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WaterFurnace Versatec 700 Operation & Maintenance Manual
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WaterFurnace Versatec 700 Operation & Maintenance Manual

WaterFurnace Versatec 700 Operation & Maintenance Manual

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OPERATION & MAINTENANCE
Versatec 700 10-90 Ton
60HZ
OMV7-0010W
All Versatec 700 10-90 Ton Series product is safety listed under UL1995 thru ETL and
performance listed with AHRI in accordance with standard 13256-1.

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Summary of Contents for WaterFurnace Versatec 700

  • Page 1 OPERATION & MAINTENANCE Versatec 700 10-90 Ton 60HZ OMV7-0010W All Versatec 700 10-90 Ton Series product is safety listed under UL1995 thru ETL and performance listed with AHRI in accordance with standard 13256-1.

  • Page 2: For The User

    Definition of Warnings and Symbols WARNING Indicates a situation that results in death or DANGER serious injury. WARNING: Before performing service or maintenance Indicates a situation that could result in operations on the system, turn off main power switches WARNING death or serious injury.

  • Page 3: Table Of Contents

    Table of Contents UNIT OVERVIEW General Installation ..............4 Nomenclatures .

  • Page 4: General Installation

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE General Installation Information No person carrying out work in relation to a REFRIGERATING NOTICE: Do not store or install units in corrosive environments SYSTEM which involves exposing any pipe work shall use any or in locations subject to temperature or humidity extremes.

  • Page 5: Installation Space Requirements

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE General Installation Information Installation Space Requirements WARNING Ventilated Area: ensure that the area is in the open or that it NOTE: Equipment with refrigerant charge less than 62 oz does is adequately ventilated before breaking into the system of not require have a minimum floor area requirement and does not conducting any hot work.

  • Page 6: Nomenclatures

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Nomenclatures 24-26 Brand Non-Standard Options V – WaterFurnace SSS – None Versatec Drain Pan Option Model 2 – Stainless Steel 7 – 700 Series Air Coil Option Option Type 1 – All-Aluminum, Uncoated A –...

  • Page 7: Ahri Data

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE AHRI Data AHRI/ASHRAE/ISO 13256-1 English (IP) Units Water Loop Heat Pump Ground Water Heat Pump Ground Loop Heat Pump Flow Rate Cooling Brine Heating Brine Cooling Heating Cooling Heating Capacity Full Load 77°F Full Load 32°F Model...
  • Page 8 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE AHRI Data cont The performance standard AHRI/ASHRAE/ISO 13256-1 became effective January 1, 2000 and replaces AHRI 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 9: Electrical Availability

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Electrical Availability Voltage ● ● 208-230/60/3 ● ● 460/60/3 ●● ●● 575/60/3 9/3/24 ● - Available ●● - Special request with step down transformer...

  • Page 10: Physical Data

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Physical Data Variable Speed Model Compressor Scroll (1 each) Factory Charge R454B, oz [kg] (each circuit) 152 [4.31] 174 [4.93] Blower Motor & Blower Blower Motor - Quantity Blower Motor Type/Speeds EC Backward Inclined Plenum Fan/12 Blower Motor 230V - hp [kW] 4.8 [3.6]...

  • Page 11: Dimensional Data

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data LEFT RETURN "H" "F" END DISCHARGE SHOWN FIELD REMOVABLE BRACKETS AND DUCT FLANGES DRAIN CONNECTION SIDE DISCHARGE "J" FIELD REMOVABLE BRACKETS AND DUCT FLANGES "J" "K" "N" "G" DUCT FLANGE "L"...
  • Page 12 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. LEFT RETURN SHOWN "N" "J" "M" "B" "L" "H" TOP DISCHARGE FIELD REMOVABLE BLOWER PANEL INSERT 1.00 "G" "L" "M" "N" BLOWER ACCESS PANEL "K" SIDE DISCHARGE FIELD REMOVABLE BLOWER PANEL INSERT...
  • Page 13 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. LEFT RETURN "P" SHOWN BOTH SIDES "R" "F" 1.8 (3) "E" "D" CONTROL BOX ACCESS DOOR VENTED ACCESS PANEL BOTH SIDES "C" BLOWER ACCESS PANEL AIR COIL "K"...
  • Page 14 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. FRONT FRONT RIGHT RETURN LEFT RETURN "C" "C" "F" "D" "G" "G" "D" "F" DISCHARGE DISCHARGE OPENING OPENING "E" "B" "B" "E" "A" "A" FRONT FRONT Weight Distribution Table Horizontal Weight Distribution Vertical Horizontal...

  • Page 15: Waterside Economizer Option

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. Waterside Economizer Option LEFT RETURN SHOWN "A" "N" ECONO OUT "J" "M" "B" (TO UNIT IN) ECONO IN 2' SERVICE ACCESS "L" 2' SERVICE "H" ACCESS TOP DISCHARGE FIELD REMOVABLE BLOWER PANEL INSERT...
  • Page 16 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. Waterside Economizer Option RIGHT RETURN SHOWN 1.00 "N" "M" "J" "B" ECONO OUT (TO UNIT IN) ECONO IN "L" "H" 2' SERVICE TOP DISCHARGE ACCESS 2' SERVICE ACCESS FIELD REMOVABLE BLOWER PANEL...
  • Page 17 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. LEFT RETURN SHOWN "P" 4.20 BOTH 1.60 SIDES "R" 1.8 (4) 13.6 "E" 20.2 "D" CONTROL BOX ACCESS DOOR VENTED ACCESS PANEL BOTH SIDES "C" BLOWER ACCESS AIR COIL PANEL "K"...
  • Page 18 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. RIGHT RETURN SHOWN "P" "R" BOTH BOTH SIDES SIDES 10.6 1.8 (4) "E" 20.2 "D" CONTROL BOX ACCESS DOOR VENTED ACCESS PANEL BOTH SIDES "C" AIR COIL BLOWER ACCESS "K"...
  • Page 19 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. LEFT RETURN "H" END DISCHARGE "F" SHOWN FIELD REMOVABLE BRACKETS AND DUCT FLANGES DRAIN CONNECTIONS SIDE DISCHARGE "J" FIELD REMOVABLE BRACKETS AND 1 5/8" UNISTRUT 42" & 50" DUCT FLANGES CUT LENGTH 3 REQUIRED NOT SUPPLIED BY WFI...
  • Page 20 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. "H" RIGHT RETURN "F" SHOWN DRAIN CONNECTIONS END DISCHARGE "J" FIELD REMOVABLE SIDE DISCHARGE BRACKETS AND FIELD REMOVABLE DUCT FLANGES BRACKETS AND DUCT FLANGES "N" "K" DUCT "J"...

  • Page 21: Electrical Information

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Electrical Information WARNING WARNING Do not apply any permanent inductive or capacitance During repairs to sealed components, all electrical supplies shall be disconnected from the equipment being loads to the circuit with out ensuring that this will not exceed the permissible voltage and current permitted for worked upon prior to any removal of sealed covers, etc.

  • Page 22: Blower Performance Data

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Blower Performance Data Integrated EC Backward Curved Plenum Fan Performance Model 120 Airflow [scfm] at External Static Pressure [in. wg.] Speed 600 1526 1349 1166 700 1835 1711 1566 1400 1214 1008 800 2145 2030 1895 1740 1564 1368 1151...
  • Page 23 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Blower Performance Data cont. Setting Blower Speed - Variable Speed ECM ECM Speed Setup - These screens allow the technician to select the G, low, high, and auxiliary heat blower speed for The ABC board’s Yellow Config LED will flash the current ECM the ECM blower motor.

  • Page 24: Antifreeze Corrections

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Antifreeze Corrections Antifreeze Corrections Catalog performance can be corrected for antifreeze use. Please use the following table and note the example given. Antifreeze Cooling Heating Antifreeze Type Pressure Drop % by wt Capacity Capacity EWT - degF [DegC]...

  • Page 25: Correction Factor Tables

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Correction Factor Tables Cooling Heating Operating Limits (°F) (°C) (°F) (°C) Air Limits Min. Ambient Air Rated Ambient Air 26.7 21.1 Max. Ambient Air 37.8 29.4 Min. Entering Air 10.0 NOTE: Minimum/maximum limits are only for start-up conditions, and Rated Entering Air db/wb 80.6/66.2 27/19...

  • Page 26: Pressure Drop

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Correction Factor Tables Airfl ow Cooling Heating CFM Per Ton % of Nominal Total Cap Sens Cap Power Heat of Rej Htg Cap Power Heat of Ext of Clg 0.709 0.585 0.821 0.749...

  • Page 27: Water Quality

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Water Quality In ground water situations where scaling could be heavy with extremely hard water, the owner should be informed or where biological growth such as iron bacteria will be that the heat exchanger may require occasional flushing.

  • Page 28: Operating Limits And Parameters

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Operating Limits Cooling Heating Operating Limits (°F) (°C) (°F) (°C) Air Limits Min. Ambient Air Rated Ambient Air 26.7 21.1 Max. Ambient Air 37.8 29.4 Min. Entering Air 10.0 NOTE: Minimum/maximum limits are only for start-up conditions, and Rated Entering Air db/wb 80.6/66.2 27/19 20.0...

  • Page 29: Aurora Controls Operation

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System Aurora Controls The Aurora Control System is a complete commercial comfort system that can bring all aspects of the HVAC system into one cohesive module network. The Aurora System is available in two configurations: Aurora Base Control and Aurora Advanced Control both with optional Aurora UPC for DDC applications.

  • Page 30: Control Features

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System cont. Aurora ‘Advanced Variable Speed’ Optional Aurora UPC When coupled with the optional Aurora UPC, the system Control can communicate all of these same heat pump parameters to the BAS as network points using either BACnet, N2 or Lon protocols.

  • Page 31: Monitoring Sensors

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System cont. Variable Speed ECM Blower Motor Loop Pump Linking This input and output are provided so that two units can A variable speed ECM blower motor is driven directly using be linked together with a common flow center.
  • Page 32 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System cont. and LED1 (red) will be continuously lit. During the variable Special Modes and Applications speed ECM configuration mode LED2 (yellow) will flash each Communicating Digital Thermostats of the 12 possible blower speeds 3 times.
  • Page 33 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System cont. Variable Speed ECM Blower Speeds Lockout – when locked out, the blower will operate continuously in “G” blower speed setting. The Alarm output The blower speeds can be changed either by using the (ALM) and Lockout output (L) will be turned on.

  • Page 34: Operation Description

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System cont. Freeze Detection-(Coax) - set points shall be either 30°F Operation Description or 15°F. When the thermistor temperature drops below Power Up - The unit will not operate until all the inputs and the selected set point, the control shall begin counting safety controls are checked for normal conditions.
  • Page 35 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System cont. Blower (G) - The blower will start immediately upon Aurora Advanced VS Control LED Displays receiving a thermostat G command. If there are no other These three LEDs display the status, configuration, and commands from the thermostat the variable speed ECM fault codes for the control.
  • Page 36 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System cont.
  • Page 37 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System cont. ABC Control Board Layout AXB Control Board Layout See Figure 1 for DHW wiring. LED 1 LED 2 FP1 – 15 F/30 ECM PWM FP2 – 15 F/30 RV –...
  • Page 38 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Controls - UPC DDC Control (optional) Aurora UPC Controller ZS Series Sensors The Aurora Unitary Protocol Converter (UPC) is designed The Aurora UPC is implemented with the Aurora Base to add-on to any Aurora based heat pump control. The Controller (ABC) heat pump control into our latest water Aurora Unitary Protocol Convertor (UPC) is designed source heat pumps.
  • Page 39 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Controls - UPC DDC Control (optional) Modbus BACnet Rnet Aurora UPC Features Aurora UPC Optional Features • Rugged enclosure made of GE C2950 Cycoloy plastic • AID Tool for Aurora ABC configuration •...
  • Page 40 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Controls - UPC DDC Control (optional) Port 1a is used to communicate to the Building Automation System (BAS). This port’s settings are configured through 24Vac the onboard dip switches. Port 2 is used to communicate to Dip switches for the Aurora Base...
  • Page 41 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Controls - UPC DDC Control (optional) Leaving Air Temperature (LAT) Sensor – This 10 kOhm Dirty Filter Switch – This optional field installed switch NTC sensor is factory installed on all UPC equipped is connected to confirm dirty filter operation.
  • Page 42 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Controls - UPC DDC Control (optional) Aurora Base or Advanced Control Configuration and Status Codes Status LED (LED3, Green) Description of Operation Fault LED, Green Normal Mode Control is Non-functional Test Mode Slow Flash Lockout Active...
  • Page 43 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Controls - UPC DDC Control (optional) Aurora Advanced Control Configuration and Options Accessory Relay2 – A second, configurable, accessory relay on the AXB is provided that can be cycled with the compressor 1 or 2 , blower, or the Dehumidifier (DH) input.
  • Page 44 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Controls - UPC DDC Control (optional) Performance Monitoring (Requires flow meter) - Aurora Advanced Control Performance Monitoring includes: three temperature Optional Sensor Kits sensors, entering and leaving water, leaving air Energy Monitoring (Standard) - Energy Monitoring temperature and a water flow rate sensor.
  • Page 45 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Controls - UPC DDC Control (optional) ZS Series RNet Sensor Overview This is done using (2) 18 AWG twisted pair unshielded cables for a total of 4 wires connected to the Rnet port. The ZS Series line of intelligent zone sensors provides the The sensor gets its power from the UPC controller and function and flexibility you need to manage the conditions...
  • Page 46 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Controls - UPC DDC Control (optional) RNet Sensor Physical and Electrical Data Sensing Element Range Accuracy Temperature (on non-Humidity models) -4° to 122° F (-20° C to 50° C) ±0.35° F (0.2° C) Temperature (on Humidity models) 50°...

  • Page 47: Refrigerant Circuit Guideline

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Refrigerant Circuit Guideline Head Suction Compressor Air Temp. Water Temp. Symptom Superheat Subcooling Pressure Pressure Amp Draw Differential Differential Under Charged System (Possible Leak) High Over Charged System High High High Normal High...

  • Page 48: System Cleaning And Flushing

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE System Cleaning and Flushing Refill the system with clean water. Test the system water Cleaning and Flushing for acidity and treat as required to leave the water slightly Prior to start up of any heat pump, the water circulating alkaline (pH 7.5 to 8.5).

  • Page 49: Open Loop Ground Water Systems

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Open Loop Ground Water Systems Typical open loop piping is shown below. Always maintain Discharge water from the unit is not contaminated in any water pressure in the heat exchanger by placing water manner and can be disposed of in various ways, depending control valves at the outlet of the unit to prevent mineral on local codes, i.e.

  • Page 50: Reference Calculations And Legend

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Reference Calculations Heating Calculations: Cooling Calculations: LWT = EWT - LWT = EWT + gpm x 500 gpm x 500 LAT = EAT + LAT(DB) = EAT(DB) - cfm x 1.08 cfm x 1.08 LC = TC - SC TH = HC + HWC...

  • Page 51: Compressor And Thermistor Resistance

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Compressor and Thermistor Resistance Compressor Resistance Chart Model 208-230/60/3 460/60/3 0.681 0.681 0.203 0.203 9/23/16 Thermistor Resistance Chart Thermistor Resistance (10k Ohm) for FP1, Thermistor Resistance (1k Ohm) for suction Thermistor Resistance (86k Ohm) for FP2, HWL, LWT, LLT, and EWT line, LAT, and compressor ambient...

  • Page 52: Troubleshooting Checklist

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Troubleshooting Checklist Equipment will not start or operate • Return air temperature may be below 50°F. Block off air coil temporarily to improve flow of refrigerant through the system. Air •...

  • Page 53: Control Board Troubleshooting Steps

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Control Board Troubleshooting Steps 1) General Check Other items to check when troubleshooting a water flow lockout are superheat, water flow through the coaxial heat exchanger and • If any new device was installed, or any wiring was changed, antifreeze composition.

  • Page 54: Other Faults

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Control Board Troubleshooting Steps cont. 4) Other Faults Auxiliary Heater Does Not Function – Measure the voltage output between P3-1, P3-2, and P3-3, P3-4. The output should be 24 VDC. If ECM Motor Will Not Start voltage is not present, check thermostat operation and wiring.

  • Page 55: Control Board Troubleshooting Flow Charts

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE CONTROL BOARD FLOW CHARTS...

  • Page 56: Compressor Will Not Start

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 57 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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...
  • Page 58 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 59 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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...
  • Page 60 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 61 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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...
  • Page 62 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 63 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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...
  • Page 64 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 65 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 66 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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.
  • Page 67 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 Check for 240 VAC Did the loop pump...
  • Page 68 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Communicating Thermostat Troubleshooting Guide TPCC32U01*, TPCM32U03A* and TPCM32U04A* Thermostat not (*GSR, GSM, E, YRK) communicating Wire non- Are you using a communicating 8 Is this a variable communicating wire thermostat speed unit? thermostat? to P1 terminal on...
  • Page 69 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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...

  • Page 70: Control Board Signals

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 71 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 72 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 73: Jumping The Control Board

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 74: Emergency Heat

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 75: Reheat Mode

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 76: Preventative Maintenance

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Preventative Maintenance Water Coil Maintenance 1. Keep all air out of the water. An open loop system should be checked to ensure that the well head is not allowing air to infiltrate the water line.

  • Page 77: Troubleshooting

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Troubleshooting Should a major problem develop, refer to the following information for possible causes and corrective steps. If compressor won’t run: The fuse may be open or the circuit breaker is tripped. Check electrical circuits and motor windings for shorts or grounds.

  • Page 78: Decommissioning

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Decommissioning Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its detail. It is recommended good practice that all refriger- ants are recovered safely.

  • Page 79: Refrigerant Recovery

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Refrigerant Recovery When removing refrigerant from a system, either for servicing The recovered refrigerant shall be processed according to or decommissioning, it is recommended good practice that all local legislation in the correct recovery cylinder, and the refrigerants are removed safely.

  • Page 80: Charging Procedures

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Charging procedures In addition to conventional charging procedures, the following requirements shall be followed. • Ensure that contamination of different refrigerants does not occur when using charging equipment. • Hoses or lines shall be as short as possible to minimise the amount of refrigerant contained in them.

  • Page 81: Revision Guide

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Revision Guide Pages: Description: Date: 29 Aug 2024 Document Creation...
  • Page 82 Document: Operation & Maintenance Manual OMV7-0010W 01/25 ©2025 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.