35E Single-Duct Terminal Units Variable Volume System

Installation and Start-Up Instructions

CONTENTS
Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1 PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CONTROL ARRANGEMENTS. . . . . . . . . . . . . . . . . . . .3,4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Step 1 Install Volume Control Box . . . . . . . . . . . . . 4 Step 2 Make Duct Connections . . . . . . . . . . . . . . . . 4 Step 3 Install Sensors and Make Field Wiring Connections Electronic Analog or DDC (Direct Digital Controls) . . . . . . . . . . . . . . . . 4 CONTROL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Field Adjustments of Minimum and Maximum Airflow Set Points . . . . . . . . . . . . . . . . . . . 7 System Calibration of the Linear Averaging Flow Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PNEUMATIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . .7-11 Preparation for Balancing (Control Sequences 1102 and 1103) . . . . . . . . . . . . . . . . . . . . . 7 Balancing Procedure (Control Sequences 1102 and 1103) . . . . . . . . . . . . 9 DIRECT ACTING THERMOSTAT, NORMALLY OPEN DAMPER (Control Sequence 1102) REVERSE ACTING THERMOSTAT, NORMALLY CLOSED DAMPER (Control Sequence 1103) Balancing Procedure (Control Sequences 1104-1110) . . . . . . . . . . . . . . . 10 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . 10 Pneumatic Control Troubleshooting . . . . . . . . . . . . . 10 ANALOG CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . 11-13 Balancing Procedures (Control Sequences 2100-2105) . . . . . . . . . . . . . . . 11 Analog Control Troubleshooting . . . . . . . . . . . . . . . . 13 ComfortID CONTROLS . . . . . . . . . . . . . . . . . . . . . 13-21 Install Sensors and Make Field-Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 GENERAL SUPPLY-AIR TEMPERATURE SENSOR INSTALLATION SPACE TEMPERATURE SENSOR INSTALLATION AND WIRING WIRING THE SPACE TEMPERATURE SENSOR AND SET POINT ADJUSTMENT SLIDEBAR WIRING THE CCN NETWORK COMMUNICATION SERVICE JACK PRIMARY AIR TEMPERATURE SENSOR INSTALLATION INDOOR-AIR QUALITY SENSOR INSTALLATION INDOOR-AIR QUALITY SENSOR WIRING HUMIDITY SENSOR (Wall-Mounted) INSTALLATION Connect the CCN Communication Bus . . . . . . . . . . 19 COMMUNICATION BUS WIRE SPECIFICATIONS CONNECTION TO THE COMMUNICATION BUS Water Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . 19 ComfortID Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 GENERAL PRIMARY SYSTEM CHECK ComfortID CONTROL SYSTEM CHECK CCN System Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 VVT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-23 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DIRECT DRIVE HIGH TORQUE ACTUATOR RELAY PACKAGE ADDITIONAL SENSOR INFORMATION THERMOSTATS Thermostat Placement . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CCN COMMUNICATIONS THERMOSTAT TO TERMINAL CONTROL BOX Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 VVT Configuration/Testing . . . . . . . . . . . . . . . . . . . . . . 23 Control Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 GENERAL PRIMARY SYSTEM CHECK

SAFETY CONSIDERATIONS SAFETY NOTE

Air-handling equipment will provide safe and reliable service when operated within design specifications. The equipment should be operated and serviced only by authorized personnel who have a thorough knowledge of system operation, safety devices and emergency procedures. Good judgement should be used in applying any manufacturers instructions to avoid injury to personnel or damage to equipment and property.

Disconnect all power to the unit before performing maintenance or service. Unit may automatically start if power is not disconnected. Electrical shock and personal injury could result.

If it is necessary to remove and dispose of mercury contactors in electric heat section, follow all local, state, and federal laws regarding disposal of equipment containing hazardous materials.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 533-530 Printed in U.S.A. Form 35E-2SI Pg 1 3-06 Replaces: 35E-1SI Book 3 Tab 6a

PRE-INSTALLATION General The 35E is a single duct, variable volume terminal available with factory-installed pneumatic, analog electronic, Carrier Comfort Network (CCN) or VVT (variable volume and temperature) electronic control options that can be used in conjunction with unit-mounted electric or hot water heat options. Figure 1 shows the basic box. Figure 2 is an example of a unit identification label. STORAGE AND HANDLING Inspect for damage upon receipt. Shipping damage claims should be filed with shipper at time of delivery. Store in a clean, dry, and covered location. Do not stack cartons. When unpacking units, care should be taken that the inlet collars and externally mounted components do not become damaged. Do not lift units using collars, sensors or externally mounted components as handles. If a unit is supplied with electric or hot water heat, care should be taken to prevent damage to these devices. Do not lay uncrated units on end or sides. Do not stack uncrated units over 6 ft high. Do not manhandle. Do not handle control boxes by tubing connections or other external attachments. Table 1 shows component weights. INITIAL INSPECTION Once items have been removed from the carton, check carefully for damage to duct connections, coils or controls. File damage claim immediately with transportation agency and notify Carrier. UNIT IDENTIFICATION Each unit is supplied with a shipping label and an identification label (Fig. 2). INSTALLATION PRECAUTION Check that construction debris does not enter unit or ductwork. Do not operate the central-station air-handling fan without final or construction filters in place. Accumulated dust and construction debris distributed through the ductwork can adversely affect unit operation. SERVICE ACCESS Provide service clearance for unit access. CODES Install units in compliance with all applicable code requirements. UNIT SUSPENSION See Fig. 3 for unit suspension details.

Warranty All Carrier-furnished items carry the standard

Carrier warranty. No periodic preventative maintenance required, unless called for specific control sequence.

Fig. 1 35E Single Duct Box (Sizes 4-16)

Fig. 2 Unit Identification Label

Table 1 35E Unit Weights

35E SIZE 4, 5, 6 7, 8 9, 10 12 14 16 22 UNIT ONLY (lb) 14 16 21 26 34 38 65 WITH PNEUMATIC CONTROLS (lb) 18 20 25 30 38 42 69 WITH DDC OR ANALOG CONTROLS (lb) 23 25 30 35 43 47 74 WITH ELECTRIC HEAT CONTROLS (lb) 32 39 44 56 65 75 91 WITH HOT WATER (1 ROW/2 ROW) (lb) 19/20 21/23 28/30 35/38 44/49 50/55 82/90

LEGEND DDC Direct Digital Controls NOTE: Data is based on the following conditions: 1. Unit casing is 22 gage. 2. Unit insulation is 1/2-in. thick, 1.5-lb Tuf-Skin Rx, dual density. 3. Units rated with standard linear flow sensor.

FIELD SUPPLIED HANDING WIRE

BRACKET DETAIL

Fig. 3 Typical Unit Suspension with Brackets

CONTROL ARRANGEMENTS
The 35E single-duct unit is offered with a wide variety of factory-mounted controls that regulate the volume of air delivery from the unit and respond to cooling and heating load requirements of the conditioned space. Stand-alone controls will fulfill the thermal requirements of a given control space. These devices are available in both pneumatic and electronic arrangements. Carrier VVT electronic controls and PIC (Product Integrated Control) DDC (Direct Digital Controls) are communicating controls which are integrated with the building system. The PIC controls are compatible with the CCN system. A number of DDC control packages by others are available for consignment mounting, as indicated. Control offerings are: 35EA: Analog Electronic 35EC: PIC Direct Digital Electronic 35EP: Pneumatic 35EV: VVT Electronic (Gen. III or 3V controls) 35EN: None or DDC by others Each control approach offers a variety of operating functions; a control package number identifies combinations of control functions. The following listings contain the basic function arrangements for each control offering. Because of the variety of functions available, circuit diagrams, operating sequences, and function descriptions are contained in separate Application Data publications. Refer to the specific control publication for details.

CCN Thermostats (Ordered Separately)

Thermostat: 33ZCT56SPT: RT (room temperature) sensor, with set point adjust and override. Thermostat: 33ZCT55SPT: RT (room temperature) sensor, with override only. Thermostat: 33ZCT58SPT: Communicating room temperature sensor with LCD (liquid crystal diode), set point adjust, fan control and occupancy override. Thermostat: 33ZCT56CO2: RT (room temperature) and CO2 sensor, with set point adjust and override. Thermostat: 33ZCT55CO2: RT (room temperature) and CO2 sensor, with override only.

CCN Control Arrangements Carrier Comfort Network (CCN) controls are factory-installed in a control enclosure. Factory-mounted transformers are available as an option. Thermostats are supplied separately as a field-installed accessory. Carrier Comfort Network control packages must be used in combination with a thermostat. Thermostats are not included in the CCN package. 4140: Cooling only 4141: Single-stage and 2-stage electric heat 4142: 3-stage electric heat 4143: On-Off hot water 4144: Proportional (floating) hot water heat 4145: Cooling only with supply return tracking 4147: Single-stage, 2-stage and 3-stage electric heat with supply return tracking 4149: Proportional (floating) hot water with supply return tracking 4150: Return air damper

VVT Electronic Control Arrangement Variable volume and temperature (VVT) controls are factoryinstalled in a control enclosure. Factory-mounted transformers are available as an option. Thermostats are supplied separately as a field-installed accessory. GEN. III CONTROL CODES AND DESCRIPTIONS 8200: Pressure dependent, cooling only 8201: Pressure dependent, cooling with 2-stage electric heat 8202: Pressure dependent cooling with on/off hot water heat 8206: Pressure independent, cooling only 8207: Pressure independent, cooling with 2-stage electric heat 8208: Pressure independent cooling with on/off hot water heat 8209: Variable air volume (VAV) pressure dependent unit control zone (Monitor) 8210: Bypass controller, 2-in. wg transducer 3V CONTROL CODES AND DESCRIPTIONS 8220: Pressure dependent cooling only 8221: Pressure dependent cooling with 3-stage electric heat 8222: Pressure dependent cooling with on/off hot water heat 8223: Pressure dependent cooling with modulating hot water heat 8224: Pressure dependent cooling with combination baseboard and 2-stage electric heat 8226: Pressure independent cooling only 8227: Pressure independent cooling with 2-stage electric heat 8228: Pressure independent cooling with on/off hot water heat 8230: Bypass control Analog Electronic Control Arrangement
Pressure independent control packages are available without supplemental heat, with on/off hot water or electric heat, proportional hot water heat, or with cooling/heating automatic changeover control.

All analog control arrangements include a standard linear inlet flow sensor, 24-v transformer (optional), control enclosure and wall thermostat to match the control type. 2100: Heating control 2101: Cooling control 2102: Cooling with on/off electric heat control 2103: Cooling with on/off hot water heat control 2104: Cooling/heating automatic changeover control 2105: Cooling with proportional hot water heat control

INSTALLATION

LOCK OUT AND TAG heater electrical disconnect before working on this equipment. Otherwise, one leg of the 3-leg heater remains energized. Electrical shock or personal injury could result.

Step 1 Install Volume Control Box

1. Move unit to installation area. Remove unit from shipping package. Do not handle by controls or damper extension rod. 2. The unit has factory-installed brackets on unit as shown in Fig. 3. 3. Suspend units from building structure with straps, rods, or hanger wires. Secure the unit and level it in each direction. Note that reheat coil is in heavy end of unit.

Pneumatic Control Arrangement All control packages are pressure independent (unless otherwise noted) and available with or without hot water heat, dual maximum airflow, heating and cooling maximum airflow and dual minimum airflow. All control arrangements include a standard linear inlet flow sensor. 1100 (Actuator only): DA-NC pressure dependent control 1101 (Actuator only): RA-NO pressure dependent control 1102 (Single function controller): DA-NO with or without hot water or electric heat 1103 (Single function controller): RA-NC with or without hot water or electric heat 1104 (Multi-function controller): DA-NO with or without hot water or electric heat 1105 (Multi-function controller): DA-NC with or without hot water or electric heat 1106 (Multi-function controller): RA-NO with or without hot water or electric heat 1107 (Multi-function controller): RA-NC with or without hot water or electric heat 1108 (Dual Maximum Control): DA-NO with or without hot water or electric heat 1109 (Heating/Cooling Maximum Control): DA-NO with or without hot water or electric heat 1110 (Dual Minimum Control): DA-NO with or without hot water or electric heat PNEUMATIC CONTROL LEGEND DA: Direct-acting thermostat RA: Reverse-acting thermostat NO: Normally open damper position NC: Normally closed damper position The single function controller provides single functions, i.e., DA-NO. Multi-function controllers are capable of providing DA-NO, DA-NC, RA-NC or RA-NO functions. Direct Digital Electronic Control Arrangements (Field-Supplied) Control packages are fieldsupplied for factory mounting, unless otherwise noted. All DDC control arrangements include a standard linear inlet flow sensor, transformer to 24 volts and control enclosure. Contact Carrier for detail about mounting field-supplied controls. NO CONTROL 0000: 35E box only D000: 35E box with control box only (For units without electric heat requiring a 24 v control transformer: the control transformer must be ordered from the unit accessories list in Quote Builder.) D001: 35E box with control box and 24 v transformer P000: 35E box without controls (for DA pneumatic controlled heat unit) P001: 35E box without controls (for RA pneumatic controlled electric heat unit)

Step 2 Make Duct Connections

1. Install supply ductwork on unit inlet collar. Check that air-supply duct connections are airtight and follow all accepted medium-pressure duct installation procedures. (Refer to Table 2 for pressure data.) NOTE: To ensure proper equipment performance, it is recommended that a length of rigid straight duct equal to 3 times the duct diameter be provided to the inlet. 2. Install the discharge duct. Where a multiple outlet connector is used on the box, connect appropriately sized ductwork to the outlets. Use adapter caps to seal unused outlets. Fully open all balancing dampers. To ensure use of common-diameter air duct, coordinate diameters of box inlet and multiple outlet collars. Insulate duct as required. Ninety degree elbows or tight radius flexible duct immediately upstream of inlet collar should be avoided.

Step 3 Install Sensors and Make Field Wiring Connections Electric Analog or DDC (Direct Digital Controls) Refer to specific unit dimensional submittals and control application diagrams for control specifications. All field wiring must comply with National Electrical Code (NEC) and local requirements. Refer to the wiring diagram on the unit for specific wiring connections. A field-supplied transformer is required if the unit was not equipped with a factory-installed transformer. See Fig. 4. Single duct terminal units with electric heat are supplied with a single point wiring connection in the heater control box. All unit power is supplied through this connection. Models with electric heat are factory equipped with a control transformer. See Fig. 5. Wiring and unit ampacities are referenced in Tables 3A and 3B. NOTE: Refer to wiring diagram attached to each unit for specific information on that particular unit. Units with 480-3-60 electric heater REQUIRE 4-wire, wye connected power. units with 208/230 v, 3-phase heater can be connected with 3-wire power. Unit airflow should not be set outside of the range noted in Fig. 6. The minimum recommended airflow for units with electric heat must be at least 75 cfm per kW and not drop below the minimum values listed in the performance data table. The maximum unit discharge temperature should not exceed 120 F. Prevent air stratification by setting the discharge temperature no more than 15 degrees above the room temperature. Example: 90 F discharge in a 75 F room.

Table 2 35E Basic Pressure Data

INLET SIZE (in.) (Area) 4 (0.09) CFM 55 110 170 230 85 170 265 360 100 240 380 520 140 330 525 710 190 440 675 925 240 550 875 1200 300 675 1075 1450 425 1000 1550 2100 580 1375 2125 2900 750 1775 2725 3700 1800 3300 5200 7100 MIN AIRFLOW (Cfm)* ELECTRIC HEAT** MAX kW Cooling Only or Electric Velocity Press AT 55 F EAT Cooling with Hot Water Heat ( VPS) 1.1 0.02 50 2.3 0.10 or 55 3 0.23 0 3 0.43 1.7 0.02 75 3.5 0.09 or 85 5 0.23 0 5 0.43 2.1 0.02 110 4.9 0.09 or 110 7.5 0.22 0 7.5 0.42 2.9 0.02 140 6.8 0.09 or 140 9.5 0.23 0 9.5 0.41 3.9 0.02 185 9.1 0.09 or 190 13 0.21 0 13 0.39 4.9 0.02 240 11.3 0.08 or 240 16 0.21 0 16 0.40 6.2 0.02 290 13.9 0.08 or 300 21 0.20 0 21 0.36 8.7 0.01 420 20.6 0.08 or 425 30 0.19 0 30 0.34 11.9 0.01 580 28.3 0.07 or 580 36 0.17 0 36 0.31 15.4 0.01 740 36 0.06 or 750 36 0.14 0 36 0.25 36 0.02 1400 36 0.07 or 1800 36 0.16 0 36 0.31 LEGEND PS The difference in static pressure from inlet to discharge with damper fully open VPS Change in velocity pressure MINIMUM INLET STATIC PRESSURE (Unit and Heat Pressure Drop) Basic Unit Basic + 1 Row Basic + 2 Row Basic + 3 Row Basic + 4 Row Basic + Heater ( PS) Coil ( PS) Coil ( PS) Coil ( PS) Coil ( PS) ( PS) 0.00 0.00 0.01 0.01 0.01 0.00 0.01 0.02 0.03 0.03 0.04 0.01 0.02 0.04 0.06 0.08 0.10 0.02 0.03 0.07 0.11 0.15 0.18 0.03 0.00 0.01 0.02 0.02 0.03 0.00 0.02 0.04 0.06 0.08 0.10 0.02 0.04 0.10 0.15 0.20 0.24 0.04 0.08 0.18 0.27 0.36 0.45 0.08 0.01 0.01 0.02 0.03 0.03 0.01 0.04 0.08 0.12 0.16 0.20 0.04 0.09 0.20 0.30 0.40 0.50 0.09 0.17 0.38 0.57 0.75 0.94 0.17 0.01 0.01 0.02 0.03 0.04 0.01 0.04 0.08 0.12 0.16 0.20 0.04 0.09 0.20 0.30 0.40 0.50 0.09 0.17 0.37 0.55 0.73 0.91 0.17 0.01 0.02 0.03 0.05 0.06 0.01 0.04 0.12 0.19 0.25 0.32 0.04 0.09 0.27 0.44 0.60 0.76 0.09 0.17 0.51 0.82 1.13 1.43 0.17 0.01 0.02 0.03 0.04 0.05 0.01 0.07 0.12 0.17 0.22 0.27 0.07 0.17 0.31 0.44 0.57 0.69 0.17 0.32 0.59 0.83 1.07 1.31 0.32 0.01 0.02 0.04 0.05 0.07 0.01 0.04 0.12 0.20 0.27 0.35 0.04 0.10 0.31 0.50 0.69 0.89 0.10 0.17 0.56 0.91 1.26 1.62 0.17 0.01 0.02 0.04 0.06 0.07 0.01 0.04 0.14 0.22 0.31 0.40 0.04 0.09 0.33 0.54 0.75 0.96 0.09 0.17 0.60 0.99 1.37 1.76 0.17 0.01 0.02 0.04 0.05 0.06 0.01 0.04 0.13 0.21 0.28 0.36 0.04 0.10 0.31 0.49 0.68 0.86 0.10 0.19 0.57 0.92 1.26 1.60 0.19 0.01 0.02 0.04 0.06 0.07 0.01 0.04 0.14 0.22 0.31 0.40 0.04 0.09 0.32 0.53 0.73 0.94 0.09 0.17 0.59 0.97 1.35 1.73 0.17 0.01 0.05 0.09 0.13 0.16 0.01 0.04 0.17 0.30 0.42 0.55 0.04 0.09 0.43 0.74 1.05 1.36 0.09 0.17 0.81 1.38 1.95 2.53 0.17 voltage, phase, max capacity and design (see Electrical Data in the Product Data catalog). Min cfm for electric heat is based on UL/ETL listings. (Diffuser) performance will likely be poor at this low flow rate.) The ASHRAE (American Society of Heating, Refrigeration and Air Conditioning Engineers) Handbook of Fundamentals does not recommend a discharge temperature exceeding 90 F for satisfactory air mixing and comfort. Max. kW is limited by design. NOTES: 1. To obtain Total Pressure (Pt), add the Velocity Pressure for a given cfm to the Static Pressure drop ( PS) of the desired configuration. Example: Pt for a Size 8 Basic Unit at 925 cfm = 0.39 + 0.17 = 0.56 2. The electric heat max kW is based on 3 phase power. For more details, refer to the air terminal selection program.

5 (0.14)

6 (0.20)

7 (0.27)

8 (0.35)

9 (0.44)

10 (0.55)

12 (0.78)

14 (1.07)

16 (1.40)

22 (2.63)

CCN DDC EAT UL

Carrier Comfort Network Direct Digital Controls Entering Air Temperature Underwriters Laboratories

*Minimums are for all except CCN controls, which may be lower. Minimum for DDC by others is to be provided by the controls provider. A minimum 0.03 in. wg discharge static pressure is required to set the flow switch in the electric heater. **Maximum discharge temperatures with electric heat are set at 120 F by the National Electric Code. Max kW shown assumes 55 F entering air and is limited by units selected

Table 3A 35E Heater Power Wiring and Fuse Sizing (Single Phase, 60 Hz)
HEATER SIZE (kW) 0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 BTUH 1,707 3,413 6,826 10,239 13,652 17,085 20,478 23,898 27,304 30,717 34,130 37,130 40,956 LEGEND AWG FLA American Wire Gage Full Load Amps 120 V Heater AWG* FLA 4.2 14 8.3 14 16.7 10 25.0 8 33.3 8 41.7 5 50.0 5 58.3 4 66.7 4 75.0 3 83.3 2 91.7 2 100.0 1 208/240 V Heater AWG* FLA 2.1 14 4.2 14 8.3 14 12.5 12 16.7 10 20.8 10 25.0 8 29.2 8 33.3 8 37.5 6 41.7 6 45.8 6 50.0 6 277 V Heater AWG* FLA 1.8 14 3.6 14 7.2 14 10.8 14 14.4 12 18.1 10 21.7 10 25.3 8 28.9 8 32.6 8 36.1 6 39.7 6 43.3 6

Table 3B 35E Heater Power Wiring and Fuse Sizing (3 Phase, 60 Hz)
HEATER SIZE (kW) 0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0 26.0 28.0 30.0 32.0 34.0 36.0 AWG FLA BTUH 1,707 3,413 6,826 10,239 13,652 17,085 20,478 23,898 27,304 30,717 34,130 40,956 47,782 54,608 61,434 68,260 75,086 81,912 88,738 95,564 102,390 109,216 116,042 122,868 208 V Heater FLA 1.4 2.8 5.6 8.3 11.1 13.9 16.7 19.4 22.2 25.0 27.8 33.3 38.8 44.4 50.0 55.5 61.1 66.6 72.3 77.8 83.4 89.0 94.5 100.1 AWG* 14 14 14 14 14 12 10 10 10 8 8 8 6 6 6 4 4 4 3 3 2 2 1 1 480 V Heater FLA 0.6 1.2 2.4 3.6 4.8 6.0 7.2 8.4 9.6 10.8 12.0 14.4 16.8 19.2 21.6 24.0 26.4 28.8 31.3 33.7 36.1 38.6 41.0 43.4 AWG* 10 10 10 10 10 10 10 10 10 10 10 12 12 10 10 10 8 8 8 8 6 6 6 6

*Values based on 75 C copper wire.

LEGEND American Wire Gage Full Load Amps

*Recommended minimum wire size.

L1 120VAC 208VAC 240VAC 277VAC

10000 8000 6000 4000 2000

SIZ 2 E2

7250 3709 2840 2086

CFM AT ONE INCH SIGNAL

CLASS II TRANSFORMER (OPTIONAL)

1000 800 600

CFM

400 200 100 80 60 40 20 10 0.01

24VAC GROUND 24 VAC POWER BLU YEL

ANALOG OR DDC CONTROLLER

6 E1 SIZ 14 E SIZ 12 E SIZ 0 E1 Z SI E9 Z SI E 8 Z SI E7 SIZ E6 SIZ E5 SIZ E4 SIZ

1449 1174 927 710 522 362 232

DDC

LEGEND Direct Digital Controls Field Wiring Factory Wiring

.03

NOTE: Drawing is typical refer to actual unit wiring diagram for details.

.05 0.1 0.3 FLOW PROBE IN.WG VOLTS (ANALOG CONTROLS)

0.5

Fig. 4 Wiring of Optional Factory-Mounted Transformer

Fig. 6 Linear Probe CFM vs Pressure Signal Graph

ANALOG OR DDC CONTROLLER SEPARATE CONTROL ENCLOSURE

LEGEND AFS Airflow Switch DDC Direct Digital Controls NOTE: Drawing is typical of 480V, 3-phase, 4-wire heater and control. Refer to actual unit wiring diagram.

Fig. 5 Typical Power Connections for 35E Units with 3-Stage Electric Heat 6

CONTROL SETUP General The 35E single-duct VAV (variable air volume) terminal is designed to supply a varying quantity of cold primary air to a space in response to a thermostat demand. Some units have reheat options to provide heating demand requirements as well. Most VAV terminals are equipped with pressure compensating controls to regulate the response to the thermostat independent of the pressure in the supply ductwork. To balance the unit, it is necessary to set both the maximum and minimum set points of the controller. The many types of control options available each have specific procedures required for balancing the unit. Set Points Maximum and minimum airflow set points
are normally specified for the job and specific for each unit on the job. Where maximum and minimum airflow levels are not specified on the order, default values are noted on unit ID label.

Record the information on a performance sheet (see Fig. 7). This will provide a permanent record of the balancing information. installation location information box size cooling minimum airflow (cfm) limit cooling maximum airflow (cfm) limit reheat (cfm) limit (if applicable) heating minimum airflow (cfm) limit (if applicable) heating maximum airflow (cfm) limit (if applicable) calibration gain (after balancing) set points

PNEUMATIC CONTROLS Preparation for Balancing (Control Sequences 1102 and 1103)
1. Inspect all pneumatic connections to assure tight fit and proper location. 2. Verify that the thermostat being used is compatible with the control sequence provided (direct acting or reverse acting). 3. Check main air pressure at the controller(s). The main air pressure must be between 15 psi and 25 psi. (If dual or switched-main air pressure is used, check the pressure at both high and low settings.) The difference between high pressure main and low pressure main should be at least 4 psi, unless otherwise noted, and the low setting difference should exceed 15 psi. 4. Check that the unit damper will fail to the proper position when main air pressure is lost. Disconnect the pneumatic actuator line from the velocity controller and observe the VAV damper position. The damper should fail to either a normally open position (indicator mark on shaft end is horizontal) or a normally closed position (indicator mark on shaft end is vertical). 5. Check that there is primary airflow in the inlet duct. 6. Connect a Magnehelic gage, inclined manometer or other differential pressure measuring device to the balancing taps provided in the velocity probe sensor lines. The manometer should have a full scale reading of 0.0 to 1.0 in. wg. The high pressure signal is delivered from the front sensor tap (away from the valve), and the low pressure signal is delivered from the back line (near the valve). The pressure differential between high and low represents the amplified velocity pressure in the inlet duct. 7. Read the differential pressure and enter the Linear Averaging Probe Chart to determine the airflow in the terminal unit. This chart is shown in Fig. 6 and is also attached to the side of each unit. For example, a differential pressure of 0.10 in. wg for a size 8 unit yields an airflow of 275 cfm. Volume controllers for 35EP units are shown in Fig. 8-10. Identification for each controller is shown in Table 4.

Field Adjustment of Minimum and Maximum Airflow Set Points Each 35E unit is equipped with a
flow probe that measures a differential pressure proportional to the airflow. The relationship between flow probe pressures and cfm is shown in the Linear Probe CFM vs Pressure Signal Graph (Fig. 6). This chart is attached to each unit.

System Calibration of the Linear Averaging Flow Probe To achieve accurate pressure independent
operation, the velocity sensor and linear averaging flow probe must be calibrated to the controller. This will ensure that airflow measurements will be accurate for all terminals at system start-up. System calibration is accomplished by calculating a flow coefficient that adjusts the pressure fpm characteristics. The flow coefficient is determined by dividing the flow for a given unit (design air volume in cfm), at a pressure of 1.0 in. wg differential pressure, by the standard pitot tube coefficient of 4005. This ratio is the same for all sizes if the standard linear averaging probe is used. Determine the design air velocity by dividing the design air volume (the flow at 1.0 in. wg) by the nominal inlet area (sq ft). This factor is the K factor. Carrier inlet areas are shown in the table below. The design air volume is also shown in this table. It can be determined from this table that the average design air velocity for 35E units is equal to 2656 fpm at 1.0 in. wg.
UNIT SIZE 35E INLET DIAMETER AIRFLOW (Cfm) AT 1 in. wg INLET AREA (sq ft)
.

04 4.0 232 0.087

05 5.0 362 0.136

06 6.0 502 0.196

07 7.0 710 0.267

08 8.0 927 0.349

09 9.0 1174 0.442

35E UNIT SIZE INLET DIAMETER AIRFLOW (Cfm) AT 1 in. wg INLET AREA (sq ft)

10 10.0 1449 0.545

12 12.0 2086 0.785

14 14.0 2840 1.069

16 16.0 3709 1.396

22 16 x 24 7250 2.640

NOTE: For Carrier ComfortID terminals, all flow sizes are normalized using a single Probe Multiplier (PMF) for all sizes equal to 2.273.

AIR TERMINAL PERFORMANCE SHEET

JOB NAME ______________________________________________ JOB LOCATION __________________________________________ CUSTOMER _____________________________________________ ENGINEER ______________________________________________

BUILDING LOCATION/FLOOR ______________________________ BUS NUMBER ___________________________________________

Tag Number

Zone Address #

Box Size (in./cfm)

CONTROL Cooling Reheat (cfm) cfm min max

SET POINTS Heating (cfm) min max Heat Type kW Btu Occupied min max Unoccupied min max Calibration Gain mult.

Fig. 7 Air Terminal Performance Sheet

Table 4 Pneumatic Volume Controller Identification

CONTROL SEQUENCE 1102 1103 1104 1105 1106 1107 1108 1109 1110 FUNCTION ARRANGEMENT IDENTIFICATION DA-NO RA-NC DA-NO DA-NC RA-NO RA-NC DUAL MAX HTG/CLG MAX DUAL MIN FIG. NO. 8 9 10 10 10 10 10 10 10 KREUTER PART NO. CSC-2003 CSC-2004 CSC-3011 CSC-3011 CSC-3011 CSC-3011 CSC-3011 (2) CSC-3011 CSC-3011

LEGEND DA Direct Acting NO Normally Open NC Normally Closed RA Reverse Acting

Balancing Procedure 1102 and 1103)

LO
A CRE SE IN

(Control

Sequences

.O. DMPR.N
CSC-2003 0-1 P D.A.

A CRE SE IN

HI

Fig. 8 Pneumatic Volume Controller (Normally Open) for 35EP Unit (Beige Color)

HI
A CRE SE IN

CSC-2004 0-1 P R.A.

.C. DMPR.N

A CRE SE IN

LO

Fig. 9 Pneumatic Volume Controller (Normally Closed) for 35EP Unit (Grey Color)

T H B NC L
RESET START LO STAT P

IN

CR

IN

CR

HI STAT P

NO M
DAMPER
RESET SPAN

Fig. 10 CSC 3000 Series Reset Volume Controller 9

DIRECT ACTING THERMOSTAT, NORMALLY OPEN DAMPER (Control Sequence 1102) Refer to Fig. 8. 1. Minimum volume setting: a. Disconnect the thermostat line from the volume controller. b. Adjust the minimum volume control knob (marked LO and located in the center of the controller) to achieve the required minimum flow. To determine the required pressure differential, refer to Tables 2 and 5 and the Linear Averaging Probe Chart provided on the side of the VAV unit and in Fig. 6. c. Reconnect the thermostat line. 2. Maximum volume setting: a. Disconnect the thermostat line from the volume controller. b. Apply 15 + psi to the thermostat port on the volume controller (marked T) by tapping into the main air pressure line. c. Adjust the maximum volume control knob (marked HI and located at the side of the controller) until the desired pressure differential is registered on the manometer. To determine the required pressure differential, refer to Table 5 and the Linear Probe CFM vs Pressure Signal Graph provided on the side of the VAV unit and in Fig. 6. d. Reconnect the thermostat line. REVERSE ACTING THERMOSTAT, NORMALLY CLOSED DAMPER (Control Sequence 1103) Refer to Fig. 9. 1. Maximum volume setting: a. Disconnect the thermostat line from the velocity controller. b. Adjust the maximum volume control knob (marked HI and located in the center of the controller) to achieve the required minimum flow. To determine the required pressure differential, refer to Tables 2 and 5 and the Linear Averaging Probe Chart provided on the side of the VAV unit and in Fig. 6. c. Reconnect the thermostat line. 2. Minimum volume setting: a. Disconnect the thermostat line from the velocity controller. b. Apply 15 + psi to the thermostat port on the volume controller (marked T) by tapping into the main air pressure line.

c. Adjust the minimum volume control knob (marked LO and located at the side of the controller) until the desired pressure differential is registered on the manometer. To determine the required pressure differential, refer to Table 5 and the Linear Averaging Probe Chart provided on the side of the VAV unit and in Fig. 6. d. Reconnect the thermostat line.

Balancing Procedure 1104-1110)

(Control Sequences

1. Damper action is factory set at N.O. (normally open) or N.C. (normally closed). To reselect, loosen damper selection switch screw, align pointer with damper pointer and tighten screw. The spring range of the actuator is not critical since the controller will output the necessary pressure to the actuator to position the damper according to set point. (See Fig. 11.) 2. Pipe the controller: Connect port B to the damper actuator. Connect port M to the clean, dry main air. Connect port T to the thermostat output. Connect port H to the total pressure tap on the airflow sensor. Connect port L to the static pressure tap on the airflow sensor. The controller can be set up for cooling or heating applications using either a Direct Acting (DA) or Reverse Acting (RA) thermostat signal. The two flow adjustments are labeled LO STAT P and HI STAT P. LO STAT P setting is the desired airflow limit when the thermostat pressure is less than, or equal to, the reset start point. For DA Cooling or RA Heating: Adjust LO STAT P to the desired minimum airflow with 0 psig (or a pressure less than the reset start point) at port T. The LO STAT P must be set first. The LO STAT P will affect the HI STAT P setting. For RA Cooling or DA Heating: Adjust LO STAT P to the desired maximum airflow with 0 psig (or a pressure less than the reset start point) at port T. The LO STAT P must be set first. The LO STAT P will affect the HI STAT P setting. HI STAT P setting is the desired airflow limit when the thermostat pressure is greater than, or equal to, the reset stop-point. The reset stop-point is the reset span pressure added to the reset start-point pressure.

For DA Cooling or RA Heating (see Fig. 12): Adjust HI STAT P to the desired maximum airflow with 20 psig (or a pressure greater than the reset stop point) at port T. The HI STAT P must be set last. The HI STAT P setting will be affected by the LO STAT P setting. For RA Cooling or DA Heating (see Fig. 12): Adjust HI STAT P to the desired minimum airflow with 20 psig (or a pressure greater than the reset stop point) at port T. The HI STAT P must be set last. The HI STAT P setting will be affected by the LO STAT P setting. NOTE: After the LO STAT P and HI STAT P initial adjustments are made, cycle the thermostat pressure a few times to settle the internal reset mechanisms and verify settings. Fine tune the settings if necessary. The thermostat pressure may be left at a high pressure and the G port cap may be removed and replaced to cycle the reset mechanism. RESET START setting is factory set at 8.0 psig. This is the lowest thermostat pressure that the LO STAT P airflow will begin to reset towards the HI STAT P airflow. To change the RESET START setting: regulate thermostat pressure to the T port to the desired reset start point pressure, adjust RESET START adjustment until pressure at the G port is slightly higher than 0 psig, i.e., 0.1 psig. NOTE: The G port taps into the controllers internal reset chamber, which always starts at 0 psig. The RESET START adjustment is a positive bias adjustment that sets the desired thermostat start point to the controllers internal reset start point of 0 psig. RESET SPAN setting is factory set at 5.0 psig. This is the required change in thermostat pressure that the controller will reset between the LO STAT P setting and the HI STAT P setting. To change the RESET SPAN setting: adjust RESET SPAN adjustment until pressure at the G port equals the desired reset span pressure. NOTE: The G port taps into the controllers internal reset chamber, which will always be at a pressure between 0 psig and the RESET SPAN pressure.

Preventative Maintenance
1. Inspect pneumatic tubing for loose connections or leaks. 2. Clean out pneumatic line filters regularly according to manufacturers recommendations.

Pneumatic Control Troubleshooting See Table 5.

Table 5 Troubleshooting
PROBLEM Controller does not reset to maximum or minimum set point during balance procedure. Controller does not reset to maximum or minimum set point during operation. Pneumatic actuator does not stroke fully. Air valve stays in wide open position. NOTE: Always Check: 1. Main air pressure (15 psi to 25 psi) at the controller. 2. Disconnected or kinked pneumatic lines to the controller. 3. Quality of compressed air (oil or water in lines). PROBABLE CAUSE Balancer is using the thermostat for control signal. An artificial signal must be provided in place of the thermostat. Thermostat is not demanding maximum or minimum air volume. Main air pressure at the controller is less than 15 psi. Leak in pneumatic line between the controller and the actuator. Main air pressure at the controller is less than 15 psi. Leak in the diaphragm. Velocity probe is blocked by an obstruction (sandwich bag, etc.). Insufficient supply air in the inlet duct. 4. 5. 6. 7. Proper thermostat signal and logic (Direct/Reverse Acting). Blocked velocity probe or insufficient primary supply air. Leaks in the actuator diaphragm. Mechanical linkage of the actuator/air valve.

10

TO THERMOSTAT BRANCH SIGNAL (RESET SIGNAL) RESET START POINT ADJUSTMENT (FACTORY SET AT 8 PSI) * TO STATIC PRESSURE TO TOTAL PRESSURE *(DIFFERENCE IS: DIFFERENTIAL PRESSURE, OR DEVICE VELOCITY PRESSURE) PUSH ON NIPPLES FOR 3/16 (5) I.D. FR TUBING (5) TO DAMPER ACTUATOR TO MAIN AIR SUPPLY LOOSEN SCREW TO CHANGE DAMPER ACTION (SUPPLIED IN N.O. POSITION)
B T H L
RESET START LO STAT P

NC

IN

NO M
DAMPER

CR

IN

HI STAT P

CR

DIFFERENTIAL PRESSURE (FLOW) LIMIT ADJUSTMENT WHEN TSTAT PRESSURE IS HIGH (HI STAT) (FACTORY SET AT 0.65 IN.WG.)** **- FIELD ADJUSTMENT REQUIRED DIFFERENTIAL PRESSURE (FLOW) LIMIT ADJUSTMENT WHEN TSTAT PRESSURE IS LOW (LO STAT) (FACTORY SET AT 0 IN.WG.)** ALL ADJUSTMENTS CCW TO INCREASE (1/8-5/32 FLATBLADE SCREWDRIVER) RESET SPAN ADJUSTMENT (FACTORY SET AT 5 PSI)

RESET SPAN

GAGE TAP. LEAVE CAP ON UNLESS CONNECTING GAGE FOR RESET START OR RESET SPAN ADJUSTMENT

DAMPER ACTION SELECTION (FACTORY SET AT NORMALLY OPEN) NOTE: SCREW MUST BE TIGHT AND ARROWS IN PERFECT ALIGNMENT FOR DEVICE TO FUNCTION PROPERLY.

Fig. 11 3011 CSC Controller

MAX F L O W MIN 0

DA HEATING* Reset Span

MAX LO STAT P HI STAT P F L O W MIN 0

DA COOLING Reset Span LO STAT P HI STAT P 3

13 psig 8 Reset Start* ROOM TEMPERATURE

13 psig 8 Reset Start ROOM TEMPERATURE

MAX F L O W MIN

RA HEATING Reset Span

MAX HI STAT P LO STAT P F L O W MIN

RA COOLING* Reset Span

LO STAT P HI STAT P

8 3 0 psig Reset Start ROOM TEMPERATURE

13

8 3 0 psig Reset Start* ROOM TEMPERATURE 13

*May require changing the RESET START from 8.0 to 3.0 psig if sequencing is involved.

b. Small flat blade (1/8 in.) screwdriver c. Digital voltmeter capable of displaying a 0 to 10 vdc range which will display in hundredths of vdc d. HSO-5001 Test Leads (optional for meter taps) 2. Remove thermostat cover: Thermostat cover is removed by loosening the setscrews on each side of the thermostat. Using a 1/6 in. hex/key wrench turn the setscrews clockwise until cover is loose. 3. Check voltages: Verify 16 vdc between (+) and () terminals. CONTROL SEQUENCE 2100 (Heating Only) 1. Be certain the ambient room temperature at the thermostat is within the range of the thermostat (55 to 85 F). 2. Adjust the heating set point slider all the way to the left for minimum heating. 3. Read the DC voltage across the meter taps on the heating (left) side. Adjust the minimum set point (MIN INCR) potentiometer (clockwise to increase or counterclockwise to decrease) to the DC voltage equal to the desired airflow (cfm) as shown on the calibration curve (Fig. 14). NOTE: The minimum set point must be adjusted first. Adjustment of the MIN INCR potentiometer directly affects the maximum set point. 4. Adjust the heating set point slider all the way to the right for maximum heating. 5. Read the DC voltage across the meter taps on the heating (left) side. Adjust the maximum set point (MAX INCR) potentiometer (clockwise to increase or counterclockwise to decrease) to the DC voltage equal to the desired airflow (cfm) as shown on the calibration curve (Fig. 14). NOTE: The maximum set point must be adjusted last. Adjustment of the MIN INCR potentiometer directly affects the maximum set point. 6. Return the heating set point slider to the desired set point. Insert set point slider stops. Replace thermostat cover.
90

Fig. 12 Reset Cycle for CSC-3011 Control

ANALOG CONTROLS Balancing Procedures (Control Sequences 2100-2105) The analog electronic control system is a
GEAR DISENGAGEMENT BUTTON
0

45

pressure independent volume reset control that uses a Krueger CSP-5001 controller-actuator (see Fig. 13). The system provides for independently adjustable set points for minimum, maximum, and auxiliary airflow limits. Room temperature control is provided by the associated room thermostat which is selected according to the application. The room thermostat provides a fixed 2 degrees F reset span regardless of the minimum and maximum velocity limit set points. Adjustments for the minimum and maximum airflows are made at the thermostat. The thermostat (CTE-5100 series) operates on a 16 vdc power supply from the CSP controller and outputs a 0 to 10 vdc signal on the T terminals; T1 in the cooling mode (DA) and T2 in the heating mode (RA). See the reference sequence diagram on unit for details on which T terminals are used on each model thermostat, but in general T1 and T3 are used for the cooling mode, T2 and T4 for heating. Terminals T1 and T2 are adjustable to limit minimum and maximum flow. Terminals T3 and T4 have a fixed 0 to 10 vdc output signal. 1. Required tools: a. 1/16 in. hex/key wrench

ADJUSTABLE END STOPS

P PORTS

L H
NOR MAX MIN N O M M A X % M I N C ccw cw E

METER 16 I V N DC O U I 24V AC + RED-CLS GRN-OPN LED

WIRING
0-10V VELOCITY OUTPUT 0-10V INPUT SIGNAL 16V DC OUTPUT (THERMOSTAT POWER) 16 I O V N U T DC 24 V AC

COMMON (16V DC, INPUT, OUTPUT) POWER SUPPLY

Fig. 13 CSP-5001 Controller

11

10000 8000 6000 4000

7250

3709 2840

2000

E SIZ

22

2086 1449 1174 927 710 522 362 232 CFM AT ONE INCH SIGNAL

1000 800 600 CFM 400

200

100 80 60 40

6 E1 SIZ 4 E1 SIZ 2 E1 SIZ 0 E1 SIZ 9 E SIZ E8 SIZ E7 SIZ E6 SIZ E5 SIZ SIZ E4

20

10 VOLTS DIFFERENTIAL PRESSURE

1.2 .02

1.8 .04

2.3 .06

3.4 0.1

4.6 0.2

5.8 0.3

7.2 0.5

9.7 11 0.8 1

Fig. 14 Calibration Curve 35E CONTROL SEQUENCE 2101 (Cooling Only) 1. Be certain the ambient room temperature is within the range of the thermostat (55 to 85 F). 2. Adjust the cooling set point slider all the way to the right for minimum cooling. 3. Read the DC voltage across the meter taps on the cooling (right) side. Adjust the minimum set point (MIN INCR) potentiometer (clockwise to increase or counterclockwise to decrease) to the DC voltage equal to the desired airflow (cfm) as shown on the calibration curve. NOTE: The minimum set point must be adjusted first. Adjustment of the MIN INCR potentiometer directly affects the maximum set point. 4. Adjust the cooling set point slider all the way to the left for maximum cooling. 5. Read the DC voltage across the meter taps on the cooling (right) side. Adjust the maximum set point (MAX INCR) potentiometer (clockwise to increase or counterclockwise to decrease) to the DC voltage equal to the desired airflow (cfm) as shown on the calibration curve. NOTE: The maximum set point must be adjusted last. Adjustment of the MIN INCR potentiometer directly affects the maximum set point. 6. Return the cooling set point slider to the desired set point. Insert set point slider stops. Replace thermostat cover. CONTROL SEQUENCE 2102 (Cooling with On/Off Electric Heat Control) Cooling Side of the Thermostat 1. Follow steps 1 through 5 for cooling sequence 2101. NOTE: Be sure to adjust the cooling set point slider all the way to the left for maximum cooling. (The heating set point slider will have to be adjusted all the way to the left also.) 12 NOTE: The minimum set point must be adjusted first. Adjustment of the MIN INCR potentiometer directly affects the maximum set point and auxiliary set point. 2. Adjustment of auxiliary set point if required: Read the DC voltage across the meter taps on the heating (left) side. Adjust the MAX/AUX INCR potentiometer (clockwise to increase or counterclockwise to decrease) to the DC voltage equal to the desired airflow (cfm). 3. Return the cooling set point slider and the heating set point slider to their desired set points. Insert or reinsert set point slider stops. Replace thermostat cover. CONTROL SEQUENCE 2104 (Cooling/Heating with Automatic Changeover Control) Cooling Side of the Thermostat Follow steps 1 through 5 for cooling sequence 2101. NOTE: Be sure to adjust the cooling set point slider all the way to the left for maximum cooling. (The heating set point slider will have to be adjusted all the way to the left also.) CONTROL SEQUENCE 2103 (Cooling with On/Off Hot Water Heat Control) OR 2105 (Cooling with Proportional Hot Water Heat Control) Cooling Side of the Thermostat Follow steps 1 through 5 for cooling sequence 2101. NOTE: Be sure to adjust the cooling set point slider all the way to the left for maximum cooling. (The heating set point slider will have to be adjusted all the way to the left also.) NOTE: The minimum set point must be adjusted first. Adjustment of the MIN INCR potentiometer directly affects the maximum set point and auxiliary set point.

Analog Control Troubleshooting The following troubleshooting procedure is directed towards single duct cooling applications. The same concepts can be applied to other configurations. CONTROLLER 1. Verify 24 vac at terminals ~ (phase) and - (ground). Tolerance can be 15% to +20% (20.4 to 28.8 vac). 2. Verify 16 vdc at terminals (16 VDC) and (-). a. Tolerance is 15.0 to 17.0 vdc power supply to thermostat. b. If not correct, disconnect thermostat and recheck. If still incorrect, replace CSP controller. 3. Check Requested Flow voltage on terminal IN and -. a. Use chart on page 12 to correlate into cubic feet per minute (cfm). b. If reading is not what is desired, see System Calibration of the Linear Averaging Flow Probe section to adjust thermostat. 4. Check Actual Flow voltage on terminal OUT and - for 0 to 10 vdc. Use chart on page 12, Fig. 14 to correlate into cfm. 5. Check box movement, damper rotation, etc. a. Review Requested Flow and Actual Flow above to determine if unit should be satisfied (within 50 fpm) or driving open or closed. b. If damper is not moving, verify damper is not stuck or at end of travel. Check rotation jumpers for proper position. c. Change Requested Flow to make unit drive opposite direction. This can be accomplished by moving the set point sliders or 1) and 2) below. 1) To manually open the box, remove wiring from terminal IN and jumper terminal IN to terminal 16VDC. This will tell unit to control at 3300 fpm/full airflow, and the green LED should turn on (and the box should drive open). 2) To manually close the box, remove wiring from terminal IN, jumper and IN terminal to - terminal. This will tell unit to control at zero fpm/no airflow, and the red LED should be on (and the box should drive closed).

Wire the control as shown on the control package diagram for the specific installation. Control wiring diagrams can be found inside the control box. If the 35E unit is equipped with electric heat, only power to the electric heater must be supplied; no additional power source is required for the control. If the unit does not have an electric heater or the control transformer option, a fieldsupplied dedicated 24-vac/Class II power source must be installed and wired to the zone controller, to terminals 1 and 2 of connector J1. Refer to unit wire label diagram for minimum size (VA) and grounding requirements for each unit. SUPPLY-AIR TEMPERATURE (SAT) SENSOR INSTALLATION On terminals with heat, the SAT sensor is provided. The sensor is factory wired to the controller and shipped in the control box. The SAT must be field-installed in the duct downstream from the air terminal. The SAT sensor part number is 33ZCSENSAT. See Table 6 for resistance information. To install the sensor, proceed as follows: 1. Remove the plug from one of the 7/8-in. openings in the control box and pass the sensor probe through the hole. 2. Drill or punch a 1/2-in. hole in the duct downstream of the unit, at a location meeting the requirements shown in Fig. 15. 3. Using 2 self-drilling screws (supplied), secure the sensor probe to the duct. The SAT sensor probe is 6 inches in length. The tip of the probe must not touch the inside of the duct. Use field-supplied bushings as spacers when mounting the probe in a duct that is 6 in. or less in diameter. If the unit is a cooling only unit, the SAT sensor is not provided and is not required. If the unit has a multiple outlet attenuator connected directly at the discharge, install the sensor in the multiple outlet attenuator. See Fig. 15. For units equipped with electric reheat, locate the sensor as far downstream as possible. This ensures the sensor will not be affected by excessive radiant heat from the heater coil. Install the sensor a minimum of 2 ft downstream of the coil for units with hot water heat.

Never jumper terminal 16 VDC to - as this would cause a short, and possibly damage the power supply. NOTE: When using the same transformer for more than one control, the phase and ground must be consistent with each device.

DO NOT run sensor or relay wires in the same conduit or raceway with Class 1 service wiring. DO NOT abrade or nick the outer jacket of cable. DO NOT pull or draw cable with a force that may harm the physical or electrical properties. DO NOT bend a cable through a radius sharper than that recommended by its manufacturer. AVOID splices in any control wiring. Perform the following steps if state or local code requires the use of conduit, or if your installation requires a cable length of more than 8 ft: 1. Disconnect the sensor cable from the ComfortID zone controller, at the terminals labeled SAT and GND. 2. Mount the sensor to the duct (see steps 2 and 3 above). 3. Mount a field supplied 4 in x 4 in x 20 in. extension box over the duct sensor. 4. Connect a conduit (1/2-in. nominal) to the zone controller enclosure and extension box. 5. Pass the sensor probe through the extension box opening and into the conduit. 6. Reconnect the sensor leads to the zone controller labeled SAT and GND.

ComfortID CONTROLS Install Sensors Connections and Make Field Wiring

GENERAL All field wiring must comply with National Electrical Code and local requirements. Refer to Tables 6-9 for electrical and wiring specifications.

Disconnect electrical power before wiring inside the controller. Electrical shock, personal injury, or damage to the zone controller can result.

13

Table 6 Thermistor Resistance vs Temperature Values for Supply-Air Temperature Sensor, Primary Air Temperature Sensor and Space Temperature Sensor
RESISTANCE (Ohms) 29481 28732 28005 27298 26611 25943 25295 24664 24051 23456 22877 22313 21766 21234 20716 20212 19722 19246 18782 18332 17893 17466 TEMP (F) 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 RESISTANCE (Ohms) 17050 16646 16253 15870 15497 15134 14780 14436 14101 13775 13457 13148 12846 12553 12267 11988 11717 11452 11194 10943 10698 10459 TEMP (F) 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 RESISTANCE (Ohms) 10227 10000 9779 9563 9353 9148 8948 8754 8563 8378 8197 8021 7849 7681 7517 7357 7201 7049 6900 6755 6613 6475 TEMP (F) 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 RESISTANCE (Ohms) 6340 6209 6080 5954 5832 5712 5595 5481 5369 5260 5154 5050 4948 4849 4752 4657 4564 4474 4385 4299 4214 4132 TEMP (F) 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 RESISTANCE (Ohms) 4051 3972 3895 3819 3745 3673 3603 3533 3466 3400 3335 3272 3210 3150 3090 3033 2976 2920 2866 2813 2761 TEMP (F) 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140

UNIT WITH ELECTRIC HEAT

2 FT. MIN.

PRIMARY AIR INLET

AIR TERMINAL UNIT

ZC

HEAT

SAT

UNIT WITH MULTIPLE OUTLET ATTENUATOR

2 FT. MIN.

PRIMARY AIR INLET

AIR TERMINAL UNIT

MULTIPLE OUTLET ATTENUATOR

LEGEND SAT Supply Air Temperature Sensor ZC Zone Controller

ZC

HEAT

SAT

Fig. 15 Supply Air Temperature Probe (Part No. 33ZCSENSAT) Locations SPACE TEMPERATURE SENSOR INSTALLATION AND WIRING The space temperature (SPT) sensor accessory is ordered separately for field installation. It is installed on interior walls to measure room space air temperature. See Fig. 16-20 and Table 6. The wall plate accommodates both the NEMA (National Electrical Manufacturing Association) standard and the European 1/4 DIN standard. The use of a junction box to accommodate the wiring is recommended for installation. The sensor may be mounted directly on the wall, if acceptable by local codes. DO NOT mount the sensor in drafty areas such as near heating or air-conditioning ducts, open windows, fans, or over heat sources such as baseboard heaters or radiators. Sensors mounted in those areas will produce inaccurate readings. Avoid corner locations. Allow at least 3 ft between the sensor and any corner. Air in corners tends to be stagnant, resulting in inaccurate sensor readings. 14 Sensor should be mounted approximately 5 ft up from the floor, in an area that best represents the average temperature found in the space (zone). The space temperature sensor cover includes a service jack connector. If wiring connection is made to the service jack, the connector can then be used to connect a network service tool with the Carrier Comfort Network system. Before installing the space temperature sensor, decide whether or not the service jack wiring connection will be made. If connection is desired, the CCN communication cable should be available at time of sensor installation, for convenient wiring connections. The cable selected must meet the requirements for the entire network. See Connect the CCN Communication Bus section for CCN communication cable specifications.

3 (MIN)

D 5
1 2 3 4 5 6 RED(+) WHT(GND) BLK(-)

OR 2/3 OF WALL HEIGHT

CCN COM

Fig. 16 Typical Space Temperature Sensor Room Location

SEN SW1

BLK (GND) RED (SPT)

SENSOR WIRING

Fig. 19 Space Temperature Sensor Wiring (33ZCT55SPT)

Cool

Warm

Fig. 17 Space Temperature Sensor (P/N 33ZCT56SPT Shown)

1 2 3 4 5 6 RED(+) WHT(GND) BLK(-)

CCN COM

SEN SW1

SET

WHT (T56) BLK (GND) RED (SPT)

SENSOR WIRING

JUMPER TERMINALS AS SHOWN

Cool

Warm

Fig. 20 Space Temperature Sensor Wiring (33ZCT56SPT)

NOTE: Dimensions are in inches.

Fig. 18 Space Temperature Sensor and Wall Mounted Humidity Sensor Mounting 15

Install and wire the space temperature sensor as follows: NOTE: Space temperature sensor will be identified as T55 or T56. Refer to Control Sequence Drawings to determine which SPT is part of the particular control package being installed. (The difference between T55 and T56 is that T56 includes set point adjustment capability.) 1. Locate the two Allen type screws at the bottom of the sensor. 2. Turn the two screws clockwise to release the cover from the sensor wall mounting plate. 3. Lift the cover from the bottom and then release it from the top fasteners. 4. Feed the wires from the electrical box through the opening in the center of the sensor mounting plate. 5. Using two no. 6-32 x 1 mounting screws (provided with the sensor), secure the sensor to the electrical box. 6. Use 20 gage wire to connect the sensor to the controller. The wire is suitable for distances of up to 500 ft. Use a three-conductor shielded cable for the sensor and set point adjustment connections. The standard CCN communication cable may be used. Refer to Table 8. If the set point adjustment (slide-bar) is not required, then an unshielded, 18 or 20 gage, two-conductor, twisted pair cable may be used. Refer to Table 7. The CCN network service jack requires a separate, shielded CCN communication cable. Always use separate cables for CCN communication and sensor wiring. (Refer to Fig. 19 and 20 for wire terminations.) 7. Replace the cover by inserting the cover at the top of the mounting plate first, then swing the cover down over the lower portion. Rotate the two Allen head screws counterclockwise until the cover is secured to the mounting plate and locked in position. 8. For more sensor information, see Table 6 for thermistor resistance vs temperature values. NOTE: Clean sensor with damp cloth only. Do not use solvents. Table 7 Recommended Sensor and Device Wiring
MANUFACTURER Belden Columbia American Quabik Alpha Manhattan PART NUMBER Regular Plenum 8205 88442 D6451 A21501 A48301 6130 1895 M13402 M64430

c. For T56 sensors, connect the remaining wire (WHITE/CLR) to the T56 terminal on the controller. Connect the other end of the wire to the right most terminal on the SET terminal block. d. In the control box, connect the cable shield to J1-3, equipment ground. e. Install a jumper between the two center terminals (right SEN and left SET). WIRING THE CCN NETWORK COMMUNICATION SERVICE JACK To wire the service jack, perform the following: 1. Strip back the jacket from the CCN communication cable(s) at least 3 inches. Strip 1/4-in. of insulation from each conductor. Remove the shield and separate the drain wire from the cable. Twist together all the shield drain wires and fasten them together using an closed end crimp lug or a wire nut. Tape off any exposed bare wire to prevent shorting. 2. Connect the CCN + signal wire(s) (RED) to Terminal 5. 3. Connect the CCN signal wire(s) (BLACK) to Terminal 2. 4. Connect the CCN GND signal wire(s) (WHITE/CLR) to Terminal 4. PRIMARY AIR TEMPERATURE SENSOR INSTALLATION A primary air temperature (PAT) sensor is used on a zone controller which is functioning as a Linkage Coordinator for a non-CCN Linkage compatible air source. The part number is 33ZCSENPAT. See Fig. 21. The sensor is also available as field-supplied accessory. When used on a zone controller, try to select a zone controller which will allow installation of the PAT sensor in the main trunk, as close to the air source as possible. See Fig. 22. To mount the PAT sensor, remove sensor cover. 1. Drill a 1/2-in. hole in supply duct. 2. Using field-supplied drill tap screw, secure sensor to duct. 3. Connect sensor to zone controller using field-supplied 2-conductor cable. Refer to Table 7. 4. Use field-supplied wire nuts to connect cable to sensor. 5. At zone controller, connect sensor wires to PAT and GND terminals.

NOTE: Wiring is 20 gage, 2 conductor twisted cable.

WIRING THE SPACE TEMPERATURE SENSOR AND SET POINT ADJUSTMENT SLIDEBAR To wire the sensor and slidebar, perform the following: 1. Identify which cable is for the sensor wiring. 2. Strip back the jacket from the cables at least 3 inches. Strip 1/4-in. of insulation from each conductor. Cut the shield and drain wire from the sensor end of the cable. 3. Connect the sensor cable as follows: a. Connect one wire from the cable (RED) to the SPT terminal on the controller. Connect the other end of the wire to the left terminal on the SEN terminal block of the sensor. b. Connect another wire from the cable (BLACK) to the ground terminal on the controller. Connect the other end of the wire to the remaining open terminal on the SEN terminal block. 16

Fig. 21 Primary Air Temperature Sensor (Part Number 33ZCSENPAT)

INDOOR-AIR QUALITY SENSOR INSTALLATION The indoor-air quality (IAQ) sensor accessory monitors carbon dioxide levels. This information is used to increase the airflow to the zone and may also modify the position of the outdoor-air dampers to admit more outdoor air as required to provide the desired ventilation rate. The wall sensor is used to monitor the conditioned space. The sensor uses infrared technology to measure the levels of CO2 present in the air. The wall sensor is available with or without an LCD readout to display the CO2 level in ppm and is also available in a combination model which senses both temperature and CO2 level. The CO2 sensors are factory set for a range of 0 to 2000 ppm and a linear voltage output of 0 to 10 vdc. Refer to the instructions supplied with the CO2 sensor for electrical requirements and terminal locations. The sensor requires a separate field-supplied 24 vac 25 va transformer to provide power to the sensor. The transformer may be mounted in the control box if space is provided (except electric heat units). For factory configuration changes to some models of the sensor, the User Interface Program (UIP) or Sensor Calibration Service Kit is required. To accurately monitor the quality of the air in the conditioned air space, locate the sensor near the return air grille so it senses the concentration of CO2 leaving the space. The sensor should be mounted in a location to avoid direct breath contact. Do not mount the space sensor in drafty areas such as near supply diffusers, open window, fans, or over heat sources. Allow at least 3 ft between the sensor and any corner. Avoid mounting the sensor where it is influenced by the supply air; the sensor gives inaccurate readings if the supply air is blown directly onto the sensor. To mount the sensor, refer to the installation instructions shipped with the accessory kit. INDOOR AIR QUALITY SENSOR WIRING To wire the sensor after it is mounted in the conditioned air space, see Fig. 23-25 and the instructions shipped with the sensor. Use two 2-conductor 20 American Wire Gage (AWG) twisted-pair cables (see Table 7) to connect the field-supplied separate isolated 24 vac power source to the sensor and to connect the sensor to the control terminals. To connect the sensor to the control, identify the positive (+) and ground (GND) terminals on the sensor and connect the positive terminal to the RH/IAQ terminal on the control and connect the ground terminal to terminal GND. HUMIDITY SENSOR (Wall-Mounted) INSTALLATION The accessory space humidity sensor is field supplied and installed on an interior wall to measure the relative humidity of the air within the occupied space. See Fig. 26. The use of a standard 2 x 4-in. electrical box to accommodate the wiring is recommended for installation. The sensor can be mounted directly on the wall, if acceptable by local codes. If the sensor is installed directly on a wall surface, install the humidity sensor using 2 screws and 2 hollow wall anchors (field-supplied); do not overtighten screws.

Fig. 22 Primary Air Temperature Sensor Installation (Air-Handling Unit Discharge Locations)

Fig. 23 Indoor Air Quality Sensor (Wall-Mounted Version Shown) 33ZCSENCO2

Do NOT clean or touch the sensing element with chemical solvents; they can permanently damage the sensor. The sensor must be mounted vertically on the wall. The Carrier logo should be oriented correctly when the sensor is properly mounted. Fig. 24 Ventilation Rates Based on CO2 Set Point

17

IAQ GND
0
HF23BJ042
Made in Switzerland by Belimo Automation

21
35 in-lb (4 Nm) 80...110s

87

LR 92800

NEMA2
LISTED 94D5 TEMP. IND. & REG. EQUIP.

UL
24VAC/DC 50/60Hz 3VA 2W
COM WIP

Class 2 Supply

24VAC*
3
wht

LINE VOLTAGE SEPARATE POWER SUPPLY REQUIRED*

5K

1
ora blk

2
red

yel

blu

*Do not connect to the same transformer that supplies power to the zone controller.

Fig. 25 Indoor Air Quality Sensor Wiring

DO NOT mount the sensor in drafty areas such as near heating or air-conditioning ducts, open windows, fans, or over heat sources such as baseboard heaters, radiators, or wall-mounted light dimmers. Sensors mounted in those areas will produce inaccurate readings. Avoid corner locations. Allow at least 4 ft between the sensor and any corner. Airflow near corners tends to be reduced, resulting in erratic sensor readings. Sensor should be vertically mounted approximately 5 ft up from the floor, beside the space temperature sensor. For distances up to 500 feet, use a 3-conductor, 18 or 20 AWG cable. A CCN communication cable can be used, although the shield is not required. The shield must be removed from both ends of the cable if this cable is used. The power for the sensor is provided by the control board. The board provides 24 vdc for the sensor. No additional power source is required. To wire the sensor, perform the following: 1. At the sensor, remove 4 in. of jacket from the cable. Strip 1/ in. of insulation from each conductor. Route the cable 4 through the wire clearance opening in the center of the sensor. 2. Connect the RED wire to the sensor screw terminal marked (+). 3. Install one lead from the resistor (supplied with the sensor) and the WHITE wire, into the sensor screw terminal marked (). After tightening the screw terminal, test the connection by pulling gently on the resistor lead. 4. Connect the remaining lead from the resistor to the BLACK wire and secure using a field-supplied closed end type crimp connector or wire nut. 5. Using electrical tape, insulate any exposed resistor lead to prevent shorting. 6. At the control box, remove the jacket from the cable. 7. Strip 1/4 in. of insulation from each conductor.

8. Connect the RED wire to terminal +24v on the control board. 9. Connect the BLACK wire to terminal GND on the control board. 10. Connect the WHITE/CLEAR wire to terminal RH/IAQ on the control board.

Fig. 26 Wall Mounted Relative Humidity Sensor (P/N 33AMSENRHS000)

18

Connect the CCN Communication Bus The

zone controllers connect to the bus in a daisy chain arrangement. The zone controller may be installed on a primary CCN bus or on a secondary bus from the primary CCN bus. Connecting to a secondary bus is recommended. At 9,600 baud, the number of controllers is limited to 128 zones maximum, with a limit of 8 systems (Linkage Coordinator configured for at least 2 zones). Bus length may not exceed 4000 ft, with no more than 60 devices on any 1000-ft section. Optically isolated RS-485 repeaters are required every 1000 ft. At 19,200 and 38,400 baud, the number of controllers is limited to 128 maximum, with no limit on the number of Linkage Coordinators. Bus length may not exceed 1000 ft. The first zone controller in a network connects directly to the bridge and the others are wired sequentially in a daisy chain fashion. The CCN communication bus also connects to the zone controller space temperature sensor. Refer to the Install Sensors and Make Field-Wiring Connections section for sensor wiring instructions. COMMUNICATION BUS WIRE SPECIFICATIONS The Carrier Comfort Network (CCN) communication bus wiring is field-supplied and field-installed. It consists of shielded three-conductor cable with drain (ground) wire. The cable selected must be identical to the CCN communication bus wire used for the entire network. See Table 8 for recommended cable. Table 8 Recommended Cables
MANUFACTURER Alpha American Belden Columbia CABLE PART NO. 2413 or 5463 A22503 8772 02525

NOTE: The communication bus drain wires (shield) must be tied together at each zone controller. If the communication bus is entirely within one building, the resulting continuous shield must be connected to ground at only one single point. If the communication bus cable exits from one building and enters another building, connect the shields to ground at a lightning suppressor in each building where the cable enters or exits (one point only).

Water Valve Installation

Disconnect power before wiring the terminal control unit or electrical shock and personal injury could result. Water valves are field supplied. Carrier offers two different hot water valve applications: on/off and floating point modulating proportional control. See Table 10 for specifications for compatible water valves. To connect the field-supplied water valves to the wiring harness terminal board located in the terminal control unit, refer to the wiring labels for the control package.

Follow the valve manufacturers recommended installation instructions. Table 10 Valve Specifications
3 POINTS FLOATING VALVE Voltage 24 vac 24 vac (15%) Frequency 50/60 Hz 50/60 Hz Power Requirement Not to exceed 15 va Not to exceed 15 va max inrush TYPE ON/OFF VALVE

NOTE: Conductors and drain wire must be at least 20 AWG (American Wire Gage), stranded, and tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of 20 C to 60 C is required.

ComfortID Start-Up
GENERAL Air volume delivery to the conditioned space is controlled by the modulating of the primary air damper and the sequencing of the air source supply fan. The controller positions the damper by way of an actuator and turns the fan on and off through linkage for the CCN compatible air source equipment control. PRIMARY SYSTEM CHECK 1. Check that all controls, control box, and ductwork have been properly installed and set according to installation instructions and job requirements. 2. Check that final filters have been installed in the airhandling apparatus. Dust and debris can adversely affect system operation. 3. Check fan and system controls for proper operation. 4. Check electrical system and connections of any optional electric reheat coil. If hot water reheat is used, check piping and valves per job drawings. 5. Check that all air duct connections are tight. 6. See that all balancing dampers at box outlets are in fullopen position. ComfortID CONTROL SYSTEM CHECK 1. Check interconnections between thermostats and unit controls. 2. Force all dampers to control to the maximum cooling cfm using the Building Supervisor, ComfortWORKS, Network Service Tool or ComfortID Test and Balance Tool software. 3. Set supply-duct balancing dampers, if used, in maximum cool position.

CONNECTION TO THE COMMUNICATION BUS 1. Strip the ends of the red, white, and black conductors of the communication bus cable. 2. Connect one end of the communication bus cable to the bridge communication port labeled COMM2 (if connecting on a secondary bus). When connecting the communication bus cable, a color code system for the entire network is recommended to simplify installation and checkout. See Table 9 for the recommended color code. Table 9 Color Code Recommendations
SIGNAL TYPE + Ground CCN BUS WIRE COLOR Red White Black PLUG PIN NUMBER 1 2 3

3. Refer to Fig. 27. Connect the other end of the communication bus cable to the terminal block labeled CCN in the zone controller of the first air terminal. Following the color code in Table 9, connect the Red (+) wire to Terminal 1. Connect the White (ground) wire to Terminal 2. Connect the Black () wire to Terminal 3. 4. Connect additional zone controllers in a daisy chain fashion, following the color coded wiring scheme in Table 9. 19

15

LOW

US
1 1 2 J6

0
HF23BJ042
Made in Switzerland by Belimo Automation

35 in-lb (4 Nm) 80...110s

ZONE Controller
J8 SEC DMP Part Number: 33ZCFANTRM S/N: 3 Bus#: Element#: Unit#:

+24V RH/IAQ SPT GND GND FAN AC SECFLOW FAN SAT +10V 24VAC T56 DMPPOS N/A GND HEAT3 GND PAT TEST N/A GND J4 1 1 1 2

16

CCN COMMUNICATION CONNECTOR RED (+) WHITE (GND)

J7

J2B LEN

J2A CCN

- G

LR 92800

CW COM CCW

+ - G

CCN

NEMA 2
LISTED 94D5 TENP IND & REG. EQUIP.

3 SRVC J3

Class 2 Supply

BLACK ()

CCW COM CW HEAT1 24VAC HEAT2

J1

5K WIP yel blu ora

24VAC

HIGH

24VAC/DC 50/60 Hz 3VA 2W

COM

J6 + G 6 1 3

1 2 3
blk red wht

Fig. 27 CCN Terminations at Zone Controller

4. Check that the static pressure available at each box is above the minimum required, force all dampers to control to the minimum cooling cfm and verify that the static pressure is below the maximum safe operating limits when the damper is providing minimum cooling airflow. 5. Set air source supply fan speed and duct static pressure regulator to obtain satisfactory static pressure at design airflow. 6. While at peak system load, check system operation and pressures. 7. Check duct pressure at various points in the system. If system static pressure probe has been properly located, pressure at last units of all branch headers should remain essentially the same. If pressure has changed considerably, recheck the supply air static pressure controller or relocate the probe to better sense system pressure changes. 8. Remove all forces and balance each control box zone using through the balancing procedure described on page 11. 9. Check that each heating coil is fully operational and that proper airflow is maintained during heating. It is important to maintain sufficient airflow to units with electric heating elements. Supply-air temperature should NOT EXCEED 105 F in any stage of heating operation. Check the system to make sure that it does not cycle on and off during heating.

CCN System Start-Up The Building Supervisor,

ComfortWORKS, and the Network Service Tool can aid in system start-up and troubleshooting.

All set-up and set point configurations are factory set and field adjustable. Changes are made by using either Building Supervisor, ComfortWORKS or the Network Service Tool. The Network Service Tool can be used as a portable device to change system set-up and set points from a zone sensor or terminal control module. During start-up, the Building Supervisor or the Network Service Tool can also be used to verify communication with each controller. For specific operating instructions, refer to the appropriate user manual. See Table 11 for troubleshooting information. ComfortID TEST AND BALANCE TOOL SOFTWARE The ComfortID Test and Balance Tool software is used for testing each controller if the Network Service Tool or CCN are not available. The ComfortID Test and Balance Tool is compatible with Windows95 and higher and Windows NT4 (with Service Pack Level 3 or better) operating systems. This software is used for control calibration. It allows for various functions that expedite system checks and testing. Carrier requires the use of the B&B485CARLP9A Port Powered RS232 to RS485 Converter for proper operation. NOTE: The B&B485CARLP9A Port Powered RS232 to RS485 is available through: B&B Electronics 1500 Boyce Memorial Drive P.O. Box 1040 Ottawa, IL 61350 Refer to the ComfortID Test and Balance Tool Software Installation and Operation Instructions (Carrier publication no. 533-360) for additional information.

20

Table 11 Troubleshooting Guide For ComfortID Terminal Controls

PROBLEM Measured Airflow Does Not Agree With Display Value. Supply Air Temperature (SAT) Displays 0.0. Terminal Not Equipped With Heat or Field Installed. Baseboard Perimeter Heat Does Not Work. CAUSE Terminal airflow not calibrated or airflow sensor not calibrated. Wrong terminal inlet size. No heat type configured or ducted heat not configured. No heat type configured. CORRECTIVE ACTION Perform damper/transducer and zone calibration. Check and correct terminal inlet size if necessary. For terminals without heat, the SAT sensor is not used. If required, configure Heat Type = 2 and Ducted Heat = YES. Configure Heat Type. If modulating baseboard, then Ducted Heat must equal YES and sensor HH79NZ078 must be affixed to measure leaving water temperature. Readjust the following service configuration parameters: Heat Start Value = 110 F Maximum Duct Temperature = 180 F P Gain = 20 I Gain = 1.3 Check fuses and disconnect. Verify airflow exceeds 500 fpm. Adjust Reheat CFM Limit if required to operate below 120 F discharge with all stages operating. Repair as required. Check wiring and correct if necessary. Retest water valve operation. Check and readjust maximum airflow limits. Check system static pressure. Reduce pressure if required. Replace with proper size. Install PAT sensor and configure as a Linkage Master with a system size of 1 zone.

Modulating Baseboard Hot Water Heat Does Not Control Properly.

Improperly configured.

Electric Reheat Does Not Operate.

No power to heater. Airflow too low or high temperature limit tripped. No hot water available. Water valve wired wrong or not functioning. Airflow limits not set properly. Excessive system static pressure. Diffusers too small. Primary air temperature sensor not installed and no Linkage Master is used (PAT sensor required for control package 4140 and 4145, cooling only, stand-alone operation).

Hot Water Reheat Does Not Operate.

Excessive Air Noise.

Unit Will Not Provide Modulating Damper Control During Air Source Heating/Warm-Up Mode.

VVT CONTROLS General

DIRECT DRIVE HIGH TORQUE ACTUATOR The direct-drive high torque actuator is used in VVT (variable volume and variable temperature) systems for changing the damper position. The actuator is factory-installed on the terminal damper and is controlled by a zone controller or a monitor thermostat. The thermostat calculates how much heating or cooling is required to each zone in the VVT system. The actuator receives the commands from its controlling device and moves its damper to change the amount of heated or conditioned air that is sent to its zone. If the 35E unit is equipped with electric heat, only power to the electric heater must be supplied. If the unit does not have an electric heater, then a field-supplied dedicated 24 vac/Class II power source must be installed and wired to the VVT controller. Refer to Table 12 for the minimum VA requirement and to the wire label diagram for power connections. RELAY PACKAGE The relay package is factory-supplied as required depending on the control package ordered. The relay pack output harness is connected to the output connector on the relay pack. The pigtail is routed through the grommet the bottom of actuator. For hot water heat applications, connect the white wire from the relay pack output harness to the field-supplied two-position water valve. See the unit wiring diagram for more information. ADDITIONAL SENSOR INSTALLATION Additional sensors are required for certain control sequences. A pressure transducer is factory supplied, wired, piped, and installed inside the control box for units with pressure independent controls. Follow the installation instructions provided with each sensor. NOTE: Pressure sensor is NOT installed inside the actuator housing. There is no clearance available for the pressure transducer inside the actuator. THERMOSTATS Thermostats are sold separately and are not provided as part of any VVT control package. Refer to the specific control publication for thermostat operation.

Thermostat Placement Begin the thermostat installation by determining where the device will be located. In most cases, this will be pre-determined by the building plans. The thermostat should be located on an interior wall, about 5 ft from the floor. The device should be located away from direct sunlight, drafts, or interior heat sources which may influence temperature readings. The device may also be mounted in a remote location with the use of an optional remote room sensor. To mount the thermostat, perform the following: 1. Cut a hole in the wall for the terminal board housing. The hole should be 13/4 in. by 13/4 inches. See Fig. 29. NOTE: A 2-in. x 4-in. electric box mounted horizontally may be used instead of cutting the hole. 2. Remove the cover from the thermostat/controller. Carefully remove the circuit board from the backplate of the thermostat/controller. Line up the backplate with the hole in the wall. Push the protruding part of the backplate into the hole. Pull the thermostat/controller wires out through the backplate. 3. Attach backplate to wall with screws provided. Wiring Requirements The wiring requirements for
the Carrier Comfort Network system are: CCN COMMUNICATIONS 18 or 20 gage, 3-conductor, shielded, stranded wire, color coded (RED, BLACK, GREEN), plenum rated if required, long enough to run from thermostat to thermostat in daisy-chain configuration. (Refer to Table 12 for specific control package requirements.) Table 12 Minimum VA Requirements
CONTROL SEQ NO. 8200 8201 8202 8206 8207 8208 8209 8210 MIN VA REQUIREMENT 30 Factory Supplied (75) 40 35 Factory Supplied (75) 45 30 35

21

WITH COVER
ACTUATOR COVER

COVER REMOVED
3 PIN TEMPERATURE SENSOR CONNECTOR (2) 5/16-18 SET SCREWS

5 PIN T-STAT CONNECTOR COVER SCREW (HIDDEN) COVER SCREW

10 PIN ANALOG CONNECTION

THRU HOLE FOR TEMP. SENSOR

KMC

ACTUATOR SHIPPED AT CLOSED POSITON 8 PIN RELAY CONNECTOR

GROMMET

MOUNTING BRACKET

(2) 3 PIN POWER CONNECTOR

WIRING HARNESSES

Fig. 28 High Torque Actuator

1 3/4

1 3/4

Fig. 29 Mounting Hole Dimensions

THERMOSTAT TO TERMINAL CONTROL BOX 18 gage, 5-conductor, shielded, stranded wire, color coded (RED, WHITE, BLUE, YELLOW, GREEN), plenum rated if required, long enough to run from thermostat to damper actuator to the control box.

Wiring Connections

2. Push the wires back into the wall. 3. Align the terminal board with the right track in the back plate housing. See Fig. 31. The ribbon strip side of the terminal block should be away from the wall. Push the terminal block into the track until about 1/2 in. is left protruding. 4. Align the ribbon cable from the thermostat/controller circuit board with the ribbon connector on the terminal board and push gently to connect. 5. Push the terminal board fully into backplate until the latch clicks into place. 6. Place the foam backing on the circuit board. Slide the circuit board under the back plate securing bars. DO NOT CREASE RIBBON CABLE. 7. Align thermostat board with alignment pin. Gently pull down on the thermostat latch and press firmly until the circuit board snaps into place. 8. If optional locking thermostat cover is purchased, insert locking clip on the inside of the thermostat cover. Push firmly into place. 9. Insert tabs on thermostat cover into top slots on the backplate. Press firmly on the bottom of the thermostat cover to snap cover into lace. NOTE: If the optional locking thermostat cover was installed, the key must be inserted into the locking device to remove front cover.

Electric shock can cause injury or death. Ensure power to the HVAC unit has been disconnected before wiring. To wire the thermostat/controller, perform the following: 1. Connect the communication bus and damper actuator wiring to the terminal board of the thermostat. See Fig. 29 and 30. 22

Fig. 30 Wiring Connections System parameters such as system type (pressure dependent or independent), and controller address along with user parameters such as occupancy and set point schedules, must be entered before final checkout and commissioning. For more information and details regarding specific control configuration parameters and programming procedures, refer to the Carrier Comfort Network system Variable Volume and Temperature (VVT) Product Data literature and the configuration instructions provided with the thermostat. Refer to the specific control sequence (35E-82XX) for detailed operational information. This information should be used to test and commission the control.

Control Start-Up
GENERAL Air volume delivery to the conditioned space is controlled by the modulating of the primary air damper and the sequencing of the air source supply fan. The VVT controller positions the damper by way of an actuator and turns the fan on and off through relay contactors. PRIMARY SYSTEM CHECK 1. Check that all controls, control box, and ductwork have been properly installed and set according to installation instructions and job requirements. 2. Check that final filters have been installed in the airhandling apparatus. Dust and debris can adversely affect system operation. 3. Check fan and system controls for proper operation. 4. Check electrical system and connections of any optional electric reheat coil. If hot water reheat is used, check piping and valves per job drawings. 5. Check that all air duct connections are tight. 6. See that all balancing dampers at box outlets are in fullopen position. 23

Fig. 31 Terminal Board Installation

VVT Control Configuration/Testing Carrier

VVT controls require a field-supplied VVT thermostat for the specific application based on the control package ordered. The thermostat is factory-supplied with default configuration. This allows pressure dependent cooling only terminals to operate in a stand-alone mode, during the construction phase. The installer is required to configure the terminal, system and user specific parameters. All programming can be done at the thermostat without the use of a PC. Terminal parameters include inlet area (pressure independent), airflow limits (pressure independent), minimum or maximum damper position adjustments, and damper position factor (reheat applications).

Copyright 2006 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 3 Catalog No. 533-530 Printed in U.S.A. Form 35E-2SI Pg 24 3-06 Replaces: 35E-1SI Tab 6a