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Carrier WEATHERMAKER 48AJ020, Installation, Start-Up And Service Instructions Manual

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Carrier WEATHERMAKER 48AJ020 Installation, Start-Up And Service Instructions Manual Download Page 94

94

Main Burners — 

For all applications, main burners are

factory set and should require no adjustment.
MAIN BURNER REMOVAL (Fig. 76)

1. Shut off (field-supplied) manual main gas valve.
2. Shut off power supply to unit.
3. Remove heating access panel.
4. Disconnect gas piping from gas valve inlet.
5. Remove wires from gas valve.
6. Remove wires from rollout switch.
7. Remove sensor wire and ignitor cable from IGC board.
8. Remove 2 screws securing manifold bracket to basepan. 
9. Remove 4 screws that hold the burner support plate

flange to the vestibule plate.

10. Lift burner assembly out of unit.

11. Reverse procedure to re-install burners.

Liquid Pressure at Liquid Valve (PSIG)

CHARGING CHART

BOTH CIRCUITS

ALL OUTDOOR FANS MUST BE OPERATING

Liquid T

emperature at Liquid V

alve (deg F)

140

120

100

80

60

40

50

100

150

200

250

300

350

400

Add Charge if Above Curve

Reduce Charge if Below Curve

Fig. 73 — Cooling Charging Chart,

48EJ,EK,EW,EY054-068

Fig. 74 — Cooling Charging Chart,

48AJ,AK,AW,AY020-060

OFF

ON

W-1

W-2

D-1 D-2

C1

C2

PILOT

ADJ.

INLET PRESSURE TAP
(PLUGGED)
1/8 - 27 N.P.T. THDS.

2 LEADS, #18 WIRE 1/32 INSULATION,
600V. MAX., 105

°

C

REGULATOR
ADJUSTMENT SCREW
(REMOVE COVER)

OUTLET PRESSURE
TAP (PLUGGED)
1/8-27 N.P.T. THDS.

PILOT CONNECTION
FOR 1/4” O.D. TUBING
(PLUGGED)

RECEPTACLE AND
TAB COMBINATION
TERMINAL

RECEPTACLE TERMINAL

Fig. 75 — Gas Valve (Part Number EF33CB271)

Fig. 76 — Main Burner Removal

Summary of Contents for WEATHERMAKER 48AJ020

Page 1: ...orking 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 Wear safety glasses and work gloves Use quenching cloth for unbrazing operations Have fire extinguishers available for all brazing operations INSTALLATION Step 1 Provide Unit Support Before performing service or maintena...

Page 2: ...ocated adjacent to public walkways flue assem bly must be at least 7 ft above grade ROOF MOUNT Check building codes for weight distribu tion requirements See Fig 17 Unit operating weight is shown in Table 2 Step 3 Field Fabricate Ductwork Secure all ducts to building structure Use flexible duct connectors be tween unit and ducts as required Insulate and weatherproof all external ductwork joints an...

Page 3: ...3 Fig 1 Roof Curb 48AJ AK020 030 and 48EJ EK024 034 Units ...

Page 4: ...4 Fig 2 Roof Curb 48AJ AK034 050 and 48EJ EK038 048 Units ...

Page 5: ...5 Fig 3 Roof Curb 48AJ AK060 and 48EJ EK054 068 Units ...

Page 6: ...strip Total length required is 75 linear ft 4 If existing seal strip around roof curb seems damaged replace it Total length required is 62 linear ft 5 Five crossrails are field located per dimensions shown and secured using self tapping screws 6 48A and 48E series units will overhang existing DD or DF roof curbs by 2 98 at indoor motor end and 15 08 at compressor end 7 Ductwork field supplied must...

Page 7: ...2 3 4 48AJ AK Low Heat 020 5142 6 0 3 8 3 6 3 16 1082 1174 1502 1384 48AJ High Heat 020 5222 6 1 5 16 3 6 11 16 1126 1194 1494 1408 48AJ AK Low Heat 025 5228 5 9 5 8 3 8 1103 1103 1511 1511 48AJ High Heat 025 5308 5 10 3 32 3 8 5 16 1135 1120 1516 1537 48AJ AK Low Heat 027 5325 5 9 5 8 3 8 1123 1123 1539 1539 48AJ High Heat 027 5405 5 10 3 32 3 8 5 16 1156 1140 1544 1565 48AJ AK Low Heat 030 5325 ...

Page 8: ... curb 6 Dimensions are in inches mm UNIT SIZE OPERATING WEIGHT lbs A ft in B ft in CORNER WEIGHT lbs 1 2 3 4 48AJ AK Low Heat 035 6004 7 8 11 16 3 10 7 8 1380 1209 1595 1820 48AJ High Heat 035 6164 7 10 1 8 3 11 3 16 1447 1251 1607 1859 48AJ AK Low Heat 040 6514 7 5 5 16 3 10 7 8 1442 1264 1779 2030 48AJ High Heat 040 6674 7 6 13 16 3 11 3 16 1512 1307 1787 2068 48AJ AK Low Heat 050 6725 7 3 11 16...

Page 9: ...AKD 8930 4051 48AJE 9170 4159 UNIT SIZE CENTER OF GRAVITY OF TOTAL WEIGHT AT EACH CORNER ft in Millimeters A B A B 1 2 3 4 48AJD AKD060 10 7 11 16 3 10 19 32 3242 1184 21 7 19 3 27 7 31 2 48AJE060 11 2 11 16 4 19 32 3422 1235 23 9 19 4 25 4 31 3 5 Bottom ducts designed to be attached to accessory roof curb If unit is mounted on dunnage it is recommended the ducts must be supported by cross braces ...

Page 10: ...2 6 1 5 16 3 6 11 16 1134 1203 1505 1419 48AW AY Low Heat 025 5268 5 9 5 8 3 8 1111 1111 1523 1523 48AW High Heat 025 5348 5 10 1 8 3 8 5 16 1144 1128 1527 1548 48AW AY Low Heat 027 5365 5 9 5 8 3 8 1132 1132 1551 1551 48AW High Heat 027 5445 5 10 1 8 3 8 5 16 1165 1149 1555 1577 48AW AY Low Heat 030 5365 5 9 5 8 3 8 1132 1132 1551 1551 48AW High Heat 030 5445 5 10 1 8 3 8 5 16 1165 1149 1555 1577...

Page 11: ...GHT lbs 1 2 3 4 48AW AY Low Heat 035 6044 7 8 11 16 3 10 7 8 1389 1217 1606 1832 48AW High Heat 035 6204 7 10 1 8 3 11 3 16 1456 1259 1617 1871 48AW AY Low Heat 040 6554 7 3 11 16 3 10 7 8 1451 1271 1790 2042 48AW High Heat 040 6714 7 6 13 16 3 11 3 16 1521 1315 1798 2080 48AW AY Low Heat 050 6765 7 3 11 16 3 10 1 2 1458 1301 1889 2117 48AW High Heat 050 6925 7 5 3 16 3 10 13 16 1528 1345 1897 215...

Page 12: ...NIT SIZE CENTER OF GRAVITY OF TOTAL WEIGHT AT EACH CORNER ft in Millimeters A B A B 1 2 3 4 48AWD AYD060 10 7 11 16 3 10 19 32 3242 1184 21 7 19 3 27 7 31 2 48AWE060 11 2 11 16 4 19 32 3422 1235 23 9 19 4 25 4 31 3 5 Base unit weights include outdoor air hoods and filters indoor fan motor is not included Add indoor motor FIOPs and accessories for total operating weight 6 VAV motor weights include ...

Page 13: ...erhang Condenser Coil 4 0 1219 Economizer Side 6 0 1829 Heat Side 4 0 1219 Filter Access Side 10 0 3048 For removal of evaporator coil 4 For smaller service and operational clearances contact Carrier Appli cation Engineering Department 5 Bottom ducts designed to be attached to accessory roof curb If unit is mounted on dunnage it is recommended the ducts must be supported by cross braces as done on...

Page 14: ...erhang Condenser Coil 4 0 1219 Economizer Side 6 0 1829 Heat Side 4 0 1219 Filter Access Side 10 0 3048 For removal of evaporator coil 4 For smaller service and operational clearances contact Carrier Appli cation Engineering Department 5 Bottom ducts designed to be attached to accessory roof curb If unit is mounted on dunnage it is recommended the ducts must be supported by cross braces as done on...

Page 15: ...s and filters indoor fan motor is not included Add indoor motor FIOPs and acces sories for total operating weight 7 VAV motor weights include indoor motor VFD compressor electric unloaders VFD transducer and associated wiring 8 Dimensions in are in inches mm BASE UNIT WEIGHTS See Note 6 lbs kg 054 058 064 068 48EJD EKD 6805 3087 7055 3200 7305 3314 7480 3393 48EJE 7045 3196 7295 3309 7545 3422 772...

Page 16: ...ge facing econo mizer inlet Min Clearances to be Adjacent Units 15 0 4572 Top of Units No Overhang Condenser Coil 4 0 1219 Economizer Side 6 0 1829 Heat Side 4 0 1219 Filter Access Side 15 0 4572 For removal of evaporator coil 4 For smaller service and operational clearances contact Carrier Application Engineering Department 5 Dimensions in are in inches mm ...

Page 17: ...ge facing econo mizer inlet Min Clearances to be Adjacent Units 15 0 4572 Top of Units No Overhang Condenser Coil 4 0 1219 Economizer Side 6 0 1829 Heat Side 4 0 1219 Filter Access Side 15 0 4572 For removal of evaporator coil 4 For smaller service and operational clearances contact Carrier Application Engineering Department 5 Dimensions in are in inches mm ...

Page 18: ...d wiring 7 For side supply return applications a single return and supply ductwork connection is rec ommended for covering all three return and all three supply openings The entire area around the duct openings is available for a 1 5 duct flange attachment 8 Dimensions in are in inches mm BASE UNIT WEIGHTS See Note 6 lbs kg 054 058 064 068 48EWD EYD 6845 3105 7095 3218 7345 3332 7520 3411 48EWE 70...

Page 19: ...1 21 1 28 9 28 9 48AJE030 70 1 44 3 1781 1125 21 4 21 1 28 6 29 0 48AW AYD030 69 6 44 0 1768 1118 21 1 21 1 28 9 28 9 48AWE030 70 1 44 3 1781 1125 21 4 21 1 28 6 29 0 48AJ AKD035 92 7 46 9 2355 1191 23 0 20 1 26 6 30 3 48AJE035 94 1 47 2 2390 1199 23 5 20 3 26 1 30 2 48AW AYD035 92 7 46 9 2355 1191 23 0 20 1 26 6 30 3 48AWE035 94 1 47 2 2390 1199 23 5 20 3 26 1 30 2 48AJ AKD040 89 3 46 9 2268 1191...

Page 20: ...48EJ EWE024 73 3 42 7 1862 1085 21 6 22 9 28 6 27 0 48EJ EW EK EYD028 69 6 44 0 1768 1118 21 1 21 1 28 9 28 9 48EJ EWE028 70 1 44 3 1781 1125 21 4 21 1 28 6 29 0 48EJ EW EK EYD030 69 6 44 0 1768 1118 21 1 21 1 28 9 28 9 48EJ EWE030 70 1 44 3 1781 1125 21 4 21 1 28 6 29 0 48EJ EW EK EYD034 69 6 44 0 1768 1118 21 1 21 1 28 9 28 9 48EJ EWE034 70 1 44 3 1781 1125 21 4 21 1 28 6 29 0 48EJ EW EK EYD038 ...

Page 21: ... 1200 1200 1200 Motor Pulley Pitch Diameter 4 9 4 4 5 7 5 4 6 1 5 5 4 4 4 9 5 9 4 4 5 7 5 9 Nominal Motor Shaft Diameter in 11 8 13 8 13 8 13 8 13 8 15 8 13 8 15 8 15 8 13 8 15 8 15 8 Fan Pulley Pitch Diameter in 12 4 8 6 9 1 12 4 11 1 8 7 9 4 8 1 8 7 9 0 9 1 8 7 Nominal Fan Shaft Diameter in 115 16 115 16 115 16 115 16 Belt Quantity 1 2 2 1 1 2 2 2 2 2 2 2 Belt Type BX56 BX50 5VX530 BX56 5VX590 5...

Page 22: ...1200 Motor Pulley Pitch Diameter 6 1 5 3 5 7 5 3 5 7 7 5 6 3 8 1 7 5 5 3 8 1 9 4 Nominal Motor Shaft Diameter in 13 8 15 8 15 8 15 8 15 8 17 8 15 8 17 8 17 8 17 8 17 8 21 8 Fan Pulley Pitch Diameter in 13 7 9 5 9 5 9 5 9 5 11 1 11 1 12 5 11 1 9 1 12 5 13 6 Nominal Fan Shaft Diameter in 115 16 115 16 115 16 115 16 Belt Quantity 1 2 2 2 2 2 2 2 2 3 3 2 Belt Type 5VX610 5VX530 5VX550 5VX530 5VX550 5V...

Page 23: ...00 1200 1200 Motor Pulley Pitch Diameter 4 9 4 4 5 7 5 4 6 1 5 5 4 4 4 9 5 9 4 4 5 7 5 9 Nominal Motor Shaft Diameter in 11 8 13 8 15 8 13 8 13 8 15 8 13 8 15 8 15 8 13 8 15 8 15 8 Fan Pulley Pitch Diameter in 12 4 8 6 9 1 12 4 11 1 8 7 9 4 8 1 8 7 9 0 9 1 8 7 Nominal Fan Shaft Diameter in 115 16 115 16 115 16 115 16 Belt Quantity Type 1 BX56 2 BX50 2 5VX530 1 BX56 1 5VX570 2 5VX530 2 BX50 2 5VX50...

Page 24: ... Motor Bearing Type Ball Ball Ball Maximum Allowable Rpm 1200 1200 1200 Motor Pulley Pitch Diameter 6 1 5 3 5 7 5 3 5 7 7 5 6 3 8 1 7 5 Nominal Motor Shaft Diameter in 13 8 15 8 15 8 15 8 15 8 17 8 15 8 17 8 17 8 Fan Pulley Pitch Diameter in 13 7 9 5 9 5 9 5 9 5 11 1 11 1 12 5 11 1 Nominal Fan Shaft Diameter in 115 16 115 16 115 16 Belt Quantity Type 1 5VX610 2 5VX530 2 5VX550 2 5VX530 2 5VX550 2 ...

Page 25: ... Motor Shaft Diameter in 15 8 15 8 17 8 15 8 17 8 17 8 17 8 17 8 21 8 17 8 17 8 21 8 Fan Pulley Pitch Diameter in 11 1 11 1 12 5 11 1 11 1 11 1 9 1 12 5 13 6 12 5 9 5 13 6 Nominal Fan Shaft Diameter in 115 16 115 16 115 16 115 16 Belt Quantity Type 2 5VX550 2 5VX570 2 5VX630 2 5VX570 2 5VX590 2 5VX590 3 5VX530 2 5VX630 2 5VX650 2 5VX610 3 5VX550 2 5VX650 Length in 55 57 63 57 59 59 53 63 65 61 55 ...

Page 26: ...305 7480 48EJE 4367 4453 4453 4453 5172 5398 5685 7045 7295 7545 7720 48EW EYD 4327 4413 4413 4413 5052 5278 5565 6845 7095 7345 7520 48EWE 4407 4493 4493 4493 5212 5438 5725 7085 7335 7585 7760 OPTION ACCESSORY OPTION ACCESSORY WEIGHTS Lb 024 028 030 034 038 044 048 054 058 064 068 Barometric Relief 300 300 300 300 300 300 300 450 450 450 450 Power Exhaust 450 450 450 450 450 450 450 675 675 675 ...

Page 27: ...1 035 038 10 1 375 779 1B5V60 6 1 NONE 1 375 1B5V136 13 7 B 1 9375 5VX610 12 15 1 625 976 2B5V52 5 3 B 1 625 2B5V94 9 5 B 1 9375 2 5VX530 10 20 1 625 1050 2B5V56 5 7 B 1 625 2B5V94 9 5 B 1 9375 2 5VX550 11 040 044 15 1 625 976 2B5V52 5 3 B 1 625 2B5V94 9 5 B 1 9375 2 5VX530 10 20 1 625 1050 2B5V56 5 7 B 1 625 2B5V94 9 5 B 1 9375 2 5VX550 11 25 1 875 1182 2B5V74 7 5 B 1 875 2B5V110 11 1 B 1 9375 2 ...

Page 28: ...reeze up Condensate pans are sloped so that water will completely drain from the condensate pan to comply with indoor air quali ty guidelines The condensate drain pans are not insulated Step 7 Install Gas Piping Unit is equipped for use with natural gas Installation must conform with local building codes or in the absence of local codes with the Na tional Fuel Gas Code ANSI Z223 1 Install manual g...

Page 29: ...rtWORKS Building Supervisor and Service Tool or remote enhanced display accessory installed to access the base control board and optional factory installed staged gas control See Table 5 NOTE Access to the base control board allows unit occu pancy schedules unit timeclock and various set points to be changed from their factory defined default settings Table 4 48A E Series Staged Gas Implementation...

Page 30: ...ith a space sensor and timeclock the machine will operate at default values unless they are changed using appropriate in put devices The space sensor senses space temperature and may be equipped with a timed override feature which allows unit operation during unoccupied periods The space sensors may be used in multiples of 4 or 9 to achieve space temperature averaging The use of a space sensor als...

Page 31: ...ring unoccupied periods as required to maintain space temperature within the unoc cupied set points adjustment of space temperature set points of 5 F when using a T 56 sensor provides CCN Carrier Comfort Network IAQ Indoor Air Quality participation control of modulating economizer damper to maintain indoor air quality IAQ when outdoor conditions are suitable this function is provided in the base u...

Page 32: ...s Heating and cooling in both on and off modes is controlled to default values by the base unit control Set points may be changed with appropriate input devices The control has an on board occupancy schedule which can be set using an input device and eliminates the need for an ex ternal timeclock During both the on and off periods cooling operation is controlled to the supply air setting and heati...

Page 33: ...re sensor and which have not had the base unit control board accessed via software to set an occupancy schedule the remote start stop closure will allow the unit to operate in the pre configured occupied default set points of 55 F supply air temperature cooling and 68 F return air temperature heating Without an occupancy schedule the unit will control to the unoccupied default set points of 90 F r...

Page 34: ...software version number Fig 27 Control Board Diagram CCN Carrier Comfort Network N O Normally Open COM Common R Relay D Diode SIO Serial Input Output DIP Dual In Line Package SW Switch LED Light Emitting Diode T Terminal N C Normally Closed ...

Page 35: ...3 6 23 6 125 4 123 9 150 150 10 30 8 28 0 115 9 113 1 150 150 23 6 23 6 139 5 136 7 175 175 15 46 2 42 0 133 1 127 8 175 150 23 6 23 6 156 7 151 4 200 175 460 414 508 19 9 114 11 5 80 2 2 7 ea 5 7 6 49 4 60 12 6 62 0 80 10 14 55 8 70 12 6 68 4 80 15 21 63 1 80 12 6 75 7 90 575 518 632 16 91 9 6 64 2 2 4 ea 5 6 1 40 5 50 12 6 53 1 60 10 11 45 4 60 12 6 58 0 70 15 17 51 7 60 12 6 64 3 80 025 208 230...

Page 36: ... 6 23 6 153 0 150 2 175 175 15 46 2 42 0 146 6 141 3 175 175 23 6 23 6 170 2 164 9 200 200 20 59 4 54 0 163 1 156 3 200 200 23 6 23 6 186 7 179 9 225 225 460 414 508 19 9 114 19 9 114 2 2 7 ea 10 14 64 2 80 12 6 76 8 90 15 21 71 5 90 12 6 84 1 100 20 27 79 0 100 12 6 91 6 110 575 518 632 16 91 16 91 2 2 4 ea 10 11 51 8 60 12 6 64 4 80 15 17 58 1 70 12 6 70 7 80 20 22 64 3 80 12 6 76 9 90 030 208 2...

Page 37: ... 201 3 250 250 15 46 2 42 0 195 9 191 7 250 225 23 6 23 6 219 5 215 3 250 250 20 59 4 54 0 209 7 203 7 250 250 23 6 23 6 233 3 227 3 250 250 460 414 508 25 6 120 25 6 120 4 2 7 ea 10 14 82 4 100 12 6 95 0 110 15 21 89 4 110 12 6 102 0 125 20 27 95 8 110 12 6 108 4 125 575 518 632 20 5 96 20 5 96 4 2 4 ea 10 11 66 7 80 12 6 79 3 90 15 17 72 7 90 12 6 85 3 100 20 22 78 1 100 12 6 90 7 110 040 208 23...

Page 38: ...300 300 25 74 8 68 0 253 1 244 9 300 300 23 6 23 6 276 7 268 5 350 300 30 88 80 0 269 6 259 6 350 300 23 6 23 6 293 2 283 2 350 350 460 414 508 28 8 173 28 8 173 4 2 7 ea 20 27 102 6 125 12 6 115 2 125 25 34 110 9 125 12 6 123 5 150 30 40 118 4 150 12 6 131 0 150 575 518 632 26 7 120 26 7 120 4 2 4 ea 20 22 91 7 110 12 6 104 3 125 25 27 96 8 110 12 6 109 4 125 30 32 103 0 125 12 6 115 6 125 060 20...

Page 39: ... 0 96 122 8 120 6 150 150 23 6 41 6 0 96 146 4 144 2 175 175 10 30 8 28 0 0 96 129 4 126 6 150 150 23 6 41 6 0 96 153 0 150 2 175 175 15 46 2 42 0 0 96 144 8 140 6 175 175 23 6 41 6 0 96 168 4 164 2 200 200 460 414 508 19 9 114 19 9 114 2 1 2 7 7 5 11 0 0 5 61 2 80 12 6 23 6 0 5 73 8 90 10 14 0 0 5 64 2 80 12 6 23 6 0 5 76 8 90 15 21 0 0 5 71 2 90 12 6 23 6 0 5 83 8 100 575 518 632 16 0 91 16 0 91...

Page 40: ... 96 180 5 177 7 225 225 23 6 41 6 0 96 204 1 201 3 250 250 15 46 2 42 0 0 96 195 9 191 7 250 225 23 6 41 6 0 96 219 5 215 3 275 250 20 59 4 54 0 0 96 209 1 203 7 250 250 23 6 41 6 0 96 232 7 227 3 275 275 460 414 508 25 6 120 25 6 120 4 1 2 7 10 14 0 0 5 82 4 100 12 6 23 6 0 5 95 0 110 15 21 0 0 5 89 4 110 12 6 23 6 0 5 102 0 125 20 27 0 0 5 95 4 110 12 6 23 6 0 5 108 0 125 575 518 632 20 5 96 20 ...

Page 41: ...35 0 300 300 35 4 62 4 1 44 274 6 270 4 350 350 20 59 4 54 0 1 44 252 4 247 0 300 300 35 4 62 4 1 44 287 8 282 4 350 350 25 74 8 68 0 1 44 267 8 261 0 300 300 35 4 62 4 1 44 303 2 296 4 350 350 460 414 508 43 6 223 30 8 173 4 1 2 7 15 21 0 0 75 117 1 150 18 9 35 4 0 75 136 0 175 20 27 0 0 75 123 1 150 18 9 35 4 0 75 142 0 175 25 34 0 0 75 130 1 150 18 9 35 4 0 75 149 0 175 575 518 632 34 6 164 26 ...

Page 42: ...9 450 450 35 4 62 4 1 44 396 3 386 3 500 450 460 414 508 52 6 253 43 6 223 6 1 2 7 25 34 0 0 75 159 5 200 18 9 35 4 0 75 178 4 225 30 40 0 0 75 165 5 200 18 9 35 4 0 75 184 4 225 40 52 0 0 75 177 5 225 18 9 35 4 0 75 196 4 225 575 518 632 40 4 176 34 6 164 6 1 2 4 25 27 0 0 75 126 5 150 18 9 35 4 0 75 145 4 175 30 32 0 0 75 131 5 150 18 9 35 4 0 75 150 4 175 40 41 0 0 75 140 5 175 18 9 35 4 0 75 1...

Page 43: ...or terminals during compressor opera tion must be within the voltage range indicated on the unit nameplate On 3 phase units phases must be balanced within 2 Use the formula in Tables 7 and 8 to determine the percent age of voltage imbalance Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components On ...

Page 44: ...mpressor Contactor CB Circuit Breaker CCB Control Circuit Breaker CR Control Relay DIP Dual In Line Package EQUIP Equipment FU Fuse GND Ground HR Heater Relay IFC Indoor Fan Circuit IFCB Indoor Fan Circuit Breaker IFR Indoor Fan Relay NEC National Electrical Code OFC Outdoor Fan Contactor PEC Power Exhaust Controller PES Power Exhaust Sequencer PESC Power Exhaust Sequencer Controller TB Terminal B...

Page 45: ...de Heat Interlock relay part number is HN61KK040 See Fig 35 for HIR wiring Remote Field Control A switch closure across terminals R and W1 on TB 3 will initiate the Occupied mode This can be done manually as well as through a field supplied timeclock Service Tool Building Supervisor and ComfortWORKS Software Access to the control board can be achieved through the terminal marked CCN via a 3 wire b...

Page 46: ...it Breaker HR Heater Relay PES Power Exhaust Sequencer CCN Carrier Comfort Network IFC Indoor Fan Circuit PESC Power Exhaust Sequencer Control ler CR Control Relay IFCB Indoor Fan Circuit Breaker SIO Serial Input Output DIP Dual In Line Package IFR Indoor Fan Relay TB Terminal Block EQUIP Equipment NEC National Electrical Code TRAN Transformer ...

Page 47: ...g one point per building only To connect the unit to the network 1 Turn off power to the control box 2 Cut the CCN wire and strip the ends of the red white ground and black conductors If a different network color scheme is used substitute appropriate colors 3 Remove the 3 pin male plug from the base control board in the main control box and connect the wires as follows a Insert and secure the red ...

Page 48: ...s on every unit Each hood has two lower filter tracks one slotted side and one side without slots Construct the assembly so that the slotted side is adjacent to the other hood when mounted on the unit The 48AJ AK AW AY060 and 48EJ EK EW EY054 068 units have 3 hoods on every unit Each hood has two lower fil ter tracks one slotted side and one side without slots Construct the two outer hood assembli...

Page 49: ... sen sor onto the hood side furthest from the control box The OAT or enthalpy sensor is installed on the inside upper right hand corner using the mounting bracket and mount ing holes provided Attach wiring to unit controls If ac cessory enthalpy sensor is used quick connects must be attached to enthalpy sensor wires 11 Remove screws along bottom of damper assembly Lo cate and mount blockoff baffle...

Page 50: ...lose DIP switch no 4 during the 30 seconds immediately after the de sired outdoor air minimum damper position The 30 second time period is to allow time where DIP switch no 4 can be closed The default value of the minimum outdoor air damper position is 20 If the desired minimum position is 30 al lows the damper position to go to 10 for 30 seconds then 20 for 30 seconds and when it reaches 30 close...

Page 51: ...eplace the economizer filters 9 Return power to unit Accessory Differential Enthalpy Control Fig 46 The control HH57AC077 in conjunction with the accessory en thalpy sensor HH57AC078 controls economizer operation according to the differential enthalpy The control is mounted in the economizer hood The sensor is mounted in the return duct 48AJ AK and 48EJ EK or return air plenum 48AW AY and 48EW EY ...

Page 52: ...3 screws along the bottom Save screws 2 Pivot each damper assembly outward until edges of damper assembly rest against inside wall of unit 3 Secure each damper assembly to unit with 6 screws across top 3 screws provided and bottom 3 screws from Step 1 of damper 4 With screws saved from Step 1 install brackets on each side of damper assembly 5 Remove tape from damper blades VAV DUCT PRESSURE TRANSD...

Page 53: ...hrometric Chart for Enthalpy Control NOTE Partitions shown indicate both side supply AW AY EW EY and vertical supply AJ AK EJ EK units Fig 49 Economizer Details CONTROL CURVE CONTROL POINT APPROX DEG AT 50 RH F C A 73 23 B 70 21 C 67 19 D 63 17 ...

Page 54: ...and 5 8 in long Holes for wind baffles are pre punched in the unit sheet metal The wind baffles attach to flanges formed on the outer sheet metal of the unit corner post The other end of the baffle is at tached to the center panel between the condenser coil and the indoor section Two baffles are required To avoid damage to the refrigerant coils and electrical com ponents use recommended screw size...

Page 55: ... the Motormaster III control Signal Selection Switch Remove the cover of the Motor master III control Set the switch to accept the thermistor sensor input signal Set the frequency to match the unit power supply 60 Hz Motormaster III Control The recommended mounting loca tion is in the indoor fan section mounted on the panel that sep arates the indoor and outdoor sections On VAV units this location...

Page 56: ...W AY035 and 48EJ EK EW EY038 044 Fig 53C Motormaster III Sensor Location 48AJ AK AW AY040 050 and 48EJ EK EW EY048 Fig 53D Motormaster III Sensor Location 48EJ EK EW EY054 064 Fig 53E Motormaster III Sensor Location 48AJ AK AW AY060 and 48EJ EK EW EY068 ...

Page 57: ...e a minimum 3 4 in flange for connection to the unit cabinet The unit does not have duct flanges for this conversion Side Supply and Return Units 48AW AY EW EY With Field Installed Power Exhaust in Return Duct Space must be available in the return duct to mount the power exhaust fan gravity relief modules Dimensions and suggested locations are shown in Fig 55 These instructions are a guideline and...

Page 58: ...one suction port located in the top of the compressor motor casing All units also have one service port on the liquid line valve and one on the compressor discharge valve Be sure that caps on the ports are tight 42 56 42 MIN S A R A ECONOMIZER HOOD ECONOMIZER HOOD J BOX PLENUM RATED CABLE FIELD SUPPLIED 12 94 UNIT OPENING NOTE 024 048 020 050 SIZES SHOWN 2 POWER EXHAUST FANS 060 054 068 SIZES HAVE...

Page 59: ... static pressure perform the following procedure 1 Open the Indoor Fan Circuit Breaker IFCB This will shut off power to the VFD 2 Wait for the VFD display to go blank and remove VFD cover without touching any interior components Make sure that the charge indicator lamp is out indicating that the VFD is discharged The lamp is located on the upper right hand corner of the terminal block It may take ...

Page 60: ...ay take several minutes 13 Replace jumper across terminals ST and CC 14 Replace VFD cover 15 Close the IFCB The VFD is now powered and the fan will operate Table 12 Carrier Default Program Parameter Values These settings differ from the Toshiba defaults and are required for Carrier applications IMPORTANT The Carrier factory default values for the VFD may be different than the default values of the...

Page 61: ...tact closure between terminals S1 and CC 10 If the VFD is to be controlled by an external control sys tem other than the factory supplied duct static pressure transducer follow these steps a Install a jumper between S2 and CC This jumper will disable the PID Proportional Integral Deriva tive control loop in the VFD The VFD is set to follow an external speed reference signal from the control system...

Page 62: ...ded Parameters F115 0115 Input Terminal Selection 5 S2 14 F116 0116 Input Terminal Selection 6 S3 11 Frequency Parameters F201 0201 VIA II Input Point 1 Setting 20 F202 0202 VIA II Input Point 1 Frequency 0 0 Hz F203 0203 VIA II Input Point 2 Setting 100 F204 0204 VIA II Input Point 2 Frequency 60 0 Hz Operation Mode Parameters F300 0300 PWM Carrier Frequency 4 KHz F301 0301 Auto Restart Control S...

Page 63: ...common connections The next 2 terminals are for the 0 to 10 vdc signal Consult the wiring label for wire identi fication if replacing the module The 3 left hand terminals are not used for this application The S353 module has an LED light emitting diode a set of 4 jumper pins and 2 potentiometers The LED will light whenever the module is activated providing a visual indication of the number of exha...

Page 64: ...ection Table 16A Power Exhaust Default Set Points 48AJ AK AW AY020 050 and 48EJ EK EW EY024 048 Table 16B Power Exhaust Default Set Points 48AJ AK AW AY060 and 48EJ EK EW EY054 068 Table 17 DIP Switch Configuration LEGEND NOTES 1 The OPEN side of the DIP switch is marked OPEN When the rocker switch is on the OPEN side of the switch the switch is OPEN 2 The configuration of DIP switches 2 and 5 are...

Page 65: ... 849 10 85 884 11 44 917 12 02 948 12 59 978 13 16 1006 13 73 1034 14 30 14 000 868 12 20 904 12 86 937 13 48 968 14 08 998 14 68 1026 15 27 1054 15 86 1081 16 45 15 000 924 14 40 959 15 08 990 15 73 1020 16 37 1049 16 99 1076 17 61 1103 18 22 1128 18 83 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm ...

Page 66: ...04 1031 19 65 1055 20 27 1078 20 89 1101 21 52 18 000 987 19 98 1010 20 56 1033 21 16 1056 21 78 1078 22 41 1101 23 05 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 7 000 797 5 22 834 5 67 869 6 12 902 6 57 934 7 04 965 7 50 995 7 98 1024 8 45 8 000 816 6 10 852 6 56 886 7 03 919 7 50 951 7 99 98...

Page 67: ...8 85 20 000 1140 27 60 1161 28 25 1181 28 92 1202 29 59 1222 30 27 1242 30 95 1262 31 64 1281 32 33 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 8 000 839 6 40 874 6 86 907 7 34 940 7 81 971 8 30 1001 8 79 1030 9 29 1059 9 79 9 000 864 7 49 897 7 97 930 8 46 961 8 95 991 9 46 1021 9 97 1050 10 4...

Page 68: ...7 1040 32 70 1068 33 81 1095 34 92 1122 36 04 27 000 948 30 49 981 31 95 1012 33 24 1041 34 46 1070 35 62 1097 36 76 1123 37 90 1149 39 04 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 12 000 819 10 93 851 11 85 881 12 78 911 13 72 939 14 67 967 15 62 993 16 58 1019 17 54 14 000 859 13 11 890 14 ...

Page 69: ... 1011 14 97 1040 15 56 1067 16 16 1094 16 75 1120 17 34 15 000 981 15 52 1011 16 17 1040 16 80 1068 17 42 1095 18 04 1121 18 65 1146 19 27 1171 19 88 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 4 000 763 4 01 799 4 44 833 4 87 865 5 31 896 5 75 926 6 20 955 6 64 983 7 09 5 000 789 4 64 824 5 10...

Page 70: ...8 18 92 1082 19 53 1105 20 14 17 000 989 18 58 1013 19 18 1037 19 79 1060 20 41 1084 21 03 1107 21 66 1129 22 29 1151 22 92 18 000 1044 21 49 1067 22 10 1090 22 73 1112 23 37 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 7 000 811 5 39 847 5 83 882 6 29 915 6 75 947 7 21 977 7 68 1007 8 15 1035 8...

Page 71: ...19 000 1146 26 04 1167 26 69 1188 27 35 1209 28 02 1230 28 69 1250 29 37 1270 30 04 1290 30 72 20 000 1203 29 65 1224 30 32 1244 31 00 1263 31 69 1283 32 38 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 8 000 857 6 63 891 7 09 923 7 57 955 8 05 986 8 54 1016 9 03 1045 9 53 1073 10 03 9 000 885 7 ...

Page 72: ...1113 32 48 1138 33 59 25 000 978 28 56 1008 29 77 1037 30 93 1065 32 07 1092 33 20 1119 34 32 1144 35 44 1169 36 58 26 000 1015 31 52 1044 32 76 1072 33 96 1099 35 13 1125 36 29 1151 37 44 1176 38 59 27 000 1052 34 66 1080 35 94 1107 37 18 1133 38 38 1159 39 57 1184 40 75 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rp...

Page 73: ...12 86 936 13 45 966 14 05 996 14 64 1025 15 23 1053 15 83 1080 16 43 15 000 929 14 50 960 15 10 990 15 71 1019 16 33 1047 16 94 1074 17 55 1101 18 17 1127 18 79 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 4 000 759 3 97 796 4 42 831 4 87 865 5 34 897 5 81 929 6 30 959 6 79 988 7 28 5 000 780 4 ...

Page 74: ...0 26 1023 20 88 1046 21 51 1068 22 14 1091 22 77 1113 23 41 1135 24 05 19 000 1027 19 77 1050 23 17 1072 23 82 1094 24 46 1115 25 11 1137 25 76 1158 26 42 1179 27 07 20 000 1079 22 53 1100 26 33 1122 27 00 1142 27 66 1163 28 33 1183 29 00 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 7 000 794 5 ...

Page 75: ...28 1078 20 89 1101 21 52 18 000 986 17 47 1010 20 53 1033 21 16 1056 21 79 1078 22 42 1101 23 06 1123 23 70 1145 24 34 19 000 1038 20 05 1061 23 49 1083 24 13 1105 24 78 1126 25 44 1147 26 09 1169 26 75 1190 27 41 20 000 1091 22 84 1112 26 69 1133 27 36 1154 28 03 1174 28 70 1195 29 37 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm ...

Page 76: ...0 33 53 26 000 873 26 25 921 27 91 963 29 45 1001 30 91 1035 32 31 1068 33 67 1098 35 00 1127 36 29 27 000 903 28 82 950 30 53 991 32 12 1028 33 63 1062 35 09 1094 36 49 1124 37 86 1153 39 21 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 10 000 755 8 24 783 8 92 809 9 60 835 10 29 859 10 98 883 1...

Page 77: ...000 942 25 1 982 26 5 1018 27 8 1051 29 0 1082 30 2 1111 31 4 1138 32 6 1165 33 7 26 000 976 27 7 1015 29 1 1050 30 4 1083 31 7 1113 33 0 1142 34 2 1169 35 4 1195 36 6 27 000 1011 30 4 1048 31 9 1083 33 2 1115 34 6 1145 35 9 1173 37 1 1200 38 4 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 10 000...

Page 78: ...0 0 23 4 56 5110 10 500 0 17 4 66 5220 10 900 0 12 4 75 5330 11 300 0 07 4 80 5380 11 700 0 04 4 83 5420 Bhp Brake Horsepower ESP External Static Pressure in wg Watts Input Watts to Motor AIRFLOW Cfm LOW SPEED MEDIUM SPEED HIGH SPEED 208 v 230 460 575 v 208 v 230 460 575 v 208 v 230 460 575 v ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts 9 750 0 32 4 23 4740 0...

Page 79: ...31 0 23 918 91 7 30 35 6 95 0 28 742 92 4 34 7 48 0 47 0 28 015 92 4 40 42 0 110 0 55 0 48 8 33 690 93 0 HIGH EFFICIENCY MOTORS Nominal Bhp Maximum Bhp Maximum Amps Maximum Watts Maximum Efficiency 230 v 460 v 5 5 9 15 8 7 9 4 918 89 5 7 5 8 7 22 0 7 078 91 7 9 5 12 0 7 728 91 7 10 10 2 28 0 8 298 91 7 11 8 15 0 9 600 91 7 15 15 3 43 8 12 273 93 0 18 0 21 9 14 439 93 0 20 22 4 58 2 17 853 93 6 23 ...

Page 80: ... allow ac cess to unit control by non Carrier energy management sys tems EMS The occupied or unoccupied comfort set points must be se lected and the space temperature offset input will be used if present The Occupied Heat set point default value is 68 F The Occupied Cool set point default value is 78 F The Unoccupied Heat set point default value is 55 F The Unoccupied Cool set point value is 90 F ...

Page 81: ...ata SPT Space Temperature HS2 Heat Stage 2 SAT Supply Air Temperature STO Space Temp Offset RAT Return Air Temperature CVPE1 CV Power Exhaust Stg 1 OAT Outside Air Temperature CVPE2 CV Power Exhaust Stg 2 CLSP Control Set Point VAV Data CCAP Cooling Total Capacity HIR Heat Interlock Relay HCAP Heating Total Capacity SPTRESET Space Temp Reset ECOS Economizer Active CMP1 Compressor 1 SFSTAT Supply F...

Page 82: ...tics for alarms alerts respond to CCN communications and perform any con figured network POC product outboard controls functions such as time and outdoor air temperature broadcast and global broadcast and perform Fire Smoke control if equipped with power exhaust GAS HEATING CONSTANT VOLUME CV UNITS The gas heat units incorporate 2 48AJ AK AW AY020 050 and 48EJ EK EW EY024 048 or 3 48AJ AK AW AY060...

Page 83: ... cy cle will not terminate until 1 minute after heat became active When heating is satisfied the power will be interrupted to the IGC board and W1 and W2 of the main gas valve If the unit is controlled through a room sensor the indoor fan will be operat ing in the Occupied mode and turned off after 45 seconds in the Unoccupied mode STAGED GAS UNIT HEATING The Staged Gas Control option offered on 4...

Page 84: ...om left side of the display Pressing the and keys simultaneously will scroll a text description across the display indicating the full meaning of each display acronym Pressing the and keys when the display is blank Mode LED lev el will return the display to its default menu of rotating display items In addition the password will be disabled requiring that it be entered again before changes can be ...

Page 85: ...ni mum damper position MDP and the RAT return air tempera ture must be less than the OHSP occupied heat set point minus 2 5 F Table 40 summarizes the operational require ments and controlling factors for occupied heat and morning warm up MORNING WARM UP VAV Only with Stand Alone Operation When the unit operates in stand alone mode morning warm up occurs when the unit is energized in Occu pied mode...

Page 86: ...supply air temperature will be reset upward as a function of the reset ratio Default is 3 Reset ratio is expressed in degrees change in supply air temperature per degree of space tempera ture change A reset limit will exist which will limit the maxi mum number of degrees the supply air temperature may be raised Default is 10 F Both the reset ratio and the reset limit are user definable The sequenc...

Page 87: ...not make recommendations as to specific smoke detector location due to liability considerations INDOOR AIR QUALITY IAQ CONTROL The acces sory IAQ sensor is required for IAQ control on the base control board The Carrier sensors operate with a 4 to 20 mA signal The 4 to 20 mA signal is connect to T13 and T14 on the base control board for the IAQ sensor and T15 and T16 on the base control board for t...

Page 88: ...below the SAT1TRIP the compres sor will be unloaded The unloading sequence will be as follows The Y1 Low SAT Limit has an adjustable range from 50 F to 65 F with a factory setting of 53 F If the temperature of the SAT rise above the Y1 Low SAT Limit plus 2 F the compressor will be loaded in the reverse order in which it was unloaded following the pre described time guards There will be a 90 second...

Page 89: ... seconds The compressors will now deenergize followed by the out door fan contactors and indoor fan contactors If the unit is equipped with the Integrated Gas Control IGC board the in door fan will continue to operate for an additional 30 seconds after deenergizing the circuit The field test is then complete SERVICE Service Access All unit components can be reached through clearly labelled hinged ...

Page 90: ...or air conditions Inspect coil monthly clean as required CONDENSATE DRAIN Check and clean each year at start of cooling season In winter keep drains and traps dry FILTERS Clean or replace at start of each heating and cool ing season or more often if operating conditions require Refer to Tables 1A and 1B for type and size NOTE The unit requires industrial grade throwaway filters capable of withstan...

Page 91: ...d motor pulleys 1 Shut off unit power supply 2 Loosen fan shaft pulley bushing 3 Slide fan pulley along fan shaft 4 Make angular alignment by loosening motor from mounting plate 5 Retighten pulley 6 Return power to the unit Evaporator Fan Coupling Assembly If the cou pling has been removed for other blower assembly component repair or replacement it is critical that the coupling be reassem bled an...

Page 92: ...nturi on opposite side of bearing 8 Lift out wheel 9 Reverse above procedure to reinstall fan 10 Check and adjust belt tension as necessary 11 Restore power to unit Belt Tension Adjustment To adjust belt tension 1 Turn off unit power supply 2 Loosen motor mounting nuts and bolts See Fig 69 3 Loosen fan motor nuts 4 Turn motor jacking bolts to move motor mounting plate left or right for proper belt...

Page 93: ...is below line carefully reclaim some of the charge Recheck suction pressure as charge is adjusted NOTE Indoor air cfm must be within normal operating range of unit All outdoor fans must be operating Thermostatic Expansion Valve TXV Each circuit has a TXV The TXV is nonadjustable and is factory set to main tain 10 to 13 F superheat leaving the evaporator coil The TXV controls flow of liquid refrige...

Page 94: ... Reverse procedure to re install burners Liquid Pressure at Liquid Valve PSIG CHARGING CHART BOTH CIRCUITS ALL OUTDOOR FANS MUST BE OPERATING Liquid Temperature at Liquid Valve deg F 140 120 100 80 60 40 50 100 150 200 250 300 350 400 Add Charge if Above Curve Reduce Charge if Below Curve Fig 73 Cooling Charging Chart 48EJ EK EW EY054 068 Fig 74 Cooling Charging Chart 48AJ AK AW AY020 060 OFF ON W...

Page 95: ...own in Fig 78 and 79 Control Circuit 115 V This control circuit is pro tected against overcurrent by a 5 2 amp circuit breaker CB3 Breaker can be reset If it trips determine cause of trouble be fore resetting A typical 115 v control wiring schematic is shown in Fig 80 and 81 Compressor Lockout Logic If any of the safeties trip the circuit will automatically reset providing the safety has reset and...

Page 96: ... equal to or less than 156 FLA for CB1 and CB2 All others are 140 4 If any of the original wire furnished must be replaced it must be replaced with Type 90 C wire or its equivalent 5 Compressors and or fan motors are thermally protected 6 Three phase motors are protected against pri mary single phasing conditions TABLE 1A The following compressors have two parallel wires run from TB1 to the compre...

Page 97: ...97 Fig 78 Typical 48EK VAV 24 V Control Circuit ...

Page 98: ...98 NOTE Red wire and violet wire are spliced together at the factory The brown wire has a wire nut added at the factory Fig 79 Typical CV 24 V Control Circuit ...

Page 99: ...99 Fig 80 Typical 48EK VAV 115 V Control Circuit ...

Page 100: ...100 Fig 81 Typical 48EJ CV 115 V Control Circuit ...

Page 101: ...101 Fig 82 Label Diagram Staged Gas Heat 48AJ AK AW AY020 050 and 48EJ EK EW EY024 048 Units ...

Page 102: ...102 Fig 83 Label Diagram Staged Gas Heat 48AJ AK AW AY060 and 48EJ EK EW EY054 068 Units ...

Page 103: ...in Fig 84 93 An algorithm diagram of the IGC Integrated Gas Unit Controller control is shown in Fig 94 LEGEND Fig 84 Typical Refrigerant Circuiting 48AJ AK AW AY020 025 and 48EJ EK EW EY024 034 FPS Freeze Protection Switch HPS High Pressure Switch LPS Low Pressure Switch ...

Page 104: ...Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass 4 Pass TXV 1 TXV 2 Compressor 1 Muffler Compressor 1 Muffler HPS LPS mounted on compressor HPS LPS mounted on compr...

Page 105: ...4 Pass 4 Pass 4 Pass 12 Pass 4 Pass 12 Pass 4 Pass 12 Pass 4 Pass 12 Pass 4 Pass 12 Pass 4 Pass 12 Pass 4 Pass 12 Pass 4 Pass 12 Pass 4 Pass 12 Pass 4 Pass 12 Pass 12 Pass 12 Pass 12 Pass 6 Pass 6 Pass 6 Pass 6 Pass TXV 1 TXV 2 Compressor 1 Muffler HPS LPS mounted on compressor HPS HK02ZA428 Cut In 320 PSI Cut out 420 PSI LPS HK02ZB027 Cut In 22 PSI Cut out 7 PSI Compressor 1 Muffler HPS LPS mount...

Page 106: ...106 LEGEND Fig 87 Typical Refrigerant Circuiting 48EJ EK EW EY038 044 FPS Freeze Protection Switch HPS High Pressure Switch LPS Low Pressure Switch ...

Page 107: ...Pass 4 Pass 8 Pass 4 Pass 4 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass 8 Pass TXV 1 TXV 2 Compressor 1 Muffler Compressor 1 Muffler HPS LPS mounted on compressor HPS LPS mounted on compressor HPS HK02ZA428 Cut In 320 PSI Cut out...

Page 108: ...108 LEGEND Fig 89 Typical Refrigerant Circuiting 48EJ EK EW EY048 FPS Freeze Protection Switch HPS High Pressure Switch LPS Low Pressure Switch ...

Page 109: ...109 LEGEND Fig 90 Typical Refrigerant Circuiting 48EJ EK EW EY054 and 058 HPS High Pressure Switch LPS Low Pressure Switch TXV Thermostatic Expansion Valve ...

Page 110: ... 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass 6 Pass 4 Pass 6 Pass TXV 1 TXV 2 Compressor 1 Muf...

Page 111: ...111 LEGEND Fig 92 Typical Refrigerant Circuiting 48EJ EK EW EY064 HPS High Pressure Switch LPS Low Pressure Switch TXV Thermostatic Expansion Valve ...

Page 112: ...112 Fig 93 Typical Refrigerant Circuiting 48EJ EK EW EY068 LEGEND HPS High Pressure Switch LPS Low Pressure Switch TXV Thermostatic Expansion Valve ...

Page 113: ...113 LEGEND NOTE Thermostat Fan Switch in the AUTO position or sensor equipped unit Fig 94 IGC Control Heating and Cooling IDM Induced Draft Motor IGC Integrated Gas Unit Controller ...

Page 114: ...been tripped 3 times in 90 minutes compressor no 2 will be locked out until the control board has been manually reset 4 HF 15 Thermostat Failure Automatic Alarm generated The thermostat is calling for both heating and cooling at the same time The unit will operate on a first call basis and will automatically reset 5 HF 05 SAT Thermistor Failure Automatic Heating cooling and economizer disabled The...

Page 115: ...27 Economizer Pos AO 4 20 mA T7 8 SAT 5KV Thermistor T28 29 Heat 1 Relay DO 24 v T9 10 T30 29 Heat Interlock Relay DO 24 v T11 12 SAT Reset AI 4 to 20 mA T31 32 Modulated Power Exhaust DO 24 vac T13 14 IAQ Indoor AI 4 to 20 mA T33 32 T15 16 IAQ Outdoor AI 4 to 20 mA T34 35 Condenser Fan DO 115 vac T17 25 Remote Start Stop DI 24 vac T36 35 OFC2 DO 115 vac T18 25 T37 38 Unloader 1 DO 115 vac T19 25 ...

Page 116: ...sed in this manual including Unit Familiarization Maintenance Installation Overview Operating Sequence A large selection of product theory and skills programs are available using popular video based formats and materials All include video and or slides plus companion book Classroom Service Training which includes hands on experience with the products in our labs can mean increased confidence that ...

Page 117: ... BELTS ARE PROPERLY TENSIONED VERIFY THAT SUCTION DISCHARGE AND LIQUID SERVICE VALVES ON EACH CIRCUIT ARE OPEN VERIFY THAT CRANKCASE HEATERS HAVE BEEN ON 24 HOURS BEFORE START UP START UP ELECTRICAL SUPPLY VOLTAGE L1 L2 __________ L2 L3 __________ L3 L1 __________ COMPRESSOR AMPS COMPRESSOR NO 1 L1 __________ L2 __________ L2 _________ COMPRESSOR AMPS COMPRESSOR NO 2 L1 __________ L2 __________ L2...

Page 118: ...____________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________...

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