Instruction/ maintenance manual of the product EK Carrier
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Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERA TIONS ...................1 INST ALLA TION ............................. 1-31 Step 1 — Provide Unit Support ...............1 • ROOF CURB • AL TERNA TE UNIT SUPPOR T Step 2 — Rig and Place Unit .
AL TERNA TE UNIT SUPPOR T — When the preferred curb or slab mount cannot be used, support unit with sleepers on perimeter , using unit curb support area. If sleepers cannot be used, support long sides of unit (refer to Fig. 3-6) with a minimum number of 4-in.
NOTES: 1. All roof curb parts are to be 16 ga galvanized steel. 2. Dimensions are in inches. 3. T o prevent standing water in the drain pan of the indoor section and the heat exchangers, unit can only be pitched as shown. UNIT LEVELING TOLERANCES DIMENSIONS* (Degrees and Inches) AB Deg.
NOTES: 1. All roof curb parts are to be 16 ga galvanized steel. 2. Dimensions are in inches. 3. T o prevent standing water in the drain pan of the indoor section and the heat exchangers, unit can only be pitched as shown. UNIT LEVELING TOLERANCES DIMENSIONS* (Degrees and Inches) AB Deg.
VFD — V ariable Frequency Drive NOTES: 1. Weights include economizer (STD). 2. Center of gravity . 3. Do not locate adjacent units with flue dis- charge facing economizer inlet.
VFD — V ariable Frequency Drive NOTES: 1. Weights include economizer (STD). 2. Center of gravity . 3. Do not locate adjacent units with flue discharge facing econo- mizer inlet.
VFD — V ariable Frequency Drive NOTES: 1. Weights include economizer (STD). 2. Center of gravity . 3. Do not locate adjacent units with flue discharge facing economizer inlet.
VFD — V ariable Frequency Drive NOTES: 1. Weights include economizer (STD). 2. Center of gravity . 3. Do not locate adjacent units with flue discharge facing economizer inlet.
UNIT WEIGHT A B C lb kg in. mm in. mm in. mm 48EJ,EK,EW ,EYD024 4176 1894 87.68 2227 72.4 1839 42.4 1072 48EJ,EWE024 4256 1930 73.3 1862 42.7 1085 48EJ,EK,EW ,EYD028 4262 1933 69.6 1768 44.0 1 1 18 48EJ,EK,EW ,EYD030 48EJ,EK,EW ,EYD034 48EJ,EWE028 4342 1969 70.
T able 1 — Physical Data UNIT 48EJ,EK,EW ,EY 024D/E 028D/E 030D/E 034D/E NOMINAL CAP ACITY (tons) 20 25 27 30 OPERA TING WEIGHT (lb)* Unit Al/Al† (Lo Heat/Hi Heat) 4176/4256 4262/4342 4262/4342 4262/4342 Al/Cu† (Lo Heat/Hi Heat) 4396/4476 4482/4562 4482/4562 4482/4562 Roof Curb (14-in.
T able 1 — Physical Data (cont) UNIT 48EJ,EK,EW ,EY 038D/E 044D/E 048D/E NOMINAL CAP ACITY (tons) 35 40 45 OPERA TING WEIGHT (lb)* Unit Al/Al† (Lo Heat/Hi Heat) 4442/4602 4668/4828 4955/5115 Al/Cu† (Lo Heat/Hi Heat) 4727/4887 4953/51 13 5335/5495 Roof Curb (14-in.
T able 2 — Evaporator Fan Motor Data (Units with Starting Serial Numbers 4197 and Later) UNIT SIZE 48E MOTOR HP MOTOR SHAFT DIA. (in.) FA N SHAFT SPEED (rpm) MOTOR SHEA VE MOTOR SHEA VE PITCH DIAMETER (in.) BUSHING DIAMETER (in.) FA N SHEA VE FA N SHEA VE PITCH DIAMETER (in.
S t e p5—T r a p Condensate Drain — See Fig. 3-6 for drain location. Condensate drain is open to atmosphere and must be trapped. Install a trapped drain at the drain lo- cation. A trap at least 4-in. deep must be used. See Fig. 12. T rap must be installed to prevent freeze-up.
T able 3 — Controls Options and Configurations (Non-Thermostat Applications) UNIT CONFIGURA TION DEF AUL T COOLING DEF AUL T HEA TING CV or V A V Unit with SPT Sensor Unoccupied Cooling — 90 F (S.
Features with Sensor Control of Unit (Network Applica- tions) — The base control board provides, as standard, a con- nection for use with a Carrier VVT system and can also be integrated into a Carrier Comfort Network.
When a V A V unit with a space temperature sensor is ac- cessed via a computer , the following additional features are available: • ability to initiate timed override from T -55 sensors • temperat.
LEGEND CCN — Carrier Comfort Network COM — Common D— Diode LED — Light-Emitting Diode N.C. — Normally Closed N.O. — Normally Open R— Relay SIO — Serial Input/Output SW — Switch T— T erminal Fig. 16 — Control Board Diagram *Where X is the unit control software version number .
T able 4 — Electrical Data UNIT SIZE 48E NOMNAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST COMBUSTION F AN MOTOR POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA FLA MCA MOCP* 024 208/230 187 254 39.
T able 4 — Electrical Data (cont) UNIT SIZE 48E NOMINAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST COMBUSTION F AN MOTOR POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA FLA MCA MOCP* 034 208/230 187 254 57.
T able 4 — Electrical Data (cont) UNIT SIZE 48E NOMINAL VOL T AGE (3 Ph 60 Hz) VOL T AGE RANGE COMPRESSOR OFM IFM POWER EXHAUST COMBUSTION F AN MOTOR POWER SUPPL Y No. 1 No. 2 Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA FLA LRA FLA MCA MOCP* 044 208/230 187 254 69.
IMPOR T ANT : THE V A V (variable air volume) units use variable frequency drives, which generate, use and can radiate radio frequency energy . If units are not in- stalled and used in accordance with these instructions, they may cause radio interference.
LEGEND Fig. 20 — Field Control Thermostat Wiring NOTE: Sensor part numbers are as follows: T -55 — CEC0121448-01 T -56 — CEC0121503-01 Fig. 21 — Field Control T emperature Sensor Wiring (CV or.
Remote Field Control — A switch closure across terminals R and W1 on TB-3 will initiate the Occupied mode. This can be done manually as well as through a field-supplied timeclock. Service T ool, Building Supervisor , and ComfortW orks™ Software — Access to the control board can be achieved through the terminal marked CCN via a 3-wire bus.
IMPOR T ANT : When connecting the CCN communi- cation bus to a system element, use a color coding sys- tem for the entire network to simplify installation and checkout. See T able 6. T able 6 — Color Code Recommendations SIGNAL TYPE CCN BUS CONDUCTOR INSULA TION COLOR CCN PLUG PIN NO.
HOOD SIDE TOP FLANGE SEAL STRIP BLACK Fig. 23 — Adding Seal Strip to T op of Hood Sides NOTE: Left side economizer hood has mounting angle without tabs and filter track assembled end on the opposite side. Fig. 24 — Economizer Hood Assembly (Right Side Economizer Hood Shown) HOOD SIDE MOUNTING FLANGE Fig.
The outdoor-air damper closes. The control allows 90 sec- onds for the damper to close in case it is in the full open position. Next, the indoor-fan contactor will ener gize. The outdoor-air damper will remain at 0% for 30 seconds. It will then move to the 10% position for another 30 seconds.
Dif ferential Enthalpy Sensor Installation — T o install the con- trol, perform the following procedure: 1. T urn of f all power . Ensure disconnect is locked out. 2. Remove the economizer inlet filters from the bottom of the right hand economizer hood.
NOTE: Switches shown in high enthalpy state. T erminals 2 and 3 close on enthalpy decrease. Fig. 34 — Wiring Connections for Solid-State Enthalpy Control (HH57AC077) CONTROL CURVE CONTROL POINT (APPROX. DEG.) A T 50% RH A 73 (23) B 70 (21) C 67 (19) D 63 (17) RH — Relative Humidity Fig.
Step 10 — Position Power Exhaust/Barometric Relief Damper Hood — All electrical connections have been made and adjusted at the factory . The power exhaust blowers and barometric relief dampers are shipped as- sembled and tilted back into the unit for shipping.
Step 1 1 — Install All Accessories — After all the factory-installed options have been adjusted, install all field- installed accessories. Refer to the accessory installation in- structions included with each accessory .
ST ART -UP Use the following information and Start-Up Checklist on page CL-1 to check out unit PRIOR to start-up. Unit Preparation — Check that unit has been installed in accordance with these installation instructions and appli- cable codes.
T o set the VFD, the VFD must be powered up; however , since it is located near the indoor air fan, operation of the fan is not desirable. T o disable the fan, perform the follow- ing procedure: 1. Open the indoor fan circuit breaker . 2. Remove the jumper between CC and ST on the terminal strip of the VFD (see Fig.
At the upper right corner of the board is a set of 5 pins and jumper , which determines the time constant for the control. The time constant is the delay in response built into the con- trols. The jumper should be on the middle or bottom two pins, for the maximum time constant.
T able 9 — Power Exhaust Default Set Points ST AGE OFFSET DIFFERENTIAL OFF VOL T AGE ON VOL T AGE OFF ST A TIC PRESSURE (in. wg) 1 50% 3% 6.0 6.3 0.00 2 55% 3% 6.
T able 12 — Fan Performance, 48EJ/EK024-034 — V ertical Discharge Units (For EW/EY units, reduce net available external static pressure by 0.3 in. wg) AIRFLOW (Cfm) A V AILABLE EXTERNAL ST A TIC PRESSURE (in. wg) 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 4,000 340 0.
T able 13 — Fan Performance, 48EJ,EK038,044 — V ertical Discharge Units (For EW/EY units, reduce net available external static pressure by 0.5 in. wg) AIRFLOW (Cfm) A V AILABLE EXTERNAL ST A TIC PRESSURE (in. wg) 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 7,000 429 1.
T able 14 — Fan Performance, 48EJ,EK048 — V ertical Discharge Units (For EW/EY units, reduce net available external static pressure by 0.5 in. wg) AIRFLOW (Cfm) A V AILABLE EXTERNAL ST A TIC PRESSURE (in. wg) 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 9,000 528 3.
T able 15 — Fan Performance — Power Exhaust 48EJ,EK,EW ,EY024-048 (20 THRU 45 TONS) Airflow (Cfm) Low Speed Medium Speed High Speed 208 v 230, 460, 575 v 208 v 230, 460, 575 v 208 v 230, 460, 575 v ESP Bhp W atts ESP Bhp Watts ESP Bhp W atts ESP Bhp W atts ESP Bhp Watts ESP Bhp W atts 6,500 0.
T able 17 — Air Quantity Limits UNIT 48EJ,EK,EW ,EY MINIMUM HEA TING AIRFLOW (Low Heat) MINIMUM HEA TING AIRFLOW (High Heat) MINIMUM COOLING AIRFLOW (V A V) A T FULL LOAD OPERA TION MINIMUM COOLING .
T able 18 — User Defined Set Points SET POINT NAME FORMA T DESCRIPTION LIMITS DEF AUL T OHSP xx.xF Occupied Heat Set Point 55 to 80 F 68 F OCSP xx.xF Occupied Cool Set Point 55 to 80 F 78 F UHSP xx.xF Unoccupied Heat Set Point 40 to 80 F 55 F UCSP xx.
When cooling, the control will energize the power ex- haust enable output to the external power exhaust controller , when power exhaust is used. If occupied, the control will perform economizer control (economizer control same as described above for CV units).
MORNING W ARM-UP (V A V Only) (Stand-Alone Opera- tion) — When the unit operates in stand-alone mode, morn- ing warm-up occurs when the unit is energized in Occupied mode and return-air temperature (RA T) is below 68 F . W arm-up will not terminate until the RA T reaches 68 F .
Space T emperature Reset Example — The occupied cooling set point is set to 73 F . The Reset Ratio is set to 5. The Reset Limit is set to 20° F . The Reset Ratio determines how many degrees F the temperature is reset. At 72 F , the supply tem- perature will be reset 5 degrees higher .
• When the outdoor air quality is greater than the outdoor air quality set point (ppm) High priority — When the priority is set to high, the IAQ set point controls the outside air damper exclusively , with no regard to comfort conditioning.
T o open, loosen the latch bolt using a 7 ⁄ 16 -in. wrench. Pivot the latch so it is not in contact with the door . Open the door . T o shut, reverse the above procedure. NOTE: Disassembly of the top cover may be required under special service circumstances.
Evaporator Fan Performance Adjustment (Fig. 49) — Fan motor pulleys are designed for speed shown in T able 1 (factory speed setting). IMPOR T ANT : Check to ensure that the unit drive matches the duct static pressure using T ables 12-14. T o change fan speeds, change pulleys.
Evaporator-Fan Motor Replacement 1. Shut of f unit power supply . 2. Remove upper outside panel and open hinged door to gain access to motor . 3. Fully retract motor plate adjusting bolts. 4. Loosen the two rear (nearest the evaporator coil) motor plate nuts.
Main Burners — For all applications, main burners are factory set and should require no adjustment. MAIN BURNER REMOV AL (Fig. 55) 1. Shut of f (field-supplied) manual main gas valve. 2. Shut of f power to unit. 3. Remove heating access panel. 4. Disconnect gas piping from gas valve inlet.
Crankcase Heater — Each compressor has a crankcase heater to prevent absorption of liquid refrigerant by oil in the crank- case when the compressor is idle. Since power for the crank- case heaters is drawn from the unit incoming power , main unit power must be on for the heaters to be energized.
LEGEND and NOTES for Fig. 56-60 — T ypical Wiring Schematics AHA — Adjustable Heat Anticipator BP — Building Pressure BR — Burner Relay C— Contactor , Compressor CAP — Capacitor CB — Cir.
Fig. 56 — T ypical Power Schematic; 48EJ,EK,EW ,EY024-034; 208/230-3-60 and 460-3-60 51.
Fig. 57 — T ypical V A V 1 15-v Control Circuit 52.
Fig. 58 — T ypical CV 1 15-v Control Circuit 53.
Fig. 59 — T ypical V A V 24-v Control Circuit 54.
Fig. 60 — T ypical CV 24-v Control Circuit 55.
TROUBLESHOOTING T ypical refrigerant circuiting diagrams are shown in Fig. 61-63. An algorithm diagram of the IGC (Integrated Gas Unit Con- troller) control is shown in Fig. 64. LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig.
LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 62 — T ypical Refrigerant Circuiting (48EJ,EK,EW ,EY038,044) 57.
LEGEND FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch Fig. 63 — T ypical Refrigerant Circuiting (48EJ,EK,EW ,EY048) 58.
NOTE: Thermostat Fan Switch in the ‘ ‘AUTO’’ position or sensor-equipped unit. Fig. 64 — IGC Control (Heating and Cooling) LEGEND IDM — Induced-Draft Motor IGC — Integrated Gas Unit Cont.
The alarm codes for the IGC control board are shown in T able 22. T able 22 — IGC Control Board LED Alarms INDICA TION ERROR MODE ON Normal Operation OFF Hardware Failure 1 FLASH Fan ON/OFF Delay Mo.
T ables 24-26 show the input and output channel designations. T able 24 — I/O Channel Designations Base Module — CV TERMINAL NO. ASSIGNMENT TERMINAL NO.
P ACKAGED SERVICE TRAINING Our packaged service training programs provide an excellent way to increase your knowledge of the equipment discussed in this manual. Product programs cover: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A lar ge selection of product, theory , and skills programs is available.
ST ART -UP CHECKLIST MODEL NO.: SOFTW ARE VERSION (SEE FIG. 16) DA TE: SERIAL NO.: TECHNICIAN: PRE-ST ART -UP: M VERIFY THA T DIP SWITCH SETTINGS ARE CORRECT M VERIFY THA T ALL P ACKING MA TERIALS HA .
GENERAL M SET ECONOMIZER MINIMUM VENT POSITION TO JOB REQUIREMENTS M ENSURE DRIVES OPERA TE WITHIN LIMITS OF F AN PERFORMANCE T ABLES HIGH PRESSURE SWITCH SETTING psig LOW PRESSURE SWITCH SETTING psig MOTOR PULLEY P AR T NUMBER F AN PULLEY P AR T NUMBER BEL T P AR T NUMBER BEL T SIZE in.
An important point after buying a device Carrier EK (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Carrier EK yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Carrier EK - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Carrier EK you will learn all the available features of the product, as well as information on its operation. The information that you get Carrier EK will certainly help you make a decision on the purchase.
If you already are a holder of Carrier EK, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Carrier EK.
However, one of the most important roles played by the user manual is to help in solving problems with Carrier EK. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Carrier EK along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
