Carrier GT-PX Split Series, GT-GS Indoor Split Series, GT-S Outdoor Split Series Installation, Operation & Maintenance Instructions Manual

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Page 1

Split Products

GT-PX Split (50YDS) Series

GT-GS Indoor Split (50YCS) Series

GT-S Outdoor Split (38WQS) Series

Indoor and Outdoor Split

Geothermal Heat Pumps

Installation, Operation &

Table of Contents

Model Nomenclature 3

Safety 4

Storage 5

Pre-Installation 5

Equipment Selection 6

Air Coil Match-ups 6-7

Air Handler Selection 8

Installation 9

Water Connections 10-11

Ground Loop Applications 11-13

Open Loop - Ground Water Systems 14-15

Water Quality Standards 16

Refrigeration Installation 17-22

Lineset Information 17

Hot Water Generator 23-24

Electrical - Line Voltage 27-26

Electrical - Line Voltage 27-28

Electrical - HWG Wiring 29

Electrical - Low Voltage Wiring 30-32

Thermostat Wiring 32

CXM Controls 33-36

Unit Start-Up and Operating Conditions 37-38

Unit Start-Up Procedure 39

Unit Operating Conditions 40-42

Preventive Maintenance 43

Troublesh o o t i n g 4 4

CXM Process Flow Chart 45

Functional Troubleshooting Charts 46-47

Troublesh o o t i n g Fo r m 48

Revision Log 50

Maintenance Instructions

97B0048N01

Revision: 5 June, 2008

Page 2

Page 3

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Model Nomenclature: for Indoor Split Series

321

YDS05

YDS = INDOOR TWO-STAGE PURON

SPLIT SYSTEM CONDENSING UNIT

YCS = INDOOR SPLIT SYSTEM

YCS

018 024 030 036 042 048 060

NOTE: Some options/configurations not availaible on all series. Please consult Engineering Guides for model specific options.

UNIT TYPE:

CONDENSING UNIT

SIZE:

YDS 026

038

049

064

AIRFLOW CONFIGURATION:

N = NONE

CONTROL:

YDS - C = CXM

YCS - L = CXM

86754

C06N

HEAT EXCHANGER OPTIONS:

C = COPPER WATER COIL

D = COPPER WATER COIL W/HOT WATER GENERATOR

N = CUPRO-NICKEL WATER COIL

P = CUPRO-NICKEL WATER COIL W/HOT WATER GENERATOR

NOTE: Above model nomenclature is a general reference. Consult individual speciﬁ cation catalogs for detailed information.

1211109

PACKAGING:

1=SINGLE PACK,DOMESTIC

REVISION LEVEL:

0 = CURRENT REV IS ION

VOLTAGE:

3 = 208V, 230V/1PH/60Hz

Rev.: 08/15/05D

Model Nomenclature: for Outdoor Split Series

38 SS0 2 4 C 3 1 1

Prefix

WQS = Extended Range Ultra High Efficiency Residential Outdoor Split

Series

018, 024, 030, 036, 042, 048, 060

1 2 3

WQS

Unit Size

4 5 6 7 8 9 10 11 12

Voltage

3 = 208-230/60/1

Standard

SS = Standard

Heat Exchanger Options

Standard

Packaging

1 = Single Pack, Domestic

Revision Level

1 = Current Revision

Copper Cupro-Nickel

Carrier: Turn to the Experts

Page 4

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Safety

Warnings, cautions and notices appear throughout this manual. Read these items carefully before attempting any installation, service or troubleshooting of the equipment.

DANGER: Indicates an immediate hazardous situation, which if not avoided will result in death or serious injury. DANGER labels on unit access panels must be observed.

WARNING: Indicates a potentially hazardous situation, which if not avoided could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation or an unsafe practice, which if not avoided could result in minor or moderate injury or product or property damage.

NOTICE: Notiﬁ cation of installation, operation or maintenance information, which is important, but which is not hazard-related.

 WARNING! 

WARNING! 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. If a compressor is removed from this unit, refrigerant circuit oil will remain in the compressor. To avoid leakage of compressor oil, refrigerant lines of the compressor must be sealed after it is removed.

 CAUTION! 

CAUTION!

these units as a source of heating or cooling during the construction process. The mechanical components and ﬁ lters will quickly become clogged with construction dirt and debris, which may cause system damage.

To avoid equipment damage, DO NOT use

 WARNING! 

WARNING! Verify refrigerant type before proceeding. Units are shipped with R-22, R-407c and R-410A (Puron®) refrigerants. The unit label will indicate which refrigerant is provided. The Puron® Application and Service Manual should be read and understood before attempting to service refrigerant circuits with R-407c or R-410A.

 WARNING! 

WARNING! To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must be serviced only by technicians who meet local, state, and federal proﬁ ciency requirements.

Water-Source Heating and Cooling Systems

Page 5

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

General Information

Inspection

Upon receipt of the equipment, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the packaging of each unit, and inspect each unit for damage. Insure that the carrier makes proper notation of any shortages or damage on all copies of the freight bill and completes a common carrier inspection report. Concealed damage not discovered during unloading must be reported to the carrier within 15 days of receipt of shipment. If not ﬁ led within 15 days, the freight company can deny the claim without recourse. Note: It is the responsibility of the purchaser to ﬁ le all necessary claims with the carrier. Notify your equipment supplier of all damage within ﬁ fteen (15) days of shipment.

Storage

Equipment should be stored in its original packaging in a clean, dry area. Store units in an upright position at all times. Stack units a maximum of 3 units high.

Unit Protection

Cover units on the job site with either the original packaging or an equivalent protective covering. Cap the open ends of pipes stored on the job site. In areas where painting, plastering, and/or spraying has not been completed, all due precautions must be taken to avoid physical damage to the units and contamination by foreign material. Physical damage and contamination may prevent proper start-up and may result in costly equipment clean-up.

5. Loosen compressor bolts on units equipped with compressor spring vibration isolation until the compressor rides freely on the springs. Remove shipping restraints.

6. REMOVE COMPRESSOR SUPPORT PLATE 1/4” SHIPPING BOLTS (2 on each side) TO MAXIMIZE VIBRATION AND SOUND ATTENUATION (R22 indoor units only).

7. Locate and verify any hot water generator (HWG) or other accessory kit located in the compressor section.

 CAUTION! 

CAUTION! DO NOT store or install units in corrosive environments or in locations subject to temperature or humidity extremes (e.g., attics, garages, rooftops, etc.). Corrosive conditions and high temperature or humidity can signiﬁ cantly reduce performance, reliability, and service life. Always move and store units in an upright position. Tilting units on their sides may cause equipment damage.

NOTICE! Failure to remove shipping brackets from springmounted compressors will cause excessive noise, and could cause component failure due to added vibration.

 CAUTION! 

Examine all pipes, ﬁ ttings, and valves before installing any of the system components. Remove any dirt or debris found in or on these components.

Pre-Installation

Installation, Operation, and Maintenance instructions are provided with each unit. Horizontal equipment is designed for installation above false ceiling or in a ceiling plenum. Other unit conﬁ gurations are typically installed in a mechanical room. The installation site chosen should include adequate service clearance around the unit. Before unit start-up, read all manuals and become familiar with the unit and its operation. Thoroughly check the system before operation.

Prepare units for installation as follows:

1. Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped.

2. Keep the cabinet covered with the original packaging until installation is complete and all plastering, painting, etc. is ﬁ nished.

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

4. Inspect all electrical connections. Connections must be clean and tight at the terminals.

CAUTION! CUT HAZARD - Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing heat pumps.

Carrier: Turn to the Experts

Page 6

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Equipment Selection

The installation of geothermal 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.

General

Proper indoor coil selection is critical to system efﬁ ciency. Using an older-model coil can affect efﬁ ciency and may not provide the customer with rated or advertised EER and COP. Coil design and technology have dramatically improved operating efﬁ ciency and capacity in the past 20 years. Homeowners using an older coil are not reaping these cost savings and comfort beneﬁ ts. NEVER MATCH AN R-22 INDOOR COIL WITH AN R-410A COMPRESSOR SECTION.

Newer indoor coils have a larger surface area, enhanced ﬁ n design, and grooved tubing. These features provide a larger area for heat transfer, improving efﬁ ciency and expanding capacity. Typical older coils may only have one-third to onehalf the face area of these redesigned coils.

Table 1a: GT-PX Air Handler Matches for ARI Ratings

Indoor Coil Selection - GT-PX Split (50YDS)

Carrier Geothermal split system heat pumps are rated in the ARI directory with a speciﬁ c indoor coil match. GT-PX Split (50YDS) models are rated with Carrier/Bryant FV4 or FE4 series variable speed air handlers as shown in Table 1a. Other brands of air handlers may attain the same ARI ratings providing that the speciﬁ cations meet or exceed those listed in Table 1a AND Table 1b. An ECM motor and TXV is required. Cap tubes and ﬁ xed oriﬁ ces are not acceptable. PSC fans may be used if matched to Table 1b, but will not meet ARI ratings. If using PSC fan, compressor section must be operated as a single stage unit (i.e. wired for either 1st stage or 2nd stage). Without the ability to vary the airﬂ ow, supply air temperatures may not be acceptable if the compressor is allowed to change stages when used with a PSC fan motor.

Compressor Section 026 038 049 064

Air Handler Model FV4

003 005 006 006

Refrigerant R-410A

Metering Device TXV (required)

Air Coil Type Rows - Fins/in. Face Area (sq. ft.)

Cabinet Conﬁ gura-

Slope

3 - 14.5

3.46

3 - 14.5

5.93

Upﬂ ow/Downﬂ ow/Horizontal (Multipoise)

3 - 14.5

7.42

3 - 14.5

7.42

tion

ECM Settings for ARI Ratings (FV4 Fan Coil)

AC/HP size: 036

System Type:

Comfort AC/HP

CFM Adjust: Nom

AC/HP size: 036

System Type:

HP-Efﬁ c AC/HP

CFM Adjust: High

AC/HP size: 048

System Type:

Comfort AC/HP

CFM Adjust: High

AC/HP size: 060

System Type:

Comfort AC/HP

CFM Adjust: High

Fan Motor Type - HP ECM - 1/2 ECM - 1/2 ECM - 3/4 ECM - 3/4

Water-Source Heating and Cooling Systems

Page 7

Residential Split - 60Hz R22 &R410A

Table 1b: GT-PX Air Handler Characteristics for Brands other than Above Models

Rev.: 5 June, 2008

Equipment Selection

Model*

Nominal

Tons*

Evaporator

Temp (ºF)

CFM

Capacity

(MBtuh)**

026 - Part Load 1.5 50 530 19.2 - 22.4

026 - Full Load 2.0 52 880 24.2 - 28.2

038 - Part Load 2.5 51 700 25.2 - 29.2

038 - Full Load 3.0 50 1200 34.5 - 40.1

049 - Part Load 3.5 47 1000 34.3 - 39.9

049 - Full Load 4.0 48 1650 46.3 - 53.8

064 - Full Load 5.0 48 1850 54.5 - 63.3

* Nominal tons are at ARI/ISO 13256-1 GLHP conditions. Two-stage units may be operated in single-stage mode if desired, where smaller

capacity is required. For example, a model 026 may be used as a 1-1/2 ton unit if “locked” into 1st stage operation only. If PSC fan is used, unit must be “locked” into either 1st or 2nd stage. An ECM fan is required for two-stage operation and for ARI ratings. Size air handler for “Full Load” if operating in two-stage mode.

**When selecting an air handler based upon the above conditions, choose entering WB temperature of 67ºF. Use evaporator temperature,

CFM and capacity requirements as listed above. The air handler capacity must be at least at the minimum capacity shown in the table in order for the ARI rating condition to be valid. See Figure 1 for an example selection.

Indoor Coil Selection - R-22 Units

Geothermal split system heat pumps with R-22 refrigerant are rated in the ARI directory with a “generic” indoor coil match and PSC fan. Selection of air handlers that attain the published ARI ratings must meet or exceed the speciﬁ cations listed in Table 2. A TXV is required. Cap tubes and ﬁ xed oriﬁ ces are not acceptable.

Table 2: R-22 Air Handler Characteristics

Model*

Nominal

Tons*

018 1.5 50 600 18.5 - 21.3

024 2.0 47 800 25.5 - 29.3

030 2.5 49 1000 31.5 - 36.2

036 3.0 48 1200 37.0 - 42.5

042 3.5 45 1400 42.2 - 48.5

048 4.0 46 1600 50.0 - 57.5

060 5.0 45 2000 58.0 - 66.7

* Nominal tons are at ARI/ISO 13256-1 GLHP conditions. **When selecting an air handler based upon the above conditions, choose entering WB temperature of 67ºF. Use evaporator temperature,

Evaporator

Temp (ºF)

CFM

Capacity

(MBtuh)**

Carrier: Turn to the Experts

Page 8

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Equipment Selection

Air Handler Selection Example

Figure 1 shows a typical performance table for a heat pump air handler. Suppose the evaporator temperature required is 50ºF, the capacity required is 35,000 Btuh and the airﬂ ow required is 1,200 CFM. Each evaporator temperature listed in the table shows three wet bulb temperatures. As recommended in the table notes above, select the 67ºF WB column. At 1,200 CFM, the model 003 capacity is 36 MBtuh, which is higher than the minimum capacity required of 35,000 Btuh. In this example, model 003 would be the appropriate match.

Figure 1: Selecting Air Handler

Utilizing the Existing Air Handler or Coil (R22 units only)

It is recommended that a new coil or air handler be installed with any geothermal split system compressor section due to the low initial cost of the additional equipment versus the reliability and beneﬁ t of new technology, increased reliability and warranty. However, if the existing air handler must be used (R22 systems only), the following conditions apply:

• If the existing coil currently uses an oriﬁ ce, the oriﬁ ce

must be removed and replaced with a TXV. If the coil utilizes capillary tubes, it will not operate properly with the geothermal split system and should be replaced.

• If life expectancy of indoor coil (and associated components

- fan, cabinet, etc.) is less than 7-10 years, indoor section should be replaced.

Water-Source Heating and Cooling Systems

Page 9

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Installation

NOTICE! Failure to remove shipping brackets from springmounted compressors will cause excessive noise, and could cause component failure due to added vibration.

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.

Removing Existing Condensing Unit (Where Applicable)

1. Pump down condensing unit. Close the liquid line service valve of existing condensing unit and start compressor to pump refrigerant back into compressor section. Then, close suction service valve while compressor is still running to trap refrigerant in outdoor section. Immediately kill power to the condensing unit.

2. Disconnect power and low voltage and remove old condensing unit. Cut or unbraze line set from unit. Remove condensing unit.

3. If condensing unit is not operational or will not pump down, refrigerant should be recovered using appropriate equipment.

4. Replace line set, especially if upgrading system from R22 to R-410A refrigerant. If line set cannot be replaced, it must be thoroughly ﬂ ushed before installing new compressor section. R-410A compressors use POE oil instead of mineral oil (R-22 systems). Mineral oil is not compatible with POE oil, and could cause system damage if not completely ﬂ ushed from the line set.

“Indoor” Compressor Section Location

Both “indoor” and “outdoor” versions of the geothermal split system compressor section are available. “Indoor” version is not designed for outdoor installation. Locate the unit in an INDOOR area that allows enough space for service personnel to perform typical maintenance or repairs without removing unit. Units are typically installed in a mechanical room or closet. Never install units in areas subject to freezing or where humidity levels could cause cabinet condensation (such as unconditioned spaces subject to 100% outside air). Consideration should be given to access for easy removal of service access panels. Provide sufﬁ cient room to make water, electrical, and line set connections.

2. Provide adequate clearance for maintenance and service. Do not block access panels with piping, conduit or other materials.

3. Provide access for servicing the compressor and coils without removing the unit.

4. Provide an unobstructed path to the unit within the closet or mechanical room. Space should be sufﬁ cient to allow removal of the unit, if necessary.

In limited side access installations, pre-removal of the control box side mounting screws will allow control box removal for future servicing (R22 units only).

6. Provide access to water valves and ﬁ ttings and screwdriver access to the unit side panels and all electrical connections.

“Outdoor” Compressor Section Loacation

Locate the unit in an outdoor area that allows easy loop and lineset access and also has enough space for service personnel to perform typical maintenance or repairs. The “outdoor” compressor section is usually installed on a condensor pad directly outside the lineset access into the building. The service valve side can be located toward the building, keeping the loop access end away from the building. Conform to the following guidelines when selecting unit location:

1. Provide adequate access for loop trench excavation.

Locate unit directly outside lineset penetration if possible. Utilize existing condensor pad where possible.

3. Provide access for servicing and maintenance.

“Outdoor” compressor section may be mounted on a vibration isolation pad with loop access hole as shown in Figure 3. When mounting on an existing concrete condenser pad, 3” [76mm] holes should be bored through the pad to accomodate the pipe (1-1/4” - 32mm) and insulation (1/2” [13mm] wall thickness). Figure 3 illustrates location and dimensions of the holes required.

Air Handler Installation

This manual speciﬁ cally addresses the compressor section of the system. Air handler location and installation should be according to the instructions provided with the air handling unit.

Any access panel screws that would be difﬁ cult to remove after the unit is installed should be removed prior to setting the unit. Refer to Figure 2 for an illustration of a typical installation. Refer to “Physical Dimensions” section for dimensional data. selecting unit location:

Install the unit on a piece of rubber, neoprene or other

1. mounting pad material for sound isolation. The pad should be at least 3/8” [10mm] to 1/2” [13mm] in thickness. Extend the pad beyond all four edges of the unit.

Conform to the following guidelines when

Carrier: Turn to the Experts

Page 10

Residential Split - 60Hz R22 &R410A

Air Pad with access hole

Existing Pad larger than 22" x 33" [54 x 84cm]

Bottom view

of Unit

22" x 33"

[56 x 84cm]

Flow

Controller

8.00"

25"

[63.5cm]

Drill 3" [76mm] holes for

clearance of 1-1/4" [32mm] pipe

with 1/2" [13mm] wall insulation

5.5"

[14.0cm]

8.25"

[21.0cm]

Gasket

Swivel Nut

Stainless steel

snap ring

Brass Adaptor

Hand Tighten

Only!

Do Not

Overtighten!

Rev.: 5 June, 2008

Installation

Figure 2: 50YDS/GT-GS Installation

Figure 3: GT-S Installation

External Flow Controller Mounting

The Flow Controller can be mounted beside the unit as shown in Figure 7. Review the Flow Controller installation manual for more details.

Water Connections-Residential (Distributor) Models

Residential models utilize swivel piping ﬁ ttings for water connections that are rated for 450 psi (3101 kPa) operating pressure. The connections have a rubber gasket seal similar to a garden hose gasket, which when mated to the

ﬂ ush end of most 1” threaded male pipe ﬁ ttings provides a leak-free seal without the need for thread sealing tape or joint compound. Insure that the rubber seal is in the swivel connector prior to attempting any connection (rubber seals are shipped attached to the swivel connector). DO NOT OVER TIGHTEN or leaks may occur.

Water-Source Heating and Cooling Systems

The female locking ring is threaded onto the pipe threads which holds the male pipe end against the rubber gasket, and seals the joint. HAND TIGHTEN ONLY! DO NOT OVERTIGHTEN!

Figure 4: Water Connections (Indoor Compressor Section)

Page 11

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Installation

Internal Flow Controller Mounting “Outdoor” Compressor Section Only

The Flow Controller can be mounted in the “outdoor” compressor section directly inside the cabinet as shown in Figure 5. Remove the water legs from the outdoor unit at the union ﬁ ttings. Attached the AFC4T 1” MPT x o-ring ﬁ ttings to the removed water legs. Carefully attached the Flow Controller to the loop piping and mount to the outdoor unit using the mounting lugs attached to the unit. Insert the water legs into the Flow Controller using the o-ring ﬁ ttings. Re- connect the water leg unions.

NOTICE! Opening in the bottom of the unit for loop piping must be sealed to prevent rodents from getting into the cabinet and damaging control wiring. Spray type foam may be used to seal the opening(s).

Figure 6: AFC4T Connector

Figure 5: Water Connections (Outdoor Compressor Section)

1” IPT Water Connections

Mount Flow Controller

on studs provided

Wire pump power

using provided wires

for L1 and L2

GROUND-LOOP HEAT PUMP APPLICATIONS

 CAUTION! 

CAUTION! The following instructions represent industry accepted installation practices for closed loop earth coupled heat pump systems. Instructions are provided to assist the contractor in installing trouble free ground loops. These instructions are recommendations only. State/provincial and local codes MUST be followed and installation MUST conform to ALL applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations.

Pre-Installation

Prior to installation, locate and mark all existing underground utilities, piping, etc. Install loops for new construction before sidewalks, patios, driveways, and other construction has begun. During construction, accurately mark all ground loop piping on the plot plan as an aid in avoiding potential future damage to the installation.

Piping Installation

The typical closed loop ground source system is shown in Figures 7 and 8. All earth loop piping materials should be limited to polyethylene fusion only for in-ground sections of the loop. Galvanized or steel ﬁ ttings should not be used at any time due to their tendency to corrode. All plastic to metal threaded ﬁ ttings should be avoided due to their potential to leak in earth coupled applications. A ﬂ anged ﬁ tting should be substituted. P/T plugs should be used so that ﬂ ow can be measured using the pressure drop of the unit heat exchanger.

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Page 12

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Ground-Loop Heat Pump Applications

Earth loop temperatures can range between 25 and 110°F [-4 to 43°C]. Flow rates between 2.25 and 3 gpm per ton [2.41 to 3.23 l/m per kW] of cooling capacity is recommended in these applications.

Test individual horizontal loop circuits before backﬁ lling. Test vertical U-bends and pond loop assemblies prior to installation. Pressures of at least 100 psi [689 kPa] should be used when testing. Do not exceed the pipe pressure rating. Test entire system when all loops are assembled.

Flushing the Earth Loop

Once piping is completed between the unit, Flow Controller and the ground loop (Figures 7 and 8), the loop is ready for ﬁ nal purging and charging. A ﬂ ush cart with at least a 1.5 hp [1.1 kW] pump is required to achieve enough ﬂ uid velocity in the loop piping system to purge air and dirt particles. An antifreeze solution is used in most areas to prevent freezing. All air and debris must be removed from the earth loop piping before operation. Flush the loop with a high volume of water at a minimum velocity of 2 fps (0.6 m/s) in all piping. The steps below must be followed for proper ﬂ ushing.

1. Fill loop with water from a garden hose through the ﬂ ush cart before using the ﬂ ush cart pump to insure an even ﬁ ll.

2. Once full, the ﬂ ushing process can begin. Do not allow the water level in the ﬂ ush cart tank to drop below the pump inlet line to avoid air being pumped back out to the earth loop.

3. Try to maintain a ﬂ uid level in the tank above the return tee so that air cannot be continuously mixed back into the ﬂ uid. Surges of 50 psi (345 kPa) can be used to help purge air pockets by simply shutting off the return valve going into the ﬂ ush cart reservoir. This “dead heads” the pump to 50 psi (345 kPa). To purge, dead head the pump until maximum pumping pressure is reached. Open the return valve and a pressure surge will be sent through the loop to help purge air pockets from the piping system.

4. Notice the drop in ﬂ uid level in the ﬂ ush cart tank when the return valve is shut off. If air is adequately purged from the system, the level will drop only 1-2 inches (2.5

- 5 cm) in a 10” (25 cm) diameter PVC ﬂ ush tank (about a half gallon [2.3 liters]), since liquids are incompressible. If the level drops more than this, ﬂ ushing should continue since air is still being compressed in the loop ﬂ uid. Perform the “dead head” procedure a number of times.

Note: This ﬂ uid level drop is your only indication of air in the loop.

Antifreeze may be added before, during or after the ﬂ ushing procedure. However, depending upon which time is chosen, antifreeze could be wasted when emptying the ﬂ ush cart tank. See antifreeze section for more details.

Loop static pressure will ﬂ uctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This ﬂ uctuation is normal and should be considered when charging the system initially. Run the unit in either heating or cooling for a number of minutes to condition the loop to a homogenous temperature. This is a good time for tool cleanup, piping insulation, etc. Then, perform ﬁ nal ﬂ ush and pressurize the loop to a static pressure of 50-75 psi [345-517 kPa] (winter) or 35-40 psi [241-276 kPa] (summer). After pressurization, be sure to loosen the plug at the end of the Grundfos loop pump motor(s) to allow trapped air to be discharged and to insure the motor housing has been ﬂ ooded. This is not required for Taco circulators. Insure that the Flow Controller provides adequate ﬂ ow through the unit by checking pressure drop across the heat exchanger and compare to the pressure drop tables at the back of the manual.

Antifreeze

In areas where minimum entering loop temperatures drop below 40°F [5°C] or where piping will be routed through areas subject to freezing, antifreeze is required. Alcohols and glycols are commonly used as antifreeze; however your local sales manager should be consulted for the antifreeze best suited to your area. Freeze protection should be maintained to 15°F [9°C] below the lowest expected entering loop temperature. For example, if 30°F [-1°C] is the minimum expected entering loop temperature, the leaving loop temperature would be 25 to 22°F [-4 to -6°C] and freeze protection should be at 15°F [-10°C]. Calculation is as follows: 30°F - 15°F = 15°F [-1°C - 9°C = -10°C].

All alcohols should be premixed and pumped from a reservoir outside of the building when possible or introduced under the water level to prevent fumes. Calculate the total volume of ﬂ uid in the piping system. Then use the percentage by volume shown in Table 2 for the amount of antifreeze needed. Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure speciﬁ c gravity.

Low Water Temperature Cutout Setting CXM or DXM Control

When antifreeze is selected, the FP1 jumper (JW3) should be clipped to select the low temperature (antifreeze 13°F [-10.6°C]) set point and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). NOTE: Low water temperature operation requires extended range equipment.

Water-Source Heating and Cooling Systems

Page 13

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Ground-Loop Heat Pump Applications

Table 1: Approximate Fluid Volume (U.S. gal. [L]) per 100' of Pipe

Fluid Volume (gal [liters] per 100’ [30 meters) Pipe)

Pipe Size Volume (gal) [liters]

1” 4.1 [15.3]

Copper

Rubber Hose 1” 3.9 [14.6]

Polyethylene

Unit Heat Exchanger Typical 1.0 [3.8]

Flush Cart Tank

1.25” 6.4 [23.8]

2.5” 9.2 [34.3]

3/4” IPS SDR11 2.8 [10.4]

1” iPS SDR11 4.5 [16.7]

1.25” IPS SDR11 8.0 [29.8]

1.5” IPS SDR11 10.9 [40.7]

2” IPS SDR11 18.0 [67.0]

1.25” IPS SCH40 8.3 [30.9]

1.5” IPS SCH40 10.9 [40.7]

2” IPS SCH40 17.0 [63.4]

10” Dia x 3ft tall

[254mm x 91.4cm tall]

10 [37.9]

Figure 7: Loop Connection (Indoor Compressor Section)

Unit Power Disconnect

AH & Thermostat Wiring

Air Pad or Extruded polystyrene insulation board

Flow

Controller

Insulated

Hose Kit

To Loop

P/T Plugs

Figure 8: Loop Connection (Outdoor Compressor Section)

P/T Ports

Flow Controller

Insulate all piping with 1/2"

[13mm] closed cell insulation

Backfill carefully to avoid stress on piping and flow

controller connection

Air Pad with access hole

Header Pit

Table 2: Antifreeze Percentages by Volume

Type

Methanol 100% USP food grade Propylene Glycol Ethanol*

10°F [-12.2°C] 15°F [-9.4°C] 20°F [-6.7°C] 25°F [-3.9°C]

25% 38% 29%

Minimum Temperature for Low Temperature Protection

NOTICE! Cabinet opening around loop piping (outdoor compressor section) must be sealed to prevent entry of rodents that could potentially damage unit wiring by chewing on the insulation.

NOTICE! Outdoor compressor section may not be tilted more than 5 degrees from level. Damage to the compressor or stress on the loop piping could result if unit is tilted. A concrete pad, anchor posts and/or soil compaction may be required to avoid tilting as ground settles.

21% 25% 25%

16% 22% 20%

10% 15% 14%

* Must not be denatured with any petroleum based product

Carrier: Turn to the Experts

Page 14

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Ground-Water Heat Pump Applications “Indoor” Compressor Section Only

Open Loop - Ground Water Systems (“Indoor” Compressor Section Only)

The “outdoor” version of the compressor section may not be used with open loop systems due to potential freezing of water piping. Typical open loop piping is shown in Figure 9. Shut off valves should be included for ease of servicing. Boiler drains or other valves should be “tee’d” into the lines to allow acid ﬂ ushing of the heat exchanger. Shut off valves should be positioned to allow ﬂ ow through the coax via the boiler drains without allowing ﬂ ow into the piping system. P/T plugs should be used so that pressure drop and temperature can be measured. Piping materials should be limited to copper or PVC SCH80. Note: Due to the pressure and temperature extremes, PVC SCH40 is not recommended.

Water quantity should be plentiful and of good quality. Consult Table 3 for water quality guidelines. The unit can be ordered with either a copper or cupro-nickel water heat exchanger. Consult Table 3 for recommendations. Copper is recommended for closed loop systems and open loop ground water systems that are not high in mineral content or corrosiveness. In conditions anticipating heavy scale formation or in brackish water, a cupro-nickel heat exchanger is recommended. In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, an open loop system is not recommended. Heat exchanger coils may over time lose heat exchange capabilities due to build up of mineral deposits. Heat exchangers must only be serviced by a qualiﬁ ed technician, as acid and special pumping equipment is required. Desuperheater coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional acid ﬂ ushing. In some cases, the desuperheater option should not be recommended due to hard water conditions and additional maintenance required.

Water Quality Standards

Table 3 should be consulted for water quality requirements. Scaling potential should be assessed using the pH/Calcium hardness method. If the pH <7.5 and the Calcium hardness is less than 100 ppm, scaling potential is low. If this method yields numbers out of range of those listed, the Ryznar Stability and Langelier Saturation indecies should be calculated. Use the appropriate scaling surface temperature for the application, 150°F [66°C] for direct use (well water/ open loop) and DHW (desuperheater); 90°F [32°F] for indirect use. A monitoring plan should be implemented in these probable scaling situations. Other water quality issues such as iron fouling, corrosion prevention and erosion and clogging should be referenced in Table 3.

Expansion Tank and Pump

Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. The expansion tank should be sized to provide at least one minute continuous run time of the pump using its drawdown capacity rating to

prevent pump short cycling. Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local building codes (e.g. recharge well, storm sewer, drain ﬁ eld, adjacent stream or pond, etc.). Most local codes forbid the use of sanitary sewer for disposal. Consult your local building and zoning department to assure compliance in your area.

The pump should be sized to handle the home’s domestic water load (typically 5-9 gpm [23-41 l/m]) plus the ﬂ ow rate required for the heat pump. Pump sizing and expansion tank must be chosen as complimentary items. For example, an expansion tank that is too small can causing premature pump failure due to short cycling. Variable speed pumping applications should be considered for the inherent energy savings and smaller expansion tank requirements.

Water Control Valve

Note the placement of the water control valve in ﬁ gure 9. Always maintain water pressure in the heat exchanger by placing the water control valve(s) on the discharge line to prevent mineral precipitation during the off-cycle. Pilot operated slow closing valves are recommended to reduce water hammer. If water hammer persists, a mini-expansion tank can be mounted on the piping to help absorb the excess hammer shock. Insure that the total ‘VA’ draw of the valve can be supplied by the unit transformer. For instance, a slow closing valve can draw up to 35VA. This can overload smaller 40 or 50 VA transformers depending on the other controls in the circuit. A typical pilot operated solenoid valve draws approximately 15VA (see Figure 24). Note the special wiring diagrams for slow closing valves (Figures 25 & 26).

Flow Regulation

Flow regulation can be accomplished by two methods. One method of ﬂ ow regulation involves simply adjusting the ball valve or water control valve on the discharge line. Measure the pressure drop through the unit heat exchanger, and determine ﬂ ow rate from Tables 11a through 11b. Since the pressure is constantly varying, two pressure gauges may be needed. Adjust the valve until the desired ﬂ ow of

1.5 to 2 gpm per ton [2.0 to 2.6 l/m per kW] is achieved. A second method of ﬂ ow control requires a ﬂ ow control device mounted on the outlet of the water control valve. The device is typically a brass ﬁ tting with an oriﬁ ce of rubber or plastic material that is designed to allow a speciﬁ ed ﬂ ow rate. On occasion, ﬂ ow control devices may produce velocity noise that can be reduced by applying some back pressure from the ball valve located on the discharge line. Slightly closing the valve will spread the pressure drop over both devices, lessening the velocity noise. NOTE: When EWT is below

50°F [10°C], a minimum of 2 gpm per ton (2.6 l/m per kW) is required.

Water-Source Heating and Cooling Systems

Page 15

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Ground-Water Heat Pump Applications

Water Coil Low Temperature Limit Setting

For all open loop systems the 30°F [-1.1°C] FP1 setting (factory setting-water) should be used to avoid freeze damage to the unit. See “Low Water Temperature Cutout Selection” in this manual for details on the low limit setting.

 CAUTION! 

CAUTION! Many units installed with a factory or ﬁ eld supplied manual or electric shut-off valve. DAMAGE WILL OCCUR if shut-off valve is closed during unit operation. A high pressure switch must be installed on the heat pump side of any ﬁ eld provided shut-off valves and connected to the heat pump controls in series with the built-in refrigerant circuit high pressure switch to disable compressor operation if water pressure exceeds pressure switch setting. The ﬁ eld installed high pressure switch shall have a cut-out pressure of 300 psig and a cut-in pressure of 250 psig. This pressure switch can be ordered from Carrier Geothermal with a 1/4” internal ﬂ are connection as part number 39B0005N02.

 CAUTION! 

CAUTION! Refrigerant pressure activated water regulating

valves should never be used with Carrier Geothermal equipment.

Figure 9: Water Well Connections

Wate r

Control

Va l v e

P/T Plugs

Flow

Regulator

Boiler

Drains

Pressure

Ta n k

Water Out

Water In

Shut-Off

Valve

Optional

Filter

Carrier: Turn to the Experts

Page 16

Residential Split - 60Hz R22 &R410A



Rev.: 5 June, 2008

Water Quality Standards

Table 3: Water Quality Standards

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7HYHTL[LY

4H[LYPHS

*SVZLK

9LJPYJ\SH[PUN

6WLU3VVWHUK9LJPYJ\SH[PUN>LSS

:JHSPUN7V[LU[PHS7YPTHY`4LHZ\YLTLU[

(IV]L[OLNP]LUSPTP[ZZJHSPUNPZSPRLS`[VVJJ\Y:JHSPUNPUKL_LZZOV\SKILJHSJ\SH[LK\ZPUN[OLSPTP[ZILSV^

W/*HSJP\T/HYKULZZ

4L[OVK

(SS



W/#HUK*H/HYKULZZ#WWT

0UKL_3PTP[ZMVY7YVIHISL:JHSPUN:P[\H[PVUZ6WLYH[PVUV\[ZPKL[OLZLSPTP[ZPZUV[YLJVTTLUKLK

:JHSPUNPUKL_LZZOV\SKILJHSJ\SH[LKH[-B*DMVYKPYLJ[\ZLHUK/>.HWWSPJH[PVUZHUKH[ -B*DMVYPUKPYLJ[/?\ZL (TVUP[VYPUNWSHUZOV\SKILPTWSLTLU[LK

9`aUHY :[HIPSP[`0UKL_ 0M%TPUPTPaLZ[LLSWPWL\ZL

3HUNLSPLY :H[\YH[PVU0UKL_

(SS

 



0M#TPUPTPaLZ[LLSWPWL\ZL)HZLK\WVU-B*D/

[V

+PYLJ[^LSS-B *D0UKPYLJ[>LSS/?

0YVU-V\SPUN

0YVU-L-LYYV\Z )HJ[LYPHS0YVUWV[LU[PHS

0YVU-V\SPUN

(SS





MLYYV\Z%WWT^P[OW/6#WWTJOLJRMVYPYVU

0M-L

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#WWT-LYYV\Z

#WWTVM6_`NLU

*VYYVZPVU7YL]LU[PVU

/`KYVNLU:\SMPKL/

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4H_PT\T *OSVYPKL3L]LSZ

:





(SS

*VWWLY  #WWT 59 NR

*\WYV5PJRLS  #WWT 59 NR

::  #WWT #WWT <150 p ::  #WWT #WWT < 375 p

;P[HUP\T  %WWT %WWT >375 p

4VUP[VY[YLH[HZ

ULLKLK

 #WWT



4PUPTPaLZ[LLSWPWLILSV^HUKUVVWLU[HURZ^P[OW/#

([/

:%WWTH]VPK\ZLVMJVWWLYHUKJVWWLYUPJRLSWPWPU



*VWWLYHSSV`IYVUaLVYIYHZZJHZ[JVTWVULU[ZHYL62[V#

-* -* 100¯F (3

9V[[LULNNZTLSSHWWLHYZH[WWTSL]LS

4H_PT\T(SSV^HISLH[TH_PT\T^H[LY[LTWLYH[\YL



#WWT

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#WWTVMWHY[PJSLZ

7HY[PJ\SH[L:PaLHUK ,YVZPVU

HUKHTH_PT\T ]LSVJP[`VMMWZBTZD

(SS

-PS[LYLKMVYTH_PT\T TPJYVUBTT TLZODZPaL

#WWT#WWTZHUKMYLLMVYYLPUQLJ[PVUVMWHY[PJSLZHUKH ]LSVJP[`VMMWZBTZD-PS[LYLKMVYTH_PT\TTPJYVUB TLZODZPaL(U`WHY[PJ\SH[L[OH[PZUV[YLTV]LKJHUWV[LU[PH JSVNJVTWVULU[Z

Notes:

s#LOSED2ECIRCULATINGSYSTEMISIDENTIFIEDBYA

s2ECIRCULATINGOPENWELLSSHOULDOBSERVETHEOPENRECIRCULATINGDESIGNCONSIDERATIONS

s.2Application not recommended. s.ODESIGN-AXIMUM

CLOSEDPRESSURIZEDPIPINGSYSTEM

Water-Source Heating and Cooling Systems

Page 17

 CAUTION! 

CAUTION! R-410A systems operate at higher pressures than R-22 systems. Be certain that service equipment (gauges, tools, etc.) is rated for R-410A. Some R-22 service equipment may not be acceptable.

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Refrigeration Installation

R-410A models are shipped with a ﬁ lter drier (loose) inside the cabinet that must be installed in the liquid line at the line set.

All brazing should be performed using nitrogen circulating at 2-3 psi [13.8-20.7 kPa] to prevent oxidation inside the tubing. All linesets should be insulated with a minimum of 1/2” [13mm] thick closed cell insulation. All insulation tubing should be sealed using a UV resistant paint or covering to prevent deterioration from sunlight.

 CAUTION! 

CAUTION! Installation of a factory supplied liquid line bi-directional ﬁ lter drier is required. Never install a suction line ﬁ lter in the liquid line.

When passing refrigerant lines through a wall, seal opening with silicon-based caulk. Avoid direct contact with water pipes, duct work, ﬂ oor joists, wall studs, ﬂ oors or other structural components that could transmit compressor vibration. Do not suspend refrigerant tubing from joists with rigid straps. Do not attach line set to the

Line Set Installation

Figures 12a through 13b illustrate typical installations with the “indoor” and “outdoor” versions of the compressor section

wall. When necessary, use hanger straps with isolation sleeves to minimize transmission of line set vibration to the structure.

matched to either an air handler (fan coil) or add-on furnace coil. Table 4 shows typical line-set diameters at various lengths. Lineset lengths should be kept to a minimum and should always be installed with care to avoid kinking. Line sets over 60 feet [18 meters] long are not recommended due to potential oil transport problems and excessive pressure drop. If the line set is kinked or distorted, and it cannot be formed back into its original shape, the damaged portion of the line should be replaced. A restricted line set will effect the performance of the system.

Installing the Lineset at the Compressor Section

Braze the line set to the service valve stubs as shown in Figure

10. On installations with long line sets, copper adapters may be needed to connect the larger diameter tube to the stubs. Nitrogen should be circulated through the system at 2-3 psi [13.8-20.7 kPa] to prevent oxidation contamination. Use a low silver phos-copper braze alloy on all brazed connections.

Compressor section is shipped with a factory charge. Therefore, service valves should not be opened until the

A reversible heat pump ﬁ lter drier is installed on the liquid line inside the compressor section cabinet (R-22 units only).

line set has been leak tested, purged and evacuated. See “Charging the System.”

Table 4: Lineset Diameters and Charge Information

Factory†

Model

018 70 [1.98] 55 [1.56] 3/8” 3/4” 3/8” 3/4” 3/8” 3/4”

024 74 [2.10] 59 [1.67] 3/8” 3/4” 3/8” 3/4” 3/8” 7/8”

030 108 [3.06] 93 [2.64] 3/8” 3/4” 3/8” 7/8” 3/8” 7/8”

036 117 [3.32] 102 [2.89] 3/8” 3/4” 3/8” 7/8” 3/8” 7/8”

042 122 [3.46] 107 [3.03] 3/8” 7/8” 3/8” 7/8” 3/8” 7/8”

048 130 [3.69] 115 [3.26] 3/8” 7/8” 3/8” 7/8” 1/2” 1-1/8”

060 136 [3.86] 121 [3.43] 3/8” 1-1/8” 1/2” 1-1/8” 1/2” 1-1/8”

026 90 [2.55] 75 [2.13] 3/8” 3/4” 3/8” 3/4” 3/8” 7/8”

038 104 [2.95] 89 [2.52] 3/8” 7/8” 3/8” 7/8” 3/8” 7/8”

049 126 [3.57] 111 [3.15] 3/8” 7/8” 3/8” 7/8” 1/2” 1-1/8”

064 168 [4.76] 138 [3.91] 1/2” 1-1/8” 1/2” 1-1/8” 1/2” 1-1/8”

• Basic charge includes only the amount required for the condensing unit and the evaporating coil.

An additional amount should be added allowing 0.6oz per ft. for 3/8” [0.6g per cm] and 1.2oz per ft. for 1/2” [1.1g per cm] of lineset used. †Factory charge is preset for 25’ [7.6 meters] lineset.

Charge (oz)

[kg]

Basic*

Charge (oz)

[kg]

20 Feet [6 meters] 40 Feet [12 meters] 60 Feet [18 meters]

Liquid Suction Liquid Suction Liquid Suction

GT-GS/GT-S Series

50YDS Series

Carrier: Turn to the Experts

Page 18

Residential Split - 60Hz R22 &R410A

Fully Insulated

Suction Line

Fully Insulated

Liquid Line

Nitrogen Braze

Service ports for

gauges

CCW

Rev. 05/31/00

Replace Caps after adjusting

service valves

Braze

connection

Service ports for

attaching refrigerant

gauges

Replace caps after adjusting service valves

Rev.: 5 June, 2008

Refrigeration Installation

Figure 10: Braze Instructions

Figure 11: Air Coil Connection

Bulb

(Must be Insulated)

Equalizer

Line

Suction Line

Liquid Line

Add-On Heat Pump Applications

The indoor coil should be located in the supply side of the furnace to avoid condensation damage to the furnace heat exchanger for add-on heat pump applications. A high temperature limit switch should be installed as shown in Figures 12b and 13b just upstream of the coil to de-energize the compressor any time the furnace is energized to avoid blowing hot air directly into the coil, elevating refrigerant pressures during operation. The heat pump will trip out on high pressure lockout without some method of disengaging the compressor during furnace operation. Alternatively, some thermostats with “dual fuel” mode will automatically de-energize the compressor when second stage (backup) heat is required.

TXV (‘IN’ toward

compressor section)

TXV has internal

check valve

Table 5: Service Valve Positions

Installing the Indoor Coil and Lineset

Figure 11 shows the installation of the lineset and TXV to a typical indoor coil. An indoor coil or air handler (fan coil) with a TXV is required. Coils with cap tubes may not be used. If coil includes removable ﬁ xed oriﬁ ce, the oriﬁ ce must be removed and a TXV must be installed as shown in Figure 11. Fasten the copper line set to the coil. Nitrogen should be circulated through the system at 2-3 psi [13.8-20.7 kPa] to prevent oxidation inside the refrigerant tubing. Use a low silver phoscopper braze alloy on all brazed connections.

Water-Source Heating and Cooling Systems

The TXV should be brazed into place as shown in Figure 11, keeping the “IN” side toward the compressor section. The TXV has an internal check valve and must be installed in the proper direction for operation. Always keep the valve body cool with a brazing shield and wet rags to prevent damage to the TXV. Attach the bulb to the suction line using the supplied hose clamp. Be careful not to overtighten the clamp and deform the bulb.

NOTICE! The air coil should be thoroughly washed with a ﬁ lming agent, (dishwasher detergent like Cascade) to help condensate drainage. Apply a 20 to 1 solution of detergent and water. Spray both sides of coil, repeat and rinse thoroughly with water.

Evacuation and Charging the Unit LEAK TESTING -

The refrigeration line set must be pressurized and checked for leaks before evacuating and charging the unit. To pressurize the line set, attach refrigerant gauges to the service ports and add an inert gas (nitrogen or dry carbon dioxide) until pressure reaches 60-90 psig [413-620 kPa]. Never use oxygen or acetylene to pressure test. Use a halogen leak tester or a good quality bubble solution to detect leaks on all connections made in the ﬁ eld. Check the service valve ports and stem for leaks. If a leak is found, repair it and repeat the above steps. For safety reasons do not pressurize system above 150 psig [1034 kPa]. System is now ready for evacuation and charging.

Page 19

Residential Split - 60Hz R22 &R410A

Figure 12a: Typical Split/Air Handler Installation (Indoor Compressor Section)

Power

Disconnects

Insulated

Linesets

PVC Condensate

with vented trap

Compressor Section

Rev.: 5 June, 2008

Refrigeration Installation

TXV 'IN' toward

Compressor

Section

Low Voltage

Air pad or Extruded

polystryene

Figure 12b: Typical Split/Add-on Coil Fossil Fuel Furnace Installation (Indoor Compressor Section)

TXV 'IN' toward

Compressor

Compressor Section

Section

Air Temperature

Limit Switch

PVC Condensate

with vented trap

Air pad or Extruded

polystyrene

Carrier: Turn to the Experts

Page 20

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Refrigeration Installation

Figure 13a: Typical Split/Air Handler Installation (Outdoor Compressor Section)

Power

Compressor

Section

Disconnects

Insulated line set

with UV Paint

Air Handler

TXV ‘IN’ toward

compressor

section

Return Plenum

Pad

Low Voltage

Wiring

PVC

Condensate with

vented trap

Figure 13b: Typical Split/Add-on Coil Fossil Fuel Furnace Installation (Outdoor Compressor Section)

TXV ‘IN’ toward

compressor section

Power

Compressor

Section

Disconnects

Insulated

line set with

UV Paint

Fossil

Furnace

Add-On

‘A’ Coil

Air

Temperature

Limit Switch

Return

Plenum

Pad

Low Voltage

Wiring

Water-Source Heating and Cooling Systems

PVC

Condensate with

vented trap

Page 21

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Refrigeration Installation

Evacuation Of The Lineset And Coil

The line set and coil must be evacuated to at least 500 microns to remove any moisture and noncondensables. Evacuate the system through both service ports in the shipping position (full CW in - see table 5) to prevent false readings on the gauge because of pressure drop through service ports. A vacuum gauge or thermistor capable of accurately meausuring the vacuum depth is crucial in determining if the system is ready for charging. If the system meets the requirements in Figure 14, it is ready for charging.

Figure 14: Evacuation Graph

There are two methods of charging a refrigerant system. One method is the total charge method, where the volume of the system is determined and the refrigerant is measured and added into the evacuated system. The other method is the partial charge method where a small initial charge is added to an evacuated system, and remaining refrigerant added during operation.

Total Charge Method - See Table 4 for the compressor section basic charge. For line sets with 3/8” liquid lines add 0.6 ounces of refrigerant to the basic charge for every installed foot of liquid line [0.6 grams per cm]. Add 1.2 oz. per foot [1.1 grams per cm] if using l/2” line. Once the total charge is determined, the factory pre-charge (Table 4) is subtracted and the remainder is the amount needed to be added to the system. This method should be used with the ARI matched air handler.

EXAMPLE: R22 model 048 with 40 feet [12 meters] of installed liquid line (3/8” O.D.). The basic charge of model 048 is 115 oz [3.26 kg]. The 40 ft. [12 meter] 3/8” line set requires 24 oz. [0.72 kg] (40 ft. x 0.6 oz./ft = 24 oz. -1200cm x 0.6g/cm = 720g). Total charge = 115 + 24 = 139 oz [3.26 + 0.72 = 3.98 kg]. The compressor section is shipped from the factory with 130 oz. [3.69 kg] of refrigerant (for 25 ft [7.6m] lineset), so the amount to be added is 9 oz. [0.29 kg] (total charge - shipped charge = charge to be added).

Charging The System

Table 6a: R-22 Charging Values

 NOTICE! 

NOTICE: Use tables 14a to 15 for superheat/subcooling

values. These tables use discharge pressure (converted to saturation temperature) and liquid line temperature for subcooling calculations. If using liquid line pressure, subtract 3°F from the table values.

Turn service valves full out CCW (see Table 5) and then turn back in one-half turn to open service ports. Add the required

Table 6b: R-410A Charging Values

 NOTICE! 

NOTICE: Use tables 14a to 15 for superheat/subcooling

Carrier: Turn to the Experts

Page 22

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Refrigeration Installation

refrigerant so that the total charge calculated for the unit and line set is now in the system. Open the service valve fully counter clockwise so that the stem will backseat and prevent leakage through the schrader port while it is not in use. Start unit in the heating mode and measure superheat and subcooling values after 5 minutes of run time. See tables 14a to 15 for superheat and sub-cooling values. Superheat is measured using suction temperature and pressure at the compressor suction line. Subcooling should be measured using the liquid line temperature immediately outside the compressor section cabinet and either the liquid line service valve pressure or the compressor discharge pressure. Note that different values from tables 14a to 15 will be obtained due to the pressure losses through the condenser heat exchanger. Adding refrigerant will increase sub-cooling while superheat should remain fairly constant allowing for a slight amount of hunting in TXV systems. This increase in subcooling will require 5 minutes or so of operation before it should be measured. After values are measured, compare to the chart and go to “FINAL EVALUATION.”

PARTIAL CHARGE METHOD - Open service valve fully counterclockwise and then turn back in one-half turn to open service port. Add vaporized (Gas) into the suction side of the compressor until the pressure in the system reaches approximately 60-70 psig (R-22 systems) or 100120 psig (R-410A systems). Never add liquid refrigerant into the suction side of a compressor. Start the unit in heating and add gas to the suction port at a rate not to exceed ﬁ ve pounds [2.27 kg] per minute. Keep adding refrigerant until the complete charge has been entered. Superheat is measured using suction temperature and pressure at the compressor suction line. Subcooling should be measured using the liquid line temperature immediately outside the compressor section cabinet and either the liquid line service valve pressure or the compressor discharge pressure. Note that different values from tables 14a to 15 will be obtained due to the pressure losses through the condenser heat exchanger. Adding refrigerant will increase sub-cooling while superheat should remain fairly constant allowing for a slight amount of hunting in TXV systems. This increase in subcooling will require 5 minutes or so of operation before it should be measured. After values are measured, compare to the chart and go to “FINAL EVALUATION.”

FINAL EVALUATION -In a split system, cooling subcooling values can be misleading depending on the location of the measurement. Therefore, it is recommended that charging be monitored in the heating mode. Charge should be evaluated by monitoring the subcooling in the heating mode. After initial check of heating sub-cooling, shut off unit and allow to sit 3-5 minutes until pressures equalize. Restart unit in the cooling mode and check the cooling superheat against Tables 14a to 15. If unit runs satisfactorily, charging is complete. If unit does not perform to speciﬁ cations the cooling TXV (air coil side) may need to be readjusted (if possible) until the cooling superheat values are met.

Checking Superheat and Subcooling

Determining Superheat:

1. Measure the temperature of the suction line at a point

near the expansion valve bulb.

2. Determine the suction pressure by attaching refrigeration

gauges to the suction schrader connection at the compressor.

3. Convert the pressure obtained in step 2 to saturation

temperature (boiling point) by using the pressure/ temperature conversion table on the gauge set.

4. Subtract the temperature obtained in step 3 from step

1. The difference will be the superheat of the unit or the total number of degrees above saturation temperature. Refer to Tables 14a to 15 for superheat ranges at speciﬁ c entering water conditions.

Example (R-22 refrigerant):

The temperature of the suction line at the sensing bulb is 50°F. The suction pressure at the compressor is 65 psig which is equivalent to 38°F saturation temperature from the R-22 press/temp conversion table on the gauge set. 38°F subtracted from 50°F = 12°F Superheat.

Determining Sub-Cooling:

1. Measure the temperature of the liquid line on the smaller

refrigerant line (liquid line) just outside of the cabinet. This location will be adequate for measurement in both modes unless a signiﬁ cant temperature drop in the liquid line is anticipated.

2. Determine the condensor pressure (high side) by

attaching refrigerant gauges to the schrader connection on the liquid line service valve. If the hot gas discharge line of the compressor is used, refer to the appropriate column in Tables 14a to 15.

3. Convert the pressure obtained in step 2 to the

saturation temperature by using the press/temp conversion table on the gauge set.

Subtract the temperature of Step 3 from the temperature of Step 1. The difference will be the sub-cooling value for that unit (total degrees below the saturation temperature). Refer to Tables 14a or 6b for sub-cooling values at speciﬁ c entering water temperatures.

Example (R-22 refrigerant):

The condenser pressure at the service port is 225 psig, which is equivalent to 110°F saturation temperature. Discharge pressure is 236 psig at the compressor (113°F saturation temperature). Measured liquid line temperature is 100°F. 100°F subtracted from 110°F = 10 degrees subcooling (13 degrees if using the compressor discharge pressure).

Water-Source Heating and Cooling Systems

Page 23

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Hot Water Generator

The HWG (Hot Water Generator) or desuperheater option provides considerable operating cost savings by utilizing excess heat energy from the heat pump to help satisfy domestic hot water requirements. The HWG is active throughout the year, providing virtually free hot water when the heat pump operates in the cooling mode or hot water at the COP of the heat pump during operation in the heating mode. Actual HWG water heating capacities are provided in the appropriate heat pump performance data.

Heat pumps equipped with the HWG option include a built-in water to refrigerant heat exchanger that eliminates the need to tie into the heat pump refrigerant circuit in the ﬁ eld. The control circuit and pump are also built in for residential equipment. Figure 15 shows a typical example of HWG water piping connections on a unit with built-in pump. This piping layout minimizes scaling potential.

Electric water heaters are recommended. If a gas, propane, or oil water heater is used, a second preheat tank must be installed (Figure 16). If the electric water heater has only a single center element, the dual tank system is recommended to insure a usable entering water temperature for the HWG.

Typically a single tank of at least 52 gallons (235 liters) is used to limit installation costs and space. However, a dual tank, as shown in Figure 16, is the most efﬁ cient

system, providing the maximum storage and temperate source water to the HWG. Using a concentric or coaxial hot water tank connection ﬁ tting eliminates the need to tie into the hot water tank cold water piping, but is more susceptible to scaling. The optional concentric ﬁ tting (part # S69619804) is available from your equipment supplier and should be installed as shown in Figure 17 for applications with low scaling potential or where a water softener is used. Consult Table 3 for scaling potential tests.

It is always advisable to use water softening equipment on domestic water systems to reduce the scaling potential and lengthen equipment life. In extreme water conditions, it may be necessary to avoid the use of the HWG option since the potential cost of frequent maintenance may offset or exceed any savings.

R-410 systems inherently have a lower hot gas temperature than R-22 systems because the equipment is more efﬁ cient (i.e. less waste heat is available). It is possible that energy could be transferred from the water heater to the hot gas line instead of from the hot gas line to the water heater during certain times of the year. To prevent this from occuring, a temperature switch will deactivate the pump at those conditions that typically occur in the cooling mode with entering water temperatures of less than 50°F [10°C].

Figure 15: Typical HWG Installation (Indoor Compressor Section)

Domestic

Cold Supply

Shut-off Valve #2

Shut-off Valve #3

Shut-off

Valve #4

Insulated water lines -

5/8” OD, 50 ft maximum [16mm OD, 15 meters maximum]

Figure 16: HWG Double Tank In stal la tion (Indoor Compressor Section)

Cold Inlet

Hot Outlet

to home

Shut-off Valve

Upper

element to

120 - 130°F

[49 - 54°C]

Lower

Powered

Water Heater

element to

100 - 110°F

[38 - 43°C]

Tee and drain

Carrier: Turn to the Experts

Shut Off Valve #2

Hot Outlet to

Cold Inlet from

Domestic supply

Hot Outlet

Shut-off Valve #3

Water Heater

Insulated water lines - 5/8” OD, 50 ft maximum

[16mm OD, 15 meters maximum]

house

Shut-off

Valve #4

Unpowered

Field Supplied 3/4” brass nipple and “T”

Shut-off

Valve #1

Water Heater

Cold Inlet

Powered

Upper element to 130°F [54°C]

(or owner preference)

Lower element to 120°F [49°C]

Page 24

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Hot Water Generator

Figure 17: Alternate HWG Piping with concentric/coaxial ﬁ tting (part #S69619804 not included with unit)

(Indoor Compressor Section)

Hot Outlet

Cold Inlet

Upper element to

120-130ϒF

[49-54ϒC]

Insulated water lines 5/8" OD, 50 ft [15m] maximum

Compressor Section

Waste Vent Coupling

at high point

Coaxial

Fitting

Water Heater

Lower element to

100-110

[38-43

The heat pump, water piping, pump, and hot water tank should be located where the ambient temperature does not fall below 50°F [10°C]. Keep water piping lengths at a minimum. DO NOT use a one way length greater than 50 ft. [15 m].

All installations must be in accordance with local codes. The installer is responsible for knowing the local requirements, and for performing the installation accordingly. DO NOT connect the pump wiring until “Initial Start-Up” section, below. Powering the pump before all installation steps are completed will damage the pump.

Water Tank Preparation

1. Turn off power or fuel supply to the hot water tank.

2. Connect a hose to the drain valve on the water tank.

3. Shut off the cold water supply to the water tank.

4. Open the drain valve and open the pressure relief valve or a hot water faucet to drain tank.

5. When using an existing tank, it should be ﬂ ushed with cold water after it is drained until the water leaving the drain hose is clear and free of sediment.

6. Close all valves and remove the drain hose.

7. Install HWG water piping.

HWG Water Piping

1. Using at least 5/8” [16mm] O.D. copper, route and install the water piping, valves and air vent as shown in Figures 14, 15, or 16. An appropriate method must be employed to purge air from the HWG piping. This may be accomplished by ﬂ ushing water through the HWG (as In Figures 14 and 15) or by Installing an air vent at the high point of the HWG piping system (as in Figure 16).

2. Insulate all HWG water piping with no less than 3/8” [10mm] wall closed cell insulation.

3. Open both shut off valves and make sure the tank drain valve is closed.

Water Tank Reﬁ ll (Figures 14 and 15)

1. Close valve #4. Ensure that the HWG valves (valves #2 and #3) are open. Open the cold water supply (valve #1) to ﬁ ll the tank through the HWG piping. This will purge air from the HWG piping.

2. Open a hot water faucet to vent air from the system until water ﬂ ows from the faucet; turn off faucet. Open valve #4.

Water Tank Reﬁ ll (Figure 16)

1. Open the cold water supply to ﬁ ll the tank. Use the air vent to bleed air from the HWG piping.

2. Open a hot water faucet to vent air from the system until water ﬂ ows from the faucet; turn faucet off.

Water Tank Reﬁ ll (All)

Depress the hot water tank pressure relief valve handle to ensure that there is no air remaining in the tank.

4. Inspect all work for leaks.

Before restoring power or fuel supply to the water heater, adjust the temperature setting on the tank thermostat(s) to insure maximum utilization of the heat available from the refrigeration system and conserve the most energy. On tanks with both upper and lower elements and thermostats, the lower element should be turned down to 100°F [38°C] or the lowest setting; the upper element should be adjusted to 120-130°F [49-54°C]. Depending upon the speciﬁ c needs of the customer, you may want to adjust the upper element differently. On tanks with a single thermostat, a preheat tank should be used (ﬁ gure 16).

6. Replace access cover(s) and restore power or fuel supply.

Initial Start-Up

1. Make sure all valves in the HWG water circuit are fully open.

2. Turn on the heat pump and allow it to run for 10-15 minutes.

Figure 18: HWG In stal la tion (shown with optional concentric/coaxial ﬁ tting part #S69619804 not included with unit) (Outdoor Compressor Section)

Water

Heater

Waste Vent

Coupling

Coaxial

Fitting

Cold Inlet

Insulated

line set with

UV Paint

Insulated water

Insulated lineset

enters structure

Add-On Hot Water

Generator with

internal pump

lines

Hot

Outlet

Water-Source Heating and Cooling Systems

Page 25

Residential Split - 60Hz R22 &R410A

Unbraze u-tube

Hot water generator

service valve assembly

(inside cabinet)

Hot Gas to

Reversing Valve

Hot Gas from

Compressor

Field connection of

Hot Water lineset

Pinch off here after evacuating

lineset and opening valves

Open Valves CW Close

valves CCW as looking up

from underneath

Rev.: 5 June, 2008

Hot Water Generator Module Refrigeration Installation -

Outdoor Compressor Section Only

3. Turn the heat pump and heat pump power supply “OFF” and CONNECT POWER TO THE HWG PUMP as shown in the unit wiring diagram. Connect the pump power lead as instructed on the tag attached to the pump wiring.

4. The HWG pump should not run if the compressor is not running.

5. The temperature difference between the water entering and leaving the HWG coil should be approximately 5-10°F [3-6°C].

6. Allow the unit to operate for 20 to 30 minutes to insure that it is functioning properly.

General Information

The HWG Module consists of an all-copper, vented doublewall heat exchanger and a water-cooled water circulating pump. The pump is controlled by the use of one or more limit switches. Power for the pump is provided from either the compressor contactor of the outdoor section of the heat pump, or it may come from a remote power source if the appropriate controls are used.

Location/Mounting

The HWG module should be mounted as close to the heat pump outdoor section as possible, in order to minimize the length of refrigerant run. Indoor mounting is preferred, where practical, to reduce the likelihood of freezing ambient temperature. It is recommended that the HWG module be mounted above the system compressor in order to promote proper oil movement and drain-down. This means that the

HWG module can be wall mounted in any orientation except for stubs up. Mounting should be accomplished

by fastening the HWG module cabinet to the wall or other selected vertical surface. A ﬂ ange is provided at the top rear of the unit. Any fastener suitable for supporting a 12 pound [5.4] vertical load is acceptable.

Table 7: HWG Module Lineset Sizing

the lineset to 500 microns through the hot gas valves in the outdoor unit. Open the valves up fully (CCW looking up from cap end). Check the lineset for leaks. Pinch the bypass tubing as shown in Figure 19 being careful not to damage the tubing. Verify that lineset tubing is completely insulated with a minimum 1/2” thick closed cell and painted to prevent deterioration of the insulation due to ultra violet light and weather. Make the connections with high temperature solder or brazing rod. The recommended line size is dependent on the one way distance between the Heat Recovery Unit and the compressor; and the size of the system. Use the Table 7 as a guideline.

Figure 19: HWG Connection Details

Capacity

2 Ton Up to 16 ft.

3 Ton Up to 9 ft.

4 Ton Up to 5 ft.

5 Ton N/A Up to 9 ft.

1/2” OD 5/8” OD 3/4” OD

[4.9m]

[2.7m]

[1.5m]

Line Set Size

Up to 30 ft.

[9.1m]

Up to 25 ft.

[7.6m]

Up to 13 ft.

[4.0m]

[2.7m]

N/A

Up to 30 ft.

[9.1m]

Up to 30 ft.

[9.1]

Up to 25 ft.

[7.6m]

As a guideline add 1.0 oz. of R-22 for the heat exchanger plus 1.0 oz. for each 10 ft of 1/2” OD refrigerant line, if the weighed charge method is used (28g for the heat exchanger plus 9g per meter of 1/2” OD refrigerant line).

SPECIAL NOTE: The selected mounting location and orientation must allow the circulator pump to be positioned with the motor shaft horizontal. DO NOT install the Heat

Recovery Unit ﬂ at on its back.

Refrigerant Line Installation

Before starting the installation into the refrigerant circuit, inspect and note the condition and performance of the heat pump. Disconnect power to the heat pump outdoor unit. Any system deﬁ ciencies must be corrected prior to installing the HWG module. Addition of the unit will not correct system problems. Record the suction and discharge pressures and compressor amperage draw. These will be used for comparison with system operation after the refrigerant line installation is complete and before the water line installation is performed. Install the Add-On HWG kit using the installation instructions below. Locate the HWG as close to the water heater as possible. Unbraze the hot gas u-bend as shown in Figure 19. Take care to avoid overheating components. Install the dual 1/2” lineset to the HWG. Maximum length should be 30 feet one way. Evacuate

Carrier: Turn to the Experts

Page 26

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Hot Water Generator Module Refrigeration Installation Outdoor Compressor Section Only

 CAUTION! 

CAUTION! The HWG module must be installed in an area

that is not subject to freezing temperatures.

NOTICE! Make sure the compressor discharge line is connected to the “Hot Gas In” stub on the Heat Recovery Unit.

 CAUTION! 

CAUTION! Locate Refrigerant lines to avoid accidental

damage by lawnmowers or children.

 WARNING! 

WARNING! The HWG module is an appliance that operates

in conjunction with the heat pump system, the hot water system and the electrical system. Installation should only be performed by skilled technicians with appropriate training and experience. The installation must be in compliance with local codes and ordinances. Local plumbing and electrical building codes take precedence over instructions contained herein. The Manufacturer accepts no liability for equipment damaged and/or personal injury arising from improper installation of the HWG module.

Water-Source Heating and Cooling Systems

Page 27

 WARNING! 

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

 CAUTION! 

CAUTION!

electrical wiring. Unit terminals are not designed to accept other types of conductors.

Electrical - Line Voltage

All ﬁ eld installed wiring, including electrical ground, must comply with the National Electrical Code as well as all applicable local codes. Refer to the unit electrical data for fuse sizes. Consult wiring diagram for ﬁ eld connections that must be made by the installing (or electrical) contractor.

Use only copper conductors for ﬁ eld installed

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Electrical - Line Voltage

All ﬁ nal electrical connections must be made with a length of ﬂ exible conduit to minimize vibration and sound transmission

to the building.

General Line Voltage Wiring

Be sure the available power is the same voltage and phase shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.

Power Connection

Line voltage connection is made by connecting the incoming line voltage wires to the “L” side of the contactor as shown in Figures 21a through 21c. Consult Tables 8a through 8c for correct fuse size.

208-230 Volt Operation

Verify transformer tap with air handler wiring diagram to insure that the transformer tap is set to the correct voltage, 208V or 230V.

Table 8a: GT-PX (50YDS) Series Electrical Data

Model

Compressor

RLA LRA Qty

026 10.3 52.0 1 0.4 4.0 14.7 17.3 25 10 107 (32.7)

038 16.7 82.0 1 0.4 4.0 21.1 25.3 40 10 73 (22.3)

049 21.2 96.0 1 0.4 4.0 25.6 30.9 50 8 95 (29.2)

064 25.6 118.0 1 0.4 4.0 30.0 36.4 60 8 81 (24.8)

Rated Voltage of 208/230/60/1 Min/Max Voltage of 197/254 HACR circuit breaker in USA only All fuses Class RK-5 Wire length based on one way measurement with 2% voltage drop Wire size based on 60°C copper conductor and Minimum Circuit Ampacity.

HWG

Pump

FLA

External

Pump

FLA

Total

Unit FLA

Min

Circuit

Amps

Max

Fuse/

HACR

Min

AWG

Max Wire

Ft.

(m)

Table 8b: GT-GS (50YCS) Series Electrical Data

Model

Compressor

RLA LRA Qty

018

024

030

036

042

048

060

7.7 40.3 1 0.40 4.0 12.1 14.0 20 12 76 (23.3)

10.3 56.0 1 0.40 4.0 14.7 17.3 25 10 107 (32.7)

12.2 67.0 1 0.40 4.0 16.6 19.7 30 10 94 (28.7)

13.5 73.0 1 0.40 4.0 17.9 21.3 35 10 87 (26.5)

16.5 95.0 1 0.40 4.0 20.9 25.0 40 10 74 (22.6)

18.3 109.0 1 0.40 4.0 22.7 27.3 45 10 67 (20.7)

25.0 148.0 1 0.40 4.0 29.4 35.7 60 8 82 (25.2)

HWG

Pump

FLA

External

Pump

FLA

Total

Unit

FLA

Min

Circuit

Amps

Max

Fuse/

HACR

Min

AWG

Max Wire

(m)

Carrier: Turn to the Experts

Page 28

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Electrical - Line Voltage

Table 8c: GT-S Outdoor (38WQS) Series Electrical Data

Compressor

Model

018

024

030

036

042

048

060

Rated Voltage of 208-230/60/1 Min/Max Voltage of 197/254 HACR circuit breaker in USA only All fuses Class RK-5 Wire length based on one way measurement with 2% voltage drop Wire size based on 60°C copper conductor and Minimum Circuit Ampacity.

RLA LRA Qty

7.1 38.0 1 N/A 0.40 4.0 11.5 13.3 20 12 87 (26.6)

10.3 56.0 1 0.17 0.40 4.0 14.9 17.4 25 10 106 (32.5)

12.2 67.0 1 0.17 0.40 4.0 16.8 19.8 30 10 93 (28.6)

13.5 73.0 1 0.17 0.40 4.0 18.1 21.4 30 10 86 (26.4)

16.5 95.0 1 0.17 0.40 4.0 21.1 25.2 40 10 73 (22.4)

18.3 109.0 1 0.17 0.40 4.0 22.9 27.4 45 10 67 (20.6)

25.0 148.0 1 0.29 0.40 4.0 29.7 35.9 60 8 82 (25.1)

Crank-

case

HWG

Pump

FLA

Ext Loop

Pump

FLA

Total

Unit FLA

Min

Circuit

Amps

Max

Fuse/

HACR

Min

AWG

Max

Wire Ft

(m)

ELECTRICAL - POWER WIRING

Electrical - Line Voltage

All ﬁ nal electrical connections must be made with a length of ﬂ exible conduit to minimize vibration and sound transmission to the building.

General Line Voltage Wiring

Power Connection

208-230 Volt Operation

Verify transformer tap with air handler wiring diagram to insure that the transformer tap is set to the correct voltage, 208V or 230V.

Figure 20: HWG Module Wiring

Figure 21a: R-410A Compressor Section Line Voltage Field Wiring

Unit Power Supply

(see electrical table for wire

and breaker size)

Water-Source Heating and Cooling Systems

Page 29

Residential Split - 60Hz R22 &R410A

Capacitor

Transformer

CXM Control

Circ Brkr

Contactor -CC

Low Voltage Connector

HWG PB2

Loop PB1

Unit Power Supply

See electrical table for

wire and breaker size

External Pump Power Supply

See electrical table for

wire and breaker size

Grnd

Install HWG Pump

Power after insuring

water is in HWG circuit

Pink

Blk

Rev.: 5 June, 2008

Electrical - HWG Wiring

Figure 21b: R-22 Indoor Compressor Section Line Voltage Field Wiring

Figure 21c: R-22 Outdoor Compressor Section Line Voltage Field Wiring

CRC

CRR

CXM Control

Low Voltage Connector

T2 T1

L2 L1

FCR

Grnd

HWG Wiring - “Indoor” Compressor Section

The hot water generator pump power wiring is disabled at the factory to prevent operating the HWG pump “dry.” After all HWG piping is completed and air purged from the water piping, the pump power wires should be applied to terminals on the HWG power block PB2 as shown in the unit wiring diagram. This connection can also serve as a HWG disable when servicing the unit.

HWG Wiring - “Outdoor” Compressor Section

The HWG module should be wired to the outdoor section pump controls (see Figure 20). A safety disconnect should be installed at the HWG module to allow servicing of the module. If wired as shown, any time the compressor is energized, the HWG module pump will be activated, which will circulate water from the water heater tank to the HWG module. DO NOT energize the pump until all HWG piping is completed and air is purged from the water piping to avoid running the pump “dry.”

Consult Electrical Table for wire and fuse size

All power wiring per local code

Note: See FC Mounting for Flow Controller Wiring

208-230 Volt Operation

Verify transformer tap with air handler wiring diagram to insure that the transformer tap is set to the correct voltage, 208V or 230V.

Carrier: Turn to the Experts

Page 30

Residential Split - 60Hz R22 &R410A

Capacitor

CXM Control

Circ Brkr

Contactor -CC

Low Voltage Connector

HWG PB2

Loop PB1

Grnd

FCR

Thermostat Connection

See Thermostat section

for Wiring Details

CRC

Grnd

L2 L1

T2 T1

CXM Control

Low Voltage Connector

Rev.: 5 June, 2008

Electrical - Low Voltage Wiring

ELECTRICAL - LOW VOLTAGE WIRING

Thermostat Connections

The thermostat should be wired directly to the CXM board. Figures 22a through 22c show low voltage wiring. Note that the air handler or furnace transformer will be used to power the CXM board in the compressor section. See “Electrical – Thermostat” for speciﬁ c terminal connections.

Figure 22a: 50YDS Low Voltage Field Wiring

Low voltage ﬁ eld wiring

Figure 22b: GT-GS Low Voltage Field Wiring

Figure 22c: GT-S Low Voltage Field Wiring

Low Water Temperature Cutout Selection

The CXM control allows the ﬁ eld selection of low water (or water-antifreeze solution) temperature limit by clipping jumper JW3, which changes the sensing temperature associated with thermistor FP1. Note that the FP1 thermistor is located on the refrigerant line between the coaxial heat exchanger and expansion device (TXV). Therefore, FP1 is sensing refrigerant temperature, not water temperature, which is a better indication of how water ﬂ ow rate/temperature is affecting the refrigeration circuit.

Water-Source Heating and Cooling Systems

The factory setting for FP1 is for systems using water (30°F [-1.1°C] refrigerant temperature). In low water temperature (extended range) applications with antifreeze (most ground loops), jumper JW3 should be clipped as shown in Figure 23 to change the setting to 10°F [-12.2°C] refrigerant temperature, a more suitable temperature when using an antifreeze solution. All residential units include water/ refrigerant circuit insulation to prevent internal condensation, which is required when operating with entering water temperatures below 59°F [15°C].

Page 31

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Electrical - Low Voltage Wiring

Figure 23: FP1 Limit Setting

JW3-FP1 jumper

should be clipped

for low temperature

CXM PCB

Accessory Connections

A terminal paralleling the compressor contactor coil has been provided on the CXM control. Terminal “A” is designed to control accessory devices, such as water valves. Note: This terminal should be used only with 24 Volt signals and not line voltage. Terminal “A” is energized with the compressor contactor. See Figure 24 or the speciﬁ c unit wiring diagram for details.

Figure 24: Accessory Wiring

operation

Note: This valve can overheat the anticipator of an electromechanical thermostat. Therefore, only relay or triac based thermostats should be used.

Two-stage Units

Two-stage units should be designed with two parallel valves for ground water applications to limit water use during ﬁ rst stage operation. For example, at 1.5 gpm/ton [2.0 l/m per kW], a model 049 unit requires 6 gpm [23 l/m] for full load (2nd stage) operation, but only 4 gpm [15 l/m] during 1st stage operation. Since the unit will operate on ﬁ rst stage 80- 90% of the time, signiﬁ cant water savings can be realized by using two parallel solenoid valves with two ﬂ ow regulators. In the example above, stage one solenoid would be installed with a 4 gpm [15 l/m] ﬂ ow regulator on the outlet, while stage two would utilize a 2 gpm [8 l/m] ﬂ ow regulator. When stage one is operating, the second solenoid valve will be closed. When stage two is operating, both valves will be open, allowing full load ﬂ ow rate.

Figure 27 illustrates piping for two-stage solenoid valves. Review ﬁ gures 24-26 for wiring of stage one valve. Stage two valve should be wired between “Y2” (compressor solenoid

-- wire nut connection) and terminal “C.” NOTE: When EWT

is below 50°F [10°C], a minimum of 2 gpm per ton (2.6 l/m per kW) is required.

Water Solenoid Valves - “Indoor” Compressor Section Only

An external solenoid valve(s) should be used on ground water installations to shut off ﬂ ow to the unit when the compressor is not operating. A slow closing valve may be required to help reduce water hammer. Figure 24 shows typical wiring for a 24VAC external solenoid valve. Figures 25 and 26 illustrate typical slow closing water control valve wiring for Taco 500 series (Carrier Geothermal P/N AVM…) and Taco ESP series valves. Slow closing valves take approximately 60 seconds to open (very little water will ﬂ ow before 45 seconds). Once fully open, an end switch allows the compressor to be energized. Only relay or triac based electronic thermostats should be used with slow closing valves. When wired as shown, the slow closing valve will operate properly with the following notations:

Figure 25: AMV Valve Wiring

Heater Switch

Thermostat

Figure 26: Taco SBV Valve Wiring

AVM

Taco Valve

1. The valve will remain open during a unit lockout.

2. The valve will draw approximately 25-35 VA through the “Y” signal of the thermostat.

Carrier: Turn to the Experts

Page 32

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Electrical - Low Voltage Wiring

Figure 27: Two-Stage Piping

OUT

Solenoid

Valve

Stage 2

From Water Source

NOTE: Shut-off valves, strainers and other re

Flow

Regulator

To Discharge

Stage 1

uired components not shown.

 CAUTION! 

CAUTION! Refrigerant pressure activated water regulating

valves should never be used with Carrier Geothermal equipment.

Figure 28b: Typical Thermostat Wiring, Single-Stage Units (2 Heat/1 Cool)

CXM Board

(Compressor

Section)

Typical

Air Handler

Y/Y2

Optional

Jumper

Typical

T-stat

ELECTRICAL - THERMOSTAT WIRING

Thermostat Installation

The thermostat should be located on an interior wall in a larger room, away from supply duct drafts. DO NOT locate the thermostat in areas subject to sunlight, drafts or on external walls. The wire access hole behind the thermostat may in certain cases need to be sealed to prevent erroneous temperature measurement. Position the thermostat back plate against the wall so that it appears level and so the thermostat wires protrude through the middle of the back plate. Mark the position of the back plate mounting holes and drill holes with a 3/16” (5mm) bit. Install supplied anchors and secure plate to the wall. Thermostat wire must be 18 AWG wire. Wire the appropriate thermostat as shown in Figures 28a and 28b to the low voltage terminal strip on the CXM control board. Practically any heat pump thermostat will work with these units, provided it has the correct number of heating and cooling stages.

AL1

Figure 28a: Typical Thermostat Wiring, Two-Stage Units (3 Heat/2 Cool)

From Compressor

Solenoid Valve

CXM Board

(Compressor

Section)

Typical

Air Handler

Y/Y2

Typical

T-stat

Water-Source Heating and Cooling Systems

AL1

Page 33

Residential Split - 60Hz R22 &R410A

Description of Operation LED Alarm Relay

Normal Mode On Open Normal Mode with UPS Warning On Cycle (closed 5 sec., Open 25 sec.) CXM is non-functional Off Open Fault Retry Slow Flash Open Lockout Fast Flash Closed Over/Under Voltage Shutdown Slow Flash Open (Closed after 15 minutes)

Test Mode - No fault in memory Flashing Code 1 Cycling Code 1

Test Mode - HP Fault in memory Flashing Code 2 Cycling Code 2

Test Mode - LP Fault in memory Flashing Code 3 Cycling Code 3

Test Mode - FP1 Fault in memory Flashing Code 4 Cycling Code 4

Test Mode - FP2 Fault in memory Flashing Code 5 Cycling Code 5

Test Mode - CO Fault in memory Flashing Code 6 Cycling Code 6

Test Mode - Over/Under shutdown in memory

Flashing Code 7 Cycling Code 7

Test Mode - UPS in memory Flashing Code 8 Cycling Code 8

Test Mode - Swapped Thermistor Flashing Code 9 Cycling Code 9

Rev.: 5 June, 2008

CXM Controls

CXM Control

For detailed control information, see CXM/DXM Application, Operation and Maintenance (AOM) manual (part #97B0003N08).

Field Selectable Inputs

Test mode: Test mode allows the service technician to check the operation of the control in a timely manner. By momentarily shorting the test terminals, the CXM control enters a 20 minute test mode period in which all time delays are sped up 15 times. Upon entering test mode, the status LED will ﬂ ash a code representing the last fault. For diagnostic ease at the thermostat, the alarm relay will also cycle during test mode. The alarm relay will cycle on and off similar to the status LED to indicate a code representing the last fault, at the thermostat. Test mode can be exited by shorting the test terminals for 3 seconds. Retry Mode: If the control is attempting a retry of a fault, the status LED will slow ﬂ ash (slow ﬂ ash = one ﬂ ash every 2 seconds) to indicate the control is in the process of retrying.

Field Conﬁ guration Options

Note: In the following ﬁ eld conﬁ guration options, jumper wires should be clipped ONLY when power is removed from the CXM control.

Water coil low temperature limit setting: Jumper 3 (JW3FP1 Low Temp) provides ﬁ eld selection of temperature limit setting for FP1 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature).

Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].

Air coil low temperature limit setting: Jumper 2 (JW2-FP2 Low Temp) provides ﬁ eld selection of temperature limit setting for FP2 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Note: This jumper should only be clipped under extenuating circumstances, as recommended by the factory.

Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].

Alarm relay setting: Jumper 1 (JW1-AL2 Dry) provides ﬁ eld selection of the alarm relay terminal AL2 to be jumpered to 24VAC or to be a dry contact (no connection).

Not Clipped = AL2 connected to R. Clipped = AL2 dry contact (no connection).

DDC operation. If set to “DDC Output at EH2,” the EH2 terminal will continuously output the last fault code of the controller. If set to “EH2 normal,” EH2 will operate as standard electric heat output.

On = EH2 Normal. Off = DDC Output at EH2.

NOTE: Some CXM controls only have a 2 position DIP switch package. If this is the case, this option can be selected by clipping the jumper which is in position 4 of SW1.

Jumper not clipped = EH2 Normal. Jumper clipped = DDC Output at EH2.

DIP switch 5: Factory Setting - Normal position is “On.” Do not change selection unless instructed to do so by the factory.

-Slow Flash = 1 ﬂ ash every 2 seconds

-Fast Flash = 2 ﬂ ashes every 1 second

Table 9a: CXM LED And Alarm Relay Operations

-Flash code 2 = 2 quick ﬂ ashes, 10 second pause, 2 quick ﬂ ashes, 10 second pause, etc.

-On pulse 1/3 second; off pulse 1/3 second

DIP Switches

Note: In the following ﬁ eld conﬁ guration options, DIP switches should only be changed when power is removed from the CXM control. DIP switch 1: Unit Performance Sentinel Disable - provides ﬁ eld selection to disable the UPS feature.

On = Enabled. Off = Disabled.

DIP switch 2: Stage 2 Selection - provides selection of whether compressor has an “on” delay. If set to stage 2, the compressor will have a 3 second delay before energizing. Also, if set for stage 2, the alarm relay will NOT cycle during test mode.

On = Stage 1. Off = Stage 2

DIP switch 3: Not Used. DIP switch 4: DDC Output at EH2 - provides selection for

Carrier: Turn to the Experts

Page 34

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

CXM Controls

Safety Features – CXM Control

The safety features below are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions. Anti-short cycle protection: The control features a 5 minute anti-short cycle protection for the compressor. Note: The 5 minute anti-short cycle also occurs at power up. Random start: The control features a random start upon power up of 5-80 seconds. Fault Retry: In Fault Retry mode, the Status LED begins slowly ﬂ ashing to signal that the control is trying to recover from a fault input. The control will stage off the outputs and then “try again” to satisfy the thermostat input call. Once the thermostat input call is satisﬁ ed, the control will continue on as if no fault occurred. If 3 consecutive faults occur without satisfying the thermostat input call, the control will go into “lockout” mode. The last fault causing the lockout will be stored in memory and can be viewed by going into test mode. Note: FP1/FP2 faults are factory set at only one try. Lockout: In lockout mode, the status LED will begin fast ﬂ ashing. The compressor relay is turned off immediately. Lockout mode can be “soft” reset by turning off the thermostat (or satisfying the call). A “soft” reset keeps the fault in memory but resets the control. A “hard” reset (disconnecting power to the control) resets the control and erases fault memory. Lockout with emergency heat: While in lockout mode, if W becomes active (CXM), emergency heat mode will occur. High pressure switch: When the high pressure switch opens due to high refrigerant pressures, the compressor relay is de-energized immediately since the high pressure switch is in series with the compressor contactor coil. The high pressure fault recognition is immediate (does not delay for 30 continuous seconds before deenergizing the compressor).

High pressure lockout code = 2

Example: 2 quick ﬂ ashes, 10 sec pause, 2 quick ﬂ ashes, 10 sec. pause, etc. Low pressure switch: The low pressure switch must be open and remain open for 30 continuous seconds during “on” cycle to be recognized as a low pressure fault. If the low pressure switch is open for 30 seconds prior to compressor power up it will be considered a low pressure (loss of charge) fault. The low pressure switch input is bypassed for the initial 60 seconds of a compressor run cycle.

Low pressure lockout code = 3

Water coil low temperature (FP1): The FP1 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP1 fault. The FP1 input is bypassed for the initial 60 seconds of a compressor run cycle. FP1 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP1 fault has occurred.

FP1 lockout code = 4

Water-Source Heating and Cooling Systems

Air coil low temperature (FP2): The FP2 thermistor temperature must be below the selected low temperature limit setting for

30 continuous seconds during a compressor run cycle to be recognized as a FP2 fault. The FP2 input is bypassed for the initial 60 seconds of a compressor run cycle. FP2 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP2 fault has occurred.

FP2 lockout code = 5

Condensate overﬂ ow: The condensate overﬂ ow sensor must sense overﬂ ow level for 30 continuous seconds to be recognized as a CO fault. Condensate overﬂ ow will be monitored at all times.

CO lockout code = 6

Over/under voltage shutdown: An over/under voltage condition exists when the control voltage is outside the range of 19VAC to 30VAC. Over/under voltage shut down is a self-resetting safety. If the voltage comes back within range for at least 0.5 seconds, normal operation is restored. This is not considered a fault or lockout. If the CXM is in over/under voltage shutdown for 15 minutes, the alarm relay will close.

Over/under voltage shut down code = 7

Unit Performance Sentinel-UPS (patent pending): The UPS feature indicates when the heat pump is operating inefﬁ ciently. A UPS condition exists when: a) In heating mode with compressor energized, FP2 is

greater than 125°F [52°C] for 30 continuous seconds, or:

b) In cooling mode with compressor energized, FP1 is

greater than 125°F [52°C] for 30 continuous seconds, or:

In cooling mode with compressor energized, FP2 is less than 40°F [4.5°C] for 30 continuous seconds. If a UPS condition occurs, the control will immediately go to UPS warning. The status LED will remain on as if the control is in normal mode. Outputs of the control, excluding LED and alarm relay, will NOT be affected by UPS. The UPS condition cannot occur during a compressor off cycle. During UPS warning, the alarm relay will cycle on and off. The cycle rate will be “on” for 5 seconds, “off” for 25 seconds, “on” for 5 seconds, “off” for 25 seconds, etc.

UPS warning code = 8

Swapped FP1/FP2 thermistors: During test mode, the control monitors to see if the FP1 and FP2 thermistors are in the appropriate places. If the control is in test mode, the control will lockout, with code 9, after 30 seconds if: a) The compressor is on in the cooling mode and the FP1

sensor is colder than the FP2 sensor, or:

b) The compressor is on in the heating mode and the FP2

sensor is colder than the FP1 sensor.

Swapped FP1/FP2 thermistor code = 9.

Diagnostic Features

The LED on the CXM board advises the technician of the current status of the CXM control. The LED can display either the current CXM mode or the last fault in memory if in test mode. If there is no fault in memory, the LED will ﬂ ash Code 1 (when in test mode).

Page 35

CXM Control Start-up Operation

The control will not operate until all inputs and safety controls are checked for normal conditions. The compressor will have a 5 minute anti-short cycle delay at power-up. The ﬁ rst time after power-up that there is a call for compressor, the compressor will follow a 5 to 80 second random start delay. After the random start delay and anti-short cycle delay, the compressor relay will be energized. On all subsequent compressor calls, the random start delay is omitted.

Table 9b: Unit Operation

50YDS GT-GS/GT-S GT-GS/GT-S

T-stat signal

G Fan only Fan only Fan only

G, Y or Y1 Stage 1 heating

G, Y1, Y2 Stage 2 heating

G, Y1, Y2, W Stage 3 heating

G, W Emergency heat Emergency heat Emergency heat

G, Y or Y1, O Stage 1 cooling

G, Y1, Y2, O Stage 2 cooling

Variable Speed

Air Handler

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

CXM Controls

Variable Speed

Air Handler

Stage 1 heating

Stage 2 heating

Stage 3 heating

Stage 1 cooling

Stage 2 cooling

PSC Air Handler

Stage 1 heating

Stage 2 heating

N/A

Cooling

N/A

1 Stage 1 = 1st stage compressor, 1st stage fan operation Stage 2 = 2nd stage compressor, 2nd stage fan operation Stage 3 = 2nd stage compressor, auxiliary electric heat, 2nd or 3rd stage fan operation (depending on fan settings) 2 Stage 1 = 1st stage compressor, 1st stage fan operation, reversing valve Stage 2 = 2nd stage compressor, 2nd stage fan operation, reversing valve 3 Stage 1 = compressor, 1st stage fan operation Stage 2 = compressor, 2nd stage fan operation Stage 3 = compressor, auxiliary electric heat, 2nd or 3rd stage fan operation (depending on fan settings) 4 Stage 1 = compressor, 1st stage fan operation, reversing valve Stage 2 = compressor, 2nd stage fan operation, reversing valve 5 Stage 1 = compressor, fan Stage 2 = compressor, auxiliary electric heat, fan 6 Cooling = compressor, fan, reversing valve

Carrier: Turn to the Experts

Page 36

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

CXM Controls

Table 10: Nominal resistance at various temperatures

ϒ ϒ ϒ ϒ

CXM Thermostat Details Thermostat Compatibility - Most all heat pump thermostats can be used with the CXM control. However Heat/Cool stats are NOT compatible with the CXM.

Anticipation Leakage Current - Maximum leakage current

for "Y" is 50 mA and for "W" is 20mA. Triacs can be used if leakage current is less than above. Thermostats with anticipators can be used if anticipation current is less than that speciﬁ ed above.

Thermostat Signals -

• "Y" and "W" have a 1 second recognition time when

being activated or being removed.

• "O" and "G" are direct pass through signals but are

monitored by the micro processor.

• "R" and "C" are from the transformer.

• "AL1" and "AL2" originate from the alarm relay.

• "A" is paralleled with the compressor output for use

with well water solenoid valves.

• The "Y" 1/4" quick connect is a connection point to the

"Y" input terminal P1 for factory use. This "Y" terminal can be used to drive panel mounted relays such as the loop pump relay.

Water-Source Heating and Cooling Systems

Page 37

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Unit Starting and Operating Conditions

Operating Limits

Environment – “Indoor” compressor section is designed for indoor installation only. Never install “indoor” compressor section in areas subject to freezing or where humidity levels could cause cabinet condensation (such as unconditioned spaces subject to 100% outside air). “Outdoor” unit is designed for conditions where ambient air is below freezing (see Table 11). Power Supply – A voltage variation of +/– 10% of nameplate utilization voltage is acceptable.

Starting Conditions

Consult Table 11 for the particular model. Starting conditions vary depending upon model and are based upon the following notes:

Notes:

1. Conditions in Table 11 are not normal or continuous operating conditions. Minimum/maximum limits are start-up conditions to bring the building space up to occupancy temperatures. Units are not designed to operate under these conditions on a regular basis.

Table 11: Unit Operation

2. Voltage utilization range complies with ARI Standard 110.

Determination of operating limits is dependent primarily upon three factors: 1) return air temperature. 2) water temperature, and 3) ambient temperature. When any one of these factors is at minimum or maximum levels, the other two factors should be at normal levels to insure proper unit operation.

Extreme variations in temperature and humidity and/or corrosive water or air will adversely affect unit performance, reliability, and service life.

GT-PX/GT-GS GT-S

Operating Limits

Cooling Heating Cooling Heating

Air Limits

Min. ambient air, DB 45°F [7°C] 39°F [4°C] -10°F [-23°C] -10°F [-23°C]

Rated ambient air, DB 80.6°F [27°C] 68°F [20°C] 80.6°F [27°C] 68°F [20°C]

Max. ambient air, DB 110°F [43°C] 85°F [29°C] 110°F [43°C] 85°F [29°C]

Min. entering air, DB/WB 50°F [10°C] 40°F [4.5°C] 50°F [10°C] 50°F [10°C]

Rated entering air, DB/WB 80.6/66.2°F [27/19°C] 68°F [20°C] 80.6/66.2°F [27/19°C] 68°F [20°C]

Max. entering air, DB/WB 110/83°F [43/28°C] 80°F [27°C] 110/83°F [43/28°C] 80°F [27°C]

Water Limits

Min. entering water 30°F [-1°C] 20°F [-6.7°C] 30°F [-1°C] 20°F [-6.7°C]

Normal entering water 50-110°F [10-43°C] 30-70°F [-1 to 21°C] 50-110°F [10-43°C] 30-70°F [-1 to 21°C]

Max. entering water 120°F [49°C] 90°F [32°C] 120°F [49°C] 90°F [32°C]

Normal water ﬂ ow

1.5 to 3.0 gpm/ton 1.5 to 3.0 gpm/ton

2.0 to 3.9 l/m per kW 2.0 to 3.9 l/m per kW

Carrier: Turn to the Experts

Page 38

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Unit Starting and Operating Conditions

Unit and System Checkout

BEFORE POWERING SYSTEM, please check the following:

UNIT CHECKOUT

 Balancing/shutoff valves: Insure that all isolation valves

are open and water control valves are wired.

 Line voltage and wiring: Verify that voltage is within

an acceptable range for the unit and wiring and fuses/ breakers are properly sized. Verify that low voltage wiring is complete.

 Unit control transformer: Insure that transformer has the

properly selected voltage tap. Residential 208-230V units are factory wired for 230V operation unless speciﬁ ed otherwise.

 Loop/water piping is complete and purged of air. Water/

piping is clean.

 Antifreeze has been added if necessary.  Entering water and air: Insure that entering water and air

temperatures are within operating limits of Table 7.

 Low water temperature cutout: Verify that low water

temperature cut-out on the CXM/DXM control is properly set.

 Unit fan: Manually rotate fan to verify free rotation and

insure that blower wheel is secured to the motor shaft. Be sure to remove any shipping supports if needed. DO NOT oil motors upon start-up. Fan motors are preoiled at the factory. Check unit fan speed selection and compare to design requirements.

 Condensate line: Verify that condensate line is open and

properly pitched toward drain.

 HWG pump is disconnected unless piping is completed

and air has been purged from the system.

 Water ﬂ ow balancing: Record inlet and outlet water

temperatures for each heat pump upon startup. This check can eliminate nuisance trip outs and high velocity water ﬂ ow that could erode heat exchangers.

 Unit air coil and ﬁ lters: Insure that ﬁ lter is clean and

accessible. Clean air coil of all manufacturing oils.

 Unit controls: Verify that CXM ﬁ eld selection options are

properly set. Low voltage wiring is complete.

 Blower speed is set.  Service/access panels are in place.

SYSTEM CHECKOUT

 System water temperature: Check water temperature

for proper range and also verify heating and cooling set points for proper operation.

 System pH: Check and adjust water pH if necessary to

maintain a level between 6 and 8.5. Proper pH promotes longevity of hoses and ﬁ ttings (see Table 3).

 System ﬂ ushing: Verify that all air is purged from the

system. Air in the system can cause poor operation or system corrosion. Water used in the system must be potable quality initially and clean of dirt, piping slag, and strong chemical cleaning agents. Some antifreeze solutions may require distilled water.

Water-Source Heating and Cooling Systems

 Flow Controller pump(s): Verify that the pump(s) is wired

and in operating condition.

 System controls: Verify that system controls function and

operate in the proper sequence.

 Low water temperature cutout: Verify that low water

temperature cut-out controls are set properly (FP1 - JW3).

 Miscellaneous: Note any questionable aspects of

the installation.

 CAUTION! 

CAUTION! Verify that ALL water control valves are open and allow water ﬂ ow prior to engaging the compressor. Freezing of the coax or water lines can permanently damage the heat pump.

NOTICE! Failure to remove shipping brackets from springmounted compressors will cause excessive noise, and could cause component failure due to added vibration.

 CAUTION! 

CAUTION! To avoid equipment damage, DO NOT leave system ﬁ lled in a building without heat during the winter unless antifreeze is added to the water loop. Heat exchangers never fully drain by themselves and will freeze unless winterized with antifreeze.

Unit Start-up Procedure

1. Turn the thermostat fan position to “ON.” Blower should start.

2. Balance air ﬂ ow at registers.

3. Adjust all valves to their full open position. Turn on the line power to all heat pump units.

4. Room temperature should be within the minimummaximum ranges of Table 11. During start-up checks, loop water temperature entering the heat pump should be between 30°F [-1°C] and 95°F [35°C].

Two factors determine the operating limits of water source heat pumps, (a) return air temperature, and (b) water temperature. When any one of these factors is at a minimum or maximum level, the other factor must be at normal level to insure proper unit operation.

a. Adjust the unit thermostat to the warmest setting.

Place the thermostat mode switch in the “COOL” position. Slowly reduce thermostat setting until the compressor activates.

b. Check for cool air delivery at the unit grille within a

few minutes after the unit has begun to operate.

Note: Units have a ﬁ ve minute time delay in the

control circuit that can be eliminated on the CXM/ DXM control board as shown below in Figure 29. See controls description for details.

Page 39

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Unit Start-Up Procedure

c. Verify that the compressor is on and that the water

ﬂ ow rate is correct by measuring pressure drop through the heat exchanger using the P/T plugs and comparing to Tables 12a through 12b.

d. Check the elevation and cleanliness of the

condensate lines. Dripping may be a sign of a blocked line. Check that the condensate trap is ﬁ lled to provide a water seal.

e. Refer to Table 13. Check the temperature of both

entering and leaving water. If temperature is within range, proceed with the test. If temperature is outside of the operating range, check refrigerant pressures and compare to Tables 14 and 15. Verify correct water ﬂ ow by comparing unit pressure drop across the heat exchanger versus the data in Tables 12a through 12b. Heat of rejection (HR) can be calculated and compared to catalog data capacity pages. The formula for HR for systems with water is as follows: HR = TD x GPM x 500, where TD is the temperature difference between the entering and leaving water, and GPM is the ﬂ ow rate in U.S. GPM, determined by comparing the pressure drop across the heat exchanger to Tables 12a through 12b.

Check air temperature drop across the air coil when compressor is operating. Air temperature drop should be between 15°F and 25°F [8°C and 14°C].

g. Turn thermostat to “OFF” position. A hissing noise

indicates proper functioning of the reversing valve.

6. Allow ﬁ ve (5) minutes between tests for pressure to equalize before beginning heating test.

a. Adjust the thermostat to the lowest setting. Place the

thermostat mode switch in the “HEAT” position.

b. Slowly raise the thermostat to a higher temperature

until the compressor activates.

c. Check for warm air delivery within a few minutes after

the unit has begun to operate.

d. Refer to Table 13. Check the temperature of both

HE = TD x GPM x 500, where TD is the temperature

difference between the entering and leaving water, and GPM is the ﬂ ow rate in U.S. GPM, determined by comparing the pressure drop across the heat exchanger to Tables 12a through 12b.

Check air temperature rise across the air coil when

compressor is operating. Air temperature rise should be between 20°F and 30°F [11°C and 17°C].

f. Check for vibration, noise, and water leaks.

7. If unit fails to operate, perform troubleshooting analysis (see troubleshooting section). If the check described fails to reveal the problem and the unit still does not operate, contact a trained service technician to insure proper diagnosis and repair of the equipment.

8. When testing is complete, set system to maintain desired comfort level.

9. BE CERTAIN TO FILL OUT AND RETURN ALL WARRANTY REGISTRATION PAPERWORK.

Note: If performance during any mode appears abnormal, refer to the CXM section or troubleshooting section of this manual. To obtain maximum performance, the air coil should be cleaned before start-up. A 10% solution of dishwasher detergent and water is recommended.

 WARNING! 

WARNING! When the disconnect switch is closed, high

voltage is present in some areas of the electrical panel. Exercise caution when working with energized equipment.

 CAUTION! 

CAUTION! Verify that ALL water control valves are open and allow water ﬂ ow prior to engaging the compressor. Freezing of the coax or water lines can permanently damage the heat pump.

Figure 29: Test Mode Pins

Short test pins together

to enter Test Mode and

speed-up timing and delays

for 20 minutes.

Carrier: Turn to the Experts

Page 40

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Unit Operating Conditions

Table 12a: Two-Stage R-410A Compressor Section Coax Water Pressure Drop

Model GPM

4.0

026

038

049

064

6.0

7.0

8.0

4.0

6.0

8.0

9.0

5.5

8.3

11.0

12.0

7.0

10.5

14.0

15.0

30°F 50°F 70°F 90°F

1.5

3.1

4.1

5.1

1.2

2.6

4.5

5.7

1.1

2.2

3.9

4.5

0.5

1.9

3.9

4.8

Pressure Drop (psi)

1.3

2.6

3.4

4.3

1.0

2.5

4.2

5.2

0.9

2.1

3.6

4.2

0.3

1.8

3.5

4.3

1.1

2.3

3.0

3.8

0.8

2.3

4.0

4.8

0.8

2.0

3.2

3.8

0.2

1.7

3.2

3.9

1.0

2.1

2.7

3.4

0.6

2.1

3.7

4.4

0.7

1.8

3.1

3.5

0.1

1.6

2.9

3.5

Table 12b: R-22 Compressor Section Coax Water Pressure Drop

Model GPM

018

024

030

036

042

048

060

4 5 6

3 5 6 8

4 6 8

5 7 9

8 11 13

9 12 15

8 11 15 18

30°F 50°F 70°F 90°F

0.6

1.6

2.1

2.8

0.6

1.3

1.8

2.9

0.9

1.8

2.9

4.2

1.6

2.6

3.9

6.4

2.1

3.2

5.5

7.3

2.1

3.9

6.4

9.4

1.2

2.1

3.6

5.0

Pressure Drop (psi)

0.6

1.4

2.0

2.6

0.6

1.2

1.7

2.7

0.9

1.7

2.7

3.9

1.4

2.4

3.7

5.9

1.9

3.0

5.1

6.8

1.9

3.7

5.9

8.7

1.2

2.0

3.4

4.7

0.5

1.3

1.8

2.4

0.5

1.1

1.5

2.5

0.8

1.5

2.5

3.6

1.3

2.3

3.4

5.5

1.8

2.8

4.7

6.3

1.8

3.4

5.5

8.1

1.1

1.8

3.1

4.3

0.5

1.3

1.7

2.3

0.5

1.1

1.4

2.3

0.8

1.4

2.3

3.4

1.3

2.1

3.2

5.2

1.7

2.6

4.5

5.9

1.7

3.2

5.2

7.6

1.0

1.7

2.9

4.1

Table 13: Water Temperature Change Through Heat Exchanger

Water-Source Heating and Cooling Systems

Page 41

Residential Split - 60Hz R22 &R410A

Unit Operating Conditions

Table 14a: Size 026 Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

110

Water

Flow

GPM/

ton

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

Suction

Pressure

PSIG

122-132 122-132 122-132

132-142 132-142 132-142

139-149 139-149 139-149

141-151 141-151 141-151

145-155 145-155 145-155

Full Load Cooling - without HWG active Full Load Heating - without HWG active

Discharge

Pressure

PSIG

159-179 146-166 132-152

186-206 172-192 158-178

281-301 267-287 253-273

374-394 360-380 346-366

473-493 458-478 441-461

Super-

heat

13-18 13-18 14-19

8-13 8-13 8-13

7-12 7-12 7-12

Sub-

cooling

9-14 7-12 7-12

8-13 6-11 6-11

8-13 8-13 7-12

9-14 9-14 8-13

10-15 10-15

9-14

Water Temp

Rise °F

16.7-18.7

12.3-14.3

7.9-9.9

16.3-18.3

12.1-14.1

7.8-9.8

15.7-17.7

11.6-13.6

7.6-9.6

14.6-16.6

10.7-12.7

6.9-8.9

13.6-15.6

9.9-11.9

6.2-8.2

Air Temp

Drop °F

18-24 19-25 19-25

18-24 18-24 18-24

17-23 17-23 17-23

16-22 16-22 16-22

Suction

Pressure

PSIG

77-87 79-89 82-92

107-117 111-121 115-125

139-149 145-155 152-162

177-187 181-191 186-196

Discharge

Pressure

PSIG

278-298 280-300 282-302

314-334 315-335 317-337

350-370 352-372 354-374

392-412 397-417 402-422

Super-

heat

4-9 4-9 4-9

6-11 6-11 6-11

7-12 7-12 7-12

9-14 10-15 11-16

Operation Not Recommended

Sub-

cooling

10-15 10-15 10-15

13-18 13-18 13-18

15-20 15-20 15-20

17-22 17-22 17-22

Rev.: 5 June, 2008

Water Temp

Drop °F

5.9-7.9

4.2-6.2

2.7-4.7

8.9-10.9

6.7-8.7

4.5-6.5

11.3-13.3

8.5-10.5

5.8-7.8

14.4-16.4

10.8-12.8

7.1-9.1

Air Temp

Rise °F

18-24 19-25 20-26

25-31 26-32 26-32

31-38 32-39 32-39

37-45 38-46 38-46

Table 14b: Size 038 Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

110

Water

Flow

GPM/

ton

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

Suction

Pressure

PSIG

122-132 121-131 121-131

131-141 130-140 130-140

138-148 137-147 137-147

142-152 142-152 142-152

147-157 147-157 147-157

Full Load Cooling - without HWG active Full Load Heating - without HWG active

Discharge

Pressure

PSIG

153-173 145-165 135-155

222-242 208-228 194-214

299-319 280-300 263-283

388-408 367-387 347-367

486-506 465-475 444-464

Super-

heat

18-23 18-23 18-23

13-18 13-18 14-19

8-13 8-13 8-13

6-11 7-12 7-12

Sub-

cooling

9-14 8-13 8-13

10-15

9-14 9-14

13-18 12-17 12-17

13-18

8-13 8-13

13-18

8-13 8-13

Water Temp

Rise °F

22.1-24.1

16.8-18.8

10.5-12.5

21.9-23.9

16.1-18.1

10.3-12.3

21.5-23.5

15.8-17.8 10-12

20.5-22.5

14.9-16.9

9.3-11.3

19-21 14-16

9-11

Air Temp

Drop °F

19-25 20-26 20-26

18-24 18-24 18-24

Suction

Pressure

PSIG

71-81 75-85 78-88

103-113 107-117 112-122

134-144 140-150 146-156

172-182 184-194 196-206

Discharge

Pressure

PSIG

263-283 267-287 270-290

292-312 296-316 301-321

322-342 328-358 334-354

360-380 369-389 378-398

Super-

heat

5-10 5-10 5-10

6-11 6-11 6-11

7-12 7-12 7-12

8-13 8-13 8-13

Operation Not Recommended

Table 14c: Size 049 Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

30 30 30

50 50 50

70 70 70

90 90 90

110 110 110

Water

Flow

GPM/

ton

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

Suction

Pressure

PSIG

112-122 111-121 111-121

125-135 123-133 122-132

133-143 132-142 131-141

138-148 137-147 136-146

144-154 143-153 142-152

Full Load Cooling - without HWG active Full Load Heating - without HWG active

Discharge

Pressure

PSIG

187-207 167-187 147-167

245-265 227-247 208-228

314-334 294-314 274-294

401-421 379-399 357-377

502-522 477-497 452-472

Super-

heat

18-23 18-23 18-23

13-18 13-18 14-19

9-14 9-14

10-15

8-13 8-13 9-14

Sub-

cooling

23-28 21-26 20-25

19-24 18-23 16-21

17-22 16-21 14-19

16-21 15-20 13-18

14-19 13-18 12-17

Water Temp

Rise °F

20.7-22.7

15.5-17.5

10.2-12.2

20.9-22.9

15.6-17.6

10.2-12.2

20.5-22.5

15.2-17.2

9.9-11.9

19.2-21.2

14.3-16.3

9.3-11.3

18-20

13.3-15.3

8.5-10.5

Air Temp

Drop °F

19-25 19-25 19-25

20-26 20-26 20-26

19-25 19-25 19-25

18-24 18-24 18-24

Suction

Pressure

PSIG

66-76 69-79 72-82

93-103 98-108

103-113

123-133 130-140 137-147

167-177 177-187 187-197

Discharge

Pressure

PSIG

261-281 264-284 267-287

289-309 295-315 301-321

319-339 329-349 336-356

365-385 374-394 388-408

Super-

heat

8-13 8-13 8-13

7-12 7-12 7-12

Operation Not Recommended

Sub-

cooling

2-5 2-5 2-5

2.5-7

Sub-

cooling

5-10 5-10 5-10

Water Temp

Drop °F

8.1-10.1

5.9-7.9

3.7-5.7

11.5-13.5

8.6-10.6

5.7-7.7

14.5-16.5

11.1-13.1

7.7-9.7

20.5-22.5 15-17 10-12

Water Temp

Drop °F

8-10

6-8 4-6

11.5-13.5

8.7-10.7

5.9-7.9

15-17

11.5-13.5

7.9-9.9

19.6-21.6 15-17

10.3-12.3

Air Temp

Rise °F

17-23 18-24 19-25

23-29 24-30 24-30

28-35 29-36 30-37

36-44 37-45 39-47

Air Temp

Rise °F

18-24 19-25 19-25

23-29 24-30 25-31

28-35 29-36 30-37

37-45 38-46 39-47

Carrier: Turn to the Experts

Page 42

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Unit Operating Conditions

Table 14d: Size 064 Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

110

Water

Flow

GPM/

ton

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

1.5

2.25 3

Suction

Pressure

PSIG

117-127 116-126 115-125

126-136 124-134 123-133

130-140 129-139 128-138

133-143 132-142 132-142

138-148 137-147 136-146

Full Load Cooling - without HWG active Full Load Heating - without HWG active

Discharge

Pressure

PSIG

160-180 133-153 125-145

228-248 212-232 195-215

305-325 286-306 266-286

398-418 376-396 354-374

505-525 483-503 459-479

Super-

heat

16-21 17-22 18-23

8-13 11-16 14-19

8-13

9-14 11-16

8-13

6-11

Sub-

cooling

8-13 6-11 5-10

10-15

9-14 7-12

10-15

9-14 7-12

10-15

9-14 8-13

Water Temp

Rise °F

17.5-19.5

11.9-13.9

6.3-8.3

19.8-21.8

14.2-16.2

8.5-10.5

20.3-22.3

14.8-16.8

9.3-11.3

19.4-21.4

14.1-16.1

8.8-10.8

18.3-20.3

13.3-15.3

8.3-10.3

Air Temp

Drop °F

16-22 16-22 16-22

20-26 20-26 20-26

21-27 21-27 21-27

20-26 20-26 20-26

19-25 19-25 19-25

Suction

Pressure

PSIG

66-76 69-79 72-82

95-105 100-110 105-115

128-138 133-143 139-149

173-183 177-187 182-192

Discharge

Pressure

PSIG

282-302 285-305 289-309

318-338 321-341 324-344

360-380 364-384 368-388

407-427 411-431 415-435

Super-

heat

9-15 9-15 9-15

8-14 8-14 8-14

Operation Not Recommended

Sub-

cooling

8-13 8-13 9-14

12-17 12-17 12-17

13-18 13-18 14-19

Water Temp

Drop °F

8-10

6-8 4-6

11.3-13.3

8.5-10.5

5.7-7.7

14-16

10.6-12.6

7.3-9.3

18.2-20.2

13.9-15.9

9.6-11.6

Air Temp

Rise °F

21-27 21-27 22-28

27-33 28-34 30-36

33-38 34-40 35-41

42-50 43-51 44-52

Table 15: R-22 Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

Water

Flow

GPM/

ton

1.5

2.3

1.5

2.3

1.5

2.3

1.5

2.3

Suction

Pressure

PSIG

61-70 62-71

62-71

79-85 75-83

72-82

78-88 78-90

78-91

79-82 80-93

80-93

* Based on Nominal 400 CFM per ton per circuit ariﬂ ow and 70°F EAT heating and 80/67°F cooling. ** Cooling air and water numbers can vary greatly with changes in humidity. *** Water temperature difference based upon 1.5 - 3 GPM per ton of active circuit water ﬂ ow. **** Using liquid line pressure.

Full Load Cooling - without HWG active Full Load Heating - without HWG active

Discharge

Pressure

PSIG

100-117

92-109 88-104

145-170 130-155 125-150

180-200 169-187 160-180

230-272 215-248 208-240

Super-

12-18 12-18 12-18

10-15 10-15 10-15

8-12 8-12 8-12

8-10 8-10 8-10

heat

Sub-

cooling

****

12-22 12-22 12-22

9-16 9-16 9-16

7-12 7-12 7-12

7-11 7-11 7-11

Water Temp

Rise *** °F

21-24 13-16

6-11

20-23 12-15

8-12

19-22 11-14

7-12

18-21 10-14

6-11

Air Temp

Drop °F

21-26 21-26 21-26

20-25 20-25 20-25

19-24 19-24 19-24

17-23 17-23 17-23

Suction

Pressure

PSIG

34-39 37-42 38-44

51-58 53-62 55-65

71-82 77-89 81-92

Discharge

Pressure

PSIG

163-183 165-185 167-186

175-202 178-206 180-208

215-250 203-235 200-235

Super-

heat

5-10 5-10 5-10

9-12 9-12 9-12

10-14 10-14 10-14

Operation Not Recommended

Sub-

cooling

****

5-9 5-9 5-9

8-12 8-12 8-12

6-10 6-10 6-10

Water Temp

Drop *** °F

7.6-8.4

4.8-5.6

3.4-4.2

10.8-11.9

6.7-8.1

5.1-5.9

14.0-15.2

9.0-10.2

6.7-7.9

Air Temp

Rise °F

14-20 16-22 16-22

23-29 24-30 25-31

28-34 30-37 31-38

Water-Source Heating and Cooling Systems

Page 43

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Preventive Maintenance

Water Coil Maintenance (Direct ground water applications only) If the system is installed in an area with a known high mineral content (125 P.P.M. or greater) in the water, it is best to establish a periodic maintenance schedule with the owner so the coil can be checked regularly. Consult the well water applications section of this manual for a more detailed water coil material selection. Should periodic coil cleaning be necessary, use standard coil cleaning procedures, which are compatible with the heat exchanger material and copper water lines. Generally, the more water ﬂ owing through the unit, the less chance for scaling. Therefore, 1.5 gpm per ton [2.0 l/m per kW] is recommended as a minimum ﬂ ow. Minimum ﬂ ow rate for entering water temperatures below 50°F [10°C] is 2.0 gpm per ton [2.6 l/m per kW].

Water Coil Maintenance

(All other water loop applications) Generally water coil maintenance is not needed for closed loop systems. However, if the piping is known to have high dirt or debris content, it is best to establish a periodic maintenance schedule with the owner so the water coil can be checked regularly. Dirty installations are typically the result of deterioration of iron or galvanized piping or components in the system. Open cooling towers requiring heavy chemical treatment and mineral buildup through water use can also contribute to higher maintenance. Should periodic coil cleaning be necessary, use standard coil cleaning procedures, which are compatible with both the heat exchanger material and copper water lines. Generally, the more water ﬂ owing through the unit, the less chance for scaling. However, ﬂ ow rates over 3 gpm per ton (3.9 l/m per kW) can produce water (or debris) velocities that can erode the heat exchanger wall and ultimately produce leaks.

Hot Water Generator Coils

See water coil maintenance for ground water units. If the potable water is hard or not chemically softened, the high temperatures of the desuperheater will tend to scale even quicker than the water coil and may need more frequent inspections. In areas with extremely hard water, a HWG is not recommended.

Condensate Drain

In areas where airborne bacteria may produce a “slimy” substance in the drain pan, it may be necessary to treat the drain pan chemically with an algaecide approximately every three months to minimize the problem. The condensate pan may also need to be cleaned periodically to insure indoor air quality. The condensate drain can pick up lint and dirt, especially with dirty ﬁ lters. Inspect the drain twice a year to avoid the possibility of plugging and eventual overﬂ ow.

Compressor

Conduct annual amperage checks to insure that amp draw is no more than 10% greater than indicated on the serial plate data.

Fan Motors

Consult air handler I.O.M. for maintenance requirements.

Air Coil

The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean. Care must be taken not to damage the aluminum ﬁ ns while cleaning. CAUTION: Fin edges are sharp.

Cabinet - “Indoor” Compressor Section

Do not allow water to stay in contact with the cabinet for long periods of time to prevent corrosion of the cabinet sheet metal. Generally, cabinets are set up from the ﬂ oor a few inches [7 - 8 cm] to prevent water from entering the cabinet. The cabinet can be cleaned using a mild detergent.

Refrigerant System

To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Reference the operating charts for pressures and temperatures. Verify that air and water ﬂ ow rates are at proper levels before servicing the refrigerant circuit.

Filters

Filters must be clean to obtain maximum performance. Filters should be inspected every month under normal operating conditions and be replaced when necessary. Units should never be operated without a ﬁ lter.

Washable, high efﬁ ciency, electrostatic ﬁ lters, when dirty, can exhibit a very high pressure drop for the fan motor and reduce air ﬂ ow, resulting in poor performance. It is especially important to provide consistent washing of these ﬁ lters (in the opposite direction of the normal air ﬂ ow) once per month using a high pressure wash similar to those found at selfserve car washes.

Carrier: Turn to the Experts

Page 44

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Troubleshooting

General

If operational difﬁ culties are encountered, perform the preliminary checks below before referring to the troubleshooting charts.

• Verify that the unit is receiving electrical supply power.

• Make sure the fuses in the fused disconnect switches are intact.

After completing the preliminary checks described above, inspect for other obvious problems such as leaking connections, broken or disconnected wires, etc. If everything appears to be in order, but the unit still fails to operate properly, refer to the “CXM Troubleshooting Process Flowchart” or “Functional Troubleshooting Chart.”

CXM Board

CXM board troubleshooting in general is best summarized as simply verifying inputs and outputs. After inputs and outputs have been veriﬁ ed, board operation is conﬁ rmed and the problem must be elsewhere. Below are some general guidelines for troubleshooting the CXM control.

Field Inputs

All inputs are 24VAC from the thermostat and can be veriﬁ ed using a volt meter between C and Y, G, O, W. 24VAC will be present at the terminal (for example, between “Y” and “C”) if the thermostat is sending an input to the CXM board.

Sensor Inputs

All sensor inputs are ‘paired wires’ connecting each component to the board. Therefore, continuity on pressure switches, for example can be checked at the board connector.

Test Mode

Test mode can be entered for 20 minutes by shorting the test pins. The CXM board will automatically exit test mode after 20 minutes.

CXM Troubleshooting Process Flowchart/Functional Troubleshooting Chart

The “CXM Troubleshooting Process Flowchart” is a quick overview of how to start diagnosing a suspected problem, using the fault recognition features of the CXM board. The “Functional Troubleshooting Chart” on the following page is a more comprehensive method for identifying a number of malfunctions that may occur, and is not limited to just the CXM controls. Within the chart are ﬁ ve columns:

• The “Fault” column describes the symptoms.

• Columns 2 and 3 identify in which mode the fault is likey to occur, heating or cooling.

• The “Possible Cause column” identiﬁ es the most likely sources of the problem.

• The “Solution” column describes what should be done to correct the problem.

 WARNING! 

WARNING! HAZARDOUS VOLTAGE! DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death.

The thermistor resistance should be measured with the connector removed so that only the impedance of the thermistor is measured. If desired, this reading can be compared to the thermistor resistance chart shown in the CXM/DXM AOM manual. An ice bath can be used to check calibration of the thermistor.

Outputs

The compressor relay is 24VAC and can be veriﬁ ed using a voltmeter. The fan signal is passed through the board to the external fan relay (units with PSC motors only). The alarm relay can either be 24VAC as shipped or dry contacts for use with DDC controls by clipping the JW1 jumper. Electric heat outputs are 24VDC “ground sinking” and require a volt meter set for DC to verify operation. The terminal marked “24VDC” is the 24VDC supply to the electric heat board; terminal “EH1” is stage 1 electric heat; terminal “EH2” is stage 2 electric heat. When electric heat is energized (thermostat is sending a “W” input to the CXM controller), there will be 24VDC between terminal “24VDC” and “EH1” (stage 1 electric heat) and/or “EH2” (stage 2 electric heat). A reading of 0VDC between “24VDC” and “EH1” or “EH2” will indicate that the CXM board is NOT sending an output signal to the electric heat board.

Water-Source Heating and Cooling Systems

Page 45

See “Does

not Operate

in Clg”

See “Only

Comp

Runs”

Start

Did Unit

Attempt to

Start?

Did Unit

Lockout at

Start-up?

Unit Short

Cycles?

Only Fan

Runs?

Only

Compressor

Runs?

Did unit lockout

after a period of

operation?

Does unit

operate in

cooling?

Unit is OK!

‘See Performance

Troubleshooting’ for

further help

Check Main

power (see power

problems)

Check fault LED code

on control board

Yes

See HP

Fault

See

LP/LOC

Fault

See FP1

Fault

See FP2

Fault

See

Condensate

Fault

See Over/

Under

Voltage

No fault

shown

Replace

CXM

See “Unit

short

cycles”

See “Only

Fan Runs”

Yes

CXM Functional Troubleshooting Chart

 WARNING! 

WARNING! HAZARDOUS VOLTAGE! DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death.

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

CXM Process Flow Chart

Carrier: Turn to the Experts

Page 46

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Functional Troubleshooting

Fault Htg Clg Possible Cause Solution Main power Problems X X Green Status LED Off Check Line Voltage circuit breaker and disconnect

HP Fault-Code 2 X Reduced or no water flow Check pump operation or valve operation/setting

High pressure in cooling

LP/LOC Fault-Code 3 X X Insufficient charge Check for refrigerant leaks

Low Pressure/Loss of Charge X

FP1 Fault - Code 4 X Reduced or no water flow Check pump operation or water valve operation/setting Water Coil low

temperature limit

FP2 fault - Code 5 X Reduced or no Air flow Check for dirty air filter and clean or replace

Air Coil low temperature limit

Condensate Fault-Code

Over/Under VoltageCode 7

(Auto resetting) Check power supply wire size

Unit Performance Sentinel-Code 8

No Fault Code Shown X X No compre ssor operation See "Only fan operates"

Unit Short Cycles X X Dirty Air Filter Check and Clean air filter

Only Fan Runs X X Thermostat position Insure thermostat set for heating or cooling operation

Water Temperature out of range in cooling

X Reduced or no Air flow Check for dirty air filter and clean or replace

in heating Check fan motor operation and airflow restrictions

Air Temperature out of range in heating

Overcharged with refrigerant

Bad HP Switch Check switch continuity and operation. Replace

Compressor pump down at startup

in heating Plugged strainer or filter. Clean or replace.

X Inadequate anti-freeze level Check antifreeze density with hydrometer

Improper temperature limit setting

(30°F vs 10°F [-1°C vs -12°C]) X Water Temperature out of range Bring water temp within design parameters X X Bad thermistor Check temp and impedance correlation per chart

in cooling Check fan motor operation and airflow restrictions

X Air Temperature out of range

Improper temperature limit setting

(30°F vs 10°F [-1°C vs -12°C]) X X Bad thermistor Check temp and impedance correlation per chart

X X Blocked Drain Check for blockage and clean drain X X Improper trap Check trap dimensions and location ahead of vent

X Poor Drainage Check for piping slope away from unit

X Moisture on sensor Check for moisture shorting to air coil

X X Under Voltage

Over Voltage

X Heating mode FP2>125°F [52°C] Check for poor air flow or overcharged unit.

Cooling Mode FP1>125°F [52°C]

OR FP2< 40ϒF [4ϒC]

X X Compressor Overload Check and Replace if necessary

X X Control board Reset power and check operation

X X Unit in "Test Mode" Reset p ower or wait 20 minutes for auto exit.

X X Unit selection

X X Compressor Overload Check and Replace if necessary

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 for line voltage between L1 and L2 on the contactor Check for 24VAC between R and C on CXM/DXM Check primary/secondary voltage on transformer

Check water flow adjust to proper flow rate Bring water temp within design parameters

Dirty Air Coil- construction dust etc. Too high of external static. Check static vs blower table

Bring return air temp within design parameters

Check superheat/subcooling vs typical operating condition table

Check charge and start-up water flow

Check water flow adjust to proper flow rate

Clip JW3 jumper for antifreeze (10°F [-12°C]) use

Too high of external static. Check static vs blower table Too much cold vent air? Bring entering air temp within

design parameters Normal airside applications will require 30°F [-1°C] only

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

Check power supply and 24VAC voltage before and during operation.

Check compressor starting. Need hard start kit? Check 24VAC and unit transformer tap for correct power

supply voltage Check power supply voltage and 24VAC before and during

operation. Check 24VAC and unit transformer tap for correct power

supply voltage

Check for poor water flow, or air flow

Unit may be oversized for space. Check sizing for actual load of space.

Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode.

Water-Source Heating and Cooling Systems

Page 47

Residential Split - 60Hz R22 &R410A

Functional Troubleshooting

Fault Htg Clg Possible Cause Solution Main power Problems X X Green Status LED Off Check Line Voltage circuit breaker and disconnect

HP Fault-Code 2 X Reduced or no water flow Check pump operation or valve operation/setting

High pressure in cooling

LP/LOC Fault-Code 3 X X Insufficient charge Check for refrigerant leaks

Performance Troubleshooting

Low Pressure/Loss of Charge X

FP1 Fault - Code 4 X Reduced or no water flow Check pump operation or water valve operation/setting Water Coil low

temperature limit

FP2 fault - Code 5 X Reduced or no Air flow Check for dirty air filter and clean or replace Air Coil low

temperature limit

Condensate Fault-Code

Over/Under VoltageCode 7

(Auto resetting) Check power supply wire size

Unit Performance Sentinel-Code 8

No Fault Code Shown X X No compressor operation See "Only fan operates"

Unit Short Cycles X X Dirty Air Filter Check and Clean air filter

Water Temperature out of range in cooling

X Reduced or no Air flow Check for dirty air filter and clean or replace

in heating Check fan motor operation and airflow restrictions

Air Temperature out of range in heating

Overcharged with refrigerant

Bad HP Switch Check switch continuity and operation. Replace

ompressor pump down at start-

in heating Plugged strainer or filter. Clean or replace.

X Inadequate anti-freeze level Check antifreeze density with hydrometer

Improper temperature limit setting

(30°F vs 10°F [-1°C vs -12°C]) X Water Temperature out of range Bring water temp within design parameters X X Bad thermistor Check temp and impedance correlation per chart

in cooling Check fan motor operation and airflow restrictions

X Air Temperature out of range

Improper temperature limit setting

(30°F vs 10°F [-1°C vs -12°C]) X X Bad thermistor Check temp and impedance correlation per chart

X X Blocked Drain Check for blockage and clean drain X X Improper trap Check trap dimensions and location ahead of vent

X Poor Drainage Check for piping slope away from unit

X Moisture on sensor Check for moisture shorting to air coil

X X Under Voltage

Over Voltage

X Heating mode FP2>125°F [52°C] Check for poor air flow or overcharged unit.

Cooling Mode FP1>125°F [52°C]

OR FP2< 40ϒF [4ϒC]

X X Compressor Overload Check and Replace if necessary

X X Control board Reset power and check operation

X X Unit in "Test Mode" Reset power or wait 20 minutes for auto exit.

X X Unit selection

X X Compressor Overload Check and Replace if necessary

Check for line voltage between L1 and L2 on the contacto Check for 24VAC between R and C on CXM/DXM Check primary/secondary voltage on transformer

Check water flow adjust to proper flow rate Bring water temp within design parameters

Dirty Air Coil- construction dust etc. Too high of external static. Check static vs blower table

Bring return air temp within design parameters

Check superheat/subcooling vs typical operating condition table

Check charge and start-up water flow

Check water flow adjust to proper flow rate

Clip JW3 jumper for antifreeze (10°F [-12°C]) use

Too high of external static. Check static vs blower table Too much cold vent air? Bring entering air temp within

design parameters Normal airside applications will require 30°F [-1°C] only

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

Check power supply and 24VAC voltage before and durin operation.

Check compressor starting. Need hard start kit? Check 24VAC and unit transformer tap for correct power

supply voltage Check power supply voltage and 24VAC before and durin

operation. Check 24VAC and unit transformer tap for correct power

supply voltage

Check for poor water flow, or air flow

Unit may be oversized for space. Check sizing for actual load of space.

Rev.: 5 June, 2008

Carrier: Turn to the Experts

Page 48

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Troubleshooting Form

Customer: _____________________________________ Antifreeze: ________________

Model#: ________________________ Serial#: ________________ Loop type: ________

Complaint: _________________________________________________________________

HEATING CYCLE ANALYSIS -

AIR HANDLER SECTION COMPRESSOR SECTION

Refrigerant Type:

R410A

R22

R407C

Look up pressure drop in I.O.M. or spec. catalog to determine flow rate.

COOLING CYCLE ANALYSIS -

AIR HANDLER SECTION COMPRESSOR SECTION

AIR

COIL

ϒF ϒF

COOLING

EXPANSION

VALVE*

HEATING

EXPANSION

VALV E* *

ϒF

LIQUID LINE

COAX

ϒF ϒF

PSI PSI

WATER IN WATER OUT

HWG

PSI

ϒF

SUCTION

COMPRESSOR

DISCHARGE

ϒF

PSI

ϒF

SAT

AIR

COIL

ϒF ϒF

COOLING

EXPANSION

VALVE*

Look up pressure drop in I.O.M. or spec. catalog to determine flow rate.

*Cooling expansion valve meters in the cooling mode, and bypasses in the heating mode. **Heating expansion valve meters in the heating mode, and bypasses in the cooling mode.

HEATING

EXPANSION

VALV E* *

ϒF

LIQUID LINE

COAX

ϒF ϒF

PSI PSI

WATER IN WATER OUT

HWG

SUCTION

COMPRESSOR

DISCHARGE

ϒF

PSI

SAT

Heat of Extraction ( Absorbtion) or Heat of Rejection =

________ flow rate (gpm) x ________ temp. diff. (deg. F) x __________ fluid factor

Superheat

Subcooling

Note: Never connect refrigerant gauges during startup procedures. Conduct water-side analysis using P/T ports to determine water ﬂ ow and temperature difference. If water-side analysis shows poor performance, refrigerant troubleshooting may be required. Connect refrigerant gauges as a last resort.

suction temperature - suction saturation temp.

discharge saturation temp. - liquid line temp.

†

Use 500 for water, 485 for antifreeze.

†

= _____________

(Btu/hr)

(deg F)

Water-Source Heating and Cooling Systems

Page 49

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Carrier: Turn to the Experts

Page 50

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Section Revision Log

Date Page # Description

01 Jan, 09 All Reformatted Document Size

03 Mar, 08 27 Updated GT-GS Electrical Data

28 June, 07 11 Updated Flow Controller Mounting Instructions

01 Oct, 06 All First Published

ISO 9001:2000 Certified

Quality: First & Always

*97B0048N01*

97B0048N01

The Manufacturer works continually to improve its products. As a result, the design and speciﬁ cations of each product at the time for order may be changed without notice and may not be as described herein. Please contact the Manufacturer’s Customer Service Department at 1-405-745-6000 for speciﬁ c information on the current design and speciﬁ cations. Statements and other information contained herein are not express warranties and do not form the basis of any bargain between the parties, but are merely Manufacturer’s opinion or commendation of its products.

The management system governing the manufacture of Manufacturer’s products is ISO 9001:2000 certiﬁ ed.

Water-Source Heating and Cooling Systems

7300 S.W. 44th Street

Oklahoma City, OK 73179

Phone: 405-745-2920

Fax: 405-745-6620

Rev.: 30 June, 2008B