WaterFurnace Versatec Ultra User Manual

Commercial
Geothermal/Water Source Heat Pump

• R-410A Refrigerant

• 0.75-6 Tons

Installation Information

Water Piping Connections

Hot Water Connections

Electrical

Startup Procedures

Troubleshooting

Preventive Maintenance

Versatec Ultra Series Installation Manual

IM1200AUB 05/14

Table of Contents

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

General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Installing Horizontal Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hanger Bracket Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Duct System and Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

System Cleaning and Flushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Open Loop Ground Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Hot Water Generator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Freeze Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-21

Blower Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-27

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-30

Controls - Aurora Base Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-34

Controls - UPC (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-43

Unit Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Operating Limits and Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Reference Calculations and Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Refrigerant Circuit Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Compressor and Thermistor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Heat of Extraction/Rejection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Startup/Troubleshooting Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-52

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54-55

Revision Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

VERSATEC ULTRA SERIES INSTALLATION MANUAL

U S

1 3 4-6 7 8 9

10 11 12 14

V 036 T L 0 0 0 C A N13N15A16517N18019020SS

21-22*23

2

Model Nomenclature

Model Type

U – Versatec Ultra

Operation Range

S – Single Stage

Cabinet Configuration

V – Vertical
H - Horizontal

Unit Capacity (MBTUH)
009, 012, 015, 018,
023 (Horizontal)
024, 030, 036,
041 (Vertical)
042, 048, 060, 070

Discharge Configuration

T – Top (Vertical)
E – End (Horizontal)
S – Side (Horizontal)

Return Air Configuration

L – Left
R – Right

Voltage

0 – 208-230/60/1
2 – 265-277/60/1 (009-036)
3 – 208-230/60/3 (023-070)
4 – 460/60/3 (023-070)
5 – 575/60/3 (PSC Only 041-070)

Hot Water Generation Option

0 – No HWG, No IntelliStart®
2 – HWG w/o Pump, No IntelliStart
(Vertical 015-070)
3 – No HWG, IntelliStart
5 – HWG w/o Pump, IntelliStart
(Vertical 018-070)

Blower Options

0 – PSC Blower
1 – Variable Speed ECM Blower (015-070)
2 – High Static Variable Speed ECM Blower
(042-048)
3 – High Static PSC Blower (024, 030, 042, 048)
4 – 5-Speed ECM Blower (015-070)

Water Coil Option

C – Copper
N – CuproNickel

2

Vintage

* - Factory Use Only

Non-Standard Options

SS – Standard

Drain Pan Option

0 – Composite, No Secondary Connection
1 – Composite, 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 MERV 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

Phase Guard

N – No Phase Guard, No Disconnect
P – Phase Guard, No Disconnect
B – Phase Guard, Disconnect
D – No Phase Guard, Disconnect

All-Aluminum Air Coil Option

5 – AlumiSeal
6 – AlumiSeal/Standard Range
7 – No Coating/Extended Range
8 – No Coating/Standard Range

Control Option

A – Aurora
E – Aurora UPC DDC Controller
F – Aurora UPC DDC Controller with LON

Water Control Option

N – None
R – Water Flow Regulator (015-070)
V – 2-Way Valve (015-070)
B – 2-Way Valve w/ Water Flow Regulator
(015-070)

Refrigeration Option

0 – None
G – Hot Gas Bypass (015-072)
R – Hot Gas Reheat (015-072)
B – Hot Gas Bypass w/Hot Gas Reheat (015-072)

Sound Kit Option

A – None
B – Sound Kit (Not Available on H009-012)

1

TM

/Extended Range

TM

Base Control (ABC)

Notes:
1 - Phase Guard Only Available on 208-230/60/3, 460/60/3, and 575/60/3
2 - IntelliStart is not available with Phase Guard

Rev.: 24 April 2014D

4

General Installation Information

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Safety Considerations

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.

Moving and Storage

Move units in the normal “up” orientation. Horizontal units
may be moved and stored per the information on the
packaging. Do not stack more than three units in total
height. Vertical units may be stored one upon another to
a maximum height of two units. Do not attempt to move
units while stacked. 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 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 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 (see
figure below).

Vertical Unit Mounting

2 in. PEX Foam

5

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Vertical Dimensional Data

A

RN

S

Q

AIR COIL SIDE

P

B

AIR COIL SIDE

F

4
3

FRONT

1.4 in (3.5 cm)

M

M

G

Top View - Right Return Top View - Left Return

Air coil

A

N

FRONT

1.4 in (3.5 cm)

Standard filter rails for

open return applications

Deluxe filter rack for

ductable return applications

Air coil

Q

P

B

2' (61 cm)

G

Alternate
Service Access

4
3

F

2' (61 cm)

Service Access Left Return

(Right Return opposite side)

Air coil

ACCESS

PANEL

Isometric View - Left Return

U

Field installed
duct flange

T

W

ACCESS

PANEL

C

1.6 in (4.1 cm)
Condensate 3/4 in

PVC glue socket

1.6 in (4.1 cm)

5

H

2

E

1

D

6
8

1 in (25.4 mm)

1/2" (12.7 mm)

J

L

Power supply

knockout

Low voltage

knockout

L

K

Front View - Right Return

ACCESS

PANEL

Condensate

3/4 in PVC

glue socket

1.6 in (4.1 cm)

8
7

5
2

1

Front View - Left Return

1.6 in
(4.1 cm)

H

E

D

V

C

6

ACCESS

J

8

L

PANEL

8
7

L

K

Right View - Right Return

Left View - Left Return

6

Vertical Dimensional Data cont.

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Overall Cabinet

Vertical

Models

009-012

015-018

024-030

036

041

042-048

060

070

009-012

015-018

024-030

036

041

042-048

060

070

Condensate is 3/4 in. PVC female glue socket and is switchable from side to front.

*Dimensions for return connections are for the deluxe fi lter rack that is suitable for ducted return applications and extends 3.25 in.
[8.26 cm] from the unit. The open fi lter rack, used in non-ducted returns, extends 2.2 in. [5.59 cm] from the unit.

**Discharge fl ange is fi eld installed and extends 1 in. (25.4 mm) from top of cabinet.

cm. 57.2 56.4 60.2 6.6 14.2 N/A N/A 22.4 12.7 mm N/A 18.8 8.6 13.7

cm. 57.2 56.4 91.9 6.6 19.3 3.6 7.4 27.4 19.1 mm 22.2 mm 23.9 13.7 18.8

cm. 57.2 66.5 102.1 6.6 19.3 3.6 11.2 27.4 19.1 mm 22.2 mm 25.7 15.5 20.6

cm. 57.2 66.5 112.3 6.6 19.3 3.6 11.2 27.4 19.1 mm 22.2 mm 25.7 15.5 20.6

cm. 57.2 66.5 112.3 6.6 19.3 3.6 7.4 27.4 19.1 mm 22.2 mm 25.7 15.5 20.6

cm. 64.8 79.2 112.3 6.6 19.3 3.6 11.2 27.4 25.4 mm 22.2 mm 25.7 15.5 20.6

cm. 64.8 79.2 122.4 6.6 19.3 3.6 11.2 27.4 25.4 mm 22.2 mm 25.7 15.5 20.6

cm. 64.8 79.2 132.6 6.6 19.3 3.6 11.2 27.4 25.4 mm 22.2 mm 25.7 15.5 20.6

Vertical

Models

cm. 5.6 25.4 25.4 15.5 23.9 23.9 5.3 46.0 25.4 4.8

cm. 5.6 35.6 35.6 10.4 10.9 19.6 5.3 46.0 50.8 4.8

cm. 5.6 35.6 35.6 15.5 11.4 19.6 5.3 56.1 56.1 4.8

cm. 5.6 35.6 35.6 15.5 11.4 19.6 5.3 56.1 66.3 4.8

cm. 5.6 45.7 45.7 10.4 9.9 9.9 5.3 56.1 66.3 4.8

cm. 5.6 45.7 45.7 16.8 11.7 16.0 4.1 71.4 66.0 5.1

cm. 5.6 45.7 45.7 16.8 11.7 16.0 4.1 71.4 76.2 5.1

cm. 5.6 45.7 45.7 16.8 11.7 16.0 4.1 71.4 86.4 5.1

A B C D E F G H Loop

Width Depth Height** In Out

in. 22.5 22.2 23.7 2.6 5.6 N/A N/A 8.8 1/2 N/A 7.4 3.4 5.4

in. 22.5 22.2 36.2 2.6 7.6 1.4 2.9 10.8 3/4 0.875 9.4 5.4 7.4

in. 22.5 26.2 40.2 2.6 7.6 1.4 4.4 10.8 3/4 0.875 10.1 6.1 8.1

in. 22.5 26.2 44.2 2.6 7.6 1.4 4.4 10.8 3/4 0.875 10.1 6.1 8.1

in. 22.5 26.2 44.2 2.6 7.6 1.4 2.9 10.8 3/4 0.875 10.1 6.1 8.1

in. 25.5 31.2 44.2 2.6 7.6 1.4 4.4 10.8 1 0.875 10.1 6.1 8.1

in. 25.5 31.2 48.2 2.6 7.6 1.4 4.4 10.8 1 0.875 10.1 6.1 8.1

in. 25.5 31.2 52.2 2.6 7.6 1.4 4.4 10.8 1 0.875 10.1 6.1 8.1

MNPQR S T UVW

Filter Rack

Width

in. 2.2 10.0 10.0 6.1 9.4 9.4 2.1 18.1 10.0 1.9

in. 2.2 14.0 14.0 4.1 4.3 7.7 2.1 18.1 20.0 1.9

in. 2.2 14.0 14.0 6.1 4.5 7.7 2.1 22.1 22.1 1.9

in. 2.2 14.0 14.0 6.1 4.5 7.7 2.1 22.1 26.1 1.9

in. 2.2 18.0 18.0 4.1 3.9 3.9 2.1 22.1 26.1 1.9

in. 2.2 18.0 18.0 6.6 4.6 6.3 1.6 28.1 26.0 2.0

in. 2.2 18.0 18.0 6.6 4.6 6.3 1.6 28.1 30.0 2.0

in. 2.2 18.0 18.0 6.6 4.6 6.3 1.6 28.1 34.0 2.0

Supply

Width

12345 678

Discharge Connection

duct fl ange installed (±0.10 in)

Supply

Depth

Water Connections Electrical Knockouts

HWGInHWG

Out

Cond-

ensate

Knock-

Water

FPT

out

HWG

Provisions

Return Connection*

using deluxe fi lter rack (±0.10 in)

Return
Depth

JKL

1/2 in.

cond

Return
Height

1/2 in.

cond

1 in.

cond

11/10/09

Vertical Disconnect

When using disconnect, do not use dimension L from
the standard vertical dimensional data. Use dimension
LL from the vertical disconnect dimensional data.

Vertical Models LL

009-012
015-018

024-030

036

042-048

060
070

Dimensions in inches [cm] 02/06/13

Externally Mounted

18.8 [47.8]

14.3 [36.3]

15.3 [38.9]

14.3 [36.3]

14.3 [36.3]

14.3 [36.3]

Disconnect Located on this

Side for a Right Return
Disconnect
Location

Alternative
Power

Power

Location

Supply

LL

1.8 in.

[4.6 cm]

Vertical Shown in

Left Return Configuration

7

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Horizontal Dimensional Data

Right Return

Condensate
"X" PVC size

End Discharge

Deluxe filter rack option shown

H

2.3 in. [5.8 cm]

FILTER RACK

AIR COIL SIDE

2.1 in. [5.3 cm]

Right Return

End Discharge

N

BLOWER

OUTLET

A

Standard filter rails

1 in. [2.5 cm] knockout

0.5 in. [1.3 cm] knockout

Front

AP

CMP

Service Access

Side Discharge

P

M

C

L

2' (61 cm)

1.7 in.
[5.3 cm]

K

J

E

D

AP = Alternate Service Panel
BP = Blower Service Panel
CP = Control Access Panel
CMP = Compressor Service Panel

CP

AP

A

RR Front View

1.7

CP

AP

LR Front View

Legend

1.7

1.7 in.
[5.3 cm]

E

D

J

0.5 in. [1.3 cm]
knockout

1 in. [2.5 cm]

K

knockout

Standard filter rails

Front

AP

CMP

2' (61 cm)

Service Access

Side Discharge

Deluxe filter rack option shown
P

N

L

C

M

BLOWER

OUTLET

2.1 in. [5.3 cm]

Left Return

End Discharge

Left Return

Condensate

"X" PVC size

End Discharge

2.3 in.
[5.8 cm]

AIR COIL SIDE

FILTER RACK

H

A

BP

Front

P

N

L

M

Air Coil

BLOWER

OUTLET

Right Return Side Discharge

C

FILTER RACK CONNECTION FILTER RACK CONNECTION

Right Return Side View

B

1.5 in. [3.8 cm]

AP

CMP

SQ

0.5 in. [1.3 cm]

K

Front

1 in. [2.5 cm]

knockout

J

0.5 in. [1.3 cm]
knockout

T

Deluxe filter

rack option

(shown)

R

knockout

Front

C

J

K

T

R

1.5 in. [3.8 cm]

AP

CMP

S

BLOWER

OUTLET

Left Return Side Discharge

Q

B

Left Return Side View

P

N

BP

M

L

Air Coil

Front

8

Horizontal Dimensional Data cont.

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Overall Cabinet

Horizontal

Models

009-012

015-023

024-030

036

042-048

060

070

Horizontal

Models

009-012

015-023

024-030

036

042-048

060

070

*Dimensions for return connections are for the deluxe fi lter rack that is suitable for ducted return applications and extends 3.25 in.
[8.26 cm] from the unit. The open fi lter rack, used in non-ducted returns, extends 2.2 in. [5.59 cm] from the unit.

Condensate 3/4 in. PVC stub extends from cabinet approximately 1-1/2 in. [38.1 mm]

in. 19.2 30.9 11.9 1.8 4.8 0.8 1/2 4.5 4.5

cm. 48.8 78.5 30.2 4.6 12.2 2.0 12.7 mm 11.4 11.4

in. 22.5 42.0 17.2 1.8 6.8 0.8 3/4 7.1 7.1

cm. 57.2 106.7 43.7 4.6 17.3 2.0 19.05 mm 18.0 18.0

in. 22.5 42.0 19.2 1.8 6.8 0.8 3/4 9.2 7.1

cm. 57.2 106.7 48.8 4.6 17.3 2.0 19.05 mm 23.4 18.0

in. 22.5 45.0 19.2 1.8 6.8 0.8 3/4 9.2 7.1

cm. 57.2 114.3 48.8 4.6 17.3 2.0 19.05 mm 23.4 18.0

in. 25.5 48.0 21.2 1.8 6.8 0.8 1 9.2 9.1

cm. 64.8 121.9 53.8 4.6 17.3 2.0 25.4 mm 23.4 23.1

in. 25.5 53.0 21.2 1.8 6.8 0.8 1 9.2 9.1

cm. 64.8 134.6 53.8 4.6 17.3 2.0 25.4 mm 23.4 23.1

in. 25.5 61.0 21.2 1.8 6.8 0.8 1 9.2 9.1

cm. 64.8 154.9 53.8 4.6 17.3 2.0 25.4 mm 23.4 23.1

in. 2.3 8.0 10.0 2.3 15.4 9.4 3.0 1.4 1/2

cm. 5.8 20.3 25.4 5.8 39.1 23.9 7.6 3.6 1.3

in. 5.7 10.5 9.4 4.9 23.4 14.5 2.0 1.4 3/4

cm. 14.5 26.7 23.9 12.4 59.4 36.8 5.1 3.6 1.9

in. 6.7 10.5 9.4 4.9 27.4 16.4 2.0 1.5 3/4

cm. 17.0 26.7 23.9 12.4 69.6 41.7 5.1 3.8 1.9

in. 6.7 10.5 9.4 4.9 30.4 16.4 2.1 1.5 3/4

cm. 17.0 26.7 23.9 12.4 77.2 41.7 5.3 3.8 1.9

in. 4.9 13.6 13.2 4.6 35.4 18.6 2.4 1.5 3/4

cm. 12.4 34.5 33.5 11.7 89.9 47.2 6.1 3.8 1.9

in. 4.9 13.6 13.2 4.6 40.4 18.4 2.4 1.5 3/4

cm. 12.4 34.5 33.5 11.7 102.6 46.7 6.1 3.8 1.9

in. 4.9 13.6 13.2 4.6 45.6 18.6 2.3 1.5 3/4

cm. 12.4 34.5 33.5 11.7 115.8 47.2 5.8 3.8 1.9

A B C D E H Loop 1/2 in. cond 1 in. cond

Width Depth Height* In Out

LMNPQRS TX

Discharge Connection

duct fl ange installed (±0.10 in)

Supply

Width

Supply

Depth

123 JK

Water Connections Electrical Knockouts

Cond-

ensate

using deluxe fi lter rack option (±0.10 in)

Return

Depth

Return Connection*

Return
Height

Water FPT Low Voltage

Power

Supply

PVC Size

10/29/13

Horizontal Disconnect

When using disconnect, do not use dimension K from the
standard horizontal dimensional data. Use dimension KK from
the horizontal disconnect dimensional data.

Horizontal Models KK

009-012

015-018

024-030

036

042-048

060
070

Dimensions in inches [cm] 02/06/13

Externally Mounted

8.2 [20.8 ]

9.2 [23.4]

9.2 [23.4]

11.2 [28.4]

10.2 [25.9]

11.2 [28.4]

Disconnect Located

on this Side for a

Left Return

9

2.1 in.

[5.3 cm]

Disconnect
Location

KK

Power Supply

Horizontal Shown in

Right Return Configuration

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Installing Horizontal Units

Installing Horizontal Units

Remove and discard the compressor hold down shipping
bolt located at the front of the compressor mounting
bracket prior to setting the unit in place. Horizontal units
are available with side or end discharge.

NOTE: Left (Right) Return Side Discharge cannot be
converted to Left (Right) Return End Discharge or vice
versa, without additional custom sheet metal parts.
Horizontal units are normally suspended from a ceiling by
four (009-060 models) or five (070-072 models) 3/8 in.
diameter threaded rods. The rods are usually attached to
the unit by hanger bracket kits furnished with each unit.

Lay out the threaded rods per the Hanger Bracket
Dimensions table. Assemble the hangers to the unit as
shown. Securely tighten the brackets to the unit using the
weld nuts located on the underside of the bottom panel.
When attaching the hanger rods to the bracket, a double
nut is required since vibration could loosen a single nut.

To allow filter access, install hanger brackets as illustrated
in the Hanger Bracket Locations section. The unit should
be pitched approximately 1/4 in. towards the drain in both
directions to facilitate the removal of condensate. Use only
the bolts provided in the kit to attach hanger brackets. The
use of longer bolts could damage internal parts.

Some applications require the installation of horizontal
units on an attic floor. In this case, the unit should be set
in a full size secondary drain pan on top of a vibration
absorbing pad. The secondary drain pan prevents possible
condensate overflow or water leakage damage to the
ceiling. The secondary drain pan is usually placed on a
plywood base isolated from the ceiling joists by additional
layers of vibration absorbing material.

CAUTION: Do not use rods smaller than 3/8 in.
diameter since they may not be strong enough
to support the unit. The rods must be securely
anchored to the ceiling.

10

Hanger Bracket Locations

VERSATEC ULTRA SERIES INSTALLATION MANUAL

D

Compressor

Section

B

E

Hanger Dimensions

Model

009-012

015-023

024-030

036

042-048

060

070

Hanger Kit

Part Number

in.

99S500A04

cm [80.5] [55.4] [46.0]

in.

99S500A04

cm [108.6] [63.8] [54.4]

in.

99S500A04

cm [108.7] [63.8] [54.4]

in.

99S500A04

cm [116.3] [63.8] [54.4]

in.

99S500A04

cm [124.0] [71.4] [62.0]

in.

99S500A04

cm [136.7] [71.4] [62.0]

in.

99S500A04

cm [157.0] [71.4] [62.0]

Right

F

C

Air Handler

Section

G

A

3/8”

Threaded Rod

(not supplied)

Bolt and
Lockwasher

Unit Hanger Dimensions

ABC

31.7 21.8 18.1

42.8 25.1 21.4

42.8 25.1 21.4

45.8 25.1 21.4

48.8 28.1 24.4

53.8 28.1 24.4

61.8 28.1 24.4

10/29/13

E

Compressor

Section

D

Vibration Isolator

Washer

Hex Nuts
(not supplied)

Weight Distribution

Model

009

012

015

018

023

024

030

036

041

042

048

060

070

Vertical

Shipping

Weight

lb. 110 120 46 23 26 25
kg [50] [54] [21] [11] [12] [11]
lb. 115 125 48 24 27 26
kg [52] [57] [22] [11] [12] [12]
lb. 165 175 67 34 37 36
kg [75] [79] [31] [15] [17] [17]
lb. 170 180 69 35 38 38
kg [77] [82] [31] [16] [17] [17]
lb. na 185 71 36 39 39
kg na [84] [32] [16] [18] [17]
lb. 230 245 94 47 52 51
kg [104] [111] [43] [22] [24] [23]
lb. 240 255 98 49 54 53
kg [109] [116] [44] [22] [25] [24]
lb. 265 285 110 55 61 59
kg [120] [129] [50] [25] [28] [27]
lb. 275 na na na na na
kg [125] na na na na na
lb. 285 300 115 58 64 63
kg [129] [136] [52] [26] [29] [28]
lb. 290 310 119 60 66 65
kg [132] [141] [54] [27] [30] [29]
lb. 335 360 138 70 77 75
kg [152] [163] [63] [32] [35] [34]
lb. 380 405 156 78 86 84
kg [172] [184] [71] [36] [39] [38]

Horizontal

Shipping

Weight

Left

G

Air Handler

Section

F

Horizontal Weight Distribution

Front Back

DEFG

11/10/09

11

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Duct System

An air outlet collar is provided on vertical top flow units
and all horizontal units to facilitate a duct connection.
A flexible connector is recommended for discharge
and return air duct connections 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, check the duct
system to ensure that it has the capacity to accommodate
the air required for the unit application. If the duct is too
small, as in the replacement of heating only systems, larger
ductwork should be installed. All existing ductwork should
be checked for leaks and repaired if necessary.

Water Piping

The proper water flow must be provided to each unit
whenever the unit operates. To assure proper flow, use
pressure/temperature ports to determine the flow rate.
These ports should be located at the supply and return
water connections on the unit. The proper flow rate cannot
be accurately set without measuring the water pressure
drop through the refrigerant-to-water heat exchanger.

The duct system should be sized to handle the design
airflow quietly and efficiently. To maximize sound
attenuation of the unit blower, the supply and return
plenums should include an internal duct liner of fiberglass
or constructed of ductboard for the first few feet. On
systems employing a sheet metal duct system, canvas
connectors should be used between the unit and the
ductwork. If air noise or excessive airflow is a problem, the
blower speed can be changed.

All source water connections on commercial units are
fittings that accept a male pipe thread (MPT). Insert the
connectors by hand, then tighten the fitting with a wrench
to provide a leakproof joint. When connecting to an open
loop (groundwater) system, thread any copper MPT fitting
into the connector and tighten in the same manner as
described above.

Condensate Drain

On vertical units, the internal condensate drain assembly
consists of a drain tube which is connected to the drain
pan, a 3/4 in. PVC female adapter and a flexible connecting
hose. The female adapter may exit either the front or the
side of the cabinet. The adapter should be glued to the
field-installed PVC condensate piping. On vertical units, a
condensate hose is inside all cabinets as a trapping loop;
therefore, an external trap is not necessary.

Vent (if needed)

1/2” or 3/4” PVC
1/8 in. per foot

1/2” or 3/4”

PVC tube stub

1/2” or 3/4”
PVC Coupling

1.5 in.

Tube Stub

1.5 in.

On horizontal units, a PVC stub or stainless steel tube
is provided for condensate drain piping connection. An
external trap is required (see below). If a vent is necessary,
an open stand pipe may be applied to a tee in the field­installed condensate piping.

Unit Pitch for DrainHorizontal Drain Connection (Composite Drain Pan)

1/2'' Pitch

Drain

12

Water Quality

VERSATEC ULTRA SERIES INSTALLATION MANUAL

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

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.
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. In areas

Material Copper 90/10 Cupronickel 316 Stainless Steel

pH Acidity/Alkalinity

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

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

Iron Oxide

Suspended Solids

Threshold Velocity

(Fresh Water)

Less than 0.5 ppm (rotten egg

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

2

+ (Ferrous)

smell appears at 0.5 ppm)

Less than 1 ppm, above this

level deposition will occur

Less than 10 ppm and filtered

for max. of 600 micron size

7 - 9 7 - 9 7 - 9

(Total Hardness)

less than 350 ppm

< 0.2 ppm < 0.2 ppm < 0.2 ppm

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

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.

(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

13

VERSATEC ULTRA SERIES INSTALLATION MANUAL

System Cleaning and Flushing

Cleaning and Flushing

Prior to start up of any heat pump, the water circulating
system must be cleaned and flushed of all dirt and debris.

If the system is equipped with water shutoff valves, the
supply and return runouts must be connected together
at each unit location (This will prevent the introduction of
dirt into the unit, see Flushing with Water Shutoff Valve
Equipped Systems illustration). The system should be filled
at the water make-up connection with all air vents open.
After filling, vents should be closed.

Flushing with Water Shutoff Valve Equipped Systems

Return Runout

Supply Runout

Mains

Rubber Hose

Runouts Initially
Connected Together

The contractor should start the main circulator with the
pressure reducing valve makeup open. Vents should be
checked in sequence to bleed off any trapped air and to
verify circulation through all components of the system.

As water circulates through the system, the contractor
should check and repair any leaks found in the piping
system. Drain(s) at the lowest point(s) in the system should
be opened for initial flush and blowdown, making sure
water fill valves are set at the same rate. Check the pressure
gauge at the pump suction and manually adjust the make­up water valve to hold the same positive pressure both
before and after opening the drain valves. Flushing should
continue for at least two hours, or longer if required, until
drain water is clean and clear.

The supplemental heater and/or circulator pump, if used,
should be shut off. All drains and vents should be opened
to completely drain the system. Short-circuited supply and
return runouts should now be connected to the unit supply
and return connections.

Refill the system with clean water. Test the system water
for acidity and treat as required to leave the water slightly
alkaline (pH 7.5 to 8.5). The specified percentage of
antifreeze may also be added at this time. Use commercial
grade antifreeze designed for HVAC systems only.
Environol™ brand antifreeze is recommended.

Once the system has been filled with clean water and
antifreeze (if used), precautions should be taken to protect
the system from dirty water conditions. Dirty water will
result in system-wide degradation of performance, and
solids may clog valves, strainers, flow regulators, etc.
Additionally, the heat exchanger may become clogged
which reduces compressor service life and can cause
premature unit failure.

In boiler/tower application, set the loop control panel
set points to desired temperatures. Supply power to all
motors and start the circulating pumps. After full flow has
been established through all components including the
heat rejector (regardless of season), air vented and loop
temperatures stabilized, each of the units will be ready for
check, test and start up and for air and water balancing.

Ground Source Loop System Checkout

Once piping is completed between the unit pumping
system and ground loop, final purging and charging of
the loop is needed. A high pressure 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 40-50
PSI (summer) or 50-75 PSI (winter). This is normally
adequate for good system operation. Loop static pressure
may decrease soon after initial installation, due to pipe
expansion and loop temperature change. Running the
unit for at least 30 minutes after the system has been
completely purged of air will allow for the “break-in”
period. It may be necessary to adjust static loop pressure
(by adding water) after the unit has run for the first time.
Loop static pressure will also 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.

Ensure the pump provides adequate flow through the unit
by checking pressure drop across the heat exchanger.
Usually 2.25-3.0 gpm of flow per ton of cooling capacity is
recommended in earth loop applications.

14

Open Loop Ground Water Systems

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Typical open loop piping is shown below. 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
to minimize mineral formation due to air exposure. Insure
proper water flow through the unit by checking pressure
drop across the heat exchanger and comparing it to the
figures in unit capacity data tables in the specification
catalog. 1.5-2 gpm of flow per ton of cooling capacity is
recommended in open loop applications. Due to only minor
differences in flow rate from low to high, only one solenoid
valve should be used. The valve should be sized for full flow.

Open System - Groundwater Application

Unit Supply

Aux. Heat Supply

Flexible
Duct Collar

Rubber Bladder
Expansion Tank

Hot Water Generator

Connections

Solenoid

Valve

Drain

Disconnects

(IfApplicable)

Compressor
Line Voltage

Low Voltage

to Thermostat

and Valve

P/T Plugs

Vibration

Absorbing Pad

Strainer

Boiler Drains

For HX Flushing

Shut Off Valves

(to isolate solenoid

valve while acid flushing)

Discharge water from the unit is not contaminated in any
manner and can be disposed of in various ways, depending
on local codes, i.e. recharge well, storm sewer, drain field,
adjacent stream or pond, etc. Most local codes forbid
the use of sanitary sewer for disposal. Consult your local
building and zoning departments to assure compliance in
your area.

Flow Control

Valve

(on outlet of

Solenoid Valve)

Water Out

Water In

Shut Off Valves

15

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Hot Water Generator Connections

The heat reclaiming hot water generator coil is of vented
double-wall copper construction and is suitable for
potable water.

To maximize the benefits of the hot water generator 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 hot water generator. A water softener is
recommended with hard water (greater than 10 grains or
170 total hardness).

Water Tank Preparation

To install a unit with a hot water generator, follow these
installation guidelines.

1. Turn off the power to the water heater.

2. Attach a water hose to the water tank drain connection and
run the other end of the hose to an open drain or outdoors.

3. Close the cold water inlet valve to the water heater tank.

4. Drain the tank by opening the valve on the bottom of the
tank, then open the pressure relief valve or hot water faucet.

5. Flush the tank by opening the cold water inlet valve to
the water heater to free the tank of sediments. Close
when draining water is clear.

6. Disconnect the garden hose and remove the drain valve
from the water heater.

7. Refer to Plumbing Installation and Hot Water
Generator Startup.

Typical Hot Water Generator Installation

3/4 in. x 3/4 in. x 1/2 in. Tee

Ball Valve

Vent

HWG

Water Out

Field Installed

HWG Pump

HWG

Water In

Cold

Water In

Drain Valve

P/T Relief

Valve

Water Out

In

Hot

Hot Water Generator Installation In Preheat Tank

Cold

3/4 in. x 3/4 in. x 1/2 in. Tee

Ball Valve

Vent

Water Out

Field Installed

HWG

Water In

HWG

HWG Pump

Water In

P/T Relief

Valve

In

Drain Valve

NOTE: This configuration maximizes hot water
generator capability.

Hot

Water Out

P/T Relief

Valve

Plumbing Installation

1. Inspect the dip tube in the water heater cold inlet

for a check valve. If a check valve is present it must
be removed or damage to the hot water generator
circulator will occur.

2. Remove drain valve and fitting.

3. Thread the 3/4-inch NPT x 3-1/2-inch brass nipple into

the water heater drain port.

4. Attach the center port of the 3/4-inch FPT tee to the

opposite end of the brass nipple.

5. Attach the 1/2-inch copper to 3/4-inch NPT adaptor to

the side of the tee closest to the unit.

6. Install the drain valve on the tee opposite the adaptor.

7. Run interconnecting tubing from the tee to HWG

water out.

CAUTION: Elements will burn out if energized dry.

8. Cut the cold water “IN” line going to the water heater.

9. Insert the reducing solder tee in line with cold water
“IN” line as shown.

10. Run interconnecting copper tubing between the unit
DHW water “IN” and the tee (1/2-inch nominal). The
recommended maximum distance is 50 feet.

11.

To prevent air entrapment in the system, install a vent
coupling at the highest point of the interconnecting lines.

12. Insulate all exposed surfaces of both connecting water
lines with 3/8-inch wall closed cell insulation.

NOTE: All plumbing and piping connections must comply
with local plumbing codes.

16

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Hot Water Generator Connections cont.

Hot Water Generator Startup

1. Make sure the power is off to the heat pump. Connect
the wire from the hot water generator pump to T1 on
the contactor.

2. Close the drain valve to the water heater.

3. Open the cold water supply to the tank.

4. Open a hot water faucet in the building to bleed air
from the system. Close when full.

5. Open the pressure relief valve to bleed any remaining
air from the tank, then close.

6. If so equipped, turn the venting (burping) screw in the
center of the pump two (2) turns open (water will drip out),
wait until all air is purged from the pump, then tighten the
plug. Use vent couplings to bleed air from the lines.

7. Carefully inspect all plumbing for water leaks and
correct as required.

8. Before restoring electrical supply to the water heater,
adjust the temperature setting on the tank.

• On tanks with both upper and lower elements,
the lower element should be turned down to
the lowest setting, approximately 100°F. The
upper element should be adjusted to 120°F to
130°F. Depending upon the specific needs of
the customer, you may want to adjust the upper
element differently.

• On tanks with a single element, lower the
thermostat setting to 120°F.

9. After the thermostat(s) is adjusted, replace the access
cover and restore electrical supply to the water heater.

10. Make sure that any valves in the hot water generator
circuit are open.

11. Turn on the unit to heating.

12. The HWG pump should be running. When the pump
is first started, turn the venting (burping) screw (if
equipped) in the center of the pump two (2) turns open
until water dribbles out, then replace. Allow the pump
to run for at least five minutes to ensure that water has
filled the circulator properly.

13. The temperature difference between the water entering
and leaving the hot water generator should be 5°F to
15°F. The water flow should be approximately 0.4 gpm
per ton of nominal cooling.

14. Allow the unit to heat water for 15 to 20 minutes to be
sure operation is normal.

CAUTION: Never operate the HWG circulating
pump while dry. If the unit is placed in operation
before the hot water generator piping is
connected, be sure that the pump wires are
disconnected from the contactor.

17

VERSATEC ULTRA SERIES INSTALLATION MANUAL

Freeze Detection

For Aurora Base Control, set SW2-1, FP1, on the printed
circuit board for applications using a closed loop antifreeze
solution to 15°F [-9.4°C]. On applications using an open
loop/ground water system (or closed loop no antifreeze), set
this dip switch to 30°F [-1.1°C], the factory default setting.
(Refer to the Dip Switch Field Selection table).

Electrical Connections

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.

Power Connection

Connect the incoming line voltage wires to L1 and L2 of the
contactor for single-phase unit. Consult the Electrical Data
tables for correct fuse sizes.

Aurora Base Control Box

208 Volt Operation

All Versatec Ultra Series 208/230 units are factory wired
for 230 volt operation. For 208 volt operation, the red and
blue transformer wires must be switched on terminal strip PS.

CAUTION: When installing a unit with an ECM
blower motor in 460/60/3 voltage, a neutral wire
is required to allow proper unit operation.

18