Page 2 - attached to the; Instructions continued on page 28.
2 ROOF CURB — For vertical discharge units, assemble or in- stall accessory roof curb in accordance with instructions shipped with this accessory. See Fig. 1-4. Install insulation, cant strips, roofing, and counter flashing as shown. Ductwork can be installed to roof curb before unit is set in place...
Page 19 - Fig. 17 — Rigging Information; UNIT
19 48AJ,AK,AW,AY UNITS Fig. 17 — Rigging Information UNIT CENTER OF GRAVITY PERCENT OF TOTAL WEIGHT AT EACH CORNER (%) Inches Millimeters A B A B 1 2 3 4 48AJ,AKD020 72.4 42.2 1839 1072 21.0% 22.8% 29.2% 26.9% 48AJE020 73.3 42.7 1862 1085 21.6% 22.9% 28.6% 27.0% 48AW,AYD020 72.4 42.2 1839 1072 21.0%...
Page 20 - RIGGING WEIGHTS; hoods. Includes 45 lbs for the economizer hood packaging.
20 48EJ,EK,EW,EY UNITS RIGGING WEIGHTS 48AJ,AK,AW,AY UNITS *Includes outdoor-air hoods, filters, largest available indoor-fan motor, modulating power exhaust, and the largest available variablefrequency drive (VFD). NOTES: 1. Center of gravity. 2. On 020-050 includes 500 lbs and on 060 725 lbs for m...
Page 26 - Table 2 — Operating Weights
26 Table 2 — Operating Weights 48AJ,AK,AW,AY Units 48EJ,EK,EW,EY Units LEGEND *Outdoor-air hoods and filters included in base unit weights; indoor- fan motors are NOT included. NOTES: 1. Base unit weight includes outdoor-air hoods. Base unit weight does NOT include indoor-fan motor. ADD indoor-fan m...
Page 27 - Table 3 — Evaporator Fan Motor Data
27 Table 3 — Evaporator Fan Motor Data NOTES: 1. Motor shaft speed is 1750 rpm. The fan shaft diameter is 1 15 / 16 inches. 2. All indoor fan motors meet the minimum efficiency requirements as established by the Energy Policy Act of 1992 (EPACT), effectiveOctober 24, 1997. UNIT SIZE 48AJ,AK, AW,AY U...
Page 28 - TOP VIEW; Fig. 20A — Flue Hood Location
28 Step 5 — Install Flue Hood 48AJ,AK,AW,AY020-050 AND 48EJ,EK,EW,EY024-048 UNITS — Flue hood is shipped inside gas section of unit. To install, secure flue hood to access panel. See Fig. 20A.48AJ,AK,AW,AY060 AND 48EJ,EK,EW,EY054-068 UNITS — Flue hood and wind baffle are shipped inside gas section o...
Page 29 - Step 8 — Controls Options —; Table 4 — 48A,E Series Staged Gas Implementation
29 Size gas-supply piping for 0.5-in. wg maximum pressure drop. Do not use supply pipe smaller than unit gas connection. OPTIONAL STAGED GAS UNITS — The staging pattern is selected based on Heat Stage Type (HTSTGTYP). Max Capacity per changes default value is selected based on Capac- ity Maximum Sta...
Page 30 - Table 6 — Thermistor Designations
30 Table 5 — Controls Options and Configurations (Non-Thermostat Applications) LEGEND *With DIP Switch No. 5 configured to OPEN (Occupied Heat Enabled).NOTE: Space temperature sensor and remote start/stop switch are field-supplied. STAGED GAS UNIT APPLICATIONS — The rooftop units may be ordered with...
Page 31 - Fig. 24 — Supply-Air Thermistor Connections
31 Features with Thermostat Control of Unit• two-stage heating • two-stage cooling • control of unit using Y1, Y2, W1, W2, and G thermostat inputs • control of the indoor fan • outdoor-air temperature/supply-air temperature monitoring • control of an outdoor air condenser fan based on out- door-air ...
Page 32 - Fig. 25 — Indoor Air Quality Sensor Configuration; LEGEND; Fig. 26 — Field Control Remote Start/Stop; Field Supplied Wiring
32 An electronic expansion board may be field-installed to pro- vide the following features:• provide discrete inputs for fan status, filter status, field- applied status, and demand limit • provide an output for the external alarm light indicator • provide power exhaust fire outputs for direct cont...
Page 33 - Step 9 — Make Electrical Connections
33 • control of one stage of heat to maintain return-air tem- perature at heating set point during occupied periods • provide a variable frequency drive high voltage relay output to enable VFD • control of heat interlock relay • IAQ (Indoor Air Quality) sensor • OAQ (Outdoor Air Quality) sensor • DX...
Page 39 - See Legend and Notes on page 42.
39 Table 8 — Electrical Data — 48EJ,EK,EW,EY Units See Legend and Notes on page 42. UNIT SIZE 48EJ,EK, EW,EY NOMNAL VOLTAGE (3 Ph, 60 Hz) VOLTAGE RANGE COMPRESSOR OFM IFM POWER EXHAUST COMBUSTION FAN MOTOR POWER SUPPLY No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA FLA MCA MOCP* ...
Page 43 - Fig. 28 — Field Power Wiring Connections; GND —; Ground; NEC —; National Electrical Code; TB; Terminal Block
43 Routing Through Bottom of Unit — If wiring is brought in through bottom of unit, use field-supplied watertight conduit to run power wiring from basepan out through bottom 3 1 / 2 -in. hole to the disconnect box and back into unit to the main con- trol box. Use strain relief going into control box...
Page 47 - RED; Fig. 32 — Field Control Thermostat Wiring; NOTE: Sensor part numbers are as follows:; Fig. 33 — Field Control Temperature Sensor
47 Conductors and drain wire must be 20 AWG minimum stranded, tinned copper. Individual conductors must be insulat- ed 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 op- erating...
Page 48 - Step 10 — Make Outdoor-Air Inlet Adjustments; SPACE TEMPERATURE AVERAGING — 9 SENSOR APPLICATION; Fig. 34 — Space Temperature Averaging Wiring; SPACE TEMPERATURE AVERAGING — 4 SENSOR APPLICATION
48 Step 10 — Make Outdoor-Air Inlet Adjustments ECONOMIZERNOTE: If accessory power exhaust or barometric relief pack- ages are being added to the unit, install power exhaust or baro- metric relief before installing economizer hoods.Economizer Hood Assembly — The economizer hood is shipped in a packa...
Page 49 - Fig. 36 — Adding Seal Strip to Top of Hood Sides
49 Perform the following procedure to assemble the economiz- er hood. 1. Apply black seal strip (provided in package) to outside top-edge of hood sides. Wrap seal strip over edge to cover top flange (6 hood sides). Make sure seal strip covers screw holes. Allow strip to overhang 1 / 8 -in. past the ...
Page 51 - Attached to Filter Track Assembly
51 ECONOMIZER SETTINGSAccessory Enthalpy Control (Fig. 46) — The control (HH57AC077) is mounted in the economizer hood. See Fig. 37. The enthalpy setting adjustment is on the enthalpy con- trol. For maximum benefit of outdoor air, set enthalpy control to A. See Fig. 47 and 48. The enthalpy controls ...
Page 52 - Fig. 46 — Differential Enthalpy Control and Sensor
52 7. Route the wires from the enthalpy sensor to the return air enthalpy control through the holes on the inside of the hinged filter access panel. The holes are blocked by plug buttons which should be removed. 8. Use field-supplied wire ties to attach the violet wire to the + terminal and the blue...
Page 53 - RH —; Relative Humidity; Fig. 48 — Psychrometric Chart for Enthalpy Control; CONTROL
53 LEGEND RH — Relative Humidity Fig. 48 — Psychrometric Chart for Enthalpy Control NOTE: Partitions shown indicate both side supply (AW,AY,EW,EY) and vertical supply (AJ,AK,EJ,EK) units. Fig. 49 — Economizer Details CONTROL CURVE CONTROL POINT (APPROX. DEG.)AT 50% RH F (C) A 73 (23) B 70 (21) C 67 ...
Page 54 - Step 12 — Install All Accessories —; VAV —; Variable Air Volume; Fig. 51 — Pressure Transducer Locations
54 Step 12 — Install All Accessories — After all the factory-installed options have been adjusted, install all field-in- stalled accessories. Refer to the accessory installation instruc- tions included with each accessory.MOTORMASTER® III CONTROL INSTALLATIONInstall Field-Fabricated Wind Baffles — W...
Page 55 - Fig. 52 — Motormaster III Control Baffle Details; UNIT SIZE; Fig. 53A — Motormaster III Sensor Location
55 Install Motormaster® III Controls — Only one Motormaster III control is required per unit. Motor — One outdoor-fan motor (OFM) must be changed out in the field to accommodate the Motormaster III accessory. The replacement motor part no. is HD52AK652. For 48AJ,AK,AW,AY020-030 and 48EJ,EK,EW,EY024-...
Page 57 - Step 13 — Field Modifications; Fig. 54 — Side Return Air Conversion
57 Step 13 — Field Modifications DUCTWORKBottom Return Units (48AJ,AK,EJ,EK) Field-Modified for Side Return — 48AJ,AK and 48EJ,EK units with bottom re- turn air connections may be field-modified to accommodate side return air connections. Conversion to horizontal return requires that the bottom re- ...
Page 58 - Fig. 55 — Power Exhaust Relocated to Side Return Duct
58 START-UP Use the following information and Start-Up Checklist on pages CL-1 and CL-2 to check out unit PRIOR to start-up. Unit Preparation — Check that unit has been installed in accordance with these installation instructions and applicable codes. Compressor Mounting — Loosen the compressor hold...
Page 59 - Crankcase Heaters —; Table 11 — Toshiba TOSVERT VFD Set Point; PRESSURE; Factory-Installed Jumpers
59 Crankcase Heaters — Crankcase heaters are energized as long as there is power to the unit, except when the compres-sors are operating. Variable Frequency Drive (VFD) — The variable frequency drives are factory set. These settings include factory-installed jumpers and software configurations. The ...
Page 60 - Table 12 — Carrier Default Program Parameter Values; PARAMETER GROUP
60 8. Press “READ/WRITE” key, to enter the new value. The desired set point value will alternately flash to indicate that the new value has been stored. 9. Fire-speed override mode is available by contact closure between terminals S1 and CC. 10. If the VFD is to be controlled by an external control ...
Page 62 - Fig. 58 — Toshiba TOSVERT VF-S9 VFD Factory-Installed Jumpers
62 Table 14 — Carrier VFD (Toshiba TOSVERT VF-S9) Program Parameter Values *These settings differ from the Toshiba defaults and are required for Carrier applications. Table 15 — Motor Electronic Thermal Protection (tHr) for Toshiba TOSVERT VF-S9 VFD *IFM Letter refers to the 15th digit (Motor Option...
Page 63 - Power Exhaust —; offset; BUILDING PRESSURE
63 Power Exhaust — The optional non-modulating power exhaust (CV only) is a two-stage design where the operation of the exhaust fans is linked to economizer position. When the supply fan is running and the economizer is 25% open, the base control board closes contacts, activating 2 (48AJ,AK,AW, AY02...
Page 64 - Table 17 — DIP Switch Configuration
64 • DIP switch 6 configures the Time Guard® override and, when used with the field test function, sets the minimum damper position • DIP switch 7 configures the unit for gas heat or electric heat • DIP switch 8 configures the unit for heat pump or air conditioner operation. Crankcase Heater — Units...
Page 66 - Table 20 — Fan Performance, 48AJ,AK035 — Vertical Discharge Units
66 Table 20 — Fan Performance, 48AJ,AK035 — Vertical Discharge Units LEGEND Bhp — Brake Horsepower NOTES: 1. Fan performance is based on wet coils, economizer, roof curb, cabinet losses, and clean 2-in. filters. 2. Conversion — Bhp to watts: 3. Variable Air Volume units will operate down to 70 cfm/t...
Page 67 - Table 21 — Fan Performance, 48AJ,AK040,050 — Vertical Discharge Units
67 Table 21 — Fan Performance, 48AJ,AK040,050 — Vertical Discharge Units LEGEND Bhp — Brake Horsepower NOTES: 1. Fan performance is based on wet coils, economizer, roof curb, cabinet losses, and clean 2-in. filters. 2. Conversion — Bhp to watts: 3. Variable Air Volume units will operate down to 70 c...
Page 68 - Table 22 — Fan Performance, 48AJ,AK060 — Vertical Discharge Units
68 Table 22 — Fan Performance, 48AJ,AK060 — Vertical Discharge Units LEGEND Bhp — Brake Horsepower NOTES: 1. Fan performance is based on wet coils, economizer, roof curb, cabinet losses, and clean 2-in. filters. 2. Conversion — Bhp to watts: 3. Variable Air Volume units will operate down to 70 cfm/t...
Page 70 - Table 24 — Fan Performance, 48AW,AY035 — Horizontal Discharge Units
70 Table 24 — Fan Performance, 48AW,AY035 — Horizontal Discharge Units LEGEND Bhp — Brake Horsepower NOTES: 1. Fan performance is based on wet coils, economizer, roof curb, cabinet losses, and clean 2-in. filters. 2. Conversion — Bhp to watts: 3. Variable Air Volume units will operate down to 70 cfm...
Page 72 - Table 26 — Fan Performance, 48AW,AY060 — Horizontal Discharge Units
72 Table 26 — Fan Performance, 48AW,AY060 — Horizontal Discharge Units LEGEND Bhp — Brake Horsepower NOTES: 1. Fan performance is based on wet coils, economizer, roof curb, cabinet losses, and clean 2-in. filters. 2. Conversion — Bhp to watts: 3. Variable Air Volume units will operate down to 70 cfm...
Page 73 - Table 27 — Fan Performance, 48EJ,EK024,034 — Vertical Discharge Units
73 Table 27 — Fan Performance, 48EJ,EK024,034 — Vertical Discharge Units (For EW,EY units, reduce net available external static pressure by 0.3 in. wg) LEGEND Bhp — Brake Horsepower NOTES: 1. Fan performance is based on wet coils, economizer, roof curb, cabinet losses, and clean 2-in. filters. 2. Co...
Page 74 - Table 28 — Fan Performance, 48EJ,EK038,044 — Vertical Discharge Units
74 Table 28 — Fan Performance, 48EJ,EK038,044 — Vertical Discharge Units (For EW,EY units, reduce net available external static pressure by 0.5 in. wg) LEGEND Bhp — Brake Horsepower NOTES: 1. Fan performance is based on wet coils, economizer, roof curb, cabinet losses, and clean 2-in. filters. 2. Co...
Page 75 - Table 29 — Fan Performance, 48EJ,EK048 — Vertical Discharge Units
75 Table 29 — Fan Performance, 48EJ,EK048 — Vertical Discharge Units (For EW,EY units, reduce net available external static pressure by 0.5 in. wg) LEGEND Bhp — Brake Horsepower NOTES: 1. Fan performance is based on wet coils, economizer, roof curb, cabinet losses, and clean 2-in. filters. 2. Conver...
Page 76 - Table 30 — Fan Performance, 48EJ,EK054-068 — Vertical Discharge Units
76 Table 30 — Fan Performance, 48EJ,EK054-068 — Vertical Discharge Units LEGEND Bhp — Brake Horsepower NOTES: 1. Fan performance is based on dry coils, economizer, roof curb, cabinet losses, and clean 2-in. filters. 2. Conversion — Bhp to watts: 3. Variable Air Volume units will operate down to 70 c...
Page 83 - Fig. 59 — Heat Interlock Relay Wiring; CB
83 GAS HEATING, VARIABLE AIR VOLUME (VAV) UNITS — All of the gas heating control is performed through the integrated gas control (IGC) board. The control module board serves only to initiate and terminate heating operation.NOTE: The unit is factory-configured for disabled occupied heating. DIP switc...
Page 84 - Staged
84 Table 37 — Staged Gas System Components Table 38 — Stage Gas System Inputs/Outputs Operating Modes — The SGC will operate the unit in one of the following operating modes:• no mode • Cooling Mode • Heating1 Mode • Heating2 ModeNo Mode — In this mode, none of the heat stages are turned on. No mode...
Page 85 - Table 39 — Navigator Display Menu Structure; Fig. 60 — Navigator Display
85 MORNING WARM-UP (VAV only with PC Accessed/CCN Operation) — Morning warm-up occurs when the control has been programmed to turn on heat prior to the Occupied mode to be ready for occupancy mode. Morning warm-up is a condi- tion in VAV systems that occurs when the Temperature Com- pensated Start a...
Page 86 - BASE MODULE; Fig. 61 — Space Temperature Reset Wiring
86 Table 40 — Occupied Heat and Morning Warm-Up Operation and Controlling Factors LEGEND SPACE TEMPERATURE SENSOR CONTROL — If the unit is equipped with a field-supplied space sensor and a remote start/stop switch, constant volume (CV) cooling will operate as follows: Stage 1 cooling begins when the...
Page 87 - Fig. 62 — Field-Supplied Smoke Detector Wiring
87 SUPPLY AIR TEMPERATURE RESET — Supply air tem- perature reset is used to reset the supply-air temperature utility. A 4 to 20 mA signal (field-supplied) is required. The reset op- tion does not require enabling.POWER EXHAUST OPERATION — Power exhaust has two options (constant volume and modulating...
Page 89 - Fig. 64 — Spark Gap Adjustment
89 If a Y2 (or Y2_SPT) call begins while the unit was under “Y1 cooling” control, compressor no. 2 will not be started until “Y1 cooling” control has ended. If the Y2 (or Y2_SPT) call ends, with compressor 1 in an unloaded state and compressor 2 ON, then compressor 1 will be immediately brought up t...
Page 91 - Multifak 2; and Adjustment; Fig. 68 — Evaporator Fan Coupling
91 Lubrication COMPRESSORS — Each compressor is charged with the correct amount of oil at the factory. The correct oil charge is shown in Tables 1A and 1B. If oil is visible in the compressor sight glass, check unit for operating readiness as described in Start-Up section, then start the unit. Obser...
Page 92 - Fig. 69 — Belt Tension Adjustment
92 5. Be sure that hub flanges, flex members, spacer, and hard- ware are clean and free of oil. 6. Place the flanges onto the shafts with the hub facing out- ward. Do not tighten the set screws at this time. 7. Outside of the unit, assemble the flex members to the cen- ter drive shaft with 4 bolts a...
Page 94 - Main Burners —; For all applications, main burners are; Fig. 76 — Main Burner Removal
94 Main Burners — For all applications, main burners are factory set and should require no adjustment.MAIN BURNER REMOVAL (Fig. 76) 1. Shut off (field-supplied) manual main gas valve.2. Shut off power supply to unit.3. Remove heating access panel.4. Disconnect gas piping from gas valve inlet.5. Remo...
Page 103 - TROUBLESHOOTING; FPS —; Freeze Protection Switch; HPS —
103 TROUBLESHOOTING Typical refrigerant circuiting diagrams are shown in Fig. 84-93. An algorithm diagram of the IGC (Integrated Gas Unit Controller) control is shown in Fig. 94. LEGEND Fig. 84 — Typical Refrigerant Circuiting (48AJ,AK,AW,AY020,025 and 48EJ,EK,EW,EY024-034) FPS — Freeze Protection S...
Page 104 - Thermostatic Expansion Valve
104 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-Pass 4-...
Page 112 - GEN; HP; itch; LPS; Lo; TXV; The
112 F ig . 9 3 — T y p ic a l R e fr ig e ra n t C ir c u it in g ( 4 8 E J ,E K ,E W ,E Y 0 6 8 ) L E GEN D HP S — High-Pressure S w itch LPS — Lo w-Pressure Switch TXV — The rmostatic Expansion V a lv e
Page 113 - IDM; Integrated Gas Unit Controller
113 LEGEND NOTE: Thermostat Fan Switch in the “AUTO” position or sensor-equipped unit. Fig. 94 — IGC Control (Heating and Cooling) IDM — Induced-Draft Motor IGC — Integrated Gas Unit Controller
Page 114 - Table 44 — IGC Control Board LED Alarms; Diagnostic LEDs —; Table 45 — Control Board LED Alarms
114 The alarm codes for the IGC control board are shown in Table 44. Table 44 — IGC Control Board LED Alarms Diagnostic LEDs — There are 3 LEDs (red, yellow, and green) on the lower right hand side of the control board. The red light is used to check unit operation and alarms. A constant pulse is no...
Page 115 - Tables 46-48 show the input and output channel designations.; Table 46 — I/O Channel Designations Base Module — CV
115 Tables 46-48 show the input and output channel designations. Table 46 — I/O Channel Designations Base Module — CV Table 47 — I/O Channel Designations Base Module — VAV Table 48 — I/O Channel Designations Expansion Module (Field-Installed) — CV and VAV LEGEND (Tables 46-48) NOTE: All even numbere...
Page 116 - SERVICE TRAINING; Packaged Service Training; • Unit Familiarization; Classroom Service Training; descriptions and schedules are in our catalog.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. PC 111 Catalog No. 534-739 Printed in U.S.A. Form 48A,E-1SI Pg 116 107 11-01 Replaces: 48E-6SI Book 1 Tab 1a Copyright 2001 Carrier Corporation SERVICE T...
Page 118 - GENERAL
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. PC 111 Catalog No. 534-739 Printed in U.S.A. Form 48A,E-1SI CL-2 107 11-01 Replaces: 48E-6SI Book 1 Tab 1a Copyright 2001 Carrier Corporation - - - - - -...
Carrier 58CTA09010016
User Manual