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Summary of Contents for WaterFurnace 5 Series 504W11 OptiHeat
- Page 1 504W11 Geothermal Hydronic Heat Pump 3 to 5 Tons NEW Series Installation Information Water Piping Connections Electrical Data Startup Procedures Preventive Maintenance IM2508WN 02/19...
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Page 3: Table Of Contents
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Table of Contents Model Nomenclature ............. . 4 General Installation Information . -
Page 4: Model Nomenclature
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Model Nomenclature IntelliStart ® Model N – None N – 5 Series Hydronic eries H Hydro A – IntelliStart Heat Pump at Pump Controls Option Compressor Type sor Ty B – Aurora Advanced Controls E –... -
Page 5: General Installation Information
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL General Installation Information Safety Considerations Unit Location Installing and servicing air conditioning and heating Provide sufficient room to make water and electrical equipment can be hazardous due to system pressure and connections. If the unit is located in a confined space, electrical components. -
Page 6: Field Connected Water Piping
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Field Connected Water Piping General Water Quality Each unit is equipped with captive FPT water connections It is the responsibility of the system designer and installing to eliminate ‘egg-shaping’ from use of a backup wrench. contractor to ensure that acceptable water quality is For making the water connections to the unit, a Teflon tape present and that all applicable codes have been met in... - Page 7 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Field Connected Water Piping cont. Material Copper 90/10 Cupronickel 316 Stainless Steel Acidity/Alkalinity 7 - 9 7 - 9 7 - 9 Calcium and (Total Hardness) (Total Hardness) (Total Hardness) Scaling Magnesium Carbonate less than 350 ppm less than 350 ppm less than 350 ppm Less than 0.5 ppm (rotten egg...
- Page 8 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Field Connected Water Piping cont. Figure 1a: Open Loop Solenoid Valve Connection Option Open Loop Well Water Systems Typical quick operating external 24V water solenoid valve Always maintain water pressure in the heat exchanger by (type PPV100 or BPV100) wiring.
- Page 9 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Field Connected Water Piping cont. Modulating Water Valve Setup Earth Coupled Systems with Flow Center When using a modulating water valve kit (4MWVK or NOTE: For closed loop systems with antifreeze protection, set SW2-1 to the “LOOP” (15°F) position. (Refer to the DIP 5MWVK) the use of an AID Tool will be necessary to adjust Switch Settings table in the Aurora Control section.) minimum and maximum flow rates.
- Page 10 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Field Connected Water Piping cont. Multiple Units on One Flow Center Variable Speed Pump Setup NOTE: This feature is only available in the Aurora Advanced When using a variable speed pump flow center (FCV1-GL, Control package (AXB board), NOT the Aurora Base Control FCV2-GL, FCV1-GLNP or FCV2-GLNP) the use of an AID (ABC).
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Page 11: Hydronic Section
Even distribution system can easily be designed with the if local code does not require this device, WaterFurnace temperature limits in mind. In retrofits, care must be recommends its installation. If the pressure relief valve in... - Page 12 HydroZone If using HydroZone control, connect the two red wires to the two yellow wires using wire nuts. Next, connect the two WaterFurnace Geothermal Storage Tank Thermostat red wires from the top of the Geothermal Storage tank to and Thermistor “TS”...
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Page 13: External Control
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL External Control An external controller is necessary for operation. For water storage tank set point control the HydroStat HSC, HZC, and HZ0 were designed specifically for our Geo-Storage Tanks. A field supplied aquastat may also be used as the external control to the heat pump. -
Page 14: Accessories And Options
Calculate the system pressure drop then refer to the pump curves in figure 8 to select the proper pump. All four (4) of the WaterFurnace pump kits can be used for hydronic heating applications as long as they meet the 10.0... - Page 15 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Accessories and Options cont. Geo Storage Tank Dimensions From Geo To Geo 59˝ Dip Tube 1˝ x 3˝ Nipple w/1˝ x 3˝ Nipple PRIMARY ANODE 39˝ - 80 Gallon 42˝ - 119 Gallon 8˝ HOT OUTLET 3/4˝...
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Page 16: Electrical Data
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Electrical Data Compressor Rated Voltage Load Source Total Unit Min Ckt Maximum Model Voltage Min/Max Pump Pump Fuse/HACR MCC RLA LRA* 208-230/60/1 198/254 27.7 17.8 135.0 47.0 25.0 29.5 208-230/60/1 198/254 37.8 24.2 178.0 31.4 37.5 208-230/60/1... - Page 17 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Electrical Data cont. 208 Volt Operation Control Box Relocation All 208-230 volt units are factory wired for 230 volt The control box can be installed on the rear non water operation. To convert the unit from a 230V unit to a 208V line side of the unit.
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Page 18: Wiring Schematics
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Wiring Schematics Aurora Advanced EVI Water-Water 208-230/60/1 Violet/White (8) Black/White (1) Load Pump 5A Circuit Breaker Load Compr essor 208-230/60/1 Pump Pump CT Black/White (2) Violet/White (9) Blue 5A Circuit Breaker Black Black/White (3) Orange (11) Capacitor Ext Pump... - Page 19 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Wiring Schematics cont. Aurora Advanced EVI Water-Water 208-230/60/1 Blue Compr essor Black Run Winding So start Blue Pink Active Start Tan(6) Black Common Aurora LED Flash Codes Slow Flash 1 second on and 1 second off Fast Flash 100 milliseconds on and 100 milliseconds off Flash Code...
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Page 20: Unit Startup
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Unit Startup Before Powering Unit, Check the Following: 2. Aurora Setup Screen a. AXB Setup NOTE: Remove and discard the compressor hold down i. Variable Speed Pump Setup and shipping bolt located at the front of the compressor Modulating Water Valve Setup –... - Page 21 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Unit Startup cont. f. Energy monitoring can be read on any of the Configuring the Sensor Kits following components: Configuring the Sensor kits i. AID Tool – instantaneous information only The Aurora Advanced Control allows Refrigeration, Energy, ii.
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Page 22: Aurora Base Control
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL The Aurora ‘Base’ Control System Aurora ‘Base’ Control Aurora ‘Advanced’ Control The Aurora ‘Advanced’ The Aurora ‘Base’ Control Control expands on the (ABC) System is a complete capability of the Aurora residential and commercial ‘Base’... - Page 23 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL The Aurora™ Control System cont. Add On Control Feature Kits Description Aurora 'Advanced' (field or factory installed) Monitors realtime power consumption of compressor, aux heat and pump. AXB Geo Energy Monitoring Kit Standard required. Performance &...
- Page 24 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Aurora ‘Base’ Control DIP Switch (SW2) SW2-1 (Source) FP1 Selection – Low water coil temperature limit setting for freeze detection. On = 30°F; Off = 15°F. SW2-2 (Load) FP2 Selection – On = 30°F; Off = 15°F SW2-3 RV –...
- Page 25 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Fault Retry – in the fault condition, the control will stage off Over/Under Voltage Shutdown - An over/under voltage the outputs and then “try again” to satisfy the thermostat condition exists when the control voltage is outside the Y input call.
- Page 26 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Aurora ‘Base’ Control LED Displays ABC Control Board Layout These three LEDs display the status, configuration, and 5.0 in. fault codes for the control. These can also be read in plain English via the Aurora AID Tool.
- Page 27 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Modulating Water Valve Aurora ‘Advanced’ Control Features This output is provided to drive a modulating water valve. The Aurora ‘Advanced’ Through advanced design the 0-10VDC valve can be Control system expands on driven directly from the VS pump output.
- Page 28 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Home Automation 1 and 2 Inputs Monitoring Sensor Kits The Home automation inputs are simple closed contact Energy monitoring inputs that will trigger an AID Tool and thermostat alert (Standard Sensor Kit) for the homeowner.
- Page 29 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL The Aurora™ Control System cont.. Aurora ‘Advanced’ Control LED Displays These three LEDs display the status, configuration, and fault codes for the control. These can also be read in plain English via the Aurora AID Tool. Status LED (LED3, Green) Description of Operation Fault LED, Green...
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Page 30: Reference Calculations
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Reference Calculations Heating Calculations: Cooling Calculations: LWT = EWT - LWT = EWT + GPM x C* GPM x C* HE = C* x GPM x (EWT - LWT) HR = C* x GPM x (LWT - EWT) NOTE: * C = 500 for pure water, 485 for brine. -
Page 31: Water Pressure Drop
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Water Pressure Drop Model 040 Flow Rate, gpm Model 050 Flow Rate, gpm... -
Page 32: Pressure Drop
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Water Pressure Drop cont. Model 066 Flow rate, gpm Pressure Drop Pressure Drop (psi) Model 30°F 50°F 70°F 90°F 110°F 130°F 150°F 10.0 12.5 11.5 15.0 18.5 10.0 14.5 19.0 23.5 11.5 11.3 11.0 10.8 10.3 10.1... -
Page 33: Operating Limits
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Operating Limits Cooling Heating Operating Limits °F °C °F °C Source Side Water Limits Minimum Entering Water -1.1 -6.7 Normal Entering Water 29.4 15.6 Maximum Entering Water 43.3 32.2 Load Side Water Limits Minimum Entering Water 10.0 15.6 Normal Entering Water... -
Page 34: Heating & Cooling Operating Envelope
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Heating Operating Envelope Operation Not Allowed Caution: Sensitive Operating Range Safe Operating Range Source Entering Temperature, Cooling Operating Envelope... -
Page 35: Thermistor And Compressor Resistance
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Thermistor and Compressor Resistance Thermistor Resistance Compressor Resistance Chart 208-230/60/1 Thermistor Microprocessor Model Temperature (°F) Resistance (Ohms) Start 0.46 0.85 75757-70117 57392-53234 0.36 0.97 43865-40771 0.36 0.97 33809-31487 Note: Table values have a +/- 7% tolerance 7/8/14 26269-24513 20570-19230... - Page 36 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Operating Parameters cont. Cooling Mode Entering Entering Suction Discharge Superheat Subcooling Load Temp ( Source Temp ( Pressure (psig) Pressure (psig) 86-99 135-160 12-22 2-15 92-107 191-214 10-19 4-15 98-115 248-268 5-15 6-16 101-119 335-367 6-15 8-16...
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Page 37: Antifreeze Correction
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Antifreeze Correction Catalog performance can be corrected for antifreeze use. Please use the following table and note the example given. Heating Cooling Antifreeze Antifreeze Pressure Type % by wt Drop Load Source Load Source EWT - °F [°C] 80 [26.7] 30 [-1.1]... -
Page 38: Troubleshooting Guideline For Refrigerant Circuit
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Troubleshooting Guideline for Refrigerant Circuit The chart below will assist in determining if measurements taken at the unit are within factory specifications and aid in accurate diagnosis (SYMPTOM) and repair. The chart is general in nature and represents whether a symptom would result in normal, high, or low readings from the typical operating range. -
Page 39: Hr Data
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL HR Data Heat of Rejection (MBtuh) Table Load Flow-5 GPM Load Flow-8 GPM Load Flow-10 GPM Source Source EST °F 50°F 70°F 90°F 110°F 50°F 70°F 90°F 110°F 50°F 70°F 90°F 110°F 33.8 36.4 39.1 41.7 34.6... -
Page 40: He Data
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL HE Data Heat of Extraction (MBtuh) Table Load Flow-5 GPM Load Flow-8 GPM Load Flow-10 GPM Source Source EST °F 60°F 80°F 100°F 130°F 140°F 60°F 80°F 100°F 130°F 140°F 60°F 80°F 100°F 130°F 140°F 25.4 24.6... -
Page 41: Heating And Cooling Cycle Analysis
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Cooling Cycle Analysis PSIG = Load Discharge Coax Injection Coax Suction VI Port Electronic Compressor Source Coax PSIG = Unit Amp Draw Entering Source Water Line Voltage Entering Water Pressure PSIG Loop: Open Closed Leaving Source Water Subcooling Leaving Water Pressure... -
Page 42: Troubleshooting Form
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL 5 Series 504W11 OptiHeat Startup and Troubleshooting Form Company Name: _________________________________ Company Phone No: ______________________________ Technician Name: ________________________________ Date: __________________________________________ Model No: ______________________________________ Serial No:_______________________________________ Owner’s Name: __________________________________ Open or Closed Loop: _____________________________ Installation Address: ______________________________... -
Page 43: Troubleshooting
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Troubleshooting Should a major problem develop, refer to the following Noisy Unit Operation information for possible causes and corrective steps: Check compressor for loosened mounting bolts. Make sure compressor is floating free on its isolator mounts. Compressor Won’t Run 2. -
Page 44: Preventive Maintenance
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Preventive Maintenance Keep all air out of the water lines. An open loop system 4. Connect a plastic hose from the circulating pump inlet should be checked to ensure that the well head is not to the bottom of a plastic five (5) gallon pail (refer to allowing air to infiltrate the water line. -
Page 45: Service Parts
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Service Parts - Residential Part Description 208-230/60/1 Compressor 208-230/60/1 34P663-01 34P664-01 34P665-01 Compressor Capacitor 208-230/60/1 16P002D25 16P002D41 Compressor Sound Jacket 92P526-01 Thermal Expansion Valve 33P605-10 33P605-15 33P605-07 VI Electronic Expansion Valve 33P617-01 VI Electronic Expansion Valve Solenoid 33P617-02 Filter Drier for ‘Reversible Models’... - Page 46 5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Notes...
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Page 47: Revision Guide
5 SERIES OPTIHEAT 504W11 INSTALLATION MANUAL Revision Guide Pages: Description: Date: Misc. Added Compressor Monitoring kit, misc. updates 15 Feb 2019 Literature Creation 5 Feb 2015... - Page 48 3-5 Tons Document: Installation Manual IM2508WN 02/19 ©2019 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy of continual product research and development and reserves the right to change design and specifi cations without notice.
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