5 Series 500A11 Installation Manual

Transcription

1 500A eothermal Heat Pump -40A efrigerant,.5,,.5,,.5, 4, 5, 6 Ton Single Speed,, 4, 5, 6 Ton Dual apacity Installation Information Water Piping onnections Hot Water enerator erator onnections 5 Series 500A Installation Manual Electrical Startup Procedures Troubleshooting Preventive Maintenance IM500AN /7

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3 5 SEIES 500A INSTALLATION MANUAL Table of ontents Model Nomenclature eneral Installation Information losed Loop round Source Systems Open Loop round Water Systems Hot Water enerator onnections Electrical onnections Electronic Thermostat Installation Auxiliary Heat atings Auxiliary Heat Electrical Data Electrical Data Blower Performance Data Dimensional Data Physical Data The Aurora ontrol System eference alculations and Legend Wiring Schematics Unit Startup Operating Parameters Pressure Drop ompressor and Thermistor esistance efrigerant ircuit uideline Heat of Extraction/ejection Troubleshooting Preventive Maintenance eplacement Procedures Service Parts List

4 5 SEIES 500A INSTALLATION MANUAL Model Nomenclature N D V 049 * T L 0 5 A 6 N ompressor or Type D Dual-Stage S Single Stage Model Type N 5 Series Water-to-Air r abinet onfiguration n V Vertical H - Horizontal ontal Unit apacity ac (MBTUH) 0, 08, 0, 06, 00 06, 08, 04, 048, , 064, 070, 07 Vintage * Internal Factory Use Only Voltage 08-0/60/ Hot Water eneration 0 No Hot Water eneration Hot Water eneration eration with Factory Installed Pump Blower Options 0 PS (Single Stage Only) Variable Speed EM High Static Variable Speed EM ( Only) High Static PS (0, 00, 06, 04, 048) 4 5-Speed EM (0-07) Notes: All Models include sound kits as std. equipment Available on vertical configurations only ontrol option not available with PS motor UP is not compatible with Symphony or IntelliZone IntelliStart & Air oil Option* N No IntelliStart, Uncoated oil A IntelliStart, Uncoated oil B No IntelliStart, AlumiSeal IntelliStart, AlumiSeal ontrol Option A Aurora TM Base ontrol (AB) B Aurora Advanced ontrol (AB & AXB) Aurora Performance Package (08 07, EM Blowers Only) D Aurora Performance and efrigeration Package (08 07, EM Blowers Only) E Aurora TM Base ontrol w UP, F Aurora Advanced ontrol w UP, Aurora Performance Package w UP, H Aurora Performance and efrigeration Package w UP, Filter Option 0 inch MEV Filter AlpinePure 4 (Vertical Only, 0-07) eturn Air onfiguration L Left ight Discharge Air onfiguration T Top (Vertical) B Bottom (Vertical) ear (Vertical) S Side (Horizontal) E End (Horizontal) Water oil Option opper N upronickel ev.: 0/4/07 4

5 5 SEIES 500A INSTALLATION MANUAL 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. 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. Filter ack onversion A in. MEV filter is shipped with the heat pump. To field convert the filter rack to use in. filters, simply insert the provided plastic push pins into the holes located in the filter rack. There are holes on the top and bottom of the rack, underneath the instruction labels, for field conversion to in. filters. Installing Vertical Units Prior to setting the unit in place, remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket. Vertical units are available in left or right air return configurations. Top and rear air discharge vertical units should be mounted level on a vibration absorbing pad slightly larger than the base to provide isolation between the unit and the floor. It is not necessary to anchor the unit to the floor (see below). Bottomflow units should be mounted level and sealed well to floor to prevent air leakage. Bottomflow units require the supply air opening to be cut at least / in. larger than the unit s air outlet. Protect the edges of combustible flooring with sheet metal over-wrap or other noncombustible material. Figure : Vertical Unit Mounting 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. in. Extruded Polystyrene 5

6 5 SEIES 500A INSTALLATION MANUAL eneral Installation Information cont. Installing Horizontal Units emove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket prior to setting the unit in place. Horizontal units are available with side or end discharge. Horizontal units are normally suspended from a ceiling by four or six /8 in. diameter threaded rods. The rods are usually attached to the unit by hanger bracket kits furnished with each unit. Lay out the threaded rods per the dimensions in Figure. Assemble the hangers to the unit as shown. Securely tighten the brackets to the unit using the weld nuts located on the underside of the bottom panel. When attaching the hanger rods to the bracket, a double nut is required since vibration could loosen a single nut. To allow filter access, one bracket on the filter side should be installed 80 from Figure : Horizontal Unit Mounting the position shown in Figure. The unit should be pitched approximately /4-inch towards the drain in both directions to facilitate the removal of condensate. Use only the bolts provided in the kit to attach hanger brackets. The use of longer bolts could damage internal parts. Some residential applications require the installation of horizontal units on an attic floor. In this case, the unit should be set in a full size secondary drain pan on top of a vibration absorbing pad. The secondary drain pan prevents possible condensate overflow or water leakage damage to the ceiling. The secondary drain pan is usually placed on a plywood base isolated from the ceiling joists by additional layers of vibration absorbing material. AUTION: Do not use rods smaller than /8-inch diameter since they may not be strong enough to support the unit. The rods must be securely anchored to the ceiling. Flexible Duct ollar Insulate supply plenum and use O at least one 90 elbow to reduce noise Threaded ods To Line Power Hanging Brackets (Included) Hose Kits To Thermostat Electrical Disconnect Line Voltage Building Water Loop Ball Valves 6

7 5 SEIES 500A INSTALLATION MANUAL eneral Installation Information cont. Figure : Hanger Location and Assembly Hanger Dimensions Single Speed Dual apacity Model Hanger Kit Part Number Unit Hanger Dimensions A B D in n/a 99S500A04 cm n/a in n/a 99S500A04 cm n/a in n/a 99S500A04 cm n/a in S500A0 cm in S500A0 cm in S500A0 cm in n/a 99S500A04 cm n/a in S500A0 cm in S500A0 cm in S500A0 cm in S500A0 cm /8/ Weight Distribution Single Speed Dual apacity Model Vertical Weight Horizontal Weight Horizontal Weight Distribution Front Back [84] [84] [] [0] [0] [] [00] [00] [8] [0] [7] [5] [4] [45] [55] [9] [9] [] [49] [5] [59] [9] [47] [7] [69] [76] [67] [4] [4] [4] [76] [9] [7] [5] [59] [5] [94] [99] [6] [5] [56] [0] [0] [4] [67] [56] [60] [] [] [6] [70] [59] [6] [4] [4] [45] [55] [5] [5] [0] [7] [76] [67] [4] [4] [4] [94] [99] [6] [5] [56] [0] [4] [9] [68] [57] [6] [] [] [6] [70] [59] [64] [4] Weights are listed in lbs. [kg] /9/ 7

8 5 SEIES 500A INSTALLATION MANUAL eneral Installation Information cont. Duct System An air outlet collar is provided on vertical top and rear air discharge units and all horizontal units to facilitate a duct connection (vertical bottomflow units have no collar). A flexible connector is recommended for discharge and return air duct connections on metal duct systems. Uninsulated duct should be insulated with a minimum of -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. maintaining the brass connector in the desired direction. Tighten the connectors by hand, then gently snug the fitting with pliers to provide a leak-proof joint. When connecting to an open loop (ground water) system, thread any -inch MPT fitting (SH80 PV or copper) into the swivel connector and tighten in the same manner as noted above. The open and closed loop piping system should include pressure/temperature taps for serviceability. Never use flexible hoses smaller than -inch inside diameter on the unit. Limit hose length to 0 feet per connection. heck carefully for water leaks. Figure 4: Swivel onnections 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. AUTION: When attaching ductwork or accessories to the cabinet, make sure the fasteners do not come into contact with the air coil. Stainless Steel Snap ing asket Material Locking ing asket Support Sleeve Water Piping The proper water flow must be provided to each unit whenever the unit operates. To assure proper flow, use pressure/temperature ports to determine the flow rate. These ports should be located at the supply and return water connections on the unit. The proper flow rate cannot be accurately set without measuring the water pressure drop through the refrigerant-to-water heat exchanger. All source water connections on residential units are swivel piping fittings (see Figure 4) that accept a -inch male pipe thread (MPT). The swivel connector has a rubber gasket seal similar to a rubber hose gasket, which when mated to the flush end of any -inch threaded pipe provides a leak-free seal without the need for thread sealing tape or compound. heck to ensure that the rubber seal is in the swivel connector prior to attempting any connection. The rubber seals are shipped attached to the waterline. To make the connection to a ground loop system, mate the brass connector (supplied in K4LI connector kit) against the rubber gasket in the swivel connector and thread the female locking ring onto the pipe threads, while Water Quality It is the responsibility of the system designer and installing contractor to ensure that acceptable water quality is present and that all applicable codes have been met in these installations. Failure to adhere to the guidelines in the water quality table could result in loss of warranty. In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. The heat exchanger coils in ground water systems may, over a period of time, lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualified service mechanic, as special solutions and pumping equipment are required. Hot water generator coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional flushing. Heat pumps with cupronickel heat exchangers are recommended for open loop applications due to the increased resistance to build-up and corrosion, along with reduced wear caused by acid cleaning. 8

9 5 SEIES 500A INSTALLATION MANUAL eneral Installation Information cont. 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 Less than ppm, above this Less than ppm, above this Iron Oxide level deposition will occur level deposition will occur level 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 // Water Treatment Do not use untreated or improperly treated water. Equipment damage may occur. The use of improperly treated or untreated water in this equipment may result in scaling, erosion, corrosion, algae or slime. Purchase of a premix antifreeze could significantly improve system reliability if the water quality is controlled and there are additives in the mixture to inhibit corrosion. There are many examples of such fluids on the market today such as Environol 000 (pre-mix ethanol), and others. The services of a qualified water treatment specialist should be engaged to determine what treatment, if any, is required. The product warranty specifically excludes liability for corrosion, erosion or deterioration of equipment. The heat exchangers and water lines in the units are copper or cupronickel tube. There may be other materials in the buildings piping system that the designer may need to take into consideration when deciding the parameters of the water quality. If antifreeze or water treatment solution is to be used, the designer should confirm it does not have a detrimental effect on the materials in the system. ontaminated Water In applications where the water quality cannot be held to prescribed limits, the use of a secondary or intermediate heat exchanger is recommended to separate the unit fro the contaminated water. The table above outlines the water quality guidelines for unit heat exchangers. If these conditions are exceeded, a secondary heat exchanger is required. Failure to supply a secondary heat exchanger where needed will result in a warranty exclusion for primary heat exchanger corrosion or failure. Low Water oil Limit Set the freeze sensing switch SW- on the Aurora Base ontrol (AB) printed circuit board for applications using a closed loop antifreeze solution to LOOP (5 F). On applications using an open loop/ground water system (or closed loop no antifreeze), set this dip switch to WELL (0 F), the factory default setting. (efer to the DIP Switch Settings table in the Aurora ontrol section.) ondensate Drain On vertical units, the internal condensate drain assembly consists of a drain tube which is connected to the drain pan, a /4-inch 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. On horizontal units, a PV stub is provided for condensate drain piping connection. An external trap is required (see below). If a vent is necessary, an open stand pipe may be applied to a tee in the field-installed condensate piping. Figure 5: Horizontal Drain onnection PV tube stub PV coupling.5 in..5 in. NOTE: heck dimensional data for actual PV sizes. Figure 6: Unit Pitch for Drain Vent (if needed) PV tube stub /8 in. per foot /'' Pitch Drain 9

10 5 SEIES 500A INSTALLATION MANUAL losed Loop round Source Systems NOTE: For closed loop systems with antifreeze protection, set SW- to the LOOP (5 F) position. (efer to the DIP Switch Settings table in the Aurora ontrol section.) Once piping is completed between the unit, pumps and the ground loop (see figure below), final purging and charging of the loop is required. A flush cart (or a.5 HP pump minimum) 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 will 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 initially charging the system. After pressurization, be sure to turn the venting (burping) screw in the center of the pump two () turns open (water will drip out), wait until all air is purged from the pump, then tighten the plug. Ensure that the loop pumps provide adequate flow through the unit(s) by checking the pressure drop across the heat exchanger and comparing it to the unit capacity data in this catalog..5 to gpm of flow per ton of cooling capacity is recommended in earth loop applications. Multiple Units on One Flow enter NOTE: This feature is only available in the Aurora Advanced ontrol package (AXB board), NOT the Aurora Base ontrol (AB). When two units are connected to one loop pumping system, pump control is automatically achieved by connecting the SL terminals on connector P in both units with -wire thermostat wire. These terminals are polarity dependant (see Figure 8b). The loop pump(s) may be powered from either unit, whichever is more convenient. If either unit calls, the loop pump(s) will automatically start. The use of two units on one flow center is generally limited to a total of 0 gpm capacity. It is recommended that water solenoid valves be installed on heat pumps that share a flow center. This is to allow water flow through only the heat pump that has a demand. irculating fluid through a heat exchanger of a system that is not operating could be detrimental to the long term reliability of the compressor. NOTE: To achieve this same feature when heat pumps have only the Aurora Base ontrol, follow Figure 8a. Installer will be required to supply fuses, two relays, and wiring. Figure 8a: Primary/Secondary Wiring with Aurora Base ontrol (no AXB Board) Figure 7: losed Loop round Source Application Unit Supply Auxiliary Heat Supply eolink Polyethylene w/ Armaflex Insulation Flexible Duct ollar Auxiliary Heater Knockout eolink Flow enter TO LOOP Ext Pump / hp Total 08-0/60/ Pump Pump ircuit PB Breaker 5A 5A ircuit Breaker HW Pump Hot Water Limit Switch 0 F Purple abinet HW Switch Optional Internal HW Pump Field Supplied Fuses 5A ap Tan(6) Field Supplied elay for Heat Pump S T L ed T ompressor L Heat Pump ontactor oil Unit Power Disconnects (If Applicable) Low Voltage to Thermostat P/T P/T Plugs Vibration Absorbing Pad Hot Water enerator onnections Drain Insulated piping or hose kit NOTE: Additional information can be found in Flow enter installation manual and Flush art manual. Figure 8b: Primary/Secondary Hook-up With pump wired to Unit With pump wired to Unit 5 Series to 5 Series Units 5 Series Unit # with AXB Board SLI SLO IN OUT IN OUT SLI SLO Field Supplied elay for Heat Pump VS VS 5 Series Unit # with AXB Board With pump wired to Unit 5 Series to Envision Units 5 Series Unit # with AXB Board SLI SLO VS IN OUT Down In Shut SL With pump wired to Unit SL Out Envision Unit # 5 Series to Electromechanical Units 5 Series Unit # with AXB Board SLI SLO VS IN OUT S Heat Pump ontactor oil To Electromechanical Unit 0

11 5 SEIES 500A INSTALLATION MANUAL Open Loop round Water Systems Variable Speed Pump Setup When using a variable speed pump flow center (FV- L or FV-L) the use of an AID Tool will be necessary to adjust minimum and maximum flow rates. The factory default is: minimum=75% and maximum=00% speed levels. 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. Ensure 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. Figure 9b: Open Loop Solenoid Valve onnection Option Typical slow operating external 4V water solenoid valve (type V00FPT) wiring. W/Y V Valve Orange(9) / White() (0) Acc om A N Acc NO AB Board 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. NOTE: For open loop/groundwater systems or systems that do not contain an antifreeze solution, set SW-Switch # to the WELL (0 F) position. (efer to the DIP Switch Settings table in the Aurora ontrol section.) Slow opening/ closing solenoid valves (type V00FPT) are recommended to eliminate water hammer. Figure 9a: Open Loop Solenoid Valve onnection Option Typical quick operating external 4V water solenoid valve (type PPV00 or BPV00) wiring. SV Solenoid Valve Acc om Acc N Acc NO AB Board P P NOTE: SW-4 should be ON and SW-5 should be OFF when using a slow opening (V00FPT) water valve. Figure 9c: Modulating Water Valve onnection Option Typical 0-0VD modulating water valve. Figure 0: Open System - roundwater Application Unit Supply NO TE: ND 4 VA 0-0D Aux. Heat Supply MODULATIN VALVE White reen ed AXB BOAD VS AB BOAD Flexible Duct ollar ubber Bladder Expansion Tank NOTE: SW-4 and SW-5 should be OFF to cycle with the compressor. Auxiliary Heater Knockout Hot Water enerator onnections Solenoid Valve Flow ontrol Valve (on outlet of Solenoid Valve) Water Out Drain 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)

12 5 SEIES 500A INSTALLATION MANUAL Hot Water enerator onnections To maximize the benefits of the hot water generator a minimum 50-gallon water heater is recommended For higher demand applications, use an 80-gallon water heater or two 50-gallon water heaters connected in a series as shown below. Two tanks plumbed in a series is recommended to maximize the hot water generator capability. Electric water heaters are recommended. Make sure all local electrical and plumbing codes are met for installing a hot water generator. esidential units with hot water generators contain an internal circulator and fittings. A water softener is recommended with hard water (greater than 0 grains or 70 total hardness). NOTES: ) Using a preheat tank, as shown in Figure, will maximize hot water generator capabilities. ) The hot water generator coil is constructed of vented double wall copper suitable for potable water. Figure : Typical Hot Water enerator Installation /4 x /4 x / tee Venting Waste Valve or Vent oupling HW Water In HW Water Out old Water In Drain Valve P/T elief Valve Figure : Hot Water enerator Installation In Preheat Tank In Hot Water Out Water Tank Preparation Venting Waste Valve or Vent oupling /4" x /4" x /" tee old Water In Hot Water Out To install a unit with a hot water generator, follow these installation guidelines.. Turn off the power to the water heater.. Attach a water hose to the water tank drain connection and run the other end of the hose to an open drain or outdoors.. lose the cold water inlet valve to the water heater tank. 4. Drain the tank by opening the valve on the bottom of the tank, then open the pressure relief valve or hot water faucet. 5. Flush the tank by opening the cold water inlet valve to the water heater to free the tank of sediments. lose when draining water is clear. 6. Disconnect the garden hose and remove the drain valve from the water heater. 7. efer to Plumbing Installation and Hot Water enerator Startup. HW Water In HW Water Out P/T elief Valve Drain Valve Storage Tank NOTE: This configuration maximizes hot water generator capability. In P/T elief Valve Drain Valve Electric Powered Water Heater AUTION: Elements will burn out if energized dry.

13 5 SEIES 500A INSTALLATION MANUAL Hot Water enerator onnections cont. Plumbing Installation. Inspect the dip tube in the water heater cold inlet for a check valve. If a check valve is present it must be removed or damage to the hot water generator circulator will occur.. emove drain valve and fitting.. Thread the /4-inch NPT x -/-inch brass nipple into the water heater drain port. 4. Attach the center port of the /4-inch FPT tee to the opposite end of the brass nipple. 5. Attach the /-inch copper to /4-inch NPT adaptor to the side of the tee closest to the unit. 6. Install the drain valve on the tee opposite the adaptor. 7. un interconnecting tubing from the tee to hot water generator water out. 8. ut the cold water IN line going to the water heater. 9. Insert the reducing solder tee in line with cold water IN line as shown. 0. un interconnecting copper tubing between the unit hot water generator water IN and the tee (/-inch nominal). The recommended maximum distance is 50 feet.. To prevent air entrapment in the system, install a vent coupling at the highest point of the interconnecting lines.. Insulate all exposed surfaces of both connecting water lines with /8-inch wall closed cell insulation. NOTE: All plumbing and piping connections must comply with local plumbing codes. Hot Water enerator Switch The hot water generator switch is taped in the disabled position at the factory. Hot Water enerator Startup. Turn the hot water generator switch to the ON position. The hot water generator switch will allow the hot water generator pump to be enabled or disabled by the service technician or homeowner.. lose the drain valve to the water heater.. Open the cold water supply to the tank. 4. Open a hot water faucet in the building to bleed air from the system. lose when full. 5. Open the pressure relief valve to bleed any remaining air from the tank, then close. 6. If so equipped, turn the venting (burping) screw in the center of the pump two () turns open (water will drip out), wait until all air is purged from the pump, then tighten the plug. Use vent couplings to bleed air from the lines. 7. arefully inspect all plumbing for water leaks and correct as required. 8. Before restoring electrical supply to the water heater, adjust the temperature setting on the tank. On tanks with both upper and lower elements, the lower element should be turned down to the lowest setting, approximately 00 F. The upper element should be adjusted to 0 F to 0 F. Depending upon the specific needs of the customer, you may want to adjust the upper element differently. On tanks with a single element, lower the thermostat setting to 0 F. 9. After the thermostat(s) is adjusted, replace the access cover and restore electrical supply to the water heater. 0. Make sure that any valves in the hot water generator water circulating circuit are open.. Turn on the unit to first stage heating.. Use an AID Tool to enable HW and select the desired water heating set point. Selectable set points are 00 F 40 F in 5 F increments (default 0 F). From the Main Menu of the AID Tool select Setup, then AXB Setup.. The hot water generator pump should be running. When the pump is first started, turn the venting (burping) screw (if equipped) in the center of the pump two () turns open until water dribbles out, then replace. Allow the pump to run for at least five minutes to ensure that water has filled the circulator properly. Be sure the switch for the hot water generator pump switch is ON. 4. The temperature difference between the water entering and leaving the hot water generator should be 5 F to 5 F. The water flow should be approximately 0.4 gpm per ton of nominal cooling. 5. Allow the unit to heat water for 5 to 0 minutes to be sure operation is normal. AUTION: Never operate the HW circulating pump while dry. If the unit is placed in operation before the hot water generator piping is connected, be sure that the pump switch is set to the OFF position.

14 5 SEIES 500A INSTALLATION MANUAL 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. Unit Power onnection onnect the incoming line voltage wires to L and L of the contactor as shown in Figure for single-phase unit. onsult the Unit Electrical Data in this manual for correct fuse sizes. Open lower front access panel. emove ground fastener from bottom of control box (Figure B). Swing open control box (Figure A). Insert power wires through knockouts on lower left side of cabinet. oute wires through left side of control box and connect to contactor and ground (Figure ). lose control box and replace grounding fastener before unit start-up. Accessory elay A set of dry contacts has been provided to control accessory devices, such as water solenoid valves on open loop installations, electronic air cleaners, humidifiers, etc. This relay contact should be used only with 4 volt signals and not line voltage power. The relay has both normally open and normally closed contacts and can operate with either the fan or the compressor. Use DIP switch SW-4 and 5 to cycle the relay with blower, compressor, or control a slow opening water valve. The relay contacts are available on terminals # and # for normally closed, and # and # for normally open on P. A second configurable accessory relay is provided on the AXB board, if installed. When powering high VA draw components such as electronic air cleaners or V type open loop water valves, should be taken pre-fuse from the quick connect on the AB board and not the post-fuse terminal on the thermostat connection. If not, blown AB fuses might result. 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 PB. Figure A: Wire access (control box open) Figure B: Wire access (control box closed) Figure : Line Voltage 08-0/60/ control box L L PB T T PS Wire Insert Location round Fastener must be installed for proper unit ground 4

15 5 SEIES 500A INSTALLATION MANUAL Electrical onnections cont. Pump Power Wiring See Figure 4 for electrical connections from control box to pumps. Figure 4: Pump Wiring 08-0/60/ Wire Nuts ed ed F/F style flow centers with fixed speed pumps connect to PB in the control box. If using a variable speed pump it should be connected to L and L on the AXB. Optional External Variable Speed Loop Pump (ex. Magna eo) 08-0/60/ AXB PB External Loop Pump(s) 08-0/60/ / hp Max AB B 5

16 Microprocessor ontroller AB ontroller AB ontroller 5 SEIES 500A INSTALLATION MANUAL Electronic Thermostat Installation Position the thermostat subbase against the wall so that it is level and the thermostat wires protrude through the middle of the subbase. Mark the position of the subbase mounting holes and drill holes with a /6-inch bit. Install supplied anchors and secure base to the wall. Thermostat wire must be 8-conductor (4 or 5 counductor for communicating thermostats), 0-AW (minimum) wire. Strip the wires back /4-inch (longer strip lengths may cause shorts) and insert the thermostat wires into the connector as shown. Tighten the screws to ensure secure connections. The thermostat has the same type connectors, requiring the same wiring. See instructions enclosed in the thermostat for detailed installation and operation information. The W terminal on TPMU0A and TPMU04A communicating thermostats may be hard wired to provide aux/emergency heat in the event communication is lost between the thermostat and the AB microprocessor. NOTE: Aurora Base ontrol (AB) DIP switch SW-7 is required to be in the OFF position for the control to operate with FaultFlash or omfortalk thermostats. SW-7 in the ON position configures the control to operate with typical thermostats (continuous lockout signal). There must be a wire connecting Y on the Aurora controller to nd stage compressor on the thermostat for proper operation. SW-7 DIP switch position is not relevant with communicating thermostats. Figure 5a: Thermostat Wiring (Y Style Signals) P7 W P Y Y W O L 4VA (ommon) 4VA (Hot) B- ommunication + A+ ommunication W (Optional) Thermostat onnection TPMU0A/TPMU04A Monochrome Thermostats 4VA (Hot) 4VA (ommon) ompressor (st Stage) ompressor (nd Stage) Aux. Heat eversing Valve Blower elay System Monitor Figure 5b: Thermostat Wiring (ommunicating Style Signals) P7 Thermostat onnection 4VA (ommon) 4VA (Hot) DX- ommunication + DX+ ommunication TPU0 olor Touchscreen Thermostat Thermostat onnection 6

17 5 SEIES 500A INSTALLATION MANUAL Auxiliary Heat atings kw Btu/h Model Size ompatibility Model Stages Min cfm 08V 0V 08V 0V EAS(H)4*.9.8 9,700, EAM(H)5*.6 4.8,00 6, EAM(H)8* ,400 5, EAM(H)0* ,600, EAL(H)0* ,600, EAL(H)5* ,900 49,00 50 EAL(H)0* ,00 65, Order the H part number when installed on horizontal and vertical rear discharge units /7/04 Air flow level for auxiliary heat (Aux) must be above the minimum cfm in this table Auxiliary Heat Electrical Data Model Supply Heater Amps Min ircuit Amp Fuse (USA) Fuse (AN) KT BK ircuit 08 V 40 V 08 V 40 V 08 V 40 V 08 V 40 V 08 V 40 V EAS(H)4* Single EAM(H)5* Single EAM(H)8* Single EAM(H)0* Single EAL(H)0* Single EAL(H)5* Single L/L L/L Single EAL(H)0* L/L L/L All heaters rated single phase 60 cycle and include unit blower load /7/04 All fuses type D time delay (or HA circuit breaker in USA) Supply wire size to be determined by local codes 7

18 5 SEIES 500A INSTALLATION MANUAL Electrical Data Single Speed Unit with Variable Speed EM Motor Model ated Voltage Voltage Min/Max * With optional hp EM motor ** With optional IntelliStart ated voltage of 08/0/60/ All fuses lass K-5 HA circuit breaker in USA only ompressor M LA LA LA** HW Pump FLA Ext Loop FLA Blower Motor FLA /60/ 87/ n/a /60/ 87/ /60/ 87/ /60/ 87/ * 08-0/60/ 87/ /60/ 87/ * 08-0/60/ 87/ /60/ 87/ * 08-0/60/ 87/ /60/ 87/ /60/ 87/ Single Speed Unit with 5-Speed EM Motor Model ated Voltage Voltage Min/Max ompressor M LA LA LA** /60/ 87/ /60/ 87/ /60/ 87/ /60/ 87/ /60/ 87/ /60/ 87/ /60/ 87/ ** With optional IntelliStart 4/6/ ated voltage of 08/0/60/ All fuses lass K-5 HA circuit breaker in USA only Single Speed Unit with PS Motor Model ated Voltage Voltage Min/Max ompressor M LA LA LA** /60/ 87/ n/a /60/ 87/ n/a /60/ 87/ * 08-0/60/ 87/ /60/ 87/ * 08-0/60/ 87/ /60/ 87/ * 08-0/60/ 87/ /60/ 87/ * 08-0/60/ 87/ /60/ 87/ * 08-0/60/ 87/ /60/ 87/ /60/ 87/ * With optional high static motor 4/6/ ** With optional IntelliStart ated voltage of 08/0/60/ All fuses lass K-5 HA circuit breaker in USA only HW Pump FLA HW Pump FLA Ext Loop FLA Ext Loop FLA Blower Motor FLA Blower Motor FLA Total Unit FLA Total Unit FLA Total Unit FLA Min irc Amp Min irc Amp Min irc Amp Max Fuse/ HA 4/6/ Max Fuse/ HA Max Fuse/ HA 8

19 5 SEIES 500A INSTALLATION MANUAL Electrical Data cont. Dual apacity Unit with Variable Speed EM Motor Model ated Voltage Voltage Min/Max ompressor M LA LA LA** HW Pump FLA Ext Loop FLA Blower Motor FLA /60/ 87/ /60/ 87/ * 08-0/60/ 87/ /60/ 87/ * 08-0/60/ 87/ /60/ 87/ /60/ 87/ * With optional hp EM motor ** With optional IntelliStart ated voltage of 08/0/60/ All fuses lass K-5 HA circuit breaker in USA only Dual apacity Unit with 5-Speed EM Motor Model ated Voltage Voltage Min/Max ompressor M LA LA LA** HW Pump FLA Ext Loop FLA Blower Motor FLA Total Unit FLA Total Unit FLA Min irc Amp Min irc Amp Max Fuse/ HA 9// /60/ 87/ /60/ 87/ /60/ 87/ /60/ 87/ /60/ 87/ //5 ** With optional IntelliStart ated voltage of 08/0/60/ All fuses lass K-5 HA circuit breaker in USA only Max Fuse/ HA 9

20 5 SEIES 500A INSTALLATION MANUAL Blower Performance Data Single Speed Unit with Variable Speed EM Motor Model Max ESP w/hp* w/hp* w/hp* Airflow Speed Settings L H Aux L H Aux L H Aux L H Aux L H Aux L H Aux L H Aux L H Aux L H Aux L H Aux L H Aux Factory settings are at recommended -L-H-Aux speed settings L-H settings MUST be located within boldface cfm range Aux is factory setting for auxiliary heat and must be equal to or above the H setting as well as at least the minimum required for the auxiliary heat package may be located anywhere within the airflow table fm is controlled within ±5% up to the maximum ESP Max ESP includes allowance for wet coil and standard filter 6/8/ Dual apacity Unit with Variable Speed EM Motor Model Max ESP w/hp* w/hp* Airflow Switch Settings L H Aux L H Aux L H Aux L H Aux L H Aux L H Aux L H Aux Factory settings are at recommended -L-H-Aux speed settings L-H settings MUST be located within boldface cfm range Aux is factory setting for auxiliary heat and must be equal to or above the H setting as well as at least the minimum required for the auxiliary heat package may be located anywhere within the airflow table fm is controlled within ±5% up to the maximum ESP Max ESP includes allowance for wet coil and standard filter 6/8/ 0

21 5 SEIES 500A INSTALLATION MANUAL Blower Performance Data cont. Setting Blower Speed - Variable Speed EM The AB board s Yellow onfig LED will flash the current EM blower speed selections for, low, and high continuously with a short pause in between. The speeds can also be confirmed with the AID Tool under the Setup/ EM Setup screen. The Aux will not be flashed but can be viewed in the AID Tool. The EM blower motor speeds can be field adjusted with or without using an AID Tool. EM Setup without an AID Tool The blower speeds for, Low (Y), High (Y), and 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 EM onfiguration Mode portion of the Aurora Base ontrol System section. The Aux cannot be set manually without an AID Tool. EM Setup with an AID Tool A much easier method utilizes the AID Tool to change the airflow using the procedure below. First navigate to the Setup screen and then select EM Setup. This screen displays the current EM settings. It allows the technician to enter the setup screens to change the EM settings. hange the highlighted item using the and buttons and then press the button to select the item. EM Speed Info Blower Only Speed Lo ompressor 6 Hi ompressor 9 Aux Heat 0 Selecting YES will enter EM speed setup, while selecting NO will return to the previous screen. EM Speed Setup - These screens allow the technician to select the, low, high, and auxiliary heat blower speed for the EM blower motor. hange the highlighted item using the and buttons. Press the button to select the speed EM Speed Info Option Enter Lo EM Speed Info Option ooling Airflow Setup Enter --- EM Only --- The airflow will be adjusted by the chosen amount in cooling mode. Adjustment: -5% Want To hange? Yes No Option Enter EM Speed Info Lo Hi Option Enter EM Speed Info Lo Hi Option ooling Airflow Setup --- EM Only --- The airflow will be adjusted by the chosen amount in cooling mode. Adjustment: -5% hange Enter Aux Enter After the auxiliary heat speed setting is selected the AID Tool will automatically transfer back to the EM Setup screen. ooling Airflow Setup - These screens allow the technician to select -5%, -0%, -5%, None or +5%. hange the adjustment percentage using the and buttons. Press the button to save the change. Want To hange? Yes Option No Enter

22 5 SEIES 500A INSTALLATION MANUAL Blower Performance Data cont. Single Speed Unit with 5-Speed EM Motor Model Motor Motor T stat Blower Motor Airflow (cfm) at External Static Pressure (in. wg) Speed Tap nct. Size HP High 5 W Med High 4 Y Med 9 x 7 / Med Low Low High Med High 4 W Med Y 9 x 7 / Med Low Low High 5 W Med High 4 Y Med x 0 / Med Low Low High Med High 4 W Med x Med Low Y Low High Med High 4 W Med Y x Med Low Low High 5 W Med High Med x Med Low Y Low High 5 W Med High 4 Y Med x Med Low Low Factory speed settings are in Bold 6/4/ Air flow values are with dry coil and standard filter For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [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. Highest setting is for auxiliary heat (W) and lowest setting is for constant blower (). The Y and Y settings must be between the and W settings. The gray wire is not factory wired to the motor and is tied to the wire harness. This wire can be field connected and can be used with ht/cl thermostats or IntelliZone to deliver the required air flow for the Y signal. 5-Speed EM onstant Torque Motors The 5-Speed EM is a onstant Torque EM motor and delivers air flow similar to a PS but operates as efficiently as an EM Motor. Because it s an EM Motor, the 5-Speed EM can ramp slowly up or down like the 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. 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 or with Fan,,, and E output 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 4 VA. 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 ()

23 5 SEIES 500A INSTALLATION MANUAL Blower Performance Data cont. Dual apacity Unit with 5-Speed EM Model Motor Motor T stat Blower Motor Airflow (cfm) at External Static Pressure (in. wg) Speed Tap nct. Size HP High 5 W Med High 4 Y Med 9 x 7 / Med Low Y Low High 5 W Med High 4 Y Med Y x 0 / Med Low Low High 5 W Med High Med Y x Med Low Y Low High 5 W Med High 4 Y Med x Med Low Y Low High 5 W Med High 4 Y Med x Med Low Y Low Factory speed settings are in Bold 6/4/ Air flow values are with dry coil and standard filter For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [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. Highest setting is for auxiliary heat (W) and lowest setting is for constant blower (). The Y and Y settings must be between the and W settings. Setting Blower Speed - 5-Speed EM 5-Speed EM blower motors have five (5) speeds of which three () are selectable on single speed and four (4) are selectable on dual capacity. AUTION: Disconnect all power before performing this operation. 5-Speed EM Motor onnections - Single Speed 5-Speed EM Motor onnections - Dual apacity - L - Orange - reen High Voltage onnections /6 in. L N N - Brown - L - Orange - reen High Voltage onnections /6 in. L N N - Brown - Y - ed 4 5 Low Voltage onnections /4 in. AUX - ray - Y - ed 4 5 Low Voltage onnections /4 in. AUX - ray Y - Tan

24 5 SEIES 500A INSTALLATION MANUAL Blower Performance Data cont. Unit with Standard PS Motor Model Motor Blower Motor Airflow (cfm) at External Static Pressure (in. wg) Spd Size HP 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 0 x 0 / L H M 0 x 0 / L H M 0 x 0 / L H M x L H M x L /7/ Unit with Optional High Static PS Motor Model Motor Blower Motor Airflow (cfm) at External Static Pressure (in. wg) Spd Size HP H M 9 x 7 / L H M 9 x 7 / L H M 0 x 0 / L H M 0 x 0 / L H M 0 x 0 / L Factory settings are in Bold /5/ High-Static option not available for 0, 08, 060, and 070 Air flow values are with dry coil and standard filter For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [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 Blower Speed - PS AUTION: Disconnect all power before performing this operation. BLOWE SPEED WIE HIH MEDIUM LOW PS BLOWE MOTO BODY 4

25 5 SEIES 500A INSTALLATION MANUAL Vertical Dimensional Data Top Air Discharge LEFT ETUN IHT ETUN Q P O Q L O M L N N TOP TOP.9in [4.8cm] T T.9in [4.8cm] S S KJ I A FONT DEHF ft [6cm] Primary Service Access B LEFT SIDE B IHT SIDE Vertical Top Flow Model Overall abinet Water onnections Electrical onnections I /4 in. cond J / in. cond K / in. cond Discharge onnection duct flange installed (±0.0 in) eturn onnection using std deluxe filter rack (±0.0 in) A B D E F H Loop HW L M N O P Q S T Water Sweat Width Depth Height Loop Loop HW HW ond- Power Ext Low Supply Supply eturn eturn In Out In Out ensate FPT (I.D.) Supply Pump Voltage Width Depth Depth Height 0 in in. / in cm Swivel Female in in. / in cm Swivel Female in in. / in cm Swivel Female in in. / in cm Swivel Female in in. / in cm Swivel Female in in. / in cm Swivel Female ondensate is /4 in. PV female glue socket and is switchable from side to front 7// Unit shipped with deluxe in. (field adjustable to in.) duct collar/filter rack extending from unit.5 in. and is suitable for duct connection. Discharge flange is field installed and extends in. [5.4 mm] from cabinet Decorative molding and/or water connections extend. in. [0.5 mm] beyond front of cabinet. Top panel has.75 in. and.5 in. knockouts for electrical connections. 5

26 5 SEIES 500A INSTALLATION MANUAL Vertical Dimensional Data cont. Bottom Air Discharge LEFT ETUN IHT ETUN 4.70 (4. cm) S S T T K J I D E F B LEFT SIDE Q B IHT SIDE Q.90 (4.7 cm) 5 L A FONT H ft [6cm] Primary Service Access O N L M N O P LEFT BOTTOM DISHAE FLOO FOOT PINT IHT BOTTOM DISHAE FLOO FOOT PINT Bottom Flow Models Overall abinet Water onnections 4 5 I /4 in. cond Electrical Knockouts J / in. cond K / in. cond Discharge onnection duct flange installed (±0.0 in) eturn onnection using std deluxe filter rack (±0.0 in) A B D E F H Loop HW L M N O P Q S T Power Ext Low HW HW ondensate FPT (I.D.) Width Depth Depth Height Water Sweat Width Depth Height In Out Supply Pump Voltage Supply Supply eturn eturn In Out 0- in in. / in cm Swivel Female in in. / in cm Swivel Female ondensate is /4 in. PV female glue socket and is switchable from side to front 7// Vertical bottom flow unit shipped with deluxe in. (field adjustable to in.) duct collar/filter rack extending from unit.5 in. and is suitable for duct connection. Water connections extend. in. (0.5mm) beyond front of cabinet. Top panel has.75 in. and.5 in. knockouts for electrical connections. 6

27 5 SEIES 500A INSTALLATION MANUAL Vertical Dimensional Data cont. ear Air Discharge K J I E H F A FONT D O Q T T Q P M M L S S L N N A B B A EA VIEW LEFT ETUN SIDE VIEW LEFT ETUN SIDE VIEW IHT ETUN EA VIEW IHT ETUN Vertical ear Discharge Models Overall abinet Water onnections A B D E F H Loop Water Width Depth Height Loop Loop HW HW ond- FPT In Out In Out ensate HW Sweat (I.D.) Electrical onnections I /4 in. cond J / in. cond K / in. cond Discharge onnection duct flange installed (±0.0 in) eturn onnection using std deluxe filter rack (±0.0 in) L M N O P Q S T Power Ext Low Supply Supply eturn eturn Supply Pump Voltage Width Depth Depth Height 04- in / cm Swivel female in / cm Swivel female ondensate is /4 in. PV female glue socket and is switchable from side to front 7// Unit shipped with deluxe in. (field adjustable to in.) duct collar/filter rack extending from unit.5 in. and is suitable for duct connection. Discharge flange is field installed and extends in. [5.4mm] from cabinet Decorative molding and water connections extend. in. [0.5mm] beyond front of cabinet. Top panel has.75 in. and.5 in. knockouts for electrical connections. 7

28 5 SEIES 500A INSTALLATION MANUAL Horizontal Dimensional Data TOP VIEW Q P.in [5.4cm] MOUNT () HANE BAKETS AS SHOWN TO ALLOW AESS TO FILTE ft [6cm] Primary Service Access.9in [4.8cm] FONT VIEW A S SIDE DISHAE VIEW B N O L L END VIEW O S M KJ I D E F AS SHOWN L UNIT ( UNIT ON OPPOSITE SIDE SAME DIMENSIONS) H Horizontal Model Overall abinet Water onnections Units Not Shown Above L O ight eturn End Discharge in cm 7..8 ight eturn Side Discharge in cm Left eturn End Discharge in cm Left eturn Side Discharge in cm Electrical onnections I /4 in. cond J / in. cond K / in. cond Discharge onnection duct flange installed (±0.0 in) eturn onnection using std deluxe filter rack (±0.0 in) A B D E F H Loop HW L M N O P Q S Width Depth Height In Out HW HW ond- Water Sweat Power Ext Low Supply Supply eturn eturn In Out ensate FPT (I.D.) Supply Pump Voltage Height Depth Depth Height 0 in in. / in cm Swivel Female in in. / in cm Swivel Female in in. / in cm Swivel Female in in. / in SEE.6. SEE cm Swivel Female HAT HAT in in. / in SEE.6. SEE cm Swivel Female HAT HAT in in. / in SEE.6. SEE cm Swivel Female HAT HAT ondensate is /4 in. PV female glue socket and is switchable from side to front 7// Unit shipped with deluxe in. (field adjustable to in.) duct collar/filter rack extending from unit.5 in. and is suitable for duct connection. Discharge flange is field installed and extends in. [5.4mm] from cabinet Decorative molding and/or water connections extend. in. [0.5mm] beyond front of cabinet. 8

29 5 SEIES 500A INSTALLATION MANUAL Physical Data Single Speed SINLE SPEED Model ompressor ( each) otary Scroll Factory harge 40a, oz [kg] (Aluminum tube and fin air coil) Vertical 6 [.0] 4 [.9] 56 [.58] 64 [.8] 8 [.] 84 [.8] 9 [.60] [.7] 4 [.79] Factory harge 40a, oz [kg] (Aluminum tube and fin air coil) Horizontal 6 [.0] 4 [.9] 54 [.5] 64 [.8] 76 [.5] 84 [.8] 9 [.60] 88 [.49] 0 [.] Blower Motor & Blower VS EM n/a Variable Speed EM 5-Spd EM n/a n/a 5 Speed EM Blower Motor Type/Speeds PS - PS PS - Speeds 4 Speeds VS EM n/a / [7] / [7] / [7] / [7] / [7] / [7] [746] [746] Blower Motor- hp [W] 5-Spd EM n/a n/a / [7] / [7] / [7] [746] [746] [746] [746] PS /0 [75] /6 [4] /5 [49] / [49] / [7] / [7] / [7] [746] [746] High Static Blower Motor - hp [W] VS EM n/a n/a n/a n/a [746] [746] [746] n/a n/a PS n/a n/a / [49] / [49] / [7] /4 [560] /4 [560] n/a n/a Blower Wheel Size (Dia x W), in. [mm] High Static Blower Wheel Size (Dia x W), in. [mm] oax and Water Piping VS EM & 9 x 7 n/a 5-Spd EM [9 x 78] 6 x 8 PS [5 x 0] 9 x 7 [9 x 78] 9 x 7 9 x 7 x 0 x 0 x 0 x 0 [9 x 78] [9 x 78] [79 x 54] [79 x 54] [79 x 54] [79 x 54] 9 x 7 [9 x 78] 9 x 7 0 x 0 0 x 0 0 x 0 x 0 [9 x 78] [54 x 54] [54 x 54] [54 x 54] [79 x 54] x 0 x 0 x 0 VS EM n/a n/a n/a n/a n/a [79 x 54] [79 x 54] [79 x 54] 9 x 7 PS n/a n/a [9 x 78] 9 x 7 0 x 0 0 x 0 0 x 0 n/a [9 x 78] [54 x 54] [54 x 54] [54 x 54] x 0 [79 x 54] x 0 [79 x 54] n/a n/a Water onnections Size - Swivel - in [mm] [5.4] [5.4] [5.4] [5.4] [5.4] [5.4] [5.4] [5.4] [5.4] HW onnection Size - Female Sweat I.D. - in [mm] n/a / [.7] / [.7] / [.7] / [.7] / [.7] / [.7] / [.7] / [.7] oax & Piping Water Volume - gal [l] 0.5 [.] 0.40 [.5] 0.7 [.6].0 [.8]. [4.9]. [4.9].6 [6.].6 [6.]. [8.7] Vertical Air oil Dimensions (H x W), in. [mm] 6 x 6 9 x 0 4 x 0 8 x 0 8 x 5 x 5 x 5 6 x 5 6 x 5 [406 x 406] [48 x 508] [60 x 54] [7 x 54] [7 x 65] [8 x 65] [8 x 65] [94 x 65] [94 x 65] Air oil Total Face Area, ft [m].8 [0.67].6 [0.4]. [0.0].9 [0.6] 4.9 [0.45] 5.6 [0.570] 5.6 [0.570] 6. [0.64] 6. [0.64] Air oil Tube Size, in [mm] /8 [9.5] 5/6 [7.9] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] Air oil Number of rows 4 4 Filter Standard - [5mm] 6 x 0 0 x 4 Pleated MEV Throwaway, in [mm] [406 x 508] [508 x 60] 8 x 4 [7 x 60] 8 x 4 8 x 0 [7 x 60] [7 x 76] x 0 [8 x 76] x 0 6 x 0 [8 x 76] [94 x 76] 6 x 0 [94 x 76] Weight - Operating, lb [kg] 65 [75] 00 [9] 9 [] 08 [40] 5 [60] 68 [67] 408 [85] 44 [0] 468 [] Weight - Packaged, lb [kg] 85 [84] 0 [00] [4] 8 [49] 7 [69] 88 [76] 48 [94] 46 [0] 488 [] Horizontal 6 x 6 8 x 8 x 7 8 x 0 0 x 5 0 x 40 0 x 40 0 x 45 Air oil Dimensions (H x W), in. [mm] [406 x 406] [457 x 5] [457 x 686] [457 x 76] [508 x 889] [508 x 06] [508 x 06] [508 x 4] 0 x 45 [508 x 4] Air oil Total Face Area, ft [m].8 [0.67].6 [0.4].4 [0.6].9 [0.6] 4.9 [0.45] 5.6 [0.570] 5.6 [0.570] 6. [0.64] 6. [0.64] Air oil Tube Size, in [mm] /8 [9.5] 5/6 [7.9] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] Air oil Number of rows - 0 x 0-0 x 0-0 x 5-0 x 5 Filter Standard - [5mm] Pleated MEV - 6 x 0-8 x 4-8 x - 8 x - 0 x 7 [508 x 508] [508 x 508] [508 x 65] [508 x 65] Throwaway, in [mm] [406 x 508] [457 x 60] [457 x 8] [457 x 8] [686 x 940] - 0 x - 0 x - 0 x - 0 x [508 x 559] [508 x 559] [508 x 559] [508 x 559] Weight - Operating, lb [kg] 65 [75] 00 [9] 00 [6] 5 [4] 68 [67] 40 [8] 48 [90] 45 [05] 478 [7] Weight - Packaged, lb [kg] 85 [84] 0 [00] 0 [45] 5 [5] 88 [76] 4 [9] 48 [99] 47 [5] 498 [6] //07 9

30 5 SEIES 500A INSTALLATION MANUAL Physical Data cont. Dual apacity DUAL APAITY Model ND06 ND08 ND049 ND064 ND07 ompressor ( each) opeland UltraTech, Dual apacity Scroll Factory harge 40a, oz [kg] (Aluminum tube and fin air coil) Vertical 56 [.58] 70 [.98] 9 [.6] [.7] 0 [.68] Factory harge 40a, oz [kg] (Aluminum tube and fin air coil) Horizontal 58 [.64] 76 [.5] 9 [.6] [.7] 6 [.85] EM Blower Motor & Blower Blower Motor Type/Speeds VS EM Variable Speed EM 5-Spd EM 5 Speed EM Blower Motor- hp [W] VS EM / [7] / [7] / [7] [746] [746] 5-Spd EM / [7] / [7] [746] [746] [746] High Static Blower Motor - hp [W] VS EM n/a [746] [746] n/a n/a Blower Wheel Size (Dia x W), in. [mm] VS EM 9 x 7 x 0 x 0 x 0 x 0 [9 x 78] [79 x 54] [79 x 54] [79 x 54] [79 x 54] 5-Spd EM 9 x 7 x 0 x 0 x 0 x 0 [9 x 78] [79 x 54] [79 x 54] [79 x 54] [79 x 54] High Static Blower Wheel Size - [Dia. x W], in. [mm] VS EM n/a x 0 x 0 [79 x 54] [79 x 54] n/a n/a oax and Water Piping Water onnections Size - Swivel - in [mm] [5.4] [5.4] [5.4] [5.4] [5.4] HW onnection Size - Female Sweat I.D. - in [mm] / [.7] / [.7] / [.7] / [.7] / [.7] oax & Piping Water Volume - gal [l] 0.7 [.6]. [4.9].6 [6.].6 [6.]. [8.7] Vertical Air oil Dimensions (H x W), in. [mm] 4 x 0 8 x 5 x 5 6 x 5 6 x 5 [60 x 54] [7 x 65] [8 x 65] [94 x 65] [94 x 65] Air oil Total Face Area, ft [m]. [0.0] 4.9 [0.45] 5.6 [0.570] 6. [0.64] 6. [0.64] Air oil Tube Size, in [mm] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] Air oil Number of rows 4 4 Filter Standard - [5mm] Pleated MEV Throwaway, in [mm] 8 x 4 [7 x 60] 8 x 0 [7 x 76] x 0 [8 x 76] 6 x 0 [94 x 76] 6 x 0 [94 x 76] Weight - Operating, lb [kg] 9 [] 58 [6] 408 [85] 45 [05] 468 [] Weight - Packaged, lb [kg] [4] 78 [7] 48 [94] 47 [5] 488 [] Horizontal Air oil Dimensions (H x W), in. [mm] 8 x 7 0 x 5 0 x 40 0 x 45 0 x 45 [457 x 686] [508 x 889] [508 x 06] [508 x 4] [508 x 4] Air oil Total Face Area, ft [m].4 [0.6] 4.9 [0.45] 5.6 [0.570] 6. [0.64] 6. [0.64] Air oil Tube Size, in [mm] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] /8 [9.5] Air oil Number of rows x 0-0 x 5-0 x 5 Filter Standard - [5mm] Pleated MEV Throwaway, in [mm] - 8 x [457 x 8] - 0 x 7 [686 x 940] [508 x 508] - 0 x [508 x 65] - 0 x [508 x 65] - 0 x [508 x 559] [508 x 559] [508 x 559] Weight - Operating, lb [kg] 00 [6] 68 [67] 48 [90] 46 [0] 480 [8] Weight - Packaged, lb [kg] 0 [45] 88 [76] 48 [99] 48 [9] 500 [7] //07 0

31 5 SEIES 500A INSTALLATION MANUAL The Aurora ontrol System Aurora Base ontrol The Aurora Base ontrol (AB) System is a complete residential and commercial comfort system that brings all aspects of the HVA system into one cohesive module network. The AB features microprocessor control and HP, LP, condensate and freeze detection, over/under voltage faults, along with communicating thermostat capability for complete fault detection text at the thermostat. Aurora uses the Modbus communication protocol to communicate between modules. Each module contains the logic to control all features that are connected to the module. The Aurora Base ontrol (AB) has two Modbus channels. The first channel is configured as a master for connecting to devices such as a communicating thermostat, expansion board, or other slave devices. The second channel is configured as a slave for connecting the Aurora Interface Diagnostics Tool (AID Tool). Aurora Advanced ontrol The Aurora Advanced ontrol expands on the capability of the Aurora Base ontrol (AB) System by adding the Aurora Expansion Board (AXB). The additional features include compressor current monitoring, loop pump slaving, intelligent hot water generator control, variable speed pump capability, and also allows for optional energy, refrigeration, and performance monitoring factory installed add-on sensor kits. The AXB also features a second field configurable accessory relay, and two home automation inputs that are AID configurable for different types of alarms from sump pumps to home security. The Smart rid input is AID configurable with many options to react to Utility controlled relay operation for ON Peak optimization. The AXB also expands the communication capability for IntelliZone ready operation as well as other expansion with the limatetalk protocol. Aurora ontrol Features Description Aurora Base Aurora 'Advanced' Microprocessor ompressor ontrol Advanced Microprocessor Features Base Hot Water enerator Operation Microprocessor control of compressor for timings with FP, HP, LP, ondensate, assignable Acc relay Smart rid, Home Automation Alarm Inputs, and Accessory elay (HV/EV) - ompressor ontactor powers Hot Water enerator Pump with inline circuit breaker and thermostat limit. See below Advanced Hot Water enerator ontrol Microprocessor and separate power relay for Hot Water enerator Pump with digital temperature monitoring and multiple HW setpoint selection. - Base Loop Pump ontrol ompressor ontactor powers Loop Pump with inline circuit breaker and no loop pump slaving capability. See below Advanced Speed Pump ontrol Variable Speed Pump ompressor Monitoring Microprocessor and separate power relay for loop pump and inline circuit breakers and loop pump slaving. apable of setup, monitoring and controlling a variable speed flow center. ontrol monitors compressor starts for high current, missing let etc Active Dehumidification oil temperature is monitored and air flow is reduced for maximum latent moisture removal. - 7 Series Variable Speed Only Smart rid/utility Input Home Automation Alarm Input HAN/Smart rid om (AWL and Portal) Kit Allows simple input to externally enable of occupied/ unoccupied mode for basic utility time of use programs. Allows simple input to signal sump, security, or smoke/o sensor alarms from other home automation or security systems. The two inputs can be field configured to a number of options and logic. Allows direct communication of the Aurora to Smart Meters, Home Automation Network and Internet. - Dry ontact x - Dry ontactx - Optional AWL IntelliZone ompatibility IntelliZone communicates Modbus to the heat pump via the AXB board. With Optional AXB Kit and IntelliZone Optional IntelliZone IntelliZone 4V ompatibility ommunicates to the heat pump via 4VA (AXB not required) -

32 5 SEIES 500A INSTALLATION MANUAL The Aurora ontrol System cont. Service Device Description Aurora Base Aurora 'Advanced' Allows setup, monitoring and troubleshooting of any Aurora ontrol. Aurora Interface and Diagnostics (AID) Tool NOTE: Although the AB has basic compatibility with all Aurora, new product features may not be available on older AID Tools. To simplify the basic compatibility ensure the version of AID is at least the same or greater than the AB software version. For Service (Ver..xx or greater) For Service (Ver..xx or greater) Add On ontrol Feature Kits (field or factory installed) eo Energy Monitoring Kit efrigeration Monitoring Kit Performance Monitoring Kit Data Logging (AWL) Kit HAN/Smart rid om (AWL and Portal) Kit AXB Kit for advanced hot water generator control, flow center linking, variable speed pump, IntelliZone Description Aurora Base Aurora 'Advanced' Monitors realtime power consumption of compressor, blower, aux heat and pump. equires thermostat TPMUOA, TPMUO4A, or TPUO. AXB required. Monitors realtime pressures, temperatures, superheat, and subcooling. AXB required. Monitors air and water temperatures, and water flow rate and calculates heat of extraction/rejection. AXB required. Allows data logging of up to months. AXB required. an also be temporarily installed. Allows direct communication of the Aurora to Smart Meters, HAN, and internet. AXB required. Added to 5 Series for key features of advanced hot water generator control, advanced loop control/linking, IntelliZone communication, and variable speed pump control. - Standard - Optional Sensor Kit - Optional Sensor Kit - Optional - Optional Optional (Field Kit) Standard Add On Thermostats and Zoning Description Aurora Base Aurora Advanced TPU0/04 - Monohrome Traditional Y, Y Thermostat Elite Stat with full English fault codes and alerts, traditional Y, Y thermostat. Not compatible with AWL. Optional Optional Traditional Y, Y thermostat. Not compatible with AWL. Optional Optional TPS0/0 - Traditional Y, Y Thermostat TPMU0A/04A - Monohrome ommunicating Thermostat Elite Stat with full English fault codes and alerts, communicating thermostat. Monochrome thermostat allows instantaneous energy measurement only. ompatible with AWL. Optional Optional TPU0 - olor Touchscreen ommunicating Thermostat 4. in. color touchscreen communicating thermostat with full English fault codes and alerts. olor thermostat allows instantaneous energy measurement and month energy usage history. ompatible with AWL. Optional Optional IntelliZone 4V Zoning ompatibility IntelliZone 4V is a non-communicating zoning system requiring Y, Y signals that controls up to 4 zones (dual capacity) and zones (single speed.) For heat pumps without the optional AXB board. Optional (5-Speed EM or Variable Speed EM Preferred) Optional (IntelliZone Preferred) IntelliZone is a communicating zoning system that includes color main thermostat and up to 6 zones (with variable speed, 4 zones (with dual capacity), and zones (with single speed). There are thermostat options (MasterStat, SensorStat, ZoneStat). ompatible with AWL. - Optional (IntelliZone Preferred) IntelliZone Zoning

33 5 SEIES 500A INSTALLATION MANUAL The Aurora Base ontrol System cont. Aurora Base ontrol NOTE: efer to the Aurora Base ontrol Application and Troubleshooting uide and the Instruction uide: Aurora Interface and Diagnostics (AID) Tool for additional information. ontrol Features Software AB Standard Version.0 Single or Dual apacity ompressors Either single or dual capacity compressors can be operated. Variable Speed EM Blower Motor Option A Variable Speed EM blower motor can be driven directly using the onboard PWM output. Four blower speeds are available based upon the, Y, Y, and W input signals to the board. The blower speeds can be changed either by the EM manual configurations mode method or by using the Aurora AID Tool directly. All four blower speeds can be set to the same speed if desired. 5-Speed EM Blower Motor Option A 5-Speed EM blower motor will be driven directly using the thermostat connections. Any of the, Y, or Y/W signals can drive any of the 5 available pre-programmed blower speeds on the motor. All 5 Series "" vintage units will be wired this way at the factory. 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) Modbus communication (slave) 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. Test mode can be exited by pressing and holding the SW button for to 5 seconds or by cycling the power. NOTE: Test mode will automatically be exited after 0 minutes. Variable Speed EM onfiguration Mode The control is placed in the EM configuration mode by holding the pushbutton switch SW for 5 to 0 seconds, the high, low, and EM speeds can be selected by following the LED display lights. LED (yellow) will fast flash when entering the EM configuration. When setting speed LED (green) will be continuously lit, for low speed LED (red) will be continuously lit, and for high speed both LED (green) and LED (red) will be continuously lit. During the 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. speed has now been selected. Next select low speed, and high speed blower selections following the same process above. After third selection has been made, the control will exit the EM configuration mode. Aux fan speed will remain at default or current setting and requires the AID Tool for adjustment. 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 Low water coil temperature limit setting for freeze detection. On = 0 F; Off = 5 F. SW- FP Selection On = 0 F; Off = N/A 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 Access elay Operation SW-4 SW-5 ycle with Blower ON ON ycle with ompressor OFF OFF Water Valve Slow Opening ON OFF ycle with omm. T-stat Hum md OFF ON

34 5 SEIES 500A INSTALLATION MANUAL The Aurora Base ontrol System cont. 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. SW-6 Operation selection of single or dual capacity compressor. On = Single Stage; Off = Dual apacity SW-7 Lockout and Alarm Outputs (P) selection of a continuous or pulsed output for both the LO and ALM Outputs. On = ontinuous; Off = Pulsed SW-8 Future Use 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 EM manual configurations mode method or by using the Aurora AID Tool directly (see Instruction uide: Aurora Interface and Diagnostics (AID) Tool topic). Field Selectable Options via Software (Selectable via the Aurora AID Tool) Variable Speed EM Blower Speeds An EM blower motor can be driven directly using the onboard PWM output. Four blower speeds are available, based upon the, Y (low), Y (high), and Aux input signals to the board. The blower speeds can be changed either by the EM manual configurations mode method (see EM onfiguration Mode topic) or by using the Aurora AID Tool directly. All four blower speeds can be set to the same speed if desired. Aux blower speed will remain at default or current setting and requires the AID Tool for adjustment. Safety Features The following safety features are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions. Fuse a amp automotive type plug-in fuse provides protection against short circuit or overload conditions. Anti-Short ycle Protection 4 minute anti-short cycle protection for the compressor. 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 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 seconds. To reset lockout conditions with SW-8 Off, thermostat inputs Y, Y, W, and DH must be removed for at least seconds. Lockout may also be reset by turning power off for at least 0 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 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 minutes. When the W input is removed, all of the emergency heat outputs will turn off, and the EM blower will shift to 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 hardwired 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. Freeze Detection (oax) - 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. Freeze Detection (Air oil) - uses the FP input to protect against ice formation on the air coil. The FP input will operate exactly like FP except that the set point is 0 degrees and is not field adjustable. 4

35 5 SEIES 500A INSTALLATION MANUAL The Aurora Base ontrol System cont. 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 selfresetting 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 speed immediately and the compressor is energized 0 seconds after the Y input is received. The EM blower motor is switched to low 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 EM blower will shift to high speed 5 seconds after the Y input is received. Heating, rd Stage (Y, Y, W) - The hot water pump is deenergized and 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 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 Aux speed. If the emergency heat demand is not satisfied after minutes the second electric heat stage will be energized. Blower () - The blower will start immediately upon receiving a thermostat command. If there are no other commands from the thermostat the EM will run on speed until the command is removed. egardless of blower input () from the thermostat, the blower will remain on for 0 seconds at the end of each heating cycle. 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 speed immediately and the compressor is energized 0 seconds after the Y input is received. The EM blower motor is switched to low 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 is received. The EM blower will shift to high speed 5 seconds after the Y input is received. Blower () - The blower will start immediately upon receiving a thermostat command. If there are no other commands from the thermostat the EM will run on speed until the command is removed. egardless of blower input () from the thermostat, the blower will remain on for 0 seconds at the end of each heating, cooling, and emergency heat 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 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. 5

36 5 SEIES 500A INSTALLATION MANUAL The Aurora Base ontrol System cont. Aurora Base ontrol 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 (Future Use) Flash ode (Future Use) Flash ode 4 Load Shed Flash ode 5 ESD Flash ode 6 (Future Use) Flash ode 7 onfiguration LED (LED, Yellow) Description of Operation No Software Overwritten DIP Switch was Overwritten EM onfiguration Mode Fault LED (LED, ed) ed Fault LED onfiguration LED, Yellow Flashing EM Setting Slow Flash Fast Flash LED Flash ode* Lockout eset/ emove Normal - No Faults OFF Fault - Input No Auto Fault - High Pressure Yes Hard or Soft Fault - Low Pressure Yes Hard or Soft Fault - Freeze Detection FP 4 Yes Hard or Soft Fault - Freeze Detection FP 5 Yes Hard or Soft Fault - ondensate Overflow 7 Yes Hard or Soft Fault - Over/Under Voltage 8 No Auto Fault - FP Sensor Error Yes Hard or Soft Fault - ritomerr 9 NO Auto NOTE: All codes > use long flash for tens digit and short flash for the ones digit. 0, 0, 40, 50, etc. are skipped. AB Basic Faults Aurora Interface and Diagnostics (AID) Tool The Aurora Interface and Diagnostics (AID) Tool is a device that is a member of the Aurora network. The AID Tool is used to troubleshoot equipment which uses the Aurora control via Modbus 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 EM airflow settings. The AID Tool simply plugs into the exterior of the cabinet in the AID Tool port. AB ontrol Board Layout F Y JW - Alarm HP HP LP LP FP FP FP FP EV EV LO HI F F Factory Factory P P4 P5 PWM FM EM PWM P SW Test V K K Hi K Fan K4 Alarm K5 Acc K6 Fi eld onnections Faul t LED A Dip 5 Dual/Single L Pulse/ontinuous Status eheat/normal P9 LO P LED Factory Use P AUOA BASE ONTOL Off FP 5 o F/0 o F FP 5 o F/0 o F V B/O A Dip 4 Factory Fan onnection O/B Y Y Fi eld onnections 8 SW W On LED Y onfig DH om om A-Fuse P Factory P6 S485 Exp P7 S 485 P8 S485 NET EH EH EH O N/A (+) (-) ES LS ALM AL A c A no A nc LO O/B Y Y W DH 6

37 5 SEIES 500A INSTALLATION MANUAL The Aurora Advanced ontrol System Aurora Advanced ontrol Features The Aurora Advanced ontrol system expands on the capability of the Aurora Base ontrol (AB) by adding the Aurora Expansion Board (AXB). All of the preceding features of the Aurora Base ontrol are included. The following control description is of the additional features and capability of the Aurora advanced control. It is highly recommended the installing/servicing contractor obtain an Aurora Interface and Diagnostic Tool (AID) and specialized training before attempting to install or service an Aurora Advanced control system. The additional AXB features include the following: AXB DIP Switch DIP - ID: This is the AXB ModBus ID and should always read On. DIP & - Future Use DIP 4 & 5 - Accessory elay: A second, DIP configurable, accessory relay is provided that can be cycled with the compressor or, blower, or the Dehumidifier (DH) input. This is to complement the Accessory elay on the AB board. Position DIP 4 DIP 5 Description ON ON ycles with Fan or EM (or ) OFF ON ycles with first stage of compressor or compressor spd -6 ON OFF ycles with second stage of compressor or compressor spd 7-4 OFF OFF ycles with DH input from AB board Advanced Hot Water enerator ontrol (Domestic Hot Water Option) In lieu of the Base Hot Water enerator ontrol, the Advanced features an AID Tool selectable temperature limit and microprocessor control of the process. This will maximize hot water generation and prevent undesirable energy use. An alert will occur when the hot water input temperature is at or above setpoint (00 F - 40 F) for 0 continuous seconds (0 F is the default setting). This alert will appear as an E5 on the AID Tool and the hot water pump de-energizes. Hot water pump operations resume on the next compressor cycle or after 5 minutes of continuous compressor operation during the current thermostat demand cycle. Since compressor hot gas temperature is dependent on loop temperature in cooling mode, loop temperatures may be too low to allow proper heating of water. The control will monitor water and refrigerant temperatures to determine if conditions are satisfactory for heating water. LED (red LED) will flash code 5 when the DHW limit is reached and when conditions are not favorable for water heating. Error code 5 will also be displayed on the AID Tool in the fault screen. This flash code is a noncritical alert and does not necessarily indicate a problem. ompressor Monitoring The AXB includes two current transducers to monitor the compressor current and starting characteristics. Open circuits or welded contactor faults will be detected. A fault will produce an E0 code. IntelliZone Zoning ompatibility (Optional IntelliZone ommunicating Zoning) A dedicated input to connect and communicate with the IntelliZone (IZ) zoning system is provided on P7 on the AXB. The is a dedicated communication port using a proprietary ModBus protocol. An AXB is required. onsult the IntelliZone literature for more information. AWL Aurora Weblink (optional accessory) AWL is an add-on WiFi router that connects to the AB and offers many features: emote access to thermostat settings, schedules, etc. with your smartphone, tablet or laptop eceive Lockout/Fault info via text or View heat pump energy usage from the Internet for the day, week, month, year or real-time Internet AID Tool capability allows remote troubleshooting for the technician emote AID Tool capability at the heat pump with smartphone, tablet or laptop for the technician Allows data acquisition of the heat pump through the Internet, see graphs of performance and chart historical data for the technician Stores historical data on SD card Variable Speed Pump This input and output are provided to drive and monitor a variable speed pump. The VS pump output is a PWM signal to drive the variable speed pump. The minimum and maximum level are set using the AID Tool. 75% and 00% are the default settings respectively. The VS data input allows a separate PWM signal to return from the pump giving fault and performance information. Fault received from the variable speed pump will be displayed as E6. 7

38 5 SEIES 500A INSTALLATION MANUAL The Aurora Advanced ontrol System cont. Modulating Water Valve This output is provided to drive a modulating water valve. Through advanced design the 0-0VD valve can be driven directly from the VS pump output. The minimum and maximum level are set in the same way as the VS pump using the AID Tool. 75% and 00% are the default settings respectively. Loop Pump Linking This input and output are provided so that two units can be linked together with a common flow center. When either unit has a call for loop pump, both unit s loop pump relays and variable speed pumps are energized. The flow center then can simply be wired to either unit. The output from one unit should be routed to the input of the other. If daisy chained up to 6 heat pumps can be wired and linked together in this fashion. Advanced ommunication Ports ommunication ports P6 and P8 will provide future expansion via dedicated protocols. These are for future use. Smart rid-on Peak (S) Input The 'On Peak' input was designed to allow utilities to utilize simple radio controlled switches to control the On Electric Peak behavior of the 5 and 7 Series eothermal Heat Pumps. With a closed contact signal, this input will limit the operation and thus the power consumption of the unit by one of the below selections. The AID Tool will allow configuration of this input for the action of: No Action Disable compressor operation until removed o to On Peak thermostat settings until removed [equires om T-Stat] (Future elease) ompressor limited to 50% or low cap until removed [dual capacity or variable speed only] (Future elease) Disable compressor operation for / hr (can be removed immediately) (Future elease) Then Flash ode 7 on the reen LED for the 'On Peak' mode. And On Peak will display on communicating thermostats. Home Automation and Inputs The Home automation inputs are simple closed contact inputs that will trigger an AID Tool and thermostat alert for the homeowner. These would require optional sensors and or equipment for connection to the AXB board. With two inputs two different sensors can be selected. The selected text will then be displayed on the AID Tool and communicating thermostats. These events will NOT alter functionality or operation of the heat pump/accessories and is for homeowner/ service notification only. Home Automation - E HA With a closed dry contact signal, this input will cause an alarm and Alert ode to indicate on the stat or flash on AB. The AID Tool will allow configuration of this input between the following selections: No Action Home Automation Fault [no lockout info only] - Output from home automation system Security Alarm [no lockout info only] - Output from home security Sump Alarm Fault [no lockout info only] - Switch output from sump sensor Smoke/O Alarm Fault [no lockout info only] - Switch output from Smoke/O sensor Dirty Filter Alarm [no lockout info only] - Output from dirty filter sensor Home Automation E4 HA With a closed dry contact signal, this input will cause an alarm and Alert ode 4 to indicate on the stat or flash on AB. The AID Tool will allow configuration of this input between the following selections: No Action Home Automation Fault [no lockout info only] - Output from home automation system Security Alarm [no lockout info only] - Output from home security Sump Alarm Fault [no lockout info only] - Switch output from sump sensor Smoke/O Alarm Fault [no lockout info only] - Switch output from Smoke/O sensor Dirty Filter Alarm [no lockout info only] - Output from dirty filter sensor Monitoring Sensor Kits Energy Monitoring (Standard Sensor Kit on Advanced models) The Energy Monitoring Kit includes two current transducers (blower and electric heat) added to the existing two compressor sensors so that the complete power usage of the heat pump can be measured. The AID Tool provides configuration detail for the type of blower motor, power adjustment and a line voltage calibration procedure to improve the accuracy, and a power adjustment setting that allows the compressor power to be adjusted to match the unit's line voltage using the provided tables. This information can be displayed on the AID Tool or selected communicating thermostats. The TPMU0A/04A will display instantaneous energy use while the color touchscreen TPU0 will in addition display a month history in graph form. efer to Unit Start Up Energy Monitoring for configuration details. Single Speed Power Adjustment Voltage Model

39 5 SEIES 500A INSTALLATION MANUAL The Aurora Advanced ontrol System cont. Dual apacity Power Adjustment Model Unit Voltage apacity Full Load Part Load Full Load Part Load Full Load Part Load Full Load Part Load Full Load Part Load efrigerant Monitoring (optional sensor kit) The optional efrigerant Monitoring Kit includes two pressure transducers, and three temperature sensors, heating liquid line, suction temperature and existing cooling liquid line (FP). These sensors allow the measurement of discharge and suction pressures, suction and liquid line temperatures as well as superheat and subcooling. This information will only be displayed on the AID Tool. Performance Monitoring (optional sensor kit) The optional Performance Monitoring Kit includes three temperature sensors, entering and leaving water, leaving air temperature and a water flow rate sensor. With this kit heat of extraction and rejection will be calculated. This requires configuration using the AID Tool for selection of water or antifreeze. Special Modes and Applications 5-Speed EM Blower Motor Normally the 5-Speed EM motor can be driven off of thermostat signals and the AB connector P9. ommunicating thermostats, however present a special problem in this application since they operate without 4 VA thermostat signals. The AB board is wired to operate these systems from the alternate relay output signals,, Fan, and EH and should be wired for this. Fault LED (LED, ed) ommunicating Digital Thermostats The Aurora controls system also features either monochromatic or color touch screen graphic display thermostats for user interface. These displays not only feature easy to use graphical interface but display alerts and faults in plain English. Many of the features discussed here may not be applicable without these thermostats. Dehumidification Passive In passive dehumidification mode, the airflow is reduced by 5% from the heating airflow setting. If cooling airflow is set to +5, -5 or -0% of heating airflow it will automatically be set to -5% of heating airflow whenever the dehumidification call is present in the communicating stat or from the thermostat input DH. If the airflow for cooling is already set to -5% no airflow change will be noticed from normal cooling. Dehumidification mode will be shown on the AB and the communicating thermostats. Aurora Advanced ontrol 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 Load Shed Flash ode 5 Emergency Shutdown Flash ode 6 On Peak Mode Flash ode 7 (Future Use) Flash ode 8 (Future Use) Flach ode 9 onfiguration LED (LED, Yellow) Description of Operation No Software Overwritten DIP Switch Overwritten EM onfiguration Mode eset onfiguration Mode onfiguration LED, Yellow EM Setting Slow Flash Fast Flash OFF ed Fault LED LED Flash ode * Lockout eset/ emove Fault ondition Summary Normal - No Faults Off - Fault-Input No Auto Tstat input error. Autoreset upon condition removal. Fault-High Pressure Yes Hard or Soft HP switch has tripped (>600 psi) Fault-Low Pressure Yes Hard or Soft Low Pressure Switch has tripped (<40 psi for 0 continuous sec.) Fault-Freeze Detection FP 4 Yes Hard or Soft Freeze protection sensor has tripped (<5 or 0 degf for 0 continuous sec.) Fault-Freeze Detection FP 5 Yes Hard or Soft Freeze protection sensor has tripped (<5 or 0 degf for 0 continuous sec.) Fault-ondensate Overflow 7 Yes Hard or Soft ondensate switch has shown continuity for 0 continuous sec. Fault-Over/Under Voltage 8 No Auto Instantaneous voltage is out of range. **ontrols shut down until resolved. Fault-FP Sensor Error Yes Hard or Soft FP Sensor Open or Shorted Fault-ompressor Monitor 0 Yes Hard or Soft Open rkt, un, Start or welded cont Non-riticAXB SnsrErr No Auto Any Other Sensor Error riticaxbsnsrerr 4 Yes Hard or Soft Sensor Error for EEV or HW Alert-HotWtr 5 No Auto HW over limit or logic lockout. HW pump deactivated. Fault-VarSpdPump 6 No Auto Alert is read from PWM feedback. Non-ritomErr 8 No Auto Any non-critical com error Fault-ritomErr 9 No Auto Any critical com error. Auto reset upon condition removal Alarm - Low Loop Pressure No Auto Loop pressure is below psi for more than minutes Alarm - Home Automation No Auto losed contact input is present on Dig input - Text is configurable Alarm - Home Automation 4 No Auto losed contact input is present on Dig input - Text is configurable NOTES: *All codes > use long flash for tens digit and short flash for the ones digit. 0, 0, 40, 50 etc. are skipped! Alert is a noncritical sensor or function that has failed. Normal operation of the heat pump is maintained but service is desired at some point. AB Basic Faults AB & AXB Advanced 9

40 5 SEIES 500A INSTALLATION MANUAL The Aurora Advanced ontrol System cont. Aurora ontrol w/up BAnet The Aurora Unitary Protocol onverter (UP) is an integrated solution and communicates directly with the Aurora Heat Pump ontrols and allows access/control of a variety of internal Aurora Heat pump operations such as sensors, relay operation, faults and other information. In turn, the UP then converts internal Aurora Modbus protocol to BAnet MS/TP protocol and communicates to the HAS system. This provides the great benefit of complete control integration and a myriad of information available to the HAS from the heat pump control. Plus it also allows individual unit configuration such as EM fan speeds or freeze protection setting directly over the HAS without the need for access to the actual heat pump. The Aurora UP is implemented with the Aurora Base ontroller (AB) heat pump control into our latest water source heat pumps. All internal Aurora points are accessible to the UP via firmware providing an integrated solution. All zone temperatures and zone sensors are connected to the UP on an Net bus, simplifying hook up at the unit. Net sensors can include a combination of zone temperature and humidity, O, and VO sensors. The UP includes built-in support for a custom configurable keypad/display unit. Optional Equipment Touch Display BAnet MS/ TP UP Sensors & Thermostats ZS Standard Description Aurora Base Aurora Base Aurora Advanced Local access port /No user control Optional Optional Optional ZS Plus ZS Pro ZS Pro-F Local access port/slide potentiometer to make the zone warmer or cooler /ontrol button to override the schedule and put the zone in an occupied state, or force the zone to an unoccupied state/reen LED to Indicate occupied state. Local access port/led display/ontrol button to override the schedule and put the zone in an occupied state, or force the zone to an unoccupied state/arrow UP and DOWN buttons to change any editable property, such as the setpoint temperature/ibutton to cycle through information defined in the control program/reen LED to Indicate occupied state. Local access port/led display/ontrol button to override the schedule and put the zone in an occupied state, or force the zone to an unoccupied state/arrow UP and DOWN buttons to change any editable property, such as the setpoint temperature/ibutton to cycle through information defined in the control program/reen LED to Indicate occupied state/mode button to turn on heating, cooling, or fan only, or to set auto control/ Fan button to adjust fan speed/ F/ button to set temperature to Fahrenheit of elsius Optional Optional Optional Optional Optional Optional Optional Optional Optional NOTE: A ZS type sensor/thermostat is necessary for compatibility with UP. Aurora UP An optional Aurora UP for DD applications communicates directly with the entire Aurora system and provides DD protocol of BAnet MS/TP for connection to the HAS providing a wide variety of points covering configurations. sensors, airflow and freeze protection. For more information on the Aurora UP, please consult the Aurora UP Application uide for Single and Dual apacity Applications. NOTE: The UP is not compatible with IntelliZone or Symphony. Aurora Touch Interface Utilizing a touch-screen interface, the UP provides a technician the ability to configure and diagnose equipment at the unit or from any room sensor for added accessibility and simpler troubleshooting. The technician will have full access to equipment status, parameter values, temperature, and humidity sensing as well as access to alarm and trend history. With website-like navigation, the Aurora Touch Interface is easy to use and provides important insight into the system so your home can operate as efficiently as possible. 40

41 5 SEIES 500A INSTALLATION MANUAL eference alculations Heating alculations: HE LWT = EWT - gpm x 500 ooling alculations: H LWT = EWT + gpm x 500 H LAT = EAT + cfm x.08 TH = H + HW LAT (DB) = EAT (DB) - L = T - S S S/T = T S cfm x.08 Legend Abbreviations 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 4

42 T T 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics Aurora Advanced with EM and IntelliStart Ext Pump Pump / hp Total 08-0/60/ Pump PESSUE TANSDUE ND OU T 5D T T T T White ed EFIEATION OPTION FLOW METE ND OU T 5D 4 4 Brown(5) Brown(5) ray(6) ray(5) reen White Brown Purple Purple White White PEFOMANE OPTION Pump Sl ave Input/Output Future Use Smart rid Home Automati on DISH P4 P6 S Variable Speed VS Pump Pump 08-0/60/ 0D ND PWM NA 4 VAIABLE SPEED PUMP LOW VOLTAE 4 NO TE: 0 ND 4 VA 0-0D SEE DETAIL LLT LAT FLOW LWT EWT P P4 P HA HA SI P +5 OUT S +5 IN VS PUMP SLAVE LOOP VS DATA PUMP MOTO X VAIABLE SPEED PUMP LOW VOLTAE AXB BOAD Brown NO TE: 7 MODULATIN VALVE White reen ed VS PUMP S +5 VS DATA AXB BOAD VS AB BOAD PB TX NOTE 8 L ed V+ P8 S485 (+) Or ang e(9) Brown(0) ed L (-) K6 AID Tool See Figure for DHW wiring. Status NO OM P6 ZONE (+) ommunica ng Thermostat (-) K5 AXB (Aurora Expansion Board) Modbus Add. ID Future Use Future Use Acc Dip Acc Dip NO OM OFF P7 AB (+) SW (-) L K K K ON 4 5 L P7 P8 P5 P P0 P5 P T T T T HW SU P ST STEPPE ANA A DH DIV P9 Thermostat White White Or ang e Or ang e LO O Y Y W DH Violet(8) Violet(7) ed ed (04) (0) Brown(0) Brown(0) 5A ircuit Breaker EFIEATION OPTION PESSU E TANSDUE ND White OU T ed 5D (5) (5) Traditional Thermostat T Pink(40) Pink(9) T HOT WATE OPTION Not Used apacitor T 5A ircuit Breaker Solenoid Accessory SV Valve Output Analog Output 0-0VD P LO O/B Y W DH P ES LS ALM AL NOTE 6 Auxi liary Heat T A OM A NO A N Y EH ompressor ommon T NOTE 5 Blower T reen() u n a pac itor () () F K5-Alarm elay K6-Acc elay T P8 P9 Tan (6) om LED5 S485 NET L T S ed L Unit Power 08-0/60/ JW reen/yellow T Violet(4) (5) T ray/white(4) Op onal Ultra Tech /White(5) P S F F P5 HI LO K4-Fan elay om LED5 S485 NET - + P7 ompr essor K- el ay K- elay Aurora Base ontrol (AB) S485 EXP - + P6 NOTE O Brown(5) ondensate NOTE PB Or ang e(0) V V Or ang e() ed 08V FP Yellow(6) Yellow(7) 40V FP (9) (8) Transformer LP () () () (4) BLOWE UENT TANSDUE (T) 4V HP (4) (5) EVEVFP FP FP FP LPS LPSHPSHPSP4 K-V elay SW Test Mode EH EH P Y Status LED Faul t LED () Brown(06) Or ang e(05) /White F-A PWM FM reen(07) Yellow P Off On FP 5 F/0 F FP 5 F/0 F V B/O Acc Dip 4 45 Acc Dip 5 Dual/Single 6 L Output Type 7 Future Use 8 SW onfig LED Y F NOTE 9 NOTE P Violet() 4 5 (0) Yellow(09) EM Blower Motor P PWM FM reen/yellow(08) 4 To P on Elec tric Heat Board 4

43 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics cont. Aurora Advanced with EM and IntelliStart cont. P9 5 4 Violet Brown Orange With optional EA Series 0kW Auxiliary Electric Heat Shown 60 AMP BK 60 AMP BK L L L L Pink TS L Factory Low voltage wiring Factory Line voltage wiring Light emitting diode - reen Fi eld l ow voltage wiring Field line voltage wiring FB Fused Backup Optional block D Voltage PB traces K* Electric Heat elay Internal juncti on Qui ck connect terminal P Polarized connector Thermal Limi t Switch Field wire lug round N.O., N.. Legend PB - Power block HE - Heater element Breaker ray Yellow K K5 ray reen 4 5 P ray OM NO K OM NO K6 ray FB HE TS onnects to vari able speed EM motor only OM NO K OM NO K7 FB Yellow HE TS Yellow OM NO OM NO FB HE TS Yellow K4 K8 Pink Pink OM NO OM NO FB4 HE4 TS4 EA Series PB Pink 4 P 4 P Aux heat stagi ng O EH EH P P on Aurora AB Board NOTE - Use copper o r aluminum conductors. - Use manufacturer s part numb er 9P59-0 (jumper bar assembly) when si ngle source power is required. Jumpers wires are Factory Installed, and are required for auxiliary heat operation. 4 Low voltage wiring LASS. Notes - Switch blue and red wires for 08V operation. - The blk/wh and gray/wh wires are removed when Aux Heat is installed When Auxiliary Heat is field installed the harnes s will then be c onnected to the auxiliary heat unit. The auxiliary heat unit will then power the blower. efer to EAS/EAM/EAL Auxiliary Heat kit installation instructions. 4 Low voltage wiring LASS. 5 Brown blower power wire routed through urrent Transducer two times. 6 Field onnected: efer to Installation Manual and Auxiliary Heat Instructions for urrent Transducer installation. 7 Variable speed pump low v oltage harnes s provided with Variable Speed Flow enter. 8 Variable speed pump power wires to connect the pump to L and L on the AXB board are provided with Variable Speed Flow enter. 9 - Wires provided for Auxiliar y Heat low voltage contr ol. Wires are secured at blower. 0 - Wiring harness supplied with valve. L - O - K6 K5-4 - S - F and F - HE - HP - E to E4 - LP - Factory Low voltage wiring Factory Line voltage wiring Fi eld l ow voltage wiring Field line voltage wiring Optional block D Voltage PB traces Junction Quick connect terminal Wire nut Field wire lug round elay on tacts- N.O., N.. Fuse Breaker ompressor ontactor ondensate overflow sensor DHW pump relay Loop pump relay PS Fan Speed elay PS Fan Power elay ompressor Solenoi d Fuses Heater element High pressure switch Aux heat stage relays Low pressure switch Legend P T PB, PB - PS - V - SW - SW - SW - TS - HWL - S - S - WL - Thermistor Light emitting diode - reen elay coil apacitor w/ bleed resistor Switch - ondensate overflow Switch - High pressure Switch - Low pressure Polarized connector urrent Transducer (T) Power blocks Power strip eversi ng Valve coil DIP package 5 position AXB TEST MODE AB Board DIP package 8 position AB Board Thermal limit switch Hot water limit sensor Start ontactor Start elay Water oil Limit Sensor 4

44 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics Aurora Advanced with EM and IntelliStart AXB BOAD Slow Flash Fast Flash Flash ode Aurora LED Flash odes second on and second off 00 milliseconds on and 00 milliseconds off 00 milliseconds on and 400 milliseconds off with a second pause before repeating Fault LED (LED, ed) andom Start Delay (Alternating olors) Normal Mode OFF Status LED (LED, reen) Fast Flash Input Fault Lockout Flash ode onfiguration LED (LED, Yellow) Fast Flash High Pressure Lockout Flash ode Fault LED (LED, ed) Fast Flash Low Pressure Lockout Flash ode onfiguration LED (LED, Yellow) Freeze Detection - FP Flash ode 4 No Software Overide OFF Freeze Detection - FP Flash ode 5 DIP Switch Overide Slow Flash eserved Flash ode 6 Status LED (LED, reen) ondensate Overflow Lockout Flash ode 7 Normal Mode ON Over/Under Voltage Shutdown Flash ode 8 ontrol is Non - Functional OFF Future Use Flash ode 9 Test Mode Slow Flash ompressor Monitoring Flash ode 0 Fault- FP Sensor Error Flash ode Future Use Flash ode Non-ritical AXB Sensor Error Flash ode ritical AXB Sensor Error Flash ode 4 Alarm - Hot Water Flash ode 5 Fault Variable Speed Pump Flash ode 6 Future Use Flash ode 7 Non-ritical ommunication Error Flash ode 8 Fault - ritical ommunication Error Flash ode 9 Alarm - Low Loop Pressure Flash ode Fault - ommunication EM Fan Motor Error Flash ode Lockout Active Fast Flash Dehumidification Mode Flash ode Future Use Flash ode Future Use Flash ode 4 Load Shed Flash ode 5 ESD Flash ode 6 Future Use Flash ode 7 Fault LED (LED, ed) ont. Alarm - Home Automation Flash ode Alarm - Home Automation Flash ode 4 Fault - EEV Error Flash ode 5 44

45 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics cont. Aurora Advanced with EM and IntelliStart cont. F Y HP HP LP LP FP FP FP FP EV EV LO HI F F ES Factory P5 Factory JW - Alarm P P4 LS PWM FM EM PWM P ALM AL SW Test A c V K K Hi K Fan K4 Alarm K5 Acc K6 Fi eld onnections A no A nc P9 LO P LO P Off FP 5 o F/0 o F AUOA BASE ONTOL FP 5 o F/0 o F Faul t V B/O A Dip 4 A Dip 5 Dual/Single L Pulse/ontinuous Status eheat/normal Factory Use Factory Fan onnection O/B O/B Y Y Y Fi eld onnections Y SW W W On DH DH Y onfig om om A-Fuse P Factory P6 S 485 EH S485 Exp P7 P8 S485 NET EH EH O N/A (+) (-) ommunicating Thermostat Dual Fuel Wiring Diagram Using Field Installed elay Note : Fiel d i nstalled SPST dual fuel rel ay (equired for dual fuel installation) EH AB Board Tra ditional Thermostat Dual Fuel Wiring Diagram Using Field Installed elay Fossil Fuel Furnace W ommon 4 VA Auxiliary Heat elay Fan Auxiliary Heat elay T he rmo st at Y Y Note : Fiel d i nstalled SPST dual fuel rel ay (equired for dual fuel installation) O L W Figure : Optional Internal Hot Water eneration Pump Wiring Schematic To Fossil Fuel Furnace W input eversing Valve Fault Signal ommon 4 VA 4 VD st Stage ompressor nd Stage ompressor Au xil iary He at ela y OM K6 elay NO f rom Foss il Fuel Furnace AB Board Y Y O LO = chassis ES P P onnects to L and NO on AXB Board L AXB Accessory DIP Settings SW-4 SW-5 DESIPTION ON ON ycles with Blower OFF ON ycles with first stage compressor or compressor spd - ON OFF ycles with second stage of compressor or comp spd 7- OFF OFF ycles with DH from AB board DHW Pump abinet HW Switch Purple AB SW Accessory elay DESIPTION SW-4 SW-5 ycle with Blower ON ON ycle with ompressor OFF OFF Water Valve Slow Opening ON OFF ycle with omm. T-stat Hum md OFF ON WATE SIEN AXB P4 HOME SMAT HA HA ID HOME AUTOMATION AESSOIES L - O - K5 - K S - F and F - HE - HP - E to E4 - LP - Factory Low voltage wiring Factory Line voltage wiring Fi eld l ow voltage wiring Field line voltage wiring Optional block D Voltage PB traces Junction Qui ck connect terminal Wire nut Field wire lug round elay on tacts- N.O., N.. Fuse Breaker ompressor ontactor ondensate overflow sensor DHW pump relay Loop pump relay PS Fan Speed elay PS Fan Power elay ompressor Solenoi d Fuses Heater element High pressure switch Aux heat stage relays Low pressure switch Legend P T PB, PB - PS - V - SW - SW - SW - TS - HWL - S - S - WL - Thermistor Light emitting diode - reen elay coil apacitor w/ bleed resistor Switch - ondensate overflow Switch - High pressure Switch - Low pressure Polarized connector urrent Transducer (T) Power blocks Power strip eversi ng Valve coil DIP package 5 position AXB TEST MODE AB Board DIP package 8 position AB Board Thermal limit switch Hot water limit sensor Start ontactor Start elay Water oil Limit Sensor 45

46 L T T 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics cont. Aurora Advanced with 5-Speed EM Ext Pump Pump / hp Total 08-0/60/ Pump PESSUE TANSDUE ND OU T 5D T T T T White ed EFIEATION OPTION FLOW METE ND OU T 5D 4 4 Brown Brown reen White Brown ray ray Purple Purple White White PEFOMANE OPTION Future Use Smart rid Home Automati on on DISH P4 P6 LLT LAT FLOW LWT EWT P P4 P HA HA SI +5 S S +5 P OUT IN VS PUMP SLAVE LOOP DATA VS PUMP MOTO X PB TX L V+ P8 S485 (+) Or ang e(9) Brown(0) L (-) K6 AID Tool NO OM P6 ZONE (+) ommunicating Thermostat (-) K5 NO OM P7 AB (+) (-) L K K K L P7 P8 P5 P P0 P5 P +5 STEPPE ANA A DH DIV OMP OMP 4 AUX FAN 4 ST SU P HW Variable Speed VS Pump Pump 08-0/60/ 0D ND PWM NA 4 ND 4 VA 0-0D Pump Sl ave Input/Output VAIABLE SPEED PUMP LOW VOLTAE 4 NO TE: SEE DETAIL VAIABLE SPEED PUMP LOW VOLTAE Brown NO TE: 9 MODULATIN VALVE White reen ed AXB BOAD VS PUMP S +5 VS DATA AXB BOAD VS AB BOAD NOTE 0 ed ed See Figure for DHW wiring. Status AXB (Aurora Expansion Board) Modbus Add. ID Future Use Future Use Acc Dip Acc Dip OFF SW ON 4 5 P9 Thermostat Violet(8) Violet(7) 5A ircuit Breaker PESSUE TANSDUE ND White OU T ed 5D EFIEATION OPTION LO O Y Y W DH White White Or ang e Or ang e Pink Traditional Thermostat ed ed Brown Brown T Pink T HOT WATE OPTION Not Used Solenoid Valve Analog Output 0-0VD P P SV apacitor T NOTE 8 Auxi liary Heat T ES LS ALM AL 5A ircuit Breaker ompressor ommon T A OM A NO A N LO O/B Y Y W DH Accessory Output NOTE 7 Blower T EH r een() u n a pac itor () () T Tan (6) L T S ed L T Unit Power 08-0/60/ JW Violet(4) ray (5) T Tan Optional /White (5) ray/white (4) Ultra Tech P P9 F F F HI LO K5-Alarm elay K6-Acc elay S485 NET om LED4 P8 S485 NET (-) (+) r een/yellow K4-Fan elay om LED5 P7 K- elay K- elay S485 EXP ed S P5 (-) (+) NOTE NOTE 5 P6 Brown() ondensate NOTE Aurora Base ontrol (AB) O EH PB Or ang e(0) V V Or ang e(0) ed 08V FP Yellow Yellow BLOWE UENT TANSDUE (T) 40V FP () Transformer LP (08) (07) (0) Brown 4V HP (09) Or ang e Brown (0) EVEVFP FP FP FP LPS LPSHPSHPSP4 K-V elay SW Test Mode EH P Y Status LED Faul t LED FP 5 F/0 F FP 5 F/0 F V B/O Acc Dip 4 Acc Dip 5 Dual/Single L Output Type Future Use onfig LED Y () Or ang e NOTE Yellow /White F-A Off PWM FM P SW F On NOTE 6 reen NOTE 4 N 5 4 reen To P on Elec tric Heat Board 5 Speed EM Blower Motor P Switch blue and - The blk/wh and g When Auxiliary heat unit. The auxil Auxiliary Heat kit in 4 Low voltage wir 5 - Y input wire Ta 6 - Wires provided f 7 Br own blower po 8 Field onnec ted urrent Transducer 9 Variable speed 0 Variable speed are provided with Va - Field installed - efer to units 5 factory settings. - Wiring harness 46

47 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics cont. Aurora Advanced with 5-Speed EM cont. With optional EA Series 0kW Auxiliary Electric Heat Shown reen P Use copper o r aluminum conductors. When Auxil iary Heat is installe d the BLK/WHT wire from -L to PB- and the Y/WHT wire from -L to PB- must be removed (located in the heat pump control box). Jumpers wires are Factory Installed, and are equired for auxiliary heat operation. 4 Low voltage wiring LASS. reen P9 08-0/60/ L L To PB Brown Orange 5 4 Brown Orange ray 5 Speed EM Blower Motor Violet TB 4 reen ray K 4 5 P NO ray FB HE TS K onnects to vari able speed EM motor only NO FB HE TS Legend Factory Low voltage wiring Factory Line voltage wiring Fi eld l ow voltage wiring Field line voltage wiring Optional block D Voltage PB traces Internal juncti on Qui ck connect terminal Light emitting diode - reen FB Fused Backup K* Electric Heat elay K NO K4 ray ray TS Thermal Limi t Switch P Polarized connector NO L Field wire lug round N.O., N.. PB - Power block HE - Heater element Breaker P 4 EA Seri es PB P 4 NOTE O EH EH P ondensate P on Aurora AB Board Notes Legend - Switch blue and red wires for 08V operation. - The blk/wh and gray/wh wires are removed when Aux Heat is installed When Auxiliary Heat is field installed the harness will be connected to the auxiliary heat unit. The auxiliary heat unit will then power the blower. efer to EAS/EAM/EAL Auxiliary Heat kit installation instructions. Wires are secured at blower 4 Low voltage wiring LASS. 5 - Y input wire Tan not connected on Single Speed units. Wire is secured at blower. 6 - Wires provided for Auxiliary Heat low voltage control. Wires are secured at blower. 7 Brown blower power wire routed through urrent Transducer two times. 8 Field onnected: efer to Installation Manual and Auxiliary Heat Instructions for urrent Transducer installation. 9 Variable speed pump low voltage harness provided with Variable Speed Flow enter. 0 Variable speed pump power wires to connect the pump to L and L on the AXB board are provided with Variable Speed Flow enter. - Field installed SPST relay required for dual fuel installation. - efer to units 5 SPEED EM MOTO LOW VOLTAE ONNETION table for factory settings. - Wiring harness supplied with valve. o P on ctric Heat Board L - O - K6 - K S - F and F - HE - HP - E to E4 - LP - Factory Low voltage wiring Factory Line voltage wiring Fi eld l ow voltage wiring Field line voltage wiring Optional block D Voltage PB traces Junction Qui ck connect terminal Wire nut Field wire lug round elay on tacts- N.O., N.. Fuse Breaker ompressor ontactor ondensate overflow sensor DHW pump relay Loop pump relay PS Fan Speed elay PS Fan Power elay ompressor Solenoi d Fuses Heater element High pressure switch Aux heat stage relays Low pressure switch P T PB, PB - PS - V - SW - SW - SW - TS - HWL - S - S - WL - Thermistor Light emitting diode - reen elay coil apacitor w/ bleed resistor Switch - ondensate overflow Switch - High pressure Switch - Low pressure Polarized connector urrent Transducer (T) Power blocks Power strip eversi ng Valve coil DIP package 5 position AXB TEST MODE AB Board DIP package 8 position AB Board Thermal limit swi tch Hot water limit sensor Start ontactor Start elay Water oil Limit Sensor 47

48 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics cont. Aurora Advanced with 5-Speed EM HP HP LP LP FP FP FP FP EV EV P4 Factory V K FP FP Faul t L Puls Status Factory AU O ES LS ALM AL A c LO HI F F K Hi K Fan K4 Alarm K5 Acc K6 A no A nc LO PWM FM EM PWM P SW Test AXB BOAD P5 Factory Use P F JW - Alarm P9 Fa Y LO P Fi eld onnections P Slow Flash Fast Flash Flash ode Aurora LED Flash odes second on and second off 00 milliseconds on and 00 milliseconds off 00 milliseconds on and 400 milliseconds off with a second pause before repeating Fault LED (LED, ed) andom Start Delay (Alternating olors) Normal Mode OFF Status LED (LED, reen) Fast Flash Input Fault Lockout Flash ode onfiguration LED (LED, Yellow) Fast Flash High Pressure Lockout Flash ode Fault LED (LED, ed) Fast Flash Low Pressure Lockout Flash ode onfiguration LED (LED, Yellow) Freeze Detection - FP Flash ode 4 No Software Overide OFF Freeze Detection - FP Flash ode 5 DIP Switch Overide Slow Flash eserved Flash ode 6 Status LED (LED, reen) ondensate Overflow Lockout Flash ode 7 Normal Mode ON Over/Under Voltage Shutdown Flash ode 8 ontrol is Non - Functional OFF Future Use Flash ode 9 Test Mode Slow Flash ompressor Monitoring Flash ode 0 Fault- FP Sensor Error Flash ode Future Use Flash ode Non-ritical AXB Sensor Error Flash ode ritical AXB Sensor Error Flash ode 4 Alarm - Hot Water Flash ode 5 Fault Variable Speed Pump Flash ode 6 Future Use Flash ode 7 Non-ritical ommunication Error Flash ode 8 Fault - ritical ommunication Error Flash ode 9 Alarm - Low Loop Pressure Flash ode Fault - ommunication EM Fan Motor Error Flash ode Lockout Active Fast Flash Dehumidification Mode Flash ode Future Use Flash ode Future Use Flash ode 4 Load Shed Flash ode 5 ESD Flash ode 6 Future Use Flash ode 7 Fault LED (LED, ed) ont. Alarm - Home Automation Flash ode Alarm - Home Automation Flash ode 4 Fault - EEV Error Flash ode 5 5 SPEED EM M OTO LOW VOLTAE ONNETIONS SINLE SPEED Model TAP- TAP- TAP- TAP-4 TAP-5 BLUE ED AY 0 BLUE ED AY 6 BLUE ED AY 4 BLUE ED AY 48 BLUE ED AY 60 BLUE ED AY 70 BLUE ED AY 5 SPEED EM MOTO LOW VOLTAE ONNETIONS DUAL APAITY Model TAP- TAP- TAP- TAP-4 TAP-5 6 BLUE ED TAN AY 8 BLUE ED TAN AY 49 BLUE ED TAN AY 64 BLUE ED TAN AY 7 BLUE ED TAN AY 48

49 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics cont. Aurora Advanced with 5-Speed EM cont. Figure : Optional Internal Hot Water eneration Pump Wiring Schematic OM K6 elay NO onnects to L and NO on AXB Board F HP HP LP LP FP FP FP FP EV EV LO HI F F P4 Factory P5 Factory JW - Alarm PWM FM EM PWM P SW Test V K K Hi K Fan K4 Alarm K5 Acc K6 P9 P Off FP 5 o F/0 o F FP 5 o F/0 o F Faul t V B/O A Dip 4 A Dip 5 Dual/Single L Pulse/ontinuous Status eheat/normal Factory Use AUOA BASE ONTOL Factory Fan onnection SW On Y onfig om om P Factory P6 EH S485 Exp P7 S 485 P8 S485 NET EH EH O N/A (+) (-) ommunicating Thermostat Dual Fuel Wiring Diagr am Using Field Installed elay Note : Fiel d i nstalled SPST dual fuel rel ay (equired for dual fuel installation) EH AB Board Tra ditional Thermostat Dual Fuel Wiring Diagr am Using Field Installed elay Fossil Fuel Furnace W ommon 4 VA Thermostat Y Y O L To Fossil Fuel Furnace W input eversing Valve Fault Signal ommon 4 VA 4 VD st Stage ompressor nd Stage ompressor f rom Foss il Fuel Furnace AB Board Y Y O LO DHW Pump P abinet HW Switch L Purple Y P Fi eld onnections LO P O/B Y Y Fi eld onnections W DH A-Fuse Auxiliary Heat elay Fan W Au xil iary He at ela y ES P ES LS ALM AL A c A no A nc LO O/B Y Y W DH Auxiliary Heat elay Note : Fiel d i nstalled SPST dual fuel rel ay (equired for dual fuel installation) = chassis AXB Accessory DIP Settings LOW VOLTAE ONNETIONS SINLE SPEED SW-4 SW-5 DESIPTION TAP- TAP- TAP-4 TAP-5 BLUE ED AY ED AY ED AY ED AY ED AY ED AY ED AY LOW VOLTAE ONNETIONS DUAL APAITY TAP- TAP- TAP-4 TAP-5 ED TAN AY ED TAN AY ED TAN AY ED TAN AY ED TAN AY ON ON ycles with Blower OFF ON ycles with first stage compressor or compressor spd - ON OFF ycles with second stage of compressor or comp spd 7- OFF OFF ycles with DH from AB board AB SW Accessory elay DESIPTION SW-4 SW-5 ycle with Blower ON ON ycle with ompressor OFF OFF Water Valve Slow Opening ON OFF ycle with omm. T-stat Hum md OFF ON WATE SIEN AXB P4 HOME SMAT HA HA ID HOME AUTOMATION AESSOIES 49

50 T T 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics cont. Aurora Base with PS F Y HP HP LP LP FP FP FP FP EV EV LO HI F F ES Factory Factory JW - Alarm P P4 P5 LS PWM FM ALM AL A c EM PWM P SW Test V K K Hi K Fan K4 Alarm K5 Acc K6 Fi eld onnections A no A nc Tra ditional Thermostat Dual Fuel Wiring Diagr am Using Field Installed elay Fossil Fuel Furnace W ommon 4 VA Auxiliary Heat elay Fan Auxiliary Heat elay Notes - Switch blue a nd red wires for 08V operation. - The blk/wh and gray/wh wi re s are removed when Aux He at is installed - Use manufacturer s part numb er 9P59-0 (jumper bar assembly) when si ngle source power is required. 4 - When connected the Auxiliary Heat powers blower and controls. Wires are secured at blower. 5 Low voltage wiring LASS. 6 - efer to FAN SPEED table for factory settings. 7 - Wires provided for Auxiliary Heat low voltage control. Wires are secured at blower. 8 - Field installed SPST relay required for dual fuel installation. P9 LO LO LED AUOA BASE ONTOL 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 minutes 0 seconds Fault ecognition Delay Low Pressure 0 seconds 0 seconds Start-Up Bypass Low Water oil Limit minutes 0 seconds Fault ecognition Delay Low Water oil Limit 0 seconds 0 seconds Fault ecognition Delay ondensate Overflow 0 seconds 0 seconds Thermostat all ecognition Time seconds seconds omfort Alert ecog niti on Ti me 90 seconds 90 seconds Auxi liary Heat Stagi ng Del ay 5 minutes 0 seconds Emergency Heat Stagi ng Dela y minutes 7.5 seconds Water Valve Slow Open Delay 90 seconds 90 seconds FP 5 of/0of Off FP 5 of/0of Faul t V B/O A Dip 4 A Dip 5 LED Dual/Single L Pulse/ontinuous Status eheat/normal P P T he rmo st at Y Y Factory Use Note 8: Fiel d i nstalled SPST dual fuel rel ay (equired for dual fuel installation) O L W O/B O/B AB SW Accessory elay Factory Fan onnection Y Y Y Fi eld onnections Y st Stage ompressor nd Stage ompressor eversing Valve Fault Signal ommon 4 VA Au xil iary He at ela y SW W W DESIPTION SW-4 SW-5 ycle with Blower ON ON ycle with ompressor OFF OFF Water Valve Slow Opening ON OFF ycle with omm. T-stat Hum md OFF ON On DH DH LED Y onfig om om A-Fuse LED5 LED4 AB Board Y Y O LO = chassis ES EH P Factory P6 S485 Exp P7 S 485 P8 S485 NET P P Ext Pump / hp Total 08-0/60/ EH EH O N/A (+) (-) Pump ommunicating Thermostat Pump AID Tool DHW Pump UNIT UNIT Traditional Thermostat PB Hot Water Limit Switch 0 F Thermostat abinet HW Switch LO O Y Y W DH Violet(7) Violet(8) Optional Internal Hot Water eneration Pump Purple FATOY SET FAN SPEED STANDAD PS H M M M M M M M H HIH STATI PS M M M M M Water Solenoid (see Open Loop roundwater Systems section) ircuit Breaker 5A 5A ircuit Breaker P P ES LS Unit Power Supply 08-0/60/ NOTE 6 ALM AL A OM A NO A N LO O/B Y Y W DH EH rn P () () PS Blower Motor H M L reen() Brn ap ap Wht Airflow Settings F K5-Alarm elay K6-Acc elay Tan(6) S485 NET S P8 5 T L ed B 4 P9 om LED5 JW reen/yellow T L ompr essor B /White(5) ray/white(4) White() (5) () Violet (4) S485 NET - + om LED5 P7 NOTE White F F HI LO K4-Fan elay K- elay K- elay S485 EXP P5 - + P6 () Aurora Base ontrol (AB) O Brown() ondensate EH PB NOTE V Orange V Orange ed 08V FP Yellow Yellow 40V FP () () Tra nsformer LP (0) Brown Orange 4V HP EVEVFP FP FP FP LPS LPSHPSHPSP4 K-V elay SW Test Mode EH P Y Status LED Faul t LED FP 5 F/0 F FP 5 F/0 F V B/O Acc Dip 4 Acc Dip 5 Dual/Single L Output Type Future Use onfig LED Y Yellow /White NOTE 7 NOTE 4 F-A Off PWM FM F P SW On reen 4 P 5 4 To P on Elec tric Heat Board 50

51 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics cont. Aurora Base with PS cont. With optional EA Series 0kW Auxiliary Electric Heat Shown - Use copper o r aluminum conductors. When Auxil iary Heat is installe d the BLK/WHT wire from -L to PB- and the Y/WHT wire from -L to PB- must be removed (located in the heat pump control box). Jumpers wires are Factory Installed, and are equired for auxiliary heat operation. 4 Low voltage wiring LASS. reen P9 08-0/60/ L L To PB Brown Orange 5 4 Brown Orange ray Violet TB reen ray K 4 5 P NO ray FB HE TS K onnects to vari able speed EM motor only NO FB HE TS Legend Factory Low voltage wiring Factory Line voltage wiring Fi eld l ow voltage wiring Field line voltage wiring Optional block D Voltage PB traces Internal juncti on Qui ck connect terminal Light emitting diode - reen FB Fused Backup K* Electric Heat elay K NO K4 ray ray TS Thermal Limi t Switch P Polarized connector NO L Field wire lug round N.O., N.. PB - Power block HE - Heater element Breaker P 4 EA Seri es PB P 4 NOTE O EH EH P ondensate P on Aurora AB Board ommunicating Thermostat Dual Fuel Wiring Diagr am Using Field Installed elay To Fossil Fuel Furnace W input f rom Foss il Fuel Furnace Legend Note 8: Fiel d i nstalled SPST dual fuel rel ay (equired for dual fuel installation) EH AB 4 VD Board 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 (Alternating olors) onfiguration LED (LED, Yellow) Status LED (LED, reen) Fast Fl ash No Software Overide OFF onfiguration LED (LED, Yellow) Fast Fl ash DIP Switch Overide Slow Flash Faul t LED (LED, ed) Fast Fl ash Fault LED (LED, ed) Status LED (LED, reen) Normal Mode OFF Normal Mode ON Input Fault Lockout Flash ode ontrol is Non-Functional OFF High Pressure Lockout Flash ode Test Mode Slow Flash Low Pressure Lockout Flash ode Lockout Active Fast Fl ash Future Use Flash ode 4 Dehumidification Mode Flash ode Freeze Detection FP Flash ode 5 Future Use Flash ode eserved Flash ode 6 Future Use Flash ode 4 ondensate Overflow Lockout Flash ode 7 Load Shed Flash ode 5 Over/Under Voltage Shutdown Flash ode 8 ESD Flash ode 6 Future Use Flash ode 9 Future Use Flash ode 7 Future Use Flash ode 0 FP Sensor Error Flash ode L - O - K5 - K S - F and F - HE - HP - E to E4 - LP - Factory Low voltage wiring Factory Line voltage wiring Fi eld l ow voltage wiring Field line voltage wiring Optional block D Voltage PB traces Junction Qui ck connect terminal Wire nut Field wire lug round elay on tacts- N.O., N.. Fuse Breaker ompressor ontactor ondensate overflow sensor DHW pump relay Loop pump relay PS Fan Speed elay PS Fan Power elay ompressor Solenoi d Fuses Heater element High pressure switch Aux heat stage relays Low pressure switch P T PB, PB - PS - V - SW - SW - SW - TS - HWL - S - S - WL - Thermistor Light emitting diode - reen elay coil apacitor w/ bleed resistor Switch - ondensate overflow Switch - High pressure Switch - Low pressure Polarized connector urrent Transducer (T) Power blocks Power strip eversi ng Valve coil DIP package 5 position AXB TEST MODE AB Board DIP package 8 position AB Board Thermal limit swi tch Hot water limit sensor Start ontactor Start elay Water oil Limit Sensor 5

52 T T 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics cont. Aurora Base with EM, IntelliStart and UP F Y HP HP LP LP FP FP FP FP EV EV LO HI F F - Switch blue a nd red wires for 08V operation. - The blk/wh and gray/wh wi re s are removed when Aux He at is installed - Use manufacturer s part numb er 9P59-0 (jumper bar assembly) when si ngle source power is required. 4 - When installed the Auxiliary Heat powers blower and controls. 5 Low voltage wiring LASS. 6 - Wires provided for Auxiliary Heat low voltage control. Wires are secured at blower. 7 - Field installed SPST relay required for dual fuel installation. ES Factory Factory JW - Alarm P P4 P5 LS PWM FM ALM AL A c EM PWM P SW Test V K K Hi K Fan K4 Alarm K5 Acc K6 Fi eld onnections A no A nc LO AUOA BASE ONTOL 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 ycl e 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 minutes 0 seconds Fault ecognition Delay Low Pressure 0 seconds 0 seconds Start-Up Bypass Low Water oil Limit minutes 0 seconds Fault ecognition Delay Low Water oil Limit 0 seconds 0 seconds Fault ecognition Delay ondensate Overflow 0 seconds 0 seconds Thermostat all ecognition Time seconds seconds omfort Alert ecog niti on Ti me 90 seconds 90 seconds Auxi liary Heat Stagi ng Del ay 5 minutes 0 seconds Emergency Heat Stagi ng Dela y minutes 7.5 seconds Water Valve Slow Open Delay 90 seconds 90 seconds Tra ditional Thermostat Dual Fuel Wiring Diagr am Using Field Installed elay Fossil Fuel Furnace W ommon 4 VA Auxiliary Heat elay Fan Auxiliary Heat elay Notes P9 LO LED FP 5 of/0of Off FP 5 of/0of Faul t V B/O A Dip 4 LED A Dip 5 Dual/Single L Pulse/ontinuous Status eheat/normal P P Factory Use T he rmo st at Y Y Note 7: Fiel d i nstalled SPST dual fuel rel ay (equired for dual fuel installation) O L W Factory Fan onnection O/B O/B Y Y Y Fi eld onnections Y SW W W st Stage ompressor nd Stage ompressor eversing Valve Fault Signal ommon 4 VA Au xil iary He at ela y On DH DH LED Y onfig om om A-Fuse LED5 LED4 AB Board Y Y O LO = chassis ES EH P Factory P6 S485 Exp P7 S 485 P8 S485 NET P P Ext Pump / hp Total 08-0/60/ EH EH O N/A (+) (-) Pump Pump DHW Pump ommunicating Thermostat Dual Fuel Wiring Diagr am Using Field Installed elay PB Hot Water Limit Switch 0 F Note 7: Fiel d i nstalled SPST dual fuel rel ay (equired for dual fuel installation) EH AB Board UP ontroller abinet HW Switch Violet(7) Violet(8) Optional Internal Hot Water eneration Pump To Fossil Fuel Furnace W input Water Solenoid (see Open Loop roundwater Systems section) ZS Sensor 4 VD Purple f rom Foss il Fuel Furnace ircuit Breaker 5A 5A ircuit Breaker P P ES LS ALM AL LO O/B Y W DH Unit Power Supply 08-0/60/ A OM A NO A N Y EH () () reen() ap F K5-Alarm elay K6-Acc elay Tan(6) S485 NET S P8 P9 T L om LED5 JW T L S485 NET r een/yellow - + ompr essor ed Violet(4) om LED5 P7 /White(5) ray/white(4) (5) Dual apacity Units Only (6) Pink NOTE P F F HI LO K4-Fan elay K- elay K- elay Ultra Tech S (8) S485 EXP P5 Aurora Base ontrol (AB) - + P6 O Bro wn(5) ondensate NOTE un Winding Active Start ommon EH PB Orange(0) V V Orange() ed 08V FP Yellow(6) Inte llist art Yellow(7) 40V FP (8) (9) Tra nsformer LP () () (4) () 4V HP (4) () (5) EVEVFP FP FP FP LPS LPSHPSHPSP4 K-V elay SW Test Mode EH P Y Status LED Faul t LED FP 5 F/0 F FP 5 F/0 F V B/O Acc Dip 4 Acc Dip 5 Dual/Single L Output Type Future Use onfig LED Y Bro wn(06) Orange(05) NOTE 6 Yellow /White F-A Off PWM FM F P SW On reen(07) P Violet() 4 5 (0) Yellow(09) EM Blower Motor PWM 5 0 reen/yellow(08) 4 FM P 6 To P on Elec tric Heat Board S Fa Fl S Fa N In H Lo Fu Fr O Fu Fu FP 5

53 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics cont. Aurora Base with EM, IntelliStart and UP cont. P9 5 4 Violet Brown Orange With optional EA Series 0kW Auxiliary Electric Heat Shown 60 AMP BK 60 AMP BK L L L L Pink TS L Factory Low voltage wiring Factory Line voltage wiring Light emitting diode - reen Fi eld l ow voltage wiring Field line voltage wiring FB Fused Backup Optional block D Voltage PB traces K* Electric Heat elay Internal juncti on Qui ck connect terminal P Polarized connector Thermal Limi t Switch PB - Power block Field wire lug HE - Heater element round Breaker N.O., N.. Legend ray Yellow K K5 ray reen 4 5 P ray OM NO K OM NO K6 ray FB HE TS onnects to vari able speed EM motor only OM NO K OM NO K7 FB Yellow HE TS Yellow OM NO OM NO FB HE TS Yellow K4 K8 Pink Pink OM NO OM NO FB4 HE4 TS4 EA Series PB Pink P 4 4 P Aux heat stagi ng O EH EH P P on Aurora AB Board NOTE - Use copper o r aluminum conductors. - Use manufacturer s part numb er 9P59-0 (jumper bar assembly) when si ngle source power is required. Jumpers wires are Factory Installed, and are required for auxiliary heat operation. 4 Low voltage wiring LASS. AB SW Accessory elay DESIPTION SW-4 SW-5 ycle with Blower ON ON ycle with ompressor OFF OFF Water Valve Slow Opening ON OFF ycle with omm. T-stat Hum md OFF ON 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 (Alternating olors) onfiguration LED (LED, Yellow) Status LED (LED, reen) Fast Fl ash No Software Overide OFF onfiguration LED (LED, Yellow) Fast Fl ash DIP Switch Overide Slow Flash Faul t LED (LED, ed) Fast Fl ash Fault LED (LED, ed) Status LED (LED, reen) Normal Mode OFF Normal Mode ON Input Fault Lockout Flash ode ontrol is Non-Functional OFF High Pressure Lockout Flash ode Test Mode Slow Flash Low Pressure Lockout Flash ode Lockout Active Fast Fl ash Future Use Flash ode 4 Dehumidification Mode Flash ode Freeze Detection FP Flash ode 5 Future Use Flash ode eserved Flash ode 6 Future Use Flash ode 4 ondensate Overflow Lockout Flash ode 7 Load Shed Flash ode 5 Over/Under Voltage Shutdown Flash ode 8 ESD Flash ode 6 Future Use Flash ode 9 Future Use Flash ode 7 Future Use Flash ode 0 FP Senso r Error Flash ode L - O - K5 - K S - F and F - HE - HP - E to E4 - LP - Factory Low voltage wiring Factory Line voltage wiring Fi eld l ow voltage wiring Field line voltage wiring Optional block D Voltage PB traces Junction Qui ck connect terminal Wire nut Field wire lug round elay on tacts- N.O., N.. Fuse Breaker ompressor ontactor ondensate overflow sensor DHW pump relay Loop pump relay PS Fan Speed elay PS Fan Power elay ompressor Solenoi d Fuses Heater element High pressure switch Aux heat stage relays Low pressure switch Legend P T PB, PB - PS - V - SW - SW - SW - TS - HWL - S - S - WL - Thermistor Light emitting diode - reen elay coil apacitor w/ bleed resistor Switch - ondensate overflow Switch - High pressure Switch - Low pressure Polarized connector urrent Transducer (T) Power blocks Power strip eversi ng Valve coil DIP package 5 position AXB TEST MODE AB Board DIP package 8 position AB Board Thermal limit swi tch Hot water limit sensor Start ontactor Start elay Water oil Limit Sensor 5

54 5 SEIES 500A INSTALLATION MANUAL Wiring Schematics cont. Aurora UP To AB - P Or ang e ed White r een Brown Yellow BAnet or N Network on nections Devices Must Be Wired in Daisy hain onfiguration NET+ NET- NET- OM NET+ OM POWE NET+ NET- OM LE D TX LE D POWE ND 4 VA NET+ LE D X FO MA T BAT T NET- N/ N/ Signal ND N ET+ N ET- +V N ET 4W LO N ADAPTE POT LE D6 LOA L A ESS TX LE D7 W X ND LN+ LN- + /S LE D4 UN LE D5 E ON TEN S ONE S ommunication Options NOTE MA Address Setting ZS Sensor Addr: 0 ND N ET+ N ET- +V ZS Sensor Addr: ND N ET+ N ET- +V ZS Sensor Addr: ND N ET+ N ET- +V ZS Sensor Information Zone Sensors can be wired in daisy chain as shown or in a star or hybrid configuration. Maximum of 5 sensors per UP. Maximum allowable load 0mA. See the UP install manual for possible sensor combinations. Notes. Use DIP Switches 5 8 to change communication protocol and DIP switches to change BAnet baud rate. DIP switches factory set for BAnet MSTP (s) DIP Switch Value ON Each ZS sensor must have a unique address, but the addresses do not need to be sequential. Use the DIP switches on the back of the ZS sensor to set an address from 0 to 4. (0 is the factory default.) Each DIP switch has the value shown in the figure to the left. Turn on as many DIP switches as you need so that their total value equals the address. Legend Factory Low Voltage Wiring Field Low Voltage Wiring J45 onnector