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50ZH030-060
3-Phase Packaged Heat Pump
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Installation, Start-Up and Service Instructions
NOTE: Read the entire instruction manual before starting the installation.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS .....................................................1
INTRODUCTION ..........................................................................2
RECEIVING AND INSTALLATION ..........................................2
Check Equipment......................................................................2
IDENTIFY UNIT ................................................................2
INSPECT SHIPMENT ........................................................2
Provide Unit Support ................................................................2
SLAB MOUNT ...................................................................2
GROUND MOUNT ............................................................2
Provide Clearances....................................................................2
Place Unit..................................................................................2
Select and Install Ductwork .....................................................2
INSTALL FLANGES FOR DUCTWORK CONNEC-
TIONS (50ZH060 ONLY) ..................................................2
CONVERTING HORIZONTAL DISCHARGE UNITS TO
DOWNFLOW (VERTICAL) DISCHARGE......................6
Provide for Condensate Disposal .............................................6
Install Electrical Connections...................................................7
HIGH-VOLTAGE CONNECTIONS..................................7
ROUTING POWER LEADS INTO UNIT ........................7
CONNECTING GROUND LEAD TO UNIT GROUND .7
ROUTING CONTROL POWER WIRES ..........................7
ACCESSORY ELECTRIC HEAT WIRING .....................7
SPECIAL PROCEDURES FOR 208-V OPERATION .....7
PRE-START-UP ............................................................................9
START-UP .....................................................................................9
Check for Refrigerant Leaks ....................................................9
LOCATE AND REPAIR REFRIGERANT LEAKS AND
CHARGE THE UNIT AS FOLLOWS: .............................9
Start-Up Cooling Section and Make Adjustments ................10
CHECKING COOLING CONTROL OPERATION .......10
COMPRESSOR ROTATION ...........................................10
Refrigerant Charge..................................................................10
NO CHARGE ....................................................................10
LOW CHARGE COOLING .............................................10
TO USE THE COOLING CHARGING CHART............11
HEATING MODE CHARGE...........................................11
Indoor Airflow and Airflow Adjustments..............................11
FOR 208/230-V .................................................................11
FOR 460-V MOTORS ......................................................11
Unit Controls...........................................................................11
HIGH-PRESSURE RELIEF VALVE...............................11
LOSS OF CHARGE SWITCH.........................................11
COMPRESSOR OVERLOAD..........................................11
Sequence of Operation............................................................14
FAN OPERATION............................................................14
COOLING..........................................................................14
HEAT PUMP HEATING..................................................14
DEFROST..........................................................................14
ELECTRIC RESISTANCE HEATING............................14
C00155
Fig. 1—Unit 50ZH
MAINTENANCE.........................................................................14
Air Filter..................................................................................16
Unit Top Removal (Outdoor-Coil Side) ................................16
Indoor Blower and Motor.......................................................16
Outdoor Coil, Indoor Coil, and Condensate Drain Pan ........17
Outdoor Fan ............................................................................19
Electrical Controls and Wiring...............................................19
Refrigerant Circuit ..................................................................19
Indoor Airflow ........................................................................19
Metering Devices ....................................................................19
Lubrication ..............................................................................19
Liquid Line Strainer................................................................19
High Flow Valves...................................................................19
TROUBLESHOOTING ...............................................................22
START-UP CHECKLIST............................................................23
NOTE TO INSTALLER—Before installation, READ THESE
INSTRUCTIONS CAREFULLY AND COMPLETELY. Also, make sure the User’s Manual and Replacement Guide are left with the unit after installation.
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified workers should install, repair, or service air-conditioning equipment.
Untrained workers can perform basic maintenance functions of cleaning coils and filters. All other operations should be performed by trained service people. When working on air-conditioning equipment, pay attention to precautions in the literature, tags, and labels attached to the unit, and other safety precautions that may apply.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 6 8
PC 101 Printed in U.S.A.
Catalog No. 50ZH-6SI Pg 1 2-06 Replaces: New
Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations.
Before performing service or maintenance operations on system, turn off main power to unit and install lockout tag.
Turn off accessory heater power switch if applicable. Electrical shock can cause serious injury or death.
Recognize safety information. This is the safety-alert symbol .
When you see this symbol 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 a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which would 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.
These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices. We require these instructions as a minimum for a safe installation.
INTRODUCTION
50ZH heat pump units are fully self-contained and designed for outdoor installation (See Fig. 1). As shown in Fig. 2-4, units are shipped in a horizontal-discharge configuration for installation on a ground-level slab. All units can be field-converted to downflow discharge configurations for rooftop applications with a fieldsupplied plenum.
RECEIVING AND INSTALLATION
Step 1—Check Equipment
IDENTIFY UNIT
The unit model number and serial number are stamped on the unit identification plate. Check this information against shipping papers. Verify that unit voltage and amperage listed on unit rating plate agree with power supplied for equipment.
INSPECT SHIPMENT
Inspect for shipping damage while unit is still on shipping pallet.
If unit appears to be damaged or is torn loose from its securing points, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company.
Manufacturer is not responsible for any damage incurred in transit.
Check all items against shipping list. Immediately notify the nearest Carrier Air Conditioning office if any item is missing.
To prevent loss or damage, leave all parts in original packages until installation.
Step 2—Provide Unit Support
SLAB MOUNT
Place the unit on a rigid, level surface, suitable to support the unit weight. A concrete pad or a suitable fiberglass mounting pad is recommended. The flat surface should extend approximately 2-in.
beyond the unit casing on the 2 sides. The duct connection side and condensate drain connection sides should be flush with the edge of the flat surface.
2
A 6-in. wide gravel apron should be used around the flat surface to prevent airflow blockage by grass or shrubs. Do not secure the unit to the flat surface except where required by local codes.
The unit should be level to within 1/4 inch. This is necessary for the unit drain to function properly.
GROUND MOUNT
The unit may also be installed directly on the ground if local codes permit. Place unit on level ground prepared with gravel for condensate discharge.
Step 3—Provide Clearances
The required minimum service clearances and clearances to combustibles are shown in Fig. 2-4. Adequate ventilation and outdoor coil air must be provided.
The outdoor fan pulls air through the outdoor coil and discharges it through the fan on the top cover. Be sure that the fan discharge does not recirculate to the outdoor coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48 in. above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48 inches.
Do not place the unit where water, ice, or snow from an overhang or roof will damage or flood the unit. The unit may be installed on wood flooring or on Class A, B, or C roof covering materials.
Do not restrict outdoor coil airflow. An air restriction at either the outdoor-air inlet or the fan discharge can be harmful to compressor life.
Step 4—Place Unit
Unit can be moved with the rigging holds provided in the unit base.
Refer to Table 1 for operating weights. Use extreme caution to prevent damage when moving the unit. Unit must remain in an
upright position during all moving operations. The unit must be level with in 1/4” for proper condensate drainage; the ground-level pad must be level before setting the unit in place. When a field-fabricated support is used, be sure that the support is level and that it properly supports the unit.
Step 5—Select and Install Ductwork
The design and installation of the duct system must be in accordance with:
• the standards of the NFPA (National Fire Protection Association) for installation of nonresidence-type air conditioning and ventilating systems
• NFPA90A or residence-type, NFPA90B; and/or local codes and residence-type, NFPA 90B
• and/or local codes and ordinances
Select and size ductwork, supply-air registers and return-air grilles according to ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) recommendations.
Use the duct flanges provided on the supply- and return-air openings on the side of the unit. See Fig. 2-4 for connection sizes and locations. The 14-in. round duct collars (size 030-048 units) are shipped inside the unit attached to the indoor blower. They are field-installed and must be removed from the indoor cavity prior to start-up, even if they are not used for installation.
INSTALL FLANGES FOR DUCTWORK CONNECTIONS
(50ZH060 ONLY)
The 50ZH060 units are shipped with flanges which must be field-installed on the unit.
To install unit flanges:
REQUIRED CLEARANCE TO COMBUSTIBLE MATL.
INCHES [mm]
TOP OF UNIT .........................................................................................0
DUCT SIDE OF UNIT.............................................................................0
SIDE OPPOSITE DUCTS ......................................................................0
BOTTOM OF UNIT .................................................................................0
NEC. REQUIRED CLEARANCES.
INCHES [mm]
BETWEEN UNITS, POWER ENTRY SIDE ....................................42.00 [1066.8]
UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE .36.00 [914.0]
UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]
REQUIRED CLEARANCE FOR OPERATION AND SERVICING
INCHES [mm]
CONDENSER COIL ACCESS SIDE..............................................30.00 [762.0]
POWER ENTRY SIDE....................................................................30.00 [762.0]
(EXCEPT FOR NEC REQUIREMENTS)
UNIT TOP .......................................................................................48.00 [1219.2]
SIDE OPPOSITE DUCTS ..............................................................30.00 [762.0]
LEGEND
NEC – National Electrical Code
NOTES:
1. Clearances must be maintained to prevent recirculation of air from outdoorfan discharge, with the exception of the condenser coil (36.00 in [914.0 mm]. A removable fence or barricade requires no clearance.
2. Dimensions are in inches. Dimensions in [ ] are in millimeters.
UNIT
50ZH030
ELECTRICAL CHARACTERISTICS
208/230–3–60
UNIT WEIGHT lb kg
254 116
C00156
X
CENTER OF GRAVITY IN. (MM)
Y Z
14.0 (356) 19.0 (483) 12.0 (305)
Fig. 2—Unit Base Dimensions—50ZH030
3
REQUIRED CLEARANCE TO COMBUSTIBLE MATL.
INCHES [mm]
TOP OF UNIT .........................................................................................0
DUCT SIDE OF UNIT.............................................................................0
SIDE OPPOSITE DUCTS ......................................................................0
BOTTOM OF UNIT .................................................................................0
NEC. REQUIRED CLEARANCES.
INCHES [mm]
BETWEEN UNITS, POWER ENTRY SIDE ....................................42.00 [1066.8]
UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE .36.00 [914.0]
UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]
REQUIRED CLEARANCE FOR OPERATION AND SERVICING
INCHES [mm]
CONDENSER COIL ACCESS SIDE..............................................
(EXCEPT FOR NEC REQUIREMENTS)
30.00 [762.0]
POWER ENTRY SIDE....................................................................30.00 [762.0]
UNIT TOP .......................................................................................48.00 [1219.2]
SIDE OPPOSITE DUCTS ..............................................................30.00 [762.0]
LEGEND
NEC – National Electrical Code
NOTES:
1. Clearances must be maintained to prevent recirculation of air from outdoorfan discharge, with the exception of the condenser coil (36.00 in [914.0 mm]. A removable fence or barricade requires no clearance.
2. Dimensions are in inches. Dimensions in [ ] are in millimeters.
UNIT
50ZH036
50ZH042
50ZH048
C00003
ELECTRICAL CHARACTERISTICS
UNIT WEIGHT
Lb Kg X
CENTER OF GRAVITY IN. (MM)
Y Z
208/230-3-60,
460–3–60
208/230-3-60,
460–3–60
208/230-3-60,
460–3–60
277
295
328
126
134
149
14.0 (356)
14.0 (356)
14.0 (356)
Fig. 3—Unit Base Dimensions—50ZH036–048
4
19.0 (483)
19.0 (483)
19.0 (483)
15.0 (381)
15.0 (381)
15.0 (381)
REQUIRED CLEARANCE TO COMBUSTIBLE MATL.
INCHES [mm]
TOP OF UNIT .........................................................................................0
DUCT SIDE OF UNIT.............................................................................0
SIDE OPPOSITE DUCTS ......................................................................0
BOTTOM OF UNIT .................................................................................0
NEC. REQUIRED CLEARANCES.
INCHES [mm]
BETWEEN UNITS, POWER ENTRY SIDE ....................................42.00 [1066.8]
UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE .36.00 [914.0]
UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]
REQUIRED CLEARANCE FOR OPERATION AND SERVICING
INCHES [mm]
CONDENSER COIL ACCESS SIDE..............................................30.00 [762.0]
POWER ENTRY SIDE....................................................................30.00 [762.0]
(EXCEPT FOR NEC REQUIREMENTS)
UNIT TOP .......................................................................................48.00 [1219.2]
SIDE OPPOSITE DUCTS ..............................................................30.00 [762.0]
LEGEND
NEC – National Electrical Code
NOTES:
1. Clearances must be maintained to prevent recirculation of air from outdoorfan discharge, with the exception of the condenser coil (36.00 in [914.0 mm]. A removable fence or barricade requires no clearance.
2. Dimensions are in inches. Dimensions in [ ] are in millimeters.
UNIT
50ZH060
ELECTRICAL CHARACTERISTICS
208/230-3-60, 460-3-60
UNIT WEIGHT
Lb Kg
368 167
C00158
X
CENTER OF GRAVITY IN. (MM)
Y Z
14.0 (356) 20.0 (508) 16.0 (406)
Fig. 4—Unit Base Dimensions—50ZH060
5
1. Five pieces of flange are shipped on the return-air opening of the unit. Remove the flanges from the shipping position (See
Fig. 5). Screws are field-supplied.
2. One piece of flange is used as it is shipped (straight). Bend the other 4 pieces at right angles.
3. Install the straight flange on the right side of the return-air opening in holes provided. (See Fig. 6). Flanges should stick out from unit to allow for connection of ductwork.
4. Install 2 hand-formed flanges onto return air opening in holes provided to form a rectangle around the return air opening.
5. Install remaining 2 hand-formed flanges around discharge air opening in holes provided.
6. Ductwork can now be attached to flanges.
When designing and installing ductwork, consider the following:
When connecting ductwork to units, do not drill deeper than
3/4 inch in shaded area shown in Fig. 7 or coil may be damaged.
• All units should have field-supplied filters installed in the return-air side of the unit. Recommended sizes for filters are shown in Table 1.
• Avoid abrupt duct size increases and reductions. Abrupt change in duct size adversely affects air performance.
IMPORTANT: Use flexible connectors between ductwork and unit to prevent transmission of vibration. Use suitable gaskets to ensure weathertight and airtight seal. When electric heat is installed, use fire proof canvas (or similar heat resistant material) connector between ductwork and unit discharge connection. If flexible duct is used, insert a sheet metal sleeve inside duct. Heat resistant duct connector (or sheet metal sleeve) must ectend 24–in.
from the unit discharge connection flange into the ductwork.
• Size ductwork for cooling air quantity (cfm). The minimum air quantity for proper electric heater operation is listed in Table 2.
Heater limit switches may trip at air quantities below those recommended.
• Insulate and weatherproof all external ductwork. Insulate and cover with a vapor barrier all ductwork passing through conditioned spaces. Follow latest Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air
Conditioning Contractors Association (ACCA) minimum installation standards for residential heating and air conditioning systems.
• Secure all ducts to building structure. Flash, weatherproof, and vibration-isolate duct openings in wall or roof according to good construction practices.
Fig. 8 shows a typical duct system with 50ZH unit installed.
CONVERTING HORIZONTAL DISCHARGE UNITS TO
DOWNFLOW (VERTICAL) DISCHARGE
Before performing service or maintenance operations on system, turn off main power to unit and install lockout tag.
Turn off accessory heater power switch if applicable. Electrical shock can cause serious injury or death.
Units are dedicated side supply products. They are not convertible to vertical air supply. A field-supplied plenum must be used to convert to vertical air discharge.
Step 6—Provide for Condensate Disposal
NOTE: Be sure that condensate-water disposal methods comply with local codes, restrictions, and practices.
6
FIVE PIECES OF DUCT
FLANGE ATTACHED
HERE FOR SHIPMENT
C00005
Fig. 5—Shipping Location of Duct Flanges
(Size 060 Only)
HAND
FORM
HAND FORM
STRAIGHT PIECE
C00006
Fig. 6—Flanges Installed on 50ZH060 Units
Unit removes condensate through a 1 3/64-in. ID hole (using
3/4-in. OD piping or tubing) which is located at the end of the unit.
See Fig. 2-4 for location of condensate connection.
Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in groundlevel installations. Install a field-supplied condensate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. lower than the drain-pan condensate connection to prevent the pan from overflowing. Prime the trap with water. When using a gravel apron, make sure it slopes away from the unit.
If the installation requires draining the condensate water away from the unit, install a 2-in. trap using a 3/4-in. OD tubing or pipe.
(See Fig. 9 and 10.) Make sure that the outlet of the trap is at least
1 in. lower than the unit drain-pan condensate connection to prevent the pan from overflowing. Prime the trap with water.
Connect a drain tube using a minimum of 3/4-in. PVC, 3/4-in.
19.17
″ 3.92
″ from the unit. Refer to the unit rating plate for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing. See Table 3 for electrical data.
The field-supplied disconnect may be mounted on the unit over the high-voltage inlet hole. See Fig. 2-4.
C00007
Fig. 7—Area Not to Be Drilled More Than 3/4-in.
CPVC, or 3/4-in. copper pipe (all field supplied). Do not undersize the tube. Pitch the drain tube downward at a slope of at least 1 in.
for every 10 ft of horizontal run. Be sure to check the drain tube for leaks. Prime trap at the beginning of the cooling season start-up. Allowable glues for condensate trap connection are:
Standard ABS, CPVC, or PVC cement.
Step 7—Install Electrical Connections
The 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 an electrical wire connected to the unit ground in the control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National
Electrical Code), ANSI (American National Standards
Institute)/NFPA (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes. Failure to adhere to this warning could result in serious injury or death.
Failure to follow these precautions could result in damage to the unit being installed:
1. Make all electrical connections in accordance with NEC
ANSI/NFPA (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1
Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram.
2. Use only copper conductor for connections between field-supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
3. Be sure that high-voltage power to unit is within operating voltage range indicated on unit rating plate.
4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are run in same conduit as high-voltage wires.
5. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc. On all
3-phase units, ensure phases are balanced within 2 percent.
Consult local power company for correction of improper voltage and/or phase imbalance.
HIGH-VOLTAGE CONNECTIONS
The unit must have a separate electrical service with a fieldsupplied, waterproof disconnect switch mounted at, or within sight
7
Operation of unit on improper line voltage constitutes abuse and may cause unit damage that could affect warranty.
ROUTING POWER LEADS INTO UNIT
Use only copper wire between disconnect and unit. The highvoltage leads should be in a conduit until they enter the unit; conduit termination at the unit must be watertight. Run the high-voltage leads through the hole on the control box side of the unit (see Fig. 11 for location). When the leads are inside the unit, run leads to the control box (Fig. 12). On 3-phase units, connect the leads to the black, yellow, and blue wires (see Fig. 13).
CONNECTING GROUND LEAD TO UNIT GROUND
Refer to Fig. 12 and 13. Connect the ground lead to the chassis using the unit ground lug in the control box.
ROUTING CONTROL POWER WIRES
Form a drip-loop with the thermostat leads before routing them into the unit. Route the thermostat leads through grommeted hole provided in unit into unit control box (See Fig. 11). Connect thermostat leads and unit power leads as shown in Fig. 13 & 14.
Route thermostat wires through grommet providing a drip-loop at the panel. Connect low-voltage leads to the thermostat as shown in
Fig. 14.
The unit transformer supplies 24-v power for complete system including accessory electrical heater. Transformer is factory wired for 230-v operation. If supply voltage is 208 v, rewire transformer primary as described in the Special Procedures for 208-v Operation section below.
ACCESSORY ELECTRIC HEAT WIRING
Refer to accessory electric heat installation instructions for information on installing accessory electric heat. Accessory electric heat wiring is shown in Fig. 15 - 17.
SPECIAL PROCEDURES FOR 208-V OPERATION
Make sure that the power supply to the unit is switched OFF and install lockout tag before making any wiring changes.
Electrical shock can cause serious injury or death.
1. Remove wire nut from connection of ORG wire to BLK wire.
Disconnect the ORG transformer-primary lead from the BLK wire. Save wire nut. See unit wiring label.
2. Remove the wire nut from the terminal on the end of the RED transformer-primary lead.
3. Save the wire nut.
4. Connect the RED lead to the BLK wire from which the ORG lead was disconnected. Insulate with wire nut from Step 1.
5. Using the wire nut removed from the RED lead, insulate the loose terminal on the ORG lead.
6. Wrap the wire nuts with electrical tape so that the metal terminals cannot be seen.
Indoor blower-motor speeds may need to be changed for 208-v operation. Refer to Indoor Airflow and Airflow Adjustments section. (See Table of Contents for page number.)
Table 1 — Physical Data
UNIT 50ZH
OPERATING WEIGHT (lbs)
COMPRESSOR TYPE
REFRIGERANT Charge (lb)
REFRIGERANT METERING DEVICE
OUTDOOR COIL
Rows...Fins/in.
Face Area (sq ft)
OUTDOOR-FAN MOTOR CFM
Nominal Rpm
Motor Hp
Diameter (in.)
INDOOR COIL
Rows...Fins/in.
Face Area (sq ft)
INDOOR FAN MOTOR
Blower Motor Size (in.)
Nominal Cfm
Rpm Range
Number of Speeds
Factory Speed Setting
Motor Hp
CONNECTING DUCT SIZES
Supply Air (in.)
Return Air (in.)
FIELD-SUPPLIED RETURN-AIR FILTER†
Throwaway (in.)
030
254
5.8
2...17
6.7
2000
1100
1/4
20
3...15
3.1
10 x 8
1000
550-1000
3
Med
1/4
24 x 24
036
277
042
295
048
328
Scroll
R-22
6.6
5.9
2...17
9.3
Propeller
9.1
Acutrol™ System
Copper Tubes, Aluminum Plate Fins
1...17
11.1
2...17
11.1
2600
1100
1/4
20
2600
1100
1/4
20
2600
1100
1/4
20
Copper Tubes, Aluminum Plate Fins
3...15
4.0
3...15
4.0
Direct Drive
4...15
4.4
10 x 9
1200
800-1050
3
Low
1/2
24 x 24
Round
14
14
10 x 9
1400
800-1050
3
Med
1/2
24 x 24
10 x 9
1600
1000-1100
2
Low
3/4
24 x 30
060
368
9.7
2...17
12.7
3200
1100
1/2
20
4...15
4.9
10 x 10
2000
950-1100
3
Low
1
Square
13.9 x 13.9
13.9 x 27.8
24 x 30
* 460-v motors are 2-speed or 3-speed.
†Required filter sizes shown are based on the ARI (Air Conditioning and Refrigeration Institute) rated airflow at a velocity of 300 ft/min for throwaway type or 450 ft/min for high capacity type. Recommended filters are 1-in. thick.
8
PRE-START-UP
INDOOR
THERMOSTAT
Failure to observe the following warnings could result in serious injury or death:
1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.
2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured.
3. Do not remove compressor terminal cover until all electrical sources are disconnected and lockout tag is installed.
4. Relieve all pressure from both high- and low-pressure sides of the system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals. Use accepted methods to recover refrigerant.
5. Never attempt to repair soldered connection while refrigerant system is under pressure.
6. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective goggles and proceed as follows: a. Shut off electrical power to unit and install lockout tag.
b. Relieve all refrigerant from system using both high- and low-pressure ports. Use accepted methods to recover refrigerant.
c. Cut component connecting tubing with tubing cutter and remove component from unit.
d. Carefully unsweat remaining tubing stubs when necessary. Oil can ignite when exposed to torch flame.
Use the Start-Up Checklist supplied at the end of this book and proceed as follows to inspect and prepare the unit for initial start-up:
1. Remove all access panels.
2. Read and follow instructions on all DANGER, WARNING,
CAUTION, and INFORMATION labels attached to, or shipped with, unit.
Make the following inspections: a. Inspect for shipping and handling damages such as broken lines, loose parts, disconnected wires, etc.
b. Inspect for oil at all refrigerant tubing connections and on unit base. Detecting oil generally indicates a refrigerant leak. Leak-test all refrigerant tubing connections using electronic leak detector, or liquid-soap solution. If a refrigerant leak is detected, see following Check for Refrigerant
Leaks section.
c. Inspect all field- and factory-wiring connections. Be sure that connections are completed and tight. Ensure wires do not contact refrigerant tubing or sheet metal edges.
d. Inspect coil fins. If damaged during shipping and handling, carefully straighten fins with a fin comb.
3. Verify the following conditions: a. Make sure that outdoor-fan blade is correctly positioned in fan orifice. Top edge of blade should be 3.125 in. down from outdoor coil outlet grille (size 030–048, See Fig. 23) or hub should be 0.708-in. away from motor end bell (size
060, See Fig. 24). See Outdoor Fan Adjustment section.
b. Make sure that air filter is in place.
c. Make sure that condensate drain trap is filled with water to ensure proper drainage.
9
TOP COVER
RETURN
AIR
Fig. 9—Condensate Trap (Using Tubing)
C99013
1" min.
TRAP
OUTLET
FROM
POWER
SOURCE
Power Wiring
Control Wiring
POWER AND
LOW-VOLTAGE
ENTRY
COMPOSITE
RUST-PROOF
BASEPAN
CONDENSATE
DRAIN
CONNECTION
DISCONNECT
PER NEC*
(UNIT AND
ELECTRIC
HEATER)
Condenser Airflow
Evaporator Airflow
*Separate disconnect per NEC
(National Electrical Code) required for electric heater when singlepoint conection is not used.
C00008
C00008
Table 2—Minimum Airflow for Safe Electric Heater
Operation (CFM)
030
750
036
900
042
1050
SIZE
048
1200
Fig. 8—Typical Installation
060
1500
1” (25mm) MIN.
TRAP
OUTLET
2” (50mm) MIN.
2" min.
C00009
Fig. 10–PVC Condensate Trap
d. Make sure that all tools and miscellaneous loose parts have been removed.
START-UP
Use the Start-Up Checklist supplied at the end of this book and proceed as follows:
Step 1—Check for Refrigerant Leaks
LOCATE AND REPAIR REFRIGERANT LEAKS AND
CHARGE THE UNIT AS FOLLOWS:
1. Using both high- and low-pressure ports, locate leaks and reclaim remaining refrigerant to relieve system pressure.
2. Repair leak following accepted practices.
NOTE: Install a liquid-line filter drier whenever the system has been opened for repair.
HIGH-VOLTAGE
POWER WIRING
ENTRY HOLE
LOW-VOLTAGE
WIRING ENTRY
HOLE
Fig. 11—Unit Electrical Connection
C00010
ELECTRIC
HEATER
FUSES
GROUND
LUG
INDOOR
FAN
RELAY
OUTDOOR FAN MOTOR
AND COMPRESSOR
START CAPACITOR
HIGH
VOLTAGE
LEADS
C00011
Fig. 12—Control Box Wiring
Step 2—Start-Up Cooling Section and Make Adjustments
Complete the required procedures given in the Pre-Start- Up section this page before starting the unit. Do not jumper any safety devices when operating the unit.
Do not operate the compressor in cooling mode when the outdoor temperature is below 40 F.
Do not rapid-cycle the compressor. Allow 5 minutes between
‘‘on’’ cycles to prevent compressor damage.
CHECKING COOLING CONTROL OPERATION
Start and check the unit for proper cooling control operation as follows:
10
1. Place room thermostat SYSTEM switch in OFF position.
Observe that blower motor starts when FAN switch is placed in ON position and shuts down within 30 seeconds when FAN switch is placed in AUTO position.
2. Place SYSTEM switch in COOL position and FAN switch in
AUTO position. Set cooling control below room temperature.
Observe that compressor, outdoor fan, and indoor blower motors start and that reversing valve shifts. Observe that cooling cycle shuts down when control setting is satisfied.
Reversing valve (RV) remains energized.
3. Place system switch in HEAT position. Observe that compressor, indoor fan and outdoor fan energize (Reversing Valve is deenergized in heat pump heating mode). Set control above room temperature. Observe that heating cycle shuts down when control setting is satisfied.
4. When using an automatic changeover room thermostat, place both SYSTEM and FAN switches in AUTO. positions.
Observe that unit operates in Cooling mode when temperature control is set to ‘‘call for cooling’’ (below room temperature), and unit operates in Heating mode when temperature control is set to “call for heating” (above room temperature).
COMPRESSOR ROTATION
On all 3–Phase units it is important to be certain compressor is rotating in the proper direction. To determine whether or not compressor is rotating in the proper direction:
1. Connect service gauges to suction and discharge pressure fittings.
2. Energize the compressor.
3. The suction pressure should drop and the discharge pressure should rise, as is normal on any start-up.
If the suction pressure does not drop and the discharge pressure does not rise to normal levels:
1. Turn off power to the unit and tag disconnect.
2. Reverse any two of the unit power leads.
3. Turn on power to the unit.
The suction and discharge pressure levels should now move to their normal start-up levels.
NOTE: When the compressor is rotation in the wrong direction, the unit makes an elevated level of noise and does not provide cooling.
Step 3—Refrigerant Charge
Refrigerant Charge — Amount of refrigerant charge is listed on unit nameplate and in Table 1. Refer to Carrier Refrigerant Service
Techniques Manual, Refrigerants section. Unit panels must be in place when unit is operating during charging procedure. Unit must operate a minimum of 15 minutes before checking charge.
NO CHARGE
Refer to Carrier Refrigerant Service Techniques. Use standard evacuating techniques. After evacuating system, weigh in the specified amount of refrigerant (refer to Table 1).
LOW CHARGE COOLING
Using cooling charging chart (see Fig. 18–22),Vary refrigerant until conditions of the chart are met. Note that charging chart is different from those normally used. Charts are based on charging the units to the correct superheat for the various operating conditions. An accurate pressure gauge and temperature-sensing device is required. Connect the pressure gauge to the service port on the suction line. Connect temperature sensing device to the suction line near the compressor and insulate it so that outdoor ambient temperature does not affect reading.
3-PHASE
CONNECTIONS
TO DISCONNECT
PER NEC
SINGLE-PHASE
CONNECTIONS
TO DISCONNECT
PER NEC
L
L
L
GROUND
LEAD
UNIT GROUND
BLK
YEL
BLU
C00012
Fig. 13—Line Power Connections
TO USE THE COOLING CHARGING CHART
This method is to be used in cooling mode only. Take the outdoor ambient temperature and read the suction pressure gauge. Refer to charts to determine what the suction temperature should be. If suction temperature is high, add refrigerant. If suction temperature is low, carefully recover some of the charge. Recheck the suction pressure as charge is adjusted.
Example: (See Fig. 18)
Outdoor Temperature —85°F
Suction Pressure—74 psig
Suction Temperature should be—60°F
Note—Suction Temperature may vary +/- 5°F.
HEATING MODE CHARGE
Do not attempt to adjust charge by cooling methods while in heat pump heating mode. Recover refrigerant and weigh in according to unit data plate refrigerant data.
Step 4—Indoor Airflow and Airflow Adjustments
NOTE: For cooling operation, the recommended airflow is 350 to
450 cfm per each 12,000 Btuh of rated cooling capacity.
Table 4 shows dry coil air delivery for horizontal discharge units.
Tables 5-7 show pressure drops.
NOTE: Be sure that all supply- and return-air grilles are open, free from obstructions, and adjusted properly.
Disconnect electrical power to the unit and install lockout tag before changing blower speed. Electrical shock can cause serious injury or death.
Airflow can be changed by changing the lead connections of the blower motor.
Units 50ZH 036, 048, and 060 blower motors are factory wired for low speed operation. Units 50ZH030 and 042 are factory wired for medium speed operation.
FOR 208/230-V
The motor leads are color-coded as follows:
3-SPEED black = high speed blue = medium speed red = low speed
2-SPEED black = high speed
red = low speed
11
C
BRN
O
ORN
R
RED
G
GRN
Y
YEL
E
WHT
W2
THERMOSTAT
AND SUBBASE
UNIT CONTROL POWER
SPLICE BOX
C99056
Fig. 14—Control Connections
To change the speed of the indoor fan motor (IFM), remove the fan motor speed leg lead from the indoor fan relay (IFR) with units
030, 042, 048 & 060 or the time delay relay (TDR) on 036 size and replace with lead for desired blower motor speed. Insulate the removed lead to avoid contact with chassis parts.
FOR 460-V MOTORS
The motor leads are color coded as follows:
3-SPEED (060 ONLY) black = high speed
orange = medium speed blue = low speed
2-SPEED black = to purple yellow = line purple = to black red = line
To change the speed of the indoor fan motor (IFM) from low speed to high speed, remove the red lead from the indoor-fan relay (IFR).
ON 2–Speed Motors: Insulate the red lead to avoid contact with any chassis parts. Separate the black lead from the purple lead.
Connect the black lead to the IFR. Insulate the purple lead to avoid contact with any chassis parts. ON 3–Speed Motors: remove the fan motor speed leg lead from the indoor (indoor) fan relay (IFR) and replace with lead for desired blower motor speed.
Step 5—Unit Controls
All compressors have the following internal-protection controls.
HIGH-PRESSURE RELIEF VALVE
This valve opens when the pressure differential between the low and high side becomes excessive.
LOSS OF CHARGE SWITCH
Located on the outdoor liquid line is a low-pressure switch which functions as a loss-of-charge switch. This switch contains a
Schrader core depressor. This switch opens at 7 psig and closes at
22 psig. No adjustment is necessary.
COMPRESSOR OVERLOAD
This overload interrupts power to the compressor when either the current or internal temperature become excessive, and automatically resets when the internal temperature drops to a safe level.
This overload may require up to 60 minutes (or longer) to reset; therefore, if the internal overload is suspected of being open, disconnect the electrical power to the unit and check the circuit through the overload with an ohmmeter or continuity tester.
Fig. 15—208/230-3-60 Wiring Diagram
12
A06055
Fig. 16—460-3-60 Wiring Diagram
13
A06056
TO
UNIT POWER
WIRING
C
W1
W1
BLK
YEL
BRN (COMMON)
VIO (STEP 2)
WHT ( STEP 1)
YEL
CONTACTOR 2
BRN
YEL
L2
L1
FUSE BLOCK
F3 YEL
F4
F1
YEL
BLK
F2
BLK
YEL
CONTACTOR 1
BRN
YEL
YEL YEL
EL 1
EL 2
EL 3
AUTO-LIMIT
BLK
BLK
BLK
C00014
Step 6—Sequence of Operation
Fig. 17—Accessory Electric Heater Wiring
FAN OPERATION
The FAN switch on the thermostat controls indoor fan operation.
When the FAN switch is placed in the ON position, the IFR
(indoor-fan relay) is energized through the G terminal on the thermostat. The normally-open contacts close, which then provide power to the indoor (evaporator) fan motor (IFM). The IFM will run continuously when the FAN switch is set to ON.
When the FAN switch is set to AUTO, the thermostat deenergizes the IFR (provided there is not a call for cooling). The contacts open and the IFM is deenergized. The IFM will be energized only when there is a call for cooling, in heat pump heating mode or if the unit is equipped with accessory electric heat, the indoor-fan motor will also run while the accessory electric heat is energized.
NOTE: Some units are equipped with a time-delay relay. On these units, the indoor fan remains on for 30 seconds after G or Y is deenergized.
Should room temperature continue to fall, circuit R-W is made through second-stage thermostat bulb. If optional electric heat package is used, a relay is energized, bringing on first bank of supplemental electric heat. When thermostat is satisfied, contacts open, deenergizing contactor and relay; motors and heaters deenergize. The IFM may be controlled by a time-delay relay that keeps the fan on for 30 seconds.
DEFROST
Defrost board (DB) is a time and temperature control, which includes a field-selectable time period between checks for defrost
(30, 50 and 90 minutes). The time period is factory-set at 30 minutes and should only be adjusted by a trained service person.
Electronic timer and defrost cycle start only when contactor is energized and defrost thermostat (DFT) is closed.
Defrost mode is identical to Cooling mode. The outdoor fan motor stops because of “OF1” and “OF2” contacts opening on the defrost board, a bank of optional electric heat turns on to warm air supplying the conditioned space.
COOLING
With the thermostat subbase in the cooling position, the thermostat makes circuit R-O. This energizes the reversing valve solenoid
(RVS) and places the unit in standby condition for cooling.
NOTE: The defrost control board has a 5 minute compressor anti-short cycle time delay built in between compressor starts.
On a call for cooling, the compressor contactor (C) and the IFR are energized through the Y and G terminals of the thermostat.
Energizing the compressor contactor supplies power to the compressor and the outdoor (condenser) fan motor (OFM). Energizing the IFR provides power to the IFM.
When the need for cooling has been satisfied, the OFM, compressor, and IFM (FAN on AUTO) are deenergized. If the unit is equipped with a 30-second delay (036 size only), the indoor fan will remain energized for 30 seconds after the compressor is deenergized. The reversing valve solenoid remains energized.
MAINTENANCE
To ensure continuing high performance, and to reduce the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This cooling unit should be inspected at least once each year by a qualified service person. To troubleshoot cooling of units, refer to Troubleshooting chart in back of book.
NOTE TO EQUIPMENT OWNER: Consult your local dealer about the availability of a maintenance contract.
HEAT PUMP HEATING
On a call for heat, thermostat makes circuits R-Y and R-G. When compressor time delay (5-minute ± 2 minutes) is completed, a circuit is made to C, starting COMP and OFM. Circuit R-G also energizes IFR and starts IFM after 1-second delay.
ELECTRIC RESISTANCE HEATING
If accessory electric heaters are installed, on a call for “Emergency
Heat” the thermostat energizes W which energises the heater relay and in turn energizes the electric heaters. The IFR is energized which starts the indoor-fan motor. If the heaters are staged, W2 is energized when the second stage of heating is required. When the need for heating is satisfied, the heater and IFM are deenergized.
14
UNIT 50ZH
SIZE
(–SERIES, IF
USED)
030
036
042
048
060
V-PH-HZ
208/230–3–6 187 254
460–3–60
208/230–3–60 187 254
460–3–60
208/230–3–60 187 254
460–3–60
208/230–3–60 187 254
460–3–60
VOLTAGE
RANGE
MIN MAX
208/230–3–60 187 254
414 508
414 508
414 508
414 508
COMPRESSOR
RLA LRA
10.0
11.4
5.7
13.9
6.8
12.8
6.4
15.9
8.0
Table 3—Electrical Data—50ZH
63.0
77.0
39.0
88.0
44.0
93.0
46.5
124.0
59.6
OFM
FLA
IFM
FLA
1.5
1.5
0.8
1.5
0.8
1.5
0.8
3.1
1.5
5.8
2.8
1.5
2.8
1.5
4.2
2.1
6.2
3.2
ELECTRIC HEAT
Nominal KW*
—
5
10
15
20
-/-
3.8/5.0
7.5/10.0
11.3/15.0
15/20
—
5
10
15
20
-/-
3.8/5.0
7.5/10.0
11.3/15.0
14.9/19.9
—
5
10
15
19.9
-/-
3.8/5.0
7.5/10.0
11.3/15.0
-/-
3.8/5.0
7.5/10.0
11.3/15.0
—
5
10
15
-/-
3.8/5.0
7.5/10.0
11.3/15.0
15/20
FLA
—
6.0
12.0
18.0
24.1
-/-
10.5/12.0
20.8/24.1
31.4/36.1
41.4/47.9
—
6.0
12.0
18.0
24.1
-/-
10.5/12.0
20.8/24.1
31.4/36.1
41.4/47.9
—
6.0
12.0
18 .0
23.9
-/-
10.4/12.0
20.8/24.1
31.3/36.1
-/-
10.4/12.0
20.8/24.1
31.3/36.1
—
6.0
12.0
18.0
-/-
10.5/12.0
20.8/24.1
31.4/36.1
41.4/47.9
10.8
18.3
25.8
33.3
40.9
21.7/21.70
34.8/36.7
47.7/51.8
61.0/66.8
73.7/81.8
10.9
18.4
25.9
33.4
41.0
29.2/29.2
42.3/44.2
55.2/59.3
68.4/74.3
81.2/89.3
14.7
22.2
29.7
37.2
44.6
16.8
29.9/31.8
42.8/46.9
56.1/61.9
18.6/18.6
31.7/33.6
44.6/48.7
57.8/63.7
9.9
16.9
24.4
31.9
21.7/21.7
34.8/36.7
47.7/51.8
60.9/66.8
73.4/81.6
SINGLE POINT POWER SUPPLY
MCA
25/25
35/40
50/60
—
—
15
20
30
35
45
30/30
35/40
50/50
—
—
15
20
30
35
45
35/35
45/45
60/60
—
—
20
25
30
40
45
FUSE OR
CKT BKR
20
35/35
45/50
60/–
25/25
35/35
45/50
60/-
15
20
25
35
MOCP
—
—
—
—
—
—
—
—
70/80
90/90
—
—
—
—
—
—
—
—
70/70
80/90
—
—
—
—
—
—
—
—
—
—
—
—
70/70
80/90
—
—
—
–/70
—
—
—
–/70
(See legend following Electrical Data charts)
LEGEND
FLA
LRA
— Full Load Amps
— Locked Rotor Amps
MCA — Minimum Circuit Amps
MOCP — Maximum Overcurrent Protection
RLA — Rated Load Amps
CKT BKR — Circuit Breaker
®
NOTES:
1. In compliance with NEC (National Electrical Code) requirements for multimotor and combination load equipment (refer to NEC
Articles 430 and 440), the overcurrent protective device for the unit shall be Power Supply fuse . Canadian units may be fuse or circuit breaker.
2. Minimum wire size is based on 60 C copper wire. If other than
60 C wire is used, or if length exceeds wire length in table, determine size from NEC.
3. 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.
% Voltage imbalance
= 100 x max voltage deviation from average voltage average voltage
EXAMPLE: Supply voltage is 460-3-60.
AB = 452 v
BC = 464 v
AC = 455 v
Average Voltage =
452 + 464 + 455
3
=
1371
3
= 457
Determine maximum deviation from average voltage.
(AB) 457
(BC) 464
452 = 5 v
457 = 7 v
(AC) 457 455 = 2 v
Maximum deviation is 7 v.
Determine percent of voltage imbalance.
% Voltage Imbalance = 100 x
7
457
= 1.53%
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.
15
The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment, other than those procedures recommended in the User’s Manual. FAILURE
TO HEED THIS WARNING COULD RESULT IN SERI-
OUS INJURY, DEATH OR DAMAGE TO THIS EQUIP-
MENT.
The minimum maintenance requirements for this equipment are as follows:
1. Inspect air filter(s) each month. Clean or replace when necessary.
2. Inspect indoor coil, outdoor coil, drain pan, and condensate drain each cooling and heating season for cleanliness. Clean when necessary.
3. Inspect blower motor and wheel for cleanliness each cooling and heating season. Clean when necessary. For first heating season, inspect blower wheel bimonthly to determine proper cleaning frequency.
4. Check electrical connections for tightness and controls for proper operation each cooling season. Service when necessary.
5. Check the drain channel in the top cover periodically for blockage (leaves, insects). Clean as needed.
Failure to follow these warnings could result in serious injury or death:
1. Turn off electrical power to the unit and install lockout tag before performing any maintenance or service on the unit.
2. Use extreme caution when removing panels and parts. As with any mechanical equipment, personal injury can result from sharp edges, etc.
3. Never place anything combustible either on, or in contact with, the unit.
Step 1—Air Filter
NOTE: Never operate the unit without a suitable air filter in the return-air duct system. Always replace the filter with the same size as originally installed. See Table 1 for recommended filter sizes
Inspect air filter(s) at least once each month and replace
(throwaway-type) or clean (cleanable-type) at least twice during each cooling season or whenever the filters become clogged with dust and lint.
Replace filters with the same dimensional size and type as originally provided, when necessary.
Step 2—Unit Top Removal (Outdoor-Coil Side)
NOTE: When performing maintenance or service procedures that require removal of the unit top, be sure to perform all of the routine maintenance procedures that require top removal, including coil inspection and cleaning, and condensate drain pan inspection and cleaning.
Disconnect and tag electrical power to the unit before removing top. Failure to adhere to this warning could cause serious injury or death.
Only qualified service personnel should perform maintenance and service procedures that require unit top removal.
Refer to the following top removal procedures:
1. Remove 7 screws on unit top cover surface. (Save all screws.)
2. Remove 2 screws on unit top cover flange. (Save all screws.)
3. Lift top from unit carefully. Set top on edge and make sure that top is supported by unit side that is opposite duct (or plenum) side.
4. Carefully replace and secure unit top to unit, using screws removed in steps 1 and 2 above, when maintenance and/or service procedures are completed.
Step 3—Indoor Blower and Motor
For longer life, operating economy, and continuing efficiency, clean accumulated dirt and grease from the blower wheel and motor annually.
Disconnect and tag electrical power to the unit before cleaning the blower wheel. Failure to adhere to this warning could cause serious injury or death.
To clean the blower wheel:
1. Access the blower assembly as follows: a. Remove top access panel.
b. Remove 3 screws that hold blower orifice ring to blower housing. Save screws.
c. Loosen setscrew(s) which secure wheel to motor shaft.
2. Remove and clean blower wheel as follows:
758 110
OUTDOOR TEMP
O
F
O
C
115 46
683 100
621 90
552 80
483 70
414 60
105 41
95 35
85 29
75 24
65 18
55 13
45 7
345 50
276 40
207 30
30
-1
40 50 60 70
SUCTION LINE TEMPERATURE ( O F)
80
4 10 16 21
SUCTION LINE TEMPERATURE ( O C)
27
90
32
Fig. 18—Cooling Charging Chart—50ZH030
C00163
16
758 110
683 100
621 90
552 80
483 70
414 60
683 100
621 90
552 80
483 70
414 60
OUTDOOR TEMP
O
F
O
C
115 46
105 41
95 35
85 29
75 24
65 18
55 13
45 7
345 50
276 40
207 30
30
-1
40 50 60 70
SUCTION LINE TEMPERATURE ( O F)
80
4 10 16 21
SUCTION LINE TEMPERATURE ( O C)
27
90
32
C00164
Fig. 19—Cooling Charging Chart—50ZH036 Units
758 110
OUTDOOR TEMP
O
F
O
C
115 46
105 41
95 35
85 29
75 24
65 18
55 13
45 7
758 110
683 100
621 90
552 80
OUTDOOR TEMP
O F O C
115 46
105 41
95 35
85 29
75 24
65 18
55 13
45 7
483 70
414 60
345 50
276 40
207 30
30
-1
40 50 60 70
SUCTION LINE TEMPERATURE ( O F)
80
4 10 16 21
SUCTION LINE TEMPERATURE ( O C)
27
90
32
C00166
Fig. 21—Cooling Charging Chart—50ZH048 Units
758 110
OUTDOOR TEMP
O
F
O
C
683 100
621 90
552 80
483 70
115 46
105 41
95 35
85 29
75 24
65 18
55 13
45 7
414 60
345 50
276 40
345 50
276 40
207 30
30 40 50 60 70
SUCTION LINE TEMPERATURE ( O F)
80 90
-1 4 10 16 21
SUCTION LINE TEMPERATURE ( O C)
27 32
C00165
Fig. 20—Cooling Charging Chart—50ZH042 Units
a. Lift wheel from housing. When handling and/or cleaning blower wheel, be sure not to disturb balance weights (clips) on blower wheel vanes.
b. Remove caked-on dirt from wheel and housing with a brush. Remove lint and/or dirt accumulations from wheel and housing with vacuum cleaner, using a soft brush attachment. Remove grease and oil with a mild solvent.
c. Reassemble blower into housing. Place upper orifice ring on blower to judge location of the blower wheel. Blower wheel should be approximately 0.2-in. below bottom of orifice ring when centered correctly. Be sure setscrews are tightened on motor and are not on round part of shaft.
d. Set upper orifice ring in place with 3 screws removed in step 1 above.
17
207 30
30
-1
40 50 60 70
SUCTION LINE TEMPERATURE ( O F)
80
4 10 16 21
SUCTION LINE TEMPERATURE ( O C)
27
90
32
C00167
Fig. 22—Cooling Charging Chart—50ZH060 Units
e. Replace top access panel.
Step 4—Outdoor Coil, Indoor Coil, and Condensate
Drain Pan
Inspect the outdoor coil, indoor coil, and condensate drain pan at least once heating and cooling season. Proper inspection and cleaning requires the removal of the unit top. See Unit Top
Removal section above.
Remove all obstructions (including weeds and shrubs) that interfere with the airflow through the outdoor coil. Straighten bent fins with a fin comb. If coated with dirt or lint, clean the coils with a vacuum cleaner, using a soft brush attachment. Be careful not to bend the fins. If coated with oil or grease, clean the coils with a mild detergent-and-water-solution. Rinse coils with clear water, using a garden hose. Be careful not to splash water on motors,
Table 4—Dry Coil Air Delivery* Horizontal Discharge
(Deduct 10 percent for 208 Volt Operation)
Unit
030
036
042 †
048 †
060 †
Motor Speed
Low
Med
High
Low
Med
High
Low
Med
High
Low
Med
High
Low
Med
High
Watts/CFM
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
Watts
Cfm
0.1
288
875
390
1131
528
1891
450
1231
470
1302
660
1700
478
1303
481
1310
-
-
-
-
-
-
-
-
890
1834
1040
2230
1073
2230
230 AND 460 VOLT
External Static Pressure (in. wg)
0.2
285
0.3
282
0.4
279
0.5
274
0.6
268
820
383
1090
520
1660
458
1270
468
1280
798
1338
435
1218
450
1264
635
1736
-
-
-
-
-
-
850
1820
1018
2102
1038
2202
802
378
1038
510
1285
420
1204
445
1205
610
1581
440
1224
450
1241
678
1688
801
1898
-
-
870
2000
810
1791
1000
2025
1001
2160
734
369
978
495
1200
400
1120
410
1163
575
1450
411
1179
438
1181
647
1618
760
1841
-
-
842
1903
790
1762
950
1960
958
2122
668
360
917
480
1115
380
1008
388
1081
540
1297
378
1126
404
1110
618
1510
730
1757
-
-
818
1799
735
1703
890
1901
896
2052
582
350
830
460
1190
350
1022
370
1022
578
1018
335
950
359
940
505
1421
688
1682
-
-
782
1718
680
1640
835
1855
840
1926
0.7
261
478
340
721
450
920
326
863
338
873
485
1095
327
911
338
943
540
1309
650
1564
-
-
696
1625
580
1415
790
1752
800
1791
† 460-v motors are 2-speed.
Air delivery values are based on operating voltage of 230-v. or 460-v., dry coil, without filter or electric heater. Deduct wet coil, filter, and electric heater pressure drops to obtain external static pressure availabe for ducting.
Do not operate the unit at a cooling airflow that is less than 350 cfm for each 12,000 Btuh of rated cooling capacity. Evaporator coil frosting may occur at airflows below this point.
Dashes indicate portions of the table that are beyond the blower motor capacity or are not recommended.
1187
600
1429
-
-
632
999
317
816
320
811
500
-
311
751
321
783
460
0.8
-
-
-
-
-
1446
480
1159
650
1468
691
1588
1060
570
1333
-
-
628
-
-
-
-
-
460
-
-
-
-
-
-
0.9
-
-
-
-
-
1365
422
950
580
1121
575
1202
030
036
042
048
060
Table 5—Wet Coil Pressure Drop
UNIT SIZE
50ZH
AIRFLOW
(CFM)
900
1000
1200
1000
1200
1400
1600
1800
1700
1800
2100
2300
1600
1000
1200
1400
1600
1400
PRESSURE DROP
(IN. WG)
0.06
0.06
0.08
0.07
0.09
0.11
0.08
0.09
0.07
0.08
0.09
0.10
0.12
0.04
0.06
0.08
0.09
0.07
Table 6—Filter Pressure Drop (In. wg)
UNIT
SIZE
50ZH
FILTER
SIZE
(IN.) 500 600 700 800 900
CFM
1000 1100 1200 1300 1400
030-042 24 x 24 0.06 0.07 0.08 0.08 0.09
0.09
0.09
0.10
0.11
0.12
048, 060 24 x 30 0.08
0.09
UNIT
SIZE
50ZH
FILTER
SIZE
(IN.)
CFM
1500 1600 1700 1800 1900 2000 2100 2200 2300
030-042 24 x 24 0.14
0.15
-
048,060 24 x 30 0.10
0.11
0.12
0.13
0.14
0.15
0.16
0.17
0.18
18 insulation, wiring or air filter(s). For best results, spray outdoorcoil fins from inside to outside the unit. On units with an outer and inner outdoor coil, be sure to clean between the coils. Be sure to flush all dirt and debris from the unit base.
Inspect the drain pan and condensate drain line when inspecting the coils. Clean the drain pan and condensate drain by removing all foreign matter from the pan. Flush the pan and drain tube with clear water. Do not splash water on the insulation, motor, wiring,
Table 7—Accessory Electric Heat Pressure Drop
(In. wg)
HEATER KW
5-20
CFM
600 800 1000 1200 1400 1600 1800 2000 2200
0.06 0.08 0.10
0.13
0.15
0.18
0.20
0.23
0.25
or air filter(s). If the drain tube is restricted, clear it with a
‘‘plumbers snake’’ or similar probe device. Ensure that the auxiliary drain port above the drain tube is also clear.
Step 5—Outdoor Fan
Keep the Outdoor fan free from all obstructions to ensure proper cooling operation. Never place articles on top of the unit. Damage to unit may result.
1. Shut off unit power supply and install lockout tag.
2. Remove outdoor-fan assembly (grille, motor, motor cover, and fan) by removing screws and flipping assembly onto unit top cover.
3. Loosen fan hub setscrews.
4. Adjust fan height as shown in Fig. 23 or 24.
5. Tighten setscrews.
6. Replace outdoor-fan assembly.
Step 6—Electrical Controls and Wiring
Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit and install lockout tag.
Remove the top panel to locate all the electrical controls and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any smoky or burned connections are noticed, disassemble the connection, clean all the parts, restrip the wire end and reassemble the connection properly and securely.
3.125 in.
C00021
Fig. 23—Outdoor-Fan Adjustment (030–048 Size)
0.708in.
C02017
Fig. 24—Outdoor-Fan Adjustment (060 Size)
Check to ensure no wires are touching refrigerant tubing or sharp sheet metal edges. Move and secure wires to isolate from tubing and sheet metal edges.
After inspecting the electrical controls and wiring, replace all the panels. Start the unit, and observe at least one complete cooling cycle to ensure proper operation. If discrepancies are observed in operating cycle, or if a suspected malfunction has occurred, check each electrical component with the proper electrical instrumentation. Refer to the unit wiring label when making these checkouts.
NOTE: Refer to the Sequence of Operation section, as an aid in determining proper control operation.
Step 7—Refrigerant Circuit
Inspect all refrigerant tubing connections and the unit base for oil accumulations annually. Detecting oil generally indicates a refrigerant leak.
If oil is detected or if low cooling performance is suspected, leak-test all refrigerant tubing using an electronic leak-detector, or liquid-soap solution. If a refrigerant leak is detected, refer to Check for Refrigerant Leaks section. (See Table of Contents for page number.)
If no refrigerant leaks are found and low cooling performance is suspected, refer to Refrigerant Charge. (See Table of Contents for page number.)
Step 8—Indoor Airflow
The cooling airflow does not require checking unless improper performance is suspected. If a problem exists, be sure that all supply- and return-air grilles are open and free from obstructions,
and that the air filter is clean. When necessary, refer to Indoor
Airflow and Airflow Adjustments section to check the system airflow.
Step 9—Metering Devices
Refrigerant metering devices are fixed orifices and are located in the inlet header to the indoor and outdoor coils.
Check valves are also located in the liquid lines near the strainers.
The check valves are the smaller of the two components.
Step 10—Lubrication
COMPRESSOR—The compressor is charged with the correct amount of oil at the factory.
FAN MOTOR BEARINGS—Fan motor bearings are permanently lubricated. No further lubrication of outdoor or indoor fan motors is required.
Step 11—Liquid Line Strainer
The liquid line strainer (to protect metering device) is made of wire mesh and is located in the liquid line on the inlet side of the metering device.
Check valves are also located in the liquid lines near the strainers.
The Strainers are the larger of the two components.
Step 12—High Flow Valves
Located on the compressor hot gas and suction tubes are High
Flow Valves. Large black plastic caps distinguish these valves with O-rings located inside the caps. These valves cannot be accessed for service in the field. Ensure the plastic caps are in place and tight or the possibility of refrigerant leakage could occur.
19
OUTDOOR COIL INDOOR COIL
A
B
LCS
D
Check Valves
A
B
Open
Closed
C
D
Open
LCS
Closed
LEGEND
Loss of Charge Switch
Acutrol Metering Device
Check Valve (Arrow indicates direction of flow)
C
STRAINER
HEATING CYCLE
1. Hot gas from compressor flows through the 4-way valve and is directed to the cooling liquid line check valve. It is then condensed and directed through subcooling circuits and out to the strainer and the check valve in the heating liquid line.
2. The refrigerant then feeds the outdoor coil through the Acutrol metering device on each circuit.
3. Each circuit evaporates the refrigerant and the circuits are combined in the outdoor header with some of the circuits flowing through the check valve.
4. The refrigerant then flows through the 4-way valve, accumulator, and back to the compressor.
Fig. 25–Typical Heat Pump Operation, Heating Mode
C95045
20
OUTDOOR COIL INDOOR COIL
A
B
LCS
D
60000
50000
40000
30000
20000
10000
0
80000
Check Valves
A
B
Closed
Open
C
D
Closed
LCS
Open
LEGEND
Loss of Charge Switch
Acutrol Metering Device
Check Valve (Arrow indicates direction of flow)
C
STRAINER
COOLING CYCLE
1. Hot gas from compressor flows through the 4-way valve and is directed to the heating liquid line check valve. It is then condensed and subcooled through converging circuits. Refrigerant leaves the outdoor coil by way of the strainer and the check valve in the cooling liquid line.
2. The refrigerant then feeds the indoor coil through the Acutrol metering device on each circuit.
3. Each circuit evaporates the refrigerant and the circuits are combined in the indoor coil header with some of the circuits flowing through the check valve.
4. The refrigerant then flows through the 4-way valve, accumulator, and back to the compressor.
Fig. 26–Typical Heat Pump Operation, Cooling Mode
Balance Point Worksheet
70000
-10 0 10 20 30
Outdoor Air Temp (Deg F)
Fig. 27–50ZH Balance Point Chart
21
40 50 60
C95044
030
036
042
048
060
C01038rev2
SYMPTOM
Table 8—Troubleshooting—Cooling and Heating
Compressor and outdoor fan will not start.
CAUSE
Power Failure
Loss of Charge
Switch open
Fuse blown or circuit breaker tripped
Defective thermostat, contractor, transformer, or control relay
Insufficient line voltage
Incorrect or faulty wiring
Thermostat setting too high
REMEDY
Call power company
Evaluate unit for possible refrigerant leak
Replace fuse or reset circuit breaker
Replace component
Determine cause and correct
Check wiring diagram and rewire correctly
Lower thermostat setting below room temperature
Compressor will not start but outdoor fan runs.
Faulty wiring or loose connections in compressor circuit
Compressor motor burned out, seized, or internal overload open
Defective run/start capacitor, overload, start relay
One leg of 3-phase power dead
Check wiring and repair or replace
Determine cause
Replace compressor
Determine cause and replace
Replace fuse or reset circuit breaker
Determine cause
Low input voltage
(20 percent low)
Determine cause and correct
Refrigerant overcharge or undercharge
Recover refrigerant, evacuate system, and recharge to capacities shown on nameplate
Compressor cycles
(other than normally satisfying thermostat).
Compressor operates continuously.
Excessive head pressure.
Loss of Charge
Switch open
Defective compressor
Insufficient line voltage
Blocked outdoor coil (cooling)
Defective run/start capacitor, overload or start relay
Defective thermostat
Faulty outdoor-fan motor or capacitor
Restriction in refrigerant system
Dirty air filter
Unit undersized for load
Thermostat set too low
Low refrigerant charge
Leaking valves in compressor
Frosted outdoor coil with incorrect defrost operation (heating)
Air in refrigerant system outdoor coil dirty or restricted
Dirty air filter
Dirty outdoor coil
Refrigerant overcharged
Air in refrigerant system
Evaluate unit for possible refrigerant leak
Replace and determine cause
Determine cause and correct
Determine cause and correct
Determine cause and replace
Replace thermostat
Replace
Locate restriction and remove
Replace filter
Decrease load or increase unit size
Reset thermostat
Locate leak, repair, and recharge
Replace compressor
Check defrost time settings. Reset as necessary.
Check defrost temperature switch. Replace as necessary.
Recover refrigerant, evacuate system, and recharge
Clean coil or remove restriction
Replace filter
Clean coil
Recover excess refrigerant
Recover refrigerant, evacuate system, and recharge
Head pressure too low.
Excessive suction pressure.
Suction pressure too low.
Compressor runs but outdoor fan does not.
Outdoor or indoor air restricted or air is recirculating
Low refrigerant charge
Compressor valves leaking
Restriction in liquid tube
High heat load
Compressor valves leaking
Refrigerant overcharged
Dirty air filter (cooling)
Low refrigerant charge
Metering device or low side restricted
Insufficient indoor airflow (cooling)
Temperature too low in conditioned area (cooling)
Outdoor ambient below 40°F (cooling)
Field-installed filter-drier restricted
Normally closed contacts on defrost board open
Determine cause and correct
Check for leaks, repair and recharge
Replace compressor
Remove restriction
Check for source and eliminate
Replace compressor
Recover excess refrigerant
Replace Filter
Check for leaks, repair, and recharge
Remove source of restriction
Increase air quantity
Check filter- replace if necessary
Reset thermostat
Install low-ambient kit
Replace
Check condition of relay on board.
Replace board if necessary.
22
START-UP CHECKLIST
(REMOVE AND STORE IN JOB FILE)
I. PRELIMINARY INFORMATION
Model No .............................................................................................................................................................
Serial No ..............................................................................................................................................................
Date ......................................................................................................................................................................
Technician ...........................................................................................................................................................
Customer Information(Name/Address) ...........................................................................................................................................................
II. PRE-START-UP
____ Verify that all packing materials have been removed from unit
____ Verify that condensate connection is installed per installation instructions
____ Check all electrical connections and terminals for tightness
____ Check wire proximity to refrigerant tubes and sheet metal edges
____ Check that indoor (indoor) air filter is clean and in place
____ Verify that unit installation is level
____ Check fan wheel propeller for location in housing and setscrew tightness
III. START-UP
Supply Voltage: L1-L2 __________ L2-L3 __________ L3-L1 __________
Compressor Amps: L1(C) __________ L2(S) __________ L3(R) __________
Indoor Fan Amps: __________ Outdoor Fan Amps: __________
TEMPERATURE-Cooling Mode
Outdoor Air Temperature: __________ DB ____________WB
Return-Air Temperature: __________ DB __________ WB
Cooling Supply Air: __________DB___________WB
PRESSURES-Cooling Mode
Refrigerant Suction __________ psig
Suction Line Temp* ___________
Refrigerant Discharge __________ psig
Discharge Temp†__________
TEMPERATURE-Heating Mode
Outdoor Air Temperature: __________ DB ____________WB
Return-Air Temperature: __________ DB __________ WB
Cooling Supply Air: __________DB___________WB
PRESSURES-Heating Mode
Refrigerant Suction __________ psig
Suction Line Temp* ___________
Refrigerant Discharge __________ psig
Discharge Temp†__________
____ Verify Refrigerant charge using charging tables
____ Verify that 3-phase scroll compressor is rotating in correct direction.
*Measured at suction inlet to compressor
†Measured at liquid line leaving outdoor coil
23
Copyright 2006 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 6 8 PC 101 Printed in U.S.A.
Catalog No. 50ZH-6SI Pg 24 2-06 Replaces: New
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