Page 1: Table Of Contents
• INSTALLATION • CONFIGURATION • OPERATING SEQUENCE Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. PC 111 Catalog No. 534-763 Book 1 Tab 1a 1b Variable-Air Volume Rooftop Units...
Page 2: Safety Considerations
Use this guide in conjunction with the separate Installation Instructions literature packaged with the unit. Carrier 48FK,FM,JK and 50FK,FM,FS,FY,JK,JY units pro- vide ventilation, cooling, and heating (when equipped) in Vari- able Air Volume (VAV) applications. These units contain facto- ry-installed controls which provide full system management.
Page 3: Processor Board
The VAV control system monitors and controls the follow- ing functions of the rooftop unit: • supply-air temperature (unit capacity) • morning warm-up or electric heat (if equipped) • head pressure control, fan cycling • economizer position • diagnostic display •...
Page 4 LEGEND — Thermistor Field Wiring Accessory Fig. 2 — Pin Terminal Connector J1 Thermistor Inputs Table 2 — Pin Terminal Connector J2 Status Switch Inputs CONNECTOR J2 STATUS SWITCH TERMINAL NO. Oil Pressure, Circuit 2 Oil Pressure, Circuit 1 Loss of Charge, Circuit 2 Loss of Charge, 9,10...
Page 5: P3 - Reset Limit
All of the potentiometers must be set before the unit is start- ed in order for the unit to function properly. See Start Up, Po- tentiometers section on page 27 for information on establishing set points. Each of the potentiometers has a valid range that is used by the control.
Page 6 Table 3 — Output Pin and Terminal Assignments OUTPUT PIN- TERMINAL Stage 1 J6-1 Compressor Relay (K1)* Stage 2 J6-2 Compressor Relay (K2)* Stage 3 J6-3 Compressor Relay (K3)* J6-4 Compressor Relay (K4)† Stage 5 J6-5 Compressor Relay (K5)† Stage 6 J6-6 Compressor Relay (K6)†...
Page 7: Compressor Operation
P1 SUPPLY AIR TWO-DIGIT SET POINT DISPLAY POTENTIMETER Fig. 6 — Display/Set Point Board Compressor Operation CONTROL RELAY (CR) — This relay provides information to the processor about compressor operation (one control relay per compressor). The relay controls and protects the compres- sor and also controls the crankcase heater.
Page 8 GAS SECTION HORIZONTAL SUPPLY SECTION (48FK,JK ONLY) (50FY,JY ONLY) AND EXTENDED PLENUM SECTION (50FKX,FKY,JKX,JKY) Fig. 7 — Thermistor T1 Location, 48FK,JK, 50FY,JY and 50FKX,FKY,JKX,JKY 034-048 Units FAN DISCHARGE/ELECTRIC HEAT SECTION Fig. 8 — Thermistor T1 Location, 50FK,JK034-048 Units...
Page 9 GAS SECTION HORIZONTAL SUPPLY SECTION (50FS,FY,JY) AND EXTENDED (48FK,FM,JK) PLENUM SECTION (50FKX,FKY,FMX,FMY,JKX,JKY) Fig. 9 — Thermistor T1 Location, 48FK,FM,JK, 50JY and 50JKX,JKY 054-074 Units and 50FKX,FKY,FMX,FMY and 50FS,FY054-104 Units FAN DISCHARGE/ELECTRIC HEAT SECTION Fig. 10 — Thermistor T1 Location, 50FK,JK054-074 Units...
Page 10: Economizer
STANDARD FILTERS Fig. 11 — Thermistor T2 Location, Size 034-048 Units BAG FILTERS STANDARD FILTERS AND (054-074 Only) PLEATED FILTERS Fig. 12 — Thermistor T2 Location, Size 034-048 Units Economizer — Economizer control is used to control the outside and return air dampers of the unit, to satisfy space cool- ing demand using all outside air (when permitted), and to satis- fy cooling in conjunction with compressor operation (when conditions permit).
Page 11 054 UNITS 064, 074, 078 UNITS 088, 104 UNITS Fig. 14 — Thermistor T3 and T4 Locations, Size 054-104 Units...
Page 12: Supply Fan Variable Frequency Drive (Vfd)
LEGEND ECON — Economizer — Minimum — Potentiometer — Variable-Air Volume Fig. 15 — Accessory Relay Board (Standard; Factory Supplied) LEGEND — Integrated Circuit — Input — Potentiometer RTN — Return Fig. 16 — Two-Step Demand Limit Module Fig. 17 — Enthalpy Sensor Location (48FK,JK and 50FK,FY,JK,JY Units Only) Supply Variable...
Page 13: Temperature Reset
Fig. 25. If multiple sensors are required to average the space temper- ature, see Fig. 26. Use only Carrier Part Number HH79NZ014 sensor, in arrangements of 4 or 9 sensors, with total wiring not to exceed 1000 ft.
Page 14 Fig. 20 — Unit Control Box Arrangement, Sizes 034-048...
Page 17 034-048: TB3 054-104: TB4 OCCUPIED/UNOCCUPIED SWITCH NIGHT SETBACK THERMOSTAT NOTES: 1. Occ/Unocc switch closes when occupied. 2. Night setback thermostat closes when in night setback heating. Fig. 23 — Occupied/Unoccupied Switch with Night Setback Thermostat 034-048: TB3 054-104: TB4 N.O. N.C.
Page 18: Installation
SIZES 034-048 TO ACCESSORY SPACE TEMPERATURE RESET CONTROL BOARD SIZES 054-104 SENSOR 1 SPACE TEMPERATURE RESET — 4 SENSOR AVERAGING APPLICATION SIZES 034-048 TO ACCESSORY SPACE TEMPERATURE RESET CONTROL BOARD SIZES 054-104 NOTE: Sensor part number is HH79NZ014. SPACE TEMPERATURE RESET — 9 SENSOR AVERAGING APPLICATION Fig.
Page 19: Single-Step Demand Limit
Connect the potentiometer end terminals to terminals 8 and 9 on control terminal block TB3 (sizes 034-048) or TB4 (sizes 054-104) (see Fig 27). Connect the switch terminals to the potentiometer wiper arm terminal and to terminal 10 on TB3 or TB4. To enable demand limit function, change DIP switch 5 to position ON.
Page 20: Single-Step Demand Limit
VFDs that permit direct communi- cation between the VFD and several BMS communication sys- tems. Contact your Carrier representative for information on selecting an appropriate accessory interface board and the name of the local service office (for sale and installation of the...
Page 21: Smoke Control Modes
EXTERNAL ALARM SIGNAL — The unit controls provide an external alarm status signal via a 115-vac output signal at the relay board J5, available at TB2-4 and TB2-5 (common). This signal can be forwarded to the BMS by adding a signal relay at the alarm output, placing its coil across terminals TB2- 4 and TB2-5 and using its contacts to control a discrete input to the BMS (see Fig.
Page 22: Fire Shutdown Mode
SMOKE PURGE MODE — Smoke Purge mode removes smoke from the interior spaces and replaces it with fresh out- side air. The economizer and power exhaust are required for this function. The economizer and power exhaust are standard on 48FM and 50FM,FS units. The economizer is a factory- installed option and the power exhaust is a factory-installed option or field-installed accessory on 48FK,JK and 50FK,JK units.
Page 23: Air Pressure Tubing
SWITCH CONFIGURATION NUMBER SW-1 N.C. N.C. SW-2 SW-3 N.O. SW-4 N.O. SW-5 N.C. SW-6 N.O. SW-7 N.O. SW-8* N.C. A: N.O. SW-9A/B B: N.C. *Not required on 48FM and 50FM,FS units (units with high capacity power exhaust). LEGEND — Building Pressure DPS —...
Page 24 034-048 UNITS SW-1 REMOVE JUMPER SW-2 REMOVE JUMPER SW-3 SW-4 SW-5 REMOVE JUMPER SW-6 SW-9A SW-9B REMOVED FROM TB3-7 REMOVED FROM C-DPS LEGEND — Differential Pressure Switch — Heat Interlock Relay PEVFD — Power Exhaust Variable Frequency Drive — Switch —...
Page 25: Modulating Power Exhaust
Fig. 33 — Modulating Power Exhaust and Inlet Guide Vane Differential Pressure Switch (Sizes 034-048) Fig. 34 — Inlet Guide Vane Differential Pressure Switch and Variable Frequency Drive (Sizes 054-104) Fig. 35 — Modulating Power Exhaust Differential Pressure Switch (Sizes 054-104) MODULATING POWER EXHAUST 48FK,JK and 50FK, JK Units —...
Page 26: Configuration Header
Table 9 — Potentiometer Inputs and Ranges POTENTIOMETER DESCRIPTION Supply Air Set Point Economizer Position Reset Limit Demand Limit, P4† Single-Step DLCM-P1 Demand Limit, 2-Step DLCM-P2 Minimum Economizer Position Warm-Up Set Point Reset P7** Temperature *Optional factory-installed economizer is required. Potentiometer P2 is not a set point. †Accessory two-step demand limit module is required (which has 2 potentiometers), or a 5 to 20 k-ohm field-supplied potentiometer is required for single-step demand limit.
Page 27: Adjusting Set Points
DIP SWITCH NO. 1 — Supply Air Set Point (SASP) Reset Type. Factory setting is OFF. Do not change. DIP SWITCH NO. 2 — SASP Reset Enabled. Factory setting is OFF (no SASP reset enabled). If SASP reset has been installed, enable it by changing switch position to ON.
Page 28: Supply Fan Control With Igv Option
Supply Fan Control with IGV Option — guide vane option will modulate the supply fan airflow in order to maintain the static pressure in the supply duct. The set point for duct static pressure is established at the differential pressure switch for the IGV control.
Page 29: Installation
Troubleshooting, Supply Fan Variable Frequency Drive section (page 52). IMPORTANT: The Carrier factory default values for the VFD may be different than the default values of the manufacturer. Refer to the Service section when check- ing default values.
Page 30: Modulating Power Exhaust Option Or Accessory) (48Fk,Jk And 50Fk,Jk Units)
Table 13 — VFD Set Point (Frequency Command) for Duct Pressure PRESSURE VFD SET POINT (Hz) (in. wg) 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 Table 14 — Changing the VFD Set Point (Frequency Command)* KEY OPERATION LED MESSAGE XX.X or OFF ↓...
Page 31: Start Unit
Table 15 — PE VFD Set Point (Frequency Command) for Building Pressure CONTROL PRESSURE PRESSURE SET POINT SIGNAL (in. wg) (in. wg) (Hz) (mA) 0.50 4.00 0.00 0.45 4.80 –0.05 0.40 5.60 –0.10 0.35 6.40 –0.15 0.30 12.0 7.20 –0.20 0.25 15.0 8.00...
Page 32 Table 16 — Quick Test, Unit Configuration and Switch Check QUICK NORMAL TEST DISPLAY STEP NO. 0 or 1 0 or 1 0 or 1 0 or 1 0 or 1 1.0. 1.1. 1.2. 1.3. LEGEND DIP — Dual, In-Line Package —...
Page 33 Table 17 — Quick Test, Thermistor and Potentiometer Check QUICK NORMAL TEST DISPLAY STEP NO. 1 — Thermistor OK 1.4. 0 — Thermistor Faulty 1 — Thermistor OK 1.5. 0 — Thermistor Faulty 1 — Thermistor OK 1.6. 0 — Thermistor Faulty 1 —...
Page 34: Operating Information
Table 19 — Sensor Resistance Values TEMP RESISTANCE TEMP RESISTANCE (Ohms) (Ohms) –60 362,640 11,396 –55 297,140 9,950 –50 245,245 8,709 –45 202,841 7,642 –40 168,250 6,749 –35 139,960 5,944 –30 116,820 5,249 –25 98,420 4,644 –20 82,665 4,134 –15 69,685 3,671 –10...
Page 35: Operating Sequence
Operating Sequence — The sequence presented be- low assumes that the unit is equipped with heat for morning warm-up and an economizer. If these items are not enabled with the appropriate DIP switches, the processor bypasses these subroutines. This sequence is also based on an EPROM (erasable, programmable, read-only memory) processor chip with the identification ‘HT204485-1-XX,’...
Page 36: Head Pressure Control
SIZE 044 UNITS — These units have 2 compressors and 1 unloader on compressor no. 1. See Fig. 42 for compressor and condenser fan motor locations. The unit operating sequence is as follows: Stage 1 Relays K1 and K3 are energized. Compressor no. 1 starts with the unloader energized.
Page 37 054, 064 UNITS 054-088 UNITS 074, 078 UNITS 088, 104 UNITS 104 UNITS Fig. 43 — Component Arrangement, 054-104 Units...
Page 38: Supply Fan Control With Igv
Supply Fan Control with IGV — the supply fan static pressure is controlled by inlet guide vanes. The inlet guide vanes operate independently from the micro- processor. The supply static pressure is controlled by a differ- ential pressure switch. For example, assume that set point on supply fan differen- tial switch is 1.9 in.
Page 39 Fig. 44 — Modulating Power Exhaust Component Locations; Sizes 034-048...
Page 41 Fig. 46 — Modulating Power Exhaust Return End Sheet Metal Skin Detail; Sizes 034-048 Fig. 47 — Modulating Power Exhaust Return End Sheet Metal Skin Detail; Sizes 054-104...
Page 42 PE VFD EXHAUST Fig. 48 — Modulating Power Exhaust Return End Sheet Metal Skin Detail; 48FM and 50FM,FS Units Table 20 — Compressor Loading and Unloading Sequences COOLING Lead Circuit STAGE Unloader Comp 1 COOLING Lead Circuit STAGE Unloader Comp 1 LARGE ECONOMIZER HOOD LOCATION POWER EXHAUST...
Page 43 Table 20 — Compressor Loading and Unloading Sequences (cont) COOLING Lead Circuit STAGE Comp 1 COOLING Lead Circuit STAGE Unloader Comp 1 COOLING Lead Circuit STAGE Unloader Comp 1 COOLING Lead Circuit STAGE Unloader Comp 1 COOLING Lead Circuit STAGE Unloader Comp 1 SIZE 044 UNITS...
Page 44 Table 20 — Compressor Loading and Unloading Sequences (cont) COOLING STAGE Comp 1 COOLING Lead Circuit STAGE Unloader Comp 1 TROUBLESHOOTING By using the display module, actual operating conditions of the unit are displayed while it is running. The Quick Test func- tion allows proper operation of compressors, compressor un- loaders, fans, and other components to be checked while unit is stopped.
Page 45 Table 22 — Operation Status Codes CODE MEANING 0 cooling stages active 1 cooling stage active 2 cooling stages active 3 cooling stages active 4 cooling stages active 5 cooling stages active 6 cooling stages active 7 cooling stages active 8 cooling stages active Initialization mode (Allow 2 minutes for initialization.
Page 46: Configuration
DISPLAY DESCRIPTION OF FAILURE Compressor 1 failure Compressor 2 failure Compressor 3 failure Compressor 4 failure Loss-of-charge circuit 1 Loss-of-charge circuit 2 Low oil pressure circuit 1 Low oil pressure circuit 2 Illegal unit configuration Supply-air thermistor failure Return-air thermistor failure Circuit 1 saturated condensing thermistor Circuit 2 saturated condensing thermistor Reset temperature thermistor failure...
Page 47 CODE 82: SUPPLY-AIR TEMPERATURE SET POINT POTENTIOMETER FAILURE — If supply-air set point potentiometer (P1 — located on display board) fails, control will use a default value. A failure will cause an error code of 82 to be displayed on display board when display button is pushed;...
Page 48 The failure will automatically reset once potentiometer re- turns to normal. If a failure occurs, one of the following is the probable cause: DIP Switch 4 — If this switch is in the ON position and the accessory board is not installed (accessory board is standard on these units, so it should always be on the unit).
Page 49 Step 5 — Check Relay Board Outputs from the Processor Board — This step involves checking the output signals from relays K1-K3 on the relay board. 1. Turn power to OFF position. 2. Connect negative test probe to TP19 (meter still set to dc).
Page 50 6. If voltage is not correct, replace processor board. Step 7 — Potentiometer Connection Checkout 1. Turn power to OFF position. 2. Remove plug connection from pin terminal strip J3. 3. Connect negative meter lead to terminal 2 of J3. 4.
Page 51: Two-Step Demand Limit
RELAY BOARD TROUBLESHOOTING — The relay board contains 13 electromechanical relays. The small relays are 24 vac, and the large relays are 115 vac. These relays are con- trolled by the processor through the ribbon cable attached to the relay board. The following procedure can be used to check out the oper- ation of the relays.
Page 52: Configuration
NOTE: The VFDs (part no. TOSVERT130-E3) are specially modified for use on Carrier equipment. Some specifications and control configuration defaults for Carrier applications will differ from the VFD manufacturer manual included in the packet. See Table 30 for listing of Carrier-specific default values. LIMIT SWITCHES CAPACITOR...
Page 53 PID logic function of the VFD must be dis- abled. To disable the PID control: 1. Disconnect and lock out all power to the Carrier rooftop unit. 2. Remove the VFD access cover.
Page 54 (Protection) Gr.Ut (Utility) *These settings differ from the Toshiba defaults and are required for Carrier applications. NOTE: To restore original factory settings, change tYP to 6 in Setup mode (SEtP). This restores the VFD original factory settings. PARAMETER DEFAULT VALUE...
Page 55 Occasionally it may be necessary to restore the VFD de- faults to the general Carrier use values. These are stored in an OPTION ROM (read-only memory chip). However, some variables may need to be manually changed to match the spe- cific unit’s factory default settings.
Page 56 (Protection) Gr.Ut (Utility) *These settings differ from the Toshiba defaults and are required for Carrier applications. NOTE: To restore original factory settings, change tYP to 6 in SEtup mode (SEtP). This restores the VFD original factory settings. P24 RES RR FM AM CC Fig.
Page 57 This will recall the specific factory defaults for this unit. Occasionally it may be necessary to restore the power ex- haust VFD defaults to the general Carrier use values. These are stored in an OPTION ROM (read-only memory chip). Howev- er, some variables may need to be manually changed to match the specific unit’s factory default settings.
Page 58 LEGEND AND NOTES FOR FIG. 57 — Alarm — Contactor — Circuit Breaker — Control Circuit Breaker COMP — Compressor — Crankcase Heater — Control Relay — Differential Pressure Switch — Discharge Pressure Transducer — Enering-Air Temperature — Enthalpy Control —...
Page 62: Installation
Course descriptions and schedules are in our catalog. [ ] Packaged Service Training Copyright 2000 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 63: Two-Step Demand Limit
MODEL NO.: _____________________________________ DATE: ___________________________________________ I. PRE-START-UP: VERIFY THAT UNIT IS LEVEL VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT LOOSEN ALL SHIPPING HOLDDOWN BOLTS AND REMOVE SHIPPING BRACKETS PER INSTRUCTIONS VERIFY THAT COMPRESSOR SUSPENSION SPRINGS HAVE BEEN LOOSENED PER INSTRUCTIONS VERIFY OPENING OF ECONOMIZER HOODS VERIFY INSTALLATION OF EXHAUST HOODS CONFIRM THAT TUBING FOR SPACE AND SUPPLY DUCT PRESSURES HAS BEEN INSTALLED...
Page 64: Installation
VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS IN UNIT INSTALLATION INSTRUCTIONS GENERAL ECONOMIZER MINIMUM VENT SETTING TO JOB REQUIREMENTS IV. NOTES Copyright 2000 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.

Carrier PC 111 Operating And Troubleshooting Manual

Quick Links

CIRCUIT 2

Related Manuals for Carrier PC 111

Summary of Contents for Carrier PC 111

This manual is also suitable for:

Table of Contents