Carrier 50DL User Manual

Number One Air Conditioning

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mstaflation, Start-Up and Service Instructions

Carrier Parkway • Syracuse NY 13221

Single-Package Cooling Units

INSTALLATION

Rigging and Unit Placement — Inspect unit for

transportation damage. File claim with transporta tion agency. Do not remove shipping skid until unit is ready to be set in final location. Do not drop unit; keep upright. Use spreader bars over unit to prevent sling or cable damage. Rollers may be used to move unit across a roof. Level by using unit frame as reference. See Fig. 1 for additional information.

Unit weight is shown in Table 1.

Fig. 1 — Rigging Details

Units are designed to be hoisted only. However, units with optional shipping skids may be moved with a fork truck. Refer to Accessory Roof Curb

Installation Instructions for additional information

as required.

Roof Curb — Assemble and install as described in

instructions shipped with this accessory. Accessory

roof curb and information required to field fabricate

a roof curb of 2-in. x 14-in. planks is shown in Fig. 2.

Install insulation, cant strips, roofing and flashing as required. For unit drains to function properly, curb

must be level or within tolerances shown in Fig. 3.

Roof Mount — Check building codes for weight

distribution requirements. Unit weight is shown

in Table 1.

Slab Mount — Provide a level concrete slab that

extends beyond unit cabinet at least 6 inches. Make a slab 8 in. thick with 4 in. above grade. Use gravel apron in front of condenser air inlet to prevent grass and foliage from obstructing airflow.

Alternate Unit Support Methods — Where the

preferred curb or slab mount cannot be used, support unit with sleepers on perimeter, using curb support area. However, if sleepers cannot be used, support long sides of unit (dimension “A,” Fig. 4)

with 4-in. X 4-in. pads equally spaced on each side. Unit may sag if supported by corners only.

Positioning — Unit condenser air inlets and outlets

may be located in any compass direction since they are not affected by wind. Provide clearances around and above unit for airflow, safety and service access (Fig. 4).

Do not install unit in an indoor location. Do not locate air inlets near exhaust vents or other sources of contaminated air.

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

Field-Fabricated Ductwork — Secure all ducts to

building structure. Use flexible duct connectors be tween unit and ducts as required. Insulate and weatherproof all external ductwork, joints and all

roof openings with flashing and mastic in accord

ance with applicable codes.

Carrier Corporation 1983 Form 50DL-1SI

Roof Curb Dimensions

Insulate ducts passing thru unconditioned spaces

and cover with a vapor barrier.

Maintain one-in. minimum clearance between supply air duct and any combustible material for at least 3 ft of duct run from unit.

Unit is shipped set up for thru-the-bottom duct connections. Ductwork openings are shown in

Fig. 4.

Economizer Section

ECONOMIZER HOODS INSTALLATION (Fig.

5) — The economizer mechanism and all electrical connections are factory installed and adjusted except as noted below. Hood assembly, outdoor air

inlet screens and required hardware are shipped separately and must be field installed. Units have 2 hood assemblies.

Install economizer hoods and enthalpy control

as follows:

1. Loosen unit top panel sheet metal screws above outdoor air inlet opening.

2. Assemble hood top panel, side panels and

support channel.

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3. Insert hood flange between unit top panel flange and unit. Slots are provided in hood flange to clear sheet metal screws. Tighten sheet metal screws. Apply RTV sealant to surfaces as shown in Fig. 5.

4. Secure hood side panels to outdoor air opening flanges, using screws provided.

5. Install hood support bracket(s) between U-

channel and support channel.

6. Install screen retainer on support channel,

using screws in the slots. Do not tighten.

8. Remove enthalpy control assembly from ship ping location on horizontal deck in return air filter compartment.

9. Using 4 no. 10-1/2 screws from envelope in con trol assembly junction box, mount enthalpy control assembly to inside of economizer hood side panel nearest condenser section (Fig. 4).

Fig. 3 — Unit Leveling Tolerances

10. Route the red and yellow wires thru knockout in side plate. Wrap end of blue wire with electrical tape. Using wire connectors from envelope in

junction box, wire enthalpy control assembly as

shown in Fig. 6. Use strain reliefs from envelope on side plate and junction box.

11. Install outdoor air screens.

12. Push retainer snugly against screens and tighten screws.

Exhaust Air Hood Installation — The optional

power exhaust package hood damper assemblies and required sheet metal screws are shipped in the compartment at right of indoor air fan motor com partment. Using screws provided, install a hood damper assembly over each exhaust air opening as shown in Fig. 4. Power exhaust is applied only to economizer units using bottom duct connections.

Exhaust fan and motor assembly is factory wired and adjusted. Refer to Service, Power Exhaust Air Fan Adjustment if required.

Indoor Air Fans — The fan belt and pulleys are

factory installed and adjusted. If required, adjust as described in Service, Indoor Air Fan Adjustment.

Condensate Drains — See Fig. 4 for drain loca

tions. Condensate drain is open to atmosphere and must be trapped. Install a trapped drain line at con nection to be used. Trap must be at least 3in. deep

and made of flexible material or be installed to pre vent freeze-up.

Condensate drain pan under unit is fitted with a one-in. FPT coupling. A gasket is shipped taped to this drain. Install gasket in unit basepan opening or alternate opening on end of unit.

Field Power Supply — Unit is factory wired for

voltage shown on nameplate. The main power ter minal block is suitable for use with aluminum or copper wire. Units have circuit breakers for com pressors, fan motors and control circuit. If required by local codes, provide an additional disconnect switch.

If an external electrical source is used, unit must be electrically grounded in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI Cl-1978.

All field wiring must comply with National Elec trical Code and local requirements.

Install conduit connector in unit basepan or side panel openings provided as shown in Eig. 4. Route power lines thru connector to terminal connections

in control box as shown in Fig. 8, 9 and 10.

Affix crankcase heater sticker to unit disconnect

switch.

Voltage to compressor terminals during com pressor operation must be within voltage range indicated on unit nameplate. Also, see Tables 2 and

3. Phases must be balanced within 2%. Contact local power company for correction of improper voltage or phase unbalance. Failure due to operation of unit on improper line voltage or with excessive phase unbalance constitutes abuse and may cause damage to unit electrical components.

Field Control Wiring

STANDARD UNIT (WITHOUT ENERGY MANAGEMENT OPTION) — Install a Carrier-

approved accessory electronic thermostat on a sub

base (or a transmitter on subbase if remote sensor is used) per installation instructions included with the accessory. Note that the subbase must be used oh constant volume units without night setback. Locate thermostat, or remote sensor, if used, in the condi tioned space where it will sense average temperature.

Route thermostat cable or equivalent single leads of no. 18 AWG colored wire from subbase terminals thru connector on unit to low-voltage connections in main control box as shown on unit wiring dia gram and in Pig. 8.

UNITS WITH ENERGY MANAGEMENT OPTION — In addition to the standard control box, units with Energy Management option are also equipped with a remote box and a night setback box. The remote box contains a 7-day time clock, a bypass switch that can manually bypass the time clock for up to 5 hours, 6 indicator lights and 2 terminal blocks for field wiring connections. Mount this box remote from the unit in an indoor or

Table 1 — Physical Data

UNIT 50DL OPERATING WEIGHT (lb)

Base Unit Economizer 225 250 Roof Curb 200 225

COMPRESSOR

Quantity...Type Quantity Cylinders (ea)...Rpm 4 1750 4 6 1750 Capacity Steps (%) (Standard) 50, 100 60, 100

With Accessory Unloaders 25, 50, 75, 100

Capacity Steps (%) (Variable Volume)

With Electric Unloaders

REFRIGERANT CHARGE

System 1...System 2 (lb) 37 0 37 0 53 0 42 0

OUTDOOR AIR FANS

Quantity...Diameter (in.) 3 30 4 30 Nominal Cfm 21,000

Motor Hp...Rpm 1 1050

CONDENSER COIL

Rows...Fins/in. 3 158

Total Face Area (sq ft)

INDOOR AIR FANt

Quantity...Size (in.) Maximum Allowable Rpm Nominal Cfm Standard Motor and Drive

Motor Hp Motor Frame Size

Single Speed Two Speed

Fan Pulley Pitch Diameter (in.) Fan Pulley Bore I’Me Single-Speed Motor Rpm

Two-Speed Motor Rpm

Motor Pulley Pitch Diameter (in.)

Pulley A Pulley B

Resulting Fan Rpm

Single-Speed with Pulley A. .B Two-Speed with Pullley A...B

Alternate Motor and Drive

Motor Hp Motor Frame Size

Single Speed

Two Speed

Fan Pulley Pitch Diameter (in.) Fan Pulley Bore I'Me I'Me Single-Speed Motor Rpm Two-Speed Motor Rpm

Motor Pulley Pitch Diameter (in.)

Pulley A Pulley B

Resulting Fan Rpm

Single-Speed with Pulley A...B

Two-Speed with Pulley A...B

EXHAUST FAN MOTOR Quantity...Hp EVAPQRATQR CQIL

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

ELECTRIC RESISTANCE HEATERS

HeatikW

INDQQR AIR FILTERS

No. ...Size

Standard; 2-in Throwaway

Bag Type; 12-in. (Optional)

044

5406 6100

Serviceable, Hermetic

2 06E 2. .06E*

20, 40, 60, 80, 100

25, 50, 75, 100 20, 40, 60, 80, 100

Type 22; Controlled by Thermostatic Expansion Valve

Direct Driven, Propeller Type

28,000 1 1050

61 0

Belt Driven, Centrifugal Type

4 15x9

4 15x11

1300

16,000

20,000

254T 284T

10 6

1750

1750/1170

6 5

5 6 60

1073 925

1073/751

925/617

1073 ..991 1073/751

991/661

256T 286T

80 80

1750

1750/1170

5 3 5 6

1159 1225* 1159 1225

1159/773.

1225/817

1159/773.

1225/817

2 3 2 3

4 15 30 2

Open Nichrome Wire Elements with Multiple-Stage Control

See Electrical Data tables

27 16x25

21 16x25

6 12x24 6 24x24 7 24x24

054 064

6485

250 225

2 06E

6 1750

50, 100

16, 33, 50, 67, 83, 100 16, 33, 50, 67, 83, 100

81 0 81 0

4 30

31,000

1 1150

3 158

81 5

1300

256T 284T 286T

106

I’Me

1750

6 5

25t

284T 286T —

4 15.8

81 25

4 15x11

1450

24,000

286T

1750

1750/1170

56 60

1225 1312 1225/817.

1312/875

30t

286T

10 6

1750

5 3 5 6

4 15 35 4

9 20x25

7 12x24

1750

1750/1170

8 0

1321 —

1321/881

2 3

4 139

35 4

9 20x25

21 16x25

*Unit contains one 06EA250 and one 06EA275 compressor tStandard fan motor supplied with standard fan drive pulleys and

belts; alternate fan motor supplied with alternate fan drive pulleys and belts Other combinations are field supplied Pulley A is installed in unit; Pulley B is shipped with unit (044 and 054).

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JDue to large frame size, the 25-hp, 208-230-volt and 30-hp

motors are available in single speed only

**The 50DL064 alternate drive is supplied with Pulley A only

Fig. 4 — Base Unit Dimensions

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APPLY RTV SEALANT TO AREAS SHOWN

Fig. 5 — Economizer Outdoor Air

Inlet Hood Assembly

Fig. 6 — Enthalpy Control Assembly

Fig. 7 — Psychrometric Chart for

Enthalpy Control

MAIN POWER TERMINAL BLOCK IN UNIT CONTROL BOX OR HEATER COMPARTMENT

FIELD POWER

SUPPLY

THERMOSTAT SUBBASE

NOTE Thermostat subbase required.

Fig. 8 — Field Wiring Connections

Constant Volume Units Without

Energy Management Option

TB4 MAIN CONTROL BOX

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weathertight space. The night setback box contains a terminal block for field wiring connections, a morning warmup thermostat and the setback/ setup module. The night setback box remains in the unit. Shipping locations of remote box and permanent location of night setback box are shown in Fig. 11.

1. Remove remote box and mount in a restricted access area (indoors or in a weathertight space).

Run separate 115-volt, 60-Hz (230-volt, 50-Hz)

power to the remote box per Fig. 9. Use no. 14

AWG wire or larger and a proper field-supplied

electrical connector.

Install a Carrier-approved accessory electronic thermostat or transmitter if remote sensor is used (subbase not required) according to the installa tion instructions included with the accessory.

Note that the subbase is not used on units with

the Energy Management option. Locate the ther

mostat or remote sensor, if used, in the condi

tioned space where it will sense average

temperature.

Route thermostat cable or equivalent single leads

of no. 18 AWG eolored wire from thermostat or

transmitter terminals thru connector on unit to

low-voltage (TB4) connections in main control

box as shown on unit label wiring diagram and

in Fig. 9.

Run 24-volt wires between the remote box and night setback box per Fig. 9. Use no. 18 AWG wire for lengths up to 100 feet. Local codes may dictate use of conduitfor low voltage. Knockouts are provided in the night setback box and in the fan deck separating heating section from section containing the night setback box (Fig. 11). A watertight connector is installed in side of unit.

Two rubber grommets are taped inside the night

setback box. Use grommets in knockouts in fan deck and night setback box.

288

MAIN POWER TERMINAL

~r~

NOTE Subbase not used

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FIELD POWER

SUPPLY

BLOCK IN UNIT CONTROL

BOX OR HEATER COMPARTMENT

Fig. 9 — Field Wiring Connections

Constant Volume Unit With Energy Management Option

Fig. 10 — Field Wiring Connections for 50DL VAV

Fig. 11 — Shipping Location — Remote Box

UNITS WITH VARIABLE VOLUME OPTION — Units do not use room thermostats or sensors. In addition to the main control box, units are equipped with a remote box and a variable volume box. Remote box is described above (Units With

Energy Management Option). The variable volume box (Fig. 12) contains a microprocessor, a morning warmup thermostat, a time-delay relay, 3 unloader

relays, an interlock relay, a night relay, a day relay

and a terminal block for field wiring. Shipping loca tion of remote box is shown in Fig. 11.

1. Remove the remote box and mount in a restricted access area (indoors or in a weathertight space).

2. Run separate 115-volt, 60-Hz (230-volt, 50-Hz) power to the remote box per Fig. 10. Use no. 14 AWG wire or larger and proper electrical con nector (field supplied).

3. Run 24-volt wires between remote box and variable volume box per Fig. 10. Use no. 18 AWG wire for lengths up to 100 feet. Run wire in con duit to unit if local codes dictate. Knockouts are provided in the variable volume box and the fan deck separating heating section from section con taining the variable volume box (Fig. 11). Water tight connectors are installed in unit cornerpost

and side of unit. Two rubber grommets are shipped taped inside variable volume box. Use grommets in knockouts in fan deck and variable volume box.

288

4. If the unit is equipped with electric heat, the room terminals must be controlled to go fully open when unit goes into heating. An interlock relay is provided in the variable volume box. When unit goes into heating, the interlock relay energizes providing switch closure to open the room ter minals. Field connections for the interlock relay are terminals 1 and 2 of the terminal block (TB10) located in upper left corner of electric heat sec tion (Fig. 11).

Route field-supplied power wiring thru watertight connector supplied in unit cornerpost. Make TBIO connections as shown in Fig. 13.

Return Air Filters — Check that return air filters

are of the correct type and size and installed in unit filter racks. Filter data is shown in Table 1. Do not operate unit without return air filters.

Fig. 13 — Morning Warmup Interlock

Outdoor Air Inlet Screens — Outdoor air inlet

screens must be in place before operating unit.

Compressor(s) — Loosen compressor holddown

bolts until sidewise movement of the washer under each holddown bolt head occurs. Do not loosen completely as bolts are self-locking and will main tain their adjustment.

Open the compressor discharge and suction service valves. Replace and tighten valve caps to prevent leaks.

Liquid Line Service Valve — Open the liquid line

service valve. Replace and tighten valve cap to prevent leaks.

Low Ambient Compressor Lockout (Fig. 14) —

All units are equipped with an adjustable low ambient lockout thermostat to lock off the compressor(s) at low outdoor air ambients. Thermostat is located in the main control box. Setting will depend on specific installation but should be approximately 50 F on VAV units and 55 F on constant volume units.

Convenience Outlet — All units are equipped

with a 115-volt convenience outlet for handling

small power load or service light. See Fig. 14.

CIRCUIT BREAKERS CONVENIENCE OUTLET LOW AMBIENT LOCKOUT

Fig. 14 — Control Box

THERMOSTAT

LOGIC PANEL

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