Air Conditioner User Manual

ManualsBrandsCarrier ManualsAir CompressorSINGLE PACKAGE ROOFTOP UNITS ELECTRIC COOLING/GAS HEATING 48EJ

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

PC 111 Catalog No. 534-739 Printed in U.S.A. Form 48A,E-1SI Pg 1 107 11-01 Replaces: 48E-6SI

Book 1

Ta b 1 a

Installation, Start-Up and

Service Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58

Step 1 — Provide Unit Support . . . . . . . . . . . . . . . . . . . 1

• ROOF CURB

• ALTERNATE UNIT SUPPORT

Step 2 — Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . 2

• POSITIONING

• ROOF MOUNT

Step 3 — Field Fabricate Ductwork. . . . . . . . . . . . . . . 2

Step 4 — Make Unit Duct Connections . . . . . . . . . . . 2

Step 5 — Install Flue Hood . . . . . . . . . . . . . . . . . . . . . . 28

Step 6 — Trap Condensate Drain . . . . . . . . . . . . . . . . 28

Step 7 — Install Gas Piping . . . . . . . . . . . . . . . . . . . . . 28

Step 8 — Controls Options . . . . . . . . . . . . . . . . . . . . . . 29

• STAGED GAS UNIT APPLICATIONS

• THERMISTORS

• CONSTANT VOLUME APPLICATIONS

• VARIABLE AIR VOLUME (VAV) APPLICATIONS

Step 9 — Make Electrical Connections . . . . . . . . . . 33

•POWER WIRING

• FIELD POWER SUPPLY

• FIELD CONTROL WIRING

Step 10 — Make Outdoor-Air Inlet

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

• ECONOMIZER

• ECONOMIZER SETTINGS

Step 11 — Position Power Exhaust/Barometric

Relief Damper Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Step 12 — Install All Accessories . . . . . . . . . . . . . . . 54

Step 13 — Field Modifications. . . . . . . . . . . . . . . . . . . 57

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-89

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89-102

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . 103-115

START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . CL-1,CL-2

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can

be hazardous due to system pressure and electrical compo-

nents. Only trained and qualified service personnel should in-

stall, repair, or service air-conditioning equipment.

Untrained personnel can perform the basic maintenance

functions of cleaning coils and filters and replacing filters. All

other operations should be performed by trained service per-

sonnel. When working on air-conditioning equipment, observe

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

and other safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work

gloves. Use quenching cloth for unbrazing operations. Have

fire extinguishers available for all brazing operations.

INSTALLATION

Step 1 — Provide Unit Support

Before performing service or maintenance operations on

unit, turn off main power switch to unit. Electrical shock

could cause personal injury.

1. Improper installation, adjustment, alteration, service,

or maintenance can cause property damage, personal

injury, or loss of life. Refer to the User’s Information

Manual provided with this unit for more details.

2. Do not store or use gasoline or other flammable va-

pors and liquids in the vicinity of this or any other

appliance.

What to do if you smell gas:

1. DO NOT try to light any appliance.

2. DO NOT touch any electrical switch, or use any

phone in your building.

3. IMMEDIATELY call your gas supplier from a neigh-

bor’s phone. Follow the gas supplier’s instructions.

4. If you cannot reach your gas supplier, call the fire

department.

Disconnect gas piping from unit when pressure testing at

pressure greater than 0.5 psig. Pressures greater than

0.5 psig will cause gas valve damage resulting in hazardous

condition. If gas valve is subjected to pressure greater than

0.5 psig, it must be replaced before use. When pressure

testing field-supplied gas piping at pressures of 0.5 psig or

less, a unit connected to such piping must be isolated by

closing the manual gas valve(s).

1. All panels must be in place when rigging.

2. Unit is not designed for handling by fork truck.

48AJ,AK,AW,AY020-060

with Reciprocating Compressor

48EJ,EK,EW,EY024-068

Single Package Rooftop Units

Electric Cooling/Gas Heating

Summary of content (118 pages)

PAGE 1
48AJ,AK,AW,AY020-060 with Reciprocating Compressor 48EJ,EK,EW,EY024-068 Single Package Rooftop Units Electric Cooling/Gas Heating Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58 Step 1 — Provide Unit Support . . . . . . . . . . . . . . . . . . . 1 • ROOF CURB • ALTERNATE UNIT SUPPORT Step 2 — Rig and Place Unit . . . . . . . . . . . . . . . . .
PAGE 2
When unit is located adjacent to public walkways, flue assembly must be at least 7 ft above grade. ROOF MOUNT — Check building codes for weight distribution requirements. See Fig. 17. Unit operating weight is shown in Table 2. ROOF CURB — For vertical discharge units, assemble or install accessory roof curb in accordance with instructions shipped with this accessory. See Fig. 1-4. Install insulation, cant strips, roofing, and counter flashing as shown.
PAGE 3
Fig.
PAGE 4
Fig.
PAGE 5
Fig.
PAGE 6
Fig. 4 — Roof Curb Adapter — (48AJ,AK060 and 48EJ,EK054-068 Units on 48DD,DF054-064 Retrofit, Part No. CRRCADPT005A00) NOTES: 1. Unless otherwise specified, all dimensions are to outside of part. 2. Seal strip to be placed covering reference holes. 3. Phantom lines represent seal strip. Total length required is 75 linear ft. 4. If existing seal strip around roof curb seems damaged, replace it. Total length required is 62 linear ft. 5.
PAGE 7
Center of Gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572]. Top of Units: No Overhang. Condenser Coil: 4′-0″ [1219]. Economizer Side: 6′-0″ [1829]. Heat Side: 4′-0″ [1219]. Filter Access Side: 10′-0″ [3048]. (For removal of evaporator coil.) 4. For smaller service and operational clearances contact Carrier Application Engineering Department. 5. Bottom ducts designed to be attached to accessory roof curb.
PAGE 8
Center of Gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572]. Top of Units: No Overhang. Condenser Coil: 4′-0″ [1219]. Economizer Side: 6′-0″ [1829]. Heat Side: 4′-0″ [1219]. Filter Access Side: 10′-0″ [3048]. (For removal of evaporator coil.) 4. For smaller service and operational clearances contact Carrier Application Engineering Department. 5. Bottom ducts designed to be attached to accessory roof curb.
PAGE 9
Center of Gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572]. Top of Units: No Overhang. Condenser Coil: 4′-0″ [1219]. Economizer Side: 6′-0″ [1829]. Heat Side: 4′-0″ [1219]. Filter Access Side: 15′-0″ [4572]. (For removal of evaporator coil.) 4. For smaller service and operational clearances contact Carrier Application Engineering Department. 2. NOTES: 1. Weights include economizer (standard).
PAGE 10
Center of Gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572]. Top of Units: No Overhang. Condenser Coil: 4′-0″ [1219]. Economizer Side: 6′-0″ [1829]. Heat Side: 4′-0″ [1219]. Filter Access Side: 10′-0″ [3048]. (For removal of evaporator coil.) 4. For smaller service and operational clearances contact Carrier Application Engineering Department. 5. Dimensions are in inches [mm]. 2. NOTES: 1.
PAGE 11
Center of Gravity. 48AW/AY (Low Heat) 035 48AW (High Heat) 035 48AW/AY (Low Heat) 040 48AW (High Heat) 040 48AW/AY (Low Heat) 050 48AW (High Heat) 050 UNIT SIZE 48AW/AY (Low Heat) 035 48AW (High Heat) 035 48AW/AY (Low Heat) 040 48AW (High Heat) 040 48AW/AY (Low Heat) 050 48AW (High Heat) 050 UNIT SIZE Fig. 9 — Base Unit Dimensions — 48AW,AY035-050 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572].
PAGE 12
Center of Gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572]. Top of Units: No Overhang. Condenser Coil: 4′-0″ [1219]. Economizer Side: 6′-0″ [1829]. Heat Side: 4′-0″ [1219]. Filter Access Side: 15′-0″ [4572]. (For removal of evaporator coil.) 4. For smaller service and operational clearances contact Carrier Application Engineering Department. 2. NOTES: 1. Weights include economizer (standard).
PAGE 13
Center of Gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572]. Top of Units: No Overhang. Condenser Coil: 4′-0″ [1219]. Economizer Side: 6′-0″ [1829]. Heat Side: 4′-0″ [1219]. Filter Access Side: 10′-0″ [3048]. (For removal of evaporator coil.) 4. For smaller service and operational clearances contact Carrier Application Engineering Department. 5. Bottom ducts designed to be attached to accessory roof curb.
PAGE 14
Center of Gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572]. Top of Units: No Overhang. Condenser Coil: 4′-0″ [1219]. Economizer Side: 6′-0″ [1829]. Heat Side: 4′-0″ [1219]. Filter Access Side: 10′-0″ [3048]. (For removal of evaporator coil.) 4. For smaller service and operational clearances contact Carrier Application Engineering Department. 5. Bottom ducts designed to be attached to accessory roof curb.
PAGE 15
Center of Gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572]. Top of Units: No Overhang. Condenser Coil: 4′-0″ [1219]. Economizer Side: 6′-0″ [1829]. Heat Side: 4′-0″ [1219]. Filter Access Side: 15′-0″ [4572]. (For removal of evaporator coil.) 4. For smaller service and operational clearances contact Carrier Application Engineering Department. 5. Bottom ducts designed to be attached to accessory roof curb.
PAGE 16
Center of Gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572]. Top of Units: No Overhang. Condenser Coil: 4′-0″ [1219]. Economizer Side: 6′-0″ [1829]. Heat Side: 4′-0″ [1219]. Filter Access Side: 15′-0″ [4572]. (For removal of evaporator coil.) 4. For smaller service and operational clearances contact Carrier Application Engineering Department. 5. Dimensions in are in inches [mm]. 2. NOTES: 1.
PAGE 17
Center of Gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572]. Top of Units: No Overhang. Condenser Coil: 4′-0″ [1219]. Economizer Side: 6′-0″ [1829]. Heat Side: 4′-0″ [1219]. Filter Access Side: 15′-0″ [4572]. (For removal of evaporator coil.) 4. For smaller service and operational clearances contact Carrier Application Engineering Department. 5. Dimensions in are in inches [mm]. 2. NOTES: 1.
PAGE 18
Center of Gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min Clearances to be: Adjacent Units: 15′-0″ [4572]. Top of Units: No Overhang. Condenser Coil: 4′-0″ [1219]. Economizer Side: 6′-0″ [1829]. Heat Side: 4′-0″ [1219]. Filter Access Side: 15′-0″ [4572]. (For removal of evaporator coil.) 4. For smaller service and operational clearances contact Carrier Application Engineering Department. 5.
PAGE 19
A 2 3 B 4 1 48AJ,AK,AW,AY UNITS UNIT 48AJ,AKD020 48AJE020 48AW,AYD020 48AWE020 48AJ,AKD025 48AJE025 48AW,AYD025 48AWE025 48AJ,AKD027 48AJE027 48AW,AYD027 48AWE027 48AJ,AKD030 48AJE030 48AW,AYD030 48AWE030 48AJ,AKD035 48AJE035 48AW,AYD035 48AWE035 48AJ,AKD040 48AJE040 48AW,AYD040 48AWE040 48AJ,AKD050 48AJE050 48AW,AYD050 48AWE050 48AJ,AKD060 48AJE060 48AW,AYD060 48AWE060 CENTER OF GRAVITY Inches Millimeters A B A B 72.4 42.2 1839 1072 73.3 42.7 1862 1085 72.4 42.2 1839 1072 73.3 42.7 1862 1085 69.
PAGE 20
48EJ,EK,EW,EY UNITS UNIT 48EJ,EW,EK,EYD024 48EJ,EWE024 48EJ,EW,EK,EYD028 48EJ,EWE028 48EJ,EW,EK,EYD030 48EJ,EWE030 48EJ,EW,EK,EYD034 48EJ,EWE034 48EJ,EW,EK,EYD038 48EJ,EWE038 48EJ,EW,EK,EYD044 48EJ,EWE044 48EJ,EW,EK,EYD048 48EJ,EWE048 48EJ,EW,EK,EYD054 48EJ,EWE054 48EJ,EW,EK,EYD058 48EJ,EWE058 48EJ,EW,EK,EYD064 48EJ,EWE064 48EJ,EW,EK,EYD068 48EJ,EWE068 CENTER OF GRAVITY Inches Millimeters A B A B 72.4 42.2 1839 1072 73.3 42.7 1862 1085 69.6 44.0 1768 1118 70.1 44.3 1781 1125 69.6 44.0 1768 1118 70.1 44.
PAGE 21
Table 1A — Physical Data — 48AJ,AK,AW,AY Units UNIT 48AJ,AK,AW,AY NOMINAL CAPACITY (tons) BASE UNIT OPERATING WEIGHT (lb) COMPRESSOR Quantity...Type (Ckt 1 , Ckt 2) Number of Refrigerant Circuits Oil (oz) (Ckt 1 , Ckt 2) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1 Circuit 2 CONDENSER COIL * Quantity Rows...Fins/in. Total Face Area (sq ft) CONDENSER FAN Nominal Cfm Quantity...Diameter (in.) Motor Hp EVAPORATOR COIL Tube Size (in.) Rows...Fins/in. Total Face Area (sq ft) EVAPORATOR FAN Quantity...
PAGE 22
Table 1A — Physical Data — 48AJ,AK,AW,AY Units (cont) UNIT 48AJ,AK,AW,AY NOMINAL CAPACITY (tons) BASE UNIT OPERATING WEIGHT (lb) COMPRESSOR Quantity...Type (Ckt 1 , Ckt 2) Number of Refrigerant Circuits Oil (oz) (Ckt 1 , Ckt 2) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1 Circuit 2 CONDENSER COIL * Quantity Rows...Fins/in. Total Face Area (sq ft) CONDENSER FAN Nominal Cfm Quantity...Diameter (in.) Motor Hp EVAPORATOR COIL Tube Size (in.) Rows...Fins/in.
PAGE 23
Table 1B — Physical Data — 48EJ,EK,EW,EY Units UNIT 48EJ,EK,EW,EY NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) COMPRESSOR Type Ckt 1 Ckt 2 Number of Refrigerant Circuits Oil (oz) (Ckt 1, Ckt 2) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1* Circuit 2 CONDENSER COIL Quantity Rows...Fins/in. Total Face Area (sq ft) CONDENSER FAN Nominal Cfm Quantity...Diameter (in.) Motor Hp (1075 Rpm) EVAPORATOR COIL Rows...Fins/in. Total Face Area (sq ft) EVAPORATOR FAN Quantity...Size (in.
PAGE 24
Table 1B — Physical Data — 48EJ,EK,EW,EY Units (cont) UNIT 48EJ,EK,EW,EY NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) COMPRESSOR Type Ckt 1 Ckt 2 Number of Refrigerant Circuits Oil (oz) (Ckt 1, Ckt 2) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1* Circuit 2 CONDENSER COIL Quantity Rows...Fins/in. Total Face Area (sq ft) CONDENSER FAN Nominal Cfm Quantity...Diameter (in.) Motor Hp (1075 Rpm) EVAPORATOR COIL Rows...Fins/in. Total Face Area (sq ft) EVAPORATOR FAN Quantity...Size (in.
PAGE 25
Table 1B — Physical Data — 48EJ,EK,EW,EY Units (cont) UNIT 48EJ,EK,EW,EY NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) COMPRESSOR Quantity...Type (Ckt 1, Ckt 2) Number of Refrigerant Circuits Oil (oz) (Ckt 1, Ckt 2) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1* Circuit 2 CONDENSER COIL Quantity Rows...Fins/in. Total Face Area (sq ft) CONDENSER FAN Nominal Cfm Quantity...Diameter (in.) Motor Hp (1075 Rpm) EVAPORATOR COIL Rows...Fins/in. Total Face Area (sq ft) EVAPORATOR FAN Quantity...Size (in.
PAGE 26
Table 2 — Operating Weights 48AJ,AK,AW,AY Units UNIT 020 4287 4367 4327 4407 48AJD,AKD 48AJE 48AWD,AYD 48AWE 025 4373 4453 4413 4493 OPTION/ ACCESSORY 020 300 450 500 220 365 Barometric Relief Power Exhaust Modulating Power Exhaust Cu Tubing/Cu Fin Condenser Coil Roof Curb (14-in.
PAGE 27
Table 3 — Evaporator Fan Motor Data MOTOR UNIT UNIT FAN MOTOR SHEAVE SIZE SIZE MOTOR SHAFT MOTOR SHAFT DIA. PITCH 48AJ,AK, 48EJ,EK, HP SPEED SHEAVE (in.) DIAMETER AW,AY EW,EY (rpm) (in.) 5 1.125 717 BK55 4.9 020 024 10 1.375 924 2BK50 4.4 15 1.625 1096 2B5V56 5.7 7.5 1.375 773 BK60H 5.4 025 028 10 1.375 962 1B5V60 6.1 15 1.625 1106 2B5V54 5.5 10 1.375 848 2BK50 4.4 027 030 15 1.625 1059 2B5V48 4.9 20 1.625 1187 2B5V58 5.9 10 1.375 884 2BK50 4.4 030 034 15 1.625 1096 2B5V56 5.7 20 1.625 1187 2B5V58 5.9 10 1.
PAGE 28
Step 5 — Install Flue Hood 48AJ,AK,AW,AY020-050 AND 48EJ,EK,EW,EY024-048 UNITS — Flue hood is shipped inside gas section of unit. To install, secure flue hood to access panel. See Fig. 20A. 48AJ,AK,AW,AY060 AND 48EJ,EK,EW,EY054-068 UNITS — Flue hood and wind baffle are shipped inside gas section of unit. To install, secure flue hood to access panel. Install the two pieces of the wind baffle over the flue hood. See Fig. 20B. NOTE: When properly installed, flue hood will line up with combustion fan housing.
PAGE 29
OPTIONAL STAGED GAS UNITS — The staging pattern is selected based on Heat Stage Type (HTSTGTYP). Max Capacity per changes default value is selected based on Capacity Maximum Stage (CAPMXSTG). See Table 4. For complete information and service instructions for Staged Gas Control Units, see Control Operation and Troubleshooting literature. IMPORTANT: Natural gas pressure at unit gas connection must not be less than 5 in. wg or greater than 13.5 in. wg. Size gas-supply piping for 0.5-in.
PAGE 30
Table 5 — Controls Options and Configurations (Non-Thermostat Applications) UNIT CONFIGURATION CV or VAV Unit with SPT Sensor CV Unit with SPT Sensor and Remote Start/Stop Switch VAV Unit Remote Start/Stop Switch Only VAV Unit with SPT Sensor and Remote Start/Stop Switch CV NA RAT SAT SPT VAV DEFAULT COOLING Unoccupied Cooling — 90 F (32 C) (SPT) Occupied Cooling — NA Unoccupied Cooling — 90 F (32 C) (SPT) Occupied Cooling — 78 F (26 C) (SPT) Unoccupied Cooling — 90 F (32 C)(SPT) Occupied Cooling — 55 F (1
PAGE 31
NOTE: A CV unit without a thermostat requires a fieldsupplied sensor for operation. Features with Sensor Control of Unit (Stand-Alone Applications — Unit control is limited to CV unoccupied default set points, 90 F for cooling, 55 F for heating unless a computer has been used to change the set points.
PAGE 32
See Carrier TEMP or VVT® (Variable Volume and Temperature) literature for complete TEMP (single zone) or VVT (multi-zone) application information. Features with Sensor Control of Unit (Network Applications) — The base control board provides, as standard, a connection for use with a Carrier VVT system and can also be integrated into a Carrier Comfort Network.
PAGE 33
operation. The occupied default set points are 55 F (supply-air temperature) cooling and 68 F (return-air temperature) heating. See Fig. 26 for remote start/stop wiring.
PAGE 34
— — — — — — LEGEND Carrier Comfort Network Common Diode Dual In-Line Package Light-Emitting Diode Normally Closed N.O. R SIO SW T — — — — — Normally Open Relay Serial Input/Output Switch Terminal *Where X is the unit control software version number. CCN COM D DIP LED N.C. Fig.
PAGE 35
Table 7 — Electrical Data — 48AJ,AK,AW,AY Units UNIT SIZE 48AJ,AK, AW,AY COMPRESSOR VOLTAGE RANGE OFM NOMINAL No. 1 No. 2 VOLTAGE (3 PH, 60 Hz) Min Max RLA LRA RLA LRA Qty FLA Hp 208/230 020 460 575 208/230 025 460 575 FLA — HACR — IFM — LRA — MCA — MOCP— NEC — OFM — RLA — 187 414 518 187 414 518 253 508 632 253 508 632 39.1 19.9 16 39.1 19.9 16 228 114 91 228 114 91 25.6 11.5 9.6 39.1 19.
PAGE 36
Table 7 — Electrical Data — 48AJ,AK,AW,AY Units (cont) UNIT SIZE 48AJ,AK, AW,AY COMPRESSOR VOLTAGE RANGE OFM NOMINAL No. 1 No. 2 VOLTAGE (3 PH, 60 Hz) Min Max RLA LRA RLA LRA Qty FLA Hp 208/230 027 460 575 208/230 030 460 575 FLA — HACR — IFM — LRA — MCA — MOCP— NEC — OFM — RLA — 187 414 518 187 414 518 253 508 632 253 508 632 39.1 19.9 16 57.1 25.6 20.5 256 114 91 266 120 96 39.1 19.9 16 39.1 19.
PAGE 37
Table 7 — Electrical Data — 48AJ,AK,AW,AY Units (cont) UNIT SIZE 48AJ,AK, AW,AY COMPRESSOR VOLTAGE RANGE OFM NOMINAL No. 1 No. 2 VOLTAGE (3 PH, 60 Hz) Min Max RLA LRA RLA LRA Qty FLA Hp 208/230 035 460 575 208/230 040 460 575 FLA — HACR — IFM — LRA — MCA — MOCP— NEC — OFM — RLA — 187 414 518 187 414 518 253 508 632 253 508 632 57.1 25.6 20.5 57.1 25.6 20.5 266 120 96 266 120 96 57.1 25.6 20.5 69.2 28.8 26.
PAGE 38
Table 7 — Electrical Data — 48AJ,AK,AW,AY Units (cont) UNIT SIZE 48AJ,AK, AW,AY NOMINAL VOLTAGE (3 PH, 60 Hz) 208/230 050 460 575 208/230 060 460 575 FLA — HACR — IFM — LRA — MCA — MOCP— NEC — OFM — RLA — VOLTAGE RANGE Min 187 414 518 187 414 518 Max 253 508 632 253 508 632 COMPRESSOR No. 1 No. 2 OFM IFM RLA LRA RLA LRA Qty FLA Hp 69.2 28.8 26.7 82.1 43.6 34.6 345 173 120 446 223 164 69.2 28.8 26.7 82.1 43.6 34.
PAGE 39
Table 8 — Electrical Data — 48EJ,EK,EW,EY Units COMPRESSOR POWER COMBUSTION NOMNAL VOLTAGE UNIT POWER SUPPLY OFM IFM EXHAUST FAN MOTOR No. 1 No. 2 VOLTAGE RANGE SIZE (3 Ph, 48EJ,EK, FLA Min Max RLA LRA RLA LRA Qty Hp (ea) Hp FLA FLA LRA FLA MCA MOCP* 60 Hz) EW,EY — — 0.96 101.8/100.3 125/125 5 16.7/ 15.2 23.6 41.6 0.96 125.4/123.9 150/150 — 0.96 115.9/113.1 150/150 30.8/ — 208/230 187 254 39.1 228 25.6 160 2 1 5.3 10 28.0 23.6 41.6 0.96 139.5/136.7 175/175 — 0.96 131.3/127.1 150/150 46.2/ — 15 42.0 23.6 41.
PAGE 40
Table 8 — Electrical Data — 48EJ,EK,EW,EY Units (cont) COMPRESSOR POWER COMBUSTION NOMNAL VOLTAGE UNIT POWER SUPPLY OFM IFM EXHAUST FAN MOTOR No. 1 No. 2 VOLTAGE RANGE SIZE (3 Ph, 48EJ,EK, FLA Min Max RLA LRA RLA LRA Qty Hp (ea) Hp FLA FLA LRA FLA MCA MOCP* 60 Hz) EW,EY — — 0.96 169.9/167.1 225/200 10 30.8/ 28.0 23.6 41.6 0.96 193.5/190.7 250/225 — 0.96 185.3/181.1 200/200 46.2/ — 208/230 187 254 57.1 266 57.1 266 2 1 5.3 15 42.0 23.6 41.6 0.96 208.9/204.7 250/250 — 0.96 198.5/193.1 250/250 59.4/ — 20 54.
PAGE 41
Table 8 — Electrical Data — 48EJ,EK,EW,EY Units (cont) COMPRESSOR NOMNAL VOLTAGE UNIT OFM IFM No. 1 No. 2 VOLTAGE RANGE SIZE (3 Ph, 48EJ,EK, FLA Min Max RLA LRA RLA LRA Qty Hp (ea) Hp FLA 60 Hz) EW,EY 208/230 048 460 575 208/230 054 460 575 208/230 058 460 575 187 254 414 508 518 632 187 254 414 508 518 632 82.1 42.3 34.6 82.1 43.6 34.6 446 69.2 345 223 28.8 173 164 26.7 120 446 69.2 345 223 30.8 173 164 26.9 120 187 254 106.4 506 69.2 345 414 508 518 632 52.6 40.
PAGE 42
Table 8 — Electrical Data — 48EJ,EK,EW,EY Units (cont) UNIT NOMNAL VOLTAGE SIZE VOLTAGE RANGE 48EJ,EK, (3 Ph, Min Max EW,EY 60 Hz) 208/230 COMPRESSOR No. 1 No. 2 OFM IFM 460 FLA FLA LRA FLA MCA MOCP* 25 74.6/ 68.0 30 88.0/ 80.0 — 35.4 — 35.4 — 35.4 — 18.9 — 18.9 — 18.9 — 18.9 — 18.9 — 18.9 — 35.4 — 35.4 — 35.4 — 18.9 — 18.9 — 18.9 — 18.9 — 18.9 — 18.9 1.44 1.44 1.44 1.44 1.44 1.44 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 1.44 1.44 1.44 1.44 1.44 1.44 0.75 0.75 0.75 0.75 0.
PAGE 43
Routing Through Bottom of Unit — If wiring is brought in through bottom of unit, use field-supplied watertight conduit to run power wiring from basepan out through bottom 31/2-in. hole to the disconnect box and back into unit to the main control box. Use strain relief going into control box through 21/2-in. diameter hole provided. After wires are in unit control box, connect to power terminal block (see Power Wiring section on page 33).
PAGE 44
SENSOR CONNECTION LOCATION LEGEND — Compressor/ Contactor CB — Circuit Breaker CCB — Control Circuit Breaker CR — Control Relay DIP — Dual In-Line Package EQUIP — Equipment FU — Fuse GND — Ground HR — Heater Relay IFC — Indoor-Fan Circuit IFCB — Indoor-Fan Circuit Breaker IFR — Indoor-Fan Relay NEC — National Electrical Code OFC — Outdoor-Fan Contactor PEC — Power Exhaust Controller PES — Power Exhaust Sequencer PESC — Power Exhaust Sequencer Controller TB — Terminal Block TRAN — Transformer DIP SWITCHES
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TI T2 T3 SEE DETAIL B DETAIL B (SENSOR CONNECTION LOCATION) R Y1 Y2 W1 W2 G C X TB3 SEE DETAIL A DETAIL A (THERMOSTAT CONNECTION LOCATION) C CB CCB CCN — Compressor/Contactor — Circuit Breaker — Control Circuit Breaker — Carrier Comfort Network CR — Control Relay DIP — Dual In-Line Package EQUIP — Equipment IFC LEGEND — Fuse — Ground — Heater Relay — Indoor-Fan Circuit IFCB IFR NEC — Indoor-Fan Circuit Breaker — Indoor-Fan Relay — National Electrical Code FU GND HR OFC PEC PES — Outdoor-Fan
PAGE 46
— Compressor/Contactor — Circuit Breaker — Control Circuit Breaker — Carrier Comfort Network CR — Control Relay DIP — Dual In-Line Package EQUIP — Equipment CCN C CB CCB IFCB IFR NEC IFC FU GND HR — Indoor-Fan Circuit Breaker — Indoor-Fan Relay — National Electrical Code LEGEND — Fuse — Ground — Heater Relay — Indoor-Fan Circuit — Outdoor-Fan Contactor — Power Exhaust Controller — Power Exhaust Sequencer PESC — Power Exhaust Sequencer Controller SIO — Serial Input/Output TB — Terminal Block TRAN
PAGE 47
Table 9 — CCN Connection Approved Shielded Cables MANUFACTURER Alpha American Belden Columbia CABLE PART NO. 2413 or 5463 A22503 8772 02525 IMPORTANT: When connecting the CCN communication bus to a system element, use a color coding system for the entire network to simplify installation and checkout. See Table 10. Table 10 — Color Code Recommendations SIGNAL TYPE Positive (+) Ground Negative (-) Fig.
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SPACE TEMPERATURE AVERAGING — 4 SENSOR APPLICATION SPACE TEMPERATURE AVERAGING — 9 SENSOR APPLICATION Fig. 34 — Space Temperature Averaging Wiring Step 10 — Make Outdoor-Air Inlet Adjustments TB2 ECONOMIZER NOTE: If accessory power exhaust or barometric relief packages are being added to the unit, install power exhaust or barometric relief before installing economizer hoods.
PAGE 49
NOTE: The filter track assembly end with screws should face away from the other hood when mounted on the unit. Be sure the filters are installed with the airflow in the correct direction. NOTE: Tabs from both filter tracks will be in the same space. After one filter track has been inserted into hood side, bend the tabs so they will not interfere with installation of the second/ center hood. 17. Attach black seal strip (provided) to filter cover.
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HOOD SIDE (SLOTTED) MOUNTING FLANGE HOOD TOP HOOD SIDE Fig. 41 — Adding Foam Strip to Hood Side Fig. 38 — Adding Seal Strip to Sides of Hood Top Mounting Flange BLOCKOFF BAFFLE HOOD TOP HOOD SIDE GRAY FOAM STRIP Fig. 39 — Adding Seal Strip to Back of Hood Top Mounting Flange Fig. 42 — Adding Seal Strip to Blockoff Baffle Minimum Damper Position (MDP) Setting — Setting of the outdoor air damper position is performed in conjunction with a shortened version of the field run test.
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ECONOMIZER SETTINGS Accessory Enthalpy Control (Fig. 46) — The control (HH57AC077) is mounted in the economizer hood. See Fig. 37. The enthalpy setting adjustment is on the enthalpy control. For maximum benefit of outdoor air, set enthalpy control to A. See Fig. 47 and 48. The enthalpy controls operation of the economizer outdoorair damper to provide free cooling on a signal form the cooling thermostat.
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4. Cap off both wires. When the connection is broken the base control board is fooled into thinking that the enthalpy is not acceptable and economizer operation is disabled. 5. Return power to unit. NOTE: When the economizer is disabled, the damper will function as a 2-position damper. 7. Route the wires from the enthalpy sensor to the return air enthalpy control through the holes on the inside of the hinged filter access panel. The holes are blocked by plug buttons which should be removed. 8.
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CONTROL CONTROL POINT (APPROX. DEG.) CURVE AT 50% RH F (C) A 73 (23) B 70 (21) C 67 (19) D 63 (17) LEGEND RH — Relative Humidity Fig. 48 — Psychrometric Chart for Enthalpy Control NOTE: Partitions shown indicate both side supply (AW,AY,EW,EY) and vertical supply (AJ,AK,EJ,EK) units. Fig.
PAGE 54
NOTES: 1. Unless otherwise specified, all dimensions are to outside of part. 2. Dimensions are in inches. 3. On 48AW,AY and 48EW,EY units, accessory barometric relief or power exhaust must be mounted in the field-supplied return ductwork. Fig. 50 — Barometric Relief Damper and Power Exhaust Mounting Details Step 12 — Install All Accessories — After all the factory-installed options have been adjusted, install all field-installed accessories.
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Install Motormaster® III Controls — Only one Motormaster III control is required per unit. Motor — One outdoor-fan motor (OFM) must be changed out in the field to accommodate the Motormaster III accessory. The replacement motor part no. is HD52AK652. For 48AJ,AK,AW,AY020-030 and 48EJ,EK,EW,EY024034 units, the Motormaster controlled OFM is the no. 2 OFM and is located at the left side of the unit looking from the compressor end. The no.
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Fig. 53B — Motormaster® III Sensor Location (48AJ,AK,AW,AY035 and 48EJ,EK,EW,EY038, 044) Fig. 53D — Motormaster III Sensor Location (48EJ,EK,EW,EY054-064) Fig. 53C — Motormaster III Sensor Location (48AJ,AK,AW,AY040, 050 and 48EJ,EK,EW,EY048) Fig.
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48AJ,AK060 and 48EJ,EK054-068 units. These openings are normally used for power exhaust or barometric relief. 3. Run the return air ductwork up to the openings. One single duct is recommended to connect to the unit over the return air openings. See Fig. 54. The return duct must incorporate a minimum 3/4-in. flange for connection to the unit cabinet. The unit does not have duct flanges for this conversion.
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ECONOMIZER HOOD 42.56” LOCATION BAROMETRIC RELIEF OR POWER EXHAUST “SIDE #2” ECONOMIZER HOOD 23.28” TYP “END #2” 42” MIN. 12.94 (UNIT OPENING) R/A S/A “SIDE #1” “END #1” J BOX 23.28” 42.62” PLENUM RATED CABLE (FIELD SUPPLIED) 42.62 TYP ALTERNATE LOCATION (END) J BOX R/A S/A NOTE: 024-048, 020-050 SIZES SHOWN (2 POWER EXHAUST FANS) 060, 054-068 SIZES HAVE 3 POWER EXHAUST FANS. ALL UNIT SIZES HAVE THE SAME SIZE POWER EXHAUST. Fig.
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Crankcase Heaters — Crankcase heaters are energized as long as there is power to the unit, except when the compressors are operating. TOSHIBA TOSVERT130-E3 VFD — The VFD must be powered up, however, since it is located near the indoor fan, operation of the fan is not desirable. To disable the fan and set the duct static pressure, perform the following procedure: 1. Open the Indoor Fan Circuit Breaker (IFCB). This will shut off power to the VFD. 2.
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8. Press “READ/WRITE” key, to enter the new value. The desired set point value will alternately flash to indicate that the new value has been stored. IMPORTANT: The Carrier factory default values for the VFD may be different than the default values of the manufacturer. Refer to the Carrier literature when checking default values. The following default values have been changed from the manufacturer settings to closely match the VFD operation with a Carrier VAV unit. Refer to Tables 12 and 13. 11. 12. 13.
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Table 13 — Motor Electronic Thermal Protection (tHr) for Toshiba TOSVERT 130-E3 VFD MOTOR Hp kW 5 7.5 10 15 20 25 30 40 3.73 5.60 7.46 11.19 14.92 18.65 22.38 29.
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CC VIA VIB PP II FM R F RST S2 S1 S3 CC P24 OUT E-STOP TWO-WIRE TRANSDUCER 4-20mA LEGEND Typical Factory Wiring Optional Field Wiring - + FIRE SPEED OVER-RIDE Fig.
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the mode of operation (direct or reverse). The 2 jumpers must be arranged horizontally for direct action (factory set). At the top of the module are two potentiometers. The left potentiometer adjusts the offset. The right potentiometer adjusts the differential. The potentiometers are factory set for a nominal 0 in. wg building pressure. The offset set point is defined as the point at which a module turns off a fan, and is measured in terms of percent of the input signal.
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• DIP switch 6 configures the Time Guard® override and, when used with the field test function, sets the minimum damper position • DIP switch 7 configures the unit for gas heat or electric heat • DIP switch 8 configures the unit for heat pump or air conditioner operation. quantity limits. Static pressure drop for power exhaust is negligible. To alter fan performance, see Evaporator Fan Performance Adjustment section on page 91. Condenser Fans and Motors — Condenser fans and motors are factory set.
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Table 18 — DIP Switch Factory Settings UNIT 48AJ,AW and 48EJ,EW 48AK,AY and 48EK,EY 1 Closed Open 2 Closed Closed 3 Closed Closed 4 Closed Closed 5 Closed Closed 6 Closed Closed 7 Open* Open 8 Closed Closed *On 48EJ,EW,AJ,AW units equipped with staged gas option, DIP switch 7 should be closed.
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Table 20 — Fan Performance, 48AJ,AK035 — Vertical Discharge Units AIRFLOW (Cfm) 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 AIRFLOW (Cfm) 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 AIRFLOW (Cfm) 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 0.2 Rpm 433 480 528 577 627 677 728 779 831 883 935 987 Bhp 2.01 2.73 3.59 4.62 5.83 7.22 8.80 10.59 12.60 14.82 17.28 19.98 0.
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Table 21 — Fan Performance, 48AJ,AK040,050 — Vertical Discharge Units AIRFLOW (Cfm) 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 AIRFLOW (Cfm) 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 AIRFLOW (Cfm) 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 0.2 Rpm 512 561 611 662 714 766 819 872 925 979 1032 1086 1140 Bhp 2.98 3.90 5.00 6.27 7.74 9.41 11.29 13.40 15.74 18.32 21.
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Table 22 — Fan Performance, 48AJ,AK060 — Vertical Discharge Units AIRFLOW (Cfm) 12,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 AIRFLOW (Cfm) 12,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 AIRFLOW (Cfm) 12,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 0.2 Rpm 476 536 566 597 628 659 691 723 755 787 819 851 883 916 948 Bhp 4.33 6.19 7.
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Table 23 — Fan Performance, 48AW,AY020-030 — Horizontal Discharge Units AIRFLOW (Cfm) 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 AIRFLOW (Cfm) 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 AIRFLOW (Cfm) 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 0.2 Rpm 394 398 451 506 562 620 679 738 798 859 920 981 Bhp 1.06 1.32 1.90 2.65 3.56 4.65 5.93 7.40 9.09 11.01 13.14 15.52 0.
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Table 24 — Fan Performance, 48AW,AY035 — Horizontal Discharge Units AIRFLOW (Cfm) 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 AIRFLOW (Cfm) 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 AIRFLOW (Cfm) 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 0.2 Rpm 455 505 556 608 661 715 769 824 879 934 989 1044 Bhp 2.15 2.92 3.85 4.96 6.26 7.76 9.46 11.39 13.54 15.94 18.58 21.49 0.
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Table 25 — Fan Performance, 48AW,AY040,050 — Horizontal Discharge Units AIRFLOW (Cfm) 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 AIRFLOW (Cfm) 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 AIRFLOW (Cfm) 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 0.2 Rpm 536 588 642 696 751 807 863 919 975 1032 1089 1146 1203 Bhp 3.18 4.17 5.35 6.72 8.29 10.09 12.12 14.38 16.90 19.67 22.
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Table 26 — Fan Performance, 48AW,AY060 — Horizontal Discharge Units AIRFLOW (Cfm) 12,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 AIRFLOW (Cfm) 12,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 AIRFLOW (Cfm) 12,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 0.2 Rpm 516 584 619 654 689 725 760 796 832 869 905 942 978 1015 1052 Bhp 4.81 6.
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Table 27 — Fan Performance, 48EJ,EK024,034 — Vertical Discharge Units (For EW,EY units, reduce net available external static pressure by 0.3 in. wg) AIRFLOW (Cfm) 4,000 5,000 6,000 7,000 8,000 8,250 9,000 10,000 11,000 12,000 12,500 13,000 13,750 14,000 15,000 AIRFLOW (Cfm) 4,000 5,000 6,000 7,000 8,000 8,250 9,000 10,000 11,000 12,000 12,500 13,000 13,750 14,000 15,000 AIRFLOW (Cfm) 4,000 5,000 6,000 7,000 8,000 8,250 9,000 10,000 11,000 12,000 12,500 13,000 13,750 14,000 15,000 0.
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Table 28 — Fan Performance, 48EJ,EK038,044 — Vertical Discharge Units (For EW,EY units, reduce net available external static pressure by 0.5 in. wg) AIRFLOW (Cfm) 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 AIRFLOW (Cfm) 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 AIRFLOW (Cfm) 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 0.
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Table 29 — Fan Performance, 48EJ,EK048 — Vertical Discharge Units (For EW,EY units, reduce net available external static pressure by 0.5 in. wg) AIRFLOW (Cfm) 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 AIRFLOW (Cfm) 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 AIRFLOW (Cfm) 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000 17,000 18,000 19,000 20,000 0.2 Rpm 528 577 627 677 728 779 830 882 934 986 1038 1091 Bhp 3.20 4.
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Table 30 — Fan Performance, 48EJ,EK054-068 — Vertical Discharge Units AIRFLOW (Cfm) 10,000 12,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 AIRFLOW (Cfm) 10,000 12,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 AIRFLOW (Cfm) 10,000 12,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 0.2 Rpm 420 473 556 584 612 640 669 698 726 756 785 814 843 873 903 Bhp 2.89 4.
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Table 31 — Fan Performance, 48EW,EY054-068 — Horizontal Discharge Units AIRFLOW (Cfm) 10,000 12,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 AIRFLOW (Cfm) 10,000 12,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 AIRFLOW (Cfm) 10,000 12,000 15,000 16,000 17,000 18,000 19,000 20,000 21,000 22,000 23,000 24,000 25,000 26,000 27,000 0.2 Rpm 447 509 606 639 672 705 738 772 806 840 874 908 942 976 1011 Bhp 2.9 4.
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Table 32A — Fan Performance — Power Exhaust, 48AJ,AK,AW,AY020-050 and 48EJ,EK,EW,EY024-048 AIRFLOW (Cfm) 6,500 6,700 6,900 7,100 7,300 7,500 7,700 7,900 8,100 8,500 8,900 9,300 9,700 10,100 10,500 10,900 11,300 11,700 ESP 0.32 0.23 0.17 0.13 0.09 — — — — — — — — — — — — — 208 v Bhp 2.82 2.87 2.92 2.93 2.97 — — — — — — — — — — — — — LOW SPEED 230, 460, 575 v Watts ESP Bhp Watts 3160 0.70 2.98 3340 3220 0.63 3.03 3400 3270 0.59 3.09 3460 3290 0.56 3.11 3490 3330 0.53 3.15 3530 — 0.51 3.19 3580 — 0.48 3.
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Table 33 — Motor Limitations Nominal Bhp Maximum Bhp 5 5.9 8.7 9.5 10.2 11.8 15.3 18.0 22.4 23.4 28.9 29.4 35.6 34.7 42.0 7.5 10 15 20 25 30 40 STANDARD EFFICIENCY MOTORS Maximum Amps 230 v 460 v 575 v 14.6 7.9 6.0 22.0 — — — 12.0 10.0 28.0 — — — 14.6 12.0 43.8 — — — 21.9 19.0 62.0 — — — 28.7 23.0 72.0 — — — 37.4 31.0 95.0 — — — 48.0 47.0 110.0 55.0 48.8 Nominal Bhp Maximum Bhp 5 5.9 8.7 9.5 10.2 11.8 15.3 18.0 22.4 23.4 28.9 29.4 35.6 34.7 42.0 7.
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Start is active, the unit will be controlled as in the Occupied mode. User-defined set points are shown in Table 35. Table 36 lists the software link points addressable by DataPort™ and DataLINK™, Carrier devices that allow access to unit control by non-Carrier energy management systems (EMS). The occupied or unoccupied comfort set points must be selected and the space temperature offset input will be used, if present. The Occupied Heat set point default value is 68 F.
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Table 35 — User Defined Set Points SET POINT NAME OHSP OCSP UHSP UCSP SASP OATL NTLO RTIO LIMT MDP FORMAT DESCRIPTION xx.xF xx.xF xx.xF xx.xF xx.xF xx.xF xx.xF xx.x xx.xF xxx% LOWMDP xxx% IAQS UHDB UCDB LTMP HTMP PES1 PES2 xxxx xx.xF xx.
PAGE 82
The control will run continuous diagnostics for alarms/ alerts; respond to CCN communications and perform any configured network POC (product outboard controls) functions such as time and outdoor-air temperature broadcast and global broadcast; and perform Fire/Smoke control if equipped with power exhaust.
PAGE 83
If the call for heat lasted less than 1 minute, the heating cycle will not terminate until 1 minute after heat became active. When heating is satisfied, the power will be interrupted to the IGC board and W1 and W2 of the main gas valve. If the unit is controlled through a room sensor, the indoor fan will be operating in the Occupied mode and turned off after 45 seconds in the Unoccupied mode.
PAGE 84
Table 37 — Staged Gas System Components ITEM Heating Controller (SGC) Supply-Air Thermistors (SAT) FUNCTION Logic and Output Relays Sense unit leaving-air temperature Cooling Supply Air Set Point Potentiometer (CLSASP) Specify set point for tempering heat control Set Point Range: 35 to 70 F Specify set point for First-Stage Heating control Set Point Range: 80 to 125 F Prove Supply Fan operation Heating Supply Air Set Point Potentiometer (HTSASP) Air Flow Switch (AFS) LOCATION Heating section Supply duc
PAGE 85
Com NA MO Run fort VIG Lin ATO R™ NOTE: To utilize Morning Warm-Up mode, the unit occupancy schedule must be accessed via Service Tool, Building Supervisor, or ComfortWORKS® software or accessory Remote Enhanced Display. The PC can access the base control board via the 3-wire communication bus or via an RJ-11 connection to the CCN terminal on the base control board. See Fig. 27. For current software (version 3.
PAGE 86
the temperature trends stop improving but the demand still exceeds 2.0° F, then Stage 2 heating will be energized SPACE TEMPERATURE RESET SENSOR (VAV Only) — An accessory space temperature sensor (T-55 or T-56 without offset) is required. Space temperature reset is used to reset the supply-air temperature set point of a VAV system higher, as the space temperature falls below the Occupied Cool set point.
PAGE 87
SUPPLY AIR TEMPERATURE RESET — Supply air temperature reset is used to reset the supply-air temperature utility. A 4 to 20 mA signal (field-supplied) is required. The reset option does not require enabling.
PAGE 88
Table 41 — Smoke Control Modes DEVICE Economizer Indoor Fan/VFD Power Exhaust (all outputs) Heat Stages Cool Stages HIR PRESSURIZATION 100% ON OFF OFF OFF ON SMOKE PURGE 100% ON ON OFF OFF ON EVACUATION 100% OFF ON OFF OFF OFF FIRE SHUTDOWN 0% OFF OFF OFF OFF OFF LEGEND HIR — Heat Interlock Relay VFD — Variable Frequency Drive A VAV unit configured to run off thermostat input or a space sensor will have the capability for two stages of heating, however, modification to the control wiring will be requi
PAGE 89
Each door is held closed with 3 latches. The latches are secured to the unit with a single 1/4-in. - 20 x 1/2-in. long bolt. See Fig. 63. To open, loosen the latch bolt using a 7/16-in. wrench. Pivot the latch so it is not in contact with the door. Open the door. To shut, reverse the above procedure. NOTE: Disassembly of the top cover may be required under special service circumstances. It is very important that the orientation and position of the top cover be marked on the unit prior to disassembly.
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NOTES: 1. Torque set screws on blower wheel to 70 in. lbs ± 2 in. lbs. 2. Torque set screw on propeller fan to 15 in. lbs ± 2 in. lbs. 3. Dimensions are in inches. Fig. 65 — Typical Gas Heating Section To inspect blower wheel, remove heat exchanger access panel. Shine a flashlight into opening to inspect wheel. If cleaning is required, remove motor and wheel assembly by removing screws holding motor mounting plate to top of combustion fan housing (Fig. 65 and 66).
PAGE 91
5. Retighten pulley. 6. Return power to the unit. Lubrication COMPRESSORS — Each compressor is charged with the correct amount of oil at the factory. The correct oil charge is shown in Tables 1A and 1B. If oil is visible in the compressor sight glass, check unit for operating readiness as described in Start-Up section, then start the unit. Observe oil level and add oil, if required, to bring oil level in compressor crankcase up to between 1/4 and 1/3 of sight glass during steady operation.
PAGE 92
3. Fully retract motor plate adjusting bolts. 4. Loosen the 2 rear (nearest the evaporator coil) motor plate nuts. 5. Remove the 2 front motor plate nuts and carriage bolts. 6. Slide motor plate to the rear (toward the coil) and remove fan belt(s). 7. Slide motor plate to the front and hand tighten one of the rear motor plate nuts (tight enough to prevent the motor plate from sliding back but loose enough to allow the plate to pivot upward). 8.
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Power Failure — The economizer damper motor is a spring return design. In event of power failure, dampers will return to fully closed position until power is restored. Refrigerant Charge — Amount of refrigerant charge is listed on unit nameplate and in Tables 1A and 1B. Refer to Carrier GTAC II; Module 5; Charging, Recovery, Recycling, and Reclamation section for charging methods and procedures. Unit panels must be in place when unit is operating during charging procedure.
PAGE 94
Main Burners — For all applications, main burners are factory set and should require no adjustment. MAIN BURNER REMOVAL (Fig. 76) 1. Shut off (field-supplied) manual main gas valve. 2. Shut off power supply to unit. 3. Remove heating access panel. 4. Disconnect gas piping from gas valve inlet. 5. Remove wires from gas valve. 6. Remove wires from rollout switch. 7. Remove sensor wire and ignitor cable from IGC board. 8. Remove 2 screws securing manifold bracket to basepan. 9.
PAGE 95
Filter Drier — Replace whenever refrigerant system is ex- FREEZE PROTECTION THERMOSTAT (FPT) — Freeze protection thermostats are located on the evaporator coil for each circuit. One is located at the top and bottom of each coil. It detects frost build-up and turns off the compressor, allowing the coil to clear. Once the frost has melted, the compressor can be reenergized. posed to atmosphere.
PAGE 96
Fig. 77 — Typical Power Schematic 48EJ,EK,EW,EY024-034; 208/230-3-60 and 460-3-60 TABLE 2B The following fan motors have two parallel wires run from TB1 to the fan motors. Indoor Wire Voltage Motor Quantity 20 HP 208/230-3-60 2 TABLE 1A The following compressors have two parallel wires run from TB1 to the compressors. Wire Compressor Voltage Quantity Model 06D-537 208/230-3-60 2 NOTES: 1. Connect TRAN1 to H4 for 460 v units. Connect to H3 for 230 v.
PAGE 97
Fig.
PAGE 98
Fig. 79 — Typical CV 24-V Control Circuit NOTE: Red wire and violet wire are spliced together at the factory. The brown wire has a wire nut added at the factory.
PAGE 99
Fig.
PAGE 100
Fig.
PAGE 101
Fig.
PAGE 102
Fig.
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TROUBLESHOOTING Typical refrigerant circuiting diagrams are shown in Fig. 84-93. An algorithm diagram of the IGC (Integrated Gas Unit Controller) control is shown in Fig. 94. LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig.
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4-Pass 4-Pass HPS & LPS mounted on compressor 4-Pass 4-Pass 4-Pass Muffler TXV #1 4-Pass 4-Pass Compressor #1 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass TXV #2 4-Pass HPS- HK02ZA428 Cut-In - 320 PSI Cut-out - 420 PSI 4-Pass 4-Pass LPS - HK02ZB027 Cut -In - 22 PSI Cut-out - 7 PSI 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass HPS & LPS mounted on compressor 4-Pass 4-Pass 4-Pass Muffler 4-Pass 4-Pass 4-Pass Compre
PAGE 105
12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass HPS & LPS mounted on compressor Muffler Compressor #1 TXV #1 6-Pass 6-Pass 6-Pass 6-Pass TXV #2 HPS- HK02ZA428 Cut-In - 320 PSI Cut-out - 420 PSI LPS - HK02ZB027 Cut -In - 22 PSI Cut-out - 7 PSI 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass 12-Pass HPS & LPS mounted on compressor Muffler Compressor #1 6-Pass 6-Pass 6-Pass 6-Pass FPS HPS LPS TXV —
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LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig.
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8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass HPS & LPS mounted on compressor Muffler Compressor #1 TXV #1 TXV #2 8-Pass HPS- HK02ZA428 Cut-In - 320 PSI Cut-out - 420 PSI 8-Pass LPS - HK02ZB027 Cut -In - 22 PSI Cut-out - 7 PSI 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass 8-Pass
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LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig.
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LEGEND HPS — High-Pressure Switch LPS — Low-Pressure Switch TXV — Thermostatic Expansion Valve Fig.
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6-Pass HPS & LPS mounted on compressor 4-Pass 6-Pass 6-Pass 4-Pass Muffler TXV #1 6-Pass 6-Pass Compressor #1 4-Pass 6-Pass 6-Pass 4-Pass 6-Pass 6-Pass 4-Pass 6-Pass 6-Pass 4-Pass 6-Pass 6-Pass 4-Pass 6-Pass 6-Pass TXV #2 4-Pass HPS- HK02ZA428 Cut-In - 320 PSI Cut-out - 420 PSI 6-Pass 6-Pass LPS - HK02ZB027 Cut -In - 22 PSI Cut-out - 7 PSI 6-Pass 6-Pass 4-Pass 4-Pass 6-Pass 6-Pass 4-Pass 6-Pass 6-Pass 4-Pass 6-Pass 6-Pass 4-Pass 6-Pass 6-Pass 4-Pass 6-Pass 6-Pass 4-Pass 6-Pass 6-Pass 4-Pass 6-
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LEGEND HPS — High-Pressure Switch LPS — Low-Pressure Switch TXV — Thermostatic Expansion Valve Fig.
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Fig.
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LEGEND IDM — Induced-Draft Motor IGC — Integrated Gas Unit Controller NOTE: Thermostat Fan Switch in the “AUTO” position or sensor-equipped unit. Fig.
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The alarm codes for the IGC control board are shown in Table 44. Diagnostic LEDs — There are 3 LEDs (red, yellow, and green) on the lower right hand side of the control board. The red light is used to check unit operation and alarms. A constant pulse is normal unit operation. A series of quick blinks indicates an alarm. Refer to Table 45 below for a description of alarms. The yellow LED blinks during transmission with the CCN (Carrier Comfort Network).
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Tables 46-48 show the input and output channel designations. Table 46 — I/O Channel Designations Base Module — CV TERMINAL NO.
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SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Installation Overview • Maintenance • Operating Sequence A large selection of product, theory, and skills programs are available, using popular video-based formats and materials. All include video and/or slides, plus companion book.
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START-UP CHECKLIST MODEL NO.: _________________________________ SERIAL NO.: ______________________________________ SOFTWARE VERSION (SEE FIG.
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SET ECONOMIZER MINIMUM VENT POSITION TO JOB REQUIREMENTS ENSURE DRIVES OPERATE WITH LIMITS OF FAN PERFORMANCE TABLES HIGH PRESSURE SWITCH SETTING psig LOW PRESSURE SWITCH SETTING psig MOTOR PULLEY PART NUMBER FAN PULLEY PART NUMBER BELT PART NUMBER BELT SIZE in. FILTER QUANTITY FILTER SIZES in.