AQUAZONE™
50PSW036-360
Water-to-Water Water Source Heat Pump
with PURON® Refrigerant (R-410A)
50 Hz
Installation, Start-Up, and
Service Instructions
Page
CONTENTS
Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Retry Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Aquazone Deluxe D Control LED Indicators . . . . . 17
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18,19
Water Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Condenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Checking System Charge . . . . . . . . . . . . . . . . . . . . . . . 19
Refrigerant Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . .1,2
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Step 1 — Check Jobsite . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 2 — Check Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
• STORAGE
• PROTECTION
• INSPECT UNIT
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 19-21
50PSW START-UP CHECKLIST . . . . . . . . . . . CL-1,CL-2
Step 3 — Locate Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Step 4 — Mount Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Step 5 — Connect Piping. . . . . . . . . . . . . . . . . . . . . . . . . 5
• WATER SUPPLY AND QUALITY
• WATER LOOP APPLICATIONS
IMPORTANT: Read the entire instruction manual before
starting installation.
• GROUND-WATER APPLICATIONS
• GROUND-LOOP APPLICATIONS
• UNIT LOAD PIPING
Step 6 — Wire Electrical Connections. . . . . . . . . . . . 7
• POWER CONNECTION
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.
• SUPPLY VOLTAGE
• EXTERNAL LOOP POWER CONNECTION
• 220-V OPERATION
• 380-V OPERATION
Step 7 — Wire Low Voltage Connections . . . . . . . . 12
• THERMOSTAT CONNECTIONS
• WATER FREEZE PROTECTION
• ACCESSORY CONNECTIONS
Untrained personnel can perform basic maintenance func-
tion of cleaning coils. All other operations should be performed
by trained service personnel. When working on air-condition-
ing equipment, observe precautions 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.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for brazing operations. Have fire
extinguisher available. Read these instructions thoroughly and
follow all warnings or cautions attached to the unit. Consult
local building codes and the National Electrical Code (NEC,
U.S.A.) for special installation requirements.
Understand the signal words — DANGER, WARNING,
and CAUTION. DANGER identifies the most serious hazards
which will result in severe personal injury or death. WARN-
ING signifies hazards that could result in personal injury or
death. CAUTION is used to identify unsafe practices, which
would result in minor personal injury or product and property
damage.
• WATER SOLENOID VALVES
PRE-START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
System Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FIELD SELECTABLE INPUTS . . . . . . . . . . . . . . . .13,14
Complete C Control Jumper Settings. . . . . . . . . . . 13
Complete C Control DIP Switches. . . . . . . . . . . . . . 13
Deluxe D Control Jumper Settings . . . . . . . . . . . . . 13
Deluxe D Control DIP Switches . . . . . . . . . . . . . . . . 13
Deluxe D Control Accessory Relay
Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Unit Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Scroll Compressor Rotation. . . . . . . . . . . . . . . . . . . . . 14
Flow Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cleaning and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cooling Tower/Boiler Systems . . . . . . . . . . . . . . . . . . 16
Ground Coupled, Closed Loop and Plateframe
Heat Exchanger Well Systems . . . . . . . . . . . . . . . . 16
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Units with Aquazone Complete C Control . . . . . . . 16
Units with Aquazone Deluxe D Control . . . . . . . . . . 16
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16,17
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53500073-01 Printed in U.S.A. Form 50PSW-C1SI Pg 1 10-10 Replaces: New
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B
4.6 cm
A
5
6
2.5 cm
4
2.5 cm
C
3
J
H
G
M
F
E
2
1
L
K
D
Required
Service Access
Optional
Service Access
18.5 cm
SIZES 036,060
4.3 cm
A
B
5
6
4
6.9 cm
3
1
2
3.3 cm
C
Required
Service Access
Optional
Service Access
SIZE 120
WATER CONNECTIONS (mm)
OVERALL CABINET
(mm)
ELECTRIC ACCESS PLUGS
(mm)
1
2
3
4
5
6
50PSW
UNIT
Source (Outdoor)
Load (Indoor)
HWG
SIZE
K
L
M
A
B
C
D
E
F
G
H
J
Low
External Power
Depth Width Height Water In Water Out Water In Water Out Return In Water Out
Voltage Pump
531
759
Supply
785
874
036,060
120
778
778
645
1344
838
940
69
640
239
640
493
765
622
765
709
886
772
886
582
810
LEGEND
HWG — Hot Water Generator
HACR —
Heating, Air Conditioning, and Refrigeration
NOTES:
1. Dimensions shown in centimeters unless noted otherwise.
2. HACR circuit breaker in U.S.A. only.
Fig. 1 — 50PSW036-120 Unit
3
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Fault/Run Lights
31.3
38.1
11.4
10.8
163.8
Power Supply Wiring
34.9 x 50.8 mm Double Knockout
Top
View
53.3
Control Wiring
28.6 x 34.9 mm Double Knockout
10.8
11.4
2”FPTWater Connections
38.1
13.8
Left
Side
View
Front
View
114.6
66.9
Source
Load
Top
Header
Access
Panel
LEGEND
FPT — Female Pipe Thread
Electrical
Access
Panel
NOTES:
1. Dimensions shown in centimeters unless noted other-
wise.
2. For multiple units placed side by side, allow 1.2 m mini-
mum front access for service and maintenance.
Refrig.
Circuit
Access
Panel
Compressor
Access
Panel
Side
Front
Minimum 91cm
Required Service
Access
Optional (Single Unit)
91cm Additional
Service Access
Fig. 2 — 50PSW180,360 Unit
PROTECTION — Once the units are properly positioned on
the jobsite, they must be covered with either a shipping carton,
vinyl film, or an equivalent protective covering. Open ends of
pipes stored on the jobsite must be capped. This precaution is
especially important in areas where painting, plastering, or
spraying of fireproof material, etc., is not yet complete. Foreign
material that is allowed to accumulate within the units can pre-
vent proper start-up and necessitate costly clean-up operations.
INSPECT UNIT — To prepare the unit for installation, com-
plete the procedures listed below:
1. Compare the electrical data on the unit nameplate with
ordering and shipping information to verify that the
correct unit has been shipped.
2. Verify that the unit is the correct model for the entering
water temperature of the job.
3. Wait to remove the packaging until the unit is ready for
installation.
Before installing any of the system components, be sure to
examine each pipe, fitting, and valve, and remove any dirt or
foreign material found in or on these components.
4. Verify that the refrigerant tubing is free of kinks or dents,
and that it does not touch other unit components.
CAUTION
5. Inspect all electrical connections. Be sure connections are
clean and tight at the terminals.
DO NOT store or install units in corrosive environments or
in locations subject to temperature or humidity extremes
(e.g., attics, garages, rooftops, etc.). Corrosive conditions
and high temperature or humidity can significantly reduce
performance, reliability, and service life. Always move
units in an upright position. Tilting units on their sides may
cause equipment damage.
6. Loosen bolts and remove shipping clamps on compres-
sors equipped with external spring vibration isolators.
Compressors are internally spring-mounted.
7. Locate and verify any accessory kit located in compressor
section.
4
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8. Remove any access panel screws that may be difficult to
remove once unit is installed.
In all applications, the quality of the water circulated
through the heat exchanger must fall within the ranges listed in
the Water Quality Guidelines table. Consult a local water treat-
ment firm, independent testing facility, or local water authority
for specific recommendations to maintain water quality within
the published limits.
Step 3 — Locate Unit — The following guidelines
should be considered when choosing a location for the WSHP:
• Units are for indoor use only.
• Provide sufficient space for water and electrical
connections.
• Locate unit in an area that allows for easy access and
removal of access panels.
• Allow enough space for service personnel to perform
maintenance.
WATER LOOP APPLICATIONS — Water loop applica-
tions usually include a number of units plumbed to a common
piping system. Maintenance to any of these units can introduce
air into the piping system. Therefore, air elimination
equipment comprises a major portion of the mechanical room
plumbing.
The flow rate is usually set between 2.9 L/m and 3.9 L/m
per kW of cooling capacity. For proper maintenance and ser-
vicing, pressure-temperature (P/T) ports are necessary for tem-
perature and flow verification.
Step 4 — Mount Unit — Mount unit as shown in Fig. 3.
Rod attachments must be able to support the weight of the unit.
See Table 1 for unit operating weight.
In addition to complying with any applicable codes, consid-
er the following for system piping:
Load Connections (Hot
Water/Chilled Water)
Automatic Flow
Regulator
Ball Valve
with Pressure
Temperature Port
• Piping systems utilizing water temperatures below
10.0 C require 13 mm closed cell insulation on all piping
surfaces to eliminate condensation.
Source Connections
(Boiler/Tower/Ground)
• All plastic to metal threaded fittings should be avoided
due to the potential to leak. Use a flange fitted substitute.
• Teflon* tape thread sealant is recommended to minimize
internal fouling of the heat exchanger.
• Use backup wrench. Do not overtighten connections.
• Route piping to avoid service access areas to unit.
• The piping system should be flushed prior to operation to
remove dirt and foreign materials from the system.
Ball Valve
with Pressure
Temperature Port
Y Strainer with
Blow Down Valve
Power
Disconnect
Control
Wiring
a50-8138
Cooling tower/boiler systems typially use a common loop
maintained between 16 and 32 C. The use of a closed circuit
evaporative cooling tower with a secondary heat exchanger be-
tween the tower and the water loop is recommended. If an open
type cooling tower is used continuously, chemical treatment
and filtering will be necessary.
Fig. 3 — Typical Water Loop System —
GROUND-WATER APPLICATIONS — In addition to
complying with any applicable codes, consider the following
for system piping:
• Install shut-off valves for servicing.
• Install pressure-temperature plugs to measure flow and
temperature.
• Boiler drains and other valves should be connected using
a “T” connector to allow acid flushing for the heat
exchanger.
• Do not overtighten connections.
• Route piping to avoid service access areas to unit.
• Use PVC SCH80 or copper piping material.
NOTE: PVC SCH40 should not be used due to system high
pressure and temperature extremes.
GROUND-LOOP APPLICATIONS — Temperatures be-
tween –3.9 and 43.3 C and a cooling capacity of 2.9 L/m and
3.9 L/m per kW are recommended. In addition to complying
with any applicable codes, consider the following for system
piping:
• Piping materials should be limited to only polyethylene
fusion in the buried sections of the loop.
• Galvanized or steel fittings should not be used at any
time due to corrosion.
Boiler, Tower, or Ground (Sizes 180,360 Shown)
Step 5 — Connect Piping — Depending on the appli-
cation, there are 3 types of WSHP piping systems to choose
from: water loop, ground-water and ground loop. Refer to the
Carrier System Design Manual for additional information.
All WSHP units utilize low temperature soldered female
pipe thread fittings for water connections to prevent annealing
and out-of-round leak problems which are typically associated
with high temperature brazed connections. When making pip-
ing connections, consider the following:
• A backup wrench must be used when making screw con-
nections to unit to prevent internal damage to piping.
• Insulation may be required on piping to avoid condensa-
tion in the case where fluid in loop piping operates at
temperatures below dew point of adjacent air.
• Piping systems that contain steel pipes or fittings may
be subject to galvanic corrosion. Dielectric fittings may
be used to isolate the steel parts of the system to avoid
galvanic corrosion.
• Units may be manifolded together via top water connects
to get increased temperatures, when piped in series, or
greater capacity, when piped in parallel.
• All plastic to metal threaded fittings should be avoided
due to the potential to leak. Use a flange fitted substitute.
• Do not overtighten connections.
• Route piping to avoid service access areas to unit.
• Pressure-temperature (P/T) plugs should be used to mea-
sure flow of pressure drop.
WATER SUPPLY AND QUALITY — Check water supply.
Water supply should be plentiful and of good quality. See
Table 2 for water quality guidelines.
IMPORTANT: Failure to comply with the above required
water quality and quantity limitations and the closed-
system application design requirements may cause damage
to the tube-in-tube heat exchanger that is not the responsi-
bility of the manufacturer.
*Teflon is a trademark of E. I. du Pont de Nemours and Company.
5
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Table 2 — Water Quality Guidelines
HX
MATERIAL*
CLOSED
RECIRCULATING†
CONDITION
OPEN LOOP AND RECIRCULATING WELL**
Scaling Potential — Primary Measurement
Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below.
pH/Calcium
All
N/A
pH < 7.5 and Ca Hardness, <100 ppm
Hardness Method
Index Limits for Probable Scaling Situations (Operation outside these limits is not recommended.)
Scaling indexes should be calculated at 150 F for direct use and HWG applications, and at 90 F for indirect HX use. A monitoring plan should be
implemented.
Ryznar Stability Index
6.0 - 7.5
If >7.5 minimize steel pipe use.
All
N/A
Langelier Saturation Index
–0.5 to +0.5
All
N/A
If <–0.5 minimize steel pipe use.
Based upon 150 F HWG and direct well, 85 F indirect well HX.
Iron Fouling
Iron Fe2+ (Ferrous)
<0.2 ppm (Ferrous)
If Fe2+ (ferrous) >0.2 ppm with pH 6 - 8, O2<5 ppm check for
iron bacteria.
(Bacterial Iron Potential)
All
All
N/A
N/A
Iron Fouling
<0.5 ppm of Oxygen
Above this level deposition will occur.
Corrosion Prevention††
pH
6 - 8.5
6 - 8.5
All
All
Monitor/treat as needed.
Minimize steel pipe below 7 and no open tanks with pH <8.
Hydrogen Sulfide (H2S)
<0.5 ppm
At H2S>0.2 ppm, avoid use of copper and cupronickel piping of HXs.
Rotten egg smell appears at 0.5 ppm level.
N/A
N/A
Copper alloy (bronze or brass) cast components are okay to <0.5 ppm.
Ammonia Ion as Hydrox-
ide, Chloride, Nitrate and
Sulfate Compounds
<0.5 ppm
All
Maximum Chloride Levels
Maximum allowable at maximum water temperature.
50 F (10 C)
75 F (24 C)
100 F (38 C)
Copper
Cupronickel
304 SS
N/A
N/A
N/A
N/A
N/A
<20 ppm
<150 ppm
<400 ppm
<1000 ppm
>1000 ppm
NR
NR
<250 ppm
<550 ppm
>550 ppm
NR
NR
<150 ppm
<375 ppm
>375 ppm
316 SS
Titanium
Erosion and Clogging
Particulate Size and
Erosion
<10 ppm of particles and
a maximum velocity of <10 ppm (<1 ppm “sandfree” for reinjection) of particles and a maxi-
All
6 fps.
Filtered for maximum
800 micron size.
mum velocity of 6 fps. Filtered for maximum 800 micron size. Any par-
ticulate that is not removed can potentially clog components.
LEGEND
HWG— Hot Water Generator
HX — Heat Exchanger
N/A — Design Limits Not Applicable Consid-
ering Recirculating Potable Water
NR — Application Not Recommended
SS — Stainless Steel
††If the concentration of these corrosives exceeds the maximum
allowable level, then the potential for serious corrosion problems
exists.
Sulfides in the water quickly oxidize when exposed to air, requir-
ing that no agitation occur as the sample is taken. Unless tested
immediately at the site, the sample will require stabilization with a
few drops of one Molar zinc acetate solution, allowing accurate
sulfide determination up to 24 hours after sampling. A low pH and
high alkalinity cause system problems, even when both values are
within ranges shown. The term pH refers to the acidity, basicity, or
neutrality of the water supply. Below 7.0, the water is considered
to be acidic. Above 7.0, water is considered to be basic. Neutral
water contains a pH of 7.0.
*Heat exchanger materials considered are copper, cupronickel,
304 SS (stainless steel), 316 SS, titanium.
†Closed recirculating system is identified by a closed pressurized
piping system.
**Recirculating open wells should observe the open recirculating
design considerations.
To convert ppm to grains per gallon, divide by 17. Hardness in
mg/l is equivalent to ppm.
UNIT LOAD PIPING — For applications with wide temper-
ature variation such as heating/cooling coils:
• Use piping materials that are rated for the maximum tem-
perature and pressure combination. This excludes PVC
for most heating applications.
Swimming Pool Hot Tub Applications — Load heat ex-
changer should be isolated with secondary heat exchanger
constructed of anti-corrosion material in all chlorine/bromine
fluid applications.
Potable Water Applications
• Ensure load water flow in high temperature heating
applications is at least 3.2 L/m per kW to improve perfor-
mance and reduce nuisance high pressure faults.
• DO NOT employ plastic to metal threaded joints.
• Utilize a pressure tank and air separator vent system to
equalize pressure and remove air.
• Load coax material should always be vented double
walled for use in potable water systems.
• Ensure load water flow in high temperature heating
applications is at least 3.2 L/m per kW to improve perfor-
mance and reduce nuisance high pressure faults.
• Employ an 800-micron particulate strainer in both load
and source plumbing to protect the plate heat exchanger.
6
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Voltages between phases must be balanced within 2%.
Use the following formula to determine the percentage voltage
imbalance:
Step 6 — Wire Electrical Connections
WARNING
% Voltage Imbalance
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. Install lockout tag.
max voltage deviation from average voltage
= 100 x
average voltage
Example: Supply voltage is 380-3-50.
AB = 372 volts
BC = 376 volts
AC = 384 volts
CAUTION
Use only copper conductors for field-installed electrical
wiring. Unit terminals are not designed to accept other
types of conductors. Failure to heed this warning could
result in equipment damage.
372 + 376 + 384
Average Voltage =
3
1132
=
3
All field-installed wiring, including the electrical ground,
MUST comply with the National Electrical Code (NEC) as
well as applicable local codes. In addition, all field wiring must
conform to the Class II temperature limitations described in the
NEC.
Operating voltage must be the same voltage and phase as
shown in Table 3.
Refer to unit wiring diagrams Fig. 4-8 for a schematic of the
field connections which must be made by the installing (or
electrical) contractor.
Consult the unit wiring diagram located on the inside of the
compressor access panel to ensure proper electrical hookup.
The installing (or electrical) contractor must make the field
connections when using field-supplied disconnect.
Make all final electrical connections with a length of flexi-
ble conduit to minimize vibration and sound transmission to
the building.
POWER CONNECTION — Line voltage connection is
made by connecting incoming line voltage wires to L1, L2, and
L3 on the power distribution block.
= 377
Determine maximum deviation from average voltage:
(AB) 372 – 377 = 5 v
(BC) 376 – 377 = 1 v
(AC) 384 – 377 = 7 v
Maximum deviation is 7 v.
Determine percent voltage imbalance.
7
% Voltage Imbalance = 100 x
377
= 1.86%
This amount of phase imbalance is satisfactory as it is
below the maximum allowable 2%.
Operation on improper line voltage or excessive phase
imbalance constitutes abuse and may cause damage to electri-
cal components.
NOTE: If more than 2% voltage imbalance is present, contact
local electric utility.
SUPPLY VOLTAGE — Operating voltage to unit must be
within voltage range indicated on unit nameplate.
Table 3 — 50PSW Electrical Data
COMPRESSOR
50PSW UNIT
SIZE
VOLTAGE
(V-Ph-Hz)
VOLTAGE RANGE
MIN/MAX
TOTAL
FLA
MCA
MOCP*
RLA
13.5
5.4
LRA
67
38
QTY
1
1
1
1
2
2
1
1
220/240-1-50
380/420-3-50
220/240-1-50
380/420-3-50
220/240-1-50
380/420-3-50
220/240-1-50
380/420-3-50
220/240-1-50
380/420-3-50
198/264
342/462
198/264
342/462
198/264
342/462
198/264
342/462
198/264
342/462
13.5
5.4
24.5
9.6
49.0
19.2
44.9
18.6
89.8
37.2
16.9
6.8
30
15
50
20
80
30
100
40
125
60
036
060
120
180
360
24.5
9.6
24.5
9.6
44.9
18.6
44.9
18.6
153
74
153
74
273
118
273
118
30.6
12.0
55.1
21.6
56.1
23.3
101.0
46.6
2
2
LEGEND
FLA
— Full Load Amps
HACR — Heating, Air Conditioning, and Refrigeration
LRA — Locked Rotor Amps
MCA — Minimum Circuit Amps
MOCP — Minimum Overcurrent Protection
RLA — Rated Load Amps
*Time-delay fuse or HACR circuit breaker.
7
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a50-8621
8
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ACCESSORY CONNECTIONS — The terminal labeled A
on the control is provided to control accessory devices such as
water valves, electronic air cleaners, humidifiers, etc. This sig-
nal operates with the compressor terminal. See Fig. 10. Refer
to the specific unit wiring schematic for details.
L1 L2 L3
Grnd
Power Distribution
Block
Terminal Strip
Transformer
C
Typical
Water
Valve
C Control #1
24 VAC
Contactor -CC2
Contactor -CC1
A
C Control #2
Fig. 10 — Typical Aquazone Accessory Wiring
(Deluxe D Control Shown)
Fig. 8 — Typical Field Wiring
NOTE: The A terminal should only be used with 24-v signals,
not line voltage signals.
EXTERNAL LOOP POWER CONNECTION — If the unit
is to be connected to an external loop pump or flow controller,
connect the pump to the loop pump terminal block PB1. The
maximum power handling is 4 amps at 240-v. The pumps will
automatically cycle as required by the unit.
IMPORTANT: Two-compressor units with Complete C or
Deluxe D controls wired to terminal A will be turned off if
the controls are in lockout mode, even if the other board is
in normal operating mode.
WATER SOLENOID VALVES — Water solenoid valves
may be used on variable flow systems and ground water instal-
lations. A typical well water control valve wiring which can
limit waste water in a lockout condition is shown in Fig. 10. A
slow closing valve may be required to prevent water hammer.
When using a slow closing valve, special wiring conditions
need to be considered. The valve takes approximately 60 sec-
onds to open (very little water will flow before 45 seconds) and
it activates the compressor only after the valve is completely
opened by closing its end switch. When wired as shown, the
valve will have the following operating characteristics:
220-V OPERATION — All 220/240-v units are factory
wired for 220-v. The transformers may be switched to 240-v
operation (as illustrated on the wiring diagram) by switching
the red (220-v) wire with the orange (240-v) wire at the L2
terminal.
380-VOLT OPERATION — All 380/415 volt units are factory
wired for 420 volts. The transformers may be switched to
380-volt operation by switching the brown (380 volt) wire
with the violet (420 volt) wire at the L1 terminal.
Step 7 — Wire Low Voltage Connections
THERMOSTAT CONNECTIONS
1. Remain open during a lockout.
2. Draw approximately 25 to 35-va through the “Y” signal
of the thermostat.
The thermostat should be wired directly to the Aquazone™
control board. See Fig. 4-7.
WATER FREEZE PROTECTION — The Aquazone control
allows the field selection of source fluid freeze protection
points through jumpers. The factory setting of jumper JW3
(FP1) is set for water at –1.1 C. In earth loop applications,
jumper JW3 should be clipped to change the setting to –12.2 C
when using antifreeze in colder earth loop applications. See
Fig. 9.
IMPORTANT: This can overheat the anticipators of
electromechanical thermostats. Only use relay based
electronic thermostats.
PRE-START-UP
System Checkout — When the installation is complete,
follow the system checkout procedure outlined below before
starting up the system. Be sure:
1. Voltage is within the utilization range specifications of the
unit compressor and fan motor, and voltage is balanced
for 3-phase units.
2. Fuses, breakers and wire are correct size.
3. Low voltage wiring is complete.
4. Piping and system flushing is complete.
5. Air is purged from closed loop system.
6. System is balanced as required. Monitor if necessary.
7. Isolation valves are open.
8. Water control valves or loop pumps are wired.
9. Transformer switched to lower voltage tap if necessary.
10. Service/access panels are in place.
11. Control field-selected settings are correct.
Fig. 9 — Typical Aquazone Control Board
Jumper Locations (Complete C Control Shown)
12
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(units with 2 compressors and 2 Deluxe D controls) or in mas-
ter/slave applications. In master/slave applications, each com-
pressor and fan will stage according to its switch 2 setting. If
switch is set to Stage 2, the compressor will have a 3-second
delay before energizing during Stage 2 demand.
FIELD SELECTABLE INPUTS
Jumpers and DIP (dual in-line package) switches on the
control board are used to customize unit operation and can be
configured in the field.
NOTE: If DIP switch is set for Stage 2, the alarm relay will not
cycle during Test mode.
IMPORTANT: Jumpers and DIP switches should only
be clipped when power to control board has been turned
off.
Heating/Cooling Thermostat Type — Switch 3 provides selec-
tion of thermostat type. Heat pump or heat/cool thermostats
can be selected. Select OFF for heat/cool thermostats. When in
heat/cool mode, Y1 is used for cooling Stage 1, Y2 is used for
cooling Stage 2, W1 is used for heating Stage 1 and O/W2 is
used for heating Stage 2. Select ON for heat pump applications.
In heat pump mode, Y1 used is for compressor Stage 1, Y2 is
used for compressor Stage 2, W1 is used for heating Stage 3 or
emergency heat, and O/W2 is used for RV (heating or cooling)
depending upon switch 4 setting.
Complete C Control Jumper Settings (See
Fig. 4-6)
WATER COIL FREEZE PROTECTION (FP1) LIMIT
SETTING — Select jumper 3, (JW3-FP1 Low Temp) to
choose FP1 limit of –12.2 C or –1.1 C. To select –1.1 C as the
limit, DO NOT clip the jumper. To select –12.2 C as the limit,
clip the jumper.
ALARM RELAY SETTING — Select jumper 1 (JW1-AL2
Dry) for connecting alarm relay terminal (AL2) to 24 vac (R)
or to remain as a dry contact (no connection). To connect AL2
to R, do not clip the jumper. To set as dry contact, clip the
jumper.
O/B Thermostat Type — Switch 4 provides selection for heat
pump O/B thermostats. O is cooling output. B is heating out-
put. Select ON for heat pumps with O output. Select OFF for
heat pumps with B output.
Switches 5, 6, 7, 8 — Not used.
Complete C Control DIP Switches — The
Complete C control has one DIP switch block with five
switches. See Fig. 4-6.
PERFORMANCE MONITOR (PM) — DIP switch 1 will
enable or disable this feature. To enable the PM, set the switch
to ON. To disable the PM, set the switch to OFF.
STAGE 2 — DIP switch 2 will enable or disable compressor
delay. Set DIP switch to OFF for Stage 2 in which the compres-
sor will have a 3-second delay before energizing. DIP switch 3
is not used. DIP switch 4 is not used. DIP switch 5 is used to
initiate one or 3 tries for the FP1 fault. If water freeze protec-
tion for the water coil is needed, then DIP switch 5 can be set to
lock out on the FP1 fault after one try.
DIP SWITCH BLOCK 2 (S2) — Used for accessory relay
configurations.
Deluxe D Control Accessory Relay Configura-
tions (See Tables 4 and 5) — The following acces-
sory relay settings are applicable for Deluxe D control only:
CYCLE WITH COMPRESSOR — In this configuration, the
relay will be ON any time the compressor relay is on.
DIGITAL NIGHT SETBACK (NSB) — In this configura-
tion, the relay will be ON if the NSB input is connected to
ground C.
NOTE: If there are no relays configured for digital NSB, then
the NSB and OVR inputs are automatically configured for
mechanical operation.
MECHANICAL NIGHT SETBACK — When NSB input is
connected to ground C, all thermostat inputs are ignored. A
thermostat setback heating call will then be connected to the
OVR input. If OVR input becomes active, then the Deluxe D
control will enter night low limit (NLL) staged heating mode.
The NLL staged heating mode will then provide heating during
the NSB period.
Deluxe D Control Jumper Settings (See
Fig. 7)
WATER COIL FREEZE PROTECTION (FP1) LIMIT
SETTING — Select jumper 3, (JW3-FP1 Low Temp) to
choose FP1 limit of –12.2 C or –1.1 C. To select –1.1 C as the
limit, DO NOT clip the jumper. To select –12.2 C as the limit,
clip the jumper.
ALARM RELAY SETTING — Select jumper 4 (JW4-AL2
Dry) for connecting alarm relay terminal (AL2) to 24 vac (R)
or to remain as a dry contact (no connection). To connect AL2
to R, do not clip the jumper. To set as dry contact, clip the
jumper.
LOW PRESSURE SETTING — The Deluxe D control can
be configured for Low Pressure Setting (LP). Select jumper 1
(JW1-LP Norm Open) for choosing between low pressure in-
put normally opened or closed. To configure for normally
closed operation, do not clip the jumper. To configure for nor-
mally open operation, clip the jumper.
WATER VALVE (SLOW OPENING) — If relay is config-
ured for water valve (slow opening), the relay will start 60 sec-
onds prior to starting compressor relay.
CAUTION
To avoid equipment damage, DO NOT leave system filled
in a building without heat during the winter unless anti-
freeze is added to system water. Condenser coils never
fully drain by themselves and will freeze unless winterized
with antifreeze.
Deluxe D Control DIP Switches — The Deluxe D
control has 2 DIP switch blocks. Each DIP switch block has 8
switches and is labeled either S1 or S2 on the circuit board. See
Fig. 7.
Table 4 — DIP Switch Block S2 —
Accessory 1 Relay Options
DIP SWITCH BLOCK 1 (S1) — This set of switches offers
the following options for Deluxe D control configuration:
DIP SWITCH POSITION
ACCESSORY 1
RELAY OPTIONS
1
2
3
Performance Monitor (PM) — Set switch 1 to enable or dis-
able performance monitor. To enable the PM, set the switch to
ON. To disable the PM, set the switch to OFF.
Compressor Relay Staging Operation — Switch 2 will en-
able or disable compressor relay staging operation. The com-
pressor relay can be set to turn on with Stage 1 or Stage 2 call
from the thermostat. This setting is used with dual stage units
Digital NSB
Water Valve — Slow Opening
Off
On
On
Off
On
On
LEGEND
NSB — Night Setback
NOTE: All other DIP switch combinations are invalid.
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Table 5 — DIP Switch Block S2 —
Accessory 2 Relay Options
6. If unit fails to operate, perform the following system
checks:
a. Check the voltage and current. Be sure they com-
ply with electrical data on unit nameplate.
b. Check for loose terminal screws where wire con-
nections have been made on both the line and low-
voltage terminal boards.
DIP SWITCH POSITION
ACCESSORY 2
RELAY OPTIONS
4
5
6
On
On
Digital NSB
Water Valve — Slow Opening
Off
On
On
Off
LEGEND
NSB — Night Setback
c. Check the supply and return piping. Be sure they
are properly connected to the inlet and outlet con-
nections on the unit.
NOTE: All other DIP switch combinations are invalid.
d. If the checks described above fail to reveal the
problem and the unit still will not operate, contact
a trained service technician to ensure proper
diagnosis.
START-UP
Use the procedure outlined below to initiate proper unit
start-up.
NOTE: This equipment is designed for indoor installation
only.
Scroll Compressor Rotation — It is important to be
certain compressor is rotating in the proper direction. To
determine whether or not compressor is rotating in the proper
direction:
1. Connect service gages to suction and discharge pressure
fittings.
2. Energize the compressor.
3. The suction pressure should drop and the discharge
pressure should rise, as is normal on any start-up.
If the suction pressure does not drop and the discharge
pressure does not rise to normal levels:
1. Turn off power to the unit. Install disconnect tag.
2. Reverse any two of the unit power leads.
3. Reapply power to the unit and verify pressures are cor-
rect. The suction and discharge pressure levels should
now move to their normal start-up levels.
Operating Limits (See Table 6)
ENVIRONMENT — This equipment is designed for indoor
installation ONLY. Extreme variations in temperature, humidi-
ty and corrosive water or air will adversely affect the unit per-
formance, reliability and service life.
POWER SUPPLY — A voltage variation of ± 10% of name-
plate utilization voltage is acceptable.
NOTE: These operating conditions are not normal or continu-
ous operating conditions. It is assumed that start-up is for the
purpose of bringing the building space up to occupancy
temperature.
WARNING
When the disconnect switch is closed, high voltage is pres-
ent in some areas of the electrical panel. Exercise caution
when working with the energized equipment.
CAUTION
When the compressor is rotating in the wrong direction, the
unit makes an elevated level of noise and does not provide
cooling. Damage to compressor will occur if allowed to
operate in this manner.
Table 6 — 50PSW Unit Operating Limits (C)
BUILDING COMMISSIONING
After a few minutes of reverse operation, the scroll com-
pressor internal overload protection will open, thus activating
the unit lockout. This requires a manual reset. To reset, turn the
thermostat on and then off.
NOTE: There is a 5-minute time delay before the compressor
will start.
COOLING
Load
HEATING
Load Ambient
50PSW
Source
Ambient Source
UNIT SIZE
Min/Max Min/Max Min/Max Min/Max Min/Max Min/Max
036
060,120
180,360
10/43
10/49
10/32
16/27
16/32
16/32
7/43
7/43
7/43
–1/27
–1/27
10/21
16/49
16/49
27/49
4/29
4/29
4/29
BUILDING OPERATING
COOLING
Flow Regulation — Flow regulation can be accom-
plished by two methods. Most water control valves have a flow
adjustment built into the valve. By measuring the pressure drop
through the unit heat exchanger, the flow rate can be deter-
mined. Adjust the water control valve until the flow of 0.09 to
0.13 L/s is achieved. Since the pressure constantly varies, two
pressure gages may be needed in some applications. See
Table 7 for heat exchanger pressure drops.
HEATING
Load
50PSW
Source
Load
Ambient Source
Ambient
UNIT SIZE
Min/Max Min/Max Min/Max Min/Max Min/Max Min/Max
036
060,120
180,360
10/49
10/49
10/43
10/32
10/32
10/32
7/43
7/43
7/43
–7/27
–7/27
–7/21
16/54
16/54
16/49
4/29
4/29
4/29
Unit Start-Up
1. Turn off all power to unit.
2. Adjust all valves to full open position.
3. Restore power to unit.
4. Operate each unit in the cooling cycle. See Table 6 for
unit entering water temperatures.
An alternative method is to install a flow control device.
These devices are typically an orifice of plastic material de-
signed to allow a specified flow rate that are mounted on the
outlet of the water control valve. Occasionally these valves
produce a velocity noise that can be reduced by applying some
back pressure. To accomplish this, slightly close the leaving
isolation valve of the water regulating device.
5. Operate each heat pump in the heating cycle immediately
after checking cooling cycle operation.
NOTE: A time delay will prevent the compressor from
re-starting for approximately 5 minutes. The time delay
function can be overridden on the Complete C control
board.
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Table 7 — Heat Exchanger Pressure Drop
6. Raise the loop temperature to approximately 29.4 C.
Open the drain at the lowest point in the system. Adjust
the make-up water replacement rate to equal the rate of
bleed.
7. Refill the system and add trisodium phosphate in a pro-
portion of approximately 0.5 kg per 750 L of water (or
other equivalent approved cleaning agent).
UNIT SIZES 036-120
PRESSURE DROP (kPa)
50PSW
UNIT SIZE
L/s
–1 C
10 C
21 C
32 C
Source/Outdoor Coax
0.28
0.43
0.57
0.47
0.71
0.95
0.95
1.42
1.89
11.7
28.3
49.0
10.3
27.6
47.6
11.7
30.3
52.4
9.0
23.4
41.4
9.0
23.4
42.8
9.7
26.2
46.9
6.9
19.3
35.2
17.2
47.6
88.3
8.3
22.8
42.1
5.5
16.5
31.0
14.5
42.1
80.0
6.2
18.6
34.5
036
060
120
CAUTION
To avoid possible damage to a plastic (PVC) piping sys-
tem, do not allow temperatures to exceed 43.3 C.
Raise the loop temperature to 37.8 C. Circulate the solu-
tion for a minimum of 8 to 24 hours. At the end of this
period, shut off the circulating pump and drain the solu-
tion. Repeat system cleaning if desired.
Load/Outdoor Coax
0.28
0.43
0.57
0.47
0.71
0.95
0.95
1.42
1.89
—
—
—
—
—
—
—
—
—
4.1
9.7
3.4
9.0
2.1
7.6
036
060
120
18.0
16.5
15.2
8. When the cleaning process is complete, remove the short-
circuited hose. Reconnect the hoses to the proper supply,
and return the connections to each of the units. Refill the
system and bleed off all air.
9. Test the system pH with litmus paper. The system water
should be slightly alkaline (pH of 7.5 to 8.5). Add chemi-
cals, as appropriate, to maintain acidity levels.
10. When the system is successfully cleaned, flushed, refilled
and bled, restore power.
11. Check the main system panels, safety cutouts and alarms.
Set the controls to properly maintain loop temperatures.
9.7
24.1
42.8
11.0
26.2
46.9
9.0
22.1
40.0
9.7
24.1
44.1
8.3
20.7
37.9
2.1
22.8
41.1
UNIT SIZES 180,360
PRESSURE DROP (kPa)
50PSW
UNIT SIZE
L/s
0 C
10 C
20 C
30 C
Source/Outdoor Coax
1.10
1.67
2.21
2.21
3.34
4.42
4.82
17.92
32.40
11.03
26.88
48.95
2.76
11.72
22.75
8.27
24.82
44.82
1.72
11.38
21.37
7.22
23.10
41.36
0.88
9.47
180
360
19.30
CAUTION
6.29
21.29
38.47
DO NOT use “Stop Leak” or any similar chemical agent in
this system. Addition of these chemicals to the loop water
will foul the system and inhibit unit operation.
NOTE: Bold values indicate use of antifreeze is required.
Antifreeze — In areas where entering loop temperatures
drop below 4.4 C or where piping will be routed through areas
subject to freezing, antifreeze is needed.
Alcohols and glycols are commonly used as antifreeze
agents. Freeze protection should be maintained to 8.3° C below
the lowest expected entering loop temperature. For example, if
the lowest expected entering loop temperature is –1.1 C, the
leaving loop temperature would be –5.6 to –3.9 C. Therefore,
the freeze protection should be at –9.4 C (–1.1 C – 8.3 C =
–9.4 C).
Cleaning and Flushing — Cleaning and flushing of
the piping system is the single most important step to ensure
proper start-up and continued efficient operation of the system.
WARNING
To avoid possible injury or death due to electrical shock,
open the power supply disconnect switch and secure it in
an open position before flushing system. Install lockout
tag.
IMPORTANT: All alcohols should be pre-mixed and
pumped from a reservoir outside of the building or
introduced under water level to prevent alcohols from
fuming.
Follow the instructions below to properly clean and flush
the system:
1. Verify electrical power to the unit is disconnected and
lockout tag installed.
2. Install the system with the supply hose connected directly
to the return riser valve. Use a single length of flexible
hose.
3. Open all air vents. Fill the system with the water. DO
NOT allow system to overflow. Bleed all air from the
system. Pressurize and check the system for leaks and re-
pair appropriately.
4. Verify all strainers are in place. Start the pumps, and sys-
tematically check each vent to ensure all air is bled from
the system.
Calculate the total volume of fluid in the piping system. See
Table 8. Use the percentage by volume in Table 9 to determine
the amount of antifreeze to use. Antifreeze concentration
should be checked from a well mixed sample using a hydrome-
ter to measure specific gravity.
FREEZE PROTECTION SELECTION — The –1.1 C FP1
factory setting (water) should be used to avoid freeze damage
to the unit.
Once antifreeze is selected, the JW3 jumper (FP1) should
be clipped on the control to select the low temperature (anti-
freeze –12.2 C) set point to avoid nuisance faults.
5. Verify make-up water is available. Adjust make-up water
appropriately to replace the air which was bled from the
system. Check and adjust the water/air level in the expan-
sion tank.
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Table 8 — Approximate Fluid Volume (L)
per 30 M of Pipe
NOTE: On all subsequent compressor calls the random start
delay is omitted.
HEATING STAGE 2 — To enter Stage 2 mode, terminal W is
active (Y is already active). Also, the G terminal must be active
or the W terminal is disregarded.
PIPE
Copper
DIAMETER (in.) [mm] VOLUME (gal.) [L]
1 [25.4]
1.25 [31.8]
1.5 [38.1]
4.1 [15.5]
6.4 [24.2]
9.2 [34.8]
Units with Aquazone Deluxe D Control
STANDBY — The compressor will be off. The reversing
valve (RV) relays will be on if inputs are present.
Rubber Hose
Polyethylene
1 [25.4]
3.9 [14.8]
3/4 IPS SDR11
1 IPS SDR11
11/4 IPS SDR11
1/2 IPS SDR11
2 IPS SDR11
11/4 IPS SCH40
11/2 IPS SCH40
2 IPS SCH40
2.8 [10.6]
4.5 [17.0]
8.0 [30.8]
10.9 [41.3]
18.0 [68.1]
8.3 [31.4]
10.9 [41.3]
17.0 [64.4]
HEATING STAGE 1 — In Heating Stage 1 mode, the fan en-
able and compressor relays are turned on immediately. Once
the demand is removed, the relays are turned off and the con-
trol reverts to standby mode. If there is a master/slave or dual
compressor application, all compressor relays and related func-
tions will operate per their associated DIP switch 2 setting on
S1.
HEATING STAGE 2 — In Heating Stage 2 mode, the com-
pressor relays remain on. The control reverts to Heating Stage
1 mode once demand is removed. If there is a master/slave or
dual compressor application, all compressor relays and related
functions will operate per their associated DIP switch 2 setting
on S1.
LEGEND
IPS — Internal Pipe Size
SCH — Schedule
SDR — Standard Dimensional Ratio
NOTE: Volume of heat exchanger is approximately 1.0 gallon
(3.78 liters).
Table 9 — Antifreeze Percentages by Volume
COOLING STAGE 1 — In Cooling Stage 1 mode, the com-
pressor and RV relays are turned on immediately. If configured
as stage 2 (DIP switch set to OFF) then the compressor and fan
will not turn on until there is a stage 2 demand. The compressor
relays are turned off immediately when the Cooling Stage 1 de-
mand is removed. The control reverts to standby mode. The
RV relay remains on until there is a heating demand. If there is
a master/slave or dual compressor application, all compressor
relays and related functions will track with their associated DIP
switch 2 on S1.
COOLING STAGE 2 — In Cooling Stage 2 mode, the com-
pressor and RV relays remain on. The control reverts to Cool-
ing Stage 1 mode once the demand is removed. If there is a
master/slave or dual compressor application, all compressor re-
lays and related functions will track with their associated DIP
switch 2 on S1.
NIGHT LOW LIMIT (NLL) STAGED HEATING — In NLL
staged heating mode, the override (OVR) input becomes
active and is recognized as a call for heating and the control
will immediately go into a Heating Stage 1 mode. With an
additional 30 minutes of NLL demand, the control will go into
Heating Stage 2 mode. With another additional 30 minutes of
NLL demand, the control will go into Heating Stage 3 mode.
MINIMUM TEMPERATURE FOR FREEZE
PROTECTION (C)
ANTIFREEZE
Methanol (%)
100% USP Food Grade
Propylene Glycol (%)
–12.2
–9.4
–6.7
–3.9
25
21
16
10
38
29
30
25
22
20
15
14
Ethanol (%)
Cooling Tower/Boiler Systems — These systems
typically use a common loop maintained at 15.6 to 32.2 C. The
use of a closed circuit evaporative cooling tower with a second-
ary heat exchanger between the tower and the water loop is rec-
ommended. If an open type cooling tower is used continuously,
chemical treatment and filtering will be necessary.
Ground Coupled, Closed Loop and Plateframe
Heat Exchanger Well Systems — These systems al-
low water temperatures from –1.1 to 43.3 C. The external loop
field is divided up into 51 mm polyethylene supply and return
lines. Each line has valves connected in such a way that upon
system start-up, each line can be isolated for flushing using only
the system pumps. Air separation should be located in the pip-
ing system prior to the fluid re-entering the loop field.
OPERATION
Power Up Mode — The unit will not operate until all the
inputs, terminals and safety controls are checked for normal
operation.
NOTE: The compressor will have a 5-minute anti-short cycle
upon power up.
SYSTEM TEST
System testing provides the ability to check the control
operation. The control enters a 20-minute Test mode by mo-
mentarily shorting the test pins. All time delays are increased
15 times. See Fig. 11.
Units with Aquazone™ Complete C Control
STANDBY — The Y and W terminals are not active in Stand-
by mode, however the O and G terminals may be active, de-
pending on the application. The compressor will be off.
COOLING — The Y and O terminals are active in Cooling
mode. After power up, the first call to the compressor will initi-
ate a 5 to 80 second random start delay and a 5-minute anti-
short cycle protection time delay. After both delays are com-
plete, the compressor is energized.
TEST
BR BRG CCG CC
MODE
PINS
C
R
C
Off On
Test
R
JW3
FP1
NOTE: On all subsequent compressor calls the random start
delay is omitted.
Fig. 11 — Test Mode Pins Location
HEATING STAGE 1 — Terminal Y is active in heating
Stage 1. After power up, the first call to the compressor will
initiate a 5 to 80 second random start delay and a 5-minute anti-
short cycle protection time delay. After both delays are
complete, the compressor is energized.
Test Mode — Enter the Test mode on Complete C or
Deluxe D controls by momentarily shorting the test terminals.
The Complete C or Deluxe D control will enter a 20-minute
test mode period in which all time delays are sped up 15 times.
16
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Upon entering Test mode, the status LED (light-emitting di-
ode) will flash a code representing the last fault. For diagnostic
ease at the thermostat, the alarm will also cycle during Test
mode. The alarm relay will cycle on and off similar to the sta-
tus LED to indicate a code representing the last fault, at the
thermostat. Test mode can be exited by shorting the test termi-
nals for 3 seconds. See Tables 10-12.
NOTE: Deluxe D control has a flashing code and alarm relay
cycling code that will both have the same numerical label.
For example, flashing code 1 will have an alarm relay cycling
code 1. Code 1 indicates the control has not faulted since the
last power off to power on sequence.
Aquazone™ Deluxe D Control LED Indica-
tors — There are 3 LED indicators on the Deluxe D control:
STATUS LED — Status LED indicates the current status or
mode of the Deluxe D control. The Status LED light is green.
TEST LED — Test LED will be activated any time the De-
luxe D control is in Test mode. The Test LED light is yellow.
FAULT LED — Fault LED light is red. The fault LED will
always flash a code representing the last fault in memory. If
there is no fault in memory, the fault LED will flash code 1 on
the display and appear as 1 fast flash alternating with a
10-second pause. See Table 12.
Retry Mode — In Retry mode, the status LED will start to
flash slowly to signal that the control is trying to recover from
an input fault. The control will stage off the outputs and try to
again satisfy the thermostat used at terminal Y. Once the ther-
mostat input calls are satisfied, the control will continue normal
operation.
NOTE: If 3 consecutive faults occur without satisfying the
thermostat input call to terminal Y, the control will go into
lockout mode. The last fault causing the lockout is stored in
memory and can be viewed by entering Test mode.
Table 11 — Complete C Control LED Code and
Fault Descriptions
LED
CODE
1
FAULT
DESCRIPTION
No fault in memory
There has been no fault since
the last power-down to power-up
sequence
2
3
High-Pressure Switch
Low-Pressure Switch
HP Open Instantly
LP open for 30 continuous
seconds before or during a
call (bypassed for first
60 seconds)
Table 10 — Complete C Control Current LED
Status and Alarm Relay Operations
4
5
7
Freeze Protection
FP1 below Temp limit for
30 continuous seconds
(bypassed for first 60 seconds of
operation)
(Source) Coax — FP1
DESCRIPTION OF
OPERATION
LED STATUS
ALARM RELAY
Freeze Protection (Load) FP2 below Temp limit for
Coil — FP2
30 continuous seconds
(bypassed for first 60 seconds of
operation)
Normal Mode
Open
Cycle
(Closed 5 sec.,
Open 25 sec.)
On
Normal Mode with PM Warning
Over/Under Voltage
(Autoreset) Shutdown
"R" power supply is <19 vac
or >30 vac
Off
Control is non-functional
Fault Retry
Open
Open
8
PM Warning
Performance Monitor
Warning has occurred.
Open
Slow Flash
Fast Flash
9
FPI and FP2
Thermistors are
swapped
FP1 temperature is higher than
FP2 in heating/test mode, or FP2
temperature is higher than FP1
in cooling/test mode.
Over/Under Voltage Shutdown
Lockout
(Closed after
15 minutes)
Closed
Flashing Code 1 Test Mode — No fault in memory
Flashing Code 2 Test Mode — HP Fault in memory
Flashing Code 3 Test Mode — LP Fault in memory
Flashing Code 4 Test Mode — FP1 Fault in memory
Flashing Code 5 Test Mode — FP2 Fault in memory
Cycling Code 1
Cycling Code 2
Cycling Code 3
Cycling Code 4
Cycling Code 5
LEGEND
FP
HP
LP
—
—
—
Freeze Protection
High Pressure
Low Pressure
Test Mode — Over/Under shut-
Flashing Code 7
Cycling Code 7
Cycling Code 8
Cycling Code 9
down in memory
Flashing Code 8
Flashing Code 9
Test Mode — PM in memory
Test Mode — FP1/FP2 swapped
fault in memory
LEGEND
FP
—
—
—
—
—
Freeze Protection
HP
LED
LP
High Pressure
Light-Emitting Diode
Low Pressure
Performance Monitor
PM
NOTES:
1. Slow flash is 1 flash every 2 seconds.
2. Fast flash is 2 flashes every 1 second.
3. EXAMPLE: “Flashing Code 2” is represented by 2 fast flashes followed
by a 10-second pause. This sequence will repeat continually until the
fault is cleared.
17
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Table 12 — Aquazone™ Deluxe D Control Current LED Status and Alarm Relay Operations
STATUS LED
(Green)
TEST LED
(Yellow)
DESCRIPTION
Normal Mode
FAULT LED (Red)
Flash Last Fault Code in Memory
Flashing Code 8
ALARM RELAY
On
Off
Open
Cycle (closed 5 sec,
open 25 sec, …)
Normal Mode with PM
On
Off
Control is Non-Functional
Test Mode
Off
Off
On
—
Off
Open
—
Flash Last Fault Code in Memory
Flash Last Fault Code in Memory
Flash Last Fault Code in Memory
Flash Last Fault Code in Memory
Flashing Code 1
Cycling Appropriate Code
Night Setback
ESD
Invalid T-stat Inputs
No Fault in Memory
HP Fault
Flashing Code 2
Flashing Code 3
Flashing Code 4
On
—
—
—
—
—
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Open
Slow Flash
Slow Flash
Slow Flash
Slow Flash
Slow Flash
Slow Flash
Fast Flash
Fast Flash
Fast Flash
Fast Flash
Fast Flash
Flashing Code 2
Open
LP Fault
FP1 Fault
FP2 Fault
CO Fault
Flashing Code 3
Open
Flashing Code 4
Open
Flashing Code 5
Open
Flashing Code 6
Open
Over/Under Voltage
HP Lockout
LP Lockout
Flashing Code 7
Open (closed after 15 minutes)
Flashing Code 2
Closed
Closed
Closed
Closed
Closed
Flashing Code 3
FP1 Lockout
FP2 Lockout
CO Lockout
Flashing Code 4
Flashing Code 5
Flashing Code 6
LEGEND
NOTES:
1. If there is no fault in memory, the Fault LED will flash code 1.
2. Codes will be displayed with a 10-second Fault LED pause.
3. Slow flash is 1 flash every 2 seconds.
CO
ESD
FP
—
—
—
—
—
—
Condensate Overflow
Emergency Shutdown
Freeze Protection
High Pressure
Low Pressure
Performance Monitor
4. Fast flash is 2 flashes every 1 second.
HP
LP
5. EXAMPLE: “Flashing Code 2” is represented by 2 fast flashes followed
by a 10-second pause. This sequence will repeat continually until the
fault is cleared.
PM
Check P trap frequently for proper operation.
SERVICE
Perform the procedures outlined below periodically, as
indicated.
CAUTION
To avoid fouled machinery and extensive unit clean-up,
DO NOT operate units without filters in place. DO NOT
use equipment as a temporary heat source during
construction.
IMPORTANT: When a compressor is removed from this
unit, system refrigerant circuit oil will remain in the com-
pressor. To avoid leakage of compressor oil, the refrigerant
lines of the compressor must be sealed after it is removed.
IMPORTANT: To avoid the release of refrigerant into the
atmosphere, the refrigerant circuit of this unit must only be
serviced by technicians which meet local, state and federal
proficiency requirements.
Refrigerant System — Verify air and water flow rates
are at proper levels before servicing. To maintain sealed circuit-
ry integrity, do not install service gages unless unit operation
appears abnormal.
Condenser Cleaning — Water-cooled condensers may
require cleaning of scale (water deposits) due to improperly
maintained closed-loop water systems. Sludge build-up may
need to be cleaned in an open water tower system due to
induced contaminants.
IMPORTANT: All refrigerant discharged from this unit
must be recovered without exception. Technicians must fol-
low industry accepted guidelines and all local, state and fed-
eral statutes for the recovery and disposal of refrigerants.
Local water conditions may cause excessive fouling or
pitting of tubes. Condenser tubes should therefore be cleaned at
least once a year, or more often if the water is contaminated.
Proper water treatment can minimize tube fouling and
pitting. If such conditions are anticipated, water treatment
analysis is recommended. Refer to the Carrier System Design
Manual, Part 5, for general water conditioning information.
WARNING
To prevent injury or death due to electrical shock or contact
with moving parts, open unit disconnect switch before ser-
vicing unit.
Water Coil — Keep all air out of the water coil. Check
open loop systems to be sure the well head is not allowing air
to infiltrate the water line. Always keep lines airtight.
CAUTION
Inspect heat exchangers regularly, and clean more frequent-
ly if the unit is located in a “dirty” environment. The heat
exchanger should be kept full of water at all times. Open loop
systems should have an inverted P trap placed in the discharge
line to keep water in the heat exchanger during off cycles.
Closed loop systems must have a minimum of 103 kPa during
the summer and 276 kPa during the winter.
Follow all safety codes. Wear safety glasses and rubber
gloves when using inhibited hydrochloric acid solution.
Observe and follow acid manufacturer’s instructions.
Clean condensers with an inhibited hydrochloric acid solu-
tion. The acid can stain hands and clothing, damage concrete,
and, without inhibitor, damage steel. Cover surroundings to
guard against splashing. Vapors from vent pipe are not harmful,
18
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but take care to prevent liquid from being carried over by the
gases.
3. After unit conditions have stabilized, read head pressure
on discharge line gage.
Warm solution acts faster, but cold solution is just as effec-
tive if applied for a longer period.
NOTE: Operate unit a minimum of 15 minutes before
checking charge. From standard field-supplied Pressure-
Temperature chart for R-410A, find equivalent saturated
condensing temperature.
GRAVITY FLOW METHOD — Do not add solution faster
than vent can exhaust the generated gases.
When condenser is full, allow solution to remain overnight,
then drain condenser and flush with clean water. Follow acid
manufacturer’s instructions. See Fig. 12.
4. Read liquid line temperature on thermometer; then
subtract from saturated condensing temperature. The dif-
ference equals subcooling temperature.
Refrigerant Charging
WARNING
FILL CONDENSER WITH
CLEANING SOLUTION. DO
PAIL
NOT ADD SOLUTION
MORE RAPIDLY THAN
VENT CAN EXHAUST
GASES CAUSED BY
To prevent personal injury, wear safety glasses and gloves
when handling refrigerant. Do not overcharge system —
this can cause compressor flooding.
FUNNEL
CHEMICAL ACTION.
1-IN.
(25 mm)
PIPE
NOTE: Do not vent or depressurize unit refrigerant to atmo-
sphere. Remove and recover refrigerant following accepted
practices.
VENT
PIPE
1.5 m APPROX
1.0 TO 1.2 m
CONDENSER
TROUBLESHOOTING
When troubleshooting problems with a WSHP, refer to
Table 13.
Thermistor — A thermistor may be required for single-
phase units where starting the unit is a problem due to low
voltage. See Fig. 14 for thermistor nominal resistance.
PAIL
Control Sensors — The control system employs 2 nom-
inal 10,000 ohm thermistors (FP1 and FP2) that are used for
freeze protection. Be sure FP1 is located in the discharge fluid
and FP2 is located in the air discharge. See Fig. 15.
Fig. 12 — Gravity Flow Method
FORCED CIRCULATION METHOD — Fully open vent
pipe when filling condenser. The vent may be closed when
condenser is full and pump is operating. See Fig. 13.
90.0
80.0
70.0
60.0
50.0
40.0
30.0
20.0
10.0
0.0
GAS VENT
PUMP
PRIMING
CONN.
GLOBE
VALVES
SUCTION
SUPPLY
PUMP
SUPPORT
1-IN.
(25 mm)
PIPE
CONDENSER
TANK
REMOVE WATER
REGULATING VALVE
-17.7
-6.6
4.4
15.6
26.7
37.8
48.9
60.0
Temperature (C)
RETURN
FINE MESH
SCREEN
Fig. 14 — Thermistor Nominal Resistance
Fig. 13 — Forced Circulation Method
Regulate flow to condenser with a supply line valve. If
pump is a nonoverloading type, the valve may be fully closed
while pump is running.
For average scale deposit, allow solution to remain in con-
denser overnight. For heavy scale deposit, allow 24 hours.
Drain condenser and flush with clean water. Follow acid manu-
facturer’s instructions.
Checking System Charge — Units are shipped with
full operating charge. If recharging is necessary:
1. Insert thermometer bulb in insulating rubber sleeve on
liquid line near filter drier. Use a digital thermometer for
all temperature measurements. DO NOT use a mercury
or dial-type thermometer.
2. Connect pressure gage to discharge line near compressor.
19
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AIR
COIL
SUCTION
AIRFLOW
(°C)
AIRFLOW
(°C)
COMPRESSOR
THERMISTOR
EXPANSION
VALVE
COAX
DISCHARGE
FP2
FP1
a50-8163
CONDENSATE
OVERFLOW
(CO)
LIQUID
LINE
WATER IN
WATER OUT
AIR COIL
WATER
COIL
PROTECTION
FREEZE
a50-8592
PROTECTION
LEGEND
COAX — Coaxial Heat Exchanger
Airflow
Refrigerant Liquid Line Flow
Fig. 15 — FP1 and FP2 Thermistor Location
20
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Table 13 — Troubleshooting
FAULT
HEATING COOLING
POSSIBLE CAUSE
SOLUTION
Main Power Problems
X
X
Green Status LED Off
Check line voltage circuit breaker and disconnect.
Check for line voltage between L1 and L2 on the contactor.
Check for 24-vac between R and C on controller.
Check primary/secondary voltage on transformer.
Check pump operation or valve operation/setting.
Check water flow adjust to proper flow rate.
HP Fault — Code 2
High Pressure
X
X
Reduced or no water flow in
cooling
Water temperature out of range Bring water temperature within design parameters.
in cooling
X
X
X
X
X
X
X
Overcharged with refrigerant
Bad HP switch
Check superheat/subcooling vs. typical operating condition.
Check switch continuity and operation. Replace.
Check for refrigerant leaks.
LP/LOC Fault — Code 3
Low Pressure/Loss of
Charge
Insufficient charge
Compressor pump down at
start-up
Check charge and start-up water flow.
FP1 Fault — Code 4
Source Water Freeze
Protection
X
Reduced or no water flow in
heating
Check pump operation or water valve operation/setting.
Plugged strainer or filter. Clean or replace.
Check water flow adjust to proper flow rate.
Check antifreeze density with hydrometer.
X
X
Inadequate antifreeze level
Improper freeze protect setting Clip JW3 jumper for antifreeze (–12.2 C) use.
(–1.1 C vs –12.2 C)
X
X
Water temperature out of range Bring water temperature within design parameters.
X
X
Bad thermistor
Check temperature and impedance correlation.
Check pump operation or water valve operation/setting.
Plugged strainer or filter. Clean or replace.
FP2 Fault — Code 5
Load Coil Freeze
Protection
Reduced or no water flow in
heating
Check water flow adjust to proper flow rate.
X
Improper freeze protect setting Clip JW3 jumper for antifreeze (–12.2 C) use.
(–1.1 C vs –12.2 C)
X
X
X
Water temperature out of range Bring water temperature within design parameters.
X
X
Bad thermistor
Under voltage
Check temperature and impedance correlation.
Check power supply and 24-vac voltage before and during operation.
Check power supply wire size.
Over/Under Voltage —
Code 7
(Auto Resetting)
Check compressor starting.
Check 24-vac and unit transformer tap for correct power supply voltage.
Check power supply voltage and 24-vac before and during operation.
Check 24-vac and unit transformer tap for correct power supply voltage.
Check for overcharged unit.
X
X
X
X
Over voltage
Performance Monitor —
Code 8
Heating mode FP2>51.7 C
Cooling mode FP1>51.7 C OR Check for poor water flow or airflow.
FP2< 4.4 C
No Fault Code Shown
Unit Short Cycles
X
X
X
X
X
X
X
X
X
X
X
X
X
No compressor operation
Compressor overload
Control board
See scroll compressor rotation section.
Check and replace if necessary.
Reset power and check operation.
Unit in Test mode
Unit selection
Reset power or wait 20 minutes for auto exit.
Unit may be oversized for space. Check sizing for actual load of space.
Check and replace if necessary.
Compressor overload
Reversing valve
Unit Does Not Operate in
Cooling
Set for cooling demand and check 24-vac on RV coil and at control.
If RV is stuck, run high pressure up by reducing water flow and while operat-
ing engage and disengage RV coil voltage to push valve.
X
X
X
X
X
X
X
Thermostat setup
Check for ‘O’ RV setup not ‘B’.
Thermostat wiring
Check O wiring at heat pump. Jumper O and R for RV coil.
Check superheat and subcooling.
Insufficient Capacity/
Not Cooling or Heating
Properly
X
X
Low refrigerant charge
Restricted metering device
Defective reversing valve
Check superheat and subcooling. Replace.
Perform RV touch test.
X
X
Thermostat improperly located Check location and for air drafts behind thermostat.
Unit undersized Recheck loads and sizing. Check sensible cooling load and heat pump
capacity.
Scaling in water heat exchanger Perform scaling check and clean if necessary.
Inlet water too hot or cold Check load, loop sizing, loop backfill, ground moisture.
Scaling in water heat exchanger Perform scaling check and clean if necessary.
X
X
X
X
X
X
X
X
High Head Pressure
X
X
X
X
Unit overcharged
Check superheat and subcooling. Reweigh in charge.
Vacuum system and reweigh in charge.
Non-condensables in system
Restricted metering device
Reduced water flow in heating
Check superheat and subcooling. Replace.
Check pump operation or water valve operation/setting.
Plugged strainer or filter. Clean or replace.
Check water flow adjust to proper flow rate.
Low Suction Pressure
X
Water temperature out of range Bring water temperature within design parameters.
LEGEND
FP
HP
—
—
Freeze Protection
High Pressure
LED — Light-Emitting Diode
LOC — Loss of Charge
LP
RV
—
—
Low Pressure
Reversing Valve
21
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Copyright 2010 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53500073-01
Printed in U.S.A.
Form 50PSW-C1SI
Pg 22
10-10
Replaces: New
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50PSW
START-UP CHECKLIST
CUSTOMER:___________________________
MODEL NO.:___________________________
LOOP TYPE:___________________________
JOB NAME: _______________________________________
SERIAL NO.:____________________
DATE:_________
ANTIFREEZE TYPE AND %:_________________________
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)
IS AN AIR FILTER INSTALLED? (Y/N)
II. START-UP
IS FAN OPERATING WHEN COMPRESSOR OPERATES? (Y/N)
IF 3-PHASE SCROLL COMPRESSOR IS PRESENT, VERIFY PROPER ROTATION PER INSTRUCTIONS.
(Y/N)
UNIT VOLTAGE — COOLING OPERATION
PHASE AB VOLTS
PHASE BC VOLTS
(if 3 phase)
PHASE CA VOLTS
(if 3 phase)
PHASE AB AMPS
PHASE BC AMPS
(if 3 phase)
PHASE CA AMPS
(if 3 phase)
CONTROL VOLTAGE
IS CONTROL VOLTAGE ABOVE 21.6 VOLTS? (Y/N)
.
IF NOT, CHECK FOR PROPER TRANSFORMER CONNECTION.
TEMPERATURES
FILL IN THE ANALYSIS CHART ATTACHED.
COAXIAL HEAT COOLING CYCLE:
EXCHANGER
FLUID IN
C
C
C
C
FLUID OUT
FLUID OUT
AIR OUT
C
KPA
KPA
FLOW
FLOW
HEATING CYCLE:
FLUID IN
C
C
C
AIR COIL
COOLING CYCLE:
AIR IN
HEATING CYCLE:
AIR IN
AIR OUT
CL-1
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HEATING AND COOLING CYCLE ANALYSIS
HEATING POSITION
COOLING POSITION
WATER-TO-WATER UNITS
REFRIG FLOW - HEATING
REFRIG FLOW - COOLING
REVERSING
VALVE
11 13
2
1
SUCTION
CONDENSER (COOLING)
Load
EVAPORATOR (HEATING)
COMPRESSOR
DISCHARGE
10 12
3
4
EXPANSION
VALVE
COAX
FILTER
DRIER
CONDENSER (HTG)
EVAPORATOR (CLG)
HWG*
Source
FP2:
5
FP1:
5
HEATING
LIQUID
LINE
COOLING
LIQUID
LINE
6
8
7
9
LEGEND
CLG
HTG
—
—
Cooling
Heating
a50-8465
*Turn off HWG (hot water generator)
before troubleshooting.
DESCRIPTION
Voltage
HEATING
COOLING
NOTES
Compressor Amp
1
2
Suction Temperature
Suction Pressure
2a Saturation Temperature
2b Superheat
3
4
Discharge Temperature
Discharge Pressure
4a Saturation Temperature
4b Subcooling
5
6
7
8
9
Liquid Line Temperature
Source Water In Temperature
Source Water Out Temperature
Source Water In Pressure
Source Water Out Pressure
Temperature Difference —
Temperature Difference —
9a Pressure Drop
9b Flow Rate (L/s)
10 Load Water In Temperature
11 Load Water Out Temperature
12 Load Water In Pressure
13 Load Water Out Pressure
13a Pressure Drop
13b Flow Rate (gpm)
HEAT OF EXTRACTION (ABSORPTION) OR HEAT OF REJECTION =
FLOW RATE (L/s) x TEMP. DIFF. (DEG. C) x
FLUID FACTOR* =
(kW)
SUPERHEAT = SUCTION TEMPERATURE – SUCTION SATURATION TEMPERATURE
(DEG C)
=
SUBCOOLING = DISCHARGE SATURATION TEMPERATURE – LIQUID LINE TEMPERATURE
(DEG C)
=
*Use 500 for water, 485 for antifreeze.
Copyright 2010 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53500073-01
Printed in U.S.A.
Form 50PSW-C1SI
Pg CL-2
10-10
Replaces: New
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