Contents

Carrier 48KC04 06 Installation Instructions PDF

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Summary of Content for Carrier 48KC04 06 Installation Instructions PDF

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480255-01 Printed in U.S.A. Form 48KC-4-6-04SI Pg 1 6-2020 Replaces: 48KC-4-6-03SI

Installation Instructions CONTENTS

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

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rated Indoor Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 1 Plan for Unit Location . . . . . . . . . . . . . . . 11 ROOF MOUNT Step 2 Plan for Sequence of Unit Installation . . 11 CURB-MOUNTED INSTALLATION PAD-MOUNTED INSTALLATION FRAME-MOUNTED INSTALLATION Step 3 Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 4 Provide Unit Support . . . . . . . . . . . . . . . . 12 ROOF CURB MOUNT SLAB MOUNT (HORIZONTAL UNITS ONLY) ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR

SLAB MOUNT) Step 5 Field Fabricate Ductwork . . . . . . . . . . . . . 12 Step 6 Rig and Place Unit . . . . . . . . . . . . . . . . . . 12 POSITIONING ON CURB Step 7 Convert to Horizontal and Connect

Ductwork (When Required) . . . . . . . . . . . . . . . . . 13 Step 8 Install Outside Air Hood . . . . . . . . . . . . . 14 ECONOMIZER AND TWO POSITION DAMPER HOOD

PACKAGE REMOVAL AND SETUP (FACTORY OPTION)

ECONOMIZER AND TWO-POSITION HOOD Step 9 Units with Hinged Panels Only . . . . . . . . 15 Step 10 Install Flue Hood . . . . . . . . . . . . . . . . . . . 15 Step 11 Install Gas Piping . . . . . . . . . . . . . . . . . . 16 FACTORY OPTION THRU-BASE CONNECTIONS

(GAS CONNECTIONS) Step 12 Install External Condensate Trap

and Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Step 13 Make Electrical Connections . . . . . . . . . 19 FIELD POWER SUPPLY UNITS WITH FACTORY-INSTALLED NON-FUSED

DISCONNECT OR HACR UNITS WITHOUT FACTORY-INSTALLED NON-

FUSED DISCONNECT OR HACR ALL UNITS CONVENIENCE OUTLETS HACR AMP RATING FACTORY-OPTION THRU-BASE CONNECTIONS

(ELECTRICAL CONNECTIONS) UNITS WITHOUT THRU-BASE CONNECTIONS

(ELECTRICAL CONNECTIONS) FIELD CONTROL WIRING THERMOSTAT HEAT ANTICIPATOR SETTINGS HUMIDI-MIZER CONTROL CONNECTIONS TYPICAL UNIT WIRING DIAGRAMS

Low Ambient Control (Factory Option) . . . . . . . . . .30 Integrated Gas Controller . . . . . . . . . . . . . . . . . . . . .30 EconoMi$er X (Factory Option) . . . . . . . . . . . . . . .33 SYSTEM COMPONENTS SPECIFICATIONS INPUTS OUTPUTS ENVIRONMENTAL ECONOMIZER MODULE WIRING DETAILS INTERFACE OVERVIEW SETUP AND CONFIGURATION ENTHALPY SETTINGS CHECKOUT TROUBLESHOOTING Outdoor Air Enthalpy Control

(P/N 33CSENTHSW) . . . . . . . . . . . . . . . . . . . . . . . .44 DIFFERENTIAL ENTHALPY CONTROL RETURN AIR ENTHALPY SENSOR Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 COMPLETING RETURN AIR SMOKE SENSOR

INSTALLATION ADDITIONAL APPLICATION DATA PremierLink Controller (Factory Option) . . . . . . .45 RTU Open Controller (Factory-Installed Option) . .45 Step 14 Adjust Factory-Installed Options . . . . . .45 SMOKE DETECTORS ECONOMI$ER IV OCCUPANCY SWITCH Step 15 Install Accessories . . . . . . . . . . . . . . . . .45 Step 16 Check Belt Tension . . . . . . . . . . . . . . . . .46 BELT FORCE DEFLECTION METHOD BELT TENSION METHOD START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . .CL-1

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

WeatherMaker

48KC04-06 Single Package Rooftop Gas Heating/Electric Cooling Unit

2

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

Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation. There may be more than one disconnect switch. Tag all disconnect locations to alert others not to restore power until work is completed.

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).

WARNING

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

WARNING

PERSONAL INJURY AND ENVIRONMENTAL HAZARD Failure to follow this warning could cause personal injury or death. Relieve pressure and recover all refrigerant before system 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.

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

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

3

MODEL NUMBER NOMENCLATURE AND DIMENSIONS

See Fig. 1 for 48KC model number nomenclature. See Fig. 2-6 for unit dimensional drawings. See Fit. 7 for roof curb information. Fig. 4 shows service clearance dimensions.

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

Table 1 Rated Indoor Airflow

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.

MANIFOLD

GAS VALVE

MANIFOLD PRESSURE TAP SET SCREW

MODEL NUMBER FULL LOAD AIRFLOW (CFM) 48KC*A/B04 1050 48KC*A/B05 1400 48KC*A/B06 1750

4

Fig. 1 48KC 04-06 Model Number Nomenclature (Example)

4 8 K C D A 0 4 A 1 A 5 0 A 0 A 0

Cooling Tons 04 - 3 ton 05 - 4 ton 06 - 5 ton

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

Heat Options D = Low Gas Heat E = Medium Gas Heat F = High Gas Heat L = Low NOx Low Gas Heat M = Low NOx Medium Gas Heat N = Low NOx High Gas Heat S = Low Heat w/ Stainless Steel Exchanger R = Medium Heat w/ Stainless Steel Exchanger T = High Heat w/ Stainless Steel Exchanger (Low Nox models include Stainless Steel HX)

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 0 = Direct Drive ECM 1 = Standard Static Option 2 = Medium Static Option 3 = High Static Option

Coil Options - Round Tube/Plate Fin Condenser Coil (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 3 = 208-230/1/60 5 = 208-230/3/60 6 = 460/3/60

Design Revision = Factory Design Revision

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

Intake / Exhaust Options A = None B = Temperature Economizer w/ Barometric Relief F = Enthalpy Economizer w/ Barometric Relief K = 2-Position Damper U = Temperature Ultra Low Leak Economizer w/ Barometric Relief W = Enthalpy Ultra Low Leak Economizer w/ Barometric Relief

Service Options 0 = None 1 = Unpowered Convenience Outlet 2 = Powered Convenience Outlet 3 = Hinged Access Panels 4 = Hinged Access Panels and Unpowered Convenience Outlet 5 = Hinged Panels and Powered Convenience Outlet

Factory Assigned 0 = Standard 1 = LTL

Electrical Options A = None C = Non-Fused Disconnect D = Thru-The-Base Connections F = Non-Fused Disconnect and Thru-The-Base Connections

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

Note: On single phase (-3 voltage code) models, the following are not available as a factory installed option: - Humidi-MiZer - Coated Coils or Cu Fin Coils - Louvered Hail Guards - Economizer or 2 Position Damper - Powered 115 Volt Convenience Outlet

Unit Heat Type 48 - Gas Heat Packaged Rooftop

Model Series - WeatherMaker

KC - Standard 14 SEER Efficiency

5

Fig. 2 Dimensional Drawing of Units Built On and After 4/15/19

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Fig. 3 Dimensional Drawing for Units Built On and Prior to 4/14/19

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Fig. 4 Unit Corner Weights and Clearances

8

Fig. 5 Base Rail Details

9

Fig. 6 Thru-the-Base Charts

10

Fig. 7 Roof Curb Details

E E

7/16" [11]

4 9/16" [115.5]

1/4" [7.0]

5' 7-3/8" [1711.3]

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

1-3/4" [44.4]

2-3/8" [61]

1-3/4" [44.5]

1.00" [25.4]

"A"

1-3/4" [44.4]

21.74" [552.2]

5.42" [137.7]

11.96" [303.8]

4.96" [126.0] 70.87"

[1800.2]

40.69" [1033.5]

21.84" [554.7]

16.03" [407.2]

1.75" [44.5]

20.41" [518.3]

3.00" [76.2]

13.78" [350.0]

14.00" [355.6]

3.00" [76.2]

15.19" [385.8]

32.19" [817.6]

3'-1 3/16" [944.6]

"A"

1-3/4" [44.5]

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

1/2" [12.7] NPTCRRFCURB002A01

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

CONTROL WIRING FITTING

ACCESSORY CONVENIENCE OUTLET WIRING CONNECTOR

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

CRBTMPWR003A01 THRU THE BOTTOM

ROOF CURB ACCESSORY # A

CRRFCURB001A01 14" [356]

24" [610]

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

TYPICAL (4) SIDES

SUPPLY AIR RETURN AIR

ROOFING MATERIAL (FIELD SUPPLIED)

CANT STRIP (FIELD SUPPLIED)

ROOFING FELT (FIELD SUPPLIED)

COUNTER FLASHING (FIELD SUPPLIED)

UNITGASKET (SUPPLIED WITH CURB)

RIGID INSULATION (FIELD SUPPLIED)

DUCT (FIELD SUPPLIED)

NAIL (FIELD SUPPLIED)

VIEW "B" CORNER DETAIL

SEE VIEW "B"

RETURN AIRSUPPLY AIRSUPPLY AIR OPENING

RETURN AIR OPENING

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

SEE NOTE #2

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

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

1/3/4"[44.5]

SCALE 0.250 E-ESECTION

48TC400427

11

INSTALLATION

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

cal Code) ANSI/NFPA 70 for special installation require- ments.

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

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

Step 1 Plan for Unit Location Select a location for the unit and its support system (curb or other) that provides for the minimum clearances required for safety. This includes the clearance to combustible surfaces, unit performance and service access below, around and above unit as specified in unit drawings. See Fig. 7. NOTE: Consider also the effect of adjacent units. Be sure that unit is installed such that snow will not block the combustion intake or flue outlet. Unit may be installed directly on wood flooring or on Class A, B, or C roof-covering material when roof curb is used.. Do not install unit in an indoor location. Do not locate air inlets near exhaust vents or other sources of contaminated air. For proper unit operation, adequate combustion and ventilation air must be provided in accordance with Section 5.3 (Air for Combustion and Ventilation) of the National Fuel Gas Code, ANSI Z223.1 (Ameri- can National Standards Institute) and NFPA (National Fire Protec- tion Association) 54 TIA54841. In Canada, installation must be in accordance with the CAN1B149 installation codes for gas burning appliances. Although unit is weatherproof, avoid locations that permit water from higher level runoff and overhangs to fall onto the unit. Locate mechanical draft system flue assembly at least 4 ft (1.2 m) from any opening through which combustion products could enter the building, and at least 4 ft (1.2 m) from any adjacent building (or per local code). Locate the flue assembly at least 10 ft (3.05 m) from an adjacent units fresh air intake hood if within 3 ft (0.91 m) of same elevation (or per local code). When unit is located adja- cent to public walkways, flue assembly must be at least 7 ft (2.1 m) above grade. Select a unit mounting system that provides adequate height to al- low installation of condensate trap per requirements. Refer to In- stall External Condensate Trap and Line on page 19 for required trap dimensions. ROOF MOUNT Check building codes for weight distribution requirements. Unit operating weights are shown in Table 2.

Table 2 Operating Weights

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

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

4. Prepare bottom condensate drain connection to suit planned condensate line routing (refer to Install External Condensate Trap and Line on page 19 for details)

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

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

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

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

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

48KC-- UNIT LB (KG)

04 05 06 Base Unit 490 (222) 544 (246) 597 (270) Economizer Vertical 50 (23) 50 (23) 50 (23) Horizontal 80 (36) 80 (36) 80 (36) Humidi-MiZer System 50 (23) 50 (23) 50 (23) Cu Fins 25 (11) 43 (20) 56 (25) Powered Outlet 35 (16) 35 (16) 35 (16) Curb 14 in. (356 mm) 115 (52) 115 (52) 115 (52) 24 in. (610 mm) 197 (89) 197 (89) 197 (89)

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Fig. 8 Unit Leveling Tolerances

Step 4 Provide Unit Support ROOF CURB MOUNT Accessory roof curb details and dimensions are shown in Fig. 7. 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. 7. Improperly applied gasket can also result in air leaks and poor unit performance. Curb should be level. This is necessary for unit drain to function properly. Unit leveling tolerances are shown in Fig. 8. Refer to Accessory Roof Curb Installation Instructions for additional infor- mation as required. Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb and not to the unit. The accessory thru-the-base power and gas connection package must be installed before the unit is set on the roof curb. If field-installed thru-the-roof curb gas connections are desired, use factory-sup- plied 1/2-in. pipe coupling and gas plate assembly to mount the thru-the-roof curb connection to the roof curb. Gas connections and power connections to the unit must be field-installed after the unit is installed on the roof curb. If electric and control wiring is to be routed through the basepan, attach the accessory thru-the-base service connections to the base- pan in accordance with the accessory installation instructions. 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 con- denser coil air inlet to prevent grass and foliage from obstructing airflow. NOTE: Horizontal units may be installed on a roof curb if re- quired. ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR SLAB MOUNT) A non-combustible sleeper rail can be used in the unit curb sup- port area. If sleeper rails cannot be used, support the long sides of the unit with a minimum of 3 equally spaced 4-in. x 4-in. (102 mm x 102 mm) pads on each side.

Step 5 Field Fabricate Ductwork Cabinet return-air static pressure (a negative condition) shall not exceed 0.35 in. wg (87 Pa) with economizer or 0.45 in. wg (112 Pa) without economizer. For vertical ducted applications, secure all ducts to roof curb and building structure. Do not connect ductwork to unit. Fabricate supply ductwork so that the cross sectional dimensions are equal to or greater than the unit supply duct opening dimen- sions for the first 18 in. (458 mm) of duct length from the unit basepan. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with ap- plicable codes. Ducts passing through unconditioned spaces must be insulated and covered with a vapor barrier. If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes. A minimum clearance is not required around ductwork.

Step 6 Rig and Place Unit Keep unit upright and do not drop. Spreader bars are required. Rollers may be used to move unit across a roof. Rigging materials under unit (cardboard or wood) must be removed PRIOR to plac- ing the unit on the roof curb. Level by using unit frame as a refer- ence. See Table 2 and Fig. 9 for additional information. Lifting holes are provided in base rails as shown in Fig. 9. Refer to rigging instructions on unit. Rigging materials under unit (cardboard or wood to prevent base pan damage) must be removed PRIOR to placing the unit on the roof curb. When using the standard side drain connection, ensure the red plug in the alternate bottom connection is tight. Do this before set- ting the unit in place. The red drain plug an be tightened with a 1/2- in. square socket drive extension. For further details, see Install External Condensate Trap and Line on page 19. Before setting the unit onto the curb, recheck gasketing on curb.

A

B

C

MAXIMUM ALLOWABLE DIFFERENCE IN. (MM)

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

CAUTION

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

CAUTION

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

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Fig. 9 Rigging Details

POSITIONING ON CURB Position unit on roof curb so that the following clearances are maintained: 1/4 in. (6.4 mm) clearance between the roof curb and the base rail inside the front and rear, 0.0 in. clearance between the roof curb and the base rail inside on the duct end of the unit. This will result in the distance between the roof curb and the base rail inside on the condenser end of the unit being approximately 1/4 in. (6.4 mm). Although unit is weatherproof, guard against water from higher level runoff and overhangs. Flue vent discharge must have a minimum horizontal clearance of 4 ft (1220 mm) from electric and gas meters, gas regulators, and gas relief equipment. Minimum distance between unit and other electrically live parts is 48 inches (1220 mm). Flue gas can deteriorate building materials. Orient unit such that flue gas will not affect building materials. Locate mechanical draft system flue assembly at least 48 in. (1220 mm) from an adjacent building or combustible material. Installation of accessory flue discharge deflector kit will reduce the minimum clearance to combustible material to 18 in. (460 mm). After unit is in position, remove rigging skids and shipping materials.

Step 7 Convert to Horizontal and Connect Ductwork (When Required) Unit is shipped in the vertical duct configuration. Unit without factory-installed economizer or return-air smoke detector option may be field-converted to horizontal ducted configuration. To convert to horizontal configuration, remove screws from side duct opening covers (see Fig. 10) and remove covers. Use the screws to install the covers on vertical duct openings with the insulation-side

down. The panels must be inserted into the notches on the basepan to properly seal. The notches are covered by the tape used to secure the insulation to the basepan and are not easily seen. See Fig. 11 for position of the notches in the basepan. Seals around duct openings must be tight. Secure with screws as shown in Fig. 12. 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. 10 Horizontal Conversion Panels

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

DUCT END

SEE DETAIL "A""A"

(914-1371) 36"- 54"

"C"

"B"

SPREADER BARS

REQUIRED

UNIT MAX WEIGHT DIMENSIONS

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

48KC-A04 795 361 74.5 1890 39 990 33.5 850 48KC-A05 890 405 74.5 1890 39 990 33.5 850 48KC-A06 1020 464 74.5 1890 39 990 41.5 1055

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

wooden top to prevent rigging straps from damaging unit.

REMOVABLE HORIZONTAL SUPPLY DUCT OPENING COVER

REMOVABLE HORIZONTAL RETURN DUCT OPENING COVER

14

Fig. 11 Location of Notches

Fig. 12 Horizontal Duct Panels In Place

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

Fig. 13.

Fig. 13 Typical Access Panel Locations

2. Locate the (2) screws holding the metal tray to the basepan and remove. Locate and cut the (2) plastic tie-wraps securing the assembly to the damper. See Fig. 14. Be careful to not damage any wiring or cut tie-wraps securing any wiring.

Fig. 14 Economizer and Two-Position Damper Hood Parts Location

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

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

hood. Remove the screws along the sides and bottom of the indoor coil access panel. See Fig. 15.

BASEPAN

NOTCHES NOTCHES

SCREWS

DUCT COVERS SHEET METAL FACE UP

BASEPAN

FILTER ACCESS PANEL

OUTDOOR-AIR OPENING AND INDOOR COIL ACCESS PANEL

COMPRESSOR ACCESS PANEL

HOOD PARTS

PLASTIC TIE WRAP QTY (2)

SCREWS FOR METAL TRAY QTY (2)

15

Fig. 15 Indoor Coil Access Panel Relocation

2. Swing out indoor coil access panel and insert the hood sides under the panel (hood top). Use the screws provided to attach the hood sides to the hood top. Use screws provided to attach the hood sides to the unit. See Fig. 16.

Fig. 16 Economizer Hood Construction

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

4. Insert the hood divider between the hood sides. See Fig. 16 and 17. Secure hood divider with 2 screws on each hood side. The hood divider is also used as the bottom filter rack for the aluminum filter.

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

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

7. Replace the filter access panel.

Fig. 17 Economizer Filter Installation

Step 9 Units with Hinged Panels Only Relocate latch shipped inside the compressor compartment behind the hinged compressor door to location shown in Fig. 18 after unit installation. If the unit does not have hinged panels, skip this step and continue at Step 10 below.

Fig. 18 Compressor Door Latch Location

Step 10 Install Flue Hood Flue hood is shipped screwed to the basepan beside the burner compartment access panel. Remove from shipping location and using screws provided, install flue hood and screen in location shown in Fig. 19.

Fig. 19 Flue Hood Details

TOP PANEL

INDOOR COIL ACCESS PANEL

INDOOR COIL ACCESS PANEL

CAULK HERE

TOP PANEL

B

TOP PANEL

INDOOR COIL ACCESS PANEL

19 1/16 SCREW

HOOD DIVIDER

LEFT HOOD SIDE

33 3/8 (848mm)

(483mm)

DIVIDER

BAROMETRIC RELIEF

CLEANABLE ALUMINUM FILTER

FILTER

HOOD

FILTER CLIP

OUTSIDE AIR

COMPRESSOR DOOR OUTDOOR COIL

LATCH

BLOWER ACCESS PANELFLUE OPENING

16

Step 11 Install Gas Piping Installation of the gas piping must be accordance with local build- ing codes and with applicable national codes. In U.S.A., refer to NFPA 54/ANSI Z223.1 National Fuel Gas Code (NFGC). In Canada, installation must be accordance with the CAN/CSA B149.1 and CAN/CSA B149.2 installation codes for gas burning appliances. This unit is factory equipped for use with Natural Gas fuel at ele- vations 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. Furnace gas input rate on rating plate is for installation up to 2000 ft (610 m) above sea level. The input rating for altitudes above 2000 ft (610 m) must be derated by 4% for each 1000 ft (305 m) above sea level. For natural gas applications, gas pressure at unit gas connection must not be less than 4 in. wg (996 Pa) or greater than 13 in. wg (3240 Pa) while the unit is operating. On 48KCF*05-06 (high- heat) units, the gas pressure at unit gas connection must not be less than 5 in. wg (1245 Pa) or greater than 13 in. wg (3240 Pa) while the unit is operating, see Table 3. For liquified petroleum applica- tions, the gas pressure must not be less than 11 in. wg (2740 Pa) or greater than 13.0 in. wg (3240 Pa) at the unit connection, see Table 4. Table 3 Natural Gas Supply Line Pressure Ranges

Table 4 Liquid Propane Supply Line Pressure Ranges

The gas supply pipe enters the unit at the burner access panel on the front side of the unit, through the long slot at the bottom of the access panel. The gas connection to the unit is made to the 1/2-in. FPT gas inlet port on the unit gas valve. Manifold pressure is factory-adjusted for natural gas fuel use. Ad- just as required to obtain best flame characteristics. See Table 5.

Table 5 Natural Gas Manifold Pressure Ranges

Manifold pressure for LP fuel use must be adjusted to specified range. Follow instructions in the accessory kit to make initial read- justment, see Table 6.

Table 6 Liquid Propane Manifold Pressure Ranges

Install a gas supply line that runs to the unit heating section. Refer to the NFPA 54/NFGC or equivalent code for gas pipe sizing data. Do not use a pipe size smaller than 1/2-in. Size the gas supply line to allow for a maximum pressure drop of 0.5 in. wg (124 Pa) be- tween 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. 20.

Fig. 20 Gas Piping Guide (with Accessory Thru-the-Curb Service Connections)

FACTORY OPTION THRU-BASE CONNECTIONS (GAS CONNECTIONS) This service connection kit consists of a 1/2-in. electrical bulkhead connector and a 3/4-in. electrical bulkhead connector, connected to an L bracket covering the embossed (raised) section of the unit basepan in the condenser section (see Fig. 21 for shipping position). The 3/4-in. bulkhead connector enables the low-voltage control wires to pass through the basepan. The 1/2-in. bulkhead connector

UNIT MODEL UNIT SIZE MIN. MAX.

48KCD/E/L/M/S/R 04, 05, 06 4.0 in. wg (996 Pa)

13.0 in. wg (3240 Pa)

48KCF/N/T (High Heat Units Only) 05, 06 5.0 in. wg

(1245 Pa) 13.0 in. wg (3240 Pa)

UNIT MODEL UNIT SIZE MIN. MAX.

48KCD/E/S/R 04, 05, 06 11.0 in. wg (2740 Pa)

13.0 in. wg (3240 Pa)

48KCFT (High Heat Units Only) 05, 06 11.0 in. wg

(2740 Pa) 13.0 in. wg (3240 Pa)

UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE

48KCD/E/L/M/S/R 04, 05, 06 3.5 in. wg (872 Pa)

SEE NOTE BELOW

48KCF/N/T (High Heat Units Only) 05, 06 3.5 in. wg

(872 Pa) SEE NOTE

BELOW NOTE: LOW FIRE, 1.7 in. wg (423 Pa), applies to the following three phase voltage units only: 48KCE*04 and 48KCF*05/06.

UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE

48KCD/E/S/R 04, 05, 06 10 in. wg (2490 Pa)

SEE NOTE BELOW

48KCF/T (High Heat Units Only) 05, 06 10 in. wg

(2490 Pa) SEE NOTE

BELOW NOTE: LOW FIRE, 5.0 in. wg (1245 Pa), applies to the following three phase voltage units only: 48KCE*04 and 48KCF*05/06.

CAUTION

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

X

BASE UNIT

BASE RAIL ROOF CURB

9 MINIMUM CLEARANCE FOR PANEL REMOVAL

MANUAL GAS SHUTOFF VALVE*

GAS REGULATOR*

48 MINIMUM

DRIP LEG PER NFGC*

FIELD-FABRICATED SUPPORT*

FROM GAS METER

LEGEND *Field supplied.

NOTE: Follow all local codes. NFGC National Fuel Gas

Code

STEEL PIPE NOMINAL DIAMETERS (IN.)

SPACING OF SUPPORTS X DIMENSION (FT.)

1/2 6 3/4 or 1 8

1-1/4 or larger 10

17

allows the high-voltage power wires to pass through the basepan. See Fig. 22.

Fig. 21 Thru-the-Base Fitting Assembly (Shown in Shipping Position)

Fig. 22 Thru-Base Connection Fittings

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

discard the L bracket, but retain the washer head screws

and the gasket (located between the L bracket and the con- nector 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, align-

ing the holes in the gasket to the holes in the basepan. See Fig. 22.

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

The thru-base gas connector has male and female threads. The male threads protrude above the basepan of the unit; the female threads protrude below the basepan. Check tightness of connector lock nuts before connecting gas piping. Install a 1/2-in. NPT street elbow on the thru-base gas fitting. At- tach a 1/2-in. pipe nipple with minimum length of 16-in. (406 mm) (field-supplied) to the street elbow and extend it through the ac- cess panel at the gas support bracket. See Fig. 23.

Fig. 23 Gas Line Piping for 3 to 5 Ton Units Only

Other hardware required to complete the installation of the gas supply line includes a manual shutoff valve, a sediment trap (drip leg) and a ground-joint union. A pressure regulator valve may also be required (to convert gas pressure from pounds to inches of pres- sure). The manual shutoff valve must be located within 6 ft (1.83 m) of the unit. The union, located in the final leg entering the unit, must be located at least 9 in. (230 mm) away from the access panel to permit the panel to be removed for service. If a regulator valve is installed, it must be located a minimum of 4 ft (1220 mm) away from the units flue outlet. Some municipal codes require that the manual shutoff valve be located upstream of the sediment trap. See Fig. 24 and 25 for typical piping arrangements for gas piping that has been routed through the sidewall of the curb. See Fig. 26 for typical piping arrangement when thru-base is used. En- sure that all piping does not block access to the units main control box or limit the required working space in front of the control box.

LOW VOLTAGE CONDUIT CONNECTOR

HIGH VOLTAGE CONDUIT CONNECTOR

BRASS FITTING FOR 3 TO 6 TON UNITS

AUXILIARY POWER SUPPLY (OPTIONAL)

BRASS FITTING FOR GAS PIPING

SUPPORT BRACKETEMBOSSMENT

18

Fig. 24 Gas Piping, Typical Curb Sidewall Piping (Example 1)

Fig. 25 Gas Piping, Typical Curb Sidewall Piping (Example 2)

Fig. 26 Gas Piping, Typical Thru-Base Connections

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

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

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

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

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

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

NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of cor- rect size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics. See Fig. 27.

9 (229mm) MIN

UNION

SHUT OFF VALVE

DRIP LEG

THRU-CURB ADAPTER

UNIT BASE RAIL

SHUT OFF VALVE

UNION

9 (229 mm) MIN

UNIT BASE RAIL

BURNER ACCESS PANEL

THRU-CURB ADAPTER

DRIP LEG

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.

19

Fig. 27 Orifice Hole

Step 12 Install External Condensate Trap and Line The unit has one 3/4-in. condensate drain connection on the end of the condensate pan and an alternate connection on the bottom. See Fig. 28. Unit airflow configuration does not determine which drain connection to use. Either drain connection can be used with vertical or horizontal applications. When using the standard side drain connection, ensure the red plug in the alternate bottom connection is tight. Do this before setting the unit in place. The red drain pan can be tightened with a 1/2-in. square socket drive extension. To use the alternate bottom drain connection, remove the red drain plug from the bottom connection (use a 1/2-in. square socket drive extension) and install it in the side drain connection. The piping for the condensate drain and external trap can be com- pleted after the unit is in place. See Fig. 29.

Fig. 28 Condensate Drain Pan (Side View)

Fig. 29 Condensate Drain Pan Piping Details

All units must have an external trap for condensate drainage. In- stall a trap at least 4 in. (102 mm) deep and protect against freeze-up. If drain line is installed downstream from the external trap, pitch the line away from the unit at 1 in. per 10 ft (25 mm per 3 m) of run. Do not use a pipe size smaller than the unit con- nection (3/4-in.).

Step 13 Make Electrical Connections

NOTE: Field-supplied wiring shall conform with the limitations of minimum 63F (33C) rise. FIELD POWER SUPPLY If equipped with optional Powered Convenience Outlet, the power source leads to the convenience outlets transformer primary are not factory connected. Installer must connect these leads accord- ing to required operation of the convenience outlet. If an always- energized convenience outlet operation is desired, connect the source leads to the line side of the unit-mounted disconnect. (Check with local codes to ensure this method is acceptable in your area.) If a de-energize via unit disconnect switch operation of the convenience outlet is desired, connect the source leads to the load side of the unit disconnect. On a unit without a unit-mounted disconnect, connect the source leads to compressor contactor C and indoor fan contactor IFC pressure lugs with unit field power leads. See Convenience Outlets on page 22 for power transformer connections. The field power wires are connected to the unit at line-side pres- sure lugs on compressor contactor C and indoor fan contactor IFC (see wiring diagram label for control box component arrange- ment) or at factory-installed option non-fused disconnect switch or HACR. Maximum wire size is #2ga AWG (copper only) per pole on contactors and #2ga AWG (copper only) per pole on optional

BURNER ORIFICE

DRAIN (FACTORY-INSTALLED)

PLUG

CONDENSATE PAN (SIDE VIEW)

STANDARD SIDE DRAIN

ALTERNATE BOTTOM DRAIN

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

20

disconnect or HACR. See Fig. 30 and unit label diagram for field power wiring connections. NOTE: Unit may be equipped with short test leads (pigtails) on the field line connection points on contactor C or optional discon- nect switch. These leads are for factory-run test purposes only; re- move and discard before connecting field power wires to unit con- nection points. Make field power connections directly to line con- nection pressure lugs only. See Fig. 31 for proper wiring details.

Fig. 30 Power Wiring Connections

Fig. 31 Disconnect Switch and Unit

UNITS WITH FACTORY-INSTALLED NON-FUSED DIS- CONNECT OR HACR The factory-installed option non-fused disconnect (NFD) or HACR switch is located in a weatherproof enclosure located un- der the main control box. The manual switch handle and shaft are shipped in the disconnect or HACR enclosure. Assemble the shaft and handle to the switch at this point. Discard the factory test leads (see Fig. 32).

Connect field power supply conductors to LINE side terminals when the switch enclosure cover is removed to attach the handle. Field-Install the NFD Shaft and Handle 1. Remove unit front panel (see Fig. 2 or 3). 2. Remove (3) hex screws on the NFD enclosure (2) on the

face of the cover and (1) on the left side cover. See Fig. 32. 3. Remove the front cover of the NFD enclosure. 4. Make sure the NFD shipped from the factory is at OFF posi-

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

horizontal position. See Fig. 33. 6. Measure from the tip of the shaft to the top surface of the

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

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

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

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

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

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

Fig. 32 NFD Enclosure Location

Fig. 33 NFD Handle and Shaft Assembly

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.

C 11 23

Disconnect per

NEC

208/230-1-60

or

Disconnect per

NEC

11 13 13 23

L1 L2 L3

TB

C IFC Direct Drive IFM

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

1-ph Belt Drive IFM

3

Equip GR Lug

Ground (GR)

Ground (GR)

Equip GR Lug

Equip GR Lug

Ground (GR)

3 Phase Only 3 Phase Only

COPPER

WIRE ONLY

ELECTRIC DISCONNECT

SWITCH

ALUMINUM WIRE

21

Field-Install the HACR Shaft and Handle 1. Remove unit front panel (see Fig. 2 and 3). 2. Remove (3) hex screws on the HACR enclosure (2) on the

face of the cover and (1) on the left side cover. See Fig. 34. 3. Remove the front cover of the HACR enclosure. 4. Make sure the HACR shipped from the factory 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. See Fig. 35. 6. Tighten the locking screw to secure the shaft to the HACR. 7. Turn the handle to the OFF position with red arrow pointing

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 enclosure. 11. Re-install the unit front panel.

Fig. 34 HACR Enclosure Location

Fig. 35 HACR Handle and Shaft Assembly

UNITS WITHOUT FACTORY-INSTALLED NON-FUSED DISCONNECT OR HACR When installing units, provide a disconnect switch per NEC (National Electrical Code) of adequate size. Disconnect sizing data is provided on the unit informative plate. Locate on unit cabi- net or within sight of the unit per national or local codes. Do not cover unit informative plate if mounting the disconnect on the unit cabinet. ALL UNITS All field wiring must comply with NEC and all local codes. Size wire based on MCA (Minimum Circuit Amps) on the unit infor- mative plate. See Fig. 30 and the unit label diagram for power wir- ing connections to the unit power terminal blocks and equipment ground. Maximum wire size is #2ga AWG (copper only) per pole on contactors. See Fig. 30 and unit label diagram for field power wiring connections. Provide a ground fault and short circuit over-current protection de- vice (fuse or breaker) per NEC Article 440 (or local codes). Refer to unit informative data plate for MOCP (Maximum Over-Current Protection) device size. Units ordered with factory installed HACR do not need an addi- tional ground fault and short circuit over-current protective device unless required by local codes. All field wiring must comply with the NEC and local require- ments. All units except 208/230v units are factory wired for the voltage shown on the nameplate. If the 208/230v unit is to be connected to a 208v power supply, the control transformer must be rewired by moving the black wire with the 1/4-in. female spade connector from the 230v connection and moving it to the 200v 1/4-in. male termi- nal on the primary side of the transformer. Refer to unit label dia- gram for additional information. Field power wires will be con- nected at line-side pressure lugs on the power terminal block or at factory-installed option non-fused disconnect. Check all factory and field electrical connections for tightness.

22

CONVENIENCE OUTLETS

Two types of convenience outlets are offered on 48KC models: non-powered and unit-powered. Both types provide a 125-volt GFCI (ground-fault circuit interrupter) duplex receptacle rated at 15A behind a hinged waterproof access cover, located on the end panel of the unit. See Fig. 36. NOTE: Unit powered convenience outlets are not available as fac- tory-installed options for single phase (-3 voltage code models).

Fig. 36 Convenience Outlet Location

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.

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

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

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

4. Mount the weatherproof cover to the backing plate as shown in Fig. 37.

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

6. Check for full closing and latching.

Fig. 37 Weatherproof Cover Installation

Non-Powered Convenience Outlet This type requires the field installation of a general-purpose 125v 15A circuit powered from a source elsewhere in the building. Ob- serve national and local codes when selecting wire size, fuse or breaker requirements, and disconnect switch size and location. Route 125v power supply conductors into the bottom of the utility box containing the duplex receptacle. Unit-Powered Convenience Outlet A unit-mounted transformer is factory-installed to step down the main power supply voltage to the unit to 115v at the duplex recep- tacle. This option also includes a manual switch with fuse, located in a utility box and mounted on a bracket behind the convenience outlet; access is through the units control box access panel. See Fig. 36. The primary leads to the convenience outlet transformer are not factory-connected. Selection of primary power source is a custom- er option. If local codes permit, the transformer primary leads can be connected at the line-side terminals on the unit-mounted non- fused disconnect or HACR breaker switch; this will provide ser- vice power to the unit when the unit disconnect switch or HACR switch is open. Other connection methods will result in the conve- nience outlet circuit being de-energized when the unit disconnect or HACR switch is open. See Fig. 38.

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.

WARNING

PERSONAL INJURY HAZARD Failure to follow this caution could result in personal injury or death. Disconnect all power to unit and convenience outlet. Lock-out and tag-out all power.

CONVENIENCE OUTLET GFCI

PWD-CO FUSE SWITCH

PWD-CO TRANSFORMER

CONTROL BOX ACCESS PANEL

COVER - WHILE-IN-USE WEATHERPROOF

BASEPLATE FOR GFCI RECEPTACLE

GASKET

GFCI RECEPTACLE NOT INCLUDED

TOP

TO P

TOP

WET LOCATIONS

W ET LOCATIONS

23

Fig. 38 Powered Convenience Outlet Wiring

Using Unit-Mounted Convenience Outlets Units with unit-mounted convenience outlet circuits will often re- quire that two disconnects be opened to de-energize all power to the unit. Treat all units as electrically energized until the conve- nience outlet power is also checked and de-energization is con- firmed. Observe National Electrical Code Article 210, Branch Cir- cuits, for use of convenience outlets. Fuse On Power Type The factory fuse is a Bussman Fusetron T-15, non-renewable screw-in (Edison base) type plug fuse. Duty Cycle The unit-powered convenience outlet has a duty cycle limitation. The transformer is intended to provide power on an intermittent basis for service tools, lamps, etc; it is not intended to provide 15- amps loading for continuous duty loads (such as electric heaters for overnight use). Observe a 50% limit on circuit loading above 8 amps. Convenience outlet usage rating: Continuous usage: 8 amps maximum Intermittent usage: Up to 15 amps maximum for up to 2

hours maximum See Fig. 39. 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. 39 Convenience Outlet Utilization Notice Label

HACR AMP RATING The amp rating of the HACR factory-installed option is based on the size, voltage, indoor motor and other electrical options of the unit as shipped from the factory. If field-installed accessories are added or changed in the field (for example, power exhaust, ERV), the HACR may no longer be of the proper amp rating and there- fore 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 (Fig. 40). See unit nameplates for the proper fuse, HACR or maximum over-current protection device required on the unit with field- installed accessories.

Fig. 40 HACR Caution Label

FACTORY-OPTION THRU-BASE CONNECTIONS (ELEC- TRICAL CONNECTIONS) This service connection kit consists of a 1/2-in. NPT gas adapter fitting (brass), a 1/2-in. electrical bulkhead connector, and a 3/4-in. electrical bulkhead connector, all factory-installed in the embossed (raised) section of the unit basepan in the condenser section. The 3/4-in. bulkhead connector enables the low-voltage control wires to pass through the basepan. The 1/2-in. electrical bulkhead connector allows the high-voltage power wires to pass through the basepan. See Fig. 21 on page 17. 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

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

24

made. Connect the control power conduit to the unit control box at this hole. UNITS WITHOUT THRU-BASE CONNECTIONS (ELEC- TRICAL 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. 30 on page 19. 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 shown in the example below to de- termine the percent of voltage imbalance. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty.

Example: Supply voltage is 230-3-60

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

This amount of phase imbalance is satisfactory as it is below the maxi- mum allowable 2%.

FIELD CONTROL WIRING The 48KC unit requires an external temperature control device. 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 stand alone control) or the RTU Open Controller for Building Management Systems using non-CCN protocols (RTU Open is available as a factory-installed option only). THERMOSTAT Install a Carrier-approved accessory thermostat according to in- stallation instructions included with the accessory. For complete economizer function, select a two-stage cooling thermostat. Lo- cate the thermostat accessory on a solid wall in the conditioned space to sense average temperature in accordance with the ther- mostat installation instructions. Typical low-voltage connections are shown in Fig. 41.

Fig. 41 Low-Voltage Thermostat Connections

If the thermostat contains a logic circuit requiring 24v power, use a thermostat cable or equivalent single leads of different colors with minimum of seven leads. If the thermostat does not require a 24v source (no C connection required), use a thermostat cable or equivalent with minimum of six leads. Check the thermostat in- stallation instructions for additional features which might require additional conductors in the cable. For wire runs up to 50 ft (15 m), use no. 18 AWG (American Wire Gage) insulated wire [95F (35C) minimum]. For 50 to 75 ft (15 to 23 m), use no. 16 AWG insulated wire [95F (35C) minimum]. For over 75 ft (23 m), use no. 14 AWG insulated wire [95F (35C) minimum]. Wire sizes larger than no. 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat. Thermostat Wiring, Units Without Thru-Base Connection Kit Pass the thermostat control wires through the hole provided in the corner post; then feed the wires through the raceway built into the corner post to the control box. Pull the wires over to the terminal strip on the upper-left corner of the Central Terminal Board (CTB). See Fig. 42. If thru-the-bottom connections accessory is used, refer to the ac- cessory installation instructions for information on routing power and control wiring.

% Voltage Imbalance = 100 x

max voltage deviation from average voltage average voltage

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

Average Voltage = (224 + 231 + 226)

= 681

= 227 3 3

% Voltage Imbalance = 100x 4

= 1.78% 227

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

A B C

MOTOR

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.

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

Field Wiring

Central Terminal Board

Typical Thermostat Connections

25

Fig. 42 Field Control Wiring Raceway

HEAT ANTICIPATOR SETTINGS Set heat anticipator settings at 0.14 amp for the first stage and 0.14 amp for second-stage heating, when available. HUMIDI-MIZER CONTROL CONNECTIONS Humidi-MiZer Space RH Controller NOTE: The Humidi-MiZer system is a factory-installed option which is only available for units equipped with belt-drive motors. Humidi-MiZer system is not available for single phase (-3 voltage code) models. The Humidi-MiZer dehumidification system requires a field-sup- plied and field-installed space relative humidity control device. This device may be a separate humidistat control (contact closes on rise in space RH above control setpoint) or a combination ther- mostat-humidistat control device such as Carriers Edge Pro Thermidistat device with isolated contact set for dehumidifica- tion control. See Fig. 43 and 44. The humidistat is normally used in applications where a temperature control is already provided (units with PremierLink control).

Fig. 43 Accessory Field-Installed Humidistat

Fig. 44 Edge Pro Thermidistat

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

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

Fig. 42) to the 24v barrier located on the left side of the con- trol box. The raceway provides the UL-required clearance between high-voltage and low-voltage wiring.

3. Use wire nuts to connect humidistat cable to two PINK leads in the low-voltage wiring as shown in Fig. 45.

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

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

2. Feed wires through the raceway built into the corner post (see Fig. 42) to the 24-v barrier located on the left side of the con- trol box. The raceway provides the UL-required clearance between high-voltage and low-voltage wiring.

3. The Thermidistat has dry contacts at terminals D1 and D2 for dehumidification operation (see Fig. 46). 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.

TYPICAL UNIT WIRING DIAGRAMS See Fig. 47 and 48 for examples of typical unit control and power wiring diagrams. These wiring diagrams are mounted on the in- side of the unit control box cover.

RACEWAY

HOLE IN END PANEL (HIDDEN)

% RELATIVE HUMIDITY

26

Fig. 45 Typical Humidi-MiZer Adaptive Dehumidification System Humidistat Wiring

27

Fig. 46 Typical Rooftop Unit with Humidi-MiZer Adaptive Dehumidification System and Edge Pro Thermidistat Device

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 Pro THERMIDISTAT Unit CTB

THERMOSTAT

*Connection not required.

Humidi-MiZer FIOP

28

Fig. 47 Typical Control Wiring Diagram Electro-Mechanical with W7212

29

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

30

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 op- tion, then refer to its installation control manual for details on ad- justing Cooling Lock-Out setting and configure for the specific job requirements.

Integrated Gas Controller This unit contains an Integrated Gas Controller (IGC) board. The IGC control board uses a flue gas pressure switch that senses pres- sure drop in the heat exchanger due to the combustion inducer. See Fig. 49.

Fig. 49 Flue Gas Pressure Switch and Pressure Sense Tube (Typical Location)

When the thermostat calls for heating, power is sent to W on the Integrated Gas Controller (IGC) board. An LED (light emitting di- ode) on the IGC board turns on and remains on during normal op- eration. A check is made to ensure that the rollout switch and limit switch are closed, and that the pressure switch is open. If the check was successful, the induced draft motor is energized. When the pressure in the heat exchanger is low enough to close the pressure switch, the ignition activation period begins. Once ignition occurs, the IGC board will continue to monitor the condition of the rollout switch, the limit switches, the pressure switch, and the flame sen- sor. Assuming the unit is controlled through a room thermostat set for fan auto, 45 seconds after ignition occurs, the indoor fan mo- tor will energize, and the outdoor air dampers will open to their minimum position. If the over temperature limit opens prior to the start of the indoor fan blower, the IGC will shut down the burners, and the control will shorten the 45 second delay to 5 sec- onds less than the time to tip the limit. For example, if the limit trips at 37 seconds, the control will change the fan on delay from 45 seconds to 32 seconds. Once the fan on delay has been modified, it will not change back to 45 seconds unless power is re- set to the control. On units with 2 stages of heat, W2 closes and initiates power to the second stage of the main gas valve when ad- ditional heat is required. When the thermostat is satisfied, W1 and W2 open and the gas valve closes, interrupting the flow of gas to the main burners. If the call for W1 lasted less than 1 minute, the heating cycle will not terminate until 1 minute after W1 became active. If the unit is controlled through a room thermostat set for fan auto, the indoor fan motor will continue to operate for an additional 45 seconds, then stop. An LED indicator is provided on the IGC to monitor operation. See Fig. 50 for IGC board component layout. Figure 51 is a typi- cal IGC control wiring diagram. Table 7 lists the IGC board LED alarm codes.

FLUE GAS PRESSURE

SWITCH

FLUE GAS PRESSURE

SENSE TUBE

31

Table 7 IGC Board LED Alarm Codes

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

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

LED FLASH CODE

DESCRIPTION ACTION TAKEN BY CONTROL RESET METHOD PROBABLE CAUSE

On Normal

Off Hardware Failure No gas heating.

Loss of power to the IGC. Check 5 amp fuse on IGC, power to unit, 24V circuit breaker, transformer, and wiring to the IGC.

1 Flash Indoor Fan On/Off Delay Modified

5 seconds subtracted from On delay. 5 seconds added to Off delay (3 min max).

Power reset.

High temperature limit switch opens during heat exchanger warm-up period before fan-on delay expires. High temperature limit switch opens within 10 minutes of heat call (W) Off. See Limit Switch Fault.

2 Flashes Limit Switch Fault

Gas valve and igniter Off. Indoor fan and inducer On.

Limit switch closed, or heat call (W) Off.

High temperature limit switch is open. Check the operation of the indoor (evaporator) fan motor. Ensure that the supply-air temperature rise is within the range on the unit nameplate. Check wiring and limit switch operation.

3 Flashes Flame Sense Fault Indoor fan and inducer On. Flame sense normal.

Power reset for LED reset. The IGC sensed a flame when the gas valve should be closed. Check wiring, flame sensor, and gas valve operation.

4 Flashes Four Consecutive Limit

No gas heating. Heat call (W) Off. Power reset for LED reset.

4 consecutive limit switch faults within a single call for heat. See Limit Switch Fault.

5 Flashes Ignition Fault No gas heating. Heat call (W) Off. Power reset for LED reset.

Unit unsuccessfully attempted ignition for 15 minutes. Check igniter and flame sensor electrode spacing, gaps, etc. Check flame sense and igniter wiring. Check gas valve operation and gas supply.

6 Flashes Induced Draft Motor Fault

If heat off: no gas heating. If heat on: gas valve Off and inducer On.

Inducer sense normal, or heat call (W) Off.

Inducer sense On when heat call Off, or inducer sense Off when heat call On. Check wiring, voltage, and operation of IGC motor. Check speed sensor wiring to IGC.

7 Flashes Rollout Switch Lockout

Gas valve and igniter Off. Indoor fan and inducer On. Power reset.

Rollout switch has opened. Check gas valve operation. Check induced-draft blower wheel is properly secured to motor shaft.

8 Flashes Internal Control Lockout No gas heating. Power reset.

IGC has sensed internal hardware or software error. If fault is not cleared by resetting 24 v power, replace the IGC.

9 Flashes Temporary Software No gas heating. 1 hour auto reset, or

power reset. Electrical interference is disrupting the IGC software.

IGC Integrated Gas Unit Control LED Light-Emitting Diode

32

Fig. 50 IGC Board Component Layout

Fig. 51 Typical IGC Control Wiring Diagram

LOCKING TAB CONNECTOR

OVERCURRENT FUSE PROTECTION

REDUNDANT GAS VALVE RELAY

LOCKING TAB CONNECTOR

SPADE CONNECT IGNITOR

STATUS LED

33

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

Fig. 52 W7220 Economizer Module

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

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

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

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

External Sensors Power Output 21 vdc 5% at 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 Re- turn Air (RA) bus sensor can be added to the system for differen- tial enthalpy or dry bulb changeover. For differential dry bulb changeover a 20k ohm sensor is required in the OA and a bus sen- sor in the RA. DIP switch on RA bus sensor must be set in the RA position. Dry Bulb Temperature (optional) and Mixed Air (required), 20k NTC 2-wire (18 to 22 AWG); Temperature range 40F to 150F (40C to 65C) Temperature accuracy: 0F/+2F Temperature and Humidity, C7400S1000 (optional) S-Bus; 2-wire (18 to 22 AWG) Temperature: range 40F to 150F (40C to 65C) Temperature accuracy: 0F/+2F Humidity: range 0 to 100% RH with 5% accuracy. NOTE: Up to three (3) S-Bus sensors may be connected to the W7220 economizer module for outdoor air (OA), return air (RA) and discharge (supply) air (DA). 4 Binary Inputs 1-wire 24 vac + common GND (see page 34 for wiring details). 24 vac power supply 20 to 30 vac 50/60 Hz; 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)

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

34

Relative Humidity 5% to 95% RH non-condensing ECONOMIZER MODULE WIRING DETAILS Use Fig. 53 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. 53 W7220 Wiring Terminals

*Sylk is a trademark of Honeywell International Inc.

S-Bus Sensor Wiring The labels on the sensors and controller are color coded for ease of installation. Orange labeled sensors can only be wired to orange terminals on the controller. Brown labeled sensors can only be wired to S-bus (brown) terminals. Use Fig. 54 and Table 10 to lo- cate the wiring terminals for each S-Bus sensor. Use Fig. 53 and Table 10 to locate the wiring terminals for each enthalpy control sensor.

Fig. 54 S-Bus Sensor DIP Switches

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

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)

35

Use Fig. 54 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. 55 for CO2 sensor wiring.

Fig. 55 CO2 Sensor Wiring

INTERFACE OVERVIEW This section describes how to use the EconoMi$er X user inter- face 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. 56) to scroll through the menus and menu items, select menu items, and to change parame- ter and configuration settings.

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

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

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

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

and return to the list of menus.

Fig. 56 W7220 Controller Navigation Buttons

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

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

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

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

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

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

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

menu. Menu Structure Table 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

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

36

the cooling coil. This unit application has the control sensor located 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.

37

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).

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

38

STATUS (cont)

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.

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 1F

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 1F

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 43 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.

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 1F

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.

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.

Table 12 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME Notes

39

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.

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. 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.

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 1F

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.

Table 12 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME Notes

40

ADVANCED SETUP (cont)

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

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

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

2SP FAN DELAY 5 Minutes 0 to 20 minutes in

1 minute increments

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

CHECKOUT***

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

system. 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.

Table 12 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME Notes

41

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 sig-

nal 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 roof- top units, the economizer control sensor is located downstream of the evaporator/indoor coil in the supply fan section where this sen- sor is designated as Supply Air Temperature (SAT) sensor.

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

4. SYSTEM SETUP parameters must be configured as noted for 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 or without DCV, see Tables 14 and 15. For enthalpy operation with or without DCV, see Tables 16 and 17.

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

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

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

Table 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 N/A N/A

YES VENT MIN VMAXHS VENT MAX VMAXHS

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

42

*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 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 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.

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

43

Fig. 57 Single Enthalpy Curve Boundaries

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 57 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 18 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 57 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. 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 35. 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 35. Checkout Tests Use the Checkout menu (see page 40) 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 35. 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.

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 18 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

44

TROUBLESHOOTING Alarms The economizer module provides alarm messages that display on the 2-line LCD. NOTE: Upon power up, the module waits 60 minutes before checking for alarms. This allows time for all the configured devic- es (e.g. sensors, actuator) to become operational. The exception is the SAT sensor which will alarm immediately. If one or more alarms are present and there has been no keypad ac- tivity for at least 5 minutes, the Alarms menu displays and cycles through the active alarms. You can also navigate to the Alarms menu at any time. Clearing Alarms Once the alarm has been identified and the cause has been 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. If the alarm still exists after clearing it, it is redisplayed within 5 seconds.

Outdoor Air Enthalpy Control (P/N 33CSENTHSW) The enthalpy control (33CSENTHSW) is available as a field-in- stalled accessory to be used with the EconoMi$er2 damper sys- tem. The outdoor air enthalpy sensor is part of the enthalpy con- trol. The separate field-installed accessory return air enthalpy sen- sor (33CSENTSEN) is required for differential enthalpy control. See Fig. 58. Locate the enthalpy control in the economizer next to the actuator motor. Locate two GRA leads in the factory harness and connect the gray lead labeled ESL to the terminal labeled LOW. See Fig. 58. Connect the enthalpy control power input terminals to economizer actuator power leads RED (connect to 24V) and BLK (connect to GND). The outdoor enthalpy changeover setpoint is set at the enthalpy controller.

Fig. 58 Enthalpy Switch (33CSENTHSW) Connections

DIFFERENTIAL ENTHALPY CONTROL Differential enthalpy control is provided by sensing and compar- ing the outside air and return air enthalpy conditions. Install the outdoor air enthalpy control as described above. Add and install a return air enthalpy sensor. RETURN AIR ENTHALPY SENSOR Mount the return-air enthalpy sensor (33SENTSEN) in the return- air section of the economizer. The return air sensor is wired to the enthalpy controller (33CSENTHSW). See Fig. 59.

Fig. 59 Outside and Return Air Enthalpy Sensor Wiring

Wiring the Return Air Enthalpy Sensor 1. Use a 2-conductor, 18 or 20 AWG, twisted pair cable to con-

nect the return air enthalpy sensor to the enthalpy controller. 2. Connect the field-supplied RED wire to (+) spade connector

on the return air enthalpy sensor and the (+) terminal on the enthalpy controller. Connect the BLK wire to () spade con- nector on the return air enthalpy sensor and the () terminal on the enthalpy controller.

Smoke Detectors Smoke detectors are available as factory-installed options on 48KC models. Smoke detectors may be specified for Supply Air only or for Return Air without or with economizer, or in combina- tion of Supply Air and Return Air. Return Air smoke detectors are arranged for vertical return configurations only. All components necessary for operation are factory-provided and mounted. The unit is factory-configured for immediate smoke detector shutdown operation; additional wiring or modifications to unit terminal 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. 60 for the as-shipped location.

CAUTION

EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in equipment damage. Be sure to allow enough time for compressor start-up and shutdown between checkout tests so that you do not short- cycle the compressors. 7 CTB ECON

(PLINK: to J4-2) or (RTU Open: to J2-6)

LOW

GND

24V

Enthalpy Switch

GRA

BLK

RED

FACTORY WIRING HARNESS

PL6-1 (24-V)

PL6-4 (COM)

GRA

BLK

RED 4-20 MAIN

+ VDC OUT

4-20 MAIN OUT

+ 24-36 VDC IN

LOW

GND

24V

7

PL6-1 (24-V)

PL6-4 (COM)

OUTSIDE AIR ENTHALPY SWITCH

RETURN AIR ENTHALPY SENSOR

CTB ECON (PLINK: to J4-2) or (RTU Open: to J2-6)

45

COMPLETING RETURN AIR SMOKE SENSOR INSTALLATION 1. Unscrew the two screws holding the Return Air Smoke

Detector assembly. See Fig. 61, 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. 61, Step 2.

3. Screw the sensor and detector plate into its operating position using screws from Step 1. See Fig. 61, Step 3.

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

Fig. 60 Return Air Smoke Detector, Shipping Position

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 detectors including multiple unit coordination.

PremierLink Controller (Factory Option) For details on operating 48KC*04-06 units equipped with the fac- tory-installed PremierLink controller option, refer to the Premier- Link Retrofit Rooftop Controller Version 3.x Installation, Start- Up, and Configuration Installation manual.

RTU Open Controller (Factory-Installed Option) For details on operating 48KC*04-06 units equipped with the fac- tory-installed RTU Open controller refer to the Factory-Installed RTU Open Multi-Protocol Controller Control, Start-Up, Opera- tion and Troubleshooting manual.

Step 14 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$ER IV OCCUPANCY SWITCH See Fig. 62 for general EconoMi$er IV wiring. External occupan- cy control is managed through a connection on the Controls Con- nections 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 15 Install Accessories Available accessories include: Curb Thru-base connection kit (must be installed before unit is

set on curb) LP conversion kit Flue discharge deflector Manual outside air damper Two-position motorized outside air damper EconoMi$er IV (with control) EconoMi$er2 (without control/for external signal) Power Exhaust Differential dry-bulb sensor (EconoMi$er IV) Outdoor enthalpy sensor Differential enthalpy sensor CO2 sensor DDC interface (PremierLink Controls) Louvered hail guard Motormaster head pressure controls Phase monitor control Refer to separate installation instructions for information on in- stalling these accessories.

RETURN AIR SMOKE DETECTOR (AS SHIPPED)

46

Fig. 61 Completing Installation of Return Air Smoke Sensor

Fig. 62 EconoMi$er IV Wiring

Step 16 Check Belt Tension Measure the belt span length as shown in Fig. 63. 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 pulleys.

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. 63). 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. 64) and slide the plate towards the fan (to reduce tension) or away from the fan (to increase tension). Ensure the blower shaft and motor shaft are parallel to each other (pulleys aligned). Tighten all bolts securely when finished.

STEP 1 STEP 2 STEP 3

47

Fig. 63 V-Belt Force Label

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

Fig. 64 Belt Drive Motor Mounting

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. 04-53480255-01 Printed in U.S.A. Form 48KC-4-6-04SI Pg 50 6-2020 Replaces: 48KC-4-6-03SI

2020 Carrier

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480255-01 Printed in U.S.A. Form 48KC-4-6-04SI Pg CL-1 6-2020 Replaces: 48KC-4-6-03SI

START-UP CHECKLIST FOR 48KC04-06 SINGLE PACKAGE ROOFTOP GAS HEATING/ELECTRIC COOLING UNIT

(REMOVE AND USE FOR JOB FILE)

I. PRELIMINARY INFORMATION MODEL NO ____________________________________________

JOB NAME_____________________________________________

SERIAL NO ____________________________________________

ADDRESS _____________________________________________

START-UP DATE________________________________________

TECHNICIAN NAME _____________________________________

ADDITIONAL ACCESSORIES

_____________________________________________________________________________________________________

II. PRE-START-UP Verify that all packaging materials have been removed from unit (Y/N) _____ Verify installation of outdoor air hood (Y/N) _____ Verify installation of flue exhaust and inlet hood (Y/N) _____ Verify that condensate connection is installed per instructions (Y/N) _____ Verify that all electrical connections and terminals are tight (Y/N) _____ Verify gas pressure to unit gas valve is within specified range (Y/N) _____ Check gas piping for leaks (Y/N) _____ Check that indoor-air filters are clean and in place (Y/N) _____ Check that outdoor air inlet screens are in place (Y/N) _____ Verify that unit is level (Y/N) _____ Check fan wheels and propeller for location in housing/orifice and verify setscrew is tight (Y/N) _____ Verify that fan sheaves are aligned and belts are properly tensioned (Y/N) _____ Verify that scroll compressors are rotating in the correct direction (Y/N) _____ Verify installation of thermostat (Y/N) _____ Verify that crankcase heaters have been energized for at least 24 hours (Y/N) _____

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

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

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

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480255-01 Printed in U.S.A. Form 48KC-4-6-04SI Pg CL-2 6-2020 Replaces: 48KC-4-6-03SI

2020 Carrier

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

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

CIRCUIT B _____________ PSIG Refrigerant Discharge CIRCUIT A _____________ PSIG

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

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

IV. HUMIDI-MIZER START-UP STEPS

1. Check CTB for jumper 5, 6, 7 (Jumper 5, 6, 7 must be cut and open) (Y/N) _____ 2. Open humidistat contacts (Y/N) _____ 3. Start unit In cooling (Close Y1) (Y/N) _____

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

4. Check unit charge per charging chart (Y/N) _____ (Jumper 32L Motormaster temperature sensor during this check. Remove jumper when complete.)

5. Switch unit to high-latent mode (sub-cooler) by closing humidistat with Y1 closed (Y/N) _____

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

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

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

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

8. Open W

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