Carrier 50ZP036300 User manual

50ZP
10 SEER
Single Packaged Air Conditioner
3-—5 Nominal Tons (Sizes 036—060)
turn to the experts
UNIT SHIPPED DRY, CHARGE WITH R-—22
REFRIGERANT BEFORE START—UP
Installation
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS ........ 0.00.00 ce eee eee 1
General 2... eee eee 2
RECEIVING AND INSTALLATION ...............005 5-9
Check Equipment .. 0.0.0... 00. eee eee 5
Identify Unit 2... ene 5
Inspect Shipment ..... 0.0.0... . eee eee 5
Provide Unit Support .. 2.0.0... eee ee eee 5
Slab Mount 2.00.0... 0. 0c eee 5
Provide Clearances 2.0... 0... eee eee 5
Place Unit 2.0.0... eee ene 5
Select and Install Ductwork... 0... ee 5
Install Flanges for Ductwork Connections (SOZP060 only) . 5
Converting Horizontal Discharge Units to Downflow (Vertical)
Discharge 2.0.0... ee eee eens 6
Charging Unit .. 0.0... 0... ee 6
Provide for Condensate Disposal .. 2.0.0.0... 0.000.000 05 6
Install Electrical Connections ©... 0.0... eee 8
High Voltage Connections .. 0.0.0... 0.0.0 e eevee eee 8
Routing Power Leads into Unit... 0.0.0.0... 0. 0.00000- 8
Connecting Ground Lead to Unit Ground .............. 8
Routing Control Power Wires . 2.0.0.0... 0.000000 ee eee 8
Special Procedures for 208-V Operation ............... 9
PRE-START-UP .. 0.2... eee 9
START-UP... ee 10-11
MAINTENANCE ..... 0.0.00 .0. 000000 eee eee 11-13
TROUBLESHOOTING .............0.0 000000 eee 13
START-UP CHECKLIST ................0. 0.0 .000005 13
NOTE: TO INSTALLER - Before the installation , READ
THESE INSTRUCTIONS CAREFULLY AND COMPLETELY.
Also, make sure the User’s Manual is left with the unit after
installation.
SAFETY CONSIDERATIONS
Improper installation adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory-authorized kits or accessories
when modifying this product Refer to the individual instructions
packaged with the kits or accessories when installing.
Instructions
2
°
e
L
Mf
MLL
ELE
LLL
a
fe
ML
|
LL
AKI
G
AE
Aa
MMM
AT
AI
AUC
LMM
Mt
\
ss
00001
Fig. 1 - 50ZP (Size 036 Shown)
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have a fire extinguisher available. Read these instructions
thoroughly and follow ail warnings or cautions included in
literature and attached to the unit. Consult local building codes, the
current editions of the National Electrical Code (NEC) NFPA 70.
In Canada refer to the current editions of the Canadian Electrical
Code CSA C22.1.
Recognize safety information. This is the safety-alert symbol AY
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand
these signal words; DANGER, WARNING, and CAUTION. These
words are used with the safety-alert symbol. DANGER identifies
the most serious hazards which will result in severe personal injury
or death. WARNING signifies hazards which could result in
personal injury or death. CAUTION is used to identify unsafe
practices which may result in minor personal injury or product and
property damage. NOTE is used to highlight suggestions which
will result in enhanced installation, reliability, or operation.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be
more than one disconnect switch.

11.57 16.06
[294.0] [408.0]
p=
REQUIRED CLEARANCE TO COMBUSTIBLE MATL.
TOP OF UNIT
DUCT SIDE OF UNIT...
SIDE OPPOSITE DUCTS
BOTTOM OF UNIT
INCHES [mm]
NEC. REQUIRED CLEARANCES.
INCHES [rnm]
BETWEEN UNITS, POWER ENTRY SIDE... ee 42,00 [1066.8]
° UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE .36.00 [914.0]
UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE......000000... 42,00 [1066.8]
9.75 REQUIRED CLEARANCE FOR OPERATION AND SERVICING
[247.6] . INCHES [m m|
CONDENSER COIL ACCESS SIDE... [
POWER ENTRY SIDE 00 [
ft (EXCEPT FOR NEC REQUIREMENTS)
UNIT TOP 00 [1219.2]
SIDE OPPOSITE DUCTS 0 [762.0]
14.0 DIA. LEGEND
[356.0]
REAR VIEW DUCT OPENINGS
NEC — National Electrical Code
50.98 NOTES:
[1295.0] . Clearances must be maintained to prevent recirculation of air from outdoor
BOTTOM OF UNIT fan discharge, with the exception of the condenser coil (36.00 in [914.0 mm], A
removable fence or barricade requires no clearance,
EVAP, COIL i ¢ 2, Dimensions are in inches. Dimensions in [] are in millimeters.
COND H
COIL
oN
rt m m m
31.99
[812.5]
BOTTOM OF UNIT
<< BLOWER, CONTROL BOX AND EVAP.
ACCESS PANEL
COMPRESSOR PANEL
FIELD ENTRY TO
SERVICE PORTS
COIL
272 21.61
[69.0] [594.0]
1.75 DIA.
[44.5]
17.60
[447.0]
, . h . . i
La. 20
[30.6] 19.61 2.50
LEFT SIDE VIEW FRONT VIEW [498.1] [63.5}
1.0540 1.DB x 50 DEEP
[26.772 x 12.7] RIGHT SIDE VIEW
Co00002
Fig. 2 - Base Unit Dimensions, 50ZP036
UNIT WEIGHT CENTER OF GRAVITY IN. (MM)
UNIT ELECTRICAL CHARACTERISTICS
ib kg X Y Zz
50ZP036 208/230-1-60, 208/230-3-60 234 406 (3:00) (0.00) (0.50)
bo

__ 11.57
[294.0]
Eos
REQUIRED CLEARANCE TO COMBUSTIBLE MATL.
TOP OF UNIT...
DUCT SIDE OF
SIDE OPPOSITE DU:
BOTTOM OF UNIT........
INCHES [mm]
2000
NEC. REQUIRED CLEARANCES.
INCHES [mm]
BETWEEN UNITS, POWER ENTRY SIDE.. 2.00 [1066.8}
UNIT AND UNGROUNDED SURFACES, POWER ENTRY ‘SIDE 38. 00 [914.0]
UNIT AND BLOCK OR CONCRETE WALLS AND OTHE
GROUNDED SURFACES, POWER ENTRY GE 42.00 [1066.8}
REQUIRED CLEARANCE FOR OPERATION AND SERVICING
INCHES [mm]
CONDENSER COIL ACCESS SIDE
POWER ENTRY SIDE
(EXCEPT FOR NEC REQUIREMENT
UNIT TOP
SIDE OPPOSITE DUCT:
30.00 [762.0]
«30.00 [762.0}
48.00 [1219.2]
9.75 0.00 [762.0]
[247.6] LEGEND
J # NEC - National Electrical Code
14.0 DIA. NOTES:
REAR VIEW [356.0] 1. Clearances must be maintained to prevent recirculation of air from outdoor-
DUCT OPENINGS fan discharge, with the exception of the condenser coil (36.00 in [914.0 mm]. A
removable fence or barricade requires no clearance.
2. Dimensions are in inches. Dimensions in [] are in millimeters.
50.98
[1295.0]
BOTTOM OF UNIT
EVAPORATOR
COIL
CONDENSER | b
COIL L
J
TT
||
|
Lota F
||
If 31.99
| i [812.5]
| iy t6 BOTTOM OF UNIT
|
|| ~
lI
e ils
COM
\
BLOWER, CONTROL BOX AND
EVAPORATOR COIL ACCESS PANEL
2.72 21.64
[69.0] [549.0]
0.88 DIA.
[22.2]
\ .
\_1.75 DIA. -
25.60. |
[650.2] [44.5]
, || .
beg / 19.61 2.50
_f [498.1] [63.5]
LEFT SIDE VIEW FRONT VIEW 1.0540 1.D. x .50 DEEP
[26.772 x 12.7] RIGHT SIDE VIEW
C00003
Fig. 3 - Base Unit Dimensions, 50ZP048
UNIT WEIGHT CENTER OF GRAVITY IN. (MM)
UNIT ELECTRICAL CHARACTERISTICS
ib kg X Y Z
50ZP048 208/230-1-60, 208/230-3-60 308 440 (3:00) (0.00) (12.60)

DIMENSIONS IN [] ARE IN mm
13.89
— [352.7] REQUIRED CLEARANCE TO COMBUSTIBLE MATL.
4.63 _. 13.89 e (e211 INCHES [mm]
[117.6]
[352.8]
153.7]
TOP
OF
UNIT
0
DUCT SIDE OF UNIT.. 0
SIDE OPPOSITE DUCTS... 0
BOTTOM OF UNIT 0
P ia = NEC. REQUIRED CLEARANCES.
INCHES [mm]
BETWEEN UNITS, POWER ENTRY SIDE... eee 42,00 [1066.8]
UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE .36.00 [914.0]
| UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE... 42.00 [1066.8]
I ce = 3 do REQUIRED CLEARANCE FOR OPERATION AND SERVICING
27-80 INCHES [mm]
: - [708.0] CONDENSER COIL ACCESS SIDE... ...30.00 [762.0]
: POWER ENTRY SIDE »,..30,00 [762.0]
13.88 4 (EXCEPT FOR NEC REQUIREMENTS)
[352.5] 7 4] UNIT TOP 48.00 [1219.2]
i SIDE OPPOSITE DUCTS »,..30.00 [762.0]
i . . |:
5.44 ; a LEGEND
* - i i NEC — National Electrical Code
8.50 NOTES:
88.9 .
REAR VIEW f ] 1. Clearances must be maintained to prevent recirculation of air from outdoor-
fan discharge, with the exception of the condenser coil (86.00 in [914.0 mm]. A
removable fence or barricade requires no clearance.
50.98 2. Dimensions are in inches. Dimensions in [] are in millimeters.
[1295.0]
BOTTOM OF UNIT
31.99
[812.5]
BOTTCK OF UNIT
NN
NS
S
SN,
N
. AND EVAP. COIL
27200 21.61 -
69.0 [549.0]
COMPRESSOR PANEL \
F
5 1.75 DIA. 232) iA.
[44.5] \ ,
\ i
_ a
oN
N/ \
34.13 [*
[867.0] 2960 |
[751.8]
1
1.20
LEFT
SIDE
VIEW
FRONT
VIEW
20S
|
geet
00
[25.4]
1,0540 1.D. x .50 DEEP~
(26.772 x 12.7] RIGHT SIDE VIEW
coo004
Fig. 4 - Base Unit Dimensions, 50ZP060
UNIT WEIGHT CENTER OF GRAVITY IN. (MM)
UNIT ELECTRICAL CHARACTERISTICS
ib kg X Y Z
50ZP060 208/230-1-60, 208/230-3-60 344 156 (3:00) (0.00) (3:00)

4 CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate clothing.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing
residential construction practices. We require these instructions as a
minimum for a safe installation.
GENERAL — 50ZP cooling units are fully self-contained and
designed for outdoor installation. See Fig. 1. As shown in Fig. 2-4,
units are shipped in a horizontal-discharge configuration for
installation on a ground-level slab. All units can be
field-converted to downflow discharge configurations for rooftop
applications with a field-supplied plenum
RECEIVING AND INSTALLATION
Step 1 — Check Equipment
IDENTIFY UNIT — The unit model number and serial number
are stamped on the unit identification plate. Check this information
against shipping papers.
INSPECT SHIPMENT — Inspect for shipping damage while unit
is still on shipping pallet. If unit appears to be damaged or is torn
loose from its securing points, have it examined by transportation
inspectors before removal. Forward claim papers directly to
transportation company. Manufacturer is not responsible for any
damage incurred in transit.
Check all items against shipping list. Immediately notify the
nearest Carrier Air Conditioning office if any item is missing.
To prevent loss or damage, leave all parts in original packages until
installation.
Step 2 — Provide Unit Support
SLAB MOUNT — Place the unit on a rigid, level surface, suitable
to support the unit weight. The flat surface should extend
approximately 2-in. (51 mm) beyond the unit casing on the 2
sides. The duct connection side and condensate drain connection
sides should be flush with the edge of the flat surface. A concrete
pad or a suitable fiberglass mounting pad is recommended.
A 6-in. (152 mm) wide gravel apron should be used around the
flat surface to prevent airflow blockage by grass or shrubs. Do not
secure the unit to the flat surface except where required by local
codes.
The unit should be level to within 1/4 in. (6 mm). This is necessary
for the unit drain to function properly.
Step 3 — Provide Clearances
The required minimum service clearances and clearances to
combustibles are shown in Fig. 2-4. Adequate ventilation and
condenser air must be provided.
The condenser fan pulls air through the condenser coil and
discharges it through the fan on the top cover. Be sure that the fan
discharge does not recirculate to the condenser coil. Do not locate
the unit in either a corner or under an overhead obstruction. The
minimum clearance under a partial overhang (such as a normal
house overhang) is 48 in. (1219 mm) above the unit top. The
maximum horizontal extension of a partial overhang must not
exceed 48 in. (1219 mm).
Do not place the unit where water, ice, or snow from an overhang
or roof will damage or flood the unit. The unit may be installed on
wood flooring or on Class A, B, or C roof covering materials.
Step 4 — Place Unit
Unit can be moved with the handholds provided in the unit
basepan. Refer to Table 1 for operating weights. Use extreme
caution to prevent damage when moving the unit. Unit must
remain in an upright position during all moving operations. The
unit must be level for proper condensate drainage; the
ground-level pad must be level before setting the unit in place.
When a field-fabricated support is used, be sure that the support is
level and that it properly supports the unit.
Step 5 — Select and Install Ductwork
The design and installation of the duct system must be in
accordance with:
* the standards of the NFPA (National Fire Protection Association)
for installation of nonresidence-type air conditioning and
ventilating systems;
¢ NFPA9OA or residence-type, NFPA90B; and/or local codes and
residence-type, NFPA 90B;
¢ and/or local codes and ordinances.
Select and size ductwork, supply-air registers and return-air grilles
according to ASHRAE (American Society of Heating,
Refrigeration, and Air Conditioning Engineers) recommendations.
Use the duct flanges provided on the supply- and return-air
openings on the side of the unit. See Fig. 2-4 for connection sizes
and locations. The 14-in. (356 mm) round duct collars (size
036-048 units) are shipped inside the unit attached to the indoor
blower. They are field-installed and must be removed from the
indoor cavity prior to start-up, even if they are not used for
installation.
INSTALL FLANGES FOR DUCTWORK CONNECTIONS
(S0ZP060 ONLY) — The 50ZP060 units are shipped with flanges
which must be field-installed on the unit.
To install unit flanges:
1. Five pieces of flange are shipped on the return-air opening
of the unit. Remove the flanges from the shipping position.
See Fig. 5. Screws are field-supplied.
bo . One piece of flange is used as it is shipped (straight). Bend
the other 4 pieces at right angles.
3. Install the straight flange on the right side of the return-air
opening in holes provided. See Fig. 6. Flanges should stick
out from unit to allow for connection of ductwork.
4. Install 2 hand-formed flanges onto return air opening in
holes provided to form a rectangle around the return air
opening.
5. Install remaining 2 hand-formed flanges around discharge
air opening in holes provided.
6. Ductwork can now be attached to flanges.
When designing and installing ductwork, consider the following:
UNIT DAMAGE HAZARD
Failure to follow this caution may result in damage to unit
components.
When connecting ductwork to units, do not drill deeper
than 3/4 in. (19.1 mm) in shaded area shown in Fig. 7 or
coil may be damaged.
e¢ All units should have field-supplied filters installed in the
return-air side of the unit. Recommended sizes for filters are
shown in Table 1.
¢ Avoid abrupt duct size increases and reductions. Abrupt change
in duct size adversely affects air performance. Use flexible
connectors between ductwork and unit to prevent transmission of
vibration. Use suitable gaskets to ensure weathertight and airtight
seal.
5

¢ Size ductwork for cooling air quantity (CFM).
¢ Insulate and weatherproof all external ductwork. Insulate and
cover with a vapor barrier all ductwork passing through
conditioned spaces. Follow latest Sheet Metal and Air
Conditioning Contractors National Association (SMACNA) and
Air Conditioning Contractors Association (ACCA) minimum
installation standards for residential heating and air conditioning
systems.
¢ Secure all ducts to building structure. Flash, weatherproof, and
vibration-isolate duct openings in wall or roof according to good
construction practices.
Fig. 8 shows a typical duct system with 5OZP unit installed.
FIVE PIECES OF DUCT
FLANGE ATTACHED
HERE FOR SHIPMENT
00005
Fig. 5 - Shipping Location of Duct Flanges (Size 060 Only)
00006
Fig. 6 - Flanges Installed on 50ZP060 Units
Converting Horizontal Discharge Units to Downflow
(Vertical) Discharge
CE UA Le:
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before performing service or maintenance operations on the
system, turn off main power to unit and install lockout tag.
There may be more than one disconnect switch.
Units are dedicated side supply products. They are not convertible
to vertical air supply. A field-supplied plenum must be used to
convert to vertical air discharge.
Step 6 — Charging Unit
Unit is shipped with a nitrogen holding charge only. Slowly release
nitrogen charge from unit using service gages and using a vacuum
pump evacuate unit to 500 microns or lower. To locate charging
ports, remove top panel which provides access to control box and
blower. Charging ports are located under top panel. Charge unit by
weight using an electronic scale. R-22 charge quantity can be
found in table 1 and on unit rating plate. Do not over charge.
Step 7 — Provide for Condensate Disposal
NOTE: Be sure that condensate-water disposal methods comply
with local codes, restrictions, and practices.
Unit removes condensate through a 1-3/64 -in. (26.6 mm) ID hole
which is located at the end of the unit. See Fig. 2-4 for location of
condensate connection.
19.17" 3.92" se)
(486.9 mm) (99.6 mm)
a
nuvi
EY
aN
ay
NY,
Ae
i
SSS
p
i
aN
HAA
CD
C00007
Fig. 7 - Area Not to Be Drilled More Than 3/4-in.
[@[s) THERMOSTAT
"se DISCONNECT
PER NEC*
ie COMPOSITE
pect RUST-PROOF —
col RS BASEPAN ——
~ CONDENSATE
CONNECTION
mmm Power Wiring
Control Wiring
»> Condenser Airflow
: > Evaporator Airflow
*Separate disconnect per NEC
(National Electrical Code)
A10018
Fig. 8 - Typical Installation

Table 1 - Physical Data
UNIT 50ZP 036 048 060
SHIPPING WEIGHT (Ibs) 278 352 388
(kg) 126 160 176
COMPRESSOR TYPE Reciprocating Scroll Reciprocating
REFRIGERANT R22
Charge (Ib) 4.2 5.5 6.9
(kg) 1.9 25 3.4
REFRIGERANT METERING DEVICE Acutrol™ Device Piston
CONDENSER COIL Copper Tubes, Aluminum Plate Fins
Rows...Fins/in. 2.17 2.17 2.17
Face Area (sq ft) 6.2 8.6 10.7
CONDENSER-FAN Propeller Propeller
MOTOR CFM 2000 2600 2800
Nominal Rpm 1100 1100 1100
Motor Hp 1/4 1/4 1/4
Diameter (in.) 20 20 20
(mm) 508 508 508
EVAPORATOR COIL Copper Tubes, Aluminum Plate Fins
Rows...Fins/in. 3...15 3...15 4.15
Face Area (sq ft) 3.1 4.3 49
EVAPORATOR FAN MOTOR Direct Drive
Blower Motor Size (in.) 10x8 10x9 10x10
(mm) 254 x 203 254 x 229 254 x 254
Nominal CFM 1200 1650 1700
Rpm Range 800-1050 1000-1100 950-1100
Number of Speeds 3 2 3
Factory Speed Setting Low Low Low
Motor Hp 1/2 3/4 1
CONNECTING DUCT SIZES Round Square
Supply Air (in.) 14 13.9x 13.9
(mm) 356 353 x 353
Return Air (in.) 14 13.9 x 27.8
(mm) 356 353 x 706
FIELD-SUPPLIED RETURN-AIR FILTERt
Throwaway (in.) 24 x 24 24 x 30
(mm) 610 x 610 610 x 762
tRequired filter sizes shown are based on the AHRI (Air Conditioning, Heating and Refrigeration Institute) rated airflow at a velocity of 300 ft/min for throwaway
type or 450 ft/min for high capacity type. Recommended filters are 1—in. (25 mm) thick.
1” (25 mm) MIN,
V
TRAP
OUTLET Y
2” (51 mm) MIN.
A08001
Condensate Trap (Using Tubing)
\ PN
l-in. 5 mm) min. i
TRAP
OUTLET
<¢—
A
2-in. (51 mm) min.
t
A09052
Condensate Trap (Using PVC Piping)
Fig. 9 - Condensate Trap
HIGH-VOLTAGE ~=LOW-VOLTAGE
POWER WIRING WIRING ENTRY
ENTRY HOLE HOLE
Fig. 10 - Unit Electrical Connection Entry Holes
00010

Condensate water can be drained directly onto the roof in rooftop
installations (where permitted) or onto a gravel apron in ground
level installations. Install a field-supplied condensate trap at end of
condensate connection to ensure proper drainage. Make sure that
the outlet of the trap is at least 1 in. (25 mm) lower than the
drain-pan condensate connection to prevent the pan from
overflowing. See Fig. 9. Prime the trap with water. When using a
gravel apron, make sure it slopes away from the unit.
If the installation requires draining the condensate water away from
the unit, install a 2-in. (51 mm) trap using a 3/4 -in. OD tubing or
pipe. See Fig. 9. Make sure that the outlet of the trap is at least 1 in.
(25 mm) lower than the unit drain-pan condensate connection to
prevent the pan from overflowing. Prime the trap with water.
Connect a drain tube using a minimum of 3/4 -in. PVC, 3/4 -in.
CPVC, or 3/4 -in. copper pipe (all field supplied). Do not
undersize the tube. Pitch the drain tube downward at a slope of at
least 1 in. (25 mm) for every 10 ft (3 m) of horizontal run. Be sure
to check the drain tube for leaks. Prime trap at the beginning of the
cooling season start-up. Allowable glues for condensate trap
connection are: Standard ABS, CPVC, or PVC cement.
Step 8 — Install Electrical Connections
4 WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
The unit cabinet must have an uninterrupted, unbroken
electrical ground to minimize the possibility of personal
injury if an electrical fault should occur. This ground may
consist of an electrical wire connected to the unit ground
screw in the control compartment, or conduit approved for
electrical ground when installed in accordance with NEC,
ANSI/NFPA 70 American National Standards Institute/
National Fire Protection Association (latest edition) (in
Canada, Canadian Electrical Code CSA C22.1) and local
electrical codes.
4 CAUTION
UNIT COMPONENT DAMAGE HAZARD
Failure to follow this caution may result in damage to the
unit being installed.
1. Make all electrical connections in accordance with NEC
ANSI/NFPA 70 (latest edition) and local electrical codes
governing such wiring. In Canada, all electrical
connections must be in accordance with CSA standard
C22.1 Canadian Electrical Code Part 1 and applicable
local codes. Refer to unit wiring diagram.
bo . Use only copper conductor for connections between
field-supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
3. Be sure that high-voltage power to unit is within
operating voltage range indicated on unit rating plate. On
3-phase units, ensure phases are balanced within 2
percent. Consult local power company for correction of
improper voltage and/or phase imbalance.
4. Do not damage internal components when drilling
through any panel to mount electrical hardware, conduit,
etc.
HIGH-VOLTAGE CONNECTIONS — The unit must have a
separate electrical service with a field-supplied, waterproof
disconnect switch mounted at, or within sight from the unit. Refer
to the unit rating plate for maximum fuse/circuit breaker size and
minimum circuit amps (ampacity) for wire sizing.
The field-supplied disconnect may be mounted on the unit over
the high-voltage inlet hole. See Fig. 2-4.
Operation of unit on improper line voltage constitutes abuse and
may cause unit damage that could affect warranty.
ROUTING POWER LEADS INTO UNIT — Use only copper
wire between disconnect and unit. The high-voltage leads should
be in a conduit until they enter the unit; conduit termination at the
unit must be watertight. Run the high-voltage leads through the
hole on the contro! box side of the unit (see Fig. 10 for location).
When the leads are inside the unit, run leads to the control box
(Fig. 11). For single-phase units, connect leads to the black and
yellow wires; for 3-phase units, connect the leads to the black,
yellow, and blue wires (see Fig. 12).
CONNECTING GROUND LEAD TO UNIT GROUND — Refer
to Fig. 11 and 12. Connect the ground lead to the chassis using the
unit ground lug in the control box.
COMPRESSOR
CONTACTOR
TRANSFORMER
GROUND INDOOR OUTDOOR FAN MOTOR HIGH
LUG FAN AND COMPRESSOR VOLTAGE
RELAY START CAPACITOR LEADS
At10019
Fig. 11 - Control Box Wiring
UNIT GROUND
GROUND
~~ Teap f
SINGLE-PHASE |) 20 dg Ke
3-PHASE CONNECTIONS
CONNECTIONS JTODISCONNECT), _ A YEL-
TO DISCONNECT |PER NEC
PER NEC
L------4 ~ BLu-
C00012
Fig. 12 - Line Power Connections
ROUTING CONTROL POWER WIRES — Form a drip-loop
with the thermostat leads before routing them into the unit. Route
the thermostat leads through grommeted hole provided in unit (see
Fig. 10) into unit control box. Connect thermostat leads to unit
control power leads as shown in Fig. 13.
Route thermostat wires through grommet providing a drip-loop at
the panel. Connect low-voltage leads to the thermostat as shown in
Fig. 13.
The unit transformer supplies 24-v power for complete system.
Transformer is factory wired for 230-v operation. If supply voltage
is 208 v, rewire transformer primary as described in the Special
Procedures for 208-v Operation section below.

YEL—+
OOO0e
‘ [
UNIT CONTROL BOX
THERMOSTAT
AND SUBBASE
c00018
Fig. 13 - Control Connections
SPECIAL PROCEDURES FOR 208-V OPERATION
4 WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before performing service or maintenance operations on the
system, turn off main power to unit and install lockout tag.
There may be more than one disconnect switch.
1. Remove wirenut from connection of ORG wire to BLK
wire. Disconnect the ORG transformer-primary lead from
the BLK wire. Save wirenut. See unit wiring label.
bo . Remove the wirenut from the terminal on the end of the
RED transformer-primary lead.
3. Save the wirenut.
4. Connect the RED lead to the BLK wire from which the
ORG lead was disconnected. Insulate with wirenut from
Step 1.
5. Using the wirenut removed from the RED lead, insulate the
loose terminal on the ORG lead.
6. Wrap the wirenuts with electrical tape so that the metal
terminals cannot be seen.
Indoor blower-motor speeds may need to be changed for 208-v
operation. Refer to Indoor Airflow and Airflow Adjustments
section.
PRE-START-UP
CE UA Le:
FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD
Failure to follow this warning could result in personal
injury or death and/or property damage.
1. Follow recognized safety practices and wear protective
goggles when checking or servicing refrigerant system.
bo . Relieve and recover all refrigerant from system before
touching or disturbing anything inside terminal box if
refrigerant leak is suspected around compressor
terminals.
3. Never attempt to repair soldered connection while
refrigerant system is under pressure.
4. Do not use torch to remove any component. System
contains oil and refrigerant under pressure.
5. To remove a component, wear protective goggles and
proceed as follows:
a. Shut off electrical power to unit and install
lockout tag.
b. Relieve and reclaim ail refrigerant from system
using both high- and low-pressure ports.
c. Cut component connecting tubing with tubing
cutter and remove component from unit.
d. Carefully unsweat remaining tubing stubs when
necessary. Oil can ignite when exposed to flame.
Use the Start-Up Checklist supplied at the end of this book and
proceed as follows to inspect and prepare the unit for initial
start-up:
1. Remove all access panels.
2. Read and follow instructions on all DANGER, WARNING,
CAUTION, and INFORMATION labels attached to, or
shipped with, unit. Make the following inspections:
a. Inspect for shipping and handling damages such as
broken lines, loose parts, disconnected wires, etc.
b. Inspect for oil at all refrigerant tubing connections and
on unit base. Detecting oil generally indicates a
refrigerant leak. Leak-test all refrigerant tubing
connections using electronic leak detector, or
liquid-soap solution. If a refrigerant leak is detected, see
following Check for Refrigerant Leaks section.
c. Inspect all field- and factory-wiring connections. Be
sure that connections are completed and tight.
d. Inspect coil fins. If damaged during shipping and
handling, carefully straighten fins with a fin comb.
3. Verify the following conditions:
a. Make sure that outdoor-fan blade is correctly positioned
in fan orifice. Top edge of blade should be 3.125 in.
(79.4 mm) down from condenser outlet grille. See
Condenser Fan section.
b. Make sure that air filter is in place.
c. Make sure that condensate drain pan and trap are filled
with water to ensure proper drainage.
d. Make sure that all tools and miscellaneous loose parts
have been removed.

START-UP
Use the Start-Up Checklist supplied at the end of this book, and
proceed as follows:
Step 1 — Check for Refrigerant Leaks
LOCATE AND REPAIR REFRIGERANT LEAKS AND
CHARGE THE UNIT AS FOLLOWS:
1. Using both high- and low-pressure ports, locate leaks and
reclaim remaining refrigerant to relieve system pressure.
2. Repair leak following accepted practices.
NOTE: Instail a filter drier whenever the system has been opened
for repair.
3. Check system for leaks using an approved method.
4. Evacuate refrigerant system and reclaim refrigerant if no
additional leaks are found.
5. Charge unit with R-22 refrigerant, using a
volumetric-charging cylinder or accurate scale. Refer to
unit rating plate for required charge. Be sure to add extra
refrigerant to compensate for internal volume of
field-installed filter drier.
Step 2 — Start-Up Cooling Section and Make
Adjustments
CHECKING COOLING CONTROL OPERATION — Start and
check the unit for proper cooling control operation as follows:
1. Place room thermostat SYSTEM switch in OFF position.
Observe that blower motor starts when FAN switch is
placed in ON position and shuts down when FAN switch is
placed in AUTO position.
. Place SYSTEM switch in COOL position and FAN switch
in AUTO position. Set cooling control below room
temperature. Observe that compressor, condenser fan, and
evaporator blower motors start. Observe that cooling cycle
shuts down when control setting is satisfied.
bo
3. When using an automatic changeover room thermostat,
place both SYSTEM and FAN switches in AUTO.
positions. Observe that unit operates in Cooling mode when
temperature control is set to “call for cooling” (below room
temperature).
Step 3 — Refrigerant Charge
Amount of refrigerant charge is listed on unit nameplate (also refer
to Table 1). Refer to Carrier Refrigerant Service Techniques
Manual, Refrigerants section.
Unit panels must be in place when unit is operating during
charging procedure.
NO CHARGE — Use standard evacuating techniques. After
evacuating system, weigh in the specified amount of refrigerant
(refer to Table 1).
LOW CHARGE COOLING — Use Cooling Charging Charts, Fig.
14-16. Vary refrigerant until the conditions of the appropriate chart
are met. Note that charging charts are different from the type
normally used. Charts are based on charging the units to the correct
superheat for the various operating conditions. Accurate pressure
gage and temperature sensing device are required.
To measure suction pressure, perform the following:
1. Connect the pressure gage to the service port on the suction
line.
2. Mount the temperature sensing device on the suction line
and insulate it so that outdoor ambient temperature does not
affect the reading. Indoor-air cfm must be within the
normal operating range of the unit.
TO USE COOLING CHARGING CHARTS
1. Take the outdoor ambient temperature and read the suction
pressure gage.
bo . Refer to appropriate chart to determine what the suction
temperature should be.
an . If suction temperature is high, add refrigerant. If suction
temperature is low, carefully recover some of the charge.
4. Recheck the suction pressure as charge is adjusted.
EXAMPLE: (Fig. 14)
Outdoor Temperature «00... cee 85°F (29°C)
Suction Pressure ....... ccs 80 psig
Suction Temperature should be ........... 70°F (21°C)
(Suction Temperature may vary +5° F, [2.8°C])
If Chargemaster© charging device is used, temperature and
pressure readings must be accomplished using the charging
chart.
Step 4 — Indoor Airflow and Airflow Adjust-
ments
NOTE: | For cooling operation, the recommended airflow is 350
to 450 CFM for each 12,000 Btuh of rated cooling capacity.
Table 2 shows dry coil air delivery for horizontal discharge units.
Tables 3-4 show pressure drops.
NOTE: Be sure that all supply- and return-air grilles are open,
free from obstructions, and adjusted properly.
CUANDO:
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Disconnect electrical power to the unit and install lockout
tag before changing blower speed. There may be more than
one disconnect switch.
Airflow can be changed by changing the lead connections of the
blower motor.
Units 50ZP036,048, and 060 blower motors are factory wired for
low speed operation.
FOR 208/230-V — The motor leads are color-coded as follows:
3-SPEED
black = high speed
2-SPEED
black = high speed
blue = medium speed
red = low speed red = low speed
To change the speed of the blower motor (BM), remove the fan
motor speed leg lead from the indoor (evaporator) fan relay (IFR)
and replace with lead for desired blower motor speed. Insulate the
removed lead to avoid contact with chassis parts.
10