Conforms To UL STDS 60335-1 & 60335-2-40 Certified To CSA STDS C22.2 # 60335-1 & 60335-2-40

OPERATION & MAINTENANCE

TRUCLIMATE 100

10-15 Ton Hydronic Heat Pump

OMT1-0015WR-454B / 60Hz

All TruClimate 100 Series models are safety listed and conforms to UL STDS 60335-1 & 60335-2-40 / Certified to CSA STDSC22.2 60335-1 & 60335-2-40 through ETL. Performance verified in accordance with ASHRAE/ANSI/AHRI/ ISO Standard 13256-2 The T100 Series (up to the 120 in Single Phase) is also Energy Star listed.

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 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.

For the User

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.

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.

WARNING

NOTICE

WARNING Definition of Warnings and Symbols

CAUTION

NOTICE

WARNING

DANGER Indicates a situation that results in death or serious injury.

Indicates a situation that could result in death or serious injury.

Indicates a situation that could result in minor or moderate injury.

Indicates a situation that could result in equipment or property damage.

OPERATION & MAINTENANCE: 10-15 TON HYDRONIC HEAT PUMP

Table of Contents

UNIT OVERVIEW

General Installation Information Nomenclatures AHRI Data Physical Data Dimensional Data Two-Stage Hydronic Typical Application Piping

OPERATING PRINCIPLES

Electrical Data Electrical Information Antifreeze Corrections Heat Of Extraction/Rejection Water Quality Operating Parameters Pressure Drop Flow Rates Aurora Control System HydroZone Controller Instructions Thermistor and Compressor Resistance

CHECK TEST / START-UP / SERVICE AND TROUBLESHOOTING

Reference Calculations Legend Preventative Maintenance Troubleshooting Aurora Interface Diagnostic Tool Preliminary Checkout Procedure Troubleshooting Checklist Control Board Troubleshooting Steps Control Board Troubleshooting Flow Charts Communicating Thermostat Troubleshooting Guide Control Board Signal Jumping the Control Board Troubleshooting Heating/Cooling Cycle Analysis Troubleshooting Form Service Parts List Decommissioning Unit Labeling Requirements Refrigerant Recovery Refrigerant Removal and Evacuation Charging Procedures

REVISION GUIDE

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 compo-nents. 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 pre-cautions 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 qual-ification 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:

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 re-main 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 con-fined spaces shall be avoided.

The area shall be checked with an appropriate refrigerant detec-tor 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.

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

WARNING

Instructions for Equipment Using R-454B Refrigerant

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 room without continuously operating ignition sources (example: open flames, an operating gas appliance or an operating electric heater)

WARNING

General Installation Information

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 REFRIG- ERANTS, 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 This equipment has been evaluated to be installed up to a maxi-mum altitude of 3000m (9843ft) and should not be installed at an altitude greater than 3000m. For installation only in locations not accessible to the general public.

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 de-tection of refrigerant leaks. A halide torch (or any other detector using a naked flame) shall not be used.

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.

WARNING

Installation Space Requirements

NOTE: Equipment with refrigerant charge less than 63 oz does not have a minimum floor area requirement and does not require a refrigerant leak detection sensor.

The sensor might be added as a feature.

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.

WARNING

It is not recommended to use a potable water source for this equipment water supply.

CAUTION

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.

WARNING

Nomenclature

Nomenclature: TruClimate 100 Series Water-to-Water Heat Pump Drawing Number: 96D684-01 Rev: A

EC#

EC-0007861

Revision Log:

Original Release

Date 09/16/24

Author

SS

T

Brand T – TruClimate

Model 1 – 100 Series

Type W – Water-to-Water

Cabinet Configuration M – Medium Enclosure

Unit Capacity (MBTUH) 120, 180

Compressor Type S – Single Stage Scroll

Compressor Feature N – None

Number of Circuits 2 – Two Circuits

Voltage 0 – 208-230/60/1 3 – 208-230/60/3 4 – 460/60/3 5 – 575/60/3

Vintage

* – Factory Use

Non-Standard Options SSS – None

Future Option N – None

Future Option N – None

Future Option N – None

Water Control Option 00B – Back Mounted Connections 00T – Top Mounted Connections

Future Option N – None

Control Box Location 1 – Front 2 – Back

Control Option H – Aurora Premium Control B – Aurora HydroLink2 (BACnet)

Electrical Option N – None

Revision

* - Factory Use

T1WM180SN23**AH1N00TNNNSSS

SSS00T

2 5-7 8 10 11 12 13 1614 17 18-20 21 22 23 24-2691 3 4 15 1 W M 180 S N 1 3 * * A H 1 N N N N

Notes:

1 – Voltage Option 0 requires dual power feed.

AHRI Data

The performance standard AHRI/ASHRAE/ISO 13256-2 became effective January 1, 2000. This new standard has three major categories: Water Loop, Ground Water, and Ground Loop.

Unit of Measure: The Cooling COP

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

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.

ISO Capacity and Efficiency Calculations The following equations illustrate cooling calculations:

• ISO Cooling Capacity = Cooling Capacity (Btuh) x 3.412

• ISO EER Efficiency (W/W) = ISO Cooling Capacity (Btuh) x 3.412 / [Power Input (Watts) + Pump Power Correction (Watt)] The following equations illustrate heating calculations:

• ISO Heating Capacity = Heating Capacity (Btuh) x 3.412

• ISO COP Efficiency (W/W) = ISO Heating Capacity (Btuh) x 3.412 / [Power Input (Watts) + Pump Power Correction (Watt)]

Test Conditions ISO/AHRI 13256-2

WLHP

ISO/AHRI

13256-2

GWHP

ISO/AHRI

13256-2

GLHP

Cooling Liquid Entering Indoor Side - °F

Standard Rating Test Liquid Entering Heat Exchanger - °F

Part-load Rating Test Liquid Entering Heat Exchanger

Fluid Flow Rate

Heating Liquid Entering Indoor Side - °F

Standard Rating Test Liquid Entering Outdoor-side Heat Exchanger - °F

Part-load Rating Test Liquid Entering Outdoor-side Heat Exchanger

Fluid Flow Rate

53.6

53.6

53.6

NOTES: *Flow rate is specified by the manufacturer

WLHP = Water Loop Heat Pump; GWHP = Ground Water Heat Pump;

GLHP = Ground Loop Heat Pump

Conversions

AHRI Data

Energy Star Compliance Table

Model Tier 3

Ground Water Ground Loop

120 Yes Yes

180 No No

12/17/10

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

EER COP

Model Capacity Modulation

Flow Rate

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

Cooling

EST 86°F

ELT 53.6oF

Heating

EST 68°F

ELT 104oF

Cooling

EST 59°F

ELT 53.6oF

Heating

EST 50°F

ELT 104oF

Cooling Full EST 77°F Part EST 68oF

ELT 53.6oF

Heating Full EST 32°F Part ELT 41oF

ELT 104oF

Sgpm Lgpm Capacity Btuh

EER

Btuh/W

Capacity Btuh COP Capacity

Btuh

EER

Btuh/W Capacity

Btuh COP Capacity Btuh

EER

Btuh/W

Capacity Btuh COP

Full 28 28 109,200 13.10 147,400 4.20 115,600 19.90 122,900 3.60 113,600 15.40 93,400 2.90

Part 28 28 60,700 14.20 75,300 4.30 62,000 20.50 62,400 3.70 62,600 18.10 56,700 3.30

Full 36 36 150,400 12.30 209,300 3.90 165,700 18.10 172,200 3.20 156,700 14.20 131,100 2.70

Part 36 36 78,600 12.60 106,100 4.20 87,200 17.90 87,500 3.60 84,400 16.00 79,900 3.20

All ratings based upon 208V operation 10/14/24

Physical Data

Model 120 180

Compressor (2 each)

Factory Charge R-454B, oz [kg] 40 [1.13] 46 [1.30]

Load Water Connection

FPT - in 2 2

Source Water Connection

FPT - in 2 2

Weight - Operating, lb [kg] 400 [181] 420 [190]

Weight - Packaged, lb [kg] 395 [179] 415 [188]

Dimensional Data

LOAD

SOURCE

CONTROL BOX

FRONT LOCATION

CONTROL BOX

2' ALTERNATE

SERVICE ACCESS

OPTIONAL LOW VOLTAGE

(7/8" KNOCKOUT)

2' ALTERNATE

SERVICE ACCESS

OPTIONAL LOW

VOLTAGE

(7/8" KNOCKOUT)

OPTIONAL

TOP WATER

CONNECTIONS

LINE VOLTAGE

(1-3/8" KNOCKOUTS)

LOW VOLTAGE

(7/8" KNOCKOUT)

LINE VOLTAGE

(1-3/8" KNOCKOUTS)

LOW VOLTAGE

(7/8" KNOCKOUT)

CONTROL BOX

BACK LOCATION

CONTROL BOX

17.00

12.11

33.59

25.58

24.01

2.16 21.06 2.16

2.96 10.18

12.11

14.05

12.11

33.60

25.58

24.01

10.18

12.11

14.05

5.28

5.82

2.2621.072.26

LOAD

SOURCE

FRONT

BACK

WATERLINES

FRONT

BACK

WATERLINES

2'

PRIMARY

SERVICE

ACCESS

2'

PRIMARY

SERVICE

ACCESS

LOAD

SOURCE

CONTROL BOX

FRONT LOCATION

CONTROL BOX

2' ALTERNATE

SERVICE ACCESS

OPTIONAL LOW VOLTAGE

(7/8" KNOCKOUT)

2' ALTERNATE

SERVICE ACCESS

OPTIONAL LOW

VOLTAGE

(7/8" KNOCKOUT)

OPTIONAL

TOP WATER

CONNECTIONS

LINE VOLTAGE

(1-3/8" KNOCKOUTS)

LOW VOLTAGE

(7/8" KNOCKOUT)

LINE VOLTAGE

(1-3/8" KNOCKOUTS)

LOW VOLTAGE

(7/8" KNOCKOUT)

CONTROL BOX

BACK LOCATION

CONTROL BOX

17.00

12.11

33.59

25.58

24.01

2.16 21.06 2.16

2.96 10.18

12.11

14.05

12.11

33.60

25.58

24.01

10.18

12.11

14.05

5.28

5.82

2.2621.072.26

LOAD

SOURCE

FRONT

BACK

WATERLINES

FRONT

BACK

WATERLINES

2'

PRIMARY

SERVICE

ACCESS

2'

PRIMARY

SERVICE

ACCESS

120-180 - Top Waterline Configuration

120-180 - Back Waterline Configuration

Two-Stage Hydronic Typical Application Piping

LOAD PUMP

HYDRONIC

LOAD

Source OUT

P/T Ports

Ball Valve

Dielectric Unions

Dielectric Unions

NOTE: * A 30 PSI pressure relief valve (Part No: SRV30) should be used in hydronic applications.

1-1/2˝

FPT

Expansion Tank

Air Vent

Pressure Gauge

30 PSI

RELIEF VALVE

Air Separator

Back Flow Preventer / Pressure Relief Valve

GEO

STORAGE

TANK

3-Way Valves

Y-Strainer (required to prevent damage from fouling)

Hose Kit

Pressure Reduction

Pressure Reduction

Hose Kit

P/T Ports

Source IN

Y-Strainer (required to prevent damage from fouling) Flow Switch (optional)

Heat Pump

NOTE:

Due to compressor reliability direct to load application are not recommended. A buffer tank must be installed in they system.

Electrical Data

Figure 1 - Control Box

Model Supply Circuit

Rated Voltage

Voltage Min/Max

Compressor* Load Pump

FLA

Source Pump

FLA

Total Unit

FLA

Min Circ Amp

Max Fuse/

HACRMCC RLA LRA LRA**

L1/L2 208-230/60/1 187/253 47.0 30.1 170.0 59.5 30.1 37.6 70

L3/L4 208-230/60/1 187/253 47.0 30.1 170.0 59.5 4.2 4.2 38.5 46.0 80

Single 208-230/60/3 187/253 33.0 21.2 156.5 21.2 26.5 50

Single 460/60/3 414/506 14.2 9.1 74.8 9.1 11.4 25

Single 575/60/3 517/633 12.0 7.7 47.8 7.7 9.6 20

L1/L2 208-230/60/1 187/253 50.0 32.1 185.0 65.0 32.1 40.1 70

L3/L4 208-230/60/1 187/253 50.0 32.1 185.0 65.0 4.2 4.2 40.5 48.5 80

Single 208-230/60/3 187/253 40.6 26.0 190.0 26.0 32.5 60

Single 460/60/3 414/506 20.3 13.0 100.0 13.0 16.3 30

Single 575/60/3 517/633 14.5 9.3 72.0 9.3 11.6 25

HACR circuit breaker in USA only

* - Ratings per each compressor - unit supplied with two ** - With optional IntelliStart

Aurora Controls Aurora 'Base' Control and Aurora 'Advanced' Control

(shown)

Field Low Voltage Connections

75VAC

Transformer

HydroLink Controller

AXB A

AXB B

ABC A

ABC B

Compressor Contactors

Power Block

Power Board 24 UDC

Electrical Information

WARNING

During repairs to sealed components, all electrical supplies shall be disconnected from the equipment being worked upon prior to any removal of sealed covers, etc. If it is absolutely necessary to have an electrical supply to equipment during servicing, then a permanently operating form of leak detection shall be located at the most critical point to warn of a potentially hazardous situation.

Sealed electrical components shall be replaced.

WARNING

Do not apply any permanent inductive or capacitance loads to the circuit with out ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use.

Intrinsically safe components must be replaced.

Replace components only with parts specified by the manufacturer. Other parts may result in the ignition of refrigerant in the atmosphere from a leak.

NOTE The use of silicon sealant can inhibit the effectiveness of some types of leak detection equipment.

Intrinsically safe components do not have to be isolated prior to working on them.

Antifreeze Corrections

Catalog performance can be corrected for antifreeze use. Please use the following table and note the example given.

Antifreeze Correction Example Antifreeze solution is propylene glycol 20% by weight for the source and methanol 10% for the load. Determine the corrected heating at 30°F source and 80°F load as well as pressure drop at 30°F for a Hydronic 120.

Also, determine the corrected cooling at 90°F source and 50°F load.

The corrected heating capacity at 30°F/80°F would be:

98,500 MBTUH x 0.913 x 0.985 = 88,582 MBTUH The corrected cooling capacity at 90°F/50°F would be:

113,200 x 0.969 x 0.962 = 105,523 MBTUH The corrected pressure drop at 30°F and 36 GPM would be:

4.9 psi x 1.270 = 6.22 psi

Antifreeze Type Antifreeze % by wt

Heating Cooling Pressure DropLoad Source Load Source

EWT - °F [°C] 80 [26.7] 30 [-1.1] 50 [10.0] 90 [32.2] 30 [-1.1]

Water 0 1.000 1.000 1.000 1.000 1.000

Ethylene Glycol

10 0.990 0.973 0.976 0.991 1.075

20 0.978 0.943 0.947 0.979 1.163

30 0.964 0.917 0.921 0.965 1.225

40 0.953 0.890 0.897 0.955 1.324

50 0.942 0.865 0.872 0.943 1.419

Propylene Glycol

10 0.981 0.958 0.959 0.981 1.130

20 0.967 0.913 0.921 0.969 1.270

30 0.946 0.854 0.869 0.950 1.433

40 0.932 0.813 0.834 0.937 1.614

50 0.915 0.770 0.796 0.922 1.816

Ethanol

10 0.986 0.927 0.945 0.991 1.242

20 0.967 0.887 0.906 0.972 1.343

30 0.944 0.856 0.869 0.947 1.383

40 0.926 0.815 0.830 0.930 1.523

50 0.907 0.779 0.795 0.911 1.639

Methanol

10 0.985 0.957 0.962 0.986 1.127

20 0.969 0.924 0.929 0.970 1.197

30 0.950 0.895 0.897 0.951 1.235

40 0.935 0.863 0.866 0.936 1.323

50 0.919 0.833 0.836 0.920 1.399

WARNING: Gray area represents antifreeze concentrations greater than 35% by weight and should be avoided due to the extreme performance penalty they represent.

Heat of Extraction / Rejection

Model Source

GPM

Load

GPM

EST

ºF

Heat Of Extraction (HE) Heat of Rejection (HR)

60°F 80°F 100°F 120°F 50°F 70°F 90°F 110°F

120 36 36

30 91.3 81.9 72.4 63.0 154.3 172.5 190.7 208.9

50 115.9 106.5 97.0 87.6 151.6 169.9 188.2 206.5

70 140.5 131.1 121.6 122.2 148.9 167.3 185.7

90 163.1 154.5 146.7 165.1 183.4

110 144.5 162.8

180 48 48

30 122.3 106.1 90.0 73.8 200.8 243.3 285.7 328.2

50 153.4 135.3 117.3 99.2 192.0 231.7 271.5 311.3

70 184.4 164.5 144.5 124.6 183.1 22.0 257.3

90 218.6 198.7 178.5 211.5 244.5

110 173.9 202.8

10/14/24

Water Quality

General Two-Stage Hydronic systems may be successfully applied in a wide range of residential, commercial, and industrial applications. 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.

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. 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 in the units are 316 stainless steel plates with copper brazing. The water piping in the heat exchanger is steel. There may be other materials in the building’s piping system that the designer may need to take into consideration when deciding the parameters of the water quality.

If an 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 from the contaminated water.

Material Copper 90/10 Cupronickel 316 Stainless Steel pH Acidity/Alkalinity 7 - 9 7 - 9 7 - 9

Scaling Calcium and

Magnesium Carbonate (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm

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

2/22/12

The following table 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.

Strainers These units must have properly sized strainers upstream of both brazed plate heat exchangers to protect them against particles in the fluid. Failure to install proper stainers and perform regular service can result in serious damage to the unit, and cause degraded performance, reduced operating life and failed compressors. Improper installation of the unit (which includes not having proper strainers to protect the heat exchangers) can also result in voiding the warranty.

Field supplied strainers with 20-40 mesh (530-1060 microns) are recommended, with 30 mesh (800 microns) being the optimum choice. The strainers selected should have a mesh open area of at least 6 square inches (39 square centimeters) for each unit being serviced by the strainer. Using strainers with a smaller amount of open area will result in the need for more frequent cleaning.

Strainers should be selected on the basis of acceptable pressure drop, and not on pipe diameter. The strainers selected should have a pressure drop at the nominal flow rate of the units low enough to be within the pumping capacity of the pump being used.

WARNING: Must have intermediate heat exchanger when used in pool applications.

Water Quality Guidelines

Operating Parameters

Heating Mode

Entering Entering Suction Discharge Superheat Subcooling

Load Temp (oF) Source Temp (oF) Pressure (psig) Pressure (psig) (oF) (oF)

30 75-100 200-215 10-12 10-13

50 100-125 200-215 12-14 8-12

70 125-150 215-230 14-18 8-12

90 150-165 230-255 25-30 8-12

30 75-100 285-300 10-12 10-13

50 100-125 300-315 12-14 8-12

70 125-150 315-330 14-18 8-12

90 150-165 330-345 25-30 8-12

30 85-110 365-380 10-12 7-11

50 110-135 385-400 12-14 7-11

70 135-165 400-415 14-18 3-7

50 110-135 485-500 12-14 7-11

70 135-165 500-515 14-18 3-7

10/14/24 Note: Operating data based on normal conditions with 3 gpm/ton for the load and source.

Cooling Mode

Entering Entering Suction Discharge Superheat Subcooling

Load Temp (oF) Source Temp (oF) Pressure (psig) Pressure (psig) (oF) (oF)

30 80-90 140-175 15-20 3-6

50 90-100 200-235 11-15 6-9

70 100-110 250-285 11-15 9-12

90 100-120 330-365 8-12 12-14

110 110-130 430-465 8-12 14-19

30 80-90 150-185 15-20 3-6

50 90-100 210-245 11-15 6-9

70 100-110 260-295 11-15 9-12

90 110-120 340-375 8-12 12-14

110 110-140 440-485 8-12 14-19

30 80-90 150-185 15-20 3-6

50 90-100 210-245 11-15 6-9

70 100-110 260-295 11-15 9-12

90 110-120 340-375 8-12 12-14

30 90-100 160-195 40-45 3-6

50 110-130 220-255 30-40 6-9

10/14/24 Note: Operating data based on normal conditions with 3 gpm/ton for the load and source.

Pressure Drop

Model GPM Pressure Drop (psi)

30°F 50°F 70°F 90°F 110°F

18 1.6 1.3 1.1 0.8 0.6

28 3.4 3.2 2.9 2.7 2.1

36 4.9 4.7 4.4 4.2 3.3

40 5.6 5.4 5.1 4.9 3.9

24 2.7 2.4 2.2 1.9 1.5

36 4.9 4.7 4.4 4.2 3.3

48 7.1 6.9 6.6 6.4 5.1

60 9.3 9.1 8.8 8.6 7.0

3/9/09

Flow Rates

Load Flow Rate The load flow on all water to water products including the Two-Stage Hydronic Series should be 3 gpm per ton (typically the rated flow and the highest flow shown in the capacity charts). Refer to the table below. This flow rate is required especially when heating water to limit the effects of the higher condensing temperatures of water heating for radiant floor heating or domestic water use.

Source Flow Rate The source flow can range between 2.25 and 3 gpm per ton for earth loops. For open loop well water systems the minimum flow should be 1.5 gpm per ton. In earth loop systems where entering water temperatures are expected to be above 95°F, 3 gpm per ton should be used. In well systems where the water temperature is below 50°F, 2 gpm per ton should be used to avoid nuisance freeze detection trips.

Source Flow Rate Load Flow Rate

Minimum Open Loop

Open Loop

< 50°F

Closed Loop Range (Min - Full Flow)

120 18 24 27 36 36

180 24 32 36 48 48

Aurora Control System

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 Loop Pump Control Compressor Contactor powers Loop Pump and no loop pump linking capability. • See below

Compressor Monitoring Control monitors compressor starts for high current, missing leg 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

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 primary for connecting to devices such as a communicating thermostat, expansion board, or other secondary devices.

The second channel is configured as a secondary 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 linking, 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.

Aurora Control System

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

Geo Energy Monitoring Kit Monitors realtime power consumption of compressor, aux heat and pump. AXB required. - Standard

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

Performance Monitoring Kit Monitors water temperatures - Standard

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

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 go to Aurora

Toolbox for latest firmware version

For Service go to Aurora

Toolbox for latest firmware version

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

HZO Non-communicating controller for up to two heat pumps. Standard Standard

Aurora Control System

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

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.

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 (Source) FP1 Selection – Low water coil temperature limit setting for freeze detection. On = 30°F;

Off = 15°F.

SW2-2 (Load) FP2 Selection – On = 30°F; Off = 15°F 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 n/a

Cycle with Compressor OFF OFF Water Valve Slow Opening ON OFF

Cycle with Comm. T-stat Hum Cmd n/a

Cycle with Blower - (Not used on water-to-water) 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.

Field Selectable Options via Software (Selectable via the Aurora AID Tool)

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.

Aurora Control System

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 – 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.

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.

Freeze Detection (Source 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 (Load Coax) - uses the FP2 input to protect against ice formation on the coax. The FP2 input will operate exactly like FP1.

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 compressor will be off.

Heating Operation Heating, 1st Stage (Y1) - The compressor is energized 10 seconds after the Y1 input is received.

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 compressor is energized 10 seconds after the Y1 input is received.

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.

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 Control System

CCA

Violet (14) Black (15)

Orange (01) Orange (02)

Condensate

Brown (23)

RVA

HPALPA

T

FDARVA

Blue (07) Blue (08) Black (09) Black (10)

Yellow Yellow

CFM

P13

P4

SW1

P5JW

P9

LO

O/B

Y2 W

DH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On

Reheat L Output Type

CC – Dual/Single Acc – Dip 5 Acc – Dip 4

RV – B/O

FP2 – 15°F/30°F

FP1 – 15°F/30°F

Com1

LED5

Com2

LED5

Test Mode

F1-3A

P9

C

PWM

ALM

ALG

ACC COM

ACC NO

ACC NC

R C

G Y1

EH2CEH1CCOC R - +C R - +

Off

Faul t

LED1

R

Status

LED3

Config

LED2

CC2 CC F C R F FG CC CCGCC2

HI

CC2

LO

CC2

G REVREVFP1 FP1 FP2 FP2 LPS LPSHPSHPS

Aurora Base Control A

(ABC - A)

K1-RV Relay

K2-CC Relay

K3-CC2 Relay

K4-Fan RelayK5-Alarm Relay

K6-Acc Relay

F

R

C

CCGY1C

R

ES

LS

P2

EH1

YG G

G

LAT

Thermistor Array

Black Black

CCB

Violet (14) Black (15)

RVB

HPBLPB

T

FDBRVB

Yellow Yellow

CFM

P13

P4

SW1

P5JW

P9

LO

O/B

Y2 W

DH

P8 P7

RS485 NET RS485 NET

P6

RS485 EXP

P3

SW2

On

Reheat L Output Type

CC – Dual/Single Acc – Dip 5 Acc – Dip 4

RV – B/O

FP2 – 15°F/30°F

FP1 – 15°F/30°F

Com1

LED5

Com2

LED5

Test Mode

F1-3A

P1

C

PWM

ALM

ALG

ACC COM

ACC NO

ACC NC

R C

G Y1

EH2CEH1CCOC R - +C R - +

Off

Faul t

LED1

R

Status

LED3

Config

LED2

CC2 CC F C R F FG CC CCGCC2

HI

CC2

LO

CC2

G REVREVFP1 FP1 FP2 FP2 LPS LPSHPSHPS

Aurora Base Control B

(ABC - B)

K1-RV Relay

K2-CC Relay

K3-CC2 Relay

K4-Fan RelayK5-Alarm Relay

K6-Acc Relay

F

R

C

CCGY1C

R

ES

LS

P2

EH1

YG G

G

Condensate

Brown (23)

T T

T T

Gray Gray

RB

Compressor A

CC1

T1

L1

T2

L2

T3

L3

T1T3

T2

Compressor B

CC2

T1

L1

T2

L2

T3

L3

T1T3

T2

Green

Yellow (78) Brown (79)

Gray (80) Green

Belt Drive Blower Motor

Gray (83)Brown (82)Yellow (81)

RBT2 T1T3

L2 L1L3

Red (69) Red (66) Yellow (63)

Brown (64)

NOTE 2

Yellow (70) Black (71) Yellow (67)

Black (68) Gray (65)

Unit Power Supply

460-575/60/3

L3L1 L2 G

Red (84) Yellow (85)

Black (86) Red (87) Yellow (88)

Black (89)

Belt Drive Blower Motor

PB1

Transformer

Black

Blue

Yellow

Black/White

White

Green

Accessory Relay

Cycle with Blower Cycle with Compressor Water Valve Slow Open Outdoor Air Damper

SW2-4 SW2-5

On On Off Off On Off Off On

Operation

Event Normal Mode Test Mode Random Start Delay Compressor On Delay Compressor Minimum On Time Compressor Short Cycle Delay Blower Off Delay Faul t Recogn ition Delay – High Pressure Start-Up Bypass – Low Pressure Faul t Recogn ition Delay – Low Pressure Start-Up Bypass – Low Water/Air Coil Limit Faul t Recogn ition Delay – Low Water/Air Coil Limit Faul t Recogn ition Delay – Condensate Overflow Thermostat Call Recognition Time Auxi liary Heat Staging Delay Emergency Heat Staging Delay

Less than 1 second

5 to 80 seconds 1 second 5 seconds < 1 second

30 seconds 2 seconds Less than 1 second

2 minutes 5 seconds 4 minutes 15 seconds

2 minutes

2 minutes

30 seconds 30 seconds 30 seconds

30 seconds 30 seconds

30 seconds 30 seconds 30 seconds

2 seconds 2 seconds 5 minutes 2 minutes

20 seconds

7.5 seconds

Aurora Timing Events

Reheat Delay 30 seconds 30 seconds Water Valve Slow Open Delay 90 seconds 90 seconds

Slow Flash Fast Flash Flash Code

Status LED (LED1, Green) Configuration LED (LED2, Yellow) Faul t LED (LED3, Red)

Sta tus LED (LED1, Green) Normal Mode Control is Non-Functional Test Mode Lockout Active Dehumidification Mode Reserved Reserved Load Shed

ESD

1 second on and 1 second off

Random Start Delay Fast Flash

OFF

ON

Slow Flash Fast Flash

Flash Code 2 Flash Code 3

Flash Code 6

Flash Code 4 Flash Code 5

Aurora LED Flash Codes

100 milliseconds on and 100 milliseconds off 100 milliseconds on and 400 milliseconds off with a 2 second pause before repeating

Reserved Flash Code 7

Configuration LED (LED2, Yellow) Fault LED (LED3, Red)

Fast Flash Fast Flash

No Software Overide Flash ECM Settin g DIP Switch Overide Slow Flash

Normal Mode Input Fault Lockout High Pressure Lockout Low Pressure Lockout

Low Water Coil Limi t Lockout - FP1 Low Air Coil Limi t Lockout - FP2

Reserved Condensate Overflow Lockout Over/Under Voltage Shutdown Reserved Reserved Air/Water Coil Limit Sensor Error

Flash Code 1

OFF

Flash Code 2 Flash Code 3 Flash Code 4 Flash Code 5

Flash Code 8

Flash Code 6 Flash Code 7

Flash Code 9 Flash Code 10 Flash Code 11

ECM Configu re Mode Fast Flash Reset Configure Mode Off

CC2

EH1

Fa ct ory

Faul t

AL

G

AL

MLSES AC

C c

Status

AURORA BASE

CONTROL™

RV – K1

CC

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

AC

C no

AC

C nc

O/

BCRLO G Y1 Y2 W DH

3A -Fu se

O/

BCRLO G Y1 Y2 W DH

LO

G

HI

CCG

CC

FG

F R

HP

HP

LP

FP2

FP2

FP1

REV

REV

CF

M

PW

M

ECM PWM

Fa ct ory

Factory Fan Connection

R R

C C

C

RS

EH2

C

EH1

C

CO

R

CRS

5 E xp Fa ct ory

Com1

Com2

Config

G

G

G

YR

SW1 Test

FP1 – 15oF/30oF

JW2 -

Alarm

P11

P5

P2 P1

P8

P7

P9

P6

P3

SW2

P13 P4 FP2 – 15oF/30oF

RV – B/O

ACC – Dip 4

ACC – Dip 5 CC – Dual/Single

L – Pulse/Continuous Reheat/Normal

Fa ct ory U se

Field ConnectionsField Connections

C

LP

FP1

F

CC

G

Y1

Off On

N/A

RS

5 N

ET

LED3

LED2LED1

Thermistor

Relay Coi l

Switch - Condensate Overflow Switch - High pressure

Switch - Low pressure

Polarized connector

Factory Low Voltage Wiring Factory Line Vol tage Wiring Field Low Voltage Wiring Field Line Voltage Wi ring Optional Block DC Voltage PCB Traces

Internal Junction Quick Connect Terminal

Field Wiring Lug

Ground

Relay Con tacts – N.O., N.C.

Field Zone Sensor Wi ring

Legend

L1

Capacitor

T

CCA – Compressor Contactor A CCB – Compressor Contactor B CO – Condensate Overflow Sensor ES – Emergency Shutdown HPA – High Pressure Switch A HPB – High Pressure Switch B LPA – Low Pressure Switch A LPB – Low Pressure Switch B FDA – Freeze De tection Sensor A FDB – Freeze De tection Sensor B F1 – Fuse

Fuse

Light Emitti ng Diode - GreenG

Light Emitti ng Diode - YellowY

Light Emitti ng Diode - RedR

SW1 – Push button SW2 – DIP package 8 position RB – Blower Relay RVA – Reversing Valve Coi l A RVB – Reversing Valve Coi l B PGM – Phase Guard Moni tor RH – Reheat Valve Coi l

Dual Compressor Aurora 460-575/60/3

1/23/15 97P876-02

470Ω

470Ω Resistor

1 – Only on units equipped with two fan motors.

Notes:

TB

ESEmerg Shutdown

LSLoad Shed

LO1Lockout Circuit A

R24VAC

C24VAC Common

OReversing Valve

GFan

Y1Compressor A

WElectric Heat

DHDehumidification

LO2Lockout Circuit B

Y2Compressor B

W hite (12)

Black (13)

W hite (12)

W hit e (

) Black/White (16)

Black/White (17)

Yellow (18)

Yellow (19)

Orange/W hite (21)

Orange/W ht (22)

Blue/W hite (27)

Blue/W hite (28)

Black/W hite (29)

Black/W hite (30)

Class 2

ABC Control Board LayoutAurora ‘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 LED (LED3, Green) Description of Operation Fault LED, Green

Normal Mode ON Control is Non-functional OFF Test Mode Slow Flash Lockout Active Fast Flash Dehumidification Mode Flash Code 2 (Future Use) Flash Code 3 (Future Use) Flash Code 4 Load Shed Flash Code 5 ESD Flash Code 6 (Future Use) Flash Code 7

Fault LED (LED1, Red)

Red Fault LED LED Flash Code* Lockout Reset/

Remove

A B

C B as ic

F au lt s

Normal - No Faults OFF – Fault - Input 1 No Auto Fault - High Pressure 2 Yes Hard or Soft Fault - Low Pressure 3 Yes Hard or Soft Fault - Freeze Detection FP2 4 Yes Hard or Soft Fault - Freeze Detection FP1 5 Yes Hard or Soft Fault - Condensate Overflow 7 Yes Hard or Soft Fault - Over/Under Voltage 8 No Auto Fault - FP1 & FP2 Sensor Error 11 Yes Hard or Soft

NOTE: All codes >11 use long flash for tens digit and short flash for the ones digit. 20, 30, 40, 50, etc. are skipped.

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, 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 Control System

Aurora ‘Advanced’ Control Features The Aurora ‘Advanced’ Control system expands on the capability of the Aurora ‘Base’ Control (ABC) by adding the Aurora Expansion Board (AXB).

All of the preceding features of the Aurora ‘Base’ Control are included.

The following control description is of the additional features and capability of the Aurora advanced control.

It is highly recommended the installing/servicing contractor obtain an Aurora Interface and Diagnostic Tool…