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AQUAZONE TM
50PSW036-360
Water-to-Water Source Heat Pump
with PURON ® Refrigerant
(R-410A)
Installation, Start-Up, and
Service Instructions
CONTENTS
SAFETY CONSIDERATIONS
...................
GENERAL ........................................
INSTALLATION .............................
Step 1 -- Check Jobsite ........................
Step 2 u Check Unit ...........................
• STORAGE
• PROTECTION
• INSPECT UNIT
Step 3 -- Locate Unit .............................
Step 4 -- Mount Unit .............................
Step 5 -- Connect Piping .........................
• WATER SUPPLY AND QUALITY
• WATER LOOP APPLICATIONS
• GROUND-WATER APPLICATIONS
• GROUND-LOOP APPLICATIONS
• UNIT LOAD PIPING
Step 6 -- Wire Electrical Connections ............
• POWER CONNECTION
• SUPPLY VOLTAGE
• EXTERNAL LOOP POWER CONNECTION
• 208-V OPERATION
• 460-V OPERATION
Step 7 -- Wire Low Voltage Connections ........
• THERMOSTAT CONNECTIONS
• WATER FREEZE PROTECTION
• ACCESSORY CONNECTIONS
• WATER SOLENOID VALVES
PRE-START-UP
..................................
System Checkout .............................
Page
1,2
2
2-16
2
2
4
4
5
7
15
16
16
FIELD SELECTABLE INPUTS ................
Complete C Control Jumper Settings ...........
Complete C Control DIP Switches ..............
Deluxe D Control Jumper Settings .............
Deluxe D Control DIP Switches ................
Deluxe D Control Accessory Relay
Configurations
.............................
START-UP ....................................
Operating Limits
................................
Unit Start-Up ....................................
Scroll Compressor Rotation .....................
Flow Regulation .................................
Cleaning and Flushing ..........................
Antifreeze .......................................
Cooling Tower/Boiler Systems ..................
Ground Coupled, Closed Loop and Plateframe
Heat Exchanger Well Systems ................
16,17
16
16
16
16
19
OPERATION ...................................
Power Up Mode .................................
19,20
19
Units with Aquazone Complete C Control .......
19
Units with Aquazone Deluxe D Control ..........
19
SYSTEM TEST ................................
20,21
17
17-19
17
17
17
18
18
18
19
Test Mode .......................................
Page
20
Retry Mode ......................................
21
Aquazone Deluxe D Control LED Indicators .....
21
SERVICE ......................................
Water Coil .......................................
Refrigerant System ..............................
Condenser Cleaning ............................
Checking System Charge .......................
Refrigerant Charging ............................
Air Coil Fan Motor Removal .....................
TROUBLESHOOTING ........................
21,22
21
21
21
22
22
22
22-24
50PSW START-UP CHECKLIST ...........
CL-1,CL-2
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components.
Only trained and qualified service personnel should install, repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All other operations should be performed by trained service personnel.
When working on air-conditioning equipment, observe precautions in the literature, tags and labels attached to the unit, and other safety precautions that may apply.
Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage.
Consult a qualified installer, service agency, or your distributor or branch for information or assistance.
The qualified installer or agency must use factory-authorized kits or accessories when modifying this product.
Refer to the individual instructions packaged with the kits or accessories when installing.
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 the National Electrical Code (NEC) 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-
1NG 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.
]
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53500054-01 Printed in U.S.A.
Form 50PSW-2SI Pg 1 7-09 Replaces: 50PSW-1SI
Recognize safety information.
This is the safety alert symbol (!t',).
When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal iniury.
Electrical shock can cause personal Njury 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.
Install lockout tag.
GENERAL
The Aquazone
TM
50PSW water source heat pump (WSHP) is a single-package vertically mounted unit with electronic controls designed for year-round cooling and heating.
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 responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations.
INSTALLATION
Step I E Check Jobsite E 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.
Units are designed for indoor installation only. Be sure to allow adequate space around the unit for servicing.
See Fig.
1 and 2 for overall unit dimensions.
Step 2 _
Cheek
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 carton 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 the location chosen for unit installation provides 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.
Provide sufficient access to allow maintenance and servicing of the compressor and coils.
5.
Provide an unobstructed path to the unit within the closet or mechanical room. Space should be sufficient to allow removal of unit if necessary.
6.
Provide ready access to water valves and fittings, and screwdriver access to unit side panels.
7.
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 for firanediate installation upon its arrival 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 thnes. If carton stacking is necessary, stack units a maxiinure of 3 cartons high. Do not remove any equipment from its shipping package until it is needed for installation.
To avoid equipment damage, do not use these units as a source of heating or cooling during the construction process. The mechanical components used in these units can quickly become clogged with construction dirt and debris which may cause system damage.
50PSW UNIT SIZE
NOMINAL CAPACITY (tons)
WEIGHT (Ib)
Operating
Packaged
COMPRESSOR (qty)
REFRIGERANT TYPE
CONNECTIONS, IPT (in.)
Factory Charge Per Circuit (Ib)
HWG Water In/Out
LEGEND
HWG -Hot Water Generator
IPT -Internal Pipe Thread
TXV -Thermostatic Expansion Valve
Table I -- 50PSW Unit Physical Data
036
3
060
5
120
10
348
373
Scroll (1)
360
385
Scroll (1)
726
770
Scroll (2)
R-410A
i
6,25
1/2
180
14
790
800
Scroll (1)
360
30
1330
1340
Scroll (2)
N/A
NOTES:
1, Maximum working pressure on the base unit is 500 psig,
2, Units have a dual isolated compressor mounting,
3, Units have a balanced port expansion valve (TXV),
4, Insulated source and load water coils are standard,
5, Insulated refrigerant circuit is standard,
6, Compressor is on (green) light and fault on (red) light,
A
C
SIZES 036,060
B
C
Access
Required
Service Access
SIZE 120
50PSW
UNIT
SIZE
OVERALL
CABINET
Source (Outdoor)
D E
Water In Water Out
WATER CONNECTIONS
3 I
Load (Indoor)
4
F
Water In
G
Water Out
A B
C
Depth Width Height
036,060
120
30.6
30.6
25.4
52.9
33.0
37.0
2.70
25.2
LEGEND
HWG -Hot Water Generator
HACR -Heating, Air Conditioning, and Refrigeration
9.4
25.2
NOTES:
1. Dimensions shown inches.
2.
HACR circuit breaker in U.S.A. only.
19.4
30.1
24.5
30.1
HWG
H J
Return In Water Out
27.9
34.9
30.4
34.9
ELECTRIC
ACCESS PLUGS
K
Low
Voltage
20.9
29.9
L
External
Pump
22.9
31.9
M
Power
Supply
30.9
34.4
Fig. 1 -- 50PSW036-120
Unit
12.3
15.0
4.5
Load Source
Electrical
Access
Panel
63.2;;
[1604]
[138] [381] \\ [114]
\ 2" IPTWater Connections
Fault/Run Lights
Compressor
Access
Panel
62.0
[1575]
4inimum
3ft [91cm]
Required Service//
Aoz/
/
Left
Side
View
Front
View
NOTES:
1.
Dimensions shown in inches [mm].
2.
Front and side access is preferred for service access.
All components may be accessed from the front of the unit.
45.1
26,3
[1146] ............................................................................
[669] ......................................
Fig. 250PSW180,360 Unit
PROTECTION -Once the units are properly positioned on the jobsite, they must be covered with either a shipping carton, vinyl fihn, or an equivalent protective covering.
Open ends of pipes stored on the jobsite must be capped.
This precaution is especially important in areas where painting, plastering, or spraying of fireproof material, etc., is not yet complete.
Foreign material that is allowed to accumulate 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.
DO NOT store or install units in corrosive enviromnents or in locations subject to temperature or humidity extremes
(e.g., attics, garages, rooftops, etc.). Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life.
Always move units in an upright position.
Tilting units on their sides may cause equipment damage.
INSPECT UNIT -To prepare the unit for installation, complete the procedures listed below:
1. Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped.
2.
Verify that the unit is the correct model for the entering water temperature of the job.
3.
4.
5.
6.
7.
8.
Wait to remove the packaging until the unit is ready for installation.
Verify that the refrigerant tubing is free of kinks or dents, and that it does not touch other unit components.
Inspect all electrical connections.
Be sure connections are clean and tight at the terminals.
Loosen bolts and remove shipping clamps on compressors equipped with external spring vibration isolators.
Compressors are internally spring-mounted.
Locate and verify any accessory kit located in compressor section.
Remove any access panel screws that may be difficult to remove once unit is installed.
Step 3 -- Locate
Unit
-The following guidelines should be considered when choosing a location for the WSHP:
•
• Units are for indoor use only.
Provide connections.
sufficient space for water and electrical
Locate unit in an area that allows for easy access and removal of access panels.
Allow enough space for service personnel to perform maintenance.
Step 4 _ Mount Unit
_ Mount unit as shown in Fig. 3.
Rod attachinents must be able to support the weight of the unit.
See Table 1 for unit operating weight.
Source Connections
(Boiler/Tower/Ground)
Control
Wiring
Load Connections
Water/Chilled
(Hot
Water) Automatic
Regulator
Flow
Valve with Pressure
Temperature Port
,_
/'
e
Power
Disconnect with Pressure emperature Port
Y Strainer with
Fig. 3
--
Typical Water Loop System --
Boiler, Tower, or Ground (Sizes
180,360
Shown)
Step 5 E Connect Piping
E
Depending
on the application, there are 3 types of WSHP piping systems to choose from: water loop, ground-water and ground loop. Refer to the
Carrier System Design Manual for additional information.
All WSHP units utilize 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.
When making piping connections, consider the following:
• A backup wrench must be used when making screw connections to unit to prevent internal damage to piping.
• Insulation may be required on piping to avoid condensation 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 may be used to isolate the steel parts of the system to avoid galvanic corrosion.
• Units may be manifolded together via top water connects to get increased temperatures, when piped in series, or greater capacity, when piped in parallel.
WATER SUPPLY AND QUALITY -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 closedsystem application design requirements may cause damage to the robe-in-robe heat exchanger that is not the responsibility 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 treatment firm, independent testing facility, or local water authority for specific recolranendations to maintain water quality within the published lhnits.
WATER LOOP APPLICATIONS -- Water loop applications usually include a number of units plumbed to a colmnon piping 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 2.25 and 3 gpm per ton 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, consider the following for system piping:
• Piping systems utilizing water temperatures below
50 F require 1/2-in. closed cell insulation on all piping surfaces to eliminate condensation.
• All plastic to metal threaded fittings should be avoided 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.
• The piping system should be flushed prior to operation to remove dirt and foreign materials from the system.
GROUND-WATER APPLICATIONS -In addition complying with any applicable codes, consider the following for system piping: to
• Install shut-off valves for servicing.
• Install pressure-temperature plugs to measure flow and temperature.
• Boiler drains and other valves should be connected using a "T" connector 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.
GROUND-LOOP APPLICATIONS -Temperatures between 25 and 110 F and a cooling capacity of 2.25 to 3 gpm of flow per ton are recolmnended.
In addition to complying with any applicable codes, consider the following for system piping:
• Piping materials should be limited to only polyethylene fusion in the buried sections of the loop.
• Galvanized or steel fittings should not be used at any time due to corrosion.
• All plastic to metal threaded fittings should be avoided due to the potential to leak. Use a flange fitted substitute.
• Do not overtighten connections.
• Route piping to avoid service access areas to unit.
• Pressure-temperature (P/T) plugs should be used to measure flow of pressure drop.
UNIT LOAD PIPING -- For applications with wide temperamre variation such as heating/cooling coils:
• Use piping materials that are rated for the maximum temperature and pressure combination.
This excludes PVC for most heating applications.
• Ensure load water flow in high temperature heating applications is at least 3 gpm per ton to improve performance and reduce nuisance high pressure faults.
• DO NOT employ plastic to metal threaded joints.
• Utilize a pressure tank and air separator vent system to equalize pressure and remove air.
• Employ an 800-micron particulate strainer in both load and source plumbing to protect the plate heat exchanger.
Swilmnin_ Pool Hot Tub Applications -Load heat exchanger should be isolated with secondary heat exchanger constructed of anti-corrosion material in all chlonne/bromine fluid applications.
Potable Water Applications
• Load coax material should always be vented double walled for use in potable water systems.
• Ensure load water flow in high temperature heating applications is at least 3 gpm per ton to improve performance and reduce nuisance high pressure faults.
*Teflon is a trademark of E. I. du Pont de Nemours and Company.
Table 2 -- Water Quality Guidelines
CONDITION
I
I
CLOSED
I
OPEN LOOP AND RECIRCULATING
WELL**
Scaling Potential -- Primary Measurement
Above the given limits, scaling is likely to occur, Scaling indexes should be calculated using the limits below,
I
All
I
N/A
I
pH<7.5andOaHardness,<100ppm
Index Limits for Probable Scaling Situations (Operation outside these limits is not recommended.)
Scaling indexes should be calculated at 150 F for direct use and HWG applications, and at 90 F for indirect HX use, A monitoring plan should be implemented,
Ryznar Stability Index All N/A
6.0 - 7.5
If >7,5 minimize steel pipe use,
Langelier Saturation Index
All N/A
-0.5 to +0.5
If <-0,5 minimize steel pipe use,
Based upon 150 F HWG and direct well, 85 F indirect well HX,
Iron Fouling
Iron Fe 2+ (Ferrous)
(Bacterial Iron Potential) All N/A
<0.2 ppm (Ferrous)
If Fe 2+(ferrous) >0,2 ppm with pH 6 - 8, 02<5 ppm check for iron bacteria,
Iron Fouling All N/A <0.5 ppm of Oxygen
Above this level deposition will occur,
Corrosion Preventiont¢ pH
Hydrogen Sulfide (H2S)
All
All
6 - 8,5
Monitor/treat as needed,
N/A
6 - 8.5
Minimize steel pipe below 7 and no open tanks with pH <8,
<0.5 ppm
At H2S>0,2 ppm, avoid use of copper and cupronickel piping of HXs,
Rotten egg smell appears at 0,5 ppm level,
Copper alloy (bronze or brass) cast components are okay to <0,5 ppm,
<0.5 ppm Ammonia Ion as Hydroxide, Chloride, Nitrate and
Sulfate Compounds
Maximum Chloride Levels
All N/A
Copper
Cupronickel
304 SS
316 SS
Titanium
N/A
N/A
N/A
N/A
N/A
Maximum allowable at maximum water temperature,
50 F (10 C)
<20 ppm
<150 ppm
<400 ppm
<1000 ppm
>1000 ppm
75 F (24 C)
NR
NR
<250 ppm
<550 ppm
>550 ppm
100 F (38 C)
NR
NR
<150 ppm
<375 ppm
>375 ppm
Erosion and Clogging
Particulate Size and
Erosion
All
<10 ppm of particles and a maximum velocity of
6 fps,
Filtered for maximum
800 micron size,
<10 ppm (<1 ppm "sandfree" for reinjection) of particles and a maximum velocity of 6 fps, Filtered for maximum 800 micron size, Any particulate that is not removed can potentially clog components,
LEGEND
HWG--
Hot Water Generator
HX -Heat Exchanger
N/A -Design Limits Not Applicable Considering Recirculating Potable Water
NR -Application Not Recommended
SS -Stainless Steel
*Heat exchanger materials considered are copper, cupronickel,
304 SS (stainless steel), 316 SS, titanium, fCIosed recirculating system is identified by a closed pressurized piping system,
**Recirculating open wells should observe the open recirculating design considerations, ttlf the concentration of these corrosives exceeds the maximum allowable level, then the potential for serious corrosion problems exists,
Sulfides 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 determination 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,
To convert ppm to grains per gallon, divide by 17, Hardness in mg/I is equivalent to ppm,
Step 6 E Wire Electrical
Connections
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.
Install lockout tag.
Use only copper conductors for field-installed electrical wiring.
Unit terminals are not designed to accept other types of conductors.
Failure to heed this warning could result in equipment damage.
All field-installed wiring, including the electrical ground,
MUST comply with the National Electrical Code (NEC) as well as applicable local codes. In addition, all field wiring must conform to the Class II temperature limitations described in the
NEC.
Operating voltage must be the same voltage and phase as shown in Table 3.
Refer to unit wiring diagrams Fig. 4-12 for a schematic of the field connections which must be made by the installing (or electrical) contractor.
Consult the unit wiring diagram located on the inside of the compressor access panel to ensure proper electrical hookup.
The installing (or electrical) contractor must make the field connections when using field-supplied disconnect.
Make all final electrical connections with a length of flexible conduit to minimize vibration and sound transmission to the building.
POWER CONNECTION--Line voltage connection is made by connecting incoming line voltage wires to L1, L2, and
L3 on the power distribution block.
50PSW UNIT
SIZE
036
060
120
180
360
FLA
--
HACR
--
LRA
--
MCA
--
MOCP
--
RLA
--
VOLTAGE
(V-Ph-Hz)
208/230-1-60
265-1-60
208/230-3-60
460-3-60
575-3-60
208/230-1-60
208/230-3-60
460-3-60
575-3-60
208/230-1-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
LEGEND
Full Load Amps
Heating, Air Conditioning, and Refrigeration
Locked Rotor Amps
Minimum Circuit Amps
Minimum Overcurrent Protection
Rated Load Amps
VOLTAGE RANGE
MINIMAX
187/254
239/292
187/254
414/506
518/633
187/254
187/254
414/506
518/633
187/254
187/254
414/506
518/633
187/254
414/506
518/633
187/254
414/506
518/633
*Time-delay fuse or HACR circuit breaker,
NOTE: The 460-v units using an internal secondary pump will require a neutral wire from the supply side in order to feed the accessory with 265-v,
Table 3 -- 50PSW Electrical Data
7,6
53,6
20,7
16,4
53,6
20,7
16,4
30,1
20,5
9,6
7,6
30,1
20,5
9,6
RLA
COMPRESSOR
LRA
16,7
13,5
10,4
5,8
3,8
79,0
72,0
73,0
38,0
36,5
54,0
245,0
125,0
100,0
245,0
125,0
100,0
158,0
155,0
75,0
54,0
158,0
155,0
75,0
QTY
1
1
1
1
1
2
2
2
1
1
2
1
2
2
1
2
1
1
1
15,2
53,6
20,7
16,4
107,2
41,4
32,8
30,1
20,5
9,6
7,6
60,2
41,0
19,2
TOTAL
FLA
16,7
13,5
10,4
5,8
3,8
MCA
17,1
67,0
25,9
20,5
120,6
46,6
36,9
37,6
25,6
12,0
9,5
67,7
46,1
21,6
20,9
16,9
13,0
7,3
4,8
MOCP*
2O
110
45
35
150
6O
5O
6O
45
2O
15
9O
6O
3O
35
30
20
15
15
Go
AL
CB
CC
COMP
FP1
FP2
HP
JW4
LED
LOC
NEC
P1
PDB
-Alarm Relay Contacts
-Circuit Breaker
-Compressor Contactor
-Compressor
-Sensor, Source Low Temp Protection
-Sensor, Load Low Temp Protection
-High Pressure Switch
-Jumper Wire for Alarm
-Light-Emitting Diode
-Loss of Charge Pressure Switch
-National Electrical Code
-Field Wiring Terminal Block
-Power Distribution Block
RVS
TRANS
LEGEND
-Reversing Valve Solenoid
-Transformer
Factory Line Voltage Wiring
Factory Low Voltage Wiring
Field Line Voltage Wiring
Field Low Voltage Wiring
Printed Circuit Trace cO e Relay/Contactor Coil
POWER SUPPLY REFER TO DATA PLATE
USE COPPER CONDUCTORS ONLY,
SEE NOTE 2 o4m
@
_L
Solenoid Coil
Thermistor
Ground
Indicator Light
G=Green, R=Red
(Comp On) (Alarm Light)
O--r%O Circuit Breaker
_
_
O-_
High Pressure Switch
Low Pressure Switch
Fuse
*Optional.
NOTES:
1. Compressor motor thermally protected internally.
2. All wiring to the unit must comply with NEC and local codes.
3. Power Suuulv: 460 v and 575 v -Transformer is factory wired for 460 v and
575 v power supply with wire lead colors as shown in the chart. The transformer is 75 va and is protected with a circuit breaker in the secondary circuit.
4. Power Supply: 208-230 v -Transformer is factory wired for 208 v power supply. For 230 v power supply, disconnect red lead at H2 and reconnect it at
H3. The transformer is 150 va and is protected with primary and secondary fuses.
5. FP1 thermistor provides low temp protection for source water.
When using antifreeze solutions, cut JW3 jumper.
6. 24-v alarm signal shown. For dry alarm contact, cut JW1 jumper and dry contact will be available between ALl and AL2.
7. Transformer secondary ground via Complete C board standoffs, and screws to control box. (Ground available from top two standoffs as shown.)
8. Suffix 1 designates association with lead compressor, suffix 2 with lag compressor. Exception ALl, AL2, FP1, FP2, are per legend.
9. Refer to Thermostat Installation, Application and Operation Manual for control wiring to the unit. Low voltage wiring must be "Class 1" and voltage rating equal to or greater than unit supply voltage.
__-
_.
]
!
\ol
/
BRN _BLU
BRN BI
U
_r--'_
-_Z
SEE
_ NOTE i
7
R6
I
,
,
R_LAY
/ P _
n!,
'
z
ic
' '
!
.... ..¢_f ,o_......_
....
CO 12
Fig. 4 -- Typical
Aquazone
TM
50PSW360 Complete C Control Wiring, 3-Phase
LEGEND
AL
CAP
CC
FP1
--
FP2
HP
JWl
LOC
NEC
P1
RVS --
TRANS --
--
--
Alarm Relay Contacts
Compressor Capacitor
Sensor, Source Low Temp Protection
Sensor, Load Low Temp Protection
High Pressure Switch
Jumper Wire for Alarm
Loss of Charge Pressure
Factory Line Voltage Wiring
Factory Low Voltage Wiring
Field Line Voltage Wiring
Field Low Voltage Wiring
Printed Circuit Trace
Switch
National Electrical Code
Field Wiring Terminal Block
Reversing Valve Solenoid
Transformer
Relay/Contactor Coil
O_,-O Solenoid Coil
Thermistor
_L_
-_-
_O_
O--f"=.O
Ground
Indicator Light
G=Green, R=Red
(Comp On) (Alarm Light)
Circuit Breaker
O-_
O-[[]_
High Pressure Switch
Low Pressure Switch
Fuse
NOTES:
1. Compressor thermally protected internally.
2. All wiring to the unit must comply with NEC and local codes.
3. Transformer is wired to 265-v (BRN) lead for 265-1-60 units. For 220-240-v or
230-v units, disconnect BRN lead at L1 and connect ORG lead to L1. Close open end of BRN and RED leads with insulation tape. For 208-v unit, disconnect BRN lead at L1 and connect RED lead to L1. Close open ends of BRN and ORG leads with insulation tape. Transformer is energy limiting or may have circuit breaker.
4. FP1 thermistor provides freeze protection for source water. When using antifreeze solutions, cut JW3 jumper.
5. Check installation wiring information for controller hookup. Control wiring must be Class 1 and voltage rating equal to or greater than unit supply voltage.
6. Transformer secondary ground via Complete C board standoff and screws to control box. (Ground available from top 2 standoffs as shown.)
1
ALARM
COMPRESSOR
RUN
NEUTRAL ON 265V SYSTEMS
_-RED
SEE
NOTE 6
_ZqSEE
NOTE 6 [_ mm
BLK COM
TRANS
SEE NOTE 3 BLU
_O
RED RED LK
_ BL_
="1
B
B
i
B
!
I i
I uI
_
B
II
|
|
|
|
I
II
B
I
|
I_
B
I_
I u u l _
I
I
I
I NOTE 2
I
I
I
I
_
--
208V 230V
TYPECAL
PUMP
HEAT
CONTROLLER
5 SEE r .................
......
NOTE
0
TO AQUA
!
i
I
"
" AND
0
CHANGE
SWITCH
L .................
STAT
OVER
1 COMPRESSOR
I
J i
" COOUNG
I-....
I
"
L _"VAC__
VlO
POWER SUPPLY
REFER
TO DATA PLATE
USE COPPER CONDUCTORS ONLY
SEE NOTE2
CONTROL LOGIC
P
BLU _LOC
BRN
GRY
"_FPF
GRY
VlO
VIO
.._._jNOTE
SEE
FPE
A
BRN
ORG
_RVS
GROUI
COMPONENT LOCATION
TRANS _
©
Fig. 5 -- Typical Aquazone
TM
50PSW036-180
Complete C Control Wiring, Single-Phase
S j i"
..
J __N
O O co_ _% z
E_
O O co RR_ I
I i
LEGEND
AL
CB
CC
COMP
FP1
FP2
-Alarm Relay Contacts
-Circuit Breaker
-Compressor Contactor
-Compressor
-Sensor, Source Low Temp Protection
-Sensor, Load Low Temp Protection
HP
JW4
LED
LOC
LON
NEC
-High Pressure Switch
-Jumper Wire for Alarm
-Light-Emitting Diode
-Loss of Charge Pressure
-Local Operating Network
-National Electrical Code
Switch
P1
PDB
-Field Wiring Terminal Block
-Power Distribution Block
RVS -Reversing Valve Solenoid
TRANS -Transformer
Factory Line Voltage Wiring
Factory Low Voltage Wiring
Field Line Voltage Wiring
Field Low Voltage Wiring
Printed Circuit Trace oUO r,.-A,.._
Relay/Contactor Coil
Solenoid Coil
Thermistor
_L
('')
O-"%'O
""-2:_ "
Ground
Indicator Light
G=Green, R=Red
(Comp On) (Alarm Light)
Circuit Breaker
High Pressure Switch
_:_
Low Pressure Switch
Fuse
*Optional.
NOTES:
1. Compressor motor thermally protected internally.
2. All wiring to the unit must comply with NEC and local codes.
3. Power SUDDIV: 460 V and 575 v -- Transformer is factory wired for 460 v and
575 v power supply with wire lead colors as shown in the chart. The transformer is 75 va and is protected with a circuit breaker in the secondary circuit.
4. Power Supply: 208-230 v -Transformer is factory wired for 208 v power supply. For 230 v power supply, disconnect red lead at H2 and reconnect it at
H3. The transformer is 150 va and is protected with primary and secondary fuses.
5. FP1 thermistor provides low temp protection for source water. When using antifreeze solutions, cut JW3 jumper.
6. Factory cut JWl jumper.
Dry contact will be available between ALl and AL2.
7. Transformer secondary ground via Complete C board standoffs, and screws to control box. (Ground available from top two standoffs as shown.)
8. Suffix 1 designates association with lead compressor, suffix 2 with lag compressor. Exception ALl, AL2, FP1, FP2, are per legend.
9. Refer to LON, or Thermostat Installation, Application and Operation Manual for control wiring to the unit. Low voltage wiring must be "Class 1" and voltage rating equal to or greater than unit supply voltage.
POWER SUPPLY REFER TO DATA PLATE
USE COPPER CONDUCTORS ONLY,
SEE NOTE 2 us i i COMPLETE
SEE NOTE
O I
8
,io
VlO
Fig. 6 -- Typical
Aquazone
TM
50PSW360 Complete C and LON Controller Control Wiring, 3-Phase
AL
ASTAT
CB
CAP
CC
FP1
FP2
GND
HWG
HP
JWl
LOC
NEC
-Alarm Relay Contacts
-Aquastat
-Circuit Breaker
-Compressor Capacitor
--
Compressor Contactor
-Sensor, Source Low Temp Protection
-Sensor, Load Low Temp Protection
-Ground
-Hot Water Generator
-High Pressure Switch
-Jumper Wire for Alarm
-Loss of Charge Pressure Switch
-National Electrical Code
PRIMARY
VOLTAGE
PRi_ARY
LEAD COLOR
< t
F*
2_0
380
_ZO
_60 bib
1RANSFORHER
LEAD COLORS
ORG
_10
BRN
BLK/RED
GRY
PRIMARY i i
P_v"_--=ZT-CD
', i ....
[
]
P1
PDB
RVS
TRANS
--
•
LEGEND
--
--
--
--
Field Wiring Terminal Block
Power Distribution Block
Reversing Valve Solenoid
Transformer
Factory Line Voltage Wiring
Factory Low Voltage Wiring
Field Line Voltage Wiring
Field Low Voltage Wiring
Printed Circuit Trace
Relay/Contactor Coil
POWER SUPPLY
RE=ER TO DATA P_ATE
USE COPPER CONDUCTORS
SEE NOTE 2
ONLY
(_
_0_
Solenoid
Thermistor
Coil
Ground
Indicator Light
G=Green, R=Red
(Comp On) (Alarm Light)
0-'_'-.,0
_
_
O-E]-O
Circuit Breaker
High Pressure Switch
Low Pressure Switch
Fuse
NOTES:
1. Compressor thermally protected internally.
2. All wiring to the unit must comply with NEC and local codes.
3. 208/230-v transformers will be connected for 208-v operation.
For 230-v operation, disconnect RED lead at L1, and attach ORG lead to L1. Close open end of RED lead with insulating tape. 380/420-v transformers will be connected for
380-v operation.
For 420-v operation, disconnect VIO lead at L1, and attach
BRN lead to L1. Close open end of ViO lead with insulating tape.
4. FP1 thermistor provides freeze protection for source water.
When using antifreeze solutions, cut JW3 jumper.
5. Typical heat pump thermostat wiring shown.
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.
6. Transformer secondary ground via Complete C board standoff and screws to control box. (Ground available from top 2 standoffs as shown.)
7. Suffix 1 designates association with lead compressor.
Suffix 2 designates lag compressor.
Exceptions are ALl, AL2, FP1, FP2.
cl t, ,, onP E
I_-
B_K z_fi
T_ 3
)
_b con"
u
SRN
RED
SR"
Rt
GRY
BLU
OR at K
NOTE TRmNS
2&V
BLU zq,
VlO _
BRN _
YEL
YEL _ SE
"
_ l
BR _
BRN BLU
BLU
-_NOTE (_
I
I
I_A_
J
' '
I
Is_
' z h
I
....
L .....
-_
I
HP _
_
_o,_
--
BLU
_
....
_
I
HPI
LOC
TY E
I
_ "_
----)
.......
uPS , ' FPI _=
I i+-R
9 --fJRN
FFI >
COOUN', za
VAC
CO_ION
....
M"
._.
,_J
-
-
--_--_Pr _
I i i _--ER,
CB
I
I
I
I
I
............
Complete C I
(NOTE 7)
J
ORO
J
I
Fig. 7 --Typical Aquazone _M50PSW036-180 Complete C Control Wiring,
3-Phase
Complete C 2
Co
AL
CB
CC
COMP
FP1
FP2
HP
JW4
LED
LOC
NEC
P1
PDB
-Alarm Relay Contacts
-Circuit Breaker
-Compressor Contactor
-Compressor
-Sensor, Source Low Temp Protection
-Sensor, Load Low Temp Protection
-High Pressure Switch
-Jumper Wire for Alarm
-Light-Emitting Diode
-Loss of Charge Pressure Switch
-National Electrical Code
-Field Wiring Terminal Block
-Power Distribution Block o o
COHPR RUN I
[pANS
0_
i
I.
L
O_lu_Do o
CO*_R o b\ 2
=Z
J
I
POWER SUPPLY
SEE NOTE2
USE COPPER CONDUCTORS
GR.D
_ i
REFER
II
TO DATA
_
PLATE
ONLY,
WRE COLORS
_
L I
]
RVS
TRANS
LEGEND
-Reversing Valve Solenoid
-Transformer
Factory Line Voltage Wiring
Factory Low Voltage Wiring
Field Line Voltage Wiring
Field Low Voltage Wiring
Printed Circuit Trace
Relay/Contactor Coil
L _ _
(2o8v
H5
(25BV)
2&VAC
_YEL
X BU
COM z.v
I l
E
LEAD COLOR
_
BRN
VOL AG
3so bib
O_,-O
@
Solenoid Coil
Thermistor
__L__
Ground
Indicator Light
G=Green, R=Red
(Comp On) (Alarm Light)
O-,"'-O
_
O-_ o-EE_
Circuit Breaker
High Pressure Switch
Low Pressure Switch
Fuse
*Optional.
NOTES:
1. Compressor motor thermally protected internally.
2. All wiring to the unit must comply with NEC and local codes.
3. Power SuuDIv: 460 v and 575 v -Transformer is factory wired for 460 v and
575 v power supply with wire lead colors as shown in the chart. The transformer is 75 va and is protected with a circuit breaker in the secondary circuit.
4. Power Supply: 208-230 v -Transformer is factory wired for 208 v power supply. For 230 v power supply, disconnect red lead at H2 and reconnect it at
H3. The transformer is 150 va and is protected with primary and secondary fuses.
5. FP1 thermistor provides low temp protection for source water.
When using antifreeze solutions, cut JW3 jumper.
6. 24-v alarm signal shown. For dry alarm contact, cut JW1 jumper and dry contact will be available between ALl and AL2.
7. Transformer secondary ground via Deluxe D board standoffs, and screws to control box. (Ground available from top two standoffs as shown.)
8. Suffix 1 designates association with lead compressor, suffix 2 with lag compressor. Exception ALl, AL2, FP1, FP2, are per legend.
9. Refer to Thermostat Installation, Application and Operation Manual for control wiring to the unit. Low voltage wiring must be "Class 1" and voltage rating equal to or greater than unit supply voltage.
_7
:_
: ::::_:_ : sT
_s L_
::_
Fig. 8 -- Typical
Aquazone
TM
50PSW360 Deluxe D Control Wiring, 3-Phase
AL
CB
CC
COMP
FP1
FP2
HP
JW4
LED
LOC
LON
NEC
P1
-Alarm Relay Contacts
-Circuit Breaker
-Compressor Contactor
-Compressor
-Sensor, Source Low Temp Protection
-Sensor, Load Low Temp Protection
-High Pressure Switch
-Jumper Wire for Alarm
-Light-Emitting Diode
-Loss of Charge Pressure Switch
-Local Operating Network
-National Electrical Code
-Field Wiring Terminal Block
J
7
I
o
LEGEND
PDB
RVS
TRANS
--.
--
-Power Distribution Block
-Reversing Valve Solenoid
-Transformer
Factory Line Voltage Wiring
Factory Low Voltage Wiring
Field Line Voltage Wiring
Field Low Voltage Wiring
Printed Circuit Trace cO e
Relay/Contactor
Coil
Solenoid Coil
O_"%'O
_
Circuit Breaker
High Pressure Switch
_O_
Thermistor
Ground
Indicator Light
G=Green, R=Red
(Comp On) (Alarm Light)
_
@-[Z] -O
Low Pressure
Fuse
Switch
*Optional.
NOTES:
1. Compressor motor thermally protected internally.
2. All wiring to the unit must comply with NEC and local codes.
3. Power Supply: 460 v and 575 v -- Transformer is factory wired for 460 v and
575 v power supply with wire lead colors as shown in the chart.
The transformer is 75 va and is protected with a circuit breaker in the secondary circuit.
4. Power Suoolv: 208-230 v -Transformer is factory wired for 208 v power supply. For 230 v power supply, disconnect red lead at H2 and reconnect it at
H3. The transformer is 150 va and is protected with primary and secondary fuses.
5. FP1 thermistor provides low temp protection for source water. When using antifreeze solutions, cut JW3 jumper.
6. Factory cut JW4 jumper.
Dry contact will be available between ALl and AL2.
7. Transformer secondary ground via Deluxe D board standoffs, and screws to control box. (Ground available from top two standoffs as shown.)
8. Suffix 1 designates association with lead compressor, suffix 2 with lag compressor. Exception ALl, AL2, FP1, FP2, are per legend.
9. Refer to LON, or Thermostat Installation, Application and Operation Manual for control wiring to the unit. Low voltage wiring must be "Class 1" and voltage rating equal to or greater than unit supply voltage.
Fig. 9 -- Typical
Aquazone
TM
50PSW360 Deluxe D and LON Controller Control Wiring, 3-Phase
t _:; _ Z
-:;7_
:?l
[ ut,
PREMIER
LINK
PWR
HS1/EXH/RVS im--
@
CR im--
CR --
LWT --
SAT --
SPT --
LEGEND
Control Relay
Leaving Water Temperature
Supply Air Temperature
Sensor
Sensor
Space Temperature Sensor
NOTE: Reversing valve is on in Cooling mode, ll--
L_
_
CMP1
FAN
O
0d6 35 J4
I
4-
I
I
I
T
I r-
I
I
I
CR
COMPLETE
C
CONTROL
Fig. 10 -- PremierLink
TM
Controller Applications with Complete C Control
LEGEND
LWT -Leaving Water Temperature Sensor
SAT -Supply Air Temperature Sensor
SPT -Space Temperature Sensor
NOTE: Reversing valve is on in Cooling mode,
PREMIER
LINK
@
I I-.---
PWR
HS2 im i-.il
0-
-----0
HS1
CMP2
CMP1 r-g
IO--
Llm
--O
FAN
0-
0-
O-
"1
I
I
L
I
I
"T
I p.
.J
I
I
F-
.L
I
I
I
I
.....
_l
I
I
I
I
I
"1 ....
"1 ....
I
I
I
I
DELUXE
D
CONTROL
"q_ Y1
4D Y2
4P W1
4 IPO/W2
4 b G
R
P C
-
,..!
D ALl
0-
J6 J5 J4
Fig. 11 -- PremierLink Controller Applications
with Deluxe D Control
14
Grnd
L_ _r k rx_%, 1
Contactor -CCl Contactor -CC2
]
_2
_c
33
C Control #1 g_
_o
[
J
C Control #2
Fig. 12 -- Typical Field Wiring
SUPPLY VOLTAGEOperating voltage to unit must be within voltage range indicated on unit nameplate.
Voltages between phases must be balanced within 2%.
Use the following formula to determine the percentage voltage imbalance:
% Voltage Imbalance
= 100 x max voltage deviation from average voltage average voltage
Example: Supply voltage is 460-3-60.
A B
C
AB = 452-v
AC = 455-v
BC = 464-v
452 + 464 + 455
3
1371
3
= 457
Determine maximum deviation from average voltage:
(AB) 457 - 452 = 5-v
(BC) 464 - 457 = 7-v
(AC) 457 - 455 = 2-v
Maximum deviation is 7-v.
Determine percent voltage hnbalance.
7
% Voltage hnbalance = 100 x 45----5-
= 1.53%
This amount of phase hnbalance is satisfactory as it is below the maximum allowable 2%.
Operation on hnproper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components.
NOTE: If more than 2% voltage imbalance is present, contact local electric utility.
EXTERNAL LOOP POWER CONNECTION -If the unit is to be connected to an external loop pump or flow controller, connect the pump to the loop pump terminal block PB1. The maxilnum power handling is 4 amps at 240-v. The pumps will automatically cycle as required by the unit.
208-V OPERATION--All 208/240-v units are factory wired for 208-v. The transformers may be switched to 240-v operation (as illustrated on the wiring diagram) by switching the red (208-v) wire with the orange (240-v) wire at the L2 terminal.
460-VOLT OPERATION--Units using 460-v and internal secondary pump will require a neutral wire from the supply side in order to feed accessory with 265-v.
Step 7 -- Wire Low Voltage
Connections
THERMOSTAT CONNECTIONS
The thermostat should be wired directly to the Aquazone
TM control board. See Fig. 4-9.
WATER FREEZE PROTECTION -The Aquazone control allows the field selection of source fluid freeze protection points through jumpers.
The factory setting of julnper JW3
(FP1) is set for water at 30 E In earth loop applications, julnper
JW3 should be clipped to change the setting to 10 F when using antifreeze in colder earth loop applications.
See Fig. 13.
©
) BR
BRG
CCG
CC
P2
Clip JW3 protection s,_ _
_:P_, T,,_
O
Y
12
P3
©
Clip for dry contact
=gg
©
Fig. 13 _ Typical Aquazone Control Board
Jumper Locations (Complete C Control Shown)
ACCESSORY CONNECTIONSThe terminal labeled A on the control is provided to control accessory devices such as water valves, electronic air cleaners, humidifiers, etc. This signal operates with the compressor terminal.
See Fig. 14. Refer to the specific unit wiring schematic for details.
Terminal Strip
Typical
Water
Valve
{C)v v
+
Fig. 14 -- Typical Aquazone Accessory Wiring
(Deluxe D Control Shown)
NOTE: The A terminal should only be used with 24-v signals, not line voltage signals.
IMPORTANT: Two-compressor units with Complete C or
Deluxe D controls wired to terminal A will be turned off if the controls are in lockout mode, even if the other board is in normal operating mode.
15
lations.
SOLENOID maybeused flowsystems
A typicalwellwatercontrolvalvewiringwhichcan limitwaste slowclosing will flowbefore
60secthecompressor and onlyafterthevalveis completely byclosing valvewillhave toprevent
Whenusinga slowclosingvalve,special
Thevalvetakes wiringconditions approximately through
'°Y" signal of the thermostat.
electromechanical thennostats.
Only use relay based
This can overheat the anticipators of I
I
PRE-START-UP
System Checkout
E
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.
2.
Fuses, breakers and wire are correct size.
3.
Low voltage wiring is complete.
4.
Piping and system flushing is complete.
5.
Air is purged from closed loop system.
6.
System is balanced as required.
Monitor if necessary.
7.
Isolation valves are open.
8.
Water control valves or loop pumps are wired.
9.
Transfonner switched to lower voltage tap if necessary.
10.
Service/access panels are in place.
11. Control field-selected settings are correct.
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.
be clipped when power to control board has been turned off.
Jumpers and DIP switches should only [
I
Complete C Control Jumper Settings (See
Fig. 4-7)
WATER COIL FREEZE PROTECTION (FP1) LIMIT
SETTING--Select jumper 3, (JW3-FP1 Low Temp) to choose FP1 limit of 10 F or 30 E To select 30 F as the lhnit,
DO NOT clip the jumper.
To select 10 F as the limit, clip the jumper.
ALARM RELAY SETTING -Select jumper 1 (JWl-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.
Complete C Control DIP Switches
E The
Complete C control has one DIP switch block with five switches.
See Fig. 4-7.
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 compressor will have a 3-second delay before energizing.
DIP switch 3 is not used. DIP switch 4 is not used. DIP switch 5 is used to initiate one or 3 tries for the FP1 fault. If water freeze protection for the water coil is needed, then DIP switch 5 can be set to lock out on the FP1 fault after one try.
Deluxe D Control
Fig. 8 and 9)
Jumper Settings (See
WATER COIL FREEZE PROTECTION
SETTING--Select jumper 3, (JW3-FP1
(FP1)
Low
LIMIT
Temp) to choose FP1 lhnit of 10 F or 30 E To select 30 F as the limit,
DO NOT clip the jumper.
To select 10 F as the lhnit, clip the jumper.
ALARM RELAY SETTINGSelect 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 Deluxe D control can be configured 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.
Deluxe D Control DIP
Switches
_ The Deluxe D control has 2 DIP switch blocks. Each DIP switch block has 8 switches and is labeled either S1 or $2 on the circuit board. See
Fig. 8 and 9.
DIP SWITCH BLOCK 1 (S1) -This set of switches offers the following options for Deluxe D control configuration:
Performance Monitor (PM) -Set switch 1 to enable or disable performance monitor.
To enable the PM, set the switch to
ON. To disable the PM, set the switch to OFE
Compressor Relay Staging Operation -Switch 2 will enable or disable compressor relay staging operation.
The compressor relay can be set to turn on with Stage 1 or Stage 2 call from the thermostat.
This setting is used with dual stage units
(units with 2 compressors and 2 Deluxe 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 energizing 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 selection 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, Wl 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, Wl 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 output. 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 dehumidification mode.
The fan speed relay will remain OFF during cooling Stage 2. Select ON for normal mode. The fan speed relay will turn on during cooling Stage 2 in normal mode.
Switches 6. 7. 8 -- Not used.
DIP SWITCH BLOCK 2 ($2) -- Not used.
16
Deluxe D Control Accessory Relay Configurations (See Tables
4 and 5) -- The following
acces-
sory relay settings are applicable for Deluxe D control only:
CYCLE WITH COMPRESSOR -In this configuration, the relay will be ON any time the compressor relay is on.
DIGITAL NIGHT SETBACK (NSB) -In this configuration, 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 SETBACK -When NSB input is connected to ground C, all thermostat inputs are ignored.
A thermostat setback heating call will then be connected to the
OVR input. If OVR input becomes active, then the Deluxe 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 OPEN1NG) -If relay is configured for water valve (slow opening), the relay will start 60 seconds prior to starting compressor relay.
To avoid equipment damage, DO NOT leave system filled in a building without heat during the winter unless antifreeze is added to system water.
Condenser coils never fully drain by themselves and will freeze unless winterized with antifreeze.
Table 4 -- DIP Switch Block $2 --
Accessory 1 Relay Options
ACCESSORY 1
RELAY OPTIONS
Digital NSB
Water Valve -- Slow Opening
LEGEND
NSB -Night Setback
DIP SWITCH POSITION
1
Off
On
NOTE: All other DIP switch combinations are invalid,
2
On
Off
3
On
On
Table 5 -- DIP Switch Block $2 --
Accessory 2 Relay Options
ACCESSORY 2
RELAY OPTIONS
Digital NSB
Water Valve -- Slow Opening
DIP SWITCH POSITION
4 5 6
Off
On
On
Off
On
On
LEGEND
NSB -Night Setback
NOTE: All other DIP switch combinations are invalid,
START-UP
Use the procedure outlined below to initiate proper unit start-up.
NOTE: This equipment is designed for indoor installation only.
Operating Limits (See Table 6)
ENVIRONMENTThis equipment is designed for indoor installation ONLY. Extreme variations in temperature, humidity and corrosive water or air will adversely affect the unit performance, reliability and service life.
POWER SUPPLYA voltage variation of+ 10% of nameplate utilization voltage is acceptable.
UNIT STARTING CONDITIONS -All units start and operate in an ambient of 45 F with entering air at 40 F and entering water at 20 F.
NOTE: These operating conditions are not normal or continuous operating conditions.
It is assumed that start-up is for the purpose of bringing the building space up to occupancy temperature.
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.
Table 6 --
50PSW Unit Operating Limits
WATER LIMITS
SOURCE COIL
Min Entering Water
Normal Entering Water
Max Entering Water
LOAD COIL
Min Entering Water
Normal Entering Water
Max Entering Water
COOLING
(F)
50
85
110
50
60
90
HEATING
(F)
20
60
70
60
100
120
Unit Start-Up
1. Turn off all power to unit.
2.
Adjust all valves to full open position.
3.
Restore power to unit.
4.
Operate each unit in the cooling cycle. See Table 6 for unit entering water temperatures.
5.
Operate each heat pump in the heating cycle ilranediately after checking cooling cycle operation.
NOTE: A time delay will prevent the compressor from re-starting for approximately 5 minutes.
The time delay function can be ovemdden on the Complete C control board.
6. If unit fails to operate, perform the following system checks: a.
Check the voltage and current.
Be sure they comply with electrical data on unit nameplate.
b.
Check for loose terminal screws where wire connections have been made on both the line and lowvoltage terminal boards.
c.
Check the supply and return piping.
Be sure they are properly connected to the inlet and outlet connections on the unit.
d.
If the checks described above fail to reveal the problem and the unit still will not operate, contact a trained service technician to ensure proper diagnosis.
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.
17
If thesuction pressure power rect.Thesuction
nowmove anddischarge start-up
Cleaning and Flushing
E
Cleaning and flushing of the piping system is the single most important step to ensure proper start-up and continued efficient operation of the system.
When the compressor is rotating in the wrong direction, the unit makes an elevated level of noise and does not provide cooling. Damage to compressor will occur if allowed to operate in this manner.
After a few minutes of reverse operation, the scroll compressor 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.
Flow Regulation
E Flow regulation can be accomplished 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 determined. Adjust the water control valve until the flow of 1.5 to
2 gpm is achieved.
Since the pressure constantly varies, two pressure gages may be needed in some applications.
See
Table 7 for heat exchanger pressure drops.
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 con be reduced by applying some back pressure.
To accomplish this, slightly close the leaving isolation valve of the water regulating device.
Table
7 --
Heat Exchanger Pressure Drop
Load/Outdoor Coax
UNIT
50PSW
036
060
120
180
360
UNIT
50PSW
036
060
120
180
360
GPM
15.0
22.6
30.0
18.0
27.0
35.0
5.0
7.0
9.0
7.5
11.3
15.0
35.0
53.0
70.0
30 ° F
4.2
5.8
8.4
3.1
5.0
7.4
4.3
7.0
10.3
0.8
2.7
4.8
1.6
4.0
7.2
PRESSURE
DROP (psi)
50 ° F 70 ° F
2.3
4.1
5.3
1.9
3.4
5.6
1.6
2.9
4.6
1.4
2.9
4.6
2.6
4.8
7.8
0.4
1.7
3.3
1.2
3.6
6.5
2.0
3.9
6.4
0.2
1.5
3.0
1.0
3.3
5.9
GPM
15.0
22.6
30.0
18.0
27.0
35.0
5.0
7.0
9.0
7.5
11.3
15.0
35.0
53.0
70.0
30 ° F
4.2
5.8
8.4
3.1
5.0
7.4
4.3
7.0
10.3
0.8
2.7
4.8
1.6
4.0
7.2
Source/Outdoor Coax
PRESSURE
DROP (psi)
50 ° F 70 ° F
2.6
4.1
6.0
2.2
4.0
6.1
2.3
4.1
5.5
1.9
3.6
5.5
3.1
5.6
8.5
0.4
1.7
3.3
1.2
3.6
6.5
2.7
5.0
7.7
0.2
1.5
3.0
1.0
3.3
5.9
90 ° F
1.3
2.6
4.3
1.1
2.2
3.9
1.6
3.1
5.3
0.1
1.4
2.8
0.9
3.0
5.5
90 ° F
1.8
3.1
4.9
1.5
3.1
5.0
2.1
4.3
7.0
0.1
1.4
2.8
0.9
3.0
5.5
18
To avoid possible Njury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position before flushing system.
Install lockout tag.
Follow the instructions below to properly clean and flush the system:
1. Verify electrical power to the unit is disconnected and lockout tag installed.
2.
Install the system with the supply hose connected directly to the return riser valve.
Use a single length of flexible hose.
3.
Open all air vents. Fill the system with the water.
DO
NOT allow system to overflow.
Bleed all air from the system. Pressurize and check the system for leaks and repair appropriately.
4.
Verify all strainers are in place. Start the pumps, and systematically check each vent to ensure all air is bled from the system.
5.
Verify make-up water is available.
Adjust make-up water appropriately to replace the air which was bled from the system. Check and adjust the water/air level in the expansion tank.
6. Raise the loop temperature to approximately 85 E Open the drain at the lowest point in the system. Adjust the make-up water replacement rate to equal the rate of bleed.
7. Refill the system and add trisodium phosphate in a proportion of approximately one pound per 150 gal. of water
(or other equivalent approved cleaning agent).
To avoid possible damage to a plastic (PVC) piping system, do not allow temperatures to exceed 110 F.
Raise the loop temperature to 100 F. Circulate the solution for a minimum of 8 to 24 hours. At the end of this period, shut off the circulating pump and drain the solution. Repeat system cleaning if desired.
8.
When the cleaning process is complete, remove the shortcircuited hose. Reconnect the hoses to the proper supply, and return the connections to each of the units. Refill the system and bleed offall air.
9.
Test the system pH with litmus paper. The system water should be slightly alkaline (pH of 7.5 to 8.5). Add chemicals, as appropriate, to maintain acidity levels.
10.
When the system is successfully cleaned, flushed, refilled and bled, restore power.
11. Check the main system panels, safety cutouts and alarms.
Set the controls to properly maintain loop temperatures.
DO NOT use "Stop Leak" or any similar chemical agent in this system. Addition of these chemicals to the loop water will foul the system and inhibit unit operation.
Antifreeze
_
In areas where entering loop temperatures drop below 40 F or where piping will be routed through areas subject to freezing, antifreeze is needed.
Alcoholsandglycols used as antifreeze agents. Freeze protection should be maintained to 15 F below the lowest expected entering loop temperature.
For example, if
!he lowest expected entering loop temperature is 30 F, the leaving loop temperature would be 22 to 25 E Therefore, the freeze
_rotection should be at 15 F (30 F - 15 F = 15 F).
IMPORTANT: All alcohols should be pre-mixed and pumped from a reservoir outside of the building or introduced under water level to prevent alcohols from fuming.
Calculate the total volume of fluid in the piping system.
See
Table 8. Use the percentage by volume in Table 9 to determine the amount of antifreeze to use.
Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specific gravity.
FREEZE PROTECTION SELECTION -The 30 F 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 (antifreeze 10 F) set point to avoid nuisance faults.
Table 8 -- Approximate Fluid Volume (gal.) per 100 Ft of Pipe
PIPE
Copper
Rubber Hose
Polyethylene
DIAMETER (in.)
1
1.25
1.5
1
3/4 IPS SDR11
1 IPS SDR11
11/4 IPS SDR11
1/2 IPS SDR11
2 IPS SDR11
11/4
IPS SCH40
11/2 IPS SCH40
2 IPS SCH40
LEGEND
IPS -Internal Pipe Size
SeN -Schedule
SDR -Standard Dimensional Ratio
VOLUME (gal.)
4.1
6.4
9.2
3.9
2.8
4.5
8.0
10.9
18.0
8.3
10.9
17.0
NOTE: Volume of heat exchanger is approximately 1.0 gallon.
Table 9 -- Antifreeze Percentages
by Volume
ANTIFREEZE
Methanol (%)
100% USP Food Grade
Propylene Glycol (%)
MINIMUM TEMPERATURE FOR
10
FREEZE PROTECTION (F)
15 20 25
25 21 16 10
38 30 22 15
Cooling Tower/Boiler Systems
-These
systems
typically use a colrnnon loop maintained at 60 to 90 E The use of a closed circuit evaporative cooling tower with a secondary heat exchanger between the tower and the water loop is recommended.
If an open type cooling tower is used continuously, chemical treatment and filtering will be necessary.
Ground Coupled, Closed Loop and Plateframe
Heat Exchanger Well Systems--These
systems allow water temperatures from 30 to 110 E The external loop field is divided up into 2 in. 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. Air separation should be located in the piping system prior to the fluid re-entering the loop field.
19
OPERATION
Power Up Mode
-The unit will not operate until all the inputs, terminals and safety controls are checked for normal operation.
NOTE: The compressor will have a 5-minute anti-short cycle upon power up.
Units with Aquazone
TM
Complete C Control
STANDBY -The Y and W terminals are not active in Standby mode, however the O and G terminals may be active, depending on the application.
The compressor will be off.
COOLINGThe 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 antishort 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 antishort cycle protection tflne 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 active or the W terminal is disregarded.
The compressor relay will remain on and EH1 (emergency heat) is ilmnediately 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 ot_ if FP1
(freeze protection) temperature is greater than 45 F and FP2 is greater than 110 E
EMERGENCY HEAT -In emergency heat (EH) mode, terminal W is active while terminal Y is not. Terminal G must be active or the W terminal is disregarded.
EH1 is ilrnnediately 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 ilrnnediately turn on. If there is a Fan 2 demand, the fan enable and fan speed will ilrnnediately 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 ilrnnediately.
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 remain on. The fan speed relay is turned on ilmnediately and turned off hrunediately 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 operate per their associated DIP switch 2 setting on S 1.
HEATING STAGE 3 -- In Heating Stage 3 mode, the fan enable, fan speed and compressor relays remain on. The EH1 output is turned on ilrnnediately.
With continuing Heat Stage 3 demand, EH2 will turn on after 10 minutes.
EH1 and EH2 are turned off hrunediately when the Heating Stage 3 demand is removed. The control reverts to Heating Stage 2 mode.
EH2will beoffifFP1isgreater
(whenshorted) mode.
is greater
Thiscondition
Also,during fanspeed willhavea30-second
Heating 3mode, willbeONif Ginputisnotactive.
EMERGENCY enable turned Withcontinuing man&EH2will turnonafter5 minutes.
areturned
Fanenable offaftera60-second
EH1,EH2,fanenable, theGinputisnotactive
COOLING enable,
If configured andfanwill notturnonuntilthereisastage
Thefanenable
2(DIPswitch relays
1demand
2demand.
off ilrnneditostandby
Thecondemand.
onuntil
If thereis a master/slave relays ordual
DIPswitch func-
COOLING enable, layis turned
Stage Thecontrolreverts
If thereisamaster/slave relays ordualcompressor andrelated
NIGHTLOWLIMIT(NLL)STAGED staged activeandis recognized will hmnediately asa callforheating
30minutes
Stage1 mode.Withan
ofNLLdemand,
2 mode.
thecontrol thecontrol additional willgointoHeating
30minutes
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. All thne delays are increased
15 times. See Fig. 15.
0
C
_
BR BRG
_ _c-C-G__
MODE
R
JW3
#"--%
FP1
g--,,.
Fig. 15 -- Test Mode Pins Location
Test Mode-
To enter Test mode on Complete C or
Deluxe D controls, cycle the power 3 thnes within 60 seconds.
The LED (light-emitting diode) will flash a code representing the last fault when entering the Test mode. The alarm relay will also power on and off during Test mode.
See Tables 10-12. 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.
Table 10 -- Complete C Control Current LED
Status and Alarm Relay Operations
LED STATUS
DESCRIPTION
OF
OPERATION
Normal Mode
On
Normal Mode with
PM Warning
Off Control is non-functional
Fault Retry
Fast Flash
Flashing
Code 1
Flashing
Code 2
Flashing
Code 3
Flashing
Code 4
Flashing
Code 5
Flashing
Code 6
Flashing
Code 7
Flashing
Code 8
Flashing
Code 9
Slow Flash
Over/Under
Voltage Shutdown
Lockout
Test Mode -- No fault
In memory
Test Mode -HP Fault
In memory
Test Mode -- LP Fault
In memory
Test Mode -- FP1 Fault
In memory
Test Mode -- FP2 Fault
In memory
Test Mode -- CO Fault
In memory
Test Mode -- Over/Under shutdown in memory
Test Mode -PM in memory
Test Mode -- FP1/FP2 swapped fault in memory
LEGEND
CO
FP
-Condensate Overflow
-Freeze Protection
HP
-High Pressure
LED -Light-Emitting Diode
LP -Low Pressure
PM
-Performance Monitor
ALARM RELAY
Open
Cycle
(Closed 5 sec.,
Open 25 sec.)
Open
Open
Open
(Closed after
15 minutes)
Closed
Cycling Code 1
Cycling Code 2
Cycling Code 3
Cycling Code 4
Cycling Code 5
Cycling Code 6
Cycling Code 7
Cycling Code 8
Cycling Code 9
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 lO-second pause. This sequence will repeat continually until the fault is cleared.
Table 11 -- Complete C Control LED Code and
Fault Descriptions
LED
CODE
1
2
3
4
5
6
7
(Autoreset)
8
9
FAULT
No fault in memory
High-Pressure Switch
Low-Pressure Switch
Freeze Protection
Coax -FP1
Freeze Protection Air
Coil -- FP2
Condensate overflow
Over/Under Voltage
Shutdown
PM Warning
FPI and FP2
Thermistors are swapped
DESCRIPTION
There has been no fault since the last power-down to power-up sequence
HP Open Instantly
LP open for 30 continuous seconds before or during a call (bypassed for first
60 seconds)
FP1 below Temp limit for
30 continuous seconds
(bypassed for first 60 seconds of operation)
FP2 below Temp limit for
30 continuous seconds
(bypassed for first 60 seconds of operation)
Sense overflow (grounded) for
30 continuous seconds
"R" power supply is <19 vac or >30 vac
Performance Monitor
Warning has occurred.
FP1 temperature is higher than
FP2 in heating/test mode, or FP2 temperature is higher than FP1 in cooling/test mode.
LEGEND
FP
-Freeze Protection
HP -High Pressure
LP -Low Pressure
2O
DESCRIPTION
Normal Mode
Normal Mode with PM
co
ESD
FP
HP
LP
PM
Control is Non-Functional
Test Mode
Night Setback
ESD
Invalid T-stat Inputs
No Fault in Memory
HP Fault
LP Fault
FP1 Fault
FP2 Fault
CO Fault
Over/Under Voltage
HP Lockout
LP Lockout
FP1 Lockout
FP2 Lockout
CO Lockout
LEGEND
-Condensate Overflow
-Emergency Shutdown
-Freeze Protection
-High Pressure
-Low Pressure
-Performance Monitor
Table 12 -- Aquazone
TM
Deluxe D Control Current LED Status and Alarm Relay Operations
STATUS LED
(Green)
On
On
Off
--
Flashing Code 2
Flashing Code 3
Flashing Code 4
On
Slow Flash
Slow Flash
Slow Flash
Slow Flash
Slow Flash
Slow Flash
Fast Flash
Fast Flash
Fast Flash
Fast Flash
Fast Flash
TEST LED
(Yellow)
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
--
Off
Off
Off
Off
On
--
--
FAULT LED (Red) ALARM RELAY
Flash Last Fault Code in Memory
Flashing Code 8
Open
Cycle (closed 5 sec, open 25 sec, ...)
Off
Flash Last Fault Code in Memory
Flash
Flash
Flash
Last Fault Code in Memory
Last Fault Code in Memory
Last Fault Code in Memory
Flashing Code 1
Flashing Code 2
Flashing Code 3
Flashing Code 4
Flashing Code 5
Flashing Code 6
Flashing Code 7
Flashing Code 2
Flashing Code 3
Flashing Code 4
Flashing Code 5
Flashing Code 6
Open
Cycling Appropriate
Open
Open
Open
Open
Open
Open
Open (closed after 15 minutes)
Closed
Closed
Closed
Closed
Closed
Code
NOTES:
1.
If there is no fault in memory, the Fault LED will flash code 1.
2.
Codes will be displayed with a 10-second Fault LED pause.
3.
Slow flash is 1 flash every 2 seconds.
4.
Fast flash is 2 flashes every 1 second.
5.
EXAMPLE: "Flashing Code 2" is represented by 2 fast flashes followed by a 10-second pause. This sequence will repeat continually until the fault is cleared.
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 at terminal Y. Once the thermostat input calls are satisfied, the control will 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
TM
Deluxe D Control LED Indicators
-There are 3 LED indicators on the Deluxe D control:
STATUS LED -Status LED indicates the current status or mode of the Deluxe D control.
The Status LED light is green.
TEST LED -- Test LED will be activated any time the Deluxe 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 display and appear as 1 fast flash alternating with a
10-second pause. See Table 12.
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 compressor.
To avoid leakage of compressor oil, the refrigerant lines of the compressor must be sealed after it is removed.
IMPORTANT: To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must only be serviced by technicians which meet local, state and federal proficiency requirements.
IMPORTANT: All refrigerant discharged from this unit must be recovered without exception.
Technicians must follow industry accepted guidelines and all local, state and federal statutes for the recovery and disposal of refrigerants.
To prevent Njury or death due to electrical shock or contact with moving parts, open unit disconnect switch before servicing unit.
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 frequently if the unit is located in a "dirty" enviromnent.
The heat exchanger should be kept 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 15 psig during the SUlruner and 40 psig during the winter.
Check P trap frequently for proper operation.
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.
Refrigerant System --
Verify
air and water flow rates are at proper levels before servicing. To maintain sealed circuitry integrity, do not install service gages unless unit operation appears abnormal.
Condenser Cleaning
-Water-cooled condensers may require cleaning of scale (water deposits) due to improperly maintained closed-loop water systems.
Sludge build-up may
21
needto becleaned contaminants.
Localwaterconditions pittingofrobes.
least
Condenser onceayear, canminilnize pitting.If suchconditions analysis areanticipated, isrecommended.
Manual,
RefertotheCarrier
Part5,forgeneral
Followall safetycodes.
gloves
Observe condensers tion.Theacidcanstainhands
and,withoutinhibitocdamage splashing.
buttakecaretoprevent gases.
fromventpipearenotharmful, overbythe solution tiveif applied
Regulate flow to condenser with a supply line valve. If pump is a nonoverloading type, the valve may be fully closed while pump is running.
For average scale deposit, allow solution to remain in condenser overnight. For heavy scale deposit, allow 24 hours.
Drain condenser and flush with clean water. Follow acid manufacturer'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 lninimum of 15 minutes before checking charge. From standard field-supplied Pressure-
Temperature chart for R-410A, find equivalent saturated condensing temperature.
4.
Read liquid line temperature on thermometer; then subtract from saturated condensing temperature.
The difference equals subcooling temperature.
Refrigerant Charging
is full,allowsolution thendraincondenser manufacturer's andflushwithclean instructions.
FILL CONDENSER
CLEANING
WITH
SOLUTION.
NOT ADD SOLUTION
MORE RAPIDLY THAN
VENT
GASES
CAN
CHEMICAL
EXHAUST
CAUSED
ACTION.
BY
DO
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 atmosphere.
Remove and recover refrigerant following accepted practices.
Air Coil Fan Motor Removal
5'APPROX
CONDENSER
Fig. 16Gravity Flow Method
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.
17.
PUMP PRIMING
CONN,
SUCTION
PUMP
SUPPORT
CONDENSER
TANK
REMOVE WATER
REGULATING VALVE
FINE MESI
SCREEN
Fig. 17Forced Circulation Method
Before attempting to remove fan motors or motor mounts, place a piece of plywood over evaporator coils to prevent coil damage.
Motor power wires need to be disconnected 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 motoffbracket assembly to extreme fight 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
When troubleshooting problems with a WSHP, refer to
Table 13.
22
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
No Fault Code Shown
Unit Short Cycles
Only Fan Runs
LEGEND
BR -Blower Relay
FP -Freeze Protection
HP -High Pressure
LED -Light-Emitting Diode
LOC -Loss of Charge
LP -Low Pressure
RV -Reversing Valve
HEATING
X x x x x x x x x x x x x x x x x x x x x x x x x
X
X
X
X
X
X
X
X
X
X
X
COOLING
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Table 13 -- Troubleshooting cooling
POSSIBLE
Reduced
CAUSE
Green Status LED Off or no water flow in
SOLUTION
Check line voltage circuit breaker and disconnect.
Check for line voltage between L1 and L2 on the contactor.
Check for 24-vac between R and C on controller.
Check primary/secondary voltage on transformer.
Check pump operation or valve operation/setting.
Check water flow adjust to proper flow rate.
Bring water temperature within design parameters.
Water temperature out of range in cooling
Reduced or no airflow in heating Check for dirty air filter and clean or replace.
Check fan motor operation and airflow restrictions.
Dirty air coil --construction
Clean air coil.
dust, etc. Perform preventitive maintenance;
High external static. Check duct design and downstream interference.
Bring return-air temperature within design parameters.
Air temperature out of range in heating
Overcharged with refrigerant
Bad HP switch
Insufficient charge
Compressor pump down at start-up
Reduced or no water flow in heating
Check superheat/subcooling
Check switch continuity
Check for refrigerant
Check charge leaks.
and start-up vs. typical operating and operation.
water flow.
Replace.
condition.
Check pump operation or water valve operation/setting.
Plugged strainer or filter. Clean or replace.
Check water flow adjust to proper flow rate.
Check antifreeze density with hydrometer.
Clip JW3 jumper for antifreeze (10 F) use.
Inadequate antifreeze level
Improper freeze protect setting
(30 F vs 10 F)
Water temperature out of range
Bad thermistor
Reduced or no airflow in cooling
Air temperature out of range
Bring water temperature
Check temperature within design parameters.
and impedance correlation.
Check for dirty air filter and clean or replace.
Check fan motor operation and airflow restrictions.
High external static. Check duct design and downstream interference.
Too much cold vent air. Bring entering-air temperature within design parameters.
Normal airside applications will require 30 F only.
Improper freeze protect setting
(30 F vs. 10 F)
Bad thermistor
Blocked drain
Improper trap
Poor drainage
Moisture on sensor
Under voltage
Over voltage
Check temperature and impedance correlation.
Check for blockage and clean drain.
Check trap dimensions and location ahead of vent.
Check for piping slope away from unit.
Check slope of unit toward outlet.
Poor venting.
Check vent location.
Check for moisture shorting to air coil.
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.
Check power supply voltage and 24-vac before and during operation.
Check 24-vac and unit transformer tap for correct power supply voltage.
Check for poor airflow or overcharged unit.
Check for poor water flow or airflow.
Heating mode FP2>125 F
Cooling mode FP1>125 F OR
FP2< 40 F
No compressor operation
Compressor overload
Control board
Dirty air filter
Unit in Test mode
Unit selection
Compressor overload
Thermostat position
Unit locked out
Compressor overload
Thermostat wiring
See scroll compressor rotation section.
Check and replace if necessary.
Reset power and check operation.
Check and clean air filter.
Reset power or wait 20 minutes for auto exit.
Unit may be oversized for space. Check sizing for actual load of space.
Check and replace if necessary.
Ensure thermostat set for heating or cooling operation.
Check for lockout codes. Reset power.
Check compressor overload.
Replace if necessary.
Check Y and W wiring at heat pump. Jumper Y and R for compressor operation in Test mode.
23
FAULT
Only Compressor Runs
Unit Does Not Operate in
Cooling
Insufficient Capacity/
Not Cooling or Heating
Properly
High Head Pressure
Low Suction Pressure
Low Discharge Air
Temperature in Heating
High Humidity
HEATING
X
X
COOLING
X
X x x x
X
X x x x x
X
X
X
X
X
X x x x x x x x x x x x x x x x x x x x x x x x x x x x
Table 13 -- Troubleshooting
(cont)
cooling
POSSIBLE
Thermostat wiring
Fan motor relay
Fan motor
Thermostat
Reversing
Reduced
Restricted
Defective
Reduced wiring valve
CAUSE
Thermostat setup
Thermostat wiring
Dirty filter
Reduced or no airflow in heating or no airflow in cooling
Leaky ductwork
Low refrigerant
Unit undersized charge metering device reversing valve
Thermostat improperly located
Scaling in water heat exchanger
Inlet water too hot or cold
Reduced or no airflow in heating or no water flow in
SOLUTION
Check G wiring at heat pump. Jumper G and R for fan operation.
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.
Check Y and W wiring at heat pump. Jumper Y and R for compressor operation in Test mode.
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.
Check for 'O' RV setup not 'B'.
Check O wiring at heat pump. Jumper O and R for RV coil.
Replace or clean.
Check for dirty air filter and clean or replace.
Check fan motor operation and airflow restrictions.
High external static. Check duct design and downstream interference.
Check for dirty air filter and clean or replace.
Check fan motor operation and airflow restrictions.
High external static. Check duct design and downstream interference.
Check supply and return air temperatures at the unit and at distant duct registers if significantly different, duct leaks are present.
Check superheat and subcooling.
Check superheat and subcooling.
Replace.
Perform RV touch test.
Check location and for air drafts behind thermostat.
Recheck loads and sizing. Check sensible cooling load and heat pump capacity.
Perform scaling check and clean if necessary.
Check load, loop sizing, loop backfill, ground moisture.
Check for dirty air filter and clean or replace.
Check fan motor operation and airflow restrictions.
High external static. Check duct design and downstream interference.
Check pump operation or valve operation/setting.
Check water flow. Adjust to proper flow rate.
Check load, loop sizing, loop backfill, ground moisture.
Bring return air temperature within design parameters.
Inlet water too hot
Air temperature out of range in heating
Scaling in water heat exchanger
Unit overcharged
Non-condensables in system
Restricted metering device
Reduced water flow in heating
Water temperature
Reduced
Air temperature
Insufficient airflow in cooling out of range charge
Too high airflow
Poor performance
Too high airflow
Unit oversized out of range
Perform scaling check and clean if necessary.
Check superheat
Vacuum system and reweigh
Check superheat
Check pump operation or water valve operation/setting.
Plugged strainer or filter. Clean or replace.
Check water flow adjust to proper flow rate.
Bring water temperature within design parameters.
Check for dirty air filter and clean or replace.
Check fan motor operation and airflow restrictions.
High external static. Check duct design and downstream interference.
Too much cold vent air. Bring entering air temperature within design parameters.
Check for refrigerant leaks.
Check blower.
See 'Insufficient
Check blower.
capacity.
and subcooling.
in charge.
and subcooling.
Capacity' above.
Reweigh
Replace.
in charge.
Recheck loads and sizing. Check sensible cooling load and heat pump
LEGEND
BR -Blower Relay
FP -Freeze Protection
HP -High Pressure
LED -Light-Emitting Diode
LOC -Loss of Charge
LP -Low Pressure
RV -Reversing Valve
24
Copyright 2009 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53500054-01 Printed in U.S.A.
Form 50PSW-2Sl Pg 26 7-09 Replaces: 50PSW-1SI
CUSTOMER:
MODEL NO.:
LOOP TYPE:
50PSW
START-UP CHECKLIST
JOB NAME:
SERIAL NO.:
ANTIFREEZE TYPE AND %:
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 IS A TRAP INSTALLED?
IS AN AIR FILTER INSTALLED?
(Y/N)
__
(Y/N)
__
II.
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 AB AMPS
PHASE BC VOLTS
(if 3 phase)
PHASE BC AMPS
(if 3 phase)
CONTROL VOLTAGE
PHASE CA VOLTS
(if 3 phase)
PHASE CA AMPS
(if 3 phase)
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
HEATING CYCLE:
FLUID IN
AIR COIL COOLING CYCLE:
AIR IN
HEATING CYCLE:
AIR IN
F
F
F
F
FLUID OUT
FLUID OUT
AIR OUT
AIR OUT
F
F
F
F
PSI
PSI
FLOW
FLOW
CL-1
HEATING AND COOLING CYCLE ANALYSIS
HEATING POSITION COOLING POSITION
WATER-TO-WATER UNITS
REFRIG FLOW - HEATING REFRIG FLOW - COOLING
Loa
REVERSING
VALVE
CONDENSER (COOLING)
EVAPORATOR (HEATING)
|CONDENSER
VAPORATOR
(HTG)
(CkG)
LEGEND
CLG -Cooling
HTG
-Heating
@FP2:
HEATING
LIQUID
LINE
*Turn off HWG (hot water generator) before troubleshooting.
EXPANSION
VALVE FILTER
DRIER
@FPI:
COOLING
LIQUID
LINE
*
@
@
Source
_y
@
@
®
COMPRESSOR
DISCHARGE
DESCRIPTION
Voltage
Compressor Amp
1 Suction Temperature
2 Suction Pressure
2a Saturation Temperature
2b Superheat
3 Discharge Temperature
4 Discharge Pressure
4a Saturation Temperature
4b Subcooling
5 Liquid Line Temperature
6 Source Water In Temperature
7 Source Water Out Temperature
8 Source Water In Pressure
9 Source Water Out Pressure
9a Pressure Drop
9b Flow Rate (gpm)
10 Load Water In Temperature
11 Load Water Out Temperature
12 Load Water In Pressure
13 Load Water Out Pressure
13a Pressure Drop
13b Flow Rate (gpm)
HEATING COOLING
Temperature Difference --
Temperature Difference --
NOTES
HEAT OF EXTRACTION (ABSORPTION) OR HEAT OF REJECTION =
FLOW RATE (GPM) x
SUPERHEAT
TEMP. DIFE (DEG. F) x FLUID FACTOR* =
(Btu/hr)
= SUCTION TEMPERATURE - SUCTION SATURATION TEMPERATURE
= __ (DEG F)
SUBCOOLING = DISCHARGE SATURATION TEMPERATURE - LIQUID LIN_ TEMPERATURE
= __ (DEG F)
*Use 500 for water, 485 for antifreeze.
97BOO63N02
Copyright 2009 Carrier Corporation
Manufacturer reserves the right to discontinue,
or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53500054-01 Printed in U.S.A.
Form 50PSW-2SI Pg CL-2 7-09 Replaces: 50PSW-1 SI iii
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