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Heating and Air Conditioning
INSTALLATION MANUAL
AFFINITY
GEOTHERMAL HEAT PUMPS
DUAL CAPACITY COMBINATION
MODELS:
YACT038 - 072
(3 THRU 6 NOMINAL TONS)
Due to continuous product improvement, specifications are
subject to change without notice.
Visit us on the web at www.york-geothermal.com
Additional rating information can found at
www.ahridirectory.org
FOR DISTRIBUTION USE ONLY - NOT TO BE USED AT POINT OF RETAIL SALE
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Table of Contents
Troubleshooting
Related Manuals for York YACT038-072
Summary of Contents for York YACT038-072
- Page 1 (3 THRU 6 NOMINAL TONS) Due to continuous product improvement, specifications are subject to change without notice. Visit us on the web at www.york-geothermal.com Additional rating information can found at www.ahridirectory.org FOR DISTRIBUTION USE ONLY - NOT TO BE USED AT POINT OF RETAIL SALE...
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Page 3: Table Of Contents
AFFINITY COMBINATION INSTALLATION MANUAL Table of Contents Model Nomenclature ..............4 General Installation Information . -
Page 4: Model Nomenclature
AFFINITY COMBINATION INSTALLATION MANUAL Model Nomenclature Model Vintage YAC – Affinity Combo * – Factory Use Only Stage Controls Option T – Dual Capacity S – Microprocessor Unit Capacity(MBTUH) Future Option 038,049,064,072 0 – Standard Discharge Configuration Filter Option & Coil Option T –... -
Page 5: General Installation Information
AFFINITY COMBINATION INSTALLATION MANUAL General Installation Information Safety Considerations Filter Rack Conversion Installation and servicing of heating and air conditioning A 2 in. MERV 11 filter is shipped with the heat pump. To field equipment can be hazardous due to system pressure and convert the filter rack to use 1 in. - Page 6 AFFINITY COMBINATION INSTALLATION MANUAL General Installation Information cont. Water Piping Female Locking Ring 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 Stainless Locking water connections on the unit.
- Page 7 AFFINITY COMBINATION INSTALLATION MANUAL General Installation Information cont. Water Quality (pre-mix ethanol), and others. The services of a qualified It is the responsibility of the system designer and installing water treatment specialist should be engaged to determine contractor to ensure that acceptable water quality is what treatment, if any, is required.
- Page 8 AFFINITY COMBINATION INSTALLATION MANUAL General Installation Information cont. Freeze Detection Limit (Water Flow) Condensate Drain Set the freeze detection limit switch SW2 #2 to “Loop” on The internal condensate drain assembly consists of a drain the printed circuit board for applications using a closed tube, which is attached to the drain pan, a 3/4 in.
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Page 9: Closed Loop Ground Source Systems
AFFINITY COMBINATION INSTALLATION MANUAL Closed Loop Ground Source Systems Once piping is completed between the unit, flow center flow through the unit by checking pressure drop across the and the ground loop, final purging and charging of the heat exchanger (Refer to Pressure Drop table). Usually 2.5- loop is needed. -
Page 10: Open Loop Ground Water Systems
AFFINITY COMBINATION INSTALLATION MANUAL Open Loop Ground Water Systems Typical open loop piping is shown in the Open System: Discharge water from the unit is not contaminated in any Ground Water Application. Always maintain water pressure manner and can be disposed of in various ways such as in the heat exchanger by placing water control valves at recharge well, storm sewer, drain field, adjacent stream or the outlet of the unit to prevent mineral precipitation. -
Page 11: Hot Water Generator Connections
AFFINITY COMBINATION INSTALLATION MANUAL Hot Water Generator Connections To maximize the benefits of the hot water generator a kit is supplied with installation instructions, circulator, tank minimum 50-gallon water heater is recommended. For adaptor and temperature limit switch. Be sure to burp the higher demand applications, use an 80-gallon water heater pump. -
Page 12: Hydronic Section
AFFINITY COMBINATION INSTALLATION MANUAL Hydronic Section General guidelines are shown below for component there is a restriction in the screen, the system could go to selection and design/installation criteria for the piping 0 psi (0 kPa), potentially causing pumps(s) failure. A valve system. - Page 13 AFFINITY COMBINATION INSTALLATION MANUAL Hydronic Section cont. Adequate rate of flow (GPM) is very important to Geothermal Storage Tank Thermostat system performance and long term reliability. Follow the guidelines for recommended flow and pipe sizing in the Recommendations table. The unit uses an external temperature sensor such as the lower thermostat in a water heater storage tank to control the tank temperature.
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Page 14: Electrical Connections
AFFINITY COMBINATION INSTALLATION MANUAL Electrical Connections Unit Line Voltage 208-230/60/1 General 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 Code, whichever is applicable. -
Page 15: Electronic Thermostat Installation
AFFINITY COMBINATION INSTALLATION MANUAL Electronic Thermostat Installation Thermostat Wiring Installation Position the thermostat subbase against the wall so that it is level and the thermostat wires protrude through the 24VAC (Hot) subbase. Mark the position of the subbase mounting holes and drill holes with a 3/16 in. -
Page 16: Auxiliary Heat
AFFINITY COMBINATION INSTALLATION MANUAL Auxiliary Heat Auxiliary Heat Electrical Data Supply Heater Amps Min Circuit Amp Max Fuse (USA) Max Fuse (CAN) Max CKT BRK Model Circuit 208V 240V 208V 240V 208V 240V 208V 240V 208V 240V EAL(H)10A Single 34.7 53.3 Single 52.0... -
Page 17: Electrical And Blower Performance Data
AFFINITY COMBINATION INSTALLATION MANUAL Electrical Data Compressor Blower Total Rated Voltage Model Pump Loop Motor Unit Circ Fuse/ Voltage Min/Max LRA** HACR 208-230/60/1 187/253 23.8 15.2 83.0 30.0 1.07 25.7 29.5 038* 208-230/60/1 187/253 23.8 15.2 83.0 30.0 1.07 28.7 32.5 208-230/60/1 187/253... -
Page 18: Dimensional Data
AFFINITY COMBINATION INSTALLATION MANUAL Dimensional Data Topflow Discharge LEFT RETURN RIGHT RETURN LEFT FRONT RIGHT FRONT Electrical Connections Overall Cabinet Water Connections Vertical Topflow 1/2” cond 3/4” cond 1/2” cond Loop Hydronic Model Hydronic Hydronic Cond- Water Water Sweat Power Width Depth Height... - Page 19 AFFINITY COMBINATION INSTALLATION MANUAL Dimensional Data cont. Rear Discharge FRONT LEFT RETURN RIGHT RETURN REAR REAR RIGHT SIDE LEFT SIDE Electrical Connections Overall Cabinet Water Connections Vertical Backflow 1/2” cond 3/4” cond 1/2” cond Loop Hydronic Model Hydronic Hydronic Cond- Water Water Sweat...
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Page 20: Physical Data
AFFINITY COMBINATION INSTALLATION MANUAL Physical Data Model Compressor (1 each) Copeland Scroll Factory Charge R410a, oz [kg] 82 [2.32] 102 [2.89] 120 [3.40] 120 [3.40] ECM Fan Motor & Blower Fan Motor Type/Speeds Variable Speed ECM Fan Motor- hp [W] [373] [373] 1 [746]... -
Page 21: Microprocessor Control
AFFINITY COMBINATION INSTALLATION MANUAL Microprocessor Control Startup Testing The unit will not operate until all the inputs and safety The control allows service personnel to shorten most timing controls are checked for normal conditions. At first power- delays for faster diagnostics (Refer to Dip Switch description). up, a four minute delay is employed before the compressor is energized. - Page 22 AFFINITY COMBINATION INSTALLATION MANUAL Microprocessor Control cont. Heating Operation Hot Water Operation After a hot water input is received, the diverting valve, loop Heat, 1st Stage (Y1) pump and load water pump are turned on. Five seconds The blower motor is started on low speed immediately, the after hot water input is received the compressor is activated loop pump is energized 5 seconds after the “Y1”...
- Page 23 AFFINITY COMBINATION INSTALLATION MANUAL Microprocessor Control cont. Hydronic Operation ComforTalk and FaultFlash Thermostats SW4 (Status Board Switch) When the heat pump microprocessor control is configured In the OFF position, the hydronic mode is for ComforTalk or FaultFlash (SW2-8 ‘off’) thermostats the disabled and the damper connected to CR3/ thermostats will flash or display alert codes when a lockout CR4 is opened.
- Page 24 AFFINITY COMBINATION INSTALLATION MANUAL Microprocessor Control cont. Airflow Selection DIP Switches (SW1) See Blower Performance Data section. Factory Setup DIP Switches (SW2) DIP Switch Description OFF Position ON Position Number Service Test Mode Allows field selection of “NORMAL” or “TEST” operational modes. Test mode accelerates Normal Speed SW2- Test Mode...
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Page 25: Operation Logic
AFFINITY COMBINATION INSTALLATION MANUAL Operation Logic Heating Cooling Hot Water Mode STG1 STG2 STG3 EMERG STG1 STG2 Compressor Stg 2 On Reversing Valve Loop Pump Load Pump Aux Heater Staged Staged Acc Relay Diverting Valve ECM Speed T-Stat Signal Y1, Y2 Y1, Y2, W Y1, O Y1, Y2, O... -
Page 26: Wiring Schematics
AFFINITY COMBINATION INSTALLATION MANUAL Wiring Schematics 208-230/60/1 ECM Compressor Black Blue Tan(16) Unit Power NOTE 3 Ext Pump 208-230/60/1 1/2 hp Total Blk/Wh(11) Brown 208-230/60/1 Gry/Wh(10) Orange Gray(9) Pump Pump Yellow(8) Black Green(18) NOTE 2 208V Load Orange(14) Pump NOTE 1 Brown(15) Damper Blue... - Page 27 AFFINITY COMBINATION INSTALLATION MANUAL Wiring Schematics cont. 208-230/60/1 ECM cont. With optional EA Series 10kW Auxiliary Electric Heat shown Desuperheater Place auxiliary heat schematic from kit here Option Pump Blue Pink 1 - Use copper or aluminum conductors. 208-230/60/1 2 – When Auxiliary Heat is installed the BLK/WHT wire from CC-L1 to PS1-C and the GRY/WHT wire Blue Blue...
- Page 28 AFFINITY COMBINATION INSTALLATION MANUAL Wiring Schematics cont. 208-230/60/1 ECM with IntelliStart Blue Pink Blue Black Run Winding Blue IntelliStart Pump Blue Blue Active Pink Start Blue Blue Tan(16) Desuperheater Common Black Option NOTE 3 Unit Power Ext Pump 208-230/60/1 1/2 hp Total Blk/Wh(11) Brown 208-230/60/1...
- Page 29 AFFINITY COMBINATION INSTALLATION MANUAL Wiring Schematics cont. 208-230/60/1 ECM with IntelliStart cont. With optional EA Series 20kW Auxiliary Electric Heat Shown 208-230/60/1 208-230/60/1 Note 2 1 - Use copper or aluminum conductors. Circuit 2 Circuit 1 2 - Use manufacturer’s part number 19P592-01 (jumper bar assembly) when single source power is required.
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Page 30: Unit Startup
AFFINITY COMBINATION INSTALLATION MANUAL Unit Startup Before powering unit, check the 9. Instruct the owner/operator in the proper operation of the hydronic temperature control and system maintenance. following: • Fuses, breakers and wire size are correct and match the Forced Air Startup Instructions name plate. -
Page 31: Operating Parameters
AFFINITY COMBINATION INSTALLATION MANUAL Operating Parameters 1st Stage Operating Parameters 038-072 Forced Air Cooling Forced Air Heating Suction Discharge Water Air Temp Suction Discharge Water Air Temp Water Flow Super-heat Sub-cooling Super-heat Sub-cooling EWT °F Pressure Pressure Temp Rise Drop °F Pressure Pressure Temp Rise... -
Page 32: Pressure Drop
AFFINITY COMBINATION INSTALLATION MANUAL Pressure Drop Pressure Drop (psi) Model 30°F 50°F 70°F 90°F 110°F full load part load full load part load full load part load full load 10.8 10.1 part load 6/8/11... -
Page 33: Compressor And Thermistor Resistance
AFFINITY COMBINATION INSTALLATION MANUAL Compressor Resistance 208-230/60/1 Compressor Model Model No. Start ZPS30K5E-PFV 0.81 - 0.94 1.41 - 1.63 ZPS40K5E-PFV 0.48 - 0.55 1.72 - 1.99 ZPS51K5E-PFV 0.36 - 0.42 1.51 - 1.74 ZPS60K5E-PFV 0.31 - 0.36 1.72 - 1.98 9/24/2013 Thermistor Resistance Thermistor... -
Page 34: Heat Of Extraction/Rejection
AFFINITY COMBINATION INSTALLATION MANUAL Heat of Extraction/Rejection Heat of Extraction (kBtuh) Heat of Rejection (kBtuh) Model 30°F 50°F 70°F 90°F 30°F 50°F 70°F 90°F 110°F 18.5 25.1 30.9 34.8 33.5 32.1 Part Load 12.0 19.1 26.4 32.8 29.4 34.9 33.6 32.1 30.4 12.9... -
Page 35: Antifreeze Corrections
AFFINITY COMBINATION INSTALLATION MANUAL Antifreeze Corrections Catalog performance can be corrected for antifreeze use. Please use the following table and note the example given. Antifreeze Type Antifreeze % by wt Heating Cooling Pressure Drop EWT - °F [°C] 30 [-1.1] 90 [32.2] 30 [-1.1] Water... -
Page 36: Correction Factor Tables
AFFINITY COMBINATION INSTALLATION MANUAL Correction Factor Tables Air Flow Corrections (Dual Capacity Part Load) Airflow Cooling Heating CFM Per Ton % of Nominal Total Cap Sens Cap Power Heat of Rej Htg Cap Power Heat of Ext of Clg 0.922 0.778 0.956 0.924... -
Page 37: Operating Limits, Reference Calculations, Legend And Notes
AFFINITY COMBINATION INSTALLATION MANUAL Operating Limits NOTES: Minimum/maximum limits are only for Cooling Heating Operating Limits start-up conditions, and are meant for bringing the °F °C °F °C space up to occupancy temperature. Units are not Air Limits designed to operate at the minimum/maximum Minimum Ambient Air conditions on a regular basis. -
Page 38: Troubleshooting
AFFINITY COMBINATION INSTALLATION MANUAL Troubleshooting Standard Microprocessor Controls To check the unit control board for proper operation: 1. Disconnect thermostat wires at the control board. 2. Jumper the desired test input (Y1, Y2, W, O or G) to the R terminal to simulate a thermostat signal. To simulate a hot water call, jumper tan wires 11 and 14 on P5 connector. -
Page 39: Startup And Troubleshooting Form
AFFINITY COMBINATION INSTALLATION MANUAL 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: ______________________________ Installation Date: _________________________________ Check One Start up/Check-out for new installation Troubleshooting Problem:___________________________________... -
Page 40: Heating And Cooling Analysis
AFFINITY COMBINATION INSTALLATION MANUAL Heating Cycle Analysis ______PSI = ______SAT°F ______°F Air Coil Suction °F °F Compressor Source Discharge Coax ______PSI = ______SAT°F open ______°F Refrigerant charge compensator Load Inactive Coax circuit Unit Amp Draw ____________ Entering Source Water ________°F Line Voltage _________ Entering Water Pressure Drop _____ PSI Loop:______ Open ______ Closed... -
Page 41: Hot Water Cycle Analysis
AFFINITY COMBINATION INSTALLATION MANUAL Hot Water Cycle Analysis ______PSI = ______SAT°F ______°F Air Coil Suction Compressor Source Discharge Coax ______°F Liquid Line ______PSI = ______SAT°F closed ______°F Refrigerant charge compensator Coax Entering Source Water ________°F Entering Water Pressure Drop _____ PSI Unit Amp Draw ____________ Leaving Source Water ________°F Line Voltage _________... -
Page 42: Preventative Maintenance And Replacement Procedures
AFFINITY COMBINATION INSTALLATION MANUAL Preventative Maintenance Water Coil Maintenance Condensate Drain In areas where airborne bacteria produce a slime in the 1. Keep all air out of the water. An open loop system drain pan, it may be necessary to treat chemically to should be checked to ensure that the well head is not minimize the problem. -
Page 43: Service Parts List
AFFINITY COMBINATION INSTALLATION MANUAL Service Parts List Dual Capacity Vertical Units Parts Compressor (ZPSK5Es) 34P641-01 34P642-01 34P643-01 34P644-01 Run Capacitor 16P002D20 16P002D18 16P002D31 Sound Jacket 92P504A16 Power Harness 11P781-01 Solenoid Harness 11P782-02 Blower Assembly 54S564-01N 54S560-01N ECM Motor 14S564-01 14S557-01 High Static Blower Assembly 54S560-01N Blower Module Assembly... -
Page 44: Revision Guide
AFFINITY COMBINATION INSTALLATION MANUAL Revision Guide Pages: Description: Date: Misc. Updated for Aluminum Coils, Wiring Schematics 15 May 2017 26-29 Updated Wiring Schematics for Auxiliary Heat Changes, Updated ETL logo, Service 14 April 2015 Parts List 4, 9 Updated Nomenclature Hot Water Generation Option and Updated Open Loop 30 Sept 2014 Solenoid Valve Connection Option Wiring Diagrams. - Page 45 AFFINITY COMBINATION INSTALLATION MANUAL...
- Page 46 ©2015 The manufacturer has a policy of continual product research and development and reserves the right to change design and specifi cations without notice. York and Affi nity are registered trademarks of Johnson Controls, Inc., and are used with permission.
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