radio controlled switches to control the On Electric Peak behavior of the Premium V Series Geothermal Heat Pumps and provide demand reduction. With a closed contact signal, this input will limit the operation and thus the power consumption of the unit by disabling the compressor and electric heat as long as the signal is present. Code 7 will flash on the Green LED signifying the 'On Peak' mode. On Peak will also display on communicating thermostats. IntelliZone2 Zoning Compatibility (Optional IntelliZone2 Zoning) A dedicated input to connect and communicate with the IntelliZone2 (IZ2) zoning system is provided on P7. There is a dedicated communication port using a proprietary ModBus protocol. The AXB is standard on variable speed systems. An AXB can be added to other selected ABC only systems as well. Then an advanced communicating IntelliZone2 zoning system can be added to ABC-only systems. Consult the IntelliZone2 literature for more information. Home Automation 1 and 2 Inputs The electronic expansion valve is operated by the EEV board and is set to maintain optimal superheat setting for maximum efficiency. All operation parameters are communicated to the VS drive and the Aurora system. The Home Automation inputs are simple closed contact inputs that will trigger an AID Tool and thermostat alert for the homeowner. These would require optional sensors and or equipment for connection to the AXB board. With two inputs, two different sensors can be selected. The selected text will then be displayed on the AID Tool and communicating thermostats. These events will NOT alter functionality or operation of the heat pump/accessories and is for homeowner/service notification only. Variable Speed Pump Home Automation 1 - E23 HA1 This input and output are provided to drive and monitor a variable speed pump. The VS pump output is a PWM signal to drive the variable speed pump. The minimum and maximum level are set using the AID Tool. 50% and 100% are the default settings respectively. The VS data input allows a separate PWM signal to return from the pump giving fault and performance information. Fault received from the variable speed pump will be displayed as E16. With a closed dry contact signal, this input will cause an alarm and Alert Code 23 to indicate on the stat or flash on ABC. The AID Tool will allow configuration of this input between the following selections: • No Action • Home Automation Fault [no lockout info only] - Output from home automation system • Security Alarm [no lockout info only] - Output from home security • Sump Alarm Fault [no lockout info only] - Switch output from sump sensor • Smoke/CO Alarm Fault [no lockout info only] - Switch output from Smoke/CO sensor • Dirty Filter Alarm [no lockout info only] - Output from dirty filter sensor Electronic Expansion Valve Modulating Water Valve This output is provided to drive a modulating water valve. Through advanced design the 0-10VDC valve can be driven directly from the VS Pump output. The minimum and maximum level are set in the same way as the VS pump using the AID Tool. 50% and 100% are the default settings respectively. Home Automation 2 – E24 HA2 Loop Pump Slaving With a closed dry contact signal, this input will cause an alarm and Alert Code 24 to indicate on the stat or flash on ABC. The AID Tool will allow configuration of this input between the following selections: • No Action • Home Automation Fault [no lockout info only] - Output from home automation system • Security Alarm [no lockout info only] - Output from home security • Sump Alarm Fault [no lockout info only] - Switch output from sump sensor This input and output are provided so that two units can be slaved together with a common flow center. When either unit has a call for loop outputs, both unit’s loop pump relays and variable speed pumps are energized. The flow center then can simply be wired to either unit. The output from one unit should be routed to the input of the other. If daisy chained, up to 16 heat pumps can be wired and slaved together in this fashion. 24 PREMIUM V INSTALLATION MANUAL The Aurora Advanced VS Control System cont. • Smoke/CO Alarm Fault [no lockout info only] - Switch output from Smoke/CO sensor • Dirty Filter Alarm [no lockout info only] - Output from dirty filter sensor Dehumidification – Active Active dehumidification will only activate during cooling operation and is based upon the humidity setpoint of the thermostat being at least 5% below the actual relative humidity and being within the temperature parameters described here. The green status LED will flash code 2 when active. The unit can operate a maximum of 2°F below the cooling setpoint. The compressor will ramp up and airflow will begin at a low level. Airflow is then reduced periodically until air coil temperature setpoint is reached. If coil temperature continues to drop, the airflow is increased until air coil setpoint is maintained. After 20 minutes of operation in the Active Dehumidification mode, normal cooling operation will resume for 5 minutes. This cycle continues until the dehumidification setpoint is reached, room temperature is more than 2°F below cooling setpoint, or more than 1°F above cooling setpoint (normal cooling takes over). In IntelliZone2 systems, the main zone will remain open during active dehumidification. Monitoring Sensor Kits Energy Monitoring (Standard on all Premium V Series units) The Energy Monitoring Kit includes two current transducers (blower and electric heat) added to the existing two compressor sensors so that the complete power usage of the heat pump can be measured. The AID Tool provides configuration detail for the type of blower motor and a line voltage calibration procedure to improve the accuracy. This information can be displayed on the AID Tool or selected communicating thermostats. The TPCM32U04GSM will display instantaneous energy use while the color touchscreen TPCC32U01GSM will, in addition, display a 13 month history in graph form. Field Hardware Selectable Options ABC Field Selectable Options via Button (SW1) Refrigerant Monitoring Test/Configuration Button (See SW1 Operation Table) (Standard on all Premium V Series units) The optional Refrigerant Monitoring Kit includes two pressure transducers, and three temperature sensors, heating liquid line, suction temperature and existing cooling liquid line (FP1). These sensors allow the measurement of discharge and suction pressures, suction and liquid line temperatures as well as superheat and subcooling. This information will only be displayed on the AID Tool. Test Mode The control is placed in the test mode by holding the push button switch on the ABC SW1 for 2 - 5 seconds. In test mode most of the control timings will be shortened by a factor of sixteen (16). LED3 (green) will flash at 1 second on and 1 second off. Additionally, when entering test mode LED1 (red) will flash the last lockout one time. Test mode will automatically time out after 30 minutes. Test mode can be exited by pressing and holding the SW1 button for 2 to 5 seconds or by cycling the power. NOTE: Test mode will automatically be exited after 30 minutes. Performance Monitoring (Optional sensor kit) The optional Performance Monitoring Kit includes three temperature sensors, entering and leaving water, leaving air temperature and a water flow rate sensor. With this kit heat of extraction and rejection will be calculated. This requires configuration using the AID Tool for selection of water or antifreeze. Variable Speed ECM Configuration Mode The control is placed in the variable speed ECM configuration mode by holding the push-button switch SW1 for 5 to 10 seconds, the high, low, and G variable speed ECM speeds can be selected by following the LED display lights. LED2 (yellow) will fast flash when entering the variable speed ECM configuration. When setting G speed LED3 (green) will be continuously lit, for low speed LED1 (red) will be continuously lit, and for high speed both LED3 (green) and LED1 (red) will be continuously lit. During the variable speed ECM configuration mode LED2 (yellow) will flash each of the 12 possible blower speeds 3 times. When the desired speed is flashed press SW1, LED2 will fast flash until SW1 is released. G speed has now been selected. Next select low speed, and high speed blower selections following the same process above. After third selection has been made, the control will exit the variable speed ECM configuration mode. Aux blower speed will remain at default or current setting and requires the AID Tool for adjustment. Special Modes and Applications Communicating Digital Thermostats The Aurora VS controls system also requires either the monochromatic or color touch screen graphic display thermostats for user interface. These displays not only feature easy to use graphical interface but display alerts and faults in plain English. ‘SuperBoost’ Cooling Mode Occasionally there can be a requirement for a short term ‘boost’ of cooling capacity during a large party etc. The Premium V Series allows the user to select ‘SuperBoost’ mode on the thermostat which will allow the Premium V Series VS to ramp up an extra 30% of cooling capacity if needed. This extra ‘SuperBoost’ will only be available for a 24 hr period and then the unit will revert to normal operation. The short term boost does not affect ground loop sizing since it is limited in operation. Continuous use of SuperBoost will result in overheating of the ground loop. 25 PREMIUM V INSTALLATION MANUAL The Aurora Advanced VS Control System cont. Reset Configuration Mode AXB DIP Switch (SW1) The control is placed in reset configuration mode by holding the push button switch SW1 on the ABC for 50 to 60 seconds. This will reset all configuration settings and the EEPROM back to the factory default settings. LED3 (green) will turn off when entering reset configuration mode. Once LED3 (green) turns off, release SW1 and the control will reset. DIP 1 - ID: This is the AXB ModBus ID and should always read On. DIP 2 & 3 - Future Use DIP 4 & 5 - Accessory Relay2: A second, DIP configurable, accessory relay is provided that can be cycled with the compressor 1 or 2 , blower, or the Dehumidifier (DH) input. This is to complement the Accessory 1 Relay on the ABC board. ABC DIP Switch (SW2) SW2-1 SW2-2 SW2-3 SW2-4 and 2-5 FP1 Selection – Low water coil temperature limit setting for freeze detection. On = 30°F; Off = 15°F. FP2 Selection – Low air coil temperature limit setting for freeze detection. On = 30°F; Off = Not Used 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. Access Relay Operation (P2) SW2-4 Cycle with Blower ON ON OFF OFF Water Valve Slow Opening ON OFF Cycle with Comm. T-stat Hum Cmd OFF ON SW2-8 DIP 5 ON 2 OFF ON 3 ON OFF 4 OFF OFF Description Cycles with blower or ECM (or G) Cycles with CC1 first stage of compressor or compressor spd 1-12 Cycles with CC2 second stage of compressor or compressor spd 7-12 Cycles with DH input from ABC board Field Selectable Options via Software Many options are field selectable and configurable in Aurora software via the AID Tool. Consult the installation manual or Aurora documentation for further details. SW2-5 Cycle with Compressor SW2-7 DIP 4 ON (Selectable via the Aurora AID Tool) Access Relay Operation SW2-6 Position 1 Basic Aurora Safety Features The following safety features are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions. CC Operation – selection of single or dual capacity compressor. On = Single Stage; Off = Dual Capacity NOTE: SW2-6 is not applicable to the Premium V Series Lockout and Alarm Outputs (P2) – selection of a continuous or pulsed output for both the LO and ALM Outputs. On = Continuous; Off = Pulsed NOTE: SW2-7 is not applicable to the Premium V Series Future Use 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. Alarm Jumper Clip Selection Fault Retry – in the fault condition, the control will stage off the outputs and then “try again” to satisfy the thermostat VS call. Once the thermostat input calls are satisfied, the control will continue on as if no fault occurred. If 3 consecutive faults occur without satisfying the thermostat VS call, then the control will go to Lockout mode. From the factory, ALM is connected to 24 VAC via JW2. By cutting JW2, ALM becomes a dry contact connected to ALG. Variable Speed ECM Blower Speeds The blower speeds can be changed either by using the variable speed ECM manual configurations mode method or by using the Aurora AID Tool directly (see Instruction Guide: Aurora Interface and Diagnostics (AID) Tool topic). Lockout – when locked out, the blower will operate continuously in “G” blower speed setting. The Alarm output (ALM) and Lockout output (L) will be turned on. The fault type identification display LED1 (Red) shall flash the fault code. To reset lockout conditions with SW2-8 On, the demand call must be removed for at least 30 seconds. To reset lockout conditions with SW2-8 Off, the demand call must be removed for at least 30 seconds. Lockout may also be reset by turning power off for at least 30 seconds or by enabling the emergency shutdown input for at least 30 seconds. CAUTION: Frequent cycling of power to the drive can damage the drive! Wait at least 5 minutes between cycles (connecting and disconnecting power to the drive). 26 PREMIUM V INSTALLATION MANUAL The Aurora Advanced VS Control System cont. Lockout With Emergency Heat - if the control is locked out in the heating mode, and a call for emergency heat is received, the control will operate in the emergency heat mode while the compressor is locked out. The first emergency heat output will be energized 10 seconds after the W input is received, and the blower will shift to high speed. If the control remains locked out, and the W input is present, additional stage of emergency heat will stage on after 2 minutes. When the W input is removed, all of the emergency heat outputs will turn off, and the variable speed ECM blower will shift to low speed. Other Lockouts and Alarms Several other lockouts and alarms are shown in the Status LED1 (LED1, Red) table with the associated codes visible on the thermostat, ABC Fault LED, and in text in the AID Tool. Operation Description Power Up - The unit will not operate until all the inputs and safety controls are checked for normal conditions. The unit has a 5 to 80 second random start delay at power up. Then the compressor has a 4 minute anti-short cycle delay after the random start delay. 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. Standby - In standby mode the compressor, pump, and blower motor are not active. The RV may be active. The blower and compressor will be off. Heating Operation - The unit will operate based upon demand as calculated by the room setpoint algorithm. The resulting compressor speed (1-12) will also select an appropriate blower speed for the selected compressor speed. Aux Heat will not be available (on IntelliZone2 Aux Heat is available on compressor speeds 10-12) until after the 12th compressor speed has been operational and still is not satisfying the thermostat, then auxiliary electric heat will be activated. 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. Condensate Overflow - fault is recognized when the impedance between this line and 24 VAC common or chassis ground drops below 100K ohms for 30 seconds continuously. Emergency Heat (W) - The blower will be started on G speed, 10 seconds later the first stage of electric heat will be turned on. 5 seconds after the first stage of electric heat is energized the blower will shift to Aux speed. If the emergency heat demand is not satisfied after 2 minutes the second electric heat stage will be energized. Freeze Detection-Coax - set points shall be either 30°F or 15°F. When the thermistor temperature drops below the selected set point, the control shall begin counting down the 30 seconds delay. If the thermistor value rises above the selected set point, then the count should reset. The resistance value must remain below the selected set 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. Cooling Operation - The unit will operate based upon demand as calculated by the room setpoint algorithm. The resulting compressor speed, speeds 1-9, (speeds 10-12 are reserved for SuperBoost mode only) will also select an appropriate blower speed. The blower mode will also have the cooling airflow adjustment applied. In all cooling operations, the reversing valve directly tracks the O input. Thus, anytime the O input is present, the reversing valve will be energized. Freeze Detection-Air Coil - Air Coil Freeze Detection will use the FP2 input to protect against ice formation on the air coil. The FP2 input will operate exactly like FP1 except that the set point is 30 degrees and is not field adjustable. Blower (G) - The blower will start immediately upon receiving a thermostat G command. If there are no other commands from the thermostat the variable speed ECM will run on low speed until the G command is removed. Regardless of blower input (G) from the thermostat, the blower will remain on low speed for 30 seconds at the end of each heating, cooling, and emergency heat cycle. Loss of Charge – fault is recognized when the Normally Closed Low Pressure Switch, P4-7/8 is open prior to the compressor starting. 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 self-resetting 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. 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. 27 PREMIUM V INSTALLATION MANUAL The Aurora Advanced VS Control System cont. 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. Aurora Advanced VS Control LED Displays These three LEDs display the status, configuration, and fault codes for the control. These can also be read in plain English via the Aurora AID Tool. See the LED tables for further explanation. Load Shed - The LS input disables all outputs with the exception of the blower output. When the LS input has been cleared, the antishort cycle timer and random start timer will be initiated. Input must be tied to common to activate. Aurora Interface and Diagnostics (AID) Tool The Aurora Interface and Diagnostics (AID) Tool is a device that is a member of the Aurora network. The AID Tool is used to troubleshoot equipment which uses the Aurora control via Modbus RTU communication. The AID Tool provides diagnostics, fault management, variable speed ECM setup, and system configuration capabilities to the Aurora family of controls. An AID Tool is recommended, although not required, for variable speed ECM airflow settings. The AID Tool simply plugs into the exterior of the cabinet in the AID Tool port. Status LED (LED3, Green) Description of Operation Normal Mode Fault LED, Green ON Control is Non-functional OFF Test Mode Slow Flash Lockout Active Fast Flash Dehumidification Mode Flash Code 2 Load Shed Flash Code 5 Emergency Shutdown Flash Code 6 On Peak Mode Flash Code 7 Warning! VS Derated Flash Code 8 Warning! VS SafeMode Flash Code 9 Configuration LED (LED2, Yellow) Description of Operation 28 Configuration LED, Yellow No Software Overwritten ECM Setting DIP Switch Overwritten Slow Flash ECM Configuration Mode Fast Flash Reset Configuration Mode OFF Miscellaneous ABC & AXB Basic Faults 29 Danfoss VS Drive 43 44 Derate-LoSucPres Derate-LoConPres 54 55 Fault-ConPrsSnr Fault-LowSupVolt Fault-OutEnvelop 59 61 71 72 73 74 Fault-DrvIntErr MOC/AOC Fault-MultSafeMd Fault-LossofCharge SafeMd-SucTmpSnr SafeMd-LATSensor SafeMd-MaxOpPres 58 53 Fault-SucPrsSnr Fault-HiDrivTemp 52 Fault-DisTmpSnr 56 51 SafeMd-AmbTmpSnr 57 49 SafeMd-EEVOutCom Fault-Over/UnderVolt 48 SafeMd-EEVIndCom Fault-OverCurrnt 46 47 Derate-OutPwrLmt 45 42 Derate-HiDisTemp Derate-HiConPres 24 41 Alarm - Home Automation 1 Derate-DriveTemp 23 Alarm - Low Loop Pressure Alarm - Home Automation 2 19 21 Fault-CritComErr 16 18 15 Alarm-HotWtr Non-CritComErr 14 CriticAXBSnsrErr Fault-VarSpdPump 11 13 Non-CriticAXBSnsrErr 10 Fault-Compressor Monitor Fault-FP1 & 2 Snsr Error 8 Fault-Over/Under Voltage 4 Fault-Freeze Detection FP2 5 3 Fault-Low Pressure 7 2 Fault-High Pressure Fault-Condensate Overflow 1 Fault-Input Fault-Freeze Detection FP1 Off Normal - No Faults No No No Yes Yes Yes Yes Yes Auto Auto Auto Hard or Soft Hard or Soft Hard or Soft Hard or Soft Hard or Soft Hard or Soft Hard or Soft 10x then Yes Yes Hard or Soft Hard or Soft 10x then Yes Yes Hard or Soft Hard or Soft Auto Auto Auto Auto Auto Auto Auto Auto Auto Auto Auto Auto Auto Auto Auto Auto Hard or Soft Auto Hard or Soft Hard or Soft Auto Hard or Soft Hard or Soft Hard or Soft Hard or Soft Hard or Soft Auto Reset/ Remove Yes Yes No No No No No No No No No No No No No No No No Yes No Yes Yes No Yes Yes Yes Yes Yes No - LED Flash Lockout Code * Normal Lockout Suction pressure has exceeded that maximum operating level for 90 sec. Leaving Air Temperature Sensor is invalid (-76 to 392 F) SafeMode Normal SafeMode High superheat and high EEV opening % for a long time will trigger a loss of charge fault Suction Temperature Sensor is invalid (-76 to 392 F) Lockout Lockout Lockout Lockout Lockout Norm then Lockout Lockout Norm then Lockout Lockout Lockout SafeMode SafeMode SafeMode Derated Derated Derated Derated Derated Derated Normal Normal Normal Normal Normal Normal Normal Lockout Normal Lockout Lockout Lockout Lockout Lockout Lockout Lockout Lockout Code 74 Code 73 Code 72 Code 71 Code 61 Code 59 Code 58 Code 57 Code 56 Code 55 Code 54 Code 53 Code 52 Code 51 Code 49 Code 48 Code 47 Code 46 Code 45 Code 44 Code 43 Code 42 Code 41 Code 24 Code 23 Code 21 Code 19 Code 18 Code 16 Code 15 Code 14 Code 13 Code 11 Code 10 Code 8 Code 7 Code 5 Code 4 Code 3 Code 2 Code 1 ABC Red Fault LED ABC Action ABC Green Status LED More than one SafeMode condition is present requiring lockout. The MOC has encountered an internal fault or an internal error. Probably fatal. Drive Temp has reached critical High Temp >239 F DC Link Voltage to compressor is >253V or at minimum Volt. Over current tripped by phase loss, earth fault, short circuit, low water flow, low air flow, or major drive fault. Comp Operating out of envelope (P0) more than 90 sec. Retry 10x. Supply Voltage is <175 V (190V to reset) or powered off/on too quickly (<30 sec.). Low condensing pressure (PD) or invalid (0 to 870 psi) Retry 10x. Suction Pressure (P0) is invalid (0 to 232 psi) Discharge Sensor (Sd) is > 280 F or invalid (-76 to 392 F) Ambient Temperature (Tamb) is <-76 or > 212 F and out of range or invalid Com with EEV is interupted EEV has gone independent mode Com with EEV is interupted EEV has gone independent mode Supply Voltage is <208V or Max Pwr is reached due to high pressure Condensing pressure is critically high Condensing pressure is critically low Suction Pressure is critically low Compressor Discharge isexceeded limit for 90 continuous sec.. Drive Temp has reached critical High Temp Closed contact input is present on Dig 3 input - Text is configurable Closed contact input is present on Dig 2 input - Text is configurable Loop pressure is below 3 psi for more than 3 minutes Any critical com error. Auto reset upon condition removal Any non-critical com error Alert is read from PWM feedback. HW over limit or logic lockout. HW pump deactivated. Sensor Err for EEV or HW Any Other Sensor Error If FP1 or 2 Sensor Error Open Crkt, Run, Start or welded cont Instantaneous Voltage is out of range. **Controls shut down until resolved. Condensate switch has shown continuity for 30 continuous sec. Freeze protection sensor has tripped (<15 or 30 degF for 30 continuous sec.) Freeze protection sensor has tripped (<15 or 30 degF for 30 continuous sec.) Low Pressure Switch has tripped (<40 psi for 30 continous sec.) HP switch has tripped (>600 psi) Tstat input error. Autoreset upon condition removal. Fault Condition Summary NOTES: *All codes >11 use long flash for tens digit and short flash for the ones digit. 20, 30, 40, 50 etc. are skipped! Alert’ is a noncritical sensor or function that has failed. Normal operation of the heat pump is maintained but service is desired at some point. Ind/Pkg Danfoss EEV2 Red Fault LED Status LED (LED1, Red) Warning! SafeMode - E74 MaxOpPress Alert - E73 LAT Sensor Warning! SafeMode - E72 SucTmpSnr Lockout! - E71 LossCharge Lockout! - E61 MultSafeMd Lockout! - E59 DrvIntErr Lockout! - E58HiDrivTemp Lockout! - E57 Over/Under Volt Lockout! - E56 OverCurrnt Lockout! - E55 OutEnvelop Lockout! - E54 LowSupVolt Lockout! - E53 ConPrsSnr Lockout! - E52 SucPrsSnr Lockout! - E51 DisTmpSnr Warning! SafeMode - E49 Warning! SafeMode - E48EEVOutCom Warning! SafeMode - E47 EEVIndCom Warning! Derated - E46 OutPwrLmt Warning! Derated - E45 HiConPress Warning! Derated - E44 LoConPress Warning! Derated - E43 LoSucPres Warning! Derated - E42 HiDisTemp Warning! Derated - E41 DriveTemp Alert - E24 Selected Choice Alert - E23 Selected choice Alert - E51 Low Loop Pressure Alert - E19 Critical Communication Error Alert - E18 Non-Critical Communication Error Alert - E16 Var Spd Pump Err Alert - E15 Hot Water Temp Limit Lockout - E14 Critical AXB Sensor Error Alert - E13 Non-Critical AXB Sensor Error Lockout - E11 FP1/FP2 Sensor Error Lockout - E10 Compress Monitor Lockout - E8 Over/Under voltage Lockout - E7 Condensate Lockout - E5 Freeze Detection FP1 Lockout - E4 Freeze Detection FP2 Lockout - E3 Low Press Lockout - E2 High Press AID Tool Display and History Warning! SafeMode - E74 MaxOpPress No Display Warning! SafeMode - E72 SucTmpSnr Lockout! - E71 LossCharge Lockout! - E61 MultSafeMd Lockout! - E59 DrvIntErr Lockout! - E58HiDrivTemp Lockout! - E57 Over/Under Volt Lockout! - E56 OverCurrnt No Display Lockout! - E54 LowSupVolt Lockout! - E53 ConPrsSnr Lockout! - E52 SucPrsSnr Lockout! - E51 DisTmpSnr Warning! SafeMode - E49 Warning! SafeMode - E48EEVOutCom Warning! SafeMode - E47 EEVIndCom Warning! Derated - E46 OutPwrLmt Warning! Derated - E45 HiConPress Warning! Derated - E44 LoConPress Warning! Derated - E43 LoSucPres Warning! Derated - E42 HiDisTemp Warning! Derated - E41 DriveTemp Alert - E24 Selected Choice Alert - E23 Selected choice No Display Alert - E19 Critical Communication Error Alert - E18 Non-Critical Communication Error Alert - E16 Var Spd Pump Err No Display Lockout - E14 Critical AXB Sensor Error Alert - E13 Non-Critical AXB Sensor Error Lockout - E11 FP1/FP2 Sensor Error Lockout - E10 Compress Monitor Lockout - E8 Over/Under voltage Lockout - E7 Condensate Lockout - E5 Freeze Detection FP1 Lockout - E4 Freeze Detection FP2 Lockout - E3 Low Press Lockout - E2 High Press IntelliZone2 and Thermostat Display PREMIUM V INSTALLATION MANUAL The Aurora Advanced VS Control System cont. PREMIUM V INSTALLATION MANUAL The Aurora Advanced VS Control System cont. P11 DH EEV Board Layout KM5 1 2 3 4 KM9 30 SPR ANA CT1 2 1 P5 CT2 4 3 CT1 2 1 CT2 4 3 P15 R (-) C P9 ABC (+) R (-) C P7 ZONE (+) R (-) V+ RS485 (+) C R TX P6 Variable Speed Drive KM6 KM1 1 2 1 1 3 4 2 2 KM2 KM7 STEPPER P10 HA1 HA2 P4 MOTOR RX P8 SCT Acc 2 – Dip 4 Acc 2 – Dip 5 5 P18 Future Use Future Use 4 P12 Modbus Add. ID 2 3 P17 LOOP R SGI R DIV K1 K2 PWM P3 OFF ON 1 SW1 KM4 1 2 3 4 L2 L2 COM COM K5 NO NO L1 K6 VS C C DH W Y2 G Y1 C 3A-Fuse W DH Y2 G Y1 O/B C C R LO O/B LO R Field Connections P1 ACC nc ACC c ACC no ALG LS ES ALM Field Connections P2 SUC P G P8 Factory Fan Connection Y1 AXB™ (Aurora Expansion Board) HW Acc – K6 G R DISCH R C Com2 P9 (-) +5 LED 4 JW2 - Alarm CC (+) C P11 Alarm – K5 G Status G P1 Fan – K4 RS 485 Com1 Factory Use Factory CC2 LED 5 P7 CC Hi – K3 (+) (-) R C K3 Aurora Base Control TM CC – K2 F P6 RS485 Exp CC2 P5 P14 SW2 RV – K1 G LO HI CCG CC FG F R 7 8 Reheat/Normal LLT Status P16 6 EH2 C EH1 C CO N/A LAT CC – Dual/Single L – Pulse/Continuous P3 FLOW 5 LWT 4 ACC – Dip 2 EWT ACC – Dip 1 Y Config P2 G 3 SLO LED 3 SW1 Test 2 FP2 – 15oF/30oF RV – B/O SLI R Fault Factory ECM PWM P13 See Figure 1 for DHW wiring. EH1 RS485 NET C PWM CFM P4 Factory HP HP LP LP FP2 FP2 FP1 FP1 REV REV On 1 LED 2 Off LED 1 FP1 – 15oF/30oF L1 AXB Control Board Layout C ABC Control Board Layout PREMIUM V INSTALLATION MANUAL Operation Logic Heating Mode Variable Speed Loop Pump When the variable speed controls determine that heating is needed in the space the blower will be turned on, the compressor will be ramped to speed 6 and the loop pump will be started. The compressor will continue to run at speed 6 for 60 seconds for oil circulation. During the 60 second oil circulation the controls will calculate what speed the compressor will need to operate at to maintain the set point in the space. If the compressor is operating at speed 12 and the unit is unable to maintain set point the controls will stage on the electric heat. Electric heat will not operate unless the compressor is already running at speed 12. Every 30 minutes if the compressor has been operating lower than speed 6, the controls will increase the compressor to speed 6 for one minute for oil circulation. The variable speed controls will operate the variable speed loop pump similar to the way the ECM blower motor operates. The speed of the pump will be increased as the compressor speed is increased to maintain adequate water flow. Safe Mode The system has encountered an unsafe operating condition that prevents automatic speed control, e.g. lost a sensor signal. To avoid damage to the system, the drive is running the compressor at a fixed speed of 2400 rpm awaiting the problem to be solved and eventually returning to normal operation. If the problem cannot be solved the drive stops and issues an alarm. (See fault/ alarm table.) Cooling Mode Derating When the variable speed controls determine that cooling is needed in the space the blower will be turned on, the reversing valve will be enabled, the compressor will be ramped to speed 6, and the loop pump will be started. The compressor will continue to run at speed 6 for 60 seconds for oil circulation. During the 60 second oil circulation the controls will calculate what speed the compressor will need to operate at to maintain the set point in the space. The compressor will be limited to a maximum of speed 9 for cooling. If additional capacity is needed SuperBoost mode can be enabled from the thermostat allowing the compressor to run at speeds higher than 9 for a period of 24 hours. Every 30 minutes if the compressor has been operating lower than speed 6, the controls will increase the compressor to speed 6 for one minute for oil circulation. The VS compressor utilizes ‘envelope control’ to maintain performance within operational limits and improve reliability. To accomplish this, pressure sensors for discharge and suction pressure as well as hot gas temperature sensing are used to monitor the conditions in which the compressor operates. The envelope does vary based upon operating speed (rpm). When operating out of these limits the control will attempt to improve the situation by moderating the compressor speed for a larger envelope. When this occurs it can be observed on the Aurora control as an ‘E’ code. The control will automatically try to resolve the situation. If the situation progresses, a fault and lockout will be generated by the control. ECM Blower Motor The variable speed controls will vary the ECM blower output to maintain optimum air flow at each of the 12 compressor speeds. If dehumidification mode is selected during the cooling operation the airflow will be varied to allow for maximum moisture removal. 31 PREMIUM V INSTALLATION MANUAL Wiring Schematics Aurora Variable Speed 1 Orange(9) 1 2 208-230/60/1 PB1 2 Brown(10) G Violet(8) NOTE 12 VS Pump Violet(7) Red Black Black Circuit Breaker L2 L2 NO BLOWER CURRENT TRANSDUCER (CT) CC T2 T1 L1 COM DISCH COM L2 Black/White(5) ACC2 ANA (Aurora Expansion Board) P15 CT2 CT1 4 3 2 1 SGI P3 C S +5 C S +5 2 1 C OUT C IN LOOP VS DATA VS PUMP PUMP SLAVE AUXILIARY HEAT CT Black Brown BLOWER CT Brown Transformer Yellow 24V Black/White OFF ON 1 2 3 Future Use 4 RV RV Acc 2 – Dip 4 Acc 2 – Dip 5 5 P18 SCT P17 HW HA1 P9 C R (-) R C P7 ABC (+) (-) C P6 ZONE (+) R (-) C R V+ P8 RS485 (+) ALG K5-Alarm Relay K1-RV Relay LS ALM K3-CC2 Relay TX C R ES K2-CC Relay MOTOR RX REVREVFP1 FP1 FP2 FP2 LPS LPSHPSHPS P4 P2 K4-Fan Relay +5 HA2 Black(10) P4 HP Black(09) Black CC2 CC2 CC2 P5 F FG CC CCG HI LO G R Blue(08) C LP Blue(07) F Black P9 CC Yellow CC2 FP2 Yellow Orange(01) EH1 Orange(02) Blue Blue Black(15) Violet(14) T HOT WATER OPTION JW2 Pink Pink FP1 T Modbus Add. ID Future Use F1-3A Violet(42) F ACC COM MODULATING VALVE ACC NO ACC NC AXB BOARD 0-10DC 3 PWM K6-Acc Relay Aurora Base Control (ABC) LO R AID Tool VS 1 2 GND 1 24 VAC 2 P11 NOTE: 9 Black SW1 Home Automation 5 Red 208V CC Smart Grid Black T Future Use 4 ECM Blower Motor Analog Output 0-10VDC Orange STEPPER Blue Black NOTE: 4 3 Blue 240V Orange NOTE: 8 P12 VARIABLE SPEED PUMP LOW VOLTAGE 10DC 1 1 GND 2 2 PWM 3 3 NA 4 4 Brown 2 P10 Pump Slave Input/Output Unit Power 208-230/60/1 Accessory 2 Output Black 12 15 10 16 1 3 P2 PERFORMANCE OPTION 1 Black R G PWM CFM C1 C2 AXB™ P1 White Dehumidification Output White P5 CT2 CT1 4 3 2 1 EWT White Green G White SUC P Purple 3 PS DIV P11 DH K2 K3 LWT Purple T Status G FLOW Green White Brown T Black(2) K1 P16 LAT Gray Gray FLOW METER GND 3 3 OUT 2 2 5DC 4 4 Orange 1 NOTE 1 LLT Brown Brown 2 Gray/White(4) Black(3) Brown NOTE 7 NOTE 2 K5 K6 NO L1 R L1 P14 L1 and L2 on VS Drive 5A Circuit Breaker See Figure 1 for DHW wiring. 5A Circuit Breaker C 208-230/60/1 T Red Circuit Breaker G SW1 Test Mode CFM Status LED3 G O/B C 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 ABC BOARD W DH Communicating Thermostat Yellow(25) Green/Yellow(28) P13 On 1 2 3 4 5 6 7 8 SW2 Off G R C Fault LED1 R C Blue(24) P1 RS485 NET R C Com2 LED5 G Com1 LED5 Config LED2 Y G RS485 NET P8 C R - RS485 EXP + P7 C R - + P6 CO C EH1 C EH2 P3 Y1 G CC Green(11) NOTE 6 Brown(23) Black(21) Black(20) C 1 To Master on A- 2 Condensate VS Drive B+ 3 32 Black(22) 4 3 2 1 C Variable Speed Pump 2 Pump L1 L2 Pump 1 Ext Pump 1/2 hp Total To P2 on Electric Heat Board P12 PREMIUM V INSTALLATION MANUAL Wiring Schematics cont. Aurora Variable Speed cont. With optional ' EA' Series Auxiliary ElectricHeat Typical schematic shown NOTE 3 208-230/60/1 208-230/60/1 Circuit 2 Circuit 1 G L2 L1 L2 L1 Auxiliary Electric Heat Power G P9 1 2 Green 3 Brown Orange 5 Brown 4 Orange Blue Pink Violet Yellow Black Gray PB2 Pink Green Black Yellow ER1 Gray G 1 2 3 4 5 NO P11 Gray ER2 HE1 ECM Blower Motor G TS1 Gray NO Black Black HE2 Yellow ER3 TS2 Yellow Pink R G PWM CFM C1 C2 HE3 NO G P12 HE4 ER4 G NO P1 PWM CFM C 3 C 1 2 3 4 C 1 2 3 Single Disconnect Power 208-230/60/1 4 P13 P13 on ABC Board EA Staging NOTE 5 TS4 CSA installed units only Local codes may require a single source of power supply EA Series PCB P2 F TS3 Pink 12 15 10 16 1 3 Breaker box furnished by installer L1 L2 Circuit Breakers CO C EH1 C EH2 P3 Condensate L1 L2 Aux Elect Power 208-230/60/1 Figure 1: Optional Internal Hot Water Generation Pump Wiring Schematic Connects to L2 and NO on AXB Board K6 Relay COM NO L2 Blue DHW Pump Cabinet HW Switch Blue 3 1 2 Purple L1 L2 P3 on ABC Board Unit Power 208-230/60/1 Notes 1 - Switch blue and red wires for 208V operation. 2 - The blk/wh and gray/wh wires are removed when Aux Heat is installed 3 - Use manufacturer’s part number 19P592-01 (jumper bar assembly) when single source power is required. 4 – Variable speed pump low voltage harness provided with Variable Speed Flow Center. 5 - For additional Auxiliary Heat staging place jumpers as shown. 6 - Wires provided for Auxiliary Heat low voltage control. Wires are secured at blower. 7 – When Auxiliary Heat is field installed the harness will then be connected to the auxiliary heat unit. The auxiliary heat unit will then power the blower. Refer to EAS/EAM/EAL Auxiliary Heat kit installation instructions. 8 – Brown blower power wire routed through Current Transducer two times. 9 – Field Connected: Refer to Installation Manual and Auxiliary Heat Instructions for Current Transducer installation. 10 – Communication cable routed through Ferrite Toroid four times. 11 – Compressor power cable routed through Ferrite Toroid three times. 12 – Variable speed pump power wires to connect the pump to L1 and L2 on the AXB board are provided with Variable Speed Flow Center. 97P842-01A 02/14/13 33 PREMIUM V INSTALLATION MANUAL Wiring Schematics cont. Aurora Variable Speed Drive/EEV Wiring 2 COM 3 OUT 1 5 VDC 4 N/A R 4 A- 3 B+ 2 C 1 EEV2 G 1 2 L1 L2 Master Danfoss Variable Speed Drive C 1 (-) 2 (+) 3 NOTE 10 RS485 EXP Ferrite Toroid (+) B+ (+) (-) R C Green White Red NOT USED R R (-) C (+) ABC P6 To Aurora Board AXB P9 To AXB Board Black NOT SUCTION USED TEMP Off C LED1 FP1 – 15oF/30oF R FP2 – 15oF/30oF P13 3 ACC – Dip 4 4 ACC – Dip 5 5 Factory G CC – Dual/Single 6 EH1 Y Config LED3 SW1 Test 2 RV – B/O Fault L – Pulse/Continuous 7 Reheat/Normal 8 Status P3 Factory P4 On 1 LED2 P6 CC2 AURORA BASE CONTROL™ P5 CC Hi – K3 Fan – K4 G (+) (-) R RS485 NET Com2 G Acc – K6 P9 AXB™ P8 JW2 - Alarm CC (+) (-) R C C P11 Alarm – K5 F RS 485 P7 Com1 Factory Use Factory CC2 CC – K2 G LO HI CCG CC FG F R EH2 C EH1 C CO N/A SW2 RV – K1 RS485 Exp PWM CFM EEV CONTROL BOARD ECM PWM C W DH DH Y2 W G Y1 O/B C C Factory Fan Connection R LO G Y2 Y1 G C R LO O/B C 3A-Fuse Field Connections P1 ACC nc ACC no ALG ALM ACC c Field Connections LS P2 ES Y1 R R 34 5VAC C EEV COIL HP HP LP LP FP2 FP2 FP1 FP1 REV REV ABC (-) LAT EEV COMM NOTE 11 Ferrite Toroid T1 T2 T3 1 2 3 B 1 COM 2 O 3 RLY-1 Black 4 N/A Blue Brown COM 1 OUT 2 5 VDC 3 P-C Black 4 N/A Blue Brown COM 1 OUT 2 5 VDC 3 Red Red Black Red + 1 - 2 P-O T1 Circuit Breaker S-D Black + 1 - 2 S-AUX Black Black + 1 - 2 Black S-Ambient L1 T2 CC Circuit Breaker Discharge Pressure T Red T T L2 G Black Unit Power 208-230/60/1 Suction Pressure 2 COM 3 OUT 1 5 VDC 4 N/A Entering Compressor Water Temp Discharge Ambient Line Temp EWT PREMIUM V INSTALLATION MANUAL Wiring Schematics cont. Aurora Variable Speed Drive/EEV Wiring cont. Bipolar Stepper Motor 1 2 3 4 5 Orange Red Yellow Black Gray 1 2 3 4 5 12 VDC X1 X2 Y1 Y2 Black T Black EEV Output KM9 T2 Black Green Black GND 1 S2 2 Leaving Air Temp (LAT) KM3 Black GND 1 S2 2 T1 Suction Temp KM2 Blue Red Connector (4 Pin) T3 Power KM4 Metal Flexible Conduit R 4 C 1 B+ 2 A- 3 VS Compressor Red Black T + X1 X2 Y1 Y2 Suction Discharge Line Temp Air Temp Danfoss EEV Control Aurora LED Flash Codes Legend Slow Flash 1 second on and 1 second off EEV 1 Fast Flash 100 milliseconds on and 100 milliseconds off Flash Code 100 milliseconds on and 400 milliseconds off with a 2 second pause before repeating Random Start Delay (Alternating Colors) Fault LED (LED 1, Red) MASTER EEV 2 S_AMBIENT S_AUX S_D P_O P_C RLY 1 Fast Flash OFF Input Fault Lockout Flash Code 1 Configuration LED (LED 2, Yellow) Fast Flash High Pressure Lockout Flash Code 2 Fault LED (LED 3, Red) Fast Flash Configuration LED (LED 2, Yellow) Low Pressure Lockout Flash Code 3 Freeze Detection- FP2 Flash Code 4 No Software Overide OFF Freeze Detection - FP1 Flash Code 5 DIP Switch Overide Slow Flash Relay coil Capacitor w/ bleed resistor Switch - Condensate overflow L1 Field wire lug Switch - Low pressure Flash Code 7 Normal Mode ON Ground Over/Under Voltage Shutdown Flash Code 8 Control is Non - Functional OFF Future Use Flash Code 9 Test Mode Slow Flash Relay ContactsN.O., N.C. Compressor Monitoring Flash Code 10 Lockout Active Fast Flash Fuse Fault- FP1 and FP2 Sensor Error Flash Code 11 Dehumidification Mode 2 3 Flash Code 2 Future Use Flash Code 12 Future Use Flash Code 3 Non-Critical AXB Sensor Error Flash Code 13 Future Use Flash Code 4 Critical AXB Sensor Error Flash Code 14 Load Shed Flash Code 5 Alarm - Hot Water Flash Code 15 ESD Fault Variable Speed Pump Flash Code 16 Future Use Future Use Flash Code 17 Non-Critical Communication Error Flash Code 18 Safe Mode - Ambient Temperature SeFlash Code 49 Flash Code 6 Flash Code 7 Fault LED (LED 1, Red) Cont. Fault - Critical Communication Error Flash Code 19 Fault - Discharge Temperature SensoFlash Code 51 Alarm - Low Loop Pressure Flash Code 21 Fault - Suction Pressure Sensor Flash Code 52 Fault - Communication ECM Fan Moto Flash Code 22 Fault - Condensing Pressure Sensor Flash Code 53 Alarm - Home Automation 1 Flash Code 23 Fault - Low Supply Voltage Alarm - Home Automation 2 Flash Code 24 Fault - Compressor Out of Envelope Flash Code 55 Fault - EEV Error Flash Code 25 Fault - Over Current Flash Code 56 Flash Code 41 Fault - Over/Under Voltage Flash Code 57 Compressor Contactor Condensate overflow sensor DHW pump relay Loop pump relay PSC Fan Speed Relay PSC Fan Power Relay Compressor Solenoid Fuses Heater element High pressure switch Aux heat stage relays Low pressure switch PB1, PB2 PS RV SW1 SW1 SW2 - Power blocks Power strip Reversing Valve coil DIP package 5 position AXB TEST MODE ABC Board DIP package 8 position ABC Board TS HWL SC SR WCL - Thermal limit switch Hot water limit sensor Start Contactor Start Relay Water Coil Limit Sensor 97P842-01B Flash Code 58 Derate - Low Suction Temperature Flash Code 43 Fault - Drive Internal Error MOC/AOCFlash Code 59 Derate - Low Condensing Pressure Flash Code 44 Fault - Multiple Safe Modes Flash Code 61 Derate - High Condensing Pressure Flash Code 45 Fault - Loss of Charge Flash Code 71 Derate - Outer Power Limit Flash Code 46 Safe Mode - Suction Temperature Se Flash Code 72 T3 POWER TO T2 COMPRESSOR T1 Safe Mode - EEV (Outdoor) Commun Flash Code 48 Safe Mode - Max Operating PressureFlash Code 74 SW1-5 ON ON OFF OFF AXB Accessory 2 DIP Seƫngs DESCRIPTION Cycles with Blower Cycles with CC Įrst stage compressor or compressor spd 1-12 Cycles with CC2 second stage of compressor or comp spd 7-12 Cycles with DH from ABC board 35 Polarized connector Current Transducer (CT) CC CO K5 K6 CR3 CR4 CS F1 and F2 HE HP ER1 to ER4 LP - Flash Code 54 Derate - High Discharge Temperature Flash Code 42 Fault - High Drive Temperature SW1-4 ON OFF ON OFF 1 P Safe Mode - EEV (Indoor) CommunicaFlash Code 47 Safe Mode - LAT Temperature SensoFlash Code 73 VARIABLE SPEED DRIVE END VIEWS Light emitting diode - Green Switch - High pressure Status LED (LED 3, Green) Flash Code 6 Thermistor T G Wire nut Condensate Overflow Lockout Derate - Drive Temperature L1 POWER TO L2 VS DRIVE Status LED (LED1, Green) Normal Mode Reserved EXT. FAN Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block DC Voltage PCB traces Junction Quick connect terminal ABC SW2 Accessory Relay DESCRIPTION SW2-4 Cycle with Blower ON Cycle with Compressor OFF Water Valve Slow Opening ON Cycle with Comm. T-stat Hum Cmd OFF SW2-5 ON OFF OFF ON 1/4/13 PREMIUM V INSTALLATION MANUAL Unit Startup 2. Aurora Setup Screen a. ECM Setup for Heating Airflow – select G, low, high and aux blower speeds as appropriate for the unit and electric heat. b. Cooling Airflow % – sets the cooling airflow % from heating airflow. c. AXB Setup i. DHW Enable – Ensure air is purged from HW system before enabling (remember the HW switch on the front cabinet) ii. DHW Setpoint – 130 °F is the default but can be changed from 100 to 140 °F iii. Variable Speed Pump Setup and Modulating Water Valve Setup – Can be setup to a range between 5% and 100%. Defaults are 50% and 100%. - From the Main Menu of the AID Tool go to AXB Setup and select “Yes” at the bottom of the screen to Make Changes - Set VS Pump Control to MIN - The pump(s) or water valve should begin to operate and flow rate is visible on this screen, it may take several seconds for flow to stabilize. Adjust the minimum % until the minimum flow rate is achieved. - Go back to Set VS Pump Control and select MAX. - The pump(s) or water valve should begin to operate and flow rate is visible on this screen, it may take several seconds for flow to stabilize. Adjust the maximum % until the maximum flow rate is achieved. - Press Enter. d. Sensor Kit Setup i. Brine Selection – for HE/HR capacity calculation ii. Flow Meter – activates the flow meter iii. Select blower energy – PSC or ECM/5-Speed ECM iv. Activate energy option v. Blower and Aux heat current sensor activation vi. Line Voltage calibration – Voltmeter required to calibrate line voltage during heating or cooling. Refer to Line Voltage Calibration in this manual for more details. e. Smart Grid Setup – Select action option for utility received On Peak signal f. Home Automation 1 and 2 Setup – Select type of sensor for two home automation inputs. Before Powering Unit, Check the Following: NOTE: Remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket. • • • • • • • • • • • • • • • • • • High voltage is correct and matches nameplate. Fuses, breakers and wire size correct. Low voltage wiring complete. Piping completed and water system cleaned and flushed. Air is purged from closed loop system. Isolation valves are open, water control valves or loop pumps wired. Condensate line open and correctly pitched. Transformer switched to 208V if applicable. Black/white and gray/white wires in unit control box have been removed if auxiliary heat has been installed. Dip switches are set correctly. Hot water generator pump switch is “OFF” unless piping is completed and air has been purged. Blower rotates freely. Blower speed is correct. Air filter/cleaner is clean and in position. Variable speed drive filter is clean and in place. Service/access panels are in place. Return air temperature is between 50-80°F heating and 60-95°F cooling. Check air coil cleanliness to ensure optimum performance. Clean as needed according to maintenance guidelines. To obtain maximum performance the air coil should be cleaned before startup. A 10-percent solution of dishwasher detergent and water is recommended for both sides of coil, a thorough water rinse should follow. Powering The Controls Initial Configuration of the Unit Before operating the unit, apply power and complete the following Aurora Startup procedure for the controls configuration. An AID Tool is required for setup, configuration, and troubleshooting on the variable speed system. AID Tool version 2.01 or greater is preferred. 1. Configure Aurora Screen a. Confirm AXB is added and communicating. b. Confirm AOC is added and communicating. c. Confirm MOC is added and communicating. d. Confirm EEV2 is added and communicating. e. Confirm IntelliZone2 is added and communicating if installed. Set zoning system to OFF. f. Confirm communicating thermostat is added and communicating if IntelliZone2 is not installed. Set thermostat mode to OFF. NOTE: The AOC and MOC are the two boards that comprise the VS drive. Configuring the Sensor Kits Configuring the Sensor kits The Aurora Advanced Control allows Refrigeration, Energy, and Performance Monitoring sensor kits. These kits can be factory or field installed. The following description is for field activation of a factory installation of the sensor kits. 36 PREMIUM V INSTALLATION MANUAL Unit Startup cont. Once sensors are installed for discharge pressure, suction pressure, suction, liquid line cooling, liquid line heating, and leaving air temperature no further setup is required. a. Turn on unit in Heating or Cooling. b. Use the AID Tool to view the refrigerant performance in the ‘Refrigerant Monitor’ screen. c. Refrigerant monitoring can be read on any of the following components: i. AID Tool – instantaneous information only Energy Monitoring (Standard Sensor Kit Variable Speed Models) The Energy Monitoring Kit includes two current transducers (blower and electric heat) added to the existing two compressor sensors so that the complete power usage of the heat pump can be measured. The AID Tool provides configuration detail for the type of blower motor and a line voltage calibration procedure to improve the accuracy. This information can be displayed on the AID Tool or selected communicating thermostats. The TPCM32U04GSM will display instantaneous energy use while the color touchscreen TPCC32U01GSM will in addition display a 13 month history in graph form. Ensure the Energy Kit has been enabled by accessing the ‘Sensor Kit Setup’ in the AID Tool and complete the following: a. Select ‘Blower Energy’ – PSC or ECM/5-Speed ECM b. Activate ‘Energy Option’ to activate the sensors on for compressor (2), blower and aux heat current sensor. c. Select ‘Pump’ option of FC1, FC2, VS pump, VS pump + 26-99, or open loop. This selects the pump watts used in the calculation. Pump watts are not measured but estimated. d. Line Voltage Calibration – Voltmeter required to calibrate line voltage during heating or cooling. i. Turn on Unit in Heating or Cooling . ii. Use multimeter at L1 and L2 to measure line voltage iii. In the Sensor Kit Setup screen adjust the ‘Base Voltage’ to the nearest value to that is measured iv. Then use the ‘Fine Adjust’ to select the exact voltage being measured at L1 and L2. v. Exit ‘Sensor Setup’ Screen e. Energy monitoring can be read on any of the following components: i. AID Tool – instantaneous information only ii. TPCM32U04GSM Communicating Thermostat (B/W) - instantaneous information only iii. TPCC32U01GSM Color Touchscreen Thermostat – Both Instantaneously and historical (13 months) Performance Monitoring (Optional Sensor Kit) The optional Performance Monitoring Kit includes three temperature sensors, entering and leaving water, leaving air temperature and a water flow rate sensor. With this kit heat of extraction and rejection will be calculated. This requires configuration using the AID Tool for selection of water or antifreeze. Ensure the Performance Kit has been enabled by accessing the ‘Sensor Kit Setup’ in the AID Tool and complete the following: a. Select ‘Brine’ – and then choose Water or Antifreeze for the proper factor b. Activate ‘Flowmeter’ to activate the flow sensor select the appropriate 3/4 in., 1 in., or none (1 in. is standard on variable speed units). c. Exit ‘Sensor Kit Setup’ screen. d. Turn on unit in Heating or Cooling. e. Use the AID Tool to view the performance in the ‘Performance Monitor’ screen. f. Performance monitoring can be read on any of the following components: i. AID Tool – instantaneous information only Startup Steps NOTE: Complete the Equipment Startup/Commissioning Check Sheet during this procedure. Refer to thermostat operating instructions and complete the startup procedure. Verify that the compressor shipping bolt has been removed. 1. Initiate a control signal to energize the blower motor. Check blower operation through the AID Tool. 2. Initiate a control signal to place the unit in the cooling mode. Cooling setpoint must be set below room temperature. 3. First stage cooling will energize after a time delay. 4. Be sure that the compressor and water control valve or loop pump(s) are activated. 5. Verify that the water flow rate is correct by measuring the pressure drop through the heat exchanger using the P/T plugs and comparing to unit performance data in catalog or view on the AID Tool if Performance Kit is installed. 6. Check the temperature of both the supply and discharge water (see the Unit Operating Parameters tables). 7. Check for an air temperature drop of 15°F to 25°F across the air coil (cooling compressor speed 9), depending on the blower speed and entering water temperature. Refrigerant Monitoring (Standard on Variable Speed Models) The Refrigerant Monitoring Kit includes two pressure transducers, and three temperature sensors, heating liquid line, suction temperature, and existing cooling liquid line (FP1). These sensors allow the measurement of discharge and suction pressures, suction and liquid line temperatures as well as superheat and subcooling. This information will only be displayed on the AID Tool. Ensure the Refrigerant Monitoring has been setup by accessing the ‘Sensor Kit Setup’ in the AID Tool. 37 PREMIUM V INSTALLATION MANUAL Unit Startup cont. 8. Decrease the cooling set point several degrees and verify highspeed blower operation. 9. Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop pumps deactivate. 10. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature. 11. First stage heating will energize after a time delay. 12. Check the temperature of both the supply and discharge water (see the Unit Operating Parameters tables). 13. Check for an air temperature rise of 12°F to 35°F across the air coil (heating compressor speed 12), depending on the fan speed and entering water temperature. 14. If auxiliary electric heaters are installed, increase the heating setpoint until the electric heat banks are sequenced on (must get to compressor speed 12 before auxiliary heat enables). All stages of the auxiliary heater should be sequenced on when the thermostat is in the Emergency Heat mode. Check amperage of each element. 15. Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps deactivate. 16. During all testing, check for excessive vibration, noise or water leaks. Correct or repair as required. 17. Set system to desired normal operating mode and set temperature to maintain desired comfort level. 18. Instruct the owner/operator in the proper operation of the thermostat and system maintenance. Pressure Drop Thermistor Resistance NOTE: Be certain to fill out and forward all warranty registration papers. Pressure Drop (psi) Model Thermistor Resistance (10k Ohm) for FP1, FP2, HWL, LWT and LLT (EWT with Performance Option) gpm 30° F 50° F 70° 90° F 110° F 11.5 3.40 3.20 3.00 2.80 2.60 9.0 2.70 2.60 2.40 2.20 2.10 7.0 1.65 1.55 1.45 1.35 1.25 5.5 1.10 1.00 0.90 0.85 0.75 4.5 0.68 0.64 0.60 0.55 0.51 13.5 4.60 4.40 4.10 3.80 3.50 10.5 2.90 2.70 2.50 2.30 2.20 7.5 1.70 1.60 1.50 1.40 1.30 6.0 1.20 1.10 1.00 0.96 0.91 4.0 0.62 0.61 0.60 0.58 0.56 17.0 6.40 6.00 5.60 5.20 4.80 13.5 4.10 3.80 3.60 3.30 3.10 9.5 2.20 2.10 2.00 1.80 1.70 7.5 1.70 1.60 1.50 1.40 1.30 5.0 0.68 0.62 0.58 0.55 0.53 36 48 60 Thermistor Temperature (°F) 5 14 23 32 41 50 59 68 77 86 95 104 113 122 131 140 149 6/29/12 Compressor Resistance Model Compressor Model No. 036 048 060 VRJ028UKNP6 VRJ035UKNP6 VRJ044UKNP6 Winding Resistance 208-230/60/1 0.255 0.210 0.210 4/23/12 38 Thermistor Resistance (Ohms) 75757-70117 57392-53234 43865-40771 33809-31487 26269-24513 20570-19230 16226-15196 12889-12093 10310-9688 8300-7812 6723-6337 5480-5172 4490-4246 3700-3504 3067-2907 2554-2424 2149-2019 4/24/12 Thermistor Resistance (1k Ohm) for compressor discharge line, suction line, LAT, compressor ambient and EWT Thermistor Thermistor Temperature Resistance (°F) (Ohms) 20 974.4-973.4 25 985.4-984.4 30 996.1-995.1 35 1007.0-1006.0 40 1017.8-1016.8 45 1028.6-1027.6 50 1039.5-1038.5 55 1050.2-1049.2 60 1061.2-1060.2 65 1072.9-1071.9 70 1082.7-1081.7 75 1093.4-1092.4 80 1103.0-1102.0 85 1115.5-1114.5 90 1126.2-1125.2 95 1136.6-1135.6 100 1147.2-1146.2 105 1158.1-1157.1 110 1168.8-1167.8 115 1179.4-1178.4 120 1190.1-1189.1 125 1200.3-1199.3 130 1212.2-1211.2 4/24/12 PREMIUM V INSTALLATION MANUAL Refrigerant Circuit Guideline Symptom Under Charged System (Possible Leak) Over Charged System Low Air Flow Heating Low Air Flow Cooling Low Water Flow Heating Low Water Flow Cooling High Air Flow Heating High Air Flow Cooling High Water Flow Heating High Water Flow Cooling Low Indoor Air Temperature Heating Low Indoor Air Temperature Cooling High Indoor Air Temperature Heating High Indoor Air Temperature Cooling Restricted EEV Insufficient Compressor (Possible Bad Valves) 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 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 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 6/1/12 Heat of Extraction/Rejection Model 036 048 060 Full Load Full Load Full Load gpm Heat of Extraction (MBtu/h) gpm Heat of Rejection (MBtu/h) 30°F 50°F 70°F 90°F 30°F 50°F 70°F 90°F 110°F 5.5 26.4 36.6 46.2 54.5 4.5 42.2 48.3 43.1 42.6 40.4 8.0 26.7 37.7 47.8 57.6 7.0 41.9 48.8 47.0 42.5 40.2 11.5 27.5 38.5 49.7 58.6 9.0 42.3 49.1 46.8 42.7 40.3 6.5 32.4 44.6 54.9 68.6 5.5 56.1 63.2 56.2 53.7 52.7 10.0 32.6 46.0 57.9 72.6 8.0 55.7 63.1 59.3 53.5 52.6 13.5 33.7 47.0 60.3 73.7 10.5 56.2 63.3 59.1 53.7 52.7 8.5 40.3 54.7 70.7 85.9 6.5 75.2 77.8 74.4 68.9 64.3 13.0 40.6 56.4 74.2 93.1 10.0 74.7 77.6 74.2 68.7 64.0 17.0 42.0 57.6 77.3 94.4 13.5 75.3 77.9 73.9 68.8 64.1 6/29/12 39 PREMIUM V INSTALLATION MANUAL Operating Parameters Model 060 - Comp Speed 9 (1800 cfm) - 70°F DB Heating & 80°F DB/67°F WB Cooling Cooling -- No Hot Water Generation Entering Water Temp °F Water Flow 30 50 70 90 110 13.5 13.5 13.5 13.5 13.5 Suction Pressure psig 122-127 138-143 143-148 147-152 149-154 Discharge Pressure psig 162-172 215-225 280-290 357-367 450-460 Superheat Subcooling 20-24 6-10 6-10 6-10 6-10 5-10 6-11 8-12 11-15 15-19 Water Temp Rise °F 8-12 8-12 8-12 8-12 8-12 Air Temp Drop °F DB 19-25 19-25 19-25 17-22 17-22 Model 060 - Comp Speed 12 (2200 cfm) - 70°F DB Heating & 80°F DB/67°F WB Cooling Heating - No Hot Water Generation Entering Water Temp °F Water Flow 30 50 70 90 17.0 17.0 17.0 17.0 Suction Pressure psig 80-85 111-116 153-158 188-193 Discharge Pressure psig 345-355 350-360 395-405 440-450 Superheat Subcooling 6-10 6-10 6-10 8-12 15-20 10-15 13-18 18-23 Water Temp Drop °F 4-8 4-8 6-10 8-12 Air Temp Rise °F DB 20-26 24-30 32-38 39-45 Model 048 - Comp Speed 9 (1400 cfm) - 70°F DB Heating & 80°F DB/67°F WB Cooling Cooling -- No Hot Water Generation Entering Water Temp °F Water Flow 30 50 70 90 110 10.5 10.5 10.5 10.5 10.5 Suction Pressure psig 123-128 140-145 142-147 143-148 145-150 Discharge Pressure psig 150-160 190-200 260-270 343-348 440-450 Superheat Subcooling 17-22 10-14 10-14 10-14 10-14 9-14 4-9 6-11 8-13 10-15 Water Temp Rise °F 8-13 8-13 8-13 7-12 7-12 Air Temp Drop °F DB 19-25 19-25 18-24 17-23 17-23 Model 048 - Comp Speed 12 (1800 cfm) - 70°F DB Heating & 80°F DB/67°F WB Cooling Heating - No Hot Water Generation Entering Water Temp °F Water Flow 30 50 70 90 13.5 13.5 13.5 13.5 Suction Pressure psig 75-80 108-113 145-150 183-188 Discharge Pressure psig 321-331 345-355 400-410 450-460 Superheat Subcooling 6-10 6-10 7-12 11-16 20-25 21-26 22-27 24-29 Water Temp Drop °F 4-8 5-9 8-12 9-13 Air Temp Rise °F DB 20-25 28-33 34-39 31-36 Water Temp Rise °F 6-10 6-10 6-10 6-10 5-9 Air Temp Drop °F DB 15-20 20-25 20-25 18-23 16-21 Water Temp Drop °F 3-7 4-9 4-9 7-11 Air Temp Rise °F DB 17-22 23-28 30-35 35-40 5/23/13 Model 036 - Comp Speed 9 (1300 cfm) Cooling -- No Hot Water Generation Entering Water Temp °F Water Flow 30 50 70 90 110 9 9 9 9 9 Suction Pressure psig 114-119 135-140 142-148 147-152 153-158 Discharge Pressure psig 142-152 198-208 268-275 345-355 445-455 Superheat Subcooling 17-25 5-10 5-10 5-10 5-10 8-13 5-10 5-10 9-14 9-14 Model 036 - Comp Speed 12 (1500 cfm) Heating - No Hot Water Generation Entering Water Temp °F Water Flow 30 50 70 90 11.5 11.5 11.5 11.5 Suction Pressure psig 80-85 115-120 158-163 189-194 Discharge Pressure psig 288-298 315-325 345-355 425-435 40 Superheat Subcooling 6-10 6-10 5-9 13-18 6-11 6-11 4-9 5-10 PREMIUM V INSTALLATION MANUAL Reference Calculations Heating Calculations: Legend Abbreviations and Definitions Cooling Calculations: HR LWT = EWT - HE gpm x 500 LWT = EWT + LAT = EAT + HC cfm x 1.08 LAT (DB) = EAT (DB) - cfm EWT gpm WPD EAT HC TC SC kW HR HE HWC EER gpm x 500 SC cfm x 1.08 LC = TC - SC TH = HC + HW S/T = SC TC COP LWT LAT TH LC S/T = = = = = = = = = = = = = = = = = = = = = 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 Troubleshooting Aurora Control System Refrigerant Systems NOTE: Refer to the Aurora Base Control Application and Troubleshooting Guide and the Instruction Guide: Aurora Interface and Diagnostics (AID) Tool for additional information. Refrigerant pressures are monitored by the control system; to maintain sealed circuit integrity, do not install service gauges unless pressure sensor is suspected to be inoperative. Compare the change in temperature on the air side as well as the water side to the Unit Operating Parameters tables. If the unit’s performance is not within the ranges listed, make sure the airflow and water flow are correct. Check superheat and subcooling with an AID Tool. If superheat and subcooling are outside recommended ranges, an adjustment to the refrigerant charge may be necessary. To check the unit control board for proper operation: 1. General Check • If any new device was installed, or any wiring was changed, check the connections to ensure the wiring is correct, and all the wires are in good condition. • Verify all the plugs are securely connected and in good condition. • Check the DIP switch (SW2) positions are correct. • Measure 24 VAC between R and C. (The actual reading may be from 18 to 30 VAC). Check the incoming power and the power transformer if the R and C voltage reading is not correct. 2. No LEDs are On • Check 24 VAC on board. • Check the 3 amp fuse. Replace the fuse if needed. • Verify transformer circuit breaker has not tripped if no low voltage is present. • Disconnect the thermostat connection P1. • Replace the Aurora base control board. NOTE: Refrigerant tests must be made with hot water generator turned “OFF”. Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit. 41 PREMIUM V INSTALLATION MANUAL Troubleshooting cont. Sensor Locations Leaving Water Thermistor (Sensor Wire Wrapped 4 Times Around Water Line) Blower Entering Water Thermistor (Sensor Wire Wrapped 4 Times Around Water Line) Air Coil Water OUT Coax Flow Sensor Flow Meter Entering Water Thermistor (Sensor Wire Wrapped 4 Times Around Water Line) Leaving Air Thermistor WĞƌĨŽƌŵĂŶĐĞKƉƟŽŶKŶůǇ ( Wire Bundle In Blower Compartment) FP2 Sensor Water Line View of Coax Performance KƉƟŽŶKŶůǇ Pressure Transducer Line Thermistor Ambient Air Thermistor ( Wire Bundle In Compressor Compartment) Rev. Valve Discharge Pressure Transducer Water OUT Coax Compressor Discharge DƵŋĞƌ Line Thermistor Water IN EEV ( Filter Dryer LLT FP1 Sensor 42 Water IN PREMIUM V INSTALLATION MANUAL Startup/7roubleshooting Form Controls Info: Dealer: ABC Version: Phone #: AXB Version: Date: Problem: IZ2 Version: Model #: T-Stat Version: Serial #: Installed Sensors: COOLING CYCLE ANALYSIS PSI = °F °F °F High Speed Loop: Unit Amp Draw: °F AIR COIL Open Closed Line Voltage: °F SAT °F Low Speed SUCTION COMPRESSOR ELECTRONIC EXPANSION VALVE COAX LOAD REVERSING VALVE COAX SOURCE DISCHARGE Hot Water Generator $F °F LIQUID LINE °F °F High Speed °F °F PSI PSI High Speed PSI PSI Low Speed °F °F BRINE IN SAT $F PSI = °F Superheat °F Subcooling BRINE OUT Water to Water Application PSI Low Speed BRINE IN PSI BRINE OUT +HDWRI([WUDFWLRQ5HMHFWLRQ JSP[IRUZDWHUDQWLIUHH]H[¨7 1RWH'2127 hook up pressure gauges unless pressure sensors are suspect. HEA7,1*&<&/( ANALYSIS PSI = °F °F °F High Speed Loop: Unit Amp Draw: °F AIR COIL Open Closed Line Voltage: °F SAT °F Low Speed SUCTION COMPRESSOR ELECTRONIC EXPANSION VALVE COAX LOAD REVERSING VALVE COAX SOURCE DISCHARGE Hot Water Generator $F $F LIQUID LINE °F °F High Speed °F °F PSI PSI High Speed PSI PSI Low Speed °F °F BRINE IN BRINE OUT 43 PSI = °F °F SAT $F Superheat Subcooling PREMIUM V INSTALLATION MANUAL Troubleshooting cont. Variable Speed Startup/Troubleshooting Form 1. Job Information Model # Job Name: Serial # Install Date: 2. Flow Rate in gpm Loop: Open / Closed Hot Water Generator: Y / N SOURCE COAX HEATING SPEED 12 HEATING SPEED 4 COOLING SPEED 9 COOLING SPEED 3 WATER IN Pressure: a. psi a. psi a. psi a. psi WATER OUT Pressure: b. psi b. psi b. psi b. psi Pressure Drop: a - b c. psi c. psi c. psi c. psi Look up flow rate in table: d. gpm d. gpm d. gpm d. gpm 3. Temperature Rise/Drop Across Coaxial Heat Exchanger1 HEATING SPEED 12 HEATING SPEED 4 COOLING SPEED 9 COOLING SPEED 3 WATER IN Pressure: e. °F e. °F e. °F e. WATER OUT Pressure: f. °F f. °F f. °F f. °F Temperature Difference: g. °F g. °F g. °F g. °F °F 4. Temperature Rise/Drop Across Air Coil HEATING SPEED 12 HEATING SPEED 4 COOLING SPEED 9 COOLING SPEED 3 SUPPLY AIR Temperature: h. °F h. °F h. °F h. °F RETURN AIR Temperature: i. °F i. °F i. °F i. °F Temperature Difference: j. °F j. °F j. °F j. °F Btu/h l. Btu/h l. Btu/h l. 5. Heat of Rejection (HR)/Heat of Extraction (HE) Brine Factor2: k. HR/HE = d x g x k l. HEATING SPEED 12 HEATING SPEED 4 COOLING SPEED 9 COOLING SPEED 3 Btu/h STEPS 6-9 NEED ONLY BE COMPLETED IF A PROBLEM IS SUSPECTED. USE HEATING SPEED 12 AND COOLING SPEED 9 FOR STEPS 6-9. ENERGY MONITOR 6. Watts HEATING SPEED 12 COOLING SPEED 9 Volts: m. Volts m. Volts Total Amps (Comp. + Blower)3: n. Amps n. Amps Watts = m x n x 0.85: o. Watts o. Watts 7. Capacity HEATING SPEED 12 Cooling Capacity = l - (o x 3.413): Heating Capacity = l + (o x 3.413): p. COOLING SPEED 9 Btu/h p. Btu/h 8. Efficiency HEATING SPEED 12 Cooling EER = p / o: Heating COP = p / (o x 3.413): q. COOLING SPEED 9 Btu/h q. Btu/h 9. Superheat (S.H.)/Subcooling (S.C.) HEATING SPEED 12 Software Version COOLING SPEED 9 Suction Pressure: r. psi r. psi Suction Saturation Temperature: s. °F s. °F Suction Line Temperature: t. °F t. °F S.H. = t - s u. °F u. °F Head Pressure: v. psi v. psi High Pressure Saturation Temp: w. °F w. °F Liquid Line Temperature4: x. °F x. °F S.C. = w - x y. °F y. °F NOTES: ABC: AXB: IZ2: TSTAT: 1 Steps 3-9 should be conducted with the hot water generator disconnected. 2 Use 500 for pure water, 485 for methanol or Environol™. (This constant is derived by multiplying the weight of one gallon of water (8.34) times the minutes in one hour (60) times the specific heat of the fluid. Water has a specific heat of 1.0. 3 If there is only one source of power for the compressor and blower, amp draw can be measured at the source wiring connection. 4 Liquid line is between the coax and the expansion device in the cooling mode; between the air coil and the expansion device in the heating mode. 44 PREMIUM V INSTALLATION MANUAL Preventive Maintenance Water Coil Maintenance Other Maintenance 1. Filters 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. Air filters and variable speed drive filter must be clean to obtain maximum performance. They should be inspected monthly under normal operating conditions and be replaced when necessary. Units should never be operated without a filter. The VS drive filter is located on the lower left corner of the cabinet. Removing the two screws in the honey comb grill allows access to the filter. Run the filter under warm water and gently rub. Let the filter dry. Then, re-install the filter and cover. 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. Condensate Drain In areas where airborne bacteria produce a slime in the drain pan, it may be necessary to treat chemically to minimize the problem. The condensate drain can pick up lint and dirt, especially with dirty filters. Inspect twice a year to avoid the possibility of overflow. Blower Motors ECM blower motors are equipped with sealed ball bearings and require no periodic oiling. Hot Water Generator Coil See Water Coil Maintenance section above. Air Coil The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum (with a brush attachment) clean. Care must be taken not to damage the aluminum fins while cleaning. CAUTION: Fin edges are sharp. Replacement Procedures Obtaining Parts In-Warranty Material Return When ordering service or replacement parts, refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and the date of failure, along with an explanation of the malfunctions and a description of the replacement parts required. Material may not be returned except by permission of authorized warranty personnel. Contact your local distributor for warranty return authorization and assistance. 45 PREMIUM V INSTALLATION MANUAL Service Parts List 048 060 34P648-01 34P649-01 92P504A05 92P504A05 92P504A05 11P853-01 11P853-01 11P853-01 ECM Motor 208-230/60/1 14S545-01 14S546-01 14S547-01 ECM Blower Housing 53P501B01 53P501B01 53P501B01 ECM Harness - Low Voltage 11P827-02 11P827-02 11P827-02 ECM Power Harness 11P585B03 11P585B03 11P585B03 1” Electrostatic Filter EAF3032 EAF3032 EAF3036 Air Coil 61S606-02 61S606-02 61S701-02 Coax 62I543A01 62I555-01 62I555-01 33P617-01 33P526-05 33P526-05 Discharge Muffler 36P503B02 36P503B02 36P503B02 Filter Dryer 36P500B01 36P500B02 36P500B02 Hot Water Generator 62P516-03 62P516-03 62P516-03 Hot Water Generator Pump 24P501A01 24P501A01 24P501A01 Contactor 13P004A03 13P004A03 13P004A03 Transformer 208-230/60/1 15P501B01 15P501B01 15P501B01 3 Pole Power Block 12P503-06 12P503-06 12P503-06 2 Pole Screw Term. Block 12P500A01 12P500A01 12P500A01 EEV Solenoid Coil 33P617-02 33P617-02 33P617-02 EEV/VS Drive Communication Cable 11P843-01 11P843-01 11P843-01 ABC/AXB/VS Drive Communication Cable 11P836-01 11P836-01 11P836-01 Keystone Category 5 Coupler (AID Port) 12P553-01 12P553-01 12P553-01 Category 5 cable (AID Port to ABC) 11P846-01 11P846-01 11P846-01 Current Transformer 12P557-01 12P557-01 12P557-01 Rocker Switch - HWG ON/OFF 13P607A01 13P607A01 13P607A01 Pump Circuit Breaker - 5 amp, 250v 19P583-01 19P583-01 19P583-01 Pressure Transmitter DIN Cable 11P855-01 11P855-01 11P855-01 VS Drive Control 17P560-01 17P560-02 17P560-03 Drive Circuit Breaker 19P595-01 19P595-02 19P595-03 EEV Board 17P561-01 17P561-01 17P561-01 ABC Board 17X553-02 17X553-02 17X553-02 AXB Board 17P557-01 17P557-01 17P557-01 Freeze Detection Thermistor-FP1-Yellow 12P505-09 12P505-09 12P505-09 HWL Thermistor-Pink (AXB P17) 12P555-04 12P555-04 12P555-04 Thermistor FP2 12P550-01 12P550-01 12P550-01 Thermistor LAT/EWT/Suct Line/Compr Ambient 12P556-01 12P556-01 12P556-01 Thermistor - Compressor Discharge Line 12P556-02 12P556-02 12P556-02 Thermistor - Heating Liquid Line 12P555-03 12P555-03 12P555-03 Thermistor - Leaving Water Temperature 12P555-02 12P555-02 12P555-02 Transmitter, Flow Meter (sensor, clip, harness) Pressure Transmitter Replacement, High Pressure Pressure Transmitter Replacement, Low Pressure 29P535-01 29P535-01 29P535-01 SK7SHPT SK7SHPT SK7SHPT SK7SLPT SK7SLPT SK7SLPT Switch, High Pressure SKHPE600 SKHPE600 SKHPE600 Switch, Low Pressure SKLPE40 SKLPE40 SKLPE40 VS Drive Fan Filter 59P512-01 59P512-01 59P512-01 Part numbers subject to change Hot Water Generator 33P617-01 33P526-05 Electrical 33P617-01 Reversing Valve Sensors & Safeties EEV Refrigeration Components Power Harness ECM Motor & Blower 34P647-01 Sound Jacket Air Filter Compressor 208-230/60/1 Parts List - Horizontal Compressor 036 Mics Misc. Sensors & Safeties Electrical Hot Water Generator Refrigeration Components Air Filter ECM Motor & Blower Compressor Parts List - Vertical 46 048 060 Compressor 208-230/60/1 34P647-01 34P648-01 34P649-01 Sound Jacket 92P504A05 92P504A05 92P504A05 Power Harness 11P853-01 11P853-01 11P853-01 ECM Motor 208-230/60/1 14S545-01 14S546-01 14S547-01 ECM Blower Housing 53P501B01 53P501B01 53P501B01 ECM Harness - Low Voltage 11P827-01 11P827-01 11P827-01 ECM Power Harness 11P585B04 11P585B04 11P585B04 1” Electrostatic Filter EAF2042 EAF2042 EAF2047 Air Coil 61S612-02 61S612-02 61S649-02 Coax 62I543A01 62I555-01 62I555-01 EEV 33P617-01 33P617-01 33P617-01 Reversing Valve 33P526-05 33P526-05 33P526-05 Discharge Muffler 36P503B02 36P503B02 36P503B02 Filter Dryer 36P500B01 36P500B02 36P500B02 Hot Water Generator 62P516-03 62P516-03 62P516-03 Hot Water Generator Pump 24P501A01 24P501A01 24P501A01 Contactor 13P004A03 13P004A03 13P004A03 Transformer 208-230/60/1 15P501B01 15P501B01 15P501B01 3 Pole Power Block 12P503-06 12P503-06 12P503-06 2 Pole Screw Term. Block 12P500A01 12P500A01 12P500A01 EEV Solenoid Coil 33P617-02 33P617-02 33P617-02 EEV/VS Drive Communication Cable 11P843-01 11P843-01 11P843-01 ABC/AXB/VS Drive Communication Cable 11P836-01 11P836-01 11P836-01 Keystone Category 5 Coupler (AID Port) 12P553-01 12P553-01 12P553-01 Category 5 cable (AID Port to ABC) 11P846-01 11P846-01 11P846-01 Current Transformer 12P557-01 12P557-01 12P557-01 Rocker Switch - HWG ON/OFF 13P607A01 13P607A01 13P607A01 Pump Circuit Breaker - 5 amp, 250v 19P583-01 19P583-01 19P583-01 Pressure Transmitter DIN Cable 11P855-01 11P855-01 11P855-01 VS Drive Control 17P560-01 17P560-02 17P560-03 Drive Circuit Breaker 19P595-01 19P595-02 19P595-03 EEV Board 17P561-01 17P561-01 17P561-01 ABC Board 17P553-02 17P553-02 17P553-02 AXB Board 17P557-01 17P557-01 17P557-01 Freeze Detection Thermistor-FP1-Yellow 12P505-09 12P505-09 12P505-09 HWL Thermistor-Pink (AXB P17) 12P555-04 12P555-04 12P555-04 Thermistor FP2 12P550-01 12P550-01 12P550-01 Thermistor LAT/EWT/Suct Line/Compr Ambient 12P556-01 12P556-01 12P556-01 Thermistor - Compressor Discharge Line 12P556-02 12P556-02 12P556-02 Thermistor - Heating Liquid Line 12P555-03 12P555-03 12P555-03 Thermistor - Leaving Water Temperature 12P555-02 12P555-02 12P555-02 29P535-01 29P535-01 29P535-01 SK7SHPT SK7SHPT SK7SHPT Transmitter, Flow Meter (sensor, clip, harness) Pressure Transmitter Replacement, High Pressure Pressure Transmitter Replacement, Low Pressure SK7SLPT SK7SLPT SK7SLPT Switch, High Pressure SKHPE600 SKHPE600 SKHPE600 Switch, Low Pressure SKLPE40 SKLPE40 SKLPE40 VS Drive Fan Filter 59P512-01 59P512-01 59P512-01 Part numbers subject to change 2/8/13 036 2/8/13 PREMIUM V INSTALLATION MANUAL Revision Guide Pages: All Description: First Published. 47 Date: By: 24 May 2013 DS 650 Jamieson Parkway, Unit #1, Cambridge, Ontario N3C 0A5 | o: 1.866.310.6690 | f: 1.866.533.3889 GEOSMART ENERGY.COM Product: Type: Size: Premium V Series Variable Speed Geothermal/Water Source Heat Pumps 3 - 5 Ton Variable Speed Document Type: Ref. Number: Revision Date: Revision Number: Document Name: Installation, Operation & Maintenance Manual IM2700AG2 05/13 1 TEC-IOM-V_0513v1 ©2013 The manufacturer has a policy of continual product research and development and reserves the right to change design and specifications without notice.