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
manufacturer’s 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
Warranty — All Carrier-furnished items carry the standard
General — The 35E is a single duct, variable volume termi-
Carrier warranty.
No periodic preventative maintenance required, unless
called for specific control sequence.
nal 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.
Fig. 1 — 35E Single Duct Box (Sizes 4-16)
Fig. 2 — Unit Identification Label
Table 1 — 35E Unit Weights
35E
SIZE
UNIT ONLY
(lb)
4, 5, 6
7, 8
9, 10
12
14
16
22
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
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.
2
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
FIELD SUPPLIED
HANDING WIRE
BRACKET
DETAIL
Fig. 3 — Typical Unit Suspension with Brackets
CONTROL ARRANGEMENTS
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.
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.
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
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
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.
3
INSTALLATION
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
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.
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.
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)
4
Table 2 — 35E Basic Pressure Data
INLET
SIZE (in.)
(Area)
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
4
(0.09)
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)
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
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
*Minimums are for all except CCN controls, which may be lower. Minimum for DDC by
others is to be provided by the control’s 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 unit’s selected
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.
Table 3A — 35E Heater Power Wiring and
Fuse Sizing (Single Phase, 60 Hz)
Table 3B — 35E Heater Power Wiring and
Fuse Sizing (3 Phase, 60 Hz)
CCN
DDC
EAT
UL
—
—
—
—
Carrier Comfort Network®
Direct Digital Controls
Entering Air Temperature
Underwriters Laboratories
HEATER
SIZE (kW)
BTUH
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
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
∆ PS — The difference in static pressure
from inlet to discharge with damper
fully open
∆ VPS — Change in velocity pressure
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
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
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
LEGEND
AWG
FLA
—
—
American Wire Gage
Full Load Amps
*Values based on 75 C copper wire.
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
LEGEND
— American Wire Gage
— Full Load Amps
*Recommended minimum wire size.
5
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
10000
8000
6000
7250
4000
3709
2840
2086
2
E2
SIZ
2000
CLASS II
TRANSFORMER
(OPTIONAL)
CFM
1000
800
600
ANALOG OR DDC
CONTROLLER
24VAC
400
200
GROUND
100
80
60
24 VAC
POWER
BLU
YEL
DDC
362
232
40
LEGEND
— Direct Digital Controls
Field Wiring
20
10
0.01
Factory Wiring
NOTE: Drawing is typical — refer to actual unit wiring diagram
for details.
Fig. 4 — Wiring of Optional Factory-Mounted
Transformer
1449
1174
927
710
522
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
CFM AT ONE INCH SIGNAL
L1
120VAC
208VAC
240VAC
277VAC
.05
0.1
0.3
FLOW PROBE IN.WG
VOLTS (ANALOG CONTROLS)
.03
0.5
1
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
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
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
PNEUMATIC CONTROLS
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.
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
05
06
07
08
09
4.0
5.0
6.0
7.0
8.0
9.0
232
362
502
710
927
1174
0.087
0.136
0.196
0.267
0.349
0.442
.
35E UNIT SIZE
INLET DIAMETER
AIRFLOW (Cfm)
AT 1 in. wg
INLET AREA
(sq ft)
10
10.0
12
12.0
14
14.0
16
16.0
22
16 x 24
1449
2086
2840
3709
7250
0.545
0.785
1.069
1.396
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.
7
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
kW
Type
Btu
Occupied
min
Fig. 7 — Air Terminal Performance Sheet
8
max
Unoccupied
min
max
Calibration
Gain
mult.
Table 4 — Pneumatic Volume Controller Identification
FUNCTION
ARRANGEMENT
IDENTIFICATION
DA-NO
RA-NC
DA-NO
DA-NC
RA-NO
RA-NC
DUAL MAX
HTG/CLG MAX
DUAL MIN
CONTROL
SEQUENCE
1102
1103
1104
1105
1106
1107
1108
1109
1110
FIG. NO.
KREUTER
PART NO.
8
9
10
10
10
10
10
10
10
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
.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
.C.
DMPR.N
A
CRE SE
IN
LO
Fig. 9 — Pneumatic Volume Controller
(Normally Closed) for 35EP Unit (Grey Color)
T
L
H
RESET START
B
NC
LO STAT ∆P
IN
CR
IN
CR
HI STAT ∆P
NO
M
DAMPER
Sequences
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.
A
CRE SE
IN
CSC-2004
0-1” P
R.A.
(Control
RESET SPAN
G
Fig. 10 — CSC 3000 Series
Reset Volume Controller
9
•
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 controller’s 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 controller’s 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 controller’s internal reset
chamber, which will always be at a pressure between 0 psig
and the RESET SPAN pressure.
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.
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.
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.
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).
4.
5.
6.
7.
10
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.
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.
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)
T
RESET START
LO STAT ∆P
NC
TO DAMPER
ACTUATOR
TO MAIN AIR
SUPPLY
NO
M
DIFFERENTIAL PRESSURE (FLOW)
LIMIT ADJUSTMENT WHEN T’STAT
PRESSURE IS HIGH (HI STAT)
(FACTORY SET AT 0.65 IN.WG.)**
**- FIELD ADJUSTMENT REQUIRED
L
H
B
IN
CR
IN
DAMPER
LOOSEN SCREW TO
CHANGE DAMPER ACTION
(SUPPLIED IN N.O. POSITION)
HI STAT ∆P
CR
DIFFERENTIAL PRESSURE (FLOW)
LIMIT ADJUSTMENT WHEN T’STAT
PRESSURE IS LOW (LO STAT)
(FACTORY SET AT 0 IN.WG.)**
RESET SPAN
G
ALL ADJUSTMENTS CCW TO INCREASE
(1/8”-5/32” FLATBLADE SCREWDRIVER)
GAGE TAP. LEAVE CAP ON UNLESS
CONNECTING GAGE FOR RESET
START OR RESET SPAN ADJUSTMENT
RESET SPAN ADJUSTMENT
(FACTORY SET AT 5 PSI)
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
DA HEATING*
Reset
Span
MAX
F
L
O
W
LO STAT ∆P
HI STAT ∆P
MIN
0
13 psig
8
∆
Reset Start*
ROOM TEMPERATURE
MAX
F
L
O
W
3
RA HEATING
Reset
Span
DA COOLING
Reset
Span
MAX
F
L
O
W
LO STAT ∆P
MIN
HI STAT ∆P
MIN
0
13 psig
8
∆
Reset Start
ROOM TEMPERATURE
MAX
HI STAT ∆P
LO STAT ∆P
F
L
O
W
3
RA COOLING*
Reset
Span
HI STAT ∆P
MIN
13
8
3 0 psig
∆
Reset Start
ROOM TEMPERATURE
LO STAT ∆P
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.
90
Fig. 12 — Reset Cycle for CSC-3011 Control
ANALOG CONTROLS
Balancing Procedures (Control Sequences
2100-2105) — The analog electronic control system is a
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
0
L
H
N
O
M
NOR
MAX
MIN
GEAR
DISENGAGEMENT
BUTTON
METER
16 I
V N
DC
O
U
I
–
– ˜
24V
AC
M
A
X
%
M
I
N
–+
RED-CLS
GRN-OPN
LED
C
ccw cw
E
WIRING
COMMON (16V DC,
INPUT, OUTPUT)
POWER
SUPPLY
0-10V VELOCITY OUTPUT
0-10V INPUT SIGNAL
16V DC OUTPUT
(THERMOSTAT POWER)
16 I O –
V N U
T
DC
– ˜
24 V
AC
Fig. 13 — CSP-5001 Controller
11
10000
8000
7250
6000
3709
4000
2840
2000
2086
1449
1174
927
6
E1
SIZ
4
E1
SIZ
2
E1
SIZ
0
E1
SIZ
9
E
SIZ
E8
SIZ
E7
SIZ
E6
SIZ
E5
SIZ
1000
800
600
CFM
22
400
200
100
80
710
522
362
232
CFM AT ONE INCH SIGNAL
E
SIZ
E4
SIZ
60
40
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.)
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.
12
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.
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.
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.
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
SAT
HEAT
UNIT WITH MULTIPLE OUTLET ATTENUATOR
2 FT. MIN.
PRIMARY
AIR INLET
LEGEND
SAT — Supply Air Temperature Sensor
ZC — Zone Controller
AIR
TERMINAL
UNIT
ZC
MULTIPLE
OUTLET
ATTENUATOR
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.
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.
14
3’ (MIN)
D
5’
1
2
4
3
5
OR
2/3 OF WALL HEIGHT
Fig. 16 — Typical Space Temperature Sensor
Room Location
6
RED(+)
WHT(GND)
BLK(-)
CCN COM
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
SEN
SW1
5
6
RED(+)
WHT(GND)
BLK(-)
CCN COM
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
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.
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
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.
Fig. 21 — Primary Air Temperature Sensor
(Part Number 33ZCSENPAT)
16
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.
Fig. 24 — Ventilation Rates Based on
CO2 Set Point
The sensor must be mounted vertically on the wall. The
Carrier logo should be oriented correctly when the sensor is
properly mounted.
17
IAQ
GND
0
1
21
HF23BJ042
87
Made in Switzerland
by Belimo Automation
35 in-lb (4 Nm)
80...110s
LR 92800
NEMA2
LISTED
94D5
TEMP. IND. &
REG. EQUIP.
UL
Class 2 Supply
24VAC/DC
50/60Hz
3VA
2W
5K
24VAC*
LINE VOLTAGE
COM
WIP
yel
blu
ora
1
2
3
blk
red
wht
SEPARATE
POWER
SUPPLY
REQUIRED*
*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
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).
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.
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
Table 8 — Recommended Cables
MANUFACTURER
Alpha
American
Belden
Columbia
TYPE
CABLE PART NO.
2413 or 5463
A22503
8772
02525
ComfortID™ Start-Up
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.
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
ON/OFF
VALVE
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
LISTED
94D5
TENP IND &
REG. EQUIP.
1
2
1
J3
Element#:
Unit#:
ora
blk
red
- G
CCN
BLACK (–)
+
G -
J1
24VAC
1
6
3
1 2 3
WIP
blu
1
CCW
COM
CW
HEAT1
24VAC
HEAT2
COM
yel
+
J6
HIGH
5K
WHITE (GND)
J2B LEN
- G
+
Class 2 Supply
24VAC/DC
50/60 Hz
3VA 2W
RED (+)
3
Bus#:
NEMA 2
CCN
COMMUNICATION
CONNECTOR
3
S/N:
1
1
3
Part Number: 33ZCFANTRM
CW
COM
CCW
SRVC
LR 92800
J8
SEC DMP
®
ZONE Controller
35 in-lb (4 Nm)
80...110s
16
15
®
HF23BJ042
Made in Switzerland
by Belimo Automation
J2A CCN
J7
0
3
1
+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 2
J6
1
LOW
US
C
wht
Fig. 27 — CCN Terminations at Zone Controller
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.
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.
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.
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.
Hot Water Reheat Does Not Operate.
No hot water available.
Water valve wired wrong or not functioning.
Excessive Air Noise.
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).
Unit Will Not Provide Modulating
Damper Control During Air Source
Heating/Warm-Up Mode.
VVT® CONTROLS
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.
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.
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.
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
21
MIN VA REQUIREMENT
30
Factory Supplied (75)
40
35
Factory Supplied (75)
45
30
35
WITH COVER
COVER REMOVED
ACTUATOR
COVER
COVER
SCREW
(HIDDEN)
COVER
SCREW
3 PIN TEMPERATURE
SENSOR CONNECTOR
(2) 5/16-18
SET SCREWS
5 PIN T-STAT
CONNECTOR
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
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.
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
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.
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).
23
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