Heating and Air Conditioning INSTALLATION MANUAL AFFINITY INDOOR SPLIT GEOTHERMAL HEAT PUMPS SINGLE AND DUAL CAPACITY MODELS: YAZS022 - 070 (2 THRU 6 NOMINAL TONS) YAZT026 - 072 (2 THRU 6 NOMINAL TONS) Due to continuous product improvement, specifications are subject to change without notice. Visit us on the web at www.york-geothermal.com Additional rating information can found at www.ahridirectory.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Table of Contents Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Model Nomenclature 1-3 4 4-6 8 9 10 11 12 13 14 15 16 17 YAZ T 038 A A 1 4 A C A 0 A * Model YAZ – Affinity Indoor Split Vintage * - Factory Use Only Stage S – Single Speed T – Dual Capacity Controls A – AuroraTM Base Control Future Options 0 – Standard Unit Capacity 022, 026, 030, 036, 038, 042, 048, 049, 060, 064, 070, 072 Future Options A – Standard Discharge Configuration A – None Water Coax Option C – Copper N – CuproNic
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information Safety Considerations Duct System All blower coil units/air coils must be installed as specified by the manufacturer’s installation instructions; however, the following recommendations should be considered to minimize noise and service problems. 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.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. When utilizing the existing air coil or line set, only flushing compounds that vaporize should be used; which means they are packaged in a pressurized disposable cylinder. It is preferable to use a flushing agent that removes oil, water, and acid, plus, is biodegradeable and non-toxic. The flushing agent should be safe to use with both HCFC and HFC refrigerants.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. Dual Fuel Systems In add-on indoor split applications, the coil should be located in the supply side of the furnace to avoid condensation damage to the furnace heat exchanger. A high temperature limit should be installed upstream of the coil to de-energize the compressor whenever the furnace is operating. Without this switch, the indoor split will trip out on high pressure.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. Never use flexible hoses smaller than 1 in. inside diameter on the unit. Limit hose length to 10 ft. per connection. Check carefully for water leaks. 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.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. 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. Failure to adhere to the guidelines in the water quality table could result in the loss of warranty.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Closed Loop - Ground Source Systems NOTE: For closed loop systems with antifreeze protection, set SW2-1 to the “LOOP” (15°F) position. (Refer to the DIP Switch Settings table in the Aurora Control section.) Multiple Units on One Flow Center When two units are connected to one loop pumping system, pump control is achieved by following Figure 5. Installer will be required to supply fuses, two relays, and wiring.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Open Loop - Well Water Systems 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. 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.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Hot Water Generator Connections The heat reclaiming hot water generator coil is 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.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Hot Water Generator Connections cont. Plumbing Installation Hot Water Generator Startup 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.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Electrical Connections General Accessory Relay 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. A set of “dry” contacts has been provided to control accessory devices, such as water solenoid valves on open loop installations, electronic air cleaners, humidifiers, etc.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Electrical Connections cont. Figure 11: Pump Wiring 208-230/60/1 Pump Power Wiring See Figure 11 for electrical connections from control box to pumps. FC1/FC2 style flow centers with fixed speed pumps connect to PB1 in the control box.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Electronic Thermostat Installation cont. Single and Dual Capacity Wiring Diagram Field low voltage point to point wiring: From Thermostat C R G O Y1 Y2 W2 L To Compressor Section C R To Air Handler C R G O Y1 Y2 W O Y1 Y2 L 5/29/08 Air Handler transformer must be 75VA.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Dimensional Data B C A F L G J K P H M E N D Height Width Depth Model Service Valve Water In Water Out Liquid Gas HWG In HWG Out Low External Line Voltage Pump Voltage Knock Out Knock Out A B C D E F G H J K L M N P in. 19.3 22.5 26.5 1.93 6.93 15.2 16.8 9.4 11.9 12.1 14.3 9.5 4.6 8.2 cm. 49.0 57.1 67.3 4.9 17.6 38.6 42.7 23.9 30.2 30.7 36.3 24.1 11.7 20.8 in. 21.25 25.62 31.6 2.3 7.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Physical Data Model 022 030 Compressor (1 each) Factory Charge R410a, oz [kg] 036 042 048 060 070 026 038 Single Speed Scroll 56 [1.59] 56 [1.59] 56 [1.59] 74 [2.1] 90 [2.55] 049 064 72 Dual Capacity Scroll 92 [2.61] 108 [3.06] 52 [1.47] 56 [1.59] 90 [2.55] 92 [2.61] 104 [2.95] Coax and Water Piping Water Connections Size - Swivel- in [mm] HWG Connection Size - Female Sweat (I.D.) - in [mm] 1 [25.4] 1 [25.4] 1/2 [12.7] 1/2 [12.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Model Nomenclature - Air Handler 1-3 4-6 7 8-9 10 11 12 YAH 036 * 00 0 1 R Air Coil R – Refrigerant H - Hydronic Model YAH – Affinity Series Air Handler Unit Capacity Refrigeration (DX) Models with Nominal CFM 022 MBTUH 800 026 MBTUH 925 030 MBTUH 980 036 MBTUH 1225 042 MBTUH 1425 048 MBTUH 1625 060 MBTUH 1760 Hydronic Models with Nominal CFM 026 MBTUH 925 036 MBTUH 1225 048 MBTUH 1625 060 MBTUH 1760 Motor 1 – ECM 208-230/60/1 Disconnect 0 –
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Physical Data - Air Handler Air Handler Model Number (Refrigerant) 2 YAH022 YAH026 YAH030 2 Air Coil Total Face Area - ft [m ] YAH042 YAH048 YAH060 5.83 [0.54] Tube Outside Diameter - in [mm] Evaporator Coil YAH036 3/8 [9.52] Number of Rows 2 3 Fins Per Inch 12 Suction Line Connection - in [mm] Sweat 5/8 [15.87] 7/8 [22.22] Liquid Line Connection - in [mm] Sweat 3/8 [9.52] Refrigerant R-410a Nominal Cooling Capacity - Ton [kW] 1.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora™ Control System Aurora ‘Base’ Control The Aurora ‘Base’ Control (ABC) System is a complete residential and commercial comfort system that brings all aspects of the HVAC system into one cohesive module network. The ABC features microprocessor control and HP, LP, condensate and freeze detection, over/ under voltage faults, along with communicating thermostat capability for complete fault detection text at the thermostat.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora Control System cont. Aurora ‘Base’ Control 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.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Safety Features 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 self-resetting in that if the voltage comes back within range of 18 VAC to 30 VAC for at least 0.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. 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.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Reference Calculations Heating Calculations: Cooling Calculations: HR LWT = EWT - HE gpm x 500 LWT = EWT + LAT = EAT + HC cfm x 1.08 LAT (DB) = EAT (DB) - gpm x 500 SC cfm x 1.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics R Factory Fault LED3 SW1 Test G Off FP1 – 15oF/30oF On 1 LED2 FP2 – 15oF/30oF RV – B/O 2 ACC – Dip 4 4 ACC – Dip 5 5 CC – Dual/Single L – Pulse/Continuous 6 Status P6 AURORA BASE CONTROL™ CC – K2 Factory Use Com1 G P11 Alarm – K5 LO R R 24 VAC G Y2 Y1 C Capacitor w/ bleed resistor Switch - High pressure Field wire lug L1 Switch - Low pressure Ground Relay ContactsN.O., N.C.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics cont. R LED3 G SW1 Test On 1 LED2 2 4 ACC – Dip 5 5 CC – Dual/Single L – Pulse/Continuous 6 Status RS485 Exp AURORA BASE CONTROL™ Factory Use Factory LED5 G Acc – K6 P9 Y2 Y1 G C R LO O/B Y2 Reversing Valve Fossil Fuel Furnace L P1 Fault Signal LO C (+) (-) R C C Common R R 24 VAC C Field wire lug L1 R Switch - Low pressure Ground (+) (-) Relay ContactsN.O., N.C.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Refrigeration The indoor split series comes with a holding charge. The charge must be adjusted in the field based on performance. Refrigeration piping on the split consists of installing a brazed copper line set between the blower coil unit and the unit’s split compressor section. To select the proper tube diameters for the installation, refer to the Line Set Sizes table.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Refrigeration cont. If an air handler manufactured by others is used then refrigerant should be added to the indoor split factory pre-charge. Refrigerant should be added for liquid line length. This should result in a slightly under-charged system exhibiting low subcooling and high superheat. As charge is added, the subcooling should rise and the superheat should fall.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Refrigeration cont. Determining Subcooling 1. 2. 3. 4. Measure the temperature of the liquid line on the small refrigerant line (liquid line) just outside the split cabinet. This location will be adequate for measurement in both modes unless a significant temperature drop in the liquid line is anticipated. Measure the liquid line pressure by attaching refrigerant gauges to the Schrader connection on the liquid line service valve.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Pressure/Temperature Conversion Chart for R-410A PRESSURE (PSIG) 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164 166 168 170 172 174 176 178 TEMP °F 8.5 9.9 11.2 12.5 13.8 15.1 16.3 17.5 18.7 19.8 21.0 22.1 23.2 24.3 25.4 26.5 27.5 28.6 29.6 30.6 31.6 32.6 33.5 34.5 35.4 36.4 37.3 38.2 39.1 40.0 40.9 41.7 42.6 43.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Unit Startup 10. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature. 11. First stage heating will energize after a time delay. 12. Check the temperature of both the supply and discharge water (see the Unit Operating Parameters tables). 13. Check for an air temperature rise of 12°F to 35°F across the air coil, depending on the fan speed and entering water temperature. 14.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Operating Parameters Single Speed Models - YAZS022 thru YAZS070 (with YAH Series Air Handler) Cooling -- No Hot Water Generator YAZS022 thru YAZS060 YAZS070 Water Entering Water Flow GPM/ Suction Discharge Suction Discharge Temp °F Superheat Ton Pressure PSIG Pressure PSIG Pressure PSIG Pressure PSIG 1.5 115-150 205-245 115-130 205-245 12-22 50 3.0 110-145 200-235 110-125 200-235 14-26 70 90 1.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Operating Parameters cont. YAZT026 thru YAZT072 (with YAH Series Air Handler) First Stage Operation Entering Water Temp °F 50 70 90 Entering Water Temp °F 30 50 70 Cooling -- No Hot Water Generator YAZT072 Suction Discharge Pressure Pressure PSIG PSIG 130-150 200-245 1.5 YAZT026 thru YAZT064 Suction Discharge Pressure Pressure PSIG PSIG 130-150 193-230 8-16 7-14 7-20 18-24 3.0 128-153 190-230 125-140 205-240 8-16 3-10 9-14 18-25 1.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Pressure Drop Single Speed Model GPM 022 Dual Capacity Pressure Drop (PSI) Model GPM 30°F 50°F 70°F 90°F 110°F 3 4.5 6 8 0.9 1.7 2.8 4.7 0.9 1.6 2.7 4.4 0.8 1.5 2.5 4.1 0.7 1.4 2.3 3.9 0.7 1.3 2.2 3.6 026 full load 030 4 6 8 10 1.3 2.7 4.5 6.8 1.2 2.5 4.2 6.3 1.2 2.4 3.9 5.4 1.1 2.2 3.7 5.4 1.0 2.2 3.4 5.0 036 5 7 9 12 1.0 2.1 3.6 6.3 1.0 1.9 3.3 5.9 0.9 1.8 3.0 5.5 0.8 1.7 2.8 5.1 042 5 8 11 14 0.8 2.1 4.2 7.6 0.7 2.1 4.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Refrigerant Circuit Guideline Symptom Under Charged System (Possible Leak) Over Charged System Low Air Flow Heating Low Air Flow Cooling Low Water Flow Heating Low Water Flow Cooling High Air Flow Heating High Air Flow Cooling High Water Flow Heating High Water Flow Cooling Low Indoor Air Temperature Heating Low Indoor Air Temperature Cooling High Indoor Air Temperature Heating High Indoor Air Temperature Cooling Restricted TXV (Check Service Advisory) Insuf
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Heat of Extraction/Rejection Data - Dual Capacity Units Model GPM Heat of Extraction (kBtuh) 30°F 3.0 Part Load 026 038 049 064 072 110°F 22.6 21.7 23.6 23.0 21.7 20.2 23.0 21.9 23.7 23.1 21.7 20.2 17.8 23.4 28.5 31.0 31.2 30.0 6.0 13.4 18.8 24.7 29.9 29.9 31.1 31.3 29.9 28.1 8.0 13.6 19.3 25.1 30.5 30.1 31.2 31.3 29.9 28.1 17.9 23.3 28.1 32.5 31.8 30.0 6.0 12.8 18.7 24.5 29.8 29.8 32.7 32.0 30.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Heat of Extraction/Rejection Data - Single Speed Units Model GPM Heat of Extraction (kBtuh) 30°F 3.0 022 70°F 90°F 25.6 25.4 23.5 110°F 14.3 19.1 23.0 23.3 25.8 25.5 23.5 22.3 19.4 23.5 23.5 26.0 25.5 23.6 22.4 19.2 25.0 29.8 31.2 31.5 29.8 6.0 14.0 19.8 26.0 31.0 29.0 31.1 31.4 29.7 26.4 8.0 14.2 20.4 26.5 32.5 29.3 31.4 31.6 29.9 26.5 23.6 31.0 37.2 38.6 39.7 36.7 7.0 17.5 24.7 32.3 38.8 32.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Troubleshooting Aurora Control System Refrigerant Systems NOTE: Refer to the Aurora Base Control Application and Troubleshooting Guide and the Instruction Guide: Aurora Interface and Diagnostics (AID) Tool for additional information. To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Compare the change in temperature on the air side as well as the water side to the Unit Operating Parameters tables.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Unit Startup/Troubleshooting Heating Cycle Analysis Measure suction temperature here at TXV bulb in heating modes. Measure suction temperature here at TXV bulb in cooling modes.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Troubleshooting cont. Single Speed/Dual Capacity Startup/Troubleshooting Form 1. Job Information Model # Job Name: Serial # Install Date: 2. Flow Rate in gpm Loop: Open / Closed Hot Water Generator: Y / N SOURCE COAX HEATING LOAD COAX (Water-to-Water) COOLING HEATING COOLING WATER IN Pressure: a. psi a. psi a. psi a. psi WATER OUT Pressure: b. psi b. psi b. psi b. psi Pressure Drop: a - b c. psi c. psi c. psi c.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Preventive Maintenance Water Coil Maintenance Other Maintenance 1. Filters 2. Keep all air out of the water. An open loop system should be checked to ensure that the well head is not allowing air to infiltrate the water line. Lines should always be airtight. Keep the system under pressure at all times. It is recommended in open loop systems that the water control valve be placed in the discharge line to prevent loss of pressure during off cycles.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Service Parts List Single Speed Split Units Compressor YAZS022 YAZS030 YAZS036 YAZS042 YAZS048 YAZS060 YAZS070 Compressor 34P581-01 34P582-01 34P583-01 34P578-01 34P579-01 34P580-01 34P646-01 Run Capacitor 16P002-18 16P002-25 16P002-41 16P002-20 Sound Jacket 16P002-21 92P504A05 92P504A16 Power Harness 11P781-01 Solenoid Harness Accumulator Coax Refrigeration Components N/A 36P509-02 62I594-01 62I588-01 TXV 33P609-01 Reversing
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Service Parts List cont.
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Notes 45
AFFINITY INDOOR SPLIT SERIES INSTALLATION MANUAL Revision Guide Pages: All Description: First Published 46 Date: By: 03 Sept 2013 DS
Product: Type: Size: Affinity Indoor Split Series Geothermal/Water Source Heat Pump 2-6 Ton Single Speed 2-6 Ton Dual Capacity Document Type: Part Number: Release Date: Installation Manual IM2503SK6 09/13 ©2013 The manufacturer has a policy of continual product research and development and reserves the right to change design and specifications without notice. York and Affinity are registered trademarks of Johnson Controls, Inc., and are used with permission.
