Carrier 50ZH024, 50ZH030, 50ZH036, 50ZH042, 50ZH048 Installation, Start-up And Service Instructions Manual

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Page 1

50ZH024-060

Packaged Heat Pump Units

Installation, Start-Up and Service Instructions

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

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

INTRODUCTION..........................................................................2

RECEIVING AND INSTALLATION..........................................2

Check Equipment......................................................................2

IDENTIFY UNIT................................................................2

INSPECT SHIPMENT........................................................2

Provide Unit Support................................................................2

SLAB MOUNT ...................................................................2

GROUND MOUNT ............................................................2

Provide Clearances....................................................................2

Place Unit..................................................................................2

Select and Install Ductwork .....................................................2

INSTALL FLANGES FOR DUCTWORK CONNEC-

TIONS (50ZH060 ONLY)..................................................6

CONVERTING HORIZONTAL DISCHARGE UNITS TO

DOWNFLOW (VERTICAL) DISCHARGE......................6

Provide for Condensate Disposal.............................................6

Install Electrical Connections...................................................7

HIGH-VOLTAGE CONNECTIONS..................................7

ROUTING POWER LEADS INTO UNIT........................8

CONNECTING GROUND LEAD TO UNIT

GROUND ............................................................................8

ROUTING CONTROL POWER WIRES..........................8

ACCESSORY ELECTRIC HEAT WIRING .....................8

SPECIAL PROCEDURES FOR 208-V OPERATION .....8

PRE-START-UP ............................................................................9

START-UP.....................................................................................9

Check for Refrigerant Leaks..................................................10

LOCATE AND REPAIR REFRIGERANT LEAKS AND

CHARGE THE UNIT AS FOLLOWS: ...........................10

Start-Up Cooling Section and Make Adjustments ................10

CHECKING COOLING CONTROL OPERATION .......10

COMPRESSOR ROTATION ...........................................10

Refrigerant Charge..................................................................10

NO CHARGE....................................................................10

LOW CHARGE COOLING .............................................10

TO USE THE COOLING CHARGING CHART............10

HEATING MODE CHARGE...........................................11

Indoor Airflow and Airflow Adjustments..............................11

FOR 208/230-V.................................................................12

FOR 460-V MOTORS......................................................12

Unit Controls...........................................................................12

HIGH-PRESSURE RELIEF VALVE...............................12

LOSS OF CHARGE SWITCH.........................................12

COMPRESSOR OVERLOAD..........................................12

Sequence of Operation............................................................12

FAN OPERATION............................................................12

COOLING..........................................................................14

HEAT PUMP HEATING..................................................14

DEFROST..........................................................................15

ELECTRIC RESISTANCE HEATING............................15

MAINTENANCE.........................................................................15

Air Filter..................................................................................16

Unit Top Removal (Outdoor-Coil Side)................................16

Indoor Blower and Motor.......................................................16

Outdoor Coil, Indoor Coil, and Condensate Drain Pan........16

Outdoor Fan............................................................................17

Electrical Controls and Wiring...............................................18

Refrigerant Circuit..................................................................18

Indoor Airflow........................................................................18

Metering Devices....................................................................18

Lubrication..............................................................................18

Liquid Line Strainer................................................................18

High Flow Valves...................................................................19

TROUBLESHOOTING...............................................................22

START-UPCHECKLIST............................................................23

NOTE TO INSTALLER—Before installation, READ THESE INSTRUCTIONS CAREFULLY AND COMPLETELY. Also, make sure the User’s Manual and Replacement Guide are left with the unit after installation.

SAFETY CONSIDERATIONS

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

Untrained workers can perform basic maintenance functions of cleaning coils and filters. All other operations should be performed by trained service people. When working on air-conditioning

Fig. 1—Unit 50ZH

C00155

Visit www.carrier.com

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

Book 1 4 Tab 6 8

PC 101 Catalog No. 535-00080 Printed in U.S.A. Form 50ZH-5SI Pg 1 7-03 Replaces: 50ZH-4SI

Page 2

equipment, pay attention to precautions in the literature, tags, and labels attached to the unit, and other safety precautions that may apply.

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

Before performing service or maintenance operations on system, turn off main power to unit and install lockout tag. Turn off accessory heater power switch if applicable. Electrical shock can cause serious injury or death.

Recognize safety information. This is the safety-alert symbol . When you see this symbol in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices. We require these instructions as a minimum for a safe installation.

INTRODUCTION

50ZH heat pump units are fully self-contained and designed for outdoor installation (See Fig. 1). As shown in Fig. 2-4, units are shipped in a horizontal-discharge configuration for installation on a ground-level slab. All units can be field-converted to downflow discharge configurations for rooftop applications with a fieldsupplied plenum.

RECEIVING AND INSTALLATION

Step 1—Check Equipment

IDENTIFY UNIT The unit model number and serial number are stamped on the unit

identification plate. Check this information against shipping papers. Verify that unit voltage and amperage listed on unit rating plate agree with power supplied for equipment.

INSPECT SHIPMENT Inspect for shipping damage while unit is still on shipping pallet.

If unit appears to be damaged or is torn loose from its securing points, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit.

Check all items against shipping list. Immediately notify the nearest Carrier Air Conditioning office if any item is missing.

To prevent loss or damage, leave all parts in original packages until installation.

Step 2—Provide Unit Support

SLAB MOUNT Place the unit on a rigid, level surface, suitable to support the unit

weight. A concrete pad or a suitable fiberglass mounting pad is recommended. The flat surface should extend approximately 2-in.

beyond the unit casing on the 2 sides. The duct connection side and condensate drain connection sides should be flush with the edge of the flat surface.

A 6-in. wide gravel apron should be used around the flat surface to prevent airflow blockage by grass or shrubs. Do not secure the unit to the flat surface except where required by local codes.

The unit should be level to within 1/4 inch. This is necessary for the unit drain to function properly.

GROUND MOUNT The unit may also be installed directly on the ground if local codes

permit. Place unit on level ground prepared with gravel for condensate discharge.

Step 3—Provide Clearances

The required minimum service clearances and clearances to combustibles are shown in Fig. 2-4. Adequate ventilation and outdoor coil air must be provided.

The outdoor fan pulls air through the outdoor coil and discharges it through the fan on the top cover. Be sure that the fan discharge does not recirculate to the outdoor coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48 in. above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48 inches.

Do not place the unit where water, ice, or snow from an overhang or roof will damage or flood the unit. The unit may be installed on wood flooring or on Class A, B, or C roof covering materials.

Do not restrict outdoor coil airflow. An air restriction at either the outdoor-air inlet or the fan discharge can be harmful to compressor life.

Step 4—Place Unit

Unit can be moved with the rigging holds provided in the unit base. Refer to Table 1 for operating weights. Use extreme caution to

prevent damage when moving the unit. Unit must remain in an upright position during all moving operations. The unit must be

level with in 1/4” for proper condensate drainage; the ground-level pad must be level before setting the unit in place. When a field-fabricated support is used, be sure that the support is level and that it properly supports the unit.

Step 5—Select and Install Ductwork

The design and installation of the duct system must be in accordance with:

• the standards of the NFPA (National Fire Protection Association) for installation of nonresidence-type air conditioning and ventilating systems

• NFPA90A or residence-type, NFPA90B; and/or local codes and residence-type, NFPA 90B

• and/or local codes and ordinances

Select and size ductwork, supply-air registers and return-air grilles according to ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) recommendations.

Use the duct flanges provided on the supply- and return-air openings on the side of the unit. See Fig. 2-4 for connection sizes and locations. The 14-in. round duct collars (size 024-048 units) are shipped inside the unit attached to the indoor blower. They are field-installed and must be removed from the indoor cavity prior to start-up, even if they are not used for installation.

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Fig. 2—Unit Base Dimensions, 50ZH024-030

UNIT ELECTRICAL CHARACTERISTICS

UNIT WEIGHT CENTER OF GRAVITY IN. (MM)

lb kg X Y Z

50ZH024 208/230-1-60 232 106 14.0 (356) 19.0 (483) 12.0 (305) 50ZH030

208/230-1-60,

208/230–3–60

254 116 14.0 (356) 19.0 (483) 12.0 (305)

C00156

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

INCHES [mm]

CONDENSER . COIL ACCESS SIDE..............................................30.00 [762.0]

POWER ENTRY SIDE....................................................................30.00 [762.0]

(EXCEPT FOR NEC REQUIREMENTS)

UNIT TOP.......................................................................................48.00 [1219.2]

SIDE OPPOSITE DUCTS ..............................................................30.00 [762.0]

LEGEND

NEC – National Electrical Code NOTES:

1. Clearances must be maintained to prevent recirculation of air from outdoor-

fan discharge, with the exception of the condenser coil (36.00 in [914.0 mm]. A removable fence or barricade requires no clearance.

2. Dimensions are in inches. Dimensions in [ ] are in millimeters.

REQUIRED CLEARANCE TO COMBUSTIBLE MATL.

INCHES [mm]

TOP OF UNIT.........................................................................................0

DUCT SIDE OF UNIT.............................................................................0

SIDE OPPOSITE DUCTS ......................................................................0

BOTTOM OF UNIT.................................................................................0

NEC. REQUIRED CLEARANCES.

INCHES [mm]

BETWEEN UNITS, POWER ENTRY SIDE....................................42.00 [1066.8]

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE.36.00 [914.0] UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]

Page 4

Fig. 3—Unit Base Dimensions, 50ZH036–048

UNIT ELECTRICAL CHARACTERISTICS

UNIT WEIGHT CENTER OF GRAVITY IN. (MM)

lb kg X Y Z

50ZH036

208/230-1-60, 208/230-3-60,

460–3–60

277 126 14.0 (356) 19.0 (483) 15.0 (381)

50ZH042

208/230-1-60, 208/230-3-60,

460–3–60

295 134 14.0 (356) 19.0 (483) 15.0 (381)

50ZH048

208/230-1-60, 208/230-3-60,

460–3–60

328 149 14.0 (356) 19.0 (483) 15.0 (381)

C00003

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

INCHES [mm]

CONDENSER . COIL ACCESS SIDE.............................................. 30.00 [762.0]

POWER ENTRY SIDE....................................................................30.00 [762.0]

(EXCEPT FOR NEC REQUIREMENTS)

UNIT TOP.......................................................................................48.00 [1219.2]

SIDE OPPOSITE DUCTS ..............................................................30.00 [762.0]

LEGEND

NEC – National Electrical Code

NOTES:

1. Clearances must be maintained to prevent recirculation of air from outdoor-

fan discharge, with the exception of the condenser coil (36.00 in [914.0 mm]. A removable fence or barricade requires no clearance.

2. Dimensions are in inches. Dimensions in [ ] are in millimeters.

REQUIRED CLEARANCE TO COMBUSTIBLE MATL.

INCHES [mm]

TOP OF UNIT.........................................................................................0

DUCT SIDE OF UNIT.............................................................................0

SIDE OPPOSITE DUCTS ......................................................................0

BOTTOM OF UNIT.................................................................................0

NEC. REQUIRED CLEARANCES.

INCHES [mm]

BETWEEN UNITS, POWER ENTRY SIDE....................................42.00 [1066.8]

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE.36.00 [914.0] UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]

Page 5

Fig. 4—Unit Base Dimensions, 50ZH060

UNIT ELECTRICAL CHARACTERISTICS

UNIT WEIGHT CENTER OF GRAVITY IN. (MM)

lb kg X Y Z

50ZH060 208/230-1-60, 208/230-3-60, 460-3-60 368 167 14.0 (356) 20.0 (508) 16.0 (406)

C00158

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

INCHES [mm]

CONDENSER . COIL ACCESS SIDE..............................................30.00 [762.0]

POWER ENTRY SIDE....................................................................30.00 [762.0]

(EXCEPT FOR NEC REQUIREMENTS)

UNIT TOP.......................................................................................48.00 [1219.2]

SIDE OPPOSITE DUCTS ..............................................................30.00 [762.0]

LEGEND

NEC – National Electrical Code

NOTES:

1. Clearances must be maintained to prevent recirculation of air from outdoor-

fan discharge, with the exception of the condenser coil (36.00 in [914.0 mm]. A removable fence or barricade requires no clearance.

2. Dimensions are in inches. Dimensions in [ ] are in millimeters.

REQUIRED CLEARANCE TO COMBUSTIBLE MATL.

INCHES [mm]

TOP OF UNIT.........................................................................................0

DUCT SIDE OF UNIT.............................................................................0

SIDE OPPOSITE DUCTS ......................................................................0

BOTTOM OF UNIT.................................................................................0

NEC. REQUIRED CLEARANCES.

INCHES [mm]

BETWEEN UNITS, POWER ENTRY SIDE....................................42.00 [1066.8]

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE.36.00 [914.0] UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]

Page 6

INSTALL FLANGES FOR DUCTWORK CONNECTIONS (50ZH060 ONLY)

The 50ZH060 units are shipped with flanges which must be field-installed on the unit.

To install unit flanges:

1. Five pieces of flange are shipped on the return-air opening of the unit. Remove the flanges from the shipping position (See Fig. 5). Screws are field-supplied.

2. One piece of flange is used as it is shipped (straight). Bend the other 4 pieces at right angles.

3. Install the straight flange on the right side of the return-air opening in holes provided. (See Fig. 6). Flanges should stick out from unit to allow for connection of ductwork.

4. Install 2 hand-formed flanges onto return air opening in holes provided to form a rectangle around the return air opening.

5. Install remaining 2 hand-formed flanges around discharge air opening in holes provided.

6. Ductwork can now be attached to flanges.

When designing and installing ductwork, consider the following:

When connecting ductwork to units, do not drill deeper than 3/4 inch in shaded area shown in Fig. 7 or coil may be damaged.

• All units should have field-supplied filters installed in the return-air side of the unit. Recommended sizes for filters are shown in Table 1.

• Avoid abrupt duct size increases and reductions. Abrupt change in duct size adversely affects air performance.

IMPORTANT: Use flexible connectors between ductwork and unit to prevent transmission of vibration. Use suitable gaskets to ensure weathertight and airtight seal. When electric heat is installed, use fire proof canvas (or similar heat resistant material) connector between ductwork and unit discharge connection. If flexible duct is used, insert a sheet metal sleeve inside duct. Heat resistant duct connector (or sheet metal sleeve) must ectend 24–in. from the unit discharge connection flange into the ductwork.

• Size ductwork for cooling air quantity (cfm). The minimum air quantity for proper electric heater operation is listed in Table 2. Heater limit switches may trip at air quantities below those recommended.

• Insulate and weatherproof all external ductwork. Insulate and cover with a vapor barrier all ductwork passing through conditioned spaces. Follow latest Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors Association (ACCA) minimum installation standards for residential heating and air conditioning systems.

• Secure all ducts to building structure. Flash, weatherproof, and vibration-isolate duct openings in wall or roof according to good construction practices.

Figure 8 shows a typical duct system with 50ZH unit installed.

CONVERTING HORIZONTAL DISCHARGE UNITS TO DOWNFLOW (VERTICAL) DISCHARGE

Units are dedicated side supply products. They are not convertible to vertical air supply. A field-supplied plenum must be used to convert to vertical air discharge.

Step 6—Provide for Condensate Disposal NOTE: Be sure that condensate-water disposal methods comply

with local codes, restrictions, and practices.

Fig. 5—Shipping Location of Duct Flanges

(Size 060 Only)

C00005

FIVE PIECES OF DUCT FLANGE ATTACHED HERE FOR SHIPMENT

Fig. 6—Flanges Installed on 50ZH060 Units

C00006

HAND FORM

STRAIGHT PIECE

Page 7

Unit removes condensate through a 1 3/64-in. ID hole (using 3/4-in. OD piping or tubing) which is located at the end of the unit. See Fig. 2-4 for location of condensate connection.

Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in groundlevel installations. Install a field-supplied condensate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. lower than the drain-pan condensate connection to prevent the pan from overflowing. Prime the trap with water. When using a gravel apron, make sure it slopes away from the unit.

If the installation requires draining the condensate water away from the unit, install a 2-in. trap using a 3/4-in. OD tubing or pipe. (See Fig. 9 and 10.) Make sure that the outlet of the trap is at least 1 in. lower than the unit drain-pan condensate connection to prevent the pan from overflowing. Prime the trap with water. Connect a drain tube using a minimum of 3/4-in. PVC, 3/4-in. CPVC, or 3/4-in. copper pipe (all field supplied). Do not undersize the tube. Pitch the drain tube downward at a slope of at least 1 in. for every 10 ft of horizontal run. Be sure to check the drain tube for leaks. Prime trap at the beginning of the cooling season start-up. Allowable glues for condensate trap connection are: Standard ABS, CPVC, or PVC cement.

Step 7—Install Electrical Connections

The unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of an electrical wire connected to the unit ground in the control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code), ANSI (American National Standards Institute)/NFPA (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes. Failure to adhere to this warning could result in serious injury or death.

Failure to follow these precautions could result in damage to the unit being installed:

1. Make all electrical connections in accordance with NEC ANSI/NFPA (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between field-supplied electrical disconnect switch and unit. DO NOT USE ALUMINUM WIRE.

3. Be sure that high-voltage power to unit is within operating voltage range indicated on unit rating plate.

4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are run in same conduit as high-voltage wires.

5. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc. On 3-phase units, ensure phases are balanced within 2 percent. Consult local power company for correction of improper voltage and/or phase imbalance.

HIGH-VOLTAGE CONNECTIONS

The unit must have a separate electrical service with a fieldsupplied, waterproof disconnect switch mounted at, or within sight from the unit. Refer to the unit rating plate for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing. See Table 3 for electrical data.

Fig. 7—Area Not to Be Drilled More Than 3/4-in.

C00007

19.17″ 3.92″

Fig. 8—Typical installation

Table 2—Minimum Airflow for Safe Electric Heater

Operation (CFM)

SIZE

024 030 036 042 048 060 600 750 900 1050 1200 1500

C00008

TOP COVER

INDOOR THERMOSTAT

DISCONNECT PER NEC* (UNIT AND ELECTRIC HEATER)

FROM POWER SOURCE

RETURN AIR

POWER AND LOW-VOLTAGE ENTRY

COMPOSITE RUST-PROOF BASEPAN

CONDENSATE DRAIN CONNECTION

*Separate disconnect per NEC (National Electrical Code) required for electric heater when singlepoint conection is not used.

Power Wiring Control Wiring

Condenser Airflow

Evaporator Airflow

Fig. 9—Condensate Trap (Using Tubing)

C99013

1” (25mm) MIN.

2” (50mm) MIN.

TRAP OUTLET

Page 8

The field-supplied disconnect may be mounted on the unit over the high-voltage inlet hole. See Fig. 2-4.

Operation of unit on improper line voltage constitutes abuse and may cause unit damage that could affect warranty.

ROUTING POWER LEADS INTO UNIT Use only copper wire between disconnect and unit. The high-

voltage leads should be in a conduit until they enter the unit; conduit termination at the unit must be watertight. Run the high-voltage leads through the hole on the control box side of the unit (see Fig. 11 for location). When the leads are inside the unit, run leads to the control box (Fig. 12). For single-phase units, connect leads to the black and yellow wires; for 3-phase units, connect the leads to the black, yellow, and blue wires (see Fig. 13).

CONNECTING GROUND LEAD TO UNIT GROUND Refer to Fig. 12 and 13. Connect the ground lead to the chassis

using the unit ground lug in the control box.

ROUTING CONTROL POWER WIRES Form a drip-loop with the thermostat leads before routing them

into the unit. Route the thermostat leads through grommeted hole provided in unit into unit control box (See Fig. 11). Connect thermostat leads and unit power leads as shown in Fig. 13 & 14.

Route thermostat wires through grommet providing a drip-loop at the panel. Connect low-voltage leads to the thermostat as shown in Fig. 14.

The unit transformer supplies 24-v power for complete system including accessory electrical heater. Transformer is factory wired for 230-v operation. If supply voltage is 208 v, rewire transformer primary as described in the Special Procedures for 208-v Operation section below.

ACCESSORY ELECTRIC HEAT WIRING Refer to accessory electric heat installation instructions for infor-

mation on installing accessory electric heat. Accessory electric heat wiring is shown in Fig. 15A & 15B.

SPECIAL PROCEDURES FOR 208-V OPERATION

Make sure that the power supply to the unit is switched OFF and install lockout tag before making any wiring changes. Electrical shock can cause serious injury or death.

1. Remove wirenut from connection of ORG wire to BLK wire. Disconnect the ORG transformer-primary lead from the BLK wire. Save wirenut. See unit wiring label.

2. Remove the wirenut from the terminal on the end of the RED transformer-primary lead.

3. Save the wirenut.

Table 1 — Physical Data

UNIT 50ZH 024 030 036 042 048 060

OPERATING WEIGHT (lbs) 232 254 277 295 328 368

COMPRESSOR TYPE Scroll

REFRIGERANTCharge(lb)

R-22

3.7 5.85.96.69.19.7

REFRIGERANT METERING DEVICE Acutrol™ System

OUTDOOR COIL

Rows...Fins/in.

Face Area (sq ft)

Copper Tubes, Aluminum Plate Fins

1...17

7.9

2...17

6.7

1...17

11.1

2...17

9.3

2...17

11.1

2...17

12.7

OUTDOOR-FAN MOTOR CFM

Nominal Rpm

Motor Hp

Diameter (in.)

Propeller

1800

825

1/8

2000 1100

1/4

2600 1100

1/4

2600 1100

1/4

2600 1100

1/4

3200 1100

1/2

INDOOR COIL Copper Tubes, Aluminum Plate Fins

Rows...Fins/in.

Face Area (sq ft)

2...15

3.1

3...15

3.1

3...15

4.0

3...15

4.0

4...15

4.4

4...15

4.9

INDOOR FAN MOTOR

Blower Motor Size (in.)

Nominal Cfm

Rpm Range

Number of Speeds

Factory Speed Setting

Motor Hp

Direct Drive

10x8

800

550-1000

Low

1/4

10x8

1000

550-1000

Med

1/4

10x9

1200

800-1050

Low

1/2

10x9

1400

800-1050

Med

1/2

10x9

1600

1000-1100

Low

3/4

10x10

2000

950-1100

Low

CONNECTING DUCT SIZES

Supply Air (in.) Return Air (in.)

Round

14 14

Square

13.9 x 13.9

13.9 x 27.8

FIELD-SUPPLIED RETURN-AIR FILTER†

Throwaway (in.)

24x24 24x24 24x24 24x24 24x30 24x30

* 460-v motors are 2-speed or 3-speed. †Required filter sizes shown are based on the ARI (Air Conditioning and Refrigeration Institute) rated airflow at a velocity of 300 ft/min for throwaway type or 450 ft/min for high capacity type. Recommended filters are 1-in. thick.

Fig. 10–PVC Condensate Trap

C00009

TRAP OUTLET

2" min.

1" min.

Page 9

4. Connect the RED lead to the BLK wire from which the ORG lead was disconnected. Insulate with wirenut from Step 1.

5. Using the wirenut removed from the RED lead, insulate the loose terminal on the ORG lead.

6. Wrap the wirenuts with electrical tape so that the metal terminals cannot be seen.

Indoor blower-motor speeds may need to be changed for 208-v operation. Refer to Indoor Airflow and Airflow Adjustments section. (See Table of Contents for page number.)

PRE-START-UP

Failure to observe the following warnings could result in serious injury or death:

1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.

2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured.

3. Do not remove compressor terminal cover until all electrical sources are disconnected and lockout tag is installed.

4. Relieve all pressure from both high- and low-pressure sides of the system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals. Use accepted methods to recover refrigerant.

5. Never attempt to repair soldered connection while refrigerant system is under pressure.

6. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective goggles and proceed as follows: a. Shut off electrical power to unit and install lockout tag. b. Relieve all refrigerant from system using both high- and

low-pressure ports. Use accepted methods to recover refrigerant.

c. Cut component connecting tubing with tubing cutter and

remove component from unit.

d. Carefully unsweat remaining tubing stubs when neces-

sary. Oil can ignite when exposed to torch flame.

Use the Start-Up Checklist supplied at the end of this book and proceed as follows to inspect and prepare the unit for initial start-up:

1. Remove all access panels.

2. Read and follow instructions on all DANGER, WARNING, CAUTION, and INFORMATION labels attached to, or shipped with, unit.

Make the following inspections:

a. Inspect for shipping and handling damages such as broken

lines, loose parts, disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections and on

unit base. Detecting oil generally indicates a refrigerant leak. Leak-test all refrigerant tubing connections using electronic leak detector, or liquid-soap solution. If a refrigerant leak is detected, see following Check for Refrigerant Leaks section.

c. Inspect all field- and factory-wiring connections. Be sure

that connections are completed and tight. Ensure wires do not contact refrigerant tubing or sheet metal edges.

d. Inspect coil fins. If damaged during shipping and handling,

carefully straighten fins with a fin comb.

3. Verify the following conditions:

a. Make sure that outdoor-fan blade is correctly positioned in

fan orifice. Top edge of blade should be 3.125 in. down from outdoor coil outlet grille (size 024–048, See Fig. 21) or hub should be 0.708-in. away from motor end bell (size

060, See Fig. 22). See Outdoor Fan Adjustment section. b. Make sure that air filter is in place. c. Make sure that condensate drain trap is filled with water to

ensure proper drainage. d. Make sure that all tools and miscellaneous loose parts have

been removed.

START-UP

Use the Start-Up Checklist supplied at the end of this book and proceed as follows:

Fig. 11—Unit Electrical Connection

C00010

HIGH-VOLTAGE POWER WIRING ENTRY HOLE

LOW-VOLTAGE WIRING ENTRY HOLE

Fig. 12—Control Box Wiring

C00011

ELECTRIC HEATER FUSES

GROUND LUG

INDOOR FAN RELAY

OUTDOOR FAN MOTOR AND COMPRESSOR START CAPACITOR

HIGH VOLTAGE LEADS

Page 10

Step 1—Check for Refrigerant Leaks

LOCATE AND REPAIR REFRIGERANT LEAKS AND CHARGE THE UNIT AS FOLLOWS:

1. Using both high- and low-pressure ports, locate leaks and reclaim remaining refrigerant to relieve system pressure.

2. Repair leak following accepted practices.

NOTE: Install a liquid-line filter drier whenever the system has been opened for repair.

Step 2—Start-Up Cooling Section and Make Adjustments

Complete the required procedures given in the Pre-Start- Up section this page before starting the unit. Do not jumper any safety devices when operating the unit. Do not operate the compressor when the outdoor temperature is below 40 F. Do not rapid-cycle the compressor. Allow 5 minutes between ‘‘on’’ cycles to prevent compressor damage.

CHECKING COOLING CONTROL OPERATION Start and check the unit for proper cooling control operation as

follows:

1. Place room thermostat SYSTEM switch in OFF position. Observe that blower motor starts when FAN switch is placed in ON position and shuts down within 30 seeconds when FAN switch is placed in AUTO position.

2. Place SYSTEM switch in COOL position and FAN switch in AUTO position. Set cooling control below room temperature. Observe that compressor, outdoor fan, and indoor blower motors start and that reversing valve shifts. Observe that cooling cycle shuts down when control setting is satisfied. Reversing valve (RV) remains energized.

3. Place system switch in HEAT position. Observe that compressor, indoor fan and outdoor fan energize (Reversing Valve is deenergized in heat pump heating mode). Set control above room temperature. Observe that heating cycle shuts down when control setting is satisfied.

4. When using an automatic changeover room thermostat, place both SYSTEM and FAN switches in AUTO. positions. Observe that unit operates in Cooling mode when temperature control is set to ‘‘call for cooling’’ (below room temperature), and unit operates in Heating mode when temperature control is set to “call for heating” (above room temperature).

COMPRESSOR ROTATION On 3–Phase units it is important to be certain compressor is

rotating in the proper direction. To determine whether or not compressor is rotating in the proper direction:

1. Connect service gages to suction and discharge pressure fittings.

2. Energize the compressor.

3. The suction pressure should drop and the discharge pressure should rise, as is normal on any start-up.

If the suction pressure does not drop and the discharge pressure does not rise to normal levels:

1. Turn off power to the unit and tag disconnect.

2. Reverse any two of the unit power leads.

3. Turn on power to the unit.

The suction and discharge pressure levels should now move to their normal start-up levels.

NOTE: When the compressor is rotation in the wrong direction, the unit makes an elevated level of noise and does not provide cooling.

Step 3—Refrigerant Charge

Refrigerant Charge — Amount of refrigerant charge is listed on unit nameplate and in Table 1. Refer to Carrier Refrigerant Service Techniques Manual, Refrigerants section. Unit panels must be in place when unit is operating during charging procedure. Unit must operate a minimum of 15 minutes before checking charge.

NO CHARGE Refer to Carrier Refrigerant Service Techniques. Use standard

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

LOW CHARGE COOLING Using cooling charging chart (see Fig. 16–21),Vary refrigerant

until conditions of the chart are met. Note that charging chart is different from those normally used. Charts are based on charging the units to the correct superheat for the various operating conditions. An accurate pressure gage and temperature-sensing device is required. Connect the pressure gauge to the service port on the suction line. Connect temperature sensing device to the suction line near the compressor and insulate it so that outdoor ambient temperature does not affect reading.

TO USE THE COOLING CHARGING CHART This method is to be used in cooling mode only. Take the outdoor

ambient temperature and read the suction pressure gauge. Refer to

3-PHASE CONNECTIONS TO DISCONNECT PER NEC

SINGLE-PHASE CONNECTIONS TO DISCONNECT PER NEC

GROUND

LEAD

UNIT GROUND

BLK YEL BLU

L L L

C00012

Fig. 13—Line Power Connections

THERMOSTAT

AND SUBBASE

UNIT CONTROL POWER

SPLICE BOX

BRN

WHT

YEL

GRN

RED

ORN

C99056

Fig. 14—Control Connections

Page 11

charts to determine what the suction temperature should be. If suction temperature is high, add refrigerant. If suction temperature is low, carefully recover some of the charge. Recheck the suction pressure as charge is adjusted.

Example: (See Fig. 16) Outdoor Temperature —85°F Suction Pressure—74 psig Suction Temperature should be—60°F Note—Suction Temperature may vary +/- 5°F.

HEATING MODE CHARGE Do not attempt to adjust charge by cooling methods while in heat

pump heating mode. Recover refrigerant and weigh in according to unit data plate refrigerant data.

Step 4—Indoor Airflow and Airflow Adjustments NOTE: For cooling operation, the recommended airflow is 350 to

450 cfm per each 12,000 Btuh of rated cooling capacity. Table 4 shows dry coil air delivery for horizontal discharge units.

Tables 5-7 show pressure drops.

Fig. 15A—Typical Unit Electrical Diagram (208/230–1–60)

C01022

Page 12

NOTE: Be sure that all supply- and return-air grilles are open, free from obstructions, and adjusted properly.

Disconnect electrical power to the unit and install lockout tag before changing blower speed. Electrical shock can cause serious injury or death.

Airflow can be changed by changing the lead connections of the blower motor.

Units 50ZH024, 036, 048, and 060 blower motors are factory wired for low speed operation. Units 50ZH030 and 042 are factory wired for medium speed operation.

FOR 208/230-V The motor leads are color-coded as follows:

To change the speed of the indoor fan motor (IFM), remove the fan motor speed leg lead from the indoor fan relay (IFR) with units 024, 030, 042, 048 & 060 or the time delay relay (TDR) on 036 size and replace with lead for desired blower motor speed. Insulate

the removed lead to avoid contact with chassis parts.

FOR 460-V MOTORS The motor leads are color coded as follows:

To change the speed of the indoor fan motor (IFM) from low speed to high speed, remove the red lead from the indoor-fan relay (IFR). ON 2–Speed Motors: Insulate the red lead to avoid contact with any chassis parts. Separate the black lead from the purple lead.

Connect the black lead to the IFR. Insulate the purple lead to avoid contact with any chassis parts. ON 3–Speed Motors: remove the fan motor speed leg lead from the indoor (indoor) fan relay (IFR) and replace with lead for desired blower motor speed.

Step 5—Unit Controls

All compressors have the following internal-protection controls. HIGH-PRESSURE RELIEF VALVE

This valve opens when the pressure differential between the low and high side becomes excessive (024 size has temperature relief only).

LOSS OF CHARGE SWITCH Located on the outdoor liquid line is a low-pressure switch which

functions as a loss-of-charge switch. This switch contains a Schrader core depressor. This switch opens at 7 psig and closes at 22 psig. No adjustment is necessary.

COMPRESSOR OVERLOAD This overload interrupts power to the compressor when either the

current or internal temperature become excessive, and automatically resets when the internal temperature drops to a safe level. This overload may require up to 60 minutes (or longer) to reset; therefore, if the internal overload is suspected of being open, disconnect the electrical power to the unit and check the circuit through the overload with an ohmmeter or continuity tester.

Step 6—Sequence of Operation

FAN OPERATION The FAN switch on the thermostat controls indoor fan operation.

When the FAN switch is placed in the ON position, the IFR (indoor-fan relay) is energized through the G terminal on the thermostat. The normally-open contacts close, which then provide power to the indoor (evaporator) fan motor (IFM). The IFM will run continuously when the FAN switch is set to ON.

When the FAN switch is set to AUTO, the thermostat deenergizes the IFR (provided there is not a call for cooling). The contacts open and the IFM is deenergized. The IFM will be energized only when there is a call for cooling, in heat pump heating mode or if the unit is equipped with accessory electric heat, the indoor-fan motor will also run while the accessory electric heat is energized.

Fig. 15B—Accessory Electric Heater Wiring

C00014

C W1 W1

UNIT POWER

WIRING

BLK YEL

BRN (COMMON) VIO (STEP 2) WHT ( STEP 1)

CONTACTOR 2

YEL

BRN YEL

CONTACTOR 1

YEL YEL

BRN YEL YEL

FUSE BLOCK

L2 L1

YEL YEL BLK BLK

F3 F4 F1 F2

EL 1

EL 2

EL 3

BLK BLK BLK

AUTO-LIMIT

3-SPEED 2-SPEED

black = high speed black = high speed

blue = medium speed -

red = low speed red = low speed

3-SPEED (060 ONLY) 2-SPEED

black = high speed black = to purple

- yellow = line

orange = medium speed purple = to black

blue = low speed red = line

Page 13

Table 3—Electrical Data—50ZH

UNIT 50ZH

SIZE

(–SERIES, IF

USED)

V-PH-HZ

VOLTAGE

RANGE

COMPRESSOR

OFM

FLA

IFM

FLA

ELECTRIC HEAT SINGLE POINT POWER SUPPLY

MIN MAX RLA LRA Nominal KW* FLA MCA

FUSE OR CKT BKR

MOCP

024–311 208/230–1–60 187 254 11.4 56.0 0.9 2.4

-/-

3.8/5.0

5.6/7.5

7.5/10.0

-/-

18.3/20.8

26.9/31.3

36.1/41.7

17.6/17.6

40.4/43.6

51.2/56.7

62.7/69.7

25/25 45/45 60/60

70/70

024–321 208/230–1–60 187 254 12.1 54.0 0.9 2.4

-/-

3.8/5.0

5.6/7.5

7.5/10.0

-/-

18.3/20.8

26.9/31.3

36.1/41.7

18.4/18.4

41.3/44.4

52.1/57.6

63.6/70.6

25/25

45/45

60/60

—

— — —

70/80

030

208/230–1–60 187 254 14.4 73.0 1.5 2.4

-/-

3.8/5.0

5.6/7.5

7.5/10.0

11.3/15.0

-/-

18.3/20.8

26.9/31.3

36.1/41.7

54.2/62.5

21.9/21.9

44.8/47.9

55.5/61.0

67.0/74.0

89.8/100.0

30/30 45/50

60/–

—

–

— —

–/70

70/80

90/110

208/230–3–6 187 254 10.0 63.0 1.5 5.8

-/-

3.8/5.0

7.5/10.0

11.3/15.0

-/-

10.4/12.0

20.8/24.1

31.3/36.1

16.8

29.9/31.8

42.8/46.9

56.1/61.9

20 35/35 45/50

60/–

— — —

–/70

036

208/230–1–60 187 254 17.7 93.0 1.5 2.8

-/-

3.8/5.0

5.6/7.5

7.5/10.0

11.3/15.0

-/-

18.1/20.8

26.9/31.3

36.1/41.7

54.2/62.5

26.4/26.4

49.3/52.4

60.1/65.6

74.6/78.6

94.3/104.6

35/35 50/60

—

— 70/70 80/80

100/110

208/230–3–60 187 254 11.4 77.0 1.5 2.8

-/-

3.8/5.0

7.5/10.0

11.3/15.0

-/-

10.4/12.0

20.8/24.1

31.3/36.1

18.6/18.6

31.7/33.6

44.6/48.7

57.8/63.7

25/25 35/35 45/50

60/-

—

–/70

460–3–60 414 508 5.7 39.0 0.8 2.0

—

5 10 15

—

6.0

12.0

18.0

9.9

17.4

24.9

32.4

15 20 25 35

— — — —

042

208/230–1–60 187 254 22.0 103.0 1.5 2.8

-/-

3.8/5.0

5.6/7.5

7.5/10.0

11.3/15.0 15/20

-/-

18.3/20.8

26.9/31.3

36.1/41.7

54.3/62.5

72.1/83.3

31.8/31.8

54.7/57.8

65.4/70.9

76.9/83.9

99.7/109.9

121.9/135.9

40/40 60/60

— — — —

—

— 70/80 80/90

100/110 125/150

208/230–3–60 187 254 13.9 88.0 1.5 2.8

-/-

3.8/5.0

7.5/10.0

11.3/15.0 15/20

-/-

10.5/12.0

20.8/24.1

31.4/36.1

41.4/47.9

21.7/21.7

34.8/36.7

47.7/51.8

60.9/66.8

73.4/81.6

30/30 35/40 50/50

— —

— 70/70 80/90

460–3–60 414 508 6.8 44.0 0.8 2.0

—

5 10 15 20

—

6.0

12.0

18.0

24.1

11.3

18.8

26.3

33.8

41.4

15 20 30 35 45

— — — — —

048

208/230–1–60 187 254 21.8 124.0 1.5 4.2

-/-

3.8/5.0

5.6/7.5

7.5/10.0

11.3/15.0 15/20

-/-

18.3/20.8

26.9/31.3

36.1/41.7

54.2/62.5

72.2/83.3

33.0/33.0

55.8/59.0

66.6/72.1

78.1/85.1

100.8/111.1

123.1/137.1

40/40 60/60

— — — —

—

— 70/80 80/90

110/125 125/150

208/230–3–60 187 254 12.8 93.0 1.5 4.2

-/-

3.8/5.0

7.5/10.0

11.3/15.0 15/20

-/-

10.5/12.0

20.8/24.1

31.4/36.1

41.4/47.9

21.7/21.70

34.8/36.7

47.7/51.8

61.0/66.8

73.5/81.6

25/25 35/40 50/60

— —

— 70/70 80/90

460–3–60 414 508 6.4 46.5 0.8 4.2

—

5 10 15 20

—

6.0

12.0

18.0

24.1

10.9

18.4

25.9

33.4

40.8

15 20 30 35 45

— — — — —

060

230–1–60 187 254 27.7 170.0 3.1 6.2

—

3.8/5

5.6/7.5

7.5/10

11.3/15

15.0/20

—

18.3/20.8

26.9/31.3

36.1/41.7

54.3/62.5

72.1/83.3

43.9/43.9

66.8/69.9

77.6/83.1

89.1/96.1

111.8/122.1

134.1/148.1

60/60

— — — — —

— 70/70 80/90

90/100 125/125 150/150

208/230–3–60 187 254 15.9 124.0 3.1 6.2

-/-

3.8/5.0

7.5/10.0

11.3/15.0

14.9/19.9

-/-

10.5/12.0

20.8/24.1

31.4/36.1

41.4/47.9

29.2/29.2

42.3/44.2

55.2/59.3

68.4/74.3

80.9/89.1

35/35 45/45 60/60

— —

— 70/80 90/90

460–3–60 414 508 8.0 59.6 1.5 3.2

—

5 10 15

19.9

—

6.0

12.0

18 .0

23.9

14.7

22.2

29.7

37.2

44.6

20 25 30 40 45

— — — — —

(See legend following Electrical Data charts)

→

Page 14

NOTE: Some units are equipped with a time-delay relay. On these units, the indoor fan remains on for 30 seconds after G or Y is deenergized.

COOLING With the thermostat subbase in the cooling position, the thermostat

makes circuit R-O. This energizes the reversing valve solenoid (RVS) and places the unit in standby condition for cooling.

NOTE: The defrost control board has a 5 minute compressor anti-short cycle time delay built in between compressor starts.

On a call for cooling, the compressor contactor (C) and the IFR are energized through the Y and G terminals of the thermostat. Energizing the compressor contactor supplies power to the compressor and the outdoor (condenser) fan motor (OFM). Energizing the IFR provides power to the IFM.

When the need for cooling has been satisfied, the OFM, compressor, and IFM (FAN on AUTO) are deenergized. If the unit is equipped with a 30-second delay (036 size only), the indoor fan will remain energized for 30 seconds after the compressor is deenergized. The reversing valve solenoid remains energized.

HEAT PUMP HEATING On a call for heat, thermostat makes circuits R-Y and R-G. When

compressor time delay (5-minute ± 2 minutes) is completed, a circuit is made to C, starting COMP and OFM. Circuit R-G also energizes IFR and starts IFM after 1-second delay.

Should room temperature continue to fall, circuit R-W is made through second-stage thermostat bulb. If optional electric heat package is used, a relay is energized, bringing on first bank of

C99024

452=5v 457=7v 455=2v

LEGEND

FLA — Full Load Amps LRA — Locked Rotor Amps MCA — Minimum Circuit Amps MOCP — Maximum Overcurrent Protection RLA — Rated Load Amps

NOTES:

1. In compliance with NEC (National Electrical Code) requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be Power Supply fuse. Canadian units may be fuse or circuit breaker.

2. Minimum wire size is based on 60 C copper wire. If other than 60 C wire is used, or if length exceeds wire length in table, determine size from NEC.

3. Unbalanced 3-Phase Supply Voltage

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

Use the following formula to determine

the percentage of voltage imbalance. % Voltage imbalance

max voltage deviation from average voltage

= 100 x

average voltage

EXAMPLE: Supply voltage is 460-3-60.

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

452 + 464 + 455

Average Voltage =

1371

= 457

Determine maximum deviation from average voltage.

(AB) 457 (BC) 464

(AC) 457 Maximum deviation is 7 v. Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x

457

= 1.53%

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

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

CKT BKR

—

Circuit Breaker

758 110

683 100

621 90

552 80

483 70

414 60

345 50

276 40

207 30

30 40 50 60 70 80 90

-1 41016212732

SUCTION LINE TEMPERATURE (

SUCTION LINE TEMPERATURE (OC)

OUTDOOR TEMP

OFO

115 46 105 41

95 35 85 29 75 24 65 18 55 13

45 7

SUCTION LINE PRESSURE (KILOPASCALS)

SUCTION LINE PRESSURE (PSIG)

C00162

Fig. 16—Cooling Charging Chart, 50ZH024 Units

758 110

683 100

621 90

552 80

483 70

414 60

345 50

276 40

207 30

30 40 50 60 70 80 90

-1 41016212732

SUCTION LINE TEMPERATURE (

SUCTION LINE TEMPERATURE (OC)

SUCTION LINE PRESSURE (KILOPASCALS)

SUCTION LINE PRESSURE (PSIG)

OUTDOOR TEMP

OFO

115 46

105 41

95 35 85 29

75 24 65 18

55 13

45 7

C00163

Fig. 17—Cooling Charging Chart, 50ZH030

Page 15

supplemental electric heat. When thermostat is satisfied, contacts open, deenergizing contactor and relay; motors and heaters deenergize. The IFM may be controlled by a time-delay relay that keeps the fan on for 30 seconds.

DEFROST Defrost board (DB) is a time and temperature control, which

includes a field-selectable time period between checks for defrost (30, 50 and 90 minutes). The time period is factory-set at 30 minutes and should only be adjusted by a trained service person. Electronic timer and defrost cycle start only when contactor is energized and defrost thermostat (DFT) is closed.

Defrost mode is identical to Cooling mode. The outdoor fan motor stops because of “OF1” and “OF2” contacts opening on the defrost board, a bank of optional electric heat turns on to warm air supplying the conditioned space.

ELECTRIC RESISTANCE HEATING If accessory electric heaters are installed, on a call for “Emergency

Heat” the thermostat energizes W which energises the heater relay and in turn energizes the electric heaters. The IFR is energized which starts the indoor-fan motor. If the heaters are staged, W2 is energized when the second stage of heating is required. When the need for heating is satisfied, the heater and IFM are deenergized.

MAINTENANCE

To ensure continuing high performance, and to reduce the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This cooling unit should be inspected at least once each year by a qualified service person. To troubleshoot cooling of units, refer to Troubleshooting chart in back of book.

758 110

683 100

621 90

552 80

483 70

414 60

345 50

276 40

207 30

30 40 50 60 70 80 90

-1 41016212732

SUCTION LINE TEMPERATURE (

SUCTION LINE PRESSURE (KILOPASCALS)

SUCTION LINE PRESSURE (PSIG)

OUTDOOR TEMP

OFO

115 46 105 41

95 35 85 29

75 24 65 18

55 13 45 7

C00164

Fig. 18—Cooling Charging Chart, 50ZH036 Units

Fig. 19—Cooling Charging Chart, 50ZH042 Units

C00165

758 110

683 100

621 90

552 80

483 70

414 60

345 50

276 40

207 30

30 40 50 60 70 80 90

-1 41016212732

SUCTION LINE TEMPERATURE (

SUCTION LINE TEMPERATURE (OC)

SUCTION LINE PRESSURE (KILOPASCALS)

SUCTION LINE PRESSURE (PSIG)

OUTDOOR TEMP

OFO

115 46 105 41

95 35 85 29

75 24 65 18

55 13

45 7

758 110

683 100

621 90

552 80

483 70

414 60

345 50

276 40

207 30

30 40 50 60 70 80 90

-1 41016212732

SUCTION LINE TEMPERATURE (

SUCTION LINE PRESSURE (KILOPASCALS)

SUCTION LINE PRESSURE (PSIG)

OUTDOOR TEMP

OFO

115 46 105 41

95 35 85 29

75 24 65 18 55 13 45 7

C00166

Fig. 20—Cooling Charging Chart, 50ZH048 Units

758 110

683 100

621 90

552 80

483 70

414 60

345 50

276 40

207 30

30 40 50 60 70 80 90

-1 41016212732

SUCTION LINE TEMPERATURE (

SUCTION LINE TEMPERATURE (OC)

SUCTION LINE PRESSURE (KILOPASCALS)

SUCTION LINE PRESSURE (PSIG)

OUTDOOR TEMP

OFO

115 46 105 41

95 35 85 29 75 24

65 18 55 13

45 7

C00167

Fig. 21—Cooling Charging Chart, 50ZH060 Units

Page 16

NOTE TO EQUIPMENT OWNER: Consult your local dealer about the availability of a maintenance contract.

The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment, other than those procedures recommended in the User’s Manual. FAILURE TO HEED THIS WARNING COULD RESULT IN SERIOUS INJURY, DEATH OR DAMAGE TO THIS EQUIPMENT.

The minimum maintenance requirements for this equipment are as follows:

1. Inspect air filter(s) each month. Clean or replace when necessary.

2. Inspect indoor coil, outdoor coil, drain pan, and condensate drain each cooling and heating season for cleanliness. Clean when necessary.

3. Inspect blower motor and wheel for cleanliness each cooling and heating season. Clean when necessary. For first heating season, inspect blower wheel bimonthly to determine proper cleaning frequency.

4. Check electrical connections for tightness and controls for proper operation each cooling season. Service when necessary.

5. Check the drain channel in the top cover periodically for blockage (leaves, insects). Clean as needed.

Failure to follow these warnings could result in serious injury or death:

1. Turn off electrical power to the unit and install lockout tag before performing any maintenance or service on the unit.

2. Use extreme caution when removing panels and parts. As with any mechanical equipment, personal injury can result from sharp edges, etc.

3. Never place anything combustible either on, or in contact with, the unit.

Step 1—Air Filter NOTE: Never operate the unit without a suitable air filter in the

return-air duct system. Always replace the filter with the same size as originally installed. See Table 1 for recommended filter sizes

Inspect air filter(s) at least once each month and replace (throwaway-type) or clean (cleanable-type) at least twice during each cooling season or whenever the filters become clogged with dust and lint.

Replace filters with the same dimensional size and type as originally provided, when necessary.

Step 2—Unit Top Removal (Outdoor-Coil Side) NOTE: When performing maintenance or service procedures that

require removal of the unit top, be sure to perform all of the routine maintenance procedures that require top removal, including coil inspection and cleaning, and condensate drain pan inspection and cleaning.

Disconnect and tag electrical power to the unit before removing top. Failure to adhere to this warning could cause serious injury or death.

Only qualified service personnel should perform maintenance and service procedures that require unit top removal.

Refer to the following top removal procedures:

1. Remove 7 screws on unit top cover surface. (Save all screws.)

2. Remove 2 screws on unit top cover flange. (Save all screws.)

3. Lift top from unit carefully. Set top on edge and make sure that top is supported by unit side that is opposite duct (or plenum) side.

4. Carefully replace and secure unit top to unit, using screws removed in Steps 1 and 2, when maintenance and/or service procedures are completed.

Step 3—Indoor Blower and Motor

For longer life, operating economy, and continuing efficiency, clean accumulated dirt and grease from the blower wheel and motor annually.

Disconnect and tag electrical power to the unit before cleaning the blower wheel. Failure to adhere to this warning could cause serious injury or death.

To clean the blower wheel:

1. Access the blower assembly as follows: a. Remove top access panel. b. Remove 3 screws that hold blower orifice ring to blower

housing. Save screws.

c. Loosen setscrew(s) which secure wheel to motor shaft.

2. Remove and clean blower wheel as follows: a. Lift wheel from housing. When handling and/or cleaning

blower wheel, be sure not to disturb balance weights (clips) on blower wheel vanes.

b. Remove caked-on dirt from wheel and housing with a

brush. Remove lint and/or dirt accumulations from wheel and housing with vacuum cleaner, using a soft brush attachment. Remove grease and oil with a mild solvent.

c. Reassemble blower into housing. Place upper orifice ring

on blower to judge location of the blower wheel. Blower wheel should be approximately 0.2-in. below bottom of orifice ring when centered correctly. Be sure setscrews are tightened on motor and are not on round part of shaft.

d. Set upper orifice ring in place with 3 screws removed in

step 1.

e. Replace top access panel.

Step 4—Outdoor Coil, Indoor Coil, and Condensate Drain Pan

Inspect the outdoor coil, indoor coil, and condensate drain pan at least once heating and cooling season. Proper inspection and cleaning requires the removal of the unit top. See Unit Top Removal section above.

Remove all obstructions (including weeds and shrubs) that interfere with the airflow through the outdoor coil. Straighten bent fins with a fin comb. If coated with dirt or lint, clean the coils with a vacuum cleaner, using a soft brush attachment. Be careful not to bend the fins. If coated with oil or grease, clean the coils with a

Page 17

mild detergent-and-water-solution. Rinse coils with clear water, using a garden hose. Be careful not to splash water on motors, insulation, wiring or air filter(s). For best results, spray outdoorcoil fins from inside to outside the unit. On units with an outer and inner outdoor coil, be sure to clean between the coils. Be sure to flush all dirt and debris from the unit base.

Inspect the drain pan and condensate drain line when inspecting the coils. Clean the drain pan and condensate drain by removing all foreign matter from the pan. Flush the pan and drain tube with clear water. Do not splash water on the insulation, motor, wiring, or air filter(s). If the drain tube is restricted, clear it with a ‘‘plumbers snake’’ or similar probe device. Ensure that the auxiliary drain port above the drain tube is also clear.

Step 5—Outdoor Fan

Keep the Outdoor fan free from all obstructions to ensure proper cooling operation. Never place articles on top of the unit. Damage to unit may result.

1. Shut off unit power supply and install lockout tag.

2. Remove outdoor-fan assembly (grille, motor, motor cover, and fan) by removing screws and flipping assembly onto unit top cover.

3. Loosen fan hub setscrews.

4. Adjust fan height as shown in Fig. 21 or 22.

5. Tighten setscrews.

6. Replace outdoor-fan assembly.

Table 4—Dry Coil Air Delivery* Horizontal Discharge

(Deduct 10 percent for 208 Volt Operation)

230 AND 460 VOLT

Unit Motor Speed Watts/CFM

External Static Pressure (in. wg)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

024

Low

Watts 288 285 282 279 274 268 261 - -

Cfm 875 820 802 734 668 582 478 - -

Med

Watts 390 383 378 369 360 350 340 - -

Cfm 1131 1090 1038 978 917 830 721 - -

High

Watts 528 520 510 495 480 460 450 - -

Cfm 1391 1338 1285 1200 1115 1018 920 - -

030

Low

Watts 288 285 282 279 274 268 261 - -

Cfm 875 820 802 734 668 582 478 - -

Med

Watts 390 383 378 369 360 350 340 - -

Cfm 1131 1090 1038 978 917 830 721 - -

High

Watts 528 520 510 495 480 460 450 - -

Cfm 1891 1338 1285 1200 1115 1018 920 - -

036

Low

Watts 450 435 420 400 380 335 326 311 -

Cfm 1231 1218 1204 1120 1008 950 863 751 -

Med

Watts 470 450 445 410 388 359 338 321 -

Cfm 1302 1264 1205 1163 1081 940 873 783 -

High

Watts 660 635 610 575 540 505 485 460 -

Cfm 1700 1660 1581 1450 1297 1190 1095 999 -

042 †

Low

Watts 478 458 440 411 378 350 327 317 -

Cfm 1303 1270 1224 1179 1126 1022 911 816 -

Med

Watts 481 468 450 438 404 370 338 320 -

Cfm 1310 1280 1241 1181 1110 1022 943 811 -

High

Watts - 798 678 647 618 578 540 500 460

Cfm - 1736 1688 1618 1510 1421 1309 1187 1060

048 †

Low

Watts - - 801 760 730 688 650 600 570

Cfm - - 1898 1841 1757 1682 1564 1429 1333

Med

Watts ---------

Cfm ---------

High

Watts - - 870 842 818 782 696 632 628

Cfm - - 2000 1903 1799 1718 1625 1446 1365

060 †

Low

Watts 890 850 810 790 735 680 580 480 422

Cfm 1834 1820 1791 1762 1703 1640 1415 1159 950

Med

Watts 1040 1018 1000 950 890 835 790 650 580

Cfm 2230 2102 2025 1960 1901 1855 1752 1468 1121

High

Watts 1073 1038 1001 958 896 840 800 691 575

Cfm 2230 2202 2160 2122 2052 1926 1791 1588 1202

† 460-v motors are 2-speed. Air delivery values are based on operating voltage of 230-v. or 460-v., dry coil, without filter or electric heater. Deduct wet coil, filter, and electric heater pressure drops to obtain external static pressure availabe for ducting. Do not operate the unit at a cooling airflow that is less than 350 cfm for each 12,000 Btuh of rated cooling capacity. Evaporator coil frosting may occur at airflows below this point. Dashes indicate portions of the table that are beyond the blower motor capacity or are not recommended.

Page 18

Step 6—Electrical Controls and Wiring

Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit and install lockout tag.

Remove the top panel to locate all the electrical controls and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any smoky or burned connections are noticed, disassemble the connection, clean all the parts, restrip the wire end and reassemble the connection properly and securely.

Check to ensure no wires are touching refrigerant tubing or sharp sheet metal edges. Move and secure wires to isolate from tubing and sheet metal edges.

After inspecting the electrical controls and wiring, replace all the panels. Start the unit, and observe at least one complete cooling cycle to ensure proper operation. If discrepancies are observed in

operating cycle, or if a suspected malfunction has occurred, check each electrical component with the proper electrical instrumentation. Refer to the unit wiring label when making these checkouts.

NOTE: Refer to the Sequence of Operation section, as an aid in determining proper control operation.

Step 7—Refrigerant Circuit

Inspect all refrigerant tubing connections and the unit base for oil accumulations annually. Detecting oil generally indicates a refrigerant leak.

If oil is detected or if low cooling performance is suspected, leak-test all refrigerant tubing using an electronic leak-detector, or liquid-soap solution. If a refrigerant leak is detected, refer to Check for Refrigerant Leaks section. (See Table of Contents for page number.)

If no refrigerant leaks are found and low cooling performance is suspected, refer to Refrigerant Charge. (See Table of Contents for page number.)

Step 8—Indoor Airflow

The cooling airflow does not require checking unless improper performance is suspected. If a problem exists, be sure that all

supply- and return-air grilles are open and free from obstructions, and that the air filter is clean. When necessary, refer to Indoor

Airflow and Airflow Adjustments section to check the system airflow.

Step 9—Metering Devices

Refrigerant metering devices are fixed orifices and are located in the inlet header to the indoor and outdoor coils.

Check valves are also located in the liquid lines near the strainers. The check valves are the smaller of the two components.

Step 10—Lubrication

COMPRESSOR—The compressor is charged with the correct amount of oil at the factory.

FAN MOTOR BEARINGS—Fan motor bearings are permanently lubricated. No further lubrication of outdoor or indoor fan motors is required.

Step 11—Liquid Line Strainer

The liquid line strainer (to protect metering device) is made of wire mesh and is located in the liquid line on the inlet side of the metering device.

Table 5—Wet Coil Pressure Drop

UNIT SIZE

50ZH

AIRFLOW

(CFM)

PRESSURE DROP

(IN. WG)

024

600 0.02 700 0.05 800 0.06 900 0.07

030

900 0.06 1000 0.06 1200 0.08

036

1000 0.07 1200 0.09 1400 0.11 1600 0.12

042

1000 0.04 1200 0.06 1400 0.08 1600 0.09

048

1400 0.07 1600 0.08 1800 0.09

060

1700 0.07 1800 0.08 2100 0.09 2300 0.10

Table 6—Filter Pressure Drop (in. wg)

UNIT SIZE

50ZH

FILTER

SIZE

(IN.)

CFM

500 600 700 800 900 1000 1100 1200 1300 1400

024-042 24 x 24 0.06 0.07 0.08 0.08 0.09 0.09 0.09 0.10 0.11 0.12

048, 060 24x30------ - -0.08 0.09

UNIT

SIZE

50ZH

FILTER

SIZE (IN.)

CFM

1500 1600 1700 1800 1900 2000 2100 2200 2300

024-042 24 x 24 0.14 0.15 ------- 048,060 24 x 30 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18

Table 7—Accessory Electric Heat Pressure Drop

(in. wg)

HEATER KW

5-20

CFM

600 800 1000 1200 1400 1600 1800 2000 2200

0.06 0.08 0.10 0.13 0.15 0.18 0.20 0.23 0.25

Fig. 21—Outdoor-Fan Adjustment (024–048 Size)

C00021

3.125 in.

Fig. 22—Outdoor-Fan Adjustment (060 Size)

C02017

0.708in.

Page 19

Check valves are also located in the liquid lines near the strainers. The Strainers are the larger of the two components.

Step 12—High Flow Valves

Located on the compressor hot gas and suction tubes are High Flow Valves. Large black plastic caps distinguish these valves with O-rings located inside the caps. These valves can not be accessed for service in the field. Ensure the plastic caps are in place and tight or the possibility of refrigerant leakage could occur.

Fig. 23–Typical Heat Pump Operation, Heating Mode

C95045

STRAINER

ACCUMULATOR

COMPRESSOR

STRAINER

LCS

OUTDOOR COIL

INDOOR COIL

Check Valves

Open

Closed

Open

Closed

LEGEND

LCS Loss of Charge Switch

Acutrol Metering Device Check Valve (Arrow indicates direction of flow)

HEATING CYCLE

1. Hot gas from compressor flows through the 4-way valve and is directed to the cooling liquid line check valve. It is then condensed and directed through subcooling circuits and out to the strainer and the check valve in the heating liquid line.

2. The refrigerant then feeds the outdoor coil through the Acutrol metering device on each circuit.

3. Each circuit evaporates the refrigerant and the circuits are combinedintheoutdoorheaderwithsomeofthecircuits flowing through the check valve.

4. The refrigerant then flows through the 4-way valve, accumulator, and back to the compressor.

Page 20

Fig. 24–Typical Heat Pump Operation, Cooling Mode

C95044

STRAINER

ACCUMULATOR

COMPRESSOR

STRAINER

LCS

OUTDOOR COIL

INDOOR COIL

Check Valves

Closed

Open

Closed

Open

LEGEND

LCS Loss of Charge Switch

Acutrol Metering Device Check Valve (Arrow indicates direction of flow)

COOLING CYCLE

1. Hot gas from compressor flows through the 4-way valve and is directed to the heating liquid line check valve. It is then condensedandsubcooledthroughconverging circuits. Refrigerant leaves the outdoor coil by way of the strainer and the check valve in the cooling liquid line.

2. The refrigerant then feeds the indoor coil through the Acutrol metering device on each circuit.

3. Each circuit evaporates the refrigerant and the circuits are combined in the indoor coil header with some of the circuits flowing through the check valve.

4. The refrigerant then flows through the 4-way valve, accumulator, and back to the compressor.

Page 21

Fig. 25–50ZH Balance Point Chart

C01038

Balance Point Worksheet

10000

20000

30000

40000

50000

60000

70000

80000

-100 102030405060 Outdoor Air Temp (Deg F)

024 030 036 042 048 060

Building Heat Loss, BTUH

Unit Integrated Heating Capacity (BTUH)

Page 22

Table 8—Troubleshooting—Cooling and Heating

SYMPTOM CAUSE REMEDY

Compressor and outdoor fan will not start.

Power Failure Call power company

Loss of Charge

Switch open

Evaluate unit for possible refrigerant leak

Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker

Defective thermostat, contractor, transformer, or

control relay

Replace component

Insufficient line voltage Determine cause and correct

Incorrect or faulty wiring Check wiring diagram and rewire correctly

Thermostat setting too high

Lower thermostat setting below room tempera-

ture

Compressor will not start but outdoor fan

runs.

Faulty wiring or loose connections in compressor

circuit

Check wiring and repair or replace

Compressor motor burned out, seized, or internal

overload open

Determine cause

Replace compressor

Defective run/start capacitor, overload, start relay Determine cause and replace

One leg of 3-phase power dead

Replace fuse or reset circuit breaker

Determine cause

Low input voltage

(20 percent low)

Determine cause and correct

Compressor cycles

(other than normally satisfying thermostat).

Refrigerant overcharge or undercharge

Recover refrigerant, evacuate system, and re-

charge to capacities shown on nameplate

Loss of Charge

Switch open

Evaluate unit for possible refrigerant leak

Defective compressor Replace and determine cause

Insufficient line voltage Determine cause and correct

Blocked outdoor coil (cooling) Determine cause and correct

Defective run/start capacitor, overload or start

relay

Determine cause and replace

Defective thermostat Replace thermostat

Faulty outdoor-fan motor or capacitor Replace

Restriction in refrigerant system Locate restriction and remove

Compressor operates continuously.

Dirty air filter Replace filter

Unit undersized for load Decrease load or increase unit size

Thermostat set too low Reset thermostat Low refrigerant charge Locate leak, repair, and recharge

Leaking valves in compressor Replace compressor

Frosted outdoor coil with incorrect

defrost operation (heating)

Check defrost time settings. Reset as necessary.

Check defrost temperature switch. Replace as necessary.

Air in refrigerant system

Recover refrigerant, evacuate system, and re-

charge

outdoor coil dirty or restricted Clean coil or remove restriction

Excessive head pressure.

Dirty air filter Replace filter

Dirty outdoor coil Clean coil

Refrigerant overcharged Recover excess refrigerant Air in refrigerant system

Recover refrigerant, evacuate system, and re-

charge

Outdoor or indoor air restricted

or air is recirculating

Determine cause and correct

Head pressure too low.

Low refrigerant charge Check for leaks, repair and recharge

Compressor valves leaking Replace compressor

Restriction in liquid tube Remove restriction

Excessive suction pressure.

High heat load Check for source and eliminate

Compressor valves leaking Replace compressor

Refrigerant overcharged Recover excess refrigerant

Suction pressure too low.

Dirty air filter (cooling) Replace Filter

Low refrigerant charge Check for leaks, repair, and recharge

Metering device or low side restricted Remove source of restriction

Insufficient indoor airflow (cooling)

Increase air quantity

Check filter- replace if necessary

Temperature too low in conditioned area (cooling) Reset thermostat

Outdoor ambient below 40°F (cooling) Install low-ambient kit

Field-installed filter-drier restricted Replace

Compressor runs but

outdoor fan does not.

Normally closed contacts on

defrost board open

Check condition of relay on board.

Replace board if necessary.

Page 23

START-UP CHECKLIST

(REMOVE AND STORE IN JOB FILE)

I. PRELIMINARY INFORMATION

Model No .............................................................................................................................................................

Serial No ..............................................................................................................................................................

Date ......................................................................................................................................................................

Technician ...........................................................................................................................................................

Customer Information(Name/Address) ...........................................................................................................................................................

II. PRE-START-UP

____ Verify that all packing materials have been removed from unit ____ Verify that condensate connection is installed per installation instructions ____ Check all electrical connections and terminals for tightness ____ Check wire proximity to refrigerant tubes and sheet metal edges ____ Check that indoor (indoor) air filter is clean and in place ____ Verify that unit installation is level ____ Check fan wheel propeller for location in housing and setscrew tightness

III. START-UP

Supply Voltage: L1-L2 __________ L2-L3 __________ L3-L1 __________ Compressor Amps: L1(C) __________ L2(S) __________ L3(R) __________ Indoor Fan Amps: __________ Outdoor Fan Amps: __________

TEMPERATURE-Cooling Mode

Outdoor Air Temperature: __________ DB ____________WB Return-Air Temperature: __________ DB __________ WB Cooling Supply Air: __________DB___________WB

PRESSURES-Cooling Mode

Refrigerant Suction __________ psig

Suction Line Temp* ___________

Refrigerant Discharge __________ psig

Discharge Temp†__________

TEMPERATURE-Heating Mode

Outdoor Air Temperature: __________ DB ____________WB Return-Air Temperature: __________ DB __________ WB Cooling Supply Air: __________DB___________WB

PRESSURES-Heating Mode

Refrigerant Suction __________ psig

Suction Line Temp* ___________

Refrigerant Discharge __________ psig

Discharge Temp†__________

____ Verify Refrigerant charge using charging tables ____ Verify that 3-phase scroll compressor is rotating in correct direction.

*Measured at suction inlet to compressor †Measured at liquid line leaving outdoor coil

Page 24

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

Book 1 4 Tab 6 8

PC 101 Catalog No. 535-00080 Printed in U.S.A. Form 50ZH-5SI Pg 24 7-03 Replaces: 50ZH-4SI