5 Series 500RO11 Installation Manual 500RO11 Outdoor Split Geothermal Heat Pump • R-410A Refrigerant • 2, 3, 4, 5, 6 Ton Dual Capacity Installation Information Water Piping Connections Electrical Data Startup Procedures Troubleshooting Preventive Maintenance need new photo C US IM2504SN 10/13
5 SERIES 500RO11 INSTALLATION MANUAL Table of Contents Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Water Piping . . . . .
5 SERIES 500RO11 INSTALLATION MANUAL Model Nomenclature 1 2 3 4-6 7 8 9 10 11 12 13 14 15 16 N D S 049 * 1 0 A C N N 0 A N Model N – 5 Series IntelliStart Option N – None A - IntelliStart Stage D – Dual Capacity Controls A – AuroraTM Base Control (ABC) Cabinet Configuration S – Outdoor Split Future Options 0 – None Unit Capacity 026, 038, 049, 064, 072 Future Options N – None Vintage * - Factory Use Only Future Options N – None Voltage 1 – 208-230/60/1 Water Coax Opti
SERIES 500RO11 INSTALLATION MANUAL General Installation Information Safety Considerations Condensate Drain Follow the blower coil manufacturer’s instructions. WARNING: Before performing service or maintenance operations on a system, turn off main power switches to both units. Turn off accessory heater power switch if applicable. Electrical shock could cause personal injury. Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components.
5 SERIES 500RO11 INSTALLATION MANUAL General Installation Information cont. benefits of reliability, warranty, etc. versus the short term installation cost savings. However, the existing air handler may be retained provided the following: • Coil currently is R-410A rated • Coil uses a TXV.
5 SERIES 500RO11 INSTALLATION MANUAL General Installation Information cont. Dual Fuel Systems In add-on 5 Series Split applications, the coil should be located in the supply side of the furnace to avoid condensation damage to the furnace heat exchanger. A high temperature limit should be installed upstream of the coil to de-energize the compressor whenever the furnace is operating. Without this switch, the 5 Series Split will trip out on high pressure.
5 SERIES 500RO11 INSTALLATION MANUAL Water Quality In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. The heat exchanger coils in ground water systems may, over a period of time, lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualified service mechanic, as special solutions and pumping equipment are required.
5 SERIES 500RO11 INSTALLATION MANUAL Water Piping Residential NDS split units are supplied standard with GeoLink swivel connections with P.T. ports. Flow Center Installation Flow centers FC1-GL or FC2-GL, as needed, may be internally mounted on the NDS splits, Two stub tubes with barbs are pre connected to the coax. Two tubes with brass fittings, to adapt to the flow center, 2 hoses to connect between the two sets of tubes, and four hose clamps are included with each NDS unit.
5 SERIES 500RO11 INSTALLATION MANUAL Electrical Connections General Accessory Relay Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable. A set of “dry” contacts has been provided to control accessory devices, such as water solenoid valves on open loop installations, electronic air cleaners, humidifiers, etc.
5 SERIES 500RO11 INSTALLATION MANUAL Electrical Connections cont. Figure 14: Pump Wiring 208-230/60/1 Pump Power Wiring See Figure 14 for electrical connections from control box to pumps. FC1/FC2 style flow centers with fixed speed pumps connect to PB1 in the control box.
5 SERIES 500RO11 INSTALLATION MANUAL Electronic Thermostat Installation cont.
5 SERIES 500RO11 INSTALLATION MANUAL Electrical Data Compressor Model Rated Voltage Voltage Min/Max MCC RLA LRA 026 208-230/60/1 187/253 18.2 11.6 58.3 LRA* Ext Loop FLA Total Unit FLA Min Circ Amp Max Fuse/ HACR 21.0 5.4 17.0 19.9 30 038 208-230/60/1 187/253 23.8 15.2 83.0 30.0 5.4 20.6 24.4 40 049 208-230/60/1 187/253 33.0 21.1 104.0 37.0 5.4 26.5 31.8 50 064 208-230/60/1 187/253 42.3 27.1 152.9 54.0 5.4 32.5 39.3 70 072 208-230/60/1 187/253 46.
5 SERIES 500RO11 INSTALLATION MANUAL Dimensional Data Cabinet Dimensions and Refrigerant Piping Connections B A C E D F G H L J K Model 026 thru 072 in [cm] A B C D E F G H J K L 36.0 [91.4] 23.9 [60.7] 26.7 [67.8] 5.4 [13.7] 6.0 [15.2] 8.2 [20.8] 10.8 [27.4] 14.0 [35.6] 9.0 [22.9] 20.2 [51.3] 7.2 [18.
5 SERIES 500RO11 INSTALLATION MANUAL Model Nomenclature - Air Handler 1-3 4-6 7 8-9 10 11 12 NAH 036 * 00 0 1 R Air Coil R – Refrigerant H - Hydronic Model NAH – Envision Series Air Handler Unit Capacity Refrigeration (DX) Models with Nominal CFM 022 MBTUH 800 026 MBTUH 925 030 MBTUH 980 036 MBTUH 1225 042 MBTUH 1425 048 MBTUH 1625 060 MBTUH 1760 Hydronic Models with Nominal CFM 026 MBTUH 925 036 MBTUH 1225 048 MBTUH 1625 060 MBTUH 1760 Motor 1 – ECM 208-230/60/1 Disconnect 0 – No Breaker In
5 SERIES 500RO11 INSTALLATION MANUAL Physical Data - Air Handler Air Handler Model Number (Refrigerant) NAH022 NAH026 NAH030 NAH036 Air Coil Total Face Area - ft2 [m2] Tube Outside Diameter - in [mm] NAH048 NAH060 3/8 [9.52] Number of Rows Evaporator Coil NAH042 5.83 [0.54] 2 3 Fins Per Inch 12 Suction Line Connection - in [mm] Sweat 5/8 [15.87] 7/8 [22.22] Liquid Line Connection - in [mm] Sweat 3/8 [9.52] Refrigerant R-410a Nominal Cooling Capacity - Ton [kW] 1.8 [6.44] 2.1 [7.
5 SERIES 500RO11 INSTALLATION MANUAL The Aurora™ Control System Aurora ‘Base’ Control The Aurora ‘Base’ Control (ABC) System is a complete residential and commercial comfort system that brings all aspects of the HVAC system into one cohesive module network. The ABC features microprocessor control and HP, LP, and freeze detection, over/under voltage faults, along with communicating thermostat capability for complete fault detection text at the thermostat.
5 SERIES 500RO11 INSTALLATION MANUAL The Aurora Control System cont. Reset Configuration Mode Aurora ‘Base’ Control The control is placed in reset configuration mode by holding the push button switch SW1 for 50 to 60 seconds. This will reset all configuration settings and the EEPROM back to the factory default settings. LED3 (green) will turn off when entering reset configuration mode. Once LED3 (green) turns off, release SW1 and the control will reset.
5 SERIES 500RO11 INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. point for the entire length of the appropriate delay to be recognized as a fault. This fault will be ignored for the initial 2 minutes of the compressor run time. Safety Features The following safety features are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions.
5 SERIES 500RO11 INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Emergency Shutdown - Four (4) seconds after a valid ES input, P2-7 is present, all Aurora control outputs will be turned off and remain off until the emergency shutdown input is no longer present. The first time that the compressor is started after the control exits the emergency shutdown mode, there will be an anti-short cycle delay followed by a random start delay. Input must be tied to common to activate.
5 SERIES 500RO11 INSTALLATION MANUAL Reference Calculations Heating Calculations: LWT = EWT - Cooling Calculations: HE GPM x 500 LAT = EAT + LWT = EWT + HC CFM x 1.08 HR GPM x 500 LAT (DB) = EAT (DB) - SC CFM x 1.
5 SERIES 500RO11 INSTALLATION MANUAL Wiring Schematics Dual Capacity Split - 208-230/60/1 Flow Center Ext Pump 1/2 hp Total 208-230/60/1 Pump Pump G PB1 Yellow(8) 11 Gray(9) 2 Compressor 1 2 Blue Note 1 S C R Cap Green(17) Violet(6) Ground Lug G Red Tan(16) Black 5A Violet(7) Circuit Breaker Unit Power Supply Black(2) T2 208-230/60/1 5A G Circuit Breaker T1 CC L2 Black L1 Crankcase Heater Black(1) Black Black(3) 2 RP 4 5 FP Red(11) Red(12) UltraTech RV FP1 LP HP
5 SERIES 500RO11 INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split - 208-230/60/1 cont.
5 SERIES 500RO11 INSTALLATION MANUAL Wiring Schematics cont.
5 SERIES 500RO11 INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split with IntelliStart - 208-230/60/1 cont.
5 SERIES 500RO11 INSTALLATION MANUAL Refrigeration After initial charge, the system should be operated and the system subcooling and superheat verified to the Unit Operating Parameters table. Leak Testing The refrigeration line set must be pressurized and checked for leaks before purging and charging the unit. To pressurize the line set, attach refrigerant gauges to the service ports and add an inert gas (nitrogen or dry carbon dioxide) until pressure reaches 60 to 90 PSIG.
5 SERIES 500RO11 INSTALLATION MANUAL Refrigeration cont. adjusting the superheat stem clockwise (superheat increase) and the stop is reached, any further clockwise turning adjustment will damage the valve. Determining Subcooling 1. 2. 3. 4. Measure the temperature of the liquid line on the small refrigerant line (liquid line) just outside the split cabinet. This location will be adequate for measurement in both modes unless a significant temperature drop in the liquid line is anticipated.
5 SERIES 500RO11 INSTALLATION MANUAL Pressure/Temperature Conversion Chart for R-410A PRESSURE (PSIG) 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164 166 168 170 172 174 176 178 TEMP °F 8.5 9.9 11.2 12.5 13.8 15.1 16.3 17.5 18.7 19.8 21.0 22.1 23.2 24.3 25.4 26.5 27.5 28.6 29.6 30.6 31.6 32.6 33.5 34.5 35.4 36.4 37.3 38.2 39.1 40.0 40.9 41.7 42.6 43.4 44.3 45.
5 SERIES 500RO11 INSTALLATION MANUAL Unit Startup 9. Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop pumps deactivate. 10. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature. 11. First stage heating will energize after a time delay. 12. Check the temperature of both the supply and discharge water (see the Unit Operating Parameters tables). 13.
5 SERIES 500RO11 INSTALLATION MANUAL Operating Parameters First Stage Operation Entering Water Temp °F 50 70 90 Entering Water Temp °F 30 50 70 Water Flow GPM/Ton 1.5 3.0 1.5 3.0 1.5 3.0 Water Flow GPM/Ton 1.5 3.0 1.5 3.0 1.5 3.
5 SERIES 500RO11 INSTALLATION MANUAL Pressure Drop Compressor Resistance Dual Capacity Compressor Resistance Chart (Ohms) Model 026 full load 026 part load 038 full load 038 part load 049 full load 049 part load 064 full load 064 part load 072 full load 072 part load GPM 4 6 8 10 3 5 7 9 5 7 9 11 4 6 8 10 6 9 12 15 5 8 11 14 8 12 16 20 6 10 14 18 12 15 18 21 10 13 16 19 30°F 1.4 2.8 4.7 7.0 0.8 2.0 3.6 5.8 1.2 2.2 3.4 4.9 0.9 1.7 2.8 4.2 1.2 2.4 3.9 5.7 0.9 2.0 3.4 5.0 1.8 3.8 6.5 9.7 1.0 2.
5 SERIES 500RO11 INSTALLATION MANUAL Refrigerant Circuit Guideline Head Pressure Under Charged System (Possible Leak) Low Over Charged System High Low Air Flow Heating High Low Air Flow Cooling Low Low Water Flow Heating Low/Normal Low Water Flow Cooling High High Air Flow Heating Low High Air Flow Cooling Low High Water Flow Heating Normal High Water Flow Cooling Low Low Indoor Air Temperature Heating Low Low Indoor Air Temperature Cooling Low High Indoor Air Temperature Heating High High Indoor Air Tempe
5 SERIES 500RO11 INSTALLATION MANUAL Troubleshooting Aurora Control System Refrigerant Systems NOTE: Refer to the Aurora Base Control Application and Troubleshooting Guide and the Instruction Guide: Aurora Interface and Diagnostics (AID) Tool for additional information. To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Compare the change in temperature on the air side as well as the water side to the Unit Operating Parameters tables.
5 SERIES 500RO11 INSTALLATION MANUAL Startup and Troubleshooting Heating Cycle Analysis Measure suction temperature here at TXV bulb in heating modes. Measure suction temperature here at TXV bulb in cooling modes.
5 SERIES 500RO11 INSTALLATION MANUAL Troubleshooting cont. Single Speed/Dual Capacity Startup/Troubleshooting Form 1. Job Information Model # Job Name: Serial # Install Date: 2. Flow Rate in gpm Loop: Open / Closed Hot Water Generator: Y / N SOURCE COAX HEATING LOAD COAX (Water-to-Water) COOLING HEATING COOLING WATER IN Pressure: a. psi a. psi a. psi a. psi WATER OUT Pressure: b. psi b. psi b. psi b. psi Pressure Drop: a - b c. psi c. psi c. psi c.
5 SERIES 500RO11 INSTALLATION MANUAL Preventive Maintenance Water Coil Maintenance 1. 2. 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. Lines should always be airtight. Keep the system under pressure at all times. It is recommended in open loop systems that the water control valve be placed in the discharge line to prevent loss of pressure during off cycles.
5 SERIES 500RO11 INSTALLATION MANUAL Service Parts List Dual Capacity Split Units Compressor Part Description 026 038 049 064 072 Compressor 34P640-01 34P641-01 34P642-01 34P643-01 34P644-01 Run Capacitor 16P002D19 16P002D20 Sound Jacket Power Harness Crankcase Heater Refrigeration Components Sensors & Safeties 19P535-07 19P535-08 11P782-02 36P509-02 36P509-01 Coax 62I594-01 62I542B01 TXV 33P609-01 33P609-03 Reversing Valve 33P506-04 Filter Dryer 16P002D31 11P781-01 19P535-0
5 SERIES 500RO11 INSTALLATION MANUAL Revision Guide Pages: All Description: First Published 38 Date: By: 30 Oct 2013 DS
Manufactured by WaterFurnace International, Inc. 9000 Conservation Way Fort Wayne, IN 46809 www.waterfurnace.com Product: Type: Size: Document: 5 Series 500RO11 Outdoor Split Geothermal Heat Pump 2-6 Ton Dual Capacity Installation Manual C US ISO 17025 Accredited ©2013 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 specifications without notice.
