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Summary of Contents for WaterFurnace Synergy3D
- Page 1 Geothermal Heat Pump with Water Heating for Radiant Floor Applications • R-410A Refrigerant • 3, 4, 5, 6 Ton Dual Capacity Installation Information Water Piping Connections Hot Water Generator Connections Electrical Startup Procedures Troubleshooting Preventive Maintenance IM1300YS 07/15...
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Page 3: Table Of Contents
SYNERGY3D INSTALLATION MANUAL Table of Contents Model Nomenclature ..............4 General Installation Information . -
Page 4: Model Nomenclature
SYNERGY3D INSTALLATION MANUAL Model Nomenclature ® Model Type IntelliStart Option S – Synergy3D N – None A – IntelliStart Compressor Type D – Dual Capacity Control Option S - Microprocessor Cabinet Configuration V – Vertical Filter Option 0 – 2 inch MERV11 Filter Unit Capacity (MBTUH) 1 –... -
Page 5: General Installation Information
SYNERGY3D INSTALLATION MANUAL General Installation Information Safety Considerations Filter Rack Conversion Installation and servicing of heating and air conditioning A 2 in. MERV 11 filter is shipped with the heat pump. To equipment can be hazardous due to system pressure and field convert the filter rack to use 1 in. - Page 6 All Synergy3D source water connections are swivel piping fittings that accept a 1 in. Male Pipe Thread (MPT) (see Female Locking Ring illustration). The swivel pipe connector has a rubber gasket seal similar to a garden hose gasket, NOTE: Load side fittings are same type as source.
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Page 7: Water Quality
SYNERGY3D INSTALLATION MANUAL General Installation Information cont. Water Quality can likewise become scaled and possibly plugged. In areas In ground water situations where scaling could be heavy with extremely hard water, the owner should be informed that the heat exchanger may require occasional flushing. -
Page 8: Closed Loop Ground Source Systems
SYNERGY3D INSTALLATION MANUAL Closed Loop Ground Source Systems Once piping is completed between the unit, flow center flow through the unit by checking pressure drop across the and the ground loop, final purging and charging of the heat exchanger (Refer to Pressure Drop table). Usually 2.5- loop is needed. -
Page 9: Open Loop Ground Water Systems
SYNERGY3D INSTALLATION MANUAL Open Loop Ground Water Systems Typical open loop piping is shown in the Open System: Discharge water from the unit is not contaminated in any Ground Water Application. Always maintain water pressure manner and can be disposed of in various ways such as... -
Page 10: Hot Water Generator Connections
A water softener is installing a hot water generator. The Synergy3D is not recommended with hard water (greater than 10 grains or supplied with an internal circulator. A DPK5 kit will need 170 ppm total hardness). -
Page 11: Hydronic Section
The thermostat should be must be at least the same diameter as the valve outlet wired to the Synergy3D P5 connector wires, P5-11 and P5-4 (never reduce), and valves may not be added to this pipe. - Page 12 The yellow thermistor wires will not operate ® end of the pump motor (if Grundfos pumps are used) to allow with the Synergy3D as they are used with the NSW Series trapped air to be discharged and to ensure the motor housing has water-to-water. been flooded.
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Page 13: Electrical Connections
PB1 in the unit electrical box as shown. The pumps will automatically be cycled as required by the unit or by a secondary signal from another Synergy3D unit sharing the flow center. (Refer to the Wiring Schematics section.) -
Page 14: Electronic Thermostat Installation
System Monitor Other Thermostats The Synergy3D unit is compatible with virtually any 24VAC thermostat. However, the multi-stage nature of this product requires a 3-stage heating/2-stage cooling type thermostat. NOTE: DIP switch SW2-8 is required to be in the “OFF”... -
Page 15: Auxiliary Heat
SYNERGY3D INSTALLATION MANUAL Auxiliary Heat Auxiliary Heat Electrical Data Supply Heater Amps Min Circuit Amp Max Fuse (USA) Max Fuse (CAN) Max CKT BRK Model Circuit 208V 240V 208V 240V 208V 240V 208V 240V 208V 240V EAL(H)10A Single 34.7 53.3 Single 52.0... -
Page 16: Electrical Data
SYNERGY3D INSTALLATION MANUAL Electrical Data Compressor Blower Total Rated Voltage Model Pump Loop Motor Unit Circ Fuse/ Voltage Min/Max LRA** HACR 208-230/60/1 187/254 23.8 15.2 83.0 30.0 1.07 25.7 29.5 038* 208-230/60/1 187/254 23.8 15.2 83.0 30.0 1.07 28.7 32.5... -
Page 17: Blower Performance Data
Lowest and Highest DIP switch settings are assumed to be L and H respectively A 12-position DIP switch package on the Synergy3D control allows the airflow levels to be set for Low, Medium and High speed when using the variable speed ECM blower motor. -
Page 18: Dimensional Data
SYNERGY3D INSTALLATION MANUAL Dimensional Data Topflow Discharge Left Return Right Return Left Front Right Front Electrical Connections Overall Cabinet Water Connections Vertical 1/2” 1/2” 3/4” Topflow Loop Hydronic cond cond cond Model Hydronic Hydronic Loop Cond- Water Water Sweat Width... - Page 19 SYNERGY3D INSTALLATION MANUAL Dimensional Data cont. Rear Discharge Front Right Return Left Return Rear Rear Left Side Right Side Electrical Connections Overall Cabinet Water Connections Vertical 1/2” 1/2” 3/4” Backflow cond cond cond Loop Hydronic Model Hydronic Hydronic Loop Cond-...
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Page 20: Physical Data
SYNERGY3D INSTALLATION MANUAL Physical Data Model Compressor (1 each) Copeland Scroll Factory Charge R410a, oz [kg] 94 [2.66] 107 [3.03] 132 [3.74] 132 [3.74] ECM Fan Motor & Blower Fan Motor Type/Speeds Variable Speed ECM Fan Motor- hp [W] [373]... -
Page 21: Microprocessor Control
Resistance Heat Control (208-230 Units) Loop Pump Linking Signals The electric heat control module contains the appropriate A signal between multiple Synergy3D control boards at the high-voltage control relays. Control signals energize the inputs and outputs (SL1-In and Out) will provide for remote relays in the proper sequence, and the LED display board control of the loop pump on any unit. -
Page 22: Heating Operation
P6-pin 15 violet wire) This lockout mode occurs when the normally closed switch The Synergy3D control board must be operating in cooling is opened for 30 continuous seconds. <40 PSI mode (Y1 and O inputs) or the cooling slave signal is ignored. -
Page 23: Hydronic Operation
SYNERGY3D INSTALLATION MANUAL Microprocessor Control cont. Hydronic Operation SW3 (4 and 5 Override Selection DIP Switches) These DIP switches configure the time that the unit will SW4 (Status Board Switch) run in the current mode of operation if it is not the priority In the OFF position, the hydronic mode is mode (SW2 #3 FAH/Hydronics) of operation selected. - Page 24 SYNERGY3D INSTALLATION MANUAL Microprocessor Control cont. Airflow Selection DIP Switches (SW1) See Blower Performance Data section. Factory Setup DIP Switches (SW2) DIP Switch Description OFF Position ON Position Number Service Test Mode Allows field selection of “NORMAL” or “TEST” operational modes. Test mode accelerates...
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Page 25: Operation Logic
SYNERGY3D INSTALLATION MANUAL Operation Logic Heating Cooling Hot Water Mode STG1 STG2 STG3 EMERG STG1 STG2 Compressor Stg 2 On Reversing Valve Loop Pump Load Pump Aux Heater Staged Staged Acc Relay Diverting Valve ECM Speed T-Stat Signal Y1, Y2... -
Page 26: Wiring Schematics
SYNERGY3D INSTALLATION MANUAL Wiring Schematics 208-230/60/1 ECM Compressor Desuperheater Option Pump Blue Pink Black Blue Blue Blue Tan(16) Blue Unit Power NOTE 3 Blue Ext Pump 208-230/60/1 1/2 hp Total Blk/Wh(11) Brown 208-230/60/1 Gry/Wh(10) Orange Gray(9) Pump Pump Yellow(8) Black... - Page 27 Reversing Valve shown. Loop Pump 3 - The blk/wh and gray/wh wires are removed when Aux Heat is installed Load Pump 4 – Use WaterFurnace part number 19P592-01 (jumper bar assembly) when single source power is required. Aux Heater Staged Staged...
- Page 28 SYNERGY3D INSTALLATION MANUAL Wiring Schematics cont. 208-230/60/1 ECM with IntelliStart Blue Pink Blue Black Run Winding Blue IntelliStart Pump Blue Blue Active Pink Start Blue Blue Tan(16) Desuperheater Common Black Option Unit Power NOTE 3 Ext Pump 208-230/60/1 1/2 hp Total...
- Page 29 3 - The blk/wh and gray/wh wires are removed when Aux Heat is installed Field line voltage wiring Optional block Relay coil 4 – Use WaterFurnace part number 19P592-01 (jumper bar assembly) DC Voltage PCB traces when single source power is required. Internal junction...
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Page 30: Unit Startup
14. During all testing, check for excessive vibration, noise or 5. Using a digital thermometer, measure the load-side water leaks. Correct or repair as required. water temperature leaving the Synergy3D unit. Refer 15. Set system to desired normal operating mode and set to Operating Parameters table and compare measured temperature to maintain desired comfort level. -
Page 31: Operating Parameters
SYNERGY3D INSTALLATION MANUAL Operating Parameters Synergy3D 1st Stage Operating Parameters 038-072 Forced Air Cooling Forced Air Heating Suction Discharge Water Air Temp Suction Discharge Water Air Temp Water Flow Super-heat Sub-cooling Super-heat Sub-cooling EWT °F Pressure Pressure Temp Rise Drop °F... -
Page 32: Pressure Drop
SYNERGY3D INSTALLATION MANUAL Pressure Drop Pressure Drop (psi) Model 30°F 50°F 70°F 90°F 110°F full load part load full load part load full load part load full load 10.8 10.1 part load 6/8/11... -
Page 33: Compressor And Thermistor Resistance
SYNERGY3D INSTALLATION MANUAL Compressor Resistance 208-230/60/1 Compressor Model Model No. Start ZPS30K5E-PFV 0.81 - 0.94 1.41 - 1.63 ZPS40K5E-PFV 0.48 - 0.55 1.72 - 1.99 ZPS51K5E-PFV 0.36 - 0.42 1.51 - 1.74 ZPS60K5E-PFV 0.31 - 0.36 1.72 - 1.98 9/24/2013... -
Page 34: Heat Of Extraction/Rejection
SYNERGY3D INSTALLATION MANUAL Heat of Extraction/Rejection Heat of Extraction (kBtuh) Heat of Rejection (kBtuh) Model 30°F 50°F 70°F 90°F 30°F 50°F 70°F 90°F 110°F 18.5 25.1 30.9 34.8 33.5 32.1 Part Load 12.0 19.1 26.4 32.8 29.4 34.9 33.6 32.1 30.4... -
Page 35: Correction Factor Tables
SYNERGY3D INSTALLATION 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 0.956... -
Page 36: Operating Limits
SYNERGY3D INSTALLATION MANUAL Operating Limits NOTES: Minimum/maximum limits are only for Cooling Heating Operating Limits start-up conditions, and are meant for bringing the °F °C °F °C space up to occupancy temperature. Units are not Air Limits designed to operate at the minimum/maximum Minimum Ambient Air conditions on a regular basis. -
Page 37: Troubleshooting
SYNERGY3D INSTALLATION MANUAL Troubleshooting Standard Microprocessor Controls To check the unit control board for proper operation: 1. Disconnect thermostat wires at the control board. 2. Jumper the desired test input (Y1, Y2, W, O or G) to the R terminal to simulate a thermostat signal. To simulate a hot water call, jumper tan wires 11 and 14 on P5 connector. -
Page 38: Startup And Troubleshooting Form
SYNERGY3D INSTALLATION MANUAL 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 39: Heating, Cooling, And Hot Water Cycle Analysis
SYNERGY3D INSTALLATION MANUAL Heating Cycle Analysis ______PSI = ______SAT°F ______°F Air Coil Suction °F °F Compressor Source Discharge Coax ______PSI = ______SAT°F open ______°F Refrigerant charge compensator Load Inactive Coax circuit Unit Amp Draw ____________ Entering Source Water ________°F Line Voltage _________... - Page 40 SYNERGY3D INSTALLATION MANUAL Hot Water Cycle Analysis ______PSI = ______SAT°F ______°F Air Coil Suction Compressor Source Discharge Coax ______°F Liquid Line ______PSI = ______SAT°F closed ______°F Refrigerant charge compensator Coax Entering Source Water ________°F Entering Water Pressure Drop _____ PSI Unit Amp Draw ____________ Leaving Source Water ________°F...
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Page 41: Preventative Maintenance
SYNERGY3D INSTALLATION MANUAL Preventative Maintenance Water Coil Maintenance Condensate Drain In areas where airborne bacteria produce a slime in the 1. Keep all air out of the water. An open loop system drain pan, it may be necessary to treat chemically to should be checked to ensure that the well head is not minimize the problem. -
Page 42: Service Parts List
SYNERGY3D INSTALLATION MANUAL Service Parts List Synergy3D Dual Capacity Vertical Units Parts Compressor (ZPSK5Es) 34P641-01 34P642-01 34P643-01 34P644-01 Run Capacitor 16P002D20 16P002D18 16P002D31 Sound Jacket 92P504A16 Power Harness 11P781-01 Solenoid Harness 11P782-02 Blower Assembly 54S551-01N 54S552-01N ECM Motor 14S552-01 14S553-01... -
Page 43: Revision Guide
SYNERGY3D INSTALLATION MANUAL Revision Guide Pages: Description: Date: 26-29,42 Updated Wiring Schematic for Auxiliary Heat Changes, ETL Logo, Service Parts List 14 April 2015 4, 9 Updated Nomenclature Hot Water Generation Option, updated Open Loop 30 Sept 2014 Solenoid Valve Connection Option Wiring Diagrams... - Page 44 Document: Installation Manual ISO 17025 Accredited ©2015 WaterFurnace International, Inc., 9000 Conservation Way, Fort Wayne, IN 46809-9794. WaterFurnace has a policy IM1300YS 07/15 of continual product research and development and reserves the right to change design and specifi cations without notice.
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