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5 SERIES 500A11 INSTALLATION MANUAL

Troubleshooting cont.

FP2 Sensor

LLT

(Liquid Line Heating)

FP1 Sensor

Filter

Dryer

Compressor

Coax

Water IN

Water OUT

Rev. Valve

TXV

Suction

Line

Thermistor

Suction
Pressure
Transducer

Discharge

Pressure

Transducer

Air

Coil

Blower

Leaving Air

Thermistor

(

Wire Bundle In

Blower

Compartment)

Coax

Flow Meter

Water

OUT

Water

Flow

Sensor

Entering Water

Thermistor

(Sensor Wire

Wrapped 4

Times Around

Water Line)

Leaving Water

Thermistor

(Sensor Wire

Wrapped 4

Times Around

Water Line)

Water Line View of Coax

Performance Option Only

Refrigeration Package Only

Refrigeration

Package Only

Summary of Contents for 500A11

Page 1: ...ections Electrical Startup Procedures Troubleshooting Preventive Maintenance 5 Series 500A11 Installation Manual Geothermal Heat Pump R 410A Refrigerant 1 1 5 2 2 5 3 3 5 4 5 6 Ton Single Speed 2 3 4...

Page 2: ......

Page 3: ...xiliary Heat Ratings 16 Auxiliary Heat Electrical Data 16 Electrical Data 17 Blower Performance Data 19 Dimensional Data 24 Physical Data 28 The Aurora Control System 30 Reference Calculations and Leg...

Page 4: ...c PSC 022 030 036 042 048 4 5 Speed ECM 022 072 NOTES All models include sound kits as standard equipment 1 Available on vertical configurations only not available on horizontal models 2 Control optio...

Page 5: ...e 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 i...

Page 6: ...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...

Page 7: ...29 3 cm 196 6 70 6 61 2 74 4 064 in 99S500A03 82 4 27 8 24 1 29 3 cm 209 3 70 6 61 2 74 4 072 in 99S500A03 82 4 27 8 24 1 29 3 cm 209 3 70 6 61 2 74 4 2 8 12 Weight Distribution Model Vertical Weight...

Page 8: ...ity 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...

Page 9: ...s with extremely hard water the owner should be informed that the heat exchanger may require occasional flushing Units with cupronickel heat exchangers are recommended for open loop applications due t...

Page 10: ...d Flush Cart manual Closed Loop Ground Source Systems Figure 8b Primary Secondary Hook up 5 Series to Electromechanical Units T o Electromechanical Unit 5 Series to Envision Units Envision Unit 2 5 Se...

Page 11: ...to Thermostat and Valve Unit Supply Aux Heat Supply Water Out Water In Shut Off Valves Boiler Drains For HX Flushing Disconnects IfApplicable Rubber Bladder Expansion Tank Solenoid Valve Shut Off Val...

Page 12: ...llation In Preheat Tank In Venting Waste Valve or Vent Coupling 3 4 x 3 4 x 1 2 tee Cold Water In Hot Water Out P T Relief Valve P T Relief Valve HWG Water In HWG Water Out Drain Valve Drain Valve Sto...

Page 13: ...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 wate...

Page 14: ...trol box closed Figure 13A Wire access control box open Electrical Connections Accessory Relay A set of dry contacts has been provided to control accessory devices such as water solenoid valves on ope...

Page 15: ...type connectors requiring the same wiring See instructions enclosed in the thermostat for detailed installation and operation information The W1 terminal on TPCM32U03 and TPCM32U04 communicating therm...

Page 16: ...0 0 96 7 110 0 100 110 100 110 100 100 L1 L2 34 7 40 0 53 3 60 0 60 60 60 60 60 60 L3 L4 34 7 40 0 43 3 50 0 45 50 45 50 40 50 All heaters rated single phase 60 cycle and include unit blower load All...

Page 17: ...26 0 0 4 5 4 4 1 24 0 27 5 40 042 208 230 60 1 197 253 26 0 16 6 79 0 28 0 0 4 5 4 7 6 30 0 34 2 50 048 208 230 60 1 197 253 31 0 19 8 109 0 38 0 0 4 5 4 7 6 33 2 38 2 50 060 208 230 60 1 197 253 41...

Page 18: ...253 46 3 29 6 179 2 63 0 0 4 5 4 7 0 42 4 49 8 70 4 6 12 With optional 1 hp ECM motor With optional IntelliStart Rated voltage of 208 230 60 1 All fuses Class RK 5 HACR circuit breaker in USA only Du...

Page 19: ...as well as at least the minimum re quired for the auxiliary heat package G may be located anywhere within the airflow table Cfm is controlled within 5 up to the maximum ESP Max ESP includes allowance...

Page 20: ...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 Au...

Page 21: ...99 1261 1242 1222 1202 1181 1157 1132 1111 1090 937 874 830 Low 1 G 1243 1182 1121 1061 1000 964 928 856 784 744 703 647 592 042 High 5 11 x 10 1 1934 1910 1886 1871 1855 1827 1799 1780 1760 1747 1734...

Page 22: ...1855 1827 1799 1780 1760 1747 1734 1700 1659 1617 Med High 4 1799 1783 1767 1744 1720 1693 1666 1649 1631 1617 1603 1560 1530 1492 Med 3 Y2 1694 1680 1666 1642 1617 1592 1567 1552 1537 1519 1500 1453...

Page 23: ...505 1335 1175 070 H 11 x 10 1 2430 2400 2365 2330 2290 2255 2215 2180 2140 2095 2045 1945 1835 1715 1510 1330 M 2265 2235 2205 2175 2145 2110 2070 2035 2000 1960 1915 1825 1730 1605 1440 1260 L 2075 2...

Page 24: ...2 1 in Swivel 1 2 in Female 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 3 036 038 in 25 6 3...

Page 25: ...h Return Height 022 030 in 22 5 26 5 52 5 35 3 40 2 46 7 49 7 3 6 1 in Swivel 1 2 in Female 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 11...

Page 26: ...15 9 18 9 10 6 1 Swivel 1 2 female 9 5 12 1 14 3 13 3 13 6 39 4 9 1 8 1 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 33 8 34 5 100 1 23 1 20 6 4 3 71 4 76 2 4 3 060 072...

Page 27: ...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 8 022 030 in 22 5 63 0 19 3 2 0 7 0 13 5 16 5 0 8 1 in Swivel...

Page 28: ...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 16x16 406x406 19x20 483x508 24 x 20 610 x 542 28 x 20 711 x 542 28 x 25 711 x 635 32 x 25 813...

Page 29: ...2 6 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 24 x 20 610 x 542 28 x 25 711 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 3...

Page 30: ...onal AWL IntelliZone2 Compatibility IntelliZone requires traditional TStat inputs IntelliZone2 communicates to the heat pump via the AXB board With Optional AXB kit and IntelliZone2 Optional IntelliZo...

Page 31: ...1 02 Traditional Y1 Y2 Thermostat Traditional Y1 Y2 thermostat Optional Optional TPCM32U03 04 MonoChrome Communicating Thermostat Elite Stat with full English fault codes and alerts communicating ther...

Page 32: ...nd 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...

Page 33: ...type identification display LED1 Red shall flash the fault code To reset lockout conditions with SW2 8 On thermostat inputs Y1 Y2 and W must be removed for at least 3 seconds To reset lockout conditi...

Page 34: ...ECM will run on G speed until the G command is removed Regardless of blower input G from the thermostat the blower will remain on for 30 seconds at the end of each heating cycle Cooling Operation In a...

Page 35: ...irflow settings The AID Tool simply plugs into the exterior of the cabinet in the AID Tool port ABC Control Board Layout Aurora Base Control LED Displays These three LEDs display the status configurat...

Page 36: ...r and refrigerant temperatures to determine if conditions are satisfactory for heating water LED1 red LED will flash code 15 when the DHW limit is reached and when conditions are not favorable for wat...

Page 37: ...larm Fault no lockout info only Switch output from Smoke CO sensor Dirty Filter Alarm no lockout info only Output from dirty filter sensor Home Automation 2 E24 HA2 With a closed dry contact signal th...

Page 38: ...ticed from normal cooling Dehumidification mode will be shown on the ABC and the communicating thermostats Fault LED LED1 Red Red Fault LED LED Flash Code Lockout Reset Remove Fault Condition Summary...

Page 39: ...psi and feet of water EAT entering air temperature Fahrenheit dry bulb wet bulb HC air heating capacity MBtu h TC total cooling capacity MBtu h SC sensible cooling capacity MBtu h kW total power unit...

Page 40: ...lement High pressure switch Low pressure switch Power blocks Power strip Reversing Valve coil DIP package 5 position AXB TEST MODE ABC Board DIP package 8 position ABC Board Thermal limit switch Legen...

Page 41: ...lash Code 17 Non Critical Communication Error Flash Code 18 Future Use Flash Code 12 Non Critical AXB Sensor Error Flash Code 13 Critical AXB Sensor Error Flash Code 14 Future Use Flash Code 9 Compres...

Page 42: ...es with Blower OFF ON Cycles with CC rst stage compressor or compressor spd 1 12 ON OFF Cycles with CC2 second stage of compressor or comp spd 7 12 OFF OFF Cycles with DH from ABC board AXB Accessory...

Page 43: ...B board are provided with Variable Speed Flow Center 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 4 Refer to units 5 SPEED...

Page 44: ...lue Traditional Thermostat Communicating Thermostat AID Tool Cabinet HW Switch NOTE 7 H M L P3 PSC Blower Motor Grn Wht Brn Cap 3 Airflow Settings P11 2 3 4 5 1 Brown Orange Green 5 2 4 RB Black Black...

Page 45: ...Use Future Use Load Shed ESD OFF ON Slow Flash Fast Flash Flash Code 2 Flash Code 3 Flash Code 6 Flash Code 4 Flash Code 5 Future Use Flash Code 7 Configuration LED LED2 Yellow No Software Overide OF...

Page 46: ...EVREV FP1 FP1 FP2 FP2 LPS LPS HPSHPS Aurora Base Control ABC K1 RV Relay K2 CC Relay K3 CC2 Relay K4 Blower Relay K5 Alarm Relay K6 Acc Relay F R C CC G Y1 C R NOTE 1 Violet 42 Blue 24 Yellow 25 Green...

Page 47: ...lash Code 3 Lockout Active Dehumidification Mode Fast Flash Future Use Flash Code 4 Flash Code 2 Freeze Detection FP1 Flash Code 5 Future Use Flash Code 3 Reserved Condensate Overflow Lockout Flash Co...

Page 48: ...trols Confirm IntelliZone2 if installed is added and communicating Set Zoning system to off mode 2 Aurora Setup Screen a ECM Setup for Heating Airflow select G low high and aux blower speeds as approp...

Page 49: ...e measurement of discharge and suction pressures suction and liquid line temperatures as well as superheat and subcooling This information will only be displayed on Unit Startup cont the AID Tool Ensu...

Page 50: ...ger 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 tem...

Page 51: ...performance based on entering air temperatures of 80 F DB 67 F WB Heating performance based on entering air temperature of 70 F DB 2 15 12 Second Stage Operation Entering Water Temp F Water Flow gpm t...

Page 52: ...9 1 8 5 7 9 7 3 2 7 12 Dual Capacity Model gpm Pressure Drop psi 30 F 50 F 70 F 90 F 110 F 026 full load 4 1 4 1 3 1 2 1 1 1 0 6 2 8 2 6 2 4 2 3 2 1 8 4 7 4 4 4 1 3 8 3 5 10 7 0 6 6 6 2 5 8 5 3 026 pa...

Page 53: ...gh High Low Low Insufficient Compressor Possible Bad Valves Low High Low High Normal High Low Low TXV Bulb Loss of Charge Low Low Low High High Low Low Scaled Coaxial Heat Exchanger Heating Low Low Lo...

Page 54: ...haded areas 2 13 12 Dual Capacity Model gpm Heat of Extraction kBtuh Heat of Rejection kBtuh 30 F 50 F 70 F 90 F 30 F 50 F 70 F 90 F 110 F 026 Part Load 3 0 14 0 18 8 22 8 26 7 26 6 24 3 5 0 10 2 14 8...

Page 55: ...is correct Refer to the Aurora Base Control Application and Troubleshooting Guide and the Instruction Guide Aurora Interface and Diagnostics AID Tool for additional information Troubleshooting Refrig...

Page 56: ...cer Discharge Pressure Transducer Air Coil Blower Leaving Air Thermistor Wire Bundle In Blower Compartment Coax Flow Meter Water OUT Water IN Flow Sensor Entering Water Thermistor Sensor Wire Wrapped...

Page 57: ...Q 5HMHFWLRQ JSP IRU ZDWHU DQWLIUHH H 7 1RWH 2 127 hook up pressure gauges unless there appears to be a performance problem Line Voltage Loop Open Unit Amp Draw Closed COAX SOURCE COAX LOAD HEA7 1 ANAL...

Page 58: ...ts ENERGY MONITOR HEATING COOLING 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 COOLING Cooling Capacity l o x 3 413 p Btu h p Btu...

Page 59: ...the unit and the date of failure along with an explanation of the malfunctions and a description of the replacement parts required CAUTION Fin edges are sharp Preventive Maintenance Replacement Proce...

Page 60: ...62P516 05 62P516 05 62P516 05 62P516 05 62P516 03 62P516 03 62P516 03 62P516 03 Hot Water Generator Pump n a 24P501A01 24P501A01 24P501A01 24P501A01 24P501A01 24P501A01 24P501A01 24P501A01 Electrical...

Page 61: ...P516 05 62P516 03 62P516 03 62P516 03 Hot Water Generator Pump 24P501A01 24P501A01 24P501A01 24P501A01 24P501A01 Electrical Contactor 13P004A03 13P004A03 13P004A03 13P004A03 13P004A03 Transformer 208...

Page 62: ...62 5 SERIES 500A11 INSTALLATION MANUAL Notes...

Page 63: ...TALLATION MANUAL Revision Guide Pages Description Date By 24 26 Updated Dimensional Drawings 22 Feb 2013 DS 40 43 Updated Wiring Diagrams 22 Feb 2013 DS All Revision Table Added Minor Formatting Corre...

Page 64: ...nservation Way Fort Wayne IN 46809 9794 WaterFurnace has a policy of continual product research and development and reserves the right to change design and speci cations without notice IM2500AN 02 13...

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