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Carrier 50RHE006-060 Air Conditioner User Manual

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1. Table 5 DIP Switch Block S2 Accessory 1 Relay Options ACCESSORY 1 DIP SWITCH POSITION RELAY OPTIONS 3 Cycle with Fan On Digital NSB On Water Valve Slow Opening On OAD Off LEGEND NSB Night Setback OAD Outdoor Air Damper NOTE All other DIP switch combinations are invalid Table 6 DIP Switch Block S2 Accessory 2 Relay Options ACCESSORY 2 DIP SWITCH POSITION RELAY OPTIONS 6 Cycle with Fan On Digital NSB On Water Valve Slow Opening On OAD Off LEGEND NSB Night Setback OAD Ouitdoor Air Damper NOTE All other switch combinations are invalid Auto Dehumidification Mode or High Fan Mode Switch 7 provides selection of auto dehumidification fan mode or high fan mode In auto dehumidification fan mode the fan speed relay will remain off during cooling stage 2 if terminal H is active In high fan mode the fan enable and fan speed relays will turn on when terminal H is active Set the switch to ON for auto dehumidification fan mode or to OFF for high fan mode Switch 8 Not used D Control Accessory Relay Configurations The following accessory relay settings are applicable for both D controls only CYCLE WITH FAN In this configuration the relay will be ON any time the Fan Enable relay is on CYCLE WITH COMPRESSOR In this configuration the relay will be ON any time the Compressor relay is on DIGITAL NIGHT SET BACK NSB In this c
2. PM DISABLEFNARLE AT HEAT COOL HEAT PUMP Jw2 PAS LOW JWI N O OFFON ca EA PST FUNCTIONS GOMR C 4 RV ON B ACC2 o EE g RERUMIDINORMAL FUNCTIONS EE 7 BOILERLESS ENABLE DISABLE H HI FAN DEHUMID CE 8 BOILERLESS 40 F 50 F NOT USED S1 s2 DIP SWITCH PACKAGE DIP SWITCH PACKAGE LEGEND AL Alarm Relay Contacts PM Performance Monitor No feat a BM Blower Motor PSC Permanent Split Capacitor o Circuit Breaker BMC Blower Motor Capacitor RVS Reversing Valve Solenoid ae ee ee TRANS Transformer Optional Wiring A LED Compressor Capacitor F ri CB E sec ee asas ia ai ites es 00 Capacitor co Sensor Condensate Overflow ield Low Voltage Wiring oA o FP1 Sensor Water Coil Freeze Protection Printed Circuit Trace Solenoid Coil FP2 Sensor Air Coil Freeze Protection ENE So Optional Wiring Relay Contacts N O HP High Pressure Switch A oa 6 Temperature Switch HWTS High Leaving Water Temp Switch Ye Relay Contactor Coil p JW Clippable Field Selection Jumper A Q Switch Loss of Charge LOC Loss of Charge Pressure Switch P Thermistor l MV Motorized Valve Ground P1 Field Wiring Terminal Block eo Condensate Pan PB Power Block Q Wire Nut Optional wiring NOTES Compressor thermally protected internally z 3 All wiring to the unit must
3. If condensate pump is present on unit be sure drain con nections have a check valve to prevent back flow of con densate into other units 65 mm Pitch for Drainage el lt Drain Drain Connection Fig 6 Horizontal Unit Pitch gt TO UNIT MINIMUM PITCH ONE IN PER 10 FT OF LINE SEE NOTE DRAIN PLUG NOTE Trap should be deep enough to offset maximum unit static difference A 102 mm trap is recommended Fig 7 Trap Condensate Drain Step 7 Piping Connections Depending on the application there are 3 types of WSHP piping systems to choose from water loop ground water and ground loop Refer to Piping Section of Carrier System Design Manual for addi tional information All WSHP units use low temperature soldered female pipe thread fittings for water connections to prevent annealing and out of round leak problems which are typically associated with high temperature brazed connections Refer to Table 1 for connection sizes When making piping connections consider the following e Use a backup wrench when making screw connections to unit to prevent internal damage to piping Insulation may be required on piping to avoid condensa tion in the case where fluid in loop piping operates at temperatures below dew point of adjacent air Piping systems that contain steel pipes or fittings may be subject to galvanic corrosion Dielectric fittings should be used to isolate the steel parts of the s
4. 1 1 C as the limit DO NOT clip the jumper To select 12 2 C as the limit clip the jumper ALARM RELAY SETTING Select jumper 1 JW1 AL2 Dry for connecting alarm relay terminal AL2 to 24 vac R or to remain as a dry contact no connection To connect AL2 to R do not clip the jumper To set as dry contact clip the jumper C Control DIP Switches The C Control has 1 DIP switch block with five switches See Fig 9 and 10 PERFORMANCE MONITOR PM DIP switch 1 will enable or disable this feature To enable the PM set the switch to ON To disable the PM set the switch to OFF STAGE 2 DIP switch 2 will enable or disable compressor delay Set DIP switch to OFF for stage 2 in which the compres sor will have a 3 second delay before energizing SWITCHES 3 AND 4 Not used 1 OR 3 TRIES DIP switch 5 provides selection of whether there are or 3 tries for FP1 and FP2 This only applies to FP1 and FP2 and not to any other faults Set DIP switch 5 to ON for 1 try or to OFF for 3 tries NOTE The alarm relay will not cycle during Test mode if switch is set to OFF stage 2 D Control Jumper Settings See Fig 11 and 12 WATER COIL FREEZE PROTECTION FP1 LIMIT SETTING Select jumper 3 JW3 FP1 Low Temp to choose FP1 limit of 12 2 C or 1 1 C To select 1 1 C as the limit DO NOT clip the jumper To select 12 2 C as the limit clip the jumper AIR COIL FREEZE PROTECTION FP2 LIMIT SET TING
5. Select jumper 2 JW2 FP2 Low Temp to choose FP2 limit of 12 2 C or 1 1 C To select 1 1 C as the limit DO NOT clip the jumper To select 12 2 C as the limit clip the jumper ALARM RELAY SETTING Select jumper 4 JW4 AL2 Dry for connecting alarm relay terminal AL2 to 24 vac R or to remain as a dry contact no connection To connect AL2 to R do not clip the jumper To set as dry contact clip the jumper LOW PRESSURE SETTING The D Control can be con figured for Low Pressure Setting LP Select jumper 1 JW1 LP Norm Open for choosing between low pressure input normally opened or closed To configure for normally closed operation do not clip the jumper To configure for normally open operation clip the jumper 17 D Control DIP Switches The D Control has 2 DIP switch blocks Each DIP switch block has 8 switches and is labeled either S1 or S2 on the circuit board See Fig 11 and 12 DIP SWITCH BLOCK 1 S1 This set of switches offers the following options for D Control configuration Performance Monitor PM Set switch 1 to enable or dis able performance monitor To enable the PM set the switch to ON To disable the PM set the switch to OFF Compressor Relay Staging Operation Switch 2 will en able or disable compressor relay staging operation The com pressor relay can be set to turn on with stage or stage 2 call from the thermostat This setting is used with dual stage units un
6. Book 1 4 Tab 5a 5a Printed in U S A Form 50RHE C1SI Pg t 2 04 Replaces New Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for brazing operations Have fire extinguisher available Read these instructions thoroughly and follow all warnings or cautions attached to the unit Consult local building codes and electrical codes for special installation requirements Understand the signal words DANGER WARNING and CAUTION DANGER identifies the most serious hazards which will result in severe personal injury or death WARN ING signifies hazards that could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage Recognize safety information This is the safety alert symbol When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury A WARNING Electrical shock can cause personal injury or death Before installing or servicing system always turn off main power to system There may be more than one disconnect switch Turn off accessory heater power if applicable GENERAL This Installation and Start Up Instructions literature is for Aquazone Water Source Heat Pump units bearing the Mark of The European Community CE These units are designed in accordance with European Standard EN60335 2 400 Water Source Heat Pump WSHP
7. To exit Test mode short the terminals for 3 seconds or cycle the power 3 times within 60 seconds NOTE Deluxe D Control has a flashing code and alarm relay cycling code that will both have the same numerical label For example flashing code 1 will have an alarm relay cycling code 1 Code 1 indicates the control has not faulted since the last power off to power on sequence 22 Table 13 C Control Current LED Status and Alarm Relay Operations LED STATUS DESCRIPTION OF OPERATION ALARM RELAY Normal Mode Open Cycle on Normal Moda with closed 5 sec Open 25 sec Off C Control is non functional Open Slow Flash Fault Retry Open Fast Flash Closed Open Slow Flash Over Under Voltage Shutdown Closed after 15 minutes Flashing Code 7 Flashing Code 2 Flashing Code 3 Flashing Code 4 Flashing Code 5 Flashing Code 6 Flashing Code 7 Flashing Code 8 Cyaing Code 8 Test Mode FP1 FP2 Flashing Code 9 Swapped Fault in memory Cycling Code 9 LEGEND Cycling Code 1 Cycling Code 2 Cycling Code 3 Cycling Code 4 Cycling Code 5 Cycling Code 6 Cycling Code 7 CO Condensate Overflow FP Freeze Protection HP High Pressure LED Light Emitting Diode LP Low Pressure PM Performance Monitor NOTES 1 Slow flash is 1 flash every 2 seconds 2 Fast flash is 2 flashes every 1 second 3 EXAMPLE Flashing Code 2 is represented by 2 fast flashes followed by a 10 second pause This sequence wi
8. W is active while terminal Y is not Terminal G must be active or the W terminal is disregarded EH1 is immediately turned on EH2 will turn on after 5 minutes of continual emergency heat demand Units with Aquazone Deluxe D Control STANDBY FAN ONLY The compressor will be off The Fan Enable Fan Speed and reversing valve RV relays will be on if inputs are present If there is a Fan 1 demand the Fan Enable will immediately turn on If there is a Fan 2 demand the Fan Enable and Fan Speed will immediately turn on NOTE DIP switch 5 on S1 does not have an effect upon Fan 1 and Fan 2 outputs HEATING STAGE 1 In Heating Stage 1 mode the Fan Enable and Compressor relays are turned on immediately Once the demand is removed the relays are turned off and the control reverts to Standby mode If there is a master slave or dual compressor application all compressor relays and related functions will operate per their associated DIP switch 2 setting on S1 HEATING STAGE 2 In Heating Stage 2 mode the Fan Enable and Compressor relays are remain on The Fan Speed relay is turned on immediately and turned off immediately once the demand is removed The control reverts to Heating Stage 1 mode If there is a master slave or dual compressor application all compressor relays and related functions will op erate per their associated DIP switch 2 setting on S1 HEATING STAGE 3 In Heating Stage 3 mode the Fan Enable Fan Speed and
9. Cycles Only Fan Runs LEGEND RV Reversing Valve gt X lt gt X lt X lt gt lt gt X lt gt lt gt lt gt lt gt lt gt lt gt X lt gt lt gt X lt gt lt gt lt gt lt gt lt gt lt X lt gt lt Table 16 Troubleshooting X X Green Status LED Off Check line voltage circuit breaker and disconnect Check for line voltage between L1 and L2 on the contactor Check primary secondary voltage on transformer X Reduced or no water flow in Check pump operation or valve operation setting cooling Check water flow adjust to proper flow rate X Reduced or no airflow in Check for dirty air filter and clean or replace heating Check fan motor operation and airflow restrictions External static too high Check Table 4 X Air temperature out of range Bring return air temperature within design parameters in heating rx x Bad HP switch Check switch continuity and operation Replace x X_ Insufficient charge Check for refrigerant leaks X Reduced or no water flow in Check pump operation or water valve operation setting Plugged strainer or filter Clean or replace Check water flow adjust to proper flow rate x inadequate antifreeze level_ Check antifreeze density with hydrometer ae el Water temperature out of Bring water temperature within design parameters range Bad thermistor Check temperature and impedance correlation Check fan motor operation and air
10. Flushing Once the piping is complete units require final purging and loop charging A flush cart pump of at least 1 5 hp 1 12 kW is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop Flush the loop in both directions with a high volume of water at a high velocity Follow the steps below to properly flush the loop 1 Verify power is off 2 Fill loop with water from hose through flush cart before using flush cart pump to ensure an even fill Do not allow the water level in the flush cart tank to drop below the pump inlet line to prevent air from filling the line 20 NOTES 1 Based on nominal 54 L s per kW airflow and 21 C EAT heating and 26 7 194 C EAT cooling 2 Cooling air and water numbers can vary greatly with changes in humidity 3 Subcooling is based upon the head pressure at compressor service port 3 Maintain a fluid level in the tank above the return tee to avoid air entering back into the fluid 4 Shutting off the return valve that connects into the flush cart reservoir will allow 345 kPa surges to help purge air pockets This maintains the pump at 345 kPa 5 To purge keep the pump at 345 kPa until maximum pumping pressure is reached 6 Open the return valve to send a pressure surge through the loop to purge any air pockets in the piping system 7 A noticeable drop in fluid level will be seen in the flush cart tank This is the only indication of air
11. Ground Water Systems 0 027 I s per kW 19 Unit Start Up Heating Mode NOTE Operate the unit in heating cycle after checking the cooling cycle Allow five minutes between tests for the pres sure or reversing valve to equalize 1 Turn thermostat to lowest setting and set thermostat switch to HEAT position 2 Slowly turn the thermostat to a higher temperature until the compressor activates 3 Check for warm air delivery at the unit grille within a few minutes after the unit has begun to operate 4 Check the temperature of both supply and discharge water Compare to Table 9 If temperature is within range proceed If temperature is outside the range check the heating refrigerant pressures in Table 9 5 Once the unit has begun to run check for warm air deliv ery at the unit grille 6 Check air temperature rise across the coil when compres sor is operating Air temperature rise should be between 11 1 and 16 7 C after 15 minutes at load 7 Check for vibration noise and water leaks Flow Regulation Flow regulation can be accom plished by two methods Most water control valves have a flow adjustment built into the valve By measuring the pressure drop through the unit heat exchanger the flow rate can be deter mined See Table 10 Adjust the water control valve until the flow of 027 to 054 L s per kW cooling is achieved Since the pressure constantly varies two pressure gages may be needed in some appl
12. IS A TRAP INSTALLED Y N IS AN AIR FILTER INSTALLED Y N START UP IS FAN OPERATING WHEN COMPRESSOR OPERATES Y N IF 3 PHASE SCROLL COMPRESSOR IS PRESENT VERIFY PROPER ROTATION PER INSTRUCTIONS Y N ___ UNIT VOLTAGE COOLING OPERATION PHASE AB VOLTS PHASE BC VOLTS PHASE CA VOLTS if 3 phase if 3 phase PHASE AB AMPS PHASE BC AMPS PHASE CA AMPS if 3 phase if 3 phase CONTROL VOLTAGE IS CONTROL VOLTAGE ABOVE 21 6 VOLTS Y N IF NOT CHECK FOR PROPER TRANSFORMER CONNECTION TEMPERATURES FILL IN THE ANALYSIS CHART ATTACHED COAXIAL HEAT COOLING CYCLE EXCHANGER FLUID IN C FLUID OUT C kPa L S HEATING CYCLE FLUID IN C FLUID OUT C kPa L S AIR COIL COOLING CYCLE AIR IN C AIROUT C HEATING CYCLE AIR IN C AIROUT C CL 1 HEATING CYCLE ANALYSIS SUCTION oG o COMPRESSOR EXPANSION DISCHARGE LIQUID LINE C C kPa kPa WATER IN WATER OUT gt LOOK UP PRESSURE DROP IN TABLE 10 TO DETERMINE FLOW RATE COOLING CYCLE ANALYSIS SUCTION COMPRESSOR EXPANSION VALVE DISCHARGE LIQUID LINE C C kPa kPa WATER IN WATER OUT gt LOOK UP PRESSURE DROP IN TABLE 10 TO DETERMINE FLOW RATE HEAT OF EXTRACTION ABSORPTION OR HEAT OF REJECTION FLOW RATE L S x TEMP DIFF DEG C x FLUID FACTOR kW SUPERHEAT SUCTION TEMPERATURE SUCTION DEW POINT TEMPERATURE DEG C SUBCOOLING DISCHARGE BUBBLE POINT TEMPERATUR
13. antifreeze solutions cut JW3 jumper Typical heat pump thermostat wiring shown Refer to thermostat installation instructions for wiring to the unit and dry contact will be available between AL1 and AL2 Transformer secondary ground via microprocessor board stand offs and screws to control box Ground available from top two standoffs as shown Fan motors factory wired for medium speed For high or low speed remove BLU wire from fan motor speed tap M and con nect to H for high or L for low Fig 9 Typical Aquazone Complete C Control Wiring Single Phase Unit 10 COMPONENT LOCATION AL BR CAP CB cc co POWER SUPPLY REFER TO DATA PLATE USE COPPER CONDUCTORS ONLY LUG CB TRANS PE SEE NOTE 3 SEE NOTE 8 240V SEE NOTE 7 i R T CA BRN YEL GRY BRN SEE NOTE 7 CCG cc 7 gt z TEST PINS Ae COMPRESSOR a RED O 0 P PICA T STAT l 3 BLU oF Loc YQ COMPR i rs 4 BAN DIP SWITCH SEE NOTE 4 GRY AA SIAGE2 GRY _ FPA OOLIN j o H 2 NOT YSED viO vio ane UNITS cO FAN ii CAP T
14. in the loop NOTE If air is purged from the system while using a 254 mm PVC flush tank the level drop will only be 25 to 51 mm since liquids are incompressible If the level drops more than this flushing should continue since air is still being compressed in the loop If level is less than 25 to 51 mm reverse the flow 8 Repeat this procedure until all air is purged 9 Restore power Antifreeze may be added before during or after the flushing process However depending on when it is added in the process it can be wasted Refer to the Antifreeze section for more detail Loop static pressure will fluctuate with the seasons Pres sures will be higher in the winter months than during the warm er months This fluctuation is normal and should be considered when charging the system initially Run the unit in either heat ing or cooling for several minutes to condition the loop to a homogenous temperature When complete perform a final flush and pressurize the loop to a static pressure of 275 to 345 kPa for winter months or 105 to 135 kPa for summer months After pressurization be sure to remove the plug from the end of the loop pump motor s to allow trapped air to be discharged and to ensure the motor housing has been flooded Be sure the loop flow center provides adequate flow through the unit by checking pressure drop across the heat exchanger Compare the results to the data in Table 10 Antifreeze In areas where enterin
15. therefore be cleaned at least once a year or more often if the water is contaminated Proper water treatment can minimize tube fouling and pitting If such conditions are anticipated water treatment analysis is recommended Refer to the Carrier System Design Manual Part 5 for general water conditioning information A CAUTION Follow all safety codes Wear safety glasses and rubber gloves when using inhibited hydrochloric acid solution Observe and follow acid manufacturer s instructions Clean condensers with an inhibited hydrochloric acid solu tion The acid can stain hands and clothing damage concrete and without inhibitor damage steel Cover surroundings to guard against splashing Vapors from vent pipe are not harmful but take care to prevent liquid from being carried over by the gases Warm solution acts faster but cold solution is just as effec tive if applied for a longer period GRAVITY FLOW METHOD Do not add solution faster than vent can exhaust the generated gases When condenser is full allow solution to remain overnight then drain condenser and flush with clean water Follow acid manufacturer s instructions See Fig 18 FORCED CIRCULATION METHOD Fully open vent pipe when filling condenser The vent may be closed when condenser is full and pump is operating See Fig 19 24 Regulate flow to condenser with a supply line valve If pump is a nonoverloading type the valve may be fully closed whi
16. units are single package horizontal mounted units with electronic controls designed for year round cooling and heating Aquazone 5ORHE WSHP units are designed for high efficiency operation using HFC 407C refrigerant IMPORTANT The installation of water source heat pump units and all associated components parts and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and MUST conform to all applicable codes It is the responsi bility of the installing contractor to determine and comply with ALL applicable codes and regulations INSTALLATION Step 1 Check Jobsite Installation operation and maintenance instructions are provided with each unit Before unit start up read all manuals and become familiar with the unit and its operation Thoroughly check out the system before operation Complete the inspections and instructions listed below to prepare a unit for installation See Table 1 for unit physical data Horizontal units are designed for indoor installation only Be sure to allow adequate space around the unit for servicing See Fig 1 for overall unit dimensions Refer to Fig 2 for an illustration of a typical horizontal installation A CAUTION To avoid equipment damage do not use these units as a source of heating or cooling during the construction process The mechanical components and filters used in these units quickly become clogged wi
17. 1 2 2 IPS SDR11 68 1 11 4 IPS SCH40 31 4 11 5 IPS SCH40 41 2 2 IPS SCH40 64 3 LEGEND IPS Internal Pipe Size SCH Schedule SDR Standard Dimensional Ratio NOTE Volume of heat exchanger is approximately 3 78 liters Table 12 Antifreeze Percentages by Volume MINIMUM TEMPERATURE FOR FREEZE PROTECTION C ANTIFREEZE Methanol 100 USP Food Grade Propylene Glycol Cooling Tower Boiler Systems These systems typ ically use a common loop temperature maintained at 15 6 to 32 2 C Carrier recommends using a closed circuit evaporative cooling tower with a secondary heat exchanger between the tower and the water loop If an open type cooling tower is used continuously chemical treatment and filtering will be necessary The optional cupronickel heat exchanger must also be used in this case Ground Coupled Closed Loop and Plateframe Heat Exchanger Well Systems These systems al low water temperatures from 1 1 to 43 3 C The external loop field is divided up into 51 mm polyethylene supply and return lines Each line has valves connected in such a way that upon system start up each line can be isolated for flushing using only the system pumps Locate air separation in the piping sys tem prior to the fluid re entering the loop field 21 OPERATION Power Up Mode The unit will not operate until all the inputs terminals and safety controls are checked for normal operation
18. 288 250 198 015 212 160 MED 321 302 274 241 189 LO 293 278 255 222 179 HI 326 311 283 250 203 019 264 198 MED 302 288 260 227 189 LO 293 269 245 217 179 HI 396 368 335 302 260 024 307 231 MED 387 359 326 297 255 LO 368 340 311 278 231 HI 529 496 463 425 378 330 030 349 264 MED 510 477 448 415 368 326 LO 458 439 406 378 340 297 HI 614 576 519 463 415 373 036 437 326 MED 580 543 488 434 392 349 LO 505 472 429 387 349 HI 743 691 629 566 501 435 042 530 396 MED 637 593 539 485 429 LO 498 463 421 HI 793 738 672 604 535 464 048 630 472 MED 777 723 658 592 524 455 LO 762 709 645 580 514 446 p A HI 757 668 552 High mao 630 472 MED 787 710 623 529 LO 797 748 690 612 516 HI 896 866 833 796 755 710 060 790 595 MED 818 803 779 747 707 658 LO 748 731 709 683 653 618 LEGEND NOTES Shaded areas are below minimum CFM This data is 1 Units factory shipped on medium speed Other speeds require field selection 2 For dual voltage units airflow is rated at lowest voltage 3 Performance data shown is based n wet coil and clean air filter provided for troubleshooting information only Step 9 Low Voltage Wiring See Fig 15 O 22 THERMOSTAT CONNECTIONS The thermostat should oe ee CLIP JW2 FP2 mi ee be wired directly to the Aquazone control board See eat JUMPER FOR fe ANTI FREEZE Fig 9 12 SYSTEMS WATER FREEZE PROTECTION The Aquazone co
19. 568 658 6 9 1 3 3 4 14 17 0 027 225 254 535 592 5 9 4 8 11 12 11 13 212 245 613 688 8 11 1 3 8 9 21 0 041 222 251 502 556 5 9 4 7 7 9 11 13 218 254 628 712 8 11 1 3 5 6 17 21 0 054 219 248 472 523 5 9 4 7 4 7 11 13 227 263 8 11 1 3 3 4 17 21 0 027 225 254 685 75 5 9 4 8 10 12 9 13 254 284 658 777 10 16 1 3 8 9 0 041 222 251 652 721 5 9 4 7 6 8 9 13 269 299 673 792 10 16 1 3 6 7 0 054 219 248 622 688 5 9 4 7 3 6 9 13 284 314 688 807 10 16 1 3 5 0 027 231 260 837 957 4 8 6 14 9 11 8 11 0 041 228 257 807 927 4 8 6 13 5 7 8 11 0 054 225 254 777 897 4 8 6 12 3 6 8 11 LEGEND DB Dry Bulb EAT Entering Air Temperature Table 10 50RHE Coaxial Water Pressure Drop UNIT PRESSURE DROP kPa 50RHE 30 C 0 047 48 006 0 071 6 9 0 095 0 11 7 6 9 6 6 009 10 5 9 9 20 9 20 0 16 7 16 1 012 36 2 34 7 57 7 55 0 16 7 14 7 14 1 015 32 6 28 7 27 2 55 9 48 7 46 3 12 9 11 1 10 8 019 23 0 20 3 19 1 0 284 45 4 39 8 37 7 0 189 13 8 i 11 7 11 4 024 0 284 28 7 25 1 23 9 0 379 47 8 i 41 9 39 8 0 237 9 9 9 0 8 4 8 1 030 0 347 17 0 15 8 14 7 14 1 0 473 26 9 25 4 23 6 22 4 0 284 7 8 7 2 6 9 6 6 036 0 426 15 0 13 8 2 9 12 3 0 568 23 9 22 4 0 9 20 0 0 331 9 9 9 3 8 7 8 4 042 0 498 19 7 18 5 17 0 16 4 0 663 31 1 29 3 27 5 26 0 0 379 14 1 13 2 12 3 11 7 048 0 568 26 9 25 4 23 6 22 4 0 757 44 0 41 0 38 3 36 5 0 473 33 5 31 4 29 3 27 8 060 0 713 58 3 54 4 50 8 48 4 0 947 88 5 82 8 77 1 73 3
20. Aquazone 50RHE006 060 Water Source Heat Pumps Horizontal Unit 50 Hz CE Mark R 407C Installation Start Up and CONTENTS Page Ground Coupled Closed Loop and Plateframe Page Heat Exchanger Well Systems 21 SAFETY CONSIDERATIONS 1 2 OPERATION 21 22 GENERAL is cnc tees tt ae Aaah E 2 Power Up Mode 0 0 00 0 eee 21 INSTALLATION 0 000 cee eee 2 16 Units with Aquazone Complete C Control 21 Step 1 Check Jobsite 2 Units with Aquazone Deluxe D Control 21 Step 2 Check Unit 5 2 SYSTEM TEST fer iren pages phage ined ae 22 23 e STORAGE Test Mode 0 cece eee eee eee eens 22 e PROTECTION Retry Mode 0 c cece eee eens 23 e INSPECT UNIT Aquazone Deluxe D Control LED Indicators 23 Step 3 Unit Location n sossar 6 SERVICE p ka aE A sane 23 25 e FIELD CONVERSION OF DISCHARGE AIR FLOPS o site a Ab icv ars EEE aad eS 23 Step 4 Mounting the Unit J Water Coil L e eked ag ea tees 23 Step 5 Duct System 4 5 7 Condensate Drain Pans 24 e SOUND ATTENUATION Refrigerant System 0 aaeocae 24 EXISTING DUCT SYSTEM Condensate Drain Cleaning 24 Step 6 Condensate Drain 7 Air Coil Cleaning 000000e 24 e VENTING Conden
21. CONTACT ALARM SEE MICRO j elt RELAY NOTE processor 6 CONTROL LOGIC SIZES 006 009 012 LEGEND AL Alarm Relay Contacts PM Performance Monitor es BR Blower Relay PSC Permanent Split Capacitor Condensate Pan CAP Compressor Capacitor RVS Reversing Valve Solenoid oO Circuit Breaker CB Circuit Breaker TRANS Transformer Optional Wiring CC Compressor Contactor Field Line Voltage Wiring O4F Relay Contacts N C co Sensor Condensate Overflow i i f i FP1 Sensor Water Coil Freeze Protection Field Low Voltage Wiring o Solenoid Coil ND a Air Coil Freeze Protection Printed Circuit Trace HH Relay Contacts N O HP High Pressure Switch tem Optional Wiring switch Temperature JW Clippable Field Selection Jumper oe Relay Contactor Coil LOC Loss of Charge Pressure Switch reS Switch Low Pressure P1 Field Wiring Terminal Block l PB Power Block K Thermistor Ground C Wire Nut Optional wiring NOTES 1 Compressor and blower motor thermally protected internally 6 24 v alarm signal shown For dry alarm contact cut JW1 jumper 2 3 4 5 All wiring to the unit must comply with NEC and local codes Transformer is wired to 240 v ORG lead for 240 50 1 units switch RED and ORG leads to PB 1 and insulate ORG lead FP1 thermistor provides freeze protection for water When using
22. Compressor relays remain on The EH1 output is turned on immediately With continuing Heat Stage 3 demand EH2 will turn on after 10 minutes EH1 and EH2 are turned off immediately when the Heating Stage 3 demand is re moved The control reverts to Heating Stage 2 mode Output EH will be off if FP1 is greater than 7 2 C and FP2 when shorted is greater than 43 3 C during Heating Stage 3 mode This condition will have a 30 second recognition time Also during Heating Stage 3 mode EH1 EH2 Fan Enable and Fan Speed will be ON if G input is not active EMERGENCY HEAT In Emergency Heat mode the Fan Enable and Fan Speed relays are turned on The EH1 output is turned on immediately With continuing Emergency Heat de mand EH2 will turn on after 5 minutes Fan Enable and Fan Speed relays are turned off after a 60 second delay The control reverts to Standby mode Output EH1 EH2 Fan Enable and Fan Speed will be ON if the G input is not active during Emergency Heat mode COOLING STAGE 1 In Cooling Stage 1 mode the Fan Enable compressor and RV relays are turned on immediately If configured as stage 2 DIP switch set to OFF then the com pressor and fan will not turn on until there is a stage 2 demand The fan Enable and compressor relays are turned off immedi ately when the Cooling Stage 1 demand is removed The con trol reverts to Standby mode The RV relay remains on until there is a heating demand If there is a master slave
23. E LIQUID LINE TEMPERATURE DEG C Use 4 16 for water 4 03 for antifreeze Copyright 2004 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 Catalog No 005 00042 Printed in U S A Form 50RHE C1SI Pg CL 2 2 04 Replaces New Tab 5a 5a CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE s i S
24. EUTRAL ONLY L SEE NOTE 3 CB TRANS EE r A YELI BLU ORs He U 240V hEm ED BRN SIZES 006 009 012 BRN SEE NOTE 7 TYPICAL HEAT aaa og FANENABLE PUMP T STAT _ COM2 COM1 SOM SEE NOTE 5 NOS GRY Sd COMPR ogl COOLING com n FAN 5 GH DXM NO ROLZAVAC MICROPROCESSOR GRY BLK HWTS C o COMMON a CONTROL LOGIC REDo Lo Buel kig ALARM he SEE RED BLK NOTE 6 BLU LOC ALARM eee SEE NOTE 6 FOR RELAY Jw4 a SEE NOTE 4 DRY CONTACT e ny STATUS GRY FOR ALARM AL2 __DRY4 test GRY FP1 TXV UNITS i VIO CAP TUBE VIO pe FAULT B UNITS OR aca RRA COMPONENT LOCATION RV RELAY BRNS TEST O O PINS yYeEL 00 TL JIW3 SEE cr __ IW Low LOW NOTE 4 BR2 Hp DN Fp2 LO L N uw M mlp PM AE uo Eon ere a ay c1 acct TENE B UNIT STAGE 2 1 BRNA p 8 T STAT HEAT OOO HEAT PUMP Em 3 FUNCTIONS z o Lit RV ON B RV ON 0 ACC2 s DEHUMID NORMAL FUNCTIONS YEL Be NOT USED ee at GON m M He U BOILERLESS ENABLE DISABLE H HI FAN DEHUMID RED Ey eqs BOILERLESS 40 F 50 F 8 NOT USED 2 S1 S2 SIZES 015 060 DIP SWITCH PACKAGE DIP SWITCH PACKAGE LEGEND AL Alarm Relay Contacts P1 Field Wiring Terminal Block of F BM Blower Motor PB Power Block Thermistor BMC Blower Motor Capacitor PM Performance Monitor c gt ondensate Pan BR Blower Relay f PSC Permanent Split Capacitor ERT CAP Compressor Capacitor RVS Reversing Valve Solenoid LED CB Circuit Br
25. ND FLA Full Load Amps HACR Heating Air Conditioning and Refrigeration LRA Locked Rotor Amps RLA Rated Load Amps POWER CONNECTION Make line voltage connection by connecting the incoming line voltage wires to the L side of the CC terminal as shown in Fig 13 See Table 3 for correct wire and maximum overcurrent protection sizing SUPPLY VOLTAGE Operating voltage to unit must be within voltage range indicated on unit nameplate On 3 phase units voltages under load between phases must be balanced within 2 Use the following formula to deter mine the percentage voltage imbalance Voltage Imbalance max voltage deviation from average voltage NA average voltage Example Supply voltage is 460 3 60 AB 452 volts BC 464 volts AC 455 volts A B C f Average Voltage oe 1371 3 457 Determine maximum deviation from average voltage AB 457 452 5v BC 464 457 7 v AC 457 455 2v Maximum deviation is 7 v Determine percent voltage imbalance 7 Voltage Imbalance 100 x BT 1 53 This amount of phase imbalance is satisfactory as it is below the maximum allowable 2 14 Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electri cal components NOTE If more than 2 voltage imbalance is present contact local electric utility 220 VOLT OPERATION All 220 240 volt units are factory wired for 208 volts T
26. NOTE The compressor will have a 5 minute anti short cycle upon power up Units with Aquazone Complete C Control STANDBY Y and W terminals are not active in standby mode however the O and G terminals may be active depend ing on the application The compressor will be off COOLING Y and O terminals are active in Cooling mode After power up the first call to the compressor will initiate a 5 to 80 second random start delay and a 5 minute anti short cycle protection time delay After both delays are complete the compressor is energized NOTE On all subsequent compressor calls the random start delay is omitted HEATING STAGE 1 Terminal Y is active in heating stage 1 After power up the first call to the compressor will initiate a 5 to 80 second random start delay and a 5 minute anti short cycle protection time delay After both delays are complete the compressor is energized NOTE On all subsequent compressor calls the random start delay is omitted HEATING STAGE 2 To enter Stage 2 mode terminal W is active Y is already active Also the G terminal must be ac tive or the W terminal is disregarded The compressor relay will remain on and EH1 is immediately turned on EH2 will turn on after 10 minutes of continual stage 2 demand NOTE EH2 will not turn on or if on will turn off if FP1 tem perature is greater than 7 2 C and FP2 is greater than 43 3 C EMERGENCY HEAT In emergency heat mode terminal
27. Plugged strainer or filter Clean or replace Check water flow adjust to proper flow rate i el Water temperature out of Bring water temperature within design parameters range X Reduced airflow in cooling Check for dirty air filter and clean or replace e Check fan motor operation and airflow restrictions External static too high Check blower Table 4 E Too much cold vent air Bring entering air temperature within design parameters Check for refrigerant leaks x Too high airflow Check blower Table 4 x Poor performance See insufficient Capacity x Too high airflow Check blower Table 4 rea Se Recheck loads and sizing check sensible cooling load and heat pump capacity 27 Copyright 2004 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations mat 4 Catalog No 005 00042 Printed in U S A Form 50RHE C1SI Pg 30 2 04 Replaces New Tab 5a 5a 50RHE R 407C UNIT START UP CHECKLIST CUSTOMER JOB NAME MODEL NO SERIAL NO DATE PRE START UP DOES THE UNIT VOLTAGE CORRESPOND WITH THE SUPPLY VOLTAGE AVAILABLE Y N HAVE THE POWER AND CONTROL WIRING CONNECTIONS BEEN MADE AND TERMINALS TIGHT Y N HAVE WATER CONNECTIONS BEEN MADE AND IS FLUID AVAILABLE AT HEAT EXCHANGER Y N HAS PUMP BEEN TURNED ON AND ARE ISOLATION VALVES OPEN Y N HAS CONDENSATE CONNECTION BEEN MADE AND
28. UBE e FP2 24VAC UNITS OR VIO R BRN o COMMON STATUS RVS cO tal LED ORG ALARM LO fit NOT USED E ty CXM YEL co SEE NOTE 6 FOR SEE MICROPROCESSOR 2 1 DRY ALARM CONTACT MALARM NOTE6 CONTROL LOGIC Alarm Relay Contacts Blower Relay Compressor Capacitor Circuit Breaker Compressor Contactor Sensor Condensate Overflow COMP Compressor FP1 FP2 GND HP JW LOC P1 PB Ground Optional wiring NOTES High Pressure Switch Clippable Field Selection Jumper Loss of Charge Pressure Switch Field Wiring Terminal Block Power Block Sensor Water Coil Freeze Protection Sensor Air Coil Freeze Protection LEGEND PM Performance Monitor A PSC Permanent Split Capacitor o O Circuit Breaker RVS Reversing Valve Solenoid TRANS Transformer Optional Wiring O4FO Relay Contacts N C Field Line Voltage Wiring oA o Solenoid Coil _ Field Low Voltage Wiring obo Relay Contacts N O Printed Circuit Trace ono i Optional Wiring Switch Temperature Ye Relay Contactor Coil a Switch Low Pressure e Ground KP Thermistor aq Wire Nut l Condensate Pan cl Splice Cap 1 Compressor and blower motor thermally protected internally All wiring to the unit must comply with NEC and local codes Transformer is wired to 240 v ORG lead for 240 50 1 units FP1 thermistor provides freeze protection
29. ation is not required be sure that a proper air path is provided for ventilation air to unit to meet ventilation requirement of the space Air Handler Section Compressor C A Section DIMENSIONS mm ciel e o LE 006 024 518 030 036 518 042 048 518 oso 504 Fig 5 Horizontal Hanger Bracket Factory Installed Step 6 Condensate Drain Slope the unit to ward the drain at a 6 5 mm per 30 cm pitch See Fig 6 If it is not possible to meet the required pitch install a condensate pump at the unit to pump condensate to building drain Horizontal units are not internally trapped therefore an ex ternal trap is necessary Install each unit with its own individual trap and means to flush or blowout the condensate drain line Do not install units with a common trap or vent For typical condensate connections see Fig 7 NOTE Never use a pipe size smaller than the connection VENTING Install a vent in the condensate line of any application that may allow dirt or air to collect in the line Con sider the following e Always install a vent where an application requires a long horizontal run e Always install a vent where large units are working against higher external static pressure and to allow proper drainage for multiple units connected to the same condensate main e Be sure to support the line where anticipated sagging from the condensate or when double trapping may occur
30. be required for single phase units where starting the unit is a problem due to low voltage See Fig 20 for thermistor nominal resistance Control Sensors The control system employs 2 nom inal 10 000 ohm thermistors FP1 and FP2 that are used for freeze protection Be sure FP1 is located in the discharge fluid and FP2 is located in the air discharge See Fig 21 90 0 80 0 f 70 0 60 0 50 0 40 0 30 0 Resistance kOhm 20 0 10 0 0 0 0 0 20 0 40 0 60 0 80 0 100 0 120 0 140 0 Temperature degF Fig 20 Thermistor Nominal Resistance A WATER IN AIRFLOW AIRFLOW F F THERMISTOR EXPANSION VALVE N FP2 FP1 SS CONDENSATE OVERFLOW LIQUID CO LIN AIR COIL FREEZE WATER PROTECTION COIL PROTECTION LEGEND COAX Coaxial Heat Exchanger c Airflow gt Refrigerant Liquid Line Flow SUCTION COMPRESSOR DISCHARGE WATER OUT Fig 21 FP1 and FP2 Thermistor Location FAULT Main Power Problems HP Fault Code 2 High Pressure LP LOC Fault Code 3 Low Pressure Loss of Charge FP1 Fault Code 4 Water Freeze Protection FP2 Fault Code 5 Air Coil Freeze Protection Condensate Fault Code 6 Over Under Voltage Code 7 Auto Resetting Performance Monitor Code 8 FP1 and FP2 Thermistors Code 9 No Fault Code Shown Unit Short
31. comply with NEC and local codes Neutral of 380 415 3 50 is required Transformer is wired to 240 v ORG lead for 415 3 50 For 380 3 50 switch ORG and RED leads at PB 3 and insulate ORG lead Transformer uses separate circuit breaker FP1 thermistor provides freeze protection for water When using antifreeze solutions cut JW3 jumper Check installation wiring information for specific thermostat hookup Refer to thermostat installation instructions for wiring to the unit Thermostat wiring must be Class 1 and voltage rating equal to or greater than unit supply voltage 24 v alarm signal shown For dry alarm contact cut JW4 jumper and dry contact will be available between AL1 and AL2 Transformer secondary ground via microprocessor board standoffs and screws to control box Ground available from top two standoffs as shown Blower motor is factory wired for medium and high speeds For any other combination of speeds at the motor attach black wire to the higher of the two desired speed taps and the blue wire to the lower of the two desired speed taps Blower motor is factory wired for high and low speeds No other combina tion of speeds is available Fig 12 Typical Aquazone Deluxe D Control Wiring 3 Phase Unit 13 Table 3 Electrical Data 50RHE VOLTS PHASE VOLTAGE COMPRESSOR Peete Tore anit MAX UNIT 50 Hz MIN MAX FEA ELA AMP FUSE HACR rE onsas sae s2 0o 17 so 69 15 LEGE
32. de Switch 6 Not used Boilerless Operation Switch 7 provides selection of boiler less operation and works in conjunction with switch 8 In boilerless operation mode only the compressor is used for heating when FP1 is above the boilerless changeover tempera ture set by switch 8 below Select ON for normal operation or select OFF for boilerless operation Boilerless Changeover Temperature Switch 8 on S1 pro vides selection of boilerless changeover temperature set point Select OFF for set point of 10 C or select ON for set point of 4 4C If switch 8 is set for 10 C then the compressor will be used for heating as long as the FP1 is above 10 C The compressor will not be used for heating when the FP1 is below 10 C and the compressor will operates in emergency heat mode staging on EH1 and EH2 to provide heat If a thermal switch is being used instead of the FP1 thermistor only the compressor will be used for heating mode when the FP1 terminals are closed If the FP1 terminals are open the compressor is not used and the control goes into emergency heat mode DIP SWITCH BLOCK 2 S2 This set of DIP switches is used to configure accessory relay options See Fig 11 and 12 Switches 1 to 3 These DIP switches provide selection of Accessory 1 relay options See Table 5 for DIP switch combinations Switches 4 to6 These DIP switches provide selection of Accessory 2 relay options See Table 6 for DIP switch combinations
33. e Whenever any of these factors are at a minimum or maximum level the other two factors must be at a normal level to ensure proper unit operation See Table 7 Table 7 Operating Limits 50RHE Units AIR LIMITS HEATING C Min Ambient Air 7 2 Rated Ambient Air 21 1 Max Ambient Air 29 4 Min Entering Air 4 4 Rated Entering Air db wb 20 15 Max Entering Air db wb 27 WATER LIMITS Min Entering Water 6 7 Normal Entering Water 1 1 to 15 6 LEGEND db Dry Bulb wb Wet Bulb NOTE Value in heating column is dry bulb only Any wet bulb read ing is acceptable AUNE Scroll Compressor Rotation It is important to be certain compressor is rotating in the proper direction To determine whether or not compressor is rotating in the proper direction 1 Connect service gages to suction and discharge pressure fittings 2 Energize the compressor 3 The suction pressure should drop and the discharge pressure should rise as is normal on any start up If the suction pressure does not drop and the discharge pressure does not rise to normal levels 1 Turn off power to the unit Install disconnect tag 2 Reverse any two of the unit power leads 3 Reapply power to the unit and verify pressures are correct The suction and discharge pressure levels should now move to their normal start up levels When the compressor is rotating in the wrong direction the unit makes more noise and does not provide cooling After a few m
34. e the subcooling temperature with the normal temperature listed in Table 9 If the measured liquid line temperature does not agree with the required liquid line temperature ADD refrigerant to raise the temperature or REMOVE refrigerant using standard practices to lower the temperature allow a tolerance of 1 7 C Refrigerant Charging A WARNING To prevent personal injury wear safety glasses and gloves when handling refrigerant Do not overcharge system this can cause compressor flooding NOTE Do not vent or depressurize unit refrigerant to atmo sphere Remove and reclaim refrigerant following accepted practices Air Coil Fan Motor Removal A CAUTION Before attempting to remove fan motors or motor mounts place a piece of plywood over evaporator coils to prevent coil damage Disconnect motor power wires from motor terminals before motor is removed from unit 1 Shut off unit main power supply 2 Loosen bolts on mounting bracket so that fan belt can be removed 3 Loosen and remove the 2 motor mounting bracket bolts on left side of bracket 4 Slide motor bracket assembly to extreme right and lift out through space between fan scroll and side frame Rest motor on a high platform such as a step ladder Do not allow motor to hang by its power wires TROUBLESHOOTING Fig 20 and 21 and Table 16 When troubleshooting problems with a WSHP consider the following Thermistor A thermistor may
35. eaker TRANS Transformer Optional Wiring co Sensor Condensate Overflow sri oo Solenoid Coil Field Line Voltage Wiring FP1 Sensor Water Coil Freeze Protection f B HH FP2 Sensor Air Coil Freeze Protection Field Low Voltage Wiring Relay Contacts N O GND Ground Pri ai i F rint ircuit Tr on Temperature Switch HP High Pressure Switch ted S a ae emp rature Swite HWTS High Leaving Water Temp Switch Optional Wiring aad Switch Loss of Charge JW Clippable Field Selection Jumper LOC Loss of Charge Pressure Switch Ye Relay Contactor Coil a Ground MV Motorized Valve C Wire Nut Optional wiring NOTES 1 2 3 Compressor thermally protected internally All wiring to the unit must comply with NEC and local codes Transformer is wired to 240 v ORG lead for 240 50 1 units 6 switch RED and ORG leads to PB 1 and insulate ORG lead for 220 50 1 FP1 thermistor provides freeze protection for water When using antifreeze solutions cut JW3 jumper Check installation wiring information for specific thermostat hookup Refer to thermostat installation instructions for wiring to the unit Thermostat wiring must be Class 1 and voltage rating equal to or greater than unit supply voltage 24 v alarm signal shown For dry alarm contact cut JW4 jumper and dry contact will be available between AL1 and AL2 Transformer secondary grou
36. ere the refrigerant circuit of this unit must only be serviced by technicians which meet local state and federal proficiency requirements IMPORTANT To prevent injury or death due to electrical shock or contact with moving parts open unit disconnect switch before servicing unit Filters Filters must be clean for maximum performance Inspect filters every month under normal operating conditions replace when necessary IMPORTANT Units should never be operated with out a filter Water Coil Keep all air out of the water coil Check open loop systems to be sure the well head is not allowing air to infiltrate the water line Always keep lines airtight Inspect heat exchangers regularly and clean more frequent ly if the unit is located in a dirty environment Keep the heat exchanger full of water at all times Open loop systems should have an inverted P trap placed in the discharge line to keep water in the heat exchanger during off cycles Closed loop systems must have a minimum of 105 kPa during the summer and 275 kPa during the winter Check P trap frequently for proper operation Table 15 Aquazone D Control Current LED Status and Alarm Relay Operations DESCRIPTION Normal Mode Normal Mode with PM Test Mode Night Setback STATUS LED TEST LED elon FAULT LED Red o_o E Flash Last Fault Code in Memory Open D Control is non functional ai o 0o L o Flash Last Fault EKT in Memory Cycling A
37. flow before 45 seconds and it Ga CLIP JW3 JW3 6 FP1 Low Temp FOR JW2 6 FP2 Low Temp Typical Water Valve activates the compressor only after the valve is completely opened by closing its end switch When wired as shown the valve will have the following operating characteristics A O 1 Remain open during a lockout 2 Draw approximately 25 to 35 VA through the Y signal Fig 17 Typical D Control Accessory Wiring of the thermostat IMPORTANT Connecting a water solenoid valve can overheat the anticipators of electromechanical thermo stats Only use relay based electronic thermostats PRE START UP System Checkout When the installation is complete follow the System Checkout procedure outlined below before starting up the system Be sure 1 Voltage is within the utilization range specifications of the unit compressor and fan motor and voltage is balanced for 3 phase units Fuses breakers and wire are correct size Low voltage wiring is complete Piping and system flushing is complete Airis purged from closed loop system System is balanced as required Monitor if necessary Isolation valves are open Water control valves or loop pumps are wired Condensate line is open and correctly pitched Transformer switched to lower voltage tap if necessary Blower rotates freely shipp
38. flow restrictions External static too high Check Table 4 X Air temperature out of range Too much cold vent air Bring entering air temperature within design parameters x Improper freeze protect set Normal airside applications will require 1 1 C only ting 1 1 C vs 12 2 C Blocked drain Check for blockage and clean drain Improper trap Check trap dimensions and location ahead of vent X Moisture on sensor Check for moisture shorting to air coil X X Under voltage Check power supply and 24 vac voltage before and during operation Check power supply wire size Check compressor starting Check 24 vac and unit transformer tap for correct power supply voltage x Heating mode FP2 gt 51 7 C Check for poor airflow or overcharged unit X Cooling mode FP1 gt 51 7 C Check for poor water flow or airflow OR FP2 lt 4 4 C X FP2 temperature is higher Swap FP1 and FP2 thermistors than FP1 temperature rx x No compressor operation See scroll compressor rotation section rx x Control board Reset power and check operation x X _ Dirty air filter Check and clean air filter rf x x Unit selection Unit may be oversized for space Check sizing for actual load of space x x Compressor overload Check and replace if necessary rx x Unit locked out Check for lockout codes Reset power Compressor overload Check compressor overload Replace if necessary HEATING COOLING POSSIBLE CAUSE SOLUTION Check for 24 vac betwee
39. for water When using antifreeze solutions cut JW3 jumper 2 3 switch RED and ORG leads to PB 3 and insulate ORG lead 4 5 Typical heat pump thermostat wiring shown Refer to thermostat installation instructions for wiring to the unit 11 6 7 24 v alarm signal shown For dry alarm contact cut JW1 jumper and dry contact will be available between AL1 and AL2 Transformer secondary ground via microprocessor board stand offs and screws to control box Ground available from top two standoffs as shown Fan motors factory wired for medium speed For high or low speed remove BLU wire from fan motor speed tap M and con nect to H for high or L for low Fig 10 Typical Aquazone Complete C Control Wiring 3 Phase Unit START ASSIST WHEN NEEDED SEE NOTE 8 power suppLy EARTH GRD RED BLU REFER TO ree DATA PLATE USE COPPER CONDUCTORS N N
40. g and shipping information to verify that the 9 Remove any access panel screws that may be difficult to correct unit has been shipped 2 Verify that the unit is the correct model for the entering water temperature of the job remove once unit is installed Table 1 Physical Data Aquazone 50RHE006 060 Units UNIT 50RHE 060 COMPRESSOR 1 each Scroll FACTORY CHARGE R 407C kg 2 41 PSC FAN MOTOR AND BLOWER Fan Motor Type Speeds PSC 3 Fan Motor Hp w 1 746 Blower Wheel Size D x W mm 279 x 254 HORIZONTAL Air Coil Dimensions H x w mm 254 x 406 406 x 406 457 x 559 457 x 787 508 x 889 Total Face Area m 0 103 0 165 0 255 0 360 0 452 Tube Size mm 9 5 i 9 5 Distance Between Fins mm 2 2 2 7 Number of Rows 2 4 Filter Standard Throwaway 1 305 x 508 Qty Size mm Teena eae 1 635 x 508 Weight 25 4 mm kg Operating 146 8 Packaged 153 6 LEGEND NOTES PSC Permanent Split Capacitor 1 All units have spring compressor mountings TXV thermostatic expan sion valve expansion devices and 1 2 and 3 in electrical knockouts 2 Size 048 available as high static unit WATER OVERALL anra CABINET Cond win oi Depth Height BARAL ELECTRICAL KNOCKOUTS a DISCHARGE CONNECTION RETURN CONNECTION Duct Flange Installed 0 10 in Using Return Air Opening 50RHE 3 UNITS EARM oc duit Low Power Supply sone Return Retai rics Supply o fege Depth Depth Heig
41. g loop temperatures drop below 4 4 C or where piping will be routed through areas subject to freezing antifreeze is needed Alcohols and glycols are commonly used as antifreeze agents Freeze protection should be maintained to 8 3 K below the lowest expected entering loop temperature For example if the lowest expected entering loop temperature is 1 1 C the leaving loop temperature would be 5 6 to 3 9 C Therefore the freeze protection should be at 9 4 C 1 1 C 8 3 C 94C IMPORTANT All alcohols should be pre mixed and pumped from a reservoir outside of the building or introduced under water level to prevent fuming Calculate the total volume of fluid in the piping system See Table 11 Use the percentage by volume in Table 12 to deter mine the amount of antifreeze to use Antifreeze concentration should be checked from a well mixed sample using a hydrome ter to measure specific gravity FREEZE PROTECTION SELECTION The 1 1 C FP1 factory setting water should be used to avoid freeze damage to the unit Once antifreeze is selected the JW3 jumper FP1 should be clipped on the control to select the low temperature anti freeze 13 F set point to avoid nuisance faults Table 11 Approximate Fluid Volume L per 30 m of Pipe PIPE DIAMETER in VOLUME I Copper 1 15 5 1 25 24 2 1 5 34 8 Rubber Hose 1 14 7 Polyethylene 3 4 IPS SDR11 10 6 1 IPS SDR11 17 0 11 4 IPS SDR11 30 0 1 2 IPS SDR11 4
42. he transformers may be switched to 220 volt operation by switching the red 220 volt wire with the orange 240 volt wire at the TB1 1 terminal for single phase and TB1 3 for 3 phase Unit Power Supply See electrical table for wire and breaker size Fig 13 50RHE Typical Single Phase Line Voltage Power Connection PSC PERMANENT SPLIT CAPACITOR BLOWER SPEED CONNECT THE BLUE WIRE TO SELECTION All Water Source Heat Pumps are factory set H FOR HIGH SPEED FAN to deliver rated airflow at nominal static 37 Pa on medium MEOR low SPEED EAN TAN speed Where higher static is needed high speed can be BLU utilized 100 to 125 Pa Low speed will deliver approximately fa 85 of rated airflow 25 Pa The PSC blower fan speed can be changed on all units by swapping wires connected to the relay contacts that control the fan See Table 4 and Fig 14 NOTE Available airflow for all units is shown in Table 4 MEDIUM FACTORY SETTING FAN MOTOR Fig 14 50RHE Blower Speed Selection Table 4 50RHE Blower Performance BORE NOMINAL MINIMUM AIRFLOW L s AIRFLOW AIRFLOW External Static Pressure Pa UNIT o 50 75 100 125 HI 133 123 112 89 78 006 81 61 MED 110 99 87 68 LO 98 90 75 60 HI 165 151 142 118 99 009 113 85 MED 160 146 127 113 94 LO 151 137 123 109 90 HI 170 165 151 137 123 109 012 140 104 MED 165 151 142 127 118 LO 146 137 127 118 104 HI 345 316
43. ht 006 012 22 4 43 1 11 3 aA Ea oe E HR 5 8 8 0 Ea 1 5 17 1 9 3 2 2 56 8 109 5 28 7 1 5 E Ea 14 7 20 3 3 8 43 4 23 6 5 6 015 024 22 4 43 1 17 3 2 4 E 0 6 3 5 10 2 EA 10 4 9 3 Ea 1 5 17 1 15 3 2 2 56 8 109 5 43 9 6 1 12 4 1 5 8 9 19 1 25 9 26 4 23 6 12 7 3 8 43 4 38 9 5 6 22 4 53 2 19 3 2 4 5 4 06 5 7 9 7 12 2 5 0 6 8 10 4 9 3 5 0 2 1 23 1 17 3 22 56 8 135 1 49 0 6 1 13 7 1 5 14 5 24 6 31 0 12 7 17 3 26 4 23 6 12 7 5 3 58 7 43 9 5 6 22 4 53 2 19 3 2 4 0 6 5 7 9 7 12 2 2 9 3 8 13 5 13 1 2 9 19 23 1 17 3 2 2 56 8 135 1 49 0 6 1 1 5 14 5 24 6 31 0 7 4 a 34 3 33 3 7 4 4 8 58 7 43 9 5 6 22 4 62 2 19 3 2 4 5 4 56 8 158 0 49 0 6 1 13 7 25 4 71 2 21 3 2 4 ae 64 5 180 8 54 1 6 1 1 NOTES 1 Condensate is 3 4 in FPT copper 2 Horizontal unit shipped with filter bracket only This bracket should be removed for return duct connection front 3 Hanger kit is factory installed Isolation grommets are provided 4 Right and left orientation is determined by looking at water connection side 13 5 13 1 9 1 9 32 1 17 3 34 3 33 3 4 48 81 5 43 9 13 6 13 3 8 2 9 36 1 19 3 34 5 33 8 14 7 7 4 91 7 49 0 NN an DN 0Oj 0 a woja 060 oe P an DN LEFT RETURN RIGHT RETURN Legend CAP Control Access Panel 2 61cm Service elo ee Optional J 61em CSP Compressor Service Panel ont Access Access Front i es BSP B
44. ications An alternative method is to install a flow control device These devices are typically an orifice of plastic material designed to allow a specified flow rate that are mounted on the outlet of the water control valve Occasionally these valves produce a velocity noise that can be reduced by applying some back pressure To accomplish this slightly close the leaving isolation valve of the well water setup A WARNING To avoid possible injury or death due to electrical shock open the power supply disconnect switch and secure it in an open position before flushing system Table 9 Typical Unit Operating Pressures and Temperatures HEATING ENTERING water COOLING WATER FLOW Suction Discharge Super Sub Water Temp Air Temp Suction Discharge Super Sub Water Tem Air TEMP C i s per kw Pressure Pressure heat cooling Rise Drop C Pressure Pressure heat cooling Drop C DS Temp EWT kPa kPa C C C DB kPa kPa C C P Rise C 225 254 269 314 14 22 7 11 12 13 12 14 102 117 499 556 7 9 1 2 4 5 8 11 1 14 22 0 7 9 12 14 1 7 9 1 2 3 4 9 12 14 22 6 9 6 12 14 5 6 7 9 1 2 3 9 12 0 027 225 254 374 463 7 11 6 10 11 13 11 14 150 179 538 628 6 9 1 3 6 7 10 222 251 359 425 7 11 5 9 7 8 11 14 158 185 6 9 1 3 4 5 13 17 219 248 344 413 7 11 4 8 4 7 11 14 164 194
45. in Pans Check condensate drain pans for algae growth twice a year If algae growth is apparent consult a water treatment specialist for proper chemical treat ment Applying an algaecide every three months will typically eliminate algae problems in most locations Refrigerant System Verify air and water flow rates are at proper levels before servicing To maintain sealed circuit ry integrity do not install service gauges unless unit operation appears abnormal Check to see that unit is within the superheat and subcool ing temperature ranges shown in Table 16 If the unit is not within these ranges recover and reweigh in refrigerant charge Condensate Drain Cleaning Clean the drain line and unit drain pan at the start of each cooling season Check flow by pouring water into drain Be sure trap is filled to main tain an air seal Air Coil Cleaning Remove dirt and debris from evap orator coil as required by condition of the coil Clean coil with a stiff brush vacuum cleaner or compressed air Use a fin comb of the correct tooth spacing when straightening mashed or bent coil fins Condenser Cleaning Water cooled condensers may require cleaning of scale water deposits due to improperly maintained closed loop water systems Sludge build up may need to be cleaned in an open water tower system due to induced contaminants Local water conditions may cause excessive fouling or pitting of tubes Condenser tubes should
46. indoor installation only Operating Limits ENVIRONMENT This equipment is designed for indoor installation ONLY Extreme variations in temperature humidi ty and corrosive water or air will adversely affect the unit per formance reliability and service life POWER SUPPLY A voltage variation of 10 of name plate utilization voltage is acceptable UNIT STARTING CONDITIONS Depending on the mod el units start and operate in an ambient temperature of 7 2 C with entering air temperature at 4 4 C or 10 C entering water temperature at 6 7 C or 10 C and with both air and water at the flow rates used NOTE These operating limits are not normal or continuous operating conditions Assume that such a start up is for the purpose of bringing the building space up to occupancy tem perature See Table 7 for operating limits A WARNING When the disconnect switch is closed high voltage is present in some areas of the electrical panel Exercise caution when working with the energized equipment Restore power to system Turn thermostat fan position to ON Blower should start Balance airflow at registers Adjust all valves to the full open position and turn on the line power to all heat pump units 5 Operate unit in the cooling cycle Refer to Table 7 for unit operating limits NOTE Three factors determine the operating limits of a unit 1 entering air temperature 2 water temperature and 3 ambient temperatur
47. ing support is removed Blower speed is on correct setting Air filter is clean and in position Service access panels are in place Return air temperature is between 4 4 to 26 7 C heating and 10 to 43 3 C cooling Air coil is clean Control field selected settings are correct TODD RARUN Aquazone C See Note l eS Se AUN Low Voltage n I NOTE Low voltage connector may be removed for easy installation Fig 15 Low Voltage Field Wiring men eN jan 16 AIR COIL To obtain maximum performance clean the air coil before starting the unit A ten percent solution of dish washing detergent and water is recommended for both sides of the coil Rinse thoroughly with water FIELD SELECTABLE INPUTS Jumpers and DIP dual in line package switches on the control board are used to customize unit operation and can be configured in the field IMPORTANT Jumpers and DIP switches should only be clipped when power to control board has been turned off C Control Jumper Settings See Fig 9 and 10 WATER COIL FREEZE PROTECTION FP1 LIMIT SETTING Select jumper 3 JW3 FP1 Low Temp to choose FP1 limit of 12 2 C or 1 1 C To select 1 1 C as the limit DO NOT clip the jumper To select 12 2 C as the limit clip the jumper AIR COIL FREEZE PROTECTION FP2 LIMIT SET TING Select jumper 2 JW2 FP2 Low Temp to choose FP2 limit of 12 2 C or 1 1 C To select
48. inutes of reverse operation the scroll com pressor internal overload protection will open thus activating the unit lockout This requires a manual reset To reset turn the thermostat on and then off NOTE There is a 5 minute time delay before the compressor will start Unit Start Up Cooling Mode 1 Adjust the unit thermostat to the warmest position Slowly reduce the thermostat position until the compres sor activates 2 Check for cool air delivery at unit grille a few minutes after the unit has begun to operate 3 Verify that the compressor is on and that the water flow rate is correct by measuring pressure drop through the heat exchanger using P T plugs See Table 8 Check the elevation and cleanliness of the condensate lines any dripping could be a sign of a blocked line Be sure the condensate trap includes a water seal 4 Check the temperature of both supply and discharge wa ter Compare to Table 9 If temperature is within range proceed If temperature is outside the range check the cooling refrigerant pressures in Table 9 5 Check air temperature drop across the coil when com pressor is operating Air temperature drop should be between 8 3 and 13 9 Table 8 Water Temperature Change Through Heat Exchanger HEATING COOLING RISE C DROP C Min Max Min Max WATER FLOW RATE I s For Closed Loop Ground Source or Cooling Boiler Systems at 0 054 I s per kW For Open Loop
49. its with 2 compressors and 2 D controls or in master slave applications In master slave applications each compressor and fan will stage according to its switch 2 setting If switch is set to stage 2 the compressor will have a 3 second delay before ener gizing during stage 2 demand NOTE If DIP switch is set for stage 2 the alarm relay will not cycle during Test mode Heating Cooling Thermostat Type Switch 3 provides selec tion of thermostat type Heat pump or heat cool thermostats can be selected Select OFF for heat cool thermostats When in heat cool mode Y1 is used for cooling stage 1 Y2 is used for cooling stage 2 W1 is used for heating stage 1 and O W2 is used for heating stage 2 Select ON for heat pump applications In heat pump mode Y1 used is for compressor stage 1 Y2 is used for compressor stage 2 W1 is used for heating stage 3 or emergency heat and O W2 is used for RV heating or cooling depending upon switch 4 setting O B Thermostat Type Switch 4 provides selection for heat pump O B thermostats O is cooling output B is heating out put Select ON for heat pumps with O output Select OFF for heat pumps with B output Dehumidification Fan Mode Switch 5 provides selection of normal or dehumidification fan mode Select OFF for dehu midification mode The fan speed relay will remain OFF dur ing cooling stage 2 Select ON for normal mode The fan speed relay will turn on during cooling stage 2 in normal mo
50. lative humidity is no greater than 75 e Provide sufficient space for water electrical and duct connections e Locate unit in an area that allows easy access and removal of filter and access panels e Allow enough space for service personnel to perform maintenance e Return air must be able to freely enter the space if unit needs to be installed in a confined area such as a closet NOTE Correct placement of the horizontal unit can play an important part in minimizing sound problems Since duct work is normally applied to these units the unit can be placed so that the principal sound emission is outside the oc cupied space in sound critical applications A fire damper may be required by the local code if a fire wall is penetrated FIELD CONVERSION OF DISCHARGE AIR The dis charge air of the SORHE horizontal units can be converted between side and back discharge in the field The conversion process is the same for right and left return configurations See Fig 3 and 4 NOTE It is not possible to convert return air between left or right return models in the field due to refrigerant piping changes Preparation The unit should be on the ground in a well lit area for conversion Hung units should be taken down to ground level before converting Side to Back Discharge Conversion 1 Remove screws to free the top and discharge panels See Fig 3 2 Remove the access panel and set aside 3 Lift the discharge panel from
51. le pump is running For average scale deposit allow solution to remain in con denser overnight For heavy scale deposit allow 24 hours Drain condenser and flush with clean water Follow acid manu facturer s instructions Checking System Charge Units are shipped with full operating charge If recharging is necessary 1 Insert thermometer bulb in insulating rubber sleeve on liquid line near filter drier Use a digital thermometer for all temperature measurements DO NOT use a mercury or dial type thermometer 2 Connect pressure gage to discharge line near compressor 3 After unit conditions have stabilized read head pressure on discharge line gage NOTE Operate unit a minimum of 15 minutes before checking charge 4 From standard field supplied Pressure Temperature chart for R 407C find equivalent bubble point temperature FILL CONDENSER WITH CLEANING SOLUTION DO NOT ADD SOLUTION MORE RAPIDLY THAN VENT CAN EXHAUST GASES CAUSED BY CHEMICAL ACTION FUNNEL VENT PIPE 5 APPROX 3 TO 4 CONDENSER Fig 18 Gravity Flow Method GAS VENT gt PRIMING SONN GLOBE j U a lt D MP SS SUPPORT van TANK K REMOVE WATER REGULATING VALVE FINE MESH RETURN SCREEN Fig 19 Forced Circulation Method 5 Read liquid line temperature on thermometer then subtract from bubble point temperature The difference equals subcooling temperature 6 Compar
52. ll continue normal operation NOTE If 3 consecutive faults occur without satisfying the thermostat input call to terminal Y the control will go into lockout mode The last fault causing the lockout is stored in memory and can be viewed by entering Test mode Aquazone Deluxe D Control LED Indica tors There are 3 LED indicators on the D Control STATUS LED Status LED indicates the current status or mode of the D control The Status LED light is green TEST LED Test LED will be activated any time the D control is in test mode The Test LED light is yellow FAULT LED Fault LED light is red The fault LED will always flash a code representing the last fault in memory If there is no fault in memory the fault LED will flash code 1 on the and appear as 1 fast flash alternating with a 10 second pause See Table 15 SERVICE Perform the procedures outlined below periodically as indicated IMPORTANT When a compressor is removed from this unit system refrigerant circuit oil will remain in the com pressor To avoid leakage of compressor oil the refrigerant lines of the compressor must be sealed after it is removed IMPORTANT All refrigerant discharged from this unit must be recovered without exception Technicians must fol low industry accepted guidelines and all local state and fed eral statutes for the recovery and disposal of refrigerants IMPORTANT To avoid the release of refrigerant into the atmosph
53. ll repeat continually until the fault is cleared Table 14 C Control LED Code and Fault Descriptions LED CODE FAULT DESCRIPTION 1 No fault in memory There has been no fault since the last power down to power up sequence High Pressure Switch HP Open Instantly 3 Low Pressure Switch LP open for 30 continuous sec onds before or during a call bypassed for first 60 seconds 4 Freeze Protection Coax FP1 below Temp limit for 30 con FP1 tinuous seconds bypassed for first 60 seconds of operation 5 Freeze Protection Air Coil FP2 below Temp limit for 30 con FP2 tinuous seconds bypassed for first 60 seconds of operation 6 Condensate overflow Sense overflow grounded for 30 continuous seconds 7 Over Under Voltage R power supply is lt 19VAC or Autoreset Shutdown gt 30VAC 8 PM Warning Performance Monitor Warning has occurred 9 FP1 and FP2 Thermistors FP1 temperature is higher than are swapped FP2 in heating test mode or FP2 temperature is higher than FP1 in cooling test mode N LEGEND FP Freeze Protection HP High Pressure LED Light Emitting Diode LP Low Pressure PM Performance Monitor Retry Mode In Retry mode the status LED will start to flash slowly to signal that the control is trying to recover from an input fault The control will stage off the outputs and try to again satisfy the thermostat used to terminal Y Once the ther mostat input calls are satisfied the control wi
54. lower Service Panel ASP Alternate Service Panel Optional 2 61cm Service Access NS Left Return Power Supply Right Return we lt lt 3 4 Knockout wg 1 2 N Knockout 3 25 82 6mm 826mm Low Voltage Ko 1 2 Knockout o k CAP A J O 7 Discharge a O e e i Cond t pigs e oy ERT C Condensate 7 Front View Sieber Discharge Unit Hanger Detail E R Q p 3 3 B a Blower BSP slic cls Outlet o W Blower A S Ol Outlet Ys Z 2 Jl z x z a g D Q A A Left Return Back Discharge x Right Return Back Discharge P M N o Blower BSP p ASP BSP 9 Outlet fe Blower CSP Outlet oO N Front L Front Left Return Right Discharge Hm Right Return Left Discharge 1 Air Coil v U Ss Air Coil 27 9mml S u V P o ie o cT CSP ASP T Front Front B B Left Return Left View Right Return Right View Air Coil Opening Air Coil Opening Note Shaded areas are recommended service areas not required Fig 1 50RHE Dimensional Data ReturnLoop 3 8 threaded rods by others ee Filter Acce
55. mperature Connect boiler drains and other valves using a T con nector to allow acid flushing for the heat exchanger Do not overtighten connections Route piping to avoid service access areas to unit Use PVC SCH80 or copper piping material NOTE PVC SCH40 should not be used due to system high pressure and temperature extremes Water Flow Pressure Control Regulator Tank Valve me e Water Out Water In e Ns lt 5 From Pump e i ve A D es q KS k Shut Off iS SS e Valve e N cnc C2 Strainer Field Installed Accessory gt amp 16 to 20 mesh recommended for filter sediment Boiler n Drains Pressure Temperature Plugs Fig 8 Typical Ground Water Piping Installation Water Supply and Quantity Check water supply Water supply should be plentiful and of good quality See Table 2 for water quality guidelines IMPORTANT Failure to comply with the above required water quality and quantity limitations and the closed system application design requirements may cause damage to the tube in tube heat exchanger that is not the responsi bility of the manufacturer In all applications the quality of the water circulated through the heat exchanger must fall within the ranges listed in the Water Quality Guidelines table Consult a local water treat ment firm independent testing facility or local water authority for specific recommendations to maintain water quality within the published limi
56. n R and C on controller X Water temperature out of Bring water temperature within design parameters range in cooling Dirty air coil construction dust etc x X__ Overcharged with refrigerant Check superheat subcooling vs typical operating condition Table 9 Compressor pump down at Check charge and start up water flow start up X Improper freeze protect set Clip JW2 jumper for antifreeze 12 2 C use ting 1 1 C vs 12 2 C X Reduced or no airflow in Check for dirty air filter and clean or replace cooling Bad thermistor Check temperature and impedance correlation X Poor drainage Check for piping slope away from unit Check slope of unit toward outlet Poor venting Check vent location X X Over voltage Check power supply voltage and 24 vac before and during operation Check 24 vac and unit transformer tap for correct power supply voltage X FP1 temperature is higher Swap FP1 and FP2 thermistors than FP2 temperature i ae ee eee Compressor overload Check and replace if necessary rf x x Unit in Test Mode Reset power or wait 20 minutes for auto exit fr x x Thermostat position Ensure thermostat set for heating or cooling operation Thermostat wiring Check Y and W wiring at heat pump Jumper Y and R for compressor operation in Test mode x x x x 26 FAULT Only Compressor Runs Unit Does Not Operate in Cooling Insufficient Capacity Not Cooling or Heating Properly High Head Pressure Low S
57. n working on air conditioning equipment observe precau D Control DIP Switches press tee ees 17 tions in the literature tags and labels attached to the unit and D Control Accessory Relay Configurations 18 other safety precautions that may apply Water Valve Slow Opening 18 Improper installation adjustment alteration service main Outdoor Air Damper OAD 18 i prop sacJusiment ax eee enance or use can cause explosion fire electrical shock or START UP eRe 18 21 other conditions which may cause personal injury or property Operating Limits Pee 18 damage Consult a qualified installer service agency or your Scroll Compressor Rotation 19 distributor or branch for information or assistance The Unit Start Up Cooling Mode 19 qualified installer or agency must use factory authorized kits or Unit Start Up Heating Mode 19 accessories when modifying this product Refer to the individ Flow Regulation see e ee eee 19 ual instructions packaged with the kits or accessories when Flushing relies E coed Pee wet Ott ad ea T case tart 20 installing Antifreeze estes ccd oe dhe oh te eee ooh 21 Cooling Tower Boiler Systems 21 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 005 00042
58. nation up to 24 hours after sampling A low pH and high alkalinity cause system problems even when both values are within ranges shown The term pH refers to the acidity basicity or neutrality of the water supply Below 7 0 the water is considered to be acidic Above 7 0 water is considered to be basic Neutral water contains a pH of 7 0 NOTE Hardness in mg l is equivalent to ppm POWER SUPPLY EARTH GRD e264 REFER TO DATA PLATE USE COPPER CONDUCTORS ONLY SEE NOTE 3 TRANS COMPONENT LOCATION CR AN a N NEUTRAL START ASSIST E WHEN NEEDED BLU RED 2 4 BR yer CAPACITOR 3 AIR FLOW SETTINGS FCTRY SETTING MED SEE NOTE 8 G Y ca 7 SEE Ka NOTE 7 9 0 Loo ae Pl eee TEST PINS tet Fe SEE COMPRESS RED NOTE 5 Lo RELAY ep ed HP TYPICAL TSTAT COMPR NOTE 4 aa amp _ Loc SIZES 015 036 YO fae es BRN laws DIP SWITCH GRY SFE NOTE 4 FP1 LOW TEMP ary o COOLING awe E o v TXV UNITS FAN cap TuBE VIOS GO LOW TEMP UNITS OR vio FP2 24 VAC OFF nO COMMON q see f RVS cO i status ORG ALARM LO FH uwi LED NOT USED i ejs d YEL _ co SEE NOTE 6 FOR CXM wma DRY ALARM
59. nd via microprocessor board stand offs and screws to control box Ground available from top two standoffs as shown Blower motor is factory wired for medium and high speeds For any other combination of speeds at the motor attach black wire to the higher of the two desired speed taps and the blue wire to the lower of the two desired speed taps Fig 11 Typical Aquazone Deluxe D Control Wiring Single Phase Unit 12 COMPONENT LOCATION DATA PLATE USE COPPER CONDUCTORS ONLY yer CB ver gs EARTH GND POWER SUPPLY N NEUTRAL REFER TO 24V BLU SEE NOTE 8 240V BRN BRN SEE RED NOTE 7 RED SEE TYPICAL HEAT mae SS FAN ENABLE PUMP T STAT CoM CONT SEE NOTE 5 i con Y SL COMPR 1 nog 2 COOLING 2 OST FAN 2 SSF z4vac 5 OPROCESS MICROPROCESSOR lt HWTS sd COMMON 8 CONTROL LOGIC BLK aay K 7 r xi ALARM 3 e A Bik SEE NOTE 6 FOR SaN A OC DRY CONTACT SEE NOTE 4 FOR ALARM status _ GRY SE p y TEST Y vio NITS FAULT B VIO FP2 TEST PINS co e 2 SEE PIELEN LOW NOTE4 UNIT STAG Z 7 7 O
60. nt Low refrigerant charge Check superheat and subcooling Table 9 Restricted metering device _ Check superheat and subcooling Table 9 Replace O0 x Defective reversing valve Perform RV touch test X X Thermostat improperly Check location and for air drafts behind thermostat located X X Unit undersized Recheck loads and sizing check sensible cooling load and heat pump capacity X X Scaling in water heat Perform scaling check and clean if necessary exchanger Inlet water too hot or cold _ Check load loop sizing loop backfill ground moisture X Reduced or no airflow in Check for dirty air filter and clean or replace al heating Check fan motor operation and airflow restrictions External static too high Check blower Table 4 X Reduced or no water flow in Check pump operation or valve operation setting rn Check water flow adjust to proper flow rate See Table 8 x inlet watertoo hot Check load loop sizing loop backfill ground moisture X Air temperature out of range Bring return air temperature within design parameters in heating X Scaling in water heat Perform scaling check and clean if necessary exchanger Unit overcharged Check superheat and subcooling Reweigh in charge X X Non condensables in Vacuum system and reweigh in charge system Restricted metering device _ Check superheat and subcooling per Table 9 Replace X Reduced water flow in Check pump operation or water valve operation setting heating
61. ntrol allows the field selection of source fluid freeze protection points through jumpers The factory setting of jumper JW3 FP1 is set ae for water at 1 1 C In earth loop applications jumper JW3 should be clipped to change the setting to 10 6 C when using antifreeze in colder earth loop applications See Fig 16 AIR COIL FREEZE PROTECTION The air coil freeze protection jumper JW2 FP2 is factory set for 1 1 C and Lc G should not need adjusting Suwi arz ony TED ACCESSORY CONNECTIONS Terminal A on the control is provided to control accessory devices such as water valves electronic air cleaners humidifiers etc This signal operates CLIP with the compressor terminal See Fig 17 Refer to the specific FOR DRY agen CONTACT unit wiring schematic for details NOTE The A terminal should only be used with 24 volt AQUAZONE CONTROL C Control Shown signals not line voltage signals WATER SOLENOID VALVES Water solenoid valves may Fig 16 Typical Aquazone Control Board be used on primary secondary pump and ground water installa Jumper Locations tions A typical well water control valve wiring approach which can limit waste water in a lockout condition is shown in Fig 17 A slow closing valve may be required to prevent water Terminal Strip P2 hammer When using a slow closing valve consider special wiring conditions The valve takes approximately 60 seconds c O to open very little water will
62. onfigura tion the relay will be ON if the NSB input is connected to ground C NOTE If there are no relays configured for digital NSB then the NSB and OVR inputs are automatically configured for mechanical operation MECHANICAL NIGHT SET BACK When NSB input is connected to ground C all thermostat inputs are ignored A thermostat set back heating call will then be connected to the OVR input If OVR input becomes active then the D control will enter Night Low Limit NLL staged heating mode The NLL staged heating mode will then provide heating during the NSB period Water Valve Slow Opening If relay is config ured for Water Valve slow opening the relay will start 60 sec onds prior to starting compressor relay Outdoor Air Damper OAD If relay is configured for OAD the relay will normally be ON any time the Fan Enable relay is energized The relay will not start for 30 min utes following a return to normal mode from NSB when NSB is no longer connected to ground C After 30 minutes the relay will start if the Fan Enable is set to ON A CAUTION To avoid equipment damage DO NOT leave system filled in a building without heat during the winter unless anti freeze is added to system water Condenser coils never fully drain by themselves and will freeze unless winterized with antifreeze START UP Use the procedure outlined below to initiate proper unit start up NOTE This equipment is designed for
63. onnection 7 Provide adequate clearance for filter replacement and drain pan cleaning Do not allow piping conduit etc to block filter access 8 Provide sufficient access to allow maintenance and servicing of the fan and fan motor compressor and coils Removal of the entire unit from the closet should not be necessary 9 Provide an unobstructed path to the unit within the closet or mechanical room Space should be sufficient to allow removal of unit if necessary 10 Provide ready access to water valves and fittings and screwdriver access to unit side panels discharge collar and all electrical connections 11 Where access to side panels is limited pre removal of the control box side mounting screws may be necessary for future servicing STORAGE If the equipment is not needed immediately at the jobsite it should be left in its shipping carton and stored in a clean dry area of the building or in a warehouse Units must be stored in an upright position at all times If carton stacking is necessary stack units a maximum of 3 high Do not remove any equipment from its shipping package until it is needed for installation PROTECTION Once the units are properly positioned on the jobsite cover them with either a shipping carton viny film or an equivalent protective covering Cap open ends of pipes stored on the jobsite This precaution is especially important in areas where painting plastering or spraying of firep
64. or dual compressor application all compressor relays and related func tions will track with their associated DIP switch 2 on S1 COOLING STAGE 2 In Cooling Stage 2 mode the Fan Enable compressor and RV relays remain on The Fan Speed relay is turned on immediately and turned off immediately once the Cooling Stage 2 demand is removed The control re verts to Cooling Stage 1 mode If there is a master slave or dual compressor application all compressor relays and related func tions will track with their associated DIP switch 2 on S1 NIGHT LOW LIMIT NLL STAGED HEATING In NLL staged Heating mode the override OVR input becomes ac tive and is recognized as a call for heating and the control will immediately go into a Heating Stage 1 mode With an addition al 30 minutes of NLL demand the control will go into Heating Stage 2 mode With another additional 30 minutes of NLL demand the control will go into Heating Stage 3 mode SYSTEM TEST System testing provides the ability to check the control operation The control enters a 20 minute Test mode by momentarily shorting the test pins see Fig 9 12 All time delays are reduced by a factor of 15 Test Mode To enter Test mode on C or D controls cycle the power 3 times within 60 seconds The LED light emitting diode will flash a code representing the last fault when enter ing the Test mode The alarm relay will also power on and off during Test mode See Tables 13 and 14
65. ppropriate Code Flashing Code2 Flash Last Fault Code in Memory ALARM RELAY Cycle closed 5 sec open 25 sec Open ESD Flashing Code3 Flash Last Fault Code in Memory Invalid T stat Inputs No Fault in Memory Flashing Code4 Flash Last Fault Code in Memory Flashing Code 1 Open HP Fault Slow Flash Flashing Code 2 Open LP Fault Slow Flash Flashing Code 3 Open FP1 Fault FP2 Fault Slow Flash Flashing Code 4 Open Slow Flash Flashing Code 5 Open CO Fault Slow Flash Flashing Code 6 Open Over Under Voltage HP Lockout LP Lockout FP1 Lockout FP2 Lockout CO Lockout LEGEND CO Condensate Overflow ESD Emergency Shutdown FP Freeze Protection HP High Pressure LP Low Pressure PM Performance Monitor Open closed after 15 minutes Closed Closed Closed Closed Closed NOTES If there is no fault in memory the Fault LED will flash code 1 Codes will be displayed with a 10 second Fault LED pause Slow flash is 1 flash every 2 seconds Fast flash is 2 flashes every 1 second EXAMPLE Flashing Code 2 is represented by 2 fast flashes followed by a 10 second pause This sequence will repeat contin ually until the fault is cleared akon A CAUTION To avoid fouled machinery and extensive unit clean up DO NOT operate units without filters in place DO NOT use equipment as a temporary heat source during construction Condensate Dra
66. roof mate rial etc is not yet complete Foreign material that accumulates within the units can prevent proper start up and necessitate costly clean up operations Before installing any of the system components be sure to examine each pipe fitting and valve and remove any dirt or foreign material found in or on these components 3 Do not remove the packaging until the unit is ready for A CAUTION installation 4 Verify that the refrigerant tubing is free of kinks or dents and that it does not touch other unit components DO NOT store or install units in corrosive environments or in locations subject to temperature or humidity extremes e g attics garages rooftops etc Corrosive conditions 5 Inspect all electrical connections Be sure connections are and high temperature or humidity can significantly reduce clean and tight at the terminals performance reliability and service life Always move 6 Compressors are internally isolated Compressors units in an upright position Tilting units on their sides may equipped with external spring vibration isolators must cause equipment damage have bolts loosened and shipping clamps removed 7 Remove any blower support cardboard from inlet of the INSPECT UNIT To prepare the unit for installation com blower plete the procedures listed below 8 Locate and verify any accessory kit located in compressor 1 Compare the electrical data on the unit nameplate with section orderin
67. ser Cleaning 000005 24 Step 7 Piping Connections 8 Checking System Charge 24 WATER LOOP APPLICATIONS Refrigerant Charging 05 25 N a ts ROR Air Coil Fan Motor Removal 25 Step 8 Electrical Wiring 9 Ree OOnNS BS Fc ak EES Aree Cg os Suey ee ae Control Sensors 0 0 0 2 eee 25 e 220 VOLT OPERATION START UP CHECKLIST ee ed CL 1 CL 2 St ESC BLOWER OED SELECTION IMPORTANT Read the entire instruction manual before ep 9 Low Voltage Wiring 16 cari ne installation e THERMOSTAT CONNECTIONS g i e WATER FREEZE PROTECTION e AIR COIL FREEZE PROTECTION SAFETY CONSIDERATIONS ae ao Lote Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical compo PRE START UP 0 0 eee eee 16 17 nents Only trained and qualified service personnel should System Checkout 00 16 install repair or service air conditioning equipment FIELD SELECTABLE INPUTS EE TE asc sie eG 17 18 Untrained personnel can perform basic maintenance func C Control Jumper Settings 17 tions of cleaning coils and filters and replacing filters All other C Control DIP Switches aha A nr 17 operations should be performed by trained service personnel D Control Jum per Settings 17 Whe
68. side of unit and rotate it to back using care not to damage blower wiring 4 Check blower wire routing and connections for excessive tension or contact with sheet metal edges Re route if necessary 5 Check refrigerant tubing for contact with other compo nents Adjust if necessary 6 Reinstall top panel using screws set aside in Step 1 NOTE Location for some screws at bottom of discharge panel may have to be changed 7 Manually spin fan wheel to check for obstructions Adjust for any obstruction found 8 Replace access panel Back to Side Discharge Conversion Follow instructions above for Side to Back Discharge Conversion noting the panels would be reversed Move to Side Replace Screws Return Air Drain Back Discharge Discharge Air Fig 3 Conversion Left Return Side Discharge to Back Discharge Water Connection End Return Air LJ b Side Discharge Water Connection End Back Disch Discharge Air ack Discharge Fig 4 Conversion Right Return Side Discharge to Back Discharge Step 4 Mounting the Unit Horizontal units should be mounted using the factory installed hangers Proper attachment of hanging rods to building structure is critical for safety See Fig 2 and 5 Rod attachments must be able to sup port the weight of the unit See Table 1 for unit operating weights Step 5 Duct System Size the duct system to han dle the design airflow quie
69. ss Return Air Ductwork not shown Supply Loop Water In Water Out Thermostat Wiring Field supplied transition to minimize pressure loss Power Wiring Balancing Valve Field installed and calibrated accessory Field supplied stainless steel braid hose with integral J swivel Supply Air Low Pressure Drop Water Control Valve optional field installed accessory Flexible Insulated supply duct with Connection at least one 90 degree elbow Field Supplied Unit Power d to reduce air noise Electric Heat Disconnect field supplied if applicable A Water Out Water In Ball Valve with optional integral P T plug typical for supply and return piping Unit Hanger 3 8 Threaded Rod by others Vibration Isolator white compressor end and red blower end size 042 070 by others Double Hex Nuts by others 50RHR RHS Install screw as shown Sizes 042 060 Optional on smaller sizes 50RHC Screw must only be 1 2 long to Integral hanger support prevent damage pre attached in factory UNIT HANGER ISOLATION DETAIL Fig 2 Typical Installation 50RHE Units Step 3 Unit Location The following guidelines should be considered when choosing a location for a WSHP unit e Units are for indoor use only e Locate in areas where ambient temperatures are between 4 4 C and 37 8 C and re
70. th construction dirt and debris which may cause system damage Step 2 Check Unit Upon receipt of shipment at the jobsite carefully check the shipment against the bill of lading Make sure all units have been received Inspect the car ton or crating of each unit and inspect each unit for damage Ensure the shipping company makes proper notation of any shortages or damage on all copies of the freight bill Concealed damage not discovered during unloading must be reported to the shipping company within 15 days of receipt of shipment NOTE It is the responsibility of the purchaser to file all necessary claims with the shipping company 1 Verify unit is correct model for entering water tempera ture of job 2 Be sure that the location chosen for unit installation pro vides ambient temperatures maintained above freezing Well water applications are especially susceptible to freezing 3 Be sure the installation location is isolated from sleeping areas private offices and other acoustically sensitive spaces NOTE A sound control accessory package may be used to help eliminate sound in sensitive spaces 4 Check local codes to be sure a secondary drain pan is not required under the unit 5 Be sure unit is mounted at a height sufficient to provide an adequate slope of the condensate lines If an appropri ate slope cannot be achieved a field supplied condensate pump may be required 6 Provide sufficient space for duct c
71. tly NOTE Depending on the unit the fan wheel may have a ship ping support installed at the factory This must be removed before operating unit SOUND ATTENUATION To eliminate the transfer of vibration to the duct system a flexible connector is recom mended for both discharge and return air duct connections on metal duct systems The supply and return plenums should include internal duct liner of fiberglass or be made of duct board construction to maximize sound attenuation of the blower Installing the WSHP unit to uninsulated ductwork in an unconditioned space is not recommended since it will sweat and adversely affect the unit s performance To reduce air noise at least one 90 degree elbow could be included in the supply and return air ducts provided system performance is not adversely impacted The blower speed can also be changed in the field to reduce air noise or excessive air flow provided system performance is not adversely impacted EXISTING DUCT SYSTEM If the unit is connected to existing ductwork consider the following e Verify that the existing ducts have the proper capacity to handle the unit airflow If the ductwork is too small install larger ductwork e Check existing ductwork for leaks and repair as necessary NOTE Local codes may require ventilation air to enter the space for proper indoor air quality Hard duct ventilation may be required for the ventilating air supply If hard ducted venti l
72. trical hookup The installing or electrical contractor must make the field connections when using field supplied disconnect Operating voltage must be the same voltage and phase as shown in Electrical Data shown in Table 3 Make all final electrical connections with a length of flexi ble conduit to minimize vibration and sound transmission to the building Table 2 Water Quality Guidelines CONDITION ACCEPTABLE LEVEL pH 7 to 9 range for copper Cupronickel may be used in the 5 to 9 range Total Calcium and magnesium carbonate should not exceed 350 ppm Hardness Iron Oxides Less than 1 ppm Iron Bacteria No level allowable Corrosion Max Allowable Level Coaxial Metal Ammonia Ammonium Hydroxide 0 5 ppm Cu Ammonium Chloride Ammonium Nitrate 0 5 ppm Cu Ammonium Sulfate 0 5 ppm Cu Chlorine Chlorides 0 5 ppm CuNi Hydrogen Sulfidet None Allowable Brackish Use Cupronickel heat exchanger when concentrations of calcium or sodium chloride are greater than 125 ppm are present Seawater is approximately 25 000 ppm If the concentration of these corrosives exceeds the maximum allowable level then the potential for serious cor rosion problems exists tSulfides in the water quickly oxidize when exposed to air requiring that no agitation occur as the sample is taken Unless tested immediately at the site the sample will require stabilization with a few drops of one Molar zinc acetate solution allowing accurate sulfide determi
73. ts GROUND LOOP APPLICATIONS Temperatures between 4 to 43 C and a liquid flow rate of 0 040 to 0 054 I s per kW of cooling capacity is recommended In addition to complying with any applicable codes consider the following for system piping e Limit piping materials to only polyethylene fusion in the buried sections of the loop e Do not use galvanized or steel fittings at any time due to corrosion e Avoid all plastic to metal threaded fittings due to the potential to leak Use a flange fitted substitute e Do not overtighten connections e Route piping to avoid service access areas to unit e Use pressure temperature P T plugs to measure flow of pressure drop Step 8 Electrical Wiring A WARNING To avoid possible injury or death due to electrical shock open the power supply disconnect switch and secure it in an open position during installation A CAUTION Use only copper conductors for field installed electrical wiring Unit terminals are not designed to accept other types of conductors All field installed wiring including the electrical ground MUST comply with applicable local national and regional codes Refer to unit wiring diagrams Fig 9 12 for a schematic of the field connections which must be made by the installing or electrical contractor Refer to Electrical Data for fuse sizes Consult the unit wiring diagram located on the inside of the compressor access panel to ensure proper elec
74. uction Pressure Low Discharge Air Temperature in Heating High Humidity LEGEND RV Reversing Valve Table 16 Troubleshooting cont HEATING COOLING POSSIBLE CAUSE SOLUTION Check G wiring at heat pump Jumper G and R for fan operation X X Fan motor relay Jumper G and R for fan operation Check for line voltage across BR contacts Check fan power enable relay operation if present Check for line voltage at motor Check capacitor X X Thermostat wiring Check Y and W wiring at heat pump Jumper Y and R for compressor operation in Test mode X Reversing valve Set for cooling demand and check 24 vac on RV coil and at control If RV is stuck run high pressure up by reducing water flow and while operating engage and disengage RV coil voltage to push valve x Thermostat setup Check for O RV setup not B x Thermostat wiring Check O wiring at heat pump Jumper O and R for RV coil Click Dirty filter Replace or clean X Reduced or no airflow in Check for dirty air filter and clean or replace Check fan motor operation and airflow restrictions External static too high Check blower Table 4 X Reduced or no airflow in Check for dirty air filter and clean or replace Check fan motor operation and airflow restrictions External static too high Check blower Table 4 X X Leaky ductwork Check supply and return air temperatures at the unit and at distant duct registers if significantly different duct leaks are prese
75. ystem to avoid galvanic corrosion WATER LOOP APPLICATIONS Water loop applications usually include a number of units plumbed to a common pip ing system Maintenance to any of these units can introduce air into the piping system Therefore air elimination equipment comprises a major portion of the mechanical room plumbing The flow rate is usually set between 0 040 and 0 054 1 s per kW of cooling capacity For proper maintenance and servicing pressure temperature P T ports are necessary for temperature and flow verification In addition to complying with any applicable codes consid er the following for system piping e Piping systems using water temperatures below 10 C require 12 7 mm closed cell insulation on all piping surfaces to eliminate condensation Avoid all plastic to metal threaded fittings due to the potential to leak Use a flange fitted substitute Teflon tape thread sealant is recommended to minimize internal fouling of the heat exchanger Use backup wrench Do not overtighten connections Route piping to avoid service access areas to unit Flush the piping system prior to operation to remove dirt and foreign materials from the system GROUND WATER APPLICATIONS Typical ground water piping is shown in Fig 8 In addition to complying with any applicable codes consider the following for sys tem piping e Install shut off valves for servicing Install pressure temperature plugs to measure flow and te

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