Johnson Controls RBS009, RBS012, RBS006, RBS015, RBS024 Engineering Manual

...

RB Series

Commercial

Water Source/Geothermal Heat Pump

• R-410A Refrigerant

• 0.5-6 Ton

Design Features Factory Options Accessories

RB Series Engineering Guide

Dimensional Data Physical Data Performance Data Engineering Guide Speciﬁ cations

Form: 146.07-EG2 (1018)

Supercedes: 146.07-EG1 (318)

Table of Contents

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

AHRI Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

The RB Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Inside the RB Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-14

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-19

Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22

Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-25

Vertical Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-27

Horizontal Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-29

RB SERIES ENGINEERING GUIDE

Hanger Bracket Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Electrical Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-35

Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36-39

Selection Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-41

Reference Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Legend and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Correction Factor Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45-65

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66-71

Engineering Guide Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72-74

Revision Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

RB SERIES ENGINEERING GUIDE

RB S

1-2 4 5-7 8 9 10

Model Type

RB – RB S eries

Operation Range

S – Single Stage

Cabinet Configuration

V – Vertical H - Horizontal

Unit Capacity (MBTUH)

006, 009, 012, 015,

018, 024, 030, 036, 041* (Vertical)

042, 048, 060, 070

Discharge Conf iguration

T – Top (Vertical)

E – End (Horizontal) S – Side (Horizontal)

Return Air Conf iguration

L – Left R – Right

Voltage

0 – 208-230/60/1 2 – 265-277/60/1 (018-036)

3 – 208-230/60/3 (024-070)

4 – 460/60/3 (024-070) 5 – 575/60/3 (PSC Only 042-070)

9 – 115/60/1 (006-012)

Future Option

0 – None

Blower Options

0 – PSC Blower

1 – Variable Speed ECM Blower (015-070)

4 – 5-Speed ECM Blower (015-070)

Water Coil Option

C – Copper N – CuproNickel

Sound Kit Option

A – None

B – Sound Kit (Not Available on H006-012 )

Future Option

N – None

Vintage

* – Factory Use Only

Non-Standard Options

SS – Standard

SA – Split Access Panel SB – Service Ports located to the front of the unit

SD – Split Access Panel and Service Ports located to

the front of the un it

Drain Pan Option

0 – Composite, No Secondary Connection 1 – Comp osite, Secondary Connection

2 – Stainless Steel, No Secondary Connection

3 – Stainless Steel, Secondary Connection

Cabinet Option

0 – Unpainted, 1 in MERV 4, Filter Rail

1 – Painted, 1 in MERV 4, Filter Rail

2 – Unpainted, 2 in MERV 13, Filter Rail 3 – Painted, 2 in MERV 13, Filter Rail

4 – Unpainted, 1 in ME RV 4, Filter Rack

5 – Painted, 1 in MERV 4, Filter Rack 6 – Unpainted, 2 in MERV 13, Filter Rack

7 – Painted, 2 in MERV 13, Filter Rack

Electrical Option

N – No Phase Guard, No Disconnect D – No Phase Guard, Di sconnect

P – Phase Guard, No Disconnect

B – Phase Gu ard, Disconnect

Air Coil O ption

5 – All-Aluminum, AlumiSealTM, Extended Range 6 – All-Aluminum, AlumiSeal, Standard Range

7 – All-Aluminum, No Coating, Extended Range

8 – All-Aluminum, No C oating, Standard Range

Co ntrol Option

A – Aurora

Base Control (ABC)

Z – AuroraTM with SMART Equipment DDC

Water Control Op tion

N – None

R – Water Flow Regulator (015-070) V – 2-Way Valve (015-070)

B – 2-Way Valve w/ Water Flow Regulator (015-070 )

W – Waterside Economizer

S – Waterside Ec onomizer w/ Water

Flow Regulator E – Waterside Economizer w/ 2-Way Valve

C – Waterside Economizer w/ 2-Way Valve &

Water Flow Regulator

11 12 13 15

V 036 T L 0 0 0 C A N14N16A

ype

igu

rizonta

(

030

)

060

(

tic

d(Horiz

(

Horiz

onf

518N19020021SS

22-23*24

(

006

012

)

Note: Phase Guard Only Available on 208-230/60/3 and 460/60/3

50VA Transformer with Aurora and 75VA Transformer with SMART Equipment

Waterside economizer option must be ordered with stai nless steel drain pan and either 5-speed ECM or variable speed ECM (024-070) *2 way valve, water flow regulator, economizer, disconnect, 2" filter and filter rack not available in RBSV041.

Model Nomenclature

B Ser

n Ra

le St

Conf

acit

e Co

ir C

rtical

Ver

ion

ration

rtical

Only

d ECM Blower 157

Blower

Not Available on

All RB Series product is safety listed under UL1995 thru ETL and performance listed with AHRI in accordance with standard 13256-1.

AHRI Data

PSC Motors

AHRI/ASHRAE/ISO 13256-1 English (IP) Units

AHRI 500* Water Loop Heat Pump Ground Water Heat Pump Ground Loop Heat Pump

Flow Rate

Model

gpm cfm

006

2.0 250 16.7 16.3 7,100 13.4 8,000 4.3 8,400 21.3 6,800 3.8 7,400 15.5 5,400 3.2

009

3.0 350 15.3 16.2 8,100 12.2 11,400 4.6 9,900 19.2 9,600 4.0 8,900 14.5 7,600 3.4

012

3.0 400 14.7 15.5 10,200 12.2 15,200 4.4 12,200 18.2 12,600 3.9 11,200 14.2 10,200 3.5

015

4.0 500 16.0 16.4 13,200 12.5 15,400 4.5 16,000 20.0 13,000 4.0 14,000 15.3 10,400 3.2

018

5.0 600 16.3 16.1 17,300 13.4 19,000 4.3 19,800 20.5 16,000 3.7 18,000 15.4 12,600 3.2

024

6.0 800 15.7 16.3 22,900 13.0 26,000 4.5 27,000 19.8 22,600 4.0 24,500 14.8 17,000 3.3

030

8.0 1000 16.8 16.7 28,400 13.8 34,000 4.5 33,500 21.0 28,000 4.0 30,000 16.0 21,000 3.3

036

9.0 1150 17.3 17.3 34,500 14.0 43,800 4.7 40,000 22.0 35,600 4.2 36,000 16.3 26,000 3.3

041

11.0 1100 16.1 16.0 37,600 13.5 48,000 4.3 44,500 20.4 38,500 3.8 40,000 15.0 28,500 3.2

042

11.0 1400 16.1 16.8 39,200 13.2 51,000 4.7 47,000 20.4 41,400 4.3 42,000 15.2 30,500 3.3

048

12.0 1600 16.3 16.5 47,200 13.0 59,000 4.6 57,000 19.8 48,000 4.0 49,500 15.0 36,500 3.3

060

15.0 1900 16.4 16.2 57,000 13.5 66,000 4.3 67,000 21.0 55,000 4.0 58,000 15.2 43,000 3.3

070

18.0 2100 16.4 16.5 66,000 14.0 80,000 4.5 75,000 20.5 64,000 4.0 68,000 15.6 49,000 3.3

Cooling capacities based upon 80.6°F DB, 66.2°F WB entering air temperature Heating capacities based upon 68°F DB, 59°F WB entering air temperature All ratings based upon 208V operation

IEER SCHE

EER

Btuh/W

COP

Cooling

EWT 86°F

Capacity

Btuh

EER

Btuh/W

H e a t i n g

EWT 68°F

Capacity

Btuh

COP

Cooling

EWT 59°F

Capacity

Btuh

EER

Btuh/W

H e a t i n g

EWT 50°F

Capacity

Btuh

RB SERIES ENGINEERING GUIDE

COP

Cooling

EWT 77°F

Capacity

Btuh

EER

Btuh/W

H e a t i n g

EWT 32°F

Capacity

Btuh

COP

8/9/18

Variable Speed ECM, 5 Speed ECM motor

AHRI/ASHRAE/ISO 13256-1 English (IP) Units

Flow Rate

Model

gpm cfm

006 2.0 250 17.2 16.7 7,150 14.0 8,500 4.4 8,600 22.0 7,100 4.0 7,600 16.0 5,500 3.2 009 3.0 350 16.7 17.3 8,300 13.4 11,500 4.8 10,300 22.0 9,600 4.1 9,100 15.0 7,600 3.4

012 3.0 400 15.9 16.3 10,300 13.0 14,500 4.5 12,800 20.0 11,900 4.0 11,300 15.0 10,200 3.5

015 4.0 500 16.6 16.9 13,800 13.2 16,100 4.6 16,000 21.0 13,400 4.1 14,200 15.7 11,000 3.3 018 5.0 600 17.3 17.0 17,300 14.2 19,000 4.5 19,800 22.0 16,000 3.9 18,000 16.2 12,600 3.3 024 6.0 800 16.5 17.0 22,900 13.6 26,000 4.7 27,000 20.8 22,600 4.2 24,500 15.6 17,000 3.5

030 8.0 900 17.9 17.6 28,400 14.7 34,000 4.7 33,500 22.5 28,000 4.2 30,000 17.0 21,000 3.5

036 9.0 1150 18.1 18.1 34,500 14.5 43,800 4.9 40,000 23.0 35,600 4.4 36,000 17.0 26,000 3.5 041 11.0 1300 16.8 17.1 39,000 13.9 48,500 4.7 45,000 21.0 38,500 4.1 41,000 16.0 28,500 3.4 042 11.0 1400 17.5 17.8 39,200 14.2 51,000 4.9 47,000 22.0 41,400 4.5 42,000 16.6 30,500 3.5 048 12.0 1600 16.8 17.3 47,200 14.0 59,000 4.8 57,000 21.0 48,000 4.2 49,500 16.0 36,500 3.5

060 15.0 1900 17.2 17.1 57,000 14.0 66,000 4.6 67,000 22.0 55,000 4.2 58,000 16.0 43,000 3.5

070 18.0 2100 17.5 17.4 66,000 14.6 80,000 4.7 75,000 22.0 64,000 4.2 68,000 16.6 49,000 3.5

Cooling capacities based upon 80.6°F DB, 66.2°F WB entering air temperature Heating capacities based upon 68°F DB, 59°F WB entering air temperature All ratings based upon 208V operation

The purpose of this standard is to establish an IEER and SCHE Method of Calculation for Water/Brine Source Heat Pumps. This standard utilizes the Published, Certiﬁ ed Data, of performance standard ISO/AHRI/ANSI/ASHRAE 13256-1:1998, and includes the deﬁ nitions; rating requirements; minimum data requirements for Published Ratings; marking and nameplate data; and conformance conditions required.

AHRI 500* Water Loop Heat Pump Ground Water Heat Pump Ground Loop Heat Pump

IEER SCHE

EER

Btuh/W

COP

Cooling

EWT 86°F

Capacity

Btuh

EER

Btuh/W

H e a t i n g

EWT 68°F

Capacity

Btuh

COP

Cooling

EWT 59°F

Capacity

Btuh

EER

Btuh/W

H e a t i n g

EWT 50°F

Capacity

Btuh

COP

Cooling

EWT 77°F

Capacity

Btuh

EER

Btuh/W

Capacity

H e a t i n g

EWT 32°F

Btuh

8/9/18

COP

RB SERIES ENGINEERING GUIDE

AHRI Data cont.

The performance standard AHRI/ASHRAE/ISO 13256-1 became effective January 1, 2000 and replaces AHRI Standards 320, 325, and

330. This new standard has three major categories: Water Loop (comparable to ARI 320), Ground Water (ARI 325), and Ground Loop (ARI

330). Although these standards are similar there are some differences:

Unit of Measure: The Cooling COP

The cooling efficiency is measured in EER (US version measured in Btu/h per Watt. The Metric version is measured in a cooling COP (Watt per Watt) similar to the traditional COP measurement.

Water Conditions Differences

Entering water temperatures have changed to reflect the centigrade temperature scale. For instance the water loop heating test is performed with 68°F (20°C) water rounded down from the old 70°F (21.1°C).

Air Conditions Differences

Entering air temperatures have also changed (rounded down) to reflect the centigrade temperature scale. For instance the cooling tests are performed with 80.6°F (27°C) dry bulb and 66.2°F (19°C) wet bulb entering air instead of the traditional 80°F (26.7°C) DB and 67°F (19.4°C) WB entering air temperatures. 80.6/66.2 data may be converted to 80/67 using the entering air correction table. This represents a significantly lower relative humidity than the old 80/67 of 50% and will result in lower latent capacities.

Pump Power Correction Calculation

Within each model, only one water flow rate is specified for all three groups and pumping Watts are calculated using the following formula. This additional power is added onto the existing power consumption.

• Pump power correction = (gpm x 0.0631) x (Press Drop x 2990) / 300 Where ‘gpm’ is waterflow in gpm and ‘Press Drop’ is the pressure drop through the unit heat exchanger at rated water flow in feet of head.

Blower Power Correction Calculation

Blower power is corrected to zero external static pressure using the following equation. The nominal airflow is rated at a specific external static pressure. This effectively reduces the power consumption of the unit and increases cooling capacity but decreases heating capacity. These Watts are significant enough in most cases to increase EER and COPs fairly dramatically over ARI 320, 325, and 330 ratings.

• Blower Power Correction = (cfm x 0.472) x (esp x 249) / 300 Where ‘cfm’ is airflow in cfm and ‘esp’ is the external static pressure at rated airflow in inches of water gauge.

ISO Capacity and Efficiency Calculations

The following equations illustrate cooling calculations:

• ISO Cooling Capacity = Cooling Capacity (Btu/h) + (Blower Power Correction (Watts) x 3.412)

• ISO EER Efficiency (W/W) = ISO Cooling Capacity (Btu/h) x 3.412 / [Power Input (Watts) - Blower Power Correction (Watts) + Pump Power Correction (Watt)] The following equations illustrate heating calculations:

• ISO Heating Capacity = Heating Capacity (Btu/h) - (Blower Power Correction (Watts) x 3.412)

• ISO COP Efficiency (W/W) = ISO Heating Capacity (Btu/h) x 3.412 / [Power Input (Watts) - Blower Power Correction (Watts) + Pump Power Correction (Watt)]

Comparison of Test Conditions

ARI 320

Cooling

Entering Air - DB/WB °F 80/67 80.6/66.2 80/67 80.6/66.2 80/67 80.6/66.2 Entering Water - °F 85 86 50/70 59 77 77 Fluid Flow Rate * ** ** ** ** **

Heating

Entering Air - DB/WB °F 70 68 70 68 70 68 Entering Water - °F 70 68 50/70 50 32 32 Fluid Flow Rate * ** ** ** ** **

Note *: Flow rate is set by 10°F rise in standard cooling test Note **: Flow rate is specified by the manufacturer

Part load entering water conditions not shown. WLHP = Water Loop Heat Pump; GWHP = Ground Water Heat Pump; GLHP = Ground Loop Heat Pump

Conversions:

Airflow (lps) = cfm x 0.472; Water Flow (lps) = gpm x 0.0631; esp (Pascals) = esp (in wg) x 249; Press Drop (Pascals) = Press Drop (ft hd) x 2990

ISO/AHRI

13256-1

WLHP

ARI 325

ISO/AHRI

13256-1

GWHP

ARI 330

ISO/AHRI

13256-1 GLHP

RB SERIES ENGINEERING GUIDE

The RB Series

The RB Series raises the bar for boiler/tower applications by providing ﬂ exibility and efﬁ ciency into a compact cabinet at a competitive price. A compact cabinet is important when choosing a replacement heat pump. Many water source heat pumps of the 1980-90’s were relatively low efﬁ ciency models with a small footprint. Once they are installed in a building and piping and ductwork is piped around the unit replacement with a larger footprint is nearly impossible. The RB Series combines the high efﬁ ciency of 21 pump for easy replacement. The chart below shows a comparison of a typical 1980 legacy wshp and current competitor data versus the RB Series.

Year WaterSource Heat Pump

3 Ton Horizontal WSHP

1980 Typical Legacy Unit 11.6/- 21.0 20.2 41.2 2018 Competitor A Compact Unit 14.2/- 19.0 22.0 54.5 2018 Competitor B Compact Unit 13.5/14 21.0 20.1 47.1 2018 Competitor C Compact Unit 13.7/- 19.0 25.0 50.0 2018 RB Series 14/14.5 19.2 22.5 42.0

4 Ton Horizontal WSHP

1980 Typical Legacy Unit 10.4/- 21.0 27.2 46.2 2018 Competitor A Compact Unit 13/- 21.0 25.0 54.5 2018 Competitor B Compact Unit 13.3/14.2 21.0 24.1 54.1 2018 Competitor C Compact Unit 13.13/- 21.0 33.0 58.0 2018 RB Series 13/14 19.2 22.5 45.0

WLHP EER (PSC/ECM)

This full range product offers all the standard commercial voltages using high efﬁ ciency rotary and scroll compressors along with either 3-speed permanent split-capacitor (PSC), 5-speed ECM, or variable speed ECM blower motors.

century product in a footprint that matches a 1980 heat

Height

[in.]

Width

[in.]

Length

[in.]

RB Series Highlights

• High efﬁ ciency performance

- With PSC Blower Motor Up to 14.0 EER and 4.7 COP (ISO/AHRI 13256-1-WLHP)

- With Variable Speed ECM Blower Motor Up to 14.7 EER and 4.9 COP (ISO/AHRI 13256-1-WLHP)

- With 5-Speed ECM Blower Motor Up to 14.7 EER and 4.9 COP (ISO/AHRI 13256-1-WLHP)

• Unrivaled cabinet footprint that can ﬁ t most application requirements

- A four ton horizontal unit less than four feet long means the smallest horizontal cabinets in the industry!

• All-Aluminum riﬂ ed tube-and-ﬁ n air coils are not susceptible to formicary corrosion.

• Dedicated 460V 5-Speed ECM does not require use of a neutral!

• Aurora Base microprocessor control capable of operating 5-speed ECM or variable speed ECM with internally mounted 2-way valve

• Flexible factory installed options

- Corrosion-proof composite or stainless steel drain pan; including internally mounted secondary drain connection option

- Copper or cupronickel heat exchanger and optional low temperature insulation

- Filter options: standard 1 in. MERV 4 or option 2 in. MERV 13 with either ﬁ lter rails or option deluxe four sided ﬁ lter rack that is ﬁ eld switchable between 1 in. and 2 in.

- Aurora Base Control FEC 2611 with N2, LonWorks, or BACnet cards

- Factory mounted internal water valve and/or ﬂ ow regulator for variable speed pumping systems saves on installation costs

- Other options: Sound Kit, Coated Air Coil, Phase Guard, Internally Mounted Non-fused Power Disconnect

Vertical RB Series

Models RBSV 006-070 (0.5-6 tons) Single Speed

Horizontal RB Series

Models RBSH 006-070 (0.5-6 tons) Single Speed

RB SERIES ENGINEERING GUIDE

The RB Series cont.

Product Features: Vertical Cabinet

Versatec Compact vertical units are designed for high efficiency, maximum flexibility, and primary servicing from the front.

deluxe filter rack (shown), field

Oversized rifled tube/lanced fin

all-aluminum air coil (optional

Corrosion-resistant, composite

protection, optional secondary

Optional stainless steel drain

pan with overflow protection,

t Features: Vertical Cabinet

ompact vertical units are designed for high efficiency, maximum flexibility, and primary servicing from the front.

Standard filter rail, field

switchable for 1 in. or

2 in. filters

Optional factory mounted

switchable for 1 in. or

2 in. filters

AlumiSeal

drain pan with overflow

optional secondary drain

coil coating).

drain connection

connection

Removable inlet rings for easy blower removal

Insulated divider panel

Optional ThermaShield coated coaxial heat exchanger

High efficiency rotary or scroll compressor

Internally trapped condensate line

Microprocessor control

Aurora - Standard

Smart Equipment

Controls - Optional

Fault and status LEDs (

Base Control only

AID Tool for diagnosing

and controlling the Aurora

Aurora

)

control

A true left and right return option is available.

Fault and status LEDs (

Base Control only

)

Aurora

RB SERIES ENGINEERING GUIDE

The RB Series cont.

Product Features: Horizontal Cabinet

Horizontal units are designed for compact installation, maximum flexibility, and primary servicing from the front.

Oversized rifled tube/lanced fin all-

aluminum air coil

(optional AlumiSeal coil coating).

Optional factory mounted filter rail accepts 1 in. and 2 in. filters (field

switchable)

Fault and diagnostic

LEDs (Aurora Base

Control only)

High efficiency rotary or

Microprocessor control

ABC - Standard

Smart Equipment

Controls - Optional

Four blower deck options are available. Factory or field conversion option of end or side discharge using switchable access panels and a factory only option of true left or right return air coil.

Easily removable control box

scroll compressor

Smallest Cabinet in Industry

Optional ThermaShield coated coaxial heat exchanger

Left hand return with

end discharge

Left hand return with

side discharge

Right hand return

with end discharge

Right hand return

with side discharge

RB SERIES ENGINEERING GUIDE

The RB Series cont.

Flexible Product with Several Standard Options

• Compact cabinet design, vertical and horizontal with true left and right return configurations

• Horizontal end and side discharge with vertical top discharge air configurations

• Capacities of 18,000 through 70,000 Btu/h

• All commercial voltages including 208-230/60/1, 265-277/60/1, 208-230/60/3, 460/60/3, and 575/60/3.

• 3 speed PSC, 5-Speed ECM, or optional Variable Speed ECM blower motors

• AlumiSeal coated air coils

• Extended range insulation option

• Super Quiet Sound Package, including multi-density compressor blanket

• Quiet rotary scroll compressors

• 2-dimension refrigerant piping vibration loops to isolate

the compressor

• Discharge mufflers on sizes 048-070

• Heavy gauge cabinet and 4 vibration isolating hanger brackets

• Internally mounted water flow regulator and/or water solenoid valve for variable speed pumping systems

• Standard Aurora Base Control or FEC 2611 Control with optional N2, Lonworks, or BACnet DDC cards

• Phase guard with optional ‘dial’ disconnect

• Polymer composite drain pan or stainless steel drain pan with optional secondary drain connection

• 1 in. MERV 4 or 2 in. MERV 13 filters

Indoor Air Quality (IAQ)

All units feature several IAQ benefits:

• Corrosion-free composite double-sloped drain pan to eliminate standing water and prevent bacterial growth

• A washable surface on insulation in all air handler compartments to allow cleanability and inhibit bacteria growth. Optional nonfibrous closed cell insulation is also available for more sensitive applications by special request through commercial sales..

• Open filter rail comes standard for non-ducted return applications. Filter rail is field switchable from 1 in. to 2 in. [2.54 to 5.1 cm] for more filter options.

• Optional factory mounted, four sided, deluxe filter rack that is field switchable from 1 in. to 2 in. [2.54 to 5.1 cm] is available for ducted return applications.

• Standard supplied filter is a pleated MERV 4, 1 in. [2.54 cm]. An optional low static high efficiency 2 in. [5.1 cm] MERV 13, for LEED certification points, is also available.

Other options are available by special request through sales.

High Efficiency

The RB Series is a high efficiency water source heat pump in a compact vertical and horizontal cabinet. The product features highly efficient and reliable single capacity rotary scroll compressors mated with large blowers. These blowers are driven by efficient 3 speed PSC blower motors, 5-Speed ECM blower motors, or highly efficient Variable Speed ECM blower motors.

Quiet Operation

All RB Series product incorporates several noise reduction technologies and is ARI 260 sound rated using third party sound testing. Room Noise Criteria Curves (NC Curve) may be calculated using data from the ARI 260 ratings giving the engineer total flexibility in assuring a quiet environment. Please refer to the separate Sound Ratings and Performance Catalog concerning this standard and RB Series sound performance data.

Super Quiet Option

An optional Super Quiet Sound Package is also available for a modest cost and features multi-density laminate lined compressor blanket designed to completely surround the compressor and suppress low frequency noise.

Flexible Control Options

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. Aurora uses the Modbus communication protocol to communicate between modules. Each module contains the logic to control all features that are connected to the module. The Aurora Base Control (ABC) has two Modbus channels. The first channel is configured as a master for connecting to devices such as a communicating thermostat, expansion board, or other satellite devices. The second channel is configured as a satellite for connecting the Aurora Interface Diagnostic Tool (AID Tool).

The Aurora Interface and Diagnostics (AID) Tool is a device that is a member of the Aurora network. The AID tool is used to troubleshoot equipment which uses the Aurora control via Modbus RTU communication. The AID tool provides diagnostics, fault management, ECM setup, and system configuration capabilities to the Aurora family.

Aurora Base Control

and AID Tool

The RB Series cont.

RB SERIES ENGINEERING GUIDE

Internally Mounted Solenoid Valve Option

When variable speed circulating pump systems are designed, low pressure drop (high Cv) solenoid valves are specified at each unit to vary the pump according to flow required. It is important that these valves be low pressure drop to avoid unwanted pump watts. This option factory installs this valve inside the unit.

Secondary Drain Connection Option

Some local building authority’s interpretation of codes require more condensate overflow protection than standard microprocessor based condensate sensors offer. In these areas a full secondary drain pan might be required causing both increased cost and unit service access issues. In many of these cases a secondary drain connection option can be added to the unit to pass this local interpretation of condensate drain redundancy. This option adds a second PVC drain connection to the drain pan at a higher level.

Phase Guard

Factory mounted phase guard device is available to protect the compressor against loss of phase.

Factory Quality

• All refrigerant brazing is performed in a nitrogen environment.

• Computer controlled deep vacuum and refrigerant charging system.

• All joints are leak detected for maximum leak rate of less than 1/4 oz. per year.

• Computer bar code equipped assembly line ensures all components are correct.

• All units are computer run-tested with water to verify both function and performance.

Disconnect

An optional factory mounted, internally wired disconnect is available to avoid scheduling problems with the electrical contractor. Other features include:

• Non-fused, ‘dial’ type switch with “on/off” position

• Compact design

• “Lockout/Tagout” feature to keep the unit “off” during service

Low Ceiling Height Requirement (Horizontal 006-012)

Utilizing a raised drain pan, the condensate drain trap on horizontal models 006 through 012 can be made within the height of the cabinet. This allows the RB Series to be installed without any additional ceiling height, or in areas where ceiling height is at a premium. The RB Series 006-012 models have the lowest ceiling height installation requirements of any AHRI listed manufacturer.

RB SERIES ENGINEERING GUIDE

Inside the RB Series

Refrigerant

All units feature zero ozone depletion and low global warming potential refrigerant R-410A.

Cabinet

All units are constructed of corrosion resistant galvanized sheet metal. One large lift-out access panel provides access to the compressor and air handler section to allow servicing of blower motor, blower, and drain pan. Refrigerant circuit is designed to allow primary serviceability from the front. Six (6) horizontal and six (6) vertical cabinets are provided for application flexibility. The blower motor and blower can be completely serviced or replaced without removal of the unit. Service of the blower and blower motor is made easier via the removable orifice ring on the housing.

Flexible configurations include four (4) blower deck options for horizontals and a true left and right return on both horizontal and vertical.

Filter Rack

All units come standard with an open filter rail, for use in open return applications, or an optional deluxe filter rack/duct collar for use with ducted returns. Both filter options are field switchable between 1 in. [2.54 cm] and 2 in. [5.1 cm] thick filters for filter flexibility. A MERV 4, 1 in. [2.54 cm] is standard with an optional 2 in. [5.1 cm] MERV 13 for LEED certification points and high efficiency filtration.

Horizontal Hanger Kits

Each horizontal unit includes a hanger kit to meet seismic specification requirements while still allowing filter access.

Drain Pan

All condensate connections are PVC glue for economical corrosion free connections. Bacteria resistant composite drain pan is sloped to promote complete drainage and will never rust or corrode. Complete drainage helps to inhibit bacterial or microbial growth. Vertical units feature an internally trapped condensate line using clear PVC hose for easy inspection and reduced installation cost. Optional factory installed stainless steel drain pans are also available.

Electrical Box

Unit controls feature quick connect wiring harnesses for easy servicing. Separate knockouts for low voltage and two sides of the electrical corner post for easy access to the control box. 50VA or large 75VA transformer assures adequate controls power for accessories.

Compressors

High efficiency R-410A reciprocating compressors are used on every model. Reciprocating compressors provide both high efficiency and great reliability.

Inside the RB Series cont.

RB SERIES ENGINEERING GUIDE

Air Handler Insulation

Washable air handler insulation surface provides cleanability to further enhance IAQ.

Thermostatic Expansion Valve

All units utilize a balanced port bidirectional thermostatic expansion valve (TXV) for refrigerant metering. This allows precise refrigerant flow in a wide range of entering water variation (20 to 120°F [-7 to 49°C]) found in geothermal systems. The TXV is located in the compressor compartment for easy access.

Service Connections and Serviceability

Two Schrader service ports are provided in every unit. The suction side and discharge side ports are for field charging and servicing access. All valves are 7/16 in. SAE connections. All water and electrical connections are made from the front of the unit. Unit is designed for front access serviceability.

4-Way Reversing Valve

All units feature a reliable all-brass pilot operated refrigerant reversing valve. The reversing valve operation is limited to change of mode by the control to enhance reliability.

Water-to-Refrigerant Coaxial Heat Exchanger Coil

Coaxial refrigerant to water heat exchangers provide unparalleled efficiency. The coaxes are designed for low pressure drop and low flow rates. All coaxes are pressure rated to 450 psi water side and 600 psi on the refrigerant side. Optional ThermaShield coating is available on the water-to-refrigerant heat exchanger to prevent condensation in low temperature loop operation.

All-Aluminum Air Coil

These air coils are constructed of lanced fin and rifled tube aluminum that is not susceptible to formicary corrosion. For additional condensate runoff and meeting project specifications, an optional AlumiSeal e-coating is available.

RB SERIES ENGINEERING GUIDE

Inside the RB Series cont.

Blower Motor and Housing

High efficiency low rpm galvanized direct drive blower featuring 3 speed permanently split capacitor (PSC) motor, 5-Speed ECM motor, and optional Variable Speed ECM blower motor. The Variable Speed ECM motor is controlled directly through the unit's microprocessor control. The lower rpm blower also reduces air noise. All PSC and 5-Speed ECM motors have speed selection terminal strip on the motor for easy speed change. All motors are vibration isolated to reduce noise. Horizontal units can be field converted from end to side discharge as well.

NOTE: 460V 5-Speed ECM blower motor does not require a neutral wire.

5-Speed ECM Constant Torque Motors

The 5-Speed ECM is a ‘Constant Torque’ ECM motor and delivers airflow similar to a PSC but operates as efficiently as an Variable Speed ECM motor. Because it’s an ECM motor, the 5-Speed ECM can ramp slowly up or down like the Variable Speed ECM motor. There are 5 possible speed taps available on the 5-Speed ECM motor with #1 being the lowest airflow and #5 being the highest airflow. These speed selections are preset at the time of manufacture and are easily changed in the field if necessary.

5-Speed ECM Benefits:

- High efficiency

- Soft start

- 5 speeds with up to 4 speeds on-line

- Built in logic allows air flow to change with G, Y1, Y2 and W signals

- Super efficient low airflow continuous blower setting (G)

RB SERIES ENGINEERING GUIDE

Controls

Aurora Base Control

Control General Description Application Display/Interface Protocol

Aurora Base Control The ABC microprocessor provides all the features

necessary to operate today's standard WSHPs that utilize dual capacity compressors and Variable Speed ECM/5-Speed ECM blower motors with hot gas reheat. This control can communicate to a handheld diagnostic tool to help the installing contractor or service technician with equipment setup and service. By utilizing Modbus RTU communication protocol, the ABC board can communicate with additional devices on the Aurora network.

Used for residential and commercial applications that use single or dual capacity compressors with PSC, 5-Speed ECM, or Variable Speed ECM blower motors. This base control can also communicate to the AID Tool to display faults, inputs/outputs, and software revision. Commercial features such as hot gas reheat, slow opening water valve, and random start are also capable with the ABC board.

Optional AID Tool can be used for field service.

Standalone

RB SERIES ENGINEERING GUIDE

Controls - Aurora Base Control

Aurora ‘Base’ Control

Field Selectable Options via Hardware

DIP Switch (SW1) – Test/Configuration Button (See SW1

Operation Table)

Test Mode

The control is placed in the test mode by holding the push button switch SW1 for 2 - 5 seconds. In test mode most of the control timings will be shortened by a factor of sixteen (16). LED3 (green) will flash at 1 second on and 1 second off. Additionally, when entering test mode LED1 (red) will

NOTE: Refer to the Aurora Base Control Application and Troubleshooting Guide and the Instruction Guide: Aurora Interface and Diagnostics (AID) Tool for additional information.

flash the last lockout one time. Test mode will automatically time out after 30 minutes. Test mode can be exited by pressing and holding the SW1 button for 2 to 5 seconds or by cycling the power. NOTE: Test mode will automatically be exited after 30 minutes.

Control Features

oftware ABC Standard Version 3.0

Single or Dual Capacity Compressors

Either single or dual capacity compressors can be operated.

Variable Speed ECM Blower Motor Option (If Applicable)

A Variable Speed ECM blower motor can be driven directly using the onboard PWM output. Four blower speeds are available based upon the G, Y1, Y2, and W input signals to the board. The blower speeds can be changed either by the ECM manual configurations mode method or by using the Aurora AID Tool directly. All four blower speeds can be set to the same speed if desired.

5-Speed ECM Blower Motor Option (If Applicable)

A 5-Speed ECM blower motor will be driven directly using the thermostat connections. Any of the G, Y1, or Y2/W signals can drive any of the 5 available pre-programmed blower speeds on the motor. All 5 Series "G" vintage units will be wired this way at the factory.

Other Control Features

• Random start at power up

• Anti-short cycle protection

• High and low pressure cutouts

• Loss of charge

• Water coil freeze detection

• Air coil freeze detection

• Over/under voltage protection

• Condensate overflow sensor

• Load shed

• Dehumidification (where applicable)

• Emergency shutdown

• Hot gas reheat operation (where applicable)

• Diagnostic LED

• Test mode push button switch

• Two auxiliary electric heat outputs

• Alarm output

• Accessory output with N.O. and N.C.

• Two Modbus communication Ports

Variable Speed ECM Configuration Mode (If Applicable)

The control is placed in the ECM configuration mode by holding the pushbutton switch SW1 for 5 to 10 seconds, the high, low, and “G” ECM speeds can be selected by following the LED display lights. LED2 (yellow) will fast flash when entering the ECM configuration. When setting “G” speed LED3 (green) will be continuously lit, for low speed LED1 (red) will be continuously lit, and for high speed both LED3 (green) and LED1 (red) will be continuously lit. During the ECM configuration mode LED2 (yellow) will flash each of the 12 possible blower speeds 3 times. When the desired speed is flashed press SW1, LED2 will fast flash until SW1 is released. “G” speed has now been selected. Next select low speed, and high speed blower selections following the same process above. After third selection has been made, the control will exit the ECM configuration mode. Aux fan speed will remain at default or current setting and requires the AID Tool for adjustment.

Reset Configuration Mode

The control is placed in reset configuration mode by holding the push button switch SW1 for 50 to 60 seconds. This will reset all configuration settings and the EEPROM back to the factory default settings. LED3 (green) will turn off when entering reset configuration mode. Once LED3 (green) turns off, release SW1 and the control will reset.

DIP Switch (SW2)

SW2-1 FP1 Selection – Low water coil temperature limit

setting for freeze detection. On = 30°F; Off = 15°F.

SW2-2 FP2 Selection – On = 30°F; Off = N/A 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 Operation SW2-4 SW2-5

Cycle with Blower ON ON

Cycle with Compressor OFF OFF

Water Valve Slow Opening ON OFF

Cycle with Comm. T-stat Hum Cmd OFF ON

Controls - Aurora Base Control cont.

RB SERIES ENGINEERING GUIDE

Cycle with Blower - The accessory relay will cycle with the blower output.

Cycle with Compressor - The accessory relay will cycle with the compressor output.

Water Valve Slow Opening - The accessory relay will cycle and delay both the blower and compressor output for 90 seconds.

SW2-6 CC Operation – selection of single or dual capacity

compressor. On = Single Stage; Off = Dual Capacity

SW2-7 Lockout and Alarm Outputs (P2) – selection of a

continuous or pulsed output for both the LO and ALM Outputs. On = Continuous; Off = Pulsed

SW2-8 Future Use

Alarm Jumper Clip Selection

From the factory, ALM is connected to 24 VAC via JW2. By cutting JW2, ALM becomes a dry contact connected to ALG.

Variable Speed ECM Blower Speeds

The blower speeds can be changed either by using the ECM manual configurations mode method or by using the Aurora AID Tool directly (see Instruction Guide: Aurora Interface and Diagnostics (AID) Tool topic).

Field Selectable Options via Software

(Selectable via the Aurora AID Tool)

ECM Blower Speeds

An ECM blower motor can be driven directly using the onboard PWM output. Four blower speeds are available, based upon the “G”, Y1 (low), Y2 (high), and Aux input signals to the board. The blower speeds can be changed either by the ECM manual configurations mode method (see ECM Configuration Mode topic) or by using the Aurora AID Tool directly. All four blower speeds can be set to the same speed if desired. Aux blower speed will remain at default or current setting and requires the AID Tool for adjustment.

Lockout – when locked out, the blower will operate continuously in “G” speed, and PSC blower motor output will remain on. The Alarm output (ALM) and Lockout output (L) will be turned on. The fault type identification display LED1 (Red) shall flash the fault code. To reset lockout conditions with SW2-8 On, thermostat inputs “Y1”, “Y2”, and “W” must be removed for at least 3 seconds. To reset lockout conditions with SW2-8 Off, thermostat inputs “Y1”, “Y2”, “W”, and “DH” must be removed for at least 3 seconds. Lockout may also be reset by turning power off for at least 30 seconds or by enabling the emergency shutdown input for at least 3 seconds.

Lockout With Emergency Heat - if the control is locked out in the heating mode, and a Y2 or W input is received, the control will operate in the emergency heat mode while the compressor is locked out. The first emergency heat output will be energized 10 seconds after the W input is received, and the blower will shift to high speed. If the control remains locked out, and the W input is present, additional stage of emergency heat will stage on after 2 minutes. When the W input is removed, all of the emergency heat outputs will turn off, and the ECM blower will shift to “G” speed and PSC blower motor output will remain on.

High Pressure – fault is recognized when the Normally Closed High Pressure Switch, P4-9/10 opens, no matter how momentarily. The High Pressure Switch is electrically in series with the Compressor Contactor and serves as a hardwired limit switch if an overpressure condition should occur.

Low Pressure - fault is recognized when the Normally Closed Low Pressure Switch, P4-7/8 is continuously open for 30 seconds. Closure of the LPS any time during the 30 second recognition time restarts the 30 second continuous open requirement. A continuously open LPS shall not be recognized during the 2 minute startup bypass time.

Loss of Charge – fault is recognized when the Normally Closed Low Pressure Switch, P4-7/8 is open prior to the compressor starting.

Safety Features

The following safety features are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions.

Fuse – a 3 amp automotive type plug-in fuse provides protection against short circuit or overload conditions.

nti-Short Cycle Protection – 4 minute anti-short cycle

protection for the compressor.

Random Start – 5 to 80 second random start upon power up.

Fault Retry – in the fault condition, the control will stage off the outputs and then “try again” to satisfy the thermostat Y input call. Once the thermostat input calls are satisfied, the control will continue on as if no fault occurred. If 3 consecutive faults occur without satisfying the thermostat Y input call, then the control will go to Lockout mode.

Condensate Overflow - fault is recognized when the impedance between this line and 24 VAC common or chassis ground drops below 100K ohms for 30 seconds continuously.

Freeze Detection (Coax) - set points shall be either 30°F or 15°F. When the thermistor temperature drops below the selected set point, the control shall begin counting down the 30 seconds delay. If the thermistor value rises above the selected set point, then the count should reset. The resistance value must remain below the 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 (Air Coil) - uses the FP2 input to protect against ice formation on the air coil. The FP2 input will operate exactly like FP1 except that the set point is 30 degrees and is not field adjustable.

RB SERIES ENGINEERING GUIDE

Controls - Aurora Base Control cont.

Over/Under Voltage Shutdown - An over/under voltage condition exists when the control voltage is outside the range of 18 VAC to 30 VAC. If the over/under voltage shutdown lasts for 15 minutes, the lockout and alarm relay will be energized. Over/under voltage shutdown is selfresetting in that if the voltage comes back within range of 18 VAC to 30 VAC for at least 0.5 seconds, then normal operation is restored.

Operation Description

Power Up - The unit will not operate until all the inputs and safety controls are checked for normal conditions. The unit has a 5 to 80 second random start delay at power up. Then the compressor has a 4 minute anti-short cycle delay after the random start delay.

tandby In standby mode, Y1, Y2, W, DH, and G are not active. Input O may be active. The blower and compressor will be off.

Heating Operation

ingle Compressor Heating, 2nd Stage (Y1, Y2) The compressor will be staged to full capacity 20 seconds after Y2 input is received. The ECM blower will shift to high speed seconds after the Y2 input is received.

Dual Compressor Heating, 2nd Stage (Y1, Y2) In dual compressor operation, two ABC boards used in 24 VAC operation, there will be a Y2 call to the Y1 input on the second ABC. The compressor will stage to full capacity 30 seconds after Y1 input is received to the second board.

ingle Compressor Heating, 3rd Stage (Y1, Y2, W) The hot water pump is de-energized and the first stage of electric heat is energized 10 seconds after the W command is received. If the demand continues the second stage of electric heat will be energized after 5 minutes.

Dual Compressor Heating, 3rd Stage (Y1, Y2, W) The first stage of electric heat is energized 10 seconds after the W command is received. If the demand continues the second stage of electric heat will be energized after 5 minutes

Emergency Heat (W) - The blower will be started on “G” speed, 10 seconds later the first stage of electric heat will be turned on. 5 seconds after the first stage of electric heat is energized the blower will shift to Aux speed. If the emergency heat demand is not satisfied after 2 minutes the second electric heat stage will be energized.

Cooling Operation

In all cooling operations, the reversing valve directly tracks the O input. Thus, anytime the O input is present, the reversing valve will be energized.

Single Compressor Cooling, 2nd Stage (Y1, Y2, 0) The compressor will be staged to full capacity 20 seconds after Y2 input was received. The ECM blower will shift to high speed 15 seconds after the Y2 input was received.

Dual Compressor Cooling, 2nd Stage (Y1, Y2, O) In dual compressor operation, two ABC boards used in 24 VAC operation, there will be a Y2 call to the Y1 input on the second ABC. The compressor will stage to full capacity 30 seconds after Y1 input is received to the second board.

Blower (G) - The blower will start immediately upon receiving a thermostat G command. If there are no other commands from the thermostat the ECM will run on “G” speed until the G command is removed. Regardless of blower input (G) from the thermostat, the blower will remain on for 30 seconds at the end of each heating, cooling, and emergency heat cycle.

Dehumidification (Y1, O, DH or Y1, Y2, O, DH) - When a DH command is received from the thermostat during a compressor call for cooling the ECM blower speed will be reduced by 15% to increase dehumidification.

Emergency Shutdown - Four (4) seconds after a valid ES input, P2-7 is present, all control outputs will be turned off and remain off until the emergency shutdown input is no longer present. The first time that the compressor is started after the control exits the emergency shutdown mode, there will be an anti-short cycle delay followed by a random start delay. Input must be tied to common to activate.

Continuous Blower Operation - The blower output will be energized any time the control has a G input present, unless the control has an emergency shutdown input present. The blower output will be turned off when G input is removed.

Load Shed - The LS input disables all outputs with the exception of the blower output. When the LS input has been cleared, the anti-short cycle timer and random start timer will be initiated. Input must be tied to common to activate.

Controls - Aurora Base Control cont.

RB SERIES ENGINEERING GUIDE

Aurora ‘Base’ Control LED Displays

These three LEDs display the status, configuration, and fault codes for the control. These can also be read in plain English via the Aurora AID Tool.

Status LED (LED3, Green)

Description of Operation Fault LED, Green

Normal Mode ON Control is Non-functional OFF Test Mode Slow Flash Lockout Active Fast Flash Dehumidification 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

Configuration LED (LED2, Yellow)

Description of Operation Configuration LED, Yellow

No Software Overwritten Flashing ECM Setting DIP Switch was Overwritten Slow Flash ECM Configuration Mode Fast Flash

Fault LED (LED1, Red)

Red Fault LED

LED Flash

Code*

Lockout

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 Detection FP1 5 Yes Hard or Soft Fault - Condensate Overflow 7 Yes Hard or Soft

ABC Basic Faults

Fault - Over/Under Voltage 8 No Auto Fault - FP1 & FP2 Sensor Error 11 Yes Hard or Soft

NOTE: All codes >11 use long flash for tens digit and short flash for the ones digit. 20, 30, 40, 50, etc. are skipped.

Reset/

Remove

Aurora Interface and Diagnostics (AID) Tool

The Aurora Interface and Diagnostics (AID) Tool is a device that is a member of the Aurora network. The AID Tool is used to troubleshoot equipment which uses the Aurora control via Modbus RTU communication. The AID Tool provides diagnostics, fault management, ECM setup, and system configuration capabilities to the Aurora family of controls. An AID Tool is recommended, although not required, for ECM airflow settings. The AID Tool simply plugs into the exterior of the cabinet in the AID Tool port.

ABC Control Board Layout

F/30oF

RV – B/O

ACC – Dip 4 ACC – Dip 5

O/B

Field ConnectionsField Connections

O/B

Off

LED2LED1

Config

4 5

6 7 8

SW2

Com1

Com2

3A-Fuse

EH1

EH2

EH1

Fact ory

N/A

(+)

(-)

RS485 Exp

RS 485

RS485 NET

CC2

JW2 Alarm

FP2

FP2 FP1 FP1

REV

CCG

CFM

PWM

HP HP LP LP

G LO HI

CC FG

ECM PWM

P13

Fact ory

SW1 Test

RV – K1

CC – K2

CC Hi – K3

Fact ory

Fan – K4

Alarm – K5

Acc – K6

ALG

ALM

ACC c

ACC n c

ACC n o

FP1 – 15oF/30oF

FP2 – 15

Faul t

LED3

CC – Dual/Single

L – Puls e/Cont inuous

Status

Reheat/Normal

AURORA BASE

CONTROL™

Fact o ry U se

P11

Factory Fan Connection

RB SERIES ENGINEERING GUIDE

Application Notes

The Closed Loop Heat Pump Concept

The basic principle of a water source heat pump is the transfer of heat into water from the space during cooling, or the transfer of heat from water into the space during heating. Extremely high levels of energy efficiency are achieved as electricity is used only to move heat, not to produce it. Using a typical RB Series, one unit of electricity will move four to five units of heat.

When multiple water source heat pumps are combined on a common circulating loop, the ultimate in energy efficiency is created: The heat pump units on cooling mode are adding heat to the loop which the units in heating mode can absorb, thus removing heat from the area where cooling is needed, recovering and redistributing that heat for possible utilization elsewhere in the system. In modern commercial structures, this characteristic of heat recovery from core area heat generated by lighting, office equipment, computers, solar radiation, people or other sources, is an important factor in the high efficiency and low operating costs of closed source heat pump systems.

Return Water

RB Series

Unit

RB Series

Unit

on individual units without system shut-down. Conditions remain comfortable since each unit operates separately, allowing cooling in one area and heating in another. Tenant spaces can be finished and added as needed. Power billing to tenants is also convenient since each unit can be individually metered: each pays for what each uses. Nighttime and/or weekend uses of certain areas are possible without heating or cooling the entire facility. A decentralized system also means if one unit should fault, the rest of the system will continue to operate normally, as well as eliminating air cross-contamination problems and expensive high pressure duct systems requiring an inefficient electric resistance reheat mode.

The RB Series Approach

There are a number of proven choices in the type of RB Series system which would be best for any given application. Most often considered are:

Vertical - Closed Loop/Ground Source

Heater/

Rejector

Pumps

RB Series

Unit

RB Series

Unit

Supply Water

RB Series

Unit

RB Series

Unit

In the event that a building's net heating and cooling requirements create loop temperature extremes, RB Series units have the extended range capacity and versatility to maintain a comfortable environment for all building areas. Excess heat can be stored for later utilization or be added or removed in one of three ways; by ground-source heat exchanger loops: plate heat exchangers connected to other water sources, or conventional cooler/boiler configurations. Your sales representative has the expertise and computer software to assist in determining optimum system type for specific applications.

The Closed Loop Advantage

A properly applied water source heat pump system offers many advantages over other systems. First costs are low because units can be added to the loop on an “as needed basis”- perfect for speculative buildings. Installed costs are low since units are self-contained and can be located adjacent to the occupied space, requiring minimal ductwork. Maintenance can be done

• Closed Loop/Ground-Source Systems utilize the stable temperatures of the earth to maintain proper water source temperatures (via vertical or horizontal closed loop heat exchangers) for RB Series extended range heat pump system. Sizes range from a single unit through many hundreds of units. When net cooling requirements cause closed loop water temperatures to rise, heat is dissipated into the cooler earth through buried high strength plastic pipe “heat exchangers.” Conversely if net space heating demands cause loop heat absorption beyond that heat recovered from building core areas, the loop temperature will fall causing heat to be extracted from the earth. Due to the extended loop temperatures, AHRI/ISO 13256-1 Ground Loop Heat Pumps are required for this application.

Application Notes cont.

RB SERIES ENGINEERING GUIDE

Because auxiliary equipment such as a fossil fuel boiler and cooling tower are not required to maintain the loop temperature, operating and maintenance costs are very low.

Ground-source systems are most applicable in residential and light commercial buildings where both heating and cooling are desired, and on larger envelope dominated structures where core heat recovery will not meet overall heating loads. Both vertical and horizontally installed closed-loops can be used. The land space required for the “heat exchangers” is 100-250 sq. ft./ton on vertical (drilled) installations and 750-1500 sq. ft./ton for horizontal (trenched) installations. Closed loop heat exchangers can be located under parking areas or even under the building itself.

On large multi-unit systems, sizing the closed loop heat exchanger to meet only the net heating loads and assisting cooling loads with a closed circuit cooling tower may be the most cost effective choice.

Surface Water - Closed Loop/Ground Source

surface run-off. Sizing requirements for the surface water is a minimum of 500 sq. ft./ton of surface area at a minimum depth of 8 feet. Your sales representative should be contacted when designs for heating dominated structures are required.

Plate Heat Exchanger - Closed Loop/Ground Water

• Closed Loop/Ground-Source Surface Water Systems also

utilize the stable temperatures of Surface Water to maintain proper water source temperatures for RB Series extended range heat pump systems. These systems have all of the advantages of horizontal and vertical closed loop systems. Due to the extended loop temperatures, AHRI/ISO 13256-1 Ground Water or Ground Loop Heat Pumps are required for this application.

In cooling dominated structures, the ground-source surface water systems can be very cost effective especially where local building codes require water retention ponds for short term storage of

• Closed Loop/Ground Water Plate Heat Exchanger Systems utilize lake, ocean, well water or other water sources to

maintain closed loop water temperatures in multi-unit RB Series systems. A plate frame heal exchanger isolates the units from any contaminating effects of the water source, and allows periodic cleaning of the heat exchanger during off peak hours.

Operation and benefits are similar to those for ground-source systems. Due to the extended loop temperatures, AHRI/ISO 13256-1 Ground Loop Heat Pumps are required for this application. Closed loop plate heat exchanger systems are applicable in commercial, marine, or industrial structures where the many benefits of a water source heat pump system are desired, regardless of whether the load is heating or cooling dominated.

RB SERIES ENGINEERING GUIDE

Application Notes cont.

Cooler/Boiler - Closed Loop

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 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. Hot water generator coils can likewise become scaled and possibly plugged.

• Closed Loop /Cooler-Boiler Systems utilize a closed heat recovering loop with multiple water source heat pumps in the more conventional manner. Typically a boiler is employed to maintain closed loop temperatures above 60°F and a cooling tower to maintain loop temperatures below 90°F. These systems are applicable in medium to large buildings regardless of whether the load is heating or cooling dominated. Due to the moderate loop temperatures, AHRI/ISO 13256-1 Water Loop Heat Pumps are required for this application.

In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional flushing. Failure to adhere to the guidelines in the water quality table could result in loss of warranty.

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.

Material Copper 90/10 Cupronickel 316 Stainless Steel

pH Acidity/Alkalinity 7 - 9 7 - 9 7 - 9

Scaling

Corrosion

Iron Fouling

(Biological Growth)

Erosion

NOTES: Grains = ppm divided by 17

mg/L is equivalent to ppm

Calcium and

Magnesium Carbonate

Hydrogen Sulfide

Sulfates Less than 125 ppm Less than 125 ppm Less than 200 ppm

Chlorine Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Chlorides Less than 20 ppm Less than 125 ppm Less than 300 ppm

Carbon Dioxide Less than 50 ppm 10 - 50 ppm 10 - 50 ppm

Ammonia Less than 2 ppm Less than 2 ppm Less than 20 ppm

Ammonia Chloride Less than 0.5 ppm 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, FE

Bacterial Iron Potential

+ (Ferrous)

Iron Oxide

Suspended Solids Threshold Velocity

(Fresh Water)

(Total Hardness)

less than 350 ppm

Less than 0.5 ppm (rotten egg

smell appears at 0.5 ppm)

< 0.2 ppm < 0.2 ppm < 0.2 ppm

Less than 1 ppm, above this level

deposition will occur

Less than 10 ppm and filtered for

max. of 600 micron size

< 6 ft/sec < 6 ft/sec < 6 ft/sec

(Total Hardness)

less than 350 ppm

10 - 50 ppm Less than 1 ppm

Less than 1 ppm, above this level

deposition will occur

Less than 10 ppm and filtered for

max. of 600 micron size

(Total Hardness)

less than 350 ppm

Less than 1 ppm, above this level

deposition will occur

Less than 10 ppm and filtered for

max. of 600 micron size

2/22/12

Installation Notes

RB SERIES ENGINEERING GUIDE

Typical Unit Installation

Unit Location

Locate the unit in an indoor area that allows for easy removal of the filter and access panels. Location should have enough space for service 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. Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit. On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping. 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.

Installing Vertical Units

Prior to setting the unit in place, remove and discard the compressor hold down shipping bolt located at the front of the compressor mounting bracket. Vertical units are available in left or right air return configurations. Top flow 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.

WARNING: Before performing service or maintenance operations on a system, turn off main power switches to the indoor unit. If applicable, turn off the accessory heater power switch. Electrical shock could cause personal injury.

Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service heating and air conditioning equipment. Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing filters.

All other operations should be performed by trained service personnel. When working on heating and 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 a quenching cloth for brazing operations and have a fire extinguisher available.

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