Water Furnace 500A11 5 Series Installation Manual

IM2500AN 02/13Installation InformationWater Piping ConnectionsHot Water Generator ConnectionsElectricalStartup ProceduresTroubleshootingPreventive Ma

105 SERIES 500A11 INSTALLATION MANUALFigure 7: Closed Loop Ground Source Application NOTE: For closed loop systems with antifreeze protection, set SW

115 SERIES 500A11 INSTALLATION MANUALTypical open loop piping is shown below. Always maintain water pressure in the heat exchanger by placing water co

125 SERIES 500A11 INSTALLATION MANUALTo maximize the benefits of the hot water generator a minimum 50-gallon water heater is recommended For higher d

135 SERIES 500A11 INSTALLATION MANUALHot Water Generator Startup1. Turn the hot water generator switch to the “ON” position. The hot water generator

145 SERIES 500A11 INSTALLATION MANUALGeneralBe sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and

155 SERIES 500A11 INSTALLATION MANUALPump Power Wiring See Figure 14 for electrical connections from control boxto pumps. FC1/FC2 style flow centers w

165 SERIES 500A11 INSTALLATION MANUALAuxiliary Heat RatingsAuxiliary Heat Electrical DataModelSupply CircuitHeater Amps Min Circuit Amp Fuse (USA) Fus

175 SERIES 500A11 INSTALLATION MANUALElectrical Data* With optional 1 hp ECM motor** With optional IntelliStart®Rated voltage of 208/230/60/1All fuses

185 SERIES 500A11 INSTALLATION MANUALDual Capacity Unit with Variable Speed ECM MotorModelRatedVoltageVoltageMin/MaxCompressor HWGPumpFLAExtLoopFLABlo

195 SERIES 500A11 INSTALLATION MANUALSingle Speed Unit with Variable Speed ECM MotorModelMax ESPAirflow Speed Settings1234567891011120180.50300 400500

205 SERIES 500A11 INSTALLATION MANUALECM Speed Info 1▶ 2 ◀ G 3 4 5 6 7 8 9 10 11 12Option ◀▶ Enter ◙ECM Speed Info 1 2 G▶ 3 ◀ Lo 4 5

215 SERIES 500A11 INSTALLATION MANUAL5-Speed ECM Constant Torque MotorsThe 5-Speed ECM is a ‘Constant Torque’ ECM motor and delivers air flow similar

225 SERIES 500A11 INSTALLATION MANUALLGNCHigh VoltageConnections3/16 in. 12345G - BlueY1 - RedAUX - GrayC - BlackL - OrangeG - GreenN - BrownLow Volta

235 SERIES 500A11 INSTALLATION MANUALPSC BLOWER MOTOR BODYHIGHLOWMEDIUMBLOWER SPEED WIREUnit with Standard PSC MotorModelMotor SpdBlower SizeMotor HPA

245 SERIES 500A11 INSTALLATION MANUALLEFT RETURN RIGHT RETURNFRONTTOP2ft [61cm]Primary Service AccessTOPADEHFKJ I G1.9in[4.8cm]1.9in[4.8cm]MRQNOLRNOLP

255 SERIES 500A11 INSTALLATION MANUAL2ft [61cm]Primary Service AccessLEFT SIDERIGHT SIDEBCSTBCSTLEFT RETURNRIGHT RETURNRQLNOPAFRONTDEFGHIJK1.90(4.7 cm

265 SERIES 500A11 INSTALLATION MANUALREAR VIEWLEFT RETURNSIDE VIEWRIGHT RETURNSIDE VIEWLEFT RETURNREAR VIEWRIGHT RETURNFRONTCCCCAAABBDEHFGIJKLLMNMNPOQ

275 SERIES 500A11 INSTALLATION MANUAL2ft [61cm]Primary Service AccessBC2.1in [5.4cm]HLONMSRQPMOUNT (2) HANGER BRACKETSAS SHOWN TO ALLOW ACCESSTO FILTE

285 SERIES 500A11 INSTALLATION MANUALSingle SpeedModelSingle Speed012 018 022 030 036 042 048 060 070 Compressor (1 each) Rotary Scroll Factory Char

295 SERIES 500A11 INSTALLATION MANUALDual CapacityModelDual Capacity026 038 049 064 072 Compressor (1 each) Copeland UltraTech, Dual Capacity Scroll

5 SERIES 500A11 INSTALLATION MANUALTable of ContentsModel Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

305 SERIES 500A11 INSTALLATION MANUALAurora Control Features Description Aurora ‘Base’ Aurora ‘Advanced’Microprocessor Compressor ControlMicroprocesso

315 SERIES 500A11 INSTALLATION MANUALAdd On Control Feature Kits(field or factory Installed)Description Aurora ‘Base’ Aurora ‘Advanced’Geo Energy Moni

325 SERIES 500A11 INSTALLATION MANUALAurora ‘Base’ ControlNOTE: Refer to the Aurora Base Control Application and Troubleshooting Guide and the Instruc

335 SERIES 500A11 INSTALLATION MANUALCycle with Blower - The accessory relay will cycle with the blower output.Cycle with Compressor - The accessory r

345 SERIES 500A11 INSTALLATION MANUALOver/Under Voltage Shutdown - An over/under voltage condition exists when the control voltage is outside the rang

355 SERIES 500A11 INSTALLATION MANUALCC2FactoryFaultALGALMLSESACC cStatusAuroraTM BaseControlRV – K1CC2CC – K2CC Hi – K3Fan – K4Alarm – K5Acc – K6ACC

365 SERIES 500A11 INSTALLATION MANUALAurora ‘Advanced’ Control FeaturesThe Aurora ‘Advanced’ Control system expands on the capability of the Aurora ‘B

375 SERIES 500A11 INSTALLATION MANUALAdvanced Communication PortsCommunication ports P6 and P8 will provide future expansion via dedicated protocols.

385 SERIES 500A11 INSTALLATION MANUALAurora ‘Advanced’ Control LED DisplaysThese three LEDs display the status, configuration, and fault codes for the

395 SERIES 500A11 INSTALLATION MANUALHEgpm x 500Reference CalculationsHeating Calculations: Cooling Calculations:LWT = EWT + LAT (DB) = EAT (DB) - LC

45 SERIES 500A11 INSTALLATION MANUAL1N2D3V4-60497G819110111C12T13L14015A16NModel Type N = 5 Series Water-to-AirCompressor Type D = Dual Capacity S

405 SERIES 500A11 INSTALLATION MANUALWiring SchematicsAurora Advanced with ECM and IntelliStartExt Pump 1/2 hp Total 208-230/60/1PumpPumpG12PB121Orang

415 SERIES 500A11 INSTALLATION MANUALWiring Schematics cont.Aurora Advanced with ECM and IntelliStart cont.BrownTransformer24VECM Blower MotorP12P112

425 SERIES 500A11 INSTALLATION MANUALWiring Schematics cont.Aurora Advanced with 5-Speed ECMExt Pump 1/2 hp Total 208-230/60/1PumpPumpG12PB121Orange(9

435 SERIES 500A11 INSTALLATION MANUALWiring Schematics cont.Aurora Advanced with 5-Speed ECM cont.BLOWER CURRENT TRANSDUCER (CT)Transformer24VTo P2 on

445 SERIES 500A11 INSTALLATION MANUALWiring Schematics cont.Aurora Base with PSCTransformer24VTo P2 on Electric Heat BoardRVCCHPCondensateBlackBlackBl

455 SERIES 500A11 INSTALLATION MANUALWiring Schematics cont.Aurora Base with PSC cont.EventNormal ModeTest ModeRandom Start DelayCompressor On DelayCo

465 SERIES 500A11 INSTALLATION MANUALWiring Schematics cont.Aurora Base with ECM and IntelliStartTransformer24VECMBlower MotorP12P112 3 4 51Green16 11

475 SERIES 500A11 INSTALLATION MANUALWiring Schematics cont.Aurora Base with ECM and IntelliStart cont.97P840-02 6/22/12PB2VioletBlueWith optiona

485 SERIES 500A11 INSTALLATION MANUALUnit StartupBefore Powering Unit, Check the Following:NOTE: Remove and discard the compressor hold down shipping

495 SERIES 500A11 INSTALLATION MANUALEnergy Monitoring (Standard Sensor Kit on most ‘Advanced’ models)The Energy Monitoring Kit includes two current t

55 SERIES 500A11 INSTALLATION MANUALWARNING: Before performing service or maintenance operations on a system, turn off main power switches to the indo

505 SERIES 500A11 INSTALLATION MANUALOperating ParametersSingle Speed ModelsEntering Water Temp °FWater Flowgpm/tonCooling -- No Hot Water Generation

515 SERIES 500A11 INSTALLATION MANUALOperating Parameters cont.Dual Capacity ModelsFirst Stage OperationEntering Water Temp °FWater Flowgpm/tonCoolin

525 SERIES 500A11 INSTALLATION MANUALSingle SpeedModel gpmPressure Drop (psi)30°F 50°F 70°F 90°F 110°F0121.5 0.3 0.3 0.3 0.3 0.32.5 1.0 1.0 1.0 1.0 1.

535 SERIES 500A11 INSTALLATION MANUALSymptomHead PressureSuction PressureCompressorAmp DrawSuperheat SubcoolingAir Temp. DifferentialWater Temp. Diffe

545 SERIES 500A11 INSTALLATION MANUALHeat of Extraction/RejectionSingle SpeedModel gpmHeat of Extraction (kBtuh) Heat of Rejection (kBtuh)30°F 50°F 70

555 SERIES 500A11 INSTALLATION MANUALAurora Control SystemNOTE: Refer to the Aurora Base Control Application and Troubleshooting Guide and the Instruc

565 SERIES 500A11 INSTALLATION MANUALTroubleshooting cont.FP2 SensorLLT(Liquid Line Heating)FP1 SensorFilter DryerMuŋerCompressorCoaxWater INWater OUT

575 SERIES 500A11 INSTALLATION MANUALTroubleshooting cont.COOLING CYCLE ANALYSISHot WaterGenerator-EXPANSIONVALVEAIRCOIL°FPSI°FPSIBRINE INBRINE OUTBRI

585 SERIES 500A11 INSTALLATION MANUALTroubleshooting cont.Single Speed/Dual Capacity Startup/Troubleshooting Form1. Job InformationModel # Job N

595 SERIES 500A11 INSTALLATION MANUALWater Coil Maintenance1. Keep all air out of the water. An open loop system should be checked to ensure that the

65 SERIES 500A11 INSTALLATION MANUALGeneral Installation Information cont.Insulate supplyplenum and useat least one 90 elbow toreduce noiseElectrical

605 SERIES 500A11 INSTALLATION MANUALService Parts ListParts ListSingle Speed Units012 018 022 030 036 042 048 060 070CompressorCompressor 208-230/60

615 SERIES 500A11 INSTALLATION MANUALService Parts List cont.Parts ListDual Capacity Units026 038 049 064 072CompressorCompressor 208-230/60/1 34P640

625 SERIES 500A11 INSTALLATION MANUALNotes

635 SERIES 500A11 INSTALLATION MANUALRevision GuidePages: Description: Date: By:24-26 Updated Dimensional Drawings 22 Feb 2013 DS40-43 Updated Wiring

Manufactured byWaterFurnace International, Inc.9000 Conservation WayFort Wayne, IN 46809www.waterfurnace.com©2013 WaterFurnace International, Inc., 90

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85 SERIES 500A11 INSTALLATION MANUALthe swivel connector prior to attempting any connection. The rubber seals are shipped attached to the waterline. T

95 SERIES 500A11 INSTALLATION MANUAL1/2'' PitchDrain1.5 in.1.5 in.PVC tube stubPVC couplingVent (if needed)PVC tube stub1/8 in. per footNOTE