Contents

Carrier 48FCG 04 06 Installation Instructions PDF

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Summary of Content for Carrier 48FCG 04 06 Installation Instructions PDF

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480294-01 Printed in U.S.A. Form 48FCG-4-6-01SI Rev. D Pg 1 8-21 Replaces: New

Installation Instructions CONTENTS

Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1 MODEL NUMBER NOMENCLATURE AND

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rated Indoor Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Step 1 Plan for Unit Location . . . . . . . . . . . . . . . . 8 ROOF MOUNT Step 2 Plan for Sequence of Unit Installation . . . 8 CURB-MOUNTED INSTALLATION PAD-MOUNTED INSTALLATION FRAME-MOUNTED INSTALLATION Step 3 Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . 8 Step 4 Provide Unit Support . . . . . . . . . . . . . . . . . 8 ROOF CURB MOUNT SLAB MOUNT (HORIZONTAL UNITS ONLY) ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR

SLAB MOUNT) Step 5 Field Fabricate Ductwork . . . . . . . . . . . . . 10 Step 6 Rig and Place Unit . . . . . . . . . . . . . . . . . . 10 POSITIONING ON CURB Step 7 Convert to Horizontal and Connect

Ductwork (When Required) . . . . . . . . . . . . . . . . . 11 Step 8 Install Outside Air Hood . . . . . . . . . . . . . . 12 ECONOMIZER AND TWO-POSITION DAMPER HOOD

PACKAGE REMOVAL AND SETUP (FACTORY OPTION)

ECONOMIZER AND TWO-POSITION HOOD Step 9 Units with Hinged Panels Only . . . . . . . . 13 Step 10 Install Flue Hood . . . . . . . . . . . . . . . . . . . 13 Step 11 Install Gas Piping . . . . . . . . . . . . . . . . . . 13 FACTORY OPTION THRU-BASE CONNECTIONS

(GAS CONNECTIONS) Step 12 Install External Condensate Trap and

Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Step 13 Make Electrical Connections . . . . . . . . . 17 FIELD POWER SUPPLY UNITS WITH FACTORY-INSTALLED NON-FUSED

DISCONNECT UNITS WITHOUT FACTORY-INSTALLED

NON-FUSED DISCONNECT ALL UNITS CONVENIENCE OUTLETS FACTORY-OPTION THRU-BASE CONNECTIONS

(ELECTRICAL CONNECTIONS) UNITS WITHOUT THRU-BASE CONNECTIONS

(ELECTRICAL CONNECTIONS) FIELD CONTROL WIRING THERMOSTAT HEAT ANTICIPATOR SETTINGS HUMIDI-MIZER CONTROL CONNECTIONS TYPICAL UNIT WIRING DIAGRAMS Integrated Gas Controller . . . . . . . . . . . . . . . . . . . . . 29

EconoMi$er X (Factory Option) . . . . . . . . . . . . . . . .32 SYSTEM COMPONENTS SPECIFICATIONS INPUTS OUTPUTS ENVIRONMENTAL ECONOMIZER MODULE WIRING DETAILS S-BUS SENSOR WIRING CO2 SENSOR WIRING INTERFACE OVERVIEW SETUP AND CONFIGURATION TIME-OUT AND SCREENSAVER ENTHALPY SETTINGS STANDARD OR SINGLE SPEED FAN OPERATION 2 SPEED FAN OPERATION 2SP H/C (2 SPEED HEAT/COOL) FAN OPERATION

(SINGLE PHASE UNITS ONLY) 3 SPEED FAN OPERATION CHECKOUT TROUBLESHOOTING RTU Open Controller (Factory Option) . . . . . . . . . .45 SystemVu Controller (Factory Option) . . . . . . . . .45 Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . .45 LOW AMBIENT Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Step 14 Adjust Factory-Installed Options . . . . . .47 SMOKE DETECTORS ECONOMI$ER IV OCCUPANCY SWITCH Step 15 Install Accessories . . . . . . . . . . . . . . . . .47 Step 16 Fan Speed Set Up . . . . . . . . . . . . . . . . . .48 UNITS WITH ELECTRO-MECHANICAL CONTROLS UNITS WITH SYSTEMVU CONTROLS START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair, or service air-conditioning equipment. Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags and labels attached to the unit, and other safety precautions that may apply. Follow all safety codes, including ANSI (American National Standards Institute) Z223.1. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations. It is important to recognize safety information. This is the safety- alert symbol . When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

WeatherMaker 48FCG*04-06 Single Package Rooftop

Ultra Low NOx (14 ng/J) Gas Heating/Electric Cooling Unit with Puron (R-410A) Refrigerant

2

Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices, which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

DANGER

ELECTRICAL SHOCK HAZARD Failure to follow this warning will result in personal injury or death. Before performing service or maintenance operations on unit, turn off main power switch to unit and install lock(s) and lock- out tag(s). Ensure electrical service to rooftop unit agrees with voltage and amperage listed on the unit rating plate. Unit may have more than one power switch.

WARNING

FIRE, EXPLOSION HAZARD Failure to follow this warning could result in death, serious personal injury and/or property damage. Disconnect gas piping from unit when pressure testing at pressure greater than 0.5 psig (3450 Pa). Pressures greater than 0.5 psig will cause gas valve damage resulting in hazardous condition. If gas valve is subjected to pressure greater than 0.5 psig, it must be replaced before use. When pressure testing field-supplied gas piping at pressures of 0.5 psig or less, a unit connected to such piping must be isolated by closing the manual gas valve(s).

WARNING

UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause personal injury, death and/or equipment damage. R-410A refrigerant systems operate at higher pressures than standard R-22 systems. Do not use R-22 service equipment or components on R-410A refrigerant equipment.

WARNING

PERSONAL INJURY AND ENVIRONMENTAL HAZARD Failure to follow this warning could cause personal injury or death. Relieve pressure and recover all refrigerant before system repair or final unit disposal. Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils.

WARNING

CARBON-MONOXIDE POISONING HAZARD Failure to follow instructions could result in severe personal injury or death due to carbon-monoxide poisoning, if combustion products infiltrate into the building. Check that all openings in the outside wall around the vent (and air intake) pipe(s) are sealed to prevent infiltration of combustion products into the building. Check that furnace vent (and air intake) terminal(s) are not obstructed in any way during all seasons.

AVERTISSEMENT

RISQUE DINTOXICATION AU MONOXYDE DE CARBONE Si ces directives ne sont pas suivies, cela peut entraner des blessures graves ou une intoxication au monoxyde de carbone pouvant causer la mort, si des produits de combustion sinfiltrent dans le btiment. Vrifier que toutes les ouvertures pratiques dans le mur extrieur autour du ou des tuyaux dvent (et de la prise dair) sont scelles de manire empcher linfiltration de produits de combustion dans le btiment. Veiller ce que la ou les sorties de lvent de lappareil de chauffage (et la prise dair) ne soient, en aucune faon, obstrues, quelle que soit la saison.

WARNING

FIRE HAZARD Failure to follow this warning could result in severe personal injury and/or property damage. Inlet pressure tap set screw must be tightened and 1/8-in. NPT pipe plug must be installed to prevent gas leaks.

GAS VALVE

INLET PRESSURE TAP SET SCREW

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MODEL NUMBER NOMENCLATURE AND DIMENSIONS

See Fig. 1 for 48FCG model number nomenclature. See Fig. 2 for unit dimensional drawings. Figure 2 also shows service clearance dimensions.

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

WARNING

FIRE HAZARD Failure to follow this warning could result in severe personal injury and/or property damage. Manifold pressure tap set screw must be tightened and 1/8-in. NPT pipe plug must be installed to prevent gas leaks.

WARNING

UNIT OPERATION HAZARD Failure to follow this warning can result in equipment damage. Do Not adjust the inducer motor. The inducer motor is factory set; no field adjustment is required.

CAUTION

PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing air conditioning equipment.

CAUTION

Units can not operated with LP (liquid propane) gas under any circumstances.

CAUTION

Units can not operated at altitudes greater than 2,000 feet under any circumstances.

MANIFOLD GAS VALVE

MANIFOLD PRESSURE TAP SET SCREW

CAUTION

Do not detach the burner box from the heat exchanger panel. If the burner box must be replaced, refer to the Service and Maintenance Instructions for the unit.

ATTENTION

A particular air odor may be experienced coming from the flue discharge during initial gas heating start up. This is normal and will subside after minimal use.

Table 1 Rated Indoor Airflow

MODEL NUMBER RATED INDOOR AIRFLOW (CFM) 48FCG*04 1050 48FCG*05 1500 48FCG*06 2000

FLUE DISCHARGE HOOD

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Fig. 1 48FCG 04-06 Model Number Nomenclature

Model Series - WeatherMaker

FC >14.0 SEER Standard Efficiency

Unit Heat Type 48 Gas Heat Packaged Rooftop

Nominal Cooling Tons 04 = 3 tons 05 = 4 tons 06 = 5 tons

Heat Size G = Ultra Low NOx - Low Gas Heat (14 ng/J) (All Ultra Low NOx models include Stainless Steel HX)

Sensor Options A = None B = Return Air (RA) Smoke Detector C = Supply Air (SA) Smoke Detector D = RA and SA Smoke Detectors E = CO2 Sensor F = RA Smoke Detector and CO2 Sensor G = SA Smoke Detector and CO2 Sensor H = RA and SA Smoke Detectors plus CO2 Sensor J = Condensate Overflow Switch K = Condensate Overflow Switch plus RA Smoke Detector L = Condensate Overflow Switch plus RA and SA Smoke Detectors M = Condensate Overflow Switch plus SA Smoke Detector N = Condensate Overflow Switch plus CO2 Sensor P = Condensate Overflow Switch plus CO2 Sensor and RA Smoke Detector Q = Condensate Overflow Switch plus CO2 Sensor and SA Smoke Detector R = Condensate Overflow Switch plus CO2 Sensor, RA and SA Smoke Detectors

Vane Axial Fan - Indoor Fan Options 1 = Direct Drive EcoBlue Standard Static 2 = Direct Drive EcoBlue Medium Static 3 = Direct Drive EcoBlue High Static

Refrig. Systems Options A = One Stage Cooling Models B = One Stage Cooling Models with Humidi-MiZer system

Coil Options (Condenser - Evaporator - Hail Guard) A = Al/Cu - Al/Cu B = Precoat Al/Cu - Al/Cu C = E-coat Al/Cu - Al/Cu D = E-coat Al/Cu - E-coat Al/Cu E = Cu/Cu - Al/Cu F = Cu/Cu - Cu/Cu M = Al/Cu - Al/Cu Louvered Hail Guard N = Precoat Al/Cu - Al/Cu Louvered Hail Guard P = E-coat Al/Cu - Al/Cu Louvered Hail Guard Q = E-coat Al/Cu - E-coat Al/Cu Louvered Hail Guard R = Cu/Cu - Al/Cu Louvered Hail Guard S = Cu/Cu - Cu/Cu Louvered Hail Guard

Design Revision - = Factory Design Revision

Base Unit Controls 0 = Electro-mechanical Controls can be used with field-installed W7212 EconoMi$er IV (Non-Fault Detection and Diagnostic) 2 = RTU Open Multi-Protocol Controller 3 = SystemVuTM Intelligent System Controller with Display 6 = Electro-mechanical Controls can be used with W7220 EconoMi$er X (with Fault Detection and Diagnostic)

Intake / Exhaust Options A = None B = Temperature Economizer w/ Barometric Relief F = Enthalpy Economizer w/ Barometric Relief K = Two-Position Damper U = Temperature Ultra Low Leak Economizer w/ Barometric Relief W = Enthalpy Ultra Low Leak Economizer w/ Barometric Relief

Service Options 0 = None 1 = Unpowered Convenience Outlet 2 = Powered Convenience Outlet 3 = Hinged Panels 4 = Hinged Panels and Unpowered Convenience Outlet 5 = Hinged Panels and Powered Convenience Outlet 6 = MERV-8 High Efficiency Filters 7 = MERV-8 High Efficiency Filters, Unpowered Convenience Outlet 8 = MERV-8 High Efficiency Filters, Powered Convenience Outlet 9 = MERV-8 High Efficiency Filters, Hinged Panels A = MERV-8 High Efficiency Filters, Hinged Panels, Unpowered Convenience Outlet B = MERV-8 High Efficiency Filters, Hinged Panels, Powered Convenience Outlet

Packaging & Seismic Compliance 0 = Standard 1 = LTL

Electrical Options A = None C = Non-Fused Disconnect (NFD)* D = Thru-The-Base Connections F = Non-Fused Disconnect and Thru-The-Base Connections* N = Phase Monitor/Protection Q = Phase Monitor/Protection and NFD* R = Phase Monitor/Protection and Thru-The-Base T = Phase Monitor/Protection, NFD, and Thru-The-Base*

Example: Position:

4 8 F C G A 0 6 A 2 A 5 - 0 A 0 A 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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

NOTE: On single phase (-3 voltage code) models, the following are not available as a factory-installed option: - Humidi-MiZer System - Coated Coils or Cu Fin Coils - Louvered Hail Guards - Economizer or Two-Position Damper - Powered 115 Volt Convenience Outlet

* Non-Fused Disconnect is not available for 460/3/60 voltage units.

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Fig. 2 Unit Dimensional Drawing

6

Fig. 2 Unit Dimensional Drawing (cont)

7

Fig. 2 Unit Dimensional Drawing (cont)

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INSTALLATION

Jobsite Survey Complete the following checks before installation. 1. Consult local building codes and the NEC (National Elec-

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

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

3. Check for possible overhead obstructions which may inter- fere with unit lifting or rigging.

Step 1 Plan for Unit Location Select a location for the unit and its support system (curb or other) that provides for the minimum clearances required for safety. This includes the clearance to combustible surfaces, unit performance and service access below, around and above unit as specified in unit drawings. See Fig. 2 on page 6. NOTE: Consider also the effect of adjacent units. Be sure that unit is installed such that snow will not block the combustion intake or flue outlet. Unit may be installed directly on wood flooring or on Class A, B, or C roof-covering material when roof curb is used. Do not install unit in an indoor location. Do not locate air inlets near exhaust vents or other sources of contaminated air. For proper unit operation, adequate combustion and ventilation air must be provided in accordance with Section 5.3 (Air for Combustion and Ventilation) of the National Fuel Gas Code, ANSI Z223.1 (Ameri- can National Standards Institute) and NFPA (National Fire Protec- tion Association) 54 TIA-54-84-1. In Canada, installation must be in accordance with the CAN1-B149 installation codes for gas burning appliances. Although unit is weatherproof, avoid locations that permit water from higher level runoff and overhangs to fall onto the unit. Locate mechanical draft system flue assembly at least 4 ft (1.2 m) from any opening through which combustion products could enter the building, and at least 4 ft (1.2 m) from any adjacent building (or per local code). Locate the flue assembly at least 10 ft (3.05 m) from an adjacent units fresh air intake hood if within 3 ft (0.91 m) of same elevation (or per local code). When unit is located adja- cent to public walkways, flue assembly must be at least 7 ft (2.1 m) above grade. Select a unit mounting system that provides adequate height to allow installation of condensate trap per requirements. Refer to Install External Condensate Trap and Line on page 16 for re- quired trap dimensions. ROOF MOUNT Check building codes for weight distribution requirements. Unit operating weights are shown in Table 2.

Step 2 Plan for Sequence of Unit Installation The support method used for this unit will dictate different se- quences for the steps of unit installation. For example, on curb- mounted units, some accessories must be installed on the unit be- fore the unit is placed on the curb. Review the following for rec- ommended sequences for installation steps. CURB-MOUNTED INSTALLATION 1. Install curb 2. Install field-fabricated ductwork inside curb 3. Install accessory thru-base service connection package

(affects curb and unit) (refer to accessory installation instruc- tions for details)

4. Prepare bottom condensate drain connection to suit planned condensate line routing (refer to Install External Condensate Trap and Line on page 16 for details)

5. Rig and place unit 6. Install outdoor air hood 7. Install flue hood 8. Install gas piping 9. Install condensate line trap and piping 10. Make electrical connections 11. Install other accessories

PAD-MOUNTED INSTALLATION 1. Prepare pad and unit supports 2. Check and tighten the bottom condensate drain connection

plug 3. Rig and place unit 4. Convert unit to side duct connection arrangement 5. Install field-fabricated ductwork at unit duct openings 6. Install outdoor air hood 7. Install flue hood 8. Install gas piping 9. Install condensate line trap and piping 10. Make electrical connections 11. Install other accessories

FRAME-MOUNTED INSTALLATION Frame-mounted applications generally follow the sequence for a curb installation. Adapt the sequence as required to suit specific installation plan.

Step 3 Inspect Unit Inspect unit for transportation damage. File any claim with trans- portation agency. Confirm before installation of unit that voltage, amperage and cir- cuit protection requirements listed on unit data plate agree with power supply provided. On units with hinged panel option, check to be sure all latches are snug and in closed position. Locate the carton containing the outside air hood parts. Do not remove carton until unit has been rigged and located in final position.

Step 4 Provide Unit Support ROOF CURB MOUNT Accessory roof curb details and dimensions are shown in Fig. 3 (on page 9). Assemble and install accessory roof curb in accor- dance with instructions shipped with the curb.

Table 2 Operating Weights

48FCG- UNIT lb (kg) 04 05 06

Base Unit 512 (233) 575 (260) 586 (266) Economizer Vertical 50 (23) 50 (23) 50 (23) Horizontal 80 (36) 80 (36) 80 (36) Humidi-MiZer System 50 (23) 50 (23) 80 (36 Cu Fins 25 (11) 43 (20) 56 (25) Powered Outlet 35 (16) 35 (16) 35 (16) Curb 14-in. (356 mm) 115 (52) 115 (52) 115 (52) 24-in. (610 mm) 197 (89) 197 (89) 197 (89)

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Fig. 3 Roof Curb Details

E E

7/16" [11]

4 9/16" [115.5]

1/4" [7.0]

5' 7-3/8" [1711.3]

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

1-3/4" [44.4]

2-3/8" [61]

1-3/4" [44.5]

1.00" [25.4]

"A"

1-3/4" [44.4]

21.74" [552.2]

5.42" [137.7]

11.96" [303.8]

4.96" [126.0] 70.87"

[1800.2]

40.69" [1033.5]

21.84" [554.7]

16.03" [407.2]

1.75" [44.5]

20.41" [518.3]

3.00" [76.2]

13.78" [350.0]

14.00" [355.6]

3.00" [76.2]

15.19" [385.8]

32.19" [817.6]

3'-1 3/16" [944.6]

"A"

1-3/4" [44.5]

CRBTMPWR001A01 3/4" [19] NPT 3/4" [19] NPT

1/2" [12.7] NPTCRRFCURB002A01

CONNECTOR PKG. ACC. GAS CONNECTION TYPE GAS FITTING POWER WIRING FITTING

CONTROL WIRING FITTING

ACCESSORY CONVENIENCE OUTLET WIRING CONNECTOR

THRU THE CURB 1/2" [12.7] NPT 1/2" [12.7] NPT

CRBTMPWR003A01 THRU THE BOTTOM

ROOF CURB ACCESSORY # A

CRRFCURB001A01 14" [356]

24" [610]

NOTES: 1. ROOFCURB ACCESSORY IS SHIPPED DISASSEMBLED. 2. INSULATED PANELS: 25.4 [1"] THK. POLYURETHANE FOAM, 44.5 [1-3/4] # DENSITY. 3. DIMENSIONS IN [ ] ARE IN MILLIMETERS. 4. ROOFCURB: 18 GAGE STEEL. 5. ATTACH DUCTWORK TO CURB. (FLANGES OF DUCT REST ON CURB). 6. SERVICE CLEARANCE 4 FEET ON EACH SIDE. 7. DIRECTION OF AIR FLOW. 8. CONNECTOR PACKAGE CRBTMPWR001A01 IS FOR THRU-THE-CURB GAS TYPE PACKAGE CRBTMPWR003A01 IS FOR THRU-THE-BOTTOM TYPE GAS CONNECTIONS.

TYPICAL (4) SIDES

SUPPLY AIR RETURN AIR

ROOFING MATERIAL (FIELD SUPPLIED)

CANT STRIP (FIELD SUPPLIED)

ROOFING FELT (FIELD SUPPLIED)

COUNTER FLASHING (FIELD SUPPLIED)

UNITGASKET (SUPPLIED WITH CURB)

RIGID INSULATION (FIELD SUPPLIED)

DUCT (FIELD SUPPLIED)

NAIL (FIELD SUPPLIED)

VIEW "B" CORNER DETAIL

SEE VIEW "B"

RETURN AIRSUPPLY AIRSUPPLY AIR OPENING

RETURN AIR OPENING

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

SEE NOTE #2

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

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

1/3/4"[44.5]

SCALE 0.250 E-ESECTION

48TC400427

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NOTE: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket supplied with the roof curb as shown in Fig. 3. Improperly applied gasket can also result in air leaks and poor unit performance. Curb should be level. This is necessary for unit drain to function properly. Unit leveling tolerances are shown in Fig. 4. Refer to Accessory Roof Curb Installation Instructions for additional infor- mation as required. Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb and not to the unit. The accessory thru-the-base power and gas connection package must be installed before the unit is set on the roof curb. If field-installed thru-the-roof curb gas connections are desired, use factory-sup- plied 1/2-in. pipe coupling and gas plate assembly to mount the thru-the-roof curb connection to the roof curb. Gas connections and power connections to the unit must be field-installed after the unit is installed on the roof curb. NOTE: If electric and control wiring is to be routed through the basepan, attach the accessory thru-the-base service con- nections to the basepan in accordance with the accessory in- stallation instructions.

Fig. 4 Unit Leveling Tolerances

SLAB MOUNT (HORIZONTAL UNITS ONLY) Provide a level concrete slab that extends a minimum of 6-in. (150 mm) beyond unit cabinet. Install a gravel apron in front of condenser coil air inlet to prevent grass and foliage from obstruct- ing airflow. NOTE: Horizontal units may be installed on a roof curb if required. ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR SLAB MOUNT) A non-combustible sleeper rail can be used in the unit curb sup- port area. If sleeper rails cannot be used, support the long sides of the unit with a minimum of 3 equally spaced 4-in. x 4-in. (102 mm x 102 mm) pads on each side.

Step 5 Field Fabricate Ductwork Cabinet return-air static pressure (a negative condition) shall not exceed 0.35 in. wg (87 Pa) with economizer or 0.45 in. wg (112 Pa) without economizer. For vertical ducted applications, secure all ducts to roof curb and building structure. Do not connect ductwork to unit. Fabricate supply ductwork so that the cross sectional dimensions are equal to or greater than the unit supply duct opening dimen- sions for the first 18-in. (458 mm) of duct length from the unit basepan.

Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with ap- plicable codes. Ducts passing through unconditioned spaces must be insulated and covered with a vapor barrier. If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes. A minimum clearance is not required around ductwork.

Step 6 Rig and Place Unit

Keep unit upright and do not drop. Spreader bars are required. Rollers may be used to move unit across a roof. Rigging materials under unit (cardboard or wood) must be removed PRIOR to plac- ing the unit on the roof curb. Level by using unit frame as a refer- ence. See Table 2 and Fig. 5 for additional information. Lifting holes are provided in base rails as shown in Fig. 5. Refer to rigging instructions on unit. Rigging materials under unit (cardboard or wood to prevent base- pan damage) must be removed PRIOR to placing the unit on the roof curb. When using the standard side drain connection, ensure the red plug in the alternate bottom connection is tight. Do this before setting the unit in place. The red drain plug an be tightened with a 1/2-in. square socket drive extension. For further details, see Install External Condensate Trap and Line on page 16. Before setting the unit onto the curb, recheck gasketing on curb. POSITIONING ON CURB

Position unit on roof curb so that the following clearances are maintained: 1/4-in. (6.4 mm) clearance between the roof curb and the base rail inside the front and rear, 0.0-in. clearance between the roof curb and the base rail inside on the duct end of the unit. This will result in the distance between the roof curb and the base rail inside on the condenser end of the unit being approximately 1/4-in. (6.4 mm). Although unit is weatherproof, guard against water from higher level runoff and overhangs. Flue vent discharge must have a minimum horizontal clearance of 4 ft (1220 mm) from electric and gas meters, gas regulators, and gas relief equipment. Minimum distance between unit and other electrically live parts is 48-in. (1220 mm).

A

B

C

MAXIMUM ALLOWABLE DIFFERENCE IN. (MM)

A-B B-C A-C 0.5 (13) 1.0 (25) 1.0 (25)

CAUTION

PROPERTY DAMAGE HAZARD Failure to follow this caution may result in damage to roofing materials. Membrane roofs can be cut by sharp sheet metal edges. Be careful when placing any sheet metal parts on such roof.

CAUTION

UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage. All panels must be in place when rigging. Unit is not designed for handling by fork truck when packaging is removed. If using top crate as spreader bar, once unit is set, carefully lower wooden crate off building roof top to ground. Ensure that no people or obstructions are below prior to lowering the crate.

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Fig. 5 Rigging Details

Flue gas can deteriorate building materials. Orient unit such that flue gas will not affect building materials. Locate mechanical draft system flue assembly at least 48-in. (1220 mm) from an adjacent building or combustible material. NOTE: Installation of accessory flue discharge deflector kit will reduce the minimum clearance to combustible material to 18-in. (460 mm). After unit is in position, remove rigging skids and shipping materials.

Step 7 Convert to Horizontal and Connect Ductwork (When Required) Unit is shipped in the vertical duct configuration. Unit without factory-installed economizer or return-air smoke detector option may be field-converted to horizontal ducted configuration. To convert to horizontal configuration, remove screws from side duct opening covers (see Fig. 6) and remove covers. Use the screws to install the covers on vertical duct openings with the insulation-side down. The panels must be inserted into the notches on the basepan to properly seal. The notches are covered by the tape used to secure the insulation to the basepan and are not easily seen. See Fig. 7 for position of the notches in the basepan. Seals around duct openings must be tight. Secure with screws as shown in Fig. 8. Cover seams with foil duct tape. Field-supplied flanges should be attached to horizontal duct openings and all ductwork should be secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof or building openings with counter flashing and mastic in accordance with applicable codes. Do not cover or obscure visibility to the units informative data plate when insulating horizontal ductwork.

Fig. 6 Horizontal Conversion Panels

Fig. 7 Location of Notches

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

DUCT END

SEE DETAIL "A""A"

(914-1371) 36"- 54"

"C"

"B"

SPREADER BARS

REQUIRED

NOTES: 1. SPREADER BARS ARE REQUIRED. Top damage will occur if spreader bars are not used. 2. Dimensions in () are in millimeters. 3. Hook rigging shackles through holes in base rail, as shown in Detail A. Holes in base rails are centered around the unit center of

gravity. Use wooden top to prevent rigging straps from damaging unit.

UNIT MAX WEIGHT DIMENSIONS

A B C lb kg in. mm in. mm in. mm

48FCG*04 784 356 74.5 1890 37.6 955 33.5 850 48FCG*05 890 404 74.5 1890 36.5 925 33.5 850 48FCG*06 903 410 74.5 1890 36.5 925 33.5 850

REMOVABLE HORIZONTAL SUPPLY DUCT OPENING COVER

REMOVABLE HORIZONTAL RETURN DUCT OPENING COVER

BASEPAN

NOTCHES NOTCHES

12

Fig. 8 Horizontal Duct Panels In Place

Step 8 Install Outside Air Hood ECONOMIZER AND TWO-POSITION DAMPER HOOD PACKAGE REMOVAL AND SETUP (FACTORY OPTION) NOTE: Economizer and two-position damper are not available as factory installed options for single phase (-3 voltage code) models. The hood is shipped in knock-down form and must be field as- sembled. The indoor coil access panel is used as the hood top while the hood sides, divider and filter are packaged together, at- tached to a metal support tray using plastic stretch wrap, and shipped in the return air compartment behind the indoor coil ac- cess panel. The hood assemblys metal tray is attached to the base- pan and also attached to the damper using two plastic tie-wraps. 1. To gain access to the hood, remove the filter access panel. See

Fig. 9. 2. Locate the (2) screws holding the metal tray to the basepan

and remove. Locate and cut the (2) plastic tie-wraps securing the assembly to the damper. See Fig. 10. Be careful to not damage any wiring or cut tie-wraps securing any wiring.

3. Carefully lift the hood assembly (with metal tray) through the filter access opening and assemble per the steps outlined in the Economizer Hood and Two-Position Hood section.

Fig. 9 Typical Access Panel Locations

Fig. 10 Economizer and Two-Position Damper Hood Parts Location

ECONOMIZER AND TWO-POSITION HOOD NOTE: If the power exhaust accessory is to be installed on the unit, the hood shipped with the unit will not be used and must be discarded. Save the aluminum filter for use in the power exhaust hood assembly. 1. The indoor coil access panel will be used as the top of the

hood. Remove the screws along the sides and bottom of the indoor coil access panel. See Fig. 11.

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

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

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

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

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

7. Replace the filter access panel.

SCREWS

DUCT COVERS SHEET METAL FACE UP

BASEPAN

FILTER ACCESS PANEL

OUTDOOR-AIR OPENING AND INDOOR COIL ACCESS PANEL

COMPRESSOR ACCESS PANEL

HOOD PARTS

PLASTIC TIE WRAP QTY (2)

SCREWS FOR METAL TRAY QTY (2)

13

Fig. 11 Indoor Coil Access Panel Relocation

Fig. 12 Economizer Hood Construction

Fig. 13 Economizer Filter Installation

Step 9 Units with Hinged Panels Only If the unit does not have hinged panels, skip this step and continue at Step 10. Relocate latch shipped inside the compressor compartment behind the hinged compressor door to location shown in Fig. 14 after unit installation.

Fig. 14 Compressor Door Latch Location

Step 10 Install Flue Hood Flue hood is shipped screwed to the basepan beside the burner compartment access panel. Remove from shipping location and using screws provided, install flue hood and screen in location shown in Fig. 15.

Fig. 15 Flue Hood Details

Step 11 Install Gas Piping Installation of the gas piping must be accordance with local building codes and with applicable national codes. In U.S.A., re- fer to NFPA 54/ANSI Z223.1 National Fuel Gas Code (NFGC). In Canada, installation must be accordance with the CAN/CSA B149.1 and CAN/CSA B149.2 installation codes for gas burning appliances. This unit is factory equipped for use with Natural Gas (NG) fuel at elevations up to 2000 ft (610 m) above sea level. Furnace gas input rate on rating plate is for installation up to 2000 ft (610 m) above sea level.

For natural gas applications, gas pressure at unit gas connection must not be less than 5 in. wg (1246 Pa) or greater than 11 in. wg (2740 Pa) while the unit is operating. See Table 3.

The gas supply pipe enters the unit at the burner access panel on the front side of the unit, through the long slot at the bottom of the access panel. The gas connection to the unit is made to the 1/2-in. gas inlet port on the unit gas valve. Manifold pressure is factory-adjusted for natural gas fuel use. See Table 4.

TOP PANEL

INDOOR COIL ACCESS PANEL

INDOOR COIL ACCESS PANEL

CAULK HERE

TOP PANEL

B

TOP PANEL

INDOOR COIL ACCESS PANEL

19 1/16 SCREW

HOOD DIVIDER

LEFT HOOD SIDE

33 3/8 (848mm)

(483mm)

DIVIDER

BAROMETRIC RELIEF

CLEANABLE ALUMINUM FILTER

FILTER

HOOD

FILTER CLIP

OUTSIDE AIR

CAUTION

Units can not operated at altitudes greater than 2,000 feet under any circumstances.

Table 3 Natural Gas Supply Line Pressure Ranges

UNIT MODEL UNIT SIZE MIN. MAX.

48FCG* 04, 05, 06 5.0 in. wg (1246 Pa)

11.0 in. wg (2740 Pa)

COMPRESSOR DOOR OUTDOOR COIL

LATCH

BLOWER ACCESS PANELFLUE OPENING

14

Install a gas supply line that runs to the unit heating section. Refer to the NFPA 54/NFGC or equivalent code for gas pipe sizing data. Do not use a pipe size smaller than 1/2-inch. Size the gas supply line to allow for a maximum pressure drop of 0.5-in. wg (124 Pa) between gas regulator source and unit gas valve connection when unit is operating at high-fire flow rate. The gas supply line can approach the unit in three ways: horizon- tally from outside the unit (across the roof), thru-curb/under unit basepan (accessory kit required), or through unit basepan (factory option or accessory kit required). Consult accessory kit installation instructions for details on these installation methods. Observe clearance to gas line components per Fig. 16.

Fig. 16 Gas Piping Guide (with Accessory Thru-the-Curb Service Connections)

FACTORY OPTION THRU-BASE CONNECTIONS (GAS CONNECTIONS) This service connection kit consists of a 1/2-in. electrical bulkhead connector and a 3/4-in. electrical bulkhead connector, connected to an L bracket covering the embossed (raised) section of the unit basepan in the condenser section (see Fig. 17 for shipping position). The 3/4-in. bulkhead connector enables the low-voltage control wires to pass through the basepan. The 1/2-in. bulkhead connector allows the high-voltage power wires to pass through the basepan. See Fig. 18.

Fig. 17 Thru-the-Base Fitting Assembly (Shown in Shipping Position)

Fig. 18 Thru-Base Connection Fittings

1. Remove the L bracket assembly from the unit. 2. Remove connector plate assembly from the L bracket

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

NOTE: Take care not to damage the gasket, as it is reused in the following step. 3. Place the gasket over the embossed area in the basepan,

aligning the holes in the gasket to the holes in the basepan. See Fig. 18.

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

The thru-base gas connector has male and female threads. The male threads protrude above the basepan of the unit; the female threads protrude below the basepan.

Table 4 Natural Gas Manifold Pressure

UNIT MODEL UNIT SIZE MANIFOLD PRESSURE

48FCG* 04, 05, 06 3.2 in. wg (797 Pa)

CAUTION

EQUIPMENT DAMAGE Failure to follow this caution may result in equipment damage. When connecting the gas line to the unit gas valve, the installer MUST use a backup wrench to prevent damage to the valve.

X

BASE UNIT

BASE RAIL ROOF CURB

9 MINIMUM CLEARANCE FOR PANEL REMOVAL

MANUAL GAS SHUTOFF VALVE*

GAS REGULATOR*

48 MINIMUM

DRIP LEG PER NFGC*

FIELD-FABRICATED SUPPORT*

FROM GAS METER

STEEL PIPE NOMINAL DIAMETERS (IN.)

SPACING OF SUPPORTS X DIMENSION (FT)

1/2 6 3/4 or 1 8

11/4 or larger 10

LEGEND *Field supplied.

NFGC National Fuel Gas Code NOTE: Follow all local codes.

LOW VOLTAGE CONDUIT CONNECTOR

HIGH VOLTAGE CONDUIT CONNECTOR

BRASS FITTING FOR 3 TO 6 TON UNITS

AUXILIARY POWER SUPPLY (OPTIONAL)

15

Check tightness of connector lock nuts before connecting gas piping. Install a 1/2-in. NPT street elbow on the thru-base gas fitting. At- tach a 1/2-in. pipe nipple with minimum length of 16-in. (406 mm) (field-supplied) to the street elbow and extend it through the ac- cess panel at the gas support bracket. See Fig. 19.

Fig. 19 Gas Line Piping

Other hardware required to complete the installation of the gas supply line includes a manual shutoff valve, a sediment trap (drip leg) and a ground-joint union. A pressure regulator valve may also be required (to convert gas pressure from pounds to inches of pres- sure). The manual shutoff valve must be located within 6 ft (1.83 m) of the unit. The union, located in the final leg entering the unit, must be located at least 9-in. (230 mm) away from the access panel to permit the panel to be removed for service. If a regulator valve is installed, it must be located a minimum of 4 ft (1220 mm) away from the units flue outlet. Some municipal codes require that the manual shutoff valve be located upstream of the sediment trap. See Fig. 20 and 21 for typical piping arrangements for gas piping that has been routed through the sidewall of the curb. See Fig. 22 for typical piping arrangement when thru-base is used. En- sure that all piping does not block access to the units main control box or limit the required working space in front of the control box.

Fig. 20 Gas Piping, Typical Curb Sidewall Piping (Example 1)

Fig. 21 Gas Piping, Typical Curb Sidewall Piping (Example 2)

Fig. 22 Gas Piping, Typical Thru-Base Connections

When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to the NFPA 54/ANSI Z223.1 NFGC latest edition (in Canada, CAN/CSA B149.1). In the ab- sence of local building codes, adhere to the following pertinent recommendations: Avoid low spots in long runs of pipe. Grade all pipe 1/4-in.

per every 15 ft (7 mm per every 5 m) to prevent traps. Grade all horizontal runs downward to risers. Use risers to connect to heating section and to meter.

Protect all segments of piping system against physical and thermal damage. Support all piping with appropriate straps, hangers, etc. Use a minimum of one hanger every 6 ft (1.8 m). For pipe sizes larger than 1/2-in., follow recommendations of national codes.

Apply joint compound (pipe dope) sparingly and only to male threads of joint when making pipe connections. Use only pipe dope that is resistant to action of liquefied petro- leum gases as specified by local and/or national codes. If using PTFE (Teflon1) tape, ensure the material is Double Density type and is labeled for use on gas lines. Apply tape per manufacturers instructions.

Pressure-test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit.

BRASS FITTING FOR GAS PIPINGEMBOSSMENT

9 (229mm) MIN

UNION

SHUT OFF VALVE

DRIP LEG

THRU-CURB ADAPTER

UNIT BASE RAIL

1. Teflon is a registered trademark of DuPont.

SHUT OFF VALVE

UNION

9 (229 mm) MIN

UNIT BASE RAIL

BURNER ACCESS PANEL

THRU-CURB ADAPTER

DRIP LEG

16

NOTE: Pressure test the gas supply system after the gas supply piping is connected to the gas valve. The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0.5 psig (3450 Pa). Pres- sure test the gas supply piping system at pressures equal to or less than 0.5 psig (3450 Pa). The unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the ground-joint union. Check for gas leaks at the field-installed and factory-installed gas lines after all piping connections have been completed. Use soap-and-water solution (or method specified by local codes and/or regulations).

NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of cor- rect size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics. See Fig. 23.

Fig. 23 Orifice Hole

Step 12 Install External Condensate Trap and Line The unit has one 3/4-in. condensate drain connection on the end of the condensate pan and an alternate connection on the bottom. See Fig. 24. Unit airflow configuration does not determine which drain connection to use. Either drain connection can be used with vertical or horizontal applications.

Fig. 24 Condensate Drain Pan (Side View)

WARNING

Failure to follow this warning could result in personal injury, death and/or property damage. Connect gas pipe to unit using a backup wrench to

avoid damaging gas controls. Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a

commercially available soap solution made specifically for the detection of leaks to check all connections.

Use proper length of pipe to avoid stress on gas control manifold.

BURNER ORIFICE

ATTENTION

After the installation of the unit gas piping and prior to gas heat start up, ensure that the distances between the main burner orifice and the burner box inlet tube meet those shown below. If not, loosen the orifice alignment screw on the bracket shown, slide the assembly to meet those distances then tighten the screw to secure the gas orifice assembly.

A

B

DETAIL "A" GAS COMBUSTION TUBE

GAS ORIFICE

GAS VALVE

GAS MANIFOLD PRESSURE PORT

ORIFICE ASSEMBLY ALIGNMENT SCREW

A 11/16 in. 17.4 mm

B 7/16 in. 11.1 mm

BURNER BOX

GAS INDUCER MOTOR

SEE DETAIL "A"

FRONT VIEW - GAS ASSEMBLY AND BURNER BOX

DRAIN (FACTORY-INSTALLED)

PLUG

CONDENSATE PAN (SIDE VIEW)

STANDARD SIDE DRAIN

ALTERNATE BOTTOM DRAIN

17

When using the standard side drain connection, ensure the red plug in the alternate bottom connection is tight. Do this before setting the unit in place. The red drain pan can be tightened with a 1/2-in. square socket drive extension. To use the alternate bottom drain connection, remove the red drain plug from the bottom connection (use a 1/2-in. square socket drive extension) and install it in the side drain connection. The piping for the condensate drain and external trap can be com- pleted after the unit is in place. See Fig. 25. All units must have an external trap for condensate drainage. In- stall a trap at least 4-in. (102 mm) deep and protect against freeze-up. If drain line is installed downstream from the external trap, pitch the line away from the unit at 1-in. per 10 ft (25 mm per 3 m) of run. Do not use a pipe size smaller than the unit con- nection (3/4-in.).

Fig. 25 Condensate Drain Pan Piping Details

Step 13 Make Electrical Connections

NOTE: Field-supplied wiring shall conform with the limitations of minimum 63F (33C) rise. FIELD POWER SUPPLY If equipped with optional Powered Convenience Outlet, the power source leads to the convenience outlets transformer primary are not factory connected. Installer must connect these leads accord- ing to required operation of the convenience outlet. If an always- energized convenience outlet operation is desired, connect the source leads to the line side of the unit-mounted disconnect. (Check with local codes to ensure this method is acceptable in your area.) If a de-energize via unit disconnect switch operation of the convenience outlet is desired, connect the source leads to the load side of the unit disconnect. On a unit without a unit-mounted disconnect, connect the source leads to compressor contactor C and indoor fan contactor IFC pressure lugs with unit field power leads. See Convenience Outlets on page 19 for power transformer connections.

The field power wires are connected to the unit at line-side pres- sure lugs on compressor contactor C and indoor fan contactor IFC (see wiring diagram label for control box component arrange- ment) or at factory-installed option non-fused disconnect switch or HACR. Maximum wire size is #2ga AWG (copper only) per pole on contactors and #2ga AWG (copper only) per pole on optional disconnect or HACR. See Fig. 26 and unit label diagram for field power wiring connections. NOTE: Unit may be equipped with short test leads (pigtails) on the field line connection points on contactor C or optional discon- nect switch. These leads are for factory-run test purposes only; re- move and discard before connecting field power wires to unit con- nection points. Make field power connections directly to line con- nection pressure lugs only. See Fig. 27.

Fig. 26 Power Wiring Connections

Fig. 27 Disconnect Switch and Unit

UNITS WITH FACTORY-INSTALLED NON-FUSED DISCONNECT The factory-installed option non-fused disconnect (NFD) switch is located in a weatherproof enclosure located under the main con- trol box. The manual switch handle and shaft are shipped in the disconnect enclosure. Assemble the shaft and handle to the switch at this point. Discard the factory test leads (see Fig. 26). NOTE: Non-fused disconnect is not available on 460V units.

WARNING

Failure to follow this warning could result in personal injury or death. Do not use gas piping as an electrical ground. Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code); ANSI/NFPA 70, latest edition (in Canada, Canadian Electrical Code CSA [Canadian Standards Association] C22.1), and local electrical codes.

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

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

BASE RAIL

OPEN VENT

TO ROOF DRAIN

DRAIN PLUG

ROOF CURB

SEE NOTE

3 (76 mm) MIN

WARNING

FIRE HAZARD Failure to follow this warning could result in personal injury, death, or property damage. Do not connect aluminum wire between disconnect switch and unit. Use only copper wire.

Disconnect per

NEC

Disconnect per

NEC

208/230-1-60

11 12 11 12 13

L1 L2 L3

TB TB

208/230-3-60 460-3-60 575-3-60

Units Without Non-Fused Disconnect Option

Units With Non-Fused Disconnect Option

2

4

6

1

3

5

L1

L2

L3

Optional Disconnect

Switch

Disconnect factory test leads; discard.

Factory Wiring

COPPER

WIRE ONLY

ELECTRIC DISCONNECT

SWITCH

ALUMINUM WIRE

18

Connect field power supply conductors to LINE side terminals when the switch enclosure cover is removed to attach the handle. Field-Install the NFD Shaft and Handle 1. Remove the Control Box access panel. The NFD enclosure is

located below the Control Box (see Fig. 28). 2. Remove (3) cap head screws that secure the NFD enclosure

front cover (2) on the face of the cover and (1) on the left side cover. See Fig. 29.

3. Remove the front cover of the NFD enclosure. 4. Make sure the NFD shipped from the factory is at OFF posi-

tion (the arrow on the black handle knob is at OFF). 5. Insert the shaft with the cross pin on the top of the shaft in the

horizontal position. See Fig. 29. 6. Measure from the tip of the shaft to the top surface of the

black pointer; the measurement should be 3.75 to 3.88 in. (95 to 99 mm).

7. Tighten the locking screw to secure the shaft to the NFD. 8. Turn the handle to the OFF position with red arrow pointing

at OFF. 9. Install the handle on to the painted cover horizontally with the

red arrow pointing to the left. 10. Secure the handle to the painted cover with (2) screws and

lock washers supplied. 11. Engaging the shaft into the handle socket, re-install (3) hex

screws on the NFD enclosure. 12. Re-install the unit front panel.

Fig. 28 NFD Enclosure Location

Fig. 29 NFD Handle and Shaft Assembly

UNITS WITHOUT FACTORY-INSTALLED NON-FUSED DISCONNECT When installing units, provide a disconnect switch per NEC (Na- tional Electrical Code) of adequate size. Disconnect sizing data is provided on the unit informative plate. Locate on unit cabinet or within sight of the unit per national or local codes. Do not cover unit informative plate if mounting the disconnect on the unit cabinet. ALL UNITS All field wiring must comply with NEC and all local codes. Size wire based on MCA (Minimum Circuit Amps) on the unit infor- mative plate. See Fig. 26 and the unit label diagram for power wir- ing connections to the unit power terminal blocks and equipment ground. Maximum wire size is #2ga AWG (copper only) per pole on contactors. See Fig. 26 and unit label diagram for field power wiring connections. Provide a ground fault and short circuit over-current protection de- vice (fuse or breaker) per NEC Article 440 (or local codes). Refer to unit informative data plate for MOCP (Maximum Over-Current Protection) device size. All units except 208/230v units are factory wired for the voltage shown on the nameplate. If the 208/230v unit is to be connected to a 208v power supply, the control transformer must be rewired by moving the black wire with the 1/4-in. female spade connector from the 230v connection and moving it to the 200v 1/4-in. male termi- nal on the primary side of the transformer. Refer to unit label dia- gram for additional information. Field power wires will be connected at line-side pressure lugs on the power terminal block or at factory-installed option non-fused disconnect. Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate. On 3-phase units, volt- ages between phases must be balanced within 2% and the current within 10%. Use the following formula to determine the percent of voltage imbalance. Operation on improper line voltage or ex- cessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any ap- plicable Carrier warranty.

Example: Supply voltage is 230-3-60

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

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

BLK YEL BLU

% Voltage Imbalance = 100 x

max voltage deviation from average voltage average voltage

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

Average Voltage = (224 + 231 + 226)

= 681

= 227 3 3

% Voltage Imbalance = 100x 4

= 1.78% 227

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.

A B C

MOTOR

19

CONVENIENCE OUTLETS

Two types of convenience outlets are offered on 48FCG models: non-powered and unit-powered. Both types provide a 125-v GFCI (ground-fault circuit interrupter) duplex receptacle rated at 15A behind a hinged waterproof access cover, located on the end panel of the unit. See Fig. 30. Figure 31 shows the Convenience Outlet Utilization label, which is located below the convenience outlet.

Fig. 30 Convenience Outlet Location

Fig. 31 Convenience Outlet Utilization Notice Label

NOTE: Unit powered convenience outlets are not available as fac- tory installed options for single phase (-3 voltage code models). Installing Weatherproof Cover A weatherproof while-in-use cover for the factory-installed conve- nience outlets is now required by UL standards. This cover cannot be factory-mounted due its depth; it must be installed at unit instal- lation. For shipment, the convenience outlet is covered with a blank cover plate. On units with electro-mechanical controls the weatherproof cover kit is shipped in the units control box. The kit includes the hinged cover, a backing plate, and gasket. On units with a factory installed direct digital controller (SystemVu or RTU Open) the weather- proof cover kit is secured to the basepan underneath the control box (see Fig. 32).

Fig. 32 Weatherproof Cover Shipping Location on Units with Factory Installed DDC

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

2. Loosen the two screws at the GFCI duplex outlet, until approximately 1/2-in. (13 mm) under screw heads is exposed. Press the gasket over the screw heads.

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

4. Mount the weatherproof cover to the backing plate as shown in Fig. 33.

Fig. 33 Weatherproof Cover Installation

WARNING

ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death. Units with convenience outlet circuits may use multiple disconnects. Check convenience outlet for power status before opening unit for service. Locate its disconnect switch, if appropriate, and open it. Lock-out and tag-out this switch, if necessary.

CONVENIENCE OUTLET GFCI

PWD-CO FUSE SWITCH

PWD-CO TRANSFORMER

WARNING

ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death. Using unit-mounted convenience outlets: Units with unit- mounted convenience outlet circuits will often require that two disconnects be opened to de-energize all power to the unit. Treat all units as electrically energized until the convenience outlet power is also checked and de-energization is confirmed. Observe National Electrical Code Article 210, Branch Circuits, for use of convenience outlets.

WEATHERPROOF COVER

COVER - WHILE-IN-USE WEATHERPROOF

BASEPLATE FOR GFCI RECEPTACLE

GASKET

GFCI RECEPTACLE NOT INCLUDED

TOP

TO P

TOP

WET LOCATIONS

W E

T L

O C

A T

IO N

S

20

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

6. Check for full closing and latching. Non-Powered Convenience Outlet This type requires the field installation of a general-purpose 125-v 15A circuit powered from a source elsewhere in the building. Ob- serve national and local codes when selecting wire size, fuse or breaker requirements, and disconnect switch size and location. Route 125v power supply conductors into the bottom of the utility box containing the duplex receptacle. Unit-Powered Convenience Outlet A unit-mounted transformer is factory-installed to step down the main power supply voltage to the unit to 115v at the duplex recep- tacle. This option also includes a manual switch with fuse, located in a utility box and mounted on a bracket behind the convenience outlet; access is through the units control box access panel. See Fig. 30. The primary leads to the convenience outlet transformer are not factory-connected. Selection of primary power source is a custom- er option. If local codes permit, the transformer primary leads can be connected at the line-side terminals on the unit-mounted non- fused disconnect switch; this will provide service power to the unit when the unit disconnect switch is open. Other connection meth- ods will result in the convenience outlet circuit being de-energized when the unit disconnect switch is open. See Fig. 34.

Fig. 34 Powered Convenience Outlet Wiring

Fuse On Power Type The factory fuse is a Bussman1 Fusetron T-15, non-renewable screw-in (Edison base) type plug fuse. Test the GFCI receptacle by pressing the TEST button on the face of the receptacle to trip and open the receptacle. Check for proper grounding wires and power line phasing if the GFCI receptacle does not trip as required. Press the RESET button to clear the tripped condition. Using Unit-Mounted Convenience Outlets Units with unit-mounted convenience outlet circuits will often re- quire that two disconnects be opened to de-energize all power to

the unit. Treat all units as electrically energized until the conve- nience outlet power is also checked and de-energization is con- firmed. Observe National Electrical Code Article 210, Branch Cir- cuits, for use of convenience outlets. FACTORY-OPTION THRU-BASE CONNECTIONS (ELECTRICAL CONNECTIONS) This service connection kit consists of a 1/2-in. NPT gas adapt- er fitting (brass), a 1/2-in. electrical bulkhead connector, and a 3/4-in. electrical bulkhead connector, all factory-installed in the embossed (raised) section of the unit basepan in the condenser section. The 3/4-in. bulkhead connector enables the low-voltage control wires to pass through the basepan. The 1/2-in. electrical bulkhead connector allows the high-voltage power wires to pass through the basepan. See Fig. 18 on page 14. NOTE: If electrical connections are not going to occur at this time, tape or otherwise cover the fittings so that moisture does not get into the building or conduit in the interim. Check tightness of connector lock nuts before connecting electri- cal conduits. Field-supplied and field-installed liquid tight conduit connectors and conduit may be attached to the connectors on the basepan. Pull correctly rated high voltage and low voltage through appro- priate conduits. Connect the power conduit to the internal discon- nect (if unit is so equipped) or to the external disconnect (through unit side panel). A hole must be field cut in the main control box bottom on the left side so the 24-v control connections can be made. Connect the control power conduit to the unit control box at this hole. UNITS WITHOUT THRU-BASE CONNECTIONS (ELECTRICAL CONNECTIONS) 1. Install power wiring conduit through side panel openings.

Install conduit between disconnect and control box. 2. Install power lines to terminal connections as shown in

Fig. 26 on page 17.

FIELD CONTROL WIRING The 48FCG unit requires an external temperature control device. This device can be a thermostat (field-supplied) or a SystemVu controller (available as factory-installed option for use on a Carrier Comfort Network or as a stand alone control) or the RTU Open Controller for Building Management Systems using non-CCN protocols (RTU Open controller is available as a factory-installed option only). THERMOSTAT Install a Carrier-approved accessory thermostat according to in- stallation instructions included with the accessory. For complete economizer function, select a two-stage cooling thermostat. Lo- cate the thermostat accessory on a solid wall in the conditioned space to sense average temperature in accordance with the ther- mostat installation instructions. Typical low-voltage connections are shown in Fig. 35. If the thermostat contains a logic circuit requiring 24-v power, use a thermostat cable or equivalent single leads of different colors with minimum of seven leads. If the thermostat does not require a 24-v source (no C connection required), use a thermostat cable or equivalent with minimum of six leads. Check the thermostat in- stallation instructions for additional features which might require additional conductors in the cable. For wire runs up to 50 ft (15 m), use no. 18 AWG (American Wire Gage) insulated wire [95F (35C) minimum]. For 50 to 75 ft (15 to 23 m), use no. 16 AWG insulated wire [95F (35C) minimum]. For over 75 ft (23 m), use no. 14 AWG insulated wire [95F (35C) minimum]. Wire sizes larger than no. 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat.1. Bussman and Fusetron are trademarks of Cooper Technologies

Company.

UNIT VOLTAGE

CONNECT AS

PRIMARY CONNECTIONS

TRANSFORMER TERMINALS

208, 230 240 L1: RED + YEL L2: BLU + GRA

H1 + H3 H2 + H4

460 480 L1: RED Splice BLU + YEL L2: GRA

H1 H2 + H3

H4

21

Fig. 35 Low-Voltage Thermostat Connections

Thermostat Wiring, Units Without Thru-Base Connection Kit Pass the thermostat control wires through the hole provided in the corner post; then feed the wires through the raceway built into the corner post to the control box. Pull the wires over to the terminal strip on the upper-left corner of the Unit Control Board. See Fig. 36. NOTE: If thru-the-bottom connections accessory is used, refer to the accessory installation instructions for information on routing power and control wiring.

Fig. 36 Field Control Wiring Raceway

HEAT ANTICIPATOR SETTINGS Set heat anticipator settings at 0.14 amp for the first stage and 0.14 amp for second-stage heating, when available.

HUMIDI-MIZER CONTROL CONNECTIONS Humidi-MiZer Space RH Controller NOTE: The Humidi-MiZer system is a factory-installed option. Humidi-MiZer system is not available for single phase (-3 voltage code) models. The Humidi-MiZer dehumidification system requires a field- supplied and field-installed space relative humidity control device. This device may be a separate humidistat control (contact closes on rise in space RH above control setpoint) or a combination ther- mostat-humidistat control device such as Carriers Edge Pro Thermidistat device with isolated contact set for dehumidifica- tion control. See Fig. 37 and Fig. 38. The humidistat is normally used in applications where a temperature control is already provid- ed (units with SystemVu control).

Fig. 37 Accessory Field-Installed Humidistat

Fig. 38 Edge Pro Thermidistat

Connecting the Carrier Humidistat (HL38MG029) 1. Route the humidistat 2-conductor cable (field-supplied)

through the hole provided in the unit corner post. 2. Feed wires through the raceway built into the corner post (see

Fig. 36) to the 24v barrier located on the left side of the con- trol box. The raceway provides the UL-required clearance between high-voltage and low-voltage wiring.

3. Connect one of the leads from the 2-conductor cable to the HUM terminal on the UCB (Unit Control Board). Connect the other lead to the R terminal on the UCB. See Fig. 39.

HUM

G

W2W2

G

W1

O/B/Y2 Y2

R

W1

R

Y1 Y1

T H E R M O S T A T

(Note 1) (Note 2)

Note 1: Typical multi-function marking. Follow manufacturers configuration Instructions to select Y2.

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

Field Wiring

Unit Control Board

Typical Thermostat Connections

CC

RACEWAY

HOLE IN END PANEL (HIDDEN)

% RELATIVE HUMIDITY

22

Fig. 39 Humidistat Connections to UCB

Connecting the Thermidistat device (33CS2PPRH-01) 1. Route the Thermidistat multi-conductor thermostat cable

(field-supplied) through the hole provided in the unit corner post.

2. Feed wires through the raceway built into the corner post (see Fig. 36) to the 24-v barrier located on the left side of the con- trol box. The raceway provides the UL-required clearance between high-voltage and low-voltage wiring.

3. The Thermidistat has dry contacts at terminals D1 and D2 for dehumidification operation (see Fig. 40). Connect D1 to the R terminal on the UCB. Connect D2 to the HUM termi- nal on the UCB. Refer to the installation instructions included with the Carrier Edge Pro Thermidistat device for more information.

TYPICAL UNIT WIRING DIAGRAMS See Fig. 41 - 45 for examples of typical unit control and power wiring diagrams. These wiring diagrams are mounted on the in- side of the unit control box cover.

Fig. 40 Typical Rooftop Unit with Humidi-MiZer Adaptive Dehumidification System and Edge Pro Thermidistat Device

HUMIDISTAT

UNIT CONTROL BOARD

THERMOSTAT

C HUM G W2 W1 Y2 Y1 R

Rc Rh W1

G Y2 C

O/W2/B Y1

OAT RRS

SRTN HUM

D1 D2 V+ Vg

C

HUM

G

W2

W1

Y2

Y1

R

PROGRAMMABLE THERMOSTAT UNIT CONTROL BOARD

THERMOSTAT CONNECTIONS

23

Fig. 41 Typical Control Wiring Diagram, Electro-Mechanical with W7212 (48FCG 04-06 208/230-3-60 Unit Shown)

24

Fig. 42 Typical Control Wiring Diagram, Electro-Mechanical with W7220 (48FCG 04-06 208/230-3-60 Unit Shown)

25

Fig. 43 Typical Control Wiring Diagram, SystemVu Controller (48FCG 04-06 208/230, 460V Unit Shown)

26

Fig. 44 Typical Control Wiring Diagram, RTU Open Controller (48FCG 04-06 208/230-3-60 Unit Shown)

27

T

Fig. 45 Typical 48FCG 04-06 Power Wiring Diagram, 208/230-3-60 Unit Shown

28

T

Fig. 46 Typical 48FCG 04-06 Power Wiring Diagram for 460-3-60 Electro-Mechanical and All SystemVu Controller Units Shown

29

Integrated Gas Controller This unit contains an Integrated Gas Controller (IGC) board. The IGC control board uses a flue gas pressure switch that senses pres- sure drop in the heat exchanger due to the combustion inducer. See Fig. 47.

Fig. 47 Flue Gas Pressure Switch and Pressure Sense Tube (Typical Location)

When the thermostat calls for heating, power is sent to W on the Integrated Gas Controller (IGC) board. An LED (light emitting di- ode) on the IGC board turns on and remains on during normal op- eration. A check is made to ensure that the burner thermal switch

and limit switch are closed, and that the pressure switch is open. If the check was successful, the induced draft motor is energized. When the pressure in the heat exchanger is low enough to close the pressure switch, the ignition activation period begins. Once ig- nition occurs, the IGC board will continue to monitor the condi- tion of the burner thermal switch, the limit switches, the pressure switch, and the flame sensor. Assuming the unit is controlled through a room thermostat set for fan auto, 30 seconds after ig- nition occurs, the indoor fan motor will energize, and the outdoor air dampers will open to their minimum position. If the over tem- perature limit opens prior to the start of the indoor fan blower, the IGC will shut down the burners, and the control will shorten the 30 second delay to 5 seconds less than the time to trip the limit. For example, if the limit trips at 37 seconds, the control will change the fan on delay from 45 seconds to 32 seconds. Once the fan on delay has been modified, it will not change back to 30 seconds unless power is reset to the control. When the thermostat is satisfied, W opens and the gas valve clos- es, interrupting the flow of gas to the main burners. If the call for W lasted less than 1 minute, the heating cycle will not terminate until 1 minute after W became active. If the unit is controlled through a room thermostat set for fan auto, the indoor fan motor will continue to operate for an additional 45 seconds, then stop. An LED indicator is provided on the IGC to monitor operation. See Table 5 for a listing of the LED alarm codes. See Fig. 48 for IGC board component layout. Fig. 49 is a typical IGC control wiring diagram. See Fig. 50 for a flow chart detailing the operating sequence for the IGC.

Fig. 48 IGC Board Component Layout

FLUE GAS PRESSURE SWITCH

FLUE GAS PRESSURE SENSE TUBE

CAUTION

Do not detach the burner box from the heat exchanger panel. If the burner box must be replaced, refer to the Service and Maintenance Instructions for the unit.

SPADE CONNECT IGNITOR

STATUS LED

OVERCURRENT FUSE PROTECTION

REDUNDANT GAS VALVE RELAY

30

Fig. 49 Typical IGC Control Wiring Diagram

LEGEND NOTES: 1. There is a 3-second pause between alarm code displays. 2. If more than one alarm code exists, all applicable alarm codes will

be displayed in numerical sequence. 3. Alarm codes on the IGC will be lost if power to the unit is interrupted.

UNIT CONTROL BOARD

Table 5 IGC Board LED Alarm Codes

FLASH CODE SYMPTOM CAUSE REMEDY

ON Normal Operation OFF No Power or Hardware Failure Loss of power to control module

(IGC) Check 5-amp fuse on the ICG, power to unit, 24V circuit breaker, and transformer. Units without a 24V circuit breaker have an internal overload in the 24V transformer. If the overload trips, allow 10 minutes for automatic reset.

1 Flash Check Fuse, Low Voltage Circuit Fuse is blown or missing, or short circuit in secondary (24VAC) wiring.

Replace fuse if needed. Verify no short circuit in low voltage (24VAC) wiring.

2 Flashes Limit Switch Fault High temperature limit switch is open.

Check the operation of the indoor (evaporator) fan motor. Ensure that the supply-air temperature rise is in accordance with the range on the unit nameplate. Clean or replace filters.

3 Flashes Flame is Sense Fault The IGC sensed flame that should not be present.

Reset unit. If problem persists, replace the IGC board.

4 Flashes Four Consecutive Limit Switch Faults

Inadequate airflow to unit. Check the operation of the indoor (evaporator) fan motor and that supply-are temperature rise agrees with range on the unit nameplate information.

5 Flashes Ignition Lockout Fault Unit unsuccessfully attempted ignition for 4 times.

Check igniter and flame sensor electrode spacing, gaps, etc. Ensure that flame sense and ignition wires are properly terminated. Verify that unit is obtaining proper amount of gas.

6 Flashes Pressure Switch Fault Open pressure switch. Verify wiring connections to pressure switch and inducer motor. Verify pressure switch hose is tightly connected to both inducer housing and pressure switch. Verify inducer wheel is properly attached to inducer motor shaft. Verify inducer motor shaft is turning. In 460V units check the transformer designed for the inducer motor is operational. Also check the fuses for the inducer motor transformer (460V units only).

7 Flashes Burner Thermal Switch Fault Burner thermal switch is open The burner thermal switch will automatically reset, but IGC will continue to lockout unit. Check any possible blockage in the access panel louver, intake tube connected to the burner box, and the flue gas exhaust. Check gas valve operation. Ensure that induced-draft blower wheel is properly secured to motor shaft. Inspect the burner mesh inside the burner box by opening the side window on the burner box. Reset the unit disconnect.

8 Flashes Internal Control Fault Microprocessor has sensed an error in the software or hardware.

If error code is not cleared by resetting unit power, replace the IGC board.

IGC Integrated Gas Unit Control LED Light-Emitting Diode

31

Fig. 50 IGC Operating Sequence

Call for heat: W terminal is energized

Pre-purge: Induced draft motor starts and runs for 30 seconds at

ignition speed, Speed 1

Ignition: Gas valve and igniter energize for 2

seconds

Rectification: Flame sensor activates for

2 seconds after ignition period

Is flame sensed after ignition trial?

Do any limit switches trip after 90 second fan off-delay time?

Gas valve and igniter de-energerized

Unit locks-out for 1 hour (1 hour auto reset)

Post-purge: Induced draft motor runs for 30 seconds. Indoor fan off-delay time

starts for 90 seconds.

Call-off for heat: W terminal is de-energized.

Warm-up: Indoor fan on-delay time starts for 30 seconds.

Inducer motor automatically ramps up to second speed

with 100 rpm/s rate and then to steady state rpm/s (third speed) with 10 rpm/s rate.

Is it the fourth trial?

15 seconds is added to fan off-delay time up to a maximum of 3 minutes.

Normal operation, no error.

Yes

No

No

No

Yes

Yes

32

EconoMi$er X (Factory Option) The EconoMi$er X system is an expandable economizer control system, which includes a W7220 economizer module (controller) with an LCD and keypad (see Fig. 51). The W7220 can be config- ured with optional sensors.

Fig. 51 W7220 Economizer Module

The W7220 economizer module can be used as a stand-alone economizer module wired directly to a commercial set-back space thermostat and sensors to provide outside air dry-bulb economizer control. The W7220 economizer module can be connected to optional sensors for single or differential enthalpy control. The W7220 economizer module provides power and communications for the sensors. The W7220 economizer module automatically detects sensors by polling to determine which sensors are present. If a sensor loses communications after it has been detected, the W7220 economizer controller indicates a device fail error on its LCD. SYSTEM COMPONENTS The EconoMi$er X system includes an economizer module, 20k mixed air sensor, damper actuator, and either a 20k outdoor air temperature sensor or S-Bus enthalpy sensors. Economizer Module The module is the core of the EconoMi$er X system. The module is mounted in the units control box, and includes the user inter- face for the system. The W7220 economizer module provides the basic inputs and outputs to provide simple economizer control. When used with the optional sensors, the economizer module pro- vides more advanced economizer functionality. S-Bus Enthalpy Control Sensors The sensor is a combination temperature and humidity sensor which is powered by and communicates on the S-Bus. Up to three sensors may be configured with the W7220 economizer module. CO2 Sensor (optional) The sensor can be added for Demand Controlled Ventilation (DCV). SPECIFICATIONS W7220 Economizer Module The module is designed for use with 2 to 10 Vdc or bus communi- cating actuator. The module includes terminals for CO2 sensor, Mixed Air sensor, and an Outdoor Dry Bulb sensor. Enthalpy and other options are available with bus sensors. User Interface Provides status for normal operation, setup parameters, checkout tests, and alarm and error conditions with a 2-line 16 character LCD display and four button keypad.

Electrical Rated Voltage 20 to 30 Vac RMS, 50/60 Hz Transformer 100 va maximum system input Nominal Power Consumption (at 24 Vac, 60 Hz)

11.5 VA without sensors or actuators Relay Digital Output Rating at 30 Vac (maximum power

from Class 2 input only) 1.5A run: 3.5A inrush at 0.45PF (200,000 cycles) or 7.5A inrush at 0.45PF (100,000 cycles)

External Sensors Power Output 21 Vdc 5% at 48 mA

INPUTS Sensors NOTE: A Mixed Air (MA) analog sensor is required on all W7220 units; either an Outdoor Air (OA) sensor for dry bulb change over or an OA bus sensor for outdoor enthalpy change over is required in addition to the MA sensor. An additional Re- turn Air (RA) bus sensor can be added to the system for differen- tial enthalpy or dry bulb changeover. For differential dry bulb changeover a 20k ohm sensor is required in the OA and a bus sen- sor in the RA. DIP switch on RA bus sensor must be set in the RA position. Dry Bulb Temperature (optional) and Mixed Air (required), 20k NTC 2-wire (18 to 22 AWG) Temperature range 40F to 150F (40c to 65C) Temperature accuracy 0F/+2F Temperature and Humidity, C7400S1000 (optional) S-Bus; 2-wire (18 to 22 AWG) Temperature range: 40F to 150F (40C to 65C) Temperature accuracy: 0F/+2F Humidity range: 0 to 100% RH with 5% accuracy. NOTE: Up to three (3) S-Bus sensors may be connected to the W7220 economizer module. For outdoor air (OA), return air (RA) and discharge (supply) air (DA). 4 Binary Inputs 1-wire 24 Vac + common GND (see page 34 for wiring details). 24 Vac power supply 20 to 30 Vac 50/60Hz; 100 VA Class 2 transformer. OUTPUTS Actuator Signal 2-10 Vdc; minimum actuator impedance is 2k ohm; bus two-wire output for bus communicating actuators. Exhaust fan, Y1, Y2 and AUX1 O All Relay Outputs (at 30 Vac): Running: 1.5A maximum Inrush: 7.5A maximum ENVIRONMENTAL Operating Temperature 40F to 150F (40C to 65C). Exception of display operation down to 4F (20C) with full re- covery at 4F (20C) from exposure to 40F (40C) Storage Temperature 40F to 150F (40C to 65C) Shipping Temperature 40F to 150F (40C to 65C)

Relative Humidity 5% to 95% RH non-condensing

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

33

ECONOMIZER MODULE WIRING DETAILS Use Fig. 52 and Tables 6 and 7 to locate the wiring terminals for the Economizer module. NOTE: The four terminal blocks are removable. Slide out each terminal block, wire it, and then slide it back into place.

Fig. 52 W7220 Wiring Terminals

*Sylk is a trademark of Honeywell International Inc.

S-BUS SENSOR WIRING The labels on the sensors and controller are color coded for ease of installation. Orange labeled sensors can only be wired to orange terminals on the controller. Brown labeled sensors can only be wired to S-bus (brown) terminals. Use Fig. 53 and Table 8 to lo- cate the wiring terminals for each S-Bus sensor. Use Fig. 53 and Table 8 to locate the wiring terminals for each en- thalpy control sensor.

Fig. 53 S-Bus Sensor DIP Switches

Table 6 Economizer Module - Left Hand Terminal Blocks

LABEL TYPE DESCRIPTION Top Left Terminal Block

MAT MAT

20k NTC and COM

Mixed Air Temperature Sensor (Polarity Insensitive Connection)

OAT OAT

20k NTC and COM

Outdoor Air Temperature Sensor (Polarity Insensitive Connection)

S-BUS S-BUS

S-BUS (Sylk* Bus)

Enthalpy Control Sensor (Polarity Insensitive Connection)

Bottom Left Terminal Block IAQ 2-10 2-10 vdc Air Quality Sensor Input (e.g. CO2 sensor) IAQ COM COM Air Quality Sensor Common IAQ 24V 24 vac Air Quality Sensor 24 vac Source ACT 2-10 2-10 vdc Damper Actuator Output (2-10 vdc) ACT COM COM Damper Actuator Output Common ACT 24v 24 vac Damper Actuator 24 vac Source

NA

AUX2-

OCC

E-GND

EXH1

AUX1-O

Y2-

Y1-

Y2-O

Y1-O

C

R

50048848-002 Rev. A

NA

A2

OCC

EX

A1

Y2I

Y2O

Y1I

Y1O

C

R

MAT

MAT

OAT

OAT

S-BUS

S-BUS

IAQ 2-10

IAQCOM

IAQ 24V

ACT 2-10

ACT COM

ACT 24V

MA MA

OA OA

SB SB

SB SB

SB SB

V C R

V C R

NA

50040839-001 Rev. G

HJW10 www.energy.ca.gov

Certified FDD Product California Title 24, Part 6

Table 7 Economizer Module - Right Hand Terminal Blocks

LABEL TYPE DESCRIPTION Top Right Terminal Blocks

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

OCC 24 vac IN

Shut Down (SD) or HEAT (W) Conventional only and Heat Pump Changeover (O-B) in Heat Pump mode.

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

AUX1 O 24 vac OUT

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

Bottom Right Terminal Blocks

Y2-I 24 vac IN Y2 in - Cooling Stage 2 Input from space thermostat

Y2-O 24 vac OUT Y2 out - Cooling Stage 2 Output to stage 2 mechanical cooling

Y1-I 24 vac IN Y1 in - Cooling Stage 2 Input from space thermostat

Y1-O 24 vac OUT Y1 out - Cooling Stage 2 Output to stage 2 mechanical cooling

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

DIP SWITCH LABEL

DIP SWITCHES (3)

S-BUS 2 PIN SIDE CONNECTOR

S-BUS TERMINALS (1 AND 2)

34

Use Fig. 53 and Table 9 to set the DIP switches for the desired use of the sensor.

NOTE: When an S-Bus sensor is connected to an existing net- work, it will take 60 minutes for the network to recognize and auto-configure itself to use the new sensor. During the 60 minute setup period, no alarms for sensor failures (except SAT) will be issued and no economizing function will be available. CO2 SENSOR WIRING When using a CO2 sensor, the black and brown common wires are internally connected and only one is connected to IAQ COM on the W7220. Use the power from the W7220 to power the CO2 sensor OR make sure the ground for the power supplies are com- mon. See Fig. 54 for CO2 sensor wiring.

Fig. 54 CO2 Sensor Wiring

INTERFACE OVERVIEW This section describes how to use the EconoMi$er user interface for: Keypad and menu navigation Settings and parameter changes Menu structure and selection

User Interface The user interface consists of a 2-line LCD display and a 4-button keypad on the front of the economizer controller. Keypad Use the four navigation buttons (see Fig. 55) to scroll through the menus and menu items, select menu items, and to change parame- ter and configuration settings.

To use the keypad when working with menus: Press the (Up arrow) button to move to the previous

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

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

currently displayed menu. Press the (Menu Up/Exit) button to exit a menus item

and return to the list of menus.

Fig. 55 W7220 Controller Navigation Buttons

To use the keypad when working with Setpoints, System and Ad- vanced Settings, Checkout tests and Alarms: 1. Navigate to the desired menu. 2. Press the (Enter) button to display the first item in the

currently displayed menu. 3. Use the and buttons to scroll to the desired parameter. 4. Press the (Enter) button to display the value of the cur-

rently displayed item. 5. Press the button to increase (change) the displayed param-

eter value. 6. Press the button to decrease (change) the displayed param-

eter value. NOTE: When values are displayed, pressing and holding the or button causes the display to automatically increment or decrement. 1. Press the (Enter) button to accept the displayed value and

store it in nonvolatile RAM. CHANGE STORED displays. 2. Press the (Enter) button to return to the current menu

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

menu. Menu Structure Table 10 illustrates the complete hierarchy of menus and parame- ters for the EconoMi$er X system. The Menus in display order are: STATUS SETPOINTS SYSTEM SETUP ADVANCED SETUP CHECKOUT ALARMS

Table 8 HH57AC081 Sensor Wiring Terminations

TERMINAL TYPE DESCRIPTION

NUMBER LABEL

1 S-BUS S-BUS

S-BUS Communications (Enthalpy Control

Sensor Bus)

2 S-BUS S-BUS

S-BUS Communications (Enthalpy Control

Sensor Bus)

Table 9 HH57AC081 Sensor DIP Switch

USE DIP SWITCH POSITIONS FOR SWITCHES 1, 2, AND 3

1 2 3 DA OFF ON OFF RA ON OFF OFF OA OFF OFF OFF

CO2 SENSOR

24V

ANALOG OUT

L1 (HOT) L2

RED

BLACK

YELLOW

BROWN

ORANGE

GREEN

+

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

1

1

35

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

SETUP AND CONFIGURATION Before being placed into service, the W7220 Economizer module must be set up and configured for the installed system.

The setup process uses a hierarchical menu structure that is easy to use. Press the and arrow buttons to move forward and back- ward through the menus and press the button to select and confirm setup item changes. TIME-OUT AND SCREENSAVER When no buttons have been pressed for 10 minutes, the LCD dis- plays a screen saver, which cycles through the Status items. Each Status items displays in turn and cycles to the next item after 5 seconds.

IMPORTANT: Table 10 illustrates the complete hierarchy. Your menu parameters may be different depending on your configuration. For example, if you do not have a DCV (CO2) sensor, then none of the DCV parameters appear and only MIN POS will display. If you have a CO2 sensor, the DCV MIN and DCV MAX will appear.

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

36

Table 10 W7220 Menu Structure*

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

NOTES

STATUS

ECONO AVAIL NO YES/NO FIRST STAGE COOLING DEMAND (Y1IN) YES = economizing available; the system can use outside air for free cooling when required

ECONOMIZING NO YES/NO FIRST STAGE COOLING RELAY OUTPUT YES = outside air being used for 1 stage cooling

OCCUPIED NO YES/NO

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

HEAT PUMP N/A** COOL HEAT

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

COOL Y1IN OFF ON/OFF

FIRST STAGE COOLING DEMAND (Y1-IN) Y1I signal from space thermostat or unitary controller for cooling stage 1. ON = 24 Vac on terminal Y1I OFF = 0 Vac on terminal Y1I

COOL Y1OUT OFF ON/OFF FIRST STAGE COOLING RELAY OUTPUT Cool stage 1 Relay Output to stage 1 mechanical cooling (Y1OUT terminal)

COOL Y2IN OFF ON/OFF

SECOND STAGE COOLING DEMAND (Y2IN) Y2I signal from space thermostat our unitary controller for second stage cooling. ON = 24 Vac on terminal Y2I OFF = 0 Vac on terminal Y2I

COOL Y2OUT OFF ON/OFF SECOND STAGE COOLING RELAY OUTPUT Cool Stage 2 Relay Output to mechanical cooling (Y2OUT terminal).

MA TEMP _ _ . _ F 0F to 140F (17C to 60C)

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

DA TEMP _ _ . _ F 0F to 140F (17C to 60C)

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

OA TEMP _ _ . _ F 40F to 140F (40C to 60C)

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

OA HUM _ _ % 0 to 100% OUTSIDE AIR RELATIVE HUMIDITY Displays measured value of outdoor humidity from OA sensor. Displays _ _% if not connected short, or out-of-range.

RA TEMP _ _ . _ F 0F to 140F (17C to 60C)

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

RA HUM _ _ % 0 to 100% RETURN AIR RELATIVE HUMIDITY Displays measured value of return air humidity from RA sensor. Displays _ _% if sensor sends invalid value, if not connected, short or out-of-range.

IN CO2 _ _ _ ppm 0 to 2000 ppm SPACE/RETURN AIR CO2 Displays value of measured CO2 from CO2 sensor. Invalid if not connected, short or out-of-range.

DCV STATUS N/A ON/OFF DEMAND CONTROLLED VENTILATION STATUS Displays ON if above setpoint and OFF if below setpoint, and ONLY if a CO2 sensor is connected.

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

ACT COUNT N/A 1 to 65535 Displays number of times actuator has cycled. 1 cycles equals 180 deg. of actuator movement in any direction.

ACTUATOR N/A OK/Alarm (on Alarm menu) Displays ERROR if voltage or torque is below actuator range.

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

EXH2 OUT OFF ON/OFF EXHAUST STAGE 2 RELAY OUTPUT Output of AUX terminal; displays only if AUX = EXH2

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

37

STATUS (cont)

MECH COOL ON or HEAT STAGES ON

0 0, 1, or 2 Displays stage of mechanical cooling that is active.

Displays the stage of heat pump heating that is active.

FAN SPEED N/A LOW or HIGH SUPPLY FAN SPEED Displays speed setting of fan on a 2-speed fan unit.

W (HEAT ON) N/A ON/OFF HEAT DEMAND STATUS Displays status of heat demand on a 2-speed fan unit.

SETPOINTS

MAT SET 53F 38F to 70F (3C to 21C); increment by 1F

MIXED AIR SETPOINT Setpoint determines where the economizer will modulate the OA damper to maintain the mixed air temperature.

LOW T LOCK 32F 45F to 80F (43C to 27C); increment by 1F

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

DRYBLB SET 63F 48F to 80F (9C to 27C); increment by 1F

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

DRYBLB DIFF 0F 0F to 6F Increment by 2F

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

ENTH CURVE ES3 ES1,ES2,ES3, ES4, or ES5

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

DCV SET 1100ppm 500 to 2000 ppm; increment by 100

DEMAND CONTROLLED VENTILATION SETPOINT Displays only if CO2 sensor is connected. Setpoint for Demand Controlled Ventilation of space. Above the setpoint, the OA dampers will modulate open to bring in additional OA to maintain a space ppm level below the setpoint.

MIN POS 4.4 V 2 to 10 Vdc VENTILATION MINIMUM POSITION. Only displayed if controller is set for single speed unit under FAN TYPE, and if DCV is NOT used.

MIN POS L 6.0 V 2 to 10 Vdc

VENTILATION MINIMUM POSITION AT LOW SPEED. Only displays if unit is set for 2 or 3 speed and CO2 is not used. If using 2 speed with 1 heat and 1 cool then set for HEATING ventilation. If using 3 speed with 1 heat and 2 cool then set for LOW SPEED COOLING ventilation.

MIN POS M 5.4 V 2 to 10 Vdc VENTILATION MINIMUM POSITION AT MEDIUM SPEED. Only displays if unit is set for 3 speed with 1 heat and 2 cool, and CO2 is not used. Set for HEATING ventilation.

MIN POS H 4.4 V 2 to 10 Vdc

VENTILATION MINIMUM POSITION AT HIGH SPEED. Only displays if unit is set for 2 or 3 speed and CO2 is not used. IF using 2 speed with 1 heat and 1 cool then set for COOLING ventilation. If using 3 speed with 1 heat and 2 cool then set for HIGH SPEED COOLING ventilation.

VENTMAX L 6.0V 2 to 10 Vdc

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

VENTMAX M 5.4 V 2 to 10 Vdc DCV MAXIMUM DAMPER POSITION AT MEDIUM SPEED. Only displays if unit is set for 3 speed with 1 heat and 2 cool. Set for HEATING ventilation.

VENTMAX H 4.4 V 2 to 10 Vdc

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

VENTMIN L 3.7 V 2 to 10 Vdc

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

VENTMIN M 3.4 V 2 to 10 Vdc DCV MINIMUM DAMPER POSITION AT MEDIUM SPEED. Only displays if unit is set for 3 speed with 1 heat and 2 cool. Set for HEATING ventilation.

VENTMIN H 2.8 V 2 to 10 Vdc

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

Table 10 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

NOTES

38

SETPOINTS (cont)

ERV OAT SP 32F 0F to 50F (18C to 10C); increment by 1F

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

EXH1 SET 50% 0 to 100% Exhaust fan set point for single speed units. Based on OA Damper position to activate power exhaust.

EXH1 L SET 65% 0 to 100% EXHAUST FAN 1 SETPOINT AT LOW SPEED on 2 speed or 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

EXH1 M SET 60% 0 to 100% EXHAUST POINT 1 SETPOINT AT MEDIUM SPEED. Only displays if unit is set for 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

EXH1 H SET 50% 0 to 100% EXHAUST FAN 1 SETPOINT AT HIGH SPEED on 2 speed or 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

EXH2 L SET 80% 0 to 100% EXHAUST FAN 2 SETPOINT AT LOW SPEED on 2 speed or 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

EXH2 M SET 77% 0 to 100% EXHAUST FAN 2 SETPOINT AT MEDIUM SPEED. Only displays if unit is set for 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

EXH2 H SET 75% 0 to 100% EXHAUST FAN 2 SETPOINT AT HIGH SPEED on 2 speed or 3 speed with 1 heat and 2 cool. Based on economizer OA damper position to activate power exhaust.

SYSTEM SETUP

INSTALL 01/01/17 N/A Display order = MM/DD/YY Setting order = DD, MM, then YY.

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

EQUIPMENT CONV Conventional or HP

CONV = conventional; HP O/B = Enable Heat Pump mode. Use AUX2 I for Heat Pump input from thermostat or controller. See Menu Note 4.

AUX2 IN W SD/W or HP(O)/ HP(B)

In CONV mode: SD + Enables configuration of shutdown (default); W = Informs controller that system is in heating mode. NOTE: If using 2-speed fan mode, you must program CONV mode for W. Shutdown is not available in 2-speed fan mode. See Menu Note 4. In HP O/B mode: HP(O) = energize heat pump on Cool (default); HP(B) = energize heat pump on heat.

FAN SPEED 2 speed 1 speed 2 speed 2SP H/C 3 speed

Sets the economizer controller operation based on 1 speed, 2 speed, 2 speed heat/cool (2SP H/C), or 3 speed supply fan. NOTE: Multi-speed fan options also need Heat (W1) programmed in AUX 2 In. See Menu Note 4.

FAN CFM 5000cfm 100 to 15000 cfm; increment by 100

UNIT DESIGN AIRFLOW (CFM) Enter only if using DCVAL ENA = AUTO The value is found on the nameplate label for the specific unit.

AUX1 OUT NONE NONE ERV EXH2 SYS

Select OUTPUT for AUX1 O relay NONE = not configured (output is not used) ERV = Energy Recovery Ventilator

EXH2 = second damper position relay closure for second exhaust fan SYS = use output as an alarm signal

OCC INPUT INPUT or ALWAYS

OCCUPIED MODE BY EXTERNAL SIGNAL When using a setback thermostat with occupancy out (24 vac), the 24 vac is input INPUT to the OCC terminal. If no occupancy output from the thermostat then change program to ALWAYS OR add a jumper from terminal R to OCC terminal.

FACTORY DEFAULT NO NO or YES

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

ADVANCED SETUP

MA LO SET 45F 35F to 55F (2C to 13C); Incremented by 10F

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

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

CO2 ZERO 0ppm 0 to 500 ppm; Increment by 10 CO2 ppm level to match CO2 sensor start level.

CO2 SPAN 2000ppm 1000 to 3000 ppm; Increment by 10 CO2 ppm span to match CO2 sensor.

Table 10 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

NOTES

39

ADVANCED SETUP (cont)

STG3 DLY 2.0h 0 min, 5 min, 15 min, then 15 min intervals. Up to 4 hrs or OFF

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

SD DMPR POS CLO CLO or OPN

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

DA LO ALM 45F (7C) 35F to 65F (2C to 18C); Incremented by 5F.

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

DA HI ALM 80F (27C) 70F to 180F (21C to 82C); Incremented by 5F

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

DCVCAL ENA MAN MAN (manual) AUTO

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

MAT T CAL 0.0F 2.5F SUPPLY AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

OAS T CAL 0.0F 2.5F OUTSIDE AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

OA H CAL 0% RH 10% RH OUTSIDE AIR HUMIDITY CALIBRATION Allows for operator to adjust for an out of calibration humidity sensor.

RA T CAL 0.0F 2.5F RETURN AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

RA H CAL 0% RH 10% RH RETURN AIR HUMIDITY CALIBRATION Allows for operator to adjust for an out of calibration humidity sensor.

DA T CAL 0.0F 2.5F DISCHARGE AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

2SP FAN DELAY 5 Minutes 0 to 20 minutes in 1 minute increments

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

CHECKOUT

DAMPER MINIMUM POSITION N/A N/A The checkout for the damper minimum position is based on the

system.

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

DAMPER CLOSE N/A N/A Positions damper to the fully closed position CONNECT Y1O N/A N/A Closes the Y1-O relay (Y1-O) CONNECT Y2O N/A N/A Closes the Y2-O relay (Y2-O)

CONNECT AUX1-O N/A N/A

Energizes the AUX output. If Aux setting is: NONE not action taken ERV 24 Vac out. Turns on or signals an ERV that the conditions are not good for economizing but are for ERV operation.

SYS 24 Vac out. Issues a system alarm. CONNECT EXH1 N/A N/A Closes the power exhaust fan 2 relay (EXH1)

ALARMS

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

MA T SENS ERR N/A N/A SUPPLY AIR TEMPERATURE SENSOR ERROR Mixed air sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

CO2 SENS ERR N/A N/A CO2 SENSOR ERROR CO2 sensor has failed, gone out of range or become disconnected - check wiring then replace sensor if the alarm continues.

OA SYLK T ERR N/A N/A OUTSIDE AIR S-BUS SENSOR ERROR Outdoor air enthalpy sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.OA SYLK H ERR N/A N/A

RA SYLK T ERR N/A N/A RETURN AIR S-BUS SENSOR ERROR Return air enthalpy sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.RA SYLK H ERR N/A N/A

Table 10 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

NOTES

40

LEGEND

* Table 10 illustrates the complete hierarchy. Your menu parameters may be different depending on your configuration. For example if you do not have a DCV (CO2) sensor, then none of the DCV parameters appear.

When values are displayed, pressing and holding the or button causes the display to automatically increment.

** N/A = Not Applicable. ERV Operation: When in cooling mode AND the conditions are NOT

OK for economizing - the ERV terminal will be energized. In the Heat- ing mode, the ERV terminal will be energized when the OA is below the ERV OAT setpoint in the setpoint menu.

NOTES: 1. STATUS OCCUPIED The factory-standard Occupancy signal

originates with a thermostat or other controller call for indoor fan operation at UCB terminal G. This signal passes through the Unit Control Boards OCCUPANCY jumper to the ECONO connector and to the W7220s OCC input terminal. An external timeclock or relay is required to implement an Occupancy schedule on the economizer damper position.

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

3. SETPOINTS DRYBLB SET This point is not displayed if a Return Air (differential) temperature sensor or an Outdoor Air enthalpy sensor is connected.

4. SYSTEM SETUP parameters must be configured as noted for Multi-Speed unit operation: EQUIPMENT = CONV AUX2 IN = W FAN SPEED = 2SPEED or FAN SPEED = 2SP C/H NOTE: 3SPEED is not used on 48FCG units.

ALARMS (cont)

DA SYLK T ERR N/A N/A DISCHARGE AIR S-BUS SENSOR ERROR Discharge air sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

OA SENS T ERR N/A N/A OUTSIDE AIR TEMPERATURE SENSOR ERROR Outdoor air temperature sensor has failed or become disconnected - check wiring then replace if the alarm continues.

ACT ERROR N/A N/A

ACTUATOR ERROR Actuator has failed or become disconnected - check for stall, over voltage, under voltage and actuator count. Replace actuator if damper is movable and supply voltage is between 21.6 V and 26.4 V. Check actuator count on STATUS menu.

FREEZE ALARM N/A N/A Check if outdoor temperature is below the LOW Temp Lockout on setpoint menu. Check if Mixed air temperature on STATUS menu is below the Lo Setpoint on Advanced menu. When conditions are back in normal range then the alarm will go away.

SHUTDOWN ACTIVE N/A N/A AUX2 IN is programmed for SHUTDOWN and 24 V has been applied to AUX2 IN terminal.

DMP CAL RUNNING N/A N/A

DAMPER CALIBRATION ROUTINE RUNNING If DCV Auto enable has been programmed, when the W7220 is completing a calibration on the dampers, this alarm will display. Wait until the calibration is completed and the alarm will go away. Must have OA, MA and RA sensors for DCV calibration; set up in the Advanced setup menu.

DA SENS ALM N/A N/A DISCHARGE AIR TEMPERATURE SENSOR ALARM Discharge air temperature is out of the range set in the ADVANCED SETUP Menu. Check the temperature of the discharge air.

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

ACT UNDER V N/A N/A ACTUATOR VOLTAGE LOW Voltage received by actuator is above expected range.

ACT OVER V N/A N/A ACTUATOR VOLTAGE HIGH Voltage received by actuator is below expected range.

ACT STALLED N/A N/A ACTUATOR STALLED Actuator stopped before achieving commanded position.

Table 10 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

NOTES

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

41

ENTHALPY SETTINGS When the OA temperature, enthalpy and dew point are below the respective setpoints, the Outdoor Air can be used for economiz- ing. Figure 56 shows the new single enthalpy boundaries in the W7220. There are 5 boundaries (setpoints ES1 through ES5), which are defined by dry bulb temperature, enthalpy and dew point. Refer to Table 11 for ENTH CURVE setpoint values. The W7220 calculates the enthalpy and dew point using the OA temperature and humidity input from the OA enthalpy sensor. When the OA temperature, OA humidity and OA dew point are

all below the selected boundary, the economizer sets the econo- mizing mode to YES, economizing is available. When all of the OA conditions are above the selected boundary, the conditions are not good to economize and the mode is set to NO. Figure 56 shows the 5 current boundaries. There is also a high lim- it boundary for differential enthalpy. The high limit boundary is ES1 when there are no stages of mechanical cooling energized and HL (high limit) when a compressor stage is energized.

Fig. 56 Single Enthalpy Curve Boundaries

ECONOMIZING AVAILABLE

NOT AVAILABLE

ENTHALPY RA HUM (%

RH)

R A

TE M

P

TEMPERATURE

AB SO

LU TE

H U

M ID

IT Y

ES5 ES4 ES3 ES2 ES1 HL

P1 (T,RH)

P2 (T,RH)

SINGLE ENTHALPY

DUAL ENTHALPY HIGH LIMIT

Table 11 Single Enthalpy and Dual Enthalpy High Limit Curves

ENTHALPY CURVE

TEMP. DRY BULB (F)

TEMP. DEWPOINT (F)

ENTHALPY (btu/lb/da)

POINT P1 POINT P2

TEMP. (F) HUMIDITY (%RH) TEMP. (F) HUMIDITY

(%RH) ES1 80 60 28.0 80 36.8 66.3 80.1 ES2 75 57 26.0 75 39.6 63.3 80.0 ES3 70 54 24.0 70 42.3 59.7 81.4 ES4 65 51 22.0 65 44.8 55.7 84.2 ES5 60 48 20.0 60 46.9 51.3 88.5 HL 86 66 32.4 86 38.9 72.4 80.3

42

STANDARD OR SINGLE SPEED FAN OPERATION The W7220 controller will control a standard 1 speed unit when configured for FAN TYPE = 1 SPEED. Refer to Table 12 for economizer operation.

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

Table 12 Economizer Operation - FAN TYPE = 1SPEED

INPUTS OUTPUTS DEMAND

CONTROLLED VENTILATION

(DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE W

(HEAT ON) COOL Y1-IN

COOL Y2-IN

COOL Y1-OUT

COOL Y2-OUT

FAN SPEED (reference

only)

DAMPER POSITION

OCCUPIED UNOCCUPIED

NONE

NO N/A OFF OFF OFF OFF HIGH MIN POS Closed N/A ON OFF ON OFF HIGH MIN POS Closed N/A ON ON ON ON HIGH MIN POS Closed

YES

N/A OFF OFF OFF OFF HIGH MIN POS Closed

N/A ON OFF OFF OFF HIGH MIN POS to Full Open

Closed to Full Open

N/A ON ON ON OFF* HIGH MIN POS to Full Open

Closed to Full Open

Below CO2 Set

NO N/A OFF OFF OFF OFF HIGH VENTMIN Closed N/A ON OFF ON OFF HIGH VENTMIN Closed N/A ON ON ON ON HIGH VENTMIN Closed

YES

N/A OFF OFF OFF OFF HIGH VENTMIN Closed

N/A ON OFF OFF OFF HIGH VENTMIN to Full Open

Closed to Full Open

N/A ON ON ON OFF* HIGH VENTMIN to Full Open

Closed to Full Open

Above CO2 Set

NO

N/A OFF OFF OFF OFF HIGH VENTMIN to VENTMAX Closed

N/A ON OFF ON OFF HIGH VENTMIN to VENTMAX Closed

N/A ON ON ON ON HIGH VENTMIN to VENTMAX Closed

YES

N/A OFF OFF OFF OFF HIGH VENTMIN to VENTMAX Closed

N/A ON OFF OFF OFF HIGH VENTMIN to Full Open

Closed to Full Open

N/A ON ON ON OFF* HIGH VENTMIN to Full Open

Closed to Full Open

43

2 SPEED FAN OPERATION The W7220 controller has the capability to work with a system us- ing a 2-speed supply fan. The W7220 does not control the supply directly but uses the following input status to determine the speed of the supply fan and controls the OA damper to the required posi- tion, see Table 13.

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

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

open and fan on high speed and the call will turn off OR If the call for additional cooling in the space has not been

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

Refer to Tables 14 and 15 for economizer operation.

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

Table 13 Fan Speed

STATE FAN SPEED OCC Low Y1 Low Y2 High W High

Table 14 Economizer Operation - FAN TYPE = 2SPEED

INPUTS OUTPUTS DEMAND

CONTROLLED VENTILATION

(DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE W

(HEAT ON) COOL Y1-IN

COOL Y2-IN

COOL Y1-OUT

COOL Y2-OUT

FAN SPEED (reference

only)

DAMPER POSITION

OCCUPIED UNOCCUPIED

NONE

NO

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

YES

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

OFF ON OFF OFF OFF LOW MIN POS L to Full Open

Closed to Full Open

OFF ON ON ON OFF* HIGH MIN POS H to Full Open

Closed to Full Open

Below CO2 Set

NO

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

YES

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

OFF ON OFF OFF OFF LOW VENTMIN L to Full Open

Closed to Full Open

OFF ON ON ON OFF* HIGH VENTMIN H to Full Open

Closed to Full Open

Above CO2 Set

NO

ON N/A N/A OFF OFF HIGH VENTMIN H to VENTMAX H Closed

OFF OFF OFF OFF OFF LOW VENTMIN L to VENTMAX L Closed

OFF ON OFF ON OFF LOW VENTMIN L to VENTMAX L Closed

OFF ON ON ON ON HIGH VENTMAX H to VENTMAX H Closed

YES

ON N/A N/A OFF OFF HIGH VENTMIN H to VENTMAX H Closed

OFF OFF OFF OFF OFF LOW VENTMIN L to VENTMAX L Closed

OFF ON OFF OFF OFF* LOW VENTMIN L to Full Open

Closed to Full Open

OFF ON ON ON OFF* HIGH VENTMIN H to Full Open

Closed to Full Open

44

2SP H/C (2 SPEED HEAT/COOL) FAN OPERATION (SIN- GLE PHASE UNITS ONLY) The W7220 controller does not actually control the fan speed or the heat output of the unit, and only uses this information to help determine the damper position. On single phase units, the unit control board (UCB) will reduce the fan speed during heating when the configured fan speed is set outside the optimized heating speed window. If the job site application forces this reduction in fan speed during heat, the economizer FAN TYPE must be set to keep the appropriate outside air intake.

On single phase 48FCG 3 to 5 ton units, if reduced the heating fan speed is lower than the cooling speed and the economizer FAN TYPE needs to be set to 2SP H/C (2 speed Heat/Cool). This indi- cates that the heating and vent mode fan speed is less than then cooling mode fan speed in the unit. Refer to Table 15 for econo- mizer operation. 3 SPEED FAN OPERATION FAN TYPE = 3SPEED is not used on 48FCG units.

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

Table 15 Economizer Operation - FAN TYPE = 2SP H/C

INPUTS OUTPUTS DEMAND

CONTROLLED VENTILATION

(DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE W

(HEAT ON) COOL Y1-IN

COOL Y2-IN

COOL Y1-OUT

COOL Y2-OUT

FAN SPEED (reference

only)

DAMPER POSITION

OCCUPIED UNOCCUPIED

NONE

NO

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

YES

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

OFF ON OFF OFF OFF HIGH MIN POS H to Full Open

Closed to Full Open

OFF ON ON ON OFF* HIGH MIN POS H to Full Open

Closed to Full Open

Below CO2 Set

NO

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

YES

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

OFF ON OFF OFF OFF HIGH VENTMIN H to Full Open

Closed to Full Open

OFF ON ON ON OFF* HIGH VENTMIN H to Full Open

Closed to Full Open

Above CO2 Set

NO

ON N/A N/A OFF OFF LOW VENTMIN L to VENTMAX L Closed

OFF OFF OFF OFF OFF LOW VENTMIN L to VENTMAX L Closed

OFF ON OFF ON OFF HIGH VENTMIN H to VENTMAX H Closed

OFF ON ON ON ON HIGH VENTMAX H to VENTMAX H Closed

YES

ON N/A N/A OFF OFF LOW VENTMIN L to VENTMAX L Closed

OFF OFF OFF OFF OFF LOW VENTMIN L to VENTMAX L Closed

OFF ON OFF OFF OFF* HIGH VENTMIN H to Full Open

Closed to Full Open

OFF ON ON ON OFF* HIGH VENTMIN H to Full Open

Closed to Full Open

45

CHECKOUT Inspect all wiring connections at the economizer modules termi- nals, and verify compliance with the installation wiring diagrams. For checkout, review the Status of each configured parameter and perform the Checkout tests. NOTE: For information about menu navigation and use of the keypad see Interface Overview on page 34.

Power Up After the W7220 module is mounted and wired, apply power. Initial Menu Display On initial start up, Honeywell displays on the first line and econo- mizer W7220 on the second line. After a brief pause, the revision of the software appears on the first line and the second line will be blank. Power Loss (Outage or Brownout) All setpoints and advanced settings are restored after any power loss or interruption. NOTE: All settings are stored in non-volatile flash memory. Status Use the Status menu (see Table 10) to check the parameter values for the various devices and sensors configured. NOTE: For information about menu navigation and use of the keypad, see Interface Overview on page 34. Checkout Tests Use the Checkout menu (see page 39) to test the damper operation and any configured outputs. Only items that are configured are shown in the Checkout menu. NOTE: For information about menu navigation and use of the keypad, see Interface Overview on page 34. To perform a Checkout test: 1. Scroll to the desired test in the Checkout menu using the

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

appears. 3. Press the (Enter) button to start the test. The unit pauses

and then displays IN PROGRESS. When the test is complete, DONE appears.

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

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

TROUBLESHOOTING Alarms The economizer module provides alarm messages that display on the 2-line LCD. NOTE: Upon power up, the module waits 60 minutes before checking for alarms. This allows time for all the configured devic- es (e.g. sensors, actuator) to become operational. The exception is the SAT sensor which will alarm immediately. If one or more alarms are present and there has been no keypad ac- tivity for at least 5 minutes, the Alarms menu displays and cycles through the active alarms. You can also navigate to the Alarms menu at any time. Clearing Alarms Once the alarm has been identified and the cause has been removed (e.g. replaced faulty sensor) the alarm can be cleared from the display. To clear an alarm, perform the following: 1. Navigate to the desired alarm. 2. Press the (Enter) button. ERASE? displays. 3. Press the (Enter) button. ALARM ERASED displays. 4. Press the (Menu Up/Exit) button to complete the action

and return to the previous menu. NOTE: If the alarm still exists after clearing it, it is redisplayed within 5 seconds.

RTU Open Controller (Factory Option) For details on operating 48FCG*04-06 units equipped with the factory-installed RTU Open controller option, refer to the Factory- Installed Option RTU Open Multi-Protocol Controller Controls, Start-Up, Operation and Troubleshooting manual.

SystemVu Controller (Factory Option) For details on operating 48FCG*04-06 units equipped with the factory-installed SystemVu controller option, refer to the FC/GC Series Single Package Rooftop Units with SystemVu Controller Controls, Start-up, Operation and Troubleshooting manual.

Controller Options LOW AMBIENT If the unit comes with Electro-Mechanical (EM) controls, then no adjustment is necessary. If the unit comes with SystemVu or RTU Open controller op- tion, then refer to its installation control manual for details on ad- justing Cooling Lock-Out setting and configure for the specific job requirements.

Smoke Detectors Smoke detectors are available as factory-installed options on 48FCG models. Smoke detectors may be specified for supply air only, for return air without or with economizer, or in combination of supply air and return air. Return-air smoke detectors are ar- ranged for vertical return configurations only. All components necessary for operation are factory-provided and mounted. The unit is factory-configured for immediate smoke detector shutdown operation; additional wiring or modifications to unit terminal

WARNING

ELECTRIC SHOCK HAZARD Failure to follow this warning could result in personal injury, property damage, or death. Before performing service or maintenance operations on unit, always turn off main power switch to unit and install lock(s) and lockout tag(s). Unit may have more than one power switch. Ensure electrical service to rooftop unit agrees with voltage and amperage listed on the unit rating plate. If any wiring changes are required, first be sure to remove power from the economizer module before starting work. Pay particular attention to verifying the power connection (24 vac).

CAUTION

EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in equipment damage. Be sure to allow enough time for compressor start-up and shutdown between checkout tests so that you do not short- cycle the compressors.

46

board may be necessary to complete the unit and smoke detector configuration to meet project requirements. Units equipped with factory-optional return-air smoke detectors require a relocation of the sensor module at unit installation. See Fig. 57 for the as-shipped location. Completing Return Air Smoke Sensor Installation 1. Unscrew the two screws holding the return air smoke detector

assembly. See Fig. 58, Step 1. Save the screws. 2. Turn the assembly 90 degrees and then rotate end to end.

Make sure that the elbow fitting is pointing down. See Fig. 58, Step 2.

3. Screw the sensor and detector plate into its operating position using screws from Step 1. See Fig. 58, Step 3.

4. Connect the flexible tube on the sampling inlet to the sam- pling tube on the basepan.

Additional Application Data Refer to the application data document Factory Installed Smoke Detectors for Small and Medium Rooftop Units 2 to 25 Tons for discussions on additional control features of these smoke detectors including multiple unit coordination.

Fig. 57 Return Air Smoke Detector, Shipping Position

Fig. 58 Completing Installation of Return Air Smoke Sensor

RETURN AIR SMOKE DETECTOR (AS SHIPPED)

STEP 1 STEP 2 STEP 3

47

Step 14 Adjust Factory-Installed Options SMOKE DETECTORS Smoke detector(s) will be connected at the Unit Control Board (UCB), at terminals marked Smoke Shutdown. Detach the jumper covering the Smoke Shutdown terminals on the UCB and then attach the wiring harness from the smoke detector. ECONOMI$ER IV OCCUPANCY SWITCH See Fig. 59 for general EconoMi$er IV wiring. External occu- pancy control is managed through a connection on the Unit Con- trol Board. If external occupancy control is desired, connect a time clock or remotely controlled switch (closed for Occupied, open for Unoc- cupied sequence) at terminals marked OCCUPANCY. Detach the jumper covering the Occupancy terminals on the UCB and then attach the required connections.

Step 15 Install Accessories Available accessories include: Roof curb Thru-base connection kit (must be installed before unit is

set on roof curb) Flue discharge deflector Manual outside air damper Two-position motorized outside air damper EconoMi$er IV (with control) EconoMi$er2 (without control/for external signal) Power Exhaust Differential dry-bulb sensor (EconoMi$er IV) Outdoor enthalpy sensor Differential enthalpy sensor CO2 sensor Louvered hail guard Phase monitor control

Refer to separate installation instructions for information on in- stalling these accessories.

Fig. 59 EconoMi$er IV Wiring

48

Step 16 Fan Speed Set Up UNITS WITH ELECTRO-MECHANICAL CONTROLS The fan speed set up controls are located on the lower section of the Unit Control Board (UCB). See Fig. 60 for the location on 3 phase voltage units or Fig. 61 for the location on single phase volt- age units. 1. Check the job specifications for the CFM (cubic feet per min-

ute) and ESP (external static pressure) required. 2. Using the chart on the Fan Speed Set Up labels (see Fig. 63),

calculate the Vdc from the CFM and ESP for the base unit. Then add Vdc for any accessories installed per the Field Accessories section of the label.

NOTE: The Fan Speed Set Up labels are located on the High Volt- age cover in the Control Box. 3. Connect a multimeter to the Vdc terminals on the UCB. 4. Set the Range Switch to either A, B, or C per the Switch

Range table. 5. Using a straight blade screwdriver, turn the Vdc control dial

to fine tune the Vdc reading. 6. Record the reading in the Field Setting field. NOTE: Fan set-up Vdc is not affected by the operating stage of the unit.

Fig. 60 UCB Fan Speed Controls - 3-Phase Units

Fig. 61 UCB Fan Speed Controls - Single Phase Units

NOTE: On single phase units, the approximate static pressure of the ductwork must be set for optimal unit efficiency. The unit is factory set for greater than 1.0 in. wg. If the external static pressure is less than 1.0 in. wg, slide switch 1 on the 5-pin DIP to the ON position. See Fig. 62.

Fig. 62 Detail 5-Pin DIP Switch

FAN SPEED SET UP CONTROLS

FAN SPEED SET UP CONTROLS

SWITCH 1 5-PIN DIP

49

Fig. 63 Example of Fan Speed Set Up Labels for Electro-Mechanical Controls

UNITS WITH SYSTEMVU CONTROLS On units equipped with the factory-installed SystemVu control- ler, the Fan Speed settings are accessed through the SystemVu interface. 1. Check the job specifications for the CFM (cubic feet per min-

ute) and ESP (external static pressure) required. 2. Using the chart on the Fan Speed Set Up labels (see Fig. 64),

calculate the RPM from the CFM and ESP for the base unit plus any field accessories (as listed on the label).

NOTE: The Fan Speed Set Up labels are located on the High Volt- age cover in the Control Box. 3. Press any key on the SystemVu interface to activate the dis-

play backlight and then press the MENU key. 4. Using the UP and DOWN arrow keys highlight SETTINGS

and then press ENTER. 5. Use the DOWN arrow key highlight the UNIT CONFIGU-

RATIONS menu then press ENTER.

6. Highlight UNIT CONFIGURATIONS then press ENTER. 7. Highlight INDOOR FAN and then press ENTER. 8. Refer to the job specifications to set the following, determin-

ing the values per the RPM Calculator label (see Fig. 64). Use the UP and DOWN arrow keys and the BACK key to set the values. Press ENTER after setting each value to continue to the next selection.

IDF VENT SPD IDF HEAT SPD IDF LOW COOL SPD IDF HIGH SPD IDF FREE COOL SPD

For further details, see the FC/GC Series Single Package Rooftop Units with SystemVu Controller Controls, Start-up, Operation and Troubleshooting manual.

Factory Setting: 9.0 VDC

Field Setting:

V

Switch Range:

A B C

BA C

Field Accessories:

ESP in. wgVDC Calculator

C FM

0.2

6.0 6.3 6.7 7.1 7.5 7.9 8.3 8.7 9.1

1500

1625

1750

1875

2000

2125

2250

2375

2500

0.1

0.4

6.7 7.1 7.4 7.7 8.1 8.4 8.8 9.2 9.5

0.1

0.6

7.4 7.7 8.0 8.3 8.7 9.0 9.4 9.7

0.1

0.8

8.0 8.3 8.6 8.9 9.2 9.5 9.9

0.1

1.0

8.5 8.8 9.1 9.4 9.7

0.1

1.2

9.0 9.3 9.5 9.8

0.1

1.4

9.5 9.7

10.0

0.1

1.6 1.8 2.0

9.9

0.1Economizer

U N

IT M

O D

E L

N U

M B

E R

4.1 - 7.5 6.9 - 8.7 7.7 - 10.0

Record field setting here

*

* Overlap in A, B, C switch range designed for maximum field adjustment potential. For example 7.2 can be set at either A or B.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480294-01 Printed in U.S.A. Form 48FCG-4-6-01SI Rev. D Pg 50 8-21 Replaces: New

2021 Carrier

Fig. 64 Example of Fan Speed Set Up Labels for SystemVu Controls

Field Accessories:

2500

Economizer

ESP in. wgRPM Calculator

C FM

0.2

1425 1512 1601 1692 1784 1878 1973 2069 2166

1500

1625

1750

1875

2000

2125

2250

2375

65

0.4

1609 1688 1768 1850 1933 2018 2104 2192 2282

65

0.6

1764 1839 1916 1994 2073 2153 2235 2317

0.8

1902 1974 2047 2123 2200 2277 2356

65

1.0

2028 2097 2168 2241 2316

65

1.2

2147 2212 2280 2351

65

1.4

2260 2322 2387

65

1.6 1.8 2.0

2367

65 65

U N

IT M

O D

E L

N U

M B

E R

FAN SPEED SETUP (RPM)MAIN MENU:

DETERMINE RPM FROM BELOW

UNIT CONFIGURATIONS

INDOOR FAN

IDF VENT SPD -RPM IDF HEAT SPD -RPM IDF LOW COOL SPD -RPM IDF HIGH COOL SPD -RPM IDF FREE COOL SPD -RPM

SETTINGS

48TC003136 REV. A

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480294-01 Printed in U.S.A. Form 48FCG-4-6-01SI Rev. D Pg CL-1 8-21 Replaces: New

START-UP CHECKLIST FOR 48FCG 04-06 SINGLE PACKAGE ROOFTOP GAS HEATING/ELECTRIC COOLING UNIT

(Remove and use for job file)

I. PRELIMINARY INFORMATION MODEL NO. ____________________________________________

JOB NAME_____________________________________________

SERIAL NO. ____________________________________________

ADDRESS _____________________________________________

START-UP DATE________________________________________

TECHNICIAN NAME _____________________________________

ADDITIONAL ACCESSORIES

_____________________________________________________________________________________________________

II. PRE-START-UP Verify that all packaging materials have been removed from unit (Y/N) _____ Verify installation of outdoor air hood (Y/N) _____ Verify installation of flue exhaust and inlet hood (Y/N) _____ Verify that condensate connection is installed per instructions (Y/N) _____ Verify that all electrical connections and terminals are tight (Y/N) _____ Verify gas pressure to unit gas valve is within specified range (Y/N) _____ Check gas piping for leaks (Y/N) _____ Verify the gas orifice placement dimension (Ultra Low NOx models only) is as shown in the gas piping section (Y/N) _____ Check that indoor-air filters are clean and in place (Y/N) _____ Check that outdoor air inlet screens are in place (Y/N) _____ Verify that unit is level (Y/N) _____ Verify that fan assembly is free of obstructions and rotor spins freely (Y/N) _____ Verify that scroll compressors are rotating in the correct direction (Y/N) _____ Verify installation of thermostat (Y/N) _____ Verify that crankcase heaters have been energized for at least 24 hours (Y/N) _____

III. START-UP ELECTRICAL Supply Voltage L1-L2_____________ L2-L3_____________ L3-L1_____________ Compressor Amps 1 L1 _____________ L2 _____________ L3 _____________ Compressor Amps 2 L1 _____________ L2 _____________ L3 _____________ Supply Fan Amps L1 _____________ L2 _____________ L3 _____________

TEMPERATURES Outdoor-air Temperature _____________ F DB (Dry Bulb) Return-air Temperature _____________ F DB _____________ F WB (Wet Bulb) Cooling Supply Air Temperature _____________ F Gas Heat Supply Air _____________ F

NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sec- tions of this Installation Instruction document.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480294-01 Printed in U.S.A. Form 48FCG-4-6-01SI Rev. D Pg CL-2 8-21 Replaces: New

2021 Carrier

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PRESSURES Gas Inlet Pressure in. wg _____________ in. wg Gas Manifold Pressure STAGE 1 _____________ in. wg

STAGE 2 _____________ in. wg Refrigerant Suction CIRCUIT A _____________ PSIG

CIRCUIT B _____________ PSIG Refrigerant Discharge CIRCUIT A _____________ PSIG

CIRCUIT B _____________ PSIG Verify Refrigerant Charge using Charging Charts (Y/N) _____

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

IV. HUMIDI-MIZER SYSTEM START-UP STEPS

1. Check UCB (Unit Control Board) for jumper 1, 2, 3 (Jumper 1, 2, 3 must be cut and open) (Y/N) _____ 2. Open humidistat contacts (Y/N) _____ 3. Start unit In cooling (Close Y1) (Y/N) _____

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

4. Switch unit to high-latent mode (sub-cooler) by closing humidistat with Y1 closed (Y/N) _____ 5. Check unit charge per charging chart (Y/N) _____

OBSERVE A. Reduction in suction pressure (5 to 7 psi expected) (Y/N) _____ B. Discharge pressure unchanged (Y/N) _____ C. Liquid temperature drops to 50F to 55F range (Y/N) _____ D. LSV solenoid energized (valve closes) (Y/N) _____

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

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

7. With unit in dehumid mode close W1 compressor and outdoor fan stop; LSV and DSV solenoids de-energized (Y/N) _____

8. Open W1 restore uni

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