Carrier 50RTG User Manual

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Page 1

Rooftop Water Source Heat Pump Units

Installation, Start-Up, and

Service Instructions

50RTG

CONTENTS

Page

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

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

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

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

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

• STORAGE

• PROTECTION

• INSPECT UNIT

Step 3 — Location of Unit . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 4 — Mounting the Unit . . . . . . . . . . . . . . . . . . . . . . 6

Step 5 — Condensate Drain . . . . . . . . . . . . . . . . . . . . . . 6

Step 6 — Piping Connections . . . . . . . . . . . . . . . . . . . . 6

• WATER LOOP APPLICATIONS

• GROUND-WATER APPLICATIONS

• GROUND-LOOP APPLICATIONS

Step 7 — Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . . 7

• SUPPLY VOLT AGE

• 208-VOLT OPERATION

• BLOWER SELECTION

Step 8 — Low Voltage Wiring. . . . . . . . . . . . . . . . . . . . 14

• THERMOSTAT CONNECTIONS

• WATER FREEZE PROTECTION

• AIR COIL FREEZE PROTECTION

• ACCESSORY CONNECTIONS

• WATER SOLENOID VALVES

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14,15

System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

FIELD SELECTABLE INPUTS . . . . . . . . . . . . . . . .15,16

C Control Jumper Settings . . . . . . . . . . . . . . . . . . . . 15

C Control DIP Switches . . . . . . . . . . . . . . . . . . . . . . . 15

D Control Jumper Settings . . . . . . . . . . . . . . . . . . . . 15

D Control DIP Switches . . . . . . . . . . . . . . . . . . . . . . . 15

D Control Accessory Relay Configurations . . . . . 16

Water Valve (Slow Opening) . . . . . . . . . . . . . . . . . . . 16

Outside Air Damper (OAD) . . . . . . . . . . . . . . . . . . . . 16

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Scroll Compressor Rotation. . . . . . . . . . . . . . . . . . . . . 17

Unit Start-Up Cooling Mode . . . . . . . . . . . . . . . . . . . . . 17

Unit Start-Up Heating Mode . . . . . . . . . . . . . . . . . . . . . 17

Flow Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Cooling Tower/Boiler Systems . . . . . . . . . . . . . . . . . . 18

Ground Coupled, Closed Loop and Plateframe

Heat Exchanger Well Systems . . . . . . . . . . . . . . . . 18

Page

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Power Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Units with Aquazone™ Complete C Control . . . . . 19

Units with Aquazone Deluxe D Control . . . . . . . . . . 19

SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19,20

Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Retry Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Aquazone Deluxe D Control LED Indicators . . . . . 20

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Wat er Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Condensate Drain Pans . . . . . . . . . . . . . . . . . . . . . . . . . 21

Refrigerant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Condensate Drain Cleaning . . . . . . . . . . . . . . . . . . . . . 21

Air Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Condenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Checking System Charge . . . . . . . . . . . . . . . . . . . . . . . 22

Refrigerant Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Air Coil Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . 22

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 22-25

Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Control Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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 functions of cleaning coils and filters and replacing filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the li terature, t ags and labe ls attached to the uni t, 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.

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. 535-004 Printed in U.S.A. Form 50R-2SI Pg 1 8-02 Replaces: New

Page 2

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and the National Electrical Code (NEC) for special installation requirements.

Understand the signal words — DANGER, WARNING, and CAUTION. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards that could result in personal injury or death. CAUTION is used to identify unsafe practices , which would result in minor personal injury or product and property damage.

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

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

This Installati on and Start-Up Instructions liter ature is for Aquazone™ Rooftop W ater Source Heat Pump systems.

Rooftop Water Source Heat Pumps (WSHP) are singlepackage outdoor units with electronic controls desi gned for year-round cooling and heat ing.

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 becom e 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 Ta ble 1 f or u nit physical data.

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

Step 2 — Check Unit —

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

Installation, operation and

Upon receipt of shipment at

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 to provide freeze protection for piping, as required. Well water applications are espec ially susceptible to freezing.

3. Be sure the installation location is isolated from sleeping areas, private offices and other acoustically sensitive spaces.

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

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

6. Provide sufficient space fo r duct connection.

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

8. Provide sufficient access to allow maintenance and servicing of the fan and fan motor, compressor and coils.

9. Provide an unobstructed path to the unit. Space should be sufficient to allow removal of unit if necessary.

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

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

STORA GE — If the equi pment is not installed immediately 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 unit stacking is necessary, stack 50RTG03-10 units a maximum of 2 high. Do not stack units larger than 50RTG10. Do not remove any equipment from its shipping package until it is needed.

PROT ECT ION — Onc e 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.

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.

Page 3

INSP EC T 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 enteri ng water temperature of the job.

3. Do not remove the packaging until the unit is ready for installatio n.

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. Compressors are internally spring-mounted. Compressors equipped with external spring vibration isolators must have bolts loosened and shipping clamps removed.

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

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

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

Step 3 — Location of Unit —

The following guidelines should be considered when choosing a location for WSHP. Refer to Fig. 1 and 2 for unit dimensional data:

• Provide sufficient space for water, electrical and duct

connections

• Locate unit in an area that allows for easy access and

removal of filter and access panels

• Allow enough space for service personnel to perform

maintenance

Table 1 — Physical Data — Aquazone™ 50RTG03-20 Units

UNIT 50RTG 03 04 05 07 08 10 12 15 20 OPERATING WEIGHT (lb) 735 785 835 880 1080 1125 1175 1770 1960 SHIPPING WEIGHT (lb) 750 800 850 900 1100 1150 1200 1800 2000 REFRIGERANT TO AIR HEAT EXCHANGER

Face Area (sq ft) 5 5 5 7.5 9.3 9.3 10.5 20 20 Rows Deep 233333344 Copper Tube Size (in.)

No. Fins per Inch 12 12 12 12 12 12 12 12 12 REFRIGERANT CHARGE R-22/Ckt (oz) 52 68 86 132 68 86 88 141 160 NUMBER OF CIRCUITS 111122222 BLOWER DATA

Diameter (qty-in.) 1-10 1-10 1-10 1-12 1-15 1-15 1-15 2-15 2-15

Width (in.) 6 6 10 11 11 11 11 11 11 FILTER DATA

Size (in.) 16 x 20 16 x 20 16 x 20 16 x 20 16 x 20 16 x 20 16 x 20 16 x 20 16 x 20

Quantity 4444666106

Page 4

OUTSIDE AIR

OPENING

AIR

OUTSIDE

NOTES:

AIR

RETURN

AIR

FLOW

AIR

RETURN

1" FPT

CONDENSATE DRAIN

TOP

AIR

SUPPLY

and specification of each product at the time of order may be changed with-

out notice.

1. All dimensions are in inches.

2. Carrier works continuously to improve its products. As a result, the design

3. Assembly tolerances ±

9-13/16

VIEW

SIDE

AIR

SUPPLY

VIEW

5-13/16

DIMENSIONS (in.)

Water

Outside Air

UNITS

50RTG

In/Out (FPT)

Opening Size

ABCDEF

03/04 39.52 43.90 81.00 12.32 4.692 6.614 12.57 x 30.00

PIPE CHASE

ELECTRICAL &

Fig. 1 — 50RTG Dimensional Data

FRONT

VIEW

05 39.52 43.90 81.00 12.32 4.692 6.614 12.57 x 30.00 1

07 39.52 43.90 81.00 12.32 4.692 6.614 12.57 x 30.00 1

08 45.40 49.90 91.07 16.48 5.692 6.614 18.95 x 36.00 1

10/12 45.40 49.90 91.07 16.48 5.692 6.614 18.95 x 36.00 1

15/20 50.62 88.00 91.07 16.48 4.543 6.566 18.95 x 74.00 2

Page 5

RETURN AIR

TRANSITION

SUPPLY AIR

TRANSITION

(TYP)

3.000 3.000

(TYP)

REQUIREMENTS

BY CONTRACTOR'S

HEIGHT DETERMINED

3-7/8"

TO THE NOTED DIMENSIONS. THIS IS TO ALLOW

CLEARANCE FOR MOUNTING UNIT TO CURB.

ROOF DECK/ROOFING

FLASHING

14.00 (REF)

ROOF CURB ASSEMBLY DETAILS

(FIELD SUPPLIED)

TRANSITION DETAIL

IMPORTANT NOTE: WHEN INSTALLING CURB, FLASHING MUST CONFORM

BASE PAN OF UNIT

CURB WALL

STRUCTURAL SUPPORT

23.000

Fig. 2 — 50RTG Roof Curb Dimensional Data

14-15/16

Return Air Transition Supply Air Transition

DIMENSIONS (in.)

GH J K GH J K

ABCEF

ROOF CURB

50RTGACURBCAAA 35.25 72.25 18.00 1.50 12.50 22.00 16.00 39.25 33.25 27.00 21.00 39.25 33.25

50RTGACURBBAAA 41.25 82.25 21.00 1.50 12.50 25.00 19.00 45.25 39.25 27.00 21.00 45.25 39.25

Return Air

Supply

Air

50RTGACURBAAAA 78.875 82.25 21.00 5.00 9.00 25.00 19.00 82.875 76.875 27.00 21.00 82.875 76.875

2.00 TYP.

14.00 (REF)

Page 6

Step 4 — Mounting the Unit —

For proper operation, units must be mounted on a roof curb as shown in Fig. 3. Follow these guidelines when installing the roof curb:

1. Set unit on curb.

2. Align unit so that its return and supply air direction match the return and supply air opening in the roof curb frame.

3. Run both the return and supply loop piping, as well as the electrical supply line, through the pipe chase provided in the curb.

Step 5 — Condensate Drain

1. Install a condensate trap at each unit with the top of the trap positioned below the unit condensate drain connection.

2. Design the length of the trap (water seal) based on the amount of positive or negative pressure on the drain pan. As a rule, 1 in. of trap is required for eac h inch of negative pressure on the unit.

Note that condensate is allowed to drain onto the roof.

Step 6 — Piping Connections —

application, there are 3 types of WSHP piping systems to choose from: water loop, ground-water and ground loop. Refer to Piping Section of Carrier System Design Manual for additional information.

All WSHP units use 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. Refer to Table 1 for connection sizes. When making piping connections, consider the following:

• Use a backup wrench when making screw connections to

unit to prevent internal damage to piping.

• Ins ulat ion may b e re quir ed on pipin g t o avoi d co nden sa-

tion 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.

Depending on the

50 RTG UNIT

WA TER 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 2.25 and 3 gpm per ton of cooling capacity. For proper maintenance and servicing, pressure-temperature (P/T) ports are necessary for temperat ure and flow verification.

In addition to complying with any applicable codes, consider the following for system piping:

• Piping systems utilizing water temperatures below

50 F require

/2-in. closed cell insulation on all pipi ng

surfaces to eliminate condensation.

• All plastic to me tal threaded fittings should be avoided

due to the potential to leak. Use a flange fitted substitute.

• Teflon tape thread sealant is recommended to minimize

internal fouling of the heat exchanger.

• Use backup wrench. Do not overtighten connections.

• Route piping to avoid service access areas to unit.

• The piping system should be flushed prior to operation to

remove dirt and foreign materials from the system. GROUND-WATER APPLICATIONS — In addition to com-

plying with any applicable codes, consider the following for system piping:

• Install shut-off valves for servici ng.

• Install pressure-temperature plugs to measure flow and

temperature.

• Boiler drains and other valves should be connected using

a “T” connector to allow acid flushing for the heat

exchanger.

• Do not overtighten connections.

• Route piping to avoid service access areas to unit.

• Use PVC SCH80 or copper piping material. NOTE: PVC SCH40 should not be used due to system high

pressure and temperature extremes. Water Supply and Quantity

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

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

GASKET

CURB

Fig. 3 — 50RTG Curb Installation

FLASHING

ROOF

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.

GROUND-LOO P APPL ICATIONS — Te mp erat ure s b etw een 25 to 110 F and a cooling capacity of 2.25 to 3 gpm of fl ow per ton is 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 me tal threaded fittings should be avoided

due to the potential to leak. Use a flange fitted substitute.

• Do not overtighten connections.

• Route piping to avoid service access areas to unit.

• Pressure-temperature (P/T) plugs should be used to mea-

sure flow of pressure drop.

Page 7

Step 7 — Electrical Wiring

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.

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

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

Refer to unit wiring diagram Fig. 4 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.

Operating voltage must be the same voltage and phase as shown in Electrical Data shown in T able 3.

Make all final electrical connections with a length of flexible conduit to minimize vibration and sound transmission to the building.

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

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

% Voltage Imbalance

= 100 x Example: Supply voltage is 460-3-60.

max voltage deviation from average voltage

average voltage

AB = 452 volts BC = 464 volts AC = 455 volts

A verage Voltage =

452 + 464 + 455

1371

= 457 Determine maximum deviation from average voltage: (AB) 457 – 452 = 5 v

(BC) 464 – 457 = 7 v (AC) 457 – 455 = 2 v

Maximum deviation is 7 v. Determine percent voltage imbalance.

% Voltage Imbalance = 100 x

457

= 1.53%

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.

208-VOLT OPERATION — A ll 208-230 volt units are factory wired for 208 volts. The transformers may be switched to 230-volt operation (as illustrated on the wiring diagram) by switching the red (208 volt) wire with t he orange (230 volt) wire at the L1 terminal.

BLOW E R SEL EC TI O N — All water source heat pumps are factory set with the appropriate motor and sheave combination to achieve the desired airflow performance. Performance is selected by matching the desired performance with the appropriate region in Tables 4-12. Per the table notes, regions designated by A, B, C and D represent motor drive options.

NOTE: Factory-installed sheaves are field adjustable. Refer to T ables 4-12 for adjustment points.

Table 2 — Water Quality Guidelines

CONDITION ACCEPTABLE LEVEL pH Total Hardness Iron Oxides Iron Bacteria Corrosion*

Brackish

*If the concentration of these corrosives exceeds the maximum allowable level, then the potential for serious corrosion

problems exists.

†Sulfides in the water quickly oxidize when exposed to air, requiring that no agitation occur as the sample is taken.

Unless tested immediately at the site, the sample will require stabilization with a few drops of one Molar zinc acetate solution, allowing accurate sulfide determination up to 24 hours after sampling. A low pH and high alkalinity cause system problems, even when both values are within ranges shown. The term pH refers to the acidity, basicity, or neutrality of the water supply. Below 7.0, the water is considered to be acidic. Above 7.0, water is considered to be basic. Neutral water contains a pH of 7.0.

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

7 to 9 range for copper. Cupro-nickel may be used in the 5 to 9 range. Calcium and magnesium carbonate should not exceed 20 grains per gallon (350 ppm). Less than 1 ppm. No level allowable.

Ammonia, Ammonium Hydroxide 0.5 ppm Cu Ammonium Chloride, Ammonium Nitrate 0.5 ppm Cu Ammonium Sulfate 0.5 ppm Cu Chlorine/Chlorides 0.5 ppm CuNi Hydrogen Sulfide† None Allowable —

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

Max Allowable Level Coaxial Metal

Page 8

50RTG03-07 WITH ECONOMIZER AND COMPLETE C CONTROLLER

Ground

24V

SEE NOTE 7

BLU

YEL

AL1 AL2

GRY

Alarm Relay

Disconnect

OR CB

(Optional)

GRY

BRG

Test Pins

FP1 FP2

JW1

SEE NOTE 6

Power Supply

Refer to Data Plate

Use copper conductors only.

RED (208V)

VIO or BLK/RED

(460V)

BLU

BLK

SEE

NOTE 3

ORG

230V

Compressor

Cooling

Fan

24 V A C

Common

Alarm

Typical T-stat

SEE NOTE 5

LEGEND

AL — Alarm Relay Contacts BC — Blower Mtr Contactor CB — Circuit Breaker CC — Compressor Contactor ECR — Economizer Relay EH1 — Auxiliary Heat Stage 1 EH2 — Auxiliary Heat Stage 2 ES — Enthalpy Sensor FP1 — Sensor, Water Coil Freeze Protection FP2 — Sensor, Air Coil Freeze Protection HP — High Pressure Switch JW1 — Jumper, Alarm Mode LAR — Low Ambient Relay LOC — Loss-of-Charge Pressure Switch MAS — Mixed Air Sensor NEC — National Electrical Code OAT — Outside Air Thermostat

BRN

SEE NOTE 4

BLK

CCG

LAR

BRN

Compressor Relay

Dip Switch

Off On

Power

Distribution

Block

1 2

Not Used

Status

LED

YEL

Microprocessor

Control Logic

PM — Performance Monitor P1 — Field Wiring Terminal Block RVS — Reversing Valve Solenoid

Relay Contactor Coil

Solenoid Coil

Thermistor

Ground

Field Line Voltage Wiring

Field Low Voltage Wiring

Printed Circuit Trace

LOC

FP1

FP2

24V DC

EH1 EH2

BLK

2 3

4 5

6 7

8 9

SEE NOTE 7

Not Used

115V / 1PH

BLK

BRN

VIO

BRN

TR1

TR S

RED RED BLU BRN GRY GRY VIO VIO BRN ORG

Compressor

Blower Motor

YEL

NOTES:

1. Compressor and blower motor thermally protected internally.

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

3. 208/230 v transformers will be connected for 208 v operations. For 230 v operations, disconnect Red lead at L1, and attach Orange lead to L1. Close open end of Red Lead with insulating tape.

4. FP1 jumper provides freeze protection for WATER. When using ANTI-FREEZE solutions, cut FP1 jumper.

5. Typical ther mostat wiring shown. Refer to thermostat Installation Instructions for wiring to the unit.

6. 24 v alarm signal shown. For dry alarm contact, cut JW1 jumper and dry contact will be available between AL1 and AL2.

7. Transformer secondary ground via Complete C board standoffs and screws to control box. (Ground available from top two standoffs as shown.)

Logic Module

(Damper Actuator)

BLUGRY

600 150

Ohm Ohm

BLK

YEL

OAT

WHT TAN

ECR

BRN

LOC

FP1

FP2

RVS

BRN

ECR

WHT GRN

Field

BLK

Wiring

GFI

(Optional)

MAS

GRY BRN

134TT1P

BRN

LAR

ORG

Fig. 4 — Typical Aquazone™ Complete C Control Wiring

Page 9

Table 3 — 50RTG Electrical Data

UNIT

50RTG

LEGEND

FLA — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration LRA — Lock Rotor Amps RLA — Rated Load Amps

NOTE: Contact factory for oversize blower motor electrical data.

POWER SUPPLY

Voltage Hz Ph RLA LRA QTY HP FLA QTY

208/230 60 3 10.7 63.0 1 1 3.6 1 25 Amp 17.0

460 60 3 5.0 31.0 1 1 1.8 1 15 Amp 8.1

208/230 60 3 13.9 88.0 1 1 3.6 1 30 Amp 21.0

460 60 3 6.4 44.0 1 1 1.8 1 15 Amp 9.8 575 60 3 5.3 34.0 1 1 1.6 1 15 Amp 8.2

208/230 60 3 20.0 123.0 1 1 3.6 1 45 Amp 28.6

460 60 3 7.5 49.5 1 1 1.8 1 15 Amp 11.2 575 60 3 6.4 40.0 1 1 1.6 1 15 Amp 9.6

208/230 60 3 20.7 156.0 1 2 6.2 1 50 Amp 32.1

460 60 3 10.0 70.0 1 2 3.1 1 25 Amp 15.6 575 60 3 8.2 54.0 1 2 2.3 1 20 Amp 12.6

208/230 60 3 13.9 88.0 2 2 6.2 1 50 Amp 37.5

460 60 3 6.4 44.0 2 2 3.1 1 20 Amp 17.5 575 60 3 5.3 34.0 2 2 2.3 1 15 Amp 14.2

208/230 60 3 20.0 123.0 2 2 6.2 1 70 Amp 51.2

460 60 3 7.5 49.5 2 2 3.1 1 25 Amp 20.0 575 60 3 6.4 40.0 2 2 2.3 1 20 Amp 16.7

208/230 60 3 19.3 123.0 2 3 9.2 1 70 Amp 52.6

460 60 3 10.0 62.0 2 3 4.3 1 35 Amp 26.8 575 60 3 7.8 50.0 2 3 3.4 1 25 Amp 21.0

208/230 60 3 20.7 156.0 2 3 9.2 1 70 Amp 55.8

460 60 3 10.0 70.0 2 3 4.3 1 35 Amp 26.8 575 60 3 8.2 54.0 2 3 3.4 1 30 Amp 21.9

208/230 60 3 33.3 232.0 2 5 13.2 1 125 Amp 88.1

460 60 3 17.0 116.0 2 5 6.6 1 60 Amp 44.9 575 60 3 12.8 97.0 2 5 5.6 1 45 Amp 34.4

COMPRESSOR

(each)

BLOWER

MOTOR

MAX. FUSE

OR HACR

BREAKER

MINIMUM

CIRCUIT

AMPACITY

Table 4 — 50RTG03 Blower Performance

SCFM

AIRFLOW

975

1050

1125

1200

1275

1350

1425

LEGEND

BHP — Brake Horsepower SCFM — Standard Cubic Feet Per Minute

NOTES:

1. Fan BHP includes drive losses.

2. Region “A” is standard drive package.

3. Regions “B” and “C” require optional drive packages.

4. For applications requiring higher static pressures, contact your local representative.

BHP 0.12 0.14 0.17 0.19 0.21 0.23 0.26 0.29 0.31 0.33

RPM 550 609 667 724 779 833 885 933 980 1024

Turns Out 5.0 3.5 4.5 3.5 2.5 1.5 1.0 0.0 2.0 1.5

BHP 0.14 0.17 0.19 0.22 0.24 0.26 0.30 0.32 0.35 0.37

RPM 580 636 691 745 798 849 898 946 991 1035

Turns Out 4.0 3.0 4.0 3.0 2.5 1.5 0.5 0.0 2.0 1.5

BHP 0.18 0.20 0.23 0.25 0.28 0.31 0.33 0.36 0.39 0.42

RPM 619 670 721 772 821 870 917 963 1008 1051

Turns Out 3.5 4.5 3.5 3.0 2.0 1.0 0.5 2.5 2.0 1.0

BHP 0.22 0.24 0.26 0.29 0.32 0.35 0.37 0.41 0.44 0.46

RPM 658 705 752 799 846 892 937 982 1025 1066

Turns Out 4.5 4.00 3.00 2.5 1.5 1.0 0.0 2.0 1.5 1.0

BHP 0.26 0.29 0.31 0.33 0.36 0.40 0.42 0.45 0.48 0.52

RPM 688 732 777 822 867 911 954 997 1038 1079

Turns Out 4.0 3.5 2.5 2.0 1.5 0.5 2.5 2.0 1.5 1.0

BHP 0.29 0.32 0.35 0.39 0.41 0.44 0.47 0.51 0.54 0.57

RPM 721 764 807 850 893 935 976 1017 1057 1096

Turns Out 3.5 3.0 2.5 1.5 1.0 0.0 2.0 1.4 1.0 0.5

BHP 0.4 0.40 0.42 0.44 0.46 0.50 0.53 0.56 0.61 0.64

RPM 763 803 843 883 923 963 1003 1041 1080 1118

Turns Out 3.0 2.5 1.5 1.0 0.5 2.5 2.0 1.5 1.0 0.5

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

EXTERNAL STATIC PRESSURE (in. wg)

Page 10

Table 5 — 50RTG04 Blower Performance

SCFM

AIRFLOW

1300

1400

1500

1600

1700

1800

1900

LEGEND

BHP — Brake Horsepower SCFM — Standard Cubic Feet Per Minute

NOTES:

1. Fan BHP includes drive losses.

2. Region “A” is standard drive package.

3. Regions “B” and “C” require optional drive packages.

4. Region “D” represents oversized motor and special sheaves.

5. For applications requiring higher static pressures, contact your local representative.

BHP 0.26 0.30 0.33 0.36 0.40 0.42

RPM 633 694 755 812 869 925

Turns Out 5 3.5 4.5 3.5 2.5 1.5

BHP 0.33 0.36 0.40 0.43 0.46 0.50 0.53 Operation Not Recommended

RPM 668 725 782 836 890 943 995

Turns Out 4 3.0 4.0 3.0 2.0 1.0 0.5

BHP 0.418 0.45 0.48 0.52 0.55 0.58 0.62 0.65

RPM 712 766 819 871 922 970 1017 1063

Turns Out 3.0 4.5 3.5 2.5 1.5 0.5 3.5 3.0

BHP 0.506 0.54 0.57 0.61

RPM 750 801 851 900 948 995 1040 1083 1125 1166

Turns Out 4.5 3.5 3.0 2.0 1.0 0.0 3.5 1.5 2.0 1.5

BHP 0.572 0.62 0.66 0.70 0.74 0.78 0.81 0.86 0.89 0.94

RPM 792 840 887 934 979 1024 1068 1110 1152 1194

Turns Out 4.0 3.0 2.0 1.5 0.5 3.5 3.0 2.5 1.5 1.0

BHP 0.671 0.72 0.76 0.80 0.85 0.89 0.94 0.97 1.01 1.06

RPM 832 878 923 967 1010 1053 1095 1136 1176 1219

Turns Out 3.0 2.5 1.5 1.0 0.0 3.0 2.5 2.0 1.5 1.0

BHP 0.80 0.85 0.89 0.94 0.98 1.02 1.07 1.11 1.16 1.20

RPM 875 919 961 1003 1045 1086 1127 1166 1204 1242

Turns Out 2.5 1.5 1.0 0.0 3.0 2.5 2.0 1.5 1.0 0.5

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

EXTERNAL STATIC PRESSURE (in. wg)

0.64

0.67 0.70 0.75 0.78 0.83

Table 6 — 50RTG05 Blower Performance

SCFM

AIRFLOW

1700

1800

1900

2000

2100

2200

2300

LEGEND

BHP — Brake Horsepower SCFM — Standard Cubic Feet Per Minute

NOTES:

1. Fan BHP includes drive losses.

2. Region “A” is standard drive package.

3. Regions “B” and “C” require optional drive packages.

4. Region “D” represents oversized motor and special sheaves.

5. For applications requiring higher static pressures, contact your local representative.

BHP 0.37 0.42 0.45 0.50 0.54 0.58 0.63 0.67

RPM 797 845 892 938 984 1029 1072 1114

Turns Out 3.5 2.5 1.5 3.0 2.5 1.5 1.0 0.5

BHP 0.44

RPM 836 882 927 971 1015 1057 1099 1140 1180

Turns Out 2.5 1.5 3.5 2.5 2.0 1.0 0.5 0.5 0.0

BHP 0.52 0.56 0.61 0.65 0.69 0.74 0.78 0.84 0.88 0.94

RPM 880 923 966 1008 1049 1090 1131 1170 1208 1246

Turns Out 1.5 3.5 3.0 2.0 1.5 0.5 0.5 0.0 3.0 2.5

BHP 0.61 0.65 0.69 0.74 0.78 0.84 0.88 0.94 0.98 1.03

RPM 926 967 1007 1047 1087 1126 1164 1203 1240 1277

Turns Out 3.5 3.0 2.0 1.5 1.0 0.5 0.0 3.0 2.5 2.0

BHP 0.69 0.74 0.78 0.84 0.88 0.94 0.98 1.03 1.09 1.14

RPM 966 1005 1044 1082 1120 1158 1195 1231 1268 1303

Turns Out 3.0 2.0 1.5 1.0 0.5 0.0 3.0 2.5 2.0 1.5

BHP 0.79 0.84 0.89 0.94 0.99 1.05 1.09 1.14 1.20 1.25

RPM 1009 1047 1084 1120 1157 1193 1229 1264 1298 1333

Turns Out 2.0 1.5 1.0 0.5 3.5 3.0 2.5 2.0 1.5 1.0

BHP 0.9 0.96 1.00 1.06 1.11 1.17 1.22 1.28 1.33 1.39

RPM 1055 1091 1126 1161 1196 1231 1265 1299 1332 1365

Turns Out 1.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

0.48

0.53 0.56 0.61 0.65 0.70 0.75 0.79

EXTERNAL STATIC PRESSURE (in. wg)

Operation Not

Recommended

Page 11

Table 7 — 50RTG07 Blower Performance

SCFM

AIRFLOW

1950

2200

2400

2600

2800

3000

3250

LEGEND

BHP — Brake Horsepower SCFM — Standard Cubic Feet Per Minute

NOTES:

1. Fan BHP includes drive losses.

2. Region “A” is standard drive package.

3. Regions “B” and “C” require optional drive packages.

4. Region “D” represents oversized motor and special sheaves.

5. For applications requiring higher static pressures, contact your local representative.

BHP 0.42 0.46 0.51 0.56 0.62 0.67 0.73 0.78

RPM 620 664 707 750 792 832 870 908 Operation Not Recommended

Turns Out 4.5 3.5 2.5 4.5 3.5 2.5 2.0 1.5

BHP 0.56 0.62 0.67 0.73 0.78 0.85 0.90 0.97 1.03 1.10 1.17

RPM 675 716 755 793 831 869 905 941 975 1007 1038

Turns Out 3 2.0 4.5 3.5 3.0 2.0 1.5 0.5 5.0 3.0 2.5

BHP 0.70 0.76 0.83 0.88 0.95 1.00 1.07 1.14 1.21 1.28 1.34 1.41

RPM 721 758 795 830 865 900 935 969 1002 1034 1066 1097

Turns Out 2.0 4.5 3.5 3.0 2.0 1.5 0.5 0.0 4.5 4.0 3.5 3.0

BHP 0.87 0.94 0.99 1.06 1.12 1.19 1.25 1.33 1.40 1.47 1.55 1.63 1.69 1.77

RPM 765 800 835 868 901 933 965 997 1029 1060 1090 1120 1149 1178

Turns Out 4 3.5 3.0 2.0 1.5 0.5 0.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5

BHP 1.07 1.13 1.20 1.27 1.33 1.40 1.47 1.54 1.62 1.69 1.77 1.86 1.94 2.01

RPM 812 845 877 908 939 970 1000 1030 1059 1089 1118 1147 1175 1203

Turns Out 3.5 2.5 2.0 1.5 0.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0

BHP 1.28 1.35 1.42 1.50 1.56 1.64 1.72 1.79 1.87 1.95 2.02 2.11 2.20 2.28

RPM 857 889 919 949 978 1007 1035 1064 1091 1119 1147 1174 1202 1228

Turns Out 2.5 1.5 1.0 0.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 1.0

BHP 1.60 1.67 1.75 1.83 1.90 1.98 2.06 2.13 2.22 2.30 2.39 2.48 2.56 2.65

RPM 915 945 974 1001 1029 1056 1082 1109 1135 1161 1187 1212 1238 1263

Turns Out 1.0 0.5 5.0 4.5 4.0 3.5 3.0 2.5 2.5 2.0 1.5 1.0 1.0 0.5

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5

EXTERNAL STATIC PRESSURE (in. wg)

Table 8 — 50RTG08 Blower Performance

SCFM

AIRFLOW

2400

2650

2900

3200

3450

3700

4000

LEGEND

BHP — Brake Horsepower SCFM — Standard Cubic Feet Per Minute

NOTES:

1. Fan BHP includes drive losses.

2. Region “A” is standard drive package.

3. Regions “B” and “C” require optional drive packages.

4. Region “D” represents oversized motor and special sheaves.

5. For applications requiring higher static pressures, contact your local representative.

BHP 0.40 0.45 0.50 0.55 0.61 0.66 0.72 0.77 0.83 0.87 0.91 0.98 1.03 1.10

RPM 482 521 559 594 629 661 693 723 751 779 806 832 858 883

Turns Out 4.5 3.5 2.0 4.5 3.5 2.5 1.5 1.0 0.0 4.5 4.0 3.5 3.0 2.5

BHP 0.51 0.56 0.62 0.67 0.74 0.79 0.86 0.91 0.98 1.05 1.10 1.16 1.21 1.27

RPM 514 550 585 619 651 683 713 742 770 797 823 848 872 895

Turns Out 4 2.5 4.5 3.5 3.0 2.0 1.0 0.5 4.5 4.0 3.5 3.0 2.5 2.0

BHP 0.64 0.69 0.76 0.83 0.88 0.95 1.01 1.08 1.14 1.22 1.29 1.35 1.42 1.49

RPM 549 583 615 647 677 707 736 764 791 818 843 868 894 915

Turns Out 2.5 4.5 4.0 3.0 2.0 1.5 0.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0

BHP 0.81 0.88 0.95 1.02 1.09 1.16 1.23 1.30 1.38 1.45 1.52 1.60 1.67 1.74

RPM 588 619 649 679 707 735 763 789 815 841 865 890 913 936

Turns Out 5 3.5 3.0 2.0 1.5 0.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5

BHP 1.00 1.07 1.14 1.21 1.29 1.36 1.44 1.52 1.60 1.67 1.75 1.83 1.90 1.99

RPM 623 652 681 709 736 763 789 814 839 863 887 911 934 956

Turns Out 3.5 3.0 2.0 1.5 0.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0

BHP 1.20 1.28 1.35 1.43 1.51 1.60 1.67 1.75 1.84 1.91 2.00 2.08 2.17 2.26

RPM 657 685 712 739 764 790 815 839 863 886 909 932 954 976

Turns Out 2.5 2.0 1.0 0.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5

BHP 1.47 1.56 1.64 1.73 1.82 1.89 1.98 2.07 2.16 2.24 2.33 2.42 2.51 2.61

RPM 699 725 750 775 799 823 847 870 892 915 937 958 980 1001

Turns Out 1.5 1.0 0.0 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5

EXTERNAL STATIC PRESSURE (in. wg)

Page 12

Table 9 — 50RTG10 Blower Performance

SCFM

AIRFLOW

3000

3300

3600

4000

4300

4700

5000

LEGEND

BHP — Brake Horsepower SCFM — Standard Cubic Feet Per Minute

NOTES:

1. Fan BHP includes drive losses.

2. Region “A” is standard drive package.

3. Regions “B” and “C” require optional drive packages.

4. Region “D” represents oversized motor and special sheaves.

5. For applications requiring higher static pressures, contact your local representative.

BHP 0.69 0.76 0.83 0.89 0.96 1.02 1.09 1.16 1.22 1.29 1.36 1.43 1.50 1.57

RPM 563 596 628 658 688 718 746 773 800 826 851 876 900 923

Turns Out 4.5 3.5 2.5 1.5 1.0 4.0 3.5 3.0 2.5 2.0 1.5 0.5 0.0 2.5

BHP 0.89 0.96 1.03 1.10 1.18 1.24 1.32 1.39 1.46 1.54 1.62 1.69 1.77 1.85

RPM 604 635 664 693 721 748 775 801 827 852 876 900 923 946

Turns Out 3 2.5 1.5 4.5 4.0 3.5 3.0 2.5 2.0 1.0 0.5 0.0 2.5 2.0

BHP 1.12 1.201.28 1.35 1.431.511.581.661.751.83 1.90 1.99 2.07 2.16

RPM 647 676 703 730 756 782 807 832 856 880 903 926 949 971

Turns Out 2.0 1.0 4.5 4.0 3.5 2.5 2.0 1.5 1.0 0.5 0.0 2.5 2.0 1.5

BHP 1.47 1.56 1.64 1.73 1.82 1.89 1.98 2.07 2.16 2.24 2.33 2.42 2.51 2.61

RPM 699 725 750 775 799 823 847 870 892 915 937 958 980 1001

Turns Out 4.5 4.0 3.5 3.0 2.5 2.0 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5

BHP 1.82 1.90 1.99 2.09 2.18 2.27 2.35 2.45 2.54 2.64 2.73 2.83 2.93

RPM 746 770 794 817 840 863 885 907 929 950 971 991 1012

Tu r ns O ut 3 . 5 3 . 0 4.5 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 1.0 0.5

BHP 2.32 2.42 2.52 2.61 2.71 2.81 2.90

RPM 803 825 848 869 891 912 933

Tu r ns O ut 4.5 4.0 3.5 3.5 3.0 2.5 2.0

BHP 2.76 2.86 2.96

RPM 847 868 889

Tu r ns O ut 3.5 3.5 3.0

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5

EXTERNAL STATIC PRESSURE (in. wg)

Operation Not Recommended

Table 10 — 50RTG12 Blower Performance

SCFM

AIRFLOW

3600

4000

4400

4800

5200

5600

6000

LEGEND

BHP — Brake Horsepower SCFM — Standard Cubic Feet Per Minute

NOTES:

1. Fan BHP includes drive losses.

2. Region “A” is standard drive package.

3. Regions “B” and “C” require optional drive packages.

4. Region “D” represents oversized motor and special sheaves.

5. For applications requiring higher static pressures, contact your local representative.

BHP 1.02 1.10 1.18 1.25 1.33 1.41 1.49 1.56 1.64 1.72 1.80 1.88 1.97 2.05

RPM 609 639 667 695 722 748 774 800 825 849 873 896 919 942

Turns Out 5.5 4.5 3.5 2.5 1.5 5.5 4.5 3.5 3.0 2.5 1.5 1.0 4.5 4.0

BHP 1.38 1.45 1.54 1.62 1.71 1.78 1.87 1.96 2.05 2.13 2.22 2.31 2.40 2.49

RPM 664 691 717 742 767 792 816 839 863 886 908 930 952 973

Turns Out 4.5 3.0 2.0 5.5 4.5 4.0 3.5 2.5 2.0 1.5 4.5 4.0 3.5 3.0

BHP 1.77 1.86 1.96 2.05 2.13 2.23 2.32 2.41 2.51 2.61 2.70 2.79 2.89 2.98

RPM 716 741 765 789 812 835 858 879 901 923 944 965 985 1006

Turns Out 2.0 5.5 4.5 4.0 3.5 3.0 2.0 1.5 5.0 4.5 4.0 3.5 3.0 2.5

BHP 2.23 2.33 2.43 2.53 2.63 2.73 2.83 2.93 3.03 3.12 3.23 3.33 3.43 3.54

RPM 765 788 810 833 854 876 897 918 938 959 978 998 1018 1037

Turns Out 5.5 4.0 3.5 3.0 2.5 1.5 1.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5

BHP 2.82 2.93 3.04 3.14 3.25 3.36 3.47 3.58 3.69 3.78 3.89 4.00 4.11

RPM 825 846 867 888 908 928 948 968 987 1006 1025 1044 1062

Turns Out 4.5 2.5 5.5 5.0 4.5 4.0 3.5 3.5 3.0 2.5 2.0 1.5 1.0

BHP 3.47 3.58 3.70 3.81 3.93 4.04 4.16 4.27 4.39 4.51 4.62

RPM 879 899 918 938 957 976 995 1013 1031 1050 1067

Turns Out 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.5 1.0

BHP 4.20 4.33 4.46 4.58 4.70 4.82 4.95

RPM 933 952 970 989 1007 1025 1042

Turns Out 4.0 3.5 3.0 3.0 2.5 2.0 1.5

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5

EXTERNAL STATIC PRESSURE (in. wg)

Operation Not

Recommended

Page 13

Table 11 — 50RTG15 Blower Performance

SCFM

AIRFLOW

4500

5000

5500

6000

6500

7000

7500

LEGEND

BHP — Brake Horsepower SCFM — Standard Cubic Feet Per Minute

NOTES:

1. Fan BHP includes drive losses.

2. Region “A” is standard drive package.

3. Regions “B” and “C” require optional drive packages.

4. Region “D” represents oversized motor and special sheaves.

5. For applications requiring higher static pressures, contact your local representative.

BHP 0.68 0.78 0.88 0.98 1.08 1.17 1.28 1.39 1.43 1.54 1.65 1.76 RPM 465 506 545 582 617 650 681 711 740 768 795 821

Turns Out 5.0 3.5 2.5 4.5 4.0 3.5 2.5 2.0 1.0 4.0 3.5 3.0

BHP 0.87 0.98 1.09 1.20 1.31 1.42 1.52 1.65 1.76 1.87 1.94 2.07 2.16 2.31 RPM 493 531 568 603 636 669 701 732 762 791 819 846 872 897

Turns Out 4.0 3.0 2.0 4.5 3.5 3.0 2.0 1.0 4.0 3.5 3.0 2.5 1.5 1

BHP 1.10 1.22 1.33 1.45 1.57 1.71 1.83 1.94 2.07 2.20 2.31 2.44 2.51 2.64 RPM 525 561 595 627 659 690 720 749 777 804 830 855 879 902

Turns Out 3.0 2.0 4.5 4.0 3.0 2.0 1.5 4.5 4.0 3.0 2.5 2.0 1.5 1

BHP 1.36 1.49 1.62 1.75 1.88 2.01 2.15 2.28 2.42 2.55 2.71 2.84 2.97 3.102 RPM 556 589 621 652 682 712 740 768 795 821 846 871 895 918

Turns Out 2.0 4.5 4.0 3.0 2.5 1.5 1.0 4.0 3.5 3.0 2.5 2.0 1.0 0.5

BHP 1.69 1.83 1.97 2.10 RPM 593 624 654 683 711 739 766 793 819 844 868 890 913 936

Turns Out 4.5 4.0 3.0 2.5 1.5 1.0 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5

BHP 2.05 2.19 2.34 2.49 2.64 2.79 2.95 3.10 3.26 3.41 3.56 3.73 3.88 RPM 625 654 683 710 737 764 790 815 840 864 888 911 934

Turns Out 4.0 3.0 2.5 2.0 1.0 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5

BHP 2.46 2.62 2.77 2.94 3.09 3.26 3.41 3.58 3.74 3.91 4.08 4.25 RPM 660 687 714 740 766 791 816 840 864 887 910 933

Turns Out 3.0 2.5 1.5 1.0 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5

EXTERNAL STATIC PRESSURE (in. wg)

2.39 2.53 2.67 2.83 2.97 3.12 3.26 3.41 3.564

2.24

Operation Not

Recommended

Operation Not

Recommended

Table 12 — 50RTG20 Blower Performance

SCFM

AIRFLOW

6,000

6,600

7,200

8,000

8,600

9,300

10,000

LEGEND

BHP — Brake Horsepower SCFM — Standard Cubic Feet Per Minute

NOTES:

1. Fan BHP includes drive losses.

2. Region “A” is standard drive package.

3. Regions “B” and “C” require optional drive packages.

4. Region “D” represents oversized motor and special sheaves.

5. For applications requiring higher static pressures, contact your local representative.

BHP 1.38 1.51 1.63 1.76 1.89 2.02 2.16 2.30 2.43 2.57 2.71 2.84 2.99 3.12 RPM 560 592 624 655 685 715 743 771 797 823 849 874 897 921

Turns Out 5.5 4.0 3.0 5.5 4.5 3.5 2.5 1.5 1.0 0.0 4.0 3.5 2.5 2.0

BHP 1.83 1.73 2.10 2.24 2.39 2.53 2.67 2.83 2.97 3.12 3.28 3.34 3.50 3.65 RPM 614 644 673 702 729 757 783 809 834 859 883 895 919 941

Turns Out 3.5 2.0 5.0 4.0 3.0 2.0 1.5 0.5 4.5 3.5 3.0 2.5 2.0 1.5

BHP 2.30 2.44 2.60 2.75 2.90 3.06 3.22 3.38 3.54 3.70 3.86 4.03 4.20 4.27 RPM 656 684 711 738 764 790 815 839 863 887 910 933 957 966

Turns Out 5.5 4.5 3.5 3.0 2.0 1.0 0.0 4.5 3.5 3.0 2.5 1.5 1.0 0.5

BHP 2.94 3.10 3.27 3.44 3.61 3.77 3.95 4.13 4.30 4.47 4.65 4.83 5.01 RPM 696 722 747 772 797 821 844 867 890 912 935 956 978

Turns Out 4.0 3.5 2.5 1.5 1.0 0.0 4.0 3.5 3.0 2.0 1.5 1.0 0.5

BHP 3.71 3.88 4.06 4.25 4.42 4.61 4.79 4.97 5.16 5.35 5.53 RPM 756 780 803 827 849 872 894 916 937 958 979

Turns Out 2.0 1.5 0.5 4.5 4.0 3.5 3.0 2.0 1.5 1.0 0.5

BHP 4.59 4.77 4.97 5.16 5.36 5.56 5.75 5.95 6.15 RPM 805 828 850 872 893 914 935 955 976

Turns Out 0.5 4.5 4.0 3.5 2.5 2.0 1.5 1.0 0.5

BHP 5.43 5.63 5.84 6.05 6.26 6.47 6.68 6.89 RPM 838 859 881 901 922 942 962 981

Turns Out 4.5 3.5 3.0 2.5 2.0 1.5 0.5 0.0

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5

EXTERNAL STATIC PRESSURE (in. wg)

Operation Not

Recommended

Page 14

Step 8 — Low Voltage Wiring

THERMOSTAT CONNECTIONS — The thermostat should be wired directly to the Aquazone™ control board. See Fig. 4 and 5.

WA TER 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 30 F. In earth loop applications, jumper JW3 should be clipped to change the setting to 13 F when using antifreeze in colder earth loop applications. See Fig. 6.

AIR COIL FREEZE PROTECTION — The air coil freeze protection jumper JW2 (FP2) is factory set for 30 F and should not need adjusting, unless using anti-freeze.

ACCESSOR Y CONNECTIONS — Terminal labeled A on the control is provided to control accessory devices such as water valves, electronic air cleaners, humidif iers, et c. This signal operates with the compressor terminal. See Fig. 7. Refer to the specific unit wiring schematic for details.

NOTE: The A terminal should only be used with 24 volt signals — not line voltage signals.

WA TER SOLENOID VALVES — Water solenoid valves may be used on primary secondary pump and ground water installations. A typical well water control valve wiring which can limit waste water in a lockout condition is shown in Fig. 7. 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 t he compressor on ly after the val ve is completel y 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.

Capacitor

Contactor-CC

Transformer

THERMOSTAT WIRED DIRECTLY TO CONTROL BOARD

NOTE: Low voltage connector may be removed for easy installation.

Grnd

Fig. 5 — Low Voltage Field Wiring

Circ Brkr

Aquazone “C”

See Note

Low Voltage

Connector

AQUAZONE CONTROL (C Control Shown)

Fig. 6 — Typical Aquazone Control Board

Jumper Locations

Terminal Strip P2

Typical

24 VAC

Water

Valve

Fig. 7 — Typical D Control Accessory Wiring

PRE-START-UP

System Checkout —

and the system is cleaned and flushed, follow the System Checkout procedure outlined below.

1. Voltage: Ensure th at the voltage is wi thin the utilizati on

range specifications of the unit compressor and fan motor.

2. System Water Temperature: Ensure that the system

water temperature is w ith in an accept able range to faci litate start-up. (When conducting this check, also verify proper heating and cooling set points.)

3. System Water pH: Verify system water acidity

(pH = 7.5 or 8.5). Proper pH promotes the longevity of hoses and heat exchangers.

4. System Flushing: Properly clean and flush the system

periodically. Ensure that all supply and return hoses are connected end-to-end to facilitate system flushing and prevent fouling of the heat exchanger by system water. Water used in the system must be potable and should not contain dirt, piping slag, and chemical cleaning agents.

5. Closed-T ype Cooling Tower or Open T owe r with Heat Exchanger: Check equipment for proper temperature set points and operation.

6. Verify Balanced Water Flow Rate to Heat Pump.

7. Standby Pump: Verify that the standby pump is properly installed and in operating condition.

8. Access Panels: Assure that all access panels i n the filter and fan section are securely closed.

9. Air Dampers: Assure that all air dampers are properly set.

When the installation is complete

Page 15

10. System Controls: To ensure that no catastrophic system

failures occur, verify that system controls are functioning and that the sequencing is correct.

11. Freeze Protection for Water System: Verify t hat freez e

protection is provided for the building loop water system when outdoor design conditions require it. Inadequate freeze protection can lead to expensive tower and system piping repairs.

12. System Water Loop: Verify that all air is bled from t he

system. Air in the system impedes unit operation and causes corrosion in the system piping.

13. Unit Filters: To avoid system damage, check that the unit

filter is cl ean .

14. Unit Fans: Manually rotate fans to assure free rotation.

Ensure that fans are properly secured to the fan shaft. Do not oil fan motors on start-up since they are lubricated at the factory.

15. System Control Center: Examine the system control

and alarm panel for proper installation and operation to ensure control of the temperature set-points for operation of the system’s heat rejector and boiler (when used).

16. Miscellaneous: Note any questionable aspects of the

installatio n.

17. Air Coil: To obtain maximum performance, the air coil

should be cleaned before starting the unit. A ten percent solution of dishwasher detergent and water is recommended for both sides of the coil. Rinse thoroughly with water.

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.

C Control Jumper Settings (See Fig. 4)

WATER COIL FREEZE PROTECTION (FP1) LIMIT SETTING — Select jumper 3, (JW3-FP1 Low Temp) to choose FP1 limit of 10 F or 30 F. To select 30 F as the limit, DO NOT clip the jumper. To select 10 F as the limit, clip the jumper.

AIR COIL FREEZE PROTECTION (FP2) LIMIT SETTING — Select jumper 2 (JW2-FP2 Low Temp) to choose FP2 limit of 10 F or 30 F . To select 30 F as the limit, DO NOT clip the jumpe r. To se lect 10 F a s the lim it, c lip th e ju mper.

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.

C Control DIP Switches —

switch block with two switches. See Fig. 4. PERFORMANCE MONITOR (PM) — DIP switch 1 will

enable or disable this f eature. 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.

NOTE: The alarm relay will not cycle during Test mode if switch is set to OFF, stage 2.

The C Control has 1 DIP

D Control Jumper Settings

AIR COIL FREEZE PROTECTION (FP2) LIMIT SETTING — Select jumper 2 (JW2-FP2 Low Temp) to choose FP2 limit of 10 F or 30 F . To select 30 F as the limit, DO NOT clip the jumper. To select 10 F as the limit (for anti-freeze systems), clip the jumper.

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 D Control can be configured for Low Pressure Setting (LP). Select jumper 1 (JW1LP 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.

D Control DIP Switches —

switch blocks. Each DIP switch block has 8 switches and is labeled either S1 or S2 on the circuit board.

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

Performance Monitor (PM) able performance monitor. To enable the PM, set the switch to ON. T o disa ble th e PM , set th e swit ch t o OF F.

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 c all from the thermostat. This setting is used with dual stage units (units with 2 compressors and 2 D controls) or in master/slave applications. In master/slave applications, each compressor and fan will stage acc ording to i ts switch 2 sett ing. If switc h 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 tion 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 pump O/B thermostats. O is cooling output. B is heating output. Select ON for heat pumps with O output. Select OFF for heat pumps with B output.

Dehumidification Fan Mode (Not used on 50R TG) 5 provides selection of normal or dehumidification fan mode. Select OFF for dehumidification mode. The fan speed relay will remain OFF during cooling stage 2. Select ON for normal mode. The fan speed relay will turn on during cooling stage 2 in normal mode.

Switch 6 Boilerless Operation

less operation and works in conjunction with switch 8. In boilerless operation mode, only the compressor is used for heating when FP1 is above the boilerless changeover temperature set by switch 8 below. Select ON for normal operation or select OFF for boilerless operation.

— Not used.

— Switch 4 provides selection for heat

— Switch 7 provides selection of boiler-

The D Control has 2 DIP

— Set swi tch 1 to ena ble or dis -

— Switch 2 will en-

— Switch 3 provides selec-

— Switch

Page 16

Boilerless Changeover Temperature

— Switch 8 on S1 provides selection of boilerless changeover temperature set point. Select OFF for set point of 50 F or select ON for set point of 40 F .

If switch 8 is set for 50 F, then the c ompressor will be used for heating as long as the FP1 is above 50 F. The compressor will not be used for heating when the FP1 is below 50 F and the compressor will operates in emergency heat mode, staging on EH1 and EH2 to provide heat. If a thermal switch is being used instead of the FP1 thermistor, onl y the compressor will be used for heating mode when the FP1 terminals are closed. If the FP1 terminals are open, the compressor is not used and the control goes into emergency heat mode.

DIP SWITCH BLOCK 2 (S2) — This set of DIP switches is used to configure accessory relay options.

Switches 1 to 3

— These DIP switches provide selection of Accessory 1 relay options. See Table 13 for DIP switch combinations.

Switches 4 to 6

— These DIP switches provide selection of Accessory 2 relay options. See Table 14 for DIP switch combinations.

Table 13 — DIP Switch Block S2 —

Accessory 1 Relay Options

DIGITAL NIGHT SET BACK (NSB) — In this configuration, the relay will be ON if the NSB input i s 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 SET BACK — When NSB input is connected to ground C, all thermostat inputs are ignored. A thermostat set back heating call will then be c onnected to the OVR input. If OVR input becomes active, then the 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 W ater Valve (slow opening), the relay will start 60 seconds prior to starting compressor relay.

Outside Air Damper (OAD) —

If relay is configured for OAD, the relay will normally be ON any time the Fan Enable relay is energized. The relay will not start for 30 minutes following a return to normal mode from NSB, when NSB is no longer connected to ground C. After 30 minutes, the relay will start if the Fan Enable is set to ON.

ACC ESS ORY 1

RELAY OPTIONS

Cycle with Fan On On On

Digital NSB Off On On

Water Valve — Slow Opening On Off On

OAD On On Off

LEGEND

NSB — Night Setback OAD — Outside Air Damper

NOTE: All other DIP switch combinations are invalid.

DIP SWITCH POSITION

123

Table 14 — DIP Switch Block S2 —

Accessory 2 Relay Options

ACC ESS ORY 2

RELAY OPTIONS

Cycle with Fan On On On

Digital NSB Off On On

Water Valve — Slow Opening On Off On

OAD On On Off

LEGEND

NSB — Night Setback OAD — Outside Air Damper

NOTE: All other switch combinations are invalid.

DIP SWITCH POSITION

456

Auto Dehumidification Mode or High Fan Mode (Not used on 50RTG) — Switch 7 provides selection of auto dehumidification fan mode or high fan mode. In auto dehumidification fan mode the fan speed relay will remain off during cooling stage 2 if terminal H is active. In high fan mode, the fan enable and fan speed relays will turn on when terminal H is active. Set the switch to ON for auto dehumidification fan mode or to OFF for high fan mode.

Switch 8

— Not used.

D Control Accessory Relay Configurations —

The following accessory relay settings are applicable for both D controls only:

CYCLE WITH FAN — In this configuration, the relay will be ON any time the Fan Enable relay is on.

CYCLE WITH COMPRESSOR — In this configuration, the relay will be ON any time the Compressor relay is on.

To avoid equipmen t 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.

START-UP

Use the procedure outlined below to initiate proper unit

start-up. NOTE: This equipment is designed for indoor installation only .

Operating Limits

ENVIRONMENT — This equipment is designed for outdoor installation ONLY. Extreme variations in temperat ure, 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.

UNIT STARTING CONDITIONS — All units start and operate with entering air at 40 F, entering water at 20 F and with both air and water at the flow rates used.

NOTE: These operating limits are not normal or continuous operating conditions. It is assumed that such a start-up is for the purpose of bringing the building space up to occupancy temperature. See Table 15 for operating limits.

When the disconnect switch is closed, high voltage is present in some areas of the electr ical panel. Exercise caution when w ork ing wi th the ener gi zed e quipm en t.

1. Restore power to system.

2. Turn thermostat fan position to ON. Blower should start.

3. Balance airflow at registers.

4. Adjust all valves to the full open position and turn on the line power to all heat pump units.

5. Operate unit in the cooling cycle. Room temperature should be approximately 70 to 75 F dry bulb. Loop water temperature entering the heat pumps should be between 60 and 110 F.

Page 17

NOTE: Three factors determine the operating limits of a unit: (1) entering air temperature, (2) water temperature and (3) ambient temperature. Whenever any of these fact ors are at a minimum or maximum level, the other two factors must be at a normal level to ensure proper unit operation. See Table 15.

Table 15 — Operating Limits — 50RTG Units

AIR LIMITS COOLING HEATING Rated Ambient Air 80° F70° F Min. Entering Air 50° F40° F Rated Entering Air db/wb 80/67° F70° F Max. Entering Air db/wb 110/83° F80° F

WATER LIMITS Min. Entering Water 25° F25° F Normal Entering Water 85° F70° F Max. Entering Water 115° F 115° F

LEGEND

db — Dry Bulb wb — Wet Bulb

NOTE: Value in heating column is dry bulb only. Any wet bulb reading is acceptable.

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 pr oper 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 uni t and verify pressures ar e correct.

The suction and discharge pressure levels should now move

to their normal start-up levels.

When the compressor is rotating in the wrong direction, the unit makes an elevated level of noise and does not provide cooling.

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 compress or will start.

Unit Start-Up Cooling Mode

1. Adjust the unit thermostat to the warmest position. Slowly reduce the thermostat position until the compressor activates.

2. Check for cool air delivery at unit grille a few minutes after the unit has begun to operate.

3. Verify that the compressor is on and that the water flow rate is correct by measuring pressure drop through the heat exchanger using P/T plugs. Check the el evation and cleanliness of the condensate lines; any dripping could be a sign of a blocked line. Be sure the condensate trap includes a water seal.

4. Check the temperature of both supply and discharge water. If temperature is within range, proceed. If temperature is outside the range, check the cooling refrigerant pressures.

5. Air temperature drop across the coil should be checked when compressor is operating. Air temperature drop should be between 15 and 25 F.

Unit Start-Up Heating Mode

NOTE: Operate the unit in heating cycle after checking the cooling cycle. Allow five minutes betwe en tests for the pressure or reversing valve to equalize.

1. Turn thermostat to lowest setting and set thermostat switch to HEAT position.

2. Slowly turn the thermostat to a higher t emperature until the compres so r act iv ate s.

3. Check for warm air delivery at the unit grille within a few minutes after the unit has begun to operate.

4. Check the temperature of both supply and discharge water. If temperature is within range, proceed. If temperature is outside the range, check the heating refrigerant pressures.

5. Once the unit has begun to run, check for warm air delivery at the unit grille.

6. Air temperature rise across the coil should be checked when compressor is operating. Air temperature rise should be between 20 and 30 F after 15 minutes at load.

7. Check for vibration, noise and water leaks.

Flow Regulation —

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. See Table 16. Adjust the water control valve until the flow of 1.5 to 2 gpm is achieved. Since the pressure constantly varies, two pressure gages may be needed in some applications.

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 well water setup.

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.

Flushing —

loop charging is needed. A flush cart pump of at least 1.5 hp is needed to achieve adequate flow ve locity in the loop to purge air and dirt particles from the loop. Flush the loop in both directions with a high volume of water at a high velocity . Follow the steps below to properly flush the loop:

1. Verify power is off.

2. Fill loop with water from hose through flush cart before using flush cart pump to ensure an even fill. Do not allow the water level in the flush cart tank to drop below the pump inlet line to prevent air from filling the line.

3. Maintain a fluid level in the tank above the return tee to avoid air entering back into the fluid.

4. Shutting off the return valve that connects into the flush cart reservoir will allow 50 psi surges to help purge air pockets. This maintains the pump at 50 psi.

5. T o purge, keep the pump at 50 psi until maximum pumping pressure is reached.

Once the piping is complete, final purging and

Flow regulation can be accom-

Page 18

6. Open the return valve to send a pressure surge through the loop to purge any air pockets in the piping system.

7. A noticeable drop in fluid level will be seen in the flush cart tank. This is the only indication of air in the loop.

NOTE: If air is purged from the system while using a 10 in. PVC flush tank, only a 1 to 2 in. level drop will be noticed since liquids are incompressible. If the level drops more than this, flushing should continue since air is still being compressed in the loop. If level is less than 1 to 2 in., reverse the flow .

8. Repeat this procedure until all air is purged.

9. Restore power.

Antifreeze may be added before, during or after the flushing process. However, depending on when it is added in the process, it can be wasted. Refer to the Antifreez e section for more detail.

Loop static pressure will fluctuate with the seasons. Pressures will be higher in the winter months than during the warmer months. This fluctuation is normal and should be considered when charging the system initially. Run the unit in either heating or cooling for several minutes to condition the loop to a homogenous temperature.

When complete, perform a final flush and pressurize the loop to a static pressure of 40 to 50 psi for winter months or 15 to 20 psi for summer months.

After pressurization, be sure to remove the plug from the end of the loop pump motor(s) to allow trapped air to be discharged and to ensure the motor housing has been flooded. Be sure the loop flow center provides adequate flow through the unit by checking pressure drop across the heat exchanger. Compare the results to the data in Table 16.

Table 16 — 50RTG Coaxial Water Pressure Drop

UNIT

50RTG

GPM

4.0 3.1 2.8 2.8 2.8

6.0 6.1 5.3 5.3 5.3

8.0 9.9 8.9 8.9 8.9

10.0 14.3 12.9 12.9 12.9

5.5 4.2 3.4 3.4 3.4

8.5 8.9 7.8 7.8 7.8

11.5 14.8 13.2 13.2 13.2

14.0 20.5 18.6 18.6 18.6

7.0 8.1 5.3 5.3 5.3

11.0 16.9 11.2 11.2 11.2

15.0 28.5 18.9 18.9 18.9

18.0 38.8 25.6 25.6 25.6

10.0 3.4 2.3 2.3 2.3

15.0 10.1 6.7 6.7 6.7

20.0 16.0 10.7 10.7 10.7

24.0 22.3 14.9 14.9 14.9

11.0 4.5 3.5 3.5 3.5

17.0 9.4 8.1 8.1 8.1

22.0 14.2 12.7 12.7 12.7

27.0 20.0 18.2 18.2 18.2

14.0 8.3 5.5 5.5 5.5

22.0 17.6 11.7 11.7 11.7

30.0 29.4 19.7 19.7 19.7

36.0 39.9 26.7 26.7 26.7

17.0 4.8 3.2 3.2 3.2

25.0 9.4 6.0 6.0 6.0

34.0 13.1 10.3 10.3 10.3

40.0 22.0 13.5 13.5 13.5

21.0 5.2 2.9 2.9 2.9

32.0 10.7 7.4 7.4 7.4

42.0 17.4 11.6 11.6 11.6

51.0 24.3 16.5 16.5 16.5

31.0 10.6 6.4 6.4 6.4

47.0 21.2 13.1 13.1 13.1

62.0 34.2 20.8 20.8 20.8

74.0 46.2 28.0 28.0 28.0

WATER TEMPERATURE (F)

30 50 70 90

Pressure Drop (ft. H

Antifreeze —

In areas where entering loop temperatures drop below 40 F or where piping will be routed through areas subject to freezing, antifreeze is needed.

Alcohols and glycols are commonly used as antifreeze agents. Freeze protection should be maintained to 15 F below the lowest expected entering loop temperature. For example, if the lowest expected entering loop temperature is 30 F, the leaving loop temperature would be 22 to 25 F. Therefore, the freeze protection should be at 15 F (30 F – 15 F = 15 F).

IMPORTANT: All alcohols should be pre-mixed and pumped from a reservoir outside of the building or introduced under water level to prevent fumes.

Calculate the total volume of fluid in the piping system. See Ta ble 17. Use the percentage by volume i n Table 18 to determine the amount of antifreeze to use. Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specific gravity.

FREEZE PROTECTION SELECTION — The 30 F FP1 factory setting (water) should be used to avoid freeze damage to the unit.

Once antifreeze is selected , the JW3 jumper (FP1) should be clipped on the control to select the low temperature (antifreeze 13 F) set point to avoid nuisance faults.

Table 17 — Approximate Fluid Volume (gal.)

per 100 Ft of Pipe

PIPE DIAMETER (in.) VOLUME (gal.)

Copper 14.1

Rubber Hose 13.9 Polyethylene

LEGEND

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

NOTE: Volume of heat exchanger is approximately 1.0 gallon.

1.25 6.4

1.5 9.2

/4 IPS SDR11 2.8

1 IPS SDR11 4.5

/4 IPS SDR11 8.0

/2 IPS SDR11 10.9

2 IPS SDR11 18.0

/4 IPS SCH40 8.3

/2 IPS SCH40 10.9

1 2 IPS SCH40 17.0

Table 18 — Antifreeze Percentages by Volume

MINIMUM TEMPERATURE FOR

ANTIFREEZE

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

Propylene Glycol (%)

Cooling Tower/Boiler Systems —

FREEZE PROTECTION (F)

10 15 20 25

38 30 22 15

These systems typically use a common loop maintained at 60 to 90 F. 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 —

low water temp eratures from 30 to 110 F. The external loop field is divided up into 2 in. polyethylene supply and return lines. Each line has valves connected in such a way that upon system start-up, each line can be isolated for flushing using only the system pumps. Air separation should be located in the piping system prior to the fluid re-entering the loop field.

These systems al-

Page 19

OPERATION

Power Up Mode —

inputs, terminals and safety controls are checked for normal operation.

NOTE: The compressor will have a 5-minute anti-short cycle upon power up.

The unit will not operate until all the

Units with Aquazone™ Complete C Control

STANDBY — 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 — Y and O terminals are act ive in Cooling mode. After power up , the first call to th e compressor wi ll initiate a 5 to 80 second random start delay and a 5-mi nute anti-short 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 wi ll 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 2 — To enter Stage 2 mode, terminal W is active (Y is already active). Also, the G terminal must be active or the W terminal is disregarded. The c ompressor relay will remain on and EH1 is immediately turned on. EH2 will turn on after 10 minutes of continual stage 2 demand.

NOTE: EH2 will not turn on (or if on, will turn off) if FP1 temperature is greater than 45 F and FP2 is greater than 110 F.

EMERGENCY HEAT — In emergency heat mode, terminal W is active while terminal Y is not. Terminal G must be active or the W terminal is disregarded. EH1 is immediately turned on. EH2 will turn on after 5 minutes of continual emergency heat demand.

Units with Aquazone Deluxe D Control

STANDBY/ FAN ONLY — The compressor will be off. The Fan Enable, Fan Speed, and reversing valve (RV) relays will be on if inputs are present. If there is a Fan 1 demand, the Fan Enable will immediately turn on. If there is a Fan 2 demand, the Fan Enable and Fan Speed will immediately turn on.

NOTE: DIP switch 5 on S1 does not have an effect upon Fan 1 and Fan 2 outputs.

HEATING STAGE 1 — In Heating Stage 1 mode, the Fan Enable and Compressor relays are turned on 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 Fan Enable and Compressor relays remain on. The Fan Speed relay is turned on immediately and turned off immediately once the demand is removed. The control reverts to Heating Stage 1 mode. If there is a master/slave or dual compressor application, all compressor relays and related functions will operate per their associated DIP switch 2 setting on S1.

HEATING STAGE 3 — In Heating Stage 3 mode, the Fan Enable, Fan Speed and Compressor relays remain on. The EH1 output is turned on immediately. With continuing Heat Stage 3 demand, EH2 will turn on after 10 minutes. EH1 and EH2 a re turned off immediately when the Heating Stage 3 demand is removed. The control reverts to Heating Stage 2 mode.

Output EH2 will be off if FP1 is greater than 45 F AND FP2 (when shorted) is greater than 110 F during Heating Stage 3 mode. This condition will have a 30-second recognition time. Also, during Heating Stage 3 mode, EH1, EH2, Fan Enable, and Fan Speed will be ON if G input is not active.

EMERGENCY HEAT — In Emergency Heat mode, the Fan Enable and Fan Speed relays are turned on. The EH1 output is turned on immediately. With continuing Emergency Heat demand, EH2 will turn on after 5 minutes. Fan Enable and Fan Speed relays are turned off after a 60-second delay. The control reverts to Standby mode.

Output EH1, EH2, Fan Enable, and Fan Speed will be ON if the G input is not active during Emergency Heat mode.

COOLING ST AGE 1 — In Cooling Stage 1 mode, the Fan Enable, compressor and RV re lays 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 fan Enable and 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 ST AGE 2 — In Cooling Stage 2 mode, the Fan Enable, compressor and RV relays remain on. The Fan Speed relay is turned on immediately and turned immediately once the Cooling Stage 2 demand is removed. The control reverts to Cooling Stage 1 mode. If there is a master/slave or dual c ompressor 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.

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. 4.

Test Mode —

the power 3 times within 60 seconds. The L ED (light-emitting diode) will flash a code representing the last fault when entering the Test mode. The alarm rel ay will also power on and off during Test mode. See Tables 19 and 20. To exit Test mode, short the terminals for 3 seconds or cycle the power 3 times within 60 seconds.

NOTE: Deluxe D Control has a flashing code and alarm relay cycling code that will both have the same numerical label. For example, flashing code 1 will have an alarm relay cy cling code 1. Code 1 indicates the control has not faulted since the last power off to power on sequence.

T o enter Test mode on C or D controls, cycle

Page 20

Table 19 — C Control Current LED Status

and Alarm Relay Operations

LED STATUS DESCRIPTION OF OPERATION ALARM RELAY

Normal Mode Open

Off C Control is non-functional Open

Slow Flash Fault Retry Open

Fast Flash Lockout Closed

Slow Flash Over/Under Voltage Shutdown

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 Te s t M od e — FP1 Fault in memory Cycling Code 4 Flashing Code 5 Te s t M od e — FP2 Fault in memory Cycling Code 5 Flashing Code 6 Test Mode — CO Fault in memory Cycling Code 6

Flashing Code 7

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

Flashing Code 9

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

NOTES:

1. Slow flash is 1 flash every 2 seconds.

2. Fast flash is 2 flashes every 1 second.

3. EXAMPLE: “Flashing Code 2” is represented by 2 fast flashes followed by a

LEGEND

10-second pause. This sequence will repeat continually until the fault is cleared.

Normal Mode with

PM Warning

Test Mode — Over/Under

shutdown in memory

Test Mode — Test Mode — FP1/

FP2 Swapped Fault in memory

Cycle (closed 5 sec., Open 25 sec.)

Open

(Closed after

15 minutes)

Cycling Code 7

Cycling Code 9

Table 20 — C Control LED Code and

Fault Descriptions

LED

CODE

1 No fault in memor y There has been no fault since

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

4 Freeze Protection Coax

— FP1

5 Freeze Protection Air Coil

— FP2

6 Condensate overflow Sense overflow (grounded) for

(Autoreset)

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

Over/Under Voltage Shutdown

8 PM Warning Performance Monitor Warning

9 FP1 and FP2 Thermistors

are Swapped

LEGEND

Retry Mode —

FAULT DESCRIPTION

the last power-down to power-up sequence

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

FP1 below Temp limit for 30 continuous seconds (bypassed for first 60 seconds of operation)

FP2 below Temp limit for 30 continuous seconds (bypassed for first 60 seconds of operation)

30 continuous seconds "R" power supply is <19VAC or

>30VAC

has occurred. FP1 temperature is higher than

FP2 in heating/test mode, or FP2 temperature is higher than FP1 in cooling/test 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 to terminal Y. Once the thermostat input calls are satisfied, the control will continue normal operation.

NOTE: If 3 consecutive faults occur without satisfying the thermostat input call to terminal Y, the control will go into lockout mode. The last fault causing the lockout is stored in memory and can be viewed by entering Test mode.

Aquazone™ Deluxe D Control LED Indicators —

STATUS LED — Status LED indicates the current status or mode of the D control. The Status LED light is green.

TEST LED — Test LED will be activated any time the 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 and appear as 1 fast flash alternating with a 10-second pause. See Tabl e 21.

There are 3 LED indicators on the D Control:

SERVICE

Perform the procedures outlined below periodically, as

indicated.

IMPORTANT: When a compressor is removed from this unit, system ref rigerant cir cuit oil will remain in th e compressor. To avoid leakage of compressor oil, the refrigerant lines of the compressor must be sealed after it is removed.

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.

IMPORTANT: To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must only be serviced by technicians whic h me et l ocal, s tate a nd fede ral proficiency requirements.

IMPORTANT: To prevent injury or death due t o electrical shock or contact with moving parts, open unit disconnect switch before servicing unit.

Filters —

Inspect filters every month under normal oper ating conditions. replace when necessary.

IMPORTANT: Units should never be operated without a filter.

Water Coil —

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 15 PSI during the summer and 40 PSI during the winter.

Check P trap frequently for proper operation.

Filters must be clean for maximum performance.

Keep all air out of the water coil. Check

Page 21

Table 21 — Aquazone 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

D Control is non-functional Off Off Off Open

Test Mode — 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.

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.

Condensate Drain Pans —

Check condensate drain pans for algae growth twice a year. If algae growth is apparent, consult a water treatment special ist for proper chemical treatment. The application of an algaecide every three months will typically eliminate algae problems in most locations.

Refrigerant System —

Verify air and water flow rates are at proper levels before servicing. To maintain sealed circuitry integrity, do not install service gauges unless unit operation appears abnormal. Check to see that unit is within the superheat and subcooling ranges.

Condensate Drain Cleaning —

Clean the drain line and unit drain pan at the start of each cooling season. Check flow by pouring water into drain. Be sure trap is filled to maintain an air seal.

Air Coil Cleaning —

Remove dirt and debris from evaporator coil as required by condition of the coi l. Cle an coil with a stiff brush, vacuum cleaner, or compressed air. Use a fin comb of the correct tooth spacing when straightening mashed or bent coil fins.

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.

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. V apors from vent pipe are not harmful, but take care to prevent liquid from being carried over by the gases.

War m sol ution acts fa ster, but cold s oluti on is ju st a s effective 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. 8.

FORCED CIRCULATIO N METHOD — Fully open vent pipe when filling condenser. The vent may be closed when condenser is full and pump is operating. See Fig. 9.

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 sca le deposit , allow solution to rem ain in co ndenser overnight. For heavy scale deposit, allow 24 hours. Drain condenser and flush with clean water. F ollow acid manufacturer’s instructions.

Page 22

FILL CONDENSER WITH CLEANING SOLUTION. DO NOT ADD SOLUTION MORE RAPIDLY THAN VENT CAN EXHAUST GASES CAUSED BY CHEMICAL ACTION.

VENT PIPE

3’ TO 4’

Fig. 8 — Gravity Flow Method

PUMP

SUCTION

PUMP SUPPORT

TANK

FINE MESH SCREEN

PRIMING CONN.

Fig. 9 — Forced Circulation Method

PAIL

1” PIPE

5’ APPROX

GAS VENT

GLOBE VALV ES

SUPPLY

1” PIPE

FUNNEL

RETURN

PAIL

CONDENSER

REMOVE WATER REGULATING VALVE

Refrigerant Charging

To pr event 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 reclaim refrigerant following accepted practices.

Air Coil Fan Motor Removal

Before attempting to remove fan motors or motor mounts, place a piece of plywood over evaporat or coils to prevent coil damage.

Motor power wires need to be disconnected from motor

terminals before motor is removed from unit.

1. Shut off unit main power supply .

2. Loosen bolts on mounting bracket so that fan belt can be removed.

3. Loosen and remove the 2 motor mounting bracket bolts on left side of bracket.

4. Slide motor/bracket assembly to extreme right and lift out through space between fan scroll and side frame. Rest motor on a high platform such a s a step ladder. Do not allow motor to hang by its power wires.

TROUBLESHOOTING

(Fig. 10 and 11, and Table 22)

When troubleshooting problems with a WSHP, consider the

following.

Thermistor —

phase units where starting the unit is a problem due to low voltage. See Fig. 10 for thermistor nominal resistance.

Control Sensors —

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. 11.

A thermistor may be required for single-

The control system employs 2 nom-

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 merc ury or dial-type thermometer.

2. Connect pressure gage to discharge line near compressor.

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

NOTE: Operate unit a minimum of 15 minutes before checking charge.

4. From standard field-supplied Pressure-Temperature chart for R-22, find equivalent saturated condensing temperature.

5. Read liquid line temperature on thermometer; then subtract from saturated condensing temperature. The difference equals subcooling temperature.

6. ADD refrigerant to raise the temperature or REMOVE refrigerant (using standard practices) to lower the temperature (allow a tolerance of ± 3° F), as required.

90.0

80.0

70.0

60.0

50.0

40.0

30.0

Resistance (kOhm)

20.0

10.0

0.0

0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0

Temperature (F)

Fig. 10 — Thermistor Nominal Resistance

Page 23

AIR

COIL

°F

THERMISTOR

CONDENSATE

OVERFLOW

(CO)

AIR COIL FREEZE PROTECTION

LEGEND

COAX — Coaxial Heat Exchanger

Airflow Refrigerant Liquid Line Flow

°F

FP2

EXPANSION

VALV E

LIQUID LINE

WATER COIL PROTECTION

FP1

WATER IN

COAX

WATER OUT

Fig. 11 — FP1 and FP2 Thermistor Location

SUCTION

COMPRESSOR

DISCHARGE

Page 24

FAULT HEATING COOLING POSSIBLE CAUSE SOLUTION

Main Power Problems

HP Fault — Code 2 High Pressure

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

FP1 Fault — Code 4 Water Freeze Protection

FP2 Fault — Code 5 Air Coil Freeze Protection

Condensate Fault — Code 6

Over/Under Voltage — Code 7 (Auto Resetting)

Performance Monitor — Code 8

FP1 and FP2 Thermistors — Code 9

No Fault Code Shown

Unit Short Cycles

Only Fan Runs

LEGEND

Reversing Valve

RV —

Table 22 — Troubleshooting

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.

X Reduced or no water flow in

cooling

X Water temperature out of

range in cooling

X Reduced or no airflow in

X Air temperature out of range

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

X Water temperature out of

X X Bad thermistor Check temperature and impedance correlation.

X X Bad thermistor Check temperature and impedance correlation. X X Blocked drain Check for blockage and clean drain. X X Improper trap Check trap dimensions and location ahead of vent.

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>125 F Check for poor airflow or overcharged unit.

X FP1 temperature is higher

X X No compressor operation See scroll compressor rotation section. X X Compressor overload Check and replace if necessary. X X Control board Reset power and check operation. X X Dirty air filter Check and clean air filter. X X Unit in 'Test Mode' Reset power or wait 20 minutes for auto exit. 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 Thermostat position Ensure thermostat set for heating or cooling operation. X X Unit locked out Check for lockout codes. Reset power. X X Compressor overload Check compressor overload. Replace if necessary. X X Thermostat wiring Check Y and W wiring at heat pump. Jumper Y and R for compressor

heating

in heating

start-up

heating

ting (30 F vs 10 F)

range

X Reduced or no airflow in

cooling

X Air temperature out of range Too much cold vent air. Bring entering air temperature within

X Improper freeze protect set-

ting (30 F vs 10 F)

X Poor drainage Check for piping slope away from unit.

X Moisture on sensor Check for moisture shorting to air coil.

X Cooling mode FP1>125 F

OR FP2< 40 F

than FP2 temperature

X FP2 temperature is higher

than FP1 temperature

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

Check for dirty air filter and clean or replace. Check fan motor operation and airflow restrictions. Dirty air coil — construction dust etc. External static too high. Check Tables 4-12. Bring return air 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 JW2 jumper for antifreeze (10 F) use.

Bring water temperature within design parameters.

Check for dirty air filter and clean or replace. Check fan motor operation and airflow restrictions. External static too high. Check Tables 4-12.

design parameters. Normal airside applications will require 30°F only.

Check slope of unit toward outlet. Poor venting. Check vent location.

Check power supply wire size. Check compressor star ting. 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.

Swap FP1 and FP2 thermistors.

operation in Test mode.

Page 25

FAULT HEATING COOLING POSSIBLE CAUSE SOLUTION

Only Compressor Runs

Unit Does Not Operate in Cooling

Insufficient capacity/ Not cooling or heating properly

High Head Pressure

Low Suction Pressure

Low discharge air temperature in heating

High humidity

LEGEND

Reversing Valve

RV —

Table 22 — Troubleshooting (cont)

X X Thermostat wiring Check G wiring at heat pump. Jumper G and R for fan operation. X X Fan motor relay Jumper G and R for fan operation. Check for line voltage across BR

X X Fan motor Check for line voltage at motor. Check capacitor. X X Thermostat wiring Check Y and W wiring at heat pump. Jumper Y and R for compressor

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 'Click'. X X Dirty filter Replace or clean. X Reduced or no airflow in

X X Leaky ductwork Check supply and return air temperatures at the unit and at distant duct

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

X X Thermostat improperly

X X Unit undersized Recheck loads and sizing check sensible cooling load and heat pump

X X Scaling in water heat

X X Inlet water too hot or cold Check load, loop sizing, loop backfill, ground moisture. X Reduced or no airflow in

X Air temperature out of range

X X Unit overcharged Check superheat and subcooling. Reweigh in charge. X X Non-condensables in

X X Restricted metering device Check superheat and subcooling. Replace metering device. X Reduced water flow in

X Water temperature out of

X X Insufficient charge Check for refrigerant leaks. X Airflow too high Check blower Tables 4-12. X Poor performance See 'Insufficient Capacity'.

heating

X Reduced or no airflow in

cooling

X Defective reversing valve Perform RV touch test.

located

exchanger

heating

X Reduced or no water flow in

cooling

X Inlet water too hot Check load, loop sizing, loop backfill, ground moisture.

in heating

X Scaling in water heat

exchanger

system

heating

range

X Reduced airflow in cooling Check for dirty air filter and clean or replace.

X Air temperature out of range Too much cold vent air. Bring entering air temperature within design

X Airflow too high Check blower Tables 4-12.

X Unit oversized Recheck loads and sizing check sensible cooling load and heat pump

contacts. Check fan power enable relay operation (if present).

operation in test mode.

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

Check for dir ty air filter and clean or replace. Check fan motor operation and airflow restrictions. External static too high. Check blower Tables 4-12. Check for dir ty air filter and clean or replace. Check fan motor operation and airflow restrictions. External static too high. Check blower Tables 4-12.

registers if significantly different, duct leaks are present.

Check location and for air drafts behind thermostat.

capacity. Perform Scaling check and clean if necessary.

Check for dir ty air filter and clean or replace. Check fan motor operation and airflow restrictions. External static too high. Check blower Tables 4-12. Check pump operation or valve operation/setting. Check water flow and adjust to proper flow rate.

Bring return air temperature within design parameters.

Perform Scaling check and clean if necessary.

Vacuum system and reweigh in charge.

Check pump operation or water valve operation/setting. Plugged strainer or filter. Clean or replace. Check water flow adjust to proper flow rate. Bring water temperature within design parameters.

Check fan motor operation and airflow restrictions. External static too high. Check blower Tables 4-12.

parameters.

capacity.

Page 26

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. 535-004 Printed in U.S.A. Form 50R-2SI Pg 26 8-02 Replaces: New

Page 27

50RTG

START-UP CHECKLIST

CUSTOMER:___________________________ JOB NAME: _______________________________________ MODEL NO.:___________________________ SERIAL NO.:____________________ DA TE:_________

I. PRE-START-UP

DOES THE UNIT VOL TAGE 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 HEA T EXCHANGER?

(Y/N) HAS PUMP BEEN TURNED ON AND ARE ISOLATION VAL VES 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 COMPRE SSO R O PER ATES? (Y/N) IF 3-PHASE SCROLL COMPRESSOR IS PRESENT, VERIFY PROPER ROTA TION PER INSTRUCTIONS.

(Y/N)

UNIT VOLTAGE — COOLING OPERATION

PHASE AB VOL TS PHASE BC VOLTS PHASE CA VOL TS

(if 3 phase) (if 3 phase)

PHASE AB AMPS

PHASE BC AMP S PHASE CA AMPS

(if 3 phase) (if 3 phase)

CONTROL VOLTAGE

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

TEMPERATURES

FILL IN THE ANALYSIS CHART ATT ACHED.

COAXIAL HEAT EXCHANGER

COOLING CYCLE: FLUID IN

FFLUID OUT F PSI FLOW

HEATING CYCLE: FLUID IN

FFLUID OUT F PSI FLOW

AIR COIL COOLING CYCLE:

AIR IN HEATING CYCLE:

AIR IN

FAIR OUT F

CL-1

Page 28

HEATING CYCLE ANALYSIS

AIR

COIL

°F

LIQUID LINE

COOLING CYCLE ANALYSIS

EXPANSION

VALV E

°F

WATER IN

COAX

°F

PSI

°F

WATER OUT

PSI

LOOK UP PRESSURE DROP IN TABLE 16 TO DETERMINE FLOW RATE

PSI

SAT

°F

SUCTION

COMPRESSOR

DISCHARGE

SAT

AIR

COIL

°F

EXPANSION

VALV E

LIQUID LINE

COAX

°F

WATER IN

°F

PSI

WATER OUT

°F

PSI

LOOK UP PRESSURE DROP IN TABLE 16 TO DETERMINE FLOW RATE

HEAT OF EXTRACTION (ABSORPTION) OR HEAT OF REJECTION =

FLOW RATE (GPM) x TEMP. DIFF. (DEG. F) x FLUID FACTOR* =

°F

SUCTION

COMPRESSOR

DISCHARGE

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

(Btu/hr)

SUPERHEAT =SUCTION TEMPERATURE – SUCTION SATURATION TEMPERATURE

(DEG F)

SUBCOOLING =DISCHARGE SATURATION TEMPERATURE – LIQUID LINE TEMPERATURE

*Use 500 for water, 485 for antifreeze.

(DEG F)

*97B0014N02*

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. 535-004 Printed in U.S.A. Form 50R-2SI Pg CL-2 8-02 Replaces: New

97B0014N02

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