Carrier 50FK Specifications

Carrier 50FK Specifications
48FK,JK034-104
48FM078-104
50FK,FY,JK,JY034-104
50FM,FS078-104
Variable-Air Volume Rooftop Units
Controls Operation,
and Troubleshooting
CONTENTS
Page
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Rooftop Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
VAV Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
• P1 — SUPPLY-AIR SET POINT
• P2 — ECONOMIZER POSITION
• P3 — RESET LIMIT
• P4 — DEMAND LIMIT
• P5 — ECONOMIZER MINIMUM POSITION
• P6 — WARM-UP SET POINT
• P7 — SASP RESET TEMPERATURE
• PROCESSOR BOARD OUTPUTS
• CONFIGURATION HEADER AND DIP SWITCH
ASSEMBLY
Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
• T1 — SUPPLY-AIR TEMPERATURE THERMISTOR
• T2 — RETURN-AIR TEMPERATURE THERMISTOR
• T3 — SATURATED CONDENSING TEMPERATURE,
CIRCUIT 1
• T4 — SATURATED CONDENSING TEMPERATURE,
CIRCUIT 2
• T10 — RESET TEMPERATURE
Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
• CONTROL RELAY (CR)
Accessory Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
• P3 — RESET LIMIT
• P5 — ECONOMIZER MINIMUM POSITION
• P6 — MORNING WARM-UP TEMPERATURE
Single-Step Demand Unit. . . . . . . . . . . . . . . . . . . . . . . . . 7
Demand Limit Control Module (DLCM) . . . . . . . . . . . 7
Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
• ENTHALPY CONTROL
• DIFFERENTIAL ENTHALPY
Supply Fan Variable Frequency Drive (VFD). . . . . 12
High Capacity Modulating Power
Exhaust Variable Frequency Drive . . . . . . . . . . . . 12
Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CONTROLS INSTALLATION. . . . . . . . . . . . . . . . . . 13-25
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
• NIGHT SETBACK THERMOSTAT
• SPACE TEMPERATURE RESET ACCESSORY
(50DJ900021)
Space Temperature Reset . . . . . . . . . . . . . . . . . . . . . . 13
• INSTALLATION
• CONFIGURATION
• OPERATING SEQUENCE
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
• SINGLE-STEP DEMAND LIMIT
• TWO-STEP DEMAND LIMIT
• INSTALLATION
• CONFIGURATION
• OPERATING SEQUENCE
Page
Control From Remote Building Management
System (BMS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
• OCCUPIED/UNOCCUPIED
• NIGHT SETBACK CONTROL
• UNIT SUPPLY AIR SET POINT ADJUSTMENT
• DEMAND UNIT (1-STAGE OR 2-STAGE)
• SUPPLY DUCT PRESSURE SET POINT ADJUSTMENT
• EXTERNAL ALARM SIGNAL
• REMOTE ECONOMIZER CONTROL
Smoke Control Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
• FIRE SHUTDOWN MODE
• PRESSURIZATION MODE
• EVACUATION MODE
• SMOKE PURGE MODE
• INSTALLATION
• CONFIGURATION
• OPERATING SEQUENCE
Air Pressure Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
• INLET GUIDE VANES
• SUPPLY FAN VARIABLE FREQUENCY DRIVE
• MODULATING POWER EXHAUST
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-31
Initial Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Configuration Header . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Adjusting Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Potentiometers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Supply Fan Control with IGV Option . . . . . . . . . . . . 28
Supply Fan Control with VFD Option . . . . . . . . . . . . 28
Modulating Power Exhaust Option or
Accessory) (48FK,JK and 50FK,JK Units) . . . . . 30
High Capacity Power Exhaust
(48FM and 50FM,FS Units) . . . . . . . . . . . . . . . . . . . . 30
START UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-34
Quick Test Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATING INFORMATION. . . . . . . . . . . . . . . . . . 34-44
Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
• CODES 0 THROUGH 8, CAPACITY STEPS
• CODES 20 THROUGH 30 AND 88, OPERATIONAL
STATUS
• CODES 51 THROUGH 87, DIAGNOSTIC
INFORMATION
Operating Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
• SIZE 034, 038 AND 048-088 UNITS
• SIZE 044 UNITS
• SIZE 104 UNITS
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Supply Fan Control with IGV . . . . . . . . . . . . . . . . . . . . 38
Supply Fan Control with VFD. . . . . . . . . . . . . . . . . . . . 38
Modulating Power Exhaust (48FK,JK and
50FK,JK Units Option or Accessory) . . . . . . . . . . 38
High Capacity Modulating Power Exhaust
(48FM and 50FM,FS Units) . . . . . . . . . . . . . . . . . . . . 38
Unit Staging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 111
Catalog No. 534-763
Printed in U.S.A.
Form 48/50F,J-3T
Pg 1
3-00
Replaces: 48/50F,J-1T
Book 1 1
Tab 1a 1b
CONTENTS (cont)
handling, rigging, and setting this equipment, and in handling
all electrical components.
Page
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 44-60
Checking Display Codes . . . . . . . . . . . . . . . . . . . . . . . . 44
Complete Unit Stoppage . . . . . . . . . . . . . . . . . . . . . . . . 44
Single Circuit Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . 44
Restart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
• CODES 51, 52, 55, 56: COMPRESSOR FAILURE
• CODES 59 AND 60: LOW-PRESSURE SWITCH
• CODES 63 AND 64: OIL PRESSURE SWITCH
• CODE 70: ILLEGAL UNIT CONFIGURATION
• CODES 71 TO 76: THERMISTOR/RESISTOR
FAILURE
• CODE 81: RESET THERMISTOR OR
POTENTIOMETER FAILURE
• CODE 82: SUPPLY-AIR TEMPERATURE SET POINT
POTENTIOMETER FAILURE
• CODE 83: ECONOMIZER FEEDBACK
POTENTIOMETER FAILURE
• CODE 84: RESET LIMIT POTENTIOMETER
FAILURE
• CODE 85: DEMAND LIMIT POTENTIOMETER (P4)
FAILURE
• CODE 86: MINIMUM POSITION ECONOMIZER
POTENTIOMETER FAILURE
• CODE 87: WARM-UP TEMPERATURE SET POINT
FAILURE
Thermistor Troubleshooting. . . . . . . . . . . . . . . . . . . . . 48
Electronic Controls Checkout . . . . . . . . . . . . . . . . . . . 48
• PROCESSOR BOARD CHECKOUT
• RELAY BOARD TROUBLESHOOTING
• DISPLAY BOARD CHECKOUT
• ACCESSORY BOARD CHECKOUT
• TWO-STEP DEMAND LIMIT CONTROL MODULE
(DLCM) TROUBLESHOOTING
Enthalpy Sensor Checkout . . . . . . . . . . . . . . . . . . . . . . 52
Economizer Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Supply Fan Variable Frequency Drive . . . . . . . . . . . 52
• STANDARD TRANSDUCER CONTROL
• EXTERNAL SIGNAL CONTROL
• SUPPLY FAN MOTOR OVERLOAD PROTECTION
• VFD OPERATION
• VFD OPERATIONAL STATUS
• RESTORING FACTORY VFD DEFAULTS
Power Exhaust Variable Frequency Drive . . . . . . . 55
• STANDARD TRANSDUCER CONTROL
• EXTERNAL SIGNAL CONTROL
• POWER EXHAUST FAN MOTOR NO. 1 OVERLOAD
PROTECTION
• POWER EXHAUST VFD OPERATION
• POWER EXHAUST VFD OPERATIONAL STATUS
• RESTORING FACTORY POWER EXHUAST VFD
DEFAULTS
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
START-UP CHECKLIST. . . . . . . . . . . . . . . . . . CL-1, CL-2
Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation and service. There may be more than one disconnect switch. Tag
all disconnect locations to alert others not to restore power
until work is completed.
This unit uses a microprocessor-based electronic control
system. Do not use jumpers or other tools to short out components, or to bypass or otherwise depart from recommended procedures. Any short-to-ground of the control
board or accompanying wiring may destroy the electronic
modules or electrical components.
GENERAL
IMPORTANT: This literature contains controls, operation, and troubleshooting data for 48FK,FM,JK and
50FK,FM,FS,FY,JK,JY variable air volume rooftop
units. Use this guide in conjunction with the separate
Installation Instructions literature packaged with the
unit.
Carrier 48FK,FM,JK and 50FK,FM,FS,FY,JK,JY units provide ventilation, cooling, and heating (when equipped) in Variable Air Volume (VAV) applications. These units contain factory-installed controls which provide full system management.
The unit controls also perform self diagnostic tests at unit startup, monitor operation of the unit, and provide alarms. Information on system operation and status are sent to the central processors by various sensors that are located at the unit and in the
conditioned space. Each unit is equipped with a display board.
Rooftop Information — The rooftop controls cycle
supply-fan motor, compressors, and unloaders to maintain the
proper temperature conditions. The controls also cycle condenser fans to maintain suitable head pressure. Safeties are
continuously monitored to prevent the unit from operating under abnormal conditions. The controls provide control of economizer and cycle or control heating as required.
The controls also allow the service person to operate a
‘quick test’ so that all the controlled components can be
checked for proper operation.
IMPORTANT: The field-supplied and installed switch
(or timeclock) MUST BE CLOSED to put unit into the
Occupied mode. Unit WILL NOT START until this is
accomplished. See base unit installation instructions literature for details.
VAV Control System — The 30 to 100-ton VAV rooftop units contain a microprocessor-based electronic control
system that controls and monitors the rooftop unit functions.
The VAV control system is composed of several components:
• processor board
• relay board
• display board
• thermistors
• compressor operation feedback (control relay)
• accessory board
• temperature reset package*
• single-step demand limit*
• two-step demand limit control module*
*Field-installed accessories.
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment can be
hazardous due to system pressures, electrical components, and
equipment location (roof, elevated structures, etc.). Only
trained, qualified installers and service mechanics should install, start up, and service this equipment.
When working on this equipment, observe precautions in
the literature; on tags, stickers, and labels attached to the equipment, and any other safety precautions that apply. Follow all
safety codes. Wear safety glasses and work gloves. Use care in
2
The VAV control system monitors and controls the following functions of the rooftop unit:
• supply-air temperature (unit capacity)
• morning warm-up or electric heat (if equipped)
• head pressure control, fan cycling
• economizer position
• diagnostic display
• unit check-out (quick test)
• supply air temperature reset (if equipped)
• demand limiting (if equipped)
Several status switches are also monitored. These switches
are connected to the processor at pin terminal connector J2. See
Fig. 3 and Table 2.
In addition to the unit status switch inputs, the processor
board also accepts inputs from several potentiometers. These
potentiometers control various operational characteristics of
the system. Inputs are received by the processor through pin
terminal connector J3. See Fig. 4.
Table 1 — Pin Terminal Connector J1
Thermistor Inputs
Processor Board — The processor board, shown in
CONNECTOR J1
TERMINAL NO.
1,2
Fig. 1, contains the logic and the necessary hardware to drive
the outputs and the display board. The processor board is enclosed by a sheet metal cover and a heater. The heater is controlled by a thermostat to keep the processor temperature above
32 F (0° C). All electrical connections are made to the processor board through wire and ribbon cables.
Several temperature inputs are connected to the processor.
There are either 4 or 5 thermistors (depending on the fieldinstalled accessories) which input temperature data into the
processor through pin terminal connector J1. See Table 1 and
Fig. 2.
14,15
16,17
18,19
20,21
TEMPERATURE
INPUT
Reset Temperature*
Saturated Condensing
Temp., Circuit 2
Saturated Condensing
Temp., Circuit 1
Return-Air Temperature
Supply-Air Temperature
UNIT SIZE
034-104
T10
T4
T3
T2
T1
LEGEND
T — Thermistor
*If equipped with accessory temperature reset package.
NOTE: Terminal numbers 3-13 are not used on these units.
LEGEND
DIP
— Dual In-Line Package
EPPOM — Erasable, Programmable Read-Only Memory
EXV
— Electronic Expansion Valve
*EPROM HT204485-1-XX where “XX” is the current revision
number.
NOTE: Processor Board is positioned in unit with J3 and J10
connections at the bottom.
Do not remove label covering EPROM. Removal causes program to be erased.
Fig. 1 — Processor Board
3
T
—
LEGEND
CR — Control Relay
EC — Enthalpy Control
LPS — Low-Pressure Switch
LEGEND
Thermistor
Field Wiring
Accessory
Fig. 3 — Pin Terminal Connector J2
Status Switch Inputs
Fig. 2 — Pin Terminal Connector J1
Thermistor Inputs
Table 2 — Pin Terminal Connector J2
Status Switch Inputs
CONNECTOR J2
TERMINAL NO.
1,2
3,4
7,8
9,10
13,14
15,20
15,24
STATUS SWITCH
Oil Pressure,
Circuit 2
Oil Pressure,
Circuit 1
Loss of Charge,
Circuit 2
Loss of Charge,
Circuit 1
Economizer
Changeover
Compressor Fault
Signal
Compressor Fault
Signal
UNIT SIZE
034-104
Jumpered
Jumpered
LPS2
LPS1
EC
CR2
CR1
LEGEND
CR — Control Relay
EC — Enthalpy Control
LPS — Low-Pressure Switch
IN
P
RNT
SW
NOTE: Terminal numbers 5, 6, 11, 12, 16-19, and 21-23 are not used
on these units.
—
—
—
—
LEGEND
Input
Potentiometer
Return
Switch
Factory Wiring
Field Wiring
Accessory
Fig. 4 — Pin Terminal Connector J3
Potentiometer Inputs
4
CONFIGURATION HEADER AND DIP SWITCH ASSEMBLY — The processor board is programmed to control a variety of air conditioning units. To tailor the processor to the particular unit being controlled, 2 devices are used. One is the
configuration header, and the other is the DIP switch assembly.
The configuration header (part no. 30GB660001) is a series
of 8 small wires that are broken or unbroken in a pattern to indicate several unique characteristics of the unit. The configuration header is factory set and should not be changed. Changing
the factory setting may cause the unit to malfunction.
The DIP switches configure the unit for several field-installed options, as well as for several other options that may be
unique to the unit. The DIP switches are located under a plastic
enclosure which must be removed for access. The switches can
be field adjusted, but must be adjusted only when the unit control circuit breaker is off.
All of the potentiometers must be set before the unit is started in order for the unit to function properly. See Start Up, Potentiometers section on page 27 for information on establishing
set points. Each of the potentiometers has a valid range that is
used by the control. The valid range is defined as the potentiometer’s resistance value that the control will not consider to
be in error. This is usually between 10% and 90% of the potentiometer’s total resistance. The control has been programmed
to accept an operational range for the potentiometer, which
may not be the same as the valid range.
The potentiometer locations and functions are as follows:
P1 — SUPPLY-AIR SET POINT — This potentiometer is
located on the display board. The supply-air set point is the
cooling mode control temperature which the VAV control system will attempt to maintain at Thermistor T1 by control of
economizer position and/or cycling unloaders and compressors.
P2 — ECONOMIZER POSITION — Economizer feedback
potentiometer is located on the economizer motor. The microprocessor is programmed to indicate an alarm if the travel during initialization is less than 10% of the total potentiometer’s
resistance. An alarm condition will also be signaled if the
potentiometer fails during operation, indicating that the
damper blades are stuck. If either situation occurs, the processor will try to drive the economizer dampers closed.
P3 — RESET LIMIT — This potentiometer is located on the
accessory board (provided standard from the factory) in the
unit main control box and establishes the maximum amount of
reset that can be applied to the supply-air set point (P1). Reset
is limited by the P1 default of 70 F. This potentiometer is used
only when accessory, field-installed temperature reset is used.
If temperature reset is used, DIP (dual, in-line package) switch
2 must be in the ON position.
P4 — DEMAND LIMIT — This potentiometer is located near
TRAN4 in the unit control box. The demand limit potentiometer is used only if accessory, field-installed demand limit is
used, and if DIP switch 5 is in the ON position. For single-step
demand limit, a field-installed 5 to 20 Kohm potentiometer and
switch must be used.
P5 — ECONOMIZER MINIMUM POSITION — This
potentiometer is on the accessory board (provided standard
from the factory) located in the unit main control box. This
potentiometer specifies the minimum opening position for the
optional economizer. If a fault condition is detected by the processor, an alarm condition will be signaled and the economizer
dampers will close.
P6 — WARM-UP SET POINT — This potentiometer is on
the accessory board (provided standard from the factory)
located in the unit main control box. This potentiometer establishes the set point temperature for the Morning Warm-Up
function. When the temperature is reached, Morning Warm-Up
is terminated and VAV operation begins. DIP switch 4 must be
in the ON position if morning warm-up heat is to be used.
P7 — SASP (SUPPLY AIR SET POINT) RESET TEMPERATURE — This 10 Kohm potentiometer is used only if the
accessory, field-installed temperature reset package is installed.
This potentiometer determines the temperature at which reset
will begin. It is located on the accessory temperature reset
board. DIP switch 2 must be in the ON position to enable
SASP reset.
PROCESSOR BOARD OUTPUTS — The processor board
also controls outputs through the relay board. The relay board
plugs into the processor board using a ribbon cable.
In addition, the processor board controls the display board. The
display board is connected to the processor board by a ribbon
cable, and has an LED (light-emitting diode) display showing
the status of the unit and diagnostic information.
Relay Board — The relay board is used to control 24-v
and 115-v loads. See Fig. 5. The relay board is connected to the
processor board by a ribbon cable at pin J9. Electrical connections to the relay board are made through pins J5 (115 v) and J6
(24 v). The relay board has eight 24-v relays and five 115-v relays. See Table 3.
Display Board — The display board is located in the
main unit control box and is connected to the J10 port of the
processor board through a ribbon cable. The display board contains the supply-air set point potentiometer P1; a 2-digit, LED
display; and the display button (see Fig. 6). The LED display is
used to convey the operating information and operational error
codes.
Thermistors — The processor uses up to 5 thermistors to
sense the temperatures at various points in the system. See Table 1 and Fig. 7-14. All the thermistors have identical temperature versus resistance and voltage drop characteristics, and are
monitored by the processor for a short or open circuit. The valid range for a thermistor is 362,640 to 219 ohms. Thermistor
details and locations are as follows:
T1 — SUPPLY-AIR TEMPERATURE THERMISTOR —
This thermistor is located in the unit supply fan discharge. It
provides information for the processor to stage the number of
capacity steps required to maintain a desired supply-air temperature.
T2 — RETURN-AIR TEMPERATURE THERMISTOR —
This thermistor is located in the mixed-air portion of the unit
cabinet. The thermistor’s primary function is to provide morning warm-up information. This sensor will also provide differential information for the processor during cooling operation
(such as the rate of change for a capacity step).
T3 — SATURATED CONDENSING TEMPERATURE,
CIRCUIT 1 — This thermistor is located on the condenser coil
return bend. See Fig. 13 and 14. It controls the staging of the
unit condenser fans based on the condensing temperature of
the refrigerant at the designated position on the condenser coil.
T4 — SATURATED CONDENSING TEMPERATURE,
CIRCUIT 2 — This thermistor is located on the condenser coil
return bend. See Fig. 13 and 14. It controls the staging of the
unit condenser fans based on the condensing temperature of
the refrigerant at the designated position on the condenser coil.
T10 — RESET TEMPERATURE — This thermistor is used
only if the accessory temperature reset package is used. It provides occupied space temperature information to the processor,
which determines whether or not reset is required. The thermistor is remotely mounted outside the unit in the conditioned
space.
5
Table 3 — Output Pin and Terminal Assignments
OUTPUT PINTERMINAL
J6-1
J6-2
J6-3
J6-4
J6-5
J6-6
J6-7
J6-8
J5-1
J5-2
J5-3
J5-4
J5-5
ALM
CR
ECR
EOR
HIR
IFC
OFC
U
—
—
—
—
—
—
—
—
NAME
RATING
Stage 1
Compressor Relay (K1)*
Stage 2
Compressor Relay (K2)*
Stage 3
Compressor Relay (K3)*
Compressor Relay (K4)†
Stage 5
Compressor Relay (K5)†
Stage 6
Compressor Relay (K6)†
Economizer Open Relay (K7)
Economizer Close Relay (K8)
Supply Fan Relay (K9)
Morning Warm-Up Relay (K10)
Stage 1 Condenser
Fan Relay (K11)
Stage 2 Condenser
Fan Relay (K12)
External Alarm Relay (K13)
LEGEND
Alarm
Control Relay
Economizer Close Relay
Economizer Open Relay
Heat Interlock Relay
Indoor (Evaporator) Fan Contactor
Outdoor (Condenser) Fan Contactor
Unloader
DEVICE
CR1
U2**
U1
24 vac
Not Used
CR2
Not Used
EOR
ECR
IFC
HIR
115 vac
OFC2/OFC3††
OFC4||
ALM
*Circuit 1.
†Circuit 2.
**U2 is not used on 044 units.
††OFC2 on 034-048 units; OFC3 on 054-104 units.
||Used on 054-104 units only.
LEGEND
CR — Control Relay
J
— Terminal Pin Connectors
K — Relay
Fig. 5 — Relay Board
6
P1 SUPPLY AIR
SET POINT
POTENTIMETER
TWO-DIGIT
DISPLAY
P3 — RESET LIMIT — The processor board is programmed
for occupied space temperature reset. In order for reset to
work, the accessory temperature reset board must be used.
Potentiometer P3 is the maximum set point temperature to
which the supply air can be reset.
P5 — ECONOMIZER MINIMUM POSITION — This
potentiometer controls the set point for the minimum position
of the economizer.
P6 — MORNING WARM-UP TEMPERATURE — This
potentiometer controls the morning warm-up temperature set
point.
DISPLAY
BUTTON
Single-Step Demand Limit — The single step demand limit provides a means to limit the capacity of the VAV
unit using an external switch. Single step demand limit will
limit the compressor displacement based on the ratio of the
wiper arm to the full scale resistance. The exact percentage of
capacity reduction differs depending on the number of capacity
steps.
A 3-wire, 5 to 20 Kohm, field-supplied potentiometer (P4)
is required for this option. The potentiometer should be wired
to the processor J3 connections. In order to control the demand
limit, the wiper arm of the potentiometer should be switched
open and closed based on the demand limit requirement. The
control switch is also field-supplied and installed.
If the wiper arm wire is open, all capacity stages can be
used. When the wiper arm wire is closed, the capacity is reduced by the amount set on potentiometer P4.
Fig. 6 — Display/Set Point Board
Compressor Operation
CONTROL RELAY (CR) — This relay provides information
to the processor about compressor operation (one control relay
per compressor). The relay controls and protects the compressor and also controls the crankcase heater.
A control signal to check the safety statuses and to start the
compressor is sent from the relay board. This signal travels
through all of the safeties: the high-pressure switch, and the internal protector (where used) and on to the control relay coil.
Once the control relay coil has been energized, the control relay completes a feedback circuit for the processor, informs the
processor of the status of the compressor safeties, energizes the
compressor contactor coil, and deenergizes the crankcase heaters. A fault will be detected by the processor if the control relay
opens during operation or startup. The processor will lock the
compressor or the circuit off by deenergizing the appropriate
relay(s) on the relay board and energizing an alarm signal.
Demand Limit Control Module (DLCM) — The
DLCM provides a 2-step demand limit control using an external switch. The first step is between 50% and 100% of the
maximum compressor displacement. See Fig. 16. The second
step is between 0% and 49% of the maximum compressor displacement. The exact percentage differs depending on the
number of capacity steps.
Two adjustable potentiometers are used to set the 2 demand
limit points. Potentiometer P1 is used to set a demand limit
between 50% and 100% of the unit capacity. Potentiometer P2
is used to set a demand limit between 0% and 49% of unit
capacity.
If no power is supplied to the demand limit control module,
all capacity stages can be used. When power is supplied to terminal IN1 only, the first step of the demand limit control is energized and the capacity is reduced by the amount set on potentiometer P1. When power is supplied to terminal IN2 only, or
to both IN1 and IN2, the capacity is reduced by the amount set
on potentiometer P2.
Accessory Board — The accessory board is standard
(factory supplied) in the VAV rooftop units. See Fig. 15. This
board is located in the control box of each unit. Each board has
a prewired connector supplied with it to connect directly to the
processor board. It has 3 potentiometers: P3, P5, and P6.
7
GAS SECTION
(48FK,JK ONLY)
HORIZONTAL SUPPLY SECTION
(50FY,JY ONLY) AND EXTENDED
PLENUM SECTION (50FKX,FKY,JKX,JKY)
Fig. 7 — Thermistor T1 Location, 48FK,JK, 50FY,JY and 50FKX,FKY,JKX,JKY 034-048 Units
FAN DISCHARGE/ELECTRIC HEAT SECTION
Fig. 8 — Thermistor T1 Location, 50FK,JK034-048 Units
8
GAS SECTION
(48FK,FM,JK)
HORIZONTAL SUPPLY SECTION (50FS,FY,JY)
AND EXTENDED
PLENUM SECTION (50FKX,FKY,FMX,FMY,JKX,JKY)
Fig. 9 — Thermistor T1 Location, 48FK,FM,JK, 50JY and
50JKX,JKY 054-074 Units and 50FKX,FKY,FMX,FMY and 50FS,FY054-104 Units
FAN DISCHARGE/ELECTRIC HEAT SECTION
Fig. 10 — Thermistor T1 Location, 50FK,JK054-074 Units
9
STANDARD
FILTERS
BAG
FILTERS
Fig. 11 — Thermistor T2 Location, Size 034-048 Units
Fig. 13 — Thermistor T3 and T4 Locations,
Size 034-048 Units
STANDARD FILTERS AND
PLEATED FILTERS
ENTHALPY CONTROL
48FK,JK and 50FK,FY,JK,JY Units — Outside air enthalpy
control is standard with the factory-installed economizer option. Enthalpy is sensed by a controller located behind the end
outside air hood. The control can be accessed by removing the
upper hood filter. See Fig. 17.
48FM and 50FM,FS Units — The control is located on the
metal upright between the two economizer hoods, on the right
hand side of the unit, and can be accessed by removing the filter on either economizer hood.
DIFFERENTIAL ENTHALPY — Added efficiencies in economizer control can be gained by installing a differential enthalpy sensor in the return air duct. When differential enthalpy
control is installed, the economizer control will use the air
stream with lower enthalpy (outside air or return air) to provide
for lower compressor operating costs during integrated economizer cycle operation. The differential enthalpy sensor is
installed in the return-air duct.
BAG FILTERS
(054-074 Only)
Fig. 12 — Thermistor T2 Location, Size 034-048 Units
Economizer — Economizer control is used to control the
outside and return air dampers of the unit, to satisfy space cooling demand using all outside air (when permitted), and to satisfy cooling in conjunction with compressor operation (when
conditions permit). During Occupied periods without cooling
demand, the outside-air dampers will be at the user-configured
Minimum Damper Position (at P5 on accessory board). During
Unoccupied periods, the outside-air dampers will be closed.
The economizer is a standard feature on 48FM and
50FM,FS units and is available as a factory-installed option on
48FK,JK and 50FK,FY,JK,JY units.
The user can install an accessory differential enthalpy sensor to enhance economizer control. Refer to the installation
section for field wiring of the sensor.
10
054 UNITS
064, 074, 078 UNITS
088, 104 UNITS
Fig. 14 — Thermistor T3 and T4 Locations, Size 054-104 Units
11
ECON
MIN
P
VAV
The unit is supplied with a pressure transducer capable of
measuring from 0.0 to 5.0 in. wg. The pressure transducer will
send a 4 to 20 mA signal to the VFD to modulate the speed of
the indoor fan motor to precisely control the fan to the desired
static pressure set point. The VFD is factory set at 2.5 in. wg
duct static pressure. Refer to the Operating Sequence section
for more information on the VFD.
The VFD has been programmed and wired at the factory for
this application. No further adjustments (except for Duct Static
Pressure Set Point) should be necessary at start-up. Factory
jumper wire configurations are shown in the Supply Fan Control with VFD Option section on page 28.
A separate service manual for the factory-installed VFD is
supplied with each unit. Refer to the VFD manual for more information on the VFD controls.
LEGEND
— Economizer
— Minimum
— Potentiometer
— Variable-Air
Volume
High Capacity Modulating Power Exhaust
Variable Frequency Drive (48FM and 50FM,FS
Units Only) — The power exhaust VFD (PE VFD) is used
to modulate the power exhaust fan motor no. 1 and stage the
power exhaust fan motor no. 2 in order to maintain building
static pressure. The PE VFD is located at the return air end of
the unit of the opposite side from the auxiliary control box and
can be accessed by opening the access door.
The unit is supplied with a pressure transducer capable of
measuring from –0.5 to +0.5 in. wg. The pressure transducer
will send a 4 to 20 mA signal to the PE VFD to modulate the
speed of the power exhaust motor no. 1 and also stage on/off
the power exhaust motor no. 2 to precisely maintain the desired
building pressure set point. The PE VFD is factory set at
0 in. wg. Refer to Operating Sequence section for more information on the PE VFD.
The PE VFD has been programmed and wired at the factory
for this application. No further adjustments (except for Building Pressure Set Point) should be necessary at start-up. Factory
jumper wire configurations are shown in the Power Exhaust
Variable Frequency Drive section in the Troubleshooting section on page 55.
Fig. 15 — Accessory Relay Board
(Standard; Factory Supplied)
IC
IN
P
RTN
LEGEND
— Integrated Circuit
— Input
— Potentiometer
— Return
Fig. 16 — Two-Step Demand Limit Module
Fig. 18 — Variable Frequency Drive,
Sizes 034-048 and 078-104
Fig. 17 — Enthalpy Sensor Location
(48FK,JK and 50FK,FY,JK,JY Units Only)
Supply Fan Variable Frequency Drive
(VFD) — The optional VFD is used to modulate supply fan
airflow to maintain duct static pressure on VAV applications.
The VFD is located in the supply fan section (see Fig. 18 and
19), and can be accessed by opening the fan section access
door.
Fig. 19 — Variable Frequency Drive, Sizes 054-074
12
control box. When unit goes into Heating mode, interlock relay
is energized providing switch closure or opening (depending
on how field power source is set up) to open the room terminals. Field connections for interlock relays are terminals 3 and
4 (for normally open contacts) and terminals 3 and 7 (for normally closed contacts) on terminal block 3 (sizes 034-048) or
terminal block 4 (sizes 054-104). See Fig. 24. Note that a fieldsupplied power source is required.
There are no required 115-volt field wiring connections,
therefore no provisions have been made in the unit for running
115-volt wiring. If any of the field-installed options requiring
115-volt connections are desired, the unit must be modified in
the field for 115-volt wiring.
NIGHT SETBACK THERMOSTAT — Wire field-supplied
thermostat (suitable for 24-v circuit) between terminals 1 and 2
on terminal block 3 (sizes 034-048) or terminal block 4
(sizes 054-104). This thermostat is used to bypass the timeclock occupied/unoccupied switch and is used to operate unit
during unoccupied times at more economical temperatures.
(See Fig. 23.)
SPACE TEMPERATURE RESET ACCESSORY (50DJ900021)
— Consists of a thermistor (T10) and a reset board with a potentiometer (P7) that is used to set space temperature at which reset
starts. Mount reset board in unit control box or other convenient
place. Wire thermistor in series with P7 and connect to terminals
12 and 15 on terminal block 3 (sizes 034-048) or terminal block 4
(sizes 054-104) in unit control box. If there is a long run to conditioned space, it is necessary to splice additional wire to thermistor.
The reset board has 2 pressure connectors for field wiring. (See
Fig. 25.)
A separate service manual for the factory installed PE VFD
is supplied with each unit. Refer to PE VFD manual for more
information on the PE VFD.
Temperature Reset — Accessory temperature reset allows the unit to automatically adjust (‘‘reset’’) the supply-air
temperature set point to a higher value once most of the space
cooling load has been met. When the space conditions are satisfied, the VAV terminals will close to the minimum position.
All VAV units will sense the decrease in actual supply-air temperature and the unit controls respond by reducing capacity
stages to maintain user-established supply-air set point temperature. When VAV units are also equipped with optional supply
duct pressure controls (either inlet guide vanes [IGV] or variable frequency drive package), the unit also senses an increase
in duct static pressure and responds by closing IGV dampers or
slowing fan wheel speed to maintain user-configured set points
for supply duct pressure. Allowing the supply-air temperature
to be reset to a higher value maintains air circulation in the
space without costly overcooling.
The accessory package is required for temperature reset.
The accessory includes:
• thermistor T10, to monitor space temperature
• reset temperature potentiometer P7, to establish start
temperature for reset operation
• reset limit potentiometer P3, to establish maximum level
of modified supply-air temperature
More than one space sensor may be used if an average
space temperature is desired for initiating temperature reset.
Refer to installation section for sensor part number and wiring
schematic.
Temperature reset will start when space temperature (at
T10) drops to the set point at P7. When Temperature Reset
is active, the LED (light-emitting diode) display will show
code 21 . Automatic adjustment of supply-air temperature set
point will end when modified SASP equals reset limit set point
at P3. (See formula for automatic modification of SASP in
Controls Installation, Space Temperature Reset section on this
page.)
Space Temperature Reset
INSTALLATION — Install the accessory temperature reset
package in accordance with instructions provided with the
accessory kit.
Mount the reset board in the unit control box (or other suitable location) per instructions.
Locate the thermistor T10 in a suitable location in the occupied space per instructions.
Wire T10 to the reset board and to the unit control terminal
block per Fig. 25. Wire the other terminal on the reset board to
the unit control terminal block per Fig. 25.
If multiple sensors are required to average the space temperature, see Fig. 26. Use only Carrier Part Number HH79NZ014
sensor, in arrangements of 4 or 9 sensors, with total wiring not
to exceed 1000 ft.
To enable reset function, change DIP (dual in-line package)
switch 2 to position ON. (Disconnect control power before
changing DIP switch positions; reconnect power after all
changes have been made.)
CONFIGURATION — Set points for reset operation are
established at potentiometers P7 and P3 (on the reset board).
Potentiometer P7 — Reset temperature set point (temperature
at which reset function will start). Maximum of 80 F, minimum 0° F. Set below normal room cooling set point level to
sense overcooling in the occupied space.
NOTE: It is difficult to accurately set the P7 potentiometer to
the desired set point. Use the procedure below.
Proper setting of the P7 potentiometer may be made on a resistance basis. The microprocessor initiates reset when it detects a resistance of the thermistor plus the potentiometer of
13,084 ohm. The potentiometer set point may be calculated using the following formula:
P7R = 13,084 – T10R
Where:
P7R = the desired set point of the P7 potentiometer in ohms
T10R = the resistance of the T10 thermistor for the desired
set point
CONTROLS INSTALLATION
The VAV units may be used in applications with additional
control features, options, or accessories. Refer to the appropriate accessory installation instructions for more information on
installing that accessory. Unit control box component arrangement is shown in Fig. 20-22. Control options and accessories
available for VAV units are:
• smoke control modes
• differential enthalpy sensor
• electric heaters (sizes 034-074 only)
• modulating power exhaust
• Motormaster® I control
• space temperature reset
• night setback thermostat (field-supplied)
• single step demand limit
• two-step demand limit
• inlet guide vanes
• variable frequency drive
• variable frequency drive remote display kit
Control Wiring — A switch or timeclock (field supplied)
must be wired in to control when unit will go into and out of
Occupied mode. Connect switch or timeclock between terminals 1 and 2 on terminal block 3 (sizes 034-048) or terminal
block 4 (sizes 054-104) in unit control box. See Fig. 23. The
circuit potential is 24 v.
Variable air volume units equipped with warm-up heat require that room terminals be controlled to go fully open when
unit goes into the Heating mode. Heating interlock relay (HIR)
is provided for this function. The relay is located in the unit
13
Fig. 20 — Unit Control Box Arrangement, Sizes 034-048
14
15
Fig. 21 — Unit Control Box Arrangement, Sizes 054-078
16
Fig. 22 — Unit Control Box Arrangement, Sizes 088 and 104
NOTES:
1. Occ/Unocc switch closes when occupied.
2. Night setback thermostat closes when in night setback heating.
OPERATING SEQUENCE — If space temperature is above
reset set point (T10 > P7), no reset will occur.
If space temperature is equal to or less that reset set point
(T10 < P7), the LED will display 20 and reset will begin.
Control will automatically adjust leaving air temperature by
the following formula:
MSP = SP + [(P3 - SP) / 3] x (P7 – T10)
where:
MSP = Modified Leaving-Air Set Point
SP = Supply-Air Set Point
P3 = Maximum Supply-Air Temperature (reset limit)
P7 = Reset Initiation Temperature (reset set point)
T10 = Actual Space Temperature
3
= Ratio for reset (F) (fixed parameter)
Fig. 23 — Occupied/Unoccupied Switch with
Night Setback Thermostat
Table 4 — Thermistor Resistance and Voltage
Drop Characteristics
034-048: TB3
054-104: TB4
034-048: TB3
054-104: TB4
1
2
OCCUPIED/UNOCCUPIED
SWITCH
NIGHT SETBACK THERMOSTAT
TEMP
(F)
31.0
32.0
33.0
34.0
35.0
36.0
37.0
38.0
39.0
40.0
41.0
42.0
43.0
44.0
45.0
46.0
47.0
48.0
49.0
50.0
51.0
52.0
53.0
54.0
55.0
56.0
57.0
58.0
59.0
60.0
61.0
62.0
63.0
64.0
65.0
66.0
67.0
68.0
69.0
70.0
71.0
72.0
73.0
74.0
75.0
76.0
77.0
78.0
79.0
80.0
034-048: TB3
054-104: TB4
3
6
4
4
FIELD
SUPPLIED
POWER
SOURCE
V
N.O.
SIGNAL
TO ROOM
TERMINALS
5
7
N.C.
Fig. 24 — Heat Interlock Relay
034-048: TB3
054-104: TB4
T10
12
P7
RESET
BOARD
15
Fig. 25 — Accessory Reset Board
EXAMPLE:
T10 desired set point is 70 F.
T10R from Table 4 for 70 F is 5929 ohms.
P7R = 13,084 – 5929
P7R = 7155 ohms
Using an ohmmeter, set the P7 potentiometer to 7155 ohms
to achieve a reset initiation set point of 70 F.
Potentiometer P3 — Reset limit set point (maximum temperature value for modified supply air set point). Maximum of 70 F,
minimum 40 F. Set between leaving air set point (P1) and 70 F
(maximum range permitted by control).
17
RESISTANCE
(Ohms)
16813.8
16345.7
15892.2
15452.7
15026.7
14613.9
14213.6
13825.5
13449.2
13084.2
12730.1
12386.6
12053.3
11730.0
11416.1
11111.5
10815.8
10528.7
10250.0
9979.3
9716.5
9461.3
9213.4
8972.6
8738.6
8511.4
8290.6
8076.1
7867.7
7665.1
7468.3
7277.1
7091.2
6910.6
6735.1
6564.4
6398.6
6237.5
6080.8
5928.6
5780.6
5636.8
5497.0
5361.2
5229.1
5100.8
4976.0
4854.8
4736.9
4622.4
VOLTAGE
DROP (v)
3.582
3.553
3.523
3.494
3.464
3.434
3.404
3.373
3.343
3.312
3.281
3.250
3.219
3.187
3.156
3.124
3.093
3.061
3.029
2.997
2.965
2.933
2.901
2.869
2.837
2.805
2.772
2.740
2.708
2.676
2.644
2.612
2.581
2.549
2.517
2.486
2.454
2.423
2.391
2.360
2.329
2.299
2.268
2.237
2.207
2.177
2.147
2.117
2.088
2.058
RED
BLK
RED
BLK
SIZES 034-048
TB3
RED
12
BLK
15
RED
RED
BLK
BLK
TO ACCESSORY SPACE
TEMPERATURE RESET
CONTROL BOARD
SIZES 054-104
TB4
12
15
SENSOR 1
SENSOR 2
SENSOR 3
SENSOR 4
SPACE TEMPERATURE RESET — 4 SENSOR AVERAGING APPLICATION
SIZES 034-048
TB3
12
15
RED
BLK
BLK
RED
BLK
TO ACCESSORY SPACE
TEMPERATURE RESET
CONTROL BOARD
SIZES 054-104
TB4
12
RED
BLK
RED
SENSOR 1
15
RED
RED
BLK
BLK
SENSOR 5
SENSOR 6
RED
BLK
SENSOR 4
NOTE: Sensor part number is HH79NZ014.
SENSOR 3
SENSOR 2
SENSOR 7
RED
RED
BLK
BLK
SENSOR 8
SENSOR 9
SPACE TEMPERATURE RESET — 9 SENSOR AVERAGING APPLICATION
Fig. 26 — Space Temperature Sensor Averaging
Demand Limit — The demand limit function provides a
Control Module kit plus installation of 2 field-supplied control
switches (SPST-NO each). This accessory control provides for
a first step reduction of 50% to 100% of the maximum compressor staging; the second step provides for reduction
between 0% and 49%. The exact percentage of capacity reduction differs depending on the number of capacity steps.
When demand limit is active, the LED display will show
code 22 .
INSTALLATION
Single-Step Demand Limit — A 3-wire 5 to 20 K-ohm potentiometer must be field-supplied and installed. A singlepole normally open switch is also required (field-supplied
and -installed). Locate the potentiometer (designated P4) and
the switch in a suitable location (external from the unit or in the
unit control box).
means to limit the cooling capacity of the VAV unit using an
external discrete switch function. When enabled by the closure
of the external switch, the control will limit the available compressor staging capacity according to user set points established
at demand limit potentiometer(s).
The unit controls support two types of demand limit: singlestep and 2-step control.
SINGLE-STEP DEMAND LIMIT — This function will limit
the total compressor staging based on the ratio of the set point
potentiometer’s wiper arm position to the full scale resistance
of the potentiometer. The exact percentage of capacity reduction differs depending on the number of capacity steps.
A field-supplied potentiometer and control switch are required for this function. See installation section for specification on potentiometer and field wiring.
TWO-STEP DEMAND LIMIT — Two-step demand limit is
provided with the installation of the accessory Demand Limit
18
Connect the potentiometer end terminals to terminals 8
and 9 on control terminal block TB3 (sizes 034-048) or TB4
(sizes 054-104) (see Fig 27). Connect the switch terminals to
the potentiometer wiper arm terminal and to terminal 10 on
TB3 or TB4.
To enable demand limit function, change DIP switch 5 to
position ON. (Disconnect control power before changing DIP
switch positions. Reconnect power after all changes have been
made.)
Set the potentiometer P4 to desired capacity reduction value.
Two-Step Demand Limit — Install the demand limit control
module (DLCM) according to the installation instructions provided with the accessory. Disconnect existing leads at connector J3 on the processor board (see instructions) and connect the
plug from the DLCM harness to connector J3.
Connect the field input control power wires (from the external control relays) at the terminal strips marked IN1, RTN1,
IN2 and RTN2 (see Fig. 28 and 29).
To enable demand limit function, change DIP switch 5 to
position ON. (Disconnect control power before hanging DIP
switch positions. Reconnect power after all changes have been
made.)
Set the potentiometers DLCM-P1 and DLCM-P2 to desired
capacity reduction values.
Check the operation of demand limit function by using the
Quick Test procedures.
CONFIGURATION
Single-Step Demand Limit — Field-installed potentiometer
P4 establishes capacity reduction value for demand limit operation. Set this potentiometer between 0% and 100%. The exact
percentage of capacity reduction differs depending on the number of capacity steps.
Two-Step Demand Limit — Potentiometer P1 and P2 (located on the accessory demand limit control module) establish the
capacity reduction values for each step of demand limit. Set potentiometer DLCM-P1 between 50% and 100%. Set potentiometer DLCM-P2 between 0% and 49%. The exact percentage
of capacity reduction differs depending on the number of capacity steps.
OPERATING SEQUENCE
Single-Step Demand Limit — If the field control switch to
the wiper arm terminal is open, all capacity stages will be available (no demand limit in effect). When the field control switch
is closed, the compressor cooling capacity is reduced by the
amount set on potentiometer P4.
When demand limit is in effect, the LED display will show
code 22 . If a potentiometer setting or input is out of range, the
control will terminate the demand limit function and show
code 84 at the display LED.
Two-Step Demand Limit — If the field control switches are
both open (no power supplied to the Demand Limit Control
Module), all capacity stages will be available (no demand limit
in effect). When control power is supplied to terminal IN1 only
(field switch SW1 closes), the first step of the demand limit is
energized and the compressor cooling capacity is reduced by
the amount set on potentiometer DLCM-P1. When control
power is supplied to terminal IN2 (field switch SW2 closes),
the second step of the demand limit is energized and compressor cooling capacity is reduced by the amount set on potentiometer DLCM-P2.
When demand limit is in effect, the LED display will show
code 22 . If a potentiometer setting or input is out of range, the
control will terminate the demand limit function and show
code 84 at the display LED.
034-048: TB3
054-104: TB4
8
5-20K
POTENTIOMETER
(P4)
9
10
SWITCH
Fig. 27 — Single-Step Demand Limit
Fig. 28 — Two-Step Demand Limit Module
NOTES:
1. Demand limit switches are field supplied and wired.
2. Demand limit control module terminal blocks will accept up to
12-gage wire.
3.
is field wiring.
Fig. 29 — 115-Volt Field Wiring to Accessory
2-Step Demand Limit Control Module
Control From Remote Building Management
System (BMS) — The unit control system is not a communicating control system, and it cannot be accessed directly
by a DDC (Direct Digital Control) control system (or by a
BACnet communication system). However, it is possible to
control some functions of these units via 4 to 20 mA or 2 to
10 vdc signals and discrete inputs (relay contact closures).
Functions that can be managed from or accessed from an
external control system include:
• Occupied/Unoccupied Status
• Night Setback Control
• Unit Supply Air Set Point Adjustment
• Demand Limit (1-stage or 2-stage)
• Supply Duct Pressure Set Point Adjustment
• External Alarm Signal
Remote control of the economizer cycle on these units is not
recommended. Refer to the Operating Sequence section on
page 35 for a discussion on the economizer cycle operation.
19
Configuration — Configure as follows:
1. Set DIP switch no. 2 to ON.
2. Adjust manual potentiometer to 12.6 to 12.8 k-ohm.
3. Configure transducer for job site input signal from BMS.
4. Adjust Potentiometer (P3) on the rooftop to MAXIMUM
SASP value (typically 65 to 70 F). The maximum P3 SASP
control limit is 70 F.
Operation — Unit will initiate SASP Reset (adjust configured
SASP upward) when the sum of the resistance (fixed resistance
+ potentiometer + transducer) exceeds 13.1 k-ohm. Once reset
is initiated, full range of reset (P3 setting minus configured
SASP) will be reached with 500-ohm increase in transducer resistance (TR).
During Reset mode operation, Code 21 will appear on unit
display board.
Formula:
MSP = SASP +
OCCUPIED/UNOCCUPIED — The unit control system will
initiate normal occupied mode functions (including Morning
Warm-up, Economizer Minimum Position, and Cooling Cycle)
whenever a contact closure is made that emulates the normal
timeclock contacts. See Fig. 23. (‘‘Occupied/Unoccupied
Switch’’). The contact closure from the BMS must be an isolated contact set, normally open, and suitable for 24 volts AC
pilot duty.
NIGHT SETBACK CONTROL — Night setback control is
used to control the space to a set point level that is typically
lower than during normal occupied periods (Heating Only
mode). Some applications also require a limitation on the maximum space temperature during unoccupied periods (Cooling
mode). Both modes are possible by closing the same contacts
used in the Occupied/Unoccupied control, or by installing a
dedicated contact set in parallel with the Occupied/ Unoccupied control contacts, and using the BMS space temperature
sensing system and its logic to determine when to initiate unit
operation.
Once the unit operation has been initiated by the BMS contact closure, the unit operates in its normal occupied mode
manner, initiating morning warm-up if needed (as sensed by return air temperature to the unit) or cooling (controlling to current SASP value). The Night Setback Control contacts will interrupt normal unit operation when the BMS senses that space
temperatures have returned to unoccupied set point levels, and
the unit will shut down normally.
The contact closure from the BMS must be an isolated contact set, normally open, suitable for 24 volts AC pilot duty.
NOTE: If the rooftop unit is equipped with a VFD and night
setback cooling operation is intended, the fan system must be
controlled to permit FULL SUPPLY FAN AIR DELIVERY
during unoccupied cooling operation. This is most conveniently attained by replicating the HIR relay function of the
rooftop unit. An HIR control sequence will force all room terminals to their minimum heating CFM position, thus assuring
adequate airflow through the rooftop unit during night setback
cooling operation. During night setback cooling operation, the
return-air temperature (RAT) will be well above normal levels.
The higher RAT means that the air temperature leaving the
evaporator coil will also be well above normal levels. This situation is interpreted by the unit control system as a demand for
additional cooling stages. The unit control responds to this
demand by bringing on more stages, until typically all stages
are active. If the VFD is not working in-step with the refrigeration system demand, it is possible to produce low suction pressures and local frosting on the evaporator coil during the night
setback cooling operation.
UNIT SUPPLY AIR SET POINT ADJUSTMENT — The
minimum Supply Air Set Point (SASP) temperature is established by the setting at Potentiometer P1 on the unit display
board (see Fig. 6). The control point can also be adjusted
upward by emulating the function of the accessory Space Temperature Reset package. The BMS can be used to cause this
reset by adjusting the resistance value in a variable resistance
transducer with a 4 to 20 mA or 2 to 10 vdc signal generated
by the BMS.
This emulation requires the following field-supplied parts:
• Variable resistance transducer (Kele RES-1 or equivalent, range 0 to 1000 ohms)
• Series resistance with potentiometer, suitable for manual
adjustment to 12.5 to 13.0 k-ohms total resistance
Field Connections (see Fig. 30) — Connect fixed resistance
with manual potentiometer and variable resistance transducer
in series.
Connect wiring to rooftop unit at:
Size 034-044: TB3-12 and TB3-15
Size 054-104: TB4-12 and TB4-15
[
(P3 — SASP)
(0.6 F)
X
X (TR — [email protected])
(3)
(100 ohm)
]
MSP: Modified SASP (SASP plus Reset)
TR: Resistance at transducer
[email protected]: TR required to reach 13.1 k-ohm start level
DEMAND LIMIT (1-STAGE OR 2-STAGE) — Both of the
Demand Limit functions on the units rely on external switches
to initiate the reset functions. Contact closures by the BMS can
be used in place of these switches. Contacts must be isolated
and suitable for 115-vac pilot duty operation.
For Single-Step Demand Limit, emulate function of switch
SW with contact closure controlled by the BMS. Set potentiometer P4 manually at the unit control box. Alternatively, potentiometer P4 might also be emulated by a variable resistance
transducer, with the BMS now able to adjust the amount of demand limit.
For 2-Step Demand Limit, install the accessory Demand
Limit Control Module (DLCM) according the instructions on
page 18. Replace switch functions Switch 1 and Switch 2 with
contact closures controlled by the BMS (see Fig. 29).
Follow unit control configuration instructions in the Demand Limit section on page 18.
SUPPLY DUCT PRESSURE SET POINT ADJUSTMENT
— Supply duct pressure set point adjustment from a remote
BMS is possible when the unit has been equipped with a factory-option VFD (variable frequency drive). There are two
methods available:
• Direct 4 to 20 mA signal
• DDC direct to the VFD
Direct 4 to 20 mA Signal — During normal unit operation,
the factory-installed VFD receives a 4 to 20 mA signal from
the Duct Pressure (DP) transducer which indicates current supply duct pressure. The VFD then determines the appropriate
fan speed (using its internal PID logic feature) and adjusts its
output to the supply fan motor to suit. It is possible to emulate
this 4 to 20 mA control signal by the BMS, which will transfer
control of the VFD to the BMS.
NOTE: When providing a direct 4 to 20 mA signal to the VFD
from a BMS with DP logic, disable the PID (proportion integrated derivative calculation process) feature of the VFD.
DDC Direct to the VFD — Several accessory interface
boards are available for the VFDs that permit direct communication between the VFD and several BMS communication systems. Contact your Carrier representative for information on
selecting an appropriate accessory interface board and the
name of the local service office (for sale and installation of the
accessory boards).
20
EXTERNAL ALARM SIGNAL — The unit controls provide
an external alarm status signal via a 115-vac output signal at
the relay board J5, available at TB2-4 and TB2-5 (common).
This signal can be forwarded to the BMS by adding a signal
relay at the alarm output, placing its coil across terminals TB24 and TB2-5 and using its contacts to control a discrete input to
the BMS (see Fig. 31).
The alarm signal output is energized when any of the diagnostic codes is tripped.
REMOTE ECONOMIZER CONTROL — Economizer control is tightly integrated into the unit’s capacity control algorithms and diagnostic routines. Consequently, control
modifications that interfere with this standard operating
sequence are not recommended.
Economizer position is determined by the unit processor
board based on current outdoor air enthalpy status and cooling
capacity demand. The economizer damper actuator is a floating
point device with an internal brake and spring return. Its position is determined by the sequencing of relays EOR (Economizer Open Relay) and ECR (Economizer Close Relay). The
economizer’s current position is sensed by the processor board
through position feedback potentiometer P2.
Whenever the economizer position potentiometer signal is
not consistent with the processor board’s commanded position,
a fault condition is determined by the processor board and an
alarm signal is initiated. The processor board also attempts to
return the economizer damper to its fully closed position during this fault condition by energizing the ECR relay.
Any attempt to effect an external control of the economizer
actuator will lead to an alarm condition and an automatic response by the unit control to attempt to close the dampers.
034-048: TB3
054-104: TB4
R
TRANSDUCER
P
BMS
CONTROL
12
(4 TO 20 MA
OR
2 TO 10 VDC
SIGNAL)
15
P
R
—
—
LEGEND
Manual Potentiometer
Fixed Resistor
Field Wiring
Fig. 30 — Remote SASP Wiring
TB2
TB2
4
5
LIGHT
R
RELAY
SIGNAL TO BMS
Smoke Control Modes — It is common practice to use
rooftop units for aid in building smoke control in the event of a
building fire. The available functions include: Fire Shutdown,
Pressurization, Evacuation, and Smoke Purge. These functions
are enhanced when multiple rooftop units are used to zone a
building.
Implementation of the various Smoke Control modes on
these units requires the installer to modify the unit wiring to
add contacts (via either manual switches or relays) that will selectively interrupt and override standard factory control sequences. See Table 5.
Smoke control mode Pressurization requires the economizer function. Evacuation and Smoke Purge modes require both
economizer and power exhaust functions. Both functions are
standard features on 48FM and 50FM,FS units. These functions require factory-installed options, field-installed accessories and/or field-supplied exhaust systems on 48FK,JK and
50FK,FY,JK,JY units. Consult price pages for specific details.
FIRE SHUTDOWN MODE — Fire Shutdown mode terminates all unit operation (cooling, heating, supply fan and power
exhaust). This mode prevents recirculation of contaminated air
back into the space or the admission into the space of unsuitable outside air.
PRESSURIZATION MODE — Pressurization mode is
intended to keep smoke out of a zone. The economizer is
required for this function. The economizer is standard on
48FM and 50FM,FS units. The economizer is a factoryinstalled option on 48FK,JK and 50FK,FY,JK,JY units. Pressurization is accomplished by:
• opening the economizer
R
LEGEND
— Fixed Resistor
Factory Wiring
Field Wiring
Fig. 31 — External Alarm Indication
•
running the supply fan (optional inlet guide vanes open
or optional VFD [variable frequency drive] at normal
duct static pressure set point)
• shutting off the power exhaust fans (Standard on 48FM
and 50FM,FS units. Factory-installed option or fieldinstalled accessory on 48FK,JK and 50FK,JK units)
This allows the space to be overpressurized relative to adjacent zones and prevents or slows entry of smoke into this space
from adjacent zones.
EVACUATION MODE — Evacuation mode removes smoke
or undesirable air from interior spaces without reintroducing
unsuitable air. The economizer and power exhaust are required
for this function. The economizer and power exhaust are
standard on 48FM and 50FM,FS units. The economizer is a
factory-installed option and the power exhaust is a factoryinstalled option or field-installed accessory on 48FK,JK and
50FK,JK units. Evacuation is accomplished by:
• turning supply fan off
• opening the economizer
• running the exhaust fans
• opening the exhaust dampers
21
CONFIGURATION — No set points required for Smoke Control modes. Modes are activated by energizing all switches
appropriate for each Smoke Control mode.
OPERATING SEQUENCE
Fire Shutdown — At command from the field switches (see
Table 5), all unit operation (cooling, heating, supply fan and
power exhaust) will terminate.
Pressurization — At command from the field switches for
Pressurization mode (see Table 5):
1. Economizer dampers will open.
2. The HIR function will energize, opening room terminals
to full-open (heating) positions.
3. Supply fan will run. (If equipped with IGV: control vanes
will open. If equipped with VFD: the VFD will control to
duct static set point or best available with all terminals
open.)
4. Power exhaust dampers (if equipped) will close.
5. Power exhaust fans (if equipped) will turn off.
Evacuation — At command from the field switches for Evacuation mode (see Table 5):
1. Supply fan will turn off.
2. Economizer dampers will open.
3. Exhaust fans will run at maximum capacity.
4. Exhaust dampers will open.
Smoke Purge — At command from the field switches for
Smoke Purge mode (see Table 5):
1. Economizer dampers will open.
2. The HIR function will energize, opening room terminals
to full-open (heating) positions.
3. Supply fan will run. (If equipped with IGV: Control vanes
will open. If equipped with VFD: the VFD will control to
duct static set point or best available with all terminals
open.)
4. Exhaust fans will run at maximum capacity.
5. Exhaust dampers will open.
SMOKE PURGE MODE — Smoke Purge mode removes
smoke from the interior spaces and replaces it with fresh outside air. The economizer and power exhaust are required for
this function. The economizer and power exhaust are standard
on 48FM and 50FM,FS units. The economizer is a factoryinstalled option and the power exhaust is a factory-installed
option or field-installed accessory on 48FK,JK and 50FK,JK
units. Smoke purge is accomplished by:
• turning supply fan on
• opening the economizer
• running the exhaust fans
• opening the exhaust dampers
INSTALLATION — To enable one or more of the possible
smoke control modes available with these units, determine the
switches required for the desired mode(s) from Table 6, fieldsupply and install the appropriate switches and field wire per
Fig. 32. Switch functions are shown in Table 7.
Table 5 — Smoke Control Modes
FUNCTION
Supply Fan
IGV/VFD†
Economizer
Return Air
Damper
Exhaust
Fans
Exhaust
Damper
Fire
Shutdown
Off
—
Closed
MODE
Pressur- Evacuation*
ization
On
Off
Open/On
—
Open
Open
Smoke
Purge*
On
Open/On
Open
Open
Closed
Closed
Closed
Off
Off
On
On
Closed
Closed
Open
Open
LEGEND
IGV — Inlet Guide Vane
VAV — Variable Air Volume
VFD — Variable Frequency Drive
*Power exhaust function required for this mode.
†Applicable to VAV units with appropriate options.
Table 6 — Smoke Control Switches Required for Each Mode
FIRE
SHUTDOWN
SW-1
SW-2
EVACUATION
(Modulating Power
Exhaust)
SW-1
SW-2
SW-3
SW-5
SW-6
SW-7
SW-8*
PRESSURIZATION
SW-1
SW-2
SW-4
SW-5
SW-6
SW-9A/B
*Not required on 48FM and 50FM,FS units (high capacity power exhaust units).
NOTE: All switches are shown in “as installed” (power OFF or deenergized) position. In these
positions, none of these modes will be activated; normal unit operation is permitted by the base
unit controls. To initiate any mode, all switches listed under this mode in the table must be energized, causing the depicted contact position to change from depicted positions to energized positions. Switches may be manually or electrically operated.
22
SMOKE
PURGE
SW-1
SW-2
SW-3
SW-4
SW-9A/B
Table 7 — Switch Functions
SWITCH
NUMBER
SW-1
SW-2
SW-3
SW-4
SW-5
SW-6
CONFIGURATION
VOLTAGE
FUNCTION
N.C.
N.C.
N.O.
N.O.
N.C.
N.O.
115
115
24
115
115
115
SW-7
N.O.
24
SW-8*
N.C.
A: N.O.
B: N.C.
Deenergize 115-v (OFC, Comp, IFC, Electric Heaters)
Deenergize TRAN7 (Process Board)
Energize EOR (Open Economizer Outside Air Dampers)
Energize IFC and CR-3 (IGV/VFD)
Isolate IFC and PEC for Separate Operation
Energize PEC (Power Exhaust)
Open PED at DPS (48FK,JK and 50FK,JK Units) Force Power Exhaust VFD
to Maximum Speed (48FM and 50FM,FS Units)
Block Auto-Close at DPS (Due to Low BP)
SW-9A/B
24
115 max
Signal Room Terminals to Open (HIR1)
*Not required on 48FM and 50FM,FS units (units with high capacity power exhaust).
BP —
DPS —
EOR —
HIR —
IFC —
IGV —
N.C. —
N.O. —
PEC —
PED —
OFC —
VFD —
LEGEND
Building Pressure
Differential Pressure Switch
Economizer Open Relay
Heat Interlock Relay
Indoor Fan Contactor
Inlet Guide Vane
Normally Closed
Normally Open
Power Exhaust Contactor
Power Exhaust Damper
Outdoor Fan Contactor
Variable Frequency Drive
Air Pressure Tubing — Before options such as inlet
INLET GUIDE VANES — The tubing for the duct pressure
(DP) control option should sample supply duct pressure about
2/3 of the way out from the unit in the main trunk duct, at a
location where a constant duct pressure is desired.
The inlet guide vanes are controlled by a differential pressure switch (DPS). On sizes 034-048, the DPS is located in the
auxiliary control box at the economizer end of the unit (see
Fig. 33). On sizes 054-104, the DPS is located in the supply fan
section. See Fig. 34. Use a nominal 3/8-in. plastic tubing.
SUPPLY FAN VARIABLE FREQUENCY DRIVE — The
tubing for the duct pressure (DP) control option should sample
supply duct pressure about 2/3 of the way out from the unit in
the main trunk duct, at a location where a constant duct pressure is desired.
The duct pressure is sensed by a pressure transducer. The
pressure transducer output is directed to the VFD. On 034-048
units the DP transducer is located in the auxiliary control box.
On 054-104 units, the DP transducer is located in the supply
fan section. See Fig. 34. Use a nominal 1/4-in. plastic tubing.
guide vanes (IGV), variable frequency drive (VFD), and/or
modulating power exhaust can operate properly, the pneumatic
tubing for pressure sensing must be installed. Use fire-retardant
plenum tubing (field-supplied). Tubing size depends on type of
control device (see Table 8 below). Tubing must be run from
the appropriate sensing location (in the duct or in the building
space) to the control device location in the unit.
Table 8 — Tubing Size
OPTION
UNITS
Inlet Guide Vanes (IGV)
Supply Fan Variable
Frequency Drive (VFD)
ALL
NOMINAL TUBE
SIZE (in.)
3/
8
ALL
1/
FK,FKX,JK,JKX
Modulating Power Exhaust
FM,FS
4
3/
8
1/ 4
23
054-104 UNITS
034-048 UNITS
TB2
SW-1
5
TB2
TB2
6
13
SW-1
14
REMOVE JUMPER
TB2
SW-2
1
REMOVE JUMPER
TB2
TB2
2
7
SW-2
SW-3
1
SW-4
TB2
5
TB2
SW-5
8
REMOVE JUMPER
TB3
TB4
5
1
TB2
TB2
9
13
TB2
TB2
9
1
SW-3
SW-6
5
SW-9A
TB3
3
HIR
TB3
3
4
SW-9B
5
SW-4
2
SW-5
TB2
REMOVE JUMPER
TB2
TB2
8
13
TB3
TB4
4
3
TB2
SW-6
1
SW-9A
TB4
4
TB3
TB4
7
3
HIR
4
SW-9B
5
REMOVED FROM TB4-7
48FK, JK AND 50FK, JK034-104 UNITS
SW-7
DPS
SW-8
WHT
NC
C
VIO
NO
REMOVED
FROM C-DPS
GRA
48FM, AND 50FM, FS034-104 UNITS
PEVFD
SW7
PEVFD
S1
CC
—
—
—
—
—
TB2
2
REMOVED FROM TB3-7
DPS
HIR
PEVFD
SW
TB
TB4
5
REMOVE JUMPER
TB2
TB2
8
REMOVE JUMPER
TB3
TB2
LEGEND
Differential Pressure Switch
Heat Interlock Relay
Power Exhaust Variable Frequency Drive
Switch
Terminal Block
Fig. 32 — Smoke Control Wiring
24
TB4
7
MODULATING POWER EXHAUST
48FK,JK and 50FK, JK Units — The tubing for the building
pressure control (achieved via the Modulating Power Exhaust
option/accessory) should sample building pressure in the area
near the entrance lobby (or other appropriate and sensitive
location) so that location is controlled as closely to design pressures as possible.
A differential pressure switch (DPS) is used to control the
actuator on the modulating discharge damper in exhaust fan
no. 1. The building pressure (BP) DPS is located in the auxiliary control box of the unit. See Fig. 33 and 35. Use a nominal
3/ -in. plastic tubing.
8
For instructions on adjusting BP control set points, refer to
Start-Up, Modulating Power Exhaust section in this book.
48FM and 50FM,FS Units — The tubing for the building
pressure control (achieved through the High Capacity Modulating Power Exhaust) should sample the building pressure in
the area near the entrance lobby (or other appropriate and sensitive location) so that the location is controlled as closely to
design pressures as possible.
A building pressure transducer (BPT) is used to sense the
building pressure and supply a 4 to 20 mA signal to the power
exhaust VFD (PE VFD) which controls the speed of exhaust
fan motor no. 1 and stages on/off power exhaust fan motor
no. 2 to maintain the building pressure. The BPT is located in
the auxiliary control box. Use a nominal 1/4-in. plastic tubing.
For instructions on adjusting the BP control set point, refer
to Start-Up, High Capacity Modulating Power Exhaust section
in this book.
Fig. 33 — Modulating Power Exhaust and Inlet
Guide Vane Differential Pressure Switch
(Sizes 034-048)
START-UP
Initial Check
IMPORTANT: Do not attempt to start unit, even
momentarily, until all items on the Controls Start-Up
Checklist (in installation instructions) and the following
steps have been completed.
Fig. 34 — Inlet Guide Vane Differential
Pressure Switch and Variable Frequency Drive
(Sizes 054-104)
1. Verify unit has been installed per the Installation Instructions included in the unit installation packet.
2. Verify that all auxiliary components (sensors, controls,
etc.) have been installed and wired to the unit control
boxes per these instructions, the unit Installation Instructions, and the unit wiring label diagrams.
3. Verify that air pressure hoses (static, duct, etc.) are properly attached, routed, and free from pinches or crimps that
may affect proper control operation.
4. Set any control configurations that are required (fieldinstalled accessories, etc.). The unit is factory configured
for all appropriate factory-installed options with the applicable controls programmed to the default values.
5. Check and adjust unit set points. See Table 9.
6. Check tightness of all electrical connections.
7. Perform quick test (see Quick Test Program section on
page 31).
Fig. 35 — Modulating Power Exhaust Differential
Pressure Switch (Sizes 054-104)
25
Table 9 — Potentiometer Inputs and Ranges
POTENTIOMETER
P1
P2*
DESCRIPTION
LOCATION
Supply Air
Set Point
Economizer
Position
Display
Board
Economizer
Motor
Accessory
Board
CONTROL
VALID
RANGE
45 to 70 F
DEFAULT VALUE
45 F if -22 F < P1 < 45 F
70 F if P1 > 70 F OR IF P1 < -22 F
0 to 100%
None (0 if P2 is bad)
0 to 80 F
None (limited to 70 F maximum)
P3
Reset Limit
P4†
Demand Limit,
Single-Step
Main Control Box
0 to 100%
None
DLCM-P1
DLCM-P2
Demand Limit,
2-Step
DLCM Board
DLCM Board
50 to 100%
0 to 49%
None
None
P5*
Minimum Economizer
Position
Accessory Board
0 to 100%
None
P6
Warm-Up
Set Point
Accessory Board
40 to 80 F
P7**
Reset
Temperature
Reset Board
40 to 100 F
40 F if 0° F < P6 < 40 F OR IF P6 < 95 F
OR IF P6 < 0
80 F if 80 F < P6 < 95 F
None
*Optional factory-installed economizer is required. Potentiometer P2 is not a set point.
†Accessory two-step demand limit module is required (which has 2 potentiometers), or a 5 to 20 k-ohm
field-supplied potentiometer is required for single-step demand limit.
**Accessory temperature reset is required.
NOTE: Potentiometers P1-P6 input data to pin terminal connector J3.
Potentiometer P7 inputs data to pin terminal connector J1.
Configuration Header — The configuration header is a
series of 8 small wires that are broken (open circuit) or unbroken (closed circuit) in a pattern to indicate several unique characteristics of the unit. The configuration header is factory set
and should not be changed; changing the factory setting may
cause the unit to malfunction.
Before start-up, visually check the configuration header
against the factory setting for the unit size. See Table 10 for
factory settings. See Table 11 for purpose for each jumper.
Table 11 — Configuration Header Jumpers
JUMPER
NUMBER
1,2
3,4,5
6
7
8
DIP
■
■
MEANING
VAV Rooftop Unit
2 Compressors
TXV
60 Hz
No Significance
UNIT SIZES
UNIT SIZE
UNIT SIZE
034-038,
044
104
JUMPER OR
048-088
SWITCH NO.
Header Switch Header Switch Header Switch
Position Position Position Position Position Position
1
Off
Off
Off
2
■
Off
■
Off
■
Off
3
■
On/Off*
■
On/Off*
■
On/Off*
4
On/Off*
On/Off*
■
On/Off*
5
Off
Off
Off
6
■
Off
■
On
■
On
7
On
Off
Off
8
■
Off
■
Off
■
Off
Unit Type
Qty Compressors
Expansion Valve
Power Frequency
Not Used
FACTORY
SETTING
■
■
■
LEGEND
TXV — Thermostatic Expansion Valve
VAV — Variable-Air Volume
— Broken Jumper (open circuit)
■
— Unbroken Jumper (closed circuit)
Table 10 — Configuration Header and
DIP Switch Factory Settings
FUNCTION
DIP Switches — The DIP switches configure the unit for
several factory-installed options and field-installed accessories,
plus factory unloaders. The DIP switches are located under a
plastic enclosure which must be removed for access. See
Fig. 1. The switches can be field adjusted. Switches must only
be adjusted when control power is deenergized. See Table 12
for DIP switch purposes and Table 10 for factory settings of the
switch positions.
LEGEND
— Dual, In-Line Package
— Broken Jumper (open circuit)
— Unbroken Jumper (closed circuit)
Disconnect control power before changing the settings of
the DIP switches. To disconnect control power, open the
control circuit breaker.
*Depending on factory-installed options or field-installed accessories.
26
Potentiometer inputs and ranges are summarized in Table 9.
Information on individual set point potentiometers (including
function, location and range data) are shown below:
SUPPLY AIR SET POINT (Leaving-Air Temperature) (P1)
— This potentiometer establishes the set point for cooling
cycle operation of the VAV unit. The VAV control uses a valid
control range of 45 to 70 F, and the potentiometer has a valid
range of –22 to 70 F. If the set point is between –22 and 45 F,
the control will use a value of 45 F. If the set point is outside
the valid range (less than –22 F or greater than 70 F), an alarm
condition will be signaled and a default value of 70 F will be
used.
ECONOMIZER MINIMUM POSITION (P5) — This potentiometer specifies the minimum opening position for the
optional economizer during running periods. It has both a valid
range and an operational range of 0 to 100%.
SASP RESET TEMPERATURE (P7) — This potentiometer
establishes the space temperature at which the control will initiate the reset of the SASP (i.e., the unit control begins to raise
the base SASP, to prevent overcooling of the space). The
potentiometer has a valid range of 40 to 100 F. Refer to Space
Temperature Reset section on page 13 for further discussion of
SASP Reset operation.
RESET LIMIT (P3) — Used in conjunction with P7 potentiometer, this potentiometer establishes the maximum temperature for the modified SASP value during the Reset function.
This potentiometer has a valid range of 0° to 80 F.
DEMAND LIMIT, SINGLE-STEP (P4) — This potentiometer establishes the maximum amount of compressor capacity
permitted by the unit control when single-step demand limit
operation is implemented (by closing contact set to potentiometer wiper arm). This potentiometer is field-supplied and
-installed and will be located in the main control box. The
valid range is 0% to 100%, which is also the operational range.
If the wiper arm is open, all capacity stages can be used.
When the wiper arm is closed, the capacity is reduced by the
amount set on potentiometer P4.
DEMAND LIMIT, 2-STEP — The accessory 2-step demand
limit control is a 2-potentiometer system. The demand limit
control board (DLCM) accessory board is field-installed in the
main control box; the 2 control potentiometers are located on
the DLCM. Potentiometer DLCM-P1 establishes the maximum amount of compressor capacity available when SW1 is
closed and has a valid range is 50% to 100%. Potentiometer
DLCM-P2 establishes the maximum amount of compressor
capacity available when SW2 is closed and has a valid range is
0% to 49%.
If no power is supplied to the DLCM, all capacity stages
can be used. When power is supplied to terminal IN1 only, the
first step of demand limit control is energized and the capacity
is reduced by the amount set on potentiometer P1. When power
is supplied to IN2 (or IN1 and IN2), the capacity is reduced by
the amount set on potentiometer P2.
MORNING WARM-UP (P6) — This potentiometer establishes the set point temperature for the Morning Warm-Up
function. This is the temperature at which the morning warmup sequence is terminated and VAV cooling operation begins.
The valid control range is 0° to 95 F, but the control is programmed to accept a range of 40 to 80 F. If the set point is
between 0° and 40 F, the control will use a value of 40 F. If the
set point is between 80 and 95 F, the control will use a value of
80 F. If the set point is outside the valid range (less than 0° F or
greater than 95 F, an alarm condition will be signaled and a
default value of 40 F will be used.
DIP SWITCH NO. 1 — Supply Air Set Point (SASP) Reset
Type. Factory setting is OFF. Do not change.
DIP SWITCH NO. 2 — SASP Reset Enabled. Factory setting
is OFF (no SASP reset enabled). If SASP reset has been
installed, enable it by changing switch position to ON.
DIP SWITCH NO. 3 — Economizer option. If economizer
option has been installed, this switch will be ON. If there is no
economizer installed, this switch will be OFF. For all 48FM
and 50FM,FS units, this switch will be ON. Confirm setting
per Table 10. Change only if in error.
DIP SWITCH NO. 4 — Morning Warm-Up. For 48FK,FM,JK
units, this switch will be ON (morning warm-up enabled). For
50FK,JK units with factory-installed electric heaters, this
switch will be ON. For all other units, this switch will be OFF.
If accessory electric heaters are installed (for 50FK,JK 034074 units without plenum option), change this switch to ON.
DIP SWITCH NO. 5 — Demand Limit. Factory setting is OFF
(demand limit not enabled). If Demand Limit (single-step or
2-step accessory) has been installed, change this switch to ON.
DIP SWITCHES NO. 6 AND NO. 7 — Unloader Configuration. These are factory set to match unit size. Confirm settings per Table 12. Change only if in error.
Table 12 — DIP Switches
SWITCH
NO.
FUNCTION
2
Reset
Mode
Reset
Select
3
Economizer
1
5
Morning
Warm-Up
Demand
Limit
6,7
Unloaders
8
Not Used
4
SWITCH
POSITION*
Off
On
Off
On
Off
On
Off
On
Off
Off, Off
On, Off
Off, On
Off
MEANING
Space or Outdoor-Air Reset
(DO NOT CHANGE)
Reset Used
Reset Not Used
Enable Economizer
Disable Economizer†
Enable Morning Warm-Up**
Disable Morning Warm-Up**
Enable Demand Limit
Disable Demand Limit
No Unloaders
1 Unloader
2 Unloaders
No Significance
LEGEND
DIP — Dual, In-Line Package
*Control circuit breaker must be off before changing the setting of the DIP
switch.
†No economizer.
**And/or electric heat (50FK,JK034-074 units without plenum only).
Adjusting Set Points — Set points for unit operation
are established via potentiometer settings. Set points for Supply
Fan controls are set at the VFD keypad (if installed) or at the
IGV differential pressure switch (DPS1) (if IGV option installed). Set points for modulating power exhaust (option or accessory) are set at the differential pressure switch (DPS2).
Set points for high capacity modulating power exhaust
(48FM and 50FM,FS units) are set at the power exhaust VFD
keypad.
Potentiometers — All of the set point potentiometers
must be set before the unit is started in order for the unit to
function properly. Each of the potentiometers has a valid range
that is used by the control. The valid range is defined as the potentiometer’s resistance value that the control will not consider
to be in error. This is usually between 10% and 90% of the potentiometer’s total resistance. The control has been programmed to accept an operational range for the potentiometer,
which may not be the same as the valid range.
27
Supply Fan Control with IGV Option — The inlet
guide vane option will modulate the supply fan airflow in order
to maintain the static pressure in the supply duct. The set point
for duct static pressure is established at the differential pressure
switch for the IGV control.
SIZE 034-048 UNITS — The inlet guide vane differential
pressure switch is located in the auxiliary control box mounted
in the corner under the side air hood that is next to the access
door marked FILTER SECTION. To gain access to this control
box, remove the auxiliary control box cover. When replacing
cover, be sure to properly secure it in order to prevent water
from being drawn into the unit. See Fig. 36 and 37.
SIZE 054-104 UNITS — The inlet guide vane differential
pressure witch is mounted on an upright located behind the
supply-fan motor. See Fig. 36-38.
The IGV differential pressure switch has an adjustable set
point range of 1.1 to 3.5 in. wg. and a factory setting of
1.9 in. wg.
To adjust set point, turn set point adjusting screw (see
Fig. 39) clockwise to decrease set point and counterclockwise
to increase set point. This switch also has an adjustable null
span. The null span is the pressure change that can be made
without contacts opening or closing. It is adjustable from
0.06 in. wg to 0.17 in. wg when set point is at minimum position (1.1 in. wg) and 0.11 in. wg to 0.31 in. wg when set point is
at maximum position (3.5 in. wg). To adjust null span, turn a
null adjusting screw (Fig. 39) clockwise to decrease span and
counterclockwise to increase span. All switches leave factory
with null span set at maximum position. The smaller the null
span, the closer the pressure will be maintained to desired set
point.
*The inlet guide vane differential pressure switch for the 034-048
units is located in the back of the unit in the auxiliary control box. Its
location is not shown in this figure.
Fig. 36 — Inlet Guide Vane Motor,
50FK,JK034-074 Units
Supply Fan Control with VFD Option — The VFD
option will modulate Supply Fan motor (and thus wheel) speed
to maintain the static pressure in the ductwork. Set point for the
VFD option is set at the VFD, using the display keyboard on
the front of the VFD enclosure. See Fig. 40.
NOTE: The VFD will always provide the proper phase
sequence to the supply-fan motor. The supply-fan motor operates in proper rotation regardless of the phase sequence to the
unit. If, upon start-up, the outdoor fans operate backwards but
the supply fan operates in the correct direction, reverse any two
leads to the main terminal block. All fans will then operate in
the correct direction.
The supply duct pressure transducer has a range of 0.0 to
5.0 in. wg. Its output is a 4 to 20 mA signal, scaled to this
range. The VFD translates this 4 to 20 mA input signal to represent a frequency value over the control range of 0 to 60 Hz.
The factory default set point is 30 Hz, representing a supply
duct pressure of 2.5 in. wg.
*The inlet guide vane differential pressure switch for the 034-048
units is located in the back of the unit in the auxiliary control box. Its
location is not shown in this figure.
Fig. 37 — Inlet Guide Vane Motor, 48FK,JK, 50FJ,JY,
and 50FJX,FJY,FKX,FKY034-074 Units
Factory-installed optional VFD is located near the supply
fan and motor. During any service work or programming at
the VFD, operation of the fan and motor is not desirable
and may be dangerous. Either disable the unit supply fan
(following instructions below) or install the accessory VFD
remote display accessory.
Fig. 38 — Inlet Guide Vane Motor,
Size 078-104 Units
28
DISABLE SUPPLY FAN MOTOR — To disable the supply
fan motor and change programming of VFD set point:
1. Turn off Indoor Fan Circuit Breaker (IFCB). This will remove power to the VFD.
CAPACITOR
NULL
ADJUSTMENT
COM
N.C.
N.O.
Ensure the “CHARGE” lamp on the VFD is unlit. This
may take up to 4 minutes. The “CHARGE” lamp indicates
that the main capacitors in the VFD are charged. Internal
components of the VFD should not be touched until the
“CHARGE” lamp is completely out. Electrical shock can
cause injury or death.
NULL DECREASE
SET POINT
DECREASE
SET
POINT
ADJUSTMENT
PLA
2. Wait for the VFD display to go blank and remove VFD
cover without touching any interior components.
3. Ensure that the charge indicator lamp is out which indicates that the VFD is discharged. The lamp is located on
the upper right hand corner of the terminal block. If still
lit, wait until lamp goes completely out. This may take
several minutes.
4. Remove jumper from terminals ST-CC (see Fig. 41) and
replace VFD cover.
5. Turn on IFCB.
6. The drive output will now be disabled but the programming can be changed.
7. Change VFD set point according to Table 14 shown
on page 30.
8. Once the program changes are completed, turn off IFCB.
9. Wait for the VFD display to go blank and remove VFD
cover without touching any interior components.
10. Ensure that the charge indicator lamp is out which indicates that the VFD is discharged. The lamp is located on
the upper right hand corner of the terminal block. If still
lit, wait until lamp goes completely out. This may take
several minutes.
11. Replace jumper to terminals ST-CC.
12. Replace VFD cover.
13. Turn on IFCB to enable the drive.
For additional information on the VFD (including basic
troubleshooting, factory jumper arrangements, and Carrier factory defaults programming), refer to Troubleshooting, Supply
Fan Variable Frequency Drive section (page 52).
NE
SET
POINT
INDICATOR
LEGEND
COM — Common
N.C. — Normally Closed
N.O. — Normally Open
Fig. 39 — Differential Pressure Switch for Inlet
Guide Vane and Static Pressure Control Option
and Modulating Power Exhaust Option
HZ
PERCENT
SECONDS
KW/AMPS/VOLTS
SETUP
PROGRAM
RUN
MONITOR
READ
STOP
WRITE
RESET
LOCAL/REMOTE
SPEED CTRL
MANUAL/AUTO
IMPORTANT: The Carrier factory default values for the
VFD may be different than the default values of the
manufacturer. Refer to the Service section when checking default values.
RUN MODE
Fig. 40 — Variable Frequency Drive Keypad
P24 RES RR
DETERMINE VFD SET POINT — The unit of measure for
the Duct Pressure set point at the VFD is output frequency
(Hz), corresponding to the desired DP set point (DPSP) in
inches of water gage (in. wg). To convert desired DPSP into
the VFD set point, refer to Table 13. Locate the pressure value
in the table closest to the desired DPSP for this installation
and use the corresponding VFD set point (Hz) value. If necessary, interpolation between duct static pressure values is
permissible.
ADJUST VFD SET POINT — To adjust the VFD set point,
the VFD must be powered; however, since it is located near the
supply fan and motor, operation of the fan and motor is not
desirable. Either disable the Supply Fan or install the accessory
VFD remote display accessory.
ST
F
FM AM CC
R
S1
CC
S2
RX
S3
PP
S4 RCH P24 LOW LOW
IV
FP FLC FLB FLA
REMOVE
JUMPER
Fig. 41 — Jumper Removal to Disable Motor
29
Table 13 — VFD Set Point (Frequency Command) for Duct Pressure
PRESSURE
(in. wg)
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
VFD SET POINT (Hz)
0
3
6
9
12
15
18
21
CONTROL SIGNAL
(mA)
4.0
4.8
5.6
6.4
7.2
8.0
8.8
9.6
PRESSURE
(in. wg)
2.00
2.25
2.50
2.75
3.00
3.25
3.50
VFD SET POINT
(Hz)
24
27
30
33
36
39
42
CONTROL SIGNAL
(mA)
10.4
11.2
12.0
12.8
13.6
14.4
15.2
Table 14 — Changing the VFD Set Point (Frequency Command)*
KEY OPERATION
↓
↓↑
READ
WRITE
LED MESSAGE
EXPLANATION
Standard Monitor Mode (output frequency). If drive is disabled, display
XX.X or OFF
will read “OFF”. If enabled, display will show current output frequency
60.0
Pressing arrow key once will display the current frequency set point
45.0 (flashing)
Pressing up/down arrow keys changes the desired set point
When the Read/Write key is pressed, the parameter name (FC) and the new value (45.0)
FC and 45.0 (flashing) will alternately flash to indicate that the new value has been stored. After 2 cycles, the display will
return to the standard monitor mode.
Standard Monitor Mode (output frequency). If drive is disabled, display
XX.X or OFF
will read “OFF”. If enabled, display will show current output frequency
*Choose set point from Table 13 according to desired duct pressure or Table 15 according to desired building pressure.
Modulating Power Exhaust (Option or Accessory) (48FK,JK and 50FK,JK Units) — The Mod-
power exhaust fan motor no. 2 to maintain the building pressure. The set point for the building pressure control is set at the
power exhaust VFD using the keyboard on the front of the
power exhaust VFD enclosure. See Fig. 40.
NOTE: The VFD will always provide the proper phase
sequences to the power exhaust fan motor.
The exhaust fan motor operates in proper rotation regardless
of the phase sequence to the unit. If, upon start-up, the outdoor
fans operate backwards but the exhaust fan operates in the correct direction, reverse any two leads on the main terminal
block. All fans will then operates in the correct direction.
The building pressure transducer has a range of –0.5 to
+0.5 in. wg. The output is a 4 to 20 mA signal, scaled to this
range. The VFD translates the 4 to 20 mA signal to represent a
frequency value over the control range of 0 to 60 Hz. See
Table 15. The set point for duct pressure control is established
at the power exhaust VFD keypad in terms of Hz. The factory
default set point is 30 Hz, representing a building pressure of
0.0 in. wg.
DETERMINE POWER EXHAUST VFD SET POINT —
The unit of measure for the building pressure set point (BPSP)
at the power exhaust VFD is output frequency (Hz), representing the desired BPSP (in. wg). To convert the desired BPSP
into the power exhaust VFD set point, refer to Table 15. Locate
the pressure value in the table closet to the desired BPSP for
the application and use the corresponding set point (Hz) value.
If necessary, interpolation between duct static pressure values
is permissible.
ADJUST PE VFD SET POINT — To adjust the PE VFD set
point, the PE VFD must be powered. Since it is located in the
indoor section of the unit, use caution to ensure that the service
access door is blocked open and will not close suddenly.
Change PE VFD set point according to Table 14.
ulating Power Exhaust system will maintain space pressure by
modulating power exhaust fan no. 1 and staging power exhaust
fan no. 2. Building pressure set point is established at the modulating power exhaust differential pressure switch (DPS).
SIZE 034-048 UNITS — The modulating power exhaust differential pressure switch is located in the auxiliary control box
mounted in the corner next to the power exhaust motor door.
To gain access to this control box, remove the auxiliary control
box cover. When replacing cover, be sure to properly secure it
in order to prevent water from being drawn into the unit. See
Fig. 33.
SIZE 054-104 UNITS — The modulating power exhaust differential pressure switch is mounted below the auxiliary control box next to the access door labeled FILTER SECTION.
See Fig. 35.
DIFFERENTIAL PRESSURE SWITCH — The modulating
power exhaust DPS has a set point range of 0.5 in. wg to
–0.5 in. wg. Factory setting is +0.1 in. wg. To adjust set point,
turn set point adjusting screw (see Fig. 39) clockwise to
decrease set point and counterclockwise to increase set point.
This switch also has an adjustable null span. The null span is
the pressure change that can be made without contacts opening
or closing. It is adjustable from 0.06 in. wg to 0.14 in. wg when
set point is at minimum position (–0.5 in. wg) and 0.07 in. wg
to 0.14 in. wg when set point is at maximum position
(+0.5 in. wg). To adjust null span, turn null adjusting screw
(Fig. 39) clockwise to decrease span and counterclockwise to
increase span. All switches leave factory with null span set at
maximum position. The smaller the null span, the closer the
pressure will be maintained to desired set point.
High Capacity Power Exhaust (48FM and
50FM,FS Units) — The power exhaust VFD will modulate the power exhaust fan motor no. 1 speed and stage (on/off)
30
Table 15 — PE VFD Set Point (Frequency
Command) for Building Pressure
PRESSURE
(in. wg)
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
VFD
SET POINT
(Hz)
0.0
3.0
6.0
9.0
12.0
15.0
18.0
21.0
24.0
27.0
CONTROL
SIGNAL
(mA)
4.00
4.80
5.60
6.40
7.20
8.00
8.80
9.60
10.40
11.20
PRESSURE
(in. wg)
0.00
–0.05
–0.10
–0.15
–0.20
–0.25
–0.30
–0.35
–0.40
–0.45
–0.50
VFD
SET POINT
(Hz)
30.0
33.0
36.0
39.0
42.0
45.0
48.0
51.0
54.0
57.0
60.0
display board will be energized. This indicates that control system is ready to run quick test program.
CONTROL
SIGNAL
(mA)
12.00
12.80
13.60
14.40
15.20
16.00
16.80
17.60
18.40
19.20
20.00
IMPORTANT: Do not allow unit control circuit to
remain energized with 20 showing on display for more
than 2 minutes. If display button is not pressed within
this time period, control will attempt to start unit.
For each step of the 33-step program, display button must
be pressed twice. On first press, step number is displayed;
second press initiates required action and appropriate code is
displayed.
NOTE: The step number is a numeral followed by a decimal
point (a 2-digit number has a decimal point after each
numeral). The action code number is one or 2 digits with no
decimal point(s).
IMPORTANT: Once quick test is initiated, display button must be pressed at least once every 10 minutes for
control to remain in Quick Test mode. If button is not
pressed within this time, control will attempt to start the
unit.
START UNIT
To start unit:
1. Close the unit-mounted ON/OFF switch (located in the
main control box).
2. Close the field-supplied and -installed timeclock (or control) switch (contacts located at Terminals 1 and 2 (TB3
for 034-048, TB4 for 054-104).
To recheck any step in quick test program, control must be
recycled by turning unit control switch off for a few seconds,
and then turning it back on again. Restart quick test program as
described above and proceed through quick test steps. Press
display button twice for each step until step to be rechecked is
reached.
The quick test program is divided into 3 sections as described below and shown in Tables 16-18.
1. Quick Test Steps 1.-1.3. — Unit Configuration and
Switch Check
The microprocessor in unit control system is programmed by 2 switch assemblies located on processor
board (Fig. 1). The configuration header is factory set and
cannot be changed in the field. The DIP switch assembly
contains 8 microswitches that must be set in accordance
with the various options selected by the customer. All
DIP switches should be checked and set to proper position for options selected prior to the quick test. See Configuration of Header and DIP Switch Assembly section
on page 5 for factory switch settings. The DIP switch
functions and display codes are shown in Table 16.
2. Quick Test Steps 1.4.-2.3. — Thermistor and Set Point
Potentiometer Check
In these steps, the microprocessor checks resistance values of all sensors and set point potentiometers to ensure
that they are functional, connected properly, and set within proper range for unit configuration.
Nominal resistance values for all sensors range from
363,000 to 219 ohms in accordance with Table 19. Normal display code for good sensors and potentiometers
is 1. A display code of 0 indicates a faulty potentiometer,
thermistor or wiring. A 0 display also indicates that option is not being used.
Table 17 shows thermistor and set point potentiometer
functions and quick test display codes.
IMPORTANT: The field-supplied and installed switch
(or timeclock) MUST BE CLOSED to put unit in
Occupied mode. Unit WILL NOT START until this is
accomplished.
3. Initialization mode begins (see Operating Information
section on page 34 for complete description of sequences
and display codes).
4. Run Quick Test. If the display button is pressed during
the initialization mode period, the unit will run its selfdiagnostic routine. When this is in effect, an 88 will appear in the display screen. Refer to Quick Test Program
section below, for instructions on completing the Quick
Test program.
Quick Test Program — Turn on power to unit.
IMPORTANT: The field-supplied switch (or timeclock)
must be closed to put unit into the occupied mode.
The quick test program utilizes the 2-digit LED display (see
Fig. 6) on the set point board to show status of all input and
output signals to microprocessor. Display action and quick test
procedures are described below.
The quick test program is a 33-step program that provides a
means of checking all input and output signals of controls prior
to unit start-up. This check ensures that all control options,
thermistors, and control switches are in proper working order.
When unit control circuit is switched to Occupied mode, a
20 will appear on the display. Immediately press display button
once. An 88 will appear on the display and alarm light on
31
Table 16 — Quick Test, Unit Configuration and Switch Check
QUICK
TEST
STEP NO.
NORMAL
DISPLAY
1.
01
Type Unit — Air-Cooled VAV
Configuration Header
2.
2
No. of Compressors
Configuration Header
No. of Unloaders
(034,038,048-088)
DIP Switch No. 6 and 7
3.
DESCRIPTION
CONTROL SWITCH
2
1
(044, 104)
4.
60
60-Hertz Power
Configuration Header
5.
0 or 1
0 — No Reset (Switch Off)
1 — Reset On (Switch On)
DIP Switch No. 2
6.
0 or 1
0 — No Economizer (Switch Off)
1 — Economizer On (Switch On)
DIP Switch No. 3
7.
0 or 1
0 — No Warm-Up (Switch Off)
1 — Warm-Up Used (Switch On)
DIP Switch No. 4
0 or 1
0 — Demand Limit Not Used
(Switch Off)
1 — Demand Limit Used
(Switch On)
DIP Switch No. 5
8.
9.
0 or 1
0 — Enthalpy Switch Open
1 — Enthalpy Switch Closed
EC
1.0.
1
1 — Low-Pressure Switch Closed
Low-Pressure Switch 1
1.1.
1
1 — Low-Pressure Switch Closed
Low-Pressure Switch 2
1.2.
1
No Circuit 1 Oil Pressure Switch
None*
1.3.
1
No Circuit 2 Oil Pressure Switch
None*
LEGEND
DIP — Dual, In-Line Package
EC — Enthalpy Control
VAV — Variable Air Volume
*Units are not equipped with oil pressure switches.
32
Table 17 — Quick Test, Thermistor and Potentiometer Check
QUICK
TEST
STEP NO.
NORMAL
DISPLAY
1.4.
1
1.5.
1
1.6.
1
1.7.
1
1.8.
1
1.9.
1
2.0.
1
2.1.
1
2.2.
1
2.3.
1
THERMISTOR OR
POTENTIOMETER*
DESCRIPTION
1 — Thermistor OK
0 — Thermistor Faulty
1 — Thermistor OK
0 — Thermistor Faulty
1 — Thermistor OK
0 — Thermistor Faulty
1 — Thermistor OK
0 — Thermistor Faulty
1 — Thermistor or Potentiometer OK
0 — Thermistor or Potentiometer Faulty or
Option not used
1 — Potentiometer OK
0 — Potentiometer Faulty
1 — Potentiometer OK
0 — Potentiometer Faulty or Option not used
1 — Potentiometer OK
0 — Potentiometer Faulty or Option not used
1 — Potentiometer OK
0 — Potentiometer Faulty or Option not used
1 — Potentiometer OK
0 — Potentiometer Faulty or Option not used
Supply Air
Thermistor (T1)
Return Air
Thermistor (T2)
Circuit 1 Condenser Thermistor
(T3)
Circuit 2 Condenser Thermistor
(T4)
Accessory Space Temperature Thermistor (T10)
or Accessory Reset Potentiometer (P7)
Supply-Air Set Point
Potentiometer (P1)
Accessory Reset Limit
Potentiometer (P3)
Accessory Demand Limit
Potentiometer (P4)
Minimum Position
Economizer
Potentiometer (P5)
Warm-Up Set Point
Potentiometer (P6)
*Potentiometer P2 is not listed since it is not part of the quick test. If on unit start-up a Code 83 is displayed, check potentiometer P2.
Table 18 — Quick Test, Output Relay Check
QUICK
TEST
STEP NO.
NORMAL
DISPLAY
2.4.
1
1 — Open Economizer or Open Relay if no Economizer
K7
2.5.
1
1 — Close Economizer or Close Relay if no Economizer
K8
DESCRIPTION
RELAY NUMBER
2.6.
1
1 — Energize Fan Relay and Heat Relay
2.7.
1
Energize Stage 1 Condenser Fan(s)
K9* and K10
K11
2.8.
1
Energize Stage 2 Condenser Fan(s)
K12
2.9.
0 then 1 then 0
Energize Compressor 1†
K1
3.0.
0
Energize Unloader 2; Not Used (044, 104)
K2
3.1.
0
Energize Unloader 1
K3
3.2.
0 then 1 then 0
Energize Compressor 2†
K5
3.3.
0
Not Used
K6
LEGEND
CR — Control Relay
*K9 (fan relay) will remain on for duration of quick test.
†Compressor will be energized for 10 seconds. Zero indicates open CR; 1 indicates closed CR.
33
Table 19 — Sensor Resistance Values
TEMP
(F)
–60
–55
–50
–45
–40
–35
–30
–25
–20
–15
–10
–5
0
5
10
15
20
25
30
35
40
RESISTANCE
(Ohms)
362,640
297,140
245,245
202,841
168,250
139,960
116,820
98,420
82,665
69,685
58,915
50,284
42,765
36,475
31,216
26,786
23,164
19,978
17,276
14,980
13,085
TEMP
(F)
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
RESISTANCE
(Ohms)
11,396
9,950
8,709
7,642
6,749
5,944
5,249
4,644
4,134
3,671
3,265
2,913
2,600
2,336
2,092
1,879
1,689
1,527
1,377
1,244
1,126
TEMP
(F)
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
enthalpy is good. As long as the outdoor-air enthalpy is acceptable, no mechanical cooling will take place until the economizer dampers are fully open. The rest of the steps and the operational sequence vary due to the number of compressors and unloaders. Refer to Operating Sequence section on page 35 for
the unit stages of operation.
CODES 20 THROUGH 30 AND 88, OPERATIONAL STATUS — These codes indicate special operational modes, such
as initialization, morning warm-up, temperature reset, demand
limit, or an internal failure of the board. Codes 23-25 and
27-29 are not used on these units.
Initialization — When the control is turned on, the display
shows a 20 for approximately 2 minutes to indicate that the
control is in the initialization mode. During this time, the economizer dampers open and close to determine the resistance
range of the economizer position potentiometer (P2) for full
economizer operation. The processor loads the necessary constants for proper unit operation and checks the thermistors and
other potentiometers for their values and validity. After the initialization period, the display screen goes blank until the display button is pressed. If the display button is pressed during
the 2-minute initialization period, the control goes into the
Quick Test mode.
Temperature Reset — If the unit is equipped with the accessory temperature reset package, and DIP switch 2 is in the ON
position, the unit will reset the supply-air temperature to a calculated value when necessary. When this condition is in effect,
a 21 will appear in the display.
Demand Limit — If the unit is equipped with the accessory
demand limit control module or the field-supplied, single-step
demand limit potentiometer, and DIP switch 5 is in the ON
position, the unit will limit the capacity stages to a predetermined value. When this condition is in effect, a 22 will appear
in the display.
Morning Warm-Up — If the morning warm-up heat routine is
enabled using DIP switch 4, and conditions of the occupied
space warrant, the unit will begin the morning warm-up routine. When this condition is in effect, a 26 will appear in the
display.
Internal Failure — If the unit detects an internal fault (such as
a time measurement failure), or detects an incorrect voltage on
an input channel, a 30 will be displayed, and the unit will shut
down.
Quick Test — If the display button is pressed during the initialization period of the processor, the unit will run its self-diagnostic routine. When this is in effect, an 88 will appear in the
display screen.
CODES 51 THROUGH 87, DIAGNOSTIC INFORMATION
— These codes indicate diagnostic information when there is a
unit problem such as a faulty thermistor, potentiometer, or
compressor fault. Refer to Diagnostic Codes section on
page 45 for more details. Codes 53, 54, 57, 58, 61, 62, 65-69,
73, 74, and 77-80 are not used on these units.
Under normal operation, only the stage number is displayed
when the display button is pressed. If a status or overload code
is displayed, the display will rotate every 2 seconds and will
display up to 3 codes. Overload information takes priority over
all other codes. The codes are stored in the microprocessor as
long as the board remains energized.
RESISTANCE
(Ohms)
1,020
929
844
768
699
640
585
535
490
449
414
380
350
323
299
276
255
236
219
3. Quick Test Steps 2.4.-3.3. — Output Relay Check
These quick test steps allow microprocessor to check output signals from relay boards in unit control system. In
addition, operation of all the condenser fans, compressors, and economizer (if equipped) are checked at each
step.
Normal display for Steps 2.4. through 2.8. is 1. In Steps
2.9. through 3.2., each compressor and unloader is started
and allowed to run for approximately 10 seconds. At
startup, a 0 will appear on the display followed by a
1 (Steps 2.9. and 3.2.) in a few seconds. Steps 3.0. and
3.1. will always be 0 since there are unloaders, and Step
3.3. will always be zero since it is not used.
At end of the 10-second time period, a 0 will return to the
display board indicating that test step has been successfully completed (Steps 2.9. and 3.2.). The 1 indicates that
was tested.
Fan and compressor operating sequence for quick test
Steps 2.4. through 3.3. are shown in Table 18.
If the quick test steps do not operate as described above, a
defect exists in one or more of the following: relay being tested, electronic control, or unit wiring. Determine problem and
correct.
OPERATING INFORMATION
Digital Display — The VAV control system uses a 2-digit
LED display located on the display board to display operational information and diagnostic codes.
CODES 0 THROUGH 8, CAPACITY STEPS — These codes
indicate the number of cooling stages active at the time the display button is pressed. The highest code indicated on the display will be 6 for the 034,038 and 048-088 units, 4 for the 044
units, and 8 for the 104 units.
Capacity steps are directly related to pin terminal connector
J6 output. At step zero, the unit has no mechanical cooling on,
and the economizer may or may not be operating (depending
on the outdoor air conditions). Once a cooling load is detected
(T1 thermistor reads above the supply-air set point), the economizer will begin modulating to meet the load if the outdoor
34
Operating Sequence — The sequence presented below assumes that the unit is equipped with heat for morning
warm-up and an economizer. If these items are not enabled
with the appropriate DIP switches, the processor bypasses
these subroutines. This sequence is also based on an EPROM
(erasable, programmable, read-only memory) processor chip
with the identification ‘HT204485-1-XX,’ where ‘XX’ is replaced by a 2-digit number representing the current software
version. See Fig. 1 for EPROM chip location.
When power is applied to the occupied mode relay (OMR)
through the closure of either a field-installed timeclock or a
field-installed switch in the occupied space, the unit will begin
its initialization mode.
A 20 will appear in the display screen, and the initialization
period will last approximately 2 minutes. During this time, the
economizer dampers open and close to determine the resistance range for full economizer operation of the economizer
position potentiometer (P2). The processor loads the necessary
constants for unit operation, and also checks the thermistors
and other potentiometers for their values and validity. After the
initialization period, the screen goes blank until the display button is pressed.
Compressors, unloaders, and condenser fans will be cycled
to maintain a supply-air temperature 2° F below the potentiometer P1 set point once the mechanical cooling stages begin.
Each unit’s cycling is slightly different, and is based on the
number of compressors and unloaders. The operational loading
sequence of compressors is as follows:
During the start-up of the lead compressor for each circuit,
the low-pressure switch will be bypassed for 120 seconds to
prevent nuisance trips of the low-pressure switch. After startup, a low-pressure trip will be ignored for 30 seconds by the
processor.
SIZE 034,038 AND 048-088 UNITS — These units have 2
compressors and 2 unloaders on compressor 1. See Fig. 42 and
43 for compressor and condenser-fan motor locations. The
operating sequence is as follows:
Stage 1 Relays K1, K2, and K3 are energized. Compressor
no. 1 starts with both unloaders energized. Compressor no. 1 runs at 1/3 capacity. The crankcase heater for
this compressor has been deenergized, and the first
stage of condenser fans have been energized. Outdoor (condenser) fan motor no. 1 (OFM1) has started
on all units.
Stage 2 Relays K1 and K3 are energized. Compressor no. 1 is
running with unloader 1 (U1) energized. The compressor is now operating at 2/3 capacity.
Stage 3 Relay K1 is energized. Compressor no. 1 is fully
loaded.
Stage 4 Relays K1, K2, K3, and K5 are energized. Compressor no. 1 is running at 1/3 capacity, and compressor
no. 2 is running at full capacity. The crankcase heater
for compressor no. 2 has been deenergized.
Stage 5 Relays K1, K3, and K5 are energized. Compressor
no. 1 is running at 2/3 capacity, and compressor no. 2
is running at full capacity.
Stage 6 Relays K1 and K5 are energized. Both compressors
are running fully loaded.
Size 034 and 038 units have 2 condenser fans, one of which
is controlled by the microprocessor. The OFM1 is energized
with compressor no. 1. The OFM2 is controlled by the processor and is cycled based on input from circuit thermistor T3 or
T4.
Size 048 units have one fan that can be controlled by the
processor. The other 2 are controlled by the compressors. The
OFM1 is energized by compressor no. 1, and OFM3 is energized by compressor no. 2. The OFM2 is cycled by the processor based on input from either circuit (thermistors T3 and T4).
On size 054,064 units, the first 2 condenser fans energize
with the compressors; compressor no. 1 controls OFM1, and
compressor no. 2 controls OFM2. The OFM3 and OFM4 are
staged by the microprocessor based on the condensing temperature input from thermistor T3 or T4.
On size 074-078 units, the first 3 condenser fans energize
with the compressors; compressor no. 1 controls OFM1, and
compressor no. 2 controls OFM2 and OFM3. The OFM4 and
OFM5 are staged by the microprocessor based on condensing
temperature input from either circuit’s T3 or T4 thermistor.
On Size 088 units, the first 4 condenser fans energize with
the compressors; compressor no. 1 controls OFM1 and OFM3,
and compressor no. 2 controls OFM2 and OFM4. The OFM5
and OFM6 are staged by the microprocessor based on
condensing temperature input from either circuit’s T3 or T4
thermistor.
Use caution during this time (after initialization when the
screen is blank), because the unit supply and return fans
could start at any time. Personal injury could result from
contact with rotating fans.
Once the initialization period is complete, the supply fan begins operation. While the fan is operating, the economizer
dampers are closed and return air from the building is being
circulated. After 2 minutes, the processor checks the resistance
value of thermistor T2. If T2 temperature sensed is 5° F or
more below the set point of the morning warm-up potentiometer (P6), the unit will begin the morning warm-up routine, and
a 26 will be displayed.
Unit heat will be energized through the heat interlock relay
(HIR), and all of the occupied space air terminals will open.
The unit will continue heating the space until the return-air
temperature is within 2° F of set point. The unit will then shut
off the heat and continue to circulate air. The unit will cycle in
and out of the Heating mode until the return-air temperature
reaches the morning warm-up set point (P6). Once morning
warm-up has been terminated, the unit cannot return to morning warm-up until the unit is powered down and restarted. This
action signals a return to the Occupied mode.
NOTE: Occupied heat is NOT AVAILABLE on these units.
Once out of the morning warm-up routine, the unit will begin its cooling routine based on the supply-air set point (P1). At
step zero, the unit has no mechanical cooling on, and the economizer may or may not be operational. The economizer will
move to the minimum position determined by potentiometer
P5 if no cooling load is detected. Once a cooling load is detected by thermistor T1 sensing a temperature higher than the cooling demand set point (P1), the economizer will begin modulating to meet the load if the outdoor enthalpy is good. The processor will attempt to maintain a supply-air temperature of P1
± 2° F by modulating the economizer dampers.
No mechanical cooling will take place until the economizer
dampers are fully open (if the outdoor-air enthalpy permits). If
the economizer is unable to meet the cooling demand, then mechanical cooling is used in conjunction with the economizer. If
the economizer is unable to meet the load due to unacceptable
outdoor-air enthalpy, the dampers will return to the minimum
position as determined by P5.
35
Stage 5 Relays K1, K3, K5, and K5 are energized. Compressor no. 1 runs at 2/3 capacity and compressors no. 2
and no. 4 are running at full capacity. The crankcase
heater on compressor no. 4 is deenergized. Fans
OFM1, OFM2, OFM3, and OFM4 are operating.
Stage 6 Relays K1, K5, and K6 are energized. Compressors
no. 1, no. 2, and no. 4 are running fully loaded.
Stage 7 Relays K1, K2, K3, K5, and K6 are energized. Compressor no. 1 runs at 2/3 capacity and compressors no.
2, no. 3, and no. 4 are running at full capacity. Fans
OFM1, OFM2, OFM3, and OFM4 are operating.
Crankcase heater for compressor no. 3 is deenergized.
Stage 8 Relays K1, K2, K5, and K6 are energized. Compressors no. 1, no. 2, no. 3, and no. 4 are running fully
loaded.
On size 104 units, the first 4 condenser fans energize with
the compressors; circuit no. 1 compressors control OFM1 and
OFM3, and circuit no. 2 compressors control OFM2 and
OFM4. The OFM5 and OFM6 are staged by the microprocessor based on condensing temperature input from either circuit’s
T3 or T4 thermistor.
SIZE 044 UNITS — These units have 2 compressors and 1
unloader on compressor no. 1. See Fig. 42 for compressor and
condenser fan motor locations. The unit operating sequence is
as follows:
Stage 1 Relays K1 and K3 are energized. Compressor no. 1
starts with the unloader energized. Compressor no. 1
is running at 1/2 capacity. The crankcase heater on
compressor no. 1 has been deenergized, and the first
stage condenser fan has been energized. Outdoor
(condenser) fan motor no. 1 (OFM1) has started.
Stage 2 Relay K1 is energized. Compressor no. 1 is fully
loaded.
Stage 3 Relays K1, K3, and K5 are energized. Compressor
no. 1 is running at 1/2 capacity, and compressor no. 2
is running at full capacity. The crankcase heater for
compressor no. 2 is deenergized. The second stage
condenser fan has been energized. Both OFM1 and
OFM3 are operating.
Stage 4 Relays K1 and K5 are energized. Both compressors
are running fully loaded.
Size 044 units have one fan that can be controlled by the
processor. The other 2 are controlled by the compressors. The
OFM1 is energized by compressor no. 1, and OFM3 is energized by compressor no. 2. The OFM2 is cycled by the processor based on input from either circuit (thermistors T3 and T4).
SIZE 104 UNITS — These units have 4 compressors and 1
unloader on compressor no. 1. See Fig. 43 for compressor and
condenser fan motor locations. The unit operating sequence is
as follows:
Stage 1 Relays K1 and K3 are energized. Compressor no. 1
starts with unloader energized. Compressor no. 1 runs
at 2/3 capacity. The crankcase heater for this compressor has been deenergized, and first stage of condenser
fans has been energized. Outdoor (condenser) fan
motor no. 1 (OFM1) and outdoor fan motor no. 3
(OFM3) have started.
Stage 2 Relay K1 is energized. Compressor no. 1 is fully
loaded.
Stage 3 Relays K1, K3, and K5 are energized. Compressor
no. 1 runs at 2/3 capacity and compressor no. 2 is running at full capacity. The crankcase heater for compressor no. 2 is deenergized. The first stage of
condenser fans on circuit 2 has been energized. Fans
OFM1, OFM2, OFM3, and OFM4 are operating.
Stage 4 Relays K1 and K5 are energized. Both compressors
no. 1 and no. 2 are running fully loaded.
034 AND 038 UNITS
OFM
Head Pressure Control — All units have as standard a
basic head pressure control function which allows the units to
operate in cooling down to 45 F. If cooling is required at outdoor ambient temperatures lower than 45 F, refer to accessory
head pressure control literature for details.
Head pressure control is handled by the processor. The processor attempts to maintain the head pressure by cycling the
condenser-fan motors. No condenser fans will be running without a call for mechanical cooling. Thermistors T3 and T4 provide the condensing temperature information to the processor.
These VAV rooftop units have dual refrigeration circuits, and
the higher circuit temperature will govern unit operation. If the
condensing temperature is above 133 F (236 psig), a condenser
fan stage will be added. If the condensing temperature is 78 F
(142 psig) or less, the number of condenser fans operating will
be decreased. After each fan stage, the processor will wait one
minute for the head pressures to stabilize before changing
again, unless thermistor T3 or T4 senses a temperature greater
than 125 F (278 psig), in which case all condenser fans are
started.
During start-up, if the outdoor ambient is above 70 F (as
sensed by thermistor T3 or T4), the first-stage, processorcontrolled fans are turned on to prevent excessive discharge
pressures.
044 AND 048 UNITS
LEGEND
— Outdoor (Condenser) Fan Motor
Fig. 42 — Component Arrangement, 034-048 Units
36
054, 064 UNITS
054-088 UNITS
074, 078 UNITS
088, 104 UNITS
104 UNITS
Fig. 43 — Component Arrangement, 054-104 Units
37
Supply Fan Control with IGV — In most VAV units,
the supply fan static pressure is controlled by inlet guide vanes.
The inlet guide vanes operate independently from the microprocessor. The supply static pressure is controlled by a differential pressure switch.
For example, assume that set point on supply fan differential switch is 1.9 in. wg. If pressure in supply duct goes above
1.9 in. wg, switch will make to the normally open contact and
energize inlet guide vane motor to drive inlet guide vanes to a
more closed position, thus reducing airflow and lowering duct
pressure. Once set point pressure is reached, switch will open
and deenergize inlet guide vane motor. If pressure in supply
duct is below 1.9 in. wg, the switch will make to the normally
closed contact and energize inlet guide vane motor to drive inlet guide vane to a more open position; increasing airflow and
raising duct pressure. Once again, once desired pressure has
been reached, switch will open and deenergize inlet guide vane
motor. How far above or below the set point setting the switch
goes before energizing depends on setting of null span (null
span is pressure change that can be made without contacts
opening or closing). If null span is at maximum position, pressure will vary from 0.17 in. wg to 0.31 in. wg depending on set
point (if set point is at minimum setting, null span will be
0.17 in. wg, while if it is at maximum position, the null span
will be 0.31 in. wg) before switch acts. If null span is adjusted
to a minimum setting, duct pressure will vary from 0.06 in. wg
to 0.11 in. wg (again depending on switch set point) before
switch acts. Setting null span to minimum position will result
in a smaller pressure fluctuation than if it is set at maximum
position.
As the economizer actuator opens past 17% open, auxiliary
switch DMS1 closes, energizing fan contactor PEC1. Fan motor no. 1 starts and runs.
Capacity of fan no. 1 is controlled by the position of the outlet damper. As building pressure increases above set point,
the DPS will close its contact and drive the power exhaust
damper motor (PEDM) open until set point is achieved. DPS
then opens its control contacts and PEDM maintains current
position.
When space demand moves PEDM to 90% of full-open position, auxiliary switch PEDMS closes, energizing fan contactor PEC2. Fan motor no. 2 starts and runs. Increased exhaust
airflow will lower space pressure, causing DPS to drive PEDM
back towards its closed position, until the set point is achieved.
If space pressure decreases until PEDM position is reduced
to 10% of open position, PEDMS will open, deenergizing fan
contactor PEC2 and shutting off fan no. 2.
High Capacity Modulating Power Exhaust
(48FM and 50 FM,FS Units) — The high-capacity
modulating power exhaust assembly consists of two parallel
and independent belt-drive large diameter forward curve fans.
The fans, motors, and drives are located in a cabinet extension
(not over the return air opening of the unit), in a plenum beneath the outside air intake plenum. The fans discharge horizontally out the back of the unit through individual barometric
backdraft dampers with hoods. Operation is interlocked with
economizer operation. Space pressure is monitored by a
factory-installed differential pressure transducer. See Fig. 48
for component locations and sheet metal details.
The high-capacity modulating power exhaust is also available on horizontal 50FS units. Return duct opening is located
on the left-hand side of the unit; exhaust air exits the unit out
the back.
Control of the high-capacity modulating power exhaust system is accomplished via a combination modulated capacity
fan/staged fan. Modulation is provided by a variable frequency
drive controlling the direct output to fan no. 1 and controlling
the ON/OFF status of fan no. 2.
Fan no. 1 is equipped with a Variable Frequency Drive,
matched to the motor size. VFD output is determined by the
VFD’s internal PID logic in response to actual space pressure
as monitored by the Building Pressure (BP) transducer. Set
point for BP control is established at the PE VFD. Available set
point range is –0.50 to +0.50 in. wg. Building Pressure is
sensed by a pick-up (field-supplied and -installed) located in
the occupied space and connected to the BP transducer by
1/4-in. tubing (field-supplied and -installed).
Operation of the modulating power exhaust is a combination modulating/staged control, with fan no. 1 providing modulating control from 0 to 50% of total exhaust capability, and fan
no. 2 being staged On/Off (for a step of 50% of total exhaust
capability) according to VFD output level on fan no. 1.
As the economizer actuator opens past 17% open, auxiliary
PEC1. Fan motor no. 1 starts and runs.
Capacity of fan no. 1 is controlled by the output level from
the BP VFD. As building pressure increases above set point,
the VFD logic will increase the output level to fan no. 1 until
set point is reachieved.
When space demand moves PE VFD output to 100%
(60 Hz), VFD internal relay closes, energizing fan contactor
PEC2. Fan motor no. 2 starts and runs. Increased exhaust airflow will lower space pressure, causing PE VFD to reduce its
output to fan no. 1 until set point is reachieved.
If space pressure decreases until PE VFD output is reduced
to 25% of maximum output (15 Hz), VFD internal relay will
open, deenergizing fan contactor PEC2 and shutting off fan
no. 2.
Unit Staging — Compressor loading and unloading sequences are shown in Table 20.
Supply Fan Control with VFD — When equipped
with the VFD option, the supply fan static pressure is controlled by modulating the fan wheel speed. The VFD operates
independently from the microprocessor. A duct pressure transducer monitors duct static pressure. The transducer output (4 to
20 mA) is directed into the VFD. The VFD adjusts supply fan
motor speed (which changes wheel speed) as measured duct
pressure varies from set point as established at the VFD. The
VFD will modulate fan speed until the duct pressure set point is
achieved.
NOTE: The VFD will always provide the proper phase
sequence to the supply fan motor. This motor will operate in
proper rotation regardless of the phase sequence to the unit. If,
upon start-up, the outdoor fans operate backwards but the
indoor fan operates in the correct direction, reverse any two
leads to the main terminal block. All fans will then operate in
the correct direction.
Modulating Power Exhaust (48FK,JK and
50FK,JK Units Option or Accessory) — The power exhaust assembly consists of two parallel and independent
belt-drive forward curve fans. The fans, motors, and drives are
located over the return air opening of the unit, in a plenum beneath the outside air intake plenum. The fans discharge air horizontally out the back of the unit through individual barometric
backdraft dampers with hoods. (See Fig. 44 and 45.) Operation
is interlocked with economizer operation. Sheet metal installation is shown in Fig. 46 and 47.
Fan no. 1 is equipped with a variable position discharge
damper located in the outlet of the fan housing. This damper is
controlled by an actuator (PEDM), based on signals from the
building pressure differential pressure switch (DPS). Available
range on the DPS is -0.50 to +0.50 in. wg, adjustable. Building
pressure is sensed by a pick-up (field-supplied and -installed)
located in the occupied space.
Operation of the modulating power exhaust is a combination modulating/staged control, with fan no. 1 providing modulating control from 0 to 50% of total exhaust capability, and fan
no. 2 being staged On/Off (for a step of 50% of total exhaust
capability) according to damper position on fan no. 1.
38
Fig. 44 — Modulating Power Exhaust Component Locations; Sizes 034-048
39
40
Fig. 45 — Modulating Power Exhaust Component Locations; Sizes 054-104 (48FK, 50FK,JK Shown)
Fig. 46 — Modulating Power Exhaust Return End Sheet Metal Skin Detail; Sizes 034-048
Fig. 47 — Modulating Power Exhaust Return End Sheet Metal Skin Detail; Sizes 054-104
41
PE VFD
ACCESS DOOR
AUXILIARY
CONTROL BOX
LARGE ECONOMIZER
HOOD LOCATION
EXHAUST
AIR
POWER EXHAUST
ACCESS DOOR
SMALL ECONOMIZER
HOOD LOCATION
Fig. 48 — Modulating Power Exhaust Return End Sheet Metal Skin Detail; 48FM and 50FM,FS Units
Table 20 — Compressor Loading and Unloading Sequences
COOLING
STAGE
0
1
2
3
4
5
6
COOLING
STAGE
0
1
2
3
4
5
6
Comp 1
OFF
ON
ON
ON
ON
ON
ON
Comp 1
OFF
ON
ON
ON
ON
ON
ON
Lead Circuit
Unloader
U1
OFF
ON
ON
OFF
ON
ON
OFF
SIZE 034 UNITS
Lag Circuit
Unloader
Comp 2
U2
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
ON
OFF
ON
Lead Circuit
Unloader
U1
OFF
ON
ON
OFF
ON
ON
OFF
SIZE 038 UNITS
Lag Circuit
Unloader
Comp 2
U2
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
ON
OFF
ON
42
Active
Cylinders
Percent
Capacity
0
2
4
6
8
10
12
0
17
33
50
67
83
100
Active
Cylinders
Percent
Capacity
0
2
4
6
6
8
10
0
14
28
42
72
86
100
Table 20 — Compressor Loading and Unloading Sequences (cont)
COOLING
STAGE
0
1
2
3
4
COOLING
STAGE
0
1
2
3
4
5
6
COOLING
STAGE
0
1
2
3
4
5
COOLING
STAGE
0
1
2
3
4
5
6
COOLING
STAGE
0
1
2
3
4
5
6
SIZE 044 UNITS
Lag Circuit
Lead Circuit
Unloader
Comp 1
U1
OFF
OFF
ON
ON
ON
OFF
ON
ON
ON
OFF
Comp 1
OFF
ON
ON
ON
ON
ON
ON
Comp 1
OFF
ON
ON
ON
ON
ON
Comp 1
OFF
ON
ON
ON
ON
ON
ON
Comp 1
OFF
ON
ON
ON
ON
ON
ON
Comp 2
Active
Cylinders
Percent
Capacity
OFF
OFF
OFF
ON
ON
0
2
4
6
8
0
25
50
75
100
Lead Circuit
Unloader
U1
OFF
ON
ON
OFF
ON
ON
OFF
SIZE 048 UNITS
Lag Circuit
Unloader
Comp 2
U2
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
ON
OFF
ON
Lead Circuit
Unloader
U1
OFF
ON
ON
OFF
ON
OFF
SIZE 054 UNITS
Lag Circuit
Unloader
Comp 2
U2
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
Lead Circuit
Unloader
U1
OFF
ON
ON
OFF
ON
ON
OFF
SIZE 064 UNITS
Lag Circuit
Unloader
Comp 2
U2
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
ON
OFF
ON
Lead Circuit
Unloader
U1
OFF
ON
ON
OFF
ON
ON
OFF
SIZE 074, 078 UNITS
Lag Circuit
Unloader
Comp 2
U2
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
ON
OFF
ON
43
Active
Cylinders
Percent
Capacity
0
2
4
6
6
8
10
0
19
38
58
62
81
100
Active
Cylinders
Percent
Capacity
0
2
4
6
10
12
0
20
40
60
80
100
Active
Cylinders
Percent
Capacity
0
2
4
6
8
10
12
0
17
33
50
67
83
100
Active
Cylinders
Percent
Capacity
0
2
4
6
8
10
12
0
14
29
43
71
86
100
Table 20 — Compressor Loading and Unloading Sequences (cont)
COOLING
STAGE
Comp 1
OFF
ON
ON
ON
ON
ON
ON
0
1
2
3
4
5
6
COOLING
STAGE
0
1
2
3
4
5
6
7
8
Comp 1
OFF
ON
ON
ON
ON
ON
ON
ON
ON
SIZE 088 UNITS
Lag Circuit
Unloader
Comp 2
U2
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
ON
OFF
ON
Lead Circuit
Unloader
U1
OFF
ON
ON
OFF
ON
ON
OFF
Lead Circuit
Unloader
U1
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
SIZE 104 UNITS
Lag Circuit
Active
Cylinders
Percent
Capacity
0
2
4
6
8
10
12
0
16
33
50
66
83
100
Comp 3
Comp 2
Comp 4
Active
Cylinders
Percent
Capacity
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
0
4
6
10
12
14
16
18
20
0
20
30
50
60
70
80
90
100
TROUBLESHOOTING
•
•
•
By using the display module, actual operating conditions of
the unit are displayed while it is running. The Quick Test function allows proper operation of compressors, compressor unloaders, fans, and other components to be checked while unit is
stopped. If an operating fault is detected, an alarm is generated
and an alarm code(s) is displayed. For checking specific items,
see Table 21.
•
•
•
Blown fuse in the control power feed.
Open control circuit fuse.
Operation of the unit blocked by the demand limit
function.
Unit supply-air temperature (T1) thermistor failure.
Supply-air fan is not operating.
High duct static pressure.
Single Circuit Stoppage — If a single circuit stops,
there are several potential causes:
• Open contacts in the compressor high-pressure switch.
• Low refrigerant pressure.
• Thermistor failure.
• Unit supply-air temperature thermistor (T1) failure.
• Compressor circuit breaker trip.
• Operation of the circuit blocked by the demand limit
function.
Checking Display Codes — To view the digital display codes, press the button located to the right of the LED display/set point board in the control box. See Table 22 for Operational Status Codes. See Table 23 for Diagnostic Codes.
Complete Unit Stoppage — If the unit is off, there are
several conditions that can cause this situation to occur:
• Remote ON/OFF circuit in Unoccupied mode.
• Unit ON/OFF switch moved to OFF position.
• Programmed schedule at the timeclock.
• General power failure.
Table 21 — Controls Troubleshooting
SYMPTOM(S)
Controls do not seem
to be operating.
Evaporator fan does not run.
Compressor does not run.
Condenser fans do not
turn on.
Cooling demand exists and
economizer modulates, but
compression is not operating.
PROBABLE CAUSE(S)
Remote on-off function may be
keeping controls off.
1. Circuit breaker open.
2. Inverter overload (if equipped).
1. Circuit breaker is open.
2. There is no demand for cooling.
3. The control is locking out cooling operation.
4. Demand Limit in effect.
Circuit breaker is open.
Compression cannot be initiated
until economizer damper is 90% open.
44
SOLUTION(S)
Check status.
1. Find cause and reset circuit breaker.
2. Find cause and reset.
1. Find cause and reset circuit breaker.
2. Correct operation.
3. Check rotating display for alarm codes. Resolve
alarm cause and reset control by changing to
standby and back to run mode.
4. Check Demand Limit Settings.
Find cause and reset circuit breaker
Correct operation.
Table 22 — Operation Status Codes
CODE
CODES 51, 52, 55, 56: COMPRESSOR FAILURE — If control relay (CR) opens while compressor should be operating,
compressor will stop and microprocessor will energize alarm
light and display a code of 51 , 52 , 55 or 56 (depending on
compressor) when display button is pushed. The compressor
will be locked off; to reset, the ON-OFF switch must be turned
to OFF and then to ON position.
If lead compressor in a refrigerant circuit is shut down, the
other compressor in that circuit will also be shut down and
locked off. Only the error code for the lead compressor will be
displayed.
Code 51 is for compressor 1, and Code 55 is for compressor
2. Codes 52 and 56 are used for compressors 3 and 4, respectively, on size 104 units.
The microprocessor has also been programmed to indicate a
compressor failure if CR switch is closed when compressor is
not supposed to be on.
If a failure occurs, the following are possible causes:
High-Pressure Switch Open — The high-pressure switch for
each compressor is wired in series with 24-v power that energizes CR. If high-pressure switch opens during operation, CR
will stop compressor and this will be detected by microprocessor through the feedback contacts.
Internal Thermostat — The internal thermostat in each 06D
compressor is also wired in series with 24-v power that energizes CR. If thermostat fails or switch opens during operation
of compressor, compressor will shut down and failure is detected through feedback contacts (size 034 and 038 only).
CR Failure — If CR fails with large relay either open or
closed, microprocessor will detect this, lock compressor off,
and indicate an error.
Relay Board Failure — If small 24-v relay on the relay board
fails, microprocessor will detect this through feedback contacts
and indicate an error.
Processor Board Failure — If hardware that monitors feedback switch fails and processor board fails to energize the relay
board relay to ON position, an error may be indicated.
The control does not detect compressor circuit breaker
failures.
Wiring Problem — A wiring error or a loose wire may cause
the feedback circuit to be broken.
MEANING
0
0 cooling stages active
1
1 cooling stage active
2
2 cooling stages active
3
3 cooling stages active
4
4 cooling stages active
5
5 cooling stages active
6
6 cooling stages active
7
7 cooling stages active
8
8 cooling stages active
20
Initialization mode (Allow 2 minutes
for initialization. To initiate Quick Test,
press the Display button while 20 is displayed.)
21
Temperature Reset in effect
22
Demand Limit in effect
26
Morning Warm-Up in effect
30
Internal failure detected
88
Self-diagnostic mode in effect
Restart Procedure — Before attempting to restart the
machine, check the display for alarm codes to determine the
cause of the shutdown. If the unit, circuit, or compressor stops
more than once as a result of a safety device, determine and
correct the cause before attempting to start the unit again.
After the cause of the shutdown has been corrected, unit
restart may be automatic or manual depending upon the fault.
Diagnostic Codes — Diagnostic codes are warnings of
abnormal or fault conditions, and may cause either one circuit
or the whole unit to shut down. They are assigned code numbers as described below.
Table 23 contains a description of each diagnostic code error and possible cause. Manual reset is accomplished by moving the ON/OFF Switch to the OFF position, then back to ON.
The 2-digit LED display is used to display the diagnostic
codes and the alarm light (located next to display) is energized
whenever a diagnostic code is tripped. When a problem is
suspected, always check the display first for diagnostic
information.
NOTE: Codes 53, 54, 57, 58, 61, 62, 65-69, 73, 74, and 77-80
are not used on these units.
IMPORTANT: The microprocessor memory and the display will be cleared if the power to the microprocessor is
shut off. DO NOT attempt to bypass, short, or modify
the control circuit or electronic boards in any way to correct a problem. This could result in a hazardous operating condition.
45
Table 23 — Diagnostic Codes
51
55
52
56
Compressor 1 failure
Compressor 2 failure
Compressor 3 failure
Compressor 4 failure
ACTION TAKEN
BY CONTROL
Circuit 1 shut off
Circuit 2 shut off
Compressor 3 shut off
Compressor 4 shut off
59
60
Loss-of-charge circuit 1
Loss-of-charge circuit 2
Circuit 1 shut off
Circuit 2 shut off
Manual
Manual
63
64
70
71
72
75
Low oil pressure circuit 1
Low oil pressure circuit 2
Illegal unit configuration
Supply-air thermistor failure
Return-air thermistor failure
Circuit 1 saturated condensing thermistor
Circuit 1 shut off
Circuit 2 shut off
Unit will not start
Unit shut off
Use default value
Unit shut off
Manual
Manual
Manual
Auto.
Auto.
Auto.
76
Circuit 2 saturated condensing thermistor
Unit shut off
Auto.
81
82
83
84
85
86
87
Reset temperature thermistor failure
Supply-air set point potentiometer failure
Economizer potentiometer failure
Reset limit set point potentiometer failure
Demand limit potentiometer failure
Minimum economizer potentiometer failure
Warm-up set point potentiometer failure
Stop reset
Use default value
Close economizer
Stop reset
Stop demand limit
Close economizer
Use default value
Auto.
Auto.
Auto.
Auto.
Auto.
Auto.
Auto.
DISPLAY
DESCRIPTION OF FAILURE
RESET
METHOD
Manual
Manual
Manual
Manual
PROBABLE CAUSE
High-pressure switch or high discharge gas thermostat switch
trip, compressor ground current
>2.5 amp or compressor board
relay on when it is not supposed
to be on. Wiring error between
electronic control and compressor protection module.
This indicates either a low refrigerant charge, or a loss-of-charge
switch failure.
Not used; Check jumper on processor board.
Configuration error (see Note 1).
Thermistor or resistor failure, wiring error, or thermistor or resistor
not connected to the processor
board.
Potentiometer improperly connected, potentiometer setting out
of range, potentiometer failure or
wiring error.
NOTES:
1. Illegal unit configuration caused by missing programmable header or both unloader DIP switches on.
2. All auto. reset failures that cause the unit to stop will restart when the error has been corrected.
3. All manual reset errors must be reset by turning the control switch off and then back on.
4. Valid resistance range for the thermistors is 363,000 to 585 ohms.
5. Codes 53, 54, 57, 58, 61, 62, 65-69, 73, 74, and 77-80 are not used on these units.
been corrected. If a failure occurs, the following are possible
causes:
Thermistor or Resistor Failure — A shorted or open thermistor or resistor will cause the failure.
Wiring Failure — If a wiring error exists that causes a shorted
or open circuit, this will cause a failure.
Processor Board Failure — If circuitry on processor board
fails, this could cause an error.
The codes are designated as follows:
Code 71 Supply-Air Thermistor Failure
Code 72 Return-Air Thermistor Failure
Code 73 Not used
Code 74 Not used
Code 75 Circuit 1 Saturated Condensing Thermistor
Code 76 Circuit 2 Saturated Condensing Thermistor
CODE 81: RESET THERMISTOR OR POTENTIOMETER
FAILURE — This is a unique code since the reset temperature
potentiometer (P7) is in series with the space temperature thermistor (T10). If either one of these components fail, reset will
be terminated. This error will automatically reset once the situation is corrected. If an error is detected, the most probable
cause is one of the following:
• Thermistor Failure — A shorted or open thermistor will
cause the failure.
• Potentiometer Failure — If the potentiometer is outside
of the valid range (40 to 90 F), a failure will result.
• Wiring Problem — If the circuit is open, a failure will be
detected.
• Processor Board Failure — If the processor board fails
(hardware), an alarm will be detected.
CODES 59 AND 60: LOW-PRESSURE SWITCH — These
codes are used to indicate a low-pressure switch failure.
The processor monitors the low-pressure switch. If the
switch opens, either by low refrigerant charge, circuit failure,
or wiring error, the circuit is locked off. Code 59 indicates a
failure of the lead circuit, and as a result, that circuit will be
shut down. Code 60 indicates a failure of the lag circuit, and as
a result, that circuit will be shut down. These codes will only be
displayed when the display button is pressed. To reset the circuit, the ON-OFF switch must be turned to OFF, then ON
position.
CODES 63 AND 64: OIL PRESSURE SWITCH — These
codes are used to indicate an oil pressure switch failure. Since
the units do not have oil pressure switches, these codes are not
used. The terminals on the processor board must be jumpered
together or an error will occur. If these errors occur, check
jumper between J2-1 and J2-2 for a code 63, or between J2-3
and J2-4 for a code 64 to be sure jumper is properly connected.
To reset the circuit, the ON-OFF switch must be turned to OFF
and then to ON position.
CODE 70: ILLEGAL UNIT CONFIGURATION — If the
unit configuration header is not installed and properly configured, and/or if DIP switches are not properly set, unit will not
start, and an error code of 70 will be indicated on display board
when display button is pushed. Check the header and DIP
switch settings.
CODES 71 TO 76: THERMISTOR/RESISTOR FAILURE —
If measured temperature of a thermistor is less than –60 F
(363,000 ohms) or greater than 180 F (585 ohms), the appropriate sensor error code (Table 23) will be displayed when
the display button is pushed. The unit will be shut down.
Thermistor failures will automatically reset once the error has
46
CODE 82: SUPPLY-AIR TEMPERATURE SET POINT
POTENTIOMETER FAILURE — If supply-air set point
potentiometer (P1 — located on display board) fails, control
will use a default value. A failure will cause an error code of
82 to be displayed on display board when display button is
pushed; alarm light will also be energized. A failure is determined by establishing a range of –22 F to 70 F as a valid range.
Anything outside this range will be treated as a failure. If setting is outside the –22 F to 70 F range, alarm light will be energized and an error code of 82 will be displayed when display
button is pushed; the control will use a set point of 70 F. If set
point is between –22 F and 45 F, control will use a set point of
45 F and no error code will be indicated. If potentiometer
returns to normal, control will automatically reset.
NOTE: The full range of the potentiometer is not used for the
cooling set point range of 45 F to 70 F. The full scale resistance
of the potentiometer is 10 Kohms.
If a failure occurs, one of the following is a probable cause:
Incorrect Potentiometer Setting — A potentiometer turned
fully clockwise or counterclockwise is outside the valid range
and will cause a failure.
Faulty Wiring — If wiring is incorrect between potentiometer
and processor board or display board, a failure will result.
Potentiometer Failure — If potentiometer is shorted or open, a
failure will result.
CODE 83: ECONOMIZER FEEDBACK POTENTIOMETER FAILURE — If potentiometer on economizer motor (P2)
fails, control will use a default value of 0% and economizer
outdoor-air dampers will close. The failure will energize alarm
light and cause an error code of 83 to be displayed when display button is pushed. This potentiometer is a 5 to 15 Kohm
potentiometer. If potentiometer returns to normal, control will
automatically reset. If a failure occurs, one of the following is
the probable cause.
Faulty Wiring — If the wiring between processor board and
potentiometer is wrong, this will cause a failure.
Potentiometer Failure — If potentiometer is shorted or open,
this will cause a failure.
Economizer Damper Stuck — The control has been programmed to indicate an error if potentiometer travel is less than
10% of the full range. This would happen if dampers or damper linkage were hung up and could not move properly.
CODE 84: RESET LIMIT POTENTIOMETER FAILURE —
This code is applicable only if reset is being used. If reset is
being used, DIP switch 2 must be in the ON position. This
potentiometer (P3) is located on the accessory board. If potentiometer setting is less than 0° F or greater than 80 F, alarm
light will be energized, a diagnostic code of 84 will be displayed if display button is pushed, and reset will be terminated.
The full-scale resistance of potentiometer is 10 Kohms, but
when installed on the accessory board in parallel with the other
2 potentiometers, measured resistance will be 3.3 Kohms. This
failure will automatically reset once potentiometer returns to
normal. If a failure occurs, one of the following is the probable
cause:
DIP Switch Problem — DIP switch 2 is in the ON position
and the accessory board is not installed (accessory board is
standard on these units so it should always be on the unit).
Incorrect Potentiometer Setting — A potentiometer turned
fully clockwise or counterclockwise is outside the valid range
and will result in a failure.
Faulty Wiring — If the wiring between the potentiometer and
the processor board is incorrect, a failure will result.
Potentiometer Failure — If potentiometer is shorted or open, a
failure will occur.
CODE 85: DEMAND LIMIT POTENTIOMETER (P4)
FAILURE — Used only if demand limit is being used. If
demand limit is used, DIP switch 5 must be in the ON position.
Two types of demand limit are available: a field-supplied
and installed single-step control consisting of a 10 Kohm,
3-wire linear potentiometer and an accessory 2-step control.
The single-step control has a single potentiometer while 2-step
control has 2 potentiometers (mounted on the demand limit
board, see Fig. 28).
For both types of demand limit, the control uses only 80%
of the total potentiometer resistance. If resistance of potentiometer is less than 10% or greater than 90%, alarm light will be
energized, a diagnostic code of 85 will be displayed when the
display button is pushed, and demand limit will be terminated.
If a failure occurs, it is probably due to one of the following:
Potentiometer Failure — If a potentiometer is shorted or open,
a failure will occur.
Incorrect Potentiometer Setting — A potentiometer turned
fully clockwise or counterclockwise will put potentiometer out
of range resulting in an error.
Faulty Wiring — If wiring between the potentiometer and the
processor board is incorrect, an error will occur.
DIP Switch 5 — If DIP switch 5 is in the ON position and potentiometer is not installed, an error will occur.
CODE 86: MINIMUM POSITION ECONOMIZER POTENTIOMETER FAILURE — If potentiometer P5 (on accessory
board) setting is less than 0% or greater than 100%, alarm light
will be energized, a code of 86 will be displayed when display
button is pushed and economizer outdoor air dampers will
move to the fully closed position.
The potentiometer full-scale resistance is 10 Kohm, but
when installed in parallel with the other 2 potentiometers on
the accessory board, measured resistance will be 3.3 Kohm.
This failure will automatically reset when potentiometer returns to normal.
If a failure occurs, one of the following is the probable
cause:
DIP Switch 3 — If this switch is in the ON position and the
accessory board is not installed (accessory board is standard on
these units, so it should always be on the unit).
Incorrect Potentiometer Setting — If potentiometer is turned
fully clockwise or counterclockwise, potentiometer will be out
of the allowable range, and an error will result.
Faulty Wiring — If wiring between the potentiometer and the
processor board is incorrect, an error will occur.
Potentiometer Failure — If potentiometer is shorted or open,
potentiometer will be out of range and an error will result.
CODE 87: WARM-UP TEMPERATURE SET POINT FAILURE — Applicable only if morning warm-up is used. Whether
or not unit is equipped with electric resistance heaters, use of
the morning warm-up function is recommended if the unit is
shut down at night or over weekends. In this application, cooling will remain off and the outdoor-air damper will stay closed
until heat load from the occupied space elevates return-air temperature to the warm-up set point. If warm-up function is used,
DIP switch 4 must be in the ON position. The potentiometer
(P6) is located on the accessory board. If potentiometer is set at
less than 0° F or more than 95 F, alarm light will be energized,
a diagnostic code of 87 will appear on the display when display button is pushed, and control will use a default value of
40 F. If setting is between 0° F and 40 F, control will use a
value of 40 F but no diagnostic code will be displayed; if setting is between 80 F and 95 F, control will use a value of 80 F
but no diagnostic code will be displayed.
The potentiometer full-scale resistance is 10 Kohm, but
when wired in parallel with other potentiometers on the accessory board, measured resistance is 3.3 Kohm.
47
PROCESSOR BOARD CHECKOUT — Refer to Fig. 49 and
50 for location of terminal pins and test points.
Step 1 — Check Transformer Input to the Board — Connector J4 is used to connect the control transformer to the processor board.
1. Set the volt-ohmmeter to ac voltage with a range setting
of approximately 30 v.
2. Turn control switch to ON position.
3. Check voltage at following terminals on pin terminal connector J4:
The failure will automatically reset once potentiometer returns to normal. If a failure occurs, one of the following is the
probable cause:
DIP Switch 4 — If this switch is in the ON position and the
accessory board is not installed (accessory board is standard on
these units, so it should always be on the unit).
Incorrect Potentiometer Setting — If potentiometer is turned
fully clockwise or counterclockwise, potentiometer will be out
of the allowable range, resulting in an error.
Faulty Wiring — If the wiring between the potentiometer and
the processor board is incorrect, an error will occur.
Potentiometer Failure — If potentiometer is shorted or open,
potentiometer will be out of range, resulting in an error.
TERMINALS
1 to 2
4 to 6
5 to 6
5 to 4
Thermistor Troubleshooting — The VAV control
system uses thermistors to measure temperatures of the entering and supply air, as well as the saturated condensing temperatures of the refrigerant circuits. The resistance versus temperature and electrical characteristics for all thermistors in the system are identical. To obtain an accurate reading, a highimpedance meter (such as a digital meter) must be used.
Thermistors in the VAV control system have a 5 vdc signal
applied across them any time the unit control circuit is energized. The voltage drop across the thermistor is directly proportional to the temperature and resistance of the thermistor.
To determine temperatures at the various thermistor locations, disconnect the thermistor from the processor board and
measure the resistance across the appropriate thermistor using
a high-quality digital ohmmeter. Use the resistance reading to
determine the thermistor temperature.
The microprocessor has been programmed to check the operation of the thermistors. If the measured temperature is outside of the range of –24 to 225 F or 98,010 to 282 ohms, then it
will be treated as a sensor failure and a diagnostic code will be
displayed. See Table 19 for sensor temperatures versus resistance drop. It is also possible to check the operation of the thermistors using the quick test routine.
If a thermistor has failed or the wire is damaged, replace the
complete assembly. Do not attempt to splice the wires or repair
the assembly.
VOLTAGE (AC)
15.3 to 20.9
16.2 to 22.0
8.1 to 11.0
8.1 to 11.0
4. If voltage is not within range, check primary side.
115-v transformer — 104 to 127 vac
230-v transformer — 207 to 254 vac
5. If primary voltage is not correct, check system fuse, transformer, ON-OFF switch, and wiring. If these are okay,
contact power company.
6. If primary voltage is correct, but secondary voltage (24 v
± 10%) is incorrect, replace transformer.
7. Turn control switch to OFF position.
Step 2 — Check Processor Board Power Supply
1. Set meter to approximately 20 vdc.
2. Turn power to OFF position.
3. Connect negative lead to TP18.
4. Turn power switch to ON position and press display button to enter Quick Test mode.
5. Check voltage between TP18 and each of the following
test pins:
TEST PIN
VOLTAGE (DC)
+10
TP3
+12
TP4
+5
TP6
+5
TP10
+12
TP14
+12
TP15
–5*
TP7
*If not using a digital meter, leads must be reversed.
Electronic Controls Checkout — The following will
help determine whether a processor board, a relay board, display set point board, accessory board, or 2-step demand limit
module is faulty.
Before checking out any board, do the following:
1. At initial start-up, enter the Quick Test mode. This test
will determine if all components are connected and operating properly.
2. If system has been operating and a malfunction occurs,
check display for diagnostic codes. Use diagnostic chart
located on inner panel of access door to control box section of unit; this chart will help determine probable cause
of failure.
These 2 steps will help determine if a component other than
a board is at fault or if the problem is external to control circuit.
A volt-ohmmeter will be needed to troubleshoot boards. A
digital meter is preferred but a Simpson 260 or equivalent will
work.
6. If voltage is incorrect, replace processor board.
7. Turn power to ON position.
Step 3 — Check Voltage Tolerance Circuitry
1. Turn power to OFF position.
2. Negative test probe on TP18 and system in Quick Test
mode.
3. Check voltage TP18 to TP9.
4. If voltage is greater than 11 vdc, recheck transformer input voltage.
5. If transformer is okay, replace processor board.
6. Turn power to ON position.
Step 4 — Check Processor Reset Line
1. Turn power to OFF position.
2. Negative probe on TP18.
3. Check voltage TP18 to TP11.
4. If voltage is greater than +3 vdc, reset power and recheck.
5. If voltage is still incorrect, replace processor board.
6. Turn power to ON position.
To prevent damage to solid-state electronic components on
boards, meter probes should only be placed on terminals
and test points listed in following sections. Do not short the
electrical components, and use extreme care while working
on the processor board.
48
Table 23 on pin terminal connector J9. See Fig. 51 for J9
details.
Step 6 — Display Board Connection Checkout
1. Turn power to OFF position.
2. Disconnect the ribbon cable.
3. Connect negative lead of meter to TP18.
4. Turn power to ON position and go into Quick Test mode.
5. Place the other lead on terminals shown in table below,
and check voltage at pin terminals on pin terminal connector J10 (see Fig. 52 for pin terminal connector J10
details):
Step 5 — Check Relay Board Outputs from the Processor
Board — This step involves checking the output signals from
relays K1-K3 on the relay board.
1. Turn power to OFF position.
2. Connect negative test probe to TP19 (meter still set to
dc).
3. Turn switch to ON position and enter Quick Test mode.
4. Connect positive test probe to terminal 14 on pin terminal
connector J9, and check voltage from TP19 to terminal
14 on pin terminal connector J9.
5. If not 112 ± 1 vdc, replace processor board.
6. Turn switch to OFF position.
7. Remove negative test probe from TP19. Connect positive
test probe to TP15.
8. Turn switch to ON position and go into Quick Test mode.
9. Place negative lead on terminals shown in Table 24, and
check voltage between TP15 and terminals shown in
PIN TERMINAL
VOLTAGE (DC)
5
17
5
18
2.5
20*
2.5
22*
5
24
*Voltage reading is dependent on the meter’s impedance. Readings
may vary with different meters.
Fig. 51 — Relay Board Pin Terminal Connector (J9)
LEGEND
J — Pin Terminal Strip
TP — Test Pin
Fig. 49 — Processor Board Test Points
Table 24 — Voltage Reading
J6
J5
R9
R10
R11
R12
R13
C9
C10
C11
C12
C13
CR9
CR2
CR3
C5
K2
C7
CR4
CR5
CR6
C19
C27
C15
C14
K1
C6
C21
CR1
C4
CR11
CR12
CR13
CR7
1
0
0
0
0
0
0
12
0
0
0
0
2
0
0
0
0
0
0
0
12
0
0
0
3
0
0
0
0
0
0
0
0
12
0
0
4
0
0
0
0
0
0
0
0
0
0
0
J9 PIN NUMBERS
5 6 7 8 9 10
0 0 0 0 0 0
0 0 12 0 0 0
0 0 0 12 0 0
0 0 0 12 0 12
0 0 0 12 0 0
0 0 0 12 0 0
0 0 0 12 0 0
0 0 0 12 0 0
0 0 0 12 0 0
12 0 0 12 0 0
0 12 0 12 0 0
11
0
0
0
0
12
0
0
0
0
0
0
12
0
0
0
0
0
12
0
0
0
0
0
13
12
12
12
12
12
12
12
12
12
12
12
NOTES:
1. Pins shown in boldface type will only be energized for 10 seconds.
All other pins will be energized continuously while at the proper
quick test step. The control will only stay in the Quick Test routine
for 10 minutes unless the display button is pressed.
2. Acceptable range for the voltage reading:
0 v — 0 to 4 v
12 v — 11 to 13 v
3. If any of these voltages are not measured, replace the processor
board.
C8
CR8
E3
C26
C25
C24
C23
C22
C3
C18
C2
C16
C1
CR10
QUICK TEST
STEP NO.
1.-2.3.
2.4.
2.5.
2.6.
2.7.
2.8.
2.9.
3.0.
3.1.
3.2.
3.3.
K3
LEGEND
CR — Control Relay
J
— Pin Terminal Strip
K — Relay
Fig. 50 — Relay Board Test Points
49
Table 25 — Pin Terminal Connector J1 Voltages
6. If voltage is not correct, replace processor board.
Step 7 — Potentiometer Connection Checkout
1. Turn power to OFF position.
2. Remove plug connection from pin terminal strip J3.
3. Connect negative meter lead to terminal 2 of J3.
4. Turn switch to ON position and go into Quick Test mode.
5. Place the other lead on terminals shown in table below,
and check voltage at pin terminals on terminal connector
J3:
PIN TERMINAL
1*
3
6
8*
10*
12
13*
14*
PIN
TERMINAL
1
2
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
VOLTAGE (DC)
2.5
5
5
2.5
2.5
5
2.5
2.5
*Voltage reading is dependent on the meter’s impedance. Readings
may vary with different meters.
VOLTAGE
(vdc ± 0.25 v)
0
5
0
5
0
5
0
5
0
5
0
5
0
5
0
5
0
5
Step 9 — Thermistor Input Connector Checkout
1. Turn power to OFF position.
2. Disconnect all plugs for pin terminal connector J2 and
mark them for later replacement.
3. Connect a negative test lead to test pin TP18.
4. Turn power to ON position, and enter the Quick Test
routine.
5. Place the other lead on terminals shown in Table 26, and
check the voltages.
6. If voltages are incorrect (per Table 26), replace processor
board.
7. Turn power to OFF position, and replace the plugs removed in Step 2.
8. Turn power to ON position.
6. If voltage is not correct, replace processor board.
Step 8 — Thermistor Input Connector Checkout
1. Turn power to OFF position.
2. Remove the thermistor connections from pin terminal
connector J1, and mark them for later replacement.
3. Connect the negative test lead to test pin TP18.
4. Turn power to ON position, and enter the Quick Test
routine.
5. Place the other lead on terminals shown in Table 25, and
check the voltages.
6. If voltages are incorrect (per Table 25), replace processor
board.
7. Turn power to OFF position, and replace the thermistor
connections removed in Step 2.
8. Turn power to ON position.
Table 26 — Pin Terminal Connector J2 Voltages
PIN
TERMINAL
1
2
3
4
7
8
9
10
13
14
15
17
18
19
20
21
22
23
24
VOLTAGE
(vdc ± 0.25 v)
0
5
0
5
0
5
0
5
0
5
5
5
5
5
5
5
5
5
5
If Steps 1 through 9 have been competed and the unit still
will not function properly, replace the processor board.
Fig. 52 — Display Board Pin Terminal Connector
(J10)
50
Table 28 — Terminal Strip J5 Connector
Resistance Reading
RELAY BOARD TROUBLESHOOTING — The relay board
contains 13 electromechanical relays. The small relays are
24 vac, and the large relays are 115 vac. These relays are controlled by the processor through the ribbon cable attached to
the relay board.
The following procedure can be used to check out the operation of the relays. To do this, turn the control ON/OFF switch
to the OFF position, and remove the wiring connectors connected to pin terminal connectors J5 and J6. Set the meter for
resistance. If the contacts do not close at the required quick test
step, check the relay outputs from the processor board.
Relay Board Checkout (Fig. 5)
Step 1 — Low-voltage relay resistance check.
1. Turn switch to OFF position.
2. Remove plug connection from terminal strip J6.
3. Set meter to measure resistance. Connect negative test
lead to both terminals 11 and 12 of J6.
4. Turn switch to ON position and go into Quick Test mode.
5. Place other meter lead on terminals shown in Table 27
and check resistances at each quick test step.
6. If these resistances are not correct and relay board outputs
from processor board have been checked out, replace relay board.
Step 2 — High-voltage relay resistance check.
1. Turn switch to OFF position.
2. Remove plug connection from terminal connector J5.
3. Connect negative test lead to terminal 8.
4. Check the resistance between terminals 8 and 5 before
entering Quick Test mode. The resistance should be
infinity.
5. Turn switch to ON position and go into Quick Test mode.
6. Place other meter lead on terminals shown in Table 28
and check resistance at each quick test step.
7. If these resistances are not correct and relay board outputs
from processor board have been checked per Processor
Board Checkout section on page 48, replace relay board.
DISPLAY BOARD CHECKOUT
Step 1 — Check the Output Voltage from Processor Board
to the Relay Board — Refer to Step 6 — Display Board Connection Checkout section on page 49.
QUICK TEST
STEP NO.
1. to 2.5.
2.6
2.7.
2.8.
2.9. to 3.3.
1
∞
∞
∞
∞
∞
∞
0
∞
∞
∞
∞
J6 PIN NUMBERS
3
4
5
6
∞ ∞ ∞ ∞
∞ ∞ ∞ ∞
∞ ∞ ∞ ∞
∞ ∞ ∞ ∞
∞ ∞ ∞ ∞
∞ ∞ ∞ ∞
∞ ∞ ∞ ∞
∞ ∞ ∞ ∞
0
∞
∞ ∞ ∞
0
∞ ∞ ∞
∞
0
∞ ∞ ∞ ∞
2
∞
∞
∞
∞
∞
∞
∞
0
7
∞
0
∞
8
∞
∞
0
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
J5 PIN NUMBERS
2
3
4
∞
∞
∞
0
∞
∞
∞
∞
0
0
∞
∞
∞
∞
∞
5
0
0
0
0
0
LEGEND
∞ — Infinity
Step 2 — Check the Display LEDs
1. Enter Quick Test mode.
2. If 88 is not displayed, replace display board.
Step 3 — Check Set Point Potentiometer — Advance the
display to quick test step 1.9. to determine if this potentiometer
is set and connected properly.
Step 4 — Check Display Switch — Press switch. If switch
does not click, it is faulty and the display will be energized continuously. The switch is an integral part of display board and
cannot be replaced separately.
ACCESSORY BOARD CHECKOUT — The accessory board
can be completely checked using quick test steps 2.0., 2.2., and
2.3. It can also be checked out as follows:
1. Remove the accessory board connector from the processor board and connect an ohmmeter to terminals 3 and 4
on the connector. Numbers are marked on the connector.
See Fig. 15.
2. Set the meter to 10,000 ohms. The resistance value obtained should be 3,333 ohms. Adjust the potentiometers
and the resistance value should not change.
3. Connect the ohmmeter to terminals 3 and 6. As the reset
limit potentiometer is turned clockwise, resistance should
increase from 0 to approximately 3,400 ohms.
4. Connect the ohmmeter to terminals 3 and 5. As the economizer minimum position potentiometer is turned clockwise, resistance should increase from 0 to approximately
3,400 ohms.
5. Connect the ohmmeter to terminals 3 and 2. As the
warm-up set point potentiometer is turned clockwise,
resistance should increase from 0 to approximately
3,400 ohms.
If any of the Steps 1 through 5 result in any other ohm reading, replace the board; it cannot be serviced.
TWO-STEP DEMAND LIMIT CONTROL MODULE
(DLCM) TROUBLESHOOTING — If a problem is suspected
in the DLCM board, use the following test procedure:
The board can only be checked when it is connected to the
processor and the processor is energized so that the DLCM is
supplied with 5 vdc power. The terminals referenced are shown
in Fig. 16. Potentiometers P1 and P2 refer to the DLCM potentiometers.
Table 27 — Terminal Strip J6 Connection
Resistance Reading
QUICK TEST
STEP NO.
1. to 2.3.
2.4.
2.5.
2.6.
2.7.
2.8.
2.9.
3.0.
3.1.
3.2.
3.3.
1
∞
0
0
0
0
IMPORTANT: Be careful to avoid damaging the connector or the processor board when taking the voltage
readings.
LEGEND
∞ — Infinity
NOTE: Pins shown in boldface type will be energized for only
10 seconds. All other pins will be energized continuously while at the
proper quick test step. The control will remain in the Quick Test
mode for only 10 minutes unless the display button is pressed.
51
Test under the following conditions:
No power to IN1 or IN2
Terminal 1 to 2 should read 4.5 vdc ±0.1 v
Terminal 2 to 3 should read 5.0 vdc ±0.1 v
• Power to IN2 or to both IN1 and IN2, and P2 set at 24%
Terminal 1 to 2 should read 1.5 vdc ± 0.1 v
NOTE: Voltage should vary between 0.5 vdc and 2.5 vdc as
the setting of P2 is varied between 0% and 49%.
Terminal 2 to 3 should read 5.0 vdc ± 0.1 v
• Power to IN1 only and P1 set at 50%
Terminal 1 to 2 should read 2.5 vdc ± 0.1 v
Terminal 2 to 3 should read 5.0 vdc ± 0.1 v
NOTE: Voltage should vary between 0.5 vdc and 2.5 vdc as
the setting of P2 is varied between 50% and 100%.
NOTE: If the voltages listed in these 3 tests are not obtained during testing, the DLCM board must be replaced.
•
LIMIT SWITCHES
CAPACITOR
3
CW
WINDING
(OPEN)
CCW
WINDING
(CLOSE)
Enthalpy Sensor Checkout — To test operation of
1
T2
BRAKE
WINDING
Table 29 — Enthalpy Sensor Checkout
Outdoor-air sensor:
Enthalpy sensor + terminal
should be connected to +
terminal on motor. Connect the
positive terminal of a DC
milliammeter to the S terminal
of the sensor and the negative
terminal of the meter to SO
terminal of the enthalpy board.
Indoor-air sensor:
Enthalpy sensor + terminal
should be connected to +
terminal on motor. Connect the
positive terminal of a DC
milliammeter to the S terminal
of the sensor and the negative
terminal of the meter to SR
terminal of the enthalpy board.
ECONOMIZER
MOTOR
T1
enthalpy sensor, see Table 29.
TEST
2
1
1
CW
EXPECTED RESULT
AND RESPONSE
Milliammeter reading should be
between 3 and 24 mA if sensor
is operating correctly. If reading
is 0 mA, the sensor is either
wired backwards or is defective.
2
FEEDBACK
POTENTIOMETER
3
BLU
RED
YEL
Milliammeter reading should be
between 3 and 24 mA if sensor
is operating correctly. If reading
is 0 mA, the sensor is either
wired backwards or is defective.
AUX. SWITCH
LEGEND
CCW — Counterclockwise
CW — Clockwise
Fig. 53 — Damper Motor Connection Diagram (VAV)
Economizer Motor — All control of the motor (i.e.,
Supply Fan Variable Frequency Drive
enthalpy changeover, minimum position control and mixed air
control) is accomplished from the main unit microprocessor
through a relay board. Service and installation instructions
for the unit should be consulted to verify proper operation of
these controls. The economizer motor may be checked out separately. See Fig. 52 for VAV economizer motor connection
information.
Motor Test
Apply 24 volt AC power to terminals T1 and T2 of motor.
Connections to motor terminals 2 and 3 must be disconnected
A Motor Test
A Expected Result and Response
Jumper 1 to
Motor drives open; if not, 2 at motor
replace motor.
B Motor Test
B Expected Result and Response
Jumper 1 to
Motor drives closed; if not,
3 at motor
replace motor.
Factory-installed optional VFD is located near the supply
fan and motor. During any service work or programming at
the VFD, operation of the fan and motor is not desirable.
Either disable the supply fan or install an accessory VFD
remote display.
NOTE: The VFDs (part no. TOSVERT130-E3) are specially
modified for use on Carrier equipment. Some specifications
and control configuration defaults for Carrier applications will
differ from the VFD manufacturer manual included in the
packet. See Table 30 for listing of Carrier-specific default
values.
52
STANDARD TRANSDUCER CONTROL — The VFD monitors and controls duct pressure (DP) via a differential pressure
transducer. The pressure transducer is located in the auxiliary
control box (034-048 units) or in the supply fan compartment
(see Fig. 34). The pressure transducer’s low pressure reference
port is connected to the outside of the unit cabinet by a factoryinstalled tubing section. The pressure transducer’s high pressure reference point must be field-connected to the duct pressure pick-up (field-supplied and installed in the supply duct).
The DP transducer monitors the static pressure in the supply
duct and provides a 4 to 20 mA signal directly to the VFD. (Refer to Table 13 for transducer output signal [mA] for actual duct
static pressure.) The internal logic of the VFD compares this
signal representing actual duct pressure to the user-configured
DP set point. The VFD automatically adjusts its output to the
supply fan motor to maintain the desired DP set point. When
operating with the factory-standard DP transducer, the internal
PID logic of the VFD is enabled. EXTERNAL SIGNAL
CONTROL — If the VFD is to be controlled by an external
control system other than the factory supplied pressure transducer, the internal PID logic function of the VFD must be disabled. To disable the PID control:
1. Disconnect and lock out all power to the Carrier rooftop
unit.
2. Remove the VFD access cover.
P24 RES RR
ST
F
FM AM CC
R
SI
S2
RX
CC
S4 RCH P24 LOW LOW
S3
PP
IV FP
FLC FLB FLA
4-20mA
Fig. 54 — Supply Fan Variable Frequency Drive
Terminal Block (Size 034-048 Units)
P24 RES RR
ST
F
FM AM CC
R
CC
SI
S2
RX
PP
S3
S4 RCH P24 LOW LOW
IV FP
FLC FLB FLA
4-20mA
Fig. 55 — Supply Fan Variable Frequency Drive
Terminal Block (Size 054-104 Units)
Ensure the “CHARGE” lamp on the VFD is unlit. This
may up to 4 minutes. The “CHARGE” lamp indicates that
the main capacitors in the VFD are charged. Internal components of the VFD should not be touched until the
“CHARGE” lamp is completely out. Electrical shock can
cause injury or death.
VFD OPERATION — When troubleshooting the VFD, check
first that all required conditions for VFD operation are
satisfied.
For the VFD to run, the following conditions must be met at
the VFD:
1. Drive enable jumper is installed from terminals CC-ST
(factory supplied) (see Fig. 54 and 55).
2. Proper rotation jumper is installed at terminals R-CC (reverse rotation, factory supplied) or terminals F-CC (forward rotation, factory supplied).
3. Install a jumper across S2-CC (see Fig. 54 and 55 for
VFD terminal board connections).
4. Remove factory-supplied cable attached to IV and CC.
5. Remove other end of the same cable from the pressure
sensor.
6. Connect field supplied speed reference (4 to 20 mA)
across terminals IV-CC.
7. Disable the supply fan motor operation.
8. Reconnect power to the unit and VFD.
9. Reprogram the VFD to accept an external reference (in
the Utility parameters group [Gr.Ut], set parameter item
Fnod [no.312] = 4).
10. Enable supply fan motor and return power to the unit.
SUPPLY FAN MOTOR OVERLOAD PROTECTION — The
VFD provides operating overload protection for the supply fan
motor. The factory has programmed the VFD overload function to match the factory-installed motor (motor size and efficiency). If the supply fan motor is changed from the original
factory selection, the overload value may need to be changed
by the service person. Contact your local Carrier representative
for assistance in determining the proper overload setting.
NOTE: Variable frequency drive size is matched to factoryinstalled motor size. Do not increase motor size without also
changing to equivalent VFD size.
UNIT SIZES
034-048
054-074
078-104
ROTATION
Reverse
Forward
Forward
JUMPER
R-CC
F-CC
F-CC
3. Emergency stop jumper is installed from terminals
S4-CC (factory supplied).
4. A 4 to 20 mA signal is applied across terminals IV-CC
(from pressure transducer, factory supplied).
5. DIP switch SW1 (located on the VFD’s printed circuit
control panel) must be set to ‘‘I’’ (indicating usage of a 4
to 20 mA input signal at terminals ‘‘IV’’).
6. Speed Control (located on the VFD’s keypad/display) set
for ‘‘Remote’’ (press the ‘‘Speed Ctrl’’ button until LED
‘‘Remote’’ is illuminated).
7. Programmed according to Carrier defaults.
8. Duct Pressure set point established by user, or use factory
default (30 Hz indicating 2.50-in. wg) (see Table 13).
53
Table 30 — Carrier Default Program Parameter Values (Supply Fan VFD)
PARAMETER GROUP
SEtP
(Setup)
Gr.F
(Fundamental)
Gr.Fb
(Feedback)
Gr.SF
(Frequency Settings)
PARAMETER
ACC1
DEC1
UL
LL
Luln
P3
F-P3
P4
F-P4
tHr1
StC1
StL1
OLN
tYP
FH
Pt
FbP1
Fbln
GP
Gl
GA
GFS
P1LL
PuL
PuUl
PuLL
Fsor
Sr.n
SrN1
DEFAULT VALUE
60.0 Sec
60.0 Sec
60.0 Hz
10.0 Hz*
1
20%
0.0 Hz
100%
60 Hz
See Table 32
0
110%
1
5*
60 Hz
2
1*
2
.30
2 sec
0
80
10
1
10
10
60 Hz
1* (054-104 only)
0* (054-104 only)
Fr
0*
1t
1t0
1t1
1t2
1t3
1t4
UuC
UuCt
ArSt
Cnod
bLSF
Fnod
bLPn
1
0
56
13
3
10
1*
2
3
1*
1* (054-104 only)
2*
1*
Gr.Pn
(Panel Control)
Gr.St
(Terminal Selection)
Gr.Pr
(Protection)
Gr.Ut
(Utility)
*These settings differ from the Toshiba defaults and are required for Carrier applications.
NOTE: To restore original factory settings, change tYP to 6 in Setup mode (SEtP). This restores the VFD original factory settings.
54
logic of the power exhaust VFD compares this signal representing actual duct pressure to the user-configured BP set
point. The power exhaust VFD automatically adjusts its output
to the power exhaust fan motor to maintain the desired BP set
point. When operating with the factory-standard BP transducer,
the internal PID logic of the power exhaust VFD is enabled.
EXTERNAL SIGNAL CONTROL — If the power exhaust
VFD is to be controlled by an external control system other
than the factory-supplied pressure transducer, the internal PID
logic function of the power exhaust VFD must be disabled. To
disable the PID control:
1. Disconnect and lock out all power to the Carrier rooftop
unit.
2. Remove the VFD access cover.
VFD OPERATIONAL STATUS — The VFDs contain extensive self-diagnostic functions which are accessed through
the VFD display panel (located on the front of the VFD or at a
remote location when the accessory remote display package
has been installed).
If using the VFD display panel, disconnect all power to
the unit and the VFD before entering unit, or use the
accessory remote display module. Disable supply fan and
motor operation before accessing VFD-mounted display
module.
When power is first supplied to the VFD, the display automatically starts with the frequency monitor function of its standard monitor mode. In the frequency monitor function, the output frequency is displayed. Push the S/P/M (Setup/ Program/
Monitor) key to switch to the Mode Selection menu. Push the
S/P/M key again to toggle the display back to the standard
monitor mode.
From the Mode Selection menu, the service person can
view all of the monitored status variables, including up to four
user-selected variables and any trip history in the memory.
Refer to the separate VFD Operation Manual for detailed
instructions on accessing diagnostic information, initiating
troubleshooting, and clearing any trip history.
RESTORING FACTORY VFD DEFAULTS — The original
factory configuration values are saved in the memory of the
VFD and can be restored by the service person if required.
There are two types of saved file data: Carrier-factory settings
(factory programmed settings made to the VFD which apply
specifically to the unit it is installed on) and standard defaults
for general Carrier unit use.
The Carrier-factory settings are maintained as user settings.
These can be restored by entering the Setup mode (in the
S/P/M menu) and setting parameter tYP = 6 on the keypad/
display. This will recall the specific factory defaults for this
unit.
Occasionally it may be necessary to restore the VFD defaults to the general Carrier use values. These are stored in an
OPTION ROM (read-only memory chip). However, some
variables may need to be manually changed to match the specific unit’s factory default settings. To recall the general Carrier
defaults, enter the Setup mode and set parameter tYP = 3. Refer to Table 31 for items requiring manual adjustment.
Ensure the “CHARGE” lamp on the VFD is unlit. This
may up to 4 minutes. The “CHARGE” lamp indicates that
the main capacitors in the VFD are charged. Internal components of the VFD should not be touched until the
“CHARGE” lamp is completely out. Electrical shock can
cause injury or death.
3. Install a jumper across S2-CC (see Fig. 56 for power exhaust VFD terminal board connections).
4. Remove factory-supplied cable attached to IV and CC.
5. Remove other end of the same cable from the pressure
sensor.
6. Connect field-supplied speed reference (4 to 20 mA)
across terminals IV-P24.
7. Disable the supply fan motor operation.
8. Reconnect power to the unit and power exhaust VFD.
9. Reprogram the power exhaust VFD to accept an external
reference (in the Utility parameters group [GR.Ut], set
parameter item Fnod [no.312] = 4).
10. Enable supply fan motor and return power to the unit.
Table 31 — Supply Fan VFD Required
User Adjusted Defaults
SIZES
All
054-104
Power Exhaust Variable Frequency Drive
(48FM and 50FM,FS)
NOTE: The VFDs (part no. TOSVERT130-E3) are specially
modified for use on Carrier equipment. Some specifications
and control configuration defaults for Carrier applications
will differ from the VFD manufacturer manual included in the
packet. See Table 33 for listing of Carrier-specific default
values.
STANDARD TRANSDUCER CONTROL — The VFD
monitors and controls building pressure (BP) via a differential
pressure transducer. The pressure transducer is located in the
auxiliary control box. The pressure transducer’s high-pressure
reference port is connected to the outside of the unit cabinet by
a factory-installed tubing section. The pressure transducer’s
low-pressure reference point must be field-connected to the
building pressure pick-up (field-supplied and installed in the
building).
The BP transducer monitors the static pressure in the occupied space and provides a 4 to 20 mA signal directly to the
power exhaust VFD. (Refer to Table 30 for transducer output
signal [mA] for actual building static pressure.) The internal
ITEM
Motor overload settings (see Table 32)
1. Check jumper CC-F
2. Gr.UT/bLSF = 1
3. Gr.SF/Sr.n = 1
4. Gr.SF/SrN1 = 0
5. SEtP/tYP = 5 (Save User Settings)
Table 32 — Supply Fan Motor Overload Settings
UNIT
IFM HP
VOLTAGE
DESIGNATION
tHr1
UNIT 48/50 DESIGNATION AND
SETTING
Model No.
Model No.
Position 12
Position 15
5
And
N
82.0
5
And
Q
86.0
FK,FY,
6
And
A
80.0
JK,JY
6
And
K
80.0
6
And
Q
80.0
6
And
Q
80.0
FKX,FKY,
JKX,JKY
6
And
T
78.0
LEGEND
IFM — Indoor Fan Motor
55
POWER EXHAUST FAN MOTOR NO. 1 OVERLOAD
PROTECTION — The VFD provides operating overload
protection for the supply fan motor. The factory has programmed the power exhaust VFD overload function to match
the factory-installed motor (motor size and efficiency). If the
power exhaust fan motor is changed from the original factory
selection, the overload value may need to be changed by the
service person. Contact your local Carrier representative for
assistance in determining the proper overload setting.
NOTE: Variable frequency drive size is matched to factoryinstalled motor size. Do not increase motor size without also
changing to equivalent VFD size.
P24 RES RR
ST
F
FM AM CC
R
CC
SI
S2
RX
PP
S3
S4 RCH P24 LOW LOW
C
A
IV FP
FLC FLB FLA
4-20mA
Fig. 56 — Variable Frequency Drive Terminal Block
Table 33 — Carrier Power Exhaust VFD Default Program Parameter Values
PARAMETER GROUP
SEtP
(Setup)
Gr.F
(Fundamental)
Gr.Fb
(Feedback)
Gr.SF
(Frequency Settings)
Gr.Pn
(Panel Control)
Gr.St
(Terminal Selection)
Gr.Pr
(Protection)
Gr.Ut
(Utility)
PARAMETER
ACC1
DEC1
UL
LL
Luln
P3
F-P3
P4
F-P4
tHr1
StC1
StL1
OLN
tYP
FH
Pt
FbP1
Fbin
GP
Gl
GA
GFS
P1LL
PuL
PuUl
PuLL
DEFAULT VALUE
60.0 Sec
60.0 Sec
59.8 Hz
10.0 Hz*
1
20%
0.0 Hz
98%
60 Hz
See Table 35
0
110%
1
5*
60 Hz
12
1*
2
.30
2 sec
0
80
10
1
10
10
Fsor
60 Hz
Fr
0*
1t
1t0
1t1
1t2
1t3
1t4
Ot1
Ot2
Ot2d
Ot2H
LF
UuC
UuCt
ArSt
Cnod
Fnod
bLPn
1
0
56
13
3
10
4*
2*
5*
100*
15*
1*
2
3
1*
2*
1*
*These settings differ from the Toshiba defaults and are required for Carrier applications.
NOTE: To restore original factory settings, change tYP to 6 in SEtup mode (SEtP).
This restores the VFD original factory settings.
56
Refer to the separate VFD Operation Manual for detailed
instructions on accessing diagnostic information, initiating
troubleshooting, and clearing any trip history.
POWER EXHAUST VFD OPERATION — When troubleshooting the power exhaust VFD, check first that all required
conditions for power exhaust VFD operation are satisfied.
For the power exhaust VFD to run, the following conditions
must be met at the power exhaust VFD:
1. Drive enable jumper is installed from terminals ST-CC
(factory supplied) (see Fig. 56).
2. Proper rotation jumper is installed at terminals R-CC (reverse rotation, factory supplied).
3. Emergency stop jumper is installed from terminals
S4-CC (factory supplied).
4. A 4 to 20 mA signal is applied across terminals IV-P24
(from pressure transducer, factory supplied).
5. DIP switch SW1 (located on the VFD’s printed circuit
control panel) must be set to “I” (indicating usage of a 4
to 20 mA input signal at terminals “IV”).
6. Speed Control (located on the VFD’s keypad/display) set
for “Remote” (press the “Speed Ctrl” button until LED
“Remote” is illuminated).
7. Programmed according to Carrier defaults.
8. Building Pressure set point established by user, or
use factory default (30 Hz indicating 0.0 in. wg) (see
Table 15).
POWER EXHAUST VFD OPERATIONAL STATUS —
The power exhaust VFDs contain extensive self-diagnostic
functions which are accessed through the power exhaust VFD
display panel (located on the front of the power exhaust VFD
or at a remote location when the accessory remote display
package has been installed.)
RESTORING FACTORY POWER EXHAUST VFD
DEFAULTS — The original factory configuration values are
saved in the memory of the power exhaust VFD and can be
restored by the service person if required. There are two types
of saved file data: Carrier-factory settings (factory programmed settings made to the power exhaust VFD which
apply specifically to the unit it is installed on) and standard
defaults for general Carrier unit use.
The Carrier-factory settings are maintained as user settings.
These can be restored by entering the Setup mode (in the
S/P/M menu) and setting parameter tYP = 6 on the keypad/display. This will recall the specific factory defaults for this unit.
Occasionally it may be necessary to restore the power exhaust VFD defaults to the general Carrier use values. These are
stored in an OPTION ROM (read-only memory chip). However, some variables may need to be manually changed to match
the specific unit’s factory default settings. To recall the general
Carrier defaults, enter the Setup mode and set parameter
tYP = 3. Refer to Tables 34 and 35 for items requiring manual
adjustment.
Table 34 — Power Exhaust VFD Required
User Adjusted Defaults
UNIT
ALL
If using the VFD display panel, disconnect all power to
the unit and the VFD before entering unit, or use the
accessory remote display module. Disable supply fan and
motor operation before accessing VFD-mounted display
module.
ITEM
Motor Overload Settings (See Table 35)
Gr.St/Ot1 = 4
Gr.St/Ot2 = 2
Gr.St/Ot2d = 5
Gr.St/Ot2H = 100
Gr.St/LF = 15
SEtP/UL = 59.8
SEtP/P4 = 98
Table 35 — Power Exhaust Motor
Overload Settings
When power is first supplied to the power exhaust VFD, the
display automatically starts with the frequency monitor function of its standard monitor mode. In the frequency monitor
function, the output frequency is displayed. Push the S/P/M
(Setup/Program/Monitor) key to switch to the Mode Selection menu. Push the S/P/M key again to toggle the display
back to the standard monitor mode.
From the Mode Selection menu, the service person can
view all of the monitored status variables, including up to four
user-selected variables and any trip history in the memory.
MODEL NUMBER
POSITION 16
H, T
J, V
K, W
L, X
M, Y
TOTAL
HP
20
30
40
50
60
MOTOR HP
(ea)
10
15
20
25
30
tHr1
SETTING
97.3
100.0
100.0
93.5
92.3
Unit Wiring — A typical wiring schematic is shown in
Fig. 57.
57
LEGEND AND NOTES FOR FIG. 57
ALM
C
CB
CCB
COMP
CH
CR
DPS
DPT
EAT
EC
ECR
EOR
EQUIP
FS
GND
HIR
HPS
HR
HTR
IDC
IDM
IFC
IFCB
IFM
IGV
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Alarm
Contactor
Circuit Breaker
Control Circuit Breaker
Compressor
Crankcase Heater
Control Relay
Differential Pressure Switch
Discharge Pressure Transducer
Enering-Air Temperature
Enthalpy Control
Economizer Close Relay
Economizer Open Relay
Equipment
Fan Status Switch
Ground
Heat Interlock Relay
High-Pressure Switch
Heater Relay
Heater
Induced Draft Contactor
Induced Draft Motor
Indoor (Evaporator) Fan Contactor
Indoor Fan Circuit Breaker
Indoor Fan Motor
Inlet Guide Vanes
IGVM
LAT
LPS
MTR
MV
NC
NO
OFC
OFM
OMR
PCB
PEC
PEDM
PEM
P, PL
RCB
RES
RFC
RFM
SCT
TB
TRAN
U
VFD
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Inlet Guide Vanes Motor
Leaving-Air Temperature
Low-Pressure Switch
Motor
Main Valve
Normally Closed
Normally Open
Outdoor Fan Contactor
Outdoor (Condenser) Fan Motor
Outdoor Motor Relay
Power Exhaust Circuit Breaker
Power Exhaust Contactor
Power Exhaust Damper Motor
Power Exhaust Motor
Plug
Return Fan Circuit Breaker
Resistor
Return Fan Contactror
Return Fan Motor
Saturated Condensing Thermistor
Terminal Block
Transformer
Unloader
Variable Frequence Drive
Field Wiring
Factory Wiring
NOTES:
1.Connect TRAN1 to H4 for 460 v units. Connect to H3 for 230 v
units. If 208/230 v units are run with a 208 v power supply connect to H2 .
2.Connect TRAN2 to BLK lead for 460 v units. Connect to ORN
lead for 230 v units. If 208/230 v units are run with a 208 v
power supply connect to RED lead.
3.Circuit breaker must trip amps are equal to or less than 156%
FLA (full load amps) for CB1 and CB2. All others are 140%.
4.If any of the original wire furnished must be replaced, it must
be replaced with type 90° C wire or its equivalent.
5.Number(s) indicates the line location of contacts. A bracket
over (2) numbers signifies single pole double throw contacts.
An underlined number signifies a normally closed contact.
Plain numbers (no lines), signify a normally opened contact.
6.Condenser fan motors are thermally protected.
7.Three phase motors are protected under primary single phasing conditions.
58
59
Fig. 57 — Typical Wiring Schematic; 48FK,JK and 50FK,FY,JK,JY Units (054-074 Shown)
60
Fig. 57 — Typical Wiring Schematic; 48FK,JK and 50FK,FY,JK,JY Units (054-074 Shown) (cont)
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:
• Unit Familiarization
• Maintenance
• Installation Overview
• Operating Sequence
A large selection of product, theory, and skills programs are available, using popular video-based formats and materials. All include video and/or slides, plus companion book.
Classroom Service Training which includes ‘‘hands-on’’ experience with the products in our labs can
mean increased confidence that really pays dividends in faster troubleshooting and fewer callbacks.
Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212
[ ] Packaged Service Training
[ ] Classroom Service Training
Copyright 2000 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 111
Catalog No. 534-763
Printed in U.S.A.
Form 48/50F,J-3T
Pg 62
3-00
Replaces: 48/50F,J-1T
Book 1 1
Tab 1a 1b
START-UP CHECKLIST
MODEL NO.: _____________________________________
SERIAL NO.: ______________________________________
DATE: ___________________________________________
TECHNICIAN:_____________________________________
I. PRE-START-UP:
VERIFY THAT UNIT IS LEVEL
VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
LOOSEN ALL SHIPPING HOLDDOWN BOLTS AND REMOVE SHIPPING BRACKETS PER INSTRUCTIONS
VERIFY THAT COMPRESSOR SUSPENSION SPRINGS HAVE BEEN LOOSENED PER INSTRUCTIONS
VERIFY OPENING OF ECONOMIZER HOODS
VERIFY INSTALLATION OF EXHAUST HOODS
CONFIRM THAT TUBING FOR SPACE AND SUPPLY DUCT PRESSURES HAS BEEN INSTALLED
VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS
VERIFY THAT POWER SUPPLY MATCHES UNIT DATA PLATE
VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT
CHECK GAS PIPING FOR LEAKS (48FK,JK ONLY)
CHECK THAT INDOOR-AIR FILTERS ARE CLEAN AND IN PLACE
CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE, AND VERIFY SET SCREWS ARE
TIGHT
VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED
OPEN SUCTION, DISCHARGE, AND LIQUID LINE SERVICE VALVES
CHECK COMPRESSOR OIL LEVEL SIGHT GLASS AND VERIFY PROPER LEVEL
VERIFY THAT CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR 24 HOURS
CHECK VOLTAGE IMBALANCE
LINE-TO-LINE VOLTS:
AB
V
AC
V
BC
(AB + AC + BC)/3 = AVERAGE VOLTAGE =
V
V
MAXIMUM DEVIATION FROM AVERAGE VOLTAGE =
VOLTAGE IMBALANCE = 100 X (MAX DEVIATION)/(AVERAGE VOLTAGE) =
IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START SYSTEM!
CALL LOCAL POWER COMPANY FOR ASSISTANCE.
V
II. PRELIMINARY CHECKLIST ITEMS:
CONTROL SETTINGS
DIP SWITCHES SET TO MATCH INSTALLED ACCESSORIES:
SUPPLY AIR SET POINT RESET (DIP SWITCH NO. 4 ON)
MORNING WARM-UP (DIP SWITCH NO. 4 ON)
DEMAND LIMIT (DIP SWITCH NO. 5 ON)
SUPPLY AIR SET POINT (P1) SET BETWEEN 45 AND 70 F
ECONOMIZER MINIMUM POSITION (P5) SET PER PLANS
SUPPLY AIR SET POINT RESET SETTINGS:
RESET INITIATION TEMPERATURE (P7) (TYPICALLY 68 TO 72 F)
RESET LIMIT TEMPERATURE (P3) (TYPICALLY 60 TO 70 F)
MORNING WARM-UP TEMPERATURE (TYPICALLY 50 TO 65 F)
IGV/VFD DUCT PRESSURE SET POINT PER PLANS
BUILDING PRESSURE (MODULATING POWER EXHAUST) SET PER PLANS
DEMAND LIMIT SETTINGS PER PLAN:
SINGLE STEP DEMAND LIMIT (P4) SET (TYPICALLY 25 TO 50%)
TWO-STEP DEMAND LIMIT
DLCM-P1 SET (TYPICALLY 50 TO 75%)
DLCM-P2 SET (TYPICALLY 0 TO 25%)
OCCUPIED/UNOCCUPIED SWITCH INSTALLED PER FIG. 23 (CLOSE TO START UNIT)
CL-1
%
CHECK EVAPORATOR FAN SPEED AND RECORD.
CHECK CONDENSER FAN SPEED AND RECORD.
AFTER AT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS:
COMP A1
COMP A2
COMP B1
COMP B2
OIL PRESSURE
SUCTION PRESSURE
SUCTION LINE TEMP
DISCHARGE PRESSURE
DISCHARGE LINE TEMP
ENTERING CONDENSER AIR TEMP
LEAVING CONDENSER AIR TEMP
EVAP ENTERING AIR DB TEMP
EVAP ENTERING AIR WB TEMP
EVAP LEAVING AIR DB TEMP
EVAP LEAVING AIR WB TEMP
COMPRESSOR AMPS (L1)
COMPRESSOR AMPS (L2)
COMPRESSOR AMPS (L3)
ELECTRICAL
SUPPLY FAN AMPS
EXHAUST FAN AMPS
ELECTRIC HEAT AMPS L1
L2
L3
(50 SERIES UNITS ONLY)
TEMPERATURES
OUTDOOR-AIR TEMPERATURE
F
DB (Dry-Bulb)
RETURN-AIR TEMPERATURE
F
DB
COOLING SUPPLY AIR
F
F WB (Wet-Bulb)
PRESSURES
GAS INLET PRESSURE
IN. WG (48 SERIES UNITS ONLY)
GAS MANIFOLD PRESSURE STAGE NO. 1
UNITS ONLY)
REFRIGERANT SUCTION
IN. WG
STAGE NO. 2
IN. WG (48 SERIES
CIRCUIT NO. 1
PSIG
CIRCUIT NO. 2
PSIG
REFRIGERANT DISCHARGE CIRCUIT NO. 1
PSIG
CIRCUIT NO. 2
PSIG
VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS IN UNIT INSTALLATION INSTRUCTIONS
GENERAL
ECONOMIZER MINIMUM VENT SETTING TO JOB REQUIREMENTS
IV. NOTES
Copyright 2000 Carrier Corporation
Book
Tab
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
1 1
PC 111
Catalog No. 534-763
Printed in U.S.A.
Form 48/50F,J-3T
Pg CL-2
3-00
Replaces: 48/50F,J-1T
1a 1b
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
III. START-UP
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