Application and Service Guide andService Application 500A11 700A11 CUS AG2500AN 5/13 AG2500AN 5 andd 7 SeriesS i ApplicationA li ti and Service Guide 5 AND 7 SERIES APPLICATION AND SERVICE GUIDE Table of Contents How it Works . 4 Aurora Fault/Alarm Codes (ABC-Red LED) . 7 Variable Capacity Technology Description. 11 Sensors. .13 7 Series Thermostats. 14 Variable Speed Airflow (7 Series Only) . .15 SuperBoost Cooling (7 Series Only) . 16 Waterflow . 16 Dehumidification . .17 Revision Guide . 19 5 AND 7 SERIES APPLICATION AND SERVICE GUIDE How it Works The Aurora Control System - Base, automation inputs that are AID configurable for different Advanced, and Advanced VS types of alarms from sump pumps to home security. The Smart Grid input is AID configurable with many options A new sophisticated Aurora Control system is modular and to react to Utility controlled relay operation for ON Peak designed to grow with the application. The base Aurora optimization. The AXB also expands the communication Control features a microprocessor control to sequence all capability for IntelliZone2 ready operation as well as other components during operation for optimum performance, expansion with the ClimateTalk protocol. The advanced and provides easy-to-use troubleshooting features with control is available on the 5 Series. fault lights and on-board diagnostics and a hand held Aurora Interface Diagnostic (AID) Tool. The Advanced Aurora Advanced VS Control Aurora Control Adds the Aurora Expansion Board (AXB) to further extend the capability of the system to include The Advanced VS of the 7 Series adds special programming compressor current monitoring, advanced loop and DHW of the ABC for the variable speed 7 Series to the Advanced pump control as well as service, performance and energy Control and adds variable speed compressor and electronic monitoring sensor kit capability. expansion valve capability. Several documents detail the operation of individual Aurora Components components of the Aurora System: The Aurora Control functions around the concept • ABC Application Guide for early ABC Base Controls of modularity: (software STD Ver 1.*) • Aurora Base Control • ABC Application Guide for later 5 Series and other Base (ABC) This main board Controls as well as 5 series Advanced (software STD Ver 2.*) controls the basic • ABC Application Guide for 7 Series Aurora Advanced VS functions of compressor Variable Speed (software VSPD Ver 2.*) blower motor, RV, • AID Tool Application Guide thermostat and other • AWL Application Guide basic component control. 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 • Aurora Interface and network. The ABC features microprocessor control and HP, Diagnostics (AID) Tool is LP, Condensate & Freeze detection, over/under voltage a hand held tool that can faults along with communicating thermostat capability for be plugged into any ABC complete fault detection text at the thermostat. board for quick setup, Aurora uses the Modbus communication protocol to configuration, diagnostic communicate between modules. Each module contains and troubleshooting the logic to control all features that are connected to capability. 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 • Aurora Expansion thermostat, expansion board, or other slave devices. The Board (AXB) is added second channel is configured as a slave for connecting to include compressor the Aurora Interface Diagnostic Tool (AID Tool). The base current monitoring, control is only available on the 5 Series. loop pump slaving, intelligent HWA control, VS pump capability, Aurora Advanced Control and also allows optional The Aurora Advanced Control expands on the capability energy, refrigeration and of the Aurora Base Control (ABC) System by adding the performance monitoring Aurora Expansion Board (AXB). The additional features add-on sensor kits include compressor current monitoring, loop pump slaving, intelligent HWA control, VS pump capability, and also allows optional energy, refrigeration and performance monitoring add-on sensor kits. The AXB also features a second field configurable accessory relay, and two home 4 5 AND 7 SERIES APPLICATION AND SERVICE GUIDE How it Works cont. • Aurora Weblink (AWL) is a device that can be added on The AXB has 3 other independent com ports for differing for ‘black box capability to record all sensor and control protocols; for IntelliZone2, ClimateTalk Components, and events for forensic diagnosis onto an SD memory card Communicating ECM fan motors. None of these ports and for wireless connection to the internet comply with the ModBus protocol set up for the rest of the • Thermostats – several Aurora system and are for proprietary communications to communicating thermostatt external components. models are available for connection to the Aurora The ModBus communication is accomplished within the system with varying cabinet using shielded and ground cabling. This shield is features. (Traditional Y1/ most important in 7 Series applications where the VS Drive Y2 stats can be used with component, by its very nature, emits electro-magnetic many models but some interference and can interfere with ModBus communications. features will be eliminated). Round ferrite ‘donuts’ can be observed at various locations The 7 Series requires a to aid in ‘cleaning’ the communication lines. communicating thermostat. Each line is comprised of an R (+24VAC), C (common) and a ‘+’ and ‘-‘ communication line. At times the ‘R’ and ‘C’ lines may not be connected or needed depending upon whether the connecting device needs powered. The terminals marked ‘+’ and ‘-‘ should not be switched. • IntelliZone2 (IZ2) is Although damage may not occur to the boards directly, added to the system communication will not be possible. but requires the AXB for a dedicated The communication voltage and current are communication port small, therefore 24 awg wire is adequate for these specifically designed communication lines and although a shield is not for the IZ2. IZ2 allowss required, it is recommended in high electro-magnetic for up to 2 zones withh interference (EMI) environments such as with a variable single speed, 4 zones speed compressor drive. An extra Aurora communication with dual capacity andd ‘expansion’ connector is available for connecting future 6 zones with variable devices such as the AWL and other devices onto the main speed compressors. ABC ModBus line for future expansion. • Other communicating components - Variable Speed Compressor Drive (VS Drive) A small green LED is located next to each of the this drive communicates with the ABC for communication ports to aid in evaluating active commands and returns status, sensor values communication at that specific port. This is true for each and faults. board. The blinking indicates transmission or receiving - Electronic Expansion Valve (EEV) Board is a communication activity. small board connected to the VS Drive which controls the EEV via pressure and temperature Aurora Compatibility sensors and a stepper motor. The Aurora control is a - Expansion for other communicating components Config Aurora System large roll out and inevitably Dev Comm Ver such as ECM blower motor and HRV/ERVs, will include phases of ABC Y X.XX product launch. With these AXB Y X.XX Aurora Communications phases come software and The Aurora Control functions around the concept of component compatibility modularity and intercommunications between multiple issues. Current software boards. The communication is a 4 wire ModBus protocol. versions of each component ModBus protocol is an open source protocol becoming can be viewed in the Aurora more popular with equipment manufacturers for use in Config Screen shown. A HVAC equipment. The Aurora has one slave ‘bus’ for the compatibility chart is shown Add Device Remove Device ABC, AXB, AWL, VS Drive, EEV, and thermostats. in the ABC/AXB Application Back and Troubleshooting guide. Option Enter The AID Tool only plugs into the ABC AID Tool master port (RJ style connector) and will not work at any other location. 5 5 AND 7 SERIES APPLICATION AND SERVICE GUIDE How it Works cont. Aurora Status Modes (ABC-Green LED) SafeMode - The system has encountered an undesirable operation condition that prevents automatic speed control, The status (green) LED will show the current mode of the e.g. lost a sensor signal. To avoid damage to the system or heat pump i.e. normal (heating, cooling or standby) or other components, the drive operates the compressor at a fixed modes such as load shed or emergency shutdown. The speed of 2400 rpm awaiting the problem to be solved and following table shows all of the modes and the associated eventually returning to normal operation. If the problem flash codes followed by a description of each. The status cannot be solved the drive stops and issues a fault (see mode can also be read directly from the AID Tool. lockout mode). Status LED (LED3, Green) Aurora Safety Features Description of Operation Fault LED, Green Normal Mode ON The following safety features are provided to protect Control is Non-functional OFF the compressor, heat exchangers, wiring and other Test Mode Slow Flash components from damage caused by operation outside of Lockout Active Fast Flash design conditions. Dehumidification Mode Flash Code 2 Load Shed Flash Code 5 Fuse – a 3 amp automotive type plug-in fuse provides Emergency Shutdown Flash Code 6 protection against short circuit or overload conditions. On Peak Mode Flash Code 7 Warning! VS Derated Flash Code 8 Anti-Short Cycle Protection – 4 minute anti-short cycle Warning! VS SafeMode Flash Code 9 protection for the compressor. Normal Operation - The system is operating Random Start – 5 to 80 second random start upon power up. without limitations. Fault Retry – in the fault condition, the control will stage off Test Mode - The unit is in test mode and many of the the outputs and then “try again” to satisfy the thermostat timings are sped up to facilitate easier troubleshooting.