WaterFurnace 5 Series 500A11 Geothermal Heat Pumps Installation Guide

WaterFurnace 5 Series 500A11 Geothermal Heat Pumps

Specifications

• Model: 5 Series 500A11
• Refrigerant: R-454B
• Frequency: 60Hz
• Model Number: IGW5-0016W

Product Usage Instructions

Warnings

Before Installation

• Turn off main power switches to the unit to prevent electrical shock.
• Ensure compliance with electrical safety certification standards (e.g., UL 60335-240).
• Only allow factory authorized personnel to perform startup, check test, and commissioning.

For Installers

General Installation Guidelines

• Avoid corrosive environments or extreme temperature/humidity locations for storage or installation.
• Provide a minimum of 24 inches clearance for front access panel.
• Avoid using units for heating or cooling during construction to prevent system damage and voiding warranty.

Installation and Operation

• Seek assistance from your dealer if unsure about installation or operation.
• Only trained and qualified personnel should handle installation, repair, or servicing.
• Observe all safety precautions mentioned in the literature, tags, labels, and applicable safety guidelines.

Frequently Asked Questions (FAQ)

• Q: Can this unit be used in corrosive environments?
  A: It is advised not to store or install the unit in corrosive environments to maintain performance and reliability.

• Q: What should I do to prevent freezing during cold weather?
  A: Ensure adequate levels of antifreeze are used to prevent freezing, especially if the system is left without heat in cold weather.

• Q: Can children operate this appliance?
  A: This appliance is not intended for use by individuals with reduced capabilities unless supervised by a responsible person for their safety.

WARNING
WARNING: Before performing service or maintenance operations on the system, turn off main power switches to the unit. Electrical shock could cause serious personal injury.
WARNING: All WaterFurnace products are designed, tested, and manufactured to comply with the latest publicly released and available edition of UL 60335-2-40 for electrical safety certification. All field electrical connections must follow the National Electrical Code
(NEC) guide standards and / or any local codes that may be applicable for the installation.
WARNING: Only factory authorized personnel are approved for startup, check test and commissioning of this unit.
INSTALLER: Please take the time to read and understand these instructions prior to any installation. Installer must give a copy of this manual to the owner.

Definition of Warnings and Symbols

For the User

WARNING
This appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have
been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
Keep this manual in a safe place in order to provide your serviceman with necessary information.

NOTICE
NOTICE: To avoid equipment damage, do not leave the system filled in a building without heat during cold weather, unless adequate freeze protection levels of antifreeze are used. Heat exchangers do not fully drain and will freeze unless protected, causing permanent damage.

General Installation Information

NOTICE: Do not store or install units in corrosive environments or in locations subject to temperature or humidity extremes. Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life.
NOTICE: A minimum of 24 in. clearance should be allowed for access to front access panel.
NOTICE: To avoid equipment damage, DO NOT use
these units as a source of heating or cooling during the construction process. The mechanical components and filters can quickly become clogged with construction dirt and debris, which may cause system damage and void product warranty.

For the Installer
If you are NOT sure how to install or operate the unit, contact your dealer.
Installing and servicing air conditioning and heating 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. 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.
This manual contains specific information about the required qualification of the working personnel for maintenance, service and repair operations. Every working procedure that affects safety means shall only be carried out by competent persons.
Examples for such working procedures are:

• breaking into the refrigerating circuit;
• opening of sealed components or ventilated enclosures.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available for all brazing operations. Follow all procedures to remain in compliance with national gas regulations.
Prior to beginning work on systems containing FLAMMABLE REFRIGERANTS, safety checks are necessary to ensure that the risk of ignition is minimized. Work shall be undertaken under a controlled procedure so as to minimise the risk of a flammable gas or vapor being present while the work is being performed. All maintenance staff and others working in the local area shall be instructed on the nature of work being carried out. Work in confined spaces shall be avoided.
The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially toxic or flammable atmospheres. Ensure that the leak detection equipment being used is suitable for use with all applicable refrigerants, i.e. non-sparking, adequately sealed or intrinsically safe.
If any hot work is to be conducted on the refrigerating equipment or any associated parts, appropriate fire extinguishing equipment shall be available to hand. Have a dry powder or CO2 fire extin-guisher adjacent to the charging area.
No person carrying out work in relation to a REFRIGERATING SYSTEM which involves exposing any pipe work shall use any sources of ignition in such a manner that it may lead to the risk of fire or explosion. All possible ignition sources, including ciga-rette smoking, should be kept sufficiently far away from the site of installation, repairing, removing and disposal, during which refrigerant can possibly be released to the surrounding space. Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are no flammable hazards or ignition risks. “No Smoking” signs shall be displayed.
Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. At all times the manufacturer’s maintenance and service guidelines shall be followed. If in doubt, consult the manufacturer’s technical depart-ment for assistance.
The following checks shall be applied to installations using FLAM-MABLE REFRIGERANTS:

• the actual REFRIGERANT CHARGE is in accordance with the room size within which the refrigerant containing parts are installed;
• the ventilation machinery and outlets are operating ad-equately and are not obstructed;
• if an indirect refrigerating circuit is being used, the second-ary circuit shall be checked for the presence of refrigerant;
• marking to the equipment continues to be visible and leg-ible. Markings and signs that are illegible shall be corrected;
• refrigerating pipe or components are installed in a position where they are unlikely to be exposed to any substance which may corrode refrigerant containing components, unless the components are constructed of materials which are inherently resistant to being corroded or are suitably protected against being so corroded.

WARNING
If the appliance locks out on E5: FREEZE PROTECTION FP1. The appliance must set for 5 hours before being restarted.

Instructions for Equipment Using R-454B Refrigerant

WARNING

• Do NOT pierce or burn
• Do NOT use means to accelerate the defrosting process or to clean the equipment, other than those recommended by the manufacturer
• Be aware that refrigerants may not contain an odor

WARNING
the Appliance should be stored so as to prevent mechanical damage and in a well ventilated room without continuously operating ignition sources (example: open flames, an operating gas appliance or an operating electric heater) and the room size should be as specified (see “Determination of Minimum Floor Area.”)

WARNING
Ventilated Area: ensure that the area is in the open or that it
is adequately ventilated before breaking into the system of conducting any hot work. A degree of ventilation should continue during the period that the work is carried out. The ventilation should safely disperse any released refrigerant and preferably expel it. Keep ventilation area clear of obstructions!

WARNING
Do NOT use potential sources of ignition in searching for or detection of refrigerant leaks. A halide torch (or any other detector using a naked flame) shall not be used.

The following leak detection methods are deemed acceptable for all refrigerant systems. Electronic leak detectors may be used to detect refrigerant leaks but, in the case of FLAMMABLE REFRIGERANTS, the sensitivity may not be adequate, or may need re-calibration. (Detection equipment shall be calibrated in a refriger-ant-free area.) Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used. Leak detection equipment shall be set at a percentage of the LFL. of the refriger-ant and shall be calibrated to the refrigerant employed, and the appropriate percentage of gas (25% maximum) is confirmed. Leak detection fluids are also suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work. NOTE Examples of leak detection fluids are bubble method, fluorescent method agents If a leak is suspected, all naked flames shall be removed/extinguished. If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of shut off valves) in a part of the system remote from the leak. Removal of refrigerant shall follow the procedure outlined in this manual.

Installation Site
Maximum altitude for this equipment shall not exceed
2000 m. (6561 ft.) For installation only in locations not accessible to the general public.

WARNING
For appliances using A2L refrigerants connected via an air duct system to one or more rooms, only auxiliary devices approved by the appliance manufacturer or declared suitable with the refrigerant shall be installed in connecting ductwork. The manufacturer shall list in the instructions all approved auxiliary devices by manufacturer and model number for use with the specific appliance, if those devices have a potential to become an ignition source.

Installation Space Requirements
NOTE: Equipment with refrigerant charge less than 64 oz does not require have a minimum floor area requirement and does not require a refrigerant leak detection sensor.
The sensor might be added as a feature.

WARNING
Equipment containing R-454B refrigerant shall be installed, operated, and stored in a room with floor area larger than the area defined in the “Minimum Floor Area” chart based on the total refrigerant charge in the system. This requirement applies to indoor equipment with or without a factory refrigerant leakage sensor.

CAUTION
This equipment requires connections to a water supply. See the “Water Quality Guidelines” section of this manual for more information on the quality of water required for this operation. If a potable water source is used for this equipment’s water supply, the source water supply shall be protected against back siphonage by the equipment.

WARNING
This equipment comes with a factory installed Refrigerant Detection Device which is capable of determining it’s specified end-of-life and replacement instructions. Refrigerant sensors for refrigerant detection systems shall only be replaced with sensors specified by the appliance manufacture.

WARNING
Take sufficient precautions in case of refrigerant leakage. If refrigerant gas leaks, ventilate the area immediately.
POSSIBLE RISKS: Excessive refrigerant concentrations in a closed room can lead to oxygen deficiency

WARNING
ALWAYS recover the refrigerant. Do NOT release them directly into the environment. Follow handling instructions carefully in compliance with national regulations.

WARNING
Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.

Determination of Minimum Floor Area
Determine the total refrigerant charge in the system. In packaged heat pump systems, the factory charge should be the total charge for the system and there should be no reason for adding charge in the fi eld. The equipment serial plate and unit physical data table should serve as reference for the total charge. Heat pumps with a refrigerant charge of 62 oz or greater come with a refrigerant mitigation system factory installed.
The heat pump equipment is ducted and utilizes the blower for leak mitigation. Once the refrigerant leak sensor detects leaked refrigerant, the compressor and electric heat will be deactivated, and the blower will operate in the continuous fan setting. This will occur for a minimum of 5 minutes and an alarm in the control will remain until the sensor no longer detects a leak.
The minimum area where the unit can be installed, Amin, is based on the refrigerant charge and installation height of the unit, shown in the table below. Since this heat pump is ducted and is utilizing the blower for leak mitigation, the ducted/zoned fl oor area must be greater than the TAmin shown in the table below. If the heat pump is zoned, the dampers must open to allow the heat pump blower to mitigate the refrigerant leak. The continuous blower speed must be set higher than Qmin, shown in the table below. The continuous fan setting is factory set to exceed the minimum airfl ow required for mitigation.

When the location of the installation is above 1969 ft (600m), the Altitude Adjustment Factor in the table is needed to cal-culate the minimum room size”.
Example: For instance, if you are installing a 060 vertical unit. If your elevation is 5249 ft (1600m) your area factor would be 1.12. If your charge weight is 76oz (2.154kg) at a fl oor height installation. The Amin would be 127.0 square Ft or (11.9 square meters). Take 113.4 square Ft X 1.12 for a new Amin of 127.0 square feet (11.9 square meters).

Model

|

Configuration

| H 0| Charge| A min| Q min| TA min
---|---|---|---|---|---|---
in| ft| m| lbm| oz| ft2| m2| cfm| m3/h| ft2| m2

048

| Horizontal Floor| 23.6| 1.97| 0.60| 4.5| 72| 418.1| 38.8| 121.7| 206.9| 67.5| 6.3
Horizontal Floor +2 Ft| 47.6| 3.97| 1.21| 4.5| 72| 102.9| 9.6| 121.7| 206.9| 67.5| 6.3
Horoizontal Floor +4 ft| 71.6| 5.97| 1.82| 4.5| 72| 45.5| 4.2| 121.7| 206.9| 67.5| 6.3
Horizontal Suspended| 86.6| 7.22| 2.20| 4.5| 72| 67.5| 6.3| 121.7| 206.9| 67.5| 6.3

060

| Vertical| 58.4| 4.87| 1.48| 4.8| 76| 105.6| 9.8| 128.5| 218.4| 71.2| 6.6
Bottom| 62.5| 5.21| 1.59| 4.8| 76| 98.7| 9.2| 128.5| 218.4| 71.2| 6.6
Horizontal Floor| 23.6| 1.97| 0.60| 5.3| 84| 569.1| 52.9| 142.0| 241.4| 78.7| 7.3
Horizontal Floor +2 Ft| 47.6| 3.97| 1.21| 5.3| 84| 140.0| 13.0| 142.0| 241.4| 78.7| 7.3
Horoizontal Floor +4 ft| 71.6| 5.97| 1.82| 5.3| 84| 61.9| 5.8| 142.0| 241.4| 78.7| 7.3
Horizontal Suspended| 86.6| 7.22| 2.20| 5.3| 84| 78.7| 7.3| 142.0| 241.4| 78.7| 7.3

072

| Vertical| 58.4| 4.87| 1.48| 6.5| 104| 144.6| 13.4| 175.8| 298.8| 97.5| 9.1
Bottom| 62.5| 5.21| 1.59| 6.5| 104| 135.1| 12.5| 175.8| 298.8| 97.5| 9.1
Horizontal Floor| 23.6| 1.97| 0.60| 6.5| 104| 872.4| 81.0| 175.8| 298.8| 97.5| 9.1
Horizontal Floor +2 Ft| 47.6| 3.97| 1.21| 6.5| 104| 214.7| 19.9| 175.8| 298.8| 97.5| 9.1
Horoizontal Floor +4 ft| 71.6| 5.97| 1.82| 6.5| 104| 94.9| 8.8| 175.8| 298.8| 97.5| 9.1
Horizontal Suspended| 86.6| 7.22| 2.20| 6.5| 104| 97.5| 9.1| 175.8| 298.8| 97.5| 9.1

Model Nomenclature

General Installation Information – Serial Plate Example

NOTICE
NOTICE: To avoid equipment damage, do not leave the system filled in a building without heat during cold weather, unless adequate freeze protection levels of antifreeze are used. Heat exchangers do not fully drain and will freeze unless protected, causing permanent damage.
NOTICE: Do not store or install units in corrosive environments or in locations subject to temperature
or humidity extremes. Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life.

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.

Unit Location
Locate the unit in an indoor area that allows for easy removal of the filter and access panels. Location should have enough space for service personnel to perform maintenance or repair. Provide sufficient room to make water, electrical and duct connection(s). If the unit is located in a confined space, such as a closet, provisions must be made for return air to freely enter the space by means of a louvered door, etc. Any access panel screws that would be difficult to remove after the unit
is installed should be removed prior to setting the unit. On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping.

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

Installing Vertical Units
Prior to setting the unit in place, remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket.
Vertical units are available in left or right air return configurations. Top 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).
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.

Installing Horizontal Units
Remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket prior to setting the unit in place. Horizontal units are available with side or end discharge. Horizontal units are normally suspended from a ceiling by four or six 3/8 in. diameter threaded rods. The rods are usually attached to the unit by hanger bracket kits furnished with each unit.
Lay out the threaded rods per the dimensions in Figure 3. Assemble the hangers to the unit as shown. Securely tighten the brackets to the unit using the weld nuts located on the underside of the bottom panel. When attaching the hanger rods to the bracket, a double nut is required since vibration could loosen a single nut. To allow filter access, one bracket on the filter side should be installed 180° from the position shown

in Figure 3. The unit should be pitched approximately 1/4-inch towards the drain in both directions to facilitate the removal of condensate. Use only the bolts provided in the kit to attach hanger brackets. The use of longer bolts could damage internal parts.
Some residential applications require the installation of horizontal units on an attic floor. In this case, the unit should be set in a full size secondary drain pan on top of a vibration absorbing pad. The secondary drain pan prevents possible condensate overflow or water leakage damage to the ceiling. The secondary drain pan is usually placed on a plywood base isolated from the ceiling joists by additional layers of vibration absorbing material.

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.

Hanger Bracket Locations

018

| in.| ****

99S500A04

| 53.7| 25.1| 21.4| n/a
cm.| 136.4| 63.8| 54.4| n/a

024-030

| in.| ****

99S500A04

| 63.4| 24.8| 21.1| n/a
cm.| 161.0| 63.0| 53.6| n/a

036

| in.| ****

99S500A03

| 72.4| 27.8| 24.1| 29.3
cm.| 183.9| 70.6| 61.2| 74.4

042-048

| in.| ****

99S500A03

| 77.4| 27.8| 24.1| 29.3
cm.| 196.6| 70.6| 61.2| 74.4

060-072

| in.| ****

99S500A03

| 82.4| 27.8| 24.1| 29.3
cm.| 209.3| 70.6| 61.2| 74.4

Horizontal Series Corner Weights

Duct System
An air outlet collar is provided on vertical top and rear air discharge units and all horizontal units to facilitate a duct connection (vertical bottomflow units have no collar). A flexible connector is recommended for discharge and return air duct connections on metal duct systems. Uninsulated duct should be insulated with a minimum of 1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit’s performance will be adversely affected.
If the unit is connected to existing ductwork, check the duct system to ensure that it has the capacity to accommodate the air required for the unit application. If the duct is too small, as in the replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repaired if necessary.
The duct system should be sized 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.

CAUTION: When attaching ductwork or accessories to the cabinet, make sure the fasteners do not come into contact with the air coil.

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 the swivel connector and thread the female locking ring onto the pipe threads, while maintaining the brass connector in the desired direction. Tighten the connectors by hand, then gently snug the fitting with pliers to provide a leak-proof joint. When connecting to an open loop (ground water) system, thread any 1-inch MPT fitting (SCH80 PVC or copper) into the swivel connector and tighten in the same manner as noted above. The open and closed loop piping system should include pressure/temperature taps for serviceability.
Never use flexible hoses smaller than 1-inch inside diameter on the unit. Limit hose length to 10 feet per connection. Check carefully for water leaks.

Condensate Drain
On vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the
drain pan, a 3/4-inch PVC female adapter and a flexible connecting hose. The female adapter may exit either the front or the side of the cabinet. The adapter should be glued to the field-installed PVC condensate piping. On vertical units, a condensate hose is inside all cabinets as a trapping loop; therefore, an external trap is not necessary.
On horizontal units, a PVC stub is provided for condensate drain piping connection. An external trap is required (see below). If a vent is necessary, an open stand pipe may be applied to a tee in the field-installed condensate piping.

Water Quality

Corrosion

| Hydrogen Sulfide| Less than 0.5 ppm (rotten egg

smell appears at 0.5 ppm)

| 10 – 50 ppm| Less than 1 ppm
Sulfates| Less than 125 ppm| Less than 125 ppm| Less than 200 ppm
Chlorine| Less than 0.5 ppm| Less than 0.5 ppm| Less than 0.5 ppm
Chlorides| Less than 20 ppm| Less than 125 ppm| Less than 300 ppm
Carbon Dioxide| Less than 50 ppm| 10 – 50 ppm| 10 – 50 ppm
Ammonia| Less than 2 ppm| Less than 2 ppm| Less than 20 ppm
Ammonia Chloride| Less than 0.5 ppm| Less than 0.5 ppm| Less than 0.5 ppm
Ammonia Nitrate| Less than 0.5 ppm| Less than 0.5 ppm| Less than 0.5 ppm
Ammonia Hydroxide| Less than 0.5 ppm| Less than 0.5 ppm| Less than 0.5 ppm
Ammonia Sulfate| Less than 0.5 ppm| Less than 0.5 ppm| Less than 0.5 ppm
Total Dissolved Solids (TDS)| Less than 1000 ppm| 1000 – 1500 ppm| 1000 – 1500 ppm
LSI Index| +0.5 to -0.5| +0.5 to -0.5| +0.5 to -0.5

Iron Fouling (Biological Growth)

| Iron, FE2+ (Ferrous) Bacterial Iron Potential| < 0.2 ppm| < 0.2 ppm| < 0.2 ppm
Iron Oxide| Less than 1 ppm, above this

level deposition will occur

| Less than 1 ppm, above this

level deposition will occur

| Less than 1 ppm, above this

level deposition will occur

Erosion

| Suspended Solids| Less than 10 ppm and filtered for max. of 600 micron size| Less than 10 ppm and filtered for max. of 600 micron size| Less than 10 ppm and filtered for max. of 600 micron size
Threshold Velocity

(Fresh Water)

| < 6 ft/sec| < 6 ft/sec| < 6 ft/sec

NOTES: Grains = ppm divided by 17 mg/L is equivalent to ppm

Water Quality
It is the responsibility of the system designer and installing contractor to ensure that acceptable water quality is present and that all applicable codes have been met in these installations. Failure to adhere to the guidelines in the water quality table could result in loss of warranty. In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. The heat exchanger coils in ground water systems may, over a period of time, lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualified service mechanic, as special solutions and pumping equipment are required. Hot water generator coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional flushing.
Heat pumps 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.

Water Treatment
Do not use untreated or improperly treated water. Equipment damage may occur. The use of improperly treated or untreated water in this equipment may result in scaling, erosion, corrosion, algae or slime. Purchase of a pre-mix antifreeze could significantly improve system reliability if the water quality is controlled and there are additives in the mixture to inhibit corrosion. There are many examples of such fluids on the market today such as Environol™ 1000 (pre-mix ethanol), and others. The services of a qualified water treatment specialist should be engaged to determine what treatment, if any, is required. The product warranty specifically excludes liability for corrosion, erosion or deterioration of equipment.
The heat exchangers and water lines in the units are copper or cupronickel tube. There may be other materials in the buildings piping system that the designer may need to take into consideration when deciding the parameters of the water quality. If antifreeze or water treatment solution is to be used, the designer should confirm it does not have a detrimental effect on the materials in the system.

Contaminated Water
In applications where the water quality cannot be held to prescribed limits, the use of a secondary or intermediate heat exchanger is recommended to separate the unit fro
the contaminated water. The table above outlines the water quality guidelines for unit heat exchangers. If these conditions are exceeded, a secondary heat exchanger is required. Failure to supply a secondary heat exchanger where needed will result in a warranty exclusion for primary heat exchanger corrosion or failure.

Hot Water Generator Connections

Plumbing Installation

1. Inspect the dip tube in the water heater cold inlet for a check valve. If a check valve is present it must be removed or damage to the hot water generator circulator will occur.
2. Remove drain valve and fitting.
3. Thread the 3/4-inch NPT x 3-1/2-inch brass nipple into the water heater drain port.
4. Attach the center port of the 3/4-inch FPT tee to the opposite end of the brass nipple.
5. Attach the 1/2-inch copper to 3/4-inch NPT adaptor to the side of the tee closest to the unit.
6. Install the drain valve on the tee opposite the adaptor.
7. Run interconnecting tubing from the tee to hot water generator water out.
8. Cut the cold water “IN” line going to the water heater.
9. Insert the reducing solder tee in line with cold water “IN” line as shown.
10. Run interconnecting copper tubing between the unit hot water generator water “IN” and the tee (1/2-inch nominal). The recommended maximum distance is 50 feet.
11. To prevent air entrapment in the system, install a vent coupling at the highest point of the interconnecting lines.
12. Insulate all exposed surfaces of both connecting water lines with 3/8-inch wall closed cell insulation.

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

Hot Water Generator Switch
The hot water generator switch is taped in the disabled position at the factory.

NOTE: This configuration maximizes hot water generator capability.
NOTE: PEX is not recommended for hot water generation plumbing. If PEX is to be used, you must install copper to the unit for the first 10ft, then transition to PEX.

Electrical Connections

General
Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.

Unit Power Connection
Connect the incoming line voltage wires to L1 and L2 of the contactor as shown in Figure 13C for single-phase unit. Consult the Unit Electrical Data in this manual for correct fuse sizes.
Open lower front access panel. Remove ground fastener from bottom of control box (Figure 13B). Swing open control box (Figure 13A). Insert power wires through knockouts on lower left side of cabinet. Route wires through left side of control box and connect to contactor and ground (Figure 13C). Close control box and replace grounding fastener before unit start-up.

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 PB2.

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 8-conductor (4 or 5 conductor for communicating thermostats), 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 TPCM32U03A and TPCM32U04A communicating thermostats may be hard wired to provide aux/emergency heat in the event communication is lost between the thermostat and the ABC microprocessor.

NOTE: Aurora Base Control (ABC) DIP switch SW2-7 is required to be in the “OFF” position for the control to operate with FaultFlash or ComforTalk thermostats. SW2-7 in the “ON” position configures the control to operate with typical thermostats (continuous lockout signal). There must be a wire connecting Y2 on the Aurora controller
to 2nd stage compressor on the thermostat for proper operation. SW2-7 DIP switch position is not relevant with communicating thermostats.

Blower Performance Data

MODEL

|

MAX ESP

| AIR FLOW SPEED SETTINGS
---|---|---
1| 2| 3| 4| 5| 6| 7| 8| 9| 10| 11| 12
018| 0.50| 300| 400

G

| 500| 600

L

| 700

H

| 800| 875| 950| 1025| 1125

Aux

| |
024| 0.50| | 400| 500

G

| 600| 700

L

| 800| 900

H

| 1000| 1100| 1200

Aux

| |
030| 0.50| | 400| 500

G

| 600| 700

L

| 800| 900

H

| 1000| 1100| 1200

Aux

| |
036| 0.50| 650| 750

G

| 850| 1000| 1100

L

| 1200| 1300

H

| 1400| 1500| 1550

Aux

| |
042| 0.50| 650| 800| 900

G

| 1050| 1150

L

| 1250| 1350| 1450

H

| 1550| 1600

Aux

| |
048| 0.50| 650| 800

G

| 900| 1050| 1150| 1250| 1350

L

| 1450| 1550

H

| 1575

Aux

| |
060| 0.75| 800| 950

G

| 1100| 1300| 1500

L

| 1750| 1950

H

| 2100| 2300| 2325

Aux

| |
072| 0.75| 800| 950| 1100

G

| 1300| 1500| 1750

L

| 1950| 2100

H

| 2300| 2325

Aux

| |

Factory settings are at recommended G-L-H-Aux speed settings

L-H settings MUST be located within boldface CFM range
“Aux” is factory setting for auxiliary heat and must be equal to or above the “H” setting as well as at least the minimum required for the auxiliary heat package “G” may be located anywhere within the airfl ow table
CFM is controlled within ±5% up to the maximum ESP Max ESP includes allowance for wet coil and standard fi lter

Setting Blower Speed – Variable SpeedECM
The ABC board’s Yellow Config LED will flash the current ECM blower speed selections for “G”, low, and high continuously with a short pause in between. The speeds can also be confirmed with the AID Tool under the Setup/ECM Setup screen. The Aux will not be flashed but can be viewed in the AID Tool. The ECM blower motor speeds can be field adjusted with or without using an AID Tool.
ECM Setup without an AID Tool
The blower speeds for “G”, Low (Y1), High (Y2), and Aux can be adjusted directly at the Aurora ABC board which utilizes the push button (SW1) on the ABC board. This procedure is outlined in the ECM Configuration Mode portion of the Aurora ‘Base’ Control System section. The Aux cannot be set manually without an AID Tool.
ECM Setup with an AID Tool
A much easier method utilizes the AID Tool to change the airflow using the procedure below. First navigate to the Setup screen and then select ECM Setup. This screen displays the current ECM settings. It allows the technician to enter the setup screens to change the ECM settings. Change the highlighted item using the ◀ and ▶ buttons and then press the ◙ button to select the item.

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.

After the auxiliary heat speed setting is selected the AID Tool will automatically transfer back to the ECM Setup screen.
Cooling Airflow Setup – These screens allow the technician to select -15%, -10%, -5%, None or +5%. Change the adjustment percentage using the ▲ and ▼ buttons. Press the ◙ button to save the change.

Vertical Dimensional Data

Top Air Discharge

Vertical Top Flow Model

|

Overall Cabinet

|

Water Connections

| Electrical Connections|

Discharge Connection

duct flange installed (±0.10 in)

|

Return Connection

using std deluxe filter rack (±0.10 in)

---|---|---|---|---|---
I

3/4″

cond

| J

1/2″

cond

| K

1/2″

cond

A

Width

| B

Depth

| C

Height

| D

Loop In

| E

Loop Out

| F

HWG

In

| G

HWG

Out

| H

Cond- ensate

| Loop Water FPT| HWG (O.D.)| Power Supply| Ext Pump| Low Votage| L| M| N| O| P| Q| R| S| T
| | Supply

Width

| Supply

Depth

| | | Return

Depth

| Return

Height

|
018| in.| 22.5| 26.5| 39.4| 2.3| 5.3| 13.4| 16.4| 9.6| 1″

Swivel

| 1/2″

Stub

| 6.9| 9.4| 11.7| 6.3| 0.7| 14.0| 14.0| 2.7| 2.3| 22.0| 18.0| 2.0
cm.| 57.2| 67.3| 100.1| 5.8| 13.5| 34.0| 41.7| 24.4| 17.5| 23.9| 29.7| 16.0| 1.8| 35.6| 35.6| 6.9| 5.8| 55.9| 45.7| 5.1
024-

030

| in.| 22.5| 26.5| 48.5| 2.0| 7.0| 13.5| 16.5| 10.2| 1″

Swivel

| 1/2″

Stub

| 9.5| 12.1| 14.3| 6.1| 0.8| 14.0| 14.0| 4.4| 1.7| 22.2| 26.0| 1.7
cm.| 57.2| 67.3| 123.2| 5.1| 17.8| 34.3| 41.9| 25.9| 24.1| 30.7| 36.3| 15.5| 2.0| 35.6| 35.6| 11.2| 4.3| 56.4| 66.0| 4.3
036| in.| 25.6| 31.6| 50.4| 2.3| 7.3| 15.9| 18.9| 10.6| 1″

Swivel

| 1/2″

Stub

| 9.5| 12.1| 14.3| 6.9| 1.1| 18.0| 18.0| 3.8| 1.7| 28.1| 26.0| 1.7
cm.| 65.0| 80.3| 128.0| 5.8| 18.5| 40.4| 48.0| 26.9| 24.1| 30.7| 36.3| 17.5| 2.8| 45.7| 45.7| 9.7| 4.3| 71.4| 66.0| 4.3
042-

048

| in.| 25.6| 31.6| 54.4| 2.3| 7.3| 15.9| 18.9| 10.6| 1″

Swivel

| 1/2″

Stub

| 9.5| 12.1| 14.3| 6.9| 1.1| 18.0| 18.0| 3.8| 1.7| 28.1| 30.0| 1.7
cm.| 65.0| 80.3| 138.2| 5.8| 18.5| 40.4| 48.0| 26.9| 24.1| 30.7| 36.3| 17.5| 2.8| 45.7| 45.7| 9.7| 4.3| 71.4| 76.2| 4.3
060-

072

| in.| 25.6| 31.6| 58.4| 2.3| 7.3| 15.9| 18.9| 10.6| 1″

Swivel

| 1/2″

Stub

| 9.5| 12.1| 14.3| 6.9| 1.1| 18.0| 18.0| 3.8| 1.7| 28.1| 34.0| 1.7
cm.| 65.0| 80.3| 148.3| 5.8| 18.5| 40.4| 48.0| 26.9| 24.1| 30.7| 36.3| 17.5| 2.8| 45.7| 45.7| 9.7| 4.3| 71.4| 86.4| 4.3

Condensate is 3/4″ PVC female glue socket and is switchable from side to front
Unit shipped with deluxe 2″ (fi eld adjustable to 1″) duct collar/fi lter rack extending from unit 3.25″ and is suitable for duct connection. Discharge fl ange is fi eld installed and extends 1″ [25.4mm] from cabinet
Decorative molding and/or water connections extend 1.2″ [30.5mm] beyond front of cabinet.

Bottom Air Discharge

Bottom Flow Models

|

Overall Cabinet

| Water Connections| Electrical Knockouts|

Discharge Connection

duct flange installed (±0.10 in)

|

Return Connection using std deluxe filter rack (±0.10 in)

---|---|---|---|---|---

1

|

2

|

3

|

4

|

5

| | | I

3/4 in.

cond

| J

1/2 in.

cond

| K

1/2 in.

cond

A| B| C| D| E| F| G| H| Loop Water FPT| HWG (O.D.)| Power Supply| Ext Pump| Low Voltage| L| M| N| O| P| Q| R| S| T
Width| Depth| Height| In| Out| HWG

In

| HWG

Out

| Con- densate| | | Supply Width| Supply Depth| | | Return Depth| Return Height|
024-

030

| in.| 22.5| 26.5| 52.5| 35.3| 40.2| 46.7| 49.7| 3.6| 1 in. Swivel| 1/2 in.

Stub

| 41.9| 43.6| 45.1| 8.6| 6.0| 9.3| 10.5| 1.0| 2.2| 22.2| 26.0| 5.6
cm.| 57.2| 67.3| 133.4| 89.7| 102.1| 118.6| 126.2| 9.1| 106.4| 110.7| 114.6| 21.8| 15.2| 23.6| 26.7| 2.5| 5.6| 56.4| 66.0| 14.2
036-

072

| in.| 25.5| 31.5| 62.5| 43.4| 48.4| 57.0| 60.0| 3.6| 1 in. Swivel| 1/2 in.

Stub

| 48.9| 50.8| 52.2| 9.1| 4.8| 13.4| 13.6| 1.5| 1.8| 28.1| 34.0| 5.6
cm.| 64.8| 80.0| 158.8| 110.2| 122.9| 144.8| 152.4| 9.1| 124.2| 129.0| 132.6| 23.1| 12.2| 34.0| 34.5| 3.8| 4.6| 71.4| 86.4| 14.2

Condensate is 3/4 in. PVC female glue socket and is switchable from side to front
Vertical bottom flow unit shipped with deluxe 2 in. (field adjustable to 1 in.) duct collar/filter rack extending from unit 3.25 in. and is suitable for duct connection.
Water connections extend 1.2 in. (30.5mm) beyond front of cabinet.
Top panel has 1.375 in. and 1.125 in. knockouts for electrical connections.

Horizontal Dimensional Data

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

Horizontal Model| Overall Cabinet| Water Connections| Electrical Connections| Discharge Connection duct flange installed (±0.10 in)| Return Connection using std deluxe filter rack (±0.10 in)|
---|---|---|---|---|---|---
I

3/4 in.

cond

| J

1/2 in.

cond

| K

1/2 in.

cond

|
A| B| C| D| E| F| G| H| Loop Water FPT| HWG (O.D.)| L| M| N| O| P| Q| R| S|
Width| Depth| Height| In| Out| HWG

In

| HWG

Out

| Cond- ensate| Power Supply| Ext Pump| Low Voltage| | Supply Height| Supply Depth| | | Return Depth| Return Height| |
018| in.| 22.5| 53.0| 19.3| 2.3| 5.3| 13.8| 16.8| 8.0| 1 in. Swivel| 1/2 in.

Stub

| 6.9| 9.5| 11.7| 1.8| 10.5| 9.5| 8.2| 2.2| 21.8| 16.5| 1.5|
cm.| 57.2| 134.6| 49.0| 5.8| 13.5| 35.1| 42.7| 20.3| 17.5| 24.1| 29.7| 4.6| 26.7| 24.1| 20.8| 5.6| 55.4| 41.9| 3.8|
024-

030

| in.| 22.5| 63.0| 19.3| 2.0| 7.0| 13.5| 16.5| 0.8| 1 in. Swivel| 1/2 in.

Stub

| 9.5| 12.1| 14.3| 2.3| 10.5| 9.4| 5.8| 2.8| 30.5| 16.9| 1.3|
cm.| 57.2| 160.0| 49.0| 5.1| 17.8| 34.3| 41.9| 2.0| 24.1| 30.7| 36.3| 5.8| 26.7| 23.9| 14.7| 7.1| 77.5| 42.9| 3.3|
036| in.| 25.6| 72.0| 21.3| 2.3| 7.3| 15.9| 18.9| 0.8| 1 in. Swivel| 1/2 in.

Stub

| 9.5| 12.1| 14.3| SEE CHART| 13.6| 13.2| SEE CHART| 2.8| 35.5| 18.9| 1.3|
cm.| 65.0| 182.9| 54.1| 5.8| 18.5| 40.4| 48.0| 2.0| 24.1| 30.7| 36.3| 34.5| 33.5| 7.1| 90.2| 48.0| 3.3|
042-

048

| in.| 25.6| 77.0| 21.3| 2.3| 7.3| 15.9| 18.9| 0.8| 1 in. Swivel| 1/2 in.

Stub

| 9.5| 12.1| 14.3| SEE CHART| 13.6| 13.2| SEE CHART| 2.8| 40.4| 18.9| 1.3|
cm.| 65.0| 195.6| 54.1| 5.8| 18.5| 40.4| 48.0| 2.0| 24.1| 30.7| 36.3| 34.5| 33.5| 7.1| 102.6| 48.0| 3.3|
060-

072

| in.| 25.6| 82.0| 21.3| 2.3| 7.3| 15.9| 18.9| 0.8| 1 in. Swivel| 1/2 in.

Stub

| 9.5| 12.1| 14.3| SEE CHART| 13.6| 13.2| SEE CHART| 2.8| 45.4| 18.9| 1.3|
cm.| 65.0| 208.3| 54.1| 5.8| 18.5| 40.4| 48.0| 2.0| 24.1| 30.7| 36.3| 34.5| 33.5| 7.1| 115.3| 48.0| 3.3|

Condensate is 3/4 in. PVC female glue socket and is switchable from side to front
Unit shipped with deluxe 2 in. (field adjustable to 1 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.

Physical Data

Model

|
---|---
018| 024| 030| 036| 042| 048| 060| 072
Compressor (1 each)| Dual Capacity Scroll
Factory Charge R-454B, oz [kg]| Vertical| 32 [0.91]| 50 [1.42]| 56 [1.59]| 54 [1.53]| 56 [1.59]| 62 [1.76]| 76 [2.15]| 104 [2.95]
Factory Charge R-454B, oz [kg]| Horizontal| 36 [0.93]| 48 [1.36]| 54 [1.53]| 54 [1.53]| 62 [1.76]| 72 [2.04]| 84 [2.38]| 104 [2.95]
Blower Motor & Blower| |
Blower Motor Type/Speeds| VS ECM| Variable Speed ECM
Blower Motor- hp [W]| VS ECM| 1/2| [373]| 1/2| [373]| 1/2| [373]| 1/2| [373]| 1/2| [373]| 1/2| [373]| 1 [746]| 1 [746]
High Static Blower Motor – hp [W]| VS ECM| n/a| n/a| n/a| 1 [746]| 1 [746]| 1 [746]| n/a| n/a

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

|

VS ECM

| 9 x 7 [229 x 178]| 9 x 7 [229 x 178]| 9 x 7 [229 x 178]| 11 x 10 [279 x

254]

| 11 x 10 [279 x 254]| 11 x 10 [279 x 254]| 11 x 10 [279 x 254]| 11 x 10 [279 x 254]
Coax and Water Piping|
Water Connections Size – Swivel – in [mm]| 1″ [25.4]| 1″ [25.4]| 1″ [25.4]| 1″ [25.4]| 1″ [25.4]| 1″ [25.4]| 1″ [25.4]| 1″ [25.4]
HWG Connection Size – Female Sweat I.D. – in [mm]| 1/2″ [12.7]| 1/2″ [12.7]| 1/2″ [12.7]| 1/2″ [12.7]| 1/2″ [12.7]| 1/2″ [12.7]| 1/2″ [12.7]| 1/2″ [12.7]
Coax & Piping Water Volume – gal [l]| 0.40 [1.5]| 0.7 [2.6]| 1.0 [3.8]| 1.3 [4.9]| 1.3 [4.9]| 1.6 [6.1]| 1.6 [6.1]| 2.3 [8.7]
Vertical|

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

| 19 x 20 [483 x

508]

| 24 x 20 [610 x 542]| 28 x 20 [711 x 542]| 28 x 25 [711 x 635]| 32 x 25 [813 x 635]| 32 x 25 [813 x 635]| 36 x 25 [914 x 635]| 36 x 25 [914 x 635]
Air Coil Total Face Area, ft2 [m2]| 2.6 [0.242]| 3.3 [0.310]| 3.9 [0.362]| 4.9 [0.451]| 5.6 [0.570]| 5.6 [0.570]| 6.3 [0.641]| 6.3 [0.641]
Air Coil Tube Size, in [mm]| 3/8 [9.5]| 3/8 [9.5]| 3/8 [9.5]| 3/8 [9.5]| 5/16 [7.9]| 5/16 [7.9]| 3/8 [9.5]| 3/8 [9.5]
Air Coil Number of rows| 3| 3| 3| 3| 4| 4| 4| 4

Filter Standard – 2″ [51mm] Pleated MERV11 Throwaway, in [mm]

| 20 x 24 [508 x 610]| 28 x 24 [712 x 610]| 28 x 24 [712 x 610]| 28 x 30 [712 x

762]

| 32 x 30 [813 x 762]| 32 x 30 [813 x 762]| 36 x 30 [914 x 762]| 36 x 30 [914 x 762]
Weight – Operating, lb [kg]| 200 [91]| 293 [133]| 308 [140]| 353 [160]| 368 [167]| 408 [185]| 443 [201]| 468 [212]
Weight – Packaged, lb [kg]| 220 [100]| 313 [142]| 328 [149]| 373 [169]| 388 [176]| 428 [194]| 463 [210]| 488 [221]
Horizontal|

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

| 18 x 21 [457 x 533]| 18 x 27 [457 x

686]

| 18 x 30 [457 x

762]

| 20 x 35 [508 x

889]

| 20 x 40 [508 x

1016]

| 20 x 40 [508 x

1016]

| 20 x 45 [508 x

1143]

| 20 x 45 [508 x 1143]
Air Coil Total Face Area, ft2 [m2]| 2.6 [0.242]| 3.4 [0.316]| 3.9 [0.362]| 4.9 [0.451]| 5.6 [0.570]| 5.6 [0.570]| 6.3 [0.641]| 6.3 [0.641]
Air Coil Tube Size, in [mm]| 5/16 [7.9]| 3/8 [9.5]| 3/8 [9.5]| 3/8 [9.5]| 3/8 [9.5]| 3/8 [9.5]| 3/8 [9.5]| 3/8 [9.5]
Air Coil Number of rows| 3| 3| 3| 3| 3| 3| 4| 4
Filter Standard – 2″ [51mm] Pleated MERV11 Throwaway, in [mm]| 1 – 18 x 24 [457 x 610]| 1 – 18 x 32 [457 x 813]| 1 – 18 x 32 [457 x

813]

| 1 – 20 x

37 [686 x

940]

| 1 – 20 x 20 [508 x 508]

1 – 20 x 22

[508 x 559]| 1 – 20 x 20 [508 x 508]

1 – 20 x 22

[508 x 559]| 1 – 20 x 25 [508 x 635]

1 – 20 x

22 [508 x

559]

| 1 – 20 x 25 [508 x 635]

1 – 20 x 22

[508 x 559]
Weight – Operating, lb [kg]| 210 [95]| 305 [138]| 320 [145]| 373 [169]| 403 [183]| 423 [191]| 468 [212]| 483 [219]
Weight – Packaged, lb [kg]| 230 [104]| 325 [152]| 340 [154]| 393 [178]| 423 [192]| 443 [101]| 488 [221]| 503 [228]

Reference Calculations

Operating Limits

NOTE: Minimum/maximum limits are only for start-up conditions, and are meant for bringing the space up to occupancy temperature. Units are not designed to operate at the minimum/maximum conditions on a regular basis. The operating limits are dependent upon three primary factors: 1) water temperature, 2) return air temperature, and 3) ambient temperature. When any of the factors are at the minimum or maximum levels, the other two factors must be at the normal level for proper and reliable unit operation.

Unit Startup

Before Powering Unit, Check the Following
NOTE: Remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket.

• Black/white and gray/white wires in unit control box have been removed if auxiliary heat has been installed.
• Dip switches are set correctly.
• Transformer switched to 208V if applicable.
• 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.
• 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.
• 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% 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 recommended for setup, configuration and troubleshooting, especially with an Aurora ‘Advanced’ Control. AID Tool version 2.04 or greater is preferred.

1. Configure Aurora Screen

   • In advanced controls – Confirm AXB is added and communicating.
   • In advanced controls – Confirm communicating thermostats are added and communicating. Set thermostat mode to off.
   • In advanced controls – Confirm IntelliZone2, if installed, is added and communicating. Set Zoning system to off mode.
   • In advanced controls – Confirm ASB is added and communicating if Refrigerant Detection System in installed.

2. Aurora Setup Screen

   • ECM Setup for Heating Airflow – select “G”, low, high and aux blower speeds as appropriate for the unit and electric heat.
   • Cooling Airflow % – sets the cooling airflow % from heating airflow. Factory setting is -None.
   • AXB Setup
   1. DHW Enable – Ensure air is purged from HW system before enabling (remember the HW switch on the front cabinet)
   2. DHW Setpoint – 130 °F is the default but can be changed from 100 to 140 °F
   3. FCV1-GL, FCV2-GL Pump Setup
      and Modulating Water Valve Setup – Can be setup to a range between 5% and 100%. Defaults are 75% 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.
   • Sensor Kit Setup
   1. Brine Selection – for HE/HR capacity calculation
   2. Flow Meter – activates the flow meter
   3. Select Pump.
   4. Select blower energy – ECM
   5. Activate energy option
   6. Line Voltage calibration – Voltmeter required to calibrate line voltage during heat or cooling. Refer to Line Voltage Calibration in this manual for more details.
   • Smart Grid Setup – Select Action option for utility received on-peak signal
   • Home Automation 1 & 2 Setup – Select type of sensor for two home automation inputs.

Configuring the Sensor Kits
Configuring the Sensor kits
The Aurora Advanced controls come with the Energy Monitoring kit as a standard feature. The Aurora Premium controls include Energy Monitoring, Performance and Refrigeration Monitoring as standard features. The following description is for field activation of a factory installation of the sensor kits.

Energy Monitoring Kit
The Energy Monitoring Kit includes two current transducers (fan and electric heat) added to the existing two compressor sensors so that the complete power usage of the heat pump can be measured. The AID Tool provides configuration detail for the type of blower motor, a line voltage calibration procedure to improve the accuracy, and a power adjustment setting that allows the compressor power to be adjusted to match the unit’s line voltage using the provided tables. This information can be displayed on the AID Tool or selected communicating thermostats. The TPCM32U03A/04A will display instantaneous energy use while the color touchscreen TPCC32U02/MasterStat 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:

• Select ‘Blower Energy’ – ECM

• Activate ‘Energy Option’ to activate the sensors on for compressor (2), fan and aux heat current sensor.

• Select ‘Pump’ option of FC1, FC2, VS Pump, VS+26-99, or open loop. This selects the pump watts used in the calculation. Pump watts are not measured but estimated.

• Line Voltage Calibration – Voltmeter required to calibrate line voltage during heating or cooling. Refer to Line Voltage Calibration in this manual for more details.

  1. Turn on Unit in Heating or Cooling.
  2. Use multimeter at L1 and L2 to measure line voltage
  3. In the Sensor Kit Setup screen adjust the ‘Base Voltage’ to the nearest value to that is measured
  4. Then use the ‘Fine Adjust’ to select the exact voltage being measured at L1 and L2.
  5. Exit ‘Sensor Setup’ Screen

• Power Adjustment: Refer to the Single Speed and Dual Capacity Power Adjustment tables in the Aurora ‘Advanced’ Control section of the literature

  1. On the Main Menu screen select Setup
  2. Once in the Setup menu select the Power Adjustment Factor
  3. Power Adjustment – allows you to enter the unit’s compressor power setting for high and low speed operation.
  4. Refer to the tables and use the voltage that is closest to the unit’s line voltage and set the power adjustment accordingly.

• Energy monitoring can be read on any of the following components:

  1. AID Tool – instantaneous information only
  2. TPCM32U03A/04A Communicating Thermostat (B/W) – instantaneous information only
  3. TPCC32U03/MasterStat Color
     Touchscreen
  • Thermostat – Both Instantaneously and historical (13 months)
  4. WaterFurnace Web Portal via AWL device connected to Aurora

Refrigerant Monitoring
(Standard with Premium Controls)
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. Ensure the Refrigerant Monitoring has been setup by accessing the ‘Sensor Kit Setup” in the AID Tool and complete the following:
Once sensors are installed for discharge pressure, suction pressure, suction, liquid line cooling, liquid line heating and leaving air temperature no further setup is required.

• Turn on Unit in Heating or Cooling.
• Use the AID Tool to view the refrigerant performance in the ‘Refrigerant Monitor’ screen.
• Refrigerant monitoring can be read on any of the following components:
  1. AID Tool – instantaneous information only
  2. WF Web Portal via AWL device connected to Aurora

Performance Monitoring
(Standard with Premium Controls)
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 Energy Kit has been enabled by accessing the ‘Sensor Kit Setup” in the AID Tool and complete the following:

• Select ‘Brine’ – and then choose Water or Antifreeze for the proper factor
• Activate ‘Flowmeter’ to activate the flow sensor select the appropriate 3/4 in. (018-030 models), 1 in. (036-072 models), or none.
• Exit Sensor Kit Setup Screen; if the unit is connected to a Variable Speed Flow Center the min/max flow rate must be set.
  1. Enter the AXB Setup Screen and turn the VS Pump Control On.
  2. Then set the VS Pump Min % to achieve at least 2.5 gpm per ton for part load operation.
  3. Then set the VS Pump Max % to achieve at least 3.0 gpm per ton for full load operation.
• Turn on Unit in Heating or Cooling .
• Use the AID Tool to view the performance in the ‘Performance Monitor’ screen.
• Performance monitoring can be read on any of the following components:
  1. AID tool – instantaneous information only
  2. WaterFurnace Web Portal via AWL device connected to Aurora.

Startup Steps
NOTE: Complete the Equipment Start-Up/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.

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, depending on the fan speed and entering water temperature.

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

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

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

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

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

13. Check for an air temperature rise of 12°F to 35°F across the air coil, 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.
    All stages of the auxiliary heater should be sequenced on when the thermostat is in the Emergency Heat mode. Check amperage of each element.

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

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

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

18. Instruct the owner/operator in the proper operation of the thermostat and system maintenance.

NOTE: Be certain to fill out and forward all warranty registration papers.

Revision Guide

Manufactured by WaterFurnace International, Inc. 9000 Conservation Way
Fort Wayne, IN 46809
www.waterfurnace.com

• Product: 5 Series 500A11
• Type: Dual Capacity Packaged Heat Pump
• Size: 2-6 Ton Dual Capacity
• Document: Installation Guide

©2024 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy of continual product research and development and reserves the right to change design and specifi cations without notice.

References

• WaterFurnace - Smarter From The Ground Up

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