Carrier 33CSZRP-06 User manual

Installation Instructions
Part Number 33CSZRP-06
IMPORTANT: Read entire instructions before starting
the installation.
PACKAGE CONTENTS
ITEM QUANTITY
Universal Relay Pack 1
Screws 4
Wire Nuts 11
SAFETY CONSIDERATIONS
Read and follow manufacturer instructions carefully. Fol-
low all local electrical codes during installation. All wiring
must conform to local and national electrical codes. Im-
proper wiring or installation may damage relay pack.
Recognize safety information. This is the safety alert sym-
bol . When the safety alert symbol is present on equip-
ment or in the instruction manual, be alert to the potential
for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety alert sym-
bol. DANGER identifies the most serious hazards which will
result in severe personal injury or death. WARNING signi-
fies a hazard which could result in personal injury or death.
CAUTION is used to identify unsafe practices which would
result in minor personal injury or property damage.
GENERAL
The universal relay pack is used in VVTt(variable volume/
variable temperature) systems as an interface between the
HVAC (heating, ventilation, and air conditioning) unit and
the damper actuator. The universal relay pack is used on Cool-
ing Only, Heating/Cooling, and Heat Pump units. The uni-
versal relay pack is not used in Monitor-Only applications.
The universal relay pack is also used for supplemental heat
and fan relays on zone controllers.
INSTALLATION
Step 1 — Relay Pack Location — The relay pack
can be mounted either in the damper actuator or in an
accessory remote enclosure at a remote location not more
than 100 ft from the zone damper actuator.
The operating environment for the relay pack is 32 to
158 F (0° to 70 C) at a non-condensing humidity of 10 to
95%.
Step2—Wiring Requirements — The universal
relay pack wiring has the following requirements:
All system wiring must be in compliance with all appli-
cable local and national codes.
All control, communication bus, and sensor wiring
should be color coded in conformance with Carrier
recommendations.
Each unused wire should be individually capped with a
wire nut. Do not leave bare exposed wires. Electric shock
can cause injury or death.
IMPORTANT: Do not run the thermostat network and
control wire in the same conduit for more than 5 ft.
Never run wires near any cable carrying AC voltage.
Interference to signal may result.
Do not ground the shielded wire in more than one
location. If the shield is grounded in two or more
locations, an electrical charge may form around the wire
and disrupt communication.
RELAY PACK TO HVAC UNIT — All wiring must be 4-,
7-, or 9-conductor, 18-gage, wire depending on application
and type of unit. The maximum distance between the HVAC
unit to the relay pack for 18-gage wire is 100 ft.
RELAY PACK TO FAN MIXING BOX OR SUPPLE-
MENTAL HEAT — All wiring must be 4- or 6-conductor,
18-gage, wire depending on application and type of unit. The
maximum distance between the mixing box or supplemental
heat to the relay pack for 18-gage wire is 100 ft.
RELAYPACK TO DAMPERACTUATOR —A2-conductor
power cable and 7-conductor relay connector cable are factory-
installed on the universal relay pack. If the universal relay
pack is being installed inside the actuator, no field-supplied
wiring is required.
If the universal relay pack is being installed in a remote
location, the 2-conductor power cable and 7-conductor relay
connector cable will need to be cut to add additional length
to the cable. Use 18-gage wire (standard or plenum rated) to
extend the factory-supplied cables. The maximum distance
between the relay pack and damper actuator for 18-gage wire
is 100 ft.
Step 3 — Install Relay Pack
DAMPER MOUNT
IMPORTANT: Before installing the relay pack make
sure the damper shaft will not come in contact with
the relay pack once it is installed inside the actuator
cover. If the shaft touches the relay pack, the damper
shaft must be cut to bring it flush with the sleeve of the
actuator.
33CS
Universal Relay Pack
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 11a 13a PC 111 Catalog No. 533-342 Printed in U.S.A. Form 33CS-27SI Pg 1 5-98 Replaces: 690001

1. Remove cover from actuator by removing two screws on
sides of actuator. Save screws.
2. Locate the four standoffs inside the actuator cover which
have the plastic inserts inside. (The holes will be smaller.)
See Fig. 1.Align the relay pack, with the four screw holes
over the standoffs with the smaller holes. Be sure
11-pin connector is at the bottom of the cover, near the
knockout. See Fig. 2.
3. Secure the relay pack in place using the 4 Phillips head
screws provided with the relay pack
4. Connect the 2-pin power wire harness on the relay pack
to the power terminal on the actuator. See Fig. 3.
5. Connect the 7-pin connector of the wiring harness pro-
vided with the relay pack to the 7-pin connection on the
relay pack (the connector at the same end of the relay
pack as the 24 vac connector) and to the 7-pin terminal
on the actuator (directly below the damper spindle). See
Fig. 3.
6. Connect the relay pack output harness to the output con-
nector on the relay pack, then thread the pigtail through
the grommet at the bottom of the actuator.
7. Connect the relay pack output harness to the appro-
priate colored wires from the HVAC equipment using field-
supplied wire nuts. See Step 4 — Equipment Wiring
Section.
8. Replace cover on actuator and reinstall cover using 2 screws
from Step 1.
REMOTE MOUNT — To install universal relay pack in a
remote mounted location, perform the following procedure:
1. The 2-conductor power cable and 7-conductor relay con-
nector cable will need to be cut to add additional length
to the cable. Cut the relay pack 7-conductor relay cable
and 2-conductor power cable about 3.5-in. from the uni-
versal relay pack. Save connector plugs.
2. Remove cover from actuator by removing two screws
on sides of actuator. Save screws.
3. Connect the 2-pin connector plug saved from Step 1 to
the power terminal on the actuator. Strip wires.
4. Connect the 7-pin connector plug saved from Step 1
to the 7-pin connection on the on the actuator (directly
below the damper spindle). Strip wires.
5. Use 18-gage wire (standard or plenum rated) to extend
the factory-supplied cables. The maximum distance
between the relay pack and damper actuator for 18-gage
wire is 100 ft. Connect the extension wiring to the wires
stripped in Steps 3 and 4. Use field-supplied wire nuts
for connection. Run wiring to mounting location of uni-
versal relay pack. Replace cover onto actuator using screws
from Step 2.
6. Push standoffs (provided with remote enclosure acces-
sory) through back of remote enclosure mounting plate.
See Remote Enclosure installation instructions for more
information.
7. Mount remote enclosure mounting plate on wall.
8. Align universal relay pack with standoffs and push firmly
down until board clicks into place.
9. Run the extension wiring from Step 5 through the grom-
met hole in the remote enclosure cover. Splice and wire
nut the extension wiring from the damper actuator to
the cables on the relay pack cut in Step 1.
10. Connect the relay pack output harness to the output con-
nector on the relay pack, then thread the pigtail through
the grommet at the bottom of the remote enclosure.
11. Connect the relay pack output harness to the appro-
priate colored wires from the HVAC equipment using
field-supplied wire nuts. See Step 4 — Equipment Wir-
ing Section.
Step 4 — Equipment Wiring
If replacing an existing relay pack, be sure to replace
existing 7-wire harness with 7-wire harness supplied.
Reuse of old 7-wire harness could result in equipment
failure or damage to unit.
Be sure to cut off exposed wire and cap the ends of wires
not being used to prevent circuit from shorting out. Equip-
ment damage or electrical shock can result.
ZONE CONTROLLER, SUPPLEMENTAL HEAT,AND FAN
POWERED MIXING BOX — If using the relay pack with
a zone controller, fan powered mixing box, supplemental heat,
or a local exhaust fan for local IAQ (indoor air quality), the
following wiring configuration should be used:
• GREEN — Fan/Heat 3
• BROWN — Heat 2
• WHITE — Heat 1 (Normally Open)
• GRAY — Heat 1 (Normally Closed)
• PINK — 24 VAC
• ORANGE — AUX relay (Normally Open)
• BLACK — AUX relay (Normally Closed)
• VIOLET — AUX relay, 24 VAC
NOTE: This configuration should also be used if replacing
an existing HR-03 relay pack.
MONITOR THERMOSTAT — If using the relay pack with
a monitor thermostat, the following wiring configuration should
be used:
• YELLOW — Cool 1/Y1
• BLUE — Cool 2/Y2
• RED — 24 VAC/R (for cooling relays)
• WHITE — Heat 1/W1 (Normally Open)
• GRAY — Heat 1 (Normally Closed)
• BROWN — Heat 2/W2
• GREEN — Fan/G
• PINK — 24 VAC/R (for heat and fan relays)
• ORANGE —AUX/O (Normally Open, for reversing valves
energized for cooling)
• BLACK —AUX/B (Normally Closed, for reversing valves
energized for heating)
• VIOLET — 24 VAC/R (for AUX relay)
2

STANDOFFS
Fig. 1 — Damper Actuator Cover
(Inside)
PLUG
TO ZONE
DAMPER
RELAY
CONNECTION
PLUG
POWER
CABLE
TO ZONE
DAMPER
RELAY
CONNECTION
CONNECTOR
CABLE
24 VAC
AUX FAN H2 H1 C2 C1
R AUXILIARY (VIOLET)
NOT USED
AUXILIARY (NC)(BLACK)
AUXILIARY (NO)(ORANGE)
R (HEAT/FAN)(PINK)
FAN (GREEN)
HEAT 2 (BROWN)
HEAT 1 NC (GREY)
HEAT 1 NO (WHITE)
R COOL (RED)
COOL 2 (BLUE)
COOL 1 (YELLOW)
TO HVAC
UNIT
LEGEND
NC — Normally Closed
NO—Normally Open Fig. 3 — Universal Relay Pack Connections
Fig. 2 — Relay Pack Installed in Damper
Actuator Cover
3

Copyright 1998 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 11a 13a PC 111 Catalog No. 533-342 Printed in U.S.A. Form 33CS-27SI Pg 4 5-98 Replaces: 690001