Synergy3D IM1300YS User manual

IM1300YS 06/10
Installation Information
Water Piping Connections
Hot Water Generator Connections
Electrical
Startup Procedures
Troubleshooting
Preventive Maintenance
Synergy3D Installation Manual
Geothermal Heat Pump with Water Heating for Radiant Floor Applications
• R-410A Refrigerant
• 3-6 Tons

3
SYNERGY3D INSTALLATION MANUAL

Model Nomenclature 4
General Installation Information 5-7
Closed Loop Ground Source Systems  8
Open Loop Ground Water Systems  9
Hot Water Generator Connections 10
Typical Buffer Tank Installation 10
Electrical Data 11-12
Thermostat Installation12
Physical Data 13
Pressure Drop13
Dimensional Data14-15
Wiring Schematic 16-17
Hydronic Section 18-19
Microprocessor Control 20-21
Hydronic Operation 22
Microprocessor Control Operation  22-24
Operating Limits  25
Operation Logic 25
Correction Factor Tables  26
Auxiliary Heat 27
Blower Performance Data  28
Startup  29
Synergy3D Startup and Troubleshooting Form 30
Synergy3D Cycle Analysis 31-32
Operating Parameters 33
Troubleshooting34
Preventative Maintenance  35
Replacement Procedures  35
Service Parts List  36

4
SYNERGY3D INSTALLATION MANUAL

1 2 3
SD V
4-6
049
7
B
8
1
9 10
0
11
1
12
C
13 14-15
TL AP
Model Type
S = Synergy3D
Compressor Type
D = Dual Capacity
Cabinet Configuration
V = Vertical
Unit Capacity
Vintage
B = Current
Voltage
1 = 208/230/60/1
NOTES:
* Rear discharge is only available on sizes 049, 064, and 072.
The factory installed Hot Water option (hot water generator) does not
include a factory mounted circulating pump or temperature control. Kit
DPK5 (ordered separately) includes field installed circulator, hot water
tank adaptor, temperature limit, and installation instructions.
Filter Option
AP = AlpinePure 411
Return Air Configuration
L = Left
R = Right
Discharge Air Configuration
T = Top
R = Rear*
Coax Options
C = Copper
N = Cupronickel
L = Source Cupronickel & Load Copper
S = Source Copper & Load Cupronickel
Blower Options
1 = ECM
2 = Oversized ECM (038 & 049)
Hot Water Options
0 = No Hot Water Generator, No IntelliStart
2 = Hot Water Generator without factory
installed pump, No IntelliStart
3 = No Hot Water Generator, IntelliStart
5 = Hot Water Generator without factory
installed pump, IntelliStart

5
SYNERGY3D INSTALLATION MANUAL

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 hand return
configuration. 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 Vertical Unit
Mounting illustration).

An air outlet collar is provided on vertical top flow units
to facilitate a duct connection, which is shipped inside the
unit. 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 in. 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, a previous
check should have been made to assure that the duct
has the capacity to handle the air required for the unit
application. If ducting 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 when necessary
The duct system should be sized to handle the design
airflow quietly. To maximize sound attenuation of the unit
blower, the supply and return plenums should include inter-
nal duct liner of glass fiber or be of ductboard construction
for the first few feet. If air noise or excessive airflow is a
problem, the blower speed can be changed. See the Blower
Performance and Blower Speed sections.

Move units in the normal “Up” orientation. Vertical units
are not to be moved, but may be stored one upon another
to a maximum height of two units. 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.

Locate the unit in an indoor area that allows easy removal
of the filter and access panels, and has 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. 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.

Installation and servicing of 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 basic maintenance
functions of cleaning coils and cleaning and replacing
filters. All other operations should be performed by trained
service personnel. When working on 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 quenching cloth for brazing operations. Have
fire extinguisher available for all brazing operations.
 Before performing service or
maintenance operations on the system, turn off
main power switches to the unit. Turn off accessory
heater power switch if applicable. Electrical shock
could cause serious personal injury.
 A minimum of 24 in. clearance should
be allowed for access to front access panel.
Vibration
Absorbing
Mesh
Air Pad



6
SYNERGY3D INSTALLATION MANUAL

All Synergy3D source water connections are swivel piping
fittings that accept a 1 in. Male Pipe Thread (MPT) (see
Female Locking RIng illustration). The swivel pipe connector
has a rubber gasket seal similar to a garden hose gasket,
which when mated to the flush end of 1 in. threaded pipe
provides a leak-free seal without the need for thread sealing
tape or compound. Check to ensure that the rubber seal is
in the swivel connector prior to attempting any connection.
The rubber seals are shipped attached to the water line.
To make the connection to a ground loop system, mate the
brass connector (supplied in CK4L and CK4L-GL connector
kits) against the rubber gasket in the swivel connector, and
thread the female locking ring onto the pipe threads, while
maintaining the brass connector in the desired direction (see
Female Locking RIng illustration). Tighten the connectors by
hand and then gently snug the fitting with pliers to provide a
leak proof joint. When connecting to an open loop (ground
water) system, thread 1 in. MPT fitting into the swivel
connector and tighten in the same manner as noted above.
The open and closed loop piping system must include
pressure/temperature taps for serviceability.
Never use flexible hoses smaller than 1 in. inside diameter on
the unit and limit hose length to 10 ft. per connection. Check
carefully for water leaks.
Locking
Ring
Stainless
Steel
Snap Ring
Gasket
Support
Sleeve
Gasket
Material

 Load side fittings are same type as source.
 Water piping exposed to outside
temperature may be subject to freezing.


7
SYNERGY3D 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
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
Material Copper 90/10 Cupro-Nickel 316 Stainless Steel
pH Acidity/Alkalinity 7- 9 7 - 9 7 - 9
Scaling Calcium and Magnesium Carbonate (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm (Total Hardness) less than 350 ppm
Hydrogen Sulfide Less than .5 ppm (rotten egg smell
appears at 0.5 PPM) 10 - 50 ppm Less than 1 ppm
Sulfates Less than 125 ppm Less than 125 ppm Less than 200 ppm
Chlorine Less than .5 ppm Less than .5 ppm Less than .5 ppm
Chlorides Less than 20 ppm Less than125 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 .5 ppm Less than .5 ppm Less than .5 ppm
Ammonia Nitrate Less than .5 ppm Less than .5 ppm Less than .5 ppm
Ammonia Hydroxide Less than .5 ppm Less than .5 ppm Less than .5 ppm
Ammonia Sulfate Less than .5 ppm Less than .5 ppm Less than .5 ppm
Total Dissolved Solids (TDS) Less than 1000 ppm 1000-1500 ppm 1000-1500 ppm
LSI Index +0.5 to -.05 +0.5 to -.05
Iron, Fe2+ (Ferrous)
Bacterial Iron Potential < .2 ppm < .2 ppm < .2 ppm
Iron Oxide Less than 1 ppm. Above this level
deposition will occur.
Less than 1 ppm. Above this level
deposition will occur.
Less than 1 ppm. Above this level
deposition will occur.
Suspended Solids Less than 10 ppm and filtered for max of
600 micron size
Less than 10 ppm and filtered for max of
600 micron size
Less than 10 ppm and filtered for max of
600 micron size
Threshold Velocity (Fresh Water) < 6 ft/sec < 6 ft/sec < 6 ft/sec
Grains = PPM divided by 17 • mg/l is equivalent to PPM 2/8/08
Corrosion
Erosion
Iron Fouling
(Biological Growth)
+0.5 to -.05
can likewise become scaled and possibly plugged. In areas
with extremely hard water, the owner should be informed
that the heat exchanger may require occasional flushing.
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 loss of warranty.

Set the freeze detection limit switch SW2 #2 to “Loop” on
the printed circuit board for applications using a closed
loop antifreeze solution. On applications using an open
loop/ground water system, set to “Well” (the factory
setting). If using closed loop and no antifreeze solution
leave in “Well” position (the factory setting).

The internal condensate drain assembly consists of a drain
tube, which is attached 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 vertical
cabinet. The adapter will be glued to the field-installed
PVC condensate piping. A condensate hose is inside all
cabinets as a trapping loop; therefore, an external trap is
not necessary.


To obtain maximum performance the air coil should be
cleaned before start up. A 10% solution of dishwasher
detergent and water is recommended for both sides of coil;
a thorough water rinse should follow.

8
SYNERGY3D INSTALLATION MANUAL

Once piping is completed between the unit, flow center
and the ground loop (Figure 3), final purging and charging
of the loop is needed. A flush cart (at least a 1.5 HP pump)
is needed to achieve adequate flow velocity in the loop to
purge air 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 50-75 psi
(winter) or 40-50 psi (summer). This is normally adequate
for good system operation. Loop static pressure will
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.

Flexible
Duct
Collar
Vibration Absorbing Pad
P/T Plugs
LPK
Drain
Connector Kits with Armaflex
Disconnects
(IfApplicable)
GeoLink
Polyethylene w/
Armaflex
TO
LOOP
Auxiliary
Heater
Knockout
Low
Voltage to
Thermostat Unit Power
Unit Supply
Auxiliary
Heat Supply
* For complete information, refer to GeoLink®Flow Center Installation Manual
GeoLink
Flow
Center*
External
Pump
Power

When two Synergy3D units or one Envision unit and
one Synergy3D unit are connected to one loop pumping
system, pump control is automatically achieved by
connecting the slave terminals on connector P2 in both
After pressurization, be sure to burp the pump. Open
the screw 2 turns only in the end of the pump motor (if
Grundfos® pumps are used) to allow trapped air to be
discharged and to ensure the motor housing has been
flooded.Ensure the loop flow center provides adequate
flow through the unit by checking pressure drop across the
heat exchanger (Refer to Pressure Drop table). Usually 2.5-
3 gpm of flow per ton of cooling capacity is recommended
in earth loop applications. Refer to Wiring Schematics for
loop pump power wiring details.
units with 2-wire thermostat wire. These terminals are
polarity conscious (see Figure 10). The loop pump(s) may
be powered from either unit, whichever is more convenient.
If either unit calls, the loop pump(s) will automatically start.

9
SYNERGY3D INSTALLATION MANUAL
Typical open loop piping is shown in the Open System:
Ground Water Application. Always maintain water pressure
in the heat exchanger by placing water control valves at
the outlet of the unit to prevent mineral precipitation. Use
a closed, bladder-type expansion tank to minimize mineral
formation due to air exposure. Ensure proper water flow
through the unit by checking pressure drop across the heat
exchanger and comparing it to the figures in the pressure
drop tables. Normally about 2 GPM flow rate per ton of

 For open loop ground water systems or systems that do not contain and antifreeze solution,
set SW2-#2 to the “Well” position.

Flexible Duct
Collar
Vibration
Absorbing Pad
Drain
Disconnects
(If Applicable)
Auxiliary
Heater
Knockout
Unit
Supply
Aux. Heat
Supply
Rubber Bladder
Expansion Tank
Boiler Drains
For HX Flushing
Strainer
Low Voltage
to Thermostat
and Valve
Unit
Power
Shut Off Valves
(to isolate solenoid
valve while acid flushing)
Shut Off Valves
Water Out
Water In
Solenoid
Valve
Flow Control Valve
(on outlet of
Solenoid Valve)
P/T Plugs
CC-GND
CC
CCHI
Comfort
Alert
Y1
Y2
Logic Board
Violet(3)
Blk(1)
Wht(4)
Violet(2)
CC
SS
CC-GND
CC
CCHI
Comfort
Alert
Y1
Y2
Logic Board
Violet(3)
Blk(1)
Wht(4)
VM valve
Violet(2)
CC
SV
High Speed

Typical slow operating external
24V water solenoid valve (type
VM) wiring.
CC-GND
CC
CCHI
Comfort
Alert
Y1
Y2
Logic Board
Violet(3)
Blk(1)
Wht(4)
Violet(2)
CC
SS
CC-GND
CC
CCHI
Comfort
Alert
Y1
Y2
Logic Board
Violet(3)
Blk(1)
Wht(4)
VM valve
Violet(2)
CC
SV
High Speed

Typical external 24V water
solenoid valves (type PPV100,
BPV100) wiring.
cooling capacity (1.5 GPM per ton minimum at 50° F) is
needed in open loop systems.
Discharge water from the unit is not contaminated in any
manner and can be disposed of in various ways such as
recharge well, storm sewer, drain field, adjacent stream or
pond, etc. depending on local building codes. Most local
codes forbid the use of sanitary sewer for disposal. Consult
your local building and zoning department to ensure
compliance in your area.

10
SYNERGY3D INSTALLATION MANUAL
WaterFurnace
Synergy3D
GEO
STORAGE
TANK
LOAD PUMP
HYDRONIC
LOAD
Dielectric
Unions
80 or 120 gal. Geothermal Storage Tank
for hydronic load
Dielectric
Unions
1-1/2˝
FPT
Expansion
Tank
Air
Vent
Pressure
Gauge
30 PSI
RELIEF VALVE
Air
Separator
P/T Ports
80 gal. water heater tank
for hot water generation
Back Flow Preventer /
Pressure Reducing Valve
*NOTE: A 30 PSI pressure relief valve (Part No: SRV30)
should be used in hydronic applications.
Ball Valve
COLD
3/4˝ Domestic
HOT
3/4˝ Domestic
1-1/2˝
FPT
1˝ Connections
DPK5



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
as shown below or two 50-gallon water heaters connected
in a series. Electric water heaters are recommended. Make
sure all local electrical and plumbing codes are met for
installing a hot water generator. The Synergy3D is not
supplied with an internal circulator. A DPK5 kit will need
to be purchased to connect to the hot water generator.
 
   




SDV038 1.25 9 30’ 10 80 U.S. Gals
SDV049 1.25 12 30’ 10 80 U.S. Gals
SDV064 1.25 15 30’ 10 120 U.S. Gals
SDV072 1.50 18 30’ 10 120 U.S. Gals


The DPK5 kit is supplied with installation instructions,
circulator, tank adaptor and temperature limit switch.
Be sure to burp the pump. Open the screw 2 turns only
in the end of the pump motor (if Grundfos® pumps are
used) to allow trapped air to be discharged and to ensure
the motor housing has been flooded. A water softener is
recommended with hard water (greater than 10 grains or
170 ppm total hardness).

11
SYNERGY3D INSTALLATION MANUAL

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.

Line Voltage connection is made by connecting the
incoming line voltage wires to the “L” side of the contactor
as shown in Figure 9. Consult the Electrical Data table for
correct fuse size.

If the unit is to be used with an external loop pump (FC1
or FC2 flow center), the pump(s) will be connected to
the terminals on PB1 in the unit electrical box as shown
in Figure 9. The pumps will automatically be cycled as
required by the unit or by a secondary signal from another
Synergy3D unit sharing the flow center. (Refer to the
Wiring Schematics section.)

All 208-230 volt units are factory wired for 230 volt
operation. For 208 volt operation, the red and the blue
transformer wires must be switched on terminal strip PS1.
(Refer to the Wiring Schematics section.)
Shut
Down C C not
used
not
used
SL1
In
SL1
Out
Shut
Down C C not
used
not
used
SL1
In
SL1
Out
With pump
wired to
Unit 1
With pump
wired to
Unit 2
Shut
Down C C not
used
not
used
SL1
In
SL1
Out
Unit #1
Electromechanical
Unit #1
R Y O G L S C
Coil
VX, VL
Normally Open
Contacts
24v
Unit #1
Unit #2



L1
L2
EXTERNAL LOOP
208/230 VAC
1/2 HP MAX
TB

12
SYNERGY3D INSTALLATION MANUAL



Position the thermostat subbase against the wall so that
it is level and the thermostat wires protrude through the
subbase. Mark the position of the subbase mounting holes
and drill holes with a 3/16 in. bit. Install anchors and secure
base to the wall. Thermostat wire must be 8 conductor 18
AWG wire. Strip the wires back 1/4 in. (longer strip lengths
may cause shorts) and insert the thermostat wires into the
Synergy3D connector as shown inthe Thermostat Wiring
diagram. Tighten the screws to ensure good connections.
The thermostat has the same type of connectors,
requiring the same wiring. See instructions enclosed in
the thermostat for detailed installation and operation
information.

The Synergy3D unit is compatible with virtually any
24VAC thermostat. However, the multi-stage nature of this
product requires a 3-stage heating/2-stage cooling type
thermostat.
 DIP switch SW2-8 is required to be in the
“OFF” position for the control to operate with
FaultFlash or ComforTalk thermostats. SW2-8
in the “ON” position configures the control to
operate with typical thermostats (continuous
lockout signal). There must be a wire connecting
Y2 on the microprocessor controller to 2nd
stage compressor on the thermostat for proper
operation.
R
Y1
C
W
O
G
L
24VAC (Hot)
24VAC (Common)
Compressor (1st Stage)
Aux. Heat
Reversing Valve
Blower Relay
System Monitor
Microprocessor Controller
Thermostat Connection
Y2 Compressor (2nd Stage)
 



 




















   
 208-230/60/1 197/254 26.0 16.6 82.0 29.0 1.07 5.4 4.0 27.1 31.2 47.8 45
 208-230/60/1 197/254 26.0 16.6 82.0 29.0 1.07 5.4 7.0 30.1 34.2 50.8 50
 208-230/60/1 197/254 33.0 21.1 96.0 34.0 1.07 5.4 4.0 31.6 36.8 57.9 50
 208-230/60/1 197/254 33.0 21.1 96.0 34.0 1.07 5.4 7.0 34.6 39.8 60.9 60
 208-230/60/1 197/254 40.0 25.6 118.0 41.0 1.07 5.4 7.0 39.1 45.5 71.2 70
 208-230/60/1 197/254 42.5 27.2 150.0 53.0 1.07 5.4 7.0 40.7 47. 5 74.7 70
5 / 7/ 0 9
Rated Voltage of 208-230/60/1.
HACR circuit breaker in USA only.
Local electrical codes overrule any wiring recommendations.
* With optional 1 HP ECM2 motor
**With optional IntelliStart
Min/Max Voltage of 197/254.
All fuses Class RK-5.


13
SYNERGY3D INSTALLATION MANUAL

    
Compressor (1 each) Copeland Scroll
Factory Charge R410a, oz [kg] 90 [2.55] 111 [3.14] 128 [3.62] 128 [3.62]
ECM Blower Motor & Blower
Blower Motor Type/Speeds ECM Variable Speed
Blower Motor- hp [W] 1/2 [373] 1/2 [373] 1 [746] 1 [746]
Blower Wheel Size (Dia x W), in. [mm] 11 x 10 [279 x 254] 11 x 10 [279 x 254] 11 x 10 [279 x 254] 11 x 10 [279 x 254]
Coax and Water Piping
Loop Water Connections Size - Swivel - in [mm] 1 [25.4] 1 [25.4] 1 [25.4] 1 [25.4]
Hydronic Water Connections Size - Swivel - in [mm] 1 [25.4] 1 [25.4] 1 [25.4] 1 [25.4]
HWG Connection Size - Swivel - in [mm] 1 [25.4] 1 [25.4] 1 [25.4] 1 [25.4]
Coax & Piping Water Volume - gal [l] 1.3 [4.9] 1.6 [6.1] 1.6 [6.1] 1.6 [6.1]
Vertical
Air Coil Dimensions (H x W), in. [mm] 28 x 25 [711 x 635] 32 x 25 [813 x 635] 36 x 25 [914 x 635] 36 x 25 [914 x 635]
Air Coil Total Face Area, ft2 [m2] 4.9 [0.451] 5.6 [0.570] 6.3 [0.641] 6.3 [0.641]
Air Coil Tube Size, in [mm] 3/8 [9.5] 3/8 [9.5] 3/8 [9.5] 3/8 [9.5]
Air Coil Number of rows 3 3 4 4
Filter Standard - 2” [51mm] Pleated MERV11 Disposable, in [mm] 28 x 30 [712 x 762] 32 x 30 [813 x 762] 36 x 30 [914 x 762] 36 x 30 [914 x 762]
Weight - Operating, lb [kg] 425 530 540 540
Weight - Packaged, lb [kg] 445 550 560 560
6/2/08

  
    


5 1.2 1.2 1.1 1.0 1.0
7 2.2 2.1 1.9 1.8 1.7
9 3.4 3.2 3.0 2.8 2.6
11 4.9 4.6 4.3 4.0 3.7


4 0.9 0.8 0.8 0.7 0.7
6 1.7 1.6 1.5 1.4 1.3
8 2.8 2.6 2.5 2.3 2.1
10 4.2 3.9 3.7 3.4 3.2


6 1.2 1.2 1.1 1.0 1.0
9 2.4 2.2 2.1 2.0 1.8
12 3.9 3.6 3.4 3.2 2.9
15 5.7 5.3 5.0 4.7 4.3


5 1.1 1.1 1.0 0.9 0.9
8 2.0 1.8 1.7 1.6 1.5
11 3.4 3.1 2.9 2.8 2.5
14 5.0 4.7 4.4 4.1 3.8


8 2.0 1.8 1.7 1.6 1.5
12 3.9 3.6 3.4 3.2 2.9
16 6.5 6.0 5.6 5.2 4.8
20 9.7 9.1 8.5 8.0 7.4


6 1.2 1.2 1.1 1.0 1.0
10 2.6 2.5 2.3 2.1 2.0
14 5.0 4.7 4.4 4.1 3.8
18 8.1 7.6 7.1 6.6 6.1


12 3.9 3.6 3.4 3.2 2.9
15 5.7 5.3 5.0 4.7 4.3
18 8.1 7.6 7.1 6.6 6.1
21 10.8 10.1 9.5 8.9 8.2


10 2.6 2.5 2.3 2.1 2.0
13 3.4 3.3 3.0 2.7 2.6
16 6.5 6.1 5.8 5.4 5.0
19 8.9 8.4 7.9 7.4 6.9
4/9/08

14
SYNERGY3D INSTALLATION MANUAL




  









            
   
















   




 in 25.6 31.6 50.4 7.3 18.9 2.3 15.9 13.6 16.6 10.6 1 in.
Swivel
1 in.
Swivel
1 in.
Swivel
8.0 11.3 12.8
cm 65.0 80.3 128.0 18.5 48.0 5.8 40.4 34.5 42.2 26.9 20.3 28.7 32.5
 in 25.6 31.6 54.4 7.3 18.9 2.3 15.9 15.9 18.9 10.6 1 in.
Swivel
1 in.
Swivel
1 in.
Swivel
8.0 11.3 12.8
cm 65.0 80.3 138.2 18.5 48.0 5.8 40.4 40.4 48.0 26.9 20.3 28.7 32.5
 in 25.6 31.6 58.4 7.3 18.9 2.3 15.9 15.9 18.9 10.6 1 in.
Swivel
1 in.
Swivel
1 in.
Swivel
8.0 11.3 12.8
cm 65.0 80.3 148.3 18.5 48.0 5.8 40.4 40.4 48.0 26.9 20.3 28.7 32.5
 in 25.6 31.6 58.4 7.3 18.9 2.3 15.9 15.9 18.9 10.6 1 in.
Swivel
1 in.
Swivel
1 in.
Swivel
8.0 11.3 12.8
cm 65.0 80.3 148.3 18.5 48.0 5.8 40.4 40.4 48.0 26.9 20.3 28.7 32.5
Condensate is 3/4 in. PVC female glue socket and is switchable from side to front
Unit shipped with deluxe 2 in. (field adjustable to 1 in.) duct collar/filter rack extending from unit 3.25 in. and is suitable for duct connection.
Discharge flange is field installed and extends 1 in. [25.4 mm] from cabinet
Decorative molding and water connections extend 1.2 in. [30.5 mm] beyond front of cabinet.
LEFT RETURN
LEFT FRONT
TOP
RIGHT RETURN
TOP
FRONT RIGHT
3/9/10
C
X
BA
P
Q
AB
U
F
D
GE
W
F
D
GE
NO
V
T
P
Q
RS
N
J
U
V
T
S
J
C
X
W
HI
KLM
YY






 
           








 in 6.9 1.1 18.0 18.0 3.8 1.7 28.1 26.0 1.7 28.7 1.0 2.1
cm 17.5 2.8 45.7 45.7 9.7 4.3 71.4 66.0 4.3 72.9 2.5 5.3
 in 6.9 1.1 18.0 18.0 3.8 1.7 28.1 30.0 1.7 28.7 1.0 2.1
cm 17.5 2.8 45.7 45.7 9.7 4.3 71.4 76.2 4.3 72.9 2.5 5.3
 in 6.9 1.1 18.0 18.0 3.8 1.7 28.1 34.0 1.7 28.7 1.0 2.1
cm 17.5 2.8 45.7 45.7 9.7 4.3 71.4 86.4 4.3 72.9 2.5 5.3
 in 6.9 1.1 18.0 18.0 3.8 1.7 28.1 34.0 1.7 28.7 1.0 2.1
cm 17.5 2.8 45.7 45.7 9.7 4.3 71.4 86.4 4.3 72.9 2.5 5.3
3/9/10


15
SYNERGY3D INSTALLATION MANUAL

LEFT RETURN
LEFTREAR
RIGHT RETURN
REARRIGHT
3/24/10
P
Q
C
N
A
OV
C
B
U
V
T
B
C
T
V
U
V
Q
P
R
N
C
A
K
L
M
F
DJGE
A
1.90
1.90
H
IHI
X
X
W
WS
S
YY



  
             









   






   





   




 in. 25.6 31.6 54.4 7.3 18.9 2.3 15.9 15.9 18.9 10.6 1”
Swivel
1”
Swivel
1”
Swivel
8.0 11.3 12.8
cm. 65.0 80.3 138.2 18.5 48.0 5.8 40.4 40.4 48.0 26.9 20.3 28.7 32.5
 in. 25.6 31.6 58.4 7.3 18.9 2.3 15.9 15.9 18.9 10.6 1”
Swivel
1”
Swivel
1”
Swivel
8.0 11.3 12.8
cm. 65.0 80.3 148.3 18.5 48.0 5.8 40.4 40.4 48.0 26.9 20.3 28.7 32.5
 in. 25.6 31.6 58.4 7.3 18.9 2.3 15.9 15.9 18.9 10.6 1”
Swivel
1”
Swivel
1”
Swivel
8.0 11.3 12.8
cm. 65.0 80.3 148.3 18.5 48.0 5.8 40.4 40.4 48.0 26.9 20.3 28.7 32.5






 
           








 in. 39.4 9.1 13.3 13.6 8.1 1.7 28.1 30.0 1.7 28.7 1.0 2.1
cm. 100.1 23.1 33.8 34.5 20.6 4.3 71.4 76.2 4.3 72.9 2.5 5.3
 in. 43.4 9.1 13.3 13.6 8.1 1.7 28.1 34.0 1.7 28.7 1.0 2.1
cm. 110.2 23.1 33.8 34.5 20.6 4.3 71.4 86.4 4.3 72.9 2.5 5.3
 in. 43.4 9.1 13.3 13.6 8.1 1.7 28.1 34.0 1.7 28.7 1.0 2.1
cm. 110.2 23.1 33.8 34.5 20.6 4.3 71.4 86.4 4.3 72.9 2.5 5.3
3/26/10
Condensate is 3/4 in. PVC female glue socket and is switchable from side to front
Unit shipped with deluxe 2 in. (field adjustable to 1 in.) duct collar/filter rack extending from unit 3.25 in. and is suitable for duct connection.
Discharge flange is field installed and extends 1 in. [25.4 mm] from cabinet
Decorative molding and water connections extend 1.2 in. [30.5 mm] beyond front of cabinet.


16
SYNERGY3D INSTALLATION MANUAL

NOTE 4
240V L1
HP
240V L2
Premier 2
Microprocessor
Logic Control
(DC Voltage)
P1
Fused L2
C
Unit Power
208-230/60/1
G
Ext Pump
1/2 hp Total
208-230/60/1
NO
CR2 COM
NO NC
CR4 COM
F1-10A 240V
Fused L2
NO
CR1 COM
Blue(17)
Blue(13)
Load
Pump
CC
RV
1
2
3
4
5
6
7
8
1
2
3
P4 Black
Black
Orange
Orange
1
2
3C
P2
Down
C
1
2
3
4
5
6
7
Shut
SL1 In
Not
SL1 Out
Used
Status LED PCB
17P503A01 Rev A
SW4
R
R
R
R
R
G
Y
R
1 2 3
Pulse L / Constant L
(See Note 6)
Whole / FA
FAH / Hydronic
Loop / Well
Test / Norm
Outputs / Norm
Inputs / Norm
Two Speed / Single
NO NC
CR3 COM
F1-10A 240V
Compressor
NOTE 5
POPC / Spring
No RPM / RPM
Over-Ride Time
Over-Ride Time
Brown
Yellow
Tan
Tan
CC-GND
240V L2
G
W
O
R
C
Y1
Y2
LO
C
R
S
On
SW1
1
2
3
4
5
6
7
8
9
10
11
12
On
SW3
On
SW2
1
2
3
4
5
6
7
8
1
2
3
4
5
Pump Pump
G
T
Yellow FD
CO
NOTE 1
Violet
Yellow
Black
Blue
Not Used
Brown
Gray
Blk
Hydronic
Thermostat
(Note 7)
Damper
HW
R
PO
PC
Com
1
P2
1
2
P10
3
4
5
6
P10 1 2 3 4 5 6
White
Red
Tan
Pink
Orange
Blue
White
Red
Tan
Pink
Orange
Blue
HE1 TS1
HE2 TS2
HE3 TS3
HE4 TS4
P7
Pink
Yel
Blk
Gray
Gray
Blk
Yel
Pink
Gray
Pink
Blk
Yel
Pink
Yel
Blk
Gray ER1
ER2
ER3
ER4
NO
NO
NO
NO
EA Series PCB
17P514A01
1
2
3
4
With optional auxiliary electric heat
Typical schematic shown
Not Used
Hydronic Cooling Slave Signal - 24VAC Input — “0” signal from
hydronic zone thermostat (Hydronic Cooling Slave Signal under
the Microprocessor Control Operation section)
DV
Not Used
CCHI
Brown
FAC / Hydronic
Over-ride time SW3-4 SW3-5
5 minutes
15 minutes
30 minutes
60 minutes
On
Off
On
Off
On
On
Off
Off
Over-Ride Selection
Violet
P5
3
4
9
11
2
10
8
1
12
5
14
13
6
7
P6
6
5
4
8
7
12
1
2
9
10
3
13
14
16
11
15
Blk(20)
Acc Com
Acc NC
Acc NO
P3
SV
Blk(23)
White(22)
NOTE 2
ECM2
Fan Motor
Grn
15 10163 8
On/Off PWM RPM
C2
RPM grnd
P12
P112 3 4 51
Grn
PB2
Auxiliary Electric Heat Power
208-230/60/1
L4 L2
L2
Pink
Yel
Blk
Gray
Pink
Yel
Blk
Gray
F2
L1
L1 L3G G
4
3
2
1
P8
Grn
3
1
P9
2
4
Brn
Or
Brn
Or
Blue
Violet
Brn
Or
Grn
3 2 14
3 2 14
ECM2
Fan Motor
15 10163 8
On/Off
PWM RPM
C2
RPM grnd
P12
P112 3 4 51
Red Black
Blue
LP
Blue
Blue
Comfort Alert
CS
+
-
DC SOL
Cap Tan(16)
Comfort
Alert
R
Y2
C
Y
Violet(3)
Black(1)
CC Violet(2)
Yel(6)
Wht(4)
Blk(5)
Thermistor
Light emitting diode - Green
Relay coil
Capacitor w/ bleed resistor
Switch - Condensate overflow
Switch - High pressure
Switch - Low pressure
Switch -Hot Water On/Off
Polarized connector
Factory Low voltage wiring
Factory Line voltage wiring
Field low voltage wiring
Field line voltage wiring
Optional block
DC Voltage PCB traces
Internal junction
Quick connect terminal
Wire nut
Field wire lug
Ground
Fuse
CC -
CO -
CR1 -
CR2-
CR3 -
CR4 -
F1 and F2 -
FD -
HP -
LP -
PB1 -
PS1,PS2
-
RV -
SW1 -
SW2 -
SW3 -
SW4 -
Compressor Contactor
Condensate overflow sensor
HW pump relay
Loop pump relay
Fuses
Freeze Detection sensor
High pressure switch
Low pressure switch
Power block
Power strips
Reversing Valve coil
DIP package 12 position
DIP package 8 position
DIP package 5 position
Hot water enable switch
Relay Contacts-
N.O., N.C.
G
T
1 3 2
P
L1
Damper relay
Damper relay
24 vac coil
SV
CS - Compressor Solenoid
LED Flash Code Description
Green Solid Module Has Power
Red Solid Y1 Present But Compressor Not Running
Code 1 Long Run Time
Code 2 System Pressure Trip
Code 3 Short Cycling
Code 4 Locked Rotor
Code 5 Open Circuit
Code 6 Open Start Circuit
Code 7 Open Run Circuit
Code 8 Welded Contactor
Code 9 Low Voltage
Yellow
Comfort Alert Status
Y2
Y
L
R
C
DC
Sol
Data
Port
Comfort Alert
Physical Layout
POWER
ALERT
TRIP
Operation Logic Data
STG1 STG2 STG3 EMERG STG1 STG2
Compressor On On On Off On On Stg 2 On
Reversing Valve Off Off Off Off On On Off
Loop Pump On On On Off On On On
Load Pump Off Off Off Off Off Off On
Aux Heater Off Off Staged Staged Off Off Off
Acc Relay On On On Off On On Off
Diverting Valve Off Off Off Off Off Off On
ECM Speed On On On On On On Off
T-Stat Signal Y1 Y1, Y2 Y1, Y2, W W Y1, O Y1, Y2, O HW
Damper Off Off Off On Off Off Off
Auxiliary 1 - Out On On On Off On On On
Operation
Logic Table
Heating
Cooling
Hot Wa ter
Mode
Field Selection Dips - #1 On, #6 On, #7 On
Drain pan overflow lockout
FD thermister (loop<15°F, well<30°F) Lockout
High pressure lockout
Low pressure lockout
ECM2 RPM < 100 rpm lockout
Microprocessor malfunction
Hot-water disable
Drain
Water Flow
High Press
Low Press
Air Flow
Status
HW Limit
HW off
LED Normal Display Mode
#1 Off, #6 On, #7 On
Drain pan overflow
FD thermister (loop<15°F, well<30°F)
High pressure
Low pressure
ECM2 RPM < 100 rpm
Not used
Current Fault Status
#6 Off, #7 On
Y1
Y2
O
G
W
SL1
HW
HW off
Inputs
#6 On, #7 Off
Compressor
Not used
RV
FAN
HW pump
Loop pump
DV
Outputs
#6 Off, #7 Off
Blower low
Blower med
Blower hi
Aux heat #1
Aux heat #2
Aux heat #3
Aux heat #4
Outputs2
Diagnostic Modes
HW off HW off
HW off
Not usedNot used
DV - Diverting Valve
3A
Fuse
Transformer
24V
Legend
7/02/08
PS2
D
C
A
2
1
PB1
1
2
L2
T2
CC
T1
L1
PS1
C
A
NOTE 3
D
Blue
240V
Green(18)
Orange
Red
208V
Brown
Yellow(7) Yellow(21)
Gre/Yel(12)
Yellow
Blk/Wh
Blk/Wh(11)
Gray(9)
Yellow(8)
Yel(19)
Orange(14)
Brown(15)
Blk(24)
Notes
DHW
Pump
PinkBlue
BlueBlue
Blue
F1 F1
Blue
1 - Switch blue and red wires for 208V operation.
2 - Typical hook-up shown for power open -power closed damper shown.
3 - The blk/wh and gray/wh wires are removed when Aux Heat is installed
4 - Buss lugs L1 and L2 can be removed and dual power wire sets connected
directly to box lugs L1, L2, and L3, L4.
5 - Air Flow Configuration Example: SW1 configured for dip 1 as low, dip 3 as
medium, and dip 5 as high speed ECM2 fan.
6 - SW2-8 must be in the OFF position for pulsed “L” lockout signal and in th ON
position for constant “L” lockout signal.
7 - A hydronic input will generate a Y2 compressor call so that compressor only
operates in high capacity.
Desuperheater
Option
HWL- Hot Water Temperature Limit
Gry/Wh(10)
HWL

17
SYNERGY3D INSTALLATION MANUAL
NOTE 4
240V L1
HP
240V L2
Premier 2
Microprocessor
Logic Control
(DC Voltage)
P1
Fused L2
C
Unit Power
208-230/60/1
G
Ext Pump
1/2 hp Total
208-230/60/1
NO
CR2 COM
NO NC
CR4 COM
F1-10A 240V
Fused L2
NO
CR1 COM
Blue(17)
Blue(13)
Load
Pump
CC
RV
1
2
3
4
5
6
7
8
1
2
3
P4 Black
Black
Orange
Orange
1
2
3C
P2
Down
C
1
2
3
4
5
6
7
Shut
SL1 In
Not
SL1 Out
Used
Status LED PCB
17P503A01 Rev A
SW4
R
R
R
R
R
G
Y
R
1 2 3
Pulse L / Constant L
(See Note 6)
Whole / FA
FAH / Hydronic
Loop / Well
Test / Norm
Outputs / Norm
Inputs / Norm
Two Speed / Single
NO NC
CR3 COM
F1-10A 240V
Compressor
NOTE 5
POPC / Spring
No RPM / RPM
Over-Ride Time
Over-Ride Time
Brown
Yellow
Tan
Tan
CC-GND
240V L2
G
W
O
R
C
Y1
Y2
LO
C
R
S
On
SW1
1
2
3
4
5
6
7
8
9
10
11
12
On
SW3
On
SW2
1
2
3
4
5
6
7
8
1
2
3
4
5
Pump Pump
G
T
Yellow FD
CO
NOTE 1
Violet
Yellow
Black
Blue
Not Used
Brown
Gray
Blk
Hydronic
Thermostat
(Note 7)
Damper
HW
R
PO
PC
Com
1
P2
1
2
P10
3
4
5
6
P10 1 2 3 4 5 6
White
Red
Tan
Pink
Orange
Blue
White
Red
Tan
Pink
Orange
Blue
HE1 TS1
HE2 TS2
HE3 TS3
HE4 TS4
P7
Pink
Yel
Blk
Gray
Gray
Blk
Yel
Pink
Gray
Pink
Blk
Yel
Pink
Yel
Blk
Gray ER1
ER2
ER3
ER4
NO
NO
NO
NO
EA Series PCB
17P514A01
1
2
3
4
With optional auxiliary electric heat
Typical schematic shown
Not Used
Hydronic Cooling Slave Signal - 24VAC Input — “0” signal from
hydronic zone thermostat (Hydronic Cooling Slave Signal under
the Microprocessor Control Operation section)
DV
Not Used
CCHI
Brown
FAC / Hydronic
Over-ride time SW3-4 SW3-5
5 minutes
15 minutes
30 minutes
60 minutes
On
Off
On
Off
On
On
Off
Off
Over-Ride Selection
Violet
P5
3
4
9
11
2
10
8
1
12
5
14
13
6
7
P6
6
5
4
8
7
12
1
2
9
10
3
13
14
16
11
15
Blk(20)
Acc Com
Acc NC
Acc NO
P3
SV
Blk(23)
White(22)
NOTE 2
ECM2
Fan Motor
Grn
15 10163 8
On/Off PWM RPM
C2
RPM grnd
P12
P112 3 4 51
Grn
PB2
Auxiliary Electric Heat Power
208-230/60/1
L4 L2
L2
Pink
Yel
Blk
Gray
Pink
Yel
Blk
Gray
F2
L1
L1 L3G G
4
3
2
1
P8
Grn
3
1
P9
2
4
Brn
Or
Brn
Or
Blue
Violet
Brn
Or
Grn
3 2 14
3 2 14
ECM2
Fan Motor
15 10163 8
On/Off
PWM RPM
C2
RPM grnd
P12
P112 3 4 51
Red Black
Blue
LP
Blue
Blue
Comfort Alert
CS
+
-
DC SOL
Cap Tan(16)
Comfort
Alert
R
Y2
C
Y
Violet(3)
Black(1)
CC Violet(2)
Yel(6)
Wht(4)
Blk(5)
Thermistor
Light emitting diode - Green
Relay coil
Capacitor w/ bleed resistor
Switch - Condensate overflow
Switch - High pressure
Switch - Low pressure
Switch -Hot Water On/Off
Polarized connector
Factory Low voltage wiring
Factory Line voltage wiring
Field low voltage wiring
Field line voltage wiring
Optional block
DC Voltage PCB traces
Internal junction
Quick connect terminal
Wire nut
Field wire lug
Ground
Fuse
CC -
CO -
CR1 -
CR2-
CR3 -
CR4 -
F1 and F2 -
FD -
HP -
LP -
PB1 -
PS1,PS2
-
RV -
SW1 -
SW2 -
SW3 -
SW4 -
Compressor Contactor
Condensate overflow sensor
HW pump relay
Loop pump relay
Fuses
Freeze Detection sensor
High pressure switch
Low pressure switch
Power block
Power strips
Reversing Valve coil
DIP package 12 position
DIP package 8 position
DIP package 5 position
Hot water enable switch
Relay Contacts-
N.O., N.C.
G
T
1 3 2
P
L1
Damper relay
Damper relay
24 vac coil
SV
CS - Compressor Solenoid
LED Flash Code Description
Green Solid Module Has Power
Red Solid Y1 Present But Compressor Not Running
Code 1 Long Run Time
Code 2 System Pressure Trip
Code 3 Short Cycling
Code 4 Locked Rotor
Code 5 Open Circuit
Code 6 Open Start Circuit
Code 7 Open Run Circuit
Code 8 Welded Contactor
Code 9 Low Voltage
Yellow
Comfort Alert Status
Y2
Y
L
R
C
DC
Sol
Data
Port
Comfort Alert
Physical Layout
POWER
ALERT
TRIP
Operation Logic Data
STG1 STG2 STG3 EMERG STG1 STG2
Compressor On On On Off On On Stg 2 On
Reversing Valve Off Off Off Off On On Off
Loop Pump On On On Off On On On
Load Pump Off Off Off Off Off Off On
Aux Heater Off Off Staged Staged Off Off Off
Acc Relay On On On Off On On Off
Diverting Valve Off Off Off Off Off Off On
ECM Speed On On On On On On Off
T-Stat Signal Y1 Y1, Y2 Y1, Y2, W W Y1, O Y1, Y2, O HW
Damper Off Off Off On Off Off Off
Auxiliary 1 - Out On On On Off On On On
Operation
Logic Table
Heating
Cooling
Hot Wa ter
Mode
Field Selection Dips - #1 On, #6 On, #7 On
Drain pan overflow lockout
FD thermister (loop<15°F, well<30°F) Lockout
High pressure lockout
Low pressure lockout
ECM2 RPM < 100 rpm lockout
Microprocessor malfunction
Hot-water disable
Drain
Water Flow
High Press
Low Press
Air Flow
Status
HW Limit
HW off
LED Normal Display Mode
#1 Off, #6 On, #7 On
Drain pan overflow
FD thermister (loop<15°F, well<30°F)
High pressure
Low pressure
ECM2 RPM < 100 rpm
Not used
Current Fault Status
#6 Off, #7 On
Y1
Y2
O
G
W
SL1
HW
HW off
Inputs
#6 On, #7 Off
Compressor
Not used
RV
FAN
HW pump
Loop pump
DV
Outputs
#6 Off, #7 Off
Blower low
Blower med
Blower hi
Aux heat #1
Aux heat #2
Aux heat #3
Aux heat #4
Outputs2
Diagnostic Modes
HW off HW off
HW off
Not usedNot used
DV - Diverting Valve
3A
Fuse
Transformer
24V
Legend
7/02/08
PS2
D
C
A
2
1
PB1
1
2
L2
T2
CC
T1
L1
PS1
C
A
NOTE 3
D
Blue
240V
Green(18)
Orange
Red
208V
Brown
Yellow(7) Yellow(21)
Gre/Yel(12)
Yellow
Blk/Wh
Blk/Wh(11)
Gray(9)
Yellow(8)
Yel(19)
Orange(14)
Brown(15)
Blk(24)
Notes
DHW
Pump
PinkBlue
BlueBlue
Blue
F1 F1
Blue
1 - Switch blue and red wires for 208V operation.
2 - Typical hook-up shown for power open -power closed damper shown.
3 - The blk/wh and gray/wh wires are removed when Aux Heat is installed
4 - Buss lugs L1 and L2 can be removed and dual power wire sets connected
directly to box lugs L1, L2, and L3, L4.
5 - Air Flow Configuration Example: SW1 configured for dip 1 as low, dip 3 as
medium, and dip 5 as high speed ECM2 fan.
6 - SW2-8 must be in the OFF position for pulsed “L” lockout signal and in th ON
position for constant “L” lockout signal.
7 - A hydronic input will generate a Y2 compressor call so that compressor only
operates in high capacity.
Desuperheater
Option
HWL- Hot Water Temperature Limit
Gry/Wh(10)
HWL


18
SYNERGY3D INSTALLATION MANUAL
General guidelines are shown below for component
selection and design/installation criteria for the piping
system. Local codes supersede any recommendations in
this manual.
 Use full port ball valves or
gate valves for component isolation. If valves are going to
be used frequently, ball valves are recommended. Globe
valves are designed for flow regulation. Always install globe
valves in the correct direction (fluid should enter through
the lower body chamber).
 Swing check valves must be installed in the
horizontal position with the bonnet of the valve upright.
Spring check valves can be mounted in any position. A flow
check valve is required to prevent thermo-siphoning (or
gravity flow) when the circulator pump is off or when there
are two circulators on the same system.
 A buffer tank is required for all
hydronic heating systems using Synergy3D heat pumps.
The tank should be sized to provide 2 gallons of storage
capacity for every one thousand btuh’s of nominal heat
pump capacity.
 Most codes require the use of a
pressure relief valve if a closed loop heat source can be
isolated by valves. Even if local code does not require
this device, WaterFurnace recommends its installation. If
the pressure relief valve in the buffer tank is not already
rated at 30 psi (207 kPa) maximum pressure, one must be
installed. The pressure relief valve should be tested at start
up for operation. This valve can also be used during initial
filling of the system to purge air. Note that the waste pipe
must be at least the same diameter as the valve outlet
(never reduce), and valves may not be added to this pipe.
The bottom of the pipe must terminate at least 6” (15 cm)
above the floor. If the piping is connected to a drain, there
must be an air gap.
 Most codes require
backflow prevention check valves. Note that a single
check valve is not equal to a backflow prevention check
valve. Even if local code does not require this device,
WaterFurnace recommends its installation. This is
particularly important if the system will use antifreeze.
This valve
lowers the pressure from the make-up water line to the
system. Most are adjustable and directional. A “fast fill”
valve is required for initial filling of the system. Some have
screens, which must be cleaned after the initial filling. If
there is a restriction in the screen, the system could go to
0 psi (0 kPa), potentially causing pumps(s) failure. A valve
should be installed on each side of the pressure reducing

valve for servicing. Both valves should have tags reading
“Do not shut this valve under normal operation – service
valve only”.
Expansion tanks are required on hydronic
systems to help absorb the pressure swings as the
temperature in the system fluctuates.
 Long radius elbows or two 45° elbows
will lower pressure drop. Standard tees have a greater
restriction on the “T” portion than tees designed with
angled outlet ports.
 Antifreeze is required if any of the piping
system is located in areas subject to freezing.
 Dielectric unions are recommended
whenever connecting two dissimilar metals to one and
other to prevent electro-galvanic corrosion.
When using the various types of hydronic heat distribution
systems, the temperature limits of the geothermal system
must be a major consideration. In new construction,
the distribution system can easily be designed with the
temperature limits in mind. In retrofits, care must be
taken to address the operating temperature limits of the
existing distribution system. The maximum storage tank
temperature for the Synergy3D is 130°F (54.4°C). Typical
in floor radiant systems require much lower temperatures,
typically 100°-115°F, which is ideal for the Synergy3D.
The Synergy3D uses an external temperature sensor such
as the lower thermostat in a water heater storage tank to
control the tank temperature. The thermostat should be
wired to the Synergy3D P5 connector wires, P5-11 and P5-4
tan wires. When the tank temperature drops below the
thermostat setting the contacts in the thermostat will close
and initiate a signal to the Synergy3D to heat water.
A storage tank must be used to store the heated water
supplied by the Synergy3D. It is not recommended to send
heated water from the Synergy3D directly to the hydronic
zones since the Synergy3D also has the ability to condition
the space with forced air. There must be adequate storage
capacity in the storage tank to accommodate the hydronic
load while the Synergy3D is operating in forced air mode.
The hydronic storage tank should be sized to provide 2
gallons of storage capacity for every one thousand btuh’s
of nominal heat pump capacity.
Adequate rate of flow (GPM) is very important to system
performance and long term reliability. Follow the guidelines
for recommended flow and pipe sizing in the Synergy3D
Recommendations table.

19
SYNERGY3D INSTALLATION MANUAL
Be sure to burp the pump. Open the screw 2 turns only in
the end of the pump motor (if Grundfos® pumps are used)
to allow trapped air to be discharged and to ensure the
motor housing has been flooded.


Synergy3D must be wired to the thermostat screw
terminals. The yellow thermistor wires will not operate
with the Synergy3D as they are used with the EW series
water-to-water.
Thermostat

20
SYNERGY3D INSTALLATION MANUAL

The unit will not operate until all the inputs and safety
controls are checked for normal conditions. At first power-
up, a four minute delay is employed before the compressor
is energized.

Components are sequenced and delayed for optimum space
conditioning performance.

The accessory relay will be used to control a refrigerant
solenoid valve. The accessory relay will turn on when the
control is operating in forced air heating, forced air cooling
and when there is no active thermostat input. The relay will
be off when operating in hot water mode.

The control employs a minimum "off" time of four minutes
to provide for short cycle protection of the compressor.

A signal between multiple Synergy3D control boards at the
inputs and outputs (SL1-In and Out) will provide for remote
control of the loop pump on any unit.

The control board incorporates an impedance sensing
liquid sensor at the top of the drain pan. Upon a continuous
30-second sensing of the condensate, compressor operation
is suspended (see Fault Retry), and the condensate overflow
lockout LED begins flashing.

A 24VAC common signal to the “shutdown” input on
the control board puts the unit into shutdown mode.
Compressor, hot water pump and blower operation are
suspended.

The control receives separate signals for a high pressure
switch for safety, a low pressure switch to prevent loss of
charge damage, and a low suction temperature thermistor
for freeze detection limit. Upon a continuous 30-second
measurement of the fault (immediate for high pressure),
compressor operation is suspended, the appropriate lockout
LED begins flashing. (Refer to the "Fault Retry" section.)


The control allows service personnel to shorten most timing
delays for faster diagnostics (Refer to Dip Switch description).

All faults (except for low RPM faults with the ECM2 blower
motor) are retried twice before finally locking the unit out.
An output signal is made available for a fault LED at the
thermostat. The “fault retry” feature is designed to prevent
nuisance service calls.

The control board allows all inputs and outputs to be
displayed on the LEDs for fast and simple control board
diagnosis. (Refer to Dip Switch description).

The electric heat control module contains the appropriate
high-voltage control relays. Control signals energize the
relays in the proper sequence, and the LED display board
indicates which stages are energized.

Some models shall be equipped with an optional IntelliStart.
IntelliStart is a single-phase soft starter which reduces the
normal start current (LRA) by 60-70%. This allows the heat
pump to more easily go “off grid.” Using IntelliStart will also
provide a substantial reduction in light flicker, reduce start-
up noise, and improve the compressor’s start behavior. The
IntelliStart is self-callibrating and may take several starts to
optimize the compressor start behavior.
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• Automatic adjustment of the compressor starting
current to the available supply voltage —maintaining
constant starting torque and current.
• Supply line impedance monitoring and compensation.
• Automatic compensation for residual back pressure in
the system.
• Monitoring of supply voltage while compressor is
running to prevent motor stalling, causing excessive
currents, under low voltage conditions.
• Light flicker reductions of up to 10:1 over LRA under
the same conditions.