CARRIER WEATHERMAKER 50K (01) PDF DOCUMENT

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product.

Always follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Affix any labels that ship with the unit or accessory installation instructions to the unit. Consult local building codes, and the current editions of the National Electrical Code (NEC)/National Fire Protection Association (NFPA) 70. In Canada, refer to the current editions of the Canadian Electrical Code (CEC) CSA C22.1.

Recognize safety information. This is the safety-alert symbol. When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

Failure to follow this warning could result in personal injury or death. Before performing installation, service, or maintenance on this unit, turn off the main power disconnect to the unit and install lock and lockout tag. Some equipment may have multiple power disconnects.

This equipment may contain a UV-C LAMP. Look for the UVC warning on panels or doors before opening. Disconnect UV-C power before opening access doors, removing panels, or installing, maintaining, or servicing UV-C lamps or fixtures. Do not operate UV-C with open access doors or with panels removed. Do not operate UV-C outside of unit cabinet. Exposure to UV-C can cause harm to the eyes and skin. Review the UV-C lamp accessory installation instructions for details on installing, testing, and maintaining UV-C lamps.

Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing air conditioning equipment.

All airside panels include three paddle flaps with latch bolts. Use a 7/16 wrench or socket to loosen all the latch bolts and rotate the paddle flat 90 degrees to allow the door to open.

Access door retainers are available as a factory-installed option. To use the access door retainer follow these steps:

1. Open the access door to the desired opening.

2. Pull up on the retainer rod so that the end is out of the retainer bracket.

3. Rotate the retainer rod toward the door bracket.

4. Insert the rod end into one of the holes in the door bracket. Open or close the door as needed to get the rod to line up with the hole in the bracket.

The control and power box access doors are secured with cam latches. Use a flat head screwdriver to turn the cam latch 90 degrees to allow the door to open. Each door is equipped with a retainer to hold the door open. Ensure the control and power box doors are closed and secured after service to prevent dirt and water ingress.

An EXV access panel is located in the outdoor section to allow easy access to EXVs for inspection or service. To remove the EXV access panel cover, rotate the 6 cam latches 90 degrees and use a flat head screwdriver or putty knife to pull out the top of the panel. When reinstalling the EXV access panel cover, ensure the cover is properly installed to prevent air and water leaks.

The following items should be checked monthly:

• Check door latches are secure.

• Check door seals are in place.

• Inspect pre-indoor coil filters, replace if dirty.

• Inspect outdoor air inlet screens, clean if dirty.

• Inspect outdoor coil(s) (during cooling season), clean if dirty.

• Inspect indoor coil(s), clean if dirty.

• Inspect condensate drain, clean if dirty and clear if blocked.

• Inspect indoor fan system.

• Inspect indoor fan belt(s), tighten or replace as needed.

• Inspect indoor shaft fan bearings and coupling, lubricate as needed.

• Inspect power and control box.

• Check UV-light operation (if equipped).

• Review unit alarm history.

These items should be checked at the beginning of each cooling season:

• Inspect unit exterior.

• Inspect door gaskets and seals.

• Check that all electrical connections are tight.

• Check voltage and voltage imbalance for all power legs.

• Check indoor fan operation.

• Check indoor fan motor amp draw.

• Check A2L mitigation system operation.

• Inspect EXVs, verify cables are tight.

• Inspect outdoor fans.

• Check outdoor fan operation.

• Inspect refrigerant circuit piping.

• Check crank case heater operation.

• Clean condensate drain.

• Inspect compressors.

• Check compressor operation.

• Check cooling operation.

• Check compressor voltages and amp draws.

• Check refrigerant circuit pressures and temperatures.

• Check refrigerant circuit oil level.

• Check cooling air temperatures.

• Check Humidi-Mizer system operation (if equipped).

• Check economizer damper operation (if equipped).

• Check relief damper operation (if equipped).

• Check exhaust fan operation (if equipped).

• Shutdown heater (optional).

These items should be checked at the beginning of each heating season:

• Inspect unit exterior.

• Check door gaskets and seals.

• Check that all electrical connections are tight.

• Check voltage and voltage imbalance for all power legs.

• Check indoor fan operation.

• Check indoor fan motor amp draw.

• Inspect electric heater (if equipped).

• Inspect hot water coils and piping (if equipped).

• Check inducer fan operation.

• Check heating operation.

• Check heating air temperatures, including temperature rise.

• Check electric heater amp draw (if equipped).

• Check economizer damper operation (if equipped).

• Check relief damper operation (if equipped).

• Check exhaust fan operation (if equipped).

• Disable cooling operation in SmartVu™ Control (optional).

The pre-filter rack is in front of the indoor air coil and can be accessed from the filter/indoor coil access door. Follow the steps below to inspect the filters.

1. Open the filter/indoor coil access door (tool required).

2. Remove the bottom thumb screw from the filter access cover. Save screw.

3. While holding on to the cover flange, remove the top thumb screw. Save the thumb screws.

4. Lift up on the filter access cover until the cover lip is over the edge of the side panel and remove the cover. Save cover.

5. To reinstall the filter access cover, start by inserting the filter access cover lip behind the side panel rail. Then follow the steps in reverse order to secure it.

It is recommended to use the same filter type that the unit was ordered with. Changing the filter type may affect fan performance. Pre-filter racks are not field convertible between 2 and 4 inches.

Follow these steps to replace the filters:

1. Follow steps 1-4 in the “FILTER INSPECTION” section to access the filter rack.

2. Slide the black filter clip outward to remove it from the filter rack.

3. Remove the top right filter by pulling the bottom of the filter away from the middle filter rail and then sliding the filter down to remove it from the top filter rail.

4. A filter hook is included with all units for filter removal. The filter hook ships on the floor in front of the filter rack and is secured with zip ties.

5. Slide the remaining filters in the top filter rack down to the edge of the filter rack to remove. Use the filter hook as needed.

6. After all the top filters are out, remove the bottom right filter by pulling the top of the filter away from the middle filter rail and then sliding the filter up to remove it from the bottom filter rail.

7. Slide the remaining bottom filters down to the edge of the filter rack to remove, using the filter hook as needed.

8. To insert new filters, start with the bottom row of filters.

9. Insert the bottom of the first filter into the bottom filter rail and then slide the top of the filter into the middle filter rail.

10. Slide the filter to the far end of the filter rack using the next filter or the filter hook.

11. Once all the bottom filters are in place, insert the first filter of the top row into the top filter rail and then slide the bottom of the filter into the middle filter rail.

12. Slide the filter to the far end of the filter rack using the next filter or the filter hook.

13. Once all the filters are in place, re-insert the filter clip.

14. Follow the steps for “FILTER INSPECTION” to re-install the filter access panel.

NOTE: Use a marker to write the filter change date on the filter or on a piece of masking tape attached to the filter.

Inspect outdoor coils for cleanliness. For units with hail guards, remove the hail guards to inspect the coil. Use a non-metallic brush to remove any large debris from both coil faces. For units with hail guards, use the non-metallic brush to clean the hail guards before re-installing.

OUTDOOR COIL RINSING

Coil rinsing is recommended at least once per year. IMPORTANT: Do not spray water on electrical components or sensors in the outdoor section. After surface debris has been removed, use low pressure water to rinse the coil in the opposite direction of airflow (back side to front side). The back face of the coil can be accessed through the outdoor section access door. IMPORTANT: DO not use high pressure washers to clean the coil. After rinsing, ensure the coil is not packed with water before enabling cooling operation. Use low pressure air, gently pat the coil, or turn on the condenser fans in service mode to remove trapped water.

OUTDOOR COIL CLEANING

When rinsing does not clean the coil of grease or other contaminants, chemical coil cleaning is recommended. Periodic cleaning with Totaline® coil cleaners can help extend coil life. When using third-party coil cleaners, ensure the cleaner is microchannel coil safe for un-coated outdoor coils or epoxy safe and microchannel coil safe for e-coated outdoor coils.

IMPORTANT: Ensure UV emitters are disabled prior to accessing the indoor coils. Access the right side of the indoor coil through the filter/indoor coil access door. Inspect the face of the indoor coil for cleanliness. Use a non-metallic brush to remove any large debris and a fin comb to straighten any bent fins. The far side of the indoor coil can be accessed from the EXV access panel.

INDOOR COIL RINSING

Coil rinsing is recommended at least once per year. IMPORTANT: DO not spray water on the UV emitters. Protect the EXV cable connectors prior to rinsing. Do not directly spray the EXVs. Remove the mist eliminators to access the back side of the indoor coil. Use low pressure water to rinse the coil in the opposite direction of airflow. IMPORTANT: Do not use high pressure washers to clean the coil. After rinsing, ensure the coil is not packed with water.

INDOOR COILS CLEANING

When rinsing is not enough, chemical coil cleaning is recommended. Protect the EXV cable connectors. Ensure the coil cleaner is aluminum/copper coil safe for un-coated indoor coils or epoxy safe and aluminum/copper coil safe for e-coated indoor coils. For units with Humidi-Mizer system, clean the coil with an epoxy and microchannel coil safe cleaner. IMPORTANT: Do not use acid or coil brighteners to clean the coil.

CLEANING COILS WITH AIR

For applications where using water is not acceptable, a low-pressure vacuum or low pressure compressed air may be used. Clean in the opposite direction of the airflow. Ensure the vacuum or compressed air does not damage the coil fins.

BELT REPLACEMENT

1. Disconnect unit power, lock-out/tag-out.

2. Loosen motor mounting nuts and bolts.

3. Loosen fan motor nuts.

4. Turn motor jacking bolts to move motor mounting plate left to reduce belt tension, which allows removal of the belts. Remove and dispose of the used belt(s).

5. Install the new belt(s).

6. Adjust belt tension.

ADJUST BELT TENSION

1. Disconnect unit power, lock-out/tag-out.

2. Loosen motor mounting nuts and bolts.

3. Loosen fan motor nuts.

4. Turn motor jacking bolts to move motor mounting plate left or right for proper belt tension.

5. Tighten nuts.

6. Adjust bolts and nut on mounting plate to secure motor in fixed position.

7. Restore power to unit.

8. Perform fan test to check belt. A slight bow should be present in the belt on the slack side of the drive while running under full load. Adjust as necessary. NOTE: Recheck belt tension after 24 hours of operation.

This table lists the factory-installed belt size. Belt sizes may be field changed during air balancing. Verify unit installed belt size prior to ordering new belts.

First, inspect the fan and motor sheaves for excessive wear and replace as necessary. To align the sheaves:

1. Disconnect unit power, lock-out/tag-out.

2. Loosen fan shaft pulley bushing.

3. Slide fan pulley along fan shaft.

4. Make angular alignment by loosening motor from mounting plate. Use a straightedge to ensure the pulley and shafts are parallel.

5. Retighten pulley.

6. Restore power to the unit.

Inspect the fan shaft bearings and coupler (60 ton units only) to ensure they contain a grease charge. In mild climates, lubricate every 4-6 months or 2500 operating hours. For humid climates, lubricate at least every month. Lubrication may be required more frequently based on operating conditions or environment. IMPORTANT: Do not over lubricate bearings or coupler.

Units without extended lubrication lines: The right most fan shaft bearing can be accessed from the indoor fan motor access door. The far indoor fan shaft bearing and fan coupler can be accessed from the indoor fan/VFD access panels. Use a hand grease gun to install lubricant using the 1/4 in. grease fitting on the top of the bearing and coupler. Turn the fan shaft while lubricating. Stop when a light bead of grease appears around the bearing seal.

Units with extended lubrication lines: Units with the service pack or low ambient options will include extended lubrication lines. To lubricate, use the lubrication ports on the lubrication access bracket located near the top of the right most fan assembly. When using for the first time, observe the bearings during lubrication and count the number of pumps needed until a light bead of grease is visible at the bearing seal. Turn the fan while lubricating. Once a light bead of grease is visible, stop lubricating and record the number of pumps.

Recommended Lubricants:

INSPECT HEATING SYSTEM

Prior to starting up the electric heating system, perform a visual inspection of the heater conditions.

1. Using the SmartVu touchscreen, login with the user password (1111).

2. Navigate to the Start/Stop screen press the Disable button to disable unit operation.

3. Set Auto-Restart to Off.

4. Disconnect and lockout/tag-out unit power.

5. Remove the heater access panels.

6. Inspect the heater components including the heater, contactors, safeties, and SCR controller (if equipped).

7. Tighten the heater electrical connections.

HEATING SYSTEM START-UP

After inspecting the heating system, start it up by following these steps:

1. Restore unit power.

2. Use the Service Run test to confirm and check heater operation.

3. Once the start-up check is complete, reinstall the heater access panels.

4. Using the SmartVu touchscreen, login with the user password (1111).

5. Navigate to the Start/Stop screen and set the unit to Enable by pressing the Enable button, to restore normal operation, or press Disable to keep the unit disabled.

OUTDOOR AIR SCREENS: Periodically inspect the outdoor air screens. Use a non-metallic brush to remove large debris. Rinse the screens periodically to remove smaller debris. If very dirty or greasy, use a stainless-steel safe cleaner. To remove the screens:

1. Remove the screws from the screen cover.

2. Remove the screen cover.

3. Slide the vertically mounted filters up and out of the hood.

4. The horizontally mounted screens can be left in place for rinsing or cleaning.

ECONOMIZER DAMPER: Inspect the economizer damper for any damage or wear. Use the component test function in the SmartVu control to modulate the actuator between open and closed, and listen for any unusual sounds and observe any binding.

BAROMETRIC RELIEF SYSTEM: Inspect the barometric relief system. Ensure the barometric dampers can move freely.

POWER EXHAUST: Inspect the power exhaust systems. Verify the barometric dampers can move freely. Inspect the belts and blower assembly and tighten the VFD electrical connection (high-capacity power exhaust only). Use the component test function in the SmartVu control to verify exhaust fan operation.

Inspect the refrigerant circuit for signs of leaks or damage. Verify all service and isolation valves are open prior to system operation.

ELECTRONIC EXPANSION VALVES (EXVS): The EXV can be accessed through the EXV access panel. Inspect the EXVs for leaks or other signs of wear. Verify the EXV connector cables are tight. Use the component test function in the SmartVu control to modulate the EXV position. Listen for operation confirmation and signs of grinding or sticking.

COMPRESSORS: The compressors are accessed through the compressor access door. Inspect the compressors for any signs of damage or leaks. Tighten the compressor power terminals.

OUTDOOR FANS: The outdoor fans are accessed through the compressor access door. Spin the outdoor fans by hand to verify free rotation. Check the gap between the fan and fan shroud.

IMPORTANT: Make sure all air terminal units, balancing dampers, or fire dampers are open prior to testing the A2L leak dissipation system.

Prior to cooling season start up, test the A2L leak dissipation system operation by following these steps:

1. Locate the A2L leak dissipation cover on the indoor fan/VFD access panel.

2. Remove the screws in the cover and save.

3. Remove the cover and set aside.

4. Locate the test button on the A2L leak dissipation board.

5. Using the SmartVu touchscreen, login with the user password (1111).

6. Navigate to the Start/Stop screen and press the Component Test button to enable component test operation.

7. Press the test button on the A2L leak dissipation board for 1 second. This will force the unit into leak dissipation mode for 60 seconds.

8. After the test is complete, reinstall the cover using the screws. Make sure the cover is properly secured to prevent air and water leaks.

9. Using the SmartVu touchscreen, login with the user password (1111).

10. Navigate to the Start/Stop screen press the Disable to disable unit operation or Enable to enable unit operation.

WARNING: PERSONAL INJURY. Do not access unit interior while UV lights are on. Only observe UV light operation through the UV safe viewport.

Verify UV light operation. Verify UV power is on and confirm that UV lights are on using the UV light view port. Refer to the UV Emitter accessory installation instructions for details on replacing emitter bulbs.