48EJ,EK,EW,EY024-048
Single Package Rooftop Units
Electric Cooling/Gas Heating
Installation, Start-Up and
Service Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
1. Improper installation, adjustment, alteration, serv-
ice, or maintenance can cause property damage, per-
sonal 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.
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Step 1 — Provide Unit Support . . . . . . . . . . . . . . . 1
• ROOF CURB
• ALTERNATE UNIT SUPPORT
Step 2 — Rig and Place Unit . . . . . . . . . . . . . . . . . . 2
• POSITIONING
• ROOF MOUNT
What to do if you smell gas:
Step 3 — Field Fabricate Ductwork . . . . . . . . . . . . 2
Step 4 — Install Flue Hood . . . . . . . . . . . . . . . . . . 12
Step 5 — Trap Condensate Drain . . . . . . . . . . . . 13
Step 6 — Install Gas Piping . . . . . . . . . . . . . . . . . . 13
Step 7 — Controls Options . . . . . . . . . . . . . . . . . . 13
• CONSTANT VOLUME APPLICATIONS
• VARIABLE AIR VOLUME (VAV) APPLICATIONS
Step 8 — Make Electrical Connections . . . . . . . 16
• POWER WIRING
1. DO NOT try to light any appliance.
2. DO NOT touch any electrical 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.
• FIELD POWER SUPPLY
• FIELD CONTROL WIRING
Step 9 — Make Outdoor-Air Inlet
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 haz-
ardous 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).
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
• ECONOMIZER
• ECONOMIZER SETTINGS
Step 10 — Position Power Exhaust/Barometric
Relief Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Step 11 — Install All Accessories . . . . . . . . . . . . 30
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-44
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-55
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 56-61
START-UP CHECKLIST . . . . . . . . . . . . . . . . CL-1,CL-2
INSTALLATION
Step 1 — Provide Unit Support
SAFETY CONSIDERATIONS
1. All panels must be in place when rigging.
Installation and servicing of air-conditioning equipment
can be hazardous due to system pressure and electrical com-
ponents. Only trained and qualified service personnel should
install, repair, or service air-conditioning equipment.
Untrained personnel can perform the basic maintenance
functions of cleaning coils and filters and replacing filters.
All other operations should be performed by trained service
personnel. When working on air-conditioning equipment, ob-
serve precautions in the literature, tags and labels attached
to the unit, and other safety precautions that may apply.
2. Unit is not designed for handling by fork truck.
ROOF CURB — Assemble or install accessory roof curb in
accordance with instructions shipped with this accessory. See
Fig. 1 and 2. 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 nec-
essary to permit unit drain to function properly. Unit level-
ing tolerance is shown in Fig. 1 and 2. Refer to Accessory
Roof Curb Installation Instructions for additional informa-
tion as required. When accessory roof curb is used, unit may
be installed on class A, B, or C roof covering material.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire ex-
tinguishers available for all brazing operations.
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 and 2. Improperly
applied gasket can also result in air leaks and poor unit
performance.
Before performing service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury.
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. 564-962
Printed in U.S.A.
Form 48E-5SI
Pg 1
8-97
Replaces: 48E-3SI
Tab 1a
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NOTES:
UNIT LEVELING TOLERANCES DIMENSIONS*
(Degrees and Inches)
1. All roof curb parts are to be 16 ga galvanized steel.
2. Dimensions are in inches.
3. To prevent standing water in the drain pan of the indoor
section and the heat exchangers, unit can only be pitched
as shown.
A
B
Deg.
in.
Deg.
in.
1.0
2.9
.50
.75
*From edge of unit to horizontal.
Fig. 1 — Roof Curb (Sizes 024-034)
3
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NOTES:
UNIT LEVELING TOLERANCES DIMENSIONS*
(Degrees and Inches)
1. All roof curb parts are to be 16 ga galvanized steel.
2. Dimensions are in inches.
3. To prevent standing water in the drain pan of the indoor
section and the heat exchangers, unit can only be pitched
as shown.
A
B
Deg.
in.
Deg.
in.
1.0
2.9
.50
.75
*From edge of unit to horizontal.
Fig. 2 — Roof Curb (Sizes 038-048)
4
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VFD — Variable Frequency Drive
NOTES:
1. Weights include economizer (STD).
2.
Center of gravity.
3. Do not locate adjacent units with flue dis-
charge facing economizer inlet. Minimum clear-
ances to be:
Adjacent Units: 15Ј-0Љ
Top of Units: No overhang
Condenser Coil: 4Ј-0Љ
Economizer Side: 6Ј-0Љ
Gas Heat Side: 4Ј-0Љ
Filter Access Side: 10Ј-0Љ (For Removal of
Evaporator Coil)
4. For smaller service and operational clear-
ances, contact Carrier Application Engineer-
ing department.
5. Bottom ducts designed to be attached to ac-
cessory roof curb. If unit is mounted on dun-
nage, it is recommended the ducts be
supported by cross braces as done on ac-
cessory roof curb.
6. Dimensions are in inches.
OPERATING
WEIGHT
A
B
CORNER WEIGHT (lb)
UNIT
SIZE
lb
ft-in.
ft-in.
1
2
3
4
48EJ,EKD024
48EJE024
4176
4256
4262
4342
4262
4342
4262
4342
6- 03⁄8 3-63⁄8
6- 15⁄16 3-611⁄16 917 973 1218 1148
5- 95⁄8 3-8
899 899 1232 1232
5-101⁄8 3-85⁄16 929 916 1240 1257
5- 95⁄8 3-8
899 899 1232 1232
5-101⁄8 3-85⁄16 929 916 1240 1257
5- 95⁄8 3-8
899 899 1232 1232
5-101⁄8 3-85⁄16 929 916 1240 1257
879 954 1220 1124
48EJ,EKD028
48EJE028
48EJ,EKD030
48EJE030
48EJ,EKD034
48EJE034
Fig. 3 — Base Unit Dimensions, 48EJ,EK024-034
5
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VFD — Variable Frequency Drive
OPERATING
WEIGHT
A
B
CORNER WEIGHT (lb)
UNIT
SIZE
NOTES:
1. Weights include economizer (STD).
lb
ft-in.
ft-in.
1
2
3
4
2.
Center of gravity.
48EJ,EKD038
48EJE038
4442
4602
4668
4828
4955
5115
7- 811⁄16 3-107⁄8
7-101⁄8 3-113⁄16 1080 934 1200 1388
7- 55⁄16 3-107⁄8
1033 906 1275 1455
7- 613⁄16 3-113⁄16 1094 945 1293 1496
7- 311⁄16 3-101⁄2
1068 953 1384 1550
7- 53⁄16 3-1013⁄16 1129 994 1401 1592
1021 894 1180 1347
3. Do not locate adjacent units with flue discharge facing econo-
mizer inlet. Minimum clearances to be:
Adjacent Units: 15Ј-0Љ
48EJ,EKD044
48EJE044
Top of Units: No overhang
Condenser Coil: 4Ј-0Љ
48EJ,EKD048
48EJE048
Economizer Side: 6Ј-0Љ
Gas Heat Side: 4Ј-0Љ
Filter Access Side: 10Ј-0Љ (For Removal of Evaporator Coil)
4. For smaller service and operational clearances, contact
Carrier Application Engineering department.
5. Bottom ducts designed to be attached to accessory roof curb.
If unit is mounted on dunnage, it is recommended the ducts be
supported by cross braces as done on accessory roof curb.
6. Dimensions are in inches.
Fig. 4 — Base Unit Dimensions, 48EJ,EK038-048
6
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VFD — Variable Frequency Drive
OPERATING
WEIGHT
A
B
CORNER WEIGHT (lb)
UNIT
SIZE
NOTES:
1. Weights include economizer (STD).
lb
ft-in.
6- 03⁄8
6- 15⁄16
5- 95⁄8
5-101⁄8
5- 95⁄8
5-101⁄8
5- 95⁄8
5-101⁄8
ft-in.
3-63⁄8
3-611⁄16
3-8
1
2
3
4
48EW,EYD024
48EWE024
4176
4256
4262
4342
4262
4342
4262
4342
879
917
899
929
899
929
899
929
954
973
899
916
899
916
899
916
1220
1218
1232
1240
1232
1240
1232
1240
1124
1148
1232
1257
1232
1257
1232
1257
2.
Center of gravity.
3. Do not locate adjacent units with flue discharge facing economizer inlet.
Minimum clearances to be:
48EW,EYD028
48EWE028
Adjacent Units: 15Ј-0Љ
3-85⁄16
Top of Units: No overhang
48EW,EYD030
48EWE030
3-8
3-85⁄16
3-8
Condenser Coil: 4Ј-0Љ
Economizer Side: 6Ј-0Љ
Gas Heat Side: 4Ј-0Љ
48EW,EYD034
48EWE034
Filter Access Side: 10Ј-0Љ (For Removal of Evaporator Coil)
4. For smaller service and operational clearances, contact Carrier
Application Engineering department.
3-85⁄16
5. Dimensions are in inches.
6. For side-supply/return applications, a single return and supply ductwork
connection is recommended for covering both return and both supply
openings.
Fig. 5 — Base Unit Dimensions, 48EW,EY024-034
7
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VFD — Variable Frequency Drive
OPERATING
WEIGHT
A
B
CORNER WEIGHT (lb)
UNIT
SIZE
NOTES:
1. Weights include economizer (STD).
lb
ft-in.
7- 811⁄16
7-101⁄8
7- 55⁄16
7- 613⁄16
7- 311⁄16
7- 53⁄16
ft-in.
3-107⁄8
3-113⁄16
3-107⁄8
3-113⁄16
3-101⁄2
3-1013⁄16
1
2
3
4
48EW,EYD038
48EWE038
4442
4602
4668
4828
4955
5115
1021
1080
1033
1094
1068
1129
894
934
906
945
953
994
1180
1200
1275
1293
1384
1401
1347
1388
1455
1496
1550
1592
2.
Center of gravity.
3. Do not locate adjacent units with flue discharge facing economizer
inlet. Minimum clearances to be:
48EW,EYD044
48EWE044
Adjacent Units: 15Ј-0Љ
Top of Units: No overhang
48EW,EYD048
48EWE048
Condenser Coil: 4Ј-0Љ
Economizer Side: 6Ј-0Љ
Gas Heat Side: 4Ј-0Љ
Filter Access Side: 10Ј-0Љ (For Removal of Evaporator Coil)
4. For smaller service and operational clearances, contact Carrier
Application Engineering department.
5. Dimensions are in inches.
6. For side-supply/return applications, a single return and supply duct-
work connection is recommended for covering both return and both
supply openings.
Fig. 6 — Base Unit Dimensions, 48EW,EY038-048
8
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WEIGHT
lb kg
48EJ,EK,EW,EYD024 4176 1894
A
B
C
UNIT
in.
mm
in.
mm
in.
mm
72.4 1839 42.4 1072
73.3 1862 42.7 1085
48EJ,EWE024
4256 1930
48EJ,EK,EW,EYD028
48EJ,EK,EW,EYD030 4262 1933
48EJ,EK,EW,EYD034
69.6 1768 44.0 1118
70.1 1781 44.3 1125
87.68 2227
48EJ,EWE028
48EJ,EWE030
48EJ,EWE034
4342 1969
48EJ,EK,EW,EYD038 4442 2015
48EJ,EWE038 4602 2087
48EJ,EK,EW,EYD044 4668 2117
48EJ,EWE044 4828 2190
48EJ,EK,EW,EYD048 4955 2248
48EJ,EWE048 5115 2320
92.7 2355 46.9 1191
94.1 2390 47.2 1199
89.3 2268 46.9 1191
90.8 2306 47.2 1199
87.7 2228 46.5 1181
89.2 2266 46.8 1189
150
3810
NOTICE TO RIGGERS:
ALL PANELS MUST BE IN PLACE
WHEN RIGGING.
NOTE: Rig with four cables and spread with two
92 in. (2337 mm) spreader bars. Maintain a dis-
tance of 74 in. (1880 mm) from top of unit to
eyehook.
NOTE:
Add 32 lb (14.5 kg) for domestic crating.
Add 312 lb (142 kg) for export crating (024-034 units).
Add 346 lb (157 kg) for export crating (038-048 units).
Add 250 lb (113 kg) for power exhaust.
Add 220 lb (100 kg) for copper condenser coil (024-034 units).
Add 285 lb (129 kg) for copper condenser coil (038,044 units).
Add 380 lb (172 kg) for copper condenser coil (048 unit).
Fig. 7 — Rigging Label
9
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Table 1 — Physical Data
UNIT 48EJ,EK,EW,EY
024D/E
028D/E
030D/E
034D/E
NOMINAL CAPACITY (tons)
20
25
27
30
OPERATING WEIGHT (lb)*
Unit
Al/Al† (Lo Heat/Hi Heat)
Al/Cu† (Lo Heat/Hi Heat)
Roof Curb (14-in. curb)
4176/4256
4396/4476
365
4262/4342
4482/4562
365
4262/4342
4482/4562
365
4262/4342
4482/4562
365
COMPRESSOR
Type Ckt 1
06D328
06D818
2
06D328
06D328
2
06D537
06D328
2
06D537
06D537
2
Ckt 2
Number of Refrigerant Circuits
Oil (oz) (Ckt 1, Ckt 2)
115, 88
115 ea.
115 ea.
115 ea.
REFRIGERANT TYPE
Operating Charge (lb-oz)
Circuit 1**
R-22
25-0
31-0
25-0
25-0
25-0
25-0
25-0
25-0
Circuit 2
3
CONDENSER COIL
Quantity
Rows...Fins/in.
Total Face Area (sq ft)
Cross-Hatched
⁄
8Љ Copper Tubes, Aluminum Lanced, Aluminum Pre-Coated, or Copper Plate Fins
1
1
1
1
4...15
33.3
4...15
33.3
4...15
33.3
4...15
33.3
CONDENSER FAN
Nominal Cfm
Quantity...Diameter (in.)
Motor Hp (1075 Rpm)
Propeller Type
13,420
2...30
1
13,420
2...30
1
13,420
2...30
1
13,420
2...30
1
3
EVAPORATOR COIL
Rows...Fins/in.
Total Face Area (sq ft)
Cross-Hatched
⁄
8Љ Copper Tubes, Aluminum Plate Fins, Intertwined Circuits
4...15
31.7
4...15
31.7
4...15
31.7
4...15
31.7
EVAPORATOR FAN
Centrifugal Type
Quantity...Size (in.)
2...20x15
Belt
2...20x15
Belt
2...20x15
Belt
2...20x15
Belt
Type Drive
Nominal Cfm
8,000
10††
S215T
S215T
Ball
10,000
10††
S215T
S215T
Ball
11,000
15††
D254T
S254T
Ball
12,000
15††
D254T
S254T
Ball
Motor Hp
5
15
7.5
15
D254T
S254T
10
S215T
S215T
20
10
20
Motor Frame Size (Standard)
(High Efficiency)
S184T
S184T
D254T
S254T
S213T
S213T
S256T
S256T
S215T
S215T
S256T
S256T
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
1200
4.4
1200
6.1
1200
4.9
1200
5.7
4.8
11⁄8
12.4
5.7
15⁄8
9.1
5.4
13⁄8
12.4
5.5
15⁄8
8.7
4.4
13⁄8
9.4
5.9
15⁄8
8.7
4.4
13⁄8
9.0
5.9
15⁄8
8.7
13⁄8
13⁄8
15⁄8
15⁄8
8.6
11.1
8.1
9.1
115⁄16
115⁄16
115⁄16
115⁄16
1...BX59 2...BX51 2...5VX530 1...BX59 1...5VX590 2...5VX530 2...BX52 2...5VX500 2...5VX530 2...BX51 2...5VX530 2...5VX530
Belt, Length (in.)
Pulley Center Line Distance (in.)
Factory Speed Setting (rpm)
62
54
53
62
59
15.6-18.4
962
53
15.0-17.9 15.6-18.4
1106 848
55
50
53
54
15.6-18.4
884
53
53
16.0-18.7 15.6-18.4 15.0-17.9
15.0-17.9
15.0-17.9
717
924
225
1096
773
1059
1187
1096
1187
FURNACE SECTION
Rollout Switch Cutout Temp (F)ሻ
Burner Orifice Diameter
(in. ...drill size)
225
225
225
Natural Gas
Liquid Propane
Std
Alt
.111...34
.089...43
.111...34
.089...43
.111...34
.089...43
.111...34
.089...43
Thermostat Heat Anticipator
Setting (amps)
Stage 1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
Stage 2
Gas Input (Btuh)
Stage 1 Low
262,500
394,000
350,000
525,000
82
262,500
394,000
350,000
525,000
82
262,500
394,000
350,000
525,000
82
262,500
394,000
350,000
525,000
82
High
Stage 2 Low
High
Efficiency (Steady State) (%)
Temperature Rise Range
Manifold Pressure (in. wg)
15-45/35-65
15-45/35-65
15-45/35-65
15-45/35-65
Natural Gas
Std
Alt
3.5
3.5
2
3.5
3.5
2
3.5
3.5
2
3.5
3.5
2
Liquid Propane
Gas Valve Quantity
Field Gas Connection Size
(in.-FPT)
1.5
1.5
1.5
1.5
HIGH-PRESSURE SWITCH (psig)
Cutout
Reset (Auto.)
426
320
426
320
426
320
426
320
LOW-PRESSURE SWITCH (psig)
Cutout
Reset (Auto.)
7
22
7
22
7
22
7
22
OUTDOOR-AIR FILTERS
Quantity...Size (in.)
8...16 × 25
4...20 × 25
RETURN-AIR FILTERS
Quantity...Size (in.)
10...20x24x2
10...20x24x2
10...20x24x2
10...20x24x2
POWER EXHAUST
Motor, Quantity...Hp
Fan, Diameter... Width (in.)
Direct Drive, 3-Speed, Single-Phase Motor (Factory-Wired for High Speed) and Forward-Curved Fan
4...1
11...10
4...1
4...1
4...1
11...10
11...10
11...10
NOTE: High heat is for 48EJ,EW only.
LEGEND
Al
—
—
Aluminum
Copper
VFD WEIGHTS (lb)
Cu
VFD
(Hp)
208/230 v
460 v
22
575 v
60
*Weight of unit does not include variable frequency drive (VFD) barometric relief, or power
exhaust. If a VFD is installed, add the VFD weight in the table at right.
†Evaporator coil fin material/condenser coil fin material.
5
7.5
10
15
20
25
30
20
51
37
64
**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.
††Motor and drive shown will deliver approximately 2.5 in. wg net external static. See
Table 2 for more information.
51
61
64
61
63
109
109
174
180
63
111
112
118
Rollout switch is manual reset.
105
172
10
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Table 1 — Physical Data (cont)
UNIT 48EJ,EK,EW,EY
038D/E
044D/E
048D/E
NOMINAL CAPACITY (tons)
35
40
45
OPERATING WEIGHT (lb)*
Unit
Al/Al† (Lo Heat/Hi Heat)
Al/Cu† (Lo Heat/Hi Heat)
Roof Curb (14-in. curb)
4442/4602
4727/4887
410
4668/4828
4953/5113
410
4955/5115
5335/5495
410
COMPRESSOR
Type Ckt 1
06D537
06D537
2
06EA250
06EA250
2
06EA265
06EA250
2
Ckt 2
Number of Refrigerant Circuits
Oil (oz) (Ckt 1, Ckt 2)
115 ea.
224 ea.
304, 224
REFRIGERANT TYPE
Operating Charge (lb-oz)
Circuit 1**
R-22
34-0
34-0
35-0
35-0
41-0
41-0
Circuit 2
3
CONDENSER COIL
Quantity
Rows...Fins/in.
Total Face Area (sq ft)
Cross-Hatched
⁄
8Љ Copper Tubes, Aluminum Lanced, Aluminum Pre-Coated, or Copper Plate Fins
2
2
1
1
3...15
58.3
3...15
58.3
4...15
3...15
66.7
CONDENSER FAN
Nominal Cfm
Quantity...Diameter (in.)
Motor Hp (1075 Rpm)
Propeller Type
27,064
4...30
1
27,064
4...30
1
27,064
4...30
1
3
EVAPORATOR COIL
Rows...Fins/in.
Total Face Area (sq ft)
Cross-Hatched
⁄
8Љ Copper Tubes, Aluminum Plate Fins, Intertwined Circuits
3...15
34.7
3...15
34.7
4...15
34.7
EVAPORATOR FAN
Centrifugal Type
2...20x15
Belt
Quantity...Size (in.)
2...20x15
Belt
2...20x15
Belt
Type Drive
Nominal Cfm
14,000
15††
D254T
S254T
Ball
16,000
18,000
25††
Motor Hp
10
20
15
20††
S256T
S256T
Ball
25
20
30
Motor Frame Size (Standard)
(High Efficiency)
S215T
S215T
S256T
S256T
D254T
S254T
S284T
S284T
S256T
S256T
S284T
S284T
Ball
S286T
S286T
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
1200
5.3
1200
5.7
1200
6.1
5.7
15⁄8
9.5
5.3
15⁄8
9.5
7.5
17⁄8
11.1
6.3
15⁄8
11.1
5.9
7.5
17⁄8
11.1
13⁄8
13.7
15⁄8
15⁄8
17⁄8
9.5
9.5
12.5
115⁄16
2...5VX530
53
115⁄16
2...5VX550
55
115⁄16
2...5VX630
63
1...5VX650
65
15.6-18.4
779
2...5VX550
55
2...5VX530
53
2...5VX590
59
14.6-17.6
1182
2...5VX570
57
15.0-17.9
993
2...5VX610
59
Belt, Length (in.)
Pulley Center Line Distance (in.)
Factory Speed Setting (rpm)
15.0-17.9
15.0-17.9
14.6-17.6
976
225
1050
976
1050
225
1134
225
1182
FURNACE SECTION
Rollout Switch Cutout Temp (F)ሻ
Burner Orifice Diameter
(in. ...drill size)
Natural Gas
Liquid Propane
Std
Alt
.120...31
.096...41
.120...31
.096...41
.120...31
.096...41
Thermostat Heat Anticipator
Setting (amps)
Stage 1
0.1
0.1
0.1
0.1
0.1
0.1
Stage 2
Gas Input (Btuh)
Stage 1 Low
300,000
600,000
400,000
800,000
82
300,000
600,000
400,000
800,000
82
300,000
600,000
400,000
800,000
82
High
Stage 2 Low
High
Efficiency (Steady State) (%)
Temperature Rise Range
Manifold Pressure (in. wg)
10-40/30-60
10-40/30-60
10-40/30-60
Natural Gas
Std
Alt
3.5
3.5
2
3.5
3.5
2
3.5
3.5
2
Liquid Propane
Gas Valve Quantity
Field Gas Connection Size (in.-FPT)
1.5
1.5
1.5
HIGH-PRESSURE SWITCH (psig)
Cutout
Reset (Auto.)
426
320
426
320
426
320
LOW-PRESSURE SWITCH (psig)
Cutout
Reset (Auto.)
7
22
7
22
7
22
OUTDOOR-AIR FILTERS
Quantity...Size (in.)
8...16 × 25
4...20 × 25
RETURN-AIR FILTERS
Quantity...Size (in.)
10...20x24x2
10...20x24x2
10...20x24x2
POWER EXHAUST
Motor, Quantity...Hp
Fan, Diameter... Width (in.)
Direct Drive, 3-Speed, Single-Phase motor (Factory-Wired for High Speed) and Forward Curved Fan
4...1
4...1
4...1
11...10
11...10
11...10
NOTE: High heat is for 48EJ,EW only.
LEGEND
Al
—
—
Aluminum
Copper
VFD WEIGHTS (lb)
Cu
VFD
(Hp)
208/230 v
460 v
22
575 v
*Weight of unit does not include variable frequency drive (VFD) barometric relief, or power
exhaust. If a VFD is installed, add the VFD weight in the table at right.
†Evaporator coil fin material/condenser coil fin material.
5
7.5
10
15
20
25
30
20
51
60
64
37
**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.
††Motor and drive shown will deliver approximately 2.5 in. wg net external static. See
Table 2 for more information.
51
61
64
61
63
109
109
174
180
63
111
112
118
Rollout switch is manual reset.
105
172
11
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Table 2 — Evaporator Fan Motor Data (Units with Starting Serial Numbers 4197 and Later)
MOTOR
SHEAVE
PITCH
DIAMETER
(in.)
FAN
SHEAVE
PITCH
DIAMETER
(in.)
MOTOR
FAN
BELT
TENSION
(Lb at
UNIT
SIZE
48E
BUSHING
DIAMETER
(in.)
BUSHING
DIAMETER
(in.)
OUTSIDE
BELT
LENGTH
MOTOR SHAFT
SHAFT MOTOR
SPEED SHEAVE
(rpm)
FAN
SHEAVE
BELT
(QUANTITY)
HP
DIA.
(in.)
.24 in.)
5
10
15
1.12
1.38
1.62
717
924
BK55
2BK50
2B5V56
4.8
4.4
5.7
None-1.125 1B5V124
12.4
8.6
B-1.9375
B-1.9375
B-1.9375
BX59
62
54
53
5.10
5.21
6.00
024
028
030
034
038
044
048
None-1.375
B-1.625
2B5V86
2B5V90
(2) BX51
(2) 5VX530
1096
9.1
7.5
10
15
1.38
1.38
1.62
773
962
1106
BK60H
1B5V60
2B5V54
5.4
6.1
5.5
H-1.375
H-1.375
B-1.625
1B5V124
1B5V110
2B5V86
12.4
11.1
8.7
B-1.9375
B-1.9375
B-1.9375
BX59
5VX590
(2) 5VX530
62
59
53
6.48
7.37
6.12
10
15
20
1.38
1.62
1.62
848
1059
1187
2BK50
2B5V48
2B5V58
4.4
4.9
5.9
None-1.375
B-1.625
B-1.625
2B5V94
2B5V80
2B5V86
9.4
8.1
8.7
B-1.9375
B-1.9375
B-1.9375
(2) BX52
(2) 5VX500
(2) 5VX530
55
50
53
5.27
6.63
7.31
10
15
20
1.38
1.62
1.62
884
1096
1187
2BK50
2B5V56
2B5V58
4.4
5.7
5.9
H-1.375
B-1.625
B-1.625
2B5V90
2B5V90
2B5V86
9.0
9.1
8.7
B-1.9375
B-1.9375
B-1.9375
(2) BX51
(2) 5VX530
(2) 5VX530
54
53
53
5.24
6.00
7.31
10
15
20
1.38
1.62
1.62
779
976
1050
1B5V60
2B5V52
2B5V56
6.1
5.3
5.7
None-1.375 1B5V136
13.7
9.5
9.5
B-1.9375
B-1.9375
B-1.9375
5VX650
(2) 5VX530
(2) 5VX550
65
53
55
7.62
6.37
7.60
B-1.625
B-1.625
2B5V94
2B5V94
15
20
25
1.62
1.62
1.88
976
1050
1182
2B5V52
2B5V56
2B5V74
5.3
5.7
7.5
B-1.625
B-1.625
B-1.875
2B5V94
2B5V94
2B5V110
9.5
9.5
11.1
B-1.9375
B-1.9375
B-1.9375
(2) 5VX530
(2) 5VX550
(2) 5VX590
53
55
59
6.37
7.60
7.60
20
25
30
1.62
1.88
1.88
993
1134
1182
2B5V62
2B5V80
2B5V74
6.3
5.9
7.5
B-1.625
B-1.875
B-1.875
2B5V110
2B5V124
2B5V110
11.1
12.5
11.1
B-1.9375
B-1.9375
B-1.9375
(2) 5VX570
(2) 5VX630
(2) 5VX590
57
63
59
7.22
7.36
9.07
NOTE: Motor shaft speed is 1750 rpm. The fan shaft diameter is 115⁄16 inches.
Step 4 — Install Flue Hood — Flue hood is shipped
inside gas section of unit. To install, secure flue hood to ac-
cess panel. See Fig. 10.
NOTE: When properly installed, flue hood will line up with
combustion fan housing. See Fig. 11.
Fig. 8 — Air Distribution — Thru-the-Bottom
Fig. 9 — Air Distribution — Thru-the-Side
Fig. 10 — Flue Hood Location
12
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Step 5 — Trap Condensate Drain — See Fig. 3-6
for drain location. Condensate drain is open to atmosphere
and must be trapped. Install a trapped drain at the drain lo-
cation. A trap at least 4-in. deep must be used. See Fig. 12.
Trap must be installed to prevent freeze-up.
Condensate pans are sloped so that water will completely
drain from the condensate pan to comply with indoor air qual-
ity guidelines. The condensate drain pan is fitted with a 1-in.
FPT coupling.
Step 6 — 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
National Fuel Gas Code, ANSI Z223.1.
1
Install manual gas shutoff valve with a ⁄8-in. NPT pres-
sure tap for test gage connection at unit. Field gas piping
must include sediment trap and union. See Fig. 13. An
Fig. 11 — Combustion Fan Housing Location
1
⁄
8-in. NPT is also located on the gas manifold adjacent to
the gas valve.
Do not pressure test gas supply while connected to unit.
Always disconnect union before servicing.
IMPORTANT: Natural gas pressure at unit gas con-
nection must not be less than 5 in. wg or greater than
13.5 in. wg.
Size gas-supply piping for 0.5-in. wg maximum pressure
drop. Do not use supply pipe smaller than unit gas
connection.
Step 7 — Controls Options — The control options
that the units can provide are based on the following param-
eters: CV (constant volume) or VAV (variable air volume)
operation; stand-alone unit with field-supplied sensors in-
stalled (CV or VAV); as a system via Carrier Comfort Sys-
tem (TEMP or VVT); optional electronic expansion board
installed (CV or VAV); linked to the Carrier Comfort
Network; and availability of a computer and software
(ComfortWorks™ Building Supervisor, and Service Tool) or
LID-2B accessory installed to access the base control board.
See Table 3.
Fig. 12 — Condensate Drain Trap Piping Details
(Typical Roof Curb or Slab Mount Shown)
NOTE: Access to the base control board allows unit occu-
pancy schedules, unit timeclock, and various set points to be
changed from their factory-defined default settings.
All units are equipped with a supply air thermistor (SAT)
located in the supply fan discharge and an outdoor air ther-
mistor (OAT) located in the outdoor air hood. Variable air
volume 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 stand-
ard (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 op-
erate at default values unless they are changed using appro-
priate input devices. The space sensor senses space tempera-
ture and may be equipped with a timed override feature, which
allows unit operation during unoccupied periods.
Fig. 13 — Field Gas Piping
The space sensors may be used in multiples of 4 or 9 to
achieve space temperature averaging. The use of a space sen-
sor also allows the unit to be turned on and off from a re-
mote signal.
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 outdoor-
air temperature
13
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Table 3 — Controls Options and Configurations (Non-Thermostat Applications)
UNIT CONFIGURATION
DEFAULT COOLING
DEFAULT HEATING
Unoccupied Cooling — 90 F (SPT)
Occupied Cooling — NA
Unoccupied Heating — 55 F (SPT)
Occupied Heating — NA
CV or VAV Unit with SPT Sensor
CV Unit with SPT Sensor and Remote
Start/Stop Switch
Unoccupied Cooling — 90 F (SPT)
Occupied Cooling — 78 F (SPT)
Unoccupied Heating — 55 F (SPT)
Occupied Heating — 68 F (SPT)
Unoccupied Cooling — 90 F (RAT)
Occupied Cooling — 55 F (SAT)
Unoccupied Heating — 55 F (RAT)
Occupied Heating — 68 F (RAT)*
VAV Unit Remote Start/Stop Switch Only
VAV Unit with SPT Sensor and Remote
Start/Stop Switch
Unoccupied Cooling — 90 F (SPT)
Occupied Cooling — 55 F (SAT)
Unoccupied Heating — 55 F (SPT)
Occupied Heating — 68 F (RAT)*
LEGEND
*With DIP Switch No. 5 configured to OPEN (Occupied Heat
Enabled).
CV
—
—
—
—
—
—
Constant Volume
Not Available
Return-Air Temperature
Supply-Air Temperature
Space Temperature
Variable Air Volume
NA
NOTE: Space temperature sensor and remote start/stop switch are
field-supplied.
RAT
SAT
SPT
VAV
• 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
• ability to initiate timed override from T-55 or T-56 sensors
for a timed period of 1 to 4 hours
• ability to use multiple space temperature sensors to aver-
age the space temperature
• temperature compensated start to calculate early start times
before occupancy
• access to the Display, Maintenance, Configuration,
Service, and Set Point data tables through network
software
When the unit is equipped with a field-supplied space
temperature 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 default set points
are 78 F cooling and 68 F heating. See Fig. 14 for remote
start/stop wiring.
• provide power exhaust output to an external power ex-
haust 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 by accessing the stand-
ard unit control board via software with a computer. These
features are:
• electronic expansion board features (if installed)
• control board diagnostics
NOTE: For units with a field-supplied space temperature se-
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 (based on return-air
temperature) 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.
An electronic expansion board may be field-installed to
provide the following features:
• control of modulating economizer damper to maintain in-
door air quality (IAQ) when outdoor conditions are
suitable
• 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
NOTE: A CV unit without a thermostat requires a field-
supplied sensor for operation.
Features with Sensor Control of Unit (Stand-Alone Appli-
cations — Unit control is limited to CV unoccupied default
set points, 90 F for cooling, 55 F for heating. There are
2 sensor options available:
• T-55 sensor will monitor room temperature and provide
unoccupied override capability (1 hour)
• T-56 sensor will monitor room temperature, provide un-
occupied override capability (1 hour), and provide a tem-
perature offset of 5° F.
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. 15.
• 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 (modulating power
exhaust required)
When the unit is connected to the CCN (Carrier Comfort
Network), the following expansion board features can be
utilized:
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 occu-
pied 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
Additional features with sensor control of unit (with com-
puter access) are:
• perform Demand Limit functions based on CCN loadshed
commands or the state of the discrete input
• alarm monitoring of all key parameters
• CCN protocol
• provides CCN IAQ participation
• 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
See Carrier TEMP or VVT (Variable Volume and Tem-
perature) literature for complete TEMP (single zone) or VVT
(multi-zone) application information.
14
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VARIABLE AIR VOLUME (VAV) APPLICATIONS
Features with Stand-Alone Applications — The units, as
shipped, are operable as stand-alone units with the addition
of a timeclock to establish unit start and stop times.
Heating and cooling in both on and off modes is con-
trolled to default values by the base unit control. Set points
may be changed with appropriate input devices.
REMOTE
START/STOP
SWITCH
(FIELD-SUPPLIED)
R
Y1
Y2
W1
W2
G
The control has an on-board occupancy schedule which
can be set using an input device and eliminates the need for
an external timeclock.
During both the on and off periods, cooling operation is
controlled to the supply air setting and heating is controlled
to the return air setting (or to the optional space temperature
sensor). During the on period, the supply fan runs continu-
ously. During the off period, the supply fan will be activated
if the return air sensor is outside of the set points and will
run log 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.
C
X
CONTROL
BOX
LEGEND
Field Supplied Wiring
Fig. 14 — Field Control Remote Start/Stop
Base unit control supports a Heat Interlock Relay (field
supplied) to fully open the VAV terminal devices during heat-
ing operation.
JUMPER CONNECTION
FOR VOLTAGE OUTPUT
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
• control of modulating economizer to provide free cooling
when outdoor conditions are suitable, using supply-air tem-
perature as a set point
• support of remote occupied/unoccupied input to start or
stop the unit
JUMPER CONNECTION
FOR CURRENT OUTPUT
• provide power exhaust output to an external power ex-
haust controller
• support supply-air temperature reset to offset supply air
set point
• support a field test for field check out
• support linkage to DAV systems
• cooling capacity control of up to 6 stages plus economizer
with compressors and unloaders to maintain supply air tem-
perature 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 out-
put to enable VFD
Fig. 15 — Indoor Air Quality Sensor Configuration
• control of heat interlock relay
• 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.
Additional features may be provided with Electronic
Access to Unit Control Board. These features are:
• additional control board diagnostics
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
integrated into a Carrier Comfort Network.
When the unit is accessed via a PC equipped with Com-
fortWorks™, Building Supervisor, or Service Tool software,
or accessory LID-2B, the following features can be
accessed:
• electronic expansion board features (if installed)
• control of the economizer damper and indoor fan to obtain
unoccupied free cooling
• on-board timeclock can be programmed
• occupancy schedules can be programmed
• unit set points can be changed
• 365-day timeclock with backup (supports minute, hour, day,
month, and year)
• 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 communi-
cation bus. See Fig. 16. The timeclock has a 10-hour mini-
mum back-up time to provide for unit power off for servic-
ing 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.
• holiday table containing up to 18 holiday schedules
• occupancy control with 8 periods for unit operation
• support a set of display, maintenance, configuration, serv-
ice, and set point data tables for interface with Building
Supervisor, ComfortWorks, or Service Tool software soft-
ware or accessory LID-2B
15
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When a VAV unit with a space temperature sensor is ac-
cessed 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
provide the following features:
Step 8 — 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 [maxi-
mum overcurrent protection] of unit is on the informative
plate). All field wiring must comply with NEC and all local
codes. Size wire based on MCA (minimum circuit amps) on
the unit informative plate. See Fig. 17 for power wiring con-
nections to the unit power terminal block and equipment ground.
The main power terminal block is suitable for use with
aluminum or copper wire. See Fig. 17. Units have circuit
breakers for compressors, fan motors, and control circuit. If
required by local codes, provide an additional disconnect switch.
Whenever external electrical sources are used, unit must be
electrically grounded in accordance with local codes, or in
absence of local codes, with NEC, ANSI C1-latest year.
• fan status
• filter status
• field-applied status
• demand limiting
• IAQ Sensor
• OAQ Sensor
• alarm light
• fire unit shutdown
• fire pressurization
• fire evacuation
• fire smoke purge
When the unit is connected to the CCN (Carrier Comfort
Network), the following expansion board features can be
utilized:
All field wiring must comply with NEC and local code
requirements.
FIELD POWER SUPPLY — Unit is factory wired for volt-
age shown on unit nameplate. See Table 4 for electrical data.
Field wiring can be brought into the unit from bottom
(through basepan and roof curb) or through side of unit (cor-
ner post next to control box).
• CCN IAQ (indoor air quality) participation
• CCN OAQ (outdoor air quality) participation
• CCN demand limit participation
A 31⁄2-in. NPT coupling for field power wiring and a
3
⁄
4-in. NPT coupling for 24-v control wiring are provided in
basepan. In the side post, there are two 21⁄2-in. (024-034) or
3-in. (038-048) knockouts for the field power wiring. See
Fig. 3-6. If control wiring is to be brought in through the
• modulated power exhaust override
• ability to use multiple space temperature sensors (mul-
tiples of 4 and 9 only) to average space temperature (DAV
only)
7
side of unit, a ⁄8-in. diameter hole is provided in the con-
denser side post next to the control box.
Afield-supplied T-55 space temperature sensor can be added
to monitor room temperature and provide unoccupied over-
ride capability (1 hour).
If disconnect box is mounted to corner post, be careful
not to drill any screws into the condenser coil.
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
31⁄2-in. hole to the disconnect box and back into unit to the
main control box.
Use strain relief going into control box through 21⁄2-in.
diameter hole provided. After wires are in unit control box,
connect to power terminal block (see Power Wiring section
above).
Low-voltage wiring must be run in watertight conduit from
the basepan to control box and through 7⁄8-in. diameter hole
provided in bottom of unit control box. Field-supplied strain
relief must be used going into the box. After wiring is in
control box, make connections to proper terminals on ter-
minal blocks (see Field Control Wiring section on page 21).
When the unit is equipped with a field-supplied space tem-
perature sensor and a remote contact closure (remote start/
stop) the occupied default set points will monitor unit op-
eration. The occupied default set points are 55 F (supply air)
cooling and 68 F (return air temperature) heating. See
Fig. 14 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 soft-
ware to set an occupancy schedule, the remote start/stop clo-
sure will allow the unit to operate in the pre-configured oc-
cupied 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 unoccu-
pied default set points of 90 F (return air) cooling and 55 F
(return air) heating.
Features with NetworkApplications — The base control board
provides, as standard, a connection for use with a Carrier
Comfort System and can also be integrated into a Carrier
Comfort Network. When the unit is accessed via a PC equipped
with ComfortWorks™, Building Supervisor, or Service Tool
software or LID-2B accessory, the following features can be
accessed:
Install conduit connector in unit basepan as shown in
Fig. 3-6. Route power and ground lines through connector to
terminal connections in unit control box as shown on unit
wiring diagram and Fig. 17.
Routing Through Side of Unit — Route power wiring in field-
supplied watertight conduit into unit through 21⁄2-in. hole.
See Fig. 17.
Use field-supplied strain relief going into control box through
21⁄2-in. diameter hole provided. After wires are in unit con-
trol box, connect to power terminal block (see Power Wiring
section on this page).
• 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 communi-
cation bus. See Fig. 16. The internal timeclock has a 10-hour
minimum back-up time to provide for unit power off for ser-
vicing unit or during unexpected power outages. For com-
plete Carrier Comfort System (CCS) or Carrier Comfort
Network (CCN) features and benefits, refer to the product
literature.
Bring low-voltage control wiring through factory-drilled
7
⁄
8-in. diameter hole in condenser side post. Use strain relief
going into 7⁄8-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 sec-
tion on page 21).
16
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LEGEND
*Where X is the unit control software version number.
CCN
COM
D
LED
N.C.
—
—
—
—
—
Carrier Comfort Network
Common
N.O.
R
SIO
SW
T
—
—
—
—
—
Normally Open
Relay
Diode
Serial Input/Output
Switch
Light-Emitting Diode
Normally Closed
Terminal
Fig. 16 — Control Board Diagram
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Table 4 — Electrical Data
COMPRESSOR
No. 1 No. 2
VOLTAGE
RANGE
POWER COMBUSTION
EXHAUST FAN MOTOR
OFM
IFM
POWER SUPPLY
MCA MOCP*
UNIT
SIZE
NOMNAL
VOLTAGE
FLA
(ea)
48E (3 Ph 60 Hz)
Min Max RLA LRA RLA LRA Qty Hp
Hp FLA FLA LRA
FLA
—
—
0.96
0.96
0.96
0.96
0.96
0.96
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.96
0.96
0.96
0.96
0.96
0.96
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.96
0.96
0.96
0.96
0.96
0.96
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
101.8/100.3 125/125
125.4/123.9 150/150
115.9/113.1 150/150
139.5/136.7 175/175
131.3/127.1 150/150
154.9/150.7 175/175
16.7/
15.2
5
23.6 41.6
—
—
30.8/
28.0
208/230
187 254 39.1 228 25.6 160
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
5.3 10
23.6 41.6
—
—
46.2/
42.0
15
5
23.6 41.6
—
—
49.4
62.0
55.8
68.4
62.8
75.4
40.5
53.1
45.4
58.0
51.4
64.0
60
80
70
80
80
90
50
60
60
70
60
80
7.6
12.6 23.6
—
—
024
028
030
460
575
414 508 19.9 114 11.5
80
64
2.7 10 14.0
15 21.0
12.6 23.6
—
—
12.6 23.6
—
—
5
6.1
12.6 23.6
—
—
518 632 16.0
91
9.6
2.4 10 11.0
15 17.0
12.6 23.6
—
—
12.6 23.6
—
—
122.8/120.6 150/150
146.4/144.2 175/175
129.4/126.6 150/150
153.0/150.2 175/175
144.8/140.6 175/175
168.4/164.2 200/200
24.2/
7.5
22.0
23.6 41.6
—
—
30.8/
5.3 10
208/230
187 254 39.1 228 39.1 228
28.0
23.6 41.6
—
—
46.2/
15
42.0
23.6 41.6
—
—
61.2
73.8
64.2
76.8
71.2
83.8
49.8
62.4
51.8
64.4
57.8
70.4
80
90
80
90
90
100
60
70
60
80
70
80
7.5 11.0
2.7 10 14.0
15 21.0
12.6 23.6
—
—
460
414 508 19.9 114 19.9 114
12.6 23.6
—
—
12.6 23.6
—
—
7.5
9.0
12.6 23.6
—
—
575
518 632 16.0
91 16.0
91
2.4 10 11.0
15 17.0
12.6 23.6
—
—
12.6 23.6
—
—
151.9/149.1 200/200
175.5/172.7 225/225
167.3/163.1 225/225
190.9/186.7 225/225
180.5/175.1 225/225
204.1/198.7 250/250
30.8/
10
28.0
23.6 41.6
—
—
46.2/
5.3 15
208/230
187 254 57.1 266 39.1 228
42.0
23.6 41.6
—
—
59.4/
20
54.0
23.6 41.6
—
—
71.3
83.9
78.3
90.9
84.3
96.9
57.4
70.0
63.4
76.0
68.4
81.0
90
100
100
110
100
110
70
10 14.0
2.7 15 21.0
20 27.0
12.6 23.6
—
—
460
414 508 25.6 120 19.9 114
12.6 23.6
—
—
12.6 23.6
—
—
10 11.0
12.6 23.6
90
—
—
80
575
518 632 20.5
96 16.0
91
2.4 15 17.0
20 22.0
12.6 23.6
90
—
—
80
12.6 23.6
100
See Legend and Notes on page 19.
18
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Table 4 — Electrical Data (cont)
COMPRESSOR
No. 1 No. 2
VOLTAGE
RANGE
POWER COMBUSTION
EXHAUST FAN MOTOR
OFM
IFM
POWER SUPPLY
MCA MOCP*
UNIT NOMINAL
SIZE
VOLTAGE
FLA
(ea)
48E (3 Ph 60 Hz)
Min Max RLA LRA RLA LRA Qty Hp
Hp FLA FLA LRA
FLA
—
—
0.96
0.96
0.96
0.96
0.96
0.96
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.96
0.96
0.96
0.96
0.96
0.96
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
169.9/167.1 225/200
193.5/190.7 250/225
185.3/181.1 225/225
208.9/204.7 250/250
198.5/193.1 250/250
222.1/216.7 275/250
30.8/
28.0
10
23.6 41.6
—
—
46.2/
42.0
208/230
187 254 57.1 266 57.1 266
2
2
2
4
4
4
1
1
1
1
1
1
5.3 15
20
23.6 41.6
—
—
59.4/
54.0
23.6 41.6
—
—
77.0
89.6
84.0
96.6
90.0
102.6
61.9
74.5
67.9
80.5
72.9
85.5
100
110
100
110
110
125
80
10 14.0
2.7 15 21.0
20 27.0
12.6 23.6
—
—
034
460
575
414 508 25.6 120 25.6 120
12.6 23.6
—
—
12.6 23.6
—
—
10 11.0
12.6 23.6
90
—
—
80
518 632 20.5
96 20.5
96
2.4 15 17.0
20 22.0
12.6 23.6
100
90
—
—
12.6 23.6
100
—
—
180.5/177.7 225/225
204.1/201.3 250/250
195.9/191.7 250/225
219.5/215.3 275/250
209.1/203.7 250/250
232.7/227.3 275/275
30.8/
10
28.0
23.6 41.6
—
—
46.2/
5.3 15
208/230
187 254 57.1 266 57.1 266
414 508 25.6 120 25.6 120
518 632 20.5 96 20.5 96
42.0
23.6 41.6
—
—
59.4/
20
54.0
23.6 41.6
—
—
82.4
95.0
89.4
102.0
95.4
108.0
66.7
79.3
72.7
85.3
77.7
90.3
100
110
110
125
110
125
80
10 14.0
2.7 15 21.0
20 27.0
12.6 23.6
—
—
038
460
12.6 23.6
—
—
12.6 23.6
—
—
10 11.0
12.6 23.6
90
—
—
90
575
2.4 15 17.0
20 22.0
12.6 23.6
100
90
—
—
12.6 23.6
110
LEGEND
EXAMPLE: Supply voltage is 460-3-60.
AB = 452 v
BC = 464 v
AC = 455 v
FLA
—
—
Full Load Amps
HACR
Heating, Air Conditioning and
Refrigeration
IFM
—
—
—
—
—
—
—
Indoor (Evaporator) Fan Motor
Locked Rotor Amps
Minimum Circuit Amps
Maximum Overcurrent Protection
National Electrical Code
Outdoor (Condenser) Fan Motor
Rated Load Amps
452 + 464 + 455
LRA
MCA
MOCP
NEC
OFM
RLA
Average Voltage =
=
3
1371
3
or
= 457
*Fuse or HACR circuit breaker.
Determine maximum deviation from average voltage.
(AB) 457 − 452 = 5 v
(BC) 464 − 457 = 7 v
(AC) 457 − 455 = 2 v
NOTES:
Maximum deviation is 7 v.
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. Canadian units may be fuse or circuit breaker.
2. Unbalanced 3-Phase Supply Voltage
Determine percent voltage imbalance.
7
% Voltage Imbalance = 100 x
457
Never operate a motor where a phase imbalance in supply volt-
age is greater than 2%. Use the following formula to determine
the percent voltage imbalance.
= 1.53%
This amount of phase imbalance is satisfactory as it is below the
maximum allowable 2%.
% Voltage Imbalance
IMPORTANT: If the supply voltage phase imbalance is more
than 2%, contact your local electric utility company
immediately.
max voltage deviation from average voltage
= 100 x
average voltage
19
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Table 4 — Electrical Data (cont)
COMPRESSOR
No. 1 No. 2
VOLTAGE
RANGE
POWER COMBUSTION
EXHAUST FAN MOTOR
OFM
IFM
POWER SUPPLY
MCA MOCP*
UNIT NOMINAL
SIZE
VOLTAGE
FLA
(ea)
48E (3 Ph 60 Hz)
Min Max RLA LRA RLA LRA Qty Hp
Hp FLA FLA LRA
FLA
—
—
0.96
0.96
0.96
0.96
0.96
0.96
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.96
0.96
0.96
0.96
0.96
0.96
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
223.1/218.9 275/275
246.7/242.5 300/300
236.3/230.9 300/300
259.9/254.5 300/300
251.7/244.9 300/300
275.3/268.5 300/300
46.2/
42.0
15
23.6 41.6
—
—
59.4/
54.0
208/230
187 254 69.2 345 69.2 345
414 508 28.8 173 28.8 173
518 632 26.7 120 26.7 120
187 254 82.1 446 69.2 345
414 508 42.3 223 28.8 173
518 632 34.6 164 26.7 120
4
4
4
4
4
4
1
1
1
1
1
1
5.3 20
25
23.6 41.6
—
—
74.8/
68.0
23.6 41.6
—
—
96.6
109.2
102.6
115.2
109.6
122.2
86.7
125
125
125
125
125
150
110
125
110
125
110
125
15 21.0
2.7 20 27.0
25 34.0
12.6 23.6
—
—
044
460
575
12.6 23.6
—
—
12.6 23.6
—
—
15 17.0
12.6 23.6
99.3
—
—
91.7
2.4 20 22.0
25 27.0
12.6 23.6
104.3
96.7
—
—
12.6 23.6
109.3
—
—
252.4/247.0 300/300
276.0/270.6 300/300
267.8/261.0 300/300
291.4/284.6 300/300
281.0/273.0 300/300
304.6/296.6 350/300
59.4/
20
54.0
23.6 41.6
—
—
74.8/
5.3 25
208/230
68.0
23.6 41.6
—
—
88.0/
30
80.0
23.6 41.6
—
—
119.5
132.1
126.5
139.1
132.5
145.1
101.6
114.2
106.6
119.2
111.6
124.2
150
150
150
175
150
175
125
125
125
150
125
150
20 27.0
2.7 25 34.0
30 40.0
12.6 23.6
—
—
048
460
12.6 23.6
—
—
12.6 23.6
—
—
20 22.0
12.6 23.6
—
—
575
2.4 25 27.0
30 32.0
12.6 23.6
—
—
12.6 23.6
LEGEND
EXAMPLE: Supply voltage is 460-3-60.
FLA
—
—
Full Load Amps
AB = 452 v
BC = 464 v
AC = 455 v
HACR
Heating, Air Conditioning and
Refrigeration
IFM
—
—
—
—
—
—
—
Indoor (Evaporator) Fan Motor
Locked Rotor Amps
Minimum Circuit Amps
Maximum Overcurrent Protection
National Electrical Code
Outdoor (Condenser) Fan Motor
Rated Load Amps
452 + 464 + 455
LRA
MCA
MOCP
NEC
OFM
RLA
Average Voltage =
=
3
1371
3
or
= 457
*Fuse or HACR circuit breaker.
Determine maximum deviation from average voltage.
(AB) 457 − 452 = 5 v
(BC) 464 − 457 = 7 v
(AC) 457 − 455 = 2 v
NOTES:
Maximum deviation is 7 v.
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. Canadian units may be fuse or circuit breaker.
2. Unbalanced 3-Phase Supply Voltage
Determine percent voltage imbalance.
7
% Voltage Imbalance = 100 x
457
Never operate a motor where a phase imbalance in supply volt-
age is greater than 2%. Use the following formula to determine
the percent voltage imbalance.
= 1.53%
This amount of phase imbalance is satisfactory as it is below the
maximum allowable 2%.
% Voltage Imbalance
IMPORTANT: If the supply voltage phase imbalance is more than
2%, contact your local electric utility company immediately.
max voltage deviation from average voltage
= 100 x
average voltage
20
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Sensor Wiring (CV or VAV) — The temperature sensor is
wired into the unit control board. See Fig. 21.
IMPORTANT: THE VAV (variable air volume) units
use variable frequency drives, which generate, use and
can radiate radio frequency energy. If units are not in-
stalled and used in accordance with these instructions,
they may cause radio interference. They have been tested
and found to comply with limits of a Class A com-
puting device as defined by FCC (Federal Communi-
cations Commission) regulations, Subpart J of Part 15,
which are designed to provide reasonable protection
against such interference when operated in a commer-
cial environment.
The unit is controlled with a T-55 or T-56 (CV only) zone
sensor. Terminal TH (T-56) or T1 (T-55) on the sensor is
connected to T1 of the base module board. Terminal COM
(T-56) or T2 (T-55) on the sensor is connected to T2 on the
base module board. If a T-56 set point override sensor is used,
the override connection SW on the sensor is connected to T3
on the base module board.
If more than sensor is being used and averaged, sensors
must be wired in multiples of 4 or 9. See Fig. 22.
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
HN61KK041.
The unit must be electrically grounded in accordance
with local codes and NEC ANSI/NFPA 70 (National Fire
Protection Association).
Affix crankcase heater sticker (located in the installers packet)
to unit disconnect switch.
Voltage to compressor terminals during compressor op-
eration must be within the voltage range indicated on the
unit nameplate. On 3-phase units, phases must be balanced
within 2%. Contact local power company for correction of
improper voltage or phase imbalance. Unit failure due to op-
eration of unit on improper line voltage or with excessive
phase imbalance constitutes abuse and may cause damage to
unit 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
transformer 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.
LEGEND
GND
NEC
TB
—
—
—
Ground
National Electrical Code
Terminal Block
NOTE: Maximum wire size for TB1 is 500 MCM.
3. Cap orange wire.
4. Splice red wire and black unit power wire. Cap wires.
Fig. 17 — Field Power Wiring Connections
IMPORTANT: BE CERTAIN UNUSED WIRES
ARE CAPPED. Failure to do so may damage the
transformers.
FIELD CONTROL WIRING — The unit can use 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. 18 and 19.
Thermostat Wiring (CV Only) — Install a Carrier-approved
accessory thermostat assembly (per current price pages) ac-
cording 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. 20.
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 mini-
mum). 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.
LEGEND
C
—
—
—
—
—
Compressor/Contactor
Circuit Breaker
Dual In-Line Package
Fuse
IF
—
—
—
—
—
Indoor Fan
CB
DIP
FU
HR
OF
Outdoor Fan
PEC
TB
TRAN
Power Exhaust Controller
Terminal Block
Transformer
Heater Relay
Set heat anticipators to 0.1 for all voltages.
Fig. 18 — Control Box Diagram (Sizes 024-034)
21
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LEGEND
C
—
—
—
—
—
Contactor/Compressor
Circuit Breaker
Dual In-Line Package
Fuse
IF
—
—
—
—
—
Indoor Fan
CB
DIP
FU
HR
OF
Outdoor Fan
PEC
TB
TRAN
Power Exhaust Controller
Terminal Block
Transformer
Heater Relay
Fig. 19 — Control Box Diagram (Sizes 038-048)
NOTE: Sensor part numbers are as follows:
T-55 CEC0121448-01
T-56 CEC0121503-01
—
—
Fig. 21 — Field Control Temperature Sensor Wiring
(CV or VAV Units)
Fig. 20 — Field Control Thermostat Wiring
22
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SPACE TEMPERATURE AVERAGING — 4 SENSOR APPLICATION
SPACE TEMPERATURE AVERAGING — 9 SENSOR APPLICATION
Fig. 22 — Space Temperature Averaging Wiring
signal pins must be wired to signal ground pins. Wiring con-
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.
nections for CCN should be made at the 3-pin plug (CCN
located at the base board). Consult CCN literature for fur-
ther information.
Conductors and drain wire must be 20 AWG minimum
stranded, tinned copper. Individual conductors must be in-
sulated with PVC, PVC/nylon, vinyl, Teflon, or polyethyl-
ene. An aluminum/polyester 100% foil shield and an outer
jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a
minimum operating temperature range of −20 C to 60 C
(−4 F to 140 F) is required. Table 5 lists cables that meet the
requirements.
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 de-
fault element number is 1. Refer to CCN literature to
change the default values, if needed.
Carrier Comfort Network Interface — The 48E units can be
connected to the CCN. The communication bus wiring is sup-
plied 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
system element communication connector must be wired to
the positive pins of the system element on either side of it,
the negative pins must be wired to the negative pins, and the
Table 5 — CCN Connection Approved Shielded Cables
MANUFACTURER
Alpha
CABLE PART NO.
2413 or 5463
A22503
American
Belden
8772
Columbia
02525
23
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2. Assemble hood sides, top, and cross member with gas-
keted screws provided. See Fig. 24.
3. Attach 10 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. 25.
IMPORTANT: When connecting the CCN communi-
cation bus to a system element, use a color coding sys-
tem for the entire network to simplify installation and
checkout. See Table 6.
NOTE: Each hood assembly has a slotted side that should
be adjacent to the other hood when mounted to the unit.
Table 6 — Color Code Recommendations
SIGNAL
TYPE
Positive (+)
Ground
CCN BUS CONDUCTOR
INSULATION COLOR
CCN PLUG
PIN NO.
5. Apply black seal strip (provided) to hood top mounting
flange. Seal strip of hood top mounting flange must press
tightly against seal strip of hood side mounting flanges.
See Fig. 26.
6. Add gray foam strip (provided in package) to cross mem-
bers on bottom tray. See Fig. 27.
7. Place gray foam strip (provided) on inside of slotted hood
side between filter and cross member opposite the mount-
ing end. See Fig. 28.
8. Attach gray foam strip (provided) to block-off baffle on
outer face of flange. See Fig. 29.
9. Remove the screws on each end and along top of damper
assembly of unit. Remove top 2 screws on each side of
filter panel under damper assembly. Set hood assembly
in place and attach to unit using these screws.
10. Attach accessory enthalpy bracket on hood side furthest
from control box end. Locate bracket on inside upper
right-hand corner of economizer hood using hood mount-
ing holes. Mount outdoor-air thermistor to enthalpy bracket
(if purchased). Attach and wire enthalpy assembly. Place
quick connects on enthalpy 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 as-
sembled ends together.
13. Attach mounting angle (without tabs) to the assembled
end of the filter track. See Fig. 30.
14. Attach 6 green speed clips (provided) to mounting angles.
Engagement section of clip faces inside of rack.
15. Attach remaining mounting angle (with tabs) to other
end of the filter track with no. 10 screws provided. See
Fig. 31.
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 gas-
keted screws provided. Tabs can be hand bent after they
have been inserted into the side.
RED
WHITE
BLACK
1
2
3
Negative (−)
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 communica-
tion 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 communication bus cable exits from one building and
enters another, the shields must be connected to grounds at
the lightning suppressor in each building where the cable
enters or exits the building (one point per building only).
To connect the unit to the network:
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 net-
work color scheme is used, substitute appropriate
colors.)
3. Remove the 3-pin male plug from the base module 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
terminal 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.
Step 9 — Make Outdoor-Air Inlet Adjustments
ECONOMIZER
NOTE: If accessory power exhaust or barometric relief pack-
ages are being added to the unit, install power exhaust or
barometric relief before installing economizer hoods.
NOTE: The filter track assembly end with screws should
face away from the other hood when mounted on the
unit.
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 in-
stallation of the second hood.
Economizer Hood Assembly — The economizer hood is
shipped in a package secured to the outside of the unit and
must be field-assembled. There are 2 hoods on every unit.
The 48EW/EY units are side supply and side return. The re-
turn duct limits access to economizer filters from below.
Filter tracks (mounting angle without tabs) must be installed
correctly to allow access to economizer filters from each side.
Perform the following procedure to assemble the econo-
mizer hood:
17. Attach black seal strip (provided) to filter cover. Seal
strip should be applied to the center of the large flange
making sure to cover holes. See Fig. 32.
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.
NOTE: Before assembly of the economizer 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 is flush with the economizer assembly flanges.
Minimum Damper Position Setting — Setting of the out-
door 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. 18 and 19 and Direct Digital Controls DIP
Switch Configuration section on page 33.
1. Apply black seal strip (provided in package) to outside
top-edge of hood sides. Wrap seal strip over edge to cover
top flange (4 hood sides). Make sure seal strip covers
screw holes. Allow strip to overhang 1⁄8-in. past the end
opposite the mounting flange. See Fig. 23.
24
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TOP
FLANGE
BLACK
SEAL
STRIP
HOOD SIDE
MOUNTING
FLANGE
HOOD SIDE
Fig. 23 — Adding Seal Strip to Top of Hood Sides
Fig. 25 — Adding Seal Strip to Mounting Flange of
Hood Sides
HOOD TOP
HOOD SIDE
Fig. 26 — Adding Seal Strip to Hood Top
Mounting Flange
NOTE: Left side economizer hood has mounting angle without tabs
and filter track assembled end on the opposite side.
GRAY FOAM STRIP
Fig. 24 — Economizer Hood Assembly
(Right Side Economizer Hood Shown)
CROSS MEMBER
Fig. 27 — Adding Foam Strip to Cross Member
25
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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% 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 dur-
ing the 30 seconds immediately after the desired outdoor air
minimum damper position. The 30-second time period is to
allow time where DIP switch no. 4 can be closed. The de-
fault value of the minimum outdoor air damper position is
20%. If the desired minimum position is 30%, allows 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.
HOOD SIDE
(SLOTTED)
HOOD
TOP
The minimum outdoor air damper position is now set. Close
DIP switch no. 6.
ECONOMIZER SETTINGS
Accessory Enthalpy Control (Fig. 33) — The control
(HH57AC077) is mounted in the economizer hood. See
Fig. 24. The enthalpy setting adjustment is on the enthalpy
control. For maximum benefit of outdoor air, set enthalpy
control to A. See Fig. 34 and 35.
Fig. 28 — Adding Foam Strip to Hood Side
Enthalpy Control Installation — The outdoor air enthalpy con-
trol is installed on the inside panel of the outdoor air hood.
The enthalpy control should be mounted when the outdoor
air hoods are assembled. To install the control, perform the
following procedure:
BLOCKOFF BAFFLE
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. 24. See Fig. 36
for economizer details.
GRAY FOAM STRIP
3. Mount the outdoor air enthalpy sensor inside the right econo-
mizer hood on the right side panel of the hood, adjacent
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.
1
5. Install a ⁄4-in. push on terminal (field-supplied) on the
violet and brown wires.
6. Connect a 1⁄4-in. push on terminal (field provided) to one
end of a 18-gage, 6-in. jumper wire (field-provided). Con-
nect the other end to the red wire and attach a 1⁄4-in. push
on connector (field provided).
7. Connect the red wire with the jumper to terminal TR1.
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.
Fig. 29 — Adding Foam Strip to Blockoff Baffle
MOUNTING ANGLE
(WITHOUT TABS)
8. Replace the economizer filters.
9. Return power to unit.
FILTER TRACK
ASSEMBLY
Accessory Differential Enthalpy Control (Fig. 33) — The
control (HH57AC077), in conjunction with the accessory en-
thalpy sensor (HH57AC078), controls economizer opera-
tion according to the differential enthalpy. The control is
mounted in the economizer hood. The sensor is mounted in
the return duct (48EJ/EK) or return air plenum (48EW/EY).
Fig. 30 — Mounting Angle (Without Tabs) Attached
to Filter Track Assembly
26
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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. 34.
6. Remove the return-air enthalpy sensor from the acces-
sory package. Using the screws provided, mount the sen-
sor inside 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 48EW/EY units, the
enthalpy sensor can be installed in the return air section
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 blocked by
plug buttons which should be removed.
MOUNTING ANGLE
(WITH TABS)
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 econo-
mizer will not be used (areas of high humidity), the econo-
mizer should be disabled. To disable the economizer, perform
the following:
Fig. 31 — Mounting Angle (With Tabs) Attached to
Filter Track Assembly
1. Turn of power. Lock out disconnect.
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 module board to the red wire coming
from T29 on the base module board. Remove the wire
nut and break the red to violet wire splice.
BLACK SEAL STRIP
(CENTERED)
4. Cap off both wires. When the connection is broken the
base module is fooled into thinking that the enthalpy is
not acceptable and economizer operation is disabled.
HH57AC077
ENTHALPY CONTROL
FILTER COVER
Fig. 32 — Attaching Seal Strip to Filter Cover
HH57AC078
Differential Enthalpy Sensor Installation — To install the con-
trol, perform the following procedure:
1. Turn off all power. Ensure disconnect is locked out.
ENTHALPY SENSOR
(USED WITH ENTHALPY
C7400A1004
CONTROL FOR DIFFERENTIAL
ENTHALPY OPERATION)
+
2. Remove the economizer inlet filters from the bottom of
the right hand economizer hood. See Fig. 24.
3. Remove the factory-installed, 620-ohm jumper between
terminals SR and + on the enthalpy control located in-
side the outdoor air hood.
Fig. 33 — Differential Enthalpy Control and Sensor
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.
27
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CONTROL POINT
(APPROX. DEG.)
AT 50% RH
CONTROL
CURVE
A
B
C
D
73 (23)
70 (21)
67 (19)
63 (17)
NOTE: Switches shown in high enthalpy state. Terminals 2 and 3 close
on enthalpy decrease.
Fig. 34 — Wiring Connections for Solid-State
Enthalpy Control (HH57AC077)
RH
—
Relative Humidity
Fig. 35 — Psychrometric Chart for
Enthalpy Control
NOTE: Partitions shown indicate both side supply (EW/EY) and ver-
tical supply (EJ/EK) units.
Fig. 36 — Economizer Details
28
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See Fig. 38. A section of field-supplied 1⁄4-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.
The low pressure tap is factory-routed to the atmo-
sphere. For a positive-pressure building, route the high tap
to building air and low tap to atmosphere. For a negative-
pressure building, route the high tap to atmosphere and the
low tap to building air.
Step 10 — 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 as-
sembled and tilted back into the unit for shipping. Brackets
and extra screws are shipped in shrink wrap around the damp-
ers. If ordered, each unit will have 4 power exhaust blowers
and motors or 4 barometric relief dampers.
1. Remove 9 screws holding each damper assembly in place.
See Fig. 37. Each damper assembly is secured with 3 screws
on each side and 3 screws along the bottom. Save screws.
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. 38. A section of field-
supplied 1⁄4-in. plastic tubing must be run from the high pres-
sure tap on the differential pressure switch to the conditioned
space. The pressure tube must be terminated in the condi-
tioned space where a constant pressure is required. This lo-
cation 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 atmo-
sphere. For a positive-pressure building, route the high tap
to building air and low tap to atmosphere. For a negative-
pressure building, route the high tap to atmosphere and the
low tap to building air.
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 inverter pressure transducer) is lo-
cated behind the filter access door on the lower inner panel.
NOTES:
1. Unless otherwise specified, all dimensions are to outside of part.
2. Dimensions are in inches.
3. On 48EW,EY units, accessory barometric relief or power exhaust must be mounted in the field-supplied return ductwork.
Fig. 37 — Barometric Relief Damper and Power
Exhaust Mounting Details
29
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When replacing the OFM, reconnect the black, yellow, and
blue wires form the outdoor fan contactor to the black, yel-
low, 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 con-
trol to lower the supply voltage to the control to 460-v. Trans-
formers can be mounted anywhere outside the control box.
Step 11 — Install All Accessories — After all the
factory-installed options have been adjusted, install all field-
installed accessories. Refer to the accessory installation in-
structions included with each accessory.
MOTORMASTER III 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. 39 for baffle
details. Use 20-gage, galvanized sheet metal, or similar
corrosion-resistant metal for baffles. Use field-supplied screws
1
to attach baffles to unit. Screws should be ⁄4-in. diameter
5
and ⁄8-in. long. Holes for wind baffles are pre-punched in
the unit sheet metal.
To avoid damage to the refrigerant coils and electrical
components, use recommended screw sizes only.
On 48EJ,EK,EW,EY024-034 units, the wind baffles at-
tach to flanges formed on the outer sheet metal of the unit
where the condenser coil tube sheets attach.
On 48EJ,EK,EW,EY038-048 units, the wind baffles at-
tach to flanges formed on the outer sheet metal of the unit
corner post. The other end of the baffle is attached to the
center panel between the condenser coil and the indoor sec-
tion. Two baffles are required for 48EJ,EK,EW,EY038-048
units.
Install Motormaster III Controls — Only one Motormaster
III control is required per unit.
Motor — The circuit no. 1 (lead compressor) outdoor-fan
motor (OFM) will need to be changed out in the field to ac-
commodate the Motormaster III accessory. The replacement
motor part no. is HD52AK652.
VAV — Variable Air Volume
On 48EJ,EK,EW,EY038-048 units, only one OFM will need
to be changed out. The no. 1 compressor is located at the left
side of the unit looking from the compressor end. The circuit
no. 2 OFMs are controlled to shut off at 55 F and turn on at
65 F outdoor-air temperature.
Fig. 38 — Pressure Transducer Locations
Sensor — Install the sensor for thermistor input control in
the location shown in Fig. 40A-C. Connect sensor leads to
the violet and gray control signal leads on the Motormaster
III control.
1
BOTH SIDES
18
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 lo-
cation is in the indoor fan section, mounted on the panel that
separates the indoor and outdoor sections. On VAV units,
this location is next to the VFD.
77.7
0.312 DIA
HOLES
61
17.167
BETWEEN
HOLES
Do not route the Motormaster III wiring next to the VFD
on VAV units. Use a separate connector through the partition
when wiring to the OFM.
(TYPICAL)
CROSS-BREAK
78.7
0.5
Electrical Connections
4.62
NOTE: All dimensions are in inches. Material: 20 gage galvanized
steel or other non-corrosive material.
To avoid possibility of electrical shock and personal in-
jury, turn off all power to unit before making electrical
connections.
Fig. 39 — Motormaster III Baffle Details
30
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Fig. 40A — Motormaster III Sensor Location
(Sizes 024-034)
Fig. 40C — Motormaster III Sensor Location
(Size 048)
Internal Wiring — Check all electrical connections in
unit control boxes; tighten as required.
Refrigerant Service Ports — Each refrigerant sys-
tem has one suction port located in the top of the compressor
motor casing. All units also have one service port on the liq-
uid line valve and one on the compressor discharge valve.
Be sure that caps on the ports are tight.
Crankcase Heaters — Crankcase heaters are ener-
gized as long as there is power to the unit, except when the
compressors are operating.
IMPORTANT: Unit power must be on for 24 hours
prior to start-up. Otherwise, damage to compressor may
result.
Variable 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. An Opera-
tion Manual is shipped with each VAV unit. This manual should
be used if the drive needs to be customized for a particular
application.
Fig. 40B — Motormasterா III Sensor Location
(Sizes 038 and 044)
NOTE: The VFD will always provide the proper phase
sequence to the indoor-fan motor. The indoor-fan motor op-
erates in proper rotation regardless of the phase sequence to
the unit. If, upon start-up, the outdoor fans operate back-
wards 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.
START-UP
Use the following information and Start-Up Checklist
on page CL-1 to check out unit PRIOR to start-up.
Unit Preparation — Check that unit has been installed
in accordance with these installation instructions and appli-
cable codes.
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,
therefore, 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
frequency range. Refer to Table 7. The set point value is a
percentage of the maximum output frequency. Locate the duct
static pressure closest to that desired and use the correspond-
ing set point value. If necessary, interpolation between duct
static pressures is permissible.
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
completely 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 com-
pressor could result if they are left closed.
31
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To set the VFD, the VFD must be powered up; however,
since it is located near the indoor air fan, operation of the
fan is not desirable. To disable the fan, perform the follow-
ing procedure:
the base module closes contacts, activating two exhaust fans.
When the economizer position reaches 75% open, the base
module activates the other two exhaust fans. The fans will
turn off when the economizer closes below the same points.
The economizer 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 identical values at the desired point to activate all
exhaust fans.
1. Open the indoor fan circuit breaker.
2. Remove the jumper between CC and ST on the terminal
strip of the VFD (see Fig. 41).
3. Close the indoor fan circuit breaker. The VFD now is
powered but the fan will not operate.
4. On the front of the VFD is a keypad and display which
will be used to enter the set point. To access this field,
press the ‘‘PRG’’ key until the display reads ‘‘S.PrG’’
(Speed Group Parameters). Press the arrow key until ‘‘Sr1’’
is displayed. This is the VFD set point listed in Table 7.
5. Press the ‘‘READ/WRITE’’key. The set point value will
be displayed. Use the up-arrow or down-arrow key to
adjust the set point value to the value desired.
6. Press the ‘‘READ/WRITE’’ key again to enter the new
value.
7. Check the factory default values.
The optional modulating power exhaust (VAV standard,
CV optional) is controlled by a modular electronic se-
quencer system. This system consists of a model R353 sig-
nal input module and 4 model S353 staging modules. The
signal input module receives a 0 to 10 vdc signal from the
building pressure transducer, which is mounted adjacent to
the supply static transducer behind the filter access panel.
The modules are mounted just below the unit control board.
The left module is the R353, and the 4 modules on the right
are S353 modules for stages 1 through 4. On the unit wiring
label, the R353 is designated PESC, and the S353 modules
are designated PES1 through PES4.
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’’con-
nection and led into the building to a point where building
pressure is to be controlled (positive-pressure building). 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 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 stag-
ing modules are activated in sequence as the input signal
increases.
IMPORTANT: The Carrier factory default values
for the VFD may be different than the default val-
ues of the manufacturer. Refer to the Carrier lit-
erature when checking default values. The following
default values have been changed from the manu-
facturer settings to more closely match the VFD
operation to a Carrier VAV unit.
SETUP PARAMETERS (Item 6, Point 1, Output Fre-
quency) — The default value should be 20.
JUMP FREQUENCY GROUP (Item 7, PID Set Point
Control Select) — The default value is 1.
JUMP FREQUENCY GROUP (Item 8, Proportional Gain)
— The default value is 100.
JUMP FREQUENCY GROUP (Item 9, Integral Gain)
— The default value is 50.
SPEED GROUP PARAMETERS (Item 2, Multi-Speed
Run Frequency No. 1) — The factory setting is 30.
Table 7 — VFD Supply Air Pressure Set Point
SPEED GROUP PARAMETERS (Item 2, Fire Speed
Override Frequency) — The factory setting is 60.
8. Open the indoor fan circuit breaker.
9. Replace the jumper between CC and ST on the terminal
strip of the VFD.
10. Close the indoor fan circuit breaker; the VFD now is
powered and the fan will operate.
PRESSURE
(in. wg)
CONTROL
(mA)
VFD
SET POINT
0
4.0
4.8
0
3
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
2.75
3.00
3.25
3.50
5.6
6
6.4
9
7.2
12
15
18
21
24
27
30
33
36
39
42
8.0
8.8
9.6
NOTE: Any field measurement of supply fan amps must be
taken with an RMS meter between the fan circuit breaker
and fan contactor (upstream of VFD).
10.4
11.2
12.0
12.8
13.6
14.4
15.2
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,
VFD
—
Variable Frequency Drive
(SS2) (SS3)
FLA FLB FLC P24 RCH LOW FM
AM
PP
RR
IV
CC
ST
F
R
CC
SS1 JOG AD2 RST CC
+
–
NOTE: Terminal strip is located inside the VFD at the bottom.
JUMPERS
D P D P
Fig. 41 — VFD Factory-Installed Jumpers
32
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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.
At the lower left corner of the board below the terminal
strip is a resistor marked R27. This must be removed in
order to obtain 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.
brated in 1% increments, and is factory set at approximately
3%. It is recommended to leave the set point at 3%, to mini-
mize cycling of the fans.
The offset and differential potentiometers have been fac-
tory 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. How-
ever, if the building pressure is not being maintained as de-
sired, then some minor adjusting on a trial and error basis
can be made.
The R353 module has a terminal block with 7 connec-
tions 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 vdc signal. Consult the wiring label for
wire identification if replacing the module. The 3 left-hand
terminals are not used for this application.
The S353 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 indi-
cation of the number of exhaust fans running. The jumper
pins are arranged in a square format. Two jumpers are used
to determine the mode of operation (direct or reverse). The
2 jumpers must be arranged horizontally for direct action
(factory set).
Direct Digital Controls DIP Switch Configura-
tion — The Direct Digital Control (DDC) board must be
configured for each application. The DDC board is config-
ured through the DIP switches located on the board. There
are 8 DIP switches which configure 8 different applications
of the DDC. See Table 10. 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 11.
The DIP switch configurations are as follows:
• DIP switch 1 configures 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)
At the top of the module are two potentiometers. The left
potentiometer adjusts the offset. The right potentiometer
adjusts the differential. The potentiometers are factory set
for a nominal 0 in. wg building pressure.
• 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
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 20%.
The second stage will turn off at 50% signal (5 vdc), and the
offset potentiometer will be set at 40%. 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.
• DIP switch 7 configures the unit for gas heat or electric
heat
• DIP switch 8 configures the unit for heat pump or air con-
ditioner 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.
Table 8 relates building pressure to signal level.
Table 8 — Potentiometer Signal Levels
BUILDING PRESSURE
(in. wg)
SIGNAL LEVEL
(vdc)
IMPORTANT: To prevent damage to compressors, crank-
case heater should be energized 24-hours prior to
start-up.
−0.50
−0.25
0.00
2
4
6
0.25
8
Evaporator Fan — Fan belt and fixed pulleys are factory-
installed. See Tables 12-16 for fan performance and motor
limitations data. Remove tape from fan pulley, and be sure
that fans rotate in the proper direction. See Table 17 for air
quantity limits. Static pressure drop for power exhaust is neg-
ligible. To alter fan performance, see Evaporator Fan
Performance Adjustment section on page 46.
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 desired between 50% and 75%.
The default offset set points for modulating power ex-
haust are shown in Table 9.
The differential set point is the difference between the
turn off point and the turn on point for each module. It also
is calibrated in terms of percent of input signal, and has a
range of 1% to 7%. The differential potentiometer is cali-
Condenser Fans and Motors — Condenser fans and
motors are factory set. Refer to Condenser-Fan Adjustment
section on page 47 as required. Be sure that fans rotate in
the proper direction. Fan no. 2 (sizes 024-034) and fans
no. 3 and 4 (sizes 038-048) are cycled on the outdoor-air
temperature.
33
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Table 9 — Power Exhaust Default Set Points
OFF STATIC PRESSURE
(in. wg)
STAGE
OFFSET
DIFFERENTIAL
OFF VOLTAGE
ON VOLTAGE
1
2
3
4
50%
55%
60%
64%
3%
3%
3%
3%
6.0
6.5
7.0
7.4
6.3
6.8
7.3
7.7
0.00
0.06
0.12
0.18
Table 10 — DIP Switch Configuration
SETTING
OPEN
1
2
3
4
5
6
7
8
VAV —
VAV — Space Sensor
Installed
Occupied Time Guardா Override
Heat
Enabled
ON
Expansion
Board
Field Test
ON
Heat Pump
Operation
VAV
Gas Heat
CV —
Modulated
Power
IN CONJUNCTION
WITH FIELD TEST
— Set Minimum
CV — CCN or Sensors
Used
Exhaust
Damper Position
VAV —
Occupied
Heat
VAV — No Space Sensor
CV — Thermostat
Disabled
Base Control Field Test
Board Only OFF
Time Guard Override
OFF
Air Conditioner
Operation
CLOSED CV
Electric Heat
CV —
Constant
Volume
Power
Exhaust
LEGEND
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.
CCN
CV
VAV
—
—
—
Carrier Comfort Network
Constant Volume
Variable Air Volume
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.
3. When the unit is field-tested (DIP switch 4 to OPEN), the function
of DIP switch 6 changes and it is used to set the minimum damper
position.
Table 11 — DIP Switch Factory Settings
UNIT
1
2
3
4
5
6
7
8
48EJ,EW
48EK,EY
Closed
Open
Closed
Closed
Closed
Closed
Closed
Closed
Closed
Closed
Closed
Closed
Open
Open
Closed
Closed
34
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Table 12 — 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)
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
4,000
5,000
340
384
432
483
536
549
590
645
701
757
786
0.83
1.25
1.79
2.48
3.33
3.57
4.34
5.54
6.92
8.49
9.36
416
453
495
540
588
600
637
689
741
795
822
1.17
1.61
2.19
2.91
3.78
4.02
4.82
6.04
7.44
9.04
9.92
480
513
550
591
635
646
681
729
779
830
856 10.47
883 11.41
922 12.92
936 13.45
1.52
1.99
2.59
3.33
4.23
4.48
5.30
6.54
7.96
9.59
537
566
600
638
679
690
722
768
816
865 10.14
890 11.03
915 11.98
953 13.51
966 14.05
1.90
2.39
3.01
3.77
4.69
4.95
5.78
7.04
8.49
588
615
647
682
720
730
762
805
850
2.29
2.79
3.43
4.22
5.16
5.42
6.27
7.56
9.03
635
660
690
723
759
769
799
840
884
2.69
3.21
3.87
4.67
5.64
5.90
6.77
8.07
9.56
679
703
730
762
797
806
834
874
3.11
3.64
4.31
5.14
6.12
6.39
7.27
8.59
720
742
769
799
832
841
868
906
3.53
4.08
4.77
5.61
6.61
6.88
7.77
9.12
6,000
7,000
8,000
8,250
9,000
10,000
11,000
12,000
12,500
13,000
13,750
14,000
15,000
916 10.10
960 11.81
947 10.65
990 12.37
898 10.69
922 11.60
946 12.56
929 11.25
953 12.16
983 12.73 1012 13.31
814 10.28
857 11.75
871 12.27
929 14.50
849 10.84
890 12.34
904 12.86
960 15.10
976 13.13 1006 13.71 1034 14.30
983 14.10 1012 14.69 1041 15.28 1068 15.88
996 14.64 1025 15.23 1053 15.83 1080 16.43
990 15.71 1019 16.33 1047 16.94 1074 17.55 1101 18.17 1127 18.79
AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)
AIRFLOW
(Cfm)
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
4,000
5,000
759
780
805
834
866
874
901
938
3.97
4.53
5.23
6.09
7.10
7.38
8.29
9.65
796
816
840
868
899
907
932
4.42
4.99
5.70
6.57
7.60
7.89
8.80
831
851
874
901
930
938
963
4.87
5.45
6.18
7.07
8.11
8.40
9.33
865
884
906
932
961
968
992
5.34
5.93
6.67
7.56
8.62
8.92
897
916
937
962
990
998
5.81
6.41
7.16
8.07
929
946
968
992
6.30
6.90
7.66
959
976
997
6.79
988
7.28
7.91
8.69
9.63
7.40 1005
8.17 1025
9.10 1048
6,000
7,000
8.58 1020
8,000
9.14 1019
9.44 1026
9.67 1047 10.20 1074 10.74
9.97 1054 10.50 1081 11.04
8,250
9,000
9.86 1021 10.39 1049 10.93 1076 11.48 1102 12.03
10,000
11,000
12,000
12,500
13,000
13,750
14,000
15,000
968 10.18
997 10.72 1026 11.27 1054 11.82 1081 12.37 1107 12.93 1133 13.49
977 11.19 1006 11.75 1035 12.30 1062 12.87 1089 13.43 1115 14.00 1141 14.57 1166 15.15
1019 12.94 1047 13.51 1074 14.08 1100 14.66 1126 15.24 1152 15.83 1177 16.42 1201 17.01
1040 13.88 1067 14.46 1094 15.05 1120 15.63 1146 16.22 1171 16.82 1195 17.41
—
—
—
—
—
—
—
—
—
—
1062 14.88 1089 15.47 1115 16.06 1140 16.66 1166 17.25 1190 17.86
—
—
—
—
—
—
—
—
1095 16.48 1121 17.08 1147 17.68 1172 18.29 1196 18.90
—
—
—
—
—
—
1106 17.04 1132 17.64 1157 18.25 1182 18.86
1152 19.41 1177 20.04 1200 20.66
—
—
—
—
—
—
AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)
3.4 3.6 3.8
AIRFLOW
(Cfm)
LEGEND
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Bhp
—
Brake Horsepower
4,000
5,000
1017
1033
1053
1075
1100
1107
1128
1158
1190
—
7.79
8.42
9.21
10.16
11.28
11.59
12.58
14.06
15.74
—
1045
1061
1080
1102
1126
1133
1153
1183
—
8.30
8.94
9.73
10.69
11.83
12.14
13.14
14.63
—
1072
1087
1106
1127
1151
1158
1178
—
8.82
9.46
10.27
11.24
12.38
12.69
13.70
—
NOTES:
1. Fan performance is based on wet coils, economizer, roof curb,
cabinet losses, and clean 2-in. filters.
6,000
7,000
2. Conversion — Bhp to watts:
8,000
Bhp x 746
Watts =
8,250
9,000
Motor efficiency
10,000
11,000
12,000
12,500
13,000
13,750
14,000
15,000
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 (enter-
ing wet bulb) conditions.
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
35
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Table 13 — 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)
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
7,000
8,000
429
475
523
571
620
670
720
771
822 10.88
873 12.80
924 14.91
976 17.24
1.70
2.36
3.11
4.00
5.04
6.24
7.61
9.15
484
525
567
612
658
705
752
801 10.97
850 12.95
899 15.16
949 17.59
2.40
3.09
3.97
5.01
6.22
7.61
9.19
536
571
610
651
694
738
784
830 11.51
877 13.52
925 15.74
974 18.20
2.70
3.49
4.39
5.46
6.69
8.10
9.70
584
616
651
689
729
771
814 10.23
859 12.05
904 14.08
951 16.33
3.10
3.90
4.82
5.91
7.17
8.60
630
658
690
725
763
803
844 10.75
887 12.60
931 14.65
3.50
4.31
5.26
6.37
7.65
9.11
674
699
728
761
796
834
874 11.29
915 13.15
957 15.22
3.90
4.74
5.71
6.84
8.14
9.62
716
738
765
795
829
865 10.13
902 11.82
942 13.71
4.30
5.17
6.16
7.31
8.64
756
776
801
829
860
894 10.65
931 12.36
969 14.27
4.80
5.61
6.62
7.79
9.14
9,000
10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
983 15.80 1008 16.38
976 16.92 1001 17.51 1025 18.11 1049 18.71
998 18.80 1022 19.41 1045 20.03 1069 20.64 1092 21.26
999 20.26 1023 20.88 1046 21.51 1068 22.14 1091 22.77 1113 23.41 1135 24.05
1027 19.77 1050 23.17 1072 23.82 1094 24.46 1115 25.11 1137 25.76 1158 26.42 1179 27.07
1079 22.53 1100 26.33 1122 27.00 1142 27.66 1163 28.33 1183 29.00
—
—
—
—
AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)
AIRFLOW
(Cfm)
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
7,000
8,000
794
813
835
862
891
5.20
6.06
7.09
8.28
9.64
832
848
869
893
5.62
6.52
7.56
8.77
868
883
902
925
6.06
6.98
8.04
9.27
903
916
934
955
6.52
7.45
8.53
9.77
937
949
965
6.98
7.92
9.02
971
981
995
7.44 1003
8.40 1012
7.92 1035
8.89 1042
8.40
9.38
9,000
9.52 1025 10.02 1054 10.53
10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
985 10.28 1014 10.79 1043 11.31 1071 11.84
921 10.15
952 11.71
951 10.67
980 11.19 1008 11.71 1036 12.24 1064 12.78 1090 13.32
924 11.18
958 12.91
980 12.24 1008 12.78 1035 13.32 1062 13.87 1088 14.42 1114 14.98
986 13.45 1012 14.01 1039 14.56 1064 15.13 1090 15.69 1115 16.26 1140 16.83
995 14.83 1021 15.40 1046 15.97 1071 16.55 1096 17.13 1120 17.71 1144 18.29 1168 18.89
1033 16.96 1058 17.55 1082 18.14 1106 18.73 1130 19.33 1153 19.93 1176 20.54 1199 21.14
1073 19.31 1097 19.92 1120 20.52 1143 21.14 1165 21.75 1188 22.37
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
1114 21.88 1137 22.51 1159 23.13 1181 23.76
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
1156 24.69 1178 25.33 1199 25.98
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)
3.4 3.6 3.8
AIRFLOW
(Cfm)
LEGEND
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
7,000
8,000
1066
1072
1083
1098
1117
1139
1164
1191
—
8.88
9.88
11.04
12.37
13.86
15.54
17.41
19.48
—
1096
1101
1111
1125
1143
1164
1188
—
9.38
10.39
11.56
12.90
14.41
16.11
17.99
—
1125
1130
1139
1152
1169
1189
—
9.88
10.90
12.08
13.44
14.96
16.68
—
Bhp
—
Brake Horsepower
NOTES:
9,000
1. Fan performance is based on wet coils, economizer, roof curb,
cabinet losses, and clean 2-in. filters.
10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
2. Conversion — Bhp to watts:
Bhp x 746
Watts =
—
—
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 (enter-
ing wet bulb) conditions.
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
36
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Table 14 — Fan Performance, 48EJ,EK048 — 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)
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
9,000
10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
528
577
627
677
728
779
830 11.03
882 12.97
934 15.12
3.20
4.10
5.10
6.30
7.71
9.28
572
617
664
711
760
809 11.11
858 13.13
908 15.36
959 17.83
4.00
5.10
6.30
7.70
9.31
615
657
700
745
791
838 11.65
886 13.69
934 15.95
4.40
5.50
6.80
8.20
9.83
656
694
735
778
822 10.35
867 12.20
913 14.26
960 16.54
4.90
6.00
7.30
8.70
695
731
769
809
851 10.88
895 12.75
939 14.83
5.30
6.40
7.70
9.20
733
766
802
841
881 11.42
923 13.31
966 15.41
5.80
6.90
8.20
9.70
769
801
835
871 10.20
909 11.95
950 13.87
6.20
7.40
8.70
805
834
866
901 10.80
938 12.50
976 14.43
6.70
7.90
9.20
991 15.99 1017 16.57
985 17.13 1010 17.73 1034 18.33 1058 18.93
983 18.44 1008 19.05 1031 19.66 1055 20.28 1078 20.89 1101 21.52
986 17.47 1010 20.53 1033 21.16 1056 21.79 1078 22.42 1101 23.06 1123 23.70 1145 24.34
1038 20.05 1061 23.49 1083 24.13 1105 24.78 1126 25.44 1147 26.09 1169 26.75 1190 27.41
1091 22.84 1112 26.69 1133 27.36 1154 28.03 1174 28.70 1195 29.37
—
—
—
—
AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)
AIRFLOW
(Cfm)
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
9,000
10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
839
866
897
7.10
8.40
9.70
873
898
7.62
8.85
905
929
8.10
9.34
937
959
8.59
9.85
968
9.08
999
9.57 1028 10.08 1057 10.58
989 10.36 1018 10.87 1047 11.39 1075 11.91
927 10.24
958 11.82
956 10.76
985 11.28 1013 11.81 1041 12.34 1068 12.87 1095 13.41
930 11.30
965 13.04
986 12.36 1014 12.90 1041 13.44 1067 13.99 1093 14.54 1119 15.10
992 13.59 1019 14.15 1045 14.71 1071 15.27 1096 15.84 1121 16.41 1146 16.98
1002 14.99 1028 15.56 1054 16.14 1079 16.71 1103 17.30 1127 17.88 1151 18.47 1175 19.06
1041 17.15 1066 17.74 1090 18.34 1114 18.93 1138 19.53 1161 20.13 1184 20.74
—
—
—
—
—
—
—
—
—
—
—
—
1082 19.52 1105 20.14 1128 20.75 1151 21.37 1174 21.99 1196 22.61
—
—
—
—
—
—
—
—
—
—
1124 22.14 1146 22.77 1168 23.40 1190 24.03
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
1166 24.98 1188 25.63
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
LEGEND
AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)
3.4 3.6 3.8
AIRFLOW
(Cfm)
Bhp
—
Brake Horsepower
Rpm
Bhp
Rpm
Bhp
Rpm
Bhp
NOTES:
1. Fan performance is based on wet coils, economizer, roof curb,
cabinet losses, and clean 2-in. filters.
9,000
10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
1086
1102
1122
1144
1170
1198
—
11.10
12.44
13.96
15.66
17.56
19.66
—
1114
1129
1147
1169
1194
—
11.61
12.97
14.51
16.23
18.14
—
1141
1155
1173
1194
—
12.14
13.51
15.06
16.80
—
2. Conversion — Bhp to watts:
Bhp x 746
Watts =
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 and ewb conditions.
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
37
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Table 15 — Fan Performance — Power Exhaust
48EJ,EK,EW,EY024-048 (20 THRU 45 TONS)
Low Speed
230, 460, 575 v
ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts
Medium Speed
High Speed
Airflow
(Cfm)
208 v
208 v
230, 460, 575 v
208 v 230, 460, 575 v
6,500 0.32 2.82 3160 0.70 2.98 3340
—
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
6,700 0.23 2.87 3220 0.63 3.03 3400 0.60 3.01 3380 0.82 3.23 3620
6,900 0.17 2.92 3270 0.59 3.09 3460 0.55 3.07 3440 0.78 3.28 3680
7,100 0.13 2.93 3290 0.56 3.11 3490 0.49 3.12 3500 0.73 3.34 3740
7,300 0.09 2.97 3330 0.53 3.15 3530 0.43 3.18 3560 0.68 3.39 3800
7,500
7,700
7,900
8,100
8,500
8,900
9,300
9,700
10,100
10,500
10,900
11,300
11,700
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
0.51 3.19 3580 0.39 3.24 3630 0.64 3.44 3860
0.48 3.23 3620 0.33 3.27 3670 0.59 3.48 3900 0.60 3.69 4140 0.73 3.98 4460
0.45 3.27 3670 0.27 3.32 3720 0.54 3.52 3950 0.56 3.74 4190 0.69 4.02 4510
0.40 3.33 3730 0.22 3.36 3770 0.49 3.57 4000 0.51 3.78 4240 0.65 4.07 4560
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
0.17 3.47 3890 0.40 3.67 4120 0.41 3.83 4290 0.56 4.12 4620
0.00 3.58 4010 0.30 3.77 4230 0.31 3.93 4410 0.47 4.23 4740
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
0.22 3.87 4340 0.20 4.07 4560 0.37 4.37 4900
0.16 3.95 4430 0.11 4.17 4670 0.30 4.47 5010
0.12 4.03 4520 0.04 4.25 4770 0.23 4.56 5110
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
—-
0.17 4.66 5220
0.12 4.75 5330
0.07 4.80 5380
0.04 4.83 5420
LEGEND
Bhp
—
—
—
Brake Horsepower
External Static Pressure (in. wg)
Input Watts to Motor
ESP
Watts
Table 16 — Motor Limitations
STANDARD EFFICIENCY MOTORS
Maximum Amps
Nominal
Hp
Maximum
Bhp
Maximum
Watts
Motor
Efficiency
230
460
—
575
—
5.9
5.9
14.6
—
5,030
5,030
87.5
87.5
88.5
88.5
89.5
89.5
91.0
91.0
91.0
91.0
91.7
91.7
92.4
92.4
5
7.9
—
6.0
—
8.7
22.0
—
7,334
7.5
10
15
20
25
30
9.5
12.0
—
10.0
—
8,008
10.2
11.8
15.3
18.0
22.4
23.4
28.9
29.4
35.6
34.7
28.0
—
8,502
14.6
—
12.0
—
9,836
43.8
—
12,543
14,756
18,363
19,183
23,511
23,918
28,742
28,015
21.9
—
19.0
—
62.0
—
28.7
—
23.0
—
72.0
—
37.4
—
31.0
—
95.0
—
48.0
47.0
HIGH EFFICIENCY MOTORS
Maximum Amps
Nominal
Hp
Maximum
Maximum
Motor
Bhp
Watts
Efficiency
230
15.8
—
460
—
5.9
5.9
4,918
4,918
89.5
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
5
7.9
—
8.7
22.0
—
7,078
7.5
10
15
20
25
30
9.5
12.0
—
7,728
10.2
11.8
15.3
18.0
22.4
23.4
28.9
29.4
35.6
34.7
28.0
—
8,298
15.0
—
9,600
43.8
—
12,273
14,439
17,853
18,650
23,034
23,432
28,374
27,656
21.9
—
58.2
—
28.7
—
73.0
—
36.3
—
82.6
—
41.7
BHP — Brake Horsepower
NOTE: Extensive motor and electrical testing on the Carrier units has ensured that the full horsepower range of the motor can be utilized with
confidence. Using your fan motors up to the horsepower ratings shown on the Motor Limitations table will not result in nuisance tripping or premature
motor failure. Unit warranty will not be affected.
38
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Table 17 — Air Quantity Limits
MINIMUM COOLING
MINIMUM HEATING
AIRFLOW
MINIMUM HEATING
AIRFLOW
UNIT
48EJ,EK,EW,EY
AIRFLOW (VAV)
AT FULL LOAD
OPERATION
MINIMUM COOLING
AIRFLOW (CV)
MAXIMUM
AIRFLOW
(Low Heat)
(High Heat)
024
028
030
034
038
044
048
5730
5730
5730
5730
7360
7360
7360
5950
5950
5950
5950
9820
9820
9820
2000
2500
2750
3000
3500
4000
4500
6,000
7,500
10,000
12,500
13,750
15,000
17,500
20,000
22,500
8,250
9,000
10,500
12,000
13,500
LEGEND
CV
VAV
—
—
Constant Volume
Variable Air Volume
open,then sensors are employed. If switch no. 2 is closed,
thermostat is employed. Initialization clears all alarms and
alerts, remaps the input/output database for CV operation,
sets maximum heat stages to 2, and sets maximum cool stages
to 3. The control reads DIP switch no. 3 and if open, then it
sets the internal flag for expansion mode 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 func-
tions control stages cool1, cool2, heat1, heat2, and indoor
fan, respectively. If TSTAT function is NOT selected, the
control determines the occupancy state on the Time Sched-
ules or with remote occupied/unoccupied input. If tempera-
ture compensated start is active, the unit will be controlled
as in the Occupied mode. User-defined set points are shown
in Table 18.
The occupied or unoccupied comfort set points must be
selected 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 Un-
occupied Cool set point value is 90 F. The control board will
set appropriate operating mode and fan control. The control
board will turn on indoor fan, if in Occupied mode, or de-
termine if unit is in Unoccupied mode and the space tem-
perature is outside of the unoccupied 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
(di-rect expansion) cooling is requested, the outdoor fan will
operate.
The control board will operate economizer, run diagnos-
tics to monitor alarms/alerts at all times, and respond to CCN
communications to perform any configured network POC
(product outboard control) functions such as time and outdoor-
air temperature broadcast and Global occupancy broadcast.
When the optional expansion I/O board is employed, it will:
perform periodic scan and maintain database of expanded
I/O points, perform Fire/Smoke control (power exhaust re-
quired); and if in Occupied mode perform IAQ control and
monitor fan, filter, demand limit, and field-applied status (with
accessories).
Return-Air Filters — Check that correct filters are in-
stalled in filter tracks (see Table 1). Do not operate unit with-
out return-air filters.
Filter Replacement — To replace filters, open filter ac-
cess door (marked with label). Remove inner access panel.
Remove plastic filter retainer in between filter tracks by slid-
ing 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 re-
moval tool to remove the rest of the filters.
Outdoor-Air Inlet Screens — Outdoor-air inlet screens
must be in place before operating unit.
EconomizerAdjustment — 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 Minimum
Damper Position Setting section on page 24.
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 shutoff valve (see Fig. 13 on page 13).
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. Use
the field test procedure to verify heat operation. After the
unit has run for several minutes, verify that incoming pres-
sure is 5.0 in. wg or greater, and that the manifold pres-
sure is 3.5 in. wg. If manifold pressure must be adjusted,
refer to Gas Valve Adjustment section on page 47.
Sequence of Operation
NOTE: Unit is shipped with default values that can be changed
through Service Tool, Building Supervisor, or Comfort-
Works™ software. See Table 18 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
operation. Next, DIP switch no. 2 is read to determine if the
control is thermostat or sensor type operation. If switch 2 is
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.
39
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Table 18 — User Defined Set Points
SET POINT
NAME
FORMAT
DESCRIPTION
LIMITS
DEFAULT
OHSP
OCSP
UHSP
UCSP
SASP
OATL
NTLO
RTIO
LIMT
xx.xF
xx.xF
xx.xF
xx.xF
xx.xF
xx.xF
xx.xF
xx.x
Occupied Heat Set Point
Occupied Cool Set Point
Unoccupied Heat Set Point
Unoccupied Cool Set Point
Supply Air Set Point
55 to 80 F
55 to 80 F
40 to 80 F
75 to 95 F
45 to 70 F
55 to 75 F
40 to 70 F
0 to 10
68 F
78 F
55 F
90 F
55 F
65 F
50 F
3
Hi OAT Lockout Temperature
Unoccupied OAT Lockout Temperature
Reset Ratio
xx.xF
xxx%
Reset Limit
0 to 20° F
0 to 100%
10%
20%
MDP
Minimum Damper Position
Low Temperature Minimum
Damper Position Override
LOWMDP
xxx%
0 to 100%
100%
IAQS
UHDB
UCDB
LTMP
HTMP
PES1
PES2
xxxx
IAQ Set Point
1 to 5000 PPM
0 to 10° F
0 to 10° F
0 to 100%
0 to 100%
0 to 100%
0 to 100%
650 PPM
1° F
xx.xF
xx.xF
xxx%
xxx%
xxx%
xxx%
Unoccupied Heating Deadband
Unoccupied Cooling Deadband
Low Temp. Min. Position
1° F
10%
High Temp. Min. Position
CV Power Exhaust Stage 1 Point
CV Power Exhaust Stage 2 Point
35%
25%
75%
LEGEND
CV
IAQ
OAT
—
—
—
Constant Volume
Indoor Air Quality
Outdoor-Air Temperature
If thermostats are used to deenergize the G input, the con-
trol board will turn off indoor fan without any delay and close
economizer dampers.
of the control board. The initialization software then reads
DIP switch no. 1 position to determine CV or VAV opera-
tion. Initialization clears all alarms and alerts, re-maps the
input/output database for VAV operation, sets maximum heat
stages to 1 and sets maximum cool stages to 6. The control
reads DIP switch no. 3 and if open, then it sets the internal
flag for expansion mode operation.
The control board will determine if an interface (linkage)
is active and if the unit will operate in a 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 temperatures
and occupancy status with the linkage data supplied.
When cooling, G must be energized before cooling can
operate. The control board determines if outdoor conditions
are suitable for economizer cooling using the standard out-
door air thermistor. For economizer to function for free cool-
ing, the enthalpy must be low, the outdoor air must equal to
or less than the High Outdoor Air Temperature Lockout (de-
fault 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 econo-
mizer as the first stage of cooling.
When Y1 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 econo-
mizer will modulate between minimum and 100% open po-
sition. When Y2 is energized, the control will turn on com-
pressor no. 1 and continue to modulate economizer as described
above. If the Y2 remains energized and the SAT reading re-
mains 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 cool-
ing, the economizer will go to minimum position and cycle
compressor no. 1 and 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 com-
pressor is locked out, it can restart after normal time guard
period.
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.
When heating, the heat stages respond to the demand from
W1 and W2 of the thermostat input. Heating and cooling
will be mutually locked out on demand on a first call basis.
The heating and the cooling functions cannot be operating
simultaneously.
The control board will determine occupancy status from
Time Schedules (if programmed), Remote Occupied/
Unoccupied input, global occupancy, or DAV. If tempera-
ture compensated 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 unoccupied to reach the
occupied set point when occupancy occurs.
The control board will set the appropriate operating mode
and fan control. The control board will turn VFD on if Oc-
cupied mode is evident.
For units equipped with a start/stop switch only (no space
temperature sensor), if unoccupied and valid return-air tem-
perature reading is available (either from a sensor or DAV),
the control will monitor return-air temperature against Un-
occupied Heat and Cool set points.
For units with a start-stop switch and a space temperature
sensor, the control board 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
compensated start algorithm. When VFD is running in a nor-
mal mode, the control will start heating or cooling as re-
quired to maintain supply-air temperature at the supply air
set point plus the reset (when enabled). The reset value is
determined by SAT (supply-air temperature) reset and/or space
temperature reset algorithms. The space temperature reset is
only available when enabled through software.
COOLING, VARIABLE VOLUME UNITS — On power up,
the control module will activate the initialization software
40
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When cooling, the control will energize the power ex-
haust enable output to the external power exhaust controller,
when power exhaust is used.
If occupied, the control will perform economizer control
(economizer control same as described above for CV units).
If unoccupied, the control 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.
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 glo-
bal broadcast; and perform Fire/Smoke control if equipped
with power exhaust.
close. If the overtemperature limit opens after the indoor
motor is stopped within 10 minutes of W1 becoming inac-
tive, on the next cycle the time will be extended by 15 sec-
onds. The maximum delay is 3 minutes. Once modified, the
fan off 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 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 base 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).
GAS HEATING, CONSTANT VOLUME (CV) UNITS —
The gas heat units incorporate 2 separate systems to provide
gas heat. Each system incorporates its own induced-draft mo-
tor, Integrated Gas Control (IGC) board, 2 stage gas valve,
manifold, etc. The systems are operated in parallel; for ex-
ample, when there is a call for first stage heat, both induced-
draft motors operate, both 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 base mod-
ule board serves only to initiate and terminate heating
operation.
The base module board is powered by 24 vac. When the
thermostat or room sensor calls for heating, power is sent
from the base module board to W on each of the IGC boards.
An LED on the IGC board will be on during normal opera-
tion. 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 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 con-
trolled through a room thermostat set for fan auto., 45 sec-
onds after ignition occurs, the indoor-fan motor will be
energized and the outdoor-air dampers will open to their mini-
mum position. If for some reason the overtemperature limit
opens prior to the start of the indoor fan blower, on the next
attempt, the 45-second delay will be shortened to 5 seconds
less than the time from initiation of heat to when the limit
tripped. Gas will not be interrupted to the burners and heat-
ing will continue. Once modified, the fan on 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 in-
door fan will be operating in the Occupied mode and the
outdoor-air dampers will be in the minimum position.
The base module board is powered by 24 vac. When there
is a call for heating (either Morning Warm-Up, Unoccupied,
or Occupied modes), power is sent from the base module
board to W on each of the IGC boards and W2 of the main
gas valve. When heating, the control board will energize a
field-supplied heat interlock relay output to drive the VAV
terminal boxes wide open. The HIR is not required on a DAV
system. See Fig. 42. 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 closed in the Un-
occupied mode). The duct pressure sensor will signal to the
variable frequency 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 en-
sure that the rollout switches and limit switches are closed
and the induced-draft motors are not running. The induced-
draft motors are then energized and when speed is proven
with the hall effect sensor on the motor, the ignition activa-
tion 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.
If the call for heat lasted less than 1 minute, the heating
cycle will not terminate until 1 minute after heat became ac-
tive. When heating is satisfied, the power will be interrupted
to the IGC board and W1 and W2 of the main gas valve. 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.
MORNING WARM-UP (VAV only) (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 condition in VAV systems that occurs when the Tempera-
ture Compensated Start algorithm calculates a biased occu-
pied start time and the unit has a demand for heating. The
warm-up will continue into the occupied period as long as
there is a need for heat. During warm-up, the unit can con-
tinue heating into the occupied period, even if occupied heat-
ing is disabled. When the heating demand is satisfied, the
warm-up condition will terminate. 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™ software or accessory LID-
2B. The PC can access the base control board via the 3-wire
communication bus or via an RJ-11 connection to the CCN
terminal on the base control board. See Fig. 16.
If the unit is controlled with a room sensor in the Unoc-
cupied mode, the indoor fan will be energized through the
IGC board with a 45-second delay and the outside-air damp-
ers will move to the IAQ position (generally closed in the
Unoccupied mode). If IAQ is not enabled, dampers will move
to the minimum 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 W1 lasted less than 1 minute, the heating cycle will
not terminate 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 addi-
tional 45 seconds then stop and the outdoor-air dampers will
41
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MORNING WARM-UP (VAV Only) (Stand-Alone Opera-
tion) — When the unit operates in stand-alone mode, morn-
ing warm-up occurs when the unit is energized in Occupied
mode and return-air temperature (RAT) is below 68 F. Warm-up
will not terminate until the RAT reaches 68 F. The heat in-
terlock relay output is energized during morning warm-up.
(A field-installed 24-vdc heat interlock relay is required.) The
output will be energized until the morning warm-up cycle is
complete. Refer to Fig. 42 for heat interlock relay wiring.
in supply-air temperature per degree of space temperature
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. If the fan is ‘‘on,’’ the sequence will check if the system
is occupied.
SPACE TEMPERATURE RESET SENSOR (VAV Only) —
An accessory space temperature sensor wired to terminals
T1 and T2 on the control module is required. Space tem-
perature 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 tempera-
ture 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
3. If the system is occupied, the sequence will determine if
the reset 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.
TRAN2
B
COM
CB4
3.2 AMPS
SECONDARY
24 VOLT
LEGEND
CB
—
—
—
—
—
Circuit Breaker
Common
COM
HIR
T
Heat Interlock Relay
Terminal
BASE MODULE
CONTROL BOARD
TRAN
Transformer
COM
INDOOR FAN RELAY
T
30
HIR
T29
FIELD
INSTALLED
T
28
(HN61KK040)
(24V, 9.5VA)
Fig. 42 — Heat Interlock Relay Wiring
mA INPUT
DEG. F RESET
BASE MODULE
CONTROL BOARD
4
5
0.00
1.25
6
2.50
(+) T11
(–) T12
4-20 mA
INPUT
7
3.75
8
5.00
FIELD
9
6.25
SUPPLIED
10
11
12
13
14
15
16
17
18
19
20
7.50
INPUT DEVICE
8.75
10.00
11.25
12.50
13.75
15.00
16.25
17.50
18.75
20.00
LEGEND
Terminal
T
—
NOTE: The 4 to 20 mA input is a field-supplied non-
Carrier EMS (Energy Management System) device.
Fig. 43 — Space Temperature Reset Wiring
42
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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
degrees F the temperature is reset. At 72 F, the supply tem-
perature will be reset 5 degrees higher. At 71 F, the supply
temperature will be reset 10 degrees higher. At 70 F, the sup-
ply temperature 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.
SUPPLY AIR TEMPERATURE RESET — Supply air tem-
perature reset is used to reset the supply air temperature util-
ity. A 4 to 20 mA signal (field-supplied) is required. The re-
set option does not require enabling.
POWER EXHAUST OPERATION — The optional power
exhaust packages are factory- or field-installed with vertical
units and optionally installed in the return air ductwork for
horizontal applications. The standard (offered with constant
volume or variable air volume units) and the modulating power
exhaust (offered on VAV units) are the two packages offered.
The modulating power exhaust package is equipped with a
field-adjustable static pressure controller to stage up to 4 power
exhaust stages which will maintain a building static pres-
sure. The blue controller located in the control box below
the control board can be adjusted, by removing the covers
and adjusting the set point dial to the desired building pres-
sure. The blue controller monitors the 4 individual sequenc-
ers which activate the 4 individual power exhaust motors.
The standard power exhaust package controls up to 2 stages
of power exhaust to maintain building pressure. The power
exhaust package can be configured to deliver positive or nega-
tive building pressure. These power exhaust stages are staged
according to a percentage of the economizer dampers
position. Default values are 25% for Stage 1 and 75% for
Stage 2. This package has set points that are adjustable
through software (Service Tool, Building Supervisor, or
ComfortWorks™).
Fig. 44 — Field-Supplied Smoke Detector Wiring
as to specific smoke detector location due to liability
considerations.
INDOOR AIR QUALITY CONTROL — The accessory ex-
pansion board and accessory IAQ sensor are required for IAQ
control. The Carrier sensors operate with a 4 to 20 mA sig-
nal. The 4 to 20 mA signal is connected to T11 (+) and T12
(−) on the expansion board for the IAQ sensor, and T13 (+)
and T14 (−) on the expansion board for the OAQ (Outdoor
Air Quality) sensor. The sensor is field-mounted and wired
to the expansion board installed in the unit main control box.
The IAQ sensor must be powered by a field-supplied 24-v
power supply (ungrounded). Do not use the unit 24-v power
supply to power the sensor.
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 expansion 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 sen-
sor reading. The high reference (20 mA output) must be con-
figured to the maximum IAQ sensor reading.
SMOKE CONTROL MODES — The 48EJ,EK,EW,EY units
with an optional expansion board perform fire and smoke
control modes. The expansion board provides 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 19.
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
control is to the IAQ set point, but the outside air damper
position will change to its minimum position when the fol-
lowing conditions 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
supply-air temperature is less than the supply-air tem-
perature set point minus 8° F or when the supply-air
temperature is greater than the supply air temperature
set point plus 5° F for 4 minutes.
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 ‘‘B’’ terminal to the
control circuit breaker (CB4). See Fig. 44. The wire that con-
nects these two points is white and labeled ‘‘W78.’’
NOTE: On standard gas models, the indoor fan will con-
tinue to run 45 seconds after the call for heat has been ter-
minated. If fire shutdown is initiated the fan will stop im-
mediately. 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
Table 19 — Smoke Control Modes
DEVICE
Economizer
PRESSURIZATION
SMOKE PURGE
EVACUATION
100%
OFF
FIRE SHUTDOWN
100%
ON
100%
ON
0%
Indoor Fan/VFD
Power Exhaust (all outputs)
Heat Stages
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
OFF
ON
OFF
HIR
OFF
LEGEND
HIR
VFD
—
—
Heat Interlock Relay
Variable Frequency Drive
43
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• When the outdoor air quality is greater than the outdoor
air quality set point (ppm)
FIELD TEST — The field test program is initiated by mov-
ing up DIP switch no. 4 to the OPEN position. The outdoor-
air damper will close. The control allows 90 seconds for the
damper 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 20% 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.
High priority — When the priority is set to high, the IAQ
set point controls the outside air damper exclusively, with
no regard to comfort conditioning.
TIME GUARD CIRCUIT — The Time Guard function (built
into the rooftop control board) maintains a minimum off time
of 5 minutes, a minimum on time of 10 seconds, and a
10-second delay between compressor starts.
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.
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.
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. 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
outdoor-fan contactors and indoor-fan contactors. If the unit
is equipped with the Integrated Gas Control (IGC) board,
the indoor fan will continue to operate for an additional
30 seconds after deenergizing the circuit.
HEAD PRESSURE CONTROL — Each unit has a fan cy-
cling, outdoor thermostat to shut off the outdoor-fan mo-
tor(s) at 55 F (one outdoor-fan motor on 024-034 units and
two outdoor fan motors on 038-048 units). The head pres-
sure control permits unit 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 ac-
cessory fan speed control device actuated by a temperature
sensor. It is specifically designed for use on Carrier equip-
ment and controls the condenser-fan motor speed in re-
sponse to the saturated condensing temperature. For outdoor
temperatures down to −20 F, it maintains condensing tem-
perature at 100 F. Refer to the accessory Motormaster in-
stallation instructions for more information.
The field test is then complete.
SERVICE
CAPACITY CONTROL, COOLING — The cooling capac-
ity staging tables are shown in Tables 20 and 21.
Before performing service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury.
Table 20 — Cooling Capacity Staging Table, CV Units
with 2 Compressors
Service Access — All unit components can be reached
through clearly labelled hinged access doors. These doors
are not equipped with tiebacks, so if heavy duty servicing is
needed, either remove them or prop them open to prevent
accidental closure.
Stages
1
0
2
3
Economizer
Compressor 1
Compressor 2
off
off
off
off
on
off
on
on
Each door is held closed with 3 latches. The latches are
secured to the unit with a single 1⁄4-in. - 20 x 1⁄2-in. long bolt.
See Fig. 45.
NOTE: On CV units that require additional unloading, add suction pres-
sure unloaders to Compressor 1 only.
Table 21 — Cooling Capacity Staging Table VAV Units
with 2 Compressors and 2 Unloaders*
Stages
0
1
2
3
4
5
6
Compressor 1
Unloader 1
off
off
off
off
on
on
on
off
on
on
off
off
on
off
off
off
on
on
on
on
on
on
off
on
on
off
off
on
Unloader 2
Compressor 2
*40 ton units have only one unloader.
Fig. 45 — Door Latch
44
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To open, loosen the latch bolt using a 7⁄16-in. wrench. Pivot
the latch so it is not in contact with the door. Open the door.
To shut, reverse the above procedure.
NOTE: Disassembly of the top cover may be required under
special service circumstances. It is very important that the
orientation and position of the top cover be marked on the
unit prior to disassembly. This will allow proper replace-
ment of the top cover onto the unit and prevent rainwater
from leaking into the unit.
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
cooling season, or more often if operating conditions re-
quire. Refer to Table 1 for type and size.
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.
NOTE: The unit requires 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 dis-
posable filters in place of screens. See Fig. 24 for location of
screens (filter track assembly).
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
necessary. Check spark gap. See Fig. 46. Refer to Main Burn-
ers section on page 48.
Lubrication
COMPRESSORS — Each compressor is charged with the
correct amount of oil at the factory. The correct oil charge is
shown in Table 1. 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
FLUE GAS PASSAGEWAYS — The flue collector box and
heat exchanger cells may be inspected by removing gas sec-
tion access panel (Fig. 3-6), flue box cover, collector box,
and main burner assembly (Fig. 47 and 48). Refer to Main
Burners section on page 48 for burner removal sequence. If
cleaning is required, clean all parts with a wire brush. Re-
assemble using new cerafelt high-temperature insulation for
sealing.
1
1
between ⁄4 and ⁄3 of sight glass during steady operation.
If oil charge is above 1⁄3 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, Inc. . . . . . . . . . . . . . . . . . Cryol 150
Texaco, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . Capella WF-32
Witco Chemical Corp. . . . . . . . . . . . . . . . . . . . Suniso 3GS
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
determine proper cleaning frequency.
To inspect blower wheel, remove heat exchanger access
panel. Shine a flashlight into opening to inspect wheel. If
cleaning is required, remove motor and wheel assembly by
removing screws holding motor mounting plate to top of com-
bustion fan housing (Fig. 47 and 48). 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.
IMPORTANT: Do not use reclaimed oil or oil that has
been exposed to the atmosphere. Refer to Carrier Stand-
ard Service Techniques Manual, Chapter 1, Refriger-
ants section, for procedures to add or 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
Texaco
LUBRICANT
Regal AFB-2*
Mobilplex EP No. 1
Prestige 42
Mobil
Sunoco
Texaco
Multifak 2
*Preferred lubricant because it contains rust and oxidation inhibitors.
CONDENSER-AND EVAPORATOR-FAN MOTOR BEAR-
INGS — The condenser- and evaporator-fan motors have
permanently-sealed bearings, so no field lubrication is
necessary.
Fig. 46 — Spark Gap Adjustment
45
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NOTES:
1. Torque set screws on blower wheel to 70 in. lbs ± 2 in. lbs.
2. Torque set screw on propeller fan to 15 in. lbs ± 2 in. lbs.
3. Dimensions are in inches.
Fig. 47 — Typical Gas Heating Section
3. Slide fan pulley along fan shaft.
4. Make angular alignment by loosening motor from mount-
ing plate.
5. Retighten pulley.
Evaporator Fan Service and Replacement
1. Shut off unit power supply.
2. Remove supply-air section panels.
3. Remove belt and blower pulley.
4. Loosen setscrews in blower wheels.
5. Remove locking collars from bearings.
6. Remove shaft.
7. Remove venturi on opposite side of bearing.
8. Lift out wheel.
9. Reverse above procedure to reinstall fan.
10. Check and adjust belt tension as necessary.
Fig. 48 — Gas Heat Section Details
Belt Tension Adjustment — To adjust belt tension:
1. Shut off unit power supply.
Evaporator Fan Performance Adjustment
(Fig. 49) — Fan motor pulleys are designed for speed shown
in Table 1 (factory speed setting).
2. Loosen motor mounting nuts and bolts. See Fig. 50.
3. Loosen fan motor nuts.
4. Turn motor jacking bolts to move motor mounting plate
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.
IMPORTANT: Check to ensure that the unit drive
matches the duct static pressure using Tables 12-14.
To change fan speeds, change pulleys.
To align fan and motor pulleys:
1. Shut off unit power supply.
5. Tighten nuts.
6. Adjust bolts and nut on mounting plate to secure motor
in fixed position. Recheck belt tension after 24 hours of
operation. Adjust as necessary.
2. Loosen fan shaft pulley bushing.
46
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Evaporator-Fan Motor Replacement
1. Shut off unit power supply.
2. Remove upper outside panel and open hinged door to
gain access to motor.
3. Fully retract motor plate adjusting bolts.
4. Loosen the two rear (nearest the evaporator coil) motor
plate nuts.
5. Remove the two front motor plate nuts and carriage bolts.
6. Slide motor plate to the rear (toward the coil) and re-
move fan belt(s).
7. 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).
8. Pivot the front of the motor plate upward enough to al-
low access to the motor mounting hex bolts and secure
in place by inserting a prop.
9. Remove the nuts from the motor mounting hex bolts and
remove motor.
10. Reverse above steps to install new motor.
Condenser-Fan Adjustment
1. Shut off unit power supply.
2. Remove fan guard.
3. Loosen fan hub setscrews.
4. Adjust fan height on shaft using a straightedge placed across
venturi and measure per Fig. 51.
Fig. 49 — Evaporator-Fan Alignment and
Adjustment
5. Fill hub recess with permagum if rubber hubcap is
missing.
6. Tighten setscrews and replace panel(s).
7. Turn on unit power.
Thermostatic Expansion Valve (TXV) — Each cir-
cuit has a TXV. The TXV is nonadjustable and is factory set
to maintain 10 to 13° F superheat leaving the evaporator coil.
The TXV controls flow of liquid refrigerant to the evapo-
rator coils.
Power Failure — The economizer damper motor is a
spring return design. In event of power failure, dampers will
return to fully closed position until power is restored.
Gas Valve Adjustment
Refrigerant Charge — Amount of refrigerant charge
is listed on unit nameplate and in Table 1. Refer to Carrier
GTAC II; Module 5; Charging, Recovery, Recycling, and
Reclamation section for charging methods and procedures.
Unit panels must be in place when unit is operating dur-
ing charging procedure.
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 sup-
plied to terminals 1 and 2, the main valve opens to its preset
position.
NOTE: Do not use recycled refrigerant as it may contain
contaminants.
The regular factory setting is stamped on the valve body
(3.5 in. wg).
NO CHARGE — Use standard evacuating techniques. After
evacuating system, weigh in the specified amount of
refrigerant (refer to Table 1).
To adjust regulator:
1. Set thermostat at setting for no call for heat.
2. Turn main gas valve to OFF position.
LOW CHARGE COOLING — Using appropriate cooling
charging chart (see Fig. 52 and 53), add or remove refrig-
erant until conditions of the appropriate chart are met. Note
that charging chart is different from those normally used. An
accurate pressure gage and temperature sensing device are
required. Measure liquid line pressure at the liquid line serv-
ice valve using pressure gage. Connect temperature sensing
device to the liquid line near the liquid line service valve
and insulate it so that outdoor ambient temperature does not
affect reading.
1
3. Remove ⁄8-in. pipe plug from manifold. Install a water
manometer pressure-measuring device.
4. Set main gas valve to ON position.
5. Set thermostat at setting to call for heat.
6. Remove screw cap covering regulator adjustment screw
(See Fig. 54).
7. Turn adjustment screw clockwise to increase pressure or
counterclockwise to decrease pressure.
8. Once desired pressure is established, set thermostat set-
ting for no call for heat, turn off main gas valve, remove
Using the above temperature and pressure readings, find
the intersect point on the appropriate cooling charging chart.
If intersection point on chart is above line, add refrigerant.
If intersection point on chart is below line, carefully reclaim
some of the charge. Recheck suction pressure as charge is
adjusted.
1
pressure-measuring device and replace ⁄8-in. pipe plug
and screw cap.
NOTE: Indoor-air cfm must be within normal operating range
of unit. All outdoor fans must be operating.
47
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Fig. 50 — Belt Tension Adjustment
Fig. 53 — Cooling Charging Chart,
48EJ,EK,EW,EY038-048
Fig. 51 — Condenser-Fan Adjustment
Main Burners — For all applications, main burners are
factory set and should require no adjustment.
MAIN BURNER REMOVAL (Fig. 55)
1. Shut off (field-supplied) manual main gas valve.
2. Shut off power to unit.
3. Remove heating access panel.
4. Disconnect gas piping from gas valve inlet.
5. Remove wires from gas valve.
6. Remove wires from rollout switch.
7. Remove sensor wire and ignitor cable from IGC board.
8. Remove 2 screws securing manifold bracket to basepan.
9. Remove 4 screws that hold the burner support plate flange
to the vestibule plate.
10. Lift burner assembly out of unit.
11. Reverse procedure to re-install burners.
Filter Drier — Replace whenever refrigerant system is
exposed 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 trouble.
Determine the cause and correct it before resetting the breaker.
Overtemperature — Each 06D type compressor (024-038 units)
has an internal protector to protect it against excessively high
discharge gas temperatures.
Fig. 52 — Cooling Charging Chart,
48EJ,EK,EW,EY024-034
48
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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.
Compressor Lockout Logic — If any of the safe-
ties 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 circuit will be locked out and will require manual
resetting by turning off either the unit disconnect or the con-
trol circuit breaker, or opening the thermostat.
IMPORTANT: After a prolonged shutdown or serv-
ice job, energize the crankcase heaters for 24 hours
before starting the compressors.
Replacement Parts — A complete list of replacement
parts may be obtained from any Carrier distributor upon
request.
EVAPORATOR FAN MOTOR PROTECTION — A manual
reset, calibrated trip, magnetic circuit breaker protects against
overcurrent. Do not bypass connections or increase the size
of the breaker to correct trouble. Determine the cause and
correct it before resetting the breaker. If the evaporator-fan
motor is replaced with a different horsepower motor, resiz-
ing 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 ac-
tivates, that refrigerant circuit will be automatically stopped.
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
circuit. It detects frost build-up and turns off the compressor,
allowing the coil to clear. Once the frost has melted, the com-
pressor can be reenergized.
Fig. 54 — Gas Valve
Relief Devices — All units have relief devices to pro-
tect against damage from excessive pressures (i.e., fire). These
devices are installed on the suction line, liquid line, and on
the compressor.
Power Circuit — A typical power wiring schematic is
shown in Fig. 56.
Control Circuit, 115-V — This control circuit is pro-
tected against overcurrent by a 5.0 amp circuit breaker (CB3).
Breaker can be reset. If it trips, determine cause of trouble
before resetting. A typical 115-v control wiring schematic is
shown in Fig. 57 and 58.
Control Circuit, 24-V — This control circuit is pro-
tected against overcurrent by a 3.2 amp circuit breaker (CB4).
Breaker can be reset. If it trips, determine cause of trouble
before resetting. A typical 24-v control wiring schematic is
shown in Fig. 59 and 60.
Fig. 55 — Main Burner Removal
49
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LEGEND and NOTES for Fig. 56-60 — Typical Wiring Schematics
LEGEND
AHA
BP
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Adjustable Heat Anticipator
Building Pressure
Burner Relay
IFC
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Indoor Fan Contactor
Indoor Fan Circuit Breaker
Indoor-Fan Motor
Indoor-Fan Relay
Integrated Gas Unit Controller
Internal Protector
Light
TC
—
—
—
—
—
Thermostat Cooling
Thermostat Heating
Transformer
IFCB
IFM
IFR
TH
BR
TRAN
UL
VFD
C
Contactor, Compressor
Capacitor
Compressor Unloader
Variable Frequency Drive
CAP
CB
IGC
IP
L
Circuit Breaker
Terminal (Marked)
CC
Cooling Compensator
Controller Circuit Breaker
Crankcase Heater
Communication
Compressor Motor
Control Relay
CCB
CCH
COM
COMP
CR
LPS
MGV
NC
Low-Pressure Switch
Main Gas Valve
Terminal (Unmarked)
Normally Closed
Normally Open
NO
Terminal Block
OAT
OFC
OFM
PEC
PEM
PES
Outdoor-Air Thermistor
Outdoor-Fan Contactor
Outdoor-Fan Motor
Power Exhaust Contactor
Power Exhaust Motor
Power Exhaust Sequencer
Power Exhaust Sequencer
Controller
DM
Damper Motor
Duct Pressure
Splice
DP
EC
Enthalpy Control
Equipment
Factory Wiring
Field Wiring
EQUIP
FLA
FPT
FU
Full Load Amps
Freeze Protection Thermostat PESC
Fuse
Ground
To Indicate Common Potential Only,
Not To Represent Wiring
GRD
GVR
HPS
HS
HV
IDM
PL
R
RAT
RS
SAT
TB
—
—
—
—
—
—
Plug Assembly
Relay
Gas Valve Relay
High-Pressure Switch
Hall Effect Sensor
High Voltage
Return-Air Thermistor
Rollout Switch
Supply-Air Thermistor
Terminal Block
Induced-Draft Motor
NOTES:
1. Connect TRAN1 to H4 for 460 v units. Connect to H3 for 230 v. If
208/230 v units are run with a 208 v power supply connect to H2.
2. Connect TRAN2 to black lead for 460 v units. Connect to orange
lead for 230 v units. If 208/230 v units are run with a 208 v power
supply connect to red lead.
3. Circuit breaker must trip amps are equal to or less than 156% FLA
for CB1 and CB2. All others are 140%.
4. If any of the original wire furnished must be replaced, it must be
replaced with type 90 C wire or its equivalent.
5. Compressors and/or fan motors are thermally protected.
6. Three phase motors are protected against primary single phasing
conditions.
7. Red wire and violet wire are spliced together at the factory. The
brown wire has a wire nut added at the factory.
TABLE A
TABLE B
THE FOLLOWING COMPRESSORS HAVE
TWO PARALLEL WIRES RUN FROM TB1
TO THE COMPRESSORS
THE FOLLOWING FAN MOTORS HAVE TWO
PARALLEL WIRES RUN FROM TB1 TO THE
FAN MOTORS
(NOT SHOWN ON LABEL DIAGRAM)
(NOT SHOWN ON LABEL DIAGRAM)
COMPRESSOR
MODEL
WIRE
QUANTITY
INDOOR
MOTOR
WIRE
QUANTITY
VOLTAGE
VOLTAGE
06D-537
208/230-3-60
2
20 HP
208/230-3-60
2
50
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Fig. 56 — Typical Power Schematic; 48EJ,EK,EW,EY024-034; 208/230-3-60 and 460-3-60
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Fig. 57 — Typical VAV 115-v Control Circuit
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Fig. 58 — Typical CV 115-v Control Circuit
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Fig. 59 — Typical VAV 24-v Control Circuit
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Fig. 60 — Typical CV 24-v Control Circuit
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TROUBLESHOOTING
Typical refrigerant circuiting diagrams are shown in Fig. 61-63. An algorithm diagram of the IGC (Integrated Gas Unit Con-
troller) control is shown in Fig. 64.
LEGEND
FPS
HPS
LPS
—
—
—
Freeze Protection Switch
High-Pressure Switch
Low-Pressure Switch
Fig. 61 — Typical Refrigerant Circuiting (48EJ,EK,EW,EY024-034)
56
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LEGEND
FPS
HPS
LPS
—
—
—
Freeze Protection Switch
High-Pressure Switch
Low-Pressure Switch
Fig. 62 — Typical Refrigerant Circuiting (48EJ,EK,EW,EY038,044)
57
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LEGEND
FPS
HPS
LPS
—
—
—
Freeze Protection Switch
High-Pressure Switch
Low-Pressure Switch
Fig. 63 — Typical Refrigerant Circuiting (48EJ,EK,EW,EY048)
58
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LEGEND
IDM
IGC
—
—
Induced-Draft Motor
Integrated Gas Unit Controller
NOTE: Thermostat Fan Switch in the ‘‘AUTO’’ position or sensor-equipped unit.
Fig. 64 — IGC Control (Heating and Cooling)
59
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The alarm codes for the IGC control board are shown in
Table 22.
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 indicates an alarm. Refer to Table 23 below for a de-
scription of alarms. The yellow LED blinks during transmis-
sion with the CCN (Carrier Comfort Network). The green
LED blinks during transmission with the expansion board.
Table 22 — IGC Control Board LED Alarms
INDICATION
ON
ERROR MODE
Normal Operation
OFF
Hardware Failure
1 FLASH
Fan ON/OFF Delay Modified
Limit Switch Fault
2 FLASHES
3 FLASHES
4 FLASHES
5 FLASHES
6 FLASHES
7 FLASHES
8 FLASHES
Flame Sense Fault
4 Consecutive Limit Switch Faults
Ignition Lockout Fault
Induced Draft Motor Fault
Rollout Switch Fault
Internal Control Fault
Table 23 — Control Board LED Alarms
LED Blinks
1
Error Code
Description
Troubleshooting Comments
The expansion board and control board flash the red LED in one-second
intervals when the board is operating properly.
—
Normal Operation
The high or low pressure safety switch for compressor no. 1 has opened for
3 seconds. The error will be cleared and compressor no. 1 will be allowed
to turn on in 15 minutes. If the safeties have been tripped 3 times in 90 min-
utes, compressor no. 1 will be locked out until the control board has been
manually reset.
2
3
HF-13
Compressor 1 Safety
Compressor 2 Safety
The high or low pressure safety switch for compressor no. 2 has opened for
3 seconds. The error will be cleared and compressor no. 2 will be allowed
to turn on in 15 minutes. If the safeties have been tripped 3 times in 90 min-
utes, compressor no. 2 will be locked out until the control board has been
manually reset.
HF-14
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.
4
5
6
7
HF-15
HF-05
HF-06
HF-03
Thermostat Failure
The supply-air temperature (SAT) sensor has failed. First check for wiring
errors, then replace sensor.
SAT Thermistor Failure
OAT Thermistor Failure
Space Temp. Sen. Failure
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.
8
9
HF-12
SE-05
RAT Thermistor Failure
Communications between the expansion board and the control board have
been interrupted. Ensure that an expansion board is installed and wired us-
ing 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.
Loss of Communications
with Expansion Board
Generated when hardware has failed on control board. Replace the control
board.
10
11
HF-16
HF-17
Control Board Failure
Generated when hardware has failed on the expansion board. Replace the
expansion board.
Expansion Board Failure
DIP
VAV
—
—
Dual In-Line Package
Variable Air Volume
60
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Tables 24-26 show the input and output channel
designations.
Table 24 — I/O Channel Designations Base Module — CV
TERMINAL NO.
T1-2
ASSIGNMENT
SPT (CCN) — 10K⍀ Thermistor
STO (CCN) — 10K⍀ Thermistor
OAT — 5K⍀ Thermistor
SAT — 5K⍀ Thermistor
—
TERMINAL NO.
T23-25
T24-25
T26-27
T28-29
T30-29
T31-32
T33-32
T34-35
T36-35
T37-38
T39-38
K1
ASSIGNMENT
Compressor 2 Safety — DI (24 vac)
T3-4
Outside Air Enthalpy — DI (24 vac)
Economizer Pos. — AO (4-20 mA)
Heat 1 Relay — DO (24 vac)
Heat 2 Relay — DO (24 vac)
CV Power Exhaust 1/Modulating Power Exhaust — DO (115 vac)
CV Power Exhaust 2 — DO (115 vac)
Condenser Fan — DO (115 vac)
OFC2 — DO (115 vac)
T5-6
T7-8
T9-10
T11-12
T13-14
T15-16
T17-25
T18-25
T19-25
T20-25
T21-25
T22-25
SAT Reset — AI (4 to 20 mA)
—
—
Y1 or Remote Start/Stop — DI (24 vac)
Y2 — DI (24 vac)
—
W1 — DI (24 vac)
—
W2 — DI (24 vac)
Indoor Fan Relay — DO (LV)
Compr. 1 — DO (HV)
G — DI (24 vac)
K2
Compressor 1 Safety — DI (24 vac)
K3
Compr. 2 — DO (HV)
Table 25 — I/O Channel Designations Base Module — VAV
TERMINAL NO.
T1-2
ASSIGNMENT
TERMINAL NO.
T23-25
T24-25
T26-27
T28-29
T30-29
T31-32
T33-32
T34-35
T36-35
T37-38
T39-38
K1
ASSIGNMENT
Compressor 2 Safety — DI (24 vac)
Outside Air Enthalpy — DI (24 vac)
Economizer Pos. — AO (4-20 mA)
Heat 1 Relay − DO (24 vac)
Heat Interlock Relay — DO (24 vac)
Modulated Power Exhaust — DO (115 vac)
—
SPT (CCN) — 10K⍀ Thermistor
T3-4
RAT — 5K⍀ Thermistor
T5-6
OAT — 5K⍀ Thermistor
T7-8
SAT — 5K⍀ Thermistor
T9-10
—
T11-12
T13-14
T15-16
T17-25
T18-25
T19-25
T20-25
T21-25
T22-25
SAT Reset — AI (4 to 20 mA)
—
—
Condenser Fan — DO (115 vac)
OFC2 — DO (115 vac)
Remote Start/Stop — DI (24 vac)
—
Unloader 1 — DO (115 vac)
Unloader 2 — DO (115 vac)
Indoor Fan Relay — DO (LV)
Compr. 1 (HV)
—
—
—
K2
Compressor 1 Safety — DI (24 vac)
K3
Compr. 2 — DO (HV)
Table 26 — I/O Channel Designations Expansion Module (Field-Installed) — CV and VAV
TERMINAL NO.
T1-2
ASSIGNMENT
TERMINAL NO.
T23-25
T24-25
T26-27
T28-29
T30-29
T31-32
T33-32
T34-35
T36-35
T37-38
T39-38
K1
ASSIGNMENT
—
Fire — Evacuation — DI (24 vac)
T3-4
—
—
Fire — Smoke Purge — DI (24 vac)
T5-6
—
T7-8
—
—
T9-10
—
Alarm Light Indicator — DO (24 vac)
T11-12
T13-14
T15-16
T17-25
T18-25
T19-25
T20-25
T21-25
T22-25
IAQ Indoor — AI (4 to 20 mA)
IAQ Outdoor — AI (4 to 20 mA)
—
Power Exhaust Fire No. 1 — DO (115 vac)
Power Exhaust Fire No. 2 — DO (115 vac)
Power Exhaust Fire No. 3 — DO (115 vac)
Fan Status — DI (24 vac)
Filter Status − DI (24 vac)
Field Applied Status — DI (24 vac)
Demand Limit — DI (24 vac)
Fire — Unit Shutdown — DI (24 vac)
Fire — Pressurization — DI (24 vac)
Power Exhaust Fire No. 4 — DO (115 vac)
—
—
—
—
—
K2
K3
LEGEND (Tables 24-26)
K⍀
—
—
—
—
—
—
—
—
—
—
Kilo-Ohms
AI
—
—
—
—
—
—
—
—
Analog Input
LV
Low Voltage
AO
CCN
CV
DI
Analog Output
OAT
OFC
RAT
SAT
SPT
STO
T
Outdoor-Air Temperature
Outdoor Fan Contactor
Return-Air Temperature
Supply-Air Temperature
Space Temperature
Space Temperature Offset
Terminal
Carrier Comfort Network
Constant Volume
Direct Input
DO
HV
IAQ
Direct Output
High Voltage
Indoor Air Quality
VAV
Variable Air Volume
NOTE: For 4 to 20 mA signals, all even numbered terminals are negative (−) polarity, and all odd numbered terminals are positive (+) polarity.
61
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PACKAGED SERVICE TRAINING
Our packaged service training programs provide an excellent way to increase your knowledge of the
equipment discussed in this manual. Product programs cover:
• Unit Familiarization
• Installation Overview
• Maintenance
• Operating Sequence
A large selection of product, theory, and skills programs is available. All programs include a video
cassette and/or slides and a companion booklet. Use these for self teaching or to conduct full training
sessions.
For a free Service Training Material Catalog (STM), call 1-800-962-9212. Ordering instructions are
included.
Copyright 1997 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. 564-962
Printed in U.S.A.
Form 48E-5SI
Pg 62
8-97
Replaces: 48E-3SI
Tab 1a
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START-UP CHECKLIST
MODEL NO.:
SERIAL NO.:
SOFTWARE VERSION (SEE FIG. 16)
DATE:
TECHNICIAN:
PRE-START-UP:
Ⅺ VERIFY THAT DIP SWITCH SETTINGS ARE CORRECT
Ⅺ VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
Ⅺ REMOVE ALL SHIPPING HOLDDOWN BOLTS AND BRACKETS PER INSTRUCTIONS
Ⅺ VERIFY INSTALLATION OF ECONOMIZER HOOD
Ⅺ VERIFY INSTALLATION OF ALL OPTIONS AND ACCESSORIES
Ⅺ VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS
Ⅺ VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT
Ⅺ CHECK GAS PIPING FOR LEAKS
Ⅺ CHECK THAT INDOOR-AIR FILTERS ARE CLEAN AND IN PLACE
Ⅺ VERIFY THAT UNIT IS LEVEL WITHIN TOLERANCES
Ⅺ CHECK FAN WHEELS AND PROPELLERS FOR LOCATION IN HOUSING/ORIFICE, AND VERIFY SETSCREW
IS TIGHT
Ⅺ VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED
Ⅺ VERIFY THAT SUCTION, DISCHARGE, AND LIQUID SERVICE VALVES ON EACH CIRCUIT ARE OPEN
START-UP
ELECTRICAL
SUPPLY VOLTAGE L1-L2
L2-L3
L3-L1
COMPRESSOR AMPS — COMPRESSOR NO. 1 L1
— COMPRESSOR NO. 2 L1
L2
L2
L3
L3
SUPPLY FAN AMPS (CV)
(VAV)
EXHAUST FAN AMPS
*
*VAV fan supply amps reading must be taken with a true RMS meter for accurate readings.
Ⅺ ADJUST VARIABLE FREQUENCY DRIVE (VFD) TO APPLICATION REQUIREMENTS.
TEMPERATURES
OUTDOOR-AIR TEMPERATURE
RETURN-AIR TEMPERATURE
COOLING SUPPLY AIR
F DB (Dry Bulb)
F DB
F
WB (Wet Bulb)
F
F
GAS HEAT SUPPLY AIR
PRESSURES
GAS INLET PRESSURE
GAS MANIFOLD PRESSURE
REFRIGERANT SUCTION
REFRIGERANT DISCHARGE
IN. WG
IN. WG
PSIG
STAGE NO. 1
CIRCUIT NO. 1
CIRCUIT NO. 1
STAGE NO. 2
CIRCUIT NO. 2
CIRCUIT NO. 2
IN. WG
PSIG
PSIG
PSIG
Ⅺ VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGE 48
CL-1
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GENERAL
Ⅺ SET ECONOMIZER MINIMUM VENT POSITION TO JOB REQUIREMENTS
Ⅺ ENSURE DRIVES OPERATE WITHIN LIMITS OF FAN PERFORMANCE TABLES
HIGH PRESSURE SWITCH SETTING
LOW PRESSURE SWITCH SETTING
MOTOR PULLEY PART NUMBER
FAN PULLEY PART NUMBER
BELT PART NUMBER
psig
psig
BELT SIZE
in.
in.
FILTER QUANTITY
FILTER SIZES
ADDITIONAL NOTES:
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
Copyright 1997 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. 564-962
Printed in U.S.A.
Form 48E-5SI
Pg CL-2
8-97
Replaces: 48E-3SI
Tab 1a
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|