Carrier WeatherMaster Installation Instructions

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Page 1

WeatherMaster

50GC**04-06

Single Package Rooftop Cooling Only/Electric Heat Unit

with Puron

(R-410A) Refrigerant

Installation Instructions

CONTENTS

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

MODEL NUMBER NOMENCLATURE AND

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Rated Indoor Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . 2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ep 1 — Plan for Unit Location . . . . . . . . . . . . . . . . 7

• ROOF MOUNT

Step 2 — Plan for Sequence of Unit Installation . . . 7

• CURB-MOUNTED INSTALLATION

• PAD-MOUNTED INSTALLATION

• FRAME-MOUNTED INSTALLATION

Step 3 — Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 4 — Provide Unit Support . . . . . . . . . . . . . . . . . 7

• ROOF CURB MOUNT

• SLAB MOUNT (HORIZONTAL UNITS ONLY)

• ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR

SLAB MOUNT)

Step 5 — Field Fabricate Ductwork . . . . . . . . . . . . . . 9

• UNITS WITH ACCESSORY OR OPTIONAL ELECTRIC

HEATERS

Step 6 — Rig and Place Unit . . . . . . . . . . . . . . . . . . . 9

• POSITIONING ON CURB

Step 7 — Convert to Horizontal and Connect

Ductwork (When Required) . . . . . . . . . . . . . . . . . 10

Step 8 — Install Outside Air Hood . . . . . . . . . . . . . . 11

• ECONOMIZER HOOD PACKAGE REMOVAL AND

SETUP (FACTORY OPTION)

• ECONOMIZER HOOD

Step 9 — Units with Hinged Panels Only . . . . . . . . 12

Step 10 — Install External Condensate Trap and

Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

ep 11 — Make Electrical Connections . . . . . . . . . 12

• FIELD POWER SUPPLY

• UNITS WITH FACTORY-INSTALLED NON-FUSED

DISCONNECT OR HACR

• UNITS WITHOUT FACTORY-INSTALLED NON-

FUSED DISCONNECT OR HACR

• ALL UNITS

• CONVENIENCE OUTLETS

• HACR AMP RATING

• FACTORY OPTION THRU-BASE CONNECTIONS

• UNITS WITHOUT THRU-BASE CONNECTIONS

(ELECTRICAL CONNECTIONS)

• FIELD CONTROL WIRING

• THERMOSTAT

• HEAT ANTICIPATOR SETTINGS

• ELECTRIC HEATERS

• HUMIDI-MIZER® CONTROL CONNECTIONS

• TYPICAL UNIT WIRING DIAGRAMS

EconoMi$er® X (Factory Option) . . . . . . . . . . . . . . . 24

• SYSTEM COMPONENTS

• SPECIFICATIONS

• INPUTS

• OUTPUTS

• ENVIRONMENTAL

• ECONOMIZER MODULE WIRING DETAILS

• S-BUS SENSOR WIRING

• CO2 SENSOR WIRING

• INTERFACE OVERVIEW

• SETUP AND CONFIGURATION

• TIME-OUT AND SCREENSAVER

• ENTHALPY SETTINGS

• STANDARD OR SINGLE SPEED FAN OPERATION

• 2 SPEED FAN OPERATION

• 2SP H/C AND 3 SPEED FAN OPERATION

• CHECKOUT

• TROUBLESHOOTING

RTU Open Controller (Factory Option) . . . . . . . . . .35

SystemVu™ Controller (Factory Option) . . . . . . . . .35

Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . .35

• LOW AMBIENT

Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Step 12 — Adjust Factory-Installed Options . . . . . .37

• SMOKE DETECTORS

• ECONOMI$ER® IV OCCUPANCY SWITCH

Step 13 — Install Accessories . . . . . . . . . . . . . . . . .37

ep 14 — Fan Speed Set Up . . . . . . . . . . . . . . . . . .38

• UNITS WITH ELECTRO-MECHANICAL CONTROLS

• UNITS WITH SYSTEMVU™ CONTROLS

START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

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

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

Follow all safety codes, including ANSI (American National Standards Institute) Z223.1. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations.

It is important to recognize safety information. This is the safetyalert symbol . When you see this symbol on the unit and 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 safetyalert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices, which may 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.

Catalog No. 04-53500269-01 Printed in U.S.A. Form 50GC-4-6-03SI Rev. A Pg 1 3-21 Replaces: 50GC-4-6-02SI

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

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DANGER

CAUTION

ELECTRICAL SHOCK HAZARD Failure to follow this warning will result in personal injury or

death. Before performing service or maintenance operations on unit,

turn off main power switch to unit and install lock(s) and lockout tag(s). Ensure electrical service to rooftop unit agrees with voltage and amperage listed on the unit rating plate. Unit may have more than one power switch.

WARNING

UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause personal injury,

death and/or equipment damage. R-410A refrigerant systems operate at higher pressures than

standard R-22 systems. Do not use R-22 service equipment or components on R-410A refrigerant equipment.

WARNING

PERSONAL INJURY AND ENVIRONMENTAL HAZARD

Failure to follow this warning could cause personal injury or death.

Relieve pressure and recover all refrigerant before system repair or final unit disposal.

Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils.

PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and

wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing air conditioning equipment.

MODEL NUMBER NOMENCLATURE AND

DIMENSIONS

See Fig. 1 for 50GC model number nomenclature. See Fig. 2 for unit dimensional drawings and service clearance dimensions.

Rated Indoor Airflow

Table 1 lists the rated indoor airflow used for the AHRI efficiency rating for the units covered in this document.

Table 1 — Rated Indoor Airflow

MODEL NUMBER RATED INDOOR AIRFLOW (CFM)

50GC*N/M/P04 1200 50GC*N/M/P05 1400 50GC*N/M/P06 2000

Page 3

50GC–M04A1 A5–0A0A 0

Cooling Tons

04 - 3 ton 05 - 4 ton 06 - 5 ton

Example:

Position: 2 3 4 5 6 7 8 9

11 12 13 14 15 16 17 18

Heat Options

–

= No Heat A = Low Electric Heat B = Medium Electric Heat C = High Electric Heat

Sens or Options

A = None B = RA (Return Air) Smoke Detector C = SA (Supply Air) Smoke Detector D = RA + SA Smoke Detector E = CO

F = RA Smoke Detector and CO

G = SA Smoke Detector and CO

H = RA + SA Smoke Detector and CO

J = Condensate Overflow Switch K = Condensate Overflow Swtich and RA Smoke Detectors L = Condensate Overflow Switch and RA and SA Smoke Detectors M = Condensate Overflow Swtich and SA Smoke Detectors

Indoor Fan Options

1 = Direct Drive

– EcoBlue – Standard Static

2 = Direct Drive

– EcoBlue – Medium Static

3 = Direct Drive

– EcoBlue – High Static

Coil Options (RTPF) (Outdoor - Indoor - Hail Guard)

A = Al/Cu - Al/Cu B = Precoat Al/Cu - Al/Cu C = E-coat Al/Cu - Al/Cu D = E-coat Al/Cu - E-coat Al/Cu E = Cu/Cu - Al/Cu F = Cu/Cu - Cu/Cu M = Al/Cu - Al/Cu — Louvered Hail Guard N = Precoat Al/Cu - Al/Cu — Louvered Hail Guard P = E-coat Al/Cu - Al/Cu — Louvered Hail Guard Q = E-coat Al/Cu - E-coat Al/Cu — Louvered Hail Guard R = Cu/Cu - Al/Cu — Louvered Hail Guard S = Cu/Cu - Cu/Cu — Louvered Hail Guard

Voltage

1 = 575/3/60 3 = 208-230/1/60 5 = 208-230/3/60 6 = 460/3/60

Design Revision

– = Factory Design Revision

Base Unit Controls

0 = Electro-mechanical controls - can be used with field-installed W7212 EconoMi$er

IV (Non-Fault Detection and Diagnostic) 2 = RTU Open Multi-Protocol Controller 3 = SystemVu™ Controller 6 = Electro-mechanical - can be used with W7220 EconoMi$er X

(with Fault Detection and Diagnostic)

Intake / Exhaust Options

A = None B = Temperature Economizer w/ Barometric Relief F = Enthalpy Economizer w/ Barometric Relief U = Temperature Ultra Low Leak Economizer w/ Barometric Relief W = Enthalpy Ultra Low Leak Economizer w/ Barometic Relief

Service Options

0 = None 1 = Unpowered Convenience Outlet 2 = Powered Convenience Outlet 3 = Hinged Panels 4 = Hinged Panels and Unpowered Convenience Outlet 5 = Hinged Panels and Powered Convenience Outlet 6 = MERV 8 Filters C = Foil Faced Insulation

Factory Assigned

0 = Standard 1 = LTL

Electrical Options

A = None B = HACR Breaker C = Non-Fused Disconnect (NFD) D = Thru-The-Base Connections (TTB) E = HACR and Thru-The-Base Connections F = Non-Fused Disconnect and TTB N = Phase Monitor Protection P = Phase Monitor and HACR Q = Phase Monitor and NFD R = Phase Monitor and TTB S = Phase Monitor and HACR and TTB T = Phase Monitor and NFD and TTB

Refrig. Systems Options

M = Two Stage Cooling Models N = Two Stage Cooling Models with Humidi-MiZer

system (includes Low Ambient control) P = Two Stage Cooling Models with Low Ambient control

Note: On single phase (-3 voltage code) models, the following are not available as factory-installed options:

- Humidi-MiZer

System

- Coated Coils or Cu Fin Coils

- Louvered Hail Guards

- Economizer

- Powered 115 Volt Convenience Outlet

Model Series - WeatherMaster

GC - 16.1 SEER Efficiency

Unit Heat Type

50 - Electric Heat Packaged Rooftop

Fig. 1 — 50GC 04-06 Model Number Nomenclature (Example)

Page 4

Fig. 2 — 50GC 04-06 Unit Dimensional Drawing

Page 5

Fig. 2 — 50GC 04-06 Unit Dimensional Drawing (cont)

Page 6

Fig. 2 — 50GC 04-06 Unit Dimensional Drawing (cont)

Page 7

INSTALLATION

Jobsite Survey

Complete the following checks before installation.

1. Consult local building codes and the NEC (National Elec-

trical Code) ANSI/NFPA 70 for special installation requirements.

2. Determine unit location (from project plans) or select unit location.

3. Check for possible overhead obstructions which may interfere with unit lifting or rigging.

Step 1 — Plan for Unit Location

Select a location for the unit and its support system (curb or other) that provides for the minimum clearances required for safety (including clearance to combustible surfaces), unit performance and service access below, around and above unit as specified in unit drawings. See Fig. 2 on page 5.

NOTE: Consider also the effect of adjacent units. Unit may be installed directly on wood flooring or on Class A, B,

or C roof-covering material when roof curb is used. Do not install unit in an indoor location. Do not locate air inlets

near exhaust vents or other sources of contaminated air. Although unit is weatherproof, avoid locations that permit water

from higher level runoff and overhangs to fall onto unit. Select a unit mounting system that provides adequate height to al-

low installation of condensate trap per requirements. Refer to Step 10 — Install External Condensate Trap and Line on page 12 for required trap dimensions.

ROOF MOUNT Check building codes for weight distribution requirements. Unit

operating weight is shown in Table 2.

Table 2 — Operating Weights

50GC-*

Base Unit 468 (212) 510 (231) 555 (252) Economizer

Vertical 50 (23) 50 (23) 50 (23)

Horizontal 80 (36) 80 (36) 80 (36) Humidi-MiZer Cu Fins 25 (11) 43 (20) 56 (25) Powered Outlet 32 (15) 32 (15) 32 (15) Curb

14-in. (356 mm) 110 (50) 110 (50) 110 (50)

24-in. (610 mm) 145 (66) 145 (66) 145 (66)

System 27 (10) 34 (13) 34 (13)

UNIT LB (KG)

04 05 06

Step 2 — Plan for Sequence of Unit Installation

The support method used for this unit will dictate different sequences for the steps of unit installation. For example, on curbmounted units, some accessories must be installed on the unit before the unit is placed on the curb. Review the following for recommended sequences for installation steps:

CURB-MOUNTED INSTALLATION

1. Install curb

2. Install field-fabricated ductwork inside curb

3. Install accessory thru-base service connection package

(affects curb and unit) (refer to accessory installation instructions for details)

4. Prepare bottom condensate drain connection to suit planned condensate line routing (refer to Step 10 — Install External Condensate Trap and Line on page 12 for details)

5. Rig and place unit

6. Install outdoor air hood

7. Install condensate line trap and piping

8. Make electrical connections

9. Install other accessories

PAD-MOUNTED INSTALLATION

1. Prepare pad and unit supports

2. Check and tighten the bottom condensate drain connection plug

3. Rig and place unit

4. Convert unit to side duct connection arrangement

5. Install field-fabricated ductwork at unit duct openings

6. Install outdoor air hood

7. Install condensate line trap and piping

8. Make electrical connections

9. Install other accessories

FRAME-MOUNTED INSTALLATION Frame-mounted applications generally follow the sequence for a

curb installation. Adapt the sequence as required to suit specific installation plan.

Step 3 — Inspect Unit

Inspect unit for transportation damage. File any claim with transportation agency.

Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree with power supply provided.

On units with hinged panel option, check to be sure all latches are snug and in closed position.

Locate the carton containing the outside air hood parts. Do not remove carton until unit has been rigged and located in final position.

Step 4 — Provide Unit Support

ROOF CURB MOUNT Accessory roof curb details and dimensions are shown in Fig. 3.

Assemble and install accessory roof curb in accordance with instructions shipped with the curb.

Curb should be level. This is necessary for unit drain to function properly. Unit leveling tolerances are shown in Fig. 4. Refer to Accessory Roof Curb Installation Instructions for additional information as required.

Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb and not to the unit. The

accessory thru-the-base power connection package must be installed before the unit is set on the roof curb.

If electric and control wiring is to be routed through the basepan, attach the accessory thru-the-base service connections to the basepan in accordance with the accessory installation instructions.

NOTE: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket supplied with the roof curb as shown in Fig. 3. Improperly applied gasket can also result in air leaks and poor unit performance.

Page 8

ROOF CURB

ACCESSORY #

CRRFCURB001A01

[137.7]

5.42"

14"

[356]

24"

[610]

11.96"

[303.8]

NOTES:

1. ROOFCURB ACCESSORY IS SHIPPED DISASSEMBLED.

2. INSULATED PANELS: 25.4 [1"] THK. POLYURETHANE FOAM, 44.5 [1-3/4] # DENSITY.

3. DIMENSIONS IN [ ] ARE IN MILLIMETERS.

4. ROOFCURB: 18 GAGE STEEL.

5. ATTACH DUCTWORK TO CURB. (FLANGES OF DUCT REST ON CURB).

6. SERVICE CLEARANCE 4 FEET ON EACH SIDE.

7. DIRECTION OF AIR FLOW.

8. CONNECTOR PACKAGE CRBTMPWR001A01 IS FOR THRU-THE-CURB GAS TYPE PACKAGE CRBTMPWR003A01 IS FOR THRU-THE-BOTTOM TYPE GAS CONNECTIONS.

CONNECTOR PKG. ACC. GAS CONNECTION TYPE GAS FITTING

CRBTMPWR001A01 3/4" [19] NPT

CRBTMPWR003A01 THRU THE BOTTOM

1-3/4" [44.5]

1.00" [25.4]

THRU THE CURB

1/2" [12.7] NPTCRRFCURB002A01

11 3/4"[298.5] WIDE INSULATED DECK PANELS

POWER WIRING

FITTING

3/4" [19] NPT

CONTROL WIRING

FITTING

1/2" [12.7] NPT 1/2" [12.7] NPT

ACCESSORY CONVENIENCE

OUTLET WIRING CONNECTOR

"A"

21.74"

[552.2]

4.96"

[126.0]

RETURN AIR

40.69"

[1033.5]

OPENING

16.03"

[407.2]

3.00" [76.2]

13.78"

[350.0]

15.19"

[385.8]

14.00"

[355.6]

1.75"

[44.5]

1/4"

[7.0] 4 9/16" [115.5]

3.00" [76.2]

1/3/4"[44.5]

21.84"

[554.7]

SUPPLY AIR OPENING

20.41"

[518.3]

SUPPLY AIR RETURN AIR

70.87"

[1800.2]

32.19"

[817.6]

(SUPPLIED WITH CURB)

OVERALL DIM. 5'-7 3/8" WAS 5'-7 7/8; 18GA MATERIAL WA 16 GA.; NAIL FIELD SUPPLIED WAS

WITH CURB

VIEW "B"

CORNER DETAIL

GASKET

DUCT

(FIELD SUPPLIED)

UNIT

NAIL (FIELD SUPPLIED)

TYPICAL (4) SIDES

7/16" [11]

COUNTER FLASHING (FIELD SUPPLIED)

RIGID INSULATION (FIELD SUPPLIED)

ROOFING FELT (FIELD SUPPLIED)

CANT STRIP (FIELD SUPPLIED)

ROOFING MATERIAL (FIELD SUPPLIED)

E-ESECTION

SCALE 0.250

1-3/4" [44.4]

"A"

8 9/16"[217.5] WIDE INSULATED DECK PANEL

GAS SERVICE PLATE THRU THE CURB DRILL HOLE 2" [50.8] @ ASSEMBLY (IF REQUIRED) (SEE NOTE #8)

SUPPLY AIR

3'-1 3/16"

[944.6]

SEE VIEW "B"

DRAWING RELEASE LEVEL:

THIRD ANGLE PROJECTION

ENGINEERING REQUIREMENTS

1067898--MMC04/22/13

SURFACE FINISH MFG/PURCH MODEL (INTERNAL USE ONLY) NEXT DRAWING SCALE DISTRIBUTION

ECN NO.APP'DCHK'DBYDATEREVISION RECORDREV

1' 4-13/16" [427] INSIDE

RETURN AIR

1-3/4" [44.5]

2-3/8" [61]

5' 7-3/8"

[1711.3]

SEE NOTE #2

CERTIFIED DRAWING

PRODUCTION

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ON:

MATERIAL

T-005, Y-002

WEIGHT:

- PURCH - N/A MMC

1 DEC 2 DEC 3 DEC ANG

----

AUTHORIZATION NUMBER TITLE

1041738

ENGINEERING MANUFACTURING

MMC 06/17/11 - -

DRAFTER CHECKER

CURB ASY, ROOF

SIZE DRAWING NUMBER REV

48TC400427

SHEET 5 OF 5

1-3/4" [44.4]

Fig. 3 — Roof Curb Details

Page 9

MAXIMUM ALLOWABLE

DIFFERENCE IN. (MM)

A-B B-C A-C

0.5 (13) 1.0 (25) 1.0 (25)

Fig. 4 — Unit Leveling Tolerances

SLAB MOUNT (HORIZONTAL UNITS ONLY) Provide a level concrete slab that extends a minimum of 6-in.

(150 mm) beyond unit cabinet. Install a gravel apron in front of condenser coil air inlet to prevent grass and foliage from obstructing airflow.

NOTE: Horizontal units may be installed on a roof curb if required.

ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR SLAB MOUNT)

A non-combustible sleeper rail can be used in the unit curb support area. If sleeper rails cannot be used, support the long sides of the unit with a minimum of 3 equally spaced 4-in. x 4-in. (102 mm x 102 mm) pads on each side.

Step 5 — Field Fabricate Ductwork

Cabinet return-air static pressure (a negative condition) shall not exceed 0.35 in. wg (87 Pa) with economizer or 0.45 in. wg (112 Pa) without economizer.

For vertical ducted applications, secure all ducts to roof curb and building structure. Do not connect ductwork to unit.

Fabricate supply ductwork so that the cross sectional dimensions are equal to or greater than the unit supply duct opening dimensions for the first 18-in. (458 mm) of duct length from the unit basepan.

Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes.

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

If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes.

CAUTION

PROPERTY DAMAGE HAZARD Failure to follow this caution may result in damage to roofing

materials. Membrane roofs can be cut by sharp sheet metal edges. Be

careful when placing any sheet metal parts on such roof.

UNITS WITH ACCESSORY OR OPTIONAL ELECTRIC HEATERS

All installations require a minimum clearance to combustible surfaces of 1-in. (25 mm) from duct for first 12-in. (305 mm) away from unit.

Outlet grilles must not lie directly below unit discharge.

WARNING

PERSONAL INJURY HAZARD Failure to follow this warning could cause personal injury. For vertical supply and return units, tools or parts could drop

into ductwork and cause an injury. Install a 90 degree turn in the return ductwork between the unit and the conditioned space. If a 90 degree elbow cannot be installed, then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space. Due to electric heater, supply duct will require 90 degree elbow.

Step 6 — Rig and Place Unit

Keep unit upright and do not drop. Spreader bars are required. Rollers may be used to move unit across a roof. Rigging materials under unit (cardboard or wood) must be removed PRIOR to placing the unit on the roof curb. Level by using unit frame as a reference. See Table 2 on page 7 and Fig. 5 for additional information.

Lifting holes are provided in base rails as shown in Fig. 5. Refer to rigging instructions on unit.

Rigging materials under the unit (cardboard or wood to prevent base pan damage) must be removed PRIOR to placing the unit on the roof curb.

Before setting the unit onto the curb, recheck gasketing on curb.

CAUTION

UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage. All panels must be in place when rigging. Unit is not designed

for handling by fork truck when packaging is removed. If using top crate as spreader bar, once unit is set, carefully

lower wooden crate off building roof top to ground. Ensure that no people or obstructions are below prior to lowering the crate.

POSITIONING ON CURB Position unit on roof curb so that the following clearances are

maintained: the base rail inside the front and rear, 0.0-in. clearance between the roof curb and the base rail inside on the duct end of the unit. This will result in the distance between the roof curb and the base rail inside on the condenser end of the unit being approximately (6.4 mm).

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

After unit is in position, remove rigging skids and shipping materials.

/4-in. (6.4 mm) clearance between the roof curb and

/4-in.

Page 10

DETAIL "A"

PLACE ALL SEAL STRIP IN PLACE BEFORE PLACING UNIT ON ROOF CURB.

DUCT END

SEE DETAIL "A"

"A"

(914-1371)

36"- 54"

"C"

"B"

SPREADER

BARS

REQUIRED

REMOVABLE HORIZONTAL SUPPLY DUCT OPENING COVER

REMOVABLE HORIZONTAL RETURN DUCT OPENING COVER

SCREWS

DUCT COVERS SHEET METAL FACE UP

BASEPAN

UNIT

50GC-*04 780 354 74.5 1890 35.5 900 33.5 850 50GC-*05 863 391 74.5 1890 35.5 900 33.5 850 50GC-*06 969 440 74.5 1890 35.0 890 41.5 1055

NOTES:

1. SPREADER BARS REQUIRED — Top damage will occur if spreader bars are not used.

2. Dimensions in ( ) are in millimeters.

3. Hook rigging shackles through holes in base rail, as shown in detail “A.” Holes in base rails are centered around the unit center of gravity. Use wooden top to prevent rigging straps from damaging unit.

MAX WEIGHT

lb kg in. mm in. mm in. mm

Fig. 5 — Rigging Details

Step 7 — Convert to Horizontal and Connect

Ductwork (When Required)

Unit is shipped in the vertical duct configuration. Unit without factory-installed economizer or return-air smoke detector option may be field-converted to horizontal ducted configuration. To convert to horizontal configuration, remove screws from side duct opening covers (see Fig. 6) and remove covers. Use the screws to install the covers on vertical duct openings with the insulation-side down. The panels must be inserted into the notches on the basepan to properly seal. The notches are covered by the tape used to secure the insulation to the basepan and are not easily seen. See Fig. 7 for position of the notches in the basepan. Seals around duct openings must be tight. Secure with screws as shown in Fig. 8. Cover seams with foil duct tape.

Field-supplied flanges should be attached to horizontal duct openings and all ductwork should be secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof or building openings with counter flashing and mastic in accordance with applicable codes.

Do not cover or obscure visibility to the unit’s informative data plate when insulating horizontal ductwork.

DIMENSIONS

A B C

NOTCHES

BASEPAN

Fig. 7 — Location of Notches

NOTCHES

Fig. 6 — Horizontal Conversion Panels

Fig. 8 — Horizontal Duct Panels In Place

Page 11

Step 8 — Install Outside Air Hood

HOOD PARTS

PLASTIC TIE WRAP QTY (2)

SCREWS FOR METAL TRAY QTY (2)

ECONOMIZER HOOD PACKAGE REMOVAL AND SETUP (FACTORY OPTION)

NOTE: Economizer is not available as factory-installed options for single phase (-3 voltage code) models.

The hood is shipped in knock-down form and must be field assembled. The indoor coil access panel is used as the hood top while the hood sides, divider and filter are packaged together, attached to a metal support tray using plastic stretch wrap, and shipped in the return air compartment behind the indoor coil access panel. The hood assembly’s metal tray is attached to the basepan and also attached to the damper using two plastic tie-wraps.

1. To gain access to the hood, remove the filter access panel. See Fig. 9.

FILTER ACCESS PANEL

COMPRESSOR ACCESS PANEL

OUTDOOR-AIR OPENING AND INDOOR COIL ACCESS PANEL

Fig. 9 — Typical Access Panel Locations

2. Locate the (2) screws holding the metal tray to the basepan and remove. Locate and cut the (2) plastic tie-wraps securing the assembly to the damper. See Fig. 10. Avoid damaging any wiring or cutting tie-wraps securing any wiring.

1. The indoor coil access panel will be used as the top of the hood. Remove the screws along the sides and bottom of the indoor coil access panel. See Fig. 11.

TOP PAN EL

INDOOR COIL ACCESS PAN EL

CAULK HERE

Fig. 11 — Indoor Coil Access Panel Relocation

2. Swing out indoor coil access panel and insert the hood sides under the panel (hood top). Use the screws provided to attach the hood sides to the hood top. Use screws provided to attach the hood sides to the unit. See Fig. 12.

TOP PAN EL

INDOOR COIL ACCESS PANEL

Fig. 10 — Economizer Hood Parts Location

3. Carefully lift the hood assembly (with metal tray) through the filter access opening and assemble per the steps outlined in the following section, “Economizer Hood”.

ECONOMIZER HOOD NOTE: If the power exhaust accessory is to be installed on the

unit, the hood shipped with the unit will not be used and must be discarded. Save the aluminum filter for use in the power exhaust hood assembly.

LEFT HOOD SIDE

19 1/16”

(483mm)

SCREW

HOOD DIVIDER

33 3/8”

(848mm)

Fig. 12 — Economizer Hood Construction

3. Remove the shipping tape holding the economizer barometric relief damper in place (economizer only).

4. Insert the hood divider between the hood sides. See Fig. 12 and 13. Secure hood divider with 2 screws on each hood side. The hood divider is also used as the bottom filter rack for the aluminum filter.

5. Open the filter clips which are located underneath the hood top. Insert the aluminum filter into the bottom filter rack (hood divider). Push the filter into position past the open filter clips. Close the filter clips to lock the filter into place. See Fig. 13.

6. Caulk the ends of the joint between the unit top panel and the hood top.

7. Replace the filter access panel.

Page 12

To use the alternate bottom drain connection, remove the red drain

DIVIDER

BAROMETRIC RELIEF

CLEANABLE ALUMINUM FILTER

FILTER

HOOD

FILTER CLIP

OUTSIDE AIR

DRAIN (FACTORY-INSTALLED)

PLUG

CONDENSATE PAN (SIDE VIEW)

STANDARD SIDE DRAIN

ALTERNATE BOTTOM DRAIN

plug from the bottom connection (use a

/2-in. square socket drive

extension) and install it in the side drain connection. The piping for the condensate drain and external trap can be com-

pleted after the unit is in place. See Fig. 16.

MINIMUM PITCH 1˝ (25 mm) PER 10´ (3 m) OF LINE

BASE RAIL

OPEN VENT

3˝ (76 mm)

MIN

Fig. 13 — Economizer Filter Installation

Step 9 — Units with Hinged Panels Only

Relocate latch shipped inside the compressor compartment behind the hinged compressor door to location shown in Fig. 14 after unit installation.

If the unit does not have hinged panels, skip this step and continue at Step 10 below.

COMPRESSOR

DOOR

OUTDOOR COIL

LATCH

Fig. 14 — Compressor Door Latch Location

Step 10 — Install External Condensate Trap and

Line

The unit has one 3/4-in. condensate drain connection on the end of the condensate pan and an alternate connection on the bottom. See Fig. 15. Unit airflow configuration does not determine which drain connection to use. Either drain connection can be used with vertical or horizontal applications.

Fig. 15 — Condensate Drain Pan (Side View)

When using the standard side drain connection, ensure that the red plug in the alternate bottom connection is tight. Do this before setting the unit in place. The red drain pan plug can be tightened with

/2-in. square socket drive extension.

TO ROO F DRAIN

DRAIN PLUG

NOTE: Trap should be deep enough to offset maximum unit static difference. A 4-in. (102 mm) trap is recommended.

SEE NOTE

ROOF CURB

Fig. 16 — Condensate Drain Pan Piping Details

All units must have an external trap for condensate drainage. Install a trap at least 4-in. (102 mm) deep and protect against freeze-up. If drain line is installed downstream from the external trap, pitch the line away from the unit at 1-in. per 10 ft (25 mm per 3 m) of run. Do not use a pipe size smaller than the unit connection (

/4-in.).

Step 11 — Make Electrical Connections

WARNING

ELECTRIC SHOCK HAZARD Failure to follow this warning could result in personal injury or

death. 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 electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with NEC; ANSI/NFPA 70, latest edition (in Canada, Canadian Electrical Code CSA [Canadian Standards Association] C22.1), and local electrical codes.

NOTE: Field-supplied wiring shall conform with the limitations of minimum 63°F (33°C) rise.

FIELD POWER SUPPLY If equipped with optional powered convenience outlet, the power

source leads to the convenience outlet’s transformer primary are not factory connected. Installer must connect these leads according to required operation of the convenience outlet. If an alwaysenergized convenience outlet operation is desired, connect the source leads to the line side of the unit-mounted disconnect. (Check with local codes to ensure this method is acceptable in your area.) If a de-energize via unit disconnect switch operation of the convenience outlet is desired, connect the source leads to the load side of the unit disconnect. On a unit without a unit-mounted disconnect, connect the source leads to compressor contactor C and indoor fan contactor IFC pressure lugs with unit field power leads. See Convenience Outlets on page 15 for power transformer connections.

The field power wires are connected to the unit at line-side pressure lugs on compressor contactor C and indoor fan contactor IFC (see wiring diagram label for control box component

Page 13

arrangement) or at factory-installed option non-fused disconnect

COPPER

WIRE ONLY

ELECTRIC

DISCONNECT

SWITCH

ALUMINUM

WIRE

switch or HACR. Maximum wire size is #2ga AWG (copper only) per pole on contactors, #2ga AWG (copper only) per pole on optional disconnect or HACR, and 4/0 AWG (copper only) per pole on terminal or fuse blocks on units with single point box (see Fig. 17). See Fig. 18 and unit label diagram for field power wiring connections.

NOTE: Unit may be equipped with short test leads (pigtails) on the field line connection points on contactor C or optional disconnect switch. These leads are for factory-run test purposes only; remove and discard before connecting field power wires to unit connection points. Make field power connections directly to line connection pressure lugs only.

UNITS WITH FACTORY-INSTALLED NON-FUSED DISCONNECT OR HACR

The factory-installed optional non-fused disconnect (NFD) or HACR switch is located in a weatherproof enclosure located under the main control box. The manual switch handle and shaft are shipped in the disconnect or HACR enclosure. Assemble the shaft and handle to the switch at this point. Discard the factory test leads (see Fig. 18).

Units Without Single Point Box, Disconnect or HACR Option

Equip

GR Lug

TB TB

11 12

Disconnect

per

NEC

208/230-1-60

Ground

(GR)

11 12 13

Disconnect

per

NEC

L1 L2 L3

208/230-3-60

460-3-60 575-3-60

Units With Disconnect or HACR Option

3 Phase Only 3 Phase Only

Optional

Disconnect

Switch

Factory Wiring

WARNING

FIRE HAZARD Failure to follow this warning could result in personal injury,

death, or property damage. Do not connect aluminum wire between disconnect switch and

unit. Use only copper wire.

Fig. 17 — Disconnect Switch and Unit

Connect field power supply conductors to LINE side terminals when the switch enclosure cover is removed to attach the handle.

Ground

(GR)

Disconnect factory test leads; discard.

Equip GR Lug

Units With Electric Heat Option with Single Point Box

and Without Disconnect or HACR Option

Single Point Box

Ground (GR)

Terminal Block

Equip GR

Lug

— OR —

Single Point Box

Ground (GR)

Fuse/Terminal Block

Fuse

Equip GR

Lug

Fig. 18 — Power Wiring Connections

Factory Wiring

Field-Install the NFD Shaft and Handle

1. Remove the Control Box access panel. The NFD enclosure is located below the Control Box (see Fig. 19).

2. Remove (3) cap head screws that secure the NFD enclosure front cover — (2) on the face of the cover and (1) on the left side cover. See Fig. 20.

3. Remove the front cover of the NFD enclosure.

4. Make sure the NFD shipped from the factory is at OFF position (the arrow on the black handle knob is at OFF).

5. Insert the shaft with the cross pin on the top of the shaft in the horizontal position. See Fig. 20.

Page 14

6. Measure from the tip of the shaft to the top surface of the black pointer; the measurement should be 3.75 to 3.88-in. (95 to 99 mm).

7. Tighten the locking screw to secure the shaft to the NFD.

8. Turn the handle to the OFF position with red arrow pointing at OFF.

9. Install the handle on to the painted cover horizontally with the red arrow pointing to the left.

10. Secure the handle to the painted cover with (2) screws and lock washers supplied.

11. Engaging the shaft into the handle socket, re-install (3) hex screws on the NFD enclosure.

12. Re-install the unit front panel.

6. Tighten the locking screw to secure the shaft to the HACR.

7. Turn the handle to the OFF position with red arrow pointing at OFF.

8. Install the handle on to the painted cover horizontally with the red arrow pointing to the left.

9. Secure the handle to the painted cover with (2) screws and lock washers supplied.

10. Engaging the shaft into the handle socket, re-install (3) hex screws on the HACR enclosure.

11. Re-install the unit front panel.

Fig. 19 — NFD Enclosure Location

Fig. 20 — NFD Handle and Shaft Assembly

Field-Install the HACR Shaft and Handle

1. Remove the Control Box access panel. The HACR enclosure is located below the Control Box (see Fig. 21).

2. Remove (3) cap head screws that secure the HACR enclosure — (2) on the face of the cover and (1) on the left side cover. See Fig. 22.

3. Remove the front cover of the HACR enclosure.

4. Make sure the HACR shipped from the factory is at OFF position (the white arrow pointing at OFF).

5. Insert the shaft all the way with the cross pin on the top of the shaft in the horizontal position. See Fig. 22.

Fig. 21 — HACR Enclosure Location

Fig. 22 — HACR Handle and Shaft Assembly

UNITS WITHOUT FACTORY-INSTALLED NON-FUSED DISCONNECT OR HACR

When installing units, provide a disconnect switch per NEC (National Electrical Code) of adequate size. Disconnect sizing data is provided on the unit informative plate. Locate on unit cabinet or within sight of the unit per national or local codes. Do not cover unit informative plate if mounting the disconnect on the unit cabinet.

ALL UNITS All field wiring must comply with NEC and all local codes. Size

wire based on MCA (Minimum Circuit Amps) on the unit informative plate. See Fig. 18 and the unit label diagram for power wiring connections to the unit power terminal blocks and equipment ground. Maximum wire size is #2ga AWG (copper only) per pole on contactors, #2ga AWG (copper only) per pole on optional disconnect or HACR, and 4/0 AWG (copper only) per pole on

Page 15

terminal or fuse block on units with single point box. See Fig. 18

WEATHERPROOF

COVER

and unit label diagram for field power wiring connections. Provide a ground fault and short circuit over-current protection de-

vice (fuse or breaker) per NEC Article 440 (or local codes). Refer to unit informative data plate for MOCP (Maximum Over-Current Protection) device size.

NOTE: Units ordered with factory installed HACR do not need an additional ground fault and short circuit over-current protective device unless required by local codes.

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

All units except 208/230v units are factory wired for the voltage shown on the nameplate. If the 208/230v unit is to be connected to

a 208v power supply, the control transformer must be rewired by removing the black wire with the from the 230v connection and moving it to the 200v

/4-in. female spade connector

/4-in. male terminal on the primary side of the transformer. Refer to unit label diagram for additional information. Field power wires will be connected at line-side pressure lugs on the power terminal block or at factory-installed option non-fused disconnect.

NOTE: Check all factory and field electrical connections for tightness.

CONVENIENCE OUTLETS

WARNING

Fig. 24 — Convenience Outlet Utilization

Notice Label

Installing Weatherproof Cover

A weatherproof while-in-use cover for the factory-installed convenience outlets is now required by UL standards. This cover cannot be factory-mounted due its depth; it must be installed at unit installation. For shipment, the convenience outlet is covered with a blank cover plate.

On units with electro-mechanical controls the weatherproof cover kit is shipped in the unit’s control box. The kit includes the hinged cover, a backing plate and gasket.

On units with a factory installed direct digital controller (SystemVu™ controls or RTU Open controller) the weatherproof cover kit is secured to the basepan underneath the control box. See Fig. 25.

ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or

death. Units with convenience outlet circuits may use multiple

disconnects. Check convenience outlet for power status before opening unit for service. Locate its disconnect switch, if appropriate, and open it. Lock-out and tag-out this switch, if necessary.

Two types of convenience outlets are offered on 50GC models: non-powered and unit-powered. Both types provide a 125-v GFCI (ground-fault circuit interrupter) duplex receptacle rated at 15A behind a hinged waterproof access cover, located on the end panel of the unit. See Fig. 23.

Figure 23 shows the Convenience Outlet Utilization label which is located below the convenience outlet.

NOTE: Unit powered convenience outlets are not available as factory installed options for single phase (-3 voltage code) models.

CONVENIENCE OUTLET GFCI

PWD-CO TRANSFORMER

PWD-CO FUSE SWITCH

Fig. 23 — Convenience Outlet Location

Fig. 25 — Weatherproof Cover - Shipping Location

on Units with Factory-Installed DDC

WARNING

ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or

death. Using unit-mounted convenience outlets: Units with unit-

mounted convenience outlet circuits will often require that two disconnects be opened to de-energize all power to the unit. Treat all units as electrically energized until the convenience outlet power is also checked and de-energization is confirmed. Observe National Electrical Code Article 210, Branch Circuits, for use of convenience outlets.

1. Remove the blank cover plate at the convenience outlet; dis-

card the blank cover.

2. Loosen the two screws at the GFCI duplex outlet, until approximately Press the gasket over the screw heads.

3. Slip the backing plate over the screw heads at the keyhole slots and align with the gasket; tighten the two screws until snug (do not over-tighten).

-in. (13 mm) under screw heads is exposed.

Page 16

TOP

WET LOC

TIONS

WET LO

CATIONS

4. Mount the weatherproof cover to the backing plate as shown in Fig. 26.

5. Remove two slot fillers in the bottom of the cover to permit service tool cords to exit the cover.

6. Check for full closing and latching.

COVER - WHILE-IN-USE

WEATHERPROOF

BASEPLATE FOR

GFCI RECEPTACLE

NOT INCLUDED

GASKET

Fig. 26 — Weatherproof Cover Installation

Non-Powered Convenience Outlet

This type requires the field installation of a general-purpose 125-v 15A circuit powered from a source elsewhere in the building. Observe national and local codes when selecting wire size, fuse or breaker requirements, and disconnect switch size and location. Route 125-v power supply conductors into the bottom of the utility box containing the duplex receptacle.

Unit-Powered Convenience Outlet

A unit-mounted transformer is factory-installed to step down the main power supply voltage to the unit to 115-v at the duplex receptacle. This option also includes a manual switch with fuse, located in a utility box and mounted on a bracket behind the convenience outlet; access is through the unit’s control box access panel. See Fig. 23.

The primary leads to the convenience outlet transformer are not factory-connected. Selection of primary power source is a customer option. If local codes permit, the transformer primary leads can be connected at the line-side terminals on the unit-mounted nonfused disconnect or HACR breaker switch; this will provide service power to the unit when the unit disconnect switch or HACR switch is open. Other connection methods will result in the convenience outlet circuit being de-energized when the unit disconnect or HACR switch is open. See Fig. 27.

Using Unit-Mounted Convenience Outlets

Units with unit-mounted convenience outlet circuits will often require that two disconnects be opened to de-energize all power to the unit. Treat all units as electrically energized until the convenience outlet power is also checked and de-energization is confirmed. Observe National Electrical Code Article 210, Branch Circuits, for use of convenience outlets.

Fuse On Power Type

The factory fuse is a Bussman

“Fusetron” T-15, non-renewable

screw-in (Edison base) type plug fuse. Test the GFCI receptacle by pressing the TEST button on the face

of the receptacle to trip and open the receptacle. Check for proper grounding wires and power line phasing if the GFCI receptacle does not trip as required. Press the RESET button to clear the tripped condition.

1. Bussman and Fusetron are trademarks of Cooper Technologies

Company.

UNIT

VOLTAGE

208, 230 240

460 480

575 600

CONNECT ASPRIMARY

CONNECTIONS

L1: RED + YEL L2: BLU + GRA

L1: RED Splice BLU + YEL L2: GRA

L1: RED L2: GRA

TRANSFORMER

TERMINALS

H1 + H3 H2 + H4

H2 + H3

H4 H1

Fig. 27 — Powered Convenience Outlet Wiring

HACR AMP RATING The amp rating of the HACR factory-installed option is based on

the size, voltage, indoor motor and other electrical options of the unit as shipped from the factory. If field-installed accessories are added or changed in the field (for example, power exhaust, ERV), the HACR may no longer be of the proper amp rating and therefore will need to be removed from the unit. See unit nameplate and label on factory-installed HACR for the amp rating of the HACR that was shipped with the unit from the factory (Fig. 28). See unit nameplates for the proper fuse, HACR or maximum over-current protection device required on the unit with field installed accessories.

Fig. 28 — HACR Caution Label

FACTORY OPTION THRU-BASE CONNECTIONS This service connection kit consists of a 1/2-in. electrical bulkhead

connector and a 3/4-in. electrical bulkhead connector, connected to an “L” bracket covering the embossed (raised) section of the unit basepan in the condenser section (see Fig. 29 for shipping position).

Page 17

The 3/4-in. bulkhead connector enables the low-voltage control

LOW VOLTAGE CONDUIT CONNECTOR

HIGH VOLTAGE CONDUIT CONNECTOR

AUXILIARY POWER SUPPLY (OPTIONAL)

wires to pass through the basepan. The 1/2-in. bulkhead connector allows the high-voltage power wires to pass through the basepan. See Fig. 30.

Check tightness of connector lock nuts before connecting electrical conduits.

Field-supplied and field-installed liquid-tight conduit connectors and conduit may be attached to the connectors on the basepan. Pull correctly rated high voltage and low voltage through appropriate conduits. Connect the power conduit to the internal disconnect (if unit is so equipped) or to the external disconnect (through unit side panel). Remove one of the two knockouts located on the bottom left side of the unit control box. Use this hole for the control conduit.

UNITS WITHOUT THRU-BASE CONNECTIONS (ELECTRICAL CONNECTIONS)

1. Install power wiring conduit through side panel openings. Install conduit between disconnect and control box.

2. Install power lines to terminal connections as shown in Fig. 18 on page 13.

Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate. On 3-phase units, voltages between phases must be balanced within 2% and the current within 10%. Use the formula shown in the example below to determine the percent of voltage imbalance. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty.

Example: Supply voltage is 230-3-60

Fig. 29 — Thru-the-Base Fitting Assembly (Shown in

Shipping Position)

Fig. 30 — Thru-Base Connection Fittings

1. Remove the “L” bracket assembly from the unit.

2. Remove connector plate assembly from the “L” bracket and discard the “L” bracket, but retain the washer head screws and the gasket (located between the “L” bracket and the connector plate assembly).

NOTE: Take care not to damage the gasket, as it is reused in the following step.

3. Place the gasket over the embossed area in the basepan, aligning the holes in the gasket to the holes in the basepan. See Fig. 30.

4. Install the connector plate assembly to the basepan using 8 of the washer head screws.

NOTE: If electrical connections are not going to occur at this time, tape or otherwise cover the fittings so that moisture does not get into the building or conduit in the interim.

% Voltage Imbalance

Example: Supply voltage is 230-3-60

ABC

MOTOR

Average Voltage =

Determine maximum deviation from average voltage. (AB) 227-224 = 3 v (BC) 231-227 = 4 v (AC) 227-226 = 1 v Maximum deviation is 4 v. Determine percent of voltage imbalance.

% Voltage Imbalance = 100x

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.

= 100 x

AB = 224 v BC = 231 v AC = 226 v

max voltage deviation from average voltage

average voltage

(224 + 231 + 226)

3 3

227

= 1.78%

681

= 227

FIELD CONTROL WIRING The 50GC unit requires an external temperature control device.

This device can be a thermostat (field-supplied) or a SystemVu™ controller (available as factory-installed option for use on a Carrier Comfort Network

or as a stand alone control) or the RTU Open Controller for Building Management Systems using non-CCN protocols (RTU Open is available as a factoryinstalled option only).

THERMOSTAT Select a Carrier-approved accessory thermostat. When electric

heat is installed in the 50GC unit, the thermostat must be capable of energizing the G terminal (to energize the Indoor Fan Contactor) whenever there is a space call for heat (energizing the W1 terminal). The accessory thermostats listed on the unit price pages can provide this signal but they are not configured to enable this signal as shipped.

Page 18

Install the accessory thermostat according to installation instruc-

HUM

O/B/Y2

T H E R M O

T A T

(Note 1)

(Note 2)

(Note 3)

1. Typical multi-function marking. Follow manufacturer’s configuration instructions to select Y2.

2. Y2 to Y2 connection required on single-stage cooling units when integrated economizer function is desired

3. W2 connection not required on units with single-stage heating.

Field Wiring

Unit Control

Board

NOTES:

Typical

Thermostat

Connections

RACEWAY

HOLE IN END PANEL (HIDDEN)

tions included with the accessory. Locate the thermostat accessory on a solid wall in the conditioned

space to sense average temperature in accordance with the thermostat installation instructions.

If the thermostat contains a logic circuit requiring 24-v power, use a thermostat cable or equivalent single leads of different colors with minimum of seven leads. If the thermostat does not require a 24-v source (no “C” connection required), use a thermostat cable or equivalent with minimum of six leads. See Fig. 31. Check the thermostat installation instructions for additional features which might require additional conductors in the cable.

For wire runs up to 50 ft (15 m), use no. 18 AWG (American Wire Gage) insulated wire [35°C (95°F) minimum]. For 50 to 75 ft (15 to 23 m), use no. 16 AWG insulated wire [35°C (95°F) minimum]. For over 75 ft (23 m), use no. 14 AWG insulated wire [35°C (95°F) minimum]. Wire sizes larger than no. 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat.

Thermostat Wiring, Units Without Thru-Base Connection Kit

Pass the thermostat control wires through the hole provided in the corner post; then feed the wires through the raceway built into the corner post to the control box. Pull the wires over to the terminal strip on the upper-left corner of the Unit Control Board. See Fig. 32.

NOTE: If thru-the-bottom connections accessory is used, refer to the accessory installation instructions for information on routing power and control wiring.

Fig. 31 — Low-Voltage Thermostat Connections

Fig. 32 — Field Control Wiring Raceway

HEAT ANTICIPATOR SETTINGS Set heat anticipator settings at 0.14 amp for the first stage and

0.14 amp for second-stage heating, when available.

ELECTRIC HEATERS The 50GC units may be equipped with factory or field installed

electric heaters. The heaters are modular in design, with heater frames holding open coil resistance wires strung through ceramic insulators, line-break limit switches and a control contactor. One or two heater modules may be used in a unit.

Heater modules are installed in the compartment below the indoor (supply) fan outlet. Access is through the indoor access panel. See Fig. 33-35.

Not all available heater modules may be used in every unit. Use only those heater modules that are UL listed for use in a specific size unit. Refer to the label on the unit cabinet for the list of approved heaters.

Refer to the Small Roof Top Units Accessory Electric Heater and Single Point Box installation instructions for further details.

Page 19

INDOOR

OPTIONAL FACT ORYINSTALLED DISCONNECT

MAIN CONTROL BOX

CENTER POST

VANE AXIAL INDOOR FAN SYSTEM

SINGLE POINT BOX

HEATER COVER

CONTROL WIRE TERMINAL BLOCK

MANUAL RESET LIMIT SWITCH

HEATER MOUNTING BRACKET

HEATER MODULE

VIO HR1 BRN

UCB

Field Connections

HR1: Heater Circuit 1 HR2: Heater Circuit 2

(if two-circuit module installed)

PNK

ORN

ORN PNK BRN

VIO

BRN BRNVIO

TB4

VIO HR2 BRN

Elec Htr

TRAN 1

ACCESS

CONTROL BOX ACCESS PANEL

PAN EL

Fig. 33 — Typical Access Panel Location (3-5 Ton)

CONTROL WIRING

FOAM POWER

WIRING

HEATER RELAY

HEATER MOUNTING SCREWS

Fig. 36 — Typical Single Point Installation

Low-Voltage Control Connections

Pull the low-voltage control leads from the heater module — VIO and BRN (two of each if a two-circuit heater module is installed; identify for circuit #1) — to the 4-pole terminal board TB4 located on the heater bulkhead to the left of the Heater module. Connect the VIO lead from Heater circuit #1 to terminal TB4-1. For 2 stage heating, connect the VIO lead from Heater circuit #2 to terminal TB4-2. See Fig. 37.

Fig. 34 — Typical Component Location

Fig. 35 — Typical Module Installation

Single Point Boxes and Supplementary Fuses

When the unit MOCP device value exceeds 60-A, unit-mounted supplementary fuses are required for each heater circuit. These fuses are included in accessory single point boxes, with power distribution and fuse blocks. The single point box will be installed directly under the unit control box, just to the left of the partition separating the indoor section (with electric heaters) from the outdoor section. The single point box has a hinged access cover. See Fig. 36. The single point box also includes a set of power taps and pigtails to complete the wiring between the single point box and the unit’s main control box terminals. Refer to the Small Roof Top Units Accessory Electric Heater and Single Point Box installation instructions for details on tap connections on the field-installed electric heat accessory.

All fuses on 50GC units are 60-A. (Note that all heaters are qualified for use with a 60-A fuse, regardless of actual heater ampacity, so only 60-A fuses are necessary.)

Fig. 37 — Accessory Electric Heater Control

Connections

HUMIDI-MIZER

CONTROL CONNECTIONS

Humidi-MiZer Space RH Controller

NOTE: The Humidi-MiZer system is a factory-installed option. Humidi-MiZer system is not available for single phase (-3 voltage code) models.

The Humidi-MiZer dehumidification system requires a field-supplied and field-installed space relative humidity control device. This device may be a separate humidistat control (contact closes on rise in space RH above control setpoint) or a combination thermostat-humidistat control device such as Carrier’s Edge

Pro

Page 20

Thermidistat™ with isolated contact set for dehumidification con-

HUMIDISTAT

UNIT CONTROL

BOARD

THERMOSTAT

C HUM G W2 W1 Y2 Y1 R

trol. See Fig. 38 and Fig. 39. The humidistat is normally used in applications where a temperature control is already provided (units with SystemVu™ control).

% RELATIVE HUMIDITY

Fig. 38 — Accessory Field-Installed Humidistat

Connecting the Carrier Humidistat (HL38MG029)

1. Route the humidistat 2-conductor cable (field-supplied) through the hole provided in the unit corner post.

2. Feed wires through the raceway built into the corner post (see Fig. 32) to the 24v barrier located on the left side of the control box. The raceway provides the UL-required clearance between high-voltage and low-voltage wiring.

3. Connect one of the leads from the 2-conductor cable to the HUM terminal on the UCB (Unit Control Board). Connect the other lead to the R terminal on the UCB. See Fig. 40.

Fig. 39 — Edge

Pro Thermidistat

Fig. 40 — Humidistat Connections to UCB

Connecting the Thermidistat device (33CS2PPRH-01)

1. Route the Thermidistat multi-conductor thermostat cable (field-supplied) through the hole provided in the unit corner post.

2. Feed wires through the raceway built into the corner post (see Fig. 32 on page 18) to the 24-v barrier located on the left side of the control box. The raceway provides the UL-required clearance between high-voltage and low-voltage wiring.

3. The Thermidistat has dry contacts at terminals D1 and D2 for dehumidification operation (see Fig. 41). Connect D1 to the R terminal on the UCB. Connect D2 to the HUM terminal on the UCB. Refer to the installation instructions included with the Carrier Edge Pro Thermidistat device for more information.

TYPICAL UNIT WIRING DIAGRAMS See Fig. 42 and 43 for examples of typical unit control and power

wiring diagrams. These wiring diagrams are mounted on the inside of the unit control box cover.

Page 21

Rc Rh

O/W2/B

OAT

RRS

SRTN

HUM

D1 D2 V+ Vg

HUM

PROGRAMMABLE

THERMOSTAT

UNIT CONTROL BOARD

THERMOSTAT CONNECTIONS

Fig. 41 — Typical Rooftop Unit with Humidi-MiZer

and Edge

Pro Thermidistat Device

Adaptive Dehumidification System

Page 22

Fig. 42 — Typical 50GC 04-06 Control Wiring Diagram (208-230V W7220 Control Unit Shown)

Page 23

Fig. 43 — Typical 50GC 04-06 Power Wiring Diagram (208/230V Unit Shown)

Page 24

EconoMi$er® X (Factory Option)

The EconoMi$er X system is an expandable economizer control system, which includes a W7220 economizer module (controller) with an LCD and keypad (see Fig. 44). The W7220 can be configured with optional sensors.

Fig. 44 — W7220 Economizer Module

The W7220 economizer module can be used as a stand-alone economizer module wired directly to a commercial set-back space thermostat and sensors to provide outside air dry-bulb economizer control.

The W7220 economizer module can be connected to optional sensors for single or differential enthalpy control. The W7220 economizer module provides power and communications for the sensors.

The W7220 economizer module automatically detects sensors by polling to determine which sensors are present. If a sensor loses communications after it has been detected, the W7220 economizer controller indicates a device fail error on its LCD.

SYSTEM COMPONENTS The EconoMi$er X system includes an economizer module, 20k

mixed air sensor, damper actuator, and either a 20k outdoor air temperature sensor or S-Bus enthalpy sensors.

Economizer Module

The module is the core of the EconoMi$er X system. The module is mounted in the unit’s control box, and includes the user interface for the system. The W7220 economizer module provides the basic inputs and outputs to provide simple economizer control. When used with the optional sensors, the economizer module provides more advanced economizer functionality.

S-Bus Enthalpy Control Sensors

The sensor is a combination temperature and humidity sensor which is powered by and communicates on the S-Bus. Up to three sensors may be configured with the W7220 economizer module.

Sensor (optional)

The sensor can be added for Demand Controlled Ventilation (DCV).

SPECIFICATIONS

W7220 Economizer Module

The module is designed for use with 2 to 10 Vdc or bus communicating actuator. The module includes terminals for CO Mixed Air sensor, and an Outdoor Dry Bulb sensor. Enthalpy and other options are available with bus sensors.

User Interface

Provides status for normal operation, setup parameters, checkout tests, and alarm and error conditions with a 2-line 16 character LCD display and four button keypad.

sensor,

Electrical

• Rated Voltage — 20 to 30 Vac RMS, 50/60 Hz

• Transformer — 100 va maximum system input

• Nominal Power Consumption (at 24 Vac, 60 Hz) —

11.5 VA without sensors or actuators

• Relay Digital Output Rating at 30 Vac (maximum power from Class 2 input only) — 1.5A run:

3.5A inrush at 0.45PF (200,000 cycles) or

7.5A inrush at 0.45PF (100,000 cycles)

• External Sensors Power Output — 21 Vdc ± 5% at 48 mA

IMPORTANT: All inputs and outputs must be Class 2 wiring.

INPUTS

Sensors

NOTE: A Mixed Air (MA) analog sensor is required on all W7220 units; either an Outdoor Air (OA) sensor for dry bulb change over or an OA bus sensor for outdoor enthalpy change over is required in addition to the MA sensor. An additional Return Air (RA) bus sensor can be added to the system for differential enthalpy or dry bulb changeover. For differential dry bulb changeover a 20k ohm sensor is required in the OA and a bus sensor in the RA. DIP switch on RA bus sensor must be set in the RA position.

Dry Bulb Temperature (optional) and Mixed Air (required), 20k NTC

2-wire (18 to 22 AWG); Temperature range –40°F to 150°F (–40°C to 65°C) Temperature accuracy –0°F/+2°F

Temperature and Humidity, C7400S1000 (optional)

S-Bus; 2-wire (18 to 22 AWG) Temperature range: –40°F to 150°F (–40°C to 65°C) Temperature accuracy: –0°F/+2°F Humidity range: 0 to 100% RH with 5% accuracy. NOTE: Up to three (3) S-Bus sensors may be connected to the

W7220 economizer module. For outdoor air (OA), return air (RA) and discharge (supply) air (DA).

4 Binary Inputs

1-wire 24 Vac + common GND (see page 26 for wiring details).

24 Vac power supply

20 to 30 Vac 50/60Hz; 100 VA Class 2 transformer.

OUTPUTS

Actuator Signal

2-10 Vdc; minimum actuator impedance is 2k ohm; bus two-wire output for bus communicating actuators.

Exhaust fan, Y1, Y2 and AUX1 O

All Relay Outputs (at 30 Vac): Running: 1.5A maximum Inrush: 7.5A maximum

ENVIRONMENTAL

Operating Temperature

–40°F to 150°F (–40°C to 65°C). Exception of display operation down to –4°F (–20°C) with full re-

covery at –4°F (–20°C) from exposure to –40°F (–40°C)

Storage Temperature

–40°F to 150°F (–40°C to 65°C)

Shipping Temperature

–40°F to 150°F (–40°C to 65°C)

Page 25

Relative Humidity

AUX2-

OCC

E-GND

EXH1

AUX 1- O

Y2-

Y1-

Y2-O

Y1-O

50048848-002

Rev. A

OCC

Y2I

Y2O

Y1I

Y1O

MAT

OAT

S-BUS

IAQ 2-10

IAQCOM

IAQ 24V

ACT 2-10

ACT COM

ACT 24V

MA MA

OA OA

SB SB

V C R

50040839-001

Rev. G

HJW10

www.energy.ca.gov

Certified FDD Product

California Title 24, Part 6

DIP SWITCH LABEL

DIP SWITCHES (3)

S-BUS 2 PIN SIDE CONNECTOR

S-BUS TERMINALS (1 AND 2)

5% to 95% RH non-condensing

ECONOMIZER MODULE WIRING DETAILS Use Fig. 45 and Tables 3 and 4 to locate the wiring terminals for

the Economizer module. NOTE: The four terminal blocks are removable. Slide out each

terminal block, wire it, and then slide it back into place.

Table 4 — Economizer Module - Right Hand Terminal

Blocks

LABEL TYPE DESCRIPTION

Top Right Terminal Blocks

AUX2 I 24 vac IN The first terminal is not used.

Shut Down (SD) or HEAT (W)

OCC 24 vac IN

E-GND E-GND Occupied/Unoccupied Input EXH1 24 vac OUT Exhaust Fan 1 Output

AUX1 O 24 vac OUT

Bottom Right Terminal Blocks

Y2-I 24 vac IN

Y2-O 24 vac OUT

Y1-I 24 vac IN

Y1-O 24 vac OUT

C COM 24 vac Common R 24 vac 24 vac Power (hot)

Conventional only and Heat Pump Changeover (O-B) in Heat Pump mode.

Programmable: Exhaust fan 2 output or ERV or System alarm output

Y2 in - Cooling Stage 2 Input from space thermostat

Y2 out - Cooling Stage 2 Output to stage 2 mechanical cooling

Y1 in - Cooling Stage 2 Input from space thermostat

Y1 out - Cooling Stage 2 Output to stage 2 mechanical cooling

S-BUS SENSOR WIRING The labels on the sensors and controller are color coded for ease of

installation. Orange labeled sensors can only be wired to orange terminals on the controller. Brown labeled sensors can only be wired to S-bus (brown) terminals. Use Fig. 46 and Table 5 to locate the wiring terminals for each S-Bus sensor.

Use Fig. 46 and Table 5 to locate the wiring terminals for each enthalpy control sensor.

MAT MAT

OAT OAT

S-BUS S-BUS

IAQ 2-10 2-10 vdc Air Quality Sensor Input (e.g. CO IAQ COM COM Air Quality Sensor Common IAQ 24V 24 vac Air Quality Sensor 24 vac Source ACT 2-10 2-10 vdc Damper Actuator Output (2-10 vdc) ACT COM COM Damper Actuator Output Common ACT 24v 24 vac Damper Actuator 24 vac Source

*Sylk is a trademark of Honeywell International Inc.

Fig. 45 — W7220 Wiring Terminals

Table 3 — Economizer Module - Left Hand Terminal

LABEL TYPE DESCRIPTION

20k NTC and COM

S-BUS (Sylk* Bus)

Bottom Left Terminal Block

Blocks

Top Left Terminal Block

Mixed Air Temperature Sensor (Polarity Insensitive Connection)

Outdoor Air Temperature Sensor (Polarity Insensitive Connection)

Enthalpy Control Sensor (Polarity Insensitive Connection)

sensor)

Fig. 46 — S-Bus Sensor DIP Switches

Page 26

Table 5 — HH57AC081 Sensor Wiring Terminations

CO2 SENSOR

24V

ANALOG

OUT

L1 (HOT)

RED

BLACK

YELLOW

BROWN

ORANGE

GREEN

–

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

TERMINAL

NUMBER LABEL

1 S-BUS S-BUS

2 S-BUS S-BUS

TYPE DESCRIPTION

S-BUS Communications (Enthalpy Control

Sensor Bus)

S-BUS Communications (Enthalpy Control

Sensor Bus)

Use Fig. 46 and Table 6 to set the DIP switches for the desired use of the sensor.

Table 6 — HH57AC081 Sensor DIP Switch

To use the keypad when working with menus:

• Press the ▲ (Up arrow) button to move to the previous menu.

• Press the ▼ (Down arrow) button to move to the next menu.

• Press the (Enter) button to display the first item in the currently displayed menu.

• Press the (Menu Up/Exit) button to exit a menu’s item and return to the list of menus.

NOTE: When an S-Bus sensor is connected to an existing network, it will take 60 minutes for the network to recognize and auto-configure itself to use the new sensor.

During the 60 minute setup period, no alarms for sensor failures (except SAT) will be issued and no economizing function will be available.

CO When using a CO2 sensor, the black and brown common wires are

internally connected and only one is connected to “IAQ COM” on the W7220. Use the power from the W7220 to power the CO sensor OR make sure the ground for the power supplies are common. See Fig. 47 for CO

INTERFACE OVERVIEW This section describes how to use the EconoMi$er

for:

User Interface

The user interface consists of a 2-line LCD display and a 4-button keypad on the front of the economizer controller.

Keypad

Use the four navigation buttons (see Fig. 48) to scroll through the menus and menu items, select menu items, and to change parameter and configuration settings.

USE

DA OFF ON OFF RA ON OFF OFF OA OFF OFF OFF

DIP SWITCH POSITIONS FOR SWITCHES 1, 2, AND 3

1 2 3

SENSOR WIRING

sensor wiring.

Fig. 47 — CO

Sensor Wiring

user interface

• Keypad and menu navigation

• Settings and parameter changes

• Menu structure and selection

Fig. 48 — W7220 Controller Navigation Buttons

To use the keypad when working with Setpoints, System and Advanced Settings, Checkout tests and Alarms:

1. Navigate to the desired menu.

2. Press the (Enter) button to display the first item in the currently displayed menu.

3. Use the ▲ and ▼ buttons to scroll to the desired parameter.

4. Press the (Enter) button to display the value of the currently displayed item.

5. Press the ▲ button to increase (change) the displayed parameter value.

6. Press the ▼ button to decrease (change) the displayed parameter value.

NOTE: When values are displayed, pressing and holding the ▲or ▼ button causes the display to automatically increment or decrement.

1. Press the (Enter) button to accept the displayed value and store it in nonvolatile RAM. “CHANGE STORED” displays.

2. Press the (Enter) button to return to the current menu parameter.

3. Press the (Menu Up/Exit) button to return to the previous menu.

Menu Structure

Table 7 illustrates the complete hierarchy of menus and parameters for the EconoMi$er

X system.

The Menus in display order are:

• STATUS

• SETPOINTS

• SYSTEM SETUP

• ADVANCED SETUP

• CHECKOUT

• ALARMS

Page 27

IMPORTANT: Table 7 illustrates the complete hierarchy. Your menu parameters may be different depending on your configuration.

For example, if you do not have a DCV (CO

) sensor, then none

of the DCV parameters appear and only MIN POS will display. If you have a CO

sensor, the DCV MIN and DCV MAX will

appear.

NOTE: Some parameters in the menus use the letters MA or MAT, indicating a mixed air temperature sensor location before the cooling coil. This unit application has the control sensor located after the cooling coil, in the fan section, where it is designated as (Cooling) Supply Air Temperature or SAT sensor.

SETUP AND CONFIGURATION Before being placed into service, the W7220 Economizer module

must be set up and configured for the installed system.

IMPORTANT: During setup, the economizer module is live at all times.

The setup process uses a hierarchical menu structure that is easy to use. Press the ▲ and ▼ arrow buttons to move forward and backward through the menus and press the button to select and confirm setup item changes.

TIME-OUT AND SCREENSAVER When no buttons have been pressed for 10 minutes, the LCD dis-

plays a screen saver, which cycles through the Status items. Each Status items displays in turn and cycles to the next item after 5 seconds.

Page 28

Table 7 — W7220 Menu Structure*

MENU PARAMETER

ECONO AVAIL NO YES/NO

ECONOMIZING NO YES/NO

OCCUPIED NO YES/NO

HEAT PUMP N/A**

COOL Y1—IN OFF ON/OFF

COOL Y1—OUT OFF ON/OFF

COOL Y2—IN OFF ON/OFF

COOL Y2—OUT OFF ON/OFF

MA TEMP _ _ . _ F

DA TEMP _ _ . _ F

STATUS

OA TEMP _ _ . _ F

OA HUM _ _ % 0 to 100%

RA TEMP _ _ . _ F

RA HUM _ _ % 0 to 100%

IN CO2 _ _ _ ppm 0 to 2000 ppm

DCV STATUS N/A ON/OFF

DAMPER OUT 2.0v 2.0 to 10.0v Displays voltage output to the damper actuator. ACT POS N/A 0 to 100% Displays actual position of outdoor air damper actuator

ACT COUNT N/A 1 to 65535

ACTUATOR N/A

EXH1 OUT OFF ON/OFF

EXH2 OUT OFF ON/OFF

ERV OFF ON/OFF

PARAMETER

DEFAULT

VALUE

PARAMETER

RANGE AND

INCREMENT

COOL HEAT

0°F to 140°F (–17°C to 60°C)

–40°F to 140°F (–40°C to 60°C)

0°F to 140°F (–17°C to 60°C)

OK/Alarm (on Alarm menu)

†

NOTES

FIRST STAGE COOLING DEMAND (Y1–IN) YES = economizing available; the system can use outside air for free cooling when required

FIRST STAGE COOLING RELAY OUTPUT YES = outside air being used for 1 stage cooling

OCCUPIED YES = OCC signal received from space thermostat or unitary controller YES = 24 Vac on terminal OCC NO = 0 Vac on terminal OCC

HEAT PUMP MODE Displays COOL or HEAT when system is set to heat pump (Non-conventional)

FIRST STAGE COOLING DEMAND (Y1-IN) Y1–I signal from space thermostat or unitary controller for cooling stage 1. ON = 24 Vac on terminal Y1–I OFF = 0 Vac on terminal Y1–I

FIRST STAGE COOLING RELAY OUTPUT Cool stage 1 Relay Output to stage 1 mechanical cooling (Y1–OUT terminal)

SECOND STAGE COOLING DEMAND (Y2–IN) Y2–I signal from space thermostat our unitary controller for second stage cooling. ON = 24 Vac on terminal Y2–I OFF = 0 Vac on terminal Y2–I

SECOND STAGE COOLING RELAY OUTPUT Cool Stage 2 Relay Output to mechanical cooling (Y2–OUT terminal)

SUPPLY AIR TEMPERATURE, Cooling Mode Displays value of measured mixed air from MAT sensor. Displays _ _ . _ F if not connected, short or out-of-range.

DISCHARGE AIR TEMPERATURE, after Heating section Displays when Discharge Air sensor is connected and displays measured discharge temperature. Displays _ _ . _F if sensor sends invalid value, if not connected, short or out-of-range.

OUTSIDE AIR TEMP Displays measured value of outdoor air temperature. Displays _ _ . _F if sensor sends invalid value, short or out-ofrange.

OUTSIDE AIR RELATIVE HUMIDITY Displays measured value of outdoor humidity from OA sensor. Displays _ _% if not connected short, or out-of-range.

RETURN AIR TEMPERATURE Displays measured value of return air temperature from RAT sensor. Displays _ _ . _ F if sensor sends invalid value, if not connected, short or out-of-range

RETURN AIR RELATIVE HUMIDITY Displays measured value of return air humidity from RA sensor. Displays _ _% if sensor sends invalid value, if not connected, short or out-of-range

SPACE/RETURN AIR CO Displays value of measured CO2 from CO2 sensor. Invalid if not

connected, short or out-of-range DEMAND CONTROLLED VENTILATION STATUS

Displays ON if above setpoint and OFF if below setpoint, and ONLY if a CO

sensor is connected.

Displays number of times actuator has cycled. 1 cycles equals 180 deg. of actuator movement in any direction.

Displays ERROR if voltage or torque is below actuator range.

EXHAUST STAGE 1 RELAY OUTPUT Output of EXH1 terminal: ON = relay closed OFF = relay open

EXHAUST STAGE 2 RELAY OUTPUT Output of AUX terminal; displays only if AUX = EXH2

ENERGY RECOVERY VENTILATOR Output of AUX terminal; displays only if AUX = ERV

Page 29

Table 7 — W7220 Menu Structure* (cont)

MENU PARAMETER

MECH COOL ON or

STATUS

(cont)

HEAT STAGES ON

FAN SPEED N/A LOW or HIGH

W (HEAT ON) N/A ON/OFF

MAT SET 53°F

LOW T LOCK 32°F

DRYBLB SET 63°F

DRYBLB DIFF 0°F

ENTH CURVE ES3

DCV SET 1100ppm

MIN POS 4.4 V 2 to 10 Vdc

MIN POS L 6.0 V 2 to 10 Vdc

SETPOINTS

MIN POS M 5.4 V 2 to 10 Vdc

MIN POS H 4.4 V 2 to 10 Vdc

VENTMAX L 6.0V 2 to 10 Vdc

VENTMAX M 5.4 V 2 to 10 Vdc

VENTMAX H 4.4 V 2 to 10 Vdc

VENTMIN L 3.7 V 2 to 10 Vdc

VENTMIN M 3.4 V 2 to 10 Vdc

VENTMIN H 2.8 V 2 to 10 Vdc

PARAMETER

DEFAULT

VALUE

PARAMETER

RANGE AND

INCREMENT

0 0, 1, or 2

38°F to 70°F (3°C to 21°C); increment by 1°F

–45°F to 80°F (–43°C to 27°C); increment by 1°F

48°F to 80°F (9°C to 27°C); increment by 1°F

0°F to 6°F Increment by 2°F

ES1, ES2, ES3, ES4, or ES5

500 to 2000 ppm; increment by 100

†

NOTES

Displays stage of mechanical cooling that is active.

Displays the stage of heat pump heating that is active. SUPPLY FAN SPEED

Displays speed setting of fan on a 2-speed fan unit. HEAT DEMAND STATUS

Displays status of heat demand on a 2-speed fan unit. MIXED AIR SETPOINT Setpoint determines where the economizer

will modulate the OA damper to maintain the mixed air temperature.

COMPRESSOR LOW TEMPERATURE LOCKOUT Setpoint determines outdoor temperature when the mechanical cooling cannot be turned on. Commonly referred to as the Compressor lockout.

OA DRY BULB TEMPERATURE CHANGEOVER SETPOINT Setpoint determines where the economizer will assume outdoor air temperature is good for free cooling; e.g.; at 63°F unit will economize at 62°F and below and not economize at 64°F and above. There is a 2°F deadband. DRYBULB SET is only displayed if the economizer has a single dry bulb sensor.

Drybulb Differential will only show if using dual drybulb - i.e. when an outdoor air temperature sensor C7250 is attached to OAT terminals and C7400S sensor is wired to S-Bus and configured for RAT (return air). Free cooling will be assumed whenever OA temp is at or below RAT minus this drybulb setting.

ENTHALPY CHANGEOVER CURVE (Requires enthalpy sensor option) Enthalpy boundary “curves” for economizing using single enthalpy.

DEMAND CONTROLLED VENTILATION SETPOINT Displays only if CO Controlled Ventilation of space. Above the setpoint, the OA

sensor is connected. Setpoint for Demand

dampers will modulate open to bring in additional OA to maintain a space ppm level below the setpoint.

VENTILATION MINIMUM POSITION. Only displayed if controller is set for single speed unit under FAN TYPE, and if DCV is NOT used.

VENTILATION MINIMUM POSITION AT LOW SPEED. Only displays if unit is set for 2 or 3 speed and CO 2 speed with 1 heat and 1 cool then set for HEATING ventilation. If

is not used. If using

using 3 speed with 1 heat and 2 cool then set for LOW SPEED COOLING ventilation.

VENTILATION MINIMUM POSITION AT MEDIUM SPEED. Only displays if unit is set for 3 speed with 1 heat and 2 cool, and CO not used. Set for HEATING ventilation.

VENTILATION MINIMUM POSITION AT HIGH SPEED. Only displays if unit is set for 2 or 3 speed and CO 2 speed with 1 heat and 1 cool then set for COOLING ventilation. If

is not used. IF using

using 3 speed with 1 heat and 2 cool then set for HIGH SPEED COOLING ventilation

DCV MAXIMUM DAMPER POSITION AT LOW SPEED. Only displays if unit is set for 2 speed or 3 speed with 1 heat and 2 cool. IF using 2 speed with 1 heat and 1 cool then set for HEATING ventilation. If using 3 speed with 1 heat and 2 cool then set for LOW SPEED COOLING

DCV MAXIMUM DAMPER POSITION AT MEDIUM SPEED. Only displays if unit is set for 3 speed with 1 heat and 2 cool. Set for HEATING ventilation.

DCV MAXIMUM DAMPER POSITION AT HIGH SPEED. Only displays if unit is set for 2 speed or 3 speed with 1 heat and 2 cool. IF using 2 speed with 1 heat and 1 cool then set for COOLING ventilation. If using 3 speed with 1 heat and 2 cool then set for HIGH SPEED COOLING ventilation

DCV MINIMUM DAMPER POSITION AT LOW SPEED. Only displays if unit is set for 2 speed or 3 speed with 1 heat and 2 cool. IF using 2 speed with 1 heat and 1 cool then set for HEATING ventilation. If using 3 speed with 1 heat and 2 cool then set for LOW SPEED COOLING

DCV MINIMUM DAMPER POSITION AT MEDIUM SPEED. Only displays if unit is set for 3 speed with 1 heat and 2 cool. Set for HEATING ventilation.

DCV MINIMUM DAMPER POSITION AT HIGH SPEED. Only displays if unit is set for 2 speed or 3 speed with 1 heat and 2 cool. IF using 2 speed with 1 heat and 1 cool then set for COOLING ventilation. If using 3 speed with 1 heat and 2 cool then set for HIGH SPEED COOLING ventilation

Page 30

Table 7 — W7220 Menu Structure* (cont)

MENU PARAMETER

ERV OAT SP

EXH1 SET 50% 0 to 100%

EXH1 L SET 65% 0 to 100%

EXH1 M SET 60% 0 to 100%

SETPOINTS

(cont)

EXH1 H SET 50% 0 to 100%

EXH2 L SET 80% 0 to 100%

EXH2 M SET 77% 0 to 100%

EXH2 H SET 75% 0 to 100%

INSTALL 01/01/17 N/A

UNITS DEG F F or C Sets economizer controller in degrees Fahrenheit or Celsius

EQUIPMENT CONV

AUX2 IN W

FAN SPEED 2 speed

SYSTEM

SETUP

FAN CFM 5000cfm

AUX1 OUT NONE

OCC INPUT

FACTORY DEFAULT NO NO or YES

MA LO SET 45°F

ADVANCED

SETUP

FREEZE POS CLO CLO or MIN

CO2 ZERO 0ppm

CO2 SPAN 2000ppm

PARAMETER

DEFAULT

VALUE

††

32°F

PARAMETER

RANGE AND

INCREMENT

0°F to 50°F (–18°C to 10°C); increment by 1°F

†

NOTES

ENERGY RECOVERY VENTILATOR UNIT OUTDOOR AIR TEMPERATURE SETPOINT Only displayed when AUX1 O = ERV

Exhaust fan set point for single speed units. Based on OA Damper position to activate power exhaust.

EXHAUST FAN 1 SETPOINT AT LOW SPEED on 2 speed or 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

EXHAUST POINT 1 SETPOINT AT MEDIUM SPEED. Only displays if unit is set for 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

EXHAUST FAN 1 SETPOINT AT HIGH SPEED on 2 speed or 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

EXHAUST FAN 2 SETPOINT AT LOW SPEED on 2 speed or 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

EXHAUST FAN 2 SETPOINT AT MEDIUM SPEED. Only displays if unit is set for 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

EXHAUST FAN 2 SETPOINT AT HIGH SPEED on 2 speed or 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

Display order = MM/DD/YY Setting order = DD, MM, then YY.

CONV = conventional; Conventional or HP

HP O/B = Enable Heat Pump mode. Use AUX2 I for Heat Pump

input from thermostat or controller.

See Menu Note 4.

In CONV mode:

SD + Enables configuration of shutdown (default);

W = Informs controller that system is in heating mode.

SD/W or HP(O)/ HP(B)

NOTE: If using 2-speed fan mode, you must program CONV mode

for W. Shutdown is not available in 2-speed fan mode. See Menu

Note 4.

In HP O/B mode:

HP(O) = energize heat pump on Cool (default);

HP(B) = energize heat pump on heat. 1 speed

2 speed 2SP H/C 3 speed

100 to 15000 cfm; increment by 100

Sets the economizer controller operation based on 1 speed, 2

speed, 2 speed heat/cool (2SP H/C), or 3 speed supply fan.

NOTE: Multi-speed fan options also need Heat (W1) programmed

in AUX 2 In. See Menu Note 4.

UNIT DESIGN AIRFLOW (CFM)

Enter only if using DCVAL ENA = AUTO

The value is found on the nameplate label for the specific unit.

Select OUTPUT for AUX1 O relay NONE ERV EXH2 SYS

• NONE = not configured (output is not used)

• ERV = Energy Recovery Ventilator

• EXH2 = second damper position relay closure for second exhaust

††

fan

• SYS = use output as an alarm signal

OCCUPIED MODE BY EXTERNAL SIGNAL

INPUT or ALWAYS

When using a setback thermostat with occupancy out (24 vac), the

24 vac is input “INPUT” to the OCC terminal. If no occupancy

output from the thermostat then change program to “ALWAYS” OR

add a jumper from terminal R to OCC terminal.

Resets all set points to factory defaults when set to YES. LCD

will briefly flash YES and change to NO but all parameters will change to the factory default values. NOTE: RECHECK AUX2 IN and FANTYPE for required 2-speed values.

35°F to 55°F (2°C to 13°C); Incremented by 10°F

SUPPLY AIR TEMPERATURE LOW LIMIT Temperature to achieve Freeze Protection (close damper and alarm if temperature falls below setup value).

FREEZE PROTECTION DAMPER POSITION Damper position when freeze protection is active (closed or MIN POS).

0 to 500 ppm; Increment by 10

1000 to 3000 ppm; Increment by 10

ppm level to match CO2 sensor start level.

ppm span to match CO2 sensor.

Page 31

Table 7 — W7220 Menu Structure* (cont)

MENU PARAMETER

STG3 DLY 2.0h

SD DMPR POS CLO CLO or OPN

DA LO ALM 45°F (7°C)

DA HI ALM 80°F (27°C)

DCVCAL ENA MAN

ADVANCED

SETUP

(cont)

MAT T CAL 0.0°F ±2.5°F

OAS T CAL 0.0°F ±2.5°F

OA H CAL 0% RH ±10% RH

RA T CAL 0.0°F ±2.5°F

RA H CAL 0% RH ±10% RH

DA T CAL 0.0°F ±2.5°F

2SP FAN DELAY 5 Minutes

DAMPER MINIMUM POSITION

DAMPER OPEN N/A N/A

DAMPER CLOSE N/A N/A Positions damper to the fully closed position

CHECKOUT

CONNECT Y1–O N/A N/A Closes the Y1-O relay (Y1-O) CONNECT Y2–O N/A N/A Closes the Y2-O relay (Y2-O)

CONNECT AUX1-O N/A N/A

CONNECT EXH1 N/A N/A Closes the power exhaust fan 2 relay (EXH1)

Alarms display only when they are active. The menu title “ALARMS(#)” includes the number of active alarms in parenthesis ( ). When using SYLK bus sensors, “SYLK” will appear on the screen, and when using 20k OA temperature sensors, “SENS T” will

MA T SENS ERR N/A N/A

ALARMS

CO2 SENS ERR N/A N/A

OA SYLK T ERR N/A N/A OUTSIDE AIR S-BUS SENSOR ERROR

OA SYLK H ERR N/A N/A

RA SYLK T ERR N/A N/A RETURN AIR S-BUS SENSOR ERROR

RA SYLK H ERR N/A N/A

PARAMETER

DEFAULT

VALUE

0 min, 5 min, 15 min, then 15 min intervals. Up to 4 hrs or OFF

35°F to 65°F (2°C to 18°C); Incremented by 5°F.

70°F to 180°F (21°C to 82°C); Incremented by 5°F

MAN (manual) AUTO

0 to 20 minutes in 1 minute increments

N/A N/A

PARAMETER

RANGE AND

INCREMENT

appear on the screen

†

NOTES

COOLING STAGE 3 DELAY Delay after stage 2 cool has been active. Turns on second stage of cooling when economizer is first stage and mechanical cooling is second stage. Allows three stages of cooling, 1 economizer and 2 mechanical. OFF = no Stage 3 cooling

Indicates shutdown signal from space thermostat or unitary controller. When controller receives 24 Vac input on the SD terminal in conventional mode, the OA damper will open if programmed for OPN and OA damper will close if programmed for CLO. All other controls, e.g., fans, etc. will shut off.

Used for alarm for when the DA air temperature is too low. Set lower range of alarm, below this temperature the alarm will show on the display.

Used for alarm for when the DA air temperature is too high. Set upper range of alarm, above this temperature the alarm will show on the display.

Turns on the DCV automatic control of the dampers. Resets ventilation based on the RA, OA, and MA sensor conditions. Requires all 3 RA, OA, and MA sensors.

SUPPLY AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

OUTSIDE AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

OUTSIDE AIR HUMIDITY CALIBRATION Allows for operator to adjust for an out of calibration humidity sensor.

RETURN AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

RETURN AIR HUMIDITY CALIBRATION Allows for operator to adjust for an out of calibration humidity sensor.

DISCHARGE AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

TIME DELAY ON SECOND STAGE ECONOMIZING When in economizing mode this is the delay for the high speed fan to try to satisfy the call for second stage cooling before the first stage mechanical cooling is enabled.

The checkout for the damper minimum position is based on the system.

Position damper to the full open position. Exhaust fan contacts enable during the DAMPER OPEN test. Make sure you pause in the mode to allow exhaust contacts to energize due to the delay in the system.

Energizes the AUX output. If Aux setting is:

• NONE — not action taken

• ERV — 24 Vac out. Turns on or signals an ERV that the conditions are not good for economizing but are for ERV operation.

• SYS — 24 Vac out. Issues a system alarm

††

SUPPLY AIR TEMPERATURE SENSOR ERROR Mixed air sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

SENSOR ERROR

sensor has failed, gone out of range or become disconnected -

check wiring then replace sensor if the alarm continues.

Outdoor air enthalpy sensor has failed or become disconnected check wiring then replace sensor if the alarm continues.

Return air enthalpy sensor has failed or become disconnected check wiring then replace sensor if the alarm continues.

Page 32

Table 7 — W7220 Menu Structure* (cont)

MENU PARAMETER

PARAMETER

DEFAULT

VALUE

PARAMETER

RANGE AND

INCREMENT

DA SYLK T ERR N/A N/A

OA SENS T ERR N/A N/A

ACT ERROR N/A N/A

FREEZE ALARM N/A N/A

(cont)

ARMS

SHUTDOWN ACTIVE N/A N/A

DMP CAL RUNNING N/A N/A

DA SENS ALM N/A N/A

SYS ALARM N/A N/A

ACT UNDER V N/A N/A

ACT OVER V N/A N/A

ACT STALLED N/A N/A

LEGEND

CLO — Compressor Lockout ERV — Energy Recovery Ventilator LCD — Liquid Crystal Display MA — Mixed Air MAT — Mixed Air Temperature N/A — Not Applicable OA — Outdoor Air OAT — Outdoor Air Temperature OCC — Occupied RA — Return Air RAT — Return Air Temperature RTU — Rooftop Unit SYS — System

* Table 7 illustrates the complete hierarchy. Your menu parameters

may be different depending on your configuration. For example if you do not have a DCV (CO

) sensor, then none of the DCV parameters

appear.

† When values are displayed, pressing and holding the or button

causes the display to automatically increment. ** N/A = Not Applicable. †† ERV Operation: When in cooling mode AND the conditions are NOT

OK for economizing - the ERV terminal will be energized. In the Heat-

ing mode, the ERV terminal will be energized when the OA is below

the ERV OAT setpoint in the setpoint menu.

†

NOTES

DISCHARGE AIR S-BUS SENSOR ERROR Discharge air sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

OUTSIDE AIR TEMPERATURE SENSOR ERROR Outdoor air temperature sensor has failed or become disconnected

- check wiring then replace if the alarm continues. ACTUATOR ERROR

Actuator has failed or become disconnected - check for stall, over voltage, under voltage and actuator count. Replace actuator if damper is movable and supply voltage is between 21.6-v and

26.4-v. Check actuator count on STATUS menu. Check if outdoor temperature is below the LOW Temp Lockout on

setpoint menu. Check if Mixed air temperature on STATUS menu is below the Lo Setpoint on Advanced menu. When conditions are back in normal range then the alarm will go away.

AUX2 IN is programmed for SHUTDOWN and 24 V has been applied to AUX2 IN terminal.

DAMPER CALIBRATION ROUTINE RUNNING If DCV Auto enable has been programmed, when the W7220 is completing a calibration on the dampers, this alarm will display. Wait until the calibration is completed and the alarm

will

go away. Must have OA, MA and RA sensors for DCV calibration; set up in the Advanced setup menu.

DISCHARGE AIR TEMPERATURE SENSOR ALARM Discharge air temperature is out of the range set in the ADVANCED SETUP Menu. Check the temperature of the discharge air.

When AUX1-O is set to SYS and there is any alarm (e.g., failed sensors, etc.), the AUX1-O terminal has 24 Vac out.

ACTUATOR VOLTAGE LOW Voltage received by actuator is above expected range.

ACTUATOR VOLTAGE HIGH Voltage received by actuator is below expected range.

ACTUATOR STALLED Actuator stopped before achieving commanded position.

NOTES:

1. STATUS OCCUPIED — The factory-standard Occupancy signal originates with a thermostat or other controller call for indoor fan operation at UCB terminal G. This signal passes through the Unit

Control Board’s OCCUPANCY jumper to the ECONO connector and to the W7220’s OCC input terminal.An external timeclock or

relay is required to implement an Occupancy schedule on the economizer damper position.

2. STATUS  MA TEMP, SETPOINTS  MAT SET — The W7220 menu parameters and labels include designations MA, MAT and Mixed Air for the economizer cooling control sensor. On these rooftop units, the economizer control sensor is located downstream of the evaporator/indoor coil in the supply fan section where this sensor is designated as Supply Air Temperature (SAT) sensor.

3. SETPOINTS  D

RYBLB SET — This point is not displayed if a

Return Air (differential) temperature sensor or an Outdoor Air enthalpy sensor is connected.

4. SYSTEM SETUP parameters must be configured as noted for Multi-Speed unit operation: EQUIPMENT = CONV AUX2 IN = W FAN SPEED = 2SPEED NOTE: 1SPEED, 2SP H/C and 3SPEED are not used on 50GC units.

Page 33

ENTHALPY SETTINGS When the OA temperature, enthalpy and dew point are below the

respective setpoints, the Outdoor Air can be used for economizing. Fig. 49 shows the new single enthalpy boundaries in the W7220. There are 5 boundaries (setpoints ES1 through ES5), which are defined by dry bulb temperature, enthalpy and dew point.

Refer to Table 8 for ENTH CURVE setpoint values. The W7220 calculates the enthalpy and dew point using the OA

temperature and humidity input from the OA enthalpy sensor.

When the OA temperature, OA humidity and OA dew point are all below the selected boundary, the economizer sets the economizing mode to YES, economizing is available.

When all of the OA conditions are above the selected boundary, the conditions are not good to economize and the mode is set to NO.

Figure 49 shows the 5 current boundaries. There is also a high limit boundary for differential enthalpy. The high limit boundary is ES1 when there are no stages of mechanical cooling energized and HL (high limit) when a compressor stage is energized.

ECONOMIZING

AVAILABLE

NOT AVAILABLE

ENTHALPY

RA HUM (%RH)

ABSOLUTE HUMIDITY

RA TEMP

TEMPERATURE

DUAL ENTHALPY

SINGLE ENTHALPY

P2 (T,RH)

ES4

ES5

ES3

HIGH LIMIT

P1 (T,RH)

ES2 ES1

Fig. 49 — Single Enthalpy Curve Boundaries

Table 8 — Single Enthalpy and Dual Enthalpy High Limit Curves

ENTHALPY

CURVE

ES1 80 60 28.0 80 36.8 66.3 80.1 ES2 75 57 26.0 75 39.6 63.3 80.0 ES3 70 54 24.0 70 42.3 59.7 81.4 ES4 65 51 22.0 65 44.8 55.7 84.2 ES5 60 48 20.0 60 46.9 51.3 88.5

HL 86 66 32.4 86 38.9 72.4 80.3

TEMP. DRY

BULB (F)

TEMP.

DEWPOINT (F)

ENTHALPY

(btu/lb/da)

TEMP. (F)

POINT P1 POINT P2

HUMIDITY

(%RH)

TEMP. (F)

HUMIDITY

(%RH)

Page 34

STANDARD OR SINGLE SPEED FAN OPERATION FAN TYPE = 1SPEED is not used on 50GC units.

2 SPEED FAN OPERATION The W7220 controller has the capability to work with a system us-

ing a 2 speed supply fan. The W7220 does not control the supply directly but uses the following input status to determine the speed of the supply fan and controls the OA damper to the required position, see Table 9.

The W (heating mode) is not controlled by the W7220 but it requires the status to know where to position the OA damper for minimum position for the fan speed.

The 2 speed fan delay is available when the system is programmed for 2 speed fan (in the System Setup menu item). The 2 speed fan delay is defaulted to 5 minutes and can be changed in the Advanced Setup menu item. When the unit has a call for Y1 In and in the free cooling mode and there is a call for Y2 In, the 2-speed fan delay starts and the OA damper will modulate 100% open, the supply fan should be set to high speed by the unit controller. See

Table 9 — Fan Speed

STATE FAN SPEED

OCC Low

Y1 Low Y2 High

W High

Table 10. After the delay one of two actions will happen:

• The Y2 In call will be satisfied with the damper 100% open and fan on high speed and the call will turn off

OR If the call for additional cooling in the space has not been satisfied

then the first stage of mechanical cooling will be enabled through Y1 Out or Y2 Out.

Table 10 — Economizer Operation - FAN TYPE = 2SPEED

INPUTS OUTPUTS

DEMAND

CONTROLLED

VENTILATION

(DCV)

NONE

Below CO

Above CO

*With stage 3 delay (STG3 DLY) in Advanced setup, COOL Y2-OUT will be turned ON after the delay time specified. N/A = Not applicable

Set

OUTSIDE AIR

GOOD TO

ECONOMIZE

YES

(HEAT ON)

ON N/A N/A OFF OFF HIGH MIN POS H Closed OFF OFF OFF OFF OFF LOW MIN POS L Closed OFF ON OFF ON OFF LOW MIN POS L Closed OFF ON ON ON ON HIGH MIN POS H Closed

ON N/A N/A OFF OFF HIGH MIN POS H Closed OFF OFF OFF OFF OFF LOW MIN POS L Closed

OFF ON OFF OFF OFF LOW

OFF ON ON ON OFF* HIGH

ON N/A N/A OFF OFF HIGH VENTMIN H Closed OFF OFF OFF OFF OFF LOW VENTMIN L Closed OFF ON OFF ON OFF LOW VENTMIN L Closed OFF ON ON ON ON HIGH VENTMIN H Closed

ON N/A N/A OFF OFF HIGH VENTMIN H Closed OFF OFF OFF OFF OFF LOW VENTMIN L Closed

OFF ON OFF OFF OFF LOW

OFF ON ON ON OFF* HIGH

ON N/A N/A OFF OFF HIGH

OFF OFF OFF OFF OFF LOW

OFF ON OFF ON OFF LOW

OFF ON ON ON ON HIGH

ON N/A N/A OFF OFF HIGH

OFF OFF OFF OFF OFF LOW

OFF ON OFF OFF OFF* LOW

OFF ON ON ON OFF* HIGH

COOL

Y1-IN

COOL

Y2-IN

COOL

Y1-OUT

COOL

Y2-OUT

FAN SPEED

(reference

only)

OCCUPIED UNOCCUPIED

MIN POS L to

Full Open

MIN POS H to

Full Open

VENTMIN L to

Full Open

VENTMIN H to

Full Open

VENTMIN H to

VENTMAX H

VENTMIN L to

VENTMAX L

VENTMIN L to

VENTMAX L

VENTMAX H to

VENTMAX H

VENTMIN H to

VENTMAX H

VENTMIN L to

VENTMAX L

VENTMIN L to

Full Open

VENTMIN H to

Full Open

DAMPER POSITION

Closed to

Full Open Closed to

Full Open

Closed to Full Open

Closed

Closed to Full Open

Page 35

2SP H/C AND 3 SPEED FAN OPERATION FAN TYPE = 2SP H/C and FAN TYPE = 3SPEED are not used

on 50GC units.

CHECKOUT Inspect all wiring connections at the economizer module’s termi-

nals, and verify compliance with the installation wiring diagrams. For checkout, review the Status of each configured parameter and perform the Checkout tests.

NOTE: For information about menu navigation and use of the keypad see Interface Overview on page 26.

WARNING

ELECTRIC SHOCK HAZARD Failure to follow this warning could result in personal injury,

property damage, or death. Before performing service or maintenance operations on unit,

always turn off main power switch to unit and install lock(s) and lockout tag(s). Unit may have more than one power switch. Ensure electrical service to rooftop unit agrees with voltage and amperage listed on the unit rating plate.

If any wiring changes are required, first be sure to remove power from the economizer module before starting work. Pay particular attention to verifying the power connection (24 vac).

Power Up

After the W7220 module is mounted and wired, apply power.

Initial Menu Display

On initial start up, Honeywell displays on the first line and economizer W7220 on the second line. After a brief pause, the revision of the software appears on the first line and the second line will be blank.

Power Loss (Outage or Brownout)

All setpoints and advanced settings are restored after any power loss or interruption.

NOTE: All settings are stored in non-volatile flash memory.

Status

Use the Status menu (see Table 7) to check the parameter values for the various devices and sensors configured.

NOTE: For information about menu navigation and use of the keypad, see Interface Overview on page 26.

Checkout Tests

Use the Checkout menu (see page 31) to test the damper operation and any configured outputs. Only items that are configured are shown in the Checkout menu.

NOTE: For information about menu navigation and use of the keypad, see Interface Overview on page 26.

To perform a Checkout test:

1. Scroll to the desired test in the Checkout menu using the ▲ and ▼ buttons.

2. Press the (Enter) button to select the item. RUN? appears.

3. Press the (Enter) button to start the test. The unit pauses and then displays IN PROGRESS. When the test is complete, DONE appears.

4. When all desired parameters have been tested, press the (Menu Up/Exit) button to end the test.

The Checkout tests can all be performed at the time of installation or at any time during the operation of the system as a test that the system is operable.

CAUTION

EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in equipment damage. Be sure to allow enough time for compressor start-up and

shutdown between checkout tests so that you do not shortcycle the compressors.

TROUBLESHOOTING

Alarms

The economizer module provides alarm messages that display on the 2-line LCD.

NOTE: Upon power up, the module waits 60 minutes before checking for alarms. This allows time for all the configured devices (e.g. sensors, actuator) to become operational. The exception is the SAT sensor which will alarm immediately.

If one or more alarms are present and there has been no keypad activity for at least 5 minutes, the Alarms menu displays and cycles through the active alarms.

You can also navigate to the Alarms menu at any time.

Clearing Alarms

Once the alarm has been identified and the cause has been removed (e.g. replaced faulty sensor) the alarm can be cleared from the display.

To clear an alarm, perform the following:

1. Navigate to the desired alarm.

2. Press the (Enter) button. ERASE? displays.

3. Press the (Enter) button. ALARM ERASED displays.

4. Press the (Menu Up/Exit) button to complete the action and return to the previous menu.

NOTE: If the alarm still exists after clearing it, it is redisplayed within 5 seconds.

RTU Open Controller (Factory Option)

For details on operating 50GC**04-06 units equipped with the factory-installed RTU Open controller option, refer to the Factory-

Installed Option RTU Open Multi-Protocol Controller Controls, Start-Up, Operation and Troubleshooting manual.

SystemVu™ Controller (Factory Option)

For details on operating 50GC**04-06 units equipped with the factory-installed SystemVu controller option, refer to the FC/GC

Series Single Package Rooftop Units with SystemVu Controller Controls, Start-up, Operation and Troubleshooting manual.

Controller Options

LOW AMBIENT If the unit comes with Electro-Mechanical (EM) control, then no

adjustment is necessary. If the unit comes with SystemVu™ or RTU Open control option,

then refer to its installation control manual for details on adjusting “Cooling Lock-Out” setting and configure for the specific job requirements.

Smoke Detectors

Smoke detectors are available as factory-installed options on 50GC models. Smoke detectors may be specified for supply air only, for return air without or with economizer, or in combination of supply air and return air. Return-air smoke detectors are arranged for vertical return configurations only. All components necessary for operation are factory-provided and mounted. The unit is factory-configured for immediate smoke detector shutdown operation; additional wiring or modifications to unit control board

Page 36

may be necessary to complete the unit and smoke detector config-

STEP 1 STEP 2 STEP 3

uration to meet project requirements. Units equipped with factory-optional return-air smoke detectors

require a relocation of the sensor module at unit installation. See Fig. 50 for the as-shipped location.

Completing Return Air Smoke Sensor Installation

1. Unscrew the two screws holding the return-air smoke detec-

tor assembly. See Fig. 51, Step 1. Save the screws.

2. Turn the assembly 90 degrees and then rotate end to end. Make sure that the elbow fitting is pointing down. See Fig. 51, Step 2.

3. Screw the sensor and detector plate into its operating position using screws from Step 1. See Fig. 51, Step 3.

4. Connect the flexible tube on the sampling inlet to the sampling tube on the basepan.

Additional Application Data

Refer to the application data document “Factory Installed Smoke Detectors for Small and Medium Rooftop Units 2 to 25 Tons” for

discussions on additional control features of these smoke detectors including multiple unit coordination.

RETURN AIR SMOKE DETECTOR (AS SHIPPED)

Fig. 50 — Return-Air Smoke Detector,

Shipping Position

Fig. 51 — Completing Installation of Return Air Smoke Sensor

Page 37

Step 12 — Adjust Factory-Installed Options

SMOKE DETECTORS Smoke detector(s) will be connected at the Unit Control Board, at

terminals marked “Smoke Shutdown.” Detach the jumper covering the Smoke Shutdown terminals on the UCB and then attach the wiring harness from the smoke detector.

ECONOMI$ER

IV OCCUPANCY SWITCH

See Fig. 52 for general EconoMi$er IV wiring. External occupancy control is managed through a connection on the Unit Control Board.

If external occupancy control is desired, connect a time clock or remotely controlled switch (closed for Occupied, open for Unoccupied sequence) at terminals marked OCCUPANCY. Detach the jumper covering the “Occupancy” terminals on the UCB and then attach the required connections.

Step 13 — Install Accessories

Available accessories include:

• Roof curb

• Thru-base connection kit (must be installed before unit is set on curb)

• Electric heaters and single-point connection kits

• Manual outside air damper

• Two-position motorized outside air damper

• EconoMi$er IV (with control)

• EconoMi$er2 (without control/for external signal)

• Power Exhaust

• Differential dry-bulb sensor (EconoMi$er IV)

• Outdoor enthalpy sensor

• Differential enthalpy sensor

• CO

sensor

• Louvered hail guard

• Phase monitor control

Refer to separate installation instructions for information on installing these accessories.

Fig. 52 — EconoMi$er IV Wiring

Page 38

Step 14 — Fan Speed Set Up

FAN SPEED SET UP CONTROLS

UNITS WITH ELECTRO-MECHANICAL CONTROLS The fan speed set up controls are located on the lower section of

the Unit Control Board (UCB). See Fig. 53 for location.

1. Check the job specifications for the CFM (cubic feet per min-

ute) and ESP (external static pressure) required.

2. Using the chart on the fan speed set up labels (see Fig. 54), calculate the Vdc from the CFM and ESP for the base unit. Then add Vdc for any accessories installed per the “Field Accessories” section of the label.

NOTE: The fan speed set up labels are located on the High Voltage cover in the Control Box.

3. Connect a multimeter to the Vdc terminals on the UCB.

4. Set the Range Switch to either A, B, or C per the Switch Range table.

5. Using a straight blade screwdriver, turn the Vdc control dial to fine tune the Vdc reading.

6. Record the reading in the Field Setting field.

NOTE: Fan set-up Vdc is not affected by the operating stage of the unit.

Fig. 53 — UCB Fan Speed Controls

Page 39

UNITS WITH SYSTEMVU™ CONTROLS

Factory Setting:

9.0 VDC

Field Setting:



Switch Range:

A B C

Field Accessories:

ESP in. wg

VDC Calculator

CFM

0.2

5.4

5.8

6.1

6.5

6.8

7.2

7.6

7.9

8.3

1500 1625 1750 1875 2000 2125 2250 2375 2500

0.1

0.4

6.2

6.5

6.8

7.1

7.4

7.7

8.0

8.4

8.7

0.1

0.6

6.9

7.1

7.4

7.7

7.9

8.2

8.5

8.8

0.1

0.8

7.5

7.7

8.0

8.2

8.5

8.7

9.0

0.1

1.0

8.1

8.3

8.5

8.7

9.0

0.1

1.2

8.6

8.8

9.0

9.2

0.1

1.4

9.1

9.3

9.5

0.1

1.6 1.8 2.0

9.6

0.1Economizer

1 Stage E Heat 2 Stage E Heat

UNIT MODEL NUMBER

4.1 - 7.5

6.9 - 8.7

7.7 - 10.0

0.2

0.3

0.2

0.3

0.2

0.3

0.2

0.3

0.2

0.3

0.2

0.3

0.2

0.3

0.2

0.3

9.8

9.9

9.7

9.99.5

9.7

10.0

9.2

9.5

9.8

9.3

9.69.2

Record field setting here

* Overlap in A, B, C switch range

designed for maximum field adjustment potential. For example

7.2 can be set at either A or B.

On units equipped with the factory-installed SystemVu controller the Fan Speed settings are accessed through the SystemVu interface.

1. Check the job specifications for the CFM (cubic feet per min-

ute) and ESP (external static pressure) required.

2. Using the chart on the fan speed set up labels (see Fig. 55), calculate the RPM from the CFM and ESP for the base unit plus any field accessories (as listed on the label).

NOTE: The fan speed set up labels are located on the High Voltage cover in the Control Box.

3. Press any key on the SystemVu interface to activate the display backlight and then press the MENU key.

4. Using the UP and DOWN arrow keys highlight SETTINGS and then press ENTER.

5. Use the DOWN arrow key highlight the UNIT CONFIGURATIONS menu then press ENTER.

6. Highlight UNIT CONFIGURATIONS then press ENTER.

Fig. 54 — Example of Fan Speed Set Up Labels for Electro-Mechanical Controls

7. Highlight INDOOR FAN and then press ENTER.

8. Refer to the job specifications to set the following, determin-

ing the values per the RPM Calculator label (see Fig. 55). Use

• IDF VENT SPD

• IDF HEAT SPD

• IDF LOW COOL SPD

• IDF HIGH SPD

• IDF FREE COOL SPD

For further details, see the FC/GC Series Single Package Rooftop

Units with SystemVu Controller Controls, Start-up, Operation and Troubleshooting manual.

the UP and DOWN arrow keys and the BACK key to set the values. Press ENTER after setting each value to continue to the next selection.

Page 40

Fig. 55 — Example of Fan Speed Set Up Labels for SystemVu™ Controls

Field Accessories:

2500

Economizer

ESP in. wg

RPM

Calculator

CFM

0.2

1301 1381 1463 1548 1633 1720 1808 1897 1987

1500 1625 1750 1875 2000 2125 2250 2375

66 80

107

0.4

1477 1544 1615 1688 1764 1842 1921 2003 2068

0.6

1639 1699 1763 1828 1897 1967 2040 2115 2191

0.8

1788 1843 1902 1962 2025 2090 2157 2227 2298

1.0

1925 1976 2031 2087 2146 2208 2271 2336

1.2

2054 2101 2152 2206 2262 2320 2380

1.4

2174 2220 2268 2318 2372

1.6 1.8 2.0

2289 2332 2378

66 66

80 80 80 80 80 80 80

107 107 107 107 107 107 107

1 Stage E Heat 2 Stage E Heat

UNIT MODEL NUMBER

Page 41

Page 42

Catalog No. 04-53500269-01 Printed in U.S.A. Form 50GC-4-6-03SI Rev. A Pg 42 3-21 Replaces: 50GC-4-6-02SI

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

Page 43

Start-Up Checklist for 50GC**04-06 Single Package Rooftop

Cooling Only/Electric Heat Unit

(Remove and use for job file)

NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to

the safety considerations/information as outlined in preceding sec-

tions of this Installation Instruction document.

I. PRELIMINARY INFORMATION

MODEL NO. ____________________________________________

JOB NAME_____________________________________________

SERIAL NO. ____________________________________________

ADDRESS _____________________________________________

START-UP DATE________________________________________

TECHNICIAN NAME ___

DITIONAL ACCESSORIES

_____________________________________________________________________________________________________

__________________________________

II. PRE-START-UP

Verify that all packaging materials have been removed from unit (Y/N) _____ Verify installation of outdoor air hood (Y/N) _____ Verify that condensate connection is installed per instructions (Y/N) _____ Verify that all electric Check that indoor-air filters are clean and in place (Y/N) _____ Check that outdoor air inlet screens are in place (Y/N) _____ Verify that unit is level (Y/N) _____ Verify that fan assembly is free of obstructions and rotor spins freely (Y/N) _____ Verify that scroll compressors are rotating in the correct direction (Y/N) _____ Verify installation of th

al connections and terminals are tight (Y/

ermostat (Y/

N) _____

III. START-UP

ELECTRICAL

Supply Voltage L1-L2_____________ L2-L3_____________ L3-L1_____________ Compressor Amps 1 L1 _____________ L2 _____________ L3 _____________ Compressor Amps 2 L1 _____________ L2 _____________ L3 _____________ Supply Fan Amps L1 _____________ L2 _____________ L3 _____________

TEMPERATURES

Outdoor-air Temperature _____________ °F DB (Dry Bulb) Return-air Temperature _____________ °F DB _____________ °F Wb (Wet Bu Cooling Supply Air Temperature _____________ °F

lb)

Catalog No. 04-53500269-01 Printed in U.S.A. Form 50GC-4-6-03SI Rev. A Pg CL-1 3-21 Replaces: 50GC-4-6-02SI

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

Page 44

PRESSURES

Refrigerant Suction CIRCUIT A _____________ PSIG

CIRCUIT B _____________ PSIG

Refrigerant Discharge CIRCUIT A _____________ PSIG

CIRCUIT B _____________ PSIG

Verify Refrigerant Charge using Charging Charts (Y/N) _____

GENERAL

Economizer minimum vent and changeover settings to job requirements (if equipped) (Y/N) _____ Verify smoke detector unit shutdown by utilizing magnet test (Y/

N) _____

IV. HUMIDI-MIZER® START-UP

STEPS

1. Check UCB for jumper 1, 2, 3 (Jumper 1, 2, 3 must be cut and open) (Y/N) _____

2. Open humidistat contacts (Y/N) _____

3. Start unit In cooling (Close Y1) (Y/N) _____

OBSERVE AND RECORD

A. Suction pressure _______________ PSIG B. Discharge pressure _______________ PSIG C. Entering air temperature _______________ ° F D. Liquid line temperature at outlet or reheat E. Confirm correct rotation for compressor (Y/N) _____ F. Check for correct ramp-up of outdoor fan motor as condenser coil warms (Y/N) _____

4. Switch unit to high-latent mode (sub-cooler) by closing humidistat with Y1 closed (Y/N) _____

5. Check unit charge per charging chart (Y/N) _____

coil __

OBSERVE

A. Reduction in suction pressure (5 to 7 psi expected) (Y/N) _____ B. Discharge pressure unchanged (Y/N) _____

Liquid temperature drops to 50°F to 55°F range (Y/N) _____

D. LSV solenoid energized (valve closes) (Y/N) _____

6. Switch unit to dehumid (reheat) by opening Y1 (Y/N) _____

OBSERVE

A. Suction pressure increases to normal cooling level B. Discharge pressure decreases (35 to 50 psi) (Limited by head pressure control) C. Liquid temperature returns to normal cooling level D. LSV solenoid energized (valve closes) E. DSV solenoid energized, valve opens

7. Wit

h unit in dehumid mode close W1 compressor and outdoor fan stop; LSV

8. Open W1 restore unit to dehumid mode (Y/N) _____

9. Open humidistat input compressor and outdoor fan stop; LSV and DSV solenoids de-energized (Y/N) _____

10. Restore setpoints for thermostat and humidistat (Y/N) _____

_____________ ° F

and DSV solenoids de-energized (Y/N) _____

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

Catalog No. 04-53500269-01 Printed in U.S.A. Form 50GC-4-6-03SI Rev. A Pg CL-2 3-21 Replaces: 50GC-4-6-02SI

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

Carrier WeatherMaster Installation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY CONSIDERATIONS

Rated Indoor Airflow

INSTALLATION

Jobsite Survey

Step 1 — Plan for Unit Location

Step 2 — Plan for Sequence of Unit Installation

CURB-MOUNTED INSTALLATION

PAD-MOUNTED INSTALLATION

Step 3 — Inspect Unit

Step 4 — Provide Unit Support

ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR SLAB MOUNT)

Step 5 — Field Fabricate Ductwork

UNITS WITH ACCESSORY OR OPTIONAL ELECTRIC HEATERS

Step 6 — Rig and Place Unit

Step 8 — Install Outside Air Hood

ECONOMIZER HOOD PACKAGE REMOVAL AND SETUP (FACTORY OPTION)

Step 9 — Units with Hinged Panels Only

Step 11 — Make Electrical Connections

UNITS WITHOUT FACTORY-INSTALLED NON-FUSED DISCONNECT OR HACR

CONVENIENCE OUTLETS

EconoMi$er® X (Factory Option)

SPECIFICATIONS

INPUTS

OUTPUTS

ENVIRONMENTAL

2 SPEED FAN OPERATION The W7220 controller has the capability to work with a system us-

2SP H/C AND 3 SPEED FAN OPERATION FAN TYPE = 2SP H/C and FAN TYPE = 3SPEED are not used

TROUBLESHOOTING

RTU Open Controller (Factory Option)

SystemVu™ Controller (Factory Option)

Controller Options

Smoke Detectors

Step 12 — Adjust Factory-Installed Options

Step 13 — Install Accessories

Step 14 — Fan Speed Set Up

UNITS WITH SYSTEMVU™ CONTROLS