Carrier AQUAZONE 50PCH Instruction Manual

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Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53500094-01 Printed in U.S.A. Form 50PC-3SI Pg 1 3-11 Replaces: 50PC-2SI
Installation, Start-Up, and
Service Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . .1,2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Step 1 — Check Jobsite . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 2 — Check Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STORAGE
•PROTECTION
•INSPECT UNIT
Step 3 — Locate Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIELD CONVERSION OF DISCHARGE AIR
Step 4 — Mount the Unit . . . . . . . . . . . . . . . . . . . . . . . . . 8
HORIZONTAL UNITS
VERTICAL UNITS
Step 5 — Check Duct System . . . . . . . . . . . . . . . . . . . . 8
SO U ND AT TE N U AT I O N
EXISTING DUCT SYSTEM
Step 6 — Install Condensate Drain . . . . . . . . . . . . . . . 8
HORIZONTAL UNITS
VERTICAL UNITS
VENTING
Step 7 — Pipe Connections . . . . . . . . . . . . . . . . . . . . . . 9
WATER LOOP APPLICATIONS
GROUND LOOP APPLICATIONS
INSTALLATION OF SUPPLY AND RETURN HOSE
KIT
Step 8 — Wire Field Power Supply . . . . . . . . . . . . . . 10
POWER CONNECTION
SUPPLY VOLTAGE
208-VOLT OPERATION
460-VOLT OPERATION
Step 9 — Wire Field Controls. . . . . . . . . . . . . . . . . . . . 20
THERMOSTAT CONNECTIONS
WATER FREEZE PROTECTION
AIR COIL FREEZE PROTECTION
ACCESSORY CONNECTIONS
WATER SOLENOID VALVES
WSHP OPEN WIRING
PRE-START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22,23
System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PSC Blower Speed Selection . . . . . . . . . . . . . . . . . . 22
FIELD SELECTABLE INPUTS . . . . . . . . . . . . . . . .24,25
Complete C Control Jumper Settings. . . . . . . . . . . 24
Complete C Control DIP Switches. . . . . . . . . . . . . . 24
Deluxe D Control Jumper Settings . . . . . . . . . . . . . 24
Deluxe D Control DIP Switches . . . . . . . . . . . . . . . . 24
Deluxe D Control Accessory Relay
Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Water Valve (Slow Opening) . . . . . . . . . . . . . . . . . . . 25
Outside Air Damper (OAD) . . . . . . . . . . . . . . . . . . . . 25
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-33
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Scroll Compressor Rotation. . . . . . . . . . . . . . . . . . . . . 26
Unit Start-Up Cooling Mode . . . . . . . . . . . . . . . . . . . . . 26
Page
Unit Start-Up Heating Mode . . . . . . . . . . . . . . . . . . . . . 30
Unit Start-Up with WSHP Open Controls . . . . . . . . 30
Flow Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cooling Tower/Boiler Systems . . . . . . . . . . . . . . . . . . 32
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-36
Power Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Units with Aquazone Complete C Control . . . . . . . 33
Units with Aquazone Deluxe D Control
. . . . . . . . . . 33
Units with WSHP Open Multiple Protocol. . . . . . . . 33
COMPLETE C AND DELUXE D BOARD
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-38
Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
WSHP Open Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . 36
Retry Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Aquazone Deluxe D Control LED Indicators . . . . . 37
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-40
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Water Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Condensate Drain Pans . . . . . . . . . . . . . . . . . . . . . . . . . 38
Refrigerant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fan Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Condensate Drain Cleaning . . . . . . . . . . . . . . . . . . . . . 38
Air Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Condenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Checking System Charge . . . . . . . . . . . . . . . . . . . . . . . 39
Refrigerant Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Air Coil Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . 40
Replacing the WSHP Open Controller’s
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 40-42
Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Control Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
WSHP Open Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 40
APPENDIX A — WSHP OPEN SCREEN
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . 43-48
50PCH,PCV START-UP CHECKLIST . . . . . CL-1, CL-2
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical compo-
nents. Only trained and qualified service personnel should
install, repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance func-
tions of cleaning coils and filters and replacing filters. All other
operations should be performed by trained service personnel.
When working on air-conditioning equipment, observe
precautions in the literature, tags and labels attached to the unit,
and other safety precautions that may apply.
IMPORTANT: Read the entire instruction manual before
starting installation.
AQUAZONE
50PCH,PCV006-060
Compact High-Efficiency Water Source Heat Pumps
with PURON
®
Refrigerant (R-410A)
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1 2 3 4 5 6 ... 51 52

Summary of Contents

Page 1 - Service Instructions

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

Page 2

10Insulation is not required on loop water piping except wherethe piping runs through unheated areas or outside the buildingor when the loop water tem

Page 3

11NOTES:1. Compressor and blower motor thermally protected internally.2. All wiring to the unit must comply with NEC and local codes.3. Transformer fo

Page 4 - UNIT HANGER DETAIL

12NOTES:1. Compressor thermally protected internally.2. All wiring to the unit must comply with NEC and local codes.3. Transformer is wired to 208-v R

Page 5 - UNIT HANGER ISOLATION DETAIL

13NOTES:1. Compressor thermally protected internally.2. All wiring to the unit must comply with NEC and local codes.3. Transformer is wired to 460-v B

Page 6 - 50PCV006-060 UNITS

14Fig. 16 — 50PCH,PCV Units with Complete C and LON Controller (460 V)Complete Ca50-8493LEGENDAL — Alarm Relay ContactsBM — Blower MotorBMC — Blower M

Page 7

15Deluxe DNOTES:1. Compressor and blower motor thermally protected internally.2. All wiring to the unit must comply with NEC and local codes.3. Transf

Page 8 - AIR HANDLER

16WHSP-OPENFSDFig. 18 — Units with Complete C and WSHP Open Multiple Protocol ControlsA50-8697LEGENDBM — Blower MotorBR — Blower RelayCO — Condensate

Page 9

17WSHP-OPENFSDFig. 19 — Units with Deluxe D and WSHP Open Multiple Protocol ControlsA50-8698LEGENDBM — Blower MotorBR — Blower RelayCO — Condensate Ov

Page 10 - A50-7734

18012207-1BT485BTLED1DBInstall BT485 where device is located at the end of network segment only.+ 24vac(If not installed, it must be connected to DO-5

Page 11 - Complete C

19Table 3 — 50PCH,PCV Unit Electrical DataLEGEND *Units using 460-v and ECM (electronically commutated motor), modulatingHWR (hot water reheat), and/o

Page 12 - Deluxe D

2Improper installation, adjustment, alteration, service, mainte-nance, or use can cause explosion, fire, electrical shock or otherconditions which may

Page 13

20Step 9 — Wire Field ControlsTHERMOSTAT CONNECTIONS — The thermostatshould be wired directly to the Aquazone™ control board. SeeFig. 13-20, an

Page 14

21WSHP OPEN WIRING — The WSHP Open controller willbe factory wired to the Complete C or Deluxe D control board,however, the system wiring will need to

Page 15

22Wiring a Supply Air Temperature (SAT) Sensor — TheSAT sensor is required for reheat applications.If the cable used to wire the SAT sensor to the con

Page 16 - WHSP-OPEN

23Table 9 — 50PCH,PCV Blower Performance — Standard UnitNOTES:1. Shaded areas denote ESP (external static pressure) where operation isnot recommended.

Page 17 - A50-8698

24FIELD SELECTABLE INPUTSJumpers and DIP (dual in-line package) switches on thecontrol board are used to customize unit operation and can beconfigured

Page 18 - SPT PLUS Sensor

25Table 11 — DIP Switch Block S2 — Accessory 1 Relay OptionsLEGENDNOTE: All other DIP switch combinations are invalid.Table 12 — DIP Switch Block S2 —

Page 19

26Table 13 — Operating Limits — 50PCH,PCV UnitsLEGENDScroll Compressor Rotation — It is important tobe certain compressor is rotating in the proper di

Page 20 - Step 9 — Wire Field Controls

27Table 15 — 50PC006 Typical Unit Operating Pressures and TemperaturesLEGEND*Based on 15% Methanol antifreeze solution.Table 16 — 50PC009 Typical Unit

Page 21 - INNER INSULATION

28Table 18 — 50PC015 Typical Unit Operating Pressures and TemperaturesLEGEND*Based on 15% Methanol antifreeze solution.Table 19 — 50PC018 Typical Unit

Page 22 - System Checkout —

29Table 21 — 50PC030 Typical Unit Operating Pressures and TemperaturesLEGEND*Based on 15% Methanol antifreeze solution.Table 22 — 50PC036 Typical Unit

Page 23

3or an equivalent protective covering. Cap open ends of pipesstored on the jobsite. This precaution is especially important inareas where painting, pl

Page 24

30Table 24 — 50PC048 Typical Unit Operating Pressures and TemperaturesLEGEND*Based on 15% Methanol antifreeze solution.Table 25 — 50PC060 Typical Unit

Page 25

31To start-up a unit with WSHP Open controls:1. To plug in the BACview6 handheld display into a SPTsensor, point the two ears on the connector up and

Page 26 - Unit Start-Up Cooling Mode

32Flow Regulation — Flow regulation can be accom-plished by two methods. Most water control valves have a flowadjustment built into the valve. By meas

Page 27

33the water loop. If an open type cooling tower is used continu-ously, chemical treatment and filtering will be necessary.Table 27 — Approximate Fluid

Page 28

34optional CO2 IAQ (indoor air quality) sensor mounted in thespace can maximize the occupant comfort. The WSHP Opencontroller has its own hardware clo

Page 29

35of capacity. Likewise, a 45-second delay is used when stagingdown.After a compressor is staged off, it may be restarted againafter a normal time-gua

Page 30 - Unit Start-Up Heating Mode

36• The IAQ sensor reading is greater than the DCV startcontrol set point.The control has four user adjustable set points: DCV startcontrol set point,

Page 31

37stage 2 followed by heating stage 2 then reduces capacity toheating stage 1. Operates for 1 minute per step.DEHUMIDIFICATION TEST — Tests dehu

Page 32

38Table 31 — Aquazone Deluxe D Control Current LED Status and Alarm Relay OperationsLEGEND NOTES:1. If there is no fault in memory, the Fault LED will

Page 33 - Power Up Mode —

39Air Coil Cleaning — Remove dirt and debris from evap-orator coil as required by condition of the coil. A 10% solutionof dishwasher detergent and wat

Page 34

4FRIGHT RETURN STRAIGHT DISCHARGEFRONTLNOMRIGHT RETURNFRONTLEFT/STRAIGHTDISCHARGECSPBACKDISCHARGECONDENSATE3 / 4" FPT3.3"[83.8 MM]0.7"[

Page 35

40Air Coil Fan Motor RemovalDisconnect motor power wires from motor terminals beforemotor is removed from unit.1. Shut off unit main power supply.2. L

Page 36 - SYSTEM TEST

41Table 32 — TroubleshootingLEGENDRV — Reversing ValveFAULT HEATING COOLING POSSIBLE CAUSE SOLUTIONMain Power Problems X X Green Status LED Off Check

Page 37

42Table 32 — Troubleshooting (cont)LEGENDRV — Reversing ValveFAULT HEATING COOLING POSSIBLE CAUSE SOLUTIONOnly Compressor Runs X X Thermostat wiring C

Page 38

43APPENDIX A — WSHP OPEN SCREEN CONFIGURATIONLEGENDSCREEN NAME POINT NAMEPASSWORD LEVELEDITABLE RANGE DEFAULT NOTESEquipmentStatusOperating ModeNo Pas

Page 39

44APPENDIX A — WSHP OPEN SCREEN CONFIGURATION (cont)LEGENDSCREEN NAME POINT NAMEPASSWORD LEVELEDITABLE RANGE DEFAULT NOTESUnitMaintenanceOperating Mod

Page 40 - Refrigerant Liquid Line Flow

45APPENDIX A — WSHP OPEN SCREEN CONFIGURATION (cont)LEGENDSCREEN NAME POINT NAMEPASSWORDLEVELEDITABLE RANGE DEFAULT NOTESConfigurationSet PointsOccupi

Page 41 - Table 32 — Troubleshooting

46APPENDIX A — WSHP SCREEN OPEN CONFIGURATION (cont)LEGENDSCREEN NAME POINT NAMEPASSWORD LEVELEDITABLE RANGE DEFAULT NOTESConfigurationUnitConfigurati

Page 42

47APPENDIX A — WSHP SCREEN OPEN CONFIGURATION (cont)LEGENDSCREEN NAME POINT NAMEPASSWORD LEVELEDITABLE RANGE DEFAULT NOTESConfigurationServiceConfigur

Page 43

48APPENDIX A — WSHP SCREEN OPEN CONFIGURATION (cont)LEGENDSCREEN NAME POINT NAMEPASSWORD LEVELEDITABLE RANGE DEFAULT NOTESConfigurationAlarmConfigurat

Page 45

5AccessoryElectric Heat(if applicable)Filter AccessReturn LoopSupply LoopWater OutWater InIntegral hanger support-pre-attached in factoryField-supplie

Page 46

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

Page 47

CL-150PCH,PCVSTART-UP CHECKLISTCUSTOMER:___________________________ JOB NAME: _______________________________________MODEL NO.:_______________________

Page 48

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

Page 49

6ACCESS PANELSTOP VIEW-LEFT RETURNURSISOMETRICVIEWLEFT RETURN LEFT VIEW- AIR COIL OPENINGTCPOWER SUPPLY3/4" [19.1 MM] HVKNOCKOUTLOW VOLTAGE1/2&qu

Page 50

7Step 3 — Locate Unit — The following guidelinesshould be considered when choosing a location for a WSHP:• Units are for indoor use only.• Locate in a

Page 51 - TEMPERATURES

8Side to Back Discharge Conversion1. Remove screws to free the top and discharge panels. SeeFig. 5.2. Remove the access panel and set aside.3. Lift th

Page 52 - 97B0038N05

9Each unit must be installed with its own individual vent andmeans to flush or blow out the condensate drain line. Do not in-stall units with a common

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