Carrier AQUAZONE 50PCH manual

Manufacturer reserves the right to disco ntinue, or change at any time, specifications or de signs without notice and without inc urring obligations. Catalog No . 04-53500094-01 Printed in U. S.A. Form 50PC-3SI Pg 1 3-11 Replaces: 50PC-2SI Installation, Star t-Up , and Ser vice Instructions CONTENTS Page SAFETY CONSIDERA T IONS . . . . . . . . . . [...]

2 Improper installation, adjustment, alteration, service, mainte- nance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property dam- age. Consult a qualified installer , service agency , o r your distrib- utor or branch fo r information or assistance. The qualified in- staller or agency mu[...]

3 or an equivalent protective covering. Cap open ends of pipes stored on the jobsite. This precaution is especially important in areas where painting, plastering, or spraying of fireproof mate- rial, etc. is not yet complete. Foreign material that accumulates within the units can prevent proper start-up and necessitate costly clean-up operations. B[...]

4 F RIGHT RETURN S TRAIGHT DI S CHARGE FRONT L N O M RIGHT RETURN FRONT LEFT/ S TRAIGHT DI S CHARGE C S P BACK DI S CHARGE CONDEN S ATE 3 / 4" FPT 3 . 3 " [ 83 . 8 MM] 0.7" [17. 8 MM] FRONT-VIEW E D K J 2 1 1.1 [27.9 MM] A CAP B S P RIGHT RETURN RIGHT VIEW - AIR COIL OPENING AIR COIL C T S B R Q FRONT L N O M LEFT RETURN S TRAIGHT DI[...]

5 Accessory Electric Heat (if applicable) Filter Access Return Loop Supply Loop W ater Out W ater In Integral hanger support- pre-attached in factory Field-supplied transition to minimize pressure loss 3/8" threaded rods (by others) Return Air (Ductwork not shown) Thermostat Wiring Power Wiring Balancing V alve (Field installed and calibrated [...]

6 ACCE SS PANEL S T OP VIEW-LEFT RETURN U R S I S OMETRIC VIEW LEFT RETURN LEFT VIEW - AIR COIL OPENING T C POWER S UPPLY 3 /4" [19.1 MM] HV KNOCKOUT LOW V OLTAGE 1/2" [12.7 MM] L V KNOCKOUT LOW V OLTAGE 1/2" [12.7 MM] L V KNOCKOUT CONDEN S ATE 3 /4" FPT FRONT-VIEW K 1.00 [25.4 MM] F J H D L AIR COIL FIELD IN S TALLED DI S CHARG[...]

7 Step 3 — Locate Unit — The following guidelines should be considered when choosing a location for a WSHP: • Units are for indoor use only . • Locate in areas where ambient temperatures are between 40 F and 100 F and relative humidity is no greater than 75%. • Provide suf ficient space for water , electrical and duct connections. • Loc[...]

8 Side to Back Discharge Conversion 1. Remove screws to free the top and discharge panels. See Fig. 5. 2. Remove the access panel and set aside. 3. Lift the discharge panel from side of unit and rotate it to back using care not to damage blower wiring. 4. Check blower wire routing and connections for undue tension or contact with sh eet metal edges[...]

9 Each unit must be installed with its own individual vent and means to flush or blow out the condensate drain line. Do not in- stall units with a common trap or vent. VE N T IN G — Install a vent in the condensate line of any application that may allow dirt or air to collect in the line. Con- sider the following: • Always install a vent where [...]

10 Insulation is not required on loop water piping except where the piping runs through unheated areas or outside the building or when the loop water temperature is below the minimum ex- pected dew point of the pipe am bient. Insulation is required if loop water temperature drops below the dew point. Pipe joint compound is not necessary when T eflo[...]

11 NO TES: 1. Compressor and bl ower moto r thermally protected internally . 2. All wiring to the unit must comply with NEC and local codes. 3. T ransformer f or 208/230 v will be connected for 208 v oper ation. F or 230 v operatio n, s witch RED wire to O RG wire. Insula te open end of RED lead. T ransf ormer is energy limiting or may ha ve circui[...]

12 NO TES: 1. Compressor ther mally protected internally . 2. All wiring to the unit must comply with NEC and local codes. 3. T ransf ormer is wired to 208-v RED lead fo r 208-3-60 units . For 230-3-60, switch RED and ORG lea ds at L1 and insulate RED lead. T ransf ormer is energy limiting or ma y hav e circuit brea ker . 4. FP1 thermistor provides[...]

13 NO TES: 1. Compressor ther mally protected i nternally . 2. All wiring to the unit must comply with NEC and local codes . 3. T ransformer is wired to 460-v BLK/ RED lead fo r 460-3-60 units or 575-v GR Y lead f or 575- 3-60 units. T ransf ormer is energy limiting or may ha v e circuit break er . 4. FP1 thermistor provides lo w temperatur e prote[...]

14 Fig. 16 — 50PCH,PCV Units wi th Complete C and LON Contr oll er (460 V) Compl ete C a50-8493 LEGEND AL — Ala rm Relay Contacts BM — Blower Motor BMC — Blower Mo tor Capacitor BR — Blower Re lay CB — Circuit Breaker CC — Compressor Contactor CO — Sensor , Condensate Ov erflo w FP1 — Sensor, Lo w T emperature Protect ion, W ater [...]

15 Deluxe D NO TES: 1. Compressor and blow er motor ther mally protected inter nally . 2. All wiring to the unit must comply with NEC and local codes . 3. T ransformer is wired to 460-v BLK/RED lead f or 460-3-60 units . T rans- fo rmer is energy limiting or ma y have ci rcuit breaker . 4. FP1 thermistor provides lo w temperature protection f or wa[...]

16 WH S P-OPEN F S D Fig. 18 — Units wi th Complete C and WS HP Open Multiple Protocol Controls A50-8697 LEGEND BM — Blo wer Motor BR — Blow er Relay CO — Cond ensate Overflow FSD — Fire S mok e De tector LW T — Leaving Water T emperature N.C. — Normally Closed OA D — Outside Air Dam per OCC — Occupancy Input Contact RH — Relati[...]

17 W S HP-OPEN F S D Fig. 19 — Units with Deluxe D and WS HP O pen Multiple Protocol Controls A50-8698 LEGEND BM — Blo wer Motor BR — Blow er Rela y CO — Condensate Overflow FSD — Fire Smoke Detector LW T — Leaving W ater T e mperature N.C. — Normally Closed OA D — Ou tside Air Damper OCC — Occupancy Input Contact RH — Relative [...]

18 012207-1BT4 8 5BT LED1 DB In s t a ll BT4 8 5 where device i s loc a ted a t the end of network s egment only. + 24v a c (If not in s t a lled, it m us t b e connected to DO-5) DEHUMIDIFY OUTPUT CONTACT (DO-6) (FACTORY OPTION) FAN S PEED (DO-7) (MED OR LOW) OA DAMPER (AO-2) FAN S PEED (DO- 8 ) (HIGH OR FAN ON ) LWT (Inp u t 6) S AT (LAT) (Inp u [...]

19 Table 3 — 50PCH,PCV Uni t Electrical Data LEGEND *Units using 460-v and ECM (electr onically commutated motor), modulating HWR (hot water reheat), and /or internal secondary pump will require a neutral wire from the supply side in order to f eed accessory with 265-v . NO TES: 1. HACR circuit break er in U .S .A. only . 2. All fuses 3. Class RK[...]

20 Step 9 — Wire Field Contr ols THERMOST A T CONNECTIONS — Th e the rmo s t a t should be wired directly to th e Aquazone™ control board. See Fig. 13-20, and 22. W A TE R FREEZE PROTE CTION — The Aquazone control allows the field selection of source fluid freeze protection points through jumpers. The fact ory setting of jumper JW3 (FP1) is[...]

21 WS H P OP E N W I R IN G — The WSHP Open controller will be factory wired to the Complete C or Deluxe D control board, however , the system wiring will need to be completed utilizing WSHP Open controller wiring diagrams and the Third Party Integration (TPI) Guide. Factor y installation includes harness, L WT (leaving water temperature), supply[...]

22 W iring a Supply Air T emperature (SA T) Sensor — The SA T sensor is required for reheat applications. If the cable used to wire the SA T sensor to the controller will be less than 100 ft, an unshielded 22 A WG (American W ire Gage) cable should be used . If the cable will be greater than 100 ft, a shield 22 A WG cable should be used. The cabl[...]

23 Table 9 — 50PCH,PCV Blo wer Performance — Sta ndard Unit NO TES: 1. Shaded areas denote ES P (e xternal static pressure) where oper ation is not recommended. 2. Units fact ory shipped on medium speed. Other sp eeds require field selection. 3. All airflow is r ated and sho wn abov e at low est volt age if unit is dual v olt- age rated, i.e., [...]

24 FIELD SELECT ABLE 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. Complete C Control J umper Settings (Refer to Fig. 13 and 16) W A TER COIL FREEZE PROTECTION (FP1) LIMIT SETTING — Se le ct ju mpe r 3 , ( J W3 -FP 1 Lo w T emp ) t o choose FP1 [...]

25 Table 11 — DIP Switch Bloc k S2 — Accessory 1 Relay Option s LEGEND NO TE: All other DIP swi tch combinations are inv alid. Table 12 — DIP Switch Bloc k S2 — Accessory 2 Re lay Options LEGEND NO TE: All other switch combinations are in v alid. Auto Dehumidification Mode o r High Fan Mode — Switch 7 provides selection of auto dehu midif[...]

26 Table 13 — Operating Limits — 50PCH,PCV Units LEGEND Scr oll Compressor Rotation — It is important to be certain compressor is rotatin g in the proper direction. T o determine whether or not com pressor is rotating in th e prop- er direction: 1. Connect service gages to suction and disch arge p ressure fittings. 2. Energize the compressor [...]

27 Table 15 — 50PC006 Typical Uni t Operating Pressur es and Temperature s LEGEN D *Based on 15% Methanol anti freeze sol ution. Table 16 — 50PC009 Typical Unit Operating Pressures and Temperat ures LEGEN D *Based on 15% Methanol anti freeze sol ution. Table 17 — 50PC012 Typical Uni t Operating Pressur es and Temperature s LEGEN D *Based on 1[...]

28 Table 18 — 50PC015 Typical Uni t Operating Pressur es and Temperature s LEGEN D *Based on 15% Methanol anti freeze sol ution. Table 19 — 50PC018 Typical Uni t Operating Pressur es and Temperature s LEGEN D *Based on 15% Methanol anti freeze sol ution. Table 20 — 50PC024 Typical Uni t Operating Pressur es and Temperature s LEGEN D *Based on[...]

29 Table 21 — 50PC030 Typical Uni t Operating Pressur es and Temperature s LEGEN D *Based on 15% Methanol anti freeze sol ution. Table 22 — 50PC036 Typical Uni t Operating Pressur es and Temperature s LEGEN D *Based on 15% Methanol anti freeze sol ution. Table 23 — 50PC042 Typical Uni t Operating Pressur es and Temperature s LEGEND *Based on [...]

30 Table 24 — 50PC048 Typical Uni t Operating Pressur es and Temperature s LEGEN D *Based on 15% Methanol anti freeze sol ution. Table 25 — 50PC060 Typical Uni t Operating Pressur es and Temperature s LEGEN D *Based on 15% Methanol anti freeze sol ution. Unit Start-Up Heating Mode NOTE: Operate the unit in heating cycle after checking the cooli[...]

31 T o start-up a unit with WSHP Open controls: 1. T o plug in the BAC view 6 handheld display into a SPT sensor , point the two ears on the connector up and tilt the bottom of the plug toward you. Insert the plug up into the SPT sensor while pushing the bottom of the plug away from you. 2. BAC view 6 sh ould respond with "Establishing Connec-[...]

32 Flow Regulati on — Flow regulation can be accom- plished by two methods. Most wate r 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. See T able 26. Adjust the water control valve until the flow of 1.5 to 2 gpm is achieve d. Since the[...]

33 the water loop. If an open type cooling tower is used continu- ously , chemical treatment a nd filtering will be necessary . Table 27 — Approximate Fluid Volume (gal.) per 100 Ft of Pipe LEGEND NO TE: V olume of heat e xchanger is appro ximately 1.0 gallo n. Table 28 — Antifr eeze Percentages by Volume OPERA T ION Po w e r U p M o d e — Th[...]

34 optional CO 2 IAQ (indoor air quality) sensor mounted in the space can maximize the occupa nt comfort. The WSHP Open controller has its own hardware cl ock that is automatically set when the heat pump software is downloaded to the board. Oc- cupancy types are described in the scheduling section below . The following sections describe the functio[...]

35 of capacity . Likewise, a 45-second delay is used when staging down. After a compressor is staged off, it may be restarted again after a normal time-guard period of 5 minutes and if the supply-air temperature has increased above the minimum supply-air temperature limit. The WSHP Open controller provides a status input to moni- tor the compressor[...]

36 • The IAQ sensor reading is greater than the DCV start control set point . The control has four user adjustable set points: DCV start control set point, DCV maximum control set point, minimum damper position, and DCV maximum damper position. T wo-Position OA Damper — The control can be configured to operate a ventilation damper in a two-posi[...]

37 stage 2 followed by heating stage 2 then reduces capacity to heating stage 1. Operates for 1 minute per step. DE H U MI D I F I CA TI O N TE S T — T ests dehumidification mode. Operates for 2 minutes. AU X I L IA RY H EA T I N G T ES T — T ests auxiliary heat. Sequences fan on and enables heating coil for 1 minute. H 2 O ECONOMIZER TEST — [...]

38 Table 31 — Aquazone Deluxe D Co ntrol Current LED Status and Ala rm Relay Operations LEGEND NO TES: 1. If there is no f ault in memo ry , the F ault LED will flash code 1. 2. Codes will be displayed with a 10-second F ault LED pause . 3. Slow flash is 1 flash ev er y 2 seconds. 4. Fast fla sh is 2 flashes e very 1 second. 5. EXAMPLE: “Flashi[...]

39 Air Coil Cleaning — Remove dirt and debris from evap- orator coil as required by condition of the coil. A 10% solution of dishwasher deter gent and water is recommended for cleaning both sides of the coil, followed by a thorough water rinse. Clean coil with a stiff brush, vacuum cleaner , or com- pressed air . Use a fin comb of the correct too[...]

40 Air Coil Fan Motor Remo val Disconnect motor power wires from motor terminals before motor is removed from unit. 1. Shut off unit main power supp ly . 2. Loosen bolts on mounting bracket so that fan belt can be removed. 3. Loosen and remove the 2 motor mounting bracket bolts on left side of bracket. 4. Slide motor/bracket assembly to extreme rig[...]

41 Table 32 — Troubleshooting LEGEND RV — Re versing V alve F AUL T H EA TING COOLING POSSIBLE CAUSE SOLUTION Main P ower Pr oblems X X Green Statu s LED Off Check line voltage circuit breaker and disconnect. Check for line v oltage between L1 and L2 o n the contactor. Check f or 24 vac between R and C on controller . Check primar y/secondar y [...]

42 Table 32 — Troubleshooting ( cont) LEGEND RV — Re versing V alve F A UL T HEA TING COOLING POSSIBLE CA USE SOLUTION Only Compressor Runs X X Thermostat wir ing Check G wiring at heat pump. J umper G and R f or f an operation. Check Y and W wiring at heat pump. J umper Y and R for compressor oper- ation in test mode. X X F an motor relay Jump[...]

43 APPENDIX A — WSHP OPEN SCREEN CONFIGURA TION LEGEND SCREEN NAME POINT NAME PA S SWO R D LEVEL EDITABLE RANG E DEFAULT NOTES Equipment Status Operating Mode No P assword Required Off, F an Only , Economize, Cooling, Heating, Cont F an, T est, Start Delay , Dehumidify Display s unit operat ing mode SPT F Displays SPT SA T F Displa ys SA T Conden[...]

44 APPENDIX A — WSHP OPEN SCREEN CONFIGURATION (cont) LEGEND SCREEN NAME POINT NAME PA S S WO RD LEVEL EDITABLE RANGE D EFAULT NOTES Unit Maintenance Operating Mode No P assw ord required Off, F an Only ,Economize, Cooling, Heating, Cont F an, T est, Start Delay , Dehumidify Display s unit operat ing mode F an Oper ating Mode Auto /Continuou s/Al[...]

45 APPENDIX A — WSHP OPEN SCREEN CONFIGURATION (cont) LEGEND SCREEN NAME P OINT N AME PAS SW OR D LEVEL EDITABLE RANG E DEFAULT NOTES Configuration Set Points Occupied Heating User/Admin P assw ord le vel access X 40 - 90 F 72 F Defines the Occupied Heating Set P oint Occupied Cooling X 55 - 99 F 76 F Defines the Occu pied Cooling Set P oint Unoc[...]

46 APPENDIX A — WSHP SCREEN OPEN CONFIGURATION (cont) LEGEND SCREEN NAME POINT NAME PA S SWO R D LEVE L EDITABLE RANGE DEFAULT NOTES Configuration Unit Configuration F an Mode Admin P ass word lev el access only X Aut o/Continuous/ Always On Continuous Aut o= Intermittant operation during both occupied and unoccupied periods/ Continuou s = Interm[...]

47 APPENDIX A — WSHP SCREEN OPEN CONFIGURATION (cont) LEGEND SCREEN NAME POINT NAME PAS S WO RD LEVEL EDITABLE RANGE DEFAULT NOTES Configuration Service Configuration # of F an Speeds Admin P ass word lev el access only X 1,2 ,3 3 Used to set n umber of fan mot or speeds G Output T ype X F an On/F an Low F an On When set to F an On, G out put is [...]

48 APPENDIX A — WSHP SCREEN OPEN CONFIGURATION (cont) LEGEND SCREEN NAME POINT NAME PA S SWO R D LEVEL EDITABLE RANGE DEFAULT NOTES Configuration Alarm Configuration SPT Occupied Alarm Hysteresis Admin P assw ord lev el access only X2 - 2 0 F 5 F Defines the h ysteresis applied abo ve the cooling and belo w the heating set points bef ore an alarm[...]

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Manufacturer reserves the right to disco ntinue, or change at any time, specificatio ns or designs without notice and without inc urring obligations. Catalog No . 04-53500094-01 Printed in U .S.A. Form 50PC-3SI Pg 50 3-11 Replaces: 50PC-2SI Copy right 2011 Carrier Cor poration[...]

CL-1 50PCH,PCV ST A RT -UP CHECKLIST CUSTOMER: ___________________________ JOB NAME: _______________________________________ MODEL NO.:___________________________ SERIAL NO.:___________ _________ DA TE: _________ I. PRE-ST ART -UP DOES THE UNIT VOL T AGE CORRESPOND WI TH THE SUPPL Y VOL T AGE A V AILABLE? (Y/N) HA VE THE POWER AND CONTROL WIRING CO[...]

Manufacturer reserves the right to disco ntinue, or change at any time, specificatio ns or designs without notice and without inc urring obligations. Catalog No . 04-53500094-01 Printed in U. S.A. Form 50PC-3SI CL-2 5-11A 3-11 Replaces: 50PC-2SI Copy right 2011 Carrier Cor poration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -[...]