Carrier 50PSW036-360 User Manual

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Page 1

Water-to-Water Water Source Heat Pump

with PURON

Refrigerant (R-410A)

Installation, Start-Up, and

Service Instructions

AQUAZONE™

50PSW036-360

50 Hz

CONTENTS

Page

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

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

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

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 — Connect Piping. . . . . . . . . . . . . . . . . . . . . . . . . 5

• WATER SUPPLY AND QUALITY

• WATER LOOP APPLICATIONS

• GROUND-WATER APPLICATIONS

• GROUND-LOOP APPLICATIONS

• UNIT LOAD PIPING

Step 6 — Wire Electrical Connections. . . . . . . . . . . . 7

• POWER CONNECTION

• SUPPLY VOLTAGE

• EXTERNAL LOOP POWER CONNECTION

• 220-V OPERATION

• 380-V OPERATION

Step 7 — Wire Low Voltage Connections . . . . . . . . 12

• THERMOSTAT CONNECTIONS

• WATER FREEZE PROTECTION

• ACCESSORY CONNECTIONS

• WATER SOLENOID VALVES

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FIELD SELECTABLE INPUTS . . . . . . . . . . . . . . . .13,14

Complete C Control Jumper Settings. . . . . . . . . . . 13

Complete C Control DIP Switches. . . . . . . . . . . . . . 13

Deluxe D Control Jumper Settings . . . . . . . . . . . . . 13

Deluxe D Control DIP Switches . . . . . . . . . . . . . . . . 13

Deluxe D Control Accessory Relay

Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Unit Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Scroll Compressor Rotation. . . . . . . . . . . . . . . . . . . . . 14

Flow Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cleaning and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Cooling Tower/Boiler Systems . . . . . . . . . . . . . . . . . . 16

Ground Coupled, Closed Loop and Plateframe

Heat Exchanger Well Systems . . . . . . . . . . . . . . . . 16

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Power Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Units with Aquazone Complete C Control . . . . . . . 16

Units with Aquazone Deluxe D Control . . . . . . . . . . 16

SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16,17

Page

Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Retry Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Aquazone Deluxe D Control LED Indicators . . . . . 17

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18,19

Water Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Refrigerant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Condenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Checking System Charge . . . . . . . . . . . . . . . . . . . . . . . 19

Refrigerant Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 19-21

50PSW START-UP CHECKLIST . . . . . . . . . . . CL-1,CL-2

IMPORTANT: Read the entire instruction manual before starting installation.

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 function of cleaning coils. 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, U.S.A.) 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.

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

Catalog No. 04-53500073-01 Printed in U.S.A. Form 50PSW-C1SI Pg 1 10-10 Replaces: New

Page 2

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 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™ 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 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.

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.

These units are not approved for outdoor installation and must be installed indoors in the structure being conditioned. Do not locate in areas where ambient conditions are not maintained within 4.4 to 37.8 C.

Installation, operation and

CAUTION

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.

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 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 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 cartons high. Do not remove any equipment from its shipping package until it is needed for installation.

Table 1 — 50PSW Unit Physical Data

50PSW UNIT SIZE 036 060 120 180 360 NOMINAL CAPACITY (kW) 10.5 17.6 35.2 49.2 105.5 WEIGHT (kg)

Operating 158 163 329 358 604

Packag ed 169 175 349 363 608 COMPRESSOR (qty) Scroll (1) Scroll (1) Scroll (2) Scroll (1) Scroll (2) REFRIGERANT TYPE R-410A

Factory Charge Per Circuit (kg) 2.04 2.83 2.83 6.80 6.80 CONNECTIONS, FPT (in.)

Commercial Load/Source

HWG Water In/Out WATER VOL UM E ( L) 3.64 5.04 10.02 13.27 25.44

LEGEND NOTES:

HWG — Hot Water Generator

1. Maximum working pressure on the base unit is 3445 kPa.

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.

N/A

Page 3

Fig. 1 — 50PSW036-120 Unit

SIZES 036,060

LEGEND

NOTES:

1. Dimensions shown in centimeters unless noted otherwise.

2. HACR circuit breaker in U.S.A. only.

50PSW

UNIT SIZE

OVERALL CABINET

(mm)

WATER CONNECTIONS (mm)

ELECTRIC ACCESS PLUGS

(mm)

1234 5 6

Source (Outdoor) Load (Indoor) HWG

DepthBWidthCHeightDWater InEWate r OutFWater InGWater OutHReturn InJWater Out

Low

Volt ag e

External

Pump

Power

Supply

036,060 778 645 838 69 239 493 622 709 772 531 582 785

120 778 1344 940 640 640 765 765 886 886 759 810 874

HWG — Hot Water Generator HACR —

Heating, Air Conditioning, and Refrigeration

SIZE 120

4.6 cm

2.5 cm

Optional

Service Access

2.5 cm

Req

Service

uire

Access

18.5 cm

4.3 cm

3.3 cm

6.9 cm

Optional

Service Access

Required

Access

Service

Page 4

31.338.1 11.4

10.8

Power Supply Wiring

34.9 x 50.8 mm Double Knockout

10.8

Control Wiring

28.6 x 34.9 mm Double Knockout

11.4

2”FPT Water Connections

38.1

13.8

53.3

Fault/Run Lights

163.8

Left Side View

Front

View

To p

View

Load

Source

Side

Refrig. Circuit

Access

Panel

Front

Compressor

Access

Panel

Electrical

Access

Panel

Header

Access

Panel

To p

Minimum91cm

Required Service

Access

114.6

66.9

Optional (Single Unit)

91cm Additional

Service Access

Fig. 2 — 50PSW180,360 Unit

LEGEND FPT — Female Pipe Thread

NOTES:

1. Dimensions shown in centimeters unless noted otherwise.

2. For multiple units placed side by side, allow 1.2 m minimum front access for service and maintenance.

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

DO NOT store or install units in corrosive environments or in locations subject to temperature or humidity extremes (e.g., attics, garages, rooftops, etc.). Corrosive conditions 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. Wait to remove the packaging until the unit is ready for installation.

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

5. Inspect all electrical connections. Be sure connections are clean and tight at the terminals.

6. Loosen bolts and remove shipping clamps on compressors equipped with external spring vibration isolators. Compressors are internally spring-mounted.

7. Locate and verify any accessory kit located in compressor section.

Page 5

Fig. 3 — Typical Water Loop System —

Boiler, Tower, or Ground (Sizes 180,360 Shown)

Control

Wiring

Power

Disconnect

Source Connections

(Boiler/Tower/Ground)

Load Connections (Hot

Water/Chilled Water)

Automatic Flow

Regulator

Ball Valve with Pressure Temperature Port

Y Strainer with Blow Down Valve

a50-8138

8. 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 sufficient space for water and electrical connections.

• 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 attachments must be able to support the weight of the unit. See Table 1 for unit operating weight.

Step 5 — Connect Piping — Depending on the appli-

cation, 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 tube-in-tube 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 recommendations to maintain water quality within the published limits.

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 2.9 L/m and 3.9 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, consider the following for system piping:

• Piping systems utilizing water temperatures below

10.0 C require 13 mm 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.

Cooling tower/boiler systems typially use a common loop maintained between 16 and 32 C. 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-WATER APPLICATIONS — 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. GROUND-LOOP APPLICATIONS — Temperatures be-

tween –3.9 and 43.3 C and a cooling capacity of 2.9 L/m and

3.9 L/m per kW 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

e 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 mea-

sure flow of pressure drop.

*Teflon is a trademark of E. I. du Pont de Nemours and Company.

Page 6

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

Corrosion Prevention††

Erosion and Clogging

HWG— Hot Water Generator HX — Heat Exchanger N/A — Design Limits Not Applicable Consid-

NR — Application Not Recommended SS — Stainless Steel

*Heat exchanger materials considered are copper, cupronickel,

†Closed recirculating system is identified by a closed pressurized

**Recirculating open wells should observe the open recirculating

Iron Fe (Bacterial Iron Potential) All N/A

Iron Fouling

Hydrogen Sulfide (H

Ammonia Ion as Hydroxide, Chloride, Nitrate and Sulfate Compounds

Maximum Chloride Levels Maximum allowable at maximum water temperature.

Particulate Size and Erosion

304 SS (stainless steel), 316 SS, titanium.

piping system.

design considerations.

(Ferrous)

LEGEND

ering Recirculating Potable Water

MATERIAL*

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

All N/A

All

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

All

CLOSED

RECIRCULATING†

Monitor/treat as needed.

<10 ppm of particles and

6 - 8.5

a maximum velocity of

6 fps.

Filtered for maximum

800 micron size.

OPEN LOOP AND RECIRCULATING WELL**

If >7.5 minimize steel pipe use.

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

If Fe

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

At H2S>0.2 ppm, avoid use of copper and cupronickel piping of HXs.

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

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

<20 ppm NR NR

<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.

††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, requir- ing 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/l is equivalent to ppm.

If <–0.5 minimize steel pipe use.

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

Above this level deposition will occur.

Rotten egg smell appears at 0.5 ppm level.

6.0 - 7.5

–0.5 to +0.5

<0.2 ppm (Ferrous)

iron bacteria.

<0.5 ppm of Oxygen

6 - 8.5

<0.5 ppm

UNIT LOAD PIPING — For applications with wide temperature 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 3.2 L/m per kW 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.

Swimming Pool Hot Tub Applications

— Load heat exchanger should be isolated with secondary heat exchanger constructed of anti-corrosion material in all chlorine/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 3.2 L/m per kW to improve performance and reduce nuisance high pressure faults.

Page 7

Step 6 — Wire Electrical Connections

WARNING

To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation. Install lockout tag.

CAUTION

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. 4-8 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.

SUPPLY VOLTAGE — Operating 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 380-3-50.

AB = 372 volts BC = 376 volts AC = 384 volts

Average Voltage =

372 + 376 + 384

1132

= 377

Determine maximum deviation from average voltage: (AB) 372 – 377 = 5 v

(BC) 376 – 377 = 1 v (AC) 384 – 377 = 7 v

Maximum deviation is 7 v. Determine percent voltage imbalance.

% Voltage Imbalance = 100 x

377

= 1.86%

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.

Table 3 — 50PSW Electrical Data

50PSW UNIT

SIZE

036

060

120

180

360

FLA — Full Load Amps HACR — Heating, Air Conditioning, and Refrigeration LRA — Locked Rotor Amps MCA — Minimum Circuit Amps MOCP — Minimum Overcurrent Protection RLA — Rated Load Amps

*Time-delay fuse or HACR circuit breaker.

VOLTAGE

(V-Ph-Hz)

220/240-1-50 198/264 13.5 67 1 13.5 16.9 30 380/420-3-50 342/462 5.4 38 1 5.4 6.8 15 220/240-1-50 198/264 24.5 153 1 24.5 30.6 50 380/420-3-50 342/462 9.6 74 1 9.6 12.0 20 220/240-1-50 198/264 24.5 153 2 49.0 55.1 80 380/420-3-50 342/462 9.6 74 2 19.2 21.6 30 220/240-1-50 198/264 44.9 273 1 44.9 56.1 100 380/420-3-50 342/462 18.6 118 1 18.6 23.3 40 220/240-1-50 198/264 44.9 273 2 89.8 101.0 125 380/420-3-50 342/462 18.6 118 2 37.2 46.6 60

LEGEND

VOLTAGE RANGE

MIN/MAX

COMPRESSOR

RLA LRA QTY

TOTAL

FLA

MCA MOCP*

Page 8

Solenoid Coil

Thermistor

Ground

Indicator Light

G=Green, R=Red

(Comp On) (Alarm Light)

Circuit Breaker

High Pressure Switch

Low Pressure Switch

Fuse

a50-8621

Fig. 4 — Typical Aquazone™ 50PSW036-060 Complete C Control Wiring, Single-Phase

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

Relay/Contactor Coil

NOTES:

1. Compressor motor thermally protected internally.

2. All wiring to the unit must comply with NEC and local codes.

3. Transformer is wired to 265 v lead (BRN) for 265-1-50 units. For 220/240 v

operation, disconnect BRN lead at L1 and connect ORG lead to L1. Insulate

open ends of BRN and RED leads. Transformer is energy limiting or may have

circuit breaker.

4. FP1 thermistor provides freeze protection for source water. When using anti-

freeze solutions, cut JW3 jumper.

5. Refer to or Thermostat Installation, Application and Operation Manual for con-

trol wiring to the unit. Low voltage wiring must be “Class 1” and voltage rating

equal to or greater than unit supply voltage.

AL — Alarm Relay Contacts

CC — Compressor Contactor

FP1 — Sensor, Source Low Temp Protection

FP2 — Sensor, Load Low Temp Protection

HP — High Pressure Switch

JW1 — Jumper Wire for Alarm

LED — Light-Emitting Diode

LOC — Loss of Charge Pressure Switch

NEC — National Electrical Code

P1 — Field Wiring Terminal Block

Complete C

Page 9

Fig. 5 — Typical Aquazone™ 50PSW120 Complete C Control Wiring, 3-Phase

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. Transformer is wired to 380 v lead (VIO) for 380-3-50 operation. For 420 v

operation switch VIO and BRN leads at L1 and insulate VIO lead.

4. FP1 thermistor provides freeze protection for source water. When using anti-

freeze 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.)

7. Aquastat is supplied with unit and must be wired in series with the hot leg of

the pump. Aquastat is rated for voltages up to 277 v.

L-WTR — Load Water

NEC — National Electrical Code

P1 — Field Wiring Terminal Block

RVS — Reversing Valve Solenoid

S-WTR — Source Water

TRANS — Transformer

Factory Line Voltage Wiring

Factory Low Voltage Wiring

Field Line Voltage Wiring

Field Low Voltage Wiring

Printed Circuit Trace

AL — Alarm Relay Contacts

ASTAT — Aquastat Device

COMP — Compressor

CC — Compressor Contactor

DTS — Discharge Temperature Switch

FP1 — Sensor, Source Low Temp Protection

FP2 — Sensor, Load Low Temp Protection

HP — High Pressure Switch

HPWS — High Pressure Water Switch

HWG — Hot Water Generator

JW1 — Jumper Wire for Alarm

LOC — Loss of Charge Pressure Switch

Relay/Contactor Coil

Solenoid Coil

Thermistor

Ground

Indicator Light

G=Green, R=Red

(Comp On) (Alarm Light)

Complete C

Complete C Complete C

Page 10

Fig. 6 — Typical Aquazone™ 50PSW360 Complete C Control Wiring, 3-Phase

Circuit Breaker

High Pressure Switch

Low Pressure Switch

Fuse

Complete C

Complete C 1

Complete C 2

Complete C

NOTES:

1. Compressor thermally protected internally.

2. All wiring to the unit must comply with NEC and

local codes.

3. Transformer is wired to 380 v lead (VIO) for 380-

3-50 operation. For 420 v operation switch VIO

and BRN leads at L1 and insulate VIO lead.

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 volt-

age 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. Aquastat is supplied with unit and must be wired

in series with the hot leg of the pump. Aquastat is

rated for voltages up to 277 v.

MS — Motor Switch

NEC — National Electrical Code

P1 — Field Wiring Terminal Block

RVS — Reversing Valve Solenoid

S-WTR — Source Water

TRANS — Transformer

Factory Line Voltage Wiring

Factory Low Voltage Wiring

Field Line Voltage Wiring

Field Low Voltage Wiring

Printed Circuit Trace

AL — Alarm Relay Contacts

ASTAT — Aquastat Device

COMP — Compressor

CC — Compressor Contactor

DTS — Discharge Temperature Switch

FP1 — Sensor, Source Low Temp Protection

FP2 — Sensor, Load Low Temp Protection

HP — High Pressure Switch

HPWS — High Pressure Water Switch

HWG — Hot Water Generator

JW1 — Jumper Wire for Alarm

LED — Light Emitting Diode

LOC — Loss of Charge Pressure Switch

L-WTR — Load Water

Relay/Contactor Coil

Solenoid Coil

Thermistor

Ground

Indicator Light

G=Green, R=Red

(Comp On) (Alarm Light)

Page 11

Fig. 7 — Typical Aquazone™ 50PSW360 Deluxe D Control Wiring, 3-Phase

Circuit Breaker

High Pressure Switch

Low Pressure Switch

Fuse

MS — Motor Switch

NEC — National Electrical Code

P1 — Field Wiring Terminal Block

RVS — Reversing Valve Solenoid

S-WTR — Source Water

TRANS — Transformer

Factory Line Voltage Wiring

Factory Low Voltage Wiring

Field Line Voltage Wiring

Field Low Voltage Wiring

Printed Circuit Trace

AL — Alarm Relay Contacts

ASTAT — Aquastat Device

COMP — Compressor

CC — Compressor Contactor

DTS — Discharge Temperature Switch

FP1 — Sensor, Source Low Temp Protection

FP2 — Sensor, Load Low Temp Protection

HP — High Pressure Switch

HPWS — High Pressure Water Switch

HWG — Hot Water Generator

JW1 — Jumper Wire for Alarm

LED — Light Emitting Diode

LOC — Loss of Charge Pressure Switch

L-WTR — Load Water

Relay/Contactor Coil

Solenoid Coil

Thermistor

Ground

Indicator Light

G=Green, R=Red

(Comp On) (Alarm Light)

See notes on page 10.

Deluxe D

Page 12

EXTERNAL LOOP POWER CONNECTION — If the unit

Contactor -CC1

Transformer

C Control #1

Low Voltage

Connector

Grnd

L3L1

Low Voltage

Connector

Contactor -CC2

C Control #2

Power Distribution

Block

Fig. 8 — Typical Field Wiring

Fig. 9 — Typical Aquazone Control Board

Jumper Locations (Complete C Control Shown)

Typical

Water

Valve

24 VAC

Terminal Strip

Fig. 10 — Typical Aquazone Accessory Wiring

(Deluxe D Control Shown)

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-v. The pumps will automatically cycle as required by the unit.

220-V OPERATION — All 220/240-v units are factory wired for 220-v. The transformers may be switched to 240-v operation (as illustrated on the wiring diagram) by switching the red (220-v) wire with the orange (240-v) wire at the L2 terminal.

380-VOLT OPERATION — All 380/415 volt units are factory wired for 420 volts. The transformers may be switched to 380-volt operation by switching the brown (380 volt) wire with the violet (420 volt) wire at the L1 terminal.

Step 7 — Wire Low Voltage Connections

THERMOSTAT CONNECTIONS The thermostat should be wired directly to the Aquazone™

control board. See Fig. 4-7. WATER FREEZE PROTECTION — The Aquazone control

allows the field selection of source fluid freeze protection points through jumpers. The factory setting of jumper JW3 (FP1) is set for water at –1.1 C. In earth loop applications, jumper JW3 should be clipped to change the setting to –12.2 C when using antifreeze in colder earth loop applications. See Fig. 9.

ACCESSORY CONNECTIONS — The 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. 10. Refer to the specific unit wiring schematic for details.

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.

WATER SOLENOID VALVES — Water solenoid valves may be used on variable flow systems and ground water installations. A typical well water control valve wiring which can limit waste water in a lockout condition is shown in Fig. 10. A slow closing valve may be required to prevent water hammer. When using a slow closing valve, special wiring conditions need to be considered. The valve takes approximately 60 seconds to open (very little water will flow before 45 seconds) and it activates the compressor only after the valve is completely opened by closing its end switch. When wired as shown, the valve will have the following operating characteristics:

1. Remain open during a lockout.

2. Draw approximately 25 to 35-va through the “Y” signal of the thermostat.

IMPORTANT: This can overheat the anticipators of electromechanical thermostats. Only use relay based electronic thermostats.

PRE-START-UP

System Checkout —

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. Transformer switched to lower voltage tap if necessary.

10. Service/access panels are in place.

11. Control field-selected settings are correct.

When the installation is complete,

Page 13

FIELD SELECTABLE INPUTS

Jumpers and DIP (dual in-line package) switches on the control board are used to customize unit operation and can be configured in the field.

IMPORTANT: Jumpers and DIP switches should only be clipped when power to control board has been turned off.

Complete C Control Jumper Settings (See Fig. 4-6)

WATER COIL FREEZE PROTECTION (FP1) LIMIT SETTING — Select jumper 3, (JW3-FP1 Low Temp) to choose FP1 limit of –12.2 C or –1.1 C. To select –1.1 C as the limit, DO NOT clip the jumper. To select –12.2 C as the limit, clip the jumper.

ALARM RELAY SETTING — Select jumper 1 (JW1-AL2 Dry) for connecting alarm relay terminal (AL2) to 24 vac (R) or to remain as a dry contact (no connection). To connect AL2 to R, do not clip the jumper. To set as dry contact, clip the jumper.

Complete C Control DIP Switches — The

Complete C control has one DIP switch block with five switches. See Fig. 4-6.

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 Jumper Settings (See Fig. 7)

ALARM RELAY SETTING — Select jumper 4 (JW4-AL2 Dry) for connecting alarm relay terminal (AL2) to 24 vac (R) or to remain as a dry contact (no connection). To connect AL2 to R, do not clip the jumper. To set as dry contact, clip the jumper.

LOW PRESSURE SETTING — The 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 S2 on the circuit board. See Fig. 7.

DIP SWITCH BLOCK 1 (S1) — This set of switches offers the following options for Deluxe D control configuration:

Performance Monitor (PM) able performance monitor. To enable the PM, set the switch to ON. To disable the PM, set the switch to OFF.

Compressor Relay Staging Operation able 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

— Set switch 1 to enable or dis-

— Switch 2 will en-

(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, W1 is used for heating Stage 1 and O/W2 is used for heating Stage 2. Select ON for heat pump applications. In heat pump mode, Y1 used is for compressor Stage 1, Y2 is used for compressor Stage 2, W1 is used for heating Stage 3 or emergency heat, and O/W2 is used for RV (heating or cooling) depending upon switch 4 setting.

O/B Thermostat Type

— Switch 4 provides selection for heat pump O/B thermostats. O is cooling output. B is heating output. Select ON for heat pumps with O output. Select OFF for heat pumps with B output.

Switches 5, 6, 7, 8

— Not used.

DIP SWITCH BLOCK 2 (S2) — Used for accessory relay configurations.

Deluxe D Control Accessory Relay Configurations (See Tables 4 and 5) —

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 configura-

tion, the relay will be ON if the NSB input is connected to ground C.

NOTE: If there are no relays configured for digital NSB, then the NSB and OVR inputs are automatically configured for mechanical operation.

MECHANICAL NIGHT 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 OPENING) — If relay is configured for water valve (slow opening), the relay will start 60 seconds prior to starting compressor relay.

The following acces-

CAUTION

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 S2 —

Accessory 1 Relay Options

ACCE SSORY 1

RELAY OPTIONS

Digital NSB Off On On

Water Valve — Slow Opening On Off On

LEGEND

NSB — Night Setback

NOTE: All other DIP switch combinations are invalid.

DIP SWITCH POSITION

123

Page 14

Table 5 — DIP Switch Block S2 —

Accessory 2 Relay Options

ACCESSORY 2

RELAY OPTIONS

Digital NSB Off On On

Water Valve — Slow Opening On Off On

LEGEND

NSB — Night Setback

NOTE: All other DIP switch combinations are invalid.

DIP SWITCH POSITION

456

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)

ENVIRONMENT — This 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 SUPPLY — A voltage variation of ± 10% of nameplate utilization voltage is acceptable.

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.

WARNING

When the disconnect switch is closed, high voltage is present in some areas of the electrical panel. Exercise caution when working with the energized equipment.

Table 6 — 50PSW Unit Operating Limits (C)

BUILDING COMMISSIONING

50PSW

UNIT SIZE

036 10/43 16/27 7/43 –1/27 16/49 4/29 060,120 10/49 16/32 7/43 –1/27 16/49 4/29 180,360 10/32 16/32 7/43 10/21 27/49 4/29

50PSW

UNIT SIZE

036 10/49 10/32 7/43 –7/27 16/54 4/29 060,120 10/49 10/32 7/43 –7/27 16/54 4/29 180,360 10/43 10/32 7/43 –7/21 16/49 4/29

Source

Min/Max

Source

Min/Max

COOLING HEATING

Load

Min/Max

BUILDING OPERATING

COOLING HEATING

Load

Min/Max

Ambient Min/Max

Source

Min/Max

Source

Min/Max

Load

Min/Max

Load

Min/Max

Ambient Min/Max

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 immediately 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 overridden 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 com-

ply with electrical data on unit nameplate.

b. Check for loose terminal screws where wire con-

nections 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.

If the suction pressure does not drop and the discharge

pressure does not rise to normal levels:

1. Turn off power to the unit. Install disconnect tag.

2. Reverse any two of the unit power leads.

3. Reapply power to the unit and verify pressures are correct. The suction and discharge pressure levels should now move to their normal start-up levels.

CAUTION

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 — Flow regulation can be accom-

plished by two methods. Most water control valves have a flow adjustment built into the valve. By measuring the pressure drop through the unit heat exchanger, the flow rate can be determined. Adjust the water control valve until the flow of 0.09 to

0.13 L/s 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 can be reduced by applying some back pressure. To accomplish this, slightly close the leaving isolation valve of the water regulating device.

Page 15

Table 7 — Heat Exchanger Pressure Drop

UNIT SIZES 036-120

50PSW

UNIT SIZE

036

060

120

036

060

120

50PSW

UNIT SIZE

180

360

NOTE: Bold values indicate use of antifreeze is required.

L/s

Source/Outdoor Coax

0.28

0.43

0.57

0.47

0.71

0.95

1.42

1.89

Load/Outdoor Coax

0.28

0.43

0.57

0.47

0.71

0.95

1.42

1.89

UNIT SIZES 180,360

L/s

Source/Outdoor Coax

1.10

1.67

2.21

3.34

4.42

PRESSURE DROP (kPa)

–1 C 10 C 21 C 32 C

11.7

28.3

49.0

10.3

27.6

47.6

11.7

30.3

52.4

— — —

0 C 10 C 20 C 30 C

4.82

17.92

32.40

11.03

26.88

48.95

9.0

23.4

41.4

9.0

23.4

42.8

9.7

26.2

46.9

4.1

9.7

18.0

9.7

24.1

42.8

11.0

26.2

46.9

PRESSURE DROP (kPa)

2.76

11.72

22.75

8.27

24.82

44.82

6.9

19.3

35.2

17.2

47.6

88.3

8.3

22.8

42.1

3.4

9.0

16.5

9.0

22.1

40.0

9.7

24.1

44.1

1.72

11.38

21.37

7.22

23.10

41.36

5.5

16.5

31.0

14.5

42.1

80.0

6.2

18.6

34.5

2.1

7.6

15.2

8.3

20.7

37.9

2.1

22.8

41.1

0.88

9.47

19.30

6.29

21.29

38.47

6. Raise the loop temperature to approximately 29.4 C. 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 0.5 kg per 750 L of water (or other equivalent approved cleaning agent).

CAUTION

To avoid possible damage to a plastic (PVC) piping system, do not allow temperatures to exceed 43.3 C.

Raise the loop temperature to 37.8 C. 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 off all 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.

CAUTION

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.

Cleaning and Flushing — 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.

WARNING

To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position before flushing system. 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.

Antifreeze — In areas where entering loop temperatures

drop below 4.4 C or where piping will be routed through areas subject to freezing, antifreeze is needed.

Alcohols and glycols are commonly used as antifreeze agents. Freeze protection should be maintained to 8.3° C below the lowest expected entering loop temperature. For example, if the lowest expected entering loop temperature is –1.1 C, the leaving loop temperature would be –5.6 to –3.9 C. Therefore, the freeze protection should be at –9.4 C (–1.1 C – 8.3 C = –9.4 C).

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 –1.1 C FP1 factory setting (water) should be used to avoid freeze damage to the unit.

Once antifreeze is selected, the JW3 jumper (FP1) should be clipped on the control to select the low temperature (antifreeze –12.2 C) set point to avoid nuisance faults.

Page 16

Table 8 — Approximate Fluid Volume (L)

CCG

BRG

Test

Off On

FP1JW3

TEST MODE PINS

Fig. 11 — Test Mode Pins Location

per 30 M of Pipe

PIPE DIAMETER (in.) [mm] VOLUME (gal.) [L]

Copper 1 [25.4] 4.1 [15.5]

Rubber Hose 1 [25.4] 3.9 [14.8] Polyethylene

LEGEND

IPS — Internal Pipe Size SCH — Schedule SDR — Standard Dimensional Ratio

NOTE: Volume of heat exchanger is approximately 1.0 gallon (3.78 liters).

1.25 [31.8] 6.4 [24.2]

1.5 [38.1] 9.2 [34.8]

/4 IPS SDR11 2.8 [10.6]

1 IPS SDR11 4.5 [17.0]

/4 IPS SDR11 8.0 [30.8]

/2 IPS SDR11 10.9 [41.3] 2 IPS SDR11 18.0 [68.1] 11/4 IPS SCH40 8.3 [31.4]

/2 IPS SCH40 10.9 [41.3]

1 2 IPS SCH40 17.0 [64.4]

Table 9 — Antifreeze Percentages by Volume

ANTIFREEZE

Methanol (%) 25 21 16 10 100% USP Food Grade

Propylene Glycol (%) Ethanol (%) 29 25 20 14

MINIMUM TEMPERATURE FOR FREEZE

–12.2 –9.4 –6.7 –3.9

PROTECTION (C)

38 30 22 15

Cooling Tower/Boiler Systems — These systems

typically use a common loop maintained at 15.6 to 32.2 C. 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 al-

low water temperatures from –1.1 to 43.3 C. The external loop field is divided up into 51 mm polyethylene supply and return lines. Each line has valves connected in such a way that upon system start-up, each line can be isolated for flushing using only the system pumps. Air separation should be located in the piping system prior to the fluid re-entering the loop field.

OPERATION

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.

Units with Aquazone Deluxe D Control

STANDBY — The compressor will be off. The reversing valve (RV) relays will be on if inputs are present.

HEATING STAGE 1 — In Heating Stage 1 mode, the fan enable and compressor relays are turned on immediately. Once the demand is removed, the relays are turned off and the control reverts to standby mode. If there is a master/slave or dual compressor application, all compressor relays and related functions will operate per their associated DIP switch 2 setting on S1.

HEATING STAGE 2 — In Heating Stage 2 mode, the compressor relays remain on. The control reverts to Heating Stage 1 mode once demand is removed. 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.

COOLING STAGE 1 — In Cooling Stage 1 mode, the compressor and RV relays are turned on immediately. If configured as stage 2 (DIP switch set to OFF) then the compressor and fan will not turn on until there is a stage 2 demand. The compressor relays are turned off immediately when the Cooling Stage 1 demand is removed. The control reverts to standby mode. The RV relay remains on until there is a heating demand. If there is a master/slave or dual compressor application, all compressor relays and related functions will track with their associated DIP switch 2 on S1.

COOLING STAGE 2 — In Cooling Stage 2 mode, the compressor and RV relays remain on. The control reverts to Cooling Stage 1 mode once the demand is removed. If there is a master/slave or dual compressor application, all compressor relays and related functions will track with their associated DIP switch 2 on S1.

NIGHT LOW LIMIT (NLL) STAGED HEATING — In NLL staged heating mode, the override (OVR) input becomes active and is recognized as a call for heating and the control will immediately go into a Heating Stage 1 mode. With an additional 30 minutes of NLL demand, the control will go into Heating Stage 2 mode. With another additional 30 minutes of NLL demand, the control will go into Heating Stage 3 mode.

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™ 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.

COOLING — The 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 time delay. After both delays are complete, the compressor is energized.

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 time delays are increased 15 times. See Fig. 11.

Test Mode — Enter the Test mode on Complete C or

Deluxe D controls by momentarily shorting the test terminals. The Complete C or Deluxe D control will enter a 20-minute test mode period in which all time delays are sped up 15 times.

Page 17

Upon entering Test mode, the status LED (light-emitting diode) will flash a code representing the last fault. For diagnostic ease at the thermostat, the alarm will also cycle during Test mode. The alarm relay will cycle on and off similar to the status LED to indicate a code representing the last fault, at the thermostat. Test mode can be exited by shorting the test terminals for 3 seconds. See Tables 10-12.

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.

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.

Table 10 — Complete C Control Current LED

Status and Alarm Relay Operations

LED STATUS

Off Control is non-functional Open

Slow Flash

Fast Flash Lockout Closed

Flashing Code 1 Test Mode — No fault in memory Cycling Code 1 Flashing Code 2 Test Mode — HP Fault in memory Cycling Code 2 Flashing Code 3 Test Mode — LP Fault in memory Cycling Code 3 Flashing Code 4 Test Mode — FP1 Fault in memory Cycling Code 4 Flashing Code 5 Test Mode — FP2 Fault in memory Cycling Code 5

Flashing Code 7

Flashing Code 8 Test Mode — PM in memory Cycling Code 8

Flashing Code 9

FP — Freeze Protection HP — High Pressure LED — Light-Emitting Diode LP — Low Pressure PM — Performance Monitor

NOTES:

LEGEND

1. Slow flash is 1 flash every 2 seconds.

2. Fast flash is 2 flashes every 1 second.

3. EXAMPLE: “Flashing Code 2” is represented by 2 fast flashes followed by a 10-second pause. This sequence will repeat continually until the fault is cleared.

DESCRIPTION OF

OPERATION

Normal Mode Open

Normal Mode with PM Warning

Fault Retry Open

Over/Under Voltage Shutdown

Test Mode — Over/Under shut-

down in memory

Test Mode — FP1/FP2 swapped

fault in memory

ALARM RELAY

Cycle

(Closed 5 sec.,

Open 25 sec.)

Open

(Closed after

15 minutes)

Cycling Code 7

Cycling Code 9

Aquazone™ Deluxe D Control LED Indicators —

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.

(Autoreset)

FP — Freeze Protection HP — High Pressure LP — Low Pressure

There are 3 LED indicators on the Deluxe D control:

Table 11 — Complete C Control LED Code and

Fault Descriptions

LED

CODE

1 No fault in memory There has been no fault since

2 High-Pressure Switch HP Open Instantly 3 Low-Pressure Switch LP open for 30 continuous

4 Freeze Protection

5 Freeze Protection (Load)

8 PM Warning Performance Monitor

9 FPI and FP2

LEGEND

FAULT DESCRIPTION

the last power-down to power-up sequence

seconds before or during a call (bypassed for first 60 seconds)

(Source) Coax — FP1

Coil — FP2

Over/Under Voltage Shutdown

Thermistors are swapped

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)

"R" power supply is <19 vac or >30 vac

Warning has occurred. FP1 temperature is higher than

FP2 in heating/test mode, or FP2 temperature is higher than FP1 in cooling/test mode.

Page 18

Table 12 — Aquazone™ Deluxe D Control Current LED Status and Alarm Relay Operations

DESCRIPTION

Normal Mode On Off Flash Last Fault Code in Memory Open

Normal Mode with PM On Off Flashing Code 8

Control is Non-Functional Off Off Off Open

Test Mo de — On Flash Last Fault Code in Memory Cycling Appropriate Code

Night Setback Flashing Code 2 — Flash Last Fault Code in Memory —

ESD Flashing Code 3 — Flash Last Fault Code in Memory — Invalid T-stat Inputs Flashing Code 4 — Flash Last Fault Code in Memory — No Fault in Memory On Off Flashing Code 1 Open

HP Fault Slow Flash Off Flashing Code 2 Open

LP Fault Slow Flash Off Flashing Code 3 Open FP1 Fault Slow Flash Off Flashing Code 4 Open FP2 Fault Slow Flash Off Flashing Code 5 Open

CO Fault Slow Flash Off Flashing Code 6 Open

Over/Under Voltage Slow Flash Off Flashing Code 7 Open (closed after 15 minutes)

HP Lockout Fast Flash Off Flashing Code 2 Closed

LP Lockout Fast Flash Off Flashing Code 3 Closed FP1 Lockout Fast Flash Off Flashing Code 4 Closed FP2 Lockout Fast Flash Off Flashing Code 5 Closed

CO Lockout Fast Flash Off Flashing Code 6 Closed

LEGEND NOTES:

CO — Condensate Overflow ESD — Emergency Shutdown FP — Freeze Protection HP — High Pressure LP — Low Pressure PM — Performance Monitor

STATUS LED

(Green)

TEST LED

(Yellow)

FAULT LED (Red) ALARM RELAY

Cycle (closed 5 sec,

open 25 sec, …)

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.

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.

WARNING

To prevent injury 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” environment. 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 103 kPa during the summer and 276 kPa during the winter.

Check P trap frequently for proper operation.

CAUTION

To avoid fouled machinery and extensive unit clean-up, DO NOT operate units without filters in place. DO NOT use equipment as a temporary heat source during construction.

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 need to be cleaned in an open water tower system due to induced contaminants.

Local water conditions may cause excessive fouling or pitting of tubes. Condenser tubes should therefore be cleaned at least once a year, or more often if the water is contaminated.

Proper water treatment can minimize tube fouling and pitting. If such conditions are anticipated, water treatment analysis is recommended. Refer to the Carrier System Design Manual, Part 5, for general water conditioning information.

CAUTION

Follow all safety codes. Wear safety glasses and rubber gloves when using inhibited hydrochloric acid solution. Observe and follow acid manufacturer’s instructions.

Clean condensers with an inhibited hydrochloric acid solution. The acid can stain hands and clothing, damage concrete, and, without inhibitor, damage steel. Cover surroundings to guard against splashing. Vapors from vent pipe are not harmful,

Page 19

but take care to prevent liquid from being carried over by the

Fig. 12 — Gravity Flow Method

Fig. 13 — Forced Circulation Method

Fig. 14 — Thermistor Nominal Resistance

gases.

Warm solution acts faster, but cold solution is just as effec-

tive if applied for a longer period.

GRAVITY FLOW METHOD — Do not add solution faster than vent can exhaust the generated gases.

When condenser is full, allow solution to remain overnight, then drain condenser and flush with clean water. Follow acid manufacturer’s instructions. See Fig. 12.

FILL CONDENSER WITH

CLEANING SOLUTION. DO

NOT ADD SOLUTION

MORE RAPIDLY THAN

VENT CAN EXHAUST

GASES CAUSED BY

CHEMICAL ACTION.

VENT PIPE

1.0 TO 1.2 m

PAI L

1-IN. (25 mm) PIPE

1.5 m APPROX

FUNNEL

PAI L

CONDENSER

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. 13.

PUMP

SUCTION

PUMP SUPPORT

TANK

FINE MESH SCREEN

PRIMING CONN.

GAS VENT

GLOBE VALV ES

SUPPLY

1-IN. (25 mm) PIPE

RETURN

CONDENSER

REMOVE WATER REGULATING VALVE

3. After unit conditions have stabilized, read head pressure on discharge line gage.

NOTE: Operate unit a minimum of 15 minutes before checking charge. From standard field-supplied PressureTemperature 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

WARNING

To prevent personal injury, wear safety glasses and gloves when handling refrigerant. Do not overcharge system — this can cause compressor flooding.

NOTE: Do not vent or depressurize unit refrigerant to atmosphere. Remove and recover refrigerant following accepted practices.

TROUBLESHOOTING

When troubleshooting problems with a WSHP, refer to

Table 13.

Thermistor — A thermistor may be required for single-

phase units where starting the unit is a problem due to low voltage. See Fig. 14 for thermistor nominal resistance.

Control Sensors — The control system employs 2 nom-

inal 10,000 ohm thermistors (FP1 and FP2) that are used for freeze protection. Be sure FP1 is located in the discharge fluid and FP2 is located in the air discharge. See Fig. 15.

90.0

80.0

70.0

60.0

50.0

40.0

30.0

Resistance (kOhm)

20.0

10.0

0.0

-17.7 -6.6 4.4 15.6 26.7 37.8 48.9 60.0

Temperature (C)

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.

Page 20

SUCTIO N

COMPRESSOR

DISCHARGE

COAX

EXP ANSION

VA LV E

FP 2

FP 1

LIQUI D LIN E

WA TER IN

WA TER OUT

CONDENSA TE

OVERFLO W

(CO)

AIR COI L FREEZ E PROTECTIO N

WA TE R COI L PROTECTIO N

THERMIST OR

( °C)

AI R

COI L

AIRFLOW

AIRFLO W

a50-8163

LEGEND

Fig. 15 — FP1 and FP2 Thermistor Location

COAX — Coaxial Heat Exchanger

Airflow Refrigerant Liquid Line Flow

a50-8592

Page 21

Table 13 — Troubleshooting

FAULT HEATING COOLING POSSIBLE CAUSE SOLUTION

Main Power Problems X X Green Status LED Off Check line voltage circuit breaker and disconnect.

Check for line voltage between L1 and L2 on the contactor. Check for 24-vac between R and C on controller. Check primary/secondary voltage on transformer.

HP Fault — Code 2 High Pressure

X X Overcharged with refrigerant Check superheat/subcooling vs. typical operating condition. X X Bad HP switch Check switch continuity and operation. Replace.

LP/LOC Fault — Code 3 Low Pressure/Loss of Charge

FP1 Fault — Code 4 Source Water Freeze Protection

FP2 Fault — Code 5 Load Coil Freeze Protection

Over/Under Voltage — Code 7 (Auto Resetting)

Performance Monitor — Code 8

No Fault Code Shown X X No compressor operation See scroll compressor rotation section.

Unit Short Cycles X X Unit in Test mode Reset power or wait 20 minutes for auto exit.

Unit Does Not Operate in Cooling

Insufficient Capacity/ Not Cooling or Heating Properly

High Head Pressure X Scaling in water heat exchanger Perform scaling check and clean if necessary.

Low Suction Pressure X Reduced water flow in heating Check pump operation or water valve operation/setting.

LEGEND

FP — Freeze Protection HP — High Pressure LED — Light-Emitting Diode LOC — Loss of Charge LP — Low Pressure RV — Reversing Valve

X X Insufficient charge Check for refrigerant leaks. X Compressor pump down at

X Reduced or no water flow in

X Inadequate antifreeze level Check antifreeze density with hydrometer. X Improper freeze protect setting

X Water temperature out of range Bring water temperature within design parameters. X X Bad thermistor Check temperature and impedance correlation.

X X Bad thermistor Check temperature and impedance correlation. X X Under voltage Check power supply and 24-vac voltage before and during operation.

X X Over voltage Check power supply voltage and 24-vac before and during operation.

X Heating mode FP2>51.7 C Check for overcharged unit.

X X Compressor overload Check and replace if necessary. X X Control board Reset power and check operation.

X X Unit selection Unit may be oversized for space. Check sizing for actual load of space. X X Compressor overload Check and replace if necessary.

X X Low refrigerant charge Check superheat and subcooling. X X Restricted metering device Check superheat and subcooling. Replace.

X X Thermostat improperly located Check location and for air drafts behind thermostat. X X Unit undersized Recheck loads and sizing. Check sensible cooling load and heat pump

X X Scaling in water heat exchanger Perform scaling check and clean if necessary. X X Inlet water too hot or cold Check load, loop sizing, loop backfill, ground moisture.

X X Unit overcharged Check superheat and subcooling. Reweigh in charge. X X Non-condensables in system Vacuum system and reweigh in charge. X X Restricted metering device Check superheat and subcooling. Replace.

X Water temperature out of range Bring water temperature within design parameters.

X Reduced or no water flow in

cooling

X Water temperature out of range

in cooling

start-up

heating

(–1.1 C vs –12.2 C)

X Reduced or no water flow in

heating

X Improper freeze protect setting

(–1.1 C vs –12.2 C)

X Water temperature out of range Bring water temperature within design parameters.

X Cooling mode FP1>51.7 C OR

FP2< 4.4 C

X Reversing valve Set for cooling demand and check 24-vac on RV coil and at control.

X Thermostat setup Check for ‘O’ RV setup not ‘B’. X Thermostat wiring Check O wiring at heat pump. Jumper O and R for RV coil.

X Defective reversing valve Perform RV touch test.

Check pump operation or valve operation/setting. Check water flow adjust to proper flow rate. Bring water temperature within design parameters.

Check charge and start-up water flow.

Check pump operation or water valve operation/setting. Plugged strainer or filter. Clean or replace. Check water flow adjust to proper flow rate.

Clip JW3 jumper for antifreeze (–12.2 C) use.

Check pump operation or water valve operation/setting. Plugged strainer or filter. Clean or replace. Check water flow adjust to proper flow rate. Clip JW3 jumper for antifreeze (–12.2 C) use.

Check power supply wire size. Check compressor starting. Check 24-vac and unit transformer tap for correct power supply voltage.

Check 24-vac and unit transformer tap for correct power supply voltage.

Check for poor water flow or airflow.

If RV is stuck, run high pressure up by reducing water flow and while operating engage and disengage RV coil voltage to push valve.

capacity.

Plugged strainer or filter. Clean or replace. Check water flow adjust to proper flow rate.

Page 22

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

Catalog No. 04-53500073-01 Printed in U.S.A. Form 50PSW-C1SI Pg 22 10-10 Replaces: New

Page 23

50PSW

START-UP CHECKLIST

CUSTOMER:___________________________ JOB NAME: _______________________________________

MODEL NO.:___________________________ SERIAL NO.:____________________ DATE:_________

LOOP TYPE: ___________________________ ANTIFREEZE TYPE AND %:_________________________

I. 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? (Y/N)

IS AN AIR FILTER INSTALLED? (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 BC VOLTS PHASE CA VOLTS

(if 3 phase) (if 3 phase)

PHASE AB AMPS

PHASE BC AMPS PHASE CA AMPS

(if 3 phase) (if 3 phase)

CONTROL VOLTAGE

IS CONTROL VOLTAGE ABOVE 21.6 VOLTS? (Y/N) . IF NOT, CHECK FOR PROPER TRANSFORMER CONNECTION.

TEMPERATURES

FILL IN THE ANALYSIS CHART ATTACHED.

COAXIAL HEAT EXCHANGER

COOLING CYCLE: FLUID IN

C FLUID OUT C KPA FLOW

HEATING CYCLE: FLUID IN

AIR COIL COOLING CYCLE:

AIR IN

HEATING CYCLE: AIR IN

C FLUID OUT C KPA FLOW

C AIR OUT C

CL-1

Page 24

HEATING AND COOLING CYCLE ANALYSIS

COMPRESS OR

DISCHARGE

SUCTION

HWG*

EXPANSION

VALVE

FILTER DRIER

REVERSING

VALVE

HEATING POSITION COOLING POSITION

COAX

1210

1311

FP2: HEATING LIQUID LINE

FP1: COOLING LIQUID LINE

CONDENS ER (HTG ) EVAPORATOR (CLG)

CONDENSER ( COOLING) EVAPORATOR (HEATING)

WA TER-TO- WATER UNITS

REFRIG FLOW - HEATING REFRIG FLOW - COOLING

Source

Load

LEGEND

*Turn off HWG (hot water generator) before troubleshooting.

CLG — Cooling HTG — Heating

a50-8465

DESCRIPTION HEATING COOLING NOTES

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 Temperature Difference —

8 Source Water In Pressure

9 Source Water Out Pressure 9a Pressure Drop 9b Flow Rate (L/s) 10 Load Water In Temperature 11 Load Water Out Temperature Temperature Difference — 12 Load Water In Pressure 13 Load Water Out Pressure

13a Pressure Drop 13b Flow Rate (gpm)

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

HEAT OF EXTRACTION (ABSORPTION) OR HEAT OF REJECTION =

FLOW RATE (L/s) x TEMP. DIFF. (DEG. C) x FLUID FACTOR* =

SUPERHEAT = SUCTION TEMPERATURE – SUCTION SATURATION TEMPERATURE

SUBCOOLING = DISCHARGE SATURATION TEMPERATURE – LIQUID LINE TEMPERATURE

*Use 500 for water, 485 for antifreeze.

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

Catalog No. 04-53500073-01 Printed in U.S.A. Form 50PSW-C1SI Pg CL-2 10-10 Replaces: New

= (DEG C)

(DEG C)

(kW)

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -