Carrier Aquazone 50RWS036-360 Installation, Start-Up And Service Instructions Manual
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Carrier Aquazone 50RWS036-360 Installation, Start-Up And Service Instructions Manual

Carrier Aquazone 50RWS036-360 Installation, Start-Up And Service Instructions Manual

Water-to-water water source heat pump units
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . .1,2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Step 1 - Check Jobsite . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 2 - Check Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
• STORAGE
• PROTECTION
Step 3 - Location of Unit . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 4 - Mounting the Unit . . . . . . . . . . . . . . . . . . . . . . 6
Step 5 - Piping Connections . . . . . . . . . . . . . . . . . . . . 6
Unit Load Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Step 6 - Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . 10
• EXTERNAL LOOP POWER CONNECTION
• 208-VOLT OPERATION
Step 7 - Low Voltage Wiring. . . . . . . . . . . . . . . . . . . . 18
• THERMOSTAT CONNECTIONS
• WATER FREEZE PROTECTION
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FIELD SELECTABLE INPUTS . . . . . . . . . . . . . . . .19,20
Complete C Control Jumper Settings. . . . . . . . . . . 19
Complete C Control DIP Switches. . . . . . . . . . . . . . 19
Deluxe D Control Jumper Settings . . . . . . . . . . . . . 19
Deluxe D Control DIP Switches . . . . . . . . . . . . . . . . 20
Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Unit Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Scroll Compressor Rotation. . . . . . . . . . . . . . . . . . . . . 21
Flow Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cooling Tower/Boiler Systems . . . . . . . . . . . . . . . . . . 22
Heat Exchanger Well Systems . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22,23
Power Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 111
Book 1
4
Tab
5a 5a
Installation, Start-Up, and
Service Instructions
Page
Catalog No. 535-00094
Printed in U.S.A.
Water Source Heat Pump Units
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-25
Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Retry Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25,26
Water Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Refrigerant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Condenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Checking System Charge . . . . . . . . . . . . . . . . . . . . . . . 26
Refrigerant Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air Coil Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . 26
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 26-28
Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
IMPORTANT: Read the entire instruction manual before
starting installation.

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical compo-
nents. Only trained and qualified service personnel should
install, repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance func-
tions of cleaning coils and filters and replacing filters. All other
operations should be performed by trained service personnel.
When working on air-conditioning equipment, observe precau-
tions in the literature, tags and labels attached to the unit, and
other safety precautions that may apply.
Improper installation, adjustment, alteration, service, main-
tenance, or use can cause explosion, fire, electrical shock or
other conditions which may cause personal injury or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The
qualified installer or agency must use factory-authorized kits or
accessories when modifying this product. Refer to the individ-
ual instructions packaged with the kits or accessories when
installing.
Form 50RWS-2SI
Pg 1
TM
Water-to-Water
50RWS036-360
Page
5-03
Replaces: 50RWS-1SI

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Summary of Contents for Carrier Aquazone 50RWS036-360

  • Page 1: Table Of Contents

    Water-to-Water Water Source Heat Pump Units 50RWS036-360 Installation, Start-Up, and Service Instructions CONTENTS Page Units with Aquazone™ Complete C Control ..22 Page Units with Aquazone Deluxe D Control ..23 SAFETY CONSIDERATIONS .

  • Page 2: General

    Step 2 — Check Unit — Follow all safety codes. Wear safety glasses and work Upon receipt of shipment at gloves. Use quenching cloth for brazing operations. Have fire the jobsite, carefully check the shipment against the bill of extinguisher available. Read these instructions thoroughly and lading.
  • Page 3 LEGEND — Source Water Connection — In — Source Water Connection — Out — Load Water Connection — In Compressor Unit Fault Run LED — Load Water Connection — Out — HWG Connection — In — HWG Connection — Out EWT —...
  • Page 4 3.91 ” 3.91 ” Right Water Connections Left Water Connections ” ” ” 1.81 ” 1.81” 1.81” 1.56 ” 1.81 ” Rear Water Connections Front Water Connections LEGEND TYP — Typical WATER CONNECTIONS (in.) ELECTRICAL OVERALL CABINET (in.) KNOCKOUTS (in.) Source Coil Load Coil UNIT...
  • Page 5 28.1 39.7 [713] [1008] Source Water In Optional 2”FPT [50.8] Disconnect Switch Load Water In 2”FPT [50.8] 47.3 [1202] Load Water Out 2”FPT [50.8] Low Voltage Line Voltage Source Water Out 1/2” [12.7] 1-1/4” 2”FPT [50.8] Conduit [31.8] Conduit Recommended Service Access 30”...

  • Page 6: Inspect Unit

    See • Use PVC SCH80 or copper piping material. Fig. 2A-4. Refer to the Carrier System Design Manual for ad- NOTE: PVC SCH40 should not be used due to system high ditional information.
  • Page 7 Table 2 — Water Quality Guidelines CONDITION ACCEPTABLE LEVEL 7 to 9 range for copper. Cupro-nickel may be used in the 5 to 9 range. Total Hardness Calcium and magnesium carbonate should not exceed 20 grains per gallon (350 ppm). Iron Oxides Less than 1 ppm.
  • Page 8 Fig. 2B — Typical Water Loop (Boiler/Tower) System (50RWS360 Units Shown) Unit Power Load Heat Exchanger Disconnect Connections Automatic Balancing Valve Solenoid Expansion Valve Tank Water Out Air Pad or Extruded polystyrene Water In insulation board Shut-Off Valve Optional Concrete Filter block or brick...

  • Page 9: Ground-Loop Applications

    • Ensure load water flow in high temperature heating All Carrier heat pumps equipped with the HWG option applications is at least 3 gpm per ton to improve perfor- include a built-in water-to-refrigerant heat exchanger to elimi- mance and reduce nuisance high pressure faults.

  • Page 10: Step 6 - Electrical Wiring

    External Field-Installed Pump Fig. 5 — Typical Hot Water Generator Installation Swimming Pool Hot Tub Applications All field-installed wiring, including the electrical ground, MUST comply with the National Electrical Code (NEC) as • Load coax material should always be cupro-nickel in well as applicable local codes.
  • Page 11 Table 3 — 50RWS Electrical Data COMPRESSOR UNIT VOLTAGE VOLTAGE RANGE TOTAL MOCP* 50RWS (V-Ph-Hz) MIN/MAX 208/230-1-60 187/254 15.0 73.0 15.0 18.8 265-1-60 239/292 14.3 71.0 14.3 17.9 208/230-3-60 187/254 10.7 63.0 10.7 13.4 460-3-60 414/506 31.0 036 w/HWG† 208/230-1-60 187/254 15.0 73.0...

  • Page 12: Supply Voltage

    (230V) Aquazone Thermostat LEGEND — Alarm Relay Contacts — National Electrical Code Solenoid Coil — Blower Relay — Field Wiring Terminal Block — Circuit Breaker — Performance Monitor Thermistor — Compressor Contactor — Reversing Valve Solenoid — Sensor, Condensate Overflow TFRMR —...

  • Page 15: Supply Voltage

    (265V) (208V) AQUAZONE THERMOSTAT LEGEND — Alarm Relay Contacts — Field Wiring Terminal Block — Performance Monitor — Circuit Breaker Solenoid Coil — Compressor Contactor — Reversing Valve Solenoid Thermistor — Sensor, Condensate Overflow TRANS — Transformer FP1 — Sensor, Water Coil Freeze Protection Field Line Voltage Wiring Ground FP2 —...
  • Page 17 PREMIERLINK™ CONTROLLER APPLICATIONS WITH COMPLETE C CONTROL COMPLETE PREMIER LINK CONTROL HS1/EXH/RVS LEGEND — Control Relay LWT — Leaving Water Temperature Sensor CMP1 SAT — Supply Air Temperature Sensor SPT — Space Temperature Sensor NOTE: Reversing valve is on in Cooling mode. PREMIERLINK CONTROLLER APPLICATIONS WITH DELUXE D CONTROL PREMIER LINK...

  • Page 18: External Pump Hwg Power Connection

    SUPPLY VOLTAGE — Operating voltage to unit must be within voltage range indicated on unit nameplate. Capacitor On 3-phase units, voltages between phases must be bal- anced within 2%. Use the following formula to determine the percentage voltage imbalance: Grnd % Voltage Imbalance Contactor -CC max voltage deviation from average voltage...

  • Page 19: Accessory Connections

    ACCESSORY CONNECTIONS — Terminal labeled A on PRE-START-UP the control is provided to control accessory devices such as System Checkout — When the installation is complete, water valves, electronic air cleaners, humidifiers, etc. This sig- follow the System Checkout procedure outlined below before nal operates with the compressor terminal.

  • Page 20: Deluxe D Control Dip Switches

    LOW PRESSURE SETTING — The Deluxe D Control can WATER VALVE (SLOW OPENING) — If relay is config- be configured for Low Pressure Setting (LP). Select jumper 1 ured for Water Valve (slow opening), the relay will start 60 sec- (JW1-LP Norm Open) for choosing between low pressure in- onds prior to starting compressor relay.

  • Page 21: Unit Start-Up

    Table 6 — 50RWS036-360 Operating Limits the unit lockout. This requires a manual reset. To reset, turn the thermostat on and then off. COOLING HEATING WATER LIMITS NOTE: There is a 5-minute time delay before the compressor will start. SOURCE COIL Min.

  • Page 22: Antifreeze

    3. Open all air vents. Fill the system with the water. DO Once antifreeze is selected, the JW3 jumper (FP1) should NOT allow system to overflow. Bleed all air from the be clipped on the control to select the low temperature (anti- system.

  • Page 23: Units With Aquazone Deluxe D Control

    initiate a 5 to 80 second random start delay and a 5-minute anti- If configured as stage 2 (DIP switch set to OFF) then the com- short cycle protection time delay. After both delays are pressor and fan will not turn on until there is a stage 2 demand. complete, the compressor is energized.
  • Page 24 Table 11 — Complete C Control LED Code and Fault Descriptions TEST MODE PINS FAULT DESCRIPTION CODE Off On Test No fault in memory There has been no fault since the last power-down to power-up sequence High-Pressure Switch HP Open Instantly Low-Pressure Switch LP open for 30 continuous Fig.

  • Page 25: Service

    Proper water treatment can minimize tube fouling and vicing unit. pitting. If such conditions are anticipated, water treatment analysis is recommended. Refer to the Carrier System Design Water Coil — Keep all air out of the water coil. Check Manual, Part 5, for general water conditioning information.

  • Page 26: Checking System Charge

    Clean condensers with an inhibited hydrochloric acid solu- FILL CONDENSER WITH tion. The acid can stain hands and clothing, damage concrete, CLEANING SOLUTION. DO PAIL and, without inhibitor, damage steel. Cover surroundings to NOT ADD SOLUTION guard against splashing. Vapors from vent pipe are not harmful, MORE RAPIDLY THAN VENT CAN EXHAUST but take care to prevent liquid from being carried over by the...
  • Page 27 Table 13 — Troubleshooting FAULT HEATING COOLING POSSIBLE CAUSE SOLUTION Main Power Problems Green Status LED Off Check line voltage circuit breaker and disconnect. Check for line voltage between L1 and L2 on the contactor. Check for 24 vac between R and C on controller. Check primary/secondary voltage on transformer.
  • Page 28 Recheck loads and sizing check sensible cooling load and heat pump capacity. LEGEND RV — Reversing Valve Copyright 2003 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 PC 111 Catalog No.

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