Carrier WeatherMaster Puron 48HC D17 Service And Maintenance Instructions Download Page 1 | Manualshive

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Carrier WeatherMaster Puron 48HC D17 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. 04-53480242-01

Printed in U.S.A.

Form 48HC-17-28-02SM

Pg 1

2-2020

Replaces: 48HC-17-28-01SM

Service and Maintenance Instructions

CONTENTS

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 2
UNIT ARRANGEMENT AND ACCESS. . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SUPPLY FAN (BLOWER) SECTION  . . . . . . . . . . . . . . 4
Supply Fan Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . 4
Belt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STAGED AIR VOLUME (SAV) CONTROL:

2-SPEED FAN WITH VARIABLE FREQUENCY
DRIVE (VFD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Staged Air Volume (SAV) Indoor Fan Speed

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Identifying Factory Option . . . . . . . . . . . . . . . . . . . . . 6
Unit Installation with SAV Option . . . . . . . . . . . . . . . . 6
ADDITIONAL VFD INSTALLATION AND

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 7

MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replacing the Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Changing Fan Wheel Speed by Changing Pulleys . . 7
CONDENSER COIL SERVICE . . . . . . . . . . . . . . . . . . . 8
Round Tube Plate Fin (RTPF) Condenser Coil . . . . . 8
Recommended Condenser Coil Maintenance and

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

EVAPORATOR COILS  . . . . . . . . . . . . . . . . . . . . . . . . . 9
Evaporator Coil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Coil Maintenance and Cleaning Recommendation . . 9
Evaporator Coil Metering Devices  . . . . . . . . . . . . . . 10
Refrigerant System Pressure Access Ports  . . . . . . 10
HUMIDI-MIZER® ADAPTIVE DEHUMIDIFICATION

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Humidi-MiZer Modes  . . . . . . . . . . . . . . . . . . . . . . . . . 11
Humidi-MiZer System Components . . . . . . . . . . . . . 11
Subcooler/Reheat Coil . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating Sequences  . . . . . . . . . . . . . . . . . . . . . . . . 11
THERMOSTATIC EXPANSION VALVE (TXV) . . . . . . 14
TXV Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing TXV  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Refrigerant System Pressure Access Ports  . . . . . . 16
PURON® (R-410A) REFRIGERANT. . . . . . . . . . . . . . 16
Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
COOLING CHARGING CHARTS  . . . . . . . . . . . . . . . . 18
COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing the Compressor . . . . . . . . . . . . . . . . . . . . 22
Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjusting the Condenser-Fan . . . . . . . . . . . . . . . . . . 22
TROUBLESHOOTING COOLING SYSTEM . . . . . . . . 22
Troubleshooting Cooling System. . . . . . . . . . . . . . . 22
CONVENIENCE OUTLETS . . . . . . . . . . . . . . . . . . . . . 24

Non-Powered Type . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Unit-Powered Type . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Wet in Use Convenience Outlet Cover . . . . . . . . . . .24
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
GFCI Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Fuse On Powered Type  . . . . . . . . . . . . . . . . . . . . . . .25
Using Unit-Mounted Convenience Outlets . . . . . . . .25
Installing a Weatherproof Cover . . . . . . . . . . . . . . . .25
SMOKE DETECTORS . . . . . . . . . . . . . . . . . . . . . . . . .25
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Smoke Detector Locations. . . . . . . . . . . . . . . . . . . . .26
FIOP Smoke Detector Wiring and Response . . . . . .28
Sensor and Controller Tests . . . . . . . . . . . . . . . . . . .29
Detector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Normal State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Alarm State  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
PROTECTIVE DEVICES  . . . . . . . . . . . . . . . . . . . . . . .32
Compressor Protection  . . . . . . . . . . . . . . . . . . . . . . .32
Supply (Indoor) Fan Motor Protection  . . . . . . . . . . .32
Control Circuit, 24-v . . . . . . . . . . . . . . . . . . . . . . . . . .33
PREMIERLINK CONTROL  . . . . . . . . . . . . . . . . . . . . .33
RTU-OPEN CONTROL SYSTEM. . . . . . . . . . . . . . . . .33
GAS HEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . .33
General  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Fuel Types and Pressures . . . . . . . . . . . . . . . . . . . . .33
Flue Gas Passageways  . . . . . . . . . . . . . . . . . . . . . . .34
Combustion-Air Blower . . . . . . . . . . . . . . . . . . . . . . .34
Burners and Igniters. . . . . . . . . . . . . . . . . . . . . . . . . .35
Gas Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
ECONOMI$ER SYSTEMS . . . . . . . . . . . . . . . . . . . . . .45
EconoMi$er IV Standard Sensors . . . . . . . . . . . . . . .49
EconoMi$er® X (Factory Option)  . . . . . . . . . . . . . . .54
PRE-START-UP/START-UP  . . . . . . . . . . . . . . . . . . . .68
START-UP, GENERAL  . . . . . . . . . . . . . . . . . . . . . . . .68
Unit Preparation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Additional Installation/Inspection . . . . . . . . . . . . . . .68
FASTENER TORQUE VALUES. . . . . . . . . . . . . . . . . .70
APPENDIX A — MODEL NUMBER

NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . .71

APPENDIX B — PHYSICAL DATA . . . . . . . . . . . . . . .72
APPENDIX C — FAN PERFORMANCE . . . . . . . . . . .76
APPENDIX D — WIRING DIAGRAMS . . . . . . . . . . . .83
APPENDIX E — MOTORMASTER SENSOR

LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . .CL-1

WeatherMaster

®

48HC*D17-D28

Gas Heat/Electric Cooling

with Puron

®

(R-410A) Refrigerant

1
2
3
...
»

Summary of Contents for WeatherMaster Puron 48HC D17

Page 1: ...0A REFRIGERANT 16 Refrigerant Charge 17 COOLING CHARGING CHARTS 18 COMPRESSORS 22 Lubrication 22 Replacing the Compressor 22 Filter Drier 22 Adjusting the Condenser Fan 22 TROUBLESHOOTING COOLING SYSTEM 22 Troubleshooting Cooling System 22 CONVENIENCE OUTLETS 24 Non Powered Type 24 Unit Powered Type 24 Wet in Use Convenience Outlet Cover 24 Duty Cycle 25 GFCI Maintenance 25 Fuse On Powered Type 25...

Page 2: ... conditioning equipment WARNING FIRE EXPLOSION HAZARD Failure to follow this warning could result in death serious personal injury and or property damage Never use air or gases containing oxygen for leak testing or for operating refrigerant compressors Pressurized mixtures of air or gases containing oxygen can lead to an explosion WARNING FIRE EXPLOSION HAZARD Failure to follow this warning could ...

Page 3: ...type Access to the filters is through the vertical panel to the right of the con trol box Filters are situated on slide out racks for easy inspec tion and repair See Fig 1 Removing the Return Air Filters 1 Remove the Return Air Filter and Indoor Coil Access Panel See Fig 1 2 Reach inside and remove the filters from the filter rack 3 Replace the filters as required with similar replacement filters ...

Page 4: ...ting Fig 5 Checking Blower Motor Belt Tension ADJUSTING THE BELT TENSION Use the following steps to adjust the V belt tension See Fig 4 1 Loosen the four motor mounting nuts that attach the motor to the blower rail 2 Loosen the two jackbolt locking nuts beneath the motor mounting plate Turn the jackbolt locking nut counter clockwise to loosen 3 Turn the jack bolts counterclockwise to loosen and cl...

Page 5: ... See Fig 4 3 Loosen movable pulley flange setscrew See Fig 6 4 Screw movable flange toward fixed flange to increase speed and away from fixed flange to decrease speed Increasing fan speed increases load on motor Do not exceed maximum fan speed in the product data or motor amperage as listed on the unit rating plate 5 Set movable flange at nearest keyway or flat of pulley hub and tighten setscrew t...

Page 6: ...or wiring schematics performance charts and configuration See Fig 8 for location of the VFD as mounted on the various 48HC models Fig 8 VFD Location for 48HC 17 28 Units Fig 9 Model Number Nomenclature Example for 48HC Series Table 1 Model Size VFD Option Indicator MODEL SIZES POSITION IN MODEL NUMBER VFD FIOP INDICATOR 48HC 17 28 17 G J VARIABLE FREQUENCY DRIVE VFD 4 8 H C D D 2 4 A 2 A 6 0 A 0 G...

Page 7: ... 22 Set new motor and motor mounting bracket back onto the unit See Fig 10 23 Install four bolts four flat washers four new lock washers and four nuts attaching the motor assembly to the unit 24 Do not tighten the mounting bolts at this time 25 Install motor drive V belt to motor pulley and blower wheel pulley See CAUTION 26 Align the motor pulley and blower wheel pulley using a straight edge See ...

Page 8: ...ts more difficult Surface loaded fibers must be completely removed prior to using low velocity clean wa ter rinse PERIODIC CLEAN WATER RINSE A periodic clean water rinse is very beneficial for coils that are applied in coastal or industrial environments However it is very important that the water rinse is made with a very low ve locity water stream to avoid damaging the fin edges Monthly cleaning ...

Page 9: ...lt in reduced durability in the environment When cleaning the coils avoid the use of the following coil brighteners acid cleaning prior to painting high pressure washers poor quality water for cleaning Totaline environmentally sound coil cleaner is non flammable hypoallergenic non bacterial and a USDA accepted biode gradable agent that will not harm the coil or surrounding com ponents such as elec...

Page 10: ...th black plastic caps The hose connection fittings are standard 1 4 in SAE male flare couplings The brass fittings are two piece High Flow valves with a re ceptacle base brazed to the tubing and an integral spring closed check valve core screwed into the base See Fig 14 This schrader valve is permanently assembled into the core body and cannot be serviced separately replace the entire core body if...

Page 11: ...rflow coming from the evaporator coil The refrigerant is subcooled in this coil to a temperature ap proaching the evaporator leaving air temperature The liquid refrigerant then enters a Thermostatic Expansion Valve TXV decreasing the air pressure The refrigerant enters the TXV and evaporator coil at a tempera ture lower than the temperature in the standard cooling opera tion This lower temperature...

Page 12: ...COMPRESSOR OUTDOOR AIR INDOOR AIR RH2 x VALVE RH1 x VALVE TXV VALVE CLOSED VALVE OPEN VALVE 3 WAY VALVE CONDENSER COIL HUMIDI MIZER COIL EVAPORATOR COIL COMPRESSOR OUTDOOR AIR INDOOR AIR RH2 x VALVE RH1 x VALVE TXV VALVE CLOSED VALVE OPEN VALVE 3 WAY VALVE CONDENSER COIL HUMIDI MIZER COIL EVAPORATOR COIL COMPRESSOR OUTDOOR AIR INDOOR AIR RH2 x VALVE RH1 x VALVE TXV VALVE CLOSED VALVE OPEN VALVE 3 ...

Page 13: ... ON G OFF OFF ON R OFF OFF OFF OFF ON X OFF Normal Heat 1 OFF OFF ON G OFF OFF ON R OFF OFF OFF OFF OFF ON ON Reheat Dehumidify ON ON ON G ON ON OFF ON R ON R ON OFF OFF ON ON Subcool Cir1 Reheat Cir2 Cool1 and Cool2 Subcool Dehumidify ON ON ON G ON ON OFF OFF ON R ON ON OFF ON ON Subcool Cir1 and Cir2 Cool1 and Cool2 Subcool Dehumidify ON ON ON G ON ON OFF OFF OFF OFF OFF ON X ON Heat Override He...

Page 14: ...eck under voltage is less than 15 Check for missing coil assembly parts Check for damaged valve enclosing tube Stuck valve Replace valve Replace filter drier RDV Valve Operation NOTE Normally Closed When De energized No 24V signal to input terminals Check using Cool Reheat1 Valve Test Service Test HMZR RHV A or RHV B using ComfortLink Scrolling Marquee Check MBB relay output Check wiring Check tra...

Page 15: ...pin carrier is spring loaded exert ing pressure on the underside of the diaphragm Therefore the bulb pressure equals the evaporator pressure at the outlet of the coil plus the spring pressure If the evapora tor load increases the temperature increases at the bulb which increases the pressure on the topside of the dia phragm pushing the carrier away from the seat opening the valve and increasing th...

Page 16: ...into this core body and cannot be serviced separately replace the entire core body if neces sary Service tools are available from RCD that allow the re placement of the check valve core without having to recover the entire system refrigerant charge Apply compressor refrig erant oil to the check valve core s bottom o ring Install the fit ting body with 96 10 in lbs of torque do not over tighten PUR...

Page 17: ...service port on the suction line Mount the temperature sensing device on the suction line and insulate it so that outdoor ambient temperature does not affect the read ing Indoor air cfm must be within the normal operating range of the unit EXAMPLE Model 48HC D28 Circuit A Outdoor Temperature 85 F 29 C Suction Pressure 125 psig 862 kPa Suction Temperature should be 63 F 17 C Circuit B Outdoor Tempe...

Page 18: ...18 COOLING CHARGING CHARTS Fig 22 Cooling Charging Chart 15 Ton ...

Page 19: ...19 Fig 23 Cooling Charging Chart 17 5 Ton ...

Page 20: ...20 Fig 24 Cooling Charging Chart 20 Ton ...

Page 21: ...21 Fig 25 Cooling Charging Chart 25 Ton ...

Page 22: ...ace the filter drier 1 Using Puron R 410A gage set recover all refrigerant from system 2 Use tubing cutter to remove filter drier from line NOTE Do not use a torch to remove old filter drier The heat from the torch will allow contaminants into the air and into the open re frigeration system 3 Sweat a new replacement filter drier into refrigerant line 4 Re charge refrigerant system Adjusting the Co...

Page 23: ...lter Replace air filter Unit undersized for load Decrease load or replace with larger unit Thermostat set too low Reset thermostat Low refrigerant charge Locate leak repair and recharge Leaking valves in compressor Replace compressor Air in system Recover refrigerant evacuate system and recharge Condenser coil dirty or restricted Clean coil or remove restriction Excessive Head Pressure Dirty air f...

Page 24: ... loading for continuous duty loads such as electric heat ers for overnight use Observe a 50 limit on circuit loading above 8 amps i e limit loads exceeding 8 amps to 30 minutes of operation every hour The primary leads to the convenience outlet transformer are not factory connected Selection of primary power source is a customer option If local codes permit the transformer primary leads can be con...

Page 25: ...l closing and latching Fig 29 Weatherproof Cover Installation SMOKE DETECTORS Smoke detectors are available as factory installed options on 48HC models Smoke detectors can be specified for supply air only for return air with or without economizer or in combina tion of supply air and return air Return air smoke detectors are arranged for vertical return configurations only All compo nents necessary...

Page 26: ...e alarm control panel etc The sensor uses a photoelectric light scattering principle pro cess called differential sensing preventing gradual environmen tal changes from triggering false alarms A rapid change in en vironmental conditions such as smoke from a fire causes the sensor to signal an alarm state but dust and debris accumulated over time does not Fig 31 Smoke Detector Sensor For installati...

Page 27: ...See installation steps Fig 33 Typical Return Air Smoke Detector Location without Economizer RETURN AIR WITH ECONOMIZER The sampling tube is inserted through the side plates of the economizer housing placing it across the return air opening on the unit basepan See Fig 34 The holes in the sampling tube face downward into the return air stream The sampling tube is connected through tubing to the retu...

Page 28: ...or NO Alarm con tact will close supplying 24 v power to GRA conductor HIGHLIGHT E GRA lead at Smoke Alarm input on LCTB provides 24 v sig nal to FIOP DDC control PREMIERLINK This signal is conveyed to PremierLink FIOP s TB1 at terminal TB1 6 BLU lead This signal initiates the FSD sequence by the PremierLink control FSD status is reported to connected CCN network RTU OPEN The 24 v signal is conveye...

Page 29: ...ing it against the sensor housing again for approxi mately 2 seconds until the sensor s Alarm LED turns off REMOTE STATION TEST The remote station alarm test checks a test reset station s abili ty to initiate and indicate an alarm state SD TRK4 REMOTE ALARM TEST PROCEDURE 1 Turn the key switch to the RESET TEST position for seven seconds 2 Verify that the test reset station s Alarm LED turns on 3 ...

Page 30: ...er 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 SuperDuct duct smoke detector enters the trouble state under the following conditions A sensor s cover is removed and 20 minutes pass before it is properly secured A sensor s environmental compensa...

Page 31: ...must be reset in order to restore it to the normal state ALARM POWER TEST RESET SWITCH TROUBLE RESET ALARM TROUBLE POWER Table 7 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 when it is in the normal state Alarm LED Indicates the sensor is in the alarm state Trouble LED Indica...

Page 32: ...ection Reset is automatic after compressor motor has cooled OVERTEMPERATURE Each compressor has an internal protector to protect it against excessively high discharge gas temperatures Reset is automatic HIGH PRESSURE SWITCH Each system is provided with a high pressure switch mounted on the discharge line The switch is stem mounted and brazed into the discharge tube Trip setting is 630 psig 10 psig...

Page 33: ...system consists of a gas valve feeding mul tiple inshot burners off a manifold The burners fire into match ing primary tubes The tubes exit into the collector box the into the induced draft fan wheel inlet The induced fan wheel discharges into a flue passage and flue gases exit out a flue hood on the side of the unit The induced draft fan motor in cludes a Hall Effect sensor circuit that confirms ...

Page 34: ...3 LP Supply Line Low Pressure Switch Wiring Flue Gas Passageways To inspect the flue collector box and upper areas of the heat exchanger 1 Remove the combustion blower wheel and motor assem bly according to directions in Combustion Air Blower sec tion See Fig 44 2 Remove the flue cover to inspect the heat exchanger 3 Clean all surfaces as required using a wire brush Combustion Air Blower Clean per...

Page 35: ...ply line 2 Turn the gas valve ON OFF knob to the OFF position 3 Shut off power to unit and install lockout tag 4 Disconnect gas piping at unit gas valve 5 Remove wires connected to gas valve Mark each wire to assist in re connecting power to the gas valve BURNER ASSEMBLY GAS VALVE INDUCER FAN MOTOR ASSEMBLY VESTIBULE PLATE SUPPORT INSULATION ASSEMBLY HEATER TUBE ASSEMBLY SEAL STRIPS SPONGE RUBBER ...

Page 36: ... mm to 3 60 mm and spaced 0 18 in 4 60 mm from the end of the burner See Fig 50 5 If factory orifice has been removed check that each orifice is tight at its threads into the manifold pipe and that orifice projection does not exceed maximum valve See Fig 45 6 Reinstall burners on the rack in the same locations as they were installed at the factory The outside crossover flame regions of the outermo...

Page 37: ...37 Fig 48 Unit Control Box IGC Location IGC Board IGC Board Side view Front view ...

Page 38: ...ted When a break in power occurs the IGC will be reset resulting in a loss of fault history and the indoor evaporator fan ON OFF times will be reset The LED error code can be observed through the viewport During servicing refer to the label on the control box cover or Table 13 for an explanation of LED error code descriptions A 3 second pause exists between LED error code flashes If more than one ...

Page 39: ...113 0 1130 34 LH32RF111 0 1110 35 LH32RF110 0 1100 36 LH32RF105 0 1065 37 LH32RF104 0 1040 38 LH32RF102 0 1015 39 LH32RF103 0 0995 40 LH32RF098 0 0980 41 LH32RF096 0 0960 42 LH32RF094 0 0935 43 LH32RF089 0 0890 44 LH32RF086 0 0860 45 LH32RF082 0 0820 46 LH32RF080 0 0810 47 LH32RF079 0 0785 48 LH32RF076 0 0760 49 LH32RF073 0 0730 50 LH32RF070 0 0700 51 LH32RF067 0 0670 52 LH32RF065 0 0635 53 LH32RF...

Page 40: ...40 Fig 51 Typical IGC Wiring Diagram ...

Page 41: ...peed sensor gas section analog input J1 1 3 FS T1 Flame sensor gas section switch input W Heat stage 1 LCTB 24 vac J2 2 RS Rollout switch gas section switch input J2 5 6 LS Limit switch fan section switch input J2 7 8 CS Centrifugal switch not used switch input J2 9 10 OUTPUTS L1 CM Induced draft combustion motor gas section line VAC IFO Indoor fan control box relay J2 1 GV Gas valve heat stage 1 ...

Page 42: ...12 000 3658 372 114 400 372 161 200 372 208 000 13 000 3962 392 105 600 392 148 800 392 192 000 14 000 4267 392 96 800 392 136 400 392 176 000 KIT NO XX1 CRNGELEV001A00 XX2 CRNGELEV002A00 XX3 CRLPELEV005A00 XX4 CRLPELEV006A00 XX5 CRLPKIT9001A00 Table 17 Altitude Compensation 17 30 for Propane Gas PROPANE GAS NOMINAL HEAT INPUT ELEVATION 220k BTUH 310k BTUH 400k BTUH Feet Meters Orifice Size Input ...

Page 43: ...ve Water in gas line Drain water and install drip leg to trap water No power to furnace Check power supply fuses wiring and circuit breaker No 24 v power supply to control circuit Check transformer Transformers with internal overcurrent protection require a cool down period before resetting Miswired or loose connections Check all wiring and wire nut connections Burned out heat anticipator in therm...

Page 44: ...er reset for LED reset 4 consecutive limit switch faults within a single call for heat See Limit Switch Fault 5 Flashes Ignition Fault No gas heating Heat call W Off Power reset for LED reset Unit unsuccessfully attempted ignition for 15 minutes Check igniter and flame sensor electrode spacing gaps etc Check flame sense and igniter wiring Check gas valve operation and gas supply 6 Flashes Induced ...

Page 45: ...conoMi er 2 Component Locations IMPORTANT Any economizer that meets the economizer requirements as laid out in California s Title 24 mandatory section 120 2 fault detection and diagnostics and or pre scriptive section 140 4 life cycle tests damper leakage 5 year warranty sensor accuracy etc will have a label on the economizer Any economizer without this label does not meet California s Title 24 Th...

Page 46: ...46 Fig 57 RTU Open Overlay for Economizer Wiring ...

Page 47: ...47 Fig 58 VFD Overlay for W2770 Controller Wiring ...

Page 48: ...ion for economizer to operate 2 PremierLink control requires that the standard 50HJ540569 out side air sensor be replaced by either the CROASENR001A00 dry bulb sensor or HH57A077 enthalpy sensor 3 50HJ540573 actuator consists of the 50HJ540567 actuator and a harness with 500 ohm resistor Fig 60 EconoMi er2 with 4 to 20 mA Control Wiring FOR OCCUPANCY CONTROL REPLACE JUMPER WITH FIELD SUPPLIED TIME...

Page 49: ...en 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 62 The operating range of temperature measure ment is 40 F to 100 F 4 C to 38 C See Fig 63 SUPPLY AIR TEMPERATURE SAT SENSOR The supply air temperature sensor is a 3 K thermistor located at the inlet of the indoor fan See Fig 62 This sensor is factory installed T...

Page 50: ...outdoor air When in this mode the LED next to the free cooling setpoint potentiometer will be on The changeover temperature setpoint is controlled by the free cooling setpoint potentiometer located on the control See Fig 64 The scale on the potentiometer is A B C and D See Fig 65 for the cor responding temperature changeover values Fig 64 EconoMi er IV Controller Potentiometer and LED Locations Fi...

Page 51: ... When using this mode of changeover control turn the enthalpy set point potentiometer fully clockwise to the D setting INDOOR AIR QUALITY IAQ SENSOR INPUT The IAQ input can be used for demand controlled ventilation control based on the level of CO2 measured in the space or re turn air duct Mount the accessory IAQ sensor according to manufacturer specifications The IAQ sensor should be wired to the...

Page 52: ... field sup plied remote potentiometer Honeywell part number S963B1128 is wired to the EconoMi er IV controller the minimum position of the damper can be controlled from a re mote location To control the minimum damper position remotely remove the factory installed jumper on the P and P1 terminals on the EconoMi er IV controller Wire the field supplied potentiome ter to the P and P1 terminals on th...

Page 53: ...1 4 Press Enter to lock in the selection 5 Press Mode to exit and resume normal operation CRENTDIF004A00 and CRTEMPSN002A00 accessories are used on many different base units As such these kits may contain parts that will not be needed for installation 33ZCSENCO2 is an accessory CO2 sensor 33ZCASPCO2 is an accessory aspirator box required for duct mounted applications CRCBDIOX005A00 is an accessory...

Page 54: ...oting DCV MINIMUM AND MAXIMUM POSITION To check the DCV minimum and maximum position 1 Make sure EconoMi er IV preparation procedure has been performed 2 Connect a 9 v battery to AQ positive node and AQ1 negative node The DCV LED should turn on The actua tor should drive to between 90 and 95 open 3 Turn the DCV Maximum Position potentiometer to mid point The actuator should drive to between 20 and...

Page 55: ...lay and four button keypad Electrical Rated Voltage 20 to 30 vac RMS 50 60 Hz Transformer 100 va maximum system input Nominal Power Consumption at 24 vac 60 Hz 11 5 VA without sensors or actuators Relay Digital Output Rating at 30 vac maximum power from Class 2 input only 1 5A run 3 5A inrush at 0 45PF 200 000 cycles or 7 5A inrush at 0 45PF 100 000 cycles External Sensors Power Output 21 vdc 5 at...

Page 56: ...ensor Common IAQ 24V 24 vac Air Quality Sensor 24 vac Source ACT 2 10 2 10 vdc Damper Actuator Output 2 10 vdc ACT COM COM Damper Actuator Output Common ACT 24v 24 vac Damper Actuator 24 vac Source NA AUX2 OCC E GND EXH1 AUX1 O Y2 Y1 Y2 O Y1 O C R 50048848 002 Rev A NA A2 OCC EX A1 Y2I Y2O Y1I Y1O C R MAT MAT OAT OAT S BUS S BUS IAQ 2 10 IAQCOM IAQ 24V ACT 2 10 ACT COM ACT 24V MA MA OA OA SB SB SB...

Page 57: ...ns To use the keypad when working with Setpoints System and Advanced Settings Checkout tests and Alarms 1 Navigate to the desired menu 2 Press the Enter button to display the first item in the currently displayed menu 3 Use the and buttons to scroll to the desired parameter 4 Press the Enter button to display the value of the currently displayed item 5 Press the button to increase change the displ...

Page 58: ... Y2 I signal from space thermostat or unitary controller for second stage cooling ON 24 vac on terminal Y2 I OFF 0 vac on terminal Y2 I COOL Y2 OUT OFF ON OFF SECOND STAGE COOLING RELAY OUTPUT Cool Stage 2 Relay Output to mechanical cooling Y2 OUT terminal MA TEMP _ _ _ F or _ _ _ C 40 F to 150 F 40 C to 66 C SUPPLY AIR TEMPERATURE Cooling Mode Displays value of measured mixed air from MAT sensor ...

Page 59: ...RYBLB SET 63 F 17 C 48 F to 80 F 9 C to 27 C increment by 1 degree OA DRY BULB TEMPERATURE CHANGEOVER SETPOINT Dry bulb set point will only appear if using dry bulb changeover Set point determines where the economizer will assume outdoor air temperature is good for free cooling e g at 63 F unit will economize at 62 F and below and not economize at 64 F and above There is a 2 F deadband ENTH CURVE ...

Page 60: ...V mode for W Shutdown is not available in 2 speed fan mode In HP O B mode HP O energize heat pump on Cool default HP B energize heat pump on heat FAN SPEED 2 speed 1 speed 2 speed Sets the economizer controller for operation of 1 speed or 2 speed supply fan The controller does not control the fan but positions the OA and RA dampers to heating or cooling mode NOTE 2 speed fan option also needs Heat...

Page 61: ...f calibration humidity sensor DA T CAL 0 0 F 2 5 F DISCHARGE AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor 2SP FAN DELAY 5 Minutes 0 to 20 minutes in 1 minute increments TIME DELAY ON SECOND STAGE ECONOMIZING When in economizing mode this is the delay for the high speed fan to try to satisfy the call for second stage cooling before the f...

Page 62: ...r enthalpy sensor has failed or become disconnected check wiring then replace sensor if the alarm continues RA SYLK H ERR N A N A DA SYLK T ERR N A N A DISCHARGE AIR S BUS SENSOR ERROR Discharge air sensor has failed or become disconnected check wiring then replace sensor if the alarm continues OA SENS T ERR N A N A OUTSIDE AIR TEMPERATURE SENSOR ERROR Outdoor air temperature sensor has failed or ...

Page 63: ...0 v Off MIN POS Closed On On High 24 v On 24 v On MIN POS Closed Yes Off Off High 0 v Off 0 v Off MIN POS Closed On Off High 0 v Off 0 v Off MIN POS to Full Open Closed to Full Open On On High 24 v On 0 v Off MIN POS to Full Open Closed to Full Open Table 29 Dry Bulb Operation with DCV CO2 Sensor 1 Speed Fan DEMAND CONTROLLED VENTILATION DCV OUTSIDE AIR GOOD TO ECONOMIZE Y1 I Y2 I FAN SPEED Y1 O Y...

Page 64: ...f Off High 0 v Off 0 v Off MIN POS Closed On Off High 0 v Off 0 v Off MIN POS to Full Open Closed to Full Open On On High 24 v On 0 v Off MIN POS to Full Open Closed to Full Open Table 31 Enthalpy Operation with DCV CO2 Sensor 1 Speed Fan DEMAND CONTROLLED VENTILATION DCV OUTSIDE AIR GOOD TO ECONOMIZE Y1 I Y2 I FAN SPEED Y1 O Y2 O OCCUPIED UNOCCUPIED Below CO2 set No Off Off High 0 v Off 0 v Off V...

Page 65: ...I Y2 I FAN SPEED Y1 O Y2 O OCCUPIED UNOCCUPIED Below CO2 Set No OFF OFF LOW 0v Off 0v Off VENTMIN Closed ON OFF LOW 24v On 0v Off VENTMIN Closed ON ON HIGH 24v On 24v On VENTMIN Closed Yes OFF OFF LOW 0v Off 0v Off VENTMIN Closed ON OFF LOW 0v Off 0v Off VENTMIN to Full Open Closed to Full Open ON ON HIGH 24v On 0v Off VENTMIN to Full Open Closed to Full Open Above CO2 Set No OFF OFF LOW 0v Off 0v...

Page 66: ...us to determine the speed of the supply fan and controls the OA damper to the required posi tion see Table 36 The W heating mode is not controlled by the W7220 but it re quires the status to know where to position the OA damper for minimum position for the fan speed The 2 speed fan delay is available when the system is pro grammed for 2 speed fan in the System Setup menu item The 2 speed fan delay...

Page 67: ...ears 3 Press the Enter button to start the test The unit pauses and then displays IN PROGRESS When the test is complete DONE appears 4 When all desired parameters have been tested press the Menu Up button to end the test The Checkout tests can all be performed at the time of installa tion or at any time during the operation of the system as a test that the system is operable TROUBLESHOOTING Alarms...

Page 68: ...when field accessories have been added to the unit The factory pre configures options installed at the factory There may also be additional installation steps or inspection required during the start up process Additional Installation Inspection Inspect the field installed accessories for proper installation making note of which ones do or do not require configuration changes Inspect the RTU OPEN s...

Page 69: ...oom temperature and verify that the burners light and evaporator fan is energized Check heating effect then lower the thermostat setting below the room tem perature and verify that the burners and evaporator fan turn off Refer to Tables 16 and 17 for the correct orifice to use at high altitudes HEATING 1 Purge gas supply line of air by opening union ahead of the gas valve If gas odor is detected t...

Page 70: ...will occur at 25 seconds To prevent short cycling a 5 second re duction will only occur if a minimum of 10 minutes has elapsed since the last call for heating The evaporator fan off delay can also be modified Once the call for heating has ended there is a 10 minute period during which the modification can occur If the limit switch trips during this period the evaporator fan off delay will increase...

Page 71: ...Cu Al Cu B Precoat Al Cu Al Cu C E coat Al Cu Al Cu D E coat Al Cu E coat Al Cu E Cu Cu Al Cu F Cu Cu Cu Cu M Al Cu Al Cu Louvered Hail Guard N Precoat Al Cu Al Cu Louvered Hail Guard P E coat Al Cu Al Cu Louvered Hail Guard Q E coat Al Cu E coat Al Cu Louvered Hail Guard R Cu Cu Al Cu Louvered Hail Guard S Cu Cu Cu Cu Louvered Hail Guard Voltage 1 575 3 60 5 208 230 3 60 6 460 3 60 Design Revisio...

Page 72: ...0 Motor frame size 56 56 56 56 Fan qty Type 2 Centrifugal 2 Centrifugal 2 Centrifugal 2 Centrifugal Fan diameter in 15 x 15 15 x 15 15 x 15 15 x 15 MEDIUM STATIC Motor qty Belt qty Driver type 1 1 Belt 1 1 Belt 1 1 Belt 1 1 Belt Nominal nameplate H P 3 7 3 7 5 25 5 25 Max BHP 3 7 3 7 4 9 4 9 RPM range 679 863 679 863 713 879 713 879 Max blower Shaft RPM 1200 1200 1200 1200 Motor frame size 56 56 5...

Page 73: ...6 56 n a n a Fan qty Type 2 Centrifugal 2 Centrifugal n a n a Fan diameter in 18 x 15 15 X 11 18 x 15 15 X 11 n a n a HIGH STATIC HIGH EFFICIENCY Motor qty Belt qty Driver type n a n a 1 1 Belt 1 1 Belt Nominal nameplate H P n a n a 5 0 5 0 Max BHP n a n a 6 5 6 9 7 0 8 3 6 5 6 9 7 0 8 3 RPM range n a n a 835 1021 835 1021 Max blower Shaft RPM 1100 1100 1100 1100 Motor frame size n a n a 184T 184T...

Page 74: ...ge n a n a n a n a Max blower Shaft RPM 1200 1200 1200 1200 Motor frame size n a n a n a n a Fan qty Type n a n a n a n a Fan diameter in n a n a n a n a STANDARD STATIC HIGH EFFICIENCY Motor qty Belt qty Driver type 1 1 Belt 1 1 Belt n a n a Nominal nameplate H P 5 0 5 0 n a n a Max BHP 6 5 6 9 7 0 8 3 6 5 6 9 7 0 8 3 n a n a RPM range 690 863 690 863 n a n a Max blower Shaft RPM 1200 1200 n a n ...

Page 75: ...elt 1 1 Belt 1 1 Belt Nominal nameplate H P 7 5 7 5 7 5 7 5 Max BHP 10 5 11 9 11 9 11 10 5 11 9 11 9 11 10 5 11 9 11 9 11 10 5 11 9 11 9 11 RPM range 941 1100 941 1100 906 1100 906 1100 Max blower Shaft RPM 1100 1100 1100 1100 Motor frame size 213T 213T 213T 213T Fan qty Type 2 Centrifugal 2 Centrifugal 2 Centrifugal 2 Centrifugal Fan diameter in 18 x 15 15 X 11 18 x 15 15 X 11 18 x 15 15 X 11 18 ...

Page 76: ...BHP max High static 746 912 RPM 4 9 BHP max Table D 48HCF 17 Vertical Supply 15 Tons 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 4500 494 0 77 583 1 09 662 1 43 732 1 80 796 2 19 4900 522 0 93 605 1 27 681 1 64 750 2 03 813 2 44 5250 547 1 10 626 1 45 700 1 84 766 2 24 828 2 67 5650 577 1 32 651 1 68 721 2 09 786 2 51 846 2 96 6000 603 1...

Page 77: ...static 622 822 RPM 3 7 BHP max Medium static 713 879 RPM 4 9 BHP max High static 835 1021 RPM Voltage 208v 230v 460v 575v Max BHP 6 5 6 9 7 0 8 3 Table F 48HCF 20 Vertical Supply 17 5 Tons 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 5250 547 1 10 626 1 45 700 1 84 766 2 24 828 2 67 5700 581 1 35 655 1 72 724 2 12 789 2 55 849 3 00 6150 6...

Page 78: ...6 10 998 6 81 8500 843 4 73 896 5 45 945 6 18 991 6 93 1034 7 68 9000 886 5 52 937 6 28 984 7 06 1029 7 84 1071 8 63 9500 929 6 40 978 7 21 1024 8 02 1067 8 84 10000 973 7 38 1020 8 22 1064 9 08 CFM AVAILABLE EXTERNAL STATIC PRESSURE IN WG 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 6000 907 4 68 949 5 27 990 5 88 1028 6 50 1064 7 13 6500 939 5 29 981 5 92 1020 6 56 1058 7 21 1094 ...

Page 79: ... 1011 5 03 1059 5 51 9500 893 4 20 947 4 69 998 5 19 1046 5 69 1092 6 19 10000 934 4 85 986 5 36 1035 5 88 1082 6 40 1126 6 93 CFM AVAILABLE EXTERNAL STATIC PRESSURE IN WG 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 6000 928 2 92 978 3 28 1025 3 65 1071 4 03 1114 4 42 6500 955 3 31 1003 3 69 1050 4 09 1094 4 49 1137 4 89 7000 983 3 75 1030 4 15 1075 4 56 1119 4 98 1161 5 41 7500 10...

Page 80: ... 93 1034 7 68 9000 886 5 52 937 6 28 984 7 06 1029 7 84 1071 8 63 9500 929 6 40 978 7 21 1024 8 02 1067 8 84 10000 973 7 38 1020 8 22 1064 9 08 10500 1017 8 45 1062 9 33 11000 1061 9 63 11500 CFM AVAILABLE EXTERNAL STATIC PRESSURE IN WG 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 7500 1005 6 72 1046 7 42 1084 8 13 8000 1040 7 54 1079 8 28 8500 1075 8 45 9000 9500 10000 10500 11000 ...

Page 81: ...5 67 1131 6 15 1173 6 64 9400 1129 6 56 1172 7 07 10000 1169 7 47 10650 11250 11900 12500 Standard static 717 911 RPM 4 9 Max BHP Medium static 913 1116 RPM Voltage 208v 230v 460v 575v Max BHP 6 5 6 9 7 0 8 3 High static 941 1176 RPM Voltage 208v 230v 460v 575v Max BHP 10 5 11 9 11 9 11 0 Table K Pulley Adjustment Vertical Fan RPM at Motor Pulley Settings MODEL SIZE MOTOR DRIVE COMBO MOTOR PULLEY ...

Page 82: ... 763 746 20 3 phase Standard Static 822 802 782 762 742 722 702 682 662 642 622 Medium Static 879 862 846 829 813 796 779 763 746 730 713 High Static 1021 1002 984 965 947 928 909 891 872 854 835 24 3 phase Standard Static 863 846 828 811 794 777 759 742 725 707 690 Medium Static 1021 1002 984 965 947 928 909 891 872 854 835 High Static 1176 1153 1129 1106 1082 1059 1035 1012 988 965 941 28 3 phas...

Page 83: ... L page 86 50HE502183 F page 90 575 3 60 50HE500888 L page 87 50HE502184 F page 91 D20 208 230 3 60 50HE500889 L page 85 50HE502186 D page 89 460 3 60 50HE500752 L page 86 50HE502183 F page 90 575 3 60 50HE500888 L page 87 50HE502184 F page 91 D24 208 230 3 60 50HE500889 L page 85 50HE502186 D page 89 460 3 60 50HE500752 L page 86 50HE502183 F page 90 575 3 60 50HE500888 L page 87 50HE502184 F pag...

Page 84: ...84 Fig B 48HC D17 D28 Control Diagram 208 230 3 60 460 575 3 60 ...

Page 85: ...85 Fig C 48HC D17 D28 Power Diagram 208 230 3 60 ...

Page 86: ...86 Fig D 48HC D17 D28 Power Diagram 460 3 60 ...

Page 87: ...87 Fig E 48HC D17 D28 Power Diagram 575 3 60 ...

Page 88: ...88 Fig F 48HC D17 D28 Control Diagram with Humidi MiZer System ...

Page 89: ...89 Fig G 48HC D17 D28 Power Diagram 208 230 3 60 with Humidi MiZer System ...

Page 90: ...90 Fig H 48HC D17 D28 Power Diagram 460 3 60 with Humidi MiZer System ...

Page 91: ...91 Fig I 48HC D17 D28 Power Diagram 575 3 60 with Humidi MiZer System ...

Page 92: ...92 Fig J PremierLink System Control Wiring Diagram 50HE500891 F ...

Page 93: ...93 Fig K PremierLink System Control Wiring Diagram with Humidi MiZer System ...

Page 94: ...94 Fig L RTU OPEN Wiring Diagram ...

Page 95: ...95 Fig M RTU OPEN Wiring Diagram with Humidi MiZer System ...

Page 96: ...96 APPENDIX E MOTORMASTER SENSOR LOCATIONS Fig N MotorMaster Sensor Locations for D17 D20 and D24 Units Fig O MotorMaster Sensor Locations D28 SENSOR LOCATION SENSOR LOCATION ...

Page 97: ......

Page 98: ... discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53480242 01 Printed in U S A Form 48HC 17 28 02SM Pg 98 2 2020 Replaces 48HC 17 28 01SM Carrier Corporation 2020 ...

Page 99: ...k gas piping for leaks Y N _____ Check that indoor air filters are clean and in place Y N _____ Check that outdoor air inlet screens are in place Y N _____ Verify that unit is level Y N _____ Check fan wheels and propeller for location in housing orifice and verify setscrew is tight Y N _____ Verify that fan sheaves are aligned and belts are properly tensioned Y N _____ Verify installation of ther...

Page 100: ... and open Y N _____ 2 Open humidistat contacts Y N _____ 3 Start unit In cooling Close Y1 Y N _____ OBSERVE AND RECORD A Suction pressure _______________ PSIG B Discharge pressure _______________ PSIG C Entering air temperature _______________ F D Liquid line temperature at outlet or reheat coil _______________ F E Confirm correct rotation for compressor Y N _____ F Check for correct ramp up of ou...

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