Carrier 28QX User Manual

Number One AirCcndifoninq Maker

------- ' T

Division of

^1^ Carrier Corporation

Carrier Parkway • Syracuse NY 13221

Solaround™Heat Pump System

PUMP

PACKAGES

SOLAR

COULgCTOS PANELS

WgATHERMASTER iS

<Wt* 2SQX Coil}

HEAT PUMP

28QX

ENCASEO.COiL

Fig. 1 — Solaround System Components

Form 28QX-1SI

Page

SAFETY CONSIDERATIONS............................................4

INSTALLATION

Step 1 — Check Equipment and Jobsite

..................................................................

..........................

4 — 6

• UNPACKAGE UNITS

• INSPECT EQUIPMENT

• REVIEW SYSTEM COMPONENT DATA

• COMPLETE SYSTEM REQUIREMENTS AND CONSIDER SYSTEM RECOMMENDATIONS

Step 2 — Install Weathermaster III

Heat Pump System

..............................................................

• MAKE PIPING CONNECTIONS

• MAKE ELECTRICAL CONNECTIONS

Step 3 — Install and Insulate Water Storage Tank ... 7, 8

• TANK LOCATION

• REVIEW STORAGE TANK DESIGN REQUIREMENTS

• INSULATE STORAGE TANK

Step 4 — Install Solar Collector Panels ........................ 8 — 12

• PLAN PHYSICAL POSITION OF PANELS

• PLAN THE COLLECTOR ARRANGEMENT AND PIPING CIRCUITS

• CONSTRUCT COLLECTOR SUPPORTS

INDEX

• MOUNT THE COLLECTORS

• MAKE PIPING CONNECTIONS

• LEAK TEST THE COLLECTOR ARRAY

• INSTALL FLASHING, INSULATION AND FRAME ENCLOSURE

Step 5a — Install Plain Water Pump Package . . .

• MOUNT ON FLOOR

• MAKE WATER PIPING CONNECTIONS

• LOCATE AND INSTALL THERMISTOR SENSORS AND AQUASTAT BULBS

Step 5b — Install Glycol Pump Package

MOUNT ON FLOOR MAKE WATER/GLYCOL PIPING

CONNECTIONS

• LOCATE AND INSTALL THERMISTOR

SENSORS AND AQUASTAT BULBS

Step 6 — Make Electrical Connections ....

• INSTALL BRANCH CIRCUIT FUSED

DISCONNECTS

• CONTROLPOWER

INITIAL START-UP

..........................................

MAINTENANCE AND SERVICE DATA . .

Page

12 - 16

16 - 19

20-22

23 -26 26-30

MODEL NO. 28QX036000

280X042000

REFRIG

CONTRJOL

Bypass Accurater

NET WEIGHT

_Jlb]

95"”

i05

Fig. 2 — Dimensions and Connections

ACCESSORIES

F i Iter Rack

and Filters

i FPT i.eAV»M6 l-iQUIO CONN.-

COPPER ABSORBER PLATE —.

SELECTt'.'E SypTACe

♦ FPT £NTER^^K5 WATER 'IXJNNECTiON

PUMP

UM(T

MO.

34GL167

'34gUs7

34GL367

34WA1S7

EXT??ti&£D

ALUMJRUM ROUSINO

■NSULATiON

yjSE-!N-STR(P ■w£;G.-T7

SOU«i COtueCTOR panel

SiWGl£ GLAZED i !6 L8S OOUSLE GLAZEO 14S LBS

Fig. 2 — Dimensions and Connections (Cont'd)

34WA257

34ifA367

NOTES; 1, Oimc-nsjiX!s ar.c connecticrw (or :3iiHO/40 r-S outnp

sections are siiow:t in tne instaiiation booklets for those

cnits.

2. Ditriensionai data for field suppiied storage tank varies, with type and capacity of tank supplied. See Storaije'

. Tank lastaliatiod. Step s.

ELEC ; CAPACiTY iNETVfT'i

¡collector;

CHAR. *7 PT W.C.

(Gpin;

2;":

t:.5-;-60P-

! ACCESSORIES

(lb)

2.32

:.;is

C’'cr::c''vi 'C sN-cior T her.'ri;>:;io-

150

SAFETY CONSIDERATIONS

Installation, start-up and servicing of this equip ment can be hazardous due to system pressures, electrical components and location of equipment (roofs, elevated structures, etc.).

Only trained, qualified installers and service mechanics should install, start-up and service this equipment.

Untrained personnel can perform basic main tenance functions of cleaning coils, filters and replacing filters. All other operations should be performed by trained service personnel.

When working on the equipment, observe pre cautions in the literature, tags, stickers and labels attached to the equipment and to any other safety precautions that apply.

• Follow all safety codes.

• Wear safety glasses and work gloves.

• Use caution when handling or working on glass

covered equipment such as solar collectors.

• Use care in handling, rigging and setting bulky

equipment such as storage tanks and solar

collectors. Be sure power to equipment is shut

off before performing maintenance or service.

INSTALLATION

IMPORTAMT; Follow unit location,, height proxiimty and piping requirements in this booklet carefully to enhance system efficiency, and to avoid system failure. Read entire book let before starting installation.

Step 1 — Check Equipment and Jobsite

UNPACKAGE UNITS — Move units to final location. Slide units from cartons, taking special care not to damage service valves, pipe connec tions, compatible fittings or grilles. Rig solar collector panels prior to unpackaging to prevent possible damage, see pg 8.

INSPECT EQUIPMENT — File claim with shipping company if shipment is damaged or incomplete.

REVIEW SYSTEM COMPONENT DATA - Units comprising a Solaround''"''^ System are shown in Fig. 1 and Table 1. Dimensional data in Fig. 2. As

shown, the Solaround includes a standard 38HQ/40FS heat pump system with addition of equipment to provide solar assistance during heat ing season. The pump package, solar collector panels, water storage tank and a section of 28QX (Tri-X) indoor coil are a water heat transfer circuit. Heated water, provided by solar panels, is pumped from storage tank to indoor coil for water-toindoor-air heat transfer.

Accessory Hot Water Preheater reduces energy required for heating domestic hot water during cooling and heating seasons.

All Solaround system units are preselected with

the exception of field-supplied water storage tank. Purchase or fabricate tank according to factory specifications. See Step 3, pg 7, and 28QX Application Data booklet.

Tri-X (28QX) Indoor Coil has separate water and

refrigerant circuits essential to the Solaround

system. The Tri-X serves 3 functions: transfers heat

pump (refrigerant) heating or cooling to indoor air;

transfers heat from storage water to indoor air; transfers heat pump heat and heat from storage water to indoor air.

The Tri-X is assembled to 40FS fan section and

40FQ electric heater in same manner as other 28 Series coils.

Plain Water or Glycol/Water Pump Package and Solar Panels -- Water or glycol/water mixture is

pumped thru solar collector panels by pump package. The liquid absorbs solar heat as it flows thru the panels and is returned to storage tank (plain water system) or expansion tank (glycol system).

Both plain water or glycol systems, when

properly installed, feature fail-safe draining down of liquid from solar panels to storage tank (when circulating pump goes off). This prevents freeze-up damage to panels.

CAUTION: A glycol system }.>5 preferable in

areas where prolonged periods of sab freezing

temperatures occur. Correct solar panel piping, including a 2-1 /8 in. liquid draindown Kne, is essential for proper system operation.

Table 1 — Solaround Systems*

PUMP PACKAGES

Water

34WaT67

34WA257 34WA367

*Any size water or glycol pump package and pre-determined number

of solar panels can be used with one of the Weathermaster III heat pump assemblies above, i e 34WA257, 10 solar panels, 38HQ140, 38HQ960,40FS200/28QX042/40FQ920 - (15 kw) See Solaround system Application Data booklet for Selection Procedure

Glycol

"31GÌLÌ67 '

34GL257 34 GL 367

SOLAR COLLECTOR PANELS

Min No.

Max No.

WEATHERMASTER III HEAT PUMPS

Indoor Compr

Section

38HQ

J34

. - ^

NOTE:

On 40FQ-25 and 30 kw electric heaters, remove 60-va control trans former and replace with 75-va transformer (part no HT01 BD235) available from Carrier Service Parts Center

Outdoor

Coil

Section

38HQ

~940

^ 200

-200

^^960

2ÓÒ

Indoor Unit Assembly

Fan

4£FS

Coil

28QX

036^

036 042

Electric Heater

40FQ920-

10 to 30 kw

All water supply lines leaving storage must be more than 6 in from bottom of tank but no closer than 2 ft from lowest water level

Fig. 3 — Typical Water or Glycol — Solaround System Schematic

The plain water Solaround'''''^ System has 2 water piping loops — a solar collector panel loop and a Tri-X coil loop. The glycol system has 3 piping loops — a collector panel water/glycol loop, a water/glycol to water heat exchanger loop (thru the pump package), and a Tri-X coil water loop. See Typical Piping Schematic diagram. Fig. 3. Solar panel placement on roof must be at correct angle to absorb maximum amount of solar heat.

Solaround System Selection for each installation is provided by Carrier Solar CLIC (Computer Load Information Center). It computes number of solar collector panels required, angle placement of panels, volume of water storage tank, supply piping sizes, and most beneficial accessory hot water preheating arrangement. Capacity ratings and system selection data are contained in Solaround

System Application Data.

COMPLETE SYSTEM REQUIREMENTS AND CONSIDER SYSTEM RECOMMENDATIONS ^

Plan to locate system components as close together as possible for easier installation, service and higher system operating efficiency. Use piping schematics. Fig. 16, 17, 23 and 24, as a guide. Before starting installation, study remaining system requirements and installation data, page 4 thru 22. Adjust component location as required.

WARNING; An improper installation can cause system to .maifunction and damage could result.

Summary of System Installation Requirements necessary for proper operation of plain water or glycol systems: a. Pitch solar panel piping downward in vertical

plane a minimum of 1/4-in./ft for proper

drainage to storage tank. b. Vent storage tank with 1/4-in. tubing. c. Be sure all water pumps have a positive suction

head (minimum liquid pressure at pump inlet)

by locating pumps a minimum of 2 ft below the

lowest water level in storage tank. d. Install a storage tank drain. e. Provide a closed loop piping system for Tri-X

coil by terminating inlet and outlet line a

minimum of 6-in. from bottom of storage tank.

f. Horizontal runs of water supply lines leaving

the storage tank must not be above the lowest

water level in storage tank unless a closed loop

system (item e) is used. This prevents lines from

draining and loss of pump prime.

g. Install pump packages indoors and where tem

perature does not fall below freezing.

System Recommendations

a. Locate all indoor equipment, particularly the

storage tank, pump and control package and fan coil at the same height level and in close proximity, to each other for easier piping.

It is recommended that the Tri-X coil be at the

highest point in the coil water piping loop but

not more than 6 ft above water level in storage tank. This ensures easier air venting and elim inates special water filling procedure, pg 23.

b. Avoid additional installation, service and main

tenance problems by not burying the storage tank. See pg 7.

c. Do not use any additional valves in piping other

than those that are specified by the installation instructions.

d. Locate solar collectors directly above pump

package at a height not exceeding 30 ft from top of water in storage tank to top of collector.

e. Actual length of piping from storage tank to

the pump package must not exceed 15 ft or remote aquastat installation is required.

Step 2 — Install Weathermaster III Heat Pump System

CAUTION: Observe all precautions included in 3SHQ and 40FS installation Instruciions.

Follow normal installation procedure for 38HQ compression section, outdoor coil unit and 40FS indoor fan coil assembly. (See wiring changes on pg 20.) Refer to 38HQ and 40FS Installation Instructions supplied with units. Available acces sories for the heat pump system can be used without deviation from an application where the heat pump alone is installed.

Assemble the Tri-X coil (casing) with 40FS fan section and 40FQ electric heater in same manner as other 28 Series coil for upflow airflow. Horizontal airflow assemblies are permissible, but require a field fabricated horizontal condensate collector. Unit cannot be installed in downflow position. Coil inlet duct connection flanges are provided on 40FS filter section rack. It is recommended that as sembled fan coil be located in same area as other interior system components, with the Tri-X at highest point in water piping loop but not more than 6 ft above water level in storage tank, pg 13. The fan coil can be located elsewhere with restric tions placed only by the allowable length of interconnecting refrigerant tubing.

MAKE PIPING CONNECTIONS - Tri-X coil has Compatible Fitting refrigerant line connections and copper pipe stubs for water line sweat connection.

Replace the AccuRater'^^ refrigerant control piston in the Tri-X coil as required before connec

ting refrigerant lines. See Table 2 for piston sizes. Make refrigerant line connections. Use a back-up wrench on AccuRater when making refrigerant liquid line connections. Follow recommended piping length in 38HQ booklet.

Water line connections are described under Step

5a and 5b.

MAKE ELECTRICAL CONNECTIONS

See

Step 6 on pg 20 for wiring connections.

Table 2 — Accu Rater Refrigerant Control

Piston Data

OUTDOOR

INDOOR

COMPR

SECTION

38HQÌ27 38HQ134 38HQ140

'■'Standard factory-installed AccuRater piston. Remaining

" pistons are field installed

Step 3 — Install and Insulate Water Storage Tank

COIL SECTION

Required

Model

38HQ945 3 38HQ940 38HQ960 s

AccuRater Model

Piston (no.)

INDOOR COIL

Required

AccuRater

Piston (no.)

28QX036 5 28QXÓ36 6 28QX042

CAUTION: A large storage tank full of water weighs several ions (l-gal. of water weighs 8.3

jbs). Structure must be able to support wei^it

of full tank. Use care wlren rigging, handling and setting tank in place. Buried tanks are not

recomraended.

Capacity of tank (gal.) is specified by Carrier Solar CLIC program. See Application Data for storage tank design parameters. Review essential tank design requirements.

Use correct type of tank for building configura tion and construction status: Full or partial

basement, crawl space or slab-on-grade; new con struction versus existing building (retrofit). Loca tion of storage tank inside existing building generally requires vessels which can be assembled on site.

TANK LOCATION — Use an indoor, above ground tank whenever possible. Do not install tank where temperature falls below freezing. Consider total tank weight full of water (a full 1000 gal. steel tank weighs over 4 tons), possible condensation and water leak problems, and Solaround’''''^ System compo nent location and piping requirements (pg 6).

Above or below ground tanks require a top man hole (access) cover and service/maintenance area adjacent to piping, aquastat and thermistor sensor location (see pg 14). When excavating for below ground tank, provide service clearance as indicated.

,— SERVICE AREA—,

REVIEW STORAGE TANK DESIGN REQUIREMENTS

1. Size — The tank should be sized to hold approximately 1.5—2.5 gal./ft2 of solar collector area; 750 to 2000 gallons.

2. Temperature — The tank must be able to withstand an operating temperature range of

80 F to 200 F without degradation.

3. Durability — The tank must provide a mini mum life of 20 years.

4. Construction — The tank must be leak resist

ant. It will be necessary to treat some tanks (concrete, wood) to ensure leak resistance.

They must also resist corrosion and chemical

or moisture deterioration. They must be able to withstand the hydraulic pressures exerted by their contents.

5. Shape — The shape will be optimum when the surface to volume ratio is a minimum (to reduce insulation requirements). It is best to use a tank that will require a minimum of structural and support framing.

6. Serviceability — The tank must have an access hole to provide for servicing and maintenance. It must have openings available for placement of sensors (pg 14) and for inlet and outlet piping. The outlet piping must be: minimum 6-in. from bottom of the tank to preclude

fouling or sediment; at least 2-ft from top of

the tank so that the water pumps will have their required suction head (supplied by the tank’s hydraulic pressure). See Fig. 13. There must be provision at the top of the tank for an

atmospheric vent.

7. Heat Retention — The tank must provide a high degree of heat retention. Insulate entire tank (including bottom) to an insulation value of R-20. Insulation must be kept dry.

8. Codes — The tank must be in conformance with local codes. A recommended guide is HUD Intermediate Minimum Property Standards.

9. Make drain provision.

10. Clean tank prior to use.

, c=:

-cz

■ - ^

■'I , -

Disadvantages of below ground tank include: difficult to install, insulate and maintain; limited service access to piping and controls; higher risk of freezing; tank leaks may be nondetectable; a leak into tank can cause water fouling and system

damage. A rise in ground water level and a partially filled tank can result in tank floatation and possible damage or hazard. Insulation of buried tanks can also be adversely affected by soil conditions and moisture.

Fig. 4 — Typical Steel Tank

INSULATE STORAGE TANK - Prior to making the tank installation, consider that the tank will have to be insulated. The insulation will have to be placed all around the tank, including underneath it. This can be accomplished by either placing an insulating pad beneath the tank (one which can carry the weight without degrading) or by mount ing the tank on channels. The channels should be high enough to accommodate the necessary thick ness of insulating material. Tank should not be

completely insulated until it is leak tested. See Initial Start-Up on pg 23. The recommended

insulation level for indoor tank locations is R-20.

Acceptable insulation materials depend upon the tank type and location. Use only non-toxic insulating material. Typical insulation and thick nesses for R-20 are:

Extruded Styrofoam (not bead board) with skin

Urethane

........................................................

4-1/2 in.

................................................................

4 in.

Fiberglass, Batt......................................................6 in.

Fiberglass, High density board

.............................

5 in.

Indoor Locations a. Insulation must meet HUD flame spread limits

as follows (ASTM E84-70):

Plastic Foam 25 Other 150

b. For moisture permeable tanks such as concrete

or wood, the insulation should be designed to avoid trapping moisture. Low permeability closed cell foam insulation should be used. If fiberglass is used, a moisture barrier should be provided at the tank surface; and if a cover is used over the fiberglass, it must be permeable (such as canvas).

c. Tank lids or manholes must have a positive seal

to prevent moisture loss into the insulation or the occupied space. Lid or indoor cover must have positive lock in open position so that servicing can be done safely. Do not enter tanks without person(s) capable of pulling you out of tank in attendance.

Outside Locations (not recommended) a. Recommend foam in place of urethane insula

tion, or closed cell foam insulation boards such

as urethane and styrofoam.

b. Recommend a plastic film (10 mil poly

ethylene) liner for the excavation, into which the preinsulated tank is placed, or into which the insulation is foamed around the tank. Do

not cover controls or piping with foam. Sealing

of joints in slab type insulation should be made with mastics or adhesives recommended for the type of insulation used. Consider tank freeze-up

protection.

Step 4 — Install Solar Collector Panels

CAUTION: Be careful rigging, handling and installing solar coiiectoxs. Tops of coHectors are ^ass and ЪгеакаЫе.

Rig and lift collecior(s) to roof before un packaging from shipping crate or carton. Lift with boom tnick or crane. If Iiand-Iifted to

roof, slide single collector up 2 ladders vrith a guide rope on top and 2 men on roof pulling on rope and taking weight off 2 men below. Use extreme caution not to lose balance or control of rope.

RIGSiNG A CRATS OF COLUSCTORS

ROiSTiNG A SlNGtX COLLECTOR UP TWO LADDERS

Do not use solar collector as a primary' roof surface. Mount them on a roof constructed to good roofing standards.

Properly seal all entries thru roof including where collector sleeper frame or mounting frante is attached to roof.

Flash sieeper frame or mounting franre to prevent entry' of moisture and ice or snow build-up beneath collectors installed in areas where subfreezihg temperatures occur.

Number of panels required, mounting angle (slope) of panels and liquid supply pipe size (OD) is specified by Carrier solar CLIC program and included in job plans. Refer to Fig. 2 for panel

PRESSURE R£U£F mVE

ÎSI.VCOL SlfS^MS OWW '

EfOD.

RETliRN

UNE

SETORfi

!•. ■

~~ir

supply

„2^00

RETUSti

LSŒ

R£T«i»t

headers a minimum of 114-in.lft in vertical plane

for acceptable panel drainage. A slope of 3/8-in./ft

or 1/2-in./ft assures better panel drainage.

CAUTION: For proper system operation, install eoilectors in recommended pattern arid slope horizontal Ijeaders as specified, incorrect instaliation can result in extensive system and building damage.

Colleciors are made of ^ass. Use care in rigging and handling. Do not use panels as primary roof surface.

CONSTRUCT COLLECTOR SUPPORTS - Con struct a framework to support the collectors based on panel arrangement and circuiting pattern.

If the slope of the roof is the same as that required for the collectors, construct a wooden “sleeper frame.” Use 2-in. x 4-in. boards that lay directly on the roof. Fig. 6. Construct frame so it can be flashed and sealed. This prevents moisture from accumulating behind the collector. Treat sleepers with wood preservative and paint.

NCfTE; ^KR■ RECWitttENOEO DUE TO OECREASED EPFICSR« HOWEVER ROOP /WEA L«frAT50NS MAY liECESStTSTE TUB ARRANSEMcRT.

Fig. 5 — Collector Arrangements

dimensions. Complete the following steps to install

panels:

PLAN PHYSICAL POSITION OF PANELS - For maximum heating capacity, face the collector panels due south ± 5 degrees. The angle or slope of

the collectors above the horizontal plan is normally

the latitude of the installation 15 degrees. Any

deviation from specified mounting position can

result in reduced heating performance. Be sure not

to place collector panels in areas shaded by trees or

buildings during portions of the day when sig

nificant amounts of solar energy can be obtained. PLAN THE COLLECTOR ARRANGEMENT AND

PIPING CIRCUITS - There are 2 collector mount

ing arrangements recommended for installation in a

specific space, and for correct piping circuits. See Fig. 5. Butt collectors next to each other to minimize heat losses. Slope horizontal piping

NOTES: 1 Treat framing with preservative 2 Flash framing to prevent entry of moisture in subfreezing cli

mates (See Fig 11 )

Fig. 6 — Typical Collector "Sleeper" Framing

If an upright mounting frame is required, use 2-in. X 4-in., 2-in. X 6-in. (or heavier) boards or aluminum framing material. Construct and install frame perfectly level to the horizontal plane. Locate bottom frame members directly over roof rafter. Anchor the frame to roof rafters with screws. Seal anchor points thoroughly to prevent water leakage. A typical mounting frame is shown

in Fig. 7. There should be no horizontal surfaces

within 3 ft of the framebase, so that drifting snow cannot accumulate on collectors.

Fig. 7 — Typical Collector Mounting Frame

MOUNT THE COLLECTORS on completed frame or sleepers. Lasten in place with four mounting clips supplied with each collector. Use 2 clips on each end of the collector. See Fig. 8. Each clip has a .437-in. diameter hole to accept a field supplied mounting screw. Use a level to align the collectors exactly parallel to the horizontal plane, Fig. 9.

NOTE: There is no fixed top or bottom to a collector. It can be installed either way, although it may be preferable to install so nameplate can be read.

NOTE: Supply and return piping must be sloped

Fig. 9 — Collector Panel Leveling

attached into the collectors and solder the headers onto the stubs (Fig. 10). Solder the supply and return lines in place. Install a tee with a pressure relief valve between the leaving header and 2-1/8 in. return pipe. Use an ASME approved pressure

relief device with a 50 psig set point and a manual

release lever. (See Leak Testing below.)

If it is necessary for return and supply pipes to penetrate the roof, install a pitch pocket to seal the opening.

Install the Collector Sensor on an interior collector panel after headers have been soldered in place. Sensor location and method of attachment is described on pg 15.

MAKE PIPING CONNECTIONS - Attach supply

and return piping headers and lines to collectors. Piping supply line size is specified by Solar CLIC. Return line is 2-1/8 in. O.D. on all systems. See Fig. 10. The headers can be completely pre fabricated. Determine distance between the collector inlet connections and outlet connections

(35-in. if panels are butted up to each other). Make

headers with regularly spaced T-sections to mate

with the inlet and outlet of the collector array.

Acquire two 3/4-in. MPT to 3/4-in. sweat

copper fittings for each collector. To each fitting,

solder (95-5) a 3/4-in. copper pipe stub of appro

priate length to maintain a minimum vertical

1/4-in. slope/ft of header. It might be necessary to bend the copper stubs to maintain this vertical slope. Thread the fittings with copper stub

LEAK TEST THE COLLECTOR ARRAY ^ Using city or well water with a minimum pressure of 30 psig, leak test the collectors and piping as follows;

;a. Soft solder (50-50) a temporary cap or end of

2-1 /8 in. collector return line.

b. Attach water supply line to collector supply

pipe.

c. Fill collector array with water using release

lever on pressure relief valve (Fig. 10) to bleed air from collector system. If relief valve does not have a manual release lever, temporarily replace the relief valve with an air bleed valve.

d. Leave water pressure on to system and check

collectors and piping for leaks per local codes.

e. If leaks occur, drain water from system by

removing water pressure source. Repair leak and repeat steps b, c, d and e.

f. Using a tubing cutter, remove temporary cap

from 2-1/8 in. return line. (This liiie will be

filled with water.)

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