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Heating and Air Conditioning
INSTALLATION MANUAL
AFFINITY
GEOTHERMAL HEAT PUMPS
SINGLE SPEED HYDRONIC
WITH VAPOR INJECTION
MODELS:
YAW040 - 066
(3 THRU 5 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 AFFINITY OptiHeat YAW040
Summary of Contents for York AFFINITY OptiHeat YAW040
- Page 1 (3 THRU 5 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 SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Table of Contents Model Nomenclature ............. . 4 General Installation Information . -
Page 4: Model Nomenclature
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Model Nomenclature Vintage Model * - Factory Use Only YAW – Affinity – finity Water-to-Water ater- -to o -Water Controls Option B – AuroraTM Advanced Controls Stage D – AuroraTM Performance & Refrigeration E –... -
Page 5: General Installation Information
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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: Field Connected Water Piping
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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...
- Page 8 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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”...
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Page 10: Flow Centers
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Field Connected Water Piping cont. Figure 2: Primary/Secondary Hook-up Multiple Units on One Flow Center NOTE: This feature is only available in the Aurora Advanced AXB to AXB AXB to AXB to Control package (AXB board), NOT the Aurora Base Control Premier Electromechanical Units... -
Page 11: Electrical Information
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Electrical Information Fixed Speed Flow Center The pump(s) will be connected to the terminals on PB1 in the unit electrical box as shown in Figure 3a. The pumps will automatically be cycled as required by the unit or by a signal from another unit sharing the flow center (See Figures 5 and 6). Pumps are protected by circuit breakers (CB) shown in Figure 3a. - Page 12 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Electrical Information cont. Variable Speed Flow Center Single Pump Variable Speed Flow Center If a variable speed single pump flow center is used, the flow center will come with two red and one green wires for the high voltage wiring. The variable speed pump MUST be powered at all times and therefore MUST be wired to the “L”...
- Page 13 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Electrical Information cont. Variable Speed Flow Center cont. Two Pump Variable Speed Flow Center If a variable speed two pump flow center is used, the flow center will come with four red and two green wires for the high voltage wiring. The second set of (2) red and (1) green wires is provided for installation flexibility.
- Page 14 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Electrical Information cont. Variable Speed Units cont. Two Pump Variable Speed Flow Center cont. The use of the black wire on the left hand pump is ONLY to be connected for troubleshooting of the pumps. The left hand pump will have a closed end splice connector crimped to the black wire.
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Page 15: Hydronic Section
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Hydronic Section General guidelines are shown below for component Pressure Reducing Valves or Feed Water Valves selection and design/installation criteria for the piping This valve lowers the pressure from the make-up water line system. - Page 16 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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.
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Page 17: External Control
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 18: Accessories And Options
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Accessories and Options IntelliStart (Model 040 only) Figure 8: UPS15-42RU and UP26-99F Pump Curve IntelliStart is a single phase compressor soft starter which UPS15-42RU, and UP26-99F Single Pump Curve reduces the normal start current (LRA) by 60-70%. It should Pump Curve - Single Pump be used in applications that require low starting amps, reduced compressor start-up noise, off-grid, and improved... - Page 19 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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˝...
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Page 20: Electrical Data
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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... - Page 21 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 22: Wiring Schematics
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Wiring Schematics Aurora Advanced EVI Water-Water 208-230/60/1 Violet/White (8) Black/White (1) Load Pump Load Pump 5A Circuit Breaker Load G G G 208-230/60/1 Pump Pump Pump CT Black/White (2) Violet/White (9) 5A Circuit Breaker Black/White (3) Orange (11) Ext Pump... - Page 23 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Wiring Schematics cont. Aurora Advanced EVI Water-Water 208-230/60/1 Compr essor Blue Blue Compr essor Black Black Capacitor Run Winding Run Winding Run Winding So start So start Blue Tan(10) Pink Active Active Active Compressor Common CT...
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Page 24: Unit Startup
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 25 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 26: Aurora Base Control
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 27 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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.
- Page 28 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 –...
- Page 29 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 31 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 32 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 33 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 34: Reference Calculations
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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: Water Pressure Drop
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Water Pressure Drop Model 040 Flow Rate, gpm Model 050 Flow Rate, gpm... -
Page 36: Pressure Drop
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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... -
Page 37: Operating Limits
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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... -
Page 38: Heating & Cooling Operating Envelope
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Heating Operating Envelope Operation Not Allowed Caution: Sensitive Operating Range Safe Operating Range Source Entering Temperature, If you are experiencing E10 faults caused by the thermal limit in the compressor being tripped and the unit is operating in or close to the “Sensitive Operating Range”... -
Page 39: Thermistor And Compressor Resistance
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 40 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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...
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Page 41: Antifreeze Correction
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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]... -
Page 42: Troubleshooting Guideline For Refrigerant Circuit
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 43: Hr Data
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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... -
Page 44: He Data
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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... -
Page 45: Optiheat Sensor Location
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL OptiHeat Sensor Locations OptiHeat Sensor Locations Entering Leaving Load Load Thermistor Thermistor FP2 Thermistor (Reversible only) Heating Liquid Line Discharge Thermistor Pressure Transducer Load Coax Discharge Injection Coax Suction VI Port Electronic Compressor Source Vapor... -
Page 46: Heating And Cooling Cycle Analysis
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Cooling Cycle Analysis PSIG = Load Coax Discharge 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... -
Page 47: Troubleshooting Form
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL 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: ______________________________ Installation Date: _________________________________ Check One Start up/Check-out for new installation... -
Page 48: Troubleshooting
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 49: Preventive Maintenance
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 50: Service Parts
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT 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 16P008D25CK 16P008D41CK 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 33P617-04 Filter Drier for ‘Reversible Models’... - Page 51 AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Notes...
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Page 53: Revision Guide
AFFINITY SINGLE STAGE HYDRONIC WITH OPTIHEAT INSTALLATION MANUAL Revision Guide Pages: Description: Date: 1, 16 3 Inch Larger Cabinet 29 Feb 2020 Misc. Added Compressor Monitoring kit, misc. updates 5 Oct 2018 Literature Creation 5 Feb 2015... - Page 54 ©2020 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.