Carrier 48AK Installation, Start-Up And Service Instructions Manual
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Carrier 48AK Installation, Start-Up And Service Instructions Manual

Carrier 48AK Installation, Start-Up And Service Instructions Manual

Single package rooftop units electric cooling/gas heating, with reciprocating compressor
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CONTENTS

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58

Step 1 — Provide Unit Support . . . . . . . . . . . . . . . . . . . 1
• ROOF CURB
• ALTERNATE UNIT SUPPORT
Step 2 — Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . 2
• POSITIONING
• ROOF MOUNT
Step 3 — Field Fabricate Ductwork . . . . . . . . . . . . . . . 2
Step 4 — Make Unit Duct Connections . . . . . . . . . . . 2
Step 5 — Install Flue Hood . . . . . . . . . . . . . . . . . . . . . . 28
Step 6 — Trap Condensate Drain . . . . . . . . . . . . . . . . 28
Step 7 — Install Gas Piping . . . . . . . . . . . . . . . . . . . . . 28
Step 8 — Controls Options . . . . . . . . . . . . . . . . . . . . . . 29
• STAGED GAS UNIT APPLICATIONS
• THERMISTORS
• CONSTANT VOLUME APPLICATIONS
• VARIABLE AIR VOLUME (VAV) APPLICATIONS
Step 9 — Make Electrical Connections . . . . . . . . . . 33
• POWER WIRING
• FIELD POWER SUPPLY
• FIELD CONTROL WIRING
Step 10 — Make Outdoor-Air Inlet
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
• ECONOMIZER
• ECONOMIZER SETTINGS
Step 11 — Position Power Exhaust/Barometric
Relief Damper Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Step 12 — Install All Accessories . . . . . . . . . . . . . . . 54
Step 13 — Field Modifications. . . . . . . . . . . . . . . . . . . 57
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-89
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89-102
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 103-115
Start-Up Checklist . . . . . . . . . . . . . . . . . . . CL-1,CL-2
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical compo-
nents. Only trained and qualified service personnel should in-
stall, repair, or service air-conditioning equipment.
Untrained personnel can perform the basic maintenance
functions of cleaning coils and filters and replacing filters. All
other operations should be performed by trained service per-
sonnel. When working on air-conditioning equipment, observe
precautions in the literature, tags and labels attached to the unit,
and other safety precautions that may apply.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 111
Catalog No. 534-739
Book 1
Tab
1a
Installation, Start-Up and
Service Instructions
Page
Printed in U.S.A.
48AJ,AK,AW,AY020-060
with Reciprocating Compressor
48EJ,EK,EW,EY024-068
Single Package Rooftop Units
Electric Cooling/Gas Heating
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations. Have
fire extinguishers available for all brazing operations.
Before performing service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury.
1. Improper installation, adjustment, alteration, service,
or maintenance can cause property damage, personal
injury, or loss of life. Refer to the User's Information
Manual provided with this unit for more details.
2. Do not store or use gasoline or other flammable va-
pors and liquids in the vicinity of this or any other
appliance.
What to do if you smell gas:
1. DO NOT try to light any appliance.
2. DO NOT touch any electrical switch, or use any
phone in your building.
3. IMMEDIATELY call your gas supplier from a neigh-
bor's phone. Follow the gas supplier's instructions.
4. If you cannot reach your gas supplier, call the fire
department.
Disconnect gas piping from unit when pressure testing at
pressure greater than 0.5 psig. Pressures greater than
0.5 psig will cause gas valve damage resulting in hazardous
condition. If gas valve is subjected to pressure greater than
0.5 psig, it must be replaced before use. When pressure
testing field-supplied gas piping at pressures of 0.5 psig or
less, a unit connected to such piping must be isolated by
closing the manual gas valve(s).
INSTALLATION
Step 1 — Provide Unit Support
1. All panels must be in place when rigging.
2. Unit is not designed for handling by fork truck.
Form 48A,E-1SI
Pg 1
107
11-01
Replaces: 48E-6SI

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  • Page 1 Installation, Start-Up and Service Instructions CONTENTS SAFETY CONSIDERATIONS ..... . 1 INSTALLATION ....... . 1-58 Step 1 —...

  • Page 2: Step 2 — Rig And Place Unit

    ROOF CURB — For vertical discharge units, assemble or in- stall accessory roof curb in accordance with instructions shipped with this accessory. See Fig. 1-4. Install insulation, cant strips, roofing, and counter flashing as shown. Ductwork can be installed to roof curb before unit is set in place. Curb should be level.
  • Page 19 CENTER OF GRAVITY UNIT Inches 48AJ,AKD020 72.4 42.2 48AJE020 73.3 42.7 48AW,AYD020 72.4 42.2 48AWE020 73.3 42.7 48AJ,AKD025 69.6 44.0 48AJE025 70.1 44.3 48AW,AYD025 69.6 44.0 48AWE025 70.1 44.3 48AJ,AKD027 69.6 44.0 48AJE027 70.1 44.3 48AW,AYD027 69.6 44.0 48AWE027 70.1 44.3 48AJ,AKD030 69.6...
  • Page 20 UNIT Inches 48EJ,EW,EK,EYD024 72.4 48EJ,EWE024 73.3 48EJ,EW,EK,EYD028 69.6 48EJ,EWE028 70.1 48EJ,EW,EK,EYD030 69.6 48EJ,EWE030 70.1 48EJ,EW,EK,EYD034 69.6 48EJ,EWE034 70.1 48EJ,EW,EK,EYD038 92.7 48EJ,EWE038 94.1 48EJ,EW,EK,EYD044 89.3 48EJ,EWE044 90.8 48EJ,EW,EK,EYD048 87.7 48EJ,EWE048 89.2 48EJ,EW,EK,EYD054 130.9 48EJ,EWE054 133.8 48EJ,EW,EK,EYD058 132.1 48EJ,EWE058 139.5 48EJ,EW,EK,EYD064 125.3 48EJ,EWE064 132.2 48EJ,EW,EK,EYD068...
  • Page 21 Table 1A — Physical Data — 48AJ,AK,AW,AY Units UNIT 48AJ,AK,AW,AY NOMINAL CAPACITY (tons) BASE UNIT OPERATING WEIGHT (lb) COMPRESSOR Quantity...Type (Ckt 1 , Ckt 2) 1...06D328, 1...06D818 Number of Refrigerant Circuits Oil (oz) (Ckt 1 , Ckt 2) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1 Circuit 2...
  • Page 22 Table 1A — Physical Data — 48AJ,AK,AW,AY Units (cont) UNIT 48AJ,AK,AW,AY NOMINAL CAPACITY (tons) BASE UNIT OPERATING WEIGHT (lb) COMPRESSOR Quantity...Type (Ckt 1 , Ckt 2) Number of Refrigerant Circuits Oil (oz) (Ckt 1 , Ckt 2) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1 Circuit 2 CONDENSER COIL *...
  • Page 23 Table 1B — Physical Data — 48EJ,EK,EW,EY Units UNIT 48EJ,EK,EW,EY NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) COMPRESSOR Type Ckt 1 Ckt 2 Number of Refrigerant Circuits Oil (oz) (Ckt 1, Ckt 2) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1* Circuit 2 CONDENSER COIL Quantity Rows...Fins/in.
  • Page 24 Table 1B — Physical Data — 48EJ,EK,EW,EY Units (cont) UNIT 48EJ,EK,EW,EY NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) COMPRESSOR Type Ckt 1 Ckt 2 Number of Refrigerant Circuits Oil (oz) (Ckt 1, Ckt 2) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1* Circuit 2 CONDENSER COIL Quantity...
  • Page 25 Table 1B — Physical Data — 48EJ,EK,EW,EY Units (cont) UNIT 48EJ,EK,EW,EY NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) COMPRESSOR Quantity...Type (Ckt 1, Ckt 2) 1...06EA265, 1...06EA250 Number of Refrigerant Circuits Oil (oz) (Ckt 1, Ckt 2) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1* Circuit 2 CONDENSER COIL...
  • Page 26 UNIT 48AJD,AKD 4287 48AJE 4367 48AWD,AYD 4327 48AWE 4407 OPTION/ ACCESSORY Barometric Relief Power Exhaust Modulating Power Exhaust Cu Tubing/Cu Fin Condenser Coil Roof Curb (14-in. curb) UNIT 48EJ,EKD 4287 4373 48EJE 4367 4453 48EW,EYD 4327 4413 48EWE 4407 4493 OPTION/ ACCESSORY Barometric Relief...
  • Page 27 UNIT UNIT MOTOR SIZE SIZE MOTOR SHAFT DIA. 48AJ,AK, 48EJ,EK, SPEED (in.) AW,AY EW,EY 1.125 1.375 1.625 1.375 1.375 1.625 1.375 1.625 1.625 1.375 1.625 1.625 1.375 1.625 1.625 1.625 1.625 1.875 1.625 1.875 1.875 1.625 — 1.625 1.875 1.625 —...

  • Page 28: Step 5 — Install Flue Hood

    Step 5 — Install Flue Hood 48AJ,AK,AW,AY020-050 AND 48EJ,EK,EW,EY024-048 UNITS — Flue hood is shipped inside gas section of unit. To install, secure flue hood to access panel. See Fig. 20A. 48AJ,AK,AW,AY060 48EJ,EK,EW,EY054-068 UNITS — Flue hood and wind baffle are shipped inside gas section of unit.

  • Page 29: Step 8 — Controls Options

    CV (constant volume) or VAV (variable air volume) oper- ation; stand-alone unit with field-supplied sensors installed (CV or VAV); as a system via Carrier Comfort System (TEMP or VVT® [Variable Volume and Temperature]); optional elec- tronic expansion board installed (CV or VAV); linked to the Carrier Comfort Network;...
  • Page 30 Table 5 — Controls Options and Configurations (Non-Thermostat Applications) UNIT CONFIGURATION CV or VAV Unit with SPT Sensor CV Unit with SPT Sensor and Remote Start/Stop Switch VAV Unit Remote Start/Stop Switch Only VAV Unit with SPT Sensor and Remote Start/Stop Switch LEGEND —...
  • Page 31 • adjustment of space temperature set points of ±5° F when using a T-56 sensor • provides CCN (Carrier Comfort Network) IAQ (Indoor- Air Quality) participation • control of modulating economizer damper to maintain indoor air quality (IAQ) when outdoor conditions are...
  • Page 32 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 in- tegrated into a Carrier Comfort Network. When the unit is accessed via a PC equipped with ComfortWORKS®, Building Supervisor, Service Tool soft-...

  • Page 33: Step 9 — Make Electrical Connections

    55 F (return-air temperature) heating. Features with Network Applications — The base control board provides, as standard, a connection for use with a Carrier Comfort System and can also be integrated into a Carrier Com- fort Network (CCN). When the unit is accessed via a PC...
  • Page 35 Table 7 — Electrical Data — 48AJ,AK,AW,AY Units VOLTAGE RANGE UNIT SIZE NOMINAL 48AJ,AK, VOLTAGE AW,AY (3 PH, 60 Hz) 208/230 208/230 LEGEND — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration — Indoor (Evaporator) Fan Motor LRA — Locked Rotor Amps MCA —...
  • Page 36 Table 7 — Electrical Data — 48AJ,AK,AW,AY Units (cont) VOLTAGE RANGE UNIT SIZE NOMINAL 48AJ,AK, VOLTAGE AW,AY (3 PH, 60 Hz) 208/230 208/230 LEGEND — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration — Indoor (Evaporator) Fan Motor LRA —...
  • Page 37 Table 7 — Electrical Data — 48AJ,AK,AW,AY Units (cont) VOLTAGE RANGE UNIT SIZE NOMINAL 48AJ,AK, VOLTAGE AW,AY (3 PH, 60 Hz) 208/230 208/230 LEGEND — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration — Indoor (Evaporator) Fan Motor LRA —...
  • Page 38 Table 7 — Electrical Data — 48AJ,AK,AW,AY Units (cont) VOLTAGE RANGE UNIT SIZE NOMINAL 48AJ,AK, VOLTAGE AW,AY (3 PH, 60 Hz) 208/230 208/230 LEGEND — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration — Indoor (Evaporator) Fan Motor LRA —...
  • Page 39 Table 8 — Electrical Data — 48EJ,EK,EW,EY Units COMPRESSOR VOLTAGE UNIT NOMNAL RANGE SIZE VOLTAGE No. 1 48EJ,EK, (3 Ph, Min Max RLA LRA RLA LRA Qty Hp EW,EY 60 Hz) 208/230 187 254 39.1 414 508 19.9 518 632 16.0 208/230 187 254...
  • Page 40 Table 8 — Electrical Data — 48EJ,EK,EW,EY Units (cont) COMPRESSOR VOLTAGE UNIT NOMNAL RANGE SIZE VOLTAGE No. 1 48EJ,EK, (3 Ph, Min Max RLA LRA RLA LRA Qty Hp EW,EY 60 Hz) 208/230 187 254 57.1 414 508 25.6 518 632 20.5 208/230 187 254...
  • Page 41 Table 8 — Electrical Data — 48EJ,EK,EW,EY Units (cont) COMPRESSOR VOLTAGE UNIT NOMNAL RANGE SIZE VOLTAGE No. 1 48EJ,EK, (3 Ph, Min Max RLA LRA RLA LRA Qty Hp EW,EY 60 Hz) 208/230 187 254 82.1 414 508 42.3 518 632 34.6 208/230 187 254...
  • Page 42 Table 8 — Electrical Data — 48EJ,EK,EW,EY Units (cont) COMPRESSOR VOLTAGE UNIT NOMNAL RANGE SIZE VOLTAGE No. 1 48EJ,EK, (3 Ph, Min Max RLA LRA RLA LRA Qty Hp EW,EY 60 Hz) 208/230 187 254 106.4 506 414 508 52.6 518 632 40.4 208/230...
  • Page 43 4. Splice red wire and black unit power wire. Cap wires. IMPORTANT: BE CERTAIN UNUSED WIRES ARE CAPPED. Failure to do so may damage the transformers. FIELD CONTROL WIRING — Install either a Carrier- approved thermostat or a CCN (Carrier Comfort Network) compatible temperature sensor. Thermostats are used on CV (constant volume) units only.
  • Page 44 SENSOR CONNECTION LOCATION Fig. 29 — Control Box Diagram (48AJ,AK,AW,AY020-030 and 48EJ,EK,EW,EY024-034 Units) DIP SWITCHES (FAR SIDE) SEE DETAIL A R Y1 Y2 W1 W2 G C X DETAIL A (THERMOSTAT CONNECTION LOCATION) LEGEND — Compressor/ Contactor — Circuit Breaker —...
  • Page 45 1. Refer to CCN literature for informa- tion on network addressing or changing CCN communica- tion defaults. Carrier Comfort Network Interface — The rooftop units can be connected to the CCN. The communication bus wiring is supplied and installed in the field. Wiring consists of shielded, 3-conductor cable with drain wire.
  • Page 47 Fig. 32 — Field Control Thermostat Wiring NOTE: Sensor part numbers are as follows: T-55 — CEC0121448-01 T-56 — CEC0121448-01 Fig. 33 — Field Control Temperature Sensor Wiring (CV or VAV Units) Conductors and drain wire must be 20 AWG minimum stranded, tinned copper.

  • Page 48: Adjustments

    SPACE TEMPERATURE AVERAGING — 4 SENSOR APPLICATION SPACE TEMPERATURE AVERAGING — 9 SENSOR APPLICATION Fig. 34 — Space Temperature Averaging Wiring BASE BOARD Fig. 35 — Field HIR (Heat Interlock Relay) Wiring Step 10 — Make Outdoor-Air Inlet Adjustments ECONOMIZER NOTE: If accessory power exhaust or barometric relief pack- ages are being added to the unit, install power exhaust or baro- metric relief before installing economizer hoods.
  • Page 49 Perform the following procedure to assemble the economiz- er hood. 1. Apply black seal strip (provided in package) to outside top-edge of hood sides. Wrap seal strip over edge to cover top flange (6 hood sides). Make sure seal strip covers screw holes.
  • Page 50 MOUNTING FLANGE HOOD SIDE Fig. 38 — Adding Seal Strip to Sides of Hood Top Mounting Flange HOOD SIDE Fig. 39 — Adding Seal Strip to Back of Hood Top Mounting Flange GRAY FOAM STRIP CROSS MEMBER Fig. 40 — Adding Foam Strip to Cross Member Fig.
  • Page 51 Fig. 43 — Mounting Angle (Without Tabs) Attached to Filter Track Assembly Fig. 44 — Mounting Angle (With Tabs) Attached to Filter Track Assembly BLACK SEAL STRIP (CENTERED) Fig. 45 — Attaching Seal Strip to Filter Cover ECONOMIZER SETTINGS MOUNTING ANGL Accessory Enthalpy Control (Fig.

  • Page 52: Relief Damper Hood

    7. Route the wires from the enthalpy sensor to the return air enthalpy control through the holes on the inside of the hinged filter access panel. The holes are blocked by plug buttons which should be removed. 8. Use field-supplied wire ties to attach the violet wire to the + terminal and the blue wire to the SR terminal.
  • Page 53 CONTROL POINT CONTROL (APPROX. DEG.) CURVE AT 50% RH F (C) 73 (23) 70 (21) 67 (19) 63 (17) LEGEND RH — Relative Humidity Fig. 48 — Psychrometric Chart for Enthalpy Control NOTE: Partitions shown indicate both side supply (AW,AY,EW,EY) and vertical supply (AJ,AK,EJ,EK) units. Fig.

  • Page 54: Step 12 — Install All Accessories

    NOTES: 1. Unless otherwise specified, all dimensions are to outside of part. 2. Dimensions are in inches. 3. On 48AW,AY and 48EW,EY units, accessory barometric relief or power exhaust must be mounted in the field-supplied return ductwork. Fig. 50 — Barometric Relief Damper and Power Exhaust Mounting Details LEGEND VAV —...
  • Page 55 Install Motormaster® III Controls — Only one Motormaster III control is required per unit. Motor — One outdoor-fan motor (OFM) must be changed out in the field to accommodate the Motormaster III accessory. The replacement motor part no. is HD52AK652. For 48AJ,AK,AW,AY020-030 and 48EJ,EK,EW,EY024- 034 units, the Motormaster controlled OFM is the no.
  • Page 56 Fig. 53B — Motormaster® III Sensor Location (48AJ,AK,AW,AY035 and 48EJ,EK,EW,EY038, 044) Fig. 53C — Motormaster III Sensor Location (48AJ,AK,AW,AY040, 050 and 48EJ,EK,EW,EY048) Fig. 53D — Motormaster III Sensor Location (48EJ,EK,EW,EY054-064) Fig. 53E — Motormaster III Sensor Location (48AJ,AK,AW,AY060 and 48EJ,EK,EW,EY068)

  • Page 57: Step 13 — Field Modifications

    Step 13 — Field Modifications DUCTWORK Bottom Return Units (48AJ,AK,EJ,EK) Field-Modified for Side Return — 48AJ,AK and 48EJ,EK units with bottom re- turn air connections may be field-modified to accommodate side return air connections. IMPORTANT: The following section is a guideline and not a comprehensive procedure to field modify the units.

  • Page 58: Installation

    LOCATION BAROMETRIC RELIEF OR POWER EXHAUST “SIDE #2” 23.28” “END #2” “END #1” 42.62 ALTERNATE LOCATION (END) Fig. 55 — Power Exhaust Relocated to Side Return Duct BASE MODULE COMP #2 UNLOADER COMP #1 UNLOADER CYCLIC COND FAN CONT COND FAN POWER EXHAUST DISCRETE OUTPUTS...
  • Page 59 Crankcase Heaters — Crankcase heaters are energized as long as there is power to the unit, except when the compres- sors are operating. IMPORTANT: Unit power must be on for 24 hours prior to start-up. Otherwise, damage to compressor may result. Variable Frequency Drive (VFD) —...
  • Page 60 Gr.Pr (Protection) Gr.Ut (Utility) *These settings differ from the Toshiba defaults and are required for Carrier applications. follow an external speed reference signal from the control system. b. Connect the field-supplied speed reference (4-20 mA) signal across terminals IV and P24.
  • Page 61 Refer to the Carrier literature when checking default values. The following default values have been changed from the manufacturer settings to closely match the VFD operation with a Carrier VAV unit. Refer to Tables 14 and 15. 9. Fire-speed override mode is available by contact closure between terminals S1 and CC.
  • Page 62 0362 F363 0363 *These settings differ from the Toshiba defaults and are required for Carrier applications. Table 15 — Motor Electronic Thermal Protection (tHr) for Toshiba TOSVERT VF-S9 VFD MOTOR IFM Letter* 230V Setting 380V Setting 460V Setting IFM Letter* 230V Setting 460V Setting 3.73...
  • Page 63 The optional non-modulating power Power Exhaust — 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 control board closes contacts, activating 2 (48AJ,AK,AW, AY020-050 and 48EJ,EK,EW,EY024-048) or 3 (48AJ,AK, AW,AY060 and 48EJ,EK,EW,EY054-068) exhaust fans.
  • Page 64 Used VAV — No Space Sensor CLOSED CV — Thermostat LEGEND CCN — Carrier Comfort Network — Constant Volume VAV — Variable Air Volume NOTES: 1. The OPEN side of the DIP switch is marked ‘‘OPEN.’’ When the rocker switch is on the ‘‘OPEN’’ side of the switch, the switch is OPEN.
  • Page 65 UNIT 48AJ,AW and 48EJ,EW 48AK,AY and 48EK,EY *On 48EJ,EW,AJ,AW units equipped with staged gas option, DIP switch 7 should be closed. Table 19 — Fan Performance, 48AJ,AK020-030 — Vertical Discharge Units AIRFLOW (Cfm) 4,000 1.06 1.17 5,000 1.26 1.61 6,000 1.80...
  • Page 66 Table 20 — Fan Performance, 48AJ,AK035 — Vertical Discharge Units AIRFLOW (Cfm) 7,000 2.01 2.38 8,000 2.73 3.12 9,000 3.59 4.01 10,000 4.62 5.07 11,000 5.83 6.29 12,000 7.22 7.70 13,000 8.80 9.30 14,000 10.59 11.11 15,000 12.60 13.13 16,000 14.82 15.37 17,000...
  • Page 67 Table 21 — Fan Performance, 48AJ,AK040,050 — Vertical Discharge Units AIRFLOW (Cfm) 8,000 2.98 3.38 9,000 3.90 4.33 10,000 5.00 5.45 11,000 6.27 6.75 12,000 7.74 8.24 13,000 9.41 9.93 14,000 11.29 11.84 15,000 13.40 13.96 16,000 15.74 16.32 17,000 18.32 1003 18.92...
  • Page 68 Table 22 — Fan Performance, 48AJ,AK060 — Vertical Discharge Units AIRFLOW (Cfm) 12,000 4.33 5.04 14,000 6.19 6.96 15,000 7.28 8.09 16,000 8.48 9.34 17,000 9.80 10.71 18,000 11.25 12.21 19,000 12.82 13.84 20,000 14.53 15.60 21,000 16.37 17.49 22,000 18.35 19.53 23,000...
  • Page 69 Table 23 — Fan Performance, 48AW,AY020-030 — Horizontal Discharge Units AIRFLOW (Cfm) 4,000 1.06 1.21 5,000 1.32 1.68 6,000 1.90 2.29 7,000 2.65 3.07 8,000 3.56 4.01 9,000 4.65 5.13 10,000 5.93 6.44 11,000 7.40 7.94 12,000 9.09 9.66 13,000 11.01 11.60 14,000...
  • Page 70 Table 24 — Fan Performance, 48AW,AY035 — Horizontal Discharge Units AIRFLOW (Cfm) 7,000 2.15 2.52 8,000 2.92 3.32 9,000 3.85 4.28 10,000 4.96 5.42 11,000 6.26 6.74 12,000 7.76 8.25 13,000 9.46 9.98 14,000 11.39 11.92 15,000 13.54 14.10 16,000 15.94 16.52 17,000...
  • Page 71 Table 25 — Fan Performance, 48AW,AY040,050 — Horizontal Discharge Units AIRFLOW (Cfm) 8,000 3.18 3.58 9,000 4.17 4.60 10,000 5.35 5.80 11,000 6.72 7.20 12,000 8.29 8.80 13,000 10.09 10.62 14,000 12.12 12.67 15,000 14.38 14.96 16,000 16.90 1000 17.49 17,000 1032 19.67...
  • Page 72 Table 26 — Fan Performance, 48AW,AY060 — Horizontal Discharge Units AIRFLOW (Cfm) 12,000 4.81 5.54 14,000 6.90 7.69 15,000 8.13 8.96 16,000 9.49 10.36 17,000 10.99 11.90 18,000 12.64 13.58 19,000 14.43 15.41 20,000 16.37 17.39 21,000 18.47 19.54 22,000 20.74 21.84 23,000...
  • Page 73 Table 27 — Fan Performance, 48EJ,EK024,034 — Vertical Discharge Units (For EW,EY units, reduce net available external static pressure by 0.3 in. wg) AIRFLOW (Cfm) 4,000 0.83 1.17 5,000 1.25 1.61 6,000 1.79 2.19 7,000 2.48 2.91 8,000 3.33 3.78 8,250 3.57 4.02...
  • Page 74 Table 28 — Fan Performance, 48EJ,EK038,044 — Vertical Discharge Units (For EW,EY units, reduce net available external static pressure by 0.5 in. wg) AIRFLOW (Cfm) 7,000 1.70 2.40 8,000 2.36 3.09 9,000 3.11 3.97 10,000 4.00 5.01 11,000 5.04 6.22 12,000 6.24 7.61...
  • Page 75 Table 29 — Fan Performance, 48EJ,EK048 — Vertical Discharge Units (For EW,EY units, reduce net available external static pressure by 0.5 in. wg) AIRFLOW (Cfm) 9,000 3.20 4.00 10,000 4.10 5.10 11,000 5.10 6.30 12,000 6.30 7.70 13,000 7.71 9.31 14,000 9.28 11.11...
  • Page 76 Table 30 — Fan Performance, 48EJ,EK054-068 — Vertical Discharge Units AIRFLOW (Cfm) 10,000 2.89 3.60 12,000 4.27 5.10 15,000 7.05 8.06 16,000 8.18 9.25 17,000 9.42 10.56 18,000 10.78 11.98 19,000 12.26 13.51 20,000 13.86 15.17 21,000 15.58 16.96 22,000 17.44 18.87 23,000...
  • Page 77 Table 31 — Fan Performance, 48EW,EY054-068 — Horizontal Discharge Units AIRFLOW (Cfm) 10,000 12,000 15,000 16,000 17,000 10.8 18,000 11.2 12.3 19,000 12.8 13.9 20,000 14.5 15.6 21,000 16.3 17.5 22,000 18.3 19.5 23,000 20.4 21.7 24,000 22.7 24.0 25,000 25.1 26.5 26,000...
  • Page 78 Table 32A — Fan Performance — Power Exhaust, 48AJ,AK,AW,AY020-050 and 48EJ,EK,EW,EY024-048 LOW SPEED AIRFLOW 208 v 230, 460, 575 v (Cfm) ESP Bhp Watts ESP Bhp 6,500 0.32 2.82 3160 0.70 2.98 6,700 0.23 2.87 3220 0.63 3.03 6,900 0.17 2.92 3270 0.59 3.09 7,100...
  • Page 79 Maximum Bhp LEGEND Bhp — Brake Horsepower NOTES: 1. Extensive motor and electrical testing on the Carrier units has ensured that the full horsepower range of the motor can be utilized with confidence. Using your fan motors up to the UNIT...
  • Page 80 User-defined set points are shown in Table 35. Table 36 lists the software link points addressable by DataPort™ and DataLINK™, Carrier devices that allow ac- cess to unit control by non-Carrier energy management sys- tems (EMS). The occupied or unoccupied comfort set points must be se- lected and the space temperature offset input will be used, if present.
  • Page 81 SET POINT FORMAT NAME OHSP xx.xF OCSP xx.xF UHSP xx.xF UCSP xx.xF SASP xx.xF OATL xx.xF NTLO xx.xF RTIO xx.x LIMT xx.xF xxx% LOWMDP xxx% IAQS xxxx UHDB xx.xF UCDB xx.xF LTMP xxx% HTMP xxx% PES1 xxx% PES2 xxx% LEGEND —...
  • Page 82 The Time Guard® function maintains a minimum off time of 5 minutes, a minimum ON time of 10 seconds, and a minimum delay before starting the second compressor of 10 seconds. If the compressors have been off for more than 15 minutes and the OAT (outdoor-air temperature) is less than 45 F, then the safeties will be ignored for 5 minutes.
  • Page 83 GAS HEATING, VARIABLE AIR VOLUME (VAV) UNITS — All of the gas heating control is performed through the integrated gas control (IGC) board. The control module board serves only to initiate and terminate heating operation. NOTE: The unit is factory-configured for disabled occupied heating.
  • Page 84 ITEM Heating Controller (SGC) Supply-Air Thermistors (SAT) Cooling Supply Air Set Point Potentiometer (CLSASP) Heating Supply Air Set Point Potentiometer (HTSASP) Air Flow Switch (AFS) Table 38 — Stage Gas System Inputs/Outputs INPUT Cool1 Cool2 Heat1 Heat2 Cool Supply Set Point Heat Supply Set Point Supply Air Thermistor (1, 2 and 3) Operating Modes —...
  • Page 85 Fig. 60 — Navigator Display MORNING WARM-UP (VAV only with PC Accessed/CCN Operation) — Morning warm-up occurs when the control has been programmed to turn on heat prior to the Occupied mode to be ready for occupancy mode. Morning warm-up is a condi- tion in VAV systems that occurs when the Temperature Com- pensated Start algorithm calculates a biased occupied start time and the unit has a demand for heating.
  • Page 86 (-) T12 LEGEND T — Terminal NOTE: The 4 to 20 mA input is a field-supplied non-Carrier EMS (Energy Management System) device. the temperature trends stop improving but the demand still ex- ceeds 2.0° F, then Stage 2 heating will be energized SPACE TEMPERATURE RESET SENSOR (VAV Only) —...
  • Page 87 IAQ sensor is required for IAQ control on the base control board. The Carrier sensors operate with a 4 to 20 mA signal. The 4 to 20 mA signal is connect to T13 (+) and T14 (-) on the...
  • Page 88 Solid-State Head Pressure Control is a field-installed accessory fan speed control device actuated by a temperature sensor. It is specifically designed for use on Carrier equipment and con- trols the condenser-fan motor speed in response to the saturated condensing temperature. For outdoor temperatures down to –20 F, it maintains condensing temperature at 100 F.

  • Page 89: Service

    If a Y2 (or Y2_SPT) call begins while the unit was under “Y1 cooling” control, compressor no. 2 will not be started until “Y1 cooling” control has ended. If the Y2 (or Y2_SPT) call ends, with compressor 1 in an unloaded state and compressor 2 ON, then compressor 1 will be immediately brought up to the fully loaded state.
  • Page 90 NOTES: 1. Torque set screws on blower wheel to 70 in. lbs ± 2 in. lbs. 2. Torque set screw on propeller fan to 15 in. lbs ± 2 in. lbs. 3. Dimensions are in inches. Fig. 66 — Gas Heat Section Details Fig.
  • Page 91 Witco Chemical Corp ..... . . Suniso 3GS IMPORTANT: Do not use reclaimed oil or oil that has been exposed to the atmosphere. Refer to Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants sec- tion, for procedures to add or remove oil.
  • Page 92 5. Be sure that hub flanges, flex members, spacer, and hard- ware are clean and free of oil. 6. Place the flanges onto the shafts with the hub facing out- ward. Do not tighten the set screws at this time. 7.
  • Page 93 Refrigerant Charge — listed on unit nameplate and in Tables 1A and 1B. Refer to Carrier GTAC II; Module 5; Charging, Recovery, Recycling, and Reclamation section for charging methods and procedures. Unit panels must be in place when unit is operating during charging procedure.
  • Page 94 Fig. 73 — Cooling Charging Chart, 48EJ,EK,EW,EY054-068 CHARGING CHART BOTH CIRCUITS ALL OUTDOOR FANS MUST BE OPERATING Add Charge if Above Curve Reduce Charge if Below Curve Liquid Pressure at Liquid Valve (PSIG) Fig. 74 — Cooling Charging Chart, 48AJ,AK,AW,AY020-060 REGULATOR 2 LEADS, #18 WIRE 1/32 INSULATION, ADJUSTMENT SCREW...

  • Page 95: Protective Devices

    Determine the cause and correct it before resetting the breaker. If the evaporator-fan motor is replaced with a different horsepower motor, resizing of the circuit breaker is required. Contact Carrier Application Engineering. CONDENSER-FAN MOTOR PROTECTION — Each...

  • Page 103: Troubleshooting

    TROUBLESHOOTING Typical refrigerant circuiting diagrams are shown in Fig. 84-93. An algorithm diagram of the IGC (Integrated Gas Unit Controller) control is shown in Fig. 94. LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig.
  • Page 104 4-Pass HPS & LPS mounted on compressor 4-Pass 4-Pass Muffler 4-Pass 4-Pass Compressor #1 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass HPS- HK02ZA428 4-Pass Cut-In - 320 PSI Cut-out - 420 PSI 4-Pass LPS - HK02ZB027 4-Pass Cut -In - 22 PSI 4-Pass Cut-out - 7 PSI...
  • Page 105 HPS & LPS mounted on compressor Muffler Compressor #1 HPS- HK02ZA428 Cut-In - 320 PSI Cut-out - 420 PSI LPS - HK02ZB027 Cut -In - 22 PSI Cut-out - 7 PSI HPS & LPS mounted on compressor Muffler Compressor #1 LEGEND FPS —...
  • Page 106 LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 87 — Typical Refrigerant Circuiting (48EJ,EK,EW,EY038,044)
  • Page 107 HPS & LPS mounted on compressor Muffler Compressor #1 HPS- HK02ZA428 Cut-In - 320 PSI Cut-out - 420 PSI LPS - HK02ZB027 Cut -In - 22 PSI Cut-out - 7 PSI HPS & LPS mounted on compressor Muffler Compressor #1 LEGEND FPS —...
  • Page 108 LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 89 — Typical Refrigerant Circuiting (48EJ,EK,EW,EY048)
  • Page 109 LEGEND HPS — High-Pressure Switch LPS — Low-Pressure Switch TXV — Thermostatic Expansion Valve Fig. 90 — Typical Refrigerant Circuiting (48EJ,EK,EW,EY054 and 058)
  • Page 110 6-Pass HPS & LPS mounted on compressor 6-Pass 6-Pass Muffler 6-Pass 6-Pass Compressor #1 6-Pass 6-Pass 6-Pass 6-Pass 6-Pass 6-Pass 6-Pass 6-Pass 6-Pass 6-Pass HPS- HK02ZA428 6-Pass Cut-In - 320 PSI Cut-out - 420 PSI 6-Pass LPS - HK02ZB027 6-Pass Cut -In - 22 PSI 6-Pass Cut-out - 7 PSI...
  • Page 111 LEGEND HPS — High-Pressure Switch LPS — Low-Pressure Switch TXV — Thermostatic Expansion Valve Fig. 92 — Typical Refrigerant Circuiting (48EJ,EK,EW,EY064)
  • Page 113 LEGEND IDM — Induced-Draft Motor IGC — Integrated Gas Unit Controller NOTE: Thermostat Fan Switch in the “AUTO” position or sensor-equipped unit. Fig. 94 — IGC Control (Heating and Cooling)
  • Page 114 Refer to Table 45 below for a description of alarms. The yellow LED blinks during transmission with the CCN (Carrier Comfort Network). The green LED blinks dur- ing transmission with the expansion board. Table 45 — Control Board LED Alarms...
  • Page 115 — Analog Input OAT — Outdoor-Air Temperature AO — Analog Output OFC — Outdoor Fan Contactor CCN — Carrier Comfort Network RAT — Return-Air Temperature CV — Constant Volume SAT — Supply-Air Temperature — Direct Input SPT — Space Temperature DO —...
  • Page 116 Course descriptions and schedules are in our catalog. [ ] Packaged Service Training Copyright 2001 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 PC 111 Catalog No.
  • Page 117 MODEL NO.: _________________________________ SOFTWARE VERSION (SEE FIG. 27): ____________ DATE: _______________________________________ PRE-START-UP: VERIFY THAT DIP SWITCH SETTINGS ARE CORRECT VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT REMOVE ALL COMPRESSOR SHIPPING HOLDDOWN BOLTS AND BRACKETS PER INSTRUCTIONS VERIFY INSTALLATION OF ECONOMIZER HOOD VERIFY INSTALLATION OF ALL OPTIONS AND ACCESSORIES VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT CHECK GAS PIPING FOR LEAKS...
  • Page 118 ADDITIONAL NOTES: ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ Copyright 2001 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book PC 111 Catalog No. 534-739 psig psig Printed in U.S.A.

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