Contents

Carrier 48LC 07 Installation Instructions PDF

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Summary of Content for Carrier 48LC 07 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. 04-53480218-01 Printed in U.S.A. Form 48LC-7-06SI Pg 1 6-19 Replaces: 48LC-7-05SI

Installation Instructions NOTE: Read the entire instruction manual before starting the installation. SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1 Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Step 1 Plan for Unit Location . . . . . . . . . . . . . . . . . 6 ROOF MOUNT Step 2 Plan for Sequence of Unit Installation . . . . 7 CURB-MOUNTED INSTALLATION PAD-MOUNTED INSTALLATION FRAME-MOUNTED INSTALLATION Step 3 Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . 7 Step 4 Provide Unit Support. . . . . . . . . . . . . . . . . . 7 ROOF CURB MOUNT SLAB MOUNT (HORIZONTAL UNITS ONLY) ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR

SLAB MOUNT) Step 5 Field Fabricate Ductwork . . . . . . . . . . . . . . 9 Step 6 Rig and Place Unit . . . . . . . . . . . . . . . . . . . . 9 POSITIONING ON CURB Step 7 Convert to Horizontal and Connect

Ductwork (when required). . . . . . . . . . . . . . . . . . . 10 Step 8 Install Outside Air Hood . . . . . . . . . . . . . . 11 ECONOMIZER HOOD PACKAGE REMOVAL AND

SETUP - FACTORY OPTION ECONOMIZER HOOD Step 9 Install Flue Hood . . . . . . . . . . . . . . . . . . . . 12 Step 10 Install Gas Piping. . . . . . . . . . . . . . . . . . . 12 FACTORY-OPTION THRU-BASE CONNECTIONS

(GAS CONNECTIONS) Step 11 Install External Condensate Trap and

Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Step 12 Make Electrical Connections . . . . . . . . . 15 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 FACTORY-OPTION THRU-BASE CONNECTIONS

(ELECTRICAL CONNECTIONS) UNITS WITHOUT THRU-BASE CONNECTIONS FIELD CONTROL WIRING THERMOSTAT UNIT WITHOUT THRU-BASE CONNECTION KIT HEAT ANTICIPATOR SETTINGS Humidi-MiZer System Control Connections . . . . . 28 HUMIDI-MIZER SYSTEM SPACE RH CONTROLLER RTU Open Controller (Factory-Installed Option). . . 28 SystemVu Controller (Factory-Installed Option). . . 28 Integrated Staging Control (ISC) Board . . . . . . . . . . 29 ISC BOARD - SEQUENCE OF OPERATION EconoMi$er X (Factory Option) . . . . . . . . . . . . . . . 31

SYSTEM COMPONENTS SPECIFICATIONS INPUTS OUTPUTS ENVIRONMENTAL ECONOMIZER MODULE WIRING DETAILS INTERFACE OVERVIEW SETUP AND CONFIGURATION ENTHALPY SETTINGS TWO-SPEED FAN OPERATION CHECKOUT TROUBLESHOOTING Staged Air Volume (SAV) with Variable Frequency

Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Multi-Speed VFD Display Kit (Field-Installed

Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 ALPHA NUMERIC DISPLAY MENU KEY NAVIGATION KEYS AND STATUS LEDS OPERATION KEYS AND LEDS CONNECTING THE KEYPAD TO THE VFD PROGRAM THE VFD FOR 3 DISCRETE INDOOR FAN

SPEEDS Smoke Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 COMPLETING INSTALLATION OF RETURN AIR

SMOKE SENSOR ADDITIONAL APPLICATION DATA Step 13 Adjust Factory-Installed Options . . . . . .54 SMOKE DETECTORS Step 14 Install Accessories . . . . . . . . . . . . . . . . . .54 Step 15 Check Belt Tension . . . . . . . . . . . . . . . . .54 BELT FORCE DEFLECTION METHOD BELT TENSION METHOD Pre-Start and Start-Up . . . . . . . . . . . . . . . . . . . . . . . .54 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-

WeatherExpert 48LC 07 Single Package Rooftop Unit

Gas Heat/Electric Cooling with Puron (R-410A) Refrigerant

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

WARNING

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

WARNING

FIRE HAZARD Failure to follow this warning could result in personal inju- ry, death, 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.

WARNING

FIRE HAZARD Failure to follow this warning could result in personal inju- ry, death, 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.

GAS VALVE

INLET PRESSURE TAP SET SCREW

MANIFOLD

GAS VALVE

MANIFOLD PRESSURE TAP SET SCREW

WARNING

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

AVERTISSEMENT

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

WARNING

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

WARNING

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

WARNING

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

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Rated Indoor Airflow (cfm) Table 1 lists the rated indoor airflow used for the AHRI effi- ciency rating for the units covered in this document. See Fig. 1 for unit options, Fig. 2 for unit dimensions, and Fig. 3 for ser- vice clearances.

Fig. 1 Model Number Nomenclature

CAUTION

CUT 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.

Table 1 Rated Indoor Airflow (cfm)

MODEL NUMBER FULL LOAD AIRFLOW (CFM) 48LC**07 2250

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

Model Series - WeatherExpert

LC - Ultra High Efficiency

Unit Heat Type 48 - Gas Heat Packaged Rooftop

Cooling Tons 07 - 6 ton

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

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

F = RA Smoke Detector and CO2

G = SA Smoke Detector and CO2

H = RA + SA Smoke Detector and CO2

Indoor Fan Options 1 = Standard Static Belt Drive with VFD controller 2 = Medium Static Belt Drive with VFD controller 3 = High Static Belt Drive with VFD controller

Refrig. Systems Options 0 = Three stage cooling capacity control with TXV A = Three stage cooling capacity control with TXV and Humidi-MiZer System

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

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

Design Revision - = Factory Design Revision

Base Unit Controls 0 = Electro-mechanical Controls 1 = RTU Open Multi-Protocol Controller 4 = SystemVu Controller

Intake / Exhaust Options A = None B = Low Leak Temperature Economizer

with Barometric Relief E = Low Leak Enthalpy Economizer

with Barometric Relief N = Ultra Low Leak Temperature Economizer

with Barometric Relief R = Ultra Low Leak Enthalpy Economizer

with Barometric Relief

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

Unpowered Convenience Outlet 5 = Hinged Panels and

Powered Convenience Outlet

Packaging 0 = Standard 1 = LTL

Electrical Options A = None B = HACR Circuit Breaker C = Non-Fused Disconnect D = Thru-The-Base Connections E = HACR Circuit Breaker and Thru-The Base Connections F = Non-Fused Disconnect and Thru-The-Base Connections

Example: Position:

4

Fig. 2 Unit Dimensional Drawing

5

Fig. 2 Unit Dimensional Drawing (cont)

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

Fig. 3 Service Clearance Dimensional Drawing

INSTALLATION

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

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

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

3. Check for possible overhead obstructions which may interfere with unit lifting or rigging.

Step 1 Plan for Unit Location Select a location for the unit and its support system (curb or other) that provides for the minimum clearances required for safety. This includes the clearance to combustible surfaces, unit performance and service access below and around unit as specified in Fig. 3. 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 Com- bustion and Ventilation) of the National Fuel Gas Code, ANSI Z223.1 (American National Standards Institute) and NFPA (National Fire Protection Association) 54 TIA-54-84-1. In Canada, installation must be in accordance with the CAN1- B149 installation codes for gas burning appliances. Although unit is weatherproof, avoid locations that permit wa- ter 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 adja- cent 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 adjacent to public walkways, flue assembly must be at least 7 ft (2.1 m) above grade.

C

B A

D

LOCATION DIMENSION CONDITION

A

48-in. (1219 mm) Unit disconnect is mounted on panel 18-in. (457 mm) No disconnect, convenience outlet option 18-in. (457 mm) Recommended service clearance 12-in. (305 mm) Minimum clearance

B 42-in. (1067 mm) Surface behind servicer is grounded (e.g., metal, masonry wall) 36-in. (914 mm) Surface behind servicer is electrically non-conductive (e.g., wood, fiberglass) Special Check sources of flue products within 10 ft of unit fresh air intake hood

C 36-in. (914 mm) Side condensate drain is used 18-in. (457 mm) Minimum clearance

D 42-in. (1067 mm) Surface behind servicer is grounded (e.g., metal, masonry wall, another unit) 36-in. (914 mm) Surface behind servicer is electrically non-conductive (e.g., wood, fiberglass)

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Select a unit mounting system that provides adequate height to allow installation of condensate trap per requirements. Refer to Step 11 Install External Condensate Trap and Line on page 15 for required trap dimensions.

ROOF MOUNT

Check building codes for weight distribution requirements. Unit operating weight is shown in Table 2.

Step 2 Plan for Sequence of Unit Installation The support method used for this unit will dictate different se- quences for the steps of unit installation. For example, on curb- mounted units, some accessories must be installed on the unit before the unit is placed on the curb. Review the following for recommended sequences for installation steps.

CURB-MOUNTED INSTALLATION

1. Install curb 2. Install field-fabricated ductwork inside curb 3. Install accessory thru-base service connection package

(affects curb and unit) (refer to accessory installation instructions for details)

4. Prepare bottom condensate drain connection to suit planned condensate line routing (refer to Step 11 Install External Condensate Trap and Line on page 15 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 as required to suit specific installa- tion plan.

Step 3 Inspect Unit Inspect unit for transportation damage. File any claim with transportation agency. Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree with power supply provided.

Step 4 Provide Unit Support ROOF CURB MOUNT

Accessory roof curb details and dimensions are shown in Fig. 5. Assemble and install accessory roof curb in accordance with instructions 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. 5. Improperly applied gasket can also result in air leaks and poor unit performance. Curb should be level. This is necessary for unit drain to func- tion properly. Unit leveling tolerances are shown in Fig. 4. Re- fer to Accessory Roof Curb Installation Instructions for addi- tional information as required.

Fig. 4 Unit Leveling Tolerances

Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb and not to the unit. 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-supplied 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 condenser coil air inlet to prevent grass and foliage from ob- structing airflow. NOTE: Horizontal units may be installed on a roof curb if required.

ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR SLAB MOUNT)

A non-combustible sleeper rail can be used in the unit curb support 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.

Table 2 Operating Weights

48LC**07 UNITS LB (KG) Base Unit 1032 (468) Economizer Vertical 75 (34) Horizontal 122 (55) Powered Outlet 35 (16) Curb 14-in. (356 mm) 143 (65) 24-in. (610 mm) 245 (111)

A-B 0.5 (13)

B-C 1.0 (25)

A-C 1.0 (25)

MAXIMUM ALLOWABLE DIFFERENCE IN. (MM)

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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 dimen- sions are equal to or greater than the unit supply duct opening dimensions 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 applicable 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. Level by using unit frame as a reference. See Table 2 and Fig. 6 for additional information. Lifting holes are provided in base rails as shown in Fig. 6. Re- fer to rigging instructions on unit. Rigging materials under unit (cardboard or wood) must be re- moved PRIOR to placing the unit on the roof curb. When using the standard side drain connection, ensure the red plug in the alternate bottom connection is tight. Do this before setting the unit in place. The red plug can be tightened with a 1/2-in. square socket drive extension. For further details see Step 11 Install External Condensate Trap and Line on page 15. Before setting the unit onto the curb, recheck gasketing on curb.

POSITIONING ON CURB

Position unit on roof curb so that the following clearances are maintained: 1/4-in. (6.4 mm) clearance between the roof curb and the base rail inside the front and back, 0.0-in. clearance be- tween 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 35/16 in. (84 mm). Although unit is weatherproof, guard against water from higher level runoff and overhangs. Flue vent discharge must have a minimum horizontal clearance of 4 ft (1220 mm) from electric and gas meters, gas regulators, and gas relief equipment. Minimum distance between unit and other electrically live parts is 48-in. (1220 mm). Flue gas can deteriorate building materials. Orient unit such that flue gas will not affect building materials. Locate mechanical draft system flue assembly at least 48-in. (1220 mm) from an adjacent building or combustible material. NOTE: Installation of accessory flue discharge deflector kit will reduce the minimum clearance to combustible material to 18-in. (460 mm). After the unit is in position remove all riggings, shipping mate- rials and top skid. Recycle or dispose of all shipping materials.

CAUTION

PROPERTY DAMAGE HAZARD Failure to follow this caution may result in damage to roof- ing 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.

10

Fig. 6 Rigging Label

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 op- tion may be field-converted to horizontal ducted configuration. To convert to horizontal configuration, remove screws from side duct opening covers (see Fig. 7) 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 cov- ered by the tape used to secure the insulation to the basepan and are not easily seen. See Fig. 8 for position of the notches in the basepan. Seals around duct openings must be tight. Secure with screws as shown in Fig. 9. Cover seams with foil duct tape. Field-supplied flanges should be attached to horizontal duct openings and all ductwork should be secured to the flanges. In- sulate and weatherproof all external ductwork, joints, and roof or building openings with counter flashing and mastic in accor- dance with applicable codes. Do not cover or obscure visibility to the units informative data plate when insulating horizontal ductwork.

Fig. 7 Horizontal Conversion Panels

ALL PANELS MUST BE IN PLACE WHEN RIGGING. TOUS LES CAPOTS DOIVENT TRE EN PLACE AVANT LE LEVAGE

CAUTION - NOTICE TO RIGGERS: AVERTISSEMENT - REMARQUE LATTENTION DES MONTEURS

Hook rigging shackles through holes in base rail, as shown in Detail A. Use wooden top skid, when rigging, to prevent rigging straps from damaging unit. Max weight includes base unit plus shipping pallet plus all available FIOP's which could be on that size unit. "B" dimension is based on base unit plus economizer option only. This dimension may vary slightly with units configured with other FIOP options. Spreader bars required to lift and transport the unit. Accrocher les manilles des lingues de levages dans les trous situs dans le rail de base comme indiqu au Dtail A. Utiliser des cales en bois lors du levage pour viter que les lingues nendommagent le haut de lappareil. Le poids maximum inclut la configuration de base, le poids de la palette d'expdition, ainsi que toutes les options pouvant tre installes en usine (FIOP) pour la plateforme slectionne. La dimension de "B" provient de la configuration de base qui inclut l'option economizer seulement, Cette dimension peut varier lgrement en fonction des diffrentes options slectionnes installes en usine (FIOP). Barres d'cartement requises pour soulever et transporter l'unit.

REQUIRED

C

B

A

914-1371 (36"-54")SPREADER

BARS

SEE DETAIL A VOIR DTAIL A

PLACE ALL SEAL STRIP IN PLACE BEFORE PLACING UNIT ON ROOF CURB. INSTALLER TOUTES LES BANDES DISOLATION EN PLACE AVANT DE PLACER LAPPAREIL SUR LE REBORD DE TOIT. DUCT END

PASSAGES CONDUITES

MAX WEIGHT LB

1145 1080

KG 520 491

IN 88 88

MM 2235 2235

IN 32

30 3/8

MM 812 772

IN 49 1/2 49 1/2

MM 1257 1257

MODEL

48LC_007 50LC_007

DETAIL A DTAIL A

A B C

48TM504503 REV -

REMOVABLE HORIZONTAL SUPPLY DUCT OPENING COVER

REMOVABLE HORIZONTAL RETURN DUCT OPENING COVER

11

Fig. 8 Location of Notches

Fig. 9 Horizontal Duct Panels In Place

Step 8 Install Outside Air Hood ECONOMIZER HOOD PACKAGE REMOVAL AND SETUP - FACTORY OPTION

1. The hood is shipped in knock-down form and must be field-assembled. The indoor coil access panel is used as the hood top while the hood sides, divider and filter are packaged together, attached to a metal support tray using plastic stretch wrap, and shipped in the return-air compart- ment behind the indoor coil access panel. The hood assem- blys metal tray is attached to the basepan and also attached to the damper using two plastic tie-wraps.

2. To gain access to the hood, remove the filter access panel. (See Fig. 10)

Fig. 10 Access Panel Locations

3. 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. 11.) Be careful to not damage any wiring or cut tie-wraps securing any wiring.

Fig. 11 Economizer Hood Parts Location

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

ECONOMIZER 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. 12.

BASEPAN

NOTCHES NOTCHES

SCREWS

DUCT COVERS SHEET METAL FACE UP

BASEPAN

FILTER ACCESS PANEL

INDOOR COIL ACCESS PANEL

Hood Parts

Plastic Tie Wrap Qty (2)

Screws for Metal Tray Qty (2)

12

Fig. 12 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 pro- vided to attach the hood sides to the unit. See Fig. 13.

Fig. 13 Economizer Hood Construction

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

4. Insert the hood divider between the hood sides. See Fig. 13 and Fig. 14. Secure hood divider with 2 screws on each hood side. The hood divider is also used as the bot- tom 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. 14.

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

7. Replace the filter access panel.

Fig. 14 Economizer Filter Installation

Step 9 Install Flue Hood The flue hood is shipped screwed to the basepan beside the burner compartment access panel. Remove from shipping loca- tion and using screws provided, install flue hood and screen in location shown in Fig. 15.

Fig. 15 Flue Hood Details

Step 10 Install Gas Piping Installation of the gas piping must be in accordance with local building codes and with applicable national codes. In U.S.A., re- fer to NFPA 54/ANSI Z223.1 National Fuel Gas Code (NFGC). In Canada, installation must be in accordance with the CAN/ CSA B149.1 and CAN/CSA B149.2 installation codes for gas burning appliances. This unit is factory equipped for use with natural gas fuel at el- evations 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 ac- cessory kit installation instructions regarding these accessories. NOTE: Furnace gas input rate on rating plate is for installation up to 2000 ft (610 m) above sea level. In U.S.A. the input rating for altitudes above 2000 ft (610 m) must be derated by 4% for each 1000 ft (305 m) above sea level. 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 48LCF/T007 (high-heat)

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

BLOWER ACCESS PANEL

FLUE OPENING

13

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. For liquified petroleum applications, 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 Tables 3 and 4. The gas supply pipe enters the unit at the burner access panel on the front side of the unit, through the long slot at the bottom of the access panel. The gas connection to the unit is made to the 3/4-in. FPT gas inlet port on the unit gas valve.

Manifold pressure is factory-adjusted for natural gas (NG) fuel use. Adjust as required to obtain best flame characteristics. See Table 5. Manifold pressure for liquid propane (LP) fuel use must be ad- justed to specified range. Follow instructions in the accessory kit to make initial readjustment. See Table 6.

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) between gas regulator source and unit gas valve connection when unit is operating at high-fire flow rate. The gas supply line can approach the unit in three ways: hori- zontally from outside the unit (across the roof), thru-curb/under unit basepan (accessory kit required) or through unit basepan (factory-option or accessory kit required). Consult accessory kit installation instructions for details on these installation methods. Observe clearance to gas line components per Fig. 16.

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

FACTORY-OPTION THRU-BASE CONNECTIONS (GAS CONNECTIONS)

This service connection kit consists of a 3/4-in. NPT gas adapt- er fitting (brass), two 1/2-in. electrical bulkhead connectors and a 3/4-in. electrical bulkhead connector, all factory-installed in the embossed (raised) section of the unit basepan in the con- denser section.

Fig. 17 Fittings

The thru-base gas connector has male and female threads. The male threads protrude above the basepan of the unit; the female threads protrude below the basepan. Check tightness of connector lock nuts before connecting gas piping. Install a 3/4-in. NPT street elbow on the thru-base gas fitting. Attach a 3/4-in. pipe nipple with minimum length of 16-in. (406 mm) (field-supplied) to the street elbow and extend it through the access panel at the gas support bracket. See Fig. 18.

Table 3 Natural Gas Supply Line Pressure Ranges

UNIT MODEL UNIT SIZE MIN MAX

48LCD/E/S/R0 07 4.0 in. wg (996 Pa)

13.0 in. wg (3240 Pa)

48LCF/T0 (High Heat units only) 07 5.0 in. wg

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

Table 4 Liquid Propane Supply Line Pressure Ranges

UNIT MODEL UNIT SIZE MIN MAX

48LCD/F/E/S/R/T0 07 11.0 in. wg (2740 Pa)

13.0 in. wg (3240 Pa)

Table 5 Natural Gas Manifold Pressure Ranges

UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE

48LCD/E/S/R0 07 3.5 in. wg (872 Pa)

1.7 in. wg (423 Pa)

48LCF/T0 (High Heat units only) 07 3.5 in. wg

(872 Pa) 2.0 in. wg (498 Pa)

Table 6 Liquid Propane Manifold Pressure Ranges

UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE

48LCD/E/S/R0 07 10.0 in. wg (2490 Pa)

5.0 in. wg (1245 Pa)

48LCF/T0 (High Heat units only) 07 10.0 in. wg

(2490 Pa) 5.7 in. wg (1420 Pa)

CAUTION

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

LEGEND

*Field supplied. NOTE: Follow all local codes.

NFGC National Fuel Gas Code

STEEL PIPE NOMINAL DIAMETER

(in.)

SPACING OF SUPPORTS X DIMENSION

(ft) 1/2

3/4 or 1 11/4 or larger

6 8

10

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

LOW VOLTAGE CONDUIT CONNECTOR

HIGH VOLTAGE CONDUIT CONNECTOR

BRASS FITTING FOR 3 TO 6 TON UNITS.

14

Fig. 18 Gas Line Piping for 6 Ton Units

Other hardware required to complete the installation of the gas supply line will include a manual shutoff valve, a sediment trap (drip leg) and a ground-joint union. A pressure regulator valve may also be required (to convert gas pressure from pounds to inches of pressure). The manual shutoff valve must be located within 6 ft (1.83 m) of the unit. The union, located in the final leg entering the unit, must be located at least 9-in. (230 mm) away from the access panel to permit the panel to be removed for 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. 19 and 20 for typical piping arrangements for gas piping that has been routed through the sidewall of the curb. See Fig. 21 for typical piping arrangement when thru-base is used. Ensure that all piping does not block access to the units main control box or limit the required working space in front of the control box.

Fig. 19 Gas Piping with Direct Drip Leg

Fig. 20 Gas Piping with Offset Drip Leg

Fig. 21 Gas Piping Thru-Base Connections

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

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

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

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

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

NOTE: Pressure test the gas supply system after the gas supply piping is connected to the gas valve. The supply piping must be

EMBOSSMENT BRASS FITTING FOR 3-6 TON UNITS

SUPPORT BRACKET

9 (229mm) MIN

UNION

SHUT OFF VALVE

DRIP LEG

THRU-CURB ADAPTER

UNIT BASE RAIL

1. Teflon is a registered trademark of DuPont.

SHUT OFF VALVE

UNION

9 (229 mm) MIN

UNIT BASE RAIL

BURNER ACCESS PANEL

THRU-CURB ADAPTER

DRIP LEG

15

disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0.5 psig (3450 Pa). Pressure test the gas supply piping system at pressures equal to or less than 0.5 psig (3450 Pa). The unit heating section must be iso- lated 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 if 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. 22.

Fig. 22 Orifice Hole

Step 11 Install External Condensate Trap and Line The unit has one 3/4-in. condensate drain connection on the end of the condensate pan and an alternate connection on the bot- tom. See Fig. 23. Unit airflow configuration does not deter- mine which drain connection to use. Either drain connection can be used with vertical or horizontal applications. To use the alternate bottom drain connection, remove the red drain plug from the bottom connection (use a 1/2-in. square sock- et drive extension) and install it in the side drain connection. The piping for the condensate drain and external trap can be completed after the unit is in place. See Fig. 24. All units must have an external trap for condensate drainage. Install a trap at least 4-in. (102 mm) deep and protect against freeze-up. If drain line is installed downstream from the exter- nal trap, pitch the line away from the unit at 1-in. per 10 ft (25 mm in 3 m) of run. Do not use a pipe size smaller than the unit connection (3/4-in.).

Fig. 23 Condensate Drain Pan (Side View)

Fig. 24 Condensate Drain Piping Details

Step 12 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 according to required operation of the convenience out- let. If an always-energized convenience outlet operation is de- sired, 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 de- sired, connect the source leads to the load side of the unit dis- connect. On a unit without a unit-mounted disconnect, connect the source leads to compressor contactor C and indoor fan con- tactor IFC pressure lugs with unit field power leads (see Fig. 25).

WARNING

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

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

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

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

BURNER ORIFICE

WARNING

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

DRAIN (FACTORY-INSTALLED)

PLUG

CONDENSATE PAN (SIDE VIEW) STANDARD SIDE DRAIN

ALTERNATE BOTTOM DRAIN

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

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

BASE RAIL

OPEN VENT

TO ROOF DRAIN

DRAIN PLUG

ROOF CURB

SEE NOTE

3 in. (76 mm) MIN

16

Refer to Fig. 40 for power transformer connections and the dis- cussion on connecting the convenience outlet on page 25. Field power wires will be connected at line-side pressure lugs on the power terminal block or at factory-installed option non- fused disconnect or HACR. 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 ar- rangement), at factory-installed option non-fused disconnect switch or HACR. Max wire size is #4 AWG (copper only) per pole on contactors and #2ga AWG (copper only) per pole on optional non-fused disconnect or HACR. See Fig. 25 and the unit label diagram for field power wiring connections. NOTE: TEST LEADS - Unit may be equipped with short leads (pigtails) on the field line connection points on contactor C or op- tional disconnect switch. These leads are for factory run-test pur- poses only; remove and discard before connecting field power wires to unit connection points. Make field power connections di- rectly to line connection pressure lugs only.

Fig. 25 Power Wiring Connections

See Fig. 26 for disconnect switch information. See Fig. 27-33 for wiring diagrams.

Fig. 26 Disconnect Switch and Unit

Disconnect per

NEC

11 13 13

L1 L2 L3

C IFC

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

Units Without Disconnect or HACR Option

Units With Disconnect or HACR Option

L1

L2

L3

2

4

6

1

5

Optional Disconnect

Switch

Disconnect factory test leads; discard.

Factory Wiring

3

Ground (GR)

Equip GR Lug

Equip GR Lug

Ground (GR)

WARNING

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

COPPER

WIRE ONLY

ELECTRIC DISCONNECT

SWITCH

ALUMINUM WIRE

17

Fig. 27 48LC 07 Electro-mechanical Control Wiring Diagram

18

Fig. 28 48LC 07 RTU Open Control Wiring Diagram

19

Fig. 29 48LC 07 SystemVu Control Wiring Diagram

20

Fig. 30 48LC 07 Power Wiring Diagram, Electro-mechanical and RTU Open Controls (208/230v and 460v Units)

21

Fig. 31 48LC 07 Power Wiring Diagram, Electro-mechanical and RTU Open Controls (575v Units)

22

Fig. 32 48LC 07 Power Wiring Diagram, SystemVu Control (208/230v and 460v Units)

23

Fig. 33 48LC 07 Power Wiring Diagram, SystemVu Control (575v Units)

24

UNITS WITH FACTORY-INSTALLED NON-FUSED DIS- CONNECT OR HACR

The factory-installed optional non-fused disconnect (NFD) or HACR switch is located in a weatherproof enclosure located under the main control box. The manual switch handle and shaft is shipped in the disconnect or HACR enclosure. Assem- ble the shaft and handle to the switch at this point. Discard the factory test leads (see Fig. 25). Connect field power supply conductors to LINE side terminals when the switch enclosure cover is removed to attach the handle. Field-Install the NFD Shaft and Handle 1. Remove the Control Box access panel. The NFD enclo-

sure is located below the Control Box (see Fig. 34). 2. Remove (3) cap head screws that secure the NFD enclo-

sure front cover (2) on the face of the cover and (1) on the left side cover. See Fig. 35.

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

position (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. 35. 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 point-

ing 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) cap

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

Fig. 34 NFD Enclosure Location

Fig. 35 NFD Handle and Shaft Assembly Field-Install the HACR Shaft and Handle 1. Remove the Control Box access panel. The HACR enclo-

sure is located below the Control Box (see Fig. 36). 2. Remove (3) cap head screws that secure the HACR enclo-

sure (2) on the face of the cover and (1) on the left side cover. See Fig. 37.

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

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

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

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

head screws on the HACR enclosure. 11. Re-install the unit front panel.

Fig. 36 HACR Enclosure Location

25

Fig. 37 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 cabinet or within sight of the unit per national or local codes. Do not cover unit informative plate if mounting the disconnect on the unit cabinet.

ALL UNITS

All field wiring must comply with NEC and all local codes. Size wire based on MCA (Minimum Circuit Amps) on the unit informative plate. See Fig. 25 and unit label diagram for power wiring connections to the unit and equipment ground. Maxi- mum wire size is #4 ga AWG (copper only) per pole on contac- tors and #2 ga AWG (copper only) per pole on optional non- fused disconnect or HACR. Provide a ground-fault and short-circuit over-current protection device (fuse or breaker) per NEC Article 440 (or local codes). Refer to unit informative data plate for MOCP (Maximum Over-current Protection) device size. NOTE: Units ordered with factory-installed HACR do not need an additional ground-fault and short-circuit over-current protective device unless required by local codes. All field wiring must comply with the NEC and local requirements. All units except 208/230-v units are factory wired for the volt- age shown on the nameplate. If the 208/230-v unit is to be con- nected to a 208-v power supply, the control transformer must be rewired by moving the black wire with the 1/4-in. female spade connector from the 230-v connection and moving it to the 200-v 1/4-in. male terminal on the primary side of the trans- former. Refer to unit label diagram for additional information. Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate. On 3-phase units, voltages between phases must be balanced within 2% and the current within 10%. Use the formula shown below to determine the percent of voltage imbalance. Operation on im- proper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty. % Voltage Imbalance:

Example: Supply voltage is 230-3-60

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

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

NOTE: Check all factory and field electrical connections for tightness.

CONVENIENCE OUTLETS

Two types of convenience outlets are offered on 48LC models: non-powered and unit-powered. Both types provide a 125-v GFCI (ground-fault circuit-interrupter) duplex receptacle rated at 15-A behind a hinged waterproof access cover, located on the end panel of the unit. See Fig. 38.

Fig. 38 Convenience Outlet Location

Installing Weatherproof Cover A weatherproof while-in-use cover for the factory-installed convenience outlets is now required by UL standards. This cover cannot be factory-mounted due to its depth; it must be

= 100 x max voltage deviation from average

voltage average voltage

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

Average Voltage = (224 + 231 + 226)

= 68 1 =227

3 3

% Voltage Imbalance = 100x

4

=1.78%2 2 7

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

WARNING

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

A B C

MOTOR

CONVENIENCE OUTLET GFCI

PWD-CO FUSE SWITCH

PWD-CO TRANSFORMER

CONTROL BOX ACCESS PANEL

26

installed at unit installation. For shipment, the convenience outlet is covered with a blank cover plate. The weatherproof cover kit is shipped in the units control box. The kit includes the hinged cover, a backing plate and gasket. DISCONNECT ALL POWER TO UNIT AND CONVE- NIENCE OUTLET. LOCK-OUT AND TAG-OUT ALL POWER. Remove the blank cover plate at the convenience outlet; dis- card the blank cover. Loosen the two screws at the GFCI duplex outlet, until approx- imately 1/2-in. (13 mm) under screw heads is exposed. Press the gasket over the screw heads. Slip the backing plate over the screw heads at the keyhole slots and align with the gasket; tighten the two screws until snug (do not over-tighten). Mount the weatherproof cover to the backing plate as shown in Fig. 39. Remove two slot fillers in the bottom of the cover to permit service tool cords to exit the cover. Check for full clos- ing and latching.

Fig. 39 Weatherproof Cover Installation

Non-powered type This type requires the field installation of a general-purpose 125-v 15-A circuit powered from a source elsewhere in the building. Observe national and local codes when selecting wire size, fuse or breaker requirements and disconnect switch size and location. Route 125-v power supply conductors into the bottom of the utility box containing the duplex receptacle. Unit-powered type A unit-mounted transformer is factory-installed to stepdown the main power supply voltage to the unit to 115-v at the du- plex receptacle. 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. 38. The primary leads to the convenience outlet transformer are not factory-connected. Selection of primary power source is a customer 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 service power to the unit when the unit disconnect switch or HACR switch is open. Other connection methods will result in the convenience outlet circuit being de-energized when the unit disconnect or HACR switch is open. See Fig. 40. Using unit-mounted convenience outlets Units with unit-mounted convenience outlet circuits will often require that two disconnects be opened to de-energize all pow- er to the unit. Treat all units as electrically energized until the convenience outlet power is also checked and de-energization

is confirmed. Observe National Electrical Code Article 210, Branch Circuits, for use of convenience outlets.

Fig. 40 Powered Convenience Outlet Wiring

Fuse on power type The factory fuse is a Bussman1 Fusetron T-15, non-renew- able screw-in (Edison base) type plug fuse. Duty Cycle The unit-powered convenience outlet has a duty cycle limita- tion. The transformer is intended to provide power on an inter- mittent 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 cir- cuit loading above 8-amps. Convenience outlet usage rating See Fig. 41.

Fig. 41 Convenience Outlet Utilization Notice Label

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 re- ceptacle does not trip as required. Press the RESET button to clear the tripped condition.

HACR

The amp rating of the HACR factory-installed option is based on the size, voltage, indoor motor and other electrical options

TOP

TO P

TOP

WET LOCATIONS

W ET LOCATIONS

COVER - WHILE-IN-USE WEATHERPROOF

BASEPLATE FOR GFCI RECEPTACLE

GASKET

GFCI RECEPTACLE NOT INCLUDED

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

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

27

of the unit as shipped from the factory. If field-installed acces- sories are added or changed in the field (i.e. power exhaust, etc.), the HACR may no longer be of the proper amp rating and therefore will need to be removed from the unit. See unit nameplate and label on factory-installed HACR for the amp rating of the HACR that was shipped with the unit from the factory. See unit nameplates for the proper fuse, HACR or maximum over-current protection device required on the unit with field-installed accessories. See Fig. 42.

Fig. 42 HACR Caution Label

FACTORY-OPTION THRU-BASE CONNECTIONS (ELEC- TRICAL CONNECTIONS)

This service connection kit consists of a 1/2-in. electrical bulk- head connector and a 11/4-in. electrical bulkhead connector, all factory-installed in the embossed (raised) section of the unit basepan in the condenser section. The 1/2-in. bulkhead connec- tor enables the low-voltage control wires to pass through the basepan. The 11/4-in. electrical bulkhead connector allows the high-voltage power wires to pass through the basepan. See Fig. 17. Check tightness of connector lock nuts before connecting elec- trical conduits. Field-supplied and field-installed liquid tight conduit connec- tors and conduit may be attached to the connectors on the base- pan. Pull correctly rated high voltage and low voltage through appropriate conduits. Connect the power conduit to the internal disconnect (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 connec- tions can be made. Connect the control power conduit to the unit control box at this hole.

UNITS WITHOUT THRU-BASE CONNECTIONS

1. Install power wiring conduit through side panel openings. Install conduit between disconnect and control box.

2. Install power lines to terminal connections as shown in Fig. 25.

FIELD CONTROL WIRING

The 48LC unit requires an external temperature control device such as a thermostat (field-supplied).

THERMOSTAT

Install a Carrier-approved accessory thermostat according to in- stallation instructions included with the accessory. See Fig. 43. For complete economizer function and 3-stage compressor oper- ation select a three-stage cooling thermostat. If a 3-stage cooling thermostat is not available, use a 2-stage cooling thermostat in- stead, but note that this will limit cooling to just 2 stages. Locate the thermostat accessory on a solid wall in the conditioned space to sense average temperature in accordance with the thermostat installation instructions.

Fig. 43 Low-Voltage Connections

If the thermostat contains a logic circuit requiring 24-v power, use a thermostat cable or equivalent single leads of different col- ors with minimum of eight leads. If the thermostat does not re- quire a 24-v source (no C connection required), use a thermo- stat cable or equivalent with minimum of seven leads. Check the thermostat installation instructions for additional features which might require additional conductors in the cable. For wire runs up to 50 ft (15 m), use no. 18 AWG (American Wire Gage) insulated wire (35C minimum). For 50 to 75 ft (15 to 23 m), use no. 16 AWG insulated wire (35C minimum). For over 75 ft (23 m), use no. 14 AWG insulated wire (35C minimum). All wire sizes larger than no. 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat.

UNIT 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 (see Fig. 44) to the control box. Pull the wires over to the terminal strip on the upper-left corner of the Controls Connection Board. NOTE: If thru-the-bottom connections accessory is used, refer to the accessory installation instructions for information on routing power and control wiring.

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.

C

G

C

G

O/B/Y2 Y2

RR

Y1 Y1

Y3 Y3

(Note 1) (Notes 2, 3 & 4)

(Note 3 & 4)

W1W1

W2 W2

T H E R M O S T A T

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

Note 2: Y2 to Y3 connection required for 2-stage cooling operation and when integrated economizer function is desired.

Note 3: To Connect a 2-Stage Thermostat: Y2 to Y3 connection required for 2-stage cooling operation which provides low and high cooling states.

Note 4: SystemVu controller is default configured for 3-stage cooling and 2-stage heating thermostats; it can be configured for other thermostat types.

Field Wiring

Integrated Staging Control (ISC) Board or

SystemVuTM Controller

Typical Thermostat Connections

28

Fig. 44 Field Control Wiring Raceway

Humidi-MiZer System Control Connections NOTE: It is suggested to ensure the Auto-Changeover function of an installed thermostat is enabled when used in conjunction with the Humidi-MiZer Adaptive Dehumidification system.

HUMIDI-MIZER SYSTEM SPACE RH CONTROLLER

The Humidi-MiZer dehumidification system requires a field- supplied and installed space relative humidity control device. This device may be a separate humidistat control (contact clos- es on rise in space RH above control setpoint) or a combination thermostat-humidistat control device with isolated contact set for dehumidification control. NOTE: Use of a humidistat device is not permitted on 48LC units equipped with RTU Open control; these units require use of a field-supplied RH sensor (33ZCSENSRH-02 or 33ZHCSEN- DRH-02) or a ZS series sensor with humidity sensing. System- Vu controls requires a Space Humidistat (HL38MG029), a Wall Mount Space Humidity Sensor (33ZCSENSRH-01), or a Duct Mount Humidity Sensor (33ZCSENDRH-01).

To connect the Carrier humidistat (HL38MG029) (Fig. 45): 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. 44) to the 24-v barrier located on the left side of the control box. The raceway provides the UL-required clearance between high-voltage and low-voltage wiring.

3. Use wire nuts to connect humidistat cable to the leads in the low-voltage wiring (as shown in Fig. 46), connecting PNK to PNK and PNK/BLK to PNK/BLK.

Fig. 45 Accessory Field-Installed Humidistat

NOTE: 48LC**07 units require a 3-stage cooling thermostat de- vice and are not compatible with Carriers Edge Pro thermidistat.

RTU Open Controller (Factory-Installed Option) For details on operating 48LC**07 units equipped with the factory-installed RTU Open controller option, refer to 48/50LC 07-26 Factory Installed Option RTU Open Multi-Protocol Controller Controls, Start-up, Operation and Troubleshooting manual.

SystemVu Controller (Factory-Installed Option) For details on operating 48LC**07 units equipped with the factory-installed SystemVu control option, refer to 48/50LC 04-26 Single Package Rooftop Units with SystemVu Controls Version 2.X Controls, Start-up, Operation and Troubleshooting manual.

Fig. 46 Typical Humidi-MiZer Adaptive Dehumidification System Humidistat Wiring

RACEWAY

HOLE IN END PANEL (HIDDEN)

% RELATIVE HUMIDITY

Humidistat

29

Integrated Staging Control (ISC) Board

Fig. 47 Integrated Staging Control (ISC) Board

NOTES: 1. Green LED Blinking at 1Hz indicates normal operation. 2. Solid red LED indicates an error exists, see above LED configuration.

DDC Control

Indoor Fan On Status

IGC Board

Power Plug

Phase Monitor Relay

Auxilary Shutdown

Condensate OverflowEconomizer

Occupancy

Status Code LEDs

Thermostat

DDC Control

Remote Shutdown

Smoke Shutdown

Smoke Alarm

Low Ambient Outdoor Fan

Control

Compressors

Reheat

Low-Pressure Switch

High-Pressure Switch

Indoor Fan Motor

Outdoor Fan Motors

Table 7 Status Code Descriptions for ISC Board LEDs

ERROR # ERROR NAME LED INDICATION

LED01 LED02 LED03 LED04 LED05 1 Check Smoke Detector/PMR/AUX RED

Blinking Green LED

(Note 1)

2 Check HPS/LPS/COFS RED RED 3 Call for Y3 with no call for Y1. Check Y1 wiring. RED 4 Call for Y3 with no call for Y1/Y2. Check Y1 wiring. RED RED 5 Call for Y2 with no call for Y1. Check Y1 wiring. RED RED 6 Call for W2 with no call for W1. Check W1 wiring. RED RED 7 Call for heat (W1/W2) and cooling (Y1/Y2/Y3). Check thermostat wiring. RED RED RED RED 8 Call for heat (W1/W2) with no G. Check G wiring. RED RED RED 9 Call for cooling (Y1/Y2/Y3) with no G. Check G wiring RED RED RED

10 Call for heat (W1/W2) and cooling (Y1/Y2/Y3) with no G. Check thermostat and G wiring. RED RED RED

11 Check ISC Board and the thermostat wiring RED RED RED 12 Check ISC Board and the thermostat wiring RED 13 Check ISC Board and the thermostat wiring RED RED 14 Check ISC Board and the thermostat wiring RED 15 Check ISC Board and the thermostat wiring RED RED

30

ISC BOARD - SEQUENCE OF OPERATION

General The Carrier Integrated Staging Control (ISC) is intended for use with a standard thermostat or direct digital controls (DDC) capable of three cooling stages. After initial power to the board, a Green LED will blink with a 1 second duty cycle indi- cating the unit is running properly. In the event of the ISC board failing, the Green LED will be OFF or continuously ON. When the unit is not running properly, the Green LED will blink along with Red LED lights. The Red LED light configu- ration will indicate the type of error the board has identified. See Fig. 47 for LED locations and Table 7 for a list of the sta- tus codes. The ISC board can be remotely shutdown by removing Jumper 4 and wiring to the Remote Shutdown terminal. The Smoke Control Module can shutdown the unit by removing Jumper 3 and wiring to the Smoke Shutdown terminal. The Smoke Alarm terminal on the ISC Board provides a pass through con- nection should a smoke alarm signal be connected. In the case of the RTU Open option, the RTU Open controller provides the signal which is passed through the ISC board to the Smoke Alarm terminal. The crankcase heater will run at all times except when the compressors are running. An auxiliary power supply (24Vac) available at TB-4 Terminal is provided to power auxiliary equipment. An optional Phase Monitor Relay can be wired to the PMR terminal by removing Jumper 5. An optional Conden- sate Flow Switch can be wired to the COFS Terminal by re- moving Jumper 7. Ventilation In the Ventilation/Fan Mode (G on the thermostat), the indoor- fan will run at low speed and the damper will operate at mini- mum position. Cooling In the Cooling Mode, the small and large compressors will be sequenced to maintain the thermostat temperature setpoint. The table below shows the cooling operation based on the follow- ing conditions.

The outdoor fan and VFD controlled indoor-fan will operate at low, medium and high speed. The indoor-fan speed (rpm) is factory set by the CFM and static pressure requirements for the unit installed. Humidi-MiZer System (Optional) In the Dehumidification Mode, both compressors will run and Indoor airflow will be rise to High Speed. At subcooler reheating mode (reheat-1), during part load con- ditions when the room temperature and humidity are above the set point, the unit initiates the sub-cooling mode of operation; a call for cooling and dehumidification. RDV (Reheat Discharge Valve) and TWV (Three Way Valve) close; Indoor and Out- door airflow will rise until reaching 100% of Speed. At hot-gas-bypass reheating mode (reheat-2), when there is a call for dehumidification without a call for cooling, a portion of the hot

gas from the compressor bypasses the condenser coil when RDV opens and hot gas is fed into the liquid line, TWV closes in this mode and the system provides mainly latent cooling. Indoor air- flow will rise until reaching 100% of Speed, Outdoor airflow will run at High speed as long as outdoor temperature is above 80F (26.7C); when operating in this mode below 80F (26.7C) OAT, the system outdoor fan will operate as shown in the table below.

Economizer (Optional) When the economizer is in Free Cooling Mode and a demand for cooling exists (Y1 on the thermostat), the economizer will modulate the outdoor-air damper to provide a 50F (10C) to 55F (13C) mixed-air temperature into the zone and run the indoor fan at high speed. As mixed-air temperature fluctuates above 55F (13C) or below 50F (10C) dampers will be modulated (open or close) to bring the mixed-air temperature back within control. Upon more call for cooling (Y2 on the thermostat), the outdoor-air damper will maintain its current position, compressor C1 will run and the outdoor fan will run at low speed. If there is further demand for cooling, the out- door-air damper will maintain its current position, only com- pressor C2 will run and the outdoor fan will run at medium speed. The VFD-controlled indoor fan will operate at high speed regardless of the cooling demand. If the increase in cooling capacity causes the mixed-air tem- perature to drop below 45F (7C), the outdoor-air damper will return to the minimum position. If the mixed-air temperature continues to fall, the outdoor-air damper will close. Control re- turns to normal once the mixed-air temperature rises above 48F (9C). The power exhaust fans will be energized and de- energized, if installed, as the outdoor-air damper opens and closes. If field-installed accessory CO2 sensors are connected to the Economizer, a demand controlled ventilation strategy will be- gin to operate. As the CO2 level in the zone increases above the CO2 set-point, the minimum position of the damper will be in- creased proportionally. As the CO2 level decreases because of the increase of fresh air, the outdoor-air damper will be propor- tionally closed. For economizer operation, there must be a ther- mostat call for the fan (G). If the unit is occupied and the fan is on, the damper will operate at minimum position. Otherwise, the damper will be closed. Low Ambient Cooling Operation down to 40F (4C) In Low Ambient RTU conditions when the temperature is be- tween 55F (13C) and 40F (4C), the Low Ambient Switch (LAS) will be active and the outdoor fans will run to the pre-set factory outdoor-fan speed. When the temperature is greater than 65F (18C), the Low Ambient Switch will deactivate and the outdoor fans will run in the standard cooling mode. If the Outdoor Fan Select Switch (see Fig. 46) is in the ON position, the outdoor fans will run in the Fan Cycle Speed Mode (FCS) set to 250 rpm. If the Outdoor Fan Select Switch is in the OFF position, the outdoor fans will run in the Minimum Fan Speed Mode (MIN) set to 160 rpm regardless of the cooling demand. The 48LC size 07 units have a SPST normally open Low Am- bient Switch (LAS) wired across the TS and OF terminal and a jumper placed across the PS terminal (see Fig. 47). When the LAS is active, the switch will close making contact to the OF terminal. This is done for units that require all outdoor fans to run at the same pre-set factory Low Ambient Speed. See Fig. 48 and 49.

INPUT OUTPUT

THERMOSTAT COMPRESSOR C1

COMPRESSOR C2

INDOOR FAN

SPEED

OUTDOOR FAN

SPEED First Stage

Cooling (Y1) On Off Low Low (700 rpm)

Second Stage Cooling (Y2) Off On Medium Medium

(800 rpm)

Third Stage Cooling (Y3) On On High High

(1000 rpm)

48LC SIZE RPM NUMBER OF FANS ON

NUMBER OF FANS OFF

07 250 2 0

31

Fig. 48 Outdoor Fan Speed Select Switch

Fig. 49 Schematic of SPST Low Ambient Switch

Table 8 shows the operation of the outdoor fan for size 07 units.

Heating In the Heating Mode (W1 and G on the thermostat), the ISC board sends power to W on the IGC board. Assuming the unit is controlled through a room thermostat set for fan auto, the in- door-fan motor will energize and the outdoor-air dampers will open to their minimum position. The ISC board upon seeing W1 and G ON will turn the indoor fan to high speed. The IGC board starts its gas ignition process. A check is made to ensure that the rollout switch and limit switch are closed. If the check was successful, the induced draft motor is energized, and when its speed is satisfactory, as proven by the flue gas pressure switch, the ignition activation period begins. The burners will ignite within 5 seconds. If the burners do not light, there is a 22-second delay before another 5-second attempt. This sequence is repeated for 15 minutes or until the burners light. If, after the 15 minutes, the burners still have not lit, heat- ing is locked out. To reset the control, break 24 vac power to the thermostat. When gas ignition occurs, the IGC board will continue to mon- itor the condition of the rollout switch, the limit switches, the flue gas pressure switch, as well as the flame sensor. When W1 is turned OFF, the IGC board turns off the gas valve. The IGC board has a delay time before it turns IFO=OFF. At this time, the ISC board sees W1=OFF and IFO=ON. The ISC will keep the indoor fan ON high speed. Once the IGC board delay times out, the ISC board will see W1=OFF and IFO=OFF, which then turns the indoor fan OFF. 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. If the over temperature limit opens after the indoor motor is stopped, but within 10 minutes of W1 be- coming inactive, on the next cycle the time will be extended by 15 seconds. The maximum delay is 3 minutes. Once modified, the fan OFF delay will not change back to 45 seconds unless power is reset to the control. A LED indicator is provided on the IGC to monitor operation. When additional heat is required, W2 closes and initiates pow- er to the second stage of the main gas valve. When the thermo- stat is satisfied, the gas valve closes, interrupting the flow of gas to the main burners.

EconoMi$er X (Factory Option) The EconoMi$er X system is an expandable economizer con- trol system, which includes a W7220 economizer module (con- troller) with an LCD and keypad (see Fig. 50). The W7220 can be configured with optional sensors.

Fig. 50 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$er X system includes an economizer module, 20k mixed air sensor, damper actuator, and either a 20k out- door air temperature sensor or S-Bus enthalpy sensors. Economizer Module The module is the core of the EconoMi$er X system. The module is mounted in the units control box, and includes the user interface for the system. The W7220 economizer module provides the basic inputs and outputs to provide simple economizer control. When used with the optional sensors, the economizer module provides more advanced economizer functionality. S-Bus Enthalpy Control Sensors The sensor is a combination temperature and humidity sensor which is powered by and communicates on the S-Bus. Up to three sensors may be configured with the W7220 economizer module.

Table 8 Low Ambient Temperature Outdoor Fan Controls

48LC SIZE

NO. OF FANS ON

NO. OF FANS OFF SWITCH

OUTDOOR FAN

SELECT SWITCH

RPM

07 2 0 SPST Up 250

OF SPEED SELECT

ON FCS

MIN

OFF

JUMPER ON

LAS SPST

PS PS

TS OF

32

CO2 Sensor (optional) The CO2 sensor can be added for Demand Controlled Ventila- tion (DCV).

SPECIFICATIONS

W7220 Economizer Module The module is designed for use with 2 to 10 vdc or bus com- municating actuator. The module includes terminals for CO2 sensor, Mixed Air sensor, and an Outdoor Dry Bulb sensor. En- thalpy and other options are available with bus sensors. User Interface Provides status for normal operation, setup parameters, check- out tests, and alarm and error conditions with a 2-line 16 char- acter 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 Return Air (RA) bus sensor can be added to the system for dif- ferential enthalpy or dry bulb changeover. For differential dry bulb changeover, a 20k ohm sensor is required in the OA and a bus sensor in the RA. DIP switch on RA bus sensor must be set in the RA position. Dry Bulb Temperature (optional) and Mixed Air (required), 20k NTC 2-wire (18 to 22 AWG); Temperature range 40F to 150F (40C to 66C) Temperature accuracy: 0F/+2F Temperature and Humidity, C7400S1000 (optional) S-Bus; 2-wire (18 to 22 AWG) Temperature: range 40F to 150F (40C to 65C) Temperature accuracy: 0F/+2F (-18C/-17C) 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 33 for wiring details). 24 vac power supply 20 to 30 vac 50/60Hz; 100 VA Class 2 transformer.

OUTPUTS

Actuator Signal 2 to 10 vdc; minimum actuator impedance is 2k ohm; bus two- wire output for bus communicating actuators.

Exhaust fan, Y1, Y2 and AUX1 O All Relay Outputs (at 30 vac): Running: 1.5A maximum Inrush: 7.5A maximum

ENVIRONMENTAL

Operating Temperature 40F to 150F (40C to 65C). Exception of display operation down to 4F (20C) with full recovery at 4F (20C) from exposure to 40F (40C) Storage Temperature 40F to 150F (40C to 65C) Shipping Temperature 40F to 150F (40C to 65C) Relative Humidity 5% to 95% RH non-condensing

ECONOMIZER MODULE WIRING DETAILS

Use Fig. 51 and Tables 9 and 10 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. 51 W7220 Wiring Terminals

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

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

Cert Product California Title 24, Part 6

HJW10 www.energy.ca.gov

MAT

MAT

OAT

OAT

S-BUS

S-BUS

IAQ 2-10

IAQ COM

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

33

*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. 52 and Table 11 to locate the wiring terminals for each S-Bus and en- thalpy control sensor.

Fig. 52 S-Bus Sensor DIP Switches

Use Fig. 52 and Table 12 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 fail- ures (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 pow- er the CO2 sensor OR make sure the ground for the power sup- plies are common. See Fig. 53 for CO2 sensor wiring.

Table 9 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

Table 10 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)

Table 11 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 12 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

DIP SWITCH LABEL

DIP SWITCHES (3)

S-BUS 2 PIN SIDE CONNECTOR

S-BUS TERMINALS (1 AND 2)

34

Fig. 53 CO2 Sensor Wiring

INTERFACE OVERVIEW

This section describes how to use the EconoMi$er 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. 54) to scroll through the menus and menu items, select menu items, and to change parameter 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. 54 W7220 Controller Navigation Buttons

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

currently displayed menu. 3. Use the and buttons to scroll to the desired

parameter.

4. Press the (Enter) button to display the value of the currently displayed item.

5. Press the button to increase (change) the displayed parameter value.

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

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

and store it in nonvolatile RAM. CHANGE STORED displays.

2. Press the (Enter) button to return to the current menu parameter.

3. Press the (Menu Up/Exit) button to return to the previ- ous menu.

Menu Structure Table 13 illustrates the complete hierarchy of menus and parame- ters for the EconoMi$er X system. The Menus in display order are: STATUS SETPOINTS SYSTEM SETUP ADVANCED SETUP CHECKOUT ALARMS

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

SETUP AND CONFIGURATION

Before being placed into service, the W7220 Economizer mod- ule 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 backward 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 displays a screen saver, which cycles through the Status items. Each Status items displays in turn and cycles to the next item after 5 seconds.

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

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

35

Table 13 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

36

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 1

degree

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

DRYBLB SET 63F (17C)

48F to 80F (9C to 27C); increment by

1 degree

OA DRY BULB TEMPERATURE CHANGEOVER SETPOINT Dry bulb set point will only appear if using dry bulb changeover. Set point determines where the economizer will assume outdoor air temperature is good for free cooling; e.g.; at 63F unit will economize at 62F and below and not economize at 64F and above. There is a 2F deadband.

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

ENTHALPY CHANGEOVER CURVE ES curve will only appear if using enthalpy changeover. Enthalpy boundary curves for economizing using single enthalpy. See page 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. With 2-speed fan units, MIN POS L (low speed fan) and MIN POS H (high speed fan) settings are required. Default for MIN POS L is 3.2V and MIN POS H is 2.8V.

VENTMAX 2.8 V

2 to 10 vdc

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

100 to 9990 cfm; increment by 10

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

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

VENTMIN 2.25 V

2 to 10 vdc or 100 to 9990 cfm

increment by 10

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

100 to 9990 cfm; increment by 10

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

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

ERV OAT SP 32F (0C)

0F to 50F (18C to 10C);

increment by 1 degree

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

Table 13 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME Notes

37

SETPOINTS (cont)

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

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

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

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

SYSTEM SETUP

INSTALL 01/01/10 N/A Display order = MM/DD/YY Setting order = DD, MM, then YY.

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

EQUIPMENT CONV CONV

or HP

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

AUX2 IN W

Shutdown (SD) Heat (W1)

HP(O) HP(B)

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

FAN SPEED 2 speed 1 speed/2 speed

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

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

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

AUX1 OUT NONE

NONE ERV

EXH2 SYS

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

EXH2 = second damper position 24 vac out for second exhaust fan SYS = use output as an alarm signal

OCC INPUT INPUT or ALWAYS

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

FACTORY DEFAULT NO NO or YES Resets all set points to factory defaults when set to YES. LCD will briefly flash YES and change to NO but all parameters will change to the factory default values.

ADVANCED SETUP

MA LO SET 45F (7C)

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

1 degree

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

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

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

CO2 SPAN 2000ppm 1000 to 3000 ppm; Increment by 50

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

STG3 DLY 2.0h

0 min, 5 min, 15 min, then 15 min intervals. Up to 4 hrs or OFF

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

SD DMPR POS CLO CLO or OPN

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

DA LO ALM 45F (7C)

NONE 35F to 65F

(2C to 18C); Increment by 5F

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

Table 13 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME Notes

38

ADVANCED SETUP (cont)

DA HI ALM 80F (27C)

NONE 70F to 180F

(21C to 82C); Increment by 5F

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

DCVCAL ENA MAN MAN (manual) AUTO

Turns on the DCV automatic control of the dampers. Resets ventilation based on the RA, OA, and MA sensor conditions. Requires all (RA, OA, MA, CO2) sensors. This operation is not operable with a 2-speed fan unit.

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

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

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

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

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 14.

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.

Table 13 W7220 Menu Structure* (cont)

MENU PARAMETER PARAMETER

DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

EXPANDED PARAMETER NAME Notes

39

LEGEND

* Table 13 illustrates the complete hierarchy. Your menu parameters may be different depending on your configuration. For example, if you do not have a DCV (CO2) sensor, then none of the DCV parameters appear.

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

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

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

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

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

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

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

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

4. SYSTEM SETUP parameters must be configured as noted for 2- Speed unit operation: EQUIPMENT = CONV AUX2 I = W FAN SPEED = 2SPEED

For damper minimum position settings and checkout menu read- ings, see Table 14. For dry bulb operation with a 1 speed indoor fan, with or without DCV, see Tables 15 and 16. For enthalpy op- eration with a 1 speed indoor fan, with or without DCV, see Tables 17 and 18. For dry bulb operation with a 2 speed indoor fan, with or without DCV, see Tables 19 and 20. For enthalpy op- eration with a 2 speed indoor fan, with or without DCV, see Tables 21 and 22.

ALARMS (CONT)

FREEZE ALARM N/A N/A

Check if outdoor temperature is below the LOW Temp Lockout on set point menu. Check if Mixed air temperature on STATUS menu is below the Lo Set point on Advanced menu. When conditions are back in normal range, the alarm will go away.

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

DMP CAL RUNNING N/A N/A

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

DA SENS ALM N/A N/A

DISCHARGE AIR TEMPERATURE SENSOR ALARM Discharge air temperature is out of the range set in the ADVANCED SETUP Menu. Check the temperature of the discharge air.

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

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

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 13 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 14 Damper Minimum Position Settings and Readings on Checkout Menu

DEMAND CONTROLLED VENTILATION (CO2 SENSOR)

FAN SPEED SETPOINTS CHECKOUT

NO 1

MIN POS VMAXHS N/A N/A

2 MIN POS H VMAXHS MIN POS L VMAXLS

YES

1 VENT MIN VMAXHS VENT MAX VMAXHS

2

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

40

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

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

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

Table 15 Dry Bulb Operation 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 16 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 17 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

41

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

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

Table 18 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

Table 19 Dry Bulb Operation without DCV (CO2 Sensor) 2 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

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

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

NONE Yes

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

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

Closed to Full-Open

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

to Full-Open Closed to Full-Open

42

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

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

Table 20 Dry Bulb Operation with DCV (CO2 Sensor) 2 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE Y1-I Y2-I FAN

SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED

Below CO2 Set

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

Yes

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

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

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

Above CO2 Set

No

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

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

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

Yes

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

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

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

Full-Open Closed to Full-Open

Table 21 Enthalpy Operation without DCV (CO2 Sensor) 2 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE Y1-I Y2-I FAN

SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED

NO CO2 SENSOR

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

YES

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

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

43

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

ENTHALPY SETTINGS

When the OA temperature, enthalpy and dew point are below the respective set points, the Outdoor Air can be used for economiz- ing. Figure 55 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 24 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 55 shows the 5 current boundaries. There is also a high lim- it boundary for differential enthalpy. The high limit boundary is ES1 when there are no stages of mechanical cooling energized and HL (high limit) when a compressor stage is energized.

TWO-SPEED FAN OPERATION

NOTE: Two-Speed Fan operation applies to size 07 models only. The W7220 controller has the capability to work with a system us- ing a 2-speed supply fan. The W7220 does not control the supply directly but uses the following input status to determine the speed of the supply fan and controls the OA damper to the required posi- tion, see Table 23.

The W (heating mode) is not controlled by the W7220 but it re- quires the status to know where to position the OA damper for minimum position for the fan speed. The 2 speed fan delay is available when the system is programmed for 2 speed fan (in the System Setup menu item). The 2 speed fan delay is defaulted to 5 minutes and can be changed in the Ad- vanced Setup menu item. When the unit has a call for Y1 In and in the free cooling mode and there is a call for Y2 In, the 2-speed fan delay starts and the OA damper will modulate 100% open, the supply fan should be set to high speed by the unit controller. After the delay one of two actions will happen: The Y2 In call will be satisfied with the damper 100%

open and fan on high speed and the call will turn off OR

If the call for additional cooling in the space has not been satisfied then the first stage of mechanical cooling will be enabled through Y1 Out or Y2 Out.

Table 22 Enthalpy Operation With DCV (CO2 Sensor) 2 Speed Fan

DEMAND CONTROLLED

VENTILATION (DCV)

OUTSIDE AIR GOOD TO

ECONOMIZE Y1-I Y2-I FAN

SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED

Below CO2 Set

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

Yes

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

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

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

Above CO2 Set

No

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

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

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

Yes

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

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

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

Full-Open Closed to Full-Open

Table 23 Fan Speed

STATE FAN SPEED OCC Low Y1 Low Y2 High W High

44

Fig. 55 Single Enthalpy Curve Boundaries

CHECKOUT

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

Power Up After the W7220 module is mounted and wired, apply power. Initial Menu Display On initial start up, Honeywell displays on the first line and economizer 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 pow- er loss or interruption. NOTE: All settings are stored in non-volatile flash memory. Status Use the Status menu (see Table 13) to check the parameter val- ues for the various devices and sensors configured. NOTE: For information about menu navigation and use of the keypad, see Interface Overview on page 34. Checkout Tests Use the Checkout menu (see page 38) to test the damper opera- tion and any configured outputs. Only items that are config- ured are shown in the Checkout menu. NOTE: For information about menu navigation and use of the keypad, see Interface Overview on page 34.

To perform a Checkout test: 1. Scroll to the desired test in the Checkout menu using the

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

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

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

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

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

TROUBLESHOOTING

Alarms The economizer module provides alarm messages that display on the 2-line LCD. NOTE: Upon power up, the module waits 60 minutes before checking for alarms. This allows time for all the configured devices (e.g. sensors, actuator) to become operational. The exception is the SAT sensor which will alarm immediately. If one or more alarms are present and there has been no keypad activity for at least 5 minutes, the Alarms menu displays and cycles through the active alarms.

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 24 Single Enthalpy and Dual Enthalpy High Limit Curves

ENTHALPY CURVE

TEMP. DRY BULB (F)

TEMP. DEWPOINT (F)

ENTHALPY (btu/lb/da)

POINT P1 POINT P2

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

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

CAUTION

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.

45

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.

NOTE: If the alarm still exists after clearing it, it is redisplayed within 5 seconds.

Staged Air Volume (SAV) with Variable Fre- quency Drive The Staged Air Volume (SAV) system utilizes a Variable Fre- quency Drive (VFD) to automatically adjust the indoor fan mo- tor speed in sequence with the units ventilation, cooling and heating operation. Per ASHRAE 90.1-2016, during the first stage of cooling operation the SAV system will adjust the fan motor to provide 66% of the design airflow rate for the unit. When the call for the second stage of cooling is required, the SAV system will allow the design airflow rate for the unit es- tablished (100%). During the heating mode, the SAV system will allow total design airflow rate (100%) operation. During ventilation mode, the SAV system will operate the fan motor at 66% speed. See Fig. 56 and 57.

Fig. 56 VFD Location

Fig. 57 Variable Frequency Drive (VFD)

Multi-Speed VFD Display Kit (Field-Installed Accessory) NOTE: The Remote VFD Keypad is part of the Multi-Speed VFD display kit (P/N: CRDISKIT002A00) which is a field-in- stalled accessory. It is not included with the 48LC 07 base unit. The VFD keypad as shown in Fig. 58 consists of the following sections.

Variable Frequency Drive (VFD)

Filter - used on 575V units only!

46

Fig. 58 VFD Keypad

ALPHA NUMERIC DISPLAY

The LCD display is backlit with 2 alpha-numeric lines. All data is displayed on the LCD. See Fig. 59.

Fig. 59 LCD Alpha Numeric Display

MENU KEY

Use the Menu key to select between Status, Quick Menu or Main Menu. The triangle icon at the bottom of the LCD dis- play indicates the currently selected mode. (See number 5 in Fig. 59.)

NAVIGATION KEYS AND STATUS LEDS

The Navigation keys and Status LEDs are detailed in Fig. 60.

Fig. 60 Navigation Keys and Status LEDs

OPERATION KEYS AND LEDS

Figure 61 details the functions of the Operating keys. An illu- minated yellow LED above the key indicates the active key.

Fig. 61 Operating Keys

CONNECTING THE KEYPAD TO THE VFD

The VFD keypad can be mounted directly to the variable fre- quency drive, provided you can easily access the front panel of the VFD. If you do not have easy access to the VFD front pan- el, use the cable included with the kit to connect the keypad to the VFD. Connecting the Keypad Directly to the VFD 1. Place the bottom of the VFD keypad into the variable fre-

quency drive as shown in Fig. 62. 2. Push the top of the VFD keypad into the variable fre-

quency drive as shown in Fig. 63.

1 Parameter number and name. 2 Parameter value.

3

Setup number shows the active setup and the edit setup. If the same set-up acts as both the active and edit set-up, only that setup number is shown (factory setting). When the active and edit setup differ, both numbers are shown in the display (SETUP 12). The flashing number indicates the edit setup.

4 The symbol in the number 4 position in the figure above indicates motor direction. The arrow point either clockwise or counter- clockwise to show the motors current direction.

5 The position of the triangle indicates the currently selected menu: Status, Quick Menu or Main Menu.

Off Reset

Hand On

Alarm

Warn.

On

Com.

OKBa ck

Auto On

StatusMenu Quick Menu

Main Menu

1-20 Motor Power [2] 0.12KW-0.16HP Setup 1

ALPHA NUMERIC DISPLAY

MENU KEY

NAVIGATION KEYS AND

STATUS LEDs

OPERATION KEYS & LEDs

1-20 Motor Power [2] 0.12KW-0.16HP Setup 1

1

3 2

4

5

1 Com. LED: Flashes when bus communications is communicating.

2 Green LED/On: Control selection is working. 3 Yellow LED/Warn.: Indicates a warning. 4 Flashing Red LED/Alarm: Indicates an alarm.

5 Arrows : Use the Up and Down arrow keys to navigate between parameter groups, parameters and within parameters. Also used for setting local reference.

6 Back key: Press to move to the previous step or layer in the navigation structure.

7 OK key: Press to select the currently displayed parameter and for accepting changes to parameter settings.

1

Hand On key: Starts the motor and enables control of the variable frequency drive (VFD) via the VFD Keypad option. NOTE: Please note that terminal 27 Digital Input (5-12 Terminal 27 Digital Input) has coast inverse as default setting. This means that the Hand On key will not start the motor if there is no 24V to terminal 27, so be sure to connect terminal 12 to terminal 27.

2 Off/Reset key: Stops the motor (off). If in alarm mode the alarm will be reset.

3 Auto On key: The variable frequency drive is controlled either via control terminals or serial communication.

Alarm

Warn.

On

Com.

OKBa ck

3

4

1

2

5

6

5

7

Off Reset

Hand On

Auto On

1 2 3

47

Fig. 62 Align Bottom of VFD Keypad with Opening in VFD Front Panel

Fig. 63 Secure Keypad in Place

Using the Cable to Connect the Keypad to the VFD The VFD keypad can be connected to the variable frequency drive via the cable included with the Multi-Speed VFD display kit (PN: CRDISKIT002A00). See Fig. 64. 1. Connect the male end of the cable to the front panel of the

variable frequency drive. Use 2 of the screws included with the kit to secure the cable to the VFD.

2. Connect the female end of the cable to the back panel of the VFD Remote keypad. Secure the cable to the remote keypad using the 2 remaining screws from the kit.

Fig. 64 VFD Remote Keypad Cable

PROGRAM THE VFD FOR 3 DISCRETE INDOOR FAN SPEEDS

NOTE: This procedure requires use of the VFD Keypad which is included as part of the field-installed Multi-Speed VFD dis- play kit (P/N: CRDISKIT002A00). If the VFD keypad is not already installed, install it. See Connecting the Keypad to the VFD for details.

IMPORTANT: The 48LC 07 units are programmed at the factory for 3 discrete indoor fan speeds. The following pro- cedure is only to be used to recover this function after an event such as a system crash.

Male Connector - connect to VFD Front Panel

Female Connector - connect to back of VFD Remote Keypad

48

Fig. 65 Keypad with Power Up Screen Displayed

To program the VFD for 3 discreet indoor fan motor speeds 1. At Power-Up:

At the first power up, the LCD displays the Select Lan- guage screen (see Fig. 65). The default setting is English. To change the language, press the OK key and use the and keys to scroll to the desired language and then press OK.

2. Selecting Regional Settings: a. Press the Off Reset key. b. Press the Menu key to move the (triangle icon) so

it is positioned over Main Menu. The display shows the following.

c. Press the OK key and the display changes to:

d. With the top row highlighted, press OK. The display changes to:

NOTE: If English is not the desired language, press OK, select the desired language and press OK again.

e. Press (Down Arrow key) once; the display changes to:

f. Press OK; the [0] is now highlighted. g. Press (Down Arrow) key once; the display changes

to:

h. Press OK

NOTE: If the Alarm 060 appears, follow Step 3 to clear the alarm. Make sure to press Off Reset when done. If there is no alarm, con- tinue at Step 4.

3. Clearing Alarm 060: External Interlock: a. Press the Menu key twice to position the (triangle

icon) over Main Menu; the display changes to:

b. Press the (Down Arrow) key until the following display appears:

c. Press OK. The display changes to:

d. Press (Down Arrow) once to highlight the bottom row and press OK. The display changes to

e. Press (Down Arrow) twice; the following display appears:

f. Press OK to highlight the number in the bracket. g. Press (Down Arrow) until the following display

appears:

h. Press OK. i. Press Off Reset. The Alarm indicator disappears.

4. Entering Grid Type: a. Press the Menu key to move the (triangle icon) so

it is positioned over Main Menu. The display shows the following:

b. Press OK twice; the display changes to:

c. Press (Down Arrow) three times to reach the fol- lowing display:

d. Press OK to highlight the number in the bracket and then use the and (Up and Down Arrow) keys to select the desired voltage and Hertz for the unit.

e. Press OK to accept the selection and continue. 5. Entering Motor Data:

a. Press the Menu key to move the (triangle icon) so it is positioned over Main Menu. The display shows the following:

b. Press (Down Arrow) once to highlight the bottom row.

c. Press OK, the display changes to:

0** Operation / Display 1** Load and Motor

00* Basic Settings 01* Set-up Operations

001 Language [0] English

003 Regional Settings [0] International

003 Regional Settings [1] North America

Off Reset

Hand On

Alarm

Warn.

On

Com.

OKBa ck

Auto On

StatusMenu Quick Menu

Main Menu

Select language English [0] English SETUP 1

0** Operation / Display 1** Load and Motor

4** Limits / Warnings 5** Digital In/Out

50* Digital I/O Mode 51* Digital Inputs

510 Terminal 18 Digital In [8] Start

512 Terminal 27 Digital In [7] External Interlock

512 Terminal 27 Digital In [0] No operation

00* Basic Settings 01* Set-up Operations

001 Language [0] English

006 Grid Type [102] 200-240V/60Hz

0** Operation / Display 1** Load and Motor

10* General Settings 11* Motor Selection

49

d. Press (Down Arrow) twice to reach the following display:

e. Press OK; the following display appears:

NOTE: The number in the bracket may be different from what is shown above.

f. Press OK and then use the and (Up and Down Arrow) keys to scroll to the proper motor horsepower. Press OK again to set the selected hp.

g. Press (Down Arrow) once, the following display appears:

h. Press OK to highlight the voltage value. Use the and (Up and Down Arrow) keys to select the nameplate voltage. Press OK again to set the selected voltage.

i. Press (Down Arrow) once to display the following:

j. Press OK to highlight the Frequency value and then use the and (Up and Down Arrow) keys to select the nameplate Hz. Press OK again to set the selected Hz.

k. Press (Down Arrow) once to display the following:

l. Press OK to highlight the Current value and then use the and (Up and Down Arrow) keys to select the Max Amps value provided. Press OK again to set the selected Max Amps.

NOTE: The Max Amps is greater than the nameplate value. Check the VFD Unit Parameters (see Table 25 on page 52) and use the value listed for the given unit in the column labeled Mo- tor Current Must-Hold Amps.

m. Press (Down Arrow) once to display the following:

n. Press OK to highlight the rpm value and then use the and (Up and Down Arrow) keys to select the nameplate rpm. Press OK again to set the selected rpm.

6. Entering Parameters for 1-71, 1-73, 1-82, and 1-90: a. Press the Menu key to move the B(triangle icon) so it

is positioned over Main Menu. The display shows the following:

b. Press (Down Arrow) once to highlight the bottom row.

c. Press OK, the display changes to:

d. Press (Down Arrow) until the following display appears:

e. Press OK, the following display appears:

f. Press OK to highlight the number and then use the and (Up and Down Arrow) keys to select the num- ber provided in Table 25. Press OK again to set the selected value.

g. Press (Down Arrow) twice, the following display appears:

h. Press OK to highlight the number in the bracket and then use the and (Up and Down Arrow) keys to select the number provided in Table 25. Press OK again to set the selected value.

i. Press the Back key once, the following display appears:

j. Press (Down Arrow) once, the following display appears:

k. Press OK, the following display appears:

l. Press (Down Arrow) once, the following display appears:

m. Press OK to highlight the number and then use the and (Up and Down Arrow) keys to select the num- ber provided in Table 25. Press OK again to set the selected value.

n. Press the Back key once, the following display appears:

o. Press (Down Arrow) once, the following display appears:

p. Press OK, the following display appears:

q. Press OK to highlight the number in the bracket then use the and (Up and Down Arrow) keys to select the number provided in Table 25. Press OK again to set the selected value.

11* Motor Selection 12* Motor Data

1-20 Motor Power [9] 1.5kW - 2 hp

1-22 Motor Voltage 230V

1-23 Motor Frequency 60Hz

1-24 Motor Current 6.61A

1-25 Motor Nominal Speed 1740rpm

0** Operation / Display 1** Load and Motor

10* General Settings 11* Motor Selection

16* Load Depen. Setting 17* Start Adjustments

1-71 Start Delay 2.0s

1-73 Flying Start [1] Enabled

16* Load Depen. Setting 17* Start Adjustments

17* Start Adjustments 18* Stop Adjustments

1-80 Function at Stop [0] Coast

1-82 Min Speed for Functio 1.0 Hz

17* Start Adjustments 18* Stop Adjustments

18* Stop Adjustments 19* Motor Temperature

1-90 Motor Thermal Prote [4] ETR trip 1

50

7. Setting References: a. Press the Menu key to move the (triangle icon) so

it is positioned over Main Menu. The display shows the following:

b. Press (Down Arrow) three times, the following display appears:

c. Press OK, the following display appears:

d. Press OK again, the following display appears:

NOTE: If the bottom row displays a number other than 0.000, press OK and use the and (Up and Down Arrow) key to select 0.000.

e. Press (Down Arrow) once, the following display appears:

NOTE: If the bottom row displays a number other than 60.000, press OK and use the and (Up and Down Arrow) key to select 60.000.

f. Press the Back key until the following display appears:

g. Press (Down Arrow) once to move the highlight to the bottom row and then press OK. The following dis- play appears:

h. Press OK once to highlight the number in the bracket. Press OK again; the highlight moves to the current percent value. Use the and (Up and Down Arrow) keys and the table below to enter the required Preset Reference values.

8. Setting the Ramp Time: a. Press the Back key until the following display

appears:

b. Press (Down Arrow) twice, the following display appears:

c. Press OK, the following display appears:

d. Press OK again to highlight the bottom row and use the and (Up and Down Arrow) keys to select 10.00s. Press OK again to set the selected Ramp up Time.

e. Press (Down Arrow) once, the following display appears:

f. Press OK again to highlight the bottom row and use the and (Up and Down Arrow) keys to select 10.00s. Press OK again to set the selected Ramp Down Time.

9. Setting Limits: a. Press the Back key until the following display

appears:

b. Press (Down Arrow) once, the following display appears:

c. Press OK, the following display appears:

d. Press OK again, the following display appears:

e. Press (Down Arrow) once, the following display appears:

f. Press (Down Arrow) again, the following display appears:

NOTE: Press OK to highlight the Hz value and then use the and (Up and Down Arrow) keys to enter the required values.

g. Press (Down Arrow) once, the following display appears:

NOTE: Press OK to highlight the % value and then use the and (Up and Down Arrow) keys to enter the required value. See Table 25 for proper selection of the value for this parameter, then press OK to set the selected value.

0** Operation / Display 1** Load and Motor

2** Brakes 3** Reference / Ramps

30* Reference Limits 31* References

3-02 Minimum Reference 0.000

3-03 Maximum Reference 60.000

30* Reference Limits 31* References

3-10 Preset Reference [0]0.00%

[0]0.00% Stop

[1]LL.LL% Low Speed (see Table 25, column labeled Preset References 310[1] for the proper % for each unit)

[2]MM.MM% Medium Speed (see Table 25, column labeled Preset References 310[2] for the proper % for each unit)

[3]100% Override (High Speed)

[4]100% High Speed (100% or close to 100% to achieve the required CFM at high speed)

[5]0.00% Stop [6]0.00% Stop [7]0.00% Stop

30* Reference Limits 31* References

31* References 34* Ramp 1

3-41 Ramp 1 Ramp up Time 3.00s

3-42 Ramp 1 Ramp Down Time 3.00s

2** Brakes 3** Reference / Ramps

3** Reference / Ramps 4** Limits / Warnings

41* Motor Limits 44* Adj. Warning 2

4-10 Motor Speed Direction [2] Both Directions

4-12 Motor Speed Low Limi 0.0Hz

4-14 Motor Speed High Limi 65.0Hz

4-18 Current Limit 110%

51

h. Press (Down Arrow) once, the following display appears:

NOTE: Press OK to highlight the Hz value and then use the and (Up and Down Arrow) keys to enter the required values. 10. Setting Digital Inputs:

a. Press the Back key until the following display appears:

b. Press (Down Arrow) once, the following display appears:

c. Press OK, the following display appears:

d. Press (Down Arrow) once to move the highlight to the bottom row and then press OK. The following dis- play appears:

e. Press (Down Arrow) again. The following display appears:

f. Press (Down Arrow) again. The following display appears:

g. Press (Down Arrow) again. The following display appears:

NOTE: By pressing OK, the number in the bracket can be changed until the desired number appears. Press OK again to set the selected value. 11. Setting Analog Inputs:

a. Press the Back key until the following display appears:

b. Press (Down Arrow) until the following display appears:

c. Press OK, the following display appears:

d. Press (Down Arrow) once to move the highlight to the bottom row and then press OK. The following dis- play appears:

e. Press (Down Arrow) once to move the highlight to the bottom row and then press OK. The following dis- play appears:

f. Press (Down Arrow) once to move the highlight to the bottom row and then press OK. The following dis- play appears:

g. Press (Down Arrow) once to move the highlight to the bottom row and then press OK. The following dis- play appears:

12. Setting Reset Mode and RFI Filter: a. Press the Back key until the following display

appears:

b. Press (Down Arrow) until the following display appears:

c. Press OK, the following display appears:

d. Press (Down Arrow) twice. The following display appears:

e. Press OK, the following display appears:

f. Press OK to highlight the number in the bracket. g. Use the and (Up and Down Arrow) keys to

change the number to 3 for 3 automatic resets and then press OK. The display changes to:

h. Press (Down Arrow) once, the following display appears:

i. Press OK to highlight the number of seconds and use the and (Up and Down Arrow) keys to select 600 seconds. Press OK again to set the selected value.

4-19 Max Output Frequency 65.0Hz

3** Reference / Ramps 4** Limits / Warnings

4** Limits / Warnings 5** Digital In/Out

50* Digital I/O mode 51* Digital Inputs

5-10 Terminal 18 Digital In [8] Start

5-11 Terminal 19 Digital In [16] Preset ref bit 0

5-12 Terminal 27 Digital In [17] Preset ref bit 1

5-13 Terminal 29 Digital In [18] Preset ref bit 2

4** Limits / Warnings 5** Digital In/Out

5** Digital In/Out 6** Analog In/Out

6** Analog In/Out 61* Analog Input 53

6-10 Terminal 53 Low Voltage 2V

6-11 Terminal 53 High Voltage [10V]

6-14 Set Min Reference [0 Hz]

6-15 Set Max Reference [60 Hz]

0** Operation / Display 1** Load and Motor

13** Smart Logic 14** Special Functions

140* Inverter Switching 141* Mains On/Off

141* Mains On/Off 142* Reset Functions

14-20 Reset Mode [0] Manual reset

14-20 Reset Mode [3] Automatic reset x 3

14-21 Automatic Restart T 10s

52

j. Press the Back key once, the following display appears:

k. Press (Down Arrow) twice, the following display appears:

l. Press OK, the following display appears:

m. Press OK to highlight the number in the bracket and use the and (Up and Down Arrow) keys to select [0]. Press OK again to set the selected value.

13. To Complete Reprogramming: a. Press the Auto On key before disconnecting the VFD

Remote Keypad from the variable frequency drive.

141* Mains On/Off 142* Reset Functions

144* Energy Optimising 145* Environment

14-50 RFI Filter [1] On

Table 25 VFD Unit Parameters - 48LC 07 Units

REGIONAL SETTINGS

GRID TYPE

MOTOR POWER

MOTOR VOLTAGE

MOTOR FREQUENCY

(Hz)

MOTOR CURRENT

(MUST-HOLD AMPS)

MOTOR NOMINAL

SPEED (RPM)

Motor Option Voltage Motor

P/N VFD

Carrier P/N

VFD Mfr P/N

0-03 0-06 1-20 1-22 1-23 1-24 1-25

STD 208/230V HD56FR233 HK30WA370 131L9795 [1] [102] [9] 230 60 5.8 1695

460V HD56FR463 HK30WA376 131L9863 [1] [122] [9] 460 60 2.9 1690 575V HD56FR579 HK30WA382 131N0225 [1] [132] [9] 575 60 3.1 1690

MID 208/230V HD56FR233 HK30WA370 131L9795 [1] [102] [9] 230 60 5.8 1695

460V HD56FR463 HK30WA376 131L9863 [1] [122] [9] 460 60 2.9 1690 575V HD56FR579 HK30WA382 131N0225 [1] [132] [9] 575 60 3.1 1690

HIGH 208/230V HD58FE654 HK30WA371 131L9796 [1] [102] [10] 230 60 9.2 1735

460V HD58FE654 HK30WA377 131L9864 [1] [122] [10] 460 60 4.2 1735 575V HD58FE577 HK30WA383 131N0227 [1] [132] [11] 575 60 4.9 1710

START DELAY (SEC)

FLYING START

MIN SPEED

FOR FUNCTION

(Hz)

MOTOR THERMAL

PROTECTION

PRESET REFERENCE

Motor Option Voltage 1-71 1-73 1-82 1-90 3-10 [0] 3-10 [1] 3-10 [2] 3-10 [3] 3-10 [4] 3-10 [5] 3-10 [6] 3-10 [7]

STD 208/230V 2.0 [1] 1.0 [4] 0% 66.50% 66.50% 100% 100% 0% 0% 0%

460V 2.0 [1] 1.0 [4] 0% 66.50% 66.50% 100% 100% 0% 0% 0% 575V 2.0 [1] 1.0 [4] 0% 66.50% 66.50% 100% 100% 0% 0% 0%

MID 208/230V 2.0 [1] 1.0 [4] 0% 66.50% 66.50% 100% 100% 0% 0% 0%

460V 2.0 [1] 1.0 [4] 0% 66.50% 66.50% 100% 100% 0% 0% 0% 575V 2.0 [1] 1.0 [4] 0% 66.50% 66.50% 100% 100% 0% 0% 0%

HIGH 208/230V 2.0 [1] 1.0 [4] 0% 66.50% 66.50% 100% 100% 0% 0% 0%

460V 2.0 [1] 1.0 [4] 0% 66.50% 66.50% 100% 100% 0% 0% 0% 575V 2.0 [1] 1.0 [4] 0% 66.50% 66.50% 100% 100% 0% 0% 0%

RAMP UP TIME (SEC)

RAMP DOWN TIME (SEC)

CURRENT LIMIT

TERMINAL 18 DIGITAL INPUT

TERMINAL 19 DIGITAL INPUT

TERMINAL 27 DIGITAL INPUT

TERMINAL 29 DIGITAL INPUT

Motor Option Voltage 3-41 3-42 4-18 5-10 5-11 5-12 5-13

STD 208/230V 10.00 10.00 100% [8] [16] [17] [18]

460V 10.00 10.00 100% [8] [16] [17] [18] 575V 10.00 10.00 100% [8] [16] [17] [18]

MID 208/230V 10.00 10.00 100% [8] [16] [17] [18]

460V 10.00 10.00 100% [8] [16] [17] [18] 575V 10.00 10.00 100% [8] [16] [17] [18]

HIGH 208/230V 10.00 10.00 100% [8] [16] [17] [18]

460V 10.00 10.00 100% [8] [16] [17] [18] 575V 10.00 10.00 100% [8] [16] [17] [18]

53

Smoke Detectors Smoke detectors are available as factory-installed options on 48LC models. Smoke detectors may be specified for supply air only, for return air without or with economizer, or in combina- tion of supply air and return air. All components necessary for operation are factory-provided and mounted. The unit is facto- ry-configured for immediate smoke detector shutdown opera- tion; additional wiring or modifications to the Integrated Stag- ing Control (ISC) board may be necessary to complete the unit and smoke detector configuration to meet project requirements. Units equipped with factory-optional return air smoke detec- tors require a relocation of the sensor module at unit installa- tion. See Fig. 66 for the as-shipped location.

COMPLETING INSTALLATION OF RETURN AIR SMOKE SENSOR

1. Unscrew the two screws holding the return air smoke detector assembly. See Fig. 67, 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. 67, Step 2.

3. Screw the sensor and detector plate into its operating posi- tion using screws from Step 1. See Fig. 67, Step 3.

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

ADDITIONAL APPLICATION DATA

Refer to Factory-Installed Smoke Detectors for Small and Me- dium Rooftop Units 2 to 25 Tons for discussions on additional control features of these smoke detectors, including multiple unit coordination.

Fig. 66 Return Air Smoke Detector, Shipping Position

Fig. 67 Completing Installation of Return Air Smoke Sensor

Table 25 VFD Unit Parameters - 48LC 07 Units (cont)

TERMINAL 53 LOW

VOLTAGE

TERMINAL 53 HIGH

VOLTAGE

TERMINAL 53 LOW

REFERENCE

TERMINAL 53 HIGH

REFERENCE

RESET MODE

AUTO. RESTART TIME (S)

RFI FILTER

Motor Option Voltage 6-10 6-11 6-14 6-15 14-20 14-21 14-50

STD 208/230V 2 [10] 0 [60] [3] 600 [0]

460V 2 [10] 0 [60] [3] 600 [0] 575V 2 [10] 0 [60] [3] 600 [0]

MID 208/230V 2 [10] 0 [60] [3] 600 [0]

460V 2 [10] 0 [60] [3] 600 [0] 575V 2 [10] 0 [60] [3] 600 [0]

HIGH 208/230V 2 [10] 0 [60] [3] 600 [0]

460V 2 [10] 0 [60] [3] 600 [0] 575V 2 [10] 0 [60] [3] 600 [0]

RETURN AIR SMOKE DETECTOR

(AS SHIPPED)

Step 1 Step 2 Step 3

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480218-01 Printed in U.S.A. Form 48LC-7-06SI Pg 54 6-19 Replaces: 48LC-7-05SI

Carrier Corporation 2019

Step 13 Adjust Factory-Installed Options SMOKE DETECTORS

Smoke detector(s) will be connected at the Integrated Staging Control (ISC) board, at terminals marked Smoke Shutdown. Remove jumper JMP 3 when ready to energize unit.

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

set on curb) EconoMi$er X (with control) Power Exhaust Outdoor enthalpy sensor Differential enthalpy sensor CO2 sensor Temperature and Humidity sensors Louvered hail guard Phase monitor control

Refer to separate installation instructions for information on in- stalling these accessories. See Price Pages for a complete list of field-installed accessories.

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

32 x 1/64 = 1/2-in. deflection.

BELT FORCE DEFLECTION METHOD

Check the belt tension with a spring-force belt force deflection gage (available from drive belt manufacturer). 1. Place a straightedge along the belt between the two pul-

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

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

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

4. Adjust the belt tension as needed.

Adjust belt tension by loosing the motor mounting plate front bolts and rear bolt (see Fig. 69) and slide the plate towards the fan (to reduce tension) or away from the fan (to increase tension). Ensure the blower shaft and motor shaft are parallel to each other (pulleys aligned). Tighten all bolts securely when finished.

Fig. 68 V-Belt Force Label

BELT TENSION METHOD

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

Fig. 69 Belt Drive Motor Mounting

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

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. 04-53480218-01 Printed in U.S.A. Form 48LC-7-06SI Pg CL-1 6-19 Replaces: 48LC-7-05SI

START-UP CHECKLIST FOR 48LC SINGLE PACKAGE ROOFTOP UNIT (Remove and Store in 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 Temperature _____________ F

PRESSURES Gas Inlet Pressure _____________IN. WG Gas Manifold Pressure STAGE 1 _____________IN. WG

STAGE 2 _____________IN. WG

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. 04-53480218-01 Printed in U.S.A. Form 48LC-7-06SI Pg CL-2 6-19 Replaces: 48LC-7-05SI

Carrier Corporation 2019

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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 NOTE: Units equipped with either SystemVu or RTU Open controls have Service Test menus or modes that can assist with the Humidi-MiZer System Start-Up function and provide the means to make the observations listed for this 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 50F to 55F range (Y/N) _____ D. LSV solenoid energized (valve closes) (Y/N) _____

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

OBSERVE A. Suction pressure increases to normal cooling level B. Discharge pressure decreases (35 to 50 psi) (Limited by 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 W1 restore unit to dehumid mode (Y/N) _____ 9. Open humidistat input compressor and outdoor fan stop; LSV and DSV solenoids de

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