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Carrier NP034-074 User's Manual

1. 02 CO 00 CO CO cO 414 508 NOOO 09 59 6 3 3 0 9 0 6 3 3 0 9 0 6 3 3 0 9 0 6 3 3 0 9 0 WORWORWORWOLR 02 CO CO CO 0 OOC SSSAAASSS S SDN N 001010 LEGEND NOTES Constant Volume 1 Electric resistance heaters are rated at 208 240 v 480 v or 575 v To ETL Testin 6215 determine heater capacity kW at unit operating voltage multiply 240 v Full Load ins y 480 v or 575 v capacity by appropriate multiplier below Nominal Horsepower Indoor Evaporator Fan Motor MULTIPLICATION FACTORS VOLTAGE CV ETL ang LRA MCA MOCP OFM RLA Minima AM f HEATER kW MULTIPLICATION Circuit Amps for wire sizing Maximum Overcurrent Protection RATING DISTRIBUTION FACTOR Outdoor Condenser Fan Motor Rated Load Amps 3 0 694 0 751 0 918 1 000 0 840 0 918 1 000 0 915 Electric heat available 50 Series vertical discharge units 240 108 kW available on CV applications only 1 000 480 2 575
2. aii Ins 64 193 1334 1838 1834 BHO Mad 4 QNO 220 9836 m 55 9 214 5 3 90950 WK D 16 1 55 n eo ge 930 4 25 0 6587 282 2 G0 8 14 SdH 114 01 681709 m HOLINS 03 4 3308 031 4 20 ONY 1N1SOWM34L HLIM 531865 NI 035010 ATIVMUON cuo A HED 51211800 HAYT 3414 3206 00 bal 89513 335 WIDE svo ZUHO HED Tu 0381 HD 330 me 69 oat TAA 48 De ss p 1930 823 NL ey HED gga me 45 wl ah s 90 5 PST F20 FO 0662 nd le HED mie 5405 54403 19 5 Te Mrd 8 7 BAS 62 308 5 t 78A HD BU ne ED 22 RH KD ra 2 sz wos 283 E e 51 QA HED 089 41093 2 54403 1409 38
3. SOI IO OO ONO O D SHO 3 O O 2 D OD Na oro O OD oooiiivooo ELECTRIC HEAT E 5065565625 C O OOO 86565552 622 02 CO gt CO CO CO CO GHHGGHGGHHOHS COWDDWOOWOOW CO I CO I CO CO BASE UNIT WITH EXHAUST FAN AND OR LECTRIC HEAT Table 3 Electrical Data 034 Units cont 575 3 60 V Ph Hz BASE UNIT WITH COMPR COMPR OFM BASE UNIT EXHAUST ELECTRIC EXHAUST FAN VOLTAGE NO 1 NO 2 ONLY FAN AND OR RANGE ELECTRIC HEAT ii ONO ecoojooooooooo O O O 1 BVHHVHSNVOHANID
4. HED BU s RH KD vio 182 1019 15 08 0 2 80 11 35 ma U u3M0d BE 017314 1 181 62 1409 0 60 SHUN Maos raos er oneueuos 8319 1 OZ 7614 En ES 3 1 D lt 6 90 25 e 3 6 rsd E gt gt C 1 esd LOE OIA 4 un 014 281 lt 1190 31813313 49 913 336 11935 579 1901 eed 37 ps E 3 01 lt 01 ma pp H D pd 91007 200 m gt az alo zlo 217 501 J 100 0 08 3 GEL LEL SE 1579968 f d us 237 9 00 26 1710 LINN 31 1 2 6 2 4 0 0 3 27 8 2 40 Am e EHKD _ 10E eo X08 21412213 exon ne
5. 4 65 550 15 B5V 2 B5V 13 7 2 5VX 63 0 550 20 5 2 B5V 13 7 2 5VX 63 0 66 0 IFM Indoor Evaporator Fan Motor Table 9B Field Supplied Evaporator Fan Pulley Data 054 074 Units MOTOR PULLEY Grooves Grooves 57 Check rotation of wheel with arrow on the fan housing B5V Check fan speed with a strobe type tachometer or use this 5V formula 15 gt N lt 20 25 Indoor Evaporator Fan Motor ayo A 30 5 ayo ola Fan Rpm motor rpm x motor sheave pitch diameter in fan sheave pitch diameter in Obtain motor rpm from the fan motor nameplate and read sheave pitch diameters marked on the fan and motor sheaves Example Nameplate motor rpm 1760 Motor sheave pitch diameter Fan sheave pitch diameter in 12 4 Fan Rpm 1760 x 64 908 Rpm 12 4 The maximum allowable fan speed for the supply air fan is 900 rpm for 034 and 044 units and 750 rpm for 054 074 units The maximum rpm for the power exhaust is 1300 rpm for 034 and 044 units and 925 rpm for 054 074 units Excessive fan speed may result in condensate carryover from the evaporator coil fan motor overload or wheel failure See Table 10 for Air Quantity Limits Table 10 Air Quantity Limits cfm UNIT SIZE MA
6. 9 D ne me nma hae en seins nae BOD 2 9 wm 28 834 098 0334 _ 180818941 0 5830 E XB BEN 9901960 HAO Er SE 0 Ej 23103 5 3 mea mea nas a wa As 4 ret nas 41 63 ep i m g EH KD au 42 e 1 14409 4403 3403 Ugo _ 062 82 wol pol nes rt 14905 WA wR 2 BA TBA 0 135 2 304 ow one a HEH KD xs a ttt ALYNYAL TY 1 27 15 189 1019 09 5 098 99 6 09r 09 6 065 80 08 062 802 SILVW3HOS 04 151 set 611 511 45 56 58 54 69 58 s ES 5 62 sz 69 PACKAGED SERVICE TRAINING Our packaged service training programs provide an excellent way to increase your knowledge of the equipment discussed in this manual Product programs cover Unit Familiarization Maintenance Installation Overview Operating Sequence A large selection of product theory and skills programs is available All program
7. GO O O 4 6 518 632 O O O 6 0 2 0 8 0 6 0 2 0 8 0 6 0 2 0 8 0 6 0 2 0 8 0 1 GO 4 O ON ON 65 OS SRA sien eo ro f N oo O O O N MO 99915 6565 90 90 M SSOONNNBOH O 162 O G O 1 LEGEND NOTES Constant Volume 1 Electric resistance heaters are rated at 208 240 v 480 v or 575 v To ETL Testin Labore determine heater capacity kW at unit operating voltage multiply 240 v Full Load Amps 480 v or 575 capacity by appropriate multiplier below Nominal Horsepower Indoor Evaporator Fan Motor MULTIPLICATION FACTORS Rotor amps VOLTAGE um Circuit Amps for wire sizing HEATER kW DISTRIBUTION MULTIPLICATION Maximum Overcurrent Protection RATING 3 FACTOR Outdoor
8. 125 F 400 5 115 105 95 5 85 5 250 TOA 75 amp 85 m 2004 TOA 55 F 45 4 1 100 90 80 70 60 50 40 30 20 COMPRESSOR SUCTION PRESSURE PSIG Fig 57 Charging Chart 064 Units System 2 All Condenser Fans Running 49 T T T ALL CONDENSER FANS RUNNING TEMP OUTDOOR AIR TOA 125 115 TOA 105 95 85 75 55 55 TOA 45 e D m a e lt e o 5 e a 30 40 50 60 70 COMPRESSOR SUCTION PRESSURE PSIG 58 Charging Chart 074 Units System 1 All Condenser Fans Running Fig T 1 1 5001 NOTE ALL CONDENSER FANS RUNNING TOA TEMP OUTDOOR AIR TOA 125 TOA 115 105 95 85 78 TOA 65 TOA 55 45 COMPRESSOR DISCHARGE PRESSURE 516 ll 49 COMPRESSOR SUCTION PRESSURE PSIG 50 60 Fig 59 Charging Chart 074 Units System 2 All Condenser Fans Running AUTOMATIC PILOT ADJUSTMENT 48 Series Units Only 1 2 Set system selector switch at OFF position to shut off unit Turn off power t
9. ELECTRIC EXHAUST FAN VOLTAGE HEAT AND OR dri ELECTRIC HEAT Total Total Total 21 2 20 0 175 9 172 5 225 225 33 4 30 0 188 1 182 5 225 225 48 4 44 0 203 1 196 5 250 225 78 9 91 0 154 7 152 5 200 200 157 7 182 0 227 4 255 0 250 300 236 6 273 9 326 0 368 8 350 400 0 ooo 21 2 20 0 78 9 91 175 9 172 5 225 225 21 2 20 0 157 7 182 21 2 20 0 236 6 273 0 326 0 368 8 350 400 33 4 30 0 78 9 91 0 188 1 182 5 225 225 33 4 30 0 157 7 182 0 227 4 255 0 250 300 33 4 30 0 236 6 273 0 326 0 368 8 350 400 48 4 44 0 78 9 91 0 203 1 196 5 250 225 48 4 44 0 157 7 182 0 227 4 255 0 250 300 48 4 44 0 236 6 273 0 326 0 368 8 350 400 21 2 20 0 182 5 178 5 225 225 33 4 30 0 194 7 188 5 225 225 48 4 44 0 209 7 202 5 250 250 227 4 255 0 250 300 ooolooooooooo 6 24 2 154 7 200 75 220 1525 200 0 0 0 5 5 5 6 5 78 9 91 0 161 3 158 5 200 200 157 7 182 0 235 6 262 5 250 300 236 6 273 0 334 2 376 3 350 400 161 3 200 6 0 21 2 20 0 78 9 91 0 182 5 178 5 225 225 H 158 5 200 6 0 21 2 20 0 157 7 182 0 235 6 262 5 250 300 6 0 21 2 20 0 236 6 273 0 334 2 376 3 350 400 0 0 33 4 30 0 78 9 91 0 194 7 188 5 225 225 0 0 33 4 30 0 157 7 182 0 235 6 262 5 250 300 0 0 33 4 30 0 236 6 273 0 334 2 376 3 350 400 5 0 48 4 44 0 78 9 91 0 209 7 202 5
10. 4 s 100 31380510 t 5 T3NNYH9 YOLYALIY m _ AWA 1 0 0 GAH Jer 8055333 bes 25 2 0154 NYO 65 le 0150 NUE NiO 5 SdNY OIA NYUL SSSNYVH 4 12 INGOW NOI 1dO E 1 gm we LE 6 po 2 08916 4 555 011 3 4 03 004 se 0 4 8 8 NYO 2 S NBL 553 04 1 ZE 16 I3NNYH Mm NOL19081SN02 3 lt 18 614 1 4 1 2 9 3 a 5 s Fey gt 2 74 9 14 038 71 1140 9 34 8 24 3 9 88 88 90 8 uo A9 13538 SUYSEL 3345 3233 3 1 34 40414 il 1 8 8214 93 6273 318 2 gt gt
11. T 5 8214 5 627 v BZld 8 vat A 3 20 3 0 21 T Ht vaL ma 5 gt 5 gt ENS um OIA 014 D H H 35 88 s LL me ema n Tol ANOSS329V N01140 pe E 1 anvad 5 6 54 0 S 921 433 gt gt 039 034 N 038 gt gt 5014 039 67 SCHEMATIC WHT TRANS 689 95 WHT 2 IFC pu GRN YEL wt OX sos 4 cw BLK BLE TRAN 1 BLK MK TRAN 4 PRIMARY RED e BLK WHT TRAN 5 PRIMARY ny a c TRAN 6 77 2372 ONLY i
12. TB2 SWI TB2 5 PL8 2 BLU ECON MOTOR I S w REMOVED FROM C BASE UNIT sw4 TB2 E BASE UNIT REMOVED FROM TRAN 3 PL6 2 SWS 15 2 BLK TRAN 3 c 24 TB2 o 96 SW DPS OPTIONAL MODULATING POWER EXHAUST PL7 I SWS lt lt BLK _O ED DMSI 1 52 5 546 OPTIONAL NON MODULATING EXHAUST Gas Piping 48 Series Units Only Unit is equipped for use with natural gas only Installation must conform with local building codes or in the absence of local codes with the National Fuel Gas Code ANSI 2223 1 A 1 8 in NPT tapping plug accessible for test gage con nection must be field installed immediately upstream of gas supply connection to unit but after manual gas valve See Fig 21 Natural gas pressure at unit gas connection must not be less than 5 in wg or greater than 13 in wg Size gas supply piping for 0 5 in wg maximum pressure drop Do not use supply pipe smaller than unit gas connection CAUTION Disconnect gas piping from unit when leak testing at pressures greater than 0 5 psig Pressures greater than 0 5 psig will cause gas valve damage resulting in a haz ardous condition If gas valve is subjected to pressure greater than 0 5 psig it must be replaced Installing Flue Inlet Hoods 48 Series Units Only The flue inlet hoods are shipped in a bag taped
13. LSR PL13 1 68 ORND gt KD VIO LSR PL11 1 PL10 1 mi 9 52 ORN RED RED 0 0 RED 9 ime 171 PL10 2 PLi1 2 me eee Fig 66 Gas Heat Sections 48DJ NP034 044 Units 58 SHUN 740 suonoes 199 589 614 1 9 e zal 914 8 gt 01 4 4 4 201 Pa 1 1V3H H9IH AV3H H9IH ESY sss 1 9 Quvoga A9 lov us OID LYH D eee boa w 51 S Ed 901 2 5 1 2 5 HD 3 LT N _ veo 01 4 59 1194 9 6 0 4 1494 11 9 0114 1401 8 5 gt nua 28 weg SHUN rb0 r 0yG8r uonoes seo 89 614 T 257 c ME EP J A Zp 5 Lt Td 01 4 o o 78 0 161 151 vaL E Nua LAOH 2421 1 4 8 1114 1484 SHUN 0 90 108 01395 eH 589 69 614 1431 61 13403 09 098 20 90 SHUN Maos raos er oneueuos 5319
14. 2 Remove mixed air sensor connected between terminals 51 and 52 3 Remove outdoor air enthalpy sensor between terminals and SO 4 Refer to Table 13 Table 13 Economizer Control Board Checkout Test 1 EXPECTED RESULT AND RESPONSE Motor drives closed If not check minimum position jumper between terminals Z and Y and check terminal W and T1 connections to motor Motor drives open If not check terminal B and R connections to the motor MOTOR PROCEDURE TEST A Turn minimum position potentiometer fully counterclockwise B Turn minimum position potentiometer fully clockwise Test 2 1 Apply 24 VAC power to terminals TO and T2 of the con trol board 2 Apply 24 v between terminals 1 and T2 and jumper ter minal TO to terminal 1 3 Remove the mixed air sensor connected between termi nals 51 and 52 and replace it with 8 5490 ohm resistor 4 Remove outdoor air enthalpy sensor between terminals and SO and replace it with a 1 2 kOhm resistor 5 Turn the minimum position potentiometer fully counter clockwise 6 Refer to Table 14 Table 14 Economizer Control Board Checkout Test 2 EXPECTED RESULT AND RESPONSE The relays energize If not check return enthalpy re sistor If resistor is o k control board is faulty Motor drives open If re lays energize but motor does not drive open the control board is faulty The relays deenergize If not control board is
15. COMBUSTION AIR BLOWER 48 Series Units Only Clean periodically to assure proper airflow and heating ef ficiency Inspect blower wheel every fall and periodically dur ing the heating season For first heating season inspect blower wheel bimonthly to determine proper cleaning frequency If cleaning is required remove blower assembly from unit and then disassemble and clean See Fig 41 PRESSURE SWITCH 48 SERIES THIGH HEAT UNITS ONLY LIMIT SWITCH L BLOWER WHEEL FLUE 2 HOUSING OUTLET 5 FLUE BOX VALVE SECTION 2 PRESSURE SWITCH FLUE BLOWER OUTLET WHEEL HOUSING GAS VALVE FLUE BOX LIMIT SWITCH SECTION NO 2 NOTE High heat consists of sections 1 and 2 Low heat consists of section 1 only Fig 37 Gas Section Detail 48 Series 034 and 044 Units SECTION 2 FLUE OUTLET SECTION 3 BLOWER WHEEL HOUSING FLUE BOX NOTE High heat consists of sections 1 3 Low heat consists of section 1 and 2 only Fig 38 Gas Section Detail 48 Series 054 074 Units ECONOMIZER DAMPER MOTOR On units so equipped the economizer motor is located in the mixing box section Access to it is through the doors labeled FILTER SECTION on the sides of the unit ELECTRIC HEATER CONTROL BOX 50 Series Units Only Access to the electric heater control box is through the door on the right side of the unit
16. 1 02 614 SS ne EC me 4 3 HOIH 57 ai 7 6179 8 274 2201 1 1 54803 44803 QuvaNvis 09 E 09F 1Y3H 3 7 08 3 2 6 14 2 8114 Y EH 734 uw 1901 1 81 4 100 241 54 5 2 HDB eH HID Bo 91 8 5334 god 5 oED na TAZ HED e 92134 88 62 1 8 Bo 40 1934 1824 21 9217 08 0 2 802 F20 5830 ANO 67 6 91 m SLING 9 2 uo 90950 0 01 Hip ne 20 OIA Km 1330 9ED ns J 1 9207990 662 902 1 E2H HED me 08 HED s 309 424 HE0 I veo 8o 5013 9 24 HED 960 0 4 Y q 9 0 ua LH HED e 812 621 421 551 611 eu 85 089 41093 8 4 14305 S 14 09 078 E2H HED
17. 2 Loosen belts using motor adjusting bolts until belts can be removed without stretching them over the grooves of the pulley Remove belts Loosen setscrews on motor pulley 5 Slide pulley off motor shaft Make sure setscrews on new pulley are loose 6 Slide new pulley onto fan shaft and align it with the fan pulley as described in Pulley Alignment section above 7 Tighten setscrews 8 Install belts and tension properly as described in Pulley Alignment section above CONDENSER FAN ADJUSTMENT 1 Turn off unit power 2 Remove fan guard and loosen fan hub setscrew 3 See Fig 32 and adjust fan height using a straight edge laid across the fan deck 4 Tighten setscrew and replace rubber hubcap to prevent hub from rusting to the motor shaft Fill hub recess with Permagum if hub has no rubber hubcap 5 Replace fan guard CENTER LINES MUST COINCIDE LINES MUST BE PARALLEL FIXED SHEAVE FIXED SHEAVE Fig 45 Pulley Alignment 25 OUTDOOR AIR DAMPER See Manual Outdoor Air Damper section on page 10 for adjustment details REFRIGERANT CHARGE units are shipped with a complete operating charge of R 22 See unit nameplate and Tables 1A and 1B for amount of charge When adding a com plete charge evacuate system using standard evacuating pro cedures and weigh in the specified amount of charge units have charging charts for each refrigerant circuit See
18. 350 350 236 6 273 0 370 0 408 8 450 450 21 2 20 0 78 9 91 0 252 5 245 9 300 300 0 0 0 2 2 21 2 20 0 157 7 182 271 4 295 0 350 350 21 2 20 0 236 6 273 370 0 408 8 450 450 33 4 30 0 78 9 91 264 7 255 9 300 300 33 4 30 0 157 7 182 0 271 4 295 0 350 350 33 4 30 0 236 6 273 0 370 0 408 8 450 450 48 4 44 0 78 9 91 0 279 7 269 9 300 300 48 4 44 0 157 7 182 0 279 7 295 0 350 350 48 4 44 0 236 6 273 0 370 0 408 8 450 450 22 Table 4 Electrical Data 044 Units cont 460 3 60 V Ph Hz BASE UNIT WITH COMPR COMPR BASE UNIT EXHAUST ELECTRIC EXHAUST FAN VOLTAGE NO 1 NO 2 ONLY FAN HEAT AND OR RANGE ELECTRIC HEAT ooo 9 ONO os Na m N NV O1 O1 O O O OOO OOOOOOOOO 3 0 N 3 3 cO 414 508 6 6 6 2 2 2 0 0 0 6 2 0 9 5 2 N DN NIN LORE e O 2 23 52 2 3 2 a C
19. 65 F COMPRESSOR DISCHARGE PRESSURE PSIG T 26 30 40 50 60 70 COMPRESSOR SUCTION PRESSURE PSIG Fig 54 Charging Chart 054 Units System 1 All Condenser Fans Running 1 NOTE ALL CONDENSER FANS RUNNING TOA TEMP OUTDOOR AIR TOA 125 F 115 F F 105 TOA 95 es TOA 75 TOA 55 55 45 in e e e a c o e 30 40 50 60 COMPRESSOR SUCTION PRESSURE PSIG Fig 55 Charging Chart 054 Units System 2 All Condenser Fans Running 1 1 5004 NOTE ALL CONDENSER FANS RUNNENG TOA TEMP OUTDOOR AIR 1 5 2 4504 TOA 125 F y 400 5 115 3504 105 F 3004 TOA 95 F 85 5 2504 75 65 8 2 2004 55 x 45 8 19 01 30 40 50 60 70 80 COMPRESSOR SUCTION PRESSURE PSIG Fig 56 Charging Chart 064 Units System 1 All Condenser Fans Running T so NOTE ALL CONDENSER FANS RUNNING TOA TEMP OUTDOOR AIR 2 4504 amp
20. INLET HOOD SIDE PLATE TYP EACH SIDE Fig 23 Inlet Hood FLUE HOOD AND FLUE FLUE DEFLECTOR DEFLECTOR HOOD HOOD LOCATION SAYU INLET HOOD SMALL LARGE SE em INLET op REMOVED Fig 24 Flue Hood LARGE INLET HOOD FLUE AND LOCATION SEIT 48 SERIES DEFLECTOR FLUE DEFLECTOR HIGH HEAT 5 HOOD HOOD e 48 SERIES PE HIGH HEAT o Fig 27 Flue Inlet Hood 054 074 Units FLUE FLUE HOOD AND DEFLECTOR FLUE DEFLECTOR BAFFLE HOOD BOTTOM SMALL INLET HOOD ONLY HOOD FLUE DEFLECTOR 7 BAFFLE BOTH HOODS Fig 25 Flue Deflector Baffles 034 044 Units gt LARGE INLET a HOOD TOP INSTALLED Fig 28 Flue Inlet Hood Close Up FLUE DEFLECTOR FLUE BAFFLE DEFLECTOR PUSH BAFFLE DEFLECTOR DOWN SO BAFFLE THESE 2 HOLES FOR BOTTOM PPS HOOD ONLY Fig 26 Flue Deflector Hood 034 044 Units Assembled TOP WHEN INSTALLED Fig 29 Flue Deflector Baffle 054 074 Units Assembled 37 PRE START UP Unit Preparation Check to see that unit has been installed in acc
21. oooooo po ISIS OT O1 O1 WORWORWORWOR SSSAAASSS 2 SDN N NOOO CO C2 CO C2 CO gt CO DOWOOWOOWOOw 26 Table 5 Electrical Data 054 Units cont 575 3 60 V Ph Hz BASE UNIT WITH COMPR COMPR BASE UNIT EXHAUST ELECTRIC EXHAUST FAN VOLTAGE NO 1 NO 2 ONLY FAN HEAT AND OR RANGE ELECTRIC HEAT NL OON 02 O 1 6 N 0 01010 O O GO O 5553055655 518 632 00 SVD 6 0 2 0 8 0 6 0 2 0 8 0 6 0 2 0 8 0 6 0 2 0 8 0 4 4 ONWONWONWONW 5 565 663555635655636 SSSAAASSS N LEGEND NOTES Constant Volume 1 Electric resistance heaters are rated at 208 240 v 480 v or 575 v To ETL Testin 6215 determine heater capacity kW at unit operating voltage multip
22. 07 10 3 4 ACCESS DOOR NEAR SIDE ONLY C ACCESS DOOR NEAR SIDE ONLY POWER EXHAUST ACCESS DOOR CONTROL BOX NEAR SIDE ONLY ACCESS DOOR NEAR SIDE ONLY 612 2 0 1 87 ACCESS DOOR CONTROL BOX FAR SIDE ONLY ELECTRIC HEAT CONTROL BOX 3 3 3i A 20451 S SN 167 8 1 2 TES y Z E ELECTRIC m HEATERS 17052 23 1 5 8 ECONOMIZER OPTION AIR HOODS 3 SIDES BAROMETRIC RELIEF OR POWER EXHAUST OPTION 28213 23 1 16 14 6 13 16 ACCESS DOOR DRAIN CONN 4847 POWER 8 LOW BOTH SIDES RETURN AIR BOTH SIDES ic gt SUPPLY AIR 4 PLES 15 10 13 16 DUCT CONN VOLTAGE CONN BASE FRAME ACCESS DOOR POWER EXHAUST BOTH SIDES gt CONTROL BOX ACCESS PANELS 384 23291 612 1 3 1 8 7 7 11 16 2 0 1 8 ECONOMI ZER OPTION AIR HOODS 3 SIDES 893 RETURN AIR OPTION HOODS FIELD INSTALLED FOR 31 8 0 1 1 4 NPT DRAIN CONN 0 1 3 8 25 13 DIA 7 2 1 2 HOLE IN LIFTING LUGS LIFTING POSITION lt 2413 2476 1 8 1 OVERALL LIFTING SHIPPING DIM Fig 4D Base Unit Dimensional Drawing 50DJ DK NP054 074 Units 14 CONDENSER DRAIN HERE OR DRAIN HERE 034 UNITS DRAIN HERE OR DRAIN HERE 044 074 UNITS Fig 5 Drain Location
23. 1 089 Electric heaters are tested and ETL approved at maximum total external static pressure of 1 9 in wg 2 Boldface indicates 48 and 50 Series units All other data is for 50 Series units only 29 Table 6 Electrical Data 064 Units cont 575 3 60 V Ph Hz BASE UNIT WITH COMPR COMPR BASE UNIT EXHAUST ELECTRIC EXHAUST FAN VOLTAGE NO 1 NO 2 ONLY FAN HEAT AND OR RANGE ELECTRIC HEAT 6 SNWONWONWONW 36 0 72 0 08 0 36 0 72 0 08 0 36 0 72 0 08 0 36 0 72 0 08 0 1 518 632 SAAAUSSS oe S DNWONWONWONW 8 8 8 5 ecoOooooooocooco sok 8 585 5 5 OOOO OOO TEE N OOOOOONNN 1 O 1 O 1 GO O 30 VOLTAGE RANGE 187 254 CV ETL LRA MCA RLA Electric heat available on 50 Series vertical discharge units Table 7 Electrical Data 074 Units LEGEND Constant Volume ETL Testing Laboratory Full Load Amps Nominal Horsepower Indoor Evaporator Fan Motor Locked Rotor Amps Minimum Circuit Amps for wire sizing Maximum Overcurrent Protection Outdoor Condenser Fan Motor Rated Load Amps 108
24. 13661 2 0 1 8 612 17 6 13 16 14781 0 008 POWER EXHAUST Mks ACCESS DOOR TYP BOTH SIDES ACCESS DOOR LEGEND CONN Connection DIM Dimension NOTES 1 Dimensions in in millimeters 2 Center of Gravity includes economizer Unit weight does not include economizer 3 Unit clearances Top Do not restrict condenser fans Control Box End 6 0 Sides 6 0 Economizer End 6 0 except power exhaust units 10 0 ACCESS DOOR 9 8 3 4 1461 BOTTOI SEE ROOF CURB CERTIFIED FOR DUCT DIMENSIONS amp LOCATIONS 0 NEAR SIDE ONLY POWER EXHAUST OPTION ORAIN CONN BOTH SIDES 4 PLCS J H 044 ONLY ACCESS DOOR OR SIDE SUPPLY OPENING NEAR SIDE ONLY 0 2 50 81 48 SERIES UNITS For smaller service and operational clearances con tact Carrier Product Engineering Department 4 Vertical discharge ducts designed to be attached to accessory roof curb If unit is mounted on dunnage support the ducts using cross braces as done on the accessory roof curb 5 When unit is slab mounted locate the condensate drain as low as possible on vertical face of base rail atthe same location as the standard condensate drain using factory supplied fitting Plug factory drilled con densate hole 0 3 4 19 13 NPT LOM VOLTAGE 1 1 2 9 16 370 LOW VOLTAGE CONTROL BO
25. 25 0 lt lt 9 0 4 Sl 806 0 134 94 4 1 vs e ANO 09 57 03 20 90 SHUN 60092 009 81 551941 7614 an 656 21 m Q M 26 1 009 y jD e B91 XX 1 1 63004 33085 3 34 55384 ONIOTIN 303 SLOVLNOD 95 AYTAY 036010 04 3 BIHN 2 02 07313 oss e ge KD e x T den S Tak Sd 5 01140 3210N003 1 1 tiena 2 e zi zi BA w E 8 38 1 0 0 2 1040444 803 1338 03 006 rai 1 03 at Vesa esce NW 335 6174 1 1 1 0 L SLIM 34 gt 9 624 e ei EH HDs 0 0 600 18 4 521 nos 2939 6234 2829 2834 E 08955 903 O ma Xo me 4 me TA ACH 900 18 Meus UEM
26. 250 250 5 0 48 4 44 0 157 7 182 0 235 6 262 5 250 300 5 0 48 4 44 0 236 6 273 0 334 2 376 3 350 400 181 254 2600 6 0 21 2 20 0 197 9 192 5 250 225 0 0 33 4 30 0 210 1 202 5 250 250 5 0 48 4 44 0 225 1 216 5 250 250 78 9 91 0 176 7 172 5 250 250 157 7 182 0 254 9 280 0 300 350 60 2122 27892910 1979 1925 250 250 6 0 21 2 20 0 78 9 3 x 15 0 1952 176 EC so 212 200 157 7 182 0 254 9 280 0 300 350 5 6 0 21 2 20 0 236 6 273 0 353 5 393 6 400 400 0 0 33 4 30 0 78 9 91 0 210 1 202 5 250 250 0 0 33 4 30 0 157 7 182 0 254 9 280 0 300 350 0 0 33 4 30 0 236 6 273 0 353 5 393 8 400 400 5 0 48 4 44 0 78 9 91 0 225 1 216 5 250 250 5 0 48 4 44 0 157 7 182 0 254 9 280 0 300 350 5 0 48 4 44 0 236 6 273 0 353 5 393 8 400 400 6 0 21 2 20 0 212 6 204 7 250 250 0 0 33 4 30 0 224 8 214 7 250 250 5 0 48 4 44 0 239 9 228 7 250 250 78 9 91 0 191 4 184 7 300 300 157 7 182 0 271 4 295 0 350 350 236 6 273 0 370 0 408 8 450 450 1914 250 6 0 21 2 20 0 78 9 91 0 212 6 204 7 300 300 184 7 225 6 0 21 2 20 0 157 7 182 0 271 4 295 0 350 350 6 0 21 2 20 0 236 6 273 0 370 0 408 8 450 450 10 0 33 4 30 0 78 9 91 0 224 8 214 7 300 300 10 0 33 4 30 0 157 7 182 0 271 4 295 0 350 350 10 0 33 4 30 0 236 6 273 0 370 0 408 8 450 450 15 0 48 4 44 0 78 9 91 0 239 9 228 7 300 3
27. 7 3 10 2 10 2 10 50DW DY NB 2 10 2 10 2 10 2 10 2 10 50DJ DK NP 2 10 2 10 2 10 NOTE Weights include economizer Fig 2 Weight Distribution and Center of Gravity Field Fabricated Ductwork Units are designed for vertical supply return only Field fabricated ductwork should be attached to the roof curb Supply and return duct dimen sions are shown in Fig 3A 3C To attach ductwork to roof curb insert duct approxi mately 10 to 11 in up into roof curb Connect ductwork to 14 gage roof curb material with sheet metal screws driven from inside of the duct Secure all ducts to the building structure using flexible duct connectors between roof curb and ducts as required Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier Outlet grilles must not lie directly below unit discharge The return duct must have a 90 degree elbow before opening into the building space if unit is equipped with power exhaust Design supply duct strong enough to handle expected static pressures 5 UNIT 1 Roof curb is shipped unassembled MODEL ft in 2 Roof curb 14 gage VA03 56 steel 48DJ DK NP 3 Dimensions in are millimeters 50DW DY NB tS 50DJ DK NP 034 10 10 48DJ DK NP 44 7825 25 6 4893 16 0 50DW DY NB 044 NOTE To prevent the hazard of stagnant water build up in the 50DJ DK NP 7344 24 11 4141 13 71 5 graii pan of the indoor air section un
28. Fig 46 59 PILOT LIGHT OFF 48NP Units Only If pilots do not light as described in Heating section on page 41 be sure that pilot orifice is unobstructed then check for spark ignitor mal functions as follows 1 Turn off the control circuit breaker CCB to shut off con trol supply power to ignitor control pack ICP 2 Check that spark gap is in 5 inch 3 Check that ICP is securely grounded 4 Check that the high voltage lead is securely connected between the ICP and the electrode body 5 Turn on CCB to restore power to ICP Check that 24 v is supplied to terminal TH of the 6 Check unit label diagram for correct terminal usage if any wires are removed 47 o D E 5 2 5 g a 5 e COMPRESSOR SUCTION PRESSURE PSIG Fig 46 Charging Chart 034 Units System 1 One Condenser Fan Running COMPRESSOR DISCHARGE PRESSURE PSIG COMPRESSOR SUCTION PRESSURE PSIG Fig 47 Charging Chart 034 Units System 1 Condenser Fans Running NOTE ONE CONDENSER FAN RUNNING TOA TEMP OUTDOOR AIR e EBENE mm 8 HEH RIS EL 2 8 R eem y e ES ESLA 5 50 60 55 70 75 go COMPRESSOR SUCTION PRESSURE PSIG Fig 48 Charging Chart 034
29. CONTROL BOX ACCESS PANELS 4 5 8 117 33 AVAILABLE ALTERNATE FIELD WIRING 07 6 1 16 11541 0 4 102 998 BASE FRAME 0 1 3 8 DIA 34 9 A A LIFTING position 055 IN LIFTING sone FOR 2477 OVERALL LIFTING SHIPPING DIM 3 3 3 16 07 1 174 31 87 NPT DRAIN CONN 0 1 1 2 381 BOTH SIDES Fig 4B Base Unit Dimensional Drawing 50DJ DK NP034 044 Units 12 UNIT WEIGHT 6 mm mi fim mm mm mm 48DJD DKD NPD 8700 3946 19 7 717 22 07 2718 8 11 6541 21 5 48DJE NPE 054 8820 4000 9959 one 1163 3 91346 11 524 37 916 ane em esa 3 11 140 36 69 50DW DY NB 8250 3742 6045 19 10 7676 25 2 6 2830 6427 21 1 48DJD DKD NPD 9000 4082 7 717 22 07 271 11 41 21 5 48DJE NPE 9120 4137 i 07 1168 39 5 11 524 879 59 aao 36455 50DW DY NB 8550 3878 6045 19 10 7676 46 2830 6427 21 1 48DJD DKD NPD 9420 4273 401 21 0 22 07 3543 11 71 5715 18 9 48DJE NPE 074 9550 4332 1163 12 049 39 6 50DW DY NB 8970 4069 6477 21 3 25 2346 3694 12 154 5563 18 3 LEGEND Economizer End 6 0 except power exhaust units 10 0 CONN Connection For smaller service and operational clearances contact Carrier Product Engineering DIM Dimension Department M 4 Vertical dis
30. Condenser Fan Motor Rated Load Amps CV ETL IPM LRA MCA MOCP OFM RLA 0 694 0 751 0 918 1 000 0 840 0 918 1 000 0 915 Electric heat available on 50 Series vertical discharge units 240 t108 kW available on CV applications only 1 000 480 575 1 089 Electric heaters are tested and ETL approved at maximum total external static pressure of 1 9 in wg 2 Boldface indicates 48 and 50 Series units All other data is for 50 Series units only 21 Table 4 Electrical Data 044 Units 208 230 3 60 V Ph Hz BASE UNIT WITH COMPR COMPR BASE UNIT EXHAUST ELECTRIC EXHAUST FAN VOLTAGE NO 1 NO 2 ONLY FAN HEAT AND OR RANGE ELECTRIC HEAT Total Total Total 21 2 20 0 217 3 213 9 250 250 33 4 30 0 229 5 223 9 250 250 48 4 44 0 244 5 237 9 300 300 ER 78 9 91 0 196 1 193 9 250 250 24 2 75 220 308 28 0 46 2 42 0 59 4 54 0 aS oo 0 157 7 182 0 227 4 255 0 250 300 2 236 6 273 0 326 0 368 8 350 400 21 2 20 0 78 9 91 0 217 3 213 9 250 250 21 2 20 0 157 7 182 0 227 4 255 0 250 300 21 2 20 0 236 6 273 0 326 0 368 8 350 400 33 4 30 0 78 9 91 0 229 5 223 9 250 250 33 4 30 0 157 7 182 0 229 5 255 0 250 300 33 4 30 0 236 6 273 0 326 0 368 8 350 400 48 4 44 0 78 9 91 0 244 5 237 9 300 300 48 4 44 0 157 7 182 0 244 5 255 0 300 300 48 4 44 0 236 6 273 0 326 0 368 6 350 400 21 2 20 0 223 9 219 9 250 2
31. Connect the positive ter minal of a DC milliam meter to terminal S of the sensor Connect the negative terminal of a DC milliam meter to terminal Sg of the enthalpy board BASIC CHECK Refer to Fig 64 for control board com ponent identification NOTE plugs except P1 are labeled for easy identifi cation Plug P1 can be identified by its orange color 1 Turn unit power off Disconnect plug P1 from control board 2 Turn unit power on and check voltage across Pin R and Pin C at plug P1 If voltage reads 18 to 30 v skip to Step 5 Turn unit power off Disconnect plug P3 4 Turn unit power on and measure voltage across wires on plug P3 Pins 1 and 2 wires coming from the unit If voltage reads 18 to 30 v there is either a bad connection between plug P3 and control board or the control board is defective Verify the connection at this point and pro ceed to Step 5 If there is no voltage check the circuit breaker and transformer in the 24 v control circuit of the unit 5 Turn unit power off and disconnect plug 4 from the trol board 6 Switch scale on meter to read 115 v 7 Turn unit power on and check voltage across Pin 6 on plug 4 and unit ground wires coming from the unit If voltage reads 104 to 122 v there is adequate power avail able to the board Verify connection at this point and pro ceed to Step 8 If there is no voltage check the circuit breaker and transformer in
32. Flue deflector baffle must be assembled and installed on the access panel so that the holes in the mounting flange are at the bottom Install flue deflector hood over flue hoods Be sure that deflector scoop 15 pointed up UNIT SIZES 054 074 The 48 series high heat units have 2 large inlet hoods 2 small inlet hoods 3 flue hoods and 3 flue deflector hoods See Fig 27 and 28 The 48 series low heat units have one large inlet hood 2 small inlet hoods 2 flue hoods and 2 flue deflector hoods See Fig 27 and 28 Remove shipping block offs and shipping tape from open ings in access panels Inlet hoods are shipped unassembled and must be assembled in place See Fig 23 Inlet hoods consist of a hood 2 side plates and an inlet screen Install large and small inlet hoods using screws provided NOTE Hoods must be assembled in place on the access panel Flanges on hood and side plates go to the inside of the ac cess panel Install inlet screen in each inlet hood using speed clips and screws provided Attach flue hoods see Fig 24 to ac cess panel using screws provided Hoods go over each com bustion air outlet Sub assemble flue deflector baffle inside flue deflector hood as shown in Fig 29 Install flue deflector hoods over flue hoods See Fig 27 NOTE Be sure deflector hoods are installed as shown and not upside down The holes in the mounting flange must be at the bottom when installed on access panel INLET HOOD
33. If it trips determine cause of trouble before resetting Control Circuit 24 V This control circuit is pro tected against overcurrent by a 3 2 amp circuit breaker Breaker can be reset If it trips determine cause of trouble before resetting Electric Heat 50 Series Units Only OVERCURRENT Heaters are protected by fuses in the power circuit located in the heater control box As with cir cuit breakers determine the cause of fuses tripping before replacing them Do not replace with larger fuses All fuses are 60 amp OVERTEMPERATURE Heaters are protected by limit switches mounted in the heater box They reset automati cally once they cool Gas Heat 48 Series Units Only LIMIT SWITCHES The maximum supply air tempera ture is controlled by a limit switch located in the gas section The limit is designed to trip at 100 F above the maximum temperature rise shown in Tables 1A and 1B When the limit trips the gas valve is deenergized Once the unit cools the gas valve is reenergized ROLLOUT SWITCH This switch senses any flame or excessive heat in the main burner compartment and deen ergizes the gas valve If this occurs the gas heating system is locked out until the rollout switch is reset manually Reset by pressing the button on the rollout switch See Fig 39 When the rollout switch trips it likely indicates a flue block age Inspect the unit for any obstruction in the flue system for holes on th
34. L3 L3 L1 COMPRESSOR AMPS COMPRESSOR NO 1 1 1 L2 L3 COMPRESSOR NO 2 1 L2 L3 SUPPLY FAN AMPS EXHAUST FAN AMPS ELECTRIC HEAT AMPS L1 L2 L3 TEMPERATURES OUTDOOR AIR TEMPERATURE Dry Bulb DB WB Wet Bulb COOLING SUPPLY AIR F GAS HEAT SUPPLY AIR 48 SERIES UNITS ONLY F ELECTRIC HEAT SUPPLY AIR IF UNIT IS SO EQUIPPED F PRESSURES GAS INLET PRESSURE 48 SERIES UNITS ONLY IN WG GAS MANIFOLD PRESSURE 48 SERIES UNIT ONLY VALVE NO 1 IN VALVE NO 2 IN WG REFRIGERANT SUCTION CIRCUIT NO 1 PSIG CIRCUIT NO 2 PSIG REFRIGERANT DISCHARGE CIRCUIT NO 1 PSIG CIRCUIT NO 2 PSIG VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGES 47 49 GENERAL ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 1 PC 111 Catalog No 564 818 Printed in U S A Form 48 50D N 9SI CL 1 3 96 Replaces 48DJ DK 3Sl Tab 1 1 48 50NB NP 1SI 50DJ DK 9SI CUT ALONG DOTTED LINE
35. Selection DRAIN ASSEMBLY FACTORY SUPPLIED FIELD INSTALLED EN OF BASE RAIL Fig 6 Condensate Drain Location 16 GAGE METAL SEAL PLATE FACTORY SUPPLIED BOTTOM OF FIELD INSTALLED BASE RAIL Fig 7 Seal Plate Location 15 UNIT BASE RAIL PITCH DRAIN LINE TO OFFSET LINE FRICTION SEALANT DRAIN ASSEMBLY FACTORY SUPPLIED FIELD INSTALLED FIELD SUPPLIED ROOF MOUNT DRAIN 4 MIN 102 mm 4 MIN 105 mm SLAB MOUNT DRAIN Fig 8 Condensate Drain Piping Details OUTDOOR AIR HOOD RTV ALL HOODS Fig 9 Outdoor Air Hood BLADE LIMITER SCREWS FULLY CLOSED DAMPER Fig 10 Outdoor Air Damper Adjustments Inside of Hood Shown ENTHALPY SENSOR Fig 11 Enthalpy Sensor END ECONOMIZER HOOD UPPER HOOD ON 50 75 TON ENTHALPY SENSOR 105 100 95 90 85 80 75 70 65 60 55 50 45 40 5 DRY BULB TEMPERATURE APPROXIMATE FAHRENHEIT CONTROL CONTROL POINT CURVE Approx Deg AT 50 RH A 73 B 68 63 56 Fig 13 Chart for Enthalpy Control 16 24 VAC SUPPLY FROM CONTROL TRANSFORMER IN UNIT CONTROL BOX TO SENSOR SEE FIG 11 620 ohm JUMPER FROM ECONOMIZER HARNESS FROM ECONOMIZER HARNESS NOTES 1 Switches shown in high enthalpy state Terminals 2 and 3 close on enthalpy decrease
36. TRAN 9 PRIMARY HT A A A TRAN 2 ue S TRAN 2 24V lt 0510 J3 5 e 2 AMPS caw vel 8 12 2 8 HIR 645 gt PEAT RED 5 s HEAT OPTION 3e 25 Tez gt BRN O HIR2 25 O HIR Co GD 2 QD CRI 102 ut D 0502 D ora TRAN2 U2A 0FCI DUI orci bui 357 C2 25 27 29 ED GRA 208 230 064 074 380 074 35 37 39 1 W 644 0 373 BLU WHE Co 1 3 6 m ioa 6 WHT 2 WHT WHT TRANI 53 55 57 379 4 2 Wak WHT E2 0 61 WHT RFC 125 127 129 3 E 118 117 118 RED WHT 2 RC FAN OPTION 1 E x M me pm me 2 WHT KE 115 117 119 i i Ep 2 CONTROL 2 2 2 f E MODULATING POWER EXHAUST OPTION WIRING TB2 m m awe LECTRIC GAS HEAT OPTION ERIS XC 2 96 87 08 oFc1 pu2 am C2 orc N lt orca orc2 35 97 BLK ate 2 2 2 2 2 i 355 ELECTR
37. Units System 2 One Condenser Fan Running TILL LLL 2 20 1 NM sis 5 LLL HHTTILL i ies 5 TOR EG 150 4 MR E Fig 49 Charging Chart 034 Units System 2 All Condenser Fans Running COMPRESSOR DISCHARGE PRESSURE 519 111111 L 60 55 70 75 COMPRESSOR SUCTION PRESSURE PSIG Fig 50 Charging Chart 044 Units System 1 One Condenser Fan Running NOTE ALL CONDENSER FANS RUNNING TOA TEMP OUTDOOR AIR COMPRESSOR DISCHARGE PRESSURE PSIG 65 COMPRESSOR SUCTION PRESSURE PSIG Fig 51 Charging Chart 044 Units System 1 All Condenser Fans Running 48 NOTE CONDENSER FAN RUNNING TOA TEMP OUTDOOR AIR COMPRESSOR DISCHARGE PRESSURE PSIG ms LIL N COMPRESSOR SUCTION PRESSURE PSIG Fig 52 Charging Chart 044 Units System 2 One Condenser Fan Running 5 8 a 8 5 5 Fig 53 Charging Chart 044 Units System 2 All Condenser Fans Running 5004 NOTE ALL CONDENSER FANS RUNNING TOA TEMP OUTDOOR AIR 125 115 105 95 85 TOA 75 55 TOA
38. after 110 5 seconds evaporator fan motor shuts off 50 Series Units Unit power on system selector switch set at HEAT position fan switch set at AUTO position On a call for heating W1 on the thermostat closes and evaporator fan and the first stage of electric heat are ener gized On a further drop in room temperature W2 on the thermostat closes energizing the second stage of electric heat NOTE Units equipped with low electric heat option have only one stage Reset thermostat to a setting below room temperature Electric heat and evaporator fan shut off COOLING UNITS WITH ECONOMIZER With sub base switch set at COOL position and fan switch set at AUTO position evaporator fan is energized when Y1 on thermostat closes If enthalpy is below setting on enthalpy switch the economizer outdoor air dampers will modulate open to sat isfy the cooling requirement If outdoor air alone will not meet the cooling requirements Y2 on the thermostat will close energizing compressor no to work in conjunction with the modulating economizer to meet the cooling require ment While the unit is operating using outdoor air com pressor no 2 cannot be energized If enthalpy is above set ting on enthalpy switch the economizer outdoor air dampers move to the minimum ventilation position and condenser fan numbers and 2 cycle on and off as described in Cool ing Units Without Economizer section on page 41 NOTE If fan switch is O
39. at ON position continuous fan operation and setting the system selector switch to OFF position Then turn adjustment screw slowly until the damp ers assume the desired vent position Do not manually op erate the damper motor damage to the motor may result Economizer Damper Linkage Adjustment When replac ing economizer damper motors or if the linkage has come loose it is critical that the linkages be adjusted correctly They are sensitive and incorrect adjustment can cause the motor to stall NB NP Unit Minimum Position Set Point Minimum mizer position is set using the keypad and display module Refer to Control and Troubleshooting literature for more details 2 5 T p z r UNIT _ Ib kg mm ftin ftin mm mm ftin 48DJD DKD NPD 5641 50DW DY NB 5970 48DJD DKD NPD 6541 48DJE NPE 044 4497 14 97 8496 27 10 2328 7 7 2091 6 105 4706 15 5 3363 11 036 3769 12 436 4762 15 71 50DW DY NB 6620 UNIT mm 8 8 fe 48DJD DKD NPD 48DJE NPE 4741 15 6 6797 22 3 50DW DY NB 48DJD DKD NPD 48DJE NPE 5576 8 3 8015 26 3 6 50DW DY NB 5 10 1 4 0 5 13 16 0 10 11 16 1148 272 15 167 5 8 07 10 10151 2701 0 5 13 18 4 5 3 4 11481
40. dependent on length of current path There are no required 115 v field wiring connections there fore no provisions have been made in the unit for running 115 v wiring If any of the field installed options requiring 115 v connections are desired the unit must be modified in the field for 115 v wiring Options requiring 24 v or 115 v control wiring are listed below Building Pressurization or Smoke Purge Mode Refer to appropriate unit Controls and Troubleshooting literature as necessary for additional information See Fig 20 and unit wiring label for wiring details 1 Firestat or smoke detector field supplied normally closed switch 1 Remove factory installed jumper wire and wire a field supplied firestat or smoke detector con tactor between terminals 5 and 6 034 044 units or ter minals 2 and 3 054 074 units on terminal block 2 in the unit control box 2 Switch to drive economizer outdoor air damper fully open field supplied normally open switch 2 Wire a field supplied switch between terminals 8 and 9 on econo mizer motor no 1 When this switch is manually closed it will drive the outdoor air damper fully open 3 Switch to disconnect power to economizer motors field supplied normally closed switch 3 Wire a field supplied switch between terminal C on the economizer motor and Plug 8 Pin 2 PL8 2 4 Building pressurization switch field supplied normally open switch 4 Wire a field suppli
41. faulty Motor drives closed If re lays deenergize by motor does not drive closed the control board is faulty MOTOR PROCEDURE TEST A Turn enthalpy set point potentiometer to the A position B Turn enthalpy set point potentiometer to the D position Test 3 1 Apply 24 VAC power to terminals TO and T2 of the con trol board 2 Apply 24 v between terminals 1 and T2 and jumper ter minal TO to terminal 1 3 Remove the mixed air sensor connected between termi nals 51 and 52 and replace it with 8 5490 ohm resistor 4 Remove outdoor air enthalpy sensor between terminals and SO and replace it with a 1 2 kOhm resistor 5 Turn the minimum position potentiometer fully counter clockwise 6 Turn enthalpy set point potentiometer to the A setting 7 Refer to Table 15 Table 15 Economizer Control Board Checkout Test 3 MOTOR PROCEDURE TEST A Turn mixed air potenti ometer to the midpoint position EXPECTED RESULT AND RESPONSE Motor should drive to mid stroke with the set point set between 60 and 70 If not the control board is faulty Motor drives open If not the control board is faulty B Turn mixed air potentiometer fully counterclockwise 6 Turn mixed air potenti ometer fully clockwise Motor drives closed If not the control board is faulty Test 4 Refer to Table 16 for the correct procedure for test 4 Unit Control Board Checkout The following tools are
42. next to the condenser sec tion See Fig 16 and 17 The electric heater control box contains power terminal block HTB HTB1 HTB2 not used on all voltages 44 CROSSOVER TUBE 1111 1 1 1 1 78 alil ROLLOUT SWITCH Fig 39 Burner Section Detail 48 Series Units Only FLUE BOX BLOWER WHEEL FLUE OUTLET INDUCED DRAFT MOTOR eS Ti BURNER ASSEMBLY Fig 40 Flue Box Assembly 48 Series Units Only Shown with Burner Assembly Fig 41 Combustion Blower Removal fuse blocks FB1 FB2 etc fuses FU 3 per fuse block heater contactors etc plug No 20 PL20 HEATER 50 Series Units Only Access to the heater box is through the door on the left side sizes 034 and 044 or right side sizes 054 074 of the unit next to the con denser section See Fig 16 and 17 See Fig 42 for heater box contents NOTE Only the heater element contactors located in the heater box The heaters are located in the unit airstream 25 OUTDOOR AIR DAMPER Access to adjust the damper is through the hoods Remove filters to gain access into unit to adjust linkage arms MODULATING POWER EXHAUST DAMPER MOTOR The modulating power exhaust damper motor is located in the return air end of the unit On unit sizes 034 and 044 it is accessed by removing the access panel on the left hand corner post See Fig 35 IMPORTANT When
43. occu pied unoccupied and holiday periods See Schedule Func tion section in Controls and Troubleshooting literature for details on setting periods 7 Verify that control time periods programmed meet cur rent requirements 8 Check all electrical connections to be sure they are tight START UP General 1 Put the ON OFF switch in the ON position Close the con trol circuit breaker CCB which will energize the con trol circuit and the crankcase heaters 2 For PIC and VAV units refer to Controls and Trouble shooting literature for quick test details 3 Complete Pre Start Up section items and Start Up Check list Operating Sequences Base unit operating se quences are presented below Refer to unit Controls and Trouble shooting literature for details on VAV and PIC controls op eration COOLING UNITS WITHOUT ECONOMIZER Unit power on system selector switch set at COOL or AUTO position fan switch set at AUTO position On a for cooling 1 on the thermostat subbase closes energizing compressor no as first stage of cooling Com pressor no is always the larger of the 2 unit compressors If cooling load cannot be satisfied with only first stage cool ing Y2 on the thermostat will close energizing compressor no 2 Condenser fans are energized with compressor no 1 The no fan runs continuously while the unit is on mechanical cooling the no 2 fan is cycled on and off in response t
44. replacing panel be sure to prop erly secure it in order to prevent water from being drawn into the unit On unit sizes 054 074 the motor is accessed through the small door below the side economizer hoods on the left side of the unit See Fig 36 RETURN AIR FILTERS Access to these filters is through the door marked FILTER SECTION Filters in upper and lower bag filter tracks can only be removed from the left side of the unit when facing condenser end CONDENSER FANS AND FAN MOTORS Remove the wire fan guard on top of the unit to gain access to the con denser fans and motors INLET GUIDE VANE MOTOR The inlet guide vane mo tor is located on the evaporator fan sled on the side opposite the fan motor See Fig 43 Access is through the door la beled FAN SECTION on the left side of the unit 2 FB3 Ba Boo Da eoG OG LEGEND C Contactor PL20 FB Fuse Block FU Fuse HC Heat Element Contactor HTB Heater Terminal Block PL Plug Assembly 42 Typical Electric Heat Control Box 45 Cleaning Inspect unit at the beginning of each heating and cooling season and during each season as operating con ditions may require Clean condenser coil with a vacuum cleaner fresh water compressed air or a bristle brush not wire Coil cleaning should be a part of the planned maintenance progr
45. required to perform the troubleshooting tasks detailed in this section 5 v battery 2 sets of jumper wires with alligator clips Multimeter Toggle switch with 14 in wires terminated with V4 in spade connectors DANGER Read these instructions completely before attempting to troubleshoot the control board Failure to follow the steps precisely could result in damage to unit personal in jury or death The control board checkout procedure consists of 2 parts A basic check to verify availability of 24 and 115 v to the control board and a detailed check of each circuit within the board 53 Table 16 Economizer Control Board Checkout Test 4 MOTOR PROCEDURE EXPECTED RESULT TEST AND RESPONSE A Outdoor 1 Connect the enthalpy Milliammeter reading Air Sensor sensor terminal to should be between terminal on the motor 3 and 24 mA if the Connect the positive ter sensor is operating minal of a DC milliam correctly If the read meter to terminal S of ing is 0 mA the the sensor sensor is either Connect the negative wired backward or 15 terminal of a DC milliam defective meter to terminal So of the enthalpy board B Indoor 1 Connect the enthalpy Milliammeter reading Air Sensor sensor terminal to should be between 3 and 24 mA if the sensor is operating correctly If the read ing is 0 mA the sensor is either wired backward or is defective terminal on the motor
46. the 115 v control circuit of the unit 8 After verifying that 24 v and 115 v supply power is avail able to the control board turn unit power off and recon nect plugs P1 P3 and P4 Proceed to Detailed Check section below DETAILED CHECK NOTE Plug P1 must be disconnected in order to perform any of the troubleshooting steps detailed in this section To save time reconnect plug P1 only after you have completed all of the required troubleshooting 0 21 o Di6 o 1917 O BIS o 022 o 220 121 o 010191 112210 026 024 O 62 015510 21 01 o 00 ER Due o 200 LEGEND CLO Compressor Lockout P Plug SC Safety Circuit 5 of pormo e D12 2 JS ap 1 n J6 K6 V4 3 Elo DI 716 9053 o 4 nfo o O04 vlo 11 O 1 npzalo clo apsjo clo 01159 R O 1 1 10 e Fig 64 Control Board Component Arrangement Symptom Evaporator fan will not operate Turn unit power off and disconnect plug P1 from the con trol board 2 Install a jumper across Pin R and Pin G at plug P1 on the control board 3 Turn unit power on and check if the indoor evaporator fan contactor IFC coil has been pulled in If the con tactor has not been pulled in check the voltage across the IFC coil If there is v
47. turns NOTE Check the tension at least twice during the first day of operation as there is normally a rapid decrease in tension until the belts have run in Check tension periodically thereafter and keep it at the recommended tension With the correct belt tension belts may slip and squeal momentarily on start up This slippage is normal and dis appears after wheel reaches operating speed Excessive belt tension shortens belt life and may cause bearing and shaft damage 46 HOLDDOWN BOLTS Fig 44 Motor Plate Adjustment PULLEY ALIGNMENT For proper belt life the motor and fan pulleys must be properly aligned To check first turn off unit power Place a straightedge against the motor and fan pulleys See Fig 45 If the pulleys are properly aligned the straightedge should be parallel to the belts If they are not parallel check that the motor shaft and fan shaft are parallel If they are not adjust the motor plate ad justing bolts until they are After verifying that the shafts are parallel loosen the set screws on the motor pulley Move pulley on the shaft until the pulleys are parallel To move the sheave on the shaft loosen the belts If necessary blower sheave can also be moved on the shaft INSTALLING ALTERNATE MOTOR PULLEY Evapora tor Fan Only On all units the alternate motor pulley is field supplied To install the alternate pulley 1 Turn off unit power
48. with 1 in half coupling welded to it are shipped in the unit fan section Also included are 16 gage seal plates to cover the drain holes not being used Open the access door marked FAN SECTION to find the drain assem blies seal plates and 4 screws for each mounting taped to the unit basepan After the unit has been set in place on the roof Select the appropriate drain locations The 034 units have 6 drain holes 3 per side and the 044 074 units have 8 drain holes 4 per side Two holes on each side must be selected for condensate drains as shown in Fig 5 and the remaining holes must be sealed 2 Remove the drain assemblies and attach them to the bot tom of the unit base rails at the preferred drain locations using the screws provided See Fig 6 NOTE Use a trap at least 4 in deep 3 Cover the remaining drain holes with the seal plates and screws provided See Fig 7 4 Apply a bead of RTV or similar sealant around the drain assemblies and seal plates where they attach to the base rail See Fig 8 NOTE If unit is slab mounted holes will need to be drilled in the side of the base rail and the holes factory drilled in the bottom of the base rail will need to be plugged Install Outdoor Hoods UNIT SIZES 034 AND 044 25 Outdoor Air Hoods Option 1 Outdoor air hoods are shipped bolted to the unit in a ship ping position Remove the 6 screws holding each 25 air hood shipping cover in place 2 Repla
49. 00 15 0 48 4 44 0 157 7 182 0 271 4 295 0 350 350 15 0 48 4 44 0 236 6 273 0 370 0 408 8 450 450 LEGEND NOTES 1 Electric resistance heaters are rated at 208 240 v 480 v or 575 v To E Constant determine heater capacity kW at unit operating voltage multiply 240 v FLA Full Lead oratory 480 v or 575 v capacity by appropriate multiplier below Nominal Horsepower IFM Indoor Evaporator Fan Motor MULTIPLICATION LRA Locked Rotor Amps VOLTAGE MCA Minimum Circuit Amps for wire sizing HEATER kW DISTRIBUTION MULTIPLICATION MOCP Maximum Overcurrent Protection RATING 3 60 FACTOR OFM Outdoor Condenser Fan Motor RLA Rated Load Amps 200 0 694 Aw 240 208 0 751 Electric heat available on 50 Series vertical discharge units 230 0 918 108 kW available on CV applications only 240 1 000 440 0 840 480 0 918 480 1 000 0 915 575 1 000 1 089 Electric heaters are tested ETL approved at maximum total external static pressure of 1 9 in wg 2 Boldface indicates 48 and 50 Series units All other data is for 50 Series units only 19 VOLTAGE RANGE 414 508 28 8 Table 3 Electrical Data 034 Units cont 460 3 60 V Ph Hz 20 EXHAUST FAN h 1 92 99
50. 034 044 units the inlet guide vane differential pressure switch is located in the auxiliary control box The auxiliary control box is mounted in the corner of the unit under the side air hood that is next to the access door marked FILTER SECTION To gain access to the aux iliary box remove the auxiliary control box cover When re placing the auxiliary control box cover be sure to secure the cover properly in order to prevent water from being drawn into the auxiliary control box On 054 074 units the inlet guide vane differential pressure switch is mounted on an upright located behind the evaporator fan motor See Fig 43 BELT INSTALLATION AND TENSIONING IMPORTANT When installing or replacing belts al ways use a complete set of new matched belts to pre vent potential vibration problems Mixing belts often results in premature breakage of the new belts Turn off unit power Adjust motor plate so belts can be installed without stretch ing over the grooves of the pulley Forcing the belts can result in uneven belt stretching and a mismatched set of belts 3 Before tensioning the belts equalize belt slack so that it is on the same side of the belt for all belts Failure to do so may result in uneven belt stretching Tighten belts using the motor plate adjusting bolts Adjust until proper belt tension 1 2 in deflection with one finger is obtained Be sure to adjust both adjusting bolts the same number of
51. 16 56 0 0 33 4 30 4 46 2 310 1 0 334 304 42 0 305 9 0 334 304 0 484440 0 484 440 0 484 440 0 61 6 56 0 0 61 6 56 0 0 61 6 56 0 0 33 4 30 4 0 484 440 0 616 66 0 0 33 4 30 4 4 323 3 0 33 4 30 4 0 317 9 0 334 304 0 484 440 0 484440 0 484440 0 61 6 56 0 107 7 107 0 0 33 4 30 4 0 48 4 44 0 0 61 6 56 0 0 33 4 30 4 8 338 7 0 334 304 0 331 9 0 33 4 30 4 0 484440 0 484440 0 484440 0 61 6 56 0 0 61 6 56 0 0 61 6 56 0 0 33 4 30 4 0 48 4 44 0 0 61 6 56 0 0 33 4 30 4 0 351 9 0 334 304 0 3439 0 33 4 30 4 0 484440 0 484440 0 484440 0 61 6 56 0 0 61 6 56 0 0 61 6 56 0 28 ELECTRIC HEAT 78 9 91 157 7 182 236 6 273 78 9 91 157 7 182 236 6 273 157 7 182 0 236 6 273 0 78 9 91 157 7 182 236 6 273 78 9 91 157 7 182 236 6 273 236 6 273 0 78 9 91 0 157 7 182 0 236 6 273 0 78 9 91 0 157 7 182 0 236 6 273 0 78 9 91 0 157 7 182 0 236 6 273 0 78 9 91 0 157 7 182 0 236 6 273 0 78 9 91 0 157 7 182 0 236 6 273 0 78 9 91 157 7 182 236 6 273 78 9 91 157 7 182 236 6 273 236 6 273 0 78 9 91 0 157 7 182 0 236 6 273 0 343 5 336 3 358 5 349 9 371 7 361 9 310 1 305 9 310 1 305 9 353 5 393 8 343 5 336 3 343 5 336 3 353 5 393 8 358 5 349 9 358 5 349 9 358 5 393 8 371 7 361 9 371 7 361 9 371 7 393 8 356 7 348 3 371 7 361 9 384 9 3
52. 1783443 HOLSTWUSHL ans i 5 3016106 Ol ma 8 2 Nuo lt E NYO 8 e 541 5 5 14 1190 3NVA 30109 1 Mc E 1196 23 8 114 4 1 02804 1 4 5 914 5 6 ina gt gt ma EL Dp KENE ma 56 0114 OIA tar 01A C 01A lt E ola 4 236 2338 9 34 8 54 avans 2 6 16 UOISIRUSHL CN j SIND 2 65 we pi 4 5 YOLSIWUBHL NOI LONLSNOD Cw E OHer Cw vinis pouce E uo 5 Et TaNNVHO Qty Cw 95 508 58011491 2 z II A31 034 i 396 3 f 0154 Duna WHO 1 LVWSHOS 71091403 66 1409 UMOUS t 0 rS0 SHUN 04400 T3NNYHO 96 2 IP 1 3 L 83 410 4 MO IRAN 1 Si T3NNYHO 1 13 SP 313101
53. 2 When standard economizer is used with accessory differential en thalpy sensor set enthalpy control to D setting Fig 14 Wiring Connections for Solid State Enthalpy Sensor 57 077 B CAP CONNECTOR CONNECTOR ENTHALPY ENTHALPY CONTROL cR EA N POSITION MIXED AIR MAN SETTING THERMISTOR ADJUSTMENT ADJUSTMENT CLOCKWISE TO INCREASE Fig 15 Mixed Air Thermistor and Economizer Position Setting Adjustments Top of Economizer Motor FILTER SECTION SECTION EVAPORATOR COIL Field Wire Routing UNIT SIZES 034 AND 044 Field wiring can be brought into the unit through the basepan and roof curb or through the corner post in the side of the unit next to the control box A 3 1 2 in NPT coupling for field power and a 3 4 in NPT coupling for 24 v control wiring are provided in the basepan There are two 4 5 8 in knockouts in the corner post for field power wiring If field power wiring is brought through the roof curb route wiring out through one of the 4 5 8 in knockouts to the field supplied disconnect and then back into the unit through the other knockout See Fig 16 for recommended disconnect location If power wiring is brought through the side of the unit route wiring from field supplied disconnect through top 4 5 8 in knockouts into unit If control wiring is to be brought in through the side of the unit a 7 8 in diameter hole must be drilled in the corner post next to the
54. 2 is energized and a second coil in the main gas valve is ener gized This brings on an additional stage of heat When second stage thermostat is satisfied the second stage gas valve coil is deenergized When additional heat is needed on 054 074 units W2 is energized and pilot valve number 2 opens Gas flows to second stage pilot and spark ignitor ignites pilot flame Sensor de tects flame energizes the main gas valve coil and main gas valve number 2 opens Gas flows to main burners and second stage burners ignite Second stage spark ignitor shuts off When second stage thermostat is satisfied the second stage gas valve coil is deenergized When the first stage thermostat is satisfied first stage main gas valve and the pilot valve close Induced draft motor shuts off Time delay relay built into constant volume control board opens and timer sequence begins When sequence is com plete after 110 5 seconds evaporator fan motor shuts off 48 Series High Heat Units Unit power on thermostat sys tem switch set at HEAT or AUTO position and fan switch set at AUTO position First stage thermostat W1 calls for heat Time delay re lay built into constant volume control board controlling evaporator fan begins timer sequence approximately 55 10 second delay When time delay sequence is complete time delay relay closes and evaporator fan starts When evaporator fan starts airflow switch closes closing indu
55. 334 304 157 7 182 0 420 8 411 0 68 0 380 6 500 10 0 334 304 236 6 273 0 420 8 426 3 15 0 484 440 78 9 91 0 435 8 424 6 15 0 48 4440 157 7 182 0 435 8 4246 15 0 484 440 236 6 273 0 435 8 426 3 20 0 61 6 56 0 78 9 91 0 449 0 436 6 20 0 61 6 56 0 157 7 182 0 449 0 436 6 20 0 61 6 56 0 236 6 273 0 449 0 436 6 10 0 33 4 30 4 434 0 423 0 15 0 48 4 44 0 449 0 436 6 20 0 61 6 56 0 462 2 448 6 78 9 91 400 6 392 6 157 7 182 400 6 392 6 22 236 6 273 405 7 441 3 33 4 30 4 78 9 91 434 0 423 0 33 4 30 4 157 7 182 434 0 423 0 33 4 30 4 236 6 273 434 0 441 3 48 4 44 0 449 0 436 6 48 4 44 0 449 0 436 6 48 4 44 0 236 6 273 0 449 0 441 3 61 6 56 0 78 9 91 0 462 2 448 6 61 6 56 0 157 7 182 0 462 2 448 6 61 6 66 0 236 6 273 0 462 2 448 6 SSON 88 0 400 6 500 80 0 392 6 500 5 500 500 500 500 500 500 500 450 500 450 500 450 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 600 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 600
56. 450 400 20 0 61 6 56 0 157 7 182 0 351 6 340 6 450 400 187 254 20 0 61 6 56 0 236 6 273 0 370 0 408 8 450 450 10 0 33 4 30 4 338 8 329 0 400 400 15 0 48 4 44 0 353 8 342 6 450 450 20 0 61 6 56 0 367 0 354 6 450 450 78 9 91 0 305 4 298 6 400 400 157 7 182 0 305 4 312 5 450 450 100 33 4304 78 91 910 338 4329 0 400 400 185 3088 300 100 334 304 157 7 182 0 338 8 329 0 450 450 10 0 33 4 30 4 236 6 273 0 389 3 426 3 500 500 15 0 48 4 44 0 78 9 91 0 353 8 342 6 450 450 15 0 48 4 44 0 157 7 182 0 353 6 342 6 450 450 15 0 48 4 44 0 236 6 273 0 389 3 426 3 500 500 20 0 61 6 56 0 78 9 91 0 367 0 354 6 450 450 20 0 61 6 56 0 157 7 182 0 367 0 354 6 450 450 20 0 61 6 56 0 236 6 273 0 389 3 426 3 500 500 10 0 33 4 30 4 352 0 341 0 450 400 15 0 48 4 44 0 367 0 354 6 450 450 20 0 61 6 56 0 380 2 366 6 450 450 78 9 91 318 6 310 6 400 400 157 7 182 318 6 327 5 500 500 83 1884 2201 RR o 880 318 6 300 100 334 304 157 7 182 0 352 0 341 0 500 500 10 0 33 4 30 4 236 6 273 405 7 441 3 500 500 15 0 48 4 44 0 j 367 0 354 6 450 450 15 0 48 4 44 0 367 0 354 6 500 500 15 0 48 4 44 0 236 6 273 0 405 7 441 3 500 500 20 0 61 6 56 0 78 9 91 0 380 2 366 6 450 450 20 0 61 6 56 0 157 7 182 0 380 2 366 6 500 500 20 0 61 6 56 0 236 6 273 0 405 7 441 3 500
57. 476 21 9 6 6965 22 1095 NOTE prevent the hazard of stagnant water build up in the 50DJ DK NP 3367 110 7444 2457e 5933 19 grain pan of the indoor air section unit can only be pitched as CONDENSER D UNIT LEVELING TOLERANCES COMPRESSOR DIMENSIONS degrees and inches JE Dub CONDENSER AND COMPRESSOR COMPRESSOR END END From edge of unit to horizontal X 07 4 1287 881 104 6510 FIELD POWER 6 10 13 16 SEE NOTE 4 275 2 4 5 7 1 47 2134 1708 CONDENSER END SUPPORT 9 25 034 mE 0 5 1 4 Lo 1 1 4 32 0 1 15 16 5 1 0 10 13 16 275 0 7 8 22 3510 LOW VOLTAGE SEE NOTE 4 0 1 374 44 7 ALL SIDES BASE RAIL CROSS SECTION TYP ALL BASE RAILS SCALE 1 3 3 10 7 8 11913 07 10 16 256 TYPICAL 4 CORNERS 6 8 9 16 2046 5 5 3 16 116551 GASKET SUPPLIED WITH CURB 6 COUNTER FLASHING FIELD SUPPLIED 6 ROOF ING FELT FIELD SUPPLIED CANT STRIP FIELD SUPPLIED ROOF ING MATERIAL FIELD SUPPLIED 76 VIEW B CORNER CONNECTIONS AND 00 SPLICE PLATE CONNECTIONS RIGIO INSULATION FIELD SUPPLIED Fig 3B Roof Curb 054 074 Units UNIT LEVELING TOLERANCES DIMENSIONS degrees and inches DIMENSION X SIZE 054 064 0 10 6 From edge o
58. 48DJ DK NP034 074 50DJ DK DW DY NB NP034 074 Single Package Heating and Cooling Units Installation Start Up and Service Instructions COMMERCIAL UNITARY CONTENTS Page Page GENERAL cora uoto te Ye EUREN DA 2 COOLING UNITS WITH ECONOMIZER HEATING UNITS WITH ECONOMIZER SAFETY CONSIDERATIONS 2 VENTILATION AIR CIRCULATION Continuous Fan INSTALLATION 2 37 AUTOMATIC CHANGEOVER USING AUTOMATIC Rigging and Unit Placement 2 CHANGEOVER THERMOSTAT Roof Curb 2 Head Pressure Control 42 Roof Mount 2 SERVICE eaten 42 53 Slab Mount 2 Service Access ee RC ena 42 Positioning ET 3 COMPRESSORS Field Fabricated Ductwork 6 LIQUID SERVICE VALVES FILTER DRIERS AND Condensate Drains 10 SIGHT GLASSES Install Outdoor Hoods 10 UNIT SIZES 034 AND 044 UNIT SIZES 054 074 Outdoor Air Inlet Adjustments 10 MANUAL OUTDOOR AIR DAMPER ECONOMIZER SETTINGS Field Wire Routing 17 UNIT SIZES 034 AND 044 UNIT SIZES 054 074 Field Electrical Connections 17 POWER WIRING CONTROL WIRING Gas Piping 48 Series Units Only 36 Installing Flue Inlet H
59. 50 33 4 30 0 236 1 229 9 300 250 48 4 44 0 251 1 243 9 300 300 78 9 91 0 202 7 199 9 250 250 0 235 6 262 5 157 7 182 0 m 236 6 273 0 334 2 376 3 350 400 21 2 20 0 78 9 91 0 223 9 219 9 250 250 0 0 0 ocooolooooooooo 21 2 20 0 157 7 182 235 6 262 5 250 300 21 2 20 0 236 6 273 334 2 376 3 350 400 33 4 30 0 78 9 91 236 1 229 9 300 250 33 4 30 0 157 7 182 0 236 1 262 5 300 300 33 4 30 0 236 6 273 0 334 2 376 3 350 400 48 4 44 0 78 9 91 0 251 1 243 9 300 300 48 4 44 0 157 7 182 0 251 1 262 5 300 300 48 4 44 0 236 6 273 0 334 2 376 3 350 400 21 2 20 0 239 3 233 9 300 300 33 4 30 0 251 5 243 9 300 300 48 4 44 0 266 5 257 9 300 300 78 9 91 0 218 1 213 9 250 250 157 7 182 0 254 9 280 0 300 350 236 6 273 0 353 5 393 8 400 400 21 2 20 0 78 9 91 0 239 3 233 9 300 300 0 0 0 187 254 21 2 20 0 157 7 182 254 9 280 0 300 350 21 2 20 0 236 6 273 353 5 393 8 400 400 33 4 30 0 78 9 91 251 5 243 9 300 300 33 4 30 0 157 7 182 0 254 9 280 0 300 350 33 4 30 0 236 6 273 0 353 5 393 8 400 400 48 4 44 0 78 9 91 0 266 5 257 9 300 300 48 4 44 0 157 7 182 0 266 5 280 0 300 350 48 4 44 0 236 6 273 0 353 5 393 8 400 400 21 2 20 0 252 5 245 9 300 300 33 4 30 0 264 7 255 9 300 300 48 4 44 0 279 7 269 9 300 300 78 9 91 0 231 3 225 9 300 300 157 7 182 0 271 4 295 0
60. 500 at 208 240 v 480 575 v 1 Electric resistance heaters are rated at v Constant volame determine heater capacity kW at unit operating voltage multiply 240 v Full Load oratory 480 v or 575 v capacity by appropriate multiplier below H Nominal Horsepower Indoor Evaporator Fan Motor MULTIPLICATION FACTORS LRA Locked Rotor Amps MCA Minimum Circuit Amps for wire sizing HEATER kW MULTIPLICATION MOCP Maximum Overcurrent Protection RATING FACTOR OFM Outdoor Condenser Fan Motor RLA Rated Load Amps Electric heat available on 50 Series vertical discharge units 240 0 918 108 kW available on CV applications only 1 000 0 840 480 0 918 1 000 0 915 575 1 000 1 089 Electric heaters are tested ETL approved at maximum total external static pressure of 1 9 in wg 2 Boldface indicates 48 and 50 Series units All other data is for 50 Series units only 25 Table 5 Electrical Data 054 Units cont 460 3 60 V Ph Hz BASE UNIT WITH COMPR COMPR BASE UNIT EXHAUST ELECTRIC EXHAUST FAN VOLTAGE NO 1 NO 2 ONLY FAN HEAT AND OR RANGE ELECTRIC HEAT WORWORWORWODL SOWDOWOOWOOW 6 3 3 0 9 0 6 3 3 0 9 0 6 3 3 0 9 0 6 3 3 0 9 0 4 9 3 5 4 5 9 5 13 2 4 2 9 2 3 4 9 13 414 508 6020000000000
61. 500 600 500 600 500 1 Electric resistance heaters are rated at 208 240 v 480 v 575 v To determine heater capacity kW at unit operating voltage mu 480 v or 575 v capacity by appropriate multiplier below MULTIPLICATION FACTORS HEATER kW RATING MULTIPLICATION FACTOR 0 694 0 751 0 918 1 000 0 840 0 918 1 000 0 915 1 000 1 089 240 480 575 tiply 240 v Electric heaters are tested and ETL approved at maximum total external static pressure of 1 9 in wg 2 Boldface indicates 48 and 50 Series units All other data is for 50 Series units only 31 VOLTAGE RANGE 414 508 Table 7 Electrical Data 074 Units cont 460 3 60 V Ph Hz BASE UNIT WITH COMPR COMPR OFM BASE UNIT EXHAUST ELECTRIC EXHAUST FAN NO 1 NO 2 ONLY FAN HEAT AND OR ELECTRIC HEAT 2121 127 22 WORWORWORWODL SOWDOWOOWOOW oo00o0o00o0o00o0do000o0lll OOoUpooooouvooo N NOOO WORWORWORWOL 6020000000000 oooooo po ISIS OT O1 O1 WORWORWORWOR 253 0 32 09 3 N OOOOOO
62. 56010 SIOVINOO HY TY 381 3 3 0 5 00 ONY 344 3 0 3 01313 wane ng i esto us us syo _ xa n gt 1 lt H st 0 08 13153814 Xe 65 120 780 SHUN 2 BuuriM 04002 319 1 zal 01 lt E 014 lt E 281 9274 4 NYO 80 gt 880 92 NYO 2 9214 2 2 ma 9 18 gt 01 1 91 4 14 91 1140 3321404023 S Slld 1 01A 259 014 5 gt 01 5 1 038 OL T3NNVHO 1 4 8114 6 0 5 me gt gt 58 8 9 55 28 1 4 725332 35735 81 1140 on 8 1 y 1 21 13313 8 9 zal is a eee GIA 4 69 Cw 380
63. 73 9 323 3 317 9 323 3 317 9 370 0 408 8 356 7 348 3 356 7 348 3 370 0 408 8 371 7 361 9 371 7 361 9 371 7 408 8 384 9 373 9 384 9 373 9 384 9 408 8 372 1 362 3 387 1 375 9 400 3 387 9 338 7 331 9 338 7 331 9 389 3 426 3 372 1 362 3 372 1 362 3 389 3 426 3 387 1 375 9 387 1 375 9 389 3 426 3 400 3 387 9 400 3 387 9 400 3 426 3 385 3 374 3 400 3 387 9 413 5 399 9 351 9 343 9 351 9 343 9 405 7 441 3 385 3 374 3 385 3 374 3 405 7 441 3 400 3 387 9 400 3 387 9 405 7 441 3 413 5 399 9 413 5 399 9 413 5 441 3 BASE UNIT WITH EXHAUST FAN AND OR ELECTRIC HEAT 450 400 450 450 450 450 400 400 400 400 400 400 450 400 450 400 450 400 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 400 400 400 400 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 450 500 450 400 400 450 450 500 500 450 450 450 450 500 500 450 450 450 450 500 500 500 450 500 450 500 500 450 450 500 450 500 500 450 450 500 500 500 500 450 450 500 500 500 500 500 450 500 500 500 500 500 500 500 500 500 500 Table 6 Electrical Data 064 Units cont 460 3 60 V Ph Hz BASE UNIT WITH COMPR COMPR BASE UNIT EXHAUST ELECTRIC EXHAUST FAN VOLTAGE NO 1 NO 2 ONLY FAN HEAT AND OR RANGE ELECTRIC HEAT CO 02 CO CO gt CO
64. 8DJE NPE044 128 6 3267 48DJD DKD NPD054 48DJE NPE054 48DJD DKD NPD064 48DJE NPE064 48DJD DKD NPD074 48DJE NPE074 50DJ DK NP034 9950 4513 3 10 080 4572 3 134 7 3421 134 7 3421 5700 2585 5 84 8 2153 120 8 3067 6270 2844 1 76 4 1940 102 5 2604 121 5 3086 126 8 3221 50DW DY NB034 02 95 3216 22664 2753 50DJ DK NP054 8230 3733 1 120 8 3066 126 8 3221 02 654 3071 S0DW DY NBOS4 3221 50DJ DK NPO74 3495 S0DW DY NB074 2769 Includes optional economizer Fig 1 Rigging Label If roof curb is not used support unit with steel beams along Do not install unit in an indoor location Do not locate air its entire length and then support steel as required As a mini mum unit must be supported across its width at each lifting lug location Positioning Provide clearance around and above unit for airflow safety and service access Do not restrict top area above condenser fans in any way Allow at least 6 ft on all sides for rated performance code compliance and service inlets near exhaust vents or other sources of contaminated air On units equipped with or power exhaust option high ve locity air is exhausted out the hoods Unit should be posi tioned with at least 10 ft clearance between the exhaust hoods and any obstruction Although unit is weatherproof guard against water from higher level runoff and overhangs Table Physical Data 034 044 Units BASE UNIT NOMINAL CAPACITY tons O
65. Diameter Quantity 4 4 4 Rows Fins in Aluminum 2 17 0 3 17 0 3 17 0 3 17 0 Copper Optional 2157 3 15 7 3 15 7 3 157 Total Area sq ft 72 4 72 4 108 4 EVAPORATOR COILS Tube Diameter Quantity 2 2 Rows Fins in 4 17 0 4 17 0 Total Area sq ft 61 5 61 5 Refrigerant Feed Device 2 TXV 2 No per Circuit HEATING SECTION 48 Series Units Only Number of Heat Exchangers Input MBtuh Output MBtuh Temperature Rise Range F Efficiency Burner Orifice Diameter Quantity in drill no Pilot Orifice Diameter Quantity in drill no Firing Stages Number of Gas Valves CONDENSER FANS Quantity Diameter in Nominal Cfm Motor Hp Rpm EVAPORATOR FAN Nominal Cfm Maximum Allowable Cfm Maximum Allowable Rpm Shaft Diameter at Pulley in EVAPORATOR FAN MOTOR AND DRIVE Motor Hp Motor Frame Size Efficiency at Full Load Standard Efficiency High Efficiencyt Fan Pulley Pitch Diameter in Motor Pulley Pitch Diameter in Resulting Fan Rpm Belts Quantity Model No 48 Series and 50 Series Horizontal Discharge 50 Series Vertical Discharge Center Distance Range in 48 Series and 50 Series Horizontal Discharge 50 Series Vertical Discharge OPTIONAL POWER EXHAUST Quantity Motor Hp Motor Frame Size Efficiency at Full Load Fan Pulley Pitch Diameter in Motor Pulley Pitch Diameter in Shaft Diameter at Pulley in Resulting Fan Rpm M
66. END Economizer End 6 0 except power exhaust units 10 0 CONN Connection For smaller service and operational clearances contact Carrier Product En DIM Dimension gineering Department Dimension shown is for 48 series units On 50 series units dimension given 4 Vertical discharge ducts designed to be attached to accessory roof curb If is measured from economizer end of unit to drain connection closest to con unit is mounted on dunnage support the ducts using cross braces as done on the accessory roof curb 50DJ DK NP denser fans NOTES 5 When unit is slab mounted locate the condensate drain as low as possible 1 Dimensions are in millimeters on vertical face of base rail at the same location as the standard conden 2 Center of Gravity includes economizer Unit weight does not include sate drain using factory supplied fitting Plug factory drilled condensate economizer hole 3 Unit clearances Top Do not restrict condenser fans Control Box End 6 0 Sides 6 0 except power exhaust units 10 0 RM 074 ONLY 120 0 4 3 4 104 65 0 4 1 8 D FIELD POWER POWER 2032 1770 6 8 5 9 11 16 0189 BOTTOM 57 6 1 4 RETURN 23 aie BASERAIL 9717 BOTTOM SUPPLY AL ca SEE ROOFCURB CERTIFIED 0 2 15 18 DIMENSIONS 8 LOCATIONS 22 35 07 0 7 8 D LOW VOLTAGE 274
67. IC HEAT OPTION 1 PL4 1 PL20 1 249 us 8 O BIKE 4 PL20 4 HCl DUi PL20 5 9120 6 2 435 10 4 10 39 010 943 20 5 5 610 PLS 4 PL6 4 77 2 441 BLK REI BKE oxo ie L 2 PL7 4 WHT PER 125 127 129 RED D MODULATING POWER EXHAUST OPTION Fig 72 Typical Control Wiring Schematic 48 50NP 50NB Units 054 074 Shown cont 68 09r pue 06 80 t40 vS0 SHUN gNoS dNOS 8r 6010111 4 1551941 27 gt 6 e EHED 21 104000444 6 2 22 HOIH 8 89 2201 S TA w 4 l T ES 1 01140 1 3H Ju n J 5 81 4 0 4 TT gt 5 13 A 1 814 0 8114 1 39 1 0 LIND TA 2181 0 4 803 133 803 NY3 9 gm CEN m sti 33H rai He 0 p ne 8 3 1306 ZHI 584 2939 2934 282 2834 1
68. LICATION FAG TORS Locked Rotor Amps VOLTAGE Minimum Circuit Amps for wire sizing HEATER kW DISTRIBUTION MULTIPLICATION Maximum Overcurrent Protection RATING FACTOR Outdoor Condenser Fan Motor Rated Load Amps 3 0 694 0 751 0 918 1 000 0 840 0 918 1 000 0 915 Electric heat available 50 Series vertical discharge units 240 108 kW available on CV applications only 1 000 480 2 575 1 089 Electric heaters are tested and ETL approved at maximum total external static pressure of 1 9 in wg 2 Boldface indicates 48 and 50 Series units All other data is for 50 Series units only 33 CONTROL WIRING Install Carrier approved acces sory 24 v thermostat assembly according to the installation instructions shipped with the accessory Locate thermostat assembly to sense average temperature Route thermostat cable or equivalent leads of colored wire from subbase terminals to terminal board P1 The terminal board P1 is located on the constant volume control board on units with no econo mizer and on the economizer board on units with the econo mizer option Total wire lengths should not exceed the following limits 50 ft of 18 AWG 80 ft of 16 AWG or 125 ft of 14 AWG See Fig 19 for field wiring connections between the thermostat and the unit 24 v terminal block Once wire length from unit to thermostat is determined the length should be doubled to obtain total wire length required Voltage drop is
69. N Sr u nat ma i 4993 EHED mao ge ns 5 4 32 as bi ti _4 a lt 33404 a mas 1 quu 1 GEH HE T8 99 Ee 5 189 8 181 69 09 09 05 08 06 802 15 08 062 802 9I1VN3H2S 64 a OX o r oun 1409 0 60 SHUN 60092 009 81 oneueuos 7614 65 1 12238 wla 090553907 val 41 1 06 or 18 48 315 31015 66662 T 9 8 Hi OT 1 1 21d 9 gt gt 8 234 2179 Dy ws vn 51 4 014 3 014 014 oy 59 5174 d Ze 335 20 1710 3iV1udOddY 803 LIJNS iet 891340 319 329 1 074 9 lt 1 78 oo 5 ra O 4 na na 8 0234 SI 504 0 434 w gt i gt 0 01140 NY3 03
70. N position and the room thermostat is satisfied the outdoor air dampers move to the minimum position 42 HEATING UNITS WITH ECONOMIZER Operation is the same as described in Heating Units Without Econo mizer sections on page 41 except that the outdoor air damp ers move to the minimum position on a call for heat VENTILATION AIR CIRCULATION Continuous Fan Turn unit power on Set system selector switch at OFF HEAT or COOL position and set fan switch at ON position Evaporator fan contactor is energized through the switch on the thermostat and the evaporator fan runs continuously The damper moves to the minimum position AUTOMATIC CHANGEOVER USING AUTOMATIC CHANGEOVER THERMOSTAT Turn unit power on Set system selector switch at AUTO position When the temperature of the conditioned space rises to the cooling selector lever setting unit automatically switches from heating to cooling mode When the temperature of the conditioned space falls to the heating selector switch setting unit automatically changes from cooling to heating mode The thermostat is interlocked so that cooling and heating sys tems do not operate at the same time Head Pressure Control All units have a fan cy cling thermostat which cycles the no 2 condenser fan This switch opens at 60 3 and closes at 70 F 3 This allows the unit to operate down to 45 F outdoor ambient temperature NOTE Accessory 20 F Low Ambient K
71. NNN WORWORWORWOR 6555655655 Table 7 Electrical Data 074 Units cont 575 3 60 V Ph Hz BASE UNIT WITH COMPR COMPR BASE UNIT EXHAUST ELECTRIC EXHAUST FAN VOLTAGE NO 1 NO 2 ONLY FAN HEAT AND OR RANGE ELECTRIC HEAT NL OON O 1 6 N 0 01010 O O O 8 5553555655 5 OOOOOOOOOOOO 518 632 1 O 1 O 1 O 39 1 176 0 276 0 LEGEND NOTES ONWONWONWONW 5 8 8 9 6 ORA N IIS 1 Electric resistance heaters are rated at 208 240 v 480 v or 575 v de termine heater capacity kW at unit operating voltage multiply 240 v 480 v or 575 v capacity by appropriate multiplier below CV ETL ang LRA MCA MOCP OFM RLA Constant Volume ETL Testing Laboratory ominal Horsepower Indoor Evaporator Fan Motor MULTIP
72. O I CO I CO No a a I C2 CO CO TOTO TO 21021 En oooiivivooo Di su LEGEND NOTES Constant Volume 1 Electric resistance heaters are rated at 208 240 v 480 v or 575 v To ETL Testin LADO determine heater capacity kW at unit operating voltage multiply 240 v Full Load Amps 480 v or 575 capacity by appropriate multiplier below Nominal Horsepower Indoor Evaporator Fan Motor MULTIPLICATION FACTORS Locked Rotor Amps Minimum Circuit Amps for wire sizing HEATER kW Maximum Overcurrent Protection RATING Outdoor Condenser Fan Motor Rated Load Amps CV ETL deu IPM LRA MCA MOCP OFM RLA VOLTAGE DISTRIBUTION 3 MULTIPLICATION FACTOR 0 694 0 751 0 918 1 000 0 840 0 918 1 000 0 915 Electric heat available on 50 Series vertical discharge units 240 1108 kW available on CV applications only 1 000 480 575 1 089 Electric heaters are tested and ETL approved at maximum total external
73. PERATING WEIGHT Ib Base Unit 48 Series Low Heat 48 Series High Heat 50 Series Horizontal Discharge 50 Series Vertical Discharge With Economizer 48 Series Low Heat 48 Series High Heat 50 Series Horizontal Discharge 50 Series Vertical Discharge COMPRESSORS Quantity Type Capacity Steps Number of Refrigerant Circuits ie 044 2 060 17 33 00 86 83 100 40 5641 6541 5770 6670 5970 6620 5400 6050 5941 6841 6070 6970 6270 6920 5700 6350 Semi Hermetic 2 06E 25 50 79 100 REFRIGERANT Operating Charge Ib Sys 1 Sys 2 Without Hot Gas Bypass With Hot Gas Bypass CONDENSER COILS Quantity Rows Fins in Aluminum Copper Optional Total Face Area sq ft 29 0 29 0 31 0 29 0 40 0 40 0 42 0 40 0 Tube Diameter 2 2 EVAPORATOR COILS Quantity Rows Fins in Total Face Area sq ft Refrigerant Feed Device No per Circuit Ve in Tube Diameter HEATING SECTION 48 Series Units Only Number of Heat Exchangers Input MBtuh Output MBtuh Temperature Rise Range F 0 30 Efficiency Burner Orifice Diameter Quantity in drill no Pilot Orifice Diameter Quantity in drill no Firing Stages Number of Gas Valves CONDENSER FANS Quantity Diameter in Nominal Cfm Motor Hp Rpm EVAPORATOR FAN Nominal Cfm Maximum Allowable Cfm Maximum Allowable Rpm Shaft Diameter at Pulley in EVAPORATOR FAN MOTOR AND DRIVE Motor Hp 7 5 Motor Fram
74. S RAIL Fig 30 Shipping Brackets 034 044 Units and 50 Series Vertical Discharge 054 074 Units 38 Refrigerant Service Valves All units have a Schrader type service port on both suction lines Be sure that caps on the ports are tight All units have discharge and suc tion service valves on each compressor and a service valve on each liquid line Be sure the valves are open before start ing unit Crankcase Heaters The crankcase heaters must be firmly locked into the compressors The crankcase heaters are energized when there is power to the unit Crankcase heaters must be energized with discharge and suction serv ice valves open for at least 24 hours prior to unit start up in order to remove liquid refrigerant from the compressor crank case and to prevent oil foaming Compressor Oil Check that compressor oil is vis ible in the sight glass of the compressor All units are factory charged with oil See Table 8 Observe oil level closely at start up If oil level is below the sight glass and cannot be seen add oil until the level is approximately 1 4 of sight glass See Carrier Standard Service Techniques Refriger ants section for procedures to add or remove oil SHIPPING BRACKET FAN SLED RAIL I 71 5 15 16 EE CROSS pz ra U TYPICAL 4 PLACES R Fig 31 Shipping Brackets 48 Series 054 074 Units and 50 Series Horizontal Discharge 054 074 Units Table 8 Oil Charge
75. SIDE ONLY FLUE BOXES CONTROL BOX 173 1 8 ACCESS DOOR 48 SERIES AIR HOODS NEAR SIDE ONLY UNITS N 181081 A AIR HOODS 074 ONLY 16 8 1 2 3 SIDES lt 0 L ___ __ m 1 BAROMETRIC RELIEF ACCESS 0008 POWER EXHAUST BURNERS 55 1 FIELD SUPPLY ACCESS DOOR POWER 8 LOW BOTH SIDES 25 91 16 1 2 NPT GAS PIPE CONNECTION 48 VOLTAGE CONN G SERIES UNITS FRAMED RETURN AIR CONN t SUPPLY AIR DU CONN 2821 44401 BOTH SIDES 168151 25 CONN 9 4 3 8 14 6 13 16 TYP 4 PLCS 22 4 3 8 3841 CONTROL BOX 6121 ACCESS PANELS 2 0 1 8 ECONOMIZER OPTION AIR HOODS 3 SIDES BASE FRAME 23241 7 7 1 2 LIFTING POSITION 24131 7 11 124761 8 1 1 2 OVERALL LIFTING SHIPPING DIM 0 1 3 8 35 1 DIA HOLE IN LIFTING LUGS RETURN AIR OPTION CHOODS FIELD INSTALLED FOR 31 8 0 1 1 4 NPT DRAIN CONN Fig 4C Base Unit Dimensional Drawing 48DJ DK NP 50DW DY NB054 074 Units 13 5537 162 1163 595 10 34 47 9 4 10 092 33 15 176 3824 5969 21 3 1163 3 976 11 37 474 12 29 11 001 36 1 14 875 LEG
76. T Table 5 Electrical Data 054 Units 208 230 3 60 V Ph Hz BASE UNIT WITH BASE UNIT EXHAUST ELECTRIC EXHAUST FAN VOLTAGE ONLY FAN AND OR RANGE ELECTRIC HEAT ae Total 310 2 303 0 400 400 48 4 44 0 325 2 316 6 400 400 46 2 276 8 350 42 0 272 6 350 59 4 290 0 350 54 0 284 6 350 61 6 56 0 338 4 238 6 400 400 78 9 91 276 8 272 6 350 350 2 157 7 182 276 8 280 0 350 350 236 6 273 353 5 393 8 400 400 33 4 30 4 78 9 91 310 2 303 0 400 400 33 4 30 4 157 7 182 310 2 303 0 400 400 33 4 30 4 236 6 273 353 5 393 8 400 400 48 4 44 0 5 325 2 316 6 400 400 48 4 44 0 325 2 316 6 400 400 48 4 44 0 353 5 393 8 400 400 61 6 56 0 338 4 328 6 400 400 61 6 56 0 157 7 1820 338 4 328 6 400 400 61 6 56 0 236 6 273 0 353 5 393 6 400 400 33 4 30 4 323 4 315 0 400 400 48 4 44 0 338 4 328 6 400 400 61 6 56 0 351 6 340 6 450 400 78 9 91 290 0 284 6 350 350 157 7 182 290 0 295 0 350 350 236 6 273 370 0 408 8 450 450 33 4 30 4 78 9 91 323 4 315 0 400 400 10 0 10 0 33 4 30 4 157 7 182 323 4 315 0 400 400 10 0 33 4 30 4 236 6 273 370 0 408 8 450 450 15 0 48 4 44 0 338 4 328 6 400 400 15 0 48 4 44 0 338 4 328 6 400 400 15 0 48 4 44 0 236 6 273 0 370 0 408 8 450 450 20 0 61 6 56 0 78 9 91 0 351 6 340 6
77. UNIT SIZE OIL CHARGE pints 034 16 8 each circuit 044 28 14 each circuit 054 33 19 ckt 1 14 ckt 2 064 38 19 each circuit 074 38 19 each circuit If oil charge is above sight glass do not remove any oil until the compressor crankcase heater has been on for at least 24 hours When additional oil or a complete charge is needed use only Carrier approved compressor oil Approved oils Texaco tees Capella WF 32 Shrieve Chemical Co Zerol 150 Synthetic es ed Suniso 3GS Do not reuse drained oil and do not use any oil that has been exposed to the atmosphere Gas Manifold Pressure 48 Series Units Only Check pressure to ensure it matches the pressure stamped on the valve body See Gas Valve Adjustment section on page 50 for more details Unit Voltage Be sure power source agrees with the unit nameplate rating Leak Test and Dehydration Be sure there are no refrigerant leaks All units are shipped with a complete op erating charge of R 22 Tables 1A and 1B and should be under sufficient pressure for leak testing after installation If there is no system pressure add refrigerant until a pressure is observed and then check for leaks After leaks are re paired remove and recover refrigerant from the system For leak testing procedures see Carrier Standard Service Tech niques Refrigerants section Do not use the system com pressors to remove refrig
78. X OPENING 0 7 8 22 21 DIA 0 3 1 2 88 91 FIELD POWER 48 SERIES UNITS 48 SERIES UNITS AIR HOODS CONTROL BOX 57 10 5 8 48 SERIES UNITS 17941 0 3 9 16 901 5 8 5 15 GAS BURNERS 48 SERIES 117351 UNITS NPT GAS PIPE CONN L RETURN AIR SUPPLY AIR DUCT CONN CONN 7 7 11 16 ECONOMIZER OPTION 2329 AIR HOODS 3 SIDES E 167 SIDE HOODS FIELD INSTALLED 0 4 5 87 1117 31 1 gt AVAILABLE ALTERNATE 84 2413 LIFTING POSITION 8 1 1 2 2477 OVERALL LIFTING SHIPPING DIM LUGS FIELD WIRING 12801 7 ia 2 3 3 16 23241 9 9961 BASE FRAME 11021 7 11 0 1 3 8DIA 34 9 HOLE IN LIFTING A A FoR CONTROL BOX ACCESS PANELS 0 1 1 4 31 81 5 NPT DRAIN CONN 0 1 1 2 1381 BOTH SIDES Fig 4A Base Unit Dimensional Drawing 48DJ DK NP 50DW DY NB034 044 Units 11 WEIGH TA al E 50DJ DK NP 0 5 13716 0 10 11 16 LEGEND CONN Connection DIM Dimension NOTES 1 Dimensions in are in millimeters Center of Gravity includes economizer Unit weight does not include economizer 3 Unit clearances Top Do not restrict condenser fans Control Box End 6 0 Sides 6 0 oo End 6 0 except power exhaust units 2 2 5 16 668 For small
79. XIMUM 034 15 000 044 20 000 054 25 000 064 30 000 074 30 000 BLOWER PULLEY Size in 16 1 15 5 RES 13 7 18 5 16 1 15 5 13 7 18 5 16 1 15 5 13 7 16 1 15 5 15 5 40 50 Series Vertical Discharge Units 48 Series and 50 Series Horizontal Discharge Units 18 132 112 123 132 5VX 123 132 5VX 3 125 5VX Bok 0 1 Condenser Fans and Motors Each unit has mul tiple condenser fans and motors these are positioned at the factory See Fig 32 for correct location of fan in orifice Check that fan propeller rotation is correct it should be counter clockwise when facing the fans If fan propeller rotation is incorrect switch motor leads Return Air Filters Check that the correct filters are installed in the filter rack See Tables 1A and 1B for quan tities and sizes Access is through the door marked FILTER SECTION Do not operate the unit without return air filters Economizer Inlet Screens Check that they are in place before operating the unit Economizer Dampers With no power to the unit the economizer outdoor air dampers should be fully closed Check by opening the access door marked FILTER SEC TION On units with economizer be sure economizer mini mum position is set at the desired setting Be sure hood is installed properly 25 Outdoor Air Damper On units without econo mizer be sure 25 outdoor air damper is set at the des
80. YS 48 Series Units Only COMBUSTION AIR BLOWER 48 Series Units Only ECONOMIZER DAMPER MOTOR ELECTRIC HEATER CONTROL BOX 50 Series Units Only HEATER BOX 50 Series Units Only 25 OUTDOOR AIR DAMPER MODULATING POWER EXHAUST DAMPER MOTOR RETURN AIR FILTERS CONDENSER FANS AND FAN MOTORS INLET GUIDE VANE MOTOR Cleaning sonet ee 45 Lubrication ens 45 COMPRESSORS FAN SHAFT BEARINGS INLET GUIDE VANE BEARINGS Units With Optional Inlet Guide Vanes FAN MOTOR BEARINGS DOOR HINGES Adjustments 46 EVAPORATOR FAN AND POWER EXHAUST MOTOR PLATE MODULATING POWER EXHAUST DIFFERENTIAL PRESSURE SWITCH INLET GUIDE VANE DIFFERENTIAL PRESSURE SWITCH Units With Optional Inlet Guide Vanes and Static Pressure Control BELT INSTALLATION AND TENSIONING PULLEY ALIGNMENT INSTALLING ALTERNATE MOTOR PULLEY Evaporator Fan Only CONDENSER FAN ADJUSTMENT 25 OUTDOOR AIR DAMPER REFRIGERANT CHARGE PILOT LIGHT OFF 48 Series Units Only Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 564 818 Book 1 1 PC 111 Tab 06 Printed in U S A Form 48 50D N 9SI Pg 1 3 96 Replaces 48DJ DK 3Sl 48 50 1 1 50DJ DK 9SI CONTENTS cont AUTOMATIC PILOT ADJUSTMENT 48 Series Units Only GAS VALVE ADJUSTMENT 48 Ser
81. aft Diameter at Pulley in 15416 136 136 Resulting Fan 843 1040 1264 Maximum Allowable Rpm 1300 1300 1300 Belts Quantity No 2 3VX670 2 3VX670 2 3VX710 FILTERS Standard Efficiency Throwaway Standard 12 20 x 25 x2 12 20 x 25 x2 Quantity Size in 4 16 x 20x2 4 16 x 20x 2 Medium Efficiency 30 Pleated Optional 12 20 x 25x 2 12 20 x 25 x 2 Quantity Size in 4 16 x 20 x 2 4 16 x 20x 2 High Efficiency 90 Bag Filters with Prefilters Optional 6 20 x 24 x 22 6 20 x 24 x 22 Quantity Size in 6 20 x 20 x 22 6 20 x 20 x 22 TXV Thermostatic Expansion Valve Data is for all 48 and 50 Series units of the size listed unless otherwise specified tNot available on 575 v units BASE NOMINAL CAPACITY tons OPERATING WEIGHT Ib Base Unit 48 Series Low Heat 48 Series High Heat 50 Series Horizontal Discharge 50 Series Vertical Discharge With Economizer 48 Series Low Heat 48 Series High Heat 50 Series Horizontal Discharge 50 Series Vertical Discharge COMPRESSORS Quantity Type Capacity Steps Number of Refrigerant Circuits Table 1B Physical Data 054 074 Units 2 06E 20 40 80 100 Semi Hermetic 2 06E 17 33 83 100 14 2 06 28 s 85 100 REFRIGERANT Operating Charge Ib Sys 1 Sys 2 Without Hot Gas Bypass 59 0 44 5 61 0 61 0 70 5 64 5 With Hot Gas Bypass 62 0 44 5 64 0 61 0 73 5 64 5 CONDENSER COILS 3840 Tube
82. air damper fully open normally open Switch 3 Switch to disconnect power to economizer motors Drives economizer outdoor air damper fully closed normally closed Switch 4 Building pressurization switch energize evaporator fan motor normally open Switch 5 Switch to isolate evaporator fan motor normally closed Switch 6 Switch to energize power exhaust motors normally open Switch 7 Switch to fully open power exhaust damper normally open 34 LEGEND Contactor DPS Differential Pressure Switch DMS Damper Motor Switch ECON Economizer IFC Indoor Evaporator Fan Contactor MPE Modulating Power Exhaust NC Normally Closed NO Normally Open PEC Power Exhaust Contactor Coil PL Plug SW Switch TB Terminal Block TRAN Transformer NOTES 1 Power exhaust option can be unit mounted on vertical supply return units only is field wiring is field wiring Switches 1 7 are field supplied For building pressurization field supplied power source must drive room terminals wide open 034 AND 044 UNITS TB2 SWI TB2 8 0 0 48 PL8 2 BLU ECON MOTOR SW3 REMOVED FROM C SW4 TB2 p o BASE UNIT REMOVED FROM TRAN 3 SWS HSV QP TRAN 3 OPTIONAL NON MODULATING EXHAUST Fig 20 Field Wiring for Building Pressurization and Smoke Purge 054 074 UNITS
83. al protector to protect it against excessively high discharge gas temperatures Each compressor has an external dis charge gas thermostat See Fig 62 They will reset but the circuit will automatically be locked out by the control board Unit must be manually reset by interrupting control power Crankcase Heater Each compressor has a crankcase heater to prevent absorption of liquid refrigerant by oil in the crank case when the compressor is idle Since 115 v power for the crankcase heaters is drawn from the unit control circuit main unit power must be on for the heaters to be energized IMPORTANT After a prolonged shutdown or service job energize the crankcase heaters for 24 hours before starting the compressor Compressor Lockout If any of the safeties compressor internal thermostat 06D compressors only high pressure or low pressure trip or if there is a loss of power to the compressors the compressors will be locked out To reset DJ DW units manually move the thermostat setting To re set DK DY NB NP units consult the controls and trouble shooting literature for the appropriate unit for details EVAPORATOR FAN MOTOR PROTECTION A manual reset calibrated trip magnetic circuit breaker protects against overcurrent Do not bypass connections or increase the size of the breaker to correct trouble Determine the cause and correct it before resetting the breaker CONDENSER FAN MOTOR PROTECTION Each
84. am Clean evaporator coil with a stiff bristle brush not wire vacuum cleaner or compressed air Check and clean condensate drain annually at the start of the cooling season Replace return air filters at the start of each heating and cooling season or as often as necessary during each season depending on operating conditions See Tables 1A and 1B for filter types quantities and sizes 1 Remove economizer outdoor air filters from the hoods by removing the filter retainers 2 Clean filters with steam or hot water and mild detergent 3 Reinstall filters in hoods after cleaning Never replace clean able filters with throwaway filters Lubrication COMPRESSORS Each compressor is correctly charged at the factory Refer to 06D and 06 Compressor Service Manuals if additional information regarding compressor lu brication system is required See Compressor Oil section on page 38 and Table 8 FAN SHAFT BEARINGS Lubricate fan shaft bearings at least once a year with suitable bearing grease Extended grease lines are provided on pulley side of blower Typical lubri cants are given below MANUFACTURER LUBRICANT Texaco Regal AFB 2 Mobil Mobilplex EP No 1 Sunoco Prestige 42 Texaco Multifak 2 Preferred lubricant because it contains rust and oxidation inhibitors INLET GUIDE VANE BEARINGS Units With Optional Inlet Guide Vanes These bearings are oil impregnated Lubricate annually with a few drops of nondete
85. and must be replaced NOTE The control board part number HK37AA001 has no time delay 5 If there is continuity between these points the problem is at the connection at plug P4 or external to the control board 6 Turn unit power off Reconnect plugs 1 and 0 06 12 e J2 To 4 1918 015 a 077 1015 222 520 a 021 018 026 a 024 025 223 01 04 O RZ O 0105 ES 93 o K6 01 4 2 K1 Y2 2 6 01158 o R 03158 P LEGEND CLO Compressor Lockout Plug SC Safety Circuit Fig 65 Compressor Lockout Connections 56 LEGEND FOR FIG 66 73 Accessory Building Pressure Contactor Circuit Breaker Control Circuit Breaker Check Filter Switch Compressor Lockout Common Communication Plug Compressor Condenser Control Relay Centrifugal Switch Constant Volume Duct Pressure Discharge Pressure Transducer High Voltage Relay Module Dummy Enthalpy Control Equipment Fan Status Switch Fuse Ground Gas Relay Hydronic Humidifier Relay Heat Interlock Relay High Pressure Switch Heater Relay Keypad and Display Module High Voltage Hydronic Ignitor Ignitor Control Pack Induced Draft Contactor Induced Draft Motor In
86. aximum Allowable Rpm Low Heat 12 540 432 5 35 80 12 1285 30 2 076 48 2 2 15 0 254T 84 5 90 0 13 7 4 5 555 810 648 15 45 80 3 4 30 40 000 1 0 1140 17 500 25 000 750 1 2 5VX1120 2 5VX1230 48 25 44 00 44 25 39 75 Centrifugal 18 x 15 in 2 5 0 184 64 0 10 6 4 5 1216 740 925 High Heat 18 18 1285 30 3 076 2 Low Heat 12 540 432 5 35 80 12 1285 30 High Heat 18 810 648 15 45 80 18 1285 30 54 43 48 2 076 48 3 076 48 2 3 2 Propeller Type 4 30 40 000 1 0 1140 Centrifugal 30 x 27 in 21 000 30 000 750 16 Any motor available on any unit 0 0 25 0 256T 284 87 5 87 1 91 0 91 7 13 7 13 7 5 1 5 5 625 660 2 5VX1150 2 5VX1150 2 5VX1230 2 5VX1230 48 25 44 00 44 25 39 75 48 50 44 25 44 00 40 00 213T 82 9 10 6 5 0 1746 820 925 Low Heat 12 5 35 80 12 1285 30 2 076 48 2 Any motor available on any unit 2 7 5 High Heat 18 0 810 2 648 15 45 80 18 1285 30 3 076 48 2 3 5 30 50 000 1 0 1140 24 500 30 000 750 116 30 0 286T 88 3 92 4 15 5 5 9 700 2 5VX1180 2 5VX1230 48 50 44 25 44 00 40 00 2 10 0 215T 85 6 10 6 5 6 1746 920 925 FILTERS Standard Efficiency Throwaway Standard Quantity Size in Medium Efficiency 30 Pleat
87. ce the 6 screws 3 Remove the holddown screw from each upper corner of each hood 4 Pivot hoods outward 2 hoods total 5 Install 17 screws around outside of each hood Screws are in the fastener package taped to the basepan inside the fan section 6 Apply a bead of RTV or similar sealant to corner of each hood at pivot point to prevent water leaks See Fig 9 Economizer Hoods Units With Economizer Option Fol low the same procedure described in 25 Outdoor Air Hoods section above UNIT SIZES 054 074 25 Outdoor Air Hoods The outdoor air hoods are fac tory installed on the 054 074 units Economizer Hoods Units With Economizer Option 1 Remove the 6 screws holding each of the 4 economizer shipping covers in place 2 Replace the screws Units Without Economizer 10 3 Remove the holddown screw from each upper corner of each economizer hood 4 Pivot hoods outward There is a total of 4 hoods 5 Install 18 screws 5 each side 6 top and 2 bottom around the outside of each hood Screws are in the fastener pack age taped to the basepan inside the fan section 6 Apply a bead of RTV or similar sealant to corner of econo mizer hood at pivot point to prevent water leaks See Fig 9 Outdoor Air Inlet Adjustments MANUAL OUTDOOR AIR DAMPER Units Without Econo mizer Option All units except those equipped with a factory installed economizer have a manual outdoor air da
88. ced draft contactor and induced draft motor starts Centrifugal switch closes Pilot valve opens allowing gas to flow to first stage pilot Spark ignitor ignites pilot flame Sensor detects flame energizes main gas valve coil and main gas valve opens Gas flows to main burners and first stage burners ignite Spark ignitor shuts off and pilot remains on The spark ignitor will continue to spark for 90 seconds until pilot flame is sensed If the pilot fails to ignite or the sensor fails to detect flame the pilot valve closes and the spark ignitor shuts off for 300 seconds 5 minutes During this time the induced draft motor remains on to purge any unburnt gas from the combustion tubes This ignition se quence will repeat indefinitely When additional heat is needed W2 is energized Pilot valve no 2 opens allowing gas to flow to second stage pi lot Spark ignitor ignites pilot flame Sensor detects flame energizes main gas valve coil and main gas valve no 2 opens Gas flows to main burners and second stage burners ignite Second stage spark ignitor shuts off When the second stage thermostat is satisfied W2 is deenergized and the second induced draft motor and gas valve are shut off When the first stage thermostat is satisfied first stage main gas valve and the pilot valve close Induced draft motor shuts off Time delay relay built into constant volume control board opens and timer sequence begins When sequence is com plete
89. charge ducts designed to be attached to accessory roof curb If unit is mounted Dimension shown is for 48 series units On 50 series units dimension given is measured from economizer end of unit to drain connection closest to condenser fans NOTES 1 Dimensions in are in millimeters 2 Center of Gravity includes economizer Unit weight does not include economizer 3 Unit clearances Top Do not restrict condenser fans Control Box End 6 0 Sides 6 0 except power exhaust units 10 0 1481 1583 0 5 13 16 5 2 5 16 BOTTOM RETURN dunnage support the ducts using cross braces as done on the accessory roof curb 5 When unit is slab mounted locate the condensate drain as low as possible on vertical face of base rail at the same location as the standard condensate drain using factory supplied fitting Plug factory drilled condensate hole 1191 37 10 7 8 120 0 4 3 4 104 653 0 4 1 8 D FIELD POWER POWER 20321 1770 6 8 5 9 11 16 CONTROL 10 65 BOTTOM i 50 5 6 1 4 RETURN BASERAIL 279 U48 o n BOTTOM SUPPLY e 0 5 13 16 ROOFCURB CERTIFIED 0 2 15 1 07 10 3 4 4 1 1 2 DIMENSIONS LOCATIONS 22 351 0 0 7 6 D LOW VOLTAGE 5 ACCESS DOOR ACCESS 0008 2 Te POWER EXHAUST NEAR SIDE ONLY ACCESS DOOR NEAR SIDE ONLY 6 ON FAR
90. condenser fan motor is internally protected against over temperature They are also protected against a severe over current condition by manual reset calibrated trip magnetic circuit breakers on a common circuit As with the circuit break ers do not bypass connections or increase breaker size to correct trouble Determine the cause and correct it before resetting the breaker HIGH AND LOW PRESSURE SWITCHES See Fig 62 for compressor mounting locations Settings for these switches are shown in Table 11 If either switch trips that refrigerant circuit will be automatically locked out by the controls To reset interrupt control power NOTE When a pressure transducer is used the low pres sure trip point is the same as the low pressure switch Relief Devices units have relief devices to pro tect against damage from excessive pressures 1 e fire These devices protect the high and low side UNLOADER COILS LOW PRESSURE DISCHARGE LOW PRESSURE SWITCH G 1 AS THERMOSTAT SWITCH UNLOADER UNLOADER IL COILS 60 065 6 CYL PRESSURE PRESSURE PRESSURE PRESSURE SWITCH SWITCH SWITCH SWITCH Fig 62 Typical Compressor Overtemperature High and Low Pressure Switch Locations Table 11 Pressure Switch Settings psig SWITCH CUTOUT CUT IN High 426 7 320 20 Low 67 7 Control Circuit 115 This control circuit is pro tected against overcurrent by a 5 amp circuit breaker Breaker can be reset
91. control board possibly the pressure switches If there is continuity pro ceed to Step 3 3 Reconnect the wires removed in Step 1 4 With the unit power still off disconnect plug P1 from con trol board Install a jumper wire across Pin R and Pin Y1 at plug P1 on the control board 5 Connect a voltmeter across the coil for compressor no 1 contactor 6 Energize unit and monitor the voltage for a few seconds IMPORTANT Do not run compressor too long 7 a If proper voltage is indicated at the contactor but con tactor fails to close replace contactor b If voltage is indicated for a few seconds i e the con tactor momentarily pulls in and is then deenergized the compressor lockout CLO logic has shut down the unit This is an indication that the board is not sens ing proper compressor current or that one of the safe ties has tripped Proceed to Step 8 to verify compres sor lockout logic operation If proper voltage is indicated at the contactor and tactor closes the board is operating properly 8 To verify compressor lockout logic a Disconnect CLO sensor wires connected to at the control board Check wires for continuity If there is no continuity replace the sensor b Connect the multimeter to read voltage between Pin X at plug 1 and ground c Turn unit power on and check the multimeter Within a few seconds the meter should indicate 24 v If it does not the contro
92. control box UNIT SIZES 054 074 Field wiring is brought into the unit through the bottom of the control box Wiring can be brought through the roof curb through field supplied water tight connections See Fig 17 A 4 5 32 in hole for field power wiring and a 7 8 in hole for 24 v control wiring are provided in the bottom of the control box Field supplied couplings must be used when rout ing wiring into the control box See Fig 17 for recommended disconnect location Field Electrical Connections IMPORTANT The 48 50DK DY NB NP units gener ate use and can radiate radio frequency energy If units are not installed and used in accordance with these instructions they may cause radio interference They have been tested and found to comply with limits of a Class A computing device as defined by FCC Federal Communications Commission regulations Subpart J of Part 15 which are designed to provide reasonable protection against such interference when operated in a commercial environment ELECTRIC HEAT CONTROL BOX CONTROL ACCESS THIS SIDE BOX CD ED 1 9 EXHAUST FAN ELECTRIC HEATER ACCESS RECOMMENDED OPPOSITE SIDE FIELD SUPPLIED LIMIT SWITCH ACCESS DISCONNECT THIS SIDE LOCATION CAUTION Use when drilling into corner po
93. door Evaporator Fan Contactor Indoor Evaporator Fan Circuit Breaker Indoor Evaporator Fan Motor Inlet Guide Vanes 57 IGVM Inlet Guide Vanes Motor Low Pressure Switch Limit Switch Limit Switch Relay Main Gas Main Gas Valve Head Control Pressure Device Modulating Power Exhaust Relay Main Valve Normally Closed Normally Open Outdoor Condenser Fan Motor Power Exhaust Circuit Breaker Power Exhaust Contactor Power Exhaust Damper Motor Power Exhaust Motor Pilot Gas Pilot Gas Valve Processor Integrated Controls Plug Power Supply 5 VDC Processor Module Pilot Valve Power Resistor Return Fan Contactor Return Fan Damper Motor Rollout Switch Sensor Suction Pressure Transducer Switch Terminal Block Timed Discrete Output Thermostat Transformer Valve Field Wiring Factory Wiring LOW HEAT PL12 3 PST TH per RED BRN PL11 6 M6V 1 7 TE Py VIO BRN PL12 4 1 1 BRN CC BNN GND 7 PLIt 1 10 1 HIGH HEAT PL11 3 PLIO 3 PHK gt 1 51 r gt RED o RED an lid PL12 1 L PL12 5 6 1 BRN PLI2 4 51 152 1 lt 10 Gg BRN 2 2 cas 10 5 on mm lt 8 d ay orn 4 PLIO 4
94. e VAV controls and troubleshooting refer to appropriate Controls and Troubleshooting literature also en closed in this literature packet SAFETY CONSIDERATIONS Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical com ponents Only trained and qualified service personnel should install repair or service air conditioning equipment Untrained personnel can perform basic maintenance func tions of cleaning coils and filters and replacing filters other operations should be performed by trained service per sonnel When working on air conditioning equipment ob serve 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 Na tional Standards Institute Z223 1 Wear safety glasses and work gloves Use quenching cloth for unbrazing operations Have fire extinguisher available for all brazing operations WARNING Before performing service maintenance operations unit turn off main power switch to unit Electrical shock could cause personal injury FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any elec trical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you can not reach your gas supplier call the fi
95. e Size 213T Efficiency at Full Load Standard Efficiency 82 9 High Efficiencyt Fan Pulley Pitch Diameter in 13 7 Motor Pulley Pitch Diameter in 34 4 Resulting Fan Rpm Belts Quantity Model No 48 Series and 50 Series Horizontal Discharge 50 Series Vertical Discharge Center Distance Range in 48 Series and 50 Series Horizontal Discharge 50 Series Vertical Discharge OPTIONAL POWER EXHAUST Low Heat 6 6 1285 30 1 076 48 2 2 BX60 2 BX60 17 74 14 30 19 86 15 67 High Heat 12 529 264 529 423 211 423 15 45 0 30 15 45 79 79 79 6 1285 30 Low Heat High Heat 6 12 12 1285 30 12 1285 30 2 076 48 1 076 48 2 076 48 2 2 2 2 1 2 Propeller Type 2 30 3 30 18 600 26 000 1 0 1140 1 0 1140 Centrifugal 25 x 25 in 10 500 14 000 15 000 20 000 900 900 11746 11146 Any motor available any unit 20 0 215T 254T 256T 85 6 84 5 87 5 89 5 90 0 91 0 13 7 13 7 13 7 4 3 4 9 5 5 510 580 660 2 5VX630 2 5VX630 17 74 14 30 17 63 14 01 17 63 14 01 19 86 15 67 19 04 15 00 19 04 15 00 Centrifugal 15 x 15 in Any motor available on any unit 2 5 0 2 5VX630 2 5VX630 2 5VX630 2 5VX630 Quantity Motor Hp 2 3 0 1 7 5 Motor Frame Size 56HZ 184T 213T Efficiency at Full Load 81 0 84 0 82 9 Fan Pulley Pitch Diameter in 6 9 6 9 6 9 Motor Pulley Pitch Diameter in 3 35 4 12 5 0 Sh
96. e and install as described in in structions shipped with the accessory Accessory roof curb and information required to field fabricate a roof curb is shown in Fig 3A 3C Install insulation cant strips roofing and counter flashing as required For unit condensate drains to function properly curb must be level or within tolerances shown in Fig Roof Mount Check building codes for weight distri bution requirements Unit weight is shown in Tables 1A and 1B Unit may be mounted on class A B or C roofing material Slab Mount Provide a level concrete slab that ex tends beyond unit cabinet at least 6 inches Make a slab 8 in thick with 4 in above grade Use gravel apron in front of condenser coil air inlet to prevent grass and foliage from ob structing airflow SIZES 034 044 SIZES 054 074 SPREADER SPREADER BARS IN MM A ae 45 8 IN 1163 MM NOTES 1 Sizes 034 044 Rig with 4 cables and spread with two 95 in 2413 mm and 2 A long spreader bars Sizes 054 074 Rig with 4 cables and spread with four 95 in 2413 mm and A long spreader bars 2 Center of gravity includes economizer CAUTION 1 panels must be in place when rigging 2 Unit is not designed for handling by forklift truck RIGGING WEIGHTS AND DIMENSIONS m A lb Kg m mm i mm 48DJD DKD NPD034 ner e 109 4 2780 48DJE NPE034 110 4 2804 48DJD DKD NPD044 pum 127 6 3240 4
97. e flue box or for a defective centrifugal switch or loose combustion blower See Fig 63 for proper location of the rollout capillary TROUBLESHOOTING Economizer The economizer control consists of an electronic control board mounted on the back of the cover plate of the economizer motor with the adjustments and elec trical plugs accessible through the top of the cover The econo mizer control is factory wired to the terminals on the motor All potentiometers and adjustments are a part of the control board 52 CAPILLARY TUBE Fig 63 Location of Rollout Switch Capillary Tube ECONOMIZER MOTOR CHECKOUT The motor may be checked out separately from the control board See Table 12 for motor checkout To check out the motor apply 24 VAC power to terminals TO and T2 of the control board NOTE The connections to motor terminals 1 and R must remain in place Table 12 Economizer Motor Checkout MOTOR PROCEDURE TEST EXPECTED RESULT AND RESPONSE A Remove wire connected to Motor drives open If not terminal on the motor replace the motor B Remove wire connected to Motor drives closed If not terminal B on the motor leaving W wire discon replace the motor nected Test A CONTROL BOARD CHECKOUT To check out the con trol board motor conduct the following 4 tests Test 1 1 Apply 24 VAC power to terminals TO and T2 of control board
98. ed Optional Quantity Size in High Efficiency 90 Bag Filters with Prefilters Optional Quantity Size in TXV Thermostatic Expansion Valve oo 20 x 25 x 2 16 x 20 x 2 20 x 25 x 2 16 x 20 x 2 20 x 24x 22 24 x 24 x 22 Data is for all 48 and 50 Series units of the size listed unless otherwise specified TNot available on 575 v units 20 x 25 x 2 16 x 20 x 2 20 x 25 x 2 16x 20 x 2 oo 20 24 x 22 24 24 22 15 20 25 2 5 16 x 20 x 2 15 20 x 25 x 2 5 16 x 20 x 2 6 20 x 24 x 22 6 24 x 24 x 22 Table 2 Operating Weights of Options and Accessories OPTION OR ACCESSORY SIZE L 9 8 gu Roof Curb 450 480 515 515 515 48DJ DK NP 450 480 560 560 560 SODW DY NB 380 465 515 515 515 50DJ DK NP Condenser Section Roof Curb x a j cde 50 j 50 625 Economizer 530 Power Exhaust 60 eo 7 70 710 Barometric Relief 200 200 High Efficiency Filters 20 20 20 20 20 Bag filters 35 35 40 40 40 Hail Guard 210 Copper Condenser Coil Fins 235 420 Electric Heatt 150 Inlet Guide Vanes 115 Includes hood 50 Series vertical discharge units UNIT CENTER OF GRAVITY AND CORNER WEIGHTS CORNER WEIGHT Ib DIMENSIONS Ft in 1 Jj 5 0 3 8 3 8 48DJD DKD NPD 2 10 2 10 2 10 2 10 2 10 480 2 10 064 2393 2373 2378 2506 19
99. ed switch between THERMOSTAT SUBBASE LOW VOLTAGE TERMINAL BLOCK IN UNIT CONTROL BOX Fig 19 Field Control Thermostat Wiring TB2 and the Cl connection on the evaporator fan con tactor coil IFC on unit label diagram 5 Switch to isolate evaporator fan motor field supplied normally closed switch 5 Modulating Power Exhaust Wire a field supplied switch in series with the black wire removed from TRAN3 primary Constant Volume Power Exhaust Wire a field supplied switch in series with the black wire from Plug 7 Pin 1 PL7 1 to the red wire on economizer motor no 2 DMS1 on unit label diagram 6 Switch to energize power exhaust motor field supplied normally open switch 6 Wire a field supplied switch from terminal 5 on 034 044 units or terminal 2 054 074 units on terminal block 2 in series with the red wire from switch 5 to the damper motor switch DMS1 on economizer motor 2 or in parallel with SWS 7 Switch to fully open power exhaust damper field supplied normally open switch 7 Wire a field supplied switch between terminal C and the normally closed switch on DPS2 NOTES AND LEGEND FOR FIG 20 BUILDING PRESSURIZATION SMOKE PURGE ALARM Switch 1 Switch 1 Switch 1 Switch 2 Switch 2 Switch 3 Switch 4 Switch 5 Switch 5 Switch 6 Switch 7 MPE Switch 1 Remove jumper Firestat or smoke detector normally closed Switch 2 Switch to drive economizer outdoor
100. em measured in parts per mil lion ppm changes the color of the indicator Green moisture below 45 ppm dry Chartreuse 45 to 130 ppm caution Yellow moisture above 130 ppm wet Change filter driers at the first sign of moisture in the sys tem See Carrier Charging Handbook for more information IMPORTANT Unit must be in operation at least 12 hours before moisture indicator can give an accu rate reading With unit running indicating element must be in contact with liquid refrigerant to give a true reading Filter Drier Replace whenever the moisture liquid in dicator shows moisture in the system Liquid Line Service Valve Located immediately ahead of the filter drier this valve has a 1 4 in flare con nection for field charging With the liquid circuit shut the compressor can be used to pump the refrigerant down into the high side The refrigerant can then be stored there by closing the compressor discharge valve 51 Compressor Discharge Service Valve Each compressor has one Compressor Suction Service Valve Each com pressor has one Protective Devices COMPRESSOR PROTECTION Overcurrent Each compressor has one manual reset cali brated trip magnetic circuit breaker Do not bypass connec tions or increase the size of the circuit breaker to correct trouble Determine the cause and correct it before resetting the breaker Overtemperature Each 06D compressor has an intern
101. er service and operational clearances con tact Carrier Product Engineering Department 4 Vertical discharge ducts designed to be attached to accessory roof curb If unit is mounted on dunnage support the ducts using cross braces as done on the accessory roof curb 5 When unit is slab mounted locate the condensate drain as low as possible on vertical face of base rail at the same location as the standard condensate drain using factory supplied fitting Plug factory drilled con densate hole 0 3 4 19 11 NPT LOW VOLTAGE 1 2 7 782 379 13 16 044 BOTTOM SUPPLY SEE ROOF CURB CERTIFIED FOR DUCT DIMENSIONS amp LOCATIONS 2721 15 167 4 1015 4 5 3 42 13661 0 10 5 8 270 0 5 13 16 148 0 ACCESS DOOR ACCESS DOOR NEAR SIDE ONLY 1 9 16 370 lt f LOW EE CONTROL BOX OPENI 89778 22 2 DIA 0 3 1 2 88 9 NPT FIELD POWER ONLY 2 0 1 8 NEAR SIDE ONLY ELECTRIC HEAT 1612 ACCESS DOOR CONTROL BOX Ls 13 16 TYP BOTH SIDES ACCESS DOOR 5 10 5 8 FAR SIDE ONLY 1794 044 ONLY ELECTRIC HEATERS OPTION DRAIN CONN m gt BOTH SIDES dicas lo H 044 ONLY J TYP 4 PLCS K BASE FRAME RETURN AIR SUPPLY AIR DUCT CONN DUCT CONN ECONOMIZER OPTION AIR HOODS ES 325 510 HOODS FIELD INSTALLED 7 7 11 16 12329 1 6 13 16 478
102. erant from the system Evaporator Fan Belts Pulleys and Sheaves Belts pulleys and sheaves are factory installed All pulleys are nonadjustable See Tables 1A and 1B for fan shaft center distance ranges and shaft sizes when making selections for field supplied drives See Tables 9A and 9B for a complete listing of field supplied pulleys and belt connections Check the lubrication of fan and motor bearings Bearings are shipped full of grease for corrosion protection and may run warm temporarily on start up until the excess grease has discharged Check bearing setscrews for tightness Also check the tightness of the setscrews on the fan wheel and on the fan and motor sheaves Check fan shaft bearing mountings for tightness Recheck sheave alignment and belt tension See Adjust ments section on page 46 for instructions Hand turn the fan to make sure the fan wheel does not rub on the fan housing The fan shaft and motor shaft must be free wheeling before power is applied to the unit Following the necessary electrical checks check for fan vibration If excessive vibration occurs check for drive misalignment mismatched belts wheel or sheaves loose on shaft loose bearings loose mounting bolts motor out of balance sheaves eccentric or out of balance wheel out of balance replace if necessary Table 9A Field Supplied Evaporator Fan Pulley Data 034 044 Units MOTOR PULLEY BLOWER PULLEY 61 8 s 518
103. f unit to horizontal NOTE To prevent the hazard of stagnant water 4 build up the pan of the indoor air section je eo unit can only be pitched as shown CONDENSER SECTION SUPPLY AIR CONDENSER AND COMPRESSOR END CONDENSER AND COMPRESSOR END CONDENSER AND COMPRESSOR END ATTACH TO ROOF CURB WITH 1 4 20 SELF DRILLING SCREWS 1 2 X 2 SEAL STRIP PLAN VIEW OF ROOF CURB EN ROOF CURB 6 22 13 16 x 2 SEAL STRIP 134 1 2 Xp BOTH SIDES 0 5 1 4 501 07 1 15 16 1 47 8 X 5 8 16 SCREWS 761 0 3 BASE RAIL CROSS SECTION TYP ALL BASE RAILS SCALE 1 3 1 8 X 1 SEAL STRIP STANDARD ROOF CURB 074 ONLY SPLICE PLATE 1 8 X 1 SEAL STRIP TYP BOTH SIDES 121341 X at 07 37 78 SEE VIEW GASKET SUPPLIED WITH CURB NAIL 1 8 x 1 COUNTER FLASHING SEAL STRIP SLOPED ROOF FIELD SUPPLIED CURB PAN 6 ROOFING FELT FIELD SUPPLIED CANT STRIP FIELD SUPPLIED ROOFING MATERIAL cross FIELD SUPPLIED Su SECTION TYPICAL 3 PLACES CORNER CONNECTIONS AND RIGID INSULATION SCALE 1 3 SPLICE PLATE CONNECTIONS FIELD SUPPLIED Fig 3C Condenser Section Roof Curb 054 074 Units Only Condensate Drains See Fig 4A 4D and Fig 5 for drain locations The drain assemblies each consisting of a 10 gage plate
104. ies Units Only MAIN BURNER ADJUSTMENT 48 Series Units Only Main Burner Removal 48 Series Units Only 50 Switch Adjustment 50 Refrigerant Feed Components 50 Thermostatic Expansion Valve TXV 50 Moisture Liquid Indicator 51 Filter Drier oo 51 Liquid Line Service Valve 51 Compressor Discharge Service Valve 51 Compressor Suction Service Valve 51 Protective Devices 51 COMPRESSOR PROTECTION EVAPORATOR FAN MOTOR PROTECTION CONDENSER FAN MOTOR PROTECTION HIGH AND LOW PRESSURE SWITCHES Relief Devices 51 Control Circuit 115 V 52 Control Circuit 24 52 Electric Heat 50 Series Units Only 52 OVERCURRENT OVERTEMPERATURE Gas Heat 48 Series Units Only 52 LIMIT SWITCHES ROLLOUT SWITCH TROUBLESHOOTING 52 60 Economizer e EAMUS 52 ECONOMIZER MOTOR CHECKOUT ECONOMIZER CONTROL BOARD CHECKOUT Unit Control Board Checkout 53 BASIC CHECK DETAILED CHECK START UP CHECKLIST CL 1 GENERAL This installation instruction contains base unit installa tion start up and service instructions only For complete in formation on PIC Product Integrated Controls and variable air volum
105. ired position Also be sure hood is installed properly Fig 32 Condenser Fan Adjustment Initial Check IMPORTANT Do not attempt to start unit even mo mentarily until all items on the Start Up Checklist and the following steps have been completed 1 Verify unit has been installed per the Installation section of this literature 2 Certify that all auxiliary components sensors controls etc have been installed and wired to the control boxes per these instructions the Controls and Troubleshooting literature DK DY NB NP units only and the unit wiring label diagrams 3 Verify that pressure hoses static duct etc are properly attached routed and free from pinches or crimps that may affect proper control operation 4 Set any control configurations that are required field installed accessories etc The unit is factory configured for all appropriate factory installed options with the ap plicable controls programmed to the default values See unit Controls and Troubleshooting literature for appli cable configuration values 5 Enter unit set points if applicable The unit is shipped with the set point default values shown in the Controls and Troubleshooting literature as applicable If a dif ferent set point is required change per the example shown under Set Point Function section in appropriate unit Con trols and Troubleshooting literature 6 Configure schedule subfunctions if applicable
106. is through the door labeled HEAT SEC TION on the left side of the unit when facing condenser end See Fig 37 and 38 All gas system components are in the gas section MAIN AND PILOT BURNERS 48 Series Units Only At the beginning of each heating season inspect for dete rioration due to corrosion or other causes Observe the pilot and main burner flames and adjust if necessary See Auto matic Pilot Adjustment or Main Burners Adjustment Section on pages 49 and 50 FLUE GAS PASSAGEWAYS 48 Series Units Only The flue collector box and heat exchanger cells may be inspected by removing the combustion air blower s flue box cover and main burner assembly See Fig 39 and 40 If cleaning is required remove heat exchanger baffles through the flue box and clean all parts with a wire brush When replacing heat exchanger baffles be sure to replace screw through clamp on baffle retaining rod into the vestibule plate ACCESS ix p 5 2 BASE RAIL ROUND HOLES Fig 34 Typical Filter Drier and Liquid Service Valve Access 43 POWER EXHAUST ACCESS MODULATING POWER EXHAUST DAMPER MOTOR ACCESS Fig 35 Modulating Power Exhaust Damper Motor Access 034 and 044 Units MODULATING POWER EXHAUST DAMPER MOTOR ACCESS POWER EXHAUST ACCESS Fig 36 Modulating Power Exhaust Motor Access 054 074 Units
107. it can only be pitched as CONDENSER AND COMPRESSOR UNIT LEVELING TOLERANCES DIMENSIONS degrees and inches CONDENSER CONDENSER 5 AND AND From edge of unit to horizontal COMPRESSOR COMPRESSOR END END S 7 57 7 1 4 21341 17081 708 Sy 1 4 321 0 3 4 1441 ALL SIDES 72 13 16 50 0 1 15 16 11341 07 5 1 4 761 NOT 500 DK NPO34 0 3 BASE RAIL CROSS SECTION TYP ALL BASE RAILS SCALE 143 2 2 11 18 5781 6 28 9 16 5 2 12046 gt 2 46 1716 27 GASKET SUPPLIED WITH CURB NAIL COUNTER FLASHING FIELD SUPPLIED 0 9 ROOFING FELT FIELD SUPPLIED CANT STRIP FIELD SUPPLIED ROOFING MATERIAL SS FIELD SUPPLIED 2 1761 2 VIEW B CORNER CONNECTIONS AND RIGID INSULATION SPLICE PLATE CONNECTIONS FIELD SUPPLIED Fig 3A Roof Curb 034 044 Units 7 2 5 UNIT UNIT 1 Roof curb is shipped unassembled ft in Roof curb 14 gage VA03 56 steel an Dimensions in are millimeters 2 3 48DJ DK NP 054 064 2474 8 1 8476 27 9146 6965 22 10 6 4 Suggested hole location for field wiring 50DW DY NB 054 064 through roof curb holes to be field drilled 50DJ DK NP 15 57 48DJ DK NP 50DW DY NB 074 3989 150388 8
108. it is available which allows mechanical cooling to 20 F outdoor ambient See accessory installation instructions for mounting and opera tion details SERVICE Service Access All unit components can be reached through clearly labeled hinged access doors These doors are not equipped with tiebacks so if heavy duty servicing is needed either remove them or prop them open to prevent accidental closure Each door is held closed with 3 latches The latches are secured to the unit with a single 1 4 in 20 x 1 2 in long bolt See Fig 33 To open loosen the latch bolt using a 7 16 in wrench Pivot the latch so it is not in contact with the door Open the door To shut reverse the above procedure NOTE Disassembly of the top cover may be required under special service circumstances It is very important that the orientation and position of the top cover be marked on the unit prior to disassembly This will allow proper replace ment of the top cover onto the unit and prevent rainwater from leaking into the unit IMPORTANT After servicing is completed make sure door is closed and relatched properly and that the latches are tight Failure to do this can result in water leakage into the indoor air section of the unit COMPRESSORS Sizes 034 and 044 Access to the compressors is through the doors on the condenser end of the unit This door also provides access to the discharge and suction service valves the crankca
109. k and equipment ground Operating voltage to the compressor must be within the voltage range indicated on the unit nameplate Voltages be tween phases must be balanced within 2 and the current must be balanced within 1096 See Tables 3 7 for unit elec trical data DISCONNECT PER NEC LEGEND EQUIP Equipment GND Ground NEC National Electrical Code TB Terminal Block Fig 18 Field Power Wiring Connections 18 Use the following formula to determine the percent voltage imbalance Voltage Imbalance 100 x voltage deviation from average voltage average voltage Example Supply voltage is 460 3 60 AB 452 v BC 464 v 455 v 452 464 455 3 Average Voltage 1371 3 457 Determine maximum deviation from average voltage 457 452 5 v BC 464 457 7 v 457 455 2 v Maximum deviation is 7 v Determine percent voltage imbalance 7 457 Voltage Imbalance 100 x 1 53 This amount of phase imbalance is satisfactory as it is be low the maximum allowable 2 IMPORTANT If the supply voltage phase imbalance is more than 2 contact local utility immediately Unit failure as a result of operation on improper line volt age or excessive phase imbalance constitutes abuse and may cause damage to electrical components Table 3 Electrical Data 034 Units 208 230 3 60 V Ph Hz BASE UNIT WITH COMER COMER BAST
110. kW available on CV applications only 65 208 230 3 60 V Ph Hz BASE UNIT WITH BASE UNIT EXHAUST ELECTRIC EXHAUST FAN ONLY FAN HEAT AND OR ELECTRIC HEAT Total Total xx mocr MCA 5 392 2 385 0 0 48 4 44 0 407 2 398 6 0 61 6 56 0 420 4 410 6 23 78 9 91 0 358 8 354 6 157 7 182 0 358 8 354 6 33 4 30 4 2289 910 39258850 46 2 358 8 500 4 30 9 91 2 385 0 33 4 30 4 157 7 182 0 392 2 385 0 420 8546 450 0 334 304 236 6 273 0 392 2 393 8 0 454440 9 91 0 407 2 398 6 0 484 440 7 182 0 407 2 398 6 0 48 4 44 0 6 273 0 407 2 398 6 61 6 56 0 420 4 410 6 0 61 6 56 0 157 7 182 0 420 4 410 6 0 61 6 56 0 236 6 273 0 420 4 410 6 0 33 4 30 4 405 4 397 0 0 48 4 44 0 420 4 410 6 0 61 6 56 0 433 6 422 6 78 9 91 0 372 0 366 6 157 7 182 0 372 0 366 6 E ne 59 4 372 0 500 4 30 100 33 4 30 4 157 7 182 0 405 4 397 0 64 0 366 6 500 10 0 334 304 236 6 273 0 405 4 408 8 15 0 484 440 9 91 0 420 4 410 6 15 0 48 4440 0 420 4 410 6 15 0 48 4440 236 6 273 0 420 4 410 6 20 0 61 6 56 0 78 9 91 0 433 6 4226 20 0 61 6 56 0 157 7 182 0 433 6 422 6 20 0 61 6 56 0 236 6 273 0 433 6 422 6 10 0 33 4 30 4 420 8 411 0 15 0 48 4 44 0 2 435 8 424 6 200 61 6 56 0 449 0 436 6 78 9 91 0 387 4 380 6 157 7 182 0 387 4 380 6 issue 74 8 387 4 500 4 30 EE 10 0
111. l board is defective and must be replaced d Turn unit power off Use a toggle switch to connect a fresh 1 5 v battery to the terminals marked CLO1 shown in Fig 65 CAUTION The negative pole of the battery must be con nected to the inner terminal and the positive Ve pole must be connected to the outer terminal as shown in Fig 65 e Turn unit power on and use the toggle switch to make and break the connection between the outer CLOI ter minal and the positive Ve pole of the battery f If the multimeter shows 24 v when the battery is dis connected and no voltage when the battery is con nected the CLO logic is good If the multimeter shows no change the CLO logic is defective and the board must be replaced Symptom Compressor no 2 will not operate 1 Be sure unit power is off Disconnect the 2 wires attached to the terminals marked SC2 2 Check continuity between the 2 wires If there is no con tinuity the problem is external to the control board pos sibly the pressure switches If there is continuity proceed to Step 3 3 Reconnect the wires removed in Step 1 4 With unit power still off disconnect plug P1 from the con trol board and install jumper wire across Pins R and Y2 at plug P1 5 Connect a voltmeter across the coil for compressor no 2 contactor 6 Energize unit and monitor the voltage for a few seconds IMPORTANT Do not run compressor too long 7 a If pr
112. ll for heat Turn main gas valve to OFF position Install a suitable pressure measuring device Set main gas valve to ON position Set thermostat to call for high fire W2 Remove screw cap or plastic cover covering the regula tor adjustment screw 7 Turn adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure 8 Once desired pressure is established remove pressure measuring device and replace screw cap MAIN BURNERS ADJUSTMENT 48 Series Units Only Main burners are factory set and should require no ad justment However if burner adjustment is necessary Perform Automatic Pilot Adjustment page 49 2 Turn gas valve to ON position Allow unit to operate at least 15 minutes with heat section access panel closed 3 Open heat section access panel 4 Loosen primary air shutter and adjust to a minimum open ing of 8 inch 5 Retighten primary air shutter and close access panel To check ignition of main burners and fan switch opera tion move thermostat dial above and below room tempera ture several times pausing at least one minute between cycles SN WN Burner Removal 48 Series Units Only NOTE For high heat units the side posts must be removed before the burner assembly can be removed 1 Shut off main gas valve 2 Shut off power to unit 3 Unplug PL9 and PL10 on high heat and all sensor and ignitor wires 4 Disconnect gas co
113. ly 240 v Full Load ins y 480 v or 575 v capacity by appropriate multiplier below Nominal Horsepower Indoor Evaporator Fan Motor MULTIPLICATION FACTORS VOLTAGE CV ETL ang LRA MCA MOCP OFM RLA Minima AM f HEATER kW MULTIPLICATION Circuit Amps for wire sizing Maximum Overcurrent Protection RATING DISTRIBUTION FACTOR Outdoor Condenser Fan Motor Rated Load Amps 3 0 694 0 751 0 918 1 000 0 840 0 918 1 000 0 915 Electric heat available 50 Series vertical discharge units 240 108 kW available on CV applications only 1 000 480 2 575 1 089 Electric heaters are tested and ETL approved at maximum total external static pressure of 1 9 in wg 2 Boldface indicates 48 and 50 Series units All other data is for 50 Series units only 27 Table 6 Electrical Data 064 Units 208 230 3 60 V Ph Hz COMPR COMPR BASE UNIT EXHAUST VOLTAGE NO 1 NO 2 ONLY FAN RANGE Total Total Total Na 187 254 aaa oaol 0 0 2 2 VPN 0 484 440 0 6
114. mper to provide ventilation air This damper can be preset to admit up to 25 outdoor air into the return air compartment To adjust loosen the blade limiter screws as shown in Fig 10 and move the damper to the desired position Then retighten the blade limiter screws to secure the damper See Fig 10 To make this adjustment it is necessary to remove the screens covering the hood opening and make adjustments from in side the hood ECONOMIZER SETTINGS Enthalpy Sensor See Fig 11 This sensor is located be hind the filters in the end economizer hood the upper hood on sizes 054 074 See Fig 12 For maximum benefit of out door air set enthalpy sensor control to the A setting At this setting when the relative humidity is 50 and the outdoor air is below 74 F the sensor s relay contacts will be closed See Fig 13 and 14 NOTE Enthalpy control setting dial is on the economizer motor Mixed Air Thermistor MAT This control set point ad justment is on the top of the economizer motor This motor is located in the return air section and is accessed by open ing the access panel marked FILTER SECTION See Fig 15 Set MAT set point adjustment dial to the desired setting The factory setting is 55 5 range is 40 to 90 F The MAT is located on the filter rack Damper Vent Position The position setting adjustment is located on the cover of the economizer motor See Fig 15 Adjust by setting the fan switch
115. nnection s from between gas valve s and field supplied piping See Fig 37 and 38 5 Remove 2 screws securing burner assembly to unit 6 Slide burner assembly from unit Switch Adjustment All units with an economizer have an auxiliary switch located on the economizer damper motor This switch is factory set to prevent the power ex haust from operating when the economizer damper is less than 50 open If other than the factory setting is desired follow the steps below CAUTION Do not turn motor shaft by hand or with a wrench Dam age to the gear train will result 50 1 Remove top cover from motor to gain access to motor terminals and cam adjustments 2 Disconnect controller from motor Connect RED WHITE and BLUE terminals on the 135 ohm manual potentiom eter to corresponding RED WHITE and BLUE termi nals on the motor Connect 24 vac power to Terminals 1 and 2 See Fig 60 3 Adjust the 135 ohm potentiometer so that the motor shaft turns to the position where auxiliary equipment is to be switched 4 Adjust auxiliary cam by inserting a 10 straight blade screwdriver into slot on cam and moving TOP of screw driver to the right or left See Fig 61 5 To close auxiliary switch RED and BLUE contacts as the motor travels open energizing the power exhaust mo tor the switch differential can only be 10 degrees on both switches To adjust either cam perform the following steps a If RED and BLUE c
116. o outdoor ambient temperature for head pressure control Check cooling effects at a setting below room temperature Reset thermostat at a setting above room temperature Compres sors will shut off HEATING UNITS WITHOUT ECONOMIZER 48 Series Low Heat Units Unit power on thermostat sys tem switch set at HEAT or AUTO position and fan switch set at AUTO position First stage thermostat W1 calls for heat Time delay re lay built into constant volume control board controlling evaporator fan begins timer sequence 55 10 second de lay Induced draft contactor closes and induced draft motor starts Centrifugal switch closes Pilot valve opens allowing gas to flow to first stage pilot Spark ignitor ignites pilot flame Sensor detects flame energizes main gas valve coil and main gas valve opens Gas flows to main burners and first stage burners ignite Spark ignitor shuts off and pilot remains on The spark ignitor will continue to spark for 90 seconds until pilot flame is sensed If the pilot fails to ignite or the sensor fails to detect flame the pilot valve closes and the spark ignitor shuts off for 300 seconds 5 minutes During this time the induced draft motor remains on to purge any unburnt gas from the combustion tubes This ignition se quence will repeat indefinitely When time delay sequence is complete time delay relay closes and evaporator fan motor starts When additional heat is needed on 034 044 units W
117. o unit Remove screw cap cover on pilot gas valve to expose adjusting screw To ensure that main burners do not ignite remove wire from gas valve terminal 2 Tape wire Do not allow wire to be grounded Turn on power to unit Set system selector switch to HEAT position and set thermostat to a setting that will call for heat Pilot ignites With a small screwdriver turn adjustment screw until flame fully engulfs sensor Replace cap on pilot gas valve Turn off power to unit Return valve s to original position Check for proper burner operation by cycling the burn ers Wait 30 seconds between burner cycles Check that all panels are closed securely before leaving the unit GAS VALVE ADJUSTMENT 48 Series Units Only The gas valve opens and closes in response to the thermostat or limit control When power is supplied to valve terminal 3 D1 on low heat the pilot valve opens to the preset posi tion When power is supplied to terminal 2 W1 on low heat the main valve opens to its preset position The regulator factory manifold pressure setting 2 9 in wg and is stamped on the valve body Manifold pressure is the pressure at the factory supplied pressure tap on the manifold downstream of the gas valve This is not the same as the pressure at the tap on the gas valve body Always use the tap on the manifold to read mani fold pressure To adjust regulator Set thermostat at setting for no ca
118. oltage at this point the IFC con tactor is defective If there is no voltage proceed to Step 4 4 Turn unit power off and disconnect plug P4 from the con trol board 5 Turn unit power on and check for continuity across Pin 6 and Pin 3 at plug P4 on the control board If there is no continuity the board is defective Replace control board If there is continuity then there is a bad con nection between the board and plug P4 Correct the connection 6 Turn unit power off Reconnect plug P1 if troubleshoot ing is complete and plug P4 Symptom Condenser fan no 1 will not operate 1 Turn unit power off Disconnect plugs P1 and P3 from the control board 2 Check for continuity between Pin 8 at plug P3 on the con trol board and Pin Y1 at plug P1 on the control board If there is no continuity the board is defective If there is continuity either the connection is bad between plug P3 and the control board or the problem is external to the board Reconnect plug P1 if troubleshooting is com plete and plug P3 to the board 54 Symptom Condenser fan no 2 5 will not operate 1 Check operation of condenser fan no 1 If fan no 1 op erates properly the problem is external to the board Symptom Compressor no 1 will not operate Turn unit power off Disconnect the 2 wires attached to the terminals marked 5 1 2 Check continuity between the 2 wires If there is no continuity the problem is external to the
119. ontacts are open rotate the cam counterclockwise until the contacts close b If the RED and BLUE contacts are closed rotate the cam clockwise until the contacts open Refrigerant Feed Components Each refrigerant circuit 2 per unit has all the necessary refrigerant controls Thermostatic Expansion Valve TXV On size 034 each circuit has one On size 044 each circuit has 2 The superheat is nonadjustable On sizes 054 074 each cir cuit has 2 TXVs on which superheat may be adjusted if ab solutely necessary The is set to maintain 10 to 13 F superheat leaving the evaporator coil It controls the flow of refrigerant to the evaporator coils 135 OHM POTENTIOMETER INNER AUXILIARY SWITCH CAM BLUE INNER AUXILIARY SWITCH OUTER AUXILIARY SWITCH AUXILIARY END OF MOTOR OUTER AUXILIARY SWITCH CAM RED Fig 60 Auxiliary Switch Stroke Adjustment TO ADJUST CAMS MOVE TOP OF SCREWDRIVER ONLY 1 8 IN STRAIGHT BLADE SCREWDRIVER INNER AUXILIARY SWITCH FAST RISE PORTION N SLOW RISE PORTION INNER AUXILIARY CAM BLUE OUTER AUXILIARY CAM RED MOTOR MOTOR CLOSE OPEN AUXILIARY END VIEW Fig 61 Auxiliary Switch Adjustment Moisture Liquid Indicator A clear flow of liquid refrigerant indicates sufficient charge in the system Bubbles indicate undercharged system or the presence of noncon densables Moisture in the syst
120. oods 48 Series Units 36 UNIT SIZES 034 AND 044 UNIT SIZES 054 074 PRE START UP 38 41 Unit Preparation 38 Compressor Mounting 38 Evaporator Fan Shipping Brackets 38 UNIT SIZES 034 AND 044 UNIT SIZES 054 074 Internal Wiring 38 Refrigerant Service Valves 38 Crankcase Heaters 38 Compressor 38 Gas Manifold Pressure 48 Series Units Only Weel wie 39 Unit Voltage 39 Leak Test and Dehydration 39 Evaporator Fan Belts Pulleys and Sheaves 39 Condenser Fans Motors 40 Return Air Filters 40 Economizer Inlet Screens 40 Economizer Dampers 40 25 Outdoor Air Damper 40 Initial Check 41 START UP oe odo 41 42 41 Operating Sequences 41 COOLING UNITS WITHOUT ECONOMIZER HEATING UNITS WITHOUT ECONOMIZER EVAPORATOR FAN MOTORS PULLEYS AND BELTS POWER EXHAUST MOTORS PULLEYS AND BELTS UNIT CONTROL BOX GAS HEAT SECTION 48 Series Units Only MAIN AND PILOT BURNERS 48 Series Units Only FLUE GAS PASSAGEWA
121. oper voltage is indicated at the contactor but con tactor fails to close replace contactor b If voltage is indicated for a few seconds i e the con tactor momentarily pulls in and is then deenergized the Compressor Lockout CLO logic has shut down the unit This is an indication that the board is not sens ing proper compressor current or that one of the safe ties has tripped Proceed to Step 8 to verify compres sor lockout logic operation c If proper voltage is indicated at the contactor and con tactor closes the board is operating properly 55 8 To verify compressor lockout logic a Disconnect CLO sensor wires connected to CLO2 at the control board Check wires for continuity If there is no continuity replace the sensor b Connect the multimeter to read voltage between Pin X on plug P1 and ground c Turn unit power on and check the multimeter Within a few seconds the meter should indicate 24 v If it does not the control board is defective and must be replaced d Turn unit power off Connect a fresh 1 5 v battery to terminals marked CLO2 as shown in Fig 65 CAUTION The negative pole of the battery must be con nected to the inner terminal and the positive Ve pole must be connected to the outer terminal as shown in Fig 65 e Turn unit power on Make and break the connection between the outer CLO2 terminal and the positive X Ve pole of the battery f If the multimete
122. ordance with these Installation Instructions and all applicable codes Compressor Mounting Loosen compressor hold down bolts until sidewise movement of the washer under each holddown bolt head can be obtained Do not loosen completely as bolts are self locking and will maintain adjustment Evaporator Fan Shipping Brackets Evapor ator fan shipping brackets 4 per unit must be removed from each corner of the fan sled before starting unit UNIT SIZES 034 AND 044 1 To remove brackets raise fan sled by turning adjusting bolt counterclockwise until spring is compressed slightly 2 Remove screws holding shipping bracket to unit cross rail 3 Remove shipping bracket top of bracket is slotted so that it will slide out 4 After removing all shipping brackets level fan sled using the adjusting screws On all 4 corners dimension from cross rail to fan sled should be as shown in Fig 30 UNIT SIZES 054 074 To remove shipping brackets re move the 6 screws holding each bracket to the cross rail There are 8 brackets per unit See Fig 30 or 31 After removing all shipping brackets level fan sled using the adjusting screws On all 4 corners dimension from cross rail to fan sled should be as shown in Fig 30 or 31 Internal Wiring Check all electrical connections in the unit control box tighten as required FAN SLED RAIL SHIPPING BRACKET 4 15 16 034 044 6 15 16 054 074 i UNIT CROS
123. r shows 24 v when the battery is dis connected and no voltage when the battery is con nected the CLO logic is good If the multimeter shows no change the CLO logic is defective and the board must be replaced Remove all jumpers and replace all plugs except plug P1 Replace plug P1 only if no fur ther troubleshooting is required Symptom First or second stage of heating will not operate 1 Turn unit power off Disconnect plugs P1 and P3 2 Check continuity between Pin W1 at plug P1 and Pin 5 at plug P3 If there is continuity the board is good and the problem is either the connection at P3 or external to the control board If there is no continuity the control board 15 defective and must be replaced 3 Check continuity between Pin W2 at plug P1 and Pin 7 at plug P3 If there is continuity the board is good and the problem is either at the connection at plug P3 or ex ternal to the board If there is not continuity the board is defective and must be replaced Reconnect plug P3 to the control board Reconnect plug P1 only if no further trouble shooting is required Symptom Evaporator fan will not energize on a call for heat 1 Turn unit power off Disconnect plug P1 and plug P4 2 Install jumper wire between Pin and Pin at plug Pl 3 Turn unit power on Check for continuity between Pin 6 and Pin 3 at plug P4 on control board 4 If there is no continuity between these points the board is defective
124. re department FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WARNING Improper installation adjustment alteration service maintenance can cause injury or property damage Re fer to this manual For assistance or additional infor mation consult a qualified installer service agency or the gas supplier CAUTION Disconnect gas piping from 48 Series units when leak testing at pressures greater than 0 5 psig Pressures greater than 0 5 psig will cause gas valve damage resulting in a hazardous condition If gas valve is subjected to pres sure greater than 0 5 psig it must be replaced When pressure testing field supplied gas piping at pressures of 0 5 psig or less the unit connected to such piping must be isolated by manually closing the gas valve INSTALLATION Rigging and Unit Placement Inspect unit for trans portation damage File claim with transportation agency Do not drop unit keep upright Use spreader bars over unit to prevent sling or cable damage Sheets of plywood placed along the condenser coils will provide additional protection All lifting lugs MUST be used when lifting unit Level by using unit frame as a reference See Fig 1 for information Unit and accessory weights are shown in Tables 1A 1B and 2 Weight distribution and center of gravity can be found in Fig 2 Roof Curb Assembl
125. rgent SAE 20 oil FAN MOTOR BEARINGS The condenser and evaporator fan motors have sealed bearings so no field lubrication is required DOOR HINGES All door hinges should be lubricated at least once a year INLET GUIDE VANE DIFFERENTIAL PRESSURE SWITCH SIZES 054 074 INLET GUIDE VANE MOTOR Fig 43 Inlet Guide Vane Motor Adjustments EVAPORATOR FAN AND POWER EXHAUST MOTOR PLATE Adjust using 16 in wrench on the adjusting bolts 1 Loosen holddown bolts See Fig 44 2 Turn the adjusting bolts to move the motor mounting plate toward or away from the fan to loosen or tighten the belts Make the same number of turns to each bolt 3 Retighten holddown bolts MODULATING POWER EXHAUST DIFFERENTIAL PRESSURE SWITCH On 034 044 units the differential pressure switch is located in the auxiliary control box The auxiliary control box is mounted in the corner next to the power exhaust motor door To gain access to the auxiliary control box remove the auxiliary control box cover When replacing the auxiliary control box cover be sure to secure the cover properly in order to prevent water from being drawn into the auxiliary control box On 054 074 units the differential pressure switch is mounted below the auxiliary control box next to the access door la beled FILTER SECTION INLET GUIDE VANE DIFFERENTIAL PRESSURE SWITCH Units With Optional Inlet Guide Vanes and Static Pressure Control On
126. s include a video cassette and or slides and a companion booklet Use these for self teaching or to conduct full training sessions For a free Service Training Material Catalog STM call 1 800 962 9212 Ordering instructions are included U S A and Canada only Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 500811 1 PC 111 Catalog No 564 818 Printed in U S A Form 48 50D N 9SI Pg 70 3 96 Replaces 48DJ DK 3SI Tab 1 10 48 50 1 1 50DJ DK 9SI START UP CHECKLIST MODEL NO SERIAL DATE TECHNICIAN PRE START UP VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT LOOSEN ALL SHIPPING HOLDDOWN BOLTS AND REMOVE SHIPPING BRACKETS PER INSTRUCTIONS VERIFY INSTALLATION OF ECONOMIZER HOOD VERIFY INSTALLATION OF EXHAUST HOOD VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT CHECK GAS PIPING FOR LEAKS 48 SERIES UNITS ONLY CHECK THAT INDOOR AIR FILTER IS CLEAN AND IN PLACE VERIFY THAT UNIT IS LEVEL CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND VERIFY SET SCREW IS TIGHT VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED START UP ELECTRICAL SUPPLY 11 12 L2
127. se heaters and the high and low pressure switches Compressor no is always the compressor on the left when facing main control box Sizes 054 074 The oil pump end compressor access of each compressor is readily accessible from sides of unit as shown in Fig 17 Access the motor end of the compressor through the condenser end of the unit or by removing compressor LATCH BOLT Fig 33 Door Latch LIQUID SERVICE VALVES FILTER DRIERS AND SIGHT GLASSES Sizes 034 and 044 Access to these components is through the access panel on the right side of the unit See Fig 34 There is also a Schrader port in each suction line that is ac cessible through this same panel When charging unit route service line through the round holes and replace panel to mini mize air bypass Sizes 054 074 Access to these components is from the side of the unit as shown in Fig 34 EVAPORATOR FAN MOTORS PULLEYS AND BELTS Access to these components is through the 2 doors la beled FAN SECTION on each side of the unit POWER EXHAUST MOTORS PULLEYS AND BELTS Access to these components is through the door below the side economizer hoods on either side of the unit See Fig 35 and 36 UNIT CONTROL BOX Access to this component is through the doors marked ELECTRICAL SECTION on the con denser end of the unit when facing the condenser coil GAS HEAT SECTION 48 Series Units Only Access to the gas heat section
128. st to avoid damage to denser coil Fig 16 Disconnect Location 034 and 044 Units 50 Series Vertical Discharge Unit Shown 17 ELECTRIC HEAT CONTROL BOX RECOMMENDED FIELD SUPPLIED THIS SIDE DISCONNECT LOCATION 5 23 Sele Ds m gt 5 ps 1 0 TN A gt FO n gt r 2 Y A 2 2 2 b RE 228 COMPRESSOR ACCESS BOTH SIDES ELECTRIC HEATER ELEMENT FIELD WIRING THROUGH ROOF CURB AND LIMIT SWITCH ACCESS TO CONTROL BOX FIELD SUPPLIED THIS SIDE WATERTIGHT CONNECTIONS A CAUTION Use care when drilling into corner post to avoid damage to con denser coil Fig 17 Disconnect Location 054 074 Units 50 Series Horizontal Discharge Shown POWER WIRING Units are factory wired for the voltage shown on the unit nameplate The main terminal block is suitable for use with aluminum or copper wires Maximum wire size is 3 0 AWG American Wire Gage When installing units provide a disconnect per NEC National Electrical Code of adequate size MOCP Maxi mum Overcurrent Protection of unit is on the informative plate 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 for power wiring connections to the unit power terminal bloc
129. static pressure of 1 9 in wg 2 Boldface indicates 48 and 50 Series units All other data is for 50 Series units only 23 VOLTAGE RANGE 518 632 Table 4 Electrical Data 044 Units cont 575 3 60 V Ph Hz EXHAUST FAN 1 ONN ONO OOO OOOOOOOOO ONO OOONNN O O O O O O O O O 8 99 92 Ii Io Fo TO 65 55 24 ELECTRIC HEAT E ONWONWONWONW amp O 4 O O O 5 8 9 6 0 2 0 8 0 6 0 2 0 8 0 6 0 2 0 8 0 6 0 2 0 8 0 4 1 4 1 ONWONWONWONW 8 9 6 BASE UNIT WITH EXHAUST FAN AND OR LECTRIC HEA
130. to the basepan in the gas section UNIT SIZES 034 AND 044 The 48 series units have 2 inlet hoods 2 flue hoods and 2 flue deflector hoods See Fig 22 The 48 series low heat units have one inlet hood one flue hood and one flue deflector hood UNION FOR SERVICING 1 8 NPT PLUG BASE UNIT MANUAL GAS VALVE FROM GAS METER plug is field supplied NOTE Follow all local codes Fig 21 Gas Piping Details FLUE HOOD AND FLUE DEFLECTOR HOOD 48 SERIES HIGH HEAT ONLY INLET HOOD 48 SERIES HIGH HEAT ONLY FLUE HOOD AND DEFLECTOR INLET HOOD Fig 22 Flue Inlet Hood 034 044 Units 36 Remove shipping block offs and shipping tape from open ings in access panel Inlet hoods are shipped unassembled and must be assembled in place See Fig 23 The inlet hood consists of a hood 2 side plates and an inlet screen Install inlet hoods using screws provided NOTE Hoods must be assembled in place on the access panel Flanges on hood and side plates go to the inside of the ac cess panel Install inlet screen on each inlet hood using speed clips and screws provided Attach flue hoods see Fig 24 to ac cess panel using screws provided Hoods go over each com bustion air outlet Sub assemble flue deflector baffle inside the flue deflector hood as shown in Fig 25 and 26

Carrier NP034-074 User's Manual

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