Carrier 50EJ Installation, Start-Up And Service Instructions Manual
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Carrier 50EJ Installation, Start-Up And Service Instructions Manual

Carrier 50EJ Installation, Start-Up And Service Instructions Manual

Single-package rooftop units electric cooling with electric heat option
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CONTENTS

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Step 1 — Provide Unit Support . . . . . . . . . . . . . . 1
• ROOF CURB
• ALTERNATE UNIT SUPPORT
Step 2 — Rig and Place Unit . . . . . . . . . . . . . . . . . 8
• POSITIONING
• ROOF MOUNT
Step 3 — Field Fabricate Ductwork . . . . . . . . . . . 11
Step 4 — Make Unit Duct Connections . . . . . . . 11
Step 5 — Trap Condensate Drain . . . . . . . . . . . . . 11
Step 6 — Controls Options . . . . . . . . . . . . . . . . . . 12
• CONSTANT VOLUME APPLICATIONS
• VARIABLE AIR VOLUME (VAV)
APPLICATIONS
Step 7 — Make Electrical Connections . . . . . . . 15
• POWER WIRING
• FIELD POWER SUPPLY
• FIELD CONTROL WIRING
Step 8 — Make Outdoor-Air Inlet
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
• ECONOMIZER
• ECONOMIZER SETTINGS
Step 9 — Position Power Exhaust/
Barometric Relief Damper Hood . . . . . . . . . . . . . 29
Step 10 — Install Accessories . . . . . . . . . . . . . . . 30
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-42
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-45
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 46-51
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 com-
ponents. Only trained and qualified service personnel should
install, repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance func-
tions 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, ob-
serve precautions in the literature, tags and labels attached
to the unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire ex-
tinguishers 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.
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. 535-006
Tab
1b
Electric Cooling with Electric Heat Option
Installation, Start-Up and
Service Instructions
Page
Printed in U.S.A.
50EJ,EK,EW,EY024-048
Single-Package Rooftop Units
IMPORTANT — READ BEFORE INSTALLING
IMPORTANT: Due to upgrades in unit control soft-
ware and hardware, units produced currently are slightly
different than original design units. The unit control
software (which has changed) is designated with a sticker
on the unit control board, chip U8 (the large chip in
the center of the board), which states the software Ver-
sion number. Version 1.0 is the original version. Ver-
sion 2.0 is the current version. Differences in instal-
lation, configuration, and start-up procedures in this
manual will be identified by Version number.

INSTALLATION

Step 1 — Provide Unit Support
All panels must be in place when rigging. Unit is not
designed for handling by fork truck.
Roof Curb — Assemble and install accessory roof curb
in accordance with instructions shipped with the curb. Ac-
cessory roof curb and information required to field fabricate
a roof curb or horizontal adapter are shown in Fig. 1 and 2.
Install insulation, cant strips, roofing, and counter flashing
as shown. Ductwork can be secured to roof curb before unit
is set in place.
IMPORTANT: The gasketing of the unit to the roof
curb is critical for a leak-proof seal. Install gasket sup-
plied with the roof curb as shown in Fig. 1. Improp-
erly applied gasket can result in air leaks and poor unit
performance.
Curb should be level. This is necessary to permit unit drain
to function properly. Unit leveling tolerance is shown in
Fig 1 and 2. Refer to Accessory Roof Curb Installation In-
structions for additional information as required. When ac-
cessory roof curb is used, unit may be installed on class A,
B, or C roof covering material.
ALTERNATE UNIT SUPPORT — When the curb or adapter
cannot be used, support unit with sleepers using unit curb or
adapter support area. If sleepers cannot be used, support long
sides of unit (refer to Fig. 3-6) with a minimum number of
equally spaced 4-in. x 4-in. pads as follows:
50EJ,EK,EW,EY024-034 units require 3 pads on each side;
50EJ,EK,EW,EY038-048 require 4 pads on each side. Unit
may sag if supported by corners only.
Form 50E-3SI
Pg 1
8-96
Replaces: 50E-1SI

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  • Page 1 (refer to Fig. 3-6) with a minimum number of equally spaced 4-in. x 4-in. pads as follows: 50EJ,EK,EW,EY024-034 units require 3 pads on each side; 50EJ,EK,EW,EY038-048 require 4 pads on each side. Unit may sag if supported by corners only.
  • 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. NOTE: To prevent standing water in the drain pan of the indoor section and the heat exchangers, UNIT CAN ONLY BE PITCHED AS SHOWN.
  • 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. NOTE: To prevent standing water in the drain pan of the indoor section and the heat exchangers, UNIT CAN ONLY BE PITCHED AS SHOWN.
  • Page 4 4102 5- 8 ⁄ 4102 5- 8 ⁄ Fig. 3 — Base Unit Dimensions, 50EJ/EK024-034 NOTES: 1. Weights include economizer (Std) Center of gravity. 3. Do not locate adjacent units with dis- charge facing economizer inlet. Mini- mum clearances to be:...
  • Page 5 Economizer Side: 6 -0 Filter Access Side: 10 -0 (for removal of evaporator coil) 4. For smaller service and operational clearances, contact Carrier Applica- tion Engineering department. 5. Bottom ducts designed to be attached to accessory roof curb. If unit is mounted on dunnage, it is recommended the ducts be supported by cross braces as done on accessory roof curb.
  • Page 6 Filter Access Side: 10 -0 (for removal of evaporator coil) 4. For smaller service and operational clearances, con- tact Carrier Application Engineering department. 5. Dimensions are in inches. Dimensions in [ ] are in millimeters. 6. For units equipped with electric heat, a field-supplied 90°...
  • Page 7 Condenser Coil: 4 -0 Economizer Side: 6 -0 Filter Access Side: 10 -0 (for removal of evaporator coil) 4. For smaller service and operational clearances, contact Carrier Application Engineering department. 5. Dimensions are in inches. Dimensions in [ ] are in millimeters.

  • Page 8: Step 2 — Rig And Place Unit

    MODEL 50EJ/EK/EW/EY 038* 048* *Sizes 038 and 048 are 50EJ,EW units only. Four lifting lugs are provided on the unit base rails as shown Inspect unit for trans- in Fig. 7. Refer to rigging instructions on unit. POSITIONING — Provide clearance around and above unit for airflow, safety, and service access (Fig.
  • Page 9 10...20x24x2 8...16x25 4...20x25 Direct Drive, 3-Speed, Single-Phase Motor (Factory-Wired For High Speed) and Forward Curved Fan NOTES: 1. See Table 2 for evaporator fan motor data. 2. Sizes 038 and 048 are 50EJ,EW units only. (Hp) 4102 4322 06D537 06D328 115 ea.
  • Page 10 Direct Drive, 3-Speed, Single-Phase Motor (Factory-Wired For High Speed) and Forward Curved Fan 4...1 11...10 NOTES: 1. See Table 2 for optional evaporator fan motor data. 2. Sizes 038 and 048 are 50EJ,EW units only. (Hp) 4795 5175 06EA265 06EA250...

  • Page 11: Installation

    Outlet grilles must not lie directly below unit discharge. Step 4 — Make Unit Duct Connections 50EJ,EK UNITS — Unit is shipped for through-the-bottom duct connections. Ductwork openings are shown in Fig. 3 and 4. Attach all ductwork to roof curb. Air distribution is shown in Fig.

  • Page 12: Step 6 — Controls Options

    CV (constant volume) or VAV (variable air volume) operation; stand-alone unit with field-supplied sensors in- stalled (CV or VAV); as a system via the Carrier Comfort System (TEMP or VVT); optional electronic expansion board installed (CV or VAV); linked to the Carrier Comfort Net- work;...
  • Page 13 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-...
  • Page 15 • demand limiting • IAQ sensor • OAQ sensor • alarm light When the unit is connected to the CCN (Carrier Comfort Network), the following expansion board features can be utilized: • CCN IAQ (indoor air quality) participation • CCN OAQ (outdoor air quality) participation •...
  • Page 16 Failure to do so may damage the transformers. ⁄ -in. diameter hole FIELD CONTROL WIRING — Install either a Carrier- approved accessory thermostat or a CCN (Carrier Comfort Network) compatible temperature sensor. Thermostats are used on CV (constant volume) units only. Control box diagrams are shown in Fig.
  • Page 17 Table 4 — Electrical Data — 50EJ,EK,EW,EY024-048 COMPRESSOR VOLTAGE NOMINAL UNIT RANGE VOLTAGE No. 1 SIZE (3 Ph 60 Hz) 208/230 39.1 19.9 16.0 LEGEND — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration — Indoor (Evaporator) Fan Motor —...
  • Page 18 Table 4 — Electrical Data — 50EJ,EK,EW,EY024-048 (cont) COMPRESSOR VOLTAGE NOMINAL UNIT RANGE VOLTAGE No. 1 SIZE (3 Ph 60 Hz) 208/230 39.1 19.9 16.0 No. 2 FLA (ea) 24.2/ 22.0 30.8/ 39.1 28.0 46.2/ 42.0 19.9 16.0 POWER ELECTRIC...
  • Page 19 Table 4 — Electrical Data — 50EJ,EK,EW,EY024-048 (cont) COMPRESSOR VOLTAGE NOMINAL UNIT RANGE VOLTAGE No. 1 SIZE (3 Ph 60 Hz) 208/230 57.1 25.6 20.5 LEGEND — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration — Indoor (Evaporator) Fan Motor —...
  • Page 20 Table 4 — Electrical Data — 50EJ,EK,EW,EY024-048 (cont) COMPRESSOR VOLTAGE NOMINAL UNIT RANGE VOLTAGE No. 1 SIZE (3 Ph 60 Hz) 208/230 57.1 25.6 20.5 No. 2 FLA (ea) 30.8/ 28.0 46.2/ 57.1 42.0 59.4/ 54.0 25.6 20.5 POWER ELECTRIC...
  • Page 21 Table 4 — Electrical Data — 50EJ,EK,EW,EY024-048 (cont) COMPRESSOR VOLTAGE NOMINAL UNIT RANGE VOLTAGE No. 1 SIZE (3 Ph 60 Hz) 208/230 57.1 25.6 20.5 LEGEND — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration — Indoor (Evaporator) Fan Motor —...
  • Page 22 Table 4 — Electrical Data — 50EJ,EK,EW,EY024-048 (cont) COMPRESSOR VOLTAGE NOMINAL UNIT RANGE VOLTAGE No. 1 SIZE (3 Ph 60 Hz) 208/230 69.2 28.8 26.7 No. 2 FLA (ea) 46.2/ 42.0 59.4/ 69.2 54.0 74.8/ 68.0 28.8 26.7 POWER ELECTRIC...
  • Page 23 Table 3 — Electrical Data — 50EJ,EK,EW,EY024-048 (cont) COMPRESSOR VOLTAGE NOMINAL UNIT RANGE VOLTAGE No. 1 SIZE (3 Ph 60 Hz) 208/230 82.1 42.3 34.6 LEGEND — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration — Indoor (Evaporator) Fan Motor —...
  • Page 24 — Dual In-Line Package PEC − Power Exhaust Controller Fig. 14 — Control Box Diagram (Sizes 024-034) — Dual In-Line Package PEC — Power Exhaust Controller Fig. 15 — Control Box Diagram (Sizes 038-048)

  • Page 25: Adjustments

    CCN com- munication defaults. Carrier Comfort Network Interface — The 50E units can be connected to the CCN. The communication bus wiring is sup- plied and installed in the field. Wiring consists of shielded, 3-conductor cable with drain wire.
  • 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. Trim 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.
  • Page 27 HOOD SIDE Fig. 21 — Adding Seal Strip to Hood Top Mounting Flange GRAY FOAM STRIP CROSS MEMBER Fig. 22 — Adding Foam Strip to Cross Member HOOD Fig. 23 — Adding Foam Strip to Hood Side HOOD TOP BLOCKOFF BAFFLE Fig.
  • Page 28 The control is mounted in the economizer hood. The sensor is mounted in the return duct (50EJ/EK) or return air plenum (50EW/EY). NOTE: Switches shown in high enthalpy state. Terminals 2 and 3 close on en- thalpy decrease.

  • Page 29: Step 9 — Position Power Exhaust Barometric Relief Damper Hood

    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.

  • Page 30: Step 10 — Install Accessories

    VAV — Variable Air Volume Fig. 33A — Motormaster III Sensor Location (Sizes 024-034) Fig. 32 — Pressure Transducer Locations 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.
  • Page 31 Fig. 33C — Motormaster III Sensor Location (Size 048) Fig. 33B — Motormaster III Sensor Location (Sizes 038 and 044)

  • Page 32: Start-Up

    START-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 under each holddown bolt head can be obtained.
  • 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 module activates the other 2 exhaust fans.
  • Page 34 CV — CCN or Sensors Used VAV — No Space Sensor CLOSED CV — Thermostat LEGEND CCN — Carrier Comfort Network — Constant Volume VAV — Variable Air Volume Table 11A — DIP Switch Factory Settings (Version 1.0 of Unit Control Software) UNIT 50EJ/EW...
  • Page 35 DIP switch configurations for Version 1.0 of the Unit Con- trol Software are as follows: • DIP switch 1 configures the unit to operate as a variable air volume (VAV) or constant volume (CV) unit • DIP switch 2 configures what type of sensors or thermo- stats are used with the unit •...
  • Page 36 Table 12 — Fan Performance, 50EJ/EK024-034 — Vertical Discharge Units FOR EW/EY UNITS, REDUCE NET AVAILABLE EXTERNAL STATIC PRESSURE BY 0.3 IN. WG AIRFLOW (Cfm) 4,000 0.77 1.09 5,000 1.14 1.50 6,000 1.62 2.01 7,000 2.22 2.65 8,000 2.97 3.42 8,250 3.18...
  • Page 37 Table 13 — Fan Performance, 50EJ038,044 and 50EK044 — Vertical Discharge Units For EW/EY UNITS, REDUCE NET AVAILABLE EXTERNAL STATIC PRESSURE BY 0.5 IN. WG AIRFLOW (Cfm) 8,000 2.18 2.87 9,000 2.87 3.68 10,000 3.69 4.63 11,000 4.65 5.75 12,000 5.75 7.02 13,000...
  • Page 38 18,000 — — — 19,000 — — — 20,000 — — — UNIT MINIMUM HEATING 50EJ,EK,EW,EY 6,000 7,500 8,250 9,000 10,500 12,000 13,500 LEGEND — Constant Volume VAV — Variable Air Volume AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 9.09 9.60 10.77...
  • Page 39 — — NOTE: 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 horsepower ratings shown on the Motor Limi- tations table will not result in nuisance tripping or premature motor failure.
  • Page 40 (when power exhaust is used). The control module will run continuous diagnostics for alarms/alerts; respond to CCN (Carrier Comfort Network) communications; perform any configured network POC (Prod- uct Outboard Control) functions such as time/outdoor air tem- perature broadcast and global broadcast;...
  • 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 off, but will energize upon the call for heat. The outdoor-air dampers will move to the IAQ unoccupied position (generally set to zero in the Unoccupied mode).

  • Page 42: Service

    The Motormaster III device is specifically designed for use on Carrier equipment and controls the outdoor-fan mo- tor speed in response to the saturated condensing tempera- ture. For outdoor temperatures down to −20 F, the Motor- master III device maintains condensing temperature at 100 F.
  • Page 43 Witco Chemical Corp....Suniso 3GS IMPORTANT: Do not use reclaimed oil or oil that has been exposed to the atmosphere. Refer to Carrier Stand- ard Service Techniques Manual, Chapter 1, Refriger- ants section, for procedures to add or remove oil.
  • Page 44 Refrigerant Charge — Amount of refrigerant charge is listed on unit nameplate and in Table 1. Refer to Carrier GTAC II; Module 5; Charging, Recovery, Recycling, and Rec- lamation section for charging methods and procedures. Unit panels must be in place when unit is operating dur- ing charging procedure.
  • Page 45 Determine the cause and correct it before resetting the breaker. If the evaporator- fan motor is replaced with a different horsepower motor, re- sizing of the circuit breaker is required. Contact Carrier Ap- plication Engineering. CONDENSER-FAN MOTOR PROTECTION — Each condenser-fan motor is internally protected against overtemperature.

  • Page 46: Troubleshooting

    TROUBLESHOOTING Typical refrigerant circuiting diagrams are shown in Fig. 43-45. LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 43 — Typical Refrigerant Circuiting (50EJ,EK,EW,EY024-034)
  • Page 47 LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 44 — Typical Refrigerant Circuiting (50EJ,EK,EW,EY038,044)
  • Page 48 LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 45 — Typical Refrigerant Circuiting (50EJ,EW048)
  • Page 49 VAV — Variable Air Volume to Table 20 below for a description of alarms. The yellow There LED blinks during transmission with the CCN (Carrier Com- fort Network). The green LED blinks during transmission with the expansion board. Table 20 — Control Board LED Alarms DESCRIPTION The expansion board and control board flash the red LED in one-...
  • Page 50 Compr. 1 — DO (HV) Compr. 2 — DO (HV) LEGEND (Tables 21 and 22) — Analog Input — Analog Output CCN — Carrier Comfort Network — Constant Volume — Direct Input — Direct Output — High Voltage — Kilo-Ohms OAT —...
  • Page 51 Table 23 — I/O Channel Designations Expansion Module — CV and VAV TERMINAL ASSIGNMENT T1-2 T3-4 T5-6 T7-8 T9-10 T11-12 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 —...
  • Page 54 For a free Service Training Material Catalog (STM), call 1-800-962-9212. Ordering instructions are included. Copyright 1996 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 55 MODEL NO.: SOFTWARE VERSION (SEE FIG. 15) DATE: PRE-START-UP: VERIFY THAT DIP SWITCH SETTINGS ARE CORRECT VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT REMOVE ALL SHIPPING HOLDDOWN BOLTS AND BRACKETS PER INSTRUCTIONS VERIFY INSTALLATION OF ECONOMIZER HOOD VERIFY INSTALLATION OF ALL OPTIONS AND ACCESSORIES VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT...
  • Page 56 BELT PART NUMBER BELT SIZE FILTER QUANTITY FILTER SIZES ADDITIONAL NOTES: Copyright 1996 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. 535-006...

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