50PSW ИНСТРУКЦИЯ По монтажу и эксплуатации

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50PSW ИНСТРУКЦИЯ По монтажу и эксплуатации | Manualzz

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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