Page 3 - Copy continues on page 14.
INSTALLATION Jobsite Survey — Complete the following checks be- fore installation.1. Consult local building codes and the NEC (National Electrical Code) (ANSI/NFPA [National Fire ProtectionAssociation] 70) for special installation requirements. 2. Determine unit location (from project plans) or sele...
Page 4 - Table 1 — Physical Data
Table 1 — Physical Data BASE UNIT 48/50MP 62L 70M 82N NOMINAL CAPACITY (tons) 80 90 105 OPERATING WEIGHT (lb) Base Unit (48MP/50MP) 16,810/16,550 18,060/17,800 22,660/22,400 Copper Condenser Coils 675 725 725 Exhaust Fan 1,675 1,775 2,375 COMPRESSORS Semi-Hermetic Number of Refrigerant Circuits 2 2 ...
Page 14 - Branch circuit for power supply to unit must be protected; SLAB MOUNT DRAIN; Fig. 9 — Condensate Drain Piping Details
Make Electrical Connections POWER SUPPLY — Electrical characteristics of availablepower supply must agree with unit nameplate rating. Supplyvoltage must be within the limits shown in Table 5. Field Wire Routing — Field wiring is brought into the unitthrough the bottom of the control box. A 3 5 ⁄ 8 -...
Page 15 - — Ground; Fig. 12 — Field Power Wiring Connections
Disconnect must be located within sight of the unit and read-ily accessible from the unit in compliance with NECArticle 440-14.All field wiring must comply with NEC and all local codes.Size wire based on MCA (Minimum Circuit Amps) valueshown on the unit informative plate. See Fig. 12 for powerwiring...
Page 16 - Table 5 — Electrical Data
Table 5 — Electrical Data UNIT 48MP/ 50MP VOLTAGE 3 Ph, 60 Hz VOLTAGE RANGE COMP NO. A1 COMP NO. A2 COMP NO. B1 COMP NO. B2 CONDENSER FAN MOTORS EVAPORATOR FAN MOTOR POWER EXHAUST FAN MOTOR MCA MOCP Min Max RLA LRA RLA LRA RLA LRA RLA LRA Qty FLA Hp FLA Hp FLA Hp 62L 460 414 508 65.4 345 — — 65.4 34...
Page 17 - Control Wiring; Table 6 — Recommended Sensor and
Control Wiring — See Fig. 13 for sensor wiring con- nections to main and auxiliary control boxes. The recom-mended types of control wiring for 48/50MP unit devicesare shown in Table 6. Table 6 — Recommended Sensor and Device Non-Shielded Cable MANUFACTURER PART NO. Regular Wiring Plenum Wiring Alpha...
Page 18 - — Switch; Fig. 13 — Space Temperature Sensor Wiring
LEGEND COM — CommonSW — Switch T — Terminal TB — Terminal Block TH — Thermostat Heating AccessoryField Wiring *Constant volume applications only. Fig. 13 — Space Temperature Sensor Wiring 18
Page 19 - SPACE TEMPERATURE AVERAGING — 4 SENSOR APPLICATION; RED; SPACE TEMPERATURE AVERAGING — 9 SENSOR APPLICATION; Fig. 14 — Space Temperature Sensor Averaging; TB
2 1 TB3 RED BLK TO PROCESSORMODULE NO. 1 SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 4 RED BLK RED BLK RED BLK RED BLK SPACE TEMPERATURE AVERAGING — 4 SENSOR APPLICATION 1 2 RED BLK TB3 TO PROCESSORMODULE NO. 1 RED BLK RED BLK RED BLK SENSOR 1 SENSOR 2 SENSOR 3 RED BLK SENSOR 6 SENSOR 5 RED BLK SENSOR 4 RED B...
Page 20 - Fig. 15 — Heat Interlock Relay; DSIO — Relay Module; Fig. 17 — Remote Start; TB — Terminal Block; Fig. 18 — Accessory Humidity Control; TB — Terminal Block; Fig. 20 — Indoor Air Quality
8 9 10 12 11 10 DSIO2 J5 CHANNEL 60 TB3 FIELDCONTROLWIRING RED BLU ORN LEGEND TB — Terminal Block Field Wiring Component Terminal □ Terminal Block Terminal Fig. 15 — Heat Interlock Relay SR + ENTHALPY CONTROL REMOVE620 Ω RESISTOR S + ENTHALPY SENSOR DIFFERENTIALENTHALPY SENSOR (RETURN AIR) Fig. 16 —...
Page 22 - TRANSDUCER ACCESSORY; DPT — Duct Pressure; SPT — Suction Pressure; Fig. 28 — CCN Building Supervisor
+ _ BLK WHT RED + _ BLK WHT RED + _ BLK WHT RED + _ BLK WHT RED DPT1 DPT2 SPT1 SPT2 BLK BLK BLK BLK BLK RED RED BRN BRN WHT WHT RES RES BLK RED 4 5 TB3 WHT WHT WHT WHT RES RES 7 8 10 11 13 14 10K OHM 1/2 WATT 5% + - 10K OHM 1/2 WATT 5% + - 10K OHM 1/2 WATT 5% + - 10K OHM 1/2 WATT 5% + - 16 17 PSIO N...
Page 23 - Carrier Comfort Network Interface; — The; Table 7 — CCN Connection Approved; VFD; Fig. 29 — Optional VFD — Wiring Connections
Carrier Comfort Network Interface — The 48/50MP units can be connected to the CCN if desired. Thecommunication bus wiring is supplied and installed inthe field. It consists of shielded, 3-conductor cable withdrain wire. The system elements are connected to the communication bus in a daisy chain arra...
Page 24 - Air Pressure Tubing —; Fig. 30 — Space Sensor to Communication Bus Wiring
The following color code is recommended: SIGNAL TYPE CCN BUS CONDUCTOR INSULATION COLOR COMM1 PLUG PIN NO. 1 RED 1 GROUND WHITE 2 2 BLACK 3 NOTE: If a cable with a different color scheme is selec-ted, a similar color code should be adopted for the entirenetwork. At each system element, the shields o...
Page 25 - Fig. 33 — Air Pressure Tubing Locations
Fig. 31 — Auxiliary Control Box Location (50MP70M Unit Shown) VARIABLEFREQUENCYDRIVE DUCT PRESSURETRANSDUCER BUILDING PRESSURETRANSDUCER(HIDDEN) Fig. 32 — Auxiliary Control Box FACTORYINSTALLEDTUBING DPC BPC LO HI LO HI TOBUILDINGPRESSURE TO SUPPLYDUCT FIELDINSTALLEDTUBING TO OUTDOORREFERENCEPRESSUR...
Page 26 - Fig. 35 — Flue and Inlet Hood Locations; Fig. 36 — Inlet Hood Assembly
Gas Piping (48 Series Units Only) — Unit is equipped for use with natural gas only. Installation must conform withlocal building codes, or in the absence of local codes, withthe National Fuel Gas Code, ANSI Z223.1. A 1 ⁄ 8 -in. NPT tapping plug, accessible for test gage con- nection, must be field i...
Page 27 - Fan Isolator Adjustment —; Remove shipping hard-; Check Compressor Mounting; For applications requiring; Fig. 40 — Outer View, Compressor Mounting; Fig. 39 — Fan isolator Adjustment
Fan Isolator Adjustment — Remove shipping hard- ware from both the supply fan and the optional exhaust fan.The indoor fan shipping blocks on both the supply fan andthe optional power exhaust fan (4 per fan) must be removedfrom each corner of the fan sled before starting unit. Re-move shipping bolt c...
Page 28 - System Check; Fig. 41 — Compressor Mounting —; Fig. 43 — Rear View of Compressor Mounting
PRE-START-UP IMPORTANT: Before beginning Pre-Start-Up or Start-Up, review Start-Up Checklist at the center of thispublication. The Checklist assures proper start-up of aunit and provides a record of unit condition, applica-tion requirements, system information, and operationat initial start-up. Do n...
Page 29 - Compressor Oil —; Fig. 44 — Operating Oil Levels
11. Check supply fan belts, sheaves, and bearings. Check the lubrication of the fan and motor bearings. Check bear-ing and bearing set screws for tightness. Check sheavealignment and belt tension. Hand turn fan to ensure fanwheel does not rub on housing. The fan shaft and motorshaft must turn freely...
Page 35 - Controls Configuration and Quick Test; The switch must be set prior to unit operation. To set the; Table 22 — Filter Switch Dirty Set Point
Table 18 — Component Pressure Drop (in. wg) COMPONENT 22,000 26,400 30,000 34,000 38,000 42,000 45,800 48,200 52,000 HEAT EXCHANGER (48MP ONLY) 0.31 0.40 0.49 0.58 0.70 0.82 0.95 1.03 1.23 Table 19 — Maximum Allowable Supply Fan Wheel Speed (Rpm) 48/50MP FAN TYPE Forward Curved Airfoil 62L, 70M 835 ...
Page 36 - Table 23 — HSIO Keypad Key Usage; Fig. 46 — Psychrometric Chart for; Fig. 47 — Wiring Connections for Solid-State
KEYPAD AND DISPLAY MODULE (HSIO)CONFIGURATION IMPORTANT: The HSIO keypad and display moduleis required for initial start-up of these units. All unitsare shipped in standby mode, and the HSIO should beused to change the unit to run mode. Once the unit isin run mode, the HSIO is not required for norma...
Page 37 - Table 24 — Set Point Ranges and Defaults
If the unit is being used in a CV application, then performthe following:1. Enter the configuration function by pressing and . 2. Scroll down to unit type. TYPE 1 will be displayed. ENTER 3. Press and to change the unit type to CV. 4. Scroll down to data reset. DTRS will be displayed. Press ENTER an...
Page 38 - Table 25 — Basic Configuration Data; Gas Pressure Check —
Table 25 — Basic Configuration Data SET POINT SUBFUNCTION DISPLAY DEFAULT RANGE Unit Type TYPE 1 = VAV CV = 0, VAV = 1 CV Fan Mode FANM 1 (Continuous) Auto = 0, Cont = 1 Economizer MinimumDamper Position MDP 20 percent 0 to 100 Heating Occupied* OHSP 68 (F) 55 to 80 Cooling Occupied OCSP 78 (F) 55 t...
Page 39 - General; Operating
General NOTE: If unit is equipped with REMOTE START function,place the LOCAL/REMOTE switch in the LOCAL (Off)position.1. Put the ON/OFF switch in the ON position. Close the con- trol circuit breaker (CCB), which will energize the con-trol circuit and the crankcase heaters. 2. Using the HSIO or Build...
Page 40 - Table 26 — IGC Control Board LED Alarms; IGC
5. As actual SAT approaches CCSR value, stages are re- leased. The minimum time delay between stages on de-creasing demand is 90 seconds.NOTE: Demand for heating has priority and Master Loopwill either terminate existing or prevent initiation ofCooling Cycle by issuing a CCSR at the maximum limit.Th...
Page 41 - Control Loop Checkout; Table 27 — 48/50MP Units SMG, SCV and MLG Recommended Starting Values
Control Loop Checkout The checkout and adjustment of control loops shouldonly be done by certified Carrier Comfort Network(CCN) technicians. The following checkout procedureis offered as a guide and presumes the user has obtainedbasic knowledge of controls through CCN training. TO CHECK OPERATION OF...
Page 42 - IAQ Control Loop Adjustment —; Table 29 — Index of Lead/Lag Circuits and; LEAD CIRCUIT; Final Checks —
8. Once the submaster loop is adjusted, remove all forced values and proceed with verification and adjustment ofmaster loop. 9. To check the master loop: Create a demand in the master loop. For example: Forcethe actual space temperature to a value less than the heat-ing set point or greater than the...
Page 43 - Default Set Points/Changing Set Points —
KEYPAD AND DISPLAY MODULE (HSIO) IMPORTANT: The HSIO (human sensor input/output)keypad and display module is required for initial start-upof these units. All units are shipped in standby mode,and the HSIO must be used to change the unit to runmode. Once the unit is in run mode, the HSIO is notrequir...
Page 45 - Table 30 — Variable Frequency Drive (VFD) Display; SERVICE; All unit components can be reached; SEQ; DSPL; REMOTE; RUN; Fig. 49 — VFD Digital Operator
Table 30 — Variable Frequency Drive (VFD) Display DISPLAY ACTION Fref Not used. Fout Displays the output frequency at which the VFD is cur-rently operating. This is a display only function. The usercannot change this displayed value. lout Displays the level of output current that the VFD is cur-rent...
Page 46 - Cleaning —
UNIT CONTROL BOX — Viewed facing compressors, thecontrol box is at the left end of the unit. Incoming power forcontrols, refrigerant system, and fan system enters throughthe control box. The control box contains power compo-nents and electronic controls. Outer panels are hinged andlatched for easy o...
Page 47 - Lubrication; Coil Cleaning —; Clean the coils with a vacuum cleaner,; Refrigerant Circuit; Schrader connection for charging liquid refrigerant.; Fig. 52 — Burner Section Detail; Fig. 53 — Removing Heat Exchanger Ceramic
MAIN BURNERS (48MP Only) — At the beginning of eachheating season, inspect for deterioration or blockage due tocorrosion or other causes. Observe the main burner flames.Refer to Main Burners section on page 52. FLUE GAS PASSAGEWAYS (48MP Only) — The flue col-lector box and heat exchanger cells may b...
Page 49 - Moisture/Liquid Indicator —; ALL OUTDOOR FANS MUST BE OPERATING
Charging with Unit Off and Evacuated — Close liquidline service valve before charging. Weigh in charge shownin Table 1. Open liquid line service valve; start unit andallow it to run several minutes fully loaded. Check for a clearsight glass. Be sure clear condition is liquid and not vapor.Complete c...
Page 50 - Table 31 — Pressure Switch Settings,; SWITCH; Low-Pressure Switch —
Replace the filter cores whenever the moisture/liquid in- dicator shows moisture in the system. Follow instructions on the packaging for the replacement cores for disassembling and reassembling the filter assem-blies and housings. Liquid Line Service Valve — Located immediately ahead of the filter d...
Page 51 - Fig. 61 — Motor Plate Adjustment
CYLINDERHEADS MUFFLER HIGH-PRESSURESWITCH MOUNTINGSPRING(HIDDEN) SIGHTGLASS LOW-PRESSURESWITCH OILEQUALIZERLINE CRANKCASEHEATER RAIL SIGHTGLASS PRESSURE RELIEFVALVE NOTE: Units 48/50MP62L compressors are pan mounted. Units 48/50MP70M and 82Ncompressors are mounted on rails. Fig. 60 — 06E Compressors...
Page 52 - Fig. 62 — Pulley Alignment
PULLEY ALIGNMENT — For proper belt life, the motorand fan pulleys must be properly aligned. To check, first turnoff unit power. Place a straightedge against the motor andfan pulleys. See Fig. 62. If the pulleys are properly aligned,the straightedge should be parallel to the belts. If they are not pa...
Page 53 - Control Modules —
CONDENSER-FAN MOTOR PROTECTION — Eachcondenser-fan motor is internally protected against over-temperature. They are also protected against a severe over-current condition by manual reset, calibrated trip, magneticcircuit breakers on a common circuit. As with the circuit break-ers, do not bypass conn...
Page 54 - Refrigerant Feed Components —
Processor Module(s) (PSIO) INPUTS — Each input channel has 3 terminals; 2 are used. OUTPUTS— Output of the PSIO module is 24 vdc or4 to 20 mA dc. There are 3 terminals; 2 are used. REPLACING DEFECTIVE PSIO MODULES — The re-placement part number is printed on a label on the front ofthe PSIO module. T...
Page 55 - TORQUE; TROUBLESHOOTING; Fig. 64 — Condenser Fan Adjustment
Hot Gas Bypass — An optional hot gas bypass system may be factory installed on circuit no. 1. This system willintroduce discharge vapor from the compressor discharge lineinto the distributors and evaporator coil circuits on circuitno. 1 when suction pressures drop to damaging levels. Nofield adjustm...
Page 56 - TROUBLESHOOTING AND DIAGNOSTICS
TROUBLESHOOTING AND DIAGNOSTICS PROBLEM SOLUTION COMPRESSOR DOES NOT RUN Contactor Open 1. Power off. 1. Restore power. 2. Fuses blown in field power circuit. 2. After finding cause and correcting, replace with correct size fuse. 3. Alarm tripped. 3. Check alarm history on HSIO. 4. No control power....
Page 58 - Refer to Fig. 65 for IGC troubleshooting information.
Refer to Fig. 65 for IGC troubleshooting information. Fig. 65 — IGC Control (Heating) — 48MP Units Only LEGEND IGC — Integrated Gas Unit ControllerPIC — Product Integrated Control 58
Page 60 - PACKAGED SERVICE TRAINING; ] Packaged Service Training
PACKAGED SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equip-ment discussed in this manual, including: • Unit Familiarization• Installation Overview • Maintenance• Operating Sequence A large selection of product, theory, and skills program...
Page 61 - II. PRELIMINARY CHECKLIST ITEMS; CONTROL SETTINGS FOR NON-NETWORKED, FREESTANDING UNIT
START-UP CHECKLIST MODEL NO.: DATE: SERIAL NO.: TECHNICIAN: I. PRE-START-UP: M VERIFY THAT UNIT IS LEVEL M VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT M LOOSEN ALL SHIPPING HOLDDOWN BOLTS AND REMOVE SHIPPING BRACKETS PER INSTRUCTIONS M VERIFY THAT COMPRESSOR SUSPENSION SPRINGS HAVE...
Carrier 58CTA09010016
User Manual