WATER SOURCE HEAT PUMPS. INSTALLATION, OPERATION, MAINTENANCE Supercedes: NOM3 (115) Form NOM1 (317) RL SERIES 7 25 TONS LD20072 R-410A

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1 WATE SOUE HEAT PUMPS INSTALLATION, OPEATION, MAINTENANE Supercedes: NOM3 (115) Form NOM1 (317) L SEIES 7 25 TONS LD A Issue Date: March 28, 2017

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3 Table of ontents Model Nomenclature eneral Installation Information Vertical Dimensions Horizontal Dimensions Installing Horizontal Units Installation Vertical Units Water Quality System leaning and Flushing Electrical onnections Electrical Data Blower Performance Data Wiring Schematics ontrols Blower Drive Sheaves Unit Startup Operating Parameters Pressure Drop Startup/Troubleshooting Form Preventive Maintenance eplacement Procedures

4 Model Nomenclature LX V 120 T L 3 0 A A N 16 N 17 A SS 21 * Model Type LL L Standard ange LX L Extended ange abinet onfiguration V Vertical H - Horizontal Unit apacity (MBTUH) 080, 095, 120, , 240, 300 Discharge onfiguration T Top (Vertical) E End (Horizontal) ontal) S Side (Horizontal) ontal) eturn Air onfiguration L Left ight Voltage /60/3 / /60/ /60/3 Future Option 0 Future Blower Options A Standard Static, Standard Motor B Low Static, Standard Motor 1 High Static, Standard Motor 2 D Standard Static, Large Motor 2,3 E High Static, Large Motor 3 Vintage * - Factory Use Only Non-Standard Options SS Standard QP 2" MEV 13 Filter SF Stainless Steel Drain Pan 4 S 2" MEV 13 Filter, Stainless Steel Drain Pan 4 Air oil/insulation Option 3 Uncoated 4 AlumiSeal TM ontrol Option A Aurora TM Base ontrol (AB) Z Aurora TM with SMAT Equipment DD Water ontrol Option N None V 2-Way Valve Hot as Bypass/eheat Option N None Hot as Bypass Hot as eheat B Hot as Bypass w/hot as eheat Sound Kit Option A None B Sound Kit Water oil Option opper N upronickel Notes: 1 Not available on LXV/LLV095, 180, LXH/LLH080 2 Not available on LXV/LLV080, Not available on LXH/LLH120, LXV/LLV300 4 Not available on LXV/LLV Stainless steel is standard on LXV/LLV

5 eneral Installation Information Safety onsiderations WANIN: Before performing service or maintenance operations on a system, turn off main power switches to the indoor unit. If applicable, turn off the accessory heater power switch. Electrical shock could cause personal injury. Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service heating and air conditioning equipment. Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on heating and air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply. Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations and have a fire extinguisher available. Moving and Storage Move units in the normal up orientation. Horizontal units may be moved and stored per the information on the packaging. Do not stack more than three units in total height. Vertical units may be stored one upon another to a maximum height of two units. Do not attempt to move units while stacked. When the equipment is received, all items should be carefully checked against the bill of lading to be sure all crates and cartons have been received. Examine units for shipping damage, removing the units from the packaging if necessary. Units in question should also be internally inspected. If any damage is noted, the carrier should make the proper notation on the delivery receipt, acknowledging the damage. Unit Location Locate the unit in an indoor area that allows for easy removal of the filter and access panels. Location should have enough space for service personnel to perform maintenance or repair. Provide sufficient room to make water, electrical and duct connection(s). If the unit is located in a confined space, such as a closet, provisions must be made for return air to freely enter the space by means of a louvered door, etc. Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit. On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping. are should be taken when units are located in unconditioned spaces to prevent damage from frozen water lines and excessive heat that could damage electrical components. Installing Vertical Units Prior to setting the unit in place, remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket. Figure 1: Vertical Unit Mounting (LXV ) Vertical units are available in left or right air return configurations. Top flow vertical units should be mounted level on a vibration absorbing pad slightly larger than the base to provide isolation between the unit and the floor. It is not necessary to anchor the unit to the floor (see right). 5

6 Vertical Dimensions 7-10 Tons TOP DISHAE SIDE DISHAE ONTOL BOX AND WATE LEFT ETUN Legend AP = Alternate Service Panel BP = Blower Service Panel P = ontrol Access Panel MP = ompressor Service Panel ONTOL BOX AND WATE LEFT ETUN 2 PIMAY SEVIE AESS FO LEFT ETUN P ONTOL BOX IHT ETUN 2 PIMAY SEVIE AESS FO LEFT ETUN P ONTOL BOX IHT ETUN AP MP P AP MP P 2 SEONDAY SEVIE AESS 2 PIMAY SEVIE AESS FO IHT ETUN 2 SEONDAY SEVIE AESS 2 PIMAY SEVIE AESS FO IHT ETUN 2.9 in [7.4 cm] 61.3 in [155.8 cm] 58.1 in [147.6 cm] 2.9 in [7.4 cm] 61.3 in [155.7 cm] 58.1 in [147.6 cm] 34.1 in [86.6 cm] 16.1 in [40.9 cm] TOP VIEW Left or ight eturn 34.1 in [86.6 cm] 21.6 in [54.9 cm] 18.1 in [46.0 cm] 1.42 in [3.6 cm] 22.6 in [57.4 cm] 16.1 in [40.9 cm] TOP PANEL OVE 1 in [2.5 cm] 1.8 in [4.6 cm] SIDE VIEW Left or ight eturn 18.1 in [46 cm] 56 in [142.2 cm] 56 in [142.2 cm] 2 in [5.1 cm] 2 in [5.1 cm] AI OILS AI OILS 36.3 in [92.2 cm] 34.4 in [87.4 cm] 7.2 in [18.3 cm] DAIN ONNETION LEFT ETUN 2.2 in [5.6 cm] ELETIAL ONNETIONS TOP O SIDE DISHAE IHT ETUN 2.2 in [5.6 cm] ELETIAL ONNETIONS 34.4 in [87.4 cm] 7.2 in [18.3 cm] 36.3 in [92.2 cm] DAIN ONNETION 12.5 in [31.8 cm] 15.6 in [39.6 cm] 15.6 in [39.6 cm] 12.5 in [31.8 cm] 2.6 in [6.6 cm] WATE OUT WATE IN 2.0 in [5.1 cm] 10.1 in [25.7 cm] 4.0 in [10.2 cm] 2.2 in [5.6 cm] 10.1 in [25.7 cm] 4.0 in [10.2 cm] 2.2 in [5.6 cm] 2.0 in [5.1 cm] 2.6 in [6.6 cm] WATE OUT WATE IN 6 EV 2/11/08

7 Vertical Dimensions cont Tons TOP DISHAE ONTOL BOX AND WATE IHT ETUN SIDE DISHAE ONTOL BOX AND WATE LEFT ETUN 2 PIMAY SEVIE AESS ONTOL BOX LEFT ETUN P P ONTOL BOX IHT ETUN AP MP 2 SEONDAY SEVIE AESS AP MP 2 PIMAY SEVIE AESS P Legend AP = Alternate Service Panel BP = Blower Service Panel P = ontrol Access Panel MP = ompressor Service Panel P 2 PIMAY SEVIE AESS 88.1 in cm 86.3 in cm 2.9 in 7.3 cm 2.9 in 7.3 cm 88.1 in cm 86.3 in cm 34.0 in 86.4 cm TOP VIEW L or eturn 34.0 in 86.4 cm 16.0 in 16.0 in 40.6 cm 40.6 cm 14.2 in 36.1 cm 1.5 in 3.7 cm 18.0 in 45.7 cm 18.0 in 45.7 cm 14.2 in 36.1 cm 1.5 in 3.7 cm 13.8 in 35.1 cm 18.0 in 45.8 cm TOP PANEL OVE 18.0 in 45.8 cm 13.8 in 35.1 cm 1.0 in 2.5 cm 1.0 in 2.5 cm 2.0 in 5.1 cm 88.1 in cm 2.0 in 5.1 cm SIDE VIEW L or eturn 16.0 in 40.6 cm 16.0 in 40.6 cm 66.0 in cm 66.0 in cm AI OILS 2.0 in 5.1 cm 2.0 in 5.1 cm AI OILS 41.8 in cm 40.4 in cm LEFT ETUN TOP O SIDE DISHAE IHT ETUN 40.4 in cm 41.8 in cm ELETIAL ONNETIONS ELETIAL ONNETIONS DAIN ONNETION 24.5 in 62.2 cm 19.0 in 48.2 cm 15.2 in 38.7 cm 13.0 in 33.0 cm WATE OUT WATE IN WATE OUT WATE IN 13.0 in 33.0 cm DAIN ONNETION 15.2 in 38.7 cm 19.0 in 48.2 cm 24.5 in 62.2 cm 2.6 in 6.5 cm 6.5 in 16.5 cm 1.7 in 4.4 cm 6.0 in 15.2 cm 6.0 in 15.2 cm 1.7 in 4.4 cm 2.6 in 6.5 cm 6.5 in 16.5 cm EV 8/16/07 7

8 Horizontal Dimensions 7-10 Tons IHT ETUN LEFT ETUN BP BP Legend AP = Alternate Service Panel BP = Blower Service Panel P = ontrol Access Panel MP = ompressor Service Panel MP MP 2 SEONDAY SEVIE AESS MP P 2 PIMAY SEVIE AESS P MP 2 SEONDAY SEVIE AESS 4.1 TOP VIEW WATE OUT SIDE VIEW WATE OUT SIDE DISHAE OPTION WATE IN WATE IN SIDE DISHAE OPTION END VIEW END DISHAE OPTION DAIN ONNETION END DISHAE OPTION DAIN ONNETION EV 4/28/08 8

9 Installing Horizontal Units Mounting Horizontal Units Units are available with side or end discharge in left-hand or right-hand return air configurations. Horizontal units are normally suspended from a ceiling by four 1/2 in. diameter threaded rods. The rods are usually attached to the unit corners by the bottom panel mounting channel and the mounting grommets furnished with each unit. AUTION: Do not use rods smaller than 1/2 in. diameter since they may not be strong enough to support the unit. The rods must be securely anchored to the ceiling (the units are approximately 800 lbs.). Figure 1: Typical Horizontal Application 1/2 Threaded ods (4) Power Disconnect Low Voltage Flexible Duct ollar P/T Plugs Isolation rommets (Included) ondensate Drain onnection Hose Kits Insulate supply plenum and use at least a 90 elbow to reduce noise Ball Valves Water Loop Layout the threaded rods per the dimensions in Figure 2. Assemble the hangers to the unit as shown in Figure 3. Securely tighten the brackets to the unit. When attaching the hanger rods to the bracket, a double nut is recommended since vibration could loosen a single nut. The unit should be pitched approximately 1/2 in. towards the drain in both directions, to facilitate condensate removal. Figure 2: Mounting od Layout Top View Figure 3: Mounting Hardware 1/2 in. Threaded od (not included) Vibration Isolator Washer (not included) 90.5 Hex Nuts (not included) 9

10 Installing Horizontal Units cont. Horizontal Unit orner Weight Distribution A B D Front Front Back Back Model eturn / Discharge Left ight ight Left Left / Side or End 30% 26% 22% 22% ight / Side or End 26% 30% 22% 22% A D B Approximate ontrols Duct System An air outlet collar is provided on vertical top flow units and all horizontal units to facilitate a duct connection. A flexible connector is recommended for discharge and return air duct connections on metal duct systems. Uninsulated duct should be insulated with a minimum of 1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit s performance will be adversely affected. If the unit is connected to existing ductwork, check the duct system to ensure that it has the capacity to accommodate the air required for the unit application. If the duct is too small, as in the replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repaired if necessary. The duct system should be sized to handle the design airflow quietly and efficiently. To maximize sound attenuation of the unit blower, the supply and return plenums should include an internal duct liner of fiberglass or constructed of ductboard for the first few feet. On systems employing a sheet metal duct system, canvas connectors should be used between the unit and the ductwork. If air noise or excessive airflow is a problem, the blower speed can be changed. Water Piping The proper water flow must be provided to each unit whenever the unit operates. To assure proper flow, use pressure/temperature ports to determine the flow rate. These ports should be located at the supply and return water connections on the unit. The proper flow rate cannot be accurately set without measuring the water pressure drop through the refrigerant-to-water heat exchanger. All source water connections on commercial units are fittings that accept a male pipe thread (MPT). Insert the connectors by hand, then tighten the fitting with a wrench to provide a leakproof joint. When connecting to an open loop (groundwater) system, thread any copper MPT fitting into the connector and tighten in the same manner as described above. Figure 4: Suggested Layout of ondensate Figure 5: Unit Pitch for Drain 1/2'' Pitch 3/4 in. PV oupling Vent (if needed) 3/4 in. PV 3/4 in. PV tube stub 1.5 in. 1.5 in. 1/8 in. per foot 10

11 Installing Vertical Units Mounting Vertical Units Units are available with top/side discharge, left-hand or right-hand return air configurations. Vertical units are assembled on rails which facilitate moving and placement of the units. It is not necessary to anchor the unit to the floor. Duct System A supply air duct flange is provided for field installation to facilitate the secure duct connection at the job site. A flexible connector is recommended for discharge and return air duct connections on metal duct systems to prevent vibration transmission. It is recommended that all ductwork be insulated with a minimum of 1/2-inch coated insulation. Installation of the units with uninsulated ductwork in an unconditioned space is not recommended, as the system s performance will be adversely affected. ondensate Drain In vertical units, the internal condensate drain assembly consists of a flexible drain tube which is attached to the drain pan and a 3/4-inch (7-10 tons) and 1-inch (13-25 tons) female pipe thread. An external water trap is not required as the drain tube serves as a trapping loop. The field-installed piping and unit connection must be properly installed and sealed to prevent water leakage. Figure 6: Typical Vertical Application Flexible duct ollar ontrol Box Water Supply and eturn onnections ondensate Drain AESS PANEL AESS PANEL AESS PANEL 11

12 Water Quality Water Quality uidelines 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. Hot water generator coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional flushing. Units with cupronickel heat exchangers are recommended for open loop applications due to the increased resistance to build-up and corrosion, along with reduced wear caused by acid cleaning. Material opper 90/10 upronickel 316 Stainless Steel ph Acidity/Alkalinity Scaling alcium and (Total Hardness) (Total Hardness) (Total Hardness) Magnesium arbonate less than 350 ppm less than 350 ppm less than 350 ppm Hydrogen Sulfide Less than 0.5 ppm (rotten egg smell appears at 0.5 ppm) ppm Less than 1 ppm Sulfates Less than 125 ppm Less than 125 ppm Less than 200 ppm hlorine Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm hlorides Less than 20 ppm Less than 125 ppm Less than 300 ppm arbon Dioxide Less than 50 ppm ppm ppm orrosion Ammonia Less than 2 ppm Less than 2 ppm Less than 20 ppm Ammonia hloride Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm Ammonia Nitrate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm Ammonia Hydroxide Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm Ammonia Sulfate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm Total Dissolved Solids (TDS) Less than 1000 ppm ppm ppm LSI Index +0.5 to to to -0.5 Iron, FE 2 + (Ferrous) Iron Fouling Bacterial Iron Potential < 0.2 ppm < 0.2 ppm < 0.2 ppm (Biological rowth) Less than 1 ppm, above this Less than 1 ppm, above this Less than 1 ppm, above this Iron Oxide level deposition will occur level deposition will occur level deposition will occur Erosion Water onnections Suspended Solids Threshold Velocity (Fresh Water) Less than 10 ppm and filtered for max. of 600 micron size Less than 10 ppm and filtered for max. of 600 micron size Less than 10 ppm and filtered for max. of 600 micron size < 6 ft/sec < 6 ft/sec < 6 ft/sec All supply and return water connections are female pipe thread of size specified in physical dimensions. Never use flexible hoses smaller than separate water connections on the unit and limit hose length to 10 ft. per connection. heck carefully for water leaks. Interior Piping All units are recommended to be connected to supply and return piping in a two-pipe reverse return configuration. A reverse return system is inherently self-balancing and requires only trim balancing when multiple quantities of units with different flow and pressure drop characteristics are connected to the same loop. A direct return system may also be made to work acceptably, but proper water flow balance is more difficult to achieve and maintain. Supply and return runouts are usually connected to the unit by short lengths of high pressure flexible hose which are sound attenuators for both unit operating noise and hydraulic pumping noise. One end of the hose should have a swivel fitting to facilitate removal for service. Hard piping can also be connected directly to the unit although it is not recommended since no vibration or noise attenuation can be accomplished. The hard piping must have unions to facilitate unit removal (see figure 1 & 6) for typical application). Some flexible hose threaded fittings are supplied with sealant compound. If not, apply Teflon tape to assure a tight seal. Supply and return shutoff valves are required at each unit. The return shutoff valve can be used for balancing and should be adjusted for proper flow required, or a manual or automatic flow control device should be on the leaving water hose assembly. No unit should be connected to the supply and return piping until the water system has been cleaned and flushed completely. After the cleaning and flushing has taken place, the initial connection should have all valves wide open in preparation for water system filling. 12

13 System leaning and Flushing leaning and Flushing Prior to start up of any heat pump, the water circulating system must be cleaned and flushed of all dirt and debris. If the system is equipped with water shutoff valves, the supply and return runouts must be connected together at each unit location (This will prevent the introduction of dirt into the unit, see Figure 7). The system should be filled at the water make-up connection with all air vents open. After filling, vents should be closed. Figure 7: Flushing with Water Shutoff Valve Equipped Systems eturn unout Supply unout The contractor should start the main circulator with the pressure reducing valve Mains makeup open. Vents should be checked in sequence to bleed off any trapped air ubber Hose and to verify circulation through all components of the system. unouts Initially onnected Together As water circulates through the system, the contractor should check and repair any leaks found in the piping system. Drain(s) at the lowest point(s) in the system should be opened for initial flush and blowdown, making sure water fill valves are set at the same rate. heck the pressure gauge at the pump suction and manually adjust the make-up water valve to hold the same positive pressure both before and after opening the drain valves. Flushing should continue for at least two hours, or longer if required, until drain water is clean and clear. The supplemental heater and/or circulator pump, if used, should be shut off. All drains and vents should be opened to completely drain the system. Short-circuited supply and return runouts should now be connected to the unit supply and return connections. efill the system with clean water. Test the system water for acidity and treat as required to leave the water slightly alkaline (ph 7.5 to 8.5). The specified percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVA systems only. Environol brand antifreeze is recommended.. Once the system has been filled with clean water and antifreeze (if used), precautions should be taken to protect the system from dirty water conditions. Dirty water will result in system-wide degradation of performance, and solids may clog valves, strainers, flow regulators, etc. Additionally, the heat exchanger may become clogged which reduces compressor service life and can cause premature unit failure. In boiler/tower application, set the loop control panel set points to desired temperatures. Supply power to all motors and start the circulating pumps. After full flow has been established through all components including the heat rejector (regardless of season), air vented and loop temperatures stabilized, each of the units will be ready for check, test and start up and for air and water balancing. round Source Loop System heckout Once piping is completed between the unit pumping system and ground loop, final purging and charging of the loop is needed. A high pressure pump is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop itself. Antifreeze solution is used in most areas to prevent freezing. Flush the system adequately to remove as much air as possible; then pressurize the loop to a static pressure of PSI (summer) or PSI (winter). This is normally adequate for good system operation. Loop static pressure may decrease soon after initial installation, due to pipe expansion and loop temperature change. unning the unit for at least 30 minutes after the system has been completely purged of air will allow for the break-in period. It may be necessary to adjust static loop pressure (by adding water) after the unit has run for the first time. Loop static pressure will also fluctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This fluctuation is normal and should be considered when charging the system initially. Ensure the pump provides adequate flow through the unit by checking pressure drop across the heat exchanger. Usually PM of flow per ton of cooling capacity is recommended in earth loop applications. 13

14 Electrical onnections eneral 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 ode. Unit Power onnection Line voltage connection is made by connecting the incoming line voltage wires to the terminal block as shown on the unit s wiring diagram attached to the inside front panel. onsult the Unit Electrical Data below for correct fuse size. 208 Volt Operation NOTE: All volt units are factory wired for 230 volt operation. For 208 volt operation, the red and the blue transformer wires must be switched between terminal strip PS and contactor B. 14

15 Electrical Data Model Blower Blower Total Min Max ated Voltage ompressor* Voltage Min/Max Motor HP Unit irc Fuse/ M LA LA FLA*** *** FLA Amp HA Horizontal /60/3 187/ /60/3 414/ /60/3 518/ /60/3 187/ ** 460/60/3 414/ /60/3 518/ /60/3 187/ /60/3 414/ /60/3 518/ /60/3 187/ ** 460/60/3 414/ /60/3 518/ /60/3 187/ /60/3 414/ /60/3 518/ Vertical /60/3 187/ /60/3 414/ /60/3 518/ /60/3 187/ ** 460/60/3 414/ /60/3 518/ /60/3 187/ /60/3 414/ /60/3 518/ /60/3 187/ ** 460/60/3 414/ /60/3 518/ /60/3 187/ /60/3 414/ /60/3 518/ /60/3 187/ ** 460/60/3 414/ /60/3 518/ /60/3 187/ /60/3 414/ /60/3 518/ /60/3 187/ ** 460/60/3 414/ /60/3 518/ /60/3 187/ /60/3 414/ /60/3 518/ /60/3 187/ ** 460/60/3 414/ /60/3 518/ /60/3 187/ /60/3 414/ /60/3 518/ /60/3 187/ ** 460/60/3 414/ /60/3 518/ /60/3 187/ /60/3 414/ /60/3 518/ *atings per each compressor - unit supplied with two 06/19/2015 **With optional motor ***atings per each blower motor - Vertical models supplied with two. HA circuit breaker in USA only All fuses lass K-5 15

16 LLH080 - Blower Performance Data Belt Drive Airflow in FM with dry coil and clean air filter. External Static Pressure (in. w.g.) ated FM MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE D BHP PM TUNS OPEN MT/SHEAVE A BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE E BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN /25/07 Bold Face equires Larger 2 HP Motor A=Std Static/Std Mtr;B=Low Static/Std. Mtr;=High Static/Std. Mtr;D=Std Static/Large Mtr;E=High Static/Large Mtr Units factory shipped with standard static sheave and drive at 2.5 turns open ( in. ESP). Other speeds require field selection. ISO/AHI rating point with standard static sheave and drive at 1.5 turns open ( in. ESP). Other speeds require field selection. For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions. Do not operate in gray region. "na" = information not available at time of printing. All airflow is rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for V units. For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [cfm] / Face Area [sq ft]). Then for velocities of 200 fpm reduce the static capability by 0.03 in. wg, 300 fpm by 0.08 in. wg, and 400 fpm by 0.12in. wg. 16

17 LLH095 - Blower Performance Data Belt Drive Airflow in FM with dry coil and clean air filter. ated FM External Static Pressure (in. w.g.) MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE B D BHP PM TUNS OPEN MT/SHEAVE A BHP PM TUNS OPEN MT/SHEAVE E BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN /25/07 Bold Face equires Larger 2 HP Motor A=Std Static/Std Mtr;B=Low Static/Std. Mtr;=High Static/Std. Mtr;D=Std Static/Large Mtr;E=High Static/Large Mtr Units factory shipped with standard static sheave and drive at 2 turns open ( in. ESP). Other speeds require field selection. ISO/AHI rating point with standard static sheave and drive at 2 turns open ( in. ESP). Other speeds require field selection. For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions. Do not operate in gray region. "na" = information not available at time of printing. All airflow is rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for V units. For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [cfm] / Face Area [sq ft]). Then for velocities of 200 fpm reduce the static capability by 0.03 in. wg, 300 fpm by 0.08 in. wg, and 400 fpm by 0.12in. wg. 17

18 LLH120 - Blower Performance Data Belt Drive Airflow in FM with dry coil and clean air filter. External Static Pressure (in. w.g.) ated FM MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE B BHP PM TUNS OPEN MT/SHEAVE A BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN A=Std Static/Std Mtr;B=Low Static/Std. Mtr;=High Static/Std. Mtr;D=Std Static/Large Mtr;E=High Static/Large Mtr Units factory shipped with standard static sheave and drive at 3.0 turns open ( in. ESP). Other speeds require field selection. ISO/AHI rating point with standard static sheave and drive at 2.0 turns open ( in. ESP). Other speeds require field selection. For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions. Do not operate in gray region. "na" = information not available at time of printing. All airflow is rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for V units. For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [cfm] / Face Area [sq ft]). Then for velocities of 200 fpm reduce the static capability by 0.03 in. wg, 300 fpm by 0.08 in. wg, and 400 fpm by 0.12in. wg. 07/23/07 18

19 LLV080 - Blower Performance Data Belt Drive Airflow in FM with dry coil and clean air filter. External Static Pressure (in. w.g.) ated FM MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE B 2400 BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE A BHP PM TUNS OPEN MT/SHEAVE E BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN Bold Face equires 1.5 HP Motor A=Std Static/Std Mtr;B=Low Static/Std. Mtr;=High Static/Std. Mtr;D=Std Static/Large Mtr;E=High Static/Large Mtr Units factory shipped with standard static sheave and drive at 3 turns open ( in. ESP). Other speeds require field selection. ISO/AHI rating point with standard static sheave and drive at 3 turns open ( in. ESP). Other speeds require field selection. For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions. Do not operate in gray region. "na" = information not available at time of printing. All airflow is rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for V units. For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [cfm] / Face Area [sq ft]). Then for velocities of 200 fpm reduce the static capability by 0.03 in. wg, 300 fpm by 0.08 in. wg, and 400 fpm by 0.12in. wg. 07/25/07 19

20 LLV095 - Blower Performance Data Belt Drive Airflow in FM with dry coil and clean air filter. External Static Pressure (in. w.g.) ated FM MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE D 2800 BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE A BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN E MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN Bold Face equires Larger 2 HP Motor A=Std Static/Std Mtr;B=Low Static/Std. Mtr;=High Static/Std. Mtr;D=Std Static/Large Mtr;E=High Static/Large Mtr Units factory shipped with standard static sheave and drive at 2 turns open ( in. ESP). Other speeds require field selection. ISO/AHI rating point with standard static sheave and drive at 1 turns open ( in. ESP). Other speeds require field selection. For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions. Do not operate in gray region. "na" = information not available at time of printing. All airflow is rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for V units. For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [cfm] / Face Area [sq ft]). Then for velocities of 200 fpm reduce the static capability by 0.03 in. wg, 300 fpm by 0.08 in. wg, and 400 fpm by 0.12in. wg. 7/25/07 20

21 LLV120 - Blower Performance Data Belt Drive Airflow in FM with dry coil and clean air filter. External Static Pressure (in. w.g.) ated FM MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE B BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE A BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE E BHP PM TUNS OPEN MT/SHEAVE D BHP PM TUNS OPEN Bold Face equires Larger 3 HP Motor A=Std Static/Std Mtr;B=Low Static/Std. Mtr;=High Static/Std. Mtr;D=Std Static/Large Mtr;E=High Static/Large Mtr Units factory shipped with standard static sheave and drive at 3 turns open ( in. ESP). Other speeds require field selection. ISO/AHI rating point with standard static sheave and drive at 1 turns open ( in. ESP). Other speeds require field selection. For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions. Do not operate in gray region. "na" = information not available at time of printing. All airflow is rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for V units. For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [cfm] / Face Area [sq ft]). Then for velocities of 200 fpm reduce the static capability by 0.03 in. wg, 300 fpm by 0.08 in. wg, and 400 fpm by 0.12 in. wg. 07/25/07 21

22 LLV160 - Blower Performance Data Belt Drive Airflow in FM with dry coil and clean air filter. External Static Pressure (in. w.g.) ated FM MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE 2.0B BHP PM TUNS OPEN MT/SHEAVE A BHP PM TUNS OPEN MT/SHEAVE E BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN Bold Face equires Larger 1.5 HP Motor A=Std Static/Std Mtr;B=Low Static/Std. Mtr;=High Static/Std. Mtr;D=Std Static/Large Mtr;E=High Static/Large Mtr Units factory shipped with standard static sheave and drive at 3 turns open ( in. ESP). Other speeds require field selection. ISO/AHI rating point with standard static sheave and drive at 2.0 turns open ( in. ESP). Other speeds require field selection. For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions. Do not operate in gray region. "na" = information not available at time of printing. All airflow is rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for V units. For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [cfm] / Face Area [sq ft]). Then for velocities of 200 fpm reduce the static capability by 0.03 in. wg, 300 fpm by 0.08 in. wg, and 400 fpm by 0.12 in. wg. BHP is given for each blower. Multiply BHP x 2 for unit BHP. 7/25/07 22

23 LLV180 - Blower Performance Data Belt Drive Airflow in FM with dry coil and clean air filter. External Static Pressure (in. w.g.) ated FM MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE A D BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE E BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN /25/07 Bold Face equires Larger 2.0 HP Motor A=Std Static/Std Mtr;B=Low Static/Std. Mtr;=High Static/Std. Mtr;D=Std Static/Large Mtr;E=High Static/Large Mtr Units factory shipped with standard static sheave and drive at 3 turns open ( in. ESP). Other speeds require field selection. ISO/AHI rating point with standard static sheave and drive at 1.5 turns open ( in. ESP). Other speeds require field selection. For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions. Do not operate in gray region. "na" = information not available at time of printing. All airflow is rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for V units. For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [cfm] / Face Area [sq ft]). Then for velocities of 200 fpm reduce the static capability by 0.03 in. wg, 300 fpm by 0.08 in. wg, and 400 fpm by 0.12 in. wg. BHP is given for each blower. Multiply BHP x 2 for unit BHP. 23

24 LLV240 - Blower Performance Data Belt Drive Airflow in FM with dry coil and clean air filter. External Static Pressure (in. w.g.) ated FM MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE B BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE A BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE E BHP PM TUNS OPEN MT/SHEAVE D BHP PM TUNS OPEN /25/07 Bold Face equires Larger 3.0 HP Motor A=Std Static/Std Mtr;B=Low Static/Std. Mtr;=High Static/Std. Mtr;D=Std Static/Large Mtr;E=High Static/Large Mtr Units factory shipped with standard static sheave and drive at 2.5 turns open ( in. ESP). Other speeds require field selection. ISO/AHI rating point with standard static sheave and drive at 2 turns open ( in. ESP). Other speeds require field selection. For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions. Do not operate in gray region. "na" = information not available at time of printing. All airflow is rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for V units. For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [cfm] / Face Area [sq ft]). Then for velocities of 200 fpm reduce the static capability by 0.03 in. wg, 300 fpm by 0.08 in. wg, and 400 fpm by 0.12 in. wg. BHP is given for each blower. Multiply BHP x 2 for unit BHP. 24

25 LLV300 - Blower Performance Data Belt Drive Airflow in FM with dry coil and clean air filter. External Static Pressure (in. w.g.) ated FM MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE B A BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN MT/SHEAVE BHP PM TUNS OPEN /25/07 A=Std Static/Std Mtr;B=Low Static/Std. Mtr;=High Static/Std. Mtr;D=Std Static/Large Mtr;E=High Static/Large Mtr Units factory shipped with standard static sheave and drive at 3.0 turns open ( in. ESP). Other speeds require field selection. ISO/AHI rating point with standard static sheave and drive at 3.0 turns open ( in. ESP). Other speeds require field selection. For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions. Do not operate in gray region. "na" = information not available at time of printing. All airflow is rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for V units. For wet coil performance first calculate the face velocity of the air coil (Face Velocity [fpm] = Airflow [cfm] / Face Area [sq ft]). Then for velocities of 200 fpm reduce the static capability by 0.03 in. wg, 300 fpm by 0.08 in. wg, and 400 fpm by 0.12 in. wg. BHP is given for each blower. Multiply BHP x 2 for unit BHP. 25

26 Wiring Schematic - Dual ompressor with Aurora 460/-575/60/3 LAT Thermistor Array T T T T VA FDA LPA HPA Black (10) Black (09) Blue (08) ray ray T Blue (07) Black Black Yellow Yellow VA Orange (02) Orange (01) Black (15) A Violet (14) B Black (13) White (12) White (12) TB Emerg Shutdown Lo ad Shed Lockout ircuit A 24VA 24VA ommon eversing Valve Fan ompressor A Electric Heat Dehumidi ca on Lockout ircuit B ompressor B ES LS LO1 O Y1 W DH LO2 Y2 P2 ES LS ALM AL A OM A NO A N LO O/B Y1 P9 Y2 W DH EH1 2 F K5-Alarm elay K6-Acc elay P8 P9 om2 LED5 S485 NET JW2 F F 2 HI K4-Fan elay om1 LED5 S485 NET - + P7 K2- el ay 2 LO K3-2 elay 2 P5 Aurora Base ontrol A (AB - A) EVEVFP1 FP1 FP2 FP2 LPS LPSHPSHPSP4 K1-V elay SW1 Test Mode S485 EXP - + P6 O EH1 EH2 P3 Status LED3 Y1 F1-3A PWM FM Faul t LED1 P13 Off On FP1 15 F/30 F 1 FP2 15 F/30 F 2 V B/O 3 Acc Dip 4 4 Acc Dip 5 5 Dual/Single 6 L Output Type 7 eheat 8 SW2 onfig LED2 Y F la ss 2 reen Brown (23) ondensate VB 470 FDB esistor LPB HPB Black/White (30) Black/White (29) Blue/White (28) Blue/White (27) 470 T VB Yellow Yellow Orange/Wht (22) Orange/White (21) Black (15) B Violet (14) White (12) P2 ES LS ALM AL A OM A NO A N LO O/B Y1 P1 Y2 W DH EH1 2 F K5-Alarm elay K6-Acc elay P8 P9 om2 LED5 S485 NET JW2 F F 2 HI K4-Fan elay om1 LED5 S485 NET - + P7 K2- elay 2 LO K3-2 elay 2 S485 EXP P5 Aurora Base ontrol B (AB - B) EVEVFP1 FP1 FP2 FP2 LPS LPSHPSHPSP4 K1-V elay SW1 Test Mode - + P6 O EH1 EH2 P3 Status LED3 Y1 F1-3A PWM FM Faul t LED1 P13 Off On FP1 15 F/30 F 1 FP2 15 F/30 F 2 V B/O 3 Acc Dip 4 4 Acc Dip 5 5 Dual/Single 6 L Output Type 7 eheat 8 SW2 onfig LED2 Y F White Brown (23) ondensate 26

27 Wiring Schematic - Dual ompressor with Aurora 460/-575/60/3 ompressor A T3 T1 ompressor B T3 T1 reen Belt Drive Blower Motor ray (80) reen Belt Drive Blower Motor 97P /23/15 L1 Unit Power Supply /60/3 L2 L3 T2 T2 ed (84) Black (86) ed (87) Black (89) Yellow (85) Yellow (88) T3 T2 1 T1 T3 T2 2 T1 Yellow (78) Brown (79) T3 T2 T1 B Yellow (81) ray (83) Brown (82) NOTE 2 L3 L2 L1 L3 L2 L1 L3 L2 L1 ed (69) Yellow (70) Black (71) ed (66) Yellow (67) Black (68) Yellow (63) Brown (64) ray (65) Black/White Transformer Black Blue Black/White (16) Black/White (17) PB1 1 Yellow Yellow (18) Yellow (19) 2 3 Accessor y elay Operation SW2-4 SW2-5 ycl e with Blower On On ycle with ompressor Off Off Water Valve Slow Open On Off Outdoor Air Damper Off On Aurora Timing Events Event Normal Mode Test Mode andom Start Delay 5 to 80 seconds 1 second ompressor On Delay 5 seconds < 1 second ompressor Minimum On Time 2 minutes 5 seconds ompressor Short ycl e Delay 4 minutes 15 seconds Blower Off Delay 30 seconds 2 seconds Fault ecognition Delay High Pressure Less than 1 second Less than 1 second Start-Up Bypass Low Pressure 2 minutes 30 seconds Fault ecognition Delay Low Pressure 30 seconds 30 seconds Start-Up Bypass Low Water/Air oil Limit Fault ecognition Delay Low Water/Air oil Limit Fault ecognition Delay ondensate Overflow 2 minutes 30 seconds 30 seconds 30 seconds 30 seconds 30 seconds Thermostat all ecognition Time 2 seconds 2 seconds Auxi liary Heat Stagi ng Del ay Emergency Heat Stagi ng Dela y 5 minutes 2 minutes 20 seconds 7.5 seconds Water Valve Slow Open Delay 90 seconds 90 seconds eheat Delay 30 seconds 30 seconds Aurora LED Flash odes Slow Flash Fast Flash Flash ode 1 second on and 1 second off 100 milliseconds on and 100 milliseconds off 100 milliseconds on and 400 milliseconds off with a 2 second pause before repeating andom Start Delay Status LED (LED1, reen) onfiguration LED (LED2, Yellow) Fault LED (LED3, ed) Status LED (LED1, reen) Fast Fl ash Fast Fl ash Fast Fl ash onfiguration LED (LED2, Yellow) Fault LED (LED3, ed) Normal Mode ON No Software Overide Flash EM Setting Normal Mode OFF ontrol is Non-Functional OFF DIP Switch Overide Slow Flash Input Fault Lockout Flash ode 1 Test Mode Slow Flash EM onfigure Mode Fast Flash High Pressure Lockout Flash ode 2 Lockout Active Dehumidification Mode eserved eserved Load Shed ESD eserved Fast Fl ash Flash ode 2 Flash ode 3 Flash ode 4 Flash ode 5 Flash ode 6 Flash ode 7 eset onfigure Mode Off Low Pressure Lockout Low Air oil Limit Lockout - FP2 Low Water oil Limit Lockout - FP1 eserved ondensate Overflow Lockout Over/Under Voltage Shutdown eserved eserved Air/Water oil Limit Sensor Error Flash ode 3 Flash ode 4 Flash ode 5 Flash ode 6 Flash ode 7 Flash ode 8 Flash ode 9 Flash ode 10 Flash ode 11 L1 Factory Low Voltage Wiring Factory Line Voltage Wiring Field Low Voltage Wiring Fi eld Li ne Voltage Wi ri ng Optional Block D Voltage PB Traces Fi eld Zone Sensor Wi ri ng Internal Junction Qui ck on nect Terminal Fi eld Wiring Lug round elay ontacts N.O., N.. apacitor Fuse A ompressor ontactor A B ompressor ontactor B O ondensate Overflow Sensor ES Emergency Shutdown HPA High Pressure Switch A HPB High Pressure Switch B LPA Low Pressure Switch A LPB Low Pressure Switch B FDA Freeze Detection Sensor A FDB Freeze Detection Sensor B F1 Fuse Legend 3 T 2 Y 1 Thermistor elay oil Switch - ondensate Overflow Switch - High pressure Switch - Low pressure Polarized connector Light Emitting Diode - reen Light Emitting Diode - Yellow Light Emitting Diode - ed SW1 Push button SW2 DIP package 8 position B Blower elay VA eversing Valve oil A VB eversi ng Valve oi l B PM Phase uard Monitor H eheat Valve oi l Notes: 1 Only on units equipped with two fan motors. 2 2 F Y1 JW2 - Alarm HP HP LP LP FP2 FP2 FP1 FP1 EV EV LO HI F F Factory Factory P2 P4 P5 PWM FM EM PWM P13 SW1 Test V K1 K2 Hi K3 Fan K4 Alarm K5 Acc K6 Fi eld onnections ES LS ALM AL A c A no A nc Off On LED1 FP1 15 o F/30 o F 1 LED2 FP2 15 o F/30 o F 2 Y Faul t V B/O 3 onfig A Dip 4 4 LED3 A Dip 5 5 Dual/Single 6 L Pulse/ontinuous 7 Status eheat/normal 8 SW2 P9 LO P1 LO Factory Use P11 AUOA BASE ONTOL Factory Fan onnection O/B Fi eld onnections O/B Y1 Y2 W Y1 Y2 W DH DH om1 om2 3A-Fuse P3 Factory P6 S485 Exp P7 S 485 P8 S485 NET EH1 EH2 EH1 O N/A (+) (-) 27

28 ontrols - Aurora Base ontrol Aurora Base ontrol NOTE: efer to the Aurora Base ontrol Application and Troubleshooting uide and the Instruction uide: Aurora Interface and Diagnostics (AID) Tool for additional information. ontrol Features Software AB Standard Version 2.0 Single or Dual apacity ompressors Either single or dual capacity compressors can be operated. EM Blower Motor Option An EM blower motor can be driven directly using the onboard PWM output. Four blower speeds are available based upon the, Y1, Y2, and W input signals to the board. The blower speeds can be changed either by the EM manual configurations mode method or by using the Aurora AID Tool directly. All four blower speeds can be set to the same speed if desired. 5-Speed EM Blower Motor Option A 5-Speed EM blower motor will be driven directly using the thermostat connections. Any of the, Y1, or Y2/W signals can drive any of the 5 available pre-programmed blower speeds on the motor. Other ontrol Features andom start at power up Anti-short cycle protection High and low pressure cutouts Loss of charge Water coil freeze detection Air coil freeze detection Over/under voltage protection ondensate overflow sensor Load shed Dehumidification (where applicable) Emergency shutdown Hot gas reheat operation (where applicable) Diagnostic LED Test mode push button switch Two auxiliary electric heat outputs Alarm output Accessory output with N.O. and N.. Modbus communication (master) Modbus communication (slave) Field Selectable Options via Hardware DIP Switch (SW1) Test/onfiguration 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. In test mode most of the control timings will be shortened by a factor of sixteen (16). LED3 (green) will flash at 1 second on and 1 second off. Additionally, when entering test mode LED1 (red) will flash the last lockout one time. Test mode will automatically time out after 30 minutes. Test mode can be exited by pressing and holding the SW1 button for 2 to 5 seconds or by cycling the power. NOTE: Test mode will automatically be exited after 30 minutes. EM onfiguration Mode The control is placed in the EM configuration mode by holding the pushbutton switch SW1 for 5 to 10 seconds, the high, low, and EM speeds can be selected by following the LED display lights. LED2 (yellow) will fast flash when entering the EM configuration. When setting speed LED3 (green) will be continuously lit, for low speed LED1 (red) will be continuously lit, and for high speed both LED3 (green) and LED1 (red) will be continuously lit. During the EM configuration mode LED2 (yellow) will flash each of the 12 possible blower speeds 3 times. When the desired speed is flashed press SW1, LED2 will fast flash until SW1 is released. speed has now been selected. Next select low speed, and high speed blower selections following the same process above. After third selection has been made, the control will exit the EM configuration mode. Aux fan speed will remain at default or current setting and requires the AID Tool for adjustment. eset onfiguration Mode 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 EEPOM 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. DIP Switch (SW2) SW2-1 FP1 Selection Low water coil temperature limit setting for freeze detection. On = 30 F; Off = 15 F. SW2-2 FP2 Selection On = 30 F; Off = N/A SW2-3 V O/B - thermostat type. Heat pump thermostats with O output in cooling or B output in Heating can be selected. On = O; Off = B. SW2-4 Access elay Operation (P2) and 2-5 Access elay Operation SW2-4 SW2-5 ycle with Blower ON ON ycle with ompressor OFF OFF Water Valve Slow Opening ON OFF ycle with omm. T-stat Hum md OFF ON 28

29 ontrols - Aurora Base ontrol cont. SW2-6 SW2-7 SW2-8 ycle with Blower - The accessory relay will cycle with the blower output. ycle with ompressor - The accessory relay will cycle with the compressor output. Water Valve Slow Opening - The accessory relay will cycle and delay both the blower and compressor output for 90 seconds. Operation selection of single or dual capacity compressor. On = Single Stage; Off = Dual apacity Lockout and Alarm Outputs (P2) selection of a continuous or pulsed output for both the LO and ALM Outputs. On = ontinuous; Off = Pulsed Future Use Alarm Jumper lip Selection From the factory, ALM is connected to 24 VA via JW2. By cutting JW2, ALM becomes a dry contact connected to AL. EM Blower Speeds The blower speeds can be changed either by using the EM manual configurations mode method or by using the Aurora AID Tool directly (see Instruction uide: Aurora Interface and Diagnostics (AID) Tool topic). Field Selectable Options via Software (Selectable via the Aurora AID Tool) EM Blower Speeds An EM blower motor can be driven directly using the onboard PWM output. Four blower speeds are available, based upon the, Y1 (low), Y2 (high), and Aux input signals to the board. The blower speeds can be changed either by the EM manual configurations mode method (see EM onfiguration Mode topic) or by using the Aurora AID Tool directly. All four blower speeds can be set to the same speed if desired. Aux blower speed will remain at default or current setting and requires the AID Tool for adjustment. 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. Fuse a 3 amp automotive type plug-in fuse provides protection against short circuit or overload conditions. Anti-Short ycle Protection 4 minute anti-short cycle protection for the compressor. andom Start 5 to 80 second random start upon power up. Fault etry in the fault condition, the control will stage off the outputs and then try again to satisfy the thermostat Y input call. Once the thermostat input calls are satisfied, the control will continue on as if no fault occurred. If 3 consecutive faults occur without satisfying the thermostat Y input call, then the control will go to Lockout mode. Lockout when locked out, the blower will operate continuously in speed, and PS blower motor output will remain on. The Alarm output (ALM) and Lockout output (L) will be turned on. The fault type identification display LED1 (ed) shall flash the fault code. To reset lockout conditions with SW2-8 On, thermostat inputs Y1, Y2, and W must be removed for at least 3 seconds. To reset lockout conditions with SW2-8 Off, thermostat inputs Y1, Y2, W, and DH must be removed for at least 3 seconds. Lockout may also be reset by turning power off for at least 30 seconds or by enabling the emergency shutdown input for at least 3 seconds. Lockout With Emergency Heat - if the control is locked out in the heating mode, and a Y2 or W input is received, the control will operate in the emergency heat mode while the compressor is locked out. The first emergency heat output will be energized 10 seconds after the W input is received, and the blower will shift to high speed. If the control remains locked out, and the W input is present, additional stage of emergency heat will stage on after 2 minutes. When the W input is removed, all of the emergency heat outputs will turn off, and the EM blower will shift to speed and PS blower motor output will remain on. High Pressure fault is recognized when the Normally losed High Pressure Switch, P4-9/10 opens, no matter how momentarily. The High Pressure Switch is electrically in series with the ompressor ontactor and serves as a hard-wired limit switch if an overpressure condition should occur. Low Pressure - fault is recognized when the Normally losed Low Pressure Switch, P4-7/8 is continuously open for 30 seconds. losure of the LPS any time during the 30 second recognition time restarts the 30 second continuous open requirement. A continuously open LPS shall not be recognized during the 2 minute startup bypass time. Loss of harge fault is recognized when the Normally losed Low Pressure Switch, P4-7/8 is open prior to the compressor starting. ondensate Overflow - fault is recognized when the impedance between this line and 24 VA common or chassis ground drops below 100K ohms for 30 seconds continuously. Freeze Detection (oax) - set points shall be either 30 F or 15 F. When the thermistor temperature drops below the selected set point, the control shall begin counting down the 30 seconds delay. If the thermistor value rises above the selected set point, then the count should reset. The resistance value must remain below the selected set 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. Freeze Detection (Air oil) - uses the FP2 input to protect against ice formation on the air coil. The FP2 input will operate exactly like FP1 except that the set point is 30 degrees and is not field adjustable. 29

30 ontrols - Aurora Base ontrol cont. Over/Under Voltage Shutdown - An over/under voltage condition exists when the control voltage is outside the range of 18 VA to 30 VA. If the over/under voltage shutdown lasts for 15 minutes, the lockout and alarm relay will be energized. Over/under voltage shutdown is self-resetting in that if the voltage comes back within range of 18 VA to 30 VA for at least 0.5 seconds, then normal operation is restored. Operation Description Power Up - The unit will not operate until all the inputs and safety controls are checked for normal conditions. The unit has a 5 to 80 second random start delay at power up. Then the compressor has a 4 minute anti-short cycle delay after the random start delay. Standby In standby mode, Y1, Y2, W, DH, and are not active. Input O may be active. The blower and compressor will be off. Heating Operation Heating, 1st Stage (Y1) - The blower is started on speed immediately and the compressor is energized 10 seconds after the Y1 input is received. The EM blower motor is switched to low speed 15 seconds after the Y1 input. Heating, 2nd Stage (Y1, Y2) - The compressor will be staged to full capacity 20 seconds after Y2 input is received. The EM blower will shift to high speed 15 seconds after the Y2 input is received. Heating, 3rd Stage (Y1, Y2, W) - The hot water pump is deenergized and the first stage of electric heat is energized 10 seconds after the W command is received. If the demand continues the second stage of electric heat will be energized after 5 minutes. Emergency Heat (W) - The blower will be started on speed, 10 seconds later the first stage of electric heat will be turned on. 5 seconds after the first stage of electric heat is energized the blower will shift to Aux speed. If the emergency heat demand is not satisfied after 2 minutes the second electric heat stage will be energized. Blower () - The blower will start immediately upon receiving a thermostat command. If there are no other commands from the thermostat the EM will run on speed until the command is removed. egardless of blower input () from the thermostat, the blower will remain on for 30 seconds at the end of each heating cycle. ooling Operation In all cooling operations, the reversing valve directly tracks the O input. Thus, anytime the O input is present, the reversing valve will be energized. ooling, 1st Stage (Y1, O) - The blower is started on speed immediately and the compressor is energized 10 seconds after the Y1 input is received. The EM blower motor is switched to low speed 15 seconds after the Y1 input. ooling, 2nd Stage (Y1, Y2, O) - The compressor will be staged to full capacity 20 seconds after Y2 input is received. The EM blower will shift to high speed 15 seconds after the Y2 input is received. Blower () - The blower will start immediately upon receiving a thermostat command. If there are no other commands from the thermostat the EM will run on speed until the command is removed. egardless of blower input () from the thermostat, the blower will remain on for 30 seconds at the end of each heating, cooling, and emergency heat cycle. Dehumidification (Y1, O, DH or Y1, Y2, O, DH) - When a DH command is received from the thermostat during a compressor call for cooling the EM blower speed will be reduced by 15% to increase dehumidification. Emergency Shutdown - Four (4) seconds after a valid ES input, P2-7 is present, all 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. ontinuous Blower Operation - The blower output will be energized any time the control has a input present, unless the control has an emergency shutdown input present. The blower output will be turned off when input is removed. Load Shed - The LS input disables all outputs with the exception of the blower output. When the LS input has been cleared, the antishort cycle timer and random start timer will be initiated. Input must be tied to common to activate. 30

31 ontrols - Aurora Base ontrol cont. Aurora Base ontrol 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, reen) Description of Operation Fault LED, reen Normal Mode ON ontrol is Non-functional OFF Test Mode Slow Flash Lockout Active Fast Flash Dehumidification Mode Flash ode 2 (Future Use) Flash ode 3 (Future Use) Flash ode 4 Load Shed Flash ode 5 ESD Flash ode 6 (Future Use) Flash ode 7 onfiguration LED (LED2, Yellow) Description of Operation No Software Overwritten DIP Switch was Overwritten EM onfiguration Mode Fault LED (LED1, ed) ed Fault LED onfiguration LED, Yellow Flashing EM Setting Slow Flash Fast Flash LED Flash ode* Lockout eset/ emove Normal - No Faults OFF Fault - Input 1 No Auto Fault - High Pressure 2 Yes Hard or Soft Fault - Low Pressure 3 Yes Hard or Soft Fault - Freeze Detection FP2 4 Yes Hard or Soft Fault - Freeze Detection FP1 5 Yes Hard or Soft Fault - ondensate Overflow 7 Yes Hard or Soft Fault - Over/Under Voltage 8 No Auto Fault - FP1 & FP2 Sensor Error 11 Yes Hard or Soft NOTE: All codes >11 use long flash for tens digit and short flash for the ones digit. 20, 30, 40, 50, etc. are skipped. AB Basic Faults Aurora Interface and Diagnostics (AID) Tool The Aurora Interface and Diagnostics (AID) Tool is a device that is a member of the Aurora network. The AID Tool is used to troubleshoot equipment which uses the Aurora control via Modbus TU communication. The AID Tool provides diagnostics, fault management, EM setup, and system configuration capabilities to the Aurora family of controls. An AID Tool is recommended, although not required, for EM airflow settings. The AID Tool simply plugs into the exterior of the cabinet in the AID Tool port. AB ontrol Board Layout 2 2 F Y1 JW2 - Alarm HP HP LP LP FP2 FP2 FP1 FP1 EV EV LO HI F F Factory Factory P2 P4 P5 PWM FM EM PWM P13 SW1 Test V K1 K2 Hi K3 Fan K4 Alarm K5 Acc K6 Fi eld onnections Faul t LED3 A Dip 5 Dual/Single L Pulse/ontinuous Status eheat/normal P9 LO P1 LED1 Factory Use P11 AUOA BASE ONTOL Off FP1 15 o F/30 o F FP2 15 o F/30 o F V B/O A Dip 4 Factory Fan onnection O/B Y1 Y2 Fi eld onnections 8 SW2 W On 1 LED2 2 Y 3 onfig DH om1 om2 3A-Fuse P3 Factory P6 S485 Exp P7 S 485 P8 S485 NET EH1 EH2 EH1 O N/A (+) (-) ES LS ALM AL A c A no A nc LO O/B Y1 Y2 W DH 31

32 Blower Drive Sheaves Blower Sheave Adjustment Follow the procedures listed below if airflow of heat pump is to be changed from factory setting. (efer to Figure 10.) 1. Loosen the blower motor fastening nuts from the motor mount. 2. Turn the adjusting bolts until the tension is off the drive belt. 3. emove belt from sheave and loosen allen heat set screw B. 4. Adjust sheave pitch diameter for desired speed by opening or closing moveable portion in or out in 1/2-turn increments. Do not open more than 5 full turns. 5. Sheave should be mounted with set screw A toward the motor. Be sure driven and drive sheaves are in alignment and parallel. 6. etighten set screw B and replace drive belt on sheaves. 7. Turn motor mount adjusting bolts until belt has approximately 1/2-inch of deflection midway between sheaves (4 lbs. tension if measured with gauge, see Figure 11). 8. etighten motor mounting nuts. Belt tension of a new belt will drop rapidly during the first few hours of operation. 9. heck and readjust as needed. Figure 10: Blower Motor Sheave Adjustments and Settings Figure 11: hecking Drive Belt Tension Keyway Moveable Portion Driven Sheave Deflection Drive Sheave Set Screw A Set Screw B 32

33 Unit Startup Before powering the unit, check the following: High voltage is correct and matches nameplate Fuses, breakers and wire size are correct Low voltage wiring is complete Piping has been completed and water system cleaned and flushed Air is purged from closed loop system Isolation valves are open and water control valves or loop pumps wired ondensate line is open and correctly pitched Transformer has been switched to lower voltage tap if needed Blower rotates freely Blower speed is correct Air filter is clean and in position Service/access panels are in place eturn air temperature is between 60 F-80 F in heating and 70 F-95 F in cooling Air coil has been cleaned Startup Steps 1. Initiate a control signal to energize the blower motor. heck blower operation. 2. Initiate a control signal to place the unit in the cooling mode. ooling set point must be set below room temperature. 3. First stage cooling will energize after a time delay. heck for correct rotation of scroll compressors in 120, 080, 095 units. Incorrect rotation will cause unusual noise and low refrigerant pressures. Switch any two power leads at the compressor or contractor to reverse rotation. 4. Be sure the compressor and water control valve or loop pumps are activated. 5. Initiate a control signal to energize second stage cooling. 6. Second stage cooling will energize after a time delay. heck for correct rotation as indicated in step Verify that the water flow rate is correct by measuring pressure drop through the heat exchanger using the P/T plugs and comparing to Water Pressure Drop Table on page heck the temperature of both the supply and discharge water. efer to Unit Operating Pressures and Temperatures 9. heck for an air temperature drop of 15 to 25 F across the air coil, depending on blower speed and entering water temperature. 10. Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or pumps deactivate. 11. Initiate a control signal to place the unit in the heating mode. Heating setpoint must be set above room temperature. 12. First stage heating will energize after a time delay. 13. Initiate a control signal to energize second stage heating. 14. Second stage heating will energize after a time delay. 15. heck the temperature of both the supply and discharge water. efer to Unit Operating Pressures and Temperatures. 16. heck for an air temperature rise of 20 F to 25 F across the air coil, depending on the blower speed and entering water temperature. 17. Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps deactivate. 18. During all testing, check for excessive vibration, noise or water leaks. 19. Set system to desired normal operating mode and set temperature to maintain desired comfort level. 20. Instruct the owner/operator in the proper operation of the thermostat and system maintenance. 21. heck belt tension and readjust as necessary after first few hours. 33

34 Operating Parameters Entering Water Temp F Water Flow PM/Ton Suction Pressure PSI Discharge Pressure PSI Superheat ooling Water Temp Subcooling ise F Air Temp Drop F DB Entering Water Temp F Water Flow PM/Ton Suction Pressure PSI Discharge Pressure PSI Superheat Heating Water Temp Subcooling Drop F Air Temp ise F DB Note: ooling performance based on entering air temperatures of 80º F DB, 67º F WB. Heating performance based on entering air temperature of 70º F DB. 7/25/07 Pressure Drop Model PM Pressure Drop (psi) 30 F 50 F 70 F 90 F 110 F

35 DEALE: PHONE #: POBLEM: MODEL #: SEIAL #: DATE: Startup/Troubleshooting Form OOLIN YLE ANALYSIS PSI = SAT F F Unit Amp Draw: Loop: Open F AI OIL F Line Voltage: losed SUTION OAX LOAD EXPANSION VALVE OAX SOUE EVESIN VALVE OMPESSO DISHAE Hot Water - enerator F F F LIQUID LINE F F F PSI = SAT F PSI BINE IN PSI BINE OUT PSI BINE IN PSI BINE OUT F F Superheat Subcooling Water to Water Application Heat of Extraction/ejection = PM x 500 (485 for water/antifreeze) x T Note: DO NOT hook up pressure gauges unless there appears to be a performance problem. HEATIN YLE ANALYSIS PSI = SAT F F Unit Amp Draw: Loop: Open F AI OIL F Line Voltage: losed SUTION F PSI BINE IN OAX LOAD F PSI BINE OUT Water to Water Application F LIQUID LINE EXPANSION VALVE F PSI BINE IN OAX SOUE F PSI BINE OUT Hot Water - enerator F EVESIN VALVE F F OMPESSO DISHAE PSI = SAT F Superheat Subcooling 35

36 Preventive Maintenance Water oil 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. Lines should always be airtight. 2. 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. losed loop systems must have positive static pressure or air vents may draw air into the system. NOTES: If the installation is performed in an area with a known high mineral content (125 P.P.M. or greater) in the water, it is best to establish with the owner a periodic maintenance schedule so the coil can be checked regularly. Should periodic coil cleaning be necessary, use standard coil cleaning procedures which are compatible with either the cupronickel or copper water lines. enerally, the more water flowing through the unit, the less chance for scaling. Other Maintenance Filters Filters must be clean to obtain maximum performance. They should be inspected every two to three months under normal operating conditions and be replaced when necessary. Units should never be operated without a filter. ondensate Drain In areas where airborne bacteria produce a residual buildup in the drain pan, it may be necessary to chemically treat the pan to minimize the problem. The condensate drain can pick up lint and dirt, especially with dirty filters. Inspect twice a year to avoid the possibility of overflow. Air oil The air coil must be clean to obtain maximum performance. heck once a year under normal operating conditions and brush, vacuum or chemically clean the air coil if necessary. are must be taken not to damage or disturb the aluminum fins while cleaning. AUTION: Fin edges are sharp. Drive Belts heck periodically for proper tension. eplacement Procedures Obtaining Parts ontact your distributor for service or replacement parts required. In-warranty Material eturn Material may not be returned except by permission of authorized service personnel. ontact your local distributor for warranty return authorization and assistance. 36

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38 P.O. Box 1592, York, Pennsylvania USA opyright by Johnson ontrols 2017 Form NOM1 (317) Issue Date: March 28, 2017 Supercedes: NOM3 (115) Subject to change without notice. Printed in USA ALL IHTS ESEVED