Carrier WeatherMaker 48TC 04-07 Rooftop with Gas Heat/Electric Cooling Installation Guide

Installation Guide for Carrier models including: Carrier, WeatherMaker, 48TC 04-07, Single Package Rooftop with, Gas Heat, Electric Cooling

48TC-4-7-03SI

Installation Instructions

Installation Instructions - Climaproyectos S.A. de C.V.

2 fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and appropriate national electrical

48TC-4-7-03SI - Installation Manual - CP | Climaproyectos S.A. de C.V.

File Info : application/pdf, 60 Pages, 5.12MB

48TC-4-7-03SI-Installation-Manual-CP

WeatherMaker® 48TC 04-07
Single Package Rooftop with Gas Heat/Electric Cooling

Installation Instructions

48TC 07 units for installation in the United States contain use of Carrier's Staged Air Volume (SAVTM) 2-speed indoor fan control system. This complies with the U.S. Department of Energy (DOE) efficiency standard of 2018. 48TC 07 units for installation outside the United States may or may not contain use of the SAV 2-speed indoor fan control system as they are not required to comply with the U.S. Department of Energy (DOE) efficiency standard of 2018. For specific details on operation of the Carrier SAV 2-speed indoor fan system refer to the Variable Frequency Drive (VFD) Factory-Installed Option 2-Speed Motor Control Installation, Setup, and Troubleshooting manual.

CONTENTS
Page GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 1-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Job-Site Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Step 1 -- Plan for Unit Location. . . . . . . . . . . . . . . . . 6 Step 2 -- Plan for Sequence of Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 · CURB-MOUNTED INSTALLATION · PAD-MOUNTED INSTALLATION · FRAME-MOUNTED INSTALLATION Step 3 -- Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Step 4 -- Provide Unit Support . . . . . . . . . . . . . . . . . 7 · ROOF CURB MOUNT · SLAB MOUNT (HORIZONTAL UNITS ONLY) · ALTERNATE UNIT SUPPORT (IN LIEU OF CURB
OR SLAB MOUNT) Step 5 -- Field Fabricate Ductwork. . . . . . . . . . . . . . 9 Step 6 -- Rig and Place Unit . . . . . . . . . . . . . . . . . . . . 9 · POSITIONING ON CURB Step 7 -- Convert to Horizontal and Connect
Ductwork (When Required) . . . . . . . . . . . . . . . . . 10 Step 8 -- Install Outside Air Hood. . . . . . . . . . . . . . 10 · ECONOMIZER AND TWO POSITION DAMPER
HOOD PACKAGE REMOVAL AND SETUP -- FACTORY OPTION · ECONOMIZER HOOD AND TWO-POSITION HOOD Step 9 -- Install Flue Hood . . . . . . . . . . . . . . . . . . . . 11 Step 10 -- Install Gas Piping . . . . . . . . . . . . . . . . . . 11 · FACTORY-OPTION THRU-BASE CONNECTIONS (GAS CONNECTIONS) Step 11 -- Install External Condensate Trap and Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Step 12 -- Make Electrical Connections . . . . . . . . 14 · FIELD POWER SUPPLY · UNITS WITH FACTORY-INSTALLED NON-FUSED DISCONNECT · UNITS WITHOUT FACTORY-INSTALLED NONFUSED DISCONNECT · CONVENIENCE OUTLETS · FACTORY-OPTION THRU-BASE CONNECTIONS (ELECTRICAL CONNECTIONS)

· HUMIDI-MIZER® CONTROL CONNECTION · ECONOMI$ER X (FACTORY-INSTALLED OPTION) · ECONOMIZER MODULE WIRING DETAILS · INTERFACE OVERVIEW · PREMIERLINKTM (FACTORY-OPTION) · PREMIERLINK FIELD CONNECTIONS · ECONOMIZER CONTROLS · RTU OPEN CONTROL SYSTEM · RTU OPEN CONTROL SYSTEM FIELD
CONNECTIONS · RTU OPEN COMMUNICATION WIRING
PROTOCOLS · LOCAL ACCESS · OUTDOOR AIR ENTHALPY CONTROL · SMOKE DETECTORS Step 13 -- Adjust Factory-Installed Options . . . . 57 · SMOKE DETECTORS · ECONOMI$ER IV OCCUPANCY SWITCH Step 14 -- Install Accessories . . . . . . . . . . . . . . . . . 57 Step 15 -- Check Belt Tension . . . . . . . . . . . . . . . . 57 · BELT FORCE -- DEFLECTION METHOD · BELT TENSION METHOD Pre-Start and Start-Up . . . . . . . . . . . . . . . . . . . . . . . . 58
START-UP CHECKLIST . . . . . . . . . . . . . . . . CL-1, CL-2
GENERAL
These installation instructions cover the 48TC units with gas heat and electric cooling. Units are pre-wired and precharged with environmentally sound Puron® (R-410A) refrigerant at the factory. See Fig. 1 for model number nomenclature. See Fig. 2 for unit dimensions. See Fig. 3 for service clearances.
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloths for brazing operations and have a

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53480140-01

Printed in U.S.A.

Form 48TC-4-7-03SI

Pg 1

1217 9-17

Replaces: 48TC-4-7-02SI

fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and appropriate national electrical codes (in USA, ANSI/NFPA70, National Electrical Code (NEC); in Canada, CSA C22.1) for special requirements.
It is important to recognize safety information. This is the safety-alert symbol. When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices, which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.
WARNING
Failure to follow this warning could result in personal injury or death. Disconnect gas piping from unit when leak testing at pressure greater than 0.5 psig (3450 Pa). Pressures greater than 0.5 psig (3450 Pa) will cause gas valve damage resulting in hazardous condition. If gas valve is subjected to pressure greater than 0.5 psig (3450 Pa), it must be replaced before use. When pressure testing fieldsupplied gas piping at pressures of 0.5 psig (3450 Pa) or less, a unit connected to such piping must be isolated by closing the manual gas valve.
WARNING
Failure to follow this warning could cause personal injury or death. Before performing service or maintenance operations on unit, always turn off main power switch to unit and install lock(s) and lockout tag(s). Unit may have more than one power switch.

!
WARNING
Failure to follow this warning could cause personal injury, death and/or equipment damage.
Puron (R-410A) refrigerant systems operate at higher pressures than standard R-22 systems. Do not use R-22 service equipment or components on Puron refrigerant equipment.

WARNING
Failure to follow this warning could cause personal injury or death.
Relieve pressure and recover all refrigerant before system repair or final unit disposal.
Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils.

CAUTION
Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing air conditioning equipment.

Rated Indoor Airflow (cfm) -- Table 1 lists the rated
indoor airflow used for the AHRI efficiency rating for the units covered in this document.

Table 1 -- AHRI Efficiency -- Rated Indoor Airflow

MODEL NUMBER

FULL LOAD AIRFLOW (CFM)

48TC*A04

1275

48TC*A05

1400

48TC*A06

1800

48TC*A/B07

2200

Position: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Example: 4 8 T C D A 0 4 A 1 A 5 - 0 A 0 A 0

Unit Heat Type 48 - Gas Heat Packaged Rooftop
Model Series - WeatherMaker ® TC - Standard Efficiency

Packaging & Seismic Complience 0 = Standard 1 = LTL 3 = California Seismic Compliant Label 4 = LTL and CA Seismic Compliant Label

Heat Options D = Low Heat E = Medium Heat F = High Heat L = Low NOx, Low Heat M = Low NOx, Medium Heat N = Low NOx, High Heat S = Low Heat w/ Stainless Steel Exchanger R = Medium Heat w/ Stainless Steel Exchanger T = High Heat w/ Stainless Steel Exchanger
Refrig. Systems Options A = Standard One Stage Cooling Models B = Standard One Stage Cooling Models with
Humidi-MiZer® (07 models only)
Cooling Tons 04 = 3 tons 05 = 4 tons 06 = 5 tons 07 = 6 tons
Sensor Options A = None B = RA Smoke Detector C = SA Smoke Detector D = RA + SA Smoke Detector E = CO2 F = RA Smoke Detector and CO2 G = SA Smoke Detector and CO2 H = RA + SA Smoke Detector and CO2
Indoor Fan Options 0 = Direct Drive, Standard Static Option (04/05/06 models only) 1 = Belt Drive, Standard Static Option 2 = Belt Drive, Medium Static Option 3 = Belt Drive, High Static Option
Coil Options RTPF (Outdoor - Indoor - Hail Guard) A = Al/Cu - Al/Cu B = Precoat Al/Cu - Al/Cu C = E-coat Al/Cu - Al/Cu D = E-coat Al/Cu - E-coat Al/Cu E = Cu/Cu - Al/Cu F = Cu/Cu - Cu/Cu M = Al/Cu -Al/Cu -- Louvered Hail Guard N = Precoat Al/Cu - Al/Cu -- Louvered Hail Guard P = E-coat Al/Cu - Al/Cu -- Louvered Hail Guard Q = E-coat Al/Cu - E-coat Al/Cu -- Louvered Hail Guard R = Cu/Cu - Al/Cu -- Louvered Hail Guard S = Cu/Cu - Cu/Cu -- Louvered Hail Guard
Coil Options Novation (Outdoor - Indoor - Hail Guard) G = Al/Al - Al/Cu H = Al/Al - Cu/Cu J = Al/Al - E-coat Al/Cu K = E-coat Al/Al - Al/Cu L = E-coat Al/Al - E-coat Al/Cu T = Al/Al - Al/Cu -- Louvered Hail Guard U = Al/Al - Cu/Cu -- Louvered Hail Guard V = Al/Al - E-coat Al/Cu -- Louvered Hail Guard W = E-coat Al/Al - Al/Cu -- Louvered Hail Guard X = E-coat Al/Al - E-coat Al/Cu -- Louvered Hail Guard

Electrical Options A = None C = Non-Fused Disconnect D = Thru-The-Base Connections F = Non-Fused Disconnect and
Thru-The-Base Connections G = 2 Speed Indoor Fan (SAV)
Service Options 0 = None 1 = Unpowered Convenience Outlet 2 = Powered Convenience Outlet 3 = Hinged Panels 4 = Hinged Panels and
Unpowered Convenience Outlet 5 = Hinged Panels and
Powered Convenience Outlet
Intake / Exhaust Options A = None B = Temperature Economizer w/ Barometric Relief F = Enthalpy Economizer w/ Barometric Relief K = 2-Position Damper U = Temperature Ultra Low Leak Economizer
w/ Barometric Relief W = Enthalpy Ultra Low Leak Economizer
w/ Barometric Relief
Base Unit Controls 0 = Electro-mechanical Controls can be used with W7212
EconoMi$er® IV (Non-Fault Detection and Diagnostic) 1 = PremierLinkTM Controller* 2 = RTU Open Multi-Protocol Controller 6 = Electro-mechanical w/ 2-Speed Fan and W7220
Economizer Controller Controls. Can be used with W7220 EconoMi$er X (w/ Fault Detection & Diagnostic)
Design Revision - = Factory Design Revision
Voltage 1 = 575/3/60 3 = 208-230/1/60 5 = 208-230/3/60 6 = 460/3/60
* PremierLinkTM cannot be used with Staged Air Volume (SAVTM) 2-speed indoor fan motor.
NOTES: 1. On single phase (-3 voltage code) models, the following are not available as a factory-installed option: Coated Coils or Cu Fin Coils Louvered Hail Guards Economizer or 2 Position Damper Powered 115-volt Convenience Outlet 2. Staged Air Volume (SAVTM) is available on size 07 only.

Fig. 1 -- 48HC**04-07 Units Model Number Nomenclature

Fig. 2 -- Unit Dimensional Drawing 4

Fig. 2 -- Unit Dimensional Drawing (cont) 5

C D

B A

LOCATION A B C D

DIMENSION in. (mm)
48 (1219) 18 (457) 18 (457) 12 (305)
42 (1067) 36 (914) Special
36 (914) 18 (457)
48 (1219) 42 (1067) 36 (914) Special

CONDITION
Unit disconnect is mounted on panel. No disconnect, convenience outlet option. Recommended service clearance. Minimum clearance.
Surface behind servicer is grounded (e.g., metal, masonry wall). Surface behind servicer is electrically non-conductive (e.g., wood, fiberglass). Check for sources of flue products within 10-ft of unit fresh air intake hood.
Side condensate drain is used. Minimum clearance.
No flue discharge accessory installed, surface is combustible material. Surface behind servicer is grounded (e.g., metal, masonry wall, another unit). Surface behind servicer is electrically non-conductive (e.g., wood, fiberglass). Check for adjacent units or building fresh air intakes within 10-ft (3 m) of this unit's flue outlet.

Fig. 3 -- Service Clearances -- 48HC**04-07 Units

NOTE: Unit is not designed to have overhead obstruction. Contact Application Engineering for guidance on any application planning overhead obstruction or for vertical clearances.
INSTALLATION
Job-Site Survey -- Complete the following checks be-
fore installation.
1. Consult local building codes and the NEC (National Electrical Code) ANSI/NFPA 70 for special installation requirements.
2. Determine unit location (from project plans) or select unit location.
3. Check for possible overhead obstructions which may interfere with unit lifting or rigging.
Step 1 -- Plan for Unit Location -- Select a loca-
tion for the unit and its support system (curb or other) that provides for the minimum clearances required for safety. This includes the clearance to combustible surfaces, unit performance and service access below, around and above unit as specified in unit drawings. See Fig. 2.

NOTE: Consider also the effect of adjacent units. Be sure that unit is installed such that snow will not block the combustion intake or flue outlet.
Unit may be installed directly on wood flooring or on class A, B, or C roof-covering material when roof curb is used.
Do not install unit in an indoor location. Do not locate air inlets near exhaust vents or other sources of contaminated air. For proper unit operation, adequate combustion and ventilation air must be provided in accordance with Section 5.3 (Air for Combustion and Ventilation) of the National Fuel Gas Code, ANSI Z223.1 (American National Standards Institute) and NFPA (National Fire Protection Association) 54 TIA-54-84-1. In Canada, installation must be in accordance with the CAN1B149 installation codes for gas burning appliances.
Although unit is weatherproof, avoid locations that permit water from higher level runoff and overhangs to fall onto the unit.
Locate mechanical draft system flue assembly at least 4 ft (1.2 m) from any opening through which combustion products could enter the building, and at least 4 ft (1.2 m) from any adjacent building (or per local code). Locate the flue assembly at least 10 ft (3.05 m) from an adjacent unit's fresh air intake hood if within 3 ft (0.91 m) of same elevation (or per local code).

When unit is located adjacent to public walkways, flue assembly must be at least 7 ft (2.1 m) above grade.
Select a unit mounting system that provides adequate height to allow installation of condensate trap per requirements. Refer to Step 11 -- Install External Condensate Trap and Line for required trap dimensions.
ROOF MOUNT -- Check building codes for weight distribution requirements. Unit operating weight is shown in Table 2.
Step 2 -- Plan for Sequence of Unit Installation -- The support method used for this unit will dictate dif-
ferent sequences for the steps of unit installation. For example, on curb-mounted units, some accessories must be installed on the unit before the unit is placed on the curb. Review the following for recommended sequences for installation steps.

Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree with power supply provided.
Step 4 -- Provide Unit Support
ROOF CURB MOUNT -- Curb should be level. This is necessary for unit drain to function properly. Unit leveling tolerances are show in Fig. 4. Refer to Accessory Roof Curb Installation Instructions for additional information as required.
C

CURB-MOUNTED INSTALLATION

1. Install curb 2. Install field-fabricated ductwork inside curb 3. Install accessory thru-base service connection package
(affects curb and unit) (refer to accessory installation instructions for details) 4. Prepare bottom condensate drain connection to suit planned condensate line routing (refer to Step 11 for details) 5. Rig and place unit 6. Install outdoor air hood 7. Install flue hood 8. Install gas piping 9. Install condensate line trap and piping 10. Make electrical connections 11. Install other accessories
PAD-MOUNTED INSTALLATION
1. Prepare pad and unit supports 2. Check and tighten the bottom condensate drain connec-
tion plug 3. Rig and place unit 4. Convert unit to side duct connection arrangement 5. Install field-fabricated ductwork at unit duct openings 6. Install outdoor air hood 7. Install flue hood 8. Install gas piping 9. Install condensate line trap and piping 10. Make electrical connections 11. Install other accessories FRAME-MOUNTED INSTALLATION -- Frame-mounted applications generally follow the sequence for a curb installation. Adapt as required to suit specific installation plan.
Step 3 -- Inspect Unit -- Inspect unit for transporta-
tion damage. File any claim with transportation agency.

A TO B B TO C A TO C

in. (mm) in. (mm) in. (mm)

0.5 (13) 1.0 (25) 1.0 (25)

Fig. 4 -- Unit Leveling Tolerances
Accessory roof curb details and dimensions are shown in Fig. 5. Assemble and install accessory roof curb in accordance with instructions shipped with the curb.
NOTE: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket supplied with the roof curb as shown in Fig. 5. Improperly applied gasket can also result in air leaks and poor unit performance.
Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb and not to the unit. The accessory thru-the-base power and gas connection package must be installed before the unit is set on the roof curb. If field-installed thru-the-roof curb gas connections are desired, use factory-supplied 1/2-in. pipe coupling and gas plate assembly to mount the thru-the-roof curb connection to the roof curb. Gas connections and power connections to the unit must be field installed after the unit is installed on the roof curb.
If electric and control wiring is to be routed through the basepan, attach the accessory thru-the-base service connections to the basepan in accordance with the accessory installation instructions.
SLAB MOUNT (HORIZONTAL UNITS ONLY) -- Provide a level concrete slab that extends a minimum of 6 in. (150 mm) beyond unit cabinet. Install a gravel apron in front of condenser coil air inlet to prevent grass and foliage from obstructing airflow.
NOTE: Horizontal units may be installed on a roof curb if required.
ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR
SLAB MOUNT) -- A non-combustible sleeper rail can be used in the unit curb support area. If sleeper rails cannot be used, support the long sides of the unit with a minimum of three equally spaced 4-in. x 4-in. (102 mm x 102 mm) pads on each side.

48TC
Base Unit Economizer Humidi-MiZer® System Cu Fins Powered Outlet Curb
14-in. (356 mm) 16-in. (610 mm)

A04 438 (199)
35 (16) 15 (7) 25 (11) 32 (15)

Table 2 -- Operating Weights

UNITS -- lb (kg)

A05

A06

494 (224)

524 (238)

35 (16)

15 (7)

43 (20)

56 (25)

32 (15)

110 (50) 145 (66)

A07 607 (275)
35 (16) 24 (7) 73 (33) 32 (15)
110 (50) 145 (66)

Fig. 5 -- Roof Curb Details 8

ROOF CURB ACCESSORY # CRRFCURB001A01
CRRFCURB002A01

5.42" [137.7]
21.74" [552.2]

4.96" [126.0]

15.19" [385.8]

3.00" [76.2]

14.00" [355.6]
1.75" [44.5]

4 9/16" [115.5]

1/4" [7.0]

A
14" [356]
24" [610]

NOTES:

1. ROOFCURB ACCESSORY IS SHIPPED DISASSEMBLED.

2. INSULATED PANELS: 25.4 [1"] THK. POLYURETHANE FOAM, 44.5 [1-3/4] # DENSITY.

3. DIMENSIONS IN [ ] ARE IN MILLIMETERS.

4. ROOFCURB: 18 GAGE STEEL.

5. ATTACH DUCTWORK TO CURB. (FLANGES OF DUCT REST ON CURB).

6. SERVICE CLEARANCE 4 FEET ON EACH SIDE.

DIRECTION OF AIR FLOW.

8. CONNECTOR PACKAGE CRBTMPWR001A01 IS FOR THRU-THE-CURB GAS TYPE

PACKAGE CRBTMPWR003A01 IS FOR THRU-THE-BOTTOM TYPE GAS CONNECTIONS.

11.96" [303.8]

CONNECTOR PKG. ACC. CRBTMPWR001A01 CRBTMPWR003A01

GAS CONNECTION TYPE THRU THE CURB
THRU THE BOTTOM

GAS FITTING 3/4" [19] NPT 1/2" [12.7] NPT

POWER WIRING FITTING
3/4" [19] NPT

CONTROL WIRING FITTING

ACCESSORY CONVENIENCE OUTLET WIRING CONNECTOR

1/2" [12.7] NPT

1-3/4" [44.5]
"A"

1.00" [25.4]

11 3/4"[298.5] WIDE INSULATED DECK PANELS

1/3/4"[44.5]
21.84" [554.7]

RETURN AIR OPENING
E

SUPPLY AIR OPENING

16.03" [407.2]

20.41" [518.3]
40.69" [1033.5]

3.00" [76.2]
13.78" [350.0]

SUPPLY AIR

RETURN AIR

70.87" [1800.2]

1-3/4" [44.4]
SECTION E-E
SCALE 0.250

8 9/16"[217.5] WIDE INSULATED DECK PANEL
GAS SERVICE PLATE THRU THE CURB DRILL HOLE 2" [50.8] @ ASSEMBLY (IF REQUIRED) (SEE NOTE #8)

1' 4-13/16" [427] INSIDE

2-3/8" [61]

SEE NOTE #2

E
32.19" [817.6]

VIEW "B"
CORNER DETAIL

SUPPLY AIR

RETURN AIR
1-3/4" [44.5]

1-3/4" [44.4]

GASKET (SUPPLIED WITH CURB)
DUCT (FIELD SUPPLIED)

UNIT

"A"

NAIL (FIELD SUPPLIED)

7/16" [11]

TYPICAL (4) SIDES
COUNTER FLASHING (FIELD SUPPLIED)

3'-1 3/16" [944.6]

5' 7-3/8" [1711.3]

ROOFING FELT (FIELD SUPPLIED)
CANT STRIP (FIELD SUPPLIED)
ROOFING MATERIAL (FIELD SUPPLIED)

RIGID INSULATION (FIELD SUPPLIED)

OVERALL DIM. 5'-7 3/8" WAS 5'-7 7/8; 18GA A MATERIAL WA 16 GA.; NAIL FIELD SUPPLIED WAS
WITH CURB

REV

REVISION RECORD

04/22/13 MMC -

DATE

BY CHK'D APP'D

SEE VIEW "B"

CERTIFIED DRAWING

1067898 ECN NO.

DRAWING RELEASE LEVEL:

THIRD ANGLE PROJECTION

MATERIAL

ENGINEERING REQUIREMENTS

T-005, Y-002

WEIGHT: -

SURFACE FINISH

MFG/PURCH

PURCH

PRODUCTION

UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ON:

1 DEC

2 DEC

3 DEC

ANG -

THIS DOCUMENT AND THE INFORMATION CONTAINED THEREIN IS PROPRIETARY TO CARRIER CORPORATION AND SHALL NOT BE USED OR DISCLOSED TO OTHERS, IN WHOLE OR IN PART, WITHOUT THE WRITTEN AUTHORIZATION OF CARRIER CORPORATION.

AUTHORIZATION NUMBER 1041738
ENGINEERING

TITLE
CURB ASY, ROOF

(004-007)

DRAFTER

MMC 06/17/11 -

CHECKER

- SIZE
-D

DRAWING NUMBER

REV

48TC400427

SHEET 5 OF 5

MODEL (INTERNAL USE ONLY)

NEXT DRAWING

SCALE

DISTRIBUTION

N/A

MMC

Step 5 -- Field Fabricate Ductwork -- Cabinet
return-air static pressure (a negative condition) shall not exceed 0.35 in. wg (87 Pa) with economizer or 0.45 in. wg (112 Pa) without economizer. For vertical ducted applications, secure all ducts to roof curb and building structure. Do not connect ductwork to unit. Fabricate supply ductwork so that the cross sectional dimensions are equal to or greater than the unit supply duct opening dimensions for the first 18 in. (458 mm) of duct length from the unit basepan. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes.
Ducts passing through unconditioned spaces must be insulated and covered with a vapor barrier. If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes.
A minimum clearance is not required around ductwork.
CAUTION
Failure to follow this caution may result in damage to roofing materials.
Membrane roofs can be cut by sharp sheet metal edges. Be careful when placing any sheet metal parts on such roof.
Step 6 -- Rig and Place Unit -- Keep unit upright
and do not drop. Spreader bars are required. Rollers may be used to move unit across a roof. Level by using unit frame as a reference. See Table 1 and Fig. 6 for additional information.
Lifting holes are provided in base rails as shown in Fig. 6. Refer to rigging instructions on unit.
Rigging materials under unit (cardboard or wood to prevent base pan damage) must be removed PRIOR to placing the unit on the roof curb. When using the standard side drain connection, ensure the red plug in the alternate bottom connection is tight. Do this before setting the unit in place. The red drain pan can be tightened with a 1/2-in. square socket drive extension.

For further details see Step 11 -- Install External Condensate Trap and Line on page 14.
Before setting the unit onto the curb, recheck gasketing on curb.
CAUTION
Failure to follow this caution may result in equipment damage.
All panels must be in place when rigging. Unit is not designed for handling by fork truck.
POSITIONING ON CURB -- Position unit on roof curb so that the following clearances are maintained: 1/4 in. (6.4 mm) clearance between the roof curb and the base rail inside the front and back, 0.0 in. clearance between the roof curb and the base rail inside on the duct end of the unit. This will result in the distance between the roof curb and the base rail inside on the condenser end of the unit being approximately 1/4 in. (6.4 mm).
Although unit is weatherproof, guard against water from higher level runoff and overhangs.
Flue vent discharge must have a minimum horizontal clearance of 4 ft (1220 mm) from electric and gas meters, gas regulators, and gas relief equipment. Minimum distance between unit and other electrically live parts is 48 inches (1220 mm).
Flue gas can deteriorate building materials. Orient unit such that flue gas will not affect building materials. Locate mechanical draft system flue assembly at least 48 in. (1220 mm) from an adjacent building or combustible material.
NOTE: Installation of accessory flue discharge deflector kit will reduce the minimum clearance to combustible material to 18 in. (460 mm).
After unit is in position, remove rigging skids and shipping materials.

"B"
REQUIRED SPREADER
BARS

36"- 54" (914-1371)
"C"

PLACE ALL SEAL STRIP IN PLACE BEFORE PLACING UNIT ON ROOF CURB.
DUCT END

DETAIL "A"

"A"

SEE DETAIL "A"

UNIT

MAX WEIGHT

DIMENSIONS B

48TC-A04

772

350

74.5

1890

39.0

990

33.5

850

48TC-A05

826

375

74.5

1890

39.0

990

33.5

850

48TC-A06

896

406

74.5

1890

39.0

990

33.5

850

48TC-A07

1075

489

74.5

1890

39.0

990

41.5

1055

NOTES: 1. SPREADER BARS REQUIRED -- Top damage will occur if spreader bars are not used.

2. Dimensions in () are in millimeters.

3. Hook rigging shackles through holes in base rail, as shown in detail "A." Holes in base rails are centered around the unit center of gravity. Use wooden top to prevent rigging straps from damaging unit.

4. Max weight includes base unit plus shipping pallet plus all available FIOPs which could be on that size unit.

Fig. 6 -- Rigging Details

1017

Step 7 -- Convert to Horizontal and Connect Ductwork (When Required) -- Unit is shipped in the
vertical duct configuration. Unit without factory-installed economizer or return air smoke detector option may be fieldconverted to horizontal ducted configuration. To convert to horizontal configuration, remove screws from side duct opening covers and remove covers. Using the same screws, install covers on vertical duct openings with the insulation-side down. Seals around duct openings must be tight. See Fig. 7.
REMOVABLE HORIZONTAL RETURN DUCT OPENING COVER
REMOVABLE HORIZONTAL SUPPLY DUCT OPENING COVER
Fig. 7 -- Horizontal Conversion Panels Field-supplied flanges should be attached to horizontal duct openings and all ductwork should be secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof or building openings with counter flashing and mastic in accordance with applicable codes. Do not cover or obscure visibility to the unit's informative data plate when insulating horizontal ductwork.
Step 8 -- Install Outside Air Hood
ECONOMIZER AND TWO POSITION DAMPER HOOD PACKAGE REMOVAL AND SETUP -- FACTORY OPTION
NOTE: Economizer and two position damper are not available as factory installed options for single phase (-3 voltage code) models. 1. The hood is shipped in knock-down form and must be
field assembled. The indoor coil access panel is used as the hood top while the hood sides, divider and filter are packaged together, attached to a metal support tray using plastic stretch wrap, and shipped in the return air compartment behind the indoor coil access panel. The hood assembly's metal tray is attached to the basepan and also attached to the damper using two plastic tiewraps. 2. To gain access to the hood, remove the filter access panel. See Fig. 8.

FILTER ACCESS PANEL
COMPRESSOR ACCESS PANEL OUTDOOR-AIR OPENING AND INDOOR COIL ACCESS PANEL
Fig. 8 -- Typical Access Panel Locations 3. Locate the (2) screws holding the metal tray to the base-
pan and remove. Locate and cut the (2) plastic tie-wraps securing the assembly to the damper. (See Fig. 9.) Be careful to not damage any wiring or cut tie-wraps securing any wiring.
Hood Parts
Plastic Tie Wrap Qty (2)
Screws for Metal Tray Qty (2)
Fig. 9 -- Economizer and Two-Position Damper Hood Parts Location
Carefully lift the hood assembly (with metal tray) through the filter access opening and assemble per the steps outlined in Economizer Hood and TwoPosition Hood, below. ECONOMIZER HOOD AND TWO-POSITION HOOD NOTE: If the power exhaust accessory is to be installed on the unit, the hood shipped with the unit will not be used and must be discarded. Save the aluminum filter for use in the power exhaust hood assembly.

1. The indoor coil access panel will be used as the top of the hood. Remove the screws along the sides and bottom of the indoor coil access panel. See Fig. 10.

7. Replace the filter access panel.

TOP PANEL

INDOOR COIL ACCESS PANEL

CAULK HERE

TOP PANEL
INDOOR COIL ACCESS PANEL

Fig. 10 -- Indoor Coil Access Panel Relocation
2. Swing out indoor coil access panel and insert the hood sides under the panel (hood top). Use the screws provided to attach the hood sides to the hood top. Use screws provided to attach the hood sides to the unit. See Fig. 11.
TOP PANEL
INDOOR COIL ACCESS PANEL

LEFT HOOD SIDE 19 1/B16"
(483mm)

SCREW

33 3/8" (848mm)
HOOD DIVIDER
Fig. 11 -- Economizer Hood Construction
3. Remove the shipping tape holding the economizer barometric relief damper in place (economizer only).
4. Insert the hood divider between the hood sides. See Fig. 11 and 12. Secure hood divider with 2 screws on each hood side. The hood divider is also used as the bottom filter rack for the aluminum filter.
5. Open the filter clips which are located underneath the hood top. Insert the aluminum filter into the bottom filter rack (hood divider). Push the filter into position past the open filter clips. Close the filter clips to lock the filter into place. See Fig. 12.
6. Caulk the ends of the joint between the unit top panel and the hood top.

DIVIDER

OUTSIDE AIR

HOOD
CLEANABLE ALUMINUM FILTER FILTER

BAROMETRIC RELIEF

FILTER CLIP

Fig. 12 -- Economizer Filter Installation

Step 9 -- Install Flue Hood -- Flue hood is shipped
screwed to the basepan beside the burner compartment access panel. Remove from shipping location and using screws provided, install flue hood and screen in location shown in Fig. 13.

BLOWER ACCESS PANEL
Fig. 13 -- Flue Hood Details
Step 10 -- Install Gas Piping -- Installation of the
gas piping must be accordance with local building codes and with applicable national codes. In U.S.A., refer to NFPA 54/ ANSI Z223.1 National Fuel Gas Code (NFGC). In Canada, installation must be accordance with the CAN/CSA B149.1 and CAN/CSA B149.2 installation codes for gas burning appliances. This unit is factory equipped for use with Natural Gas fuel at elevations up to 2000 ft (610 m) above sea level. Unit may be field converted for operation at elevations above 2000 ft (610 m) and/or for use with liquefied petroleum fuel. See accessory kit installation instructions regarding these accessories.
NOTE: Furnace gas input rate on rating plate is for installation up to 2000 ft (610 m) above sea level. In U.S.A. the input rating for altitudes above 2000 ft (610 m) must be derated by 4% for each 1000 ft (305 m) above sea level. In Canada the input rating must be derated by 10% for altitudes of 2000 ft (610 m) to 4500 ft (1372 m) above sea level.
For natural gas applications, gas pressure at unit gas connection must not be less than 4 in. wg (996 Pa) or greater than 13 in. wg (3240 Pa) while the unit is operating, see Table 3. For liquefied petroleum applications, the gas pressure must not be less than 11 in. wg (2740 Pa) or greater than 13.0 in. wg (3240 Pa) at the unit connection, see Table 4.

1217

Table 3 -- Natural Gas Supply Line Pressure Ranges

UNIT MODEL

UNIT SIZE

MIN.

MAX.

48TCD/E/F

04, 05, 06, 07

4.0 in. wg (996 Pa)

13.0 in. wg (3240 Pa)

Table 4 -- Liquid Propane Supply Line Pressure Ranges

UNIT MODEL

UNIT SIZE

MIN.

MAX.

48TCD/E/F

04, 05, 06, 07

11.0 in. wg (2740 Pa)

13.0 in. wg (3240 Pa)

The gas supply pipe enters the unit at the burner access panel on the front side of the unit, through the long slot at the bottom of the access panel. The gas connection to the unit is made to the 1/2-in. FPT gas inlet port on the unit gas valve.

Manifold pressure is factory-adjusted for NG fuel use. Adjust as required to obtain best flame characteristics. See Table 5 for ranges.

Table 5 -- Natural Gas Manifold Pressure Ranges

UNIT MODEL

UNIT SIZE

HIGH FIRE.

LOW FIRE

48TCD/E/F

04, 05, 06, 07

11.0 in. wg (2740 Pa)

13.0 in. wg (3240 Pa)

Manifold pressure for LP fuel use must be adjusted to specified range, see Table 6. Follow instructions in the accessory kit to make initial readjustment.

Table 6 -- Liquid Propane Manifold Pressure Ranges

UNIT MODEL

UNIT SIZE

HIGH FIRE.

LOW FIRE

48TCD/E/F

04, 05, 06, 07

11.0 in. wg (2740 Pa)

13.0 in. wg (3240 Pa)

CAUTION

Failure to follow this caution may result in damage to equipment.
When connecting the gas line to the unit gas valve, the installer MUST use a backup wrench to prevent damage to the valve.

Install a gas supply line that runs to the unit heating section. Refer to the NFPA 54/NFGC or equivalent code for gas pipe sizing data. Do not use a pipe size smaller than 1/2-in. Size the gas supply line to allow for a maximum pressure drop of 0.5in.wg (124 Pa) between gas regulator source and unit gas valve connection when unit is operating at high-fire flow rate.
The gas supply line can approach the unit in three ways: horizontally from outside the unit (across the roof), thru-curb/ under unit basepan (accessory kit required) or through unit basepan (factory-option or accessory kit required). Consult accessory kit installation instructions for details on these installation methods. Observe clearance to gas line components per Fig. 14.

BASE UNIT

9" MINIMUM CLEARANCE FOR PANEL REMOVAL
MANUAL GAS
SHUTOFF VALVE*

GAS
REGULATOR*

48" MINIMUM

BASE RAIL
FROM GAS METER

ROOF CURB

DRIP LEG
PER NFGC *

FIELD-FABRICATED
SUPPORT *

STEEL PIPE NOMINAL DIAMETER (in.)
1/2 3/4 or 1 1 1/4 or larger

SPACING OF SUPPORTS X DIMENSIONS (FT)
6
8 10

LEGEND NFGC -- National Fuel Gas Code * Field-Supplied.

Fig. 14 -- Gas Piping Guide (with Accessory Thruthe-Curb Service Connections)
FACTORY-OPTION THRU-BASE CONNECTIONS (GAS CONNECTIONS) -- This service connection kit consists of a 1/2-in. NPT gas adapter fitting (brass), a 1/2-in. electrical bulkhead connector and a 3/4-in. electrical bulkhead connector, all factory-installed in the embossed (raised) section of the unit basepan in the condenser section. See Fig. 15.

LOW VOLTAGE CONDUIT CONNECTOR

HIGH VOLTAGE CONDUIT CONNECTOR
BRASS FITTING FOR 3 TO 6 TON UNITS.
Fig. 15 -- Thru-Base Connection Fittings The thru-base gas connector has male and female threads. The male threads protrude above the basepan of the unit; the female threads protrude below the basepan. Check tightness of connector lock nuts before connecting gas piping. The thru-base gas connector has male and female threads. The male threads protrude above the basepan of the unit; the female threads protrude below the basepan. Check tightness of connector lock nuts before connecting gas piping. Install a 1/2-in. NPT street elbow on the thru-base gas fitting. Attach a 1/2-in. pipe nipple with minimum length of 16-in.

(406 mm) (field-supplied) to the street elbow and extend it through the access panel at the gas support bracket. See Fig. 16.

EMBOSSMENT

BRASS FITTING FOR 3-6 TON UNITS

SUPPORT BRACKET

Fig. 16 -- Gas Line Piping (3 to 6 Ton Units Only)
Other hardware required to complete the installation of the gas supply line will include a manual shutoff valve, a sediment trap (drip leg) and a ground-joint union. A pressure regulator valve may also be required (to convert gas pressure from pounds to inches of pressure). The manual shutoff valve must be located within 6-ft (1.83 m) of the unit. The union, located in the final leg entering the unit, must be located at least 9-in. (230 mm) away from the access panel to permit the panel to be removed for service. If a regulator valve is installed, it must be located a minimum of 4-ft (1220 mm) away from the unit's flue outlet. Some municipal codes require that the manual shutoff valve be located upstream of the sediment trap. See Fig. 17 and 18 for typical piping arrangements for gas piping that has been routed through the sidewall of the curb. See Fig. 19 for typical piping arrangement when thru-base is used. Ensure that all piping does not block access to the unit's main control box or limit the required working space in front of the control box.

Burner Access Panel
Thru-Curb Adapter

9" (229mm) min Union

Unit Base Rail
Drip Leg Shut Off Valve
Fig. 18 -- Gas Piping with Thru-Curb Accessory (Alternate Layout)

9" (229mm) min

Thru-Curb Adapter

Union

Unit Base Rail
Shut Off Valve
Drip Leg
Fig. 17 -- Gas Piping with Thru-Curb Accessory

Fig. 19 -- Gas Piping Thru-Base Connections
When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to the NFPA 54/ ANSI Z223.1 NFGC latest edition (in Canada, CAN/CSA B149.1). In the absence of local building codes, adhere to the following pertinent recommendations:
1. Avoid low spots in long runs of pipe. Grade all pipe 1/4-in. in every 15 ft (7 mm in every 5 m) to prevent traps. Grade all horizontal runs downward to risers. Use risers to connect to heating section and to meter.
2. Protect all segments of piping system against physical and thermal damage. Support all piping with appropriate straps, hangers, etc. Use a minimum of one hanger every 6 ft (1.8 m). For pipe sizes larger than 1/2-in., follow recommendations of national codes.
3. Apply joint compound (pipe dope) sparingly and only to male threads of joint when making pipe connections. Use only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and/or national codes. If using PTFE (Teflon*) tape, ensure the material is Double Density type and is labeled for use on gas lines. Apply tape per manufacturer's instructions.
4. Pressure-test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit.
* Teflon is a registered trademark of DuPont.
13

NOTE: Pressure test the gas supply system after the gas supply piping is connected to the gas valve. The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0.5 psig (3450 Pa). Pressure test the gas supply piping system at pressures equal to or less than 0.5 psig (3450 Pa). The unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the ground-joint union.
Check for gas leaks at the field-installed and factory-installed gas lines after all piping connections have been completed. Use soap-and-water solution (or method specified by local codes and/or regulations).
WARNING
Failure to follow this warning could result in personal injury, death and/or property damage. · Connect gas pipe to unit using a backup wrench to
avoid damaging gas controls. · Never purge a gas line into a combustion chamber. · Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the detection of leaks to check all connections. · Use proper length of pipe to avoid stress on gas control manifold.
NOTE: If orifice hole appears damaged or it is suspected to have been re-drilled, check orifice hole with a numbered drill bit of correct size. Never re-drill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics. See Fig. 20.
BURNER ORIFICE
Fig. 20 -- Orifice Hole
Step 11 -- Install External Condensate Trap and Line -- The unit has one 3/4-in. condensate drain con-
nection on the end of the condensate pan and an alternate connection on the bottom. See Fig. 21. Unit airflow configuration does not determine which drain connection to use. Either drain connection can be used with vertical or horizontal applications.
To use the alternate bottom drain connection, remove the red drain plug from the bottom connection (use a 1/2-in. square socket drive extension) and install it in the side drain connection.

CONDENSATE PAN (SIDE VIEW)

STANDARD SIDE DRAIN

ALTERNATE

DRAIN PLUG

BOTTOM DRAIN

(FACTORY-INSTALLED)

Fig. 21 -- Condensate Drain Pan (Side View)
The piping for the condensate drain and external trap can be completed after the unit is in place. See Fig. 22.
NOTE: If the alternate bottom drain is not used check the drain plug for tightness prior to setting the unit on the roof curb.

MINIMUM PITCH 1" (25mm) PER 10' (3m) OF LINE

BASE RAIL

OPEN VENT

2 in. (51) MIN

TO ROOF DRAIN

SEE NOTE

DRAIN PLUG

ROOF CURB

Fig. 22 -- Condensate Drain Piping Details
All units must have an external trap for condensate drainage. Install a trap at least 4-in. (102 mm) deep and protect against freeze-up. If drain line is installed downstream from the external trap, pitch the line away from the unit at 1-in. per 10 ft (25 mm in 3 m) of run. Do not use a pipe size smaller than the unit connection (3/4-in.).
Step 12 -- Make Electrical Connections

WARNING

Failure to follow this warning could result in personal injury or death.
Do not use gas piping as an electrical ground. Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code); ANSI/ NFPA 70, latest edition (in Canada, Canadian Electrical Code CSA [Canadian Standards Association] C22.1), and local electrical codes.

NOTE: Field-supplied wiring shall conform with the limitations of minimum 63°F (33°C) rise.

FIELD POWER SUPPLY -- If equipped with optional Powered Convenience Outlet: The power source leads to the convenience outlet's transformer primary are not factory connected. Installer must connect these leads according to required operation of the convenience outlet. If an always-energized convenience outlet operation is desired, connect the source leads to the line side of the unit-mounted disconnect. (Check with local codes to ensure this method is acceptable in your area.) If a de-energize via unit disconnect switch operation of the convenience outlet is desired, connect the source leads to the load side of the unit disconnect. On a unit without a unitmounted disconnect, connect the source leads to compressor contactor C and indoor fan contactor IFC pressure lugs with unit field power leads.
Refer to Fig. 23 for power transformer connections and the discussion on connecting the convenience outlet on page 18.
Field power wires are connected to the unit at line-side pressure lugs on compressor contactor C and indoor fan contactor IFC (see wiring diagram label for control box component arrangement) or at factory-installed option non-fused disconnect switch. Max wire size is #2 AWG (copper only). (See Fig. 23.)
NOTE: TEST LEADS - Unit may be equipped with short leads (pigtails) on the field line connection points on contactor C or optional disconnect switch. These leads are for factory run-test purposes only; remove and discard before connecting field power wires to unit connection points. Make field power connections directly to line connection pressure lugs only.
Units Without Disconnect Option

C IFC

or
TB (1-ph IFM)

Disconnect per NEC
208/230-1-60

Disconnect per NEC

208/230-3-60 460-3-60 375-3-60
575-3-60

Units With Disconnect Option

Optional

Disconnect

Switch

Factory Wiring

Assemble the shaft and handle to the switch at this point. Discard the factory test leads (see Fig. 24).
Connect field power supply conductors to LINE side terminals when the switch enclosure cover is removed to attach the handle.
Fig. 24 -- Location of Non-Fused Disconnect Enclosure
To field install the NFD shaft and handle 1. Remove the unit front pane (see Fig. 2). 2. Remove (3) hex screws on the NFD enclosure - (2) on the
face of the cover and (1) on the left side cover (see Fig. 25). 3. Remove the front cover of the NFD enclosure. 4. Make sure the NFD shipped from the factory is at OFF position (the arrow on the black handle knob is at OFF). 5. Insert the shaft with the cross pin on the top of the shaft in the horizontal position. 6. Measure from the tip of the shaft to the top surface of the black pointer; the measurement should be 3.75 to 3.88 in. (95 to 99 mm). 7. Tighten the locking screw to secure the shaft to the NFD. 8. Turn the handle to the OFF position with red arrow pointing at OFF. 9. Install the handle on to the painted cover horizontally with the red arrow pointing to the left. 10. Secure the handle to the painted cover with (2) screws and lock washers supplied. 11. Engaging the shaft into the handle socket, re-install (3) hex screws on the NFD enclosure. 12. Re-install the unit front panel.

Disconnect factory test leads; discard.
Fig. 23 -- Power Wiring Connections
WARNING
Failure to follow this warning could result in intermittent operation or performance satisfaction.
Do not connect aluminum wire between disconnect switch and 48TC unit. Use only copper wire. (See Fig. 24.)
UNITS WITH FACTORY-INSTALLED NON-FUSED DISCONNECT -- The factory-installed option non-fused disconnect (NFD) switch is located in a weatherproof enclosure located under the main control box. The manual switch handle and shaft are shipped in the disconnect enclosure.
15

Fig. 25 -- Handle and Shaft Assembly for NFD

UNITS WITHOUT FACTORY-INSTALLED NON-
FUSED DISCONNECT -- When installing units, provide a disconnect switch per NEC (National Electrical Code) of adequate size. Disconnect sizing data is provided on the unit informative plate. Locate on unit cabinet or within sight of the unit per national or local codes. Do not cover unit informative late if mounting the disconnect on the unit cabinet.
All Units -- Field wiring must comply with NEC and all local codes. Size wire based on MCA (Minimum Circuit Amps) on the unit informative plate. See Fig. 23 and the unit label diagram for power wiring connections to the unit power terminal blocks and equipment ground. Maximum wire size is #4 ga AWG per pole.
Provide a ground-fault and short-circuit over-current protection device (fuse or breaker) per NEC Article 440 (or local codes). Refer to unit informative data plate for MOCP (Maximum Over-current Protection) device size.

All units except 208/230-v units are factory wired for the voltage shown on the nameplate. If the 208/230-v unit is to be connected to a 208-v power supply, the control transformer must be rewired by moving the black wire with the 1/4-in. female spade connector from the 230-v connection and moving it to the 200-v 1/4-in. male terminal on the primary side of the transformer. Refer to unit label diagram for additional information.
Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate. See Tables 7 and 8. On 3-phase units, voltages between phases must be balanced within 2% and the current within 10%. Use the formula shown in the legend for Tables 7 and 8 to determine the percent of voltage imbalance. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty.
NOTE: Check all factory and field electrical connections for tightness.

Table 7 -- Unit Wire/Fuse or HACR Breaker Sizing Data -- 2-Speed Indoor Fan Motor

NO C.O. OR UNPWR C.O.

WITH PWRD C.O.

UNIT

NOM. V-PHHZ

IFM TYPE

NO P.E.

WITH P.E. (POWERED FROM UNIT)

NO P.E.

FUSE DISC. SIZE

MCA

OR HACR

FLA

LRA

MCA

OR HACR

FLA

LRA

MCA

OR HACR

FLA

LRA

BRKR

WITH P.E. (POWERED FROM UNIT)

FUSE DISC. SIZE

MCA

OR HACR

FLA

LRA

BRKR

STD 34/33 50/50 32/32 167 35/35 50/50 35/34 169 38/38 50/50 38/38 172 40/40 50/50 40/40 174

208/230-3-60 MED 35/34 50/50 34/33 193 37/36 50/50 36/35 195 40/39 50/50 40/39 198 42/41 60/60 42/41 200

HIGH 37/36 50/50 37/36 217 39/38 50/50 39/38 219 42/41 60/60 42/41 222 44/43 60/60 44/43 224

STD 15 20 14 82 16 20 15 83 17 20 17 84 18 25 18 85

48TC*A07 460-3-60 MED 15 20 15 95 16 20 16 96 18 25 17 97 19 25 18 98

HIGH 16 20 16 107 17 25 17 108 19 25 19 109 20 25 20 110

STD 13 15 12 70 15 20 14 72 15 20 14 72 16 20 16 74

575-3-60 MED 14 15 13 79 16 20 16 81 16 20 15 81 17 20 18 83

HIGH 14 15 13 79 16 20 16 81 16 20 15 81 17 20 18 83

LEGEND AND NOTES FOR TABLES 7 AND 8

LEGEND

BRKR

-- Circuit breaker

C.O.

-- Convenience outlet

-- Direct drive

DISC

-- Disconnect

FLA

-- Full load amps

IFM

-- Indoor fan motor

LRA

-- Locked rotor amps

MCA

-- Minimum circuit amps

MOCP

-- MAX FUSE or HACR circuit breaker

P.E.

-- Power exhaust

PWRD C.O. -- Powered convenience outlet

UNPWR C.O. -- Unpowered convenience outlet

1. In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker. Canadian units may be fuse or circuit breaker.

2. Unbalanced 3-Phase Supply Voltage:

Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine the percentage of voltage imbalance:

max voltage deviation from average voltage % Voltage Imbalance = 100 x
average voltage Example: Supply voltage is 230-3-60

AB C MOTOR

AB = 224 v BC = 231 v AC = 226 v

(224 + 231 + 226)

681

Average Voltage = 100 x

= 227

Determine maximum deviation from average voltage.

(AB) 227-224 = 3 v

(BC) 231-227 = 4 v

(AC) 227-226 = 1 v

Maximum deviation is 4 v.

Determine percent of voltage imbalance.

4 % Voltage Imbalance = 100 x
227

= 1.76%

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.

Table 8 -- Unit Wire/Fuse or HACR Breaker Sizing Data --- Single Speed Indoor Fan Motor

NO C.O. OR UNPWR C.O.

WITH PWRD C.O.

UNIT

NOM. V-PH-HZ

IFM TYPE

NO P.E.

WITH P.E. (POWERED FROM UNIT)

NO P.E.

WITH P.E. (POWERED FROM UNIT)

FUSE DISC. SIZE

MCA

OR HACR

FLA

LRA

MCA

OR HACR

FLA

LRA

MCA

OR HACR

FLA

LRA

MCA

OR HACR

FLA

LRA

BRKR

STD 28 40 208/230-1-60
MED 28 40

26 95 30 45 26 95 30 45

29 97 32 45 29 97 32 45

32 100 34 50 32 100 34 50

34 102 34 102

DD-STD 21 30 21 83 23 30 23 85 26 30 26 88 28 30 28 90

STD 20 30 208/230-3-60
MED 20 30

20 96 22 30 20 96 22 30

22 98 25 30 22 98 25 30

25 101 27 30 25 101 27 30

27 103 27 103

48TC**04

HIGH 20 30 STD 11 15

20 107 22 30 11 49 12 15

22 109 25 30 12 50 13 15

25 112 27 30 13 51 14 20

27 114 14 52

460-3-60

MED 11 15 11 49 12 15 12 50 13 15 13 51 14 20 14 52

HIGH 11 15 11 55 12 15 12 56 13 15 13 57 14 20 14 58

STD 8 15 8 46 10 15 10 48 10 15 10 48 12 15 12 50

575-3-60

MED 8 15 8 46 10 15 10 48 10 15 10 48 12 15 12 50

HIGH 8 15 7 50 10 15 10 52 10 15 9 52 11 15 12 54

STD 34 50 208/230-1-60
MED 34 50

32 133 36 50 32 133 36 50

35 135 39 60 35 135 39 60

38 138 41 60 38 138 41 60

40 140 40 140

DD-STD 25 30 24 93 27 30 27 95 30 40 30 98 32 45 32 100

STD 24 30 208/230-3-60
MED 24 30

23 106 26 30 23 106 26 30

26 108 29 40 26 108 29 40

29 111 31 40 29 111 31 40

31 113 31 113

48TC**05

HIGH 24 30 STD 12 15

23 117 26 30 11 52 13 15

26 119 29 40 12 53 14 15

29 122 31 40 14 54 15 20

31 124 15 55

460-3-60

MED 12 15 11 52 13 15 12 53 14 15 14 54 15 20 15 55

HIGH 12 15 11 58 13 15 12 59 14 15 14 60 15 20 15 61

STD 9 15 9 42 11 15 11 44 11 15 11 44 13 15 13 46

575-3-60

MED 9 15 9 42 11 15 11 44 11 15 11 44 13 15 13 46

HIGH 9 15 9 46 11 15 11 48 11 15 10 48 13 15 13 50

STD 40 60 208/230-1-60
MED 42 60

37 150 42 60 40 175 44 60

40 152 44 60 42 177 47 60

43 155 46 60 45 180 48 60

45 157 48 182

DD-STD 29 40 28 122 31 45 31 124 34 45 34 127 36 50 36 129

STD 27 40 208/230-3-60
MED 27 40

26 133 29 40 26 133 29 40

28 135 31 45 28 135 31 45

31 138 33 45 31 138 33 45

33 140 33 140

48TC**06

HIGH 29 40 STD 13 20

28 170 31 45 13 63 14 20

30 172 34 45 14 64 16 20

34 175 36 50 15 65 17 20

36 177 16 66

460-3-60

MED 13 20 13 63 14 20 14 64 16 20 15 65 17 20 16 66

HIGH 14 20 14 82 15 20 15 83 16 20 16 84 17 20 17 85

STD 11 15 10 48 13 15 12 50 12 15 12 50 14 20 14 52

575-3-60

MED 11 15 10 48 13 15 12 50 12 15 12 50 14 20 14 52

HIGH 11 15 11 63 13 15 13 65 13 15 13 65 15 20 15 67

STD 32 50 30 170 34 50 32 172 36 50 36 175 38 50 38 177

208/230-3-60

MED

35/ 35

50/50 34/34 212

37/ 37

50/50 36/36 214

40/ 40

50/50 39/39 217

42/ 41

60/60 42/42 219

HIGH 37 50 36 226 39 50 39 228 42 60 42 231 44 60 44 233

48TC**07 460-3-60

STD 14 20 MED 16 20

13 83 15 20 15 104 17 20

14 84 16 20 16 105 18 25

16 85 17 25 18 106 19 25

17 86 19 107

HIGH 17 20 16 111 18 25 18 112 19 25 19 113 20 25 20 114

STD 11 15 11 68 13 15 13 70 13 15 13 70 15 20 15 72

575-3-60

MED 12 15 12 79 14 20 14 81 14 15 13 81 16 20 16 83

HIGH 12 15 12 79 14 20 14 81 14 15 13 81 16 20 16 83

CONVENIENCE OUTLETS
WARNING
Failure to follow this warning could result in personal injury or death.
Units with convenience outlet circuits may use multiple disconnects. Check convenience outlet for power status before opening unit for service. Locate its disconnect switch, if appropriate, and open it. Lock-out and tag-out this switch, if necessary.
Two types of convenience outlets are offered on 48TC models: Non-powered and unit-powered. Both types provide a 125volt GFCI (ground-fault circuit-interrupter) duplex receptacle rated at 15-A behind a hinged waterproof access cover, located on the end panel of the unit. See Fig. 26 for amp limitations. See Fig. 27 for convenience outlet location.

RTU Open) the weatherproof cover kit is secured to the basepan underneath the control box, see Fig. 28.
IMPORTANT: DISCONNECT ALL POWER TO UNIT AND CONVENIENCE OUTLET. LOCK-OUT AND TAG-OUT ALL POWER PRIOR TO INSTALLATION.

Fig. 26 -- Convenience Outlet Utilization Notice Label
NOTE: Unit powered convenience outlets are not available as factory installed options for single phase (-3 voltage code) models.

Convenience Outlet GFCI

Pwd-CO Transformer

Pwd-CO Fuse Switch

Control Box Access Panel

Weatherproof Cover

Fig. 28 -- Weatherproof Cover -- Shipping Location on Units with Factory Installed DDC

Remove the blank cover plate at the convenience outlet. Loosen the two screws at the GFCI duplex outlet, until approximately 1/2-in. (13 mm) under screw heads are exposed. Press the gasket over the screw heads. Slip the backing plate over the screw heads at the keyhole slots and align with the gasket; tighten the two screws until snug (do not over-tighten). Mount the weatherproof cover to the backing plate as shown in Fig. 29. Remove two slot fillers in the bottom of the cover to permit service tool cords to exit the cover. Check for full closing and latching.

COVER WHILE-IN-USE WEATHERPROOF

RECEPTACLE NOT SHOWN

Fig. 27 -- Convenience Outlet Location
Installing Weatherproof Cover -- is now required by UL standards for the factory-installed convenience outlets. This cover cannot be factory-mounted due its depth; it must be installed at unit installation. For shipment, the convenience outlet is covered with a blank cover plate.
On units with electro-mechanical controls the weatherproof cover kit is shipped in the unit's control box. The kit includes the hinged cover, a backing plate and gasket. On units with a factory installed direct digital controller (PremierLinkTM or

BASE PLATE FOR GFCI RECEPTACLE
Fig. 29 -- Weatherproof Cover Installation Non-powered type -- Requires the field installation of a general-purpose 125-volt 15-A circuit powered from a source elsewhere in the building. Observe national and local codes when

selecting wire size, fuse or breaker requirements and disconnect switch size and location. Route 125-v power supply conductors into the bottom of the utility box containing the duplex receptacle.
Unit-powered type -- A unit-mounted transformer which is factory-installed to step-down the main power supply voltage to the unit to 115-v at the duplex receptacle. This option also includes a manual switch with fuse, located in a utility box and mounted on a bracket behind the convenience outlet; access is through the unit's control box access panel. See Fig. 27.
The primary leads to the convenience outlet transformer are not factory-connected. Selection of primary power source is a customer-option. If local codes permit, the transformer primary leads can be connected at the line-side terminals on the unitmounted non-fused disconnect or HACR breaker switch; this will provide service power to the unit when the unit disconnect switch or HACR switch is open. Other connection methods will result in the convenience outlet circuit being de-energized when the unit disconnect or HACR switch is open. See Fig. 30.

UNIT VOLTAGE 208, 230
460
575

CONNECT AS 240
480
600

PRIMARY CONNECTIONS
L1: RED+YEL L2: BLU+YEL
L1: RED Splice BLU+YEL L2: GRA
L1: RED L2: GRA

TRANSFORMER TERMINALS
H1+H3 H2+H4
H1 H2+H3
H4
H1 H2

Fig. 30 -- Powered Convenience Outlet Wiring
Test the GFCI receptacle by pressing the TEST button on the face of the receptacle to trip and open the receptacle. Check for proper grounding wires and power line phasing if the GFCI receptacle does not trip as required. Press the RESET button to clear the tripped condition.
Fuse on power type -- The factory fuse is a Bussman "Fusetron"* T-15, non-renewable screw-in (Edison base) type plug fuse.
Test the GFCI receptacle by pressing the TEST button on the face of the receptacle to trip and open the receptacle. Check for proper grounding wires and power line phasing if the GFCI receptacle does not trip as required. Press the RESET button to clear the tripped condition.
Using unit-mounted convenience outlets: Units with unitmounted convenience outlet circuits will often require that two disconnects be opened to de-energize all power to the unit. Treat all units as electrically energized until the convenience

outlet power is also checked and de-energization is confirmed. Observe National Electrical Code Article 210, Branch Circuits, for use of convenience outlets.
FACTORY-OPTION THRU-BASE CONNECTIONS
(ELECTRICAL CONNECTIONS) -- This service connection kit consists of a 1/2-in. electrical bulkhead connector and a 1 1/4-in. electrical bulkhead connector, all factory-installed in the embossed (raised) section of the unit basepan in the condenser section. The 1/2-in. bulkhead connector enables the lowvoltage control wires to pass through the basepan. The 1 1/4-in electrical bulkhead connector allows the high-voltage power wires to pass through the basepan. See Fig. 31.
Check tightness of connector lock nuts before connecting electrical conduits.
Field-supplied and field-installed liquid tight conduit connectors and conduit may be attached to the connectors on the basepan. Pull correctly rated high voltage and low voltage through appropriate conduits. Connect the power conduit to the internal disconnect (if unit is so equipped) or to the external disconnect (through unit side panel). A hole must be field cut in the main control box bottom on the left side so the 24-v control connections can be made. Connect the control power conduit to the unit control box at this hole.
Units Without Thru-Base Connections
1. Install power wiring conduit through side panel openings. Install conduit between disconnect and control box.
2. Install power lines to terminal connections as shown in Fig. 23.
Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate. See Table 7 and 8. On 3-phase units, voltages between phases must be balanced within 2% and the current within 10%. Use the formula shown in the legend for Tables 7 and 8 to determine the percent of voltage imbalance. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty.
Field Control Wiring -- The 48TC unit requires an external temperature control device. This device can be a thermostat (field-supplied) or a PremierLink controller (available as factory-installed option or as field-installed accessory, for use on a Carrier Comfort Network® or as a stand alone control) or the RTU Open Controller for Building Management Systems using non-CCN protocols (RTU Open is available as a factory-installed option only).
Thermostat -- Install a Carrier-approved accessory 2-stage thermostat according to installation instructions included with the accessory. Locate the thermostat accessory on a solid wall in the conditioned space to sense average temperature in accordance with the thermostat installation instructions. If the thermostat contains a logic circuit requiring 24-v power, use a thermostat cable or equivalent single leads of different colors with minimum of seven leads. If the thermostat does not require a 24-v source (no "C" connection required), use a thermostat cable or equivalent with minimum of six leads. Check the thermostat installation instructions for additional features which might require additional conductors in the cable. For wire runs up to 50 ft (15 m), use no. 18 AWG (American Wire Gage) insulated wire [35 C (95 F) minimum]. For 50 to 75 ft (15 to 23 m), use no. 16 AWG insulated wire [35 C (95 F) minimum]. For over 75 ft (23 m), use no. 14 AWG insulated wire [35 C (95 F) minimum]. All wire sizes larger than no. 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat.

* Bussmann and Fusetron are trademarks of Cooper Technologies Company.
19

Typical Thermostat Connections

C
G
W2
W1 O/B/Y2
(Note 1)
Y1 R

(Note 2)

Central Terminal
Board
X

C T

O S

T Y1

NOTES: 1. Typical multi-function marking. Follow manufacturer's configuration
instructions to select Y2. Do not configure for O output. 2. Y2 to Y2 connection required on single-stage cooling units when
integrated economizer function is desired.
Field-Wiring
Fig. 31 -- Low-Voltage Connections
Unit Without Thru-Base Connection Kit -- Pass the thermostat control wires through the hole provided in the corner post; then feed the wires through the raceway built into the corner post to the control box. Pull the wires over to the terminal strip on the upper-left corner of the Controls Connection Board. See Fig. 32. NOTE: If thru-the-bottom connections accessory is used, refer to the accessory installation instructions for information on routing power and control wiring.
RACEWAY

HUMIDI-MIZER® CONTROL CONNECTIONS
Humidi-MiZer Space RH Controller
NOTE: The Humidi-MiZer is a factory installed option which is available for 07 models only.
The Humidi-MiZer dehumidification system requires a field-supplied and installed space relative humidity control device. This device may be a separate humidistat control (contact closes on rise in space RH above control setpoint) or a combination thermostat-humidistat control device such as Carrier's EDGE® Pro Thermidistat with isolated contact set for dehumidification control. The humidistat is normally used in applications where a temperature control is already provided (units with PremierLinkTM control).
To Connect the Carrier Humidistat (HL38MG029) (See Fig. 33)
1. Route the humidistat 2-conductor cable (field-supplied) through the hole provided in the unit corner post.
2. Feed wires through the raceway built into the corner post (see Fig. 32) to the 24-v barrier located on the left side of the control box. The raceway provides the UL-required clearance between high-voltage and low-voltage wiring.
3. Use wire nuts to connect humidistat cable to two PINK leads in the lowvoltage wiring as shown in Fig. 34.
To connect the Thermidistat device (33CS2PPRH-01) (See Fig. 35)
1. Route the Thermidistat multi-conductor thermostat cable (field-supplied) through the hole provided in the unit corner post.
2. Feed wires through the raceway built into the corner post (see Fig. 32) to the 24-v barrier located on the left side of the control box. The raceway provides the UL-required clearance between high-voltage and low-voltage wiring.
3. The Thermidistat has dry contacts at terminals D1 and D2 for dehumidification operation (see Fig. 36). The dry contacts must be wired between CTB terminal R and the PINK lead to the LTLO switch with field-supplied wire nuts. Refer to PremierLink Installation, Start-up, and Configuration Instructions for more information.

HOLE IN END PANEL (HIDDEN)
Fig. 32 -- Field Control Wiring Raceway
Heat Anticipator Settings -- Set heat anticipator settings at 0.14 amp for the first stage and 0.14 amp for second-stage heating, when available.

% RELATIVE HUMIDITY
Fig. 33 -- Accessory Field-Installed Humidistat

Fig. 34 -- 48TC*B07 (Unit with Humidi-MiZer® Adaptive Dehumidification System) Humidistat Wiring 21

®
Fig. 35 -- Edge® Pro Thermidistat EDGE Pro THERMIDISTAT
Rc Rh W1
G Y2
C O/W2/B
Y1

OAT RRS SRTN HUM
D1 D2 V+ Vg

Humidi-MiZer® FIOP

Unit CTB THERMOSTAT
X* C G W2
W1 Y2 Y1 R

*Connection not required. Fig. 36 -- 48TC*B07 (Unit with Humidi-MiZer Adaptive Dehumidification System
22

ECONOMI$ER® X (FACTORY-INSTALLED OPTION)
Product Description -- The EconoMi$er X system is an expandable economizer control system, which includes a W7220 economizer module (controller) with an LCD and keypad (see Fig. 37). The W7220 can be configured with optional sensors.

Relay Digital Output Rating at 30 Vac (maximum power from Class 2 input only) -- 1.5A run:
3.5A inrush at 0.45PF (200,000 cycles) or
7.5A inrush at 0.45PF (100,000 cycles)
External Sensors Power Output -- 21 Vdc ± 5% at 48mA

IMPORTANT: All inputs and outputs must be Class 2 wiring.

Fig. 37 -- W7220 Economizer Module
The W7220 economizer module can be used as a standalone economizer module wired directly to a commercial setback space thermostat and sensors to provide outside air drybulb economizer control.
The W7220 economizer module can be connected to optional sensors for single or differential enthalpy control. The W7220 economizer module provides power and communications for the sensors.
The W7220 economizer module automatically detects sensors by polling to determine which sensors are present. If a sensor loses communications after it has been detected, the W7220 economizer controller indicates a device fail error on its LCD.
System Components -- The EconoMi$er X system includes an economizer module, 20k mixed air sensor, damper actuator, and either a 20k outdoor air temperature sensor or S-Bus enthalpy sensors.
Economizer Module -- The economizer module is the core of the EconoMi$er X system. The module is mounted in the unit's control box, and includes the user interface for the system. The W7220 economizer module provides the basic inputs and outputs to provide simple economizer control. When used with the optional sensors, the economizer module provides more advanced economizer functionality.
S-Bus Enthalpy Control Sensors -- This sensor is a combination temperature and humidity sensor which is powered by and communicates on the S-Bus. Up to three sensors may be configured with the W7220 economizer module. See page 24 for details.
CO2 Sensor (optional) -- A CO2 sensor can be added for Demand Controlled Ventilation (DCV).
Specifications
W7220 Economizer Module -- The module is designed for use with 2 to 10 Vdc or bus communicating actuator. The module includes terminals for CO2 sensor, mixed air sensor, and an outdoor dry bulb sensor. Enthalpy and other options are available with bus sensors.
User Interface -- Provides status for normal operation, setup parameters, checkout tests, and alarm and error conditions with a 2-line 16 character LCD display and four button keypad.
Electrical
Rated Voltage -- 20 to 30 Vac RMS, 50/60 Hz
Transformer -- 100 va maximum system input
Nominal Power Consumption (at 24 Vac, 60 Hz) -- 11.5 VA without sensors or actuators

Inputs
Sensors NOTE: A Mixed Air (MA) analog sensor is required on all W7220 units; either an Outdoor Air (OA) sensor for dry bulb change over or an OA bus sensor for outdoor enthalpy change over is required in addition to the MA sensor. An additional Return Air (RA) bus sensor can be added to the system for differential enthalpy or dry bulb changeover. For differential dry bulb changeover a 20k ohm sensor is required in the OA and a bus sensor in the RA. DIP switch on RA bus sensor must be set in the RA position.
Dry Bulb Temperature (optional) and Mixed Air (required), 20k NTC
2-wire (18 to 22 AWG); Temperature range -40 to 150 F (-40 to 65 C) Temperature accuracy -0 F/+2 F
Temperature and Humidity, C7400S1000 (optional) S-Bus; 2-wire (18 to 22 AWG) Temperature: range -40 to 150 F (-40 to 65 C) Temperature accuracy -0 F/+2F Humidity: range 0 to 100% RH with 5% accuracy.
NOTE: Up to three (3) S-Bus sensors may be connected to the W7220 economizer module. For outdoor air (OA), return air (RA) and discharge (supply) air (DA).
4 Binary Inputs 1-wire 24 Vac + common GND (see page 25 for wiring de-
tails).
24 Vac Power Supply 20 to 30 Vac 50/60Hz; 100 VA Class 2 transformer.
Outputs
Actuator Signal 2-10 Vdc; minimum actuator impedance is 2k ohm; bus
two-wire output for bus communicating actuators.
Exhaust fan, Y1, Y2 and AUX1 All Relay Outputs (at 30 Vac): Running: 1.5A maximum Inrush: 7.5A maximum
Environmental
Operating Temperature -40 to 150 F (-40 to 65 C). Exception of display operation down to -4 F with full
recovery at -4 F from exposure to -40 F
Storage Temperature -40 to 150 F (-40 to 65 C)
Shipping Temperature -40 to 150 F (- 40 to 65 C)
Relative Humidity 5% to 95% RH non-condensing

ECONOMIZER MODULE WIRING DETAILS -- Use Fig. 38 and Tables 9 and 10 to locate the wiring terminals for the Economizer module.
NOTE: The four terminal blocks are removable. You can slide out each terminal block, wire it, and then slide it back into place.

MAT

MA MA

OAT

S-BUS

SB SB

IAQ 2-10

IAQCOM

IAQ 24V

ACT 2-10

ACT COM

ACT 24V

AUX2-

OCC

E-GND

EXH1

AUX1-O

Cert

Product

California Title 24,Part 6

HJW10

www.energy.ca.gov

Y2I

Y2-

Y2O

Y2-O

Y1I

Y1O

Y1-

Y1-O

50040839-001 Rev. G

50048848-002 Rev. A

Fig. 38 -- W7220 Wiring Terminals
S-Bus Sensor Wiring -- The labels on the sensors and controller are color coded for ease of installation. Orange labeled sensors can only be wired to orange terminals on the controller. Brown labeled sensors can only be wired to S-bus (brown) terminals. Use Fig. 38 and Table 9 to locate the wiring terminals for each S-Bus sensor.
Use Fig. 38 and Table 10 to set the DIP switches for the desired use of the sensor.

Table 9 -- Economizer Module - Left Hand Terminal Blocks

LABEL

TYPE

DESCRIPTION

Top Left Terminal Block

MAT MAT

20k NTC Mixed Air Temperature Sensor (Polarity and COM Insensitive Connection)

OAT OAT

20k NTC Outdoor Air Temperature Sensor and COM (Polarity Insensitive Connection)

S-BUS S-BUS

S-BUS

Enthalpy Control Sensor

(Sylk Bus) (Polarity Insensitive Connection)

Bottom Left Terminal Block

IAQ 2-10

2-10 vdc

Air Quality Sensor Input (e.g. CO2 sensor)

IAQ COM COM

Air Quality Sensor Common

IAQ 24V 24 vac

Air Quality Sensor 24 vac Source

ACT 2-10 2-10 vdc Damper Actuator Output (2-10 vdc)

ACT COM COM

Damper Actuator Output Common

ACT 24v 24 vac

Damper Actuator 24 vac Source

Table 10 -- Economizer Module - Right Hand Terminal Blocks

LABEL

TYPE

DESCRIPTION

Top Right Terminal Blocks

AUX2 I

24 vac IN The first terminal is not used.

OCC

24 vac IN

Shut Down (SD) or HEAT (W) Conventional only and Heat Pump Changeover (O-B) in Heat Pump mode.

E-GND

Occupied/Unoccupied Input

EXH1

24 vac OUT

Exhaust Fan 1 Output

AUX1 O

24 vac OUT

Programmable: Exhaust fan 2 output or ERV or System alarm output

Bottom Right Terminal Blocks

Y2-I

24 vac IN

Y2 in - Cooling Stage 2 Input from space thermostat

Y2-O

24 vac OUT

Y2 out - Cooling Stage 2 Output to stage 2 mechanical cooling

Y1-I

24 vac IN

Y1 in - Cooling Stage 2 Input from space thermostat

Y1-O

24 vac OUT

Y1 out - Cooling Stage 2 Output to stage 2 mechanical cooling

COM

24 vac Common

24 vac

24 vac Power (hot)

Use Fig. 39 and Table 11 to locate the wiring terminals for each enthalpy control sensor.

DIP Switch Label
DIP Switches (3)

S-Bus Terminals (1 and 2)

S-Bus 2 Pin Side Connector

Fig. 39 -- S-Bus Sensor DIP Switches

Table 11 -- HH57AC081 Sensor Wiring Terminations

TERMINAL

NUMBER

LABEL

TYPE

DESCRIPTION

S-BUS

Communications (Enthalpy Control

Sensor Bus)

S-BUS

Communications (Enthalpy Control

Sensor Bus)

Use Fig. 39 and Table 12 to set the DIP switches for the desired use of the sensor.

Table 12 -- HH57AC081 Sensor DIP Switch

DIP SWITCH POSITIONS FOR SWITCHES 1, 2, AND 3

USE

OFF

NOTE: When a S-bus sensor is connected to an existing network, it will take 60 minutes for the network to recognize and auto-configure itself to use the new sensor.
During the 60 minute setup period, no alarms for sensor failures (except SAT) will be issued and no economizing function will be available.
CO2 Sensor Wiring -- When using a CO2 sensor the black and brown common wires are internally connected and only one is connected to "IAQ COM" on the W7220. Use the power from the W7220 to power the CO2 sensor OR make sure the ground for the power supplies are common. See Fig. 40 for CO2 sensor wiring.
CO 2 SENSOR

RED 24V BLACK

+ ANALOG
OUT

YELLOW BROWN
ORANGE

L1 (HOT)
L2 1

GREEN

1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
Fig. 40 -- CO2 Sensor Wiring INTERFACE OVERVIEW -- This section describes how to use the Economizer's user interface for: · Keypad and menu navigation · Settings and parameter changes · Menu structure and selection

User Interface -- The user interface consists of a 2-line LCD display and a 4-button keypad on the front of the economizer controller.
Fig. 41 -- W7220 Controller Button Description Keypad -- The four navigation buttons (see Fig. 41) are used to scroll through the menus and menu items, select menu items, and to change parameter and configuration settings.
To use the keypad when working with menus: · Press the (Up arrow) button to move to the previous
menu. · Press the (Down arrow) button to move to the next
menu. · Press the (Enter) button to display the first item in the
currently displayed menu. Press the (Menu Up/Exit) button to exit a menu's item and return to the list of menusTo use the keypad when working with Setpoints, System and Advanced Settings, Checkout tests and Alarms: 1. Navigate to the desired menu. 2. Press the (Enter) button to display the first item in the cur-
rently displayed menu. 3. Use the (Up arrow) and (Down arrow) buttons to
scroll to the desired parameter. 4. Press the (Enter) button to display the value of the cur-
rently displayed item. 5. Press the button to increase (change) the displayed pa-
rameter value. 6. Press the button to decrease (change) the displayed pa-
rameter value. NOTE: When values are displayed, pressing and holding the or button causes the display to automatically increment. 7. Press the (Enter) button to accept the displayed value and
store it in nonvolatile RAM. 8. "CHANGE STORED" displays. 9. Press the (Enter) button to return to the current menu pa-
rameter. 10. Press the (MENU Up/Exit) button to return to the previ-
ous menu. Menu Structure -- Table 13 illustrates the complete hierarchy of menus and parameters for the EconoMi$er® X system.
The Menus in display order are: · STATUS · SETPOINTS · SYSTEM SETUP · ADVANCED SETUP · CHECKOUT · ALARMS

IMPORTANT: Table 13 illustrates the complete hierarchy. Your menu parameters may be different depending on your configuration.
For example if you do not have a DCV (CO2) sensor, then none of the DCV parameters appear and only MIN POS will display. If you have a CO2 sensor, the DCV MIN and DCV MAX will appear AND if you have 2 speed fan DCV MIN (high and low speed) and DCV MAX (high and low speed) will appear.
NOTE: Some parameters in the menus use the letters MA or MAT, indicating a mixed air temperature sensor location before the cooling coil. This unit application has the control sensor located after the cooling coil, in the fan section, where it is designated as (Cooling) Supply Air Temperature or SAT sensor.

Setup and Configuration -- Before being placed into service, the W7220 Economizer module must be setup and configured for the installed system.
IMPORTANT: During setup, the Economizer module is live at all times.
The setup process uses a hierarchical menu structure that is easy to use. You press the and arrow buttons to move forward and backward through the menus and press the button to select and confirm setup item changes.
See Table 14 for damper minimum position settings and readings on the checkout menus.
Time-Out and Screen-Saver -- When no buttons have been pressed for 10 minutes, the LCD displays a screen saver, which cycles through the Status items. Each Status items displays in turn and cycles to the next item after 5 seconds.
1 and 2 Speed Fan Operation -- For 1 speed fan dry bulb and enthalpy operation see Tables 15-18. For 2 speed fan operation see Tables 19-22.

MENU
STATUS

PARAMETER
ECONO AVAIL ECONOMIZING
OCCUPIED HEAT PUMP COOL Y1--IN COOL Y1--OUT COOL Y2--IN COOL Y2--OUT
MA TEMP DA TEMP OA TEMP OA HUM RA TEMP RA HUM
IN CO2 DCV STATUS DAMPER OUT
ACT POS

Table 13 -- Menu Structure

PARAMETER
DEFAULT VALUE

PARAMETER
RANGE AND INCREMENT

NOTES

FIRST STAGE COOLING DEMAND (Y1-IN)

YES/NO

YES = economizing available; the system can use outside air for free

cooling when required

YES/NO

FIRST STAGE COOLING RELAY OUTPUT YES = outside air being used for 1 stage cooling

OCCUPIED

YES = OCC signal received from space thermostat or

YES/NO

unitary controller

YES = 24 Vac on terminal OCC

NO = 0 Vac on terminal OCC

N/A

COOL HEAT

HEAT PUMP MODE Displays COOL or HEAT when system is set to heat pump (Non-conventional)

OFF

ON/OFF

FIRST STAGE COOLING DEMAND (Y1-IN) Y1I signal from space thermostat or unitary controller for cooling stage 1. ON = 24 Vac on terminal Y1I OFF = 0 Vac on terminal Y1I

OFF

ON/OFF

FIRST STAGE COOLING RELAY OUTPUT Cool stage 1 Relay Output to stage 1 mechanical cooling (Y1--OUT terminal)

OFF

ON/OFF

SECOND STAGE COOLING DEMAND (Y2-IN) Y2I signal from space thermostat our unitary controller for second stage cooling. ON = 24 Vac on terminal Y2I OFF = 0 Vac on terminal Y2I

OFF

ON/OFF

SECOND STAGE COOLING RELAY OUTPUT Cool Stage 2 Relay Output to mechanical cooling (Y2OUT terminal)

_ _ . _ F

0 to 140 F

SUPPLY AIR TEMPERATURE, Cooling Mode Displays value of measured mixed air from MAT sensor. Displays _ _ . _ F if not connected, short or out-of-range.

_ _ . _ F

0 to 140 F

DISCHARGE AIR TEMPERATURE, after Heating section Displays when Discharge Air sensor is connected and displays measured discharge temperature. Displays _ _ . _F if sensor sends invalid value, if not connected, short or out-of-range.

_ _ . _ F

-40 to 140 F

OUTSIDE AIR TEMP Displays measured value of outdoor air temperature. Displays _ _ . _F if sensor sends invalid value, short or out-of-range.

_ _ %

0 to 100%

OUTSIDE AIR RELATIVE HUMIDITY Displays measured value of outdoor humidity from OA sensor. Displays _ _% if not connected short, or out-of-range.

_ _ . _ F

0 to 140 F

RETURN AIR TEMPERATURE Displays measured value of return air temperature from RAT sensor. Displays _ _ . _ F if sensor sends invalid value, if not connected, short or out-of-range

_ _ %

0 to 100%

RETURN AIR RELATIVE HUMIDITY Displays measured value of return air humidity from RA sensor. Displays _ _% if sensor sends invalid value, if not connected, short or out-of-range

_ _ _ ppm

0 TO 2000 ppm

SPACE/RETURN AIR CO2 Displays value of measured CO2 from CO2 sensor. Invalid if not connected, short or out-of-range

DEMAND CONTROLLED VENTILATION STATUS

N/A

ON/OFF

Displays ON if above setpoint and OFF if below setpoint, and ONLY if a

CO2 sensor is connected.

2.0v

2.0 TO 10.0v

Displays voltage output to the damper actuator.

N/A

0 to 100%

Displays actual position of outdoor air damper actuator

Table 13 -- Menu Structure (cont)

PARAMETER

PARAMETER DEFAULT VALUE

PARAMETER RANGE AND INCREMENT

NOTES

ACT COUNT

N/A

1 to 65535

Displays number of times actuator has cycled. 1 cycles equals 180 deg. of actuator movement in any direction.

ACTUATOR

N/A

OK/Alarm (on Alarm menu)

Displays ERROR if voltage or torque is below actuator range.

EXH1 OUT

OFF

ON/OFF

EXHAUST STAGE 1 RELAY OUTPUT Output of EXH1 terminal: ON = relay closed OFF = relay open

STATUS (CONT)

EXH2 OUT ERV

OFF OFF

ON/OFF ON/OFF

EXHAUST STAGE 2 RELAY OUTPUT Output of AUX terminal; displays only if AUX = EXH2
ENERGY RECOVERY VENTILATOR Output of AUX terminal; displays only if AUX = ERV

MECH COOL ON

HEAT STAGES ON

0, 1, or 2

Displays stage of mechanical cooling that is active. Displays the stage of heat pump heating that is active.

FAN SPEED

N/A

LOW or HIGH

SUPPLY FAN SPEED Displays speed setting of fan on a 2-speed fan unit.

W (HEAT ON)

N/A

ON/OFF

HEAT DEMAND STATUS Displays status of heat demand on a 2-speed fan unit.

MAT SET

53F

38 to 65F; increment by 1

SUPPLY AIR SETPOINT Setpoint determines where the economizer will modulate the OA damper to maintain the mixed air temperature.

LOW T LOCK

32F

-45 to 80 F; increment by 1

COMPRESSOR LOW TEMPERATURE LOCKOUT Setpoint determines outdoor temperature when the mechanical cooling cannot be turned on. Commonly referred to as the Compressor lockout.

DRYBLB SET

OA DRY BULB TEMPERATURE CHANGEOVER SETPOINT

63F

48 to 80F; increment by 1

Setpoint determines where the economizer will assume outdoor air temperature is good for free cooling; e.g.; at 63 F unit will economize at 62 F and below and not economize at 64 F and above. There is a 2 F dead-

band.

ENTH CURVE

ES3

ES1,ES2,ES3,ES4, ENTHALPY CHANGEOVER CURVE

or ES5

Enthalpy boundary "curves" for economizing using single enthalpy.

DCV SET

1100ppm

500 to 2000ppm; increment by 100

DEMAND CONTROLLED VENTILATION
Displays only if CO2 sensor is connected. Setpoint for Demand Control Ventilation of space. Above the setpoint, the OA dampers will modulate open to bring in additional OA to maintain a space ppm level below the
setpoint.

SETPOINTS

MIN POS

2.8 V

VENTMAX With 2-speed fan units VENTMAX L (low speed fan) and VENTMAX H (high speed fan) settings are required

2.8 V

2 to 10 Vdc
2 to 10 Vdc
100 to 9990 cfm; increment by 10
2 to 10 Vdc

VENTILATION MINIMUM POSITION Displays ONLY if a CO2 sensor is NOT connected.
DCV MAXIMUM DAMPER POSITION Displays only if a CO2 sensor is connected. Used for Vbz (ventilation max cfm) setpoint. Displays 2 to 10 V if <3 sensors (RA,OA, and MA). In AUTO mode dampers controlled by CFM.
If OA, MA, RA, and CO2 sensors are connected and DCV CAL ENABLE is set to AUTO mode, the OA dampers are controlled by CFM and displays from 100 to 9990 CFM.
With 2-speed fan units VENT L (low speed fan) and MIN POS H (high speed fan) settings are required. Default for VENTMAX L is 3.2V and VENTMAX H is 2.8V

VENTMIN With 2-speed fan units VENTMIN L (low speed fan) and VENTMIN H (high speed fan) set

2.25 V

2 to 10 Vdc or 100 to 9990 cfm increment by 10

DCV MINIMUM DAMPER POSITION Displays only if a CO2 sensor is connected. Used for Ba (ventilation min cfm) setpoint. Displays 2 to 10 V if <3 sensors (RA, OA, and MA). Va is
only set if DCV is used. This is the ventilation for less than maximum occupancy of the space. In AUTO mode dampers controlled by CFM.

100 to 9990 cfm; increment by 10

If OA, MA, RA, and CO2 sensors are connected and DCV CAL ENABLE is set to AUTO mode, the OA dampers are controlled by CFM and dis-
plays from 100 to 9990 CFM.

2 to 10 Vdc

With 2-speed fan units VENTMIN L (low speed fan) and MIN POS H (high speed fan) settings are required. Default for VENTMIN L is 3.2V and VENTMIN H is 2.8V

ERV OAT SP

32°F

0 to 50F; increment by 1

ENERGY RECOVERY VENTILATOR UNIT OUTDOOR AIR TEMPERATURE SETPOINT Only when AUX1 O = ERV

EXH1 SET With 2-speed fan units Exh1 L (low speed fan) and Exh1 H (high speed fan) settings are required

50%

0 to 100%;increment by 1

EXHAUST FAN STAGE 1 SETPOINT Setpoint for OA damper position when exhaust fan 1 is powered by the economizer. With 2-speed fan units Exh1 L (low speed fan) and Exh1 H (high speed fan) settings are required. Default for Exh1 L is 65% and Exh1 H is 50%

EXH2 SET With 2-speed fan units Exh2 L (low speed fan) and Exh2 H (high speed fan) settings are required

75%

0 to 100%; increment by 1

EXHAUST FAN STAGE 2 SETPOINT Setpoint for OA damper position when exhaust fan 2 is powered by the economizer. Only used when AUX1 O is set to EHX2. With 2-speed fan units Exh2 L (low speed fan) and Exh2 H (high speed fan) settings are required. Default for Exh2 L is 80% and Exh2 H is 75%

PARAMETER INSTALL UNITS DEG EQUIPMENT

AUX2 IN

FAN SPEED SYSTEM SETUP
FAN CFM
AUX1 OUT

OCC

FACTORY DEFAULT MA LO SET

FREEZE POS CO2 ZERO CO2 SPAN STG3 DLY

ADVANCED SETUP

SD DMPR POS

DA LO ALM DA HI ALM DCVCAL ENA

Table 13 -- Menu Structure (cont)

PARAMETER DEFAULT
VALUE

PARAMETER RANGE AND
INCREMENT

NOTES

01/01/10

N/A

Display order = MM/DD/YY Setting order = DD, MM, then YY.

F or C

Sets economizer controller in degrees Fahrenheit or Celsius

CONV

Conventional or HP

CONV = conventional; HP O/B = Enable Heat Pump mode. Use AUX2 I for Heat Pump input from thermostat or controller. See Menu Note 4

In CONV mode:

SD + Enables configuration of shutdown (default);

W = Informs controller that system is in heating mode.

SD/W or HP(O)/ HP(B)

NOTE: If using 2-speed fan mode, you must program CONV mode for W. Shutdown is not available in 2-speed fan mode. See Menu Note 4.

In HP O/B mode:

HP(O) = energize heat pump on Cool (default);

HP(B) = energize heat pump on heat.

2 speed

1 speed/2 speed

Sets the economizer controller for operation of 1 speed or 2 speed supply fan. NOTE: 2-speed fan option also needs Heat (W1) programmed in AUX 2 In. See Menu Note 4.

5000cfm

100 to 15000 cfm; increment by 100

UNIT DESIGN AIRFLOW (CFM) Enter only if using DCVAL ENA = AUTO The value is dounf on the nameplate label for the specific unit.

NONE

NONE ERV EXH2 SYS

Select OUTPUT for AUX1 O relay · NONE = not configured (output is not used) · ERV = Energy Recovery Ventilator · EXH2 = second damper position relay closure for second exhaust fan · SYS = use output as an alarm signal

INPUT

INPUT or ALWAYS

OCCUPIED MODE BY EXTERNAL SIGNAL When using a setback thermostat with occupancy out (24 vac), the 24 vac is input "INPUT" to the OCC terminal. If no occupancy output from the thermostat then change program to "ALWAYS" OR add a jumper from terminal R to OCC terminal.

Resets all set points to factory defaults when set to YES. LCD will briefly

NO or YES

flash YES and change to NO but all parameters will change to the factory default values.

NOTE: RECHECK AUX2 IN and FANTYPE for required 2-speed values.

45°F

35 to 55 F; Incremented by 10

SUPPLY AIR TEMPERATURE LOW LIMIT Temperature to achieve Freeze Protection (close damper and alarm if temperature falls below setup value).

CLO

CLO or MIN

FREEZE PROTECTION DAMPER POSITION Damper position when freeze protection is active (closed or MIN POS).

0ppm

0 to 500 ppm; Increment by 10

CO2 ppm level to match CO2 sensor start level.

2000ppm

1000 to 3000 ppm; CO2 ppm span to match CO2 sensor. Increment by 10

2.0h

0 min, 5 min, 15

COOLING STAGE 3 DELAY

min, then 15 min

Delay after stage 2 cool has been active. Turns on second stage of cooling when economizer is first stage and mechanical cooling is sec-

intervals. Up to 4 ond stage. Allows three stages of cooling, 1 economizer and 2 mechan-

hrs or OFF

ical.

OFF = no Stage 3 cooling

CLO

CLO or OPN

Indicates shutdown signal from space thermostat or unitary controller. When controller receives 24 Vac input on the SD terminal in conventional mode, the OA damper will open if programmed for OPN and OA damper will close if programmed for CLO. All other controls, e.g., fans, etc. will shut off.

45 F (7 C)

35 to 65 F; (2 to 18 C) Incremented by 5 deg.

Used for alarm for when the DA air temperature is too low. Set lower range of alarm, below this temperature the alarm will show on the display.

80 F (27 C)

70 to 80 F; (21 to 82 C) Incremented by 5 deg.

Used for alarm for when the DA air temperature is too high. Set upper range of alarm, above this temperature the alarm will show on the display.

MAN

MAN (manual) AUTO

Turns on the DCV automatic control of the dampers. Resets ventilation based on the RA, OA, and MA sensor conditions. Requires all 3 RA, OA, and MA sensors.

MENU ADVANCED SETUP (CONT)
CHECKOUT
ALARMS

Table 13 -- Menu Structure (cont)

PARAMETER

PARAMETER DEFAULT
VALUE

PARAMETER RANGE AND
INCREMENT

NOTES

MAT T CAL

0.0°F

±2.5 F

SUPPLY AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

OAS T CAL

0.0°F

±2.5 F

OUTSIDE AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

OA H CAL

0% RH

±10% RH

OUTSIDE AIR HUMIDITY CALIBRATION Allows for operator to adjust for an out of calibration humidity sensor.

RA T CAL

0.0°F

±2.5 F

RETURN AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

RA H CAL

0% RH

±10% RH

RETURN AIR HUMIDITY CALIBRATION Allows for operator to adjust for an out of calibration humidity sensor.

DA T CAL

0.0°F

±2.5 F

DISCHARGE AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor.

2SP FAN DELAY

5 Minutes

0 to 20 minutes in 1 minute increments

TIME DELAY ON 2nd STAGE ECONOMIZING When in economizing mode this is the delay for the high speed fan to try to satisfy the call for second stage cooling before the first stage mechanical cooling is enabled.

DAMPER MINIMUM POSI- N/A

N/A

TION

The checkout for the damper minimum position is based on the system. See Table 14.

DAMPER OPEN

N/A

Position damper to the full open position. Exhaust fan contacts enable during the DAMPER OPEN test. Make sure you pause in the mode to allow exhaust contacts to energize due to the delay in the system.

DAMPER CLOSE

N/A

Positions damper to the fully closed position

CONNECT Y1O

N/A

Closes the Y1O relay (Y1O)

CONNECT Y2O

N/A

Closes the Y2O relay (Y2O)

CONNECT AUX1-O

N/A

Energizes the AUX output. If Aux setting is: · NONE -- not action taken · ERV -- 24 Vac out. Turns on or signals an ERV that the conditions are not good for economizing but are for ERV operation. · SYS -- 24 Vac out. Issues a system alarm

CONNECT EXH1

N/A

Closes the power exhaust fan 2 relay (EXH1)

Alarms display only when they are active. The menu title "ALARMS(#)" includes the number of active alarms in parenthesis ( ). When using SYLK bus sensors, "SYLK" will appear on the screen, and when using 20k OA temperature sensors, "SENS T" will appear on the screen

MA T SENS ERR

N/A

SUPPLY AIR TEMPERATURE SENSOR ERROR Mixed air sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

CO2 SENS ERR

N/A

CO2 SENSOR ERROR CO2 sensor has failed, gone out of range or become disconnected check wiring then replace sensor if the alarm continues.

OA SYLK T ERR

N/A

OA SYLK H ERR

N/A

OUTSIDE AIR S-BUS SENSOR ERROR Outdoor air enthalpy sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

RA SYLK T ERR

N/A

RA SYLK H ERR

N/A

RETURN AIR S-BUS SENSOR ERROR Return air enthalpy sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

DA SYLK T ERR

N/A

DISCHARGE AIR S-BUS SENSOR ERROR Discharge air sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

OA SENS T ERR

N/A

OUTSIDE AIR TEMPERATURE SENSOR ERROR Outdoor air temperature sensor has failed or become disconnected check wiring then replace if the alarm continues.

ACT ERROR

N/A

ACTUATOR ERROR Actuator has failed or become disconnected - check for stall, over voltage, under voltage and actuator count. Replace actuator if damper is movable and supply voltage is between 21.6 V and 26.4 V. Check actuator count on STATUS menu.

FREEZE ALARM

N/A

Check if outdoor temperature is below the LOW Temp Lockout on setpoint menu. Check if mixed air temperature on STATUS menu is below the Lo Setpoint on Advanced menu. When conditions are back in normal range then the alarm will go away.

PARAMETER SHUTDOWN ACTIVE DMP CAL RUNNING

ALARMS (CONT)

DA SENS ALM
SYS ALARM ACT UNDER V ACT OVER V ACT STALLED

Table 13 -- Menu Structure (cont)

PARAMETER DEFAULT
VALUE

PARAMETER RANGE AND
INCREMENT

NOTES

N/A

AUX2 IN is programmed for SHUTDOWN and 24 V has been applied to AUX 2IN terminal.

N/A

DAMPER CALIBRATION ROUTINE RUNNING If DCV Auto enable has been programmed, when the W7220 is completing a calibration on the dampers, this alarm will display. Wait until the calibration is completed and the alarm will go away. Must have OA, MA and RA sensors for DCV calibration; set up in the Advanced setup menu.

N/A

DISCHARGE AIR TEMPERATURE SENSOR ALARM Discharge air temperature is out of the range set in the ADVANCED SETUP Menu. Check the temperature of the discharge air.

N/A

When AUX1-0 is set to SYS and there is any alarm (e.g., failed sensors, etc.), the AUX1-0 terminal has 24 Vac out.

N/A

ACTUATOR VOLTAGE LOW Voltage received by actuator is above expected range.

N/A

ACTUATOR VOLTAGE HIGH Voltage received by actuator is below expected range.

N/A

ACTUATOR STALLED Actuator stopped before achieving commanded position.

CLO DCV ERV LCD MA MAT N/A OA OAT OCC RA RAT RTU SYS

LEGEND -- Compressor Lockout -- Demand Controlled Ventilation -- Energy Recovery Ventilator -- Liquid Crystal Display -- Mixed Air -- Mixed Air Temperature -- Not Applicable -- Outdoor Air -- Outdoor Air Temperature -- Occupied -- Return Air -- Return Air Temperature -- Rooftop Unit -- System

* Table 13 illustrates the complete hierarchy. Your menu parameters may be different depending on your configuration. For example if you do not have a DCV (CO2) sensor, then none of the DCV parameters appear.
When values are displayed, pressing and holding the or button causes the display to automatically increment.
** N/A = Not Applicable. ERV Operation: When in cooling mode AND the conditions are NOT
OK for economizing - the ERV terminal will be energized. In the Heating mode, the ERV terminal will be energized when the OA is below the ERV OAT setpoint in the setpoint menu.

NOTES: 1. STATUS --> OCCUPIED -- The factory-standard Occupancy signal originates with a thermostat or other controller call for indoor fan operation at CTB terminal G. This signal passes through the Central Terminal Board's OCCUPIED jumper JMP1 to the ECONO connector and to the W7220's OCC input terminal. An external timeclock or relay is required to implement an Occupancy schedule on the economizer damper position.
2. STATUS --> MA TEMP, SETPOINTS --> MAT SET -- The W7220 menu parameters and labels include designations MA , MAT and Mixed Air for the economizer cooling control sensor. On these rooftop units, the economizer control sensor is located downstream of the evaporator/indoor coil in the supply fan section where this sensor is designated as Supply Air Temperature (SAT) sensor.
3. SETPOINTS --> DRYBLB SET -- This point is not displayed if a Return Air (differential) temperature sensor or an Outdoor Air enthalpy sensor is connected.
4. SYSTEM SETUP parameters must be configured as noted for 2-Speed unit operation:
EQUIPMENT = CONV AUX2 I = W FAN TYPE = 2SPEED

Table 14 -- Damper Minimum Position Settings and Readings on Checkout Menu

FAN SPEED
1 1 2 2 1 1 2 2 2 2

DEMAND CONTROLLED VENTILATION (CO2 SENSOR) NO NO NO NO YES YES YES YES YES YES

SETPOINTS
MIN POS N/A
MIN POS H MIN POS L VENT MIN VENT MAX VENT MIN H VENT MAX H VENT MIN L VENT MAX L

CHECKOUT
VMAXHS N/A
VMAXHS VMAXLS VMAXHS VMAXHS VMAXHS VMAXLS
N/A N/A

Table 15 -- Dry Bulb Operation No DCV (CO2 Sensor) -- 1 Speed Fan

DEMAND CONTROLLED VENTILATION (DCV)

OUTSIDE AIR GOOD TO
ECONOMIZE

Y1-I

Y2-I

FAN SPEED

Y1-O

Y2-O

OCCUPIED

UNOCCUPIED

OFF OFF HIGH

0v/Off

MIN POS

Closed

NONE

ON OFF HIGH 24v/On

0v/Off

MIN POS

Closed

ON ON HIGH 24v/On

24v/On

MIN POS

Closed

OFF OFF HIGH

0v/Off

MIN POS

Closed

NONE

YES

ON OFF HIGH

0v/Off

MIN POS to Full Open

Closed to Full-Open

ON ON HIGH 24v/On

0v/Off*

MIN POS to Full Open

Closed to Full-Open

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for Y1I and Y2I have not been satisfied.

Table 16 -- Dry Bulb Operation with DCV (CO2 Sensor) -- 1 Speed Fan

DEMAND CONTROLLED VENTILATION (DCV)

OUTSIDE AIR GOOD TO
ECONOMIZE

Y1-I

Y2-I

FAN SPEED

Y1-O

Y2-O

OCCUPIED

UNOCCUPIED

OFF OFF HIGH

0v/Off

VENTMIN

Closed

ON OFF HIGH 24v/On

0v/Off

VENTMIN

Closed

ON ON HIGH 24v/On

24v/On

VENTMIN

Closed

Below CO2 Set

OFF OFF HIGH

0v/Off

VENTMIN

Closed

Yes

ON OFF HIGH

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

ON ON HIGH 24v/On

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

OFF OFF HIGH

0v/Off

VENTMIN to VENTMAX

Closed

ON OFF HIGH 24v/On

0v/Off

VENTMIN to VENTMAX

Closed

Above CO2 Set

ON ON HIGH OFF OFF HIGH

24v/On 0v/Off

VENTMIN to VENTMAX
VENTMIN to VENTMAX

Closed Closed

Yes

ON OFF HIGH

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

ON ON HIGH 24v/On

0v/Off*

VENTMIN to Full-Open

Closed to Full-Open

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for Y1I and Y2I have not been satisfied.

Table 17 -- Enthalpy Operation No DCV (CO2 Sensor) -- 1 Speed Fan

DEMAND CONTROLLED VENTILATION (DCV)

OUTSIDE AIR GOOD TO
ECONOMIZE

Y1-I

Y2-I

FAN SPEED

Y1-O

Y2-O

OCCUPIED

UNOCCUPIED

OFF OFF HIGH

0v/Off

MIN POS

Closed

NONE

ON OFF HIGH 24v/On

0v/Off

MIN POS

Closed

ON ON HIGH 24v/On

24v/On

MIN POS

Closed

OFF OFF HIGH

0v/Off

MIN POS

Closed

NONE

YES

ON OFF HIGH

0v/Off

MIN POS to Full Open

Closed to Full-Open

ON ON HIGH 24v/On

0v/Off*

MIN POS to Full Open

Closed to Full-Open

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for Y1I and Y2I have not been satisfied.

Table 18 -- Enthalpy Operation with DCV (CO2 Sensor) -- 1 Speed Fan

DEMAND
CONTROLLED VENTILATION (DCV)

OUTSIDE AIR
GOOD TO ECONOMIZE

Y1-I

Y2-I

FAN SPEED

Y1-O

Y2-O

OCCUPIED

UNOCCUPIED

OFF OFF HIGH

0v/Off

VENTMIN

Closed

ON OFF HIGH 24v/On

0v/Off

VENTMIN

Closed

ON ON HIGH 24v/On

24v/On

VENTMIN

Closed

Below CO2 Set

OFF OFF HIGH

0v/Off

VENTMIN

Closed

Yes

ON OFF HIGH

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

ON ON HIGH 24v/On

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

OFF OFF HIGH

0v/Off

VENTMIN to VENTMAX

Closed

ON OFF HIGH 24v/On

0v/Off

VENTMIN to VENTMAX

Closed

Above CO2 Set

ON ON HIGH OFF OFF HIGH

24v/On 0v/Off

VENTMIN to VENTMAX
VENTMIN to VENTMAX

Closed Closed

Yes

ON OFF HIGH

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

ON ON HIGH 24v/On

0v/Off*

VENTMIN to Full-Open

Closed to Full-Open

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for Y1I and Y2I have not been satisfied.

Table 19 -- Dry Bulb Operation No DCV (CO2 Sensor) -- 2 Speed Fan

DEMAND CONTROLLED VENTILATION (DCV)

OUTSIDE AIR GOOD TO
ECONOMIZE

Y1-I

Y2-I

FAN SPEED

Y1-O

Y2-O

OCCUPIED

UNOCCUPIED

OFF OFF LOW

0v/Off

MIN POS

Closed

NONE

ON OFF LOW 24v/On

0v/Off

MIN POS

Closed

ON ON HIGH 24v/On

24v/On

MIN POS

Closed

OFF OFF LOW

0v/Off

MIN POS

Closed

NONE

YES

ON OFF LOW

0v/Off

MIN POS to Full Open

Closed to Full-Open

ON ON HIGH 24v/On

0v/Off*

MIN POS to Full Open

Closed to Full-Open

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for Y1I and Y2I have not been satisfied.

Table 20 -- Dry Bulb Operation with DCV (CO2 Sensor) -- 2 Speed Fan

DEMAND
CONTROLLED VENTILATION (DCV)

OUTSIDE AIR
GOOD TO ECONOMIZE

Y1-I

Y2-I

FAN SPEED

Y1-O

Y2-O

OCCUPIED

UNOCCUPIED

OFF OFF LOW

0v/Off

VENTMIN

Closed

ON OFF LOW 24v/On

0v/Off

VENTMIN

Closed

ON ON HIGH 24v/On

24v/On

VENTMIN

Closed

Below CO2 Set

OFF OFF LOW

0v/Off

VENTMIN

Closed

Yes

ON OFF LOW

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

ON ON HIGH 24v/On

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

OFF OFF LOW

0v/Off

VENTMIN to VENTMAX

Closed

ON OFF LOW 24v/On

0v/Off

VENTMIN to VENTMAX

Closed

Above CO2 Set

ON ON HIGH OFF OFF LOW

24v/On 0v/Off

VENTMIN to VENTMAX
VENTMIN to VENTMAX

Closed Closed

Yes

ON OFF LOW

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

ON ON HIGH 24v/On

0v/Off*

VENTMIN to Full-Open

Closed to Full-Open

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for Y1I and Y2I have not been satisfied.

Table 21 -- Enthalpy Operation No DCV (CO2 Sensor) -- 2 Speed Fan

DEMAND CONTROLLED VENTILATION (DCV)

OUTSIDE AIR GOOD TO
ECONOMIZE

Y1-I

Y2-I

FAN SPEED

Y1-O

Y2-O

OCCUPIED

UNOCCUPIED

OFF OFF LOW

0v/Off

MIN POS

Closed

ON OFF LOW 24v/On

0v/Off

MIN POS

Closed

ON ON HIGH 24v/On

24v/On

MIN POS

Closed

NO CO2 SENSOR

YES

OFF ON

OFF OFF

LOW LOW

0v/Off 0v/Off

MIN POS
MIN POS to Full Open

Closed Closed to Full-Open

ON ON HIGH 24v/On

0v/Off*

MIN POS to Full Open

Closed to Full-Open

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for Y1I and Y2I have not been satisfied.

Table 22 -- Enthalpy Operation with DCV (CO2 Sensor) -- 2 Speed Fan

DEMAND CONTROLLED
VENTILATION (DCV)

OUTSIDE AIR GOOD TO
ECONOMIZE

Y1-I

Y2-I

FAN SPEED

Y1-O

Y2-O

OCCUPIED

UNOCCUPIED

OFF OFF LOW

0v/Off

VENTMIN

Closed

ON OFF LOW 24v/On

0v/Off

VENTMIN

Closed

ON ON HIGH 24v/On

24v/On

VENTMIN

Closed

Below CO2 Set

OFF OFF LOW

0v/Off

VENTMIN

Closed

Yes

ON OFF LOW

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

ON ON HIGH 24v/On

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

OFF OFF LOW

0v/Off

VENTMIN to VENTMAX

Closed

ON OFF LOW 24v/On

0v/Off

VENTMIN to VENTMAX

Closed

Above CO2 Set

ON ON HIGH OFF OFF LOW

24v/On 0v/Off

VENTMIN to VENTMAX
VENTMIN to VENTMAX

Closed Closed

Yes

ON OFF LOW

0v/Off

VENTMIN to Full-Open

Closed to Full-Open

ON ON HIGH 24v/On

0v/Off*

VENTMIN to Full-Open

Closed to Full-Open

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2O after the delay if the call for Y1I and Y2I have not been satisfied.

ECONOMIZING AVAILABLE NOT AVAILABLE

ENTHALPY

RA HUM (%RH)

DUAL ENTHALPY HIGH LIMIT
SINGLE ENTHALPY P2 (T,RH)
P1 (T,RH)

RA TEMP ABSOLUTE HUMIDITY

TEMPERATURE

ES5 ES4 ES3 ES2 ES1

Fig. 42 -- Single Enthalpy Curve Boundaries

ENTHALPY CURVE
ES1 ES2 ES3 ES4 ES5 HL

Table 23 -- Single Enthalpy and Dual Enthalpy High Limit Curves

TEMP. DRY

TEMP.

ENTHALPY

BULB (F) DEWPOINT (F) (btu/lb/da)

POINT P1

TEMP. (F)

HUMIDITY (%RH)

POINT P2

TEMP. (F)

HUMIDITY (%RH)

28.0

36.8

66.3

80.1

26.0

39.6

63.3

80.0

24.0

42.3

59.7

81.4

22.0

44.8

55.7

84.2

20.0

46.9

51.3

88.5

32.4

38.9

72.4

80.3

Enthalpy Settings -- When the OA temperature, enthalpy and dew point are below the respective setpoints, the outdoor air can be used for economizing. Figure 42 shows the new single enthalpy boundaries in the W7220. There are 5 boundaries (setpoints ES1 through ES5), which are defined by dry bulb temperature, enthalpy and dew point.
Refer to Table 23 for ENTH CURVE setpoint values.
The W7220 calculates the enthalpy and dew point using the OA temperature and humidity input from the OA enthalpy sensor. When the OA temperature, OA humidity and OA dew point are all below the selected boundary, the economizer sets the economizing mode to YES, economizing is available.
When all of the OA conditions are above the selected boundary, the conditions are not good to economize and the mode is set to NO.
Fig. 42 shows the 5 current boundaries. There is also a high limit boundary for differential enthalpy. The high limit boundary is ES1 when there are no stages of mechanical cooling energized and HL (high limit) when a compressor stage is energized.
Table 23 provides the values for each boundary limit.
Two-Speed Fan Operation
NOTE: Two-Speed Fan operation does not apply to 48TC 0406 units.
The W7220 controller has the capability to work with a system using a 2-speed supply fan. The W7220 does not control the supply directly but uses the following input status to

determine the speed of the supply fan and controls the OA damper to the required position, see Table 24.

Table 24 -- Fan Speed

STATE

FAN SPEED

OCC

Low

High

The W (heating mode) is not controlled by the W7220 but it requires the status to know where to position the OA damper for minimum position for the fan speed.

The 2 speed fan delay is available when the system is programmed for 2 speed fan (in the System Setup menu item). The 2 speed fan delay is defaulted to 5 minutes and can be changed in the Advanced Setup menu item. When the unit has a call for Y1 In and in the free cooling mode and there is a call for Y2 In, the 2-speed fan delay starts and the OA damper will modulate 100% open, the supply fan should be set to high speed by the unit controller.

After the delay one of two actions will happen:

· The Y2In call will be satisfied with the damper 100% open and fan on high speed and the call will turn off

· If the call for additional cooling in the space has not been satisfied then the first stage of mechanical cooling will be enabled through Y1 Out or Y2 Out.

Checkout
Inspect all wiring connections at the Economizer module's terminals, and verify compliance with the installation wiring diagrams.
For checkout, review the Status of each configured parameter and perform the Checkout tests.
NOTE: See Interface Overview on page 25 for information about menu navigation and use of the keypad.
WARNING
Failure to follow this warning could result in personal injury, property damage, or death.
Before performing service or maintenance operations on unit, always turn off main power switch to unit and install lock(s) and lockout tag(s). Unit may have more than one power switch. Ensure electrical service to rooftop unit agrees with voltage an amperage listed on the unit rating plate.
If any wiring changes are required, first be sure to remove power from the economizer module before starting work. Pay particular attention to verifying the power connection (24 Vac).
Power Up -- After the W7220 module is mounted and wired, apply power.
Initial Menu Display -- On initial start up, Honeywell displays on the first line and Economizer W7220 on the second line. After a brief pause, the revision of the software appears on the first line and the second line will be blank.
Power Loss (Outage or Brownout) -- All setpoints and advanced settings are restored after any power loss or interruption.
NOTE: All settings are stored in non-volatile flash memory.
Status -- Use the Status menu (see Table 13) to check the parameter values for the various devices and sensors configured.
NOTE: See Interface Overview on page 25 for information about menu navigation and use of the keypad.
Checkout Tests -- Use the Checkout menu (on page 30) to test the damper operation and any configured outputs. Only items that are configured are shown in the Checkout menu.
NOTE: See Interface Overview on page 25 for information about menu navigation and use of the keypad.
To perform a Checkout test:
1. Scroll to the desired test in the Checkout menu using the and buttons.

2. Press the button to select the item. 3. RUN? appears. 4. Press the button to start the test. 5. The unit pauses and then displays IN PROGRESS. 6. When the test is complete, DONE appears. 7. When all desired parameters have been tested, press the
(Menu Up) button to end the test.
The Checkout tests can all be performed at the time of installation or at any time during the operation of the system as a test that the system is operable. Troubleshooting
Alarms -- The Economizer module provides alarm messages that display on the 2-line LCD. NOTE: Upon power up, the module waits 60 minutes before checking for alarms. This allows time for all the configured devices (e.g. sensors, actuator) to become operational. The exception is the SAT sensor which will alarm immediately.
If one or more alarms are present and there has been no keypad activity for at least 5 minutes, the Alarms menu displays and cycles through the active alarms.
You can also navigate to the Alarms menu at any time.
Clearing Alarms -- Once the alarm has been identified and the cause has been removed (e.g. replaced faulty sensor). the alarm can be cleared from the display.
To clear an alarm, perform the following: 1. Navigate to the desired alarm. 2. Press the button. 3. ERASE? displays. 4. Press the button. 5. ALARM ERASED displays. 6. Press the (Menu up/Exit) button to complete the action
and return to the previous menu. NOTE: If the alarm still exists after you clear it, it is redisplayed within 5 seconds.
CAUTION
Failure to follow this caution may result in damage to equipment. Be sure to allow enough time for compressor startup and shutdown between checkout tests so that you do not short-cycle the compressors.

PREMIERLINKTM (FACTORY-OPTION) -- The PremierLink controller (see Fig. 43) is compatible with Carrier Comfort Network® (CCN) devices. This control is designed to allow users the access and ability to change factory-defined settings, thus expanding the function of the standard unit control board. CCN service access tools include System PilotTM, Touch PilotTM and Service Tool. (Standard tier display tools Navigator and Scrolling Marquee are not suitable for use with latest PremierLink controller (Version 2.x).)
The PremierLink control is factory-mounted in the 48TC unit's main control box to the left of the Central Terminal Board (CTB) (see Fig. 44). Factory wiring is completed through harnesses connected to the CTB thermostat. Field connections are made at a 16-pole terminal block (TB1) located on the bottom shelf of the unit control box in front of the PremierLink controller. The factory-installed PremierLink control

includes the supply-air temperature (SAT) sensor. The outdoor air temperature (OAT) sensor is included in the FIOP/accessory EconoMi$er2 package.
The PremierLink controller requires the use of a Carrier electronic thermostat or a CCN connection for time broadcast to initiate its internal time-clock. This is necessary for broadcast of time of day functions (occupied/unoccupied).
NOTE: PremierLink controller is shipped in Sensor mode. To be used with a thermostat, the PremierLink controller must be configured to Thermostat mode. Refer to PremierLink Configuration instructions for Operating Mode.
See Fig. 45 for typical PremierLink wiring. See Fig. 46 for typical PremierLink wiring when the 48TC unit is equipped with a Humidi-MiZer® system.

Fig. 43 -- PremierLink Controller Fig. 44 -- 48TC Control Box -- PremierLink Location
38

Fig. 45 -- PremierLink Wiring Schematic 39

Fig. 46 -- PremierLink Wiring Schematic with Humidi-MiZer® System 40

Supply Air Temperature (SAT) Sensor -- On FIOPequipped 48TC unit, the unit is supplied with a supply-air temperature (SAT) sensor (33ZCSENSAT). This sensor is a tubular probe type, approx 6-inches (152 mm) in length. It is a nominal 10-k ohm thermistor. The SAT is factory-wired.
The SAT probe is wire-tied to the supply-air opening (on the horizontal opening end) in its shipping position. Remove the sensor for installation. Re-position the sensor in the flange of the supply-air opening or in the supply air duct (as required by local codes), see Fig. 47. Drill or punch a 1/2-in. hole in the flange or duct. Use two field-supplied, self-drilling screws to secure the sensor probe in a horizontal orientation.

SUPPLY AIR TEMPERATURE SENSOR

SUPPLY AIR

RETURN AIR

ROOF CURB

Fig. 47 -- Typical Mounting Location for Supply Air Temperature (SAT) Sensor on Small Rooftop
Units
NOTE: Refer to PremierLink Installation, Start-up, and Configuration Instructions for complete PremierLink configuration, operating sequences and troubleshooting

information. Have a copy of this manual available at unit start-up. NOTE: The sensor must be mounted in the discharge airstream downstream of the cooling coil and any heating devices. Be sure the probe tip does not come in contact with any of the unit's heater surfaces.
Outdoor Air Temperature (OAT) Sensor -- The OAT is factory-mounted in the EconoMi$er2 (FIOP or accessory) system. It is a nominal 10k ohm thermistor attached to an eyelet mounting ring.
EconoMi$er2 -- The PremierLink control is used with the EconoMi$er2 (option or accessory) system for outdoor air management. The damper position is controlled directly by the PremierLink control; The EconoMi$er2 system has no internal logic device.
Outdoor air management functions can be enhanced with field-installation of these accessory control devices:
· Enthalpy control (outdoor air or differential sensors) · Space CO2 sensor · Outdoor air CO2 sensor
Refer to Table 25 for accessory part numbers.
PREMIERLINK FIELD CONNECTIONS -- Field connections for accessory sensor and input devices are made at the 16pole terminal block (TB1) located on the control box bottom shelf in front of the PremierLink control (see Fig. 45 and 46). Some input devices also require a 24-vac signal source; connect at CTB terminal R at "THERMOSTAT" connection strip for this signal source. See connections figures on following pages for field connection locations (and for continued connections at the PremierLink board inputs).
Table 26 provides a summary of field connections for units equipped with Space Sensor. Table 27 provides a summary of field connections for units equipped with Space Thermostat.

APPLICATION

Table 25 -- PremierLinkTM Sensor Usage

OUTDOOR AIR

RETURN AIR

OUTDOOR AIR

TEMPERATURE SENSOR TEMPERATURE SENSOR ENTHALPY SENSOR

RETURN AIR ENTHALPY SENSOR

Differential Dry Bulb

Temperature with PremierLink (PremierLink
requires 4-20 mA

Included -- CRTEMPSN001A00

Required -- 33ZCT55SPT or equivalent

Actuator)

Single Enthalpy with

PremierLink (PremierLink requires 4-20 mA

Included -- Not Used

Requires -- 33CSENTHSW

Actuator)

Differential Enthalpy with

PremierLink (PremierLink requires 4-20 mA

Included -- Not Used

Actuator)

Requires -- 33CSENTHSW
or equivalent

NOTE: CO2 Sensors (Optional): 33ZCSENCO2 -- Room sensor (adjustable). Aspirator box is required for duct mounting of the sensor.
33ZCASPCO2 -- Aspirator box used for duct-mounted CO2 room sensor. 33ZCT55CO2 -- Space temperature and CO2 room sensor with override. 33ZCT56CO2 -- Space temperature and CO2 room sensor with override and setpoint.

Requires -- 33CSENTSEN or equivalent

TB1 TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Table 26 -- Space Sensor Mode
FIELD CONNECTION T55-SEN/T56-SEN RMTOCC T55-SEN/T56-SEN CMPSAFE T56-SET FSD LOOP-PWR SPS IAQ-SEN FILTER
IAQ-COM/OAQ-COM/RH-COM CCN + (RED)
OAQ-SEN/RH-SEN CCN Gnd (WHT)
AUX OUT (Power Exhaust) CCN - (BLK)

INPUT SIGNAL Analog (10k thermistor)
Discrete, 24VAC Analog (10k thermistor)
Discrete, 24VAC Analog (10k thermistor)
Discrete, 24VAC Analog, 24VDC Discrete, 24VAC Analog, 4-20mA Discrete, 24VAC Analog, 4-20mA Digital, 5VDC Analog, 4-20mA Digital, 5VDC (Output) Discrete 24VAC Digital, 5VDC

T55 T56 CCN CMPSAFE FILTER

LEGEND -- Space Temperature Sensor -- Space Temperature Sensor -- Carrier Comfort Network® (communication bus) -- Compressor Safety -- Dirty Filter Switch

FSD IAQ OAQ RH SFS

-- Fire Shutdown -- Indoor Air Quality (CO2) -- Outdoor Air Quality (CO2) -- Relative Humidity -- Supply Fan Status

Table 27 -- Thermostat Mode

TB1 TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

FIELD CONNECTION RAT SEN G RAT SEN Y1 -- Y2
LOOP-PWR W1
IAQ-SEN W2
IAQ-COM/OAQ-COM/RH-COM CCN + (RED)
OAQ-SEN/RH-SEN CCN Gnd (WHT)
AUX OUT (Power Exhaust) CCN - (BLK)

INPUT SIGNAL Analog (10k thermistor)
Discrete, 24VAC Analog (10k thermistor)
Discrete, 24VAC --
Discrete, 24VAC Analog, 24VDC Discrete, 24VAC Analog, 4-20mA Discrete, 24VAC Analog, 4-20mA Digital, 5VDC Analog, 4-20mA Digital, 5VDC (Output) Discrete 24VAC Digital, 5VDC

T55 T56 CCN CMPSAFE FILTER

LEGEND -- Space Temperature Sensor -- Space Temperature Sensor -- Carrier Comfort Network® (communication bus) -- Compressor Safety -- Dirty Filter Switch

FSD IAQ OAQ RH SFS

-- Fire Shutdown -- Indoor Air Quality (CO2) -- Outdoor Air Quality (CO2) -- Relative Humidity -- Supply Fan Status

Space Sensors -- The PremierLink controller is factoryshipped configured for Space Sensor Mode. A Carrier T-55 or T-56 space sensor must be used. T-55 space temperature sensor provides a signal of space temperature to the PremierLink control. T-56 provides same space temperature signal plus it allows for adjustment of space temperature setpoints from the face of the sensor by the occupants, see Fig. 48.

6 RED(+)

WHT(GND)

BLK(-)

SW1

SEN

BRN (GND) BLU (SPT)

CCN COM SENSOR WIRING

Fig. 48 -- T-55 Space Temperature Sensor Wiring

Connect T-55 -- See Fig. 49 for typical T-55 internal connections. Connect the T-55 SEN terminals to TB1 terminals 1 and 3 (see Fig. 49).

SEN

TB3

J6-7

SEN

J6-6

Fig. 49 -- PremierLink T-55 Sensor
Connect T-56 -- See Fig. 50 for T-56 internal connections. Install a jumper between SEN and SET terminals as illustrated. Connect T-56 terminals to TB1 terminals 1, 3, and 5 (see Fig. 51).
Connect Thermostat -- A 7-wire thermostat connection requires a 24-v power source and a common connection. Use the R and C terminals on the CTB's THERMOSTAT connection strip for these. Connect the thermostat's Y1, Y2, W1, W2 and G terminals to PremierLink TB1 as shown in Fig. 52.
If the 48TC unit is equipped with factory-installed smoke detector(s), disconnect the factory BLU lead at TB1-6 (Y2) before connecting the thermostat. Identify the BLU lead originating at CTB-DDC-1; disconnect at TB1-6 and tape off. Confirm that the second BLU lead at TB1-6 remains connected to PremierLink J4-8.

6 RED(+)

WHT(GND)

BLK(-)

SEN

SET

SW1

BLK

(T56)

BRN (GND) BLU (SPT)

CCN COM
SENSOR WIRING
JUMPER TERMINALS AS SHOWN

Cool

Warm

Fig. 50 -- T-56 Internal Connections

SEN

TB1

J6-7

SEN SET

Jumper

TB1 3

PL J6-6

SET

J6-5

Fig. 51 -- PremierLink T-56 Sensor

SPACE THERMOSTAT

CTB THERMOSTAT

TB1

J4-12

J4-10

J4-8

J4-6

J4-4

CTB

THERMOSTAT

Fig. 52 -- Space Thermostat Connections

If the 48TC unit has an economizer system and free-cooling operation is required, a sensor representing Return Air Temperature must also be connected (field-supplied and installed). This sensor may be a T-55 Space Sensor (see Fig. 48) installed in the space or in the return duct, or it may be sensor PNO 33ZCSENSAT, installed in the return duct. Connect this sensor to TB1-1 and TB1-3 per Fig. 49.
Configure the Unit for Thermostat Mode -- Connect to the CCN bus using a CCN service tool and navigate to PremierLink Configuration screen for Operating Mode. Default setting is Sensor Mode (value 1). Change the value to 0 to reconfigure the controller for Thermostat Mode.
When the PremierLink is configured for Thermostat Mode, these functions are not available: Fire Shutdown (FSD), Remote Occupied (RMTOCC), Compressor Safety (CMPSAFE), Supply Fan Status (SFS), and Filter Pressure Switch (FILTER).
ECONOMIZER CONTROLS
Indoor Air Quality (CO2) Sensor -- The indoor air quality sensor accessory monitors space carbon dioxide (CO2) levels. This information is used to monitor IAQ levels. Several types of sensors are available, for wall mounting in the space or in return duct, with and without LCD display, and in combination with space temperature sensors. Sensors use infrared technology to measure the levels of CO2 present in the space air.
The CO2 sensors are all factory set for a range of 0 to 2000 ppm and a linear mA output of 4 to 20. Refer to the instructions supplied with the CO2 sensor for electrical requirements and terminal locations. See Fig. 53 for typical CO2 sensor wiring schematic.

Wiring the Indoor Air Quality Sensor -- For each sensor, use two 2-conductor 18 AWG (American Wire Gage) twisted-pair cables (unshielded) to connect the separate isolated 24 vac power source to the sensor and to connect the sensor to the control board terminals.
To connect the sensor to the control, identify the positive (4 to 20 mA) and ground (SIG COM) terminals on the sensor. See Fig. 48. Connect the 4-20 mA terminal to terminal TB1-9 and connect the SIG COM terminal to terminal TB1-11. See Fig. 54.

IAQ Sensor 24 VAC

SEN COM

TB1

J5-5

TB1

J5-3

Fig. 54 -- Indoor CO2 Sensor (33ZCSENCO2) Connections
Refer to PremierLink Installation, Start-up, and Configuration Instructions, for detailed configuration information.
Outdoor Air Quality Sensor (P/N: 33ZCSENCO2 Plus Weatherproof Enclosure) -- The outdoor air CO2 sensor is designed to monitor carbon dioxide (CO2) levels in the outside ventilation air and interface with the ventilation damper in an HVAC system. The OAQ sensor is packaged with an outdoor cover. See Fig. 55. The outdoor air CO2 sensor must be located in the economizer outside air hood.

H G 24 VAC OR
+ - 24 VDC 2 1
J3

8 7654 32 1 J4

+ 0-10VDC - SIG COM + 4-20mA
}NC ALARM
COM RELAY NO CONTACTS

Fig. 53 -- Indoor/Outdoor Air Quality (CO2) Sensor (33ZCSENCO2) -- Typical Wiring Diagram
To accurately monitor the quality of the air in the conditioned air space, locate the sensor near a return-air grille (if present) so it senses the concentration of CO2 leaving the space. The sensor should be mounted in a location to avoid direct breath contact.
Do not mount the IAQ sensor in drafty areas such as near supply ducts, open windows, fans, or over heat sources. Allow at least 3 ft (0.9 m) between the sensor and any corner. Avoid mounting the sensor where it is influenced by the supply air; the sensor gives inaccurate readings if the supply air is blown directly onto the sensor or if the supply air does not have a chance to mix with the room air before it is drawn into the return airstream.

COVER REMOVED

SIDE VIEW

Fig. 55 -- Outdoor Air Quality Sensor Cover
Wiring the Outdoor Air CO2 Sensor -- A dedicated power supply is required for this sensor. A two-wire cable is required to wire the dedicated power supply for the sensor. The two wires should be connected to the power supply and terminals 1 and 2.
To connect the sensor to the control, identify the positive (4 to 20 mA) and ground (SIG COM) terminals on the OAQ sensor. See Fig. 48. Connect the 4 to 20 mA terminal to the TB113 terminal of the 48TC. Connect the SIG COM terminal to the TB1-11 terminal of the 48TC unit. See Fig. 56.

OAQ Sensor/RH Sensor SEN

TB1

J5-2

COM

TB1

J5-3

24 VAC

Fig. 56 -- Outdoor CO2 Sensor Connections

NOTE: The accessory space relative humidity sensor and humidistat are not available for single phase (-3 voltage code) models. Space Relative Humidity Sensor Connections -- The accessory space relative humidity sensor (33ZCSENSRH-01) is installed on an interior wall to measure the relative humidity of the air within the occupied space.
The use of a standard 2 X 4 inch electrical box to accommodate the wiring is recommended for installation. The sensor can be mounted directly on the wall, if acceptable by local codes.
CAUTION
Failure to follow this caution may result in permanent damage to the sensor.
DO NOT clean or touch the sensing element with chemical solvents as they can permanently damage the sensor.
CAUTION
Failure to follow this caution will result in inaccurate sensor readings.
DO NOT mount the sensor in drafty areas such as near heating or air-conditioning ducts, open windows, fans, or over heat sources such as baseboard heaters, radiators, or wall-mounted dimmers. Sensors mounted in those areas will produce inaccurate readings.
If the sensor is installed directly on a wall service, install the humidity sensor using 2 screws and 2 hollow wall anchors (field supplied). Do not over tighten screws. See Fig. 57.

MOUNTING HOLES

Io Vin Gnd Vo

WIRING OPENING

SW2

ON 1 2 34 5 6

Fig. 57 -- Space Relative Humidity Sensor Installation
The sensor must be mounted vertically on the wall. The Carrier logo should be orientated correctly when the sensor is properly mounted.
Avoid corner locations. Allow at least 4 ft between the sensor and any corner. Airflow near corners tends to be reduced, resulting in erratic sensor readings. The sensor should be vertically mounted approximately 5 ft up from the floor, beside the space temperature sensor.
For wiring distances up to 500 feet, use a 3-conductor, 18 or 20 AWG cable. A CCN communication cable can be used,

although the shield is not required. The shield must be removed from the sensor end of the cable if this cable is used. See Fig. 58 for wiring details.
TB1-7
TB1-13
Io Vin Gnd Vo
Fig. 58 -- Space Relative Humidity Sensor Connection
The power for the sensor is provided by the PremierLink control on terminal J5-4 (+33 to +35vdc). To Wire the Sensor 1. At the sensor, remove 4 inches of the jacket from the
cable. Strip ¼ inch of insulation from each conductor. Route the cable through the wire clearance opening in the center of the sensor. See Fig. 57. 2. Connect a field-supplied BLACK wire to the sensor screw terminal marked Vin. 3. Connect a field-supplied RED wire into the sensor screw terminal marked Io. 4. Connect the field-supplied RED wire from the sensor to TB1-13. 5. Connect the field-supplied BLACK wire from the sensor to TB1-7. Smoke Detector/Fire Shutdown (FSD) -- This function is available only when PremierLink is configured for (Space) Sensor Mode. The unit is factory-wired for PremierLink FSD operation when PremierLink is factory-installed. On 48TC units equipped with factory-installed Smoke Detector(s), the smoke detector controller implements the unit shutdown through its NC contact set connected to the unit's CTB input. The FSD function is initiated via the smoke detector's Alarm NO contact set. The PremierLink communicates the smoke detector's tripped status to the CCN building control. See Fig. 40 and 41, PremierLink wiring schematics. Filter Status Switch -- This function is available only when PremierLink is configured for (Space) Sensor Mode. PremierLink control can monitor return filter status in two ways: By monitoring a field-supplied/installed filter pressure switch or via supply fan runtime hours. Using switch input: Install the dirty filter pressure switch according to switch manufacturer's instructions, to measure pressure drop across the unit's return filters. Connect one side of the switch's NO contact set to CTB's THERMOSTAT-R terminal. Connect the other side of the NO contact set to TB1-10. Setpoint for Dirty Filter is set at the switch. See Fig. 59.

BLACK RED

Filter Switch (NO, close on rising pressure (high drop))
CTB Thermostat
R

TB1

J4-4

Fig. 59 -- PremierLink Filter Switch Connection
When the filter switch's NO contact set closes as filter pressure drop increases (indicating dirt-laden filters), the input signal to PremierLink causes the filter status point to read "DIRTY".
Using Filter Timer Hours -- Refer to PremierLink Installation, Start-up, and Configuration Instructions for instructions on using the PremierLink Configuration screens and on unit alarm sequence.
Supply Fan Status Switch -- The PremierLink control can monitor supply fan operation through a field-supplied/installed differential pressure switch. This sequence will prevent (or interrupt) operation of unit cooling, heating and economizer functions until the pressure switch contacts are closed indicating proper supply fan operation.
Install the differential pressure switch in the supply fan section according to switch manufacturer's instructions. Arrange the switch contact to be open on no flow and to close as pressure rises indicating fan operation.
Connect one side of the switch's NO contact set to CTB's THERMOSTAT-R terminal. Connect the other side of the NO contact set to TB1-8. Setpoint for Supply Fan Statuses set at the switch. See Fig. 60.

Fan (Pressure) Switch (NO, close on rise in pressure) CTB
Thermostat
R

TB1

J4-6

Fig. 60 -- PremierLink Wiring Fan Pressure Switch Connection

Remote Occupied Switch -- The PremierLink control permits a remote time-clock to override the control's on-board occupancy schedule and place the unit into Occupied mode. This function may also provide a "Door Switch" time delay function that will terminate cooling and heating functions after a 2-20 minute delay.

Connect one side of the NO contact set on the timeclock to CTB's THERMOSTAT-R terminal. Connect the other side of the timeclock contact to the unit's TB1-2 terminal (see Fig. 61).

Remote Occupied

CTB Thermostat
R

Time Clock

TB1

J4-12

Fig. 61 -- PremierLink Wiring Remote Occupied
Refer to PremierLink Installation, Start-up, and Configuration Instructions, for additional information on configuring the PremierLink control for Door Switch timer function.

Power Exhaust (Output) -- Connect the accessory Power Exhaust contactor coil(s) per Fig. 62.

Power Exhaust PEC TAN

TB1

J8-3

CTB THERMOSTAT

GRA

Fig. 62 -- PremierLink Power Exhaust Output Connection
NOTE: The Power Exhaust and Humidi-MiZer® options can not be used with PremierLink controller at the same time as both options require connection at TB1-15 (AUX OUT).
CCN Communication Bus -- The PremierLink controller connects to the bus in a daisy chain arrangement. Negative pins on each component must be connected to respective negative pins, and likewise, positive pins on each component must be connected to respective positive pins. The controller signal pins must be wired to the signal ground pins. Wiring connections for CCN must be made at the 3-pin plug.
At any baud (9600, 19200, 38400 baud), the number of controllers is limited to 239 devices maximum.
Bus length may not exceed 4000 ft, with no more than 60 total devices on any 1000-ft section. Optically isolated RS-485 repeaters are required every 1000 ft.
NOTE: Carrier device default is 9600 band.

Communications Bus Wire Specifications -- The CCN Communication Bus wiring is field-supplied and field-installed. It consists of shielded 3-conductor cable with drain (ground) wire. The cable selected must be identical to the CCN Communication Bus wire used for the entire network.
See Table 28 for recommended cable.

Table 28 -- Recommended Cables

MANUFACTURER

CABLE PART NO.

Alpha

2413 or 5463

American

A22503

Belden

8772

Columbia

02525

NOTE: Conductors and drain wire must be at least 20 AWG, stranded, and tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of -20 C to 60 C is required. Do not run communication wire in the same conduit as or next to any AC voltage wiring.
The communication bus shields must be tied together at each system element. If the communication bus is entirely within one building, the resulting continuous shield must be connected to ground at only one single point. If the communication bus cable exits from one building and enters another building, the shields must be connected to the grounds at a lightning suppressor in each building (one point only).

Connecting CCN Bus
NOTE: When connecting the communication bus cable, a color code system for the entire network is recommended to simplify installation and checkout. See Table 29 for the recommended color code.

Table 29 -- Color Code Recommendations

SIGNAL TYPE

CCN BUS WIRE COLOR

CCN PLUG PIN NUMBER

Red

Ground

White

Black

Connect the CCN (+) lead (typically RED) to the unit's TB1-12 terminal. Connect the CCN (ground) lead (typically WHT) to the unit's TB1-14 terminal. Connect the CCN (-) lead (typically BLK) to the unit's TB1-16 terminal. See Fig. 63.

CCN Bus + (RED) GND (WHT) (BLK)

TB1

J2-1

TB1

J2-2

TB1

J2-3

RTU OPEN CONTROL SYSTEM -- The RTU Open control is factory-mounted in the 48TC unit's main control box, to the left of the CTB. See Fig. 64. Factory wiring is completed through harnesses connected to the CTB. Field connections for RTU Open sensors will be made at the Phoenix connectors on the RTU Open board. The factory-installed RTU Open control includes the supply-air temperature (SAT) sensor. The outdoor air temperature (OAT) sensor is included in the FIOP/accessory EconoMi$er2 package.
The RTU Open controller is an integrated component of the Carrier rooftop unit. Its internal application programming provides optimum performance and energy efficiency. RTU Open enables the unit to run in 100% stand-alone control mode, Carrier's I-Vu® Open network, or a third party building automation system (BAS). On-board DIP switches allow you to select your protocol (and baud rate) of choice among the four most popular protocols in use today: BACnet*, Modbus, Johnson N2 and LonWorks** (see Fig. 65 and 66).
Refer to Table 30, RTU Open Controller Inputs and Outputs for locations of all connections to the RTU Open board.

Fig. 63 -- PremierLink CCN Bus Connections
Board Power

Configurable - Input_8 24 VAC
Configurable - Input_5 24 VAC
Configurable - Input_3 24 VAC
Input_9 (Humidistat) 24 VAC
24 VAC Input _8 (Enthalpy)
AO-1 (ECON) Gnd
(OAT) Gnd
(SAT)
Input_5 (SMK) Input_4 (R) BO-5 (Y1) BO-4 (Y2) BO-3 (W1) BO-2 (W2) BO-1 (G) Gnd Input_3 (X) 24 VAC IN
+24 VDC Input_2 (CO2/RH)
Gnd +24 VDC Input_1 (CO2/RH)
Gnd

(AO-1)

0-10VDC

4-20mA

BO-1

BO-2

BO-3

BO-4

BO-5

3-Volt Lithium Battery

J13

J22

AO-2

BO-6

GND

(2-10V)

BO-7

BO-8

J22
VFD Output
J11
BO-6 (H) Humidimizer BO-7 (Reversing Valve/High Speed Fan/Y3)
BO-8 (Power Exhaust)

LonWorks Option Card Port

J12

J17
Network Comm

J15
Example set for BACnet MS/TP and 76.8K baud (1, 2, and 4 ON) Recommended for all i-Vu Open installations

Protocol Selector

J20

*Remove both for 0-5V

SPT (temp input) SPT (common) SPT (offset input)

J19

J14

BACnet, Modbus, or N2 (LON connection J15)

Fig. 64 -- RTU Open Multi-Protocol Control Board

* BACnet is a registered trademark of ASHRAE (American Society of Heating, Refrigerating and Air-Conditioning Engineers).
Modbus is a registered trademark of Schneider Electric.
47 ** LonWorks is a registered trademark of Echelon Corporation.

Fig. 65 -- Typical RTU Open System Control Wiring Diagram 48

Fig. 66 -- Typical RTU Open System Control Wiring Diagram with Humidi-MiZer® System 49

POINT NAME Space Temp / Zone Temp

Table 30 -- RTU Open Controller Inputs and Outputs

BACNET OBJECT NAME

TYPE OF I/O

CONNECTION PIN NUMBER (S)

CHANNEL DESIGNATION

DEDICATED INPUTS

zone_temp

AI (10K Thermistor)

J201 & 2

Analog Input 10

Supply Air Temperature

sa_temp

AI (10K Thermistor)

J21 & 2

Analog Input 6

Outside Air Temperature Space Temperature Offset Pot Safety Chain Feedback

oa_temp stpt_adj_offset safety_status

AI (10K Thermistor)
AI(100K Potentiometer)
BI (24 VAC)

J23 & 4 J203 & 4
J19

Analog Input 7 Analog Input 11 Binary Input 4

Compressor Safety Status1

comp_status

BI (24 VAC)

J12

Binary Input 3

Fire Shutdown Status

firedown_status

BI (24 VAC)

J110

Binary Input 5

Enthalpy Status

enthalpy_status

BI (24 VAC)

J26 & 7

Binary Input 8

Humidistat Input Status

humstat_status

BI (24 VAC)

J57 & 8

Binary Input 9

Zone Temperature

n/a

J1314

Rnet

CONFIGURABLE INPUTS4

Indoor Air CO2 Outdoor Air CO2 Space Relative Humidity Supply Fan Status2 Filter Status2 Door Contact2 Remote Occupancy Input2 IGC Input2

iaq oaq space_rh sfan_status filter_status door_contact_status occ_contact_status igcovr_status

AI (420 mA) AI (420 mA) AI (420 mA) BI (24 VAC) BI (24 VAC) BI (24 VAC) BI (24 VAC) BI (24 VAC)
OUTPUTS

J42 & 3 or J45 & 6

Analog Input 2 Analog Input 1 Analog Input 10

J51 & 2 or
J53 & 4, J55 & 6 or J57 & 83

Binary Input 3, 5, 8, or 9, except where intrinsic input is used
Binary Input 3, 5, 8, or 9, except where intrinsic input is used
Binary Input 3, 5, 8, or 9, except where intrinsic input is used
Binary Input 3, 5, 8, or 9, except where intrinsic input is used
Binary Input 9. Mandatory input on gas heat units.

Economizer Output

econ_output

AO (420mA)

J25

Analog Output 1

Supply Fan VFD

vfd_output

AO (210Vdc)

J221 & 2

Analog Output 2

Supply Fan Relay Cool 1 Relay State Cool 2 Relay State Cool 3 Relay State Heat 1 Relay State Heat 2 Relay State Power Exhaust Relay State Dehumidification Relay

sfan comp_1 comp_2 comp_3 heat_1 heat_2
pexh dehum

BO Relay (24VAC, 1A)
BO Relay (24VAC, 1A)
BO Relay (24VAC, 1A)
BO Relay (24VAC, 1A)
BO Relay (24VAC, 1A)
BO Relay (24VAC, 1A)
BO Relay (24VAC, 1A)
BO Relay (24VAC, 1A)

J14
J18
J17
J115 & 6
J16
J15 J112 & 3
(N.O.) J117 & 8
(N.O.)

Binary Output 1 (G) Binary Output 5 (Y1) Binary Output 4 (Y2) Binary Output 7 (Y3) Binary Output 3 (W1) Binary Output 2 (W2) Binary Output 8 (PE) Binary Output 6

LEGEND

AI -- Analog Input
AO -- Analog Output
BI -- Binary Input
BO -- Binary Output 1. Safety Chain Feedback: 24Vac required at this terminal to provide "Run Enable" status. See Input/Output section for additional instructions. 2. These inputs are configurable. If installed, they take the place of the default input on the specific channel. See appropriate Input Configuration Sec-
tion for wiring and setup instructions. 3. Parallel pins J51 = J26, J53 = J110, J55 = J12 are used for field installation. 4. Refer to the input configuration and accessory sections of the RTU Open MultiProtocol Controller Controls, StartUp, Operation and Troubleshoot-
ing manual for more detail.

Supply Air Temperature (SAT) Sensor (33ZCSENSAT) -- This sensor is supplied with the 48TC unit. This sensor is a tubular probe type, approx 6-inches (152 mm) in length. It is a nominal 10-k ohm thermistor.
The SAT is factory-wired. The SAT probe is wire-tied to the supply-air opening (on the horizontal opening end) in its shipping position. Remove the sensor for installation. Re-position the sensor in the flange of the supply-air opening or in the supply air duct (as required by local codes). Drill or punch a 1/ 2-in. hole in the flange or duct. Use two field-supplied, selfdrilling screws to secure the sensor probe in a horizontal orientation. See Fig. 47.
Outdoor Air Temperature (OAT) Sensor -- This sensor is factory-mounted in the EconoMi$er2 (FIOP or accessory). It is a nominal 10k ohm thermistor attached to an eyelet mounting ring.
EconoMi$er2 (option or accessory) -- The EconoMi$er 2 system is used with the RTU Open control for outdoor air management. The damper position is controlled directly by the RTU Open control; the EconoMi$er2 system has no internal logic device.
Outdoor air management functions can be enhanced with field-installation of these accessory control devices:
· Enthalpy control (outdoor air or differential sensors) · Space CO2 sensor · Outdoor air CO2 sensor
RTU OPEN CONTROL SYSTEM FIELD CONNEC-
TIONS -- Field connections for accessory sensors and input devices are made the RTU Open, at plugs J1, J2, J4, J5, J11 and J20. All field control wiring that connects to the RTU Open must be routed through the raceway built into the corner post as shown in Fig. 32.
The raceway provides the UL required clearance between high and low-voltage wiring. Pass the control wires through the hole provided in the corner post, then feed the wires thorough the raceway to the RTU Open. Connect to the wires to the removable Phoenix connectors and then reconnect the connectors to the board.
Space Temperature (SPT) Sensors -- There are two types of SPT sensors available from Carrier, resistive input non-communicating (T55, T56, and T59) and Rnet communicating (SPS, SPPL, SPP, and SPPF) sensors. Each type has a variety of options consisting of: timed override button, set-point adjustment, a LCD screen, and communication tie in. Space temperature can be also be written to from a building network or zoning system. However, it is still recommended that return air duct sensor be installed to allow stand-alone operation for back-up. Refer to the configuration section for details on controller configurations associated with space sensors.
· 33ZCT55SPT, space temperature sensor with override button (T-55)
· 33ZCT56SPT, space temperature sensor with override button and set-point adjustment (T-56)
· 33ZCT59SPT, space temperature sensor with LCD (liquid crystal display) screen, override button, and setpoint adjustment (T-59)
Use 20 gauge wire to connect the sensor to the controller. The wire is suitable for distances of up to 500 ft. Use a threeconductor shielded cable for the sensor and setpoint adjustment connections. If the setpoint adjustment (slidebar) is not required, then an unshielded, 18 or 20 gauge, two-conductor, twisted pair cable may be used.

Connect T- 55 -- See Fig. 43 for typical T-55 internal connections. Connect the T-55 SEN terminals to RTU Open J20-1 and J20-2. See Fig. 67.

SEN

J20-1

SEN

J20-2

Fig. 67 -- RTU Open T-55 Sensor Connections
Connect T- 56 -- See Fig. 45 for T-56 internal connections. Install a jumper between SEN and SET terminals as illustrated. Connect T-56 terminals to RTU Open J20-1, J20-2 and J20-3 per Fig. 68.

SEN

J20-1

SEN SET

Jumper

J20-2

SET

J20-3

Fig. 68 -- RTU Open T-56 Sensor Connections

Connect T-59 -- The T-59 space sensor requires a separate, isolated power supply of 24 VAC. See Fig. 69 for internal connections at the T-59. Connect the SEN terminal (BLU) to RTU Open J20-1. Connect the COM terminal (BRN) to J20-2. Connect the SET terminal (STO or BLK) to J20-3.

BLK (STO)

J20-3

BRN (COM) BLU (SPT)

J20-2

SENSOR WIRING

J20-1

OR SET SEN

OPB COM- PWR+

24 VAC

POWER WIRING

NOTE: Must use a separate isolated transformer.

Fig. 69 -- Space Temperature Sensor Typical Wiring (33ZCT59SPT)
Indoor Air Quality (CO2) Sensor -- The indoor air quality sensor accessory monitors space carbon dioxide (CO2) levels. This information is used to monitor IAQ levels. Several types of sensors are available, for wall mounting in the space or in return duct, with and without LCD display, and in combination with space temperature sensors. Sensors use infrared technology to measure the levels of CO2 present in the space air.
The CO2 sensors are all factory set for a range of 0 to 2000 ppm and a linear mA output of 4 to 20. Refer to the instructions supplied with the CO2 sensor for electrical requirements and terminal locations. See Fig. 53 for typical CO2 sensor wiring schematic.

To accurately monitor the quality of the air in the conditioned air space, locate the sensor near a return-air grille (if present) so it senses the concentration of CO2 leaving the space. The sensor should be mounted in a location to avoid direct breath contact.
Do not mount the IAQ sensor in drafty areas such as near supply ducts, open windows, fans, or over heat sources. Allow at least 3 ft (0.9 m) between the sensor and any corner. Avoid mounting the sensor where it is influenced by the supply air; the sensor gives inaccurate readings if the supply air is blown directly onto the sensor or if the supply air does not have a chance to mix with the room air before it is drawn into the return airstream.
Wiring the Indoor Air Quality Sensor -- For each sensor, use two 2-conductor 18 AWG (American Wire Gage) twisted-pair cables (unshielded) to connect the separate isolated 24 vac power source to the sensor and to connect the sensor to the control board terminals.
To connect the sensor to the control, identify the positive (4 to 20 mA) and ground (SIG COM) terminals on the sensor. See Fig. 53. Connect the 4-20 mA terminal to RTU Open J4-2 and connect the SIG COM terminal to RTU Open J4-3. See Fig. 70.
IAQ Sensor

SEN

J4-2

COM

J4-3

24 VAC

Fig. 70 -- RTU Open/Indoor CO2 Sensor (33ZCSENCO2) Connections
Outdoor Air Quality Sensor (P/N 33ZCSENCO2 plus weatherproof enclosure) -- The sensor is designed to monitor carbon dioxide (CO2) levels in the outside ventilation air and interface with the ventilation damper in an HVAC system. The OAQ sensor is packaged with an outdoor cover. See Fig. 55. The outdoor air CO2 sensor must be located in the economizer outside air hood.
Wiring the Outdoor Air CO2 Sensor -- A dedicated power supply is required for this sensor. A two-wire cable is required to wire the dedicated power supply for the sensor. The two wires should be connected to the power supply and terminals 1 and 2.
To connect the sensor to the control, identify the positive (4 to 20 mA) and ground (SIG COM) terminals on the OAQ sensor. See Fig. 53. Connect the 4 to 20 mA terminal to RTU Open J4-5. Connect the SIG COM terminal to RTU Open J4-6. See Fig. 71.
OAQ Sensor

SEN

J4-5

COM

J4-6

24 VAC

Fig. 71 -- RTU Open / Outdoor CO2 Sensor (33ZCSENCO2) Connections
Space Relative Humidity Sensor or Humidistat
NOTE: The accessory space relative humidity sensor and humidistat are not available for single phase (-3 voltage code) models.

Humidi-MiZer® Control Wiring -- In units equipped with the Humidi-MiZer option there are two pink (PNK) wires loose in the control box used to control the dehumidification function of the unit. These pink wires are meant to be tied to a space humidistat or thermidistat on an electromechanical unit. On RTU Open equipped units these pink wires must be connected to J11-7 and 8 to allow the Open board to operate the dehumidification function for the unit. Disconnect the J11 Phoenix style connector from the board and use the plug screws to secure the pink wires in pins 7 and 8, reconnect the plug to the board at J11.
NOTE: The Humidi-MiZer system is a factory-installed option which is available for 07 models only.
Relative Humidity Sensors (Space or Duct Mounted) -- The accessory space humidity sensor (33ZCSENSRH-01) or duct humidity sensor (33ZCSENDRH-01) is used to measure the relative humidity of air within the space or return air duct. The RH reading is used to control the Humidi-MiZer option of the rooftop unit. For wiring distances up to 500 ft (152 m), use a 3-conductor, 18 or 20 AWG shielded cable. The shield must be removed from the sensor end of the cable and grounded at the unit end. The current loop power for sensor is provided by the RTU Open controller as 24vdc. Refer to the instructions supplied with the RH sensor for the electrical requirements and terminal locations. RTU Open configurations must be changed after adding an RH sensor. See Fig. 72 and 73 for typical RH sensor wiring.
· J4-1 or J4-4 = 24vdc loop power · J4-2 or J4-5 = 4-20mA signal input
NOTE: The factory default for dehumidification control is normally open humidistat.

MOUNTING HOLES

Io Vin Gnd Vo

WIRING OPENING

ON 1 2 34 5 6

SW2
Vin - J4-1 or J4-4 24Vdc Io - J4-2 or J4-5 -20mA output
Fig. 72 -- Space Relative Humidity Sensor Typical Wiring
Humidistat -- The accessory humidistat provides the RTU Open insight to the relative humidity in the space. The humidistat reads the RH level in the space and compares it to its setpoint to operate a dry contact. The humidistat is a dedicated input on the configurable input 9 and tells the RTU Open when the RH level is HIGH or LOW. The normal condition for hu-

midity is LOW. A normally open humidistat is the factory default control for the Humidi-MiZer® option.

J4-1 or J4-4 + 24 VDC SUPPLY VOLTAGE
J4-2 or J4-5 (-)4 to 20 mA Current LOOP OUTPUT TO RTU OPEN

SPAN ZERO

RELATIVE HUMIDITY SENSOR (POLARIZED MALE CONNECTOR)

4-20 VAC GND 0-5V

mA or

VDC

0-10V

ON 123456

Fig. 73 -- Duct Relative Humidity Sensor Typical Wiring
To wire in the field:
· J5-8 = 24 VAC source for dry contact · J5-7 = Signal input
Smoke Detector/Fire Shutdown (FSD) -- This control is installed on 48TC units equipped with factory-installed Smoke Detector(s). The smoke detector controller implements the unit shutdown through its NC contact set connected to the unit's CTB input. The FSD function is initiated via the smoke detector's Alarm NO contact set. The RTU Open controller communicates the smoke detector's tripped status to the BAS building control. See Fig. 65 and 66, the RTU Open System Control wiring schematics.
The Fire Shutdown Switch configuration, MENU>Config>Inputs>input 5, identifies the normally open status of this input when there is no fire alarm.
Connecting Discrete Inputs
Filter Status -- The filter status accessory is a fieldinstalled accessory. This accessory detects plugged filters. When installing this accessory, the unit must be configured for filter status by setting MENU>Config>Inputs>input 3, 5, 8, or 9 to Filter Status and normally open (N/O) or normally closed (N/C). Input 8 or 9 is recommended for easy of installation. Refer to Fig. 64-66 for wire terminations at J5.
Fan Status -- The fan status accessory is a field-installed accessory. This accessory detects when the indoor fan is blowing air. When installing this accessory, the unit must be configured

for fan status by setting MENU>Config>Inputs>input 3, 5, 8, or 9 to Fan Status and normally open (N/O) or normally closed (N/C). Input 8 or 9 is recommended for easy of installation. Refer to Fig. 64 and Fig. 65 or 66 for wire terminations at J5.
Remote Occupancy -- The remote occupancy accessory is a field-installed accessory. This accessory overrides the unoccupied mode and puts the unit in occupied mode. When installing this accessory, the unit must be configured for remote occupancy by setting MENU>Config>Inputs>input 3, 5, 8, or 9 to Remote Occupancy and normally open (N/O) or normally closed (N/C).
Also set MENU>Schedules>occupancy source to DI on/off. Input 8 or 9 is recommended for easy of installation. Refer to Fig. 64 and Table 30 for wire terminations at J5.
Power Exhaust (output) -- The relay used by the RTU Open board to control power exhaust is a dry contact which means it does not have 24vac. This 24vac must be connected to the relay to allow it to operate the power exhaust relay in the PE accessory. A 24vac source must be provided to J11-2 on the RTU Open control board. This can be provided by the unit's transformer from various sources. The "R" terminal on the unit's low voltage terminal board (LVTB) is a logical source. Refer to Fig. 64-66 for wire terminations at J11.
RTU OPEN COMMUNICATION WIRING-PROTOCOLS
General -- Protocols are the communication languages spoken by control devices. The main purpose of a protocol is to communicate information in the most efficient method possible. Different protocols exist to provide different kinds of information for different applications. In the BAS application, many different protocols are used, depending on manufacturer. Protocols do not change the function of a controller; just make the front end user different.
The RTU Open can be set to communicate on four different protocols: BACnet, Modbus, N2, and LonWorks. Switch 3 (SW3) on the board is used to set protocol and baud rate. Switches 1 and 2 (SW1 and SW2) are used to set the board's network address. See Fig. 74 and 75 for protocol switch settings and address switches. The third party connection to the RTU Open is through plug J19. See Fig. 76 for wiring.
NOTE: Power must be cycled after changing the SW1-3 switch settings.
Refer to the RTU Open v3 Integration Guide for more detailed information on protocols 3rd party wiring and networking.

SW3 PROTOCOL SELECTION

PROTOCOL

DS8

DS7

DS6

DS5

DS4

DS3

DS2

DS1

BACnet MS/TP (Master)

Unused

OFF

Select Baud Select Baud

Modbus (Slave)

Unused

OFF

Select Baud Select Baud

N2 Slave

Unused

OFF

LonWorks

Unused

OFF

LEGEND DS -- DIP Switch NOTE: BACnet MS/TP SW3 example shown.
Baud Rate Selection

COMM

OPTION

PORT

UNUSED

SET TO MSTP (MASTER)

SET TO 38.4k BAUD

BAUD RATE 9,600
19,200 38,400 76,800

DS2 OFF ON OFF ON

DS1 OFF OFF ON ON

(OFF) (ON)

PROTOCOL SELECTOR DIP SWITCHES
Fig. 74 -- RTU Open SW3 Dip Switch Settings

7 8
NET+ NETSHLD
7 8
COMM OPTION

MSB
90 1

LSB
90 1

2 3 2 3

4 5 6

SW1 SW2
Fig. 75 -- RTU Open Address Switches

J19

LOCAL ACCESS
Wall Mounted Equipment Touch -- The Equipment Touch is a wall mounted interface used to connect to the RTU Open to access the control information, read sensor values, and maintenance. This is an accessory interface that does not come with the RTU Open controller. Wire the Equipment Touch interface to the RTU Open's J13 local access port. There are 2 password protected levels in the display (User and Admin). See the Equipment Touch Installation and Setup Guide for more information. See Appendix A of the Equipment Touch Installation and Setup Guide for navigation and screen content.
Field Assistant -- Field Assistant is a computer program included with the purchase of the Tech Tool Kit (USB-TKIT). This is a field Tech Tool to set-up, service, or download application software to the RTU Open controller and includes a USB link cable. The link cable connects a USB port to the J12 local access port. The Field Assistant's menu structure is similar and functions the same as i-Vu® Open controller. See Fig. 77.
RTU Open Troubleshooting -- Troubleshooting is accomplished by viewing the communication LEDs. The LEDs indicate if the controller is speaking to the devices on the network. The LEDs should reflect communication traffic based on the baud rate set. The higher the baud rate the more solid the LEDs will appear. See Table 31 and Fig 77.

Fig. 76 -- Network Wiring

Access Port P1 P1
J12

Connect to computer's USB port

P5 P5

USB Link Kit

Connect to the Local Access port

Fig. 77 -- PC Running Field Assistant

MSB

LSB

CR2032

SW1

SW2

J15

SW3

LOCAL ACCESS
PORT
J12

RNET J13
+12 DVC RnetRnet+ GND

GND
GND
*Therm mA
*Therm mA

UI-10 UI-11

RX TX
J20

RTU Open Controller

Table 31 -- LEDs (The LEDs on the RTU Open show the status of certain functions)

IF THIS LED IS ON... Power Rx Tx DO#
2 Flashes Per Second 2 Flashes Per Second 2 Flashes Per Second
2 Flashes Per Second
2 Flashes Per Second 5 Flashes Per Second 5 Flashes Per Second 7 Flashes Per Second 14 Flashes Per Second
On

THE STATUS IS...

RTU Open has power

RTU Open is receiving data from the network segment

RTU Open is transmitting data over the network segment

The digital output is active

The Run and Error LEDs indicate control module and network status

Off

Normal

2 flashes, alternating with Run LED

Five minute auto-restart delay after system error

3 flashes, then off

Control module has just been formatted

4 flashes, then pause

Two or more devices on this network have the same ARC156

Network address

Exec start-up aborted, Boot is running

Off

Firmware transfer in progress, Boot is running

7 flashes per second, alternating with Run LED

Ten second recovery period after brownout

14 flashes per second, alternating with Run LED

Brownout

Failure. Try the following solutions:

· Turn RTU Open off, then on

· Format RTU Open

· Download memory to RTU Open

· Replace RTU Open

NOTE: Refer to the RTU Open Multi-Protocol Controller Controls, Start-Up, Operation and Troubleshooting manual for complete configuration of RTU Open, operating sequences and troubleshooting information. Refer to the RTU Open v3 Integration Guide for details on configuration and troubleshooting of connected networks. Have a copy of these manuals available at unit start-up.
OUTDOOR AIR ENTHALPY CONTROL
(PN: 33CSENTHSW) -- The enthalpy control is available as a field-installed accessory to be used with the EconoMi$er2 damper system. The outdoor air enthalpy sensor is part of the enthalpy control. (The separate field-installed accessory return air enthalpy sensor (33CSENTSEN) is required for differential enthalpy control (see Fig. 78).
Locate the enthalpy control in the economizer next to the Actuator Motor. Locate two GRA leads in the factory harness and connect the gray lead labeled "ESL" to the terminal labeled "LOW". See Fig. 78. Connect the enthalpy control power input terminals to economizer actuator power leads RED (connect to 24V) and BLK (connect to GND).

ditions. Install the outdoor air enthalpy control as described above. Add and install a return air enthalpy sensor.
Return Air Enthalpy Sensor (33SENTSEN) -- The sensor is mounted in the return-air section of the economizer. The return air sensor is wired to the enthalpy controller (33CSENTHSW). See Fig. 79.

4-20 MAIN
+ VDC OUT

24V RED

GND LOW

BLK GRA

OUTSIDE AIR ENTHALPY SWITCH

PL6-1 (24-V)

PL6-4 (COM)

CTB ECON (P'LINK: to J4-2) or

(RTU Open: to J2-6)

+ 24-36 VDC IN
4-20 MAIN OUT

RETURN AIR ENTHALPY SENSOR

48TC

Enthalpy Switch

24V GND

RED BLK

PL6-1 (24-V) PL6-4 (COM)

LOW GRA

7 CTB ECON (P'LINK: to J4-2) or (RTU Open: to J2-6)

FACTORY WIRING HARNESS

Fig. 78 -- Enthalpy Switch (33CSENTHSW) Connections
The outdoor enthalpy changeover setpoint is set at the enthalpy controller.
Differential Enthalpy Control -- Control is provided by sensing and comparing the outside air and return air enthalpy con-

Fig. 79 -- Outside and Return Air Enthalpy Sensor Wiring
SMOKE DETECTORS -- Smoke detectors are available as factory-installed options on 48TC models. Smoke detectors may be specified for Supply Air only or for Return Air without or with economizer or in combination of Supply Air and Return Air. All components necessary for operation are factoryprovided and mounted. The unit is factory-configured for immediate smoke detector shutdown operation; additional wiring or modifications to unit terminal board may be necessary to complete the unit and smoke detector configuration to meet project requirements.
Units equipped with factory-optional Return Air smoke detectors require a relocation of the sensor module at unit installation. See Fig. 80 for the as shipped location.

Return Air Smoke Detector (as shipped)

Completing Installation of Return Air Smoke Sensor
1. Unscrew the two screws holding the Return Air Smoke
Detector assembly. See Fig. 81, Step 1. Save the
screws.
2. Turn the assembly 90 and then rotate end to end. Make sure that the elbow fitting is pointing down. See Fig. 81, Step 2.
3. Screw the sensor and detector plate into its operating position using screws from Step 1. See Fig. 81, Step 3.
4. Connect the flexible tube on the sampling inlet to the sampling tube on the basepan.
Additional Application Data -- Refer to the application data sheet titled "Factory Installed Smoke Detector for Small and Medium Rooftop Units, 2 to 25 Tons" for discussions on additional control features of these smoke detectors including multiple unit coordination.

Fig. 80 -- Return Air Smoke Detector; Shipping Position

Step 1

Step 2

Step 3

Fig. 81 -- Completing Installation of Return Air Smoke Sensor

Fig. 82 -- EconoMi$er IV Wiring

Step 13 -- Adjust Factory-Installed Options
SMOKE DETECTORS -- Smoke detector(s) will be connected at the Controls Connections Board, at terminals marked "Smoke Shutdown". Cut jumper JMP 3 when ready to energize unit.
ECONOMI$ER IV OCCUPANCY SWITCH -- Refer to Fig. 82 for general EconoMi$er IV wiring. External occupancy control is managed through a connection on the Controls Connections Board.
If external occupancy control is desired, connect a time clock or remotely controlled switch (closed for Occupied, open for Unoccupied sequence) at terminals marked OCCUPANCY. Cut jumper JMP 2 to complete the installation.
Step 14 -- Install Accessories
Available accessories include:
· Curb · Thru-base connection kit (must be installed before unit is
set on curb) · LP conversion kit · Flue discharge deflector · Manual outside air damper · Two-Position motorized outside air damper · EconoMi$er IV (with control) · EconoMi$er2 (without control/for external signal)

· Power Exhaust · Differential dry-bulb sensor (EconoMi$er IV) · Outdoor enthalpy sensor · Differential enthalpy sensor · CO2 sensor · DDC interface (PremierLink) · Louvered hail guard · Motormaster® head pressure controls · Phase monitor control
Refer to separate installation instructions for information on installing these accessories.
Step 15 -- Check Belt Tension -- Measure the belt
span length as shown in Fig. 83. Calculate the required deflection by multiplying the belt span length by 1/64. For example, if the belt span length is 32 inches: 32 x 1/64 = 1/2 inch deflection.
BELT FORCE -- DEFLECTION METHOD -- Check the belt tension with a spring-force belt force deflection gauge (available from drive belt manufacturer).
1. Place a straightedge along the belt between the two
pulleys. Measure the distance between the motor shaft
and the blower shaft.
2. Set the tension gauge to the desired tension (see Table 1 in Fig. 83). Place the large O-ring at that point.

3. Press the tension checker downward on the belt until the large O-ring is at the bottom of the straightedge.
4. Adjust the belt tension as needed.
Adjust belt tension by loosing the motor mounting plate front bolts and rear bolt (see Fig. 84) and slide the plate towards the fan (to reduce tension) or away from the fan (to increase tension). Ensure the blower shaft and motor shaft are parallel to each other (pulleys aligned). Tighten all bolts securely when finished.
BELT TENSION METHOD -- Requires belt tension gauge that measures tension in belt in units of lbs force.

BLOWER PULLEY V-BELT
MOTOR PULLEY
MOTOR

BELT SMALLEST CROSS SHEAVE SECTION DIAMETER

A, AX B, BX

3.0-3.6 3.8-4.8 5.0-7.0 3.4-4.2 4.4-5.6 5.8-8.6

BELT CONDITION New Used

BELT DEFLECTION FORCE (LBS)

UNNOTCHED BELTS

NOTCHED BELTS

USED NEW USED NEW

3.7

5.5

4.1

6.1

4.5

6.8

5.0

7.4

5.4

8.0

5.7

8.4

4.9

7.2

5.3

7.9

7.1

10.5

6.3

9.4

8.5

12.6

Table 1

TENSION FORCE IN BELT (LBS) 100 80

Table 2

Fig. 83 -- V-Belt Force Label

MOUNTING BOLTS (4)

MOTOR MOUNTING PLATE

Fig. 84 -- Belt Drive Motor Mounting
Pre-Start and Start-Up -- This completes the mechan-
ical installation of the unit. Refer to the unit's Service Manual for detailed Pre-Start and Start-Up instructions. Download the latest versions from HVAC Partners (www.hvacpartners.com).

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53480140-01

Printed in U.S.A.

Form 48TC-4-7-03SI

Pg 58

1217 9-17

Replaces: 48TC-4-7-02SI

START-UP CHECKLIST -- 48TC PACKAGED ROOFTOP UNITS WITH GAS HEAT AND ELECTRIC COOLING
NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sections of this Installation Instruction document.

I. PRELIMINARY INFORMATION MODEL NO.JOB NAME ________________________ SERIAL NO. ADDRESS ________________________ START-UP DATE _____________________________ TECHNICIAN NAME __________________________ ADDITIONAL ACCESSORIES _____________________________________________________________________________________________________

II. PRE-START-UP

Verify that all packaging materials have been removed from unit (Y/N) _____ Verify installation of outdoor air hood (Y/N) _____ Verify installation of flue exhaust and inlet hood (Y/N) _____ Verify that condensate connection is installed per instructions verify that all electrical (Y/N) _____ Connections and terminals are tight (Y/N) _____ Verify gas pressure to unit gas valve is within specified range (Y/N) _____ Check gas piping for leaks (Y/N) _____ Check that indoor-air filters are clean and in place (Y/N) _____ Check that outdoor air inlet screens are in place (Y/N) _____ Verify that unit is level (Y/N) _____ Check fan wheels and propeller for location in housing/orifice and verify setscrew is tight (Y/N) _____ Verify that fan sheaves are aligned and belts are properly tensioned (Y/N) _____ Verify that scroll compressors are rotating in the correct direction (Y/N) _____ Verify installation of thermostat (Y/N) _____ Verify that crankcase heaters have been energized for at least 24 hours (Y/N) _____

II. START-UP
ELECTRICAL Supply Voltage Compressor Amps 1 Compressor Amps 2 Supply Fan Amps

L1-L2_____________ L1 _____________ L1 _____________ L1 _____________

L2-L3_____________ L2 _____________ L2 _____________ L2 _____________

L3-L1_____________ L3 _____________ L3 _____________ L3 _____________

TEMPERATURES Outdoor-air Temperature Return-air Temperature Cooling Supply Air Temperature Gas Heat Supply Air

_____________ °F DB (Dry Bulb) _____________ °F DB _____________ °F Wb (Wet Bulb) _____________ °F _____________ °F

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 05-53480140-01

Printed in U.S.A.

Form 48TC-4-7-03SI

Pg CL-1

1217 9-17

Replaces: 48TC-4-7-02SI

CUT ALONG DOTTED LINE

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PRESSURES

GAS INLET PRESSURE IN. WG

GAS MANIFOLD PRESSURE

STAGE 1 _____________ in.wg

STAGE 2 _____________ in.wg

REFRIGERANT SUCTION

CIRCUIT A _____________ PSIG

CIRCUIT B _____________ PSIG

REFRIGERANT DISCHARGE

CIRCUIT A _____________ PSIG

CIRCUIT B _____________ PSIG

VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS (Y/N) _____

GENERAL
Economizer minimum vent and changeover settings to job requirements (if equipped) (Y/N) _____ Verify smoke detector unit shutdown by utilizing magnet test (Y/N) _____
III. HUMIDI-MIZER® START-UP (48TC*B07 ONLY)

STEPS
1. Check CTB for jumper 5, 6, 7 (Jumper 5, 6, 7 must be cut and open) (Y/N) _____ 2. Open humidistat contacts (Y/N) _____ 3. Start unit In cooling (Close Y1) (Y/N) _____

OBSERVE AND RECORD

A. Suction pressure

_______________ PSIG

B. Discharge pressure

_______________ PSIG

C. Entering air temperature

_______________ ° F

D. Liquid line temperature at outlet or reheat coil _______________ ° F

E. Confirm correct rotation for compressor (Y/N) _____

F. Check for correct ramp-up of outdoor fan motor as condenser coil warms (Y/N) _____

4. Check unit charge per charging chart (Y/N) _____

(Jumper 32L Motormaster® temperature sensor during this check. Remove jumper when complete.)

5. Switch unit to high-latent mode (sub-cooler) by closing humidistat with Y1 closed (Y/N) _____

OBSERVE

A. Reduction in suction pressure (5 to 7 psi expected) (Y/N) _____ B. Discharge pressure unchanged (Limited by Motormaster) (Y/N) _____ C. Liquid temperature drops to 50 to 55 F range (Y/N) _____ D. LSV solenoid energized (valve closes) (Y/N) _____ 6. Switch unit to dehumid (reheat) by opening Y1 (Y/N) _____

OBSERVE
A. suction pressure increases to normal cooling level B. discharge pressure decreases (35 to 50 psi) C. liquid temperature returns to normal cooling level D. LSV solenoid energized (valve closes) E. DSV solenoid energized, valve opens 7. With unit in dehumid mode close W1 compressor and outdoor fan stop; LSV and DSV solenoids de-energized (Y/N) _____ 8. Open W1 restore unit to dehumid mode (Y/N) _____ 9. Open humidistat input compressor and outdoor fan stop; LSV and DSV solenoids de-energized (Y/N) _____ 10. Restore set-points for thermostat and humidistat (Y/N) _____

CUT ALONG DOTTED LINE

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 05-53480140-01

Printed in U.S.A.

Form 48TC-4-7-03SI

Pg CL-2

1217 9-17

Replaces: 48TC-4-7-02SI

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