Carrier 48EJ manual

Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERA TIONS ...................1 INST ALLA TION ............................. 1-31 Step 1 — Provide Unit Support ...............1 • ROOF CURB • AL TERNA TE UNIT SUPPOR T Step 2 — Rig and Place Unit ..................2 • POSITIONING • ROOF MOUNT Step 3 — Field Fab[...]

AL TERNA TE UNIT SUPPOR T — When the preferred curb or slab mount cannot be used, support unit with sleepers on perimeter , using unit curb support area. If sleepers cannot be used, support long sides of unit (refer to Fig. 3-6) with a minimum number of 4-in. x 4-in. pads spaced as follows: 48EJ,EK,EW ,EY024-034 units require 3 pads on each side;[...]

NOTES: 1. All roof curb parts are to be 16 ga galvanized steel. 2. Dimensions are in inches. 3. T o prevent standing water in the drain pan of the indoor section and the heat exchangers, unit can only be pitched as shown. UNIT LEVELING TOLERANCES DIMENSIONS* (Degrees and Inches) AB Deg. in. Deg. in. 1.0 2.9 .50 .75 *From edge of unit to horizontal.[...]

NOTES: 1. All roof curb parts are to be 16 ga galvanized steel. 2. Dimensions are in inches. 3. T o prevent standing water in the drain pan of the indoor section and the heat exchangers, unit can only be pitched as shown. UNIT LEVELING TOLERANCES DIMENSIONS* (Degrees and Inches) AB Deg. in. Deg. in. 1.0 2.9 .50 .75 *From edge of unit to horizontal.[...]

VFD — V ariable Frequency Drive NOTES: 1. Weights include economizer (STD). 2. Center of gravity . 3. Do not locate adjacent units with flue dis- charge facing economizer inlet. Minimum clear- ances to be: Adjacent Units: 15 8 -0 9 T op of Units: No overhang Condenser Coil: 4 8 -0 9 Economizer Side: 6 8 -0 9 Gas Heat Side: 4 8 -0 9 Filter Access[...]

VFD — V ariable Frequency Drive NOTES: 1. Weights include economizer (STD). 2. Center of gravity . 3. Do not locate adjacent units with flue discharge facing econo- mizer inlet. Minimum clearances to be: Adjacent Units: 15 8 -0 9 T op of Units: No overhang Condenser Coil: 4 8 -0 9 Economizer Side: 6 8 -0 9 Gas Heat Side: 4 8 -0 9 Filter Access S[...]

VFD — V ariable Frequency Drive NOTES: 1. Weights include economizer (STD). 2. Center of gravity . 3. Do not locate adjacent units with flue discharge facing economizer inlet. Minimum clearances to be: Adjacent Units: 15 8 -0 9 T op of Units: No overhang Condenser Coil: 4 8 -0 9 Economizer Side: 6 8 -0 9 Gas Heat Side: 4 8 -0 9 Filter Access Sid[...]

VFD — V ariable Frequency Drive NOTES: 1. Weights include economizer (STD). 2. Center of gravity . 3. Do not locate adjacent units with flue discharge facing economizer inlet. Minimum clearances to be: Adjacent Units: 15 8 -0 9 T op of Units: No overhang Condenser Coil: 4 8 -0 9 Economizer Side: 6 8 -0 9 Gas Heat Side: 4 8 -0 9 Filter Access Sid[...]

UNIT WEIGHT A B C lb kg in. mm in. mm in. mm 48EJ,EK,EW ,EYD024 4176 1894 87.68 2227 72.4 1839 42.4 1072 48EJ,EWE024 4256 1930 73.3 1862 42.7 1085 48EJ,EK,EW ,EYD028 4262 1933 69.6 1768 44.0 1 1 18 48EJ,EK,EW ,EYD030 48EJ,EK,EW ,EYD034 48EJ,EWE028 4342 1969 70.1 1781 44.3 1 125 48EJ,EWE030 48EJ,EWE034 48EJ,EK,EW ,EYD038 4442 2015 150 3810 92.7 2355[...]

T able 1 — Physical Data UNIT 48EJ,EK,EW ,EY 024D/E 028D/E 030D/E 034D/E NOMINAL CAP ACITY (tons) 20 25 27 30 OPERA TING WEIGHT (lb)* Unit Al/Al† (Lo Heat/Hi Heat) 4176/4256 4262/4342 4262/4342 4262/4342 Al/Cu† (Lo Heat/Hi Heat) 4396/4476 4482/4562 4482/4562 4482/4562 Roof Curb (14-in. curb) 365 365 365 365 COMPRESSOR T ype Ckt 1 06D328 06D32[...]

T able 1 — Physical Data (cont) UNIT 48EJ,EK,EW ,EY 038D/E 044D/E 048D/E NOMINAL CAP ACITY (tons) 35 40 45 OPERA TING WEIGHT (lb)* Unit Al/Al† (Lo Heat/Hi Heat) 4442/4602 4668/4828 4955/5115 Al/Cu† (Lo Heat/Hi Heat) 4727/4887 4953/51 13 5335/5495 Roof Curb (14-in. curb) 410 410 410 COMPRESSOR T ype Ckt 1 06D537 06EA250 06EA265 Ckt 2 06D537 06[...]

T able 2 — Evaporator Fan Motor Data (Units with Starting Serial Numbers 4197 and Later) UNIT SIZE 48E MOTOR HP MOTOR SHAFT DIA. (in.) FA N SHAFT SPEED (rpm) MOTOR SHEA VE MOTOR SHEA VE PITCH DIAMETER (in.) BUSHING DIAMETER (in.) FA N SHEA VE FA N SHEA VE PITCH DIAMETER (in.) BUSHING DIAMETER (in.) BEL T (QUANTITY) OUTSIDE BEL T LENGTH BEL T TENS[...]

S t e p5—T r a p Condensate Drain — See Fig. 3-6 for drain location. Condensate drain is open to atmosphere and must be trapped. Install a trapped drain at the drain lo- cation. A trap at least 4-in. deep must be used. See Fig. 12. T rap must be installed to prevent freeze-up. Condensate pans are sloped so that water will completely drain from [...]

T able 3 — Controls Options and Configurations (Non-Thermostat Applications) UNIT CONFIGURA TION DEF AUL T COOLING DEF AUL T HEA TING CV or V A V Unit with SPT Sensor Unoccupied Cooling — 90 F (SPT) Occupied Cooling — NA Unoccupied Heating — 55 F (SPT) Occupied Heating — NA CV Unit with SPT Sensor and Remote Start/Stop Switch Unoccupied [...]

Features with Sensor Control of Unit (Network Applica- tions) — The base control board provides, as standard, a con- nection for use with a Carrier VVT system and can also be integrated into a Carrier Comfort Network. When the unit is accessed via a PC equipped with Com- fortW orks™, Building Supervisor, or Service T ool software, or accessory [...]

When a V A V unit with a space temperature sensor is ac- cessed via a computer , the following additional features are available: • ability to initiate timed override from T -55 sensors • temperature compensated start to calculate early start time before occupancy • provide space temperature reset to reset the supply air set point upward when[...]

LEGEND CCN — Carrier Comfort Network COM — Common D— Diode LED — Light-Emitting Diode N.C. — Normally Closed N.O. — Normally Open R— Relay SIO — Serial Input/Output SW — Switch T— T erminal Fig. 16 — Control Board Diagram *Where X is the unit control software version number . 17[...]

T able 4 — Electrical Data UNIT SIZE 48E NOMNAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST COMBUSTION F AN MOTOR POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA FLA MCA MOCP* 024 208/230 187 254 39.1 228 25.6 160 2 1 5.3 5 16.7/ 15.2 — — 0.96 101.8/100.3 125/125 23.6 41.6 0.96 125.[...]

T able 4 — Electrical Data (cont) UNIT SIZE 48E NOMINAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST COMBUSTION F AN MOTOR POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA FLA MCA MOCP* 034 208/230 187 254 57.1 266 57.1 266 2 1 5.3 10 30.8/ 28.0 — — 0.96 169.9/167.1 225/200 23.6 41.6 [...]

T able 4 — Electrical Data (cont) UNIT SIZE 48E NOMINAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST COMBUSTION F AN MOTOR POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA FLA MCA MOCP* 044 208/230 187 254 69.2 345 69.2 345 4 1 5.3 15 46.2/ 42.0 — — 0.96 223.1/218.9 275/275 23.6 41.6 [...]

IMPOR T ANT : THE V A V (variable air volume) units use variable frequency drives, which generate, use and can radiate radio frequency energy . If units are not in- stalled and used in accordance with these instructions, they may cause radio interference. They have been tested and found to comply with limits of a Class A com- puting device as defi[...]

LEGEND Fig. 20 — Field Control Thermostat Wiring NOTE: Sensor part numbers are as follows: T -55 — CEC0121448-01 T -56 — CEC0121503-01 Fig. 21 — Field Control T emperature Sensor Wiring (CV or V A V Units) C— Contactor/Compressor CB — Circuit Breaker DIP — Dual In-Line Package FU — Fuse HR — Heater Relay IF — Indoor Fan OF — O[...]

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 T ool, Building Supervisor , and ComfortW orks™ Software — Access to the control board can be achieved through the terminal marked CCN via a 3-wire bus. IM[...]

IMPOR T ANT : When connecting the CCN communi- cation bus to a system element, use a color coding sys- tem for the entire network to simplify installation and checkout. See T able 6. T able 6 — Color Code Recommendations SIGNAL TYPE CCN BUS CONDUCTOR INSULA TION COLOR CCN PLUG PIN NO. Positive (+) RED 1 Ground WHITE 2 Negative (−) BLACK 3 NOTE:[...]

HOOD SIDE TOP FLANGE SEAL STRIP BLACK Fig. 23 — Adding Seal Strip to T op of Hood Sides NOTE: Left side economizer hood has mounting angle without tabs and filter track assembled end on the opposite side. Fig. 24 — Economizer Hood Assembly (Right Side Economizer Hood Shown) HOOD SIDE MOUNTING FLANGE Fig. 25 — Adding Seal Strip to Mounting Fl[...]

The outdoor-air damper closes. The control allows 90 sec- onds for the damper to close in case it is in the full open position. Next, the indoor-fan contactor will ener gize. The outdoor-air damper will remain at 0% for 30 seconds. It will then move to the 10% position for another 30 seconds. This will be repeated at every 10% increment for 30 seco[...]

Dif ferential Enthalpy Sensor Installation — T o install the con- trol, perform the following procedure: 1. T urn of f all power . Ensure disconnect is locked out. 2. Remove the economizer inlet filters from the bottom of the right hand economizer hood. See Fig. 24. 3. Remove the factory-installed, 620-ohm jumper between terminals SR and + on th[...]

NOTE: Switches shown in high enthalpy state. T erminals 2 and 3 close on enthalpy decrease. Fig. 34 — Wiring Connections for Solid-State Enthalpy Control (HH57AC077) CONTROL CURVE CONTROL POINT (APPROX. DEG.) A T 50% RH A 73 (23) B 70 (21) C 67 (19) D 63 (17) RH — Relative Humidity Fig. 35 — Psychrometric Chart for Enthalpy Control NOTE: Part[...]

Step 10 — Position Power Exhaust/Barometric Relief Damper Hood — All electrical connections have been made and adjusted at the factory . The power exhaust blowers and barometric relief dampers are shipped as- sembled and tilted back into the unit for shipping. Brackets and extra screws are shipped in shrink wrap around the damp- ers. If ordered[...]

Step 1 1 — Install All Accessories — After all the factory-installed options have been adjusted, install all field- installed accessories. Refer to the accessory installation in- structions included with each accessory . MOTORMASTER t III INST ALLA TION Install Field-Fabricated W ind Baf f les — W ind baf f les must be field-fabricated for [...]

ST ART -UP Use the following information and Start-Up Checklist on page CL-1 to check out unit PRIOR to start-up. Unit Preparation — Check that unit has been installed in accordance with these installation instructions and appli- cable codes. Compressor Mounting — Loosen the compressor hold- down bolts until sidewise movement of the washer unde[...]

T o set the VFD, the VFD must be powered up; however , since it is located near the indoor air fan, operation of the fan is not desirable. T o disable the fan, perform the follow- ing procedure: 1. Open the indoor fan circuit breaker . 2. Remove the jumper between CC and ST on the terminal strip of the VFD (see Fig. 41). 3. Close the indoor fan cir[...]

At the upper right corner of the board is a set of 5 pins and jumper , which determines the time constant for the control. The time constant is the delay in response built into the con- trols. The jumper should be on the middle or bottom two pins, for the maximum time constant. The delay can be decreased, if desired, by moving the jumper progressiv[...]

T able 9 — Power Exhaust Default Set Points ST AGE OFFSET DIFFERENTIAL OFF VOL T AGE ON VOL T AGE OFF ST A TIC PRESSURE (in. wg) 1 50% 3% 6.0 6.3 0.00 2 55% 3% 6.5 6.8 0.06 3 60% 3% 7.0 7.3 0.12 4 64% 3% 7.4 7.7 0.18 T able 10 — DIP Switch Configuration SETTING 1 2 3 4 5 6 7 8 OPEN VAV V A V — Space Sensor Installed Expansion Board Field T e[...]

T able 12 — Fan Performance, 48EJ/EK024-034 — V ertical Discharge Units (For EW/EY units, reduce net available external static pressure by 0.3 in. wg) AIRFLOW (Cfm) A V AILABLE EXTERNAL ST A TIC PRESSURE (in. wg) 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 4,000 340 0.83 416 1.17 480 1.52 537 [...]

T able 13 — Fan Performance, 48EJ,EK038,044 — V ertical Discharge Units (For EW/EY units, reduce net available external static pressure by 0.5 in. wg) AIRFLOW (Cfm) A V AILABLE EXTERNAL ST A TIC PRESSURE (in. wg) 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 7,000 429 1.70 484 2.40 536 2.70 584 [...]

T able 14 — Fan Performance, 48EJ,EK048 — V ertical Discharge Units (For EW/EY units, reduce net available external static pressure by 0.5 in. wg) AIRFLOW (Cfm) A V AILABLE EXTERNAL ST A TIC PRESSURE (in. wg) 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 9,000 528 3.20 572 4.00 615 4.40 656 4.90[...]

T able 15 — Fan Performance — Power Exhaust 48EJ,EK,EW ,EY024-048 (20 THRU 45 TONS) 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 W atts ESP Bhp Watts ESP Bhp W atts ESP Bhp W atts ESP Bhp Watts ESP Bhp W atts 6,500 0.32 2.82 3160 0.70 2.98 3340 — —- —- —- —-[...]

T able 17 — Air Quantity Limits UNIT 48EJ,EK,EW ,EY MINIMUM HEA TING AIRFLOW (Low Heat) MINIMUM HEA TING AIRFLOW (High Heat) MINIMUM COOLING AIRFLOW (V A V) A T FULL LOAD OPERA TION MINIMUM COOLING AIRFLOW (CV) MAXIMUM AIRFLOW 024 5730 5950 2000 6,000 10,000 028 5730 5950 2500 7,500 12,500 030 5730 5950 2750 8,250 13,750 034 5730 5950 3000 9,000 [...]

T able 18 — User Defined Set Points SET POINT NAME FORMA T DESCRIPTION LIMITS DEF AUL T OHSP xx.xF Occupied Heat Set Point 55 to 80 F 68 F OCSP xx.xF Occupied Cool Set Point 55 to 80 F 78 F UHSP xx.xF Unoccupied Heat Set Point 40 to 80 F 55 F UCSP xx.xF Unoccupied Cool Set Point 75 to 95 F 90 F SASP xx.xF Supply Air Set Point 45 to 70 F 55 F OA [...]

When cooling, the control will energize the power ex- haust enable output to the external power exhaust controller , when power exhaust is used. If occupied, the control will perform economizer control (economizer control same as described above for CV units). If unoccupied, the control will perform nighttime free cool and IAQ pre-occupancy purge a[...]

MORNING W ARM-UP (V A V Only) (Stand-Alone Opera- tion) — When the unit operates in stand-alone mode, morn- ing warm-up occurs when the unit is energized in Occupied mode and return-air temperature (RA T) is below 68 F . W arm-up will not terminate until the RA T reaches 68 F . The heat in- terlock relay output is energized during morning warm-up[...]

Space T emperature Reset Example — The occupied cooling set point is set to 73 F . The Reset Ratio is set to 5. The Reset Limit is set to 20° F . The Reset Ratio determines how many degrees F the temperature is reset. At 72 F , the supply tem- perature will be reset 5 degrees higher . At 71 F , the supply temperature will be reset 10 degrees hig[...]

• When the outdoor air quality is greater than the outdoor air quality set point (ppm) High priority — When the priority is set to high, the IAQ set point controls the outside air damper exclusively , with no regard to comfort conditioning. TIME GUARD t CIRCUIT — The T ime Guard function (built into the rooftop control board) maintains a mini[...]

T o open, loosen the latch bolt using a 7 ⁄ 16 -in. wrench. Pivot the latch so it is not in contact with the door . Open the door . T o shut, reverse the above procedure. NOTE: Disassembly of the top cover may be required under special service circumstances. It is very important that the orientation and position of the top cover be marked on the [...]

Evaporator Fan Performance Adjustment (Fig. 49) — Fan motor pulleys are designed for speed shown in T able 1 (factory speed setting). IMPOR T ANT : Check to ensure that the unit drive matches the duct static pressure using T ables 12-14. T o change fan speeds, change pulleys. T o align fan and motor pulleys: 1. Shut of f unit power supply . 2. Lo[...]

Evaporator-Fan Motor Replacement 1. Shut of f unit power supply . 2. Remove upper outside panel and open hinged door to gain access to motor . 3. Fully retract motor plate adjusting bolts. 4. Loosen the two rear (nearest the evaporator coil) motor plate nuts. 5. Remove the two front motor plate nuts and carriage bolts. 6. Slide motor plate to the r[...]

Main Burners — For all applications, main burners are factory set and should require no adjustment. MAIN BURNER REMOV AL (Fig. 55) 1. Shut of f (field-supplied) manual main gas valve. 2. Shut of f power 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 rol[...]

Crankcase Heater — Each compressor has a crankcase heater to prevent absorption of liquid refrigerant by oil in the crank- case when the compressor is idle. Since power for the crank- case heaters is drawn from the unit incoming power , main unit power must be on for the heaters to be energized. IMPOR T ANT : After a prolonged shutdown or serv- i[...]

LEGEND and NOTES for Fig. 56-60 — T ypical Wiring Schematics AHA — Adjustable Heat Anticipator BP — Building Pressure BR — Burner Relay C— Contactor , Compressor CAP — Capacitor CB — Circuit Breaker CC — Cooling Compensator CCB — Controller Circuit Breaker CCH — Crankcase Heater COM — Communication COMP — Compressor Motor CR[...]

Fig. 56 — T ypical Power Schematic; 48EJ,EK,EW ,EY024-034; 208/230-3-60 and 460-3-60 51[...]

Fig. 57 — T ypical V A V 1 15-v Control Circuit 52[...]

Fig. 58 — T ypical CV 1 15-v Control Circuit 53[...]

Fig. 59 — T ypical V A V 24-v Control Circuit 54[...]

Fig. 60 — T ypical CV 24-v Control Circuit 55[...]

TROUBLESHOOTING T ypical refrigerant circuiting diagrams are shown in Fig. 61-63. An algorithm diagram of the IGC (Integrated Gas Unit Con- troller) control is shown in Fig. 64. LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 61 — T ypical Refrigerant Circuiting (48EJ,EK,EW ,EY024-034) 56[...]

LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 62 — T ypical Refrigerant Circuiting (48EJ,EK,EW ,EY038,044) 57[...]

LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 63 — T ypical Refrigerant Circuiting (48EJ,EK,EW ,EY048) 58[...]

NOTE: Thermostat Fan Switch in the ‘ ‘AUTO’’ position or sensor-equipped unit. Fig. 64 — IGC Control (Heating and Cooling) LEGEND IDM — Induced-Draft Motor IGC — Integrated Gas Unit Controller 59[...]

The alarm codes for the IGC control board are shown in T able 22. T able 22 — IGC Control Board LED Alarms INDICA TION ERROR MODE ON Normal Operation OFF Hardware Failure 1 FLASH Fan ON/OFF Delay Modified 2 FLASHES Limit Switch Fault 3 FLASHES Flame Sense Fault 4 FLASHES 4 Consecutive Limit Switch Faults 5 FLASHES Ignition Lockout Fault 6 FLASHE[...]

T ables 24-26 show the input and output channel designations. T able 24 — I/O Channel Designations Base Module — CV TERMINAL NO. ASSIGNMENT TERMINAL NO. ASSIGNMENT T1-2 SPT (CCN) — 10K V Thermistor T23-25 Compressor 2 Safety — DI (24 vac) T3-4 STO (CCN) — 10K V Thermistor T24-25 Outside Air Enthalpy — DI (24 vac) T5-6 OA T — 5K V Ther[...]

P ACKAGED SERVICE TRAINING Our packaged service training programs provide an excellent way to increase your knowledge of the equipment discussed in this manual. Product programs cover: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A lar ge selection of product, theory , and skills programs is available. A[...]

ST ART -UP CHECKLIST MODEL NO.: SOFTW ARE VERSION (SEE FIG. 16) DA TE: SERIAL NO.: TECHNICIAN: PRE-ST ART -UP: M VERIFY THA T DIP SWITCH SETTINGS ARE CORRECT M VERIFY THA T ALL P ACKING MA TERIALS HA VE BEEN REMOVED FROM UNIT M REMOVE ALL SHIPPING HOLDDOWN BOL TS AND BRACKETS PER INSTRUCTIONS M VERIFY INST ALLA TION OF ECONOMIZER HOOD M VERIFY INST[...]

GENERAL M SET ECONOMIZER MINIMUM VENT POSITION TO JOB REQUIREMENTS M ENSURE DRIVES OPERA TE WITHIN LIMITS OF F AN PERFORMANCE T ABLES HIGH PRESSURE SWITCH SETTING psig LOW PRESSURE SWITCH SETTING psig MOTOR PULLEY P AR T NUMBER F AN PULLEY P AR T NUMBER BEL T P AR T NUMBER BEL T SIZE in. FIL TER QUANTITY FIL TER SIZES in. ADDITIONAL NOTES: ________[...]