in sta lla tio n , oper a tio n &

Premium Variable Speed Forced Air
Comfort System
Geothermal/Water Source Heat Pumps
Installation Information
n
Water Piping Connectionss
Electricall
Startup Proceduress
Troubleshooting
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Preventative Maintenance
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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
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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 [373]
1 [746]
1 [746]
High Static Blower Motor - hp [W]
ECM
1 [746]
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 [160]
361 [164]
385 [175]
Weight - Packaged, lb [kg]
372 [169]
381 [173]
405 [184]
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 [176]
396 [180]
415 [188]
Weight - Packaged, lb [kg]
417 [189]
426 [193]
445 [202]
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.
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