Carrier 50XJ064-104 User Manual

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50BV020-064, 50XJ064-104

Remote Air-Cooled and Water-Cooled, VAV Systems

18 to 100 Nominal Tons

Controls Operation and

Troubleshooting

OMNIZONE™

Indoor Self-Contained

CONTENTS

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

GENERAL ........................................1

MAJOR SYSTEM COMPONENTS ...............1-7

Comfort Controller Processor (PCB1) ............1

Comfort Controller I/O Module (PCB2)............2

Comfort Controller I/O Module (PCB3)............2

Local Interface Display ...........................2

PCB Addresses ..................................2

Control Module Communication.................. 2

Carrier Comfort Network Interface................4

Optional and Field-Installed

Accessory Sensors/Devices ...................4

Wiring Control Devices........................... 6

CONTROLS AND FUNCTIONS................. 8-15

Using the Local Interface Display ................ 8

Automatic Run Test ............................. 10

Power Up the LID Display .......................12

Log On to the LID Display ....................... 12

Change the Default Password ................... 12

Set the Clock.................................... 12

Configure Schedules............................13

Program Set Points ............................. 13

Check System Parameters ...................... 14

Display Alarm History ...........................14

Configure Custom Programming Selections .... 14

Set Controller Address ..........................15

Log Off from Controller ......................... 15

OPERATION.................................. 16-26

Occupancy Determination....................... 16

Fan Control .....................................16

Sequence of Operation..........................16

Diagnostic Features .............................18

50XJ Variable Frequency Drive Control..........19

50BV Variable Frequency Drive Control .........22

TROUBLESHOOTING......................... 27-29

Run Test Troubleshooting.......................27

Forcing and Clearing and Input or Output....... 27

Standard Diagnostic Features,

Alarm and Warning Lights .................... 28

APPENDIX A — WIRING DIAGRAMS ......... 30-42

APPENDIX B — CONTROL SCREENS ........ 43-64

Display Screens.................................43

Configuration Screens ..........................45

Maintenance Screens ........................... 58

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location. Only trained, qualified installers and service mechanics should install, start up, and service this equipment.

When working on this equipment, observe precautions in the literature; on tags, stickers, and labels attached to the equipment, and any other safety precautions that apply. Follow all safety codes. Wear safety glasses and work gloves. Use care in handling, rigging, and setting this equipment, and in handling all electrical components.

Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation and service. There may be more than one disconnect switch. Tag all disconnect locations to alert others not to restore power until work is completed.

This unit uses a microprocessor-based electronic control system. Do not use jumpers or other tools to short out components, or to bypass or otherwise depart from recommended procedures. Any short-to-ground of the control board or accompanying wiring may destroy the electronic modules or electrical components.

GENERAL

This publication contains Start-Up, Controls Operation, and Troubleshooting information for the 50BV,XJ units. These OMNIZONE™ packaged units are self-contained, watercooled or remote air-cooled indoor units for use in VAV (variable air volume) applications. Units are equipped with Comfort Controller 6400 (CC6400) system controls. Refer to the unit Installation Instructions for unit layout.

MAJOR SYSTEM COMPONENTS

Comfort Controller Processor (PCB1) —

The central processing unit for the OMNIZONE system control is the Comfort Controller 6400. The Comfort Controller provides general purpose HVAC (heating, ventilation and air conditioning) control and monitoring capability in a standalone or network environment using closed-loop, direct digital control. The Comfort Controller 6400 has been pre-programmed to work in either stand-alone or CCN (Carrier Comfort Network) system installations.

The CC6400 processor is designed to provide heating and cooling control, loop control, scheduling, and custom programming. The main processor provides 16 field points (8 input and 8 output). Additional points are provided by the I/O modules described on page 2. Table 1 lists the control inputs and outputs for all CC6400 modules.

Specifications for the Comfort Controller 6400 may be found in the Comfort Controller literature.

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

Book 1 1 Ta b 2 a 2 b

PC 111 Catalog No. 535-00137 Printed in U.S.A. Form 50BV,XJ-2T Pg 1 2-04 Replaces: 50BV,XJ-1T

Comfort Controller I/O Module (PCB2) — This

input/output module is factory installed in the 50XJ unit and allows additional field points (8 inputs and 8 outputs): VFD (variable frequency drive) Bypass, VAV Terminals Control, Building Ventilation, and Heating Interlock.

Comfort Controller I/O Module (PCB3) — This

accessory control input/output module can be ordered separately and field-installed in the 50XJ unit. This module allows the addition of the following field-installed sensors: Tower Sump Temperature Sensor, Leaving Water Temperature Sensor, Building Pressure Sensor, CO Humidity Sensor, and Outdoor Temperature Sensor.

The accessory I/O module provides the following control outputs (relays): 4-stage heat control, water pump request, tower request, modulating exhaust fan, and external dehumidification.

Sensor, Indoor Relative

Local Interface Display — The Local Interface Display

(LID) is mounted on the front of the 50BV,XJ units. A number of user-adjustable features are entered/changed using the display keypad. These features described in detail in the Using the Local Interface Display section of this manual.

PCB Addresses — Switch 1 (SW1) is used to set each

controller’s address. Individual DIP switches on each board are used to set the addresses for individual hardware points. PCB1 switches are factory-set for hardware points 1-15, PCB2 DIP switches are set for points 17-32, and PCB3 for points 33-48. For more information, refer to Table 1 and the Optional and Field-Installed Accessory Sensors/Devices section.

Control Module Communication — When power is

applied to the OMNIZONE™ System Control panel, the red LED (light-emitting diode) on the top front of the processor module will flash at a rapid pace (about twice a second) for the first 30 to 60 seconds. See Fig. 1. This rapid flash will then be replaced by a slower paced flash (about once per second).

The green LED below the red LED will start flashing. This LED indicates input/output communications for accessory input output modules and the LID.

The yellow LED (the third LED from the bottom of the controller [PCB1]) will flash when the controller is broadcasting CCN messages to a laptop or other computer.

Table 1 — Control Inputs and Outputs

DESCRIPTION

Inputs SW2 SW3 SW1 Main Controller (PCB1) Addr = 1-16

Supply Air Temperature SAT Analog; 10K MCI 1 1 1 Up 1 Down 1 Up VFD Duct Static Pressure DSP 4-20mA; Internally Powered 2 2 2 Up 2 Up 2 Down COL/Safeties —

(Comprs.Status; Resister Bd.) Fire Alarm/Shutdown FSD Switch closure 4 4 4 Up 4 Down 4 Down Condenser Waterflow Switch CDWF Switch closure 5 5 5 Up 5 Down 5 Down Remote Occupancy RMTOCC Switch closure 6 6 6 Up 6 Down 6 Down Duct High Static Limit Switch DHS Switch closure 7 7 7 Up 7 Down 7 Up Entering Water Temp. Sensor EWT Analog; 5K 8 8 8 Up 8 Down 8 Up

I/O Board (PCB2) Addr = 17-32

Mixed/Return Air Sensor MAT/RAT Analog; 10K MCI 1 1 1 Up 1 Down 1 Up Filter Status Switch

(Dirty Filter Detect) PhaseLossMonitor PHASE Switch closure 3 3 3 Up 3 Down 3 Down External reset RESET 0-10VDC Externally Powered 4 4 4 Up 4 Down 4 Down Water Econ. FreezeStat FREEZE Switch closure 5 — 5 Up 5 Down 5 Up Differential Enthalpy ENTH Switch closure — 5 5 Up 5 Down 6 Down Space Zone Sensor(s) SPT Analog; 10K MCI 6 6 6 Up 6 Down 7 Up VFD Bypass Enable BYPASS Switch closure 7 7 7 Up 7 Down 8 Up Refrigerant Pressure

(Compr.#1)

I/O Board (PCB3) Addr = 33-48

Tow e r S um p Te mp . TWRTEMP Analog; 10K MCI 1 1 1 Up 1 Up 1 Up Building Pressure BSP 4-20mA; Internally Powered 2 2 2 Up 2 Down 2 Down Leaving Water Temp. LWT Analog; 10K MCI 3 3 3 Up 3 Up 3 Down Indoor Air Quality IAQ 4-20mA; Internally Powered — 4 4 Up 4 Down 4 Down Indoor relative Humidity IRH 4-20mA; Internally Powered — 5 5 Up 5 Down 5 Down Outside Air Temp. OAT Analog; 10K MCI — 6 6 Up 6 Up 6 Up Unassigned —— ——————7Up Unassigned —— ——————8Up

DESCRIPTION

Outputs SW4 SW5 SW6 Main Controller (PCB1)

Compressor #1 Relay CMP1 24VDC Discrete 1 1 1 Either 1 DO — Compressor #2 Relay CMP2 24VDC Discrete 2 2 2 Either 2 DO — Compressor #3 Relay CMP3 24VDC Discrete 3 3 3 Either 3 DO — Compressor #4 Relay CMP4 24VDC Discrete 4 4 4 Either 4 DO — VFD On/Off SF 24VDC Discrete 5 5 5 Either — 1 DO VFD Speed Control SPEED 4-20mA modulating 6 6 6 Down — 2 AO Alarm Pending ALARM1 24VDC Discrete 7 7 7 Either — 3 DO Service Required ALARM2 24VDC Discrete 8 8 8 Either — 4 DO

I/O Board (PCB2)

Ventilation Output VENTOUT 24VDC Discrete 1 1 1 Either 1 DO — Terminals Occupied OCCTRM 24VDC Discrete 2 2 2 Either 2 DO — 2-Position\

Reverse Operation Valve Economizer Damper ECONO 4-20mA modulating — 3 3 Down 3 AO — Modulating Valve Econ./

Head Pressure Control Hot Water Coil Valve Control HWV 4-20mA modulating 5 5 5 Down — 1 AO Heat Interlock Relay HIR 24VDC Discrete 6 6 6 Either — 2 DO VFD Bypass Start BPSS 24VDC Discrete 7 7 7 Either — 3 DO VAV Terminals Open DAMPERS 24VDC Discrete 8 8 8 Either — 4 DO

I/O Board (PCB3)

Electric Heat Control — Stage #1 HEAT1 24VDC Discrete 1 1 1 Either 1 DO — Electric Heat Control — Stage #2 HEAT2 24VDC Discrete 2 2 2 Either 2 DO — Electric Heat Control — Stage #3 HEAT3 24VDC Discrete 3 3 3 Either 3 DO — Electric Heat Control — Stage #4 HEAT4 24VDC Discrete 4 4 4 Either 4 DO — Water Pump Request PUMP 24VDC Discrete 5 5 5 Either — 1 DO Tower Request TOWER 24VDC Discrete 6 6 6 Either — 2 DO Modulating Exhaust Fan EXH 4-20mA modulating 7 7 7 Down — 3 AO External Dehumidification DEHUM 24VDC Discrete 8 8 8 Either — 4 DO

LEGEND

AO — Analog Output DO — Discreet Output MCI — Precon Type II Thermistor VAV — Variable Air Volume VFD — Variable Frequency Drive

ABBREV. TYPE

CMP MUX Analog; 0-10VDC 3 3 3 Up 3 Down 3 Down

FLTS Switch closure 2 2 2 Up 2 Down 2 Down

PRES 4-20mA; Internally Powered 8 8 8 Up 8 Up — —

ABBREV. TYPE

ECONO 4-20mA modulating 3 3 Down 3 AO —

MODVLV 4-20mA modulating 4 4 4 Down 4 AO —

CONTROLLER I/O NO. DIP SWITCH SETTINGS

Water Econ. Units Air Econ.Units

CONTROLLER I/O NO. DIP SWITCH SETTINGS

Water Econ. Units Air Econ.Units

Switch No. and Position

STATUS

RED

(POWER)

GREEN (IO BUS COMMUNICATIONS)

YELLOW (CNN BUS COMMUNICATIONS)

Fig. 1 — CC6400 Control Module LEDs

Carrier Comfort Network Interface — The 50BV,XJ

units can be connected to the CCN (Carrier Comfort Network) if desired. System elements are connected to the communication bus in a daisy chain arrangement. The negative pin of each system element’s communication connector must be wired to the respective negative pins, and positive pins on each component must be connected to respective positive pins. The controller signal pins must be wired to the signal ground pins. Wiring connections for CCN must be made at the 3-pin plug.

At any baud rate (9600, 19200, 38400 baud), the number of controllers is limited to 239 devices maximum. Bus length may not exceed 4000 ft, with no more than 60 total devices on any 1000-ft section. Optically isolated RS-485 repeaters are required every 1000 ft.

NOTE: Carrier device default is 9600 baud.

The CCN Communication Bus wiring is field-supplied and field-installed. It consists of shielded three-conductor cable with drain (ground) wire. The cable selected must be identical to the CCN Communication Bus wire used for the entire network. See Table 2 for cable recommendations.

NOTE: Conductors and drain wire must be at least 20 AWG (American Wire Gage), stranded, and tinned copper. Individual conductors must be insulated with PVC, PVC/ nylon, vinyl, Teflon, or polyethylene. An aluminum/ polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of –20 C to 60 C is required.

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

Optional and Field-Installed Accessory Sensors/ Devices —

accessories that add functionality and control. These options and accessories are controlled by the CC6400 system as described below.

NOTE: The CC6400 Control software includes all PCB1 functions, and most of the sensors/devices associated with those functions are factory installed. However, some PCB1 sensors/devices must be field-connected to the proper terminal. PCB2 devices are field-installed accessories. The CC6400 software includes these functions, but the actual sensor/device must be installed and wired in the field. PCB3 is an accessory control module. All PCB3 sensors/devices and software are field-installed.

The 50XJ unit can be ordered with options and

Table 2 — Communication Cable Recommendations

MANUFACTURER PART NUMBER

Alpha 2413 or 5463

American A22503

Belden 8772

Columbia 02525

REMOTE OCCUPANCY CONTROL (PCB1) — This control is a field located switch, controller or timer input which, when activated, tells system when to switch from Unoccupied to Occupied mode.

When in Occupied mode, the unit turns on the supply fan and controls supply fan speed to maintain a duct static set point measured at the Duct Static Pressure Sensor (DSP). The unit operates to provide conditioning to a set point. When in Unoccupied mode, the unit provides no cooling/heating, or controls to a ‘setback’ set point.

FIRE ALARM (PCB1) — The fire alarm is a control voltage input to the 50XJ unit, which causes the controller to shut the system down in the event of a fire.

CONDENSER WATER FLOW SWITCH (50XJ PCB1) — This thermal dispersion type flow switch if factory installed, is located in the unit waterline to ensure that there is waterflow before allowing the unit to start the compressor(s). If no flow is detected, then compressor operation and economizer cooling is avoided until waterflow is again detected. An warning light (yellow) is provided during this state.

HEAT INTERLOCK OUTPUT (50XJ PCB2) — This output is activated whenever heating is activated, commanding the VAV dampers to operate in heating control mode.

NOTE: In order to this output to function, the Terminal Occupied output must also be on.

TERMINAL OCCUPIED (50XJ PCB2) — Terminal Occupied is activated to command VAV dampers to control to the cooling set point. Terminal Occupied must be on along with Heat Interlock for heating set point control to function.

EXTERNAL RESET INPUT (50XJ PCB2) — This modulating input (0 to 10 vdc) allows remote adjustment (upward) of the Supply Air Temperature (SAT) sensor set point. The default External Reset Input setting is 55 F. This variable input can raise the set point by up to 20 F for a full-range input signal, or to any point in between.

WATER ECONOMIZER COIL (50XJ PCB2) — This factoryinstalled option contains a water-to-air coil, two (2) electronic motorized water valves, and related piping. Control of the water economizer also requires a Mixed/Return Air Temperature Sensor, a Condenser Water Inlet Temperature Sensor and an Economizer Freezestat safety switch.

The electronic motorized water valves are each controlled by the unit controller via separate 4 to 20 mA variable signals to define variable valve position.

The Mixed/Return Air Sensor (MA_RA) is an air temperature sensor located in the unit, between economizer coil and evaporator.

The Condenser Water Inlet Temperature Sensor (CWT) is located at the unit water inlet connection. This sensor receives input power from the unit main controller and provides a linear variable 1 to 5 vdc signal back to the controller. The full temperature range is 32 to120 F.

The 50XJ units can be connected to two types of building water systems: variable and fixed or constant flow control. In either case, the economizer water valves are opened whenever there is a call for Cooling and the Inlet Water Temperature is colder than the Econ Start Set Point in the custom configuration.

Dependencies Fan is On, and Inlet Water Temperature is below set point; or from “Remote Scheduler,” or from “Remote Linkage.”

Economizer mode is switched to Off or no start if: there is no condenser waterflow, Fire Input is On, Fan is not On, or Unoccupied mode is On.

Variable Waterflow Systems is off, the economizer flow control valve is fully closed, and the reverse flow valve directly to the condenser is fully open. Upon engagement of the water economizer, the economizer flow control valve shall be controlled to maintain the MA_RA located between the economizer coil and the DX cooling coil, at a temperature near the supply air set point. The the reverse flow valve will be controlled in reverse of the economizer flow control valve’s position. The following formula is an example: Reverse/ Head Press Ctrl output = 100 – two-position/Econo output.

When the unit is off, both valves are closed. Constant Waterflow Systems

flow control valve is same as for variable waterflow systems. Control of the reverse flow control valve position will inversely track the economizer flow control valve, such that the total sum of the two valves open positions always equals 100%. The only difference between the variable waterflow system and the constant waterflow system is that for the constant flow system when the unit is off, the economizer valve will be closed and the reverse flow control valve will be open.

WATER ECONOMIZER COIL (50BV) — For the 50BV unit, this factory-installed option contains a water-to-air coil, a two-position diverting valve, and related piping. The water economizer is controlled by an Aquastat and a return-air thermostat.

HEATING COILS AND VALVE (50XJ PCB2) — Water or steam heating options are factory installed. Each includes a motorized, variable control water or steam flow control valve, which can be factory supplied for field installation outside the unit. Installed in the water or steam inlet pipe, this valve is wiredtotheunitmaincontrollerandoperatesona4to20mA signal. A Heating mode PID control is needed to control the valve position (i.e., coil heating capacity) variably between 10 and 100%. The PID will control a set point to + 1° F; for VAV Units this set point is at the Supply Air Temperature Sensor, or as communicated from a remote thermostat.

HEAD PRESSURE CONTROL (50XJ PCB2) — Head Pressure Control is required for unit installations that will experience entering condenser water temperatures of 55 F or lower.

NOTE: Head Pressure Control is not needed or used in conjunction with a Water Economizer. A refrigerant pressure transducer will monitor head pressure on compressor circuit 1, allowing the unit main controller to regulate water flow rate in the main water line entering the unit; i.e., flow to all condensers. (Water header design to the condensers will be optimized such as to provide relative flow rates to each condenser based on its compressor capacity, enabling successful waterflow control at the main entering pipe.) There are two possible water valving configurations, as outlined below.

Pressure transducer input is factory installed in the discharge line of compressor circuit 1. It is provided 5 vdc by the unit main controller and returns a signal 1 to 5 vdc linearly. The sensor’s range is 0 to 550 psig.

Water Valve(s) Control

Variable Building Waterflow Systems — Variable waterflow configurations use only one water valve in the main water supply pipe. The factory installed valve is a normally open motorized variable control type. The valve is controlled by a 4 to 20 mA signal from the main unit controller using the Reverse/Head Press Ctrl output, which modulates to maintain the head pressure set point (Setpoint 04).

— Water Economizer option is enabled, and

— Whenever water economizer

— Control of the economizer

Constant Building Waterflow Systems — Constant waterflow configurations use two (2) water valves, only one of which is in the main water supply pipe. The second valve is located in a bypass pipe to the main outlet water pipe branched off of the supply pipe immediately ahead of the first valve. This valve is same type, but normally closed and is controlled in unison with the first valve, but opposite position, such that the total opening of the 2 valves always equals 100%.

VFD BYPASS (50XJ PCB2) — The VFD Bypass option provides backup for the VFD Drive in VAV units. It uses a manually operated rotary switch, which includes a series of high voltage contacts. The bypass is a direct input to the unit controller, and will be activated via a switch on the unit front panel. When manually activated, the rotary switch takes the VFD out of the fan power circuit and provides the 3-phase power directly to the fan motor, running it at constant speed. A low voltage control circuit ensures that the unit controller provides a signal to allow all VAV dampers to open fully before the fan is turned on (at constant/full speed). A blue indicator light located on the front of the unit indicates that the VFD Bypass is active. A High Duct Static Switch (HDS) shuts the fan down if duct static exceeds a maximum setting.

VENTILATION OUTPUT (50XJ PCB2) — The ventilation output is controller output signal (available for field connection) to a field-supplied ventilation damper(s). This signal is activated whenever the unit is in the occupied mode.

SPACE TEMPERATURE SENSOR (50XJ PCB2) — A fieldsupplied Carrier space temperature sensor is required to maintain space temperature in sensor mode.

SUPPLY AIR RESET (50XJ PCB2) — Supply air temperature set point may be reset using either the SPT or MA_RA.

SUPPLY AIR RESET (50BV) — Reset is provided by a field-installed temperature sensor.

EXHAUST FAN CONTROL OUTPUT (50XJ PCB2) — This output is activated whenever the unit is in the Occupied mode. This is a modulating output that controls based on the Building Pressure Input set point.

CONDENSER WATER PUMP/WATER TOWER (50XJ PCB2) — This output (provided for field connection) is used to control condenser water flow. Either an On/Off signal or a variable output may be required for this feature.

PHASE LOSS/REVERSAL PROTECTION SWITCH (50XJ PCB2) — This switch monitors VFD/Fan Motor supply leads to detect phase loss or reversal. If the switch detects improper phasing, an input is sent to the unit controller, which shuts the unit down. After a time delay, the controller attempts to restart the unit.

A phase loss/reversal switch may be installed in the unit to detect over/under voltage conditions and phase loss or reversal. When the switch opens, the controller outputs are forced to off with Safety forces, the alarm output will close and the red alarm light will be lit. A system alarm will be generated and displayed on the unit keypad. Unit reset is automatic when the voltage and power phases have been restored.

FREEZE THERMOSTAT (FREEZSTAT) (50XJ PCB2) — The Economizer Freezestat, used in conjunction with an optional water economizer coil or heating coil, is a factory installed averaging (capillary tube) air temperature sensor positioned in the unit inlet airstream.

If the freeze protection switch contacts open the ventilation request output will be closed for 15 minutes and the warning light will light. If the freeze protection switch contacts are still open after 15 minutes the supply fan will be stopped, all compressor cooling will stop, the economizer valve will open to 100%, the pump request output will remain on, and the alarm light will light. This will maintain condenser water flow through the coil to prevent freezing the coil while stopping all other operations that could have contributed or will be affected

by the freeze condition. Unit reset is automatic when the contacts on the freeze protection switch close again. The contacts on the freeze protection switch open below 37 F.

TOWER SUMP TEMPERATURE SENSOR (50XJ PCB3) — This sensor is used for monitoring (only) the tower sump temperature.

LEAVING WATER TEMPERATURE SENSOR (50XJ PCB3) — This sensor is used for monitoring (only) the leaving water temperature.

BUILDING STATIC PRESSURE SENSOR (50XJ PCB3) — This sensor is used to control both the speed of the building exhaust fan and the building static pressure.

INDOOR AIR QUALITY (CO PCB3) — This sensor monitors CO

)SENSOR(50XJ

levels.

INDOOR RELATIVE HUMIDITY SENSOR (50XJ PCB3) — This sensor monitors and controls the humidity control relay.

OUTDOOR AIR TEMPERATURE SENSOR (50XJ PCB3) — This sensor is used to monitor outdoor air and broadcast the value over the Carrier Comfort Network (CCN).

STAGE HEAT RELAYS (50XJ PCB3) — These relays control up to four stages of electric heat, or other heating methods.

PUMP REQUEST RELAY (50XJ PCB3) — This relay turns on a tower pump when requested.

TOWER REQUEST/CONTROL RELAY (50XJ PCB3) — This relay is used to activate a tower fan.

BUILDING EXHAUST FAN SPEED CONTROL (50XJ PCB3) — This output controls building exhaust fan speed.

HUMIDITY CONTROL RELAY (50XJ PCB3) — This relay controls a humidifier or dehumidification device.

Wiring Control Devices — Standard controls for the

50XJ require no field-wiring. Standard 50XJ controls include: Supply Air Temperature (SAT), Duct Static Pressure (DSP), Duct High Static Limit Switch (DHS), Filter Status Switch (FLTS), Entering Water Temperature (EWT), Compressor Status (CSMUX), Supply Fan Start/Stop (SF), Supply Fan Speed (SPEED), and Mixed/Air Return/Air sensor (MA_RA).

NOTE: The MA_RA sensor will be located in the return air steam if the unit does not have a water economizer, and in the mixed airstream if the unit is equipped with a water economizer.

For the 50BV unit, standard controls include: Duct Static Pressure (DSP), Duct High Static Limit Switch (DHS), Compressor Status (CSMUX), Supply Fan Start/Stop (SF), and Supply Fan Speed (SPEED).

For the 50XJ unit, optional controls will be wired to the field terminal blocks (TB5 and TB6) provided. Refer to Fig. 2A and the descriptions below.

For the 50BV unit, optional controls are wired to field terminal block TB2 as shown in Fig. 2B.

EXTERNAL 0 TO 10 VOLT DC RESET SIGNAL (RESET) (50XJ PCB2) — This field-supplied 0 to 10 vdc signal is used to reset the 50XJ supply-air temperature. The controller will scale the signal to provide 0 reset at 0 volts and 20 degrees of reset at 10 volts. Wire the positive of the signal to the RESET terminal and the negative to the C or common terminal.

SUPPLY AIR RESET (50BV) — Use a 5k ohm sensor installed at the Entering Water Temperature sensor (EWT) location on PCB1. For space temperature averaging, two 10k ohm Space Temperature Sensors (SPT) can be wired in parallel.

SPACE TEMPERATURE SENSOR (50XJ PCB2) — The space temperature sensor (33ZCT55SPT) is used in the following cases:

• When using the optional water economizer and not using

Carrier’s ComfortID™ System.

Fig. 2A — Field Terminal Blocks for 50XJ Unit

Fig. 2B — Field Terminal Block for 50BV Unit

• To determine the average temperature of the space being served.

• To determine supply-air temperature reset, occupied heating, unoccupied heating and cooling (refer to Sequence of Operation in the Start-Up section.).

To wire the sensor, perform the following (see Fig. 3). Identify which cable is for the sensor wiring.

1. Strip back the jacket from the cable for at least 3 inches. Strip

/4-in. of insulation from each conductor. Cut the shield and drain wire from the sensor end of the cable.

2. Wire the sensor to the SPT and C terminals on the field terminal block (TB5). A typical 10K thermistor such as the 33ZCT55SPT sensor may be used. If the SPT sensor is not installed and the MA_RA (mixed air/ return air) sensor is configured for return air, the 50XJ unit will use this sensor to control supply air reset, occupied heat, and unoccupied heating and cooling

See Fig. 4 for space temperature sensor averaging.

HOT WATER OR STEAM VALVE (HWV) (50XJ PCB2) — The HWV terminal supplies the positive signal to control a 4 to 20 mA hot water or steam valve for occupied and unoccupied heat. Connect the common side of the valve to the C terminal or an equipment ground.

AIR TERMINALS AND FRESH AIR DAMPER (50XJ PCB2) — The VAV Terminal Open (TRMOP), Ventilation Output (VENTR), VAV Terminals Control (TRMCT), and Heat Interlock Relay (HIR) terminals provide dry contacts to command the VAV terminals open; a ventilation damper open; VAV terminals to control to their cooling set points; and VAV terminals to control to their heat set points, respectively.

REMOTE OCCUPANCY (ROCC) (TB2 50BV, TB6 50XJ) — The 50XJ,BV unit may be commanded by a remote control system or a twist timer to become occupied and run when a set of dry contacts close. In order for this to occur, wire the contacts to ROCC and C.

SMOKE DETECTOR/FIRE ALARM SHUTDOWN (FSD) (TB2 50BV, TB6 50XJ) — To allow a smoke detector to shut the 50XJ,BV unit down, remove the jumper from FSD to C and wire these terminals to a set of normally closed contacts on the smoke detector.

ALARM (ALARM) AND WARNING (WARN) OUTPUTS (TB2 50BV, TB6 50XJ) — Two dry contacts output a discrete signal when the alarm and warning lights on the display are lit. To pick up the alarm output signal, wire between the ALARM and ALM-CM terminals. To pick up the warning output signal, wire between the WARN and ALM-CM terminals.

RED(+)

WHT(GND)

BLK(-)

BRN (GND) BLU (SPT)

CCN COM

SENSOR WIRING

SW1

SEN

Fig. 3 — Space Temperature Sensor

Typical Wiring (33ZCT55SPT)

RED

BLK

RED

BLK

RED

BLK

SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 4

RED

BLK

RED

BLK

SPACE TEMPERATURE AVERAGING — 4 SENSOR APPLICATION

RED

BLK

SENSOR 1

RED

BLK

RED

BLK

SENSOR 2

RED

BLK

SENSOR 3

RED

BLK

LEGEND

Field Wiring

BLK

SENSOR 4

RED

BLK

SENSOR 7

SENSOR 5

SENSOR 8

SPACE TEMPERATURE AVERAGING — 9 SENSOR APPLICATION

Fig. 4 — Space Temperature Averaging

SENSOR 6

RED

BLK

SENSOR 9

CONTROLS AND FUNCTIONS

Table 4 — Operative Keys

Using the Local Interface Display —

The Local Interface Device (LID) is a CCN operator interface that gives the user the capability to view and modify all configuration and service data for the CC6400 control system. The LID also allows the user to override all point display and maintenance data.

MENU STRUCTURE — The LID operates on a hierarchy of four levels (menus).

The top level contains the LID’s major functions. Each function has a corresponding key on the LID. For an explanation of each function key, refer to Table 3.

The second level separates the major functions (items) into types with corresponding type numbers that can be used for quick access.

The third level gives the user the capability to access each occurrence of an item. For example, the application may require two DO (Discreet Output) — Analog Comparison algorithms. Thus, the CC6400 Controller would have two occurrences of the DO — Analog Comparison algorithm.

The fourth level gives the user the capability to access maintenance and configuration data associated with the selected occurrence of the item.

DEFAULT SCREEN — Figure 5 shows the LID. The LID’s screen provides the user with the 24-character controller name and the controller’s current time, date, and alarm status. This screen appears when the LID is powered up and communicating with the controller or there is no keyboard activity for 10 minutes.

KEYPAD AND DISPLAY — The LID consists of a keypad with 8 function keys, 4 operative keys, 12 numeric keys (0 to 9,., and -) and a two-line, alphanumeric liquid crystal display (LCD). Each line on the LCD can display up to 24 characters. See Fig. 5. Table 4 defines the purpose of the LID’s operative keys. Table 5 defines the purpose of the LID’s numeric keys.

Table 3 — LID Function Keys

OPERATIVE

KEYS

Status — gives access to maintenance values and configuration data for points.

Alarm — gives access to maintenance and configuration data for alarms.

History — gives access to maintenance and configuration data for history system functions.

Service — gives access to maintenance and configuration data for service system functions.

Setup — gives access to configuration data for setup system functions.

Schedule — gives access to maintenance and configuration data for schedules.

Algorithm — gives access to maintenance and configuration data for AO, DO, and global algorithms. It also gives access to BEST custom programs.

Edit — gives the capability to switch from Status mode to Edit (configuration) mode for the selected item.

LEGEND

AO — Analog Output DO — Digital/Discreet Output

USE

++™

OPERATIVE

KEYS

CLEAR

ENTER

Clear — performs three operations:

• Cancels a data entry before the user presses Enter, thus leaving the current value unchanged.

• Returns a forced point to automatic control.

• Redisplays the previous menu level.

Enter — performs two operations:

• Selects the displayed item, thus displaying either its maintenance or configuration data, depending on whether the user is in the Status mode or the Edit mode.

• Accepts the value entered in a configuration decision as new configuration data or as a force.

Down arrow — displays the next configured item or decision. When the last configured item or decision is displayed, the LID re-displays the first configured item or decision. For example, when the user presses the down arrow key while viewing the last configuration decision of an algorithm, the LID re-displays the first configuration decision.

Up arrow — Displays the previous configured item or decision.

USE

Table 5 — Numeric Keys

OPERATIVE

KEYS

Numeric keys

Performs two operations:

• Separates items, such as an algorithm from its occurrence or hours from minutes.

• Serves as a decimal point in numeric values.

Performs two operations:

• Negates the value of numeric keys.

• Clears current data entry value any time it is not the first key pressed during the data entry sequence.

USE

VIEWING MODES — The user can view items in either the Status (maintenance) mode or the Edit (configuration) mode.

Status Mode

— When the user first powers up the LID, it displays the CC6400 controller items in Status (maintenance) mode. The user may view the current value or status of an item in Status mode without actually logging on to the Controller. Knowing the current values or status of items can be useful when troubleshooting. For example, the user could determine if a point was forced.

NOTE: Not all items have maintenance data. If the item you select does not have maintenance data, the LID will display “No maintenance.”

Accessing Items in Status Mode

— The user can access

maintenance data in Status mode in two ways:

• Pressing the appropriate function key (i.e., )

ALRM once to access a category (i.e., alarms) and then continuing to press that key ( ) to scroll through all the

ALRM items in that category (i.e., Limit Alarm, Set point Alarm, Discrete Alarm, First Out Alarm, Runtime Alarm, and Number of Starts Alarm). Press to

ENTER

display the first maintenance decision.

NOTE: Scrolling by repeatedly pressing the function key displays the name of all the items in that category, whether or not they are actually configured. Scrolling by pressing the up or down arrow displays only the configured items within that category.

• Pressing the appropriate LID numeric key (i.e., 2) and the appropriate function key (i.e., ) to directly

ALRM access an item without having to scroll through all the items in that category. Press to display the first

ENTER

maintenance decision.

Edit Mode

— Because the LID first displays items in Status mode when it is powered up, the user must log on to the connected CC6400 Controller and press the key to

EXPN/EDIT

switch to Edit mode.

While in Edit mode, the user can change the configuration of items. For example, the user could change the value of an algorithm’s configuration decision.

NOTE: Not all items have configuration data. If the item selected does not have configuration data, pressing the

EXPN/EDIT

key will have no effect. The LID will display

“No configuration.”

Accessing Items in Edit Mode

— The two ways to access items in Edit mode are the same as in Status mode, except for an additional step — pressing the key.

EXPN/EDIT

The user can access configuration data in Edit mode in two

ways:

• Pressing the appropriate function key (i.e., ) once

to access a category (i.e., alarms), pressing and then continuing to press that key ( ) to scroll

ALRM

EXPN/EDIT

ALRM

through all the items in that category (i.e., Limit Alarm,

Set point Alarm, Discrete Alarm, First Out Alarm, Runtime Alarm, and Number of Starts Alarm).

• Pressing the appropriate LID numeric key (i.e., 2), the appropriate function key (i.e., ), and

EXPN/EDIT

to directly access an item without having

ALRM

to scroll through all the items in that category.

QUICK ACCESS IN EITHER STATUS OR EDIT MODE — Use Table 6 as a reference to directly access

CC6400 Controller items using a LID in either Status or Edit mods. For example, to access maintenance data for the AO — Heating VAV algorithm, press , , and . To

6 ALGO ENTER access configuration data for the AO (Analog Output) — Heating VAV algorithm, press , , , and . If the database consisted of two AO — Heating

ENTER VAV algorithms, to access the second one, press , (decimal), ,, ,and .

2 ALGO EXPN/EDIT ENTER

6 ALGO EXPN/EDIT

6 .

FUNCTION KEYS

OPERATIVE KEYS

OMNIZONE VPAC 12:00 02-06-04

EXPN

STAT

SET

EDIT

SCHD

–

NUMERIC KEYS

Fig. 5 — Local Interface Display (LID)

TEST

SRVC

ALRM

HIST ALGO

CLEAR

ENTER

FUNCTION KEYS

OPERATIVE KEYS

Table 6 — Quick Access Chart

LID

NUM.

KEY

1 AO—Adaptive Control Hardware Points Alarm History Function Definition Limit Set Clock Occupancy 2 AO—Cooling CV Software Points Analog Point Trace Channel Definition Setpoint Real Time Clock Setpoint 3 AO—Cooling VAV Temperature Input Discrete Point Trace System Definition Discrete Controller Password Holiday 4 AO—Fan Tracking Milliamp Input Consumable Channel Setpoint Definition First out N/A S/W Setpoint 5 AO—Heating CV Custom Milliamp Input Internal Consumable Database Control Runtime N/A Network Time 6 AO—Heating VAV Voltage Input Runtime Channel Comfort Controller # of starts N/A N/A 7 AO—Humidity Control Custom Voltage Input N/A CCN Control N/A N/A N/A 8 AO—Mixed Air CV w/IAQ Sensed Discrete Input N/A LID Preferences N/A N/A N/A

9 AO—Mixed Air VAV w/IAQ Latched Discrete Input N/A N/A N/A N/A N/A 10 AO—Permissive Interlock Pulsed Discrete Input N/A N/A N/A N/A N/A 11 AO—Reset Milliamp Output N/A N/A N/A N/A N/A 12 AO—Shared Transducer Custom Milliamp Output N/A N/A N/A N/A N/A 13 AO—Static Pressure Voltage Output N/A N/A N/A N/A N/A 14 DO—Analog Custom Voltage Output N/A N/A N/A N/A N/A 15 DO—DX-Staging VAV Discrete Output N/A N/A N/A N/A N/A 16 DO—Electric Heat CV Stepper Motor Output N/A N/A N/A N/A N/A 17 DO—Electric Heat VAV Discrete Software Point N/A N/A N/A N/A N/A 18 DO—Enthalpy Comparison Analog Software Point N/A N/A N/A N/A N/A 19 DO—Interlock Network Data Out N/A N/A N/A N/A N/A 20 DO—Lighting Control Network Data In N/A N/A N/A N/A N/A 21 DO—Permissive Interlock N/A N/A N/A N/A N/A N/A 22 DO—Pump Control N/A N/A N/A N/A N/A N/A 23 DO—Prop Ther mo N/A N/A N/A N/A N/A N/A 24 DO—Prop Thermo 2 Pipe N/A N/A N/A N/A N/A N/A 25 DO—Prop Thermo 4 Pipe N/A N/A N/A N/A N/A N/A 26 DO—Staged Thermostat N/A N/A N/A N/A N/A N/A 27 DO—Staging Control N/A N/A N/A N/A N/A N/A 28 DO—Time Clock N/A N/A N/A N/A N/A N/A 29 DO—Time Clock w/Check N/A N/A N/A N/A N/A N/A 30 AOSS Schedule N/A N/A N/A N/A N/A N/A 31 Network Broadcast N/A N/A N/A N/A N/A N/A 32 Linkage/AOSS Schedule N/A N/A N/A N/A N/A N/A 33 NTFC w/Enthalpy Check N/A N/A N/A N/A N/A N/A 34 Sensor Group N/A N/A N/A N/A N/A N/A 35 WSM Air Source N/A N/A N/A N/A N/A N/A 36 WSM Cool Source N/A N/A N/A N/A N/A N/A 37 Custom Program N/A N/A N/A N/A N/A N/A

AO — Analog Output AOS S — Adaptive Optimal Star t/Stop CV — Constant Volume DO — Digital Output IAQ — Indoor Air Quality N/A — Not Available NTFC — Nighttime Free Cooling VAV — Variable Air Volume WSM — Water System Manager

Algorithms

(ALGO)

LEGEND NOTES:

Status (STAT)

LID FUNCTION KEYS

History

(HIST)

1. To change from Edit mode to Status mode, press or press

EXPN/EDIT

2. Not all available selections will have items to select in sublevels.

Service (SRVC)

again.

Alarm

(ALRM)

Setup (SET)

Schedules

CLEAR

(SCHD)

Automatic Run Test — The 50BV,XJ unit controls are

programmed with an automatic run test that checks connection and operation of major components. To perform the run test:

Verify that the control display (LID device/System Monitor)

interface cable is connected to internal jack on main controller; that the fire alarm/shutdown switch input (FSD) has a factory jumper or field input; that Bypass (if installed) is set in the DRIVE position; and that the Local/Off/Remote switch is set to the REMOTE position.

NOTE: When the Local/Off/Remote switch is in the REMOTE position, the controller time schedule is pre-set (from the factory) as unoccupied. This means that the unit will not turn on until the run test is enabled. However, if the controller schedule has already been modified in the field, and the current time of day is occupied, then the supply fan will start. The run test will shut the fan down when it

begins. The run test will complete and then the supply will automatically restart.

NOTE: If the Local/Off/Remote switch is in the OFF position, it is normal for the red alarm light on the display panel to be lit, indicating that the unit is disabled.

NOTE: If the red light stays on when the switch is moved to REMOTE, or if any other problems occur during the run test, refer to the Troubleshooting section of this manual.

To perform the Run Test:

1. Turn unit power on.

The LID display will show the controller identification, time and date (Fig. 5):

OMNIZONE VPAC

hh:mm mm-dd-yy

2. Press 3 and then . The LID display will show: Controller Password

3. Press . The LID display will show:

4. Key in the password and press .

5. The LID display will show:

6. Press . The LID display will show:

7. Press again. The LID display will show:

8. Press . The LID display will show:

9. Press 6 times. The LID display will show:

10. Press 1 then , The LID display will show:

11. The control module will now check if there is input from

ENTER LogintoController Enter Password NOTE: The LID display has two modes: Edit mode and Status/Maintenance mode. If the LID display is in Edit mode, then the display will only show the word “password.” Press the key to toggle to the Status mode.

Press the to display:

LogintoController

Enter Password

NOTE: The default password is 1111.

LogintoController Logged In

NOTE: At this point, for the 50BV unit only, the run test will follow these steps:

a. Press 37 . The display will show:

Custom Program

b. Press . The display will show:

2.0 Global Dictionary OMNIZONE

c. Press (NOTE: Display will flash,

indicating that the device is now in edit mode.) The display will show:

2.0 Global Dictionary OMNIZONE

d. Press . The display will show:

Compressor Stages

4.00 NOTE: A 50BV unit with only 2 compressors will

display 2.00. Skip to Step 6.

e. Input 2.00 and Press . The display will show:

Compressor Stages

2.00 STAT

Hardware Points

STAT

Software Points

ENTER

Compressor 1 Status

Factory/Field Test Stop

Factory/Field Test Start NOTE: At this point, the yellow warning light on the

display panel will be lit and will stay on throughout the run test. After each successful step, the red alarm light will blink once.

BYPAS(50XJ),DHS,FSD,SAT,DSP,andCSMUX.

SET

EXPN/EDIT

ENTER

ALGO

ENTER

EXPN/EDIT

ENTER

If the control does not receive open/open/closed/ in range/in range/in range, the red alarm LED will go on and the test will stop.

If the inputs are OK, the red alarm LED blinks once and the test continues.

12. Next, the control forces the Supply Fan (SF) and all of the Compressors (COMP) off, and waits 15 seconds.

For the 50XJ unit, if the REMOTE LED and AUTO LED on the VFD display are on, the red LED blinks once and the test continues.

NOTE: For the 50XJ unit, if the controller is configured with a water Economizer, the delay is 2 min. and both valves are commanded to 0%. Both water valves will close.

13. The control forces SF on and SPEED to 20 percent and then waits 30 seconds.

If the VFD display shows “10.6 Hz,” the Remote and Auto LEDs blink, and the fan goes on, then the red LED on the control module blinks once and the test continues.

NOTE: For the 50XJ unit, if the controller is configured with a water Economizer the delay is 2 min. and Econo valve is commanded to 100%. The economizer valve will open and the RVS/HD (reverse/head pressure) valve will remain closed.

14. The control forces SF on and SPEED to 35 percent and then waits 30 seconds.

If the VFD display shows “20.0 Hz,” the Remote and Auto LEDs blink, and the fan goes on, then the red LED on the control module blinks once and the test continues.

NOTE: For the 50XJ unit, if the controller is configured with a water Economizer the delay is 2 min. and RVS/ HD valve is commanded to 100%. The economizer valve is commanded to 0% and the RVS/HD valve will open.

15. The control forces SF off then waits 15 seconds. If the VFD display shows “Off,” the Remote and Auto

LEDs are off, and the fan goes off, then the red LED on the control module blinks once and the test continues.

NOTE: For the 50XJ unit, if the controller is configured with a water Economizer both valves are commanded to 0%. The economizer valve and RVS/HD will close.

NOTE: For the 50BV unit, the steps below (16-24) will be completed for the number of compressors configured.

16. The control forces CMP1 (compressor 1) on then waits 5 seconds.

If CSMUX is not in range the red LED will go on and the test will stop.

If CSMUX is in range, the red LED blinks once and the test continues.

17. The control forces CMP1 off.

18. The control forces CMP2 (compressor 2) on then waits 5 seconds.

If CSMUX is not in range the red LED will go on and the test will stop.

If CSMUX is in range, the red LED blinks once and the test continues.

19. The control forces CMP2 off.

20. The control forces CMP3 (compressor 3) on, if configured, then waits 5 seconds.

If CSMUX is not in range the red LED will go on and the test will stop.

If CSMUX is in range, the red LED blinks once and the test continues.

21. The control forces CMP3 off.

22. The control forces CMP4 (compressor 4) on, if configured, then waits 5 seconds.

The LID display shows: Factory/Field Test Stop The yellow LED will go off, and the red LED will go

off.

23. The control forces CMP4 off.

24. The run test is complete.

Power Up the LID Display — After completing the

automatic run test, perform the following procedures to change the controller password, set the controller clock, configure schedules, set parameters, view settings, and view alarm history.

1. Set the Remote/Local/Off switch on the front of the unit to the OFF position. This prevents operation of the fan and compressors while still providing power to the unit controls.

NOTE: When the switch is in the OFF position, the red alarm LED will be lit; this is normal. The bypass point will also indicate OK.

2. If the unit access panel (for power and controls) is still on the unit, remove it in order to view the control modules during start-up.

3. Switch the main unit power disconnect to ON.

When power is applied to the OMNIZONE™ System Control panel, the red LED on the top front of the processor module will flash at a rapid pace (about twice a second) for the first 30 to 60 seconds. This rapid flash will then be replaced by a slower paced flash (about once per second).

The green LED below the red LED will start flashing. This LED indicates input/output communications for accessory input output modules and the LID display.

The yellow LED will flash when the controller is broadcasting CCN messages to a laptop or other computer.

The third LED from the bottom of the controller (PCB1) will light.

The LID display will show the controller identification, time and date as shown below.

OMNIZONE VPAC

hh:mm mm-dd-yy

Log On to the LID Display — ToLogOntotheLID

display, perform the following procedure:

1. Press 3 and then . The LID display will show: Controller Password

2. Press . The LID display will show:

3. Key in the password and press .

ENTER LogintoController Enter Password NOTE: The LID display has two modes: Edit mode and

Status/Maintenance mode. Edit mode allows the user to change settings on the configurations screens. Status/ Maintenance mode only allows the user to look at the settings.

If the LID display is in Edit mode, then the display will only show the word “password.” Press the

EXPN/EDIT

sure the LID display shows: LogintoController

Enter Password

NOTE: The default password is 1111.

SET

key to toggle to the Status mode. Make

ENTER

4. The LID display will show: LogintoController Logged In NOTE: The user will be automatically logged off after

15 min. of non-use.

Change the Default Password — To change the

default password, perform the following procedure: NOTE: The password must have already been entered to

perform this procedure.

1. Press 3 and then . The LID display will show: Controller Password

2. Press . The LID display will show:

3. Press . The LID display will show:

4. Enter the new password (up to 6 digits) and press

5. Press twice to leave the password screen and re-

ENTER LogintoController Logged in

EXPN/EDIT Password 1111 (default password, or previous password entered)

ENTER Password (password just entered) NOTE: Remember this password; write it down.

CLEAR

turn to the default display screen.

SET

. The LID display will show:

Set the Clock — The user must be logged in to set the

clock. To set the clock, perform the following procedure:

1. Press 1 and then . The LID display will show: Set Clock

2. Press . The LID display will show:

3. Press . The LID display will show:

4. Enter the time. The time is entered in military time (for

5. Enter the day of week. The numbers 1 through 7 corre-

6. Enter the number of the corresponding month (1 through

7. Enter the day of the month. Press then press

ENTER No Maintenance NOTE: There is no maintenance information regarding

setting the clock.

EXPN/EDIT Time 00:00

example 14.59 for 2.59 pm). Press then press the button. The LID display will show:

Day of Week 1

spond to the days of the week (1 = MON, 2 = TUE, 3 = WED, 4 = THUR, 5 = FRI, 6 = SAT, 7 = SUN). Press

ENTER

Month 1

12). Press then press . The LID display will show:

Day 1

. The LID display will show: Ye a r 95

SET

ENTER

then press . The LID display will show:

ENTER

8. Enter the last two digits of the current year. Press ENTER

Update Clock No

9. Press 1 and then to cause the controller to

update the clock. The LID display will flash. Press

CLEAR

should update to the input time and date.

then press . The LID display will show:

ENTER

twice to view the default display and the clock

Configure Schedules — Schedules are one method of

starting and stopping the unit at specified intervals. To configure the schedules, perform the following procedure:

1. Press 1 and then . The LID display will show:

Occupancy Algorithm

2. Press . The LID display will show:

3. Press . If the LID display shows “MODE 0” then

4. Press . The LID display will show:

5. Press the button. The LID display will show:

6. Input the Occupancy Start time for this period.

7. Press the to input the Occupied To time for period 1.

8. Input the days and times for periods 2 through 8 as

9. Press clear to leave the occupancy programming.

ENTER Time Schedule Enter to select

ENTER the user is in Maintenance mode and the LID display is showing the maintenance information for the occupancy schedule. Press to enter the configuration mode. The LID display will show:

Manual Override Hours 0 hours This is the first configuration for each occupancy

algorithm and is used to put the schedule in or out of occupancy override for the number of hours entered.

Period 1: Day of week 00000000 The eight digits represent if this period should apply to

certain days of the week or holidays. The digits representM,Tu,W,Th,F,Sa,Su,andHol,respectively. Enter a series of 0s or 1s with a 1 corresponding to the days that this period should apply to and a 0 for the days that this schedule should not apply to. As an example, entering 11111000 would make the schedule apply to days Monday through Friday and not apply to Saturday, Sunday, or Holidays.

Period 1 occupied from 00:00

NOTE: 12.00 represents 12:00 pm.

required.

SCHD

EXPN/EDIT

Program Set Points — To program the set points,

perform the following procedure:

1. Press 2 and then . The LID display will show: Set point Schedule

2. Press . The LID display will show:

3. Press .

ENTER Supply Fan Status SETPT01

ENTER

SCHD

4. If “No maintenance” is displayed, press to view the set point information. The LID display will show:

Occupied Lo Set point

0.30 ″ H2O This is the pressure set point below which the fan is

considered to be off.

5. Press . The LID display will show: Occupied Hi Set point

0.40 ″ H2O This is the pressure set point above which the fan is

considered to be on. The down or up arrow will also display the Unoccu-

pied Low and High Temperature set points. These values should be kept the same as the occupied values.

6. Setpoint 02 internally coordinates the supply air set point reset in several of the algorithms and can not be modified.

Setpoint 03 is used for comparison by the unit to return air, Space temperature or Average space temperature through linkage to determine when to start reset of the supply air when occupied, when to turn on heat and disable cooling when occupied and when to bring the unit on for unoccupied heating or cooling.

Setpoint 04 is used to set the head pressure set point if the unit is ordered with the head pressure control option. Only the Occupied Low set point may be modified the other values will change to the Occupied low valued shortly after it is modified so that all the values remain the same.

Setpoint 05 is used to set the supply air static pressure the unit should maintain. Only the Occupied Low set point may be modified the other values will change to the Occupied low value shortly after it is modified so that all the values remain the same. The set point in the static pressure control algorithm will also follow and cannot be modified in the algorithm configuration screens.

Setpoint 06 is the Supply air temperature set point. Only the Occupied Low set point may be modified the other values will change to the Occupied low value shortly after it is modified so that all the values remain the same. The set point in DX VAV staging and some of the other algorithms will also follow and cannot be modified in the algorithm configuration screens.

Setpoint 07 is the building pressure set point for the building pressure control of a variable speed exhaust fan from a field-supplied module. Only the Occupied Low set point may be modified the other values will change to the Occupied low value shortly after it is modified so that all the values remain the same.

Setpoint 08 is the raw milliamp set point for the building pressure control and is tied to Setpoint 07 for the sensor range selected in the custom programming configuration. Several choices of building static pressure sensors may be purchased and supplied for building pressure control.

Setpoint 09 is used for the humidification/dehumidification output from a field-supplied module. This set point may be modified to enable the Humidity output to either humidify or dehumidify when the indoor relative humidity (IRH) exceeds the set point.

Table 7 lists the available controller set points and their default values.

7. Pressing the button will take the user out of the set point configuration mode.

CLEAR

EXPN/EDIT

Table 7 — Controller Set Points

DESCRIPTION

DISPLAY

SCREENS

OMNIZONE::SETPT01: Supply fan Status Occupied Lo Setpoint 0.3 in H2O OccLow Occupied Hi Setpoint 0.4 in H2O OccHgh Unoccupied Lo Setpoint 0.3 in H2O UnOccLow Unoccupied Hi Setpoint 0.4 in H2O UnOccHgh

OMNIZONE::SETPT02: VAVRESETbaseline Occupied Lo Setpoint 0 dF OccLow Occupied Hi Setpoint 0 dF OccHgh Unoccupied Lo Setpoint 0 dF UnOccLow Unoccupied Hi Setpoint 0 dF UnOccHgh

OMNIZONE::SETPT03: Heat\Cool Mode & Reset Occupied Lo Setpoint 70 dF OccLow Occupied Hi Setpoint 74 dF OccHgh Unoccupied Lo Setpoint 55 dF UnOccLow Unoccupied Hi Setpoint 85 dF UnOccHgh

OMNIZONE::SETPT04: Head Pressure Control Occupied Lo Setpoint 225 PSIG OccLow Occupied Hi Setpoint 225 PSIG OccHgh Unoccupied Lo Setpoint 225 PSIG UnOccLow Unoccupied Hi Setpoint 225 PSIG UnOccHgh

OMNIZONE::SETPT05: Supply Static Pressure Occupied Lo Setpoint 1.5 in H2O OccLow Occupied Hi Setpoint 1.5 in H2O OccHgh Unoccupied Lo Setpoint 1.5 in H2O UnOccLow Unoccupied Hi Setpoint 1.5 in H2O UnOccHgh

OMNIZONE::SETPT06: Supply Air Temperature Occupied Lo Setpoint 55 dF OccLow Occupied Hi Setpoint 55 dF OccHgh Unoccupied Lo Setpoint 55 dF UnOccLow Unoccupied Hi Setpoint 55 dF UnOccHgh

OMNIZONE::SETPT07: Building Static Pressure Occupied Lo Setpoint 0.02 in H2O OccLow Occupied Hi Setpoint 0.02 in H2O OccHgh Unoccupied Lo Setpoint 0.02 in H2O UnOccLow Unoccupied Hi Setpoint 0.02 in H2O UnOccHgh

OMNIZONE::SETPT08: BSP raw control Occupied Lo Setpoint 12.32 ma OccLow Occupied Hi Setpoint 12.32 ma OccHgh Unoccupied Lo Setpoint 12.32 ma UnOccLow Unoccupied Hi Setpoint 12.32 ma UnOccHgh

OMNIZONE::SETPT09: Humidity Control Occupied Lo Setpoint 0 %RH OccLow Occupied Hi Setpoint 99 %RH OccHgh Unoccupied Lo Setpoint 0 %RH UnOccLow Unoccupied Hi Setpoint 99 %RH UnOccHgh

LEGEND

BSP — Building Static Pressure RH — Relative Humidity

VALUE UNITS STATUS FORCE NAME

Check System Parameters — To check system

parameters, press the button. The LID display will show: “Hardware Points Table 1.” Press to view the hardware points. The user can navigate up and down through the points with the up and down arrows.

Press 2 and to display the software points. The user

STAT can navigate up and down through the points with the up and down arrows.

Refer to Tables 8 and 9 for hardware and software points.

STAT

ENTER

Display Alarm History — If the controller is indicating

there are alarms, the user can view the alarm history by

pressing the button. The LID display will show “Alarm History.” Press . The LID display will show the date

HIST

ENTER

and type of alarm.

As an example, if the LID display shows: ALARM — 10:55 11-27-02 SFS

That display indicates that on 11/27/02 at 10:55 A.M. the system Supply Fan was either on when it had not been commanded on or was off when it was commanded on.

The user can view other stored alarms by pressing the up and down arrows. The twenty-four most recent alarms are stored.

Configure Custom Programming Selections —

To configure the custom programming selections, perform the following procedure:

1. Press 37 . The LID display will show: Custom Program

2. Press . The LID display will show:

2.0 Global Dictionary OMNIZONE

3. Press . The display indicates “No Data.” Press then press . Press

ENTER

Compressor Stages

4.00

4. Press 4 and then to indicate that 4 compressors are installed.

5. Use the down and up arrows to select the other configuration parameters as required. See Table 10 for a list of configuration parameters.

6. A field-supplied 0 to 10 vdc signal to the 50XJ unit may be used to reset the supply-air temperature.

The reset will be taken off the supply air set point configured in the controller. The reset range can be changed by adjusting the High Conversion Endpoint value of the custom voltage input to a value other than

20. For example for 10 degrees of reset change the Hi input value to 10. This may be found by pressing 7

STAT custom voltage input point in the controller. The first will be CSMUX, which is the compressor status multiplexed input. Press to see the following in the LID display:

Ext. Supply Air Reset RESET Press . If the LID display shows: System Value Press . The LID display will show: Low Input Endpoint

2.0 Volts

Press three times to get to the High Conversion Endpoint. The user must be logged in to be able to change this otherwise you can only view it. See the start up section for how to log into the controller.

Configuration parameters are shown in Table 10.

ALGO

ENTER

CLEAR

EXPN/EDIT

again. The LID display should now show:

ENTER

from the Keypad. RESET will be the second

ENTER

EXPN/EDIT

Table 8 — Controller Hardware Points Table 9 — Software Points

DESCRIPTION

DISPLAY

SCREENS

OMNIZONE::HWP01-32: Hardware points Table 1 Supply Air Temperature 67 dF SAT Duct Static Pressure 0.2 in H2O DSP Comp. Status MUX 1.86 Volts CSMUX Fire Alarm/ShutDown Enable FSD Cond. Water Flow Switch Ye s C DW F Remote Occupancy Disable ROCC Duct High Press. Switch Normal DHS Entering Water Temp. 69.9 dF EWT Compressor 1 Relay Stop CMP1 Compressor 2 Relay Stop CMP2 Compressor 3 Relay Stop CMP3 Compressor 4 Relay Stop CMP4 Supply Fan/VFD Stop SF VFD Speed Signal 0 % SPEED Non Critical Fault Off WARN Critical Fault Off ALARM Mixed/Return Air Temp 77.2 dF MA_RA Dirty Filter Status Clean FLTS Phase Loss Protection Normal PHASE Ext. Supply Air Reset 0 dF RESET Water Econ. FreezeStat Normal FREEZ Space_Reset Sensor 79.2 dF SPT VFD Bypass Enable Disable BYPAS Head Pressure(Comp1) 118.76 PSIG PRES Ventilation Request Close VENTR VAV Termi nals Co ntro l No TRMCT 2-position/Econo Valve 0% ECONO Reverse/Head Press Ctrl 100 % Control MVLV Hot Water Valve 0% HWV Heat Interlock Relay Off HIR Bypass Start_Stop Stop BPS_S VAV Terminals Open MAX Close TRMOP

OMNIZONE::HWP33-64: Hardware points table 2 Cooling Tower Sump Temp. 57.5 dF TWR Building Static Milliamp 12.51 ma BSP Condenser Leaving Water 70.3 dF LWT Indoor Air Quality 587.21 IAQ Indoor Relative Humidity 49.7 % IRH Outdoor Air Temp. 76.1 dF OAT Heat Stage 1 Off HEAT1 Heat Stage 2 Off HEAT2 Heat Stage 3 Off HEAT3 Heat Stage 4 Off HEAT4 Pump Request Off PUMP Cooling Tower Request Off TOWER Exhaust Fan 0% EXH Ext. Dehumidification Stop DEHUM

VALUE UNITS STATUS FORCE NAME

DESCRIPTION

DISPLAY

SCREENS

OMNIZONE::SWP65-96: Software Points Compressor 1 Status Off CLO1 Compressor 2 Status Off CLO2 Compressor 3 Status Off CLO3 Compressor 4 Status Off CLO4 Bypass Acc Panel Secure No BP_SAFE DX VAVRESET control 0 dF VAVRESET Factory/Field Test Stop FLDTST Building Static Pressure 0.03 in H2O BSP_IN Time Clock Off TIMCLOCK Cooling Disable COOLOK Supply Fan Status Off Control SFS Ok to run Fan No OKFAN OK Fan + Sup. Fan Stat FA L SE S F_ SF S Fan + Cond. Water Flow FA LS E FAN _C DW F Equipment Mode Cool Control MODE Activate Evacuation Mode Disable EVAC Space Control Point 74 dF CTRLPT Mod. Econ Enabled No Control ECON_OK Head Pressure Control Disable Control HEAD Economizer Control Temp. 77.22 dF ECONPT Compressor Cooling Disable COMPRES Duct Static Failure Normal DSP_ALM Compressor 1 Alarm Normal C1_ALM Compressor 2 Alarm Normal C2_ALM Compressor 3 Alarm Normal C3_ALM Compressor 4 Alarm Normal C4_ALM Cond. Flow Alarm Status Disable Control CDWF_ST

VALUE UNITS STATUS FORCE NAME

Table 10 — Configuration Parameters

DESCRIPTION VALUE UNITS NAME

Compressor Stages 2.00 NUM_CMP Reset Ratio 3.00 dF RSET_RTO CDWF 0=NO,1=YES 0.00 CDFW_SWT ECON 0=NO,1=YES 0.00 EWT_SNS EWT Reset 0=NO,1=YES 1.00 EWT_RST MOD.VLV 0=NO,1=YES 0.00 MOD_ECON 0=CONST.,1=VARIABLE 0.00 FLOW_TYP 0=RAT,1=MAT 2=NONE 2.00 MARA_SNS PHASE 0=NO,1=YES 0.00 PHAS_SWT FREEZ 0=NO,1=YES 0.00 FREZ_SWT ENABLE ECON. 68.00 dF ECON_SET SPT 0=NO,1=YES 0.00 SPT_SNS PRES 0=NO,1=YES 0.00 PRES_SNS TWR 0=NO,1=YES 0.00 TWR_SNS LWT 0 =N O,1 =YE S 0.00 LWT_SNS IAQ 0=NO,1=YES 0.00 IAQ_SNS IRH 0=NO,1=YES 0.00 IRH_SNS BSP 0=NO,1=YES 0.00 BSP_SNS BSP Range 1.00 in H2O BSP_RNG BSP LOW VALUE –0.50 in H2O BSP_LOW

LEGEND

BSP — Building Static Pressure CDWF — Condenser Water Flow ECON — Economizer EWT — Entering Water Temperature IAQ — Indoor Air Quality IRH — Indoor Relative Humidity LW T — Leaving Water Temperature MAT — Mixed Air Temperature RAT — Return Air Temperature SPT — Space Temperature

Set Controller Address — To set the address of the

OMNIZONE™ System Control panel controller, perform the following procedure:

1. Press 7 and then . Press and then EXPN/EDIT

2. Type in the CCN element number and press .

SRVC ENTER

ENTER

3. Press the button. Type in the CCN bus number and

press .

ENTER

Log Off from Controller — To log off from the

OMNIZONE System controller Press 3 and then . The controller password will be displayed.

SET

1. Press . The display should show:

ENTER

EXPN/EDIT

displayed.

2. Press the button. The LID display will show: Log out of Controller Press 1. Press to log off.

ENTER

OPERATION

Occupancy Determination —

controller can determine occupancy in many ways. Local occupancy is determined by either a local schedule contained in the CC6400 controller, the use of the ROCC discrete input point or by setting the Local/Off/Remote switch to Local. In order for the CC6400 schedule or ROCC point to function the Local/ Off/Remote switch must be set to Remote.

When the OMNIZONE unit is connected to a Carrier Comfort Network and the Local/Off/Remote switch is set to Remote, the controller occupancy can be determined by a Network Group schedule, a Network Global schedule, or via Linkage from a linkage device such as a ComfortID™ linkage master.

The OMNIZONE™

Fan Control — All Variable Air Volume (VAV) units have

a Variable Frequency Drive (VFD) to provide variable fan motor speed and thus variable airflow. Fan control turns the fan on and off based on unit operating mode, and controls fan speed to maintain a particular duct static pressure at a Duct Static Pressure Sensor (DSP). The objective is to maintain a reasonably constant supply-air exit velocity at VAV system outlet grilles, regardless of damper opening positions. The duct static pressure sensor is field-installed about toward the “far end” of the ductwork. A High Duct Static Switch (HDS) provides protection by shutting the fan down if the duct static pressure exceeds a maximum setting.

For the 50XJ unit, a VFD interface display is mounted in the front of the unit. A number of user-adjustable features can be entered/changed using the keypad on the display. These features described in detail in the Variable Frequency Drive Control section.

/3of the way

Sequence of Operation — The following control

sequence of operation for the 50XJ,BV unit describes the various sequences that occur depending upon the way an operation is triggered and which software control points are involved.

SUPPLY FAN — The Supply fan can be activated in any of the following ways:

• Unoccupied space or return air temperature demand.

• Unoccupied Linkage demand.

• Local Time Schedule (TIMCLOCK software point).

• Remote Occupancy (ROCC software point).

• By placing the remote-off-local switch in the local

mode.

• Enabled by Schedule.

Once one of the above conditions exists, either TIMECLOCK or ROCC indicates ON or Enable. The software point OKFAN will turn on followed by the points TRMCT for air terminal control and PUMP and TOWER to request condenser water flow and temperature control. Approximately 20 to 30 seconds later the supply fan (SF) point will turn ON and the VFD output SPEED will increase. The SPEED point will output a signal, determined by a PID calculation, based on the duct static pressure DSP input and the Supply Static Pressure set point in SETPT05.

Once the supply fan is running and the static pressure increases above the Supply fan status set point in SETPT01, the supply fan status point (SFS) will indicate ON and the software point SF_SFS will indicate TRUE.

Enabled By Unoccupied Demand Control Point” will display the current value of the sensor used to determine unoccupied demand. The EWT sensor provides this function for the 50BV unit. The display is based on the

— A software point “Space

sensors installed and the configuration of these sensors in the custom configuration, or the status of linkage.

If the Return/Mixed air sensor is in the mixed airstream and configured as such and there is no Space temperature sensor installed and no Linkage, the Space Control Point will display a default value of 75 F, which is above the default occupied cooling set point and below the unoccupied cooling set point. If this condition exists, supply air reset from a sensor and unoccupied unit operation will not occur.

If the unit is configured to use a sensor for the Space Control Point or if Linkage is active and the space has unoccupied demand, the software point OKFAN will turn on followed by the points TRMCT for air terminal control and PUMP and TOWER to request condenser water flow and temperature control. Approximately 20 to 30 seconds later the SF point will turn ON and then the VFD output SPEED will increase. If unoccupied demand is the reason the fan is on, a control force will appear next to the OKFAN point. Otherwise there should not be a force on that point.

If the fan is running due to unoccupied heating or cooling demand, either the space temperature (if installed), return air temperature or average linkage temperature must rise or drop to within half way between the occupied and unoccupied set points in order for the fan to turn back off.

Enabled by Switching to Local Mode placed in the local mode the ROCC point will indicate enable. If ROCC is ENABLED a software routine will override the occupancy schedule so that TIMECLOCK will also turn on. When ROCC is turned off the TIMECLOCK point will turn off within 60 seconds.

Supply Fan Shutdown fied and TIMECLOCK and ROCC are off and disabled, OKFAN will turn off, SF_SFS will turn off, Tower and PUMP will turn off, and then 5 minutes later the SF point will turn off and the VFD speed will go to 0%.

During the 5-minute delay, the cooling and heating routines become disabled. This delay allows a compressor that may have just started to run for its 5-minute minimum on time with the supply fan on. For example, if the staging routine had just started Compressor 3 at the time the OK_FAN point changed to OFF, the cooling routine would become disabled and compressors 1 and 2 would shut off right away. Compressor three would continue to run for its minimum on time of 5 minutes. The fan continues running until all compressors meet the minimum on time and run with a load, preventing them from shutting down due to a safety.

Supply Fan operation with Optional Bypass (50XJ) optional VFD Bypass is installed and the Bypass switch has been turned to Bypass, and the access panel is in place, the software point Bypass access panel secure BB_SAFE has been turned to ON, and the unit operation switch has been placed back in local or remote, then the bypass start stop point BPS_S will follow the SF point when it turns on and off. The terminal open point TRMOP will go on with the TRMCT point before the fan starts.

COMPRESSOR COOLING — If the fan is on and there is no demand for Heat, the equipment mode (MODE) will be COOL, and Cooling (COOLOK) will switch to ENABLE.

If the unit is configured for variable flow the Reverse/Head Pressure CTRL valve will open (otherwise it will already be open), and if there is condenser water flow (CDWF is YES), then the Fan + Condenser water flow point will become TRUE and the Compressor Cooling (COMRES) point will switch to Enable.

— If the unoccupied demand is satis-

— When the switch is

—Ifthe

COMRES triggers the compressor staging routine that controls the number of compressors energized. Units are equipped with 4 compressors piped in separate refrigerant circuits, and staged On/Off in a fixed sequential manner (compressor no. 1 through compressor no. 4). The compressor control routine uses a PID calculation to determine the percentage of cooling required, from 1 to 100%. Demand for the PID calculation is determined from the supply air temperature and the supply air set point (SETPT06).

Compressor cooling (COMPRES) will be turned off for any of the following reasons:

• There is no condenser water flow (CDWF is Off).

• Economizer Freezestat (FREEZ) has been in alarm for

more than 15 minutes.

• MODE changes to heat.

• OK-FAN turns off during normal shut down.

• During normal compressor operation the minimum on

time is 5 minutes and the minimum off time is 5 min.

ECONOMIZER COOLING (50XJ) — The unit diverts condenser inlet water flow through an optional economizer coil to precool evaporator entering airflow. This occurs when there is demand for the cooling, and the temperature at an Entering Water Temperature (EWT) thermistor is colder than the economizer start set point. Waterflow is controlled via two electronic water flow valves. This option also incorporates an Economizer Freeze Switch (EFS), located at the inlet of the economizer coil.

Economizer water flow is in series with the condensers allowing compressor operation while the economizer is operating.

If the Fan is on, and there is no demand for heat then the equipment mode (MODE) will be COOL and Cooling (COOLOK) will switch to ENABLE.

If the unit is configured for variable flow the Reverse/Head Pressure CTRL valve will open (otherwise it will already be open), and if there is condenser water flow (CDWF is YES) then the Fan + Condenser water flow point will become TRUE.

If the entering-water temperature is below the Economizer start set point in the configuration parameters table (Table 10), then the Mod. Econ Enabled point (ECONOK) will change to enable and the Economizer valve will modulate open to lower the Economizer control temp to the supply air set point (SETPT06) temperature. The economizer modulation is controlled by a PID loop and the Reverse/Head pressure control valve will modulate in reverse of the Economizer valve using the formula MVLV = 100 – ECONO.

ECONOMIZER COOLING (50BV) — The unit diverts condenser inlet waterflow through an optional economizer coil to precool evaporator entering airflow. If the entering-water temperature is colder than the setting on the Aquastat, and the return-air temperature is warmer than the setting on the return air thermostat, the two-position diverting valve will direct water to the economizer coil.

Economizer water flow is in series with the condensers allowing compressor operation while the economizer is operating.

COOLING RESET (50XJ) — The controller can reset the supply air set point using these three methods:

• An external 0 to 10 volt input RESET

• The value of the space control point

• Linkage

The external 0 to 10 volt input reset is configured to produce a 0 to 20 degree supply air reset over the 2 to 10 volt range. If more than 1.8 volts is sensed on the input, this method of reset takes priority over other methods.

NOTE: The reset from all methods may be limited to 10 F or 15 F by changing the high end point of the custom voltage input from the default (20 F) to 15 F or 10 F.

Either the return air or a space temperature sensor will be used as the space control point. If this variable goes below the Occupied High set point in the HEAT/COOL MODE AND RESET set point (SETPT03), then for each degree that the Space control point is below the set point value the supply air set point will be reset by the value configured in the custom configuration RESET RATIO.

If Linkage is active, for each degree that the average occupied space temperature is below the average occupied cool set point, the supply air set point will be reset by the amount configured in the RESET RATIO. Reset will be limited to the maximum value the custom voltage input RESET can display.

COOLING RESET (50BV) — The 5k ohm temperature sensor will be used as the space control point. If this variable goes below the Occupied High set point in the HEAT/COOL MODE AND RESET set point (SETPT03), then for each degree that the Space control point is below the set point value the supply air set point will be reset by the value configured in the custom configuration RESET RATIO.

HEATING (50XJ) — The controller is configured to control two types of heat:

• Amodulating4to20mAoutputHotWaterValve

(HWV) in the base unit, wired to the second module.

• Four stages of staged heat wired to a third, accessory

module (PCB3).

For either method of heat to function, a space control point must be configured in the custom configuration. This control point comes from a return air sensor or space sensor, or from the average space temperature received through linkage.

Whenever the space control point is below the occupied or unoccupied heat set point the mode will change to heat and if unoccupied the fan will be started. For linkage, this occurs if the average space temperature is below the appropriate average heat set point.

Both heat control routines use a PID to calculate a supply air set point that will satisfy the heat demand in the space. The modulating output and the staged outputs will both operate at the same time to control an attached heat source, such as steam valves or electric heaters, to provide the supply-air temperature required.

The heat mode changes back to cool when the space control point is back above the occupied heat set point. For linkage, the mode changes back to cool when the average space temperature is back above the average occupied heat set point.

When unoccupied heat is enabled the fan will be stopped and the heat turned off when the space control temperature is more than halfway above the difference between the occupied heat set point and the unoccupied heat set point. For example, if the occupied heat set point is 70 and the unoccupied heat set point is 60 the unit will come on for unoccupied heating below 60 F and turn off again above 65 F. The average occupied and unoccupied set points are used when linkage is active.

HEAD PRESSURE CONTROL (HPC) (50XJ) — In installations where entering water temperature can fall below 55 F, where a water economizer (described above) is not installed, the HPC provides 1 or 2 electronic water flow control valves to vary flow to the condensers. Controlling the water flow maintains compressor discharge pressure above a minimum value, ensuring sufficient refrigerant flow out of the condenser and throughout the refrigerant circuit. Refrigerant pressure is measured at compressor circuit no. 1 by a Discharge Pressure Sensor (DPS).

Units not equipped with a water economizer can be ordered with the reverse/head pressure control valve factory installed and a pressure transducer located in the discharge line of compressor no. 1.

When the condenser water temperature gets low enough to cause the head pressure to drop, the valve will be modulated to control the head pressure of all four compressors by varying the water flow through the condensers.

When the unit is operating and the COOLOK software point is enabled and the EWT gets below 60 F, the Head software point will become enabled and the head pressure control valve will modulate to keep the head pressure at the head pressure set point (SETPT04). The default set point is 225 PSI and may be set from 200 to 250 PSI. The minimum output value for the head pressure control algorithm is 40% in order to maintain a minimum flow through the condensers. The valve will modulate between 40 and 100%. Do not set the minimum lower than 40% or the compressors may shut down due to low flow, resulting in the high-pressure switch tripping.

VENTILATION REQUEST (50XJ) — The ventilation request output will close a set of relay contacts to activate a ventilation damper whenever the supply fan and supply fan status are both true and the TIMECLOCK software point is on.

VAV TERMINAL OPERATION OUTPUT (50XJ) — The VAV terminal control output (TRMCT) closes a set of relay contacts to indicate to non-Carrier air terminals that the fan is either forced on or is going to turn on. This signals the terminals to open and start controlling to the desired CFM and Temperature set points.

VAV TERMINAL OPEN OUTPUT (50XJ) — The VAV terminal open output (TRMOP) closes a set of relay contacts to command the air terminals to open to maximum CFM at times when the fan is operating on the VFD Bypass.

PUMP AND TOWER OUTPUTS (50XJ) — The pump and Tower outputs close a set of relay contacts to indicate that the 50XJ unit is in operation and may require condenser water flow through the unit.

BUILDING PRESSURE CONTROL (50XJ) — The building pressure control output provides an analog 4 to 20 mA signal to control return fan or exhaust fan speed. Fan speed is modulated to maintain the building static pressure set point (SETPT07).

The control parameters for the building pressure set point and building pressure are read and controlled in milliamps but are converted to inches of water for ease of setting and display. The range and low start values of the sensor selected should be configured in the custom configurations screen. The raw sensor value in milliamps will be displayed on the hardware point BSP. The converted sensor reading in inches of H

Owillbe

displayed at the software point BSP_IN. The set point input in SETPT07 in inches of H

O is converted to a raw milliamp set

point in SETPT08. The algorithm controls to the milliamp values since the math required for control using the static pressure in inches generates numbers too small to be used given the range of the controller configuration parameters.

Diagnostic Features — The CC6400 provides a number

of features to help protect the unit and allow problem diagnosis.

CRITICAL FAULT — The controller provides an output (for field connection) to signal an external building systems monitor or control that the unit is not operating properly and has shut down. A red light mounted on the front of the unit provides visual indication of this alarm condition.

NOTE: If the Local/Off/Remote switch is in the OFF position, it is normal for the red alarm light on the display panel to be lit, indicating that the unit is disabled.

NON-CRITICAL FAULT — The controller provides an output for a yellow light, mounted on the front of the unit, that indicates the need for minor maintenance or service.

FIRE INPUT (FSD) — This is a normally closed input, which when opened, deenergizes an isolation relay in the unit, opening the input to the controller. When this input turns On, all control outputs are immediately turned Off, including the fan. Unit reset requires manual resetting at the main controller keypad.

DUCT HIGH STATIC INPUT (DHS) — This air switch provides backup protection for the ductwork. It is factory installed in the unit, wired to the unit main controller to receive 5 vdc. It is a normally open discreet switch, with adjustable manual setting at the switch (range is 1 to 5 in. wg). Upon switch closure, the controller immediately turns all outputs Off, including fan, and then indicates an alarm both by turning On its Alarm Output, Red Alarm light and via communications.

DIRTYFILTERSSWITCH(DFLTS)(50XJ)—Thisswitch measures the change (delta) in air pressure across the filters. When the delta increases beyond the preset setting, a yellow warning light will be lit, indicating that the filters need cleaning or replacement.

The switch receives 5 vdc from the unit controller and monitors air pressure delta across the return air filters. Switch is normally open, with manually adjustable setting at the switch between 0.5 and 1.5 in. wg. Upon closure, controller should wait to assure closure for minimum 1 minute, then indicate an alert via its non-critical alert output and via communications. All other unit operation should remain normal.

COMPRESSOR OVERLOAD (COL)/SAFETIES — Each compressor circuit is provided with a temperature overload board (Copeland Protector Bd.), a Current Overload/Sensor Board (COL), High Pressure Switch (HPS), Low Pressure Switch (LPS), and Evaporator Freeze Switch (EFS). These devices are wired in series to the contactor for each compressor. Each such circuit is then wired through a common resistor board; such that any one or more input(s) to the main controller allows it to discern which compressor is not operating when it should be.

The Current Overload Board (COL) is located in the unit control box, wired in the control power line for the compressor pilot relay (which drives the compressor contactor), and incorporates a current loop which monitors one leg of the compressor power leads. This board is powered along with the related compressor contactor.

Whenever the compressor current falls below a threshold level (i.e., compressor not operating), it activates an on-board relay which opens power to the compressor pilot relay (i.e., compressor contactor), and turns On a control power feedback line to the unit controller, via the resistor board (described above). Any one of the safety switches described herein will cause this event. In the event this occurs, the controller shall turn OFF this compressor, and start the next compressor in sequence. After a 5-minute period, the controller shall restart this compressor, and turn the other one off, as cooling demand requires. If the ‘problem’ compressor then operates for 10 minutes of run time normally, the unit reverts to normal operation and compressor sequencing. If not, and the same error occurs again, this compressor shall be shut down and replaced with the next compressor, as before, and held off for 10 minutes. It shall then be restarted and the other compressor shut down, as before. If it does not run successfully for 10 minutes of normal run time again, it is shut down and replaced a third time. This time it is held off for 15 minutes. If the “problem” compressor does not operate successfully for the 10 minutes of normal run time this third time, this compressor ONLY is shut down and locked out for servicing. Alarm output (Red light) flashes and then remains on.

HIGH-PRESSURE SWITCH (HPS) — This switch is located in the discharge refrigerant line of each compressor, and is set to open at pressures above 360 psig. It is wired in the 115 vac control power line of the compressor contactor (in series with the LPS and EFS), and activates the COL board (above) when it opens.

LOW-PRESSURE SWITCH (LPS) — The Low-Pressure Switch is located in the suction refrigerant line of each compressor, and is set to open at pressures below 27 psig. It is wired in the 115 vac control power line of the compressor contactor (in series with the HPS and EFS), and activates the COL board (above) when it opens.

EVAPORATOR FREEZE SWITCH (EFS) — This is a thermal disk type switch, mounted on a return bend of the evaporator, refrigerant circuit for which corresponds to each respective compressor, and is set to open at temperatures below 28 F. It is wired in the 115 vac control power line of the compressor contactor (in series with the HPS, and activates the COL board (above) when it opens.

COPELAND PROTECTOR BOARD — This board is provided with each compressor, installed in the terminal box, since these compressors do not have internal current protection. This board activates at an overtemperature setting, and locks out operation of the compressor for 30 minutes; there is no method to over-ride or reset this timer. Due to this timing function, please note that the compressor will not attempt to restart until the third attempt described above.

ALARMS — Alarms can be provided via 4 methods; Unit mounted Alarm Light (Red and Yellow), Keypad Display, Network Communications, or a discreet Alarm Output to the Field Low Voltage Terminal Strip. This field output circuit includes an isolation relay and dry contacts. Alarms are covered in detail in the Troubleshooting section.

50XJ Variable Frequency Drive Control — The

variable frequency drive is factory wired and programmed for proper operation with the unit controls; no installation or service adjustments are normally required. There is an interface display for the VFD, independent of the main control display, mounted on the front of the 50XJ unit.

The VFD default conditions at unit power up are: “AUTO” run mode, “REMOTE” speed control, and “OFF” in the LED display. When the fan is operating, the LED displays the output frequency in Hz.

OPERATING KEYPAD — The keypad allows users to enable or disable the keypad, input commands from the keypad, and monitor drive operation. Fig. 6 shows the operating panel keypad layout and the locations of the keys and display LEDs.

The 7-character LED displays various values, depending

upon what mode is running.

• In Standard Monitor mode: the LED displays the current output frequency.

• In Status Monitor mode: monitors the status conditions and frequency command value setting.

• In Setup mode: displays setup parameter titles and values.

• In Program mode: displays parameter group titles, individual parameter names, and parameter values.

• During a trip: displays the trip title.

The appropriate local/remote LED, which is inset into the speed control key, is lit when the unit is in Local or Remote mode.

The appropriate manual/auto LED, which is inset into the run mode key, is lit when the unit is Manual or Auto mode.

When numeric data is shown on the LED display, the corresponding unit indication LED will be lit. If no unit indication LED is lit, the current data has no unit or the corresponding unit does not exist on the display panel.

KEY FUNCTIONS — Refer to Table 11 for the functions of each key on the keypad.

NON-TRIP MESSAGES — Non-trip messages are those that may be displayed but do not cause a trip and are not recorded in the fault history. Table 12 lists the non-trip messages with their explanations.

TRIP MESSAGES — Trip messages and their causes are shown in Table 13.

CLEARING A TRIP — A trip clear can be performed after the cause of the trip has been removed. To perform a trip clear, either switch off power to the inverter or use the following procedure:

Press Stop/Reset. The display will show: CLr. Press Stop/Reset again. The display will show: 0.0, indicating that the trip is cleared and the display will return to Standard Monitor mode.

If any key other than the STOP/RESET key is pressed at the trip clear command prompt, the trip clear command is aborted and the display returns to Standard Monitor mode (where the trip title will be displayed flashing).The trip clear command does not clear the recorded past faults.

7-CHARACTER LED DISPLAY AREA

LOCAL/REMOTE LEDS

UNITS LED (TYPICAL 4)

PERCENT

SECONDS

KW/AMPS/VOLTS

SETUP

PROGRAM

MONITOR

READ

WRITE

LOCAL/REMOTE

SPEED CTRL

RUN

STOP

RESET

MANUAL/AUTO

RUN MODE

Fig. 6 — 50XJ VFD Display Keypad

KEYS (TYPICAL 8)

MANUAL/AUTO LEDS

STATUS MONITOR MODE — In Status Monitor mode, it is possible to monitor the VFD status (frequency command, output voltage, current, terminal information, etc.). Status monitor mode is entered by pressing the Setup/Program/Monitor key, then selecting MON at the mode selection menu and pressing the Read/Write key. Table 11 details the procedure for entering status monitor mode (from standard monitor mode) and viewing all the monitored status variables. The present output frequency (which, just after power is applied, is 0.0) is displayed. (If the STCC terminals are not shorted, OFF will be displayed).

Table 11 — Keys and Functions for 50XJ VFD

If either or is pressed continuously, every 0.5 sec the next/previous item will be displayed. As optional points, RUN, STOP, displaying the frequency status, and switching to local/remote and manual/auto modes can be performed.

MANUAL MODE — To override the automatic unit controls and manually operate the fan from the VFD display, press keys for “MANUAL” run mode, “LOCAL” speed control, and press the Up or Down arrow keys to increase or decrease output frequency.

KEY FUNCTION

LOCAL/REMOTE

SPEED CT RL

MANUAL/AUTO

RUN MODE

SETUP

PROGRAM

MONITOR

READ

WRITE

RUN

STOP

RESET

Local/Remote Key Switches the source of frequency command information from panel/ter minal block. The appropriate LED is lit to indicate local or remote frequency command.

Manual/Auto Key Switches the source of run/stop command information from panel/terminal block. The appropriate LED is lit to indicate manual or auto run/stop command.

Setup/Program/Monitor Key Toggles between Setup, Program, Monitor, and Frequency Mode.

Read/Write Key Mode, group, parameter, data, and frequency selection key. This key is used to select or enter a parameter value, a frequency command, or a group name.

Up Key Scrolls up the setting of the currently displayed parameter. If the key is held down, the scrolling speed gradually increases. Only RAM values are changed. Also toggles to other function group entries. Pushing Read/Write key saves the setting.

Down Key Scrolls down the setting of the currently displayed parameter. If the key is held down, the scrolling speed gradually increases. Only RAM values are changed. Also toggles to other function group entries. Pushing Read/Write key saves the setting.

Run Key This key is used to star t a RUN command (only valid when in manual control mode).

Stop/Reset Key Functions as the STOP key and emergency stop key during local operation. Functions as the RESET key when an inverter trip occurs. In all other modes, emergency off is engaged when this key is pressed twice.

Table 12 — VFD Non-Trip Messages for 50XJ Unit

LED MESSAGE EXPLANATION

OFF Displayed whenever the ST-CC connection is open. pOFF Displayed when the VFD control power supply voltage is too low. nOFF Displayed when the VFD’s main DC bus voltage is low.

rtrY Auto-restart message: alter nately displayed with the output frequency whenever the

Err1 Displayed when 2 frequency points (F-P1,F-P2,etc.) are set too close to each other.

CLr Displayed during a pending clear command (after the STOP/RESET key has been

EOFF Displayed during a pending emergency off command (after the STOP/RESET key has

CtrL Displayed during a pending coast stop command (after the Local/Remote key has

HI This maximum value warning message “HI” will be alternately displayed in the data

LO This minimum value warning message “LO” will be alternately displayed in the data

PA SS Displayed if the correct password is entered at the password prompt.

Err Displayed if an incorrect password is entered at the password prompt.

E1 Displayed when the VFD attempts to display a number that exceeds four

db Displayed when DC injection braking is being executed. dbon Displayed when motor shaft stationary control is being executed. FJOG Displayed when in forward JOG mode. rJOG Displayed when in reverse JOG mode.

L VFD/motor overload pre-alarm display. C Overcurrent pre-alarm display. P Overvoltage pre-alarm display. H Overheat pre-alarm display.

t Option board communication alarm display.

InIt Displayed when the VFD is initializing values during resetting/power-up.

VFD tries to automatically restart after a non-critical trip.

pressed ONCE after a trip).

been pressed ONCE when in terminal control mode).

been pressed once when in local control mode while the VFD is running).

field of a parameter when an attempt is made to increase the setting value greater than the parameter’s maximum value.

field of a parameter when an attempt is made to decrease the setting value less than the parameter’s minimum value.

numerical digits.

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