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WaterFurnace Synergy3D Installation Manual And Owner's Manual

Manual is about: Geothermal Heat Pump with Water Heating for Radiant Floor Applications

Summary of Synergy3D

  • Page 1

    Im1300ys 07/15 installation information water piping connections hot water generator connections electrical startup procedures troubleshooting preventive maintenance s yner gy3d ins tallation manual geothermal heat pump with water heating for radiant floor applications • r-410a refrigerant • 3, 4, 5...

  • Page 3: Table of Contents

    3 synergy3d installation manual table of contents model nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 general installation information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 4: Model Nomenclature

    4 synergy3d installation manual model nomenclature s 1 2 3 4-6 7 8 9 model type s – synergy3d compressor type d – dual capacity cabinet configuration v – vertical unit capacity (mbtuh) 038, 049, 064, 072 vintage * - factory use only voltage 1 – 208-230/60/1 hot water generation 0 – no hot water gene...

  • Page 5

    5 synergy3d installation manual filter rack conversion a 2 in. Merv 11 filter is shipped with the heat pump. To field convert the filter rack to use 1 in. Filters, simply insert the provided plastic push pins into the holes located in the filter rack. There are holes on the top and bottom of the rac...

  • Page 6

    6 synergy3d installation manual 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 inter- nal duct liner of glass fiber or be of ductboard construction for the first few feet. If air noi...

  • Page 7

    7 synergy3d installation manual water quality 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...

  • Page 8

    8 synergy3d installation manual closed loop ground source systems once piping is completed between the unit, flow center and the ground loop, final purging and 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 a...

  • Page 9

    9 synergy3d installation manual typical open loop piping is shown in the open system: ground water application. Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation. Use a closed, bladder-type expansion tank t...

  • Page 10

    10 synergy3d installation manual waterfurnace synergy3d geo storage tank load pump hydronic load dielectric unions 80 or 120 gal. Geothermal storage tank for hydronic load dielectric unions 1-1/2˝ fpt expansion tank air vent pressure gauge 30 psi relief valve air separator p/t ports 80 gal. Water he...

  • Page 11: Hydronic Section

    11 synergy3d installation manual general guidelines are shown below for component selection and design/installation criteria for the piping system. Local codes supersede any recommendations in this manual. Shut off/flow regulation valves: use full port ball valves or gate valves for component isolat...

  • Page 12: Hydronic Section Cont.

    12 synergy3d installation manual the unit uses an external temperature sensor such as the lower thermostat in a water heater storage tank to control the tank temperature. The thermostat should be wired to the unit p5 connector wires, p5-11 and p5-4 tan wires. When the tank temperature drops below th...

  • Page 13: Electrical Connections

    13 synergy3d installation manual 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. Unit power connection line voltag...

  • Page 14

    14 synergy3d installation manual electronic thermostat installation thermostat wiring installation position the thermostat subbase against the wall so that it is level and the thermostat wires protrude through the subbase. Mark the position of the subbase mounting holes and drill holes with a 3/16 i...

  • Page 15: Auxiliary Heat

    15 synergy3d installation manual auxiliary heat notes: synergy 3d requires medium and high blower setting to be above the minimum cfm for the heater selected. Rear discharge uses the horizontal auxiliary heat kits, ealh10a, 15a, or 20a. Auxiliary heat ratings auxiliary heat electrical data model kw ...

  • Page 16: Electrical Data

    16 synergy3d installation manual electrical data model rated voltage voltage min/max compressor int pump fla ext loop fla blower motor fla total unit fla min circ amp max fuse/ hacr mcc rla lra lra** 038 208-230/60/1 187/254 23.8 15.2 83.0 30.0 1.07 5.4 4.0 25.7 29.5 40 038* 208-230/60/1 187/254 23....

  • Page 17: Blower Performance Data

    17 synergy3d installation manual blower performance data 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 variable speed ecm blower motor. Only three of the dip switches can be in the “on” position. The first ...

  • Page 18: Dimensional Data

    18 synergy3d installation manual dimensional data topflow discharge vertical topflow model overall cabinet water connections electrical connections k 1/2” cond l 1/2” cond m 3/4” cond a width b depth c height d loop in e hydronic out f hydronic in g loop out h hwg in i hwg out j cond- ensate loop wa...

  • Page 19: Dimensional Data Cont.

    19 synergy3d installation manual dimensional data cont. Rear discharge condensate is 3/4 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...

  • Page 20: Physical Data

    20 synergy3d installation manual physical data model 038 049 064 072 compressor (1 each) copeland scroll factory charge r410a, oz [kg] 94 [2.66] 107 [3.03] 132 [3.74] 132 [3.74] ecm fan motor & blower fan motor type/speeds variable speed ecm fan motor- hp [w] 1/2 [373] 1/2 [373] 1 [746] 1 [746] blow...

  • Page 21: Microprocessor Control

    21 synergy3d installation manual startup the unit will not operate until all the inputs and safety controls are checked for normal conditions. At first power- up, a four minute delay is employed before the compressor is energized. Component sequencing delays components are sequenced and delayed for ...

  • Page 22: Microprocessor Control Cont.

    22 synergy3d installation manual microprocessor control cont. Heating operation heat, 1st stage (y1) the blower motor is started on low speed immediately, the loop pump is energized 5 seconds after the “y1” input is received, and the compressor is energized on low capacity 10 seconds after the “y1” ...

  • Page 23: Microprocessor Control Cont.

    23 synergy3d installation manual sw3 (4 and 5 override selection dip switches) these dip switches configure the time that the unit will run in the current mode of operation if it is not the priority mode (sw2 #3 fah/hydronics) of operation selected. Example: if the unit is operating in hydronic mode...

  • Page 24: Microprocessor Control Cont.

    24 synergy3d installation manual see blower performance data section. Airflow selection dip switches (sw1) microprocessor control cont. Factory setup dip switches (sw2) dip switch number description off position on position sw2- 1 service test mode allows field selection of “normal” or “test” operat...

  • Page 25: Operation Logic

    25 synergy3d installation manual heating cooling hot water mode stg1 stg2 stg3 emerg stg1 stg2 compressor on on on off on on stg 2 on reversing valve off off off off on on off loop pump on on on off on on on load pump off off off off off off on aux heater off off staged staged off off off acc relay ...

  • Page 26: Wiring Schematics

    26 synergy3d installation manual wiring schematics 208-230/60/1 ecm over-ride time sw3-4 sw3-5 5 minutes 15 minutes 30 minutes 60 minutes on off on off on on off off over-ride selection field selection dips - #1 on, #6 on, #7 on drain pan overflow lockout wcl thermister (loop high pressure lockout l...

  • Page 27: Wiring Schematics Cont.

    27 synergy3d installation manual wiring schematics cont. 208-230/60/1 ecm cont. Operation logic data stg1 stg2 stg3 emerg stg1 stg2 compressor on on on off on on stg 2 on reversing valve off off off off on on off loop pump on on on off on on on load pump off off off off off off on aux heater off off...

  • Page 28: Wiring Schematics Cont.

    28 synergy3d installation manual wiring schematics cont. 208-230/60/1 ecm with intellistart 240v l1 hp 240v l2 microprocessor logic control (dc voltage) p1 fused l2 c unit power 208-230/60/1 g ext pump 1/2 hp total 208-230/60/1 no cr2 com no nc cr4 com f1-10a 240v fused l2 no cr1 com blue(17) load p...

  • Page 29: Wiring Schematics Cont.

    29 synergy3d installation manual wiring schematics cont. 208-230/60/1 ecm with intellistart cont. Operation logic data stg1 stg2 stg3 emerg stg1 stg2 compressor on on on off on on stg 2 on reversing valve off off off off on on off loop pump on on on off on on on load pump off off off off off off on ...

  • Page 30: Unit Startup

    30 synergy3d installation manual unit startup before powering unit, check the following: • fuses, breakers and wire size are correct and match the name plate. • low voltage wiring is complete. • black/white and gray/white wires in unit control box have been removed if auxiliary heat has been install...

  • Page 31: Operating Parameters

    31 synergy3d installation manual synergy3d 1st stage operating parameters 038-072 forced air cooling forced air heating ewt °f water flow (gpm/ ton) suction pressure psig discharge pressure psig super-heat °f sub-cooling °f water temp rise °f air temp drop °f db suction pressure psig discharge press...

  • Page 32: Pressure Drop

    32 synergy3d installation manual 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 0.7 0.7 6 1.7 1.6 1.5 1.4 1.3 8 2.8 2.6 2.5 2.3 2.1 10 4.2 3.9 3.7...

  • Page 33: Compressor Resistance

    33 synergy3d installation manual compressor resistance thermistor resistance model compressor model no. 208-230/60/1 run start 038 zps30k5e-pfv 0.81 - 0.94 1.41 - 1.63 049 zps40k5e-pfv 0.48 - 0.55 1.72 - 1.99 064 zps51k5e-pfv 0.36 - 0.42 1.51 - 1.74 072 zps60k5e-pfv 0.31 - 0.36 1.72 - 1.98 9/24/2013...

  • Page 34: Heat of Extraction/rejection

    34 synergy3d installation manual heat of extraction/rejection model gpm heat of extraction (kbtuh) heat of rejection (kbtuh) 30°f 50°f 70°f 90°f 30°f 50°f 70°f 90°f 110°f 038 part load 4.0 18.5 25.1 30.9 34.8 33.5 32.1 6.0 12.0 19.1 26.4 32.8 29.4 34.9 33.6 32.1 30.4 8.0 12.9 20.1 27.1 32.8 29.8 35....

  • Page 35: Correction Factor Tables

    35 synergy3d installation manual correction factor tables heating capacity corrections ent air db °f heating corrections htg cap power heat of ext 45 1.062 0.739 1.158 50 1.050 0.790 1.130 55 1.037 0.842 1.096 60 1.025 0.893 1.064 65 1.012 0.945 1.030 68 1.005 0.976 1.012 70 1.000 1.000 1.000 75 0.9...

  • Page 36: Operating Limits

    36 synergy3d installation manual operating limits operating limits cooling heating °f °c °f °c air limits minimum ambient air 45 7.2 45 7.2 rated ambient air 80 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...

  • Page 37: Troubleshooting

    37 synergy3d installation manual standard microprocessor controls to check the unit control board for proper operation: 1. Disconnect thermostat wires at the control board. 2. Jumper the desired test input (y1, y2, w, o or g) to the r terminal to simulate a thermostat signal. To simulate a hot water...

  • Page 38

    38 synergy3d installation manual check one start up/check-out for new installation t troubleshooting problem:___________________________________ t 1. Flow rate in gpm (source side heat exchanger) water in pressure: a.______ psi water out pressure: b.______ psi pressure drop = a - b c.______ psi conv...

  • Page 39: Heating Cycle Analysis

    39 synergy3d installation manual heating cycle analysis cooling cycle analysis suction discharge compressor rv air coil source coax load coax dv sv open refrigerant charge compensator inactive circuit unit amp draw ____________ line voltage _________ loop:______ open ______ closed subcooling _______...

  • Page 40: Hot Water Cycle Analysis

    40 synergy3d installation manual hot water cycle analysis suction discharge compressor rv air coil source coax fd hw coax dv sv closed ina cti ve cir cu it refrigerant charge compensator ______psi = ______sat°f ______°f ______psi = ______sat°f ______°f ______°f liquid line unit amp draw ____________...

  • Page 41: Preventative Maintenance

    41 synergy3d installation manual water coil 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 recomm...

  • Page 42: Service Parts List

    42 synergy3d installation manual service parts list notes: part numbers subject to change. * hot water generator option does not include an internal pump or hw thermistor (12p505b02). A dpk5 will need to be ordered separately for the pump kit. Parts synergy3d dual capacity vertical units 038 049 064...

  • Page 43: Revision Guide

    43 synergy3d installation manual revision guide pages: description: date: by: 26-29,42 updated wiring schematic for auxiliary heat changes, etl logo, service parts list 14 april 2015 ma 4, 9 updated nomenclature hot water generation option, updated open loop solenoid valve connection option wiring d...

  • Page 44

    Manufactured by waterfurnace international, inc. 9000 conservation way fort wayne, in 46809 www.Waterfurnace.Com ©2015 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...