Table of Contents
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . .1,2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Step 1 - Check Jobsite . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 2 - Check Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
• STORAGE
• PROTECTION
• INSPECT UNIT
Step 3 - Locate Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
• FIELD CONVERSION OF DISCHARGE AIR
Step 4 - Mount the Unit . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 5 - Check Duct System . . . . . . . . . . . . . . . . . . . . 8
• SOUND ATTENUATION
• EXISTING DUCT SYSTEM
Step 6 - Install Condensate Drain . . . . . . . . . . . . . . . 8
• HORIZONTAL UNITS
• VERTICAL UNITS
• VENTING
Step 7 - Pipe Connections . . . . . . . . . . . . . . . . . . . . . . 9
• GOUND LOOP APPLICATIONS
KIT
Step 8 - Wire Field Power Supply . . . . . . . . . . . . . . 10
• POWER CONNECTION
• 208-VOLT OPERATION
• 460-VOLT OPERATION
Step 9 - Wire Field Controls. . . . . . . . . . . . . . . . . . . . 22
• WATER FREEZE PROTECTION
• ACCESSORY CONNECTIONS
• WSHP OPEN WIRING
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24,25
System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PSC Blower Speed Selection . . . . . . . . . . . . . . . . . . 24
FIELD SELECTABLE INPUTS . . . . . . . . . . . . . . . .26,27
Complete C Control Jumper Settings. . . . . . . . . . . 26
Complete C Control DIP Switches. . . . . . . . . . . . . . 26
Deluxe D Control Jumper Settings . . . . . . . . . . . . . 26
Deluxe D Control DIP Switches . . . . . . . . . . . . . . . . 26
Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Water Valve (Slow Opening) . . . . . . . . . . . . . . . . . . . 27
Outside Air Damper (OAD) . . . . . . . . . . . . . . . . . . . . 27
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-33
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Scroll Compressor Rotation. . . . . . . . . . . . . . . . . . . . . 28
Unit Start-Up Cooling Mode . . . . . . . . . . . . . . . . . . . . . 28
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53500049-01
Compact High-Efficiency Water Source Heat Pumps
Installation, Start-Up, and
Service Instructions
Printed in U.S.A.
with PURON
Unit Start-Up Heating Mode . . . . . . . . . . . . . . . . . . . . . 31
Page
Unit Start-Up with WSHP Open Controls . . . . . . . . 31
Flow Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cooling Tower/Boiler Systems . . . . . . . . . . . . . . . . . . 33
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-37
Power Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Units with Aquazone Complete C Control . . . . . . . 33
Units with Aquazone Deluxe D Control . . . . . . . . . . 33
Units with WSHP Open Multiple Protocol. . . . . . . . 34
Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
WSHP Open Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . 37
Retry Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Aquazone Deluxe D Control LED Indicators . . . . . 37
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-40
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Water Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Condensate Drain Pans . . . . . . . . . . . . . . . . . . . . . . . . . 38
Refrigerant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fan Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Condensate Drain Cleaning . . . . . . . . . . . . . . . . . . . 38
Air Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Condenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Checking System Charge . . . . . . . . . . . . . . . . . . . . . 39
Refrigerant Charging . . . . . . . . . . . . . . . . . . . . . . . . . 39
Air Coil Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . 39
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 40-42
Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Control Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
WSHP Open Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 40
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . 43-48
50PCH,PCV START-UP CHECKLIST . . . . . CL-1, CL-2
IMPORTANT: Read the entire instruction manual before
starting installation.
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical 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
precautions in the literature, tags and labels attached to the unit,
and other safety precautions that may apply.
Form 50PC-1SI
AQUAZONE™
50PCH,PCV015-060
®
Refrigerant (R-410A)
Pg 1
7-09
Page
Replaces: New
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Summary of Contents for Carrier AQUAZONE PCV015-060
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Page 1: Table Of Contents
Compact High-Efficiency Water Source Heat Pumps Installation, Start-Up, and Service Instructions CONTENTS SAFETY CONSIDERATIONS ....1,2 GENERAL ........2 INSTALLATION . -
Page 2: General
• PCV standard efficiency with vertical airflow and top discharge IMPORTANT: The installation of water source heat pump units and all associated components, parts, and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and MUST conform to all applicable codes. - Page 3 or an equivalent protective covering. Cap open ends of pipes stored on the jobsite. This precaution is especially important in areas where painting, plastering, or spraying of fireproof mate- rial, etc. is not yet complete. Foreign material that accumulates within the units can prevent proper start-up and necessitate costly clean-up operations.
- Page 4 LEFT RETURN OPTIONAL 2 FT 2 FT [610 MM] SERVICE [610 MM] ACCESS SERVICE ACCESS FRONT LEFT RETURN STRAIGHT DISCHARGE BACK NOTE: CHOOSE EITHER DISCHARGE BACK OR STRAIGHT DISCHARGE BLOWER OUTLET a50-8412 LEFT RETURN BACK DISCHARGE FRONT LEFT RETURN STRAIGHT DISCHARGE LEFT RETURN LEFT VIEW - AIR COIL OPENING OVERALL CABINET...
- Page 5 UNIT HANGER ISOLATION DETAIL Fig. 2 — Typical Installation — 50PCH Units...
- Page 6 AIR COIL AND FRONT SIDE TOP VIEW-FRONT RETURN AIR COIL SIDE TOP VIEW-RIGHT RETURN AIR COIL FRONT BACK RIGHT RETURN RIGHT VIEW - AIR COIL OPENING OVERALL CABINET WATER CONNECTIONS 50PCV UNIT SIZE Width Depth Height Loop In Loop Out 21.5 21.5 39.0...
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Page 7: Step 3 - Locate Unit
Supply Air Building Loop Flexible Connection Water Return Water Field-supplied stainless steel braid hose with integral “ J” swivel Power Thermostat Wiring Ball Valve with optional integral P/T plug Compressor (typical for supply and Access Panel return piping) NOTE: Ball valve with integral pressure temperature plug recommended. Fig. -
Page 8: Step 4 - Mount The Unit
Side to Back Discharge Conversion 1. Remove screws to free the top and discharge panels. See Fig. 5. 2. Remove the access panel and set aside. 3. Lift the discharge panel from side of unit and rotate it to back using care not to damage blower wiring. 4. -
Page 9: Water Loop Applications
3 types of WSHP piping systems to choose from: water loop, ground-water and ground loop. Refer to Piping Section of Carrier System Design Manual for addi- tional information. All WSHP units use low temperature soldered female pipe... -
Page 10: Step 8 - Wire Field Power Supply
Tighten steel fittings as necessary. Optional pressure-rated hose assemblies designed specifi- cally for use with Carrier units are available. Similar hoses can be obtained from alternate suppliers. Supply and return hoses are fitted with swivel-joint fittings at one end to prevent kink- ing during installation. - Page 16 A50-8355...
- Page 17 A50-8354...
- Page 18 A50-8356...
- Page 19 A50-8353...
- Page 20 a50-8380 GREEN Rnet+ WHITE Rnet- BLACK To WSHP Controller Rnet Terminals (J13) LED1 +12V GREEN Rnet+ WHITE Rnet- BLACK +12V To WSHP Controller Rnet Terminals (J13)
- Page 21 RATED 50PCH,PCV VOLTAGE VOLTAGE VOLTAGE UNIT SIZE CODE MIN/MAX V-Ph-Hz* 208/230-1-60 197/254 265-1-60 239/292 208/230-1-60 197/254 265-1-60 239/292 208/230-1-60 197/254 265-1-60 239/292 208/230-1-60 197/254 265-1-60 239/292 208/230-3-60 197/254 460-3-60 414/506 208/230-1-60 197/254 265-1-60 239/292 208/230-3-60 197/254 460-3-60 414/506 208/230-1-60 197/254 208/230-3-60 197/254 460-3-60...
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Page 22: Step 9 - Wire Field Controls
Step 9 — Wire Field Controls THERMOSTAT CONNECTIONS — should be wired directly to the Aquazone™ control board. See Fig. 13-22, and 24. CAPACITOR COMPLETE C CONTROL COMPRESSOR CONTACTOR TRANSFORMER a50-8197 THERMOSTAT CONNECTION NOTE: Low voltage connector may be removed for easy installation. Fig. - Page 23 NOTE: If the Rnetbus has multiple SPT Standard sensors, each sensor must be given a unique address on the Rnetbus. See the Carrier Open Sensor Installation Guide. Use the specified type of wire and cable for maximum signal integrity. See Table 6.
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Page 24: Pre-Start-Up
Wiring a Supply Air Temperature (SAT) Sensor SAT sensor is required for reheat applications. If the cable used to wire the SAT sensor to the controller will be less than 100 ft, an unshielded 22 AWG (American Wire Gage) cable should be used. If the cable will be greater than 100 ft, a shield 22 AWG cable should be used. - Page 25 Table 8 — 50PCV Blower Performance with Hot Water Reheat (HWR) Option REHEAT EXTERNAL STATIC PRESSURE (ESP) LOSS COIL FACE 015-030 036, 042 VELOCITY (fpm) (in. wg) (in. wg) 0.060 0.070 0.090 0.124 0.164 0.252 0.380 NOTE: For 50PCV units with HWR, calculate coil face velocity of the entering air.
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Page 26: Field Selectable Inputs
2, W1 is used for heating stage 1 and O/W2 is used for heating stage 2. Select ON for heat pump applications. In heat pump mode, Y1 used is for compressor stage 1, Y2 is used for compressor stage 2, W1 is used for heating stage 3 or emergency heat, and O/W2 is used for RV (heating or cooling) depending upon switch 4 setting. -
Page 27: Deluxe D Control Accessory Relay
3. Balance airflow at registers. 4. Adjust all valves to the full open position and turn on the line power to all heat pump units. 5. Operate unit in the cooling cycle first, then the heating cycle. Refer to Table 14 for unit operating limits. Al- low 15 minutes between cooling and heating tests for pressure to equalize. -
Page 28: Scroll Compressor Rotation
Table 14 — Operating Limits — 50PCH,PCV Units AIR LIMITS Cooling (F) Min. Ambient Air – db Rated Ambient Air – db 80.6 Max. Ambient Air – db Min. Entering Air – db/wb Rated Entering Air – db/wb 80.6/66.2 Max. Entering Air – db/wb 110/83 WATER LIMITS Min. - Page 29 Table 17 — 50PC024 Typical Unit Operating Pressures and Temperatures ENTERING WATER WATER Suction Discharge FLOW TEMP Pressure Pressure (GPM/ton) (psig) (psig) 115-125 154-174 2.25 115-125 141-161 115-125 127-147 115-120 209-229 2.25 115-120 195-215 115-120 181-201 136-146 275-295 2.25 136-146 261-281 136-146 247-267...
- Page 30 Table 20 — 50PC042 Typical Unit Operating Pressures and Temperatures ENTERING WATER WATER Suction Discharge FLOW TEMP Pressure Pressure (GPM/ton) (psig) (psig) 114-124 170-190 2.25 113-123 150-170 113-123 131-151 130-140 226-246 2.25 129-139 208-228 129-139 190-210 132-142 290-310 2.25 131-141 273-293 131-141 255-275...
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Page 31: Unit Start-Up Heating Mode
BAS (Building Automation System) system or provide additional capabilities to Carrier's WSHP product line. Most settings on the controller have factory defaults set for ease of installation. There are a few settings that must be configured in the field and several settings that can be adjusted if required by unique job condi- tions. -
Page 32: Flow Regulation
• The condenser water limit needs to be verified depending on design parameters and application, whether geothermal or boiler/tower. 7. To view unit configuration settings: a. Select the Unit Configuration softkey, then select Unit. b. Scroll through the unit settings by using the up and down arrow keys. -
Page 33: Antifreeze
Cooling Tower/Boiler Systems — ically use a common loop temperature maintained at 60 to 90 F. Carrier recommends using a closed circuit evaporative cooling tower with a secondary heat exchanger between the tower and the water loop. If an open type cooling tower is used continu- ously, chemical treatment and filtering will be necessary. -
Page 34: Units With Wshp Open Multiple Protocol
The WSHP Open controller has its own hardware clock that is automatically set when the heat pump software is downloaded to the board. Oc- cupancy types are described in the scheduling section below. The following sections describe the functionality of the WSHP Open multi-protocol controller. - Page 35 • Heating mode is not active and the compressor time guard has expired. • Condensate overflow input is normal. • If occupied, the SPT is greater than the occupied cooling set point. • Space temperature reading is valid. • If unoccupied, the SPT is greater than the unoccupied cooling set point.
- Page 36 heating set point should the compressor capacity be insufficient or a compressor failure occurs. Unless a compressor fault con- dition exists, the heat stage will only operate to supplement the heat provided by the compressor if the space temperature falls more than one degree below the desired heating set point.
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Page 37: Operation
operate if the loop pump status is off and therefore the WSHP compressor will not run. COMPLETE C AND DELUXE D BOARD SYSTEM TEST System testing provides the ability to check the control operation. The control enters a 20-minute Test mode by momentarily shorting the test pins. -
Page 38: Service
Table 28 — Aquazone Deluxe D Control Current LED Status and Alarm Relay Operations DESCRIPTION Normal Mode Normal Mode with PM Deluxe D Control is non-functional Test Mode Night Setback Flashing Code 2 Flashing Code 3 Invalid T-stat Inputs Flashing Code 4 No Fault in Memory HP Fault LP Fault... -
Page 39: Condenser Cleaning
Proper water treatment can minimize tube fouling and pitting. If such conditions are anticipated, water treatment analysis is recommended. Refer to the Carrier System Design Manual, Part 5, for general water conditioning information. CAUTION Follow all safety codes. -
Page 40: Replacing The Wshp Open Controller's
1. Shut off unit main power supply. 2. Loosen bolts on mounting bracket so that fan belt can be removed. 3. Loosen and remove the 2 motor mounting bracket bolts on left side of bracket. 4. Slide motor/bracket assembly to extreme right and lift out through space between fan scroll and side frame. - Page 41 Ensure thermostat set for heating or cooling operation. Unit locked out Check for lockout codes. Reset power. Compressor overload Check compressor overload. Replace if necessary. Thermostat wiring Check Y and W wiring at heat pump. Jumper Y and R for compressor operation in Test mode. SOLUTION...
- Page 42 POSSIBLE CAUSE Thermostat wiring Check G wiring at heat pump. Jumper G and R for fan operation. Check Y and W wiring at heat pump. Jumper Y and R for compressor oper- ation in test mode. Fan motor relay Jumper G and R for fan operation. Check for line voltage across BR contacts.
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Page 43: Appendix A - Wshp Open Screen Configuration
APPENDIX A — WSHP OPEN SCREEN CONFIGURATION SCREEN NAME POINT NAME Operating Mode Condenser Leaving Temperature Condenser Entering Temperature Equipment Compressor Capacity Status Damper Position O Economizer Auxiliary Heat Space RH Dehumidification IAQ CO SPT Alarm Status Alarming SPT SPT Alarm Limit SPT Sensor Alarm Status IAQ Alarm Status... -
Page 44: Appendix A - Wshp Open Screen
APPENDIX A — WSHP OPEN SCREEN CONFIGURATION (cont) PASSWORD SCREEN NAME POINT NAME Operating Mode Fan Operating Mode Occupancy Status Occupancy Control Outside Air Temperature SPT Status SPT Sensor Status Condensate Overflow Cooling Set Point Heating Set Point Unit No Password Maintenance required Set Point Adjustment... -
Page 45: Configuration
APPENDIX A — WSHP OPEN SCREEN CONFIGURATION (cont) PASSWORD SCREEN NAME POINT NAME Occupied Heating Occupied Cooling Unoccupied Heating Unoccupied Cooling Effective Heating Set Point Effective Cooling Set Point Optimal Start Configuration User/Admin Occupied RH Password level Set Point Set Points Unoccupied RH Set Point DCV CTRL Start... - Page 46 APPENDIX A — WSHP SCREEN OPEN CONFIGURATION (cont) PASSWORD SCREEN NAME POINT NAME Fan Mode Fan On Delay Fan Off Delay Heating Enable Cooling Enable Minimum SAT in Cooling Configuration Maximum SAT in Heating Admin Password level access only Damper Ventilation Position Unit Configuration...
- Page 47 APPENDIX A — WSHP SCREEN OPEN CONFIGURATION (cont) SCREEN NAME POINT NAME # of Fan Speeds G Output Type Compressor Stages Reversing Valve Type Leaving Air Auxiliary Heat Type Entering Air Water Economizer Type 2-Position Water Valve Type Modulating Water Valve Type Ventilation Damper Type...
- Page 48 APPENDIX A — WSHP SCREEN OPEN CONFIGURATION (cont) SCREEN NAME POINT NAME SPT Occupied Alarm Hysteresis SPT Alarm Delay SPT Unoccupied Low Alarm Temperature SPT Unoccupied High Alarm Temperature SAT Low SAT Alarm Limit SAT High SAT Alarm Limit Condensate Overflow Alarm Delay Space Humidity Occupied High Alarm Limit...
- Page 50 Copyright 2009 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500049-01 Printed in U.S.A. Form 50PC-1SI Pg 50 7-09 Replaces: New...
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Page 51: 50Pch,Pcv Start-Up Checklist
CUSTOMER:___________________________ MODEL NO.:___________________________ I. PRE-START-UP DOES THE UNIT VOLTAGE CORRESPOND WITH THE SUPPLY VOLTAGE AVAILABLE? (Y/N) HAVE THE POWER AND CONTROL WIRING CONNECTIONS BEEN MADE AND TERMINALS TIGHT? (Y/N) HAVE WATER CONNECTIONS BEEN MADE AND IS FLUID AVAILABLE AT HEAT EXCHANGER? (Y/N) HAS PUMP BEEN TURNED ON AND ARE ISOLATION VALVES OPEN? (Y/N) HAS CONDENSATE CONNECTION BEEN MADE AND IS A TRAP INSTALLED? (Y/N) - Page 52 SUBCOOLING = DISCHARGE SATURATION TEMPERATURE – LIQUID LINE TEMPERATURE (DEG F) *Use 500 for water, 485 for antifreeze. Copyright 2009 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500049-01...
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