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Carrier Aquazone 50PSW025, Installation, Start-Up And Service Instructions Manual

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Carrier Aquazone 50PSW025 Installation, Start-Up And Service Instructions Manual Download Page 1

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

Catalog No. 04-53500145-01

Printed in U.S.A.

Form 50PSW-4SI

Pg 1 

11-21

Replaces: 50PSW-3SI

Installation, Start-Up, and

Service Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS   . . . . . . . . . . . . . . . . . . . 1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1 — 

Check Jobsite  . . . . . . . . . . . . . . . . . . . . . . . 2

Step 2 — 

Check Unit  . . . . . . . . . . . . . . . . . . . . . . . . . . 3

• STORAGE

• PROTECTION

• INSPECT UNIT

Step 3 — 

Locate Unit   . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 4 — 

Mount Unit  . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 5 — 

Connect Piping  . . . . . . . . . . . . . . . . . . . . . . 8

• WATER SUPPLY AND QUALITY

• COOLING TOWER/BOILER APPLICATION

• WELL WATER SYSTEMS

• EARTH COUPLED GEOTHERMAL SYSTEMS

Step 6 — 

Wire Field Power Supply  . . . . . . . . . . . . . 13

PRE-START-UP  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
System Checkout   . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Step 7 — 

Wire Control Connections  . . . . . . . . . . . . 23

• COMPLETE C AND DELUXE D CONTROL

• AUXILIARY RELAY (DELUXE D ONLY)

• ENERGY MANAGEMENT SWITCH (DELUXE D 

ONLY)

• PHASE MONITOR

• ALARM OUTPUT

• W2W OPEN CONTROL

• CONTROL TRANSFORMER

Step 8 — 

Configure Unit Control Components   . . . 23

• UPM CONFIGURATION

• UPM FEATURES

• CONSIDERATIONS

START-UP   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Unit Start-Up   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operating Limits  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

• ENVIRONMENT

• POWER SUPPLY

Scroll Compressor Rotation   . . . . . . . . . . . . . . . . . . 26
Cleaning and Flushing  . . . . . . . . . . . . . . . . . . . . . . . 27
Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

• FREEZE PROTECTION

System Flow   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

• FLOW VERIFICATION

• FLOW REGULATION

Cooling Tower/Boiler Systems   . . . . . . . . . . . . . . . . 28
Ground Coupled, Closed Loop and Plateframe Heat 

Exchanger Well Systems  . . . . . . . . . . . . . . . . . . . 28

OPERATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Power Up Mode   . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Unit Protection Model (UPM)   . . . . . . . . . . . . . . . . . .31
Units with Complete C or Deluxe Controls  . . . . . . .31

• COOLING MODE

• HEATING MODE

Units with W2W Open Controls   . . . . . . . . . . . . . . . .31
SEQUENCE OF OPERATION   . . . . . . . . . . . . . . . . . .31
WSHP Open W2W   . . . . . . . . . . . . . . . . . . . . . . . . . . .31

• OCCUPANCY

• BAS (BUILDING AUTOMATION SYSTEM) ON/OFF

• REMOTE OCCUPANCY CONTACT

• SHUTDOWN

• POWER FAIL RESTART DELAY

• CHANGEOVER TIMEGUARD

• LOAD PUMP

• SOURCE WATER ISOLATION VALVE/SOURCE 

WATER PUMP OUTPUT

• COOLING (SINGLE MODULE)

• ADDITIONAL COOLING FUNCTIONS

• COOLING CONTROL MODES

• HEATING (SINGLE MODULE)

• ADDITIONAL HEATING FUNCTIONS

• HEATING CONTROL MODES

• MUTLI-UNIT MASTER

• EQUIPMENT ALARM

• SERVICE TEST

Configuring Multiple W2W WSHP for 

Master/Slave Operation . . . . . . . . . . . . . . . . . . . . .38

• W2W MASTER CONFIGURATION PARAMETERS

• W2W SLAVE CONFIGURATION

SERVICE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Water Coil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Refrigerant System  . . . . . . . . . . . . . . . . . . . . . . . . . .40
Condenser Cleaning  . . . . . . . . . . . . . . . . . . . . . . . . .40

• GRAVITY FLOW METHOD

• FORCED CIRCULATION METHOD

Checking System Charge  . . . . . . . . . . . . . . . . . . . . .41
Refrigerant Charging  . . . . . . . . . . . . . . . . . . . . . . . . .41
TROUBLESHOOTING   . . . . . . . . . . . . . . . . . . . . . . . .41
50PSW START-UP CHECKLIST. . . . . . . . . . . . .    CL-1

SAFETY CONSIDERATIONS

Installation  and  servicing  of  air-conditioning  equipment  can  be

hazardous due to system pressure and electrical components. Only

trained and qualified service personnel should  install, repair,  or

service air-conditioning equipment.

IMPORTANT:  Read  the  entire  instruction  manual  before

starting installation.

Aquazone

™

50PSW025-420

Water-to-Water Source Heat Pump

with Puron

®

 

Refrigerant (R-410A)

Summary of Contents for Aquazone 50PSW025

Page 1: ...nd Coupled Closed Loop and Plateframe Heat Exchanger Well Systems 28 OPERATION 31 Power Up Mode 31 Unit Protection Model UPM 31 Units with Complete C or Deluxe Controls 31 COOLING MODE HEATING MODE Units with W2W Open Controls 31 SEQUENCE OF OPERATION 31 WSHP Open W2W 31 OCCUPANCY BAS BUILDING AUTOMATION SYSTEM ON OFF REMOTE OCCUPANCY CONTACT SHUTDOWN POWER FAIL RESTART DELAY CHANGEOVER TIMEGUARD ...

Page 2: ...l disconnect locations to alert others not to restore power until work is completed WARNING DO NOT USE TORCH to remove any component System contains oil and refrigerant under pressure To remove a component wear protective gloves and goggles and proceed as follows a Shut off electrical power to unit b Recover refrigerant to relieve all pressure from system using both high pressure and low pressure ...

Page 3: ...panels is limited pre removal of the control box side mounting screws may be necessary for future servicing STORAGE If the equipment is not needed for immediate installation upon its arrival at the jobsite it should be left in its shipping carton and stored in a clean dry area of the building or in a warehouse Units must be stored in an upright position at all times If carton stacking is necessary...

Page 4: ... 2 55 15 70 2 55 7 15 11 00 4 25 6 55 8 05 9 55 1 25 3 4 1 2 049 2 30 2 60 14 30 2 65 3 70 2 65 15 70 2 65 7 15 11 00 4 25 6 55 8 05 9 55 1 25 1 1 2 061 2 30 2 60 14 30 2 65 3 20 2 65 15 20 2 65 7 15 11 00 4 25 6 55 8 05 9 55 1 25 1 1 2 071 2 50 2 60 21 75 4 45 2 50 2 45 21 75 2 65 7 15 11 00 4 25 6 55 8 05 9 55 1 25 1 1 2 HRP Heat Recovery Package UNIT SIZE DIMENSIONS INCHES WATER CONN FPT A B C ...

Page 5: ...Front Left Side Electrical Connections UNIT SIZE DIMENSIONS INCHES WATER CONN FPT A B C D E F G H J K L M 240 70 00 44 00 8 50 24 50 10 50 49 00 17 50 30 00 20 50 3 50 46 00 28 00 2 360 70 00 44 00 4 50 24 50 10 50 49 00 17 50 30 00 23 50 3 50 46 00 28 00 2 420 70 00 44 00 4 50 24 50 10 50 49 00 17 50 30 00 23 50 3 50 46 00 28 00 2 ...

Page 6: ...Top View Access on this side of the unit is required for piping and insulation No access panels are located on this side Water Connections Qty 2 for the source and qty 2 for the load d a o L e c r u o S Source Side Load Side p o t X H l a i x a o C p o t X H l a i x a o C and bottom and bottom No access is required on this s i s s e c c a o N e d i s required on this side Rev Valves top and bottom...

Page 7: ...bration isolators Compressors are internally spring mounted 7 Locate and verify any accessory kit located in compressor section 8 Remove any access panel screws that may be difficult to remove once unit is installed 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 c...

Page 8: ...n cooling tower may also be used It is imperative that all air is eliminated from the closed loop side of the heat exchanger to prevent condenser fouling See Fig 5 In the heating mode heat is absorbed from the condenser water loop to the unit A boiler can be utilized to maintain the loop within the proper temperature range In milder climates a flooded tower concept is often used This concept invol...

Page 9: ...trical connection locations vary depending on model Connect as required per unit labels 1 Ball Valves 2 Hose Kits 3 P T Plugs 4 Load Side Connections 5 Low Voltage Control Connection 6 Vibration Pad 7 Line Voltage Disconnect 8 Supply and Return Lines of Central System ...

Page 10: ...ater and electrical connection locations vary depending on model Connect as required per unit labels 1 Pressure Tank 2 Ball Valves 3 Solenoid Valve Slow Closing 4 Hose Kit 5 P T Kit 6 Load Side Connections 7 Low Voltage Control Connection 8 Vibration Pad 9 Line Voltage Disconnect ...

Page 11: ...ocations vary depending on model Connect as required per unit labels 1 Polybutylene or Polyethelene with Insulation 2 Ground Loop Pumping Package GLP 3 Ground Loop Connection Kit 4 P T Plugs 5 Load Side Connections 6 Low Voltage Control Connection 7 Vibration Pad 8 Line Voltage Disconnect ...

Page 12: ... 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 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 ...

Page 13: ...t in equipment damage 50PSW UNIT SIZE VOLTAGE V Ph Hz COMPRESSOR MCA MAX FUSE QTY RLA LRA 025 208 230 1 60 1 11 7 58 3 14 6 25 265 1 60 1 9 1 54 0 11 4 20 208 230 3 60 1 6 5 55 4 8 1 15 035 208 230 1 60 1 15 3 83 0 19 1 30 265 1 60 1 13 0 72 0 16 3 25 208 230 3 60 1 11 6 73 0 11 6 25 460 3 60 1 5 7 38 0 7 1 15 049 208 230 1 60 1 21 2 104 0 26 5 45 208 230 3 60 1 14 0 83 1 17 5 30 460 3 60 1 6 4 41...

Page 14: ...ase Complete C Deluxe D Control Package UPM STATUS LED BLINK CODES 1 HIGH PRESSURE FAULT 2 LOW PRESSURE FAULT 3 CONDENSER FREEZE CONDITION 4 CONDENSATE OVERFLOW FAULT 5 BROWN OUT FAULT 6 LOAD FREEZE CONDITION DWG No 50PSW111000 Rev 3 ...

Page 15: ...15 Fig 9 Unit Size 122 1 Phase Complete C Deluxe D Control Package DWG No 50PSW120000 Rev 3 ...

Page 16: ...1 1 Phase W2W Open Control Package UPM STATUS LED BLINK CODES 1 HIGH PRESSURE FAULT 2 LOW PRESSURE FAULT 3 CONDENSER FREEZE CONDITION 4 CONDENSATE OVERFLOW FAULT 5 BROWN OUT FAULT 6 LOAD FREEZE CONDITION DWG No 50PSW110001 Rev 3 ...

Page 17: ...17 Fig 11 Unit Sizes 122 1 Phase W2W Open Control Package DWG No 50PSW120001 Rev 4 ...

Page 18: ...hase Complete C Deluxe D Control Package UPM STATUS LED BLINK CODES 1 HIGH PRESSURE FAULT 2 LOW PRESSURE FAULT 3 CONDENSER FREEZE CONDITION 4 CONDENSATE OVERFLOW FAULT 5 BROWN OUT FAULT 6 EVAPORATOR FREEZE CONDITION DWG No 50PSW310000 Rev 3 ...

Page 19: ...19 Fig 13 Unit Size 122 240 420 3 Phase Complete C Deluxe D Control Package DWG No 50PSW320000 Rev 3 ...

Page 20: ...10 3 Phase W2W Open Control Package UPM STATUS LED BLINK CODES 1 HIGH PRESSURE FAULT 2 LOW PRESSURE FAULT 3 CONDENSER FREEZE CONDITION 4 CONDENSATE OVERFLOW FAULT 5 BROWN OUT FAULT 6 EVAPORATOR FREEZE CONDITION DWG No 50PSW310001 Rev 2 ...

Page 21: ...21 Fig 15 Unit Size 122 240 420 3 Phase W2W Open Control Package DWG No 50PSW320001 Rev 3 ...

Page 22: ...ONITOR RELAY FIELD WIRED COMPONENTS J1 9 CAN BE USED TO CONNECT WATER FLOW SWITCH FIRE ALARM AND OR PHASE MONITOR OPTIONS OPTIONAL COMPONENTS CMR2 COMPRESSOR MONITOR RELAY TWO STAGE UNITS 1 2 CMR 2 CONNECTOR WILL BE INCLUDED ON ALL W2W HARNESSES BUT ONLY NEEDS TO BE CONNECTED TO CMR2 ON TWO STAGE UNITS THAT HAVE 2 CMR S 2 OPTIONAL FIELD CONTROL COMPONENTS AL ALARM LIGHT OATS OUTSIDE AIR TEMPERATUR...

Page 23: ...eted at the W2W Open control board See the applicable wiring diagrams within this document for details For further instructions on W2W Open please visit HVACPartners com or Carrier com for the W2W Open Integration Guide and Points Properties Guide CONTROL TRANSFORMER All units include a 75VA transformer The VA capacity of the transformer should be considered when applying low voltage accessories s...

Page 24: ...ay Connection 9 24VAC Power Unit 10 Compressor Contact Output 11 High Pressure Switch Connection 12 Call for Compressor Y1 13 Low Pressure Switch Connection 14 24VAC Power Common 15 Condensate overflow Sensor not applicable on 50PSW 16 Dry Contact 17 UPM Ground Standoff Freeze Protection Sensor NUMBER ITEM 1 Power LED Indicator 2 Status LED Indicator 3 Source Freeze 1 Protection Temperature Select...

Page 25: ... dual tapped for 208 and 230 volts Connect the appropriate tap to ensure a minimum of 18 volts secondary control voltage 24 volts is ideal for best operation 2 Long length thermostat and control wiring leads may create voltage drop Increasing wire gauge or up size transformers may be required to ensure minimum secondary voltage supply 3 Carrier recommends the following guidelines for wiring betwee...

Page 26: ...AD EVAP TEMP F ENTERING SOURCE CONDENSER TEMPERATURE F 75 F 85 F 95 F SUCTION PRESSURE DISCHARGE PRESSURE SUCTION PRESSURE DISCHARGE PRESSURE SUCTION PRESSURE DISCHARGE PRESSURE 65 99 116 290 320 107 123 325 358 107 123 370 400 55 91 107 265 311 91 107 303 350 99 116 370 400 45 76 91 265 311 76 91 295 345 83 99 358 390 ENTERING LOAD TEMP F ENTERING SOURCE CONDENSER TEMPERATURE F 40 F 60 F 80 F SUC...

Page 27: ...Alcohols and glycols are commonly used as antifreeze agents Freeze protection should be maintained to 15 F below the lowest expected entering loop temperature For example if the lowest expected entering loop temperature is 30 F the leaving loop temperature would be 22 F to 25 F Therefore the freeze protection should be at 15 F 30 F 15 F 15 F Calculate the total volume of fluid in the piping system...

Page 28: ...ol valve These valves feature a removable cartridge that controls the maximum flow through the valve assembly Verify that the water flow control cartridge matches the application flow requirement See Fig 20 and 21 Cooling Tower Boiler Systems These systems typically use a common loop maintained at 60 F to 90 F The use of a closed circuit evaporative cooling tower with a secondary heat exchanger be...

Page 29: ... 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Pressure Drop PSIG GPM Water Side Pressure Drop 50PSW025 071 LEGEND Load Side 55F Source Side 85F 50PSW025 Load Side 50PSW025 Source Side 50PSW035 Load Side 50PSW035 Source Side 50PSW049 Load Side 50PSW049 Source Side 50PSW061 Load Side 50PSW061 Source Side 50PSW071 Load Side 50PSW071 Source Side ...

Page 30: ...4 58 62 66 70 74 78 82 86 90 Pressure Drop PSIG GPM Water Side Pressure Drop 50PSW120 420 LEGEND Load Side 55F Source Side 85F 50PSW122 Load Side 50PSW122 Source Side 50PSW180 Load Side 50PSW180 Source Side 50PSW210 Load Side 50PSW210 Source Side 50PSW240 Load Side 50PSW240 Source Side 50PSW360 Load Side 50PSW360 Source Side 50PSW420 Load Side 50PSW420 Source Side ...

Page 31: ...ecedence over all others No special configuration is necessary to utilize this function Object address information is also described in the W2W Integration Guide REMOTE OCCUPANCY CONTACT The W2W has the capability to utilize an external dry contact closure to determine the occupancy status of the unit The external contact may be normally closed or normally opened Assuming a normally open contact t...

Page 32: ... both user configurable This feature can provide energy savings by operating the unit at a higher load water temperature setpoint when the minimum chilled water temperature is not required It also can be used to better match the chilled water temperature to the cooling load requirements The following conditions must be true in order for the Cooling Setpoint OAReset algorithm to run The preconditio...

Page 33: ...peration The W2W control will operate up to four stages of compression to maintain the desired hot water supply setpoint The control point can be selected by setting the Control Type to either the leaving water temperature sensor default or the entering water temperature sensor While in the heating mode the compressor outputs are controlled by the PI Proportional integral heating loop and heating ...

Page 34: ...SPT to the configured lockout temperatures for heating and cooling and select the appropriate operating mode A valid space temperature reading hardware or network is required for this mode Once enabled equipment control is as described for heating and cooling When conditions require heating the module will operate as described in the Heating section The Outdoor Air Hot Water Supply setpoint reset ...

Page 35: ...he Isolation Valve Test energizes the controls Isolation Valve Binary Output 2 The Water Pump Test energizes the controls Water Pump Binary Output 3 The Compressor Test energizes the controls Compressor Binary Outputs 4 The Alarm Indicator Test energizes the controls Alarm Indicator Binary Output Invoking the Service Test function will disable normal equipment operation Service Test will operate i...

Page 36: ...36 Fig 22 W2W Open Control Board ...

Page 37: ...37 Fig 23 Unit Protection Module UPM Sequence Of Operation ...

Page 38: ... Control Pro gram Configuration Service Configuration Operation Type Multi unit Master default value is Single Slave Unit Total Controlled Stages 1 8 this variable is the total number of stages of all W2W units to be linked into one single system Control Mode Selection For two pipe systems Manual Heat or Manual Cool four pipe systems SPT OAT or System T1Temp Refrigerant Circuits Configure for the ...

Page 39: ...39 Fig 24 W2W Master Configuration Parameters Unit Configurations Fig 25 W2W Master Configuration Parameters Setpoints Fig 26 W2W Master Configuration Parameter Service Configuration ...

Page 40: ... 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 27 Fig 27 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 28 Regulate flow to condenser with a supp...

Page 41: ...ure Refrigerant Charging NOTE Do not vent or depressurize unit refrigerant to atmosphere Remove and recover refrigerant following accepted practices TROUBLESHOOTING When troubleshooting problems arise with a WSHP refer to Table 11 for fault codes See Table 12 for troubleshooting solu tions The UPM on each unit includes an alarm indicator with blink codes to indicate UPM fault Table 11 Fault Codes ...

Page 42: ...ure too warm Scaled or plugged condenser In HEATING mode LOAD COIL Lack of or inadequate water flow Entering water temperature too warm Scaled or plugged load coil Refrigerant Charge The unit is overcharged with refrigerant Recover refrigerant evacuate and recharge with factory recommended charge High pressure Switch Check for defective or improperly calibrated high pressure switch UNIT OFF ON LOW...

Page 43: ... 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 ATRAP 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 ...

Page 44: ...n Temperature 2b Superheat 3 Discharge Temperature 4 Discharge Pressure 4a Saturation Temperature 4b Subcooling 5 Liquid Line Temperature 6 Source Water In Temperature 7 Source Water Out Temperature Temperature Difference 8 Source Water In Pressure 9 Source Water Out Pressure 9a Pressure Drop 9b Flow Rate gpm 10 Load Water In Temperature 11 Load Water Out Temperature Temperature Difference 12 Load...

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