Carrier 35E user guide manual

35E Single-Duct Terminal Units
Variable Volume System
Installation and Start-Up Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS ...................... 1
General ..........................................2
Warranty ......................................... 2
INSTALLATION ................................. 4-6
Step 1 — Install Volume Control Box .............4
Step 2 — Make Duct Connections ................4
Step 3 — Install Sensors and Make Field
Wiring Connections — Electronic Analog
or DDC (Direct Digital Controls) ................4
CONTROL SET-UP ............................... 7
General ..........................................7
Set Points ........................................7
Field Adjustments of Minimum and
Maximum Airflow Set Points ................... 7
System Calibration of the Linear Averaging
Flow Probe.....................................7
PNEUMATIC CONTROLS .......................7-11
Preparation for Balancing (Control
Sequences 1102 and 1103)..................... 7
Balancing Procedure
(Control Sequences 1102 and 1103) ............ 9
• DIRECT ACTING THERMOSTAT, NORMALLY OPEN DAMPER (Control Sequence 1102)
• REVERSE ACTING THERMOSTAT, NORMALLY CLOSED DAMPER (Control Sequence 1103)
Balancing Procedure
(Control Sequences 1104-1110) ............... 10
Pneumatic Control Troubleshooting............. 10
Balancing Procedures
(Control Sequences 2100-2105) ............... 11
Analog Control Troubleshooting ................13
Install Sensors and Make Field-Wiring
Connections .................................. 13
• GENERAL
• SUPPLY-AIR TEMPERATURE SENSOR
INSTALLATION
• SPACE TEMPERATURE SENSOR INSTALLATION
AND WIRING
• WIRING THE SPACE TEMPERATURE SENSOR
AND SET POINT ADJUSTMENT SLIDEBAR
• WIRINGTHECCNNETWORKCOMMUNICATION
SERVICE JACK
• PRIMARY AIR TEMPERATURE SENSOR
INSTALLATION
• INDOOR-AIR QUALITY SENSOR INSTALLATION
• INDOOR-AIR QUALITY SENSOR WIRING
• HUMIDITY SENSOR (Wall-Mounted) INSTALLATION
Connect the CCN Communication Bus..........19
• COMMUNICATION BUS WIRE SPECIFICATIONS
• CONNECTION TO THE COMMUNICATION BUS
Water Valve Installation .........................19
ComfortID Start-Up.............................. 19
• GENERAL
• PRIMARY SYSTEM CHECK
• ComfortID CONTROL SYSTEM CHECK
CCN System Start-Up ........................... 20
VVT® CONTROLS ............................ 21-23
General .........................................21
• DIRECT DRIVE HIGH TORQUE ACTUATOR
• RELAY PACKAGE
• ADDITIONAL SENSOR INFORMATION
•THERMOSTATS
Wiring Requirements............................ 21
• CCN COMMUNICATIONS
• THERMOSTAT TO TERMINAL CONTROL BOX
Wiring Connections ............................. 22
Control Start-up................................. 23
• GENERAL
• PRIMARY SYSTEM CHECK
SAFETY CONSIDERATIONS
SAFETY NOTE
Air-handling equipment will provide safe and reliable service when operated within design specifications. The equipment should be operated and serviced only by autho­rized personnel who have a thorough knowledge of sys­tem operation, safety devicesand emergencyprocedures.
Good judgement should be used in applying any manufacturer’s instructions to avoid injury to personnel or damage to equipment and property.
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.
If it is necessary to remove and dispose of mercury contac­tors in electric heat section, follow all local, state, and fed­eral laws regarding disposal of equipment containing hazardous materials.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 3 Ta b 6 a
Catalog No. 533-530 Printed in U.S.A. Form 35E-2SI Pg 1 3-06 Replaces: 35E-1SI
PRE-INSTALLATION
General —
nal available with factory-installed pneumatic, analog electron­ic, Carrier Comfort Network® (CCN) or VVT®(variable vol­ume and temperature) electronic control options that can be used in conjunction with unit-mounted electric or hot water heat options. Figure 1 shows the basic box. Figure 2 is an example of a unit identification label.
STORAGE AND HANDLING — Inspect for damage upon receipt. Shipping damage claims should be filed with shipper at time of delivery. Store in a clean, dry, and covered location. Do not stack cartons. When unpacking units, care should be taken that the inlet collars and externally mounted components do not become damaged. Do not lift units using collars, sensors or externally mounted components as handles. If a unit is sup­plied with electric or hot water heat, care should be taken to prevent damage to these devices. Do not lay uncrated units on end or sides. Do not stack uncrated units over 6 ft high. Do not manhandle. Do not handle control boxes by tubing connections or other external attachments. Table 1 shows component weights.
INITIAL INSPECTION — Once items have been removed from the carton, check carefully for damage to duct connec­tions, coils or controls. File damage claim immediately with transportation agency and notify Carrier.
UNIT IDENTIFICATION — Each unit is supplied with a shipping label and an identification label (Fig. 2).
INSTALLATION PRECAUTION — Check that construction debris does not enter unit or ductwork. Do not operate the central-station air-handling fan without final or construction filters in place. Accumulated dust and construction debris distributed through the ductwork can adversely affect unit operation.
SERVICE ACCESS — Provide service clearance for unit access.
CODES — Install units in compliance with all applicable code requirements.
UNIT SUSPENSION — See Fig. 3 for unit suspension details.
The 35E is a single duct, variable volume termi-
Warranty — All Carrier-furnished items carry the standard
Carrier warranty.
No periodic preventative maintenance required, unless
called for specific control sequence.
Fig. 1 — 35E Single Duct Box (Sizes 4-16)
Fig. 2 — Unit Identification Label
Table 1 — 35E Unit Weights
35E
SIZE
4, 5, 6 14 18 23 32 19/20
7, 8 16 20 25 39 21/23
9, 10 21 25 30 44 28/30
12 26 30 35 56 35/38 14 34 38 43 65 44/49 16 38 42 47 75 50/55 22 65 69 74 91 82/90
DDC — Direct Digital Controls
NOTE: Data is based on the following conditions:
1. Unit casing is 22 gage.
2. Unit insulation is
3. Units rated with standard linear flow sensor.
LEGEND
UNIT ONLY
(lb)
1
/2-in. thick, 1.5-lb Tuf-Skin Rx™, dual density.
WITH PNEUMATIC
CONTROLS
(lb)
WITH DDC OR
ANALOG CONTROLS
(lb)
WITH ELECTRIC HEAT
CONTROLS
(lb)
WITH HOT WATER
(1 ROW/2 ROW) (lb)
2
FIELD SUPPLIED HANDING WIRE
BRACKET
DETAIL
Fig. 3 — Typical Unit Suspension with Brackets
CONTROL ARRANGEMENTS
The 35E single-duct unit is offered with a wide variety of factory-mounted controls that regulate the volume of air deliv­ery from the unit and respond to cooling and heating load re­quirements of the conditioned space. Stand-alone controls will fulfill the thermal requirements of a given control space. These devices are available in both pneumatic and electronic arrange­ments. Carrier VVT® electronic controls and PIC (Product Integrated Control) DDC (Direct Digital Controls) are commu­nicating controls which are integrated with the building system. The PIC controls are compatible with the CCN system. A num­ber of DDC control packages by others are available for con­signment mounting, as indicated.
Control offerings are: 35EA: Analog Electronic
35EC: PIC Direct Digital Electronic 35EP: Pneumatic 35EV: VVT Electronic (Gen. III or 3V™ controls) 35EN: None or DDC by others
Each control approach offers a variety of operating func­tions; a control package number identifies combinations of control functions. The following listings contain the basic func­tion arrangements for each control offering. Because of the variety of functions available, circuit diagrams, operating sequences, and function descriptions are contained in separate Application Data publications. Refer to the specific control publication for details.
CCN Control Arrangements — Carrier Comfort Net-
work® (CCN) controls are factory-installed in a control enclo­sure. Factory-mounted transformers are available as an option. Thermostats are supplied separately as a field-installed acces­sory. Carrier Comfort Network control packages must be used in combination with a thermostat. Thermostats are not included in the CCN package.
4140: Cooling only 4141: Single-stage and 2-stage electric heat 4142: 3-stage electric heat 4143: On-Off hot water 4144: Proportional (floating) hot water heat 4145: Cooling only with supply return tracking 4147: Single-stage, 2-stage and 3-stage electric heat with
supply return tracking
4149: Proportional (floating) hot water with supply return
tracking
4150: Return air damper
CCN Thermostats (Ordered Separately)
Thermostat: 33ZCT56SPT: RT (room temperature) sensor, with set point adjust and override.
Thermostat: 33ZCT55SPT: RT (room temperature) sensor, with override only.
Thermostat: 33ZCT58SPT: Communicating room tempera­ture sensor with LCD (liquid crystal diode), set point adjust, fan control and occupancy override.
Thermostat: 33ZCT56CO2: RT (room temperature) and CO sensor, with set point adjust and override.
Thermostat: 33ZCT55CO2: RT (room temperature) and CO sensor, with override only.
VVT Electronic Control Arrangement — Va r i -
able volume and temperature (VVT) controls are factory­installed in a control enclosure. Factory-mounted transformers are available as an option. Thermostats are supplied separately as a field-installed accessory.
GEN. III CONTROL CODES AND DESCRIPTIONS 8200: Pressure dependent, cooling only 8201: Pressure dependent, cooling with 2-stage electric heat 8202: Pressure dependent cooling with on/off hot water heat 8206: Pressure independent, cooling only 8207: Pressure independent, cooling with 2-stage electric heat 8208: Pressure independent cooling with on/off hot water heat 8209: Variable air volume (VAV) pressure dependent unit
control zone (Monitor)
8210: Bypass controller, 2-in. wg transducer 3V CONTROL CODES AND DESCRIPTIONS 8220: Pressure dependent cooling only
8221: Pressure dependent cooling with 3-stage electric heat 8222: Pressure dependent cooling with on/off hot water heat 8223: Pressure dependent cooling with modulating hot water
heat
8224: Pressure dependent cooling with combination base-
board and 2-stage electric heat 8226: Pressure independent cooling only 8227: Pressure independent cooling with 2-stage electric heat 8228: Pressure independent cooling with on/off hot water heat 8230: Bypass control
Analog Electronic Control Arrangement —
Pressure independent control packages are available without supplemental heat, with on/off hot water or electric heat, pro­portional hot water heat, or with cooling/heating automatic changeover control.
2
2
3
All analog control arrangements include a standard linear inlet flow sensor, 24-v transformer (optional), control enclo­sure and wall thermostat to match the control type.
2100: Heating control 2101: Cooling control 2102: Cooling with on/off electric heat control 2103: Cooling with on/off hot water heat control 2104: Cooling/heating automatic changeover control 2105: Cooling with proportional hot water heat control
Pneumatic Control Arrangement — All control
packages are pressure independent (unless otherwise noted) and available with or without hot water heat, dual maximum airflow, heating and cooling maximum airflow and dual mini­mum airflow. All control arrangements include a standard linear inlet flow sensor.
1100 (Actuator only): DA-NC pressure dependent control 1101 (Actuator only): RA-NO pressure dependent control 1102 (Single function controller): DA-NO with or without hot
water or electric heat 1103 (Single function controller): RA-NC with or without hot
water or electric heat 1104 (Multi-function controller): DA-NO with or without hot
water or electric heat 1105 (Multi-function controller): DA-NC with or without hot
water or electric heat 1106 (Multi-function controller): RA-NO with or without hot
water or electric heat 1107 (Multi-function controller): RA-NC with or without hot
water or electric heat 1108 (Dual Maximum Control): DA-NO with or without hot
water or electric heat 1109 (Heating/Cooling Maximum Control): DA-NO with or
without hot water or electric heat 1110 (Dual Minimum Control): DA-NO with or without hot
water or electric heat PNEUMATIC CONTROL LEGEND DA: Direct-acting thermostat
RA: Reverse-acting thermostat NO: Normally open damper position NC: Normally closed damper position
The single function controller provides single functions, i.e., DA-NO. Multi-function controllers are capable of providing DA-NO, DA-NC, RA-NC or RA-NO functions.
Direct Digital Electronic Control Arrange­ments (Field-Supplied) — Control packages are field-
supplied for factory mounting, unless otherwise noted. All DDC control arrangements include a standard linear inlet flow sensor, transformer to 24 volts and control enclosure.
Contact Carrier for detail about mounting field-supplied controls.
NO CONTROL 0000: 35E box only
D000: 35E box with control box only (For units without electric heat requiring a 24 v control transformer: the control transformer must be ordered from the unit accessories list in Quote Builder.)
D001: 35E box with control box and 24 v transformer P000: 35E box without controls (for DA pneumatic controlled
heat unit) P001: 35E box without controls (for RA pneumatic controlled
electric heat unit)
INSTALLATION
LOCK OUT AND TAG heater electrical disconnect before working on this equipment. Otherwise, one leg of the 3-leg heater remains energized. Electrical shock or personal injury could result.
Step 1 — Install Volume Control Box
1. Move unit to installation area. Remove unit from ship­ping package. Do not handle by controls or damper extension rod.
2. The unit has factory-installed brackets on unit as shown in Fig. 3.
3. Suspend units from building structure with straps, rods, or hanger wires. Secure the unit and level it in each direc­tion. Note that reheat coil is in heavy end of unit.
Step 2 — Make Duct Connections
1. Install supply ductwork on unit inlet collar. Check that air-supply duct connections are airtight and follow all accepted medium-pressure duct installation procedures. (Refer to Table 2 for pressure data.)
NOTE: To ensure proper equipment performance, it is recommended that a length of rigid straight duct equal to 3 times the duct diameter be provided to the inlet.
2. Install the discharge duct. Where a multiple outlet con­nector is used on the box, connect appropriately sized ductwork to the outlets. Use adapter caps to seal unused outlets. Fully open all balancing dampers.
To ensure use of common-diameter air duct, coordinate diameters of box inlet and multiple outlet collars. Insulate duct as required.
Ninety degree elbows or tight radius flexible duct immedi-
ately upstream of inlet collar should be avoided.
Step 3 — Install Sensors and Make Field Wir­ing Connections — Electric Analog or DDC (Direct Digital Controls) —
mensional submittals and control application diagrams for con­trol specifications. All field wiring must comply with National Electrical Code (NEC) and local requirements. Refer to the wiring diagram on the unit for specific wiring connections.
A field-supplied transformer is required if the unit was not equipped with a factory-installed transformer. See Fig. 4.
Single duct terminal units with electric heat are supplied with a single point wiring connection in the heater control box. All unit power is supplied through this connection. Models with electric heat are factory equipped with a control trans­former. See Fig. 5.
Wiring and unit ampacities are referenced in Tables 3A and 3B.
NOTE: Refer to wiring diagram attached to each unit for spe­cific information on that particular unit. Units with 480-3-60 electric heater REQUIRE 4-wire, wye connected power. units with 208/230 v, 3-phase heater can be connected with 3-wire power.
Unit airflow should not be set outside of the range noted in Fig. 6. The minimum recommended airflow for units with elec­tric heat must be at least 75 cfm per kW and not drop below the minimum values listed in the performance data table. The max­imum unit discharge temperature should not exceed 120 F. Prevent air stratification by setting the discharge temperature no more than 15 degrees above the room temperature. Example: 90 F discharge in a 75 F room.
Refer to specific unit di-
4
Table 2 — 35E Basic Pressure Data
INLET
SIZE (in.)
CCN — Carrier Comfort Network® ∆ PS— Thedifferenceinstaticpressure DDC — Direct Digital Controls EAT — Entering Air Temperature UL Underwriters Laboratories ∆ VPS— Change in velocity pressure
*Minimums are for all except CCN controls, which may be lower. Minimum for DDC by
†A minimum 0.03 in. wg discharge static pressure is required to set the flow switch in the
**Maximum discharge temperatures with electric heat are set at 120 F by the National
CFM
(Area)
4 110 2.3 0.10 0.01 0.02 0.03 0.03 0.04 0.01
(0.09) 170 3†† 0.23 0.02 0.04 0.06 0.08 0.10 0.02
(0.14) 265 5†† 0.23 0.04 0.10 0.15 0.20 0.24 0.04
(0.20) 380 7.5†† 0.22 0.09 0.20 0.30 0.40 0.50 0.09
(0.27) 525 9.5†† 0.23 0.09 0.20 0.30 0.40 0.50 0.09
(0.35) 675 13†† 0.21 0.09 0.27 0.44 0.60 0.76 0.09
(0.44) 875 16†† 0.21 0.17 0.31 0.44 0.57 0.69 0.17
(0.55) 1075 21†† 0.20 0.10 0.31 0.50 0.69 0.89 0.10
(0.78) 1550 30†† 0.19 0.09 0.33 0.54 0.75 0.96 0.09
(1.07) 2125 36†† 0.17 0.10 0.31 0.49 0.68 0.86 0.10
(1.40) 2725 36†† 0.14 0.09 0.32 0.53 0.73 0.94 0.09
(2.63) 5200 36†† 0.16 0.09 0.43 0.74 1.05 1.36 0.09
230 3†† 0.43 0.03 0.07 0.11 0.15 0.18 0.03
5 170 3.5 0.09 0.02 0.04 0.06 0.08 0.10 0.02
360 5†† 0.43 0.08 0.18 0.27 0.36 0.45 0.08 100
6 240 4.9 0.09 0.04 0.08 0.12 0.16 0.20 0.04
520 7.5†† 0.42 0.17 0.38 0.57 0.75 0.94 0.17 140
7 330 6.8 0.09 0.04 0.08 0.12 0.16 0.20 0.04
710 9.5†† 0.41 0.17 0.37 0.55 0.73 0.91 0.17 190
8 440 9.1 0.09 0.04 0.12 0.19 0.25 0.32 0.04
925 13†† 0.39 0.17 0.51 0.82 1.13 1.43 0.17 240
9 550 11.3 0.08 0.07 0.12 0.17 0.22 0.27 0.07
1200 16†† 0.40 0.32 0.59 0.83 1.07 1.31 0.32
300
10 675 13.9 0.08 0.04 0.12 0.20 0.27 0.35 0.04
1450 21†† 0.36 0.17 0.56 0.91 1.26 1.62 0.17
425
12 1000 20.6 0.08 0.04 0.14 0.22 0.31 0.40 0.04
2100 30†† 0.34 0.17 0.60 0.99 1.37 1.76 0.17
580
14 1375 28.3 0.07 0.04 0.13 0.21 0.28 0.36 0.04
2900 36†† 0.31 0.19 0.57 0.92 1.26 1.60 0.19
750
16 1775 36†† 0.06 0.04 0.14 0.22 0.31 0.40 0.04
3700 36†† 0.25 0.17 0.59 0.97 1.35 1.73 0.17 1800
22 3300 36†† 0.07 0.04 0.17 0.30 0.42 0.55 0.04
7100 36†† 0.31 0.17 0.81 1.38 1.95 2.53 0.17
others is to be provided by the control’s provider.
electric heater.
Electric Code. Max kW shown assumes 55 F entering air and is limited by unit’s selected
MIN AIRFLOW ( Cfm)*
Cooling Only or
Cooling with Hot Water
55
85
50
or
0
75
or
0
110
or
0
140
or
0
185
or
0
240
or
0
290
or
0
420
or
0
580
or
0
740
or
0
1400
or
0
Electric
LEGEND
ELECTRIC HEAT**
MAX kW
Heat †
1800
AT 5 5 F EAT
1.1 0.02 0.00 0.00 0.01 0.01 0.01 0.00
55
1.7 0.02 0.00 0.01 0.02 0.02 0.03 0.00
85
2.1 0.02 0.01 0.01 0.02 0.03 0.03 0.01
110
2.9 0.02 0.01 0.01 0.02 0.03 0.04 0.01
140
3.9 0.02 0.01 0.02 0.03 0.05 0.06 0.01
190
4.9 0.02 0.01 0.02 0.03 0.04 0.05 0.01
240
6.2 0.02 0.01 0.02 0.04 0.05 0.07 0.01
300
8.7 0.01 0.01 0.02 0.04 0.06 0.07 0.01
425
11.9 0.01 0.01 0.02 0.04 0.05 0.06 0.01
580
15.4 0.01 0.01 0.02 0.04 0.06 0.07 0.01
750
36†† 0.02 0.01 0.05 0.09 0.13 0.16 0.01
from inlet to discharge with damper fully open
Velocity Press
(VPS)
MINIMUM INLET STATIC PRESSURE (Unit and Heat Pressure Drop)
Basic Unit
Basic + 1 Row
(PS)
Coil (PS)
voltage, phase, max capacity and design (see Electrical Data in the Product Data cata­log). Min cfm for electric heat is based on UL/ETL listings. (Diffuser) performance will likely be poor at this low flow rate.) The ASHRAE (American Society of Heating, Refrig­eration and Air Conditioning Engineers) Handbook of Fundamentals does not recom­mend a discharge temperature exceeding 90 F for satisfactory air mixing and comfort.
††Max. kW is limited by design. NOTES:
1. To obtain Total Pressure (Pt), add the Velocity Pressure for a given cfm to the Static Pressure drop (∆ PS) of the desired configuration. Example: Pt for a Size 8 Basic Unit at 925 cfm = 0.39 + 0.17 = 0.56
2. The electric heat max kW is based on 3 phase power. For more details, refer to the air terminal selection program.
Basic + 2 Row
Coil (PS)
Basic + 3 Row
Coil (PS)
Basic + 4 Row
Coil (PS)
Basic +Heater †
(PS)
Table 3A — 35E Heater Power Wiring and
Fuse Sizing (Single Phase, 60 Hz)
HEATER
SIZE (kW)
10.0 34,130 83.3 2 41.7 6 36.1 6
11.0 37,130 91.7 2 45.8 6 39.7 6
12.0 40,956 100.0 1 50.0 6 43.3 6
AWG — American Wire Gage FLA — Full Load Amps
*Values based on 75 C copper wire.
BTUH
0.5 1,707 4.2 14 2.1 14 1.8 14
1.0 3,413 8.3 14 4.2 14 3.6 14
2.0 6,826 16.7 10 8.3 14 7.2 14
3.0 10,239 25.0 8 12.5 12 10.8 14
4.0 13,652 33.3 8 16.7 10 14.4 12
5.0 17,085 41.7 5 20.8 10 18.1 10
6.0 20,478 50.0 5 25.0 8 21.7 10
7.0 23,898 58.3 4 29.2 8 25.3 8
8.0 27,304 66.7 4 33.3 8 28.9 8
9.0 30,717 75.0 3 37.5 6 32.6 8
LEGEND
120 V 208/240 V 277 V
Heater
FLA
AWG *
Heater
FLA
AWG *
Heater
FLA
AWG *
Table 3B — 35E Heater Power Wiring and
HEATER
SIZE (kW)
0.5 1,707 1.4 14 0.6 10
1.0 3,413 2.8 14 1.2 10
2.0 6,826 5.6 14 2.4 10
3.0 10,239 8.3 14 3.6 10
4.0 13,652 11.1 14 4.8 10
5.0 17,085 13.9 12 6.0 10
6.0 20,478 16.7 10 7.2 10
7.0 23,898 19.4 10 8.4 10
8.0 27,304 22.2 10 9.6 10
9.0 30,717 25.0 8 10.8 10
10.0 34,130 27.8 8 12.0 10
12.0 40,956 33.3 8 14.4 12
14.0 47,782 38.8 6 16.8 12
16.0 54,608 44.4 6 19.2 10
18.0 61,434 50.0 6 21.6 10
20.0 68,260 55.5 4 24.0 10
22.0 75,086 61.1 4 26.4 8
24.0 81,912 66.6 4 28.8 8
26.0 88,738 72.3 3 31.3 8
28.0 95,564 77.8 3 33.7 8
30.0 102,390 83.4 2 36.1 6
32.0 109,216 89.0 2 38.6 6
34.0 116,042 94.5 1 41.0 6
36.0 122,868 100.1 1 43.4 6
LEGEND
AWG — American Wire Gage FLA Full Load Amps
*Recommended minimum wire size.
5
Fuse Sizing (3 Phase, 60 Hz)
BTUH
208 V 480 V
Heater FLA AWG* Heater FLA AWG*
L1
120VAC 208VAC 240VAC 277VAC
CLASS II TRANSFORMER (OPTIONAL)
ANALOG OR DDC
CONTROLLER
GROUND
24VAC
BLU
YEL
24 VAC
POWER
LEGEND
DDC — Direct Digital Controls
Field Wiring
Factory Wiring
NOTE: Drawing is typical — refer to actual unit wiring diagram for details.
Fig. 4 — Wiring of Optional Factory-Mounted
Transformer
10000
8000 6000
4000
7250
3709 2840
2000
1000
CFM
800 600
400
200
100
80 60
SIZE 22
SIZE 16 SIZE 14
SIZE 12
SIZE 10
SIZE 9
SIZE 8
SIZE 7
E 6
SIZ
SIZE 5
SIZE 4
2086
1449 1174 927
710
522
362
232
40
20
10
0.01
.05
.03
VOLTS (ANALOG CONTROLS)
0.1
FLOW PROBE IN.WG
0.3 0.5
1
Fig. 6 — Linear Probe CFM vs Pressure Signal Graph
CFM AT ONE INCH SIGNAL
LEGEND
AFS — Airflow Switch DDC — Direct Digital Controls
NOTE: Drawing is typical of 480V, 3-phase, 4-wire heater and control. Refer to actual unit wiring diagram.
Fig. 5 — Typical Power Connections for 35E Units with 3-Stage Electric Heat
ANALOG OR DDC CONTROLLER
SEPARATE CONTROL ENCLOSURE
6
CONTROL SETUP
General —
terminal is designed to supply a varying quantity of cold prima­ry air to a space in response to a thermostat demand. Some units have reheat options to provide heating demand require­ments as well. Most VAV terminals are equipped with pressure compensating controls to regulate the response to the thermo­stat independent of the pressure in the supply ductwork.
To balance the unit, it is necessary to set both the maximum and minimum set points of the controller. The many types of control options available each have specific procedures re­quired for balancing the unit.
The 35E single-duct VAV (variable air volume)
Set Points — Maximum and minimum airflow set points
are normally specified for the job and specific for each unit on the job. Where maximum and minimum airflow levels are not specified on the order, default values are noted on unit ID label.
Field Adjustment of Minimum and Maximum Airflow Set Points — Each 35E unit is equipped with a
flow probe that measures a differential pressure proportional to the airflow. The relationship between flow probe pressures and cfm is shown in the Linear Probe CFM vs Pressure Signal Graph (Fig. 6). This chart is attached to each unit.
System Calibration of the Linear Averaging Flow Probe — To achieve accurate pressure independent
operation, the velocity sensor and linear averaging flow probe must be calibrated to the controller. This will ensure that air­flow measurements will be accurate for all terminals at system start-up.
System calibration is accomplished by calculating a flow coefficient that adjusts the pressure fpm characteristics. The flow coefficient is determined by dividing the flow for a given unit (design air volume in cfm), at a pressure of 1.0 in. wg dif­ferential pressure, by the standard pitot tube coefficient of
4005. This ratio is the same for all sizes if the standard linear averaging probe is used.
Determine the design air velocity by dividing the design air volume (the flow at 1.0 in. wg) by the nominal inlet area (sq ft). This factor is the K factor.
Carrier inlet areas are shown in the table below. The design air volume is also shown in this table. It can be determined from this table that the average design air velocity for 35E units is equal to 2656 fpm at 1.0 in. wg.
UNIT SIZE 35E 04 05 06 07 08 09
INLET
DIAMETER
AIRFLOW (Cfm)
AT 1 i n. w g
INLET AREA
(sq ft)
.
35EUNITSIZE1012141622
INLET DIAMETER 10.0 12.0 14.0 16.0 16 x 24
AIRFLOW (Cfm)
AT 1 i n. w g
INLET AREA
(sq ft)
NOTE: For Carrier ComfortID™ terminals, all flow sizes are normal­ized using a single Probe Multiplier (PMF) for all sizes equal to
2.273.
4.0 5.0 6.0 7.0 8.0 9.0
232 362 502 710 927 1174
0.087 0.136 0.196 0.267 0.349 0.442
1449 2086 2840 3709 7250
0.545 0.785 1.069 1.396 2.640
Record the information on a performance sheet (see Fig. 7). This will provide a permanent record of the balanc­ing information.
installation location information
•boxsize
cooling minimum airflow (cfm) limit
cooling maximum airflow (cfm) limit
reheat (cfm) limit (if applicable)
heating minimum airflow (cfm) limit (if applicable)
heating maximum airflow (cfm) limit (if applicable)
calibration gain (after balancing)
set points
PNEUMATIC CONTROLS
Preparation for Balancing (Control Sequences 1102 and 1103)
1. Inspect all pneumatic connections to assure tight fit and proper location.
2. Verify that the thermostat being used is compatible with the control sequence provided (direct acting or reverse acting).
3. Check main air pressure at the controller(s). The main air pressure must be between 15 psi and 25 psi. (If dual or switched-main air pressure is used, check the pressure at both high and low settings.) The difference between “high” pressure main and “low” pressure main should be at least 4 psi, unless otherwise noted, and the “low” set­ting difference should exceed 15 psi.
4. Check that the unit damper will fail to the proper position when main air pressure is lost. Disconnect the pneumatic actuator line from the velocity controller and observe the VAV damper position. The damper should fail to either a normally open position (indicator mark on shaft end is horizontal) or a normally closed position (indicator mark on shaft end is vertical).
5. Check that there is primary airflow in the inlet duct.
6. Connect a Magnehelic gage, inclined manometer or other differential pressure measuring device to the balancing taps provided in the velocity probe sensor lines. The manometer should have a full scale reading of 0.0 to
1.0 in. wg. The high pressure signal is delivered from the front sensor tap (away from the valve), and the low pres­sure signal is delivered from the back line (near the valve). The pressure differential between high and low represents the amplified velocity pressure in the inlet duct.
7. Read the differential pressure and enter the Linear Aver­aging Probe Chart to determine the airflow in the terminal unit. This chart is shown in Fig. 6 and is also attached to the side of each unit. For example, a differential pressure of 0.10 in. wg for a size 8 unit yields an airflow of 275 cfm.
Volume controllers for 35EP units are shown in Fig. 8-10.
Identification for each controller is shown in Table 4.
7
AIR TERMINAL PERFORMANCE SHEET
JOB NAME ______________________________________________
JOB LOCATION __________________________________________
CUSTOMER _____________________________________________
ENGINEER ______________________________________________
BUILDING LOCATION/FLOOR ______________________________
BUS NUMBER ___________________________________________
CONTROL SET POINTS
Tag
Number
Zone
Address #
Box Size
(in./cfm)
Cooling
(cfm)
min max min max Type Btu min max min max mult.
Reheat
cfm
Heating
(cfm)
Heat kW Occupied Unoccupied
Calibration
Gain
Fig. 7 — Air Terminal Performance Sheet
8
Table 4 — Pneumatic Volume Controller Identification
CONTROL
SEQUENCE
1102 DA-NO 8 CSC-2003 1103 RA-NC 9 CSC-2004 1104 DA-NO 10 CSC-3011 1105 DA-NC 10 CSC-3011 1106 RA-NO 10 CSC-3011 1107 RA-NC 10 CSC-3011 1108 DUAL MAX 10 CSC-3011 1109 HTG/CLG MAX 10 (2) CSC-3011 1110 DUAL MIN 10 CSC-3011
LEGEND
DA — Direct Acting NO — Normally Open NC — Normally Closed RA — Reverse Acting
LO
A
S
E
E
R
C
N
I
PR.N.O.
CSC-2003
0-1”
D.A.
P
DM
A
S
E
E
R
C
N
I
HI
FUNCTION ARRANGEMENT IDENTIFICATION
Fig. 8 — Pneumatic Volume Controller
(Normally Open) for 35EP Unit (Beige Color)
HI
A
S
E
E
R
C
N
I
PR.N.C.
CSC-2004
0-1”
R.A.
P
DM
A
S
E
E
R
C
N
I
LO
Fig. 9 — Pneumatic Volume Controller
(Normally Closed) for 35EP Unit (Grey Color)
B
M
H
NO
DAMPER
L
NC
I
R
N
C
G
RESET START
LO STAT∆P
I
R
N
C
RESET SPAN
T
HI STAT∆P
Fig. 10 — CSC 3000 Series
Reset Volume Controller
FIG. NO.
KREUTER
PART N O.
Balancing Procedure (Control Sequences 1102 and 1103)
DIRECT ACTING THERMOSTAT, NORMALLY OPEN DAMPER (Control Sequence 1102) — Refer to Fig. 8.
1. Minimum volume setting: a. Disconnect the thermostat line from the volume
controller.
b. Adjust the minimum volume control knob
(marked “LO” and located in the center of the controller) to achieve the required minimum flow. To determine the required pressure differential, refer to Tables 2 and 5 and the Linear Averaging Probe Chart provided on the side of the VAV unit and in Fig. 6.
c. Reconnect the thermostat line.
2. Maximum volume setting: a. Disconnect the thermostat line from the volume
controller.
b. Apply 15 + psi to the thermostat port on the vol-
ume controller (marked “T”) by tapping into the main air pressure line.
c. Adjust the maximum volume control knob
(marked “HI” and located at the side of the con­troller) until the desired pressure differential is registered on the manometer. To determine the required pressure differential, refer to Table 5 and the Linear Probe CFM vs Pressure Signal Graph provided on the side of the VAV unit and in Fig. 6.
d. Reconnect the thermostat line.
REVERSE ACTING THERMOSTAT, NORMALLY CLOSED DAMPER (Control Sequence 1103) — Refer to Fig. 9.
1. Maximum volume setting: a. Disconnect the thermostat line from the velocity
controller.
b. Adjust the maximum volume control knob
(marked “HI” and located in the center of the con­troller) to achieve the required minimum flow. To determine the required pressure differential, refer to Tables 2 and 5 and the Linear Averaging Probe Chart provided on the side of the VAV unit and in Fig. 6.
c. Reconnect the thermostat line.
2. Minimum volume setting: a. Disconnect the thermostat line from the velocity
controller.
b. Apply 15 + psi to the thermostat port on the vol-
ume controller (marked “T”) by tapping into the main air pressure line.
9
c. Adjust the minimum volume control knob
(marked “LO” and located at the side of the con­troller) until the desired pressure differential is registered on the manometer. To determine the required pressure differential, refer to Table 5 and the Linear Averaging Probe Chart provided on the side of the VAV unit and in Fig. 6.
d. Reconnect the thermostat line.
Balancing Procedure (Control Sequences 1104-1110)
1. Damper action is factory set at N.O. (normally open) or N.C. (normally closed). To reselect, loosen damper selec­tion switch screw, align pointer with damper pointer and tighten screw. The spring range of the actuator is not criti­cal since the controller will output the necessary pressure to the actuator to position the damper according to set point. (See Fig. 11.)
2. Pipe the controller: Connect port “B” to the damper actu­ator. Connect port “M” to the clean, dry main air. Connect port “T” to the thermostat output. Connect port “H” to the total pressure tap on the airflow sensor. Connect port “L” to the static pressure tap on the airflow sensor.
The controller can be set up for cooling or heating applications using either a Direct Acting (DA) or Reverse Acting (RA) thermostat signal. The two flow adjustments are labeled “LO STAT P” and “HI STAT P. ”
LO STAT P setting is the desired airflow limit when the thermostat pressure is less than, or equal to, the reset start point.
For DA Cooling or RA Heating: Adjust LO STAT P to the desired minimum airflow with 0 psig (or a pressure less than the reset start point) at port “T.” The LO STAT P must be set first. The LO STAT P will affect the HI STAT P setting.
For RA Cooling or DA Heating: Adjust LO STAT P to the desired maximum airflow with 0 psig (or a pressure less than the reset start point) at port “T.” The LO STAT P must be set first. The LO STAT P will affect the HI STAT P setting.
HI STAT P setting is the desired airflow limit when the ther- mostat pressure is greater than, or equal to, the reset stop-point. The reset stop-point is the reset span pressure added to the reset start-point pressure.
For DA Cooling or RA Heating (see Fig. 12): Adjust HI STAT P to the desired maximum airflow with 20 psig (or a pressure greater than the reset stop point) at port “T.” The HI STAT P must be set last. The HI STAT P setting will be affected by the LO STAT Psetting.
For RA Cooling or DA Heating (see Fig. 12): Adjust HI STAT P to the desired minimum airflow with 20 psig (or a pressure greater than the reset stop point) at port “T.” The HI STAT P must be set last. The HI STAT P setting will be affected by the LO STAT ∆P setting.
NOTE: After the “LO STAT P” and “HI STAT P” initial adjustments are made, cycle the thermostat pressure a few times to settle the internal reset mechanisms and verify set­tings. Fine tune the settings if necessary. The thermostat pres­sure may be left at a high pressure and the “G” port cap may be removed and replaced to cycle the reset mechanism.
RESET START setting is factory set at 8.0 psig. This is the lowest thermostat pressure that the LO STAT P airflow will begin to reset towards the HI STAT P airflow. To change the RESET START setting: regulate thermostat pressure to the “T” port to the desired reset start point pressure, adjust RESET START adjustment until pressure at the “G” port is slightly higher than 0 psig, i.e., 0.1 psig.
NOTE: The “G” port taps into the controller’s internal reset chamber, which always starts at 0 psig. The RESET START adjustment is a positive bias adjustment that sets the desired thermostat start point to the controller’s internal reset start point of 0 psig.
RESET SPAN setting is factory set at 5.0 psig. This is the required change in thermostat pressure that the controller will reset between the LO STAT P setting and the HI STAT ∆P setting. To change the RESET SPAN setting: adjust RESET SPAN adjustment until pressure at the “G” port equals the desired reset span pressure.
NOTE: The “G” port taps into the controller’s internal reset chamber, which will always be at a pressure between 0 psig and the RESET SPAN pressure.
Preventative Maintenance
1. Inspect pneumatic tubing for loose connections or leaks.
2. Clean out pneumatic line filters regularly according to manufacturers recommendations.
Pneumatic Control Troubleshooting — See Table 5.
Table 5 — Troubleshooting
Controller does not reset to maximum or minimum set point during balance procedure.
Controller does not reset to maximum or minimum set point during operation.
Pneumatic actuator does not stroke fully. Leak in pneumatic line between the controller and the actuator. Main
Air valve stays in wide open position. Velocity probe is blocked by an obstruction (sandwich bag, etc.).
NOTE: Always Check:
1. Main air pressure (15 psi to 25 psi) at the controller.
2. Disconnected or kinked pneumatic lines to the controller.
3. Quality of compressed air (oil or water in lines).
PROBLEM PROBABLE CAUSE
Balancer is using the thermostat for control signal. An artificial signal must be provided in place of the thermostat.
Thermostat is not demanding maximum or minimum air volume. Main air pressure at the controller is less than 15 psi.
air pressure at the controller is less than 15 psi. Leak in the diaphragm.
Insufficient supply air in the inlet duct.
4. Proper thermostat signal and logic (Direct/Reverse Acting).
5. Blocked velocity probe or insufficient primary supply air.
6. Leaks in the actuator diaphragm.
7. Mechanical linkage of the actuator/air valve.
10
TO THERMOSTAT BRANCH SIGNAL (RESET SIGNAL)
RESET START POINTADJUSTMENT (FACTORY SETAT 8 PSI)
* TO STATIC PRESSURE
TO TOTALPRESSURE *(DIFFERENCE IS: DIFFERENTIAL PRESSURE, OR DEVICE VELOCITY PRESSURE)
PUSH ON NIPPLES FOR 3/16” (5) I.D. FR TUBING (5)
TO DAMPER ACTUATOR
TO MAIN AIR SUPPLY
LOOSEN SCREW TO CHANGE DAMPER ACTION (SUPPLIED IN N.O. POSITION)
GAGE TAP. LEAVE CAP ON UNLESS CONNECTING GAGE FOR RESET START OR RESET SPAN ADJUSTMENT
DAMPER ACTION SELECTION (FACTORY SETAT NORMALLY OPEN) NOTE: SCREW MUST BE TIGHT ANDARROWS IN PERFECT ALIGNMENT FOR DEVICE TO FUNCTION PROPERLY.
H
B
M
DAMPER
L
NC
NO
G
T
DIFFERENTIAL PRESSURE (FLOW)
RESETSTART
LO STAT∆P
I
I
R
N
R
N
C
C
RESETSPAN
LIMIT ADJUSTMENT WHEN TSTAT PRESSURE IS HIGH (HI STAT) (FACTORY SETAT 0.65 IN.WG.)**
HISTAT∆P
**- FIELD ADJUSTMENT REQUIRED
DIFFERENTIAL PRESSURE (FLOW) LIMIT ADJUSTMENT WHEN TSTAT PRESSURE IS LOW (LO STAT) (FACTORY SETAT 0 IN.WG.)**
ALL ADJUSTMENTS CCW TO INCREASE (1/8-5/32FLATBLADE SCREWDRIVER)
RESET SPANADJUSTMENT (FACTORY SETAT 5 PSI)
Fig. 11 — 3011 CSC Controller
DA HEATING*
MAX
F
L
O
W
MIN
03813 psig
ROOM TEMPERATURE
Reset Span
Reset Start*
LO STAT ∆P
HI STAT ∆P
RA HEATING
Reset
MAX
Span F L
O W
MIN
13 8
ROOM TEMPERATURE
*May require changing the RESET START from 8.0 to 3.0 psig if
sequencing is involved.
Reset Start
3
HI STAT ∆P
LO STAT ∆P
0 psig
DA COOLING
MAX
F L O W
MIN
ROOM TEMPERATURE
Reset Span
03813 psig
Reset Start
RA COOLING*
Reset
MAX
Span
F L O W
MIN
ROOM TEMPERATURE
13
Reset Start*
8
3
LO STAT ∆P
HI STAT ∆P
LO STAT ∆P
HI STAT ∆P
0 psig
Fig. 12 — Reset Cycle for CSC-3011 Control
1
b. Smallflatblade(
/8in.) screwdriver
c. Digital voltmeter capable of displaying a 0 to
10 vdc range which will display in hundredths of vdc
d. HSO-5001 Test Leads (optional for meter taps)
2. Remove thermostat cover: Thermostat cover is removed by loosening the setscrews
on each side of the thermostat. Using a
1
/6in. hex/key
wrench turn the setscrews clockwise until cover is loose.
3. Check voltages: Verify 16 vdc between (+) and (–) terminals.
CONTROL SEQUENCE 2100 (Heating Only)
1. Be certain the ambient room temperature at the thermo­stat is within the range of the thermostat (55 to 85 F).
2. Adjust the heating set point slider all the way to the left for minimum heating.
3. Read the DC voltage across the meter taps on the heating (left) side. Adjust the minimum set point (MIN INCR) potentiometer (clockwise to increase or counterclockwise to decrease) to the DC voltage equal to the desired air­flow (cfm) as shown on the calibration curve (Fig. 14).
NOTE: The minimum set point must be adjusted first. Adjust­ment of the MIN INCR potentiometer directly affects the max­imum set point.
4. Adjust the heating set point slider all the way to the right for maximum heating.
5. Read the DC voltage across the meter taps on the heating (left) side. Adjust the maximum set point (MAX INCR) potentiometer (clockwise to increase or counterclockwise to decrease) to the DC voltage equal to the desired air­flow (cfm) as shown on the calibration curve (Fig. 14).
NOTE: The maximum set point must be adjusted last. Adjust­ment of the MIN INCR potentiometer directly affects the max­imum set point.
6. Return the heating set point slider to the desired set point. Insert set point slider stops. Replace thermostat cover.
ANALOG CONTROLS
Balancing Procedures (Control Sequences 2100-2105) —
pressure independent volume reset control that uses a Krueger CSP-5001 controller-actuator (see Fig. 13).
The system provides for independently adjustable set points
for minimum, maximum, and auxiliary airflow limits.
Room temperature control is provided by the associated room thermostat which is selected according to the application. The room thermostat provides a fixed 2 degrees F reset span re­gardless of the minimum and maximum velocity limit set points.
Adjustments for the minimum and maximum airflows are made at the thermostat.
The thermostat (CTE-5100 series) operates on a 16 vdc power supply from the CSP controller and outputs a 0 to 10 vdc signal on the T terminals; T and T
in the heating mode (RA). See the reference sequence
2
diagram on unit for details on which ‘T’ terminals are used on each model thermostat, but in general T the cooling mode, T are adjustable to limit minimum and maximum flow. Terminals
and T4have a fixed 0 to 10 vdc output signal.
T
3
1. Required tools:
1
/16in. hex/key wrench
a.
The analog electronic control system is a
in the cooling mode (DA)
1
and T3are used for
and T4for heating. Terminals T1and T
2
1
90
45
ADJUSTABLE END STOPS
PPORTS
GEAR DISENGAGEMENT BUTTON
L
H
16
O
I
24V
U
V
N
DC
AC
I
WIRING
0-10V VELOCITY OUTPUT 0-10V INPUT SIGNAL 16V DC OUTPUT
(THERMOSTAT POWER)
2
16
DC
V
INO
U
T
0
MIN
MAX
NOR
METER
˜
+
RED-CLS GRN-OPN
LED
ccw cw
COMMON (16V DC, INPUT, OUTPUT)
POWER
SUPPLY
˜
24 V
AC
N O M
M A X % M
I
N
C
E
Fig. 13 — CSP-5001 Controller
11
10000
8000
6000
7250
4000
2000
1000
800
600
400
CFM
200
100
80
60
40
20
10 VOLTS DIFFERENTIAL
PRESSURE
1.2 .02
1.8 .04
2.3 .06
SIZE 22
SIZE 16
SIZE 14
SIZE 12
SIZE 10
SIZE 9
SIZE 8
SIZE 7
SIZE 6
SIZE 5
SIZE 4
3.4
0.1
5.8 7.2
4.6
0.2 0.3
0.5
9.7 11
0.8
3709
2840
2086
1449 1174
927
710
522
362
232
CFM AT ONE INCH SIGNAL
1
Fig. 14 — Calibration Curve 35E
CONTROL SEQUENCE 2101 (Cooling Only)
1. Be certain the ambient room temperature is within the range of the thermostat (55 to 85 F).
2. Adjust the cooling set point slider all the way to the right for minimum cooling.
3. Read the DC voltage across the meter taps on the cooling (right) side. Adjust the minimum set point (MIN INCR) potentiometer (clockwise to increase or counterclockwise to decrease) to the DC voltage equal to the desired air­flow (cfm) as shown on the calibration curve.
NOTE: The minimum set point must be adjusted first. Adjust­ment of the MIN INCR potentiometer directly affects the max­imum set point.
4. Adjust the cooling set point slider all the way to the left for maximum cooling.
5. Read the DC voltage across the meter taps on the cooling (right) side. Adjust the maximum set point (MAX INCR) potentiometer (clockwise to increase or counterclockwise to decrease) to the DC voltage equal to the desired air­flow (cfm) as shown on the calibration curve.
NOTE: The maximum set point must be adjusted last. Adjust­ment of the MIN INCR potentiometer directly affects the max­imum set point.
6. Return the cooling set point slider to the desired set point. Insert set point slider stops. Replace thermostat cover.
CONTROL SEQUENCE 2102 (Cooling with On/Off Elec­tric Heat Control)
Cooling Side of the Thermostat
1. Follow steps 1 through 5 for cooling sequence 2101.
NOTE: Be sure to adjust the cooling set point slider all the way to the left for maximum cooling. (The heating set point slider will have to be adjusted all the way to the left also.)
NOTE: The minimum set point must be adjusted first. Adjust­ment of the MIN INCR potentiometer directly affects the max­imum set point and auxiliary set point.
2. Adjustment of auxiliary set point if required: Read the DC voltage across the meter taps on the heating
(left) side. Adjust the MAX/AUX INCR potentiometer (clockwise to increase or counterclockwise to decrease) to the DC voltage equal to the desired airflow (cfm).
3. Return the cooling set point slider and the heating set point slider to their desired set points. Insert or reinsert set point slider stops. Replace thermostat cover.
CONTROL SEQUENCE 2104 (Cooling/Heating with Automatic Changeover Control)
Cooling Side of the Thermostat
— Follow steps 1 through 5
for cooling sequence 2101. NOTE: Be sure to adjust the cooling set point slider all the way
to the left for maximum cooling. (The heating set point slider will have to be adjusted all the way to the left also.)
CONTROL SEQUENCE 2103 (Cooling with On/Off Hot Water Heat Control) OR 2105 (Cooling with Proportional Hot Water Heat Control)
Cooling Side of the Thermostat
— Follow steps 1 through 5
for cooling sequence 2101. NOTE: Be sure to adjust the cooling set point slider all the way
to the left for maximum cooling. (The heating set point slider will have to be adjusted all the way to the left also.)
NOTE: The minimum set point must be adjusted first. Adjust­ment of the MIN INCR potentiometer directly affects the max­imum set point and auxiliary set point.
12
Analog Control Troubleshooting — The following
troubleshooting procedure is directed towards single duct cool­ing applications. The same concepts can be applied to other configurations.
CONTROLLER
1. Verify 24 vac at terminals “~” (phase) and “-” (ground). Tolerance can be –15% to +20% (20.4 to 28.8 vac).
2. Verify 16 vdc at terminals “(16 VDC)” and “(-)”. a. Tolerance is 15.0 to 17.0 vdc power supply to
thermostat.
b. If not correct, disconnect thermostat and recheck.
If still incorrect, replace CSP controller.
3. Check Requested Flow voltage on terminal “IN” and “-”. a. Use chart on page 12 to correlate into cubic feet
per minute (cfm).
b. If reading is not what is desired, see System Cali-
bration of the Linear Averaging Flow Probe sec­tion to adjust thermostat.
4. Check Actual Flow voltage on terminal “OUT” and “-” for 0 to 10 vdc.
Use chart on page 12, Fig. 14 to correlate into cfm.
5. Check box movement, damper rotation, etc. a. Review Requested Flow and Actual Flow above
to determine if unit should be satisfied (within 50 fpm) or driving open or closed.
b. If damper is not moving, verify damper is not
stuck or at end of travel. Check rotation jumpers for proper position.
c. Change “Requested Flow” to make unit drive
opposite direction. This can be accomplished by moving the set point sliders or 1) and 2) below.
1) To manually open the box, remove wiring from terminal “IN” and jumper terminal “IN” to terminal “16VDC”. This will tell unit to control at 3300 fpm/full airflow, and the green LED should turn on (and the box should drive open).
2) To manually close the box, remove wiring from terminal “IN”, jumper and “IN” terminal to “-” terminal. This will tell unit to control at zero fpm/no airflow, and the red LED should be on (and the box should drive closed).
Never jumper terminal 16 VDC to “-” as this would cause a short, and possibly damage the power supply.
NOTE: When using the same transformer for more than one control, the phase and ground must be consistent with each device.
ComfortID™ CONTROLS
Install Sensors and Make Field Wiring Connections
GENERAL — All field wiring must comply with National Electrical Code and local requirements. Refer to Tables 6-9 for electrical and wiring specifications.
Disconnect electrical power before wiring inside the con­troller. Electrical shock, personal injury, or damage to the zone controller can result.
Wire the control as shown on the control package diagram for the specific installation. Control wiring diagrams can be found inside the control box.
If the 35E unit is equipped with electric heat, only power to the electric heater must be supplied; no additional power source is required for the control. If the unit does not have an electric heater or the control transformer option, a field­supplied dedicated 24-vac/Class II power source must be in­stalled and wired to the zone controller, to terminals 1 and 2 of connector J1. Refer to unit wire label diagram for minimum size (VA) and grounding requirements for each unit.
SUPPLY-AIR TEMPERATURE (SAT) SENSOR INSTAL­LATION — On terminals with heat, the SAT sensor is provid­ed. The sensor is factory wired to the controller and shipped in the control box. The SAT must be field-installed in the duct downstream from the air terminal. The SAT sensor part num­ber is 33ZCSENSAT. See Table 6 for resistance information.
To install the sensor, proceed as follows:
1. Remove the plug from one of the control box and pass the sensor probe through the hole.
2. Drill or punch a
1
/2-in. hole in the duct downstream of
7
/8-in. openings in the
the unit, at a location meeting the requirements shown in Fig. 15.
3. Using 2 self-drilling screws (supplied), secure the sensor probe to the duct.
The SAT sensor probe is 6 inches in length. The tip of the probe must not touch the inside of the duct. Use field-supplied bushings as spacers when mounting the probe in a duct that is 6 in. or less in diameter.
If the unit is a cooling only unit, the SAT sensor is not pro­vided and is not required.
If the unit has a multiple outlet attenuator connected directly at the discharge, install the sensor in the multiple outlet attenua­tor. See Fig. 15.
For units equipped with electric reheat, locate the sensor as far downstream as possible. This ensures the sensor will not be affected by excessive radiant heat from the heater coil. Install the sensor a minimum of 2 ft downstream of the coil for units with hot water heat.
DO NOT run sensor or relay wires in the same conduit or raceway with Class 1 service wiring.
DO NOT abrade or nick the outer jacket of cable. DO NOT pull or draw cable with a force that may harm the
physical or electrical properties. DO NOT bend a cable through a radius sharper than that
recommended by its manufacturer. AVOID splices in any control wiring.
Perform the following steps if state or local code requires the use of conduit, or if your installation requires a cable length of more than 8 ft:
1. Disconnect the sensor cable from the ComfortID zone controller, at the terminals labeled SAT and GND.
2. Mount the sensor to the duct (see steps 2 and 3 above).
3. Mount a field supplied 4 in x 4 in x 20 in. extension box over the duct sensor.
1
4. Connect a conduit (
/2-in. nominal) to the zone controller
enclosure and extension box.
5. Pass the sensor probe through the extension box opening and into the conduit.
6. Reconnect the sensor leads to the zone controller labeled SAT and GND.
13
Table 6 — Thermistor Resistance vs Temperature Values for
Supply-Air Temperature Sensor, Primary Air Temperature Sensor and Space Temperature Sensor
RESISTANCE
(Ohms)
29481 32 17050 54 10227 76 6340 98 4051 120 28732 33 16646 55 10000 77 6209 99 3972 121 28005 34 16253 56 9779 78 6080 100 3895 122 27298 35 15870 57 9563 79 5954 101 3819 123 26611 36 15497 58 9353 80 5832 102 3745 124 25943 37 15134 59 9148 81 5712 103 3673 125 25295 38 14780 60 8948 82 5595 104 3603 126 24664 39 14436 61 8754 83 5481 105 3533 127 24051 40 14101 62 8563 84 5369 106 3466 128 23456 41 13775 63 8378 85 5260 107 3400 129 22877 42 13457 64 8197 86 5154 108 3335 130 22313 43 13148 65 8021 87 5050 109 3272 131 21766 44 12846 66 7849 88 4948 110 3210 132 21234 45 12553 67 7681 89 4849 111 3150 133 20716 46 12267 68 7517 90 4752 112 3090 134 20212 47 11988 69 7357 91 4657 113 3033 135 19722 48 11717 70 7201 92 4564 114 2976 136 19246 49 11452 71 7049 93 4474 115 2920 137 18782 50 11194 72 6900 94 4385 116 2866 138 18332 51 10943 73 6755 95 4299 117 2813 139 17893 52 10698 74 6613 96 4214 118 2761 140 17466 53 10459 75 6475 97 4132 119
TEMP
(F)
RESISTANCE
(Ohms)
TEMP
(F)
RESISTANCE
(Ohms)
TEMP
(F)
RESISTANCE
(Ohms)
TEMP
(F)
RESISTANCE
(Ohms)
UNIT WITH ELECTRIC HEAT
2 FT. MIN.
PRIMARY AIR INLET
AIR
TERMINAL
UNIT
TEMP
(F)
ZC
UNIT WITH MULTIPLE OUTLET ATTENUATOR
PRIMARY AIR INLET
LEGEND
SAT — Supply Air Temperature Sensor ZC Zone Controller
AIR
TERMINAL
UNIT
ZC
Fig. 15 — Supply Air Temperature Probe (Part No. 33ZCSENSAT) Locations
SPACE TEMPERATURE SENSOR INSTALLATION AND WIRING — The space temperature (SPT) sensor accessory is ordered separately for field installation. It is installed on interior walls to measure room space air temperature. See Fig. 16-20 and Table 6.
The wall plate accommodates both the NEMA (National
Electrical Manufacturing Association) standard and the Euro-
1
pean
/4DIN standard. The use of a junction box to accommo­date the wiring is recommended for installation. The sensor may be mounted directly on the wall, if acceptable by local codes.
DO NOT mount the sensor in drafty areas such as near heat­ing or air-conditioning ducts, open windows, fans, or over heat sources such as baseboard heaters or radiators. Sensors mount­ed in those areas will produce inaccurate readings.
Avoid corner locations. Allow at least 3 ft between the sen­sor and any corner. Air in corners tends to be stagnant, resulting in inaccurate sensor readings.
HEAT
HEAT
SAT
2 FT. MIN.
MULTIPLE
OUTLET
ATTENUATOR
SAT
Sensor should be mounted approximately 5 ft up from the floor, in an area that best represents the average temperature found in the space (zone).
The space temperature sensor cover includes a service jack connector. If wiring connection is made to the service jack, the connector can then be used to connect a network service tool with the Carrier Comfort Network® system.
Before installing the space temperature sensor, decide whether or not the service jack wiring connection will be made. If connection is desired, the CCN communication cable should be available at time of sensor installation, for convenient wiring connections. The cable selected must meet the requirements for the entire network. See Connect the CCN Communication Bus section for CCN communication cable specifications.
14
3(MIN)
OR
2/3 OF WALL HEIGHT
D
5
2
3
45
61
RED(+)
WHT(GND)
BLK(-)
CCN COM
Fig. 16 — Typical Space Temperature Sensor
Room Location
Cool
Warm
Fig. 17 — Space Temperature Sensor
(P/N 33ZCT56SPT Shown)
SEN
SW1
BLK (GND)
RED (SPT)
SENSOR WIRING
Fig. 19 — Space Temperature Sensor Wiring
(33ZCT55SPT)
NOTE: Dimensions are in inches.
Fig. 18 — Space Temperature Sensor and Wall
Mounted Humidity Sensor Mounting
SW1
2
3
SEN
45
61
RED(+)
WHT(GND)
BLK(-)
SET
WHT (T56)
BLK (GND)
RED (SPT)
CCN COM
SENSOR WIRING
JUMPER TERMINALS AS SHOWN
Cool Warm
Fig. 20 — Space Temperature Sensor Wiring
(33ZCT56SPT)
15
Install and wire the space temperature sensor as follows:
NOTE: Space temperature sensor will be identified as T55 or T56. Refer to Control Sequence Drawings to determine which SPT is part of the particular control package being installed. (The difference between T55 and T56 is that T56 includes set point adjustment capability.)
1. Locate the two Allen type screws at the bottom of the sensor.
2. Turn the two screws clockwise to release the cover from the sensor wall mounting plate.
3. Lift the cover from the bottom and then release it from the top fasteners.
4. Feed the wires from the electrical box through the open­ing in the center of the sensor mounting plate.
5. Usingtwono.6-32x1mounting screws (provided with the sensor), secure the sensor to the electrical box.
6. Use 20 gage wire to connect the sensor to the controller. The wire is suitable for distances of up to 500 ft. Use a three-conductor shielded cable for the sensor and set point adjustment connections. The standard CCN com­munication cable may be used. Refer to Table 8. If the set point adjustment (slide-bar) is not required, then an un­shielded, 18 or 20 gage, two-conductor, twisted pair cable may be used. Refer to Table 7.
The CCN network service jack requires a separate, shielded CCN communication cable. Always use sepa­rate cables for CCN communication and sensor wiring. (Refer to Fig. 19 and 20 for wire terminations.)
7. Replace the cover by inserting the cover at the top of the mounting plate first, then swing the cover down over the lower portion. Rotate the two Allen head screws counter­clockwise until the cover is secured to the mounting plate and locked in position.
8. For more sensor information, see Table 6 for thermistor resistance vs temperature values.
NOTE: Clean sensor with damp cloth only. Do not use solvents.
Table 7 — Recommended Sensor and Device
Wiring
MANUFACTURER
Belden 8205 88442 Columbia D6451 American A21501 A48301 Quabik 6130 Alpha 1895 Manhattan M13402 M64430
NOTE: Wiring is 20 gage, 2 conductor twisted cable.
PART NUMBER
Regular Plenum
c. For T56 sensors, connect the remaining wire
(WHITE/CLR) to the T56 terminal on the control­ler. Connect the other end of the wire to the right most terminal on the SET terminal block.
d. In the control box, connect the cable shield to
J1-3, equipment ground.
e. Install a jumper between the two center terminals
(right SEN and left SET).
WIRING THE CCN NETWORK COMMUNICATION SERVICE JACK — To wire the service jack, perform the following:
1. Strip back the jacket from the CCN communication ca­ble(s) at least 3 inches. Strip
1
/4-in. of insulation from each conductor. Remove the shield and separate the drain wire from the cable. Twist together all the shield drain wires and fasten them together using an closed end crimp lug or a wire nut. Tape off any exposed bare wire to pre­vent shorting.
2. Connect the CCN + signal wire(s) (RED) to Terminal 5.
3. Connect the CCN – signal wire(s) (BLACK) to Terminal 2.
4. Connect the CCN GND signal wire(s) (WHITE/CLR) to Terminal 4 .
PRIMARY AIR TEMPERATURE SENSOR INSTALLA­TION — A primary air temperature (PAT) sensor is used on a zone controller which is functioning as a Linkage Coordinator for a non-CCN Linkage compatible air source. The part num­ber is 33ZCSENPAT. See Fig. 21. The sensor is also available as field-supplied accessory.
When used on a zone controller, try to select a zone control­ler which will allow installation of the PAT sensor in the main trunk, as close to the air source as possible. See Fig. 22.
To mount the PAT sensor, remove sensor cover.
1
1. Drill a
/2-in. hole in supply duct.
2. Using field-supplied drill tap screw, secure sensor to duct.
3. Connect sensor to zone controller using field-supplied 2-conductor cable. Refer to Table 7.
4. Use field-supplied wire nuts to connect cable to sensor.
5. At zone controller, connect sensor wires to PAT and GND terminals.
WIRING THE SPACE TEMPERATURE SENSOR AND SET POINT ADJUSTMENT SLIDEBAR — To wire the sen­sor and slidebar, perform the following:
1. Identify which cable is for the sensor wiring.
2. Strip back the jacket from the cables at least 3 inches.
1
Strip
/4-in. of insulation from each conductor. Cut the
shield and drain wire from the sensor end of the cable.
3. Connect the sensor cable as follows: a. Connect one wire from the cable (RED) to the
SPT terminal on the controller. Connect the other end of the wire to the left terminal on the SEN ter­minal block of the sensor.
b. Connect another wire from the cable (BLACK) to
the ground terminal on the controller. Connect the other end of the wire to the remaining open termi­nal on the SEN terminal block.
Fig. 21 — Primary Air Temperature Sensor
(Part Number 33ZCSENPAT)
16
INDOOR-AIR QUALITY SENSOR INSTALLATION — The indoor-air quality (IAQ) sensor accessory monitors carbon dioxide levels. This information is used to increase the airflow to the zone and may also modify the position of the outdoor-air dampers to admit more outdoor air as required to provide the desired ventilation rate. The wall sensor is used to monitor the conditioned space. The sensor uses infrared technology to measure the levels of CO
present in the air. The wall sensor is
2
available with or without an LCD readout to display the CO level in ppm and is also available in a combination model whichsensesbothtemperatureandCO
The CO
2000 ppm and a linear voltage output of 0 to 10 vdc. Refer to
sensors are factory set for a range of 0 to
2
the instructions supplied with the CO
level.
2
sensor for electrical re-
2
quirements and terminal locations. The sensor requires a sepa­rate field-supplied 24 vac 25 va transformer to provide power to the sensor. The transformer may be mounted in the control box if space is provided (except electric heat units).
For factory configuration changes to some models of the sensor, the User Interface Program (UIP) or Sensor Calibration Service Kit is required.
To accurately monitor the quality of the air in the condi­tioned air space, locate the sensor near the return air grille so it senses the concentration of CO
leaving the space. The sensor
2
should be mounted in a location to avoid direct breath contact.
Do not mount the space sensor in drafty areas such as near supply diffusers, open window, fans, or over heat sources. Al­low at least 3 ft between the sensor and any corner. Avoid mounting the sensor where it is influenced by the supply air; the sensor gives inaccurate readings if the supply air is blown directly onto the sensor.
To mount the sensor, refer to the installation instructions shipped with the accessory kit.
INDOOR AIR QUALITY SENSOR WIRING — To wire the sensor after it is mounted in the conditioned air space, see Fig. 23-25 and the instructions shipped with the sensor. Use two 2-conductor 20 American Wire Gage (AWG) twisted-pair cables (see Table 7) to connect the field-supplied separate iso­lated 24 vac power source to the sensor and to connect the sen­sor to the control terminals. To connect the sensor to the control, identify the positive (+) and ground (GND) terminals on the sensor and connect the positive terminal to the RH/IAQ terminal on the control and connect the ground terminal to terminal GND.
HUMIDITY SENSOR (Wall-Mounted) INSTALLA­TION — The accessory space humidity sensor is field sup­plied and installed on an interior wall to measure the relative humidity of the air within the occupied space. See Fig. 26.
Theuseofastandard2x4-in.electricalboxtoaccommo­date the wiring is recommended for installation. The sensor can be mounted directly on the wall, if acceptable by local codes.
If the sensor is installed directly on a wall surface, install the humidity sensor using 2 screws and 2 hollow wall anchors (field-supplied); do not overtighten screws.
2
Fig. 22 — Primary Air Temperature
Sensor Installation
(Air-Handling Unit Discharge Locations)
Fig. 23 — Indoor Air Quality Sensor
(Wall-Mounted Version Shown) 33ZCSENCO2
Do NOT clean or touch the sensing element with chemical solvents; they can permanently damage the sensor.
The sensor must be mounted vertically on the wall. The Carrier logo should be oriented correctly when the sensor is properly mounted.
17
Fig. 24 — Ventilation Rates Based on
Set Point
CO
2
IAQ
GND
0
HF23BJ042
Made in Switzerland
by Belimo Automation
LR 92800
NEMA2
LISTED 94D5
U
TEMP.IND. &
L
REG.EQUIP.
Class 2 Supply
5K
WIP
blu
yel
ora
35 in-lb (4 Nm)
80...110s
24VAC/DC 50/60Hz 3VA 2W
COM
2
1
red
blk
1
3
wht
*Do not connect to the same transformer that supplies power to the zone controller.
Fig. 25 — Indoor Air Quality Sensor Wiring
DO NOT mount the sensor in drafty areas such as near heat-
8. Connect the RED wire to terminal +24v on the control ing or air-conditioning ducts, open windows, fans, or over heat sources such as baseboard heaters, radiators, or wall-mounted light dimmers. Sensors mounted in those areas will produce inaccurate readings.
Avoid corner locations. Allow at least 4 ft between the sen-
9. Connect the BLACK wire to terminal GND on the con-
10. Connect the WHITE/CLEAR wire to terminal RH/IAQ
sor and any corner. Airflow near corners tends to be reduced, resulting in erratic sensor readings.
Sensor should be vertically mounted approximately 5 ft up
from the floor, beside the space temperature sensor.
For distances up to 500 feet, use a 3-conductor, 18 or 20 AWG cable. A CCN communication cable can be used, although the shield is not required. The shield must be removed from both ends of the cable if this cable is used.
The power for the sensor is provided by the control board. The board provides 24 vdc for the sensor. No additional power source is required.
To wire the sensor, perform the following:
1. At the sensor, remove 4 in. of jacket from the cable. Strip
1
/4in. of insulation from each conductor. Route the cable through the wire clearance opening in the center of the sensor.
2. Connect the RED wire to the sensor screw terminal marked (+).
3. Install one lead from the resistor (supplied with the sen­sor) and the WHITE wire, into the sensor screw terminal marked (–). After tightening the screw terminal, test the connection by pulling gently on the resistor lead.
4. Connect the remaining lead from the resistor to the BLACK wire and secure using a field-supplied closed end type crimp connector or wire nut.
5. Using electrical tape, insulate any exposed resistor lead to prevent shorting.
6. At the control box, remove the jacket from the cable.
7. Strip
1
/4in. of insulation from each conductor.
Fig. 26 — Wall Mounted Relative Humidity Sensor
board.
trol board.
on the control board.
(P/N 33AMSENRHS000)
21
24VAC*
87
LINE VOLTAGE
SEPARATE
POWER SUPPLY
REQUIRED*
18
Connect the CCN Communication Bus — The
zone controllers connect to the bus in a daisy chain arrange­ment. The zone controller may be installed on a primary CCN bus or on a secondary bus from the primary CCN bus. Con­necting to a secondary bus is recommended.
At 9,600 baud, the number of controllers is limited to 128 zones maximum, with a limit of 8 systems (Linkage Coordinator configured for at least 2 zones). Bus length may not exceed 4000 ft, with no more than 60 devices on any 1000-ft section. Optically isolated RS-485 repeaters are required every 1000 ft.
At 19,200 and 38,400 baud, the number of controllers is limited to 128 maximum, with no limit on the number of Linkage Coordinators. Bus length may not exceed 1000 ft.
The first zone controller in a network connects directly to the bridge and the others are wired sequentially in a daisy chain fashion.
The CCN communication bus also connects to the zone controller space temperature sensor. Refer to the Install Sensors and Make Field-Wiring Connections section for sensor wiring instructions.
COMMUNICATION BUS WIRE SPECIFICATIONS — The Carrier Comfort Network® (CCN) communication bus wiring is field-supplied and field-installed. It consists of shielded three-conductor cable with drain (ground) wire. The cable selected must be identical to the CCN communication bus wire used for the entire network. See Table 8 for recom­mended cable.
Table 8 — Recommended Cables
MANUFACTURER CABLE PART NO. Alpha 2413 or 5463 American A22503 Belden 8772 Columbia 02525
NOTE: Conductors and drain wire must be at least 20 AWG (American Wire Gage), stranded, and tinned copper. Individual con­ductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of –20 Cto60 C is required.
CONNECTION TO THE COMMUNICATION BUS
1. Strip the ends of the red, white, and black conductors of the communication bus cable.
2. Connect one end of the communication bus cable to the bridge communication port labeled COMM2 (if connecting on a secondary bus).
When connecting the communication bus cable, a color code system for the entire network is recom­mended to simplify installation and checkout. See Table 9 for the recommended color code.
Table 9 — Color Code Recommendations
SIGNAL TYPE
+ Red 1 Ground White 2 Black 3
CCN BUS WIRE
COLOR
3. Refer to Fig. 27. Connect the other end of the commu­nication bus cable to the terminal block labeled CCN in the zone controller of the first air terminal. Follow­ing the color code in Table 9, connect the Red (+) wire to Terminal 1. Connect the White (ground) wire to Ter­minal 2. Connect the Black (–) wire to Terminal 3.
4. Connect additional zone controllers in a daisy chain fashion, following the color coded wiring scheme in Tabl e 9.
PLUG PIN
NUMBER
NOTE: The communication bus drain wires (shield) must be tied together at each zone controller. If the communica­tion bus is entirely within one building, the resulting contin­uous shield must be connected to ground at only one single point. If the communication bus cable exits from one build­ing and enters another building, connect the shields to ground at a lightning suppressor in each building where the cable enters or exits (one point only).
Water Valve Installation
Disconnect power before wiring the terminal control unit or electrical shock and personal injury could result.
Water valves are field supplied. Carrier offers two different hot water valve applications: on/off and floating point modulat­ing proportional control. See Table 10 for specifications for compatible water valves. To connect the field-supplied water valves to the wiring harness terminal board located in the ter­minal control unit, refer to the wiring labels for the control package.
Follow the valve manufacturers recommended installation instructions.
Table 10 — Valve Specifications
TYPE
Vol tag e Frequency Power Requirement
ON/OFF
VALV E
24 vac 50/60 Hz Not to exceed 15 va
3 POINTS
FLOATING
VALVE
24 vac (15%) 50/60 Hz Not to exceed 15 va max inrush
ComfortID™ Start-Up
GENERAL — Air volume delivery to the conditioned space is controlled by the modulating of the primary air damper and the sequencing of the air source supply fan. The controller po­sitions the damper by way of an actuator and turns the fan on and off through linkage for the CCN compatible air source equipment control.
PRIMARY SYSTEM CHECK
1. Check that all controls, control box, and ductwork have been properly installed and set according to installation instructions and job requirements.
2. Check that final filters have been installed in the air­handling apparatus. Dust and debris can adversely affect system operation.
3. Check fan and system controls for proper operation.
4. Check electrical system and connections of any optional electric reheat coil. If hot water reheat is used, check pip­ing and valves per job drawings.
5. Check that all air duct connections are tight.
6. See that all balancing dampers at box outlets are in full­open position.
ComfortID CONTROL SYSTEM CHECK
1. Check interconnections between thermostats and unit controls.
2. Force all dampers to control to the maximum cooling cfm using the Building Supervisor, ComfortWORKS work Service Tool or ComfortID Test and Balance Tool software.
3. Set supply-duct balancing dampers, if used, in maximum cool position.
®
,Net-
19
0
HF23BJ042
Made in Switzerland by Belimo Automation
LR 92800
NEMA 2
LISTED 94D5 TENP IND & REG. EQUIP.
Class 2 Supply
WIP
yel
blu
15
LOW
C
1
35 in-lb (4 Nm)
80...110s
24VAC/DC 50/60 Hz 3VA 2W
5K
COM
1
ora
red wht
blk
®
2
3
ZONE Controller
Part Number: 33ZCFANTRM
S/N:
Bus#:
Element#:
Unit#:
HIGH
US
1
FAN A C
J6
2 1
24VAC
J7
HEAT3
3
®
1
J8
SEC DMP
3
J6
1
CCW
COMCWHEAT1
24VAC
HEAT2
FAN
N/A
CW COM CCW
6
RH/IAQ
SECFLOW
+10V
J4
DMPPOS
GND
TEST
1
1
CCN
J2A
3
1
3
GND
GND
+
16
+24V SPT GND
SAT
T56
GND
PAT
N/A
2
1
+
LEN
G
G
-
J2B
-
3
J3
SRVC
+
-
J1
24VAC
G
CCN COMMUNICATION CONNECTOR
RED (+)
WHITE (GND)
CCN
BLACK (–)
Fig. 27 — CCN Terminations at Zone Controller
4. Check that the static pressure available at each box is above the minimum required, force all dampers to control to the minimum cooling cfm and verify that the static pressure is below the maximum safe operating limits when the damper is providing minimum cooling airflow.
5. Set air source supply fan speed and duct static pressure regulator to obtain satisfactory static pressure at design airflow.
6. While at peak system load, check system operation and pressures.
7. Check duct pressure at various points in the system. If sys­tem static pressure probe has been properly located, pres­sure atlast units of all branchheaders should remain essen­tially the same. If pressure has changed considerably, re­check the supply air static pressure controller or relocate the probe to better sense system pressure changes.
8. Remove all forces and balance each control box zone using through the balancing procedure described on page 11.
9. Check that each heating coil is fully operational and that proper airflow is maintained during heating.
It is important to maintain sufficient airflow to units with electric heating elements. Supply-air temperature should NOT EXCEED 105 F in any stage of heating operation. Check the system to make sure that it does not cycle on and off during heating.
CCN System Start-Up — The Building Supervisor,
ComfortWORKS®, and the Network Service Tool can aid in system start-up and troubleshooting.
All set-up and set point configurations are factory set and field adjustable. Changes are made by using either Building Supervisor, ComfortWORKS or the Network Service Tool. TheNetworkServiceToolcanbeusedasaportabledeviceto change system set-up and set points from a zone sensor or ter­minal control module. During start-up, the Building Supervisor ortheNetworkServiceToolcanalsobeusedtoverifycommu­nication with each controller.
For specific operating instructions, refer to the appropriate user manual. See Table 11 for troubleshooting information.
ComfortID™ TEST AND BALANCE TOOL SOFT­WARE — The ComfortID Test and Balance Tool software is used for testing each controller if the Network Service Tool or CCN are not available. The ComfortID Test and Balance Tool is compatible with Windows95 and higher and Windows NT4 (with Service Pack Level 3 or better) operating systems.
This software is used for control calibration. It allows for various functions that expedite system checks and testing.
Carrier requires the use of the B&B485CARLP9A Port Powered RS232 to RS485 Converter for proper operation.
NOTE: The B&B485CARLP9A Port Powered RS232 to RS485 is available through:
B&B Electronics 1500 Boyce Memorial Drive P.O. Box 1040 Ottawa, IL 61350
Refer to the ComfortID Test and Balance Tool Software Installation and Operation Instructions (Carrier publication no. 533-360) for additional information.
20
Table 11 — Troubleshooting Guide For ComfortID™ Terminal Controls
PROBLEM CAUSE CORRECTIVE ACTION
Measured Airflow Does Not Agree With Display Value.
Supply Air Temperature (SAT) Displays 0.0°. Terminal Not Equipped With Heat or Field Installed.
Baseboard Perimeter Heat Does Not Work.
Modulating Baseboard Hot Water Heat Does Not Control Properly.
Electric Reheat Does Not Operate. No power to heater.
Hot Water Reheat Does Not Operate. No hot water available.
Excessive Air Noise. Airflow limits not set properly.
Unit Will Not Provide Modulating Damper Control During Air Source Heating/Warm-Up Mode.
Terminal airflow not calibrated or airflow sensor not calibrated. Wrong terminal inlet size.
No heat type configured or ducted heat not configured.
No heat type configured. Configure Heat Type. If modulating baseboard,
Improperly configured. Readjust the following service configuration parameters:
Airflow too low or high temperature limit tripped.
Water valve wired wrong or not functioning.
Excessive system static pressure. Diffusers too small.
Primary air temperature sensor not installed and no Linkage Master is used (PAT sensor required for control package 4140 and 4145, cooling only, stand-alone operation).
Perform damper/transducer and zone calibration.
Check and correct terminal inlet size if necessary. For terminals without heat, the SAT sensor is
not used. If required, configure Heat Type = 2 and Ducted Heat = YES.
then Ducted Heat must equal YES and sensor HH79NZ078mustbeaffixedtomeasureleavingwater temperature.
Heat Start Value = 110 F Maximum Duct Temperature = 180 F P Gain = 20 I Gain = 1.3
Check fuses and disconnect. Verify airflow exceeds 500 fpm. Adjust Reheat CFM Limit if required to operate below 120 F discharge with all stages operating.
Repair as required. Check wiring and correct if necessary. Retest water valve operation.
Check and readjust maximum airflow limits. Check system static pressure. Reduce pressure if required. Replace with proper size.
Install PAT sensor and configure as a Linkage Master with a system size of 1 zone.
VVT® CONTROLS
General
DIRECT DRIVE HIGH TORQUE ACTUATOR — The direct-drive high torque actuator is used in VVT (variable volume and variable temperature) systems for changing the damper position. The actuator is factory-installed on the termi­nal damper and is controlled by a zone controller or a monitor thermostat. The thermostat calculates how much heating or cooling is required to each zone in the VVT system. The actua­tor receives the commands from its controlling device and moves its damper to change the amount of heated or condi­tioned air that is sent to its zone.
If the 35E unit is equipped with electric heat, only power to the electric heater must be supplied. If the unit does not have an electric heater, then a field-supplied dedicated 24 vac/Class II power source must be installed and wired to the VVT control­ler. Refer to Table 12 for the minimum VA requirement and to the wire label diagram for power connections.
RELAY PACKAGE — The relay package is factory-supplied as required depending on the control package ordered.
The relay pack output harness is connected to the output connector on the relay pack. The pigtail is routed through the grommet the bottom of actuator.
For hot water heat applications, connect the white wire from the relay pack output harness to the field-supplied two-position water valve. See the unit wiring diagram for more information.
ADDITIONAL SENSOR INSTALLATION — Additional sen­sors are required for certain control sequences. A pressure transducer is factory supplied, wired, piped, and installed in­side the control box for units with pressure independent con­trols. Follow the installation instructions provided with each sensor.
NOTE: Pressure sensor is NOT installed inside the actuator housing. There is no clearance available for the pressure trans­ducer inside the actuator.
THERMOSTATS — Thermostats are sold separately and are not provided as part of any VVT control package. Refer to the specific control publication for thermostat operation.
Thermostat Placement — Begin the thermostat instal-
lation by determining where the device will be located. In most cases, this will be pre-determined by the building plans.
The thermostat should be located on an interior wall, about 5 ft from the floor. The device should be located away from di­rect sunlight, drafts, or interior heat sources which may influ­ence temperature readings.
The device may also be mounted in a remote location with the use of an optional remote room sensor.
To mount the thermostat, perform the following:
1. Cut a hole in the wall for the terminal board housing. The hole should be 1
3
/4in. by 13/4inches. See Fig. 29.
NOTE: A 2-in. x 4-in. electric box mounted horizontally may be used instead of cutting the hole.
2. Remove the cover from the thermostat/controller. Care­fully remove the circuit board from the backplate of the thermostat/controller. Line up the backplate with the hole in the wall. Push the protruding part of the backplate into the hole. Pull the thermostat/controller wires out through the backplate.
3. Attach backplate to wall with screws provided.
Wiring Requirements — The wiring requirements for
the Carrier Comfort Network® system are: CCN COMMUNICATIONS — 18 or 20 gage, 3-conductor,
shielded, stranded wire, color coded (RED, BLACK, GREEN), plenum rated if required, long enough to run from thermostat to thermostat in daisy-chain configuration. (Refer to Table 12 for specific control package requirements.)
Table 12 — Minimum VA Requirements
CONTROL SEQ NO. MIN VA REQUIREMENT
8200 30 8201 Factory Supplied (75) 8202 40 8206 35 8207 Factory Supplied (75) 8208 45 8209 30 8210 35
21
COVER REMOVEDWITH COVER
COVER SCREW (HIDDEN)
GROMMET
ACTUATOR COVER
MOUNTING BRACKET
WIRING HARNESSES
3 PIN TEMPERATURE SENSOR CONNECTOR
5 PIN T-STAT CONNECTOR
COVER SCREW
THRU HOLE FOR TEMP. SENSOR
(2) 3 PIN POWER CONNECTOR
Fig. 28 — High Torque Actuator
KMC
(2) 5/16-18 SET SCREWS
10 PIN ANALOG CONNECTION
ACTUATOR SHIPPED AT CLOSED POSITON
8 PIN RELAY CONNECTOR
1 3/4
1 3/4
Fig. 29 — Mounting Hole Dimensions
THERMOSTAT TO TERMINAL CONTROL BOX — 18 gage, 5-conductor, shielded, stranded wire, color coded (RED, WHITE, BLUE, YELLOW, GREEN), plenum rated if re­quired, long enough to run from thermostat to damper actuator to the control box.
Wiring Connections
2. Push the wires back into the wall.
3. Align the terminal board with the right track in the back plate housing. See Fig. 31. The ribbon strip side of the terminal block should be away from the wall. Push the terminal block into the track until about
1
/2in. is left
protruding.
4. Align the ribbon cable from the thermostat/controller cir­cuit board with the ribbon connector on the terminal board and push gently to connect.
5. Push the terminal board fully into backplate until the latch clicks into place.
6. Place the foam backing on the circuit board. Slide the cir­cuit board under the back plate securing bars. DO NOT
CREASE RIBBON CABLE.
7. Align thermostat board with alignment pin. Gently pull down on the thermostat latch and press firmly until the circuit board snaps into place.
8. If optional locking thermostat cover is purchased, insert locking clip on the inside of the thermostat cover. Push firmly into place.
9. Insert tabs on thermostat cover into top slots on the back­plate. Press firmly on the bottom of the thermostat cover to snap cover into lace.
NOTE: If the optional locking thermostat cover was in­stalled, the key must be inserted into the locking device to remove front cover.
Electric shock can cause injury or death. Ensure power to the HVAC unit has been disconnected before wiring.
To wire the thermostat/controller, perform the following:
1. Connect the communication bus and damper actuator wiring to the terminal board of the thermostat. See Fig. 29 and 30.
22
Fig. 30 — Wiring Connections
Fig. 31 — Terminal Board Installation
VVT® Control Configuration/Testing — Carrier
VVT controls require a field-supplied VVT thermostat for the specific application based on the control package ordered. The thermostat is factory-supplied with default configuration. This allows pressure dependent cooling only terminals to operate in a stand-alone mode, during the construction phase. The install­er is required to configure the terminal, system and user specific parameters. All programming can be done at the thermostat without the use of a PC. Terminal parameters in­clude inlet area (pressure independent), airflow limits (pressure independent), minimum or maximum damper position adjust­ments, and damper position factor (reheat applications).
System parameters such as system type (pressure dependent or independent), and controller address along with user parame­ters such as occupancy and set point schedules, must be entered before final checkout and commissioning.
For more information and details regarding specific control configuration parameters and programming procedures, refer to the Carrier Comfort Network® system Variable Volume and Temperature (VVT) Product Data literature and the configura­tion instructions provided with the thermostat.
Refer to the specific control sequence (35E-82XX) for de­tailed operational information. This information should be used to test and commission the control.
Control Start-Up
GENERAL — Air volume delivery to the conditioned space is controlled by the modulating of the primary air damper and the sequencing of the air source supply fan. The VVT control­ler positions the damper by way of an actuator and turns the fan on and off through relay contactors.
PRIMARY SYSTEM CHECK
1. Check that all controls, control box, and ductwork have been properly installed and set according to installation instructions and job requirements.
2. Check that final filters have been installed in the air­handling apparatus. Dust and debris can adversely affect system operation.
3. Check fan and system controls for proper operation.
4. Check electrical system and connections of any optional electric reheat coil. If hot water reheat is used, check pip­ing and valves per job drawings.
5. Check that all air duct connections are tight.
6. See that all balancing dampers at box outlets are in full­open position.
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Copyright 2006 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 3 Ta b 6 a
Catalog No. 533-530 Printed in U.S.A. Form 35E-2SI Pg 24 3-06 Replaces: 35E-1SI
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