WaterFurnace 5 Series Operation & Maintenance Manual
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WaterFurnace 5 Series Operation & Maintenance Manual

WaterFurnace 5 Series Operation & Maintenance Manual

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OPERATION & MAINTENANCE
5 Series 500A11
R-454B
OMW5-0016W
60Hz

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  • Page 1 OPERATION & MAINTENANCE 5 Series 500A11 R-454B OMW5-0016W 60Hz...
  • Page 2 Electrical shock could cause serious personal injury. been given supervision or instruction concerning use of the WARNING: All WaterFurnace products are designed, appliance by a person responsible for their safety. tested, and manufactured to comply with the latest publicly...

  • Page 3: Table Of Contents

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Table of Contents UNIT OVERVIEW Nomenclatures ............... .4 AHRI Data.

  • Page 4: Nomenclatures

    Brand W – WFI W – WFI IntelliStart 0 – None Model Model 1 – Yes 5 – 5 Series 5 – 5 Series Mitigation Type Type 0 – None A – Water to Air A – Water to Air 1 –...

  • Page 5: Ahri Data

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL AHRI Data The performance standard AHRI/ASHRAE/ISO 13256-1 became effective January 1, 2000 and replaces ARI Standards 320, 325, and 330. This new standard has three major categories: Water Loop (comparable to ARI 320), Ground Water (ARI 325), and Ground Loop (ARI 330).
  • Page 6 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL AHRI Data Variable Speed ECM motor AHRI/ASHRAE/ISO 13256-1 English (IP) Units Ground Water Heat Pump Ground Loop Heat Pump Flow Rate Cooling Brine Heating Brine Cooling Heating Full Load 77°F Full Load 32°F EWT 59°F EWT 50°F Model...
  • Page 7 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL AHRI Data cont. Energy Star Compliance Table Energy Star Rating Criteria In order for water-source heat pumps to be Energy Star rated they must Tier 3 meet or exceed the minimum efficiency requirements listed below. Tier Model 3 represents the current minimum efficiency water source heat pumps Ground Water...

  • Page 8: Physical Data

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Physical Data Model Compressor (1 each) Dual Capacity Scroll Factory Charge R-454B, oz [kg] Vertical 32 [0.91] 50 [1.42] 56 [1.59] 54 [1.53] 56 [1.59] 62 [1.76] 76 [2.15] 104 [2.95] Factory Charge R-454B, oz [kg] Horizontal 36 [0.93] 48 [1.36]...

  • Page 9: Dimensional Data

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Dimensional Data Top Air Discharge LEFT RETURN RIGHT RETURN 1.9in [4.8cm] 1.9in [4.8cm] K J I D E H F FRONT 2ft [61cm] Primary Service Access RIGHT SIDE LEFT SIDE Electrical Return Connection Connections Discharge Connection...
  • Page 10 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Dimensional Data cont. Bottom Air Discharge RIGHT RETURN LEFT RETURN 1.70 (4.3 cm) LEFT SIDE RIGHT SIDE 1.90 (4.7 cm) FRONT 2ft [61cm] Primary Service Access LEFT BOTTOM DISCHARGE RIGHT BOTTOM DISCHARGE FLOOR FOOT PRINT FLOOR FOOT PRINT Electrical...
  • Page 11 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Dimensional Data cont. TOP VIEW 2.1in [5.4cm] MOUNT (2) HANGER BRACKETS AS SHOWN TO ALLOW ACCESS TO FILTER 2ft [61cm] Primary Service Access FRONT VIEW SIDE DISHCARGE VIEW END VIEW 1.9in [4.8cm] D E F G K J I...

  • Page 12: Electrical Data

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Electrical Data Dual Capacity Unit with Variable Speed ECM Motor Blower Total Compressor Rated Voltage Pump Loop Motor Unit Circ Fuse/ Model Voltage Min/Max LRA* HACR 208-230/60/1 187/253 15.0 52.0 18.2 19.4 21.8 208-230/60/1...

  • Page 13: Auxiliary Heat Ratings

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Auxiliary Heat Ratings BTU/H Model Stages Min CFM 208V 230V 208V 230V 024 - 030 036 - 042 048 - 072 EAM(H)5 12,300 16,300 • • EAM(H)8 19,400 25,900 • • EAM(H)10 24,600 32,700...

  • Page 14: Blower Performance Data

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Blower Performance Data Dual Capacity ECM Blower Table AIR FLOW SPEED SETTINGS MODEL MAX ESP 1025 1125 0.50 1000 1100 1200 0.50 1000 1100 1200 0.50 1000 1550 1100 1200 1300 1400 1500 0.50...
  • Page 15 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Blower Performance Data cont. ECM Speed Setup - These screens allow the technician to Setting Blower Speed - Variable Speed select the “G”, low, high, and auxiliary heat blower speed for the ECM blower motor.

  • Page 16: Antifreeze Corrections

    Antifreeze solution is Propylene Glycol 20% by weight. Determine the corrected heating and cooling performance at 30°F and 90°F respectively as well as pressure drop at 30°F for a 5 Series 024-ECM. The corrected cooling capacity at 90°F would be: 22,900 MBtu/h x 0.969 = 22,190 MBtu/h The corrected heating capacity at 30°F would be: 18,900 MBtu/h x 0.913 = 17,255 MBtu/h...

  • Page 17: Correction Factor Tables

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE 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...

  • Page 18: Heat Of Extraction/Heat Of Rejection

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Heat of Extraction/Heat of 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 10.1 13.0 15.2 16.7 17.2 16.4 10.6 13.1 16.2 16.8 16.9...

  • Page 19: Water Quality

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Water Quality 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 20: Operating Parameters

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Operating Parameters Dual Capacity Models First Stage Operation Cooling -- No Hot Water Generation Entering Water Water Flow gpm/ Suction Pressure Discharge Pressure Water Temp Air Temp Drop °F Temp °F Superheat Subcooling psig...

  • Page 21: Pressure Drop

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Pressure Drop Dual Capacity Pressure Drop Pressure Drop (psi) Pressure Drop (psi) Model Model 30°F 50°F 70°F 90°F 110°F 30°F 50°F 70°F 90°F 110°F full load full load part load part load full load full load part load...

  • Page 22: Operation Logic Data Table

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Operation Logic Data Table Heating Cooling Operation Logic Table STG1 STG2 STG3 EMERG Fan Only STG1 STG2 Fan Only Compressor Reversing Valve Staged Staged Aux Heat Acc Relay High High High High ECM Speed T-Stat Signal...

  • Page 23: Aurora Controls Operation

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora 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 24 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Control System Service Device Description Aurora 'Advanced' Allows setup, monitoring and troubleshooting of any Aurora Control. For Service NOTE: Although the ABC has basic compatibility with all Aurora, new product features (Ver.
  • Page 25 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Control System Aurora ‘Base’ Control Field Selectable Options via Hardware DIP Switch (SW1) – Test/Configuration Button (See SW1 Operation Table) Test Mode The control is placed in the test mode by holding the push button switch SW1 for 2 - 5 seconds.
  • Page 26 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Control System Cycle with Blower - The accessory relay will cycle with Lockout – when locked out, the blower will operate the blower output. continuously in “G” speed, and PSC blower motor output will remain on.
  • Page 27 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Control System Over/Under Voltage Shutdown - An over/under voltage Cooling Operation condition exists when the control voltage is outside the In all cooling operations, the reversing valve directly tracks range of 18 VAC to 30 VAC. If the over/under voltage the O input.
  • Page 28 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Control System cycle. Since compressor hot gas temperature is dependent Aurora ‘Advanced’ Control Features Control Features on loop temperature in cooling mode, loop temperatures may The Aurora ‘Advanced’ be too low to allow proper heating of water. The control will Control system expands on monitor water and refrigerant temperatures to determine if the capability of the Aurora...
  • Page 29 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Control System Aurora ‘Base’ Control LED Displays ASB Sensor Board These three LEDs display the status, configuration, and Refrigerant Leak Detection fault codes for the control. These can also be read in plain The Aurora control system uses the ASB control board to English via the Aurora AID Tool.
  • Page 30 REQUIRES WaterFurnace dealer login The AID Tool will allow configuration of this input for the action credentials SCC is for WaterFurnace dealer technicians ONLY and includes: • No Action •...
  • Page 31 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Control System Home Automation 1 - E23 HA1 Dual Capacity Power Adjustment With a closed dry contact signal, this input will cause an alarm Voltage and Alert Code 23 to indicate on the stat or flash on ABC. The AID Model Unit Capacity Tool will allow configuration of this input between the following...
  • Page 32 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Control System The Aurora Unitary Protocol Converter (UPC) Aurora Control The Aurora UPC is implemented with is an integrated solution and communicates w/UPC BACnet the Aurora Base Controller (ABC) heat directly with the Aurora Heat Pump Controls pump control into our latest water and allows access/control of a variety of internal...
  • Page 33 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Control System 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...
  • Page 34 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Control System entire length of the appropriate delay to be recognized as a Aurora now expands the Fault/Alarms in to several groups. fault. This fault will be ignored for the initial 2 minutes of the Faults are system critical faults to the heat pump and will compressor run time.
  • Page 35 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Control System E82, ASB Sensor Problem - The gas sensor has lost communi- Aurora Alarm Codes cation with the ASB board or has an internal error. These alarms are planned to alert the homeowner and the ser- vice personnel but will NOT effect system operation and are E97, Invalid System Configuration - ABC has not been config- for information only.

  • Page 36: Refrigerant Circuit Guideline

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Refrigerant Circuit Guideline Head Suction Compressor Air Temp. Water Temp. Symptom Superheat Subcooling Pressure Pressure Amp Draw Differential Differential Under Charged System High (Possible Leak) Over Charged System High High High Normal High Normal/Low...

  • Page 37: Electrical Information

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Electrical Information 208 Volt Operation General All 208/230 units are factory wired for 230 volt operation. For Be sure the available power is the same voltage and phase 208 volt operation, the red and blue transformer wires must as that shown on the unit serial plate.
  • Page 38 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Electrical Information Figure 13A: Figure 13B: Wire access (control box open) Wire access (control box closed) Ground Fastener Wire Insert must be installed for Location proper unit ground Figure 13C: Line Voltage 208-230/60/1 control box T1 T2 (018) (036-072)

  • Page 39: Electronic Thermostat Installation

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Electrical Information cont. Figure 14: Pump Wiring 208-230/60/1 Wire Nuts Optional External Variable Speed Loop Pump 208-230/60/1 External Loop Pump(s) 208-230/60/1 1/2 hp Max Electronic Thermostat Installation Position the thermostat subbase against the wall so that Figure 21: Thermostat Wiring (Y1 Style Signals) it is level and the thermostat wires protrude through the middle of the subbase.

  • Page 40: Electrical Information Flow Centers

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Electrical Information - Flow Centers Fixed Speed Flow Center The pump(s) will be connected to the terminals on PB1 in the unit electrical box as shown in Figure 15. 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).
  • Page 41 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Electrical Information - Flow Centers 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.
  • Page 42 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Electrical Information - Flow Centers 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.

  • Page 43: Closed Loop Ground Source Systems

    5 Series Units Envision Units Electromechanical Units Auxiliary Heat ® GeoLink Supply Polyethylene w/ LOOP 5 Series Unit #1 5 Series Unit #1 5 Series Unit #1 ® Armaflex Unit Supply with AXB Board with AXB Board with AXB Board...
  • Page 44 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Open Loop Ground Water Systems Variable Speed Pump Setup Figure 9b: Open Loop Solenoid Valve Connection Option When using a variable speed pump flow center (FCV1- Typical slow operating external 24V water solenoid valve GL or FCV2-GL) the use of an AID Tool will be necessary (type V100FPT) wiring.

  • Page 45: Compressor And Thermistor Resistance

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Compressor & Thermistor Resistance Thermistor Microprocessor 208-230/60/1 Compressor Model Temperature (°F) Resistance (Ohms) Model No. Start 75757-70117 YAS16K1E-PFV 1.20 - 1.38 1.66 -1.91 57392-53234 YAS20K1E-PFV 0.99 - 1.14 1.54 - 1.77 43865-40771 YAS26K1E-PFV 0.74 - 0.85...

  • Page 46: Reference Calculations And Legend

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Reference Calculations Heating Calculations: Cooling Calculations: LWT = EWT - LWT = EWT + GPM x 500* GPM x 500* NOTE: * When using water. Legend Abbreviations and Definitions EWT = Entering Water Temperature HWR = Hot Water Return EER = Energy Efficiency Ratio (TC/kW) HWS = Hot Water Supply...

  • Page 47: Preventative Maintenance

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Preventative 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 48: Troubleshooting

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Troubleshooting Aurora Control System Refrigerant Systems To maintain sealed circuit integrity, do not install service NOTE: Refer to the Aurora Base Control Application and gauges unless unit operation appears abnormal. Compare Troubleshooting Guide and the Instruction Guide: Aurora the change in temperature on the air side as well as the Interface and Diagnostics (AID) Tool for additional information.

  • Page 49: Aurora Interface Diagnostic (Aid) Tool

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Aurora Interface Diagnostic (AID) Tool Aurora Input-Output Diagnostics LED Displays Slow Flash = 1 second on and 1 second off Troubleshooting the Aurora logic board Fast Flash = 100 ms on and 100 ms off can be accomplished using nothing more Flash Code = 100 ms on and 400 ms off with a 2 second pause than a couple of jumper wires and a volt...

  • Page 50: Troubleshooting Checklist

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Troubleshooting Checklist • Return air temperature may be below 50°F. Block off air coil Equipment will not start or operate temporarily to improve flow of refrigerant through the system. Air • Follow the troubleshooting flow charts to find root cause. below 50°F cannot be tolerated on a continuing basis.

  • Page 51: Control Board Troubleshooting Steps

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Steps 1) General Check Other items to check when troubleshooting a water flow lockout • If any new device was installed, or any wiring was changed, are superheat, water flow through the coaxial heat exchanger and check the connections to ensure the wiring is correct, and all the antifreeze composition.
  • Page 52 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Steps cont. No Lockout Output – Measure the voltage output between 4) Other Faults P1-1 and C. The reading should be 24 VDC or a pulsed 24 VDC ECM Motor Will Not Start dependent on the selection of SW2-7.

  • Page 53: Control Board Troubleshooting Flow Charts

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL CONTROL BOARD FLOW CHARTS...
  • Page 54 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts Use the following flow charts to aid in troubleshooting the control board. Compressor Will Not Start Without AID Tool Compressor will not start Count the number of Is LED3 (green) lit Is LED1 (red) flashes and compare to...
  • Page 55 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts cont. Notes: 1. When measuring 24VAC actual value may be between 18 and 30VAC. Put control into test Check 24VAC Check 24VAC Check for correct Check Compressor mode, and wait 1 between CC and across contactor...
  • Page 56 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts cont. Compressor Will Not Start With AID Tool Compressor will not start Check current fault. Connect the AID Is the control in Correct fault and try to Tool Lockout? restart.
  • Page 57 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts cont. Notes: 1. When measuring 24VAC actual value may be between 18 and 30VAC. Check 24VAC Check 24VAC Check for correct Check Compressor In “System between CC and across contactor voltage on T1 and wiring, winding...
  • Page 58 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts cont. ECM Blower Will Not Start Without AID Tool Blower will not start Check for correct voltage Remove P1 and place a Put control into test Is LED3 (green) Lit between orange and jumper between R and...
  • Page 59 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts cont. Notes: 1. When measuring 24VAC actual value may be between 18 and 30VAC. There is a problem Does the blower with the thermostat or start thermostat wiring Check 24VAC Is the DC voltage on P13-1...
  • Page 60 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts cont. ECM Blower Will Not Start With AID Tool Blower will not start Check for correct voltage Connect AID Tool. Put control in test Is LED3 (green) Lit between orange and Remove P1 and put a mode and wait 1...
  • Page 61 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts cont. Notes: 1. When measuring 24VAC actual value may be between 18 and 30VAC. Put control into test Check 24VAC Check 24VAC Check for correct Check Compressor mode, and wait 1 between CC and across contactor...
  • Page 62 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts cont. Loop Pump Will Not Start Variable Speed Pump Loop Pump will not start Check pump wiring to Is AXB LED1 Is AXB LED1 AXB. Check (Green) Flashing flashing fast? communication wiring...
  • Page 63 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts cont. Notes: 1. When measuring 24VAC actual value may be between 18 and 30VAC. 2. When measuring 240VAC actual value may be between 190 and 250 VAC. Check 240 VAC Did the loop pump Is voltage on VS PMP...
  • Page 64 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts cont. Loop Pump Will Not Start Non Variable Speed Pump Loop Pump will not start Check pump wiring to Is AXB LED1 Is AXB LED1 AXB. Check (Green) Flashing flashing fast? communication wiring...
  • Page 65 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Troubleshooting Flow Charts cont. Notes: 1. When measuring 24VAC actual value may be between 18 and 30VAC. 2. When measuring 240VAC actual value may be between 190 and 250 VAC. Check for 240 VAC Check 240 VAC Did the loop pump...

  • Page 66: Communicating Thermostat Troubleshooting Guide

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Communicating Thermostat Troubleshooting Guide TPCC32U01*, TPCM32U03A* and TPCM32U04A* (*GSR, GSM, E, YRK) Thermostat not communicating Wire non- Are you using a communicating 8 Is this a variable communicating wire thermostat speed unit? thermostat? to P1 terminal on the ABC board...
  • Page 67 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Communicating Thermostat Troubleshooting Guide cont. Are all Remove what is applicable not needed or add devices present what is needed. Is Issue resolved on Configure the thermostat Aurora System communicating? screen TPCM32U03A*/TPCM32U04A* Thermostat P7 on ABC Board...

  • Page 68: Control Board Signals

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Signals To Check for 24VAC between R and C a signal and the contactor is not pulled in, check voltage across the contactor coil. If you have voltage across the contractor coil, replace the contactor.
  • Page 69 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Signals cont. To Check Operation of the Accessory Relay Put gauges on the unit to monitor high/low pressure. Place a jumper between “R” and “CC” as shown. This will bypass the safety circuit and the compressor will run whether the board is calling for it or not.
  • Page 70 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Control Board Signals cont. To Check the Condensate Sensor To Check the ECM Blower Motor Enable Signal 24 VAC VOLTS VOLTS OHMS With the AID Tool go to the “Thermostat Inputs” Menu under “Diagnostics”...

  • Page 71: Jumping The Control Board

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Jumping the Control Board Stage 1 Heating Stage 2 Heating With the AID Tool go to the “Thermostat Inputs” Menu under With the AID Tool go to the “Thermostat Inputs” Menu under “Diagnostics”...
  • Page 72 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Jumping the Control Board cont. Emergency Heat Stage 1 Cooling With the AID Tool go to the “Thermostat Inputs” Menu under With the AID Tool go to the “Thermostat Inputs” Menu under “Diagnostics”...
  • Page 73 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Jumping the Control Board cont. Reheat Mode With the AID Tool go to the “Thermostat Inputs” Menu under “Diagnostics” and over-ride the “DH” input to ON. If an AID Tool is not available remove the P1 connector to disconnect the thermostat from the board.

  • Page 74: Water Side Analysis: Heat Of Extraction/Rejection

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Water Side Analysis: Heat of Extraction/Rejection By determining the amount of heat extracted or rejected, the ∆P = 40 psi – 34.2 psi service technician can better judge the performance of the unit and ∆P = 5.8 psi verify whether or not the unit performance is acceptable.

  • Page 75: Superheat/Subcooling

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Superheat/Subcooling Checking Superheat in the Heating Mode Superheat = Suction line temperature minus suction saturation temperature Digital Thermometer Suction COIL Comp Expansion Coax Discharge Valve Hot Water Generator Checking Superheat in the Cooling Mode Superheat = Suction line temperature minus suction saturation temperature Digital...

  • Page 76: Troubleshooting Forms

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Troubleshooting...
  • Page 77 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Troubleshooting cont. Startup/ roubleshooting Form Controls Info: Dealer: ABC Version: Phone #: Date: AXB Version: IZ2 Version: Problem: T-Stat Version: Model #: Installed Sensors: Serial #: COOLING CYCLE ANALYSIS SAT °F °F Unit Amp Draw: Loop:...
  • Page 78 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE 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 LOAD COAX (Water-to-Water) HEATING...

  • Page 79: Performance Data

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data 018 - Dual Capacity with Variable Speed ECM High Speed (600 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow EWT °F Rate Airfl ow Power Airfl ow Power FT/HD MBtu/h...
  • Page 80 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 018 - Dual Capacity with Variable Speed ECM Low Speed (600 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow EWT °F Rate Airfl ow Power Airfl...
  • Page 81 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 024 - Dual Capacity with Variable Speed ECM High Speed (900 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow Rate EWT °F Airfl ow Power Airfl...
  • Page 82 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 024 - Dual Capacity with Variable Speed ECM Low Speed (700 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow Rate EWT °F Airfl ow Power Airfl...
  • Page 83 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 030 - Dual Capacity with Variable Speed ECM High Speed (900 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow EWT °F Rate Airfl ow Power Airfl...
  • Page 84 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 030 - Dual Capacity with Variable Speed ECM Low Speed (900 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow EWT °F Rate Airfl ow Power Airfl...
  • Page 85 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 036 - Dual Capacity with Variable Speed ECM High Speed (1250 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow Rate EWT °F Airfl ow Power Airfl...
  • Page 86 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 036 - Dual Capacity with Variable Speed ECM Low Speed (1050 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow EWT °F Rate Airfl ow Power Airfl...
  • Page 87 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 042 - Dual Capacity with Variable Speed ECM High Speed (1350 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow EWT °F Rate Airfl ow Power Airfl...
  • Page 88 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 042 - Dual Capacity with Variable Speed ECM Low Speed (1350 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow EWT °F Rate Airfl ow Power Airfl...
  • Page 89 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 048 - Dual Capacity with Variable Speed ECM High Speed (1550 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow Rate EWT °F Airfl ow Power Airfl...
  • Page 90 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 048 - Dual Capacity with Variable Speed ECM Low Speed (1350 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow EWT °F Rate Airfl ow Power Airfl...
  • Page 91 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 060 - Dual Capacity with Variable Speed ECM High Speed (1800 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow Rate EWT °F Airfl ow Power Airfl...
  • Page 92 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 060 - Dual Capacity with Variable Speed ECM Low Speed (1500 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow EWT °F Rate Airfl ow Power Airfl...
  • Page 93 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 072 - Dual Capacity with Variable Speed ECM High Speed (2200 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow EWT °F Rate Airfl ow Power Airfl...
  • Page 94 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Performance Data cont. 072 - Dual Capacity with Variable Speed ECM Low Speed (1700 cfm) HEATING - EAT 70°F COOLING - EAT 80/67 °F Flow Rate EWT °F Airfl ow Power Airfl...

  • Page 95: Service Parts Table

    DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Service Parts List Parts List Compressor 208-230/60/1 34P748-01 34P749-01 34P750-01 34P751-01 34P752-01 34P753-01 34P755-01 34P756-01 Run Capacitor 208-230/60/1 16P008D18K 16P008D18K 16P008D19K 16P008D21K 16P008D20K 16P008D31K 16P008D32K 16P008D34K Sound Jacket 92P504A05 92P504A05 92P504A05 92P504A05 92P504A16 92P504A16...
  • Page 96 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Notes...
  • Page 97 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Notes...
  • Page 98 DUAL CAPACITY PACKAGED HEAT PUMP OPERATING AND MAINTENANCE MANUAL Notes...

  • Page 99: Revision Guide

    Revision Guide Pages: Description: Date: Document Creation 14 March 2024...
  • Page 100 Document: Operation & Maintenance Manual OMW5-0016W 06/24 ©2024 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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