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Carrier WeatherMaker 50KCQ A04 Series, Service And Maintenance Instructions

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Carrier WeatherMaker 50KCQ A04 Series Service And Maintenance Instructions Download Page 1

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

Catalog No. 04-53500224-01

Printed in U.S.A.

Form 50KCQ-4-6-01SM

Pg 1 

2-2020

Replaces: NEW

Service and Maintenance Instructions

CONTENTS

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1
UNIT ARRANGEMENT AND ACCESS. . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Seasonal Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 3
RETURN-AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removing the Return Air Filters . . . . . . . . . . . . . . . . . 3
Re-installing the Access Panel . . . . . . . . . . . . . . . . . . 3
Outside-Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Economizer Inlet Air Screen . . . . . . . . . . . . . . . . . . . . 4
Manual Outside Air Hood Screen . . . . . . . . . . . . . . . . 4
SUPPLY FAN (BLOWER) SECTION  . . . . . . . . . . . . . . 4
Supply Fan (Direct-Drive)  . . . . . . . . . . . . . . . . . . . . . . 4
Supply Fan (Belt-Drive) . . . . . . . . . . . . . . . . . . . . . . . . 6
HEAT PUMP REFRIGERATION SYSTEM . . . . . . . . . . 8
Outdoor Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Indoor Coil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended Outdoor Coil Maintenance and 

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Reversing Valve and Checking Valve Position . . . . 10
Troubleshooting Refrigerant Pressure Problems and 

Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Metering Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Refrigerant System Pressure Access Ports  . . . . . . 14
PURON® (R-410A) REFRIGERANT. . . . . . . . . . . . . . 14
Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
COOLING CHARGING CHARTS  . . . . . . . . . . . . . . . . 14
How To Use Cooling Charging Charts . . . . . . . . . . . 14
Compressors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replacing the Compressor . . . . . . . . . . . . . . . . . . . . 18
Compressor Rotation  . . . . . . . . . . . . . . . . . . . . . . . . 18
Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Outdoor Fan Location . . . . . . . . . . . . . . . . . . . . . . . . 18
Troubleshooting Cooling System. . . . . . . . . . . . . . . 18
CONVENIENCE OUTLETS . . . . . . . . . . . . . . . . . . . . . 20
Convenience Outlet Types  . . . . . . . . . . . . . . . . . . . . 20
Installing Weatherproof Cover  . . . . . . . . . . . . . . . . . 20
HEAT PUMP CONTROLS . . . . . . . . . . . . . . . . . . . . . . 21
Central Terminal Board . . . . . . . . . . . . . . . . . . . . . . . 21
PROTECTIVE CONTROLS . . . . . . . . . . . . . . . . . . . . . 21
Compressor Protection . . . . . . . . . . . . . . . . . . . . . . . 21
COMMERCIAL DEFROST CONTROL . . . . . . . . . . . . 22
Reversing Valve Control . . . . . . . . . . . . . . . . . . . . . . 23
Compressor Control  . . . . . . . . . . . . . . . . . . . . . . . . . 23
Auxiliary (Electric) Heat Control . . . . . . . . . . . . . . . . 23
Defrost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Defrost Thermostats  . . . . . . . . . . . . . . . . . . . . . . . . . 24
Indoor Fan Off Delay  . . . . . . . . . . . . . . . . . . . . . . . . . 24

Defrost Speedup Functions . . . . . . . . . . . . . . . . . . . .24
ELECTRIC HEATERS . . . . . . . . . . . . . . . . . . . . . . . . .24
Single Point Boxes and Supplementary Fuses . . . .25
Safety Devices  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Completing Heater Installation  . . . . . . . . . . . . . . . . .25
SMOKE DETECTORS . . . . . . . . . . . . . . . . . . . . . . . . .26
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Smoke Detector Locations. . . . . . . . . . . . . . . . . . . . .27
Completing Installation of Return-Air Smoke

Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

FIOP Smoke Detector Wiring and Response . . . . . .28
Sensor and Controller Tests . . . . . . . . . . . . . . . . . . .29
Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
PREMIERLINK CONTROL  . . . . . . . . . . . . . . . . . . . . .32
RTU-OPEN CONTROL SYSTEM. . . . . . . . . . . . . . . . .32
ECONOMIZER SYSTEMS . . . . . . . . . . . . . . . . . . . . . .33
EconoMi$er IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Economi$er® X (Factory Option)  . . . . . . . . . . . . . . .43
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
START-UP, GENERAL  . . . . . . . . . . . . . . . . . . . . . . . .55
Additional Installation/Inspection . . . . . . . . . . . . . . .55
START-UP, PREMIERLINK™ . . . . . . . . . . . . . . . . . . .57
Perform System Check-Out . . . . . . . . . . . . . . . . . . . .57
START-UP, RTU-OPEN . . . . . . . . . . . . . . . . . . . . . . . .57
FASTENER TORQUE VALUES. . . . . . . . . . . . . . . . . .57

APPENDIX A — MODEL NUMBER

NOMENCLATURE. . . . . . . . . . . . . . . . . . . . . . . . . .58

APPENDIX B — PHYSICAL DATA . . . . . . . . . . . . . . .59

APPENDIX C — FAN PERFORMANCE . . . . . . . . . . .60

APPENDIX D — WIRING DIAGRAMS  . . . . . . . . . . . .68

APPENDIX E — MOTORMASTER SENSOR

LOCATIONS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

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, re-

pair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions

of cleaning coils and filters and replacing filters. All other op-

erations should be performed by trained service personnel.

When working on air-conditioning equipment, observe precau-

tions 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 extin-

guisher available for all brazing operations.

WeatherMaker

®

50KCQ 04-06 Single Package Rooftop Unit

Heat Pump/Electric Heat

with Puron

®

 (R-410A) Refrigerant

Summary of Contents for WeatherMaker 50KCQ A04 Series

Page 1: ... 24 Defrost Speedup Functions 24 ELECTRIC HEATERS 24 Single Point Boxes and Supplementary Fuses 25 Safety Devices 25 Completing Heater Installation 25 SMOKE DETECTORS 26 System 26 Controller 26 Sensor 26 Smoke Detector Locations 27 Completing Installation of Return Air Smoke Sensor 28 FIOP Smoke Detector Wiring and Response 28 Sensor and Controller Tests 29 Indicators 31 PREMIERLINK CONTROL 32 RTU...

Page 2: ...WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause personal injury death and or equipment damage R 410A refrigerant systems operate at higher pressures than standard R 22 systems Do not use R 22 service equipment or components on R 410A refrigerant equipment WARNING FIRE EXPLOSION HAZARD Failure to follow this warning could result in death serious personal injury a...

Page 3: ... outside air screen If a manual outside air damper is added it will also have an inlet air screen Each of these filters and screens will need to be periodically cleaned or replaced RETURN AIR FILTERS Return air filters are disposable fiberglass filters Access to the filters is through the lift out filter access panel located on the rear side of the unit above the indoor coil access panel See Fig 2...

Page 4: ...zes 04 05 and 06 a direct drive forward curved cen trifugal blower wheel is an available option The motor has taps to provide the servicer with the selection of one of five motor torque speed ranges to best match wheel performance with attached duct system See Fig 5 50KCQ Direct Drive Fan Assembly and Fig 6 ECM Motor Connectors Fig 5 50KCQ Direct Drive Supply Fan Assembly Fig 6 ECM Motor Connector...

Page 5: ...ach control tap setting At the Position 5 tap the motor speed is approximately 1050 RPM 17 5 r s but varies depending on fan wheel loading Selecting speed tap The five communication terminals are each programmed to pro vide a different motor torque output See Table 1 Factory default tap selection is Position 1 for lowest torque speed operation Factory Default Tap 1 VIO Selecting another speed 1 Di...

Page 6: ...on the motor The pulleys are con nected using a V belt See Fig 8 Fig 8 Typical Belt Drive Motor Mounting VARIABLE FREQUENCY DRIVE VFD For units equipped with a VFD factory installed option FIOP refer to the following supplement Variable Frequency Drive VFD Installation Setup and Troubleshooting BELT Check the belt condition and tension quarterly Inspect the belt for signs of cracking fraying or gl...

Page 7: ... 4 to 7 9 Nm 4 Recheck belt tension BEARINGS The fan system uses bearings featuring concentric split locking collars A Torx T 25 socket head cap screw is used to tighten the locking collars Tighten the locking collar by holding it tightly against the inner race of the bearing Tighten the socket head cap screw Torque cap screw to 55 to 60 in lb 6 2 to 6 8 Nm See Fig 11 Check the condition of the mo...

Page 8: ... edges Monthly cleaning as described in the following section is recommended ROUTINE CLEANING OF INDOOR COIL SURFACES Periodic cleaning with Totaline Environmentally Sound Coil Cleaner is essential in extending the life of coils This cleaner is available from Carrier Replacement Components Division part number P902 0301 for one gallon 3 8L container and part number P902 0305 for a 5 gallon 19L con...

Page 9: ...se all surfaces with low velocity clean water using downward rinsing motion of water spray noz zle Protect fins from damage from the spray nozzle CLEANING THE INDOOR COIL 1 Turn unit power off Use proper lockout tag out procedures 2 Remove indoor coil access panel 3 If economizer or two position damper is installed remove economizer by disconnecting the Molex1 plug and remov ing mounting screws 4 ...

Page 10: ...curater all 3 4 and 5 ton units Accurater 3 and 4 ton units only Acutrol COMPRESSOR ACCUMULATOR HPS Check Valve Schematic shown in Heating Mode Table 3 Cooling Mode each circuit COMPONENT STATUS POSITION Reversing Valve Energized Check Valve A Closed Check Valve B Open Check Valve C Closed Check Valve D Open Table 4 Heating Mode each circuit COMPONENT STATUS POSITION Reversing Valve De energized C...

Page 11: ...d line for cooling and heating modes respectively 2 While in cooling mode the liquid line header has Accutrol in each feeder tube Fig 15 Typical Metering Diagram for 50KCQ04 05 Evaporator Accurater Accurater Heating Mode Liquid Line Cooling Mode Liquid Line ...

Page 12: ...12 NOTE While in cooling mode the liquid line header has Accutrol in each feeder tube Fig 16 Typical Metering Diagram for 50KCQ06 Evaporator Heating Mode Liquid Line Cooling Mode Liquid Line ...

Page 13: ...ting mode the liquid header on the condenser coil has Accutrol in each feeder tube Fig 17 Typical Condenser Coil Metering Diagram Liquid Header Feeder Tube Feeder Tubes Feeder Tube Feeder Tube Feeder Tube Feeder Tube ...

Page 14: ...from the cylinder as a vapor Refrigerant Charge The amount of refrigerant charge is listed on the unit s name plate Refer to Carrier Publication GTAC2 5 Charging Recov ery Recycling and Reclamation Training Manual and the fol lowing procedures Unit panels must be in place when unit is operating during the charging procedure If unit is equipped with a head pressure con trol device bypass it to ensu...

Page 15: ...R U S S E R P E N I L N O I T C U S SUCTION LINE TEMPERATURE Cooling Charging Chart 3 Ton Heat Pump R 410A Refrigerant OUTDOOR TEMP F C 115 46 105 41 95 35 85 29 75 24 65 18 1 1 1 6 4 4 7 2 10 12 8 15 6 18 3 21 1 23 9 26 7 29 4 32 2 F C a p K e r u s s e r P n o i t c u S 1241 1172 1103 1034 965 896 827 758 690 621 552 48KC000265 Rev ...

Page 16: ... 90 100 110 120 130 140 150 160 170 180 30 35 40 45 50 55 60 65 70 75 80 85 90 a p K G I S P e r u s s e r P e n i L n o i t c u S Suction Line Temperature F C CHARGING CHART R 410A REFRIGERANT COOLING MODE OUTDOOR FAN MUST BE RUNNING 48KC000269 A 48KC000269 A 48KC000269 A 48KC000269 A 48KC000269 A OUTDOOR TEMP F C 115 46 105 41 95 35 85 29 75 24 65 18 ...

Page 17: ...ne Pressure PSIG Kpa Suction Line Temperature F C CHARGING CHART R 410A REFRIGERANT COOLING MODE OUTDOOR FAN MUST BE RUNNING 48KC000273 A OUTDOO R TEMP F C 115 46 105 41 95 35 85 29 75 24 A OUTDOO R TEMP F C 115 46 105 41 95 35 85 29 75 24 A OUTDOO R TEMP F C 115 46 105 41 95 35 85 29 75 24 OUTDOO R TEMP F C 115 46 105 41 95 35 85 29 75 24 A OUTDOO R TEMP F C 115 46 105 41 95 35 85 29 75 24 A OUTD...

Page 18: ... less than 650 psig 4482 kPa Outdoor Fan Location See Fig 22 1 Shut off unit power supply Apply lockout tag out procedures 2 Remove condenser fan assembly grille motor and fan 3 Loosen fan hub setscrews 4 Adjust fan height as shown in Fig 22 5 Tighten setscrews to 84 in lb 9 5 Nm 6 Replace condenser fan assembly Fig 22 Outdoor Fan Adjustment Troubleshooting Cooling System Refer to Table 6 for addi...

Page 19: ...ndoor fan heating motor or capacitor Replace Restriction in refrigerant system Locate restriction and remove Compressor operates continuously Dirty air filter Replace filter Unit undersized for load Decrease load or increase unit size Thermostat set too low cooling Reset thermostat Low refrigerant charge Locate leak repair and recharge Air in system Recover refrigerant evacuate system and recharge...

Page 20: ...location Route 125 vac 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 step down the main power supply voltage to the unit to 115 vac 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 ou...

Page 21: ...clud ing whether the unit is a heat pump Fig 26 Central Terminal Board CTB Jumpers JMP5 JMP6 and JMP7 are located in notches across the top of the CTB See Fig 26 These jumpers are factory cut on all heat pump units Visually check these jumpers to con firm that they have been cut PROTECTIVE CONTROLS Compressor Protection OVER CURRENT The compressor has internal line break motor protection OVER TEMP...

Page 22: ...device opens all motor power leads and the motor shuts down Reset requires a manu al reset at the overload switch This device designated IFCB is located on the side of the supply fan housing behind the fan access panel TROUBLESHOOTING SUPPLY FAN MOTOR OVER LOAD TRIP The supply fan used in the 50KCQ units is a forward curved centrifugal wheel At a constant wheel speed this wheel has a characteristi...

Page 23: ...n the end of the last defrost cycle or start of the current Heating cy cle during which no defrost will be permitted This period can be set at 30 60 90 or 120 minutes by changing the positions of DIP switches SW1 and SW2 see Fig 29 and Table 9 The de fault run periods are 60 minutes for unit sizes 04 06 Fig 29 DIP Switch Settings Defrost Board At the end of the continuous run period the defrost co...

Page 24: ...hen this mode is initiated the Defrost cycle will run for 30 secs Both modes end at the end of the Defrost cycle ELECTRIC HEATERS 50KCQ units can be equipped with field installed accessory electric heaters The heaters are modular in design with heater frames holding open coil resistance wires strung through ce ramic insulators line break limit switches and a control con tactor One or two heater mo...

Page 25: ...mit switch is located in the side plate of the indoor supply fan housing See Fig 31 and 34 Completing Heater Installation FIELD POWER CONNECTIONS Tap conductors must be installed between the base unit s field power connection lugs and the single point box with or with out fuses See Fig 33 and refer to unit wiring schematic Use copper wire only For connection using the single point box without fuse...

Page 26: ...e LEDs for Power Trouble and Alarm and a manual test reset button on the cover face Fig 39 Controller Assembly Sensor The sensor see Fig 40 includes a plastic housing a printed circuit board a clear plastic cover a sampling tube inlet and an exhaust tube The sampling tube when used and exhaust tube are attached during installation The sampling tube varies in length depending on the size of the roo...

Page 27: ...ted across the return air opening on the unit base pan See Fig 42 The holes in the sampling tube face downward into the return air stream The sampling tube is connected by tubing to the return air sensor that is mounted on a bracket high on the partition between return filter and con troller location This sensor is shipped in a flat mounting loca tion Installation requires that this sensor be relo...

Page 28: ...arm con dition de energizing the ORN conductor Fig 45 Return Air Sensor Operating Position HIGHLIGHT C 24 v power signal via ORN lead is removed at smoke detector input on CTB Control Terminal Board all unit operations cease immediately PREMIERLINK CONTROL Unit operating functions fan cooling and heating are termi nated as described above In addition HIGHLIGHT D On smoke alarm condition the smoke ...

Page 29: ...t and indicate its results Dirty Controller Test Procedure 1 Press the controller s test reset switch for two seconds 2 Verify that the controller s Trouble LED flashes A E F C D B IMPORTANT OPERATIONALTESTALERT Failure to follow this ALERT can result in an unnecessary evacuation of the facility This test places the duct detector into the alarm state Unless it is part of the test disconnect all au...

Page 30: ...e a sensor dirty test and indicate the re sults It must be wired to the controller as shown in Fig 47 and configured to operate the controller s supervision relay For more information see Changing the Dirty Sensor Test Table 11 Detector Indicators CONTROL OR INDICATOR DESCRIPTION Magnetic test reset switch Resets the sensor when it is in the alarm or trouble state Activates or tests the sensor whe...

Page 31: ...e contacts on the controller s alarm initiation relay close The controller s remote alarm LED output is activated turned on The controller s high impedance multiple fan shutdown control line is pulled to ground Trouble state The duct smoke detector enters the trouble state under the fol lowing conditions A sensor s cover is removed and 20 minutes pass before it is properly secured A sensor s envir...

Page 32: ...eck the controller s Power LED If it is off determine why the controller does not have power and make the nec essary repairs 2 Check the wiring between the sensor and the controller If wiring is loose or missing repair or replace as required Controller s Power LED is Off 1 Ensure the circuit supplying power to the controller is operational If not make sure JP2 and JP3 are set correctly on the cont...

Page 33: ...conoMi er IV and the W7220 controller is used for EconoMi er X See Fig 53 56 for econo mizer section wiring diagrams All three economizers use direct drive damper actuators Fig 50 EconoMi er X Component Locations Fig 51 EconoMi er IV Component Locations Fig 52 EconoMi er2 Component Locations OUTSIDE AIR TEMPERATURE SENSOR WIRING HARNESS ECONOMI ER IV CONTROLLER OUTSIDE AIR TEMPERATURE SENSOR LOW A...

Page 34: ...34 Fig 53 RTU Open Overlay for Economizer Wiring ...

Page 35: ...35 Fig 54 VFD Overlay for W2770 Controller Wiring ...

Page 36: ... 4 to 20 mA Control Wiring 4 3 5 2 8 6 7 1 10 11 9 12 PINK VIOLET BLACK BLUE YELLOW RUN RED WHITE ECONOMI ER2 PLUG DIRECT DRIVE ACTUATOR 4 20mA SIGNAL OAT SENSOR ACTULATOR CONTROL 4 20mA ACTULATOR FEEDBACK 2 10VDC TRANSFORMER GROUND ORANGE 500 OHM RESISTOR ...

Page 37: ...re The outdoor air temperature is used to determine when the EconoMi er IV can be used for free cooling The sensor is fac tory installed on the EconoMi er IV in the outdoor airstream See Fig 58 The operating range of temperature measure ment is 40 F to 100 F 4 C to 38 C See Fig 60 Supply Air Temperature SAT Sensor The supply air temperature sensor is a 3 K thermistor located at the inlet of the in...

Page 38: ...door air temperature is above the set point the EconoMi er IV will ad just the outside air dampers to minimum position If the out door air temperature is below the set point the position of the outside air dampers will be controlled to provided free cooling using outdoor air When in this mode the LED next to the free cooling set point potentiometer will be on The changeover temperature set point i...

Page 39: ...controller The set points are A B C and D See Fig 63 The factory installed 620 ohm jumper must be in place across ter minals SR and SR on the EconoMi er IV controller Fig 63 Enthalpy Changeover Set Points Fig 64 EconoMi er IV Control Differential Enthalpy Control For differential enthalpy control the EconoMi er IV controller uses two enthalpy sensors HH57AC078 and CRENT DIF004A00 one in the outsid...

Page 40: ...ition maintains the minimum airflow into the build ing during the occupied period When using demand ventilation the minimum damper position represents the minimum ventilation position for VOC volatile organic compound ventilation requirements The maximum de mand ventilation position is used for fully occupied ventilation When demand ventilation control is not being used the mini mum position poten...

Page 41: ...7 volts Line up the point on thegraph with the left side of the chart to determine that the range configuration for the CO2 sensor should be 1800 ppm The EconoMi er IV controller will output the 6 7 volts from the CO2 sensor to the actuator when the CO2 concentration in the space is at 1100 ppm The DCV set point may be left at 2 volts since the CO2 sensor voltage will be ignored by the EconoMi er ...

Page 42: ...hould drive fully closed 6 Turn the DCV and Exhaust potentiometers CCW until the Exhaust LED turns on The exhaust contacts will close 30 to 120 seconds after the Exhaust LED turns on 7 Return EconoMi er IV settings and wiring to normal after completing troubleshooting DCV MINIMUM AND MAXIMUM POSITION To check the DCV minimum and maximum position 1 Make sure EconoMi er IV preparation procedure has ...

Page 43: ... 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...

Page 44: ...r 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...

Page 45: ...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 Fig 70 W7220 Controller Navigation Buttons Press the Menu Up Exit button to exit a menu s item and return t...

Page 46: ...ters 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 configure...

Page 47: ... 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 40 F to 140 F 40 C to 60 C 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 out...

Page 48: ...N Displays only if CO2 sensor is connected Set point for Demand Controlled Ventilation of space Above the set point the OA dampers will modulate open to bring in additional OA to maintain a space ppm level below the set point MIN POS 2 8 V 2 to 10 vdc VENTILATION MINIMUM POSITION Displays ONLY if a CO2 sensor is NOT connected VENTMAX 2 8 V 2 to 10 vdc DCV MAXIMUM DAMPER POSITION Displays only if a...

Page 49: ...nts 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 45 F 7 C 35 F to 65 F 2 C to 18 C 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 ...

Page 50: ...he fully closed position CONNECT Y1 O N A N A Closes the Y1 O relay Y1 O CONNECT Y2 O N A N A Closes the Y2 O relay Y2 O CONNECT AUX1 O 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 ...

Page 51: ...s see Table 21 See Tables 22 25 for enthalpy and dry bulb operation 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 h...

Page 52: ...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 Ful...

Page 53: ...ood to economize and the mode is set to NO Figure 71 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 Fig 71 Single Enthalpy Curve Boundaries Table 25 Enthalpy Operation with DCV CO2 Sensor 1 Speed Fan DEMAND CON...

Page 54: ...ss 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 co...

Page 55: ...pect the SAT sensor for relocation as intended during installa tion Inspect special wiring as directed in Internal Wiring on page 56 UNIT PREPARATION Ensure the unit has been installed in accordance with installa tion instructions and applicable codes WARNING PERSONAL INJURY HAZARD Failure to follow this warning could result in personal inju ry or death 1 Follow recognized safety practices and wea...

Page 56: ...ain power supply Set system selector switch at COOL posi tion and fan switch to AUTO position Adjust thermostat to a setting below room temperature Compressor starts on closure of contactor Check unit charge Refer to Refrigerant Charge section on page 14 Reset thermostat at a position above room temperature Com pressor will shut off Evaporator fan will shut off after a 60 second delay if the dip s...

Page 57: ...ed in accordance with local codes and NEC ANSI NFPA 70 American National Standards Institute National Fire Protection Association NOTICE SET UP INSTRUCTIONS All set up and set point configurations are factory set and field adjustable Refer to PremierLink Installation Start Up and Configuration Instructions for specific operating instructions for the controller Have a copy of this manual available ...

Page 58: ...e Outlet 3 Hinged Panels 4 Hinged Panels Unpowered Convenience Outlet 5 Hinged Panels Powered Convenience Outlet Intake Exhaust Options A None B Temperature Economizer with Barometric Relief F Enthalpy Economizer with Barometric Relief K 2 Position Damper U Temp Ultra Low Leak Economizer with Baro Relief W Enthalpy Ultra Low Leak Econo with Baro Relief Base unit controls 0 Electromechanical Contro...

Page 59: ... 1200 Motor Frame Size 48 48 48 Fan Qty Type 1 Centrifugal 1 Centrifugal 1 Centrifugal Fan Diameter x Length in 10 x 10 10 x 10 11 x 10 MEDIUM STATIC 3 PHASE Motor Qty Drive Type 1 Belt 1 Belt 1 Belt Max BHP 1 5 1 5 2 0 RPM Range 819 1251 920 1303 1066 1380 Motor Frame Size 56 56 56 Fan Qty Type 1 Centrifugal 1 Centrifugal 1 Centrifugal Fan Diameter x Length in 10 x 10 10 x 10 10 x 10 HIGH STATIC ...

Page 60: ...he static pressure caused by any FIOPs or accessories 3 Tabular data accounts for pressure loss due to clean filters unit casing and wet coils Factory options and accessories can add static pressure losses 4 The Fan Performance tables offer motor drive recommendations In cases when two motor drive combinations would work Carrier recommends the lower horsepower option APPENDIX C FAN PERFORMANCE ...

Page 61: ...2 0 70 1500 0 97 0 73 LEGEND BHP Brake Horsepower CFM Cubic Feet per Minute ESP External Static Pressure Table D 50KCQ A04 DIRECT DRIVE 3 TON VERTICAL SUPPLY SPEED TORQUE TAP CFM ESP BHP 1 900 0 44 0 19 975 0 34 0 18 1050 0 24 0 17 1125 0 15 0 16 1200 0 07 0 16 1275 1350 1425 1500 2 900 0 60 0 24 975 0 49 0 23 1050 0 38 0 22 1125 0 28 0 21 1200 0 18 0 20 1275 0 09 0 19 1350 1425 1500 3 900 0 93 0 ...

Page 62: ...9 2000 0 87 0 93 LEGEND BHP Brake Horsepower CFM Cubic Feet per Minute ESP External Static Pressure Table F 50KCQ A05 DIRECT DRIVE 4 TON VERTICAL SUPPLY SPEED TORQUE TAP CFM ESP BHP 1 1200 0 87 0 43 1300 0 73 0 41 1400 0 59 0 39 1500 0 43 0 37 1600 0 27 0 34 1700 0 12 0 33 1800 1900 2000 2 1200 0 96 0 48 1300 0 84 0 46 1400 0 69 0 44 1500 0 53 0 41 1600 0 37 0 39 1700 0 21 0 36 1800 0 06 0 34 1900...

Page 63: ...2 2375 0 40 0 98 2500 0 16 0 93 LEGEND BHP Brake Horsepower CFM Cubic Feet per Minute ESP External Static Pressure Table H 50KCQ A06 DIRECT DRIVE 5 TON VERTICAL SUPPLY SPEED TORQUE TAP CFM ESP BHP 1 1500 0 27 0 32 1625 0 13 0 30 1750 1875 2000 2125 2250 2375 2500 2 1500 0 42 0 40 1625 0 25 0 37 1750 0 08 0 34 1875 2000 2125 2250 2375 2500 3 1500 1 11 0 79 1625 0 91 0 76 1750 0 70 0 74 1875 0 50 0 ...

Page 64: ... 1 59 1429 1 80 1425 1192 1 08 1260 1 26 1325 1 45 1386 1 65 1444 1 86 1500 1210 1 14 1278 1 33 1342 1 52 1403 1 72 1461 1 93 Medium static 819 1251 RPM 1 5 BHP max High static 1035 1466 RPM 2 0 BHP max Table J 50KCQ A04 3 TON VERTICAL SUPPLY CFM AVAILABLE EXTERNAL STATIC PRESSURE in wg 0 2 0 4 0 6 0 8 1 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 900 594 0 15 740 0 25 867 0 37 981 0 52 1084 0 68 97...

Page 65: ... 13 1259 1 31 1321 1 49 1380 1 67 1437 1 86 1700 1216 1 22 1282 1 40 1344 1 59 1402 1 78 1458 1 97 1800 1240 1 32 1305 1 50 1366 1 69 1424 1 89 1480 2 09 1900 1265 1 43 1329 1 61 1390 1 81 1447 2 01 1502 2 22 2000 1290 1 54 1353 1 73 1413 1 93 1470 2 14 1525 2 35 Medium static 920 1303 RPM 1 5 HP High static 1035 1466 RPM 2 0 BHP max Table L 50KCQ A05 4 TON VERTICAL SUPPLY CFM AVAILABLE EXTERNAL S...

Page 66: ... 1511 2 49 2500 1427 2 24 1487 2 47 1543 2 70 Medium static 1066 1380 RPM 2 0 HP max High static 1208 1550 RPM 2 9 BHP max Table N 50KCQ A06 5 TON VERTICAL SUPPLY CFM AVAILABLE EXTERNAL STATIC PRESSURE in wg 0 2 0 4 0 6 0 8 1 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 1500 794 0 41 902 0 55 993 0 69 1074 0 85 1147 1 00 1625 840 0 49 945 0 64 1034 0 80 1113 0 96 1185 1 13 1750 888 0 59 988 0 75 1075...

Page 67: ... 5 2 2 5 3 3 5 4 4 5 5 04 3 phase Medium static 1251 1208 1165 1121 1078 1035 992 949 905 862 819 High static 1466 1423 1380 1337 1294 1251 1207 1164 1121 1078 1035 05 3 phase Medium static 1303 1265 1226 1188 1150 1112 1073 1035 997 958 920 High static 1466 1423 1380 1337 1294 1251 1207 1164 1121 1078 1035 06 3 phase Medium static 1380 1349 1317 1286 1254 1223 1192 1160 1129 1097 1066 High static...

Page 68: ...16 page 74 A05 208 230 1 60 48TM501434 page 69 48TM501435 page 71 208 230 3 60 48TM501436 page 72 460 3 60 48TM501515 page 73 575 3 60 48TM501520 page 70 48TM501516 page 74 A06 208 230 1 60 48TM501434 page 69 48TM501435 page 71 208 230 3 60 48TM501436 page 72 460 3 60 48TM501515 page 73 575 3 60 48TM501520 page 70 48TM501516 page 74 ALL PremierLink 48TM501529 page 75 ALL RTU Open 50HE500751 page 7...

Page 69: ...69 Fig B 50KCQ A04 A05 A06 Control Wiring Diagram 208 230 1 60 208 230 3 60 460 3 60 APPENDIX D WIRING DIAGRAMS ...

Page 70: ...70 Fig C 50KCQ A04 A05 A06 Control Wiring Diagram 575 3 60 APPENDIX D WIRING DIAGRAMS ...

Page 71: ...71 Fig D 50KCQ A04 A05 A06 Power Wiring Diagram 208 230 1 60 APPENDIX D WIRING DIAGRAMS ...

Page 72: ...72 Fig E 50KCQ A04 A05 A06 Power Wiring Diagram 208 230 3 60 APPENDIX D WIRING DIAGRAMS ...

Page 73: ...73 Fig F 50KCQ A04 A05 A06 Power Wiring Diagram 460 3 60 APPENDIX D WIRING DIAGRAMS ...

Page 74: ...74 Fig G 50KCQ A04 A05 A06 Power Wiring Diagram 575 3 60 APPENDIX D WIRING DIAGRAMS ...

Page 75: ...75 Fig H 50KCQ Premier Link Control Diagram APPENDIX D WIRING DIAGRAMS ...

Page 76: ...76 Fig I 50KCQ RTU Open Control Diagram APPENDIX D WIRING DIAGRAMS ...

Page 77: ...77 Fig J 50KCQ A04 Outdoor Circuiting Fig K 50KCQ A05 A06 Outdoor Circuiting SENSOR LOCATION APPENDIX E MOTORMASTER SENSOR LOCATIONS ...

Page 78: ...ght to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53500224 01 Printed in U S A Form 50KCQ 4 6 01SM Pg 78 2 2020 Replaces NEW Carrier Corporation 2020 ...

Page 79: ...minals are tight 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 electrical wiring is not in contact with refrigerant lines or sharp metal edges Y N _____ Check pull...

Page 80: ...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 warm...

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