Installation Guide for Carrier models including: 50PEC09, 50PEC18, 50PEC09-18 Water Source Heat Pumps Console Unit, 50PEC09-18, Water Source Heat Pumps Console Unit, Heat Pumps Console Unit, Pumps Console Unit, Console Unit
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DocumentDocumentAquazoneTM 50PEC09-18 Water Source Heat Pumps Console Unit with Puron AdvanceTM Refrigerant (R-454B) Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Step 1 -- Check Jobsite . . . . . . . . . . . . . . . . . . . . . . . 2 Step 2 -- Check Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Step 3 -- Mount Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Step 4 -- Make Electrical Connections . . . . . . . . . . . 6 Step 5 -- Install Supply and Return Piping . . . . . . 11 Hose Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 6 -- Install Condensate Piping . . . . . . . . . . . . 11 PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 System Cleaning and Flushing . . . . . . . . . . . . . . . . 11 System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cooling Tower/Boiler Systems . . . . . . . . . . . . . . . . 14 Ground Coupled, Closed Loop and Plateframe Heat Exchanger Well Systems . . . . . . . . . . . . . . . . . . . 14 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Sequence of Operation of Units Without DDC Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Unit Protection Module (UPM) . . . . . . . . . . . . . . . . . 17 UPM Standard Safeties and Alarms . . . . . . . . . . . . 19 Units with Options . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Sequence of Operation for Units with TruVu DDC Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Indoor Air Quality and Demand Control Ventilation . 23 UNIT-MOUNTED CONTROLLER . . . . . . . . . . . . . . . . 26 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 28 START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . CL-1 IMPORTANT: Read the entire instruction manual before starting installation. SAFETY CONSIDERATIONS Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair, or service air-conditioning equipment. Untrained personnel can perform basic maintenance functions 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. Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, or your distributor for information or assistance. The qualified installer or service agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual 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 applicable electrical codes for special installation requirements. WARNING RISK OF FIRE Flammable Refrigerant Used -- To be repaired only by trained service personnel. DO NOT puncture refrigerant tubing. WARNING RISK OF FIRE The appliance shall be stored in a room without continuously operating ignition sources (for example: open flames, an operating gas appliance or an operating electric heater). WARNING RISK OF FIRE Flammable Refrigerant Used -- Dispose of properly in accordance with federal or local regulations. 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. Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500508-01 Printed in U.S.A. Form No. 50PEC-8SI Pg 1 5-25 Replaces: 50PEC-7SI WARNING DO NOT USE TORCH to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective gloves and goggles and proceed as follows: a. Shut off electrical power to unit. b. Recover refrigerant to relieve all pressure from system using both high-pressure and low pressure ports. c. Traces of vapor should be displaced with nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases. d. Cut component connection tubing with tubing cutter and remove component from unit. Use a pan to catch any oil that may come out of the lines and as a gauge for how much oil to add to the system. e. Carefully un-sweat remaining tubing stubs when necessary. Oil can ignite when exposed to torch flame. Failure to follow these procedures may result in personal injury or death. CAUTION 2. Keep both the chassis and cabinet covered with the shipping carton until all plastering, painting, and finish work is complete and it is time to install the chassis and cabinet. 3. Verify that the refrigerant tubing is free of kinks or dents, and that it does not touch other unit components. 4. Inspect all electrical connections. Connections must be clean and tight at the terminals. CAUTION To avoid equipment damage, do not use these units as a source of heating or cooling during the construction process. The mechanical components and filters used in these units quickly become clogged with construction dirt and debris which may cause system damage. CAUTION To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must only be serviced by technicians who meet local, regional, and national proficiency requirements. DO NOT re-use compressor oil or any oil that has been exposed to the atmosphere. Dispose of oil per local codes and regulations. DO NOT leave refrigerant system open to air any longer than the actual time required to service the equipment. Seal circuits being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be completed. Failure to follow these procedures may result in damage to equipment. GENERAL The 50PEC water source heat pump (WSHP) console unit is a decentralized room terminal designed for field connection to a closed-circuit piping loop. See Fig. 1 for model number nomenclature details. Units are typically installed in perimeter zones, usually under windows. Supply air is discharged directly into the conditioned space through discharge grilles located in the top of the unit. IMPORTANT: The installation of console 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 responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations. INSTALLATION Step 1 -- Check Jobsite Units are typically installed along an outside wall of the room. Refer to Fig. 2 for an illustration showing piping locations. Install units with adequate clearance to allow maintenance and servicing. Refer to Table 1 for physical data. Locate the console unit so that it provides adequate air circulation throughout the room. 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. 1. Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped. CAUTION All refrigerant discharged from this unit must be recovered without exception. Technicians must follow industry accepted guidelines and all local, regional, and national statutes for the recovery and disposal of refrigerants. CAUTION When a compressor is removed from this unit, system refrigerant circuit oil will remain in the compressor. To avoid leakage of compressor oil, the refrigerant lines of the compressor must be sealed after it is removed. 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 carton 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 5 days of receipt of shipment. NOTE: It is the responsibility of the purchaser to file all necessary claims with the shipping company. STORAGE CAUTION DO NOT store or install console 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. Upon the arrival of equipment at the jobsite, immediately store units in their shipping cartons in a clean, dry area. 2 CAUTION DO NOT stack units. Take care when moving the unit. The unit's weight is located on the left (compressor) end. Always store and move unit in an upright position. Take care to protect the unit cabinet and sub-base when moving or storing. Never move or lift unit by its water connections. Units must be moved and stored in an upright position, never lay the unit on it's side. UNIT PROTECTION Cover console units on the jobsite with either shipping cartons, vinyl film, or an equivalent protective covering. Cap the open ends of pipes stored on the jobsite. In areas where painting, plastering, or the spraying of fireproof material has not been completed, all due precautions must be taken to avoid physical damage to the units and contamination by foreign material. Physical damage and contamination may prevent proper start-up and may result in costly equipment clean-up. Examine all pipes, fittings, and valves before installing any of the system components. Remove any dirt found on these components. CAUTION When installing unit in cold air climates, an outside air damper must be provided to prevent possible condenser freeze-up. 5 0 P E C 12 X X A E 3 G 1 A 1 Model Series (Pos 1-5) 50 PEC AQUAZONE High Efficiency Console Water Source Heat Pump Nominal Capacity (Pos 6-7) 09 3/4 Tons 12 1 Tons 15 1-1/4 Tons 18 1-1/2 Tons Factory Installed Options (Pos 16 ) 1 Cleanable Mesh Filter with Unit Mounted Controller A OA Damper and Cleanable Mesh Filter with Unit Mounted Controller R Cleanable Mesh Filter with Remote Thermostat S OA Damper and Cleanable Mesh Filter with Remote Thermostat Water Circuit Options (Pos 8) X Left Hand Water Connection, 5/8" sweat connection A Right Hand Water Connection, 5/8" sweat connection T Left Hand Water Connection, 1/2" FPT Fittings H Right Hand Water Connection, 1/2" FPT Fittings Cabinet and Subbase Options (Pos 9) X Standard 48" Cabinet and Sub-base A 63" Cabinet and Sub-b-ase T No Cabinet and Standard Sub-base for 48" Cabinet W No Cabinet and No Sub-ba- se Control/Transformer Options (Pos 10) A Unit Protection Module (UPM)/40VAa B Unit Protection Module (UPM)/75VA E UPM + TV DDC/75VA G UPM + Compressor Status Relay (SR), 40VA xfer a H UPM + Compressor Status Relay (SR), 75VA xfer J UPM + Pump Relay (PR), 40VA xfera K UPM + Pump Relay (PR), 75VA xfer L UPM + EMS Relay (EMS), 40VA xfer a M UPM + EMS Relay (EMS), 75VA xfer U UPM + SR + PR, 40VA xfera V UPM + SR + PR, 75VA xfer W UPM + EMS + SR, 40VA xfer a X UPM + EMS + SR, 75 VA xfer Y UPM + EMS + PR, 40VA xfera Z UPM + EMS + PR, 75 VA xfer 1 UPM + EMS + SR + PR, 40VA xfer a 2 UPM + EMS + SR + PR, 75VA xfer Operating Range (Pos 15) A Extended Range Packaging (Pos 14) 1 Single Pack, Domestic Revision (Pos 13 ) G R-454B Refrigerant Voltage (Pos 12 ) 3 208/230 -1-60 4 265 -1-60 C 208/230 - 1-60 with Disconnect D 265 -1-60 with Disconnect Refrigerant Circuit Options (Pos 11) E Copper, Coated Coil (Epoxy) J CuNi, Coated Coil (Epoxy) NOTE(S): a. Standard transformer on 265-v units is 50VA. LEGEND CuNi -- CuproNickel EMS -- EMS Relay FPT -- Female Pipe Thread OA -- Outdoor Air PR -- Pump Relay SR -- Compressor Status Relay TV DDC -- TruVu Direct Digital Controller UMC -- Unit Mounted Controller UPM -- Unit Protection Module WSHP -- Water Source Heat Pump Fig. 1 -- Model Number Nomenclature 3 Left Hand Water Connections Right Hand Water Connections Rear View Outside Air Damper Opening V U Water Out Water In Condensate Water Low Voltage Access Inside E-Box O T R Q S L Line Voltage Field Access Left Hand Water Connections P 2.00 [51] 8.00 [203] 0.41 20.03 [10] [509] NOTE: All dimensions are in inches [mm]. Right Hand Water Connections Condensate Water Q U V Water Out Water In Low Voltage Access YT W Z Line Voltage Field Access L UNIT SIZEa,b A 50PEC09-18 Width Standard Length Extended Length 48.00 63.00 B Depth 12.00 C Height 23.88 D E Control Door Discharge Width Grille Width F Grilled Edge to Door, Left Hand G Clearance to Unit Bottom 6.00 45.00 6.12 3.37 H Sub-base Depth 11.00 J K L Cabinet End to Return Air, Left Hand Return Air Width Electrica Box to Chassis 12.87 30.75 5.09 30.75 UNIT SIZE 50PEC09-18 Standard Length Extended Length M Grille Edge to Door, Right Hand 2.87 N Cabinet End to Return Air, Right Hand O Control Panel Width P Return Air to Chassis End, Left Hand 12.87 12.00 1.69 Q Electrical Box Height from Sub- base 3.87 R S T U V Condensate Height from Sub-base, Left Hand Condensate Depth From Rear, Left Hand Water Connection Height From Sub-base Water Out Depth from Rear Water In Depth from Rear 3.75 1.00 10.00 2.00 1.00 UNIT SIZE 50PEC09-18 Standard Length Extended Length W Return Air to Chassis End, Right Hand 4.00 Y Condensate Height From Sub-base, Right Hand 8.69 Z Condensate Depth From Front, Right Hand 7.31 Condensate Water Connections 5/8 tube Permanent Washable Filter Size 30.12 x 7 x 0.37 NOTE(S): a. All dimensions in inches unless otherwise noted. All dimensions within ±0.125 in. Specifications subject to change without notice. b. Outside air opening (in sub-base rear): When installing unit in cold climates, an outside air damper must be provided to prevent possible condenser freeze-up. Fig. 2 -- 50PEC09-18 Unit Dimensions 4 50PEC UNIT SIZE COMPRESSOR TYPE (QTY 1) Refrigeration Charge (oz) Max Water Working Pressure (psig/kPa) Number of Refrigeration Circuits EVAPORATOR COIL Coil Type Air Coil Dimensions (H x L) Row(s) MOTOR & BLOWER Fan Motor Type/Speeds Fan Motor (HP) Blower Wheel Size (Dia. x W) WATER CONNECTION Type Size Water Coil Type Coaxial Coil Water Volume (gal) Condensate Connection (in.) CABINET Standard Filter - 1/2" Washable Aluminum (H x L) Weight - Operating (lb) Weight - Shipping (lb) LEGEND FPT -- Female Pipe Thread PSC -- Permanent Split Capacitor Table 1 -- Physical Data 009 Rotary 21.5 450 / 3100 012 Rotary 23 450 / 3100 1 1 015 Rotary 26 450 / 3100 1 018 Rotary 24.5 450 / 3100 1 Tube-Fin 10 x 27 2 PSC/2 1/10 5.5 x 8 (2) Sweat / FPT Option 5/8" / 1/2" Coaxial 0.08 5/8 Tube-Fin 10 x 27 2 PSC/2 1/4 5.5 x 8 (2) Sweat / FPT Option 5/8" / 1/2" Coaxial 0.11 5/8 Tube-Fin 10 x 27 3 PSC/2 1/4 5.5 x 8 (2) Sweat / FPT Option 5/8" / 1/2" Coaxial 0.11 5/8 Tube-Fin 10 x 27 3 PSC/2 1/4 5.5 x 8 (2) Sweat / FPT Option 5/8" / 1/2" Coaxial 0.11 5/8 7 x 31-1/4 x 3/8 131 151 7 x 31-1/4 x 3/8 138 158 7 x 31-1/4 x 3/8 144 164 7 x 31-1/4 x 3/8 144 164 5 Step 3 -- Mount Unit 1. Before installing the unit, examine each pipe, fitting and valve; remove any dirt or debris found on or in these components. Use care when installing the system components to avoid damage to the cabinet finish or chassis. 2. After removing the console unit from its packaging remove the cabinet by removing the cabinet screws on either side of the unit and lifting the cabinet off the chassis. Set the cabinet aside and cover it (the console unit's packaging can be used for this purpose). 3. Position the sub-base directly on the finished floor. Make sure the sub-base is level (use shims if necessary). The sub-base has a frame that supports the cabinet and must be secured to wall or other structure. 4. Position the chassis onto the sub-base. Check and align electrical, water and condensate connections and secure to the sub-base with 4 screws. 5. Make sure the unit's washable filter is clean and installed in the sub-base. Also make sure that the filter clip is in place. 6. Reinstall the unit cabinet via locating pins at the top of the chassis and two screws in the unit sub-base. Step 4 -- Make Electrical Connections 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 Use only copper conductors for field-installed electrical wiring. Unit terminals are not designed to accept other types of conductors. 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 unit chassis nameplate or the performance data sheet. For electrical data see Table 2. Properly sized fuses or HACR (Heating, Air Conditioning and Refrigeration) breakers must be installed for branch circuit protection. See unit chassis nameplate for maximum size. Each chassis is supplied with a 2 x 4 in. junction box for power connection. Inside this box there are 2 pigtail leads for power wiring. The field ground is to be connected to the ground connection on the junction box. On remote thermostat and primary/ secondary units there are also 5-position terminal blocks for low voltage thermostat or secondary unit connection. On remote thermostat units, connect the thermostat wires to the low voltage terminal block. On primary/secondary units connect the thermostat to the "Primary" terminal block of the lead unit and the "Secondary" terminal block to the "Primary" terminal block of the next unit, daisy chaining the units together as required. Note that there is no limit to the number of units that can be connected together in this manner as each unit provides its own low voltage power supply. For wiring diagrams, see Fig. 3-6. NOTE: All 208/230 volt (voltage code -1) units are factory wired to 230 volts unless ordered otherwise. In 208 volt applications the transformer wiring may need to be switched from the 230 volt tap to the 208 volt tap. Cap all unused leads. Table 2 -- Electrical Data -- 50PEC Units With or Without Disconnect 50PEC RATED MODELS VOLTAGE VOLTAGE MIN/MAX COMPRESSOR Qty RLA LRA BLOWER MOTOR FLA Hp TOTAL UNIT FLA MCA 009 208-230/1/60 197/253 265-277/1/60 239/291 1 1 3.2 22.2 0.9 0.10 4.1 2.6 18.8 0.7 0.10 3.3 4.9 4.0 208-230/1/60 197/253 1 4.4 27.9 0.8 0.25 5.2 6.3 012 265-277/1/60 239/291 1 3.5 22.2 0.8 0.25 4.3 5.2 208-230/1/60 197/253 1 5.2 29.0 0.8 0.25 6.0 7.3 015 265-277/1/60 239/291 1 4.2 20.0 0.8 0.25 5.0 6.1 208-230/1/60 197/253 1 7.3 39.0 0.8 0.25 8.1 9.9 018 265-277/1/60 239/291 1 5.8 31.0 0.8 0.25 6.6 8.1 LEGEND FLA Hp LRA RLA -- Full Load Amps -- Horsepower -- Locked Rotor Amps -- Rated Load Amps MOP 15 15 15 15 15 15 15 15 COMPRESSOR SERVICE Cold Winding Resistance () Single Phase: R-C Single Phase: S-C Run Capacitor (F/V) 2.95 7.35 15/370 4.27 10.74 10/440 2.32 5.93 20/370 3.47 8.69 15/440 2.31 5.45 25/450 3.58 7.39 15/440 1.97 1.42 50/440 2.54 1.87 30/440 6 FAN MOTOR SPEED TABS - 3 POLE MOTORS UNIT HI LO CAPPED 009 BLU RED BLK 012 BLU RED BLK 015 BLU RED BLK 018 BLK RED BLU FAN MOTOR SPEED TABS - 4 POLE MOTORS UNIT HI LO CAPPED CAPPED 009 ORG RED BLK BLU 012 BLU ORG BLK RED 015 BLK ORG BLU RED 018 BLK BLU ORG RED 7 UPM STATUS LED - BLINK CODES 1 HIGH PRESSURE FAULT 2 LOW PRESSURE FAULT 3 CONDENSER FREEZE CONDITION 4 CONDENSATE OVERFLOW FAULT 5 BROWN OUT FAULT 6 EVAPORATOR FREEZE CONDITION 7 REFRIGERANT LEAKAGE Fig. 3 -- Wiring Diagram with Unit Mounted Controller, Options (EMS, Pump Relay, OAD, Compressor Status Relay) UPM STATUS LED - BLINK CODES 1 HIGH PRESSURE FAULT 2 LOW PRESSURE FAULT 3 CONDENSER FREEZE CONDITION 4 CONDENSATE OVERFLOW FAULT 5 BROWN OUT FAULT 6 EVAPORATOR FREEZE CONDITION 7 REFRIGERANT LEAKAGE 8 FAN MOTOR SPEED TABS - 4 POLE MOTORS UNIT HI LO CAPPED CAPPED 009 ORG RED BLK BLU 012 BLU ORG BLK RED 015 BLK ORG BLU RED 018 BLK BLU ORG RED FAN MOTOR SPEED TABS - 3 POLE MOTORS UNIT HI LO CAPPED 009 BLU RED BLK 012 BLU RED BLK 015 BLU RED BLK 018 BLK RED BLU Fig. 4 -- PSC Motor, Single Phase/Single Stage and Options (EMS, Pump Relay, OAD, Compressor Status Relay) UO-01 Common BO-03 BO-02 Bus UPM STATUS LED - BLINK CODES 1 HIGH PRESSURE FAULT 2 LOW PRESSURE FAULT 3 CONDENSER FREEZE CONDITION 4 CONDENSATE OVERFLOW FAULT 5 BROWN OUT FAULT 6 EVAPORATOR FREEZE CONDITION 7 REFRIGERANT LEAKAGE 9 FAN MOTOR SPEED TABS - 4 POLE MOTORS UNIT HI LO CAPPED CAPPED 009 ORG RED BLK BLU 012 BLU ORG BLK RED 015 BLK ORG BLU RED 018 BLK BLU ORG RED FAN MOTOR SPEED TABS - 3 POLE MOTORS UNIT HI LO CAPPED 009 BLU RED BLK 012 BLU RED BLK 015 BLU RED BLK 018 BLK RED BLU Fig. 5 -- PSC Motor, Single Phase/Single Stage, TruVuTM DDC 10 FACTORY INSTALLED COMPONENTS (OUTPUTS): UO-1 - UNIVERSAL OUTPUT 1: [ ] G1 - FAN ON (PSC & CT ECM) [ ] ECM - FAN MODULATION (CA ECM PWM) [ ] VFD - FAN MODULATION (VFD 0-10VDC) AO-2 - ANALOG OUTPUT 2: [ ] MRV - MODULATING REHEAT VALVE TERMINATION DETAIL 7 IN-7-8: DRY CONTACT (N/C) DPS Gnd IN 7-8 BO-2 - BINARY OUTPUT 2: [ ] Y1 - COMPRESSOR TERMINATION DETAIL IN 1-2-3-6: TEMP SENSOR (77F/25C @ 10k-OHM) BO-3 - BINARY OUTPUT 3: [ ]O - REVERSING VALVE TEMP SENSOR BO-4 - BINARY OUTPUT 4: [ ] Y2 - COMRPESSOR (TWO STAGE/SPEED) [ ] WSE - WATER-SIDE ECONOMIZER VALVE (SINGLE STAGE) [ ] W1 - AUX HEAT 1ST STAGE (SINGLE STAGE) TERMINATION DETAIL Rnet BO-5 - BINARY OUTPUT 5: [ ]H [ ] W1 - DEHUMIDIFICATION (HGRH) - AUX HEAT 1ST STAGE (SINGLE OR TWO GREEN STAGE/SPEED) WHITE ZS BO-6 - BINARY OUTPUT 6: [ ] G2 - FAN ON (CT ECM) SENSOR BLACK [ ] WSE - WATER-SIDE ECONOMIZER VALVE (TWO STAGE) RED [ ] W2 - AUX HEAT 2ND STAGE (TWO STAGE/SPEED) IN 1-2-3-6 Gnd 1 Gnd Rnet + Rnet 12V BO-7 - BINARY OUTPUT 7: [ ] G3 - FAN ON (CT ECM) [ ] VFD - VFD ENABLE/DISABLE STANDARD FACTORY INSTALLED COMPONENTS (INPUTS): IN-2 - UNIVERSAL INPUT 2: [ ] LWTS - LEAVING WATER TEMPRATURE SENSOR EQUIPMENT TOUCH DEVICE WHITE BLACK Gnd Rnet + Rnet 12V IN-3 - UNIVERSAL INPUT 3: [ ] EWTS - ENTERING WATER TEMPRATURE SENSOR Optional Smart Source Water Valve and/or DCV Damper To BACnet IP Network Dip Switch to configure UO-1 as an analog (CA ECM or VFD) or binary (PSC & CT ECM) output USB Service Port 2 O1 N AC/DC NC Data Gnd Power 24V Act Net Eth0 Eth1 10/100 Base-TX Service UO-01 Analog Binary ( Dry Contact) Carrier TruVuTM Comm i-VuRReady STANDARD FACTORY PROVIDED COMPONENTS (INPUTS): IN-1 - UNIVERSAL INPUT 1: [ ] SATS - SUPPLY AIR TEMPRATURE SENSOR IN-6 - UNIVERSAL INPUT 6: [ ] RATS - RETURN AIR TEMPRETURE SENSOR End of Net? Up Yes No Port S1 Port S2 Rnet 1 OPTIONAL FACTORY INSTALLED COMPONENTS (INPUTS): IN-7 - UNIVERSAL INPUT 7: [ ] DPS - DIFFERENTIAL PRESSURE SWITCH 1 EQUIPMENT TOUCH DEVICE OR OPTIONAL ZS COMBINATION WALL SENSOR CAPABLE OF TEMPERATURE, HUMIDITY, AND CO2 READINGS. TO MODBUS CARD OPTIONAL FIELD INSTALLED COMPONENTS (INPUTS): IN-6 - UNIVERSAL INPUT 6: [ ] SPT - SPACE TEMPRETURE SENSOR IN-7 OR 8 - UNIVERSAL INPUT 7 OR 8: [ ] EMSD - EMERGENCY SHUTDOWN [ ] OCC - REMOTE OCCUPANCY [ ] SCO - SECONDARY CONDENSATE OVERFLOW [ ] FS - FLOW SWITCH [ ] FM - WATER FLOW METER 2 OPTIONAL MODULATING REHEAT VALVE (MRV) 3 TWO STAGE/SPEED UNITS: BO-4 IS ONLY AVAILABLE FOR OUTPUT SIGNAL (Y2) SINGLE STAGE/SPEED UNITS: BO-4 IS AVAILABLE FOR WSE 4 H SIGNAL IS USED ON REHEAT APPLICATIONS 5 TWO STAGE/SPEED UNITS: BO-6 IS AVAILABLE FOR WSE OUTPUT SIGNAL SINGLE STAGE/SPEED UNITS: BO-6 IS AVAILABLE FOR FAN ON G2 OUTPUT SIGNAL 6 IN-07 UTILIZED FOR OPTIONAL FACTORY INSTALLED DIFFERENTIAL PRESSURE FLOW SWITCH WHEN EQUIPPED Fig. 6 -- TruVuTM DDC Wiring Diagram Net+ Net Shield Net+ Net Shield Gnd Rnet + Rnet + 12V IN-01 Gnd IN-02 IN-03 Gnd IN-04 24 Vdc 24 Vdc IN-05 Gnd IN-06 IN-07 Gnd IN-08 DSC Common UO-01 AO-02 Gnd AO-03 Bus BO-02 BO-03 BO-04 Bus BO-05 BO-06 BO-07 Common UO-01 AO-02 Gnd AO-03 Bus BO-02 BO-03 BO-04 Bus BO-05 BO-06 BO-07 3 456 S1-Tx S1-Rx S2-Tx S2-Rx Prog Net Sys 7 Open for Optional Field Inputs RATS Step 5 -- Install Supply and Return Piping The following items should be adhered to in addition to applicable piping codes. · A drain valve at the base of each riser to enable proper flushing of the system at startup and during servicing. · Shutoff/isolation ball valves at the supply and return con- nections and unions at each unit to permit proper flow balancing and unit servicing. · Strainers at the inlet of each circulating pump. Use Teflon®1 tape on threaded pipe fittings to eliminate water leaks and ensure against air entering the system. · Flexible hose connections between the unit and the rigid system to eliminate the possibility of vibration transmission through the piping. · Insulation is not normally required on supply and return piping for boiler tower installations except in unheated sections or outdoor runs. · Insulation is required for closed-loop Geothermal installations as loop temperatures may fall below the dew point and can even fall below the freezing point of water during heating season. Hose Kits When using optional hose kits follow the manufacturer's recommendations for installation. Never stretch or twist hoses and never use hoses that show external wear or damage or are suspected of having damage. Never exceed the manufacturer's maximum working pressure recommendations. Step 6 -- Install Condensate Piping Console units are designed with a blow-through configuration in the air-handling section. This means that there is positive pressure at the unit drain pan and thus trapping is not required. Condensate is routed from the drain pan via a 5/8 in. non-pressure rated vinyl hose that is located below the supply and return water connections. Though horizontal runs of condensate piping are usually too short to pose problems, horizontal runs should be pitched at least 1 in. for every 10 ft of piping. Avoid low spots or no sloped piping, as these areas can collect sediment and eventually block condensate flow. Always inspect both internal and external condensate piping for kinks that could block condensate flow. PRE-START-UP System Cleaning and Flushing Cleaning and flushing the unit and system is the single most important step to ensure proper start-up and continued efficient operation of the system. See Table 3. WARNING To prevent injury or death due to electrical shock or contact with moving parts, open unit disconnect before servicing unit. CAUTION TO AVOID POSSIBLE DAMAGE DO NOT FLUSH SYSTEM THROUGH THE UNIT! Follow the instructions below to properly clean and flush the system: 1. Verify that electrical power to the units is disconnected, and that the circulation pump is deenergized. 2. Connect the supply hose directly to the return riser valve. Use a single length of flexible hose. NOTE: If the length of hose is too short (i.e., the resulting connection would exceed the minimum bend radius of the hose), substitute two lengths of flexible hose joined together with a field-supplied, standard NPT coupling and the flarefitting-to-pipe adapters provided with the hose kit. 3. Open all air vents. Fill the system with water. Do not allow system to overflow. Bleed all air from the system. Check the system for leaks and repair appropriately. 4. Check and adjust the water and air level in the expansion tank. 5. Verify all strainers are in place. Start the pumps, and systematically check each vent to ensure all air is bled from the system. 6. Verify make-up water is available. Adjust make-up water appropriately to replace the air that was bled from the system. Pressure test and inspect the system for leaks and make any necessary repairs. Check and adjust the water and air level in the expansion tank. 7. Open a drain at the lowest point in the system. Adjust the make-up water replacement rate to equal the rate of bleed. Continue to bleed the system until the water appears clean or for at least three hours, whichever is longest; then, completely drain the system. 8. Refill the system with clean, chemically treated water. Since water varies for each locality, contact a local water treatment company for the correct treatment chemicals to use in the area. See Table 4 for water quality guidelines. Set the boiler to raise the loop temperature to approximately 85°F. . CAUTION To avoid possible damage to piping systems constructed of plastic piping DO NOT allow loop temperature to exceed 110°F. Circulate the solution for a minimum of 8 to 24 hours. At the end of this period, shut off the circulating pump and drain the solution. Repeat system cleaning as necessary. 9. When the cleaning process is complete, remove the short-circuited hoses. Connect the hoses to the proper supply and return connections on each unit. Refill the system and bleed off all air. 10. Test the system pH with litmus paper. The system water should be slightly alkaline (pH 7.0 to 8.5). Add chemicals, as appropriate, to maintain acidity levels. CAUTION DO NOT use "Stop-Leak" or any similar chemical agent in this system. Addition of these chemicals to the loop water will foul the system and will inhibit unit operation. 11. When the system is successfully cleaned, flushed, refilled and bled, check the main system panels, safety cutouts and alarms. Set the controls to properly maintain loop temperatures. 1. Third-party trademarks and logos are the property of their respective owners. 11 Table 3 -- 50PEC Series WSHP Operating Limits FLUID TYPE Air Liquid LIMIT Minimum Ambient (°F) Maximum Ambient (°F) Rated Ambient (°F) Minimum Entering (°F db / wb) Maximum Entering (°F db / wb) Rated Entering (°F) Minimum Entering (°F) Max Entering (°F) Water Loop Rated Entering (°F) Ground Loop Ground Water Anti-Freeze Requirement (LWT / EWT °F) Maximum Operating Water Pressure (psi / kPa) Minimum Operating Flow Rate (gpm / ton) COOLING HEATING 50 40 100 85 80 68 65/57 45 95/85 80 80/67 68/57 50 20 110 80 86 68 77 32 59 50 <40 / <50 450 psi / 3100 kPa 1.5 LEGEND db EWT LWT wb -- Dry Bulb -- Entering Water Temperature -- Leaving Water Temperature -- Wet Bulb System Checkout After completing the installation, and before energizing the unit, the following system checks should be made: · Verify that the supply voltage to the heat pump is in accordance with the nameplate ratings. · Verify the control transformer is tapped for the correct voltage. · Make sure that all electrical connections are tight and secure. · Check the electrical fusing and wiring for the correct size. · Verify that the water piping is complete and correct. · Check that the water flow is correct, and adjust if necessary. · Check for water leaks and correct as necessary. · Check the blower for free rotation, and that it is secured to the shaft. · Verify that the return air filter has been installed and is clean. · Verify that vibration isolation has been provided. · Be certain that all access panels are secured in place. CAUTION Ensure cabinet and electrical box are properly grounded. Failure to follow these procedures may result in damage to equipment. · Verify that the low voltage wiring between the thermostat and the unit is correct. CAUTION To avoid equipment damage, DO NOT leave system filled in a building without heat during the winter unless antifreeze is added to system water. Condenser coils never fully drain by themselves and will freeze unless winterized with antifreeze. 12 Table 4 -- Water Quality Guidelinesa,b CONDITION HX MATERIALc CLOSED RECIRCULATINGd OPEN LOOP AND RECIRCULATING WELLe 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 0.5 to +0.5 N/A 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 <0.2 ppm (Ferrous) N/A 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 Preventionf 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 <0.5 ppm N/A 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 All N/A Compounds <0.5 ppm 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 Maximum Chloride Levels 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 Use cupronickel heat exchanger when concentrations of calcium or All N/A sodium chloride are greater than 125 ppm are present. (Seawater is approximately 25,000 ppm.) NOTE(S): a. 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 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 contains a pH of 7.0. b. To convert ppm to grains per gallon, divide by 17. Hardness in mg/l is equivalent to ppm. c. Heat exchanger materials considered are copper, cupronickel, 304 SS (stainless steel), 316 SS, titanium. d. Closed recirculating system is identified by a closed pressurized piping system. e. Recirculating open wells should observe the open recirculating design considerations. f. If the concentration of these corrosives exceeds the maximum allowable level, then the potential for serious corrosion problems exists. LEGEND HWG HX N/A NR SS -- Hot Water Generator -- Heat Exchanger -- Design Limits Not Applicable Considering Recirculating Potable Water -- Application Not Recommended -- Stainless Steel 13 START-UP NOTE: You must use the Start-Up Checklist provided on pages CL-1 and CL-2 of this document when performing unit start-up for the first time. See Table 5 and Fig. 7 for operating data. 1. Use the fan speed selector switch to set the fan to the desired speed (hi or lo). 2. Set the thermostat to the highest setting. 3. Set the thermostat system switch to "COOL" and the fan switch to the "AUTO" position. The reversing valve solenoid should energize. The compressor and fan should not run. 4. Reduce the thermostat setting approximately 5 degrees below the room temperature. 5. Verify the heat pump is operating in the cooling mode. 6. Turn the thermostat system switch to the "OFF" position. The unit should stop running and the reversing valve should de-energize. 7. Leave the unit off for approximately 5 minutes to allow for system equalization. 8. Turn the thermostat to the lowest setting. 9. Set the thermostat switch to "HEAT". 10. Increase the thermostat setting approximately 5 degrees above the room temperature. 11. Verify the heat pump is operating in the heating mode. 12. Set the thermostat to maintain the desired space temperature. 13. Check for vibrations, leaks, etc. Antifreeze In areas where entering loop temperatures drop below 50°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 leaving loop temperature would be 22 to 25°F. Therefore, the freeze protection should be at 15°F (30°F 15°F) = 15°F. IMPORTANT: All alcohols should be pre-mixed and pumped from a reservoir outside of the building or introduced under water level to prevent alcohols from fuming. Calculate the total volume of fluid in the piping system. See Table 6. Use the percentage by volume in Table 7 to determine the amount of antifreeze to use. Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specific gravity. FREEZE PROTECTION SELECTION The 25°F FP1 factory setting (water) should be used to avoid freeze damage to the unit. Once antifreeze is selected, refer to the See Fig. 8 -- on page 17 for FREEZE Protection settings on the UPM board. Cooling Tower/Boiler Systems These systems typically use a common loop maintained at 60 to 90°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. Ground Coupled, Closed Loop and Plateframe Heat Exchanger Well Systems These systems allow water temperatures from 30 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. Air separation should be located in the piping system prior to the fluid re-entering the loop field. 14 50PEC UNIT SIZE 009 012 015 ENTER FLUID TEMP (°F) 30 40 50 60 70 80 90 100 30 40 50 60 70 80 90 100 30 40 50 60 70 80 90 100 Table 5 -- Operating Temperatures and Pressures WATER FLOW (GPM) 1.25 2.50 1.25 2.50 1.25 2.50 1.25 2.50 1.25 2.50 1.25 2.50 1.25 2.50 1.25 2.50 1.50 3.00 1.50 3.00 1.50 3.00 1.50 3.00 1.50 3.00 1.50 3.00 1.50 3.00 1.50 3.00 2.00 4.00 2.00 4.00 2.00 4.00 2.00 4.00 2.00 4.00 2.00 4.00 2.00 4.00 2.00 4.00 Suction Pressure (psig) -- -- 130-147 129-146 132-149 132-149 133-150 134-151 136-153 135-152 141-158 140-157 144-161 143-160 146-163 145-162 -- -- 133-149 132-148 135-151 134-150 137-153 136-152 139-155 138-154 140-156 138-154 141-157 141-157 141-157 141-157 -- -- 126-142 126-142 129-145 127-143 131-147 130-146 134-150 132-148 137-153 136-152 139-155 137-153 140-156 140-156 COOLING Discharge Water Pressure Temp (psig) Rise °F -- -- -- -- 189-207 16-19 171-189 8-11 217-235 16-19 199-217 7-10 248-266 15-18 231-249 7-10 283-301 14-17 265-283 7-10 323-341 14-17 305-323 7-10 364-382 13-16 348-366 6-9 410-428 12-15 396-414 6-9 -- -- -- -- 180-204 18-21 160-184 9-12 206-230 18-21 184-208 9-12 235-259 17-20 213-237 8-11 267-291 17-20 247-271 8-11 302-326 16-19 284-308 8-11 339-363 15-18 325-349 7-10 351-375 15-18 335-359 7-10 -- -- -- -- 178-198 16-19 161-181 8-11 205-225 16-19 184-204 8-11 234-254 15-18 214-234 7-10 267-287 15-18 247-267 7-10 302-322 14-17 284-304 7-10 341-361 14-17 326-346 6-9 383-403 13-16 372-392 6-9 Air Temp Drop °F -- -- 18-22 18-22 18-22 18-22 17-21 18-22 17-21 17-21 18-22 18-22 18-22 18-22 17-21 17-21 -- -- 17-21 18-22 17-21 18-22 17-21 17-21 17-21 17-21 16-20 16-20 16-20 16-20 16-20 16-20 -- -- 20-24 20-24 20-24 20-24 20-24 20-24 20-24 20-24 20-24 20-24 20-24 19-23 19-23 19-23 Suction Pressure (psig) 82-92 86-96 96-106 102-112 110-120 118-128 125-135 135-145 141-151 154-164 158-168 174-184 177-187 198-208 -- -- 81-91 86-96 95-105 102-112 110-120 118-128 126-136 134-144 139-149 152-162 155-165 173-183 174-184 196-206 -- -- 76-96 81-101 89-109 95-115 104-124 110-130 116-136 127-147 132-152 145-165 150-170 166-186 169-189 190-210 -- -- HEATING Discharge Water Pressure Temp (psig) Drop °F 261-281 6-7 265-285 3-4 274-294 8-9 279-299 4-5 288-308 9-10 296-316 5-6 303-323 11-12 313-333 6-7 319-339 12-13 333-353 7-8 338-358 14-15 356-376 8-9 359-379 16-17 383-403 9-10 -- -- -- -- 275-295 7-8 278-298 3-4 287-307 8-9 295-315 4-5 304-324 10-11 313-333 5-6 322-342 12-13 331-351 6-7 336-356 14-15 352-372 7-8 355-375 15-16 376-396 8-9 377-397 17-18 404-424 10-11 -- -- -- -- 264-284 6-7 267-287 3-4 276-296 8-9 282-302 4-5 291-311 9-10 298-318 5-6 305-325 11-12 316-336 6-7 322-342 12-13 336-356 7-8 342-362 14-15 360-380 8-9 363-383 16-17 387-407 9-10 -- -- -- -- Air Temp Rise °F 14-18 15-19 17-21 18-22 20-24 21-25 22-26 24-28 25-29 28-32 28-32 31-35 32-36 36-40 -- -- 13-17 14-18 16-20 17-21 18-22 19-23 21-25 22-26 23-27 25-29 25-29 28-32 28-32 32-36 -- -- 17-21 18-22 20-24 21-25 23-27 24-28 25-29 27-31 28-32 31-35 32-36 35-39 36-40 40-44 -- -- 15 50PEC UNIT SIZE 018 Table 5 -- Operating Temperatures and Pressures (cont) ENTER FLUID TEMP (°F) 30 40 50 60 70 80 90 100 WATER FLOW (GPM) 2.25 4.50 2.25 4.50 2.25 4.50 2.25 4.50 2.25 4.50 2.25 4.50 2.25 4.50 2.25 4.50 Suction Pressure (psig) -- -- 106-131 105-129 107-133 106-131 108-135 108-133 110-137 110-136 112-140 112-138 114-142 114-141 116-145 117-144 COOLING Discharge Water Pressure Temp (psig) Rise °F -- -- -- -- 186-225 17-23 159-195 9-12 200-246 17-23 183-226 8-11 227-280 16-22 211-261 8-12 256-317 16-22 242-299 7-12 290-358 15-21 278-341 8-11 326-402 14-20 318-388 7-10 368-451 14-19 362-439 7-10 Air Temp Drop °F -- -- 23-27 23-27 22-26 22-27 21-26 22-26 21-25 22-26 21-25 21-25 21-25 21-25 20-24 20-24 Suction Pressure (psig) 71-87 76-92 81-99 87-106 92-113 100-122 105-128 115-140 118-145 132-160 134-163 151-182 152-184 173-207 -- -- HEATING Discharge Water Pressure Temp (psig) Drop °F 267-324 8-10 273-331 4-5 279-341 9-10 287-350 5-6 293-359 11-12 303-371 6-7 308-379 12-14 322-395 7-8 325-401 14-16 342-420 7-8 344-424 15-18 365-448 8-10 364-450 16-19 390-477 9-11 -- -- -- -- Air Temp Rise °F 23-27 24-29 26-30 28-33 29-34 31-37 32-38 35-41 36-42 39-46 39-46 43-50 43-51 47-55 -- -- Pressure Drop (PSI) 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 0 2 4 6 8 Flow Rate (GPM) 009 012-018 Fig. 7 -- Water Pressure Drop Curve 16 Table 6 -- Approximate Fluid Volume (gal.) per 100 ft of Pipea PIPE Copper Rubber Hose Polyethylene DIAMETER (in.) 1.00 1.25 1.50 1.00 3/4 IPS SDR11 1 IPS SDR11 1-1/4 IPS SDR11 1/2 IPS SDR11 2 IPS SDR11 1-1/4 IPS SCH40 1-1/2 IPS SCH40 2 IPS SCH40 VOLUME (gal.) 4.1 6.4 9.2 3.9 2.8 4.5 8.0 10.9 18.0 8.3 10.9 17.0 NOTE(S): a. Volume of heat exchanger is approximately 1.0 gallon. LEGEND IPS SCH SDR -- Internal Pipe Size -- Schedule -- Standard Dimensional Ratio Table 7 -- Antifreeze Percentages by Volume ANTIFREEZE Methanol (%) 100% USP Food Grade Propylene Glycol (%) MINIMUM TEMPERATURE FOR FREEZE PROTECTION (F) 10 15 20 25 25 21 16 10 38 30 22 15 1 23 4 OPERATION Sequence of Operation of Units Without DDC Controller COOLING MODE Energizing the "O" terminal energizes the unit reversing valve in the cooling mode. The fan motor starts when the "G" terminal is energized. NOTE: The fan motor will take 30 seconds to ramp up to operating speed and will run at fan only rated air flow as long as there is no call for compressor or heater operation. When the thermostat calls for cooling (Y+O) the loop pump or solenoid valve if present is energized and the capacity starts. The fan ramps up to cooling air flow. Once the thermostat is satisfied, the compressor shuts down accordingly and the fan ramps down to either fan only mode or off over a span of 30 seconds. NOTE: A fault condition initiating a lockout will de-energize the compressor irrespective of which stage is engaged. HEATING MODE The heating (Y) operates in the same manner as cooling, but with the reversing valve de-energized. Once the thermostat is satisfied, the compressor shuts down and the fan ramps down either fan only mode or off. Unit Protection Module (UPM) UNIT PROTECTION MODULE (UPM) The Unit Protection Module (UPM) as shown in Fig. 8 is a printed circuit board (PCB) included in all units, that interfaces with the thermostat or the digital direct controller. The main purpose of this device is to protect the compressors by monitoring the different states of switches and sensors of each refrigerant circuit. This device provides time delays and protects the unit against freezing of the water and refrigerant heat exchangers as well as condensate overflow when the appropriate sensors are installed. Figure 9 shows the UPM sequence of operations for units safeties. LEGEND 1 -- Compressor Contact Output 2 -- High-Pressure Switch Connection 3 -- Call for Compressor (Y1) 17 4 -- Low Pressure Switch Connection 5 5 -- Water Coil Freeze Connection (Freeze 1) 6 -- UPM Status LED Indicator (Fault Status) 6 7 -- Air Coil Freeze Connection (Freeze 2) 16 8 -- Condensate Overflow Sensor Connection 7 9 -- Ground 8 10 -- UPM Settings DIP Switch (SW1) 11 -- A2L Sensor 9 12 -- 24 Vac Power Common 13 -- 24 Vac Power Input 14 -- UPM Standoff 15 -- Power LED 15 16 -- Fan 17 -- Dry Contact 14 13 12 11 10 Fig. 8 -- Unit Protection Module (UPM) 17 START Y1 = ON NO YES POWER/ SWITCHES/SENSOR STATUS CHECK RESET ON Y NO RESET ON R YES CLEAR FAULTS YES R = 24VAC NO V > 18VAC NO YES BLINK CODE ON STATUS LED SOFT LOCKOUT RECORD ALARM START COUNTER (IF APPLICABLE) COUNTER NEEDED? NO YES HPC = CLOSED NO YES LPC =CLOSED YES NO CC OUPUT= ON NO YES START TIMER TIME > 120 SEC NO YES CNT = CNT+1 LOCKOUT CAN BE SET TO 4 VIA DIP SWITCH NO COUNT = 2 OR COUNT = 4 YES BLINK CODE ON STATUS LED NO HARD LOCKOUT? FRZ >TEMP LIMIT NO YES START TIMER TIME > 30 SEC YES NO YES BLINK CODE ON STATUS LED DISPLAY OUTPUT = PULSE ALR OUTPUT = ON/PULSE CON > 0 NO YES INITIAL POWER UP NO YES CC OUTPUT = OFF START ANTI SHORT CYCLE START RANDOM START UP NO T > ASCCOCR RS SEC YES Fig. 9 -- Sequence of Operations CC OUTPUT = ON 18 UPM Standard Safeties and Alarms HI AND LOW REFRIGERANT PRESSURE PROTECTION · High-pressure switch located in the refrigerant discharge line and wired across the HPC (High-Pressure Switch Connection) terminals on the UPM. · Low-pressure switch located in the unit refrigerant suction line and wired across the LPC (Low-Pressure Switch Connection) terminals (LPC1 and LPC2) on the UPM. WATER COIL FREEZE PROTECTION Waterside freeze protection sensor, mounted close to condensing water coil, monitors refrigerant temperature between condensing water coil and thermal expansion valve. See Fig. 10. If temperature drops below or remains at freeze limit trip for 120 seconds, the controller will shut down the compressor and enter into a soft-lockout condition. The default freeze limit trip is 25°F; however, this can be changed to 15°F by flipping DIP switch SW1. (See Fig. 8, Item 10, Fig. 10, and Table 8.) NOTE: The UPM Board Dry Contacts are Normally Open (NO). IMPORTANT: The freeze sensor will not guard against the loss of water. A flow switch is recommended to prevent the unit from running if water flow is lost or reduced. IMPORTANT: If the unit is employing a fresh water system (no anti-freeze protection), it is extremely important to have the Freeze 1 set to 25°F (DIP Switch SW1 set to Off) 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. AIR COIL FREEZE PROTECTION Air coil freeze protection sensor, mounted between the thermal expansion device and the evaporator, monitors refrigerant temperature between the evaporator coil and thermal expansion valve (see Fig. 12). If temperature drops below or remains at the 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 25°F, this can be changed to 15°F by flipping DIP switch SW1. (See Fig. 8, Item 10, Fig. 11, and Table 8.) Table 8 -- UPM DIP Switch Selectable Positions TOGGLE 1 2 3 4 5 6 7 FUNCTION Lockout Reset Alarm Test Freeze 1 Freeze 2 Pump ON 4 R Cont Yes 15°F 15°F ON OFF 2 Y Pulse No 25°F 25°F OFF FACTORY DEFAULT 2 Y Pulse No 25°F 25°F OFF Fig. 10 -- Waterside Freeze Sensor Location (FREEZE --Vertical Configuration Show 19 OFF O1 2 3 4 5 6 7 N CTS 208-7 T126 Fig. 11 -- UPM Settings DIP Switch (SW1) Brownout/Surge/Power Interruption Protection The brownout protection in the UPM board will shut down the compressor if the incoming power falls below 18 vac. The compressor will remain Off until the voltage is above 18 vac and AntiShort Cycle Timer (300 seconds) times out. The unit will not go into a hard lockout. Alarm Output Alarm output is Normally Open (NO) dry contact. If pulse is selected the alarm output will be pulsed. The fault output will depend on the DIP switch setting for "Alarm". If it is 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. (For blink code explanation, see Table 9). The remote device must have a analog input with malfunction detection capability to interpret PULSE signal when the UPM board is set to "PULSE". IMPORTANT: If 24 VAC output is needed R must be wired to ALR-COM terminal; 24 VAC will be available to the ALR-OUT terminal when the unit is in the alarm condition. Test Mode A test DIP switch is provided to reduce all time delays settings to 10 seconds during troubleshooting or verification of unit operation. Fig. 12 -- Air Coil Freeze Sensor Location (FREEZE 2) -- Vertical Configuration Shown HIGH CONDENSATE LEVEL SHUTDOWN The condensate overflow protection sensor is located in the drain pan of the unit and connected to the "COND" terminal on the UPM board. See Fig. 8, Item 8. Anti-Short Cycle Timer Five minute delay on break timer to prevent compressor short cycling. Random Start Time Delay Each controller has an unique random start delay ranging from 270 to 300 seconds on initial power up to reduce the chance of multiple units simultaneously starting at the same time after power up or after a power interruption, in order to avoid creating a large electrical spike. Low-Pressure Bypass Timer If the compressor is running and the low pressure switch opens, the controller will keep the compressor On for 120 seconds. After two minutes if the low-pressure switch remains open, the controllers 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 two or four times in one hour, the unit will enter a hard lockout. In order to exit hard lockout power to the unit would need to be reset. The reset signal is either a Y or R signal depending on the position of the DIP switch as shown in Table 8. If the reset is set to R, the board must be manually powered off and powered back on to exit the hard lock out. IMPORTANT: Operation of unit in test mode can lead to accelerated wear and premature failure of components. The "TEST" switch must be set back to "NO" after troubleshooting/servicing. INTELLIGENT ALARM RESET If a fault condition is initiated, the five minute delay on break time period is initiated and the unit will restart after these delays expire. During this period the fault LED will indicate the cause of the fault. If the fault condition still exists or occurs two or four times (depending on "2" or "4" settings for Lockout DIP Switch) before 60 minutes, the unit will go into a hard lockout and requires a manual lockout reset. See Fig. 11. HARD 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". NOTE: The blower motor will remain active during a lockout condition. Table 9 -- UPM Fault Blink Codes BLINKS None 1 2 3 4 5 6 FAULT FAULT CRITERIA None All fault conditions normal. High Pressure Refrigerant discharge pressure has exceeded 600 psig. Low Pressure Refrigerant suction pressure has fallen below 40 psig. Water Coil Freeze Condition Refrigerant temperature to the water coil has fallen below 25°F for 120 seconds. Condensate Overflow Condensate levels in the unit drain pan are too high. Brown Out Control voltage has fallen below 18 VAC Air Coil Freeze Condition Refrigerant temperature to the air coil has fallen below 25°F for 120 seconds. 20 Units with Options UPM board can be ordered with additional following options: ENERGY MANAGEMENT SWITCH Enables 24 vac external signal to control the operation of the WSHP. PUMP/VALVE RELAY Provides a signal between an isolation valve and a secondary pump. Sequence of Operation for Units with TruVu DDC Controller Units with TruVuTM DDC controller still feature a UPM board for unit operation, so the operation will be similar to the sequence for units without DDC controller. TruVuTM controller does feature advanced functionality, such as automatic fan speed control and intelligent alarming, which will differ from the units with UPM board only. Below is an overview of the different features for the TruVuTM controls. See Fig. 13 for TruVuTM Control Board overview. UPM Communication Factory-Installed Modbus Card Accesses RNET (ZS sensors, TruVu ET display) Universal Inputs Factory-Installed: SAT, LWT, EWT, Compressor Status, Fan Status 24 vdc Terminal Optional Factory-Installed: Differential Pressure Flow Switch Universal Inputs Optional Field-Installed: RAT, SPT, Emergency Shutdown, Remote Occupancy, secondary Condensate Overflow Flow Switch ActNet Devices Source Water i-Vu Smart Valves, OA Damper Actuator Network Communication BACnet/IP, BACnet/Ethernet, Modbus TCP/IP USB Service Port TruVu ET Display, Field Assistant (laptop) USB Wi-Fi Service Adapter (USB-W) Universal Output Factory -Installed: Fan On G1 / PWM ECM Fan Modulation / 0-10 VDC VFD Modulation Analog Outputs Optional Factory-Installed Dehumidification (MHGRH). Optional Field-Installed: Auxiliary Heat, Waterside Economizer, Outdoor Air Damper, Dehumidification, Source Water Valve Binary Outputs Factory-Installed: Compressor, Reversing Valve, Auxiliary Heat, Waterside Economizer, FanOn (G2/G3), Dehumidification (on/off HGRH), Cycle with Fan/Compressor Fig. 13 -- TruVuTM Control Board 21 SCHEDULING Time periods can be configured to schedule the transitions from occupied to unoccupied operation. The time periods control the space temperature to occupied heating and cooling setpoints. The unit operates continuously in the Occupied mode until a time schedule is configured by using either the TruVuTM Equipment Touch, Field Assistant, the i-Vu® application, or a third-party control system enables/disables the BAS On/Off point. The local time and date for these functions must be set to operate properly. The occupancy source can be changed to one of the following: Occupancy Schedules The controller is occupied 24/7 until you configure a time schedule using either the TruVu Equipment Touch, Field Assistant, the i-Vu® application, or a third party Enables/Disables the BAS On/Off point. You can disable this by going to Configuration > Unit Configuration > Occupancy Schedules, changing the point from Enable to Disable and clicking OK. NOTE: You must Enable this point in order for the TruVu ET Touch, Field Assistant, or the i-Vu® application to assign a time schedule to the controller. Schedule_Schedule The unit operates according to the schedule configured and stored in the unit. The schedule is accessible via the TruVu ET, the i-Vu® application, or Field Assistant. The daily schedule consists of a start and stop time (standard or 24-hour mode) and 7 days of the week, starting with Monday and ending on Sunday. CAUTION Scheduling can only be controlled from one source. Occupancy Input Contact (Option) If configured for remote occupancy control (default), the TruVuTM controller can use an external dry contact closure to determine the occupancy status of the unit. You must disable the Occupancy Schedules in order to use the occupancy contact input. The unit enters an occupied mode when it senses the abnormal input. After the input returns to its normal state, the unit stays in the occupied mode for the configured Occ Override Delay period (15 minutes default). BAS (Building Automation System) On/Off For use with a Building Automation System that supports network scheduling, you must disable the Occupancy Schedules so the BAS system can control the unit through a network communication and the BAS scheduling function. Global Occupancy Scheduling The TruVuTM controller can read the occupancy status from another unit so that a group of WSHPs can be controlled from a single occupancy schedule. The local Occupancy Schedules must be disabled in order to use the global occupancy input. BACnet® Network Occupancy Input The TruVuTM controller can accept an external BACnet®1 Binary Network Input for occupancy control. This function is only compatible with units used in BACnet® systems. You need to configure the System Occupancy BACnet® network input point to locate the device and point name where the external occupancy point information resides. You must also disable Occupancy Schedules in order to use this input. INDOOR FAN Fan Modes You can configure the indoor fan to operate in any one of 3 fan modes: · Auto - intermittent operation during both occupied and unoccupied periods · Continuous (default) - intermittent operation during unoccupied periods and continuous during occupied periods · Always On - operates the fan continuously during both occupied and unoccupied periods In the continuous default mode, the fan is turned on when any one of the following is true: · It is in occupied mode, which is determined by the occupancy status. · There is a demand for cooling or heating in unoccupied mode. · There is a call for dehumidification (optional). Fan Delay When power is reapplied after a power outage, there is a configurable delay of 5 - 600 seconds (default 60) before starting the fan. You must configure the fan delay: · The Fan On Delay defines the delay time (0 - 30 seconds, default 10) before the fan begins to operate after heating or cooling is started. · The Fan Off Delay defines the delay time (0 - 180 seconds, default 45) the fan continues to operate after heating or cooling is stopped. NOTE: The fan continues to run as long as the compressors, heating stages, or the dehumidification relays are on. If the SPT failure alarm, ZS Sensor failure alarm, or condensate overflow alarm is active, the fan is shutdown immediately, regardless of occupancy state or demand. Fan Status You can configure an optional input as either an occupancy input contact or a fan status input. If configured as fan status, the controller compares the status of the fan to the desired commanded state. When the fan is commanded to run (ON), the fan status is checked and verified to match the commanded state. If the fan status is not on, then a fan status alarm is generated after 1 minute and the equipment's compressor(s) and auxiliary heat is disabled and the optional OA damper closes. COOLING OPERATION Space Temperature Control The TruVuTM controller operates 1 or 2 stages of compression to maintain the desired cooling setpoint. The compressor outputs are controlled by the PI (Proportional-integral) cooling loop and cooling stages capacity algorithm. The algorithm calculates the desired number of stages needed to satisfy the space by comparing the control temperature (return air or space) to the appropriate cooling setpoint. NOTE: The waterside economizer, if applicable, is used for first stage cooling, in addition to the compressor(s). The following conditions must be true for the cooling algorithm to run: · Cooling is set to Enable. · The Fire/Smoke Input and Shutdown modes are inactive. · Heat mode is not active and the compressor time guard(s) have expired. · Condensate overflow alarm status is Normal. · Fan Status is True (if option is enabled). · If occupied, the control temperature is greater than the occupied cooling setpoint. · Control temperature reading is valid. 1. Third-party trademarks and logos are the property of their respective owners. 22 · If unoccupied, the control temperature is greater than the unoccupied cooling setpoint. · If economizer cooling is available and active, and the economizer alone is insufficient to provide enough cooling. · OAT > Cooling Lockout Temperature if OAT is available. · Source water pump is on (if source water linkage is active) · Water Flow Switch Status is True (if option is enabled). If all of the above conditions are met, the compressors' relays are energized as required. Otherwise, they will be de-energized. If cooling is active and if the SAT approaches the minimum SAT limit, the fan will be indexed to the next higher speed. If this is insufficient, and if the SAT falls further (equal to the minimum SAT limit), the fan will be indexed to the maximum speed. If the SAT still continues to falls 5°F below the minimum SAT limit, all cooling stages will be disabled. During Cooling, the reversing valve output is held in the cooling position (either B or O type, as configured), even after the compressor is stopped. The valve does not switch position until the heating mode is required. The configuration screens contain the Min SAT parameter as well as Cooling Lockout based on outdoor air temperature (OAT). Both can be adjusted to meet various specifications. HEATING OPERATION Space Temperature Control (Reverse Cycle Heating) The TruVuTM controller operates 1 or 2 stages of compression to maintain the desired heating setpoint. The compressor outputs are controlled by the heating PI (Proportional-integral) loop and heating stages capacity algorithm. The algorithm calculates the desired number of stages needed to satisfy the space by comparing the control temperature (return air or space) to the appropriate heating setpoint. The following conditions must be true for the heating algorithm to run: · Heating is set to Enable. · The Fire/Smoke Input and Shutdown modes are inactive. · Cool mode is not active and the compressor time guard has expired. · Condensate overflow alarm status is Normal. · Fan Status is True (if option is enabled). · If occupied, the control temperature is less than the occupied heating setpoint. · Control temperature reading is valid. · If unoccupied, the control temperature is less than the unoccupied heating setpoint. · OAT > < Heating Lockout Temperature if OAT is available. · Source Water Pump is on (if Source Water Linkage active). · Water Flow Switch Status is True (if option is enabled). If all the above conditions are met, the heating outputs are energized as required, otherwise they are de-energized. If heating is active and the SAT approaches the maximum SAT limit, the fan is indexed to the next higher speed. If this is insufficient, and if the SAT rises further and reaches the Maximum Heating SAT limit, the fan is indexed to the maximum speed. If the SAT still continues to rise 5°F above the maximum limit, all heating stages are disabled. Space Temperature Control (Reverse Cycle Heating and Auxiliary Heat) The TruVuTM controller can control a 2-position or modulating water or steam valve, connected to a coil on the discharge side of the unit and supplied by a boiler, or a single stage ducted electric heater, in order to maintain the desired heating setpoint. If the compressor capacity is insufficient, or a compressor failure occurs, the auxiliary heat is used. Unless the compressor fails, the auxiliary heat only operates to supplement the heat provided by the compressor, if the space temperature falls more than 1°F below the desired heating setpoint. (This amount is configurable.) The heat is controlled so the SAT does not exceed the Maximum Heating SAT limit. The same conditions required for Reverse Cycle Heating must be true in order for the Auxiliary Heat algorithm to run. 2-Position Hot Water / Steam Heating The control can operate a 2-position, NO or NC, hot water or steam valve, connected to a coil on the discharge side of the unit and supplied by a boiler, in order to maintain the desired heating setpoint, if the compressor capacity is insufficient or a compressor failure occurs. Unless a compressor fault condition exists, the valve only opens to supplement the heat provided by the compressor, if the space temperature falls more than 1°F below the desired heating setpoint. The valve is controlled so the SAT does not exceed the Maximum Heating SAT limit and is subject to a 2-minute minimum OFF-time to prevent excessive valve cycling. "Boilerless" Control (Auxiliary Heat) The TruVuTM controller can be configured to control the auxiliary heat source for "boilerless" types of systems or system with no means for heat injection into the source water loop. Compressor will be disabled, and the auxiliary heat source will be enabled when the entering water temperature drops below the configurable boilers electric heat setpoint. Indoor Air Quality and Demand Control Ventilation If the optional hardwired indoor air quality sensor is installed, ZS CO2 (IAQ), or the System Space AQ network input point is used, the TruVuTM controller maintains indoor air quality with a modulating OA damper, which provides demand controlled ventilation. The control operates the modulating OA damper during occupied periods, monitors the CO2 level, compares it to the configured setpoints, and adjusts the ventilation rate, as required. The control provides proportional ventilation to meet the requirements of ASHRAE specifications by providing a base ventilation rate and then increasing the rate as the CO2 level increases. The control proportionally increases ventilation when the CO2 level rises above the start ventilation setpoint and reaches the full ventilation rate when the CO2 level is at or above the maximum setpoint. Configure the minimum damper position to ensure that proper base ventilation is delivered when occupants are not present. Access the IAQ configurations through the configuration screen. The following conditions must be true in order for this algorithm to run: · Damper Control is configured for DCV. · The Fire/Smoke Input and Shutdown modes are inactive. · Fan status is True (if option is enabled). · The unit is in an occupied mode. · IAQ sensor reading is greater than the DCV start CTRL setpoint. The control has the following 4 adjustable setpoints: · DCV Start Ctrl Setpoint · DCV Max Ctrl Setpoint · Minimum Damper Pos · DCV Max Vent Damper Pos NOTE: For the damper to maintain proper base ventilation, you must configure the fan as Continuous or Always On. 2-Position OA Damper Alternatively, the controller can be configured to operate as a ventilation damper in a 2-position ventilation mode to provide the minimum ventilation requirements during occupied periods. Differential Pressure Switch / Water Flow Switch The flow switch monitors the pressure difference between two points on the waterside. An optional input can be configured as 23 condenser water flow status input. If configured, the flow status must be ON for 3 seconds to enable the compressors. COMPRESSOR STATUS The TruVuTM controller provides a status input to monitor the compressor operation. The status is monitored to determine if the compressor status matches the commanded state. This input is used to determine if a refrigerant safety switch or other safety device has tripped and caused the compressor to stop operating normally. If this occurs, an alarm is generated to indicate the faulted compressor condition. DEMAND LIMITING The TruVuTM controller can accept 3 levels of demand limit from the BACnet®1 network. In response to a demand limit, the unit decreases its heating setpoint and increases its cooling setpoint to widen the range, in order to immediately lower the electrical demand. You can configure the temperature adjustment for both heating and cooling and for each demand level. You can also set the response to a particular demand level to 0. REMOTE DISABLE Fire/Smoke Detector Input The TruVuTM controller can read the status of a normally closed FSD contact input to determine if a fire or smoke detector alarm is present. If the controller determines an alarm condition is present, all heating, cooling, and the fan are disabled. The switch is factory-set to Normally Closed and cannot be changed. Shutdown Input The TruVuTM controller has a shutdown input (software point) which, when set to its Active mode causes the WSHP to safely shutdown in a controlled fashion. Heating and cooling is disabled after any minimum runtime conditions expire and the fan is disabled after the fan-off timer expires. All alarms are reset but any active alarm remains active. After the shutdown input transitions from Active mode to Inactive, the TruVuTM controller restarts after the configured power fail restart delay expires. ALARMS High Discharge Pressure (UPM Alarm) The TruVu WSHP monitors the status of a high discharge pressure fault condition via the serial port (S1). The fault condition is determined by the Unit Protection Module (UPM) included on all WSHPs. The UPM monitors a high-pressure switch input and establishes a high-pressure fault when the discharge pressure exceeds 600 psig. Upon fault a 5-minute break is initiated (soft lockout) and the compressor is disabled. The unit will automatically restart after this time period. If the fault occurs 2 times (configurable on UPM) within 60 minutes the UPM will put the unit into hard lockout requiring manual reset. Manual reset can be accomplished remotely when the UPM is configured for the reset method "Y" by remotely disabling the unit via the TruVu WSHP. Low Suction Pressure (UPM Alarm) The TruVu WSHP monitors the status of a low suction pressure fault condition via the serial port (S1). The fault condition is determined by the Unit Protection Module (UPM) included on all WSHPs. The UPM monitors a low-pressure switch input and establishes a high-pressure fault when the discharge pressure drops below 40 psig. Upon fault a 5-minute break is initiated (soft lockout) and the compressor is disabled. The unit will automatically restart after this time period. If the fault occurs 2 times (configurable on UPM) within 60 minutes the UPM will put the unit into hard lockout requiring manual reset. Manual reset can be accomplished remotely when the UPM is configured for the reset method "Y" by remotely disabling the unit via the TruVu WSHP. 1. Third-party trademarks and logos are the property of their respective owners. Air Coil Freeze Alarm (UPM Alarm) The TruVu WSHP monitors the status of an air coil freeze fault condition via the serial port (S1). The fault condition is determined by the Unit Protection Module (UPM) included on all WSHPs. The UPM monitors the heating liquid line refrigerant temperature and establishes a high-pressure fault if the temperature drops below 26°F (configurable on UPM) for 30 seconds. Upon fault a 5-minute break is initiated (soft lockout) and the compressor is disabled. The unit will automatically restart after this time period. If the fault occurs 2 times (configurable on UPM) within 60 minutes the UPM will put the unit into hard lockout requiring manual reset. Manual reset can be accomplished remotely when the UPM is configured for the reset method "Y" by remotely disabling the unit via the TruVuTM WSHP. Water Coil Freeze Alarm (UPM Alarm) The TruVu WSHP monitors the status of a water coil freeze fault condition via the serial port (S1). The fault condition is determined by the Unit Protection Module (UPM) included on all WSHPs. The UPM monitors the cooling liquid line refrigerant temperature and establishes a high-pressure fault if the temperature drops below 26°F (configurable on UPM) for 30 seconds. Upon fault a 5-minute break is initiated (soft lockout) and the compressor is disabled. The unit will automatically restart after this time period. If the fault occurs 2 times (configurable on UPM) within 60 minutes the UPM will put the unit into hard lockout requiring manual reset. Manual reset can be accomplished remotely when the UPM is configured for the reset method "Y" by remotely disabling the unit via the TruVu WSHP. Condensate Overflow Alarm (UPM Alarm) The TruVu WSHP monitors the status of a condensate overflow fault condition via the serial port (S1). The fault condition is determined by the Unit Protection Module (UPM) included on all WSHPs. The UPM monitors a condensate overflow switch and upon fault puts the unit in a hard lockout condition, disabling the compressor. The hard lockout condition requires manual reset. Manual reset can be accomplished remotely when the UPM is configured for the reset method "Y" by remotely disabling the unit via the TruVu WSHP. Brownout Alarm (UPM Alarm) The TruVu WSHP monitors the status of a brownout fault condition via the serial port (S1). Fire/Smoke Detector Alarm The control monitors the voltage input to J1-9 to detect if a smoke detector or fire detector NC contact has opened, indicating an alarm condition. The control verifies the presence of 24 vac on this input. If the input opens at any time, an alarm is generated after 3 seconds and the equipment (fan, compressor, aux heat, and damper) immediately shuts down. Space Temperature Alarms The control provides the ability to generate an alarm when the space temperature exceeds the alarm setpoint. A separate occupied hysteresis and fixed unoccupied high and low alarm setpoints are provided. The control provides a 5-minute alarm delay during unoccupied periods. During occupied periods, the control uses the occupied temperature setpoint and applies the hysteresis value to determine the alarm setpoints. When occupancy transitions from unoccupied to occupied or the occupied temperature setpoints are changed, causing an alarm condition to occur, the control automatically calculates an alarm delay (equivalent to the configured delay time in minutes/ °F, multiplied by the temperature error, + 15 minutes). This prevents nuisance alarms when an occupancy change occurs and allows time for the unit to correct an alarming temperature condition. Source Water Temperature Alarm The control has 4 configurable alarm limits for source water temperature. The control verifies that the water temperature is within operating range (between high and low limits) for the specific operating mode (heating or cooling) before energizing 24 the compressor. Once the compressor is started, the source water temperature is further monitored to verify that it is within limits to insure sufficient water is flowing through the coil. If the leaving water temperature rises above or falls below the appropriate limits, and lasts for more than 15 seconds, an alarm is generated and the compressor shuts down. Supply Air Temperature Alarm The control has 2 configurable alarm limits for supply air temperature. The control verifies that the supply air temperature is within operating range (between high and low limits) when the compressor or auxiliary heat is operating. If the air temperature rises above or falls below the appropriate limits, and this lasts for more than 5 minutes, an alarm is generated. Fan Status Alarm The control generates a fan status alarm if the fan status input detects the fan is OFF after any fan speed output has been enabled. A 30-second alarm delay is used to allow the fan to start operation before an alarm condition is detected. The control monitors the fan output and if the fan is operating at any speed, the fan status must detect the fan is operating. Compressor Status Alarm The control generates a compressor failure alarm if the compressor status input detects the compressor is OFF after the compressor output has been energized. A 6-minute alarm delay is used to allow the compressor to start (prevents alarms due to timeguard operation) before an alarm condition is detected. The control monitors the compressor output and if the compressor output is energized, the compressor status input must detect the compressor operation. Filter Status Alarm The control provides the ability to generate a dirty filter alarm after the number of fan run hours exceeds a configurable filter alarm timer limit. The control monitors the fan output and if the fan is operating at any speed, it accumulates run time. If the fan run time hours exceed the configurable limit, an alarm is generated. To reset the alarm timer after the alarm has been generated, a Reset Filter Alarm input is provided. You can disable the filter alarm by setting the Filter Alarm Timer Delay to 0 (factory default). Indoor Air Quality Alarm The control provides the ability to generate a high CO2 level alarm during occupied periods when the CO2 sensor value exceeds the adjustable limit. When a transition from unoccupied to occupied occurs, or the occupied alarm limit is changed to a value that causes an alarm condition to occur, the control will automatically calculate an alarm delay (equivalent to the configured delay time in minutes/ppm, times the error that occurred, + 15 minutes). This prevents nuisance alarms from occurring when occupancy changes or the setpoint is changed. You can disable the IAQ alarm by setting Occupied High IAQ Alarm Limit to 0. Relative Humidity Alarm The control provides the ability to generate an alarm when the space relative humidity exceeds the alarm setpoint. Separate occupied and unoccupied high humidity alarm setpoints are provided. The control provides a 5-minute alarm delay during unoccupied periods. During occupied periods, the controller uses the occupied high RH alarm limit. When an occupancy transition from unoccupied to occupied occurs, or the occupied high alarm limit is lowered, causing an alarm condition to occur, the control automatically calculates an alarm delay (equivalent to the configured delay time in minutes/% RH, times the humidity error condition that occurred, + 15 minutes). This prevents nuisance alarms when an occupancy change occurs and allows time for the unit to correct an alarming humidity condition. Source Water Linkage Failure Alarm (if Source Water Linkage was active) The control generates a Source Water Linkage failure alarm if Linkage fails after once being active. The Linkage status is monitored and if it fails to be updated from the Loop controller, then a Source Water Linkage alarm is generated. There is a 6-minute alarm delay to prevent false alarms. NOTE: You can reset this alarm only by re-establishing Linkage and correcting the condition that caused the Linkage failure, or by momentarily setting the Shutdown point to Active. Airside Linkage Failure Alarm (if Airside Linkage was active) The control generates an Airside Linkage failure alarm if Linkage fails after once being active. The Linkage status is monitored and if it fails to be updated from the master zone controller, then an Airside Linkage alarm is generated. There is a 6-minute alarm delay to prevent false alarms. NOTE: You can reset this alarm only by re-establishing Linkage and correcting the condition that caused the Linkage failure, or by momentarily setting the Shutdown point to Active. OAT Sensor Alarm (if Network OA Temperature was active) The control generates an OAT Sensor failure alarm if the value of OAT fails to be updated through the network after once being active. The update status is monitored and if it fails to be updated, then an OAT sensor alarm is generated. There is an alarm delay (approximately 1 hour) to prevent false alarms, while minimizing the required update rate for OAT. NOTE: You can reset this alarm by momentarily setting the Shutdown point to Active. SPT Sensor Alarm (if SPT sensor was active) The control generates an SPT sensor failure alarm if the SPT sensor fails to communicate with the control for 5 minutes or greater. The update status is monitored and if it fails to be updated, then an SPT sensor alarm is generated. ZS Sensor Alarm (if ZS sensor was active) The control generates a ZS sensor failure alarm if the ZS sensor fails to communicate with the control for 5 minutes or greater. The update status is monitored and if it fails to be updated, then a ZS sensor alarm is generated. UPM Alarm - Hard lockout status The control generates Alarm when Hard lockout Alarm is active on UPM board. Configurable 2 or 4 soft lockout alarms on UPM board before unit enters to hard lock out. Soft lockout alarm history is available via controller. Low Water Flow Alarm The control monitors differential pressure switch (water flow switch), and generates alarm if water flow is not met. This alarm is presented only if unit is provided with differential (flow) pressure switch option. Air Side Delta T Alarm The control has 4 configurable alarm limits for Air Side Delta T. The control verifies that the calculates delta T based on Return and Supply Air temperatures reading and verifies if it operates within configured ranged (between high and low limits) for the specific operating mode (heating or cooling) before energizing the compressor. Source Water Valve Alarm The control generates alarm if communication with Act Net device is lost. Water Side Delta T Alarm The control has 4 configurable alarm limits for Source water Delta T. The control verifies that the calculates delta T based on Entering and Leaving water temperatures reading and verifies if it operates within configured ranged (between high and low limits) for the specific operating mode (heating or cooling) before energizing the compressor. 25 Entering Water Temperature Alarm The control has 4 configurable alarm limits for Entering Water temperature. The control verifies that the entering water temperature is within operating range (between high and low limits) for the specific operating mode (heating or cooling) before energizing the compressor. Once the compressor is started, the entering water temperature is further monitored to verify that it is within limits to insure sufficient water is flowing through the coil. If the entering water temperature rises above or falls below the appropriate limits, and lasts for more than 15 seconds, an alarm is generated and the compressor shuts down. Return Air Temperature Alarm (if RAT sensor is field provided) The control has 2 configurable alarm limits for return air temperature. The control verifies that the return air temperature is within operating range (between high and low limits) when unit is operating. If the air temperature rises above or falls below the appropriate limits, and this lasts for more than 5 minutes, an alarm is generated. UNIT-MOUNTED CONTROLLER Designed to enhance the unit operation with more flexibility, accurate control and operating modes the unit-mounted controller provides an increased level of comfort in the conditioned space together with solid-state reliability and ease of operation. See Fig. 14. Units with Unit Mounted Controller (UMC) controller still feature a UPM board for unit operation and have all safety features included with UPM board. (See Fig. 8 -- on page 17). Unit-mounted controllers are standard on all console units except for remote options. · Tactile touch pad for temperature, fan and mode adjustment · Digital display of temperature in either degrees Fahrenheit or Celsius · LED display provides indication for unit operating mode as well as fan speed and fault indication for high or low pressure lockout · Adjustable Temperature Set point from 60°F through 80°F (15.5°C through 26.7°C) · Adjustable Temperature Differential between 1°F and 6°F (0.6°C and 3.3°C) · Selectable options: - Manual/Automatic changeover - Fan speed High or Low - Fan operation constant fan or cycling with compressor Fig. 14 -- Unit Mounted Controller MAINTENANCE Filter changes or cleaning are required at regular intervals. See Fig. 15 for piping and schematic locations. 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 is sufficient. In other applications such as motels, where daily vacuuming produces a large amount of lint, filter changes may be need to be as frequent as biweekly. NOTE: Equipment should never be used during construction due to likelihood of wall board dust accumulation in the air coil of the equipment, which permanently affects the performance and may shorten the life of the equipment. An annual "checkup" is required by a licensed refrigeration technician. 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 unit's data plate and the data taken at the original start-up of the equipment. The condensate drain must be checked annually by cleaning and flushing to ensure proper drainage. 26 Hot Gas Line Water Coil Freeze Sensor (unit mounted controller) Evaporator Coil Liquid Line Air Flow Condenser Coil Water Distributor FS2 Air Coil Freeze Sensor (Complete C and D Package) Equalizer Line LPS AP Expansion Line FS1 Water Coil Freeze Sensor (Complete C and D Package) Solenoid Reversing Valve TXV Sensing Bulb Compressor Suct. In LEGEND AP -- HPS -- LPS -- -- -- Access Port High Pressure Switch Low Pressure Switch Insulated Pipe Coil HPS Disch. AP Out Fig. 15 -- Piping and Sensor Schematic 27 TROUBLESHOOTING Troubleshooting Checks and Correction column in Table 10 may reflect a possible fault that may be one of, or a combination of causes and solutions. Check each cause and adopt "process of elimination" and/or verification of each before making any conclusion. 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 technician immediately and have them check for: water flow problems, water temperature problems, air flow problems or air temperature problems. Use of the pressure and temperature charts for the unit may be required to properly determine the cause. Table 10 -- Troubleshooting PROBLEM ENTIRE UNIT DOES NOT RUN BLOWER OPERATES BUT COMPRESSOR DOES NOT UNIT OFF ON HIGH PRESSURE CONTROL UNIT OFF ON LOW PRESSURE CONTROL UNIT SHORT CYCLES INSUFFICIENT COOLING OR HEATING POSSIBLE CAUSE Power Supply Off Blown Fuse Voltage Supply Low Thermostat Thermostat Wiring Safety Controls Compressor Overload Open Compressor Motor Grounded Compressor Windings Open Discharge Pressure Too High Refrigerant Charge High Pressure Switch Suction Pressure Too Low Refrigerant Charge Low Pressure Switch Unit Oversized Thermostat Wiring and Controls Unit Undersized Loss of Conditioned Air By Leakage Airflow Refrigerant Charge Compressor Reversing Valve Operating Pressures TXV Moisture, Non Condensable CHECKS AND CORRECTION Apply power, close disconnect. Replace fuse or reset circuit breaker. Check for correct fuses If voltage is below minimum voltage specified on unit data plate, contact local power company. Set the fan to "ON"; the fan should run. Set thermostat to "COOL" and lowest temperature setting; 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. If neither the blower nor the compressor run in all three cases, the thermostat could be miswired or unit-mounted controller faulty. To ensure miswired or faulty thermostat verify 24 volts is available on the condensing section 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" in the air handler. Replace the thermostat if defective. Check setting, calibration, and wiring. Check for loose or broken wires at compressor, capacitor, or contactor. Check UPM board Alarm LED for blink code. If the compressor is cool and the overload will not reset, replace compressor. Internal winding grounded to the compressor shell. Replace compressor. If compressor burnout, install suction filter drier. After compressor has cooled, check continuity of the compressor windings. If the windings are open, replace the compressor. 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. The unit is overcharged with refrigerant. Recover refrigerant, evacuate and recharge with factory recommended charge. Check for defective or improperly calibrated high pressure switch. 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. The unit is low on refrigerant. Check for refrigerant leaks, repair, evacuate and recharge with factory recommended charge. Check for defective or improperly calibrated low pressure switch. Recalculate heating and or cooling loads. Thermostat installed near a supply air grill; relocate thermostat. Readjust heat anticipator. Check for defective or improperly calibrated low pressure switch. Recalculate heating and or cooling loads. If excessive, possibly adding insulation and shading will rectify the problem. Check for leaks in duct work or introduction of ambient air through doors or windows. Lack of adequate air flow or improper distribution of air. Replace dirty filter. Low on refrigerant charge causing inefficient operation. Check for defective compressor. If discharge is too low and suction pressure is too high, compressor is not pumping properly. Replace compressor. Defective reversing valve creating bypass of refrigerant from discharge of suction side of compressor. Replace reversing valve. Compare unit operation pressures to the pressure/temperature chart for the unit. Check thermostatic expansion valve (TXV) for possible restriction or defect. Replace if necessary. The refrigerant system may be contaminated with moisture or non condensable. Recover refrigerant, replace filter dryer, evacuate the refrigerant system, and recharge with factory recommended charge. 28 © 2025 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500508-01 Printed in U.S.A. Form No. 50PEC-8SI Pg 30 5-25 Replaces: 50PEC-7SI 50PEC UNIT START-UP CHECKLIST NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sections of this Installation, Start-Up and Service document. Customer: ________________________________ Model No.:________________________________ Job Name: ______________________________________________ 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) Is the control transformer set to the correct voltage? (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 and cleaned? (Y/N) Has the fan speed selector switch been set to the desired setting? (Y/N) II. START-UP Is fan operating when compressor operates? (Y/N) UNIT VOLTAGE -- COOLING OPERATION Phase AB volts Phase AB amps 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 COOLING CYCLE: EXCHANGER WATER IN F WATER OUT F HEATING CYCLE: WATER IN F WATER OUT F AIR COIL COOLING CYCLE: AIR IN F AIR OUT F HEATING CYCLE: AIR IN F AIR OUT F FT WG FT WG GPM GPM Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500508-01 Printed in U.S.A. Form No. 50PEC-8SI Pg CL-1 5-25 Replaces: 50PEC-7SI CUT ALONG DOTTED LINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - HEATING CYCLE ANALYSIS AI R COI L F F EXPANSION VALVE COAX ft wg F SST (SATURATED SUCTION TEMPERATURE) SUCTIO N COMPRESSOR DISCHARGE F LIQUID LINE COOLING CYCLE ANALYSIS F F ft wg ft wg WATER IN* WATER OUT* AI R COI L F F EXPANSION VALVE COAX ft wg F SST (SATURATED SUCTION TEMPERATURE) SUCTION COMPRESSOR DISCHARGE CUT ALONG DOTTED LINE F LIQUID LINE F ft wg WATER IN* F ft wg WATER OUT* HEAT OF EXTRACTION (ABSORPTION) OR HEAT OF REJECTION = FLOW RATE (gpm) x (Btu/hr) TEMP. DIFF. (DEG. F) x FLUID FACTOR = SUPERHEAT = SUCTION TEMPERATURE SATURATED SUCTION TEMPERATURE = (DEG F) SUBCOOLING = SATURATED CONDENSING TEMPERATURE LIQUID LINE TEMPERATURE = (°F) *Look up pressure drop in Fig. 7 to determine flow rate. Use 500 for water, 485 for antifreeze. © 2025 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53500508-01 Printed in U.S.A. Form No. 50PEC-8SI Pg CL-2 5-25 Replaces: 50PEC-7SIAcrobat Distiller 24.0 (Windows)