WaterFurnace Synergy3D Installation Manual Download

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SYNERGY3D INSTALLATION MANUAL

Table of Contents

Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Closed Loop Ground Source Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Open Loop Ground Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Hot Water Generator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Typical Buffer Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12

Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17

Hydronic Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19

Microprocessor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21

Hydronic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Microprocessor Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-24

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Operation Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Correction Factor Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Auxiliary Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Synergy3D Startup and Troubleshooting Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Synergy3D Cycle Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-32

Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Summary of Contents for Synergy3D

Page 1: ...tor Connections Electrical Startup Procedures Troubleshooting Preventive Maintenance Synergy3D Installation Manual Geothermal Heat Pump with Water Heating for Radiant Floor Applications R 410A Refrigerant 3 6 Tons All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 2: ...All manuals and user guides at all guides com ...

Page 3: ...p 13 Dimensional Data 14 15 Wiring Schematic 16 17 Hydronic Section 18 19 Microprocessor Control 20 21 Hydronic Operation 22 Microprocessor Control Operation 22 24 Operating Limits 25 Operation Logic 25 Correction Factor Tables 26 Auxiliary Heat 27 Blower Performance Data 28 Startup 29 Synergy3D Startup and Troubleshooting Form 30 Synergy3D Cycle Analysis 31 32 Operating Parameters 33 Troubleshoot...

Page 4: ...ordered separately includes field installed circulator hot water tank adaptor temperature limit and installation instructions Filter Option AP AlpinePure 411 Return Air Configuration L Left R Right Discharge Air Configuration T Top R Rear Coax Options C Copper N Cupronickel L Source Cupronickel Load Copper S Source Copper Load Cupronickel Blower Options 1 ECM 2 Oversized ECM 038 049 Hot Water Opti...

Page 5: ...lly 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 ...

Page 6: ...cking ring onto the pipe threads while maintaining the brass connector in the desired direction see Female Locking RIng illustration Tighten the connectors by hand and then gently snug the fitting with pliers to provide a leak proof joint When connecting to an open loop ground water system thread 1 in MPT fitting into the swivel connector and tighten in the same manner as noted above The open and ...

Page 7: ... will occur Suspended Solids 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 Threshold Velocity Fresh Water 6 ft sec 6 ft sec 6 ft sec Grains PPM divided by 17 mg l is equivalent to PPM 2 8 08 Corrosion Erosion Iron Fouling Biological Growth 0 5 to 05 can likewise become scale...

Page 8: ...ter Knockout Low Voltage to Thermostat Unit Power Unit Supply Auxiliary Heat Supply For complete information refer to GeoLink Flow Center Installation Manual GeoLink Flow Center External Pump Power Multiple Units on One Flow Center When two Synergy3D units or one Envision unit and one Synergy3D unit are connected to one loop pumping system pump control is automatically achieved by connecting the s...

Page 9: ...te solenoid valve while acid flushing Shut Off Valves Water Out Water In Solenoid Valve Flow Control Valve on outlet of Solenoid Valve P T Plugs CC GND CC CCHI Comfort Alert Y1 Y2 Logic Board Violet 3 Blk 1 Wht 4 Violet 2 CC SS CC GND CC CCHI Comfort Alert Y1 Y2 Logic Board Violet 3 Blk 1 Wht 4 VM valve Violet 2 CC SV High Speed Open Loop Solenoid Valve Connection Option Typical slow operating ext...

Page 10: ...series Electric water heaters are recommended Make sure all local electrical and plumbing codes are met for installing a hot water generator The Synergy3D is not supplied with an internal circulator A DPK5 kit will need to be purchased to connect to the hot water generator Unit Model Copper I D Pipe Size in Flow Rates GPM Maximum Feet of Pipe One Way Total Number of Elbows Recommended Storage Tank...

Page 11: ...ps 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 208 Volt Operation All 208 230 volt units are factory wired for 230 volt operation For 208 volt operation the red and the blue transformer wires must be switched on terminal strip PS1 Refer to the Wiring Schematics section Shut ...

Page 12: ...onfigures the control to operate with typical thermostats continuous lockout signal There must be a wire connecting Y2 on the microprocessor controller to 2nd stage compressor on the thermostat for proper operation R Y1 C W O G L 24VAC Hot 24VAC Common Compressor 1st Stage Aux Heat Reversing Valve Blower Relay System Monitor Microprocessor Controller Thermostat Connection Y2 Compressor 2nd Stage M...

Page 13: ...dard 2 51mm Pleated MERV11 Disposable in mm 28 x 30 712 x 762 32 x 30 813 x 762 36 x 30 914 x 762 36 x 30 914 x 762 Weight Operating lb kg 425 530 540 540 Weight Packaged lb kg 445 550 560 560 6 2 08 Pressure Drop Model GPM Pressure Drop psi 30 F 50 F 70 F 90 F 110 F 038 full load 5 1 2 1 2 1 1 1 0 1 0 7 2 2 2 1 1 9 1 8 1 7 9 3 4 3 2 3 0 2 8 2 6 11 4 9 4 6 4 3 4 0 3 7 038 part load 4 0 9 0 8 0 8 0...

Page 14: ... 4 in PVC female glue socket and is switchable from side to front Unit shipped with deluxe 2 in field adjustable to 1 in duct collar filter rack extending from unit 3 25 in and is suitable for duct connection Discharge flange is field installed and extends 1 in 25 4 mm from cabinet Decorative molding and water connections extend 1 2 in 30 5 mm beyond front of cabinet LEFT RETURN LEFT FRONT TOP RIG...

Page 15: ...vel 8 0 11 3 12 8 cm 65 0 80 3 148 3 18 5 48 0 5 8 40 4 40 4 48 0 26 9 20 3 28 7 32 5 Vertical Topflow Model Discharge Connection duct flange installed 0 10 in Return Connection using std deluxe filter rack 0 10 in Misc N O P Q R S T U V W X Y Supply Width Supply Depth Return Depth Return Height 049 in 39 4 9 1 13 3 13 6 8 1 1 7 28 1 30 0 1 7 28 7 1 0 2 1 cm 100 1 23 1 33 8 34 5 20 6 4 3 71 4 76 2...

Page 16: ... 6 5 4 8 7 12 1 2 9 10 3 13 14 16 11 15 Blk 20 Acc Com Acc NC Acc NO P3 SV Blk 23 White 22 NOTE 2 ECM2 Fan Motor Grn 15 10 16 3 8 On Off PWM RPM C2 RPM grnd P12 P11 2 3 4 5 1 Red Black Blue LP Blue Blue Comfort Alert CS DC SOL Cap Tan 16 Comfort Alert R Y2 C Y Violet 3 Black 1 CC Violet 2 Yel 6 Wht 4 Blk 5 CC CO CR1 CR2 CR3 CR4 F1 and F FD HP L1 SV CS Field Selection Dips 1 On 6 On 7 On Drain pan ...

Page 17: ... C G T 1 3 2 P L1 Damper relay Damper relay 24 vac coil SV CS Compressor Solenoid LED Flash Code Description Green Solid Module Has Power Red Solid Y1 Present But Compressor Not Running Code 1 Long Run Time Code 2 System Pressure Trip Code 3 Short Cycling Code 4 Locked Rotor Code 5 Open Circuit Code 6 Open Start Circuit Code 7 Open Run Circuit Code 8 Welded Contactor Code 9 Low Voltage Yellow Comf...

Page 18: ...r the initial filling If there is a restriction in the screen the system could go to 0 psi 0 kPa potentially causing pumps s failure A valve should be installed on each side of the pressure reducing Hydronic Section valve for servicing Both valves should have tags reading Do not shut this valve under normal operation service valve only Expansion tanks Expansion tanks are required on hydronic syste...

Page 19: ...to be discharged and to ensure the motor housing has been flooded Hydronic Section cont WaterFurnace Geothermal Storage Tank Thermostat Synergy3D must be wired to the thermostat screw terminals The yellow thermistor wires will not operate with the Synergy3D as they are used with the EW series water to water Thermostat All manuals and user guides at all guides com ...

Page 20: ...n is suspended the appropriate lockout LED begins flashing Refer to the Fault Retry section Microprocessor Control Testing The control allows service personnel to shorten most timing delays for faster diagnostics Refer to Dip Switch description Fault Retry All faults except for low RPM faults with the ECM2 blower motor are retried twice before finally locking the unit out An output signal is made ...

Page 21: ...l Flash Code Number LED Description Automatic Reset of Alert Codes Flash Code 1 Long Run Time Thirty alert free on and off cycles to reset automatically Flash Code 2 System Pressure Trip Not applicable Flash Code 3 Short Cycling Four alert free on and off cycles to reset automatically Flash Code 4 Locked Rotor Four alert free on and off cycles to reset automatically Flash Code 5 Open Circuit One a...

Page 22: ...e has expired The ECM blower changes to high speed 15 seconds after the Y2 input The Comfort Alert will delay the second stage compressor until 5 seconds after it receives a Y2 from the board Hydronic Cooling Slave Signal 24 vac input on P6 pin 15 violet wire The Synergy3D control board must be operating in cooling mode Y1 and O inputs or the cooling slave signal is ignored When Y1 and O inputs ha...

Page 23: ...iting period and clear all lockout LEDs and Comfort Alert faults High Pressure This lockout mode occurs when the normally closed safety switch is opened momentarily 600 PSI Low Pressure This lockout mode occurs when the normally closed switch is opened for 30 continuous seconds 40 PSI Freeze Detection Limit Water Flow This lockout mode occurs when the low source water thermistor temperature is at ...

Page 24: ...utputs Allows viewing the outputs from the control board such as compressor diverting valve reversing valve blower hot water pump and loop pump on the LED display Outputs Normal SW2 8 Thermostat Selection Configures the control for a pulsed lockout signal ComforTalk and FaultFlash thermostats or continuous lockout signal standard thermostat Pulse L Signal Continuous L Signal Factory Setup DIP Swit...

Page 25: ...26 7 70 21 1 Max Ambient Air 100 37 8 85 29 4 Minimum Entering Air 50 10 0 40 4 4 Rated Entering Air db wb 80 6 66 2 27 19 68 20 0 Maximum Entering Air db wb 110 83 43 28 3 80 26 7 Water Limits Minimum Entering Water 30 1 1 20 6 7 Normal Entering Water 50 110 10 43 3 30 70 1 1 Maximum Entering Water 120 48 9 90 32 2 NOTES Minimum maximum limits are only for start up conditions and are meant for br...

Page 26: ...44 0 830 0 962 0 944 0 958 1 161 0 914 300 75 0 957 0 866 0 968 0 958 0 968 1 115 0 937 325 81 0 970 0 900 0 974 0 970 0 977 1 075 0 956 350 88 0 982 0 933 0 981 0 980 0 985 1 042 0 972 375 94 0 991 0 968 0 991 0 991 0 993 1 018 0 988 400 100 1 000 1 000 1 000 1 000 1 000 1 000 1 000 425 106 1 007 1 033 1 011 1 008 1 007 0 990 1 010 450 113 1 013 1 065 1 023 1 015 1 012 0 987 1 018 475 119 1 017 1...

Page 27: ...8 V 240 V 208 V 240 V 208 V 240 V 208 V 240 V EAL H 10 Single 34 7 40 53 3 60 60 60 60 60 60 60 Single 52 0 60 75 85 80 90 80 90 70 100 L1 L2 34 7 40 53 3 60 60 60 60 60 60 60 L3 L4 17 3 20 21 7 25 25 25 25 25 20 30 Single 69 3 80 96 7 110 100 110 100 110 100 100 L1 L2 34 7 40 53 3 60 60 60 60 60 60 60 L3 L4 34 7 40 43 3 50 45 50 45 50 40 50 All heaters rated single phase 60 cycle and include unit...

Page 28: ...d standard filter Lowest and Highest DIP switch settings are assumed to be L and H respectively MODEL 038 0 50 0 75 072 0 75 049 0 50 0 75 064 0 75 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 ECM2 blower motor Only three of the DIP switches can be in the On position The first On switch the lowest positio...

Page 29: ...erating temperature to 8 maintain desired comfort level Instruct the owner operator in the proper operation 9 of the hydronic temperature control and system maintenance Forced Air Startup Instructions NOTE On initial power up a four minute time delay will occur Initiate a control signal to energize the blower motor 1 Check blower operation Initiate a control signal to place the unit in the cooling...

Page 30: ... 0 85 o _____ WATTS o ______ WATTS o ______ WATTS 6 CAPACITY Cooling Capacity HR o x 3 413 p _____ btu hr Heating Capacity HE o x 3 413 p _____ btu hr 7 EFFICIENCY Cooling EER p o q _____ EER Heating COP p o x 3 413 q _____ COP 8 SUPERHEAT S H SUBCOOLING S C COOLING HEATING HYDRONIC Suction Pressure r ______ PSI r ______ PSI r ______ PSI Suction Saturation Temperature s ______ F s ______ F s _____...

Page 31: ...I ______SAT F ______ F F F NOTE Do not attach refrigerant gauges unless a problem is suspected FD TXV CV Suction Discharge Compressor RV Air Coil Source Coax Load Coax DV Synergy3D Forced Air Cooling Cycle Analysis open Inactive circuit Refrigerant charge compensator F F ______PSI ______SAT F ______ F ______PSI ______SAT F ______ F ______ F Liquid Line Unit Amp Draw ____________ Line Voltage _____...

Page 32: ..._____SAT F ______ F ______ F Liquid Line Unit Amp Draw ____________ Line Voltage _________ Loop ______ Open ______ Closed Subcooling _______ Superheat _______ NOTE Do not attach refrigerant gauges unless a problem is suspected Entering Source Water ________ F Entering Water Pressure Drop _____ PSI Leaving Source Water ________ F Leaving Water Pressure Drop _____ PSI Entering Load Water ________ F ...

Page 33: ...emp Drop F DB Suction Pressure PSIG Discharge Pressure PSIG Super heat F Sub cooling F Water Temp Rise F Air Temp Drop F DB 20 1 5 Operation Not Recommended Operation Not Recommended 2 25 3 0 57 64 272 282 12 21 8 16 3 8 16 20 30 1 5 Operation Not Recommended Operation Not Recommended 2 25 118 114 144 182 22 40 4 18 8 13 14 22 77 90 249 284 3 18 3 16 4 9 16 20 3 0 106 114 154 192 22 40 4 18 8 13 1...

Page 34: ...s should then be installed and superheat and subcooling numbers calculated If superheat and subcooling are outside recommended ranges an adjustment to the refrigerant charge may be necessary Note Refrigerant tests must be made with hot water generator turned OFF Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit LED NORMAL DISPLAY MODE DIAGNOSTIC MOD...

Page 35: ...ce or replacement parts refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit If replacement parts are required mention the date of installation of the unit and the date of failure along with an explanation of the malfunctions and a description of the replacement parts required In Warranty Material Return Material may not be returned except by ...

Page 36: ...02 33P589B03 Solenoid Valve 33P575 01 Hyrdonic Load Pump 24P002A03 Electrical Control Box Assembly 13S826 01 13S826 02 13S826 03 Sensors Safeties Comfort Alert 19P571 02 19P571 02 19P571 02 Contactor 13P004A03 13P004A03 13P004A03 13P004A03 Transformer 15P501B01 15P501B01 15P501B01 15P501B01 3 Pole Power Block 12P503 06 12P503 06 12P503 06 12P503 06 2 Pole Screw Term Block 12P500A01 12P500A01 12P50...

Page 37: ...37 SYNERGY3D INSTALLATION MANUAL Notes All manuals and user guides at all guides com ...

Page 38: ...38 SYNERGY3D INSTALLATION MANUAL Notes All manuals and user guides at all guides com ...

Page 39: ...All manuals and user guides at all guides com ...

Page 40: ...nternational Inc 9000 Conservation Way Fort Wayne IN 46809 www waterfurnace com 2010 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 IM1300YS 06 10 All manuals and user guides at all guides com ...

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