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Carrier Aquazone 50PSV Installation Instructions PDF
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Summary of Content for Carrier Aquazone 50PSV Installation Instructions PDF
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500133-01 Printed in U.S.A. Form 50PS-5SI Pg 1 119 6-14 Replaces: NEW
Installation, Start-Up, and Service Instructions
CONTENTS Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . 1,2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Step 1 Check Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Step 2 Check Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 STORAGE PROTECTION INSPECT UNIT Step 3 Locate Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Step 4 Mount the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 VERTICAL UNITS HORIZONTAL UNIT Step 5 Check Duct System . . . . . . . . . . . . . . . . . . . . . . 6 Step 6 Install Condensate Drain . . . . . . . . . . . . . . . . . 7 Step 7 Pipe Connections . . . . . . . . . . . . . . . . . . . . . . . . 7 WATER LOOP APPLICATIONS GROUND-WATER APPLICATIONS GROUND-LOOP APPLICATIONS INSTALLATION OF SUPPLY AND RETURN HOSE
KIT Step 8 Wire Field Power Supply . . . . . . . . . . . . . . . . 10 Step 9 Wire Field Controls . . . . . . . . . . . . . . . . . . . . . 25 THERMOSTAT CONNECTIONS SAFETY DEVICES AND C BOARD CONTROLLER CONSIDERATIONS Operate ECM Interface Board . . . . . . . . . . . . . . . . . . . . . 27 PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-31 Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Scroll Compressor Rotation . . . . . . . . . . . . . . . . . . . . . . 29 Unit Start-Up Cooling Mode . . . . . . . . . . . . . . . . . . . . . . . 29 Unit Start-Up Heating Mode . . . . . . . . . . . . . . . . . . . . . . . 29 Flow Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Antifreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Cooling Tower/Boiler Systems . . . . . . . . . . . . . . . . . . . . 30 Ground Coupled, Closed Loop and Plateframe
Heat Exchanger Well Systems . . . . . . . . . . . . . . . . . . 31 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-32 Cooling Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Heating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Power Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Units with Aquazone Complete C Control . . . . . . . . . 31 Units with Aquazone Deluxe D Control . . . . . . . . . . . 31 Units with Hot Gas Reheat Option . . . . . . . . . . . . . . . . 31 Sequence of Operation - On/Off Control . . . . . . . . . . . 31 COMPLETE C AND DELUXE D BOARD
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Retry Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 LED Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Complete C Board Default Settings . . . . . . . . . . . . . . . 32
Page SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-34 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Water Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Condensate Drain Pans . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Refrigerant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Condensate Drain Cleaning . . . . . . . . . . . . . . . . . . . . . . .33 Air Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Condenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Checking System Charge . . . . . . . . . . . . . . . . . . . . . . . . .33 Refrigerant Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Air Coil Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . . .34 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .34-37 Control Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Thermostatic Expansion Valves . . . . . . . . . . . . . . . . . . .34 Moisture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 50PSH,PSV 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 such as cleaning coils and filters and replacing filters. All other operations should be performed by trained service per- sonnel. When working on air-conditioning 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 a local 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) 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.
IMPORTANT: Read the entire instruction manual before starting installation.
Aquazone
50PSH, PSV007-070 Single-Stage Water Source Heat Pumps
with Puron Refrigerant (R-410A)
2
WARNING signifies hazards that could result in personal inju- ry or death. CAUTION is used to identify unsafe practices, which would result in minor personal injury or product and property damage.
Recognize safety information. This is the safety-alert symbol ( ). When this symbol is displayed on the unit and in instructions or manuals, be alert to the potential for personal injury.
GENERAL This installation and start-up instructions literature is for
Aquazone single-stage water source heat pump systems. Water source heat pumps (WSHPs) are single-package hori-
zontally and vertically mounted units with electronic controls designed for year-round cooling and heating.
INSTALLATION
Step 1 Check Jobsite Installation, operation and maintenance instructions are provided with each unit. Before unit start-up, read all manuals and become familiar with the unit and its operation. Thoroughly check out the system before operation. Complete the inspections and instructions listed below to prepare a unit for installation. See Table 1 for unit physical data.
HORIZONTAL UNIT (50PSH) Horizontal units are design- ed for indoor installation only. Be sure to allow adequate space around the unit for servicing. See Fig. 1 for overall unit dimen- sions. VERTICAL UNITS (50PSV) Vertical units are designed for indoor installation only. While vertical units are typically installed in a floor-level closet or a small mechanical room, the unit access guidelines for these units are very similar to those described for horizontal units. See Fig. 2 for overall dimen- sions.
Step 2 Check Unit Upon receipt of shipment at the jobsite, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the car- ton or crating of each unit, and inspect each unit for damage.
Ensure the shipping company makes proper notation of any shortages or damage on all copies of the freight bill. Concealed damage not discovered during unloading must be reported to the shipping company within 15 days of receipt of shipment.
NOTE: It is the responsibility of the purchaser to file all neces- sary claims with the shipping company. 1. Be sure that the location chosen for unit installation pro-
vides ambient temperatures maintained above freezing. 2. Be sure the installation location is isolated from sleeping
areas, private offices and other acoustically sensitive spaces.
3. Be sure the unit is mounted at a height sufficient to pro- vide an adequate slope of the condensate lines. If an ap- propriate slope cannot be achieved, a field-supplied con- densate pump may be required.
4. On horizontal units, allow adequate room below the unit for condensate drain trap and do not locate the unit above supply piping.
5. Provide sufficient space for duct connection. Do not al- low the weight of the ductwork to rest on the unit.
6. Provide adequate clearance for filter replacement and drain pan cleaning. Do not allow piping, conduit, etc. to block filter access.
7. Provide sufficient access to allow maintenance and servicing of the fan and fan motor, compressor and coils. Removal of the entire unit from the closet should not be necessary.
8. Provide an unobstructed path to the unit within the closet or mechanical room. Space should be sufficient to allow return air to freely enter the space.
9. Provide ready access to water valves and fittings, and screwdriver access to unit side panels, discharge collar, and all electrical connections.
10. Where access to side 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 job site, it should be left in its shipping carton and stored in a clean, dry area. Units must only be stored or moved in the normal upright position as indicated by the UP arrows on each carton at all times. If unit stacking is required, stack units as follows: vertical units less than 6 tons, no more than two high; horizontal units less than 6 tons, no more than three high. Do not stack units larger than 6 tons. PROTECTION Once the units are properly positioned on the jobsite, cover them with either a shipping carton, vinyl film, 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 require costly clean-up operations.
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.
WARNING
Electrical shock can cause personal injury or death. Before installing or servicing system, always turn off main power to system. There may be more than one disconnect switch. Turn off accessory heater power if applicable.
IMPORTANT: The installation of water source heat pump units and all associated components, parts, and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and MUST conform to all applicable codes. It is the responsi- bility of the installing contractor to determine and comply with ALL applicable codes and regulations.
IMPORTANT: This equipment is designed for indoor installation ONLY. Extreme variations in temperature, humidity and corrosive water or air will adversely affect the unit performance, reliability and service life.
CAUTION
To avoid equipment damage, do not use these units as a source of heating or cooling during the construction pro- cess. The mechanical components and filters used in these units quickly becomes clogged with construction dirt and debris which may cause system damage.
CAUTION
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.
3
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. Do not remove the packaging until the unit is ready for installation.
3. Verify that the units refrigerant tubing is free of kinks or dents, and that it does not touch other unit components.
4. Inspect all electrical connections. Be sure connections are clean and tight at their terminations.
5. Loosen compressor bolts until the compressor rides freely on springs. Remove shipping restraints.
6. Remove the shipping bolts from compressor support plate to maximize vibration and sound alternation.
7. Remove any blower support cardboard from inlet of the blower.
Step 3 Locate Unit Locate the unit in an indoor area that allows easy removal of the filter and access panels, and has enough room for service personnel to perform mainte- nance or repair. Provide sufficient room to make fluid, electri- cal, and duct connection(s). If the unit is located in a confined space such as a closet, provisions must be made for return air to freely enter the space. On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping. These units are not approved for outdoor installation; therefore, they must be installed inside the structure being conditioned. Do not locate units in areas that are subject to freezing.
Table 1 Physical Data 50PSH, PSV 007-070 Units
LEGEND
CAUTION
Failure to remove shipping brackets from spring-mounted compressors will cause excessive noise and could cause component failure due to added vibration.
50PS UNIT SIZE 007 009 012 015 018 024 030 036 042 048 060 070
Compressor Type Rotary Rotary Rotary Rotary Rotary Scroll Scroll Scroll Scroll Scroll Scroll Scroll
Maximum Water Working Pressure (psig/kPa)
400/ 3100
400/ 3100
400/ 3100
400/ 3100
400/ 3100
400/ 3100
400/ 3100
400/ 3100
400/ 3100
400/ 3100
400/ 3100
400/ 3100
STANDARD FAN MOTOR AND BLOWER
Fan Motor Type/Speeds PSC/3 Const Torque/3-Speed
Fan Motor (hp) 1/10 1/10 1/10 1/3 1/3 1/2* / 1/3 1/2 3/4 3/4 3/4 1 1
Blower Wheel Size (Diameter x Width) 4.5 x 4.5 4.5 x 4.5 5.5 x 5.5 5.5 x 4.5 9 x 7 9 x 7 9 x 7 9 x 7 10 x 8 10 x 8 11 x 9 11 x 9
ECM CONST CFM FAN MOTOR
Fan Motor Type/Speeds NA NA NA ECM Const CFM/3-Speed
Fan Motor (hp) NA NA NA 1/3 1/3 1/3 1/2 3/4 3/4 3/4 1 1
WATER CONNECTION SIZE
FPT 3/4 3/4 3/4 3/4 3/4 3/4 1 1 1 1 1 1
Coaxial Coil Volume (gal) 0.15 0.15 0.31 0.31 0.31 0.48 0.39 0.62 0.62 0.62 0.62 0.85
VERTICAL CABINET
Refrigeration Charge (oz) 29 31 46 35 35 65 71 68 83 86 92 127
Air Coil Dimensions (HxL) 12 x 16.5
12 x 16.5 16 x 16.5 16.5 x
20 16.5 x
20 24 x 21 24 x 27 24 x 27 32 x 27 32 x 27 40 x 27 40 x 27
Standard Filter - 1-in. Throwaway (HxL) 15 x 20 15 x 20 18 x 20 20 x 20 20 x 20 24 x 24 24 x 30 24 x 30 16 x 30
(2) 16 x 30
(2) 20 x 30
(2) 20 x 30
(2)
Operating Weight (lb) 140 154 166 191 195 229 269 281 334 340 396 444
Shipping Weight (lb) 160 174 186 208 212 242 292 304 360 366 422 470
HORIZONTAL CABINET
Refrigeration Charge (oz) 29 31 46 35 35 65 71 71 80 82 90 127
Air Coil Dimensions (HxL) 12 x 16.5
12 x 16.5 16 x 16.5 18 x
18.5 18 x 18.5 18 x 28 20 x
32.5 20 x 32.5
20 x 43.25
20 x 43.25 20 x 54 20 x 54
Standard Filter - 1-in. Throwaway (HxL) 15 x 20 15 x 20 18 x 20 18 x 20 18 x 20 20 x 30 20 x
34.5 20 x 34.5
20 x 24 (2)
20 x 24 (2)
20 x 28 (2)
20 x 28 (2)
Operating Weight (lb) 165 172 173 190 198 307 358 369 400 405 452 494
Shipping Weight (lb) 185 192 205 218 222 340 404 415 465 470 520 562
ECM Electronically Controlled Motor
FPT Female Pipe Thread
4
Fig. 1 50PSH007-070 Dimensional Data
Access Panel
Return Air Opening
Return Air Opening
Return Air Opening
Return Air Opening
Access Panel
Condenser Water Out
Condensate Drain
Condensate Drain
Condensate Drain
Condensate Drain
Condenser Water In
Electrical Knock-outs
D
E
F
G
B H
A A
D
E
F
Q
QC C
C C
P
P
N
N
N
N
M
M
B
B B
A A
J
J
K
K
K
K
AIR COIL
Blower
Blower Access 18" Minimum 24" Op timum
Compressor Access and Control Access 24" Minimum 36" Optimum
Compressor
Electrical Control
Box
LEFT HAND RETURN LEFT HAND RETURN END BLOW (FLE)
LEFT HAND RETURN STRAIGHT THROUGH (FLS)
RIGHT HAND RETURN RIGHT HAND RETURN END BLOW (FRE)
RIGHT HAND RETURN STRAIGHT THROUGH (FRS)
SERVICE CLEARANCES
NOTE: The local electric codes may require 36-in. or more clearance at the electrical control box.
NOTE: All dimensions in inches unless otherwise noted. All dimensions within 0.125-in. Specifications subject to change without notice. *Total unit height is 22.75 with base rails for 030-070 units.
UNIT
A B C D E F G H J K M N P Q R T
CONDENSER WATER
CONNECTIONS
RECOMMENDED REPLACEMENT
NOMINAL FILTER SIZE
WIDTH DEPTH HEIGHT
CAB END TO
FILTER RACK
R/A DUCT WIDTH
CAB FRONT
TO FILTER RACK
WATER IN
WATER OUT
SIDE TO DISC.
DISC. WIDTH
TOP TO DISC. (FLE AND FRS)
DISC. HEIGHT
END TO DISC.
TOP TO DISC. (FRE AND FLS)
FILTER RACK
HEIGHT
R/A DUCT
FLANGE HEIGHT
007 21.75 43.25 16.75 0.50 20.25 22.25 2.25 13.87 3.50 11.75 4.62 7.75 3.50 4.62 15.00 13.00 3/4 FPT 15 x 20 x 1
009 21.75 43.25 16.75 0.50 20.25 22.25 2.25 13.87 3.50 11.75 4.62 7.75 3.50 4.62 15.00 13.00 3/4 FPT 15 x 20 x 1
012 22.25 45.25 19.75 0.62 20.25 24.25 2.50 12.50 3.62 11.75 7.12 7.75 3.62 4.75 18.00 16.00 3/4 FPT 18 x 20 x 1
015 22.25 45.25 19.75 1.62 20.25 23.25 2.50 12.50 2.75 13.75 3.12 13.75 2.75 2.87 18.00 16.00 3/4 FPT 18 x 20 x 1
018 22.25 45.25 19.75 1.62 20.25 23.25 2.50 12.50 2.75 13.75 3.12 13.75 2.75 2.87 18.00 16.00 3/4 FPT 18 x 20 x 1
024 26.25 54.75 22.00* 1.25 30.25 23.00 2.62 15.12 3.75 13.75 2.12 15.75 3.75 4.25 20.12 18.00 3/4 FPT 20 x 30 x 1
030 30.25 68.25 22.00* 2.00 35.00 31.25 2.50 13.25 4.50 15.75 4.00 15.75 4.50 2.25 20.12 18.00 1 FPT 20 x 34.5 x 1
036 30.25 68.25 22.00* 2.00 35.00 31.25 2.50 13.25 4.50 15.75 4.00 15.75 4.50 2.25 20.12 18.00 1 FPT 20 x 34.5 x 1
042 30.25 79.00 22.00* 0.75 48.25 29.62 2.75 13.25 4.50 17.75 2.25 17.75 4.50 2.12 20.12 18.00 1 FPT 20 x 24 x 1 (2)
048 30.25 79.00 22.00* 0.75 48.25 29.62 2.75 13.25 4.50 17.75 2.25 17.75 4.50 2.12 20.12 18.00 1 FPT 20 x 24 x 1 (2)
060 30.25 89.25 22.00* 1.87 56.25 31.00 2.62 13.25 4.50 17.75 2.25 17.75 4.50 2.12 20.12 18.00 1 FPT 20 x 28 x 1 (2)
070 30.25 89.25 22.00* 1.87 56.25 31.00 5.75 17.75 4.87 17.75 2.62 17.75 4.87 1.75 20.12 18.00 1 FPT 20 x 28 x 1 (2)
LEGEND
FLE Front Water, Left Return, End Supply
FLS Front Water, Left Return, Straight Through Supply
FRE Front Water, Right Return, End Supply
FRS Front Water, Right Return, Straight Through Supply
5
Fig. 2 50PSV007-070 Dimensional Data
Access Panel
Condenser Water Out
Condensate Drain
Condenser Water In
Electrical Knock-outs
DEFG
C
B
H
A
D E F Q
C P
N
M
BA
J K
A I R
C O I L
Blower Blower Access 18" Minimum 24" Op timum
Compressor Access and Electrical/Control Access 24" Minimum 36" Optimum
Compressor
Electrical Control
Box
LEFT HAND RETURN RIGHT HAND RETURN RETURN AIR (FILTER) VIEW
FRONT OF UNIT
SERVICE CLEARANCES
NOTE: The local electric codes may require 36-in. or more clearance at the electrical control box.
NOTE: All dimensions in inches unless otherwise noted. All dimensions within 0.125-in. Specifications subject to change without notice.
UNIT
A B C D E F G H J K M N P Q CONDENSER
WATER CONN.
RECOMMENDED REPLACEMENT
NOMINAL FILTER SIZE
WIDTH DEPTH HEIGHT DISCHARGE DEPTH
DISCHARGE WIDTH
CABINET EDGE TO
DISCHARGE
LEFT SIDE TO
DISC.
WATER IN
BOTTOM TO
COND. DRAIN
WATER OUT
R/A DUCT WIDTH
R/A DUCT
FLANGE HEIGHT
FILTER RACK
HEIGHT
RIGHT SIDE TO
DISCHAGE
007 21.75 21.75 32.75 11.75 7.75 5.00 8.50 2.25 8.00 13.75 18.00 13.00 15.00 5.32 3/4 FPT 15 x 20 x 1
009 21.75 21.75 32.75 11.75 7.75 5.00 8.50 2.25 8.00 13.75 18.00 13.00 15.00 5.32 3/4 FPT 15 x 20 x 1
012 21.75 21.75 32.75 11.75 7.75 5.00 8.50 2.62 7.50 12.50 18.00 16.00 18.00 5.32 3/4 FPT 18 x 20 x 1
015 21.75 21.75 39.25 13.75 13.75 4.00 6.12 2.25 7.50 12.25 18.00 18.00 20.00 4.00 3/4 FPT 20 x 20 x 1
018 21.75 21.75 39.25 13.75 13.75 4.00 6.12 2.25 7.50 12.25 18.00 18.00 20.00 4.00 3/4 FPT 20 x 20 x 1
024 21.75 26.25 47.25 13.75 15.75 6.25 4.87 2.50 8.75 15.00 22.00 22.00 24.00 4.00 3/4 FPT 24 x 24 x 1
030 24.25 33.50 47.25 15.75 15.75 8.87 7.00 2.50 8.50 14.50 28.00 22.00 24.00 4.00 1 FPT 24 x 30 x 1
036 24.25 33.50 47.25 15.75 15.75 8.87 7.00 2.50 8.50 14.50 28.00 22.00 24.00 4.00 1 FPT 24 x 30 x 1
042 26.25 33.50 58.25 17.75 17.75 7.87 6.75 3.25 8.50 13.25 28.00 30.00 32.00 4.00 1 FPT 16 x 30 x 1 (2)
048 26.25 33.50 58.25 17.75 17.75 7.87 6.75 3.25 8.50 13.25 28.00 30.00 32.00 4.00 1 FPT 16 x 30 x 1 (2)
060 26.25 33.50 66.25 17.75 17.75 7.87 7.00 3.25 8.50 13.25 28.00 38.00 40.00 4.00 1 FPT 20 x 30 x 1 (2)
070 26.25 33.50 66.25 17.75 17.75 7.87 7.25 4.25 10.00 17.00 28.00 38.00 40.00 3.00 1 FPT 20 x 30 x 1 (2)
LEGEND
FLT Front Water, Left Return, Top Supply
FRT Front Water, Left Return, Top Supply
119
6
Step 4 Mount the Unit VERTICAL UNITS (50PSV) Vertical units up to 6 tons are available in left or right-hand return air configurations. Vertical units should be mounted level on a vibration absorbing pad slightly larger than the base to minimize vibration transmission to the building structure. It is not necessary to anchor the unit to the floor. See Fig. 3. If the unit is located in a confined space such as a closet, provisions must be made for return air to free- ly enter the space.
HORIZONTAL UNIT (50PSH) While horizontal units may be installed on any level surface strong enough to hold their weight, they are typically suspended above a ceiling by threaded rods. The rods are usually attached to the unit corners by hanger bracket kits. See Fig. 4.
The rods must be securely anchored to the ceiling. Refer to the hanging bracket assembly and installation instructions for details. Horizontal units installed above the ceiling must con- form to all local codes. An auxiliary drain pan, if required by code, should be at least four inches larger than the bottom of the heat pump. Plumbing connected to the heat pump must not come in direct contact with joists, trusses, walls, etc.
Some applications require an attic floor installation of the horizontal unit. In this case the unit should be set in a full size secondary drain pan on top of a vibration absorbing mesh. The secondary drain pan prevents possible condensate overflow or water leakage damage to the ceiling. The secondary drain pan is usually placed on a plywood base isolated from the ceiling joists by additional layers of vibration absorbing mesh. In both cases, a 3/4-in. drain connected to this secondary pan should be run to an eave and able to drain to a location that will be notice- able. If the unit is located in a crawl space, the bottom of the unit must be at least 4 in. above grade to prevent flooding of the electrical parts due to heavy rains.
Locate the heat pump unit in an area that provides sufficient room to make water and electrical connections, allowing easy removal of the access panels, and replacement of air filters for routine maintenance. This will ensure proper work space for service personnel to perform maintenance or repair.
See Fig. 1 and 2 for replacement filter sizes to ensure proper clearances are provided during installation. Allow adequate room below the unit for a condensate drain trap on horizontal units.
The heat pump unit is designed for conditioned space instal- lation only. If the source water is subjected to conditions where ambient temperatures can fall below freezing, some form of freeze protection should be employed. In an open loop system this may entail running the water pump continuously to prevent freezing. An antifreeze solution wherever possible should be used if water will be subject to freezing. Consult the factory in these instances for guidance.
Step 5 Check Duct System A supply air outlet collar and return air duct flange are provided on all units to fa- cilitate duct connections. A flexible connector is recommended for supply and return air duct connections on metal duct sys- tems. All metal ducting should be insulated with a minimum of 1 in. duct insulation to avoid heat loss or gain and prevent con- densate forming during the cooling operation. Application of the unit to uninsulated duct work is not recommended as the units performance will be adversely affected. Do not connect ducts directly to the blower outlet; factory supplied duct collars should be used for the connection to minimize unit vibration and noise transmission to the ductwork and ultimately into the conditioned space. The factory-provided air filter must be re- moved when using a filter back return air grill. The factory fil- ter should be left in place on a free return system.
If the unit will be installed in a new installation which in- cludes new duct work, the installation should be designed us- ing current ASHRAE (American Society of Heating, Refriger- ating, and Air-Conditioning Engineers) procedures for duct siz- ing. If the unit is to be connected to existing ductwork, a check should be made to assure that the duct system has the capacity to handle the air required for the unit application. If the duct system is too small, larger ductwork should be installed. Check for existing leaks and repair as necessary to ensure a tight air seal within the duct. The duct system and all diffusers should be sized to handle the designed air flow quietly. To maximize sound attenuation of the unit blower, the supply and return air plenums should be insulated. There should be no direct straight air path thru the return air grille into the heat pump. The return air inlet to the heat pump must have at least one 90 degree turn away from the space return air grille. If air noise or excessive air flow are a problem, the blower speed can be changed to a lower speed to reduce air flow. (Refer to CFM motor speeds and settings in Table 2.)
VIBRATION PAD
FULL SIZE
Fig. 3 Vertical Unit on Vibration Pad
Fig. 4 Typical Horizontal Unit Hanging Bracket
CAUTION
To avoid equipment damage, ensure that the heat pump unit is installed in a location or take the proper precautions in order to prevent rupturing the water coil due to freezing conditions.
WARNING
Always disconnect power to the unit before changing motor speed to prevent damage to the motor, injury or death due to electrical shock.
7
Table 2 Motor CFM Selection (Constant Torque)
Step 6 Install Condensate Drain A drain line must be connected to the heat pump and pitched away from the unit a minimum of 1/8 in. per foot to allow the conden- sate to flow away from the unit.
This connection must be in conformance with local plumb- ing codes. A trap must be installed in the condensate line to en- sure free condensate flow. (Heat Pumps are not internally trapped). A vertical air vent is sometimes required to avoid air pockets. See Fig. 5. The length of the trap depends on the amount of positive or negative pressure on the drain pan. A second trap must not be included.
The horizontal unit should be pitched approximately 1/4-in. towards the drain in both directions, to facilitate condensate re- moval. See Fig. 6.
Step 7 Pipe Connections Depending on the application, there are 3 types of WSHP piping systems to choose from: water loop, ground-water and ground loop. Refer to Piping Section of Carrier System Design Manual for addi- tional information.
All WSHP units use 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. Refer to Table 1 for connection sizes. When making piping connections, consider the following: Use a backup wrench when making screw connections 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 gal- vanic corrosion.
WATER LOOP APPLICATIONS Water loop applications usually include a number of units plumbed to a common pip- ing 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 2.25 and 3.5 gpm per ton of cooling capacity. For proper maintenance and servicing, pressure-temperature (P/T) ports are necessary for temperature and flow verification.
Cooling tower/boiler systems typically utilize a common loop maintained at 50 to 100 F. The use of a closed circuit evaporative cooling tower with a secondary heat exchange 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.
In addition to complying with any applicable codes, consid- er the following for system piping: Piping systems using water temperatures below 50 F
require 1/2-in. closed cell insulation on all piping surfaces to eliminate condensation.
Avoid all plastic to metal threaded fittings 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. Flush the piping system prior to operation to remove dirt
and foreign materials from the system.
GROUND-WATER APPLICATIONS Typical ground- water piping is shown in Fig. 7. In addition to complying with any applicable codes, consider the following for sys- tem piping: Install shut-off valves for servicing. Install pressure-temperature plugs to measure flow and
temperature. Connect boiler drains and other valves using a T con-
nector 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.
UNIT SIZE MOTOR HP TAP 1 TAP 2 TAP 3 TAP 4 TAP 5
015 1/3 LOW MED HIGH
018 1/3 LOW MED HIGH
024 1/3 LOW MED HIGH
030 1/2 LOW MED HIGH
036 3/4 LOW MED HIGH
042 3/4 LOW MED HIGH
048 3/4 LOW MED HIGH
060 1 LOW MED HIGH
070 1 LOW MED HIGH
Fig. 5 Condensate Trapping
ELEVATION LINE
WHEN MOUNTED LEVEL 1/4
Fig. 6 Sloped Horizontal Unit Installation
8
NOTE: PVC SCH40 should not be used due to system high pressure and temperature extremes. Water Supply and Quantity Check water supply. Water supply should be plentiful and of good quality. See Table 3 for water quality guidelines.
In all applications, the quality of the water circulated through the heat exchanger must be within the ranges listed in the Water Quality Guidelines. Consult a local water firm, inde- pendent testing facility, or local water authority for specific rec-
ommendations to maintain water quality within the published limits. GROUND-LOOP APPLICATIONS Temperatures be- tween 20 and 110 F and a cooling capacity of 2.25 to 3 gpm of flow per ton is recommended. In addition to complying with any applicable codes, consider the following for system piping: Limit piping materials to only polyethylene fusion in the
buried sections of the loop. Do not use galvanized or steel fittings at any time due to
corrosion. Avoid all plastic to metal threaded fittings due to the
potential to leak. Use a flange fitted substitute. Do not overtighten connections. Route piping to avoid service access areas to unit. Use pressure-temperature (P/T) plugs to measure flow of
pressure drop.
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. This damage is not the responsibility of the manufacturer.
Boiler Drains (field-installed)
Strainer (field-installed accessory) (16 to 20 mesh recommended for filter sediment)
Shut-Off Valve (field-installed accessory)
Water Control Valve (field-installed accessory)
Flow Regulator (field-installed accessory)
Pressure Tank
Water Out
Water In From Pump
A50-7733
Fig. 7 Typical Ground-Water Piping Installation
9
Table 3 Water Quality Guidelines
LEGEND
*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.
If the concentration of these corrosives exceeds the maximum allow- able level, then the potential for serious corrosion problems exists. Sulfides in the water quickly oxidize when exposed to air, requiring 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 can 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 registers a pH of 7.0. To convert ppm to grains per gallon, divide by 17. Hardness in mg/l is equivalent to ppm. considered to be basic. Neutral water contains a pH of 7.0. To convert ppm to grains per gallon, divide by 17. Hardness in mg/l is equivalent to ppm.
CONDITION HX MATERIAL* CLOSED RECIRCULATING 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 Hardness Method All N/A pH < 7.5 and Ca Hardness, <100 ppm
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 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 bacteria.
Iron Fouling All N/A
<0.5 ppm of Oxygen Above this level deposition will occur.
Corrosion Prevention pH
All 6 - 8.5 Monitor/treat as needed.
6 - 8.5 Minimize steel pipe below 7 and no open tanks with pH <8.
Hydrogen Sulfide (H2S)
All N/A
<0.5 ppm At H2S>0.2 ppm, avoid use of copper and cupronickel piping or HXs.
Rotten egg smell appears at 0.5 ppm level. Copper alloy (bronze or brass) cast components are okay to <0.5 ppm.
Ammonia Ion as Hydroxide, Chloride, Nitrate and Sulfate Compounds
All N/A <0.5 ppm
Maximum Chloride Levels Maximum allowable at maximum water temperature. 50 F (10 C) 75 F (24 C) 100 F (38 C)
Copper N/A <20 ppm NR NR Cupronickel N/A <150 ppm NR NR
304 SS N/A <400 ppm <250 ppm <150 ppm 316 SS N/A <1000 ppm <550 ppm <375 ppm Titanium N/A >1000 ppm >550 ppm >375 ppm
Erosion and Clogging Particulate Size and Erosion
All
<10 ppm of particles and a maximum velocity of 6 fps.
Filtered for maximum 800 micron size.
<10 ppm (<1 ppm sandfree for reinjection) of particles and a maximum velocity of 6 fps. Filtered for maximum 800 micron size. Any particulate that is not removed can potentially clog components.
Brackish All N/A
Use cupronickel heat exchanger when concentrations of calcium or sodium chloride are greater than 125 ppm are present. (Seawater is approximately 25,000 ppm.)
HWG Hot Water Generator HX Heat Exchanger N/A Design Limits Not Applicable Considering Recirculating
Potable Water NR Application Not Recommended SS Stainless Steel
10
INSTALLATION OF SUPPLY AND RETURN HOSE KIT Follow these piping guidelines. 1. Install a drain valve at the base of each supply and return
riser to facilitate system flushing. 2. Install shutoff/balancing valves and unions at each unit to
permit unit removal for servicing. 3. Place strainers at the inlet of each system circulating
pump. 4. Select the proper hose length to allow slack between con-
nection points. Hoses may vary in length by +2% to 4% under pressure.
5. Refer to Table 4. Do not exceed the minimum bend radius for the hose selected. Exceeding the minimum bend radi- us may cause the hose to collapse, which reduces water flow rate. Install an angle adapter to avoid sharp bends in the hose when the radius falls below the required mini- mum. NOTE: Piping must comply with all applicable codes.
Table 4 Metal Hose Minimum Bend Radii
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 ambient. Insulation is required if loop water temperature drops below the dew point.
Pipe joint compound is not necessary when Teflon* thread- ed tape is pre-applied to hose assemblies or when flared-end connections are used. If pipe joint compound is preferred, use compound only in small amounts on the male pipe threads of the fitting adapters. Prevent sealant from reaching the flared surfaces of the joint. NOTE: When anti-freeze is used in the loop, assure that it is compatible with Teflon tape or pipe joint compound employed.
Maximum allowable torque for brass fittings is 30 ft-lb. If a torque wrench is not available, tighten finger-tight plus one quarter turn. Tighten steel fittings as necessary.
Optional pressure-rated hose assemblies designed specifi- cally for use with Carrier units are available. Similar hoses can be obtained from alternate suppliers. Supply and return hoses
are fitted with swivel-joint fittings at one end to prevent kink- ing during installation.
Male adapters secure hose assemblies to the unit and risers. Install hose assemblies properly and check them regularly to avoid system failure and reduced service life. See Fig. 8.
Step 8 Wire Field Power Supply
All field wiring must comply with local and national fire, safety and electrical codes. Power to the unit must be within the operating voltage range indicated on the units nameplate. On three phase units, phases must be balanced within 2%. Properly sized fuses or HACR (Heating, Air-Conditioning, and Refrig- eration) circuit breakers must be installed for branch circuit protection. See equipment rating plates for proper size.
The heat pump units are provided with a concentric knock- out in the front right corner post for attaching common trade sizes of conduit. Route power supply wiring through this open- ing. Flexible wiring and conduit should be used to isolate vi- bration and noise from the building structure. Be certain to con- nect the ground lead to the ground lug in the control box. Con- nect the power leads as indicated on the unit wiring diagrams. See Fig. 9-20. See Table 5 and 6 for additional electrical data.
HOSE DIAMETER (in.) MINIMUM BEND RADII (in.) 1/2 21/2 3/4 4 1 51/2
IMPORTANT: Do not bend or kink supply lines or hoses.
CAUTION
Backup wrench is required when tightening water connec- tions to prevent water line damage. Failure to use a backup wrench could result in equipment damage.
WARNING
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.
CAUTION
Operating the unit with improper line voltage or with excessive phase imbalance is hazardous to the unit and constitutes abuse and is not covered under warranty.
Rib Crimped
Length (2 ft Length Standard)
Swivel Brass Fitting
Brass Fitting
MPT
Fig. 8 Supply/Return Hose Kit
A50-7734
* Registered trademark of DuPont.
11
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LS .
4. U
P M
-1 IN
C LU
D E
S B
U IL
T IN
: 2 70
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A L
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N .
6. F
R E
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R W
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A T
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M
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F R
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ZE 1
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F
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2 S
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M IN
A LS
. 7.
A LA
R M
O U
TP U
T D
IP S
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C H
M U
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T TO
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LS E
I F
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L IG
H T
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IR E
D .
8. D
E FA
U LT
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TT IN
G S
F O
R C
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B O
A R
D F
R O
M F
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TO R
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H O
W N
. 9.
A LA
R M
O U
TP U
T IS
N O
R M
A LL
Y O
P E
N (N
O ) D
R Y
C O
N TA
C T.
IF 2
4 VA
C IS
N E
E D
E D
, C O
N N
E C
T R
T O
A LR
-C O
M T
E R
M IN
A L.
2
4 VA
C W
IL L
B E
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N S
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T H
E A
LR -O
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R M
C O
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IT IO
N . O
U TP
U T
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L B
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E
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D .
10 . F
A C
TO R
Y- M
O U
N TE
D L
O O
P P
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P O
R T
W O
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W AT
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V A
LV E
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TH D
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S W
IL L
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T B
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R E
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N T
IN T
H E
S A
M E
U N
IT .
C O
M P
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C
S E
E N
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S 5
- 9
F ig
. 1 1
E
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to r,
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C o
m p
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C C
o n
tr o
l
14
N O
TE S
: 1.
S E
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N IT
N A
M E
P LA
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O R
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C TR
IC A
L R
AT IN
G .
2. A
LL F
IE LD
W IR
IN G
M U
S T
B E
IN A
C C
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N E
C -N
FP A
#7 0,
C O
P P
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C O
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U C
TO R
S O
N LY
. 3.
2 08
/2 30
V U
N IT
S A
R E
F A
C TO
R Y
W IR
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F O
R 2
30 V
O P
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AT IO
N . F
O R
2 08
V O
P E
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IO N
, R E
M O
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A D
F R
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2 40
T E
R M
IN A
L
A N
D C
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N E
C T
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O 2
08 . C
A P
A LL
U N
U S
E D
T E
R M
IN A
LS .
4. U
P M
-1 IN
C LU
D E
S B
U IL
T IN
: 2 70
-3 00
S E
C O
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R A
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30
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S . M
U S
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A L
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N .
6. F
R E
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S E
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C O
N D
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S E
R W
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26 F
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T H
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R E
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R F
R E
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2 S
E N
S O
R T
E R
M IN
A LS
. 7.
A LA
R M
O U
TP U
T D
IP S
W IT
C H
M U
S T
B E
S E
T TO
P U
LS E
I F
B LI
N K
IN G
T -S
TA T
S E
R V
IC E
L IG
H T
IS D
E S
IR E
D .
8. D
E FA
U LT
S E
TT IN
G S
F O
R C
O M
P LE
TE C
B O
A R
D F
R O
M F
A C
TO R
Y S
H O
W N
. 9.
A LA
R M
O U
TP U
T IS
N O
R M
A LL
Y O
P E
N (N
O ) D
R Y
C O
N TA
C T.
IF 2
4 VA
C IS
N E
E D
E D
, C O
N N
E C
T R
T O
A LR
-C O
M T
E R
M IN
A L.
2 4
VA C
W IL
L B
E S
E N
S E
D
O
N T
H E
A LR
-O U
T W
H E
N T
H E
U N
IT IS
IN A
LA R
M C
O N
D IT
IO N
. O U
TP U
T W
IL L
B E
P U
LS E
D IF
P U
LS E
IS S
E LE
C TE
D .
10 . T
E R
M IN
A L
B LO
C K
T B
3 LO
C AT
E D
IN S
ID E
D IS
C O
N N
E C
T S
W IT
C H
B O
X .
11 . C
H E
C K
F O
R P
R O
P E
R P
H A
S E
R O
TA TI
O N
O N
U N
IT S
W IT
H S
C R
O LL
C O
M P
R E
S S
O R
S . R
E V
E R
S E
R O
TA TI
O N
W IL
L D
A M
A G
E T
H E
C O
M P
R E
S S
O R
A N
D V
O ID
U N
IT W
A R
R A
N TY
. 12
. F A
C TO
R Y-
M O
U N
TE D
L O
O P
P U
M P
O R
T W
O -W
AY W
AT E
R V
A LV
E . B
O TH
D E
V IC
E S
W IL
L N
O T
B E
P R
E S
E N
T IN
T H
E S
A M
E U
N IT
. 13
. P U
M P
M O
TO R
IS W
IR E
D B
E TW
E E
N L
IN E
A N
D N
E U
TR A
L FO
R 3
80 -4
60 VA
C U
N IT
S . F
O R
2 08
/2 30
VA C
U N
IT S
P U
M P
M O
TO R
IS W
IR E
D B
E TW
E E
N L
IN E
S .
C O
M P
LE TE
C
S E
E N
O TE
S 5
- 9
F ig
. 1 2
C
o n
st an
t T
o rq
u e
M o
to r,
T h
re e
P h
as e/
S in
g le
S ta
g e,
C o
m p
le te
C C
o n
tr o
l
15
N O
TE S
: 1.
S E
E U
N IT
N A
M E
P LA
TE F
O R
E LE
C TR
IC A
L R
AT IN
G .
2. A
LL F
IE LD
W IR
IN G
M U
S T
B E
IN A
C C
O R
D A
N C
E W
IT H
N E
C -N
FP A
#7 0,
C O
P P
E R
C O
N D
U C
TO R
S O
N LY
. 3.
2 08
/2 30
V U
N IT
S A
R E
F A
C TO
R Y
W IR
E D
F O
R 2
30 V
O P
E R
AT IO
N .
F
O R
2 08
V O
P E
R AT
IO N
, R E
M O
V E
L E
A D
F R
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2 40
T E
R M
IN A
L
A N
D C
O N
N E
C T
IT T
O 2
08 . C
A P
A LL
U N
U S
E D
T E
R M
IN A
LS .
4. U
P M
-1 IN
C LU
D E
S B
U IL
T IN
: 2 70
-3 00
S E
C O
N D
R A
N D
O M
S TA
R T
30
0 S
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O N
D D
E LA
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R E
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12
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S 5.
T E
S T
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IT C
H R
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LA Y
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S E
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S . M
U S
T B
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E T
TO N
O F
O R
N O
R M
A L
O P
E R
AT IO
N .
6. F
R E
E ZE
S E
N S
O R
O N
C O
N D
E N
S E
R W
IL L
O P
E R
AT E
A T
26 F
B Y
D E
FA U
LT , I
F 15
F O
P E
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R 30
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T.
I
F FR
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B E
TW E
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T H
E F
R E
E ZE
1 O
R F
R E
E ZE
2 S
E N
S O
R T
E R
M IN
A LS
. 7.
A LA
R M
O U
TP U
T D
IP S
W IT
C H
M U
S T
B E
S E
T TO
P U
LS E
I F
B LI
N K
IN G
T -S
TA T
S E
R V
IC E
L IG
H T
IS D
E S
IR E
D .
8. D
E FA
U LT
S E
TT IN
G S
F O
R C
O M
P LE
TE C
B O
A R
D F
R O
M F
A C
TO R
Y S
H O
W N
. 9.
A LA
R M
O U
TP U
T IS
N O
R M
A LL
Y O
P E
N (N
O ) D
R Y
C O
N TA
C T.
IF 2
4 VA
C IS
N E
E D
E D
, C O
N N
E C
T R
T O
A LR
-C O
M T
E R
M IN
A L.
2 4
VA C
W IL
L B
E S
E N
S E
D
O
N T
H E
A LR
-O U
T W
H E
N T
H E
U N
IT IS
IN A
LA R
M C
O N
D IT
IO N
. O U
TP U
T W
IL L
B E
P U
LS E
D IF
P U
LS E
IS S
E LE
C TE
D .
10 . T
E R
M IN
A L
B LO
C K
T B
3 LO
C AT
E D
IN S
ID E
D IS
C O
N N
E C
T S
W IT
C H
B O
X .
11 . C
H E
C K
F O
R P
R O
P E
R P
H A
S E
R O
TA TI
O N
O N
U N
IT S
W IT
H S
C R
O LL
C O
M P
R E
S S
O R
S . R
E V
E R
S E
R O
TA TI
O N
W IL
L D
A M
A G
E T
H E
C O
M P
R E
S S
O R
A N
D V
O ID
U N
IT W
A R
R A
N TY
. 12
. F A
C TO
R Y-
M O
U N
TE D
L O
O P
P U
M P
O R
T W
O -W
AY W
AT E
R V
A LV
E . B
O TH
D E
V IC
E S
W IL
L N
O T
B E
P R
E S
E N
T IN
T H
E S
A M
E U
N IT
. 13
. P U
M P
M O
TO R
IS W
IR E
D B
E TW
E E
N L
IN E
A N
D N
E U
TR A
L FO
R 3
80 -4
60 VA
C U
N IT
S . F
O R
2 08
/2 30
VA C
U N
IT S
P U
M P
M O
TO R
IS W
IR E
D B
E TW
E E
N L
IN E
S .
14 . 2
08 /2
30 V
A N
D 4
60 V
B LO
W E
R M
O TO
R S
H AV
E T
H R
E E
S P
E E
D T
A P
S . 5
75 B
LO W
E R
M O
TO R
S A
R E
S IN
G LE
S P
E E
D . F
O R
4 60
B LO
W E
R M
O TO
R S
W IR
E B
LA C
K A
N D
O R
A N
G E
LE A
D S
T O
G E
TH E
R F
O R
M E
D O
R L
O S
P E
E D
O P
E R
AT IO
N . C
A P
U N
U S
E D
L E
A D
S .
C O
M P
LE TE
C
S E
E N
O TE
S 5
- 9
F ig
. 1 3
P
S C
M o
to r,
T h
re e
P h
as e/
S in
g le
S ta
g e,
C o
m p
le te
C C
o n
tr o
l
16
N O
TE S
: 1.
S E
E U
N IT
N A
M E
P LA
TE F
O R
E LE
C TR
IC A
L R
AT IN
G .
2. A
LL F
IE LD
W IR
IN G
M U
S T
B E
IN A
C C
O R
D A
N C
E W
IT H
N E
C -N
FP A
#7 0,
C O
P P
E R
C O
N D
U C
TO R
S O
N LY
. 3.
2 08
/2 30
V U
N IT
S A
R E
F A
C TO
R Y
W IR
E D
F O
R 2
30 V
O P
E R
AT IO
N .
F
O R
2 08
V O
P E
R AT
IO N
, R E
M O
V E
L E
A D
F R
O M
2 40
T E
R M
IN A
L
A N
D C
O N
N E
C T
IT T
O 2
08 . C
A P
A LL
U N
U S
E D
T E
R M
IN A
LS .
4. U
P M
-1 IN
C LU
D E
S B
U IL
T IN
: 2 70
-3 00
S E
C O
N D
R A
N D
O M
S TA
R T
30
0 S
E C
O N
D D
E LA
Y O
N B
R E
A K
12
0 S
E C
O N
D L
O W
P R
E S
S U
R E
B Y
PA S
S 5.
T E
S T
D IP
S W
IT C
H R
E D
U C
E S
D E
LA Y
S T
O 1
0 S
E C
W H
E N
S E
T TO
Y E
S . M
U S
T B
E S
E T
TO N
O F
O R
N O
R M
A L
O P
E R
AT IO
N .
6. F
R E
E ZE
S E
N S
O R
O N
C O
N D
E N
S E
R W
IL L
O P
E R
AT E
A T
26 F
B Y
D E
FA U
LT , I
F 15
F O
P E
R AT
IO N
IS R
E Q
U IR
E D
J U
M P
E R
R 30
M U
S T
B E
C U
T.
I
F FR
E E
ZE S
E N
S O
R IS
N O
T IN
S TA
LL E
D A
J U
M P
E R
S H
A LL
B E
IN S
TA LL
E D
B E
TW E
E N
T H
E F
R E
E ZE
1 O
R F
R E
E ZE
2 S
E N
S O
R T
E R
M IN
A LS
. 7.
A LA
R M
O U
TP U
T D
IP S
W IT
C H
M U
S T
B E
S E
T TO
P U
LS E
I F
B LI
N K
IN G
T -S
TA T
S E
R V
IC E
L IG
H T
IS D
E S
IR E
D .
8. D
E FA
U LT
S E
TT IN
G S
F O
R C
O M
P LE
TE C
B O
A R
D F
R O
M F
A C
TO R
Y S
H O
W N
. 9.
A LA
R M
O U
TP U
T IS
N O
R M
A LL
Y O
P E
N (N
O ) D
R Y
C O
N TA
C T.
IF 2
4 VA
C IS
N E
E D
E D
, C O
N N
E C
T R
T O
A LR
-C O
M T
E R
M IN
A L.
2 4
VA C
W IL
L B
E S
E N
S E
D
O
N T
H E
A LR
-O U
T W
H E
N T
H E
U N
IT IS
IN A
LA R
M C
O N
D IT
IO N
. O U
TP U
T W
IL L
B E
P U
LS E
D IF
P U
LS E
IS S
E LE
C TE
D .
10 . T
E R
M IN
A L
B LO
C K
T B
3 LO
C AT
E D
IN S
ID E
D IS
C O
N N
E C
T S
W IT
C H
B O
X .
11 . C
H E
C K
F O
R P
R O
P E
R P
H A
S E
R O
TA TI
O N
O N
U N
IT S
W IT
H S
C R
O LL
C O
M P
R E
S S
O R
S . R
E V
E R
S E
R O
TA TI
O N
W IL
L D
A M
A G
E T
H E
C O
M P
R E
S S
O R
A N
D V
O ID
U N
IT W
A R
R A
N TY
. 12
. F A
C TO
R Y-
M O
U N
TE D
L O
O P
P U
M P
O R
T W
O -W
AY W
AT E
R V
A LV
E . B
O TH
D E
V IC
E S
W IL
L N
O T
B E
P R
E S
E N
T IN
T H
E S
A M
E U
N IT
. 13
. P U
M P
M O
TO R
IS W
IR E
D B
E TW
E E
N L
IN E
A N
D N
E U
TR A
L FO
R 3
80 -4
60 VA
C U
N IT
S . F
O R
2 08
/2 30
VA C
U N
IT S
P U
M P
M O
TO R
IS W
IR E
D B
E TW
E E
N L
IN E
S .
C O
M P
LE TE
C
S E
E N
O TE
S 5
- 9
F ig
. 1 4
E
O N
M o
to r,
T h
re e
P h
as e/
S in
g le
S ta
g e,
C o
m p
le te
C C
o n
tr o
l
17
N O
TE S
: 1.
S E
E U
N IT
N A
M E
P LA
TE F
O R
E LE
C TR
IC A
L R
AT IN
G .
2. A
LL F
IE LD
W IR
IN G
M U
S T
B E
IN A
C C
O R
D A
N C
E W
IT H
N E
C -N
FP A
#7 0,
C O
P P
E R
C O
N D
U C
TO R
S O
N LY
. 3.
2 08
/2 30
V U
N IT
S A
R E
F A
C TO
R Y
W IR
E D
F O
R 2
30 V
O P
E R
AT IO
N . F
O R
2 08
V O
P E
R AT
IO N
, R E
M O
V E
O R
G L
E A
D A
N D
R E
P LA
C E
W IT
H R
E D
L E
A D
. C A
P A
LL U
N U
S E
D L
E A
D S
. 4.
F O
R A
LT E
R N
AT IV
E E
M S
C O
IL V
O LT
A G
E S
C O
N S
U LT
F A
C TO
R Y.
5. U
P M
-1 IN
C LU
D E
S B
U IL
T IN
: 2 70
-3 00
S E
C O
N D
R A
N D
O M
S TA
R T
30
0 S
E C
O N
D D
E LA
Y O
N B
R E
A K
12
0 S
E C
O N
D L
O W
P R
E S
S U
R E
B Y
PA S
S 6.
T E
S T
D IP
S W
IT C
H R
E D
U C
E S
D E
LA Y
S T
O 1
0 S
E C
W H
E N
S E
T TO
Y E
S . M
U S
T B
E S
E T
TO N
O F
O R
N O
R M
A L
O P
E R
AT IO
N .
7. F
R E
E ZE
S E
N S
O R
O N
C O
N D
E N
S E
R W
IL L
O P
E R
AT E
A T
26 F
B Y
D E
FA U
LT , I
F 15
F O
P E
R AT
IO N
IS R
E Q
U IR
E D
J U
M P
E R
R 30
M U
S T
B E
C U
T.
I
F FR
E E
ZE S
E N
S O
R IS
N O
T IN
S TA
LL E
D A
J U
M P
E R
S H
A LL
B E
IN S
TA LL
E D
B E
TW E
E N
T H
E F
R E
E ZE
1 O
R F
R E
E ZE
2 S
E N
S O
R T
E R
M IN
A LS
. 8.
A LA
R M
O U
TP U
T D
IP S
W IT
C H
M U
S T
B E
S E
T TO
P U
LS E
I F
B LI
N K
IN G
T -S
TA T
S E
R V
IC E
L IG
H T
IS D
E S
IR E
D .
9. D
E FA
U LT
S E
TT IN
G S
F O
R D
E LU
X E
D B
O A
R D
F R
O M
F A
C TO
R Y
S H
O W
N .
10 . A
LA R
M O
U TP
U T
IS N
O R
M A
LL Y
O P
E N
(N O
) D R
Y C
O N
TA C
T. IF
2 4
VA C
IS N
E E
D E
D , C
O N
N E
C T
R T
O A
LR -C
O M
T E
R M
IN A
L. 2
4 VA
C W
IL L
B E
S E
N S
E D
O
N T
H E
A LR
-O U
T W
H E
N T
H E
U N
IT IS
IN A
LA R
M C
O N
D IT
IO N
. O U
TP U
T W
IL L
B E
P U
LS E
D IF
P U
LS E
IS S
E LE
C TE
D .
11 . F
A C
TO R
Y- M
O U
N TE
D L
O O
P P
U M
P O
R T
W O
-W AY
W AT
E R
V A
LV E
. B O
TH D
E V
IC E
S W
IL L
N O
T B
E P
R E
S E
N T
IN T
H E
S A
M E
U N
IT .
12 . B
C A
C O
N TA
C TS
R -Y
O P
E N
O N
D R
O P
IN W
AT E
R T
E M
P E
R AT
U R
E A
N D
R -B
C LO
S E
.
D E
LU X
E D
F ig
. 1 5
C
o n
st an
t T
o rq
u e
M o
to r,
S in
g le
P h
as e/
S in
g le
S ta
g e,
D el
u xe
D C
o n
tr o
l
18
N O
TE S
: 1.
S E
E U
N IT
N A
M E
P LA
TE F
O R
E LE
C TR
IC A
L R
AT IN
G .
2. A
LL F
IE LD
W IR
IN G
M U
S T
B E
IN A
C C
O R
D A
N C
E W
IT H
N E
C -N
FP A
#7 0,
C O
P P
E R
C O
N D
U C
TO R
S O
N LY
. 3.
2 08
/2 30
V U
N IT
S A
R E
F A
C TO
R Y
W IR
E D
F O
R 2
30 V
O P
E R
AT IO
N . F
O R
2 08
V O
P E
R AT
IO N
, R E
M O
V E
O R
G L
E A
D A
N D
R E
P LA
C E
W IT
H R
E D
L E
A D
. C A
P A
LL U
N U
S E
D L
E A
D S
. 4.
F O
R A
LT E
R N
AT IV
E E
M S
C O
IL V
O LT
A G
E S
C O
N S
U LT
F A
C TO
R Y.
5. U
P M
-1 IN
C LU
D E
S B
U IL
T IN
: 2 70
-3 00
S E
C O
N D
R A
N D
O M
S TA
R T
30
0 S
E C
O N
D D
E LA
Y O
N B
R E
A K
12
0 S
E C
O N
D L
O W
P R
E S
S U
R E
B Y
PA S
S 6.
T E
S T
D IP
S W
IT C
H R
E D
U C
E S
D E
LA Y
S T
O 1
0 S
E C
W H
E N
S E
T TO
Y E
S . M
U S
T B
E S
E T
TO N
O F
O R
N O
R M
A L
O P
E R
AT IO
N .
7. F
R E
E ZE
S E
N S
O R
O N
C O
N D
E N
S E
R W
IL L
O P
E R
AT E
A T
26 F
B Y
D E
FA U
LT , I
F 15
F O
P E
R AT
IO N
IS R
E Q
U IR
E D
J U
M P
E R
R 30
M U
S T
B E
C U
T.
I
F FR
E E
ZE S
E N
S O
R IS
N O
T IN
S TA
LL E
D A
J U
M P
E R
S H
A LL
B E
IN S
TA LL
E D
B E
TW E
E N
T H
E F
R E
E ZE
1 O
R F
R E
E ZE
2 S
E N
S O
R T
E R
M IN
A LS
. 8.
A LA
R M
O U
TP U
T D
IP S
W IT
C H
M U
S T
B E
S E
T TO
P U
LS E
I F
B LI
N K
IN G
T -S
TA T
S E
R V
IC E
L IG
H T
IS D
E S
IR E
D .
9. D
E FA
U LT
S E
TT IN
G S
F O
R D
E LU
X E
D B
O A
R D
F R
O M
F A
C TO
R Y
S H
O W
N .
10 . A
LA R
M O
U TP
U T
IS N
O R
M A
LL Y
O P
E N
(N O
) D R
Y C
O N
TA C
T. IF
2 4
VA C
IS N
E E
D E
D , C
O N
N E
C T
R T
O A
LR -C
O M
T E
R M
IN A
L. 2
4 VA
C W
IL L
B E
S E
N S
E D
O N
T H
E A
LR -O
U T
W H
E N
T H
E U
N IT
IS IN
A LA
R M
C O
N D
IT IO
N . O
U TP
U T
W IL
L B
E P
U LS
E D
IF P
U LS
E IS
S E
LE C
TE D
. 11
. F A
C TO
R Y-
M O
U N
TE D
L O
O P
P U
M P
O R
T W
O -W
AY W
AT E
R V
A LV
E . B
O TH
D E
V IC
E S
W IL
L N
O T
B E
P R
E S
E N
T IN
T H
E S
A M
E U
N IT
. 12
. B C
A C
O N
TA C
TS R
-Y O
P E
N O
N D
R O
P IN
W AT
E R
T E
M P
E R
AT U
R E
A N
D R
-B C
LO S
E .
D E
LU X
E D
F ig
. 1 6
P
S C
M o
to r,
S in
g le
P h
as e/
S in
g le
S ta
g e,
D el
u xe
D C
o n
tr o
l
19
N O
TE S
: 1.
S E
E U
N IT
N A
M E
P LA
TE F
O R
E LE
C TR
IC A
L R
AT IN
G .
2. A
LL F
IE LD
W IR
IN G
M U
S T
B E
IN A
C C
O R
D A
N C
E W
IT H
N E
C -N
FP A
#7 0,
C O
P P
E R
C O
N D
U C
TO R
S O
N LY
. 3.
2 08
/2 30
V U
N IT
S A
R E
F A
C TO
R Y
W IR
E D
F O
R 2
30 V
O P
E R
AT IO
N .
F
O R
2 08
V O
P E
R AT
IO N
, R E
M O
V E
L E
A D
F R
O M
2 40
T E
R M
IN A
L
A N
D C
O N
N E
C T
IT T
O 2
08 . C
A P
A LL
U N
U S
E D
T E
R M
IN A
LS .
4. F
O R
A LT
E R
N AT
IV E
E M
S C
O IL
V O
LT A
G E
S C
O N
S U
LT F
A C
TO R
Y. 5.
U P
M -1
IN C
LU D
E S
B U
IL T
IN : 2
70 -3
00 S
E C
O N
D R
A N
D O
M S
TA R
T
30 0
S E
C O
N D
D E
LA Y
O N
B R
E A
K
12 0
S E
C O
N D
L O
W P
R E
S S
U R
E B
Y PA
S S
6. T
E S
T D
IP S
W IT
C H
R E
D U
C E
S D
E LA
Y S
T O
1 0
S E
C W
H E
N S
E T
TO Y
E S
. M U
S T
B E
S E
T TO
N O
F O
R N
O R
M A
L O
P E
R AT
IO N
. 7.
F R
E E
ZE S
E N
S O
R O
N C
O N
D E
N S
E R
W IL
L O
P E
R AT
E A
T 26
F B
Y D
E FA
U LT
, I F
15 F
O P
E R
AT IO
N IS
R E
Q U
IR E
D J
U M
P E
R R
30 M
U S
T B
E C
U T.
I F
FR E
E ZE
S E
N S
O R
IS N
O T
IN S
TA LL
E D
A J
U M
P E
R S
H A
LL B
E IN
S TA
LL E
D B
E TW
E E
N T
H E
F R
E E
ZE 1
O R
F R
E E
ZE 2
S E
N S
O R
T E
R M
IN A
LS .
8. A
LA R
M O
U TP
U T
D IP
S W
IT C
H M
U S
T B
E S
E T
TO P
U LS
E I
F B
LI N
K IN
G T
-S TA
T S
E R
V IC
E L
IG H
T IS
D E
S IR
E D
. 9.
D E
FA U
LT S
E TT
IN G
S F
O R
D E
LU X
E D
B O
A R
D F
R O
M F
A C
TO R
Y S
H O
W N
. 10
. A LA
R M
O U
TP U
T IS
N O
R M
A LL
Y O
P E
N (N
O ) D
R Y
C O
N TA
C T.
IF 2
4 VA
C IS
N E
E D
E D
, C O
N N
E C
T R
T O
A LR
-C O
M T
E R
M IN
A L.
2 4
VA C
W IL
L B
E S
E N
S E
D
O N
T H
E A
LR -O
U T
W H
E N
T H
E U
N IT
IS IN
A LA
R M
C O
N D
IT IO
N . O
U TP
U T
W IL
L B
E P
U LS
E D
IF P
U LS
E IS
S E
LE C
TE D
. 11
. F A
C TO
R Y-
M O
U N
TE D
L O
O P
P U
M P
O R
T W
O -W
AY W
AT E
R V
A LV
E . B
O TH
D E
V IC
E S
W IL
L N
O T
B E
P R
E S
E N
T IN
T H
E S
A M
E U
N IT
. 12
. B C
A C
O N
TA C
TS R
-Y O
P E
N O
N D
R O
P IN
W AT
E R
T E
M P
E R
AT U
R E
A N
D R
-B C
LO S
E .
D E
LU X
E D
F ig
. 1 7
E
O N
M o
to r,
S in
g le
P h
as e/
S in
g le
S ta
g e,
D el
u xe
D C
o n
tr o
l
20
N O
TE S
: 1.
S E
E U
N IT
N A
M E
P LA
TE F
O R
E LE
C TR
IC A
L R
AT IN
G .
2. A
LL F
IE LD
W IR
IN G
M U
S T
B E
IN A
C C
O R
D A
N C
E W
IT H
N E
C -N
FP A
#7 0,
C O
P P
E R
C O
N D
U C
TO R
S O
N LY
. 3.
2 08
/2 30
V U
N IT
S A
R E
F A
C TO
R Y
W IR
E D
F O
R 2
30 V
O P
E R
AT IO
N .
F
O R
2 08
V O
P E
R AT
IO N
, R E
M O
V E
L E
A D
F R
O M
2 40
T E
R M
IN A
L
A N
D C
O N
N E
C T
IT T
O 2
08 . C
A P
A LL
U N
U S
E D
T E
R M
IN A
LS .
4. U
P M
-1 IN
C LU
D E
S B
U IL
T IN
: 2 70
-3 00
S E
C O
N D
R A
N D
O M
S TA
R T
30
0 S
E C
O N
D D
E LA
Y O
N B
R E
A K
12
0 S
E C
O N
D L
O W
P R
E S
S U
R E
B Y
PA S
S 5.
T E
S T
D IP
S W
IT C
H R
E D
U C
E S
D E
LA Y
S T
O 1
0 S
E C
W H
E N
S E
T TO
Y E
S . M
U S
T B
E S
E T
TO N
O
F
O R
N O
R M
A L
O P
E R
AT IO
N .
6. F
R E
E ZE
S E
N S
O R
O N
C O
N D
E N
S E
R W
IL L
O P
E R
AT E
A T
26 F
B Y
D E
FA U
LT , I
F 15
F O
P E
R AT
IO N
IS
R
E Q
U IR
E D
J U
M P
E R
R 30
M U
S T
B E
C U
T. IF
F R
E E
ZE S
E N
S O
R IS
N O
T IN
S TA
LL E
D A
J U
M P
E R
S H
A LL
B E
IN S
TA LL
E D
B E
TW E
E N
T H
E F
R E
E ZE
1 O
R F
R E
E ZE
2 S
E N
S O
R T
E R
M IN
A LS
. 7.
A LA
R M
O U
TP U
T D
IP S
W IT
C H
M U
S T
B E
S E
T TO
P U
LS E
I F
B LI
N K
IN G
T -S
TA T
S E
R V
IC E
L IG
H T
IS D
E S
IR E
D .
8. D
E FA
U LT
S E
TT IN
G S
F O
R D
E LU
X E
D B
O A
R D
F R
O M
F A
C TO
R Y
S H
O W
N .
9. A
LA R
M O
U TP
U T
IS N
O R
M A
LL Y
O P
E N
(N O
) D R
Y C
O N
TA C
T. IF
2 4
VA C
IS N
E E
D E
D , C
O N
N E
C T
R T
O A
LR -C
O M
T E
R M
IN A
L. 2
4 VA
C W
IL L
B E
S E
N S
E D
O N
T H
E A
LR -O
U T
W H
E N
T H
E U
N IT
IS IN
A LA
R M
C O
N D
IT IO
N . O
U TP
U T
W IL
L B
E P
U LS
E D
IF P
U LS
E IS
S E
LE C
TE D
. 10
. T E
R M
IN A
L B
LO C
K T
B 3
LO C
AT E
D IN
S ID
E D
IS C
O N
N E
C T
S W
IT C
H B
O X
. 11
. C H
E C
K F
O R
P R
O P
E R
P H
A S
E R
O TA
TI O
N O
N U
N IT
S W
IT H
S C
R O
LL C
O M
P R
E S
S O
R S
. R E
V E
R S
E R
O TA
TI O
N W
IL L
D A
M A
G E
T H
E C
O M
P R
E S
S O
R A
N D
V O
ID U
N IT
W A
R R
A N
TY .
12 . F
A C
TO R
Y- M
O U
N TE
D L
O O
P P
U M
P O
R T
W O
-W AY
W AT
E R
V A
LV E
. B O
TH D
E V
IC E
S W
IL L
N O
T B
E P
R E
S E
N T
IN T
H E
S A
M E
U N
IT .
13 . P
U M
P M
O TO
R IS
W IR
E D
B E
TW E
E N
L IN
E A
N D
N E
U TR
A L
FO R
3 80
-4 60
VA C
U N
IT S
. F O
R 2
08 /2
30 VA
C U
N IT
S P
U M
P M
O TO
R IS
W IR
E D
B E
TW E
E N
L IN
E S
.
S E
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S 5
- 9
F ig
. 1 8
C
o n
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t T
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re e
P h
as e/
S in
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S ta
g e,
D el
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D C
o n
tr o
l
21
N O
TE S
: 1.
S E
E U
N IT
N A
M E
P LA
TE F
O R
E LE
C TR
IC A
L R
AT IN
G .
2. A
LL F
IE LD
W IR
IN G
M U
S T
B E
IN A
C C
O R
D A
N C
E W
IT H
N E
C -N
FP A
#7 0,
C O
P P
E R
C O
N D
U C
TO R
S O
N LY
. 3.
2 08
/2 30
V U
N IT
S A
R E
F A
C TO
R Y
W IR
E D
F O
R 2
30 V
O P
E R
AT IO
N .
F
O R
2 08
V O
P E
R AT
IO N
, R E
M O
V E
L E
A D
F R
O M
2 40
T E
R M
IN A
L
A N
D C
O N
N E
C T
IT T
O 2
08 . C
A P
A LL
U N
U S
E D
T E
R M
IN A
LS .
4. F
O R
A LT
E R
N AT
IV E
E M
S C
O IL
V O
LT A
G E
C O
N S
U LT
F A
C TO
R Y.
5. U
P M
-1 IN
C LU
D E
S B
U IL
T IN
: 2 70
-3 00
S E
C O
N D
R A
N D
O M
S TA
R T
30
0 S
E C
O N
D D
E LA
Y O
N B
R E
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12
0 S
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D L
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P R
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S U
R E
B Y
PA S
S 6.
T E
S T
D IP
S W
IT C
H R
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U C
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D E
LA Y
S T
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0 S
E C
W H
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S E
T TO
Y E
S . M
U S
T B
E S
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TO N
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O R
N O
R M
A L
O P
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AT IO
N .
7. F
R E
E ZE
S E
N S
O R
O N
C O
N D
E N
S E
R W
IL L
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AT E
A T
26 F
B Y
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FA U
LT , I
F 15
F O
P E
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J U
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R 30
M U
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B E
C U
T.
I
F FR
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ZE S
E N
S O
R IS
N O
T IN
S TA
LL E
D A
J U
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S H
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B E
IN S
TA LL
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B E
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T H
E F
R E
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1 O
R F
R E
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2 S
E N
S O
R T
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M IN
A LS
. 8.
A LA
R M
O U
TP U
T D
IP S
W IT
C H
M U
S T
B E
S E
T TO
P U
LS E
I F
B LI
N K
IN G
T -S
TA T
S E
R V
IC E
L IG
H T
IS D
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IR E
D .
9. D
E FA
U LT
S E
TT IN
G S
F O
R D
E LU
X E
D B
O A
R D
F R
O M
F A
C TO
R Y
S H
O W
N .
10 . A
LA R
M O
U TP
U T
IS N
O R
M A
LL Y
O P
E N
(N O
) D R
Y C
O N
TA C
T. IF
2 4
VA C
IS N
E E
D E
D , C
O N
N E
C T
R T
O A
LR -C
O M
T E
R M
IN A
L. 2
4 VA
C W
IL L
B E
S E
N S
E D
O N
T H
E A
LR -O
U T
W H
E N
T H
E U
N IT
IS IN
A LA
R M
C O
N D
IT IO
N . O
U TP
U T
W IL
L B
E P
U LS
E D
IF P
U LS
E IS
S E
LE C
TE D
. 11
. T E
R M
IN A
L B
LO C
K T
B 3
LO C
AT E
D IN
S ID
E D
IS C
O N
N E
C T
S W
IT C
H B
O X
. 12
. C H
E C
K F
O R
P R
O P
E R
P H
A S
E R
O TA
TI O
N O
N U
N IT
S W
IT H
S C
R O
LL C
O M
P R
E S
S O
R S
. R E
V E
R S
E R
O TA
TI O
N W
IL L
D A
M A
G E
T H
E C
O M
P R
E S
S O
R A
N D
V O
ID U
N IT
W A
R R
A N
TY .
13 . F
A C
TO R
Y- M
O U
N TE
D L
O O
P P
U M
P O
R T
W O
-W AY
W AT
E R
V A
LV E
. B O
TH D
E V
IC E
S W
IL L
N O
T B
E P
R E
S E
N T
IN T
H E
S A
M E
U N
IT .
14 . P
U M
P M
O TO
R IS
W IR
E D
B E
TW E
E N
L IN
E A
N D
N E
U TR
A L
FO R
3 80
-4 60
VA C
U N
IT S
. F O
R 2
08 /2
30 VA
C U
N IT
S P
U M
P M
O TO
R IS
W IR
E D
B E
TW E
E N
L IN
E S
. 15
. B C
A C
O N
TA C
TS R
-Y O
P E
N O
N D
R O
P IN
W AT
E R
T E
M P
E R
AT U
R E
A N
D R
-B C
LO S
E .
D E
LU X
E D
F ig
. 1 9
P
S C
M o
to r,
T h
re e
P h
as e/
S in
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S ta
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D el
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D C
o n
tr o
l
22
N O
TE S
: 1.
S E
E U
N IT
N A
M E
P LA
TE F
O R
E LE
C TR
IC A
L R
AT IN
G .
2. A
LL F
IE LD
W IR
IN G
M U
S T
B E
IN A
C C
O R
D A
N C
E W
IT H
N E
C -N
FP A
#7 0,
C O
P P
E R
C O
N D
U C
TO R
S O
N LY
. 3.
2 08
/2 30
V U
N IT
S A
R E
F A
C TO
R Y
W IR
E D
F O
R 2
30 V
O P
E R
AT IO
N .
F
O R
2 08
V O
P E
R AT
IO N
, R E
M O
V E
L E
A D
F R
O M
2 40
T E
R M
IN A
L
A N
D C
O N
N E
C T
IT T
O 2
08 . C
A P
A LL
U N
U S
E D
T E
R M
IN A
LS .
4. F
O R
A LT
E R
N AT
IV E
E M
S C
O IL
V O
LT A
G E
S C
O N
S U
LT F
A C
TO R
Y. 5.
U P
M -1
IN C
LU D
E S
B U
IL T
IN : 2
70 -3
00 S
E C
O N
D R
A N
D O
M S
TA R
T
30 0
S E
C O
N D
D E
LA Y
O N
B R
E A
K
12 0
S E
C O
N D
L O
W P
R E
S S
U R
E B
Y PA
S S
6. T
E S
T D
IP S
W IT
C H
R E
D U
C E
S D
E LA
Y S
T O
1 0
S E
C W
H E
N S
E T
TO Y
E S
. M U
S T
B E
S E
T TO
N O
FO
R N
O R
M A
L O
P E
R AT
IO N
. 7.
F R
E E
ZE S
E N
S O
R O
N C
O N
D E
N S
E R
W IL
L O
P E
R AT
E A
T 26
F B
Y D
E FA
U LT
, I F
15 F
O P
E R
AT IO
N IS
R E
Q U
IR E
D J
U M
P E
R R
30 M
U S
T B
E C
U T.
I F
FR E
E ZE
S E
N S
O R
IS N
O T
IN S
TA LL
E D
A J
U M
P E
R S
H A
LL B
E IN
S TA
LL E
D B
E TW
E E
N T
H E
F R
E E
ZE 1
O R
F R
E E
ZE 2
S E
N S
O R
T E
R M
IN A
LS .
8. A
LA R
M O
U TP
U T
D IP
S W
IT C
H M
U S
T B
E S
E T
TO P
U LS
E I
F B
LI N
K IN
G T
-S TA
T S
E R
V IC
E L
IG H
T IS
D E
S IR
E D
. 9.
D E
FA U
LT S
E TT
IN G
S F
O R
D E
LU X
E D
B O
A R
D F
R O
M F
A C
TO R
Y S
H O
W N
. 10
. A LA
R M
O U
TP U
T IS
N O
R M
A LL
Y O
P E
N (N
O ) D
R Y
C O
N TA
C T.
IF 2
4 VA
C IS
N E
E D
E D
, C O
N N
E C
T R
T O
A LR
-C O
M T
E R
M IN
A L.
2 4
VA C
W IL
L B
E S
E N
S E
D
O N
T H
E A
LR -O
U T
W H
E N
T H
E U
N IT
IS IN
A LA
R M
C O
N D
IT IO
N . O
U TP
U T
W IL
L B
E P
U LS
E D
IF P
U LS
E IS
S E
LE C
TE D
. 11
. T E
R M
IN A
L B
LO C
K T
B 3
LO C
AT E
D IN
S ID
E D
IS C
O N
N E
C T
S W
IT C
H B
O X
. 12
. C H
E C
K F
O R
P R
O P
E R
P H
A S
E R
O TA
TI O
N O
N U
N IT
S W
IT H
S C
R O
LL C
O M
P R
E S
S O
R S
. R E
V E
R S
E R
O TA
TI O
N W
IL L
D A
M A
G E
T H
E C
O M
P R
E S
S O
R A
N D
V O
ID U
N IT
W A
R R
A N
TY .
13 . F
A C
TO R
Y- M
O U
N TE
D L
O O
P P
U M
P O
R T
W O
-W AY
W AT
E R
V A
LV E
. B O
TH D
E V
IC E
S W
IL L
N O
T B
E P
R E
S E
N T
IN T
H E
S A
M E
U N
IT .
14 . P
U M
P M
O TO
R IS
W IR
E D
B E
TW E
E N
L IN
E A
N D
N E
U TR
A L
FO R
3 80
-4 60
VA C
U N
IT S
. F O
R 2
08 /2
30 VA
C U
N IT
S P
U M
P M
O TO
R IS
W IR
E D
B E
TW E
E N
L IN
E S
. 15
. 2 08
/2 30
V A
N D
4 60
V B
LO W
E R
M O
TO R
S H
AV E
T H
R E
E S
P E
E D
T A
P S
. 5 75
B LO
W E
R M
O TO
R S
A R
E S
IN G
LE S
P E
E D
. F O
R 4
60 B
LO W
E R
M O
TO R
S W
IR E
B LA
C K
A N
D O
R A
N G
E
LE
A D
S T
O G
E TH
E R
F O
R M
E D
O R
L O
S P
E E
D O
P E
R AT
IO N
. C A
P U
N U
S E
D L
E A
D S
. 16
. B C
A C
O N
TA C
TS R
-Y O
P E
N O
N D
R O
P IN
W AT
E R
T E
M P
E R
AT U
R E
A N
D R
-B C
LO S
E .
D E
LU X
E D
F ig
. 2 0
E
O N
M o
to r,
T h
re e
P h
as e/
S in
g le
S ta
g e,
D el
u xe
D C
o n
tr o
l
23
Table 5 Standard Motor PSC for 007-012, Constant Torque for 015-070 Motor Electrical Data
LEGEND
50PS UNIT SIZE
RATED VOLTAGE
v-ph-Hz
COMPRESSOR BLOWER MOTOR MIN. CIRCUIT AMP MAX FUSE
Qty RLA LRA Qty FLA HP
007 280/230-1-60 1 2.5 17.7 1 0.96 0.10 4.1 15
265-1-60 1 2.6 13.5 1 0.85 0.10 4.1 15
009 208/230-1-60 1 3.4 22.2 1 0.96 0.10 5.2 15
265-1-60 1 2.9 18.8 1 0.85 0.10 4.5 15
012
115-1-60 1 9.6 58.4 1 2.20 0.10 14.2 20
208/230-1-60 1 4.6 27.9 1 0.96 0.10 6.7 15
265-1-60 1 3.8 22.2 1 0.85 0.10 5.6 15
015 208/230-1-60 1 5.6 29.0 1 2.80 0.33 9.8 15
265-1-60 1 4.6 20.0 1 2.60 0.33 8.4 15
018 208/230-1-60 1 7.4 33.0 1 2.80 0.33 12.1 15
265-1-60 1 6.0 28.0 1 2.60 0.33 10.1 15
024
208/230-1-60 1 13.5 58.3 1 2.80 0.33 19.7 30
265-1-60 1 9.0 54.0 1 2.60 0.33 13.9 20
208/230-3-60 1 7.1 55.4 1 2.80 0.33 11.7 15
460-3-60 1 3.5 28.0 1 2.10 0.50 6.5 15
030
208/230-1-60 1 12.8 58.3 1 4.10 0.50 20.1 30
265-1-60 1 9.6 54.0 1 3.60 0.50 15.6 25
208/230-3-60 1 7.7 55.4 1 2.80 0.50 12.4 20
460-3-60 1 3.6 28.0 1 2.10 0.50 6.6 15
036
208/230-1-60 1 16.0 77.0 1 6.00 0.75 26.0 40
208/230-3-60 1 10.0 71.0 1 6.00 0.75 18.5 25
460-3-60 1 4.7 38.0 1 4.60 0.75 10.5 15
042
208/230-1-60 1 16.7 79.0 1 6.00 0.75 26.9 40
208/230-3-60 1 10.4 73.0 1 6.00 0.75 19.0 25
460-3-60 1 5.8 38.0 1 4.60 0.75 11.9 15
048
208/230-1-60 1 19.9 109.0 1 6.00 0.75 30.9 50
208/230-3-60 1 13.6 83.1 1 6.00 0.75 23.0 35
460-3-60 1 6.1 41.0 1 4.60 0.75 12.2 15
060
208/230-1-60 1 25.0 134.0 1 7.60 1.00 38.9 60
208/230-3-60 1 15.9 110.0 1 7.60 1.00 27.5 40
460-3-60 1 7.1 52.0 1 4.00 1.00 12.9 20
070
208/230-1-60 1 26.3 134.0 1 7.60 1.00 40.5 60
208/230-3-60 1 15.6 110.0 1 7.60 1.00 27.1 40
460-3-60 1 7.8 52.0 1 4.00 1.00 13.8 20
FLA Full Load Amps LRA Locked Rotor Amps RLA Rated Load Amps
24
Table 6 ECM Motor Electrical Data
LEGEND
* 460-v unit contains 265-v fan motor and requires a neutral to power motor.
50PS UNIT SIZE
RATED VOLTAGE
v-ph-Hz
COMPRESSOR BLOWER MOTOR MIN. CIRCUIT AMP MAX FUSE
Qty RLA LRA Qty FLA HP
015 208/230-1-60 1 5.6 29.0 1 2.8 0.33 9.8 15
265-1-60 1 4.6 20.0 1 2.6 0.33 8.4 15
018 208/230-1-60 1 7.4 33.0 1 2.8 0.33 12.1 15
265-1-60 1 6.0 28.0 1 2.6 0.33 10.1 15
024
208/230-1-60 1 13.5 58.3 1 2.8 0.33 19.7 30
265-1-60 1 9.0 54.0 1 2.6 0.33 13.9 20
208/230-3-60 1 7.1 55.4 1 2.8 0.33 11.7 15 460-3-60* 1 3.5 28.0 1 4.1 0.50 8.5 15
030
208/230-1-60 1 12.8 58.3 1 4.3 0.50 20.3 30
265-1-60 1 9.6 54.0 1 4.1 0.50 16.1 25
208/230-3-60 1 7.7 55.4 1 4.3 0.50 13.9 20 460-3-60* 1 3.6 28.0 1 4.1 0.50 8.6 15
036
208/230-1-60 1 16.0 77.0 1 6.8 0.75 26.8 40
208/230-3-60 1 10.0 71.0 1 6.8 0.75 19.3 25 460-3-60* 1 4.7 38.0 1 5.5 0.75 11.4 15
042
208/230-1-60 1 16.7 79.0 1 6.8 0.75 27.7 40
208/230-3-60 1 10.4 73.0 1 6.8 0.75 19.8 30 460-3-60* 1 5.8 38.0 1 5.5 0.75 12.8 15
048
208/230-1-60 1 19.9 109.0 1 6.8 0.75 31.7 50
208/230-3-60 1 13.6 83.1 1 6.8 0.75 23.8 35 460-3-60* 1 6.1 41.0 1 5.5 0.75 13.1 15
060
208/230-1-60 1 25.0 134.0 1 9.1 1.00 40.4 60
208/230-3-60 1 15.9 110.0 1 9.1 1.00 29.0 40 460-3-60* 1 7.1 52.0 1 6.9 1.00 15.8 20
070
208/230-1-60 1 26.3 134.0 1 9.1 1.00 42.0 60
208/230-3-60 1 15.6 110.0 1 9.1 1.00 28.6 40 460-3-60* 1 7.8 52.0 1 6.9 1.00 16.7 20
FLA Full Load Amps LRA Locked Rotor Amps RLA Rated Load Amps
25
Step 9 Wire Field Controls
All field wiring must comply with local and national fire, safety and electrical codes. Power to the unit must be within the operating voltage range indicated on the units nameplate. On three phase units, phases must be balanced within 2%.
Properly sized fuses or HACR circuit breakers must be in- stalled for branch circuit protection. See equipment rating plates for proper size.
The heat pump units are provided with a concentric knock- out in the front right corner post for attaching common trade sizes of conduit. Route power supply wiring through this open- ing. Flexible wiring and conduit should be used to isolate vi- bration and noise from the building structure. Be certain to con- nect the ground lead to the ground lug in the control box. Con- nect the power leads as indicated on the unit wiring diagrams. THERMOSTAT CONNECTIONS Thermostat wiring is connected to a 7 position low voltage terminal block in the electrical box. The thermostat connections and their functions are as follows:
Y Compressor Operation G Fan O Reversing Valve (energized in cooling) C Transformer 24 VAC Common 3 Connections R Transformer 24 VAC Hot If the unit is being connected to a thermostat with a mal-
function light, this connection is made at the unit alarm output.
SAFETY DEVICES AND COMPLETE C CONTROL- LER Each unit is factory provided with a Complete C board controller that controls the compressor operation and monitors the safety.
If the unit is being connected to a thermostat with a mal- function light, this connection is made at the unit malfunction output or relay. See to Fig. 21. Safety controls include the following: High pressure switch located in the refrigerant discharge
line and wired across the HPC terminals on the C Board Low pressure switch located in the unit refrigerant suc-
tion line and wired across terminals LPC1 and LPC2 on the C Board
Complete C board dry contacts are normally open (NO) Water side freeze protection sensor, mounted close to
condensing water coil, monitors refrigerant temperature be- tween condensing water coil and thermal expansion valve. If temperature drops below or remains at freeze limit trip for 30 seconds, the controller will shut down the compressor and enter into a soft lockout condition. The default freeze limit trip is 30 F, however this can be changed to 15 F by cutting the R30 or Freeze1 resistor located on top of DIP switch SW1. Refer to Fig. 21, item [3] for resistor location. If unit is employing a fresh water system (no anti-freeze protection), it is extremely important to have the Freeze1 R30 resistor set to 30 F in order to shut down the unit at the appropriate leaving water temperature and protect your heat pump from freezing if a freeze sensor is included.
WARNING
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.
CAUTION
Operating the unit with improper line voltage or with excessive phase imbalance is hazardous to the unit and constitutes abuse and is not covered under warranty.
IMPORTANT: If the thermostat is provided with a mal- function light powered off of the common (C) side of the transformer, a jumper between R and COM terminal of ALR contacts must be made.
IMPORTANT: If the thermostat is provided with a mal- function light powered off of the hot (R) side of the trans- former, then the thermostat malfunction light connection should be connected directly to the (ALR) contact on the units Complete C board.
1
2
3
4
5
6 7 9 10
111213
17
1415 168
1 Board Power Indicator 2 C Board Status LED Indicator 3 Water Coil Freeze Protection Temperature Selection [R30] 4 Air Coil Freeze Protection Temperature Selection 5 C Board Settings 6 Water Coil Freeze Connection 7 Air Coil Freeze Connection 8 LED Status-Diagnostic Connection 9 24VAC Power Input
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 16 Dry Contact 17 C Board Ground Standoff
Fig. 21 Complete C Control Board
26
Evaporator freeze protection sensor, mounted between the thermal expansion device and the evaporator, moni- tors refrigerant temperature between the evaporator coil and thermal expansion valve. If temperature drops below or remains at freeze limit trip for 30 seconds, the control- ler will shut down the compressor and enter into a soft lockout condition. The default freeze limit trip is 30 F.
The condensate overflow protection sensor is located in the drain pan of the unit and connected to the COND terminal on the C board.
The C Board includes the following features: Anti-short Cycle Time A 5-minute delay on break timer to prevent compressor short cycling. Random Start Each controller has a unique random start delay ranging from 270 to 300 seconds to reduce the chances of multiple units simultaneously starting after initial power up or after a power interruption, creating a large electrical spike. Low Pressure Bypass Timer If the compressor is running and the low-pressure switch opens, then the control will keep the compressor on for 120 seconds. After 2 minutes if the low- pressure switch remains open, the control will shut down the compressor and enter a soft lockout. The compressor will not be energized until the low-pressure switch closes and the anti- short cycle time delay expires. If the low-pressure switch opens 2 to 4 times in 1 hour, the unit will enter a hard lock out and need to be reset.
Brownout/surge/power Interruption Protection The brownout protection in the C board will shut down the com- pressor if the incoming power falls below 18 VAC. The com- pressor will remain off until the voltage goes above 18 VAC and the anti short cycle timer (300 seconds) times out. The unit will not go into a hard lockout. Malfunction Output Alarm output is normally open (NO) dry contact. If 24 VAC output is needed R must be wired to the ALR-COM terminal; 24VAC will be available on the ALR- OUT terminal when the unit is in alarm condition. If pulse is selected the alarm output will be pulsed. The fault output will depend on the dip switch setting for ALARM. If it set to CONST, a constant signal will be produced to indicate a fault has occurred and the unit requires inspection to determine the type of fault. If it is set to PULSE, a pulse signal is produced and a fault code is detected by a remote device indicating the fault. See LED Fault Indication below for blink code explana- tions. The remote device must have a malfunction detection ca- pability when the C board is set to PULSE. Test DIP Switch A test DIP switch is provided to reduce all time delay settings to 10 seconds during troubleshooting or verification of unit operation. Note that operation of the unit while in test mode can lead to accelerated wear and premature failure of the unit. The TEST switch must be set back to NO for normal operation. Freeze Sensor The default setting for the freeze limit trip is 30 F (sensor number 1); however this can be changed to 15 F by cutting the R30 resistor located on top of the DIP switch SW1. The default setting for the freeze limit trip is 30 F (sensor number 1); however this can be changed to 15 F by cutting the R24 resistor located on top of the DIP switch SW1. Since freeze sensor 2 is dedicated to monitor the evaporator coil it is recommended to leave the factory default setting on the board. The C board controller will constantly monitor the refrigerant temperature with the sensor mounted close to the condensing water coil between the thermal expansion valve and water coil. If temperature drops below or remains at the freeze limit trip for 30 seconds, the controller will shut the compressor down and enter into a soft lockout condition. Both the status LED and the Alarm contact will be active. The LED will flash three times with the code associated with this alarm condition. If this alarm occurs 2 times (or 4 if DIP switch is set to 4) within an hour, the C board controller will enter into a hard lockout con- dition. It will constantly monitor the refrigerant temperature with the sensor mounted close to the evaporator between the thermal expansion valve and evaporator coil. If temperature drops below or remains at the freeze limit trip for 30 seconds, the controller will shut the compressor down and enter into a soft lockout condition. Both the status LED and the Alarm con- tact will be active. The LED will flash six times the code asso- ciated with this alarm condition. If this alarm occurs 2 times (or 4 if DIP switch is set to 4) within an hour, the controller will enter into a hard lockout condition.
Intelligent Reset If a fault condition is initiated, the 5 min- ute delay on break time period is initiated and the unit will re- start after these delays expire. During this period, the fault LED will indicate the cause of the fault. If the fault condition still ex- ists or occurs 2 or 4 times (depending on 2 or 4 setting for Lockout dip switch) before 60 minutes, the unit will go into a hard lockout and requires a manual lockout reset. A single con- densate overflow fault will cause the unit to go into a hard lock- out immediately, and will require a manual lockout reset.
C BOARD FACTORY DEFAULT SETTINGS Temperature 30 F
Lockout 2 Reset Y Alarm Pulse Test NO
C DIP SWITCH DEFAULT POSITION Lockout 4 2
Reset R Y Alarm Cont Pulse Test Yes No
IMPORTANT: If freeze protection sensor is not installed, a jumper between freeze contacts must be installed on the C board. Otherwise, unit will not start. See Fig. 22.
Fig. 22 No Freeze Protection Sensor
IMPORTANT: If unit is employing a fresh water system (no anti-freeze protection), it is extremely important to have the Freeze jumper R42 resistor set to 30 F in order to shut down the unit at the appropriate leaving water tem- perature and protect your heat pump from freezing if a freeze sensor is included.
27
Lockout Reset A hard lockout can be reset by turning the unit thermostat off and then back on when the RESET dip switch is set to Y or by shutting off unit power at the circuit breaker when the RESET dip switch is set to R. The blow- er motor will remain active during a lockout condition. CONSIDERATIONS 1. Always check incoming line voltage power supply and
secondary control voltage for adequacy. Transformer pri- maries are dual tapped for 208 and 230 volts. Connect the appropriate tap to ensure a minimum of 18 volts second- ary control voltage. 24 volts is ideal for best operation.
2. Long length thermostat and control wiring leads may cre- ate voltage drop. Increase wire gauge or up-size trans- formers may be required to ensure minimum secondary voltage supply.
3. The following guidelines are recommended for wiring between a thermostat and the unit: 18 GA up to 60 foot, 16 GA up to 100 ft and 14 GA up to 140 ft.
4. Do not apply additional controlled devices to the control circuit power supply without consulting the factory. Do- ing so may void equipment warranties.
5. Check with all code authorities on requirements involv- ing condensate disposal/over flow protection criteria.
Operate ECM Interface Board In addition to pro- viding a connecting point for thermostat wiring, the interface board also translates thermostat inputs into control commands for the Electronic Commutated Motor (ECM) DC fan motor
and provides thermostat signals to units Complete C control. The thermostat connections and their functions are shown in Fig. 23.
CFM count indicator (See Fig. 24, item 6) blinks to indicate approximate airflow in CFM and may flicker when unit is off. Each blink of the LED represents approximately 100 CFM of air delivery, so if the LED blinks 12 times, pauses, blinks 12 times, etc. the blower is delivering approximately 1200 CFM. THERMOSTAT OUTPUTS
Y1 First Stage Compressor Operation Y2 Second Stage Compressor Operation G Fan O Reversing Valve (energized in cooling) W1 Auxiliary Electric Heat (runs with compressor) EM/W2 Emergency Heat (electric heat only) NC Transformer 24 VAC Common (extra connection) C1 Transformer 24 VAC Common (primary connection) R Transformer 24 VAC Hot H Dehumidification Mode
IMPORTANT: CFM LED is an approximation. Utilize conventional Test and Balance equipment for accurate airflow measurement.
SUCTION
COMPRESSOR
DISCHARGECOAXEXPANSION VALVE
F F
AIR COIL
F
PSI WATER OUTWATER IN
F
PSI
LOOK UP PRESSURE DROP IN TABLES 20-30 TO DETERMINE FLOW RATE
F
LIQUID LINE
PSI
F
SAT
Fig. 23 Low Voltage Field Wiring
a50-8197
28
NOTE: Power must be off to the unit for at least three seconds before the ECM will recognize a speed change. The motor will recognize a change in the CFM adjust or Dehumidification mode settings while the unit is powered.
There are three different airflow settings from lowest air- flow rate (speed tap 1) to the highest airflow rate (speed tap 4).
COOLING The cooling setting determines the cooling (normal) cfm for all units with ECM motor. Cooling (normal) setting is used when the unit is not in Dehumidification mode. Tap 1 is the lowest cfm setting, while tap 4 is the highest cfm setting. To avoid air coil freeze-up, tap 1 may not be used if the Dehumidification mode is selected. HEATING The heating setting determines the heating cfm for 50PSH, PSV units. Tap 1 is the lowest cfm setting, while tap 4 is the highest cfm setting. CFM ADJUST The CFM Adjust setting allows four selec- tions. The NORM setting is the factory default position. The + or settings adjust the airflow by 15%. The + or settings are used to fine tune airflow adjustments. The TEST setting runs the ECM at 70% torque, which causes the motor to operate like a standard PSC motor, and disables the cfm counter. DEHUMIDIFICATION MODE The dehumidification mode setting provides field selection of humidity control. When operating in the normal mode, the cooling airflow settings are determined by the cooling tap setting. When dehumidification is enabled, there is a reduction in airflow in cooling to increase the moisture removal of the heat pump. The Dehumidification mode can be enabled in two ways: 1. Constant Dehumidification mode: When the Dehumidifi-
cation mode is selected via DIP switch, the ECM will operate with a multiplier applied to the cooling CFM settings (approximately 20 to 25% lower airflow). Any time the unit is running in the Cooling mode, it will oper- ate at the lower airflow to improve latent capacity. The DEHUM LED will be illuminated at all times. Heating airflow is not affected. NOTE: Do not select Dehumidification mode if cooling setting is tap 1.
2. Automatic (humidistat-controlled) Dehumidification mode: When the Dehumidification mode is selected via DIP switch AND a humidistat is connected to termi- nal DH, the cooling airflow will only be reduced when the humidistat senses that additional dehumidification is required. The DH terminal is reverse logic. Therefore, a humidistat (not dehumidistat) is required. The DEHUM LED will be illuminated only when the hu- midistat is calling for Dehumidification mode. Heating airflow is not affected. NOTE: Do not select Dehumidification mode if cooling setting is tap 1.
PRE-START-UP
System Checkout After completing the installation and before energizing the unit, the following system checks should be made prior to initial startup: 1. Verify that the supply voltage to the heat pump is in ac-
cordance with the nameplate ratings. 2. Make sure that all electrical connections are tight and se-
cure. 3. Check the electrical fusing and wiring for the correct size. 4. Verify that the low voltage wiring between the thermostat
and the unit is correct. 5. Verify that the water piping is complete and correct. 6. Check that the water flow is correct, and adjust if neces-
sary. 7. Check the blower for free rotation, and that it is secured to
the shaft. 8. Verify that vibration isolation has been provided. 9. Unit is serviceable. Be certain that all access panels are
secured in place. 10. Verify that the blower support has been removed. 11. Verify that ductwork has been properly fastened to supply
and return duct collars. 12. Make sure return air filters are positioned correctly in the
filter rack if removed during installation. AIR COIL To obtain maximum performance, clean the air coil before starting the unit. A 10% solution of dishwasher detergent and water is recommended for both sides of the coil. Rinse thoroughly with water.
R R C1 C2
10
EM W1 O Y2 Y1 G
H C
W2
W1
O
Y2
Y1
G
CFM
H
CFM ADJUST A B C D
NORM [+] [-]
TEST
HGRH
YES NO
HGRH
J01
R C G O Y1 Y2 W1 W2 H C
1 3
9 8 7 6 5 2 4 11
Fig. 24 ECM Interface Board Physical Layout
1 Motor harness plug 2 Blower CFM adjustment 3 Motor settings 4 Dehumidification indication 5 Thermostat digital contact inputs 6 CFM count indicator 7 Thermostat input status indication 8 Reheat digital outputs 9 Thermostat outputs
10 24 VAC 11 Dehumidification method selector
CAUTION
When the disconnect switch is closed, high voltage is pres- ent in some areas of the electrical panel. Exercise caution when working with energized equipment. Failure to heed this safety precaution could lead to personal injury.
29
START-UP Use the procedure outlined below to initiate proper unit
start-up. NOTE: This equipment is designed for indoor installation only. Set the thermostat to the highest setting.
Operating Limits ENVIRONMENT This equipment is designed for indoor installation only. Extreme variations in temperature, humidity and corrosive water or air will adversely affect the unit perfor- mance, reliability and service life. POWER SUPPLY A voltage variation of 10% of name- plate utilization voltage is acceptable. UNIT STARTING CONDITIONS Units start and operate in an ambient temperature of 45 F with entering-air tempera- ture at 50 F, entering-water temperature at 60 F and with both air and water at the flow rates used. NOTE: These operating limits are not normal or continuous operating conditions. Assume that such a start-up is for the purpose of bringing the building space up to occupancy tem- perature. See Table 7 for operating limits.
1. Restore power to system. 2. Turn thermostat fan position to ON. Blower should start. 3. Balance airflow at registers. 4. Adjust all valves to the full open position and turn on the
line power to all heat pump units. 5. Operate unit in the cooling cycle. Refer to Table 7 for unit
operating limits. NOTE: Three factors determine the operating limits of a unit: (1) entering air temperature, (2) water temperature and (3) ambient temperature. Whenever any of these factors are at a minimum or maximum level, the other two factors must be at a normal level to ensure proper unit operation.
Table 7 Operating Limits
LEGEND
*Antifreeze solution is required at these fluid temperatures.
Scroll Compressor Rotation It is important to be certain the compressor is rotating in the proper direction. To determine whether or not the 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 correct.
The suction and discharge pressure levels should now move to their normal start-up levels.
When the compressor is rotating in the wrong direction, the unit makes more noise and does not provide cooling.
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.
Unit Start-Up Cooling Mode 1. Adjust the unit thermostat to the warmest position.
Slowly reduce the thermostat position until the compres- sor activates.
2. Check for cool air delivery at unit grille a few minutes after the unit has begun to operate.
3. Verify that the compressor is on and that the water flow rate is correct by measuring pressure drop through the heat exchanger using P/T plugs. See Table 8. Check the elevation and cleanliness of the condensate lines; any dripping could be a sign of a blocked line. Be sure the condensate trap includes a water seal.
4. Check the temperature of both supply and discharge water. If temperature is within range, proceed. If tempera- ture is outside the range, check the cooling refrigerant pressures. Contact Carrier Commercial Services or prod- uct management for acceptable temperature ranges.
5. Check air temperature drop across the coil when com- pressor is operating. Air temperature drop should be between 15 and 25 F.
Table 8 Water Temperature Change through Heat Exchanger
Unit Start-Up Heating Mode NOTE: Operate the unit in heating cycle after checking the cooling cycle. Allow 5 minutes between tests for the pressure or reversing valve to equalize. 1. Turn thermostat to lowest setting and set thermostat
switch to HEAT position. 2. Slowly turn the thermostat to a higher temperature until
the compressor activates. 3. Check for warm air delivery at the unit grille within a few
minutes after the unit has begun to operate. 4. Check the temperature of both supply and discharge
water. If temperature is within range, proceed. If tempera- ture is outside the range, check the heating refrigerant
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. Failure to heed this warning may result in personal injury.
AIR LIMITS STANDARD UNIT
EXTENDED RANGE OPTION
COOLING Minimum ambient air temperature F 50 50 Maximum ambient air temperature F 100 100 Minimum evaporator entering air db/wb F 68/57 68/57 Rated air coil entering air db/wb F 80/67 80/67 Maximum evaporator entering air db/wb F 95/85 98/85 Minimum water coil entering fluid temperature F 50 50
Water loop typical coil entering fluid range temperature F 70/90 70/90
Maximum water coil entering fluid temperature F 110 110
HEATING Minimum ambient air temperature F 50 40 Maximum ambient air temperature F 100 85 Minimum evaporator entering air db F 50 50 Rated air coil entering air F 68 68 Maximum evaporator entering air db F 80 80 Normal water coil entering fluid range F 50-80 25-80* Minimum water coil entering Fluid F 50 20*
db Dry Bulb wb Wet Bulb
WATER FLOW RATE (GPM) COOLING RISE (F)
HEATING DROP (F)
Min Max Min Max For Closed Loop: Ground Source or Cooling/Boiler Systems at 3 gpm/ton 9 12 4 8
For Open Loop: Ground Water Systems at 1.5 gpm/ton 20 26 10 17
30
pressures. Contact Carrier Commercial Services or prod- uct management for acceptable temperature ranges.
5. Once the unit has begun to run, check for warm air deliv- ery at the unit grille.
6. Check air temperature rise across the coil when compres- sor is operating. Air temperature rise should be between 20 and 30 F after 15 minutes at load.
7. Check for vibration, noise and water leaks.
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 1.5 to 2 gpm is achieved. Since the pressure constantly varies, two pressure gages may be needed in some applications.
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 well water setup.
Flushing Once the piping is complete, units require final purging and loop charging. A flush cart pump of at least 1.5 hp is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop. Flush the loop in both direc- tions with a high volume of water at a high velocity. Follow the steps below to properly flush the loop: 1. Verify power is off. 2. Fill loop with water from hose through flush cart before
using flush cart pump to ensure an even fill. Do not allow the water level in the flush cart tank to drop below the pump inlet line in order to prevent air from filling the line.
3. Maintain a fluid level in the tank above the return tee in order to avoid air entering back into the fluid.
4. Shutting off the return valve that connects into the flush cart reservoir will allow 50 psig surges to help purge air pockets. This maintains the pump at 50 psig.
5. To purge, keep the pump at 50 psig until maximum pumping pressure is reached.
6. Open the return valve to send a pressure surge through the loop to purge any air pockets in the piping system.
7. A noticeable drop in fluid level will be seen in the flush cart tank. This is the only indication of air in the loop. NOTE: If air is purged from the system while using a 10 in. PVC flush tank, the level drop will only be 1 to 2 in. since liquids are incompressible. If the level drops more than this, flushing should continue since air is still being compressed in the loop. If level is less than 1 to 2 in., reverse the flow.
8. Repeat this procedure until all air is purged. 9. Restore power.
Antifreeze may be added before, during, or after the flush- ing process. However, depending on when it is added in the process, it can be wasted. Refer to the Antifreeze section for more detail.
Loop static pressure will fluctuate with the seasons. Pres- sures will be higher in the winter months than during the warm- er months. This fluctuation is normal and should be considered when charging the system initially. Run the unit in either
heating or cooling for several minutes to condition the loop to a homogenous temperature.
When complete, perform a final flush and pressurize the loop to a static pressure of 40 to 50 psig for winter months or 15 to 20 psig for summer months.
After pressurization, be sure to remove the plug from the end of the loop pump motor(s) to allow trapped air to be discharged and to ensure the motor housing has been flooded. Be sure the loop flow center provides adequate flow through the unit by checking pressure drop across the heat exchanger.
Antifreeze In areas where entering loop temperatures drop below 40 F 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 15 F below the lowest expected entering loop temperature. For example, if the lowest expected entering loop temperature is 30 F, the leav- ing loop temperature would be 22 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. See Table 9. Use the percentage by volume in Table 10 to deter- mine the amount of antifreeze to use. Antifreeze concentration should be checked from a well-mixed sample using a hydrom- eter to measure specific gravity. FREEZE PROTECTION SELECTION The 30 F 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 13 F) set point to avoid nuisance faults.
Table 9 Approximate Fluid Volume (gal.) per 100 Ft of Pipe
LEGEND
NOTE: Volume of heat exchanger is approximately 1.0 gallon.
Table 10 Antifreeze Percentages by Volume
Cooling Tower/Boiler Systems These systems typically use a common loop temperature maintained at 50 to 100 F. Carrier recommends using a closed circuit evaporative cooling tower with a secondary heat exchanger between the tower and the water loop. If an open type cooling tower is used continuously, chemical treatment and filtering will be necessary.
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.
IMPORTANT: All alcohols should be pre-mixed and pumped from a reservoir outside of the building or introduced under water level to prevent fuming.
PIPE DIAMETER (in.) VOLUME (gal.) Copper 1 4.1
1.25 6.4 1.5 9.2
Rubber Hose 1 3.9 Polyethylene 3/4 IPS SDR11 2.8
1 IPS SDR11 4.5 11/4 IPS SDR11 8.0 1/2 IPS SDR11 10.9 2 IPS SDR11 18.0 11/4 IPS SCH40 8.3 11/2 IPS SCH40 10.9 2 IPS SCH40 17.0
IPS Internal Pipe Size SCH Schedule SDR Standard Dimensional Ratio
ANTIFREEZE MINIMUM TEMPERATURE FOR
FREEZE PROTECTION (F) 10 15 20 25
Methanol (%) 25 21 16 10 100% USP Food Grade Propylene Glycol (%) 38 30 22 15
Ethanol (%) 29 25 20 14
31
Ground Coupled, Closed Loop and Plateframe Heat Exchanger Well Systems These systems al- low water temperatures from 25 to 110 F. The external loop field is divided up into 2 in. 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. Locate air separation in the piping sys- tem prior to the fluid re-entering the loop field.
OPERATION
Cooling Mode When the thermostat calls for cooling (Y), the loop pump or solenoid valve if present is energized and compressor will start. Once the thermostat is satisfied, the com- pressor shuts down accordingly and the fan ramps down to ei- ther fan only mode or off over a span of 30 seconds (ECM Mo- tors). NOTE: A fault condition initiating a lockout will de-energize the compressor.
Heating Mode Heating operates in the same manner as cooling, but with the reversing valve de-energized. The com- pressor will run until the desired setpoint temperature on the thermostat is achieved. Once the thermostat is satisfied, the compressor shuts down and the fan ramps down in either fan only mode or turns off over a span of 30 seconds.
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.
Units with Aquazone Complete C Control STANDBY Y and W terminals are not active in Standby mode. However, the O and G terminals may be active, depend- ing on the application. 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 270 to 300 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 active in heating stage 1. After power up, the first call to the compressor will initiate a 270 to 300 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 2 To enter Stage 2 mode (units equipped with 2 step compressor or with two compressors on- ly), terminal Y2 is active (Y is already active). Also, the G ter- minal must be active or the W terminal is disregarded. The compressor relay will remain on and EH1 is immediately turned on. EH2 will turn on after 10 minutes of continual stage 2 demand. LOCKOUT MODE The status LED will flash fast in Lockout mode and the compressor relay will be turned off immediately. Lockout mode can be soft reset via the Y input or can be reset via the disconnect depending on the DIP switch settings. The last fault causing the lockout is stored in memory and can be viewed by entering test mode. LOCKOUT WITH EMERGENCY HEAT While in Lock- out mode, if W becomes active, then Emergency Heat mode will occur. EMERGENCY HEAT In Emergency Heat mode, termi- nal W is active while terminal Y is not. Terminal G must be ac-
tive in the 50PS units the fan will be run if W is energized. EH1 is immediately turned on. EH2 will turn on.
Units with Aquazone Deluxe D Control STANDBY/FAN ONLY The compressor will be off. The Fan Enable, Fan Speed, and reversing valve (RV) relays will be on if inputs are present. NOTE: DIP switch 5 on S1 does not have an effect upon Fan 1 and Fan 2 outputs. HEATING STAGE 1 In Heating Stage 1 mode, the Fan Enable and Compressor relays are turned on immediately. Once the demand is removed, the relays are turned off and the control reverts to Standby mode. EMERGENCY HEAT In Emergency Heat mode, the Fan Enable and Fan Speed relays are turned on. The EH1 output is turned on immediately. COOLING STAGE 2 In Cooling Stage 2 mode, the Fan Enable, compressor and RV relays remain on. The Fan Speed relay is turned on immediately and turned off immediately once the Cooling Stage 2 demand is removed. The control reverts to Cooling Stage 1 when the thermostat removes all Y2 call.
Units with Hot Gas Reheat Option FAN ONLY A (G) call from the thermostat to the (G) ter- minal of the Deluxe D control board will bring the unit on in fan only mode. COOLING STAGE 1 A simultaneous call from (G), (Y1), and (O) to the (G), (Y1) will bring the unit on in Cooling Stage 1. COOLING STAGE 2 A simultaneous call from (G), (Y1), (Y2), and (O) to the (G) will bring the unit on in Cooling Stage 2. When the call is satisfied at the thermostat the unit will con- tinue to run in Cooling Stage 1 until the 49 Cooling Stage 1 call is removed or satisfied, shutting down the unit. NOTE: Not all units have two-stage cooling functionality. HEATING STAGE 1 A simultaneous call from (G) and (Y1) to the (G) and (Y1) terminals will bring the unit on in Heating Stage 1. HEATING STAGE 2 A simultaneous call from (G), (Y1), and (Y2) will bring the unit on in Heating Stage 2. When the call is satisfied at the thermostat the unit will continue to run in Heating Stage 1 until the call is removed or satisfied, shutting down the unit. NOTE: Not all units have two-stage heating functionality. REHEAT MODE A call from the humidistat/dehumidistat to the (H) terminal will bring the unit on in Reheat mode if there is no call for cooling at the thermostat. When the humidi- stat/dehumidistat call is removed or satisfied the unit will shut down. NOTE: Cooling always overrides Reheat mode. In the Cooling mode, the unit cools and dehumidifies. If the cooling thermo- stat is satisfied but there is still a call for dehumidification, the unit will continue to operate in Reheat mode.
Sequence of Operation - On/Off Control The sequence of operation in the cooling and heating mode is the same as a regular heat pump. In the reheat mode on a call from the humidistat the reheat relay coil is energized through the H circuit. The blower relay, reversing valve and compressor contactor are energized through the contacts of the reheat relay. See typical wiring diagrams at the end of the manual. The cool- ing relay remains deenergized enabling the reheat solenoid. NOTE: The reheat mode always operates in the cooling mode.
Should the temperature in the space increase above set point the compressor terminal Y is energized which will de-energize the reheat valve putting the unit into the straight cooling mode.
32
A call for cooling or heating will always take precedence over hot gas reheat.
COMPLETE C AND DELUXE D BOARD SYSTEM TEST
Test mode provides the ability to check the control opera- tion in a timely manner. The control enters a 20-minute test mode by momentarily shorting the test terminals. All time de- lays are sped up 15 times. The follow operations are common to both Complete C and Deluxe D controls.
Retry Mode In Retry mode, the staus LED will flash the code for the corresponding fault. If the fault clears and the thermostat call (Y) is still present the Complete C or Deluxe D control will run the compressor once the ASC (anti-short cycle) timer has expired and will try to satisfy the call. If the call is satisfied, the unit will resume its normal operation.
If 2 or 4 consecutive faults occur (depending on the DIP switch setting) within 1 hour, the controller will lock the com- pressor operation out and will flash the alarm code on the status LED as well as alarm dry contact output. When the Complete C or Deluxe D control enters lockout mode, the alarm will also be shown on the panel mounted LED.
LED Fault Indication Two LED indicators are pro- vided. The GREEN power LED indicates 18-30 VAC present at the board. The RED LED is a fault indicator with blink codes as follows: One Blink = High pressure lockout Two Blinks = Low pressure lockout Three Blinks = Freeze sensor lockout Four Blinks = Condensate overflow Five Blinks = Brownout
Complete C Board Default Settings The Com- plete C board will come from the factory with the following de- fault settings: Freeze Terminals not jumped on all the time Temp 30 F Lockout 2 Reset Y Alarm PULSE Test NO Dry Contact Normally Open (NO)
SERVICE Perform the procedures outlined below periodically, as
indicated. An annual checkup is recommended by a licensed refrig-
eration mechanic. Recording the performance measurements of volts, amps, and water temperature differences (both heating and cooling) is recommended. This data should be compared to the information on the units data plate and the data taken at the original startup of the equipment.
Periodic lockouts almost always are caused by air or water flow problems. The lockout (shutdown) of the unit is a normal protective measure in the design of the equipment. If continual lockouts occur, call a mechanic immediately and have them check for: water flow problems, water temperature problems, air flow problems or air temperature problems. Use of the pres- sure and temperature charts for the unit may be required to properly determine the cause.
Filters Filter changes or cleanings are required at regular intervals. The time period between filter changes will depend upon the type of environment the equipment is used in. In a single family home that is not under construction, changing or cleaning the filter every 60 days may be sufficient. In other ap- plications such as motels, where daily vacuuming produces a large amount of lint, filter changes may need to be as frequent as biweekly. See Fig. 1 and 2 for replacement filter sizes. NOTE: Horizontal units containing two filters are taped together at the factory to facilitate removal. This should be done by end user as new filters are installed.
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.
Inspect heat exchangers regularly, and clean more frequent- ly if the unit is located in a dirty environment. Keep the heat exchanger 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 15 psig during the summer and 40 psig during the winter. Check P trap frequently for proper operation.
Condensate Drain Pans The condensate drain should be checked annually by cleaning and flushing to ensure proper drainage.
Check condensate drain pans for algae growth twice a year. If algae growth is apparent, consult a water treatment specialist for proper chemical treatment. Applying an algaecide every three months will typically eliminate algae problems in most locations.
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.
Check to see that unit is within the superheat and subcool- ing temperature ranges. If the unit is not within these ranges, recover and reweigh in refrigerant charge.
Compressor Conduct annual amperage checks to en- sure that amp draw is no more than 10% greater than indicated on the serial plate data.
WARNING
To prevent injury or death due to electrical shock or contact with moving parts, open unit disconnect switch before ser- vicing unit.
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: 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.
IMPORTANT: To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must only be serviced by technicians who meet local, state and federal proficiency requirements.
IMPORTANT: Units should never be operated without a filter.
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.
33
Fan Motors All units have lubricated fan motors. Fan motors should never be lubricated unless obvious, dry opera- tion is suspected. Periodic maintenance oiling is NOT recom- mended, as it will result in dirt accumulating in the excess oil and cause eventual motor failure. Conduct annual dry opera- tion check and amperage check to ensure amp draw is no more than 10% greater than indicated on serial plate data.
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 compressed air. Use a fin comb of the correct tooth spacing when straightening mashed or bent coil fins.
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.
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.
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, but take care to prevent liquid from being carried over by the gases.
Warm solution acts faster, but cold solution is just as effec- tive if applied for a longer period. 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 manufacturers instructions. See Fig. 25. 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. 26.
Regulate flow to condenser with a supply line valve. If pump is a non overloading 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- facturers 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. 3. After unit conditions have stabilized, read head pressure
on discharge line gage. NOTE: Operate unit a minimum of 15 minutes before checking charge.
4. From standard field-supplied Pressure-Temperature chart for R-410A, find equivalent saturated condensing temperature.
5. Read liquid line temperature on thermometer; then subtract from saturated condensing temperature. The dif- ference equals subcooling temperature.
6. Compare the subcooling temperature with the normal temperature. If the measured liquid line temperature does not agree with the required liquid line temperature, ADD refrigerant to raise the temperature or REMOVE refriger- ant (using standard practices) to lower the temperature (allow a tolerance of 3 F).
CAUTION
Follow all safety codes. Wear safety glasses and rubber gloves when using inhibited hydrochloric acid solution. Observe and follow acid manufacturers instructions.
FILL CONDENSER WITH CLEANING SOLUTION. DO NOT ADD SOLUTION MORE RAPIDLY THAN VENT CAN EXHAUST GASES CAUSED BY CHEMICAL ACTION.
PAIL
FUNNEL
CONDENSER
PAIL
3 TO 4
VENT PIPE 5 APPROX
1 PIPE
Fig. 25 Gravity Flow Method A50-6286
SUCTION
PUMP SUPPORT
TANK
FINE MESH SCREEN
RETURN
GAS VENTPUMP PRIMING CONN.
GLOBE VALVES
SUPPLY
1 PIPE
CONDENSER
REMOVE WATER REGULATING VALVE
Fig. 26 Forced Circulation Method A50-6287
34
Refrigerant Charging
NOTE: Do not vent or depressurize unit refrigerant to atmo- sphere. Remove and recover refrigerant following accepted practices.
Air Coil Fan Motor Removal
Disconnect motor power wires from motor terminals before motor is removed from unit. 1. Shut off unit main power supply. 2. Loosen bolts on mounting bracket and remove inlet ring. 3. Remove motor.
Slide motor/bracket assembly to extreme right and lift out through space between 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.
TROUBLESHOOTING When troubleshooting problems with a WSHP, consider the
following:
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. 27.
Thermistor A thermistor may be required for single- phase units where starting the unit is a problem due to low voltage. See Fig. 28 for thermistor nominal resistance.
Thermostatic Expansion Valves Thermostat- ic expansion valves (TXV) are used as a means of metering the refrigerant through the evaporator to achieve a preset superheat at the TXV sensing bulb. Correct superheat of the refrigerant is important for the most efficient operation of the unit and for the life of the compressor.
Packaged heat pumps typically use one bi-flow TXV to me- ter refrigerant in both modes of operation. When diagnosing possible TXV problems it may be helpful to reverse the refrig- erant flow to assist with the diagnosis.
Geothermal and water source heat pumps are designed to op- erate through a wide range of entering water temperatures that will have a direct effect on the unit refrigerant operating pres- sures. Therefore, diagnosing TXV problems can be difficult. TXV FAILURE The most common failure mode of a TXV is when the valve fails while closed. Typically, a TXV uses spring pressure to close the valve and an opposing pressure, usually from a diaphragm, to open the valve. The amount of pressure exerted by the diaphragm will vary, depending on the pressure inside of the sensing bulb. As the temperature of and pressure within the bulb decreases, the valve will modulate closed and restrict the refrigerant flow through the valve. The result is less refrigerant in the evaporator and an increase in the superheat. As the temperature at the bulb increases, the dia- phragm pressure will increase, which opens the valve and allows more refrigerant flow and a reduction in the superheat.
WARNING
To prevent personal injury, wear safety glasses and gloves when handling refrigerant. Do not overcharge system this can cause compressor flooding.
CAUTION
Before attempting to remove fan motors or motor mounts, place a piece of plywood over evaporator coils to prevent coil damage.
SUCTION
COMPRESSOR
DISCHARGECOAXEXPANSION VALVE
FP2 FP1
LIQUID LINE WATER IN WATER OUT
CONDENSATE OVERFLOW
(CO)
AIR COIL FREEZE PROTECTION
WATER COIL PROTECTION
THERMISTOR
(F) (F)
AIR COILAIRFLOW AIRFLOW
Fig. 27 FP1 and FP2 Thermistor Location
a50-8163
LEGEND COAX Coaxial Heat Exchanger
Airflow Refrigerant Liquid Line Flow
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0
Temperature (degF)
R es
is ta
nc e
(k O
hm )
A50-6270
Fig. 28 Thermistor Nominal Resistance
35
If the sensing bulb, connecting capillary, or diaphragm assembly are damaged, pressure is lost and the spring will force the valve to a closed position. Often, the TXV will not close completely so some refrigerant flow will remain, even if inade- quate flow for the heat pump to operate.
The TXV sensing bulb must be properly located, secured, and insulated as it will attempt to control the temperature of the line to which it is connected. The sensing bulb must be located on a dedicated suction line close to the compressor. On a pack- aged heat pump, the bulb may be located almost any place on the tube running from the compressor suction inlet to the reversing valve. If the bulb is located on a horizontal section, it should be placed in the 10:00 or 2:00 position for optimal performance.
The bulb must be secured to the pipe using a copper strap. The use of heat transfer paste between the bulb and the pipe will also help ensure optimum performance.
The bulb must also be properly insulated to eliminate any influence on valve operation by the surrounding conditions. Cork tape is the recommended insulation as it can be molded tight to the bulb to prevent air infiltration. Causes of TXV Failure The most common causes of TXV failure are: 1. A cracked, broken, or damaged sensing bulb or capillary
can be caused by excessive vibration of the capillary during shipping or unit operation. If the sensing bulb is damaged or if the capillary is cracked or broken, the valve will be considered failed and must be replaced. Replacement of the TXV power head or sensing bulb, capillary, diaphragm assembly is possible on some TXVs. The power head assembly screws onto most valves, but not all are intended to be replaceable. If the assembly is not replaceable, replace the entire valve.
2. Particulate debris within the system can be caused by sev- eral sources including contaminated components, tubing, and service tools, or improper techniques used during brazing operations and component replacement. Problems associated with particulate debris can be com- pounded by refrigerant systems that use POE (polyol es- ter oil). POE oil has solvent-like properties that will clean the interior surfaces of tubing and components. Particu- lates can be released from interior surfaces and may mi- grate to the TXV strainer, which can lead to plugging of the strainer.
3. Corrosive debris within the system may happen after a failure, such as a compressor burn out, if system was not properly cleaned.
4. Noncondensables may be present in the system. Non- condensables includes any substance other than the refrigerant or oil such as air, nitrogen, or water. Contami- nation can be the result of improper service techniques, use of contaminated components, and/or improper evacu- ation of the system.
Symptoms The symptoms of a failed TXV can be varied and will include one or more of the following: Low refrigerant suction pressure High refrigerant superheat High refrigerant subcooling TXV and/or low pressure tubing frosting
Equalizer line condensing and at a lower temperature than the suction line or the equalizer line frosting
FP1 faults in the heating mode in combination with any of the symptoms listed above
FP2 faults in the cooling mode in combination with any of the symptoms listed above. Some symptoms can mimic a failed TXV but may actually be caused be another problem. Before conducting an analysis for a failed TXV the follow-
ing must be verified: Confirm that there is proper water flow and water tem-
perature in the heating mode. Confirm that there is proper airflow and temperature in
the cooling mode. Ensure coaxial water coil is clean on the inside; this
applies to the heating mode and may require a scale check.
Refrigerant may be undercharged. To verify, subcooling and superheat calculations may be required.
DiagnosticsSeveral tests may be required to determine if a TXV has failed. The following tools may be required for testing: 1. Refrigerant gage manifold compatible with the refriger-
ant in the system. 2. Digital thermometer, preferably insulated, with wire leads
that can be connected directly to the tubing. 3. Refrigerant pressure-temperature chart for the refrigerant
used. To determine that a TXV has failed, verify the following: The suction pressure is low and the valve is non-respon-
sive. The TXV sensing bulb can be removed from the suction line and warmed by holding the bulb in your hand. This action should result in an increase in the suction pressure while the compressor is operating. The sensing bulb can also be chilled by immersion in ice water, which should result in a decrease in the suction pressure while the compressor is operating. No change in the suction pres- sure would indicate a nonresponsive valve.
Simultaneous LOW suction pressure, HIGH refrigerant subcooling and HIGH superheat may indicate a failed valve.
LOW suction pressure, LOW subcooling and HIGH superheat may indicate an undercharge of refrigerant. HIGH subcooling and LOW superheat may indicate an overcharge of refrigerant. The suction pressure will usu- ally be normal or high if there is an overcharge of refrig- erant.
LOW suction pressure and frosting of the valve and/or equalizer line may indicate a failed valve. However, these symptoms may also indicate an undercharge of refrigerant. Calculate the subcooling and superheat to verify a failed valve or refrigerant charge issue.
Repair
CAUTION
Use caution when tightening the strap. The strap must be tight enough to hold the bulb securely but caution must be taken not to over-tighten the strap, which could dent, bend, collapse or otherwise damage the bulb.
WARNING
Puron refrigerant (R-410A) operates at higher pressure than R-22, which is found in other WSHPs. Tools such as manifold gages must be rated to withstand the higher pres- sures. Failure to use approved tools may result in a failure of tools, which can lead to severe damage to the unit, injury or death.
36
Moisture Check To perform moisture check: Check that connectors are orientated down (or as rec-
ommended by equipment manufacturer). Arrange harnesses with drip loop under motor. Check if condensate drain is plugged. Check for low airflow (too much latent capacity). Check for undercharged condition. Check and plug leaks in return ducts, cabinet.
Table 11 Good Practices
WARNING
Most TXVs are designed for a fixed superheat setting and are therefore considered non-adjustable. Removal of the bottom cap will not provide access for adjustment and can lead to damage to the valve or equipment, unintended vent- ing of refrigerant, personal injury, or possibly death.
CAUTION
Use caution when tightening the strap. The strap must be tight enough to hold the bulb securely but caution must be taken not to over-tighten the strap, which could dent, bend, collapse or otherwise damage the bulb.
CAUTION
Puron refrigerant (R-410A) requires the use of synthetic lubricant (POE oil). Do not use common tools on systems that contain R-22 refrigerants or mineral oil. Contamina- tion and failure of this equipment may result.
IMPORTANT: Always recover the refrigerant from the system with suitable approved tools, recovery equipment, and practices prior to attempting to remove or repair any TXV.
IMPORTANT: Due to the hygroscopic nature of the POE oil in Puron refrigerant (R-410A) and other environ- mentally balanced refrigerants, any component replace- ment must be conducted in a timely manner using caution and proper service procedure for these types of refrigerants. A complete installation instruction will be included with each replacement TXV/filter drier assem- bly. It is of critical importance these instructions are carefully understood and followed. Failure to follow these instructions can result in a system that is contami- nated with moisture to the extent that several filter drier replacements may be required to properly dry the system.
IMPORTANT: Repair of any sealed refrigerant system requires training in the use of refrigeration tools and proce- dures. Repair should only be attempted by a qualified ser- vice technician. A universal refrigerant handling certificate will be required. Local and/or state license or certificate may also be required.
CAUTION
Disconnect power from unit before removing or replacing connectors, or servicing motor. Wait 5 minutes after dis- connecting power before opening motor.
DO DO NOT Check motor, controls wiring, and connections thoroughly before replac- ing motor.
Automatically assume the motor is bad.
Orient connectors down so water cannot get in. Install drip loops. Locate connectors above 7 and 4 oclock positions. Use authorized motor and control model numbers for replacement. Replace one motor or control model number with another (unless
replacement is authorized). Keep static pressure to a minimum by: Using high efficiency, low-static filters. Keeping filters clean. Designing ductwork for minimum static and maximum comfort. Improving ductwork when replacement is necessary.
Use high pressure drop filters. Use restricted returns.
Size equipment wisely. Oversize system then compensate with low airflow. Check orientation before inserting motor connectors. Plug in power connector backwards.
Force plugs.
37
Table 12 Troubleshooting
FAULT POSSIBLE CAUSE SOLUTION Entire unit does not run Power Supply Off Apply power, close disconnect.
Blown Fuse Replace fuse or reset circuit breaker. Check for correct fuses. Voltage Supply Low If voltage is below minimum voltage specified on unit data plate, contact local power com-
pany. Thermostat Set the fan to ON, the fan should run. Set thermostat to COOL and lowest temperature set-
ting, the unit should run in the cooling mode (reversing valve energized). Set unit to HEAT and the highest temperature setting, the unit should run in the heating mode (reversing valve deenergized). If neither the blower or compressor run in all three cases, the thermostat could be miswired or faulty. To ensure miswired or faulty thermostat verify that 24 volts is available at the low voltage terminal strip between R and C, Y and C, and O and C. If the blower does not operate, verify 24 volts between terminals G and C. Replace the thermostat if defec- tive.
Blower operates but compressor does not
Thermostat Check setting, calibration, and wiring. Wiring Check for loose or broken wires at compressor, capacitor, or contactor. Safety Controls Check C board red default LED for blink code. Compressor overload open If the compressor is cool and the overload will not reset, replace compressor. Compressor motor grounded Internal winding grounded to the compressor shell. Replace compressor. Compressor windings Open After compressor has cooled, check continuity of the compressor windings. If the windings
are open, replace the compressor. Unit off on high pressure control
Discharge pressure too high In COOLING mode: Lack of or inadequate water flow. Entering water temperature is too warm. Scaled or plugged condenser. In HEATING mode: Lack of or inadequate air flow. Blower inoperative, clogged filter or restrictions in duct work
Refrigerant charge The unit is overcharged with refrigerant. Reclaim refrigerant, evacuate and recharge with factor recommended charge.
High pressure Check for defective or improperly calibrated high pressure switch. Unit off on low pressure control Suction pressure too low In COOLING mode: Lack of or inadequate air flow. Entering air temperature is too cold.
Blower inoperative, clogged filter or restrictions in duct work In HEATING mode: Lack of or inadequate water flow. Entering water temperature is too cold. Scaled or plugged condenser.
Refrigerant charge The unit is low on refrigerant. Check for refrigerant leak, repair, evacuate and recharge with factory recommended charge.
Low pressure switch Check for defective or improperly calibrated low pressure switch. Unit short cycles Unit oversized Recalculate heating and or cooling loads.
Thermostat Thermostat installed near a supply air grill; relocate thermostat. Readjust heat anticipator. Wiring and controls Check for defective or improperly calibrated low pressure switch.
Insufficient cooling or heating Unit undersized Recalculate heating and or cooling loads. If excessive, possibly adding insulation and shad- ing will rectify the problem.
Loss of conditioned air by leakage Check for leaks in duct work or introduction of ambient air through doors or windows. Airflow Lack of adequate air flow or improper distribution of air. Replace dirty filter. Refrigerant charge Low on refrigerant charge causing inefficient operation. Compressor Check for defective compressor. If discharge is too low and suction pressure is too high,
compressor is not pumping properly. Replace compressor. Reversing Valve Defective reversing valve creating bypass of refrigerant from discharge of suction side of
compressor. Replace reversing valve. Operating pressures Compare unit operation pressures to the pressure/temperature chart for the unit. TXV Check TXV for possible restriction or defect. Replace if necessary. Moisture, noncondensables The refrigerant system may be contaminated with moisture or noncondensables. Reclaim
refrigerant, replace filter dryer, evacuate the refrigerant system, and recharge with factory recommended charge.
Control board trouble shooting Compressor will not run, no fault blink code
Is Green Power LED light on and
no Red Blink Code?
Yes
No
Is there power to
the Y Call (C-Y)?
No
Yes
Check thermostat
settings and configurations
for heat pumps, and
wiring
Is there 24 V power from
C to CC?
No
Yes UPM Board
is Good
Check for Red Blink Code. If Red Blink Code is not
present, replace UPM Board
- Check all power supplies
- Check all safety switches
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500133-01 Printed in U.S.A. Form 50PS-5SI Pg 38 119 6-14 Replaces: NEW
Carrier Corporation 2014 8733953040
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500133-01 Printed in U.S.A. Form 50PS-5SI Pg CL-1 119 6-14 Replaces: NEW
50PSH,PSV START-UP CHECKLIST
CUSTOMER:___________________________ JOB NAME: _______________________________________
MODEL NO.:___________________________ SERIAL NO.: _____________ DATE: __________________
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 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 CONTROL VOLTAGE ABOVE 21.6 VOLTS? (Y/N) . IF NOT, CHECK FOR PROPER TRANSFORMER CONNECTION.
TEMPERATURES
FILL IN THE ANALYSIS CHART ATTACHED.
COAXIAL HEAT EXCHANGER
COOLING CYCLE: FLUID IN F FLUID OUT F PSI FLOW
HEATING CYCLE: FLUID IN F FLUID OUT F PSI FLOW
AIR COIL COOLING CYCLE: AIR IN F AIR OUT F
HEATING CYCLE: AIR IN F AIR OUT F
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500133-01 Printed in U.S.A. Form 50PS-5SI Pg CL-2 119 6-14 Replaces: NEW
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8733953040
HEATING CYCLE ANALYSIS
COOLING CYCLE ANALYSIS
HEAT OF EXTRACTION (ABSORPTION) OR HEAT OF REJECTION =
FLOW RATE (GPM) x TEMP. DIFF. (DEG. F) x FLUID FACTOR* = (Btu/hr)
SUPERHEAT = SUCTION TEMPERATURE SUCTION SATURATION TEMPERATURE = (DEG F)
SUBCOOLING = DISCHARGE SATURATION TEMPERATURE LIQUID LINE TEMPERATURE = (DEG F)
*Use 500 for water, 485 for antifreeze.
SUCTION
COMPRESSOR
DISCHARGE COAX EXPANSION VALVE
F F
AIR COIL
F
PSI FLUID OUT FLUID IN
F
PSI
L
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