5_SERIES_500A11_SPECIFICATION.pdf

Specification Catalog 5 Series

500A11 Geothermal heat pump

1-6 ton (single speed) 2-6 ton (dual capacity)

5 SERIES 500A11 SPECIFICATION CATALOG

Table of Contents Model Nomenclature

AHRI/ISO 13256-1 Performance Ratings

5 Series Design Features

The Aurora™ Control System

Water Quality

Dimensional Data

Physical Data

Auxiliary Heat Ratings

Auxiliary Heat Electrical Data

Electrical Data

Blower Performance Data

Reference Calculations

Legend and Notes

Operating Limits

Operation Logic Data Table

Antifreeze Corrections

Correction Factor Tables

Pressure Drop

Performance Data

Wiring Schematics

Engineering Guide Specifications

Revision Guide

WaterFurnace 5 Series products established a new industry standard for effi ciency, performance, reliability and quiet operation. The 5 Series was the fi rst unit to achieve a certifi ed GLHP rating of 30 EER and 5 COP in AHRI 13256-1. The 5 Series extends this innovation and performance with all new advanced controls and updated performance. The 5 Series is available in nine single speed sizes (1 to 6 ton) with Copeland Scroll™ (rotary in 012 and 018) compressors. The product is also available in fi ve dual capacity sizes (2 to 6 ton) with Copeland Scroll UltraTech™ compressors.

These 5 Series units utilize ozone-safe R-410A refrigerant to meet the most stringent EPA requirements. 5-Speed ECM blower motors bridge the gap of high effi ciency ECM capability with great value. ECM blowers are used to increase comfort, effi ciency, and airfl ow fl exibility. A new sophisticated AuroraTM Control system is modular and designed to grow with the application. The Aurora ‘Base’ Control (ABC) features a microprocessor control to sequence all components during operation for optimum performance. Plus, the ABC provides easy-to-use troubleshooting features with fault lights, on-board diagnostics, and a hand held Aurora Interface Diagnostic (AID) Tool. The Aurora ‘Advanced’ Control adds the Aurora Expansion Board (AXB) to further extend the capability of the system to include compressor current monitoring, advanced loop and hot water generator pump control, as well as service, performance, and energy monitoring sensor kit capability. Aurora Weblink (AWL) allows remote access to the thermostat via WiFi to the internet or smartphone as well as remote monitoring of the heat pump and receives lockout/fault info via text or e-mail. A swing-out control box provides serviceability. Unit confi gurations include vertical top, bottom, or rear discharge (left or right return) and horizontal units with left or right return a side or end discharge. Heavy-gauge metal cabinets are fully insulated and coated with an attractive and durable gray paint for long lasting protection. The cabinet’s rounded front corners, blue wave styling element, and 5 Series nameplate add a touch of elegance to the unit.

5 Series products are performance-certifi ed to AHRI/ISO 13256-1 standards, ETL listed, ENERGY STAR® qualifi ed, and tested in an ISO 17025 accredited testing lab.

As a leader in the industry, WaterFurnace is dedicated to innovation, quality, and customer satisfaction. In fact, every unit built is exposed to a wide range of quality control procedures throughout the assembly process and is then subjected to a rigorous battery of computerized run tests to certify that it meets or exceeds performance standards for effi ciency and safety, and will perform fl awlessly at startup. As further affi rmation of our quality standards, each unit carries our exclusive Quality Assurance emblem, signed by the fi nal test technician.

WaterFurnace International’s corporate headquarters ISO 9001:2008 and manufacturing facility is located in Fort Wayne, IN. A scenic three-acre pond located in front of the building serves as our geothermal heating and cooling source to comfort-condition our 110,000 square feet of manufacturing and offi ce space. As a pioneer, and now a leader in the industry, the team of WaterFurnace engineers, customer support staff , and skilled assembly technicians is dedicated to providing the fi nest comfort systems available.

By choosing or specifying WaterFurnace 5 Series products, you can be assured that your customer is investing in the ultimate comfort system and peace of mind for many years to come.

500A11 Geothermal Heat Pump compressors.

Model Nomenclature

N 1 2 3 4-6 7 8 9

Model Type N – 5 Series Water-to-Air

Compressor Type D – Dual-Stage S – Single Stage

Cabinet Configuration V – Vertical H - Horizontal

Unit Capacity (MBTUH) 012, 018, 022, 026, 030 036, 038, 042, 048, 049 060, 064, 070, 072

Vintage

* – Internal Factory Use Only

Voltage 1 – 208-230/60/1

Hot Water Generation 0 – No Hot Water Generation 1 – Hot Water Generation with

Factory Installed Pump

Blower Options 0 – PSC (Single Stage Only) 1 – Variable Speed ECM 2 – High Static Variable Speed ECM (036-049 Only) 3 – High Static PSC (022, 030, 036, 042, 048) 4 – 5-Speed ECM (022-072)

I N – No IntelliStart, Uncoated Coil A – IntelliStart, Uncoated Coil B – No IntelliStart, AlumiSeal C – IntelliStart, AlumiSeal

Control Option A – AuroraTM Base Control (ABC) B – Aurora Advanced Control

(ABC & AXB)

C – Aurora Performance Package (018 – 072, ECM Blowers Only)2

D – Aurora Performance and Refrigeration Package

(018 – 072, ECM Blowers Only)2

E – AuroraTM Base Control w UPC2,3

F – Aurora Advanced Control w UPC2,3

G – Aurora Performance Package w UPC2,3

H – Aurora Performance and Refrigeration Package w UPC2,3

Filter Option 0 – 2 inch MERV11 Filter 1 – AlpinePure 411

(Vertical Only, 022-072)1

Return Air Configuration L – Left R – Right

Discharge Air Configuration T – Top (Vertical) B – Bottom (Vertical) R – Rear (Vertical) S – Side (Horizontal) E – End (Horizontal)

Water Coil Option C – Copper N – CuproNickel

Rev.: 10/4/2017

10 11 12 14 D V 049 * 1 1 1 C T L 0

A

N p e o -S e on c o ac rnal Facto pe eries Wate or Type Stage Stage nfiguration cal ontal city (MBT 8, 022, 02 8, 042, 04 4, 070, 07 on Generation eration with d Pump ry Use O er-n

TUH)

26, 030 48, 049

-to-Air

Only r

Notes:

All Models include sound kits as std. equipment 1 Available on vertical configurations only 2 Control option not available with PSC motor 3 UPC is not compatible with Symphony or IntelliZone2

Cooling capacities based upon 80.6°F DB, 66.2°F WB entering air temperature Heating capacities based upon 68°F DB, 59°F WB entering air temperature All ratings based upon 208V operation

Cooling capacities based upon 80.6°F DB, 66.2°F WB entering air temperature Heating capacities based upon 68°F DB, 59°F WB entering air temperature All ratings based upon 208V operation

Variable Speed ECM or 5-Speed ECM Motor

AHRI/ASHRAE/ISO 13256-1

English (IP) Units

Model Capacity Modulation

Flow Rate

Water Loop Heat Pump Ground Water Heat Pump Ground Loop Heat Pump

Cooling

EWT 86° F

Heating

EWT 68° F

Cooling

EWT 59° F

Heating

EWT 50° F

Cooling Brine Full Load 77° F Part Load 68° F

Heating Brine Full Load 32°F Part Load 41°F gpm cfm Capacity Btuh

EER

Btuh/W

Capacity Btuh COP Capacity

Btuh

EER

Btuh/W Capacity

Btuh COP Capacity Btuh EER Heating

Capacity COP

026 Full 8 950 24,900 16.8 30,100 5.5 27,700 24.0 23,900 4.8 26,400 19.6 19,500 4.0

026 Part 7 750 18,900 18.6 22,000 6.1 22,200 29.7 17,500 4.9 21,000 26.0 16,400 4.5

038 Full 9 1300 36,500 17.0 43,300 5.5 40,000 24.4 35,000 4.9 38,200 19.7 28,500 4.2

038 Part 8 1150 26,500 19.0 31,300 6.4 29,900 32.1 24,900 5.1 29,500 28.0 22,900 4.8

049 Full 12 1600 49,100 17.2 59,000 5.5 54,100 24.5 47,200 4.6 50,800 19.3 38,200 4.0

049 Part 11 1400 36,300 19.1 41,700 6.1 41,600 33.0 33,600 4.7 39,800 27.4 31,000 4.4

064 Full 16 1800 62,300 16.4 73,900 5.2 69,000 23.9 60,400 4.6 65,500 19.3 47,300 3.8

064 Part 14 1500 45,800 18.1 53,200 5.9 53,000 30.7 43,500 4.8 50,500 26.5 38,200 4.3

072 Full 18 2000 70,100 15.6 88,000 4.8 79,000 22.0 71,000 4.3 73,800 18.2 55,400 3.7

072 Part 16 1500 54,200 17.0 66,000 5.1 61,500 27.6 52,700 4.3 59,400 24.9 47,400 3.9

018 Single 5 600 17,400 15.7 23,000 5.3 20,600 26.0 18,700 4.6 18,500 18.3 14,500 3.8

022 Single 8 800 18,100 15.6 23,700 6.0 21,900 27.5 19,500 5.0 19,200 18.7 15,000 4.0

030 Single 8 1000 27,000 18.9 32,900 5.6 31,200 29.5 26,000 4.8 28,100 22.0 20,500 3.9

036 Single 9 1200 32,300 18.8 36,500 5.7 36,800 28.8 29,200 4.9 33,700 22.0 24,400 4.2

042 Single 11 1300 39,000 18.6 45,600 5.8 43,900 28.1 36,100 4.9 40,700 21.7 28,900 4.0

048 Single 12 1500 44,100 16.3 55,600 5.4 50,300 25.9 44,700 4.7 45,900 18.8 36,400 4.0

060 Single 15 1800 61,100 16.4 74,100 5.5 66,900 24.3 59,200 4.7 62,200 18.4 47,900 4.0

070 Single 18 2000 66,200 15.3 85,000 5.0 75,000 22.9 68,000 4.4 69,100 17.6 54,000 3.7

NOTE: 018 not available with 5-Speed ECM motor 7/15/2015

PSC Motors

AHRI/ASHRAE/ISO 13256-1

English (IP) Units

Model Modulation

Capacity

Flow Rate

Water Loop Heat Pump Ground Water Heat Pump Ground Loop Heat Pump

Cooling

EWT 86°F

Heating

EWT 68°F

Cooling

EWT 59°F

Heating

EWT 50°F

Cooling Brine Full Load 77°F Part Load 68°F

Heating Brine Full Load 32°F Part Load 41°F gpm cfm Capacity Btuh

EER

Btuh/W

Capacity Btuh COP Capacity

Btuh

EER

Btuh/W Capacity

Btuh COP Capacity Btuh

EER

Btuh/W

Capacity Btuh COP

012 Single 4 400 11280 14 14800 5 13200 23.1 12000 4.2 12000 16.5 9500 3.5

018 Single 5 600 17400 14.8 23000 5.1 20600 24.7 18700 4.3 18500 17.3 14500 3.5

022 Single 8 850 17200 13.6 23500 5.9 20100 25.5 19400 4.8 17700 16.2 15000 3.8

030 Single 8 900 26800 17.9 32900 5.3 30800 27.1 26000 4.7 27900 21.1 20300 3.7

036 Single 9 1200 31500 14.8 40200 5.3 35100 24.4 29200 4.5 32900 19.2 24400 3.8

042 Single 11 1300 38300 15.4 45600 5.2 42300 23.3 36000 4.3 40300 18.5 28900 3.5

048 Single 12 1500 43200 13.3 55600 4.9 48900 22.3 44700 4.2 45500 16 36400 3.7

060 Single 15 1800 61000 15.2 74100 5.2 66600 22.8 57300 4.4 62300 17.4 46100 3.7

070 Single 18 2000 66200 14.4 85000 4.6 73500 20.8 67100 4 69100 16.6 53500 3.4

7/15/2015

AHRI/ISO 13256-1 Performance Ratings

Energy Star Rating Criteria In order for water-source heat pumps to be Energy Star rated they must meet or exceed the minimum efficiency requirements listed below. Tier 3 represents the current minimum efficiency water source heat pumps must have in order to be Energy Start rated.

Tier 3: 1/1/2012 – No Effective End Date Published

Water-to-Air EER COP Ground Loop 17.1 3.6 Ground Water 21.1 4.1

Water-to-Water Ground Loop 16.1 3.1 Ground Water 20.1 3.5

E - Unit with Variable Speed ECM Blower X - Unit with 5-Speed ECM Blower P - Unit with PSC Blower

Energy Star Compliance Table

Model Tier 3

Ground Water Ground Loop

012 P -

018 E, P E

022 E, X, P E, X

026 E, X E, X

030 E, X, P E, X, P

036 E, X, P E, X, P

038 E, X E, X

042 E, X, P E, X

048 E, X, P E, X

049 E, X E, X

060 E, X, P E, X, P

064 E, X E, X

070 E, X E, X

072 E, X E, X

12/14/16

AHRI/ISO 13256-1 Performance Ratings cont.

The performance standard AHRI/ASHRAE/ISO 13256-1 became effective January 1, 2000 and replaces ARI Standards 320, 325, and 330. This new standard has three major categories: Water Loop (comparable to ARI 320), Ground Water (ARI 325), and Ground Loop (ARI 330). Although these standards are similar there are some differences:

Unit of Measure: The Cooling COP

The cooling efficiency is measured in EER (US version measured in Btu/h per Watt. The Metric version is measured in a cooling COP (Watt per Watt) similar to the traditional COP measurement.

Water Conditions Differences Entering water temperatures have changed to reflect the centigrade temperature scale. For instance the water loop heating test is performed with 68°F (20°C) water rounded down from the old 70°F (21.1°C).

Air Conditions Differences Entering air temperatures have also changed (rounded down) to reflect the centigrade temperature scale. For instance the cooling tests are performed with 80.6°F (27°C) dry bulb and 66.2°F (19°C) wet bulb entering air instead of the traditional 80°F (26.7°C) DB and 67°F (19.4°C) WB entering air temperatures. 80.6/66.2 data may be converted to 80/67 using the entering air correction table. This represents a significantly lower relative humidity than the old 80/67 of 50% and will result in lower latent capacities.

Pump Power Correction Calculation Within each model, only one water flow rate is specified for all three groups and pumping Watts are calculated using the following formula. This additional power is added onto the existing power consumption.

• Pump power correction = (gpm x 0.0631) x (Press Drop x 2990) / 300

Where ‘gpm’ is waterflow in gpm and ‘Press Drop’ is the pressure drop through the unit heat exchanger at rated water flow in feet of head.

Blower Power Correction Calculation Blower power is corrected to zero external static pressure using the following equation. The nominal airflow is rated at a specific external static pressure. This effectively reduces the power consumption of the unit and increases cooling capacity but decreases heating capacity. These Watts are significant enough in most cases to increase EER and COPs fairly dramatically over ARI 320, 325, and 330 ratings.

• Blower Power Correction = (cfm x 0.472) x (esp x 249) / 300

Where ‘cfm’ is airflow in cfm and ‘esp’ is the external static pressure at rated airflow in inches of water gauge.

ISO Capacity and Efficiency Calculations

The following equations illustrate cooling calculations:

• ISO Cooling Capacity = Cooling Capacity (Btu/h) + (Blower Power Correction (Watts) x 3.412)

• ISO EER Efficiency (W/W) = ISO Cooling Capacity (Btu/h) x 3.412 / [Power Input (Watts) - Blower Power Correction

(Watts) + Pump Power Correction (Watt)] The following equations illustrate heating calculations:

• ISO Heating Capacity = Heating Capacity (Btu/h) - (Blower Power Correction (Watts) x 3.412)

• ISO COP Efficiency (W/W) = ISO Heating Capacity (Btu/h) x 3.412 / [Power Input (Watts) - Blower Power Correction

(Watts) + Pump Power Correction (Watt)]

Comparison of Test Conditions

Conversions:

Airflow (lps) = cfm x 0.472; WaterFlow (lps) = gpm x 0.0631;

ESP (Pascals) = ESP (in wg) x 249; Press Drop (Pascals) = Press Drop (ft hd) x 2990

AHRI/ISO 13256-1 Performance Ratings cont.

ISO/AHRI

13256-1 GLHP

Cooling

Entering Air - DB/WB °F 80.6/66.2 Entering Water - °F 77 Fluid Flow Rate **

Heating

Entering Air - DB/WB °F 68 Entering Water - °F 32 Fluid Flow Rate

ARI 320

80/67

ISO/AHRI

13256-1

WLHP

80.6/66.2

ARI 325

80/67 50/70

50/70

ISO/AHRI

13256-1

GWHP

80.6/66.2

ARI 330

80/67

NOTES: * Flow rate is set by 10°F rise in standard cooling test ** Flow rate is specified by the manufacturer Part load entering water conditions not shown WLHP = Water Loop Heat Pump; GWHP = Ground Water Heat Pump; GLHP = Ground Loop Heat Pump

COMPRESSOR: Rotary (012-018), Copeland Scroll™ (022-070 single speed) and Copeland Scroll UltraTech™ (dual capacity) represent the latest technology

DOUBLE ISOLATED COMPRESSOR: Double isolated compressor mounting to reduce noise and vibration

AURORA CONTROLS & AID TOOL: Aurora ‘Base’ Control, Aurora ‘Advanced’ Control, and Aurora AID Tool

OPTIONAL HOT WATER ASSIST: Provides free hot water in cooling and very high efficiency hot water generation in heating mode

COAXIAL HEAT EXCHANGER: Standard large high efficiency copper (optional cupronickel) coax with our exclusive void-free and robotically applied ThermaShield insulation coating

BALANCED PORT/BIDIRECTIONAL EXPANSION

VALVE: Balanced port bidirectional expansion valve for rock steady superheat control and reliable efficiency and operation at any condition

AIR COIL: The PinnaCoil™ is made from environmentally-friendly aluminum and designed for maximum effi ciency and durability. Anti-corrosive properties with advanced tubing design further increase performance..

DISCHARGE MUFFLER: Helps quiet compressor gas pulsations

5 Series Design Features

PSC/5-Speed/ECM BLOWER MOTOR OPTIONS:

Choice of standard PSC, high efficiency 5-Speed ECM, or high efficiency and ultra-flexible ECM blower motors

FILTER RACK: Filter rack holds 1 in. or 2 in. filters (field changeable) with exclusive snap on filter door

FILTER: High holding capacity 2 in. pleated MERV 11 filter is standard and 4 in. pleated MERV 11 Is optional

SWIVEL LOOP CONNECTIONS: Leak free swivel water connections provide a hand tight gasket connection that easily handles the temperature extremes of geothermal earth loops

INTELLISTART®: Optional single phase soft starter

INSULATION: Cleanable foil lined insulation to prevent mold growth; corrosion resistant composite drain pan

CABINET FINISH: Heavy gauge galvanized sheet metal cabinet has 1,000 hr. salt spray rated gray powder coat paint for long life

ACCESS PANELS: Lift out front bottom access panel, lift out panels for easier removal and servicing

HINGED CONTROL BOX: Hinged removable control box

HOT WATER GENERATOR SWITCH & AID TOOL PORT:

Hot water generator switch for easy enabling/disabling of the hot water generator pump; AID Tool port provides quick AID Tool connection

COMPRESSOR: Rotary (012-018), Copeland Scroll™

5 Series Design Featug resres

What’s New?

• Exceptional AHRI/ISO 13256-1 Ratings for traditional geothermal

- 28 EER and 4.8 COP

• Latest technology compressors

- LG Rotary in single speed units (sizes 012 and 018)

- Copeland K5 Scrolls™ in single speed units (sizes 022, 030, 036, 042, 048, 060, 070)

- Copeland UltraTech™ K5 Compressors in dual capacity units (sizes 026, 038, 049, 064, 072)

• Discharge line mufflers on models 022-072 to help quiet compressor discharge gas pulsations.

• PSC/5-Speed ECM/Variable Speed ECM blower motor options

- Standard PSC for low cost and solid performance

- 5-Speed ECM for high efficiency

- Variable Speed ECM blower motors for the highest in efficiency and airflow flexibility

• Communicating Digital Thermostats: The Aurora controls system features either monochromatic or color touch screen graphic display thermostats for user interface with the 5 Series system. These displays not only feature easy to use graphical interface but display alerts and faults in plain English.

• AuroraTM Communicating Control Features

- Traditional Safety Sensors: HP, LP, condensate overflow, freeze detection loop, freeze detection air coil

- Communicating Modular Design: Communicating modular design for flexibility and expandability

- Intelligent Hot Water Generator Control: The Aurora Advanced control determines operation of hot water assist dependent upon system parameters to maximize overall system efficiency

- Loop pump linking: For multiple units on one flow center with either variable speed, single, or dual capacity units (with Aurora Advanced Control);

even works with our legacy controls

- Electric Heat Powered Blower and Controls:

Prevents the compressor from tripping out and disabling heat in the house

- Internet Ready: With optional Aurora WebLink (AWL) device and Symphony Web Portal

• Advanced Service Features

- Aurora Controls with the AID Tool provide advanced service diagnostics. With this device setup and configurations as well as real-time sensors fault and lockout history can be monitored and much more.

- Aurora can be internet capable simply by adding the Aurora WebLink (AWL). This device will connect your Aurora system to web for remote monitoring and control. It also comes standard with an SD drive for storing operating and performance data. Providing ‘black box’ capability.

- Complete air flow control throughout the unit's operating range

• Cabinet Design – Improved design of access panels, control box and filter rack

• Cabinet Configurations – Vertical left or right return, downflow left or right return; Horizontal left or right return with either end or side air discharge

• Monitoring Sensor Kits

- Energy Monitoring: With this standard sensor kit, the Aurora Advanced Control will feature power monitoring of the compressor, blower, and electric heat; the information can be displayed on AID Tool, selected thermostats, or through AWL

- Refrigerant Monitoring: The 5 Series features refrigeration service sensors as an optional feature;

now superheat, subcooling, refrigerant pressures, and various temperatures needed to diagnose unit problems are readily available at your finger tips in the AID Tool

- Performance Monitoring: With this optional sensor kit installation, the Aurora controls can measure actual capacity and efficiency performance of the heat pump; the information can be displayed on AID Tool or thru AWL

• Cupronickel heat exchanger

• High static blower on some models

• Unitary Protocol Converter (UPC) for integration with

Home Automation Systems (HAS)

Application Flexibility

• Safe, efficient operation in a wide range of liquid temperatures (20°F to 120°F) and flow rates (as low as 1.5 gpm/ton in open loop applications when EWT >50°F)

• Top or rear air discharge for upflow, or bottom discharge for counterflow installations in vertical units, side or end discharge for horizontal units

• True left or right return air locations—vertical units include filter rack/duct collar

• Variable-speed ECM blowers permit various duct applications with flexible airflow selection; optional 5-Speed ECM blower motors provide ECM efficiency at PSC capability; optional PSC motors available on single speed units.

• Narrow cabinet for easy movement through doorways

• Internally trapped condensate piping on vertical units for neat, compact installation

• Optional field-installed auxiliary electric heater

• Corner-located electrical box for field wiring from two sides

• Circuit breaker protected loop pump power block for easy wiring

• Relay to control field-mounted accessories

• Field-selectable freeze detection setting for well or closed loop systems

• Loop pump linking feature allows multiple units to share one flow center (requires Aurora ‘Advanced’ Control option)

5 Series Design Features cont.

Operating Efficiencies

• AHRI/ISO 13256-1 rating for heating COPs, cooling EERs, and low water flow requirements

• Optional hot water generator with internal pump generates hot water at considerable savings while improving overall system efficiency

• High-stability expansion valve delivers optimum refrigerant flow over a wide range of conditions and provides bidirectional operation without troublesome check valves

• Efficient rotary and scroll compressors operate quietly

• Oversized coaxial tube water-to-refrigerant heat exchanger operates at low liquid pressure drops

• Convoluted copper water tube functions efficiently at low flow rates

• Oversized all-aluminum air coil with lanced fin or rifled copper tube/lanced aluminum fin air-to refrigerant heat exchanger provides high efficiencies at low-face velocity with patented 11 element fin design

• Large, low-RPM blowers with Variable Speed ECM or 5-Speed ECM motors provide quiet and efficient air movement with high static capability; optional 3-Speed PSC motors available on single speed units

• Utilizes the ozone-friendly R-410A refrigerant which produces higher efficiencies and warmer discharge air temperatures

Service Advantages

• Hinged/removable control box for added serviceability

• Removable panels: three for the compressor compartment and one (on horizontals) or two (on verticals) for the air handling compartment to provide quick access to all internal components with ductwork in place

• Easily accessible thermal expansion valve

• Brass, swivel-type water connections for quick connection union, and elimination of wrenches and sealants during installation; sweat type connections are on the hot water generator

• Insulated divider and separate air handling/compressor access panels permit service testing without air bypass

• Designed for front access in tight applications

• LED fault and status lights on the Aurora board with memory for easy diagnostics

• Aurora AID Tool provides enhanced service information via communication directly with the Aurora control including sensor inputs, fault history, and much more

• Detachable thermostat connection strip for wiring convenience

• Hot water pump shut-off switch for easy startup and service

• Control box and blower motors have quick-attach wiring plugs for easy removal

• Internal drop-out blower with permanently-lubricated ball bearing motor

• High- and low-pressure service ports in refrigerant circuit.

• Blower and transformer powered from auxiliary heat supply (when installed) to provide emergency heat with open compressor circuit breaker

5 Series Design Features cont.

Product Quality

• Heavy-gauge steel cabinets are painted with durable powder coat paint for long lasting beauty and service

• Coaxial heat exchanger, refrigerant suction lines, hot water generator coil, and all water pipes are fully insulated to reduce condensation problems in low temperature operation

• FormiShield Plus™ air coils are double coated for extended life, standard on copper tube/aluminum fin.

• Noise reduction features include double isolation mounted compressors and soft starting blower motors;

insulated compressor compartment; interior cabinet insulation using 1/2 in. coated glass fiber; all units include compressor blanket for quiet operation

• Safety features include high- and low-pressure refrigerant controls to protect the compressor, condensate overflow protection, freeze detection sensor to safeguard the coaxial heat exchanger and air coils, blower start detection, hot water high-limit hot water generator pump shutdown, compressor monitoring, and fault lockout enables emergency heat and prevents compressor operation until thermostat or circuit breaker is reset

Microprocessor Benefits

• Communicating monochromatic or color digital auto-changeover thermostat with 3-stage heating/2-stage cooling holds precise temperature and provides varying blower speed control

• Component sequencing delays for quiet startup, shutdown, and timed staging of auxiliary electric heat

• ECM blower speed control provides higher supply air temperature in heating, better dehumidification in cooling, and quiet operation at reduced airflows in all modes

• Hot water limit prevents scalding, and pump shuts down automatically when full unit capacity is needed for heating

• Communication capability for future expansions

Options and Accessories

• Communicating Digital Thermostats

- Monochromatic Graphic Display Thermostats:

For user interface with the Aurora system;

these displays not only feature easy to use graphical interface but display alerts and faults in plain English. When Energy Monitoring is added, instantaneous usage is displayed on the thermostat itself.

- Color Touch Screen Graphic Display Thermostats:

For user interface with the Aurora system; these displays not only feature easy to use graphical interface but display alerts and faults in plain English. When Energy Monitoring is added not only instantaneous usage is displayed but also weekly and annual consumptions are stored and graphed.

Other features include full color implementation, user loaded background photos, and USB port for easy configuration and software updates.

• IntelliZone2 Zone System: The IntelliZone2 zoning system provides up to 6 zones (Variable Speed), 4 zones (Dual Capacity), or 2 zones (Single Speed) of individualized comfort via communication to the Aurora Control System. Requires AXB board.

• IntelliZone2 ● 24V is a non-communicating zoning system that uses a daughter board to translate communication to 24 VAC for the heat pump (no AXB).

Maximum of 4 zones (Dual Capacity) or 2 zones (Single Speed).

• AID Tool: The Aurora Interface and Diagnostics (AID) Tool is a plug-in configuration and troubleshooting tool for the Aurora Control System.

• Aurora WebLink (AWL): The Aurora Control System can be made internet capable simply by adding the Aurora WebLink (AWL) device. The AWL will connect your Aurora system to the web for remote monitoring and control. It also comes standard with an SD disc for storing operating and performance data providing true ‘black box’ capability for troubleshooting.

• Optional Aurora ‘Advanced’ Controls (see controls description)

• Optional cupronickel heat exchangers for open loop applications

• Optional hot water generator with internally mounted pump and water heater plumbing connector

• Optional 3-speed PSC motors available on single speed units (4-speed on 012)

• Optional 5-Speed ECM motors available (022-072)

• Optional high static PSC blower motor for high static applications on single speed units (022-048)

• Optional high static ECM blower motor for high static applications on all units from 036 to 049

• Electronic auto-changeover thermostat with

3-stage heating/2-stage cooling and indicator LEDs (non-communicating)

• 24 Volt 1 in. electronic air cleaner

• 90% efficient, cleanable electrostatic filters

• Closed loop flow center in several sizes

• Auxiliary electric heater

• Hose kits

• Additional accessory relay

• AlpinePure 2 in. MERV 13 filter

• AlpinePure 4 in. MERV 11 filter

• IntelliStart soft starter

• Aurora UPC for DDC applications for connection to HAS using BACnet protocol

• Aurora Touch Interface used with Aurora UPC provides ability to configure and diagnose equipment

Manufacturing Quality

• All units are computer run-tested, with conditioned source water, in all modes to ensure efficiency and reliability

• All refrigerant brazing is performed in a nitrogen atmosphere

• All units are deep evacuated to less than 150 microns prior to refrigerant charging

• All joints are helium leak-tested to ensure an annual leak rate of less than 1/4 ounce

• All major components bar coded; eliminating possibility of mismatched parts built into unit

• All assembly technicians thoroughly trained in proper quality procedures

• All units have model number and serial number embedded in control for local or remote retrieval

• WaterFurnace International, Inc. is an ISO 9001:2008 certified manufacturing facility

• WaterFurnace International, Inc. engineering labs are ISO 17025 accredited

5 Series Design Features cont.

Aurora Control Features Description Aurora ‘Base’ Aurora 'Advanced'

Microprocessor Compressor Control Microprocessor control of compressor for timings with FP1, HP, LP, Condensate, assignable Acc relay • •

Advanced Microprocessor Features Smart Grid, Home Automation Alarm Inputs, and Accessory2 Relay (HRV/ERV) - •

Base Hot Water Generator Operation

Compressor Contactor powers Hot Water Generator Pump with inline circuit breaker and thermostat limit. • See below

Advanced Hot Water Generator Control

Microprocessor and separate power relay for Hot Water Generator Pump with digital temperature monitoring and multiple HWG setpoint selection.

Base Loop Pump Control Compressor Contactor powers Loop Pump with inline circuit breaker and no loop pump slaving capability. • See below

Advanced Speed Pump Control Microprocessor and separate power relay for loop pump and inline circuit breakers and loop pump slaving. - •

Variable Speed Pump Capable of setup, monitoring and controlling a variable speed flow center. - •

Compressor Monitoring Control monitors compressor starts for high current, missing let etc. - •

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 Contactx2

HAN/Smart Grid Com (AWL and Portal) Kit

Allows direct communication of the Aurora to Smart Meters, Home Automation Network and Internet. - Optional AWL

IntelliZone2® Compatibility IntelliZone2 communicates Modbus to the heat pump via the AXB board.

With Optional AXB Kit and IntelliZone2

Optional IntelliZone2

Aurora ‘Base’ Control The Aurora ‘Base’ Control (ABC) System is a complete residential and commercial comfort system that brings all aspects of the HVAC system into one cohesive module network. The ABC features microprocessor control and HP, LP, 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. Each module contains the logic to control all features that are connected to the module. The Aurora ‘Base’ Control (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’ Control The Aurora ‘Advanced’ Control expands on the capability of the Aurora ‘Base’ Control (ABC) System by adding the Aurora Expansion Board (AXB).

The additional features include compressor current monitoring, loop pump slaving, intelligent hot water generator control, variable speed pump capability, and also allows for optional energy, refrigeration, and performance monitoring factory installed add-on 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.

The Aurora™ Control System

Add On Thermostats and Zoning Description Aurora ‘Base’ Aurora Advanced

TP32U03/04 - MonoChrome Traditional Y1, Y2 Thermostat

Elite Stat with full English fault codes and alerts, traditional Y1, Y2 thermostat. Not compatible with AWL. Optional Optional

TP32S01/02 -

Traditional Y1, Y2 Thermostat

Traditional Y1, Y2 thermostat. Not compatible with AWL. Optional Optional

TPCM32U03A/04A - MonoChrome Communicating Thermostat

Elite Stat with full English fault codes and alerts, communicating thermostat. Monochrome thermostat allows instantaneous energy measurement only. Compatible with

AWL.

Optional Optional

TPCC32U02 - Color Touchscreen Communicating Thermostat

4.3 in. color touchscreen communicating thermostat with full English fault codes and alerts. Color thermostat allows instantaneous energy measurement and 13 month energy usage history. Compatible with AWL.

Optional Optional

IntelliZone2® Zoning

IntelliZone2® is a communicating zoning system that 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). Compatible with AWL.

Optional

(IntelliZone2 Preferred)

Add On Control Feature Kits (field or factory installed) Description Aurora ‘Base’ Aurora 'Advanced'

Geo Energy Monitoring Kit Monitors realtime power consumption of compressor, blower, aux heat and pump. Requires thermostat TPCM32UO3A, TPCM32UO4A, or TPCC32UO1. AXB required.

- Standard

Refrigeration Monitoring Kit Monitors realtime pressures, temperatures, superheat, and subcooling. AXB required. - Standard

Performance Monitoring Kit Monitors air and water temperatures, and water flow rate and calculates heat of extraction/rejection. AXB required. - Standard

Data Logging (AWL) Kit Allows data logging of up to 12 months. AXB required. Can also be temporarily installed. - Optional

HAN/Smart Grid Com (AWL and Portal) Kit

Allows direct communication of the Aurora to Smart Meters, HAN, and internet. AXB required. - Optional

AXB Kit for advanced hot water generator control, flow center linking, variable speed pump, IntelliZone2

Added to 5 Series for key features of advanced hot water generator control, advanced loop control/linking, IntelliZone2 communication, and variable speed pump control.

Optional (Field Kit) Standard

Service Device Description Aurora ‘Base’ Aurora 'Advanced'

Aurora Interface and Diagnostics (AID) Tool

Allows setup, monitoring and troubleshooting of any Aurora Control.

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.

For Service (Ver. 1.xx or greater)

For Service (Ver. 2.xx or greater)

The Aurora Control System cont.

Aurora ‘Base’ Control

NOTE: Refer to the Aurora Base Control Application and Troubleshooting Guide and the Instruction Guide: Aurora Interface and Diagnostics (AID) Tool for additional information.

Control Features Software ABC Standard Version 3.0 Single or Dual Capacity Compressors Either single or dual capacity compressors can be operated.

Variable Speed ECM Blower Motor Option A Variable Speed ECM blower motor can be driven directly using the onboard PWM output. Four blower speeds are available based upon the G, Y1, Y2, and W input signals to the board. The blower speeds can be changed either by the ECM manual configurations mode method or by using the Aurora AID Tool directly. All four blower speeds can be set to the same speed if desired.

Other Control Features

• Random start at power up

• Anti-short cycle protection

• High and low pressure cutouts

• Loss of charge

• Water coil freeze detection

• Air coil freeze detection

• Over/under voltage protection

• Condensate overflow sensor

• Load shed

• Dehumidification (where applicable)

• Emergency shutdown

• Hot gas reheat operation (where applicable)

• Diagnostic LED

• Test mode push button switch

• Two auxiliary electric heat outputs

• Alarm output

• Accessory output with N.O. and N.C.

• Modbus communication (master)

• Modbus communication (slave)

Field Selectable Options via Hardware DIP Switch (SW1) – Test/Configuration Button (See SW1 Operation Table)

Test Mode The control is placed in the test mode by holding the push button switch SW1 for 2 - 5 seconds. In test mode most of the control timings will be shortened by a factor of sixteen (16). LED3 (green) will flash at 1 second on and 1 second off. Additionally, when entering test mode LED1 (red) will flash the last lockout one time. Test mode will automatically time out after 30 minutes. Test mode can be exited by pressing and holding the SW1 button for 2 to 5 seconds or by cycling the power. NOTE: Test mode will automatically be exited after 30 minutes.

Variable Speed ECM Configuration Mode The control is placed in the ECM configuration mode by holding the pushbutton switch SW1 for 5 to 10 seconds, the high, low, and “G” ECM speeds can be selected by following the LED display lights. LED2 (yellow) will fast flash when entering the ECM configuration. When setting “G” speed LED3 (green) will be continuously lit, for low speed LED1 (red) will be continuously lit, and for high speed both LED3 (green) and LED1 (red) will be continuously lit. During the ECM configuration mode LED2 (yellow) will flash each of the 12 possible blower speeds 3 times. When the desired speed is flashed press SW1, LED2 will fast flash until SW1 is released. “G” speed has now been selected. Next select low speed, and high speed blower selections following the same process above. After third selection has been made, the control will exit the ECM configuration mode. Aux fan speed will remain at default or current setting and requires the AID Tool for adjustment.

Reset Configuration Mode The control is placed in reset configuration mode by holding the push button switch SW1 for 50 to 60 seconds.

This will reset all configuration settings and the EEPROM back to the factory default settings. LED3 (green) will turn off when entering reset configuration mode. Once LED3 (green) turns off, release SW1 and the control will reset.

DIP Switch (SW2) SW2-1 FP1 Selection – Low water coil temperature limit setting for freeze detection. On = 30°F; Off = 15°F.

SW2-2 FP2 Selection – On = 30°F; Off = N/A SW2-3 RV – O/B - thermostat type. Heat pump thermostats with “O” output in cooling or “B” output in Heating can be selected. On = O; Off = B.

SW2-4 Access Relay Operation (P2) and 2-5

Access Relay Operation SW2-4 SW2-5 Cycle with Blower ON ON

Cycle with Compressor OFF OFF Water Valve Slow Opening ON OFF

Cycle with Comm. T-stat Hum Cmd OFF ON

The Aurora ‘Base’ Control System cont.

Cycle with Blower - The accessory relay will cycle with the blower output.

Cycle with Compressor - The accessory relay will cycle with the compressor output.

Water Valve Slow Opening - The accessory relay will cycle and delay both the blower and compressor output for 90 seconds.

SW2-6 CC Operation – selection of single or dual capacity compressor. On = Single Stage; Off = Dual Capacity

SW2-7 Lockout and Alarm Outputs (P2) – selection of a continuous or pulsed output for both the LO and ALM Outputs. On = Continuous; Off = Pulsed

SW2-8 Future Use

Alarm Jumper Clip Selection From the factory, ALM is connected to 24 VAC via JW2. By cutting JW2, ALM becomes a dry contact connected to ALG.

Variable Speed ECM Blower Speeds The blower speeds can be changed either by using the ECM manual configurations mode method or by using the Aurora AID Tool directly (see Instruction Guide: Aurora Interface and Diagnostics (AID) Tool topic).

Field Selectable Options via Software (Selectable via the Aurora AID Tool) Variable Speed ECM Blower Speeds An ECM blower motor can be driven directly using the onboard PWM output. Four blower speeds are available, based upon the “G”, Y1 (low), Y2 (high), and Aux input signals to the board. The blower speeds can be changed either by the ECM manual configurations mode method (see ECM Configuration Mode topic) or by using the Aurora AID Tool directly. All four blower speeds can be set to the same speed if desired. Aux blower speed will remain at default or current setting and requires the AID Tool for adjustment.

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.

Fuse – a 3 amp automotive type plug-in fuse provides protection against short circuit or overload conditions.

Anti-Short Cycle Protection – 4 minute anti-short cycle protection for the compressor.

Random Start – 5 to 80 second random start upon power up.

Fault Retry – in the fault condition, the control will stage off the outputs and then “try again” to satisfy the thermostat Y input call. Once the thermostat input calls are satisfied, the control will continue on as if no fault occurred. If 3 consecutive faults occur without satisfying the thermostat Y input call, then the control will go to Lockout mode.

Lockout – when locked out, the blower will operate continuously in “G” speed, and PSC blower motor output will remain on. The Alarm output (ALM) and Lockout output

(L) will be turned on. The fault type identification display LED1 (Red) shall flash the fault code. To reset lockout conditions with SW2-8 On, thermostat inputs “Y1”, “Y2”, and “W” must be removed for at least 3 seconds. To reset lockout conditions with SW2-8 Off, thermostat inputs “Y1”, “Y2”, “W”, and “DH” must be removed for at least 3 seconds.

Lockout may also be reset by turning power off for at least 30 seconds or by enabling the emergency shutdown input for at least 3 seconds.

Lockout With Emergency Heat - if the control is locked out in the heating mode, and a Y2 or W input is received, the control will operate in the emergency heat mode while the compressor is locked out. The first emergency heat output will be energized 10 seconds after the W input is received, and the blower will shift to high speed. If the control remains locked out, and the W input is present, additional stage of emergency heat will stage on after 2 minutes. When the W input is removed, all of the emergency heat outputs will turn off, and the ECM blower will shift to “G” speed and PSC blower motor output will remain on.

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 hard-wired limit switch if an overpressure condition should occur.

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.

Loss of Charge – fault is recognized when the Normally Closed Low Pressure Switch, P4-7/8 is open prior to the compressor starting.

Condensate Overflow - fault is recognized when the impedance between this line and 24 VAC common or chassis ground drops below 100K ohms for 30 seconds continuously.

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.

Freeze Detection (Air Coil) - uses the FP2 input to protect against ice formation on the air coil. The FP2 input will operate exactly like FP1 except that the set point is 30 degrees and is not field adjustable.

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.

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.

Standby In standby mode, Y1, Y2, W, DH, and G are not active. Input O may be active. The blower and compressor will be off.

Heating Operation Heating, 1st Stage (Y1) - The blower is started on “G” speed immediately and the compressor is energized 10 seconds after the Y1 input is received. The ECM blower motor is switched to low speed 15 seconds after the Y1 input.

Heating, 2nd Stage (Y1, Y2) - The compressor will be staged to full capacity 20 seconds after Y2 input is received. The ECM blower will shift to high speed 15 seconds after the Y2 input is received.

Heating, 3rd Stage (Y1, Y2, W) - The hot water pump is de-energized and the first stage of electric heat is energized 10 seconds after the W command is received. If the demand continues the second stage of electric heat will be energized after 5 minutes.

Emergency Heat (W) - The blower will be started on “G” speed, 10 seconds later the first stage of electric heat will be turned on. 5 seconds after the first stage of electric heat is energized the blower will shift to Aux speed. If the emergency heat demand is not satisfied after 2 minutes the second electric heat stage will be energized.

Blower (G) - The blower will start immediately upon receiving a thermostat G command. If there are no other commands from the thermostat the ECM will run on “G” speed until the G command is removed. Regardless of blower input (G) from the thermostat, the blower will remain on for 30 seconds at the end of each heating cycle.

Cooling Operation In all cooling operations, the reversing valve directly tracks the O input. Thus, anytime the O input is present, the reversing valve will be energized.

Cooling, 1st Stage (Y1, O) - The blower is started on “G” speed immediately and the compressor is energized 10 seconds after the Y1 input is received. The ECM blower motor is switched to low speed 15 seconds after the Y1 input.

Cooling, 2nd Stage (Y1, Y2, O) - The compressor will be staged to full capacity 20 seconds after Y2 input is received. The ECM blower will shift to high speed 15 seconds after the Y2 input is received.

Blower (G) - The blower will start immediately upon receiving a thermostat G command. If there are no other commands from the thermostat the ECM will run on “G” speed until the G command is removed. Regardless of blower input (G) from the thermostat, the blower will remain on for 30 seconds at the end of each heating, cooling, and emergency heat cycle.

Dehumidification (Y1, O, DH or Y1, Y2, O, DH) - When a DH command is received from the thermostat during a compressor call for cooling the ECM blower speed will be reduced by 15% to increase dehumidification.

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.

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.

Load Shed - The LS input disables all outputs with the exception of the blower output. When the LS input has been cleared, the anti-short cycle timer and random start timer will be initiated. Input must be tied to common to activate.

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 ECM airflow settings. The AID Tool simply plugs into the exterior of the cabinet in the AID Tool port.

Aurora ‘Base’ 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.

Status…