Carrier AQUAZONE 50HQP072 Installation And Service Instructions Manual Download

Page: 1 / 36

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53500077-01

Printed in U.S.A.

Form 50HQP-C1SI

Pg 1

11-10

Replaces: New

Installation, Start-Up, and

Service Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS

. . . . . . . . . . . . . . . . . . .1,2

GENERAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Step 1 — Check Jobsite

. . . . . . . . . . . . . . . . . . . . . . . . 2

Step 2 — Check Unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2

• STORAGE

• PROTECTION

• INSPECT UNIT

Step 3 — Locate Unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 4 — Mount Unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 5 — Install Duct System

. . . . . . . . . . . . . . . . . . . . . 5

• SOUND ATTENUATION

• EXISTING DUCT SYSTEM

Step 6 — Install Condensate Piping Drain

. . . . . . . . 6

• INSTALLATION

• VENTING

Step 7 — Field Convert Air Discharge

. . . . . . . . . . . . 6

Step 8 — Install Piping Connections

. . . . . . . . . . . . . 7

• WATER LOOP APPLICATIONS

• GROUND-LOOP APPLICATIONS

• GROUND-WATER APPLICATIONS

Step 9 — Install Field Power Supply Wiring

. . . . . . 8

• POWER CONNECTION

• SUPPLY VOLTAGE

• EXTERNAL LOOP POWER CONNECTION

• 420-VOLT OPERATION

Step 10 — Install Field Control Wiring

. . . . . . . . . . . 15

• THERMOSTAT CONNECTIONS

• WATER FREEZE PROTECTION

• AIR COIL FREEZE PROTECTION

• ACCESSORY CONNECTIONS

• WATER SOLENOID VALVES

PRE-START-UP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-20

System Checkout

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Airflow and External Static Pressure

. . . . . . . . . . . 16

FIELD SELECTABLE INPUTS

. . . . . . . . . . . . . . . 20-22

Complete C Control Jumper Settings

. . . . . . . . . . . 20

Complete C Control DIP Switches

. . . . . . . . . . . . . . 20

Deluxe D Control Jumper Settings

. . . . . . . . . . . . . 20

Deluxe D Control DIP Switches

. . . . . . . . . . . . . . . . 21

Deluxe D Control Accessory Relay

Configurations

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

START-UP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-24

Operating Limits

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Air Coil Cleaning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Start Up System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Scroll Compressor Rotation

. . . . . . . . . . . . . . . . . . . . . 22

Unit Start-Up in Cooling Mode

. . . . . . . . . . . . . . . . . . . 22

Unit Start-Up in Heating Mode

. . . . . . . . . . . . . . . . . . . 23

Flow Regulation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Flushing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Page

Antifreeze

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Cooling Tower/Boiler Systems

. . . . . . . . . . . . . . . . . . 24

Ground Coupled, Closed Loop and Plateframe

Heat Exchanger Well Systems

. . . . . . . . . . . . . . . . 24

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24,25

Power Up Mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Units with Aquazone Complete C Control

. . . . . . . 24

Units with Aquazone Deluxe D Control

. . . . . . . . . . 24

SYSTEM TEST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25,26

Test Mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Retry Mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Aquazone Deluxe D Control LED Indicators

. . . . . 25

SERVICE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-29

Filters

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Water Coil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Condensate Drain Pans

. . . . . . . . . . . . . . . . . . . . . . . . . 27

Refrigerant System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Condensate Drain Cleaning

. . . . . . . . . . . . . . . . . . . . . 27

Air Coil Cleaning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Condenser Cleaning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Compressor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fan Motors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Belt

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Air Coil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Checking System Charge

. . . . . . . . . . . . . . . . . . . . . . . 28

Refrigerant Charging

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Air Coil Fan Motor Removal

. . . . . . . . . . . . . . . . . . . . . 28

Blower Fan Sheaves

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Blower Fan Performance Adjustment

. . . . . . . . . . . 29

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . 30-32

Thermistor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Control Sensors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

START-UP CHECKLIST

. . . . . . . . . . . . . . . . . . . CL-1,CL-2

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can

be hazardous due to system pressure and electrical compo-

nents. Only trained and qualified service personnel should

install, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance func-

tions of cleaning coils and filters and replacing filters. All other

operations should be performed by trained service personnel.

When working on air-conditioning equipment, observe precau-

tions in the literature, tags and labels attached to the unit, and

other safety precautions that may apply.

Improper installation, adjustment, alteration, service, main-

tenance, or use can cause explosion, fire, electrical shock or

other conditions which may cause personal injury or property

damage. Consult a qualified installer, service agency, or your

distributor or branch for information or assistance. The

qualified installer or agency must use factory-authorized kits or

IMPORTANT: Read the entire instruction manual before

starting installation.

AQUAZONE™

50HQP072-120

Horizontal Water Source Heat Pumps

with PURON

Refrigerant (R-410A)

50 Hz

Summary of Contents for AQUAZONE 50HQP072

Page 1: ...and Plateframe Heat Exchanger Well Systems 24 OPERATION 24 25 Power Up Mode 24 Units with Aquazone Complete C Control 24 Units with Aquazone Deluxe D Control 24 SYSTEM TEST 25 26 Test Mode 25 Retry Mode 25 Aquazone Deluxe D Control LED Indicators 25 SERVICE 26 29 Filters 27 Water Coil 27 Condensate Drain Pans 27 Refrigerant System 27 Condensate Drain Cleaning 27 Air Coil Cleaning 27 Condenser Clea...

Page 2: ... eliminate sound in sensitive spaces 4 Check local codes to be sure a secondary drain pan is not required under the unit 5 Be sure unit is mounted at a height sufficient to provide an adequate slope of the condensate lines If an appropri ate slope cannot be achieved a field supplied condensate pump may be required 6 Provide sufficient space for duct connection 7 Provide adequate clearance for filt...

Page 3: ... Table 1 Physical Data 50HQP072 120 Units All units have grommet and spring compressor mountings and 2 2 mm and 3 5 mm electrical knockouts 51 mm filters are available as field installed accessory NOTE Use the lowest maximum pressure rating when multiple options are combined CAUTION DO NOT store or install units in corrosive environments or in locations subject to temperature or humidity extremes ...

Page 4: ...lable on either side of the unit Plugs are shipped loose in a plastic bag tied to the water leg in front of the unit Installer must plug unused connection 4 Condensate drain connection is on end opposite of comressor 5 Electrical access is available on either side of the front of the unit 6 Electrical box is on right side but can be field converted to left LEGEND BSP Blower Service Panel CAP Contr...

Page 5: ...support installed at the factory This must be removed before operating unit SOUND ATTENUATION To eliminate the transfer of vibration to the duct system a flexible connector is recom mended for both discharge and return air duct connections on metal duct systems The supply and return plenums should in clude internal duct liner of fiberglass or be made of duct board construction to maximize sound at...

Page 6: ...ay allow dirt or air to collect in the line Consider the following Always install a vent where an application requires a long horizontal run Always install a vent where large units are working against higher external static pressure and to allow proper drainage for multiple units connected to the same condensate main Be sure to support the line where anticipated sagging from the condensate or when...

Page 7: ...ng piping 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 Diele...

Page 8: ... including the electrical ground MUST comply with the National Electrical Code NEC U S A as well as applicable local codes In addition all field wiring must conform to the Class II temperature limitations de scribed in the NEC Refer to unit wiring diagrams Fig 12 16 for fuse sizes and a schematic of the field connections which must be made by the installing or electrical contractor Consult the uni...

Page 9: ...ock PB1 The maximum power handling is 4 amps at 240 volts The pumps will automatically cycle as required by the unit 420 VOLT OPERATION All 380 420 volt units are factory wired for 380 volts The transformers may be switched to 420 volt operation as illustrated on the wiring diagram by disconnecting the VIO lead at L1 and attaching the BRN lead to L1 Close open end of VIO lead Voltage Imbalance 100...

Page 10: ...ndirect HX use A monitoring plan should be implemented Ryznar Stability Index All N A 6 0 7 5 If 7 5 minimize steel pipe use Langelier Saturation Index All N A 0 5 to 0 5 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 Bacterial Iron Potential All N A 0 2 ppm Ferrous If Fe2 ferrous 0 2 ppm with pH 6 8 O2 5 ppm check for iron b...

Page 11: ...EEZE solutions cut JW3 jumper 5 Typical heat pump thermostat wiring shown Refer to thermostat installation instructions for wiring to the unit Thermostat wiring must be Class 1 and voltage rating equal to or greater than unit supply voltage 6 24 v alarm signal shown For dry alarm contact cut JW1 jumper and dry contact will be available between AL1 and AL2 7 Transformer secondary ground via Complet...

Page 12: ...12 Fig 13 50HQP072 120 Units Typical Control Wiring with Deluxe D Control See legend and notes on page 11 Deluxe D1 Deluxe D Deluxe D2 Deluxe D Deluxe D2 Deluxe D1 ...

Page 13: ...ig 14 Premierlink Controller Applications Wiring with Complete C Control LEGEND NOTE Reversing valve is on in Cooling mode CR Control Relay LWT Leaving Water Temperature Sensor SAT Supply Air Temperature Sensor SPT Space Temperature Sensor Fig 15 Premierlink Controller Applications Wiring with Deluxe D Control LEGEND NOTE Reversing valve is on in Cooling mode LWT Leaving Water Temperature Sensor S...

Page 14: ...LY QTY RLA LRA Total Comp FLA Comp MCA Comp Max Fuse Fan Motor FLA Fan MCA FAN MAX FUSE 072 9 380 420 3 50 360 440 A B C 2 5 4 38 0 10 8 12 2 15 1 8 2 3 15 096 9 380 420 3 50 360 440 A B C 2 6 1 43 0 12 2 13 7 15 3 4 4 3 15 120 9 380 420 3 50 360 440 A B C 2 7 8 51 5 15 6 17 6 25 4 9 6 1 15 FLA Full Load Amps HACR Heating Air Conditioning and Refrigeration LRA Locked Rotor Amps MCA Minimum Circuit...

Page 15: ...ontrol accessory devices such as water valves electronic air cleaners humidifiers etc This sig nal operates with the compressor terminal See Fig 19 Refer to the specific unit wiring schematic for details NOTE The A terminal should only be used with 24 volt signals not line voltage signals WATER SOLENOID VALVES Water solenoid valves may be used on variable flow systems and ground water installa tio...

Page 16: ...ring airflows at various ESP external static pressure condi tions See Tables 5 7 for unit airflows When fully closed the sheave will produce the highest static capability higher rpm To adjust sheave position follow the procedure outlined below 1 Loosen belt tension and remove belt 2 Loosen set screw on fan motor 3 Open sheave to desired position 4 Retighten set screw and replace belt NOTE Set belt...

Page 17: ...C C C RPM 531 583 635 680 720 765 800 835 870 900 925 950 Turns Open 2 4 5 3 5 2 5 1 5 5 4 3 5 2 5 2 1 5 1 850 BkW 0 15 0 18 0 21 0 24 0 26 0 29 0 31 0 34 0 36 0 39 0 42 0 45 Sheave Mtr B B A A A A C C C C C C RPM 500 547 599 645 690 735 775 815 850 885 910 940 Turns Open 3 1 5 4 3 2 1 5 4 3 2 5 2 1 5 897 BkW 0 18 0 21 0 23 0 27 0 30 0 33 0 36 0 40 0 43 0 46 0 49 0 52 Sheave Mtr B B A A A A C C C ...

Page 18: ... A A C C C C C C RPM 557 604 650 690 730 770 810 845 885 915 950 980 1010 1040 Turns Open 3 2 5 5 4 5 3 5 3 2 1 4 3 5 2 5 2 1 5 1 1133 BkW 0 34 0 37 0 41 0 44 0 47 0 51 0 56 0 60 0 64 0 67 0 71 0 74 0 78 Sheave Mtr B A A A A A A A C C C C C RPM 583 625 665 705 745 785 825 860 895 925 960 990 1020 Turns Open 2 5 6 5 4 3 5 2 5 1 5 1 4 3 2 5 2 1 1180 BkW 0 38 0 41 0 44 0 48 0 52 0 56 0 61 0 65 0 69 0...

Page 19: ... B B A A A A A A A C C C C C RPM 615 655 690 730 770 805 840 875 910 940 975 1005 1035 1065 1095 Turns Open 3 5 3 2 5 5 5 4 3 5 2 5 2 1 3 5 3 2 1 5 1 1274 BkW 0 44 0 47 0 51 0 55 0 59 0 63 0 67 0 71 0 75 0 79 0 84 0 88 0 93 0 97 Sheave Mtr B B B A A A A A A A C C C C RPM 635 670 710 750 785 820 855 885 920 950 985 1015 1045 1075 Turns Open 3 2 5 1 5 5 4 5 3 5 3 2 5 1 5 1 3 2 5 2 1 5 1322 BkW 0 47 ...

Page 20: ...d DIP SWITCH 5 DIP switch 5 is used to initiate 1 or 3 tries for the FP1 fault If water freeze protection for the water coil then DIP switch 5 can be set to lockout on the FP1 fault after one try Deluxe D Control Jumper Settings See Fig 13 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 ...

Page 21: ... in normal mode Switch 6 Not used Boilerless Operation Switch 7 provides selection of boil erless operation and works in conjunction with switch 8 In boilerless operation mode only the compressor is used for heating when FP1 is above the boilerless changeover tempera ture set by switch 8 below Select ON for normal operation or select OFF for boilerless operation Boilerless Changeover Temperature S...

Page 22: ... a minimum or maximum level the other two factors must be at a normal level to ensure proper unit operation See Table 10 Extreme variations in temperature and humidity and or corrosive water or air will adversely affect unit perfor mance reliability and service life Table 10 Operating Limits LEGEND Scroll Compressor Rotation It is important to be certain compressor is rotating in the proper direct...

Page 23: ...e the air which was bled from the system Check and adjust the water air level in the ex pansion tank 6 Set the boiler to raise the loop temperature to approxi mately 30 C Open a drain at the lowest point in the sys tem 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 o...

Page 24: ... The compressor will be off COOLING Y and O terminals are active in Cooling mode 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 NOTE On all subsequent compressor calls the random start delay is omitted HEATING STAGE 1 Terminal Y is acti...

Page 25: ...enter Test mode on Complete C or De luxe D controls cycle the fan 3 times within 60 seconds The LED light emitting diode will flash a code representing the last fault when entering the Test mode The alarm relay will also power on and off during Test mode See Tables 14 16 To exit Test mode short the terminals for 3 seconds or cycle the power 3 times within 60 seconds NOTE The Deluxe D control has a...

Page 26: ...al Mode with PM On Off Flashing Code 8 Cycle closed 5 sec open 25 sec Deluxe D Control is non functional Off Off Off Open Test Mode On Flash Last Fault Code in Memory Cycling Appropriate Code Night Setback Flashing Code 2 Flash Last Fault Code in Memory ESD Flashing Code 3 Flash Last Fault Code in Memory Invalid T stat Inputs Flashing Code 4 Flash Last Fault Code in Memory No Fault in Memory On Of...

Page 27: ... service gages unless unit operation appears abnormal Condensate Drain Cleaning Clean the drain line and unit drain pan at the start of each cooling season Check flow by pouring water into drain Be sure trap is filled to main tain an air seal Air Coil Cleaning Remove dirt and debris from evap orator coil as required by condition of the coil Clean coil with a stiff brush vacuum cleaner or compresse...

Page 28: ...een fan scroll and side frame Rest motor on a high platform such as a step ladder Do not allow motor to hang by its power wires Blower Fan Sheaves Factory supplied drives are pre aligned and tensioned however it is recommended that the belt tension and alignment be checked before starting the unit Always check the drive alignment after adjusting belt tension Sheave and belt information is shown in...

Page 29: ... loosen the top hex nut To decrease the belt tension loosen the bottom hex nut 5 Turn the bolts by hand to the desired position then tighten the 5 16 in hex nuts 2 per bolt 6 Lower the motor assembly 7 Install the belt 8 Tension the belt per section below 9 Restore power to the unit BELT TENSION ADJUSTMENT Using a gage apply 4 lb of force to the center of the belt and adjust the tension until a de...

Page 30: ...sure FP1 is located in the discharge fluid and FP2 is located in the air discharge See Fig 27 Fig 26 Thermistor Nominal Resistance 0 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 0 17 7 6 6 4 4 15 6 26 7 37 8 48 9 60 0 Temperature C Resistance kOhm a50 8163 LEGEND Fig 27 FP1 and FP2 Thermistor Location COAX Coaxial Heat Exchanger Airflow Refrigerant Liquid Line Flow SUCTION COMPRESSOR DISCHARGE COA...

Page 31: ...r replace Check fan motor operation and airflow restrictions High external static Check duct design and downstream interference X Air temperature out of range Too much cold vent air Bring entering air temperature within design parameters X Improper freeze protect set ting 1 1 C vs 12 2 C Normal airside applications will require 1 1 C only X X Bad thermistor Check temperature and impedance correlat...

Page 32: ...ensible cooling load and heat pump capacity X X Scaling in water heat exchanger Perform scaling check and clean if necessary X X Inlet water too hot or cold Check load loop sizing loop backfill ground moisture High Head Pressure X Reduced or no airflow in heating Check for dirty air filter and clean or replace Check fan motor operation and airflow restrictions High external static Check duct desig...

Page 33: ......

Page 34: ...t to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53500077 01 Printed in U S A Form 50HQP C1SI Pg 34 11 10 Replaces New Copyright 2010 Carrier Corporation ...

Page 35: ...TION 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 PHASE CA VOLTS if 3 phase if 3 phase PHASE AB AMPS PHASE BC AMPS PHASE CA AMPS if 3 phase if 3 phase CONTROL VOLTAGE IS CON...

Page 36: ...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 SUCTION COMPRESSOR DISCHARGE COAX EXPANSION VALVE C C AIR COIL C kPa WATER OUT WATER IN C kPa LOOK UP PRESSURE DROP IN TABLE 8 TO DETERMINE FLOW RATE C LIQUID LINE kPa C DEW POINT LOOK UP PRESSURE DROP IN TABLE 11 TO DE...

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