Carrier Aquazone 50WT024 Installation, Start-Up And Service Instructions Manual
Carrier Aquazone 50WT024 Installation, Start-Up And Service Instructions Manual

Carrier Aquazone 50WT024 Installation, Start-Up And Service Instructions Manual

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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
• INSPECTION
• STORAGE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 1 — Check Jobsite . . . . . . . . . . . . . . . . . . . . . . . 6
• HORIZONTAL UNITS
• VERTICAL UNITS
• INSTALLATION GUIDELINES (ALL UNITS)
Step 2 — Check Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 6
• INSPECT UNIT
Step 3 — Locate Unit . . . . . . . . . . . . . . . . . . . . . . . . 10
• PROTECTION
Step 4 — Mount the Unit . . . . . . . . . . . . . . . . . . . . . . 10
• DUCT FLANGES
• HORIZONTAL UNITS
• VERTICAL UNITS
Step 5 — Check Duct System . . . . . . . . . . . . . . . . . 11
• HORIZONTAL SUPPLY AIR CONFIGURATION 
CONVERSION
Step 6 — Install Condensate Drain . . . . . . . . . . . . . 13
• HORIZONTAL UNITS
• VERTICAL UNITS
Step 7 — Pipe Connections . . . . . . . . . . . . . . . . . . . 13
• WATER QUALITY GUIDELINES
• INSTALLING SUPPLY AND RETURN HOSE KIT
• UNITS WITH BOILERLESS HEAT CONTROL
• UNITS WITH HOT WATER GENERATOR OPTION
(HEAT RECOVERY PACKAGE/DESUPERHEATER)
• INITIAL START-UP
• UNITS WITH WATERSIDE ECONOMIZER
Step 8 — Wire Field Power Supply . . . . . . . . . . . . . 17
• HIGH VOLTAGE WIRING
• ELECTRIC HEATER
• LOW VOLTAGE, CONTROL WIRING
• ECM INTERFACE THERMOSTAT CONNECTIONS
• THERMOSTAT AND DDC SENSORS
• ADDITIONAL CONTROLS OPTIONS WIRING
Step 9 — Configure Unit Control Components . . . 21
• UNIT PROTECTION MODULE (UPM)
UPM Standard Safeties and Alarms . . . . . . . . . . . . 22
• HI AND LOW REFRIGERANT PRESSURE
PROTECTION
• WATER COIL FREEZE PROTECTION
• AIR COIL FREEZE PROTECTION
• HIGH CONDENSATE LEVEL SHUTDOWN
• INTELLIGENT ALARM RESET
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53500450-01
Printed in U.S.A.
Two-Stage High Efficiency Water Source Heat
Pumps with Puron Advance™ Refrigerant (R-454B)
Installation, Start-Up, and
Service Instructions
Form No. 50WT-1SI
• HARD LOCKOUT RESET
• OPTION CARD
Page
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
• CLEAN AIR COIL
• CONSTANT AIRFLOW (ECM) MOTOR
System Flushing and Filling . . . . . . . . . . . . . . . . . . .38
System Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
• FLOW VERIFICATION
• FLOW REGULATION
• ANTIFREEZE
• FREEZE PROTECTION SELECTION
• START-UP
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
• ENVIRONMENT
• POWER SUPPLY
• UNIT STARTING CONDITIONS
Start-Up Procedure
• COOLING MODE START-UP
• HEATING MODE START-UP
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Power Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Unit Protection Module (UPM) . . . . . . . . . . . . . . . . .45
Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Sequence of Operation of Units Without DDC
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
• STANDBY
• COOLING
• HOT GAS REHEAT WITH OPTION CARD (OPTIONAL)
• WATERSIDE ECONOMIZER WITH OPTION CARD
(OPTIONAL)
• AUXILIARY ELECTRIC HEAT (OPTIONAL)
• TWO-POSITION MOTORIZED ISOLATION VALVE
(2-WAY SOLENOID VALVE) (OPTIONAL)
• BOILERLESS HEAT WITH OPTION CARD
(OPTIONAL)
• DIFFERENTIAL PRESSURE SWITCH / FLOW SWITCH
(OPTIONAL)
• REFRIGERANT LEAK DETECTION SYSTEM
(OPTIONAL)
• COMPRESSOR RELAY (OPTIONAL)
• PUMP/VALVE RELAY (OPTIONAL)
Sequence of Operation for Units with TruVu DDC
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
• SCHEDULING
• INDOOR FAN
• COOLING OPERATION
• HEATING OPERATION
• WATERSIDE ECONOMIZER
Indoor Air Quality and Demand Control Ventilation . .50
• COMPRESSOR STATUS
• DEMAND LIMITING
Aquazone™
50WT 024-070
. . . . . . . . . . . . . . . . . . . . . .41
Pg 1
3-25
Replaces: NEW

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  • Page 1 Aquazone™ 50WT 024-070 Two-Stage High Efficiency Water Source Heat Pumps with Puron Advance™ Refrigerant (R-454B) Installation, Start-Up, and Service Instructions • HARD LOCKOUT RESET CONTENTS • OPTION CARD Page PRE-START-UP ......35 SAFETY CONSIDERATIONS .
  • Page 2: Table Of Contents

    Carrier-approved models exclu- when servicing or repairing this product. Refer to the individual sively. Carrier bears no responsibility for the installation of instructions packaged with the kits or accessories when installing. any alternative auxiliary devices installed in the field.
  • Page 3: Pre-Installation

    IMPORTANT: Read the entire instruction manual before WARNING starting installation. Electrical shock can cause personal injury and death. Shut off PRE-INSTALLATION all power to this equipment during installation. There may be more than one disconnect switch. Lockout/tagout all discon- INSPECTION nect locations to alert others not to restore power until work is Upon receipt of shipment, carefully check the shipment against completed.
  • Page 4 – Design Revision (16) A = Initial Release Model Series (1-2) 50 = Packaged WSHP Unit Miscellaneous Options (15) – = None Tier (3 A = Waterside Economizer (WSE) B = A2L Leak Detection (LD) WT = 2-Stage Size 24-70 C = WSE + LD Hydronic Options (14) Cabinet Configuration (5)
  • Page 5 Table 1 — Physical Data — 50WT (024-070) Units UNIT SIZE Compressor Type (Qty 1) Scroll Scroll Scroll Scroll Scroll Max Water Working Pressure (psig) ECM FAN MOTOR and BLOWER Fan Motor Type Constant Airflow Constant Airflow Constant Airflow Constant Airflow Constant Airflow VT: 0.33 Fan Motor (hp)
  • Page 6: Installation

    Carrier’s recommended service clearances and for installation. See Table 1 for unit physical data. installation instructions. Please refer to the Carrier Commercial WSHP Warranty Statement (document number 04-570008-01) HORIZONTAL UNITS for details on warranty exclusions regarding equipment, access, Horizontal units are designed for indoor installation only.
  • Page 7 Refrigeration Access Access Panels Water Control Electrical Connections Access Water In Condensate Drain Return Air Opening Right Hand Return Right Hand Return Front Left Side Right Hand Return Straight Through End Blow Water Connections (left discharge) (back discharge) Access Refrigeration Panels Access Water...
  • Page 8 Access Panels Access Panels Refrigeration Refrigeration Access Access Water Out Water Out Control Control Electrical Access Access Connections Condensate Drain Condensate Drain Water In Water In Left Hand Return Right Hand Return Return Air (Filter) View Front Right Side Front Left Side Water Connections Water Connections VERTICAL UNIT DIMENSIONS (in.)
  • Page 9: Vertical Unit

    Vertical Unit Left Return, Top Discharge Left Return, Top Discharge Blower Front Access 18 in. Minimum 24 in. Optimum Compressor and Electrical Front Access 24 in. Minimum 36 in. Optimum Side View Front View Horizontal Unit Left Return, Right Discharge Left Return, Back Discharge Blower Access 18 in.
  • Page 10: Step 3 - Locate Unit

    Step 3 — Locate Unit Locate the unit in an indoor area that allows easy removal of the filter and access panels, and has enough room for service personnel to perform maintenance or repair. Provide sufficient room to make fluid, electrical, and duct connection(s). If the unit is located in a confined space such as a closet, provisions must be made for return air to freely enter the space.
  • Page 11: Vertical Units

    Hanging Bracket Installation should be set in a full size secondary drain pan on top of a vibra- tion absorbing mesh. Remove and discard factory-provided screws from location where hanging brackets will be installed. (see Fig. 7). The secondary drain pan prevents possible condensate overflow or water leakage damage to the ceiling.
  • Page 12: Horizontal Supply Air Configuration  Conversion

    A flexible connector is recommended for supply and return air 11. Reattach the motor power and control harness if disconnected duct connections on metal duct systems. All metal ducting earlier. should be insulated with a minimum of 1 in. duct insulation to 12.
  • Page 13: Step 6 - Install Condensate Drain

    Copper is adequate for ground water that is not high in mineral content. VERTICAL UNITS Carrier recommends proper testing to assure the well water Vertical configuration units are internally trapped from the fac- quality is suitable for use with water source equipment. In con- tory.
  • Page 14 Table 2 — Water Quality Guidelines CLOSED CONDITION HX MATERIAL OPEN LOOP AND RECIRCULATING WELL RECIRCULATING Scaling Potential — Primary Measurement Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below. pH/Calcium pH <...
  • Page 15: Installing Supply And Return Hose Kit

    Optional pressure-rated hose assemblies designed specifically for 3/8 in. wall closed cell insulation. Install isolation valves on use with Carrier units are available. Similar hoses can be obtained supply and return to the hot water generator. See Fig. 17. from alternate suppliers. Supply and return hoses are fitted with NOTE: Diagram is for illustration purposes only.
  • Page 16: Initial Start-Up

    Water Tank Refill Ensure the temperature difference between the water entering and leaving the heat recovery is 5 to 15°F. Open the cold water supply to the tank. Allow the unit to operate for 20 to 30 minutes to ensure it is Open a hot water faucet to vent air from the system until functioning properly.
  • Page 17: Step 8 - Wire Field Power Supply

    disconnect switches (except units with dual power supply), power Step 8 — Wire Field Power Supply is connected to the line (L) side of the compressor contactor and See Fig. 26-34 for typical wiring diagrams. See Tables 4-9 for the ground lug in the unit electrical box. additional electrical data.
  • Page 18 Table 4 — 50WT without Electric Heat — Constant Airflow ECM Blower Motor Electrical Data COMPRESSOR BLOWER MOTOR 50WT UNIT SIZE VOLTAGE/HZ/ VOLTAGE TOTAL PHASE MIN/MAX UNIT FLA Quantity 208-230/1/60 197/253 10.3 62.0 0.33 14.7 17.2 25.0 265/1/60 238/292 52.0 0.33 12.5 14.5...
  • Page 19 Table 5 — First Data Plate for Units with Electric Heater (EH) Option — Compressor Power Connection COMPRESSOR 50WT UNIT VOLTAGE/HZ/ VOLTAGE SIZE PHASE MIN/MAX Quantity 208-230/1/60 197/253 10.3 62.0 10.3 12.8 20.0 208-230/1/60 197/253 14.6 90.0 14.6 18.2 30.0 208-230/1/60 197/253 18.3...
  • Page 20 LOW VOLTAGE, CONTROL WIRING • O Reversing Valve (energized in cooling) • W1 Auxiliary Electric Heat (runs with compressor) • EM/W2 Emergency Heat (electric heat only) WARNING • NC Transformer 24 vac Common (extra connection) To avoid possible injury or death due to electrical shock, open •...
  • Page 21: Standard Construction

    TruVu DDC Controller OPTIONAL COMPONENTS TruVu is a factory installed DDC control that requires the use of Component Carrier ZS or non-communicating sensors or the Carrier TruVu Compressor Monitor Relay Equipment touch interface for space temperature sensing. TruVu Blower Monitor Relay DDC is not compatible with thermostats.
  • Page 22: Air Coil Freeze Protection

    LEGEND 1 — Compressor Contact Output 2 — High-Pressure Switch Connection 3 — Call for Compressor (Y1) 4 — Low Pressure Switch Connection 5 — Water Coil Freeze Connection (Freeze 1) 6 — UPM Status LED Indicator (Fault Status) 7 — Air Coil Freeze Connection (Freeze 2) 8 —...
  • Page 23 IMPORTANT: If 24 vac output is needed R must be wired to ALR-COM terminal; 24 vac will be available to the ALR-OUT terminal when the unit is in the alarm condition. Test Mode A test DIP switch is provided to reduce all time delays settings to 10 seconds during troubleshooting or verification of unit operation.
  • Page 24: Option Card

    Point Potentiometer). When the water loop (EWT) drops below the specified setpoint and there is a call for heating the compressor will be disabled and the option card sends a 24-v output to enable the electric heater. On/Off Hot Gas Reheat Control Hot gas reheat control is an active means of dehumidification con- trol.
  • Page 25 Cool Set Point Potentiometer Heat Set Point Potentiometer Operating Mode Dip Switch Entering Water Temperature H Signal Input O Signal Input Y Call Input LED Input Status Economizer Output “E_OUT” Hot Gas Reheat Output “H_OUT” Boilerless Control “W_OUT” Reversing Valve Output “O_OUT” Option Card Standoff LED Output Status FAN Output “G_OUT”...
  • Page 35: Pre-Start-Up

    18. Verify the unit is not in TEST mode. PRE-START-UP 19. Verify all control components have been properly configured System Checkout and that all control components have been wired. After completing the installation, and before energizing the 20. For units with TruVu DDC controller, verify a space tempera- unit, the following system checks should be made prior to ini- ture input is provided via ZS sensor, or non-communication tial start-up:...
  • Page 36 Table 13 — 50WT Vertical Units — Constant Airflow Motor Performance a,b,c DEFAULT AIRFLOW (cfm) AT EXTERNAL STATIC PRESSURE (in. wg) FACTORY UNIT SIZE FAN SPEED MOTOR 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 SETTING —...
  • Page 37 Table 14 — 50WT Horizontal Units — Constant Airflow Motor Performance a,b,c DEFAULT AIRFLOW (cfm) AT EXTERNAL STATIC PRESSURE (in. wg) FACTORY UNIT SIZE FAN SPEED MOTOR 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 SETTING —...
  • Page 38: System Flow

    This fluctuation is normal and should be considered when System Flushing and Filling charging the system initially. Run the unit in either heating or Once the piping is complete, units require final purging and loop cooling for several minutes to condition the loop to a charging.
  • Page 39 10.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0 26.0 Flow Rate (gpm) Fig. 35 — Water Pressure Drop Curve for Units without 2-Way Valve 10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0 26.0 Flow Rate (gpm) Fig. 36 — Water Pressure Drop Curve for Units with 2-Way Valve...
  • Page 40: Freeze Protection Selection

    ANTIFREEZE Operating Limits In areas where leaving water temperatures drop below 40°F or ENVIRONMENT where piping will be routed through areas subject to freezing, anti- This equipment is designed for indoor installation only. Extreme freeze is needed. variations in temperature, humidity and corrosive water or air will Alcohols and glycols are commonly used as antifreeze agents.
  • Page 41: Start-Up Procedure

    COOLING MODE START-UP Start-Up Procedure Using the thermostat or DDC control, operate the unit in the cooling cycle. Refer to Table 17 for operating limits. Allow WARNING the unit to run for a minimum of five minutes and record the operating data.
  • Page 42 Table 18 — 50WT024 Typical Unit Operating Pressures and Temperatures COOLING HEATING ENTER FLUID WATER FLOW Suction Discharge Water Air Temp Suction Discharge Water Air Temp TEMP (gpm) Pressure Pressure Temp Rise Drop Pressure Pressure Temp Drop Rise (°F) (psig) (psig) (°F) (°F)
  • Page 43 Table 20 — 50WT048 Typical Unit Operating Pressures and Temperatures COOLING HEATING ENTER FLUID WATER FLOW Suction Discharge Water Air Temp Suction Discharge Water Air Temp TEMP (gpm) Pressure Pressure Temp Rise Drop Pressure Pressure Temp Drop Rise (°F) (psig) (psig) (°F) (°F)
  • Page 44: Water Flow

    Table 22 — 50WT070 Typical Unit Operating Pressures and Temperatures COOLING HEATING ENTER FLUID WATER FLOW Suction Discharge Water Air Temp Suction Discharge Water Air Temp TEMP (gpm) Pressure Pressure Temp Rise Drop Pressure Pressure Temp Drop Rise (°F) (psig) (psig) (°F) (°F)
  • Page 45: Operation

    Unit Protection Module (UPM) (2-WAY SOLENOID VALVE) (OPTIONAL) All Carrier WSHP units feature an advanced UPM which imple- The two way water flow control valve is enabled anytime there is ments all the critical equipment safeties and allows for continuous a call for cooling (Y), heating (Y), or dehumidification (H) and safe and reliable operation.
  • Page 46 Fig. 37 — UPM Sequence of Operations...
  • Page 47 and intelligent alarming, which will differ from the units with Sequence of Operation for Units with TruVu UPM board only. Below is an overview of the different fea- DDC Controller tures for the TruVu™ controls. See Fig. 38 for TruVu™ Con- Units with TruVu™...
  • Page 48 SCHEDULING • Continuous (default) - intermittent operation during unoc- cupied periods and continuous during occupied periods Time periods can be configured to schedule the transitions from • Always on - operates the fan continuously during both oc- occupied to unoccupied operation. The time periods control the cupied and unoccupied periods space temperature to occupied heating and cooling setpoints.
  • Page 49: Cooling Operation

    COOLING OPERATION NOTE: During cooling mode, the unit cools and dehumidifies, and disables the reheat coil. However, once the call for cooling has Space Temperature Control been satisfied and there is still a call for dehumidification, the unit The TruVu operates 1 or 2 stages of compression to maintain the continues to operate in the reheat mode.
  • Page 50: Waterside Economizer

    failure occurs. Unless a compressor fault condition exists, the 2-position Waterside Economizer Control valve only opens to supplement the heat provided by the compres- 2-Position Waterside Economizer Control has the capability to sor, if the space temperature falls more than 1°F below the desired control a NO or NC, 2-position water valve to control source wa- heating setpoint.
  • Page 51: Compressor Status

    COMPRESSOR STATUS 5-minute break is initiated (soft lockout) and the compressor is disabled. The unit will automatically restart after this time period. The TruVu provides a status input to monitor the compressor oper- If the fault occurs 2 times (configurable on UPM) within 60 min- ation.
  • Page 52 Supply Air Temperature Alarm Airside Linkage Failure Alarm (if Airside Linkage was active) The control has 2 configurable alarm limits for supply air tempera- ture. The control verifies that the supply air temperature is within The control generates an Airside Linkage failure alarm if Linkage operating range (between high and low limits) when the compres- fails after once being active.
  • Page 53: Service

    temperature rises above or falls below the appropriate limits, and flammable hazards or ignition risks. “No Smoking” signs shall be lasts for more than 15 seconds, an alarm is generated and the com- displayed. pressor shuts down. VENTILATED AREA Return Air Temperature Alarm (if RAT sensor is field Ensure that the area is in the open or that it is adequately ventilated provided) before breaking into the system or conducting any hot work.
  • Page 54: Condensate Drain Pans

    Refer to the Carrier System Design Manual, Part 5, DETECTION OF FLAMMABLE REFRIGERANTS for general water conditioning information.
  • Page 55: Forced Circulation Method

    When condenser is full, allow solution to remain overnight, then • continuously flush or purge with inert gas when using drain condenser and flush with clean water. Follow acid flame to open circuit; and manufacturer’s instructions (see Fig. 39). • open the circuit.
  • Page 56: Blower Assembly Service And Removal

    The recovery equipment shall be in good working order with a set Blower Assembly Service and Removal of instructions concerning the equipment that is at hand and shall be suitable for the recovery of the flammable refrigerant. If in CAUTION doubt, the manufacturer should be consulted.
  • Page 57 Weld Pins are Located on the Side Opposite to Motor Screws are Located Above Motor Fig. 42 — Vertical Units Blower Assembly...
  • Page 58: Horizontal Configuration Units

    Remove the three screws located on the motor side of the Horizontal Configuration Units blower assembly. See Fig. 43. For horizontal configurations, if removal of the blower assembly becomes necessary, follow these steps: Twist and pull blower back from welded pins located on opposite side to the motor, near the evaporator.
  • Page 59: Troubleshooting

    UNIT PROTECTION MODULE (UPM) Causes of TXV Failure All Carrier WSHPS are equipped with a 24-v low voltage control The most common causes of TXV failure are: circuit. Units are selectable to be provided with no controls for...
  • Page 60 Diagnostics Repair Several tests may be required to determine if a TXV has failed. The following tools may be required for testing: WARNING Refrigerant gauge manifold compatible with the refrigerant in the system. Most TXVs are designed for a fixed superheat setting and are Digital thermometer, preferably insulated, with wire leads therefore considered non-adjustable.
  • Page 61 See Table 23 for compressor characteristics and Table 24 for addi- tional troubleshooting information. Table 23 — Compressor Characteristics COLD WINDING RESISTANCE VALUES (+/- 7%) 50WT MODEL VOLTAGE CODE Single Phase Three Phase CAPACITOR (μF/V) T1-T2 T2-T3 T3-T1 208-230/1/60 1.07 1.65 —...
  • Page 62 Table 24 — Troubleshooting FAULT COOLING HEATING CHECK POSSIBLE CAUSE SOLUTION High Pressure Fault - No or Check water valves and/or pumps for proper operation. Check Low Water Flow for water coil blockage. High Pressure Fault - High Check water temperature - is it in range? Water Temperature High Pressure Fault - Fouled or Check for proper flow rate and water temperature, but low...
  • Page 63 Table 24 — Troubleshooting (cont) FAULT COOLING HEATING CHECK POSSIBLE CAUSE SOLUTION Check for 24 vac between "G" and "C". Check all wiring No Fan Operation Signal connections. Make sure that the thermostat connection plug is securely connected. Check all wiring connections at motor and control box. Check Loose Wiring that power and control harnesses are securely connected.
  • Page 66 © 2025 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500450-01 Printed in U.S.A. Form No. 50WT-1SI Pg 66 3-25 Replaces: NEW...
  • Page 67: Start-Up Checklist

    50WT START-UP CHECKLIST (REMOVE AND USE FOR JOB FILE.) NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sections of this Installation, Start-Up, and Service Instructions document.
  • Page 68: Heating Cycle Analysis

    SUBCOOLING = DISCHARGE SATURATION TEMPERATURE – LIQUID LINE TEMPERATURE (DEG F) *Use 500 for water, 485 for antifreeze. © 2025 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500450-01 Printed in U.S.A.

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