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Carrier 50EK manual

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Table of contents for the manual

  • Page 1

    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 ................. 8 • POSITIONING • ROOF MOUNT Step 3 — Field Fabr[...]

  • Page 2

    NOTES: 1. Unless otherwise specified, all dimensions are to out- side of part. 2. Roof curb accessory is shipped disassembled. 3. All roof curb parts are to be 16 ga galvanized steel. 4. Dimensions are in inches. Fig. 1 — Roof Curb (Sizes 024-034) UNIT LEVELING TOLERANCES DIMENSIONS* (Degrees and Inches) AB Deg. in. Deg. in. 1.0 2.9 .50 .75 *Fro[...]

  • Page 3

    NOTES: 1. Unless otherwise specified, all dimensions are to out- side of part. 2. Roof curb accessory is shipped disassembled. 3. All roof curb parts are to be 16 ga galvanized steel. 4. Dimensions are in inches. Fig. 2 — Roof Curb (Sizes 038-048) NOTE: T o prevent standing water in the drain pan of the indoor section and the heat exchangers, UN[...]

  • Page 4

    NOTES: 1. Weights include economizer (Std) 2. Center of gravity . 3. Do not locate adjacent units with dis- charge facing economizer inlet. Mini- mum 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 Filter Access Side: 10 8 -0 9 (for re- moval of evaporator coil) 4. For smalle[...]

  • Page 5

    NOTES: 1. Weights include economizer (Std) 2. Center of gravity . 3. Do not locate adjacent units with discharge facing economizer inlet. Mini- mum 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 Filter Access Side: 10 8 -0 9 (for removal of evaporator coil) 4. For smaller se[...]

  • Page 6

    NOTES: 1. Weights include economizer (Std) 2. Center of gravity . 3. Do not locate adjacent units with 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 Filter Access Side: 10 8 -0 9 (for removal of evaporator coil) 4. For smaller se[...]

  • Page 7

    NOTES: 1. Weights include economizer (Std) 2. Center of gravity . 3. Do not locate adjacent units with 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 Filter Access Side: 10 8 -0 9 (for removal of evaporator coil) 4. For smaller serv[...]

  • Page 8

    Step 2 — Rig and Place Unit — Inspect unit for trans- portation damage. File any claim with transportation agency . Keep unit upright, and do not drop. Use spreader bars over unit to prevent sling or cable damage. Rollers may be used to move unit across a roof. Level by using unit frame as a reference; leveling tolerance is shown in Fig. 1 and [...]

  • Page 9

    T able 1 — Physical Data UNIT 50EJ,EK,EW ,EY 024 028 030 034 NOMINAL CAP ACITY (tons) 20 25 27 30 OPERA TING WEIGHT (lb)* Unit Al/Al† 4016 4102 4102 4102 Al/Cu† 4236 4322 4322 4322 Roof Curb (14-in. curb) 365 365 365 365 COMPRESSOR T ype Ckt 1 06D328 06D328 06D537 06D537 Ckt 2 06D818 06D328 06D328 06D537 Number of Refrigerant Circuits 22 2 2 [...]

  • Page 10

    T able 1 — Physical Data (cont) UNIT 50EJ,EK,EW ,EY 038 044 048 NOMINAL CAP ACITY (tons) 35 40 45 OPERA TING WEIGHT (lb)* Unit Al/Al† 4282 4508 4795 Al/Cu† 4567 4793 5175 Roof Curb (14-in. curb) 410 410 410 COMPRESSOR T ype Ckt 1 06D537 06EA250 06EA265 Ckt 2 06D537 06EA250 06EA250 Number of Refrigerant Circuits 22 2 Oil (oz) (Ckt1, Ckt 2) 1 1[...]

  • Page 11

    T able 2 — Evaporator Fan Motor Data UNIT SIZE MOTOR HP MOTOR SHAFT DIAMETER (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 OUTSIDE BEL T LENGTH BEL T TENSION (Lb @ .24 in.) 024 5 1.12 725 BK52 4.6 None-1.125 1B5V1 10 [...]

  • Page 12

    Step 6 — Controls Options — The control options that the units can provide are based on the following param- eters: CV (constant volume) or V A V (variable air volume) operation; stand-alone unit with field-supplied sensors in- stalled (CV or V A V); as a system via the Carrier Comfort System (TEMP or VVT); optional electronic expansion board [...]

  • Page 13

    Features with sensor control of unit with computer access are: • 365 day timeclock with backup (supports minute, hour , day of week, date, month, and year) • daylight savings time function • occupancy control with 8 periods for unit operation • holiday table containing up to 18 holiday schedules • ability to initiate timed override from T[...]

  • Page 14

    Fig. 12 — Control Board Diagram LEGEND CCN — Carrier Comfort Network R— Relay COM — Common SIO — Serial Input/Output D— Diode SW — Switch N.C. — Normally Closed T— T erminal N.O. — Normally Open *Where X is the unit control software version (1 or 2). 14[...]

  • Page 15

    For units running V ersion 1.0 of the unit control software, network access software is required to enable occupied heat- ing. For units running V ersion 2.0 of the unit control soft- ware, occupied heating is enabled or disabled by the posi- tion of DIP switch no. 5. Additional features may be provided with electronic ac- cess to Unit Control Boar[...]

  • Page 16

    A3 1 ⁄ 2 -in. NPT coupling for field power wiring and a 3 ⁄ 4 -in. NPT coupling for 24-v control wiring are provided in basepan. In the side post, there are two 2 1 ⁄ 2 -in. (024-034) or 3-in. (038-048) knockouts for the field power wiring. See Fig. 3-6. If control wiring is to be brought in through the side of unit, a 7 ⁄ 8 -in. diameter[...]

  • Page 17

    T able 4 — Electrical Data — 50EJ,EK,EW ,EY024-048 UNIT SIZE NOMINAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST ELECTRIC HEA T* POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA kW FLA MCA MOCP† 024 208/230 187 254 39.1 228 25.6 160 2 1 5.3 5 16.7/ 15.2 — — — — 101.8/100.3 12[...]

  • Page 18

    T able 4 — Electrical Data — 50EJ,EK,EW ,EY024-048 (cont) UNIT SIZE NOMINAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST ELECTRIC HEA T* POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA kW FLA MCA MOCP† 028 208/230 187 254 39.1 228 39.1 228 2 1 5.3 7.5 24.2/ 22.0 — — — — 122.8[...]

  • Page 19

    T able 4 — Electrical Data — 50EJ,EK,EW ,EY024-048 (cont) UNIT SIZE NOMINAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST ELECTRIC HEA T* POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA kW FLA MCA MOCP† 030 208/230 187 254 57.1 266 39.1 228 2 1 5.3 10 30.8/ 28.0 — — — — 151.9/[...]

  • Page 20

    T able 4 — Electrical Data — 50EJ,EK,EW ,EY024-048 (cont) UNIT SIZE NOMINAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST ELECTRIC HEA T* POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA kW FLA MCA MOCP† 034 208/230 187 254 57.1 266 57.1 266 2 1 5.3 10 30.8/ 28.0 — — — — 169.9/[...]

  • Page 21

    T able 4 — Electrical Data — 50EJ,EK,EW ,EY024-048 (cont) UNIT SIZE NOMINAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST ELECTRIC HEA T* POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA kW FLA MCA MOCP† 038 208/230 187 254 57.1 266 57.1 266 4 1 5.3 10 30.8/ 28.0 — — — — 180.5/[...]

  • Page 22

    T able 4 — Electrical Data — 50EJ,EK,EW ,EY024-048 (cont) UNIT SIZE NOMINAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST ELECTRIC HEA T* POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA kW FLA MCA MOCP† 044 208/230 187 254 69.2 345 69.2 345 4 1 5.3 15 46.2/ 42.0 — — — — 223.1/[...]

  • Page 23

    T able 3 — Electrical Data — 50EJ,EK,EW ,EY024-048 (cont) UNIT SIZE NOMINAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST ELECTRIC HEA T* POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA kW FLA MCA MOCP† 048 208/230 187 254 82.1 446 69.2 345 4 1 5.3 20 59.4/ 54.0 — — — — 252.4/[...]

  • Page 24

    DIP — Dual In-Line Package PEC − Power Exhaust Controller Fig. 14 — Control Box Diagram (Sizes 024-034) DIP — Dual In-Line Package PEC — Power Exhaust Controller Fig. 15 — Control Box Diagram (Sizes 038-048) 24[...]

  • Page 25

    Remote Field Control (Units Running V ersion 2.0 of Unit Control Software) — 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 Comfort W orks — Access to the control board can be achieved through t[...]

  • Page 26

    NOTE: Before assembly of the economizer hood, check along the outer edges of the economizer assembly for any seal strip protruding past the flanges. T rim the excess seal strip so that it is flush with the economizer assembly flanges. 1. Apply black seal strip (provided in package) to outside top-edge of hood sides. W rap seal strip over edge to[...]

  • Page 27

    HOOD TOP HOOD SIDE Fig. 21 — Adding Seal Strip to Hood T op Mounting Flange CROSS MEMBER GRA Y FOAM STRIP Fig. 22 — Adding Foam Strip to Cross Member HOOD SIDE (SLOTTED) HOOD TOP Fig. 23 — Adding Foam Strip to Hood Side BLOCKOFF BAFFLE GRA Y FOAM STRIP Fig. 24 — Adding Foam Strip to Blockoff Baf fle MOUNTING ANGLE (WITHOUT T ABS) FIL TER TR[...]

  • Page 28

    Minimum Damper Position Setting — Setting of the out- door air damper position is performed in conjunction with a shortened version of the field-run test. This is performed by first opening DIP (Dual In-Line Package) switch no. 6 then no. 4. See Fig. 17 and T able 7. The outdoor-air damper closes. The control allows 90 sec- onds for the damper [...]

  • Page 29

    Step 9 — 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,[...]

  • Page 30

    Step 10 — Install 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 SENSOR LOCA TION — Motor- master III sensor locations are shown in Fig. 33A-33C. Re- fer to the Motormaster [...]

  • Page 31

    Fig. 33B — Motormaster T III Sensor Location (Sizes 038 and 044) Fig. 33C — Motormaster III Sensor Location (Size 048) 31[...]

  • Page 32

    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[...]

  • Page 33

    Power Exhaust — The optional non-modulating power exhaust (CV only) is a two-stage design where the operation of the exhaust fans is linked to economizer position. When the supply fan is running and the economizer is 25% open, the base module closes contacts, activating 2 exhaust fans. When the economizer position reaches 75% open, the base modul[...]

  • Page 34

    T able 10A — DIP Switch Configuration (V ersion 1.0 of Unit Control Software) SETTING 1 2 3 4 5 6 7 8 OPEN VAV CCN/ Sensors Expansion I/O Board Field T est ON Modulated Power Exhaust T ime Guard Override ON/ Set Min. Damper Pos. ON Gas Heat Factory T est ON CLOSED CV TST A T Base Board Only Field T est OFF CV Power Exhaust T ime Guard Override O[...]

  • Page 35

    DIP switch configurations for V ersion 1.0 of the Unit Con- trol Software are as follows: • DIP switch 1 configures the unit to operate as a variable air volume (V A V) or constant volume (CV) unit • DIP switch 2 configures what type of sensors or thermo- stats are used with the unit • DIP switch 3 configures the DDC for use with the elec[...]

  • Page 36

    T able 12 — Fan Performance, 50EJ/EK024-034 — V ertical Discharge Units FOR EW/EY UNITS, REDUCE NET A V AILABLE EXTERNAL ST A TIC 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 4,000 322 0.77 401 1.09 466 1.43 52[...]

  • Page 37

    T able 13 — Fan Performance, 50EJ038,044 and 50EK044 — V ertical Discharge Units For EW/EY UNITS, REDUCE NET A V AILABLE EXTERNAL ST A TIC 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 8,000 448 2.18 498 2.87 54[...]

  • Page 38

    T able 14 — Fan Performance, 50EJ048 — V ertical Discharge Units FOR EW UNITS, REDUCE NET A V AILABLE EXTERNAL ST A TIC 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 13,000 683 7.10 715 8.59 747 9.09 777 9.60 80[...]

  • Page 39

    T able 16 — Motor Limitations ST ANDARD EFFICIENCY MOTORS Nominal Hp Maximum Bhp Maximum Amps Maximum W atts Motor Efficiency 208 230 460 575 5 5.9 17.94 16.99 — — 5,348 82.3 5.9 — — 8.50 5.78 5,240 84.0 7.5 8.7 25.52 24.36 — — 7,717 84.1 9.5 — — 13.30 9.63 8,549 82.9 10 10.2 26.93 25.50 — — 8,879 85.7 1 1.8 — — 14.75 1 1.[...]

  • Page 40

    The control module will operate economizer , run diag- nostics to monitor alarms/alerts at all times, and respond to CCN communications to perform any configured network POC (product outboard control) functions such as time/ outdoor-air temperature broadcast and global occupancy broad- cast. When the optional expansion I/O board is employed, it wi[...]

  • Page 41

    interlock relay signals for the air terminals to fully open. See Fig. 35. In the Occupied mode, the indoor-fan motor will operate continuously and the outdoor-air dampers will be in the minimum position. In the Unoccupied mode, the indoor- fan motor will be of f, but will energize upon the call for heat. The outdoor-air dampers will move to the IAQ[...]

  • Page 42

    CAP ACITY CONTROL, COOLING — The cooling capac- ity staging tables are shown in T ables 18 and 19. T able 18 — Cooling Capacity Staging T able CV Units with 2 Compressors ST AGES 0 1 ECONOMIZER 23 Compressor 1 Off Off On On Compressor 2 Off Off Of f On NOTE: On CV units that require additional unloading, add suction pres- sure unloaders on Comp[...]

  • Page 43

    Cleaning — Inspect unit interior at beginning of each heat- ing and cooling season and as operating conditions require. Remove unit top panel and/or side panels for access to unit interior . EV APORA TOR COIL — Clean as required with a commer- cial coil cleaner . CONDENSER COIL — Clean condenser coil annually and as required by location and o[...]

  • Page 44

    Belt T ension Adjustment — T o adjust belt tension: 1. Remove power to unit. 2. Remove motor mount nuts and bolts. 3. Loosen fan motor nuts. See Fig. 39. 4. T urn motor jacking bolts to move motor mounting plate left or right for proper belt tension. A slight bow should be present in the belt on the slack side of the drive while running under ful[...]

  • Page 45

    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[...]

  • Page 46

    TROUBLESHOOTING T ypical refrigerant circuiting diagrams are shown in Fig. 43-45. LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 43 — T ypical Refrigerant Circuiting (50EJ,EK,EW ,EY024-034) 46[...]

  • Page 47

    LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 44 — T ypical Refrigerant Circuiting (50EJ,EK,EW ,EY038,044) 47[...]

  • Page 48

    LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 45 — T ypical Refrigerant Circuiting (50EJ,EW048) 48[...]

  • Page 49

    Diagnostic LEDs (Light-Emitting Diodes) — There are 3 LEDs (red, yellow , and green) on the lower right hand side of the control board. The red light is used to check unit operation and alarms. A constant pulse is normal unit operation. A series of quick blinks indicates an alarm. Refer to T able 20 below for a description of alarms. The yellow L[...]

  • Page 50

    T ables 21-23 show the input and output channel designations. T able 21 — I/O Channel Designations Base Module — CV TERMINAL NO. ASSIGNMENT T1-2 SPT (CCN) — 10K V Thermistor T3-4 STO (CCN) — 10K V Thermistor T5-6 OA T — 5K V Thermistor T7-8 SA T — 5K V Thermistor T9-10 — T1 1-12 SA T Reset — AI (2-10 vdc) T13-14 — T15-16 — T17-2[...]

  • Page 51

    T able 23 — I/O Channel Designations Expansion Module — CV and V A V TERMINAL NO. ASSIGNMENT T1-2 — T3-4 — T5-6 — T7-8 — T9-10 — T1 1-12 IAQ Indoor — AI (2-10 vdc) T13-14 IAQ Outdoor — AI (2-10 vdc) T15-16 — T17-25 Fan Status — DI (24 vac) T18-25 Filter Status — DI (24 vac) T19-25 Field Applied Status — DI (24 vac) T20-25 [...]

  • Page 52

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  • Page 53

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  • Page 54

    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 • Installation Overview • Maintenance • Operating Sequence A lar ge selection of product, theory , and skills programs is available. A[...]

  • Page 55

    ST ART -UP CHECKLIST MODEL NO.: SOFTW ARE VERSION (SEE FIG. 15) 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[...]

  • Page 56

    ST ART -UP CHECKLIST (cont) GENERAL M ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS 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 [...]