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50PG03-07
Single Package Rooftop Units
Electric Cooling with PURON® (R-410A)
Refrigerant and Electromechanical Controls
Installation, Start-Up, and
Service Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS ...................... 1
INSTALLATION ................................ 2-28
Step 1 -- Plan for Unit Location .................. 2
Step 2 -- Provide Unit Support ................... 2
ROOF CURB
ALTERNATE UNIT SUPPORT
Step 3 -- Rig and Place Unit ..................... 2
INSTALLATION ONTO CURB
SLAB MOUNT (Horizontal Units Only)
Step 4 -- Field Fabricate Ductwork ............... 4
Step 5 -- Make Unit Duct Connections ........... 4
VERTICAL SUPPLY/RETURN CONFIGURATION
HORIZONTAL SUPPLY/RETURN APPLICATIONS
Step 6 -- Install External Trap
for Condensate Drain .......................... 7
Step 7 -- Make Electrical Connections ........... 9
FIELD POWER SUPPLY
FIELD CONTROL WIRING
Step 8 -- Optional EconoMiSer IV ............... 22
Step 9 -- Install All Accessories ................. 28
PRE-START-UP .................................. 29
START-UP .................................... 29-37
SERVICE ..................................... 37-44
Cleaning ........................................ 37
Lubrication ...................................... 38
Evaporator Fan Service and Replacement ....... 38
Evaporator Fan Performance Adjustment ....... 39
Evaporator Fan Belt Tension Adjustment ........ 39
Condenser-Fan Adjustment ..................... 39
Verify Sensor Performance ...................... 39
Economizer Operation During Power Failure .... 39
Evacuation ...................................... 39
Refrigerant Charge .............................. 40
Filter Drier ...................................... 42
Protective Devices .............................. 42
Relief Devices ................................... 42
Control Circuit 24-V ............................. 42
Replacement Parts .............................. 42
TROUBLESHOOTING ......................... 45-47
Unit Troubleshooting ............................ 45
EconoMi$er IV Troubleshooting ................. 46
Phase Loss Protection .......................... 47
UNIT START-UP CHECKLIST .................. CL-I
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical compo-
nents. Only trained and qualified service personnel should
install, repair, or service ai>conditioning equipment.
Untrained personnel can perform the basic maintenance
functions of cleaning coils and filters and replacing filters. All
other operations should be performed by trained service per-
sonnel. When working on ai>conditioning equipment, observe
precautions in the literature, tags and labels attached to the unit,
and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations. Have
fire extinguishers available for all brazing operations.
Before performing service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury.
Puron (R-410A) refrigerant systems operate at higher pres-
sures than stan&trd R-22 systems. Do not use R-22 service
equipment or components on Puron refrigerant equipment.
If service equipment is not rated for Puron refrigerant,
equipment dmnage or personal injuU may result.
I. Improper installation, adjustment, alteration, service,
or maintenance can cause property &tmage, personal
injury, or loss of life.
2. Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance.
IMPORTANT: Units have high ambient operating limits. If ]
limits are exceeded, the units will automatically lock the
I
compressor out of operation. Manual reset will be required
to restart the compressoc
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 111 Catalog No, 535-00139 Printed in U,S.A. Form 50PG-5SI Pg 1 8-05 Replaces: New
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1 2 3 4 5 6 ... 48 49

Inhaltsverzeichnis

Seite 1 - Service Instructions

50PG03-07Single Package Rooftop UnitsElectric Cooling with PURON® (R-410A)Refrigerant and Electromechanical ControlsInstallation, Start-Up, andService

Seite 2

Table2A-- Electrical Data -- Units Without Optional Convenience OutletUNIT NOMINAL50PG POWER SUPPLYVolts-Ph-Hz03 208/230-1-6004 208/230-1-60VOLTAGE CO

Seite 3 - Fig. 1 -- Roof Curb Details

UNIT50PGO4(cont)O5Table 2A -- Electrical Data -- Units Without Optional Convenience Outlet (cont)NOMINALPOWER SUPPLYVolts-Ph-Hz208/230-3-60460-3-60575

Seite 4 - Fig. 2 -- 50PG Rigging Label

Table 2A -- Electrical Data -- Units Without Optional Convenience Outlet (cont)UNIT NOMINAL50PG POWER SUPPLYVolts-Ph-Hz208/230-3-6005(cont)460-3-60878

Seite 5 - Con n..r Ou, r I I

UNIT50PGO6Table 2A -- Electrical Data -- Units Without Optional Convenience Outlet (cont)NOMINALPOWER SUPPLYVolts-Ph-Hz208/230-1-60208/230-3-60460-3-6

Seite 6 - ¢0 7!a'

Table 2A -- Electrical Data -- Units Without Optional Convenience Outlet (cont)UNIT50PGO6(cont)O7NOMINALPOWER SUPPLYVolte-Ph-HzVOLTAGE COMPRESSOR OFM

Seite 7

UNIT50PGO7(cont)NOMINALPOWER SUPPLYVolts-Ph-Hz460-3-60575-3-60Table 2A -- Electrical Data -- Units Without Optional Convenience OutletVOLTAGE COMPRESS

Seite 8 - .,.,.u..,To

Table 2B -- Electrical Data -- Units With Optional Convenience OutletUNIT NOMINAL50PG POWER SUPPLYVolte-Ph-Hz03 208/230-1-6004 208/230-1-60VOLTAGE COM

Seite 9 - [_ I I I

UNIT50PGO4(cont)O5Table 2B -- Electrical Data -- Units With Optional Convenience Outlet (cont)NOMINALPOWER SUPPLYVolts-Ph-Hz208/230-3-60460-3-60575-3-

Seite 10

Table 2B -- Electrical Data -- Units With Optional Convenience Outlet (cont)UNIT50PG05(cont)VOLTAGE COMPRESSOR OFMNOMINAL RANGE FLA IFMPOWER SUPPLYFLA

Seite 11

UNIT50PGO5(cont)O6Table 2B -- Electrical Data -- Units With Optional Convenience Outlet (cont)NOMINALPOWER SUPPLYVolts-Ph-Hz878-3-60208/230-1-60208/23

Seite 12

INSTALLATIONStep 1 -- Plan for Unit Location -- Select a loca-tion for the unit and its support system (curb or other) thatprovides minimum clearances

Seite 13 - 460-3-60

Table 2B -- Electrical Data -- Units With Optional Convenience Outlet (cont)UNIT50PGO6(cont)NOMINALPOWER SUPPLYVolte-Ph-Hz460-3-60575-3-60VOLTAGE COMP

Seite 14

UNIT50PGO7Table 2B -- Electrical Data -- Units With Optional Convenience Outlet (cont)NOMINALPOWER SUPPLYVolts-Ph-Hz208/230-1-60VOLTAGE COMPRESSOR OFM

Seite 15 - 575-3-60

Step 8 -- Optional EconoMi$er IV -- The optionalEconoMiSer IV comes flom file factory fully wired. Outdoorair hoods must be installed. No field wiring

Seite 16 - 187 253 12.8 60 1 1.0 4.9

Mixed-Air Temperature (MAT) Sensor -- The mixed-airtemperature sensor is a 3 K thermistor located at the dischargeof the indoor fan. The sensor is mou

Seite 17 - 187 253 20.5 109 1

19I18 %'*_ LEDON1716- -- - LED OFF15<E1413121110940 45 50LED ON55 60 65 70 75 80DEGREES FAHRENHEITFig. 15 -- Temperature Changeover Set Points

Seite 18

CONTROL CONTROL POINTCURVE APPROX. °F (°C)AT 50% RHA 73 (23)B 70 (21)C 67 (19)D 63 (17)85 90 95 100 105 110(35) (38) (43)// "Ix/ I "WI I\1\_

Seite 19

Table 3 -- EconoMi$er IV Sensor UsageAPPLICATIONECONOMI$ER IV WITH OUTDOOR AIRDRY BULB SENSORAccessories RequiredNone. The outdoor air dry bulbsensor

Seite 20

0.220.20 /0.180.16 /o14 /e 0.12° /(0¢ O.lOo0.080.06 /0.04 /0.02 /0.000 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250CFM (Cubic Feet Pe

Seite 21 - 460-3-60 414 506 9.6 75 1 0.8

Once the _lly occupied &impel position has been deter-mined, set the maximum dmnper demand control ventilationpotentiometer to this position. Do n

Seite 22 - PANEL RELIEF DAMPER SCREW

PRE-START-UP START-UPFailure to observe the following warnings could result inserious pel_onal injuu:1. Follow recognized safety practices and wear pr

Seite 23 - J EconoMi$er IV Wiring

02-2 18"63DNSIDE0-3'6 ]8" SUPPLY AR I I _OPE_ING _0 3'!I/i 3n_' l 1 s//6 .-I/ 3 15/16: o EN[N6 o[396? 03'{76 71lt_}l_ 18

Seite 24

Performance Adjustment section on page 39. See Table 18 foraccessory electric heat static pressme.Cooling -- To start unit, turn on main power supply.

Seite 25 - ";Z

AIRFLOW(Cfrn)6006507007508008509009501000Table 5 -- Fan Performance -- 50PG03 Vertical UnitsAVAILABLE EXTERNAL STATIC PRESSURE (in. wg)0.2Rpm Bhp402 0

Seite 26

AIRFLOW(Cfm)120013001400150016001700180019002000Bpm49251353455758O603627651675Table 7 -- Fan Performance -- 50PG05 Vertical UnitsAVAILABLE EXTERNAL ST

Seite 27

AIRFLOW(Cfm)1800190020002100220023002400250026002700280029003000Table 9 -- Fan Performance -- 50PG07 Vertical UnitsRprn6546807067327587858128398668949

Seite 28 - 002 Sensor Standard Settings

Bhp --AIRFLOW(Cfm)90095010001050110011501200125013001350140014501500Table 11 -- Fan Performance -- 50PG04 Horizontal Units0.2Rpm Bhp Rpm413 0.08 54442

Seite 29 - Each independent re

Table 13 -- Fan Performance- 50PG06 Horizontal UnitsAVAILABLE EXTERNAL STATIC PRESSUREAIRFLOW(Cfm) 0.2 0.4 0.6Rpm Bhp Bpm Bhp Bpm Bhp1500 491 0.19 604

Seite 30

Table 15 -- Operation Air Quantity LimitsUNIT COOLING (cfm) HEATING (cfm)ELECTRIC HEAT50PGMin Max Min Max03 600 1000 600 100004 900 1500 900 150005 12

Seite 31

Table 17 -- Fan Rpm at Motor Pulley Settings*UNIT50PG0304O50607DRIVE0Low 736High 1001Low 736High 1128Low 910High 1173Low 978High 1261Low 1128High 1438

Seite 32

High velocity water from a pressure washel: garden hose,or compressed air should never be used to clean a coil. Theforce of the water or air jet will

Seite 33

7. Re-attachelectricalwiles.8. Closefansectionaccessdool:9. Restolepowertounit.Evaporator Fan Performance Adjustment(Fig. 22 and 23) -- Fan motor pull

Seite 34

Hook rigging shackles through holes in base rail, as shown inDetail A. Holes in base rails are centered around the unitcenter of gravity. Use wooden t

Seite 35

MOTORMOUNTINGBASESCREW(HIDDEN)FAN DECKSTOPRefrigerant Charge -- Amount of refrigerant charge islisted on unit nameplate. Refer to Carder GTAC II; Modu

Seite 36

R410A REFRIGERANTOUTDOOR FAN MUST BE OPERA_NG ON HIGH SPEED[11111111111111 IIII IIIIIIIIIIIIIIII111111111111111 IIII IIIIIIIIIIIIIIII[11111111111111 I

Seite 37 - Pressure (in. wg)

R410A REFRIGERANTOUTDOOR FAN M UST BE OPERATING ON HIGH SPEED150 200 250 300 350 400 450 500 550 600Compressor Discharge Pressure, [psig]Fig. 30 -- Ch

Seite 38 - Damage to unit may result

®1IFIELD THERMOSTAT gIIFig. 31 -- Typical Control SchematicTBI+JH+_IfCCA_CAIpks++)TR^Ntc ^ikswTBI+J_O+_1_&0,575ONkY}CLOAI_DRC AIACC_IflOP> P[C_

Seite 39 - 9. Restolepowertounit

FIELD-- _I_BLKPOWER _ . : YEt --SUPPLY _" I BLU----I± I- -- -[_[E]II I EOUIP GNDI L _ " - BOX_• _ -F]OPIACCESSORY: ELE ,R=<NE=T[ "==

Seite 40 - Adjustment

TROUBLESHOOTINGUnit Troubleshooting -- See Table 20 for unit coolingtroubleshooting. See Table 21 for unit heating troubleshooting.Table 20 -- Cooling

Seite 41

Table 21 -- Heating Service AnalysisPROBLEMNo Heat.CAUSEPower failure.Fuse blown or circuit breaker tripped.Thermostat not calling for heating.No 24 v

Seite 42 - Protective Devices

4. RemovefilejumperacrossTandTl.Theactuatorshoulddrivefullyclosed.5. ReturnEconoMi$erIV settingsandwMngto normalaftercompletingtroubleshooting.ECONOMI

Seite 43

Copyright 2005 Carrier CorporationManufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and

Seite 44 - -t-itLU 0

UNIT START-UP CHECKLISTMODEL NO.: SERIAL NO.:DATE: TECHNICIAN:I. PRE-START-UP:[] VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT[] VERIF

Seite 45 - TROUBLESHOOTING

Table 1 -- Physical DataBASE UNIT 50PG 03 04 05 06 07NOMINAL CAPACITY (Tons) 2 3 4 5 6OPERATING WEIGHT (Ib)Unit* 704 704 775 829 874EconomizerVertical

Seite 46 - EconoMi$er IV Troubleshooting

_OTESl D#_RNSIONS iN ] ARE IN HILLIMETERS2 _ CENTER OF GRAVITYS I_I"OIRECIIOR OF AIR FLOW¸4 ON VERTICAL DISCHARGE UNITS¸ ODCTWORKlO BE AITACHEOTO

Seite 47

ELECTRICALOPTIONS PANELCONTROLBOXAND COMPRESSORACCESS DOOR\\\\\\\,INDOOR MOTORACCESS DOOR/fOUTDOOR AIRSCREEN(HIDDEN)\\\\CONDENSER COILACCESS PANELECON

Seite 48

SIDE DRAINPLUG__\ \ \ \_/_ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \\\\\\\\BOTTOM DRAINPLUGFig. 5 -- Condensate Drain PanlOPTIONAL UNIONSTO ALLOW FOR CONDENSATE

Seite 49 - II. START-U P

Step 7-- Make Electrical ConnectionsFIELD POWER SUPPLY -- All 2081230-v units are factorywired for 230-v power supply. If the 2081230-v unit is to bec

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