Carrier 50HQP072-120 User Manual

Horizontal Water Source Heat Pumps

with PURON® Refrigerant (R-410A)

Installation, Start-Up, and

Service Instructions

AQUAZONE™

50HQP072-120

50 Hz

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . .1,2

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Step 1 — Check Jobsite . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 2 — Check Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

• STORAGE

•PROTECTION

•INSPECT UNIT

Step 3 — Locate Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 4 — Mount Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 5 — Install Duct System. . . . . . . . . . . . . . . . . . . . . 5

• SO U N D AT T E NUATI O N

• EXISTING DUCT SYSTEM

Step 6 — Install Condensate Piping Drain. . . . . . . . 6

•INSTALLATION

• VENTING

Step 7 — Field Convert Air Discharge . . . . . . . . . . . . 6

Step 8 — Install Piping Connections . . . . . . . . . . . . . 7

• WATER LOOP APPLICATIONS

• GROUND-LOOP APPLICATIONS

• GROUND-WATER APPLICATIONS

Step 9 — Install Field Power Supply Wiring . . . . . . 8

• POWER CONNECTION

• SUPPLY VOLTAGE

• EXTERNAL LOOP POWER CONNECTION

• 420-VOLT OPERATION

Step 10 — Install Field Control Wiring. . . . . . . . . . . 15

• THERMOSTAT CONNECTIONS

• WATER FREEZE PROTECTION

• AIR COIL FREEZE PROTECTION

• ACCESSORY CONNECTIONS

• WATER SOLENOID VALVES

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-20

System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Airflow and External Static Pressure . . . . . . . . . . . 16

FIELD SELECTABLE INPUTS . . . . . . . . . . . . . . . 20-22

Complete C Control Jumper Settings. . . . . . . . . . . 20

Complete C Control DIP Switches. . . . . . . . . . . . . . 20

Deluxe D Control Jumper Settings . . . . . . . . . . . . . 20

Deluxe D Control DIP Switches . . . . . . . . . . . . . . . . 21

Deluxe D Control Accessory Relay

Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-24

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Air Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Start Up System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Scroll Compressor Rotation. . . . . . . . . . . . . . . . . . . . . 22

Unit Start-Up in Cooling Mode. . . . . . . . . . . . . . . . . . . 22

Unit Start-Up in Heating Mode. . . . . . . . . . . . . . . . . . . 23

Flow Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Page

Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Cooling Tower/Boiler Systems . . . . . . . . . . . . . . . . . . 24

Ground Coupled, Closed Loop and Plateframe

Heat Exchanger Well Systems . . . . . . . . . . . . . . . . 24

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24,25

Power Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Units with Aquazone Complete C Control . . . . . . . 24

Units with Aquazone Deluxe D Control. . . . . . . . . . 24

SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25,26

Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Retry Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Aquazone Deluxe D Control LED Indicators . . . . . 25

SERVICE

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Water Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Condensate Drain Pans . . . . . . . . . . . . . . . . . . . . . . . . . 27

Refrigerant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Condensate Drain Cleaning . . . . . . . . . . . . . . . . . . . . . 27

Air Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Condenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Air Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Checking System Charge . . . . . . . . . . . . . . . . . . . . . . . 28

Refrigerant Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Air Coil Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . 28

Blower Fan Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Blower Fan Performance Adjustment . . . . . . . . . . . 29

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 30-32

Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Control Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . CL-1,CL-2

IMPORTANT: Read the entire instruction manual before starting installation.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-29

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

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53500077-01 Printed in U.S.A. Form 50HQP-C1SI Pg 1 11-10 Replaces: New

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. WARNING signifies hazards that could result in personal injury or death. CAUTION is used to identify unsafe practices, which would result in minor personal injury or product and property damage.

Recognize safety information. This is the safety-alert symbol ( ). When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

WARNING

Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation. There may be more than one disconnect switch. Tag all disconnect locations to alert others not to restore power until work is completed.

CAUTION

This system uses R-410A, which has higher pressures than R-22 and other refrigerants. No other refrigerant may be used in this system. Suction tubing design pressure is 3068 kPa and liquid tubing design pressure is 4522 kPa. Failure to use gage set, hoses, and recovery systems designed to handle R-410A refrigerant may result in personal injury and equipment damage. If unsure about equipment, consult the equipment manufacturer.

GENERAL

This Installation and Start-Up Instructions literature is for Aquazone™ water source heat pump systems with Puron refrigerant.

Water source heat pumps (WSHPs) are single-package horizontally and vertically mounted units 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 1 — Check Jobsite —

maintenance instructions are provided with each unit. Before unit start-up, read all manuals and become familiar with the unit and its operation. Thoroughly check out the system before operation. Complete the inspections and instructions listed below to prepare a unit for installation. See Table 1 for unit physical data.

Horizontal units are designed for indoor installation only. Be sure to allow adequate space around the unit for servicing.

Installation, operation and

See Fig. 1 for overall unit dimensions. Refer to Fig. 2 for an example of a typical horizontal installation.

CAUTION

To avoid equipment damage, do not use these units as a source of heating or cooling during the construction process. The mechanical components and filters used in these units quickly becomes clogged with construction dirt and debris which may cause system damage.

Step 2 — Check Unit — Upon receipt of shipment at

the jobsite, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the 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 temperature of job.

2. Be sure that 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. Check local codes to be sure a secondary drain pan is not required under the unit.

5. Be sure unit is mounted at a height sufficient to provide an adequate slope of the condensate lines. If an appropriate slope cannot be achieved, a field-supplied condensate pump may be required.

6. Provide sufficient space for duct connection.

7. Provide adequate clearance for filter replacement and drain pan cleaning. Do not allow piping, conduit, etc. to block filter access.

8. Provide sufficient access to allow maintenance and servicing of the fan and fan motor, compressor and coils. Removal of the entire unit from the closet should not be necessary.

9. Provide an unobstructed path to the unit within the closet or mechanical room. Space should be sufficient to allow removal of unit if necessary.

10. Provide ready access to water valves and fittings, and screwdriver access to unit side panels, discharge collar, and all electrical connections.

11. Where access to side panels is limited, pre-removal of the control box side mounting screws may be necessary for future servicing.

STORAGE — If the equipment is not needed for immediate 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 times. If carton stacking is necessary, stack units a maximum of 3 high. Do not remove any equipment from its shipping package until it is needed for installation.

PROTECTION — Once the units are properly positioned on the jobsite, they must be covered with either a shipping carton, vinyl film, 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.

CAUTION

3. Verify that the unit’s refrigerant tubing is free of kinks or dents, and that it does not touch other unit components.

4. Inspect all electrical connections. Be sure connections are clean and tight at their terminations.

5. Loosen compressor bolts until the compressor rides freely on springs. Remove shipping restraints.

6. Remove the four 6 mm (

/4 in.) shipping bolts from compressor support plate (two bolts on each side) to maximize vibration and sound alternation.

DO NOT store or install units in corrosive environments or

CAUTION

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

Failure to remove shipping brackets from spring-mounted compressors will cause excessive noise and could cause component failure due to added vibration.

units in an upright position. Tilting units on their sides may cause equipment damage.

7. Remove any blower support cardboard from inlet of the blower.

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.

8. Locate and verify any accessory kit located in compressor and/or blower section.

9. Remove any access panel screws that may be difficult to remove once unit is installed.

2. Do not remove the packaging until the unit is ready for installation.

Table 1 — Physical Data — 50HQP072-120 Units

UNIT 50HQP 072 096 120 COMPRESSOR QUANTITY* Scroll Number of Circuits (Compressors) 2 Factory Charge HFC-410A (kg) per circuit 1.70 2.15 2.27 BLOWER MOTOR Blower Motor Quantity 1 Standard Motor (kW) 0.75 1.49 2.24 BLOWER No. of Blowers 1 Blower Wheel Size D x W (cm) 30.48 x 30.48 WATER CONNECTION SIZE FPT (in.) [mm] 1 COAX VOLUME Volume (liters) 6.13 6.85 9.08 CONDENSATE CONNECTION SIZE FPT (in.) [mm] AIR COIL DATA Air Coil Dimensions H x W (cm) 50.8 x 137.16 50.8 x 162.56 Air Coil Total Face Area (sq m) 0.70 0.83 Air Coil Tube Size (cm) 0.953 Air Coil Fin Spacing (fins per cm) 5.5 Air Coil Number of Rows 3 MISCELLANEOUS DATA Filter Standard - Throwaway (qty) (cm)† 40.64 x 50.80 x 2.54 Weight - Operating (kg) 265.8 292.1 316.6 Weight - Packaged (kg) 283.9 310.3 334.8

*All units have grommet and spring compressor mountings, and

2.2 mm and 3.5 mm electrical knockouts. †51 mm filters are available as field-installed accessory.

/4 [31.8] 11/2 [38.1]

/4 [19.1]

NOTE: Use the lowest maximum pressure rating when multiple options are combined:

OPTION MAXIMUM PRESSURE (kPa)

Base Unit 3100

a50-8531

Fig. 1 — Unit Dimensions

HANGER BRACKET DIMENSIONS

221cm

2.54cm

PLAN VIEW

TOP

10.8cm

86.6cm

FRONT

CONTROL BOX

3.3cm

condensate

LEFT RETURN LEFT VIEW-

AIR COIL SIDE

LEFT RETURN END DISCHARGE

CBP

EAP

BSP

CAP

FRONT

CAP

CBP

CAP

EAP

BSP

FRONT

CONTROL BOX

PLAN VIEW

TOP

RIGHT RETURN RIGHT VIEW-

AIR COIL SIDE

RIGHT RETURN END DISCHARGE

3.3cm

condensate drain

LEFT RETURN STRAIGHT DISCHARGE

CAP

FRONT

BSP

EAP

CBP

BSP

RIGHT RETURN STRAIGHT DISCHARGE

EAP

2 CAP

CAP

FRONT

CBP

SERVICE ACCESS 3’ (91 cm.) TYPICAL

ALL CONFIGURATIONS

NOTES:

1. All dimensions in centimeters, unless indicated.

2. Access is required for all removable panels and installer should take care to comply with all building codes and allow adequate clearance.

3. Water inlet and outlet connections are available on either side of the unit. Plugs are shipped loose in a plastic bag tied to the water leg in front of the unit. Installer must plug unused connection.

4. Condensate drain connection is on end opposite of comressor.

5. Electrical access is available on either side of the front of the unit.

6. Electrical box is on right side but can be field-converted to left.

LEGEND

BSP — Blower Service Panel CAP — Control Access Panel CBP — Control Box Panel EAP — Expansion Valve Access Panel

CONNECTIONS

Water Outlet

/4FPT (072,096) 11/2FPT (120)

Water Inlet

/4FPT (072,096) 1

/2FPT (120)

Condensate Drain

/4FPT

High Voltage Access

/8K.O.

Low Voltage Access

/8K.O.

UNIT

50HQP

OVERALL

CABINET

(cm)

DISCHARGE

CONNECTIONS (cm)

(Duct Flange [± 0.1 cm])

WATER

CONNECTIONS

(cm)

ELECTRICAL KNOCKOUTS

(cm)

RETURN AIR

CONNECTIONS (cm)

(Using Return Air Opening)

DepthBWidthCHeight

DESupply

Depth

F Supply Height

GKLMOPQRSReturn

Depth

T Return Height

072-120 92.2 215.6 54.9 35.6 43.2 34.3 19.8 38.1 21.1 10.2 5.1 47.8 42.7 35.1 165.1 45.7 2.5 48.0

Step 3 — Locate Unit — The following guidelines

Fig. 2 — Typical Horizontal Installation

LEGEND

BSP — Blower Service Panel CAP — Control Access Panel CBP — Control Box Panel EAP — Expansion Valve Access Panel

NOTES:

1. Access is required for all removable panels and installer should take care to comply with all building codes and allow adequate clearance.

2. Water inlet and outlet connections are available on either side of the unit. Plugs are shipped loose in a plastic bag tied to the water leg in front of the unit. Installer must plug unused connection.

3. Condensate drain connection is on end opposite of compressor.

4. Electrical access is available on either side of the front of the unit.

5. Electrical box is on right side but can be field-converted to left.

a50-8534

should be considered when choosing a location for a WSHP:

• Units are for indoor use only.

• Locate in areas where ambient temperatures are between

4.4 C and 37.8 C and relative humidity is no greater than 75%.

• Provide sufficient space for water, electrical and duct connections.

• Locate unit in an area that allows for easy access and removal of filter and access panels.

• Allow enough space for service personnel to perform maintenance.

• Provisions must be made for return air to freely enter the space if unit needs to be installed in a confined area such as a closet.

NOTE: Correct placement of the horizontal unit can play an important part in minimizing sound problems. Since ductwork is normally applied to these units, the unit can be placed so that the principal sound emission is outside the occupied space in sound-critical applications. A fire damper may be required by the local code if a fire wall is penetrated.

Step 4 — Mount Unit — Units should be mounted us-

ing the factory-installed hangers. See Fig. 3. Proper attachment

of hanging rods to building structure is critical for safety. See Fig. 2. Rod attachments must be able to support the weight of the unit. See Table 1 for unit operating weights.

Step 5 — Install Duct System — The duct system

should be sized to handle the design airflow quietly.

NOTE: Depending on the unit, the fan wheel may have a shipping support installed at the factory. This must be removed before operating unit.

SOUND ATTENUATION — To eliminate the transfer of vibration to the duct system, a flexible connector is recommended for both discharge and return air duct connections on metal duct systems. The supply and return plenums should include internal duct liner of fiberglass or be made of duct board construction to maximize sound attenuation of the blower. Installing the WSHP unit to uninsulated ductwork in an unconditioned space is not recommended since it will sweat and adversely affect the unit’s performance.

included in the supply and return air ducts, provided system performance is not adversely impacted. The blower speed can be also changed in the field to reduce air noise or excessive airflow, provided system performance is not adversely impacted.

To reduce air noise, at least one 90-degree elbow could be

EXISTING DUCT SYSTEM — If the unit is connected to

3/8" [10MM] THREADED

ROD (FIELD SUPPLIED)

VIBRATION ISOLATOR

(FACTORY SUPPLIED)

WASHER

(FIELD SUPPLIED)

DOUBLE HEX NUTS

(FIELD SUPPLIED)

a50-6260e8535

Fig. 3 — Hanger Brackets

a50-6260ef8536

Fig. 4 — Horizontal Unit Pitch

*3/4" IPT

Trap Depth

1.5" [38mm]

Min 1.5"

[38mm]

1/4" per foot (21mm per m) drain slope

3/4" PVC or Copper by others

Vent

Fig. 5 — Trap Condensate Drain

a50-6260e8537

existing ductwork, consider the following:

• Verify that the existing ducts have the proper capacity to handle the unit airflow. If the ductwork is too small, larger ductwork should be installed.

• Check existing ductwork for leaks and repair as necessary.

NOTE: Local codes may require ventilation air to enter the space for proper indoor air quality. Hard-duct ventilation may be required for the ventilating air supply. If hard ducted ventilation is not required, be sure that a proper air path is provided for ventilation air to unit to meet ventilation requirement of the space.

Step 6 — Install Condensate Piping Drain

INSTALLATION — Slope the unit toward the drain at a 1 cm per 50 cm pitch. See Fig. 4. If it is not possible to meet the required pitch, a condensate pump should be installed at the unit to pump condensate to building drain.

Install condensate trap at each unit with the top of the trap

positioned below the unit condensate drain connection as shown in Fig. 5. Design the depth of the trap (water-seal) based upon the amount of ESP (external static pressure) capability of the blower (where 2 in. wg of ESP capability requires 2 in. of trap depth). As a general rule, 38 mm trap depth is the minimum. Each unit must be installed with its own individual trap and connection to the condensate line (main) or riser.

Units are not internally trapped, therefore an external trap is

necessary. Each unit must be installed with its own individual trap and means to flush or blowout the condensate drain line. Do not install units with a common trap or vent. For typical condensate connections see Fig. 5.

NOTE: Never use a pipe size smaller than the connection. VENTING — A vent should be installed in the condensate

line of any application which may allow dirt or air to collect in the line. Consider the following:

• Always install a vent where an application requires a long horizontal run.

• Always install a vent where large units are working against higher external static pressure and to allow proper drainage for multiple units connected to the same condensate main.

• Be sure to support the line where anticipated sagging from the condensate or when “double trapping” may occur.

• If condensate pump is present on unit, be sure drain connections have a check valve to prevent back flow of condensate into other units.

1/4” Pitch for Drainage

Drain Connection

Step 7 — Field Convert Air Discharge — Hori-

zontal units can be field converted between straight (side) and back (end) discharge.

NOTE: It is not possible to field convert return air between left or right return models due to the necessity of refrigeration copper piping changes.

Field conversion must be completed on the ground. If the unit is already hung it should be taken down for the field conversion. Place in a well-lighted area. Conversion should only be attempted by a qualified service technician.

SIDE TO BACK DISCHARGE CONVERSION

1. Remove back panel and side access panel. See Fig. 6.

2. Loosen 2 motor slide nuts, raise motor slide assembly and remove belt and motor sheave. See Fig. 7.

3. Remove blower sheave. Remove motor bolts and carefully remove motor. See Fig. 8.

4. Remove 2 motor clips and reattach to opposite side. See Fig. 9.

5. Unbolt (3 per side) complete housing assembly. See Fig. 9.

6. Rotate complete assembly into new position. Locate over mounting holes in base, reattach using 3 bolts per side.

Pitch Toward Drain

REMOVE BLOWER PANEL AND ACCESS PANEL

RETURN AIR

FRONT

Fig. 6 — Removing Panels

a50-8538

MOTOR SLIDE NUTS

Fig. 7 — Removing Belt

a50-8539

REMOVE MOTOR AND BLOWER SHEAVE

ADJUSTING BOLT

REMOVE 4 MOTOR BOLTS

Fig. 8 — Removing Motor

a50-8540

MOTOR CLIPS

BOLTS

Fig. 9 — Removing Blower Assembly

a50-8541

7. Mount motor, motor sheave, blower sheave and belt.

8. Replace panels from Step 1.

BACK TO SIDE DISCHARGE CONVERSION — If the discharge is changed from back to side, use the above instructions. Note that figures will be reversed.

LEFT OR RIGHT RETURN UNITS — It is not possible to field convert return air between left or right return units due to the necessity of refrigeration copper piping changes. However, the conversion process of side to back or back to side discharge for either right or left return configuration is the same. In some cases, it may be possible to rotate the entire unit 180 degrees if the return air connection needs to be on the opposite side. Note that rotating the unit will move the piping to the other end of the unit.

Step 8 — Install Piping Connections — Depend-

ing 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.

pipe thread fittings for water connections to prevent annealing and out-of-round leak problems which are typically associated with high temperature brazed connections. Refer to Table 1 for connection sizes. When making piping connections, consider the following:

• A backup wrench must be used when making screw con-

Make sure wires are not pinched and not over sharp edges. Adjust motor downward to tighten belt. Raise or lower motor slide assembly with adjusting bolt and retighten the 2 slide nuts. Check for correct tension. Rewire motor (at contactor) for correct rotation. Spin blower wheel to ensure wheel is not obstructed.

All WSHP units utilize low temperature soldered female

nections 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.

• Do not allow hoses to rest against structural building components. Compressor vibration may be transmitted through the hoses to the structure, causing unnecessary noise complaints.

Figure 10 shows a typical supply/return hose kit assembly.

WATER LOOP APPLICATIONS — Water loop applications usually include a number of units plumbed to a common 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 2.41 and 3.23 L/m per

kW of cooling capacity. For proper maintenance and servicing, pressure-temperature (P/T) ports are necessary for temperature and flow verification.

In addition to complying with any applicable codes, consid-

er the following for system piping:

• Piping systems utilizing water temperatures below 10 C require 13 mm closed cell insulation on all piping surfaces to eliminate condensation.

Step 9 — Install Field Power Supply Wiring

RIB CRIMPED

LENGTH

(2 FT [0.6M] LENGTH STANDARD)

SWIVEL BRASS FITTING

BRASS

FITTING

EPT

Fig. 10 — Supply/Return Hose Kit

WARNING

• 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-LOOP APPLICATIONS — Temperatures between –3.9 and 43.3 C and a cooling capacity of 2.41 to

3.23 L/s per kW of flow per ton are recommended. 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.

GROUND-WATER APPLICATIONS — Typical groundwater piping is shown in Fig. 11. In addition to complying with any applicable codes, consider the following for system piping:

• 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.

Water Supply and Quantity

— Check water supply. Water supply should be plentiful and of good quality. See Table 2 for water quality guidelines.

IMPORTANT: Failure to comply with the above required water quality and quantity limitations and the closedsystem application design requirements may cause damage to the tube-in-tube heat exchanger that is not the responsibility of the manufacturer.

CAUTION

Use only copper conductors for field-installed electrical wiring. Unit terminals are not designed to accept other types of conductors.

All field-installed wiring, including the electrical ground, MUST comply with the National Electrical Code (NEC, U.S.A.) as well as applicable local codes. In addition, all field wiring must conform to the Class II temperature limitations described in the NEC.

Refer to unit wiring diagrams Fig. 12-16 for fuse sizes and 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.

Operating voltage must be the same voltage and phase as shown in electrical data shown in Tables 3A and 3B.

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 the incoming line voltage wires to the L side of the power block terminal. See Fig. 17. See Tables 3A and 3B for correct wire and maximum overcurrent protection sizing. See Table 4 for low voltage VA ratings.

SUPPLY VOLTAGE — Operating voltage to unit must be within voltage range indicated on unit nameplate.

On 3-phase units, voltages under load between phases must be balanced within 2%. Use the following formula to determine the percentage voltage imbalance:

% Voltage Imbalance

= 100 x

Example: Supply voltage is 420-3-50.

max voltage deviation from average voltage

average voltage

AB = 425 volts BC = 422 volts AC = 417 volts

Average Voltage =

425 + 422 + 417

1264

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 recommendations to maintain water quality within the published limits.

= 421

Determine maximum deviation from average voltage: (AB) 425 – 421 = 4 v

(BC) 422 – 421 = 1 v (AC) 421 – 418 = 3 v

Maximum deviation is 4 v.

Determine percent voltage imbalance.

PressureTemperature Plugs

Boiler Drains

Strainer – Field-Installed Accessory (16 to 20 mesh recommended for filter sediment)

Shut-Off Valve

Water Control Valve

Automatic Balance Valve

Expansion

Tank

Water Out

Water In From Pump

Fig. 11 — Typical Ground-Water Piping Installation

a50-8542

% Voltage Imbalance = 100 x

421

= 0.95%

This amount of phase imbalance is satisfactory as it is

below the maximum allowable 2%.

Operation on improper 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 maximum power handling is 4 amps at 240 volts. The pumps will automatically cycle as required by the unit.

420-VOLT OPERATION — All 380/420 volt units are factory wired for 380 volts. The transformers may be switched to 420-volt operation (as illustrated on the wiring diagram) by disconnecting the VIO lead at L1 and attaching the BRN lead to L1. Close open end of VIO lead.

Table 2 — Water Quality Guidelines

CONDITION

Scaling Potential — Primary Measurement

Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below.

pH/Calcium Hardness Method

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

Langelier Saturation Index

Iron Fouling

(Ferrous)

Iron Fe (Bacterial Iron Potential)

Iron Fouling

Corrosion Prevention††

Hydrogen Sulfide (H

Ammonia Ion as Hydroxide, Chloride, Nitrate and Sulfate Compounds

Maximum Chloride Levels Maximum allowable at maximum water temperature.

Erosion and Clogging

Particulate Size and Erosion

Brackish

LEGEND

HWG — Hot Water Generator HX — Heat Exchanger N/A — Design Limits Not Applicable Considering Recirculating

NR — Application Not Recommended SS — Stainless Steel

*Heat exchanger materials considered are copper, cupronickel, 304 SS (stainless steel), 316 SS, titanium. †Closed recirculating system is identified by a closed pressurized piping system. **Recirculating open wells should observe the open recirculating design considerations.

Potable Water

MATERIAL*

CLOSED RECIRCULATING† OPEN LOOP AND RECIRCULATING WELL**

All N/A pH < 7.5 and Ca Hardness, <100 ppm

All N/A

All

6 - 8.5

Monitor/treat as needed.

If >7.5 minimize steel pipe use.

Based upon 150 F HWG and direct well, 85 F indirect well HX.

If Fe

(ferrous) >0.2 ppm with pH 6 - 8, O2<5 ppm check for iron bacteria.

If <–0.5 minimize steel pipe use.

Above this level deposition will occur.

Minimize steel pipe below 7 and no open tanks with pH <8.

6.0 - 7.5

–0.5 to +0.5

<0.2 ppm (Ferrous)

<0.5 ppm of Oxygen

6 - 8.5

<0.5 ppm

At H

S>0.2 ppm, avoid use of copper and cupronickel piping or HXs.

All N/A

Copper N/A

CuproNickel N/A <150 ppm NR NR

304 SS N/A <400 ppm <250 ppm <150 ppm 316 SS N/A <1000 ppm <550 ppm <375 ppm

Titanium N/A >1000 ppm >550 ppm >375 ppm

<10 ppm of particles and a max-

All

imum velocity of 6 fps. Filtered

for maximum

800 micron size.

All N/A

<10 ppm (<1 ppm “sand free” 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.

Use cupronickel heat exchanger when concentrations of calcium or sodium chloride are greater than 125 ppm are present. (Seawater is approximately 25,000 ppm.)

Copper alloy (bronze or brass) cast components are okay to <0.5 ppm.

Rotten egg smell appears at 0.5 ppm level.

<0.5 ppm

50 F (10 C) 75 F (24 C) 100 F (38 C)

<20 ppm NR NR

††If 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. NOTE: To convert ppm to grains per gallon, divide by 17. Hardness in mg/l is equivalent to ppm.

BC — Blower Contactor CB — Circuit Breaker CC — Compressor Contactor CO — Sensor, Condensate Overflow DPP — Dual Point Power FP1 — Sensor, Water Coil Freeze Protection FP2 — Sensor, Air Coil Freeze Protection HP — High-Pressure Switch HPWR — High-Pressure Water Relay JW3 — Clippable Field Selection Jumper LOC — Loss of Charge Pressure Switch PDB — Power Distribution Block RVS — Reversing Valve Solenoid TRANS — Tr a n sf o r me r TXV — Thermostatic Expansion Valve

Factory Line Voltage Wiring Factory Low Voltage Wiring

NOTES:

1. Compressor and blower motor thermally protected internally.

2. All wiring to the unit must comply with NEC (National Electrical Code, U.S.A.) and local codes.

3. 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.

4. FPI thermistor provides freeze protection for 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. 24-v alarm signal shown. For dry alarm contact, cut JW1 jumper and dry contact will be available between AL1 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.

9. For dual point power (DPP) option, blower wire will connect to other PBD.

LEGEND

Field Line Voltage Wiring Field Low Voltage Wiring Printed Circuit Trace Optional Wiring

Relay/Contactor Coil

Thermistor

Condensate Pan

Circuit Breaker

Ground

Solenoid Coil

Relay Contacts - N.O.

Relay Contacts - N.C.

Temperature Switch

Switch - Low Pressure

Switch - High Pressure

Wire Nut

Fig. 12 — 50HQP072-120 Units — Typical Control Wiring with Complete C Control

Complete C

Complete C1

Complete C

Complete C2

Complete C1

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