York YAWS018 - 075, Installation Manual

Page 1: ... 5 THRU 6 NOMINAL TONS Due to continuous product improvement specifications are subject to change without notice Visit us on the web at www york geothermal com Additional rating information can found at www ahridirectory org FOR DISTRIBUTION USE ONLY NOT TO BE USED AT POINT OF RETAIL INSTALLATION MANUAL ...

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Page 3: ...ontrol System 26 30 The Aurora Advanced Control System 31 33 Reference Calculations 34 Legend and Notes 34 Pressure Drop 35 Operating Limits 35 Physical Data 36 Flow Rates 36 Thermistor and Compressor Resistance 36 Operating Parameters 37 Antifreeze Correction 38 Troubleshooting Guideline for Refrigerant Circuit 39 HR Data 40 HE Data 42 DHW HE Data 42 Heating and Cooling Cycle Analysis 44 Troubles...

Page 4: ...Performance3 Refrigeration Future Options 0 Standard Future Options A Standard Water Coax Option2 C Copper N CuproNickel L Source CuproNickel Load Copper S Source Copper Load CuproNickel Future Option A None Rev 18 January 2016 V Notes 1 Available on 040 050 060 and 075 only Hot Water Generator requires field installed external pump kit 2 018 and 025 heating only models are available only with cop...

Page 5: ...d in good condition Examine units for shipping damage removing unit packaging if necessary to properly inspect unit Units in question should also be internally inspected If any damage is observed the carrier should make the proper notation on delivery receipt acknowledging the damage Units are to be stored in a location that provides adequate protection from dirt debris and moisture General Instal...

Page 6: ...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 1000 1500 ppm 1000 1500 ppm LSI Index 0 5 to 0 5 0 5 to 0 5 0 5 to 0 5 Iron Fouling Biological Growth Iron...

Page 7: ...ted to prevent excess condensation from forming on the water lines NOTE Units are factory run tested using propylene glycol Prior to connecting piping to unit thoroughly flush heat exchangers The piping installation should provide service personnel with the ability to measure water temperatures and pressures The water lines should be routed so as not to interfere with access to the unit The use of...

Page 8: ...arge water from a heat pump can be disposed of in various ways depending on local building codes i e recharge well storm sewer drain field adjacent stream or pond etc Most local codes restrict the use of sanitary sewer for disposal Consult your local building and zoning departments to ensure compliance in your area Figure 9b Open Loop Solenoid Valve Connection Option Typical slow operating externa...

Page 9: ...s Unit 1 with AXB Board 5 Series Unit 2 with AXB Board 5 Series to 5 Series Units C S VS SLO SLI OUT IN C C VS SLO SLI OUT IN C C With pump wired to Unit 2 With pump wired to Unit 1 VS SLO SLI OUT IN C C Shut Down C C SL1 In SL1 Out With pump wired to Unit 1 With pump wired to Unit 2 VS SLO SLI OUT IN C C Figure 8a Primary Secondary Wiring with Aurora Base Control no AXB Board CC T2 T1 Compressor ...

Page 10: ...s NOTES A 30 psi pressure relief valve Part No SRV30 should be used in hydronic applications Vent valve or P T port at highest point in return line prior to ball valve 1 1 2 in FPT Expansion Tank Air Vent Pressure Gauge 30 psi RELIEF VALVE Air Separator FROM HWG TO HWG Back Flow Preventer Pressure Relief Valve Source IN GEO STORAGE TANK PUMP HOT Piped in series to an electric water heater COLD DOM...

Page 11: ...stalling a hot water generator The unit is not supplied with an internal circulator A DPK5 kit will need to be purchased to connect to the hot water generator The DPK5 kit is supplied with installation instructions circulator tank adaptor and temperature limit switch Be sure to burp vent the pump Open the screw 2 turns only in the end of the pump motor if Grundfos pumps are used to allow trapped a...

Page 12: ...n check valves Note that a single check valve is not equal to a backflow prevention check valve Even if local code does not require this device The manufacturer recommends its installation This is particularly important if the system will use antifreeze Pressure Reducing Valves or Feed Water Valves This valve lowers the pressure from the make up water line to the system Most are adjustable and dir...

Page 13: ...on the load side entering water line inside the unit For other field installed controllers these two red wires will need wired to the appropriate sensor input terminals Geothermal Storage Tank Thermostat and Thermistor Thermistor Wires Connected to TS and GND on HydroZone Controller Water to Water LOAD PUMP HYDRONIC LOAD Source OUT P T Ports P T Ports Ball Valve Dielectric Unions Dielectric Unions...

Page 14: ... the necessary flow IntelliStart The optional IntelliStart single phase soft starter will reduce the normal start current LRA by 60 70 This allows the heat pump to go off grid Using IntelliStart also provides a substantial reduction in light flicker reduces start up noise and improves the compressor s start behavior IntelliStart is available in a field retrofit kit part number IS60RKL or IS60RKS or as...

Page 15: ...stor 12P541 01 to be used by Water to Water Units Optional From Geo Connection Shipped with 1 1 2 Pipe Plug Installed DIAMETER 8 5 1 4 35 3 4 Lower Thermostat to be used with Combination Forced Air Hydronic DRAIN VALVE MODEL NUMBER GALLON CAPACITY ELEMENT WATTAGE 240 VOLT NUMBER OF ELEMENTS R VALUE DIMENSIONS IN INCHES APPROX SHIPPING WEIGHT lbs HEIGHT DIAMETER GEO STORAGE 80 80 4500 1 16 63 1 4 2...

Page 16: ... 230 60 1 187 253 30 1 145 0 50 8 1 8 5 4 37 3 44 8 70 075 208 230 60 1 187 253 26 9 145 0 50 8 1 8 5 4 34 1 40 8 60 Notes All fuses type D time delay or HACR circuit breaker in USA 1 15 2015 Source pump amps shown are for up to a 1 2 HP pump Load pump amps shown are for small circulators With optional IntelliStart Control Box Load Pump Power Block Transformer Run Capacitor Ground Lug Load Pump Re...

Page 17: ... signals and not line voltage power The relay has both normally open and normally closed contacts and can operate with either the fan or the compressor Use DIP switch SW2 4 and 5 to cycle the relay with blower compressor or control a slow opening water valve The relay contacts are available on terminals 1 and 3 for normally closed and 2 and 3 for normally open on P2 A second configurable accessory...

Page 18: ... OAT Brown GND HydroZone Controller GND TS OAT GND B A HZC R C O B P V C1 C2 C3 C4 L NOTE 2 Black Red Violet White 8 Violet White 9 Black White 2 Black White 1 Violet 7 Violet 6 Black 4 Black 5 LPR LPR NO NC COM Black White 3 24 VDC Current Transducer CT Thermistor Light emitting diode Green Relay coil Capacitor w bleed resistor Switch Condensate overflow Switch High pressure Switch Low pressure P...

Page 19: ...ED LED1 Red Normal Mode Input Fault Lockout High Pressure Lockout Low Pressure Lockout Future Use Freeze Detection FP1 Reserved Condensate Overflow Lockout Over Under Voltage Shutdown Future Use Future Use FP1 and FP2 Sensor Error Flash Code 1 OFF Flash Code 2 Flash Code 3 Flash Code 4 Flash Code 5 Flash Code 8 Flash Code 6 Flash Code 7 Flash Code 9 Flash Code 10 Flash Code 11 CFM P13 P4 SW1 P5 JW...

Page 20: ...te Not Used Violet White 8 Violet White 9 Black White 2 Black White 1 Violet 7 Violet 6 Black 4 Black 5 Orange 12 Brown 13 LPR LPR NO NC COM Black White 3 24 VDC LPR NO NC COM Black White 3 CC T1 NOTE 5 Geothermal Tank Thermostat Y1 NOTE 6 R Aurora Board Compressor Common CT Capacitor CT Blue Blue Red Red Pink T Pink HW HW HOT WATER OPTION T T T T Brown Brown Black Red GND OUT 5DC 1 2 3 White REFR...

Page 21: ...ode 1 OFF Flash Code 2 Flash Code 3 Flash Code 4 Flash Code 5 Flash Code 8 Flash Code 6 Flash Code 7 Flash Code 9 Flash Code 10 Flash Code 11 CFM P13 P4 SW1 P5 JW2 P9 LO O B Y2 W DH P8 P7 RS485 NET RS485 NET P6 RS485 EXP P3 SW2 On Future Use L Output Type CC Dual Single Acc Dip 5 Acc Dip 4 RV B O FP2 15 F 30 F FP1 15 F 30 F Com1 LED5 Com2 LED5 Test Mode F1 3A P1 C PWM 1 2 3 4 5 6 7 8 ALM ALG ACC C...

Page 22: ...erve as the human interface Controls and regulates water tank temperature Fahrenheit or Celsius Outdoor reset Warm weather shutdown Single Stage HydroZone HZO features HZC mounted on 7 5 x 7 5 x 3 25 electrical box HydroZone relay board 2 1 2 x 2 1 2 LCD display and five push buttons serve as the human interface Controls and regulates water tank temperature Fahrenheit or Celsius Outdoor reset Warm...

Page 23: ...t the Source Water In line to the port marked Load Water In Then connect the Source Water Out line to the port marked Load Water Out 5 Connect the Load Water In line to the port marked Source Water In Then connect the Load Water Out line to the port marked Source Water Out 6 Flip flop locations for FP1 and FP2 thermistors FP1 gets installed where FP2 is and FP2 installs where FP1 was 7 Replace the...

Page 24: ... Performance Monitoring sensor kits These kits can be factory or field installed The following description is for field activation of a factory installation of the sensor kits Energy Monitoring Standard Sensor Kit on most Advanced models The Energy Monitoring Kit includes two current transducers load pump and electric heat added to the existing two compressor sensors so that the complete power usa...

Page 25: ...itor screen c Refrigerant monitoring can be read on any of the following components i AID Tool instantaneous information only ii WF Web Portal via AWL device connected to Aurora Performance Monitoring optional sensor kit The optional Performance Monitoring Kit includes three temperature sensors source entering and leaving water load leaving water temperature and a field installed water flow rate s...

Page 26: ...utomation Network and Internet Optional AWL Aurora Base Control The Aurora Base Control ABC System is a complete residential and commercial comfort system that brings all aspects of the HVAC system into one cohesive module network The ABC features microprocessor control and HP LP condensate and freeze detection over under voltage faults along with communicating thermostat capability for complete f...

Page 27: ...ater generator control flow center linking variable speed pump Added to 5 Series for key features of advanced hot water generator control and advanced loop control linking Optional Field Kit Standard Service Device Description Aurora Base Aurora Advanced Aurora Interface and Diagnostics AID Tool Allows setup monitoring and troubleshooting of any Aurora Control NOTE Although the ABC has basic compa...

Page 28: ...green turns off release SW1 and the control will reset DIP Switch SW2 SW2 1 Source FP1 Selection Low water coil temperature limit setting for freeze detection On 30 F Off 15 F SW2 2 Load FP2 Selection On 30 F Off 15 F SW2 3 RV 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 Relay Operation P2 and 2 5 Access Relay Ope...

Page 29: ...e 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 Load Coax uses the FP2 input to protect against ice formation on the coax The FP2 input will operate exactly like FP1 Over Under Voltage Shutdown An over under voltage condition exists when the control volta...

Page 30: ...ation Mode Flash Code 2 Future Use Flash Code 3 Future Use Flash Code 4 Load Shed Flash Code 5 ESD Flash Code 6 Future Use Flash Code 7 Fault LED LED1 Red Red Fault LED LED Flash Code Lockout Reset Remove ABC Basic Faults 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...

Page 31: ...etpoint 100 F 140 F for 30 continuous seconds 130 F is the default setting This alert will appear as an E15 on the AID Tool and the hot water pump de energizes Hot water pump operations resume on the next compressor cycle or after 15 minutes of continuous compressor operation during the current thermostat demand cycle Since compressor hot gas temperature is dependent on loop temperature in cooling...

Page 32: ...t info only Output from dirty filter sensor Home Automation 2 E24 HA2 With a closed dry contact signal this input will cause an alarm and Alert Code 24 to indicate on the stat or flash on ABC The AID Tool will allow configuration of this input between the following selections No Action Home Automation Fault no lockout info only Output from home automation system Security Alarm no lockout info only...

Page 33: ... protection sensor has tripped 15 or 30 degF for 30 continuous sec Fault Condensate Overflow 7 Yes Hard or Soft Condensate switch has shown continuity for 30 continuous sec Fault Over Under Voltage 8 No Auto Instantaneous voltage is out of range Controls shut down until resolved Fault FP1 Snsr Error 11 Yes Hard or Soft If FP1 Sensor Error ABC AXB Advanced Faults Fault Compressor Monitor 10 Yes Har...

Page 34: ...3 413 LWPD load coax water pressure drop EER energy efficiency ratio cooling LWT leaving water temperature TC total cooling capacity in MBTUH EWT entering water temperature HR heat rejected in MBTUH Brine water with a freeze inhibiting solution Notes to Performance Data Tables The following notes apply to all performance data tables Three flow rates are shown for each unit The lowest flow rate sho...

Page 35: ...si 60 F 80 F 100 F 120 F 018H 3 0 0 5 0 4 0 4 0 3 4 0 1 4 1 3 1 2 1 2 5 0 2 2 2 1 2 1 2 0 6 0 3 0 2 9 2 9 2 8 025H 4 0 1 3 1 3 1 2 1 2 5 5 3 0 2 9 2 8 2 7 7 0 4 6 4 4 4 3 4 1 8 5 6 7 6 5 6 4 6 2 7 13 09 NOTES Temperatures are Entering Water Temperatures Double wall vented coax for heating potable water Vented Only Load Side Model GPM Pressure Drop psi 30 F 60 F 80 F 100 F 120 F 018R 3 0 0 5 0 4 0 ...

Page 36: ...960 87 860 Compressor Resistance Table 77 F Terminals 018 ZP16K5E 025 ZP25KSE 040 HRH034U 050 ZP51K5E 060 HRH056U 075 HLJ072T C to S 2 14 2 28 1 77 2 03 1 30 1 49 0 74 0 85 0 76 0 88 0 78 0 90 C to R 1 42 1 64 0 95 1 09 0 49 0 57 0 42 0 48 0 26 0 30 0 27 0 31 S to R 3 56 4 10 2 72 3 12 1 79 2 06 1 16 1 33 1 02 1 18 1 05 1 21 1 15 15 NOTE Resistance listed are for single phase 208 230 60Hz compress...

Page 37: ...ating conditions Some of the conditions shown above are outside of the compressor operational limits for specific models Cooling Mode Entering Load Temp F Entering Source Temp F Suction Pressure psig Discharge Pressure psig Superheat F Subcooling F 50 30 86 99 135 160 12 22 2 15 50 92 107 191 214 10 19 4 15 70 98 115 248 268 5 15 6 16 90 101 119 335 367 6 15 8 16 110 105 122 425 465 8 16 10 19 70 ...

Page 38: ... C 80 26 7 30 1 1 50 10 0 90 32 2 30 1 1 Water 0 1 000 1 000 1 000 1 000 1 000 Ethylene Glycol 10 0 990 0 973 0 976 0 991 1 075 20 0 978 0 943 0 947 0 979 1 163 30 0 964 0 917 0 921 0 965 1 225 40 0 953 0 890 0 897 0 955 1 324 50 0 942 0 865 0 872 0 943 1 419 Propylene Glycol 10 0 981 0 958 0 959 0 981 1 130 20 0 967 0 913 0 921 0 969 1 270 30 0 946 0 854 0 869 0 950 1 433 40 0 932 0 813 0 834 0 9...

Page 39: ...igh High Normal High Normal Low Water Flow Evaporator Low Normal Low Normal Low Low High High Low Water Flow Condensor High High High High Low High High Water Flow Evaporator Normal Low Normal High Normal Low High Water Flow Condensor Low Low Low Low High Low Restricted TXV Check Service Advisory High Low Normal Low High High Low Insufficient Compressor Possible Bad Valves Low High Low High Normal...

Page 40: ...5 4 38 9 29 2 32 6 35 9 39 3 30 0 33 3 36 5 39 8 7 0 28 0 31 2 34 3 37 5 28 8 31 9 34 9 37 9 29 6 32 5 35 4 38 3 70 4 0 28 4 33 9 39 4 29 2 34 8 40 3 30 0 35 7 41 3 5 5 28 2 33 5 38 8 29 1 34 4 39 7 30 0 35 3 40 7 7 0 28 0 33 1 38 2 43 3 29 0 34 1 39 1 44 2 29 9 35 0 40 0 45 0 90 4 0 27 4 33 3 28 1 34 1 28 8 35 0 5 5 27 3 33 1 28 0 34 0 28 8 34 8 7 0 27 2 33 0 28 0 33 8 28 7 34 6 110 4 0 26 5 32 7...

Page 41: ...78 8 87 9 97 1 72 5 81 1 89 7 98 2 18 0 66 1 74 5 83 0 91 4 69 2 76 9 84 6 92 2 72 2 79 2 86 2 93 1 70 9 0 65 6 80 8 96 0 67 9 82 9 98 0 70 1 85 0 99 9 13 5 65 5 79 4 93 3 67 8 81 5 95 2 70 2 83 6 97 1 18 0 65 4 77 9 90 5 103 1 67 8 80 1 92 4 104 7 70 3 82 2 94 2 106 2 90 9 0 62 8 77 4 92 0 64 7 79 4 94 0 66 7 81 4 96 1 13 5 62 7 76 5 90 4 64 6 78 6 92 5 66 6 80 6 94 6 18 0 62 5 75 7 88 8 64 5 77 ...

Page 42: ...9 6 17 2 14 8 12 5 50 4 0 24 9 22 3 19 6 17 0 25 1 22 5 19 9 17 3 25 3 22 7 20 1 17 5 5 5 25 9 23 2 20 4 17 6 26 1 23 4 20 6 17 9 26 3 23 6 20 9 18 2 7 0 27 0 24 0 21 1 18 1 27 1 24 2 21 3 18 4 27 2 24 4 21 6 18 8 70 4 0 32 1 29 0 25 9 22 9 32 1 29 1 26 1 23 1 32 2 29 3 26 3 23 4 5 5 33 4 30 2 27 0 23 7 33 5 30 3 27 2 24 0 33 5 30 4 27 3 24 3 7 0 34 8 31 4 28 0 24 6 34 8 31 5 28 2 24 8 34 8 31 6 2...

Page 43: ...3 3 38 8 34 2 29 7 42 7 38 6 34 5 30 4 50 9 0 55 7 50 2 44 7 39 3 56 2 50 8 45 4 40 1 56 7 51 4 46 1 40 9 13 5 58 4 52 5 46 6 40 6 58 5 52 8 47 2 41 5 58 5 53 2 47 8 42 4 18 0 61 1 54 7 48 4 42 0 60 7 54 8 48 9 43 0 60 4 54 9 49 4 44 0 70 9 0 71 3 64 5 57 8 51 1 71 6 65 1 58 6 52 1 72 0 65 7 59 4 53 1 13 5 74 8 67 5 60 3 53 0 74 9 68 0 61 1 54 2 75 0 68 5 61 9 55 4 18 0 78 3 70 5 62 7 55 0 78 2 70...

Page 44: ...22 7 20 2 17 8 15 4 90 3 0 24 7 22 0 24 9 22 4 25 2 22 7 4 0 5 0 025 Source EST F Source GPM Load Flow 4 GPM Load Flow 5 5 GPM Load Flow 7 GPM ELT 60 F ELT 80 F ELT 100 F ELT 120 F EL 60 F ELT 80 F ELT 100 F ELT 120 F ELT 60 F ELT 80 F ELT 100 F ELT 120 F 25 4 0 5 5 7 0 16 8 14 6 12 5 10 3 17 0 14 9 12 9 10 9 17 1 15 2 13 3 11 4 30 4 0 17 9 15 7 13 5 11 4 18 0 16 1 14 1 12 2 18 2 16 4 14 7 12 9 5 ...

Page 45: ...3 bS W U OR EObS Saac S A7 SOdW U OR EObS 4 SOdW U OR EObS Saac S A7 OR 1 Of AcQbW 2WaQVO US 1 Saa D A c QS 1 Of 42 MMMMMM A7 MMMMMMA B 4 MMMMMM 4 MMMMMM A7 MMMMMMA B 4 MMMMMM 4 MMMMMM 4 W_cWR W S OR 1 Of C Wb 2 Oe W S D ZbOUS S 1Z aSR AcPQ ZW U Ac S VSOb B3 2 b ObbOQV ST WUS O b UOcUSa c ZSaa O PZS Wa aca SQbSR 3 bS W U A c QS EObS 4 3 bS W U EObS Saac S A7 SOdW U A c QS EObS 4 SOdW U EObS Saac S...

Page 46: ...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 ______ F...

Page 47: ... will not reset until cooled down If the overload does not reset when cool it may be defective If so replace the compressor 9 The internal winding of the compressor motor may be grounded to the compressor shell If so replace the compressor 10 The compressor winding may be open Check continuity with an ohm meter If the winding is open replace the compressor Insufficient Cooling or Heating 1 Check a...

Page 48: ...rom the inlet line of the water to refrigerant heat exchanger to the plastic pail Secure tightly to ensure that circulating solution does not spill refer to the Cleaning Connections illustration 6 Partially fill the plastic pail with clear water about two thirds full and prime the circulating pump Circulate until lines are full 7 Start the circulating pump and slowly add a commercial scale remover...

Page 49: ... 35P506B02 35P506B02 35P506B02 35P506B02 35P506B02 Low Pressure Switch 35P506B01 35P506B01 35P506B01 35P506B01 35P506B01 35P506B01 Discharge Pressure Transducer 35P555 01 35P555 01 35P555 01 35P555 01 35P555 01 35P555 01 Suction Pressure Transducer 35P555 02 35P555 02 35P555 02 35P555 02 35P555 02 35P555 02 Electrical Compressor Contactor 13P004A03 13P004A03 13P004A03 13P004A03 13P004A03 13P004A03...

Page 50: ...50 Notes AFFINITY SINGLE STAGE HYDRONIC INSTALLATION MANUAL ...

Page 51: ...NITY SINGLE STAGE HYDRONIC INSTALLATION MANUAL Pages Description Date By All First Published 01 Jul 2013 DS 15 Updated 018 Electrical Data 19 May 2014 MA All Added Aurora Controls and Advanced Aurora Controls 14 June 2016 MA ...

Page 52: ... change design and specifications without notice Product Affinity Series Type Geothermal Hydronic Heat Pumps Size 1 5 6 Ton Single Speed Document Type Installation Manual Part Number IM2506WK6 Release Date 06 16 York and Affinity are registered trademarks of Johnson Controls Inc and are used with permission ...