Carrier 39L User Manual

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With Product Integrated Controls (PIC)

Installation, Operation, and

Start-Up Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS ...................2

GENERAL ...................................2

INSTALLATION .............................2-64

Service Area Requirements ...................2

Remote Control Box Option ..................2

• REMOTE CONTROL BOX CONDENSATE PREVENTION

Make Electrical Connections ..................3

Variable Frequency Drives ...................38

Water Valve Assemblies .....................38

• VALVE WIRING

Duct Static Pressure Probe (VAV Units) ......39

Space Temperature Sensor ..................40

Outdoor-Air Temperature Sensor .............42

Mixed-Air Temperature Sensor ...............42

Enthalpy Switch ............................43

• CONTROL RANGES

Supply-Air Temperature Sensor ..............44

Return-Air Temperature Sensor ..............44

Heat Interlock Relay .........................45

Fan Relay ..................................45

Duct High Humidity Switch ..................45

Wall-Mounted Relative Humidity Sensor ......46

Duct-Mounted Relative Humidity Sensor ......47

• LOCATION FOR OUTSIDE AIR RELATIVE HUMIDITY

• LOCATION FOR RETURN AIR RELATIVE HUMIDITY

Mixing Box Linkage .........................47

Airﬂow Switch ..............................48

Low-Temperature Thermostat ................48

Outdoor-Air Thermostat .....................48

Filter Status Switch .........................49

High-Pressure Switch .......................49

Air Quality Sensors .........................49

Constant Outside Air (OAC) Control ..........50

• PROBE INSTALLATION

• OAC CALIBRATION

• USING OAVP VALUES TO DETERMINE DUCT AIRFLOW

• FIELD-SUPPLIED OR HIGH-VELOCITY PRESSURE TRANSDUCERS

Field Wiring Connections ....................52

• REMOTE LOCAL INTERFACE DEVICE (HSIO)

• RETURN-AIR TEMPERATURE SENSOR, OUTDOOR-AIR TEMPERATURE SENSOR, ENTHALPY SWITCH, AND MIXED-AIR TEMPERATURE SENSOR

• SPACE TEMPERATURE SENSOR (SPT)

• DAMPER ACTUATORS

• SMOKE CONTROL OPTION

• ANALOG DEVICE FOR ANALOG OUTPUT TEMPERATURE CONTROL

39L,NX

Central Station Air-Handling Units

• DEVICE UNDER DISCRETE OUTPUT TEMPERATURE CONTROL

• DISCRETE OUTPUT DEVICE UNDER TIMECLOCK CONTROL

• HUMIDIFICATION DEVICES

• AIR QUALITY SENSOR

• OUTSIDE AIR VELOCITY PRESSURE (OAVP) SENSOR

• FAN VOLUME CONTROL

• ELECTRIC HEATER

• CARRIER COMFORT NETWORK INTERFACE

• OUTDOOR-AIR THERMOSTAT

CONTROL SYSTEM .......................64-68 Processor (PSIO Master) and Option (PSIO Slave)

Modules .................................65

Relay (DSIO) Module .......................65

Local Interface Device (HSIO) ...............67

CONTROL OPERATION ...................69-91

Accessing Functions and Subfunctions .....69

Display Functions ..........................69

• SUMMARY DISPLAY

• STATUS FUNCTION

• HISTORY FUNCTION

• TEST FUNCTION

Programming Functions ...................81

• SERVICE FUNCTION

• SET POINT FUNCTION

• SCHEDULE FUNCTION

CONTROL OPERATING SEQUENCE .......92-102 Constant Volume and Variable Air

Volume Units ............................92

Constant Volume Units Only ................96

Variable Air Volume Units Only .............99

START-UP ..............................103-108

Initial Check ..............................103

Quick Test ................................103

Electronic Valve Actuator Field Test ........108

CONTROL LOOP CHECKOUT ............108,109

To Check Operation of Analog Outputs .....108

VALVE TROUBLESHOOTING .............109-111

General ...................................109

⁄2-in. Through 11⁄4-in. Electric Hot Water/Steam

All

Valve Assemblies .......................109 All 11⁄2-in. Through 3-in. Valve Assemblies ..110

CONTROL MODULE

TROUBLESHOOTING ..................111,112

General ...................................111

Module Replacement (PSIO, DSIO) .........112

UNIT TROUBLESHOOTING ...............113-115

METRIC CONVERSION CHART .............116

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

Book 3 Tab 1b

PC 201 Catalog No. 533-913 Printed in U.S.A. Form 39L,NX-2SI Pg 1 3-96 Replaces: 39L,NX-1SI

IMPORTANT: This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with these instructions may cause radio interference. It has been tested and found to comply with the limits of a Class A computing device as deﬁned by FCC regulations, Subpart J of Part 15, which are designed to provide reasonable protection against such interference when operated in a commercial environment.

SAFETY CONSIDERATIONS

Installation and start-up of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualiﬁed service personnel should install, start up, or service air-conditioning equipment.

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, including ANSI (American National Standards Institute) Z223.1 (latest version). Wear safety glasses and work gloves.

Disconnect all power to the unit before performing maintenance or service. Unit may automatically start if power is not disconnected. Electrical shock and personal injury could result.

Do not store or use gasoline or other ﬂammable vapors and liquids in the vicinity of this or any other appliance.

GENERAL

The Product Integrated Control (PIC) option is available for 39L and 39NX indoor units with a draw-thru conﬁguration. The PIC control box can be supplied as part of a dedicated PIC section; it is factory-installed and wired and has the same hand (orientation) as the fan section. The control box can also be shipped separately for remote mounting without a PIC section. For the remote control box option, all connections from the control box to the unit are made to a junction box in the unit’s fan section.

The control box includes electronic modules, fuses, relays, transformers, terminal blocks, low-limit air temperature protection (optional), static pressure transducer (VAV

[Variable Air Volume] units only) and high-pressure switch (VAV units). An ON/OFF switch is included to shut off the power to the control box.

PIC environmental limitations are as follows:

Shipping Temperature — −20 to 165 F Shipping Humidity — 10 to 95% Operating Temperature — 32 to 125 F Operating Humidity — 30 to 90%

INSTALLATION

Follow all basic installation instructions for 39L or 39NX units as described in the 39L or 39NX Installation, Start-Up, and Service Instructions shipped with the unit. To verify the PIC and PIC option conﬁgurations according to the model numbers, see Fig. 1 and 2.

Leave protective coverings on the unit until it is installed inside and protected from the elements, construction debris, and dirt.

Use one of the keys provided in the 39L or 39NX installation packet (located in fan section) to open the control box door.Visually inspect all components and wiring for any damage. Remove the valve assembly packages and the sensor packages from the fan section. For units with PIC sections, remove protective plastic caps from the bulkhead ﬁttings (located on the top edge of the control box) and discard.

Verify that the 10.0 amp ON/OFF switch located on the PIC control box door is in the OFF position. Do not turn the

power supply on at this time.

NOTE: The 39NX and 39L air handlers are designed for indoor applications. Modiﬁed units are available for outdoor applications on pier or slab mounts (not curb mounts). Prod-

uct integrated controls are not available for outdoor applications. Consult your Carrier sales representative for further

details.

ServiceArea Requirements — Article 110-16 of the

NEC (National Electrical Code) describes electrical installation.All 39L and 39NX PIC installations must comply with the minimum clearances required for electrical installation as listed in Table 110-16(a) of the code. Make sure to provide the necessary clearance from the PIC unit to any adjoining wall. Refer to the base unit installation instructions for detailed dimensions for each unit section.

Remote Control Box Option — This option allows

the PIC control box to be mounted away from the unit; the remote control box (Fig. 3) must be wired to the supply fan section. Mount the remote control box assembly to the mechanical room wall near the unit using ﬁeld-supplied Unistrutt metal framing or equivalent supports. The control box has 4 mounting holes in the back of the enclosure for this purpose.

Mount the remote control box as follows:

1. Loosen and remove the 4 nuts securing the control panel in the control box.

2. Remove the control panel from the box; set the panel and nuts aside for reassembly later.

3. Mount the control box to the Unistrutt support using ﬁeldsupplied fasteners.

4. Locate, mark, and drill pilot holes on the top of the box for each of the following:

• Motor starter wiring

• Actuator and sensor wires to fan section junction box

• Supply power wires (ac)

• Valve wiring or tubing (water valves, ﬁeld-supplied

sensors, or other devices)

5. Expand the pilot holes as required. Recommended sizes are as follows:

• Motor starter wiring —3⁄4in. (5 wires)

• Actuator and sensor wires to fan section junction

box —

⁄4in. to 1 in. (number of wires and hole di-

ameter determined by application)

• Supply power wires (ac) —

⁄2in. or3⁄4in.

• Valve wiring or tubing — size as required

Fan section panels are provided with pilot holes that can be drilled or punched to accomodate an electrical conduit for the remote control box wiring. Where possible, install the conduit in a panel that will not be removed, such as the discharge panel. See Fig. 4.

REMOTE CONTROL BOX CONDENSATE PREVENTION — When the remote control box is installed, precautions must be taken to prevent condensation from forming inside the junction box mounted in the unit’s supply fan section. Standard installation practice is to mount the remote control box adjacent to the air handling unit and then to enclose the Class II wiring in ﬂexible conduit between the control box and the junction box in the fan section.

The sheet metal housing of the control box is not airtight, therefore warm, moist air can migrate through the ﬂexible conduit to the junction box in the fan section. Condensate can form inside the junction box and possibly on the terminal lugs.

To prevent moist air from migrating through the conduit, seal the control wires inside the conduit at the remote control box enclosure. See Fig. 4. Use a nonconductive, nonhardening sealant. Permagum (manufactured by Schnee Morehead) or sealing compound, thumb grade (manufactured by Calgon), are acceptable materials.

MakeElectrical Connections — 39L and 39NX units

have internal control wiring for the operation of the PIC section and its control devices. The control system requires a dedicated 120 vac or 230 vac (50 or 60 Hz) power circuit capable of providing a minimum of 10 amps (but not greater than 20 amps) to the control box. The actual number of controls on one power source depends on the installation and power circuit requirements. Do not run PIC power wiring in the same conduit as sensor wiring or control wiring of ﬁeldinstalled devices.

IMPORTANT: To ease installation, control wiring is located on the service side of the unit with electrical connectors provided at all unit separation points. If a unit is separated into pieces for installation, rejoin all connectors in their original alpha-numeric sequence upon reassembly. Connectors for vertical fan sections that are shipped out of the normal operating position must also be joined at ﬁnal assembly.

For units with an integral PIC section, all unit factory control wiring is internal. Only a small number of wires must be ﬁeld-installed. All internal wiring consists of plenum wires which enter the rear of the control box through sealed ﬁttings. Control wiring is 18 to 20 gage, 2-conductor twisted pair.

The electrical power disconnect and fan motor starter are ﬁeld-supplied and installed. Connections are provided in the control box to wire a ﬁeld-supplied HOA (HANDS/OFF/ AUTOMATIC) switch. If an HOA switch is used, it must be ﬁeld-installed in the supply and return fan motor starter circuit. The factory-wired high-pressure switch (variable air volume only) and low-temperature thermostat options are energized when the supply fan circuit is powered.

See Fig. 5-7 for control box component arrangements and Fig. 8 for fan motor wiring. PIC input and output points are listed in Table 1. Consult the wiring diagram located in the control box or Fig. 9-12 for further details.

Power is present in the PIC control box in the motor starter circuit even when the dedicated power to the PIC control box is off.

The supply and return fan starter circuits are independent from each other. Either circuit and its related control box interface can have 24 vac, 120 vac, or 240 vac power.

All options that require a factory-installed transformer are fused with 3.2 amp fuses on the secondary of each transformer.

When the control box is shipped separately for remote mounting, all unit wiring terminates in a junction box located in the fan section. Refer to Fig. 12 for the applicable wiring diagram and Table 2 for junction box connections.

If the unit is provided with a factory-installed smoke control option, refer to the section titled Field-Wiring Connections, Smoke Control Option, page 54.

All PIC electrical components are UL (Underwriters’Laboratories) listed. The electronic modules are approved under UL HVACEquipment Standard 873. PIC units are listed and labeled by ETL (Engineering Testing Laboratory) to comply with UL Standard 1995 for heating and cooling units, and comply with NFPA (National Fire Protection Association) Standard 90A.

LEGEND

ABX — Air Blender AF — Airfoil CV — Constant Volume IGV — Inlet Guide Vanes FC — Forward-Curved FMB — Filter Mixing Box MXB — Mixing Box PIC — Product Integrated Controls VAV — Variable Air Volume

*The cv capacity rating is the ﬂow (gpm) through a valve at 1 psi pres-

sure drop.

Fig. 1 — Basic PIC Order Number

LEGEND

AF — Airfoil CV — Constant Volume DX — Direct Expansion FC — Forward-Curved FMB — Filter Mixing Box MXB — Mixing Box N.C. — Normally Closed N.O. — Normally Open PIC — Product Integrated Controls VAV — Variable Air Volume

*The cv capacity rating is the ﬂow (gpm) through a

valve at 1 psi pressure drop.

Fig. 2 — PIC Option Order Number

NOTE: Dimensions in [ ] are in millimeters.

Fig. 3 — Control Box for Remote Mounting

Fig. 4 — Sealing Control Wiring in Flexible Conduit

LEGEND (Fig. 5-12, Table 2)

AFS — Airﬂow Switch AO — Analog Output AOTC — Analog Output Temperature Control AQ AQ C—Contactor CCW — Counterclockwise CH — Channel CR — Control Relay CUST — Condensing Unit Status CV — Constant Volume CW — Clockwise CWV — Chilled Water Valve DHH — Duct High Humidity DO — Discrete Output DOTC — Discrete Output Temperature Control DSIO — Control Module, Electric Heat and/or DX DTCC — Discrete Time Clock Control DX — Direct Expansion DXS — DX Cooling Stage DXSD — Direct Expansion Cooling Shutdown EHS — Electric Heaters ELEC — Electric ENT — Enthalpy Switch EQUIP — Equipment EVAC — Smoke Evacuation Input EXD — ExhaustAir Damper Actuator FLTS — Filter Status Switch FSD — Fire Shutdown Device FU — Fuse GND — Ground HIR — Heat Interlock Relay HOA — Hand-Off-Auto. Switch HPS — High-Pressure Switch HSIO — Keyboard and Display Module HT — Heat HUM — Humidiﬁer HWV — Hot Water Valve IGV — Inlet Guide Vane Actuator LTT — Low Temperature Thermostat MAD — Mixed-Air Damper Actuator MAT — Mixed-Air Temperature MPSIO — Master Processor Module

OAD — Outdoor-Air Damper Actuator OARH — Outdoor-Air Relative Humidity OAT — Outdoor-Air Temperature OAVP — Outdoor-Air Velocity Pressure

— Air Quality Sensor, No. 1

— Air Quality Sensor, No. 2

(Processor Module)

OT — Outside-Air Thermostat PH — Preheat PL — Plug Assembly PRESS — Smoke Pressurization Input PSIO — Processor Module PURG — Smoke Purge Input RAD — Return-Air Damper Actuator RAT — Return-Air Temperature RFAN — Return Fan RFR — Return Fan Relay RFVC — Return Fan Volume Control RH — Relative Humidity RVP — Return Velocity Pressure SAT — Supply-Air Temperature SF — Fan Status Relay SFAN — Supply Fan SFR — Supply Fan Relay SMK — Smoke SNB — Snubber SP — Static Pressure Transducer SPSIO — Slave Processor Module

SPT — Space Temperature SVP — Supply Velocity Pressure SW — Switch TB — Terminal Block Terminal TEMP — Temperature TRAN — Transformer VAV — Variable Air Volume W/ — With WO/ — Without

(Option Module)

Marked Wire or Cable Terminal (Marked) Terminal (Unmarked)

Terminal Block Splice (Factory)

Splice (Field) Wiring Factory Wiring Field Control Wiring Field Power Option or Accessory Common Potential

NOTES:

1. Use copper conductors only.

2. Wire is in accordance with National Electrical Code (NEC).Forlocalcodes, replace original wires with 90 C wire or its equivalent.

3. Replace wires fromIGV, FLTS,MAT,SAT,OAD,RAD,andELEC HTwith 125 C plenum cable conductor as required.

4. Input channel numbers and points for conﬁguration of the optional analog output temperature control (AOTC) follow:

CHANNEL SENSOR DESCRIPTION

1 SAT Supply-Air Temperature 2 OAT Outdoor-Air Temperature 3 MAT Mixed-Air Temperature 6 SPT Space-Air Temperature 7 RAT Return-Air Temperature

34 TEMP Preheat or Optional Carrier Sensor

5. Reference for wire markers, where ‘X’ represents a numeral:

X — Item number on wiring harness BX — Box wire CX — Cable KX — Accessory kit wire

ARRANGEMENT FOR SIZES 03 AND 06

ARRANGEMENT FOR SIZES 08 THROUGH 35

Fig. 5 — PIC Section Control Box Component Arrangements, 39L

Fig. 6 — PIC Section Control Box Component Arrangement, 39NX Sizes 07-21

Fig. 7 — PIC Section Control Box Component Arrangement, 39NX Sizes 26-92

Fig. 8 — Fan Motor Starter Circuit and PIC Control Wiring Interface — PIC Power for

Control Circuit From Dedicated Source

MODULE,

DEFAULT ADDRESS

PSIO (Processor) ADDRESS 1

PSIO (Option) ADDRESS 31

DSIO (Electric Heat) ADDRESS 19

DSIO (DX without Electric Heat) ADDRESS 19

DSIO (DX with Electric Heat) ADDRESS 49

Table 1 — Input and Output Points

INPUT

SAT AI 1 IGV* AO 13 OAT AI 2 MIXD AO, DO† 14 MAT AI 3 HWC AO 15 RH AI 4 CWC AO 16 LTT DI 5 SF DO 17 SPT AI 6 HIR* DO 18 RAT AI 7 — — — SP* AI 8 — — — AFS DI 9 — — — FLTS DI 10 — — — OARH AI 11 — — — ENT DI 12 — — — SVP* AI 31 RFVC* AO 43 RVP* AI 32 HUM1 AO, DO 44 DHH DI 33 HUM2 DO 45 TEMP AI 34 AOTC AO 46 PRES DI 35 DOTC DO 47 EVAC DI 36 DTCC DO 48 PURG DI 37 — — — FSD DI 38 — — — AQ1 AI 39 — — — AQ2 AI 40 — — — OAVP* AI 41 — — — METER DI 42 — — — — — — EHS1 DO 23 — — — EHS2 DO 24 — — — EHS3 DO 25 — — — EHS4 DO 26 — — — EHS5 DO 27 — — — EHS6 DO 28 — — — EHS7 DO 29 — — — EHS8 DO 30 CUST DI 19 DXS1 DO 23 DXSD DI 20 DXS2 DO 24 — — — DXS3 DO 25 — — — DXS4 DO 26 — — — DXS5 DO 27 — — — DXS6 DO 28 — — — DXS7 DO 29 — — — DXS8 DO 30 CUST DI 49 DXS1 DO 53 DXSD DI 50 DXS2 DO 54 — — — DXS3 DO 55 — — — DXS4 DO 56 — — — DXS5 DO 57 — — — DXS6 DO 58 — — — DXS7 DO 59 — — — DXS8 DO 60

INPUT

TYPE

CHANNEL

NUMBER

OUTPUT

TYPE

CHANNEL

NUMBER

AFS — Airﬂow Switch (Supply Fan AI — Analog Input

AO — Analog Output AOTC — Analog Output Temperature

AQ1, 2 — Air Quality Sensors 1, 2 CUST — Condensing Unit Status

CWC — Chilled Water Coil DI — Discrete Input DHH — Duct High Humidity DO — Discrete Output DOTC — Discrete Output Temperature

DTCC — Discrete Output Timeclock

*Available on VAV only. †Discrete output with two-position damper control.

Status Switch)

Control

(Outdoor Air Thermostat)

Control Control

LEGEND

DXS1-8 — Direct Expansion Cooling DXSD — Direct Expansion Cooling EHS1-8 — Electric Heater Stages 1-8

ENT — Enthalpy Switch EVAC — Evacuation FLTS — Filter Status Switch FSD — Fire Shutdown HIR — Heat Interlock Relay HWC — Hot Water Coil HUM1, 2 — Humidity Stages 1, 2 IGV — Inlet Guide Vanes LTT — Low Temperature Thermostat

MAT — Mixed-Air Temperature METER — Meter (Pulsed Dry-Contact

Stages 1-8 Shutdown

(also labelled FRZ)

Input)

MIXD — Mixed-Air Dampers OARH — Outdoor-Air Relative Humidity OAT — Outdoor-Air Temperature OAVP — Outdoor-Air Velocity Pressure PRES — Pressurization PURG — Purge RAT — Return-Air Temperature RFVC — Return Fan Volume Control RH — Relative Humidity RVP — Return Velocity Pressure SAT — Supply-Air Temperature SF — Supply Fan Relay SP — Static Pressure SPT — Space Temperature SVP — Supply Velocity Pressure TEMP — Optional Temperature Input