Carrier 48HC14 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. 04-53480300-01 Printed in U.S.A. Form 48HC-14-05SI Pg 1 5-2020 Replaces: 48HC-14-04SI

Installation Instructions

CONTENTS SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Step 1 Plan for Unit Location . . . . . . . . . . . . . . . . 7 ROOF MOUNT Step 2 Plan for Sequence of Unit Installation . . . 7 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) . . . . . . . . . . . . . . . . . . 12 Step 8 Install Outside Air Hood . . . . . . . . . . . . . . 12 ECONOMIZER HOOD REMOVAL AND SETUP

FACTORY OPTION TWO POSITION DAMPER HOOD REMOVAL AND

SETUP FACTORY OPTION ECONOMIZER HOOD AND TWO-POSITION HOOD Step 9 Install Flue Hood . . . . . . . . . . . . . . . . . . . . 14 Step 10 Install Gas Piping . . . . . . . . . . . . . . . . . . 14 FACTORY OPTION THRU-BASE CONNECTIONS

(GAS CONNECTION) Step 11 Install External Condensate Trap and

Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Step 12 Make Electrical Connections . . . . . . . . . 18 FIELD POWER SUPPLY ALL UNITS UNITS WITHOUT FACTORY-INSTALLED NON-

FUSED DISCONNECT OR HACR CIRCUIT BREAKER UNITS WITH FACTORY-INSTALLED NON-FUSED

DISCONNECT OR HACR CIRCUIT BREAKER

CONVENIENCE OUTLETS HACR CIRCUIT BREAKER FACTORY OPTION THRU-BASE CONNECTIONS

(ELECTRICAL CONNECTIONS) UNITS WITHOUT THRU-BASE CONNECTIONS FIELD CONTROL WIRING THERMOSTAT UNIT WITHOUT THRU-BASE CONNECTION KIT HEAT ANTICIPATOR SETTINGS Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Humidi-MiZer System Control Connections . . . . .28 HUMIDI-MIZER SPACE RH CONTROLLER EconoMi$er X (Factory Option) . . . . . . . . . . . . . . .30 SYSTEM COMPONENTS SPECIFICATIONS INPUTS OUTPUTS ENVIRONMENTAL ECONOMIZER MODULE WIRING DETAILS INTERFACE OVERVIEW SETUP AND CONFIGURATION ENTHALPY SETTINGS TWO-SPEED FAN OPERATION CHECKOUT TROUBLESHOOTING Low Ambient Control (Factory Option) . . . . . . . . . .43 Staged Air Volume (SAV) with Variable Frequency

Drive (Factory Option) . . . . . . . . . . . . . . . . . . . . . .43 ComfortLink Controls (Factory Option) . . . . . . . . . .43 PremierLink Controller (Factory Option) . . . . . . .47 RTU Open Controller System (Factory-Installed

Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 ADDITIONAL APPLICATION DATA Step 13 Adjust Factory-Installed Options . . . . . .48 SMOKE DETECTORS ECONOMI$ER IV OCCUPANCY SWITCH Step 14 Install Accessories . . . . . . . . . . . . . . . . .48 Step 15 Check Belt Tension . . . . . . . . . . . . . . . . .48 BELT FORCE DEFLECTION METHOD BELT TENSION METHOD Pre-Start and Start-Up . . . . . . . . . . . . . . . . . . . . . . . .49 START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . .CL-1

48HC units for installation in the United States contain use of Carrier's Staged Air Volume (SAV) 2-speed indoor fan control system. This complies with the U.S. Department of Energy (DOE) efficiency standard of 2018. 48HC units for installation outside the United States may or may not contain use of the SAV 2-speed indoor fan control system as they are not required to comply with the U.S. Department of Energy (DOE) efficiency standard of 2018. For specific details on operation of the Carrier SAV 2-speed indoor fan system refer to the Variable Frequency Drive (VFD) Factory-Installed Option 2-Speed Motor Control Installation, Setup, and Troubleshooting manual.

WeatherMaster

48HC14 Single Package Rooftop Gas Heat/Electric Cooling

Unit with Puron (R-410A) Refrigerant

2

SAFETY CONSIDERATIONS Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing. Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloths for brazing operations and have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and appropriate national electrical codes (in USA, ANSI/NFPA70, National Electrical Code (NEC); in Canada, CSA C22.1) for special requirements. 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. 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.

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 pres- sure 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 man- ual gas valve(s).

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

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

CARBON-MONOXIDE POISONING HAZARD Failure to follow instructions could result in severe personal injury or death due to carbon-monoxide poisoning, if combus- tion 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 ob- structed 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 sinfil- trent dans le btiment. Vrifier que toutes les ouvertures pratiques dans le mur ex- trieur 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, ob- strues, quelle que soit la saison.

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 re- pair or final unit disposal. Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refriger- ants and oils.

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.

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GENERAL See Fig. 1-3 for unit options and dimensions.

Rated Indoor Airflow (cfm) 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. 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

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.

Table 1 Rated Indoor Airflow (cfm)

MODEL NUMBER FULL LOAD AIRFLOW (CFM)

48HC*D/E/G14 4375

MANIFOLD

GAS VALVE

MANIFOLD PRESSURE TAP SET SCREW

4

Fig. 1 48HC 14 Model Number Nomenclature

Model Series - WeatherMaster

HC - High Efficiency

Unit Heat Type 48 - Gas Heat Packaged Rooftop

Cooling Tons 14 - 12.5 ton

Heat Options D = Low Gas Heat E = Medium Gas Heat F = High Gas Heat S = Low Heat w/ Stainless Steel Exchanger R = Medium Heat w/ Stainless Steel Exchanger T = High Heat w/ Stainless Steel Exchanger

Sensor Options A = None B = RA Smoke Detector C = SA Smoke Detector D = RA + SA Smoke Detector E = CO2

F = RA Smoke Detector and CO2

G = SA Smoke Detector and CO2

H = RA + SA Smoke Detector and CO2

Indoor Fan Options 1 = Standard Static Option - Belt Drive 2 = Medium Static Option - Belt Drive 3 = High Static Option - Belt Drive C = High Static Option with High Efficiency Motor - Belt Drive

Refrig. Systems Options D = Two stage cooling model E = Two stage cooling models with Humidi-MiZer G = Two stage cooling models with Motormaster Low Ambient Controller

Coil Options (RTPF) (Outdoor - Indoor - 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

Voltage 1 = 575/3/60 5 = 208-230/3/60 6 = 460/3/60

Design Revision A = Factory Design Revision

Base Unit Controls 0 = Electro-mechanical Controls Can be used with W7212 EconoMi$er IV (Non-Fault Detection and Diagnostic) 1 = PremierLink Controller 2 = RTU Open Multi-Protocol Controller 6 = Electro-mechanical w/ 2-speed fan and W7220 Econo controller Controls. Can be used with W7220 EconoMi$er X (with Fault Detection and Diagnostic) D = ComfortLink Controls

Intake / Exhaust Options A = None B = Temperature Economizer w/ Barometric Relief F = Enthalpy Economizer w/ Barometric Relief K = 2-Position Damper U = Temp Ultra Low Leak Economizer w/ Baro Relief W = Enthalpy Ultra Low Leak Economizer w/ Baro 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 C = Foil Faced Insulation D = Foil Faced Insulation with Unpowered Convenience Outlet E = Foil Faced Insulation with Powered Convenience Outlet F = Foil Faced Insulation & Hinged Panels G = Foil Faced Insulation & Hinged Panels with Unpowered Convenience Outlet H = Foil Faced Insulation & Hinged Panels with Powered Convenience Outlet

Factory Assigned 0 = Standard 1 = LTL

Electrical Options A = None B = HACR Breaker C = Non-Fused Disconnect D = Thru-The-Base Connections E = HACR and Thru-The-Base Connections F = Non-Fused Disconnect and Thru-The-Base G = 2-Speed Indoor Fan (VFD) Controller H = 2-Speed Fan Controller (VFD) and HACR J = 2 Speed Fan Controller & Non-Fused Disconnect K = 2-Speed Fan Controller w/ Thru-The-Base L = HACR w/ Thru-The-Base & 2-Speed Fan Controller M = 2-Speed Fan Controller w/ Non-Fused Disconnect & Thru-The-Base

Example:

Position:

4 8 H C D E 1 4 A 2 A 6 A 0 A 3 B 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

5

Fig. 2 Unit Dimensional Drawing 14 Size Unit

6

Fig. 2 Unit Dimensional Drawing 14 Size Unit (cont)

7

Fig. 3 Service Clearance Dimensional Drawing

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 interfere 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 at least 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. 3. NOTE: Consider also the effect of adjacent units. 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, relief valves, or other sources of contaminated air. Although unit is weatherproof, avoid locations that permit water from higher level runoff and overhangs to fall onto the unit.

Select a unit mounting system that provides adequate height to al- low installation of condensate trap per requirements. Refer to In- stall External Condensate Trap and Line on page 17 for required trap dimensions. ROOF MOUNT Check building codes for weight distribution requirements. Unit operating weight is 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 instructions for details)

4. Prepare bottom condensate drain connection to suit planned condensate line routing (refer to Install External Condensate Trap and Line on page 17 for details)

5. Rig and place unit 6. Install outdoor air hood

NOTE: Unit not designed to have overhead obstruction. Contact Application Engineering for guidance on any application planning overhead obstruc- tion or for vertical clearances.

LOCATION DIMENSION CONDITION

A

48-in. (1219 mm) 18-in. (457 mm) 18-in. (457 mm) 12-in. (305 mm)

Unit disconnect is mounted on panel No disconnect, convenience outlet option Recommended service clearance Minimum clearance

B 42-in. (1067 mm) 36-in. (914 mm) Special

Surface behind servicer is grounded (e.g., metal, masonry wall) Surface behind servicer is electrically non-conductive (e.g., wood, fiberglass) Check sources of flue products within 10 ft (3 m) of unit fresh air intake hood

C 36-in. (914 mm) 18-in. (457 mm)

Side condensate drain is used Minimum clearance

D

48-in. (1219 mm) 42-in. (1067 mm) 36-in. (914 mm) Special

No flue discharge accessory installed, surface is combustible material Surface behind servicer is grounded (e.g., metal, masonry wall, another unit) Surface behind servicer is electrically non-conductive (e.g., wood, fiberglass) Check for adjacent units or building fresh air intakes within 10 ft (3 m) of this units flue outlet

C

B A

D

8

7. Install condensate line trap and piping 8. Make electrical connections 9. 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 condensate line trap and piping 8. Make electrical connections 9. Install other accessories

FRAME-MOUNTED INSTALLATION Frame-mounted applications generally follow the sequence for a curb installation. Adapt 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; see Fig. 13 and 14. Do not remove carton until unit has been rigged and locat- ed in final position.

Step 4 Provide Unit Support ROOF CURB MOUNT Accessory roof curb details and dimensions are shown in Fig. 4. Assemble and install accessory roof curb in accordance with in- structions shipped with the curb. 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. 4. 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 show in Fig. 5. Refer to Ac- cessory Roof Curb Installation Instructions for additional informa- tion as required.

Table 2 Operating Weights

48HC**14 COMPONENT UNITS LB (KG)

BASE UNIT 1430 (649)

ECONOMIZER Vertical 103 (47)

Horizontal 242 (110)

Powered Outlet 35 (16)

Humidi-MiZer System 90 (41)

CURB 14-in. (356 mm) 180 (82)

24-in. (610 mm) 255 (116)

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Fig. 4 Roof Curb Details

10

Fig. 5 Unit Leveling Tolerances

Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb and not to the unit.

NOTE: If gas and/or 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. 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 NOTE: 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.

Step 6 Rig and Place Unit When the unit is ready to be rigged and no longer will be lifted by a fork truck, the wood protector under the basepan must be re- moved. Remove 4 screws from each base rail. Wood protector will drop to the ground. See instructions on the unit base rails. Keep unit upright and do not drop. Spreader bars are not required. Rollers may be used to move unit across a roof. Level by using unit frame as a reference. See Table 2 and Fig. 6 for additional in- formation. Lifting holes are provided in base rails as shown in Fig. 6. Refer to rigging instructions on unit.

Before setting the unit onto the curb, recheck gasketing on curb.

IMPORTANT: If the units gas connection and/or electric and control wiring is to be routed through the basepan and the unit is equipped with the factory-installed Thru-the-Base service option see the following sections: Factory-Option Thru-Base Connections (Gas Connec-

tion) on page 15 Factory-Option Thru-Base Connections (Electrical Con-

nections) on page 23 If using the field-installed Thru-the-Base accessory follow the instructions provided with the accessory kit.

MAXIMUM ALLOWABLE DIFFERENCE IN. (MM) A-B B-C A-C

0.5 (13) 1.0 (25) 1.0 (25)

A

B

C

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. 6 Rigging Details

POSITIONING ON CURB For full perimeter curbs CRRFCURB074A00 and 075A00,the clearance between the roof curb and the front and rear base rails should be 1/4-in. (6.4 mm). The clearance between the curb and the end base rails should be 1/2-in. (13 mm). For retrofit applications with curbs CRRFCURB003A01 and 4A01, the unit should be po- sitioned as shown in Fig. 7. Maintain the 151/2-in. (394 mm) and 85/8-in. (220 mm) clearances and allow the 225/16-in. (567 mm) di- mension to float if necessary.

Fig. 7 Retrofit Installation Dimensions

If the alternative condensate drain location through the bottom of the unit is used in conjunction with a retrofit curb, the hole in the curb must be moved 121/2-in. (320 mm) towards the end of the unit. (See Fig. 8.) Although unit is weatherproof, guard against water from higher level runoff and overhangs. Remove all shipping materials and top skid. Remove extra center post from the condenser end of the unit so that the condenser end of the unit matches Fig. 29 and 30. Recycle or dispose of all ship- ping materials.

Fig. 8 Alternative Condensate Drain Hole Positions

NOTE: If gas and/or 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.

NOTES: 1. SPREADER BARS 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

48HC**14 2215 1009 116.0 2945 62.5 1590 59.5 1510

DETAIL A

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

DUCT END

SEE DETAIL A

B

A

C

36"-54" (914-1371)

IMPORTANT: If the unit has the factory-installed Thru-the- Base option, make sure to complete installation of the option before placing the unit on the roof curb. See the following sec- tions: Factory-Option Thru-Base Connections (Gas Connec-

tion) on page 15 Factory-Option Thru-Base Connections (Electrical Con-

nections) on page 23

ORIGINAL POSITION

NEW POSITION (MOVED 12.5-IN.)

12

Step 7 Convert to Horizontal and Connect Ductwork (when required) Unit is shipped in the vertical duct configuration. Unit without fac- tory-installed economizer or return-air smoke detector option may be field-converted to horizontal ducted configuration using acces- sory CRDUCTCV002A00. To convert to horizontal configura- tion, remove screws from side duct opening covers (see Fig. 9) and remove covers. Discard the supply duct cover. Install accesso- ry CRDUCTCV002A00 to cover the vertical supply duct opening. Use the return duct cover removed from the unit end panel to cov- er the vertical return duct opening. 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. 10 for position of the notches in the basepan. Seals around duct open- ings must be tight. Secure with screws as shown in Fig. 11. Cover seams with foil duct tape. Field-supplied flanges should be attached to horizontal duct open- ings and all ductwork should be secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof or build- ing 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. 9 Horizontal Conversion Panels

Fig. 10 Location of Notches

Fig. 11 Horizontal Duct Panels In Place

Step 8 Install Outside Air Hood ECONOMIZER HOOD REMOVAL AND SETUP FAC- TORY OPTION 1. The hood is shipped in knock-down form and located in

the return air compartment. It is attached to the econo- mizer using two plastic tie-wraps.

2. To gain access to the hood, remove the filter access panel. (See Fig. 12.)

3. Locate and cut the (2) plastic tie-wraps, being careful to not damage any wiring. (See Fig. 13.)

4. Carefully lift the hood assembly through the filter access opening and assemble per the steps outlined in Econo- mizer Hood and Two-Position Hood on page 13.

Fig. 12 Typical Access Panel Locations

REMOVABLE HORIZONTAL SUPPLY DUCT OPENING COVER

REMOVABLE HORIZONTAL RETURN DUCT OPENING COVER

BASEPAN

NOTCHES NOTCHES

SCREWS

DUCT COVERS SHEET METAL FACE UP

BASEPAN

FILTER ACCESS PANEL

INDOOR COIL ACCESS PANEL

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Fig. 13 Economizer Hood Package Location

TWO POSITION DAMPER HOOD REMOVAL AND SETUP FACTORY OPTION 1. The hood is shipped in knock-down form and assembled

to a metal support tray using plastic stretch wrap. Located in the return air compartment, the assemblys metal tray is attached to the basepan and also attached to the damper using two plastic tie-wraps.

2. To gain access to the hood, remove the filter access panel. (See Fig. 12.)

3. Locate the (2) screws holding the metal tray to the basepan and remove. In order to remove the screws, it may be nec- essary to remove the panel underneath the two-position damper. Remove the two screws. Locate and cut the (2) plastic tie-wraps securing the assembly to the damper. (See Fig. 14.) Be careful to not damage any wiring or cut tie-wraps securing any wiring.

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

5. If removed, reattach the panel under the damper.

Fig. 14 Two-Position Damper Hood Package Location

ECONOMIZER HOOD 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. If the panel is still attached to the unit, remove the screws along the sides and bottom of the panel. See Fig. 15.

2. Swing out indoor coil access panel and insert the hood sides under the panel (hood top). Be careful not to lift the panel too far as it might fall out. Use the screws provided to attach the hood sides to the hood top. Use screws pro- vided to attach the hood sides to the unit. See Fig. 16.

3. Remove the shipping tape holding the economizer baro- metric relief damper in place.

4. Insert the hood divider between the hood sides. See Fig. 17. Secure hood divider with 3 screws on each hood side. The hood divider is also used as the bottom filter rack for the aluminum filter.

5. Attach the post that separates the filters with the screws provided.

6. Open the filter clips which are located underneath the hood top. Insert the aluminum filters into the bottom filter rack (hood divider). Push the filter into position past the open filter clips. Close the filter clips to lock the filters into place. See Fig. 17.

7. Install the two rain deflectors on the edge of the hood top as shown in Fig. 16.

8. Caulk the ends of the joint between the unit top panel and the hood top as shown in Fig. 15.

9. Replace the filter access panel.

Fig. 15 Indoor Coil Access Panel Relocation

ECONOMIZER

CUT PLASTIC TIES (2) PLACES

REMOVE HOOD PARTS

HOOD PARTS

PLASTIC TIE WRAP QTY (2)

SCREWS FORMETAL TRAY QTY (2)

TOP PANEL

INDOOR COIL ACCESS PANEL

INDOOR COIL ACCESS PANEL

CAULK HERE

TOP PANEL

14

Fig. 16 Economizer Hood Construction

Fig. 17 Economizer Filter Installation

Step 9 Install Flue Hood The flue hood is shipped screwed to the basepan beside the burner compartment access panel. Remove the panel below the control box access panel to access the flue hood shipping location. Using screws provided, install flue hood and screen in location shown in Fig. 18.

Fig. 18 Flue Hood Details

Step 10 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 in 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. Unit may be field converted for operation at elevations above 2000 ft (610 m) and/or for use with liquefied petroleum fuel. See accessory kit installation instructions regarding these accessories. NOTE: In U.S.A. the input rating for altitudes above 2000 ft (610 m) must be derated by 4% for each 1000 ft (305 m) above sea level. In Canada the input rating must be derated by 10% for altitudes of 2000 ft (610 m) to 4500 ft. (1372 m) above sea level. For natural gas applications, gas pressure at unit gas connection must not be less than 5 in. wg (1250 Pa) or greater than 13 in. wg (3240 Pa) while the unit is operating (see Tables 3 and 4). For liquified petroleum (LP) applications, the gas pressure must not be less than 11 in. wg (2740 Pa) or greater than 13 in. wg (3240 Pa) at the unit connection (see Tables 5 and 6). 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 3/4-in. FPT gas inlet port on the unit gas valve. Manifold pressure is factory-adjusted for NG fuel use. Adjust as required to obtain best flame characteristics.

TOP PANEL

INDOOR COIL ACCESS PANEL

SCREW

HOOD DIVIDER

LEFT HOOD SIDE

DIVIDER

BAROMETRIC RELIEF

CLEANABLE ALUMINUM FILTER

FILTER

HOOD

FILTER CLIP

OUTSIDE AIR

Table 3 Natural Gas Supply Line Pressure Ranges

UNIT MIN MAX 48HC**14 5.0 in. wg (1250 Pa) 13.0 in. wg (3240 Pa)

Table 4 Liquid Propane Supply Line Pressure Ranges

UNIT MIN MAX 48HC**14 11.0 in. wg (2740 Pa) 13.0 in. wg (3240 Pa)

Table 5 Natural Gas Manifold Pressure Ranges

UNIT MODEL HIGH FIRE LOW FIRE 48HC**14 3.5 in. wg (872 Pa) 2.0 in. wg (498 Pa)

FLUE HOOD

CONTROL BOX ACCESS PANEL

15

Manifold pressure for liquid propane (LP) fuel use must be adjust- ed to specified range. Follow instructions in the accessory kit to make initial readjustment.

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. 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. 19.

Fig. 19 Gas Piping Guide

FACTORY OPTION THRU-BASE CONNECTIONS (GAS CONNECTION) This service connection kit consists of a 3/4-in. NPT gas adapter fitting (stainless steel), a 1/2-in. electrical bulkhead connector and a 11/2-in. electrical bulkhead connector, connected to an L bracket covering the embossed (raised) section of the unit basepan in the condenser section. See Fig. 20.

Fig. 20 Thru-the-Base Option, Shipping Position

1. Remove the L bracket assembly from the unit (see Fig. 20).

2. Cut and discard the wire tie on the gas fitting. Hand tighten the fitting if it has loosened in transit.

3. 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. 4. Place the gasket over the embossed area in the basepan,

aligning the holes in the gasket to the holes in the basepan. See Fig. 21.

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

NOTE: If gas and/or 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. 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. Check tightness of connector lock nuts before connecting gas piping. Install a 3/4-in. NPT street elbow on the thru-base gas fitting. At- tach a 3/4-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. 22.)

Table 6 Liquid Propane Manifold Pressure Ranges

UNIT HIGH FIRE LOW FIRE 48HC**14 10.0 in. wg (2490 Pa) 5.7 in. wg (1420 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.

STEEL PIPE NOMINAL DIAMETER (in.)

SPACING OF SUPPORTS X DIMENSION (ft)

1/2 6 3/4 or 1 8

1 1/4 or larger 10

LEGEND NFGC National Fuel Gas Code * Field supplied. NOTE: Follow all local codes.

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

11/2 ELECTRICAL BULKHEAD CONNECTOR

1/2 ELECTRICAL BULKHEAD CONNECTOR

3/4 NPT GAS ADAPTER FITTING

16

Fig. 21 Completing Installation of Thru-the-Base Option

Fig. 22 Gas Line Piping

Other hardware required to complete the installation of the gas supply line will include 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 pressure). 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 ser- vice. If a regulator valve is installed, it must be located a minimum of 4 ft (1220 mm) away from the units flue outlet. Some munici- pal codes require that the manual shutoff valve be located up- stream of the sediment trap. See Fig. 23 and 24 for typical piping arrangements for gas piping that has been routed through the side- wall of the curb. See Fig. 25 for typical piping arrangement when thru-base is used. Ensure 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. 23 Gas Piping

Fig. 24 Gas Piping

Fig. 25 Gas Piping Thru-Base Connections

GASKET

CONNECTOR PLATE ASSEMBLY

3/4-in NPT STREET ELBOW

THRU-BASE GAS FITTING

GAS SUPPORT BRACKET

9 (229mm) min

Union

Shut Off Valve

Drip Leg

Thru-Curb Adapter

Unit Base Rail

Drip Leg

Shut Off Valve

Union

Thru-Curb Adapter

Burner Access Panel

9 (229mm) min

Unit Base Rail

17

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: 1. Avoid low spots in long runs of pipe. Grade all pipe 1/4-in.

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

2. 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 rec- ommendations of national codes.

3. 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.

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

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 re-drilled, check orifice hole with a numbered drill bit of cor- rect size. Never re-drill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics. See Fig. 26.

Fig. 26 Orifice Hole

Step 11 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. 27. Unit airflow configuration does not determine which drain connection to use. Either drain connection can be used with vertical or horizontal applications.

Fig. 27 Condensate Drain Pan (Side View)

When using the standard side drain connection, ensure the red plug in the alternate bottom connection is tight. Do this before set- ting 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 sock- et 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. 28. 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 in 3 m) of run. Do not use a pipe size smaller than the unit con- nection (3/4-in.).

1. Teflon is a registered trademark of DuPont.

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

DRAIN (FACTORY-INSTALLED)

PLUG

CONDENSATE PAN (SIDE VIEW)

STANDARD SIDE DRAIN

ALTERNATE BOTTOM DRAIN

18

Fig. 28 Condensate Drain Piping Details

Step 12 Make Electrical Connections

NOTE: Field-supplied wiring shall conform with the limitations of minimum 63F (3C) rise. FIELD POWER SUPPLY For those units without through-the-curb power, conduit must be used to route the main power from the condenser end, via the power entry in the corner post of the unit (see Fig. 29 and 30) to ei- ther the factory option disconnect or the bottom of the control box. A 1-in. conduit is provided wrapped around compressor. A second conduit is provided with factory-installed powered convenience outlet. For those units that require conduit larger than 1-in., it must be field supplied. Fig. 29 and 30 show the wire routings. If the field disconnect is larger than 100A, it must be attached to the unit using accessory CRDISBKT001A00 disconnect switch bracket (see Fig. 31). Follow the instructions provided with this accessory. For smaller field disconnects, be sure to use 1/2-in. screws to mount the disconnect directly to the end panel (see Fig. 32). In either case, set the disconnect vertical location on the unit so that a 90 degree fitting can be used to connect the conduit to the disconnect.

Fig. 29 Conduit into Factory Option Non-Fused Disconnect or HACR

Fig. 30 Conduit into Control Box

Fig. 31 Mounting Position for Field Disconnects (over 100A)

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 elec- trical wire connected to unit ground lug in control compart- ment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code); AN- SI/NFPA 70, latest edition (in Canada, Canadian Electrical Code CSA [Canadian Standards Association] C22.1), and lo- cal 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

19

Fig. 32 Mounting Position for Field Disconnects (up to 100A)

Field power wires are connected to the unit at line-side pressure lugs at the main terminal block (TB1) or at factory-installed option non-fused disconnect switch or HACR. Refer to Table 7 for maxi- mum wire size at connection lugs. Use copper wire only. See Fig 33 and 34.

Table 7 Connection Lug Min/Max Wire Sizes

NOTE: TEST LEADS Unit may be equipped with short leads (pigtails) on the field line connection points off the optional non- fused disconnect switch or HACR. These leads are for factory run- test purposes only; remove and discard before connecting field power wires to unit connection points. Make field power connec- tions directly to line connection pressure lugs only.

Fig. 33 Disconnect Switch and Unit

ALL UNITS All field wiring must comply with NEC and all local requirements. Size wire based on MCA (Minimum Circuit Amps) on the unit in- formative plate. See Fig. 34 and the unit label diagram for power wiring connections to the unit power terminal blocks and equip- ment ground. Refer to Table 7 for maximum wire size at connec- tion lugs. Provide a ground-fault and short-circuit over-current protection device (fuse or breaker) per NEC Article 440 (or local codes). Re- fer to unit informative data plate for MOCP (Maximum Over-cur- rent Protection) device size. NOTE: Units ordered with factory installed HACR do not need an additional ground-fault and short-circuit over-current protection device unless local codes require. 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 formula below to determine the percent of voltage imbalance.

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 maxi- mum allowable 2%.

MINIMUM MAXIMUM TB1 in unit control box #14 #1 80A Disconnect Option #14 #4 100A Disconnect Option #8 1/0 25A HACR Option #14 1/0 30A HACR Option #14 1/0 35A HACR Option #14 1/0 40A HACR Option #14 1/0 50A HACR Option #14 1/0 60A HACR Option #14 1/0 70A HACR Option #14 1/0 80A HACR Option #14 1/0 90A HACR Option #14 1/0 100A HACR Option #14 1/0

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.

IMPORTANT: Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine the percentage of voltage imbalance:

% 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.

COPPER

WIRE ONLY

ELECTRIC DISCONNECT

SWITCH

ALUMINUM WIRE

A B C

MOTOR

20

All units except 208/230-v units are factory wired for the voltage shown on the nameplate. If the 208/230-v unit is to be connected to a 208-v power supply, the control transformer must be rewired by moving the black wire with the 1/4-in. female spade connector from the 230-v connection and moving it to the 200-v 1/4-in. male terminal on the primary side of the transformer. Refer to unit label diagram for additional information.

NOTE: Check all factory and field electrical connections for tightness. UNITS WITHOUT FACTORY-INSTALLED NON-FUSED DISCONNECT OR HACR CIRCUIT BREAKER When installing units, provide a disconnect switch of adequate size per NEC (National Electrical Code). 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.

Fig. 34 Power Wiring Connections

UNITS WITH FACTORY-INSTALLED NON-FUSED DIS- CONNECT OR HACR CIRCUIT BREAKER The factory-installed option non-fused disconnect (NFD) switch (see Fig. 35) or HACR circuit breaker (see Fig. 37) is located in a weatherproof enclosure located under the main control box. The manual switch handle is shipped in the disconnect or HACR cir- cuit breaker enclosure. Assemble the shaft and handle to the switch or HACR circuit breaker at this point. Discard the factory test leads (see Fig. 34). The factory disconnect is either an 80A or 100A depending on the unit voltage, indoor motor and options.

Fig. 35 Location of Non-Fused Disconnect Enclosure

To field install the NFD shaft and handle: 1. Remove the unit front panel (see Fig. 2). 2. Remove (3) hex screws on the NFD enclosure - (2) on the

face of the cover and (1) on the bottom (see Fig. 36). 3. Remove the front cover of the NFD enclosure. Make sure

the NFD shipped from the factory is at OFF position (the arrow on the black handle knob is at OFF).

4. Insert the shaft with the cross pin on the top of the shaft in the horizontal position.

5. Measure the tip of the shaft to the top surface of the pointer to be 3.75 to 3.88-in. (95 to 99 mm) for 80A and 100A NFD and 3.43 to 3.56-in. (87 to 90 mm) for 200A NFD.

6. Tighten the locking screw to secure the shaft to the NFD. 7. Turn the handle to the OFF position with red arrow point-

ing at OFF. 8. Install the handle on to the painted cover horizontally with

the red arrow pointing to the left. 9. Secure the handle to the painted cover with (2) screws and

lock washers supplied. 10. Engaging the shaft into the handle socket, re-install (3)

hex screws on the NFD enclosure. 11. Re-install the unit front panel.

CAUTION

UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage. Operation on improper line voltage or excessive phase imbal- ance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty.

Disconnect per

NEC

11 13 13

L1 L2 L3

C IFC

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

Units Without Disconnect or HACR Option

Units With Disconnect or HACR Option

L1

L2

L3

2

4

6

1

5

Optional Disconnect

Switch

Disconnect factory test leads; discard.

Factory Wiring

3

Ground (GR)

Equip GR Lug

Equip GR Lug

Ground (GR)

21

Fig. 36 Handle and Shaft Assembly for NFD

Fig. 37 Location of HACR Circuit Breaker Enclosure

To field install the HACR circuit breaker shaft and handle: 1. Remove the unit front panel (see Fig. 2). 2. Remove (3) hex screws on the HACR circuit breaker

enclosure - (2) on the face of the cover and (1) on bottom (see Fig. 38).

3. Remove the front cover of the HACR circuit breaker enclosure.

4. Make sure the HACR circuit breaker shipped from the fac- tory is at OFF position (the white arrow pointing at OFF).

5. Insert the shaft all the way with the cross pin on the top of the shaft in the horizontal position.

6. Tighten the locking screw to secure the shaft to the HACR circuit breaker.

7. Turn the handle to the OFF position with red arrow point- ing at OFF.

8. Install the handle on to the painted cover horizontally with the red arrow pointing to the left.

9. Secure the handle to the painted cover with (2) screws and lock washers supplied.

10. Engaging the shaft into the handle socket, re-install (3) hex screws on the HACR circuit breaker enclosure.

11. Re-install the unit front panel.

Fig. 38 Handle and Shaft Assembly for HACR Circuit Breaker

CONVENIENCE OUTLETS

Two types of convenience outlets are offered on 48HC**14 mod- els: non-powered and unit-powered. Both types provide a 125-v GFCI (ground-fault circuit-interrupter) duplex receptacle rated at 15-A behind a hinged waterproof access cover, located on the pan- el beneath the control box. See Fig. 39. Non-powered type This type requires the field installation of a general-purpose 125-v 15-A circuit powered from a source elsewhere in the building. Ob- serve national and local codes when selecting wire size and con- duit requirements, fuse or breaker requirements and disconnect switch size and location. Route 125-v power supply conductors into the bottom of the utility box containing the duplex receptacle.

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.

22

Fig. 39 Convenience Outlet Location

Unit-powered type A unit-mounted transformer is factory-installed to stepdown the main power supply voltage to the unit to 115-v at the duplex re- ceptacle. This option also includes a manual switch with fuse, lo- cated in a utility box and mounted on a bracket behind the conve- nience outlet; access is through the units control box access panel. See Fig. 39. The primary leads to the convenience outlet transformer are not factory-connected. Selection of primary power source is a custom- er option (see Fig. 40). If local codes permit, the transformer pri- mary leads can be connected at the line-side terminals on the unit- mounted non-fused disconnect; this will provide service power to the unit when the unit disconnect switch is open. Other connection methods will result in the convenience outlet circuit being de-en- ergized when the unit disconnect switch is open. See Fig. 41. On a unit without a unit-mounted disconnect, connect the source leads to the main terminal block (TB1). If the convenience outlet transformer is connected to the line side of a field disconnect, the conduit provided with the unit must be used to protect the wire as they are routed from the transformer to the field disconnect. The end of the conduit with the straight con- nector attaches to the field disconnect. The other end does not need to connect to the transformer; however, the conduit must be routed so that all wiring is either in the conduit or behind the ac- cess panel. If the convenience outlet transformer is connected to the line side of the factory disconnect option, route the wires through the web bushing located on the bottom of the disconnect box. For the load side wiring to the factory option disconnect, route the wires through the hole on the right side of the disconnect. Be sure to cre- ate a drip loop at least 6-in. long. 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.

Fig. 40 Convenience Utilization Notice

Fig. 41 Unit 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.

CONVENIENCE OUTLET

GFCI

PWD-CO FUSE

SWITCH

PWD-CO TRANSFORMER

DISCONNECT ACCESS PANEL

1. Bussman and Fusetron are trademarks of Cooper Technologies Company.

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 Cir- cuits, for use of convenience outlets.

2.050HE501288

NOTICE/AVIS Convenience Outlet Utilization

Maximum Intermittent Use 15 - Amps Maximum Continuous Use 8 - Amps

Observe a 50% limit on the circuit Loading above 8 - Amps

Utilisation de la prise utilitaire Usage intermittent maximum 15 - Amps

Usage continu maximum 8 - Amps Observez une limite de 50% sur le circuit

Chargement au-dessus de 8 - Amps

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

575 600 L1: RED L2: GRA

H1 H2

23

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. The weatherproof cover kit is shipped in the units control box. The kit includes the hinged cover, a backing plate and gasket. DISCONNECT ALL POWER TO UNIT AND CONVE- NIENCE OUTLET. LOCK-OUT AND TAG-OUT ALL POWER. Remove the blank cover plate at the convenience outlet; discard the blank cover. Loosen the two screws at the GFCI duplex outlet, until approxi- mately 1/2-in. (13 mm) under screw heads are exposed. Press the gasket over the screw heads. 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). Mount the weatherproof cover to the backing plate as shown in Fig. 42. Remove two slot fillers in the bottom of the cover to per- mit service tool cords to exit the cover. Check for full closing and latching.

Fig. 42 Weatherproof Cover Installation

HACR CIRCUIT BREAKER The amp rating of the factory-installed HACR circuit breaker is based on the size, voltage, indoor motor and other electrical op- tions of the unit as shipped from the factory (see Fig. 43). If field- installed accessories are added or changed in the field (i.e., power exhaust), the HACR may no longer be of the proper amp rating and therefore will need to be removed from the unit. See unit nameplate and label on factory-installed HACR for the amp rating of the HACR that was shipped with the unit from the factory. See unit nameplates for the proper fuse, HACR or maximum over-cur- rent protection device required on the unit with field-installed ac- cessories.

Fig. 43 HACR Caution Label

FACTORY OPTION THRU-BASE CONNECTIONS (ELEC- TRICAL CONNECTIONS) This service connection kit consists of a 1/2-in. electrical bulkhead connector and a 11/2-in. electrical bulkhead connector, connected to an L bracket covering the embossed (raised) section of the unit basepan in the condenser section. See Fig. 44. The 1/2-in. bulkhead connector enables the low-voltage control wires to pass through the basepan. The 11/2-in. electrical bulkhead connector al- lows the high-voltage power wires to pass through the basepan.

Fig. 44 Thru-the Base Option, Shipping Position

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. 45.

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

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.

COVER - WHILE-IN-USE WEATHERPROOF

BASEPLATE FOR GFCI RECEPTACLE

GASKET

GFCI RECEPTACLE NOT INCLUDED

TOP

TO P

TOP

WET LOCATIONS

W ET LOCATIONS

1/2-in. ELECTRICAL BULKHEAD CONNECTOR

1-1/2-in. ELECTRICAL BULKHEAD CONNECTOR

24

Fig. 45 Completing Installation of Thru-the-Base Option

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 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. 34.

FIELD CONTROL WIRING The 48HC**14 unit requires an external temperature control de- vice. This device can be a thermostat (field-supplied) or a Premier- Link controller (available as factory-installed option or as field- installed accessory, for use on a Carrier Comfort Network or as a standalone control) or the RTU Open Controller for Building Management Systems using non-CCN protocols (RTU Open con- troller is available as a factory-installed option only). THERMOSTAT Install a Carrier-approved accessory 2-stage cooling/heating ther- mostat according to installation instructions included with the ac- cessory. Locate the thermostat accessory on a solid wall in the conditioned space to sense average temperature in accordance with the thermostat installation instructions (see Fig. 46). 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 (35C [95F] minimum). For 50 to 75 ft (15 to 23 m), use no. 16 AWG insulated wire (35C [95F] minimum). For over 75 ft (23 m), use no. 14 AWG insulated wire (35C [95F] minimum). All 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.

Fig. 46 Typical Low-Voltage Control Connections

UNIT WITHOUT THRU-BASE CONNECTION KIT Pass the thermostat control wires through the bushing on the unit end panel. Route the wire through the snap-in wire tie and up to the web bushing near the control box. Route the wire through the bushing and into the bottom left side of the control box after re- moving one of the two knockouts in the corner of the box. Using a connector at the control box to protect the wire as it passes into the control box. Pull the wires over to the terminal strip at the upper left corner of the Central Terminal Board (CTB). Use the connec- tor at the control box and the wire tie to take up any slack in the thermostat wire to ensure that it will not be damaged by contact with the condenser coil. See Fig. 47. NOTE: If thru-the-bottom connections accessory is used, refer to the accessory installation instructions for information on routing power and control wiring.

Fig. 47 Thermostat Wire Routing

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.

Wiring Diagrams See Fig. 48-50 for wiring diagrams.

GASKET

CONNECTOR PLATE ASSEMBLY

X

C

G

W2

C

W2

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. Do not configure for O output.

Note 2: W2 connection not required on units without electric heating.

Field Wiring

Central Terminal Board

Typical Thermostat Connections

Thermostat Wire

25

Fig. 48 48HC*14 Controls Wiring Diagram (208/230-v, 460-v, 575-v)

26

Fig. 49 48HC*14 Power Wiring Diagram (208/230-v, 460-v)

27

Fig. 50 48HC*14 Power Wiring Diagram (575-v)

28

Humidi-MiZer System Control Connections HUMIDI-MIZER SPACE RH CONTROLLER NOTE: The Humidi-MiZer system is a factory-installed option. The Humidi-MiZer dehumidification system requires a field-sup- plied and installed space relative humidity control device. This de- vice may be a separate humidistat control (contact closes on rise in space RH above control setpoint; see Fig. 51) or a combination thermostat-humidistat control device such as Carriers Edge Pro Thermidistat (see Fig. 52) with isolated contact set for dehumidifi- cation control. The humidistat is normally used in applications where a temperature control is already provided (units with Pre- mierLink control). To connect the Carrier humidistat (HL38MG029): 1. Route the humidistat 2-conductor cable (field-supplied)

through the bushing in the units louvered end panel (see Fig. 47).

2. Route the cable through the snap-in wire tie and up to the web bushing near the control box.

3. Feed the cable through the bushing and into the bottom left side of the control box after removing one of the two knockouts in the corner of the box. Use a connector to pro- tect the cable as it enters the control box.

4. Use the connector and the wire tie to reduce any slack in the humidistat cable to ensure that it will not be damaged by contact with the condenser coil (see Fig. 47).

5. Use wire nuts to connect humidistat cable to two PINK leads in the low-voltage wiring as shown in Fig. 53).

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

(field-supplied) through the bushing in the units louvered end panel (see Fig. 47).

2. Route the cable through the snap-in wire tie and up to the web bushing near the control box

3. Feed the cable through the bushing and into the bottom left side of the control box after removing one of the two knockouts in the corner of the box. Use a connector to pro- tect the cable as it enters the control box.

4. Use the connector and the wire tie to reduce any slack in the thermostat cable to ensure that it will not be damaged by contact with the condenser coil (see Fig. 47).

5. The Thermidistat has dry contacts at terminals D1 and D2 for dehumidification operation (see Fig. 54). The dry contacts

must be wired between CTB terminal R and the PINK lead to the LTLO switch with field-supplied wire nuts. Refer to the installation instructions included with the Carrier Edge Pro Thermidistat device for more information.

Fig. 51 Accessory Field-Installed Humidistat

Fig. 52 Edge Pro Thermidistat

% RELATIVE HUMIDITY

29

Fig. 53 Typical Humidi-MiZer Adaptive Dehumidification System Humidistat Wiring

30

Fig. 54 Typical Rooftop Unit with Humidi-MiZer Adaptive Dehumidification System with Edge Pro Thermidistat Device

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. 55). The W7220 can be config- ured with optional sensors.

Fig. 55 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 sen- sors for single or differential enthalpy control. The W7220 econo- mizer module provides power and communications for the sen- sors. 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 interface 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 provides 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 CO2 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

Rc Rh W1

G Y2 C

O/W2/B Y1

OAT RRS

SRTN HUM

D1 D2 V+ Vg

X*

C

G

W2

W1

Y2

Y1

R

Edge Programable Thermostat Unit CTB

THERMOSTAT

*Connection not required.

Humidi-MiZer FIOP

31

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 48mA

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 Return Air (RA) bus sensor can be added to the system for dif- ferential enthalpy or dry bulb changeover. For differential dry bulb changeover, a 20k ohm sensor is required in the OA and a bus sensor 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 66C) 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 32 for wiring details). 24 vac power supply 20 to 30 vac 50/60Hz; 100 VA Class 2 transformer. OUTPUTS Actuator Signal 2 to 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 recovery 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 ECONOMIZER MODULE WIRING DETAILS Use Fig. 56 and Tables 8 and 9 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. 56 W7220 Wiring Terminals

*Sylk is a trademark of Honeywell International Inc.

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

Table 8 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

32

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. 57 and Table 10 to lo- cate the wiring terminals for each S-Bus and enthalpy control sensor.

Fig. 57 S-Bus Sensor DIP Switches

Use Fig. 57 and Table 11 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. 58 for CO2 sensor wiring.

Fig. 58 CO2 Sensor Wiring

INTERFACE OVERVIEW This section describes how to use the EconoMi$er X 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. 59) to scroll through the menus and menu items, select menu items, and to change parame- ter and configuration settings.

Table 9 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)

Table 10 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 11 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

33

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. 59 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

currently displayed item. 5. Press the button to increase (change) the displayed

parameter value. 6. Press the button to decrease (change) the displayed

parameter 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 previ- ous menu.

Menu Structure Table 12 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

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

Table 12 W7220 Menu Structure*

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME Notes

STATUS

ECON 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 first 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)

34

STATUS (cont)

COOL Y2IN OFF ON/OFF

SECOND STAGE COOLING DEMAND (Y2IN) Y2I signal from space thermostat or 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 (or _ _ . _ C)

40F to 150F (40C to 66C)

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 (or _ _ . _ C)

40F to 150F (40C to 66C)

DISCHARGE AIR TEMPERATURE, after Heating section Displays when Discharge Air Sylk Bus 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 (or _ _ . _ C)

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 Sylk Bus sensor. Displays _ _% if not connected short, or out of range.

RA TEMP _ _ . _ F (or _ _ . _ C)

0F to 140F (18C to 60C)

RETURN AIR TEMPERATURE Displays measured value of return air temperature from RAT Sylk Bus 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 Sylk Bus 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. May be adjusted in Advanced menu by Zero offset and Span.

DCV STATUS N/A ON/OFF DEMAND CONTROLLED VENTILATION STATUS Displays ON if above set point and OFF if below set point, 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 actuator

ACT COUNT N/A 1 to 65,535 Displays number of times actuator has cycled. 1 cycle equals 180 degrees 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 Displays ON when damper position reaches programmed percentage set point. Output of EXH1 terminal: ON = relay closed OFF = relay open

EXH2 OUT OFF ON/OFF

EXHAUST STAGE 2 RELAY OUTPUT Output of AUX1 O terminal Displays ON when damper position reaches programmed percentage set point. ON = 24 vac output OFF = No output Displays only if AUX1 O = EXH2

ERV OFF ON/OFF ENERGY RECOVERY VENTILATOR Output of AUX1 O terminal; displays only if AUX1 O = ERV ON = 24 vac output OFF = No Output

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

Table 12 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME Notes

35

SETPOINTS

MAT SET 53F (12C) 38F to 70F

(3C to 21C); increment by

1 degree

SUPPLY AIR SETPOINT The economizer will modulate the OA damper to maintain the mixed air temperature at the set point

LOW T LOCK 32F (0C) 45F to 80F

(43C to 27C); increment by

1 degree

COMPRESSOR LOW TEMPERATURE LOCKOUT Set point determines outdoor temperature when the mechanical cooling cannot be turned on. Commonly referred to as the Compressor lockout. At or below the set point, the Y1-O and Y2- O will not be energized on the controller.

DRYBLB SET 63F (17C) 48F to 80F

(9C to 27C); increment by

1 degree

OA DRY BULB TEMPERATURE CHANGEOVER SETPOINT Dry bulb set point will only appear if using dry bulb changeover. Set point 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.

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

ENTHALPY CHANGEOVER CURVE ES curve will only appear if using enthalpy changeover. Enthalpy boundary curves for economizing using single enthalpy. See page 41 for description of enthalpy curves.

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

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

MIN POS 2.8 V 2 to 10 vdc

VENTILATION MINIMUM POSITION Displays ONLY if a CO2 sensor is NOT connected. With 2-speed fan units, MIN POS L (low speed fan) and MIN POS H (high speed fan) settings are required. Default for MIN POS L is 3.2V and MIN POS H is 2.8V.

VENTMAX 2.8 V

2 to 10 vdc

DCV MAXIMUM DAMPER POSITION Displays only if a CO2 sensor is connected. Used for Vbz (ventilation max cfm) set point. VENTMAX is the same setting as MIN POS would be if unit did not have CO2 sensor.

100 to 9990 cfm; increment by 10

If OA, MA, RA, and CO2 sensors are connected and DCV CAL ENABLE is set to AUTO mode, the OA dampers are controlled by CFM and displays from 100 to 9990 CFM.

2 to 10 vdc With 2-speed fan units, VENTMAX L (low speed fan) and VENTMAX H (high speed fan) settings are required. Default for VENTMAX L is 3.2V and VENTMAX H is 2.8V

VENTMIN 2.25 V

2 to 10 vdc or 100 to 9990 cfm

increment by 10

DCV MINIMUM DAMPER POSITION Displays only if a CO2 sensor is connected. Used for Va (ventilation min cfm) set point. This is the ventilation for less than maximum occupancy of the space.

100 to 9990 cfm; increment by 10

If OA, MA, RA, and CO2 sensors are connected and DCV CAL ENABLE is set to AUTO mode, the OA dampers are controlled by CFM and displays from 100 to 9990 CFM.

2 to 10 vdc With 2-speed fan units VENTMIN L (low speed fan) and VENTMIN H (high speed fan) settings are required. Default for VENTMIN L is 2.5V and VENTMIN H is 2.25V

ERV OAT SP 32F (0C) 0F to 50F

(18C to 10C); increment by

1 degree

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

EXH1 SET 50% 0 to 100%; increment by 1

EXHAUST FAN STAGE 1 SETPOINT Set point for OA damper position when exhaust fan 1 is powered by the economizer. With 2-speed fan units, Exh1 L (low speed fan) and Exh1 H (high speed fan) settings are required. Default for Exh1 L is 65% and Exh1 H is 50%

EXH2 SET 75% 0 to 100%; increment by 1

EXHAUST FAN STAGE 2 SETPOINT Set point for OA damper position when exhaust fan 2 is powered by the economizer. Only used when AUX1 O is set to EHX2. With 2-speed fan units, Exh2 L (low speed fan) and Exh2 H (high speed fan) settings are required. Default for Exh2 L is 80% and Exh2 H is 75%

SYSTEM SETUP

INSTALL 01/01/10 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 CONV

or HP

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

Table 12 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME Notes

36

SYSTEM SETUP (cont)

AUX2 IN W Shutdown (SD)

Heat (W1) 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. 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

Sets the economizer controller for operation of 1 speed or 2 speed supply fan. The controller does not control the fan, but positions the OA and RA dampers to heating or cooling mode. NOTE: 2-speed fan option also needs Heat (W1) programmed in AUX 2 In.

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

UNIT DESIGN AIRFLOW (CFM) Enter only if using DCVCAL ENA = AUTO This is the capacity of the RTU. 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 24 vac out 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.

ADVANCED SETUP

MA LO SET 45F (7C) 35F to 65F

(2C to 18C); Increment by

1 degree

SUPPLY AIR TEMPERATURE LOW LIMIT Temperature to activate Freeze Protection (close damper or modulate to MIN POS if temp falls below set 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 50

CO2 ppm span to match CO2 sensor; e.g.: 500-1500 sensor output would be 500 CO2 zero and 1000 CO2 span.

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 call and mechanical cooling is second stage call. 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) NONE

35F to 65F (2C to 18C);

Increment 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) NONE

70F to 180F (21C to 82C);

Increment by 5F

Used for alarm for when the DA air temperature is too high. Sets 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 (RA, OA, MA, CO2) sensors. This operation is not operable with a 2-speed fan unit.

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.

Table 12 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME Notes

37

ADVANCED SETUP (cont)

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. See Table 13.

DAMPER OPEN N/A N/A Position damper to the full open position. Exhaust fan contacts enable during the DAMPER OPEN test. Make sure to 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 AUX1O N/A N/A

Energizes the AUX output. If Aux setting is: NONE no 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 1 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

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 set point menu. Check if Mixed air temperature on STATUS menu is below the Lo Set point on Advanced menu. When conditions are back in normal range, 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, this alarm will display when the W7220 is completing a calibration on the dampers. Wait until the calibration is completed and the alarm will go away. Must have OA, MA and RA sensors for DCV calibration; set up is 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.

Table 12 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME Notes

38

LEGEND

* Table 12 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 set point in the set point menu.

*** After 10 minutes without a command or mode change, the controller will change to normal operation.

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

signal originates with a thermostat or other controller call for indoor fan operation at CTB terminal G. This signal passes through the Central Terminal 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 rooftop units, the economizer control sensor is located downstream of the evaporator/indoor coil in the supply fan section where this sensor 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 2- Speed unit operation: EQUIPMENT = CONV AUX2 I = W FAN SPEED = 2SPEED

For damper minimum position settings and checkout menu read- ings, see Table 13. For dry bulb operation with a 1-speed fan, with or without DCV, see Tables 14 and 15. For enthalpy operation with a 1-speed fan, with or without DCV, see Tables 16 and17. For dry bulb operation with a 2 speed indoor fan, with or without DCV, see Tables 18 and 19. For enthalpy operation with a 2 speed indoor fan, with or without DCV, see Tables 20 and 21.

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for YI and Y2I have not been satisfied.

ALARMS (cont)

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 12 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME 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

Table 13 Damper Minimum Position Settings and Readings on Checkout Menu

FAN SPEED DEMAND CONTROLLED

VENTILATION (CO2 SENSOR)

SETPOINTS CHECKOUT

1

NO

MIN POS VMAXHS 1 N/A N/A 2 MIN POS H VMAXHS 2 MIN POS L VMAXLS 1

YES

VENT MIN VMAXHS 1 VENT MAX VMAXHS 2 VENT MIN H VMAXHS 2 VENT MAX H VMAXLS 2 VENT MIN L N/A 2 VENT MAX L N/A

Table 14 Dry Bulb Operation without DCV (CO2 Sensor) 1 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE Y1-I Y2-I FAN SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED

NONE

No Off Off High 0-v/Off 0-v/Off MIN POS Closed On Off High 24-v/On 0-v/Off MIN POS Closed On On High 24-v/On 24-v/On MIN POS Closed

Yes

Off Off High 0-v/Off 0-v/Off MIN POS Closed

On Off High 0-v/Off 0-v/Off MIN POS to Full-Open

Closed to Full-Open

On On High 24-v/On 0-v/Off* MIN POS to Full-Open

Closed to Full-Open

39

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for YI and Y2I have not been satisfied.

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for YI and Y2I have not been satisfied.

*With 2SP FAN DELAY (Advanced Setup Menu) when in the economizing mode there is a delay for the high speed fan to try to satisfy the call for sec- ond stage cooling by turning on the fan to high and opening the OA damper 100% before the first stage mechanical cooling is enabled. With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for YI and Y2I have not been satisfied.

Table 15 Dry Bulb Operation with DCV (CO2 Sensor) 1 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE Y1-I Y2-I FAN SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED

Below CO2 set

No Off Off High 0-v/Off 0-v/Off VENTMIN Closed On Off High 24-v/On 0-v/Off VENTMIN Closed On On High 24-v/On 24-v/On VENTMIN Closed

Yes

Off Off High 0-v/Off 0-v/Off VENTMIN Closed

On Off High 0-v/Off 0-v/Off VENTMIN to Full-Open

Closed to Full-Open

On On High 24-v/On 0-v/Off* VENTMIN to Full-Open

Closed to Full-Open

Above CO2 set

No

Off Off High 0-v/Off 0-v/Off VENTMIN to VENTMAX Closed

On Off High 24-v/On 0-v/Off VENTMIN to VENTMAX Closed

On On High 24-v/On 24-v/On VENTMIN to VENTMAX Closed

Yes

Off Off High 0-v/Off 0-v/Off VENTMIN to VENTMAX Closed

On Off High 0-v/Off 0-v/Off VENTMIN to Full-Open

Closed to Full-Open

On On High 24-v/On 0-v/Off* VENTMIN to Full-Open

Closed to Full-Open

Table 16 Enthalpy Operation without DCV (CO2 Sensor) 1 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE Y1-I Y2-I FAN SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED

NONE

No Off Off High 0-v/Off 0-v/Off MIN POS Closed On Off High 24-v/On 0-v/Off MIN POS Closed On On High 24-v/On 24-v/On MIN POS Closed

Yes

Off Off High 0-v/Off 0-v/Off MIN POS Closed

On Off High 0-v/Off 0-v/Off MIN POS to Full-Open

Closed to Full-Open

On On High 24-v/On 0-v/Off* MIN POS to Full-Open

Closed to Full-Open

Table 17 Enthalpy Operation with DCV (CO2 Sensor) 1 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE Y1-I Y2-I FAN SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED

Below CO2 set

No Off Off High 0-v/Off 0-v/Off VENTMIN Closed On Off High 24-v/On 0-v/Off VENTMIN Closed On On High 24-v/On 24-v/On VENTMIN Closed

Yes

Off Off High 0-v/Off 0-v/Off VENTMIN Closed

On Off High 0-v/Off 0-v/Off VENTMIN to Full-Open

Closed to Full-Open

On On High 24-v/On 0-v/Off VENTMIN to Full-Open

Closed to Full-Open

Above CO2 set

No

Off Off High 0-v/Off 0-v/Off VENTMIN to VENTMAX Closed

On Off High 24-v/On 0-v/Off VENTMIN L to VENTMAX Closed

On On High 24-v/On 24-v/On VENTMIN H to VENTMAX Closed

Yes

Off Off High 0-v/Off 0-v/Off VENTMIN L to VENTMAX Closed

On Off High 0-v/Off 0-v/Off VENTMIN to Full-Open

Closed to Full-Open

On On High DELAY* 24-v/On 0-v/Off VENTMIN to

Full-Open Closed to Full-Open

40

*With 2SP FAN DELAY (Advanced Setup Menu) when in the economizing mode there is a delay for the high speed fan to try to satisfy the call for sec- ond stage cooling by turning on the fan to high and opening the OA damper 100% before the first stage mechanical cooling is enabled. With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for YI and Y2I have not been satisfied.

*With 2SP FAN DELAY (Advanced Setup Menu) when in the economizing mode there is a delay for the high speed fan to try to satisfy the call for sec- ond stage cooling by turning on the fan to high and opening the OA damper 100% before the first stage mechanical cooling is enabled. With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for Y1I and Y2I have not been satisfied.

*With 2SP FAN DELAY (Advanced Setup Menu) when in the economizing mode there is a delay for the high speed fan to try to satisfy the call for second stage cooling by turning on the fan to high and opening the OA damper 100% before the first stage mechanical cooling is enabled. With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for Y1I and Y2I have not been satisfied.

Table 18 Dry Bulb Operation without DCV (CO2 Sensor) 2 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE Y1-I Y2-I FAN SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED

NONE No Off Off Low 0-v/Off 0-v/Off MIN POS L Closed On Off Low 24-v/On 0-v/Off MIN POS L Closed On On High 24-v/On 24-v/On MIN POS H Closed

NONE Yes

Off Off Low 0-v/Off 0-v/Off MIN POS L Closed

On Off Low 0-v/Off 0-v/Off MIN POS L to Full-Open

Closed to Full-Open

On On High DELAY* 24-v/On 0-v/Off MIN POS H

to Full-Open Closed to Full-Open

Table 19 Dry Bulb Operation with DCV (CO2 Sensor) 2 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE Y1-I Y2-I FAN

SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED

Below CO2 Set

No OFF OFF LOW 0v/Off 0v/Off VENTMIN Closed ON OFF LOW 24v/On 0v/Off VENTMIN Closed ON ON HIGH 24v/On 24v/On VENTMIN Closed

Yes

OFF OFF LOW 0v/Off 0v/Off VENTMIN Closed

ON OFF LOW 0v/Off 0v/Off VENTMIN to Full-Open Closed to Full-Open

ON ON HIGH 24v/On 0v/Off VENTMIN to Full-Open Closed to Full-Open

Above CO2 Set

No

OFF OFF LOW 0v/Off 0v/Off VENTMIN to VENTMAX Closed

ON OFF LOW 24v/On 0v/Off VENTMIN to VENTMAX Closed

ON ON HIGH 24v/On 24v/On VENTMIN to VENTMAX Closed

Yes

OFF OFF LOW 0v/Off 0v/Off VENTMIN to VENTMAX Closed

ON OFF LOW 0v/Off 0v/Off VENTMIN to Full-Open Closed to Full-Open

ON ON HIGH DELAY* 24v/On 0v/Off VENTMIN to

Full-Open Closed to Full-Open

Table 20 Enthalpy Operation without DCV (CO2 Sensor) 2 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE Y1-I Y2-I FAN

SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED

NO CO2 SENSOR

NO OFF OFF LOW 0v/Off 0v/Off MIN POS Closed ON OFF LOW 24v/On 0v/Off MIN POS Closed ON ON HIGH 24v/On 24v/On MIN POS Closed

YES

OFF OFF LOW 0v/Off 0v/Off MIN POS Closed ON OFF LOW 0v/Off 0v/Off MIN POS to Full Open Closed to Full-Open

ON ON HIGH DELAY* 24v/On 0v/Off MIN POS to Full Open Closed to Full-Open

41

*With 2SP FAN DELAY (Advanced Setup Menu) when in the economizing mode there is a delay for the high speed fan to try to satisfy the call for second stage cooling by turning on the fan to high and opening the OA damper 100% before the first stage mechanical cooling is enabled. With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for Y1I and Y2I have not been satisfied.

ENTHALPY SETTINGS When the OA temperature, enthalpy and dew point are below the respective set points, the Outdoor Air can be used for economiz- ing. Figure 60 shows the new single enthalpy boundaries in the W7220. There are 5 boundaries (set points ES1 through ES5), which are defined by dry bulb temperature, enthalpy and dew point. Refer to Table 23 for ENTH CURVE set point 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 60 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. TWO-SPEED FAN OPERATION NOTE: Two-Speed Fan operation applies to size 07 models only. 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 22.

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-fan delay is available when the system is programmed for 2-speed fan (in the System Setup menu item). The 2-speed fan de- lay is defaulted to 5 minutes and can be changed in the Advanced 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.

Table 21 Enthalpy Operation with DCV (CO2 Sensor) 2 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE Y1-I Y2-I FAN

SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED

Below CO2 Set

No OFF OFF LOW 0v/Off 0v/Off VENTMIN Closed ON OFF LOW 24v/On 0v/Off VENTMIN Closed ON ON HIGH 24v/On 24v/On VENTMIN Closed

Yes

OFF OFF LOW 0v/Off 0v/Off VENTMIN Closed

ON OFF LOW 0v/Off 0v/Off VENTMIN to Full-Open Closed to Full-Open

ON ON HIGH 24v/On 0v/Off VENTMIN to Full-Open Closed to Full-Open

Above CO2 Set

No

OFF OFF LOW 0v/Off 0v/Off VENTMIN to VENTMAX Closed

ON OFF LOW 24v/On 0v/Off VENTMIN to VENTMAX Closed

ON ON HIGH 24v/On 24v/On VENTMIN to VENTMAX Closed

Yes

OFF OFF LOW 0v/Off 0v/Off VENTMIN to VENTMAX Closed

ON OFF LOW 0v/Off 0v/Off VENTMIN to Full-Open Closed to Full-Open

ON ON HIGH DELAY* 24v/On 0v/Off* VENTMIN to

Full-Open Closed to Full-Open

Table 22 Fan Speed

STATE FAN SPEED OCC Low Y1 Low Y2 High W High

42

Fig. 60 Single Enthalpy Curve Boundaries

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 32. 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 set points 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 12) 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 32. Checkout Tests Use the Checkout menu (see page 37) 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 32.

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) 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 devices (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.

ECONOMIZING

AVAILABLE

NOT AVAILABLE

ENTHALPY RA HUM (%

RH)

R A

TE M

P TEMPERATURE

A B

S O

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 23 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

CAUTION Failure to follow this caution may result in damage to equip- ment. Be sure to allow enough time for compressor startup and shutdown between checkout tests so that you do not short-cy- cle the compressors.

43

Clearing Alarms Once the alarm has been identified and the cause has been re- moved (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.

Low Ambient Control (Factory Option) If the unit comes with Electro-Mechanical (EM) control, then no adjustment is necessary. If the unit comes with PremierLink or RTU Open control option, then refer to its installation control manual for details on adjusting Cooling Lock-Out setting and configure for the specific job re- quirements.

Staged Air Volume (SAV) with Variable Fre- quency Drive (Factory Option) For details on operating 48HC 2 stage cooling units equipped with the factory-installed Staged Air Volume option, refer to the Vari- able Frequency Drive (VFD) Installation, Setup and Trouble- shooting Supplement.

ComfortLink Controls (Factory Option) For details on operating 48HC units equipped with the factory-in- stalled ComfortLink controls option, refer to the Controls, Start- Up, Operation and Troubleshooting for 48/50HC 04-28 Single Package Rooftop Unit with ComfortLink Controls manual. See Fig. 61-64 for ComfortLink controls and wiring diagrams.

Fig. 61 48HC14 Control Box Component Locations with ComfortLink Controls

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 shut- down between checkout tests so that you do not short-cycle the compressors.

44

Fig. 62 48HC14 ComfortLink Control Wiring Diagram

45

Fig. 63 48HC14 ComfortLink Power Wiring Diagram

46

Fig. 64 48HC14 ComfortLink with Humidi-MiZer Power Wiring Diagram

47

PremierLink Controller (Factory Option) For details on operating 48HC*14 units equipped with the factory- installed PremierLink controller option, refer to the PremierLink Retrofit Rooftop Controller Version 3.x Installation, Start-Up, and Configuration Instructions manual.

RTU Open Controller System (Factory-Installed Option) For details on operating 48HC*14 units equipped with the factory- installed RTU Open controller, refer to the Factory-Installed RTU Open Multi-Protocol Controller Control, Start-Up, Opera- tion and Troubleshooting manual.

Smoke Detectors Smoke detectors are available as factory-installed options on 48HC**14 models. Smoke detectors may be specified for sup- ply air only, for return air without or with economizer, or in com- bination of supply air and return air. Return-air smoke detectors are arranged for vertical return configurations only. All compo- nents 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 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. 65 for the as-shipped location. Completing installation of return-air smoke sensor: 1. Unscrew the two screws holding the Return Air Smoke

Detector assembly. See Fig. 66, 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. 66, Step 2.

3. Screw the sensor and detector plate into its operating posi- tion using screws from Step 1. See Fig. 66, 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 sheet titled, Factory Installed Smoke Detectors for Small and Medium Rooftop Units 2 to 25 Tons for discussions on additional control features of these smoke detec- tors, including multiple unit coordination.

Fig. 65 Return Air Smoke Detector, Shipping Position

Fig. 66 Completing Installation of Return Air Smoke Sensor

RETURN AIR SMOKE DETECTOR (AS SHIPPED)

STEP 1 STEP 2 STEP 3

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Fig. 67 EconoMi$er IV Wiring

Step 13 Adjust Factory-Installed Options SMOKE DETECTORS Smoke detector(s) will be connected at the Controls Connections Board, at terminals marked Smoke Shutdown. Cut jumper JMP 3 when ready to energize unit. ECONOMI$ER IV OCCUPANCY SWITCH Refer to Fig. 67 for general EconoMi$er IV wiring. External occu- pancy control is managed through a connection on the Controls Connections 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. Cut jumper JMP 2 to complete the installation.

Step 14 Install Accessories Available accessories include: Roof curb (must be installed before unit) Thru-base connection kit (must be installed before unit is

set on curb) Manual outside air damper Two-Position motorized outside air damper EconoMi$er IV (with control and integrated barometric

relief) EconoMi$er2 (without control/for external signal and inte-

grated barometric relief) Barometric relief Power Exhaust Differential dry-bulb sensor (EconoMi$er IV) Outdoor enthalpy sensor Differential enthalpy sensor Time Guard II compressor anti-cycle control Outdoor coil protector grille

Head pressure control Programmable setback thermostat Electrical/Mechanical thermostat and subbase Thermidistat device Humidistat Thermostat / Sensors CO2 sensor DDC interface (PremierLink controller) Louvered hail guard Phase monitor control

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

Step 15 Check Belt Tension Measure the belt span length as shown in Fig. 68. Calculate the re- quired deflection by multiplying the belt span length by 1/64. For example, if the belt span length is 32 inches:

32 x 1/64 = 1/2-in. deflection. BELT FORCE DEFLECTION METHOD Check the belt tension with a spring-force belt force deflection gage (available from drive belt manufacturer). 1. Place a straightedge along the belt between the two pul-

leys. Measure the distance between the motor shaft and the blower shaft.

2. Set the tension gage to the desired tension (see Table 1 in Fig. 68). Place the large O-ring at that point.

3. Press the tension checker downward on the belt until the large O-ring is at the bottom of the straightedge.

4. Adjust the belt tension as needed. Adjust belt tension by loosing the motor mounting plate front bolts and rear bolt (see Fig. 69) and slide the plate towards the fan (to reduce tension) or away from the fan (to increase tension). Ensure

Economizer 2 Position Damper Unit Without Economizer or 2 Position Damper

49

the blower shaft and motor shaft are parallel to each other (pulleys aligned). Tighten all bolts securely when finished.

Fig. 68 V-Belt Force Label

BELT TENSION METHOD Requires belt tension gage that measures tension in belt in units of lbs force.

Fig. 69 Belt Drive Motor Mounting

Pre-Start and Start-Up This completes the mechanical installation of the unit. Refer to the units Service Manual for detailed Pre-Start and Start-Up instruc- tions. Download the latest versions from HVAC Partners (www.hvacpartners.com).

TORQUE ALL SHEAVE SET SCREWS TO 110-130 in. lbs

SET SCREW

SET SCREW

STRAIGHT EDGE

BELT SPAN

BELT DEFLECTION FORCE - SEE TABLE 1

DEFLECTION = BELT SPAN 64

Table 1

Table 2

BELT CROSS

SECTION

SMALLEST SHEAVE

DIAMETER

BELT DEFLECTION FORCE (LBS) UNNOTCHED

BELTS NOTCHED BELTS

USED NEW USED NEW

A, AX 3.0-3.6 3.7 5.5 4.1 6.1 3.8-4.8 4.5 6.8 5.0 7.4 5.0-7.0 5.4 8.0 5.7 8.4

B, BX 3.4-4.2 4.9 7.2 4.4-5.6 5.3 7.9 7.1 10.5 5.8-8.6 6.3 9.4 8.5 12.6

BELT CONDITION TENSION FORCE IN BELT (LBS) New 100 Used 80

BLOWER PULLEY

V-BELT

MOTOR PULLEY

MOTOR

MOTOR MOUNTING PLATE

MOUNTING BOLTS (4)

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480300-01 Printed in U.S.A. Form 48HC-14-05SI Pg 50 5-2020 Replaces: 48HC-14-04SI

2020 Carrier

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480300-01 Printed in U.S.A. Form 48HC-14-05SI Pg CL-1 5-2020 Replaces: 48HC-14-04SI

START-UP CHECKLIST (Remove and use for job file)

MODEL NO.: ____________________________________________ SERIAL NO.: ____________________________

I. PRE-START-UP VERIFY THAT ALL PACKAGING MATERIALS HAVE BEEN REMOVED FROM UNIT VERIFY INSTALLATION OF OUTDOOR AIR HOOD VERIFY INSTALLATION OF FLUE EXHAUST AND INLET HOOD VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT VERIFY GAS PRESSURE TO UNIT GAS VALVE IS WITHIN SPECIFIED RANGE CHECK GAS PIPING FOR LEAKS CHECK THAT INDOOR-AIR FILTERS ARE CLEAN AND IN PLACE CHECK THAT OUTDOOR AIR INLET SCREENS ARE IN PLACE VERIFY THAT UNIT IS LEVEL CHECK FAN WHEELS AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND VERIFY

SETSCREW IS TIGHT VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED VERIFY THAT SCROLL COMPRESSORS ARE ROTATING IN THE CORRECT DIRECTION VERIFY INSTALLATION OF THERMOSTAT VERIFY THAT CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR AT LEAST 24 HOURS

II. START-UP ELECTRICAL

TEMPERATURES

PRESSURES

VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS

NOTE: To avoid injury to personnel and damage to equipment or prop- erty 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 sections of this Installation Instructions.

SUPPLY VOLTAGE L1-L2 ____________ L2-L3 _____________ L3-L1 ___________ COMPRESSOR AMPS 1 L1-L2 ____________ L2-L3 _____________ L3-L1 ___________ COMPRESSOR AMPS 2 L1-L2 ____________ L2-L3 _____________ L3-L1 ___________ SUPPLY FAN AMPS L1-L2 ____________ L2-L3 _____________ L3-L1 ___________

OUTDOOR-AIR TEMPERATURE _____________ F DB (DRY BULB) RETURN-AIR TEMPERATURE _____________ F DB _____________ F WB (WET BULB) COOLING SUPPLY AIR TEMPERATURE _____________ F GAS HEAT SUPPLY AIRS _____________ F

GAS INLET PRESSURE _____________ 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

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480300-01 Printed in U.S.A. Form 48HC-14-05SI Pg CL-2 5-2020 Replaces: 48HC-14-04SI

2020 Carrier

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GENERAL ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS (IF EQUIPPED) VERIFY SMOKE DETECTOR UNIT SHUTDOWN BY UTILIZING MAGNET TEST

III. HUMIDI-MIZER SYSTEM START-UP STEPS 1. CHECK CTB FOR JUMPER 5, 6, 7

JUMPER 5, 6, 7 MUST BE CUT AND OPEN 2. OPEN HUMIDISTAT CONTACTS 3. START UNIT IN COOLING (CLOSE Y1)

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 F. CHECK FOR CORRECT RAMP-UP OF OUTDOOR FAN MOTOR AS CONDENSER COIL WARMS

4. CHECK UNIT CHARGE PER CHARGING CHART 5. SWITCH UNIT TO HIGH-LATENT MODE (SUBCOOLER) BY CLOSING HUMIDISTAT WITH Y1 CLOSED

OBSERVE A. REDUCTION IN SUCTION PRESSURE (5 TO 7 PSI EXPECTED) B. DISCHARGE PRESSURE UNCHANGED C. LIQUID TEMPERATURE DROPS TO 50 TO 55F RANGE D. LIQUID SOLENOID VALVE (LSV) ENERGIZED (VALVE CLOSES)

6. SWITCH UNIT TO DEHUMID (REHEAT) BY OPENING Y1 OBSERVE A. SUCTION PRESSURE INCREASES TO NORMAL COOLING LEVEL B. DISCHARGE PRESSURE DECREASES (35 TO 50 PSI) C. LIQUID TEMPERATURE RETURNS TO NORMAL COOLING LEVEL D. LIQUID SOLENOID VALVE (LSV) ENERGIZED (VALVE CLOSES) E. DISCHARGE SOLENOID VALVE (DSV) ENERGIZED, VALVE OPENS

7. WITH UNIT IN DEHUMID MODE CLOSE W1 COMPRESSOR AND OUTDOOR FAN STOP; LSV AND DSV SOLENOIDS DE-ENERGIZED </