Carrier OMNIZONE 50BV020 Installation And Service Instructions Manual Download

Page: 1 / 68

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53500001-01

Printed in U.S.A.

Form 50BV-3SI

Pg 1

10-08

Replaces: 50BV-2SI

Installation, Start-Up and

Service Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS

. . . . . . . . . . . . . . . . . . . . .1,2

GENERAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

MAJOR SYSTEM COMPONENTS

. . . . . . . . . . . . . . . . . 2

Constant Volume (CV) Units

. . . . . . . . . . . . . . . . . . . . . . 2

Variable Air Volume (VAV) Units

. . . . . . . . . . . . . . . . . . 2

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Step 1 — Complete Pre-Installation Checks

. . . . . . 3

• EXAMINE THE UNIT

• UNIT STORAGE

• MODULAR UNITS

Step 2 — Rig and Place Unit

. . . . . . . . . . . . . . . . . . . . . 3

• REMOVE PACKAGING

• UNIT LOCATION

• UNIT PLACEMENT

• ACOUSTICAL CONSIDERATIONS

• ASSEMBLING MODULAR UNITS

Step 3 — Install Ductwork

. . . . . . . . . . . . . . . . . . . . . . . 19

• DUCT STATIC PRESSURE PROBE AND TUBING

(VAV Only)

• DUCT HIGH-STATIC (DHS) LIMIT SWITCH (VAV Only)

Step 4 — Make Piping Connections

. . . . . . . . . . . . . 21

• CONDENSER WATER PIPING (Water-Cooled Only)

• EVAPORATOR CONDENSATE DRAIN

• HOT WATER HEATING COIL (Optional)

• WATER ECONOMIZER (Optional)

• REMOTE REFRIGERANT PIPING

(Remote Air-Cooled Only)

Step 5 — Complete Electrical Connections

. . . . . . 24

• POWER WIRING

• CONTROL WIRING (CV Only)

• REMOTE CONDENSER FAN CONTACTOR WIRING

• CONTROL WIRING (VAV Only)

• SUPPLY AIR TEMPERATURE SENSOR (SAT)

• SMOKE DETECTOR/FIRE ALARM SHUTDOWN (FSD)

• ALARM (ALARM) AND WARNING (WARN) OUTPUTS

• REMOTE OCCUPANCY (ROCC)

• RETURN AIR TEMPERATURE SENSOR (RAS)

START-UP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48

General

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

• CRANKCASE HEATERS

• CONFIRM THE INPUT POWER PHASE SEQUENCE

• INTERNAL WIRING

• RETURN-AIR FILTERS

• COMPRESSOR MOUNTING

• REFRIGERANT SERVICE PORTS

CV Unit Start-Up

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

• EVAPORATOR FAN

• COOLING

• HEATING (Heat Pump Units Only)

VAV Unit Start-Up

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

• PERFORM AUTOMATIC RUN TEST

• CHECK VFD

• POWER UP LID DISPLAY

Page

• LOG ON TO THE LID DISPLAY

• CHANGE THE DEFAULT PASSWORD

• SET THE CLOCK

• CONFIGURE SCHEDULES

• PROGRAM SET POINTS

• CHECK SYSTEM PARAMETERS

• DISPLAY ALARM HISTORY

• CONFIGURE THE CUSTOM PROGRAMMING

SELECTIONS

• SET CONTROLLER ADDRESS

• LOG OFF FROM THE CONTROLLER

Sequence of Operation (CV Only)

. . . . . . . . . . . . . . . 47

• WATER ECONOMIZER COOLING

Sequence of Operation (VAV Only)

. . . . . . . . . . . . . . 48

• SUPPLY FAN

• COMPRESSOR COOLING

• WATER ECONOMIZER COOLING

• COOLING RESET

Diagnostic Features (CV Only)

. . . . . . . . . . . . . . . . . . 48

VAV Control and VFD Diagnostics

. . . . . . . . . . . . . . . 48

SERVICE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Compressor Rotation

. . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Fan Motor Replacement

. . . . . . . . . . . . . . . . . . . . . . . . . 49

MAINTENANCE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-51

Cleaning Unit Exterior

. . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Coil Cleaning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Air Filters

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Condensate Drains

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Water-Cooled Condensers

. . . . . . . . . . . . . . . . . . . . . . 49

• GRAVITY FLOW METHOD

• FORCED CIRCULATION METHOD

Fan Motor Lubrication

. . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Fan Bearing Lubrication

. . . . . . . . . . . . . . . . . . . . . . . . 50

Fan Sheaves

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

• ALIGNMENT

Evaporator Fan Performance Adjustment

. . . . . . . 51

• BELT TENSION ADJUSTMENT

Charging the System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

• REMOTE AIR-COOLED UNITS

Compressor Oil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . 51-65

Forcing and Clearing an Input or Output

(VAV only)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

START-UP CHECKLIST

. . . . . . . . . . . . . . . . . . .CL-1, CL-2

SAFETY CONSIDERATIONS

Installing, starting up, and servicing air-conditioning

components and equipment can be dangerous. Only trained,

qualified installers and service mechanics should install, start-

up, and service this equipment.

When working on the equipment, observe precautions in

the literature and on tags, stickers, and labels attached to the

OMNIZONE™

50BV020-064

Water-Cooled and Remote Air-Cooled

Indoor Self-Contained Systems and

Water-Cooled Heat Pumps

Summary of Contents for OMNIZONE 50BV020

Page 1: ...CV Unit Start Up 31 EVAPORATOR FAN COOLING HEATING Heat Pump Units Only VAV Unit Start Up 42 PERFORM AUTOMATIC RUN TEST CHECK VFD POWER UP LID DISPLAY Page LOG ON TO THE LID DISPLAY CHANGE THE DEFAULT...

Page 2: ...e vent compressor short cycling Low Pressure Bypass Timer bypasses the low pressure switch for 90 seconds to avoid nuisance trips during cold start up High Pressure Switch Delay is a one second delay...

Page 3: ...lar units with a fork truck using the baserails provided or use spreader bars and lifting straps as shown in Fig 1 For single piece units use spreader bars and rigging straps if lifting with a crane t...

Page 4: ...hes mm 2 VAV models 50BVJ are rear return top supply only 3 Compressor controls and condenser access are through front panels 4 Field power connections are 1 3 4 inches Control connections are 7 8 inc...

Page 5: ...r connections are 1 3 4 inches Control connections are 7 8 inches 5 Discharge hot gas connections are 1 1 8 in OD 6 Liquid line connections are 7 8 in OD 7 Optional blower orientation is selected in m...

Page 6: ...11 00 3 19 5 50 65 50 54 75 2 00 23 25 5 00 51 63 1 50 1 50 LIFTING SUPPORT RAIL 69 50 SHIPPING SECTION 10 75 3 75 B A C D a50 8201 NOTES 1 Dimensions in inches 2 All units are rear return airflow con...

Page 7: ...m service clearances are as follows a Front and rear 30 in 762 mm b Left or right side 65 in 1651 mm for coil removal c Side opposite coil removal 20 in 508 mm CONNECTIONS REPLACEMENT FILTERS EIGHT 8...

Page 8: ...49 75 21 75 9 88 19 75 9 88 111 00 3 19 5 50 65 50 65 50 4 00 54 75 2 00 2 00 23 25 5 00 51 63 1 50 1 50 LIFTING SUPPORT RAIL 69 50 SHIPPING SECTION 69 50 SHIPPING SECTION 10 75 3 75 A B C D NOTES 1 D...

Page 9: ...R IN 2 1 2 in FPT 3 in FPT 3 in FPT C CONDENSATE DRAIN 1 1 4 in FPT 1 1 4 in FPT 1 1 4 in FPT D ECONOMIZER DRAIN 1 1 4 in FPT 1 1 4 in FPT 1 1 4 in FPT NOTES 1 Dimensions in inches 2 All units are rea...

Page 10: ...ensions in inches 2 All units are rear return airflow configuration 3 Constant volume units are available with front or rear air supply 4 VAV units 50BVX are available with rear supply only 5 Recommen...

Page 11: ...gn Manual Part 3 5 Recommended minimum service clearances are as follows a Front and rear 30 in 762 mm b Left or right side 65 in 1651 mm for coil removal c Side opposite coil removal 20 in 508 mm CON...

Page 12: ...NG SECTION 69 50 SHIPPING SECTION 10 75 E F A B C D A B C D Fig 10 50BVU X044 064 High Boy Dimensions NOTES 1 Dimensions in inches 2 All units are rear return airflow configuration 3 CV units are avai...

Page 13: ...n 1651 mm for coil removal CONNECTIONS REPLACEMENT FILTERS SIXTEEN 16 AT 17 x 27 x 4 INCHES UNIT SIZE 044 054 064 A LIQUID LINE CIRCUIT 1 2 7 8 in OD 7 8 in OD 7 8 in OD B LIQUID LINE CIRCUIT 3 4 7 8...

Page 14: ...20 028 with Optional Waterside Economizer Dimensions NOTES 1 Dimensions in inches mm 2 Refer to base unit certified drawing for additional unit dimensions service clearance and alternate airflow confi...

Page 15: ...034 with Optional Waterside Economizer Dimensions NOTES 1 Dimensions in inches mm 2 Refer to base unit certified drawing for additional unit dimensions service clearances and alternate airflow configu...

Page 16: ...0 40 40 40 40 40 40 FILTER ECONOMIZER SECTION EACH NUMBER OF SECTIONS 1 2 2 2 1 2 2 2 FILTER SECTION 310 310 310 310 310 310 310 310 ECONOMIZER OPTION 200 200 200 200 200 200 200 200 FAN SECTION EACH...

Page 17: ...l RPM 5 HP 3450 3450 3450 3450 Fan Drive RPM Range Std Fan Drive 1 5 2 3 HP 753 952 753 952 753 952 Std Fan Drive 5 HP 967 1290 967 1290 967 1290 967 1290 Med Static Fan Drive 1 5 2 3 HP 872 1071 872...

Page 18: ...960 Standard 10 15 20 HP Med Static 7 5 HP 805 991 805 991 805 991 805 991 Med Static 10 15 20 HP High Static 7 5 HP 960 1146 960 1146 960 1146 960 1146 High Static 10 15 20 HP 1119 1335 1119 1335 11...

Page 19: ...onomizer section facing out and away from the main air conditioning section 2 If the unit has 2 filter economizer and 2 main air conditioning sections 40 through 60 ton units bolt the remaining filter...

Page 20: ...point should be located near the end of the main supply trunk duct in a position free from turbulence effects and at least 10 duct di ameters downstream and 4 duct diameters upstream from any major t...

Page 21: ...endent refrigerant circuits to operate while still modulating condenser water flow in response to loop water temperature A glycol solution should be used if ambient temperatures are expected to fall b...

Page 22: ...o avoid the build up of dirt and bacterial growth HOT WATER HEATING COIL Optional A factory installed one or 2 row hot water heating coil is available as an option The coil is supplied with hot water...

Page 23: ...economizer waterside pressure drop data The waterside economizer can also be ordered without factory installed piping or controls This offers additional flexibility for specific applications In this c...

Page 24: ...tion instructions for additional guidance Remote air cooled 50BV units only are shipped with a dry nitrogen holding charge After refrigerant connections are made release nitrogen evacuate leak test an...

Page 25: ...2 464 455 3 1371 3 457 7 457 IMPORTANT If supply voltage phase imbalance is more than 2 contact the local electric utility com pany immediately UNIT SIZE 50BVC E J K Q NOMINAL VOLTAGE 3 Ph 60 Hz VOLTA...

Page 26: ...5 518 633 12 4 80 12 4 80 2 7 5 7 8 68 3 80 65 2 10 10 3 73 3 80 70 2 15 15 4 83 5 90 80 4 054 208 230 187 253 47 1 318 47 1 318 2 7 5 19 4 239 0 250 227 2 10 25 8 251 8 250 240 0 15 38 6 277 4 300 26...

Page 27: ...typical thermostat wiring 50BVT U V044 064 Only Units larger than 30 tons have 4 independent refrigerant circuits These units can be controlled using a standard commercial 2 stage thermostat In this c...

Page 28: ...The sensor should be located in the supply air duct about 1 ft from the unit discharge connection Fig 30 On units with 2 fans locate the sensor ap proximately 5 duct diameters downstream from pair of...

Page 29: ...7 Modular Unit VAV Control Panel Fig 28 Single Piece Unit VAV Control Panel Fig 29 Supply Return Air Temperature Sensor P N HH79NZ043 Fig 30 Supply Air Temperature Sensor Installation Unit Discharge L...

Page 30: ...The 50BVT U V W X034 064 units include crankcase heaters Crankcase heaters are ener gized as long as there is power to the unit and the compressor is not operating Wait 24 hours before starting the c...

Page 31: ...cycle mode Set the thermostat below room temperature and confirm that the compressors and fan turn off Table 13 Fan Performance 50BVC E Q020 LEGEND NOTES 1 Units are available with the following motor...

Page 32: ...7 000 604 774 0 87 666 906 1 02 726 1029 1 16 784 1170 1 32 841 1311 1 48 7 500 634 916 1 03 693 1057 1 19 750 1189 1 34 805 1330 1 50 858 1480 1 67 8 000 667 1085 1 22 723 1226 1 38 777 1377 1 55 82...

Page 33: ...1664 1 93 816 1827 2 12 863 1989 2 31 908 2152 2 50 952 2323 2 69 10 000 802 1908 2 21 848 2080 2 41 892 2251 2 61 936 2422 2 81 978 2624 3 01 10 500 835 2179 2 53 879 2350 2 73 921 2531 2 93 963 2742...

Page 34: ...59 2 59 822 2451 2 81 864 2642 3 03 906 2833 3 25 946 3024 3 47 12 000 805 2533 2 90 848 2733 3 13 889 2933 3 36 929 3133 3 59 968 3333 3 82 12 500 835 2842 3 26 877 3042 3 49 917 3251 3 73 955 3460 3...

Page 35: ...8 780 8 260 9 91 810 8 561 10 44 839 8 990 10 97 868 9 427 11 50 13 000 777 8 595 10 49 806 9 050 11 04 835 9 504 11 59 863 9 949 12 14 891 10 403 12 69 13 500 804 9 572 11 68 832 10 043 12 25 860 10...

Page 36: ...8 1050 9 915 12 09 1076 10 257 12 51 11 500 988 9 812 11 97 1014 10 155 12 39 1040 10 506 12 82 1065 10 848 13 23 1090 11 207 13 67 12 000 1006 10 771 13 14 1031 11 130 13 58 1056 11 490 14 02 1080 11...

Page 37: ...40 691 3990 4 73 18 000 543 3001 3 56 584 3325 3 94 625 3640 4 32 664 3955 4 69 700 4252 5 04 19 000 568 3474 4 12 607 3815 4 53 646 4147 4 92 684 4488 5 32 720 4820 5 72 19 500 580 3728 4 42 619 407...

Page 38: ...78 5 08 679 4628 5 49 715 4968 5 89 749 5299 6 29 20 000 617 4226 5 01 655 4584 5 44 691 4933 5 85 726 5282 6 27 761 5654 6 71 20 500 629 4505 5 34 665 4872 5 78 701 5238 6 21 736 5618 6 67 770 5980 7...

Page 39: ...932 7 048 8 46 962 7 362 8 83 991 7 676 9 21 1019 7 999 9 60 1047 8 330 9 99 20 000 940 7 423 8 91 969 7 746 9 29 997 8 060 9 67 1025 8 253 10 07 1053 8 578 10 46 20 500 946 7 798 9 36 975 8 121 9 74...

Page 40: ...8 34 754 7 380 8 85 784 7 798 9 36 815 8 225 9 87 845 8 510 10 38 25 000 750 7 816 9 38 780 8 260 9 91 810 8 561 10 44 839 8 990 10 97 868 9 427 11 50 26 000 777 8 595 10 49 806 9 050 11 04 835 9 504...

Page 41: ...9 238 11 27 1024 9 572 11 68 1050 9 915 12 09 1076 10 257 12 51 23 000 988 9 812 11 97 1014 10 155 12 39 1040 10 506 12 82 1065 10 848 13 23 1090 11 207 13 67 24 000 1006 10 771 13 14 1031 11 130 13 5...

Page 42: ...in edit mode The display will show 2 0 Global Dictionary OMNIZONE 9 Press The display will show Compressor Stages 2 00 sizes 020 034 4 00 sizes 044 064 10 If the number of compressor stages displayed...

Page 43: ...ed alarm LED will be lit this is normal 2 If the unit access panel for power and controls is still on the unit remove it in order to view the control modules during start up 3 Switch the main unit pow...

Page 44: ...e is entered in military time for example 14 59 for 2 59 pm Press then press the button The LID display will show Day of Week 1 5 Enter the day of week The numbers 1 through 7 corre spond to the days...

Page 45: ...is the pressure set point below which the fan is con sidered to be off 5 Press The LID display will show Occupied Hi Setpoint 0 40 in H2O This is the pressure set point above which the fan is con sid...

Page 46: ...UE UNITS STATUS FORCE NAME OMNIZONE HWP01 32 Hardware points Table 1 Supply Air Temperature 67 dF SAT Duct Static Pressure 0 2 in H2O DSP Comp Status MUX 1 86 Volts CSMUX Fire Alarm ShutDown Enable FS...

Page 47: ...oil is powered by the energy man agement building automation system whose contacts are in series with the R 24 v ac terminal with potential across C transformer common With this terminal open power wi...

Page 48: ...l also turn on When ROCC is turned off the TIMECLOCK point will turn off within 60 seconds Supply Fan Shutdown If the unoccupied demand is satis fied and TIMECLOCK and ROCC are off and disabled OKFAN...

Page 49: ...y also be used to help re move grease and dirt Steam cleaning is NOT recommend ed After cleaning use a fin comb of the correct fin spacing when straightening mashed or bent coil fins Units installed i...

Page 50: ...balanced To change the drive ratio follow the steps in the Evaporator Fan Performance Adjustment section page 51 After 1 to 3 minutes of operation check the belt tension Also check tension frequently...

Page 51: ...ength of interconnecting piping and vertical separa tion between the indoor unit and the condenser s Table 25A Minimum Operating Charge lb 50BVE K Units Matched with 09DK Condensers Table 25B Minimum...

Page 52: ...ARM red LED is lit after blinking 6 times Compressor 1 does not start Wiring open Compressor resistor board wiring error or failure High pressure switch low pressure switch coil frost switch or compre...

Page 53: ...device and replace Check for missing phase Check TXV Check temperature in suction discharge line Unit is Noisy Compressor noise Check TXV and replace if necessary Compressor rotation incorrect check...

Page 54: ...t 3 2nd Stage High Pressure Lockout 4 2nd Stage Low Pressure Lockout 5 Freeze Protection Lockout 6 Condensate Overflow Lockout STEP NO INSTRUCTION ACTION RESULT 1 Press 3 SET ENTER Controller Password...

Page 55: ...board test mode jumper to yes reduces all time delays to 5 seconds 8 Freeze pins on UPM board must be jumped if freeze sensor is not installed Standard Components Legend 1 First Stage 2 Second Stage B...

Page 56: ...n break 90 second low pres sure bypass and 5 second second stage delay 7 Setting the test mode jumper to yes reduces all time delays to 5 seconds Standard Components Legend Optional Components Legend...

Page 57: ...nd void unit warranty 5 For alternative EMS coil voltages consult factory Standard Components Legend BM Blower Motor BR Blower Relay CBR 24 v Circuit Breaker CC Compressor Contactor CCH Crankcase Heat...

Page 58: ...58 a50 8236 Fig 41 50BVJ K020 034 Variable Air Volume Low Voltage Schematic NOTE Jumper installed for condenser water flow switch when not supplied...

Page 59: ...2 L3 T3 BR L1 T1 W VFD E U V R S T2 T3 T1 1 3 2 BYPASS GND 4 5 6 L3 L1 L2 TRANFORMER PRIMARY LEAD CLR PUR OR YEL BLK RED 460 575 380 240 208 GRY ORG RED L1 L2 L3 GND L3 L2 L1 PHASE L1 L3 PCB2 J1 3 COM...

Page 60: ...60 a50 8237 NOTE Jumper installed for condenser water flow switch when not supplied Fig 43 50BVW X034 064 Variable Air Volume Low Voltage Schematic...

Page 61: ...CMP 2 4 CMP 2 4 CBR BM BM T2 L2 L3 T3 BR L1 T1 T2 L2 L3 T3 BR L1 T1 W VFD E U V T R S T2 T3 T1 1 3 2 BYPASS GND 4 5 6 L3 L1 L2 TRANFORMER PRIMARY LEAD CLR PUR OR YEL BLK RED 460 575 380 240 208 GRY OR...

Page 62: ...FSD ROCC A B A B A B B A REMOTE LOCAL OFF MODE SW TB2 FIELD CONN TB1 1 TB1 2 YEL BLU DIS 7 DIS 8 HIR TRANS 1 C TRANS 1 R VENTR 5 3 HIR 5 3 ECONO OPTION BYPASS OPTION DIS 5 VENTR A B A B A B B A A B 2...

Page 63: ...0MA OTHER OTHER 10VDC AO DO AO DO CSMUX YEL DIS 1 DIS 2 DIS 3 DIS 4 YEL BLU OPTIONAL CLO1 2 OPTIONAL J6 TO SYSTEM DISPLAY COMMON C 24VAC R DISPLAY A B A B A B B A B A 10 10 144 143 137 136 135 10 139...

Page 64: ...O AO DO CSMUX YEL DIS 1 DIS 2 DIS 3 DIS 4 YEL BLU OPTIONAL CLO4 2 CLO3 2 CLO3 1 CLO3 3 CLO1 2 OPTIONAL J6 TO SYSTEM DISPLAY COMMON C 24VAC R DISPLAY A B A B A B A B A B B A B A 10 10 144 143 137 136 1...

Page 65: ...Relays OLR Compressor Motor Protector PCB1 Unit Control Board PCB2 3 I O Expansion Board PHASE Phase Rotation Monitor PHASER Phase Monitor Relay RAT Return Air Thermostat RESET External Reset ROCC Rem...

Page 66: ...o discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53500001 01 Printed in U S A Form 50BV 3SI Pg 66 10 08 Replaces 50BV 2SI Co...

Page 67: ...ION Y N _______ HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE Y N _______ ARE PROPER AIR FILTERS IN PLACE AND CLEAN Y N _______ VERIFY THAT THE UNIT IS INSTALLED WITHIN LEVELING TOLERA...

Page 68: ...____ _______________________________________________________________________________________________ _______________________________________________________________________________________________ ___...

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