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Carrier 48LC 07 Installation Instructions PDF
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
2
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.
3
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)
6
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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