Carrier 48EJ, EY024-048 User Manual 2

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Installation, Start-Up and

Service Instructions

CONTENTS

Page

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

INSTALLATION .............................1-31

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

• ROOF CURB

• ALTERNATE UNIT SUPPORT

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

• POSITIONING

• ROOF MOUNT

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

Step 4 — Install Flue Hood ..................12

Step5—TrapCondensate Drain ............13

Step 6 — Install Gas Piping ..................13

Step 7 — Controls Options ..................13

• CONSTANT VOLUME APPLICATIONS

• VARIABLE AIR VOLUME (VAV) APPLICATIONS

Step 8 — Make Electrical Connections .......16

• POWER WIRING

• FIELD POWER SUPPLY

• FIELD CONTROL WIRING

Step 9 — Make Outdoor-Air Inlet

Adjustments ...............................24

• ECONOMIZER

• ECONOMIZER SETTINGS

Step 10 — Position Power Exhaust/Barometric

Relief Hood ...............................29

Step 11 — Install All Accessories ............30

START-UP ................................31-44

SERVICE ..................................44-55

TROUBLESHOOTING ......................56-61

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

48EJ,EK,EW,EY024-048

Single Package Rooftop Units

Electric Cooling/Gas Heating

1. Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal injury, or loss of life. Refer to the User’s Information Manual provided with this unit for more details.

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

What to do if you smell gas:

1. DO NOT try to light any appliance.

2. DO NOT touch any electrical switch, or use any phone in your building.

3. IMMEDIATELY call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

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

Disconnect gas piping from unit when pressure testing at pressure greater than 0.5 psig. Pressures greater than

0.5 psig will cause gas valve damage resulting in haz-

ardous condition. If gas valve is subjected to pressure greater than 0.5 psig, it must be replaced before use. When pressure testing ﬁeld-supplied gas piping at pressures of

0.5 psig or less, a unit connected to such piping must be

isolated by closing the manual gas valve(s).

INSTALLATION

Step 1 — Provide Unit Support

SAFETY CONSIDERATIONS

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

Untrained personnel can perform the basic maintenance functions of cleaning coils and ﬁlters and replacing ﬁlters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags and labels attached to the unit, and other safety precautions that may apply.

Follow all safety codes. Wearsafety glasses and work gloves. Use quenching cloth for unbrazing operations. Have ﬁre extinguishers available for all brazing operations.

Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury.

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

Book 1 Tab 1a

PC 111 Catalog No. 564-962 Printed in U.S.A. Form 48E-5SI Pg 1 8-97 Replaces: 48E-3SI

1. All panels must be in place when rigging.

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

ROOF CURB — Assemble or install accessory roof curb in accordance with instructions shipped with this accessory.See Fig. 1 and 2. Install insulation, cant strips, rooﬁng, and counter ﬂashing as shown. Ductwork can be installed to roof curb before unit is set in place. Curb should be level. This is necessary to permit unit drain to function properly. Unit leveling tolerance is shown in Fig. 1 and 2. Refer to Accessory Roof Curb Installation Instructions for additional information as required. When accessory roof curb is used, unit may be installed on class A, B, or C roof covering material.

IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket with the roof curb as shown in Fig. 1 and 2. Improperly applied gasket can also result in air leaks and poor unit performance.

ALTERNATE UNIT SUPPORT— When the preferred curb or slab mount cannot be used, support unit with sleepers on perimeter, using unit curb support area. If sleepers cannot be used, support long sides of unit (refer to Fig. 3-6) with a minimum number of 4-in. x 4-in. pads spaced as follows: 48EJ,EK,EW,EY024-034 units require 3 pads on each side; 48EJ,EK,EW,EY038-048 units require 4 pads on each side. Unit may sag if supported by corners only.

Step 2 — Rig and Place Unit — Inspect unit for trans-

portation damage. File any claim with transportation agency.

Do not drop unit; keep upright. Use spreader bars over unit to prevent sling or cable damage. Level by using unit frame as a reference; leveling tolerance is shown in Fig. 1 and 2. See Fig. 7 for additional information. Unit operating weight is shown in Table 1.

NOTE: On retroﬁt jobs, ductwork may be attached to old unit instead of roof curb. Be careful not to damage ductwork when removing old unit. Attach existing ductwork to roof curb instead of unit.

Four lifting lugs are provided on the unit base rails as shown in Fig. 7. Refer to rigging instructions on unit.

POSITIONING — Maintain clearance, per Fig. 3-6, around and above unit to provide minimum distance from combustible materials, proper airﬂow, and service access.

Do not install unit in an indoor location. Do not locate unit air inlets near exhaust vents or other sources of contaminated air. For proper unit operation, adequate combustion and ventilation air must be provided in accordance with Section 5.3 (Air for Combustion and Ventilation) of the National Fuel Gas Code, ANSI Z223.1 (American National Standards Institute).

Although unit is weatherproof, guard against water from higher level runoff and overhangs.

Locate mechanical draft system ﬂue assembly at least 4 ft from any opening through which combustion products could enter the building, and at least 4 ft from any adjacent building. When unit is located adjacent to public walkways, ﬂue assembly must be at least 7 ft above grade.

ROOF MOUNT — Check building codes for weight distribution requirements. Unit weight is shown in Table 1.

Step 3 — Field Fabricate Ductwork

48EJ,EK UNITS — Field-fabricated ductwork should be attached to the roof curb. Supply and return duct dimensions are shown in Fig. 3 and 4. Air distribution is shown in Fig. 8.

To attach ductwork to roof curb, insert duct approximately 10 to 11 in. up into roof curb. Connect ductwork to 14-gage roof curb material with sheet metal screws driven from inside the duct.

Secure all ducts to the building structure, using ﬂexible duct connectors between roof curb and ducts as required. Ducts passing through an unoccupied space must be insulated and covered with a vapor barrier. Outlet grilles must not lie directly below unit discharge. The return duct must have a 90-degree elbow before opening into the building space if the unit is equipped with power exhaust.

For vertical supply and return units, tools or parts could drop into ductwork and cause an injury. Install 90 degree elbow turns in the supply and return ductwork between the unit and the conditioned space. If a 90 degree elbow cannot be installed, then grilles of sufficientstrength and density should be installed to prevent objects from falling into the conditioned space.

48EW,EY UNITS — Remove shipping covers from supply and return air openings. Attach ﬁeld-supplied ductwork to unit. Use a single duct over both return openings and a single duct over both supply openings. See Fig. 5 and 6 for duct opening dimensions. Secure all ducts to the building structure. See Fig. 9. Use ﬂexible duct connectors between unit and ducts as required. Insulate and weatherproof all external ductwork, joints, and building openings with counter ﬂashing and mastic in accordance with applicable codes.

Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier.

Install accesssory barometric relief or power exhaust in the ﬁeld-fabricated return ductwork. Refer to Position Power Exhaust/Barometric Relief Damper Hood section on page 26 for more information.

Instructions continued on page 12.

NOTES:

1. All roof curb parts are to be 16 ga galvanized steel.

2. Dimensions are in inches.

3. Toprevent standing water in the drain pan of the indoor sectionandtheheatexchangers,unit can only be pitched as shown.

Fig. 1 — Roof Curb (Sizes 024-034)

UNIT LEVELING TOLERANCES DIMENSIONS*

*From edge of unit to horizontal.

(Degrees and Inches)

Deg. in. Deg. in.

1.0 2.9 .50 .75

NOTES:

1. All roof curb parts are to be 16 ga galvanized steel.

2. Dimensions are in inches.

3. Toprevent standing water in the drain pan of the indoor sectionandtheheatexchangers,unit can only be pitched as shown.

Fig. 2 — Roof Curb (Sizes 038-048)

UNIT LEVELING TOLERANCES DIMENSIONS*

*From edge of unit to horizontal.

(Degrees and Inches)

Deg. in. Deg. in.

1.0 2.9 .50 .75

VFD — Variable Frequency Drive NOTES:

1. Weights include economizer (STD).

2. Center of gravity.

3. Do not locate adjacent units with ﬂue dischargefacingeconomizerinlet.Minimum clearances to be:

Adjacent Units: 158-09 Top of Units: No overhang Condenser Coil: 48-09 Economizer Side: 68-09 Gas Heat Side: 48-09 Filter Access Side: 108-09 (For Removal of Evaporator Coil)

4. For smaller service and operational clearances, contact Carrier Application Engineering department.

5. Bottom ducts designed to be attached to accessory roof curb. If unit is mounted on dunnage, it is recommended the ducts be supported by cross braces as done on accessory roof curb.

6. Dimensions are in inches.

UNIT SIZE

OPERATING

WEIGHT

lb ft-in. ft-in. 1 2 3 4

48EJ,EKD024 4176 6- 0

48EJE024 4256 6- 1

48EJ,EKD028 4262 5- 9

48EJE028 4342 5-10

48EJ,EKD030 4262 5- 9

48EJE030 4342 5-10

48EJ,EKD034 4262 5- 9

48EJE034 4342 5-10

A B CORNER WEIGHT (lb)

⁄83-63⁄8879 954 1220 1124

⁄163-611⁄16917 973 1218 1148

⁄83-8 899 899 1232 1232

⁄83-85⁄16929 916 1240 1257

⁄83-8 899 899 1232 1232

⁄83-85⁄16929 916 1240 1257

⁄83-8 899 899 1232 1232

⁄83-85⁄16929 916 1240 1257

Fig. 3 — Base Unit Dimensions, 48EJ,EK024-034

VFD — Variable Frequency Drive NOTES:

1. Weights include economizer (STD).

2. Center of gravity.

3. Do not locate adjacent units with ﬂue discharge facing economizer inlet. Minimum clearances to be:

Adjacent Units: 158-09 Top of Units: No overhang Condenser Coil: 48-09 Economizer Side: 68-09 Gas Heat Side: 48-09 Filter Access Side: 108-09 (For Removal of Evaporator Coil)

4. For smaller service and operational clearances, contact Carrier Application Engineering department.

5. Bottom ducts designed to be attached to accessory roof curb. If unit is mounted on dunnage, it is recommended the ducts be supported by cross braces as done on accessory roof curb.

6. Dimensions are in inches.

Fig. 4 — Base Unit Dimensions, 48EJ,EK038-048

UNIT SIZE

OPERATING

WEIGHT

lb ft-in. ft-in. 1 2 3 4

48EJ,EKD038 4442 7- 8

48EJE038 4602 7-10

48EJ,EKD044 4668 7- 5

48EJE044 4828 7- 6

48EJ,EKD048 4955 7- 3

48EJE048 5115 7- 5

A B CORNER WEIGHT (lb)

⁄163-107⁄81021 894 1180 1347

⁄83-113⁄161080 934 1200 1388

⁄163-107⁄81033 906 1275 1455

⁄163-113⁄161094 945 1293 1496

⁄163-101⁄21068 953 1384 1550

⁄163-1013⁄161129 994 1401 1592

VFD — Variable Frequency Drive NOTES:

1. Weights include economizer (STD).

2. Center of gravity.

3. Do not locate adjacent units with ﬂue discharge facing economizer inlet. Minimum clearances to be:

Adjacent Units: 158-09 Top of Units: No overhang Condenser Coil: 48-09 Economizer Side: 68-09 Gas Heat Side: 48-09 Filter Access Side: 108-09 (For Removal of Evaporator Coil)

4. For smaller service and operational clearances, contact Carrier Application Engineering department.

5. Dimensions are in inches.

6. For side-supply/return applications, a single return and supply ductwork connection is recommended for covering both return and both supply openings.

Fig. 5 — Base Unit Dimensions, 48EW,EY024-034

UNIT SIZE

OPERATING

WEIGHT

lb ft-in. ft-in. 1 2 3 4

48EW,EYD024 4176 6- 0

48EWE024 4256 6- 1

48EW,EYD028 4262 5- 9

48EWE028 4342 5-10

48EW,EYD030 4262 5- 9

48EWE030 4342 5-10

48EW,EYD034 4262 5- 9

48EWE034 4342 5-10

A B CORNER WEIGHT (lb)

⁄83-63⁄8879 954 1220 1124

⁄163-611⁄16917 973 1218 1148

⁄83-8 899 899 1232 1232

⁄83-85⁄16929 916 1240 1257

⁄83-8 899 899 1232 1232

⁄83-85⁄16929 916 1240 1257

⁄83-8 899 899 1232 1232

⁄83-85⁄16929 916 1240 1257

VFD — Variable Frequency Drive NOTES:

1. Weights include economizer (STD).

2. Center of gravity.

3. Do not locate adjacent units with ﬂue discharge facing economizer inlet. Minimum clearances to be:

Adjacent Units: 158-09 Top of Units: No overhang Condenser Coil: 48-09 Economizer Side: 68-09 Gas Heat Side: 48-09 Filter Access Side: 108-09 (For Removal of Evaporator Coil)

4. For smaller service and operational clearances, contact Carrier Application Engineering department.

5. Dimensions are in inches.

6. For side-supply/return applications, a single return and supply ductwork connection is recommended for covering both return and both supply openings.

Fig. 6 — Base Unit Dimensions, 48EW,EY038-048

UNIT SIZE

OPERATING

WEIGHT

lb ft-in. ft-in. 1 2 3 4

48EW,EYD038 4442 7- 8

48EWE038 4602 7-10

48EW,EYD044 4668 7- 5

48EWE044 4828 7- 6

48EW,EYD048 4955 7- 3

48EWE048 5115 7- 5

A B CORNER WEIGHT (lb)

⁄163-107⁄81021 894 1180 1347

⁄83-113⁄

⁄163-107⁄81033 906 1275 1455

⁄163-113⁄

⁄163-101⁄21068 953 1384 1550

⁄163-1013⁄161129 994 1401 1592

1080 934 1200 1388

1094 945 1293 1496

UNIT

48EJ,EK,EW,EYD024 4176 1894

48EJ,EWE024 4256 1930 73.3 1862 42.7 1085

48EJ,EK,EW,EYD028

48EJ,EK,EW,EYD034

48EJ,EWE028

48EJ,EWE034

48EJ,EK,EW,EYD038 4442 2015

48EJ,EWE038 4602 2087 94.1 2390 47.2 1199

48EJ,EK,EW,EYD044 4668 2117 89.3 2268 46.9 1191

48EJ,EWE044 4828 2190 90.8 2306 47.2 1199

48EJ,EK,EW,EYD048 4955 2248 87.7 2228 46.5 1181

48EJ,EWE048 5115 2320 89.2 2266 46.8 1189

WEIGHT A B C

lb kg in. mm in. mm in. mm

72.4 1839 42.4 1072

4262 1933 69.6 1768 44.0 111848EJ,EK,EW,EYD030

4342 1969 70.1 1781 44.3 112548EJ,EWE030

87.68 2227

92.7 2355 46.9 1191

150 3810

NOTICE TO RIGGERS:

ALL PANELS MUST BE IN PLACE

WHEN RIGGING.

NOTE: Rig with four cables and spread with two 92 in. (2337 mm) spreader bars. Maintain a distance of 74 in. (1880 mm) from top of unit to eyehook.

NOTE: Add 32 lb (14.5 kg) for domestic crating. Add 312 lb (142 kg) for export crating (024-034 units). Add 346 lb (157 kg) for export crating (038-048 units). Add 250 lb (113 kg) for power exhaust. Add 220 lb (100 kg) for copper condenser coil (024-034 units). Add 285 lb (129 kg) for copper condenser coil (038,044 units). Add 380 lb (172 kg) for copper condenser coil (048 unit).

Fig. 7 — Rigging Label

Table 1 — Physical Data

UNIT 48EJ,EK,EW,EY 024D/E 028D/E 030D/E 034D/E NOMINAL CAPACITY (tons) 20 25 27 30 OPERATING WEIGHT (lb)*

Unit

Al/Al† (Lo Heat/Hi Heat) 4176/4256 4262/4342 4262/4342 4262/4342 Al/Cu† (Lo Heat/Hi Heat) 4396/4476 4482/4562 4482/4562 4482/4562 Roof Curb (14-in. curb) 365 365 365 365

COMPRESSOR

Type Ckt 1 06D328 06D328 06D537 06D537

Ckt 2 06D818 06D328 06D328 06D537

Number of Refrigerant Circuits 22 2 2

Oil (oz) (Ckt 1, Ckt 2) 115, 88 115 ea. 115 ea. 115 ea.

REFRIGERANT TYPE R-22

Operating Charge (lb-oz)

Circuit 1** 25-0 25-0 25-0 25-0 Circuit 2 31-0 25-0 25-0 25-0

CONDENSER COIL Cross-Hatched

Quantity 11 1 1 Rows...Fins/in. 4...15 4...15 4...15 4...15 Total Face Area (sq ft) 33.3 33.3 33.3 33.3

CONDENSER FAN Propeller Type

Nominal Cfm 13,420 13,420 13,420 13,420 Quantity...Diameter (in.) 2...30 2...30 2...30 2...30 Motor Hp (1075 Rpm) 11 1 1

EVAPORATOR COIL Cross-Hatched

Rows...Fins/in. 4...15 4...15 4...15 4...15 Total Face Area (sq ft) 31.7 31.7 31.7 31.7

EVAPORATOR FAN Centrifugal Type

Quantity...Size (in.) 2...20x15 2...20x15 2...20x15 2...20x15 Type Drive Belt Belt Belt Belt Nominal Cfm 8,000 10,000 11,000 12,000 Motor Hp 5 10†† 15 7.5 10†† 15 10 15†† 20 10 15†† 20 Motor Frame Size (Standard) S184T S215T D254T S213T S215T D254T S215T D254T S256T S215T D254T S256T

Motor Bearing Type Ball Ball Ball Ball Maximum Allowable Rpm 1200 1200 1200 1200 Motor Pulley Pitch Diameter 4.8 4.4 5.7 5.4 6.1 5.5 4.4 4.9 5.9 4.4 5.7 5.9 Nominal Motor Shaft Diameter (in.) 1 Fan Pulley Pitch Diameter (in.) 12.4 8.6 9.1 12.4 11.1 8.7 9.4 8.1 8.7 9.0 9.1 8.7 Nominal Fan Shaft Diameter (in.) 1 Belt, Quantity...Type Belt, Length (in.) Pulley Center Line Distance (in.) 16.0-18.7 15.6-18.4 15.0-17.9 15.6-18.4 15.0-17.9 15.6-18.4 15.0-17.9 15.6-18.4 15.0-17.9 Factory Speed Setting (rpm) 717 924 1096 773 962 1106 848 1059 1187 884 1096 1187

FURNACE SECTION

Rollout Switch Cutout Temp (F)| 225 225 225 225 Burner Oriﬁce Diameter

(in. ...drill size)

Thermostat Heat Anticipator

Setting (amps)

Gas Input (Btuh) Stage 1 Low 262,500 262,500 262,500 262,500

Efficiency (Steady State) (%) 82 82 82 82 Temperature Rise Range 15-45/35-65 15-45/35-65 15-45/35-65 15-45/35-65 Manifold Pressure (in. wg)

Gas Valve Quantity 22 2 2 Field Gas Connection Size

HIGH-PRESSURE SWITCH (psig)

Cutout 426 426 426 426 Reset (Auto.) 320 320 320 320

LOW-PRESSURE SWITCH (psig)

Cutout 77 7 7 Reset (Auto.) 22 22 22 22

OUTDOOR-AIR FILTERS 8...16 × 25

Quantity...Size (in.) 4...20 × 25

RETURN-AIR FILTERS

Quantity...Size (in.) 10...20x24x2 10...20x24x2 10...20x24x2 10...20x24x2

POWER EXHAUST Direct Drive, 3-Speed, Single-Phase Motor (Factory-Wired for High Speed) and Forward-Curved Fan

Motor, Quantity...Hp 4...1 4...1 4...1 4...1 Fan, Diameter... Width (in.) 11...10 11...10 11...10 11...10

(High Efficiency) S184T S215T S254T S213T S215T S254T S215T S254T S256T S215T S254T S256T

⁄

13⁄

15⁄

⁄

1...BX59622...BX51542...5VX530531...BX59621...5VX590592...5VX530532...BX52552...5VX500502...5VX530532...BX51542...5VX530532...5VX530

Natural Gas Std .111...34 .111...34 .111...34 .111...34 Liquid Propane Alt .089...43 .089...43 .089...43 .089...43

Stage 1 0.1 0.1 0.1 0.1 Stage 2 0.1 0.1 0.1 0.1

High 394,000 394,000 394,000 394,000

Stage 2 Low 350,000 350,000 350,000 350,000

High 525,000 525,000 525,000 525,000

Natural Gas Std 3.5 3.5 3.5 3.5 Liquid Propane Alt 3.5 3.5 3.5 3.5

(in.-FPT)

1.5 1.5 1.5 1.5

LEGEND

Al — Aluminum Cu — Copper

*Weightof unit does not include variable frequency drive(VFD) barometric relief, or power

exhaust. If a VFD is installed, add the VFD weight in the table at right.

†Evaporator coil ﬁn material/condenser coil ﬁn material.

**Sizes 024-034: Circuit 1 uses the lowerportion of condensercoil, Circuit 2uses the upper

portion. Sizes 038-048: Circuit 1 uses the left condenser coil, Circuit 2 the right. All units have intertwined evaporator coils.

††Motor and drive shown will deliver approximately 2.5 in. wg net external static. See

Table 2 for more information. \Rollout switch is manual reset.

⁄89 Copper Tubes, Aluminum Lanced, Aluminum Pre-Coated, or Copper Plate Fins

⁄89 Copper Tubes, Aluminum Plate Fins, Intertwined Circuits

13⁄

15⁄

13⁄

15⁄

13⁄

15⁄

115⁄

NOTE: High heat is for 48EJ,EW only.

VFD (Hp)

208/230 v 460 v 575 v

VFD WEIGHTS (lb)

5 20 22 60

7.5 51 37 64 10 51 61 64 15 61 63 109 20 63 111 109 25 105 112 174 30 172 118 180

Table 1 — Physical Data (cont)

UNIT 48EJ,EK,EW,EY 038D/E 044D/E 048D/E NOMINAL CAPACITY (tons) 35 40 45 OPERATING WEIGHT (lb)*

Unit

Al/Al† (Lo Heat/Hi Heat) 4442/4602 4668/4828 4955/5115 Al/Cu† (Lo Heat/Hi Heat) 4727/4887 4953/5113 5335/5495 Roof Curb (14-in. curb) 410 410 410

COMPRESSOR

Type Ckt 1 06D537 06EA250 06EA265

Ckt 2 06D537 06EA250 06EA250

Number of Refrigerant Circuits 222

Oil (oz) (Ckt 1, Ckt 2) 115 ea. 224 ea. 304, 224

REFRIGERANT TYPE R-22

Operating Charge (lb-oz)

Circuit 1** 34-0 35-0 41-0 Circuit 2 34-0 35-0 41-0

CONDENSER COIL Cross-Hatched

Quantity 2211 Rows...Fins/in. 3...15 3...15 4...15 3...15 Total Face Area (sq ft) 58.3 58.3 66.7

CONDENSER FAN Propeller Type

Nominal Cfm 27,064 27,064 27,064 Quantity...Diameter (in.) 4...30 4...30 4...30 Motor Hp (1075 Rpm) 111

EVAPORATOR COIL Cross-Hatched

Rows...Fins/in. 3...15 3...15 4...15 Total Face Area (sq ft) 34.7 34.7 34.7

EVAPORATOR FAN Centrifugal Type

Quantity...Size (in.) 2...20x15 2...20x15 2...20x15 Type Drive Belt Belt Belt Nominal Cfm 14,000 16,000 18,000 Motor Hp 10 15†† 20 15 20†† 25 20 25†† 30 Motor Frame Size (Standard) S215T D254T S256T D254T S256T S284T S256T S284T S286T

Motor Bearing Type Ball Ball Ball Maximum Allowable Rpm 1200 1200 1200 Motor Pulley Pitch Diameter 6.1 5.3 5.7 5.3 5.7 7.5 6.3 5.9 7.5 Nominal Motor Shaft Diameter (in.) 1 Fan Pulley Pitch Diameter (in.) 13.7 9.5 9.5 9.5 9.5 11.1 11.1 12.5 11.1 Nominal Fan Shaft Diameter (in.) 1 Belt, Quantity...Type Belt, Length (in.) Pulley Center Line Distance (in.) 15.6-18.4 15.0-17.9 15.0-17.9 14.6-17.6 15.0-17.9 14.6-17.6 Factory Speed Setting (rpm) 779 976 1050 976 1050 1182 993 1134 1182

FURNACE SECTION

Rollout Switch Cutout Temp (F)| 225 225 225 Burner Oriﬁce Diameter

(in. ...drill size)

Thermostat Heat Anticipator

Setting (amps)

Gas Input (Btuh) Stage 1 Low 300,000 300,000 300,000

Efficiency (Steady State) (%) 82 82 82 Temperature Rise Range 10-40/30-60 10-40/30-60 10-40/30-60 Manifold Pressure (in. wg)

Gas Valve Quantity 222 Field Gas Connection Size (in.-FPT) 1.5 1.5 1.5

HIGH-PRESSURE SWITCH (psig)

Cutout 426 426 426 Reset (Auto.) 320 320 320

LOW-PRESSURE SWITCH (psig)

Cutout 777 Reset (Auto.) 22 22 22

OUTDOOR-AIR FILTERS 8...16 × 25

Quantity...Size (in.) 4...20 × 25

RETURN-AIR FILTERS

Quantity...Size (in.) 10...20x24x2 10...20x24x2 10...20x24x2

POWER EXHAUST Direct Drive, 3-Speed, Single-Phase motor (Factory-Wired for High Speed) and Forward Curved Fan

Motor, Quantity...Hp 4...1 4...1 4...1 Fan, Diameter... Width (in.) 11...10 11...10 11...10

(High Efficiency) S215T S254T S256T S254T S256T S284T S256T S284T S286T

⁄

1...5VX650652...5VX530532...5VX550552...5VX530532...5VX550552...5VX590592...5VX570572...5VX630632...5VX610

Natural Gas Std .120...31 .120...31 .120...31 Liquid Propane Alt .096...41 .096...41 .096...41

Stage 1 0.1 0.1 0.1 Stage 2 0.1 0.1 0.1

High 600,000 600,000 600,000

Stage 2 Low 400,000 400,000 400,000

High 800,000 800,000 800,000

Natural Gas Std 3.5 3.5 3.5 Liquid Propane Alt 3.5 3.5 3.5

15⁄

⁄

LEGEND

Al — Aluminum Cu — Copper

*Weightof unit does not include variable frequency drive(VFD) barometric relief, or power

exhaust. If a VFD is installed, add the VFD weight in the table at right.

†Evaporator coil ﬁn material/condenser coil ﬁn material.

**Sizes 024-034: Circuit 1 uses the lowerportion of condensercoil, Circuit 2uses the upper

portion. Sizes 038-048: Circuit 1 uses the left condenser coil, Circuit 2 the right. All units have intertwined evaporator coils.

††Motor and drive shown will deliver approximately 2.5 in. wg net external static. See

Table 2 for more information. \Rollout switch is manual reset.

⁄89 Copper Tubes, Aluminum Lanced, Aluminum Pre-Coated, or Copper Plate Fins

⁄89 Copper Tubes, Aluminum Plate Fins, Intertwined Circuits

15⁄

115⁄

15⁄

17⁄

15⁄

NOTE: High heat is for 48EJ,EW only.

VFD (Hp)

208/230 v 460 v 575 v

VFD WEIGHTS (lb)

5 20 22 60

7.5 51 37 64 10 51 61 64 15 61 63 109 20 63 111 109 25 105 112 174 30 172 118 180

115⁄

17⁄

Table 2 — Evaporator Fan Motor Data (Units with Starting Serial Numbers 4197 and Later)

UNIT

MOTOR

SIZE

48E

024

028

030

034

038

044

048

NOTE: Motor shaft speed is 1750 rpm. The fan shaft diameter is 1

MOTOR

SHAFT

10 1.38 924 2BK50 4.4 None-1.375 2B5V86 8.6 B-1.9375 (2) BX51 54 5.21 15 1.62 1096 2B5V56 5.7 B-1.625 2B5V90 9.1 B-1.9375 (2) 5VX530 53 6.00

7.5 1.38 773 BK60H 5.4 H-1.375 1B5V124 12.4 B-1.9375 BX59 62 6.48 10 1.38 962 1B5V60 6.1 H-1.375 1B5V110 11.1 B-1.9375 5VX590 59 7.37 15 1.62 1106 2B5V54 5.5 B-1.625 2B5V86 8.7 B-1.9375 (2) 5VX530 53 6.12

10 1.38 848 2BK50 4.4 None-1.375 2B5V94 9.4 B-1.9375 (2) BX52 55 5.27 15 1.62 1059 2B5V48 4.9 B-1.625 2B5V80 8.1 B-1.9375 (2) 5VX500 50 6.63 20 1.62 1187 2B5V58 5.9 B-1.625 2B5V86 8.7 B-1.9375 (2) 5VX530 53 7.31

10 1.38 884 2BK50 4.4 H-1.375 2B5V90 9.0 B-1.9375 (2) BX51 54 5.24 15 1.62 1096 2B5V56 5.7 B-1.625 2B5V90 9.1 B-1.9375 (2) 5VX530 53 6.00 20 1.62 1187 2B5V58 5.9 B-1.625 2B5V86 8.7 B-1.9375 (2) 5VX530 53 7.31

10 1.38 779 1B5V60 6.1 None-1.375 1B5V136 13.7 B-1.9375 5VX650 65 7.62 15 1.62 976 2B5V52 5.3 B-1.625 2B5V94 9.5 B-1.9375 (2) 5VX530 53 6.37 20 1.62 1050 2B5V56 5.7 B-1.625 2B5V94 9.5 B-1.9375 (2) 5VX550 55 7.60

15 1.62 976 2B5V52 5.3 B-1.625 2B5V94 9.5 B-1.9375 (2) 5VX530 53 6.37 20 1.62 1050 2B5V56 5.7 B-1.625 2B5V94 9.5 B-1.9375 (2) 5VX550 55 7.60 25 1.88 1182 2B5V74 7.5 B-1.875 2B5V110 11.1 B-1.9375 (2) 5VX590 59 7.60

20 1.62 993 2B5V62 6.3 B-1.625 2B5V110 11.1 B-1.9375 (2) 5VX570 57 7.22 25 1.88 1134 2B5V80 5.9 B-1.875 2B5V124 12.5 B-1.9375 (2) 5VX630 63 7.36 30 1.88 1182 2B5V74 7.5 B-1.875 2B5V110 11.1 B-1.9375 (2) 5VX590 59 9.07

DIA. (in.)

5 1.12 717 BK55 4.8 None-1.125 1B5V124 12.4 B-1.9375 BX59 62 5.10

FAN SHAFT SPEED

(rpm)

MOTOR

SHEAVE

MOTOR

SHEAVE

PITCH

DIAMETER

(in.)

BUSHING

DIAMETER

(in.)

⁄16inches.

FAN

SHEAVE

PITCH

DIAMETER

(in.)

BUSHING

DIAMETER

(in.)

BELT

(QUANTITY)

OUTSIDE

BELT

LENGTH

TENSION

Step 4 — Install Flue Hood — Flue hood is shipped

inside gas section of unit. To install, secure ﬂue hood to access panel. See Fig. 10.

NOTE: When properly installed, ﬂue hood will line up with combustion fan housing. See Fig. 11.

BELT

(Lb at

.24 in.)

Fig. 8 — Air Distribution — Thru-the-Bottom

Fig. 9 — Air Distribution — Thru-the-Side

Fig. 10 — Flue Hood Location

Step5—TrapCondensate Drain — See Fig. 3-6

for drain location. Condensate drain is open to atmosphere and must be trapped. Install a trapped drain at the drain location. A trap at least 4-in. deep must be used. See Fig. 12. Trap must be installed to prevent freeze-up.

Condensate pans are sloped so that water will completely drain from the condensate pan to comply with indoor air quality guidelines. The condensate drain pan is ﬁtted with a 1-in. FPT coupling.

Step 6 — Install Gas Piping — Unit is equipped for

use with natural gas. Installation must conform with local building codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1.

Install manual gas shutoff valve with a sure tap for test gage connection at unit. Field gas piping must include sediment trap and union. See Fig. 13. An

⁄8-in. NPT is also located on the gas manifold adjacent to

the gas valve.

Do not pressure test gas supply while connected to unit. Always disconnect union before servicing.

IMPORTANT: Natural gas pressure at unit gas connection must not be less than 5 in. wg or greater than

13.5 in. wg.

⁄8-in. NPT pres-

Fig. 11 — Combustion Fan Housing Location

Size gas-supply piping for 0.5-in. wg maximum pressure drop. Do not use supply pipe smaller than unit gas connection.

Step 7 — Controls Options — The control options

that the units can provide are based on the following parameters: CV (constant volume) or VAV (variable air volume) operation; stand-alone unit with ﬁeld-supplied sensors installed (CV or VAV); as a system via Carrier Comfort System (TEMP or VVTt); optional electronic expansion board installed (CV or VAV); linked to the Carrier Comfort Network; and availability of a computer and software (ComfortWorks™ Building Supervisor, and Service Tool) or LID-2B accessory installed to access the base control board. See Table 3.

NOTE: Access to the base control board allows unit occupancy schedules, unit timeclock, and various set points to be changed from their factory-deﬁned default settings.

All units are equipped with a supply air thermistor (SAT) located in the supply fan discharge and an outdoor air thermistor (OAT) located in the outdoor air hood. Variable air volume units are supplied with a return air thermistor (RAT) located on the return air damper support.

CONSTANT VOLUME APPLICATIONS — The units, as shipped, are operable as stand-alone units, using either a standard (mechanical or electronic) 2-stage heat, 2-stage cool thermostat, or with an electronic room sensor and a timeclock to establish unit start and stop times.

With a standard thermostat (programmable is optional), heating and cooling operation is set by space temperature.

With a space sensor and timeclock, the machine will operate at default values unless they are changed using appropriate input devices. The space sensor senses space temperature and may be equipped with a timed override feature, which allows unit operation during unoccupied periods.

Fig. 12 — Condensate Drain Trap Piping Details

(Typical Roof Curb or Slab Mount Shown)

Fig. 13 — Field Gas Piping

The space sensors may be used in multiples of 4 or 9 to achieve space temperature averaging. The use of a space sensor also allows the unit to be turned on and off from a remote signal.

Features with Thermostat Control of Unit

• two-stage heating

• two-stage cooling

• control of unit using Y1, Y2, W1, W2, and G thermostat

inputs

• control of the indoor fan

• outdoor-air temperature/supply-air temperature

monitoring

• control of an outdoor air condenser fan based on outdoor-

air temperature

Table 3 — Controls Options and Conﬁgurations (Non-Thermostat Applications)

UNIT CONFIGURATION DEFAULT COOLING DEFAULT HEATING CV or VAV Unit with SPT Sensor CV Unit with SPT Sensor and Remote

Start/Stop Switch VAV Unit Remote Start/Stop Switch Only VAV Unit with SPT Sensor and Remote

Start/Stop Switch

LEGEND

CV — Constant Volume NA — Not Available RAT — Return-Air Temperature SAT — Supply-Air Temperature SPT — Space Temperature VAV — VariableAir Volume

Unoccupied Cooling — 90 F (SPT) Occupied Cooling — NA

Unoccupied Cooling — 90 F (SPT) Occupied Cooling — 78 F (SPT)

Unoccupied Cooling — 90 F (RAT) Occupied Cooling — 55 F (SAT)

Unoccupied Cooling — 90 F (SPT) Occupied Cooling — 55 F (SAT)

*With DIP Switch No. 5 conﬁgured to OPEN (Occupied Heat

Enabled).

NOTE: Space temperature sensor and remote start/stop switch are ﬁeld-supplied.

Unoccupied Heating — 55 F (SPT) Occupied Heating — NA

Unoccupied Heating — 55 F (SPT) Occupied Heating — 68 F (SPT)

Unoccupied Heating — 55 F (RAT) Occupied Heating — 68 F (RAT)*

Unoccupied Heating — 55 F (SPT) Occupied Heating — 68 F (RAT)*

• control of modulating economizer damper to provide free cooling when outdoor conditions are suitable, using supply-air temperature as a control point

• control of the economizer damper and indoor fan to obtain unoccupied free cooling

• provide power exhaust output to an external power exhaust controller

• support a ﬁeld test for ﬁeld checkout

• control of 2 stages of CV power exhaust

• compressor Time Guardt (power up, minimum off and on times)

• compressor lockout during low supply-air temperature

Additional features are provided by accessing the standard unit control board via software with a computer. These features are:

• electronic expansion board features (if installed)

• control board diagnostics

• ability to change supply air set point (economizer control)

• ability to change high outdoor temperature lockout set point

(economizer control)

• ability to change power exhaust set points NOTE: A CV unit without a thermostat requires a ﬁeld-

supplied sensor for operation. Features with Sensor Control of Unit (Stand-Alone Appli-

cations — Unit control is limited to CV unoccupied default set points, 90 F for cooling, 55 F for heating. There are 2 sensor options available:

• T-55 sensor will monitor room temperature and provide

unoccupied override capability (1 hour)

• T-56 sensor will monitor room temperature, provide un-

occupied override capability (1 hour), and provide a temperature offset of 5° F.

Standard features are:

• support of remote occupied/unoccupied input to start and

stop the unit

• cooling capacity control of 3 stages using economizer and

2 compressors to maintain space temperature to an occupied or unoccupied set point

• enable heating or cooling during unoccupied periods as

required to maintain space temperature within the unoccupied set points

• adjustment of space temperature set points of ±5° F when

using a T-56 sensor

Additional features with sensor control of unit (with computer access) are:

• 365 day timeclock with backup (supports minute, hour,day

of week, date, month, and year)

• daylight savings time function

• occupancy control with 8 periods for unit operation

• holiday table containing up to 18 holiday schedules

• ability to initiate timed override from T-55or T-56 sensors for a timed period of 1 to 4 hours

• ability to use multiple space temperature sensors to average the space temperature

• temperature compensated start to calculate early start times before occupancy

• access to the Display, Maintenance, Conﬁguration, Service, and Set Point data tables through network software

When the unit is equipped with a ﬁeld-supplied space temperature sensor and a remote contact closure (remote start/ stop) on the base control board, the occupied default set points will monitor unit operation. The occupied default set points are 78 F cooling and 68 F heating. See Fig. 14 for remote start/stop wiring.

NOTE: For units with a ﬁeld-supplied space temperature sesor which have not had the base unit control board accessed via software to set an occupancy schedule, the remote start/ stop closure will allow the unit to operate in the preconﬁgured occupied default set points (based on return-air temperature) of 78 F cooling and 68 F heating. Without this feature, the unit will control to the unoccupied default set points of 90 F cooling and 55 F heating.

An electronic expansion board may be ﬁeld-installed to provide the following features:

• control of modulating economizer damper to maintain in-

door air quality (IAQ) when outdoor conditions are suitable

NOTE: The IAQ sensor must be set for current output (4 to 20 mA), not voltage output. Ensure the jumper on the sensor is in the upper position. See Fig. 15.

• provide discrete inputs for fan status, ﬁlter status, ﬁeld-

applied status, and demand limit

• provide an output for the external alarm light indicator

• provide power exhaust ﬁre outputs for direct control of

modulated power exhaust stages during ﬁre or smoke modes

• control of smoke control modes including evacuation, smoke

purge, pressurization, and ﬁre shutdown (modulating power exhaust required)

When the unit is connected to the CCN (Carrier Comfort Network), the following expansion board features can be utilized:

• perform Demand Limit functions based on CCN loadshed

commands or the state of the discrete input

• alarm monitoring of all key parameters

• CCN protocol

• provides CCN IAQ participation

See Carrier TEMP or VVTt (Variable Volume and Temperature) literature for complete TEMP (single zone) or VVT (multi-zone) application information.

REMOTE START/STOP SWITCH (FIELD-SUPPLIED)

Y1 Y2 W1

G C

CONTROL BOX

LEGEND

Field Supplied Wiring

Fig. 14 — Field Control Remote Start/Stop

JUMPER CONNECTION FOR VOLTAGE OUTPUT

JUMPER CONNECTION FOR CURRENT OUTPUT

Fig. 15 — Indoor Air Quality Sensor Conﬁguration

Features with Sensor Control of Unit (Network Applications) — The base control board provides, as standard, a connection for use with a Carrier VVT system and can also be integrated into a Carrier Comfort Network.

When the unit is accessed via a PC equipped with ComfortWorks™, Building Supervisor, or Service Tool software, or accessory LID-2B, the following features can be accessed:

• on-board timeclock can be programmed

• occupancy schedules can be programmed

• unit set points can be changed

• alarms can be monitored

This access is available on the base control board via a RJ-11 phone jack or a 3-wire connection to the communication bus. See Fig. 16. The timeclock has a 10-hour minimum back-up time to provide for unit power off for servicing unit or during unexpected power outages. For complete Carrier Comfort System (CCS) or Carrier Comfort Network (CCN) features and beneﬁts, refer to the product literature.

VARIABLE AIR VOLUME (VAV) APPLICATIONS Features with Stand-Alone Applications — The units, as

shipped, are operable as stand-alone units with the addition of a timeclock to establish unit start and stop times.

Heating and cooling in both on and off modes is controlled to default values by the base unit control. Set points may be changed with appropriate input devices.

The control has an on-board occupancy schedule which can be set using an input device and eliminates the need for an external timeclock.

During both the on and off periods, cooling operation is controlled to the supply air setting and heating is controlled to the return air setting (or to the optional space temperature sensor). During the on period, the supply fan runs continuously.During the off period, the supply fan will be activated if the return air sensor is outside of the set points and will run log enough to accurately sample the space temperature. The supply fan will then continue to run until any heating or cooling load is satisﬁed, at which point it will turn off.

The use of a space sensor will allow for supply air reset to conserve energy and maintain comfort. If equipped with an override feature, the sensor will allow operation during the off period for a ﬁxed length of time.

Base unit control supports a Heat Interlock Relay (ﬁeld supplied) to fully open the VAV terminal devices during heating operation.

Standard features of a VAV unit with a remote start/stop switch are:

• control board diagnostics

• control of an outdoor condenser fan based upon outdoor

air temperature

• control of modulating economizer to provide free cooling

when outdoor conditions are suitable, using supply-air temperature as a set point

• support of remote occupied/unoccupied input to start or

stop the unit

• provide power exhaust output to an external power ex-

haust controller

• support supply-air temperature reset to offset supply air

set point

• support a ﬁeld test for ﬁeld check out

• support linkage to DAV systems

• cooling capacity control of up to 6 stages plus economizer

with compressors and unloaders to maintain supply air temperature set point during occupied periods

• control of one stage of heat to maintain return-air tem-

perature at heating set point during occupied periods

• provide a variable frequency drive high voltage relay out-

put to enable VFD

• control of heat interlock relay

• compressor Time Guard override (power up, minimum off

and on times)

With the addition of a remote start/stop switch heating or cooling is enabled during unoccupied periods as required to maintain space temperature to within unoccupied set points.

Additional features may be provided with Electronic Access to Unit Control Board. These features are:

• additional control board diagnostics

• electronic expansion board features (if installed)

• control of the economizer damper and indoor fan to obtain

unoccupied free cooling

• 365-day timeclock with backup (supports minute, hour, day,

month, and year)

• holiday table containing up to 18 holiday schedules

• occupancy control with 8 periods for unit operation

• support a set of display, maintenance, conﬁguration, serv-

ice, and set point data tables for interface with Building Supervisor, ComfortWorks, or Service Tool software software or accessory LID-2B

When a VAV unit with a space temperature sensor is accessed via a computer, the following additional features are available:

• ability to initiate timed override from T-55 sensors

• temperature compensated start to calculate early start time

before occupancy

• provide space temperature reset to reset the supply air set

point upward when the temperature falls below the occupied cooling set point

An electronic expansion board may be ﬁeld-installed to provide the following features:

• fan status

• ﬁlter status

• ﬁeld-applied status

• demand limiting

• IAQ Sensor

• OAQ Sensor

• alarm light

• ﬁre unit shutdown

• ﬁre pressurization

• ﬁre evacuation

• ﬁre smoke purge

When the unit is connected to the CCN (Carrier Comfort Network), the following expansion board features can be utilized:

• CCN IAQ (indoor air quality) participation

• CCN OAQ (outdoor air quality) participation

• CCN demand limit participation

• modulated power exhaust override

• ability to use multiple space temperature sensors (mul-

tiples of 4 and 9 only) to average space temperature (DAV only)

Aﬁeld-supplied T -55space temperature sensor can be added to monitor room temperature and provide unoccupied override capability (1 hour).

When the unit is equipped with a ﬁeld-supplied space temperature sensor and a remote contact closure (remote start/ stop) the occupied default set points will monitor unit operation. The occupied default set points are 55 F (supply air) cooling and 68 F (return air temperature) heating. See Fig. 14 for remote start/stop wiring.

NOTE: For units without a space temperature sensor and which have not had the base unit control board accessed via software to set an occupancy schedule, the remote start/stop closure will allow the unit to operate in the pre-conﬁgured occupied default set points of 55 F (supply-air temperature) cooling and 68 F (return-air temperature) heating. Without an occupancy schedule, the unit will control to the unoccupied default set points of 90 F (return air) cooling and 55 F (return air) heating.

Features with NetworkApplications —The base control board provides, as standard, a connection for use with a Carrier Comfort System and can also be integrated into a Carrier Comfort Network. When the unit is accessed via a PC equipped with ComfortWorks™, Building Supervisor, or Service Tool software or LID-2B accessory,the following features can be accessed:

• on-board timeclock can be programmed

• occupancy schedules can be programmed

• unit set points can be changed

• alarms can be monitored

This access is available on the base control board via a RJ-11 phone jack or a 3-wire connection to the communication bus. See Fig. 16. The internal timeclock has a 10-hour minimum back-up time to provide for unit power off for servicing unit or during unexpected power outages. For complete Carrier Comfort System (CCS) or Carrier Comfort Network (CCN) features and beneﬁts, refer to the product literature.

Step 8 — Make Electrical Connections

POWER WIRING — Units are factory wired for the voltage shown on the unit nameplate.

When installing units, provide a disconnect per NEC (National Electrical Code) of adequate size (MOCP [maximum overcurrent protection] of unit is on the informative plate). All ﬁeld wiring must comply with NEC and all local codes. Size wire based on MCA (minimum circuit amps) on the unit informative plate. See Fig. 17 for power wiring connections to the unit power terminal block andequipment ground.

The main power terminal block is suitable for use with aluminum or copper wire. See Fig. 17. Units have circuit breakers for compressors, fan motors, and control circuit. If required by local codes, provide an additional disconnectswitch. Whenever external electrical sources are used, unit must be electrically grounded in accordance with local codes, or in absence of local codes, with NEC, ANSI C1-latest year.

All ﬁeld wiring must comply with NEC and local code requirements.

FIELD POWER SUPPLY — Unit is factory wired for voltage shown on unit nameplate. See Table 4 for electrical data.

Field wiring can be brought into the unit from bottom (through basepan and roof curb) or through side of unit (corner post next to control box).

⁄2-in. NPT coupling for ﬁeld power wiring and a

⁄4-in. NPT coupling for 24-v control wiring are provided in basepan. In the side post, there are two 21⁄2-in. (024-034) or 3-in. (038-048) knockouts for the ﬁeld power wiring. See Fig. 3-6. If control wiring is to be brought in through the side of unit, a7⁄8-in. diameter hole is provided in the condenser side post next to the control box.

If disconnect box is mounted to corner post, be careful

not to drill any screws into the condenser coil. Routing Through Bottom of Unit — If wiring is brought in

through bottom of unit, use ﬁeld-supplied watertight conduit to run power wiring from basepan out through bottom 31⁄2-in. hole to the disconnect box and back into unit to the main control box.

Use strain relief going into control box through 2 diameter hole provided. After wires are in unit control box, connect to power terminal block (see Power Wiring section above).

Low-voltage wiring must be run in watertight conduit from the basepan to control box and through

⁄8-in. diameter hole provided in bottom of unit control box. Field-supplied strain relief must be used going into the box. After wiring is in control box, make connections to proper terminals on terminal blocks (see Field Control Wiring section on page 21).

Install conduit connector in unit basepan as shown in Fig. 3-6. Route power and ground lines through connector to terminal connections in unit control box as shown on unit wiring diagram and Fig. 17.

Routing Through Side of Unit — Route power wiring in ﬁeldsupplied watertight conduit into unit through 21⁄2-in. hole. See Fig. 17.

Use ﬁeld-supplied strain relief going into control box through

⁄2-in. diameter hole provided. After wires are in unit con-

2 trol box, connect to power terminal block (see Power Wiring section on this page).

Bring low-voltage control wiring through factory-drilled

⁄8-in. diameter hole in condenser side post. Use strain relief

going into7⁄8-in. diameter hole in bottom of unit control box.

After wiring is in control box, make connection to proper terminals on terminal blocks (see Field Control Wiring section on page 21).

⁄2-in.

LEGEND

CCN — Carrier Comfort Network COM — Common D—Diode LED — Light-Emitting Diode N.C. — Normally Closed

N.O. — Normally Open R—Relay SIO — Serial Input/Output SW — Switch T—Terminal

Fig. 16 — Control Board Diagram

*Where X is the unit control software version number.

Table 4 — Electrical Data

UNIT

SIZE

48E

024

028

030

NOMNAL

VOLTAGE

(3 Ph 60 Hz)

208/230 187 254 39.1 228 25.6 160 2 1 5.3

460 414 508 19.9 114 11.5 80 2 1 2.7

575 518 632 16.0 91 9.6 64 2 1 2.4

208/230 187 254 39.1 228 39.1 228 2 1 5.3

460 414 508 19.9 114 19.9 114 2 1 2.7

575 518 632 16.0 91 16.0 91 2 1 2.4

208/230 187 254 57.1 266 39.1 228 2 1 5.3

460 414 508 25.6 120 19.9 114 2 1 2.7

575 518 632 20.5 96 16.0 91 2 1 2.4

VOLTAGE

RANGE

Min Max RLA LRA RLA LRA Qty Hp

COMPRESSOR

No. 1 No. 2

OFM IFM

POWER

EXHAUST

FLA

Hp FLA FLA LRA FLA MCA MOCP*

(ea)

— — 0.96 101.8/100.3 125/125

16.7/

15.2

23.6 41.6 0.96 125.4/123.9 150/150 — — 0.96 115.9/113.1 150/150

30.8/

28.0

23.6 41.6 0.96 139.5/136.7 175/175 — — 0.96 131.3/127.1 150/150

46.2/

42.0

23.6 41.6 0.96 154.9/150.7 175/175

5 7.6

10 14.0

15 21.0

5 6.1

10 11.0

15 17.0

7.5

7.5 11.0

10 14.0

15 21.0

7.5 9.0

10 11.0

15 17.0

10 14.0

15 21.0

20 27.0

10 11.0

15 17.0

20 22.0

— — 0.50 49.4 60

12.6 23.6 0.50 62.0 80 — — 0.50 55.8 70

12.6 23.6 0.50 68.4 80 — — 0.50 62.8 80

12.6 23.6 0.50 75.4 90 — — 0.50 40.5 50

12.6 23.6 0.50 53.1 60 — — 0.50 45.4 60

12.6 23.6 0.50 58.0 70 — — 0.50 51.4 60

12.6 23.6 0.50 64.0 80 — — 0.96 122.8/120.6 150/150

24.2/

22.0

23.6 41.6 0.96 146.4/144.2 175/175 — — 0.96 129.4/126.6 150/150

30.8/

28.0

23.6 41.6 0.96 153.0/150.2 175/175 — — 0.96 144.8/140.6 175/175

46.2/

42.0

23.6 41.6 0.96 168.4/164.2 200/200 — — 0.50 61.2 80

12.6 23.6 0.50 73.8 90 — — 0.50 64.2 80

12.6 23.6 0.50 76.8 90 — — 0.50 71.2 90

12.6 23.6 0.50 83.8 100 — — 0.50 49.8 60

12.6 23.6 0.50 62.4 70 — — 0.50 51.8 60

12.6 23.6 0.50 64.4 80 — — 0.50 57.8 70

12.6 23.6 0.50 70.4 80 — — 0.96 151.9/149.1 200/200

30.8/

28.0

23.6 41.6 0.96 175.5/172.7 225/225 — — 0.96 167.3/163.1 225/225

46.2/

42.0

23.6 41.6 0.96 190.9/186.7 225/225 — — 0.96 180.5/175.1 225/225

59.4/

54.0

23.6 41.6 0.96 204.1/198.7 250/250 — — 0.50 71.3 90

12.6 23.6 0.50 83.9 100 — — 0.50 78.3 100

12.6 23.6 0.50 90.9 110 — — 0.50 84.3 100

12.6 23.6 0.50 96.9 110 — — 0.50 57.4 70

12.6 23.6 0.50 70.0 90 — — 0.50 63.4 80

12.6 23.6 0.50 76.0 90 — — 0.50 68.4 80

12.6 23.6 0.50 81.0 100

COMBUSTION

FAN MOTOR

See Legend and Notes on page 19.

POWER SUPPLY

Table 4 — Electrical Data (cont)

UNIT

FLA — Full Load Amps HACR — Heating, Air Conditioning and

IFM — Indoor (Evaporator) Fan Motor LRA — Locked Rotor Amps MCA — Minimum Circuit Amps MOCP — Maximum Overcurrent Protection NEC — National Electrical Code OFM — Outdoor (Condenser) Fan Motor RLA — Rated Load Amps

*Fuse or HACR circuit breaker.

NOTES:

1. In compliance with NEC requirements for multimotor and combi-

2. Unbalanced 3-Phase Supply Voltage

NOMINAL

SIZE

VOLTAGE

48E

(3 Ph 60 Hz)

208/230 187 254 57.1 266 57.1 266 2 1 5.3

034

038

nation load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker. Canadian units may be fuse or circuit breaker.

Never operate a motor where a phase imbalance in supply voltage is greater than 2%.

the percent voltage imbalance. % Voltage Imbalance

= 100 x

460 414 508 25.6 120 25.6 120 2 1 2.7

575 518 632 20.5 96 20.5 96 2 1 2.4

208/230 187 254 57.1 266 57.1 266 4 1 5.3

460 414 508 25.6 120 25.6 120 4 1 2.7

575 518 632 20.5 96 20.5 96 4 1 2.4

Refrigeration

max voltage deviation from average voltage

VOLTAGE

RANGE

Min Max RLA LRA RLA LRA Qty Hp

LEGEND

Use the following formula to determine

average voltage

COMPRESSOR

No. 1 No. 2

OFM IFM

FLA

Hp FLA FLA LRA FLA MCA MOCP*

(ea)

10 14.0

15 21.0

20 27.0

10 11.0

15 17.0

20 22.0

10 14.0

15 21.0

20 27.0

10 11.0

15 17.0

20 22.0

EXAMPLE: Supply voltage is 460-3-60.

Determine maximum deviation from average voltage.

(AB) 457 − 452=5v (BC) 464 − 457=7v (AC) 457 − 455=2v

Maximum deviation is 7 v. Determine percent voltage imbalance.

% Voltage Imbalance = 100 x

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.

POWER

EXHAUST

— — 0.96 169.9/167.1 225/200

30.8/

28.0

23.6 41.6 0.96 193.5/190.7 250/225 — — 0.96 185.3/181.1 225/225

46.2/

42.0

23.6 41.6 0.96 208.9/204.7 250/250 — — 0.96 198.5/193.1 250/250

59.4/

54.0

23.6 41.6 0.96 222.1/216.7 275/250 — — 0.50 77.0 100

12.6 23.6 0.50 89.6 110 — — 0.50 84.0 100

12.6 23.6 0.50 96.6 110 — — 0.50 90.0 110

12.6 23.6 0.50 102.6 125 — — 0.50 61.9 80

12.6 23.6 0.50 74.5 90 — — 0.50 67.9 80

12.6 23.6 0.50 80.5 100 — — 0.50 72.9 90

12.6 23.6 0.50 85.5 100 — — 0.96 180.5/177.7 225/225

30.8/

28.0

23.6 41.6 0.96 204.1/201.3 250/250 — — 0.96 195.9/191.7 250/225

46.2/

42.0

23.6 41.6 0.96 219.5/215.3 275/250 — — 0.96 209.1/203.7 250/250

59.4/

54.0

23.6 41.6 0.96 232.7/227.3 275/275 — — 0.50 82.4 100

12.6 23.6 0.50 95.0 110 — — 0.50 89.4 110

12.6 23.6 0.50 102.0 125 — — 0.50 95.4 110

12.6 23.6 0.50 108.0 125 — — 0.50 66.7 80

12.6 23.6 0.50 79.3 90 — — 0.50 72.7 90

12.6 23.6 0.50 85.3 100 — — 0.50 77.7 90

12.6 23.6 0.50 90.3 110

COMBUSTION

FAN MOTOR

AB = 452 v BC = 464 v AC = 455 v

Average Voltage =

457

= 1.53%

POWER SUPPLY

452 + 464 + 455

1371

= 457

Table 4 — Electrical Data (cont)

UNIT

FLA — Full Load Amps HACR — Heating, Air Conditioning and

*Fuse or HACR circuit breaker.

NOTES:

1. In compliance with NEC requirements for multimotor and combi-

2. Unbalanced 3-Phase Supply Voltage

NOMINAL

SIZE

VOLTAGE

48E

(3 Ph 60 Hz)

208/230 187 254 69.2 345 69.2 345 4 1 5.3

044

048

nation load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker. Canadian units may be fuse or circuit breaker.

Never operate a motor where a phase imbalance in supply voltage is greater than 2%.

the percent voltage imbalance. % Voltage Imbalance

= 100 x

460 414 508 28.8 173 28.8 173 4 1 2.7

575 518 632 26.7 120 26.7 120 4 1 2.4

208/230 187 254 82.1 446 69.2 345 4 1 5.3

460 414 508 42.3 223 28.8 173 4 1 2.7

575 518 632 34.6 164 26.7 120 4 1 2.4

Refrigeration

max voltage deviation from average voltage

VOLTAGE

RANGE

Min Max RLA LRA RLA LRA Qty Hp

LEGEND

Use the following formula to determine

average voltage

COMPRESSOR

No. 1 No. 2

OFM IFM

FLA

Hp FLA FLA LRA FLA MCA MOCP*

(ea)

15 21.0

20 27.0

25 34.0

15 17.0

20 22.0

25 27.0

20 27.0

25 34.0

30 40.0

20 22.0

25 27.0

30 32.0

EXAMPLE: Supply voltage is 460-3-60.

Determine maximum deviation from average voltage.

(AB) 457 − 452=5v (BC) 464 − 457=7v (AC) 457 − 455=2v

Maximum deviation is 7 v. Determine percent voltage imbalance.

% Voltage Imbalance = 100 x

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

IMPORTANT:Ifthesupply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.

POWER

EXHAUST

— — 0.96 223.1/218.9 275/275

46.2/

42.0

23.6 41.6 0.96 246.7/242.5 300/300 — — 0.96 236.3/230.9 300/300

59.4/

54.0

23.6 41.6 0.96 259.9/254.5 300/300 — — 0.96 251.7/244.9 300/300

74.8/

68.0

23.6 41.6 0.96 275.3/268.5 300/300 — — 0.50 96.6 125

12.6 23.6 0.50 109.2 125 — — 0.50 102.6 125

12.6 23.6 0.50 115.2 125 — — 0.50 109.6 125

12.6 23.6 0.50 122.2 150 — — 0.50 86.7 110

12.6 23.6 0.50 99.3 125 — — 0.50 91.7 110

12.6 23.6 0.50 104.3 125 — — 0.50 96.7 110

12.6 23.6 0.50 109.3 125 — — 0.96 252.4/247.0 300/300

59.4/

54.0

23.6 41.6 0.96 276.0/270.6 300/300 — — 0.96 267.8/261.0 300/300

74.8/

68.0

23.6 41.6 0.96 291.4/284.6 300/300 — — 0.96 281.0/273.0 300/300

88.0/

80.0

23.6 41.6 0.96 304.6/296.6 350/300 — — 0.50 119.5 150

12.6 23.6 0.50 132.1 150 — — 0.50 126.5 150

12.6 23.6 0.50 139.1 175 — — 0.50 132.5 150

12.6 23.6 0.50 145.1 175 — — 0.50 101.6 125

12.6 23.6 0.50 114.2 125 — — 0.50 106.6 125

12.6 23.6 0.50 119.2 150 — — 0.50 111.6 125

12.6 23.6 0.50 124.2 150

COMBUSTION

FAN MOTOR

AB = 452 v BC = 464 v AC = 455 v

Average Voltage =

457

= 1.53%

POWER SUPPLY

452 + 464 + 455

1371

= 457

IMPORTANT: THE VAV (variable air volume) units use variable frequency drives, which generate, use and can radiate radio frequency energy. If units are not installed and used in accordance with these instructions, they may cause radio interference.They have been tested and found to comply with limits of a Class A computing device as deﬁned by FCC (Federal Communications Commission) regulations, Subpart J of Part 15, which are designed to provide reasonable protection against such interference when operated in a commercial environment.

The unit must be electrically grounded in accordance with local codes and NEC ANSI/NFPA 70 (National Fire Protection Association).

Aff ixcrankcase heater sticker (located in the installers packet)

to unit disconnect switch.

Voltage to compressor terminals during compressor operation must be within the voltage range indicated on the unit nameplate. On 3-phase units, phases must be balanced within 2%. Contact local power company for correction of improper voltage or phase imbalance. Unit failure due to operation of unit on improper line voltage or with excessive phase imbalance constitutes abuse and may cause damage to unit electrical components.

On 208/230-v units, transformer no. 1 is wired for 230-v. If 208/230-v unit is to be run with 208-v power supply, the transformer must be rewired as follows:

1. Remove cap from red (208 v) wire.

2. Remove cap from spliced orange (230 v) wire. Discon-

nect orange wire from black unit power wire.

3. Cap orange wire.

4. Splice red wire and black unit power wire. Cap wires.

Sensor Wiring (CV or VAV) — The temperature sensor is wired into the unit control board. See Fig. 21.

The unit is controlled with a T-55 or T-56 (CV only) zone sensor. Terminal TH (T-56) or T1 (T-55) on the sensor is connected to T1 of the base module board. Terminal COM (T-56) or T2 (T-55) on the sensor is connected to T2 on the base module board. If a T-56 set point override sensor is used, the override connection SW on the sensor is connected to T3 on the base module board.

If more than sensor is being used and averaged, sensors must be wired in multiples of 4 or 9. See Fig. 22.

Heat Interlock Relay — VAV units require a ﬁeld-supplied heat interlock relay (HIR) to drive the air terminal wide open when in heat mode. Heat Interlock relay part number is HN61KK041.

LEGEND

GND — Ground NEC — National Electrical Code TB — Terminal Block

NOTE: Maximum wire size for TB1 is 500 MCM.

Fig. 17 — Field Power Wiring Connections

IMPORTANT: BE CERTAIN UNUSED WIRES ARE CAPPED. Failure to do so may damage the transformers.

FIELD CONTROL WIRING — The unit can use either a Carrier-approved thermostat or a CCN (Carrier Comfort Network) compatible temperature sensor.Thermostats are used on CV (constant volume) units only. Control box diagrams are shown in Fig. 18 and 19.

Thermostat Wiring (CV Only) — Install a Carrier-approved accessory thermostat assembly (per current price pages) according to the installation instructions included with the accessory or these instructions. Locate the thermostat on a solid interior wall in the conditioned space to sense the average temperature.

Route the thermostat cable or equivalent single leads of colored wire from the subbase terminals to the low-voltage connection as shown on unit label wiring diagram and in Fig. 20.

NOTE: For wire runs up to 50 ft, use no. 18 AWG (American Wire Gage) insulated wire (35 C minimum). For 50 to 75 ft, use no. 16AWG insulated wire (35 C minimum). For over 75 ft, use no. 14 AWG insulated wire (35 C minimum). All wire larger than no. 18 AWG cannot be directly connected at the thermostat and will require a junction box and splice at the thermostat.

Set heat anticipators to 0.1 for all voltages.

LEGEND

C—Compressor/Contactor CB — Circuit Breaker DIP — Dual In-Line Package FU — Fuse HR — Heater Relay

IF — Indoor Fan OF — Outdoor Fan PEC — Power Exhaust Controller TB — Terminal Block TRAN — Transformer

Fig. 18 — Control Box Diagram (Sizes 024-034)

C—Contactor/Compressor CB — Circuit Breaker DIP — Dual In-Line Package FU — Fuse HR — Heater Relay

Fig. 19 — Control Box Diagram (Sizes 038-048)

LEGEND

IF — Indoor Fan OF — Outdoor Fan PEC — Power Exhaust Controller TB — Terminal Block TRAN — Transformer

NOTE: Sensor part numbers are as follows:

T-55 — CEC0121448-01 T-56 — CEC0121503-01

Fig. 20 — Field Control Thermostat Wiring

Fig. 21 — Field Control Temperature Sensor Wiring

(CV or VAV Units)

SPACE TEMPERATURE AVERAGING — 4 SENSOR APPLICATION

SPACE TEMPERATURE AVERAGING — 9 SENSOR APPLICATION

Fig. 22 — Space Temperature Averaging Wiring

Remote Field Control — A switch closure across terminals R and W1 on TB-3 will initiate the Occupied mode. This can be done manually as well as through a ﬁeld-supplied timeclock.

Service Tool, Building Supervisor, and ComfortWorks™ Software — Access to the control board can beachieved through the terminal marked CCN via a 3-wire bus.

IMPORTANT: The default bus address is 0. The default element number is 1. Refer to CCN literature to change the default values, if needed.

Carrier Comfort Network Interface — The 48E units can be connected to the CCN. The communication bus wiring is supplied and installed in the ﬁeld. Wiring consists of shielded, 3-conductor cable with drain wire.

The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it, the negative pins must be wired to the negative pins, and the

signal pins must be wired to signal ground pins. Wiring connections for CCN should be made at the 3-pin plug (CCN located at the base board). Consult CCN literature for further information.

Conductors and drain wire must be 20 AWG minimum stranded, 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 C to 60 C (−4 F to 140 F) is required. Table 5 lists cables that meet the requirements.

T able5 — CCN ConnectionApprovedShielded Cables

MANUFACTURER CABLE PART NO.

Alpha 2413 or 5463

American A22503

Belden 8772

Columbia 02525

IMPORTANT: When connecting the CCN communication bus to a system element, use a color coding system for the entire network to simplify installation and checkout. See Table 6.

Table 6 — Color Code Recommendations

SIGNAL

TYPE

Positive (+) RED 1 Ground WHITE 2 Negative (−) BLACK 3

CCN BUS CONDUCTOR

INSULATION COLOR

CCN PLUG

PIN NO.

NOTE: If a cable with a different color scheme is selected, a similar color code should be adopted for the entire network.

At each system element, the shields of the communication bus cables must be tied together. If the communication bus is entirely within one building, the resulting continuous shield must be connected to a ground at one point only.If the communication bus cable exits from one building and enters another, the shields must be connected to grounds at the lightning suppressor in each building where the cable enters or exits the building (one point per building only).

To connect the unit to the network:

1. Turn off power to the control box.

2. Cut the CCN wire and strip the ends of the red (+), white

(ground), and black (−) conductors. (If a different network color scheme is used, substitute appropriate colors.)

3. Remove the 3-pin male plug from the base module in the

main control box, and connect the wires as follows: a. Insert and secure the red (+) wire to terminal 1 of the

3-pin plug.

b. Insert and secure the white (ground) wire to

terminal 2 of the 3-pin plug.

c. Insert and secure the black (−) wire to terminal 3 of

the 3-pin plug.

4. Insert the plug into the existing 3-pin mating connector

on the base module in the main control box.

Step 9 — Make Outdoor-Air Inlet Adjustments

ECONOMIZER NOTE: If accessory power exhaust or barometric relief pack-

ages are being added to the unit, install power exhaust or barometric relief before installing economizer hoods.

Economizer Hood Assembly — The economizer hood is shipped in a package secured to the outside of the unit and must be ﬁeld-assembled. There are 2 hoods on every unit. The 48EW/EY units are side supply and side return. The return duct limits access to economizer ﬁlters from below. Filter tracks (mounting angle without tabs) must be installed correctly to allow access to economizer ﬁlters from each side. Perform the following procedure to assemble the economizer hood:

NOTE: Before assembly of the economizer hood, check along the outer edges of the economizer assembly for any seal strip protruding past the ﬂanges. Trim the excess seal strip so that it is ﬂush with the economizer assembly ﬂanges.

1. Apply black seal strip (provided in package) to outside top-edge of hood sides. Wrapseal strip over edge to cover top ﬂange (4 hood sides). Make sure seal strip covers screw holes. Allow strip to overhang opposite the mounting ﬂange. See Fig. 23.

⁄8-in. past the end

2. Assemble hood sides, top, and cross member with gasketed screws provided. See Fig. 24.

3. Attach 10 green speed clips (provided) to hood top.

4. Apply black seal strip (provided) to mounting ﬂanges of hood sides being sure to cover mounting holes. See Fig. 25.

NOTE: Each hood assembly has a slotted side that should be adjacent to the other hood when mounted to the unit.

5. Apply black seal strip (provided) to hood top mounting ﬂange. Seal strip of hood top mounting ﬂange must press tightly against seal strip of hood side mounting ﬂanges. See Fig. 26.

6. Add gray foam strip (provided in package) to cross members on bottom tray. See Fig. 27.

7. Place gray foam strip (provided) on inside of slotted hood side between ﬁlter and cross member opposite the mounting end. See Fig. 28.

8. Attach gray foam strip (provided) to block-off baffle on outer face of ﬂange. See Fig. 29.

9. Remove the screws on each end and along top of damper assembly of unit. Remove top 2 screws on each side of ﬁlter panel under damper assembly. Set hood assembly in place and attach to unit using these screws.

10. Attach accessory enthalpy bracket on hood side furthest from control box end. Locate bracket on inside upper right-hand corner of economizer hood using hood mounting holes. Mount outdoor-air thermistor to enthalpy bracket (if purchased). Attach and wire enthalpy assembly. Place quick connects on enthalpy wires.

11. Remove screws along bottom of damper assembly. Lo-

cate and mount blockoff baffle using these screws.

12. Assemble 2 ﬁlter tracks side-by-side with the as-

sembled ends together.

13. Attach mounting angle (without tabs) to the assembled

end of the ﬁlter track. See Fig. 30.

14. Attach 6 green speed clips (provided) to mounting angles.

Engagement section of clip faces inside of rack.

15. Attach remaining mounting angle (with tabs) to other

end of the ﬁlter track with no. 10 screws provided. See Fig. 31.

16. Place ﬁlter track assembly in bottom of hood by placing

tabbed end into slotted side (with tab on bottom) and attaching opposite end to hood with speed clips and gasketed screws provided. Tabs can be hand bent after they have been inserted into the side.

NOTE: The ﬁlter track assembly end with screws should face away from the other hood when mounted on the unit.

NOTE: Tabs from both ﬁlter tracks will be in the same space. After one ﬁlter track has been inserted into hood side, bend the tabs so they will not interfere with installation of the second hood.

17. Attach black seal strip (provided) to ﬁlter cover. Seal

strip should be applied to the center of the large ﬂange making sure to cover holes. See Fig. 32.

18. Slide two 20 x 25-in. ﬁlters into cross members of hood

assembly.Attach ﬁlter cover over ﬁlters with screws and speed clips provided.

Minimum Damper Position Setting — Setting of the outdoor air damper position is performed in conjunction with a shortened version of the ﬁeld run test. This is performed by ﬁrst opening DIP (Dual In-line Package) switch no. 4 then no. 6. See Fig. 18 and 19 and Direct Digital Controls DIP Switch Conﬁguration section on page 33.

TOP

FLANGE

BLACK SEAL STRIP

HOOD SIDE

Fig. 23 — Adding Seal Strip to Top of Hood Sides

MOUNTING FLANGE

HOOD SIDE

Fig. 25 — Adding Seal Strip to Mounting Flange of

Hood Sides

HOOD TO

HOOD SIDE

NOTE: Left side economizer hood has mounting angle without tabs and ﬁlter track assembled end on the opposite side.

Fig. 24 — Economizer Hood Assembly

(Right Side Economizer Hood Shown)

Fig. 26 — Adding Seal Strip to Hood Top

Mounting Flange

GRAY FOAM STRIP

CROSS MEMBER

Fig. 27 — Adding Foam Strip to Cross Member

HOOD SIDE (SLOTTED)

HOOD TOP

Fig. 28 — Adding Foam Strip to Hood Side

BLOCKOFF BAFFLE

GRAY FOAM STRIP

Fig. 29 — Adding Foam Strip to Blockoff Baffle

MOUNTING ANGLE (WITHOUT TABS)

FILTER TRACK ASSEMBLY

The outdoor-air damper closes. The control allows 90 seconds for the damper to close in case it is in the full open position. Next, the indoor-fan contactor will energize. The outdoor-air damper will remain at 0% for 30 seconds. It will then move to the 10% position for another 30 seconds. This will be repeated at every 10% increment for 30 seconds until the damper reaches 100% open. Close DIP switch no. 4 during the 30 seconds immediately after the desired outdoor air minimum damper position. The 30-second time period is to allow time where DIP switch no. 4 can be closed. The default value of the minimum outdoor air damper position is 20%. If the desired minimum position is 30%, allows the damper position to go to 10% for 30 seconds, then 20% for 30 seconds, and when it reaches 30% close DIP switch no. 4 during the 30-second period following the 30% position.

The minimum outdoor air damper position is now set. Close DIP switch no. 6.

ECONOMIZER SETTINGS Accessory Enthalpy Control (Fig. 33) — The control

(HH57AC077) is mounted in the economizer hood. See Fig. 24. The enthalpy setting adjustment is on the enthalpy control. For maximum beneﬁt of outdoor air, set enthalpy control to A. See Fig. 34 and 35.

Enthalpy Control Installation — The outdoor air enthalpy control is installed on the inside panel of the outdoor air hood. The enthalpy control should be mounted when the outdoor air hoods are assembled. To install the control, perform the following procedure:

1. Turn off all power. Ensure disconnect is locked out.

2. Remove the economizer inlet ﬁlters from the bottom of

the right hand economizer hood. See Fig. 24. See Fig. 36 for economizer details.

3. Mount the outdoor air enthalpy sensor inside the right econo-

mizer hood on the right side panel of the hood, adjacent to the outdoor-air thermistor.

4. Locate the red, violet, and brown wires near the outdoor

air thermistor. Remove the splice from the red and violet wires. Remove the cap from the brown wire.

5. Install a

⁄4-in. push on terminal (ﬁeld-supplied) on the

violet and brown wires.

6. Connect a

⁄4-in. push on terminal (ﬁeld provided) to one end of a 18-gage, 6-in. jumper wire (ﬁeld-provided). Connect the other end to the red wire and attach a1⁄4-in. push on connector (ﬁeld provided).

7. Connect the red wire with the jumper to terminal TR1. Connect the jumper to terminal 2. Connect the brown wire to terminal TR. Connect the violet wire to terminal 3.All connections are on the enthalpy control.

8. Replace the economizer ﬁlters.

9. Return power to unit.

Accessory Differential Enthalpy Control (Fig. 33) — The control (HH57AC077), in conjunction with the accessory enthalpy sensor (HH57AC078), controls economizer operation according to the differential enthalpy. The control is mounted in the economizer hood. The sensor is mounted in the return duct (48EJ/EK) or return air plenum (48EW/EY).

Fig. 30 — Mounting Angle (Without Tabs)Attached

to Filter Track Assembly

MOUNTING ANGLE (WITH TABS)

Fig. 31 — Mounting Angle (With Tabs) Attached to

Filter Track Assembly

BLACK SEAL STRIP (CENTERED)

5. Turn the enthalpy control set point potentiometer clockwise past the ‘‘D’’setting on the enthalpy control to conﬁgure the control to operate on differential enthalpy. See Fig. 34.

6. Remove the return-air enthalpy sensor from the accessory package. Using the screws provided, mount the sensor inside the return duct near the unit. Do not locate the control too far from the unit, or the wires will not reach from the sensor to the control. On 48EW/EY units, the enthalpy sensor can be installed in the return air section of the unit, under the return air dampers.

7. Route the wires from the enthalpy sensor to the return air enthalpy control through the holes on the inside of the hinged ﬁlter access panel. The holes are blocked by plug buttons which should be removed.

8. Use ﬁeld-supplied wire ties to attach the violet wire to the + terminal and the blue wire to the SR terminal.

9. Replace economizer ﬁlters.

10. Return power to unit. Disable Economizer — For applications where the econo-

mizer will not be used (areas of high humidity), the economizer should be disabled. Todisable the economizer, perform the following:

1. Turn of power. Lock out disconnect.

2. Locate the OAT (Outdoor Air Thermostat) in the right hand outdoor air damper area.

3. Locate the splice connecting the violet wire coming from T24 on the base module board to the red wire coming from T29 on the base module board. Remove the wire nut and break the red to violet wire splice.

4. Cap off both wires. When the connection is broken the base module is fooled into thinking that the enthalpy is not acceptable and economizer operation is disabled.

FILTER COVER

Fig. 32 — Attaching Seal Strip to Filter Cover

DifferentialEnthalpy Sensor Installation — Toinstall the control, perform the following procedure:

1. Turn off all power. Ensure disconnect is locked out.

2. Remove the economizer inlet ﬁlters from the bottom of the right hand economizer hood. See Fig. 24.

3. Remove the factory-installed, 620-ohm jumper between terminals SR and + on the enthalpy control located inside the outdoor air hood.

4. Connect the violet wire from the enthalpy sensor kit to the + terminal on the enthalpy control. Connect the blue wire from the enthalpy sensor kit to the SR terminal on the enthalpy control.

HH57AC077

ENTHALPY CONTROL

HH57AC078

ENTHALPY SENSOR

C7400A1004

(USED WITH ENTHALPY

CONTROL FOR DIFFERENTIAL

ENTHALPY OPERATION)

Fig. 33 — Differential Enthalpy Control and Sensor

NOTE:Switches shown in high enthalpy state. Terminals2 and 3 close on enthalpy decrease.

CONTROL

CURVE

A 73 (23) B 70 (21) C 67 (19) D 63 (17)

CONTROL POINT (APPROX. DEG.)

AT 50% RH

Fig. 34 — Wiring Connections for Solid-State

Enthalpy Control (HH57AC077)

RH — Relative Humidity

Fig. 35 — Psychrometric Chart for

Enthalpy Control

NOTE: Partitions shown indicate both side supply (EW/EY) and vertical supply (EJ/EK) units.

Fig. 36 — Economizer Details

Step 10 — Position Power Exhaust/Barometric ReliefDamper Hood —

been made and adjusted at the factory. The power exhaust blowers and barometric relief dampers are shipped assembled and tilted back into the unit for shipping. Brackets and extra screws are shipped in shrink wrap around the dampers. If ordered, each unit will have 4 power exhaust blowers and motors or 4 barometric relief dampers.

1. Remove 9 screws holding each damper assembly in place. See Fig. 37. Each damper assembly is secured with 3 screws on each side and 3 screws along the bottom. Save screws.

Be careful when tilting blower assembly. Hoods and blowers are heavy and can cause injury if dropped.

2. Pivot each damper assembly outward until edges of damper assembly rest against inside wall of unit.

3. Secure each damper assembly to unit with 6 screws across top (3 screws provided) and bottom (3 screws from Step 1) of damper.

4. With screws saved from Step 1, install brackets on each side of damper assembly.

5. Remove tape from damper blades.

VAV DUCT PRESSURE TRANSDUCER — The VAV duct pressure transducer (VAV inverter pressure transducer) is located behind the ﬁlter access door on the lower inner panel.

All electrical connections have

See Fig. 38. A section of ﬁeld-supplied

⁄4-in. plastic tubing must be run from the high pressure tap on the differential pressure switch and connected to a ﬁeld-supplied tap in the supply-air duct. The tap is usually located2⁄3of the way out on the main supply duct. Remove plug button in panel to route tubing.

The low pressure tap is factory-routed to the atmosphere. For a positive-pressure building, route the high tap to building air and low tap to atmosphere. For a negativepressure building, route the high tap to atmosphere and the low tap to building air.

VAV BUILDING PRESSURE TRANSDUCER — The VAV building pressure transducer (modulating power exhaust pressure transducer) is located behind the ﬁlter access door on the lower inner panel. See Fig. 38. A section of ﬁeldsupplied

⁄4-in. plastic tubing must be run from the high pressure tap on the differential pressure switch to the conditioned space. The pressure tube must be terminated in the conditioned space where a constant pressure is required. This location is usually in an entrance lobby so that the building exterior doors will open and close properly. Remove plug button in panel to route tubing.

NOTES:

1. Unless otherwise speciﬁed, all dimensions are to outside of part.

2. Dimensions are in inches.

3. On 48EW,EY units, accessory barometric relief or power exhaust must be mounted in the ﬁeld-supplied return ductwork.

Fig. 37 — Barometric Relief Damper and Power

Exhaust Mounting Details

Step 11 — Install All Accessories — After all the

factory-installed options have been adjusted, install all ﬁeldinstalled accessories. Refer to the accessory installation instructions included with each accessory.

MOTORMASTERt III INSTALLATION Install Field-Fabricated Wind Baffles — Wind baffles must

be ﬁeld-fabricated for all units to ensure proper cooling cycle operation at low-ambient temperatures. See Fig. 39 for baffle details. Use 20-gage, galvanized sheet metal, or similar corrosion-resistant metal for baffles.Use ﬁeld-supplied screws to attach baffles to unit. Screws should be1⁄4-in. diameter and5⁄8-in. long. Holes for wind baffles are pre-punched in the unit sheet metal.

To avoid damage to the refrigerant coils and electrical components, use recommended screw sizes only.

On 48EJ,EK,EW,EY024-034 units, the wind baffles attach to ﬂanges formed on the outer sheet metal of the unit where the condenser coil tube sheets attach.

On 48EJ,EK,EW,EY038-048 units, the wind baffles attach to ﬂanges formed on the outer sheet metal of the unit corner post. The other end of the baffle is attached to the center panel between the condenser coil and the indoor section. Two baffles are required for 48EJ,EK,EW,EY038-048 units.

Install Motormaster III Controls — Only one Motormaster III control is required per unit.

Motor — The circuit no. 1 (lead compressor) outdoor-fan motor (OFM) will need to be changed out in the ﬁeld to accommodate the Motormaster III accessory. The replacement motor part no. is HD52AK652.

On 48EJ,EK,EW,EY038-048units, only one OFM will need to be changed out. The no. 1 compressor is located at the left side of the unit looking from the compressor end. The circuit no. 2 OFMs are controlled to shut off at 55 F and turn on at 65 F outdoor-air temperature.

Sensor — Install the sensor for thermistor input control in the location shown in Fig. 40A-C. Connect sensor leads to the violet and gray control signal leads on the Motormaster III control.

Signal Selection Switch — Remove the cover of the Motormaster III control. Set the switch to accept the thermistor sensor input signal. Set the frequency to match the unit power supply (60 Hz).

Motormaster III Control — The recommended mounting location is in the indoor fan section, mounted on the panel that separates the indoor and outdoor sections. On VAV units, this location is next to the VFD.

Do not route the Motormaster III wiring next to the VFD on VAV units. Use a separate connector through the partition when wiring to the OFM.

Electrical Connections

When replacing the OFM, reconnect the black, yellow, and blue wires form the outdoor fan contactor to the black, yellow,and blue wires of the Motormaster III control. Run new wires from the red, orange, and brown wires to the leads of the new OFM. Connect the green wire from the control to ground.

NOTE: On all 575-v units, 2 transformers (part no. HT01AH851) must be used for each Motormaster III control to lower the supply voltage to the control to 460-v. Transformers can be mounted anywhere outside the control box.

VAV — Variable Air Volume

Fig. 38 — Pressure Transducer Locations

BOTH SIDES

77.7

0.312 DIA HOLES

17.167 BETWEEN HOLES (TYPICAL)

4.62

CROSS-BREAK

78.7

0.5

To avoid possibility of electrical shock and personal injury, turn off all power to unit before making electrical connections.

NOTE: All dimensions are in inches. Material: 20 gage galvanized steel or other non-corrosive material.

Fig. 39 — Motormaster III Baffle Details

Fig. 40A — Motormaster III Sensor Location

(Sizes 024-034)

Fig. 40B — MotormasterT III Sensor Location

(Sizes 038 and 044)

START-UP

Use the following information and Start-Up Checklist

on page CL-1 to check out unit PRIOR to start-up.

Unit Preparation — Check that unit has been installed

in accordance with these installation instructions and applicable codes.

CompressorMounting — Loosen the compressor hold-

down bolts until sidewise movement of the washer under each holddown bolt head can be obtained. Do not loosen completely as bolts are self-locking and will maintain adjustment.

Service Valves — Ensure that the suction, discharge,

and liquid line service valves are open. Damage to the compressor could result if they are left closed.

Fig. 40C — Motormaster III Sensor Location

(Size 048)

Internal Wiring — Check all electrical connections in

unit control boxes; tighten as required.

Refrigerant Service Ports — Each refrigerant sys-

tem has one suction port located in the top of the compressor motor casing. All units also have one service port on the liquid line valve and one on the compressor discharge valve. Be sure that caps on the ports are tight.

Crankcase Heaters — Crankcase heaters are ener-

gized as long as there is power to the unit, except when the compressors are operating.

IMPORTANT: Unit power must be on for 24 hours prior to start-up. Otherwise, damage to compressor may result.

Variable Frequency Drive (VFD) — The variable

frequency drives are factory set. These settings include factoryinstalled jumpers and software conﬁgurations. The only ﬁeld conﬁgured set point is duct static pressure. An Operation Manual is shipped with each V AV unit. This manual should be used if the drive needs to be customized for a particular application.

NOTE: The VFD will always provide the proper phase sequence to the indoor-fan motor. The indoor-fan motor operates in proper rotation regardless of the phase sequence to the unit. If, upon start-up, the outdoor fans operate backwards but the indoor fan operates in the correct direction, reverse any two leads to the main terminal block. All fans will then operate in the correct direction.

T oset the duct static pressure, perform the following steps. The factory setting is zero. The duct transducer has a range from 0 to 5 in. wg. The transducer output is 4 to 20 mA, therefore, 0 to 5 in. wg is proportional to the 4 to 20 mA and must be expressed to the VFD in terms of percentage of the frequency range. Refer to Table 7. The set point value is a percentage of the maximum output frequency.Locate the duct static pressure closest to that desired and use the corresponding set point value. If necessary, interpolation between duct static pressures is permissible.

To set the VFD, the VFD must be powered up; however, since it is located near the indoor air fan, operation of the fan is not desirable. To disable the fan, perform the following procedure:

1. Open the indoor fan circuit breaker.

2. Remove the jumper between CC and ST on the terminal strip of the VFD (see Fig. 41).

3. Close the indoor fan circuit breaker. The VFD now is powered but the fan will not operate.

4. On the front of the VFD is a keypad and display which will be used to enter the set point. To access this ﬁeld, press the ‘‘PRG’’ key until the display reads ‘‘S.PrG’’ (Speed Group Parameters). Press the arrow key until ‘‘Sr1’’ is displayed. This is the VFD set point listed in Table 7.

5. Press the ‘‘READ/WRITE’’ key.The set point value will be displayed. Use the up-arrow or down-arrow key to adjust the set point value to the value desired.

6. Press the ‘‘READ/WRITE’’ key again to enter the new value.

7. Check the factory default values.

IMPORTANT: The Carrier factory default values for the VFD may be different than the default values of the manufacturer. Refer to the Carrier literature when checking default values.The following default values have been changed from the manufacturer settings to more closely match the VFD operation to a Carrier VAV unit.

SETUP PARAMETERS (Item 6, Point 1, Output Frequency) — The default value should be 20.

JUMP FREQUENCY GROUP (Item 7, PID Set Point Control Select) — The default value is 1.

JUMPFREQUENCYGROUP(Item 8, Proportional Gain) — The default value is 100.

JUMP FREQUENCY GROUP (Item 9, Integral Gain) — The default value is 50.

SPEED GROUP PARAMETERS (Item 2, Multi-Speed Run Frequency No. 1) — The factory setting is 30.

SPEED GROUP PARAMETERS (Item 2, Fire Speed Override Frequency) — The factory setting is 60.

8. Open the indoor fan circuit breaker.

9. Replace the jumper between CC and ST on the terminal strip of the VFD.

10. Close the indoor fan circuit breaker; the VFD now is powered and the fan will operate.

NOTE: Any ﬁeld measurement of supply fan amps must be taken with an RMS meter between the fan circuit breaker and fan contactor (upstream of VFD).

Power Exhaust — The optional non-modulating power

exhaust (CV only) is a two-stage design where the operation of the exhaust fans is linked to economizer position. When the supply fan is running and the economizer is 25% open,

the base module closes contacts, activating two exhaust fans. When the economizer position reaches 75% open, the base module activates the other two exhaust fans. The fans will turn off when the economizer closes below the same points. The economizer position set points that trigger the exhaust fans can be modiﬁed, but only through use of the Service Tool, Comfort Works, or Building Supervisor software. If single-stage operation is desired, adjust the economizer set points to identical values at the desired point to activate all exhaust fans.

The optional modulating power exhaust (VAV standard, CV optional) is controlled by a modular electronic sequencer system. This system consists of a model R353 signal input module and 4 model S353 staging modules. The signal input module receivesa0to10vdcsignal from the building pressure transducer, which is mounted adjacent to the supply static transducer behind the ﬁlter access panel. The modules are mounted just below the unit control board. The left module is the R353, and the 4 modules on the right are S353 modules for stages 1 through 4. On the unit wiring label, the R353 is designated PESC, and the S353 modules are designated PES1 through PES4.

The building pressure transducer range is −0.5 to + 0.5 in. wg. It is powered bya0to10vdcsignal. A factoryinstalled hose at the ‘‘Lo’’ connection leads to atmosphere, and a ﬁeld-supplied hose must be connected to the ‘‘Hi’’connection and led into the building to a point where building pressure is to be controlled (positive-pressure building). There is a plug button in the bulkhead just above the transducers, for use in leading the hoses into the building via the return air ductwork.

There are 3 adjustments at the R353 module, all of which have been factory set. In the center of the circuit board is a set of 4 pins with a jumper, labeled J2. This determines the mode of operation. The bottom two pins must be jumpered for direct operation. Direct operation means that the staging modules are activated in sequence as the input signal increases.

Table 7 — VFD Supply Air Pressure Set Point

PRESSURE

(in. wg)

0 4.0 0

0.25 4.8 3

0.50 5.6 6

0.75 6.4 9

1.00 7.2 12

1.25 8.0 15

1.50 8.8 18

1.75 9.6 21

2.00 10.4 24

2.25 11.2 27

2.50 12.0 30

2.75 12.8 33

3.00 13.6 36

3.25 14.4 39

3.50 15.2 42

VFD — Variable Frequency Drive

CONTROL

(mA)

VFD

SET POINT

FLA FLB FLC P24 RCH LOW FM AM PP RR IV CC ST F R CC SS1 JOG AD2 RST CC

NOTE:Terminalstrip is located inside the VFD at the bottom.

Fig. 41 — VFD Factory-Installed Jumpers

DPDP

(SS3)

(SS2)

–

JUMPERS

At the upper right corner of the board is a set of 5 pins and jumper, which determines the time constant for the control. The time constant is the delay in response built into the controls. The jumper should be on the middle or bottom two pins, for the maximum time constant. The delay can be decreased, if desired, by moving the jumper progressively upward, always jumpering adjacent pins.

At the lower left corner of the board below the terminal strip is a resistor marked R27. This must be removed in order to obtain the 0 to 10 vdc signal output. There will not be a resistor on a factory-supplied module, but a resistor may be present on a replacement module and must be removed.

The R353 module has a terminal block with 7 connections available for wiring. The 2 right-hand terminals are for the 24 vac and common connections. The next 2 terminals are for the 0 to 10 vdc signal. Consult the wiring label for wire identiﬁcation if replacing the module. The 3 left-hand terminals are not used for this application.

The S353 module has an LED (light-emitting diode), a set of 4 jumper pins, and 2 potentiometers. The LED will light whenever the module is activated, providing a visual indication of the number of exhaust fans running. The jumper pins are arranged in a square format. Two jumpers are used to determine the mode of operation (direct or reverse). The 2 jumpers must be arranged horizontally for direct action (factory set).

At the top of the module are two potentiometers. The left potentiometer adjusts the offset. The right potentiometer adjusts the differential. The potentiometers are factory set for a nominal 0 in. wg building pressure.

The offset set point is deﬁned as the point at which a module turns off a fan, and is measured in terms of percent of the input signal. For control purposes, 0 offset is at an arbitrary ‘‘ﬂoor’’ which is established at 10% of the input signal, or 1 vdc. In this example, the ﬁrst stage will turn off at 30% (3 vdc), and the offset potentiometer will be set at 20%. The second stage will turn off at 50% signal (5 vdc), and the offset potentiometer will be set at 40%. The fourth stage is at the maximum 75% offset, which equates to 85% signal or 8.5 vdc. The offset potentiometer is calibrated in 10% increments.

Table 8 relates building pressure to signal level.

Table 8 — Potentiometer Signal Levels

brated in 1% increments, and is factory set at approximately 3%. It is recommended to leave the set point at 3%, to minimize cycling of the fans.

The offset and differential potentiometers have been factory set for atmospheric pressure. Do not change these settings until there is some experience with the building. In most cases the factory settings will be satisfactory. However, if the building pressure is not being maintained as desired, then some minor adjusting on a trial and error basis can be made.

Direct Digital Controls DIP Switch Conﬁguration —

conﬁgured for each application. The DDC board is conﬁgured through the DIP switches located on the board. There are 8 DIP switches which conﬁgure 8 different applications of the DDC. See Table 10. DIP switch 1 is on the left of the block. DIP switch 8 is on the right of the block. To open a DIP switch, push the switch up with suitable tool (smallblade screwdriver). To close a DIP switch, push the switch down. Factory settings are shown in Table 11.

• DIP switch 1 conﬁgures the unit to operate as a VAV or

CV unit

• DIPswitch 2 conﬁgures the unit to use a space sensor (VAV

units) or a thermostat (CV units)

• DIP switch 3 conﬁgures the DDC for use with an elec-

tronic expansion board

• DIP switch 4 is used to ﬁeld test the unit

• DIPswitch 5 is used to enable occupied heating (VAVunits)

or specify the type of power exhaust (CV units)

• DIP switch 6 conﬁgures the Time Guardt override and,

when used with the ﬁeld test function, sets the minimum damper position

• DIP switch 7 conﬁgures the unit for gas heat or electric

heat

• DIP switch 8 conﬁgures the unit for heat pump or air con-

ditioner operation.

The Direct Digital Control (DDC) board must be

The DIP switch conﬁgurations are as follows:

Crankcase Heater — Units are equipped with crank-

case heaters. Crankcase heaters are energized as long as there is power supplied to unit. Crankcase heaters deenergize while compressors are running.

BUILDING PRESSURE

(in. wg)

−0.50 2

−0.25 4

0.00 6

0.25 8

0.50 10

SIGNAL LEVEL

(vdc)

If the building pressure is controlled at 0 in. wg, offset of the ﬁrst stage should be set at 50%, which equates to 60% of the input signal, or 6 vdc. The other stages can then be set as desired between 50% and 75%.

The default offset set points for modulating power exhaust are shown in Table 9.

The differential set point is the difference between the turn off point and the turn on point for each module. It also is calibrated in terms of percent of input signal, and has a range of 1% to 7%. The differential potentiometer is cali-

IMPORTANT:To prevent damage to compressors, crankcase heater should be energized 24-hours prior to start-up.

EvaporatorFan — Fan belt and ﬁxed pulleys are factory-

installed. See Tables 12-16 for fan performance and motor limitations data. Remove tape from fan pulley, and be sure that fans rotate in the proper direction. See Table 17 for air quantity limits. Static pressure drop for power exhaust is negligible. To alter fan performance, see Evaporator Fan Performance Adjustment section on page 46.

Condenser Fans and Motors — Condenser fans and

motors are factory set. Refer to Condenser-Fan Adjustment section on page 47 as required. Be sure that fans rotate in the proper direction. Fan no. 2 (sizes 024-034) and fans no. 3 and 4 (sizes 038-048) are cycled on the outdoor-air temperature.

Table 9 — Power Exhaust Default Set Points

STAGE OFFSET DIFFERENTIAL OFF VOLTAGE ON VOLTAGE

1 50% 3% 6.0 6.3 0.00 2 55% 3% 6.5 6.8 0.06 3 60% 3% 7.0 7.3 0.12 4 64% 3% 7.4 7.7 0.18

OFF STATIC PRESSURE

(in. wg)

Table 10 — DIP Switch Conﬁguration

SETTING 1 2 3 4 5 6 7 8

VAV — Space Sensor

Installed

OPEN VAV

CV — CCN or Sensors

VAV — No Space Sensor

CLOSED CV

LEGEND

CCN — Carrier Comfort Network CV — Constant Volume VAV — Variable Air Volume

Used

CV — Thermostat

Expansion

Board

Base Control

Board Only

Field Test

OFF

VAV —

Occupied

Heat

Enabled

CV —

Modulated

Power

Exhaust

VAV —

Occupied

Heat

Disabled

CV —

Constant

Volume

Power

Exhaust

NOTES:

1. The OPEN side of the DIP switch is marked ‘‘OPEN.’’ When the

2. The conﬁguration of DIP switches 2 and 5 are dependent on DIP

3. When the unit is ﬁeld-tested (DIP switch 4 to OPEN), the function

Time GuardT Override

Time Guard Override

rocker switch is on the ‘‘OPEN’’ side of the switch, the switch is OPEN.

switch 1. If DIP switch 1 is set to OPEN (VAVoperation), then DIP switches 2 and 5 will conﬁgure VAV functions.

of DIP switch 6 changes and it is used to set the minimum damper position.

IN CONJUNCTION WITH FIELD TEST

— Set Minimum

Damper Position

OFF

Gas Heat

Electric Heat

Heat Pump

Operation

Air Conditioner

Operation

Table 11 — DIP Switch Factory Settings

UNIT 12345678

48EJ,EW Closed Closed Closed Closed Closed Closed Open Closed 48EK,EY Open Closed Closed Closed Closed Closed Open Closed

Table 12 — Fan Performance, 48EJ/EK024-034 — Vertical Discharge Units

(For EW/EY units, reduce net available external static pressure by 0.3 in. wg)

AIRFLOW

(Cfm)

4,000 340 0.83 416 1.17 480 1.52 537 1.90 588 2.29 635 2.69 679 3.11 720 3.53 5,000 384 1.25 453 1.61 513 1.99 566 2.39 615 2.79 660 3.21 703 3.64 742 4.08 6,000 432 1.79 495 2.19 550 2.59 600 3.01 647 3.43 690 3.87 730 4.31 769 4.77 7,000 483 2.48 540 2.91 591 3.33 638 3.77 682 4.22 723 4.67 762 5.14 799 5.61 8,000 536 3.33 588 3.78 635 4.23 679 4.69 720 5.16 759 5.64 797 6.12 832 6.61 8,250 549 3.57 600 4.02 646 4.48 690 4.95 730 5.42 769 5.90 806 6.39 841 6.88 9,000 590 4.34 637 4.82 681 5.30 722 5.78 762 6.27 799 6.77 834 7.27 868 7.77

10,000 645 5.54 689 6.04 729 6.54 768 7.04 805 7.56 840 8.07 874 8.59 906 9.12

11,000 701 6.92 741 7.44 779 7.96 816 8.49 850 9.03 884 9.56 916 10.10 947 10.65 12,000 757 8.49 795 9.04 830 9.59 865 10.14 898 10.69 929 11.25 960 11.81 990 12.37 12,500 786 9.36 822 9.92 856 10.47 890 11.03 922 11.60 953 12.16 983 12.73 1012 13.31 13,000 814 10.28 849 10.84 883 11.41 915 11.98 946 12.56 976 13.13 1006 13.71 1034 14.30 13,750 857 11.75 890 12.34 922 12.92 953 13.51 983 14.10 1012 14.69 1041 15.28 1068 15.88 14,000 871 12.27 904 12.86 936 13.45 966 14.05 996 14.64 1025 15.23 1053 15.83 1080 16.43 15,000 929 14.50 960 15.10 990 15.71 1019 16.33 1047 16.94 1074 17.55 1101 18.17 1127 18.79

AIRFLOW

(Cfm)

4,000 759 3.97 796 4.42 831 4.87 865 5.34 897 5.81 929 6.30 959 6.79 988 7.28 5,000 780 4.53 816 4.99 851 5.45 884 5.93 916 6.41 946 6.90 976 7.40 1005 7.91 6,000 805 5.23 840 5.70 874 6.18 906 6.67 937 7.16 968 7.66 997 8.17 1025 8.69 7,000 834 6.09 868 6.57 901 7.07 932 7.56 962 8.07 992 8.58 1020 9.10 1048 9.63 8,000 866 7.10 899 7.60 930 8.11 961 8.62 990 9.14 1019 9.67 1047 10.20 1074 10.74 8,250 874 7.38 907 7.89 938 8.40 968 8.92 998 9.44 1026 9.97 1054 10.50 1081 11.04 9,000 901 8.29 932 8.80 963 9.33 992 9.86 1021 10.39 1049 10.93 1076 11.48 1102 12.03

10,000 938 9.65 968 10.18 997 10.72 1026 11.27 1054 11.82 1081 12.37 1107 12.93 1133 13.49

11,000 977 11.19 1006 11.75 1035 12.30 1062 12.87 1089 13.43 1115 14.00 1141 14.57 1166 15.15 12,000 1019 12.94 1047 13.51 1074 14.08 1100 14.66 1126 15.24 1152 15.83 1177 16.42 1201 17.01 12,500 1040 13.88 1067 14.46 1094 15.05 1120 15.63 1146 16.22 1171 16.82 1195 17.41 — — 13,000 1062 14.88 1089 15.47 1115 16.06 1140 16.66 1166 17.25 1190 17.86 — — — — 13,750 1095 16.48 1121 17.08 1147 17.68 1172 18.29 1196 18.90 — — — — — — 14,000 1106 17.04 1132 17.64 1157 18.25 1182 18.86 — — — — — — — — 15,000 1152 19.41 1177 20.04 1200 20.66 — — — — — — — — — —

0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

AIRFLOW

(Cfm)

4,000 1017 7.79 1045 8.30 1072 8.82 5,000 1033 8.42 1061 8.94 1087 9.46 6,000 1053 9.21 1080 9.73 1106 10.27 7,000 1075 10.16 1102 10.69 1127 11.24 8,000 1100 11.28 1126 11.83 1151 12.38 8,250 1107 11.59 1133 12.14 1158 12.69 9,000 1128 12.58 1153 13.14 1178 13.70

10,000 1158 14.06 1183 14.63 — —

11,000 1190 15.74 ———— 12,000 —————— 12,500 —————— 13,000 —————— 13,750 —————— 14,000 —————— 15,000 ——————

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

3.4 3.6 3.8

Rpm Bhp Rpm Bhp Rpm Bhp

LEGEND Bhp — Brake Horsepower NOTES:

1. Fan performance is based on wet coils, economizer, roof curb,

cabinet losses, and clean 2-in. ﬁlters.

2. Conversion — Bhp to watts:

Watts =

3. Variable Air Volume units will operate down to 70 cfm/ton. Per-

formance at 70 cfm/ton is limited to unloaded operation and may be additionally limited by edb (entering dry bulb) and ewb (entering wet bulb) conditions.

Bhp x 746

Motor efficiency

Table 13 — Fan Performance, 48EJ,EK038,044 — Vertical Discharge Units

(For EW/EY units, reduce net available external static pressure by 0.5 in. wg)

AIRFLOW

(Cfm)

7,000 429 1.70 484 2.40 536 2.70 584 3.10 630 3.50 674 3.90 716 4.30 756 4.80 8,000 475 2.36 525 3.09 571 3.49 616 3.90 658 4.31 699 4.74 738 5.17 776 5.61 9,000 523 3.11 567 3.97 610 4.39 651 4.82 690 5.26 728 5.71 765 6.16 801 6.62

10,000 571 4.00 612 5.01 651 5.46 689 5.91 725 6.37 761 6.84 795 7.31 829 7.79

11,000 620 5.04 658 6.22 694 6.69 729 7.17 763 7.65 796 8.14 829 8.64 860 9.14 12,000 670 6.24 705 7.61 738 8.10 771 8.60 803 9.11 834 9.62 865 10.13 894 10.65 13,000 720 7.61 752 9.19 784 9.70 814 10.23 844 10.75 874 11.29 902 11.82 931 12.36 14,000 771 9.15 801 10.97 830 11.51 859 12.05 887 12.60 915 13.15 942 13.71 969 14.27 15,000 822 10.88 850 12.95 877 13.52 904 14.08 931 14.65 957 15.22 983 15.80 1008 16.38 16,000 873 12.80 899 15.16 925 15.74 951 16.33 976 16.92 1001 17.51 1025 18.11 1049 18.71 17,000 924 14.91 949 17.59 974 18.20 998 18.80 1022 19.41 1045 20.03 1069 20.64 1092 21.26 18,000 976 17.24 999 20.26 1023 20.88 1046 21.51 1068 22.14 1091 22.77 1113 23.41 1135 24.05 19,000 1027 19.77 1050 23.17 1072 23.82 1094 24.46 1115 25.11 1137 25.76 1158 26.42 1179 27.07 20,000 1079 22.53 1100 26.33 1122 27.00 1142 27.66 1163 28.33 1183 29.00 — — — —

AIRFLOW

(Cfm)

7,000 794 5.20 832 5.62 868 6.06 903 6.52 937 6.98 971 7.44 1003 7.92 1035 8.40 8,000 813 6.06 848 6.52 883 6.98 916 7.45 949 7.92 981 8.40 1012 8.89 1042 9.38 9,000 835 7.09 869 7.56 902 8.04 934 8.53 965 9.02 995 9.52 1025 10.02 1054 10.53

10,000 862 8.28 893 8.77 925 9.27 955 9.77 985 10.28 1014 10.79 1043 11.31 1071 11.84

11,000 891 9.64 921 10.15 951 10.67 980 11.19 1008 11.71 1036 12.24 1064 12.78 1090 13.32 12,000 924 11.18 952 11.71 980 12.24 1008 12.78 1035 13.32 1062 13.87 1088 14.42 1114 14.98 13,000 958 12.91 986 13.45 1012 14.01 1039 14.56 1064 15.13 1090 15.69 1115 16.26 1140 16.83 14,000 995 14.83 1021 15.40 1046 15.97 1071 16.55 1096 17.13 1120 17.71 1144 18.29 1168 18.89 15,000 1033 16.96 1058 17.55 1082 18.14 1106 18.73 1130 19.33 1153 19.93 1176 20.54 1199 21.14 16,000 1073 19.31 1097 19.92 1120 20.52 1143 21.14 1165 21.75 1188 22.37 — — — — 17,000 1114 21.88 1137 22.51 1159 23.13 1181 23.76 — — — — — — — — 18,000 1156 24.69 1178 25.33 1199 25.98 — — — — — — — — — — 19,000 ———————————————— 20,000 ————————————————

0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

AIRFLOW

(Cfm)

7,000 1066 8.88 1096 9.38 1125 9.88 8,000 1072 9.88 1101 10.39 1130 10.90 9,000 1083 11.04 1111 11.56 1139 12.08

10,000 1098 12.37 1125 12.90 1152 13.44

11,000 1117 13.86 1143 14.41 1169 14.96 12,000 1139 15.54 1164 16.11 1189 16.68 13,000 1164 17.41 1188 17.99 — — 14,000 1191 19.48 — — — — 15,000 —————— 16,000 —————— 17,000 —————— 18,000 —————— 19,000 —————— 20,000 ——————

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

3.4 3.6 3.8

Rpm Bhp Rpm Bhp Rpm Bhp

LEGEND Bhp — Brake Horsepower NOTES:

1. Fan performance is based on wet coils, economizer, roof curb,

cabinet losses, and clean 2-in. ﬁlters.

2. Conversion — Bhp to watts:

Watts =

3. Variable Air Volume units will operate down to 70 cfm/ton. Per-

formance at 70 cfm/ton is limited to unloaded operation and may be additionally limited by edb (entering dry bulb) and ewb (entering wet bulb) conditions.

Bhp x 746

Motor efficiency

Table 14 — Fan Performance, 48EJ,EK048 — Vertical Discharge Units

(For EW/EY units, reduce net available external static pressure by 0.5 in. wg)

AIRFLOW

(Cfm)

9,000 528 3.20 572 4.00 615 4.40 656 4.90 695 5.30 733 5.80 769 6.20 805 6.70

10,000 577 4.10 617 5.10 657 5.50 694 6.00 731 6.40 766 6.90 801 7.40 834 7.90

11,000 627 5.10 664 6.30 700 6.80 735 7.30 769 7.70 802 8.20 835 8.70 866 9.20 12,000 677 6.30 711 7.70 745 8.20 778 8.70 809 9.20 841 9.70 871 10.20 901 10.80 13,000 728 7.71 760 9.31 791 9.83 822 10.35 851 10.88 881 11.42 909 11.95 938 12.50 14,000 779 9.28 809 11.11 838 11.65 867 12.20 895 12.75 923 13.31 950 13.87 976 14.43 15,000 830 11.03 858 13.13 886 13.69 913 14.26 939 14.83 966 15.41 991 15.99 1017 16.57 16,000 882 12.97 908 15.36 934 15.95 960 16.54 985 17.13 1010 17.73 1034 18.33 1058 18.93 17,000 934 15.12 959 17.83 983 18.44 1008 19.05 1031 19.66 1055 20.28 1078 20.89 1101 21.52 18,000 986 17.47 1010 20.53 1033 21.16 1056 21.79 1078 22.42 1101 23.06 1123 23.70 1145 24.34 19,000 1038 20.05 1061 23.49 1083 24.13 1105 24.78 1126 25.44 1147 26.09 1169 26.75 1190 27.41 20,000 1091 22.84 1112 26.69 1133 27.36 1154 28.03 1174 28.70 1195 29.37 — — — —

AIRFLOW

(Cfm)

9,000 839 7.10 873 7.62 905 8.10 937 8.59 968 9.08 999 9.57 1028 10.08 1057 10.58

10,000 866 8.40 898 8.85 929 9.34 959 9.85 989 10.36 1018 10.87 1047 11.39 1075 11.91

11,000 897 9.70 927 10.24 956 10.76 985 11.28 1013 11.81 1041 12.34 1068 12.87 1095 13.41 12,000 930 11.30 958 11.82 986 12.36 1014 12.90 1041 13.44 1067 13.99 1093 14.54 1119 15.10 13,000 965 13.04 992 13.59 1019 14.15 1045 14.71 1071 15.27 1096 15.84 1121 16.41 1146 16.98 14,000 1002 14.99 1028 15.56 1054 16.14 1079 16.71 1103 17.30 1127 17.88 1151 18.47 1175 19.06 15,000 1041 17.15 1066 17.74 1090 18.34 1114 18.93 1138 19.53 1161 20.13 1184 20.74 — — 16,000 1082 19.52 1105 20.14 1128 20.75 1151 21.37 1174 21.99 1196 22.61 — — — — 17,000 1124 22.14 1146 22.77 1168 23.40 1190 24.03 — — — — — — — — 18,000 1166 24.98 1188 25.63 — — — — — — — — — — — — 19,000 ———————————————— 20,000 ————————————————

0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

AIRFLOW

(Cfm)

9,000 1086 11.10 1114 11.61 1141 12.14

10,000 1102 12.44 1129 12.97 1155 13.51

11,000 1122 13.96 1147 14.51 1173 15.06 12,000 1144 15.66 1169 16.23 1194 16.80 13,000 1170 17.56 1194 18.14 — — 14,000 1198 19.66 ———— 15,000 —————— 16,000 —————— 17,000 —————— 18,000 —————— 19,000 —————— 20,000 ——————

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

3.4 3.6 3.8

Rpm Bhp Rpm Bhp Rpm Bhp

LEGEND Bhp — Brake Horsepower NOTES:

1. Fan performance is based on wet coils, economizer, roof curb,

cabinet losses, and clean 2-in. ﬁlters.

2. Conversion — Bhp to watts:

Watts =

3. Variable Air Volume units will operate down to 70 cfm/ton. Per-

formance at 70 cfm/ton is limited to unloaded operation and may be additionally limited by edb and ewb conditions.

Bhp x 746

Motor efficiency

Table 15 — Fan Performance — Power Exhaust

48EJ,EK,EW,EY024-048 (20 THRU 45 TONS) Airﬂow

(Cfm)

10,100 —- —- —- —- —- —- —- —- —- 0.12 4.03 4520 0.04 4.25 4770 0.23 4.56 5110 10,500 —- —- —- —- —- —- —- —- —- —- —- —- —- —- —- 0.17 4.66 5220 10,900 —- —- —- —- —- —- —- —- —- —- —- —- —- —- —- 0.12 4.75 5330 11,300 —- —- —- —- —- —- —- —- —- —- —- —- —- —- —- 0.07 4.80 5380 11,700 —- —- —- —- —- —- —- —- —- —- —- —- —- —- —- 0.04 4.83 5420

Bhp — Brake Horsepower ESP — External Static Pressure (in. wg) Watts — Input Watts to Motor

ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts

6,500 0.32 2.82 3160 0.70 2.98 3340 — —- —- —- —- —- —- —- —- —- —- —- 6,700 0.23 2.87 3220 0.63 3.03 3400 0.60 3.01 3380 0.82 3.23 3620 —- —- —- —- —- —- 6,900 0.17 2.92 3270 0.59 3.09 3460 0.55 3.07 3440 0.78 3.28 3680 —- —- —- —- —- —- 7,100 0.13 2.93 3290 0.56 3.11 3490 0.49 3.12 3500 0.73 3.34 3740 —- —- —- —- —- —- 7,300 0.09 2.97 3330 0.53 3.15 3530 0.43 3.18 3560 0.68 3.39 3800 —- —- —- —- —- —- 7,500 —- —- —- 0.51 3.19 3580 0.39 3.24 3630 0.64 3.44 3860 —- —- —- —- —- —- 7,700 —- —- —- 0.48 3.23 3620 0.33 3.27 3670 0.59 3.48 3900 0.60 3.69 4140 0.73 3.98 4460 7,900 —- —- —- 0.45 3.27 3670 0.27 3.32 3720 0.54 3.52 3950 0.56 3.74 4190 0.69 4.02 4510 8,100 —- —- —- 0.40 3.33 3730 0.22 3.36 3770 0.49 3.57 4000 0.51 3.78 4240 0.65 4.07 4560 8,500 —- —- —- —- —- —- 0.17 3.47 3890 0.40 3.67 4120 0.41 3.83 4290 0.56 4.12 4620 8,900 —- —- —- —- —- —- 0.00 3.58 4010 0.30 3.77 4230 0.31 3.93 4410 0.47 4.23 4740 9,300 —- —- —- —- —- —- —- —- —- 0.22 3.87 4340 0.20 4.07 4560 0.37 4.37 4900 9,700 —- —- —- —- —- —- —- —- —- 0.16 3.95 4430 0.11 4.17 4670 0.30 4.47 5010

LEGEND

Low Speed Medium Speed High Speed

208 v 230, 460, 575 v 208 v 230, 460, 575 v 208 v 230, 460, 575 v

Table 16 — Motor Limitations

STANDARD EFFICIENCY MOTORS

Nominal

7.5

Maximum

Bhp

5.9 14.6 — — 5,030 87.5

5.9 — 7.9 6.0 5,030 87.5

8.7 22.0 — — 7,334 88.5

9.5 — 12.0 10.0 8,008 88.5

10.2 28.0 — — 8,502 89.5

11.8 — 14.6 12.0 9,836 89.5

15.3 43.8 — — 12,543 91.0

18.0 — 21.9 19.0 14,756 91.0

22.4 62.0 — — 18,363 91.0

23.4 — 28.7 23.0 19,183 91.0

28.9 72.0 — — 23,511 91.7

29.4 — 37.4 31.0 23,918 91.7

35.6 95.0 — — 28,742 92.4

34.7 — 48.0 47.0 28,015 92.4

230 460 575

Maximum Amps

Maximum

Watts

Motor

Efficiency

HIGH EFFICIENCY MOTORS

Nominal

7.5

BHP — Brake Horsepower

NOTE: Extensive motor and electrical testing on the Carrier units has ensured that the full horsepower range of the motor can be utilized with conﬁdence. Using your fan motors up to the horsepower ratings shown on the Motor Limitations table will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.

Maximum

Bhp

5.9 15.8 — 4,918 89.5

5.9 — 7.9 4,918 89.5

8.7 22.0 — 7,078 91.7

9.5 — 12.0 7,728 91.7

10.2 28.0 — 8,298 91.7

11.8 — 15.0 9,600 91.7

15.3 43.8 — 12,273 93.0

18.0 — 21.9 14,439 93.0

22.4 58.2 — 17,853 93.6

23.4 — 28.7 18,650 93.6

28.9 73.0 — 23,034 93.6

29.4 — 36.3 23,432 93.6

35.6 82.6 — 28,374 93.6

34.7 — 41.7 27,656 93.6

Maximum Amps

230 460

Maximum

Watts

Motor

Efficiency

Table 17 — Air Quantity Limits

UNIT

48EJ,EK,EW,EY

024 5730 5950 2000 6,000 10,000 028 5730 5950 2500 7,500 12,500 030 5730 5950 2750 8,250 13,750 034 5730 5950 3000 9,000 15,000 038 7360 9820 3500 10,500 17,500 044 7360 9820 4000 12,000 20,000 048 7360 9820 4500 13,500 22,500

LEGEND

CV — Constant Volume VAV — Variable Air Volume

MINIMUM HEATING

AIRFLOW

(Low Heat)

MINIMUM HEATING

AIRFLOW

(High Heat)

Return-Air Filters — Check that correct ﬁlters are in-

stalled in ﬁlter tracks (see Table 1). Do not operate unit without return-air ﬁlters.

FilterReplacement — To replace ﬁlters, open ﬁlter ac-

cess door (marked with label). Remove inner access panel. Remove plastic ﬁlter retainer in between ﬁlter tracks by sliding and pulling outward. Remove ﬁrst ﬁlter by sliding it out of the opening in ﬁlter track. Locate ﬁlter removal tool, which is shipped next to the return air dampers. Use the ﬁlter removal tool to remove the rest of the ﬁlters.

Outdoor-AirInlet Screens — Outdoor-air inlet screens

must be in place before operating unit.

EconomizerAdjustment— Remove ﬁlter access panel.

Check that outdoor-air damper is closed and return-air damper is open.

Economizer operation and adjustment are described in Sequence of Operation section on this page; and Minimum Damper Position Setting section on page 24.

Gas Heat — Verify gas pressures before turning on heat

as follows:

1. Turn off ﬁeld-supplied manual gas stop, located external

to unit.

2. Connect pressure gage to supply gas tap, located on ﬁeld-

supplied manual shutoff valve (see Fig. 13 on page 13).

3. Connect pressure gage to manifold pressure tap on unit

gas valve.

4. Supply gas pressure must not exceed 13.5 in. wg. Check

pressure at ﬁeld-supplied shut-off valve.

5. Turn on manual gas stop and initiate a heating demand.

Jumper R to W1 in the control box to initiate heat. On VAV units, the RAT (Return-Air Temperature) must be less than or equal to 68 F for heating to be energized. Use the ﬁeld test procedure to verify heat operation. After the unit has run for several minutes, verify that incoming pressure is 5.0 in. wg or greater, and that the manifold pressure is 3.5 in. wg. If manifold pressure must be adjusted, refer to Gas Valve Adjustment section on page 47.

Sequence of Operation

NOTE: Unit is shipped with default values that can be changed through Service Tool, Building Supervisor, or ComfortWorks™ software. See Table 18 for default values.

COOLING, CONSTANT VOLUME (CV) UNITS — On power up, the control module will activate the initialization software of the control board. The initialization software thenreads DIP switch no. 1 position to determine CV or VAV operation. Next, DIP switch no. 2 is read to determine if the control is thermostat or sensor type operation. If switch 2 is

MINIMUM COOLING

AIRFLOW (VAV)

AT FULL LOAD

OPERATION

MINIMUM COOLING

AIRFLOW (CV)

MAXIMUM

AIRFLOW

open,then sensors are employed. If switch no. 2 is closed, thermostat is employed. Initialization clears all alarms and alerts, remaps the input/output database for CV operation, sets maximum heat stages to 2, and sets maximum cool stages to 3. The control reads DIP switch no. 3 and if open, then it sets the internal ﬂag for expansion mode operation.

The ﬁrst time power is sent to the control board after a power outage, power up takes 5 minutes plus a random 1 to 63 seconds.

The TSTAT function performs a thermostat based control by monitoring Y1, Y2, W1, W2, and G inputs. These functions control stages cool1, cool2, heat1, heat2, and indoor fan, respectively. If TSTAT function is NOT selected, the control determines the occupancy state on the Time Schedules or with remote occupied/unoccupied input. If temperature compensated start is active, the unit will be controlled as in the Occupied mode. User-deﬁned set points are shown in Table 18.

The occupied or unoccupied comfort set points must be selected and the space temperature offset input will be used, if present. The Occupied Heat set point default value is 68 F. The Occupied Cool set point default value is 78 F. The Unoccupied Heat set point default value is 55 F. The Unoccupied Cool set point value is 90 F.The control board will set appropriate operating mode and fan control. The control board will turn on indoor fan, if in Occupied mode, or determine if unit is in Unoccupied mode and the space temperature is outside of the unoccupied comfort set points, (Unoccupied Heat or Unoccupied Cool).

The control board will then monitor space temperature against comfort set points and control heating or cooling stages as required. If system is in the Occupied mode, the economizer will operate as required. If the system is in Unoccupied mode, the system will perform nighttime free cool and IAQ (indoor air quality) pre-occupancy purge as required (when functions are enabled via software). Whenever the DX (di-rect expansion) cooling is requested, the outdoor fan will operate.

The control board will operate economizer, run diagnostics to monitor alarms/alerts at all times, and respond to CCN communications to perform any conﬁgured network POC (product outboard control) functions such as time and outdoorair temperature broadcast and Global occupancy broadcast. When the optional expansion I/O board is employed, it will: perform periodic scan and maintain database of expanded I/O points, perform Fire/Smoke control (power exhaust required); and if in Occupied mode perform IAQ control and monitor fan, ﬁlter,demand limit, and ﬁeld-applied status (with accessories).

If thermostats are used to energize the G input, the control will turn on indoor fan without delay and open economizer dampers to minimum position.

Table 18 — User Deﬁned Set Points

SET POINT

NAME

OHSP xx.xF Occupied Heat Set Point 55 to 80 F 68 F OCSP xx.xF Occupied Cool Set Point 55 to 80 F 78 F UHSP xx.xF Unoccupied Heat Set Point 40 to 80 F 55 F UCSP xx.xF Unoccupied Cool Set Point 75 to 95 F 90 F SASP xx.xF Supply Air Set Point 45 to 70 F 55 F OATL xx.xF Hi OAT Lockout Temperature 55 to 75 F 65 F NTLO xx.xF Unoccupied OAT Lockout Temperature 40 to 70 F 50 F RTIO xx.x Reset Ratio 0 to 10 3 LIMT xx.xF Reset Limit 0 to 20° F 10% MDP xxx% Minimum Damper Position 0 to 100% 20%

LOWMDP xxx% IAQS xxxx IAQ Set Point 1 to 5000 PPM 650 PPM

UHDB xx.xF Unoccupied Heating Deadband 0 to 10° F 1° F UCDB xx.xF Unoccupied Cooling Deadband 0 to 10° F 1° F LTMP xxx% Low Temp. Min. Position 0 to 100% 10% HTMP xxx% High Temp. Min. Position 0 to 100% 35% PES1 xxx% CV Power Exhaust Stage 1 Point 0 to 100% 25% PES2 xxx% CV Power Exhaust Stage 2 Point 0 to 100% 75%

CV — Constant Volume IAQ — Indoor Air Quality OAT — Outdoor-Air Temperature

LEGEND

If thermostats are used to deenergize the G input, the control board will turn off indoor fan without any delay and close economizer dampers.

When cooling, G must be energized before cooling can operate. The control board determines if outdoor conditions are suitable for economizer cooling using the standard outdoor air thermistor. For economizer to function for free cooling, the enthalpy must be low, the outdoor air must equal to or less than the High Outdoor Air Temperature Lockout (default is 65 F), the SAT (supply-air temperature) thermistor is NOT in alarm, and outdoor air reading is available. When these conditions are satisﬁed, the control board will use economizer as the ﬁrst stage of cooling.

WhenY1 input is energized, the economizer will be modulated to maintain SATat the deﬁned set point. The default is 55 F. When SAT is above the set point, the economizer will be 100% open. When SAT is below the set point, the economizer will modulate between minimum and 100% open position. When Y2 is energized, the control will turn on compressor no. 1 and continue to modulate economizer as described above. If the Y2 remains energized and the SAT reading remains above the set point for 15 minutes, compressor no. 2 will turn on. If Y2 is deenergized at any time, only the last stage of compression that was energized will be turned off. If outdoor conditions are not suitable for economizer cooling, the economizer will go to minimum position and cycle compressor no. 1 and 2 based on demand from Y1 and Y2 respectively. The compressors will be locked out when the SAT temperature is too low (less than 40 F for compressor no. 1 and less than 45 F for compressor no. 2.) After a compressor is locked out, it can restart after normal time guard period.

The Time Guardt function maintains a minimum off time of 5 minutes, a minimum ON time of 10 seconds, and a minimum delay before starting the second compressor of 10 seconds.

When heating, the heat stages respond to the demand from W1 and W2 of the thermostat input. Heating and cooling will be mutually locked out on demand on a ﬁrst call basis. The heating and the cooling functions cannot be operating simultaneously.

COOLING, VARIABLE VOLUME UNITS — On power up, the control module will activate the initialization software

FORMAT DESCRIPTION LIMITS DEFAULT

Low Temperature Minimum Damper Position Override

0 to 100% 100%

of the control board. The initialization software then reads DIP switch no. 1 position to determine CV or VAV operation. Initialization clears all alarms and alerts, re-maps the input/output database for VAV operation, sets maximum heat stages to 1 and sets maximum cool stages to 6. The control reads DIP switch no. 3 and if open, then it sets the internal ﬂag for expansion mode operation.

The control board will determine if an interface (linkage) is active and if the unit will operate in a Digital Air Volume (DAV) mode. In a DAV system, the room terminals are equipped with microprocessor controls that give commands to the base unit module. If an interface is active, the control will replace local comfort set points, space and return air temperatures and occupancy status with the linkage data supplied.

The control board will determine occupancy status from Time Schedules (if programmed), Remote Occupied/ Unoccupied input, global occupancy, or DAV. If temperature compensated start is active, the unit will be controlled as in the Occupied mode.

NOTE: The temperature compensated start is a period of time calculated to bring the unit on while unoccupied to reach the occupied set point when occupancy occurs.

The control board will set the appropriate operating mode and fan control. The control board will turn VFD on if Occupied mode is evident.

For units equipped with a start/stop switch only (no space temperature sensor), if unoccupied and valid return-air temperature reading is available (either from a sensor or DAV), the control will monitor return-air temperature against Unoccupied Heat and Cool set points.

For units with a start-stop switch and a space temperature sensor, the control board will start the VFD whenever SPT is outside of the set points (Unoccupied Heat or Unoccupied Cool). The VFD may also be started by nighttime thermostat via remote Occupied/Unoccupied input or by a temperature compensated start algorithm. When VFD is running in a normal mode, the control will start heating or cooling as required to maintain supply-air temperature at the supply air set point plus the reset (when enabled). The reset value is determined by SAT (supply-air temperature) reset and/or space temperature reset algorithms. The space temperature reset is only available when enabled through software.

When cooling, the control will energize the power exhaust enable output to the external power exhaust controller, when power exhaust is used.

If occupied, the control will perform economizer control (economizer control same as described above for CV units). If unoccupied, the control will perform nighttime free cool and IAQ pre-occupancy purge as required (when enabled through software). When DX (direct expansion) cooling is called, the outdoor fans will always operate.

The control will run continuous diagnostics for alarms/ alerts; respond to CCN communications and perform any conﬁgured network POC (product outboard controls) functions such as time and outdoor-air temperature broadcast and global broadcast; and perform Fire/Smoke control if equipped with power exhaust.

GAS HEATING, CONSTANT VOLUME (CV) UNITS — The gas heat units incorporate 2 separate systems to provide gas heat. Each system incorporates its own induced-draft motor, Integrated Gas Control (IGC) board, 2 stage gas valve, manifold, etc. The systems are operated in parallel; for example, when there is a call for ﬁrst stage heat, both induceddraft motors operate, both gas valves are energized, and both IGC boards initiate spark.

All of the gas heating control is performed through the IGC boards (located in the heating section). The base module board serves only to initiate and terminate heating operation.

The base module board is powered by 24 vac. When the thermostat or room sensor calls for heating, power is sent from the base module board to W on each of the IGC boards. An LED on the IGC board will be on during normal operation. A check is made to ensure that the rollout switches and limit switches are closed and the induced-draft motors are not running. The induced-draft motors are then energized, and when speed is proven with the hall effect sensor on the motor,the ignition activation period begins. The burners will ignite within 5 seconds.

When ignition occurs the IGC board will continue to monitor the condition of the rollout and limit switches, the hall effect sensor, as well as the ﬂame sensor. If the unit is controlled through a room thermostat set for fan auto., 45 seconds after ignition occurs, the indoor-fan motor will be energized and the outdoor-air dampers will open to their minimum position. If for some reason the overtemperature limit opens prior to the start of the indoor fan blower, on the next attempt, the 45-second delay will be shortened to 5 seconds less than the time from initiation of heat to when the limit tripped. Gas will not be interrupted to the burners and heating will continue. Once modiﬁed, the fan on delay will not change back to 45 seconds unless power is reset to the control. If the unit is controlled through a room sensor, the indoor fan will be operating in the Occupied mode and the outdoor-air dampers will be in the minimum position.

If the unit is controlled with a room sensor in the Unoccupied mode, the indoor fan will be energized through the IGC board with a 45-second delay and the outside-air dampers will move to the IAQ position (generally closed in the Unoccupied mode). If IAQ is not enabled, dampers will move to the minimum position.

When additional heat is required, W2 closes and initiates power to the second stage of the main gas valves. When the thermostat is satisﬁed, W1 and W2 open and the gas valves close interrupting the ﬂow of gas to the main burners. If the call for W1 lasted less than 1 minute, the heating cycle will not terminate until 1 minute after W1 became active. If the unit is controlled through a room thermostat set for fan auto., the indoor-fan motor will continue to operate for an additional 45 seconds then stop and the outdoor-air dampers will

close. If the overtemperature limit opens after the indoor motor is stopped within 10 minutes of W1 becoming inactive, on the next cycle the time will be extended by 15 seconds. The maximum delay is 3 minutes. Once modiﬁed, the fan off delay will not change back to 45 seconds unless power is reset to the control. If the unit is controlled through a room sensor,the indoor fan will be operating in the Occupied mode and turned off after 45 seconds in the Unoccupied mode.

GAS HEATING,VARIABLEAIR VOLUME (VAV) UNITS — All of the gas heating control is performed through the integrated gas control (IGC) board. The base module board serves only to initiate and terminate heating operation.

NOTE: The unit is factory-conﬁgured for disabled occupied heating. DIP switch 5 is used to enable occupied heating (DIP switch 5 set to OPEN).

The base module board is powered by 24 vac. When there is a call for heating (either Morning Warm-Up, Unoccupied, or Occupied modes), power is sent from the base module board to W on each of the IGC boards and W2 of the main gas valve. When heating, the control board will energize a ﬁeld-supplied heat interlock relay output to drive the VAV terminal boxes wide open. The HIR is not required on a DAV system. See Fig. 42. In the Occupied mode the indoor-fan motor will be operating and the outdoor-air dampers will be in the minimum position. In the Unoccupied mode the indoorfan motor will be off, but will energize 45 seconds after the call for heat and the outdoor-air dampers will move to the IAQ Unoccupied position (generally set to closed in the Unoccupied mode). The duct pressure sensor will signal to the variable frequency drive to operate at full speed since all terminals have been driven open. An LED on the IGC board will be on during normal operation. A check is made to ensure that the rollout switches and limit switches are closed and the induced-draft motors are not running. The induceddraft motors are then energized and when speed is proven with the hall effect sensor on the motor, the ignition activation period begins. The burners will ignite within 5 seconds.

When ignition occurs the IGC board will continue to monitor the condition of the rollout and limit switches, the hall effect sensor, and the ﬂame sensor.

If the call for heat lasted less than 1 minute, the heating cycle will not terminate until 1 minute after heat became active. When heating is satisﬁed, the power will be interrupted to the IGC board and W1 and W2 of the main gas valve. If the unit is controlled through a room sensor, the indoor fan will be operating in the Occupied mode and turned off after 45 seconds in the Unoccupied mode.

MORNING WARM-UP (VAV only) (PC Accessed/CCN Operation) — Morning warm-up occurs when the control has been programmed to turn on heat prior to the Occupied mode to be ready for occupancy mode. Morning warm-up is a condition in VAV systems that occurs when the Temperature Compensated Start algorithm calculates a biased occupied start time and the unit has a demand for heating. The warm-up will continue into the occupied period as long as there is a need for heat. During warm-up, the unit can continue heating into the occupied period, even if occupied heating is disabled. When the heating demand is satisﬁed, the warm-up condition will terminate. To increase or decrease the heating demand, use Service Tool software to change the Occupied Heating set point.

NOTE: To utilize Morning Warm-Up mode, the unit occupancy schedule must be accessed via Service Tool, Building Supervisor, or ComfortWorks™ software or accessory LID2B. The PC can access the base control board via the 3-wire communication bus or via an RJ-11 connection to the CCN terminal on the base control board. See Fig. 16.

MORNING WARM-UP (VAV Only) (Stand-Alone Operation) — When the unit operates in stand-alone mode, morning warm-up occurs when the unit is energized in Occupied mode and return-air temperature (RAT)is below 68 F.Warm-up will not terminate until the RAT reaches 68 F. The heat interlock relay output is energized during morning warm-up. (Aﬁeld-installed 24-vdc heat interlock relay is required.) The output will be energized until the morning warm-up cycle is complete. Refer to Fig. 42 for heat interlock relay wiring.

SPACE TEMPERATURE RESET SENSOR (VAV Only) — An accessory space temperature sensor wired to terminals T1 and T2 on the control module is required. Space temperature reset is used to reset the supply-air temperature set point of a VAV system higher, as the space temperature falls below the Occupied Cool set point. As the space temperature falls below the Occupied Cool set point, the supply-air temperature will be reset upward as a function of the reset ratio. (Default is 3.) Reset ratio is expressed in degrees change

TRAN2

CB4

3.2 AMPS

BASE MODULE

CONTROL BOARD

INDOOR FAN RELAY

COM

SECONDARY

24 VOLT

in supply-air temperature per degree of space temperature change. A reset limit will exist which will limit the maximum number of degrees the supply-air temperature may be raised. (Default is 10 F.) Both the reset ratio and the reset limit are user deﬁnable. The sequence of operation is as follows:

1. The on/off status of the unit supply fan is determined.

2. If the fan is ‘‘on,’’ the sequence will check if the system is occupied.

3. If the system is occupied, the sequence will determine if the reset option is enabled.

4. If the reset option is enabled, the sequence will read the space temperature and compare it to the Occupied Cool set point. If the temperature is below the Occupied Cool set point, the algorithm will compute the reset value and compare this value against the reset limit. If it is greater than the reset limit, the sequence will use the reset limit as the reset value.

COM

LEGEND

CB — Circuit Breaker COM — Common HIR — Heat Interlock Relay T—Terminal TRAN — Transformer

T29

Fig. 42 — Heat Interlock Relay Wiring

BASE MODULE

CONTROL BOARD

(+) T11

(–) T12

INPUT DEVICE

LEGEND

T—Terminal NOTE: The 4 to 20 mA input is a ﬁeld-supplied non-

Carrier EMS (Energy Management System) device.

Fig. 43 — Space T emperature Reset Wiring

4-20 mA

INPUT

FIELD

SUPPLIED

HIR

FIELD

INSTALLED

(HN61KK040)

(24V, 9.5VA)

mA INPUT DEG. F RESET

4 0.00 5 1.25 6 2.50 7 3.75 8 5.00

9 6.25 10 7.50 11 8.75 12 10.00 13 1 1.25 14 12.50 15 13.75 16 15.00 17 16.25 18 17.50 19 18.75 20 20.00

Space Temperature Reset Example — The occupied cooling set point is set to 73 F.The Reset Ratio is set to 5. The Reset Limit is set to 20° F. The Reset Ratio determines how many degrees F the temperature is reset. At 72 F, the supply temperature will be reset 5 degrees higher. At 71 F, the supply temperature will be reset 10 degrees higher.At 70 F, the supply temperature will be reset 15 degrees higher.At 69 F, the supply temperature will be reset 20 degrees higher and the Reset Limit will have been reached.

SUPPLY AIR TEMPERATURE RESET — Supply air temperature reset is used to reset the supply air temperature utility.A 4 to 20 mA signal (ﬁeld-supplied) is required. The reset option does not require enabling.

POWER EXHAUST OPERATION — The optional power exhaust packages are factory- or ﬁeld-installed with vertical units and optionally installed in the return air ductwork for horizontal applications. The standard (offered with constant volume or variable air volume units) and the modulating power exhaust (offered on VAV units) are the two packages offered. The modulating power exhaust package is equipped with a ﬁeld-adjustable static pressure controller to stage up to 4 power exhaust stages which will maintain a building static pressure. The blue controller located in the control box below the control board can be adjusted, by removing the covers and adjusting the set point dial to the desired building pressure. The blue controller monitors the 4 individual sequencers which activate the 4 individual power exhaust motors. The standard power exhaust package controls up to 2 stages of power exhaust to maintain building pressure. The power exhaust package can be conﬁgured to deliver positive or negative building pressure. These power exhaust stages are staged according to a percentage of the economizer dampers position. Default values are 25% for Stage 1 and 75% for Stage 2. This package has set points that are adjustable through software (Service Tool, Building Supervisor, or ComfortWorks™).

SMOKE CONTROL MODES — The 48EJ,EK,EW,EYunits with an optional expansion board perform ﬁre and smoke control modes. The expansion board provides 4 modes which can be used to control smoke within the conditioned area. The modes of operation are ﬁre shutdown, pressurization, evacuation, and smoke purge. See Table 19.

SMOKE DETECTOR — A smoke detector can be used to initiate ﬁre shutdown. This can be accomplished by a set of normally closed pilot relay contacts which will interrupt power from the 24-v transformer, secondary ‘‘B’’ terminal to the control circuit breaker (CB4). See Fig. 44. The wire that connects these two points is white and labeled ‘‘W78.’’

NOTE: On standard gas models, the indoor fan will continue to run 45 seconds after the call for heat has been terminated. If ﬁre shutdown is initiated the fan will stop immediately. No 45-second delay will occur.

The smoke detector may be mounted in the return air duct

or the supply duct. Carrier does not make recommendations

Fig. 44 — Field-Supplied Smoke Detector Wiring

as to speciﬁc smoke detector location due to liability considerations.

INDOORAIR QUALITY CONTROL — The accessory expansion board and accessory IAQ sensor are required for IAQ control. The Carrier sensors operate witha4to20mAsignal. The 4 to 20 mA signal is connected to T11 (+) and T12 (−) on the expansion board for the IAQ sensor, and T13 (+) and T14 (−) on the expansion board for the OAQ (Outdoor Air Quality) sensor. The sensor is ﬁeld-mounted and wired to the expansion board installed in the unit main control box. The IAQ sensor must be powered by a ﬁeld-supplied 24-v power supply (ungrounded). Do not use the unit 24-v power supply to power the sensor.

Once installed, the sensor must be enabled. The sensor is conﬁgured with default values which may be changed through network access software. To work properly, the IAQ sensor high and low reference points for the sensor that is used must match the conﬁgured values. The expansion board reacts to a 4 to 20 mA signal from the IAQ sensor. The low reference (4 mAoutput) must be conﬁgured to the minimum IAQ sensor reading. The high reference (20 mA output) must be conﬁgured to the maximum IAQ sensor reading.

The IAQ sensor can be conﬁgured to either low or high priority. The priority value can be changed by the user. The default is low.

Low priority — When the priority is set to low, the initial control is to the IAQ set point, but the outside air damper position will change to its minimum position when the following conditions occur:

• CV units with sensor — when the space temperature is greater than the occupied cooling set point plus 2° F or when the space temperature is less than the occupied heating set point minus 2° F.

• VAV units and CV units with thermostat — when the supply-air temperature is less than the supply-air temperature set point minus 8° F or when the supply-air temperature is greater than the supply air temperature set point plus 5° F for 4 minutes.

Table 19 — Smoke Control Modes

DEVICE PRESSURIZATION SMOKE PURGE EVACUATION FIRE SHUTDOWN

Economizer 100% 100% 100% 0% Indoor Fan/VFD ON ON OFF OFF Power Exhaust (all outputs) OFF ON ON OFF Heat Stages OFF OFF OFF OFF HIR ON ON OFF OFF

LEGEND

HIR — Heat Interlock Relay VFD — Variable Frequency Drive

• When the outdoor air quality is greater than the outdoor air quality set point (ppm)

High priority — When the priority is set to high, the IAQ set point controls the outside air damper exclusively, with no regard to comfort conditioning.

TIME GUARDt CIRCUIT — The TimeGuard function (built into the rooftop control board) maintains a minimum off time of 5 minutes, a minimum on time of 10 seconds, and a 10-second delay between compressor starts.

CRANKCASE HEATER — Unit main power supply must remain on to provide crankcase heater operation. The crankcase heater in each compressor keeps oil free of refrigerant while compressor is off.

HEAD PRESSURE CONTROL — Each unit has a fan cycling, outdoor thermostat to shut off the outdoor-fan motor(s) at 55 F (one outdoor-fan motor on 024-034 units and two outdoor fan motors on 038-048 units). The head pressure control permits unit to operate with correct condensing temperatures down to 35 F outdoor-air temperature.

MOTORMASTERt III CONTROL — The Motormaster III Solid-State Head Pressure Control is a ﬁeld-installed accessory fan speed control device actuated by a temperature sensor. It is speciﬁcally designed for use on Carrier equipment and controls the condenser-fan motor speed in response to the saturated condensing temperature. For outdoor temperatures down to −20 F, it maintains condensing temperature at 100 F. Refer to the accessory Motormaster installation instructions for more information.

CAPACITY CONTROL, COOLING — The cooling capacity staging tables are shown in Tables 20 and 21.

FIELD TEST — The ﬁeld test program is initiated by moving up DIP switch no. 4 to the OPEN position. The outdoorair damper will close. The control allows 90 seconds for the damper to close in case it was in the full open position. Next, the indoor-fan contactor will be energized, and the outsideair damper will begin to open to its default value of 20% and stay at that position for a short period of time. The outdoorair damper will then open to its full open position and stay at that position for a short period of time. The outdoor-air damper will then close.

If the unit is equipped with power exhaust, stage 1 will be energized for 5 seconds. If the unit is conﬁgured for stage 2 of power exhaust, stage 2 will be energized for 5 seconds after the ﬁrst stage is deenergized.

The ﬁrst stage of heat will be energized for 30 seconds, after which the second stage heat will be energized for an additional 30 seconds. Heat is then deenergized.

The last step is the Cooling mode. Outdoor-fan contactor no. 1 is energized. This is followed by each stage of cooling energized with a 10-second delay between stages. After this is complete, outdoor-fan contactor no. 2 is energized for 10 seconds.

The compressors will now deenergize, followed by the outdoor-fan contactors and indoor-fan contactors. If the unit is equipped with the Integrated Gas Control (IGC) board, the indoor fan will continue to operate for an additional 30 seconds after deenergizing the circuit.

The ﬁeld test is then complete.

SERVICE

T able20 — Cooling Capacity Staging Table,CV Units

with 2 Compressors

Stages

Compressor 1 off off on on Compressor 2 off off off on

NOTE:OnCV units that require additional unloading, add suction pressure unloaders to Compressor 1 only.

Economizer

T able21 — CoolingCapacity StagingTableV AV Units

with 2 Compressors and 2 Unloaders*

Stages

0123456

Compressor 1 offonononononon

Unloader 1 off on on off on on off Unloader 2 off on off off on off off

Compressor 2 off off off off on on on

*40 ton units have only one unloader.

Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury.

ServiceAccess — All unit components can be reached

through clearly labelled hinged access doors. These doors are not equipped with tiebacks, so if heavy duty servicing is needed, either remove them or prop them open to prevent accidental closure.

Each door is held closed with 3 latches. The latches are secured to the unit with a single See Fig. 45.

Fig. 45 — Door Latch

⁄4-in.-20x1⁄2-in. long bolt.

To open, loosen the latch bolt using a7⁄16-in. wrench. Pivot the latch so it is not in contact with the door. Open the door. To shut, reverse the above procedure.

NOTE: Disassembly of the top cover may be required under special service circumstances. It is very important that the orientation and position of the top cover be marked on the unit prior to disassembly. This will allow proper replacement of the top cover onto the unit and prevent rainwater from leaking into the unit.

IMPORTANT:After servicing is completed, make sure door is closed and relatched properly, and that the latches are tight. Failure to do so can result in water leakage into the evaporator section of the unit.

Cleaning — Inspect unit interior at beginning of each heat-

ing and cooling season and as operating conditions require. Remove unit side panels and/or open doors for access to unit interior.

MAIN BURNERS — At the beginning of each heating season, inspect for deterioration or blockage due to corrosion or other causes. Observe the main burner ﬂames and adjust if necessary.Check spark gap. See Fig. 46. Refer to Main Burners section on page 48.

FLUE GAS PASSAGEWAYS — The ﬂue collector box and heat exchanger cells may be inspected by removing gas section access panel (Fig. 3-6), ﬂue box cover, collector box, and main burner assembly (Fig. 47 and 48). Refer to Main Burners section on page 48 for burner removal sequence. If cleaning is required, clean all parts with a wire brush. Reassemble using new cerafelt high-temperature insulation for sealing.

COMBUSTION-AIR BLOWER — Clean periodically to assure proper airﬂow and heating efficiency. Inspect blower wheel every fall and periodically during heating season. For the ﬁrst heating season, inspect blower wheel bi-monthly to determine proper cleaning frequency.

To inspect blower wheel, remove heat exchanger access panel. Shine a ﬂashlight into opening to inspect wheel. If cleaning is required, remove motor and wheel assembly by removing screws holding motor mounting plate to top of combustion fan housing (Fig. 47 and 48). The motor, scroll, and wheel assembly can be removed from the unit. Remove scroll from plate. Remove the blower wheel from the motor shaft and clean with a detergent or solvent. Replace motor and wheel assembly.

EVAPORATOR COIL — Remove access panels and clean as required with commercial coil cleaner.

CONDENSER COIL — Clean condenser coil annually and as required by location and outdoor-air conditions. Inspect coil monthly; clean as required.

CONDENSATE DRAIN — Check and clean each year at start of cooling season. In winter, keep drains and traps dry.

FILTERS — Clean or replace at start of each heating and cooling season, or more often if operating conditions require. Refer to Table 1 for type and size.

NOTE: The unit requires industrial grade throwaway ﬁlters capable of withstanding face velocities up to 625 fpm.

OUTDOOR-AIR INLET SCREENS — Clean screens with steam or hot water and a mild detergent. Do not use disposable ﬁlters in place of screens. See Fig. 24 for location of screens (ﬁlter track assembly).

Lubrication

COMPRESSORS — Each compressor is charged with the correct amount of oil at the factory. The correct oil charge is shown in Table 1. If oil is visible in the compressor sight glass, check unit for operating readiness as described in Start-Up section, then start the unit. Observe oil level and add oil, if required, to bring oil level in compressor crankcase up to between1⁄4and1⁄3of sight glass during steady operation.

If oil charge is above until the compressor crankcase heater has been energized for at least 24 hours with compressor off.

When additional oil or a complete charge is required, use only Carrier-approved compressor oil:

Petroleum Specialties, Inc. .................Cryol 150

Texaco, Inc. .........................Capella WF-32

Witco Chemical Corp. ...................Suniso 3GS

IMPORTANT: Do not use reclaimed oil or oil that has been exposed to the atmosphere. Refer to Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants section, for procedures to add or remove oil.

FAN SHAFT BEARINGS — Lubricate bearings at least every 6 months with suitable bearing grease. Do not over grease. Typical lubricants are given below:

MANUFACTURER LUBRICANT

Texaco Regal AFB-2*

Mobil Mobilplex EP No. 1

Sunoco Prestige 42

Texaco Multifak 2

*Preferred lubricant because it contains rust and oxidation inhibitors.

⁄3sight glass, do not remove any oil

Fig. 46 — Spark Gap Adjustment

CONDENSER-AND EVAPORAT OR-FAN MOTORBEARINGS — The condenser- and evaporator-fan motors have permanently-sealed bearings, so no ﬁeld lubrication is necessary.

NOTES:

1. Torque set screws on blower wheel to 70 in. lbs ± 2 in. lbs.

2. Torque set screw on propeller fan to 15 in. lbs ± 2 in. lbs.

3. Dimensions are in inches.

Fig. 47 — Typical Gas Heating Section

Fig. 48 — Gas Heat Section Details

Evaporator Fan Performance Adjustment (Fig.49) —

in Table 1 (factory speed setting).

IMPORTANT: Check to ensure that the unit drive matches the duct static pressure using Tables 12-14.

To change fan speeds, change pulleys. To align fan and motor pulleys:

1. Shut off unit power supply.

2. Loosen fan shaft pulley bushing.

Fan motor pulleys are designed for speed shown

3. Slide fan pulley along fan shaft.

4. Make angular alignment by loosening motor from mounting plate.

5. Retighten pulley.

Evaporator Fan Service and Replacement

1. Shut off unit power supply.

2. Remove supply-air section panels.

3. Remove belt and blower pulley.

4. Loosen setscrews in blower wheels.

5. Remove locking collars from bearings.

6. Remove shaft.

7. Remove venturi on opposite side of bearing.

8. Lift out wheel.

9. Reverse above procedure to reinstall fan.

10. Check and adjust belt tension as necessary.

Belt Tension Adjustment — To adjust belt tension:

1. Shut off unit power supply.

2. Loosen motor mounting nuts and bolts. See Fig. 50.

3. Loosen fan motor nuts.

4. Turn motor jacking bolts to move motor mounting plate left or right for proper belt tension. A slight bow should be present in the belt on the slack side of the drive while running under full load.

5. Tighten nuts.

6. Adjust bolts and nut on mounting plate to secure motor in ﬁxed position. Recheck belt tension after 24 hours of operation. Adjust as necessary.

Evaporator-Fan Motor Replacement

1. Shut off unit power supply.

2. Remove upper outside panel and open hinged door to gain access to motor.

3. Fully retract motor plate adjusting bolts.

4. Loosen the two rear (nearest the evaporator coil) motor plate nuts.

5. Remove the two front motor plate nuts and carriage bolts.

6. Slide motor plate to the rear (toward the coil) and remove fan belt(s).

7. Slide motor plate to the front and hand tighten one of the rear motor plate nuts (tight enough to prevent the motor plate from sliding back but loose enough to allow the plate to pivot upward).

8. Pivot the front of the motor plate upward enough to allow access to the motor mounting hex bolts and secure in place by inserting a prop.

9. Remove the nuts from the motor mounting hex bolts and remove motor.

10. Reverse above steps to install new motor.

Condenser-Fan Adjustment

1. Shut off unit power supply.

2. Remove fan guard.

3. Loosen fan hub setscrews.

4. Adjust fan height on shaft using a straightedge placed across venturi and measure per Fig. 51.

5. Fill hub recess with permagum if rubber hubcap is missing.

6. Tighten setscrews and replace panel(s).

7. Turn on unit power.

Power Failure — The economizer damper motor is a

spring return design. In event of power failure, dampers will return to fully closed position until power is restored.

Refrigerant Charge — Amount of refrigerant charge

is listed on unit nameplate and in Table 1. Refer to Carrier GTAC II; Module 5; Charging, Recovery, Recycling, and Reclamation section for charging methods and procedures.

Unit panels must be in place when unit is operating dur-

ing charging procedure. NOTE: Do not use recycled refrigerant as it may contain

contaminants. NO CHARGE — Use standard evacuating techniques. After

evacuating system, weigh in the speciﬁed amount of refrigerant (refer to Table 1).

LOW CHARGE COOLING — Using appropriate cooling charging chart (see Fig. 52 and 53), add or remove refrigerant until conditions of the appropriate chart are met. Note that charging chart is different from those normally used. An accurate pressure gage and temperature sensing device are required. Measure liquid line pressure at the liquid line service valve using pressure gage. Connect temperature sensing device to the liquid line near the liquid line service valve and insulate it so that outdoor ambient temperature does not affect reading.

Using the above temperature and pressure readings, ﬁnd the intersect point on the appropriate cooling charging chart. If intersection point on chart is above line, add refrigerant. If intersection point on chart is below line, carefully reclaim some of the charge. Recheck suction pressure as charge is adjusted.

NOTE: Indoor-air cfm must be within normal operating range of unit. All outdoor fans must be operating.

Fig. 49 — Evaporator-Fan Alignment and

Adjustment

Thermostatic Expansion Valve (TXV) — Each cir-

cuit has a TXV. The TXV is nonadjustable and is factory set to maintain 10 to 13° F superheat leaving the evaporator coil. The TXV controls ﬂow of liquid refrigerant to the evaporator coils.

Gas Valve Adjustment

NATURAL GAS — The 2-stage gas valve opens and closes in response to the thermostat or limit control.

When power is supplied to valve terminals 3 and 4, the pilot valve opens to the preset position. When power is supplied to terminals 1 and 2, the main valve opens to its preset position.

The regular factory setting is stamped on the valve body (3.5 in. wg).

To adjust regulator:

1. Set thermostat at setting for no call for heat.

2. Turn main gas valve to OFF position.

3. Remove

manometer pressure-measuring device.

4. Set main gas valve to ON position.

5. Set thermostat at setting to call for heat.

6. Remove screw cap covering regulator adjustment screw

(See Fig. 54).

7. Turn adjustment screw clockwise to increase pressure or

counterclockwise to decrease pressure.

8. Once desired pressure is established, set thermostat set-

ting for no call for heat, turn off main gas valve, remove pressure-measuring device and replace and screw cap.

⁄8-in. pipe plug from manifold. Install a water

⁄8-in. pipe plug

Fig. 50 — Belt Tension Adjustment

Fig. 51 — Condenser-Fan Adjustment

Fig. 53 — Cooling Charging Chart,

48EJ,EK,EW,EY038-048

Main Burners — For all applications, main burners are

factory set and should require no adjustment. MAIN BURNER REMOVAL (Fig. 55)

1. Shut off (ﬁeld-supplied) manual main gas valve.

2. Shut off power to unit.

3. Remove heating access panel.

4. Disconnect gas piping from gas valve inlet.

5. Remove wires from gas valve.

6. Remove wires from rollout switch.

7. Remove sensor wire and ignitor cable from IGC board.

8. Remove 2 screws securing manifold bracket to basepan.

9. Remove 4 screws that hold the burner support plate flange to the vestibule plate.

10. Lift burner assembly out of unit.

11. Reverse procedure to re-install burners.

Fig. 52 — Cooling Charging Chart,

48EJ,EK,EW,EY024-034

Filter Drier — Replace whenever refrigerant system is

exposed to atmosphere.

Protective Devices

COMPRESSOR PROTECTION Overcurrent — Each compressor has one manual reset, cali-

brated trip, magnetic circuit breaker. Do not bypass connections or increase the size of the circuit breaker to correct trouble. Determine the cause and correct it before resetting the breaker.

Overtemperature — Each 06D type compressor (024-038 units) has an internal protector to protect it against excessively high discharge gas temperatures.

Crankcase Heater — Each compressor has a crankcase heater to prevent absorption of liquid refrigerant by oil in the crankcase when the compressor is idle. Since power for the crankcase heaters is drawn from the unit incoming power, main unit power must be on for the heaters to be energized.

IMPORTANT: After a prolonged shutdown or service job, energize the crankcase heaters for 24 hours before starting the compressors.

EVAPORATOR FANMOTOR PROTECTION — A manual reset, calibrated trip, magnetic circuit breaker protects against overcurrent. Do not bypass connections or increase the size of the breaker to correct trouble. Determine the cause and correct it before resetting the breaker. If the evaporator-fan motor is replaced with a different horsepower motor, resizing of the circuit breaker is required. Contact Carrier Application Engineering.

CONDENSER-FAN MOTOR PROTECTION — Each condenser-fan motor is internally protected against overtemperature.

HIGH- AND LOW-PRESSURE SWITCHES — If either switch trips, or if the compressor overtemperature switch activates, that refrigerant circuit will be automatically stopped. See Compressor Lockout Logic section on this page.

FREEZE PROTECTION THERMOSTAT (FPT) — Freeze protection thermostats are located on the evaporator coil for each circuit. One is located at the top and bottom of each circuit. It detects frost build-up and turns off the compressor, allowing the coil to clear. Once the frost has melted, the compressor can be reenergized.

Compressor Lockout Logic — If any of the safe-

ties trip, the circuit will automatically reset (providing the safety has reset) and restart the compressor in 15 minutes. If any of the safeties trip 3 times within a 90-minute period, then the circuit will be locked out and will require manual resetting by turning off either the unit disconnect or the control circuit breaker, or opening the thermostat.

Replacement Parts — A complete list of replacement

parts may be obtained from any Carrier distributor upon request.

Fig. 54 — Gas Valve

Relief Devices — All units have relief devices to pro-

tect against damage from excessive pressures (i.e., ﬁre). These devices are installed on the suction line, liquid line, and on the compressor.

Power Circuit — A typical power wiring schematic is

shown in Fig. 56.

Control Circuit, 115-V — This control circuit is pro-

tected against overcurrent by a 5.0 amp circuit breaker (CB3). Breaker can be reset. If it trips, determine cause of trouble before resetting. A typical 115-v control wiring schematic is shown in Fig. 57 and 58.

Control Circuit, 24-V — This control circuit is pro-

tected against overcurrent by a 3.2 amp circuit breaker (CB4). Breaker can be reset. If it trips, determine cause of trouble before resetting. A typical 24-v control wiring schematic is shown in Fig. 59 and 60.

Fig. 55 — Main Burner Removal

LEGEND and NOTES for Fig. 56-60 — Typical Wiring Schematics

LEGEND

AHA — Adjustable Heat Anticipator BP — Building Pressure BR — Burner Relay C—Contactor, Compressor CAP — Capacitor CB — Circuit Breaker CC — Cooling Compensator CCB — Controller Circuit Breaker CCH — Crankcase Heater COM — Communication COMP — Compressor Motor CR — Control Relay DM — Damper Motor DP — Duct Pressure EC — Enthalpy Control EQUIP — Equipment FLA — Full Load Amps FPT — Freeze Protection Thermostat FU — Fuse GRD — Ground GVR — Gas Valve Relay HPS — High-Pressure Switch HS — Hall Effect Sensor HV — High Voltage IDM — Induced-Draft Motor

NOTES:

1. Connect TRAN1 to H4 for 460 v units. Connect to H3 for 230 v. If

2. Connect TRAN2 to black lead for 460 v units. Connect to orange

3. Circuit breaker must trip amps are equal to or less than 156% FLA

4. If any of the original wire furnished must be replaced, it must be

5. Compressors and/or fan motors are thermally protected.

6. Three phase motors are protected against primary single phasing

7. Red wire and violet wire are spliced together at the factory. The

IFC — Indoor Fan Contactor IFCB — Indoor Fan Circuit Breaker IFM — Indoor-Fan Motor IFR — Indoor-Fan Relay IGC — Integrated Gas Unit Controller IP — Internal Protector L—Light LPS — Low-Pressure Switch MGV — Main Gas Valve NC — Normally Closed NO — Normally Open OAT — Outdoor-Air Thermistor OFC — Outdoor-Fan Contactor OFM — Outdoor-Fan Motor PEC — Power Exhaust Contactor PEM — Power Exhaust Motor PES — Power Exhaust Sequencer PESC — Power Exhaust Sequencer

PL — Plug Assembly R—Relay RAT — Return-Air Thermistor RS — Rollout Switch SAT — Supply-Air Thermistor TB — Terminal Block

Controller

TC — Thermostat Cooling TH — Thermostat Heating TRAN — Transformer UL — Compressor Unloader VFD — Variable Frequency Drive

208/230 v units are run with a 208 v power supply connect to H2. lead for 230 v units. If 208/230 v units are run with a 208 v power

supply connect to red lead. for CB1 and CB2. All others are 140%. replaced with type 90 C wire or its equivalent.

conditions. brown wire has a wire nut added at the factory.

Terminal (Marked) Terminal (Unmarked)

Terminal Block Splice

Factory Wiring Field Wiring To Indicate Common Potential Only,

Not To Represent Wiring

THE FOLLOWING COMPRESSORS HAVE TWO PARALLEL WIRES RUN FROM TB1

(NOT SHOWN ON LABEL DIAGRAM)

COMPRESSOR

MODEL 06D-537 208/230-3-60 2

TABLE A

TO THE COMPRESSORS

VOLTAGE

WIRE

QUANTITY

THEFOLLOWING FANMOTORS HAVETWO PARALLELWIRES RUN FROM TB1 TO THE

(NOT SHOWN ON LABEL DIAGRAM)

INDOOR

MOTOR

20 HP 208/230-3-60 2

TABLE B

FAN MOTORS

VOLTAGE

WIRE

QUANTITY

Fig. 56 — Typical Power Schematic; 48EJ,EK,EW,EY024-034; 208/230-3-60 and 460-3-60

Fig. 57 — Typical VAV 115-v Control Circuit

Fig. 58 — Typical CV 115-v Control Circuit

Fig. 59 — Typical VAV 24-v Control Circuit

Fig. 60 — Typical CV 24-v Control Circuit

TROUBLESHOOTING

Typical refrigerant circuiting diagrams are shown in Fig. 61-63. An algorithm diagram of the IGC (Integrated Gas Unit Controller) control is shown in Fig. 64.

LEGEND

FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch

Fig. 61 — Typical Refrigerant Circuiting (48EJ,EK,EW,EY024-034)

LEGEND

FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch

Fig. 62 — Typical Refrigerant Circuiting (48EJ,EK,EW,EY038,044)

LEGEND

FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch

Fig. 63 — Typical Refrigerant Circuiting (48EJ,EK,EW,EY048)

LEGEND

IDM — Induced-Draft Motor IGC — Integrated Gas Unit Controller

NOTE: Thermostat Fan Switch in the ‘‘AUTO’’ position or sensor-equipped unit.

Fig. 64 — IGC Control (Heating and Cooling)

The alarm codes for the IGC control board are shown in

Table 22.

Table 22 — IGC Control Board LED Alarms

INDICATION ERROR MODE

ON Normal Operation

OFF Hardware Failure

1 FLASH Fan ON/OFF Delay Modiﬁed 2 FLASHES Limit Switch Fault 3 FLASHES Flame Sense Fault 4 FLASHES 4 Consecutive Limit Switch Faults 5 FLASHES Ignition Lockout Fault 6 FLASHES Induced Draft Motor Fault 7 FLASHES Rollout Switch Fault 8 FLASHES Internal Control Fault

Diagnostic LEDs — There are 3 LEDs (red, yellow,

and green) on the lower right hand side of the control board. The red light is used to check unit operation and alarms. A constant pulse is normal unit operation. A series of quick blinks indicates an alarm. Refer to Table 23 below for a description of alarms. The yellow LED blinks during transmission with the CCN (Carrier Comfort Network). The green LED blinks during transmission with the expansion board.

Table 23 — Control Board LED Alarms

LED Blinks Error Code Description Troubleshooting Comments

1 — Normal Operation

2 HF-13 Compressor 1 Safety

3 HF-14 Compressor 2 Safety

4 HF-15 Thermostat Failure 5 HF-05 SAT Thermistor Failure 6 HF-06 OAT Thermistor Failure 7 HF-03 Space Temp. Sen. Failure

8 HF-12 RAT Thermistor Failure

9 SE-05

10 HF-16 Control Board Failure

11 HF-17 Expansion Board Failure

DIP — Dual In-Line Package VAV — Variable Air Volume

Loss of Communications with Expansion Board

The expansion board and control board ﬂash the red LED in one-second intervals when the board is operating properly.

The high or low pressure safety switch for compressor no. 1 has opened for 3 seconds. The error will be cleared and compressor no. 1 will be allowed to turn on in 15 minutes. If the safeties have been tripped 3 times in 90 minutes, compressor no. 1 will be locked out until the control board has been manually reset.

The high or low pressure safety switch for compressor no. 2 has opened for 3 seconds. The error will be cleared and compressor no. 2 will be allowed to turn on in 15 minutes. If the safeties have been tripped 3 times in 90 minutes, compressor no. 2 will be locked out until the control board has been manually reset.

The thermostat is calling for both heating and cooling at the same time. The unit will operate on a ﬁrst call basis and will automatically reset.

The supply-air temperature (SAT) sensor has failed. First check for wiring errors, then replace sensor.

The outside air temperature (OAT) sensor has failed. First check for wiring errors, then replace sensor.

The space temperature sensor has failed. First check for wiring errors, then replace sensor.

The return-air temperature (RAT) sensor has failed. Ensure that the unit is a VAVunit. If NOT a VAVunit set DIP switch position 1 to the closed position and reset power. Then check for wiring errors. Finally, replace sensor.

Communications between the expansion board and the control board have been interrupted. Ensure that an expansion board is installed and wired using the wire harness supplied with the expansion module. If an expansion board is not used ensure that DIP switch position 3 is in the closed position, and reset power.

Generated when hardware has failed on control board. Replace the control board.

Generated when hardware has failed on the expansion board. Replace the expansion board.

Tables 24-26 show the input and output channel

designations.

Table 24 — I/O Channel Designations Base Module — CV

TERMINAL NO. ASSIGNMENT TERMINAL NO. ASSIGNMENT

T1-2 SPT (CCN) — 10KV Thermistor T23-25 Compressor 2 Safety — DI (24 vac) T3-4 STO (CCN) — 10KV Thermistor T24-25 Outside Air Enthalpy — DI (24 vac) T5-6 OAT — 5KV Thermistor T26-27 Economizer Pos. — AO (4-20 mA) T7-8 SAT — 5KV Thermistor T28-29 Heat 1 Relay — DO (24 vac)

T9-10 — T30-29 Heat 2 Relay — DO (24 vac) T11-12 SAT Reset — AI (4 to 20 mA) T31-32 CV Power Exhaust 1/Modulating Power Exhaust — DO (115 vac) T13-14 — T33-32 CV Power Exhaust2—DO(115vac) T15-16 — T34-35 Condenser Fan — DO (115 vac) T17-25 Y1 or Remote Start/Stop — DI (24 vac) T36-35 OFC2 — DO (115 vac) T18-25 Y2 — DI (24 vac) T37-38 — T19-25 W1 — DI (24 vac) T39-38 — T20-25 W2 — DI (24 vac) K1 Indoor Fan Relay — DO (LV) T21-25 G — DI (24 vac) K2 Compr.1—DO(HV) T22-25 Compressor 1 Safety — DI (24 vac) K3 Compr.2—DO(HV)

Table 25 — I/O Channel Designations Base Module — VAV

TERMINAL NO. ASSIGNMENT TERMINAL NO. ASSIGNMENT

T1-2 SPT (CCN) — 10KV Thermistor T23-25 Compressor 2 Safety — DI (24 vac) T3-4 RAT — 5KV Thermistor T24-25 Outside Air Enthalpy — DI (24 vac) T5-6 OAT — 5KV Thermistor T26-27 Economizer Pos. — AO (4-20 mA)

T7-8 SAT — 5KV Thermistor T28-29 Heat 1 Relay − DO (24 vac)

T9-10 — T30-29 Heat Interlock Relay — DO (24 vac) T11-12 SAT Reset — AI (4 to 20 mA) T31-32 Modulated Power Exhaust — DO (115 vac) T13-14 — T33-32 — T15-16 — T34-35 Condenser Fan — DO (115 vac) T17-25 Remote Start/Stop — DI (24 vac) T36-35 OFC2 — DO (115 vac) T18-25 — T37-38 Unloader1—DO(115vac) T19-25 — T39-38 Unloader2—DO(115vac) T20-25 — K1 Indoor Fan Relay — DO (LV) T21-25 — K2 Compr. 1 (HV) T22-25 Compressor 1 Safety — DI (24 vac) K3 Compr.2—DO(HV)

Table 26 — I/O Channel Designations Expansion Module (Field-Installed) — CV and VAV

TERMINAL NO. ASSIGNMENT TERMINAL NO. ASSIGNMENT

T1-2 — T23-25 Fire — Evacuation — DI (24 vac) T3-4 — T24-25 Fire — Smoke Purge — DI (24 vac) T5-6 — T26-27 — T7-8 — T28-29 —

T9-10 — T30-29 Alarm Light Indicator — DO (24 vac) T11-12 IAQ Indoor — AI (4 to 20 mA) T31-32 Power Exhaust Fire No.1—DO(115vac) T13-14 IAQ Outdoor — AI (4 to 20 mA) T33-32 Power Exhaust Fire No.2—DO(115vac) T15-16 — T34-35 Power Exhaust Fire No.3—DO(115vac) T17-25 Fan Status — DI (24 vac) T36-35 Power Exhaust Fire No.4—DO(115vac) T18-25 Filter Status − DI (24 vac) T37-38 — T19-25 Field Applied Status — DI (24 vac) T39-38 — T20-25 Demand Limit — DI (24 vac) K1 — T21-25 Fire — Unit Shutdown — DI (24 vac) K2 — T22-25 Fire — Pressurization — DI (24 vac) K3 —

LEGEND (Tables 24-26)

AI — Analog Input AO — Analog Output CCN — Carrier Comfort Network CV — Constant Volume DI — Direct Input DO — Direct Output HV — High Voltage IAQ — Indoor Air Quality

NOTE: For 4 to 20 mA signals, all even numbered terminals are negative (−) polarity, and all odd numbered terminals are positive (+) polarity.

KV — Kilo-Ohms LV — Low Voltage OAT — Outdoor-Air Temperature OFC — Outdoor Fan Contactor RAT — Return-Air Temperature SAT — Supply-Air Temperature SPT — Space Temperature STO — Space Temperature Offset T—Terminal VAV — Variable Air Volume

PACKAGED SERVICE TRAINING

Our packaged service training programs provide an excellent way to increase your knowledge of the

equipment discussed in this manual. Product programs cover:

• Unit Familiarization • Maintenance

• Installation Overview • Operating Sequence

A large selection of product, theory, and skills programs is available. All programs include a video cassette and/or slides and a companion booklet. Use these for self teaching or to conduct full training sessions.

For a free Service Training Material Catalog (STM), call 1-800-962-9212. Ordering instructions are included.

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

Book 1 Tab 1a

PC 111 Catalog No. 564-962 Printed in U.S.A. Form 48E-5SI Pg 62 8-97 Replaces: 48E-3SI

START-UP CHECKLIST

MODEL NO.: SOFTWARE VERSION (SEE FIG. 16) DATE:

SERIAL NO.: TECHNICIAN:

PRE-START-UP:

M VERIFY THAT DIP SWITCH SETTINGS ARE CORRECT M VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT M REMOVE ALL SHIPPING HOLDDOWN BOLTS AND BRACKETS PER INSTRUCTIONS M VERIFY INSTALLATION OF ECONOMIZER HOOD M VERIFY INSTALLATION OF ALL OPTIONS AND ACCESSORIES M VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS M VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT M CHECK GAS PIPING FOR LEAKS M CHECK THAT INDOOR-AIR FILTERS ARE CLEAN AND IN PLACE M VERIFY THAT UNIT IS LEVEL WITHIN TOLERANCES M CHECK FAN WHEELS AND PROPELLERS FOR LOCATION IN HOUSING/ORIFICE, AND VERIFY SETSCREW

IS TIGHT

M VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED M VERIFY THAT SUCTION, DISCHARGE, AND LIQUID SERVICE VALVES ON EACH CIRCUIT ARE OPEN

START-UP

ELECTRICAL

SUPPLY VOLTAGE L1-L2

COMPRESSOR AMPS — COMPRESSOR NO. 1 L1 L2 L3

— COMPRESSOR NO. 2 L1 L2 L3

SUPPLY FAN AMPS (CV) EXHAUST FAN AMPS

(VAV) *

*VAV fan supply amps reading must be taken with a true RMS meter for accurate readings. M ADJUST VARIABLE FREQUENCY DRIVE (VFD) TO APPLICATION REQUIREMENTS.

TEMPERATURES

OUTDOOR-AIR TEMPERATURE RETURN-AIR TEMPERATURE COOLING SUPPLY AIR GAS HEAT SUPPLY AIR

PRESSURES

GAS INLET PRESSURE

L2-L3 L3-L1

F DB (Dry Bulb) FDB F WB (Wet Bulb) F

IN. WG GAS MANIFOLD PRESSURE STAGE NO. 1 REFRIGERANT SUCTION CIRCUIT NO. 1 REFRIGERANT DISCHARGE CIRCUIT NO. 1

M VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGE 48

IN. WG STAGE NO. 2 IN. WG

PSIG CIRCUIT NO. 2 PSIG PSIG CIRCUIT NO. 2 PSIG

CL-1

GENERAL

M SET ECONOMIZER MINIMUM VENT POSITION TO JOB REQUIREMENTS M ENSURE DRIVES OPERATE WITHIN LIMITS OF FAN PERFORMANCE TABLES

HIGH PRESSURE SWITCH SETTING LOW PRESSURE SWITCH SETTING

psig

psig MOTOR PULLEY PART NUMBER FAN PULLEY PART NUMBER BELT PART NUMBER BELT SIZE in. FILTER QUANTITY FILTER SIZES in.

ADDITIONAL NOTES:

_______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________

CUT ALONG DOTTED LINE CUTALONG DOTTED LINE

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

Book 1 Tab 1a

PC 111 Catalog No. 564-962 Printed in U.S.A. Form 48E-5SI Pg CL-2 8-97 Replaces: 48E-3SI

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Carrier 48EJ, EY024-048 User Manual 2

Specifications and Main Features

Frequently Asked Questions

User Manual