Synergy3D Installation Manual W aterFurnace
Contents
1. 5 30 06 Full Load Air Flow Corrections Airflow Cooling Heating CFM Per of Heat of Ton of Clg Nominal Total Cap Sens Cap Power Power Ext 5 30 06 Cooling Capacity Corrections Dual Capacity Full amp Part Load Entering Sensible Capacity Multipliers Entering DB F Power Heat of Air WB F Clg Cap 80 80 6 85 95 Input Rejection Faser i 3989 1 1 a a 399 oss omo 19 7 0888 os oma 1026 v2 7 7 7 7 992 pop 0820 oss 1xe 1 0885 0568 oso 1004 1082 1227 7 999 __ 0805 0748 1002 1027 1481 7 0988 e os tam wow ttr 1919 7 1 000 E pp ese ose oss 1007 1225 14 7 3959 Note Sensible capacity equals total capacity at conditions shown 7 20 06 Heating Capacity Corrections Dual Capacity Full amp Part Load Heating Corrections Ent Air DB F Htg Cap Power Heat of Ext 45 1 023 0 974 1 009 0 990 1 011 1 123 7 20 06 17 SYNERGYSD INSTALLATION MANUAL Auxiliary Heat Auxiliary Heat Electrical Data Supply Heater Amps Min Circuit Amp Max Fuse USA Max Fuse CAN Max CKT BRK Model 208 V 240 V 208 V 240 V 208 V 240 V 208 V 240 V 208 V 240 V 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 32. U o Di o o External Loop Pump Power Connection If the unit is to be used with an external loop pump FC1 or FC2 flow ollo center the pump s will be connected to the terminals on PB1 in the unit B electrical box as shown in Figure 4 The pumps 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 schematic on page 10 11 im err Ws EMO Nez i l E o o 208 Volt Operation All 208 230 volt units are factory wired for 230 volt operation For 2098 volt operation the red and the blue transformer wires must be switched on p terminal strip PS1 Refer to wiring schematic on pages 10 11 for details LILI Figure 10 Wiring Multiple Units to One Flow Center Synergy3D Unit 1 With pump wired to With pump Unit1 wired to Normally Open zd Unit 2 Contacts 1 1 1 Shut c c SL1 811 not not Down In Out used used C SL1 SL1 not not In Out used used
3. NASA I n n n y y n gl nfl gl o o of gl ty nn gg ggg ggg nn n n n n nl ol of ol of gl wg 22277 T I IL I 1 A C H O C A ie E I HT d H 1 2 B 1 B B 4 7108 Vertical Overall Cabinet Water Connections Electrical Connections Discharge Connection Return Connection Topflow K M duct flange installed 0 10 in using std deluxe filter rack 0 10 in Model 1 2 cond 1 2 cond 3 4 cond Q 5 T U V Low Power Supply Retum Retum Volage Supply Depth Depth Height 038 i i 1 Swivel 1 Swivel 049 l i A 1 Swivel 1 Swivel 064 in i 1 Swivel 1 Swivel 072 i i 1 Swivel 1 Swivel Condensate is 3 4 PVC female glue socket and is sw itchable from side to front Unit shipped w ith deluxe 2 field adjustable to 1 duct collar filter rack extending from unit 3 25 and is suitable for duct connection Discharge flange is field installed and extends 1 25 4mm from cabinet Decorative molding and w ater connections extend 1 2 30 5mm beyond front of cabinet 4 2 2008 12 SYNERGYSD INSTALLATION MANUAL Microprocessor Control Operation Heating Operation Heat 1st Stage Y1 The fan motor is started on low speed immediately PSC ON the loop pump is energized 5 seconds after the Y 1 input is received a
4. GeoLink TO A Polyethylene w LOOP Armaflex P T Plugs Emm Flexible Duct a Collar GeoLink Flow Center Auxiliary Heater S Knockout g External oe Pump Power For complete GeoLink Flow Center installation information refer to IM1961 Connector Kits with Armaflex Vibration Absorbing Pad 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 slave terminals on connector P2 in both units with 2 wire thermo stat wire These terminals are polarity conscious see Figure 5 The loop pump s may be powered from either unit which ever is more convenient If either unit calls the loop pump s will automatically start SYNERGYSD INSTALLATION MANUAL Open Loop Ground Water Systems Typical open loop piping is shown in Figure 5 Always maintain water pressure in the heat exchanger by placing wa ter contraol valves at the outlet of hte unit to prevent mineral precipitation Use a closed bladder type expansion tank to minimize mineral formation due to air exposure Ensure proper water flow through the unit by checking pressure drip across the heat exchanger and comparing it to the figures in the pressure drop tables Normally about 2 GPM flow rate per ton of cooling capacity 1 5 GPM per ton minimum at 50 F is needed in open loop systems Discharge water from the unit i
5. 25 4 Hydronic Water Connections Size Swivel in Tmm 1 25 4 1 25 4 1 25 4 1 25 4 1 6 6 1 1 25 4 1 25 4 1 25 4 1 6 6 1 HWG Connection Size Swivel in mm 1 25 4 1 25 4 Coax amp Piping Water Volume gal I 1 3 4 9 1 6 6 1 Vertical 28 x 25 32 x 25 36 x 25 36 x 25 711 x 635 813 x 635 914 x 635 914 x 635 Air Coil Total Face Area ft2 m2 4 9 0 451 5 6 0 570 6 3 0 641 Air Coil Tube Size in mm 3 8 9 5 3 8 9 5 3 8 9 5 Filter Standard 2 51mm Pleated MERV11 28 x 30 712 32x30 813 36x 30 914 36x30 914 Throwaway in mm x 762 x 762 x 762 x 762 Air Coil Dimensions H x W in mm 6 3 0 641 3 8 9 5 Weight Operating Ib kg Weight Packaged Ib kg 4 8 08 11 SYNERGYSD INSTALLATION MANUAL Dimmensional Data j y gt i 1 Y ai D v f y 7 2 lo le F 2 I PL C II 7 4 LP o 4 JJL HLL UUU LOLLI LOLA N PA 72 I P P P 4 LLL 4 4 LL I P P 4 LLL 7 P P 4 LL 4 4 npn n n nl p n p gl rg Yip fifi P Yip fifi fifi P 772 4 4 LL I P I 4 IL I I
6. 80 96 7 110 100 110 100 110 100 100 EAL H 20 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 fan load All fuses type D time delay or HACR circuit breaker in USA Auxiliary Heat Ratings Model KW BTU HR Min Model Compatibility 208V 230V Stages 208V 230V CFM 038 049 064 32700 500 TT EAL H IS 144 3 56900 49100 50 Notes High fan tap setting must be above the minimum CFM for the heater selected 18 SYNERGYSD INSTALLATION MANUAL Blower Performance Data AIR FLOW DIP SWITCH SETTINGS 650 750 850 1000 LL L NNNM 800 1000 MEM s E ud d L 950 1100 1300 L 0 L Factory settings are at recommended L M H DIP switch locations CFM is controlled within 5 up to the maximum ESP 3 18 08 M H settings MUST be located within boldface CFM range Max ESP includes allowance for wet coil and standard filter Lowest and Highest DIP switch settings are assumed to be L and H respectively A 12 position DIP switch package on the Synergy3D control allows the airflow levels to be SW1 On set for Low Medium and High speed when using the ECM2 blower motor 1 Only three of the DIP switches can be in the On position The first On switch the lowest position number determines the Low Speed Fan setting The second On switch determines 2 the Medium Speed Fan setting an
7. Rate x Temperature Difference x Brine Factor d above x g above x 485 for Methanol or Environol 500 for water Heat of Extraction Heating Mode Heat of Rejection Cooling Mode Compare results to Capacity Data Tables Note Steps 5 through 8 need only be completed if a problem is suspected 5 WATTS Volts Total Amps Comp Fan Watts m x n x 0 85 6 CAPACITY Cooling Capacity HR o x 3 413 Heating Capacity HE o x 3 413 7 EFFICIENCY Cooling EER p o Heating COP p o x 3 413 8 SUPERHEAT S H SUBCOOLING S C COOLING COOLING btu hr btu hr HEATING btu hr btu hr EER COP HEATING HYDRONIC HYDRONIC Suction Pressure Suction Saturation Temperature Suction Line Temperature Superheat t s Head Pressure High Pressure Saturation Temp Liquid Line Temperature Subcooling w x F F F PSI F F F Lo s t u V W X y PSI F F F PSI F F F Note Liquid line is between the source coax and the expansion valve in the cooling mode between the air coil and the expansion valve in the heating mode between hot water load coax and txv in hot water mode 21 PSI F F F PSI F F F SYNERGYSD INSTALLATION MANUAL Synergy3D Heating Cycle Analysis PSI SAT F I SUCTION gt Solenoid Compressor Expansi
8. iron bacteria will be pres ent 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 Desuperheater coils can likewise become Material DI Comer 90 10 Cupro Nickel ei Acidity Alkalinity Scaling Calcium and Magnesium Carbonate Total Hardness less than 350 ppm Total Hardness less than 350 ppm Less than 5 ppm Less than 5 ppm Chlorides Less than 20 ppm Less than125 ppm Less than 5 ppm Hydrogen Suinde rotten egg smell appears at 0 5 PPM TES SP ppm Sulfates Less than 125 ppm Less than 125 ppm Corrosion Total Dissolved Solids TDS Less than 1000 ppm 1000 1500 ppm Iron Fe Ferrous None None Iron Fouling Bacterial Iron Potential Biological Growth Less than 1 ppm Above this level Less than 1 ppm Above this level Iron Oxide Ji He deposition will occur deposition will occur Suspended Solids Less than 10 ppm and filtered for max Less than 10 ppm and filtered for max of 600 micron size of 600 micron size Threshold Velocity Fresh Water 5 8 ft sec 8 12 ft sec Note Grains PPM divided by 17 mg l is equivalent to PPM SYNERGYSD INSTALLATION MANUAL General Installation Information cont scaled and possibly plugged In areas with extr
9. is selected This will close field installed damper s located in ductwork NOTE The control will not operate in forced air cooling and hydronic water heating modes simultaneously Hot Water Operation After a hot water input is received the diverting valve loop pump and hot water pump are turned on Five seconds after hot water input is received the compressor is activated in second stage Fan G Only The fan starts on low speed Regardless of fan input G from thermostat the fan will remain on low speed for 30 seconds at the end of each heating cooling or emergency heat cycle 13 SYNERGYSD INSTALLATION MANUAL Microprocessor Control Operation cont Lockout Conditions During lockout mode the appropriate unit and thermostat lockout LEDs will illuminate The compressor loop pump hot water pump and accessory outputs are de energized Unless the lockout is caused by an ECM2 low RPM fault the fan will continue to run on low speed and if the thermostat calls for heating 3rd stage emergency heat operation will occur Lockout modes can be reset at the thermostat after a five second waiting period which restores normal operation but keeps the unit lockout LED illuminated Comfort Alert lockouts can not be reset at the thermostat and will not be displayed on the thermostat Interruption of power to the unit will reset a lockout without a waiting period and clear all lockout LEDs High Pressure This lockout mode occurs when
10. 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 easy removal of the filter and access panels and has enough space for ser vice 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 Care 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 caution A minimum of 24 inch clearance should be allowed for access to front access panel Setting Vertical Units Figure 1 Vertical Unit Mounting Vertical units are available in left or right hand return configuration 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 Figure 1 Vibration Absorbing Duct System Mesh An air outlet collar is provided on vertical top flow units to facilitate a duct connection which is shipped inside the unit A flexible connector is recommended for discharge and return air duct connections
11. the normally closed safety switch is opened momentarily gt 600 PSI Low Pressure This lockout mode occurs when the normally closed switch is opened for 30 continuous seconds 40 PSI Freeze Sensing Water Flow This lockout mode occurs when the freeze thermistor temperature is at or below the selected freeze protection point well 30 F or loop 15 F for 30 continuous seconds Condensate Overflow This lockout mode occurs when the condensate overflow level has been reached for 30 continuous seconds Fan RPM ECM2 The Synergy3D control board monitors fan RPM to sense if the fan is not operating This lockout mode occurs if the fan RPM falls below the low RPM limit 100 RPM for 30 continuous seconds 14 SYNERGYSD INSTALLATION MANUAL Microprocessor Control Operation cont Airflow Selection DIP Switches SW1 See Fan Speed section on page 16 Field Selection DIP Switches SW2 An 8 position DIP switch package on the Synergy3D control allows the following field selectable options 1 Service Test Mode This DIP switch on the control allows field selection of Normal or Test operational modes The test mode accelerates most timing functions 16 times to allow faster troubleshooting Test mode also allows viewing the current status of the fault inputs on the LED display 2 Freeze Sensing Setting water flow This DIP switch allows field selection of freeze thermistor fault sensing temperatures for well water o
12. 4 CCHI Logic Board SYNERGYSD INSTALLATION MANUAL Desuperheater Connections To maximize the benefits of the desuperheater a minimum 50 gallon water heater is recommended For higher demand applications use an 80 gallon water heater or two 50 gallon water heaters connected in a series as shown below Electric water heaters are recommended Make sure all local electrical and plumbing codes are met for installing a desuperheater The Synergy3D is not supplied with an internal circulator A DPK5 kit will need to be purchased to connect to the desuperheater The DPKS kit is supplied with installation instructions Typical Buffer Tank Installation Figure 8 Synergy3D with Buffer Tank lt HOT lt lt COLD 3 4 Domestic r 3 4 Domestic t 1 Connections WaterFurnace SYNERGYS3D SYNERGYSD INSTALLATION MANUAL Electrical General Be sure the available power is the same voltage and phase as that shown on the unit serial plate Line and low voltage wiring must be done in accordance with local codes or the National Electric Code whichever is applicable Figure 9 3D Line Voltage 208 230 60 1 Unit Power Connection QUIRRA RYN STOYT Cine voltage Line Voltage connection is made by connecting the incoming line volt age wires to the L side of the contactor as shown in Figure 9 Consult the Unit Electrical Data table below for correct fuse size
13. Envision or Synergy3D Unit 2 Synergy3D Unit 1 Electrical Data Int Ext Fan Total Min Max Max Model ie Compressor Pump Loop Motor Unit Circ Fuse Fuse MCC RLA LRA FLA FLA FLA FLA Amp calc HACR SDV038 197 25 48 5 SDV038 197 25 51 5 SDV049 107 254 330 211 960 175 54 40 325 375 586 SDVO49 208 230 60 1 197 254 330 211 960 175 54 70 353 405 616 SDV064 107 254 718 SDV072 208 230 60 1 197 254 150 0 1 75 5 4 7 0 41 4 With optional 1 HP ECM2 motor 3 18 08 Rated Voltage of 208 230 60 1 Min Max Voltage of 197 254 HACR circuit breaker in USA only All fuses Class RK 5 Local electrical codes overule any wiring recommendations SYNERGYSD INSTALLATION MANUAL Thermostat Installation Installation Position the thermostat subbase against the wall so that it is level and the thermostat wires protrude through the sub base Mark the position of the subbase mounting holes and drill holes with a 3 16 inch bit Install anchors and secure base to the wall Thermostat wire must be 8 conductor 18 AWG wire Strip the wires back 1 4 inch longer strip lengths may cause shorts and insert the thermostat wires into the Synergy3D connector as shown in Figure 11 Tighten the screws to ensure good connections The thermostat has the same type of connectors requiring the same wiring See instructions enclosed in the thermostat for detailed installation and operation information Figure 11 Thermostat Wirin
14. INSTALLATION MANUAL General Installation Information Safety Considerations Installation and servicing of heating and air conditioning equipment can be hazardous due to system pressure and elec trical components Only trained and qualified service personnel should install repair or service heating and air conditioning equipment Untrained personnel can perform basic maintenance functions of cleaning coils and cleaning and replacing filters All other operations should be performed by trained service personnel When working on 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 quenching cloth for brazing operations Have fire extinguisher available for all brazing operations WARNING Before performing service or maintenance operations on the system turn off main power switches to the unit Turn off accessory heater power switch if applicable Electrical shock could cause serious personal injury Moving and Storage Move units in the normal Up orientation Vertical units are not to be moved but may be stored one upon another to a maximum height of two units 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
15. SYNERGYSD Geothermal Heat Pumps with Water Heating for Radiant Floor Applications e 3 thru 6 Ton Installation Information Water Piping Connections Electrical Connections Startup Procedures Preventive Maintenance Lj Smarter from the Ground Up Ma sti PepFoRMANCE tO ARI Standard 13256 1 C o IM1602 04 08 Synergy3D Installation Manual WaterFurnace SYNERGYSD INSTALLATION MANUAL Table of Contents Model Nomenclature 2 General Installation Information 3 5 Closed Loop Systems 6 Open Loop Systems 7 Buffer Tank Installation 8 Electrical 9 Thermostat Installation 10 Physical Data 11 Dimensional Data 12 Microprocessor Control Operation 13 15 Operating Limits 16 Correction Factors 17 Auxiliary Heat 18 Blower Performance amp Auxilary Heat Data 19 Startup Checklist 20 Startup Troubleshooting Form 21 23 SYNERGYSD INSTALLATION MANUAL Model Nomenclature S D V 049 A 1 1 1 N T L Model Type __ D Return Air Configuration S Synergy3D Dual Capacity L Left R Right Compressor Type D Daul Capacity Discharge Air Configuration T Top Cabinet Configuration Coax Options V Vertical C Copper N Cupronickel Unit Capacity Fan Option 1 ECM Vintage 2 Oversized ECM Blower Option A Vintage 038 amp 049 Voltage Hot Water Option 1 208 230 60 1 0 None 1 Hot Water Generation with factory installed pump SYNERGYSD
16. ck to ensure that the rubber seal is in the swivel connector prior to attempting any connection The rubber seals are shipped at tached to the air coil inside the blower compartment To make the connection to a ground loop system mate the brass connector supplied in CK4L and CK4L GL connector kits against the rubber gasket in the Swivel connector and thread the female locking ring onto the pipe threads while maintaining the brass connector in the desired direction see Figure 2 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 inch MPT fitting into the swivel connector and tighten in the same manner as noted above The open and closed loop piping system must include pressure tempera ture taps for serviceability Never use flexible hoses smaller than 1 inch inside diameter on the unit and limit hose length to 10 feet per connection Check carefully for water leaks CAUTION Water piping exposed to outside temperature may be subject to freezing Water Quality Figure 2 Female Locking Ring Stainless Steel Snap Ringe Locking Ring N E IA Gasket Gasket Support Sleeve Material Note Load side fittings are same type as source In ground water situations where scaling could be heavy or where biological growth such as
17. d the third On switch determines the High Speed Fan 3 setting The example to the right shows SW1 on the Synergy3D control board configured for the 5 following SDV049 airflow settings Low Speed Fan 750 CFM E gt Medium Speed Fan 1200 CFM I 7 High Speed Fan 1600 CFM 3 8 9 10 11 12 19 SYNERGYSD INSTALLATION MANUAL Startup Before powering unit check the following Fuses breakers and wire size are correct and match the name plate Low voltage wiring is complete Piping has been completed and the water system is cleaned and flushed Air is purged from the closed loop system Air is purged from buffer tank hydronic system isolation valves are open and water control valves or loop pumps are wired Condensate line is open and correctly pitched Black white and gray white wires in unit control box have been removed if auxiliary heat has been installed DIP switches are set correctly Blower rotates freely and foam shipping support has been removed Blower speed is correct DIP switch setting Air filter is clean and in position Service access panels are in place Return air temperature is between 60 80 F in heating and 70 95 F in cooling Air coil is clean Forced Air Startup Instructions NOTE On initial power up a four minute time delay will occur 1 a RON EAD 10 11 12 13 14 15 16 Initiate a control signal to energize the blower motor Check blower operat
18. emely 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 Freeze Sensing Set the freeze sensing switch SW2 2 to Loop on the printed circuit board for applications using a closed loop anti freeze solution On applications using an open loop ground water system set to Well the factory setting If using closed loop and no antifreeze solution leave in Well position the factory setting Condensate Drain The internal condensate drain assembly consists of a drain tube which is attached to the drain pan a 3 4 inch PVC fe male adapter and a flexible connecting hose The female adapter may exit either the front or the side of the vertical cabinet The adapter will be glued to the field installed PVC condensate piping A condensate hose is inside all cabinets as a trap ping loop therefore an external trap is not necessary Air Coil To obtain maximum performance the air coil should be cleaned before start up A 10 solution of dishwasher detergent and water is recommended for both sides of coil a thorough water rinse should follow SYNERGYSD INSTALLATION MANUAL Closed Loop Ground Source Systems Once piping is completed between the unit flow center and the ground loop Figure 3 final purging a
19. g Re 24VAC gL Hot E c 2 ce _ Vc o e Common o5 09 9 e 95 Y1 Compressor a Q wW 6 0 Aux Heat o Q O 6 Reversing t 9 Valve 9 5 E P G_ _ 9 Blower 6 Relay E System e _ _ __ L1 Monitor Other Thermostats The Synergy3D unit is compatible with virtually any 24VAC thermostat However the multi stage nature of this product requires a 3 stage heating 2 stage cooling type thermostat ComforTalk thermostats SW2 8 in the ON position configures 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 Note DIP switch SW2 8 is required to be in the OFF position for the control to operate with FaultFlash or 10 SYNERGYSD INSTALLATION MANUAL Physical Data 038 049 064 072 Compressor 1 each Copeland Scroll Factory Charge R410a oz kg 90 2 55 ECM Fan Motor amp Blower Fan Motor Type Speeds ECM Variable Speed Fan Motor hp W 1 2 373 1 2 373 1 746 1 746 11 x 10 11 x 10 11 x 10 11 x 10 279 x 254 279 x 254 279 x 254 279 x 254 95 2 69 124 8 51 128 3 62 Blower Wheel Size Dia x W in mm Coax and Water Piping Loop Water Connections Size Swivel in mm 1 25 4 1 25 4 1
20. ications without notice 2008 WFI
21. ion Initiate a control signal to place the unit in the cooling mode Cooling setpoint must be set below room temperature First stage cooling will energize after a time delay Be sure that the compressor and water control valve or loop pumps are activated Verify that the water flow rate is correct by measuring the pressure drop through the heat exchanger using the P T plugs and comparing to water pressure drop found in table on page 22 Check the temperature of both the supply and discharge water Refer to tables on page 22 Check for an air temperature drop of 15 to 25 F across the air coil depending on the fan speed and entering water temperature See Typical Air Temperature Rise Drop Chart on page 22 Adjust the cooling setpoint above the room temperature and verify that the compressor and water valve or loop pumps deactivate Initiate a control signal to place the unit in the heating mode Heating setpoint must be set above room temperature First stage heating will energize after a time delay Check for an air temperature rise of 20 to 35 F across the air coil depending on the fan speed and entering water temperature Refer to typical Air Temperature Rise Drop Chart on page 22 If auxiliary electric heaters are installed adjust the heating setpoint until the electric heat banks are sequenced on All stages of the auxiliary heater should be sequenced on when the thermostat is in the Emergency Heat mode Check amperage
22. nd charging of the loop is needed A flush cart at least a 1 5 HP 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 50 75 psi winter or 40 50 psi summer This is normally adequate for good system operation Loop static pressure will 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 After pressurization be sure to remove the plug in the end of the loop pump motor s if Grundfos pumps are used to allow trapped air to be discharged and to ensure the motor housing has been flooded Ensure the loop flow center provides adequate flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures shown in unit capacity tables in Specification Catalog SP1554 Usually 2 5 3 gpm of flow per ton of cooling capacity is recommend ed in earth loop applications See wiring schematics on pages 10 and 11 for loop pump power wiring details Figure 3 Closed Loop Ground Source Application Unit Supply Disconnects IfApplicable p Unit Power Low Voltage to Thermostat Multiple Units on One Flow Center fu rp
23. nd the compressor is energized on low capacity 10 seconds after the Y 1 input The fan is switched to medium speed 15 seconds after Y 1 input ECM only The hot water pump is cycled 30 seconds after the Y 1 input Heat 2nd Stage Y1 Y2 Dual Capacity Units The second stage compressor will be activated 5 sec onds after receiving a Y2 input as long as the minimum first stage compressor run time of 1 minute has expired The ECM blower changes from medium to high speed 15 seconds after the Y2 input The Comfort Alert will delay the second stage compres sor until 5 seconds after it receives a Y2 from the board Heat 3rd Stage Y1 Y2 W Dual Capacity Units The hot water pump is de energized which directs all heat to satisfy the thermostat The 1st stage of resistance heat is energized 10 seconds after W input and with con tinuous 3rd stage demand the additional stages of resis tance heat engage sequentially every 5 minutes Emergency Heat W Only Low speed blower and damper output CR3 will be ener gized immediately after receiving W only The first stage auxiliary heater will be energized 10 seconds upon receiving a W only and the blower will shift to high speed 15 sec onds after receiving a W only input If the W input is not removed the second third and fourth auxiliary heat outputs will stage on one at a time every two minutes Cooling Operation Cool 1st Stage Y1 0 The blower motor and h
24. of each element Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps deactivate During all testing check for excessive vibration noise or water leaks Correct or repair as required Set system to desired normal operating mode and set temperature to maintain desired comfort level Instruct the owner operator in the proper operation of the thermostat and system maintenance 20 SYNERGYSD INSTALLATION MANUAL Synergy3D Startup and Troubleshooting Form Company Name Technician Name Synergy3 Model No Owner s Name Installation Address Check One Company Phone No Date Serial No Open or Closed Loop Installation Date Q Start up Check out for new installation A Troubleshooting Problem 1 FLOW RATE IN GPM SOURCE SIDE HEAT EXCHANGER Water In Pressure a Water Out Pressure b Pressure Drop a b es Convert Pressure Drop to Flow Rate refer to installation manual page 32 d PSI PSI PSI GPM 2 TEMPERATURE RISE OR DROP ACROSS SOURCE SIDE HEAT EXCHANGER HEATING Water In Temperature Water Out Temperature Temperature Difference COOLING 3 TEMPERATURE RISE OR DROP ACROSS AIR COIL Supply Air Temperature Return Air Temperature Temperature Difference COOLING F F F F F F HEATING 4 HEAT OF REJECTION HR HEAT OF EXTRACTION HE CALCULATION HR or HE Flow
25. on Valve Solenoid psu DISCHARGE Valve Open E F Liquid Line q E UNIT AMP DRAW Superheat LINE VOLTAGE oF F p LOOP OPEN CLOSED Subcooling Synergy3D Cooling Cycle Analysis PSI SAT F SUCTION F Liquid Line Compressor Expansion Valve Diverting DISCHARGE Solenoid Valve Valve Open Filter Drier UNIT AMP DRAW Superheat LINE VOLTAGE LOOP OPEN CLOSED Subcooling F F 22 SYNERGYSD INSTALLATION MANUAL Synergy3D Hot Water Cycle Analysis PSI SAT F SUCTION Reversing Valve EA Compressor Expansion Valve Solenoid Valve Closed Diverting DISCHARGE Valve F gt Liquid Line PSI SAT F F UNIT AMP DRAW LINE VOLTAGE oF F Superheat LOOP OPEN CLOSED Subcooling NOTE Do not attach refrigerant gauges unless a problem is suspected 23 SYNERGYSD INSTALLATION MANUAL Installation Notes 24 Smarter from the Ground Up LD Manufactured by WaterFurnace International Inc 9000 Conservation Way Fort Wayne IN 46809 www waterfurnace com IM1602 04 08 Product Synergy3D Type Geothermal Heat Pumps with Water Heating for Radiant Floor Applications Size 3 thru 6 Ton Document Installation Manual WFI has a policy of continuous product research and development and reserves the right to change design and specif
26. 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 a previous check should have been made to assure that the duct has the capacity to handle the air required for the unit application If ducting is too small as in the replacement of heating only sys tems larger ductwork should be installed All existing ductwork should be checked for leaks and repaired when necessary The duct system should be sized to handle the design airflow quietly To maximize sound attenuation of the unit blower the supply and return plenums should include internal duct liner of glass fiber or be of ductboard construction for the first few feet If air noise or excessive airflow is a problem the blower speed can be changed See the Blower Performance and Fan Speed sections on page 16 SYNERGYSD INSTALLATION MANUAL General Installation Information cont Water Piping Connections All Synergy3D source water connections are swivel piping fittings that accept a 1 inch Male Pipe Thread MPT see Figure 2 The swivel pipe connector has a rubber gasket seal similar to a garden hose gasket which when mated to the flush end of 1 inch threaded pipe provides a leak free seal without the need for thread sealing tape or compound Che
27. ot water pump are started immediately the loop pump s is energized 5 seconds after the Y 1 input is re ceived The compressor will be energized on low capacity for Dual Capacity units 10 seconds after the Y 1 input The ECM blower will shift from low to medium speed 15 seconds after the Y 1 input 8596 of medium speed if in dehumidification mode Cool 2nd Stage Y1 Y2 O Dual Capacity Units The second stage compressor will be activated 5 seconds after receiving a Y2 input as long as the minimum first stage compressor run time of 1 minute has expired The ECM blower changes to high speed 15 seconds after the Y2 input 8596 of high speed if in dehumidification mode 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 cool ing mode Y1 and O inputs or the cooling slave signal is ig nored When Y 1 and O inputs have been received and a cooling slave input from heating cooling thermostat located in a hydronic heated force air cooled zone are received the control will activate CR3 relay to open damper s which will allow for cooling to occur in zone When cooling slave input 24VAC signal is removed the control will turn off the CR3 relay output if spring damper operation is selected or ac tive the CR4 output if POPC damper operation
28. r antifreeze pro tected earth loops 3 Forced Air Heating Hydronic This DIP switch allows field selection of Heating Forced Air Priority or Hydronic Priority 4 Forced Air Cooling Hydronic This DIP switch allows field selection of Cooling Forced Air Priority or Hydronic Priority 5 Whole Forced Air Zone This DIP switch allows field selection option for constant fan When whole house is selected CR3 relay will activate and open dampers When forced air is selected a damper s located in the hydronically heated forced air cooled zone will not be opened 6 Diagnostics Inputs This DIP switch allows viewing the inputs from the thermostat to the control board such as Y 1 O G W SL1 In on the LED display 7 Diagnostics Outputs This DIP switch 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 8 Thermostat Selection Configures the control for a pulsed lockout signal ComforTalk and FaultFlash thermostats or continuous lockout signal Factory Setup DIP Switches SW3 A 5 position DIP switch package on the Synergy3D control allows the following factory setup options 1 Dual Capacity Single Speed 2 POPC Spring This switch allows field selection of Power Open Power Closed dampers or Power Open Spring Close dampers 3 No RPM RPM This DIP switch configures the con
29. s not contaminated in any manner and can be disposed of in various ways such as recharge well storm sewer drain field adjacent stream or pond etc depending on local building codes Most local codes forbid the use of sanitary sewer for disposal Consult your local building and zoning department to ensure compliance in your area Figure 5 Open System Ground Water Application Aux Heat Disconnects If Applicable Unit Low Voltage Power to Thermostat and Valve Vibration Absorbing Pad Flexible Duct Collar Heater P T Plugs Auxiliary Knockout Solenoid Valve Rubber Bladder Expansion Tank N Flow Regulator Water In Shut Off Valves Shut Off Valve to isolate solenoid valve while acid flushing Boiler Drains For HX Flushing Notes For open loop ground water systems or systems that do not contain and antifreeze solution set SW2 2 to the Well position Figure 6 Open Loop Solenoid Valve Connection Option Typical slow operating external 24V water solenoid valve type VM wiring r Violet 2 1 0 CC Comfort Alert Y2 Violet 3 BIk 1 O CC GND Wht 4 CCHI Logic Board Figure 7 BPV or PPV Valve Wiring Typical external 24V water solenoid valves type PPV100 BPV100 wiring Comfort Alert Y2 Violet 2 O CC eo BIk 1 O CC GND Violet 3 Wht
30. trol to monitor the RPM output of an ECM2 blower motor When using a PSC blower motor the control should be configured for no RPM sensing 4 and 5 Over ride Time These switches are used in conjunction to determine the override timings for forced air and hydronic operation See Override Selection table page 10 for timings 15 SYNERGYSD INSTALLATION MANUAL Operating Limits ti Limit Cooling perating Limits CF C Air Limits Min Ambient Air 45 7 2 Rated Ambient Air 80 26 7 Max Ambient Air 100 37 8 Min Entering Air 50 10 0 Rated Entering Air db wb 80 6 66 2 27 19 Max Entering Air db wb 110 83 43 28 3 Water Limits Min Entering Water Normal Entering Water Max Entering Water Notes Minimum maximum limits are only for start up conditions and are meant for bringing the space up to occupancy temperature Units are not designed to operate at the minimum maximum conditions on a regular basis The operating limits are dependant upon three primary factors 1 water temperature 2 return air temperature and 3 ambient temperature When any of the factors are at the minimum or maximum levels the other two factors must be at the normal level for proper and reliable unit operation 16 SYNERGY3D INSTALLATION MANUAL Correction Factor Tables Part Load Air Flow Corrections Airflow Cooling Heating 0 OEM Eor did Total Cap Sens Cap Power Power Heat ot Ton of Clg Nominal Ext
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