Carrier 50DJ054 Installation Instructions Manual
- Type
- Installation Instructions Manual
Installation Instructions
GENERAL
Read these instructions entirely before installing acces-
sory electric heaters. See Tables1–4foraccessory usage.
See Tables 5 and 6 for accessory parts lists.
Turn off all power to unit prior to installing accessory
electric heater package. All wiring must comply with
applicable national and local codes.
Table 1 — Accessory Data — Units 50DJ034,044
ACCESSORY HEATER HEATER
SELECTION APPLIED TO TYPICAL WIRING
PACKAGE VOLTS BASE UNIT MOUNTING DIAGRAM
50DJ901 (3 Ph, 60 Hz) 50 FIG. NO. FIG. NO.
851 208/230 Lo 36 kW DJ034,044 2, 3 7
861 208/230 Med 72 kW DJ034,044 2, 3 8
871 208/230 Hi 108 kW DJ034,044 2, 3 9
881 460 Lo 36 kW DJ034,044 2, 3 10
891 460 Med 72 kW DJ034,044 2, 3 12
901 460 Hi 108 kW DJ034,044 2, 3 13
911 575 Lo 36 kW DJ034,044 2, 3 10
921 575 Med 72 kW DJ034,044 2, 3 12
931 575 Hi 108 kW DJ034,044 2, 3 13
Table 2 — Accessory Data — Units 50DK/NK034,044 (With or Without Inlet Guide Vanes)
ACCESSORY HEATER HEATER
SELECTION APPLIED TO TYPICAL WIRING
PACKAGE VOLTS BASE UNIT MOUNTING DIAGRAM
50DJ901 (3 Ph, 60 Hz) 50 FIG. NO. FIG. NO.
941 208/230 Lo 36 kW DK/NK034,044 2, 3 7
951 208/230 Med 72 kW DK/NK034,044 2, 3 8
961 460 Lo 36 kW DK/NK034,044 2, 3 11
971 460 Med 72 kW DK/NK034,044 2, 3 12
981 575 Lo 36 kW DK/NK034,044 2, 3 11
991 575 Med 72 kW DK/NK034,044 2, 3 12
Table 3 — Accessory Data — Units 50DJ054-074
ACCESSORY HEATER HEATER
SELECTION APPLIED TO TYPICAL WIRING
PACKAGE VOLTS BASE UNIT MOUNTING DIAGRAM
50DJ901 (3 Ph, 60 Hz) 50 FIG. NO. FIG. NO.
051 208/230 Lo 36 kW DJ054-074 16, 17 21
141 208/230 Med 72 kW DJ054-074 16, 17 22
151 208/230 Hi 108 kW DJ054-074 16, 17 23
081 460 Lo 36 kW DJ054-074 16, 17 24
091 460 Med 72 kW DJ054-074 16, 17 26
101 460 Hi 108 kW DJ054-074 16, 17 27
111 575 Lo 36 kW DJ054-074 16, 17 24
121 575 Med 72 kW DJ054-074 16, 17 26
131 575 Hi 108 kW DJ054-074 16, 17 27
Table 4 — Accessory Data — Units 50DK/NK054-074 (With or Without Inlet Guide Vanes)
ACCESSORY HEATER HEATER
SELECTION APPLIED TO TYPICAL WIRING
PACKAGE VOLTS BASE UNIT MOUNTING DIAGRAM
50DJ901 (3 Ph, 60 Hz) 50 FIG. NO. FIG. NO.
161 208/230 Lo 36 kW DK/NK054-074 16, 17 21
171 208/230 Med 72 kW DK/NK054-074 16, 17 22
181 460 Lo 36 kW DK/NK054-074 16, 17 25
191 460 Med 72 kW DK/NK054-074 16, 17 26
211 575 Lo 36 kW DK/NK054-074 16, 17 25
221 575 Med 72 kW DK/NK054-074 16, 17 26
50DJ,DK,NK034-074
Accessory Electric Heat Packages
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1
Tab 1b PC 111 Catalog No. 565-119 Printed in U.S.A. Form 50DJ,DK-10SI Pg 1 12-89 Replaces: New
Table 5 — Accessory Parts List — Sizes 034, 044
ITEM
NO. DESCRIPTION ACCESSORY PACKAGE NO. 50DJ901
851 861 871 881 891 901 911 921 931 941 951 961 971 981 991
Quantity
1Heater Assembly (208-230 v) 1 1 1 — — — — — — 1 1 ————
1Heater Assembly (460 v) — — — 1 1 1 — ———— 1 1——
1Heater Assembly (575 v) —————— 1 1 1———— 1 1
2Heater Control Box Assembly 111111111111111
3Casing, Front, 3
1
⁄
2
in. deep 111111111111111
4Casing, Rear, 1
1
⁄
2
in. deep 111111111111111
5Fixed Cover, Heater Control Box 111111111111111
6Hinged Cover, Heater Control Box 111111111111111
7Mounting Bracket, Heater Control Box 111111111111111
8Heater Relay (HR) 222222222——————
9Screw, 8B-18 x
3
⁄
4
in. long 444444444——————
10 Screw, 10B-16 x
1
⁄
2
in. long 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18
11 Screw,
1
⁄
4
-14 x
5
⁄
8
in. long 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60
12 Varnish Cloth 999999999999999
13 Wire Tie 999999999999999
14 Plug Button, 1
3
⁄
4
in. 444444444444444
15 Connector, 1
1
⁄
2
in. 222222222222222
16 Connector, 1
1
⁄
4
in. 666666666666666
17 Snap Bushing, 1
3
⁄
8
in. 222222222222222
18 Wire Harness, three 6 gage, 272 in. 244222222241212
19 Casing Cover 222222222222222
20 Connector, 2 in. 111111111111111
Table 6 — Accessory Parts List — Sizes 054-074
ITEM
NO. DESCRIPTION ACCESSORY PACKAGE NO. 50DJ901
051 081 091 101 111 121 131 141 151 161 171 181 191 211 221
Quantity
1Heater Assembly (208-230 v) 1 — — — — — — 1111————
1Heater Assembly (460 v) — 1 1 1 — —————— 1 1——
1Heater Assembly (575 v) ———— 1 1 1—————— 1 1
2Heater Control Box Assembly 111111111111111
3Casing 111111111111111
4Fixed Cover, Heater Control Box 111111111111111
5Hinged Cover, Heater Control Box 111111111111111
6Mounting Bracket, Heater Control Box 111111111111111
7Heater Relay (HR) 222222222——————
8Screw, 8B-18 x
3
⁄
4
in. long 444444444——————
9Screw, 10B-16 x
1
⁄
2
in. long 777777777777777
10 Screw,
1
⁄
4
-14 x
5
⁄
8
in. long 46 46 46 46 46 46 46 46 46 46 46 46 46 46 46
11 Varnish Cloth 568868868566868
12 Wire Tie 222222222222222
13 Plug Button, 1
3
⁄
4
in. 441242222424242
14 Connector, 1
1
⁄
2
in. 222222222222222
15 Connector, 1
1
⁄
4
in. 2——————4624————
16 Connector, 1 in. — 2 6 6 2 6 6 ———— 2 6 2 6
17 Electric Washer — 4 12 12 4 12 12 ———— 412 412
18 Plug Button, 2 in. 1111111——1—1111
19 Snap Bushing, 1
3
⁄
8
in. 111111122121111
20 Wire Harness, three 6 gage, 272 in. 222222244241212
21 Casing Cover 111111111111111
2
INSTALLATION
Units 50DJ,DK,NK034,044
1. Unpack accessory and check that package contains the
correct parts as indicated in Table 5. Items 8 through 17
and 20 are shipped in a plastic bag.
2. Remove the condenser coil panel as shown in Fig. 1.
This will allow access to the indoor section bulkhead
for installation of the main power harness (item 18) com-
ing from the main control box.
3. Install connector(s) on bulkhead access knock-out holes
as shown in Fig. 2. One or 2 connectors are used de-
pending on number of power harnesses (item 18).
4. Open main control box access doors and remove access
covers. See Fig. 3 and 4. This will allow access for the
power harness (item 18) and heater relay (item 8, 50DJ
models only) installation.
5. Install connector (item 20) on main control box bottom
surface as shown in Fig. 3.
6. Run main power harness (item 18) from the main con-
trol box terminal block to the indoor fan section as shown
in Fig. 3. Using varnish cloth (item 12) provided, secure
the harness at the connector (items 15 and 20). Use wire
ties (item 13) provided with the accessory package to
dress the harness through the condenser section. Make
sure there is no excess sagging on the harness and enough
length of wire is available for connection to the electric
heat control box.
7. Fasten power harness to the load side of the power
terminal block (TB1) in the main control box. See
Fig.4-6.
8. Install heater relays (Model 50DJ only) on main
control box using 4 screws (item 9) as shown in Fig. 4.
9. Make appropriate wiring connections to the heater re-
lays (Model 50DJ only). See Fig. 4.
10. Remove indoor fan access door frames on both sides of
the unit. See Fig. 1. This will allow ample access for
heater package (item 1) and electric heat control box
(item 2) installation.
11. Assemble the control box mounting bracket (item 7) to
the electric heat control box (item 2), using screws
(item 11). See Fig. 2.
12. Install snap bushing (item 17) on the electric heat con-
trol box as shown in Fig.7-13.
13. Fasten the electric heat control box assembly to the unit
frame as shown in Fig. 2, using screws (item 11).
14. Feed the power wire harness (item 18) through the elec-
tric heat control box snap bushing installed in step 12.
Connect the pigtails on the harness to the terminal block(s)
as shown in Fig.7-13.
15. Locate the existing control wire plug fastened to the unit
upright. See Fig. 2. Release the plug assembly and con-
nect it to the bottom of the electric heat control box (see
Fig. 2).
NOTE: Two of the BLACK wires coming out of this
plug assembly will later be connected to Limit Switch
#1 on the heater package.
Fig. 1 — Unit Assembly and Installation Access Detail; Models 50DJ,DK,NK034,044
3
16. Remove the end covers from the unit heater housing.
17. Install the rear casing (item 4) on the heater housing as
shown in Fig. 2.
18. Install connector(s) (item 16) and plug button(s)
(item 14) on front casing (item 3). Follow the informa-
tion in Fig.7-13forproper location and quantity to be
used.
19. Feed the electric heat package power wires through the
appropriate set of connector(s) on the front casing as shown
in Fig. 7 - 13.
20. Locate the two BLACK wires coming off the control
wire plug and feed them through the middle connector
on the front casing. Route these two wires to the back
of the electric heat package and connect them to Limit
Switch #1. On 108 kW packages (Model 50DJ only) the
2 RED wires coming off the electric heat control box
bottom should be fed through the end connector on the
front casing, routed to the back of the heater package
and connected to Limit Switch #2. Fasten the limit switch
wires to the side of the heater package using wire ties
(item 13) and screws (item 10) (see Fig. 3).
21. Insert electric heat package into heater housing as shown
in Fig. 3. Make sure the back end of the heater package
is flush with the back end of the heater housing. Fasten
electric heat package to the unit heater housing using
screws (item 11). Heater housing fastening holes are shown
in Fig. 2.
22. Fasten the front casing to the heater housing and elec-
tric heat package using screws (item 11).
23. Secure the power harness coming out of the electric heat
package at each of the connectors using varnish cloth
(item 12).
24. Route the power wire harness coming out of the electric
heat package to the electric heat control box and feed
them through the appropriate set of connectors as shown
in Fig. 7 - 13.
25. Connect the ring terminals on the harness to the
appropriate contactor as shown in Fig. 7 - 13. Using var-
nish cloth (item 12) secure the harness(es) at the
connectors.
26. Check that all wiring connections are tight.
27. Fasten the front and rear covers (item 19) to the front
and rear casings respectively as shown in Fig. 2 and 3.
28. Dress the power and control wire harness coming out of
the electric heat package using wire ties (item 13).
29. Check that the supply power wiring is sufficient to handle
the load. The unit informative plate has the necessary
data for determining this. The upper section of the in-
formative plate has the MCA (Minimum Circuit Amps)
and MOCP (Maximum Overcurrent Protection) values
for the cooling portion of the unit. The lower section
has the same information for the heating section.
30. Match the accessory package 50DJ901T model num-
ber on the accessory heater packing crate with one of
the accessory model numbers from the lower portion of
the informative plate to determine suitability of power
wiring for handling the unit electrical load. Once the heater
package has been identified, mark the appropriate space
on the lower section of the informative plate.
UNITS 50DJ ONLY
31. Note the MCAand MOCPvalues for the heater package
and connect properly sized power wiring. Reconnect origi-
nal wires if suitable. Replace main control box access
covers. Replace all panels and door frames removed dur-
ing installation. Close and secure main control box ac-
cess doors as well as any others that are open.
32. Apply power to unit. Set thermostat to call for heat, and
check heating effect at supply air ducts.
UNITS 50DK ONLY
IMPORTANT: See Fig. 5 and 14 and locate DIP (Dual
Inline Package) switch 4 on the microprocessor board
in the main unit control box. Put this switch in the ON
position. Unit will not go into the heating mode if this
switch is not put in the ON position.
33. Note the MCAand MOCPvalues for the heater package
and connect properly sized power wiring. Reconnect origi-
nal wires if suitable. Replace all panels and door frames
removed during installation.
34. Locate the accessory board in the main control box and
set potentiometer P6 to a temperature setting that is at
least 5°F or more higher than the return air temperature.
This must be done because the unit will not go into the
heating mode unless the return air temperature is at least
5°F or more below the warm-up set point, P6. Apply
power to the unit. After the unit completes its 2-minute
initialization mode, unit should start in the heating mode.
Check supply air ducts for heating effect.
IMPORTANT: It is imperative that a field-supplied
switch be provided to drive the room air terminals
fully open when the unit is in the heating mode.
Connections are provided in the main unit control
box and the wiring connections are shown on the
unit label diagram located on the back side of one
of the main control access doors.
35. Replace main unit control box access cover. Close and
secure main control box access door as well as any oth-
ers that are open.
UNITS 50NK ONLY
36. Note the MCAand MOCPvalues for the heater package
and connect properly sized power wiring. Reconnect origi-
nal wires if suitable. Replace all panels and door frames
removed during installation.
37. Locate the Local Interface Device (HSIO) in the main
control box (see Fig. 6) and set the MWS (Morning
Warm-up Set point) to a temperature setting that is at
least 5°F or more higher than the return air temperature.
This must be done because the unit will not go into the
heating mode unless the return air temperature is at least
5°F or more below the warm-up set point, MWS.Apply
power to the unit. After the unit completes its 3-minute
initialization mode, unit should start in the heating mode.
Check supply air ducts for heating effect.
IMPORTANT: It is imperative that a field-supplied
switch be provided to drive the room air terminals
fully open when the unit is in the heating mode.
Connections are provided in the main unit control
box and the wiring connections are shown on the
unit label diagram located on the back side of one
of the main control access doors.
38. Replace main unit control box access cover. Close and
secure main control box access door as well as any oth-
ers that are open.
5
Units 50DJ,DK,NK054-074
1. Unpack accessory and check that package contains the
correct parts as indicated in Table 6. Items 6 through 19
are shipped in plastic bag.
2. Remove condenser coil panel, channel cap and top cover
as shown in Fig. 15. This will allow access to the indoor
section bulkhead and condenser section wire track for
installation of the main power harness (item 20) coming
from the main control box.
3. Remove wire track covers as shown in Fig. 16.
4. Install connector(s) on bulkhead’s access knock-out holes
as shown in Fig. 17. One or 2 connectors may be used
depending on number of power harnesses (item 20).
5. Open main control box access doors and remove access
covers. This will allow access for the power harness
(item 20) and heater relay (item 7, 50DJ models only)
installation.
6. Run main power harness (item 20) from the main con-
trol box terminal block to the indoor fan section as shown
in Fig. 16. Using varnish cloth (item 11) provided, se-
cure the harness at the connector (item 14). See Fig. 17.
Make sure enough length of wire is available for con-
nection to the electric heat control box.
7. Fasten power harness to the load side of the power
terminal block (TB1) in the main control box. See
Fig. 18 - 20.
8. Install heater relays (Models 50DJ only) on main con-
trol box using 4 screws (item 8) as shown in Fig. 18.
9. Make appropriate wiring connections to the heater re-
lays as shown in Fig. 18 (units 50DJ only).
10. Remove indoor fan access door frame on the power en-
try side of the unit. This will allow ample access for
heater package (item 1) and electric heat control box
(item 2) installation.
11. Assemble the control box mounting bracket (item 6) to
the electric heat control box (item 2), using screws
(item 10). See Fig. 17.
12. Install snap bushing (item 19) on the electric heat con-
trol box as shown in Fig. 21 - 27.
13. Fasten the electric heat control box assembly to the unit
frame structure as shown in Fig. 17, using screws
(item 10).
14. Feed the power wire harness (item 20) through the elec-
tric heat control box snap bushing installed in step 12.
Connect the pigtails on the harness to the terminal block(s)
as shown in Fig. 21 - 27.
Fig. 15 — Unit Assembly and Installation Access Detail; Models 50DJ,DK,NK054-074
17
15. Locate the existing control wire plug fastened to the unit
upright (see Fig. 17). Release the plug assembly and con-
nect it to the bottom of the electric heat control box.
NOTE: Two BLACK wires coming out of this plug as-
sembly will later be connected to Limit Switch #1 on
the heater package.
16. Remove the existing end cover off from the unit heater
housing.
17. Install connector(s) (item 15 or 16) and plug button(s)
(item 18) on the front casing (item 3). Follow the in-
formation in Fig. 21 - 27 for proper location and quan-
tity to be used.
18. Feed the electric heat package power wires through the
appropriate set of connector(s) on the front casing as shown
in Fig. 21 - 27.
19. Locate the two BLACK wires coming off the control
wire plug and feed them through the middle connector
on the front casing. Connect these two wires to Limit
Switch #1.
20. Insert electric heat package into heater housing as shown
in Fig. 17. Make sure the back end of the heater pack-
age is flush with the back end of the heater housing us-
ing screws (item 10). Heater housing fastening holes are
shown in Fig. 17.
21. Fasten the front casing to the heater housing and elec-
tric heat package using screws (item 11).
22. Secure the power harness coming out of the electric heat
package at each of the connectors using varnish cloth
(item 11).
23. Route the power wire harness coming out of the electric
heat package to the electric heat control box and feed
them through the appropriate set of connectors as shown
in Fig. 21 - 27.
24. Connect the ring terminals on the harness to the
appropriate contactor as shown in Fig. 21 - 27. Using
varnish cloth (item 11) secure the harness(es) at the
connectors.
25. Check that all wiring connections are tight.
26. Fasten the front casing cover (item 21) to the front cas-
ing as shown in Fig. 17.
27. Dress the power and control wire harness coming out of
the electric heat package using wire ties (item 12).
28. Check that the supply power wiring is sufficient to handle
the load. The unit informative plate has the necessary
data for determining this. The upper section of the in-
formative plate has the MCA (Minimum Circuit Amps)
and MOCP (Maximum Overcurrent Protection) values
for the cooling portion of the unit. The lower section
has the same information for the heating section.
29. Match the accessory package 50DJ901 model num-
ber on the accessory heater packing crate with one of
the accessory model numbers from the lower portion of
the informative plate to determine suitability of power
wiring for handling the unit electrical load. Once the heater
package has been identified, mark the appropriate space
on the lower section of the informative plate.
UNITS 50DJ ONLY
30. Note the MCAand MOCPvalues for the heater package
and connect properly sized power wiring. Reconnect origi-
nal wires if suitable. Replace main control box access
covers. Replace all panels and door frames removed
during installation. Close and secure main control box
access doors as well as any others that are open.
31. Apply power to unit. Set thermostat to call for heat, and
check heating effect at supply air ducts.
UNITS 50DK ONLY
IMPORTANT: See Fig. 14 and 19 and locate DIP (Dual
Inline Package) switch 4 on the microprocessor board
in the main unit control box. Put this switch in the ON
position. Unit will not go into the heating mode if this
switch is not put in the ON position.
32. Note the MCAand MOCPvalues for the heater package
and connect properly sized power wiring. Reconnect origi-
nal wires if suitable. Replace all panels and door frames
removed during installation.
33. Locate the accessory board in the main control box and
set potentiometer P6 to a temperature setting that is at
least 5°F or more higher than the return air temperature.
This must be done because the unit will not go into the
heating mode unless the return air temperature is at least
5°F or more below the warm-up set point, P6. Apply
power to the unit. After the unit completes its 2-minute
initialization mode, unit should start in the heating mode.
Check supply air ducts for heating effect.
IMPORTANT: It is imperative that a field-supplied
switch be provided to drive the room air terminals
fully open when the unit is in the heating mode.
Connections are provided in the main unit control
box and the wiring connections are shown on the
unit label diagram located on the back side of one
of the main control access doors.
34. Replace main unit control box access cover. Close and
secure main control box access door as well as any oth-
ers that are open.
UNITS 50NK ONLY
35. Note the MCAand MOCPvalues for the heater package
and connect properly sized power wiring. Reconnect origi-
nal wires if suitable. Replace all panels and door frames
removed during installation.
36. Locate the Local Interface Device (HSIO) in the main
control box (see Fig. 20) and set the MWS (Morning
Warm-up Set point) to a temperature setting that is at
least 5°F or more higher than the return air temperature.
This must be done because the unit will not go into the
heating mode unless the return air temperature is at least
5°F or more below the warm-up set point, MWS.Apply
power to the unit. After the unit completes its 3-minute
initialization mode, unit should start in the heating mode.
Check supply air ducts for heating effect.
IMPORTANT: It is imperative that a field-supplied
switch be provided to drive the room air terminals
fully open when the unit is in the heating mode.
Connections are provided in the main unit control
box and the wiring connections are shown on the
unit label diagram located on the back side of one
of the main control access doors.
37. Replace main unit control box access cover. Close and
secure main control box access door as well as any oth-
ers that are open.
19
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Carrier 50DJ054 Installation Instructions Manual
- Type
- Installation Instructions Manual
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