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WaterFurnace Versatec 700 Application, Operation & Maintenance
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WaterFurnace Versatec 700 Application, Operation & Maintenance

WaterFurnace Versatec 700 Application, Operation & Maintenance

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OPERATION & MAINTENANCE
Versatec 700 Indoor DOAS
10-30 Ton
60HZ
OMV7-0012W
The ERW cabinet is listed under UL 1812 thru UL.

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Summary of Contents for WaterFurnace Versatec 700

  • Page 1 OPERATION & MAINTENANCE Versatec 700 Indoor DOAS 10-30 Ton 60HZ OMV7-0012W The ERW cabinet is listed under UL 1812 thru UL.

  • 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 Information............4 Nomenclatures .

  • Page 4: General Installation Information

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE General Installation Information fire or explosion. All possible ignition sources, including ciga- NOTICE: Do not store or install units in corrosive environments or in locations subject to temperature or humidity extremes. rette smoking, should be kept sufficiently far away from the site Corrosive conditions and high temperature or humidity can of installation, repairing, removing and disposal, during which...

  • 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 63 oz does is adequately ventilated before breaking into the system of not have a minimum floor area requirement and does not require conducting any hot work.

  • Page 6: Nomenclatures

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Nomenclatures FAV Secondary Model 1 – With 1 Secondary FAV DAS – Versatec DOAS 2 – With 2 Secondary FAV Heat Pump Capacity ERW Cabinet Option 120, 180, 240, 360 S –...
  • Page 7 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Nomenclatures V7FV120BV3AM5DTLASNM312SSS 24-26...
  • Page 8 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Nomenclatures 12-13 14 15-16 19 20-21 ER W 5210 Model Vintage ER – Versatec Energy * - Factory Use Only Recovery Unit Non-Standard Option Media SS – Standard Option W-Wheel Mating Option Media Configuration 1 –...

  • Page 9: 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 10: Physical Data And Unit Weight

    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 DAS180S1 TOP FLOW STANDARD DIMENSIONS IN INCHES [mm] OPTIONAL INLET/OUTLET FIELD CONFIGURATION TOP VIEW OUTDOOR AIR INLET LARGE DOOR ON RETURN ORDERED (RIGHT RETURN SHOWN) 59.57 1513.0 109.57 2783.2 OUTDOOR OUTDOOR...
  • Page 12 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. DAS180S1 BOTTOM FLOW OPTIONAL INLET/OUTLET FIELD CONFIGURATION STANDARD DIMENSIONS IN INCHES [mm] 59.57 109.55 1513.0 2782.5 EXHAUST EXHAUST AIR OUTLET AIR OUTLET RETURN 77.66 1972.6 OUTDOOR OUTDOOR FRONT VIEW SIDE VIEW AIR INLET...
  • Page 13 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. DAS120S1 TOP FLOW STANDARD DIMENSIONS IN INCHES [mm] OPTIONAL INLET/OUTLET FIELD CONFIGURATION LARGE DOOR ON RETURN ORDERED (RIGHT RETURN SHOWN) OUTDOOR AIR INLET TOP VIEW 109.54 2782.4 59.57 1513.1 OUTDOOR...
  • Page 14 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. DAS120S1 BOTTOM FLOW OPTIONAL INLET/OUTLET STANDARD DIMENSIONS IN INCHES [mm] FIELD CONFIGURATION 109.54 2782.4 59.57 1513.1 EXHAUST EXHAUST RETURN AIR OUTLET AIR OUTLET 77.66 1972.6 OUTDOOR OUTDOOR SIDE VIEW FRONT VIEW AIR INLET...
  • Page 15 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. DAS360L2 TOP FLOW STANDARD DIMENSIONS IN INCHES [mm] 94.06 2389.1 OPTIONAL INLET/OUTLET 1.50 FIELD CONFIGURATION 38.1 109.56 2782.7 OUTDOOR TOP VIEW AIR INLET 92.60 2352.0 OUTDOOR OUTDOOR AIR INLET AIR INLET 77.66...
  • Page 16 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. DAS360L2 BOTTOM FLOW STANDARD DIMENSIONS IN INCHES [mm] 92.60 2352.0 OPTIONAL INLET/OUTLET FIELD CONFIGURATION EXHAUST EXHAUST AIR OUTLET RETURN AIR OUTLET 77.66 1972.6 OUTDOOR OUTDOOR AIR INLET SIDE VIEW FRONT VIEW AIR INLET...
  • Page 17 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. DAS240L2 TOP FLOW STANDARD DIMENSIONS IN INCHES [mm] OPTIONAL INLET/OUTLET FIELD CONFIGURATION 74.21 1885.0 1.50 38.1 109.54 2782.4 TOP VIEW 92.59 2351.7 109.54 2782.4 OUTDOOR AIR INLET OUTDOOR AIR INLET 77.66...
  • Page 18 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. DAS240L2 BOTTOM FLOW STANDARD DIMENSIONS IN INCHES [mm] OPTIONAL INLET/OUTLET FIELD CONFIGURATION 109.54 2782.4 EXHAUST EXHAUST AIR OUTLET AIR OUTLET 77.66 1972.6 OUTDOOR OUTDOOR BACK VIEW AIR INLET AIR INLET SIDE VIEW 92.59...

  • Page 19: Air Flow Configurations

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. TOP FLOW (RA) IN THIS LOCATION ON BOTTOM SIDE BACK FRONT FRONT SIDE SIDE BACK LARGE DOOR ON FRONT ON RETURN ORDERED (RIGHT RETURN SHOWN) ACCESS PANELS (2) w/ CUTOUTS ARE FIELD CHANGEABLE TO OA/EA ALTERNATE LOCATIONS BOTTOM FLOW...
  • Page 20 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. ERW52 (TOP FLOW SHOWN) STANDARD DIMENSIONS IN INCHES [mm] 30.00 14.75 6.59 762.0 374.7 167.4 20.00 508.0 8.00 203.2 3.19 30.00 14.75 81.1 762.0 374.7 LARGE DOOR ON FRONT OF RETURN ORDERED TOP VIEW (RIGHT RETURN SHOWN)
  • Page 21 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. ERW68 (TOP FLOW SHOWN) STANDARD DIMENSIONS IN INCHES [mm] 31.29 30.00 6.58 794.9 762.0 167.2 20.00 508.0 66.30 1684.0 8.00 203.2 3.19 81.1 LARGE DOOR ON FRONT TOP VIEW OF RETURN ORDERED (LEFT RETURN SHOWN)
  • Page 22 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. FAV120 TOP FLOW (RIGHT RETURN SHOWN) STANDARD DIMENSIONS IN INCHES [mm] 4.17 105.9 16.00 406.4 28.00 711.2 FRONT 1.01 25.7 43.25 2' SERVICE ACCESS 1098.6 2' SERVICE ACCESS 34.00 9.25 36.30...
  • Page 23 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. FAV120 BOTTOM FLOW (RIGHT RETURN SHOWN) STANDARD DIMENSIONS IN INCHES [mm] 34.00 9.25 36.30 863.6 235.0 HIGH VOLTAGE 922.0 1.85 47.0 4.05 102.8 9.36 237.7 17.60 20.10 447.0 510.5 4.00...
  • Page 24 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. FAV180 TOP FLOW (RIGHT RETURN SHOWN) STANDARD DIMENSIONS IN INCHES [mm] 4.20 106.7 38.00 965.2 FRONT 1.01 15.98 25.7 405.9 43.25 2' SERVICE ACCESS 1098.6 2' SERVICE ACCESS 46.30 34.00 9.25...
  • Page 25 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Dimensional Data cont. FAV180 BOTTOM FLOW (RIGHT RETURN SHOWN) STANDARD DIMENSIONS IN INCHES [mm] 46.30 1176.0 4.00 34.00 9.25 101.6 863.6 235.0 1.85 47.0 9.36 4.05 237.7 102.9 17.60 20.10 447.0 510.5 HIGH VOLTAGE...

  • Page 26: Electrical Information & Data

    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 loads to the circuit with out ensuring that this will not supplies shall be disconnected from the equipment being exceed the permissible voltage and current permitted for worked upon prior to any removal of sealed covers, etc.

  • Page 27: Electrical Data

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Electrical Data Versatec DOAS Electrical Data Compressor Supply Exhaust Wheel Total DOAS Exhaust Rated Voltage Fuse/ Blower Blower Motor Unit Circ Model Blowers Voltage Min/Max HACR MCC** LRA* Breaker 208-230/60/3 187/253 56.0 33.1...

  • Page 28: Energy Recovery

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Energy Recovery To adjust air seal clearance, loosen all seal plate retaining Energy Recovery Wheels screws holding the separate seal retaining plates to the ERU units have been equipped with an energy recovery bearing support channels and slide the seals plates away wheel.

  • Page 29: 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 30: Pressure Drop

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Pressure Drop Coaxial Heat Exchanger Pressure Drop Pressure Drop (psid) Model 30˚F 50˚F 70˚F 90˚F 110˚F 9/19/2019 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 31: Operating Limits

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Operating Limits Operating Limits Cooling Heating (°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 Rated Entering Air db/wb 80.6/66.2 27/19 20.0...

  • Page 32: Aurora Control System

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System Integrated Controls Platform The Versatec DOAS unit operates on the Aurora Controls Network (ACN) which brings together diff erent technologies such as variable speed compressors, direct drive ECM plenum fans, electronic expansion valves, CFM control, and total energy recovery to provide a complete DOAS unit.

  • Page 33: Doas Applicaitons

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System- DOAS Applications 100% Outdoor Air Model Shown: DAS360 The Versatec DOAS unit is designed to fi t a range of variable air volume (VAV) applica- tions such as single-zone VAV, multi-zone VAV, and constant air volume (CAV).

  • Page 34: Aurora Energy Packages

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Energy Control Packages Each Versatec DOAS unit comes with optional controls packages that are included in the energy recovery device which is represented by the Aurora Energy Controls. These packages are detailed below. Airside economizer functionality can be added to any of the packages below by adding air bypass dampers.

  • Page 35: Controls Layout

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Layout - Aurora Premium (ERW Cabinet) Aurora Touch HMI Layout - Aurora System Controller & AEC (ERW Cabinet) Aurora System Controller & AEC (ERW Aurora Energy Control (AEC) Cabinet)
  • Page 36 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Layout - Aurora Premium (FAV Heat Pump Controls) 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 –...

  • Page 37: Fcc Compliance

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Aurora Control System Physical Data Serial Number If you need the Aurora System controller (LS-CPU) serial number when troubleshooting, the number is on: • a sticker on the back of the main translator board •...

  • Page 38: Control Inputs

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Control Inputs All control system input values may be read from sensors physically connected to the control system, either communicating or discrete, or they may be alternatively supplied via BACnet from a BAS controller or other appropriate BACnet master building automation.

  • Page 39: Control Outputs

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Control Outputs Discrete AEC Outputs: Outdoor Air Damper – The Outdoor Air Damper output will be a 24 VAC output signal connected to the RV output on the AEC control. Energy Recovery Wheel –...

  • Page 40: Configuration Settings

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Configuration Settings Configuration setting values will be stored in non-volatile DCV Enable (DCV) memory and may be adjusted using an Aurora Touch HMI or through the BAS interface. The DCV Enable value is a Boolean control point to enable or disable demand control ventilation operation.
  • Page 41 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Configuration Settings cont. Configuration setting values will be stored in non-volatile DCV Enable (DCV) memory and may be adjusted using an Aurora Touch HMI or through the BAS interface. The DCV Enable value is a Boolean control point to enable or disable demand control ventilation operation.

  • Page 42: System Operating Modes

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE System Operation - System Operating Modes Cooling Design Energy Recovery Dew Point Economizer Energy Recovery Compressor Where Needed Energy Recovery Cooling In the energy recovery cooling mode, the bypass dampers will be closed, the energy wheel will be active, and the compressors will operate as needed to maintain supply air conditions.

  • Page 43: Target Supply Air Temperature Determination

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE System Operation - Target Supply Air Temperature Determination Nominal Target Supply Air Temperature Supply Air Temperature Reset The Target Supply Air Temperature value will be either Supply Air Temperature Reset may adjust the target NeutTgt, HeatTgt, or CoolTgt.

  • Page 44: Energy Recovery

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE System Operation - Energy Recovery operation of the system. Outdoor Air Damper The Outdoor Air Damper output will always be activated 30 If the Energy Recovery Wheel output is active and wheel seconds prior to the supply blower to allow the damper to rotation is not detected an Energy Recovery Wheel open.

  • Page 45: Heat Pump, Low Oat Shutdown, Emergency Shutdown

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE System Operation - Heat Pump Compressor The compressor will operate in the appropriate mode and at the appropriate capacity to maintain the supply air temperature setpoint when required and modulating hot gas reheat is not active or present.

  • Page 46: Standalone Control

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE System Operation - Standalone Control For internal occupancy control the Aurora System Physical Input controller has an internal occupancy schedule that will When the system occupancy is set to occupied physical allow the system to operate on its own if it has a valid thermostat inputs to the Aurora Energy Control may control temperature.
  • Page 47 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE System Operation - Standalone Control Supply differential Filter Supply air Optical Outdoor air (Plenum) pressure (airflow differential bypass wheel enthalpy Global Rnet measurement) pressure damper sensor Supply air temperature re e Filter &...

  • Page 48: 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 49: System Cleaning And Flushing

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

  • Page 50: 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 51: Reference Calculations, Legend And Notes

    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 52: Compressor & Thermistor Resistance

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

  • Page 53: General Check

    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 Steps

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Control Board Troubleshooting Charts (Next Page)

  • 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 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 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 And Replacement Procedures

    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: Energy Recovery Wheel Maintenance And Cleaning

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Energy Recovery Wheel Maintenance and Cleaning Routine Maintenance and Handling Soak in the solution until grease and tar deposits are Handle cassettes with care. All cassettes should be lifted by loosened (Note: some staining of the desiccant may remain the bearing support beam.
  • Page 78 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Energy Recovery Wheel Service Belt Replacement CAUTION Obtain access to the pulley side bearing access plate if bearing access plates are provided. Remove two bear- ing access plate retaining screws and the access plate. Disconnect electrical power before servicing Using hexagonal wrench, loosen set screw in bearing energy recovery cassette.

  • Page 79: 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 80: Startup And Troubleshooting Form

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE 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 ❑...

  • Page 81: Decomissioning

    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 82: 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 relevant waste transfer note arranged.

  • Page 83: 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 84: Revision Guide

    LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE Revision Guide Pages: Description: Date: 08 April 2025 Document Creation...
  • Page 85 LARGE CAPACITY WATER-SOURCE/GEOTHERMAL HEAT PUMP 10-90 TON OPERATION & MAINTENANCE...
  • Page 86 Document: Operation & Maintenance Manual OMV7-0012W 04/25 ©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.