Water Furnace 3 Series Installation Manual
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Water Furnace 3 Series Installation Manual

Geothermal heat pump
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300A11
Geothermal Heat Pump
• R-410A Refrigerant
• 2, 3, 4, 5, 6 Ton Dual Capacity
Installation Information
ormation
Water Piping Connections
onnections
Hot Water Generator Connections
erator Connections
Electrical
Startup Procedures
ures
Troubleshooting
g
Preventive Maintenance
ntenance
C
US
IM2300AL 09/14

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Summary of Contents for Water Furnace 3 Series

  • Page 1 300A11 Geothermal Heat Pump • R-410A Refrigerant • 2, 3, 4, 5, 6 Ton Dual Capacity Installation Information ormation Water Piping Connections onnections Hot Water Generator Connections erator Connections Electrical Startup Procedures ures Troubleshooting Preventive Maintenance ntenance IM2300AL 09/14...

  • Page 3: Table Of Contents

    3 SERIES 300A11 INSTALLATION MANUAL Table of Contents Model Nomenclature ............4 General Installation Information .

  • Page 4: Model Nomenclature

    3 SERIES 300A11 INSTALLATION MANUAL Model Nomenclature ® IntelliStart & Air Coil Option Model Type N – No IntelliStart, Uncoated Coil L – 3 Series Water-to-Air A – IntelliStart, Uncoated Coil B – No IntelliStart, AlumiSeal Compressor Type C – IntelliStart, AlumiSeal D –...

  • Page 5: General Installation Information

    3 SERIES 300A11 INSTALLATION MANUAL General Installation Information Safety Considerations Installing Vertical Units Prior to setting the unit in place, remove and discard the WARNING: Before performing service or compressor hold down shipping bolt located at the front of maintenance operations on a system, turn off main the compressor mounting bracket.
  • Page 6 3 SERIES 300A11 INSTALLATION MANUAL General Installation Information cont. hanger rods to the bracket, a double nut is required since Installing Horizontal Units vibration could loosen a single nut. To allow filter access, Remove and discard the compressor hold down shipping one bracket on the filter side should be installed 180°...
  • Page 7 3 SERIES 300A11 INSTALLATION MANUAL General Installation Information cont. Figure 3: Hanger Location and Assembly Hanger Bracket Locations Weight Distribution (See Figure 3) Horizontal Weight Distribution Hanger Kit Unit Hanger Dimensions Vertical Horizontal Model Model Front Back Part Number Weight Weight 53.7...
  • Page 8 3 SERIES 300A11 INSTALLATION MANUAL General Installation Information cont. thread the female locking ring onto the pipe threads, while Duct System maintaining the brass connector in the desired direction. An air outlet collar is provided on vertical top air discharge Tighten the connectors by hand, then gently snug the units and all horizontal units to facilitate a duct connection.
  • Page 9 3 SERIES 300A11 INSTALLATION MANUAL General Installation Information cont. Water Quality Guidelines Material Copper 90/10 Cupro-Nickel 316 Stainless Steel Acidity/Alkalinity 7- 9 7 - 9 7 - 9 Calcium and Magnesium (Total Hardness) (Total Hardness) (Total Hardness) Scaling Carbonate less than 350 ppm...

  • Page 10: Closed Loop Ground Source Systems

    3 SERIES 300A11 INSTALLATION MANUAL Closed Loop Ground Source Systems NOTE: For closed loop systems with antifreeze protection, Multiple Units on One Flow Center set SW2-1 to the “LOOP” (15°F) position. (Refer to the DIP To achieve this same feature when heat pumps have only Switch Settings table in the Aurora Control section.)

  • Page 11: Open Loop Ground Water Systems

    3 SERIES 300A11 INSTALLATION MANUAL Open Loop Ground Water Systems Typical open loop piping is shown below. Always maintain on local codes, i.e. recharge well, storm sewer, drain field, water pressure in the heat exchanger by placing water adjacent stream or pond, etc. Most local codes forbid control valves at the outlet of the unit to prevent mineral the use of sanitary sewer for disposal.

  • Page 12: Hot Water Generator Connections

    3 SERIES 300A11 INSTALLATION MANUAL Hot Water Generator Connections To maximize the benefits of the hot water generator a Figure 11: Typical Hot Water Generator Installation minimum 50-gallon water heater is recommended For Cold 3/4” x 3/4” x 1/2” tee...
  • Page 13 3 SERIES 300A11 INSTALLATION MANUAL Hot Water Generator Connections cont. Plumbing Installation Hot Water Generator Startup 1. Inspect the dip tube in the water heater cold inlet 1. Turn the hot water generator switch to the “ON” position. The hot water generator switch will allow the for a check valve.

  • Page 14: Electrical Connections

    3 SERIES 300A11 INSTALLATION MANUAL Electrical Connections General Figure 13B: Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage Line Voltage 208-230/60/1 control box wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.

  • Page 15: Electronic Thermostat Installation

    3 SERIES 300A11 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 Figure 15a: Thermostat Wiring (Y1 Style Signals) subbase mounting holes and drill holes with a 3/16-inch bit.

  • Page 16: Auxiliary Heat Ratings

    3 SERIES 300A11 INSTALLATION MANUAL Auxiliary Heat Ratings BTU/HR Model Stages Min CFM 208V 230V 208V 230V 048 - 072 EAM(H)5A 12,300 16,300 EAM(H)8A 19,400 25,900 EAM(H)10A 24,600 32,700 EAL(H)10A 24,600 32,700 1100 EAL(H)15A 10.8 14.4 36,900 49,100 1250 EAL(H)20A 14.4...

  • Page 17: Blower Performance Data

    Fan, CC, CC2, and E1 output signals. Each of those - Super efficient low airflow continuous blower setting (G) 5 speeds has a specific ‘Torque’ value programmed into 3 Series Dual Capacity with 5-Speed ECM Airflow (cfm) at External Static Pressure (in. wg) Motor Motor T’stat...

  • Page 18: Dimensional Data

    3 SERIES 300A11 INSTALLATION MANUAL Vertical Dimensional Data 3 SERIES VERTICAL SUBMITTAL DATA 2 ft [61 cm] Primary Service Access 2 ft [61 cm] Alternate RIGHT RETURN Service Access. Right Return Opposite Side LEFT RETURN 1.90 4.8 1.90 4.8 FRONT...
  • Page 19 3 SERIES 300A11 INSTALLATION MANUAL Horizontal Dimensional Data TOP VIEW 2.00 5.1 Mount (2) hanger brackets as shown to allow access to filter 2 ft [61 cm] 2 ft [61 cm] Primary Service Access Alternate Service Access Right return opposite side...

  • Page 20: Physical Data

    3 SERIES 300A11 INSTALLATION MANUAL Physical Data Dual Capacity Model Compressor (1 each) Copeland Ultra Tech, Dual Capacity Scroll Factory Charge R410a, oz [kg] Vertical 39 [1.05] 52 [1.47] 68 [1.93] 76 [2.15] 88 [2.49] Factory Charge R410a, oz [kg] Horizontal 38 [1.08]...
  • Page 21 3 SERIES 300A11 INSTALLATION MANUAL The Aurora™ Control System cont.. Aurora Control Features Description Aurora ‘Base’ Microprocessor control of compressor for timings with FP1, • Microprocessor Compressor Control HP, LP, Condensate, assignable Acc relay Base Hot Water Generator Compressor Contactor powers Hot Water Generator Pump •...
  • Page 22 3 SERIES 300A11 INSTALLATION MANUAL The Aurora Control System cont. by cycling the power. NOTE: Test mode will automatically Aurora ‘Base’ Control be exited after 30 minutes. Reset Configuration Mode The control is placed in reset configuration mode by holding the push button switch SW1 for 50 to 60 seconds.
  • Page 23 3 SERIES 300A11 INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. open requirement. A continuously open LPS shall not be Field Selectable Options via Software recognized during the 2 minute startup bypass time. (Selectable via the Aurora AID Tool) Loss of Charge – fault is recognized when the Normally...
  • Page 24 3 SERIES 300A11 INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Emergency Heat (W) - The blower will be started on “W” Aurora ‘Base’ Control LED Displays speed, 10 seconds later the first stage of electric heat These three LEDs display the status, configuration, and will be turned on.

  • Page 25: Reference Calculations And Legend

    3 SERIES 300A11 INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. AURORA BASE CONTROL™ 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 RTU communication.

  • Page 26: Wiring Schematics

    3 SERIES 300A11 INSTALLATION MANUAL Wiring Schematics Aurora BASE with 5-Speed ECM Ext Pump 1/2 hp Total 208-230/60/1 Compressor Violet(7) Pump Pump Blue Violet(8) Black Black Circuit Breaker Tan(6) Tan(6) Black(2) Black(3) Circuit Breaker Hot Water Unit Power Supply Blue...
  • Page 27 3 SERIES 300A11 INSTALLATION MANUAL Wiring Schematics cont. Aurora BASE with 5-Speed ECM cont. With optional EA Series 10kW Auxiliary Electric Heat shown Notes Place auxiliary heat schematic from kit here 1 - Switch blue and red wires for 208V operation.
  • Page 28 3 SERIES 300A11 INSTALLATION MANUAL Wiring Schematics cont. Aurora BASE with 5 Speed ECM and IntelliStart Ext Pump Blue 1/2 hp Total 208-230/60/1 Compressor Violet(7) Pump Pump Run Winding Blue IntelliStart Violet(8) Black Active Pink Start Black Circuit Breaker Tan(6)
  • Page 29 3 SERIES 300A11 INSTALLATION MANUAL Wiring Schematics cont. Aurora BASE with 5 Speed ECM and IntelliStart With optional EA Series 20kW Auxiliary Electric Heat shown Place auxiliary heat schematic from kit here Notes 208-230/60/1 208-230/60/1 1 - Switch blue and red wires for 208V operation.

  • Page 30: Unit Startup

    3 SERIES 300A11 INSTALLATION MANUAL Unit Startup Startup Steps Before Powering Unit, Check the Following: NOTE: Complete the Equipment Start-Up/Commissioning NOTE: Remove and discard the compressor hold down Check Sheet during this procedure. Refer to thermostat shipping bolt located at the front of the compressor operating instructions and complete the startup procedure.

  • Page 31: 024 Operating Parameters

    3 SERIES 300A11 INSTALLATION MANUAL 024 Operating Parameters Dual Capacity Models First Stage Operation Cooling -- No Hot Water Generation Entering Water Flow Water Temp Suction Discharge Water Temp Air Temp Drop gpm/ton Superheat Subcooling °F Pressure psig Pressure psig Rise °F...
  • Page 32 3 SERIES 300A11 INSTALLATION MANUAL 036 Operating Parameters Dual Capacity Models First Stage Operation Cooling -- No Hot Water Generation Entering Water Flow Water Temp Suction Discharge Pressure Water Temp Air Temp Drop gpm/ton Superheat Subcooling °F Pressure psig psig Rise °F...
  • Page 33 3 SERIES 300A11 INSTALLATION MANUAL 048 Operating Parameters Dual Capacity Models First Stage Operation Cooling -- No Hot Water Generation Entering Water Flow Water Temp Suction Pressure Discharge Water Temp Air Temp Drop gpm/ton Superheat Subcooling °F psig Pressure psig Rise °F...
  • Page 34 3 SERIES 300A11 INSTALLATION MANUAL 060 Unit Operating Parameters Dual Capacity Models First Stage Operation Cooling -- No Hot Water Generation Entering Water Water Flow Suction Pressure Discharge Pressure Water Temp Air Temp Drop Temp °F gpm/ton Superheat Subcooling psig psig Rise °F...
  • Page 35 3 SERIES 300A11 INSTALLATION MANUAL 072 Unit Operating Parameters Dual Capacity Models First Stage Operation Cooling -- No Hot Water Generation Entering Water Water Flow Suction Pressure Discharge Water Temp Air Temp Drop Temp °F gpm/ton Superheat Subcooling psig Pressure psig Rise °F...

  • Page 36: Pressure Drop

    3 SERIES 300A11 INSTALLATION MANUAL Pressure Drop Pressure Drop (psi) Model 30°F 50°F 70°F 90°F 110°F 024 Full Load 10.5 024 Part Load 036 Full Load 036 Part Load 048 Full Load 10.1 048 Part Load 060 Full Load 13.8 13.0...

  • Page 37: Compressor And Thermistor Resistance

    3 SERIES 300A11 INSTALLATION MANUAL Compressor Resistance Thermistor Resistance Thermistor Microprocessor 208-230/60/1 Model Compressor Model No. Temperature (°F) Resistance (Ohms) Start 75757-70117 ZPS20K5E-PFV 1.21 - 1.39 1.52 - 1.75 57392-53234 ZPS30K5E-PFV 0.81 - 0.94 1.41 - 1.63 43865-40771 ZPS40K5E-PFV 0.48 - 0.55 1.72 - 1.99...

  • Page 38: Heat Of Extraction/Rejection

    3 SERIES 300A11 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 12.6 16.1 20.1 21.1 20.8 20.1 Part Load 13.2 17.4 21.4 20.3 21.2 20.9 20.1...

  • Page 39: Antifreeze Corrections

    3 SERIES 300A11 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]...

  • Page 40: Troubleshooting

    3 SERIES 300A11 INSTALLATION MANUAL Troubleshooting cont. Startup/ roubleshooting Form Controls Info: Dealer: ABC Version: Phone #: Date: IZ2 24V Version: Problem: Model #: T-Stat Version: Installed Sensors: Serial #: COOLING CYCLE ANALYSIS SAT °F °F Unit Amp Draw: Loop:...
  • Page 41 3 SERIES 300A11 INSTALLATION MANUAL Troubleshooting cont. Single Speed/Dual Capacity Startup/Troubleshooting Form 1. Job Information Model # Job Name: Loop: Open / Closed Serial # Install Date: Hot Water Generator: Y / N 2. Flow Rate in gpm SOURCE COAX...

  • Page 42: Preventive Maintenance

    3 SERIES 300A11 INSTALLATION MANUAL Preventive Maintenance Proper maintenance is very important to obtain optimum Condensate Drain performance and longevity for the heat pump system. It is In areas where airborne bacteria produce a slime in the best to establish a periodic maintenance schedule with the drain pan, it may be necessary to treat chemically to installer so the heat pump system can be checked regularly.

  • Page 43: Service Parts List

    3 SERIES 300A11 INSTALLATION MANUAL Service Parts List Dual Capacity Units Parts List Compressor 208-230/60/1 34P640-01 34P641-01 34P642-01 34P643-01 34P644-01 Run Capacitor 208-230/60/1 16P002D19 16P002D20 16P002D18 16P002D31 16P002D31 Compressor Power Harness 11P781-01 11P781-01 11P781-01 11P781-01 11P781-01 Solenoid Harness 11P782-02 11P782-02...
  • Page 44 3 SERIES 300A11 INSTALLATION MANUAL Notes...

  • Page 45: Revision Guide

    3 SERIES 300A11 INSTALLATION MANUAL Revision Guide Pages: Description: Date: Document Creation 18 Sept 2014...
  • Page 46 Manufactured by WaterFurnace International, Inc. 9000 Conservation Way Fort Wayne, IN 46809 www.waterfurnace.com Product: 3 Series 300A11 Type: Geothermal Heat Pump 2-6 Ton Dual Capacity Document: Installation Manual ISO 17025 Accredited ©2014 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy...

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