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Carrier 48MPD User's Manual

1. 52 NATURAL GAS GENERAL This installation instruction contains base unit installa tion start up and service instructions only For complete in formation on PIC Product Integrated Controls controls and troubleshooting refer to separate Controls and Troubleshoot ing literature also enclosed in this literature packet IMPORTANT 1 Tune all loops immediately after starting units Re fer to Control Loop Checkout section on page 40 for more information on tuning loops The Data Reset function should be performed any time one or more of the unit factory configuration values are changed The HSIO human sensor input output keypad and display module is required for initial start up of unit units are shipped in STANDB Y mode The HSIO must be used to change the unit to RUN mode The HSIO is not required for normal operation how ever at any time the unit needs to be transferred back STANDYBY mode such as when servic ing a unit it must be done with the HSIO 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
2. GAS VALVE Fig 52 Burner Section Detail CERAMIC BAFFLE CLIP HEAT EXCHANGER TUBES NOTE One baffle and clip wll be in each upper tube of the heat exchanger Fig 53 Removing Heat Exchanger Ceramic Baffles and Clips Fig 54 Combustion Blower Removal LIQUID TEMPERATURE LIQUID VALVE DEG F ALL OUTDOOR FANS MUST BE OPERATING CIRCUIT A CIRCUIT B dude ADD CHARGE IF ABOVE CURVE EE PE NE ADD CHARGE IF ABOVE CURVE ATT AT L mini cue LIQUID PRESSURE AT LIQUID VALVE Psig LIQUID PRESSURE AT LIQUID VALVE Psig Fig 55 Charging Chart Unit 48 50MP62L REDUCE CHARGE IF BELOW CURVE LATT LIQUID TEMPERATURE AT LIQUID VALVE DEG F 350 ALL OUTDOOR FANS MUST OPERATING CIRCUIT A a A o A 4 ae o e o BR 5 est AR 50 100 150 200 250 300 350 400 LIQUID PRESSURE LIQUID VALVE Psig 50 100 150 200 300 350 400 LIQUID PRESSURE AT LIQUID VALVE Psig LIQUID TEMPERATU
3. 13841 1461 4 6 1 8 0 5 3 4 BOTTOM RETURN 78171 25 7 3 4 t10921 20703 dd 6 9 1 2 lt RETURN 914 3 0 BASERAIL 5 146 0 5 3 4 1803 5 11 2l 1283 4 2 172 BARDMETRIC RELIEF DR POWER EXHAUST OPTION ACCESS DOOR BOTH SIDES ACCESS DOOR 1207 NEAR SIDE ONLY 1 3 11 172 ACCESS DOOR FAR SIDE ONLY 46 9 47 8 0120 0 4 3 4 SUPPLY SEE ROOFCURB CERTIFIED DRAWING DIMENSIONS amp LOCATIONS a 38 11 ACCESS DOOR 07 1 172 FAR SIDE ONLY CONDENSER CONTROL BOX bedre ACCESS DOOR 32771 0 187710 7 8 is 10 9 70M ONLY FIELD SUPPLY POWER REF 9449 POWER EXHAUST 31 0 NEAR SIDE ONLY RETURN AIR DUCT CONN 0 1 1 2 NPT DRAIN CONN NEAR SIDE DNLY BASE FRAME 23621 7297 LIFTING 24891 ECINMUER AIR BOTH SIDES 25661 8 5 OVERALL LIFTING SHIPPING DIM LESS DISCONNECT 0 1 3 8 35 1 DIA IN LIFTING LUGS NOTES 1 Dimensions are millimeters 2 e Center of gravity Use appropriate column for units with or without exhaust fan option 3 Unit weight does not include exhaust fan option Exhaust fan add 1675 Ib 761 kg on 62L 1775 Ib 807 kg on 70M 4 Unit cl
4. ELE Fig 32 Auxiliary Control 25 TO 22225225 BUILDING FACTORY PRESSURE INSTALLED TUBING FIELD INSTALLED TUBING TO OUTDOOR REFERENCE PRESSURE PORT LEGEND BPC Building Pressure Controller DPC Duct Pressure Controller Fig 33 Air Pressure Tubing Locations 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 Z223 1 A Vs 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 34 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 48MP Units Only The flue inlet hoods are shipped in a bag taped to the basepan in the gas section of the unit UNITS SIZES 62L AND 7
5. FAN PERFORMANCE 48MP UNITS To obtain fan per formance for 48MP units 1 Enter fan performance table for appropriate base unit type and unit size 2 Determine the external static pressure from the fan per formance table using fan type field measured rpm and airflow cfm 3 Refer to the Component Pressure Drops table Table 18 on page 35 Calculate the adjusted external static pres sure value for the correct unit size and airflow for gas heat units 4 Calculate the net external static pressure for the gas heat units by subtracting the adjusted external static pressure value from Table 18 Step 3 from the external static pres sure from the fan performnce table Step 2 EXAMPLE Field Measurements Unit 48MP62L Fan Type Forward Curved RPM 500 CFM 22 000 1 Select Fan Performance Table 8 48 50MP62L with For ward Curved fan 2 Determine external static pressure using 500 rpm and 22 000 cfm ESP 1 25 3 Read the adjusted external static pressure from the Com ponent Static Pressure Drops table for 48MP62L gas heat units at 22 000 cfm Adjusted ESP 0 31 4 Calculate external static pressure ESP ESP ESP Adjusted 1 25 0 31 0 94 in wg Check rotation of wheel with arrow on the fan housing Check fan speed with a strobe type tachometer or use this formula Fan motor rpm x motor sheave pitch diameter in Rpm fan sheave pitch diameter in Obtain motor rpm from the fan motor nam
6. LEGEND NOTES re 1 Fan performance is based on wet coils and clean 2 in filters Bhp Brake Horsepower 2 Conversion Bhp to kW Refer to Fan Performance 48MP Units section for correct procedure on Bhp x 746 48MP units kW px Motor efficiency See Table 1 for motor efficiency Table 17 Fan Performance Air Foil 48 50MP10R AVAILABLE EXTERNAL STATIC PRESSURE in wg Eid os om 10 125 150 25 25 2 Rpm Bhp Rpm Bhp Bnp Rpm Bnp Bhp Bhp Rpm Bhp Rpm Bhp AIRFLOW on ng 24 7 26 5 30 2 32 0 28 6 32 2 34 1 38 0 34 000 31 0 34 5 36 2 40 3 42 4 36 000 33 5 37 2 39 0 40 3 44 5 38 000 38 3 40 1 42 0 45 9 47 8 40 000 39 2 43 2 45 1 49 1 61 2 42 000 42 2 46 4 48 5 52 6 54 7 44 000 45 7 49 8 51 9 56 2 58 4 46 000 49 3 53 6 55 7 60 1 63 6 48 000 53 1 57 5 64 2 66 5 50 000 57 2 61 7 68 7 71 0 52 000 61 4 66 1 73 2 LEGEND NOTES 1 Fan performance is based on wet coils and clean 2 filters Bhp Brake Horsepower 2 Conversion Bhp to kW Refer to Fan Performance 48MP Units section for correct procedure on Bhp x 746 48MP units kW Motor efficiency See Table 1 for motor efficiency 34 Table 18 Component Pressure Drop wg COMPONENT HEAT EXCHANGER 48MP ONLY Table 19 Maximum Allowable Supply Fan Wheel Spee
7. OPTIONAL DUTSIDE AIR INLET HOODS 0 1 OVERALL LIFTING LS OS HADIA SHIPPING DIM BOTH SIDES FDLDS DOWN FUR SHIPMENT HOLE IN LIFTING LUGS d b mm fm mm fm mm fum mm mm fum mm 22660 10255 oa 21 1 59 18957 459v 15 202 16 066 16 066 UNIT SIZE 48MPD E 49 1072 52 8 52 8 4 Unit clearances 1 Dimensions in are in millimeters Top Do not restrict condenser fans control box end 6 0 2 Center of gravity includes exhaust fan and high heat options Unit weight Sides 6 0 except on return fan equipped units 10 07 does not include exhaust fan or high heat options Economizer end 6 0 except power exhaust units 10 0 3 High heat add 260 Ib 118 kg For smaller service and operational clearances contact Carrier Application En Exhaust fan add 2275 Ib 1034 kg on 82N gineering Department e 2400 Ib 1090 kg on 90P and 10R 5 Downshot ducts designed to be attached to accessory roof curb If unit is mounted on dunnage it is recommended the ducts be supported by cross braces as done on the accessory roof curb Fig 4 Base Unit Dimensions 48MP82N 10R 10 WEIGHT EM Note arm See 2 fote 2 fin mm fi mm 4 y 14 542 C UNITS WITH EXHAUST UNITS WITHOUT EXHAUST FAND x lt
8. The VFD can be easily damaged by static electricity Use proper electrostatic discharge procedures when handling the controls of the VFD Never connect main circuit output terminals T1 T2 and T3 to AC main circuit power supply Always ground the VFD using the designated ground terminal Refer to the VFD tech nical manual for more information The VFD can indicate faults and alarms A blinking alarm condition is a warning that a trouble condition will occur or that there is a problem in the external circuitry The VFD will continue to operate during an alarm condition Alarm conditions are not entered into the fault register A steady fault indicator is displayed when the VFD fault relay has tripped The motor will coast to a stop and a fault signal is output is present Refer to the VFD technical manual for more information on alarms and faults EXHAUST FAN VFD The optional exhaust fan VFD con sists of an exhaust fan motor VFD and pressure transducer components except the tranducer are located in the re turn air section of the 48 50 through the hinged access door The BP transducer is located in the auxiliary control box Wiring should only be performed by qualified person nel All parameters have been factory set Do not change pa rameters unless necessary The VFD can be easily damaged by static electricity Use proper electrostatic discharge procedures when handling the controls of the VFD Never con
9. 38 START UP 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 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 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 applicable 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 Con trols and Troubleshooting literature If a different set point is required change per the example shown under Set Point Function section in Controls and Troubleshooting literature 6 Configure schedule subfunctions if applicable occu pied unoccupied and holiday periods See Schedule Func tion section in Controls and Troubleshooting literature for details on setting per
10. A2 6 B1 6 B2 6 265 275 265 275 265 299 265 275 19 19 19 19 19 19 19 19 15 23 30 38 45 58 65 73 85 92 100 14 21 28 35 42 61 68 75 86 93 100 R 22 85 85 86 87 93 93 93 96 Grooved Tube in OD 4 4 3 17 3 17 168 0 168 0 Smooth Tube in OD 2 2 3 14 4 14 101 4 TXV 2 60 364T 94 5 95 4 21 3 6 7 556 4 5VX1120 4 5VX1120 4 5VX1150 35 4 40 2 35 4 40 2 34 2 40 2 715 715 715 50 60 50 60 326T 364T 326T 364T 93 0 94 5 93 0 94 5 94 5 95 4 94 5 95 4 12 5 13 7 13 7 13 7 7 5 8 7 8 1 8 7 1050 1111 1035 1111 3 5VX1030 3 5VX1060 3 5VX1060 3 5VX1060 35 4 39 4 34 4 39 1 35 4 39 4 34 4 39 1 1298 1298 1298 1298 75 75 365T 365T 95 4 95 4 16 1 16 1 11 1 11 1 1207 1207 3 5VX1120 3 5VX1120 34 4 39 1 34 4 39 1 1298 1298 8 30 69 500 1 1140 Forward Curve Airfoil 52 000 40 25 1298 2 44 190 7 0 136 29 342 000 3 3 5 5 13 5 0 235 0 487 2 3 515 000 770 000 685 000 1 025 000 81 81 5 35 10 40 14 700 19 250 2 20 24 24 2 20 24 24 2 5 24 12 2 5 24 12 2 20 24 x 24 x 4 20 24 x 24 x 4 5 24 12x 4 5 24 12x 4 Cleanable Aluminum 24 20 x 25 x 1 24 20 x 25 x 1 Table 2 Optional Power Exhaust Specifications UNIT 48 50MP Type 100 Mod 10096 Non Mod 100 Mod 100 Non Mod 100 Mod 10096 Non Mod Motor Hp 30 30 40 40 40 40 Motor Frame Size 286T 286T 324T 324T 324T 324T Efficiency at Full Load
11. BASE UNIT STOP VALVE FROM GAS METER NPT plug is field supplied NOTE Follow all local codes Fig 34 Gas Piping Details INLET HOOD GAS HEAT 62L AND 70M SECTION SIZES ONLY PANEL FLUE HOOD AND FLUE DEFLECTOR HOOD HIGH HEAT UNITS ONLY Fig 35 Flue and Inlet Hood Locations 48MP Units Only INLET HOOD INLET HOOD SIDE PLATE TYP EACH SIDE Fig 36 Inlet Hood Assembly Fig 37 Flue Hood LE Check Compressor Mounting PUSH z HOOD UNITS 48 50MP62L Compressors are mounted on pans DOWN SO and are held down by 4 rail bolts during shipment After unit 2 15 installed loosen each of these bolts until the snubber washer ALIGN can be moved with finger pressure See Fig 40 and 41 UNITS 48 50MP70M 10R Compressors are mounted on rails and held down by rail bolts during shipment After unit 15 installed loosen the rail bolts to allow the rails and com pressors to float freely on the springs located under the rails See Fig 40 42 and 43 Install Accessories For applications requiring special accessories the following packages are available con denser coil hail guard package condenser coil protective TOP WHEN INSTALLED grilles and compressor security grilles Refer to the acces Fig 38 Flue Deflector Baffle Assembled sory installation instructions for information on accessory installation Fan Isolator Adjustment Remove shi
12. CONDENSER COILS Quantity Rows Fins in Total Face Area sq ft EVAPORATOR COILS Quantity Rows Fins in Standard Alternate Total Face Area sq ft Refrigerant Feed Device No per Circuit EVAPORATOR FANS Forward Curved Fan Motor Hp Motor Frame Size Efficiency at Full Load Standard Efficiency High Efficiency Fan Pulley Pitch Diameter in Motor Pulley Pitch Diameter in Fan Rpm Belts Quantity Model No Center Distance Range in Maximum Rpm Air Foil Fan Motor Hp Motor Frame Size Efficiency at Full Load Standard Efficiency High Efficiency Fan Pulley Pitch Diameter in Motor Pulley Pitch Diameter in Fan Rpm Belts Quantity Model No Center Distance Range in Maximum Rpm Air Foil Fan cont Motor Hp Motor Frame Size Efficiency at Full Load Standard Efficiency High Efficiency Fan Pulley Pitch Diameter in Motor Pulley Pitch Diameter in Fan Rpm Belts Quantity Model No Center Distance Range in Maximum Rpm CONDENSER FANS Quantity Diameter in Nominal Cfm Motor Hp Rpm SUPPLY FAN Nominal Cfm Size in Maximum Allowable Rpm Shaft Diameter at Pulley in Forward Curve Table 1 Physical Data 16 810 16 550 675 18 060 17 800 725 1 675 1 775 Semi Hermetic 2 2 A 6 B 6 1 6 A2 4 B 6 299 299 275 250 299 19 14 19 11 22 33 41 56 67 78 89 100 22 78 78 85 82 83 83 94 85 Grooved Tube OD 4 19 19 17 33 50 6
13. in long bolt See Fig 50 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 The LEDs light when REMOTE Mode has been selected DISPLAY SECTION SEQ e REF REMOTE 4 digit 7 segment LED display shows selected operation status fault code or parameter data lout kWout V F Fbias FLA PGRM DIGITAL OPERATOR JVOP 131 Function LEDs Switch between Function LEDs KEYPAD SECTION Increase parameter number or displayed Displays data to be value changed and enters new data Switch between LOCAL and REMOTE operation LOCAL Decrease parameter number modes REMOTE or displayed value Stop the motor or reset drive fault LED lights when drive is in stopped condition Run the motor LED lights when drive is
14. 32 000 35 1 34 000 38 0 36 000 414 38 000 45 2 40 000 494 42 000 54 0 44 000 59 1 46 000 64 7 48 000 70 8 50 000 773 52 000 84 3 LEGEND NOTES Bhp Brake Horsepower 1 Fan performance is based on wet coils and clean 2 in filters 2 Conversion Bhp to kW Refer to Fan Performance 48MP Units section for correct procedure on Bhp x 746 48MP units AIRFLOW Cfm 16 000 18 000 20 000 22 000 24 000 26 000 28 000 30 000 32 000 AIRFLOW Cfm 16 000 18 000 20 000 22 000 24 000 26 000 28 000 30 000 32 000 Kr va oL e RE Motor efficiency See Table 1 for motor efficiency Table 13 Fan Performance Air Foil 48 50MP62L AVAILABLE EXTERNAL STATIC PRESSURE in wg 125 15 225 25 Rpm Bhp Rpm Rpm Bhp Rpm Bhp Rpm Bhp Rpm she Rpm Up Rpm Bhp Rom Bhp Rom Bhp 3 4 4 1 4 8 5 5 i 8 0 10 8 4 5 5 2 6 0 6 8 9 5 12 3 5 8 6 7 7 6 8 4 11 2 14 3 7 4 8 4 9 3 10 2 13 0 16 4 9 2 10 2 11 2 12 3 15 3 18 7 11 4 12 5 13 7 14 8 18 1 21 5 13 9 15 1 16 3 17 5 21 1 24 7 16 6 17 9 19 2 20 5 24 4 28 2 19 8 21 2 22 6 23 9 28 1 32 2 275 300 350 425 500 PO PO PO 000 4 60 Goo WH Ci NN OA LEGEND NOTES Bhp Brake Horsepower 1 Fan performance is based on wet coils and clean 2 in
15. Displays the level of output current that the VFD is cur lout rently producing This is a display only function The user cannot change this displayed value Displays the output power that the VFD is currently pro kWout ducing This is a display only function The user cannot change this displayed value F R Sets the rotation direction of the motor when a run com mand is given Montr Press ente to access the monitor parameters U 01 through U 13 Accel Not used Decel Not used Vmtr Sets the rated voltage of the motor Sets preset pattern or allows a custom V f pattern to be set Sets the frequency reference for the analog fre 9 quency reference Fbias Sets the frequency reference bias for the analog fre quency reference FLA Sets the full load amps used for detecting motor over load When FLA is set to 0 it is disabled PID Enables or disables the PID kWsav Enables or disables the energy saving function PRGM Allows parameter programming LEGEND PID Proportional Integral Derivative REMOTE Mode indication LEDs SERVICE Service Access All unit components can be reached through clearly labeled hinged access doors These doors are equipped with tiebacks but if heavy duty servicing is needed it is recommended that the doors be removed or propped open Each door is held closed with 3 latches The latches are secured to the unit with a single 20 x
16. Inc Cryol 150A factory oil charge Texaco Inc Capella WF 32 150 Witco Chemical Co Suniso 3GS Do not reuse drained oil and do not use any oil that has been exposed to atmosphere ADD OIL Close suction shutoff valve and pump down crankcase to 2 psig 14 kPa Low pressure cutout must be jumped Wait a few minutes and repeat until pressure re mains steady at 2 psig 14 kPa Remove oil fill plug above the oil level sight glass add oil through plug hole and re place plug Run compressor for 20 minutes and check oil level 49 IMPORTANT For units with 2 compressors per re frigeration circuit both compressors must be running to adjust the oil level Two oil level equalizer lines be tween compressors distribute the oil to each compressor REMOVE OIL Pump down compressor to 2 psig 14 kPag Loosen the 4 in 6 4 mm pipe plug at the com pressor base and allow the oil to seep out past the threads of the plug NOTE The crankcase will be slightly pressurized Do not remove the plug or the entire oil charge will be lost Small amounts of oil can be removed through the oil pump discharge connection while the compressor is running Moisture Liquid Indicator clear flow of liquid refrigerant indicates sufficient charge in the system Bubbles indicate undercharged system or the presence of non condensables Moisture in the system measured in parts per million ppm changes the color of the
17. 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 Page Main Burners 52 MAIN BURNER REMOVAL Protective Devices 52 COMPRESSOR PROTECTION EVAPORATOR FAN MOTOR PROTECTION CONDENSER FAN MOTOR PROTECTION HIGH AND LOW PRESSURE SWITCHES Variable Frequency Drive VFD 53 SUPPLY FAN VFD EXHAUST FAN VFD DISPLAYING FAULT SEQUENCE Control Modules 53 Processor Module s PSIO 54 High Voltage Relay Modules DSIO1 05102 54 Refrigerant Feed Components 54 Thermostatic Expansion Valve 54 Hot Gas Bypass 55 Condenser Fans 55 Compressor Removal 55 Compressor Replacement 55 TROUBLESHOOTING 55 58 START UP CHECKLIST CL 1 to CL 4 WARNING Before performing service or maintenance operations on unit turn off main power switch to unit Electrical shock could
18. wg AIRFLOW Cfm 18 000 20 000 22 000 24 000 26 000 28 000 30 000 32 000 34 000 36 000 1 1 1 2 2 2 3 4 AIRFLOW Cfm 18 000 20 000 22 000 24 000 26 000 28 000 30 000 32 000 34 000 36 000 LEGEND Bhp Brake Horsepower Refer to Fan Performance 48MP Units section for correct procedure on 48MP units NOTES 1 Fan performance is based on wet coils and clean 2 in filters 2 Conversion Bhp to kW Bhp 746 Motor efficiency See Table 1 for motor efficiency kW O N HMMS o O OWNDOANAO 2 2 30 17 1 18 9 21 3 24 3 28 1 32 6 37 9 44 1 Im 00 O 00 O Bhp 12 6 14 5 16 9 19 7 23 0 26 8 31 0 35 9 41 3 47 8 Bhp 24 4 25 8 27 9 30 6 33 9 37 7 42 2 47 2 52 9 59 2 Table 10 Fan Performance Forward Curved 48 50MP82N AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW Cfm 5 CO ROOOO MPBINO O to to 400 AIRFLOW Cfm 2 25 Bhp Rpm Bhp Bhp LEGEND NOTES 1 Tm Bhp Brake Horsepower 1 te eve on wet coils and clean 2 in filters Refer to Fan Performance 48MP Units section for correct procedure on Bho x 7
19. 0 For smaller service and operational clearances contact Carrier Application Engineering Department 5 Downshot ducts designed to be attached to accessory roof curb If unit is mounted on dunnage it is recommended the ducts be supported by cross braces as done on the accessory roof curb Fig 3 Base Unit Dimensions 48MP62L 70M 9 BASERAIL 146 0 5 3 4 SE BASERAIL 978 091 97 0 3 5 8 D FIELD POWER 31371 10921 10 3 1 2 3 7 BOTTOM RETURN SIZE 90P AND 10R 11168 UNITS HAVE 3 10 8 CONDENSER FANS BOTTOM SUPPLY BASERAIL 1625 easerar SEE RODFCURB CERTIFIED os 3 4 1196 DINENSTONS t LOCATIONS e pe 6 3 1 4 BAROMETRIC RELIEF Von F ACCESS DOOR POWER EXHAUST 1 10 3 4 REMOVABLE ACCESS DOOR ACCESS DOOR NEAR SIDE ONLY NEAR SIDE ONLY FAR SIDE ONLY FLUE BOXES CONTROL BOX OPTION 1207 ACCESS DOR AIR HOODS 38 13 3 11 1 0 CBOTH SIDES ML td NN Q 1 1 2 01165 3 9 7 8 T GAS BURNERS 6550 70 HIGH HEAT 21 5 7 8 ACCESS DOOR EE TER POVER EXHAUST i 0 7 7 8 MN SIE 110160 FIELD SUPPLY d GAS PIPE CONNECTION POWER REP DUCT SUPPLY AIR LIFTING POSITION 38 11 0 1 1 2 NPT AIN C DUCT CONN 4 EACH SIDE NEAR SIDE ONLY LIFTING POS ITION CONTROL BOX 5 EACH SIDE ACCESS PANELS ON 90 amp 10 DISCONNECT SWITCH
20. 14 9 16 3 810 22 3 32 000 11 0 12 3 13 7 15 2 16 6 18 1 831 24 4 34 000 12 7 14 1 15 6 17 1 18 7 20 2 854 26 7 36 000 14 6 16 1 17 6 19 2 20 8 22 4 877 29 2 38 000 16 7 18 3 19 9 21 5 23 2 24 9 901 31 9 40 000 18 9 20 5 22 2 24 0 25 7 27 4 925 34 8 42 000 21 3 23 1 24 8 26 6 28 4 30 3 950 37 9 AIRFLOW Cfm 20 000 22 000 24 000 26 000 28 000 30 000 32 000 CO IO PO PO PO PO 60200030 4 0 34 000 43 4 36 000 46 0 38 000 49 0 40 000 52 5 56 2 42 000 LEGEND NOTES Bhp Brake Horsepower 1 Fan performance is based on wet coils and clean 2 in filters 2 Conversion to kW Refer to Fan Performance 48MP Units section for correct procedure on Bh 746 48MP units kW px Motor efficiency See Table 1 for motor efficiency 33 Table 16 Fan Performance Air Foil 48 50MP90P AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW Cfm 24 000 26 000 20 1 28 000 21 7 23 4 25 1 30 000 23 6 25 2 27 0 28 8 30 7 32 000 25 8 27 4 29 1 30 8 32 7 36 6 34 000 28 1 29 8 31 6 33 3 35 0 38 9 43 0 36 000 30 6 32 4 34 2 36 0 37 8 41 5 45 6 38 000 33 4 35 2 37 1 39 0 40 0 44 7 48 6 40 000 36 2 38 1 40 0 42 0 43 9 44 9 52 0 42 000 39 3 41 3 43 3 45 3 47 3 51 5 55 6 44 000 44 6 45 6 48 9 51 0 55 2 59 6 46 000 48 4 50 5 52 6 54 8 59 1 63 6
21. 5 13 5 0 235 0 487 2 3 515 000 770 000 685 000 1 025 000 81 81 10 40 20 50 12 850 15 400 2 15 24 x 24 x 2 5 24 x 12x2 15 24 x 24 x 2 5 24 x 12x 2 15 24 x 24 x 4 5 24 12x 4 15 24 x 24 x 4 5 24 x 12x 4 Cleanable Aluminum 16 20 x 25x 1 16 20 x 25x 1 190 7 0 136 29 342 000 3 3 5 5 13 5 0 235 0 487 2 3 515 000 770 000 685 000 1 025 000 81 81 5 35 10 40 14 700 19 250 2 20 24 24 2 5 24 x 12x2 20 24 x 24 x 4 5 24x 12x 4 24 20 x 25 x 1 BASE UNIT 48 50MP NOMINAL CAPACITY tons OPERATING WEIGHT Ib Base Unit 48MP 50MP Copper Condenser Coils Exhaust Fan COMPRESSORS Number of Refrigerant Circuits Circuit No of Cylinders Model 06E Oil Charge pints Capacity Steps REFRIGERANT Operating Charge Ib Sys 1 Sys 2 Standard Coil Operating Charge Ib Sys 1 Sys 2 Alternate Coil CONDENSER COILS Quantity Rows Fins in Total Face Area sq ft EVAPORATOR COILS Quantity Rows Fins in Standard Alternate Total Face Area sq ft Refrigerant Feed Device No per Circuit EVAPORATOR FANS Forward Curved Fan Motor Hp Motor Frame Size Efficiency at Full Load 95 Standard Efficiency High Efficiency Fan Pulley Pitch Diameter in Motor Pulley Pitch Diameter in Fan Rpm Belts Quantity Model No Center Distance Range in Maximum Rpm Air Foil Fan Motor Hp Motor Frame Size Efficiency at Full Load 95 Standard Effi
22. HGBP Item D page CL 1 DISABLE Disable lead lag 0 DIS 1 ENB 1 1 BLD PRES Configure building pressure control modulating power exhaust vi BPS 05 Use h for building pressure set point range 0 to 5 05 x BPS X Set building pressure set point per job requirements LOGGEDON Access log on off function v LOG OFF Use vi to access log off LOGD OFF Logged off okay 1 Es INPUTS Run quick test to verify operation of unit functions see Controls and Troubleshooting Guide through 1 SETPOINT Set system set points per job requirements OHSP X Set occupied heat set point Range 55 80 F 68 CV only wi OCSP X Set occupied cool set point Range 55 80 F 78 CV only UHSP X Set unoccupied heat set point Range 40 80 F 55 UCSP X Set unoccupied cool set point Range 75 95 F 90 SPSPX Set supply duct pressure set point Range 0 5 0 in wg 1 5 bl SASP X Set supply air set point temperature Range 45 70 F 55 3 TIME Current time date dow hh mm Set day of week and time mm dd yy Set month day and year DAYLIGHT Set daylight savings time begin end dates Required if job conditions require adjustment of clock for daylight savings time see Controls and Troubleshooting Guide 5 HOLIDAY Set holiday dates Required if job conditions require a different schedule on holidays than other days see Controls and Trouble shooting Guide PERIOD X Set occupied unoccupied schedules Requir
23. HR1 NO and HR2 NO 3 Connect pressure gage to gas supply pressure tap See Fig 34 4 Connect pressure gage to manifold pressure tap on each gas manifold 5 Turn on manual gas stop valve During the heating portion of the Quick Test 5 both the first and second stage of gas heat will be tested During the first stage all of the burner sections will operate at low fire condition approximately 75 capacity During the second stage all of the burner sections will operate at 100 capacity During the Quick Test of stage 2 after the unit has been operating for several minutes verify that the incoming gas line pressure is 5 5 in wg or greater Also verify that the manifold pressure at each burner section is 3 3 in wg If manifold pressure must be adjusted refer to the Gas Valve Adjustment section on page 52 After the unit has been in operation for 5 minutes check the temperature rise across the unit heat exchangers See the unit informative plate for correct rise range limits Air quan tities may need to be adjusted to bring the actual rise within allowable limits IMPORTANT After the Quick Test has been perfor mend for stage 2 remove the jumper betwen HR1 NO and HR2 NO Check Supply Fan Rotation 1f unit is equipped with an optional VFD check for correct fan rotation Fan direction can be changed by disconnecting power and switch ing 2 power leads downstream of the VFD output terminals T1 T2 and T3
24. SENSOR T55 e SPACE TEMPERATURE SENSOR T56 Cora SYSTEM 42 45 CV Applications Only Gonponehis 1 e SPACE TEMPERATURE AVERAGING EE FE SE ESTE HEAT INTERLOCK RELAY Units Only PROCESSOR MODULE NO 1 Not Necessary For DAV Applications PROCESSOR MODULE NO 2 OPTION AND ACCESSORY CONTROL WIRING RELAY MODULES DSIO KEYPAD AND DISPLAY MODULE HSIO Carrier Comfort Network Interface 23 Default Set Points Changing Set Points 43 Air Pressure Tubing 24 M P Gas Piping 48 Series Units Only 26 otor Protection DE LL Son day wine a sem Re 43 i Variable Frequency Drive VFD 43 Installing Flue Inlet Hoods 48MP Units 26 DISC ANDASETEAD Fan Isolator Adjustment 27 SERVICE Lee eT SESS 45 55 Check Compressor Mounting 27 Service Access 45 Install Accessories 27 UNIT CONTROL BOX 5 COMPRESSORS Sen E m LIQUID SERVICE VALVES SOLENOID VALVES Je DNE 2 FILTER DRIERS AND SIGHT GLASSES Evaporator Fan Belts Pulleys HE RO EVAPORATOR FAN MOTORS PULLEYS AND and Sheaves 29 BELTS Controls Configuration and Quick Test 35 j DURS EXHAUST MOTORS PULLEYS AND SUPPLY FAN STATUS SWITCH FS CHECK FI
25. Solid State Enthalpy Sensor HH57AC077 KEYPAD AND DISPLAY MODULE HSIO CONFIGURATION IMPORTANT The HSIO keypad and display module is required for initial start up of these units All units are shipped in standby mode and the HSIO should be used to change the unit to run mode Once the unit is in run mode the HSIO is not required for normal operation The keypad and display module provides unit function in formation at the unit See Fig 48 The module consists of a keypad with 6 function keys 5 operative keys 10 numeric keys 0 through 9 and an alphanumeric 8 character liquid crystal display LCD Key usage is explained in Table 23 Each function has one or more subfunctions 36 The HSIO keypad and display module is installed by con necting the power and communication plugs and can be easily moved from one unit to another Because of this flex ibility one HSIO can be used for several units Unit operation is controlled by the status of the run standby mode on the HSIO To access the mode press 1 on the HSIO keypad and then press vi The HSIO will display either STBY YES or STBY NO To enable the unit press or and press while at the STBY YES display To disable the unit press while at the STBY NO display Clearing alarm that has stopped unit operation is accomplished by entering the STBY YES mode IMPORTANT Use the STBY YES mode when ser vicing the unit or running the quic
26. Start SNUBBER Up review Start Up Checklist at the center of this COMPRESSOR FOOT publication The Checklist assures proper start up of a unit and provides a record of unit condition applica tion requirements system information and operation at initial start up Do not attempt to start the air conditioning system until following checks have been completed ISOLATION SPRING System Check 1 Check the outside air hoods to ensure the hoods are fully opened and secure with filters in place 2 Check the supply fan and exhaust fan suspension brack Fig 41 Compressor Mounting ets Shipping spacers should be removed and sleds 48 50MP62L Units levelled to specification 3 Check compressor suspension On 48 50MP62L units snubber washers can be moved with finger pressure On all other units rails allow compressors to float freely on compressor rail springs 4 Electrical power source must agree with unit nameplate 5 Check tightness of all electrical connections COMPRESSOR FOOT Failure to open discharge service valve prior to start ing compressor can result in damage to or failure of the compressor COMPRESSOR MOUNTING 6 RAIL Backseat open compressor suction and discharge shut off valves Close valves one turn to allow refrigerant pres sure to reach the test gages 7 Open liquid line service valves 8 Oil should be visible in the compressor sight glasses See Fig 44 An acce
27. To disable the unit press E while at the STBY NO display Clearing an alarm that has stopped unit operation is accomplished by entering the STBY YES mode IMPORTANT Use the STBY YES mode when ser vicing the unit or running the Quick Test feature IMPORTANT If unit is also equipped with REMOTE START function place LOCAL REMOTE switch in LOCAL Off position when servicing or running Quick Test feature Default Set Points Changing Set Points Re fer to Table 24 for factory default configuration and set point values Record any changes made during start up and leave with unit for future reference These values may be changed from the HSIO keypad at any time If changing values via Service Tool or CCN Build ing Supervisor the unit must be in RUN mode STBY NO which is done through HSIO input or a Remote Start input After changing the values in subfunction 3 the Data Reset function must be enabled 43 Motor Protection Manual reset calibrated trip mag netic circuit breakers are provided for each compressor sup ply fan motor and optional exhaust fan motor Outdoor fan motor circuits are also protected by circuit breakers Refer to the Service section more information on serv icing motors Variable Frequency Drive VFD An optional VFD can be factory installed and is used to modulate supply fan airflow to maintain duct static pressure on VAV applications A second VFD can be used t
28. a cooling coil submaster reference CCSR value to satisfy conditions and outputs this value to the sub master loop OCCUPIED COOLING General Economizer cycle must not be usable or damper position must be open to 9046 or higher VAV Units Supply fan must be ON for cooling control to operate Sequence is as follows 1 Unit must not be in Heating mode 2 Master Loop will survey occupancy status Supply Air Set Point SASP and any Supply Air Temperature Reset command then issue Cooling Coil Submaster Reference CCSR to Cooling Submaster Loop CSL 3 The CSL surveys actual SAT then calculates number of capacity stages required to produce the CCSR leaving the unit 4 Stages of cooling capacity are initiated From zero stages there will be a 1 5 to 3 minute delay before the first stage is initiated The time delay between stages in increasing demand is 90 seconds 5 As actual SAT approaches CCSR value stages are re leased The minimum time delay between stages on de creasing demand is 90 seconds NOTE Demand for heating has priority and Master Loop will either terminate existing or prevent initiation of Cooling Cycle by issuing a CCSR at the maximum limit This will cause the CSL to select zero stages of cooling capacity initiating a stoppage of an existing cooling cycle CV Units Supply fan must be ON for cooling control to operate Sequence is as follows 1 Master Loop will survey space temperature an
29. filters 2 Conversion Bhp to kW Refer to Fan Performance 48MP Units section for correct procedure on Bhp x 746 48MP units EEE Motor efficiency See Table 1 for motor efficiency 32 Table 14 Fan Performance Air Foil 48 50MP70M AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW i E 4 2 75 Bhp 18 000 13 3 20 000 15 2 22 000 9 1 17 3 24 000 1 0 19 7 26 000 3 4 22 5 28 000 6 0 25 6 30 000 8 8 29 0 32 000 2 1 33 1 34 000 5 7 37 4 36 000 9 6 42 1 AIRFLOW Cim 39 325 350 3 400 425 450 4 5 00 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 18 000 20 000 25 8 22 000 28 5 24 000 31 4 26 000 34 7 28 000 38 3 30 000 42 1 32 000 46 4 34 000 51 0 36 000 55 9 LEGEND NOTES 1 Fan performance is based on wet coils and clean 2 in filters Bhp Brake Horsepower 2 Conversion Bhp to kW Refer to Fan Performance 48MP Units section for correct procedure on Bh 746 48MP units kW Motor efficiency See Table 1 for motor efficiency Table 15 Fan Performance Air Foil 48 50MP82N AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW Cfm 20 000 22 000 24 000 4 1 5 0 6 0 7 0 8 1 9 4 4 9 5 9 7 0 8 1 9 2 10 3 5 9 7 0 8 1 9 2 10 4 11 6 26 000 7 0 8 1 9 3 10 5 11 7 13 0 773 18 7 28 000 8 1 9 3 10 6 11 9 13 2 14 5 787 20 2 30 000 9 6 10 8 12 1 13 5
30. 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 Driers The 48 50MP units use replaceable core type filter driers one in each refrigeration circuit The filter driers are located in the condenser sections accessible from the right side of the unit Replace the filter cores whenever the moisture liquid in dicator shows moisture in the system Follow instructions on the packaging for the replacement cores for disassembling and reassembling the filter assem blies and housings Liquid Line Service Valve Located immediately ahead of the filter drier this valve has 4 in flare connec tion for field charging With the liquid circuit shut the com pressor 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 Compressor Suction and Discharge Service Valves Each compressor is provided with suction and discharge service valves With these valves the compressor can be isolated from the refrigerant system for
31. of STANDBY or Heating mode a 4 minute delay will occur before the economizer damper is con trolled During this delay damper position is limited to CLOSED or MINIMUM position depending on current unit occu pancy status If fan status is OFF the outside air dampers will remain closed return air dampers will be open If fan status is ON the outside air dampers will normally be at minimum damper position 39 Economizer operation is permitted if the system is not in Heating mode if outdoor air enthalpy via switch or humid ity differential is acceptable and if outside air temperature is less than space temperature If economizer operation is permitted the ecomizer con trol loop checks for Cooling System operation If ON the outside air dampers will be driven to maximum position If cooling is not on for VAV units the economizer will modulate to satisfy the supply air set point If cooling is not on for CV units the economizer will modulate to satisfy the space temperature set point If Economizer operation is not permitted the outside air dampers will be driven to minimum position during Occu pied period or closed during Unoccupied period For VAV units Economizer operation is not permitted when Occupied Heating is enabled and the Return Air Tempera ture is LESS THAN OHSP 1 COOLING All Units The controls try to control the supply air temperature SAT to a system calculated coil referenc
32. oil until the level is approximately 34 to Vs of sight glass 06E 299 compressors are of sight glass See Fig 44 See Oil Charge section on page 49 for information on adding or removing oil 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 Do not reuse drained oil and do not use any oil that has been exposed to the atmosphere COMPRESSOR EXCEPT 06E 299 COMPRESSOR 06E 299 1 8 3 8 Ls Fig 44 Operating Oil Levels Sight Glass Evaporator Fan Belts Pulleys and Sheaves Belts pulleys and sheaves are factory installed All pulleys are nonadjustable See Table 1 for fan shaft center distance ranges and shaft sizes when making selections for field supplied drives Factory installed drives are fixed speed and are non adjustable Refer to Table 1 for factory supplied wheel speeds and drive set data If different wheel speeds are required for an application Carrier recommends that the installer contact the nearest Brown ing dealer The Browning dealer can develop the required information for the fan drive set 29 Observe the maximum wheel speed and unit airflow lim its for the specific unit size and fan type See Tables 8 12 for forward curve supply fan perfor mance See Tables 13 17 for air foil supply fan perfor mance
33. provide extensive troubleshooting in formation to service personnel through the use of status codes and alarm and alert codes from the control system which are displayed on the unit HSIO or through the use of Service Tool or CCN Building Supervisor For more information on diagnostics codes and possible causes refer to the Controls and Troubleshooting manual Use the Quick Test function to check control inputs and outputs including economizer actuators Refer to Controls and Troubleshooting Guide If there are indications of hunting rapid oscillations of control functions such as duct static pressure or supply air temperature or if the response rate is too slow check the gain values Refer to the Control Loop Checkout section on page 40 for more information If the unit is equipped with an optional VFD and the sup ply or exhaust fan is not running when required refer to the troubleshooting section of the separate VFD technical manual provided with the unit For troubleshooting information on mechanical systems refer to the troubleshooting and diagnostics table on the next page TROUBLESHOOTING AND DIAGNOSTICS PROBLEM COMPRESSOR DOES NOT RUN Contactor Open Power off Fuses blown in field power circuit Alarm tripped No control power Compressor circuit breaker tripped Safety device lockout circuit active Low pressure switch open NO 8 High pressure switch open 9 Loo
34. the Controls Operation and Troubleshooting instruc tions for information on the control logic used by the unit controls for gas heat operation The 48MPD units have 2 gas heat sections The 48 units have 3 gas heat sections Each individual section op erates in the same manner NOTE The 48MP units have 2 stages of heat When the PIC control calls for heating power is sent to W on each IGC integrated gas controller board An LED light emitting diode on the IGC board will be on during normal operation A check is made to ensure that the rollout switch and the limit switch are closed and the induced draft motor is not running The induced draft motor is then en ergized and when speed is proven with the hall effect sensor on the motor the ignition activation period begins The burn ers will ignite within 5 seconds If the burners do not light there is a 22 second delay be fore another 5 second attempt If the burners still do not light this sequence is repeated for 15 minutes After the 15 min utes have elapsed if the burners have not been lit heating is locked out To reset the control use the manual reset method found in the Controls Operation and Troubleshooting book When ignition occurs the IGC board will continue to moni tor the condition of the rollout and limit switches the hall effect sensor and the flame sensor When additional heat is required W2 closes and initiates power to the second stage of the m
35. type and size Replace transformer if primary windings are receiving power Check unit status at HSIO Check alerts and alarms at HSIO Cor rect as required and reset Check continuity at fan status switch contacts Check wiring from fan status switch to PSIO no 1 channel 12 Refer to separate VFD technical manual for troubleshooting instruc tions Check connections at motor lead junction box Check motor windings Check for blown fuse Check for loose connections at motor junction box Check belts Replace as complete set if necessary Check for input signal at PSIO no 1 channel 12 Replace switch if defective eae 1 Check alerts and alarms at HSIO Check status at HSIO Replace PSIO no 1 2 Check for input signal at VFD terminals FI and FC 3 Check switch continuity Replace switch if defective 57 Refer to Fig 65 for IGC troubleshooting information Nri ON Dec ON 3 FLASHES FLAME SENSOR INDICATES FLAME WITH CLOSED GAS VALVE 5 FLASHES IGNITION LOCKOUT No ignition within 15 minutes WT FROM PIC CONTROL BOARD ENERGIZES W ON IGC 1 MINUTE LOCK ON COMBUSTION RELAY ENERGIZES INDUCED DRAFT MOTOR IDM THROUGH TERMINAL CM ON IGC IF IDM IS TURNING AT CORRECT SPEED AT LEAST 2400 RPM HALL EFFECT SENSOR SENDS CORRECT SIGNAL TO TERMINAL J1 ON IF LIMIT SWITCHES AND ROLLOUT SWITCHES ARE CLOSED IGC SAFETY LOGIC WILL INITIATE IGNITION SEQUENCE LEGEND IG
36. valve For low side pressure relief a fusible plug is inserted in the side of the accumulator See Fig 60 A pres sure relief valve installed on the compressor relieves at 450 psig 3102 kPag Adjustments EVAPORATOR FAN AND POWER EXHAUST MOTOR PLATE Adjust using 16 wrench on the adjusting bolts 1 Loosen holddown bolts See Fig 61 2 Turm 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 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 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 4 Tighten belts using the motor plate adjusting bolts 5 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 turns NOTE Check the tension at least twice during the first day
37. 0M The high heat units 48 have 3 flue hoods 3 flue deflector hoods and one inlet air hood to be field installed See Fig 35 The low heat units 48MPD have 2 flue hoods 2 flue deflector hoods and one inlet air hood Remove the shipping block offs and shipping tape from the flue openings in the access panel and the corner post The inlet hood is shipped unassembled and must be as sembled before mounting to the access panel See Fig 36 Install inlet screen on inlet hood using speed clips and screws provided Attach the flue hoods to access panel and corner post us ing screws provided See Fig 37 Hoods go over each com bustion air outlet Install the flue deflector baffle inside the flue deflector hood See Fig 38 Install flue deflector hoods over each flue hood UNIT SIZES 82N 90P and 10R The high heat units 48 have 3 flue hoods and 3 flue deflector hoods to be field installed See Fig 35 The low heat units 48MPD have 2 flue hoods and 2 flue deflector hoods Remove the shipping block offs and shipping tape from the flue openings in the access panel and the corner post Attach the flue hoods to access panel and corner post us ing screws provided See Fig 37 Hoods go over each com bustion air outlet Install the flue deflector baffle inside the flue deflector hood See Fig 38 Install the flue deflector hoods over each flue hood UNION FOR SERVICING 1 8 NPT PLUG MANUAL GAS
38. 46 48MP units kW px Motor efficiency See Table 1 for motor efficiency Table 11 Fan Performance Forward Curved 48 50MP90P AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW Cfm Bhp 22 000 6 9 7 9 8 13 0 24 000 8 5 9 6 11 7 14 8 26 000 10 3 11 5 13 8 16 9 28 000 12 3 13 6 16 2 19 0 30 000 14 6 16 0 18 8 21 4 32 000 16 5 17 9 21 0 24 5 34 000 19 4 20 9 24 1 27 6 36 000 22 6 24 2 27 5 31 2 38 000 26 2 27 9 31 3 35 1 40 000 30 3 32 0 35 5 39 4 42 000 34 7 36 4 40 2 44 1 44 000 39 5 41 3 45 2 49 3 46 000 44 8 46 7 50 7 54 9 em 225 2 50 2 75 Bhp Rpm Bhp Rpm Bhp Rpm Bhp 22 000 23 5 24 000 25 5 26 000 28 0 28 000 30 5 30 000 33 0 32 000 36 5 34 000 40 4 36 000 44 1 38 000 48 1 40 000 52 6 42 000 57 6 44 000 63 0 46 000 68 0 LEGEND NOTES m Bhp Brake Horsepower i BAIN OB DRM on wet coils and clean 2 in filters Refer to Fan Performance 48MP Units section for correct procedure on Bhp x 746 48MP units kW px Motor efficiency See Table 1 for motor efficiency 31 Table 12 Fan Performance Forward Curved 48 50MP10R AVAILABLE EXTERNAL STATIC PRESSURE in wg Meth 0 75 1 50 Bhp 26 000 15 7 28 000 177 30 000 20 2 32 000 241 34 000 26 8 36 000 30 1 38 000 334 40 000 37 1 42 000 41 6 44 000 46 5 46 000 51 8 48 000 57 6 50 000 63 9 52 000 70 6 AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW Cfm BR p 26 000 26 5 28 000 29 0 30 000 315
39. 5 to 70 F SPSP 0 to 5 0 in wg UCDB Unoccupied cooling deadband 4 0 to 10 UCSP Unoccupied cool set point F 75 to 95 F UHDB Unoccupied heating Mans 0 to 10 UHSP Unoccupied heat set point F LEGEND IAQ Indoor Air Quality NFTC Unoccupied Free Cooling ppm Parts Per Million 40 to 80 F These items are found under the Service function and can only be accessed using either the Build ing Supervisor or Service Tool TThese items are found under the Service function Occupied space TtSupply duct NOTE Set points HHL HHOR and OCS OACS are displayed differently on the HSIO and Building Su pervisor The set points are shown as HHL and OCS on the HSIO The set points are shown as HHOR and OACS on Building Supervisor or Service Tool 37 Table 25 Basic Configuration Data SET POINT RANGE Damper Boston mini ZI Cooling Occupied 55 to 80 Static Pressure SPSP 0 to 5 0 Supply Air Temperature SASP 55 F 45 to 70 Date and Time TIME dow hh mm mm dd yy um Override Schedulest OVRD x HR 0 hrs 0 1 2 4 Schedule Periods OCC HH MM LEGEND CV Constant Volume Variable Air Volume Requires Occupied Heating function enabled TSee text section for discussion and instructions Gas Pressure Check Prior to performing the Quick Test install gas pressure gages and jumper as follows 1 Turn off manual gas stop valve 2 Install a jumper between
40. 66 INDOOR UNIT BASE CROSS RAIL LOCATIONS 1 31501 LA 0 A poen UNIT DRAIN CONNECTIONS n we ee sm 761 CONDENSER CONDENSER IE END END CORNER CONNECTIONS AND 0 0 1 0 0 2 SPLICE PLATE CONNECTIONS 12 71 H FT 50 81 CONDENSER CONDENSER RIGID INSULATION END END Its FIELD SUPPLIED TN 127 127 UNIT LEVELING TOLERANCES FROM EDGE OF UNIT TO HORIZONTAL UNIT BASE RAIL UNIT CROSS RAIL COUNTER FLASHING FIELD SUPPLIED gt GASKET SUPPLIED WITH CURB ROOF ING FELT FIELD SUPPLIED CANT STRIP FIELD SUPPLIED ROOFING MATERIAL FIELD SUPPLIED NOTES 1 To prevent the hazard of stagnant water build up in the drain pan on the indoor section unit cannot exceed leveling tolerances shown 2 If a Carrier roof curb is not used curb cross rails must be postioned to clear unit base rail locations shown Fig 2 Roof Curb Dimensions 48 50MP82N 10R gen 0 5 3 4 BOTTOM RETURN 78171 25 7 3 4 MENSEN ET 1 D 1 7 16 443 y POWER 2070 10921 6 9 1 2 v oo 0 3 5 8 D FIELD 1914 7 0 LP H 1 i BOTTOM SUPPLY C102 BASERAIL SEE RODFCURB CERTIFIED 0 5 3 4 DRAWING FOR DUCT 1 18031 1283 DIMENSIONS amp LOCATIONS 5 1 4 e 1 2 BAROMETRIC RELIEF UR EXHAUST F OPTION AC
41. 7 83 100 4 3 17 3 17 116 7 128 3 Smooth Tube 58 OD 2 2 3 14 3 14 4 14 4 14 62 6 70 0 TXV 2 TXV 2 3 5VX1120 4 5VX1080 40 4 45 2 39 4 44 9 1595 1595 Forward Curve Airfoil 32 000 36 000 36 000 30 0 30 0 33 0 835 835 1595 2 69 2 69 2 44 82N 105 22 660 22 400 725 2 375 A1 6 A2 4 B1 6 B2 6 265 250 265 265 19 14 19 19 18 26 35 44 53 56 65 74 82 91 100 85 82 92 88 96 1050 3 5VX1060 3 5VX1060 35 4 39 4 35 4 39 4 1298 1298 60 364T 94 5 95 4 11 0 7 1 1119 4 5VX1030 34 4 39 1 1298 6 30 52 000 1 1140 Airfoil 42 000 42 000 36 0 40 25 715 1298 2 69 2 44 FURNACE SECTION 48MP Units Only Rollout Switch Cutout Temp F Number of Burners Burner Orifice Diameter in drill size Gas Input Btuh Manifold Pressure in wg Natural Gas Gas Valve Input Pressure Range in wg psig LOW HEAT 48MPD HIGH HEAT 48MPE Number of Sections Gas Input Btuh Stage 1 Stage 2 Efficiency Steady State Temperature Rise Range F Minimum Heating Airflow cfm Field Gas Connection Size in FILTERS Medium Efficiency 3096 Pleated Standard Quantity Size in High Efficiency 90 Cartridge Filters with Prefilters Optional Quantity Size in Outdoor Air Inlet Screens Quantity Size in LEGEND Thermostatic Expansion Valve 190 7 0 136 29 342 000 3 3 5
42. 9 Standard Efficiency 92 4 92 4 i 3 93 0 High Efficiency 94 5 Fan Pulley Pitch Diameter in 20 0 Motor Pulley Pitch Diameter in 5 8 Fan Rpm 526 Belts Quantity Model No 5 BX90 Center Distance Range in 21 8 25 9 Maximum Allowable Rpm 560 Type 50 Non Mod 50 Non Mod 50 Non Mod Motor Hp 7 5 7 5 7 5 Motor Frame Size 213T 213T 213T Efficiency at Full Load Standard Efficiency 88 5 88 5 88 5 High Efficiency 91 7 91 7 91 7 Fan Pulley Pitch Diameter in i 18 4 Motor Pulley Pitch Diameter in 3 6 3 6 3 6 Fan Rpm 412 397 346 Belts Quantity Model No 2 BX75 2 77 2 BX90 Center Distance Range in 21 3 24 1 21 7 24 2 24 9 27 4 Maximum Allowable Rpm 690 650 600 Table 2 Optional Power Exhaust Specifications cont UNIT 48 50MP Type 10096 Mod 10096 Non Mod 10096 Mod 10096 Non Mod Motor Hp 50 50 60 60 Motor Frame Size 326T 326T 364T 364T Efficiency at Full Load 20 Standard Efficiency 94 5 High Efficiency 95 4 Fan Pulley Pitch Diameter in 28 1 Motor Pulley Pitch Diameter in 9 1 Fan Rpm 558 Belts Quantity Model 3 5VX1060 3 5VX1060 3 5VX1060 3 5VX1060 Center Distance Range in 21 8 25 9 21 8 25 9 20 9 25 6 20 9 25 6 Maximum Allowable 560 560 560 560 Type 50 Non Mod 50 Non Mod Motor Hp 10 15 Motor Frame Size 215T 254T Efficiency at Full Load 96 Standard Efficiency 89 5 89 5 High Efficiency 91 7 91 7 Fan Pulley Pitch Diamet
43. 95 5000 4339 4051 19 4 311 3 11 5337 5338 5290 3969 20 234 4 194 4 194 82N 6614 6326 6444 5651 22 1 5 9 21 1176 5 9 90 7156 6789 7330 6226 23 10 5 9 23 10 5 9 108 7174 6897 7345 6254 23 10 5 9 23 10 5 9 Fig 8 Unit Center of Gravity and Corner Weights 13 PITCH DRAIN LINE TO OFFSET LINE FRICTION SLAB MOUNT DRAIN Fig 9 Condensate Drain Piping Details Make Electrical Connections POWER SUPPLY Electrical characteristics of available power supply must agree with unit nameplate rating Supply voltage must be within the limits shown in Table 5 Field Wire Routing Field wiring is brought into the unit through the bottom of the control box A 3 in hole for field power wiring and a 78 hole for 24 v control wiring are provided in the bottom of the control box Field supplied couplings must be used when routing wir ing into the control box HOLD DOWN BARS Fig 10 Outdoor Air Hoods Shipping Position 14 Field Electrical Connections IMPORTANT The 48 50MP units generate use and can radiate radio frequency energy If units are not in stalled and used in accordance with these instructions they may cause radio interference They have been tested and found to comply with lim
44. A snap acting SPDT switch is factory mounted in the auxiliary control box The switch senses the differential pressure and provides the micro processor module with a signal for filter status Two lengths of plenum tubing connect the switch to probes located both upstream and downstream of the unit filters The switch must be set prior to unit operation To set the switch turn the adjustment screw on top center of switch slowly clockwise to find the pivot point where the filter status still reads clean under in the HSIO display Check the switch operation with the supply air fan running 35 22 000 26 400 30 000 34 000 38 000 42 000 45 800 48 200 52 000 1 28 and nominal cfm delivery See Table 22 for clean filter pres sure drops for help in locating the pivot point Once this point is found turn the screw clockwise to obtain the set point at which the filter status will be dirty Use Table 22 as a guide Table 22 Filter Switch Dirty Set Point INCREASED PRESSURE DROP APPROXIMATE FILTER TYPE TO DIRTY CLOCKWISE FROM PIVOT TURNS POINT 2 in Throwaway 2 4 in Pleated with 5 2 in Throwaway ENTHALPY CONTROL SET POINT The enthalpy sen sor See Fig 45 is located behind the filters in the right side economizer hood and is accessed through the filter access door For maximum benefit of outdoor air set enthalpy sen sor control to the A setting At this setting when the relative humi
45. AUST NO B1 NO B2 MOTORS FAN MOTOR FAN MOTOR MOCP FLA Hp VOLTAGE VOLTAGE RANGE NO A1 NO A2 3 Ph 60 Hz 2 UNIT 48MP 50MP Min 62L B 300 2325 250 300 300 300 350 2485 300 350 2625 550 550 502 300 350 2965 300 a o 508 65 4 345 65 4 345 3 3 RB 82N 11 7 5 277 5 300 aso 350 400 288 5 350 350 a A a i T a 65 50 353 5 350 350 400 5275 4o 400 450 N 219 0 250 11 7 5 230 0 250 dl F 4 5 6 5 6 5 6 6 6 307 2 350 77 60 3871 450 s 350 400 77 3591 450 558 5 460 414 77 E 460 414 77 247 0 300 Hl uu N a 5 14 15 359 8 450 77 60 422 8 500 LEGEND COMP Compressor FLA Full Load Amps Hp Nominal Horsepower LRA Locked Rotor Amps MCA Minimum Circuit Amps for wire sizing MOCP Maximum Overcurrent Protection RLA Rated Load Amps 16 Control Wiring See Fig 13 for sensor wiring con nections to main and auxiliary control boxes The recom mended types of control wiring for 48 50MP unit devices are shown in Table 6 Table 6 Recommended Sensor and
46. BELOW CURVE LIQUID TEMPERATURE AT LIQUID VALVE DEG F a 100 150 200 250 300 350 400 LIQUID PRESSURE LIQUID VALVE PSIG ALL OUTDOOR FANS MUST BE RUNNING Fig 59 Charging Chart Unit 48 50MP10R Charging with Unit Off and Evacuated Close liquid line service valve before charging Weigh in charge shown in Table 1 Open liquid line service valve start unit and allow it to run several minutes fully loaded Check for a clear sight glass Be sure clear condition is liquid and not vapor Complete charging the unit Charging with Unit Running If charge is to be added while unit is operating it is necessary to have all condenser fans and compressors operating It may be necessary to block con denser coils at low ambient temperatures to raise condens ing pressure to approximately 280 psig 1931 kPag to turn all condenser fans on Do not totally block a coil to do this Partially block all coils in uniform pattern Charge vapor into compressor low side service port located above oil pump crank shaft housing Charge each circuit until sight glass shows clear liquid Oil Charge Refer to Table 3 units are fac tory charged with oil Acceptable oil level for each compres sor is from 98 to on 06E299 max of sight glass see Fig 44 page 29 When additional oil or a complete charge is required use only Carrier approved compressor oil Approved oils are Petroleum Specialties
47. C Integrated Gas Unit Controller Product Integrated Control IDM STOPS SAFETY LOGIC SHUTS OFF GAS VALVE 45 DELAY EXTENDED BY 5 SECONDS FOR EACH LIMIT SWITCH TRIP MAXIMUM DELAY 3 MINUTES Fig 65 IGC Control Heating 48MP Units Only 58 PACKAGED SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equip ment discussed in this manual including Unit Familiarization Maintenance Installation Overview Operating Sequence A large selection of product theory and skills programs are available using popular video based for mats and materials All include video and or slides plus companion book Classroom Service Training which includes hands on experience with the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting and fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 9212 Packaged Service Training Classroom Service Training Copyright 1998 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 534 893 Printed in U S A Form 48 50 1 1 Pg 60 12 98 Replaces 50MP 1SI Tab 1aj1b START UP CHECKLIST MODEL SERIAL DATE TECHNICIAN l PRE START UP VERIFY THAT UNI
48. CESS DOOR GER SIDE BOTH SIDES access ee ACCESS DER 12071 NEAR oy UO FAR SIDE ONLY FLUE BOXES CONTROL BOX 3 11 AIR HOODS N 138 11y 2 HY EE FAD WH MAMMA paua ag eee NE oe ae 5 Le 340 25763 HIGH HEAD 9401 32771 18 10 7 8 6 2 3 4 1923 Pit lt 7 ONLY FIELD SUPPLY i gt 195003 50 8 POWER REF 31 2 0 2 GAS PIPE CONNECTION FRAMED RETURN AIR DUCT CONN 138 12 0 1 172 NPT M eae DRAIN CONN NEAR SIDE ONLY LIFTING POSITION 4 EACH SIDE CONTROL BOX ACCESS PANELS TI DISCONNECT SWITCH OPTIONAL 9 5 0 1 3 8 35 13 DIA DIPL OUTSIDE AIR INLET HOODS HOLE IN LIFTING LUGS BOTH SIDES FOLDS DOWN FOR SHIPMENT war oe mm La mm mm mm Rm meer veer pues ww rue pts 14 542 UNIT SIZE 48MPD E 46 974 NOTES 1 Dimensions are in millimeters 2 Center of gravity includes exhaust fan and high heat options Unit weight does not include exhaust fan or high heat options 3 High heat add 260 Ib 118 kg Exhaust fan add 1675 Ib 761 kg on 62L 1775 Ib 807 kg on 70M 4 Unit clearances Top Do not restrict condenser fans control box end 6 0 Sides 6 0 except on return fan equipped units 10 0 Economizer end 6 0 except power exhaust units 10
49. Device Non Shielded Cable PART NO MANUFACTURER Plenum Wiring Alpha 1895 American A48301 Belden 884421 Columbia Manhattan M64430 Quabik SENSORS Sensors should be wired using single twisted pairs of 20 AWG American Wire Gage conductor cable rated for the application except for the T56 accessory sensor which requires 3 conductor cable NOTE Humidity and CO sensors must be powered from isolated 24 power supplies HUMIDITY CONTROL AND HOT WATER AND STEAM VALVES These devices require 20 AWG twisted pair con ductor cables rated for the application for the 4 to 20 mA signal SPACE TEMPERATURE SENSOR T55 The space tem perature sensor P N CEC0121448 01 is shipped standard with every unit and is located in the main control box Space temperature sensor wires are to be connected to terminals in the unit main control box The space temperature sensor includes a terminal block TB1 a jumper between pins E2 and E3 and an RJ11 female connector The RJ11 connector is used to tap into the Carrier Comfort Network CCN at the sensor See RJ11 Plug Wiring section on page 24 to con nect the connector to the CCN A 3 lead cable must run from the RJ11 connector to the unit for communication through the sensor CAUTION Jumper MUST be in place between pins E2 and E3 or inaccurate readings could result To connect the space temperature sensor Fig 13 1 Connect 1 wire of the twisted p
50. E GASKET FIELD SUPPLIED VITH CURB CONDENSER END 0 27 50 81 CONDENSER CONDENSER RIGID INSULATION 0 S 0 5 FIELD SUPPLIED 1271 ET E 127 UNIT LEVELING TOLERANCE S FROM EDGE OF UNIT TO HORIZONTAL 07 3 ROOFING FELT 761 FIELD SUPPLIED CANT STRIP FIELD SUPPLIED ROOFING MATERIAL FIELD SUPPLIED VIEW B CORNER CONNECTIONS AND SPLICE PLATE CONNECTIONS NOTES 1 To prevent the hazard of stagnant water build up in the drain pan on the indoor section unit cannot exceed leveling tolerances shown f 2 Carrier roof curb is not used curb cross rails must be postioned to clear unit base rail locations shown Fig 1 Roof Curb Dimensions 48 50MP62L and 70M 1 Roof curb is shipped disassembled 2 Roof curb 14 gage VA03 56 steel 3 Dimensions are millimeters 4 To prevent standing water in the drain pan of the indoor section roof curb and unit must be level within tolerances shown ens 0 3 1 2 ST 100 12 7 1 0 3848 82N CONDENSER END SUPPORT ye or e a TEN 107 1 2 e 10 7 1 2 32393 13239 74 2 2553 0 2 29 32 e 1402 x 32 6 1 2 Use 0 1 1 4 32 50 0 1 31 32 3248 BASE RAIL CROSS SECTION TYP ALL BASE RAILS SCALE 1 3 0 1 3 4 ALL SIDES Mires Zi 117 7 9716 38 17 3545 0 1 14 5 7 1 0 17151 28 1 1 4 85
51. EFECTIVE PSIO MODULES The re placement part number is printed on a label on the front of the PSIO module The replacement module order is config ured as a generic replacement module which will require configuration in the field Before any service work is started be sure that all elec trical disconnects are open and tagged Installation 1 Verify the existing PSIO module is defective by using the procedure described in the Control Modules section on this page 2 Refer to the Start Up Checklist on pages CL 1 through CL 4 that should have been completed at start up This information is needed later in this procedure If the check list does not exist make a new checklist by filling out 3 and s configurations on paper Tailor the various options and configurations as needed for this particular installation 3 Check that all power to the unit is off Switch off all circuit breakers Carefully disconnect all wires from the defective module by unplugging the 6 connectors It is not necessary to remove any of the individual wires from the connectors Remove the green ground wire 4 Remove the PSIO module mounting screws and remove the module from the control box Save the screws 5 With a small screwdriver set the address switches S1 and S2 on the new PSIO module to match those on the defective module 6 Mount the new module in the control box using the screws saved in Step 4 7 Reinstall all 6 wire connectors and
52. ING UNIT UNIT TO BE OPERATED ON CONSTANT AIR VOLUME CV RATHER THAN VARIABLE AIR VOLUME CONFIRM THAT SPACE TEMPERATURE SENSOR T55 HAS BEEN WIRED CORRECTLY PER SPACE TEMPERATURE SENSOR T55 SECTION ON PAGE 17 CONFIRM THAT TUBING FOR SPACE AND SUPPLY DUCT PRESSURES HAS BEEN INSTALLED SET ENTHALPY CONTROL SET POINT ON ECONOMIZER SET SUPPLY FAN AND CHECK FILTER STATUS SWITCHES FOR JOB REQUIREMENTS UNIT OPTION CHECKLIST ITEM PRESENT A CONSTANT VOLUME POWER EXHAUST B VARIABLE VOLUME POWER EXHAUST VARIABLE FREQUENCY DRIVE ON SUPPLY D HOT GAS BYPASS E VAV WITH OCCUPIED HEAT 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 534 893 Printed in U S A Form 48 50MP 1SI CL 1 12 98 Replaces 50 1 1 Tab Mab PRELIMINARY CHECKLIST ITEMS cont CHANGES TO DEFAULT VALUES RECORD ALL CHANGES MADE TO FACTORY DEFAULT VALUES IV START UP CHECK EVAPORATOR FAN SPEED AND RECORD CHECK CONDENSER FAN SPEED AND RECORD AFTER AT LEAST 10 MINUTES RUNNING TIME RECORD THE FOLLOWING MEASUREMENTS COMP COMP A2 COMP 1 COMP B2 OIL PRESSURE SUCTION PRESSURE SUCTION LINE TEMP DISCHARGE PRESSURE DISCHARGE LINE TEMP ENTERING CONDENSER AIR TEMP LEAVING CONDENSER AIR TEMP EVAP ENTERING AIR DB TEM
53. LTER SWITCH CFS ENTHALPY CONTROL SET POINT KEYPAD AND DISPLAY MODULE HSIO CONFIGURATION SET UNIT TYPE ENTER JOB SET POINT VALUES CONFIGURE UNIT CONTROLS AND FUNCTIONS QUICK TEST FUNCTION GAS HEAT SECTION UNIT CONTROL BOX ECONOMIZER DAMPER MOTORS RETURN AIR FILTERS CONDENSER FANS AND FAN MOTORS Cleaning Lecce 46 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 534 893 Book 1 1 PC 111 Tab 1a 1b Printed in U S A Form 48 50MP 1SI Pg 1 12 98 Replaces 50MP 1SI CONTENTS cont Page Lubrication 47 COMPRESSORS FAN SHAFT BEARINGS FAN MOTOR BEARINGS DOOR HINGES Coil Cleaning 47 Refrigerant Circuit 47 Charge 49 Moisture Liquid Indicator 49 Filter 5 49 Liquid Line Service Valve 50 Compressor Suction and Discharge Service Valves 50 High Pressure Switch 50 Low Pressure Switch 50 Pressure Relief 50 Adjustments 50 EVAPORATOR FAN AND POWER EXHAUST MOTOR PLATE BELT INSTALLATION AND TENSIONING PULLEY ALIGNMENT Gas Valve Adjustment
54. MM Communications GND Ground e TH e 24 VAC COMM a con BUS RJ 11 WHT e CCN GND PLUG AT UNIT RED e CCN 24 Constant volume applications only RJ11 PLUG WIRING Units on the CCN can be moni tored from the space at the sensor through the RJ11 con nector if desired To wire the RJ11 connector into the CCN Fig 30 IMPORTANT The cable selected for the RJ11 con nector wiring MUST be identical to the CCN com munication bus wire used for the entire network Re fer to Table 7 for acceptable wiring 1 Cut the CCN wire and strip ends of the red white ground and black conductors If another wire color scheme is used strip ends of appropriate wires 2 Insert and secure the red wire to pin J2 1 55 or CCN T 56 of the space temperature sensor terminal block 3 Insert and secure the white ground wire to pin J3 1 55 or GND T 56 of the space temperature sensor 4 Insert and secure the black wire to pin J5 T 55 or CCN T 56 of the space temperature sensor 1 5 Connect the other end of the communication bus cable to the remainder of the CCN communication bus at the COMMI plug located on the fuse and control circuit breaker bracket in the unit main control box Air Pressure Tubing Before options such as supply fan VFD and modulating power exhaust can operate prop erly the pneumatic tubes for press
55. ND 10R UNITS 1168 HAVE 8 CONDENSER FANS BASERAIL 3 SEE RODFCURB CERTIFIED uxe nam 7 6 5 1 4 7 67 3 1 4 BAROMETRIC RELIEF DR F ACCESS DOOR HEAT ONLY POWER EXHAUST OPTION 578 NEAR SIDE ONLY 1 10 3 4 CREMDVABLE ACCESS 0008 Ed ACCESS DOOR SIDE ONLY 12071 ACCESS DOOR NEAR SIDE ONLY lt 38 11 3 11 172 BOTH SIDES Es T N i N CONTROL BOX ae 7 E IL 12073 fe EH 1 1165 3 1 an 9 7 8 ge Te 1 3 8 E 90 1089 65501 t701 e1 5 7 8 0 2 3 4 8103 2242 inae dE 1 ACCESS DOOR 279 690 174 117 7 9 16 107 7 7 8 POWER EXHAUST 101091 NEL DN FIELD SUPPLY NEAR SIDE ONLY ace E POWER REF RETURN AIR BASE FRAME DUCT CONN SUPPLY AIR LIFTING POSITION DRAIN CONN DUCT CONN 4 EACH SIDE ON 82N NEAR SIDE ONLY LIFTING POSITION 5 EACH SIDE ON 90P amp 108 CUNTRUL BDX 5181 13505 2572 8 5 1 4 S AIR GOTH SHED DISCONNECT SWITCH BASE FRAME 13429 10 3 OPTIONAL gt LIFTING POSITION 35561 11 8 SET OVERALL SHIPPING D 0 1 3 8 35 1 OUTSIDE AIR INLET HOODS HOLE IN LIFTING LUGS CBOTH SIDES FOLDS DOWN FOR SHIPMENT NOTES Sides 6 0 1 Dimensions in are in millimeters Economizer End 6 0 Except power exhaust units 10 0 Control Bo
56. P EVAP ENTERING AIR WB TEMP EVAP LEAVING AIR DB TEMP EVAP LEAVING AIR WB TEMP COMPRESSOR AMPS L1 COMPRESSOR AMPS L2 COMPRESSOR AMPS L3 ELECTRICAL SUPPLY FAN AMPS EXHAUST FAN AMPS ELECTRIC HEAT AMPS 11 L2 L3 TEMPERATURES OUTDOOR AIR TEMPERATURE F DB Dry Bulb RETURN AIR TEMPERATURE F DB F WB Wet Bulb COOLING SUPPLY AIR F PRESSURES GAS INLET PRESSURE IN WG GAS MANIFOLD PRESSURE STAGENO 1 IN WG STAGENO 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 48 AND 49 GENERAL ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS CHECK THE COMPRESSOR OIL LEVEL SIGHT GLASSES ARE THE SIGHT GLASSES SHOWING OIL LEVEL PER INSTRUCTIONS ON PAGE 29 Y N PERFORM CONTROL CONFIGURATION PROCEDURE ON PAGES CL 3 AND CL 4 CL 2 CONTROL CONFIGURATION KEYBOARD DISPLAY DESCRIPTION ENTRY VALUES IN INDICATE FACTORY DEFAULTS LOG ON Enter password followed by 4 1 1 LOGGEDON Logged on okay 3 FACT CFG Factory configuration M TYPE X Unit type 0 CV 1 VAV Default is 1 x TYPE X Verify unit type and change if necessary If CV unit see CV control configuration Data Reset Enable Data Reset s FACT CFG Factory Configuration lvi LLAG X Use vi to access lead lag option disable with
57. RE AT LIQUID VALVE DEG F N am LIQUID TEMPERATURE AT LIQUID VALVE DEG Fig 56 Charging Chart Unit 48 50MP70M ALL OUTDOOR FANS MUST BE OPERATING CIRCUIT A CIRCUIT B E Az m A e e AB 1 50 100 150 200 250 300 350 400 LIQUID PRESSURE AT LIQUID VALVE Psig 200 250 300 350 400 50 100 150 20 250 LIQUID PRESSURE LIQUID VALVE Psig LIQUID TEMPERATURE AT LIQUID VALVE DEG F LIQUID TEMPERATURE AT LIQUID VALVE DEG F Fig 57 Chrging Chart Unit 48 50MP82N 48 T 150 ES m a LIQUID TEMPERATURE a AT LIQUID VALVE DEG F a 100 150 200 ADD CHARGE IF ABOVE CURVE REMOVE CHARGE IF BELOW CURVE 300 350 400 LIQUID PRESSURE AT LIQUID VALVE PSIG ALL OUTDOOR FANS MUST BE OPERATING Fig 58 Charging Chart Unit 48 50MP90P o a o ADD CHARGE IF ABOVE CURV REMOVE CHARGE IF BELOW CURVE I LIQIUD TEMPERATURE a 5 AT LIQUID VALVE DEG 150 200 250 300 350 400 450 LIQUID PRESSURE AT LIQUID VALVE PSIG e a a ADD CHARGE IF ABOVE CURVE REMOVE CHARGE IF
58. SISTOR DIFFERENTIAL ENTHALPY SENSOR RETURN AIR Fig 16 Differential Enthalpy Sensor LOCAL REMOTE 08102 SWITCH REMOTE E e 1 24 Tann LEGEND DSIO Relay Module Fig 17 Remote Start 20 FIELD SUPPLIED 24 V ISOLATED POWER SUPPLY ACCESSORY OUTSIDE AIR RELATIVE HUMIDITY 24V FIELD SUPPLIED 24 V ISOLATED POWER SUPPLY TAIA AAN ff Y Y Y VI 24 9 Q RELATIVE HUMIDITY LEGEND TB Terminal Block Field Wiring 5 Component Terminal Terminal Block Terminal Fig 18 Accessory Humidity Control PRESSURIZATION TB2 070 6 Oo DPUAGE _ OO EVACUATION LEGEND TB Terminal Block Field Wiring O Component Terminal Terminal Block Terminal Fig 19 Fire Smoke Control FIELD SUPPLIED 24 V ISOLATED POWER SUPPLY INDOOR AIR QUALITY ACY Fig 20 Indoor Air Quality l OUTDOOR TB2 AIR TO 24 V BRN lem ISOLATED L Lee jem C NECS TRANSFORMER e LEGEND TB Terminal Block Field Wiring 5 Component Terminal Terminal Block Terminal Fig 21 Outdoor Airflow Control PSIO NO 2 1 33 pe NO HK35AA001 Fig 22 Timed Discret
59. T Duct Pressure SUCTION GAS Transducer CHANNEL 32 SPT Suction Pressure THERMISTOR r Transducer TB Terminal Block MG COMM CCN NETWORK 10 RED LEVEL II 20 GRN COMMUNICATIONS BUS COMM 30 BLK Fig 28 CCN Building Supervisor 22 PEC EXHAUST PECB EXHAUST IFC SUPPLY IFCB SUPPLY SHIELD G SUPPLY PSIO1 J6 E CHANNEL 16 7 nw EXHAUST PSIO1 J6 CHANNEL 15 lt 2 VFD EFM EXHAUST IDFM SUPPLY GROUND VOLTAGE SELECTOR IFR SUPPLY PER EXHAUST LEGEND EFM Exhaust Fan Motor IDFM Indoor Fan Motor IFC Indoor Fan Contactor IFCB Indoor Fan Circuit Breaker IFR Indoor Fan Relay PEC Power Exhaust Contactor PECB Power Exhaust Circuit Breaker PER Power Exhaust Relay VFD Variable Frequency Drive Fig 29 Optional VFD Wiring Connections Carrier Comfort Network Interface The 48 50MP units can be connected to the CCN if desired The communication bus wiring is supplied and installed in the field It consists of shielded 3 conductor cable with drain wire The system elements are connected to the communication bus in a daisy chain arrangement The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it the negative pins must be wired to the negative pins and the s
60. T IS LEVEL VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT LOOSEN ALL SHIPPING HOLDDOWN BOLTS AND REMOVE SHIPPING BRACKETS PER INSTRUCTIONS VERIFY THAT COMPRESSOR SUSPENSION SPRINGS HAVE BEEN LOOSENED PER INSTRUCTIONS VERIFY ASSEMBLY OF ECONOMIZER HOOD VERIFY INSTALLATION OF EXHAUST HOOD VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS VERIFY THAT POWER SUPPLY MATCHES UNIT DATA PLATE VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT CHECK GAS PIPING FOR LEAKS 48MP ONLY CHECK THAT INDOOR AIR FILTERS ARE CLEAN AND IN PLACE 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 OPEN SUCTION DISCHARGE AND LIQUID LINE SERVICE VALVES CHECK COMPRESSOR OIL LEVEL SIGHT GLASS AND VERIFY PROPER LEVEL VERIFY THAT CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR 24 HOURS CHECK VOLTAGE IMBALANCE LINE TO LINE VOLTS AB V AC V BC V AB AVERAGE VOLTAGE MAXIMUM DEVIATION FROM AVERAGE VOLTAGE V VOLTAGE IMBALANCE 100 X MAX DEVIATION AVERAGE VOLTAGE IF OVER 2 VOLTAGE IMBALANCE DO NOT ATTEMPT TO START SYSTEM CALL LOCAL POWER COMPANY FOR ASSISTANCE PRELIMINARY CHECKLIST ITEMS DETERMINE BEFORE CONFIGURING CONTROLS CONTROL SETTINGS FOR NON NETWORKED FREESTAND
61. ain gas valve When the thermostat is satisfied W1 and W2 open and the gas valve closes interrupitng the flow of gas to the main burners If the call for W1 lasted less than 1 minute the heating cycle will not terminate until 1 minute after W1 became active An LED indicator is provided on the IGC to monitor op eration The IGC is located by removing the side panel and viewing the IGC through the view port located in the control box access panel During normal operation the LED is con tinuously on See Table 26 for error codes Table 26 IGC Control Board LED Alarms INDICATION ERROR MODE ON Normal Operation OFF Hardware Failure 1 FLASH Fan ON OFF Delay Modified 2 FLASHES Limit Switch Fault 3 FLASHES Flame Sense Fault 4 FLASHES 4 Consecutive Limit Switch Faults 5 FLASHES Ignition Lockout Fault 6 FLASHES Induced Draft Motor Fault 7 FLASHES Rollout Switch Fault 8 FLASHES Internal Control Fault LEGEND IGG Integrated Gas Unit Controller LED Light Emitting diode NOTES 1 There is a 3 second pause between error code displays 2 f more than one error code exists all applicable error codes will be displayed in numerical sequence 3 Error codes on the IGC will be lost if power to the unit is interrupted Control Loop Checkout CAUTION The checkout and adjustment of control loops should only be done by certified Carrier Comfort Network CCN technicians The following checkout procedure is offered as a guid
62. air to terminal T1 T55 and connect the other wire to terminal T2 on terminal block 1 located on the cover of the space tempera ture sensor using a 20 AWG twisted pair conductor cable rated for the application 2 Connect the other ends of the wires to terminals 1 and 2 on TB3 located in the unit main control box NOTE This sensor should be installed for all applica tions For VAV variable air volume applications it is used to control heating and cooling during unoccupied periods For DAV digital air volume applications it is used to maintain control of the space during linkage fail ures with the TSM terminal system manager NOTE Either the T55 or T56 sensor must be connect ed for CV constant volume applications to function properly SPACE TEMPERATURE SENSOR T56 CV Applica tions Only space temperature sensor P N CEC0121503 01 wires are to be connected to termi nals in the unit main control box The space temperature sensor includes a terminal block a jumper between 17 pins E2 and and an RJ11 female connector The connector is used to tap into the CCN at the sensor See RJ11 Plug Wiring section on page 24 to connect the RJ11 con nector to the CCN A CAUTION Jumper MUST be in place between pins E2 and E3 or inaccurate readings could result To connect the space temperature sensor Fig 13 1 Connect one wire of the 3 conductor cable to terminal TH one wire to t
63. and Display Module Functions and Subfunctions FUNCTIONS FUNCTION Status History Schedule Service Set Point NO Occupied 4 E urrent Mode Log on an ystem uU Alarms Alarms Override Log off Set Point Unit Current 1 Software Demand 2 Current 2 Factory Current ANE RN oo Daylight Capacity Period 3 4 Bus Address Savings Current Period 4 Units Configure 5 Operating A Points E Ry 6 System Period 5 User Temperatures Unit Configuration System Period 6 Period 7 Analog Period 8 Occupied Discrete Mode 10 Outputs Override Economizer TDO Run Period 1 sey Mo nm gt 12 Period 2 Nighttime TDO Free Cool Adaptive 13 Optimal Start Stop 14 Period 4 Temperature TDO Reset 15 Period 5 Configure TDO Loadshed 17 Period 7 Configure TDO Humidity 18 Period 8 Building TDO Pressure 5 m gt 1 Service 21 Maintenance Alarm a omme LEGEND IAQ Indoor Air Quality TDO Timed Discrete Output Test TEST ALR Test of Inputs Analog Outputs Discrete Outputs Test Compressors Test Heat Exit Test Table 30 Variable Frequency Drive VFD Display DISPLAY ACTION Fref Not used Displays the output frequency at which the VFD is cur Fout rently operating This is a display only function The user cannot change this displayed value
64. because it contains rust and oxidation inhibitors FAN MOTOR BEARINGS The condenser and evaporator fan motors have sealed bearings so no field lubrication is required DOOR HINGES door hinges should be lubricated at least once a year Coil Cleaning Clean the coils with a vacuum cleaner compressed air water or a non wire bristle brush Refrigerant Circuit LEAK TESTING Units are shipped with a full operating charge of R 22 see Table 1 If there is no pressure in the system introduce enough nitrogen to search for the leak Repair the leak using good refrigeration practices After leaks are repaired system must be evacuated and dehydrated using methods described in GTAC II Module 4 System Dehydration REFRIGERANT CHARGE Refer to Table 1 At the liq uid line connection point on each circuit is a factory installed liquid line service valve On each valve is a 4 1 Schrader connection for charging liquid refrigerant units are shipped with a complete operating charge of R 22 See unit nameplate and Table 1 for amount of charge When adding a complete charge evacuate system using stand ard evacuating procedures and weigh in the specified amount of charge units have charging charts for each refrigerant circuit See Fig 55 59 RING GAP LOCATION ROLLOUT SWITCH
65. cause personal injury 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 or maintenance can cause injury or property damage Refer to this manual For assistance or additional infor mation consult a qualified installer or service agency WARNING This unit uses a microprocessor based electronic con trol system Do not use jumpers or other tools to short out components or to bypass or otherwise depart from recommended procedures Any short to ground of the control board or accompanying wiring may destroy the electronic modules or electrical components 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 Jobsite Survey Complete the following checks be fore installation 1 Consult local building codes and the NEC National Electrical Code ANSI NFPA National Fire Protection Association 70 for special installation requirements 2 Determine unit location
66. ciency High Efficiency Fan Pulley Pitch Diameter in Motor Pulley Pitch Diameter in Fan Rpm Belts Quantity Model No Center Distance Range in Maximum Rpm Air Foil Fan cont Motor Hp Motor Frame Size Efficiency at Full Load Standard Efficiency High Efficiency Fan Pulley Pitch Diameter in Motor Pulley Pitch Diameter in Fan Rpm Belts Quantity Model No Center Distance Range in Maximum Rpm CONDENSER FANS Quantity Diameter in Nominal Cfm Motor Hp Rpm SUPPLY FAN Nominal Cfm Size in Maximum Allowable Rpm Shaft Diameter at Pulley in FURNACE SECTION 48MP Units Only Rollout Switch Cutout Temp F Number of Burners Burner Orifice Diameter in drill size Gas Input Btuh Manifold Pressure in wg Natural Gas Gas Valve Input Pressure Range in wg psig LOW HEAT 48MPD HIGH HEAT 48MPE Number of Sections Gas Input Btuh Stage 1 Stage 2 Efficiency Steady State Temperature Rise Range F Minimum Heating Airflow cfm Field Gas Connection Size in FILTERS Medium Efficiency 30 Pleated Standard Quantity Size in High Efficiency 90 Cartridge Filters with Prefilters Optional Quantity Size in Outdoor Air Inlet Screens Quantity Size in LEGEND Thermostatic Expansion Valve Table1 Physical Data cont D 10R 115 120 24 660 24 750 950 25 110 25 100 950 2400 Semi Hermetic A1 6 A2 6 B1 6 B2 6 A1 6
67. controlling motor speed Pressing DSPL and ENTER keys simultaneously allows all parameter data to be read but not set while the drive is running Fig 49 VFD Digital Operator 45 LATCH BOLT Fig 50 Door Latch UNIT CONTROL BOX Viewed facing compressors the control box is at the left end of the unit Incoming power for controls refrigerant system and fan system enters through the control box The control box contains power compo nents and electronic controls Outer panels are hinged and latched for easy opening Remove screws to remove inner panels Outer panels can be held open for service and in spection by using a door retainer on each panel Remove bottom pin from door retainer assembly swing retainer out horizontally and engage pin in one of the retainer ears in the hinge assembly COMPRESSORS The oil pump end compressor access of each compressor is readily accessible from sides of unit as shown in Fig 51 Access the motor end of the compressor through the condenser end of the unit or by removing compressor LIQUID SERVICE VALVES SOLENOID VALVES FIL TER DRIERS AND SIGHT GLASSES These compo nents are located in the inside corner of the condenser sec tion on the right hand side of the unit Filter driers are replaceable core type See Fig 51 EVAPORATOR FAN MOTORS PULLEYS AND BELTS Access to these components is through the 2 doors labeled FAN SECTION on each side o
68. d ing discrete input DI to Channel 12 Closed Fan ON Fan operation will continue through the Occupied period During Unoccupied period with demand the control will energize fan contactor when demand is sensed After fan sta tus is confirmed operating routines will start When demand 15 removed routines will end and fan will shut off Units Continuous Fan During Occupied periods the control will energize the supply fan contactor The contactor will close energizing supply fan motor Fan wheel will turn Airflow Switch differential pressure switch contacts close providing discrete input DI to Channel 12 Closed Fan ON Fan operation will continue through the Occupied period During Unoccupied period with demand the control will energize fan contactor when demand is sensed After fan sta tus is confirmed operating routines will start When demand 1s removed routines will end and fan will shut off Units Automatic Fan Fan will be turned OFF during Occupied period when there is no demand for heating or cool ing operation When demand is sensed control will energize fan contactor and initiate cooling cycle Fan status will be confirmed When demand is removed routines will termi nate and fan will be shut off ECONOMIZER The economizer control loop will be de layed 2 minutes after the supply fan is turned ON to allow system and temperatures to stabilize before starting control When coming out
69. d Rpm FAN TYPE Forward Curved 48 50MP Airfoil 82N 90P 10R Table 20 Maximum Allowable Power Exhaust Fan Speed Rpm FAN TYPE 100 Air 690 650 600 48 50MP 62L 70M 82N 90P 10R Table 21 Air Quantity Limits cfm MINIMUM MINIMUM UNIT GAS HEATING GAS HEATING SIZE Low Heat High Heat 48 50MP Units Units 48MPD 48MPE En 15 400 15 400 19250 90 19250 for 19 250 Controls Configuration and Quick Test SUPPLY FAN STATUS SWITCH FS A snap acting single pole double throw SPDT differential pressure switch is fac tory mounted in the auxiliary control box The switch senses the change in pressure across the supply air fan and pro vides the fan status A length of plenum tubing connects the switch to the probe located in the fan discharge box The switch must be set prior to unit operation To set the switch turn the adjustment screw on top center of switch clockwise to increase set point or counterclockwise to decrease set point The set point switch range is 0 05 to 2 0 in wg with a deadband of 0 02 in wg at minimum set point and 0 1 in wg at maximum set point Set switch so that contact makes to NC when supply air fan is energized The switch should make fan on within 1 minute after supply air fan is energized and break fan off within 1 minute after the fan is deenergized CHECK FILTER SWITCH CFS
70. d Wiring Constant volume applications only Fig 13 Space Temperature Sensor Wiring 18 BED _ __ EXE cic BK 1 TBS RED RED Hiper ge enten 21 2 TO PROCESSOR MODULE 1 SENSOR 1 2 SENSOR 3 SPACE TEMPERATURE AVERAGING 4 SENSOR APPLICATION TB3 RED RED RED FT eo BLK BLK Ek uet etie TO PROCESSOR MODULE NO 1 I sensor 1 SENSOR 2 Ia zl LLI RR RED _ _ _ RED _ BIK _ I I SENSOR 4 SENSOR 5 x LU m tc RED RED Q im o 7 ERES S HERES ER cuu LEGEND TB Terminal Block Factory Wiring Field Wiring SENSOR 7 SENSOR 8 SPACE TEMPERATURE AVERAGING 9 SENSOR APPLICATION Fig 14 Space Temperature Sensor Averaging 19 SENSOR 4 SENSOR 6 SENSOR 9 FIELD TB3 CONTROL WIRING RED 8 BLU 9 10 CHANNEL 60 LEGEND TB Terminal Block Field Wiring 5 Component Terminal Terminal Block Terminal Fig 15 Heat Interlock Relay ENTHALPY ENTHALPY CONTROL SENSOR REMOVE 620 Q RE
71. d space tem perature offset inputs then calculate CCSR value 2 The CSL surveys actual SAT then calculates number of capacity stages required to satisfy space load 3 Stages of cooling capacity are initiated From zero stages there will be a 1 5 to 3 minute delay before first stage is initiated UNOCCUPIED COOLING The unoccupied cooling sequence of operation is similar to Occupied Cooling see above except for the following 1 Supply Fan will be OFF as demand is initiated 2 The Master Loop will start Supply Fan and cooling cycle Fan status must be proved as ON within 2 minutes to con tinue with cooling operation 3 Control set point will be Unoccupied Cooling Set Point UCSP 4 At end of cooling cycle Supply Fan will be turned OFF OVERRIDES First Stage and Slow Change Override The first stage over ride reduces cycling on the first stage of capacity and the slow change override prevents the addition or subtraction of another stage of capacity if the SAT is close to the set point and gradually moving towards the set point Low Temperature Override This override function pro tects against rapid load decreases by removing a stage every 30 seconds when required based on temperature and the tem perature rate of change High Temperature Override This override function pro tects against rapid load increases by adding a stage once every 60 seconds as required based on temperature and tem peratur
72. d to a ground at one point only If the communication bus cable exits from one building and enters another the shields must be connected to grounds at the lightning suppressor in each building where the cable enters or exits the building one point per building only To connect the unit to the network Turn off power to the control box Cut the CCN wire and strip the ends of the red white ground and black conductors If a different net work color scheme is used substitute appropriate colors Remove the 4 pin female plug from the fuse and control circuit breaker bracket in the main control box and con nect the wires as follows a Insert and secure the red wire to terminal 1 of the 4 pin plug b Insert and secure the white ground wire to terminal 2 of the 4 pin plug c Insert and secure the black wire to terminal 3 of the 4 pin plug 4 Insert the plug into the existing 4 pin mating connector on the fuse or control circuit breaker bracket in the main control box IMPORTANT A shorted CCN bus cable will pre vent some routines from running and may prevent unit from starting If abnormal conditions occur un Ne W plug the connector If conditions return to normal check CCN connector and run new cable if nec essary A short in one section of the bus can cause problems with all system elements on the bus LEGEND T 56 SPACE CCN Carrier Comfort Network SENSOR COM Common CO
73. dity is 50 and the outdoor air is below 74 the sen sor s relay contacts will be closed See Fig 46 and 47 NOTE Enthalpy control setting dial is on the enthalpy control 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 Check linkage for free movement and com plete range of travel Minimum Position Set Point Minimum economizer po sition is set using the keypad and display module Refer to Control and Troubleshooting literature for more details ENTHALPY SENSOR Fig 45 Enthalpy Sensor CONTROL POINT CURVE Approx Deg P A 73 85 90 95 100 105 B 68 Cc 63 D 58 RELAT HUMIDI 5 40 45 50 55 60 65 70 75 80 85 90 95 100 105 DRY BULB TEMPERATURE APPROXIMATE FAHRENHEIT Fig 46 Psychrometric Chart for Enthalpy Control ROL TRANSFORMER IN UNIT CONTROL BOX TO SENSOR SEE FIG 45 620 ohm JUMPER 24 VAC SUPPLY FROM CONT FROM ECONOMIZER HARNESS FROM ECONOMIZER HARNESS NOTES Switches shown in high enthalpy state Terminals 2 and 3 close on enthalpy decrease 2 When standard economizer is used with accessory differential enthalpy sen Sor set enthalpy control to D setting Fig 47 Wiring Connections for
74. e temperature value by cycling the compressors and the unloader s Both the supply and return air temperature sen sors are used to adjust the cycling deadband to match the actual load The control system provides cooling capacity control of up to 11 stages to maintain supply air temperature VAV or space temperature CV to an occupied or un occupied set point Automatic lead lag circuit switching occurs if configured to equalize run times per compressor for improved compressor reliability The compressor to start first is changed every time stage equals zero NOTE Automatic lead lag should be disabled if optional hot gas bypass is employed because the unit only contains hot gas bypass on one circuit The VAV control system sequence uses the modified supply air set point MSAT supply air set point reset value as the supply air temperature required to satisfy conditions sub master reference value CSSR and outputs this value to the submaster loop The submaster loop uses the modified supply air set point compared to the actual supply air temperature to determine the required number of capacity stages to satisfy the load The logic for determining when to add or subtract a stage is a time based integration of the deviation from the set point plus the rate of change of the supply air temperature The CV control system sequence reads the space sensor and performs a calculation to determine the supply air tem perature required
75. e Output HUMIDIFIER EIDEM ACTUATOR HUMIDIFIER RELAY CARRIER PART NO HK35AA001 LEGEND TB Terminal Block Field Wiring 5 Component Terminal Fig 23 Humidifier HYD VLV HYDRONIC VALVE ACTUATOR LEGEND TB Terminal Block Wiring Component Terminal Fig 24 Hydronic Heating 2 LEGEND TB Terminal Block Field Wiring 5 Component Terminal Terminal Block Terminal Fig 25 Freezestat REMOTE 2 10 VDC INPUT SPACE TEMP OFF OFFSET CV SUPPLY TEMP RESET VAV LEGEND CV Constant Volume VAV Variable Air Volume Fig 26 Remote Supply Air Temperature Reset Space Temperature Offset REMOVE BLK JUMPER 21 TRANSDUCER ACCESSORY lt BLK lt WHT WHT e WHT i BLK res lt RED 8 10K OHM lt lt BLK uu 2 lt lt WHT WHT WHT RES RED ero lt lt BIK Ae 5 SPT1 WHT 9 WHT RED NV BLK 10K OHM BLK e ud RED WHT BRN WHT RED 10K OHM BLK 1 2 WATT 596 RED PSIO NO 2 SUCTION GAS TEMPERATURE 1 THERMISTOR 31 DP
76. e and presumes the user has obtained basic knowledge of controls through CCN training TO CHECK OPERATION OF ANALOG OUTPUTS The control algorithms of the unit controls utilize the master submaster loop concept The master loop monitors the master sensor the sensor which tries to maintain the desired set point and calculates the submaster reference required to do so The submaster loop monitors the submaster sensor and controls the actual output to the controlled device These algorithms require the adjustment of a number of gain values to function properly The 48 50MP units come with preset default values However it may be necessary to adjust several of these values to achieve stable control These values are submaster loop gain SMG submaster loop cen ter value SCV and master loop gain MLG In addition proportional integral and derivative multiplier values can be accessed through the Building Supervisor Service Tool ComfortWorks software To verify or adjust submaster default values perform the following for each controlled device control loop 1 Verify that the system is in the Occupied mode and the supply air fan is running 2 Verify that the supply air fan status indicates ON If the fan status is OFF the unit control algorithms will dis able all routines 3 Verify that all forced values have been removed 4 Table 27 indicates recommended starting values for MLG and SMG for 48 50MP units V
77. e following Enter the configuration function by pressing ISERV 2 Scroll down to unit type TYPE 1 will be displayed 3 Press and to change the unit type to CV 4 Scroll down to data reset DTRS will be displayed Press 1 to save changes The fan operation type should also be configured for use in occupied time periods Fan operation can be set to continuous or auto To set press s Pto enter the subfunction Scroll down to fan mode Press o and to set to AUTO Press 1 and to set to continuous ENTER JOB SET POINT VALUES The set point func tion allows the user to view the current values set for the unit From this function the user can change the values Reading and Changing Set Points To change the set point of a particular feature enter the appropriate subfunction and scroll to the variable desired Once the desired variable has been reached type in the new value and press The new value will appear in the display For example the occupied cool set point is currently set at the default value of 78 To change the occupied set point to 72 F Press 1 e v to enter the occupied cool set point function The display will read OCSP 78 2 Press z and the display will read OCSP 72 Set points can be changed by the user provided that the values are within the allowable range for the input If the input is not within the allowable
78. e incorrect 6 Consult power company 7 Refrigerant system restrictions 7 Check or replace filter drier expansion valve etc Check that com pressor discharge valve is fully open Outdoor Fan Off 1 Fan slips on shaft 1 Tighten fan hub setscrews 2 Motor not running 2 Check power and capacitor 3 Motor bearings stuck 3 Replace bearings 4 Motor overload open 4 Check overload rating Check for fan blade obstruction 5 Motor burned out 5 Replace motor COMPRESSOR CYCLES ON LOW PRESSURE SWITCH Indoor Air Fan Running 1 Filter drier plugged 1 Replace filter drier 2 Expansion valve power head defective 2 Replace power head 3 Low refrigerant charge 3 Add charge Check low pressure switch setting Airflow Restricted 1 Coil iced up 1 Check refrigerant charge 2 Coil dirty 2 Clean coil fins 3 Air filters dirty 3 Clean or replace filters 4 Dampers closed 4 Check damper operation and position Indoor Air Fan Stopped 1 Electrical connections loose 1 Tighten all connections 2 Fan relay defective 2 Replace relay 3 Motor overload open 3 Power supply 4 Motor defective 4 Replace motor 5 Fan belt broken or slipping 5 Replace or tighten belt HSIO Human Sensory Input Output Device DSIO Processor Module VFD Variable Frequency Drive 56 TROUBLESHOOTING AND DIAGNOSTICS cont PROBLEM COMPRESSOR RUNNING BUT COOLING INSUFFICIENT Suction Pressure Low Refrigeran
79. e rate of change ADAPTIVE OPTIMAL START Optimal start is used to heat up or cool down the space prior to occupancy The purpose is to have the space temperature approach and then achieve the occupied set point by the time of occupancy The control utilizes outdoor air temperature space temperature occupied set point and a factor The K factor is ex pressed in minutes per degree and calculates a start time offset which is the time in minutes that the system shall be started in advance of the occupied time The control moni tors its results and adjusts the factor to ensure that the occupied set point is achieved at time of occupancy rather than too early or too late ADAPTIVE OPTIMAL STOP CV Applications Only Optimal stop is used to allow space temperature to drift to an expanded occupied set point during the last portion of an occupied period The control calculates a stop time offset the time in minutes prior to the scheduled unoccupied time during which expanded heating and cooling set points can be used Adaptive optimal stop utilizes space temperature an expanded occupied set point and a factor to calcu late stop time offset The amount F to expand the occupied 40 set point is user configurable Like adaptive optimal start the control corrects itself for optimal operation by adjusting the factor as required GAS HEATING OPERATION 48MP Units Only Re fer to
80. earances Top Do not restrict condenser fans BASE FRAME SUPPLY AIR DUCT CONN LIFTING POSITION 4 EACH SIDE CONTROL BOX ACCESS PANELS 0 10 3 4 621 273 0 12 V4 700 3111 DISCONNECT SWITCH OPTIONAL gt QUTSIDE AIR INLET HOODS BOTH SIDES FOLDS DOWN FOR SHIPMENT Sides 6 0 Economizer End 6 0 Except power exhaust units 10 0 Control Box End 6 0 For smaller service and operational clearances contact Carrier Application Engineering department 5 Downshot ducts designed to be attached to accessory roof curb If unit is mounted on dunnage it is recommended the ducts be supported by cross braces as done on the accessory roof curb 6 All lifting lugs must be used when rigging unit Fig 5 Base Unit Dimensions 50MP62L and 70M 11 WEIGHT C1 C2 See Note 3 See Note 2 See Note 2 kg mm mm fein mm mm fin mm fin mm fom mm T fn 22 400 10 295 see 9 02 farm 7189 23 87 157977 19 1077 or 25 6a 487777 EY TOR Gr 25 67187 1759 59 EL AA C 1 UNITS WITH EXHAUST CQ UNITS WITHOUT EXHAUST FAN BASERAIL 1461 11295 0 5 3 4 BOTTOM RETURN xr enn 2 e pue 0 4 3 4 i Tt BASERAIL ERERER ES E TES IL OX ae E JR 91 971 31371 1092 0 3 5 8 10 3 1 2 3 7 D FIELD POWER BOTTOM RETURN i SIZE 90 A
81. ed if job condi 2 be through L 2 NOTE Data in brackets is default value CL 3 tions require unit to enter unoccupied cycle at programmed times of day or days of week see Controls and Troubleshoot ing Guide CONSTANT VOLUME CONTROL CONFIGURATION KEYBOARD DESCRIPTION ENTRY DISPLAY s FACT CONFIG h FANM Fan Mode x FANMx Select Fan Mode Auto 0 Cont 1 1 o ECONOMIZER Configure Economizer vi SMG x x Submaster Gain SMG 8 0 Set SMG to 8 0 7 5 NOTES Copyright 1998 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 534 893 Printed in U S A Form 48 50 1 1 CL 4 12 98 Replaces 50 1 1 Tab 1aj1b
82. eplate and read sheave pitch diameters marked on the fan and motor sheaves EXAMPLE Nameplate motor rpm 1760 Motor sheave pitch diameter in 6 4 Fan sheave pitch diameter in 12 4 1760 x 6 4 Fan Rpm EE 908 Rpm 12 4 The maximum allowable fan speed for the supply fan is shown in Table 19 The maximum allowable fan speed for the power exhaust fan is shown in Table 20 Excessive fan speed may result in condensate carryover from the evaporator coil fan motor overload or wheel fail ure See Table 21 for Air Quantity Limits on page 35 Table 8 Fan Performance Forward Curved 48 50MP62L AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW Cfm Bhp 16 000 5 0 6 0 18 000 6 4 7 4 10 0 20 000 8 2 9 3 11 9 22 000 0 5 11 6 14 3 24 000 3 3 14 5 17 3 26 000 6 6 18 0 20 9 28 000 0 7 22 1 25 2 30 000 5 4 26 9 30 2 32 000 0 9 32 6 36 1 AIRFLOW Cfm 16 000 18 000 20 000 22 000 24 000 26 000 28 000 30 000 32 000 LEGEND Bhp Brake Horsepower Refer to Fan Performance 48MP Units section for correct procedure on 48MP units NOTES 1 Fan performance is based on wet coils and clean 2 in filters 2 Conversion Bhp to kW Bhp x 746 Motor efficiency See Table 1 for motor efficiency kW Table 9 Fan Performance Forward Curved 48 50MP70M AVAILABLE EXTERNAL STATIC PRESSURE in
83. er in 20 0 20 0 Motor Pulley Pitch Diameter in 4 5 4 0 Fan Rpm 362 371 Belts Quantity Model No 2 BX90 3 BX90 Center Distance Range in 24 9 27 4 23 9 26 8 Maximum Allowable Rpm 600 600 Table 3 Compressor Oil Charge OIL CHARGE pints Compressor Compressor Circuit A Total Circuit A Circuit B Total Circuit B A1 A2 B1 B2 62L De i ME 19 70M 19 82N 19 38 90P 19 38 10R 19 38 Table 4 Variable Frequency Drive VFD Physical Data FAN MOTOR DIMENSIONS in HP Height width 30 1122 68 40 1122 68 50 11 22 106 60 11 22 106 75 11 22 106 6 1 Roof curb is shipped disassembled 2 Roof curb 14 gage VA03 56 steel 3 Dimensions are in millimeters 4 To prevent standing water in the drain pan of the indoor section roof curb and unit must be level within tolerances shown 18 7 1 2 13848 7040 117 8 1 4 3562 621 CONDENSER END SUPPORT 24 5 pts 3 7 1 4 2 12172 se 559 1 2 Aie 140 30 4 1 2 1 3563 0 5 1 2 To 19258 0 1 174 323 0 1 31 39 9 4 7 16 0 1 3 4 ALL SIDES BASE RAIL CROSS SECTION TYP ALL BASE RAILS SCALE 1 3 UNIT DRAIN CONNECT ION THIS SIE ONLY INDDOR UNIT BASE CROSS RAIL LOCATIONS UNIT BASE RAIL 4 7 UNIT CROSS RAIL So 5 gt Ce AIL 2 A CDUNTER FLASHING N SUPPLIED
84. er droop is too large adjust the SCV as follows If the submaster droop is positive actual value greater than reference value the SCV should be decreased for HCV heating coil and IGV supply fan VFD loops and increased for CC cooling control and ECON econo mizer loops If the submaster droop is negative actual value less than reference value the SCV should be increased for HCV and IGV loops and decreased for CC and ECON loops Table 27 48 50MP Units SMG SCV and MLG Recommended Starting Values FUNCTION GAIN OR SCV Cooling Control MLG SERVICE SUBFUNCTION HSIO 8 GAIN VALUE CV Application Application 1 0 Economizer MLG 10 1 0 SMG 10 7 5 SCV 10 50 Duct Pressure VFD MLG N A 1 SMG N A 2 0 SCV N A 35 Building Pressure MLS 18 1 0 1 0 SMG 18 5 0 5 0 SCV 18 50 50 Staged Heat MLG t 11 1 0 1 0 SMG 11 5 0 5 0 Heating Coil MLG F 1 0 1 0 SMG 7 7 5 7 5 SCV 7 50 0 Humidifier MLG 17 1 0 1 0 SMG 17 7 5 7 5 SCV 17 50 50 Factory setting differs from new control setting 48MP only LEGEND CV Constant Volume MLG Master Loop Gain SCV Submaster Center Value SMG Submaster Loop Gain Variable Air Volume 41 8 Once the submaster loop is adjusted remove all forced values and proceed with verification and adjustment of master loop 9 To check the master loop Create a demand in the master loop For example Force the actual space temperature to a
85. ergized If all modules indicate a communication failure check the COMM plug on the PSIO module for proper seating If a good connection is made and the condition persists replace the PSIO module If only the DSIO module indicates a communication fail ure check the COMM plug on that module for a proper con nection If a good connection is made and the condition persists replace the DSIO module system operating intelligence resides in the PSIO mod ule This module monitors conditions through the input and output ports and the DSIO modules The machine operator communicates with the micro processor through the HSIO keypad and display module Com munication between the PSIO and the other modules is accomplished by a 3 wire sensor bus These 3 wires run in parallel from module to module On the sensor bus terminal strips terminal 1 of the PSIO1 module is connected to Terminal 1 of all of the other mod ules Terminals 2 and 3 are connected in the same manner If any of the wires are crossed the system will not work The unit processor modules the high voltage relay mod ules and the HSIO keypad module are all powered from two 21 vac power sources which connect to terminals 1 and 2 of the power input strip on each module Processor Module s PSIO INPUTS Each input channel has 3 terminals 2 are used OUTPUTS Output of the PSIO module is 24 vdc or 4 to 20 mA dc There are 3 terminals 2 are used REPLACING D
86. erify that these values have been entered by checking the service function 5 Verify adjust the SMG If the SMG is too large the loop will tend to oscillate hunt If it is too small the loop will react too slowly Verify or adjust the SMG as follows Using the HSIO keypad force the submaster reference of the control loop to a value above or below the actual sensor reading Verify that the actuator responds cor rectly If the actuator drives in the wrong direction go to the submaster gain 5 for the control loop and reverse the sign of the gain For example If the submaster loop gain is 5 0 change it to 5 0 6 Observe the operation of the controlled device for a few minutes If the device oscillates every few seconds around the forced value then lower the SMG by small amounts until the output steadies If the output to the device re sponds to a change in the temperature in small incre ments then increase the SMG in small amounts until the output steadies NOTE Do not be alarmed if the submaster sensor sta bilizes at a value greater or less than the forced value This is called the submaster droop offset and is normal 7 It is not necessary to adjust the submaster loop center value as the master loop will adjust the submaster ref erence as required to satisfy its set point However it may be desirable to keep the submaster droop to a mini mum This is most often required for economizer loops If the submast
87. erminal COM and the other wire to ter minal SW on terminal block 1 TB1 located on the cover of the space temperature sensor using a 20 AWG twisted 3 conductor cable rated for the application 2 Connect the other ends of the wires to terminals 1 2 and 3 on TB3 located in the unit main control box The wire from terminal SW MUST be connected to terminal 3 NOTE Either the T55 or the T56 sensor must be con nected for CV applications to function properly SPACE TEMPERATURE AVERAGING Applications that require averaging using multiple space temperature sensors can be satisfied using either 4 or 9 sensors as shown in Fig 14 NOTE Only Carrier sensors may be used for standard T55 space averaging Sensors must be used in multiples of 1 4 and 9 only with total sensors wiring not to exceed 1000 ft However space temperature reset can be accomplished with only one sensor NOTE Do not use T56 sensors for space temperature averaging because the 5 degree offset function will not work in a multiple sensor application HEAT INTERLOCK RELAY VAV Units Only Not Nec essary For Digital Air Volume Applications Variable air volume VAV units using optimal start morning warm up and or occupied heating require that room terminals be con trolled to the fully open position when the unit goes into heating mode The HIR Heat Interlock Relay function is provided for this control on DSIO no 2 channel 60 When the unit goes int
88. et and should require no adjustment MAIN BURNER REMOVAL 1 Shut off field supplied manual main gas valve 2 Shut off power to unit Remove gas section access door door frame and corner post Disconnect gas piping from gas valve inlet Remove wires from gas valve Remove wires from rollout switch Remove sensor wire and ignitor cable from IGC board Remove 2 screws securing manifold bracket to basepan 9 Remove 2 screws that hold the burner support plate flange to the vestibule plate 10 Lift burner assembly out of unit INA 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 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 high pressure or low pressure trip or if there is a loss of power to the compressors the comp
89. exchanger baffles When installing retaining clip be sure the center leg of the clip extends inward toward baffle See Fig 53 COMBUSTION AIR BLOWERS 48MP Only Clean pe riodically to assure proper airflow and heating efficiency In spect blower wheel every fall and periodically during heat ing season For the first heating season inspect blower wheel bi monthly to determine proper cleaning frequency To inspect blower wheel remove heat exchanger access panel Shine a flashlight into opening to inspect wheel If cleaning is required remove motor and wheel assembly by removing screws holding motor mounting plate to top of com bustion fan housing Fig 54 The motor and wheel assem bly will slide up and out of the fan housing Remove the blower wheel from the motor shaft and clean with a deter gent or solvent Replace motor and wheel assembly Lubrication COMPRESSORS Each compressor is correctly charged at the factory Refer to 06E Compressor Service Manuals if additional information regarding compressor lubrication sys tem is required See Compressor Oil section on page 29 and Table 3 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
90. f the unit POWER EXHAUST MOTORS PULLEYS AND BELTS Access to these components is through the doors at the return air end of the unit POWER EXHAUST ACCESS DOOR GAS HEAT SECTION Access to the gas heat section is through the door labeled HEAT SECTION on the right hand side of the unit All gas system components are in the gas section On 48MP62L and 70M units additional access to the gas components is through the access panels in the unit corner post at the gas section See Fig 51 UNIT CONTROL BOX Access to this component is through the doors marked ELECTRICAL SECTION on the con denser end of the unit ECONOMIZER DAMPER MOTORS The economizer motors are located in the return air section Access to the motors is through the doors labelled FAN SECTION on the each side of the unit RETURN AIR FILTERS Access to these filters is through the door marked FILTER SECTION on the right side of the unit 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 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 program Clean evaporator coil with a stiff bristle brush not wire vacuum cleaner
91. from project plans or select unit location 3 Check for possible overhead obstructions which may in terfere with unit lifting or rigging CAUTION Do not lift unit with forklift truck Move unit with overhead rigging only Unit Placement Inspect unit for transportation dam age File claim with transportation agency Provide clearance around and above unit for airflow safety and service access Do not restrict top area above con denser fans in any way Allow at least 6 ft on all sides for rated performance code compliance and service Check unit dimensional drawings for unit arrangement and minimum performance and service clearances Do not install unit in an indoor location Do not locate air inlets near exhaust vents or other sources of contaminated air On units equipped with power exhaust option high velocity air is exhausted out the hood Unit should be positioned with at least 10 ft clearance between the exhaust hood and any obstruction Although unit is weatherproof guard against water from higher level runoff and overhangs Level by using unit frame as a reference Physical data is shown in Tables 1 4 Roof Mount Check building codes for weight distri bution requirements Unit weight is shown in Table 1 Unit may be mounted on class A B or C roofing material ROOF CURB Assemble and install as described in in structions shipped with the accessory Accessory roof curb and information requi
92. g the STANDB Y RUN mode to STBY NO High Voltage Relay Modules DSIO1 and DSIO2 INPUTS Inputs on terminal strip J3 are discrete inputs on off When 24 vac is applied across the 2 terminals in a channel it reads as an on signal Zero v is read as an off signal OUTPUTS Terminal strips J4 and J5 are internal relays whose coils are energized by a signal from the microproces sor The relays switch the circuit to which they are con nected No power is supplied to these connections by the DSIO module DSIO REPLACEMENT Before any service work is started be sure that all electrical disconnects are opened and tagged Installation 1 Verify the existing DSIO module is defective by using the procedure described in the Control Modules section on page 53 2 Check that all power to the unit is off Switch off all circuit breakers Carefully disconnect all wires from the defective module by unplugging the connectors It is not necessary to remove any of the individual wires from the connectors Remove the green ground wire 3 Remove the DSIO module mounting screws and re move the module from the control box Save the screws 4 With a small screwdriver set the address switches S1 and S2 on the new DSIO module to match those on the defective module 5 Mount the new module in the control box using the screws saved in Step 3 6 Reinstall all of the wire connectors and the green ground wire 7 Carefully check all w
93. gister 5 Continue to press to display the other codes in the fault resister After the last code has been displayed the sequence will return to the first code Control Modules The standard PSIO and optional PSIO2 processor modules and standard DSIO1 and DSIO2 high voltage relay modules all perform continuous diag nostic evaluations of the hardware condition Proper opera tion of these modules is indicated by 2 light emitting diodes LED on the front surface of the DSIO modules and on the top horizontal surface of the PSIO modules RED LED Blinking continuously at a 3 to 5 second rate indicates proper operation Lit continuously indicates a prob lem requiring replacement of the module Off continuously indicates the power supply should be checked If there is no input power check the fuses If a fuse is bad check for shorted secondary of the transformer or a bad module GREEN LED On a PSIO module this is the green light that is closest to the COMM connectors The other green LED on the module indicates external communications when used The green LED should always be blinking when power is on It indicates that the modules are communicating prop erly If the green LED is not blinking check the red LED If the red LED is normal check the module addresses NOTE If the wrong address is entered for the DSIO1 and 2 and or PSIO1 and 2 then the wrong input channel will be read and the wrong output channel en
94. he 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 CENTER LINES MUST COINCIDE ja LINES MUST BE PARALLEL FIXED SHEAVE FIXED SHEAVE Fig 62 Pulley Alignment Gas Valve Adjustment NATURAL GAS The gas valve opens and closes in re sponse to the PIC control or limit control When power is supplied to valve terminals D1 and C2 the main valve opens to its preset position The regular factory setting is stamped on the valve body 3 3 in wg To adjust regulator 1 Set thermostat at setting for no call for heat 2 Turn main gas valve to OFF position 3 Remove pipe plug from manifold or gas valve pres sure tap connection Install a suitable pressure measuring device 4 Set main gas valve to ON position 5 Set thermostat at setting to call for heat 52 6 Remove screw cap covering regulator adjustment screw see Fig 63 7 Turn adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure 8 Once desired pressure is established set thermostat set ting for no call for heat turn off main gas valve remove pressure measuring device and replace pipe plug and screw cap REGULATOR REMOVE COVER Fig 63 Gas Valve Main Burners For all applications main burners are factory s
95. i gt 48MPD MPE62L 10R 50MP62L 10R Single Package Electric Cooling Units and Gas Heating Electric Cooling Units With Product Integrated Controls Installation Start Up and Service Instructions CONTENTS Page Page GENERAL 2 Gas Pressure Check 38 SAFETY CONSIDERATIONS Check Supply Fan Rotation 38 MALAM EDDIE START UP LEE E 3842 INSTALLATION 3 28 Initial CHECK jo 38 Jobsite Survey 3 General des oot keane arin Gas 39 2 Operating Sequences 39 E OO e SUPPLY FAN Slab Mount 3 ECONOMIZER pcg s Ductwork 2 COOLING Units TIMIDI OCCUPIED COOLING Condensate Drains 3 UNOCCUPIED COOLING Condensate Coil Shipping Covers 3 e OVERRIDES Install Outdoor Hoods 3 ADAPTIVE OPTIMAL START EEE 14 ADAPTIVE OPTIMAL STOP Applicati iS S 14 A HEATING OEE LEON 48 Units Only Genre ng EEE 17 Contrai Loop Checkout 41 IAQ Control Loop Adjustment 42 AND HOT WATER Leadilag picung a MALA ERN p inal Checks 1 SPACE TEMPERATURE
96. ignal pins must be wired to signal ground pins Wiring con nections for CCN should be made at the 4 pin plug COMM located at the bottom right side of the fuse bracket in the main control box Consult CCN Contractor s Manual for fur ther information NOTE Conductors and drain wire must be 20 AWG mini mum stranded tinned copper Individual conductors must be insulated with PVC PVC nylon vinyl Teflon or poly ethylene An aluminum polyester 10096 foil shield and an 23 outer jacket of PVC PVC nylon chrome vinyl or Teflon with a minimum operating temperature range of 20 C to 60 is required See Table 7 for cables that meet the requirements Table 7 CCN Connection Approved Shielded Cables MANUFACTURER CABLE PART NO Alpha 2413 or 5463 American 22503 Belden 8772 Columbia 02525 IMPORTANT When connecting the CCN communi cation bus to a system element use a color coding sys tem for the entire network to simplify installation and checkout The following color code is recommended SIGNAL CCN BUS CONDUCTOR 1 PLUG TYPE INSULATION COLOR PIN NO WHITE 2 BLACK 3 NOTE If a cable with a different color scheme is selec ted a similar color code should be adopted for the entire network At each system element the shields of its communication bus cables must be tied together If the communication bus is entirely within one building the resulting continuous shield must be connecte
97. iods 7 Verify that control time periods programmed meet cur rent requirements 8 Check all electrical connections to be sure they are tight General NOTE If unit is equipped with REMOTE START function place the LOCAL REMOTE switch in the LOCAL Off position 1 Putthe 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 Using the HSIO or Building Supervisor verify that no alarms have been detected 3 Ensure that quick test has been performed to make sure that the controls are operating properly Refer to the Con trols and Troubleshooting Guide for more information 4 Using the HSIO put the unit into Run mode a Press b Press c Press es This will put the unit in Run mode d Press The unit will change from mode 25 standby to mode 32 occupied or mode 27 unoc cupied depending on the programmed time schedule Operating Sequences Base unit operating sequences are presented below Refer to unit Controls and Troubleshooting literature for expanded details on unit con trols operation additional controls functions and logic theory SUPPLY FAN VAV Units During Occupied periods the control will en ergize the supply fan contactor The contactor will close energizing supply fan motor Fan wheel will turn Airflow Switch differential pressure switch contacts close provi
98. ire connections before restoring power to the unit 8 Verify that the unit ON OFF switch is in the ON position 9 Restore power to the unit and close the control circuit breaker CCB Verify that the red and green LEDs respond as described in the Control Modules section on page 53 The LID keypad should begin its rotating display 10 After completing the configuration steps outlined above close all remaining circuit breakers and perform a unit test 11 Complete this procedure and restore the unit to normal operation by returning the STANDBY RUN mode to STBY NO Refrigerant Feed Components Each refrigerant circuit 2 per unit has all the necessary refrigerant controls Thermostatic Expansion Valve TXV On 48 50MP units each circuit has 2 TXVs on which superheat may be adjusted if absolutely necessary The TXV is set to maintain 10 to 13 F superheat leaving the evaporator coil It controls the flow of refrigerant to the evaporator coils Hot Gas Bypass optional hot gas bypass system may be factory installed on circuit no 1 This system will introduce discharge vapor from the compressor discharge line into the distributors and evaporator coil circuits on circuit no 1 when suction pressures drop to damaging levels No field adjustments of the hot gas bypass valve should be required Condenser Fans Each fan is supported by a formed wire mount bolted to fan deck and covered with a wire guard The e
99. ischarge 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 WARNING For vertical supply and return units tools or parts could drop into ductwork and cause an injury Install 90 de gree turns in the supply and return ductwork between the unit and the conditioned space If a 90 degree elbow cannot be installed then grilles of sufficient strength and density should be installed to prevent objects from fall ing into the conditioned space Rigging not drop unit keep upright Use spreader bars over unit to prevent sling or cable damage Leave con denser coil shipping protection in place while rigging to prevent coil damage lifting lugs MUST be used when lifting unit Level by using unit frame as a reference See Fig 7 for information Unit and accessory weights are shown in Tables 1 4 Weight distribution and center of gravity can be found in Fig 8 Condensate Drains The condensate drain connec tion is a I in NPT pipe connection located on the right hand side of the unit See Fig 9 NOTE Use a trap of at least 7 in deep Condenser Coil Shipping Covers Remove and discard Install Outdoor Hoods 1 Outdoor air hoods are shipped bolted to the unit in a ship ping position To open hoods remove the 3 holddown bars holding the air hood in shipping positi
100. its of a Class A com puting device as defined by FCC Federal Communi cations Commission regulations Subpart J of Part 15 which are designed to provide reasonable protection against such interference when operated in a commer cial environment POWER WIRING Units are factory wired for 460 v as shown on the unit nameplate The main terminal block is suitable for use with aluminum or copper wires Maximum wire size is 500 MCM Branch circuit for power supply to unit must be protected against ground fault or short circuit Provide an overcurrent protection device in the branch circuit The MOCP Maxi mum Overcurrent Protection value for this device is shown on unit informative data plate When installing units provide and install a unit safety dis connect per NEC of adequate size Refer to Electrical Data tables for disconnect sizing Disconnect may incorporate branch circuit fusing if local or national codes permit but combi nation disconnect fuse is not required Disconnect must be able to be locked OFF FILTER BLOCK OFF PLATE Fig 11 Outdoor Air Hoods Installed Disconnect must be located within sight of the unit and read accessible from the unit in compliance with NEC Article 440 14 All field wiring must comply with NEC and all local codes Size wire based on MCA Minimum Circuit Amps value shown on the unit informative plate See Fig 12 for power wiring connectio
101. k test feature IMPORTANT If remote start function is used place LOCAL REMOTE switch in Local OFF position when ever unit is placed in STBY YES SET UNIT TYPE The correct unit type must be set The default unit type is VAV If the unit is being used in a VAV application then the unit type does not need to be changed Table 23 HSIO Keypad Key Usage FUNCTION KEY USE Status To display diagnostic codes and current operating information about the unit Quick Test To check inputs and outputs for proper operation alls o gt 2 HIST History To check most recent alarms Service To enter specific unit configuration information Set Point To enter operating set points and day time information Schedule To enter occupied unoccupied schedules for unit operation SRVC ISCHD 9 m 4 OPERATIVE KEYS USE Expand Display To display a non m 3 abbreviated expansion of the display Clear To clear the screen and return to previous LEA display Also used to enter data value of zero Up Arrow To return to previous display position Down Arrow To advance to next display position NTE To enter data EDB E Fig 48 Keypad and Display Module HSIO If the unit is being used in CV application then perform th
102. m crankcase heater 7 Disconnect service valves from compressor NOTE On units with 2 compressors per circuit discon nect both oil equalizer lines located on the motor barrel and on the oil pump sump 8 Units 48 SOMP62L a Remove 4 large screws securing compressor mount ing pan to unit base rail b Slide compressor on mounting pan to outside of unit frame support and or lower to ground c Unbolt compressor from mounting pan and remove 9 Units 48 50MP70M 82N 90P 10R a Remove 4 large screws securing compressor to the com pressor rails b Lift compressor off mounting bolts and remove Compressor Replacement Perform the following 1 Reverse procedure in Compressor Removal section to end of Step 4 2 Reinstall service valves and safety switches and tighten to torques as listed TORQUE COMPRESSOR S Tighten discharge valves to 20 25 ft lbs 27 34 N m 80 90 ft lbs 109 122 N m Tighten suction valves to 80 90 ft Ibs 109 122 N m 06 250 90 120 ft Ibs 122 163 N m 06E 265 275 299 Tighten the following fittings as specified 120 in Ibs 13 5 N m High Pressure Switch 120 in Ibs 13 5 N m Low Pressure Switch 06 250 06 265 275 299 3 Leak check and evacuate system reclaim refrigerant 4 Recharge system per pre start up and start up sequences Recheck oil levels 5 Energize crankcase heater for 24 hours prior to restart of system TROUBLESHOOTING The 48 50MP units
103. nect main circuit output terminals T1 T2 and T3 to AC main circuit power supply Always ground the VFD using the designated ground terminal Refer to the VFD tech nical manual for more information The VFD can indicate faults and alarms A blinking alarm condition is a warning that a trouble condition will occur or that there is a problem in the external circuitry The VFD will continue to operate during an alarm condition Alarm conditions are not entered into the fault register A steady fault indicator is displayed when the VFD fault relay has tripped The motor will coast to a stop and a fault signal is output is present Refer to the VFD technical manual for more information on alarms and faults DISPLAYING FAULT SEQUENCE Whenever the fault relay trips and shuts down the VFD the display code of the fault that caused the trip will be displayed until RESET is 53 pressed The fault code will also be entered into the fault register The register retains in sequence the last 3 fault codes A newly occurring fault code will not change the fault reg ister if it a recurrence of the most recently entered fault The contents of the register can be displayed by performing the following steps 1 Press DSPL until the MONTRI LED is on 2 Press Al until U 09 is displayed 3 Press fare The current fault code will be displayed 4 Press The display will indicate that this 15 the first code in the memory re
104. ns to the unit power terminal block and equip ment ground Operating voltage to the compressor must be within the volt age range indicated on the unit nameplate Voltages between phases must be balanced within 2 and the current must be balanced within 10 See Table 5 for unit electrical data Use the following formula to determine the percent voltage imbalance Voltage Imbalance max voltage deviation from average voltage 100 average voltage EXAMPLE Supply voltage is 460 3 60 Bg AB 452 v f BC 464 v AC 455 v 452 464 455 Average Voltage _ 1371 457 Determine maximum deviation from average voltage 457 452 5 v 464 457 7 v AC 457 455 2 v Maximum deviation is 7 v Determine percent voltage imbalance 7 Voltage Imbalance 100 x 457 1 53 15 This amount of phase imbalance is satisfactory as it 1 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 TBI DISCONNECT PER NEC LEGEND EQUIP Equipment GND Ground NEC National Electrical Code TB Terminal Block Fig 12 Field Power Wiring Connections Table 5 Electrical Data CONDENSER POWER COMP COMP EVAPORATOR FAN EXH
105. o heating mode the HIR is energized to pro vide switch closure or opening depending on how the field supplied power source is set up to open the room terminals The field connections for the HIR are Normally Closed ter minals 8 and 10 on TB3 and Normally Open terminals 8 and 9 on TB3 See Fig 15 OPTION AND ACCESSORY CONTROL WIRING The 48 50MP units may be used in applications with additional control features options or accessories Refer to the Con trols and Troubleshooting manual for more information con cerning installation and configuration of options and acces sories Figures 15 to 29 contain wiring information on the following features heat interlock relay Fig 15 differential enthalpy sensor Fig 16 remote start Fig 17 accessory humidity control Fig 18 fire smoke control Fig 19 indoor air quality Fig 20 outdoor airflow control Fig 21 timed discrete output Fig 22 humidifier Fig 23 hydronic heating Fig 24 freezestat Fig 25 remote supply air temperature space temperature offset Fig 26 transducer thermistor Fig 27 CCN Building Supervisor Fig 28 variable frequency drive VFD Fig 29 STANDARD T55 CEC0121448 01 SENSOR ACCESSORY T56 0121503 01 m SENSOR F he LEGEND COM Common SW Switch T Terminal TB Terminal Block TH Thermostat Heating Accessory Fiel
106. o modulate exhaust fan airflow to maintain building pressure on units equipped with modu lating power exhaust option The supply fan VFD is located in the auxiliary control compartment on the left hand side of the unit at the end of the supply fan section The modulating power exhaust VFD is located in the ex haust fan compartment on the right hand side of the unit at the return air end Control input to the supply fan VFD is provided by a 4 to 20 mA signal from the PSIO1 Channel 16 Control input to the exhaust fan VFD is provided by a 4 to 20 mA signal from the PSIO1 Channel 15 Set point control for the VFD is done through the HSIO or other network devices subfunction s Refer to the Controls and Troubleshooting manual for configuration in structions and sequence of operation The VFD has been programmed at the factory for 48 50MP applications No further adjustments should be nec essary at start up A separate technical and service manual for the factory installed VFD is supplied with each unit Refer to the VFD manual for more information on accessing and diagnosing the VFD controls DISPLAY AND KEYPAD functions of the VFD are accessed using the Digital Operator See Fig 49 The Digital Operator has a 4 digit LED display By pressing the DSPL key on the Digital Operator while the drive is stopped the user can step to each of the 16 functions and displays See Table 30 Table 29 HSIO Keypad
107. 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 n 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 CYLINDER HIGH HEADS PRESSURE MUFFLER SWITCH G A P d M 7 b WO E15 A O Ofo ONO of o 00 0 PRESSURE RELIEF SIGHT RAIL CRANKCASE OIL LOW SIGHT MOUNTING VALVE GLASS HEATER EQUALIZER PRESSURE GLASS SPRING LINE SWITCH HIDDEN NOTE Units 48 50MP62L compressors are pan mounted Units 48 50MP70M and 82N compressors are mounted on rails Fig 60 06E Compressors Typical HOLDDOWN BOLTS Fig 61 Motor Plate Adjustment 51 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 62 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 adjusting bolts until they are After verifying that the shafts are parallel loosen t
108. on See Fig 10 2 Lift up the highest hood top and swing out hood sides to form the outside frame of the air hood Fasten hood top to hood sides at middle and top holes only using two screws on each side See Fig 11 Remove the bottom hood block off plate and set aside 4 Swing up second hood from the top of unit into place and fasten to hood sides with screws provided using up per hole only 5 Swing up third hood from the top of unit into place and fasten to hood sides with screws provided using upper hole only 6 Swing up fourth hood bottom hood into place Before fastening hood to hood sides swing down bottom filter rack Fasten hood to hood sides with screws provided us ing upper hole only 7 Attach block off plate removed from Step 3 8 Clip wire tie holding filter track Swing filter track into position and fasten to hood sides using screws provided Repeat until all 4 filter racks have been installed 9 Apply a bead of RTV or similar sealant to corner of each hood at pivot point to prevent water leaks gt Copy continues on page 14 BASE UNIT 48 50MP NOMINAL CAPACITY tons OPERATING WEIGHT Ib Base Unit 48MP 50MP Copper Condenser Coils Exhaust Fan COMPRESSORS Number of Refrigerant Circuits Circuit No of Cylinders Model 06E Oil Charge pints Capacity Steps REFRIGERANT Operating Charge Ib Sys 1 Sys 2 Standard Coil Operating Charge Ib Sys 1 Sys 2 Alternate Coil
109. 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 Table 1 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 GAS LIQUID LINE HEAT SERVICE VALVES CONTROL BOX gt COMPRESSORS AUXILIARY CONTROL BOX ECONOMIZER AND EXHAUST FAN ACCESS PANEL EVAPORATOR COIL ACCESS PANEL LEFT HAND VIEW Fig 51 Access Locations 48MP70M Unit Shown MAIN BURNERS 48MP Only At the beginning of each heating season inspect for deterioration or blockage due to corrosion or other causes Observe the main burner flames Refer to Main Burners section on page 52 FLUE GAS PASSAGEWAYS 48MP Only The flue col lector box and heat exchanger cells may be inspected by re moving heat exchanger access panel Fig 3 and 4 flue box cover and main burner assembly Fig 52 Refer to Main Burners section on page 52 for burner removal sequence If cleaning is required remove heat exchanger baffles and clean tubes with a wire brush Use caution with ceramic heat
110. pping hard Santen ADJUSTING BOL ware from both the supply fan and the optional exhaust fan CROSS RAIL V The indoor fan shipping blocks on both the supply fan and the optional power exhaust fan 4 fan must removed from each corner of the fan sled before starting unit Re move shipping bolt connecting bottom flanges of the fan sled crossrail with the fan support rail Remove the wooden ship ping block from each corner See Fig 39 After removing all shipping blocks level fan sled using the adjusting screws of the spring isolators Verify dimen sions from fan support rail to fan sled cross rail of 7 in on all 4 corners To adjust loosen the locknut on top of the adjusting bolt SHIPPING BOLT Turn the bolt clockwise to decrease the height Turn the bolt BLOCK NG counterclockwise to increase the height Tighten the locknut after adjustment is complete Make sure that the fan sled VIEN FROM INSIDE NIT OE vut assemblies float freely during and after adjustment Fig 39 Fan isolator Adjustment i a V SHIPMENT BOLTS MOUNTING SPRINGS SHIPMENT BOLTS 48 50MP62L MOUNTING MOUNTING BOLTS RAIL BOLT 3 SHOWN BOLTS RAIL BOLT 3 2 SHOWN 48 50MP70M 10R Fig 40 Outer View Compressor Mounting 27 SNUBBER WASHER PRE START UP SELF LOCKING BOLT NEOPRENE IMPORTANT Before beginning Pre Start Up or
111. ptable oil level in the compressor is from to of sight glass 06E 299 compressors UT of sight glass Adjust the oil level as required No oil should be removed unless the crankcase heater has been Fig 42 Front View of Compressor Mounting energized for at least 24 hours Oil Charge section on Rail Assembly 48 50MP70M 10R Units page 49 for Carrier approved oils 9 Perform leak test Be sure there are no refrigerant leaks All units are shipped with a complete operating charge of R 22 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 check for leaks After leaks are repaired remove and recover refrigerant from system For leak testing procedures see GTAC 2 Module 5 Charging Recovery Recycling and Reclamation section Do not use the system compres COMPRESSOR MOUNTING FOOT sors to remove refrigerant from the system 10 Crankcase heaters must be firmly locked into compres NUT sors and must be on for 24 hours prior to start up COMPRESSOR MOUNTING RAIL CAUTION Crankcase heaters on all units are wired into the control circuit so they are always operable as long pr as the main power supply disconnect is on closed even if any safety device is open Compressor heat ers must be on for 24 hours prior to the start up of any compressor Fig 43 Rea
112. r View of Compressor Mounting Rail Assembly 48 50MP70M 10R Units 28 11 Check supply fan belts sheaves and bearings Check the lubrication of the fan and motor bearings Check bear ing and bearing set screws for tightness Check sheave alignment and belt tension Hand turn fan to ensure fan wheel does not rub on housing The fan shaft and motor shaft must turn freely before power is applied to the unit 12 Check exhaust fan belts sheaves and bearings Check the lubrication of the fan and motor bearings Check bear ing and bearing set screws for tightness Check sheave alignment and belt tension Hand turn fan to ensure fan wheel does not rub on housing 13 Check economizer linkage Economizer dampers should be fully closed Linkage should permit full and free travel 14 Check that the correct return air filters are installed in the filter tracks Do not operate unit without return air filters 15 Check that all access doors on the air handler section have been closed and secured 16 Fan motors are 3 phase Check rotation of fans during first start up check Fan rotation is clockwise as viewed from top of unit If fan is not turning clockwise reverse 2 of the power wires 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 3 Observe oil level closely at start up If oil level is below the sight glass and cannot be seen add
113. range the original value will remain displayed See Table 24 for allowable ranges and default values To change the demand limit set points the functions must first be enabled in the field configuration subfunction CONFIGURE UNIT CONTROLS AND FUNCTIONS Refer to Table 25 for a suggested sequence for entering Basic System Configuration data These values may be changed from the HSIO at any time If changing default values via the CCN the 48 50MP unit must first be in run mode STBY NO NOTE After changing any of the values in the fone configuration group enable the Data Reset function QUICK TEST FUNCTION Enable and run the Quick Test function Refer to the Controls and Troubleshooting manual for more information on Quick Test Table 24 Set Point Ranges and Defaults ALLOWABLE SET POINT DEFAULT DISPLAY DESCRIPTION VALUE RANGE BPSP Building pressure set point 0 05 in wg 0 to 50 in wg ECSO Economizer set point offset 1 to 10 HHLT HHOR High humidity override percent HTMP High temperature minimum position HUSP Humidity set point percent IAQST IAQ set point 650 ppm 0 to 100 010 100 F 0 to 100 0 to 2000 ppm LIMTt Reset limit F 0 to 20 F LSP 0 to 100 LTMP 0 to 100 F 0 to 100 NTLOt NTFC lockout temperature F 50 F 40 to 70 F OCSP 55 to 80 F OHSP 55 to 80 F PEST Power exhaust on set point percent 90 30 to 100 RTIOT Reset ratio F 0 to 10 F SASP 4
114. red to field fabricate a roof curb is shown in Fig 1 and 2 Install insulation cant strips roofing and counter flashing as required For unit condensate drain to func tion properly curb must be level or within tolerances shown in Fig 1 and 2 STEEL BEAMS If roof curb is not used support unit with steel beams along its entire length and then support steel as required As a minimum unit must be supported across its width at each lifting lug location 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 Ensure that slab is of sufficient height to allow for 7 in condensate trap 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 1 6 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 d
115. ressors will be locked out To reset consult the controls and troubleshooting 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 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 60 for compressor mounting locations Settings for these switches are shown in Table 33 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 Variable Frequency Drive VFD SUPPLY FAN VFD The optional supply fan VFD is lo cated in the auxiliary control box Wiring should only be performed by qualified personnel All parameters have been factory set Do not change parameters unless necessary
116. s for the DSIO1 and DSIO2 modules are 19 and 49 respectively Set the switch closest to the mounting plate at 1 05101 4 05102 and the other switch at 9 both modules KEYPAD AND DISPLAY MODULE HSIO IMPORTANT The HSIO human sensor input output keypad and display module is required for initial start up of these units All units are shipped in standby mode and the HSIO must be used to change the unit to run mode Once the unit is in run mode the HSIO 15 not required for normal operation The keypad and display module HSIO or local interface device LID factory installed and located in the main control box provides unit function information at the unit The module consists of a keypad with 6 function keys 5 operative keys 10 numeric keys 0 through 9 and an alphanumeric 8 character liquid crystal display LCD Key usage is explained in Table 23 Each function has one or more subfunctions as shown in Table 29 The HSIO keypad and display module is installed through connection of the power and communication plugs and can be easily moved from one unit to another Because of this flexibility one HSIO can be used for several units Unit operation is controlled by the status of the RUN STANDBY mode on the HSIO To access the mode press on the HSIO and then use the vi key The HSIO will display either STBY YES or STBY NO To enable the unit press or and press while at the STBY YES display
117. se electrical connections 10 Compressor stuck Contactor Closed 1 Compressor leads loose LEGEND SOLUTION Restore power After finding cause and correcting replace with correct size fuse Check alarm history on HSIO Check secondary fuse s replace with correct type and size Re place transformer if primary windings receiving power Check for excessive compressor current draw Reset breaker re place if defective Reset lockout circuit at HSIO or circuit breaker Check for refrigerant undercharge obstruction of indoor airflow or whether compressor suction shutoff valve is fully open Make sure liquid line solenoid valve s is open 8 Check for refrigerant overcharge obstruction of outdoor airflow air in System or whether compressor discharge valve is fully open Be sure outdoor fans are operating correctly 9 Tighten all connections 0 See 06E compressor service literature NO Check connections 2 Motor windings open 2 See 06E compressor service literature 3 Single phasing 3 Check for blown fuse Check for loose connection at compressor terminal COMPRESSOR STOPS ON HIGH PRESSURE SWITCH Outdoor Fan On 1 High pressure switch faulty 1 Replace switch 2 Airflow restricted 2 Remove obstruction 3 Air recirculating 3 Clear airflow area 4 Noncondensables in system 4 Purge and recharge as required 5 Refrigerant overcharge 5 Purge as required 6 Line voltag
118. servicing or replacing High Pressure Switch This switch has nonadjust able settings Figure 60 shows connection on a cylinder head See Table 31 for pressure switch settings Table 31 Pressure Switch Settings Psig kPag SWITCH CUTOUT CUT IN mek 426 7 320 20 g 2935 48 2205 138 2734 67 7 Low 186 28 462 48 NOTE High pressure switch must be removed from cylin der head before removing compressor from the unit TO CHECK Slowly close the discharge shutoff valve until the compressor shuts down This should be at approx imately 426 psig 2935 kPag Slowly open the valve When the pressure drops to approximately 320 psig 2205 kPag the pressure switch resets To reenergize the control circuit manually switch the fan circuit breaker off and then on The compressor starts again under Time Guard controls Low Pressure Switch The low pressure switch LPS has fixed nonadjustable settings It is located at the pump end of the compressor above the bearing head See Table 31 for pressure switch settings TO CHECK Slowly close the suction cut off valve and allow the compressor to shut down This should occur at approximately 27 psig 186 kPag Slowly open the valve The compressor restarts under Time Guard control when the pressure builds to approximately 67 psig 462 kPag 50 Pressure Relief High side pressure relief is provided by a fusible plug in the liquid line at the serv ice
119. t charge low Head pressure low Air filters dirty Expansion valve power head defective Indoor coil partially iced Indoor airflow restricted Suction Pressure High 1 Unloaders not functioning 2 Compressor valve defective 3 Heat load excessive UNIT OPERATES TOO LONG OR CONTINUOUSLY 1 Low refrigerant charge 2 Control contacts fused 3 Air in system 4 Partially plugged expansion valve or filter drier SYSTEM IS NOISY 1 Piping vibration 2 Compressor noisy SOLUTION Add refrigerant Check refrigerant charge Clean or replace filters Replace power head Check low pressure setting Remove obstruction Check unloader adjustments Check unloader setting See 06E compressor service literature Check for open doors or windows in vicinity of fan coil Add refrigerant Replace control Purge and evacuate system Clean or replace ROM Support piping as required Check valve plates for valve noise Replace compressor if bearings are worn COMPRESSOR LOSES OIL 1 Leak in system 2 Crankcase heaters not energized during shutdown FROSTED SUCTION LINE Expansion valve admitting excess refrigerant HOT LIQUID LINE 1 Shortage of refrigerant due to leak 2 Expansion valve opens too wide FROSTED LIQUID LINE Restricted filter drier COMPRESSOR WILL NOT UNLOAD 1 Defective unloader 2 Defec
120. the green ground wire 8 Check all wire connections before restoring power to the unit 9 Verify that the unit ON OFF switch is in the ON position 10 Restore power to the unit and close the control circuit breaker CCB Verify that the red and green LEDs re spond as described in the Control Modules section on this page The HSIO keypad should begin its rotating display 11 Using the HSIO keypad and display module press to verify that the software version matches the version number shown on the PSIO label 12 Press to verify that the factory configuration codes agree with the values listed in Table 24 on page 37 13 Set other applicable inputs required in 3 and 6 to match the options and accessories installed on the equipment 14 Enable data reset function to store all data The HSIO keypad display will blank out after pressing the key while displaying data reset DTRS The rotating dis play returns when the data reset has been completed 15 Press ome and verify each item is now configured as needed for this particular installation Verify the fac tory default settings for both specified unit and generic control unit 54 16 Press s to check the remainder of the user con figuration values 17 After completing the configuration steps outlined above close all remaining circuit breakers and perform a unit test 18 Complete this procedure and restore the unit to normal operation by returnin
121. tive capacity control solenoid valve 3 Miswired capacity control liquid line solenoid COMPRESSOR WILL NOT LOAD 1 Miswired capacity control liquid line solenoid 2 Defective capacity control solenoid valve 3 Plugged strainer high side 4 Stuck or damaged unloader piston or piston ring s CONTACTOR OPEN 1 Power off Fuses blown in field power circuit No control power No demand by unit control Fan status switch not closed Motor leads loose Motor windings open Single phasing Belts broken or thrown 2 3 4 5 6 VFD overload function tripped 7 8 9 0 1 Fan status switch contacts defective 1 1 CONTACTOR CLOSED 1 No output signal from control at PSIO no 1 channel 16 2 Communication failure at VFD 3 Fan status switch contacts defective LEGEND HSIO Human Sensory Input Output Device DSIO Processor Module VFD Variable Frequency Drive Repair leak 2 Check wiring and relays Check heater and replace if defective Adjust expansion valve 1 Repair leak and recharge 2 Adjust expansion valve Remove restriction or replace Replace unloader Replace valve Rewire correctly Rewire correctly Replace valve Clean or replace strainer Clean or replace the necessary parts ROM Restore power After finding cause and correcting replace with correct fuses Check secondary fuses Replace with correct
122. uits and compres sors are shown in Table 20 Table 29 Index of Lead Lag Circuits and Compressors 70M 82N 90P 10R A 1 1 1 2 2 B B B B1 B1 B1 2 Circuit only has 1 compressor UNIT 48 50MP LEAD CIRCUIT Compressor Lead Compressor Lag LAG CIRCUIT Compressor Lead Compressor Lag Final Checks Ensure all safety controls are opera ting control panel covers are on and the service panels are in place Recheck all set points against project specifications Com plete Start Up Checklist and record operating values Leave completed checklist with unit for future reference NOTE If the REMOTE START function is used in this ap plication set the LOCAL REMOTE switch to REMOTE On at the end of start up 42 CONTROL SYSTEM General The control system consists of the following components standard processor module PSIO 8088 or PSIO1 options processor module PSIO 8052 or PSIO2 two standard high voltage relay modules DSIO HV or 15101 and DSIO2 keypad and display module HSIO or LID enthalpy sensor thermistors pressure transducers accessory humidity sensors space temperature sensors standard T55 and accessory T56 supply air fan status switch check filter switch Components PROCESSOR MODULE NO The PSIO1 module moni tors and processes the following inputs outputs and system information Inputs transducers thermistors switches Outp
123. ure sensing must be in stalled The recommended field supplied tubing for this use is a nominal 4 in fire retardant tubing The tubing must be run from the appropriate location in the building to the auxiliary control box in the unit Figures 31 and 32 show the location and layout of the auxiliary control box in the 48 50MP unit Figure 33 shows the connection locations for the tubing on the duct pressure DP controller for the VFD on the supply fan and on the building pressure BP controller for the VFD on the modu lating power exhaust fan The tubing for the duct pressure control DP should sample supply duct pressure about 73 of the way out from the unit in the main trunk duct The tubing for the building pressure control BP should sample building pressure in the area near the entrance lobby so that location is controlled as closely to design pressures as possible 55 SPACE SENSOR TO CON RED COMM 1 WHT e BUS RJ 1 PLUG UNIT Bit els S Qn S T2 Fig 30 Space Sensor to Communication Bus Wiring 24 AUXILIARY CONTROL BOX PANEL LOCATED BEHIND ACCESS DOOR FAR SIDE Fig 31 Auxiliary Control Box Location 50MP70M Unit Shown VARIABLE FREQUENCY DRIVE L o DUCT PRESSURE TRANSDUCER BUILDING PRESSURE TRANSDUCER HIDDEN 000 ies
124. uts condenser fan contactors integrated economizer motor 4 to 20 mA optional supply duct static pressure control VFD 4 to 20 mA optional modulating power exhaust control VFD 4 to 20 mA System Information generates alert and alarm information via transducer ther mistor and sensor inputs supports CCN level II communications supports digital air volume DAV interface NOTE The correct module address for the PSIOI is 01 S1 set at 0 S2 set at 1 PROCESSOR MODULE NO 2 The PSIO2 module sup ports the sensors used for humidity control outdoor air cfm indoor air quality IAQ smoke control superheat monitoring only when accessory transducer ther mistor kit is field installed In addition the PSIO2 supplies the outputs for humidity and hydronic heating coil control and a discrete output with timed clock control for outdoor building or parking lot lights NOTE The correct module address for the PSIO2 is 31 S1 set at 3 S2 set at 1 HIGH VOLTAGE RELAY MODULES DSIO The DSIO modules close contacts to energize evaporator and con denser fan contactors The modules also control compressor unloaders compressor contactors compressor crankcase heat ers heat interlock function and power exhaust contactor The compressor status through the compressor lockout CLO relays and high pressure switches safety circuits are the in puts to these modules NOTE The correct module addresse
125. value less than the heat ing set point or greater than the cooling set point 10 Observe system loop response for 10 to 20 minutes to verify stable control After 10 minutes if the output con tinues to swing from full open to full closed lower the MLG and observe again 11 Do this until the loop operation is stable After 10 min utes if the loop does not seem to respond little change in submaster reference increase the MLG and observe again Do this until stable operation is achieved 12 Once satisfied with loop operation remove all forced values which may have been initiated during this procedure 13 Repeat Steps 1 12 until all loops have been checked NOTE For better tuning the building supervisor or service tool should be used to adjust the proportional and integral terms Contact your Carrier representative for more details IAQ Control Loop Adjustment The IAQ indoor air quality control loop is different from the other control loops It has one gain value that can be adjusted in the serv ice subfunction 1 sp under IAQG indoor air quality gain This gain is used to speed up or slow down the response of the economizer dampers to the difference be tween the IAQ set point and the IAQ sensor If the econo mizer is moving too slowly then the gain needs to be increased If the economizer moves too rapidly and over shoots the set point then the gain should be reduced Lead Lag Circuits Lead lag circ
126. x 6 0 2 Center of gravity Use appropriate column for units with or without ex For smaller service and operational clearances contact Carrier Application haust fan option Engineering department 3 Unit weight does not include exhaust fan option 5 Downshot ducts designed to be attached to accessory roof curb If unit is Exhaust fan add 2275 Ib 1034 kg on 82N mounted on dunnage it is recommended the ducts be supported by cross 2300 Ib 1090 on 90R 10R braces as done on the accessory roof curb 4 Unit clearances 6 All lifting lugs must be used when rigging unit Top Do not restrict condenser fans Fig 6 Base Unit Dimensions 50MP82N 10R 12 NOTICE TO RIGGERS WEIGHT ib kg Ib kg Ib kg in in in mm in in 16 810 7 624 16 550 7 507 1675 760 71 25 1810 129 00 3277 112 44 2856 138 00 3505 2572 90P 10R ONLY NOTE AII lifting lugs must be used when rigging with eight or ten cables and spread with four or five 95 in 2413 mm and two B D long suitable spreader bars Unit weight does not include CAUTION exhaust fan option All panels must be in place when rigging 1 2 Unit is not designed for handling by fork truck Fig 7 Rigging Label UNIT CORNER WEIGHT DIMENSIONS ft in DIMENSIONS ft in 48 4 A B B 62L 50
127. xposed end of the fan motor shaft is protected from weather by grease If fan motor must be removed for service or replacement be sure to regrease fan shaft and reinstall fan guard For proper performance fan should be 75 in 22 mm below top of venturi on the fan deck to top of the fan hub See Fig 64 Tighten set screws to 15 1 ft Ibs 20 1 3 N m Figure 64 shows proper position of mounted fan TOP OF VENTURI ON FAN DECK VENTURI FAN DECK NOTE Fan rotation is clockwise when viewed from top of unit Fig 64 Condenser Fan Adjustment IMPORTANT Check for proper fan rotation clock wise viewed from above If necessary to reverse switch leads Compressor Removal Access to the pump end of the compressor is from the compressor side of the unit Access to the motor end of the compressor is from the inside of the unit All compressors can be removed from the com pressor side of the unit IMPORTANT compressor mounting hardware and support brackets removed during servicing must be re installed prior to start up 1 Disconnect power to unit lockout power to compressor 2 Close suction and discharge service valves 3 Relieve refrigerant pressure into a refrigerant recovery system 4 Remove a Fan cycling pressure switch FCPS b High pressure switch c Low pressure switch 55 5 Disconnect power wires at terminal box and disconnect conduit 6 Disconnect wires fro

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