INDOOR PACKAGED EQUIPMENT COMMERCIAL WATER SOURCE / GEOTHERMAL HEAT PUMP SERIES RB R-410A TON

Transcription

1 INDOO PAKAED EQUIPMENT INSTALLATION, OPEATION, MAINTENANE Supersedes: NOM7 (0) Form NOM7 (54) OMMEIAL WATE SOUE / EOTHEMAL HEAT PUMP SEIES B -40A TON Issue Date: May 0, 04

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3 Table of ontents Model Nomenclature eneral Installation Information Dimensional Data Installing Horizontal Units Hanger Bracket Locations Duct System and Water Piping Water Quality ondensate Drain System leaning and Flushing Open Loop round Water Systems Freeze Detection Electrical onnections Electrical Data Blower Performance Data Speed EM onstant Torque Motors Wiring Schematics ontrols - Aurora Base ontrol ontrols - FX0 (optional) Unit Startup Operating Parameters and Operating Limits Pressure Drop ompressor and Thermistor esistance efrigerant ircuit uideline Heat of Extraction/ejection Data eference alculations and Legend Troubleshooting Startup/Troubleshooting Form Preventive Maintenance eplacement Procedures Service Parts evision Table

4 Model Nomenclature B S V 06 T L A 0 6 N 7 A N SS 4 * Model Type B B Series Operation ange S Single Stage abinet onfiguration V Vertical H - Horizontal Unit apacity (MBTUH) 006, 009, 0, 05, 08, 04, 00, 06, 04, 048, 060, 070 Discharge onfiguration T Top (Vertical) E End (Horizontal) S Side (Horizontal) eturn Air onfiguration L Left ight Voltage /60/ 65-77/60/ (08-06) 08-0/60/ (04-070) 4 460/60/ (04-070) 5 575/60/ (PS Only ) 9 5/60/ (006-0) Future Option 0 None Blower Options 0 PS Blower Variable Speed EM Blower (05-070) 4 5-Speed EM Blower (05-070) Water oil Option opper N upronickel Sound Kit Option A None B Sound Kit (Not Available on H006-0) Vintage * - Factory Use Only Non-Standard Options SS Standard Drain Pan Option 0 omposite, No Secondary onnection omposite, Secondary onnection Stainless Steel, No Secondary onnection Stainless Steel, Secondary onnection abinet Option 0 Unpainted, in MEV 4, Filter ail Painted, in MEV 4, Filter ail Unpainted, in MEV, Filter ail Painted, in MEV, Filter ail 4 Unpainted, in MEV 4, Filter ack 5 Painted, in MEV 4, Filter ack 6 Unpainted, in MEV, Filter ack 7 Painted, in MEV, Filter ack Phase uard N No Phase uard, No Disconnect P Phase uard, No Disconnect B Phase uard, Disconnect D No Phase uard, Disconnect Air oil Option 5 All-Aluminum, AlumiSeal TM, Extended ange 6 All-Aluminum, AlumiSeal, Standard ange 7 All-Aluminum, No oating, Extended ange 8 All-Aluminum, No oating, Standard ange ontrol Option A Aurora TM Base ontrol (AB) 4 FX0 std. No ommunications 5 FX0 w/ Open N om ard 6 FX0 w/ LonWorks om ard 7 FX0 w/ BacNet om ard Water ontrol Option N None Water Flow egulator (05-070) V -Way Valve (05-070) B -Way Valve w/ Water Flow egulator (05-070) efrigeration Option 0 None Hot as Bypass (05-07) Hot as eheat (05-07) B Hot as Bypass w/hot as eheat (05-07) Note: Phase uard Only Available on 08-0/60/, 460/60/, and 575/60/ 50VA Transformer with Aurora and 75VA Transformer with FX0 ev.: 5 April 04D All B Series product is safety listed under UL995 thru ETL and performance listed with AHI in accordance with standard

5 eneral Installation Information Safety onsiderations WANIN: Before performing service or maintenance operations on a system, turn off main power switches to the indoor unit. If applicable, turn off the accessory heater power switch. Electrical shock could cause personal injury. Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service heating and air conditioning equipment. Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on heating and air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply. Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations and have a fire extinguisher available. Unit Location Locate the unit in an indoor area that allows for easy removal of the filter and access panels. Location should have enough space for service personnel to perform maintenance or repair. Provide sufficient room to make water, electrical and duct connection(s). If the unit is located in a confined space, such as a closet, provisions must be made for return air to freely enter the space by means of a louvered door, etc. Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit. On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping. are should be taken when units are located in unconditioned spaces to prevent damage from frozen water lines and excessive heat that could damage electrical components. Installing Vertical Units Vertical units are available in left or right air return configurations. Top flow vertical units should be mounted level on a vibration absorbing pad slightly larger than the base to provide isolation between the unit and the floor. Moving and Storage Move units in the normal up orientation. Horizontal units may be moved and stored per the information on the packaging. Do not stack more than three units in total height. Vertical units may be stored one upon another to a maximum height of two units. Do not attempt to move units while stacked. When the equipment is received, all items should be carefully checked against the bill of lading to be sure all crates and cartons have been received. Examine units for shipping damage, removing the units from the packaging if necessary. Units in question should also be internally inspected. If any damage is noted, the carrier should make the proper notation on the delivery receipt, acknowledging the damage. in. PEX Foam Vertical Unit Mounting 5

6 Vertical Dimensional Data Standard filter rails for open return applications Field installed duct flange Deluxe filter rack for ductable return applications A N S A N Air coil Q Q AESS PANEL B P F FONT Top View - ight eturn AI OIL SIDE M M AI OIL SIDE FONT ' (6 cm) Alternate Service Access Top View - Left eturn ' (6 cm) Service Access Left eturn (ight eturn Opposite Side) P F B Isometric View - Left eturn U T W Air coil Air coil AESS PANEL AESS PANEL V H E D.6 in (4. cm) ondensate /4 in PV glue socket.6 in (4. cm) Water onnections* L J Power supply in (5.4 mm) knockout Low voltage /" (.7 mm) knockout L K ondensate /4 in PV glue socket.6 in (4. cm) 8 7 Water onnections* 5 E H D.6 in (4. cm) J L 6 8 AESS PANEL 8 7 K L Front View - ight eturn Front View - Left eturn ight View - ight eturn (J & L) Left View - Left eturn (K & L) NOTE: * Water connections protrude approximately.5 in. from cabinet. 6

7 Vertical Dimensional Data cont. Vertical Models Electrical Knockouts Water onnections Overall abinet J K L Loop A B D E H / in. cond / in. cond in. cond M ondensate Supply Power Filter ack Width Depth Height* In Out Water FPT Low Voltage Low Voltage Width in / in cm mm in /4 in cm mm in /4 in cm mm in /4 in cm mm in /4 in cm mm in in cm mm in in cm mm Vertical Discharge onnection duct fl ange installed (±0.0 in) **eturn onnection using deluxe fi lter rack (±0.0 in) Models N P Q S T U V W Supply Width Supply Depth eturn Depth eturn Height in cm in cm in cm in cm in cm in cm in cm ondensate is /4 in. PV female glue socket and is switchable from side to front. * Discharge fl ange is fi eld installed and extends in. (5.4 mm) from top of cabinet. ** Vertical units shipped with standard in. (field adjustable to in.) open application filter rail extending. in. from the unit and is not suitable for duct connection. For ductable return connection applications, order the in. (field adjustable to in.) duct collar/filter rack which extends to.5 in. from the unit and is suitable for duct connections. 09/6/ Vertical Disconnect When using disconnect, do not use dimension L from the standard vertical dimensional data. Use dimension LL from the vertical disconnect dimensional data. Vertical Models LL [40.] [47.8] [8.9] [5.] [6.] [6.] Dimensions in inches [cm] * Models Externally Mounted Disconnect Disconnect Location Power Supply LL Disconnect Located on this Side for a ight eturn Alternative Power Supply Vertical Shown in Left eturn onfiguration 7

8 Horizontal Dimensional Data ight eturn Standard filter rails in knockout / in knockout Front K.7.7 P AP Standard filter rails Front Left eturn J MP E AP MP A ight eturn Air Front View D AP MP.7.7 ondensate "X" PV size End Discharge Side Discharge ' (6 cm) Service Access E P AP MP / in knockout in knockout Side Discharge ondensate "X" PV size End Discharge Deluxe filter rack option shown D Left eturn Air Front View Deluxe filter rack option shown. N P P N. J K ' (6 cm) Service Access H FILTE AK AI OIL SIDE BLOWE L OUTLET Legend M AP = Alternate Service Panel M L BP P = Blower Service Panel = ontrol Access Panel BLOWE OUTLET. BP MP = ompressor Service Panel A BP A. ight eturn End Discharge Left eturn End Discharge FILTE AK AI OIL SIDE H P N.5.5 N P BP L M BLOWE OUTLET AP MP K / in knockout J in knockout Front Front " knockout J / in knockout K AP MP BLOWE OUTLET M L BP ight eturn Side Discharge Left eturn Side Discharge Front Air oil Q S T T S Q FILTE AK ONNETION Deluxe filter rack option (shown) FILTE AK ONNETION Air oil Front Water onnections* B ight eturn Side View B Left eturn Side View Water onnections* NOTE: * Water connections protrude approximately.5 in. from cabinet. 8

9 Horizontal Dimensional Data cont. Water onnections Electrical Knockouts Overall abinet Horizontal J K Loop Models A B D E H / in. cond in. cond Width Depth Height* In Out ondensate Water FPT Low Voltage Power Supply in / in ** cm mm in /4 in cm mm in /4 in cm mm in /4 in cm mm in /4 in cm mm in in cm mm.4. in in cm mm.4. Discharge onnection eturn onnection Horizontal duct fl ange installed (±0.0 in) using deluxe fi lter rack option (±0.0 in) PV Size Models L M N P Q S T X Supply Width Supply Depth eturn Depth eturn Height 006-0** in / in. cm in /4 in. cm in /4 in. cm in /4 in. cm in /4 in. cm in /4 in. cm in /4 in. cm Horizontal units shipped with standard in. (field adjustable to in.) open application filter rail extending. in. from the unit and is not 09/6/ suitable for duct connection. For ductable return connection applications, order the in. (field adjustable to in.) duct collar/filter rack which extends to.5 in. from the unit and is suitable for duct connections. ** H006-0 offers a lifted drain pan that allows the trap to be installed without additional ceiling height required. Horizontal Disconnect When using disconnect, do not use dimension K from the standard horizontal dimensional data. Use dimension KK from the horizontal disconnect dimensional data. Horizontal Models KK [0.8] [0.8] [.4] [.4] 060. [8.4] [5.9] Dimensions in inches [cm] * Models Externally Mounted Disconnect Disconnect Located on this Side for a Left eturn Disconnect Location KK Power Supply Horizontal Shown In ight eturn onfiguration 9

10 Installing Horizontal Units Installing Horizontal Units Horizontal units are available with side or end discharge and may be easily field converted by flipping the blower discharge panel. Horizontal units are normally suspended from a ceiling by four /8 in. diameter threaded rods. The rods are usually attached to the unit by hanger bracket kits furnished with each unit. Lay out the threaded rods per the dimensions below. Assemble the hangers to the unit as shown. Securely tighten the brackets to the unit using the weld nuts located on the underside of the bottom panel. When attaching the hanger rods to the bracket, a double nut is required since vibration could loosen a single nut. NOTE: The unit should be pitched approximately /4 in. towards the drain in both directions to facilitate the removal of condensate. Use only the bolts provided in the kit to attach hanger brackets. The use of longer bolts could damage internal parts. Some applications require the installation of horizontal units on an attic floor. In this case, the unit should be set in a full size secondary drain pan on top of a vibration absorbing pad. The secondary drain pan prevents possible condensate overflow or water leakage damage to the ceiling. The secondary drain pan is usually placed on a plywood base isolated from the ceiling joists by additional layers of vibration absorbing material. Insulate supply plenum and use at least one 90 elbow and flexible duct collar to reduce noise. AUTION: Do not use rods smaller than /8 in. diameter since they may not be strong enough to support the unit. The rods must be securely anchored to the ceiling. Horizontal Unit Mounting 0

11 Hanger Bracket Locations ight Left B D E ompressor Section Air Handler Section F E D ompressor Section Air Handler Section F A /8 Threaded od (not supplied) Vibration Isolator Washer Bolt and Lockwasher Hex Nuts (not supplied) Hanger Dimensions Model Hanger Kit Part Number Unit Hanger Dimensions A B in S500A04 cm in S500A04 cm in S500A04 cm in S500A04 cm in S500A04 cm in S500A04 cm in S500A04 cm /6/ Weight Distribution Model Vertical Shipping Weight Horizontal Shipping Weight Horizontal Weight Distribution Front Back D E F lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg /0/

12 Duct System An air outlet collar is provided on vertical top flow units and all horizontal units to facilitate a duct connection. A flexible connector is recommended for discharge and return air duct connections on metal duct systems. Uninsulated duct should be insulated with a minimum of -inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit s performance will be adversely affected. If the unit is connected to existing ductwork, check the duct system to ensure that it has the capacity to accommodate the air required for the unit application. If the duct is too small, as in the replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repaired if necessary. The duct system should be sized to handle the design airflow quietly and efficiently. To maximize sound attenuation of the unit blower, the supply and return plenums should include an internal duct liner of fiberglass or constructed of ductboard for the first few feet. On systems employing a sheet metal duct system, canvas connectors should be used between the unit and the ductwork. If air noise or excessive airflow is a problem, the blower speed can be changed. Water Piping The proper water flow must be provided to each unit whenever the unit operates. To assure proper flow, use pressure/temperature ports to determine the flow rate. These ports should be located at the supply and return water connections on the unit. The proper flow rate cannot be accurately set without measuring the water pressure drop through the refrigerant-to-water heat exchanger. All source water connections on commercial units are fittings that accept a male pipe thread (MPT). Insert the connectors by hand, then tighten the fitting with a wrench to provide a leakproof joint. When connecting to an open loop (groundwater) system, thread any copper MPT fitting into the connector and tighten in the same manner as described above.

13 Water Quality In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. The heat exchanger coils in ground water systems may, over a period of time, lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualified service mechanic, as special solutions and pumping equipment are required. Hot water generator coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional flushing. Failure to adhere to the guidelines in the water quality table could result in loss of warranty. Units with cupronickel heat exchangers are recommended for open loop applications due to the increased resistance to build-up and corrosion, along with reduced wear caused by acid cleaning. Material opper 90/0 upronickel 6 Stainless Steel ph Acidity/Alkalinity Scaling alcium and (Total Hardness) (Total Hardness) (Total Hardness) Magnesium arbonate less than 50 ppm less than 50 ppm less than 50 ppm Hydrogen Sulfide Less than 0.5 ppm (rotten egg smell appears at 0.5 ppm) 0-50 ppm Less than ppm Sulfates Less than 5 ppm Less than 5 ppm Less than 00 ppm hlorine Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm hlorides Less than 0 ppm Less than 5 ppm Less than 00 ppm arbon Dioxide Less than 50 ppm 0-50 ppm 0-50 ppm orrosion Ammonia Less than ppm Less than ppm Less than 0 ppm Ammonia hloride 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 000 ppm ppm ppm LSI Index +0.5 to to to -0.5 Iron, FE + (Ferrous) Iron Fouling Bacterial Iron Potential < 0. ppm < 0. ppm < 0. ppm (Biological rowth) Less than ppm, above this level Less than ppm, above this level Less than ppm, above this level Iron Oxide deposition will occur deposition will occur deposition will occur Suspended Solids Erosion Threshold Velocity (Fresh Water) NOTES: rains = ppm divided by 7 mg/l is equivalent to ppm Less than 0 ppm and filtered for max. of 600 micron size Less than 0 ppm and filtered for max. of 600 micron size Less than 0 ppm and filtered for max. of 600 micron size < 6 ft/sec < 6 ft/sec < 6 ft/sec // ondensate Drain On vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the drain pan, a /4 in. PV female adapter and a flexible connecting hose. The female adapter may exit either the front or the side of the cabinet. The adapter should be glued to the field-installed PV condensate piping. On vertical units, a condensate hose is inside all cabinets as a trapping loop; therefore, an external trap is not necessary. Horizontal Drain onnection (omposite Drain Pan) On horizontal units, a PV stub or stainless steel tube is provided for condensate drain piping connection. An external trap is required (see below). If a vent is necessary, an open stand pipe may be applied to a tee in the field-installed condensate piping. NOTE: All units equipped with electronic condensate overflow protection. Unit Pitch for Drain PV coupling Vent (if needed) PV tube stub /8 in. per foot /'' Pitch PV tube stub.5 in..5 in. Drain

14 System leaning and Flushing leaning and Flushing Prior to start up of any heat pump, the water circulating system must be cleaned and flushed of all dirt and debris. If the system is equipped with water shutoff valves, the supply and return runouts must be connected together at each unit location (This will prevent the introduction of dirt into the unit, see Flushing with Water Shutoff Valve Equipped Systems illustration). The system should be filled at the water make-up connection with all air vents open. After filling, vents should be closed. Flushing with Water Shutoff Valve Equipped Systems eturn unout Supply unout ubber Hose unouts Initially onnected Together Mains The contractor should start the main circulator with the pressure reducing valve makeup open. Vents should be checked in sequence to bleed off any trapped air and to verify circulation through all components of the system. As water circulates through the system, the contractor should check and repair any leaks found in the piping system. Drain(s) at the lowest point(s) in the system should be opened for initial flush and blowdown, making sure water fill valves are set at the same rate. heck the pressure gauge at the pump suction and manually adjust the make-up water valve to hold the same positive pressure both before and after opening the drain valves. Flushing should continue for at least two hours, or longer if required, until drain water is clean and clear. The supplemental heater and/or circulator pump, if used, should be shut off. All drains and vents should be opened to completely drain the system. Short-circuited supply and return runouts should now be connected to the unit supply and return connections. efill the system with clean water. Test the system water for acidity and treat as required to leave the water slightly alkaline (ph 7.5 to 8.5). The specified percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVA systems only. Environol brand antifreeze is recommended. Once the system has been filled with clean water and antifreeze (if used), precautions should be taken to protect the system from dirty water conditions. Dirty water will result in system-wide degradation of performance, and solids may clog valves, strainers, flow regulators, etc. Additionally, the heat exchanger may become clogged which reduces compressor service life and can cause premature unit failure. In boiler/tower application, set the loop control panel set points to desired temperatures. Supply power to all motors and start the circulating pumps. After full flow has been established through all components including the heat rejector (regardless of season), air vented and loop temperatures stabilized, each of the units will be ready for check, test and start up and for air and water balancing. round Source Loop System heckout Once piping is completed between the unit pumping system and ground loop, final purging and charging of the loop is needed. A high pressure pump is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop itself. Antifreeze solution is used in most areas to prevent freezing. Flush the system adequately to remove as much air as possible; then pressurize the loop to a static pressure of PSI (summer) or PSI (winter). This is normally adequate for good system operation. Loop static pressure may decrease soon after initial installation, due to pipe expansion and loop temperature change. unning the unit for at least 0 minutes after the system has been completely purged of air will allow for the break-in period. It may be necessary to adjust static loop pressure (by adding water) after the unit has run for the first time. Loop static pressure will also fluctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This fluctuation is normal and should be considered when charging the system initially. Ensure the pump provides adequate flow through the unit by checking pressure drop across the heat exchanger. Usually.5-.0 gpm of flow per ton of cooling capacity is recommended in earth loop applications. 4

15 Open Loop round Water Systems Typical open loop piping is shown below. Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation. Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. Insure proper water flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures in unit capacity data tables in the specification catalog..5- gpm of flow per ton of cooling capacity is recommended in open loop applications. Due to only minor differences in flow rate from low to high, only one solenoid valve should be used. The valve should be sized for full flow. Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local codes, i.e. recharge well, storm sewer, drain field, adjacent stream or pond, etc. Most local codes forbid the use of sanitary sewer for disposal. onsult your local building and zoning departments to assure compliance in your area. Open System - roundwater Application Unit Supply Aux. Heat Supply Flexible Duct ollar ubber Bladder Expansion Tank Drain Solenoid Valve Flow ontrol Valve (on outlet of Solenoid Valve) Water Out Water In Disconnects (IfApplicable) ompressor Line Voltage Low Voltage to Thermostat and Valve P/T Plugs Vibration Absorbing Pad Strainer Boiler Drains For HX Flushing Shut Off Valves Shut Off Valves (to isolate solenoid valve while acid flushing) 5

16 Freeze Detection For Aurora Base ontrol, set SW-, FP, on the printed circuit board for applications using a closed loop antifreeze solution to 5 F [-9.4 ]. On applications using an open loop/ground water system (or closed loop no antifreeze), set this dip switch to 0 F [-. ], the factory default setting. (efer to the Dip Switch Field Selection table). For FX0 board, the red wire must be removed from PB- to change from 0 F [-. ], the factory default setting, to 5 F [-9.4 ]. Electrical onnections eneral Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric ode, whichever is applicable. Power onnection onnect the incoming line voltage wires to L and L of the contactor for single-phase unit. onsult the Electrical Data tables for correct fuse sizes. 08 Volt Operation All 08/0 units are factory wired for 0 volt operation. For 08 volt operation, the red and blue transformer wires must be switched on terminal strip PS. AUTION: When installing a unit with a Variable Speed EM blower motor in 460/60/ voltage, a neutral wire is required to allow proper unit operation. Aurora Base ontrol Box FX0 ontrol Box 6

17 Electrical Data PS Motor Model ated Voltage Voltage Min/Max ompressor M LA LA 5/60/ 04/ /60/ 98/ /5 65/60/ 8/ /5 5/60/ 04/ /60/ 98/ /5 65/60/ 8/ /5 5/60/ 04/ /60/ 98/ /5 65/60/ 8/ / /60/ 98/ /60/ 8/ / /60/ 98/ /60/ 8/ /5 08-0/60/ 98/ /60/ 8/ /60/ 87/ /5 460/60/ 44/ /5 08-0/60/ 98/ /60/ 8/ /60/ 87/ /60/ 44/ /5 08-0/60/ 98/ /60/ 8/ /60/ 87/ /60/ 44/ /5 08-0/60/ 98/ /60/ 87/ /60/ 4/ /5 575/60/ 57/ /5 08-0/60/ 98/ /60/ 87/ /60/ 4/ /5 575/60/ 57/ /5 08-0/60/ 98/ /60/ 87/ /60/ 4/ /60/ 57/ /5 08-0/60/ 98/ /60/ 87/ /60/ 4/ /60/ 57/ /5 HA circuit breaker in USA only 0/0/ Blower Motor FLA Total Unit FLA Min irc Amp Max Fuse/ HA 7

18 Electrical Data cont. 5-Speed EM Motor Model ated Voltage Voltage Min/Max ompressor M LA LA /60/ 98/ /60/ 8/ / /60/ 98/ /60/ 8/ /5 08-0/60/ 98/ /60/ 8/ /60/ 87/ /60/ 44/ /5 08-0/60/ 98/ /60/ 8/ /60/ 87/ /60/ 44/ /5 08-0/60/ 98/ /60/ 8/ /60/ 87/ /60/ 44/ /5 08-0/60/ 98/ /60/ 87/ /60/ 44/ /5 08-0/60/ 98/ /60/ 87/ /60/ 44/ /60/ 98/ /60/ 87/ /60/ 44/ /60/ 98/ /60/ 87/ /60/ 44/ HA circuit breaker in USA only 0/0/ Blower Motor FLA Total Unit FLA Min irc Amp Max Fuse/ HA 8

19 Electrical Data cont. Variable Speed EM Motor Model ated Voltage Voltage Min/Max ompressor M LA LA /60/ 98/ /60/ 8/ /60/ 98/ /60/ 8/ /60/ 98/ /60/ 8/ /60/ 87/ /60/ 44/ /5 08-0/60/ 98/ /60/ 8/ /60/ 87/ /60/ 44/ /5 08-0/60/ 98/ /60/ 8/ /60/ 87/ /60/ 44/ /60/ 98/ /60/ 87/ /60/ 44/ /60/ 98/ /60/ 87/ /60/ 44/ /60/ 98/ /60/ 87/ /60/ 44/ /60/ 98/ /60/ 87/ /60/ 44/ HA circuit breaker in USA only 0/0/ Blower Motor FLA Total Unit FLA Min irc Amp Max Fuse/ HA AUTION: When installing a unit with an variable speed EM blower motor in 460/60/ voltage, a neutral wire is required to allow proper unit operation. 9

20 Blower Performance Data Standard PS Motor Model 006 Blower Spd Blower Size Motor HP Airflow (cfm) at External Static Pressure (in. wg) H MH x 8 /0 ML* L H MH x 8 /0 ML* L H MH x 8 /0 ML* L H M 9 x 7 / L H M 9 x 7 / L H M 9 x 7 / L H M 9 x 7 / L H M 9 x 7 / L H M 0x0 / L H M 0 x 0 / L H M x L H M x L Factory settings are in Bold 0/0/ Airfl ow values are with dry coil and standard fi lter For wet coil performance fi rst calculate the face velocity of the air coil (Face Velocity [fpm] = Airfl ow [cfm] / Face Area [sq ft]). Then for velocities of 00 fpm reduce the static capability by 0.0 in. wg, 00 fpm by 0.08 in. wg, 400 fpm by 0. in. wg. and 500 fpm by 0.6 in. wg. * Setting for 65V operation. Setting Blower Speed - PS AUTION: Disconnect all power before performing this operation. HIH MEDIUM LOW FAN SPEED WIE PS BLOWE MOTO BODY 0

21 Blower Performance Data cont. 5-Speed EM Motor Model 05 Motor Spd Motor Tap Blower Size Motor HP Airflow (cfm) at External Static Pressure (in. wg) High 5 Med High Med 9 x 7 / Med Low Low High Med High Med 9 x 7 / Med Low Low High Med High Med 9 x 7 / Med Low Low High Med High Med 9 x 7 / Med Low Low High Med High Med 9 x 7 / Med Low Low High Med High Med x Med Low Low High Med High Med x Med Low Low High Med High Med x Med Low Low High Med High Med x Med Low Low /6/ Factory settings are in Bold 5-Speed EM Motor onnections Airfl ow values are with dry coil and standard in. fi lter - Black L - Orange - reen High Voltage onnections /6 in. L N N - Brown - Blue Y - ed 4 5 Low Voltage onnections /4 in. AUX - ray

22 Setting Blower Speed - Variable Speed EM Variable Speed EM Motor Model Max ESP Blower Size Motor hp x 7 / Air Flow Dip Switch Settings L M H x 7 / L M H x 7 / L M H x 7 / L M H x 7 / L M H x 0 / L M H x 0 / L M H x L M H x L M H Factory settings are at recommended L-M-H DIP switch locations. 09/6/ Shaded regions are recommended for best performance. It is acceptable to operate outside of this area as long as the WSHP operates within the guidelines of the Operating Limits table and orrection Factor tables. Lowest and Highest DIP switch settings are assumed to be L and H respectively. FM is controlled within ±5% up to the maximum esp. Max esp includes allowance for wet coil and standard fi lter Setting Blower Speed - Variable Speed EM Variable Speed EM blower motors have selectable speeds and are factory set for optimum performance. To change speeds on an FX0 control, use the Medium User Interface (MUI) to enter the MAINT menu to adjust the soft switches. When applicable, the speed settings may also be adjusted through the Building Automation System (BAS). AUTION: Disconnect all power before performing this operation.

23 Blower Performance Data cont. Setting Blower Speed - Variable Speed EM The AB board s Yellow onfi g LED will fl ash the current variable speed EM blower speed selections for low, med, and high continuously with a short pause in between. The speeds can also be confi rmed with the AID Tool under the Setup/EM Setup screen. The variable speed EM blower motor speeds can be fi eld adjusted with or without using an AID Tool. Variable Speed EM Setup with an AID Tool cont. EM SPEED INFO LOW SPEED: MED SPEED: 5 HIH SPEED: 7 Selecting YES will enter variable speed EM speed setup, while selecting NO will return to the previous screen. Variable Speed EM Setup without an AID Tool The blower speeds for Low ( only), Med (Y), and High (Y/Aux) can be adjusted directly at the Aurora AB board which utilizes the push button (SW) on the AB board. This procedure is outlined in the Variable Speed EM onfiguration Mode portion of the Aurora Base ontrol System section. Variable Speed EM Setup with an AID Tool A much easier method utilizes the AID Tool to change the airfl ow using the procedure below. First navigate to the Setup screen and then select EM Setup. This screen displays the current variable speed EM settings. It allows the technician to enter the setup screens to change the variable speed EM settings. hange the highlighted item using the and buttons and then press the button to select the item. WANT TO HANE? YES OPTION NO ENTE Variable Speed EM Speed Setup - These screens allow the technician to select the low, medium, and high blower speed for the variable speed EM blower motor. hange the highlighted item using the and buttons. Press the button to select the speed. EM SPEED INFO < LOW EM SPEED INFO LOW 4 5 < MED EM SPEED INFO LOW 4 5 MED < HIH OPTION ENTE OPTION ENTE OPTION ENTE After the high speed setting is selected the AID Tool will automatically transfer back to the EM Setup screen.

24 5-Speed EM onstant Torque Motors The 5-Speed EM is a onstant Torque EM motor and delivers airflow similar to a PS but operates as efficiently as a Variable Speed EM motor. Because it s an EM motor, the 5-Speed EM can ramp slowly up or down like the Variable Speed EM motor. There are 5 possible speed taps available on the 5-Speed EM motor with # being the lowest airflow and #5 being the highest airflow. These speed selections are preset at the time of manufacture and are easily changed in the field if necessary. 5-Speed EM Benefits: - High efficiency - Soft start - 5 speeds with up to 4 speeds on-line - Built in logic allows air flow to change with, Y, Y and W signals - Super efficient low airflow continuous blower setting () If more than one tap are energized at the same time, built in logic gives precedence to the highest tap number and allows air flow to change with, Y, Y and W signals. Each of those 5 speeds has a specific Torque value programmed into the motor for each speed selection. As static pressure increases, airflow decreases resulting in less torque on the rotor. The motor responds only to changes in torque and adjusts its speed accordingly. The 5-Speed EM motor is powered by line voltage but the motor speed is energized by 4VA. Power onnection - /6 in. quick connects - Line (orange wire) to L, round (green wire) to, Line (for 08V-0V units) to N (brown wire). Signal onnection - /4 in. quick connects - ommon to, 4VA to Taps #-5. Applying 4VA power between any of the motor taps -5 (/4 in. quick connects) and common will signal the motor to run and regulate torque at the programmed level. The tap input voltage must be in the range -VA. The 5-Speed EM will have less variation over the operating static pressure range versus a PS motor as well as a significant watts reduction due to the high motor efficiency. Thermal Protection - Motor is electronically protected. Locked otor Amps - If motor speed decreases below a programmed stall speed, the motor will shut down and after a delay period, the control will attempt to restart the motor. The 5-Speed EM speed tap selections are as follows: The blue wire should be placed on the speed tap desired for the () continuous blower setting factory wired to Tap. The red wire should be placed on the speed tap desired during compressor operation (Y signal) factory wired to Tap or 4. The gray wire is not factory wired to the motor and is tied to the wire harness. It is field connected and can be used with ht/cl thermostats or IntelliZone to deliver the required air flow for the Y signal. The tan wire should be placed on the speed tap desired for auxiliary heat (W signal) factory wired to Tap 5. 4

25 B SEIES INSTALLATION MANUAL Wiring Schematics Aurora Base ontrol 08-0/60/ with PS ompressor rn P PS Blower Motor H M L Brn Wht ap Airflow Settings White S Blue ap Black ed Tan T T L L Note reen (9) Black (95) round Neutral Disconnect L L Unit Power Supply /60/ Black B Black ed (97) L L Note ed 08V L L Blue 0V 65V Black Transformer 4V Yellow Black/White Note Isolation Valve ed (5) reen (50) White (5) Note ed (5) P P Accessory elay Operation SW-4 SW-5 ycle with Blower On On ycle with ompressor Off Off Water Valve Slow Open On Off Outdoor Air Damper Off On DH W Y Y O/B LO P9 F F HI LO ES LS ALM AL A OM A NO A N LO O/B Y Y W DH F K5 K6 reen S485 NET Aurora Timing Events Event Normal Mode Test Mode andom Start Delay 5 to 80 seconds second ompressor On Delay 5 seconds < second ompressor Minimum On Time minutes 5 seconds ompressor Short ycle Delay 4 minutes 5 seconds Blower Off Delay 0 seconds seconds Fault ecognition Delay High Pressure Less than second Less than second Start-Up Bypass Low Pressure Fault ecognition Delay Low Pressure Start-Up Bypass Low Water/Air oil Limit Fault ecognition Delay Low Water/Air oil Limit Fault ecognition Delay ondensate Overflow Thermostat all ecognition Time Auxiliary Heat Staging Delay Emergency Heat Staging Delay minutes 0 seconds 0 seconds 0 seconds minutes 0 seconds 0 seconds 0 seconds 0 seconds 0 seconds seconds seconds 5 minutes 0 seconds minutes 7.5 seconds Water Valve Slow Open Delay 90 seconds 90 seconds eheat Delay 0 seconds 0 seconds P8 JW B White () S485 NET K4 Black () LED5 A- B+ P7 Violet (4) K Black (5) K S485 EXP P5 Aurora Base ontrol (AB) LED4 4V P EV EV FP FP FP FP LPS LPS HPS HPS P4 SW A- B+ P6 N/A O EH EH P Brown () ondensate K V Orange (0) V Orange (0) FD Yellow T 470 esistor Yellow Status Y 470 Fault PWM P Off On FP 5 F/0 F FP 5 F/0 F V B/O Acc Dip 4 Acc Dip 5 Dual/Single 6 L Pulse/ontinuous 7 eheat/normal 8 SW LP Blue (07) Blue (08) HP Black (09) Black (0) onfig Y F FM Black/White Aurora LED Flash odes Slow Flash second on and second off Fast Flash 00 milliseconds on and 00 milliseconds off Flash ode 00 milliseconds on and 400 milliseconds off with a second pause before repeating andom Start Delay Status LED (LED, reen) Fast Flash onfiguration LED (LED, Yellow) Fast Flash Fault LED (LED, ed) Fast Flash Status LED (LED, reen) onfiguration LED (LED, Yellow) Fault LED (LED, ed) Normal Mode ON No Software Overide Flash EM Setting Normal Mode OFF ontrol is Non-Functional OFF DIP Switch Overide Slow Flash Input Fault Lockout Flash ode Test Mode Slow Flash EM onfigure Mode Fast Flash High Pressure Lockout Flash ode Lockout Active Fast Flash eset onfigure Mode Off Low Pressure Lockout Flash ode Dehumidification Mode Flash ode Low Air oil Limit Lockout - FP Flash ode 4 eserved Flash ode Low Water oil Limit Lockout - FP Flash ode 5 eserved Flash ode 4 eserved Flash ode 6 Load Shed Flash ode 5 ondensate Overflow Lockout Flash ode 7 ESD Flash ode 6 Over/Under Voltage Shutdown Flash ode 8 eserved Flash ode 7 eserved Flash ode 9 eserved Flash ode 0 Air/Water oil Limit Sensor Error Flash ode Yellow Optional, factory installed unit mounted disconnect. Swap blue and red leads for 08V operation. Optional, factory installed internal isolation valve. L Factory Low Voltage Wiring Factory Line Voltage Wiring Field Low Voltage Wiring Field Line Voltage Wiring Optional Block D Voltage PB Traces Field Zone Sensor Wiring Internal Junction Quick onnect Terminal Field Wiring Lug round elay ontacts N.O., N.. apacitor Fuse ompressor ontactor O ondensate Overflow Sensor ES Emergency Shutdown HP High Pressure Switch LP Low Pressure Switch FD Freeze Detection Sensor F Fuse Notes: Legend T Y Thermistor elay oil Switch - ondensate Overflow Switch - High pressure Switch - Low pressure Polarized connector SW Push button SW DIP package 8 position B Blower elay V eversing Valve oil Light Emitting Diode - reen Light Emitting Diode - Yellow Light Emitting Diode - ed 97P87-0 /08/0 5

26 T B SEIES INSTALLATION MANUAL Wiring Schematics cont. Aurora Base ontrol 460/60/ with Variable Speed EM ompressor L T ed T L T T Yellow T Note Black Phase uard Orange Monitor T (PM) Note L L L Brown PB reen (9) N ray (94) L round Neutral Disconnect Unit Power Supply 460/60/ w/neutral Black (7) Black (54) L Black (95) L L White (8) ed (9) Blue (55) L Yellow (96) L L ed (56) L ed (97) L L Black (54) Blue (55) ed (56) Blue 460V Black Orange Brown reen Note 4 Transformer PM Y-OUT Y Yellow 4V Black/White 4 5 P Yellow (9) Black/White (9) Variable Speed EM Blower Motor esistor PWM FM P Note Isolation Valve V V FD LP HP ed (5) reen (50) White (5) ed (5) Note P P ES LS ALM AL LO O/B Y W DH DH W Y Y O/B LO P9 F F HI A OM A NO A N Y Accessory elay Operation SW-4 SW-5 ycle with Blower On On ycle with ompressor Off Off Water Valve Slow Open On Off Outdoor Air Damper Off On F K5 K6 reen S485 NET Aurora Timing Events Event Normal Mode Test Mode andom Start Delay 5 to 80 seconds second ompressor On Delay 5 seconds < second ompressor Minimum On Time minutes 5 seconds ompressor Short ycle Delay 4 minutes 5 seconds Blower Off Delay 0 seconds seconds Fault ecognition Delay High Pressure Less than second Less than second Start-Up Bypass Low Pressure Fault ecognition Delay Low Pressure Start-Up Bypass Low Water/Air oil Limit Fault ecognition Delay Low Water/Air oil Limit Fault ecognition Delay ondensate Overflow Thermostat all ecognition Time Auxiliary Heat Staging Delay Emergency Heat Staging Delay P8 minutes 0 seconds 0 seconds 0 seconds minutes 0 seconds 0 seconds 0 seconds 0 seconds 0 seconds seconds seconds 5 minutes 0 seconds minutes 7.5 seconds Water Valve Slow Open Delay 90 seconds 90 seconds eheat Delay 0 seconds 0 seconds JW S485 NET K4 A- B+ LED5 P7 Violet (4) K Black (5) K LO S485 EXP P5 Aurora Base ontrol (AB) A- B+ LED4 P6 N/A O 4V Brown () ondensate P EH EV EV FP FP FP FP LPS LPS HPSHPS K Orange (0) SW Orange (0) EH Yellow P 6 Yellow Status Y Blue (07) Fault P4 FP 5 F/0 F FP 5 F/0 F V B/O Acc Dip Acc Dip Dual/Single L Pulse/ontinuous eheat/normal Aurora LED Flash odes Slow Flash second on and second off Fast Flash 00 milliseconds on and 00 milliseconds off Flash ode 00 milliseconds on and 400 milliseconds off with a second pause before repeating andom Start Delay Status LED (LED, reen) Fast Flash onfiguration LED (LED, Yellow) Fast Flash Fault LED (LED, ed) Fast Flash Status LED (LED, reen) onfiguration LED (LED, Yellow) Fault LED (LED, ed) Normal Mode ON No Software Overide Flash EM Setting Normal Mode OFF ontrol is Non-Functional OFF DIP Switch Overide Slow Flash Input Fault Lockout Flash ode Test Mode Slow Flash EM onfigure Mode Fast Flash High Pressure Lockout Flash ode Lockout Active Fast Flash eset onfigure Mode Off Low Pressure Lockout Flash ode Dehumidification Mode Flash ode Low Air oil Limit Lockout - FP Flash ode 4 eserved Flash ode Low Water oil Limit Lockout - FP Flash ode 5 eserved Flash ode 4 eserved Flash ode 6 Load Shed Flash ode 5 ondensate Overflow Lockout Flash ode 7 ESD Flash ode 6 Over/Under Voltage Shutdown Flash ode 8 eserved Flash ode 7 eserved Flash ode 9 eserved Flash ode 0 Air/Water oil Limit Sensor Error Flash ode Blue (08) Black (09) onfig Y Black (0) Off PWM FM P SW F On Black/White Yellow Violet (4) Blue (4) Yellow (5) reen/yellow (8) Optional, factory installed unit mounted disconnect. Optional, factory installed internal isolation valve. Optional, factory installed phase guard. 4 Optional, factory installed phase guard. The yellow transformer wire shall be connected directly to the PU board, if this option is not installed. L Factory Low Voltage Wiring Factory Line Voltage Wiring Field Low Voltage Wiring Field Line Voltage Wiring Optional Block D Voltage PB Traces Field Zone Sensor Wiring Internal Junction Quick onnect Terminal Field Wiring Lug round elay ontacts N.O., N.. apacitor Fuse ompressor ontactor O ondensate Overflow Sensor ES Emergency Shutdown HP High Pressure Switch LP Low Pressure Switch FD Freeze Detection Sensor F Fuse Notes: Legend T Y Thermistor elay oil Switch - ondensate Overflow Switch - High pressure Switch - Low pressure Polarized connector SW Push button SW DIP package 8 position B Blower elay V eversing Valve oil PM Phase uard Monitor H eheat Valve oil Light Emitting Diode - reen Light Emitting Diode - Yellow Light Emitting Diode - ed 97P88-07 /08/0

27 L T B SEIES INSTALLATION MANUAL Wiring Schematics cont. Aurora Base ontrol 460/60/ with 5-Speed EM T T Note 4 ed T Black Phase uard Monitor (PM) L L L L T Yellow T L L T Unit Power Supply 460/60/ Black (7) White (8) ed (9) Note reen (9) round Neutral Disconnect Black (95) L L Yellow (96) L L ed (97) L L reen Note 5 Blue 460V Black Brown Orange N 5-Speed EM Blower Motor PM Y-OUT Y Yellow Transformer 4V Black/White 5 4 Note 5 Yellow (9) Black/White (9) ray (0) Tan () Note 6 ed () Blue () V esistor FD LP HP Black (5) V Note Isolation Valve ed (5) reen (50) White (5) ed (5) Note P P ES LS ALM AL LO O/B Y W DH DH W Y Y O/B LO P9 F F HI A OM A NO A N Y F K5 K6 LED4 S485 NET P8 JW LED5 S485 NET K4 A- B+ P7 Violet (4) K Black (5) K LO S485 EXP P5 Aurora Base ontrol (AB) A- B+ P6 N/A O EH EV EV FP FP FP FP LPS LPS HPS HPS K Orange (0) SW Orange (0) EH Yellow P Yellow Status Y Blue (07) Fault P4 FP 5 F/0 F FP 5 F/0 F V B/O Acc Dip Acc Dip Dual/Single L Pulse/ontinuous eheat/normal Blue (08) Black (09) onfig Y Black (0) Off PWM FM P SW F On Black/White Yellow 5-Speed EM Low Voltage onnections Model TAP- TAP- TAP- TAP-4 TAP-5 05 Blue ed ray 08 Blue ed ray 0 Blue ed ray 04 Blue ed ray 00 Blue ed ray 06 Blue ed ray 04 Blue ed ray 04 Blue ed ray 048 Blue ed ray 060 Blue ed ray 070 Blue ed ray Notes: - Optional, factory installed unit mounted disconnect. - Optional, factory installed internal isolation valve. - Optional, factory installed phase guard. 4 - Optional, factory installed phase guard. The yellow transformer wire shall be connected directly to the PU board, if this option is not installed. 5 - efer to the 5-Speed EM Low Voltage onnection Table. 6 - Wire is provided with the unit but not connected to the 5-Speed EM. Legend Accessory elay Operation SW-4 SW-5 ycle with Blower On On ycle with ompressor Off Off Water Valve Slow Open On Off Outdoor Air Damper Off On Aurora Timing Events Event Normal Mode Test Mode andom Start Delay 5 to 80 seconds second ompressor On Delay 5 seconds < second ompressor Minimum On Time minutes 5 seconds ompressor Short ycle Delay 4 minutes 5 seconds Blower Off Delay 0 seconds seconds Fault ecognition Delay High Pressure Less than second Less than second Start-Up Bypass Low Pressure Fault ecognition Delay Low Pressure Start-Up Bypass Low Water/Air oil Limit Fault ecognition Delay Low Water/Air oil Limit Fault ecognition Delay ondensate Overflow Thermostat all ecognition Time Auxiliary Heat Staging Delay Emergency Heat Staging Delay reen minutes 0 seconds 0 seconds 0 seconds minutes 0 seconds 0 seconds 0 seconds 0 seconds 0 seconds seconds seconds 5 minutes 0 seconds minutes 7.5 seconds Water Valve Slow Open Delay 90 seconds 90 seconds eheat Delay 0 seconds 0 seconds Brown () ondensate Aurora LED Flash odes Slow Flash second on and second off Fast Flash 00 milliseconds on and 00 milliseconds off Flash ode 00 milliseconds on and 400 milliseconds off with a second pause before repeating andom Start Delay Status LED (LED, reen) Fast Flash onfiguration LED (LED, Yellow) Fast Flash Fault LED (LED, ed) Fast Flash Status LED (LED, reen) onfiguration LED (LED, Yellow) Fault LED (LED, ed) Normal Mode ON No Software Overide Flash EM Setting Normal Mode OFF ontrol is Non-Functional OFF DIP Switch Overide Slow Flash Input Fault Lockout Flash ode Test Mode Slow Flash EM onfigure Mode Fast Flash High Pressure Lockout Flash ode Lockout Active Fast Flash eset onfigure Mode Off Low Pressure Lockout Flash ode Dehumidification Mode Flash ode Low Air oil Limit Lockout - FP Flash ode 4 eserved Flash ode Low Water oil Limit Lockout - FP Flash ode 5 eserved Flash ode 4 eserved Flash ode 6 Load Shed Flash ode 5 ondensate Overflow Lockout Flash ode 7 ESD Flash ode 6 Over/Under Voltage Shutdown Flash ode 8 eserved Flash ode 7 eserved Flash ode 9 eserved Flash ode 0 Air/Water oil Limit Sensor Error Flash ode Factory Low Voltage Wiring Factory Line Voltage Wiring Field Low Voltage Wiring Field Line Voltage Wiring Optional Block D Voltage PB Traces Field Zone Sensor Wiring Internal Junction Quick onnect Terminal L Field Wiring Lug round elay ontacts N.O., N.. apacitor Fuse ompressor ontactor O ondensate Overflow Sensor ES Emergency Shutdown HP High Pressure Switch LP Low Pressure Switch FD Freeze Detection Sensor F Fuse T Y SW Push button SW DIP package 8 position B Blower elay V eversing Valve oil PM Phase uard Monitor H eheat Valve oil Thermistor elay oil Switch - ondensate Overflow Switch - High pressure Switch - Low pressure Polarized connector Light Emitting Diode - reen Light Emitting Diode - Yellow Light Emitting Diode - ed 97P89-07 /8/ 7

28 P B SEIES INSTALLATION MANUAL Wiring Schematics cont. FX0 ontrol /60/ with PS rn PS Blower Motor H M L D09 D08 D07 D0 D05 D04 D0 D0 D Note 9 reen (9) Black (95) ed (97) round Neutral Disconnect L L L L L L Unit Power Supply /60/ OUND 4VA om A4 A A5 A A A5 Johnson FX-0 Wht Brn White Black (7) B 4VA J8 O 5VD K Brown (60) 4 AI Brown (6) 5 - AI5 + - AI4 + AI A4 A4 AI 5VD 4 A5 A AI 5 6 A A LED 7 5VD 8 A A A Black Yellow (50 ) J 9 PWM K 40 PWM om Note 6 ray (68) 4 PWM J7 P Transformer Yellow (5) PB Black/White (6) reen/yellow (7) Black (5) Yellow (50 ) Blue (0) ompressor S Blue ap Black ed Blue (55) White (6) FD White/Blue (6) Black (6) DA ed () Black (4) Brown () Violet (5) Yellow (8) reen (70) Orange (7) Yellow () Blue (7) ray (65) Orange (66) Orange/White (67) Note Blue () ES OS Black/ed (64) LP DF/FP Note 4 ed () ap T T Airflow Settings L L ray (65) Black (4) Brown () Yellow (5 ) Violet (5) Yellow/White (5) Note 7 Yellow/ed (5) Orange (66) Orange/White (67) J0 4 4VA om P ray/white (4) 4 DI Black (5) 44 DI reen (70) 45 DI0 Orange (7) 46 DI9 Blue (7) 47 DI8 Yellow ( ) 48 DI7 J9 Black () 49 DI /4/5/6/ om Violet () 50 DI6 ed (4) 5 DI5 ray (6) 5 DI4 Blue (7) 5 DI Pink (5) 54 DI Black/White (9) 55 9VD Orange (0) 56 DI Yellow (8) Note Black (F0) 0 Black (F9) 9 Black (F8) 8 Black (F7) 7 Black (F6) 6 Black (F5) Notes: 5 Black (F4) 4 Note Isolation Valve Black (F) Black (F) Black (F) Black (F0) 0 Black (F9) Black (F8) Black (F7) Black (F6) Black (F5) Black (F4) Black (F) Black (F) Black (F) Black ed 08V Blue 0 V 65V Yellow (0) ray (9) Yellow (8) Yellow (7) Yellow (J) Violet (5) Brown () Yellow () Disconnect for 5 degree freeze detection limit Acc output is cycled with the compressor Acc output is cycled with the blower. 4,, Y, Y, and inputs are for use with a wall mount thermostat. TO, S, S, AI, and SS are for use with a TAXXJ0 zone sensor 5 Network controllable 4VA output. 6 Network controllable PWM output. 7 Wire #5 can be used to connect a field supplied and installed 0-5 VD humidity transmitter. 8 Not Used Bundle in the air handler 9 Optional, factory installed unit mounted disconnect Optional, factory installed internal isolation valve Swap blue and red leads for 08V operation 4 Network configurable input ed (87) reen (86) White (88) Black () reen/yellow (8) Note 4 TB Terminal Board 4VA () Black () 4V OM () Black (L) Alarm (L) Black (X) Note Acc (X) Black (X) Note Acc (X) Black () Blower () Black (O) ev Valve (O) Black (Y) omp (Y) Black (Y) omp (Y) Setpoint Shift (SS) Zone Sensor Terminal Black () Black (SS) Black (44) Black (AI) AI OM (AI) oom Sensor (S) Sensor OM (S) Temp Occ (TO) Alarm irc A (L) Zone Sensor Terminal Zone Sensor Terminal Zone Sensor Terminal 5 Zone Sensor Terminal 6 Black (S) Alarm irc B (L) ray () Note 5 Blue (0) Yellow (J) Yellow (J) Orange (7) Black (6) Black (5) White (4) Violet () Yellow (J) Black () HP Black/White Yellow ed () Black (4) PB Yellow (5) Yellow (0) Yellow (7) Black/White (6) Note 5 Yellow () V Orange (40) Black/White (4) B Black (74) Violet (8) Black/ White (4) reen /Yellow (57) Note P Black (L) Black (L) Yellow (50) Black (74) B T T A Legend Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring elay coil Optional block D Voltage PB traces Field Zone Sensor Wiring apacitor w/ bleed resistor Switch - ondensate overflow Internal junction Switch - High pressure Quick connect terminal Switch - Low pressure L Field wire lug Polarized connector round Open Jumper elay ontacts- N.O., N.. ectified ompressor P Solenoid Plug losed Jumper ompressor Solenoid - ompressor ontactor OS - Occupied Switch O - ondensate Overflow Sensor PB, PB - Power blocks P - ompressor Proving P- Pump elay S - ompressor Solenoid B- Blower elay DA - Discharge Air Temperature Sensor P - ectified Solenoid ompressor Plug DF/FP Dirty Filter or Blower Proving V - eversing Valve coil DH - Dehumidification Switch or Humidistat TB - Terminal Board ES - Emergency Shutdown FD - Freeze Detection HP - High Pressure Switch PM - Phase uard Module LP - Low Pressure Switch Blue (0) 97P80-0 //09 8

29 P B SEIES INSTALLATION MANUAL Wiring Schematics cont. FX0 ontrol 460/60/ with Variable Speed EM ompressor T T 4 T Note 0 ed Yellow Black T Phase uard Monitor (PM) L L L T T Black (7) White (8) ed (9) Note 9 reen (9) round ray (94) Neutral Disconnect Black (54) L Black (95) L L Blue (55) L Yellow (96) L L ed (56) L ed (97) L L L L L OUND 4VA om Johnson FX-0 4VA Transformer ed () Black (4) Brown () Violet (5) Yellow (8) Yellow (5) Black/White (6) reen/yellow (7) D09 D08 A4 D07 D0 A A5 A A D05 D04 A5 D0 D0 D0 Orange Brown 5VD AI - AI5 + - AI4 + AI6 A4 A4 AI 5VD A5 A AI A A LED 5VD A A A PWM PWM om PWM 4VA om Note Isolation Valve ed (87) reen (86) White (88) Blue (0) ed () Black (4) Brown () Violet (5) Yellow (8) reen (70) Orange (7) Yellow () Blue (7) ray (65) DI Orange (66) DI DI0 Orange/White (67) ray (6) DI9 Black (76) Black (76) DI8 DI7 DI /4/5/6/ om PB Note Blue () ES OS LP DF/BP P O Brown (60) Brown (6) FD DA White (6) White/Blue (6) Black (6) Black/ed (64) ray (65) Note 7 Yellow (5) Yellow/White (5) Yellow/ed (5) Orange (66) Orange/White (67) Yellow (50) DI6 Note 6 ray (68) Black (5) reen (70) Orange (7) Blue (7) DI5 DI4 DI DI 9VD DI J7 Yellow () Black () Violet () ed (4) ray (6) Blue (7) Pink (5) Black/White (9) Orange (0) K K J8 J J0 J9 Black (F0) Black (F9) Black (F8) Black (F7) Black (F6) Black (F5) Black (F4) Black (F) Black (F) Black (F) Black (F0) Black (F9) Black (F8) Black (F7) Black (F6) Black (5) Black (F5) Black (F4) Black (F) Black (F) Black (F) Yellow (50) Blue (0) Blue EM Blower Motor Notes: 0 Unit Power Supply 460/60/ w/neutral Orange Brown PB Black Blue 460V Black/White Yellow - Disconnect for 5 degree freeze detection limit. - Acc output is cycled with the compressor. - Acc output is cycled with the blower. 4 -,, Y, Y, and inputs are for use with a wall mount thermostat. TO, S, S, AI, and SS are for use with a TAXXJ0 zone sensor. 5 - Network controllable 4VA output. 6 - Network controllable PWM output. 7 - Wire #5 can be used to connect a field supplied and installed 0-5 VD humidity transmitter. 9 - Optional, factory installed unit mounted disconnect 0 - Optional, factory installed phase guard - Optional, factory installed phase guard. The yellow transformer wire shall be connected directly to the PB- board, if this option is not installed. - Optional, factory installed internal isolation valve. reen/yellow (8) Note 4 TB Terminal Board 4VA () Black () Note PM Y-OUT Yellow (9) ed () Black/ White (9) Black (4) Black () 4V OM () Black (L) Alarm (L) Black (X) Note Acc (X) Black (X) PB Yellow (5) Yellow (0) Yellow (7) Black/White (6) Note Acc (X) Black () Blower () Black (O) ev Valve (O) Black (Y) omp (Y) Black (Y) omp (Y) Setpoint Shift (SS) Zone Sensor Terminal AI OM (AI) Zone Sensor Terminal oom Sensor (S) Zone Sensor Terminal Black () Sensor OM (S) Black (SS) Zone Sensor Terminal 5 Black (44) Temp Occ (TO) Zone Sensor Terminal 6 Black (AI) Alarm irc A (L) eheat Enable Black (S) Alarm irc B (L) (Dehumidistat) Black (L) Violet (8) Violet () Black/ White Yellow (0) (4) Yellow () ray (9) H ray (75) Blue Yellow (8) Yellow (7) Yellow (J) Dual Violet (5) apacity Units Only Brown () Yellow () Black (L) ray () Note 5 Blue (0) Yellow (J) Yellow (J) Orange (7) V Black (6) Orange (40) Note 0 Black/ Black (5) White (9) White (4) Black/White (4) Violet () Yellow (J) Black () HP reen/yellow (57) Variable Speed EM Blower 5 Motor 0 P Yellow (50) B T T A N Y P ray/white (4) Black (54) Blue (55) ed (56) P reen S Legend Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring elay coil Optional block D Voltage PB traces apacitor w/ bleed resistor Field Zone Sensor Wiring Switch - ondensate overflow Internal junction Switch - High pressure Quick connect terminal Switch - Low pressure L Field wire lug Polarized connector round Open Jumper elay ontacts- N.O., N.. ectified ompressor P Solenoid Plug losed Jumper ompressor Solenoid - ompressor ontactor OS - Occupied Switch O - ondensate Overflow Sensor PB, PB - Power blocks P - ompressor Proving P- Pump elay S - ompressor Solenoid B- Blower elay DA - Discharge Air Temperature Sensor P - ectified Solenoid ompressor Plug DF/BP Dirty Filter or Blower Proving V - eversing Valve coil DH - Dehumidification Switch or Humidistat TB - Terminal Board ES - Emergency Shutdown FD - Freeze Detection Sensor HP - High Pressure Switch PM - Phase uard Module LP - Low Pressure Switch H - eheat Valve oil 97P80-09 /9/ 9

30 P B SEIES INSTALLATION MANUAL reen/yellow (57) L T Phase uard Monitor (PM) L L L D09 D08 D07 D0 D05 D04 D0 D0 D0 0 9 Note reen (9) Black (95) Yellow (96) ed (97) Note 9 round Neutral Disconnect L L L L L L Black PB P Yellow (50) Page Transformer Note 0 Black (7) White (8) ed (9) Yellow (5) Black/White (6) reen/yellow (7) OUND 4VA om A4 A A5 A A A5 Johnson FX-0 Black (5) ompressor T T T ed Yellow Black T T L L J8 5VD 4VA AI AI AI AI6 A4 A4 AI 5VD 4 A5 A 5 AI 6 A A LED 7 5VD 8 A A A ed () Black (4) J 9 PWM 40 PWM om 4 PWM Brown () Violet (5) Yellow (8) reen (70) Orange (7) Yellow () Blue (7) ray (65) Orange (66) O K Brown (60) Orange/White (67) Brown (6) FD DA White (6) White/Blue (4) Black (6) Black/ed (64) ray (65) Note 7 Yellow (5) Yellow/White (5) Yellow/ed (5) Orange (66) Orange/White (67) Yellow (50) K J0 4 4VA om 4 DI 44 DI 45 DI0 46 DI9 47 DI8 48 DI7 Note 6 ray (68) P ray/white (4) Black (5) reen (70) Orange (7) Blue (7) Yellow () Tan Blue (0) PB Black () DF/BP Violet () Note ed (4) Note 4 Blue () ray (6) LP Blue (7) ES Pink (5) Yellow (50) ed () Black (4) Brown () Violet (5) Yellow (8) Black (F0) Black (F9) Black (F8) Black (F7) Black (F6) Black (F5) Black (F4) Black (F) Black (F) Black (F) Black (F0) Black (F9) Black (F8) Black (F7) Black (F6) Black (F5) Black (F4) Black (F) J9 49 DI /4/5/6/ om 50 DI6 5 DI5 5 DI4 5 DI 54 DI 55 9VD 56 DI J7 Black (F) Black (F) Yellow (0) ray (9) Yellow (8) Yellow (7) Yellow (J) Violet (5) Brown () Yellow () ray () Note 5 Blue (0) Yellow (J) Yellow (J) Orange (7) Black (6) Black (5) White (4) Yellow (J) Black () Yellow ed () Black (4) Yellow (5) Yellow (0) Yellow (7) Black/White (6) V Orange (40) Note 0 Black/ White (9) Black/White (4) Blue (0) Violet (8) Violet () Yellow () Notes: Disconnect for 5 degree freeze detection limit. Acc output is cycled with the compressor. Acc output is cycled with the blower. 4,, Y, Y, and inputs are for use with a wall mount thermostat. TO, S, S, AI, and SS are for use with a TAXXJ0 zone sensor. 5 Network controllable 4VA output. 6 Network controllable PWM output. 7 Wire #5 can be used to connect a field supplied and installed 0-5 VD humidity transmitter. Note 8 Not Used Bundle in the air handler. Isolation 9 Optional, factory installed unit mounted disconnect Valve 0 Optional, factory installed phase guard Optional, factory installed phase guard. The yellow transformer wire shall be connected directly to the PB-, if this option is not installed. Optional, factory installed internal isolation valve. ed 4 Network configurable input. (87) 5 efer to the 5-Speed EM Motor Low Voltage onnection Table. reen (86) White reen/yellow (8) (88) Note 4 TB Terminal Board 4VA () Black () Black () 4V OM () Black (L) Alarm (L) Black (X) Note Acc (X) Black (X) Note Acc (X) Black () Blower () Black (O) ev Valve (O) Black (Y) omp (Y) Black (Y) omp (Y) Setpoint Shift (SS) Zone Sensor Terminal AI OM (AI) Zone Sensor Terminal oom Sensor (S) Zone Sensor Terminal Black () Sensor OM (S) Black (SS) Zone Sensor Terminal 5 Black (44) Temp Occ (TO) Zone Sensor Terminal 6 Black (AI) Alarm irc A (L) Black (S) Alarm irc B (L) Black (L) Black/White (9) OS Orange (0) Violet () HP Black/White Note 5 Note PM Y-OUT Yellow (9) Black/ White (9) Black/ White (4) B 5-Speed EM Blower Motor T T A Y 5 4 Wiring Schematics cont. FX0 ontrol 460/60/ with 5-Speed EM ed Tan N L 5-Speed EM Low Voltage onnections Model TAP- TAP- TAP- TAP-4 TAP-5 05 Blue ed ray 08 Blue ed ray 0 Blue ed ray 04 Blue ed ray 00 Blue ed ray 06 Blue ed ray 04 Blue ed ray 04 Blue ed ray 048 Blue ed ray 060 Blue ed ray 070 Blue ed ray Tan Blue 460V Unit Power Supply 460/60/ Note 5 Blue Brown Black Black (L) Orange ed reen Legend Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring elay coil Optional block D Voltage PB traces apacitor w/ bleed resistor Field Zone Sensor Wiring Switch - ondensate overflow Internal junction Switch - High pressure Quick connect terminal Switch - Low pressure L Field wire lug Polarized connector round Open Jumper elay ontacts- N.O., N.. ectified ompressor P Solenoid Plug losed Jumper ompressor Solenoid - ompressor ontactor OS - Occupied Switch O - ondensate Overflow Sensor PB, PB - Power blocks P - ompressor Proving P- Pump elay S - ompressor Solenoid B- Blower elay DA - Discharge Air Temperature Sensor P - ectified Solenoid ompressor Plug DF/BP Dirty Filter or Blower Proving V - eversing Valve coil DH - Dehumidification Switch or Humidistat TB - Terminal Board ES - Emergency Shutdown FD - Freeze Detection Sensor HP - High Pressure Switch PM - Phase uard Module LP - Low Pressure Switch H - eheat Valve oil 97P8-04 /8/ 0

31 ontrols - Aurora Base ontrol Aurora Base ontrol Field Selectable Options via Hardware DIP Switch (SW) Test/onfiguration Button (See SW Operation Table) Test Mode The control is placed in the test mode by holding the push button switch SW for - 5 seconds. In test mode most of the control timings will be shortened by a factor of sixteen (6). LED (green) will flash at second on and second off. Additionally, when entering test mode LED (red) will flash the last lockout one time. Test mode will automatically time out after 0 minutes. ontrol Features Single or Dual apacity ompressors Either single or dual capacity compressors can be operated. Variable Speed EM Blower Motor Option A traditional variable speed EM blower motor can be driven directly using the onboard PWM output. Three blower speeds are available based upon the, Y, and Y/W input signals to the board. The blower speeds can be changed either by the variable speed EM manual configurations mode method or by using the Aurora AID Tool directly. All three blower speeds can be set to the same speed if desired. 5-Speed Blower Motor Option A 5-speed blower motor will be driven directly using the thermostat connections. Any three of the, Y, or Y/W signals can drive any of the 5 available pre-programmed blower speeds on the motor. Other ontrol Features andom 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 ondensate 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.. Modbus communication (master) (where applicable) Modbus communication (slave) (where applicable) Test mode can be exited by pressing and holding the SW button for to 5 seconds or by cycling the power. Test mode will automatically be exited after 0 minutes. Variable Speed EM onfiguration Mode The control is placed in variable speed EM configuration mode by holding the pushbutton switch SW for 5 to 0 seconds, the high, medium, and low variable speed EM speeds can be selected by following the LED display lights. LED (yellow) will fast flash when entering variable speed EM configuration. When setting low speed LED (green) will be continuously lit, for medium speed LED (red) will be continuously lit, and for high speed both LED (green) and LED (red) will be continuously lit. During variable speed EM configuration mode LED (yellow) will flash each of the possible blower speeds times. When the desired speed is flashed press SW, LED will fast flash until SW is released. Low speed has now been selected. Next select medium speed, and high speed blower selections following the same process above. After third selection has been made, the control will exit the variable speed EM configuration mode. eset onfiguration Mode The control is placed in reset configuration mode by holding the push button switch SW for 50 to 60 seconds. This will reset all configuration settings and the EEPOM back to the factory default settings. LED (green) will turn off when entering reset configuration mode. Once LED (green) turns off release SW and the control will reset. DIP Switch (SW) SW- FP Selection Temperature limit setting for freeze detection. On = 0 F; Off = 5 F. SW- FP Selection Future Use SW- V O/B - thermostat type. Heat pump thermostats with O output in cooling or B output in Heating can be selected. On = O; Off = B. SW-4 Access elay Operation (P) and -5

32 ontrols - Aurora Base ontrol cont. Access elay Operation SW-4 SW-5 ycle with Blower ON ON ycle with ompressor OFF OFF Water Valve Slow Opening ON OFF (eserved) OFF ON SW-6 SW-7 SW-8 ycle with Blower - The accessory relay will cycle with the blower output. ycle with ompressor - 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. Operation selection of single or dual capacity compressor. On = Single Stage; Off = Dual apacity Lockout and Alarm Outputs (P) selection of a continuous or pulsed output for both the LO and ALM Outputs. On = ontinuous; Off = Pulsed eheat Operation On = Normal; Off = eheat Alarm Jumper lip Selection From the factory, ALM is connected to 4 VA via JW. By cutting JW, ALM becomes a dry contact connected to AL. Variable Speed EM Blower Speeds The blower speeds can be changed either by using the variable speed EM manual configurations mode method or by using the Aurora AID Tool directly (see Instruction uide: Aurora Interface and Diagnostic (AID) Tool topic). Field Selectable Options via Software (Selectable via the Aurora AID Tool) Variable Speed EM Blower Speeds A traditional variable speed EM blower motor can be driven directly using the onboard PWM output. Three blower speeds are available, based upon the (low), Y (med), and Y/W (high) input signals to the board. The blower speeds can be changed either by the variable speed EM manual configurations mode method (see Variable Speed EM onfiguration Mode topic) or by using the Aurora AID Tool directly. All three blower speeds can be set to the same speed if desired. 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 amp automotive type plug-in fuse provides protection against short circuit or overload conditions. andom Start 5 to 80 second random start upon power up. Fault etry 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 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 low speed, and PS blower motor output will remain on. The Alarm output (ALM) and Lockout output (L) will be turned on. The fault type identification display LED (ed) shall flash the fault code. To reset lockout conditions with SW-8 On, thermostat inputs Y, Y, and W must be removed for at least three () seconds. To reset lockout conditions with SW-8 Off, thermostat inputs Y, Y, W, and DH must be removed for at least three () seconds. Lockout may also be reset by turning power off for at least 5 seconds or by enabling the emergency shutdown input for at least seconds. Lockout With Emergency Heat - if the control is locked out in the heating mode, and a Y 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 ten (0) 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 two () minutes. When the W input is removed, all of the emergency heat outputs will turn off, and the variable speed EM blower will shift to low speed and PS blower motor output will remain on. High Pressure fault is recognized when the Normally losed High Pressure Switch, P4-9/0 opens, no matter how momentarily. The High Pressure Switch is electrically in series with the ompressor ontactor and serves as a hard-wired limit switch if an overpressure condition should occur. Low Pressure - fault is recognized when the Normally losed Low Pressure Switch, P4-7/8 is continuously open for 0 seconds. losure of the LPS any time during the 0 second recognition time restarts the 0 second continuous open requirement. A continuously open LPS shall not be recognized during the minute startup bypass time. Loss of harge fault is recognized when the Normally losed Low Pressure Switch, P4-7/8 is open prior to the compressor starting. ondensate Overflow - fault is recognized when the impedance between this line and 4 VA common or chassis ground drops below 00K ohms for 0 seconds continuously. Anti-Short ycle Protection 4 minute anti-short cycle protection for the compressor.

33 ontrols - Aurora Base ontrol cont. Freeze Detection - set points shall be either 0 F or 5 F. When the thermistor temperature drops below the selected set point, the control shall begin counting down the 0 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 minutes of the compressor run time. Over/Under Voltage Shutdown - An over/under voltage condition exists when the control voltage is outside the range of 8 VA to 0 VA. If the over/under voltage shutdown lasts for 5 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 8 VA to 0 VA 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, Y, Y, W, DH, and are not active. Input O may be active. The blower and compressor will be off. Heating Operation Heating, st Stage (Y) - The blower is started on low speed immediately and the compressor is energized 0 seconds after the Y input is received. The variable speed EM blower motor is switched to medium speed 5 seconds after the Y input. Heating, nd Stage (Y, Y) - The compressor will be staged to full capacity 0 seconds after Y input is received. The variable speed EM blower will shift to high speed 5 seconds after the Y input is received. Heating, rd Stage (Y, Y, W) - The first stage of electric heat is energized 0 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 low speed, 0 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 high speed. If the emergency heat demand is not satisfied after minutes the second electric heat stage will be energized. ooling 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. ooling, st Stage (Y,O) - The blower is started on low speed immediately and the compressor is energized 0 seconds after the Y input is received. The variable speed EM blower motor is switched to medium speed 5 seconds after the Y input. ooling, nd Stage (Y, Y, O) - The compressor will be staged to full capacity 0 seconds after Y input was received. The variable speed EM blower will shift to high speed 5 seconds after the Y input was received. Blower () - The blower will start immediately upon receiving a thermostat command. If there are no other commands from the thermostat the variable speed EM will run on low speed until the command is removed. egardless of blower input () from the thermostat, the blower will remain on low speed for 0 seconds at the end of each heating, cooling, emergency heat, and reheat cycle. Dehumidification (Y, O, DH or Y, Y, O, DH) - When a DH command is received from the thermostat during a compressor call for cooling the variable speed EM blower speed will be reduced by 5% to increase dehumidification. Emergency Shutdown - Four (4) seconds after a valid ES input, P-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. ontinuous Blower Operation - The blower output will be energized any time the control has a input present, unless the control has an emergency shutdown input present. The blower output will be turned off when 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. Blower () - The blower will start immediately upon receiving a thermostat command. If there are no other commands from the thermostat the variable speed EM will run on low speed until the command is removed. egardless of blower input () from the thermostat, the blower will remain on low speed for 0 seconds at the end of each heating cycle.

34 ontrols - Aurora Base ontrol cont. 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 (LED, reen) Description of Operation Fault LED, reen Normal Mode ON ontrol is Non-functional OFF Test Mode Slow Flash Lockout Active Fast Flash Dehumidification Mode Flash ode (eserved) Flash ode (eserved) Flash ode 4 Load Shed Flash ode 5 ESD Flash ode 6 (eserved) Flash ode 7 onfiguration LED (LED, Yellow) Description of Operation No Software Overwritten DIP Switch was Overwritten Variable Speed EM onfiguration Mode Fault LED (LED, ed) onfiguration LED, Yellow Flashing Variable Speed EM Setting Slow Flash Fast Flash Description of Operation Fault LED, ed Normal Mode OFF Input Fault Lockout Flash ode High Pressure Lockout Flash ode Low Pressure Lockout Flash ode Freeze Detection - (Future Use) Flash ode 4 Freeze Detection - (oax) Flash ode 5 (eserved) Flash ode 6 ondensate Overflow Flash ode 7 Over/Under Voltage Shutdown Flash ode 8 Freeze Detection Sensor Error (Sensor is Out of ange) Flash ode Aurora Interface and Design (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 TU communication. The AID Tool provides diagnostics, fault management, variable speed EM setup, and system configuration capabilities to the Aurora family of controls. An AID Tool is recommended, although not required, for variable speed EM airflow settings. AB ontrol Board Layout 6.5 in. F Y HP HP LP LP FP FP FP FP EV EV LO HI F F Factory Factory JW - Alarm P P4 P5 PWM FM EM PWM P SW Test V K K Hi K Fan K4 Alarm K5 Acc K6 Field onnections Off LED FP 5 o F/0 o F FP 5 o F/0 o F Fault V B/O A Dip A Dip LED Dual/Single L Pulse/ontinuous Status eheat/normal P9 LO P P Factory Use 5.0 in. Aurora TM Base ontrol Factory Fan onnection O/B Field onnections SW On LED Y onfig Y Y W DH om om A-Fuse Factory P6 P S485 Exp LED 5 P7 S 485 P8 LED 4 S485 NET EH EH EH O N/A (+) (-) (+) (-) 5.75 in. ES LS ALM AL A c A no A nc LO O/B Y Y W DH 5.5 in. 4

35 ontrols - FX0 (optional) Optional FX0 Microprocessor and BAS Interface An optional Medium User Interface (MUI) for control setup and advanced diagnostics is available with some mounting kits, MUIK - Panel mount version and the MUIK4-Wall mount version. Zone Sensors There are two options for zone sensors that can be used with the FX0 control. Both sensors use a Johnson controls A99 positive temperature coefficient type sensor. The TAXXJ0 has a set point adjustment now which will give the end user a +/- 5 F adjustment from the set point as well as a push button that can be used for temporary occupancy. The control leaves the factory set to operate with a TAXXJ0 sensor, the TAXXA04 sensor through a building automation system, or with a user interface. Main FX 0 Board The FX0 is a microprocessor based control that not only monitors and controls the heat pump but also can communicate any of this information back to the building automation system (BAS). This means that not only does the control monitor the heat pump at the unit you can also monitor and control many the features over the BAS. This clearly puts the FX0 in a class of its own. The control will enumerate all fault conditions (HP, LP, O, LO, and Freeze Detection) over a BAS as well as display them on a medium user interface (MUI). HP, LP, O and Freeze Detection faults can all be reset over a BAS. A Loss Of harge fault can not be reset or bypassed until the problem has been corrected. A MUI is invaluable as a service tool for the building service team. The unit can be commanded to run by a typical heat pump thermostat or run based on heating and cooling set points supplied by a BAS. The control board is wired with quick connect harnesses for easy field change out of a bad control board. All variable speed EM blower speed settings can be changed over a BAS or with a MUI. The control has an input programmed to enable field installed emergency heat in the event that the compressor is locked out. This input can also be commanded on from a BAS as needed. An alarm history can be viewed through the MUI and will be held in memory until the unit is power cycled. elative humidity can be read by a 0-5VD humidity sensor that is displayed over the network. If you are using a variable speed EM blower motor the control can enable dehumidification mode based on a set point in the control. The dehumidification set point itself can also be changed over a BAS or with a MUI. Dehumidification mode can also be enabled by the BAS. Because the FX0 is not factory configured to read O levels, contact the factory for application assistance. Standard Features Anti Short ycle High Pressure Protection Low Pressure Protection Freeze Detection Loss Of harge Detection andom Start Display for diagnostics eset Lockout at disconnect or through BAS Accessory outputs Optional BAS add-on controls DD Operation and onnection Other optional network protocol boards that can be added to the FX0 are: Johnson ontrol N LonWorks BAnet - 9,00 Baud rate - Limit devices to 0 on a single trunk line ontrol and Safety Feature Details Emergency Shutdown The emergency shutdown mode can be activated by a command from a facility management system or a closed contact on BI-. The default state for the emergency shutdown data point is off. When the emergency shutdown mode is activated, all outputs will be turned off immediately and will remain off until the emergency shutdown mode is de-activated. The first time the compressor starts after the emergency shutdown mode has been de-activated, there will be a random start delay present. The FX0 control has unused analog and digital inputs for field installed items such as air temperature, water temperature, O or current status switches. The control has unused binary and PWM outputs that can be commanded over the BAS for field use. 5

36 ontrols - FX0 (optional) cont. Lockout Mode Lockout mode can be activated by any of the following fault signals: refrigerant system high pressure, refrigerant system low pressure, freeze detection, and condensate overflow. When any valid fault signal remains continuously active for the length of its recognition delay, the controller will go into fault retry mode, which will turn off the compressor. After the ompressor short cycle delay, the compressor will attempt to operate once again. If three consecutive faults occur in 60 minutes during a single heating or cooling demand, the unit will go into lockout mode, turning off the compressor, enabling the alarm output, and setting the blower back to low speed operation until the controller is reset. If the control faults due to the low pressure input (BI-) being open during the pre-compressor startup check, the control will go into lockout mode immediately, disabling the compressor from starting and enabling the alarm output (BO-6). The lockout condition can be reset by powering down the controller, by a command from the BAS, or by the holding the ES and eturn keys on the MUI for 5 seconds. Low Pressure (BI-) The low-pressure switch shall be a normally closed (N) switch that monitors the systems refrigerant pressure. The input shall be checked 5 seconds before compressor start up to be sure the pressure switch is closed and then ignored for the first minutes after the compressor output (BO-) is enabled. If the switch is open continuously for (0) seconds during compressor operation the compressor output (BO-) will be disabled. The compressor will not restart until the compressor short cycle time delay has been satisfied. ondensate Overflow The condensate overflow sensing circuit will monitor the condensate level as a resistance input to AI-. If the condensate water level rises resulting in the input resistance rising above the set point for the recognition delay period, the condition will be recognized as a fault. The condensate will be subjected to a (0) second lockout delay which requires that the fault be sensed for a continuous (0) seconds before suspending unit operation. Alarm Output (BO-6) The alarm output will be enabled when the control is in the lockout mode and will be disabled when the lockout is reset. Freeze Detection (AI-5) The freeze detection sensor will monitor the liquid refrigerant temperature entering the water coil in the heating mode. If the temperature drops below the freeze detection trip point for the recognition delay period, the condition will be recognized as a fault. The freeze detection trip point will be factory set for 0 F (- ) and will be field selectable for 5 F (-9 ) by removing a jumper wire on BI-5. The freeze detection fault condition will be bypassed minutes at normal compressor startup, to allow the refrigeration circuit to stabilize. If the freeze detection sensor becomes unreliable at any time compressor operation will immediately be suspended until the problem is corrected. This should be displayed as an alarm on the BAS and the MUI. This alarm will be reported as a Water Low Temp Limit fault. High Pressure (BI-) The high-pressure switch shall be a normally closed (N) switch that monitors the systems refrigerant pressure. If the input senses the high-pressure switch is open it must disable the compressor output immediately and count the fault. The compressor minimum on time does not apply if the high-pressure switch opens. The compressor will not restart until the compressor short cycle time delay has been satisfied. Test Mode aising the zone temperature input (AI-) reading to 80 0 F or by holding the ES and down arrow keys on the MUI for 5 seconds will put the control into test mode. In test mode the random start delay and the compressor fixed on delay time will both be shortened to 5 seconds and the reversing valve will be allowed to cycle with out shutting down the compressor. If an MUI is connected to the control LED 8 will flash and the words Test Mode Enabled will be shown on the LD display when the control is in test mode. Test mode will be disabled after a power cycle, 0 minute timeout, or by holding the ES and Up arrow keys on the MUI. Sequence of Operation Power Fail estart When the controller is first powered up, the outputs will be disabled for a random start delay. The delay is provided to prevent simultaneous starting of multiple heat pumps. Once the timer expires, the controller will operate normally. andom Start Delay This delay will be used after every power failure, as well as the first time the compressor is started after the control exits the unoccupied mode or the emergency shutdown mode. The delay should not be less than second and not longer than 0 seconds. If the control is in test mode the random start delay will be shortened to 5 seconds. 6

37 ontrols - FX0 (optional) cont. ompressor Fixed On Delay Time The ompressor Fixed On Delay Time will ensure that the compressor output (B0) is not enabled for 90 seconds after the control receives a call to start the compressor. This delay is adjustable from 0 00 seconds over a BAS or a MUI. If the control is in test mode the ompressor Fixed On Delay Timer will be shortened to 5 seconds. ompressor Minimum On Delay The compressor minimum on delay will ensure that the compressor output is enabled for a minimum of two () minute each time the compressor output is enabled. This will apply in every instance except in the event the high pressure switch is tripped or emergency shutdown then the compressor output will be disable immediately. ompressor Short ycle Delay Time The compressor short cycle time delay will ensure that the compressor output will not be enabled for a minimum of five (5) minutes after it is disabled. This allows for the system refrigerant pressures to equalize after the compressor is disabled. Heating ycle On a call for heating, the blower enable output and accessory output will turn on immediately after the random start delay timer has been satisfied. If the compressor short cycle time delay has been satisfied, the compressor will turn on after the blower enable and accessory output are on and the fixed compressor start delay timers have been satisfied. NOTE: Auxiliary heat output can be controlled over the BAS. Set Point ontrol Mode In set point control mode the reversing valve output will be disabled. As the temperature drops below the heating set point and begins to operate in the heating proportional band, the compressor (low capacity for two-stage compressors) output (BO-) will be enabled. For units with two-stage compressors, a PI loop in the programming of the control will determine when the full capacity compressor output (BO-4) is to be enabled. The compressor must be operating in low capacity for a minimum of 0 seconds before the full capacity compressor output can be enabled. During low capacity compressor operation the variable speed EM blower will operate in medium speed and will operate in high speed when the compressor is operating at full capacity. Thermostat ontrol Mode In thermostat mode the compressor will be cycled based on Y and Y calls from a room thermostat. When the control receives a Y command (BI-7) from the thermostat the low capacity compressor output (BO) will be enabled and the variable speed EM blower will operate in medium speed. When the control receives a Y command (BI-8) from the thermostat the variable speed EM blower will operate in high speed. During the heating cycle the reversing valve will be commanded into the off position. ooling ycle On a call for cooling, the blower enable output and accessory output will turn on immediately after the random start delay timer has been satisfied. If the compressor short cycle time delay has been satisfied, the compressor will turn on after the blower enable and accessory output are on and the fixed compressor start delay timers have been satisfied. Set Point ontrol Mode In set point control mode the reversing valve output will be enabled. As the temperature rises above the cooling set point and begins to operate in the cooling proportional band, the low capacity compressor output (BO-) will be enabled. A PI loop in the programming of the control will determine when the full capacity compressor output (BO-4) is to be enabled. The compressor must be operating in low capacity for a minimum of 0 seconds before the full capacity compressor output can be enabled. During low capacity compressor operation the variable speed EM blower will operate in medium speed and will operate in high speed when the compressor is operating at full capacity. Thermostat ontrol Mode In thermostat mode the compressor will be cycled based on Y and Y calls from a room thermostat. When the control receives a Y command (BI-7) from the thermostat the low capacity compressor output (BO) will be enabled and the variable speed EM blower will operate in medium speed. When the control receives a Y command (BI-8) from the thermostat the full capacity compressor output will be enabled and the variable speed EM blower will operate in high speed. During the cooling cycle the reversing valve will be commanded into the ON position. Variable Speed EM Blower Operation Blower speeds will be selected through the user interface or the facility management system. There will be a total of speeds selectable with only three being selected at any one time. The lowest numbered speed selection set to ON will select the lowspeed blower setting, the middle selection set to ON will select the medium-speed blower setting and the highest selection set to ON will select the high-speed blower setting. If all selections are set to OFF the software shall select speed setting 0 for low-speed, for medium-speed, and will select speed setting for high speed. If only one selection is set to ON, that selection will set the low-speed blower setting, the medium-speed setting will be, and the highspeed setting will be speed. The maximum low-speed setting will be speed 0 and the minimum high-speed setting will be speed. In addition there is a low limit setting in the software to prevent the variable speed EM blower speed from being set below acceptable limits for each unit size. 7

38 ontrols - FX0 (optional) cont. Emergency Heat/Network Enabled Output (BO-5) This output is set from the factory to enable/disable emergency heat. If a problem occurs with the unit resulting in the compressor being locked out in heating mode, the control will automatically enable this output to turn on field installed electric heat. This output is interlocked with the blower proving input BI-6 (Blower proving sensors must be field supplied and installed). BI-6 must be connected to PB position (see unit schematic) in the field if no blower proving sensor is desired. There is a configurable parameter available through a BAS network that must be enabled if this output is to be commanded over the BAS network. NOTE: For auto switch over, BO-5 must be set to "Emergency" using the MUI. MUI Alarm History eporting If a fault occurs the fault will be recorded in history for display on the medium user interface in the History Menu. Each fault type will be displayed in the history menu with a number between 0 and. A reading of + will mean that fault has occurred more than three times in the past. The history menu can be cleared with a power cycle only. Alarm date and time are not included in the history. Inputs and Outputs onfiguration Field Selectable Options Freeze Detection Set Point (BI-5) The freeze detection set point input allows you to adjust the freeze detection set point (AI-5). When the jumper is installed on BI-5 (Wire #4) the freeze detection set point is factory set for 0 F (- ). When the jumper on BI-5 (Wire #4) is removed the freeze detection set point will be 5 F (-9 ). Accessory Outputs (BO-7 and BO-8) Accessory Output will be energized 90 seconds prior to the compressor output being energized. Accessory Output will be energized with the blower output (BO-). When the corresponding compressor output is turned off the accessory output will be deactivated immediately. These outputs are selectable for normally open or normally closed operation through the MUI or through the BAS. FX0 User Interface (MUI) Physical Layout Power LED Alarm LED Up Arrow ight Arrow LED LED 4 Escape (ES) Button eturn Button LED 8 Left Arrow Down Arrow Alarm LED - Indicates a Lock-Out or a bad Freeze Sensor Power LED - Shows FX processor is operational LED - Flashing shows ompressor running LED - Flashing shows Full apacity ompressor running LED - On shows Fan running LED 4 - On shows eversing Valve in cool LED 8 - Flashing shows unit in Test Mode 8

39 ontrols - FX0 (optional) cont. MUI Menu Navigation for Single ompressor - B Series Water-to-Air Welcome Info Status Temps Outputs Settings Maint Alarms Alm-History Info Status Temps Outputs Settings Water Source Heat Pump POFXENV-XX _/_/ un Mode Auto Eff Occup y Occ Y Input OFF Y Input OFF Input OFF O Input Heat/ool Occ Input Occ Temp Occ Inp OFF ondensate NML Emg Input un Lo Press ON Hi Press ON ndm Tmr 0 BI-4 Input OFF Zone Temp 77. ºF Dis Air Temp 5.0 ºF Eff lg Setpt Eff Htg Setpt Water oil Low W Limit Humidity Warmool AI 4.6 WarmoolAdj F 66.0 F 77.8 F 0.0 F 56.7 %H nvofanstatus ON mpmd Status OFF mp apacity OFF ev Valve Heat X Output OFF X Output OFF PWMOut 98% BO5 OFF BO9 OFF AO Output 0% Unit of Measure F Occ lg Setpt 7.9 ºF Occ Htg Setpt 69.9 ºF Unocc lg 84.0 ºF Unocc Htg 60.0 ºF DeHumSetpt 0% SensorSelect TAXXJ0 Maintenance EM MinlgSetpt 60.0 ºF MaxHtgSetpt 89.9 ºF W oil LoLim 0.0 ºF W oil LoLim 5.0 ºF TmpOccTime 0 min ev Vlv Default Heating BO5 Mode Network ompstrtdly 90 sec SpaceT Offset - ºF DehumEnaDis Dis Acc Action On omp Acc Action On Fan Press right arrow key one time from Maintenance Menu SW SW SW SW4 SW5 SW6 SW7 SW8 SW9 SW0 SW SW OFF OFF ON OFF OFF OFF ON OFF OFF ON OFF OFF No more than three speeds should be ON at one time Alarms ALAM SUMMAY ^/High Pressure Alm-History Alarm #Events ondensate 0 Hi Pressure 0 Low Pressure 0 Low Temp 0 Bad Sensor 0 NOTE: This FX0 application implements an alarm history which is reset only by cycling power. This history shows on the Alm-History page. Any alarm showing 4+ events has occurred more than 4 times. Alarm lock-outs are reset by cycling power, by pressing the ES and eturn keys simultaneously for a minimum of 5 seconds, or by commanding the nvialarmeset over the BAS network. Test mode is enabled by holding the Esc and Down Arrow simultaneously for a minimum of 5 seconds and releasing. Test mode times out after 0 minutes, and may also be ended by pressing ES and Up Arrow simultaneously and releasing. Test Mode bypasses the On Delay (90 sec) and andom Start timers for quicker troubleshooting. It also allows cycling the reversing valve without compressor shutdown. 9

40 Unit Startup Before Powering Unit, heck The Following: NOTE: emove and discard the compressor shipping bolts. The bolts can then be discarded. High voltage is correct and matches nameplate. Fuses, breakers and wire size correct. Low voltage wiring complete. Piping completed and water system cleaned and flushed. Air is purged from closed loop system. Isolation valves are open, water control valves or loop pumps wired. ondensate line open and correctly pitched. Transformer switched to 08V if applicable. Dip switches are set correctly. Blower rotates freely foam shipping support has been removed. Blower speed correct. Air filter/cleaner is clean and in position. Service/access panels are in place. eturn air temperature is between F heating and F cooling. heck air coil cleanliness to insure optimum performance. lean as needed according to maintenance guidelines. To obtain maximum performance the air coil should be cleaned before startup. A 0-percent solution of dishwasher detergent and water is recommended for both sides of coil, a thorough water rinse should follow. Startup Steps NOTE: omplete the Equipment Start-Up/ommissioning heck Sheet during this procedure. efer to thermostat operating instructions and complete the startup procedure.. Initiate a control signal to energize the blower motor. heck blower operation.. Initiate a control signal to place the unit in the cooling mode. ooling setpoint must be set below room temperature.. ooling will energize after a time delay. heck for correct rotation of scroll compressors in phase applications. Incorrect rotation will compressor or contactor to reverse rotation. 4. Be sure that the compressor and water control valve or loop pump(s) are activated. 5. Verify that the water flow rate is correct by measuring the pressure drop through the heat exchanger using the P/T plugs and comparing to the pressure drop table. 6. heck the temperature of both the supply and discharge water (efer to Operating Parameters tables). 7. heck for an air temperature drop of 5 F to 5 F across the air coil, depending on the blower speed and entering water temperature. 8. Decrease the cooling set point several degrees and verify high-speed blower operation (Variable Speed EM only). 9. Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop pumps deactivate. 0. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature.. Heating will energize after a time delay.. heck the temperature of both the supply and discharge water (efer to Unit Operating Parameters tables).. heck for an air temperature rise of 0 F to 5 F across the air coil, depending on the blower speed and entering water temperature. 4. If auxiliary electric heaters are installed, increase the heating setpoint until the electric heat banks are sequenced on. All stages of the auxiliary heater should be sequenced on when the thermostat is in the Emergency Heat mode. heck amperage of each element. 5. Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps deactivate. 6. During all testing, check for excessive vibration, noise or water leaks. orrect or repair as required. 7. Set system to desired normal operating mode and set temperature to maintain desired comfort level. 8. Instruct the owner/operator in the proper operation of the thermostat and system maintenance. NOTE: Be certain to fill out and forward all warranty registration papers. 40

41 Operating Parameters Entering Water Temp F ooling Water Flow gpm/ Suction Discharge Water Temp Air Temp Drop ton Superheat Subcooling Pressure psig Pressure psig ise F F DB Entering Water Temp F Heating Water Flow gpm/ Suction Discharge Water Temp Air Temp ise ton Superheat Subcooling Pressure psig Pressure psig Drop F F DB // NOTES: ooling performance based on entering air temperatures of 80 F DB, 67 F WB. Heating performance based on entering air temperature of 70 F DB. Operating Limits Operating Limits ooling Heating ( F) ( ) ( F) ( ) Air Limits Min. Ambient Air ated Ambient Air Max. Ambient Air Min. Entering Air ated Entering Air db/wb 80.6/66. 7/ Max. Entering Air db/wb 0/8 4/ Water Limits Min. Entering Water Normal Entering Water Max. Entering Water NOTE: Minimum/maximum limits are only for start-up conditions, and are meant for bringing the space up to occupancy temperature. Units are not designed to operate at the minimum/maximum conditions on a regular basis. The operating limits are dependant upon three primary factors: ) water temperature, ) return air temperature, and ) ambient temperature. When any of the factors are at the minimum or maximum levels, the other two factors must be at the normal level for proper and reliable unit operation. 4

42 Pressure Drop Model PM Pressure Drop (psi) Pressure Valve PM v 0 F 50 F 70 F 90 F 0 F Drop (psi) Internally mounted -position solenoid water valves are not available on models / / / / / / / /5/ 9/5/ 4

43 ompressor and Thermistor esistance ompressor esistance Model 5/60/ 08-0/60/ 65/60/ un Start un Start un Start 08-0/60/ 460/60/ 575/60/ Not Available at Time of Publication /6/ Thermistor esistance Thermistor Temperature ( F) Microprocessor esistance (Ohms) FX0 esistance (Ohms) 5 7, , , , , , , , , , , , ,70 79-,60-5, , , // efrigerant ircuit uideline Symptom Head Suction ompressor Air Temp. Water Temp. Superheat Subcooling Pressure Pressure Amp Draw Differential Differential Under harged System (Possible Leak) Low Low Low High Low Low Low Over harged System High High High Normal High Normal/Low Normal Low Air Flow Heating High High High High/Normal Low High Low Low Air Flow ooling Low Low Low Low/Normal High High Low Low Water Flow Heating Low/Normal Low/Normal Low Low High Low High Low Water Flow ooling High High High High Low Low High High Air Flow Heating Low Low Low Low High Low Low High Air Flow ooling Low High Normal High Low Low Normal High Water Flow Heating Normal Low Normal High Normal Normal Low High Water Flow ooling Low Low Low Low High Normal Low Low Indoor Air Temperature Heating Low Low Low Normal High Normal Normal/High Low Indoor Air Temperature ooling Low Low Low Normal/Low High Low Low High Indoor Air Temperature Heating High High High Normal/High Normal/Low Low Normal High Indoor Air Temperature ooling High High High High Low Low High estricted TXV (heck Service Advisory) High Low Normal/Low High High Low Low Insufficient ompressor (Possible Bad Valves) Low High Low High Normal/High Low Low TXV - Bulb Loss of harge Low Low Low High High Low Low Scaled oaxial Heat Exchanger Heating Low Low Low Normal/Low High Low Low Scaled oaxial Heat Exchanger ooling High High High Normal/Low Low Low Low estricted Filter Drier heck temperature difference (delta T) across filter drier. 7/6/0 4

44 Heat of Extraction/ejection Data Model gpm Heat Of Extraction (HE) Heat of ejection (H) 0 F 50 F 70 F 90 F 0 F 50 F 70 F 90 F 0 F Values displayed in MBtu/h 09/6/ eference alculations Legend Heating alculations: HE LWT = EWT - gpm x 500 H LAT = EAT + cfm x.08 TH = H + HW ooling alculations: H LWT = EWT + gpm x 500 S LAT(DB) = EAT(DB) - cfm x.08 L = T - S S S/T = T ABBEVIATIONS AND DEFINITIONS: cfm = airflow, cubic feet/minute EWT = entering water temperature, Fahrenheit gpm = water flow in gallons/minute WPD = water pressure drop, PSI and feet of water EAT = entering air temperature, Fahrenheit (dry bulb/wet bulb) H = air heating capacity, MBtu/h T = total cooling capacity, MBtu/h S = sensible cooling capacity, MBtu/h KW = total power unit input, kilowatts H = total heat of rejection, MBtu/h HE = total heat of extraction, MBtu/h HW = hot water generator capacity, MBtu/h EE = Energy Efficient atio = BTU output/watt input OP = oefficient of Performance = BTU output/btu input LWT = leaving water temperature, F LAT = leaving air temperature, F TH = total heating capacity, MBtu/h L = latent cooling capacity, MBtu/h S/T = sensible to total cooling ratio 44

45 Troubleshooting Should a major problem develop, refer to the following information for possible causes and corrective steps. If compressor won t run:. The fuse may be open or the circuit breaker is tripped. heck electrical circuits and motor windings for shorts or grounds. Investigate for possible overloading. eplace fuse or reset circuit breakers after fault is corrected.. Supply voltage may be too low. heck it with a volt meter.. ontrol system may be faulty. heck control for correct wiring of thermostat or aquastat and check the 4 volt transformer for proper voltage. 4. Wires may be loose or broken. eplace or tighten. 5. The low pressure switch may have tripped due to one or more of the following: a) Heating ) Plugged heat exchanger on source side ) Water flow source side - (Low) ) Water too cold source side 4) Low refrigerant b) ooling ) Plugged heat exchanger on load side ) Water flow load side - (Low) ) Water too cold load side 4) Low refrigerant 6. The high pressure switch may have tripped due to one or more of the following: a) Heating ) Plugged heat exchanger on load side ) Low water flow load side ) Water too warm load side b) ooling ) Plugged heat exchanger on source side ) Low water flow on source side ) Water too warm source side 7. The compressor overload protection may be open. 8. The internal winding of the compressor motor may be grounded to the compressor shell. If so, replace the compressor. 9. The compressor winding may be open or shorted. Disconnect power. heck continuity with ohm meter. If the winding is open, replace the compressor. If sufficient cooling or heating is not obtained:. heck control for improper location or setting.. heck for restriction in water flow.. heck refrigerant subcooling and superheat for proper refrigerant charge and expansion valve operation. 4. The reversing valve may be defective and creating a bypass of refrigerant. If the unit will not heat, check the reversing valve coil. If the unit operation is noisy:. heck compressor for loosened mounting bolts. Make sure compressor is floating free on its isolator mounts. heck for tubing contact with the compressor or other surfaces. eadjust it by bending slightly.. heck screws on all panels.. heck for chattering or humming in the contactor or relays due to low voltage or a defective holding coil. eplace the component. 4. heck for proper installation of vibration absorbing material under the unit. 5. heck for abnormally high discharge pressures. 6. ompressor rotation incorrect efrigerant Systems To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. ompare the change in temperature on the air side as well as the water side to the Operating Parameters tables. If the unit s performance is not within the ranges listed, and the airflow and water flow are known to be correct, gauges should then be installed and superheat and subcooling numbers calculated. If superheat and subcooling are outside recommended ranges, an adjustment to the refrigerant charge may be necessary. NOTE: Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit. 45

46 Startup and Troubleshooting Form ompany Name: Technician Name: Model No: Owner s Name: Installation Address: ompany Phone No: Date: Serial No: Open or losed Loop: Installation Date: heck One Start up/heck-out for new installation Troubleshooting Problem:. FLOW ATE IN PM (OAXIAL HEAT EXHANE) Water In Pressure: a. PSI Water Out Pressure: b. PSI Pressure Drop = a - b c. PSI onvert Pressure Drop to Flow ate (refer to Pressure Drop table) d. PM. TEMPEATUE ISE O DOP AOSS OAXIAL HEAT EXHANE OOLIN HEATIN Water In Temperature: e. F e. F Water Out Temperature: f. F f. F Temperature Difference: g. F g. F. TEMPEATUE ISE O DOP AOSS AI OIL OOLIN HEATIN Air In Temperature: h. F h. F Air Out Temperature: i. F i. F Temperature Difference: j. F j. F 4. HEAT OF EJETION (H) / HEAT OF EXTATION (HE) ALULATION H or HE = Flow ate x Temperature Difference x Brine Factor* d. (above) x g. (above) x 485 for Methanol or Environol, 500 for water* Heat of Extraction (Heating Mode) = btu/hr Heat of ejection (ooling Mode) = btu/hr ompare results to apacity Data Tables Note: Steps 5 through 8 need only be completed if a problem is suspected 5. WATTS OOLIN HEATIN Volts: m. VOLTS m. VOLTS Total Amps (omp. + Fan): n. AMPS n. AMPS Watts = m. x n. x 0.85 o. WATTS o. WATTS 6. APAITY ooling apacity = H. - (o. x.4) p. btu/hr Heating apacity= HE. + (o. x.4) p. btu/hr 7. EFFIIENY ooling EE = p. / o. q. EE Heating OP = p. / (o. x.4) q. OP 8. SUPEHEAT (S.H.) / SUBOOLIN (S..) OOLIN HEATIN Suction Pressure: r. PSI r. PSI Suction Saturation Temperature: s. F s. F Suction Line Temperature: t. F t. F Superheat = t. - s. u. F u. F Head Pressure: v. PSI v. PSI High Pressure Saturation Temp.: w. F w. F Liquid Line Temperature*: x. F x. F Subcooling = w. - x. y. F y. F * Note: Liquid line is between the coaxial heat exchanger and the expansion valve in the cooling mode; between the air coil and the expansion valve in the heating mode. 46

47 DEALE: PHONE #: POBLEM: MODEL #: SEIAL #: DATE: Startup/Troubleshooting Form OOLIN YLE ANALYSIS PSI = SAT F F Unit Amp Draw: Loop: Open F AI OIL F Line Voltage: losed SUTION OAX LOAD EXPANSION VALVE OAX SOUE EVESIN VALVE OMPESSO DISHAE Hot Water - enerator F F F LIQUID LINE F F F PSI = SAT F PSI BINE IN PSI BINE OUT PSI BINE IN PSI BINE OUT F F Superheat Subcooling Water to Water Application Heat of Extraction/ejection = PM x 500 (485 for water/antifreeze) x T Note: DO NOT hook up pressure gauges unless there appears to be a performance problem. HEATIN YLE ANALYSIS PSI = SAT F F Unit Amp Draw: Loop: Open F AI OIL F Line Voltage: losed SUTION F PSI BINE IN OAX LOAD F PSI BINE OUT Water to Water Application F LIQUID LINE EXPANSION VALVE F PSI BINE IN OAX SOUE F PSI BINE OUT Hot Water - enerator F EVESIN VALVE F F OMPESSO DISHAE PSI = SAT F Superheat Subcooling 47

48 Preventive Maintenance Water oil Maintenance. Keep all air out of the water. An open loop system should be checked to ensure that the well head is not allowing air to infiltrate the water line. Lines should always be airtight.. Keep the system under pressure at all times. It is recommended in open loop systems that the water control valve be placed in the discharge line to prevent loss of pressure during off cycles. losed loop systems must have positive static pressure. NOTE: On open loop systems, if the installation is in an area with a known high mineral content (5 PPM or greater) in the water, it is best to establish with the owner a periodic maintenance schedule so the coil can be checked regularly. Should periodic coil cleaning be necessary, use standard coil cleaning procedures which are compatible with either the cupronickel or copper water lines. enerally, the more water flowing through the unit the less chance for scaling. Other Maintenance Filters Filters must be clean to obtain maximum performance. They should be inspected monthly under normal operating conditions and be replaced when necessary. Units should never be operated without a filter. ondensate Drain In areas where airborne bacteria produce a slime in the drain pan, it may be necessary to treat chemically to minimize the problem. The condensate drain can pick up lint and dirt, especially with dirty filters. Inspect twice a year to avoid the possibility of overflow. Blower Motors Blower motors are equipped with sealed ball bearings and require no periodic oiling. Air oil The air coil must be cleaned to obtain maximum performance. heck once a year under normal operating conditions and, if dirty, brush or vacuum (with a brush attachment) clean. are must be taken not to damage the aluminum fins while cleaning. AUTION: Fin edges are sharp. eplacement Procedures Obtaining Parts When ordering service or replacement parts, refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and the date of failure, along with an explanation of the malfunctions and a description of the replacement parts required. In-Warranty Material eturn Material may not be returned except by permission of authorized warranty personnel. ontact your local distributor for warranty return authorization and assistance. 48

49 Service Parts - Vertical ompressor 08-0/60/ 4P65-0 4P P59-0 4P59-0 4P59-0 4P66-0 4P67-0 4P65-0 4P68-0 4P69-0 4P60-0 4P6-0 65/60/ 4P65-0 4P P59-0 4P59-0 4P59-0 4P66-0 4P67-0 4P65-0 Not Available 0/60/ Not Available 4P66-0 4P67-0 4P65-0 4P68-0 4P69-0 4P60-0 4P /60/ Not Available 4P P P P P P P6-04 ompressor Variable Speed EM Motor & Blower PS Motor & Blower 5-Speed EM Motor & Blower efrigeration omponents ontrols 575/60/ Not Available 4P P P P6-05 5/60/ 4P P P59-09 Not Available un apacitor 08-0/60/ 6P00D 6P00D7 6P00D8 6P00D9 6P00D9 6P00D0 6P00D 6P00D 6P00D un apacitor 65/60/ 6P00D7 6P00D0 6P00D9 6P00D0 Not Available un apacitor 5/60/ 6P00D 6P00D6 Not Available Sound Jacket 9P504A0 9P5-0 9P54-0 Discharge Muffler Not Available 6P50B0 VS EM Motor 08-0/60/ Not Available 4P55B0 4P56B0 4P57B0 VS EM Motor 65/60/ Not Available 4P55B0 Not Available VS EM Motor 0/60/ Not Available 4P55B0 4P56B0 4P57B0 VS EM Motor 460/60/ Not Available 4P55B0 4P56B0 4P57B0 VS EM Blower Housing Not Available 5P5B0 5P55B0 PS Motor 5/60/ 4P506-0 Not Available PS Motor 08-0/60/ 4P P507B0 4P508B0 4P509B0 4P50B0 4P5B0 4P5B0 4P54B0 PS Motor 65/60/ 4P P507B0 4P508B0 4P509B0 4P50B0 Not Available PS Motor 0/60/ Not Available 4P508B0 4P509B0 4P50B0 4P5B0 4P5B0 4P54B0 PS Motor 460/60/ Not Available 4P508B0 4P509B0 4P50B0 4P5B0 4P5B0 4P54B0 PS Motor 575/60/ Not Available 4P5B0 4P5B0 4P54B0 PS Blower & Housing 5P5B0 5P57-0 5P55B0 5-Speed EM Motor 08-0/60/ Not Available 4S56-8 4S56-0 4S56-0 4S56-0 4S57-0 4S57-0 4S57-0 4S Speed EM Motor 77/60/ Not Available 4S56-9 4S56-0 4S S56-08 Not Available 5-Speed EM Motor 0/60/ Not Available 4P56-0 4S56-0 4S56-0 4S57-0 4S57-0 4S57-0 4S Speed EM Motor 460/60/ Not Available 4S56-0 4S56-0 4S56-4S S S S Speed EM Blower & Housing Not Available 5P5B0 5P55B0 Air oil 6P7-4 6P P7-4 6P P7-4 6P P75-4 oax (opper) 6P P59-0 6P P P P P57-0 6P P P57-0 6P574-0 TXV P605-9 P605-6 P605-0 P605-0 P608-0 P605- eversing Valve P50-05 P50-05 P50-05 P P P50-05 P56-04 Filter Drier 6P500B0 6P500B0 Transformer 5/60/ 5P008B0 Not Available Transformer 08-0/60/ 5P50B0 Transformer 65/60/ 5P507B0 Not Available Transformer 0/60/ Not Available 5P50B0 Transformer 460/60/ Not Available 5P505B0 Transformer 575/60/ Not Available 5P506B0 Phase uard Not Available 9P54A06 Sensors & Safeties High Pressure Switch Low Pressure Switch 5P506B0 5P506B0 Part numbers subject to change 8/9/ 49

50 Service Parts - Horizontal ompressor 08-0/60/ 4P65-0 4P P59-0 4P59-0 4P59-0 4P66-0 4P67-0 4P65-0 4P68-0 4P69-0 4P60-0 4P6-0 65/60/ 4P65-0 4P P59-0 4P59-0 4P59-0 4P66-0 4P67-0 4P65-0 Not Available 0/60/ Not Available 4P66-0 4P67-0 4P65-0 4P68-0 4P69-0 4P60-0 4P /60/ Not Available 4P P P P P P P6-04 ompressor Variable Speed EM Motor & Blower PS Motor & Blower 5-Speed EM Motor & Blower efrigeration omponents ontrols 575/60/ Not Available 4P P P P6-05 5/60/ 4P P P59-09 Not Available un apacitor 08-0/60/ 6P00D 6P00D7 6P00D8 6P00D9 6P00D9 6P00D0 6P00D 6P00D 6P00D un apacitor 65/60/ 6P00D7 6P00D0 6P00D9 6P00D0 Not Available un apacitor 5/60/ 6P00D 6P00D6 Not Available Sound Jacket 9P504A0 9P5-0 9P54-0 Discharge Muffler Not Available 6P50B0 VS EM Motor 08-0/60/ Not Available 4P55B0 4P56B0 4P57B0 VS EM Motor 65/60/ Not Available 4P55B0 Not Available VS EM Motor 0/60/ Not Available 4P55B0 4P56B0 4P57B0 VS EM Motor 460/60/ Not Available 4P55B0 4P56B0 4P57B0 VS EM Blower Housing Not Available 5P5B0 5P55B0 PS Motor 5/60/ 4P506-0 Not Available PS Motor 08-0/60/ 4P P507B0 4P508B0 4P509B0 4P50B0 4P5B0 4P5B0 4P54B0 PS Motor 65/60/ 4P P507B0 4P508B0 4P509B0 4P50B0 Not Available PS Motor 0/60/ Not Available 4P508B0 4P509B0 4P50B0 4P5B0 4P5B0 4P54B0 PS Motor 460/60/ Not Available 4P508B0 4P509B0 4P50B0 4P5B0 4P5B0 4P54B0 PS Motor 575/60/ Not Available 4P5B0 4P5B0 4P54B0 PS Blower & Housing 5P5B0 5P57-0 5P55B0 5-Speed EM Motor 08-0/60/ Not Available 4S56-8 4S56-0 4S56-0 4S56-0 4S57-0 4S57-0 4S57-0 4S Speed EM Motor 77/60/ Not Available 4S56-9 4S S S56-08 Not Available 5-Speed EM Motor 0/60/ Not Available 4P56-0 4S56-0 4S56-0 4S57-0 4S57-0 4S57-0 4S Speed EM Motor 460/60/ Not Available 4S S56-0 4S56-4S S S S Speed EM Blower & Housing Not Available 5P5B0 5P55B0 Air oil 6P76-4 6P76-4 6P76-4 6P P7-4 6P P P P70-4 oax (opper) 6P P59-0 6P P P P P57-0 6P P P57-0 6P574-0 TXV P605-9 P605-6 P605-0 P605-0 P608-0 P605- eversing Valve P50-05 P50-05 P50-05 P P P50-05 P56-04 Filter Drier 6P500B0 6P500B0 Transformer 5/60/ 5P008B0 Not Available Transformer 08-0/60/ 5P50B0 Transformer 65/60/ 5P507B0 Not Available Transformer 0/60/ Not Available 5P50B0 Transformer 460/60/ Not Available 5P505B0 Transformer 575/60/ Not Available 5P506B0 Phase uard Not Available 9P54A06 Sensors & Safeties High Pressure Switch Low Pressure Switch 5P506B0 5P506B0 Part numbers subject to change. 8/9/ 50

51 evision uide Pages: Description: Date: By: All Updated with upronickel Water oil Option 0 May 04 DS All Updated to New All-Aluminum Air oils 09 Oct 0 DS All Updated Nomenclature to eflect New Variable Speed EM Blower Nov 0 DS All Added Models 0 Oct 0 DS 5 Added evision Table 0 Oct 0 DS 5

52 P.O. Box 59, York, Pennsylvania USA Subject to change without notice. Printed in USA opyright by Johnson ontrols 04 ALL IHTS ESEVED Form NOM7 (54) Issue Date: May 0, 04 Supersedes: NOM7 (0)