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Carrier 48AK Air Conditioner User Manual

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2. 4 4 55 n Circuit 1 I TPR H 4 PASS 2 55 po de PSS 4 Ec TRS ps Passi CI EFE 4 PASS E 4 PASS d seas i TEESE a PASS HPS LPS amp Fusible Tee T PAS Liu Line rwr mounted on compressor 54 ter TPAS PASS Filter Drier T 4 PASS Muffler TPA OLLI secl Sa Pass 4 55 rae nee m 2 55 gt gt 4 4 55 Fusible 4 55 Plug PASS H 1L 4 pg ES 4 PASS e 4 55 2 4 PASS w D HPS HKO2ZA428 A PASS ni 2 55 Cutin 320 51 S PASS J U 4 55 E Cutout 426 f PRSE E yerri Em Snubber 50 0400522 PA 1777 OTPRS 4 5 lt LPS 278027 4 P amp Fes Cutin 22PSI 4 PASS Cutout 7 51 PASS TI DASS ASS Circuit 2 SPAS 4 55 SS Lea PASS a pass H HPS LPS amp Fusible Tee __ mounted on compressor 14 lt 5 ERE PASS PASS LL Muffler gg 4 55 Liquid
3. HPS amp LPS mounted _4Pass compressor 6 Pass 6 Pass 4 55 Muffler 6 Pass TXV 1 6 Pass Compressor 1 _4Pass_ 6 Pass es 6 Pass 6 Pass 4 Pass 6 6 Pass 4 Pass 6 Pass 6 Pass Eee 6 Pass HPS 22 428 Pass h Cut In 320 PSI 6 Cut out 420 PSI 6 Pass LPS HK02ZB027 1 Cut In 22 PSI Cut out 7 PSI 4 Pass 6 Pass 6 Pass Hes 6 Pass 6 Pass 4 Pass 6 Pass p 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass Leges 6 Pass 6 _4Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass Mes 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass HPS amp LPS mounted on nee compressor _4Pass 6 Pass 6 Pass 4 Pass 6 Pass E 2 NN 4 Pass Compressor 1 6 Pass 6 Pass E 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 3 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass E
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9. 0 EXPANSION BOARD ACCESSORY ONLY Le BASE MODULE 8 7 MODULATING POWER EXHAUST ONLY gt TRAN4 11 575V TRAN3 POWER F 575V ONLY 11 EXHAUST NIB gt 11 B 0 PESI PES3 PES4 1 a E o E J MM T POWER EXHAUST ONLY L LL LI 0 0 STA 4 P 9 gg 1 l H id TRANI CRI P 0 0 HH S p PEC3 B 0 TRAN2 end Em 82 NEUTRAL EE NEC o CB2 IFCB CCB TBI o I 1 1 1 joj lo 1 1 1 1 1 IEQUIP 5 11 tal l 1 lo eee I 1 1 tL Orc I l 1 1 por o e 1 1I 1 i o o o o o o IFC H Fi 5 H 9 o o por 1 p e 1 1 por o 2 por 1 4 I I I OFC FU4 FUI 1 1 1 1 00000000 1 I 1 u FU3 FU2 84 TB3 I I I gt 11 L 1 __ 1 1 1 1 Il FIELD POWER WIRING SEDALA 5 DISCONNECT PER NEC DETAILA THERMOSTAT CONNECTION LOCATION L
10. TXV iH TXV 2 HPS amp LPS mounted on compressor Muffler Compressor 1 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass LEGEND FPS Freeze Protection Switch HPS High Pressure Switch LPS Low Pressure Switch Thermostatic Expansion Valve Fig 88 Typical Refrigerant Circuiting 48AJ AK AW AY040 050 107 6 amp PAS 6 PASS IL amp PASS 6 lt PAS 6 PASS amp PASS E PASS PASS Circuit 1 6 55 BL 6 55 6 55 E PASS HPS LPS amp Relief Valve 6 55 Liquid Line E PASS Filter Drier Muffler mr B PASS 8 55 8 PASS Hai 8 55 usible 8
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12. 208v 230 460 575 208v 230 460 575v 208v 230 460 575 ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts 9 750 10 050 10 350 10 650 120 25 11 550 0 60 5 54 0 73 5 97 6690 11 850 0 56 5 61 0 69 6 03 6765 12 150 0 51 5 67 0 65 6 10 6840 12 750 0 41 5 74 0 56 6 18 6930 13 350 0 31 5 90 0 47 6 34 7110 13 950 0 20 6 10 0 37 6 56 7350 14 550 0 11 6 25 0 30 6 70 7515 15 150 0 04 6 38 0 23 6 84 7665 15 750 0 17 6 98 7830 16 350 0 12 7 13 7995 16 950 0 07 7 20 8070 17 550 0 04 7 25 8130 LEGEND Bhp Brake Horsepower ESP External Static Pressure in wg Watts Input Watts to Motor 78 Nominal Bhp 5 7 5 10 15 20 25 30 40 Nominal Bhp LEGEND 5 7 5 10 15 20 25 30 40 Bhp Brake Horsepower NOTES 1 Extensive motor and electrical testing on the Carrier units has Table 33 Motor Limitations STANDARD EFFICIENCY MOTORS Maximum Amps Maximum Maximum BhP 460v 575v Watts 5 080 a 220 gt 7717 95 120 100 8 008 w 8 502 18 146 9 836 13 488 12543 10 219 190 14756 224 18363 287 230 1918 2 720 2351 294 _ 9
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14. 1 875 938 2B5V66 6 7 B 1 875 2B5V124 12 B 1 9375 2 5VX610 1 875 1087 3B5V58 5 9 B 1 875 3B5V94 9 B 1 9375 3 5VX550 2 125 1214 2B5V94 9 4 B 2 125 2B5V136 13 6 B 1 9375 2 5VX650 NOTES 1 Motor shaft speed is 1750 rpm The fan shaft diameter is 115 1 inches 2 All indoor fan motors meet the minimum efficiency requirements as established by the Energy Policy Act of 1992 EPACT effective October 24 1997 ECONOMIZER AIR EXHAUST AIR RETURN AIR SUPPLY AIR RETURN SUPPLY i 66 CONDENSATE DRAIN Fig 18 Air Distribution Thru the Bottom Fig 19 Air Distribution Thru the Side 27 Step 5 Install Flue Hood 48AJ AK AW AY020 050 AND 48EJ EK EW EY024 048 UNITS Flue hood is shipped inside gas section of unit To install secure flue hood to access panel See Fig 20A 48AJ AK AW AY060 48EJ EK EW EY054 068 UNITS Flue hood and wind baffle are shipped inside gas section of unit To install secure flue hood to access panel In stall the two pieces of the wind baffle over the flue hood See Fig 20B NOTE When properly installed flue hood will line up with combustion fan housing See Fig 21 GAS SECTION ACCESS PANEL 2 PER UNIT Fig 20A Flue Hood Location 48AJ AK AW AY
15. 4 Pass 4 Pass 4 Pass 4 Pass Muffler Compressor 1 HPS 22 428 Cut In 320 PSI Cut out 420 PSI LPS HK02ZB027 Cut In 22 PSI Cut out 7 PSI HPS amp LPS mounted on compressor Muffler Compressor 1 LEGEND FPS Freeze Protection Switch HPS High Pressure Switch LPS Low Pressure Switch Thermostatic Expansion Valve TXV 1 4 Pass 4 Pass TXV 2 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pas
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19. 103 115 START UP CHECKLIST CL 1 CL 2 SAFETY CONSIDERATIONS Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical compo nents Only trained and qualified service personnel should in stall repair or service air conditioning equipment Untrained personnel can perform the basic maintenance functions of cleaning coils and filters and replacing filters All other operations should be performed by trained service per sonnel When working on air conditioning equipment observe precautions in the literature tags and labels attached to the unit and other safety precautions that may apply Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for unbrazing operations Have fire extinguishers available for all brazing operations A WARNING Before performing service or maintenance operations on unit turn off main power switch to unit Electrical shock could cause personal injury A WARNING 1 Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Refer to the User s Information Manual provided with this unit for more details 2 Do not store or use gasoline or other flammable va pors and liquids in the vicinity of this or any other appliance What to do if you smell gas 1 DO NOT try to light any appliance 2 DO NOT touch any electric
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22. LEGEND HPS High Pressure Switch LPS Low Pressure Switch Thermostatic Expansion Valve Fig 91 Typical Refrigerant Circuiting 48AJ AK AW AY060 110 HPS AND LPS MOUNTED ON COMPRESSOR _6 ___ MUFFLER 6 Pass COMPRESSOR e aa a NO 1 es j m Pass 1 a _ 6 HPS HKO2ZA428 CUT IN 320 PSI E ___ CUTOUT 426 PSI mcr CUT IN 22 PSI 6 Pass_ 6 Pass eras 7 HPS AND LPS MOUNTED amp Pass ON COMPRESSOR amp Pass COMPRESSOR NO 2 LEGEND HPS High Pressure Switch LPS Low Pressure Switch TXV Thermostatic Expansion Valve Fig 92 Typical Refrigerant Circuiting 48EJ EK EW EY064 111 890A3 M3 xa rasr yue uyy jeoid 26 614 NEM IN E 47 H Seed H ser Lm M 5590 7 Em 558 Em Em 1 1 55844 4 65049 T sss 59 I sse l 7952 2 E 558 1 2421212 s s s S 4 foi fo Ed dd d 558 5584 a
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26. 055 1315 150 idt ds r 1 24 20 Egg ise cns 0 ORO 175 075 1594 175 74 6 ___144 345 8 339 2 450 400 68 0 354 624 144 381 2 374 6 450 450 144 359 2 3512 450 450 208 230 187 254 106 4 506 106 4 506 1 5 3 80 0 354 624 144 __ 394 6 386 6 500 450 144 3852 8752 450 450 104 0 35 4 62 4 144 420 6 410 6 500 500 SS ae 200 5 075 1874 225 ___ 1745 2 1 27 seo _ 225 eslasa __075 2054 250 jes ar Pep OR te 150 075 1512 175 075 1373 175 M l ive 1 24 Hasta cis 175 j18 9 354 075 1652 200 LEGEND Example Supply voltage is 460 3 60 FLA Full Load Amps 4 A BC AB 452 v HACR Heating Air Conditioning and Refrigeration BC 464 v Indoor Evaporator Fan Motor 455 v MCA Minimum Cheat Amps A Average Voltage MOCP Maximum Overcurrent Protection Lise 3 NEC National Electrical Code OFM Outdoor Condenser Fan Motor or 1371 RLA Rated Load Amps 3 457 Fuse or HACR circuit breaker per NEC NOTES 1 In compliance with NEC requirements for multimotor and combi nation load equipment refer to NEC Articles 430 and 440 the overcurrent protective d
27. 5 5 5 s 5 5 E NODULATING POWER EXHAUST ONLY A 1 T b s 3 ri 5 8 11 tat rt tt tat rt FRR u TRANS ONLY PESC PES2 5 PES4 ie TM 222 7 1 cl c2 FCI 2822 Pot tector 11 S 1 mE 202 uu uu duel GRE wp ja Demum 101 alaia u TRANG Bele delek Hs is 5 PECI Pele E IT 2 E POWER EXHAUST ONLY m 11 IFC2 z U lt 2x 1 11 E 183 FU4 FU3 FUI FU2 R E 00000000 Y I d 1 11 2 FIELD POWER WIRING gt DISCONNECT PER NEC J R Y1 Y2 WZ GCX SEE DETAILA DETAILA THERMOSTAT CONNECTION LOCATION LEGEND Compressor Contactor Fuse Outdoor Fan Contactor Contact FU F OFC Outdoor Fan Contact CB Circuit Breaker GND Ground PEC Power Exhaust Controller CCB Control Circuit Breaker HR Heater Relay PES Power Exhaust Sequencer ccn Carrier Comfort Network IFC __ Indoor Fan Circuit PEsc Power Exhaust Sequencer Control ler CR Control Relay IFCB Indoor Fan Circuit Breaker SIO Serial Input Output DIP Dual In Line Package IFR ndoor Fan Relay TB Terminal Block EQUIP Equipment NEC National Electrical Code TRAN Transformer The
28. SE Ted Cs 4 NUS I 4 024 224 5 Q 20 Ww 518 TE 34 Fig 27 Control Board Diagram TO EXPANSION BOARD TERMINAL Switch Terminal Relay Serial Input Output CONNECTION SIO CONNECTION N O Normally Open R SIO CONNECTION SW T LEGEND LED POWER CONNECTION TERMINAL Carrier Comfort Network Dual In Line Package Light Emitting Diode Normally Closed Diode LED YELLOW Where X is the unit control software version number COM Common LED CCN D DIP LED N C Table 7 Electrical Data 48AJ AK AW AY Units COMPRESSOR UNIT SIZE NOMINAL VOLTAGE RANGE 48AJ AK VOLTAGE AW AY 60 Hz RLA eT POWER POWER EXHAUST SUPPLY FLA TT 101 8 100 3 125 125 FLA 5 23 6 23 6 125 4 123 9 150 150 5 3 115 9 113 1 150 150 208 2 187 2 1 228 25 6 1 1 8 28 09 230 5 ee ea 0 23 6 23 6 139 5 136 7 175 175 1331 1278 175 150 bd 90 23 6 23 6 156 7 151 4 200 175 494 60 12 6 62 0 80 27 _ 558 70 ea 12 6 68 4 80 63 1 80 12 6 75 7 90 40 5 50 12 6 53 1 60 45 4 60 12 6 58 0 70 51 7 60 12 6 64 3 80 122 8 120 6 150 150 146 4 144 2 175 175 129 4 126 6 150 150 153 0 150 2 175 175 146 6 141 3 175 175 170 2 164 9 200 200 61 2 80 73 8 90 64 2 80 76 8 90 71 5 90 84 1 100 49 8 60 62 4 70 51 8 60 64 4 80 58 1 70
29. 1 will be allowed to turn on in 15 minutes repeated 3 times in If the safeties have been tripped 3 times in 90 minutes 90 minutes compressor no 1 will be locked out until the control board has been manually reset 3 HF 14 Compressor 2 Safety Automatic Cooling disabled The high or low pressure safety switch for compressor no 2 and Automatic reset after has opened for 3 seconds The error will be cleared and Manual 15 minutes Manual if compressor no 2 will be allowed to turn on in 15 minutes repeated 3 times in If the safeties have been tripped 3 times in 90 minutes 90 minutes compressor no 2 will be locked out until the control board has been manually reset 4 HF 15 Thermostat Failure Automatic Alarm generated The thermostat is calling for both heating and cooling at the same time The unit will operate on a first call basis and will automatically reset 5 Heating cooling and The supply air temperature SAT sensor has failed HF 05 SAT Thermistor Failure Automatic 6 HF 06 OAT Thermistor Failure Automatic 7 HF 03 Space Temp Sen Failure Automatic 8 HF 12 RAT Thermistor Failure Automatic 9 SE 05 10 HF 16 Control Board Failure None Analog to Digital None Conversion Loss of Communications Automatic with Expansion Board economizer disabled NTFC IAQ purge economizer and low ambient DX cooling locked out disabled Disables unoccupied cooling heating CV economizer and CV cooling he
30. Unit Preparation Check that unit has been installed in COM COMP 1 UNLOADER CYCLIC COND FAN COM CONT COND FAN POWER EXHAUST DISCRETE OUTPUTS POWER EXHAUST ELEC HEAT 2 ELEC HEAT 1 ECONOMIZER 4 20 mA OUPUT IyJitityityityt Fig 56 Wiring Field Supplied Unloaders for Constant Volume Units accordance with these installation instructions and applicable codes Compressor Mounting Loosen the compressor hold down bolts until sidewise movement of the washer under each holddown bolt head can be obtained Do not loosen com pletely as bolts are self locking and will maintain adjustment Service Valves Ensure that the suction discharge and liquid line service valves are open Damage to the compressor could result if they are left closed Internal Wiring Check all electrical connections in unit control boxes tighten as required Refrigerant Service Ports Each refrigerant system has one suction port located in the top of the compressor motor casing All units also have one service port on the liquid line valve and one on the compressor discharge valve Be sure that caps on the ports are tight 58 Crankcase Heaters Crankcase heaters are energized as long as there is power to the unit except when the compres sors are operating IMPORTANT Unit power must be on for 24 hours prior to start up Otherwise damage to compressor may result Variable
31. 2 OUND HLIM 43114405 011235 55042 BUND 3009 4 134SV9 53015 2 dAl 91 6 01123 55082 IV 35 8 191 e 10 8 1 E try 901 9811317 NM WANOZIYOH OL LINN 30 3903 19561 J 11 130 335 39NvV43101 9NI13A31 LINN dae ei sr os 8i Jers oi 211 NI 93a NI 795 tL 2112 0 7 119130 8 Y T S3HONT ONY 9338930 tyv SNOISNINIG 66811 8 5 90 16662 1181 91 1 811 26 18 05 NMOHS Sv Q3HOlld 38 AINO NYO LINN SU3ONYHOX3 1 JI ANY NOI123S BOON JHL 30 JHL NI 1 ONIONYIS 1NJA3Ud OL 310N 144 1019 ve 199021 1 198 17601 un S8313NI111H 38V 1 NI SNOISNGRIC 6 i YO 5330 74406 ANY OL 30184 1200 ATddNS JHL NO MOg13 26 HLIM 31771581 38 LSMW 1 21812313 HLIM SLINA f 115 Q3ZINVATV9 VO 18 4 94123008 TW toler 31 11 691 Ik 03191355510 0344185 SI 00 60008024882 48095322 94023004 2 118 dhl 018 1 30 3015100 OL WIG TV 031312345 3SIMY3HLO SSIINN 71 2842 ON Hed v90 p504QQa8r uo SHUN 890 pS0x3 r38t pue 090 1Jexdepy
32. NOTE Left side economizer hood has mounting angle without tabs and filter rack assembled end on the opposite side Fig 37 Economizer Hood Assembly Right Side Center Economizer Hood Shown MOUNTING FLANGE HOOD SIDE Fig 38 Adding Seal Strip to Sides of Hood Top Mounting Flange HOOD TOP HOOD SIDE Fig 39 Adding Seal Strip to Back of Hood Top Mounting Flange GRAY FOAM STRIP CROSS MEMBER Fig 40 Adding Foam Strip to Cross Member 50 HOOD SIDE SLOTTED Fig 41 Adding Foam Strip to Hood Side BLOCKOFF BAFFLE GRAY FOAM STRIP Fig 42 Adding Seal Strip to Blockoff Baffle Minimum Damper Position MDP Setting Setting of the outdoor air damper position is performed in conjunction with a shortened version of the field run test This is performed by first opening DIP Dual In line Package switch no 4 then no 6 See Fig 27 and Direct Digital Controls DIP Switch Con figuration section on page 63 The outdoor air damper closes The control allows 90 sec onds for the damper to close in case it is in the full open position Next the indoor fan contactor will energize The outdoor air damper will remain at 0 for 30 seconds It will then move to the 10 damper motor travel position for another 30 seconds This will be repeated at every 10 increment for 30 seconds until the damper reaches 100 open Close DIP switch no 4 during the 30 seconds immediately after the de si
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35. 1061 a Se fe vid 9 1 901 9N11311 77 SYINYOJ Y dAl 966 2616 5 8 1 3172 tzi Z 11130 12 2 2 TVINOZINOH Ol LINN 10 3903 WNOUJe v 512 83101 9NI13A31 LINN amp secos e NI NI 90 21 7 8 1 q S3H2NI ONY 5338930 5 015 3 10 192171 91 1 291 11621 8 S p11 172611 1086 dAl 2 09 vI 8 t g NMOHS SV 034 2114 38 AINO NVO LINN 514415 Su3ONVH2X3 1 IHL ONY NOI1O3S 300081 019 JHL 30 JHL NI 1 ONIGNVLS 1834384 OL ve 310N i 179021 1 18 176011 1019 8 NUN LSU 19 9171 69 SYJLINITIIN 2 NI SNOISN3NIQ 75 SHINY YO 5330 IYL ATddNS OL LONG 14406 IHL NO MOSTI 06 HLIM G371VISNI 39 LSNW 1 21312313 HLIM SLINA TLS GAZINVATVD 9 38 OL 38 18 88021008 11 E bie Q3IGNASSWSIG Q3ddlHS SI 0060084124440 ANOSS32OY 88023008 Z 91 1 6 LYVd 10 1015100 OL 38 WIG 11 031312395 151 83 10 SSIINN SHUN 8 Pash pue 050 9179 z 614 03114405 41314 NOILVINSNI 01918 43114405 41314 Ht 30084 43114405 073 41815 LNVO 43114405 073 1134 9NI 3008 83114405 41314 Y ONIHS 14 YJLNNOD
36. 2 Remove fan guard 3 4 Loosen fan hub setscrews Adjust fan height on shaft using a straightedge placed across venturi and measure per Fig 70 Fill hub recess with permagum if rubber hubcap is missing Tighten setscrews and replace panel s Turn on unit power Fig 70 Condenser Fan Adjustment Power Failure The economizer damper motor is a spring return design In event of power failure dampers will re turn to fully closed position until power is restored Refrigerant Charge Amount of refrigerant charge is listed on unit nameplate and in Tables 1A and 1B Refer to Carrier IL Module 5 Charging Recovery Recycling and Reclamation section for charging methods and procedures Unit panels must be in place when unit is operating during charging procedure NOTE Do not use recycled refrigerant as it may contain contaminants NO CHARGE Use standard evacuating techniques After evacuating system weigh in the specified amount of refriger ant refer to Tables 1A and 1B LOW CHARGE COOLING Using appropriate cooling charging chart see Fig 71 74 add or remove refrigerant until conditions of the appropriate chart are met Note that charging chart is different from those normally used An accurate pres sure gage and temperature sensing device are required Mea sure liquid line pressure at the liquid line service valve using pressure gage Connect temperature sensing dev
37. Air Quality participation control of modulating economizer damper to maintain indoor air quality IAQ when outdoor conditions are suitable this function is provided in the base unit con trols on units with serial number 0600F or later NOTE The IAQ sensor must be set for current output 4 to 20 mA not voltage output Ensure the jumper on the sensor is in the upper position See Fig 25 Additional features with sensor control of unit with com puter access or Remote Enhanced Display are 365 day timeclock with backup supports minute hour day of week date month and year daylight savings time function occupancy control with 8 periods for unit operation holiday table containing up to 18 holiday schedules ability to initiate timed override from T 55 or T 56 sen sors for a timed period of 1 to 4 hours ability to use multiple space temperature sensors to aver age the space temperature supply air temperature reset for the supply air tempera ture set point temperature compensated start to calculate early start times before occupancy access to the Display Maintenance Configuration Ser vice and Set Point data tables through network software loadshed and demand limiting When the unit is equipped with a field supplied space tem perature sensor and a remote contact closure remote start stop on the base control board the occupied default set points will monitor unit operation The occupied defa
38. JUV NMOHS 5311903557 XIS 3Hl 8903r38t 890a xa arasv zzy 2261 v903r38t csv 551 vo9oaxa araese i ssoarasy 860 psoarasr vsoaxa arasv H3NHOO LV 325 LINN 1VLOL 40 ALIAVHO dO H31N3D zose 0227 cere srs 6022 5622 9612 69 1672 01211 00706 6658 7165 0058 ssoz 806 5089 axa arase 63 9 a 0N 295 SLHDISM LINN 3578 ui 8 Buum pereroosse pue HA 9499 3 5 AVA Z e101 10 5905 pue SdOl4 ppy jou 5 Ue Joopul pue 4oopino sypiam jun eseg 9 quna 001 10 959 uo euop se 55010 Aq payioddns eq snw sjonp eui si eDeuunp uo pejunoui si pun J quno Joos A osseooe payoeye eq syonp woyog 6 ueunjedeg 19e uoo pue 1 104 104 2 6 0 51 sseooy 12 161211 0 7 epis 16281 0 9 4 161211 0 1
39. 2 will be energized whenever there is a call for Y2 or 2 SPT NOTE When a VAV unit with software version 4 0 and later is configured to operate from a space thermostat VVT relay pack or a space sensor compressors start loaded and then unload as needed This is the opposite of the normal VAV unloading sequence When operating from supply air tempera ture SAT sensor VAV units will unload in the reverse sequence FIELD TEST The field test program is initiated by moving up DIP switch no 4 to the OPEN position The outdoor air damper will close The control allows 90 seconds for the damp er to close in case it was in the full open position Next the indoor fan contactor will be energized and the outside air damper will begin to open to its default value of 2096 and stay at that position for a short period of time The outdoor air damper will then open to its full open position and stay at that position for a short period of time The outdoor air damper will then close If the unit is equipped with power exhaust stage 1 will be energized for 5 seconds If the unit is configured for stage 2 of power exhaust stage 2 will be energized for 5 seconds after the first stage is deenergized The first stage of heat will be energized for 30 seconds after which the second stage heat will be energized for an additional 30 seconds Heat is then deenergized The last step is the Cooling mode Outdoor fan contactor no 1 is energized
40. 3 8 1 2 1 2 1 2 Rows Fins in 4 15 6 15 6 15 4 17 Total Face Area sq ft 34 7 31 3 31 3 48 1 EVAPORATOR FAN Centrifugal Type Quantity Size in 2 20 X15 2 20 X 15 2 20 X 15 3 20 X 15 Type Drive Belt Belt Belt Belt Nominal Cfm 14 000 16 000 20 000 24 000 Motor Hp 10 15 20 15 20 25 20 25 30 25 30 40 Motor Frame Size 215T 254T 256T 254T 256T 284T 256T 284T 286T 284T 286T 324T Motor Bearing Type Ball Ball Ball Ball Maximum Allowable Rpm 1200 1200 1300 1200 Motor Pulley Pitch Diameter 6 1 5 3 5 7 5 3 5 7 7 5 6 3 8 1 7 5 5 3 8 1 9 4 Nominal Motor Shaft Diameter in 13 g 15 8 15 8 15 8 15 8 17 8 15 8 17 8 17 8 17 8 17 8 21 8 Fan Pulley Pitch Diameter in 13 7 9 5 9 5 9 5 9 5 11 1 11 1 12 5 11 1 9 1 12 5 13 6 Nominal Fan Shaft Diameter in 115 16 115 16 115 46 115 46 Belt Quantity 1 2 2 2 2 2 2 2 2 3 3 2 Belt Type 5VX610 5VX530 5VX550 5VX530 5VX550 5VX590 5VX570 5VX630 5VX590 5VX530 5VX630 5VX650 Belt Length in 61 53 55 53 55 59 57 63 59 53 63 65 Pulley Center Line Distance in 15 6 18 4 15 0 17 9 15 0 17 9 15 0 17 9 15 0 17 9 14 6 17 6 15 0 17 9 14 6 17 6 14 6 17 6 15 2 17 5 14 7 17 2 14 2 17 0 Factory Speed Setting rpm 779 976 1050 976 1050 1182 993 1134 1182 1019 1134 1214 FURNACE SECTION Rollout Switch Cutout Temp F t 225 225 225 225 Burner Orifice Diameter in drill size Natural Gas Std 120 31 120 31 120 31 120 31 Liquid Propane Alt 096 4
41. 32 C SPT Occupied Cooling 55 F 13 C SPT Unoccupied Cooling 90 F 32 C SPT Occupied Cooling 55 F 13 C SAT DEFAULT HEATING Unoccupied Heating 55 F 13 C SPT Occupied Heating NA Unoccupied Heating 55 F 13 C SPT Occupied Heating 68 F 20 C SPT Unoccupied Heating 55 F 13 C RAT Occupied Heating 68 F 20 C RAT Unoccupied Heating 55 F 13C SPT Occupied Heating 68 F 20 C RAT NOTE Space temperature sensor and remote start stop switch are field supplied STAGED GAS UNIT APPLICATIONS The rooftop units may be ordered with an optional factory installed staged gas control system that monitors heating operation of the rooftop unit IMPORTANT An accessory field supplied Navigator dis play module is required for all staged gas control units Install Supply Air Thermistors Staged Gas Units Only Supply air thermistors are a field installed factory provided component Three supply air thermistors are shipped with staged gas units and are inside the heating section Thermistor wires must be connected to SGC staged gas controller in the heating section See Table 6 and Fig 24 The supply air ther mistors should be located in the supply duct with the following criteria downstream of the heat exchanger cells equally spaced as far as possible from the heat exchanger cells duct location where none of the supply air thermistors are
42. 4 20 IMPORTANT The Carrier factory default values for the me edal deroa RTE VFD may be different than the default values of the manu 11 Once all the changes have been made open the IFCB facturer Refer to the Carrier literature when checking 12 Wait for the VFD display to go blank and remove VFD default values The following default values have been cover without touching any interior components Make changed from the manufacturer settings to closely match sure that the charge indicator lamp is out If still lit wait the VFD operation with a Carrier VAV unit Refer to until lamp goes completely out This may take several Tables 12 and 13 minutes 13 Replace jumper across terminals ST and CC 9 Fire speed override mode is available by contact closure between terminals S1 and CC 14 Replace VFD cover 10 Ifthe is to be controlled by an external control sys 15 Close the IFCB The VFD is now powered and the fan tem other than the factory supplied duct static pressure will operate transducer follow these steps a Install a jumper between S2 and CC This jumper will disable the PID Proportional Integral Deriva tive control loop in the VFD The VFD is set to Table 12 Carrier Default Program Parameter Values PARAMETER GROUP DEFAULT VALUE 60 0 Sec 60 0 Sec 60 0 Hz 100 Hz 20 SetP F P3 0 0 Hz Setup 100 60 Fz See Table 13 0 110 i 3 Gr F 60 Hz Fundamental 2 if 30 2 sec Gr Fb 0 Feedback 8
43. 8 16 x 25 8 16 x 25 8 16 x 25 4 20 x 25 4 20 x 25 4 20 x 25 262 500 394 000 350 000 525 000 82 15 45 35 65 3 5 3 5 2 426 320 27 67 10 20 x 24x2 8 16 x 25 4 20 x 25 Sizes 020 030 Circuit 1 uses the lower portion of condenser coil Circuit 2 uses the upper portion Sizes 035 050 Circuit 1 uses the left condenser coil Circuit 2 the right All units have intertwined evaporator coils TRollout switch is manual reset NOTE High heat is for 48AJ AW only 21 Table 1A Physical Data 48AJ AK AW AY Units cont UNIT 48AJ AK AW AY 035D E 040D E 050D E 060D E NOMINAL CAPACITY tons 1 8B 7 60 BASE UNIT OPERATING WEIGHT Ib See Operating Weights Table 2 COMPRESSOR Quantity Type Ckt 1 Ckt 2 2 06D537 1 06D537 1 06EA250 2 06EA250 2 06EA265 Number of Refrigerant Circuits 2 2 2 2 Oil oz Ckt 1 Ckt 2 115 ea 115 224 224 ea 304 ea REFRIGERANT TYPE Operating Charge Ib oz Circuit 1 34 8 51 8 50 0 79 8 Circuit 2 34 8 49 8 50 0 79 8 CONDENSER COIL Cross Hatched 3 s Copper Tubes Aluminum Lanced Aluminum Pre Coated or Copper Plate Fins Quantity 2 2 2 2 Rows Fins in 3 15 4 15 4 15 4 15 Total Face Area sq ft 58 3 66 7 66 7 100 CONDENSER FAN Propeller Type Nominal Cfm 27 064 27 064 27 064 43 900 Quantity Diameter in 4 30 4 30 4 30 6 30 Motor Hp 1 1 1 1 EVAPORATOR COIL Cross Hatched Copper Tubes Aluminum Plate Fins Tube Size in
44. 968 1 189 354 075 1157 150 nv 025 1018 125 18 5 354 __075 1207 150 al zo 05 1068 125 18 9 354 075 1257 150 94 144 29842880 350 350 540 354 624 __144 828 8 323 4 400 400 74 6 Sa 308 6 302 0 400 400 EEE 344 0 337 4 450 400 1 44 3220 314 0 400 400 800 354 624 __144 3574 949 4 450 450 os 197 175 158 6 200 025 167 175 de 717 1656 200 xl aco 05 157 200 18 9 354 __075 1716 200 xl z o ss 150 18 5 354 075 1327 150 025 188 150 EP 1377 175 05 1238 150 185 354 075 1427 175 Table 8 Electrical Data 48EJ EK EW EY Units cont VOLTA RANGE NOMNAL VOLTAGE POWER COMBUSTION EXHAUST FAN MOTOR POWER SUPPLY mane a uoce 746 144 _ 321 5 314 9 400 400 80 450 450 1 44 3345 3265 100 400 208 230 187 254 106 4 506 446 1 5 3 450 450 Piper 450 450 1040 35 4 62 4 144 396 3 386 3 500 450 A 200 feola ors 1784 225 075 1655 200 27 a0 or sees seo Ee ex 225 1 554 __075 1964 225 25 27o Oe ex _ 150 1 354 or 1454 175
45. A 4 to 20 mA signal field supplied is required The reset op tion does not require enabling POWER EXHAUST OPERATION Power exhaust has two options constant volume and modulating that have the following sequence of operation The constant volume power exhaust stage 1 is en abled when the indoor fan has been energized and the desired outdoor air damper position for the economizer increases above the first constant volume CV power exhaust stage 1 point 51 The PES1 factory default value is set at 25 The constant volume power exhaust stage 2 CVPE2 is en abled when the desired outdoor air damper position for the economizer increases above the second CV power exhaust stage 2 point PES2 The PES2 factory default value is set at 75 Each stage is disabled when the desired damper position decreases below the respective set points The modulating power exhaust is enabled when the indoor fan is energized and the building pressure has exceeded the in dividual sequencer set points The default set points are 0 04 in wg 6 3 vdc for stage 1 0 10 in wg 6 8 vdc for stage 2 0 16 in wg 7 3 vdc for stage 3 and 0 23 in wg 7 8 vdc for stage 4 0 29 in wg 8 3 vdc for stage 5 and 0 35 in wg 8 8 vdc for stage 6 power exhaust sequencer Each stage also requires that the building pressure is reduced until it drops be low the disable set point The default set points are 0 in wg 6 0 vdc for stage 1 0 060 in
46. Additional features may be provided with Electronic Ac cess to Unit Control Board These features are additional control board diagnostics electronic expansion board features if installed control of the economizer damper and indoor fan to obtain unoccupied free cooling 365 day timeclock with backup supports minute hour day month and year holiday table containing up to 18 holiday schedules occupancy control with 8 periods for unit operation support a set of display maintenance configuration ser vice and set point data tables for interface with Building Supervisor ComfortWORKS or Service Tool software or accessory remote enhanced display CCNIAQ OAQ outdoor air quality participation When a VAV unit with a space temperature sensor is access ed via a computer the following additional features are available ability to initiate timed override from T 55 sensors temperature compensated start to calculate early start time before occupancy provide space temperature reset to reset the supply air set point upward when the temperature falls below the occu pied cooling set point An electronic expansion board may be field installed to pro vide the following features fan status filter status field applied status demand limiting alarm light fire unit shutdown fire pressurization fire evacuation fire smoke purge When the unit is connected to the CCN Carrier Comfort Network the follo
47. III Sensor Location 48AJ AK AW AY035 and 48EJ EK EW EY038 044 SENSOR LOCATION 31 TUBES FROM BOTTOM 5 565520 diis d c d d TAS LEFT HAND CONDENSER COIL VIEWED FROM ACCESS PANEL Fig 53C Motormaster Ill Sensor Location 48AJ AK AW AY040 050 and 48EJ EK EW EY048 56 SENSOR LOCATION 4 TUBES FROM BOTTOM Fig 53D Motormaster Ill Sensor Location 48EJ EK EW EY054 064 SENSOR LOCATION 2 TUBES FROM BOTTOM Fig 53E Motormaster Ill Sensor Location 48AJ AK AW AY060 and 48EJ EK EW EY068 Step 13 Field Modifications DUCTWORK Bottom Return Units 48AJ AK EJ EK Field Modified for Side Return 48AJ AK and 48EJ EK units with bottom re turn air connections may be field modified to accommodate side return air connections IMPORTANT The following section is a guideline and not a comprehensive procedure to field modify the units The installing contractor must provide some design initiative Field conversion is complex and is not recommended Units with electric heat must not be converted because of potential heating mode operating problems Conversion to horizontal return requires that the bottom re turn openings of the unit must be sealed with airtight panels ca pable of supporting the weight of a person The return duct work connection locations on the side of the unit are higher than normal 31 in high Unit mounted power exhau
48. Indoor Fan Relay CCB Controller Circuit Breaker IGC Integrated Gas Unit Controller CCH Crankcase Heater IP Internal Protector CLSASP Cooling Supply Air L Light Set Point Potentiometer LPS Low Pressure Switch COM Communication LS Limit Switch COMP Compressor Motor MGV Main Gas Valve CR Control Relay NC Normally Closed CV Constant Volume NO Normally Open DM Damper Motor OAT Outdoor Air Thermostat DP Duct Pressure OD Outdoor EC Enthalpy Control OFC Outdoor Fan Contactor FLA Full Load Amps OFM Outdoor Fan Motor FPT Freeze Protection Thermostat PEC Power Exhaust Contactor FU Fuse PEM Power Exhaust Motor GVR Gas Valve Relay PES Power Exhaust Sequencer HPS High Pressure Switch PESC Power Exhaust Sequencer Controller HS Hall Effect Sensor PL Plug Assembly 95 RAT Return Air Thermistor RS Rollout Switch SAT Supply Air Thermostat SEN Sensor SW Switch TB Terminal Block TC Thermostat Cooling TH Thermostat Heating TRAN Transformer UL Compressor Unloader VFD Variable Frequency Drive gt Terminal Marked Terminal Unmarked Terminal Block o Splice Factory Wiring Field Wiring To indicate common potential only Not to represent wiring 09 2 pue 09 0 2 80c 0 COA M33 rast IHEWSYIS ed jeoidA 22 614 09 2
49. OUND HLIM 43114405 53015 7 dAl 1 13 5 9 1153 55042 BUND 4004 53015 2 91 NOI123S 55082 3578 2 1911 911 x is 10 9 1 7 T WINOZIYOH OL LINN 30 3903 NOU 512 3101 9NI13A31 LINN are SL o 01 t2 ww NI 930 NI 1930 26 12 2 8 v LL vig LL SIHONI 5338930 SNOISN3NIQ 70751 11621 dAl rv 8 6 vI1 1 NMOHS Sv Q3H2Olld 38 AINO NV LINN SU30NVH2X3 LV3H FHL NOI123S 80008 JHL 10 NVd JHL NI H31VM ONIQNYIS 1N3A3Ud 01 414405 1019 22100 ve 7902 11 18 76011 91 1 r 38 019 SYJLINITIIN 38V 2 NI SNOISNGRIQ S3HONVUG YO 5410 114405 ANY OL LONG 414405 IHL 6 MO813 06 HLIM G3TIVISNI 38 1504 1V3H 21812313 SLINA 115 GIZINVATVD VO pI SlNYd 88024008 TIV 43184355 510 Q3ddlHS 51 00 90088024882 8055322 88024008 Z 91 1 l v 20 3015100 OL 3UV WIG 11 03412345 25108310 SS37ND ALON SHUN 890 pue GND 614 03119915 07313 NOILVINSNI 01918 83114405 41314 41815 INVO 43114405 07313 1134 9NI 4008 43114415 01313 ONTHSW 14 831NDO2 TIWN a a 51415 dAl
50. SI j yoo j0sseooe oj aq oi peufisep sjonp 6 ueunjedeg BuueeuiBu3 uoneo ddy 1 euoneledo pue Je euis 104 1109 eAOWA 104 850 0 01 sseooy 291 611 0 p epiS 1 162811 0 9 5 1eziuiouo23 76121 0 100 ON Silu 10 2 54 0 61 SHUN 1ueoefpy 94 UIN Jeziuouooe any sun Jou 0176 jo 19ju92 e prepueis 71 58 8 suoisueuiq yun 9528 614 COOH 27 n HT 19ejuoo seoue euonejedo pue 104 p 1109 Jo 104 122901 0 81 epig sseoov 1
51. This is followed by each stage of cooling energized with a 10 second delay between stages After this is complete outdoor fan contactor no 2 is energized for 10 seconds The compressors will now deenergize followed by the out door fan contactors and indoor fan contactors If the unit is equipped with the Integrated Gas Control IGC board the in door fan will continue to operate for an additional 30 seconds after deenergizing the circuit The field test is then complete SERVICE A WARNING Before performing service or maintenance operations on unit turn off main power switch to unit Electrical shock could cause personal injury Service Access All unit components can be reached through clearly labelled hinged access doors These doors are not equipped with tiebacks so 1f heavy duty servicing is need ed either remove them or prop them open to prevent accidental closure 89 Each door is held closed with 3 latches The latches are se cured to the unit with a single 1 4 1 20 x 2 in long bolt See Fig 63 To open loosen the latch bolt using a 7 16 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 ori entation and position of the top cover be marked on the unit prior to disassembly This will allow proper replacement
52. Unbalanced 3 Phase Supply Voltage 1 53 Never operate a motor where phase imbalance in supply volt This amount of phase imbalance is satisfactory as it is below the age is greater than 2 Use the following formula to determine maximum allowable 2 the percent of voltage imbalance Voltage imbalance IMPORTANT the supply voltage phase imbalance is 4 max voltage deviation from average voltage more than 2 contact your local electric utility company average voltage 09 immediately 36 Table 7 Electrical Data 48AJ AK AW AY Units cont COMPRESSOR UNIT SIZE NOMINAL VOLTAGE No 2 266 120 266 120 POWER POWER EXHAUST SUPPLY FLA 95 8 110 12 6 108 4 125 66 7 80 12 6 79 3 90 72 7 90 12 6 85 3 100 78 1 100 12 6 90 7 110 211 0 206 8 250 250 234 6 230 4 300 250 224 2 218 8 250 250 247 8 242 4 300 300 241 0 232 8 300 300 264 6 256 4 300 300 93 4 110 106 0 125 99 4 125 112 0 125 107 7 125 120 3 150 180 5 177 7 225 225 10 30 8 28 0 535723 6 204 1 201 3 250 250 5 8 195 9 191 7 250 225 208 230 a 266 4 19 46220 755 5556 2195 2153 250 250 209 7 203 7 250 250 20 594 540 0 23 6 238 3 227 3 250 250 1 12 6 95 0 110 4 11 035 25 6 120 4 27 ae ee 0 ea 12 6 102 0 125 k oN N e 15 46 2 42 0 345 4 53 20 59 4 54 0 25 74 8
53. cabinet losses and clean 2 in filters 2 Conversion Bhp to watts Bhp x 746 Motor Efficiency 3 Variable Air Volume units will operate down to 70 cfm ton in the cooling mode Performance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions 27 000 77 Table 32A Fan Performance Power Exhaust 48AJ AK AW AY020 050 and 48EJ EK EW EY024 048 LOWSPEED MEDIUMSPED HIGH SPEED Aem 208v 230 460 575 208v 230 460 575v 208v 230 460 575v ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts 6 500 6 700 6 900 7 100 7 300 7 500 7 700 0 60 3 69 0 73 3 98 4460 7 900 0 56 3 74 0 69 4 02 4510 8 100 0 51 3 78 0 65 4 07 4560 8 500 0 41 3 83 0 56 4 12 4620 8 900 0 31 3 93 0 47 4 23 4740 9 300 0 20 4 07 0 37 4 37 4900 9 700 0 11 4 17 0 30 4 47 5010 10 100 0 04 4 25 0 23 4 56 5110 10 500 0 17 4 66 5220 10 900 0 12 4 75 5330 11 300 0 07 4 80 5380 11 700 0 04 4 83 5420 LEGEND Bhp Brake Horsepower ESP External Static Pressure in wg Watts Input Watts to Motor Table 32B Fan Performance Power Exhaust 48AJ AK AW AY060 and 48EJ EK EW EY054 068 1 LOWSPEED MEDIUMSPED HIGH SPEED
54. more than 296 contact your local electric utility company immediately Table 8 Electrical Data 48EJ EK EW EY Units UNIT NOMNAL VOLTAGE COMPRESSOR POWER COMBUSTION SIZE VOLTAGE RANGE No 2 IFM EXHAUST FAN MOTOR POWER SUPPLY 48EJ EK 3 Ph ERES mn war mua ene m fuaa on td e rea uoce 16 7 09 101 8 100 3 125 125 152 236 416 096 125 4 123 9 150 150 30 8 096 ___ 115 9 113 1 150 150 208 230 228 25 6 160 2 1 5 3 2364161096 1395 1367 175 175 15 462 096 ___ 131 3 127 1 150 150 42 0 23 6 41 6 096 154 9 150 7 175 175 o 44 eo 125 236 05 620 80 05 558 1 Denm 80 pl C e 628 1261256 05 754 o os 405 5 126 60 m 5i el2ls 05 454 o 126 70 os s4 60 15 170 12 5 80 221280 096 122 8 120 6 150 150 7 22 0 23 6 41 6 096 ___ 146 4 144 2 175 175 a08 096 129 4 126 6 150 150 208 240 236 416 056 _ 153 0 150 2 175 175 15 462 096 144 8 140 6 175 175 42 0 23 6 41 6 0 96 168 4 164 2 200 200 o 612 rs 110 126 286 05 738 90 028 460 114 19 9 114 2 1 27 10 14 0 pex os s 126 90 95 712 126 100 05 48 eo
55. software or accessory Remote Enhanced Display The PC can access the base control board via the 3 wire communication bus or via an RJ 11 con nection to the CCN terminal on the base control board See Fig 27 For current software version 3 0 or later the Low Tem perature Minimum Damper Position Override LOWMDP has a 0 to 100 limit with a default of 100 Think of the LOWMDP as a second minimum damper position This LOWMDP limit change requires access to the unit software with a computer equipped with Building Supervisor Ser vice Tool or ComfortWORKS Software When the LOWMDP is in effect the outdoor dampers will remain at the LOWMDP position typically set to 096 closed during heating even in the Occupied period For the LOW MDP to be in effect the LOWMDP must be less than the mini mum damper position MDP and the RAT return air tempera ture must be less than the OHSP occupied heat set point minus 2 5 F Table 40 summarizes the operational require ments and controlling factors for occupied heat and morning warm up MORNING WARM UP VAV Only with Stand Alone Operation When the unit operates in stand alone mode morning warm up occurs when the unit is energized in Occu pied mode and return air temperature RAT is below 68 F Warm up will not terminate until the RAT reaches 68 F The heat interlock relay output is energized during morning warm up A field installed 24 vdc heat interlock relay is required The o
56. vide some design initiative The wiring harness that is provided with the power exhaust accessory is not long enough for the fan modules to be mount ed in the return air duct Field supplied wiring must be spliced into the harness Use a junction box at each splice The wiring may be run in the return duct as shown in Fig 55 or externally in conduit A service access panel will be needed near each power exhaust fan ELECTRIC UNLOADERS Constant Volume Units Only The rooftop units with version 4 0 control software and later are capable of controlling electronic unloaders when in the constant volume CV operating mode The unloaders may be installed in the field and wired to the control box as shown in Fig 56 Fig 54 Side Return Air Conversion 57 LOCATION BAROMETRIC RELIEF OR POWER EXHAUST SIDE 2 ALTERNATE LOCATION END ECONOMIZER HOOD 12 94 UNIT A L SIDEH 2224 J BOX 28 Pa gt 42 62 PLENUM RATED CABLE FIELD SUPPLIED JBOX R A S A NOTE 024 048 020 050 SIZES SHOWN 2 POWER EXHAUST FANS 060 054 068 SIZES HAVE 3 POWER EXHAUST FANS ALL UNIT SIZES HAVE THE SAME SIZE POWER EXHAUST Fig 55 Power Exhaust Relocated to Side Return Duct BASE MODULE COMP 2 UNLOADER START UP Use the following information and Start Up Checklist on pages CL 1 and CL 2 to check out unit PRIOR to start up
57. wards the outside of the hood side panels 15 Attach remaining mounting angle with tabs to other end of the filter track with no 10 screws provided See Fig 44 16 Place filter track assembly in bottom of hood by placing tabbed end into slotted side with tab on bottom and attaching opposite end to hood with speed clips and gasketed screws provided Tabs can be hand bent after they have been inserted into the side 49 NOTE The filter track assembly end with screws should face away from the other hood when mounted on the unit Be sure the filters are installed with the airflow in the correct direction NOTE Tabs from both filter tracks will be in the same space After one filter track has been inserted into hood side bend the tabs so they will not interfere with installation of the second center hood 17 Attach black seal strip provided to filter cover Seal strip should be applied centered over the holes of the one flange making sure to fully cover holes and centered over the other large flange See Fig 45 18 Slide two 20 x 25 in filters into cross members of hood assembly Attach filter cover over filters with screws and speed clips provided TOP FLANGE HOOD SIDE Fig 36 Adding Seal Strip to Top of Hood Sides FILTER HOOD SIDE 2 ACCESSORY ENTHALPY COVER ENTHALPY BRACKET CONTROL iG HT ANGLE SIDE CROSSMEMBER W O TABS FILTER TRACK BLOCKOFF ASSEMBLY BAFFLE WITH SCREWS
58. wg 6 5 vdc for stage 2 0 13 in wg 7 0 vdc for stage 3 0 19 in wg 7 4 vdc for stage 4 0 25 in wg 8 0 vdc for stage 5 and 0 31 in wg 8 5 vdc for stage 6 power exhaust sequencer Both of these set points are changed at the specific controlling sequencer It is not forcible from CCN If the indoor fan is on then PEXE ON If the indoor fan is off then PEXE OFF In addition on units equipped with the Expansion I O module the control module board may have di rect access 4 to 6 Modulated Power Exhausted stages bypass ing an external sequencer device These stages will be con trolled directly in fire smoke modes SMOKE CONTROL MODES 48AJ AK AW AY and 48EJ EK EW EY units with an optional expansion board per form fire and smoke control modes The expansion board pro vides 4 modes which can be used to control smoke within the conditioned area The modes of operation are fire shutdown pressurization evacuation and smoke purge See Table 41 SMOKE DETECTOR A smoke detector can be used to initiate fire shutdown This can be accomplished by a set of normally closed pilot relay contacts which will interrupt power from the 24 v transformer secondary terminal to the con trol circuit breaker CB4 See Fig 62 The wire that connects these two points is white and labeled 78 NOTE On standard gas models the indoor fan will continue to run 45 seconds after the call for heat has been terminat
59. zeci 2661 8111 8 8 6 6 G 6626 0 00A3 M38v 6121 0 2109 jesuepuoo 6671 617 6801 91 5 8 8 01 5 916 8203M387 ON Jo doy 0161 0151 2011 8 6 48 6 6 6 Eces 8200 3 4387 zZSt 0 5 51 jueoelpy 69 1 2671 19 91 11 9 91 6 1 9 1106 720311387 aq 2 2 6961 006116 1801 B E 9 8 8 0 9 LEIS 7200 3 4387 039N 1H x ES x 122 y 1 14 5 1 8004 320V ouooe any Jou S81 1H9 3M 83 509 8 Y 1H91 3M 3215 LINA 105534402 0 1 01 T 9N11V83d0 0 A el Jo 191u92 e 2 91 6 4 pyepueis 1eziuouooe 71 5910 16 8t0 8 0A3 M38t suoisueuiq eseg 91 NIG ONIddlHS gg m 9811311 TWH3AO 4 1716 STI ONT 9811311 NI 310H 15 6 101541 2211 28 j F 9 7 261 2 G 2016 ONIUIM 01313 EEE ze Li 65 VIG a 532 14 dAl 26162 99 061 261 lt 2 26 00161 1 69
60. 022 802 dH 0 Ayqueno 40 01N Joopu UJOJJ UNA OM 941 09 2 022 802 264 090 I9polN M JosseJduio5 s10sso1duioo2 01 191 OM S1ossaJduioo UL VI 318VL suonipuoo ud pejoejoud eseud eeJu pe1oejoud Jo pue sJosseidwoy s 10 9JIM 9 06 ed eq 15 ji peoejdoj eq 1 peysiusny jo Aue J Ov 19410 CAD pue 180 19 V14 991 Uey ssal JO d snw pas uoo jddns 1ewod 802 spun A O 2 802 J SHUN 055 10 peaj 0 SHUN 09r 10 cNVH L 1oeuuo ZH 0 12euuoo Ajddns 802 SHUN 0 2 80c OEZ 10 0 JO UUOD SHUN A Q9r JO PH LNVH L 1290002 SON
61. 06 15 000 18 48 16 000 21 15 17 000 24 07 18 000 27 26 19 000 30 72 20 000 AVAILABLE EXTERNAL STATIC PRESSURE in wg Nom 318 J 20 22 24 26 28 3 2 Cfm z Bhp Bhp Bhp Bhp Bhp Bhp Bhp Rpm Bhp 8 000 10 03 9 000 11 32 10 000 12 79 11 000 14 45 12 000 16 32 13 000 18 42 14 000 20 75 15 000 23 32 16 000 17 000 18 000 19 000 20 000 AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW 40 z Bhp Bhp Rpm Bhp Rpm Bhp 8 000 12 08 9 000 13 45 10 000 14 99 11 000 16 72 12 000 18 65 13 000 20 80 14 000 15 000 16 000 17 000 18 000 19 000 20 000 LEGEND Bhp Brake Horsepower NOTES 1 2 Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters Conversion Bhp to watts Bhp x 746 Watts Motor Efficiency Variable Air Volume units will operate down to 70 cfm ton Per formance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions 71 Table 26 Fan Performance 48AW AY060 Horizontal Discharge Units AVAILABLE EXTERNAL STATIC PRESSURE in wg Am o2 J 04 os os 10 12 1a J re Cfm Bhp Bhp Bhp Bhp Bhp Bhp Bhp Bhp 12 000 10
62. 1 je ene 5 CL dts 26162 19 SN uv 91 1 6 v 0L 3 BN 91138 yy Snob 4321N0N023 B VE N E X 7 i 9 57 039NIH 13NYd S 322V LINN HLIM 0300 19NI 34000 55122 9 4 Q311VISNI 1313 SOOO 03111541 1081100 uc BR 000H 8371N0NO23 01313 394130 MOT IdN 2 1 9 i 8 5 2p 1102 435439402 dvo ONIM dU THEN BOLON BOON 31018 YOON 039N1H 9000 55322 931113 V 29 V MIA 39V110A LdN v 916 21 26 62 16 4u3MOd 41314 2 1 Bg 5 2811 6 8 1 T T T F 1 01 9118 81 114405 114405 T I AJ gH lj lc E 2 X08 1081N02 8 Nun138 Nun 138 i 5 Poesie 83A02 401 mme 168 711 99 211 8 d 6 CAVA GJA CAVA 15 83MOd ONT LYINGO S7109 WAIV ND Wil 1 398 1 534001081 1H913M 9 11 3390 d 1 Jaded poguos pue 3919S 104 01 3 1109 9051 6871 160 9175 8 6 8 1 01 G 1025 0 M387 2 jo 1 404 29 0 51 9 5 sseooy 191 eesi zest eit 8 6 875 6 5 6606 750043 387 16121 0 eel 9061 5971 1601 91 5 8 8 1 01 6 1026 06034397 628 0 9 apig
63. 38 Stage Gas System Inputs Outputs INPUT Cool Cool2 Heat2 Fan Cool Supply Set Point Heat Supply Set Point Supply Air Thermistor 1 2 and 3 Operating Modes The SGC will operate the unit in one of the following operating modes no mode Cooling Mode Heatingl Mode Heating2 Mode No Mode In this mode none of the heat stages are turned on No mode occurs if the Cool Heat or Fan inputs are off or the Cool input s are on Tempering Cool Mode In this mode the SGC tempers in incoming supply air to maintain the cooling supply air set point Tempering mode occurs if the Fan input is ON and all Cool and Heat inputs are off When the SGC determines that the fan is on and the base unit control is not calling for heat or mechanical cooling the SGC will stage heat to maintain the cooling set point which is set on the CLSASP potentiometer of the SGC This set point should be slightly below the supply air set point ofthe base unit VAV control Note that the supply air temperature will still be in the cooling range Mode mode is used on applications as they have one heat stage on the base unit control CV units have two heat stages and will not operate under Heat mode In this mode heat is staged to control supply air temperature to HTSASP mode occurs only if Heatl is ON and Heat2 is OFF and and Cool2 are OFF When the base unit control calls for firs
64. 55 CEC0121448 01 T 56 CEC0121448 01 Fig 33 Field Control Temperature Sensor Wiring CV or VAV Units Conductors and drain wire must be 20 AWG minimum stranded tinned copper Individual conductors must be insulat ed with PVC PVC nylon vinyl Teflon or polyethylene An aluminum polyester 100 foil shield and an outer jacket of PVC PVC nylon chrome vinyl or Teflon with a minimum op erating temperature range of 20 C to 60 C 4 F to 140 F is re quired Table 9 lists cables that meet the requirements 47 Table 9 CCN Connection Approved Shielded Cables MANUFACTURER CABLE PART NO Alpha 2413 or 5463 American A22503 Belden 8772 Columbia 02525 IMPORTANT When connecting the CCN communica tion bus to a system element use a color coding system for the entire network to simplify installation and checkout See Table 10 Table 10 Color Code Recommendations TYPE INSULATION COLOR PIN NO Positive 1 Ground 2 Negative 3 NOTE If a cable with a different color scheme is selected a similar color code should be adopted for the entire network At each system element the shields of the communication bus cables must be tied together If the communication bus is entirely within one building the resulting continuous shield must be connected to a ground at one point only If the com munication bus cable exits from one building and enters anoth er the shields must be connected to grounds at
65. 6 918 9M w JINON 3Sva E LHM 92M 1143 ldd SdH dl LHM 92M NYO 92M 621M 22 LHM 69M REMISE LHM 89M 1 T 19 9 9 IBN SE UN 13A NU9 92 LHM LEIM X29 12 J18 SIN Y HZ 561 TRITT Ini ul TT 19 LHM SEIN AUN QNO3S INVUL 100 SHUN pue 0SO OZOAV AV 8 19H Sed 5 28 6 4 1V3H 579 03915 970 720 531835 97 DILYWAHIS SVO Ave CC 3134 889 0 1 con N36 313 NYO 66M 318 LEEN 318 EEN 318 SEEM X18 OPEM 918 318 BEEM f 951519 X 1V 21 5 ILYS Sav NYO SEEM ote 5 NYO ZEEN saw OIA TEEN NUS 86M JNA tI 116 21 WUD y18 162 038 162 Sod 962 5
66. 7 4 7 L 4 Pass COMPRESSOR a lt a HPS HKO2ZA428 4 Pass CUTOUT 426 P a CUTOUT 426 PSI Los j 4Pass re re 4 Pass L BRE LPS HKO2ZB027 CUT IN 22 PSI 4 Pass CUTOUT 7 PSI 4 Pess Pass 1 T i pen Eu 4Pass 6 s e HPS AND LPS MOUNTED amp Pass L 3 ON COMPRESSOR ess 6 m 6 5 COMPRESSOR p rre Le 5e p ess 1 amp Pass EC LEGEND HPS High Pressure Switch LPS Low Pressure Switch TXV Thermostatic Expansion Valve Fig 90 Typical Refrigerant Circuiting 48EJ EK EW EY054 and 058 109 6 Pass _
67. 70 7 80 a4 TN SR _ 5 208 230 187 253 39 1 228 39 1 256 1 1 025 414 508 19 9 19 9 114 575 518 632 16 91 12 6 LEGEND Example Supply voltage is 460 3 60 FLA Full Load Amps 452 v HACR Heating Air Conditioning and Refrigeration Indoor Evaporator Fan Motor LRA Locked Rotor Amps MCA Minimum Circuit Amps MOCP Maximum Overcurrent Protection LISTED BC 464 v 455 v National Electrical Code OFM Outdoor Condenser Fan Motor _ 1371 RLA Rated Load Amps 7 Fuse HACR circuit breaker per NEC 457 Determine maximum deviation from average voltage AB 457 452 5v LISTED 464 457 7 v AC 457 455 2 NOTES 4 5 Maximum deviation is 7 v In compliance wit requirements for multimotor and combi nation load equipment refer to NEC Articles 430 and 440 the imbalance o _ N 24 2 22 0 23 6 23 6 30 8 28 0 o 23 6 23 6 46 2 42 0 23 6 23 6 A un A 6 6 A 2 zi E E a a a a D 2 6 y 2 2 2 2 2 2 6 2 gt 91 T D 2 6 A N k 452 464 455 Average Voltage 3 oF overcurrent protective device for the unit shall b
68. 80 126 70 Ex si ml oe ae 126 80 os 58 7 BE 126 80 10 130 8 096 151 9 149 1 200 200 28 0 23 6 41 6 096 175 5 172 7 225 225 462 096 167 3 163 1 225 225 200 EET 236 416 096 _ 190 9 186 7 225 225 50 994 096 180 5 175 1 225 225 54 0 23 6 41 6 06 ____ 204 1 198 7 250 250 ___0 5 s 126 100 05 783 100 220 a 27 15 0 126 236 05 909 10 05 843 109 2 270 126 236 05 969 110 os s4 7 o 126 286 05 700 90 05 34 so ii ka EE E 2 15 170 12 6 90 os 4 20 220 125 236 05 81 0 100 See Legend and Notes on page 42 39 Table 8 Electrical Data 48EJ EK EW EY Units cont SUE VOLTAGE RANGE 2 EXHAUST FAN MOTOR 48 3 Ph RLA LRA RLA LRA Qty 2 gt E E Ix N A a are o 30 8 sear 225 200 28 0 23 6 416 0 96 ___ 193 5 190 7 250 225 res EI 200 200 250 250 meses 250 250 E 275 250 e 100 110 100 110 110 102 6 125 61 9 80 74 5 90 67 9 80 100 ee 90 100 pst 225 225 41 6 096 ___ 204 1 201 3 250 250 Is 250 2
69. Door Latch SPARK GAP 125 IN TO 140 IN SPARK GAP 142 IN TO 220 IN Fig 64 Spark Gap Adjustment PROPELLER FAN BLOWER WHEEL BLOWER MOTOR SIDE VIEW IGC MODULE NOTES 1 Torque set screws on blower wheel to 70 in Ibs 2 in Ibs 2 Torque set screw on propeller fan to 15 in Ibs 2 in Ibs 3 Dimensions are in inches Fig 65 Typical Gas Heating Section To inspect blower wheel remove heat exchanger access panel Shine a flashlight into opening to inspect wheel If clean ing is required remove motor and wheel assembly by remov ing screws holding motor mounting plate to top of combustion fan housing Fig 65 and 66 The motor scroll and wheel assembly can be removed from the unit Remove scroll from plate Remove the blower wheel from the motor shaft and clean with a detergent or solvent Replace motor and wheel assembly EVAPORATOR COIL Remove access panels and clean as required with commercial coil cleaner CONDENSER COIL Clean condenser coil annually and as required by location and outdoor air conditions Inspect coil monthly clean as required CONDENSATE DRAIN Check and clean each year at start of cooling season In winter keep drains and traps dry FILTERS Clean or replace at start of each heating and cool ing season or more often if operating conditions require Refer FLUE BOX FLUE to Tables 1A and 1B for type and size COVER oo BASE WAVE NOTE The unit requi
70. Enthalpy Control OUTDOOR AIR OA DAMPER GEAR DRIVEN DIRECT DRIVE DAMPERS RETURN AIR SEN SOR RETURNAIR lt DAMPER DAMPER LINKAGE RETURN AIR AW AY EW EY UNITS DAMPER MOTOR CONDENSATE DRAIN PARTITION DOWN SUPPLY UP RETURN RETURN AIR AJ AK EJ EK AJ AK EJ EK UNITS UNITS ONLY PARTITION SIDE SUPPLY SIDE RETURN AW AY EW EY UNITS ONLY NOTE Partitions shown indicate both side supply AW AY EW EY and vertical supply AJ AK EJ EK units Fig 49 Economizer Details 53 12 00 10 19 NOTES 1 Unless otherwise specified all dimensions are to outside of part 2 Dimensions are in inches 3 On 48AW AY and 48EW EY units accessory barometric relief or power exhaust must be mounted in the field supplied return ductwork Fig 50 Barometric Relief Damper and Power Exhaust Mounting Details MODULATING POWER EXHAUST PRESSURE TRANSDUCER d LOCATION INSIDE OF PANEL VARIABLE FREQUENCY DRIVE INVERTER DRIVE COUPLING VAV INVERTER PRESSURE TRANSDUCER LOCATION INSIDE OF PANEL LEGEND VAV Variable Air Volume Fig 51 Pressure Transducer Locations 48AJ AK AW AY060 and 48EJ EK EW EY054 068 54 Step 12 Install All Accessories After all the factory installed options have been adjusted install all field in stalled accessories Refer to the accessory installation instruc tions included with each
71. FROM BASE CONTROL BOARD ENERGIZES W ON IGC 1 MINUTE LOCK ON 1 SECOND ON DELAY FOR INDOOR FAN COMBUSTION RELAY ON IGC IS ENERGIZED COOUNG DEMAND SATISFIED COMBUSTION RELAY ENERGIZES INDUCED DRAFT MOTOR THROUGH TERMINAL CM ON COMPRESSOR AND OUTDOOR FAN STOP IF IDM IS TURNING AT CORRECT SPEED AT LEAST 2400 RPM HALL IMMEDIATELY EFFECT SENSOR SENDS CORRECT SKGNAL TO TERMINAL J1 ON 30 SECOND OFF DELAY FOR INDOOR FAN IF LIMIT SWITCH AND ROLLOUT SWITCH ARE CLOSED KGC SAFETY LOGIC WILL INITIATE KSNITION SEQUENCE IGC HIGH VOLTAGE TRANSFORMER CREATES A 10 000 VOLT SPARK FOR 5 SECONDS DOES DETECT No 2 MICROAMPS FOR 2 SECONDS SAFETY LOGIC WILL SHUT OFF GAS VALVE AND SPARK Yes AFTER 45 SECONDS OR LESS iF THE TIMING HAS BEEN REDUCED DUE TO LIMIT SWITCH TRIPS WILL ENERGIZE BLOWER RELAY DID LIMIT SWITCH OPEN BEFORE THE 45 SECONDS OR THE MODIFIED TIME HAS TIMED OUT SUBTRACT 5 SECONDS OR Yes ANOTHER 5 SECONDS FROM INDOOR FAN ON TIME DELAY IGNITION LOCKOUT 5 FLASHES OF LED STOPS SAFETY LOGIC SHUTS OFF GAS VALVE LEGEND 45 SECOND BLOWER SHUTOFF DELAY IDM Induced Draft Motor DELAY EXTENDED BY 5 SECONDS FOR EACH LIMIT SWITCH TRIP IGC Integrated Gas Unit Controller MAXIMUM DELAY 3 MINUTES NOTE Thermostat Fan Switch in the AUTO position or sensor equipped unit Fig 94 IGC Control Heating and Cooling 113 The alarm code
72. Fan Contactor IFC The VFD is now powered but the fan will not operate 5 On the front of the VFD is a keypad which is used to change the VFD set point At this point the drive should be disabled and the display read If the current output frequency is displayed then verify that the R and CC jumpers have been removed 6 Press either the DOWN ARROW or UP ARROW key once this will display the current frequency set point amount of static pressure in wg required Refer to the Table 8 to identify the VFD Set Point 8 Press ENT key to enter the new value The desired set point value will alternately flash to indicate that the new value has been stored IMPORTANT The Carrier factory default values for the VFD may be different than the default values of the manu facturer Refer to the Carrier literature when checking default values The following default values have been changed from the manufacturer settings to closely match the VFD operation with a Carrier VAV unit Refer to Tables 14 and 15 9 Fire speed override mode is available by contact closure between terminals S1 and CC 10 Ifthe VFD is to be controlled by an external control sys tem other than the factory supplied duct static pressure transducer follow these steps a Install a jumper between S2 and CC This jumper will disable the PID Proportional Integral Deriva tive control loop in the VFD The VFD is set to follow an
73. Horsepower ES Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters Conversion Bhp to watts Bhp x 746 Wales Motor Efficiency Variable Air Volume units will operate down to 70 cfm ton Per formance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions Table 30 Fan Performance 48EJ EK054 068 Vertical Discharge Units AVAILABLE EXTERNAL STATIC PRESSURE in wg 02 04 10 12 14 Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Bhp Bhp Bhp 7 57 AIRFLOW Cfm 10 000 12 000 9 56 15 000 13 31 16 000 14 78 17 000 16 36 18 000 18 06 19 000 19 88 20 000 21 82 21 000 23 89 22 000 26 10 23 000 28 44 24 000 30 91 25 000 33 53 26 000 36 29 27 000 AVAILABLE EXTERNAL STATIC PRESSURE in wg 18 20 22 24 26 28 30 Bhp Bhp Rpm Bhp Rpm Bhp Rpm Bhp Bhp Bhp Bhp AIRFLOW Cfm LEGEND Bhp Brake Horsepower NOTES 1 Fan performance is based on dry coils economizer roof curb cabinet losses and clean 2 in filters 2 Conversion Bhp to watts Bhp x 746 vale Motor Efficiency 3 Variable Air Volume units will operate down to 70 cfm ton in the cooling
74. PEA Mod Power Exhaust Stg 4 FSD Mod Power Exhaust 510 5 ____ __ Mod Power Exhaust 519 6 LEGEND CV Constant Volume VAV Variable Air Volume 81 The Time Guard function maintains a minimum off time of 5 minutes a minimum ON time of 10 seconds and a minimum delay before starting the second compressor of 10 seconds If the compressors have been off for more than 15 minutes and the OAT outdoor air temperature is less than 45 F then the safeties will be ignored for 5 minutes At all times safeties will be used Heating and cooling will be mutually locked out on demand on a first call basis The heating and the cooling functions can not be operating simultaneously COOLING VARIABLE AIR VOLUME VAV UNITS On power up the control module will activate the initialization software of the control board The initialization software then reads DIP switch no 1 position to determine CV or VAV oper ation Initialization clears all alarms and alerts re maps the in put output database for VAV operation sets maximum heat stages to 1 and sets maximum cool stages to 6 The control module reads DIP switch no 3 and determines if the unit will use expansion board operation Power up takes a random time of 1 to 63 seconds plus 5 minutes the first time power is sent to the control board after a power outage The control module will determine if an interface linkage is active and if the unit will operate in a
75. Unit operating weight is shown in Table 2 NOTE On retrofit jobs ductwork may be attached to old unit instead of roof curb Be careful not to damage ductwork when removing old unit Attach existing ductwork to roof curb instead of unit Four lifting lugs are provided on the unit base rails as shown in Fig 5 16 Refer to rigging instructions on unit POSITIONING Maintain clearance per Fig 5 16 around and above unit to provide minimum distance from combustible materials proper airflow and service access Do not install unit in an indoor location Do not locate unit air inlets near exhaust vents or other sources of contaminated air For proper unit operation adequate combustion and venti lation air must be provided in accordance with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 American National Standards Institute Although unit is weatherproof guard against water from higher level runoff and overhangs Locate mechanical draft system flue assembly at least 4 ft from any opening through which combustion products could enter the building and at least 4 ft from any adjacent building When unit is located adjacent to public walkways flue assem bly must be at least 7 ft above grade ROOF MOUNT Check building codes for weight distribu tion requirements See Fig 17 Unit operating weight is shown in Table 2 Step 3 Field Fabricate Ductwork Secure all ducts to
76. accessory MOTORMASTER III CONTROL INSTALLATION Install Field Fabricated Wind Baffles Wind baffles must be field fabricated for all units to ensure proper cooling cycle operation at low ambient temperatures See Fig 52 for baffle details Use 20 gage galvanized sheet metal or similar corro sion resistant metal for baffles Use field supplied screws to at tach baffles to unit Screws should be 4 in diameter and gt s in long Holes for wind baffles are pre punched in the unit sheet metal A CAUTION To avoid damage to the refrigerant coils and electrical com ponents use recommended screw sizes only The wind baffles attach to flanges formed on the outer sheet metal of the unit corner post The other end of the baffle is at tached to the center panel between the condenser coil and the indoor section Two baffles are required Install Motormaster Controls Only one Motormaster control is required per unit Motor One outdoor fan motor OFM must be changed out in the field to accommodate the Motormaster accessory The replacement motor part no is HD52AK652 For 48AJ AK AW AY020 030 and 48EJ EK EW EY024 034 units the Motormaster controlled OFM is the no 2 OFM and is located at the left side of the unit looking from the com pressor end The no 1 OFM is controlled to shut off at 55 F and on at 65 F outdoor air temperature and does NOT need to be changed out For 48AJ AK AW AY035 050 and 48EJ
77. building structure Use flexible duct connectors be tween unit and ducts as required Insulate and weatherproof all external ductwork joints and roof openings with counter flashing and mastic in accordance with applicable codes NOTE Due to width of the horizontal supply return ductwork provisions should be made for servicing of the outdoor air fil ters 1 e catwalk over ductwork Ducts passing through an unconditioned space must be in sulated and covered with a vapor barrier Outlet grilles must not lie directly below unit discharge The return duct must have a 90 degree elbow before opening into the building space if the unit is equipped with power exhaust To attach ductwork to roof curb insert duct approximately 10 to 11 in up into roof curb Connect ductwork to 14 gage roof curb material with sheet metal screws driven from inside the duct A WARNING For vertical supply and return units tools or parts could drop into ductwork and cause an injury Install a 90 degree elbow turn in the supply and return ductwork between the unit and the conditioned space If a 90 degree elbow cannot be installed then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space Step 4 Make Unit Duct Connections 48AJ AK EJ EK UNITS Unit is shipped for through the bottom duct connections Field fabricated ductwork should be attached to the roof curb Supply and re
78. external speed reference signal from the control system b Connect the field supplied speed reference 4 20 mA signal across terminals II and P24 See Fig 58 11 Once all the changes have been made open the IFCB 12 Wait for the VFD display to go blank and the charge lamplight to go out Remove the VFD cover without touching any interior components It may take several minutes for the VFD to fully discharge 7 Press either the DOWN ARROW or UP ARROW 13 Replace jumper across terminals R and CC key to change set point to the appropriate duct static set 14 point desired This number may be adjusted based on the e Replace VED CONGR 15 Close the IFCB The VFD is now powered and the fan will operate 61 TWO WIRE TRANSDUCER 4 20mA LEGEND Typical Factory Wiring Optional Field Wiring FIRE SPEED OVER RIDE Z Fig 58 Toshiba TOSVERT VF S9 VFD Factory Installed Jumpers Table 14 Carrier VFD Toshiba TOSVERT VF S9 Program Parameter Values PARAMETER GROUP CARRIER DEFAULT SETTINGS Basic Parameters CNOd FNOd 1 Fr a ACC 0009 10 0 sec 10 0 sec FH 60 0 Hz UL 60 0 Hz LL 10 0 Hz Pt 1 See Table 15 Sri 60 0 Hz Extended Parameters F115 14 F116 n Frequency Parameters F201 20 F202 0 0 Hz F203 100 F204 60 0 Hz Operation Mode Parameters F300 4 KHz F301 3 F302 1 303 2 360 1 F362 0 30 F363 0 20 Th
79. is accessed via a PC equipped with ComfortWORKS Building Supervisor or Ser vice Tool software or Remote Enhanced Display accessory the following features can be accessed on board timeclock can be programmed occupancy schedules can be programmed unit set points can be changed alarms can be monitored This access is available on the base control board via a RJ 11 phone jack or a 3 wire connection to the communication bus See Fig 27 The internal timeclock has a 10 hour mini mum back up time to provide for unit power off for servicing unit or during unexpected power outages For complete Carrier Comfort System CCS or Carrier Comfort Network CCN features and benefits refer to the product literature Step 9 Make Electrical Connections POWER WIRING Units are factory wired for the voltage shown on the unit nameplate When installing units provide a disconnect per NEC National Electrical Code of adequate size MOCP maximum overcurrent protection of unit is on the informative plate All field wiring must comply with NEC and all local codes and re quirements Size wire based on MCA minimum circuit amps on the unit informative plate See Fig 28 for power wiring con nections to the unit power terminal block and equipment ground The main power terminal block is suitable for use with alu minum or copper wire See Fig 28 Units have circuit breakers for compressors fan motors and control circuit If requi
80. key and an key These keys are used to navigate through the different levels of the dis play structure See Table 39 Press the ESCAPE key until the display is blank to move through the top 11 mode levels indi cated by LEDs on the bottom left side of the display Pressing the and keys simultaneously will scroll a text description across the display indicating the full meaning of each display acronym Pressing the and keys when the display is blank Mode LED lev el will return the display to its default menu of rotating display items In addition the password will be disabled requiring that it be entered again before changes can be made to password protected items When a specific item is located the display will flash show ing the operator the item item value and then the item units if any Press the key to stop the display at the item val ue Items in the Configuration and Service Test modes are password protected The display will flash PASS and WORD when required Use the and arrow keys to enter the 4 digits of the password The default password is 1111 Changing item values or testing outputs is accomplished in the same manner Locate and display the desired item Press the key to stop the display at the item value Press the key again so that the item value flashes Use the ar row keys to change the value or state of an item and press the key to accept it Press the key and the item value or units display will resume Rep
81. mounting nuts and bolts See Fig 69 3 4 Turn motor jacking bolts to move motor mounting plate Loosen fan motor nuts left or right for proper belt tension A slight bow should be present in the belt on the slack side of the drive while running under full load Tighten nuts Adjust bolts and nut on mounting plate to secure motor in fixed position Recheck belt tension after 24 hours of operation Adjust as necessary See Table 3 for proper tension values Restore power to unit Evaporator Fan Motor Replacement 1 2 Turn off unit power supply Remove upper outside panel and open hinged door to gain access to motor 92 9 10 Fully retract motor plate adjusting bolts Loosen the 2 rear nearest the evaporator coil motor plate nuts Remove the 2 front motor plate nuts and carriage bolts Slide motor plate to the rear toward the coil and remove fan belt s Slide motor plate to the front and hand tighten one of the rear motor plate nuts tight enough to prevent the motor plate from sliding back but loose enough to allow the plate to pivot upward Pivot the front of the motor plate upward enough to allow access to the motor mounting hex bolts and secure in place by inserting a prop Remove the nuts from the motor mounting hex bolts and remove motor Reverse above steps to install new motor Condenser Fan Adjustment 1 MOTOR JACKING BOLTS Turn off unit power supply
82. 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 so can result in water leakage into the evaporator section of the unit Cleaning Inspect unit interior at beginning of each heat ing and cooling season and as operating conditions require Remove unit side panels and or open doors for access to unit interior MAIN BURNERS At the beginning of each heating sea son inspect for deterioration or blockage due to corrosion or other causes Observe the main burner flames and adjust if nec essary Check spark gap See Fig 64 Refer to Main Burners section on page 94 FLUE GAS PASSAGEWAYS The flue collector box and heat exchanger cells may be inspected by removing gas section access panel Fig 5 16 flue box cover collector box and main burner assembly Fig 65 and 66 Refer to Main Burners section on page 94 for burner removal sequence If cleaning is required clean all parts with a wire brush Reassemble using new high temperature insulation for sealing COMBUSTION AIR BLOWER Clean periodically to as sure proper airflow and heating efficiency Inspect blower wheel every fall and periodically during heating season For the first heating season inspect blower wheel bi monthly to deter mine proper cleaning frequency LATCH BOLT Fig 63
83. prior to the start of the indoor fan blower on the next attempt the 45 second de lay will be shortened to 5 seconds less than the time from initi ation of heat to when the limit tripped Gas will not be inter rupted to the burners and heating will continue Once modified the fan on delay will not change back to 45 seconds unless power is reset to the control If the unit is controlled through a room sensor the indoor fan will be operating in the Occupied mode and the outdoor air dampers will be in the minimum position If the unit is controlled with a room sensor in the Unoccu pied mode the indoor fan will be energized through the IGC board with a 45 second delay and the outside air dampers will move to the IAQ position generally set to zero in the Unoccu pied mode The IAQ feature is enabled through system soft ware If IAQ is not enabled dampers will move to the mini mum position When additional heat is required W2 closes and initiates power to the second stage of the main gas valves When the thermostat is satisfied W1 and W2 open and the gas valves close interrupting the flow of gas to the main burners If the call for lasted less than 1 minute the heating cycle will not ter minate until 1 minute after W1 became active If the unit is controlled through a room thermostat set for fan auto the indoor fan motor will continue to operate for an additional 45 seconds then stop and the outdoor air dampers will close If t
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85. remove oil FAN SHAFT BEARINGS Lubricate bearings at least ev ery 6 months with suitable bearing grease Do not over grease Typical lubricants are given below MANUFACTURER LUBRICANT Texaco Regal AFB 2 Mobil Mobilplex EP No 1 Sunoco Prestige 42 Texaco Multifak 2 Preferred lubricant because it contains rust and oxidation inhibitors CONDENSER AND EVAPORATOR FAN MOTOR BEARINGS The condenser and evaporator fan motors have permanently sealed bearings so no field lubrication is necessary Evaporator Fan Performance Adjustment Fig 67 Fan motor pulleys are designed for speed shown in Tables 1A and 1B factory speed setting IMPORTANT Check to ensure that the unit drive matches the duct static pressure using Tables 19 31 To change fan speeds change pulleys To align fan and motor pulleys Shut off unit power supply Loosen fan shaft pulley bushing Slide fan pulley along fan shaft Make angular alignment by loosening motor from mounting plate pe quac CENTER DRIVE SHAFT 5 Retighten pulley 6 Return power to the unit STRAIGHTEDGE MUST BE PARALLEL WITH BELT PULLEY MOTOR AND FAN SHAFTS MUST BE PARALLEL PULLEY Fig 67 Evaporator Fan Alignment and Adjustment Evaporator Fan Coupling Assembly If the cou pling has been removed for other blower assembly component repair or replacement it is critical that the coupling be reassem bled and aligned cor
86. setting to call for heat high fire 6 Remove screw cap covering regulator adjustment screw See Fig 75 7 Turn adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure 8 Once desired pressure is established set unit to no call for heat 3 3 in wg high fire 9 Turn main gas valve to OFF position 10 Remove pressure measuring device and replace s in pipe plug and screw cap 11 Turn main gas valve to ON position and check heating operation M 93 VALVE DEG F CIRCUIT 1 ALL OUTDOOR FANS 140 MUST BE OPERATING ABOVE CURV 400 LIQUID TEMPERATURE AT LIQUI ADD CHARGE IF 100 ev EDUCE CHARGE IF BELOW CURVE 2 TT TT nam T a 50 100 150 200 250 300 350 LIQUID PRESSURE AT LIQUID VALVE PSIG CIRCUIT 2 ALL OUTDOOR FANS MUST BE OPERATING sy 140 120 gt ADD CHARGE IF ABOVE CURVE 100 80 REDUCE CHARGE IF BELOW CURVE 200 60 LEUU 50 100 150 HHE 250 300 350 LIQUID PRESSURE AT LIQUID VALVE PSIG Fig 71 C
87. tightly against seal strip of hood side mount ing flanges See Fig 39 6 Add gray foam strip provided in package to cross mem bers on bottom tray See Fig 40 7 Place gray foam strip provided on inside of slotted hood side between filter and cross member opposite the mount ing end See Fig 41 8 Attach gray foam strip provided to block off baffle on outer face of flange See Fig 42 9 Remove the screws on each end and along top of damper assembly of unit Remove top 4 screws on each side of filter panel under damper assembly Set hood assembly in place and attach to unit using these screws 10 Attach the outside air thermostat OAT that is supplied from the factory or accessory field supplied enthalpy sen sor onto the hood side furthest from the control box The OAT or enthalpy sensor is installed on the inside upper right hand corner using the mounting bracket and mount ing holes provided Attach wiring to unit controls If ac cessory enthalpy sensor is used quick connects must be attached to enthalpy sensor wires 11 Remove screws along bottom of damper assembly Lo cate and mount blockoff baffle using these screws 12 Assemble 2 filter tracks side by side with the assembled ends together 13 Attach mounting angle without tabs to the assembled end of the filter track See Fig 43 14 Attach 9 green speed clips provided to hood side panels without slots Engagement section of clip faces up and to
88. within sight of the heat exchanger cells aduct location with good mixed supply air portion of the unit THERMISTORS All units are equipped with a supply air thermistor SAT located in the supply fan discharge and an outdoor air thermistor OAT located in the outdoor air hood Variable air volume VAV units are supplied with a return air thermistor RAT located on the return air damper support CONSTANT VOLUME APPLICATIONS The units as shipped are operable as stand alone units using either a stan dard mechanical or electronic 2 stage heat 2 stage cool ther mostat or with an electronic room sensor and a timeclock to establish unit start and stop times With a standard thermostat programmable is optional heating and cooling operation is set by space temperature With a space sensor and timeclock the machine will operate at default values unless they are changed using appropriate in put devices The space sensor senses space temperature and may be equipped with a timed override feature which allows unit operation during unoccupied periods The space sensors may be used in multiples of 4 or 9 to achieve space temperature averaging The use of a space sensor also allows the unit to be turned on and off from a remote signal Table 6 Thermistor Designations PIN FUNCTION AND LOCATION THERMISTOR CONNECTION PART NO POINT Thermistors Supply Air Thermistor SAT Inserted into supply section SAT
89. 0 10 i 1 10 METUS Panel d i 0 Grst 56 Terminal Selection 13 3 1 me 1 2 m T Utility z These settings differ from the Toshiba defaults and are required for Carrier applications 60 Table 13 Motor Electronic Thermal Protection tHr for Toshiba TOSVERT 130 E3 VFD 230V 460V Setting Setting 100 100 100 91 80 85 FM Letter refers to the 15th digit Motor Option of the unit model number TOSHIBA TOSVERT VF S9 VFD The VFD must be powered up however since it is located near the indoor fan operation of the fan is not desirable To disable the fan and set the duct static pressure perform the following procedure 1 Open the Indoor Fan Circuit Breaker IFCB This will shut off power to the VFD 2 Wait for the VFD display to go blank and the charge lamplight to go out Remove the VFD cover without touching any interior components It may take several minutes for the VFD to fully discharge WARNING A high voltage potential can exist with the indoor fan cir cuit breaker open The charge lamp LED located on the upper left comer of the Toshiba TOSVERT VF S9 VFD front cover will indicate charged capacitors DO NOT TOUCH internal high voltage parts if LED is lit 3 Remove jumper between R and CC on the terminal block and replace the VFD cover This will disable the running of the VFD Refer to Fig 58 4 Close the IFCB and energize the Indoor
90. 0 MEM 134 9 175 153 8 175 LEGEND Example Supply voltage is 460 3 60 FLA Full Load Amps A B C AB 452 v HACR Heating Air Conditioning and Refrigeration BC 464 v Indoor Evaporator Fan Motor 455 LRA Locked Rotor Amps MCA Minimum Circuit Amps Ces 2 Maximum Overcurrent Protection Li stew 3 NEC National Electrical Code OFM Outdoor Condenser Fan Motor _ 1371 Rated Load Amps 3 457 Fuse or HACR circuit breaker per NEC j NOTES 1 In compliance with NEC requirements for multimotor and combi nation load equipment refer to NEC Articles 430 and 440 the overcurrent protective device for the unit shall be fuse or HACR breaker The Canadian units may be fuse or circuit breaker Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance in supply volt age is greater than 2 Use the following formula to determine the percent of voltage imbalance Voltage imbalance max voltage deviation from average voltage average voltage 09 38 Determine maximum deviation from average voltage AB 457 4522 5v 464 457 7 v AC 457 455 22v Maximum deviation is 7 v Determine percent of voltage imbalance 9 ES Voltage Imbalance 100 x 457 1 53 This amount of phase imbalance is satisfactory as it is below the maximum allowable 2 IMPORTANT the supply voltage phase imbalance is
91. 00 22 92 18 000 AVAILABLE EXTERNAL STATIC PRESSURE in wg Aum 2 2 24 8 2 80 2 Cfm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 7 000 f 2 8 63 8 000 9 71 9 000 10 94 10 000 12 33 11 000 13 92 12 000 15 71 13 000 17 72 14 000 15 000 16 000 17 000 18 000 AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW 4 0 Cfm Bhp Bhp Bhp Bhp 7 000 10 58 8 000 11 75 9 000 13 05 10 000 14 52 11 000 12 000 13 000 14 000 15 000 16 000 17 000 18 000 LEGEND Bhp Brake Horsepower NOTES 1 2 Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters Conversion Bhp to watts Bhp x 746 Mate Motor Efficiency Variable Air Volume units will operate down to 70 cfm ton Per formance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions 70 Table 25 Fan Performance 48AW AY040 050 Horizontal Discharge Units AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW _ 02 04 os os 10 12 14 1 6 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Bhp Bhp Rpm Bhp 8 000 6 16 9 000 7 31 10 000 8 65 11 000 10 18 12 000 11 92 13 000 13 88 14 000 16
92. 00 250 300 350 400 LIQUID PRESSURE AT LIQUID VALVE PSIG Fig 73 Cooling Charging Chart 48EJ EK EW EY054 068 CHARGING CHART BOTH CIRCUITS ALL OUTDOOR FANS MUST BE OPERATING 140 120 Add Charge if Above Curve 100 Reduce Charge if Below Curve 80 60 Liquid Temperature at Liquid Valve deg F 40 50 100 150 200 250 300 350 400 Liquid Pressure at Liquid Valve PSIG Fig 74 Cooling Charging Chart 48AJ AK AW AY020 060 2 LEADS 18 WIRE 1 32 INSULATION REGULATOR 600V MAX 105 C ADJUSTMENT SCREW REMOVE COVER OUTLET PRESSURE TAP PLUGGED 1 8 27 THDS RECEPTACLE AND TAB COMBINATION TERMINAL PILOT CONNECTION FOR 1 4 TUBING INLET PRESSURE TAP PLUGGED PLUGGED 1 8 27 N P T THDS RECEPTACLE TERMINAL Fig 75 Gas Valve Part Number EF33CB271 94 Main Burners For all applications main burners are factory set and should require no adjustment MAIN BURNER REMOVAL Fig 76 Shut off field supplied manual main gas valve Shut off power supply to unit Remove heating access panel 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 Remove 4 screws that hold the burner
93. 000 28 85 20 000 32 33 AVAILABLE EXTERNAL STATIC PRESSURE in wg om 18 J 20 22 24 26 28 3 2 Cfm Bhp Rpm Bhp Bhp Rpm Bhp Rpm Bhp Bhp Bhp Rpm Bhp 8 000 9 79 9 000 11 00 10 000 12 37 11 000 13 93 12 000 15 69 13 000 17 66 14 000 19 84 15 000 22 25 16 000 24 89 17 000 18 000 19 000 20 000 AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW 40 z Bhp Bhp Rpm Bhp Rpm Bhp 8 000 11 83 9 000 13 12 10 000 14 56 11 000 16 18 12 000 18 00 13 000 20 02 14 000 22 25 15 000 16 000 17 000 18 000 19 000 20 000 LEGEND Bhp Brake Horsepower NOTES 1 2 Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters Conversion Bhp to watts Bhp x 746 Watts Motor Efficiency Variable Air Volume units will operate down to 70 cfm ton Per formance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions 67 Table 22 Fan Performance 48AJ AK060 Vertical Discharge Units AVAILABLE EXTERNAL STATIC PRESSURE in wg aim o2 04 os os 10 12 1a 16 Cfm Bhp Bhp Bhp Bhp Bhp Bhp Bhp Bhp 12 000 10 02 14 000 12 15 15 000 13 38 16 000 14 73 1
94. 020 050 and 48EJ EK EW EY024 048 Units GAS SECTION ACCESS PANEL FLUE HOOD WIND BAFFLE TOP VIEW SIDE VIEW Fig 20B Flue Hood Location 48AJ AK AW AY060 and 48EJ EK EW EY054 068 Units 28 FLUE HOOD SHIPPING LOCATION COMBUSTION FAN HOUSING Fig 21 Combustion Fan Housing Location Step 6 Trap Condensate Drain See Fig 5 16 for drain location Condensate drain is open to atmosphere and must be trapped Install a trapped drain at the drain location One 1 coupling is provided inside the unit evaporator section for condensate drain connection A trap at least 4 in deep must be used See Fig 22 Trap must be installed to pre vent freeze up Condensate pans are sloped so that water will completely drain from the condensate pan to comply with indoor air quali ty guidelines The condensate drain pans are not insulated 1 A E Fig 22 Condensate Drain Trap Piping Details Typical Roof Curb or Slab Mount Shown Step 7 Install Gas Piping Unit is equipped for use with natural gas Installation must conform with local building codes or in the absence of local codes with the Na tional Fuel Gas Code ANSI Z223 1 Install manual gas shutoff valve with a s in NPT pressure tap for test gage connection at unit Field gas piping must 1n clude sediment trap and union See Fig 23 An g in NPT is also located on th
95. 1 096 41 096 41 096 41 Thermostat Heat Anticipator Setting Stage 1 amps 0 1 0 1 0 1 0 1 Stage 2 amps 0 1 0 1 0 1 0 1 Gas Input Btuh Stage 1 300 000 600 000 300 000 600 000 300 000 600 000 582 000 873 000 Stage 2 400 000 800 000 400 000 800 000 400 000 800 000 776 000 1 164 000 Efficiency Steady State 82 82 82 82 Temperature Rise Range 10 40 30 60 10 40 30 60 10 40 30 60 10 40 30 60 Manifold Pressure wg Natural Gas Std 3 5 3 5 3 5 3 8 Liquid Propane Alt 3 5 3 5 3 5 3 3 Gas Valve Quantity 2 2 2 3 HIGH PRESSURE SWITCH psig Cutout 426 426 426 426 Reset Auto 320 320 320 320 LOW PRESSURE SWITCH psig Cutout 27 27 27 27 Reset Auto 67 67 67 67 RETURN AIR FILTERS Quantity Size in 10 20 x 24x 2 10 20 x 24x 2 10 20 x 24 x2 16 20 x 24x2 OUTDOOR AIR FILTERS 8 16 x 25 8 16 x 25 8 16 x 25 12 16 x 25 Quantity Size in 4 20 x 25 4 20 x 25 4 20 x 25 6 20 x 25 LEGEND Sizes 020 030 Circuit 1 uses the lower portion of condenser coil Circuit 2 uses the upper AL cr Aluminum Bes 035 050 Circuit 1 uses the left cond il Circuit 2 the right All units h Bhp Brake Horsepower Sizes 035 050 Circuit 1 uses the left condenser coil Circui e right units have Cu Copper intertwined evaporator coils TRollout switch is manual reset NOTE High heat is for 48AJ AW only 22 UNIT 48EJ EK EW EY NOMINAL CAPACITY tons OPERATING WEIGHT Ib COMPRESSOR Type Ckt 1 Ckt 2 Number of Refrige
96. 100 jesuepuo ON siuf doy TeSt 0 6 SHun jusoelpy 0 seoueieo 2 JOZIW ouooe Jou oq Jo 19 u92 B 2 pyepueis 4eziuouooe 71 SALON 15 V 0 EZOA3 M38t suoisueuiq eseg pt 614 WIG ONT dd IHS v6 9N113I 1 T1V43AO 901 9N11311 NI 310H 211 16 2 9NIUIM 07313 vid 9 NOILISOd 9NI1311 2162 6 e m YIO 42 14 99 v r e 62 69 2 1 28 26 11 11 2 991 INE devia S30Y 1d Y dA STIVd 3578 30158 Lo 26 11 22 91 11 1 27 6 2 11 6 91 pon 16 6P 2 6 0y Lc 26 61 1 8 1 0 s t 91 11 8 AL
97. 11 816 39V110A MOT 28192 6 m 9 1 00 91 6 02 Wid 8 1 3l 91 1 8 1 67 9 1 07 saie i gt p m 2 5 114405 91 1 67 To deese uly 301 33 718 01 0311 1581 ii J104 0073 1314 9 1 EL LdN 2 1 1 0 E dY2 ONIM 8 6 2 TAWG 551229 039N1H YOOd 55322 4055344 02 08 108 039N1H NOD 55000 55422 816 01 qee 28 5 16 EE 53015 H108 3 078 4000 1102 43SN30N02 91 6 6 04 07313 LdN 2 1 5 0 6 1 39 110 7 6 0 YOLOW 3000NI TINVd S 322V 011235 SV9 583 02 401 v 1 98 sen 11445 wum E ors d n X08 1081302 8 1 5 2 1 6 g CAVA LSNVHX3 YIMOd ONILYINGON 557102 WNTV ND WAI 193981 53001001 1H9IIM ONT LVYIdO ETO 0617 992117771191761 1 TESS ror f 0100 8781 0 1 01 91 11 ELl 1199 8700 1 0187 2261 29971512190711 91 6 9 1 1029
98. 2 24 2 280 3 2 Cfm Bhp Bhp Bhp Bhp Bhp Bhp Bhp Rpm Bhp 4 000 i 7 09 5 000 7 94 6 000 8 86 7 000 9 89 8 000 11 07 9 000 12 41 10 000 13 94 11 000 15 68 12 000 13 000 14 000 15 000 AVAILABLE EXTERNAL STATIC PRESSURE wg AIRFLOW 4 0 Cfm Bhp Bhp Bhp 4 000 8 92 5 000 9 89 6 000 10 92 7 000 12 05 8 000 13 30 9 000 10 000 11 000 12 000 13 000 14 000 15 000 LEGEND Bhp Brake Horsepower NOTES 1 2 Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters Conversion Bhp to watts Bhp x 746 wants Motor Efficiency Variable Air Volume units will operate down to 70 cfm ton Per formance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions 69 Table 24 Fan Performance 48AW AY035 Horizontal Discharge Units AVAILABLE EXTERNAL STATIC PRESSURE in wg Atm o2 o o 19 12 14 16 Cfm Rpm Bhp Rpm Bhp Rpm Bhp Rem Bhe Bhp 7 000 4 95 8 000 5 87 9 000 6 96 10 000 8 24 11 000 9 70 12 000 11 35 13 000 13 22 14 000 15 30 15 000 17 60 16 000 20 14 17 0
99. 2 based on demand from Y1 and Y2 respectively The compressors will be locked out when the SAT temperature Is too low less than 40 F for compressor no 1 and less than 45 F for compressor no 2 After a compressor is locked out it can restart after normal time guard period Table 35 User Defined Set Points DESCRIPTION LIMITS DEFAULT OHSP 68 F OCSP 78F UHSP 55F UCSP 90F SASP 55 OATL 65 NTLO 50 RTIO 3 LIMT 10 MDP 20 IAQS 650 PPM UHDB PF UCDB LTMP 10 HTMP 35 PES1 25 PES2 75 LEGEND CV Constant Volume IAQ Indoor Air Quality OAT Outdoor Air Temperature Table 36 Software Control Link Points SET POINT DESCRIPTION CV Data SPT H2 Heat Stage 2 SAT Space Temp Offset RAT CV Power Exhaust Stg 1 OAT CV Power Exhaust Stg 2 CLSP VAV Data CCAP Cooling Total Capacity HR Heat Interlock Relay HCAP Space Temp Reset ECOS Compressor 1 SFSTAT Compressor 1 Safety SF Compressor 2 ECONPOS Compressor 2 Safety Unloader 1 PEXE Unloader 2 FLTS Outdoor Fan 1 FAS Outdoor Fan 2 RMTOCC Y1 Call for Cool 1 General Data Y2 Call for Cool 2 HS1 W1 Call for Heat 1 ENTH Ww W2 Call for Heat 2 IAQI G for Fan IAQO CONQUEST DEVICE CODE SATRES CONQUEST UNIT RESET ALMLIGHT CONQUEST BROADCAST ACK DL Demand Limit Switch PE Mod Power Exhaust Sig 1 EVAC 2 Mod Power Exhaust Stg 2 PRES Mod Power Exhaust Stg 3 PURG
100. 25 416 096 ___ 219 5 215 3 275 250 250 250 4181 0 96 232712273 275 275 e ss 100 110 110 102 0 125 95 4 110 108 0 125 66 7 80 79 3 90 72 7 90 10 eI 90 110 SESE 275 275 me 056 2462425 300 300 as 08 3001300 4i6 096 25992545 300 300 L 300 300 316 096 27592685 00 300 EW EY 60 Hz m 25 6 120 25 6 120 57 1 266 57 1 266 2 _ 5 5 R N m N N acr 6 23 6 Es 6 23 6 6 23 6 6 23 6 ES ag AS d E BONO co oN e a e DS 57 1 266 57 1 266 55 6 23 6 6 23 6 Ea 6 23 6 a 6 23 6 e a e a 69 2 345 69 2 345 onload AFA E A A OFFI POND m x gt A ro o 208 230 n 125 236 05 1092 125 1026 125 460 28 8 173 28 8 173 2 7 20 27 0 236 05 1152 125 os 1096 12 me ze os 1222 150 oil 5 867 110 12 6 23 6 125 05 27 no 7 26 7 120 26 7 12 2 4 2 575 57 120 25429 2e 256 os 1043 125 05 967 110 12 6 236 05 1093 125 See
101. 2B5V56 5 7 B 1 625 2B5V90 9 B 1 9375 2 5VX530 1 625 1187 2B5V58 5 9 1 625 2B5V86 8 B 1 9375 2 5VX530 1 375 779 1B5V60 6 1 NONE 1 375 1B5V136 13 B 1 9375 5VX610 1 625 976 2B5V52 5 3 B 1 625 2B5V94 9 B 1 9375 2 5VX530 1 625 1050 2B5V56 5 7 1 625 2B5V94 9 B 1 9375 2 5VX550 1 625 976 2B5V52 5 3 B 1 625 2B5V94 9 B 1 9375 2 5VX530 1 625 1050 2B5V56 5 7 B 1 625 2B5V94 9 B 1 9375 2 5VX550 1 875 1182 2B5V74 7 5 B 1 875 2B5V110 11 B 1 9375 2 5VX590 1 625 993 2B5V62 6 3 1 625 2 5 110 11 B 1 9375 2 5VX570 1 875 1134 2B5V80 8 1 B 1 875 2B5V124 12 B 1 9375 2 5VX630 1 875 1182 2B5V74 7 5 B 1 875 2B5V110 11 B 1 9375 2 5VX590 1 625 741 2B5V46 4 7 B 1 625 2B5V110 11 B 1 9375 2 5VX550 1 625 962 2B5V60 6 1 B 1 625 2B5V110 11 1 B 1 9375 2 5VX570 1 875 1134 2B5V80 8 1 B 1 875 2B5V124 12 5 B 1 9375 2 5VX630 1 625 930 2B5V58 5 9 B 1 625 2B5V110 11 1 B 1 9375 2 5VX570 1 875 1056 2B5V66 6 7 B 1 875 2B5V110 11 1 B 1 9375 2 5VX590 1 875 1182 2B5V74 7 5 1 875 2B5V110 11 1 B 1 9375 2 5VX590 1 875 1019 3B5V52 5 3 B 1 875 3B5V90 9 1 B 1 9375 3 5VX530 1 875 1134 2B5V80 8 1 B 1 875 2B5V124 12 5 B 1 9375 2 5VX630 2 125 1214 2B5V94 9 4 B 2 125 2B5V136 13 6 B 1 9375 2 5VX650 5 5 NE Bo Nuo
102. 3 48AWEOSO 31 1 18 060 31 2 48 060 31 5 4BAW AYDO6O 31 2 4BAWEOGO 31 3 Fig 17 Rigging Information 48EJ EK EW EY UNITS CENTER OF GRAVITY PERCENT OF TOTAL WEIGHT UNIT AT EACH CORNER B A B 3 2 48EJ EWEK EYDO24 263 48EJ EWEO24 270 asELEWEKEYDO 696 440 178 me 21 21 289 285 48EJ EWEO28 29 0 asELEWEKEYDOS 696 440 178 me 21 211 289 285 48EJ EWEO3O 29 0 eos 440 178 me 211 289 29 48EJ EWEO34 29 0 8EJ EW EK EYDOSS 303 48EJ EWEO38 30 2 8EJ EW EK EYDO42 312 48EJ EWEO44 310 48EJEW EK EYDO48 313 EWEDA8 814 8EJ EW EK EYDOSA 30 9 48EJ EWEO54 307 8EJ EW EK EYDOSS 48EJEWEOSS 311 8EJ EW EK EYDO64 307 48EJ EWE064 30 8 0068 512 A8EJ EWEOGS 813 A RIGGING WEIGHTS 48AJ AK AW AY UNITS MAXIMUM UNIT WEIGHTS Ib 05 97 oso 05 0 00 06 48A J AKD 8930 48AJ AKE 9170 48AW AYD 8970 48AW AYE 9210 Includes outdoor air hoods filters largest available indoor fan 3 On 020 050 includes 170 Ibs and on 060 55 Ibs for economizer motor modulating power exhaust and the largest available variable hoods Includes 45 165 for the economizer hood packaging frequency drive VFD Add 220 16 for copper coil on the 020 030 size NOTES Add 284 16 for copper coil on the 035 size Add 380 16 for copper coil on the 040 050 size Center of gravity Ad
103. 3 E 134 18M 22H 134 28 9 734 318 m X18 61 194 Hu 318 08M 12 e LOIN 241 8U3183ANT JATO 922 080 N9 N m8 LLN 2 118 81 e 9 m18 LIIN 29102 gt 134 SLM 22H 134 91M Da IEA 134 011 y18 ELM 124 Ku X18 LM o y18 901M ex A Tdans Y 318V1 ed SS 3 mm m YAMOd 2 p ec 91915 191 5 m8 118 9 HET A18 Qe ot 118 9114 1905 134 69 22H 134 OLM 22 e s 134 601M L98 2 KO y18 99H De 0 y18 501 Y 310V1 335 199 96 THRU STANDOFF GROUNDED FLAME SEN 61 142 BLU 141 BLU nao PL3 2 01 Me 038 AE SE E 100081 14 40 384 02 30553840 TRAN2 SECONDARY 24V bj ac BASE MODULE TB2 18 __ 17 SUPPLY AIR TEMP SENSOR if 115100 AIR TEMP SENSOR 13 RETURN AIR TEMP SENSOR p 4109 10 W206 RED FU OD ENTHALPY COMP 12 SAFETIES COMP 11 SAFETIES sat TB3 25 RED WIRE 4 VIOLET WIRE ARE SPLICED TOGETHER AT THE FACTORY THE BROWN WIRE HAS A WIRE NUT ADDED AT THE FACTORY a m a
104. 4 20 x 25 4 20 x 25 4 20 x 25 Direct Drive 3 Speed Single Phase Motor Factory Wired for High Speed and Forward Curved Fan 4 1 11 10 Sizes 038 048 Circuit 1 uses the left condenser coil Circuit 2 the right All units have intertwined evaporator coils and drive shown will deliver approximately 2 5 in wg net external static For more information see Table 3 Rollout switch is manual reset NOTE High heat is for 48EJ EW only 24 UNIT 48EJ EK EW EY NOMINAL CAPACITY tons OPERATING WEIGHT Ib COMPRESSOR Quantity Type Ckt 1 Ckt 2 Number of Refrigerant Circuits Oil oz Ckt 1 Ckt 2 REFRIGERANT TYPE Operating Charge Ib oz Circuit 1 Circuit 2 CONDENSER COIL Quantity Rows Fins in Total Face Area sq ft CONDENSER FAN Nominal Cfm Quantity Diameter in Motor Hp 1075 Rpm EVAPORATOR COIL Rows Fins in Total Face Area sq ft EVAPORATOR FAN Quantity Size in Type Drive Nominal Cfm Motor Hp Motor Frame Size Motor Bearing Type Maximum Allowable Rpm Motor Pulley Pitch Diameter Nominal Motor Shaft Diameter in Fan Pulley Pitch Diameter in Nominal Fan Shaft Diameter in Belt Quantity Type Length in Pulley Center Line Distance in Factory Speed Setting rpm FURNACE SECTION Rollout Switch Cutout Temp F Burner Orifice Diameter in drill size Natural Gas Std Liquid Propane Thermostat Heat Anticipator Setting amps Stage 1 Sta
105. 48AJ AK AW AY020 060 with Reciprocating Compressor 48EJ EK EW EY024 068 Single Package Rooftop Units Electric Cooling Gas Heating Installation Start Up and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS 1 1 58 Step 1 Provide Unit 1 ROOF CURB ALTERNATE UNIT SUPPORT Step 2 Rig and Place Unit 2 POSITIONING ROOF MOUNT Step 3 Field Fabricate Ductwork 2 Step 4 Make Unit Duct Connections 2 Step 5 Install Flue Hood 28 Step 6 Trap Condensate Drain 28 Step 7 Install Gas Piping 28 Step 8 Controls 29 STAGED GAS UNIT APPLICATIONS THERMISTORS CONSTANT VOLUME APPLICATIONS VARIABLE AIR VOLUME VAV APPLICATIONS Step 9 Make Electrical Connections 33 POWER WIRING FIELD POWER SUPPLY FIELD CONTROL WIRING Step 10 Make Outdoor Air Inlet Adjustments 48 ECONOMIZER ECONOMIZER SETTINGS Step 11 Position Power Exhaust Barometric Relief Damper Hood 52 Step 12 Install All Accessories 54 Step 13 Field Modifications 57 SIAREUP eorr deep ees 58 89 SERVICE rer br nd 89 102 TROUBLESHOOTING
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107. 5 1 104 jo 40 8 OPIS SSeoov Jal 6121 O epis eH 162811 0 9 1eziuuouo93 161211 0 1100 jesuepuo ON doy TeSt 0 61 swun 94 seoueiee ayeoq jou Jo 99 B pyepueis 4eziuouooe 71 SALON 104 12297 18 gt B 1 4 48AJ AK AW AY UNITS CENTER OF GRAVITY PERCENT OF TOTAL WEIGHT UNIT Mimetes EACH CORNER 8 a 8 a 4 4BAJ AKDO20 29 2 255 48 020 26 6 270 48AW AYDO20 29 2 269 48AWED20 27 0 AsALAKDUS 696 440 1768 18 21 1 21 1 289 289 48AJEO25 290 AsawavDoz 696 440 1768 mie 211 289 289 48AWED25 290 AJAKDO27 696 440 1768 18 244 24 289 289 027 29 0 AsaWaYDOZ 696 440 wes mie 21 1 2139 289 289 48AWEO27 290 _ 696 440 1766 118 241 211 289 289 48 030 290 8AW AYDO0 696 440 178 me ar 211 289 289 48AWEO3O 29 0 48AJ AKDO3S 30 3 48AJEO35 30 2 A8AW AYDOSS 30 3 48AWEO3S 30 2 48AJ AKD040 31 2 8 040 31 0 28AW AYDO40 31 2 48AWEDAO 31 0 38AJ AKD050 31 3 48 050 31 1 48AW AYDOSO 31
108. 5 225 225 111 34 111 34 111 34 111 34 089 43 089 43 089 43 089 43 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 265 600 265 600 265 600 265 600 398 400 398 400 398 400 398 400 350 000 350 000 350 000 350 000 525 000 525 000 525 000 525 000 82 82 82 82 15 45 35 65 15 45 35 65 15 45 35 65 15 45 35 65 5 13 5 5 13 5 5 13 5 5 13 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 2 2 1 5 1 5 426 426 320 320 7 7 Y 7 22 22 22 22 10 20 x 24x2 10 20 x 24x 2 10 20 x 24x2 10 20 x 24x2 8 16 x 25 8 16 x 25 8 16 x 25 8 16 x 25 4 20 x 25 4 20 x 25 4 20 x 25 4 20 x 25 Direct Drive 3 Speed Single Phase Motor Factory Wired for High Speed and Forward Curved Fan 4 1 11 10 Sizes 024 034 Circuit 1 uses the lower portion of condenser coil Circuit 2 uses the upper portion Sizes 038 048 Circuit 1 uses the left condenser coil Circuit 2 the right All units have intertwined evaporator coils tMotor and drive shown will deliver approximately 2 5 in wg net external static For more information see Table 3 Rollout switch is manual reset NOTE High heat is for 48EJ EW only 23 UNIT 48EJ EK EW EY NOMINAL CAPACITY tons OPERATING WEIGHT Ib COMPRESSOR Type Ckt 1 Ckt 2 Number of Refrigerant Circuits Oil oz Ckt 1 Ckt 2 REFRIGERANT TYPE Operating Charge Ib oz Circuit 1 Circuit 2 CONDENSER COIL Quantity Rows Fins in Total Face Area sq ft CONDENSER FAN Nominal Cfm Quantity Diameter in Motor
109. 55 8 PASS IL pua 8 PASS Te E Fusibl EFAS Plug 1 5 55 6 55 Circuit 2 HPS 0274428 SFE HKO2ZA Cutin 320PSI Cutout 426PSI PASS HPS Snuboer 50 0400532 6 55 6 55 4 LPS 922 027 Liquid Line Cutin 22251 EPA Filter Drier Cutout 7PSI 6 PASS N 6 PASS 6 PASS 6 6 E PASS 6 PASS e 6 55 HPS LPS amp Relief Valve 6 55 Muffler A BPRS bus Fusible Fusible B PASS Plug Plug U U E LEGEND FPS Freeze Protection Switch HPS High Pressure Switch LPS Low Pressure Switch Fig 89 Typical Refrigerant Circuiting 48EJ EK EW EY048 108 4 Pas 4 Pas 4 Pas 4 Pas 4 Pas 4 Pas 4 Pas HPS AND LPS MOUNTED ON COMPRESSOR 4 s 4 Pass
110. 59 14 000 12 97 15 000 14 35 16 000 15 86 17 000 17 52 18 000 19 33 19 000 21 29 20 000 23 42 21 000 25 71 22 000 28 17 23 000 30 79 24 000 33 59 25 000 36 58 26 000 m 27 000 AVAILABLE EXTERNAL STATIC PRESSURE in wg Aft 18 20 22 24 2e 28 a 32 E Bhp Rpm Bhp Bhp Rpm Bhp Rpm Bhp Bhp Bhp Bhp 18 33 21 12 22 67 24 34 26 13 28 07 30 16 LEGEND Bhp Brake Horsepower NOTES 1 Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters 2 Conversion Bhp to watts Bhp x 746 Motor Efficiency 3 Variable Air Volume units will operate down to 70 cfm ton Per formance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions 72 Table 27 Fan Performance 48EJ EK024 034 Vertical Discharge Units For EW EY units reduce net available external static pressure by 0 3 in wg AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW Cfm I5 ONFANWDDWOUW 60 OOO OT ROOM lt lt Oo NODE RONN AIRFLOW Cfm 2 o4 os 10 12 E su Si Str Em pm Sip Rm Bip am 0 SY
111. 621 NOLL iNvu4 359 00776 06 g 6 soa NILE 16 221 86211 64767 0611 pm 0571 29714 2 00 5911 88 7 dAl 0 3 FEL PY E aly 114405 1801 9527 YOSSFYdWOD 1OUINOO Q39NIH 58000 322V 0311V1SNI 4 01313 2 ONIM 530 68 1 841404 01313 LdN 672 9676 F 07111 1 H108 1102 YASNFGNOD 06 39 11 OA LdN Nvd S 322V 1234 1V3H TANYd 55322 814018 34000NI 61 SL 310H 131NI 1dN 79 039N1H Sv9 06 8004 55327 NNOD NIY3UQ 52 u 039NIH 4004 552097 431114 YOLON 400QNI o oo 16 9 EG 98 gt 81A02 221 1 3101 315 m 07228 1 177001 0 TOULNOD AINO S 31 1803587 NYJ 103 AINO SvH LINN NMOHS S3 18N3SSV NVj 8903M38t 890Q
112. 65 060537 06 250 06 250 2 2 2 115 ea 224 ea 304 224 R 22 34 0 35 0 41 0 34 0 35 0 41 0 Cross Hatched 3 s Copper Tubes Aluminum Lanced Aluminum Pre Coated or Copper Plate Fins 2 2 1 1 4 15 4 15 4 15 3 15 58 3 58 3 66 7 Propeller Type 27 064 27 064 27 064 4 30 4 30 4 30 1 1 1 Cross Hatched 3 s Copper Tubes Aluminum Plate Fins Intertwined Circuits 3 15 3 15 4 15 34 7 34 7 34 7 Centrifugal Type 2 20x15 2 20x15 2 20x15 Belt Belt Belt 14 000 16 000 18 000 10 151 20 15 201 25 20 251 30 S215T D254T S256T D254T S256T S284T S256T S284T S286T S215T S254T S256T S254T S256T 5284 5256 5284 5286 Ball Ball Ball 1200 1200 1200 6 1 5 3 5 7 5 3 5 7 7 5 6 3 8 1 7 5 13 8 15 8 15 8 15 8 15 8 17 8 15 8 17 8 17 8 13 7 9 5 9 5 9 5 9 5 11 1 11 1 12 5 11 1 115 46 115 46 115 16 1 5VX610 2 5VX530 2 5VX550 2 5VX530 2 5VX550 2 5VX590 2 5VX570 2 5VX630 2 5VX590 61 53 55 53 55 59 57 63 59 15 6 18 4 15 0 17 9 15 0 17 9 14 6 17 6 15 0 17 9 14 6 17 6 779 976 1050 976 1050 1182 993 1134 1182 225 225 225 120 31 120 31 120 31 096 41 096 41 096 41 0 1 0 1 0 1 0 1 0 1 0 1 303 500 303 500 303 500 607 000 607 000 607 000 400 000 400 000 400 000 800 000 800 000 800 000 82 82 82 10 40 30 60 10 40 30 60 10 40 30 60 5 13 5 5 13 5 5 13 5 3 5 3 5 3 5 3 5 3 5 3 5 2 1 5 426 320 7 7 T 22 22 22 10 20 x 24 2 10 20 x 24 x2 10 20 x 24 x 2 8 16 x 25 8 16 x 25 8 16 x 25
113. 68 0 27 23 6 23 6 g 23 6 23 6 208 230 23 6 23 6 E 6 25 6 56 57 1 25 6 20 5 69 2 28 8 6 7 m d TN LN m are ak 2 6 B 17 80 5 100 12 6 93 1 110 24 85 5 110 20 2 12 4 22 12 6 98 1 110 110 2 2 12 6 103 2 125 LEGEND Example Supply voltage is 460 3 60 FLA Full Load Amps A BC AB 452 v HACR Heating Air Conditioning and Refrigeration BC 464 v Indoor Evaporator Fan Motor 455 v LRA Locked Rotor Amps MCA Minimum Circuit Amps Average Voltage BEN O Eo MOCP Maximum Overcurrent Protection LISTED 3 NEC National Electrical Code OFM Outdoor Condenser Fan Motor 1371 RLA Rated Load Amps 3 Fuse or HACR circuit breaker per NEC 457 Determine maximum deviation from average voltage AB 457 4522 5v 464 457 7 v Nite s AC 457 455 2 v NOTES Maximum deviation is 7 v In compliance wit requirements for multimotor and combi nation load equipment refer to NEC Articles 430 and 440 the Determine percent of voltage imbalance overcurrent protective device for the unit shall be fuse or HACR Voltage Imbalance 100 x 27 breaker The Canadian units be fuse or circuit breaker 457 2 Unbalanced 3 Phase Suppl
114. 7 000 16 21 18 000 17 82 19 000 19 57 20 000 21 45 21 000 23 50 22 000 25 69 23 000 28 03 24 000 30 54 25 000 33 21 26 000 36 04 27 000 39 04 AVAILABLE EXTERNAL STATIC PRESSURE wg mo 18 22 24 2e 28 3o 32 m Bhp Rpm Bhp Bhp Rpm Bhp Rpm Bhp Bhp Bhp Rpm Bhp 17 54 20 13 21 56 23 08 24 71 26 46 28 33 30 33 32 47 LEGEND Bhp Brake Horsepower NOTES 1 Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters 2 Conversion Bhp to watts Bhp x 746 atom Motor Efficiency 3 Variable Air Volume units will operate down to 70 cfm ton Per formance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions 68 Table 23 Fan Performance 48AW AY020 030 Horizontal Discharge Units AVAILABLE EXTERNAL STATIC PRESSURE in wg Gm 02 o4 os os 19 12 1 6 Cfm s Lm Em Rem Sip Tom mpm Um Sp Sip Rom Eg Bhp 4 000 1 21 3 59 5 000 1 68 4 19 6 000 2 29 4 92 7 000 3 07 5 79 8 000 4 01 6 84 9 000 5 13 8 07 10 000 6 44 9 50 11 000 7 94 11 13 12 000 9 66 12 98 13 000 11 60 15 04 14 000 8 17 34 15 000 19 88 AVAILABLE EXTERNAL STATIC PRESSURE in wg um 2
115. 74 310 23918 480 470 28015 33 690 HIGH EFFICIENCY MOTORS 87 708 905 _ 7728 102 280 8298 o o one 50 59600 153 494 1223 80 219 14 459 224 52 17852 944 287 1860 9 zzo 2304 24 8363 2342 356 2894 847 417 2766 horsepower ratings shown in the Motor Limitations table will not result in nuisance tripping or premature motor failure Unit war ranty will not be affected 2 All motors comply with Energy Policy Act EPACT Standards effective October 24 1997 ensured that the full horsepower range of the motor can be utilized with confidence Using your fan motors up to the 48AJ AK AW A A8EJ EK EW EY AIRFLOW AIRFLOW AIRFLOW VAV AIRFLOW AIRFLOW Y nd Low Heat High Heat AT FULL LOAD OPERATION CV 020 024 10 000 025 028 12 500 027 030 13 500 030 034 15 000 035 038 17 500 040 044 20 000 048 22 500 050 22 500 054 25 000 058 27 000 060 064 27 000 068 27 000 LEGEND NOTE Variable Air Volume units will operate down to 70 cfm ton in CV Constant Volume Cooling mode Performance at 70 cfm ton is limited to unloaded edb Entering Dry Bulb ewb Entering Wet Bulb VAV Variable Air Volume Table 34 Air Quality Limits operation and may
116. A3 QM38t v903M38t v90QA3 QM38t 98S03M38t 8S0QA3 QM38t vS03M38tU vS0QA3 QM38U H3NHOO LV 325 LINN LHSIEM 1VLOL 40 ALIAVHO dO H3 1N3D YSO JHL INN 790 850 YO4 XIS JHL 10121 00706 69 pe ed 0121 0558 0927 1778 9852 2266 seez vice 9802 00 09 1178 0292 2588 srez 8158 9602 5012 aAa awase 65 9 a 0N 295 SLHDISM LINN 3578 0 038 LINN HLIM Q30010NI Q311VISNI 01313 5000 5000 3371W0NO23 01 727898 seuour ur 8 quawyoeye fuel Pnp 9 10 si sBuiuedo jonp eui ease y Ajddns pue ie 991 SI uonoeuuoo x1owjonp Ajddns pue uunjej Addns epis 104 7 pejeroosse pue G4 21 10sse1duioo JOOpU AVA 9 1 Jezo JO pue 4014 401oul ppy pepnjour s pue sjuBiew eseg 6 pue
117. DI 24 vac 5 Compr 2 DO HV T17 and TB2 1 T18 and TB2 1 T19 and TB2 1 T20 and TB2 1 T21 and TB2 1 T22 and TB2 1 T1 2 T3 4 T5 6 T7 8 T9 10 T11 12 T13 14 T15 16 Analog Input Analog Output Table 48 I O Channel Designations Expansion Module Field Installed CV and VAV TERMINAL NO ASSIGNMENT 28 and TB2 1_ Fire Evacuation 24 vac 21 Fire Smoke Purge DI 24 vac T26 27 Alarm Light Indicator DO 24 vac ower Exhaust Fire No 1 DO 115 vac ower Exhaust Fire No 2 DO 115 vac 0 0 T30 and TB2 2 4 N T33 T34 T36 Power Exhaust Fire No 4 DO 115 vac Fan Status DI 24 vac LEGEND Tables 46 48 OAT Outdoor Air Temperature OFC Outdoor Fan Contactor Carrier Comfort Network RAT Return Air Temperature Constant Volume SAT Supply Air Temperature Direct Input SPT Space Temperature Direct Output STO Space Temperature Offset High Voltage T Terminal Indoor Air Quality TB Terminal Block Kilo Ohms VAV Variable Air Volume Low Voltage 115 wer Exhaust Fire No 3 DO 115 vac ES Field Applied Status DI 24 vac T39 Fire Unit Shutdown DI 24 vac Fire Pressurization DI 24 vac NOTE All even numbered terminals are negative polarity and all odd numbered terminals are p
118. Digital Air Volume DAV mode In a DAV system the room terminals are equipped with microprocessor controls that give commands to the base unit module If an interface is active the control will replace local comfort set points space and return air tempera tures and occupancy status with the linkage data supplied The control module will determine occupancy status from Time Schedules if programmed Remote Occupied Unoccu pied input global occupancy or DAV If Temperature Com pensated Start is active the unit will be controlled as in the Occupied mode NOTE The temperature compensated start is a period of time calculated to bring the unit on while in Unoccupied mode to reach the occupied set point when occupancy occurs The control module will set the appropriate operating mode and fan control The control module will turn VFD on if Occu pied mode is evident For units equipped with a start stop switch only no space temperature sensor if in Unoccupied mode and valid return air temperature reading is available either from a sensor or DAV the control will monitor return air temperature against Unoccupied Heat and Cool set points For units with a start stop switch and a space temperature sensor the control module will start the VFD whenever SPT is outside of the set points Unoccupied Heat or Unoccupied Cool The VFD may also be started by nighttime thermostat via remote Occupied Unoccupied input or by a Temperature Comp
119. EGEND Compressor Contactor Circuit Breaker Control Circuit Breaker Control Relay Dual In Line Package Equipment Fuse Ground Heater Relay Indoor Fan Circuit Indoor Fan Circuit Breaker Indoor Fan Relay National Electrical Code Outdoor Fan Contactor Power Exhaust Controller Power Exhaust Sequencer Power Exhaust Sequencer Controller Terminal Block Transformer Fig 29 Control Box Diagram 48AJ AK AW AY020 030 and 48EJ EK EW EY024 034 Units 44 DETAIL DETAILB SENSOR CONNECTION LOCATION o o gt 2 Ss 1 7 1 Y TIKI m 25 L MA 2 C MET J T 11 TRAN2 EXPANSION BOARD 5 5 M UNE TRANI 1 ACCESSORY ONLY 5 ODULE PS m 5 m 255 2 FCB CCB E peo PAC tas t7 is
120. EK EW EY038 054 units the Motormaster controlled OFM is no 1 OFM and is located at the left side of the unit looking from the compres sor end and the second motor back The no 3 and 4 OFM are controlled to shut off at 55 F and on at 65 F outdoor air temper ature and do NOT need to be changed out The no 2 OFM is intended to run at all ambient temperatures For 48AJ AK AW AY060 and 48EJ EK EW EY058 068 units the Motormaster controlled OFM is no 3 OFM and is lo cated at the left side of the unit looking from the compressor end and the second motor back The no 4 5 and 6 OFMs are controlled to shut off at 55 F and on at 65 F outdoor air temperature and do NOT need to be changed out The no and 2 OFMs are intended to run at all ambient temperatures Sensor Install the sensor for thermistor input control in the location shown in Fig 53A 53E Connect sensor leads to the violet and gray control signal leads on the Motormaster III control Signal Selection Switch Remove the cover of the Motor master III control Set the switch to accept the thermistor sensor input signal Set the frequency to match the unit power supply 60 Hz Motormaster III Control The recommended mounting loca tion is in the indoor fan section mounted on the panel that sep arates the indoor and outdoor sections On VAV units this location is next to the VFD variable frequency drive Do not route the Motormaster III control wiring next to t
121. ENSOR CONTROL If the unit is equipped with a field supplied space sensor and a remote start stop switch constant volume CV cooling will operate as follows Stage 1 cooling begins when there exists a 1 5 F demand and ends when the demand returns back to 0 5 F Stage 2 cooling begins when there is a 2 0 F demand and will continue until the demand returns 1 0 F Stage 2 cannot be en ergized until a minimum of eight minutes of Stage 1 operation or as long as stage 1 is making a reduction in the space temper ature trend If the temperature trends stop improving but the demand still exceeds 2 0 F then Stage 2 cooling will be energized When economizer operation is suitable the control will use economizer as the first stage of cooling will bring on the com pressor 1 when Stage 2 demand is called for If supply air tem perature SAT remains above supply air set point SASP for 15 minutes after energizing compressor 1 then compressor 2 shall be started When Stage 2 is satisfied the last stage of compression shall be dropped When Stage 1 is satisfied the control will drop all DX cooling Ifthe unit is equipped with a field supplied space sensor and a remote start stop switch CV heating will operate as follows Stage 1 heating begins when there exists 1 5 F demand and ends when the demand returns back to 0 5 F Stage 2 heating begins when there is a 2 0 F demand and will continue until the demand returns to 1 0 F Stage 2 canno
122. ERFORMANCE TABLES HIGH PRESSURE SWITCH SETTING psig LOW PRESSURE SWITCH SETTING psig MOTOR PULLEY PART NUMBER FAN PULLEY PART NUMBER BELT PART NUMBER BELT SIZE in FILTER QUANTITY FILTER SIZES in ADDITIONAL NOTES Copyright 2001 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 PC 111 Catalog No 534 739 Printed in U S A Form 48A E 1SI CL 2 107 11 01 Replaces 48 6 1 Tab 1 CUT ALONG DOTTED LINE 00000 CUT ALONG DOTTED LINE
123. Frequency Drive VFD The variable frequency drives are factory set These settings include factory installed jumpers and software configurations The only field configured set point is duct static pressure A Toshiba Opera tion Manual is shipped with each VAV unit This manual should be used if the drive needs to be customized for a partic ular application NOTE The VFD will always provide the proper phase sequence to the indoor fan motor The indoor fan motor oper ates in proper rotation regardless of the phase sequence to the unit If upon start up the outdoor fans operate backwards but the indoor fan operates in the correct direction reverse any two leads to the main terminal block All fans will then operate in the correct direction A factory supplied 2 wire duct pressure transducer is sup plied and wired complete with cable ground to reduce electrical noise A 4 in air pressure tube must be routed to a location in the supply air ductwork where it can sense supply air duct pres sure The recommended location is about 2 3 of the way out on the supply ductwork so that a steady pressure will be provided for the transducer To set the duct static pressure perform the following steps The factory setting is zero The duct transducer has a range from 0 to 5 in wg The transducer output is 4 to 20 mA there fore 0 to 5 in wg is proportional to the 4 to 20 mA and must be expressed to the VFD in terms of percentage of the fre
124. Hp 1075 Rpm EVAPORATOR COIL Rows Fins in Total Face Area sq ft EVAPORATOR FAN Quantity Size in Type Drive Nominal Cfm Motor Hp Motor Frame Size Standard High Efficiency Motor Bearing Type Maximum Allowable Rpm Motor Pulley Pitch Diameter Nominal Motor Shaft Diameter in Fan Pulley Pitch Diameter in Nominal Fan Shaft Diameter in Belt Quantity Type Belt Length in Pulley Center Line Distance in Factory Speed Setting rpm FURNACE SECTION Rollout Switch Cutout Temp F Burner Orifice Diameter in drill size Natural Gas Std Liquid Propane Alt Thermostat Heat Anticipator Setting amps Stage 1 Stage 2 Gas Input Btuh Stage 1 Low Hig Stage 2 Low High Efficiency Steady State Temperature Rise Range Gas Pressure to Unit Range in wg Manifold Pressure in wg Natural Gas Std Liquid Propane Alt Gas Valve Quantity Field Gas Connection Size in FPT HIGH PRESSURE SWITCH psig Cutout Reset Auto LOW PRESSURE SWITCH psig Cutout Reset Auto RETURN AIR FILTERS W x H x T Quantity Size in OUTDOOR AIR FILTERS Quantity Size in POWER EXHAUST Motor Quantity Hp Fan Diameter Width in Sizes 024 034 Circuit 1 uses the lower portion of condenser coil Circuit 2 uses the upper portion Table 1B Physical Data 48EJ EK EW EY Units cont 034D E 044D E 048D E 40 45 For Operating Weights see Table 2 06D537 06 250 06 2
125. If the unit is controlled through a room sensor the indoor fan will be operat ing in the Occupied mode and turned off after 45 seconds in the Unoccupied mode STAGED GAS UNIT HEATING The Staged Gas Control option offered on 48EJ EK EW EY024 068 and 48AJ AK AW AY020 060 units adds the capability to control the rooftop unit s gas heating system to a specified Supply Air Tempera ture Set Point for purposes of tempering a cool mixed air con dition The gas heating system employs multiple heating sec tions Each section is equipped with a two stage gas valve The gas valves are sequenced by a factory installed staged gas con troller SGC as required to maintain the user specified Supply Air Set Point Up to eleven stages of heating control are avail able based on quantity and heating capacity sizes of the indi vidual heat exchanger sections provided in the base unit In addition to providing system control for tempering heat opera tion the new SGC also controls Demand Heat sequences for both First Stage W1 and Second Stage W2 or full fire operation Tempering of supply air is desirable when rooftop units are operating in ventilation mode economizer only operation at low outdoor temperatures At low outdoor temperatures the mixed air temperature combination of return from space tem perature and outdoor ventilation air temperature may become too low for the comfort of the occupants or for the terminal reheat systems The tem
126. J8 1 2 SGC underneath the gas heat section factory provided field installed _ Supply Air Thermistor SAT Inserted into supply section SAT 2 J8 3 4 SGC underneath the gas heat section factory provided field installed 79 2016 2 Supply Air Thermistor SAT Inserted into supply section SAT 3 J8 5 6 SGC underneath the gas heat section factory provided field installed 30 SATI SAT2 n SAT3 Fig 24 Supply Air Thermistor Connections Features with Thermostat Control of Unit two stage heating two stage cooling control of unit using Y1 Y2 W1 W2 and G thermostat inputs control of the indoor fan outdoor air temperature supply air temperature monitoring control of an outdoor air condenser fan based on out door air temperature control of modulating economizer damper to provide free cooling when outdoor conditions are suitable using supply air temperature as a control point control of the economizer damper and indoor fan to obtain unoccupied free cooling provide power exhaust output to an external power exhaust controller support a field test for field checkout control of 2 stages of CV power exhaust compressor Time Guard power up minimum off and on times compressor lockout during low supply air temperature Additional features are provided
127. Legend and Notes on page 42 40 187 254 208 230 208 230 208 230 See Legend and Notes on page 42 414 508 518 632 187 254 414 508 518 632 187 254 414 508 518 632 VOLTAGE COMPRESSOR VOLTAGE RANGE No 1 Table 8 Electrical Data 48EJ EK EW EY Units cont POWER COMBUSTION EXHAUST FAN MOTOR POWER SUPPLY _ _ 096 25242470 300 300 540 23 lt 6 416 096 276 0 270 6 300 300 096 267 8 261 0 300 300 82 1 69 2 345 sales 748 Denm 68 0 23 66 41 6 006 ___ 291 4 284 6 300 300 x 0 96 281 0 273 0 300 300 80 0 Dad 304 6 296 6 350 300 mol zo os nos 159 12 6 236 05 1321 150 1665 6 LE d bs Ease 1391 175 05 135 150 os 1451 175 05 1016 125 0 20 Kalas 9s 1122 125 ESSET 8 1066 125 477 1192 150 el wo c os me 125 12 6 236 05 1242 150 42 144 2592 235 300 300 420 354 624 __144 __ 274 6 270 4 350 350 594 144 252 4 247 0 300 800 oo _ EAS te 287 8 282 4 350 350 144 267 261 0 300 800 68 0 354 624 144 3032 296 4 350 350 07s 1171 150 DEN 1360 175 m al sl va ar low zo Dmm 5 1 1 i 18 5 354 075 1420 175 al o 130 1 150 18 9 354 075 1490 175 os
128. Line 4 55 n Filter Drier Bm LPS 4 55 d 4 PASSL 4 PASS 4 E pe Y 4 5 BE eye 4 PASS 4 Lape PASSE ES U ca PASS PASS 4 pace 4 PASS Puig 4 55 T gt LEGEND FPS Freeze Protection Switch HPS High Pressure Switch LPS Low Pressure Switch Fig 84 Typical Refrigerant Circuiting 48AJ AK AW AY020 025 and 48EJ EK EW EY024 034 103 4 4 4 4 Pass 4 Pass TXV 1 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass TXV 2 4 Pass 4 Pass HPS amp LPS mounted on _4Pass_ compressor 4 Pas
129. NORNOWO OO ONO NN O Xi ON O2 IO S6 RAO ron EN sho 73 LEGEND Bhp Brake Horsepower NOTES Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters 2 Conversion Bhp to watts Bhp x 746 walls Motor Efficiency 3 Variable Air Volume units will operate down to 70 cfm ton Per formance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions Table 28 Fan Performance 48EJ EK038 044 Vertical Discharge Units For EW EY units reduce net available external static pressure by 0 5 in wg AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW Cfm 1 6 2 04 10 12 14 Rpm Bhp Rem Bhb Rpm Rem Bhp Bhp Bhp Rem Bhp 7 000 4 80 8 000 5 61 9 000 6 62 10 000 7 79 11 000 9 14 12 000 10 65 13 000 12 36 14 000 14 27 15 000 16 38 16 000 18 71 17 000 21 26 18 000 24 05 19 000 27 07 20 000 AVAILABLE EXTERNAL STATIC PRESSURE in wg 18 20 22 24 26 28 30 Rpm Bhp Rem Bhe Bhp Rem Bhp Bhe Rem Bhe Rem Bhp AIRFLOW Cfm LEGEND Bhp Brake Horse
130. O 812 y18 PEEN NAB 6024 OIA t Es dur ZEZ 318 0624 D NYO ZEEN 078 622M 35 VES 12216 NYO 262K gr i Lf 682 92 9 OIA 134 30 9 218 EE J 1A 882 12 4 P ANO A2 4 E ES NOLLWANILNOD 302 71381 7081402 335 ET oi NUE G2CH NYA T18 roti 438 9 038 SZEM ASH sum a YATIOULNOD SVO 039 15 T 126 a 05 r or i NUS OCEM E DE Is y18 1224 7 D Y 48040935 OBDA 1 Ws SNL NYO LOCH NYO BOEM NBO d 41 s ESN m7 8 134 Lak IIA 122 18 SM WIG 01 M X18 g ZIEM MHD zi er 5 12 G02 Td n18 nig 022N 17581 IEE NOI LYDN I LNOD 3UIM 303 vie 134 892 lievi 304 335 EIEN gt P IEM Nd SIEN 1 0 134 LIZ we EN 134 40 91 OIA LIEM OIA BIEN JHK 118 861 izd 021d Wo 118 692 102 TROUBLESHOOTING Typical refrigerant circuiting diagrams are shown in Fig 84 93 An algorithm diagram of the IGC Integrated Gas Unit Controller control is shown in Fig 94
131. ONO23 0 3 gt 811 61 A p 1 I T 039NIH T 7 gt 8000 55322 02 8 5 27 53015 H108 11 4 SS00 010 YOOUN LdN I 5 1109 835430802 u3MNO 18 NOOQNI 13NVd 55322 YOSSIYdWOD 1OUINOO 4011235 SV9 039NIH 58000553227 03 1VISN 039N1H aq T 39V110A MOT LAN 7 lt 0 8004 320v 831114 026261 30S m J 0 038 2 3 r AlddNS NUNLIY 9 1 901 H 2 61 8 431138 2113 NO 1 830040 EE as UND PUR uo or E MAA o pss 0004 8371N0N001 03A0N38 91 1 7 E 91 L y 1 9 1 6 91 6 6 TN T F 1148405 AlddfS v2 i y 543402 401 VANYd E 108102 7 1 98 i 2 12 61 ZI i 8 OOH 91 6 27 01 81 3113 v2 9NIN340 i JAOWJY Q00H CAVA 1 Y3MOd ONILYINGON 2 S710 WNIV ND N31 19398Y1 SIGN TON 1HDIJM 941199340 E 6102 921 921 VET 01 91 S 1 1679 8 01718 8502 9691 9921 8 wef 01 1159 8 00 3 187 Twa 3S8 79 8161 8591 1021 58611 9176 11 6 1919 397 301SNI 2 1 6 quna Joo uo euop se 55010 Aq 6261 1691 1021 1221 8 1 01 Gs 2619 vvodya r 38r peuoddns JSNW sjonp eui SI 1 eBeuunp uo ees 6611 0861 1 91 76 11
132. Off On 1 3 Load Compressor no 1 Unloader no 1 and 2 Off The Y2 Low SAT Limit has an adjustable range from 45 F to 55 F with a factory default setting of 48 F If the tem perature of the SAT rise above the 2 Low SAT Limit plus 2 F the compressor will be loaded in the reverse order in which it was unloaded following the pre described Time Guard functions There will be a 90 second time guard between any change in unloaded state and the normal 5 minute time guard for change in compressor On Off state Compressor no 2 Off If a Y2 or Y2 SPT call begins while the unit was under 1 cooling control compressor no 2 will not be started until 1 cooling control has ended If the Y2 or Y2 SPT call ends with compressor 1 in an unloaded state and compressor 2 ON then compressor 1 will be immediately brought up to the fully loaded state If however the Y2 or Y2 SPT call ends with compressor 1 in an unload ed state and compressor 2 OFF then compressor 1 will be left in its unloaded state In either case the compressor 1 will be loaded unloaded as appropriate to the Y1 Low Limit The control shall lockout compressors if SAT becomes too low and an alarm shall be issued Compressor no 1 lockout at SAT 53 F Compressor no 2 lockout at SAT 48 F If SAT sensor fails the control will energize compressor no 1 fully loaded unloaders off whenever there is a Y1 or Y1 SPT call Compressor no
133. RIFY INSTALLATION OF ALL OPTIONS AND ACCESSORIES L1 VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT CHECK GAS PIPING FOR LEAKS CHECK THAT RETURN AIR FILTER AND OUTDOOR AIR FILTERS ARE CLEAN AND IN PLACE VERIFY THAT UNIT IS LEVEL WITHIN TOLERANCES FOR PROPER CONDENSER DRAINAGE CHECK FAN WHEELS AND PROPELLERS FOR LOCATION IN HOUSING ORIFICE AND SETSCREW IS TIGHT VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED VERIFY THAT SUCTION DISCHARGE AND LIQUID SERVICE VALVES ON EACH CIRCUIT ARE OPEN VERIFY THAT CRANKCASE HEATERS HAVE BEEN ON 24 HOURS BEFORE START UP START UP ELECTRICAL SUPPLY VOLTAGE L1 L2 L2 L3 L3 L1 COMPRESSOR AMPS COMPRESSOR NO 1 LI L2 L2 COMPRESSOR AMPS COMPRESSOR NO 2 11 L2 L2 SUPPLY FANS AMPS EXHAUST FAN AMPS VAV VAV fan supply amps reading must be taken with a true RMS meter for accurate readings TEMPERATURES OUTDOOR AIR TEMPERATURE F DB Dry Bulb RETURN AIR TEMPERATURE F DB F WB Wet Bulb COOLING SUPPLY AIR F GAS HEAT SUPPLY AIR F PRESSURES GAS INLET PRESSURE IN WG GAS MANIFOLD PRESSURE 1 IN WG STAGE NO 2 IN WG REFRIGERANT SUCTION CIRCUIT NO 1 PSIG CIRCUIT NO 2 PSIG REFRIGERANT DISCHARGE CIRCUIT NO 2 PSIG CIRCUIT NO 2 PSIG VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGES 93 AND 94 CL 1 GENERAL L1 SET ECONOMIZER MINIMUM VENT POSITION TO JOB REQUIREMENTS ENSURE DRIVES OPERATE WITH LIMITS OF FAN P
134. S ARE CAPPED Failure to do so may damage the transformers FIELD CONTROL WIRING Install either a Carrier approved thermostat or a CCN Carrier Comfort Network compatible temperature sensor Thermostats are used on CV constant volume units only Control box diagrams are shown in Fig 29 31 TBI LEGEND GND Ground FIELO NEC National Electrical Code B5 m 21 TB Terminal Block 222 SUPPLY is as 10 EQUIP GND Fig 28 Field Power Wiring Connections 43 SENSOR CONNECTION DIP SWITCHES LOCATION FAR SIDE
135. VERAGING 9 SENSOR APPLICATION Fig 34 Space Temperature Averaging Wiring TB2 Step 10 Make Outdoor Air Inlet Adjustments BASE BOARD Fig 35 Field HIR Heat Interlock Relay Wiring 48 ECONOMIZER NOTE If accessory power exhaust or barometric relief pack ages are being added to the unit install power exhaust or baro metric relief before installing economizer hoods Economizer Hood Assembly The economizer hood is shipped in a package secured to the outside of the unit behind the indoor access panel The hood assemblies must be field assembled The 48AW AY and 48EW EY units are side supply and side return The return duct limits access to economizer fil ters from below Filter tracks mounting angle without tabs must be installed correctly to allow access to economizer filters from each side The 48AJ AK AW AY020 050 and 48EJ EK EW EY024 048 units have two hoods on every unit Each hood has two lower filter tracks one slotted side and one side without slots Construct the assembly so that the slotted side is adjacent to the other hood when mounted on the unit The 48AJ AK AW AY060 and 48EJ EK EW EY054 068 units have 3 hoods on every unit Each hood has two lower fil ter tracks one slotted side and one side without slots Construct the two outer hood assemblies so that the slotted sides are adja cent to the center hood when mounted on the unit NOTE Before assembly of the econo
136. XTERNAL STATIC PRESSURE in wg Pm 4 1 7 1 6 Cfm Tem Sip Sip mpm Rom S Hip Rom Shp Bhp 3 55 4 11 4 79 5 61 6 59 7 75 9 09 10 62 12 36 14 30 16 45 18 83 oP ONS 09 60 CA OC SON to ooi 24 VOL an AIRFLOW Cfm 318 20 22 24 26 28 3 2 Bhp 7 09 7 88 8 74 9 70 10 80 12 05 13 49 15 12 16 96 LEGEND Bhp Brake Horsepower NOTES 1 Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters 2 Conversion Bhp to watts Bhp x 746 Motor Efficiency 3 Variable Air Volume units will operate down to 70 cfm ton Per formance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions 65 Table 20 Fan Performance 48AJ AK035 Vertical Discharge Units AVAILABLE EXTERNAL STATIC PRESSURE in wg Gm __ 2 os os 10 12 14 J 16 Cfm s Rpm Bhp Rpm Bhp Rpm Rem Bhp Rpm Bhp Rem Bhp 7 000 4 79 8 000 5 65 9 000 6 67 10 000 7 86 11 000 9 22 12 000 10 77 13 000 12 51 14 000 14 44 15 000 16 58 16 000 18 94 17 000 21 52 18 000 AVAILABLE EXTERNAL STATIC PRESSURE i
137. aS 11 79 GGM CAINO 850 720 HM 7918 EIN 05 gt 135110 dW31 12 45 EL HM 291 TNT TIT y18 y18 7 HM 12 22 0 ESM e 8 6 X18 LSM H 0 e LHM SC TM 2144 2SdH 241 N aw o ET 91 ON HM 128 80 620 WOSN3S ANIL BIY A14ans LI 2H22 9 5 918 191 5 Tm HM SEIM 2 811 914 1541 IM eA TNO 0 lt 2 802 870 HM LODE 18 8 CAINO 860 720 2 B Aen 7 m XO 12 XD ZSM y18 18 8 T y18 6 y18 96H 3 1030lN 3svga 121 HM 92H 1143 ldd I SdH 141 HM 92M NYO 92M 621M 22 SdNV 225 LHM wig ESIM e 9 v 134 89 82 LHM SEIN 918 861M ind LHM Real juvanoo3s LHM SEIN 99 044409 A SLI AD 1 1 18 614 055322 07315 15 M3MOd NILYTNCON LHM Ea asy 39 EVON 2 n18 9534 SES 27004 1 218 BEM 6534 5 ee DQE
138. al Cfm Quantity Diameter in Motor Hp EVAPORATOR COIL Tube Size in Rows Fins in Total Face Area sq ft EVAPORATOR FAN Quantity Size in Type Drive Nominal Cfm Motor Hp Motor Frame Size Motor Bearing Type Maximum Allowable Rpm Motor Pulley Pitch Diameter Nominal Motor Shaft Diameter in Fan Pulley Pitch Diameter in Nominal Fan Shaft Diameter in Belt Quantity Belt Type Belt Length in Pulley Center Line Distance in Factory Speed Setting rpm FURNACE SECTION Rollout Switch Cutout Temp F 1 Burner Orifice Diameter in drill size Natural Gas Std Liquid Propane Alt Thermostat Heat Anticipator Setting Stage 1 amps Stage 2 amps Gas Input Btuh Stage 1 Stage 2 Efficiency Steady State Temperature Rise Range Manifold Pressure in wg Natural Gas Std Liquid Propane Alt Gas Valve Quantity HIGH PRESSURE SWITCH psig Cutout Reset Auto LOW PRESSURE SWITCH psig Cutout Reset Auto RETURN AIR FILTERS Quantity Size in OUTDOOR AIR FILTERS Quantity Size in LEGEND Al Aluminum Bhp Brake Horsepower Cu Copper Table 1A Physical Data 48AJ AK AW AY Units 0200 025D E 027D E See Operating Weights Table 2 030D E 30 1 06D328 1 06D818 2 06D328 2 06D328 1 06D537 1 06D328 2 2 2 2 115 88 115 ea 115 ea 115 ea R 22 25 0 25 0 29 0 27 0 31 0 25 0 28 0 29 0 Cross Hatched 3 Copper Tubes Aluminum Lanced Aluminum P
139. al switch or use any phone in your building 3 IMMEDIATELY call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions 4 If you cannot reach your gas supplier call the fire department A WARNING Disconnect gas piping from unit when pressure testing at pressure greater than 0 5 psig Pressures greater than 0 5 psig will cause gas valve damage resulting in hazardous condition If gas valve is subjected to pressure greater than 0 5 psig it must be replaced before use When pressure testing field supplied gas piping at pressures of 0 5 psig or less a unit connected to such piping must be isolated by closing the manual gas valve s INSTALLATION Step 1 Provide Unit Support A CAUTION 1 All panels must be in place when rigging 2 Unit is not designed for handling by fork truck Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 534 739 Book 1 PC 111 Tab 1 Printed in U S A Form 48A E 1SI Pg 1 107 11 01 Replaces 48 6 1 ROOF CURB For vertical discharge units assemble or in stall accessory roof curb in accordance with instructions shipped with this accessory See Fig 1 4 Install insulation cant strips roofing and counter flashing as shown Ductwork can be installed to roof curb before unit is set in place Curb should be level This is necessary to perm
140. are not misaligned the collar in the flex member should line up with the shaft flange holes Torque nuts properly to 95 to 100 ft lb Do not turn a cou pling bolt Always turn the nut Always use thread lubri cant or anti seize compound to prevent thread galling The ends of the shafts should be flush with the inside of the shaft flange Torque the set screws to 25 ft lb After assembly is complete slowly rotate the shafts by hand for 30 to 60 seconds Tighten the bearing mounting bolts using care not to place any loads on the shaft which would cause flexure to the shafts Reinstall drive belts Refer to Belt Tension Adjustment section below Visually inspect the assembly If the shafts are overly mis aligned the drive shaft flange will not be parallel with the shaft flanges Recheck nut torque after 1 to 2 hours of operation Bolts tend to relax after being initially torqued Evaporator Fan Service and Replacement 1 11 n HA e WN Turn off unit power supply Remove supply air section panels Remove belt and blower pulley Loosen setscrews in blower wheels Remove locking collars from bearings Remove shaft Remove venturi on opposite side of bearing Lift out wheel Reverse above procedure to reinstall fan Check and adjust belt tension as necessary Restore power to unit Belt Tension Adjustment To adjust belt tension 1 7 Turn off unit power supply 2 Loosen motor
141. ase control board allows unit occu pancy schedules unit timeclock and various set points to be changed from their factory defined default settings Table 4 48A E Series Staged Gas Implementation MODEL NUMBER POSITION POSITION ee 5 SE S Default 1 Default 20 Low 5 stages A S Default 1 Default 20 Low 038 E T 044 Default 1 Default 20 High 048 035 A T 040 Default 1 Default 20 High 050 024 E Hed Default 2 Default 15 High 7 stages 2 5 Default 2 Default 15 High 030 054 058 _ i 9 stages E T 064 Default 3 Default 15 High A T 00 Defat 3 Default 15 High 054 058 S 11 stages E S 06 4 Default 4 Default 15 Low S 00 _ Default 4 Default 15 Low Table 5 Controls Options and Configurations Non Thermostat Applications UNIT CONFIGURATION CV or VAV Unit with SPT Sensor CV Unit with SPT Sensor and Remote Start Stop Switch VAV Unit Remote Start Stop Switch Only VAV Unit with SPT Sensor and Remote Start Stop Switch LEGEND CV Constant Volume NA Not Available RAT Return Air Temperature SAT Supply Air Temperature SPT Space Temperature VAV Variable Air Volume With DIP Switch No 5 configured to OPEN Occupied Heat Enabled DEFAULT COOLING Unoccupied Cooling 90 F 32 C SPT Occupied Cooling NA Unoccupied Cooling 90 F 32 C SPT Occupied Cooling 78 F 26 C SPT Unoccupied Cooling 90 F
142. ating VAV heating disabled Algorithms in expansion board are bypassed Control uses default values May seem as normal operation First check for wiring errors then replace sensor The outside air temperature OAT sensor has failed First check for wiring errors then replace sensor The space temperature sensor has failed First check for wiring errors then replace sensor The return air temperature RAT sensor has failed Ensure that the unit is a VAV unit If NOT a VAV unit set DIP switch position 1 to the closed position and reset power Then check for wiring errors Finally replace sensor Communications between the expansion board and the control board have been interrupted Ensure that an expansion board is installed and wired using the wire harness supplied with the expansion module If an expansion board is not used ensure that DIP switch position 3 is in the closed position and reset power Generated when hardware has failed on control board Replace the control board All outputs turned off 11 HF 17 Expansion Board Failure None All outputs turned off Generated when hardware has failed on the expansion board Replace the expansion board 12 SE 23 Cooling SAT Low Automatic Limit Shutdown LEGEND DIP Dual In Line Package VAV Variable Air Volume Alarm generated 114 CV operation When SAT low limits are below range and compressor shut off Tables 46 48 show the i
143. be additionally limited to edb and ewb conditions 79 Maximum Efficiency 87 5 84 1 88 5 89 5 89 5 91 0 91 0 91 0 91 0 91 7 91 7 92 4 92 4 93 0 Maximum Efficiency 89 5 91 7 91 7 91 7 91 7 93 0 93 0 93 6 93 6 93 6 93 6 93 6 93 6 94 5 Return Air Filters Check that correct filters are in stalled in filter tracks see Tables 1A and 1B Do not operate unit without return air filters Filter Replacement To replace filters open filter ac cess door marked with label Remove inner access panel Re move plastic filter retainer in between filter tracks by sliding and pulling outward Remove first filter by sliding it out of the opening in filter track Locate filter removal tool which is shipped next to the return air dampers Use the filter removal tool to remove the rest of the filters Outdoor Air Inlet Screens Outdoor air inlet screens must be in place before operating unit Economizer Adjustment Remove filter access panel Check that outdoor air damper is closed and return air damper is open Economizer operation and adjustment are described in Sequence of Operation section on this page and Step 10 Make Outdoor Air Inlet Adjustments section on page 48 Gas Heat Verify gas pressures before turning on heat as follows 1 Turn off field supplied manual gas stop located external to unit 2 Connect pressure gage to supply gas tap located on field supplied manual
144. by accessing the standard unit control board via software with a computer These features are electronic expansion board features if installed control board diagnostics ability to change supply air set point economizer control ability to change high outdoor temperature lockout set point economizer control ability to change power exhaust set points 31 NOTE A CV unit without a thermostat requires a field supplied sensor for operation Features with Sensor Control of Unit Stand Alone Applica tions Unit control is limited to CV unoccupied default set points 90 F for cooling 55 F for heating unless a computer has been used to change the set points There are 2 sensor options available e T 55 sensor will monitor room temperature and provide unoccupied override capability 1 hour T 56 sensor will monitor room temperature provide unoccupied override capability 1 hour and provide a temperature offset of 5 F Standard features are support of remote occupied unoccupied input to start and stop the unit cooling capacity control of 3 stages using economizer and 2 compressors to maintain space temperature to an occupied or unoccupied set point enable heating or cooling during unoccupied periods as required to maintain space temperature within the unoc cupied set points adjustment of space temperature set points of 5 F when using a T 56 sensor provides CCN Carrier Comfort Network IAQ Indoor
145. connecting to the odd numbered terminals and connected to the even numbered terminals Refer to Indoor Air Quality Section in the Controls Operation and Troubleshooting Manual for further sequence of operation NOTE The IAQ Control function was incorporated onto the base control board on these units with serial number of 0600F and later Once installed the sensor must be enabled The sensor is configured with default values which may be changed through network access software To work properly the IAQ sensor high and low reference points for the sensor that is used must match the configured values The base control board reacts to a 4 to 20 mA signal from the IAQ sensor The low reference 4 mA output must be configured to the minimum IAQ sensor reading The high reference 20 mA output must be config ured to the maximum IAQ sensor reading The IAQ sensor can be configured to either low or high priority The priority value can be changed by the user The default is low Low priority When the priority is set to low the initial con trol is to the IAQ set point but the outside air damper position will change to its minimum position when the following condi tions occur CV units with sensor when the space temperature is greater than the occupied cooling set point plus 2 F or when the space temperature is less than the occupied heating set point minus 2 F VAV units and CV units with thermostat when the su
146. d 651 16 for copper coil on the 060 size 2 On 020 050 includes 500 Ibs and on 060 725 Ibs for modulating power exhaust NOJA 48EJ EK EW EY UNITS MAXIMUM UNIT WEIGHTS Ib UNT 028 030 034 oss 044 048 054 058 064 068 48EJEKD 8930 9170 48EW EYD 8970 4BEWE 9210 For 064 size add 489 Ib for copper coil 2 Sizes 024 048 includes 500 and sizes 054 068 includes For 068 size add 651 Ib for copper coil 725 10 for modulating power exhaust 3 Sizes 024 048 includes 170 and sizes 054 068 includes 255 for economizer hoods Includes outdoor air hoods filters largest available indoor fan 4 Economizer hood packaging includes 45 Ib motor modulating power exhaust and the largest available variable 5 For sizes 024 034 add 220 Ib for copper coil frequency drive VFD 6 For sizes 038 044 add 284 Ib for copper coil NOTES 7 For 048 size add 380 Ib for copper coil 8 For 054 size add 271 Ib for copper coil Center of gravity 9 For 058 size add 407 Ib for copper coil 0 1 Fig 17 Rigging Information cont 20 UNIT 48AJ AK AW AY NOMINAL CAPACITY tons BASE UNIT OPERATING WEIGHT Ib COMPRESSOR Quantity Type Ckt 1 Ckt 2 Number of Refrigerant Circuits Oil oz Ckt 1 Ckt 2 REFRIGERANT TYPE Operating Charge Ib oz Circuit 1 Circuit 2 CONDENSER COIL Quantity Rows Fins in Total Face Area sq ft CONDENSER FAN Nomin
147. e 16111 0 apis 162811 0 9 epis 1eziuouo93 38 COOK 752 76 6 9 2 41 o90arver 222 eer 212 van 70126 97442 01 osoaxv arver 161211 0 H3NHOO HOVS LV 3ZIS LINN ON jo doy ewer AE 8 12297 0 81 Suun 1ueoelpy 15 0q seouereo ul 697 0 16 arver Buum pue Ca ieee Een G4A Joopur SIYBIOM AVA ZL lt ony uum stun lusoelbe lou oa 150 0668 juBiew 0 10 seuossoooe pue 5404 ppv UUM SHUN USSR IPE 3ou 090 JOU SI Joopul S1341 pue spoou iun eseg 9 Jo 2 eu 541 9 ees qino uosseooe uo euop se ssoJo Aq peuoddns aq snu sjonp eui si uo 71 SLHSIAM LINN 3578 si j qno 1004 10 999 peuoene eq syonp SALON 0 0 020A V MV8t suoisueuig yun eseg 8 614
148. e 4 1 244 NOI IVANI 1502 M04 335 LYM l 2 WIR 8 214 NYA EEM LHM BLN 2 9 z 180 ILU 318 612m cul E 2 56 0 8 Q0 281 AYWGNODIS 8 002 0 99M NYG 96M 98 HNDAID 1044409 A SLL AVA 87 1 1 08 big INVUL LSNWHX3 YSMOd ONILVINGON ate M v OIG v49 rM O 20 118 9M 7534 HM HM 2h 1 MX 20 10 9 0 DANG Sym 534 321 104100 02 8u321NONO23 HM 27 1N HM p 0 22 12 V89 1 0 2 018 vem 2534 921 H 1 3 HM IYIN H gee e orm O 5 N18 Ln z asaya amod 1534 N02 31382510 ee Hy 1 83004 Hel H 4802 LNOD 121 N02 aN QNOD 211242 HM 89M 318 69M H UN 1 402 1432 3 SLINA 11 ano HM 19 qn y18 OLM HM 89M Zi 53113495 1 4102 HM SEI XS 918 851 9311335 28 9109 HM L9M AdTWHIN 00 110 HM 291M eT 9 suit NO ODE 18 o Lom 2541 YOSN3S dW3l 3Ov
149. e fuse HACR Voltage Imbalance 100 x T breaker The Canadian units may be fuse or circuit breaker 457 2 Unbalanced 3 Phase Supply Voltage 1 53 Never operate a motor where a phase imbalance in supply volt This amount of phase imbalance is satisfactory as it is below the age is greater than 2 Use the following formula to determine maximum allowable 2 the percent of voltage imbalance Voltage imbalance IMPORTANT If the supply voltage phase imbalance is J max voltage deviation from average voltage more than 296 contact your local electric utility company average voltage immediately 35 Table 7 Electrical Data 48AJ AK AW AY Units cont COMPPESSOR_ POWER POWER EXHAUST SUPPLY FLA doi 129 4 126 6 150 150 UNIT SIZE 48AJ AK AW AY NOMINAL VOLTAGE RANGE VOLTAGE 79 0 100 12 6 91 6 110 51 8 60 12 6 64 4 80 58 1 70 12 6 70 7 80 64 3 80 12 6 76 9 90 151 9 149 1 200 200 175 5 172 7 225 225 167 3 163 1 200 200 190 9 186 7 225 225 181 1 175 1 225 225 204 7 198 7 250 250 23 6 23 6 153 0 150 2 175 175 5 8 166413 175 175 208 2 187 2 1 2 1 2 2 42 0 9 niis SE 15 499 23 6 23 6 170 2 164 9 200 200 163 1 1 200 2 _ 163 1 156 3 200 200 23 6 23 6 186 7 179 9 225 225 _ 2 80 12 6 76 8 90 __ 5 90 027 460 414 508 19 9 114 19 9 114 E TE 350
150. e gas manifold adjacent to the gas valve A WARNING Do not pressure test gas supply while connected to unit Always disconnect union before servicing Size gas supply piping for 0 5 in wg maximum pressure drop Do not use supply pipe smaller than unit gas connection MANUAL SHUTOFF GAS 4 SUPPLY PRESSURE TAP 1 8 NPT PLUG TO UNIT SEDIMENT TRAP Fig 23 Field Gas Piping OPTIONAL STAGED GAS UNITS The staging pattern is selected based on Heat Stage Type HTSTGTYP Max Capacity per changes default value is selected based on Capac ity Maximum Stage CAPMXSTG See Table 4 For complete information and service instructions for Staged Gas Control Units see Control Operation and Trouble shooting literature Step 8 Controls Options The control options that the units can provide are based on the following parame ters CV constant volume or VAV variable air volume oper ation stand alone unit with field supplied sensors installed CV or VAV as a system via Carrier Comfort System TEMP or VVT Variable Volume and Temperature optional elec tronic expansion board installed CV or VAV linked to the Carrier Comfort Network availability of a computer and soft ware ComfortWORKS Building Supervisor and Service Tool or remote enhanced display accessory installed to access the base control board and optional factory installed staged gas control See Table 5 NOTE Access to the b
151. eS 12 PASS ELI 4 PASS PASS 4 PASS HPS HKOPZA42B Cutin 320PSl 12 9 __________cl4 pass Cutout 426 51 Circuit 2 4 55 L 400532 1 4 PASS HPS Snubber 50 040053 d LPS HK PZB0e7 Eu Cutin 22251 2 L Cutout 7PSI T A PASSL TETTE A 4 PASS E 4 55 12 5 4 55 EFAS seek HPS LPS amp Fusible Tee or Relief Valve 12 LAC whee seston 4 12 55 4 PASS Uc E EN Mut fter e Pass Liquid Line A 4 PASS T E Fiter Drier 6 55 JU 2 1 Fusible 6 55 ire oss Fusible 4 2 LEGEND FPS Freeze Protection Switch HPS High Pressure Switch LPS Low Pressure Switch Fig 87 Typical Refrigerant Circuiting 48EJ EK EW EY038 044 106 H HPS amp LPS mounted on compressor Muffler Compressor 1 HPS 22 428 Cut In 320 PSI Cut out 420 PSI LPS 022 027 Cut In 22 PSI Cut out 7 PSI 8 Pass 8 Pass 8 Pass 8 8 8 Pass 8 Pass
152. eat the process as required for other items The unit alarms can be cleared through Navigator display To check the current alarms enter the Alarms menu The first submenu is the CRNT submenu The CRNT function displays the list of current alarms maximum of 25 The second sub menu item is the RCRN Reset All Current Alarms function Press to reset the current alarms The next submenu item HIST displays the list of cleared alarms maximum of 20 The HIST function can be cleared with the RHIS function Fig 60 Navigator Display MORNING WARM UP VAV only with PC Accessed CCN Operation Morning warm up occurs when the control has been programmed to turn on heat prior to the Occupied mode to be ready for occupancy mode Morning warm up is a condi tion in VAV systems that occurs when the Temperature Com pensated Start algorithm calculates a biased occupied start time and the unit has a demand for heating The warm up will con tinue into the occupied period as long as there is a need for heat During warm up the unit can continue heating into the occupied period even if occupied heating is disabled When the heating demand is satisfied the warm up condition will ter minate To increase or decrease the heating demand use Service Tool software to change the Occupied Heating set point NOTE To utilize Morning Warm Up mode the unit occu pancy schedule must be accessed via Service Tool Building Supervisor or ComfortWORKS
153. ed If fire shutdown is initiated the fan will stop immediately No 45 second delay will occur The smoke detector may be mounted in the return air duct or the supply duct Carrier does not make recommendations as to specific smoke detector location due to liability considerations INDOOR AIR QUALITY IAQ CONTROL The acces sory IAQ sensor is required for IAQ control on the base control board The Carrier sensors operate with a 4 to 20 mA signal The 4 to 20 mA signal is connect to T13 and T14 on the base control board for the IAQ sensor and T15 and T16 on the base control board for the OAQ Outdoor Air Quality sensor The sensor is field mounted and wired to the base con trol board installed in the unit main control box The IAQ sen sor must be powered by a field supplied 24 V power supply ungrounded Do not use the unit 24 V power supply to power sensor 87 TRAN2 SMOKE DETECTOR 182 3 2 AMPS 220 RED 78 WHT INDOOR FAN aww 18 EY Ty SUPPLY AIR TEMP SENSOR Fig 62 Field Supplied Smoke Detector Wiring NOTE The Carrier IAQ OAQ sensors are shipped configured for a 0 to 10 Vdc signal for use on previously designed PIC Product Integrated Control products This signal must be changed to the 4 to 20 mA signal to be used on these products which is accomplished through a jumper change The IAQ OAQ input signals are also polarized with
154. ed by plug buttons which should be removed 8 Use field supplied wire ties to attach the violet wire to the terminal and the blue wire to the SR terminal 9 Replace economizer filters 10 Return power to unit Disable Economizer For applications where the economiz er will not be used areas of high humidity the economizer should be disabled To disable the economizer perform the following 1 Turn of power Ensure disconnect is locked out 2 Locate the OAT Outdoor Air Thermostat in the right hand outdoor air damper area 3 Locate the splice connecting the violet wire coming from T24 on the base control board to the red wire coming from T29 on the base control board Remove the wire nut and break the red to violet wire splice 57 077 ENTHALPY CONTROL oop HH57AC078 ENTHALPY SENSOR USED WITH ENTHALPY CONTROL FOR DIFFERENTIAL ENTHALPY OPERATION PL4 1 PL4 2 620 ohm JUMPER PL4 4 NOTE Switches shown in high enthalpy state Terminals 2 and 3 close on enthalpy decrease Fig 47 Wiring Connections for Solid State Enthalpy Control HH57AC077 4 Cap off both wires When the connection is broken the base control board is fooled into thinking that the enthalpy is not acceptable and economizer operation is disabled 5 Return power to unit NOTE When
155. emaps the input output database for CV operation sets maxi mum heat stages to 2 and sets maximum cool stages to 3 The control module reads DIP switch no 3 and determines if the unit will use expansion board operation The first time power is sent to the control board after a power outage power up takes 5 minutes plus a random 1 to 63 seconds The TSTAT function performs a thermostat based control by monitoring Y1 Y2 W1 W2 and G inputs These functions control stages cooll cool2 heatl heat2 and indoor fan re spectively If TSTAT function is NOT selected the control de termines the occupancy state on the Time Schedules or with re mote occupied unoccupied input If Temperature Compensated 80 Start is active the unit will be controlled as in the Occupied mode User defined set points are shown in Table 35 Table 36 lists the software link points addressable by DataPort and DataLINK Carrier devices that allow ac cess to unit control by non Carrier energy management sys tems EMS The occupied or unoccupied comfort set points must be se lected and the space temperature offset input will be used if present The Occupied Heat set point default value is 68 F The Occupied Cool set point default value is 78 F The Unoccupied Heat set point default value is 55 F The Unoccupied Cool set point value is 90 F The control board will set appropriate oper ating mode and fan control The control board will turn on in doo
156. ensated Start algorithm When VFD is running in a nor mal mode the control will start heating or cooling as required to maintain supply air temperature at the supply air set point SASP plus the reset when enabled The reset value is deter mined by SAT supply air temperature reset and or space tem perature reset algorithms The space temperature reset is only available when enabled through software When cooling the control will energize the power exhaust enable output to the external power exhaust controller when power exhaust is used Ifin Occupied mode the control module will perform econ omizer control economizer control same as described above for CV units If in Unoccupied mode the control module will perform nighttime free cool and IAQ pre occupancy purge as required when enabled through software When DX direct expansion cooling is called the outdoor fans will always operate 82 The control will run continuous diagnostics for alarms alerts respond to CCN communications and perform any con figured network POC product outboard controls functions such as time and outdoor air temperature broadcast and global broadcast and perform Fire Smoke control if equipped with power exhaust GAS HEATING CONSTANT VOLUME CV UNITS The gas heat units incorporate 2 48AJ AK AW AY020 050 and 48EJ EK EW EY 024 048 or 3 48AJ AK AW AY060 and 48EJ EK EW EY054 068 separate systems to provide gas heat Each system incorpo
157. er pressure transducer is locat ed behind the filter access door on the lower inner panel See Fig 51 A section of field supplied 4 in plastic tubing must be run from the high pressure tap on the differential pressure switch and connected to a field supplied tap in the supply air duct The tap is usually located 2 3 of the way out on the main supply duct Remove plug button in panel to route tubing VAV BUILDING PRESSURE TRANSDUCER The VAV building pressure transducer modulating power exhaust pres sure transducer is located behind the filter access door on the lower inner panel See Fig 51 A section of field supplied 4 in plastic tubing must be run from the high pressure tap on the differential pressure switch to the conditioned space The pressure tube must be terminated in the conditioned space where a constant pressure is required This location is usually in an entrance lobby so that the building exterior doors will open and close properly Remove plug button in panel to route tubing The low pressure tap is factory routed to the atmosphere For a positive pressure building route the high tap to building air and low tap to atmosphere For a negative pressure build ing route the high tap to atmosphere and the low tap to build ing air oL CONTROL POINT APPROX DEG AT 50 RH F C CONTR CURV LEGEND RH Relative Humidity Fig 48 Psychrometric Chart for
158. es NOT include indoor fan motor ADD indoor fan motor e B Option FIOPs and accessories for TOTAL operating weight HP Horsepower 2 The VAV motor weights include indoor fan motor and the VFD IFM Indoor Fan Motor variable frequency drive compressor electric unloaders VFD Variable Air Volume transducers and associated wiring VFD Variable Frequency Drive Outdoor air hoods and filters included in base unit weights indoor fan motors are NOT included 26 Table 3 Evaporator Fan Motor Data MOTOR FAN MOTOR SHEAVE BUSHING SHEAVE BUSHING BELT MOTOR SHAFT DIA SHAFT M PITCH DIAMETER PITCH DIAMETER ay TENSION in DIAMETER in DIAMETER Y Ib at 25 in rpm in in 1 125 717 BK55 4 9 4 B 1 9375 56 4 6 7 B 1 9375 2 BX50 B 1 9375 2 5VX530 B 1 9375 BX56 NONE 1 125 1B5V124 12 1 375 924 2BK50 4 NONE 1 375 2B5V86 8 1 625 1096 2B5V56 5 B 1 625 2B5V90 9 1 375 773 BK60H 5 4 H 1 375 1B5V124 1 375 962 1B5V60 6 1 1 375 1B5V110 B 1 9375 5VX570 1 625 1106 2B5V54 5 5 B 1 625 2B5V86 B 1 9375 2 5VX530 1 375 848 2BK50 4 4 NONE 1 375 2B5V94 9 B 1 9375 2 BX50 1 625 1059 2B5V48 4 9 B 1 625 2B5V80 8 B 1 9375 2 5VX500 1 625 1187 2B5V58 5 9 B 1 625 2B5V86 8 B 1 9375 2 5VX530 1 375 884 2BK50 4 4 H 1 375 2B5V90 9 B 1 9375 2 50 1 625 1096
159. es the unit to operate as a VAV or CV unit DIP switch 2 configures the unit to use a space sensor VAV units or a thermostat CV units DIP switch 3 configures the DDC for use with an elec tronic expansion board DIP switch 4 is used to field test the unit DIP switch 5 is used to enable occupied heating VAV units or specify the type of power exhaust CV units DIP switch 6 configures the Time Guard override and when used with the field test function sets the minimum damper position DIP switch 7 configures the unit for gas heat or electric heat DIP switch 8 configures the unit for heat pump or air conditioner operation Crankcase Heater Units are equipped with crank case heaters Crankcase heaters are energized as long as there is power supplied to unit Crankcase heaters deenergize while compressors are running IMPORTANT To prevent damage to compressors crank case heater should be energized 24 hours prior to start up Evaporator Fan Fan belt and fixed pulleys are factory installed See Tables 19 33 for fan performance and motor limitations data Remove tape from fan pulley and be sure that fans rotate in the proper direction See Table 34 for air quantity limits Static pressure drop for power exhaust is negli gible To alter fan performance see Evaporator Fan Perfor mance Adjustment section on page 91 Condenser Fans and Motors Condenser fans and motors are factory set Refer to Conde
160. ese settings differ from the Toshiba defaults and are required for Carrier applications Table 15 Motor Electronic Thermal Protection tHr for Toshiba TOSVERT VF S9 VFD MOTOR STD EFFICIENCY HIGH EFFICIENCY HP kw iFM Letter 230v Setting 380V Setting 460V Seting 230V Setting 460V Setting 5 90 83 75 e o 5 5 84 10 7 C 85 75 8 N 5 88 o 7 Pe e 7 20 14 92 87 FM Letter refers to the 15th digit Motor Option of the unit model number 62 Power Exhaust The optional non modulating power exhaust CV only is a two stage design where the operation of the exhaust fans is linked to economizer position When the supply fan is running and the economizer is 25 open the base control board closes contacts activating 2 48AJ AK AW AY020 050 and 48EJ EK EW EY024 048 or 3 48AJ AK AW AY060 and 48EJ EK EW EY054 068 exhaust fans When the economizer position reaches 75 open the base module activates the other 2 48AJ AK AW AY020 050 and 48EJ EK EW EY 024 048 or 3 48AJ AK AW AY060 and 48EJ EK EW EY 054 068 exhaust fans The fans will turn off when the economizer closes below the same points The econ omizer position set points that trigger the exhaust fans can be modified but only through use of the Service Tool Comfort WORKS or Building Supervisor software If single stage operation is desired adjust the economizer set points to identi cal
161. evice for the unit shall be fuse or HACR breaker The Canadian units may be fuse or circuit breaker Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance in supply volt age is greater than 2 Use the following formula to determine the percent of voltage imbalance Voltage imbalance max voltage deviation from average voltage ibid average voltage Determine maximum deviation from average voltage AB 457 4522 5v BC 464 457 7 v AC 457 455 22v Maximum deviation is 7 v Determine percent of voltage imbalance Voltage Imbalance 100 x 457 1 53 This amount of phase imbalance is satisfactory as it is below the maximum allowable 2 IMPORTANT more than 2 immediately If the supply voltage phase imbalance is contact your local electric utility company Routing Through Bottom of Unit If wiring is brought in through bottom of unit use field supplied watertight conduit to run power wiring from basepan out through bottom 3 2 in hole to the disconnect box and back into unit to the main con trol box Use strain relief going into control box through 21 in di ameter hole provided After wires are in unit control box con nect to power terminal block see Power Wiring section on page 33 Low voltage wiring must be run in watertight conduit from the basepan to control box and through 7 s in diameter hole provided in bottom of unit control box Field sup
162. g expansion board features can be utilized perform Demand Limit functions based on CCN load shed commands or the state of the discrete input alarm monitoring of all key parameters CCN protocol 32 See Carrier TEMP or VVT Variable Volume and Tem perature literature for complete TEMP single zone or VVT multi zone application information Features with Sensor Control of Unit Network Applica tions The base control board provides as standard a con nection for use with a Carrier VVT system and can also be in tegrated into a Carrier Comfort Network When the unit is accessed via a PC equipped with ComfortWORKS Building Supervisor Service Tool soft ware or accessory Remote Enhanced Display the following features can be accessed on board timeclock can be programmed occupancy schedules can be programmed unit set points can be changed alarms can be monitored This access is available on the base control board via a RJ 11 phone jack or a 3 wire connection to the communication bus See Fig 27 The timeclock has a 10 hour minimum back up time to provide for unit power off for servicing unit or dur ing unexpected power outages For complete Carrier Comfort System CCS or Carrier Comfort Network CCN features and benefits refer to the product literature VARIABLE AIR VOLUME VAV APPLICATIONS Features with Stand Alone Applications The units as shipped are operable as stand alone units w
163. ge 2 Gas Input Btuh Stage 1 Stage 2 Efficiency Steady State Temperature Rise Range Gas Pressure to Unit Range in wg Manifold Pressure in wg Natural Gas Std Liquid Propane Gas Valve Quantity Field Gas Connection Size in FPT HIGH PRESSURE SWITCH psig Cutout Reset Auto LOW PRESSURE SWITCH psig Cutout Reset Auto RETURN AIR FILTERS W x H x T Quantity Size in OUTDOOR AIR FILTERS Quantity Size in POWER EXHAUST Motor Quantity Hp Fan Diameter Width in Table 1B Physical Data 48EJ EK EW EY Units cont 054D E 058D E 064D E 068D E 65 Operating Weights see Table 2 1 06EA265 1 06 250 1 06EA275 1 06EA250 1 06EA275 1 06EA265 2 06EA275 2 2 2 2 304 224 304 224 304 304 304 304 R 22 50 11 57 0 68 0 81 0 46 8 48 6 68 0 73 0 Cross Hatched 3 s in Copper Tubes Aluminum Lanced Aluminum Pre Coated or Copper Plate Fins 1 1 1 1 2 2 3 15 2 15 3 15 2 15 3 15 4 15 66 6 100 0 100 100 Propeller Type 30 000 43 900 43 900 43 900 4 30 6 30 6 30 6 30 1 1 1 1 Cross Hatched 1 2 Copper Tubes Aluminum Plate Fins Intertwined Circuits 4 17 4 17 4 17 4 17 45 0 45 0 48 1 48 1 Centrifugal Type 3 20x15 3 20x15 3 20x15 3 20x15 Belt Belt Belt Belt 20 000 22 000 24 000 26 000 15 20t 25 20 251 30 25 30t 40 25 30t 40 S254T S256T S284T S256T S284T S286T S284T S286T 5324 5284 5286 5324
164. gt 90 0200 23 6 23 6 46 2 42 0 ea 23 6 23 6 20 59 4 54 0 208 230 187 253 57 1 228 23 6 23 6 E E E E o 6 o o A N NI N NI ge TN TN a 3 90 83 9 100 78 3 100 030 460 414 508 25 6 120 19 9 114 1 110 847 110 97 3 110 n 4 70 0 90 634 80 7 1 2 20 1 1 575 518 63 0 5 619 76 0 90 68 8 90 81 4 100 LEGEND Example Supply voltage is 460 3 60 FLA Full Load Amps A BC AB 452 v HACR Heating Air Conditioning and Refrigeration BC 464 v Indoor Evaporator Fan Motor AC 455v LRA Locked Rotor Amps MCA Minimum Circuit Amps Average Voltage MOCP Maximum Overcurrent Protection LISTED 3 NEC National Electrical Code OFM Outdoor Condenser Fan Motor 1371 Rated Load Amps 3 Fuse or HACR circuit breaker per NEC 457 Determine maximum deviation from average voltage AB 457 4522 5v 464 457 7 v AC 457 455 2v we i KNEG d 5 Maximum deviation is 7 v In compliance wit requirements for multimotor and combi nation load equipment refer to NEC Articles 430 and 440 the Determine percent of voltage imbalance overcurrent protective device for the unit shall be fuse or HACR 96 Voltage Imbalance 100 x breaker The Canadian units be fuse or circuit breaker 457 2
165. he VFD on VAV units Use a separate connector through the parti tion when wiring to the OFM Electrical Connections A WARNING To avoid possibility of electrical shock and personal injury turn off all power to unit before making electrical connections When replacing the OFM reconnect the black yellow and blue wires form the outdoor fan contactor to the black yellow and blue wires of the Motormaster III control Run new wires from the red orange and brown wires to the leads of the new OFM Connect the green wire from the control to ground NOTE On all 575 v units 2 transformers part no HT01AH851 must be used for each Motormaster III control to lower the supply voltage to the control to 460 v Transform ers can be mounted anywhere outside the control box 55 gt 1 BOTH SIDES 0 312 DIA HOLES CROSS BREAK UNIT SIZE 48AJ AK AW AY020 050 and 48EJ EK EW EY024 054 48AJ AK AW AY060 and 48EJ EK EW EY058 068 NOTE All dimensions are in inches Material 20 gage galvanized steel or other non corrosive material Fig 52 Motormaster Control Baffle Details ul HH 3H 349H 4 3 cel SENSOR LOCATION 10 TUBES FROM HEADER END Fig 53A Motormaster Sensor Location 48AJ AK AW AY020 030 and 48EJ EK EW EY024 034 SENSOR LOCATION 32 TUBES FROM BOTTOM LEFT HAND CONDENSER COIL VIEWED FROM ACCESS PANEL Fig 53B Motormaster
166. he overtemperature limit opens after the indoor motor is stopped within 10 minutes of W1 becoming inactive on the next cycle the time will be extended by 15 seconds The maxi mum delay is 3 minutes Once modified the fan off delay will not change back to 45 seconds unless power is reset to the con trol If the unit is controlled through a room sensor the indoor fan will be operating in the Occupied mode and turned off after 45 seconds in the Unoccupied mode GAS HEATING VARIABLE AIR VOLUME VAV UNITS All of the gas heating control is performed through the integrated gas control IGC board The control module board serves only to initiate and terminate heating operation NOTE The unit is factory configured for disabled occupied heating DIP switch 5 is used to enable occupied heating DIP switch 5 set to OPEN Variable Air Volume VAV occupied heat is controlled by return air temperature RAT using a 5k thermistor located just below the outdoor air dampers A VAV unit without a space temperature sensor is also controlled by RAT A VAV unit with a Space temperature sensor has Unoccupied Heat controlled by space temperature SPT The control module board is powered by 24 vac When there is a call for heating either Morning Warm Up Unoccu pied or Occupied modes power is sent from the control mod ule board to W on each of the IGC boards and W2 of the main gas valve When heating the control module board will ener gize a f
167. hown will deliver approximately 2 5 in wg net external static pressure For more information see Table 3 Rollout switch is manual reset NOTE High heat is for 48EJ EW 25 Table 2 Operating Weights 48AJ AK AW Units BASE UNIT WEIGHTS Lb dd 02 05 027 os 90 oso 060 48AJD AKD 7480 48AJE 7720 48AWD AYD 7520 48AWE 7760 OPTION OPTION ACCESSORY WEIGHTS Lb ACCESSORY 05 027 oso o0 oso 06 Barometric Relief 800 450 Power Exhaust 450 675 Modulating Power Exhaust 500 725 Cu Tubing Cu Fin Condenser Coil 651 Roof Curb 14 in curb 585 48EJ EK EW EY Units BASE UNIT WEIGHTS Lb glial 024 030 034 038 044 054 058 064 068 7480 7720 48EW EYD 7520 48EWE 7760 OPTION OPTION ACCESSORY WEIGHTS Lb ACCESSORY 024 028 034 038 044 048 054 058 064 068 Barometric Relief 450 Power Exhaust 675 Modular Power Exhaust 725 Cu Tubing Cu Fin Condenser Coil 651 Roof Curb 14 in curb 585 CV MOTOR WEIGHTS Lb VAV MOTOR WEIGHTS Lb MOTOR EFFICIENCY EFFICIENCY MOTOR EFFICIENCY EFFICIENCY IFM IFM IFM IFM 5 94 5 141 92 177 135 e 211 136 222 164 m 250 156 242 is 217 15 305 220 310 m 250 m 386 258 350 m 309 e 446 319 454 36 355 552 359 494 m 415 680 410 625 LEGEND NOTES Cu Copper 1 Base unit weight includes outdoor air hoods Base unit weight do
168. ice to the liq uid line near the liquid line service valve and insulate it so that outdoor ambient temperature does not affect reading Using the above temperature and pressure readings find the intersect point on the appropriate cooling charging chart If in tersection point on chart is above line add refrigerant If inter section point on chart is below line carefully reclaim some of the charge Recheck suction pressure as charge is adjusted NOTE Indoor air cfm must be within normal operating range of unit outdoor fans must be operating Thermostatic Expansion Valve TXV Each circuit has a The is nonadjustable and is factory set to main tain 10 to 13 F superheat leaving the evaporator coil The TXV controls flow of liquid refrigerant to the evaporator coils Gas Valve Adjustment NATURAL GAS The 2 stage gas valve opens and closes in response to the thermostat or limit control When power is supplied to valve terminals 3 and 4 the pilot valve opens to the preset position When power is supplied to terminals and 2 the main valve opens to its preset position The regular factory setting is stamped on the valve body 3 5 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 s in pipe plug from manifold Install a water manometer pressure measuring device 4 Set main gas valve to ON position Set thermostat at
169. ield supplied heat interlock relay output to drive the VAV terminal boxes wide open The HIR is not required on a DAV system See Fig 59 In the Occupied mode the indoor fan motor will be operating and the outdoor air dampers will be in the minimum position In the Unoccupied mode the indoor fan motor will be off but will energize 45 seconds after the call for heat and the outdoor air dampers will move to the IAQ Unoccupied position generally set to zero in the Unoccupied mode The duct pressure sensor will signal to the variable fre quency drive to operate at full speed since all terminals have been driven open An LED on the IGC board will be on during normal operation A check is made to ensure that the rollout switches and limit switches are closed and the induced draft motors are not running The induced draft motors are then en ergized and when speed is proven with the hall effect sensor on the motor the ignition activation period begins The burners will ignite within 5 seconds 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 BASE MODULE CONTROL BOARD INDOOR FAN RELAY If the call for heat lasted less than 1 minute the heating cy cle will not terminate until 1 minute after heat became active When heating is satisfied the power will be interrupted to the IGC board W1 W2 of the main gas valve
170. ignal ground pins Wiring connections for CCN should be made at the 3 pin plug CCN located at the base board Consult CCN literature for further information JeuuojsueJj eoujoe 3 jeuoneN aL ueJ 1oopu jndingandu enas 015 JexeoJg ueJ 1oopu 19 04JUOD 1eouenbeg jsneux3 9534 yno 1 jisneux3 93 punog Jojoejuoo ueJ loopinQ 240 sn4 QN3931 NOLLWOOT NOILO3NNOO 1V1SOWH3HL 0 338 p 213103 rna 1 ONILYINGOW NON ONILYINGOW 5934 934 ANNO 1SnvHX3 H3MOd ONLY HOON ANO AHOSS322VI QHVO8 NOISNVdX3 Nou v201 NOILO3NNOO HOSN3S aas 9 1130 O3N ual goal 231 uH eurT1 u jenq Aejay ouo XJOMJ8N 1914429 2 JexeeJg did uo 822 85 238 83d 1234402516 SNIUIM 83 04 01313 46 THERMOSTAT CONTROL BOX Fig 32 Field Control Thermostat Wiring 18 00000000000000 T2 T4 T5 T6 T7 8 T9 10711712713714715 T16 CONTROL BOARD BASE MODULE NOTE Sensor part numbers are as follows T
171. input the control board will turn off indoor fan without any delay and close economizer dampers When cooling G must be energized before cooling can op erate The control board determines if outdoor conditions are suitable for economizer cooling using the standard outdoor air thermistor For economizer to function for free cooling the en thalpy must be low the outdoor air must equal to or less than the High Outdoor Air Temperature Lockout default is 65 F the SAT supply air temperature thermistor is NOT in alarm and outdoor air reading is available When these conditions are satisfied the control board will use economizer as the first stage of cooling When 1 input is energized the economizer will be modu lated to maintain SAT at the defined set point The default is 55 F When SAT is above the set point the economizer will be 100 open When SAT is below the set point the economizer will modulate between minimum and 100 open position When Y2 is energized the control module will turn on com pressor no 1 and continue to modulate economizer as de scribed above If the Y2 remains energized and the SAT read ing remains above the set point for 15 minutes compressor no 2 will turn on If Y2 is deenergized at any time only the last stage of compression that was energized will be turned off If outdoor conditions are not suitable for economizer cooling the economizer will go to minimum position and cycle compressor no 1 and
172. ir hoods are assembled To install the control perform the follow ing procedure 1 Turn off all power Ensure disconnect is locked out 2 Remove the economizer inlet filters from the bottom of the right hand economizer hood See Fig 37 See Fig 49 for economizer details 3 Mount the outdoor air enthalpy sensor inside the right economizer hood on the right side panel of the hood ad jacent to the outdoor air thermistor 4 Locate the red violet and brown wires near the outdoor air thermistor Remove the splice from the red and violet wires Remove the cap from the brown wire 5 Install a 4 in push on terminal field supplied on the vi olet and brown wires 6 Connect a 4 in push on terminal field provided to one end of a 18 gage 6 in jumper wire field provided Connect the other end to the red wire and attach a 4 in push on connector field provided 7 Connect the red wire with the jumper to terminal TRI Connect the jumper to terminal 2 Connect the brown wire to terminal TR Connect the violet wire to terminal 3 All connections are on the enthalpy control 8 Replace the economizer filters 9 Return power to unit Accessory Differential Enthalpy Control Fig 46 control 57 077 in conjunction with the accessory en sensor HH57AC078 controls economizer operation according to the differential enthalpy The control is mounted in the economizer hood The sensor is moun
173. it unit drain to func tion properly Unit leveling tolerance is shown in Fig 1 3 Refer to Accessory Roof Curb Installation Instructions for additional information as required When accessory roof curb is used unit may be installed on class A B or C roof covering material IMPORTANT The gasketing of the unit to the roof curb is critical for a watertight seal Install gasket with the roof curb as shown in Fig 1 3 Improperly applied gasket can also result in air leaks and poor unit performance ALTERNATE UNIT SUPPORT When the preferred curb or slab mount cannot be used support unit with sleepers on pe rimeter using unit curb support area If sleepers cannot be used support long sides of unit refer to Fig 5 16 with a mini mum number of 4 in x 4 in pads spaced as follows 48AJ AK AW AY 020 030 and 48EJ EK EW EY024 034 units require 3 pads on each side 48AJ AK AW AY035 050 and 48EJ EK EW EY038 048 units require 4 pads on each side 48AJ AK AW AY060 and 48EJ EK EW EY054 068 units re quire 6 pads on each side Unit may sag if supported by corners only Step 2 Rig and Place Unit Inspect unit for transportation damage See Tables 1 A and 1B for physical data File any claim with transportation agency Do not drop unit keep upright Use spreader bars over unit to prevent sling or cable damage Level by using unit frame as a reference leveling tolerance is shown in Fig 1 3 See Fig 17 for additional information
174. ith the addition of a timeclock to establish unit start and stop times Heating and cooling in both on and off modes is controlled to default values by the base unit control Set points may be changed with appropriate input devices The control has an on board occupancy schedule which can be set using an input device and eliminates the need for an ex ternal timeclock During both the on and off periods cooling operation is controlled to the supply air setting and heating 1s controlled to the return air setting or to the optional space temperature sen sor During the on period the supply fan runs continuously During the off period the supply fan will be activated if the re turn air sensor is outside of the set points and will run long enough to accurately sample the space temperature The supply fan will then continue to run until any heating or cooling load is satisfied at which point it will turn off The use of a space sensor will allow for supply air reset to conserve energy and maintain comfort If equipped with an override feature the sensor will allow operation during the off period for a fixed length of time Base unit control supports a Heat Interlock Relay field sup plied to fully open the VAV terminal devices during heating operation Standard features of a VAV unit with a remote start stop switch are control board diagnostics control of an outdoor condenser fan based upon outdoor air temperature cont
175. l Data 48EJ EK EW EY Units 024D E 028D E 0300 034D E 27 5 30 For Operating Weights see Table 2 06D328 06D328 06D537 06D537 06D818 06D328 06D328 06D537 2 2 2 2 115 88 115 ea 115 ea 115 ea R 22 25 0 25 0 25 0 25 0 31 0 25 0 25 0 25 0 Cross Hatched 3 8 Copper Tubes Aluminum Lanced Aluminum Pre Coated or Copper Plate Fins 1 1 1 1 4 15 4 15 4 15 4 15 33 3 33 3 33 3 33 3 Propeller Type 13 420 13 420 13 420 13 420 2 30 2 30 2 30 2 30 1 1 1 1 Cross Hatched 3 s Copper Tubes Aluminum Plate Fins Intertwined Circuits 4 15 4 15 4 15 31 7 31 7 31 7 31 7 Centrifugal Type 2 20x15 2 20 15 2 20 15 2 20x15 Belt Belt Belt Belt 8 000 10 000 11 000 12 000 5 101 15 7 5 101 16 10 151 20 10 151 20 S184T S215T D254T S213T S215T D254T S215T D254T S256T S215T D254T S256T S184T S215T S254T S213T S215T S254T S215T S254T S256T S215T S254T S256T Ball Ball Ball Ball 1200 1200 1200 1200 4 9 4 4 5 7 5 4 6 1 5 5 4 4 4 9 5 9 4 4 5 7 5 9 11 8 13 8 15 8 13 8 13 8 19 8 13 s 15 8 15 8 13 8 15 8 19 8 12 4 8 6 9 1 12 4 11 1 8 7 9 4 8 1 8 7 9 0 9 1 8 7 115 46 115 46 115 16 115 46 1 56 2 50 2 5 530 1 56 1 5VX570 2 5VX530 2 BX50 2 5VX500 2 5VX530 2 BX50 2 5VX530 2 5VX530 56 50 53 56 59 57 50 50 53 50 53 53 16 0 18 7 15 6 18 4 15 0 17 9 15 6 18 4 15 0 17 9 15 6 18 4 15 0 17 9 15 6 18 4 15 0 17 9 717 924 1096 773 962 1106 848 1059 1187 884 1096 1187 22
176. ls 5 2 aja 5584 55847 QN3931 uoisuedxa3 onejsouueu L U9JIMS eJnssaJg eunsseJq MOT AXL 541 SdH L ON AXL Ls ____ 55899 HO 93 oe ee a L Peo aa eseas 949 ar He 5533 ME O im SSB TEA gg Hr SL 1 TEZA 5589 seis 1 558 5844 Tg CEN NEN 55849 55849 e 899 et Leo an ON HOSSI3HdNOO YOSSAYdWOO NO 597 ONY SdH ISd 2 100100 ISd ZZ NI LN9 2208ZZ0H Sd1 ISd 1 1 ISd 0c NI LOO GerVZccONH SdH 305 54905 5 NO GSLNNOW 591 SdH 112 BOARD 1 BLOWN 5 AMP FUSE 2 DEFECTIVE 24V TRANS 3 BROKEN WIRE 4 NO POWER TO UNIT 3 FLASHES FLAME SENSOR INDICATES FLAME WITH CLOSED GAS VALVE OUTDOOR FAN MOTOR 5 FLASHES IGNITION LOCKOUT No igniton within 15 minutes 6 FLASHES INDUCED DRAFT MOTOR FAULT No signal from the Effect Sensor for 60 seconds START IMMEDIATELY W1
177. mizer hood check along the outer edges of the economizer assembly for any seal strip protruding past the flanges Trim the excess seal strip so that it 1s flush with the economizer assembly flanges Perform the following procedure to assemble the economiz er hood 1 Apply black seal strip provided in package to outside top edge of hood sides Wrap seal strip over edge to cover top flange 6 hood sides Make sure seal strip covers screw holes Allow strip to overhang s in past the end opposite the mounting flange See Fig 36 2 Assemble hood sides top and cross member with gasketed screws provided See Fig 37 3 Attach 15 green speed clips provided to hood top 4 Apply black seal strip provided to mounting flanges of hood sides being sure to cover mounting holes See Fig 38 NOTE Each hood assembly has one hood side with slots and one hood side without slots On the 48A AK AW AY 020 050 and A8EJ EK EW EY 024 048 units the two outer hood assem blies must have the hood sides with the slots located adjacent to each other when mounted on the unit On the 48AJ AK AW AY060 and 48EJ EK EW EY 054 068 units the two outer hood assemblies must have the hood sides with the slots located adjacent to the center hood The center hood assembly should have hood side with slots located on the left side 5 Apply black seal strip provided to back of hood top mounting flange Seal strip of hood top mounting flange must press
178. mode Performance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions 27 000 76 Table 31 Fan Performance 48EW EY054 068 Horizontal Discharge Units AVAILABLE EXTERNAL STATIC PRESSURE in wg Nan ___ 2 04 _ to 142 fm idi an Rem Rom Rpm Rem 10 000 2 9 3 6 4 2 4 8 5 4 6 0 12 000 4 4 5 1 5 8 6 5 7 2 7 9 9 3 15 000 7 3 8 2 9 0 9 9 10 7 11 5 13 0 16 000 8 5 9 4 10 3 11 2 12 0 12 9 14 5 17 000 9 8 10 8 11 7 12 6 13 5 14 4 16 1 18 000 11 2 12 3 13 3 14 2 15 1 16 1 17 8 19 000 12 8 13 9 14 9 15 9 16 9 17 8 19 7 20 000 14 5 15 6 16 7 17 7 18 8 19 7 21 7 21 000 16 3 17 5 18 6 19 7 20 8 21 8 23 8 22 000 18 3 19 5 20 7 21 8 22 9 24 0 26 1 23 000 20 4 21 7 22 9 24 1 25 2 26 3 28 5 24 000 22 7 24 0 25 3 26 5 5 31 0 25 000 25 1 26 5 27 8 29 0 33 7 26 000 27 7 29 1 30 4 31 7 36 6 27 000 30 4 31 9 33 2 34 6 AVAILABLE EXTERNAL STATIC PRESSURE in wg 18 20 22 24 26 28 E sm om Rm Ei Sip Tum Sip Rom Bp om AIRFLOW Cfm PRIN O 0120 00 toto WWNNMNNNNAHH LEGEND Bhp Brake Horsepower NOTES Fan performance is based on dry coils economizer roof curb
179. n wg Aum 5 2 80 92 Cfm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 7 000 8 45 8 000 9 46 9 000 10 61 10 000 11 92 11 000 13 41 12 000 15 08 13 000 16 96 14 000 19 04 15 000 16 000 17 000 18 000 AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW 4 0 Cfm Bhp Bhp Bhp 7 000 10 39 8 000 11 50 9 000 12 72 10 000 14 09 11 000 15 64 12 000 13 000 14 000 15 000 16 000 17 000 18 000 LEGEND Bhp Brake Horsepower NOTES 1 2 Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters Conversion Bhp to watts Bhp x 746 Motor Efficiency Variable Air Volume units will operate down to 70 cfm ton Per formance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions 66 Table 21 Fan Performance 48AJ AK040 050 Vertical Discharge Units AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW 02 904 os os 10 12 14 1 6 Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Bhp Bhp Rpm Bhp 8 000 5 94 9 000 7 02 10 000 8 27 11 000 9 71 12 000 11 33 13 000 13 16 14 000 15 20 15 000 17 46 16 000 19 94 17 000 22 66 18 000 25 63 19
180. nit to operate with correct condensing temperatures down to 35 F outdoor air temperature MOTORMASTER III CONTROL The Motormaster III Solid State Head Pressure Control is a field installed accessory fan speed control device actuated by a temperature sensor It is specifically designed for use on Carrier equipment and con trols the condenser fan motor speed in response to the saturated condensing temperature For outdoor temperatures down to 20 F it maintains condensing temperature at 100 F Refer to the accessory Motormaster installation instructions for more information CAPACITY CONTROL COOLING The cooling capaci ty staging tables are shown in Tables 42 and 43 Table 42 Cooling Capacity Staging Table CV Units with 2 Compressors Compressor 1 Compressor 2 NOTE On CV units that require additional unloading add suction pressure unloaders to Compressor 1 only Table 43 Cooling Capacity Staging Table VAV Units with 2 Compressors and 2 Unloaders STAGES Compressor 1 Unloader 1 Unloader 2 40 ton units have only one unloader Compressor 2 It is often desirable to use a variable air volume unit in a variable volume and temperature VVT control system because of the greater unloading capability A VAV unit with software version 4 0 and later can easily be configured in the field to run off of either space thermostat VVT relay pack input or a space sensor When configured in this ma
181. nnected to T3 on the base control board 45 If more than sensor is being used and averaged sensors must be wired in multiples of 4 or 9 See Fig 34 Heat Interlock Relay VAV units require a field supplied heat interlock relay HIR to drive the air terminal wide open when in heat mode Heat Interlock relay part number is HN61KK040 See Fig 35 for HIR wiring Remote Field Control A switch closure across terminals R and W1 on TB 3 will initiate the Occupied mode This can be done manually as well as through a field supplied timeclock Service Tool Building Supervisor and ComfortWORKS Software Access to the control board can be achieved through the terminal marked CCN via a 3 wire bus IMPORTANT The default bus address is 0 The default element number is 1 Refer to CCN literature for informa tion on network addressing or changing CCN communica tion defaults Carrier Comfort Network Interface The rooftop units can be connected to the CCN The communication bus wiring 1s supplied and installed in the field Wiring 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 sys tem element communication connector must be wired to the positive pins of the system element on either side of it the neg ative pins must be wired to the negative pins and the signal pins must be wired to s
182. nner the unit control will turn on compressors based upon load in the space If the supply air falls below predefined limits the con trol will unload the compressor in order to maintain the mini mum supply air limit If unloading is not successful in main taining the minimum supply air temperature SAT then the compressors will be turned off An alarm will be issued when the compressors are turned off PRESSURIZATION SMOKE PURGE EVACUATION ox o o 9N HIR 88 FIRE SHUTDOWN OFF OFF OFF OFF OFF A VAV unit configured to run off thermostat input or a space sensor will have the capability for two stages of heating however modification to the control wiring will be required to make this available The Variable Frequency Drive VFD for the supply fan will still be active varying the supply air fan speed to maintain supply duct pressure Upon a call for Y1 or Y2_ SPT cooling the compressor 1 will start after appropriate Time Guard functions Thirty sec onds after the SAT drops below the the compres sor will be unloaded The unloading sequence will be as follows Unloader no 1 and no 2 Off Unloader no 1 Off Unloader no 2 On Unloader no 1 and no 2 On Unloader no 1 and no 2 Off Compressor no 1 On Full Load Compressor no 1 On 2 3 Load Compressor 1 On 1 Load Compressor no 1 Off The Y1 Low SAT Limit has an adjustable range from 50 F to 65 F with a fact
183. nput and output channel designations Table 46 I O Channel Designations Base Module CV TERMINAL NO ASSIGNMENT TERMINAL NO ASSIGNMENT T1 2 SPT CCN 10KV Thermistor T23 25 Compressor 2 Safety DI 24 vac T3 4 STO CCN 10KV Thermistor Outside Air Enthalpy DI 24 vac 15 6 Economizer Pos AO 4 20 mA T7 8 Heat 1 Relay DO 24 vac 13029 Heat2 Relay DO 24 vac T11 12 CV Power Exhaust 1 Modulating Power Exhaust DO 115 vac T13 14 CV Power Exhaust 2 DO 115 vac T15 16 IAQ Outdoor Al 4 to 20 mA Condenser Fan DO 115 vac T17 25 OFC2 DO 115 vac T18 25 719 25 T2025 wa Di ava indoorFanRelay DO LV T21 25 G DI 24 vac K2 ___ 1 DO HV 22 25 ks 2 Table 47 I O Channel Designations Base Module VAV TERMINAL NO ASSIGNMENT 1 2 Compressor 2 Safety DI 24 vac 13 4 Outside Air Enthalpy DI 24 vac 15 6 Economizer Pos AO 4 20 mA 17 8 Heat 1 Relay DO 24 v T3029 Heat Interlock Relay DO 24 v T11 12 SAT Reset Al 4 to 20 mA Modulated Power Exhaust DO 24 vac T13 14 T15 16 Condenser Fan DO 115 vac 717 25 OFC2 DO 115 vac 85 T3738 ___ 1 DO 115 vac Ti925 T3938 Unloader2 DO 115 vac T2025 KT Indoor Fan Relay DO LV Comp 1 0DO HY T2225 Compressor 1 Safety
184. nser Fan Adjustment section on page 92 as required Be sure that fans rotate in the proper direction Fan no 2 48AJ AK AW AY020 030 and 48EJ EK EW EY024 034 fans no 3 and 4 48AJ AK AW AY035 050 and 48EJ EK EW EY 038 054 and fans no 4 5 and 6 48AJ AK AW AY060 and 48EJ EK EW EY058 068 are cycled on the outdoor air temperature The VFD will always provide the proper phase sequence to the indoor fan motor to operate in the proper rotation regard less ofthe phase sequence to the unit If on start up the outdoor fans operate backwards but the indoor fan operates in the cor rect direction reverse any two leads to the unit main terminal block and all fans will operate in the correct direction Table 16A Power Exhaust Default Set Points 48AJ AK AW AY020 050 and 48EJ EK EW EY024 048 OFFSET DIFFERENTIAL OFF VOLTAGE ON VOLTAGE 500 3 9 460 63 Ef 5 8359 6 968 OFF STATIC PRESSURE in wg 0 00 0 06 0 12 0 18 Table 168 Power Exhaust Default Set Points 48AJ AK AW AYO60 and 48EJ EK EW EY054 068 STAGE OFFSET DIFFERENTIAL OFF VOLTAGE ON VOLTAGE OFF STATIC PRESSURE in wg 1 5 3955 1 60 63 0 00 2 5 5 65 68 0 06 3 0 12 4 0 19 5 59 259 0 83 O 0 25 6 0 31 Table 17 DIP Switch Configuration SETTING 1 ___ 2 4 5 6 77 8 VAV Space Sensor Occupied Time Guard Override Installed Heat ON Expansion Field Test Enabled Heat P
185. nt Do not bypass connections or increase the size of the breaker to correct trouble Determine the cause and correct it before resetting the breaker If the evaporator fan motor is replaced with a different horsepower motor resizing of the circuit breaker is required Contact Carrier Application Engineering CONDENSER FAN MOTOR PROTECTION Each condenser fan motor is internally protected against overtemperature HIGH AND LOW PRESSURE SWITCHES If either switch trips or if the compressor overtemperature switch activates that refrigerant circuit will be automatically locked out See Compressor Lockout Logic section on this page FREEZE PROTECTION THERMOSTAT FPT Freeze protection thermostats are located on the evaporator coil for each circuit One is located at the top and bottom of each coil It detects frost build up and turns off the compressor allowing the coil to clear Once the frost has melted the compressor can be reenergized Relief Devices All units have relief devices to protect against damage from excessive pressures 1 fire These de vices are installed on the suction line liquid line and on the compressor Power Circuit A typical power wiring schematic is shown in Fig 77 Control Circuit 24 V This control circuit is protect ed against overcurrent by a 3 2 amp circuit breaker CB4 Breaker can be reset If it trips determine cause of trouble be fore resetting A typical 24 v cont
186. ooling Charging Chart 48EJ EK EW EY024 034 CIRCUIT 1 038 048 CIRCUIT 2 044 048 400 400 LIQUID TEMPERATURE AT LIQUID VALVE DEG F ALL OUTDOOR FANS MUST BE OPERATING Po 1405 o 120 gt 1 ADD CHARGE IF ABOVE CURVE EA 80 REDUCE CHARGE IF BELOW CURVE E 25 60 t 40 50 100 150 200 250 300 350 LIQUID PRESSURE AT LIQUID VALVE PSIG CIRCUIT 2 038 ALL OUTDOOR FANS MUST BE OPERATING 140 120 I ADD CHARGE IF ABOVE CURVE 100 7 1 REDUCE CHARGE BELOW CURVE 80 60 50 100 150 200 LIQUID PRESSURE L 250 300 350 QUID VALVE PSIG Fig 72 Cooling Charging Chart 48EJ EK EW EY038 048 uper 400 CIRCUIT 1 AND CIRCUIT 2 ALL OUTDOOR FANS MUST BE OPERATING Ii ADD CHARGE IF ABOVE CURVE 100 REDUCE CHARGE IF BELOW CURVE 80 LIQUID TEMPERATURE AT LIQUID VALVE DEG F 60 50 100 150 2
187. option is enabled 4 If the reset option is enabled the sequence will read the space temperature and compare it to the Occupied Cool set point If the temperature is below the Occupied Cool set point the algorithm will compute the reset value and compare this value against the reset limit If it is greater than the reset limit the sequence will use the reset limit as the reset value See Fig 61 NOTE A computer equipped with Carrier network access software ComfortWORKS Building Supervisor or Service Tool or an accessory Remote Enhanced Display is required to enable this function Space Temperature Reset Example The occupied cooling set point is set to 73 F The Reset Ratio is set to 5 The Reset Limit is set to 20 F The Reset Ratio determines how many de grees F the temperature is reset At 72 F the supply tempera ture will be reset 5 degrees higher At 71 F the supply tempera ture will be reset 10 degrees higher At 70 F the supply temper ature will be reset 15 degrees higher At 69 F the supply temperature will be reset 20 degrees higher and the Reset Limit will have been reached mA INPUT DEG F RESET 4 0 00 5 1 25 6 2 50 7 3 75 8 5 00 9 6 25 10 7 50 11 8 75 12 10 00 13 11 25 14 12 50 15 13 75 16 15 00 17 16 25 18 17 50 19 18 75 20 20 00 Fig 61 Space Temperature Reset Wiring SUPPLY AIR TEMPERATURE RESET Supply air tem perature reset is used to reset the supply air temperature utility
188. or modulating power exhaust are shown in Tables 16A and 16B The differential set point is the difference between the turn off point and the turn on point for each module It also is cali brated in terms of percent of input signal and has a range of 1 to 7 The differential potentiometer is calibrated in 1 increments and is factory set at approximately 3 It is recom mended to leave the set point at 3 to minimize cycling of the fans The offset and differential potentiometers have been factory set for atmospheric pressure Do not change these settings until there is some experience with the building In most cases the factory settings will be satisfactory However if the building pressure is not being maintained as desired then some minor adjusting on a trial and error basis can be made Direct Digital Controls DIP Switch Configura tion The Direct Digital Control DDC board must be configured for each application The DDC board is configured through the DIP Dual In Line Package switches located on the board There are 8 DIP switches which configure 8 differ ent applications of the DDC See Table 17 DIP switch 1 is on the left of the block DIP switch 8 is on the right of the block To open a DIP switch push the switch up with suitable tool small blade screwdriver To close a DIP switch push the switch down Factory settings are shown in Table 18 The DIP switch configurations are as follows DIP switch 1 configur
189. ory setting of 53 F If the temperature of the SAT rise above the Low SAT Limit plus 2 the compressor will be loaded in the reverse order in which it was unloaded following the pre described time guards There will be a 90 second time guard between any change in unloaded state and the normal 5 minute time guard for change in com pressor On Off state If compressor no is forced off due to 1 LOW SAT Limit an alert will be issued If economizer is suitable the economizer mode will remain active The alert will be cleared after the 5 minute time guard has expired and the compressor is restarted With or SPT input only compressor 1 can be running Upon a call for Y1 or SPT and Y2 or 2 SPT cool ing both compressor no 1 and 2 will start after appropriate time guards Thirty seconds after SAT drops below the 2 Low SAT Limit the compressor will be unloaded The unloading sequence will be as follows Compressor no Unloader no 1 and no 2 Compressor 2 On Full Load Compressor no 1 Unloader no 1 Off Compressor no 2 On On 2 3 Load Unloader no 2 On Compressor no 1 Unloader no 1 and no 2 Compressor no 2 On On 1 3 Load Compressor no 1 Unloader no 1 and no 2 Compressor no 2 Off On Full Load Compressor no 1 Unloader no 1 Off Compressor no 2 Off On 2 3 Load Unloader no 2 On Compressor no 1 Unloader no 1 and no 2 Compressor no 2
190. ositive polarity SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment 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 formats 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 2001 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 Tab 1 PC 111 Catalog No 534 739 Printed in U S A Form 48 151 Pg 116 107 11 01 Replaces 48 6 1 START UP CHECKLIST MODEL NO SERIAL NO SOFTWARE VERSION SEE FIG 27 TECHNICIAN DATE PRE START UP VERIFY THAT DIP SWITCH SETTINGS ARE CORRECT VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT REMOVE ALL COMPRESSOR SHIPPING HOLDDOWN BOLTS AND BRACKETS PER INSTRUCTIONS VERIFY INSTALLATION OF ECONOMIZER HOOD VE
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192. parts if LED is lit 3 Remove jumper between ST and CC on the terminal block and replace the VFD cover This will disable the running of the VFD Refer to Fig 57 4 Close the IFCB and energize the Indoor Fan Contactor IFC The VFD is now powered but the fan will not operate 5 On the front of the VFD is a keypad which is used to change the VFD set point At this point the drive should be disabled and the display read OFF If the current output frequency is displayed then verify that the ST and CC jumpers have been removed 6 Press either the DOWN ARROW or UP ARROW key once this will display the current frequency set point 7 Press either the DOWN ARROW or UP ARROW key to change set point to the appropriate duct static set point desired This number may be adjusted based on the amount of static pressure in wg required Refer to Table 11 to identify the VFD Set Point DP NOTES 1 Drive enable ST to CC made 2 No emergency off command S4 to CC made 3 Direction command F or R to CC made 4 Frequency reference 4 20mA signal at IV terminal Fig 57 Toshiba TOSVERT130 E3 VFD Factory Installed Jumpers 8 Press READ WRITE key to enter the new value The follow an external speed reference signal from the desired set point value will alternately flash to indicate control system that the new value has been stored b Connect the field supplied speed reference
193. pering function adds incremental steps of heat capacity to raise the temperature of the mixed air up to levels suitable for direct admission into the occupied space or to levels consistent with reheat capabilities of the space termi nals Refer to Table 37 for the staged gas heating control sys tem components Refer to Table 38 for the heating system con troller SGC inputs The heating system controller SGC out puts consist of six relays K1 through K6 which control the individual gas valves TRAN2 I SECONDARY 24 VOLT LEGEND CB Circuit Breaker COM Common HIR Heat Interlock Relay T Terminal TRAN Transformer 2 FIELD INSTALLED 61 040 24 9 5VA Fig 59 Heat Interlock Relay Wiring Table 37 Staged Gas System Components ITEM FUNCTION LOCATION Heating Controller SGC Logic and Output Relays Heating section Supply Air Thermistors SAT Cooling Supply Air Set Point Specify set point for Potentiometer CLSASP Heating Supply Air Set Point Potentiometer HTSASP Heating control Set Point Range 80 to 125 F Prove Supply Fan operation Fan supply air plenum factory installed Air Flow Switch AFS Sense unit leaving air temperature tempering heat control Set Point Range 35 to 70 F Specify set point for First Stage Supply duct factory provided field installed Heating section next to SGC Heating section next to SGC Table
194. plied strain re lief must be used going into the box After wiring is in control box make connections to proper terminals on terminal blocks see Field Control Wiring section on this page Install conduit connector in unit basepan as shown in Fig 5 16 Route power and ground lines through connector to terminal connections in unit control box as shown on unit wir ing diagram and Fig 28 Routing Through Side of Unit Route power wiring in field supplied watertight conduit into unit through 2 2 in or 3 in hole See Fig 28 Use field supplied strain relief going into control box through 2 2 in or 3 in diameter hole provided After wires are in unit control box connect to power terminal block see Pow er Wiring section on page 33 Bring low voltage control wiring through factory drilled 7 s in diameter hole in condenser side post Use strain relief going into 7 s in diameter hole in bottom of unit control box After wiring is in control box make connection to proper terminals on terminal blocks see Field Control Wiring section below IMPORTANT The VAV variable air volume units use variable frequency drives which generate use and can radiate radio frequency energy If units are not installed and used in accordance with these instructions they may cause radio interference They have been tested and found to comply with limits of a Class A computing device as defined by FCC Federal Communications Commission
195. power NOTES Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters 2 Conversion Bhp to watts Bhp x 746 aS Motor Efficiency 3 Variable Air Volume units will operate down to 70 cfm ton Per formance at 70 cfm ton is limited to unloaded operation and may be additionally limited by edb entering dry bulb and ewb entering wet bulb conditions 20 000 74 Table 29 Fan Performance 48EJ EK048 For EW EY units reduce net available external Vertical Discharge Units static pressure by 0 5 in wg AVAILABLE EXTERNAL STATIC PRESSURE in wg AIRFLOW Cfm 9 000 10 000 11 000 12 000 13 000 14 000 15 000 16 000 17 000 18 000 19 000 20 000 AVAILABLE EXTERNAL STATIC PRESSURE in wg 26 28 3 Bhp Bhp Bhp Rpm AIRFLOW Cim __18 20 22 24 Bhp Bhp Rpm Bhp Rpm Bhp 9 000 10 000 11 000 12 000 13 000 14 000 15 000 16 000 17 000 02 04 10 12 14 1 Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Rpm Bhp Rpm Bhp Rpm 7 90 9 20 10 80 12 50 14 43 16 57 18 93 21 52 24 34 27 41 11 91 13 41 15 10 16 98 19 06 18 000 19 000 20 000 Bhp NOT 1 2 75 LEGEND Brake
196. pply air temperature is less than the supply air temper ature set point minus 8 F or when the supply air temper ature is greater than the supply air temperature set point plus 5 F for 4 minutes When the outdoor air quality is greater than the outdoor air quality set point ppm High priority When the priority is set to high the IAQ set point controls the outside air damper exclusively with no re gard to comfort conditioning TIME GUARD CIRCUIT The Time Guard function built into the rooftop control module board maintains a mini mum off time of 5 minutes a minimum on time of 10 seconds and a 10 second delay between compressor starts CRANKCASE HEATER Unit main power supply must remain on to provide crankcase heater operation The crank case heater in each compressor keeps oil free of refrigerant while compressor is off Table 41 Smoke Control Modes DEVICE Economizer Indoor Fan VFD Power Exhaust all outputs Heat Stages Cool Stages LEGEND Heat Interlock Relay VFD Variable Frequency Drive HEAD PRESSURE CONTROL Each unit has a fan cy cling outdoor thermostat to shut off the outdoor fan motor s at 55 one outdoor fan motor on 48AJ AK AW AY 020 030 48EJ EK EW EY 024 034 units 2 outdoor fan motors on 48AJ AK AW AY 035 050 and 48EJ EK EW EY 038 048 units and 3 outdoor fan motors on 48AJ AK AW AY060 and 48EJ EK EW EY054 068 units The head pressure control permits u
197. quency range Refer to Table 11 The set point value is a percentage of the maximum output frequency Locate the duct static pressure closest to that desired and use the corresponding set point val ue If necessary interpolation between duct static pressures is permissible Table 11 Toshiba TOSVERT VFD Set Point Frequency Command for Supply Duct Pressure PRESSURE VFD SET POINT in wg kPa mA Hz 0 0 0 0 25 3 0 50 6 0 75 9 1 00 12 1 25 15 1 50 18 1 75 21 2 00 24 2 25 27 2 50 30 2 75 33 3 00 36 3 25 39 3 50 42 59 TOSHIBA TOSVERT130 E3 VFD The VFD must be powered up however since it is located near the indoor fan operation of the fan is not desirable To disable the fan and set the duct static pressure perform the following procedure 1 Open the Indoor Fan Circuit Breaker IFCB This will shut off power to the VFD 2 Wait for the VFD display to go blank and remove VFD cover without touching any interior components Make sure that the charge indicator lamp is out indicating that the VFD is discharged The lamp is located on the upper right hand corner of the terminal block It may take sever al minutes for the to fully discharge A WARNING A high voltage potential can exist with the indoor fan cir cuit breaker open The charge LED located in the top right hand corner of the Toshiba TOSVERT130 E3 VFD control board will indicate charged capacitors DO NOT TOUCH internal high voltage
198. r fan if in Occupied mode or determine if unit is in Unoc cupied mode and the space temperature is outside of the unoc cupied comfort set points Unoccupied Heat or Unoccupied Cool The control board will then monitor space temperature against comfort set points and control heating or cooling stages as required If system is in the Occupied mode the economizer will operate as required If the system is in Unoccupied mode the system will perform nighttime free cool and IAQ indoor air quality pre occupancy purge as required when functions are enabled via software Whenever the DX direct expansion cooling is requested the outdoor fan will operate The control board will operate economizer run diagnostics to monitor alarms alerts at all times and respond to CCN com munications to perform any configured network POC product outboard control functions such as time and outdoor air tem perature broadcast and Global occupancy broadcast When the optional expansion I O board is employed it will perform pe riodic scan and maintain database of expanded I O points per form Fire Smoke control power exhaust required and if in Occupied mode perform IAQ control and monitor fan filter demand limit and field applied status with accessories If thermostats are used to energize the G input the control will turn on indoor fan without delay and open economizer dampers to minimum position If thermostats are used to deen ergize the G
199. rO COI COLT 6021 0861 871 01 9176 6 1 2609 70043 4287 LT evs 1021 0661 9176 01 L 0266 8014197 0081 BIST 96 IT VIET 971 01 91711 81 806 0041 0187 N13 NLI 581 541 MOS E Y ASTIN 3215 LINN 94118340 lt L 2 01 NNO NIVUG LdN l 039NIH 8000 55322 8311 0 0 LINN HLIM 03001 0311V1SNI 07313 5000 000 Y4Z1WONODI 91 1 81 4 38 NI 6 pue eolAJes 1 5 104 t jo 104 2 St 40 61 9 5 5959 4 6121 0 7 epis 16281 0 9 epis 4 161211 0 100 ON SHUN jo doy 2297 0 61 suun yueoelpy 94 0 seoueJeo UIN Jeziw ouooe eBueuosip U jou Ayane Jo e pyepueis siuBIeM L SALON 17 890 1680 asva 01922 28 10 901 91411 0 8 NI 310H 5616161 618 ov vt vid VS0A3 M38t suoisueuig eseg 91 614 0 9 98 171 9811411 11 3 0 8 8
200. rant Circuits Oil oz Ckt 1 Ckt 2 REFRIGERANT TYPE Operating Charge Ib oz Circuit 1 Circuit 2 CONDENSER COIL Quantity Rows Fins in Total Face Area sq ft CONDENSER FAN Nominal Cfm Quantity Diameter in Motor Hp 1075 Rpm EVAPORATOR COIL Rows Fins in Total Face Area sq ft EVAPORATOR FAN Quantity Size in Type Drive Nominal Cfm Motor Hp Motor Frame Size Standard High Efficiency Motor Bearing Type Maximum Allowable Rpm Motor Pulley Pitch Diameter Nominal Motor Shaft Diameter in Fan Pulley Pitch Diameter in Nominal Fan Shaft Diameter in Belt Quantity Type Belt Length in Pulley Center Line Distance in Factory Speed Setting rpm FURNACE SECTION Rollout Switch Cutout Temp F Burner Orifice Diameter in drill size Natural Gas Std Liquid Propane Alt Thermostat Heat Anticipator Setting amps Stage 1 Stage 2 Gas Input Btuh Stage 1 Low High Stage 2 Low High Efficiency Steady State Temperature Rise Range Gas Pressure to Unit Range in wg Manifold Pressure in wg Natural Gas Std Liquid Propane Alt Gas Valve Quantity Field Gas Connection Size in FPT HIGH PRESSURE SWITCH psig Cutout Reset Auto LOW PRESSURE SWITCH psig Cutout Reset Auto RETURN AIR FILTERS W x H x T Quantity Size in OUTDOOR AIR FILTERS Quantity Size in POWER EXHAUST Motor Quantity Hp Fan Diameter Width in Table 1B Physica
201. rates its own induced draft motor In tegrated Gas Control IGC board 2 stage gas valve manifold etc The systems are operated in parallel for example when there is a call for first stage heat all induced draft motors oper ate all gas valves are energized and both IGC boards initiate spark All of the gas heating control is performed through the IGC boards located in the heating section The control module board serves only to initiate and terminate heating operation The control module board is powered by 24 vac When the thermostat or room sensor calls for heating power is sent from the control module board to W on each of the IGC boards An LED on the IGC board will be on during normal operation A check is made to ensure that the rollout switches and limit switches are closed and the induced draft motors are not run ning The induced draft motors are then energized and when speed is proven with the hall effect sensor on the motor the ignition activation period begins The burners will ignite within 5 seconds When ignition occurs the IGC board will continue to moni tor the condition of the rollout and limit switches the hall effect sensor as well as the flame sensor If the unit is controlled through a room thermostat set for fan auto 45 seconds after ignition occurs the indoor fan motor will be energized and the outdoor air dampers will open to their minimum position If for some reason the overtemperature limit opens
202. re Coated or Copper Plate Fins 1 1 1 1 4 15 4 15 4 15 4 15 33 3 33 3 33 3 33 3 Propeller Type 13 420 13 420 13 420 13 420 2 30 2 30 2 30 2 30 1 1 1 1 Cross Hatched Copper Tubes Aluminum Plate Fins 3 g 3 8 3 8 3 8 4 15 4 15 4 15 4 5 31 7 31 7 34 7 34 7 Centrifugal Type 2 20 X 15 2 20 X 15 2 20 15 2 20 X15 Belt Belt Belt Belt 8 000 10 000 11 000 12 000 5 10 15 7 5 10 15 10 15 20 10 15 20 184T 215T 254T 213T 215T 254T 215T 254T 256T 215T 254T 256T Ball Ball Ball Ball 1200 1200 1200 1200 4 9 4 4 5 7 5 4 6 1 5 5 44 4 9 5 9 4 4 5 7 5 9 11 8 13 8 13 8 13 8 13 8 15 8 13 8 15 8 15 8 13 8 15 8 15 8 12 4 8 6 9 1 12 4 11 1 8 7 9 4 8 1 8 7 9 0 9 1 8 7 115 46 115 16 115 46 115 46 1 2 2 1 1 2 2 2 2 2 2 2 56 50 5VX530 BX56 5VX590 5VX570 BX50 5VX500 5VX530 BX50 5VX530 5VX530 56 63 53 56 59 57 50 50 53 50 53 53 16 0 18 7 15 6 18 4 15 0 17 9 15 6 18 4 15 6 18 4 15 0 17 9 15 6 18 4 15 0 17 9 15 0 17 9 15 6 18 4 15 0 17 9 15 0 17 9 717 924 1096 773 962 1106 848 1059 1187 884 1096 1187 225 225 225 111 34 111 34 111 34 111 34 089 43 089 43 089 43 089 43 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 262 500 394 000 350 000 525 000 82 15 45 35 65 262 500 394 000 350 000 525 000 82 15 45 35 65 262 500 394 000 350 000 525 000 82 15 45 35 65 3 5 3 5 3 5 3 5 3 5 3 5 2 2 2 426 426 426 320 320 320 27 27 27 67 67 67 10 20 x 24 x2 10 20 x 24 x2 10 20 x 24 x2
203. rectly to prevent premature failures REASSEMBLING THE COUPLING INTO THE UNIT Fig 68 Prior to reassembling the coupling loosen the 4 bearing mounting bolts which secure the 2 bearings on either side of the coupling Remove the drive belts 2 Reassemble the coupling with the bearings loose This al lows the coupling to find its own self alignment position 3 Check the hub to shaft fit for close fitting clearances Replace hubs if high clearances are determined 4 Check the key for close fitted clearances on the sides and 0 015 in clearance over the top of the key Replace key if necessary FLEX SHAFT SHAFT BEARINGS MEMBER FLANGE amp Fig 68 Evaporator Fan Coupling Be sure that hub flanges flex members spacer and hard ware are clean and free of oil Place the flanges onto the shafts with the hub facing out ward Do not tighten the set screws at this time Outside of the unit assemble the flex members to the cen ter drive shaft with 4 bolts and nuts The flex members have collars that need to be inserted into the smaller hole of the drive shaft flange Assemble the flex member drive shaft assembly to one of the shaft flanges using 2 bolts and nuts Slide the other shaft flange towards the assembly and assemble using 2 bolts and nuts If the shafts
204. red by local codes provide an additional disconnect switch Whenev er external electrical sources are used unit must be electrically grounded in accordance with local codes or in absence of local codes with NEC ANSI American National Standards Insti tute C1 latest year FIELD POWER SUPPLY Unit is factory wired for volt age shown on unit nameplate See Table 7 and 8 for electrical data Field wiring can be brought into the unit from bottom through basepan and roof curb or through side of unit corner post next to control box A 3 NPT coupling for field power wiring and 3 4 in NPT coupling for 24 v control wiring are provided in basepan In the side post there are two 21 gt 48A020 030 and 48E024 034 or 3 in 48A035 060 and 48E038 068 knock outs for the field power wiring See Fig 5 16 If control wiring is to be brought in through the side of unit a 7 s in diameter hole is provided in the condenser side post next to the control box If disconnect box is mounted to corner post be careful not to drill any screws into the condenser coil DIP SWITCHES icy vila 6 6 39 170 339NVT T EADW SADA 2 08 lt C 2 oora za C 8 Occ
205. red outdoor air minimum damper position The 30 second time period is to allow time where DIP switch no 4 can be closed The default value of the minimum outdoor air damper position is 20 If the desired minimum position is 30 al lows the damper position to go to 10 for 30 seconds then 20 for 30 seconds and when it reaches 30 close DIP switch no 4 during the 30 second period following the 30 position The minimum outdoor air damper position is now set Close DIP switch no 6 MOUNTING ANGL WITHOUT TABS FILTER TRACK ASSEMBLY Fig 43 Mounting Angle Without Tabs Attached to Filter Track Assembly MOUNTING ANGLE WITH TABS Fig 44 Mounting Angle With Tabs Attached to Filter Track Assembly BLACK SEAL STRIP CENTERED FILTER COVER Fig 45 Attaching Seal Strip to Filter Cover 51 ECONOMIZER SETTINGS Accessory Enthalpy Control Fig 46 The control 57 077 is mounted in the economizer hood See Fig 37 The enthalpy setting adjustment is on the enthalpy con trol For maximum benefit of outdoor air set enthalpy control to A See Fig 47 and 48 The enthalpy controls operation of the economizer outdoor air damper to provide free cooling on a signal form the cooling thermostat Enthalpy Control Installation The outdoor air enthalpy control is installed on the inside panel of the outdoor air hood The enthalpy control should be mounted when the outdoor a
206. regulations Subpart J of Part 15 which are designed to provide reasonable protection against such interference when operated in a commercial environment rr DISCONNECT PER NEC eee pee WARNING The unit must be electrically grounded in accordance with local codes and NEC ANSI NFPA 70 National Fire Pro tection Association Affix crankcase heater sticker located in the installers pack et to unit disconnect switch Voltage to compressor terminals during compressor opera tion must be within the voltage range indicated on the unit nameplate On 3 phase units phases must be balanced within 2 Use the formula in Tables 7 and 8 to determine the percent age of voltage imbalance IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components On 208 230 v units transformer no 1 is wired for 230 v If 208 230 v unit is to be run with 208 v power supply the trans former must be rewired as follows 1 Remove cap from red 208 v wire 2 Remove cap from spliced orange 230 v wire Discon nect orange wire from black unit power wire 3 Caporange wire 4 Splice red wire and black unit power wire Cap wires IMPORTANT BE CERTAIN UNUSED WIRE
207. res industrial grade throwaway filters capable of withstanding face velocities up to 625 fpm OUTDOOR AIR INLET SCREENS Clean screens with steam or hot water and a mild detergent Do not use disposable filters in place of screens See Fig 37 for location of screens filter track assembly FLUE COLLECTOR MOTOR ASSEMBLY Fig 66 Gas Heat Section Details 90 Lubrication COMPRESSORS Each compressor is charged with the correct amount of oil at the factory The correct oil charge is shown in Tables 1A and 1B If oil is visible in the compressor sight glass check unit for operating readiness as described in Start Up section then start the unit Observe oil level and add oil if required to bring oil level in compressor crankcase up to between 4 and 1 3 of sight glass during steady operation If oil charge is above 5 sight glass do not remove any oil until the compressor crankcase heater has been energized for at least 24 hours with compressor off When additional oil or a complete charge is required use only Carrier approved compressor oil Petroleum Specialties Cryol 150 Texaco Inc eb RAPIT Capella WF 32 Witco Chemical Suniso 3GS IMPORTANT Do not use reclaimed oil or oil that has been exposed to the atmosphere Refer to Carrier Standard Service Techniques Manual Chapter 1 Refrigerants sec tion for procedures to add or
208. rmostat Wiring CV Only Install a Carrier approved accessory thermostat assembly per current price pages according to the installation instructions included with the ac cessory or these instructions Locate the thermostat on a solid interior wall in the conditioned space to sense the average temperature Route the thermostat cable or equivalent single leads of colored wire from the subbase terminals to the low voltage connection as shown on unit label wiring diagram and in Fig 32 NOTE For wire runs up to 50 ft use no 18 AWG American Wire Gage insulated wire 35 C minimum For 50 to 75 ft use no 16 AWG insulated wire 35 C minimum For over 75 ft use no 14 AWG insulated wire 35 C minimum All wire larger than no 18 AWG cannot be directly connected at the thermostat and will require a junction box and splice at the thermostat Set heat anticipators to 0 1 for all voltages Settings may be changed slightly to provide a greater degree of comfort for a particular installation Sensor Wiring CV or VAV The temperature sensor is wired into the unit control board See Fig 33 The unit is controlled with a T 55 or T 56 CV only zone sensor Terminal TH T 56 or T1 1 55 on the sensor is con nected to T1 of the base control board Terminal COM T 56 or T2 T 55 on the sensor is connected to T2 on the base con trol board If a T 56 set point override sensor is used the over ride connection SW on the sensor is co
209. rol of modulating economizer to provide free cool ing when outdoor conditions are suitable using supply air temperature as a set point support of remote occupied unoccupied input to start or stop the unit provide power exhaust output to an external power exhaust controller support supply air temperature reset to offset supply air set point support a field test for field check out support linkage to DAV digital air volume systems cooling capacity control of up to 6 stages plus econo mizer with compressors and unloaders to maintain sup ply air temperature set point during occupied periods control of one stage of heat to maintain return air tem perature at heating set point during occupied periods provide a variable frequency drive high voltage relay output to enable VFD control of heat interlock relay IAQ Indoor Air Quality sensor OAQ Outdoor Air Quality sensor DX compressor lockout occurs at 45 F outdoor air tem perature and is factory enabled on units with serial num ber 0600F or later This feature may be disabled through the use of a computer compressor Time Guard override power up minimum off and on times With the addition of a remote start stop switch heating or cooling is enabled during unoccupied periods as required to maintain space temperature to within unoccupied set points Occupied heating is enabled or disabled by the position of DIP dual in line package switch no 5
210. rol wiring schematic is shown in Fig 78 and 79 Control Circuit 115 V This control circuit is pro tected against overcurrent by a 5 2 amp circuit breaker CB3 Breaker can be reset If it trips determine cause of trouble be fore resetting A typical 115 v control wiring schematic is shown in Fig 80 and 81 Compressor Lockout Logic If any of the safeties trip the circuit will automatically reset providing the safety has reset and restart the compressor in 15 minutes If any of the safeties trip 3 times within a 90 minute period then the cir cuit will be locked out and will require manual resetting by turning off either the unit disconnect or the control circuit breaker or opening the thermostat If the compressors have bee off for more than 15 minutes and the outdoor air temperature OAT is less than 45 F then safeties will be ignored for 5 minutes Replacement Parts A complete list of replacement parts may be obtained from any Carrier distributor upon request LEGEND for Fig 77 83 Typical Wiring Schematics LEGEND AFS Airflow Switch HTSASP Heating Supply Air Set Point AHA Adjustable Heat Anticipator Potentiometer BP Building Pressure HV High Voltage BR Burner Relay IDM Induced Draft Motor C Contactor Compressor IFC Indoor Fan Contactor CAP Capacitor IFCB Indoor Fan Circuit Breaker CB Circuit Breaker IFM Indoor Fan Motor cc Cooling Compensator IFR
211. s 4 Pass 105 Fig 86 Typical Refrigerant Circuiting 48AJ AK AW AY035 fL c FPS CHHISHBO31 gt ix n PASS See ea ae 12 P Ci 1 L 4 PASS 12 PASS II Cul 12 55 12 5 4 55 12 55 LAC PASS 35 1 4 PASS EAST 4 FUERAT 4 PASS 12 E 1 4 PASSI PASS m T PRSS HPS LPS amp Fusible Tee or Relief Valve PASS 2 55 p X8 PAS L 4 55 Lee 4 Mugler Liquid Line Fitter Drier 4 PASS Fusible 4 PASS ps a Sean at Fla 4 PASS 2 2 4 PASS 4 PASS ETT 12 PASS 4 PASST LZ 4 C O
212. s zi NN LL Muffler 4 Pass 4 Pass Compressor 1 _4Pass_ 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass E 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass HPS 22 428 4 Pass Cut In 320 PSI 4 Cut out 420 PSI 4 Pass LPS HK02ZB027 Ee Cut In 22 PSI Ex Cut out 7 PSI 4 Pass ER Pass L pass 4 Pass F3 4 Pass 4 Pass HPS amp LPS mounted on 4 Pass compressor 4 Pass 4 Pass 4 Pass Muffler _4Pass 4 Pass Compressor 1 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass E 4 Pass 4 Pass 4 Pass 2 Lees 4 Pass 4 Pass 4 55 4 Pass 4 Pass 4 Pass 4 55 4 55 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass LEGEND FPS Freeze Protection Switch HPS High Pressure Switch LPS Low Pressure Switch Thermostatic Expansion Valve Fig 85 Typical Refrigerant Circuiting 48AJ AK AW AY027 030 104 HPS amp LPS mounted on compressor
213. s for the IGC control board are shown in Table 44 Table 44 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 9 FLASHES Software Lockout Diagnostic LEDs There are 3 LEDs red yellow and green on the lower right hand side of the control board The red light is used to check unit operation and alarms A constant pulse is normal unit operation A series of quick blinks indi cates an alarm Refer to Table 45 below for a description of alarms The yellow LED blinks during transmission with the CCN Carrier Comfort Network The green LED blinks dur ing transmission with the expansion board Table 45 Control Board LED Alarms LED ERROR RESET ACTION TAKEN BLINKS CODE DESCRIPTION METHOD BY CONTROL TROUBLESHOOTING COMMENTS 1 Normal Operation 5 None The expansion board and control board flash the red LED in one second intervals when the board is operating properly 2 13 Compressor 1 Safety Automatic Cooling disabled The high or low pressure safety switch for compressor no 1 and Automatic reset after has opened for 3 seconds The error will be cleared and Manual 15 minutes Manual if compressor
214. set of 4 pins with a jumper labeled J2 This determines the mode of operation The bottom two pins must be jumpered for direct operation Direct operation means that the staging modules are activated in sequence as the input signal increases At the upper right corner of the board is a set of 5 pins and jumper which determines the time constant for the control The time constant is the delay in response built into the con trols The jumper should be on the middle or bottom two pins for the maximum time constant The delay can be decreased if desired by moving the jumper progressively upward always jumpering adjacent pins Atthe lower left corner ofthe board below the terminal strip Is a resistor marked R27 This must be removed in order to ob tain the 0 to 10 vdc signal output There will not be a resistor on a factory supplied module but a resistor may be present on a replacement module and must be removed The R353 module has a terminal block with 7 connections available for wiring The 2 right hand terminals are for the 24 vac and common connections The next 2 terminals are for the 0 to 10 vde signal Consult the wiring label for wire identi fication if replacing the module The 3 left hand terminals are not used for this application The 5353 module has an LED light emitting diode a set of 4 jumper pins and 2 potentiometers The LED will light whenever the module is activated providing a visual indication of the number of e
215. shutoff valve see Fig 23 on page 29 3 Connect pressure gage to manifold pressure tap on unit gas valve 4 Supply gas pressure must not exceed 13 5 in wg Check pressure at field supplied shut off valve 5 Turn on manual gas stop and initiate a heating demand Jumper R to W1 in the control box to initiate heat On VAV units the RAT return air temperature must be less than or equal to 68 F for heating to be energized 6 Use the field test procedure to verify heat operation 7 After the unit has run for several minutes verify that in coming pressure is 6 0 in wg or greater and that the man ifold pressure is 3 5 in wg If manifold pressure must be adjusted refer to Gas Valve Adjustment section on page 93 Sequence of Operation NOTE Unit is shipped with default values that can be changed through Service Tool Building Supervisor or Comfort WORKS software or using an accessory Remote Enhanced Display See Table 35 for default values COOLING CONSTANT VOLUME CV UNITS On power up the control module will activate the initialization software of the control board The initialization software then reads DIP switch no 1 position to determine CV or VAV oper ation Next DIP switch no 2 is read to determine if the control Is thermostat or sensor type operation If switch 2 is open then sensors are employed If switch no 2 is closed thermostat is employed Initialization sequence clears all alarms and alerts r
216. st or barometric relief cannot be used because of return air ductwork will cover the power exhaust or barometric relief installation locations Power exhaust or barometric relief may be installed in the return air ductwork To convert the unit perform the following 1 Seal the bottom return openings of the unit with airtight panels capable of supporting the weight of a person 2 Remove the panels located below the economizer out door air dampers These openings will be used for the re turn air ductwork There are 2 panels on 48AJ AK020 050 and 48EJ EK024 048 units There are 3 panels on gt 97 78 020 050 024 048 150 47 060 054 068 INSIDE DIMENSION 48AJ AK060 and 48EJ EK054 068 units These open ings are normally used for power exhaust or barometric relief 3 Run the return air ductwork up to the openings One sin gle duct is recommended to connect to the unit over the return air openings See Fig 54 The return duct must in corporate a minimum 3 4 in flange for connection to the unit cabinet The unit does not have duct flanges for this conversion Side Supply and Return Units A8AW AY EW EY With Field Installed Power Exhaust in Return Duct Space must be available in the return duct to mount the power exhaust fan gravity relief modules Dimensions and suggested locations are shown in Fig 55 These instructions are a guideline and not a comprehensive procedure The design contractor must pro
217. support plate flange to the vestibule plate 10 Lift burner assembly out of unit 11 Reverse procedure to re install burners 59 199 OY ee SCALE 1 4 1 8 IN PIPE PLUG SEE DETAIL GAS VALVE SEE DETAIL MANIFOLD Sug RACK Fig 76 Main Burner Removal Filter Drier Replace whenever refrigerant system is ex posed to atmosphere 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 trou ble Determine the cause and correct it before resetting the breaker Overtemperature Each 06D type compressor 48AJ AK AW AY020 035 and 48EJ EK EW EY 024 038 units only has an internal protector to protect it against excessively high dis charge gas temperatures 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 power for the crank case heaters is drawn from the unit incoming power 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 compressors EVAPORATOR FAN MOTOR PROTECTION A manu al reset calibrated trip magnetic circuit breaker protects against overcurre
218. t be energized until a minimum of eight minutes of Stage 1 operation or as long as Stage 1 is making an increase in the space temperature trend If BASE MODULE CONTROL BOARD SU INPUT DEVICE LEGEND T Terminal NOTE The 4 to 20 mA input is a field supplied non Carrier EMS Energy Management System device the temperature trends stop improving but the demand still ex ceeds 2 0 F then Stage 2 heating will be energized SPACE TEMPERATURE RESET SENSOR VAV Only An accessory space temperature sensor T 55 or T 56 without offset is required Space temperature reset is used to reset the supply air temperature set point of a VAV system higher as the space temperature falls below the Occupied Cool set point As the space temperature falls below the Occupied Cool set point the supply air temperature will be reset upward as a function of the reset ratio Default is 3 Reset ratio is expressed in degrees change in supply air temperature per degree of space tempera ture change A reset limit will exist which will limit the maxi mum number of degrees the supply air temperature may be raised Default is 10 F Both the reset ratio and the reset limit are user definable The sequence of operation is as follows 1 The on off status of the unit supply fan is determined 2 Ifthe fan is on the sequence will check if the system is occupied 3 Ifthe system is in Occupied mode the sequence will de termine if the reset
219. t stage of heat the SGC will stage heat to maintain the heating set point set on the potentiometer of the SGC The HIR will be energized to com mand the zone terminals to open to maintain minimum heating airflow Heat2 Mode Heat2 mode is used on CV applications as they have 2 heat stages on the base unit control VAV units have only 1 heat stage and will not operate under Heat2 mode In this mode when the base unit calls for the second stage of heat the SGC will turn on all available heat stages This mode only occurs if Heat are ON and Cooll and Cool2 are OFF Accessory Navigator Display The Navigator Display is a field installed accessory See Fig 60 Navigator Display is to be connected to LEN connections at communication board DESCRIPTION Relay in parallel with Compressor 1 contactor Relay in parallel with Compressor 2 contactor 24V input from Base Unit control 24V input from Base Unit control Air proving switch contact closure on rise in static pressure Potentiometer range 35 70 F Potentiometer range 80 125 F Field installed in supply ductwork P N HH79NZ016 84 which is attached to the heating and cooling supply air set point potentiometers in heating section The Navigator Display ac cessory is required for all units with staged gas control The display module provides the user interface to the Staged Gas control system See Fig 60 The display has up and down arrow keys an
220. ted in the return duct 48AJ AK and 48EJ EK or return air plenum 48AW AY and 48EW EY Differential Enthalpy Sensor Installation To install the control perform the following procedure 1 Turn off all power Ensure disconnect is locked out 2 Remove the economizer inlet filters from the bottom of the right hand economizer hood See Fig 37 and 49 3 Remove the factory installed 620 ohm jumper between terminals SR and on the enthalpy control located inside the outdoor air hood 4 Connect the violet wire from the enthalpy sensor kit to the terminal on the enthalpy control Connect the blue wire from the enthalpy sensor kit to the SR terminal on the enthalpy control 5 Turn the enthalpy control set point potentiometer clock wise past the D setting on the enthalpy control to con figure the control to operate on differential enthalpy See Fig 47 6 Remove the return air enthalpy sensor from the accessory package Using the screws provided mount the sensor in side the return duct near the unit Do not locate the control too far from the unit or the wires will not reach from the sensor to the control On 48AW AY and 48EW EY units the enthalpy sensor can be installed in the return air sec tion of the unit under the return air dampers 7 Route the wires from the enthalpy sensor to the return air enthalpy control through the holes on the inside of the hinged filter access panel The holes are block
221. the economizer is disabled the damper will function as a 2 position damper Step 11 Position Power Exhaust Barometric Relief Damper Hood All electrical connections have been made and adjusted at the factory The power exhaust blowers and barometric relief dampers are shipped assembled and tilted back into the unit for shipping Brackets and extra screws are shipped in shrink wrap around the dampers If ordered each unit will have 4 48AJ AK AW AY 020 050 and 48EJ EK EW EYO24 048 units or 6 48A AK AW AYO60 and 48EJ EK EW EY054 068 units power exhaust blowers and motors or 4 48AJ AK AW AY020 050 and 48EJ EK EW EY024 048 units or 6 48AJ AK AW AY060 and 48EJ EK EW EY 054 068 units barometric relief dampers 1 Remove 9 screws holding each damper assembly in place See Fig 50 Each damper assembly is secured with 3 screws on each side and 3 screws along the bottom Save screws A CAUTION Be careful when tilting blower assembly Hoods and blow ers are heavy and can cause injury if dropped 2 Pivot each damper assembly outward until edges of damper assembly rest against inside wall of unit 3 Secure each damper assembly to unit with 6 screws across top 3 screws provided and bottom 3 screws from Step 1 of damper 4 With screws saved from Step 1 install brackets on each side of damper assembly 5 Remove tape from damper blades VAV DUCT PRESSURE TRANSDUCER The VAV duct pressure transducer VAV invert
222. 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 1 Turn off power to the control box 2 Cut the CCN wire and strip the ends of the red white ground and black conductors If a different network color scheme is used substitute appropriate colors 3 Remove the 3 pin male plug from the base control board in the main control box and connect the wires as follows a Insert and secure the red wire to terminal 1 of the 3 pin plug b Insert and secure the white ground wire to termi nal 2 of the 3 pin plug c Insert and secure the black wire to terminal 3 of the 3 pin plug 4 Insert the plug into the existing 3 pin mating connector on the base module in the main control box e SRE es RED _ __ n BLK BLK 1 a SSS SS SSS 1 je 222 M E WE 2 z 2 o pRC CONTROL BOARD SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 4 SPACE TEMPERATURE AVERAGING 4 SENSOR APPLICATION RED RED RED Eo ee Tila a TT TO BASE CONTROL BOARD I SENSOR 1 SENSOR 2 SENSOR 3 z le Seo eB mue BUK I r 1 INA SENSOR 4 SENSOR 5 SENSOR 6 5 E OM REIR NEM SS See 1 RR eee LLL SENSOR 7 SENSOR 8 SENSOR 9 SPACE TEMPERATURE A
223. turn duct dimensions are shown in Fig 5 7 and 11 13 Air distribution is shown in Fig 18 and 19 Refer to installation instructions shipped with roof curb for more information 48AW AY EW EY UNITS Remove shipping covers from supply and return air openings Attach field supplied ductwork to unit Connect to the unit with a single duct for all supply openings and with a single duct for all return openings Split ting of the airflow into branch ducts should not be done at the unit Sufficient duct length should be used prior to branching to ensure the air temperatures are well mixed within the duct work See Fig 8 10 and 14 16 for duct opening dimensions Secure all ducts to building structure Air distribution is shown in Fig 8 10 and 14 16 Install accessory barometric relief or power exhaust in the field fabricated return ductwork Refer to Step 11 Position Power Exhaust Barometric Relief Damper Hood section on page 52 for more information Instructions continued on page 28 SHUN pue 020 GND 614 43114405 41314 NOILYINSNI 01918 91 1 31025 Z vi13Q 335 43114405 41314 1815 INWD 43114405 41314 1134 9813008 53015 7 dhl 43114405 01313 LYN 011215 55082 GUND 3004 9NIHSV1j U31Nn02 53015 2 41 91 011235 55082 TIVE 3598 6 mo GUND HLIM 43114405 139 p 06 91 6
224. ult set points are 78 F cooling and 68 F heating if heating is present See Fig 26 for remote start stop wiring NOTE For units with a field supplied space temperature sen sor which have not had the base unit control board accessed via software to set an occupancy schedule the remote start stop closure will allow the unit to operate in the pre configured occupied default set points of 78 F cooling and 68 F heating Without this feature the unit will control to the unoccupied default set points of 90 F cooling and 55 F heating JUMPER CONNECTION FOR VOLTAGE OUTPUT JUMPER CONNECTION FOR CURRENT OUTPUT REMOTE START STOP SWITCH FIELD SUPPLIED em CONTROL BOX LEGEND Field Supplied Wiring Fig 26 Field Control Remote Start Stop An electronic expansion board may be field installed to pro vide the following features provide discrete inputs for fan status filter status field applied status and demand limit provide an output for the external alarm light indicator provide power exhaust fire outputs for direct control of modulated power exhaust stages during fire or smoke modes control of smoke control modes including evacuation smoke purge pressurization and fire shutdown modu lating power exhaust required When the unit is connected to the CCN Carrier Comfort Network the followin
225. ump OREN Board ON IN CONJUNCTION 225 Heat Operation CV CCN or Sensors Used VAV No Space Sensor CLOSED CV CV Thermostat LEGEND CCN Carrier Comfort Network Constant Volume VAV Variable Air Volume NOTES 1 The OPEN side of the DIP switch is marked OPEN When the rocker switch is on the OPEN side of the switch the switch is OPEN Base Control Board Only Field Test OFF 64 WITH FIELD TEST Set Minimum Damper Position Modulated Power Exhaust VAV Occupied Heat Disabled Constant Volume Power Exhaust Air Conditioner Operation Time Guard Override Electric Heat 2 The configuration of DIP switches 2 and 5 are dependent on DIP switch 1 If DIP switch 1 is set to OPEN VAV operation then DIP switches 2 and 5 will configure VAV functions When the unit is field tested DIP switch 4 to OPEN the func tion of DIP switch 6 changes and it is used to set the minimum damper position Recycle power to unit after modifying DIP switches This will allow the unit to access the new configurations and update its tables Table 18 DIP Switch Factory Settings UNIT L1 2 3 4 5 6 7 8 48AJ AW and 48EJ EW Closed 48AK AY and 48 Closed On 48EJ EW AJ AW units equipped with staged gas option DIP switch 7 should be closed Table 19 Fan Performance 48AJ AK020 030 Vertical Discharge Units AVAILABLE E
226. utput will be energized until the morning warm up cycle is complete Refer to Fig 59 for heat interlock relay wiring Table 39 Navigator Display Menu Structure RUN STATUS Auto Display SERVICE SUPPLY AIR VIEW TEST TEMPERATURE COOLING HEAT SUPPLY AIR OUTPUTH TEMPERATURE 1 N A SETE OINI HEAT SUPPLY AIR OUTPUT 2 TEMPERATURE 2 SERVICE TEST TEMPERATURES Software Version VERS COOLING SETPOINT 2 HEAT SUPPLY AIR OUTPUT 3 TEMPERATURE 3 HEAT OUTPUT 4 HEAT OUTPUT S HEAT OUTPUT 6 HEATING SETPOINT 2 SUPPLY FAN STATUS 85 SET OPERATING points INPUTS OUTPUTS CONFIGURATION TIME CLOCK ALARMS HEAT SETPOINT COOL SELECT INPUT 1 pini d Reset all HEAT CCN COOL Date Current INPUT H2 OUTPUT Configuration DATE N A Alarms GEN RCRN and Display Configuration DISP Currently Time Active TIME N A Alarms CRNT Occupancy Stage Gas Alarm Configuration Unoccupancy History Schedule HIST Number Reset Alarm History RHIS HEAT OUTPUT 5 Table 40 Occupied Heat and Morning Warm Up Operation and Controlling Factors OCCUPIED MORNING TEMPERATURE SOFTWARE HEAT WARM UP CONDITION VERSION ENABLED MAY START FOR HEAT DURING VIA TO START Smart start or 3 0 and Later DIP switch no 5 within RAT lt OHSP 10 minutes LEGEND OHSP Occupied Heat Set Point RAT Return Air Temperature SPACE TEMPERATURE S
227. values at the desired point to activate all exhaust fans The optional modulating power exhaust VAV standard CV optional is controlled by a modular electronic sequencer sys tem This system consists of a model R353 signal input module and 4 model 5353 staging modules for 48AJ AK AW AY 060 and 48EJ EK EW EY054 068 6 model S353 staging mod ules The signal input module receives a 0 to 10 vdc signal from the building pressure transducer which is mounted adja cent to the supply static transducer behind the filter access pan el The modules are mounted just below the unit control board The left module is the R353 and the 4 or 6 modules on the right are S353 modules for stages 1 through 4 or 6 On the unit wiring label the R353 is designated PESC and the S353 modules are designated PESI through PES4 PES6 for 48A AK AW AY060 and 48EJ EK EW EY 054 068 The building pressure transducer range is 0 5 to 0 5 in wg It is powered by a 0 to 10 vdc signal A factory installed hose at the Lo connection leads to atmosphere and a field supplied hose must be connected to the Hi connection and led into the building to a point where building pressure is to be controlled There is a plug button in the bulkhead just above the transducers for use in leading the hoses into the building via the return air ductwork There are 3 adjustments at the R353 module all of which have been factory set In the center of the circuit board is a
228. wing features can be utilized CCN demand limit participation modulated power exhaust override ability to use multiple space temperature sensors multi ples of 4 and 9 only to average space temperature CV and VAV only A field supplied T 55 space temperature sensor can be add ed to monitor room temperature and provide unoccupied over ride capability 1 hour When the unit is equipped with a field supplied space temperature sensor and a remote contact closure remote start stop the occupied default set points will monitor unit 33 operation The occupied default set points are 55 F supply air temperature cooling and 68 F return air temperature heating See Fig 26 for remote start stop wiring NOTE For units without a space temperature sensor and which have not had the base unit control board accessed via software to set an occupancy schedule the remote start stop closure will allow the unit to operate in the pre configured occupied default set points of 55 F supply air temperature cooling and 68 F return air temperature heating Without an occupancy schedule the unit will control to the unoccupied default set points of 90 F return air temperature cooling and 55 F return air temperature heating Features with Network Applications The base control board provides as standard a connection for use with a Carrier Comfort System and can also be integrated into a Carrier Com fort Network CCN When the unit
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230. xhaust fans running The jumper pins are ar ranged in a square format Two jumpers are used to determine 63 the mode of operation direct or reverse The 2 jumpers must be arranged horizontally for direct action factory set At the top of the module are two potentiometers The left potentiometer adjusts the offset The right potentiometer ad justs the differential The potentiometers are factory set for a nominal 0 in wg building pressure The offset set point is defined as the point at which a mod ule turns off a fan and is measured in terms of percent of the input signal For control purposes 0 offset is at an arbitrary floor which is established at 10 of the input signal or 1 vdc In this example the first stage will turn off at 30 3 vdc and the offset potentiometer will be set at 2096 The second stage will turn off at 50 signal 5 vdc and the offset potentiometer will be set at 4096 The fourth stage is at the maximum 75 offset which equates to 85 signal or 8 5 vdc The offset potentiometer is calibrated in 10 increments See below for building pressure to signal level BUILDING PRESSURE SIGNAL LEVEL in wg vdc 0 50 2 0 25 4 0 00 6 0 25 8 0 50 10 If the building pressure is controlled at 0 in wg offset of the first stage should be set at 50 which equates to 60 of the input signal or 6 vdc The other stages can then be set as de sired between 50 and 75 The default offset set points f
231. y Voltage 1 53 Never operate a motor where a phase imbalance in supply volt This amount of phase imbalance is satisfactory as it is below the age is greater than 2 Use the following formula to determine maximum allowable 2 the percent of voltage imbalance Voltage imbalance IMPORTANT If the supply voltage phase imbalance is J max voltage deviation from average voltage more than 296 contact your local electric utility company average voltage immediately 37 Table 7 Electrical Data 48AJ AK AW AY Units cont Em AUDI 22 88 48AJ AK VOLTAGE i ce 236 3 230 9 300 300 2 4 54 0 aa 23 6 23 6 259 9 254 5 300 300 253 1 244 9 300 300 208 230 187 253 69 2 345 74 8 68 0 E ea 23 6 23 6 276 7 268 5 350 300 TT ___ 269 6 259 6 350 300 23 6 23 6 293 2 283 2 350 350 102 6 125 12 6 115 2 125 110 12 050 414 288 4 27 cs 128 4 150 7 110 518 632 267 20 4 24 25 7 S 1030 125 ___ 291 3 284 5 350 350 25 74 980 35 4 35 4 326 7 319 9 400 400 306 0 296 5 350 350 208 230 ME gt 459 22 52900 35 4 35 4 341 4 331 9 400 400 46 414104 338 5 326 0 450 400 35 4 35 4 373 9 361 4 450 450 1483 175 154 3 175 173 2 200 1684 200 187 3 225 1193 150 138 2 150 1243 150 518 632 34 6 164 3

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