Carrier PC 111 manual

Manufactu rer reserves th e right to d iscontinue, o r change at any time, spec ifications or designs without not ice and withou t inc urring obligation s. PC 111 Catalo g No. 53 4-763 Printed in U.S.A . Form 4 8/50F,J-3 T Pg 1 3-00 Replaces : 48/50 F,J-1T Book 1 1 Tab 1a 1b Controls Operation, and Troubleshooting CO NTEN TS Page SAFETY CONSIDERATI[...]

2 CONTENTS (cont) Page TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 44-60 Checking Disp lay Codes . . . . . . . . . . . . . . . . . . . . . . . . 44 Complete Unit Stoppage . . . . . . . . . . . . . . . . . . . . . . . . 44 Single Circuit Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . 44 Rest ar t Pr oce dure . . . .[...]

3 The V A V control system monitors and controls the fol low- ing functions of the rooftop unit: • supply-air temperature (unit capacity) • morning warm-up or electric heat (if equipped) • head pressure con trol, fan cycling • economizer position • diagnostic disp lay • unit check-out (quick test) • supply ai r temperatur e reset (if [...]

4 LEGEN D Fig. 2 — Pin Terminal Connector J1 Thermistor Inputs T— Therm istor Field Wiring Accessory LEGEND Fig. 3 — Pin Terminal Connector J2 Status Switch Inputs CR — Control Relay EC — Enthalpy Control LPS — Low-Pr essure Sw itch Table 2 — Pin Terminal Connector J2 Status Switch Inputs LEGEND NOTE: Terminal numbers 5, 6, 11, 12, 16[...]

5 All of the potentiometers must be set before the unit is start - ed in order for the unit t o function properly . See Start Up, Po- tentiometers section on pa ge 27 for inform ation on establishing set points. Each of the potentiometers has a valid range that is used by the control. The valid range is defi ned as the potenti- ometer ’ s resista[...]

6 Table 3 — Output Pin and Terminal Assignments L EGEND *Circuit 1. †Circuit 2. **U2 is not us ed on 044 units. ††OFC2 on 034-048 units; OFC3 on 054-104 units. || Used on 054- 104 units only. OUTPUT PIN- TERMINAL NAME RATING DEVICE J6-1 Stage 1 Compressor R elay (K1)* 24 vac CR1 J6-2 Stage 2 Compressor R elay (K2)* U2** J6-3 Stage 3 Compres[...]

7 Compressor Operation CONTROL RELA Y (CR) — This relay provides information to the processor about compr essor operation (one control rel ay per compressor). The relay controls and protects the compres- sor and also cont rols the cra nkcase heater . A control signal t o chec k the safet y stat uses and to s tart t he compressor is sent from the [...]

8 GAS SECTION (48FK,JK O NLY) HORIZONTAL SUPPLY SECTION (50FY,JY ONLY) AND EXTENDED PLENUM SECTION (50FKX,FKY,JKX,JKY) Fig. 7 — Thermistor T1 Location, 48FK,J K, 50FY,JY a nd 50FKX,FKY,JKX ,JKY 034-048 Units FAN DISCHARGE/ELECTRIC HEAT SECTION Fig. 8 — Thermistor T1 Location, 50FK,JK034-048 Units[...]

9 GAS SECTION (48FK,FM,JK) HORIZONTAL SUPPLY SECTI ON (50FS,FY,JY) AND EXTENDED PLENUM SECTION (50FKX,FKY,FMX,FMY,JKX,JKY) Fig. 9 — Thermistor T1 Location, 48FK,FM,JK, 50 JY and 50JKX,JKY 054-074 Units and 5 0FKX,F KY,FMX, FMY and 50FS,FY0 54-104 Unit s FAN DISCHARGE/ELECTRIC HEAT SECTION Fig. 10 — Thermistor T1 Location, 50FK,JK054-074 Units[...]

10 Economizer — Economizer control is used to control the outside and return air dam pers of the unit, to satisfy space cool- ing demand using all outside air (when permitted), and to sat is- fy cooling in conjunction with compressor operation (when conditions permit). During Occupied periods without cool ing demand, the outside-air dampers will [...]

11 054 UNITS 064, 074, 078 UNITS 088, 104 U NITS Fig. 14 — Thermistor T3 and T4 Locations, Size 054-104 Units[...]

12 Supply Fan Variable Fr equency Drive (VFD) — T he opti onal VFD is used to modulate supply fan airflow to maintain duct static pressure on V A V applications. The VFD is located i n the supply fan section (see Fig. 18 and 19), and can be accessed by opening the fan section access door . The unit is supplied with a pressure transducer capable o[...]

13 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 res et al- lows the unit to automatically adjust (‘ ‘reset’ ’) the supply-air temperature set point to a higher va lue once most of the space cooling[...]

14 Fig. 20 — Unit Contro l Box Arran gement, Siz es 034-048[...]

15 Fig. 21 — Unit Control Box Arrangement, Sizes 054-078[...]

16 Fig. 22 — Unit Control Box Arrangement, Sizes 088 and 104[...]

17 EXAMPLE: T10 desired set point is 70 F . T10 R from T able 4 for 70 F is 5929 ohms. P7 R = 13,084 – 5929 P7 R = 7155 ohms Using an ohmmeter , set the P7 potentiometer to 7155 ohms to achieve a reset initiat ion set point of 70 F . Potentiometer P3 — Rese t li mit set poi nt (max imu m tem per a- ture value for modified supply air set point).[...]

18 Demand Limit — The demand limit function provides a means to limit the c ooling capacity of the V A V unit using an external discrete switch funct ion. When enabled by the closure of the exte rnal swi tc h, the cont rol will limit the available com- pressor staging capacity acc ording to user set points established at demand limit pote ntiomet[...]

19 Connect the pot entiometer 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 wipe r arm terminal and to terminal 10 on TB3 or TB4. T o enable demand limit function, change DIP switch 5 to position ON. (Disconnect control power be[...]

20 OCCUPIED/UNOCCUPIED — The unit control syst em will initiate normal occupied mode functions (including Morning W arm-up, Economizer Mi nimum Position, and Cooling Cycle) whenever a contact closure is made that emulates the normal timeclock contacts. See Fig. 23. (‘ ‘Occupied/U noccupied Switch’ ’). The contact closure from the BMS must[...]

21 EXTERNAL ALARM SIGNAL — The unit controls provide an external alarm status signal via a 1 15-vac output signal at the relay board J5, avai lable 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 TB2- 4 and TB2-5 and using i ts contacts to control[...]

22 SMOKE PURGE MODE — Smoke Purge mode removes smoke from th e interior spaces and replaces i t with fresh out - side air . The economizer and pow er exhaust are required for this function. The economizer and power exhaust are standard on 48FM and 50FM, FS units. The economizer i s a fact ory- installed option and the power exhaust is a factory-i[...]

23 Table 7 — Switch Functions *Not required on 48FM and 50FM,FS units (units with high capacity power exhaust). LEGEND Air Pressure Tubing — Before options such as inlet guide vanes (IGV), variable frequency drive (VFD), and/or modulating power exhaust can operate properl y , the pneuma tic tubing for pressure sensing must be installed. Use fir[...]

24 VIO NC NO C WHT REMOVED FROM C-DPS SW-8 SW-7 DPS GRA REMOVE JUMPER 034-048 UNITS 5 6 TB2 TB2 SW-1 1 2 TB2 TB2 SW-2 REMOVE JUMPER 8 9 TB2 TB2 SW-5 REMOVE JUMPER TB3 SW-3 TB3 1 5 TB2 TB2 5 9 SW-4 TB3 TB3 SW-9A 3 4 TB4 TB4 SW-9A 3 4 TB4 REMOVE JUMPER 054-104 UNITS 13 14 TB2 TB2 SW-1 7 8 TB2 TB2 SW-2 REMOVE JUMPER TB4 SW-3 TB4 1 5 TB2 TB2 13 2 SW-4 [...]

25 MODULA TING POWER EX HAUST 48FK, JK and 50F K, JK Un i ts — The tubing for the building pressure control (achieved vi a the Modulating Power Exha us t option/accessory) should sample building pressure i n the area near the entrance lobby (or other appropriate and sensitive location) so that locat ion is controlled as c losely to design pres- s[...]

26 Table 9 — Potentiometer Inputs and Ranges *Optional factory-installed economiz er is required. P otentiometer P2 is not a set p oint. † Accessory two-step dem and 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 tem perature reset is r[...]

27 DIP SWITCH NO. 1 — Supply Air Set Point (SASP) Reset T ype. Fa ctory setting is OFF . Do not change. DIP SWITCH NO. 2 — SASP Reset Enable d. Factory setting is OFF (no S A SP res et enabl ed). If SA SP reset has been installed, enable it by changing switch position to ON. DIP SWITCH NO. 3 — Economizer option. If economizer option has been [...]

28 Supply Fan Control with IGV Option — The in let guide vane option will modulate the supply fan airflow in order to maintain the stat ic pressure in t h e supply duct. The set point for duct static pressure is established at the di fferential pressure switch for the IGV control. SIZE 034-048 UNITS — The inlet guide vane di f ferential pressur[...]

29 DETERMINE VF D SET POINT — The unit of measure for the Duct Pressure set point at the VFD is output freque ncy (Hz), corresponding to the desired DP set point (DPSP) in inches of water gage (in. wg). T o conve rt desired DPSP into the VFD set point, refer to T able 13. Locate the pressure val ue in the table cl osest to the des ired D PSP for [...]

30 Table 13 — VFD Set Point (Frequenc y Command) for Duct Pressur e Table 14 — Changing the VFD Set Point (Freq uency Command)* *Choose set point f rom Table 13 acco rding to desired duc t pressure or T able 15 according to d esired building press ure. Modulating Power Exhaust (Option or Acces- sory) (48FK,JK and 50 FK,JK Units) — The Mod- ul[...]

31 Table 15 — PE VFD Set Point (Fr equency Command) for Building Pressure START UNIT T o s tart unit: 1. Close the unit-mounted ON/OFF switch (located i n the main control box). 2. Close the field-supplied a nd -installed timecl ock (or con- trol) switch (contacts l ocated at T erminals 1 a nd 2 (TB3 for 034-048, TB4 for 054-104). 3. Initializati[...]

32 Table 16 — Quick Test, Unit Configuration and Switch Che ck LEGEND *Units are not equipped wi th oil pressure switches. QUICK TEST STEP NO . NORMAL DISPLAY DESCRIPTION CONTROL SWITCH 1. 01 Type Unit — Air-Cooled VAV Configuration Header 2. 2 No. of Compressors Configuration Header 3. 2 1 No. of Unloaders (034,038,048-088) (044, 104) DIP Swit[...]

33 Table 17 — Quick Test, Thermistor a nd Potentiometer Check *Potentiometer P2 is not listed since it is not part of the quick test. I f on unit start-up a Code 83 is displayed, check poten tiometer P2. Tab le 1 8 — Quick Tes t, Output Relay Check LEGEND *K9 (fan relay) will rem ain on for duration o f quick test. † Compressor will be energi[...]

34 Table 19 — Sens or Resi stan ce Value s 3. Quick T est Steps 2.4.-3.3. — Output Relay Check These quick test steps allow mi croprocessor to check out- put signals from relay boards in unit control system. In addition, operation of all the condenser fa ns, compres- sors, and economizer (if equipped) are checked a t each step. Normal display f[...]

35 Operating Sequ ence — The sequence presented be- low assumes that the unit is equipped with heat for morning warm-up and an economizer . If t hese items are not enabled with the appropriate DIP switches, the processor bypasses these subroutines. This sequence is also based on an EPROM (erasable, programm able, read-only memory) processor chi p[...]

36 SIZE 044 UNITS — The se units have 2 compressors and 1 unloader on compressor no. 1. See Fig. 42 for com pressor 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 capacit y . The crankcas[...]

37 074, 078 U NITS 054-088 U NITS 088, 104 U NITS 104 UNITS Fig. 43 — Compone nt Arrange ment, 054- 104 Units 054, 064 U NITS[...]

38 Supply Fan Cont rol with IGV — In most V A V units, the supply fan static pressure is controlled by inlet guide vanes. The inlet guide vanes operate independe ntly from the micro- processor . The supply static pressure is controlled by a di f fer- ential pressu re switch. For example, assume that set point on supply fan differen- tial switch i[...]

39 Fig. 44 — Modulating Power Exhau st Component Locations; Si zes 034-048[...]

40 Fig. 45 — Modulating Power Exhaust Component Locations; S izes 054-104 (48FK, 50FK,JK Shown)[...]

41 Fig. 46 — Modulating Power Exha ust Return End Shee t Metal Skin Detail ; Sizes 034-0 48 Fig. 47 — Modulating Power Exhaus t Return End Sheet Metal Skin Detail; Siz es 054-104[...]

42 Table 20 — Compressor Loading and Unloading Sequences COOLING STAGE SIZE 034 UNITS Lead Circuit Lag Circuit Active Cylinders Percent Capacity Comp 1 Unloader U1 Unloader U2 Comp 2 0 OFF OFF OFF OF F 0 0 1 ON ON ON OFF 2 17 2 ON ON OFF OFF 4 33 3 ON OFF OFF OFF 6 50 4 ON ON ON ON 8 67 5 ON ON OFF ON 10 83 6 ON OFF OFF ON 12 100 COOLING STAGE SI[...]

43 Table 20 — Compressor Loading and Unloading Sequences (c ont) COOLING STAG E SIZE 044 UNITS Lead Circuit Lag Circuit Active Cyl inder s Percent Capacity Comp 1 Unloader U1 Comp 2 0 OFF OFF OFF 0 0 1 ON ON OFF 2 25 2 ON OFF OFF 4 50 3 ON ON ON 6 75 4 ON OFF ON 8 100 COOLING STAGE SIZE 048 UNITS Lead Circuit Lag Circuit Active Cylinders Percent [...]

44 Table 20 — Compressor Loading and Unloading Sequences (c ont) TROUBLESHOOTING By using t he display module, actual operating conditions of the unit are displayed while it is running. The Quick T est func- tion allows proper opera tion of compressors, compressor un- loaders, fans, and other components to be checked while unit is stopped. If an [...]

45 Table 22 — Operation Status Codes Restart Pr ocedure — Before attem pting to rest art t he machine, check the display for alarm codes to determine the cause of the shutdown. If the unit, c ircuit, or compressor stops more than onc e as a result of a safety de vice, determ ine and correct the c ause before atte mpting to start the unit agai n[...]

46 Table 23 — Diagnostic Cod es 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 r[...]

47 CODE 82: SUPPL Y-AIR TEMPERA TURE SET POINT POTENTIOMETE R F AILURE — If supply-air set point potentiometer (P1 — located on display board) fails, control will use a defa ult value. A fail ure will cause an error code of 82 to be displayed on display board when display button is pushed; alarm light wil l also be energized. A failure is deter[...]

48 The f ailure wi ll automa tica lly r ese t on ce pot entiomet er re- turns to normal. If a failure occurs, one of t he following is the probable cause: DIP Switch 4 — If th is s witch is in t he ON pos ition a nd t he accessory board is not installed (a ccessory board is standard on these units, so it should always be on t he unit). Incorrect [...]

49 Step 5 — Check Relay Board Outputs from the Processor Board — This step involves checking the output signals from relays K1-K3 on the relay boa rd. 1. T urn power to OFF position. 2. Connect negative test probe to TP19 (meter st ill set to dc). 3. T urn switch to ON position and enter Quick T est mode. 4. Connect positive test probe to t erm[...]

50 6. If voltage is not correct, replace processor board. Step 7 — Potentiometer Connectio n Checkout 1. T urn power to OFF position. 2. Remove plug connection from pin terminal strip J3. 3. Connect negative met er lead to terminal 2 of J3. 4. T urn switch to O N position and go into Quick T est mode. 5. Place the other lead on termi nals shown i[...]

51 REL A Y B OARD TROUBLES HOOTING — The rel ay board contains 13 electromechanical relays. The small relays ar e 24 vac, and the large relays are 1 15 vac. These relays are con- trolled by the processor through the ribbon cable attached to the relay board. The following procedure c an be used to check out t he oper- ation of the relays. T o do t[...]

52 T est under the fol lowing conditions: • No power to IN1 or IN2 T erminal 1 to 2 should r ead 4.5 vdc ± 0.1 v T erminal 2 to 3 should r ead 5.0 vdc ± 0.1 v • Power to IN2 or to both IN1 a nd IN2, and P2 set at 24% T erminal 1 to 2 s hould read 1 .5 vdc ± 0.1 v NOTE: V oltage should vary between 0.5 vdc and 2.5 vdc as the setting of P2 is [...]

53 ST AN DARD T RANSD UCER CO NTROL — The VFD mon- itors and controls duct pressure (DP) via a differential pressure transducer . The pressure trans ducer is locate d in the auxilia ry control box (034-048 units) or in the supply fan compartment (see Fig. 34). The pressure transducer ’s l ow pressure referenc e port is connected to th e outside[...]

54 Tab le 3 0 — Carrier Default Program Parameter Values (Supply Fan VFD) *These settings differ from t he Toshiba defaults and are required for Carrier applications. NOTE: To res tore original factory settings, change tY P to 6 in Setup mode (SEtP) . This restores the VFD original fact ory settin gs. PARAMETER GROUP PARAMETER DEFAULT VALUE SEtP [...]

55 VFD OPERA TIONAL ST A TUS — The VFD s co n t ai n ex- tensive self-diagnostic functions which are a ccessed through the VFD display panel (locat ed on the front of t he V FD or at a remote location when the acces sory remote display package has been installed). When power is first supplied to the VFD, the display auto- matically starts with th[...]

56 POWER EXHAUST F AN MOTOR NO. 1 OVERLOAD PR O T EC T IO N — The VFD provides operating overload protection for the supply fan motor . The fac tory has pro- grammed 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 ori ginal factory selecti[...]

57 POWER EXHAUST VFD OPERA TION — Wh e n tr oubl e- shooting the power exhaust VFD, check fi rst 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 installe d from terminal s ST-CC (factory supplied) [...]

58 LEGEND AND NOTES FOR FIG. 57 NOTES: 1.Connect TR AN1 to for 460 v units. Connect to for 230 v units. If 208/230 v units are run with a 208 v power supply con- nect to . 2.Connect T RAN2 to BL K 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 mu[...]

59 Fig. 57 — Typical Wiring Schematic; 48FK,JK and 50FK,FY,JK,JY Units (054-074 Shown)[...]

60 Fig. 57 — Typic al Wiring Schematic; 48FK,JK and 50FK,FY,JK,JY Unit s (054-074 Shown) (cont)[...]

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Manufactu rer reserves th e right to d iscontinue, o r change at any time, spec ifications or designs without notice and wit hout inc urring obliga tions. PC 111 Catalog No. 534 -763 Printed in U .S.A. Form 48/50F ,J-3T Pg 62 3-00 Repl aces: 48/50 F,J-1T Book 1 1 Tab 1a 1b Copyright 2000 Carrier Corpo ration SERVICE TRAINING Packaged Servi ce T rai[...]

CL-1 START-UP CHECKLIST MODEL NO.: _____________________________________ DA TE: ___________________________________________ SERIAL NO.: ______________________________________ TECHNICIAN: _____________________________________ I. PRE-START-UP: VERIFY THA T UNIT IS LEVEL VERIFY THA T ALL P A CKING MA TERIALS HA VE BEEN REMO VED FROM U NIT LOOSE N AL L[...]

Manufactu rer reserves th e right to d iscontinue, o r change at any time, spec ifications or designs without notice and wit hout inc urring obliga tions. PC 111 Catalog No. 534 -763 Printed in U.S.A. Form 4 8/50F,J-3 T Pg CL -2 3-00 Replaces : 48/50 F,J-1T Book 1 1 Tab 1a 1b Copyright 2000 Carrier Corpo ration - - - - - - - - - - - - - - - - - - -[...]