WaterFurnace 5 Series Installation Manual
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WaterFurnace 5 Series Installation Manual

Geothermal hydronic heat pump
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500W11
Geothermal Hydronic Heat Pump
Installation Information
Water Piping Connections
Electrical Data
Startup Procedures
Preventive Maintenance
IM2506WN 06/16

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Summary of Contents for WaterFurnace 5 Series

  • Page 1 500W11 Geothermal Hydronic Heat Pump Installation Information Water Piping Connections Electrical Data Startup Procedures Preventive Maintenance IM2506WN 06/16...

  • Page 3: Table Of Contents

    5 SERIES NSW INSTALLATION MANUAL Table of Contents Model Nomenclature ............. . 4 General Installation Information .

  • Page 4: Model Nomenclature

    3 – Flow meter for Performance option is shipped with unit, and must be externally field installed. All 5 Series NSW 500W11 product is safety listed under UL1995 thru ETL and performance listed with AHRI in accordance with standard 13256-1. The 5 Series 500W11 is also ENERGY STAR ®...

  • Page 5: General Installation Information

    5 SERIES NSW INSTALLATION MANUAL General Installation Information WARNING: To avoid equipment damage, do not Safety Considerations leave the system filled in a building without heat Installing and servicing air conditioning and heating during cold weather, unless adequate freeze equipment can be hazardous due to system pressure and protection levels of antifreeze are used.

  • Page 6: Water Quality

    5 SERIES NSW INSTALLATION MANUAL Water Quality The heat exchangers and water lines in the units are copper General or cupronickel tube. There may be other materials in the Water-to-water heat pumps may be successfully applied building’s piping system that the designer may need to take...

  • Page 7: Field Connected Water Piping

    5 SERIES NSW INSTALLATION MANUAL Field Connected Water Piping General The proper water flow must be delivered to each unit Each unit is equipped with captive FPT water connections whenever the unit heats or cools. To assure proper flow, to eliminate ‘egg-shaping’ from use of a backup wrench.
  • Page 8 5 SERIES NSW INSTALLATION MANUAL Field Connected Water Piping cont. Figure 9a: 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 NSW INSTALLATION MANUAL Field Connected Water Piping cont. Typical Closed Loop Earth Coupled Installation Earth Coupled Systems with Flow Center Once piping is completed between the unit, flow center and the earth loop, final purging and charging of the loop is needed.

  • Page 10: Potable Water Systems

    5 SERIES NSW INSTALLATION MANUAL Potable Water Systems The 018 and 025 models can be equipped to provide domestic hot water generation. An optional factory- installed hot water generator coil may be provided with the 040, 050, 060, and 075 to assist with this process.
  • Page 11 5 SERIES NSW INSTALLATION MANUAL Potable Water Systems cont. Hot Water Generator Connections The heat reclaiming hot water generator coil is vented double- wall copper construction and is suitable for potable water. To maximize the benefits of the hot water generator a minimum 50-gallon water heater is recommended.

  • Page 12: Hydronic Section

    A buffer tank is required for all hydronic heating systems Dielectric unions are recommended whenever connecting using 5 Series heat pumps. The tank should be sized two dissimilar metals to one and other to prevent electro- to provide 2 gallons of storage capacity for every one galvanic corrosion.
  • Page 13 5 SERIES NSW INSTALLATION MANUAL Hydronic Section cont. If using a Geothermal Storage tank there will be two red Adequate rate of flow (GPM) is very important to system wires exiting out of the top of the tank. These red wries performance and long term reliability.

  • Page 14: Accessories And Options

    50 feet or less. Calculate the system pressure drop then refer to the pump curves to select the proper pump. All four of the WaterFurnace Type L Copper Pressure Loss pump kits can be used for hydronic heating applications as long Ft of Hd per 100 ft as they meet the fl...
  • Page 15 5 SERIES NSW 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˝...

  • Page 16: Electrical Data

    5 SERIES NSW INSTALLATION MANUAL Electrical Data Compressor Unit Rated Voltage Load Source Total Unit Min Ckt Maximum Model Voltage Min/Max Pump Pump Fuse/HACR LRA* 208-230/60/1 187/253 48.0 16.2 18.5 208-230/60/1 187/253 14.1 73.0 25.5 21.3 24.8 208-230/60/1 187/253 20.0 115.0...
  • Page 17 5 SERIES NSW 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 of the unit. To operation. To convert the unit from a 230V unit to a 208V relocate the control box, follow the procedures below.

  • Page 18: Wiring Schematics

    5 SERIES NSW INSTALLATION MANUAL Wiring Schematics Aurora Control - 208-230/60/1 Load Pump 5A Circuit Breaker Compressor 208-230/60/1 Pump Black/White (2) Violet/White (9) Blue 5A Circuit Breaker Black Black/White (3) Capacitor Source Pump Pump Pump 1/2 hp Total Tan(10) 208-230/60/1...
  • Page 19 5 SERIES NSW INSTALLATION MANUAL Wiring Schematics cont. Aurora Control - 208-230/60/1 Blue Notes Compressor 1 - Switch blue and red wires for 208V operation. Black 2 – HydroZone controller is an optional field installed accessory. Run Winding IntelliStart Blue 3 –...
  • Page 20 5 SERIES NSW INSTALLATION MANUAL Wiring Schematics - cont. Aurora Advanced Control - 208-230/60/1 Violet/White (8) Black/White (1) Load Pump 5A Circuit Breaker Compressor 208-230/60/1 Pump Black/White (2) Violet/White (9) Blue 5A Circuit Breaker Black Black/White (3) Orange (12) Capacitor...
  • Page 21 5 SERIES NSW INSTALLATION MANUAL Wiring Schematics - cont. Aurora Advanced Control - 208-230/60/1 Blue Aurora LED Flash Codes Slow Flash 1 second on and 1 second off Compressor Fast Flash 100 milliseconds on and 100 milliseconds off Flash Code...

  • Page 22: External Control

    5 SERIES NSW INSTALLATION MANUAL External Control An external controller is necessary for operation. For water storage tank set point control the HydroStat HZC, and HZ0 may be used. A field supplied aquastat may also be used as the external control to the heat pump. If zoning is required, the Hydrologic Zone Panels and Control system can provide up to eight zones of closed loop hydronic heating and cooling.

  • Page 23: Converting To A Dedicated Cooling Unit

    5 SERIES NSW INSTALLATION MANUAL Converting to a Dedicated Cooling Unit Procedure to Convert a Heating Only Unit to a Cooling Only Unit All non-reversible units are built at the factory as dedicated heating units. Follow the procedures below to make the unit a dedicated cooling unit.

  • Page 24: Unit Startup

    5 SERIES NSW INSTALLATION MANUAL Unit Startup Before Powering Unit, Check the Following: Configuring the Sensor Kits NOTE: Remove and discard the compressor hold down Configuring the Sensor kits shipping bolt located at the front of the compressor The Aurora Advanced Control allows Refrigeration, Energy, mounting bracket.
  • Page 25 Use the AID Tool to view the performance in the ‘Performance Monitor’ screen. e. Performance monitoring can be read on any of the following components: i. AID tool - instantaneous information only ii. WaterFurnace Web Portal via AWL device connected to Aurora.

  • Page 26: The Aurora Base Control System

    5 SERIES NSW 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’ Control (ABC) System...
  • Page 27 Allows direct communication of the Aurora to Smart Meters, Optional (AWL and Portal) Kit HAN, and internet. AXB required. AXB Kit for advanced hot water Added to 5 Series for key features of advanced hot water Optional generator control, flow center Standard generator control and advanced loop control/linking.
  • Page 28 5 SERIES NSW 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 29 5 SERIES NSW 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 30 5 SERIES NSW INSTALLATION MANUAL The Aurora Base Control System cont. ABC Control Board Layout Aurora ‘Base’ Control LED Displays These three LEDs display the status, configuration, and fault codes for the control. These can also be read in plain...

  • Page 31: The Aurora "Advanced" Control System

    5 SERIES NSW INSTALLATION MANUAL The Aurora ‘Advanced’ Control System Advanced Hot Water Generator Control Aurora ‘Advanced’ Control Features (Domestic Hot Water Option) The Aurora ‘Advanced’ In lieu of the ‘Base Hot Water Generator Control’, the Control system expands on...
  • Page 32 5 SERIES NSW INSTALLATION MANUAL The Aurora ‘Advanced’ Control System cont. Smart Grid-On Peak (SG) Input Home Automation 2 – E24 HA2 With a closed dry contact signal, this input will cause an The 'On Peak' input was designed to allow utilities to...
  • Page 33 5 SERIES NSW INSTALLATION MANUAL The Aurora ‘Advanced’ 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.

  • Page 34: Reference Calculations

    5 SERIES NSW 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 35: Pressure Drop

    5 SERIES NSW INSTALLATION MANUAL Pressure Drop Vented Only Load Side Pressure Drop (psi) Model 30°F 60°F 80°F 100°F 120°F Pressure Drop (psi) Model 60°F 80°F 100°F 120°F 018R* 018H 025R* 025H 040H/R 7/13/09 NOTES: Temperatures are Entering Water Temperatures.

  • Page 36: Physical Data

    5 SERIES NSW INSTALLATION MANUAL Physical Data Model Compressor (1 each) Scroll Factory Charge R410a, oz [kg] 44.0 [1.25] 58.0 [1.64] 70 [1.98] 68 [1.93] 104 [2.95] 110 [3.12] Coax & Piping Water Volume - gal [l]* .52 [1.97] .89 [3.38] 1.0 [3.94]...

  • Page 37: Operating Parameters

    5 SERIES NSW INSTALLATION MANUAL Operating Parameters Heating Mode Entering Entering Suction Discharge Superheat Subcooling Load Temp (°F) Source Temp (°F) Pressure (psig) Pressure (psig) (°F) (°F) 52-67 195-227 8-16 5-15 67-82 208-235 7-14 6-14 95-113 216-245 7-14 6-12 124-144...

  • Page 38: Antifreeze Correction

    5 SERIES NSW 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 % Pressure Antifreeze Type by wt Drop Load Source Load Source EWT - °F [°C] 80 [26.7]...

  • Page 39: Troubleshooting Guideline For Refrigerant Circuit

    5 SERIES NSW 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 40: Hr Data

    5 SERIES NSW INSTALLATION MANUAL HR Data Heat of Rejection (kBtuh) Table Load Flow-3 GPM Load Flow-4 GPM Load Flow-5 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 19.8 21.3 22.7 24.2...
  • Page 41 5 SERIES NSW INSTALLATION MANUAL HR Data cont. Load Flow-8 GPM Load Flow-11.5 GPM Load Flow-15 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 61.9 66.6 71.3 75.9 63.8 67.8 71.9 75.9 65.7...

  • Page 42: He Data

    5 SERIES NSW INSTALLATION MANUAL HE Data Heat of Extraction (kBtuh) Table Load Flow-3 GPM Load Flow-4 GPM Load Flow-5 GPM Source Source EST °F 60°F 80°F 100°F 120°F 60°F 80°F 100°F 120°F 60°F 80°F 100°F 120°F 11.1 11.3 11.5 12.0...
  • Page 43 5 SERIES NSW INSTALLATION MANUAL HE Data cont. Heat of Extraction (kBtuh) Table Load Flow-8 GPM Load Flow-11.5 GPM Load Flow-15 GPM Source Source EST °F 60°F 80°F 100°F 120°F 60°F 80°F 100°F 120°F 60°F 80°F 100°F 120°F 11.5 15.0 35.4...

  • Page 44: Dhw He Data

    5 SERIES NSW INSTALLATION MANUAL DHW HE cont. 018 and 025 DHW Heat of Extraction (kBtuh) Table Load Flow-3 GPM Load Flow-4 GPM Load Flow-5 GPM Source Source EST °F 60°F 80°F 100°F 120°F 60°F 80°F 100°F 120°F 60°F 80°F 100°F...

  • Page 45: Heating And Cooling Cycle Analysis

    5 SERIES NSW INSTALLATION MANUAL Heating Cycle Analysis Cooling Cycle Analysis...

  • Page 46: Troubleshooting Form

    5 SERIES NSW 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: _________________________________...

  • Page 47: Troubleshooting

    5 SERIES NSW INSTALLATION MANUAL Troubleshooting Should a major problem develop, refer to the following 9. The internal winding of the compressor motor may be information for possible causes and corrective steps: grounded to the compressor shell. If so, replace the compressor.

  • Page 48: Preventive Maintenance

    5 SERIES NSW 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 49: Service Parts

    5 SERIES NSW INSTALLATION MANUAL Service Parts Aurora Controls Part Description 208-230/60/1 208-230/60/1 208-230/60/1 208-230/60/1 208-230/60/1 208-230/60/1 Compressor 34P657-01 34P583-01 34P621-01 34P580-01 34P616-01 34P614-01 Compressor Capacitor 16P002D18 16P002D20 16P002D36 16P002D25 16P002D41 16P002D41 Compressor Sound Jacket 92P504A05 92P504A05 92P519-01 92P519-02 92P519-02...
  • Page 50 5 SERIES NSW INSTALLATION MANUAL Notes...

  • Page 51: Revision Guide

    5 SERIES NSW INSTALLATION MANUAL Revision Guide Pages: Description: Date: NSW to 5 Series Update 08 Feb 2016...
  • Page 52 1.5-6 Tons Document: Installation Manual IM2506WN 6/16 ©2016 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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500w11

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