Carrier 50RLP User Manual

Aquazone™ System Control Panel

Water Source Heat Pump Units

Installation Instructions

50RLP

CONTENTS

SAFETY CONSIDERATIONS GENERAL Aquazone System Control Panel Functionality Stand-Alone Systems CCN Systems Using PremierLink™ Controls COMPONENTS Aquazone System Control Panel Hardware Water Source Heat Pumps with

PremierLink Controller Hardware

Field-Supplied Hardware

for Stand-Alone Systems

Field-Supplied Hardware for CCN Applications INSTALLATION

Inspection Mounting Location Mounting Wiring Install Thermostat, Sensors and Switches Install Loop Water Supply and Return

Temperature Sensors Install Loop Water Pressure Sensor Install Loop Water Flow Switch Connect to CCN Communication Bus

START-UP LID Power Up Display Log On to the LID Display Change the Default Password Set the Clock Configure Schedules Program Set Points Check System Parameters Display Alarm History Configure the Custom Programming Selections Set the Aquazone System Control Panel

Controller Address Log Off from Controller LID Operation Sequence of Operation

• HEAT REJECTION

• H EAT ADDITION

• WATER CIRCULATION

CONFIGURATION Hardware Points Software Points Loop Supply Water Set Point System Pressure Set Point Global Dictionary Heat Pump Default Configuration Cool Source Default Configuration Heat Source Default Configuration Occupancy Configuration Screen Network Time Schedule Holiday Schedules

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IMPORTANT: Read the ent ire instruction manual before starting installation.

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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. 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 El ectrical 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.

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.

GENERAL

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.

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

Book 1 4 Ta b 5 a 5 a

PC 111 Catalog No. 535-00077 Printed in U.S.A. Form 50RLP-1SI Pg 1 1-03 Replaces: New

The Aquazone™ System Control Panel is a single packaged system control panel for use with Aquazone water source heat pumps (WSHPs) in stand-alone or direct digital control applications using the Carrier Comfort Network (CCN). The Aquazone system control panel controls and monitors the operation of the water source heat pumps, the ancillary heat rejection, the heat addition, and the system pumps to coordinate entire system operation. The Aquazone System Control Panel is used with the following units: 50HQL, KQA, KQD, RDS, RHC, RHR, RHS, RTG, RVC, RVR, RVS, RWS, VQA, VQD.

The Aquazone system control panel includes a preprogrammed 6400 main logic comfort controller as the central processing unit. The Aquazone system control panel is compatible for use in boiler/tower (water loop) or geothermal (ground loop, ground water) water source heat pump arrangements.

Other system hardware components are specified in the 50RLP model nomenclature. Components can be added to customize the Aquazone System Control Panel for the specific type of functionality desired, including staged heat rejection and addition, dual or variable speed pump operation, and standalone or CCN installations. See Fig. 1.

Aquazone System Control Panel Functionality —

Functionality includes the ability to control up to two water-circulating pumps and monitor water temperature to initiate up to eight stages of cooling tower and/or boiler operation. The system control panel has the capability to work with variable speed pumping arrangements for maximum energy efficiency. In addition, the panel provides system control for both stand-alone and DDC water source heat pump systems (units installed with a factory-mounted PremierLink™ CCN controller).

Stand-Alone Systems —

trol strategy, non-communicating Aquazone water source heat pump thermostats are utilized to initiate the operation of individual water source heat pump equipment for eac h zone. The Aquazone System Control Panel can be ordered with the appropriate hardware to accommodate and initiate scheduled control of either 10 or 18 zones of WSHP units in stand-alone operation. See Fig. 2.

In a stand-alone type of con-

CCN Systems Using PremierLink Controls —

To implement a direct digital control type of water source heat pump system strategy , individual WSHP units are ordered with a factory-installed PremierLink controller. The Aquazone system control panel has been pre-programmed to w ork specifically with th e Pr e m ie r L in k co ntroller to trans f er a n d c o ntrol all modes of cooling/heating operation, transmit unit number, zone temperature, zone temperature set points, discharge air temperature, fan status, stages of heating, stages of cooling, leaving water temperature, and alarm status information. See Fig. 3.

COMPONENTS

Aquazone System Control Panel Hardware —

The 50RLP Aquazone System Control Panel package consists of the following hardware. See Fig. 4.

ENCL OS U RE — The Aquazone system control panel enclosure is constructed of perforated 16-gage steel and finished in a gray powder-coated finish. The panel has a height of 42 in., a width of 30 in. and a depth of 7 inches.

PROC ESSO R — The central processing units for the Aquazone system control panel are Carrier 6400 Comfort Controllers. The Comfort Controller provides general purpose HVAC control and monitoring capability in a stand-alone or network environment using closed-loop, direct digital control. The 6400 Comfort Controller has been pre-programmed to work in either stand-alone or CCN water source heat pump system installations. Specifications for the 6400 Comfort Controller may be found in the Comfort Controller literature.

PUMP CON TROL RELAYS — For both stand-alone and CCN systems (based on the type of pumping operation required) the Aquazone system control panel can be orde red with a combination of multi-voltage control relays to provide start/stop or lead/lag operation for single or dual pumps. The combination desired is specified in the 50RLP model nomenclature in digit 8. See Fig. 1.

50RLP 0 0 0 0

Unit 50RLP – Aquazone System Control Panel

System Heat Rejection 0 – 2-Stage Card (2 Stages of Cooling Tower Operation) 1 – 4-Stage Card (4 Stages of Cooling Tower Operation) 2 – 2- and 4-Stage Cards (6 Stages of Cooling Tower Operation) 3 – Two 4-Stage Cards (8 Stages of Cooling Tower Operation) 4 – No Card, Variable Speed Cooling Tower Operation

*Option is utilized with Aquazone Thermostat for each WSHP unit.

†Option is utilized with PremierLink DDC control option on individual WSHP units.

**Accepts signals from a variable frequency device.

Fig. 1 — Model Number Nomenclature

WSHP Zone Operation 0 – 10 Relays, Control 10 Zones for Stand-Alone WSHP Units* 1 – 18 Relays, Control 18 Zones for Stand-Alone WSHP Units* 2 – No Relays, Carrier Comfort Network (CCN) System†

System Pumping Operation 0 – Both Relays, Start/Stop or Lead/Lag Operation for Single or

Dual Pumps

1 – No Relays, Variable Frequency Pump Operation**

System Heat Addition 0 – 2-Stage Card (2 Stages of Boiler Operation) 1 – 4-Stage Card (4 Stages of Boiler Operation) 2 – 2 and 4-Stage Cards (6 Stages of Boiler Operation) 3 – Two 4-Stage Cards (8 Stages of Boiler Operation) 4 – No Card, Modulating Valve Operation for Steam or

Hot Water

COOLING TOWER

BOILER

EXPANSION TANK

AIR SEPARATOR

PUMP

WSHP

FLOW

SENSOR

TEMP.

SENSOR

T-S TAT

AQUAZONE

SYSTEM

CONTROL

PANEL

LEGEND

Control Wiring Loop Water Piping

Fig. 2 — Typical Stand-Alone WSHP System

If variable frequency drives are utilized for system pumps, no pump control relays are specified. Each relay contains a red light-emitting diode (LED), which indicates the relay coil is energized. The pump control relays are located in the upper left hand corner of the system control panel. See Fig. 4. Wiring is shown in Fig. 5A-5C. Specifications for the pump control relays are as follows:

Voltage Input: 24 vdc @ 15 mA, 14 vac @ 30 mA,

115 vac @ 20 mA, 230 vac @ 20 mA.

Contact Rating: 10 A res. @ 115 vac,

7 A res. @ 230 vac/28 vdc,

N.O.:

/6 hp @ 115 vac. T emperature Range: –60 F to 185 F Indication: LED Enclosure: 18 ga. metal back Dimensions: 5.125-in. x 3.125-in. x 2.5-in.

(HxWxD) or 5.125-in. x 9.5-in. x

2.5-in. (HxWxD)

OUTPUT TRANSDUCERS — For both stand-alone and CCN systems (based on the stages of heat addition or rejection required) the Aquazone™ system control panel can be ordered with a combination of 2-stage and 4-stage output transducers to provide 2, 4, 6, or 8 stages. The combination desired i s specified in the 50RLP model nomenclature in digit 6 to specify heat rejection stages and digit 7 to specify heat addition stages. See Fig. 1. If variable speed cooling tower fan operation and/or

WSHP

T-S TAT

WSHP

T-S TAT

WSHP

T-S TAT

modulating valve operation for steam or water a re utilized, no output transducer card is specified. The output transducer is a solid-state multi-stage device used for staging control from a single analog signal. Output transducers are located in the upper left hand corner of the Aquazone System Control Panel underneath the pump control relays. See Fig. 4. Specificat ions for the pump control relays are as follows:

Supply Voltage: 24 vac ± 10% @ 100 mA,

24 vdc ± 10% @ 50 mA Input Signal: 4-20 mA Output: 2 SPDT relays for 2-stage,

4 SPDT relays for 4-stage. Relay rating: 5A @ 120 vac Accuracy & repeatability: ± 1% Set point adjustment: 25-turn potentiometers Input impedance: 250 W (mA input), 10 kW

(V input) T emperature Range: 32 F to 158 F Humidity Limit: 5 to 95% relative humidity

non-condensing Dimensions: 3.25-in. x 3.5-in. x 1.375-in.

(HxWxD) for 2-stage, 3.25-in. x

5.5-in. x 1.375-in. (HxWxD)

for 4-stage Relay Differential: 0.5 mA or 0.375 V.

ZONE 2

ZONE 1

ROOM SENSOR

WSHP 2

WSHP 1

PREMIERLINK

WSHP CONTROLLER

PREMIERLINK

WSHP CONTROLLER

FAN(S)

SPRAY PUMP

STAGE 2

STAGE 1

MAIN

STANDBY

LOOP TEMP

VENTILATION FAN

COMPUTER

–PC ACCESS

LOCAL

REMOTE

TOWER

BOILER

PUMPS

TELEPHONE

LINE

AQUAZONE SYSTEM

LCP

LOOP CONTROL PANEL (CARRIER COMFORT CONTROLLER)

CARRIER COMFORT NETWORK BLDG.

MASTER CONTROL PANEL

MCP

(CARRIER COMFORT CONTROLLER)

REPEATER: INTERFACE PC TO NETWORK

TELINK WITH MODEM CONTROLLER

DATA COLLECTION

LOADSHED

COMFORT CONTROLLER

TENANT BILLING

LIGHTS

EQUIPMENT

D.C.

L.S.

CC6400

T.B.

BLDG./SYST. MANAGEMENT

Fig. 3 — CCN Water Source Heat Pump System with PremierLink™ Controllers

FLT SEQ

MODE

FLT SEQ

MODE

FLT SEQ

MODE

HOA

Pump 1

Pump 2

Cool Sta

Cool Stages 2

Heat Sta

Processor Input/Output 1 Input/Output 2

Low Volta

Zone Thermostat

Control Rela

UCS-421

MODE

INPUT

FLT SEQ

TYPE

MODE

UCS-421

24V

INPUT

CHAIN

SIGNAL

POWER

OUTPUT

COMMON

INPUT TYPE

24V

INPUT

CHAIN

SIGNAL

POWER

OUTPUT

COMMON

INPUT

TYPE

24V

INPUT

CHAIN

SIGNAL

POWER

OUTPUT

COMMON

es 1

MODE

FLT SEQ

es 1

UCS-421

MODE

INPUT

FLT SEQ

TYPE

24V

INPUT

CHAIN

SIGNAL

POWER

OUTPUT

COMMON

es 2

POWER SWITCH

CONVENIENCE OUTLET

PANDUCT® WIRING DUCT

Transformer 1 Transformer 2

CONDUIT

Fig. 4 — Aquazone™ System Control Panel

Trans former 3

COMPLETE C CONTROL

(IN WSHP)

RYW OGC

SYSTEM ZONE RELAYS (1-18)

THERMOSTAT

Fig. 5A — System Zone Relay Wiring

(Aquazone™ System Control Panel Used to

Control a Single Thermostat)

PANEL 24 VAC POWER

FIRE

FREEZE,

ETC.

SWITCH S-1

Fig. 5C — Control Relay Wiring for Pump

Start/Stop or Cooling Tower Fan

TP WIRES

(+)

(-)

TO COMFORT CONTROLLER

STARTER

COIL

CONTROL RELAY OR STAGING CARD

OL’

TO OTHER WSHP COMPLETE C CONTROLS AND THERMOSTATS

SYSTEM ZONE

RELAYS

(1-18)

Fig. 5B — System Zone Relay Wiring

(Aquazone System Control Panel Used to Control Multiple Thermostats)

COMPLETE C CONTROL

RYW OGC

TYPICAL FIELD-INSTALLED RELAYS (ONE PER WSHP)

(IN WSHP)

THERMOSTAT

ZONE THERMOSTAT CONTROL RELAYS — A unique feature of the Aquazone system control panel is the capability to add zone ther mostat contr ol rela ys. T his feat ure is used w hen th e Aquazone system control panel i s utilized in a st and-alone type of installation. Eithe r a set of 10 or 18 relays can be selected from the 50RLP model nomenclat ure in digi t 9 to control ei the r 10 or 18 zones, respectively. If selected in the model nomencl ature, zone control relays are located on the right hand side of the system control panel. See Fig. 4. See Fig. 5A-5C for wiring.

CONTROL TRANSFORMERS — Control transformers are supplied with the Aquazone system control panel and are wired to the power switch and convenience outlet. The control transformers provide power to the nominal 24 VAC circuit in Aquazone system control panel. The contractor will supply the

primary power to the power switch and conve nience outlet in the field. Transformers include a manual reset button for resetting the circuit breaker. Control transformers are located on the bottom half of the system control panel. Specifications for the control transformers are as follows:

Primary: 120/208/240 vac Secondary: 24 vac Frequency: 60 Hz

MOUNTING RAILS AND WIRING DUCT — All exposed panel wiring is low voltage. Line voltage wiring to the control transformers, control circuits for pumps, cooling tower fans, and boilers is factory-installed in conduit, using wiring duct, and on mounting rails.

POWER RECEPTACLE — A power receptacle is provided in the Aquazone™ system control panel and is located in the bottom left corner. Specifications for the power receptacle are as follows:

Power: 120 vac Rating: 15A @ 120 vac for receptacles

15A @ 120 vac for switch 250 V for fuse

WATER TEMPERATURE SENSORS — Two water temperature sensors and thermowells have been provided with the Aquazone system control panel. The first sensor is utilized to read loop supply water temperature, such that the system control panel can adjust heat rejection and heat addition equipment to maintain the loop temperature based on user input. The second sensor may be installed to monitor return loop water temperature. The active sensing element is a highly stable precision thermistor material accurate to within ± 0.36 F. The temperature range of the sensor is 10 F to 230 F.

WATER PRESSURE SENSOR — A water pressure sensor is provided with the Aquazone system control panel with variable speed pumping only , and is utilized to operate variable frequency drives for system pumps. The water sensor senses system pressure and the pressure is sent to the system control panel. The Aquazone system control panel speeds up or slows down the variable frequency drive to control the pump in order to keep the system at the correct pressure.

When a variable frequency drive is used for system pumping, the Aquazone water source heat pumps are typically furnished with a factory or field-mounted solenoid valve that allows water to flow though the heat pump. When solenoid valves open, the system pressure drops, which results in the variable frequency drive speeding up to allow the pump to

provide more water. When solenoid valves close, the system pressure rises, which results in the variable frequency drive slowing down to allow the pump to provide less water.

WATER FLOW SWITCH — A factory-provided wat er flow switch is included with the Aquazone system control panel and must be field-installed in the water loop piping. The flow switch is connected to the control panel by a cable with a watertight connector. This device uses a triac output that cannot be connected directly to the Main Base Board. Therefore, a control relay is used to signal the Main Base Board that loop water flow is detected. The switch contains a fifteen-turn adjustment potentiometer, to be used to adjust the set point in a range of 3 to 60 cm/sec. The factory set point is 20 cm/sec.

The potentiometer switch may be adjusted down to zero velocity (no flow) or above 60 cm/sec, however operation in those ranges may not be linear or reliable.

Water Source Heat Pumps with PremierLink™ Controller Hardware —

tion is implemented, a factory-mounted PremierLink controller is provided with the water source heat pump units. The package from the factory includes the PremierLink controller, supply air temperature sensor , and leavi ng water t emperatur e sensor.

PREMIERLIN K CONTROLLER — PremierLink controllers can be provided with any Aquazone water source heat pump product by selecting this option in the model nomenclature. See Fig. 6.

The PremierLink controller is provided with the Complete C

unit controller . F actory sup plied wiring is i llustrated in F ig. 7.

When a CCN system installa-

Fig. 6 — PremierLink™ Control Module

Carrier’s diagnostic standard tier display tools such as Navigator™ or Scrolling Marquee can be used with the PremierLink™ controller. Access is available via an RJ-11 connection or a 3-wire connection to the communication bus. Computers equipped with Carrier user interface software such as Service Tool, ComfortVIEW™, or ComfortWORKS® software are used to int erface with the system. W hen used as part of the CCN, other devices such as the CCN data transfer, Linkage Thermostat, or system control panel comfort controller can read data from or write data to the PremierLink Controller.

SUPPLY AIR TEMP ERATURE SENSOR — A factoryinstalled supply air temperature sensor is provided with the PremierLink controller. Wiring of the temperature sensor is shown in Fig. 7. The sensor is a 10 kohm thermistor, which is protected by a stainless steel housing probe. Probe is

/4-inch in diameter and 1.5-in. long. Wire is 22 AWG (American Wire Gage), 7/30 copper wire, PVC white, 2 conductor type.

LEAVING WATER TEMPERATURE SENSOR — A factoryinstalled leaving water temperature sensor is provided with PremierLink controller. Wiring of the temperature sensor is shown in Fig. 7. The sensor is a 10 kohm thermistor is protected by a stainless steel housing probe. Probe is

/4-inch. in diameter and 1.5-in. long. Wire is 22 AWG , 7/30 copper wi re, PVC white, 2 conductor type.

Field-Supplied Hardware for Stand-Alone Systems —

stand-alone configuration, individual Aquazone thermostats (or compatible equivalent) are required for water source heat pump units.

AQUAZONE THERMOSTAT — A field-supplied Carrier thermostat is required to maintain space temperature for standalone water source heat pump installations. There are five different Aquazone thermostats available for stand-alone applications. See Table 1.

T o utilize the Aquazone™ system control panel in a

LEGEND

CR — LW T — SAT — SPT —

NOTE: Reversing valve is on in Cooling mode.

Control Relay Leaving Water Temperature Sensor Supply Air Temperature Sensor Space Temperature Sensor

S P T

S A

PREMIER

LINK

PWR

CMPSAFE

PWR

HS1/EXH/RVS

CMP1

FAN

COMPLETE

CONTROL

AL1

AL2

Fig. 7 — PremierLink Controller Applications with Complete C Control

Table 1 — Aquazone™ Thermostats

ORDERING

NUMBER

50QE900-220WS

50QE900-220LA

50QE900-NPWS

50QE900-511WS

50QE900-250FS

THERMOSTAT TYPE FUNCTIONS

Aquazone 7-Day Programmable 2 stages heating, 2 stages cooling, auto changeover

Fahrenheit and Celsius temperature scales

Carrier

AUTO

COOL

HEAT

4 settings per day 24 vac Backlit LCD Keypad 5-minute compressor protection NEVERLOST™ memory 3 security levels

Aquazone Light Activated, 7-Day Programmable

2 stages heating, 2 stages cooling, auto changeover

4 settings per day

Carrier

AUTO

COOL

HEAT

24 vac

Keypad lockout

5-minute compressor protection

Occupied with lights on, unoccupied with lights off

NEVERLOST memory

3 security levels

Aquazone Non-programmable 2 stages heating, 2 stages cooling, auto changeover

5-minute built-in compressor protection

Locking cover included Fahrenheit and Celsius temperature scales

AUTO

COOL

HEAT

Large display Keypad lockout Backlit display or B terminal NEVERLOST memory Dual set point with adjustable deadband Back plate with terminals

Aquazone 5-1-1 day programmable 2 stages heating, 2 stages cooling, auto changeover

5-minute built-in compressor protection

Keypad lockout and locking cover included Fahrenheit and Celsius temperature scales

AUTO

COOL

HEAT

4 settings per day Backlit and configurable display O or B terminal NEVERLOST memory Dual set point with adjustable deadband Self prompting program

Aquazone Flush Mount, 7-Day Programmable 2 stages heating, 2 stages cooling, auto changeover

4 settings per day, Holiday/vacation programming Self prompting program with copy command locking

cover plate with tamperproof screws Fahrenheit and Celsius temperature scales Set point limiting Mounts flush to the wall NEVERLOST memory Dual set point with adjustable deadband and B terminal Remote sensor capability (sold separately): Wireless,

(33CSRFS-RC transmitter and 33CSRFS-RE receiver), wired with override (33CSCEN-WB), duct mounted (33CSSEN-DS)

Field-Supplied Hardware For CCN Applications —

the water source heat pump unit is configurable with a variety of Carrier space temperature sensors.

SP A CE TEMPERATURE SENSOR (SPT) — A field-supplied Carrier space temperature sensor i s required to mai ntain spac e temperature in sensor mode. There are three sensors ava ilable for this application: the 33ZCT55SPT Space Temperature Sensor with Override Button, the 33ZCT56SPT Space Temperature Sensor with Override Button and Set Point Adjustment, and the 33ZCT58SPT T58 Communicating Room

The factory-installed PremierLink™ controller for

Sensor with Override Button, Set Point Adjustment, and Manual fan control.

INDOOR AIR QUALITY CO quality sensor is required for CO

SENSOR — An indoor air

level monitoring. Three

different CO2 sensors are available for this application: the 33ZCSENCO2 sensor is an indoor, wall-mounted sensor with an LED display, the 33ZCT55CO2 sensor is an indoor, wall-mounted sensor without display (also includes a space temperature sensor with override button), the 33ZCT56CO2 sensor is an indoor, wall-mounted sensor without display (also includes a space temperature sensor with override button and temperature offset).

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