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-1SIBook 3

Tab 6a

Installation and Start-Up InstructionsCONTENTS

PageSAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2CONTROL ARRANGEMENTS. . . . . . . . . . . . . . . . . . . .3,4INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Step 1 — Install Volume Control Box . . . . . . . . . . . . . 4Step 2 — Make Duct Connections . . . . . . . . . . . . . . . . 4Step 3 — Install Sensors and Make Field

Wiring Connections — Electronic Analogor DDC (Direct Digital Controls) . . . . . . . . . . . . . . . . 4

CONTROL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Field Adjustments of Minimum and

Maximum Airflow Set Points . . . . . . . . . . . . . . . . . . . 7System Calibration of the Linear Averaging

Flow Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7PNEUMATIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . .7-11Preparation for Balancing (Control

Sequences 1102 and 1103) . . . . . . . . . . . . . . . . . . . . . 7Balancing Procedure

(Control Sequences 1102 and 1103) . . . . . . . . . . . . 9• DIRECT ACTING THERMOSTAT,

NORMALLY OPEN DAMPER (ControlSequence 1102)

• REVERSE ACTING THERMOSTAT, NORMALLYCLOSED DAMPER (Control Sequence 1103)

Balancing Procedure(Control Sequences 1104-1110) . . . . . . . . . . . . . . . 10

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . 10Pneumatic Control Troubleshooting . . . . . . . . . . . . . 10ANALOG CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . 11-13Balancing Procedures

(Control Sequences 2100-2105) . . . . . . . . . . . . . . . 11Analog Control Troubleshooting . . . . . . . . . . . . . . . . 13ComfortID™ CONTROLS . . . . . . . . . . . . . . . . . . . . . 13-21Install 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 BUSWater Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . 19ComfortID Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19• GENERAL• PRIMARY SYSTEM CHECK• ComfortID CONTROL SYSTEM CHECKCCN System Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 20VVT® CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-23General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21• DIRECT DRIVE HIGH TORQUE ACTUATOR• RELAY PACKAGE• ADDITIONAL SENSOR INFORMATION• THERMOSTATSThermostat Placement . . . . . . . . . . . . . . . . . . . . . . . . . . 21Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21• CCN COMMUNICATIONS• THERMOSTAT TO TERMINAL CONTROL BOXWiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22VVT Configuration/Testing . . . . . . . . . . . . . . . . . . . . . . 23Control Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23• GENERAL• PRIMARY SYSTEM CHECK

SAFETY CONSIDERATIONS

SAFETY NOTE

Air-handling equipment will provide safe and reliableservice when operated within design specifications. Theequipment should be operated and serviced only by autho-rized personnel who have a thorough knowledge of sys-tem operation, safety devices and emergency procedures.

Good judgement should be used in applying anymanufacturer’s instructions to avoid injury to personnelor damage to equipment and property.

Disconnect all power to the unit before performing mainte-nance or service. Unit may automatically start if power isnot disconnected. Electrical shock and personal injurycould result.

If it is necessary to remove and dispose of mercury contac-tors in electric heat section, follow all local, state, and fed-eral laws regarding disposal of equipment containinghazardous materials.

35E Single-Duct Terminal UnitsVariable Volume System

2

PRE-INSTALLATION

General — The 35E is a single duct, variable volume termi-nal available with factory-installed pneumatic, analog electron-ic, Carrier Comfort Network® (CCN) or VVT® (variable vol-ume and temperature) electronic control options that can beused in conjunction with unit-mounted electric or hot waterheat options. Figure 1 shows the basic box. Figure 2 is anexample of a unit identification label.STORAGE AND HANDLING — Inspect for damage uponreceipt. Shipping damage claims should be filed with shipperat time of delivery. Store in a clean, dry, and covered location.Do not stack cartons. When unpacking units, care should betaken that the inlet collars and externally mounted componentsdo not become damaged. Do not lift units using collars, sensorsor externally mounted components as handles. If a unit is sup-plied with electric or hot water heat, care should be taken toprevent damage to these devices. Do not lay uncrated units onend or sides. Do not stack uncrated units over 6 ft high. Do notmanhandle. Do not handle control boxes by tubing connectionsor other external attachments. Table 1 shows componentweights.INITIAL INSPECTION — Once items have been removedfrom the carton, check carefully for damage to duct connec-tions, coils or controls. File damage claim immediately withtransportation agency and notify Carrier.UNIT IDENTIFICATION — Each unit is supplied with ashipping label and an identification label (Fig. 2).INSTALLATION PRECAUTION — Check that constructiondebris does not enter unit or ductwork. Do not operate thecentral-station air-handling fan without final or constructionfilters in place. Accumulated dust and construction debrisdistributed through the ductwork can adversely affect unitoperation.SERVICE ACCESS — Provide service clearance for unitaccess.CODES — Install units in compliance with all applicable coderequirements.UNIT SUSPENSION — See Fig. 3 for unit suspension details.

Warranty — All Carrier-furnished items carry the standardCarrier warranty.

No periodic preventative maintenance required, unlesscalled for specific control sequence.

Table 1 — 35E Unit Weights

LEGENDDDC — 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.

35ESIZE

UNIT ONLY(lb)

WITH PNEUMATICCONTROLS

(lb)

WITH DDC ORANALOG CONTROLS

(lb)

WITH ELECTRIC HEATCONTROLS

(lb)

WITH HOT WATER(1 ROW/2 ROW) (lb)

4, 5, 6 14 18 23 32 19/207, 8 16 20 25 39 21/23

9, 10 21 25 30 44 28/3012 26 30 35 56 35/3814 34 38 43 65 44/4916 38 42 47 75 50/5522 65 69 74 91 82/90

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

Fig. 2 — Unit Identification Label

3

CONTROL ARRANGEMENTS

The 35E single-duct unit is offered with a wide variety offactory-mounted controls that regulate the volume of air deliv-ery from the unit and respond to cooling and heating load re-quirements of the conditioned space. Stand-alone controls willfulfill the thermal requirements of a given control space. Thesedevices are available in both pneumatic and electronic arrange-ments. Carrier VVT® electronic controls and PIC (ProductIntegrated Control) DDC (Direct Digital Controls) are commu-nicating controls which are integrated with the building system.The PIC controls are compatible with the CCN system. A num-ber of DDC control packages by others are available for con-signment mounting, as indicated.

Control offerings are:35EA: Analog Electronic35EC: PIC Direct Digital Electronic35EP: Pneumatic35EV: VVT Electronic (Gen. III or 3V™ controls)35EN: None or DDC by others

Each control approach offers a variety of operating func-tions; a control package number identifies combinations ofcontrol functions. The following listings contain the basic func-tion arrangements for each control offering. Because of thevariety of functions available, circuit diagrams, operatingsequences, and function descriptions are contained in separateApplication Data publications. Refer to the specific controlpublication for details.

CCN Control Arrangements — Carrier Comfort Net-work® (CCN) controls are factory-installed in a control enclo-sure. Factory-mounted transformers are available as an option.Thermostats are supplied separately as a field-installed acces-sory. Carrier Comfort Network control packages must be usedin combination with a thermostat. Thermostats are notincluded in the CCN package.4140: Cooling only4141: Single-stage and 2-stage electric heat4142: 3-stage electric heat4143: On-Off hot water4144: Proportional (floating) hot water heat4145: Cooling only with supply return tracking4147: Single-stage, 2-stage and 3-stage electric heat with

supply return tracking4149: Proportional (floating) hot water with supply return

tracking4150: Return air damper

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 tempera-ture sensor with LCD (liquid crystal diode), set point adjust,fan control and occupancy override.Thermostat: 33ZCT56CO2: RT (room temperature) and CO2sensor, with set point adjust and override.Thermostat: 33ZCT55CO2: RT (room temperature) and CO2sensor, with override only.

VVT Electronic Control Arrangement — Vari-able volume and temperature (VVT) controls are factory-installed in a control enclosure. Factory-mounted transformersare available as an option. Thermostats are supplied separatelyas a field-installed accessory.GEN. III CONTROL CODES AND DESCRIPTIONS8200: Pressure dependent, cooling only8201: Pressure dependent, cooling with 2-stage electric heat8202: Pressure dependent cooling with on/off hot water heat8206: Pressure independent, cooling only8207: Pressure independent, cooling with 2-stage electric heat8208: Pressure independent cooling with on/off hot water heat8209: Variable air volume (VAV) pressure dependent unit

control zone (Monitor)8210: Bypass controller, 2-in. wg transducer3V CONTROL CODES AND DESCRIPTIONS8220: Pressure dependent cooling only8221: Pressure dependent cooling with 3-stage electric heat8222: Pressure dependent cooling with on/off hot water heat8223: Pressure dependent cooling with modulating hot water

heat8224: Pressure dependent cooling with combination base-

board and 2-stage electric heat8226: Pressure independent cooling only8227: Pressure independent cooling with 2-stage electric heat8228: Pressure independent cooling with on/off hot water heat8230: Bypass control

Analog Electronic Control Arrangement —Pressure independent control packages are available withoutsupplemental heat, with on/off hot water or electric heat, pro-portional hot water heat, or with cooling/heating automaticchangeover control.

FIELD SUPPLIEDHANDING WIRE

BRACKETDETAIL

Fig. 3 — Typical Unit Suspension with Brackets

4

All analog control arrangements include a standard linearinlet flow sensor, 24-v transformer (optional), control enclo-sure and wall thermostat to match the control type.2100: Heating control2101: Cooling control2102: Cooling with on/off electric heat control2103: Cooling with on/off hot water heat control2104: Cooling/heating automatic changeover control2105: Cooling with proportional hot water heat control

Pneumatic Control Arrangement — All controlpackages are pressure independent (unless otherwise noted)and available with or without hot water heat, dual maximumairflow, heating and cooling maximum airflow and dual mini-mum airflow. All control arrangements include a standardlinear inlet flow sensor.1100 (Actuator only): DA-NC pressure dependent control1101 (Actuator only): RA-NO pressure dependent control1102 (Single function controller): DA-NO with or without hotwater or electric heat1103 (Single function controller): RA-NC with or without hotwater or electric heat1104 (Multi-function controller): DA-NO with or without hotwater or electric heat1105 (Multi-function controller): DA-NC with or without hotwater or electric heat1106 (Multi-function controller): RA-NO with or without hotwater or electric heat1107 (Multi-function controller): RA-NC with or without hotwater or electric heat1108 (Dual Maximum Control): DA-NO with or without hotwater or electric heat1109 (Heating/Cooling Maximum Control): DA-NO with orwithout hot water or electric heat1110 (Dual Minimum Control): DA-NO with or without hotwater or electric heatPNEUMATIC CONTROL LEGENDDA: Direct-acting thermostatRA: Reverse-acting thermostatNO: Normally open damper positionNC: Normally closed damper position

The single function controller provides single functions, i.e.,DA-NO. Multi-function controllers are capable of providingDA-NO, DA-NC, RA-NC or RA-NO functions.

Direct Digital Electronic Control Arrange-ments (Field-Supplied) — Control packages are field-supplied for factory mounting, unless otherwise noted. AllDDC control arrangements include a standard linear inlet flowsensor, transformer to 24 volts and control enclosure.

Contact Carrier for detail about mounting field-suppliedcontrols.NO CONTROL0000: 35E box onlyD000: 35E box with control box only (For units withoutelectric heat requiring a 24 v control transformer: the controltransformer must be ordered from the unit accessories list inQuote Builder.)D001: 35E box with control box and 24 v transformerP000: 35E box without controls (for DA pneumatic controlledheat unit)P001: 35E box without controls (for RA pneumatic controlledelectric heat unit)

INSTALLATION

Step 1 — Install Volume Control Box1. Move unit to installation area. Remove unit from ship-

ping package. Do not handle by controls or damperextension rod.

2. The unit has factory-installed brackets on unit as shownin Fig. 3.

3. Suspend units from building structure with straps, rods,or hanger wires. Secure the unit and level it in each direc-tion. Note that reheat coil is in heavy end of unit.

Step 2 — Make Duct Connections1. Install supply ductwork on unit inlet collar. Check that

air-supply duct connections are airtight and follow allaccepted medium-pressure duct installation procedures.(Refer to Table 2 for pressure data.)NOTE: To ensure proper equipment performance, it isrecommended that a length of rigid straight duct equal to3 times the duct diameter be provided to the inlet.

2. Install the discharge duct. Where a multiple outlet con-nector is used on the box, connect appropriately sizedductwork to the outlets. Use adapter caps to seal unusedoutlets. Fully open all balancing dampers.

To ensure use of common-diameter air duct, coordinatediameters of box inlet and multiple outlet collars. Insulate ductas required.

Ninety degree elbows or tight radius flexible duct immedi-ately upstream of inlet collar should be avoided.

Step 3 — Install Sensors and Make Field Wir-ing Connections — Electric Analog or DDC(Direct Digital Controls) — Refer to specific unit di-mensional submittals and control application diagrams for con-trol specifications. All field wiring must comply with NationalElectrical Code (NEC) and local requirements. Refer to thewiring diagram on the unit for specific wiring connections.

A field-supplied transformer is required if the unit was notequipped with a factory-installed transformer. See Fig. 4.

Single duct terminal units with electric heat are suppliedwith a single point wiring connection in the heater control box.All unit power is supplied through this connection. Modelswith electric heat are factory equipped with a control trans-former. See Fig. 5.

Wiring and unit ampacities are referenced in Tables 3A and3B.NOTE: Refer to wiring diagram attached to each unit for spe-cific information on that particular unit. Units with 480-3-60electric heater REQUIRE 4-wire, wye connected power.units with 208/230 v, 3-phase heater can be connected with3-wire power.

Unit airflow should not be set outside of the range noted inFig. 6. The minimum recommended airflow for units with elec-tric heat must be at least 75 cfm per kW and not drop below theminimum values listed in the performance data table. The max-imum unit discharge temperature should not exceed 120 F.Prevent air stratification by setting the discharge temperatureno more than 15 degrees above the room temperature.Example: 90 F discharge in a 75 F room.

LOCK OUT AND TAG heater electrical disconnect beforeworking on this equipment. Otherwise, one leg of the 3-legheater remains energized. Electrical shock or personalinjury could result.

5

Table 2 — 35E Basic Pressure Data

LEGEND

*Minimums are for all except CCN controls, which may be lower. Minimum for DDC byothers 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 theelectric heater.

**Maximum discharge temperatures with electric heat are set at 120 F by the NationalElectric 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 cata-log). Min cfm for electric heat is based on UL/ETL listings. (Diffuser) performance willlikely be poor at this low flow rate.) The ASHRAE (American Society of Heating, Refrig-eration and Air Conditioning Engineers) Handbook of Fundamentals does not recom-mend 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 airterminal selection program.

Table 3A — 35E Heater Power Wiring andFuse Sizing (Single Phase, 60 Hz)

LEGEND

*Values based on 75 C copper wire.

Table 3B — 35E Heater Power Wiring andFuse Sizing (3 Phase, 60 Hz)

LEGEND

*Recommended minimum wire size.

INLETSIZE (in.)

(Area)CFM

MIN AIRFLOW (Cfm)* ELECTRIC HEAT**MAX kW

AT 55 F EAT

MINIMUM INLET STATIC PRESSURE (Unit and Heat Pressure Drop)Cooling Only or

Cooling with Hot WaterElectricHeat †

Velocity Press(∆ VPS)

Basic Unit(∆ PS)

Basic + 1 RowCoil (∆ PS)

Basic + 2 RowCoil (∆ PS)

Basic + 3 RowCoil (∆ PS)

Basic + 4 RowCoil (∆ PS)

Basic + Heater †(∆ PS)

5550or0

55

1.1 0.02 0.00 0.00 0.01 0.01 0.01 0.004 110 2.3 0.10 0.01 0.02 0.03 0.03 0.04 0.01

(0.09) 170 3†† 0.23 0.02 0.04 0.06 0.08 0.10 0.02230 3†† 0.43 0.03 0.07 0.11 0.15 0.18 0.03

8575or0

85

1.7 0.02 0.00 0.01 0.02 0.02 0.03 0.005 170 3.5 0.09 0.02 0.04 0.06 0.08 0.10 0.02

(0.14) 265 5†† 0.23 0.04 0.10 0.15 0.20 0.24 0.04360 5†† 0.43 0.08 0.18 0.27 0.36 0.45 0.08100

110or0

110

2.1 0.02 0.01 0.01 0.02 0.03 0.03 0.016 240 4.9 0.09 0.04 0.08 0.12 0.16 0.20 0.04

(0.20) 380 7.5†† 0.22 0.09 0.20 0.30 0.40 0.50 0.09520 7.5†† 0.42 0.17 0.38 0.57 0.75 0.94 0.17140

140or0

140

2.9 0.02 0.01 0.01 0.02 0.03 0.04 0.017 330 6.8 0.09 0.04 0.08 0.12 0.16 0.20 0.04

(0.27) 525 9.5†† 0.23 0.09 0.20 0.30 0.40 0.50 0.09710 9.5†† 0.41 0.17 0.37 0.55 0.73 0.91 0.17190

185or0

190

3.9 0.02 0.01 0.02 0.03 0.05 0.06 0.018 440 9.1 0.09 0.04 0.12 0.19 0.25 0.32 0.04

(0.35) 675 13†† 0.21 0.09 0.27 0.44 0.60 0.76 0.09925 13†† 0.39 0.17 0.51 0.82 1.13 1.43 0.17240

240or0

240

4.9 0.02 0.01 0.02 0.03 0.04 0.05 0.019 550 11.3 0.08 0.07 0.12 0.17 0.22 0.27 0.07

(0.44) 875 16†† 0.21 0.17 0.31 0.44 0.57 0.69 0.171200 16†† 0.40 0.32 0.59 0.83 1.07 1.31 0.32

300290or0

300

6.2 0.02 0.01 0.02 0.04 0.05 0.07 0.0110 675 13.9 0.08 0.04 0.12 0.20 0.27 0.35 0.04

(0.55) 1075 21†† 0.20 0.10 0.31 0.50 0.69 0.89 0.101450 21†† 0.36 0.17 0.56 0.91 1.26 1.62 0.17

425420or0

425

8.7 0.01 0.01 0.02 0.04 0.06 0.07 0.0112 1000 20.6 0.08 0.04 0.14 0.22 0.31 0.40 0.04

(0.78) 1550 30†† 0.19 0.09 0.33 0.54 0.75 0.96 0.092100 30†† 0.34 0.17 0.60 0.99 1.37 1.76 0.17

580580or0

580

11.9 0.01 0.01 0.02 0.04 0.05 0.06 0.0114 1375 28.3 0.07 0.04 0.13 0.21 0.28 0.36 0.04

(1.07) 2125 36†† 0.17 0.10 0.31 0.49 0.68 0.86 0.102900 36†† 0.31 0.19 0.57 0.92 1.26 1.60 0.19

750740or0

750

15.4 0.01 0.01 0.02 0.04 0.06 0.07 0.0116 1775 36†† 0.06 0.04 0.14 0.22 0.31 0.40 0.04

(1.40) 2725 36†† 0.14 0.09 0.32 0.53 0.73 0.94 0.093700 36†† 0.25 0.17 0.59 0.97 1.35 1.73 0.171800

1400or0

1800

36†† 0.02 0.01 0.05 0.09 0.13 0.16 0.0122 3300 36†† 0.07 0.04 0.17 0.30 0.42 0.55 0.04

(2.63) 5200 36†† 0.16 0.09 0.43 0.74 1.05 1.36 0.097100 36†† 0.31 0.17 0.81 1.38 1.95 2.53 0.17

CCN — Carrier Comfort Network® ∆ PS — The difference in static pressurefrom inlet to discharge with damperfully open

DDC — Direct Digital ControlsEAT — Entering Air TemperatureUL — Underwriters Laboratories ∆ VPS — Change in velocity pressure

HEATERSIZE (kW) BTUH

120 V 208/240 V 277 VHeater

FLA AWG* HeaterFLA AWG* Heater

FLA AWG*

0.5 1,707 4.2 14 2.1 14 1.8 141.0 3,413 8.3 14 4.2 14 3.6 142.0 6,826 16.7 10 8.3 14 7.2 143.0 10,239 25.0 8 12.5 12 10.8 144.0 13,652 33.3 8 16.7 10 14.4 125.0 17,085 41.7 5 20.8 10 18.1 106.0 20,478 50.0 5 25.0 8 21.7 107.0 23,898 58.3 4 29.2 8 25.3 88.0 27,304 66.7 4 33.3 8 28.9 89.0 30,717 75.0 3 37.5 6 32.6 8

10.0 34,130 83.3 2 41.7 6 36.1 611.0 37,130 91.7 2 45.8 6 39.7 612.0 40,956 100.0 1 50.0 6 43.3 6

AWG — American Wire GageFLA — Full Load Amps

HEATERSIZE (kW) BTUH

208 V 480 VHeater FLA AWG* Heater FLA AWG*

0.5 1,707 1.4 14 0.6 101.0 3,413 2.8 14 1.2 102.0 6,826 5.6 14 2.4 103.0 10,239 8.3 14 3.6 104.0 13,652 11.1 14 4.8 105.0 17,085 13.9 12 6.0 106.0 20,478 16.7 10 7.2 107.0 23,898 19.4 10 8.4 108.0 27,304 22.2 10 9.6 109.0 30,717 25.0 8 10.8 10

10.0 34,130 27.8 8 12.0 1012.0 40,956 33.3 8 14.4 1214.0 47,782 38.8 6 16.8 1216.0 54,608 44.4 6 19.2 1018.0 61,434 50.0 6 21.6 1020.0 68,260 55.5 4 24.0 1022.0 75,086 61.1 4 26.4 824.0 81,912 66.6 4 28.8 826.0 88,738 72.3 3 31.3 828.0 95,564 77.8 3 33.7 830.0 102,390 83.4 2 36.1 632.0 109,216 89.0 2 38.6 634.0 116,042 94.5 1 41.0 636.0 122,868 100.1 1 43.4 6

AWG — American Wire GageFLA — Full Load Amps

6

ANALOGOR DDCCONTROLLER

SEPARATECONTROLENCLOSURE

1000080006000

4000

2000

1000800600

400

200

1008060

40

20

100.01 .03 .05 0.1 0.3 0.5 1

710522

362

232

2086

14491174927

37092840

7250

C

FM

SIZE 4 SIZE 5 SIZE 6 SIZE 7 SIZE 8 SIZE 9 SIZE 10SIZE 12SIZE 14SIZE 16

SIZE 22

CF

M A

T O

NE

INC

H S

IGN

AL

FLOW PROBE IN.WGVOLTS (ANALOG CONTROLS)

LEGEND

NOTE: Drawing is typical of 480V,3-phase, 4-wire heater and control.Refer to actual unit wiring diagram.

AFS — Airflow SwitchDDC — Direct Digital Controls

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

ANALOG OR DDCCONTROLLER24VAC

BLUYEL

CLASS IITRANSFORMER(OPTIONAL)

120VAC208VAC240VAC277VAC

L1

GROUND

24 VACPOWER

LEGEND

NOTE: Drawing is typical — refer to actual unit wiring diagramfor details.

Fig. 4 — Wiring of Optional Factory-MountedTransformer

DDC — Direct Digital ControlsField Wiring

Factory Wiring

Fig. 6 — Linear Probe CFM vs Pressure Signal Graph

7

CONTROL SETUP

General — The 35E single-duct VAV (variable air volume)terminal is designed to supply a varying quantity of cold prima-ry air to a space in response to a thermostat demand. Someunits have reheat options to provide heating demand require-ments as well. Most VAV terminals are equipped with pressurecompensating controls to regulate the response to the thermo-stat independent of the pressure in the supply ductwork.

To balance the unit, it is necessary to set both the maximumand minimum set points of the controller. The many types ofcontrol options available each have specific procedures re-quired for balancing the unit.

Set Points — Maximum and minimum airflow set pointsare normally specified for the job and specific for each unit onthe job. Where maximum and minimum airflow levels are notspecified on the order, default values are noted on unit ID label.

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

System Calibration of the Linear AveragingFlow Probe — To achieve accurate pressure independentoperation, the velocity sensor and linear averaging flow probemust be calibrated to the controller. This will ensure that air-flow measurements will be accurate for all terminals at systemstart-up.

System calibration is accomplished by calculating a flowcoefficient that adjusts the pressure fpm characteristics. Theflow coefficient is determined by dividing the flow for a givenunit (design air volume in cfm), at a pressure of 1.0 in. wg dif-ferential pressure, by the standard pitot tube coefficient of4005. This ratio is the same for all sizes if the standard linearaveraging probe is used.

Determine the design air velocity by dividing the design airvolume (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 designair volume is also shown in this table. It can be determinedfrom this table that the average design air velocity for 35E unitsis equal to 2656 fpm at 1.0 in. wg.

.

NOTE: For Carrier ComfortID™ terminals, all flow sizes are normal-ized using a single Probe Multiplier (PMF) for all sizes equal to2.273.

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

PNEUMATIC CONTROLS

Preparation for Balancing (Control Sequences1102 and 1103)

1. Inspect all pneumatic connections to assure tight fit andproper location.

2. Verify that the thermostat being used is compatible withthe control sequence provided (direct acting or reverseacting).

3. Check main air pressure at the controller(s). The main airpressure must be between 15 psi and 25 psi. (If dual orswitched-main air pressure is used, check the pressure atboth high and low settings.) The difference between“high” pressure main and “low” pressure main should beat least 4 psi, unless otherwise noted, and the “low” set-ting difference should exceed 15 psi.

4. Check that the unit damper will fail to the proper positionwhen main air pressure is lost. Disconnect the pneumaticactuator line from the velocity controller and observe theVAV damper position. The damper should fail to either anormally open position (indicator mark on shaft end ishorizontal) or a normally closed position (indicator markon 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 balancingtaps provided in the velocity probe sensor lines. Themanometer should have a full scale reading of 0.0 to1.0 in. wg. The high pressure signal is delivered from thefront sensor tap (away from the valve), and the low pres-sure signal is delivered from the back line (near thevalve). The pressure differential between high and lowrepresents the amplified velocity pressure in the inletduct.

7. Read the differential pressure and enter the Linear Aver-aging Probe Chart to determine the airflow in the terminalunit. This chart is shown in Fig. 6 and is also attached tothe side of each unit. For example, a differential pressureof 0.10 in. wg for a size 8 unit yields an airflow of275 cfm.

Volume controllers for 35EP units are shown in Fig. 8-10.Identification for each controller is shown in Table 4.

UNIT SIZE 35E 04 05 06 07 08 09INLET

DIAMETER 4.0 5.0 6.0 7.0 8.0 9.0

AIRFLOW (Cfm)AT 1 in. wg 232 362 502 710 927 1174

INLET AREA(sq ft) 0.087 0.136 0.196 0.267 0.349 0.442

35E UNIT SIZE 10 12 14 16 22INLET DIAMETER 10.0 12.0 14.0 16.0 16 x 24AIRFLOW (Cfm)

AT 1 in. wg 1449 2086 2840 3709 7250

INLET AREA(sq ft) 0.545 0.785 1.069 1.396 2.640

8

AIR TERMINAL PERFORMANCE SHEET

JOB NAME ______________________________________________

JOB LOCATION __________________________________________

CUSTOMER _____________________________________________

ENGINEER ______________________________________________

BUILDING LOCATION/FLOOR ______________________________

BUS NUMBER ___________________________________________

Fig. 7 — Air Terminal Performance Sheet

CONTROL SET POINTS

TagNumber

ZoneAddress #

BoxSize

(in./cfm)

Cooling(cfm) Reheat

cfm

Heating(cfm) Heat kW Occupied Unoccupied Calibration

Gainmin max min max Type Btu min max min max mult.

9

Table 4 — Pneumatic Volume Controller Identification

LEGEND

Balancing Procedure (Control Sequences1102 and 1103)DIRECT ACTING THERMOSTAT, NORMALLY OPENDAMPER (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 thecontroller) to achieve the required minimum flow.To determine the required pressure differential,refer to Tables 2 and 5 and the Linear AveragingProbe Chart provided on the side of the VAV unitand in Fig. 6.

c. Reconnect the thermostat line.2. Maximum volume setting:

a. Disconnect the thermostat line from the volumecontroller.

b. Apply 15 + psi to the thermostat port on the vol-ume controller (marked “T”) by tapping into themain air pressure line.

c. Adjust the maximum volume control knob(marked “HI” and located at the side of the con-troller) until the desired pressure differential isregistered on the manometer. To determine therequired pressure differential, refer to Table 5 andthe Linear Probe CFM vs Pressure Signal Graphprovided on the side of the VAV unit and in Fig. 6.

d. Reconnect the thermostat line.REVERSE ACTING THERMOSTAT, NORMALLY CLOSEDDAMPER (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 con-troller) to achieve the required minimum flow. Todetermine the required pressure differential, referto Tables 2 and 5 and the Linear Averaging ProbeChart provided on the side of the VAV unit and inFig. 6.

c. Reconnect the thermostat line.2. Minimum volume setting:

a. Disconnect the thermostat line from the velocitycontroller.

b. Apply 15 + psi to the thermostat port on the vol-ume controller (marked “T”) by tapping into themain air pressure line.

CONTROLSEQUENCE

FUNCTIONARRANGEMENTIDENTIFICATION

FIG. NO. KREUTERPART NO.

1102 DA-NO 8 CSC-20031103 RA-NC 9 CSC-20041104 DA-NO 10 CSC-30111105 DA-NC 10 CSC-30111106 RA-NO 10 CSC-30111107 RA-NC 10 CSC-30111108 DUAL MAX 10 CSC-30111109 HTG/CLG MAX 10 (2) CSC-30111110 DUAL MIN 10 CSC-3011

DA — Direct Acting NO — Normally OpenNC — Normally Closed RA — Reverse Acting

HI

LO

CSC-2003

0-1” PD.A.

DMPR.N.O.

INCREASE

INCREASE

HI

LO

CSC-2004

0-1” PR.A.

DMPR.N.C.

INCREASE

INCREASE

T

H L

B

M

NO

NC

G

RESET START

LO STAT ∆P

RESET SPAN

HI STAT ∆P

D A M P E R

IN C R IN C R

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

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

Fig. 10 — CSC 3000 SeriesReset Volume Controller

10

c. Adjust the minimum volume control knob(marked “LO” and located at the side of the con-troller) until the desired pressure differential isregistered on the manometer. To determine therequired pressure differential, refer to Table 5 andthe Linear Averaging Probe Chart provided on theside of the VAV unit and in Fig. 6.

d. Reconnect the thermostat line.

Balancing Procedure (Control Sequences1104-1110)

1. Damper action is factory set at N.O. (normally open) orN.C. (normally closed). To reselect, loosen damper selec-tion switch screw, align pointer with damper pointer andtighten screw. The spring range of the actuator is not criti-cal since the controller will output the necessary pressureto the actuator to position the damper according to setpoint. (See Fig. 11.)

2. Pipe the controller: Connect port “B” to the damper actu-ator. Connect port “M” to the clean, dry main air. Connectport “T” to the thermostat output. Connect port “H” to thetotal 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 applicationsusing either a Direct Acting (DA) or Reverse Acting (RA)thermostat signal. The two flow adjustments are labeled “LOSTAT ∆P” and “HI STAT ∆P.”LO STAT ∆P setting is the desired airflow limit when thethermostat pressure is less than, or equal to, the reset startpoint.• For DA Cooling or RA Heating:

Adjust LO STAT ∆P to the desired minimum airflowwith 0 psig (or a pressure less than the reset start point)at port “T.” The LO STAT ∆P must be set first. The LOSTAT ∆P will affect the HI STAT ∆P setting.

• For RA Cooling or DA Heating:Adjust LO STAT ∆P to the desired maximum airflowwith 0 psig (or a pressure less than the reset start point)at port “T.” The LO STAT ∆P must be set first. The LOSTAT ∆P will affect the HI STAT ∆P setting.

HI STAT ∆P setting is the desired airflow limit when the ther-mostat pressure is greater than, or equal to, the reset stop-point.The reset stop-point is the reset span pressure added to thereset start-point pressure.

• For DA Cooling or RA Heating (see Fig. 12):Adjust HI STAT ∆P to the desired maximum airflow with20 psig (or a pressure greater than the reset stop point) atport “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 airflowwith 20 psig (or a pressure greater than the reset stoppoint) at port “T.” The HI STAT ∆P must be set last. TheHI STAT ∆P setting will be affected by the LO STAT ∆Psetting.

NOTE: After the “LO STAT ∆P” and “HI STAT ∆P” initialadjustments are made, cycle the thermostat pressure a fewtimes to settle the internal reset mechanisms and verify set-tings. Fine tune the settings if necessary. The thermostat pres-sure may be left at a high pressure and the “G” port cap may beremoved and replaced to cycle the reset mechanism.RESET START setting is factory set at 8.0 psig. This is thelowest thermostat pressure that the LO STAT ∆P airflow willbegin to reset towards the HI STAT ∆P airflow. To change theRESET START setting: regulate thermostat pressure to the “T”port to the desired reset start point pressure, adjust RESETSTART adjustment until pressure at the “G” port is slightlyhigher than 0 psig, i.e., 0.1 psig.NOTE: The “G” port taps into the controller’s internal resetchamber, which always starts at 0 psig. The RESET STARTadjustment is a positive bias adjustment that sets the desiredthermostat start point to the controller’s internal reset startpoint of 0 psig.RESET SPAN setting is factory set at 5.0 psig. This is therequired change in thermostat pressure that the controller willreset between the LO STAT ∆P setting and the HI STAT ∆Psetting. To change the RESET SPAN setting: adjust RESETSPAN adjustment until pressure at the “G” port equals thedesired reset span pressure.NOTE: The “G” port taps into the controller’s internal resetchamber, which will always be at a pressure between 0 psigand the RESET SPAN pressure.

Preventative Maintenance1. 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

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. Proper thermostat signal and logic (Direct/Reverse Acting).5. Blocked velocity probe or insufficient primary supply air.6. Leaks in the actuator diaphragm.7. Mechanical linkage of the actuator/air valve.

PROBLEM PROBABLE CAUSEController does not reset to maximum or minimum set point duringbalance procedure.

Balancer is using the thermostat for control signal. An artificial signalmust be provided in place of the thermostat.

Controller does not reset to maximum or minimum set point duringoperation.

Thermostat is not demanding maximum or minimum air volume. Mainair pressure at the controller is less than 15 psi.

Pneumatic actuator does not stroke fully. Leak in pneumatic line between the controller and the actuator. Mainair pressure at the controller is less than 15 psi. Leak in the diaphragm.

Air valve stays in wide open position. Velocity probe is blocked by an obstruction (sandwich bag, etc.).Insufficient supply air in the inlet duct.

11

ANALOG CONTROLS

Balancing Procedures (Control Sequences2100-2105) — The analog electronic control system is apressure independent volume reset control that uses a KruegerCSP-5001 controller-actuator (see Fig. 13).

The system provides for independently adjustable set pointsfor minimum, maximum, and auxiliary airflow limits.

Room temperature control is provided by the associatedroom thermostat which is selected according to the application.The room thermostat provides a fixed 2 degrees F reset span re-gardless of the minimum and maximum velocity limit setpoints.

Adjustments for the minimum and maximum airflows aremade at the thermostat.

The thermostat (CTE-5100 series) operates on a 16 vdcpower supply from the CSP controller and outputs a 0 to10 vdc signal on the T terminals; T1 in the cooling mode (DA)and T2 in the heating mode (RA). See the reference sequencediagram on unit for details on which ‘T’ terminals are used oneach model thermostat, but in general T1 and T3 are used forthe cooling mode, T2 and T4 for heating. Terminals T1 and T2are adjustable to limit minimum and maximum flow. TerminalsT3 and T4 have a fixed 0 to 10 vdc output signal.

1. Required tools:a. 1/16 in. hex/key wrench

b. Small flat blade (1/8 in.) screwdriverc. Digital voltmeter capable of displaying a 0 to

10 vdc range which will display in hundredths ofvdc

d. HSO-5001 Test Leads (optional for meter taps)2. Remove thermostat cover:

Thermostat cover is removed by loosening the setscrewson each side of the thermostat. Using a 1/6 in. hex/keywrench 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 thermo-

stat 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 counterclockwiseto decrease) to the DC voltage equal to the desired air-flow (cfm) as shown on the calibration curve (Fig. 14).

NOTE: The minimum set point must be adjusted first. Adjust-ment of the MIN INCR potentiometer directly affects the max-imum set point.

4. Adjust the heating set point slider all the way to the rightfor 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 counterclockwiseto decrease) to the DC voltage equal to the desired air-flow (cfm) as shown on the calibration curve (Fig. 14).

NOTE: The maximum set point must be adjusted last. Adjust-ment of the MIN INCR potentiometer directly affects the max-imum set point.

6. Return the heating set point slider to the desired set point.Insert set point slider stops. Replace thermostat cover.

MAX

MIN

FLOW

0 3 8 13 psig

LO STAT ∆P

HI STAT ∆P

ROOM TEMPERATURE

DA HEATING*ResetSpan

Reset Start*∆

LO STAT ∆P

MAX

MIN

FLOW

13 8 3 0 psig

HI STAT ∆P

ROOM TEMPERATURE

RA HEATINGResetSpan

Reset Start∆

MAX

MIN

FLOW

13 8 3 0 psig

LO STAT ∆P

HI STAT ∆P

ROOM TEMPERATURE

RA COOLING*ResetSpan

Reset Start*∆

MAX

MIN

FLOW

0 3 8 13 psig

LO STAT ∆P

HI STAT ∆P

ROOM TEMPERATURE

DA COOLINGResetSpan

Reset Start∆

T

H L

B

M

NO

NC

G

RESET START

LO STAT ∆P

RESET SPAN

HI STAT ∆P

D A M P E R

IN C R IN C R

TO DAMPERACTUATORTO MAIN AIRSUPPLY

DIFFERENTIAL PRESSURE (FLOW)LIMIT ADJUSTMENT WHEN T’STATPRESSURE IS HIGH (HI STAT)(FACTORY SET AT 0.65 IN.WG.)****- FIELD ADJUSTMENT REQUIRED

DIFFERENTIAL PRESSURE (FLOW)LIMIT ADJUSTMENT WHEN T’STATPRESSURE IS LOW (LO STAT)(FACTORY SET AT 0 IN.WG.)**

ALL ADJUSTMENTS CCW TO INCREASE(1/8”-5/32” FLATBLADE SCREWDRIVER)

RESET SPAN ADJUSTMENT(FACTORY SET AT 5 PSI)DAMPER ACTION SELECTION

(FACTORY SET AT NORMALLY OPEN)NOTE: SCREW MUST BE TIGHT AND ARROWSIN PERFECT ALIGNMENT FOR DEVICE TO FUNCTION PROPERLY.

LOOSEN SCREW TOCHANGE DAMPER ACTION(SUPPLIED IN N.O. POSITION)

GAGE TAP. LEAVE CAP ON UNLESSCONNECTING GAGE FOR RESETSTART OR RESET SPAN ADJUSTMENT

PUSH ON NIPPLESFOR 3/16” (5) I.D.FR TUBING (5)

* TO STATIC PRESSURETO TOTAL PRESSURE

*(DIFFERENCE IS: DIFFERENTIALPRESSURE, OR DEVICEVELOCITY PRESSURE)

RESET START POINT ADJUSTMENT(FACTORY SET AT 8 PSI)

TO THERMOSTAT BRANCH SIGNAL(RESET SIGNAL)

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

Fig. 12 — Reset Cycle for CSC-3011 Control

Fig. 11 — 3011 CSC Controller

ccw cw

E

C

RED-CLSGRN-OPN

LED

METER

24VAC

– +IN

NO

RM

AX

MIN

NOM

MAX%MIN

˜––16V

DCOUI

HL

45

90

0

∆P PORTS

GEARDISENGAGEMENTBUTTON

ADJUSTABLEEND STOPS

0-10V VELOCITY OUTPUT0-10V INPUT SIGNAL16V DC OUTPUT(THERMOSTAT POWER)

COMMON (16V DC,INPUT, OUTPUT)POWERSUPPLY

16V

DC

IN

OUT

24 VAC

WIRING

– – ˜

Fig. 13 — CSP-5001 Controller

12

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 counterclockwiseto decrease) to the DC voltage equal to the desired air-flow (cfm) as shown on the calibration curve.

NOTE: The minimum set point must be adjusted first. Adjust-ment of the MIN INCR potentiometer directly affects the max-imum set point.

4. Adjust the cooling set point slider all the way to the leftfor 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 counterclockwiseto decrease) to the DC voltage equal to the desired air-flow (cfm) as shown on the calibration curve.

NOTE: The maximum set point must be adjusted last. Adjust-ment of the MIN INCR potentiometer directly affects the max-imum 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 Elec-tric 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 wayto the left for maximum cooling. (The heating set point sliderwill have to be adjusted all the way to the left also.)

NOTE: The minimum set point must be adjusted first. Adjust-ment of the MIN INCR potentiometer directly affects the max-imum 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 setpoint slider to their desired set points. Insert or reinsert setpoint slider stops. Replace thermostat cover.

CONTROL SEQUENCE 2104 (Cooling/Heating withAutomatic Changeover Control)Cooling Side of the Thermostat — Follow steps 1 through 5for cooling sequence 2101.NOTE: Be sure to adjust the cooling set point slider all the wayto the left for maximum cooling. (The heating set point sliderwill have to be adjusted all the way to the left also.)CONTROL SEQUENCE 2103 (Cooling with On/Off HotWater Heat Control) OR 2105 (Cooling with ProportionalHot Water Heat Control)Cooling Side of the Thermostat — Follow steps 1 through 5for cooling sequence 2101.NOTE: Be sure to adjust the cooling set point slider all the wayto the left for maximum cooling. (The heating set point sliderwill have to be adjusted all the way to the left also.)NOTE: The minimum set point must be adjusted first. Adjust-ment of the MIN INCR potentiometer directly affects the max-imum set point and auxiliary set point.

10000

8000

6000

4000

2000

1000

800

600

400

200

10080

60

40

20

10

710

522

362

232

2086

1449

1174927

3709

2840

7250

CF

M

CF

MA

TO

NE

INC

HS

IGN

AL

SIZE 4

SIZE 5SIZE 6SIZE 7SIZE 8SIZE 9SIZE 10SIZE 12SIZE 14SIZE 16

SIZE 22

1.2 1.8 2.3 3.4 4.6 5.8 7.2 9.7 11DIFFERENTIALPRESSURE

.02 .04 .06 0.1 0.2 0.3 0.5 0.8 1VOLTS

Fig. 14 — Calibration Curve 35E

13

Analog Control Troubleshooting — The followingtroubleshooting procedure is directed towards single duct cool-ing applications. The same concepts can be applied to otherconfigurations.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 Cali-

bration of the Linear Averaging Flow Probe sec-tion 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 (within50 fpm) or driving open or closed.

b. If damper is not moving, verify damper is notstuck or at end of travel. Check rotation jumpersfor proper position.

c. Change “Requested Flow” to make unit driveopposite direction. This can be accomplished bymoving 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 tocontrol at 3300 fpm/full airflow, and the greenLED should turn on (and the box should driveopen).

2) To manually close the box, remove wiringfrom terminal “IN”, jumper and “IN” terminalto “-” terminal. This will tell unit to control atzero fpm/no airflow, and the red LED shouldbe on (and the box should drive closed).

NOTE: When using the same transformer for more than onecontrol, the phase and ground must be consistent with eachdevice.

ComfortID™ CONTROLS

Install Sensors and Make Field WiringConnectionsGENERAL — All field wiring must comply with NationalElectrical Code and local requirements. Refer to Tables 6-9 forelectrical and wiring specifications.

Wire the control as shown on the control package diagramfor the specific installation. Control wiring diagrams can befound inside the control box.

If the 35E unit is equipped with electric heat, only power tothe electric heater must be supplied; no additional powersource is required for the control. If the unit does not have anelectric heater or the control transformer option, a field-supplied dedicated 24-vac/Class II power source must be in-stalled and wired to the zone controller, to terminals 1 and 2 ofconnector J1. Refer to unit wire label diagram for minimumsize (VA) and grounding requirements for each unit.SUPPLY-AIR TEMPERATURE (SAT) SENSOR INSTAL-LATION — On terminals with heat, the SAT sensor is provid-ed. The sensor is factory wired to the controller and shipped inthe control box. The SAT must be field-installed in the ductdownstream from the air terminal. The SAT sensor part num-ber 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 inFig. 15.

3. Using 2 self-drilling screws (supplied), secure the sensorprobe to the duct.

The SAT sensor probe is 6 inches in length. The tip of theprobe must not touch the inside of the duct. Use field-suppliedbushings as spacers when mounting the probe in a duct that is6 in. or less in diameter.

If the unit is a cooling only unit, the SAT sensor is not pro-vided and is not required.

If the unit has a multiple outlet attenuator connected directlyat the discharge, install the sensor in the multiple outlet attenua-tor. See Fig. 15.

For units equipped with electric reheat, locate the sensor asfar downstream as possible. This ensures the sensor will not beaffected by excessive radiant heat from the heater coil. Installthe sensor a minimum of 2 ft downstream of the coil for unitswith hot water heat.

Perform the following steps if state or local code requiresthe use of conduit, or if your installation requires a cable lengthof more than 8 ft:

1. Disconnect the sensor cable from the ComfortID zonecontroller, 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.

Never jumper terminal 16 VDC to “-” as this would causea short, and possibly damage the power supply.

Disconnect electrical power before wiring inside the con-troller. Electrical shock, personal injury, or damage to thezone controller can result.

DO NOT run sensor or relay wires in the same conduit orraceway 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 thephysical or electrical properties.DO NOT bend a cable through a radius sharper than thatrecommended by its manufacturer.AVOID splices in any control wiring.

14

Table 6 — Thermistor Resistance vs Temperature Values forSupply-Air Temperature Sensor, Primary Air Temperature Sensor and Space Temperature Sensor

SPACE TEMPERATURE SENSOR INSTALLATION ANDWIRING — The space temperature (SPT) sensor accessory isordered separately for field installation. It is installed oninterior walls to measure room space air temperature. SeeFig. 16-20 and Table 6.

The wall plate accommodates both the NEMA (NationalElectrical Manufacturing Association) standard and the Euro-pean 1/4 DIN standard. The use of a junction box to accommo-date the wiring is recommended for installation. The sensormay be mounted directly on the wall, if acceptable by localcodes.

DO NOT mount the sensor in drafty areas such as near heat-ing or air-conditioning ducts, open windows, fans, or over heatsources such as baseboard heaters or radiators. Sensors mount-ed in those areas will produce inaccurate readings.

Avoid corner locations. Allow at least 3 ft between the sen-sor and any corner. Air in corners tends to be stagnant, resultingin inaccurate sensor readings.

Sensor should be mounted approximately 5 ft up from thefloor, in an area that best represents the average temperaturefound in the space (zone).

The space temperature sensor cover includes a service jackconnector. If wiring connection is made to the service jack, theconnector can then be used to connect a network service toolwith the Carrier Comfort Network® system.

Before installing the space temperature sensor, decidewhether or not the service jack wiring connection will be made.If connection is desired, the CCN communication cable shouldbe available at time of sensor installation, for convenientwiring connections. The cable selected must meet therequirements for the entire network. See Connect the CCNCommunication Bus section for CCN communication cablespecifications.

RESISTANCE(Ohms)

TEMP(F)

RESISTANCE(Ohms)

TEMP(F)

RESISTANCE(Ohms)

TEMP(F)

RESISTANCE(Ohms)

TEMP(F)

RESISTANCE(Ohms)

TEMP(F)

29481 32 17050 54 10227 76 6340 98 4051 12028732 33 16646 55 10000 77 6209 99 3972 12128005 34 16253 56 9779 78 6080 100 3895 12227298 35 15870 57 9563 79 5954 101 3819 12326611 36 15497 58 9353 80 5832 102 3745 12425943 37 15134 59 9148 81 5712 103 3673 12525295 38 14780 60 8948 82 5595 104 3603 12624664 39 14436 61 8754 83 5481 105 3533 12724051 40 14101 62 8563 84 5369 106 3466 12823456 41 13775 63 8378 85 5260 107 3400 12922877 42 13457 64 8197 86 5154 108 3335 13022313 43 13148 65 8021 87 5050 109 3272 13121766 44 12846 66 7849 88 4948 110 3210 13221234 45 12553 67 7681 89 4849 111 3150 13320716 46 12267 68 7517 90 4752 112 3090 13420212 47 11988 69 7357 91 4657 113 3033 13519722 48 11717 70 7201 92 4564 114 2976 13619246 49 11452 71 7049 93 4474 115 2920 13718782 50 11194 72 6900 94 4385 116 2866 13818332 51 10943 73 6755 95 4299 117 2813 13917893 52 10698 74 6613 96 4214 118 2761 14017466 53 10459 75 6475 97 4132 119

ZC

AIRTERMINAL

UNIT

MULTIPLEOUTLET

ATTENUATOR

HEAT SAT

2 FT. MIN.

PRIMARYAIR INLET

ZC

AIRTERMINAL

UNIT

HEAT SAT

2 FT. MIN.

PRIMARYAIR INLET

LEGEND

Fig. 15 — Supply Air Temperature Probe (Part No. 33ZCSENSAT) Locations

SAT — Supply Air Temperature SensorZC — Zone Controller

UNIT WITH ELECTRIC HEAT

UNIT WITH MULTIPLE OUTLET ATTENUATOR

15

D

5’

3’ (MIN)

OR2/3 OF WALL HEIGHT

Fig. 16 — Typical Space Temperature SensorRoom Location

WarmCool

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

NOTE: Dimensions are in inches.

Fig. 18 — Space Temperature Sensor and WallMounted Humidity Sensor Mounting

2 3 4 5 61

SW1

SEN

BLK (GND)RED (SPT)

RED(+)WHT(GND)

BLK(-) CCN COM

SENSOR WIRING

Fig. 19 — Space Temperature Sensor Wiring(33ZCT55SPT)

2 3 4 5 61

SW1

SEN SET

Cool Warm

WHT(T56)

BLK (GND)RED (SPT)

RED(+)WHT(GND)

BLK(-) CCN COM

SENSOR WIRING

JUMPERTERMINALSAS SHOWN

Fig. 20 — Space Temperature Sensor Wiring(33ZCT56SPT)

16

Install and wire the space temperature sensor as follows:NOTE: Space temperature sensor will be identified as T55 orT56. Refer to Control Sequence Drawings to determine whichSPT is part of the particular control package being installed.(The difference between T55 and T56 is that T56 includes setpoint adjustment capability.)

1. Locate the two Allen type screws at the bottom of thesensor.

2. Turn the two screws clockwise to release the cover fromthe sensor wall mounting plate.

3. Lift the cover from the bottom and then release it fromthe top fasteners.

4. Feed the wires from the electrical box through the open-ing in the center of the sensor mounting plate.

5. Using two no. 6-32 x 1 mounting screws (provided withthe 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 athree-conductor shielded cable for the sensor and setpoint adjustment connections. The standard CCN com-munication cable may be used. Refer to Table 8. If the setpoint adjustment (slide-bar) is not required, then an un-shielded, 18 or 20 gage, two-conductor, twisted pair cablemay be used. Refer to Table 7.The CCN network service jack requires a separate,shielded CCN communication cable. Always use sepa-rate 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 themounting plate first, then swing the cover down over thelower portion. Rotate the two Allen head screws counter-clockwise until the cover is secured to the mounting plateand locked in position.

8. For more sensor information, see Table 6 for thermistorresistance vs temperature values.

NOTE: Clean sensor with damp cloth only. Do not usesolvents.

Table 7 — Recommended Sensor and DeviceWiring

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

WIRING THE SPACE TEMPERATURE SENSOR ANDSET POINT ADJUSTMENT SLIDEBAR — To wire the sen-sor 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 theshield 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 otherend of the wire to the left terminal on the SEN ter-minal block of the sensor.

b. Connect another wire from the cable (BLACK) tothe ground terminal on the controller. Connect theother end of the wire to the remaining open termi-nal on the SEN terminal block.

c. For T56 sensors, connect the remaining wire(WHITE/CLR) to the T56 terminal on the control-ler. Connect the other end of the wire to the rightmost terminal on the SET terminal block.

d. In the control box, connect the cable shield toJ1-3, equipment ground.

e. Install a jumper between the two center terminals(right SEN and left SET).

WIRING THE CCN NETWORK COMMUNICATIONSERVICE JACK — To wire the service jack, perform thefollowing:

1. Strip back the jacket from the CCN communication ca-ble(s) at least 3 inches. Strip 1/4-in. of insulation fromeach conductor. Remove the shield and separate the drainwire from the cable. Twist together all the shield drainwires and fasten them together using an closed end crimplug or a wire nut. Tape off any exposed bare wire to pre-vent 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 INSTALLA-TION — A primary air temperature (PAT) sensor is used on azone controller which is functioning as a Linkage Coordinatorfor a non-CCN Linkage compatible air source. The part num-ber is 33ZCSENPAT. See Fig. 21. The sensor is also availableas field-supplied accessory.

When used on a zone controller, try to select a zone control-ler which will allow installation of the PAT sensor in the maintrunk, 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.

MANUFACTURERPART NUMBER

Regular PlenumBelden 8205 88442Columbia D6451 —American A21501 A48301Quabik 6130 —Alpha 1895 —Manhattan M13402 M64430

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

17

INDOOR-AIR QUALITY SENSOR INSTALLATION —The indoor-air quality (IAQ) sensor accessory monitors carbondioxide levels. This information is used to increase the airflowto the zone and may also modify the position of the outdoor-airdampers to admit more outdoor air as required to provide thedesired ventilation rate. The wall sensor is used to monitor theconditioned space. The sensor uses infrared technology tomeasure the levels of CO2 present in the air. The wall sensor isavailable with or without an LCD readout to display the CO2level in ppm and is also available in a combination modelwhich senses both temperature and CO2 level.

The CO2 sensors are factory set for a range of 0 to2000 ppm and a linear voltage output of 0 to 10 vdc. Refer tothe instructions supplied with the CO2 sensor for electrical re-quirements and terminal locations. The sensor requires a sepa-rate field-supplied 24 vac 25 va transformer to provide powerto the sensor. The transformer may be mounted in the controlbox if space is provided (except electric heat units).

For factory configuration changes to some models of thesensor, the User Interface Program (UIP) or Sensor CalibrationService Kit is required.

To accurately monitor the quality of the air in the condi-tioned air space, locate the sensor near the return air grille so itsenses the concentration of CO2 leaving the space. The sensorshould be mounted in a location to avoid direct breath contact.

Do not mount the space sensor in drafty areas such as nearsupply diffusers, open window, fans, or over heat sources. Al-low at least 3 ft between the sensor and any corner. Avoidmounting the sensor where it is influenced by the supply air;the sensor gives inaccurate readings if the supply air is blowndirectly onto the sensor.

To mount the sensor, refer to the installation instructionsshipped with the accessory kit.INDOOR AIR QUALITY SENSOR WIRING — To wire thesensor after it is mounted in the conditioned air space, seeFig. 23-25 and the instructions shipped with the sensor. Usetwo 2-conductor 20 American Wire Gage (AWG) twisted-paircables (see Table 7) to connect the field-supplied separate iso-lated 24 vac power source to the sensor and to connect the sen-sor to the control terminals. To connect the sensor to thecontrol, identify the positive (+) and ground (GND) terminalson the sensor and connect the positive terminal to the RH/IAQterminal on the control and connect the ground terminal toterminal GND.HUMIDITY SENSOR (Wall-Mounted) INSTALLA-TION — The accessory space humidity sensor is field sup-plied and installed on an interior wall to measure the relativehumidity of the air within the occupied space. See Fig. 26.

The use of a standard 2 x 4-in. electrical box to accommo-date the wiring is recommended for installation. The sensor canbe mounted directly on the wall, if acceptable by local codes.

If the sensor is installed directly on a wall surface, install thehumidity sensor using 2 screws and 2 hollow wall anchors(field-supplied); do not overtighten screws.

The sensor must be mounted vertically on the wall. TheCarrier logo should be oriented correctly when the sensor isproperly mounted.

Do NOT clean or touch the sensing element with chemicalsolvents; they can permanently damage the sensor.

Fig. 24 — Ventilation Rates Based onCO2 Set Point

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

Fig. 22 — Primary Air TemperatureSensor Installation

(Air-Handling Unit Discharge Locations)

18

DO NOT mount the sensor in drafty areas such as near heat-ing or air-conditioning ducts, open windows, fans, or over heatsources such as baseboard heaters, radiators, or wall-mountedlight dimmers. Sensors mounted in those areas will produceinaccurate readings.

Avoid corner locations. Allow at least 4 ft between the sen-sor and any corner. Airflow near corners tends to be reduced,resulting in erratic sensor readings.

Sensor should be vertically mounted approximately 5 ft upfrom the floor, beside the space temperature sensor.

For distances up to 500 feet, use a 3-conductor, 18 or20 AWG cable. A CCN communication cable can be used,although the shield is not required. The shield must be removedfrom 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 powersource is required.

To wire the sensor, perform the following:1. At the sensor, remove 4 in. of jacket from the cable. Strip

1/4 in. of insulation from each conductor. Route the cablethrough the wire clearance opening in the center of thesensor.

2. Connect the RED wire to the sensor screw terminalmarked (+).

3. Install one lead from the resistor (supplied with the sen-sor) and the WHITE wire, into the sensor screw terminalmarked (–). After tightening the screw terminal, test theconnection by pulling gently on the resistor lead.

4. Connect the remaining lead from the resistor to theBLACK wire and secure using a field-supplied closedend type crimp connector or wire nut.

5. Using electrical tape, insulate any exposed resistor lead toprevent 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 controlboard.

9. Connect the BLACK wire to terminal GND on the con-trol board.

10. Connect the WHITE/CLEAR wire to terminal RH/IAQon the control board.

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

HF23BJ042Made in Swi tzer land

by Be l imo Automat ion

10

yel blu ora

WIP

5K

LISTED94D5TEMP. IND. &REG. EQUIP.

ULClass 2 Supply

L R 9 2 8 0 0

NEMA2

24VAC/DC50/60Hz3VA 2W

COM

1 2 3blk red wht

LINE VOLTAGE24VAC*

SEPARATEPOWERSUPPLY

REQUIRED*

IAQ

GND

21 87

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

Fig. 25 — Indoor Air Quality Sensor Wiring

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

19

Connect the CCN Communication Bus — Thezone controllers connect to the bus in a daisy chain arrange-ment. The zone controller may be installed on a primary CCNbus or on a secondary bus from the primary CCN bus. Con-necting to a secondary bus is recommended.

At 9,600 baud, the number of controllers is limited to128 zones maximum, with a limit of 8 systems (LinkageCoordinator configured for at least 2 zones). Bus length maynot exceed 4000 ft, with no more than 60 devices on any1000-ft section. Optically isolated RS-485 repeaters arerequired every 1000 ft.

At 19,200 and 38,400 baud, the number of controllersis limited to 128 maximum, with no limit on the number ofLinkage Coordinators. Bus length may not exceed 1000 ft.

The first zone controller in a network connects directly tothe bridge and the others are wired sequentially in a daisy chainfashion.

The CCN communication bus also connects to the zonecontroller space temperature sensor. Refer to the Install Sensorsand Make Field-Wiring Connections section for sensor wiringinstructions.COMMUNICATION BUS WIRE SPECIFICATIONS —The Carrier Comfort Network® (CCN) communication buswiring is field-supplied and field-installed. It consists ofshielded three-conductor cable with drain (ground) wire. Thecable selected must be identical to the CCN communicationbus wire used for the entire network. See Table 8 for recom-mended cable.

Table 8 — Recommended Cables

NOTE: Conductors and drain wire must be at least 20 AWG(American Wire Gage), stranded, and tinned copper. Individual con-ductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, orpolyethylene. An aluminum/polyester 100% foil shield and an outerjacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimumoperating temperature range of –20 C to 60 C is required.

CONNECTION TO THE COMMUNICATION BUS1. 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 (ifconnecting on a secondary bus).When connecting the communication bus cable, acolor code system for the entire network is recom-mended to simplify installation and checkout. SeeTable 9 for the recommended color code.

Table 9 — Color Code Recommendations

3. Refer to Fig. 27. Connect the other end of the commu-nication bus cable to the terminal block labeled CCNin the zone controller of the first air terminal. Follow-ing the color code in Table 9, connect the Red (+) wireto Terminal 1. Connect the White (ground) wire to Ter-minal 2. Connect the Black (–) wire to Terminal 3.

4. Connect additional zone controllers in a daisy chainfashion, following the color coded wiring scheme inTable 9.

NOTE: The communication bus drain wires (shield) mustbe tied together at each zone controller. If the communica-tion bus is entirely within one building, the resulting contin-uous shield must be connected to ground at only one singlepoint. If the communication bus cable exits from one build-ing and enters another building, connect the shields toground at a lightning suppressor in each building where thecable enters or exits (one point only).

Water Valve Installation

Water valves are field supplied. Carrier offers two differenthot water valve applications: on/off and floating point modulat-ing proportional control. See Table 10 for specifications forcompatible water valves. To connect the field-supplied watervalves to the wiring harness terminal board located in the ter-minal control unit, refer to the wiring labels for the controlpackage.

Table 10 — Valve Specifications

ComfortID™ Start-UpGENERAL — Air volume delivery to the conditioned spaceis controlled by the modulating of the primary air damper andthe sequencing of the air source supply fan. The controller po-sitions the damper by way of an actuator and turns the fan onand off through linkage for the CCN compatible air sourceequipment control.PRIMARY SYSTEM CHECK

1. Check that all controls, control box, and ductwork havebeen properly installed and set according to installationinstructions and job requirements.

2. Check that final filters have been installed in the air-handling apparatus. Dust and debris can adversely affectsystem 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 pip-ing 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 full-

open position.ComfortID CONTROL SYSTEM CHECK

1. Check interconnections between thermostats and unitcontrols.

2. Force all dampers to control to the maximum cooling cfmusing the Building Supervisor, ComfortWORKS®, Net-work Service Tool or ComfortID Test and Balance Toolsoftware.

3. Set supply-duct balancing dampers, if used, in maximumcool position.

MANUFACTURER CABLE PART NO.Alpha 2413 or 5463American A22503Belden 8772Columbia 02525

SIGNAL TYPE CCN BUS WIRECOLOR

PLUG PINNUMBER

+ Red 1Ground White 2– Black 3

Disconnect power before wiring the terminal control unitor electrical shock and personal injury could result.

Follow the valve manufacturers recommended installationinstructions.

TYPE ON/OFFVALVE

3 POINTSFLOATING

VALVEVoltageFrequencyPower Requirement

24 vac50/60 HzNot to exceed 15 va

24 vac (15%)50/60 HzNot to exceed 15 vamax inrush

20

4. Check that the static pressure available at each box isabove the minimum required, force all dampers to controlto the minimum cooling cfm and verify that the staticpressure is below the maximum safe operating limitswhen the damper is providing minimum cooling airflow.

5. Set air source supply fan speed and duct static pressureregulator to obtain satisfactory static pressure at designairflow.

6. While at peak system load, check system operation andpressures.

7. Check duct pressure at various points in the system. If sys-tem static pressure probe has been properly located, pres-sure at last units of all branch headers should remain essen-tially the same. If pressure has changed considerably, re-check the supply air static pressure controller or relocatethe probe to better sense system pressure changes.

8. Remove all forces and balance each control box zoneusing through the balancing procedure described onpage 11.

9. Check that each heating coil is fully operational and thatproper airflow is maintained during heating.

It is important to maintain sufficient airflow to units withelectric heating elements. Supply-air temperature should NOTEXCEED 105 F in any stage of heating operation. Check thesystem to make sure that it does not cycle on and off duringheating.

CCN System Start-Up — The Building Supervisor,ComfortWORKS®, and the Network Service Tool can aid insystem start-up and troubleshooting.

All set-up and set point configurations are factory set andfield adjustable. Changes are made by using either BuildingSupervisor, ComfortWORKS or the Network Service Tool.The Network Service Tool can be used as a portable device tochange system set-up and set points from a zone sensor or ter-minal control module. During start-up, the Building Supervisoror the Network Service Tool can also be used to verify commu-nication with each controller.

For specific operating instructions, refer to the appropriateuser manual. See Table 11 for troubleshooting information.ComfortID™ TEST AND BALANCE TOOL SOFT-WARE — The ComfortID Test and Balance Tool software isused for testing each controller if the Network Service Tool orCCN are not available. The ComfortID Test and Balance Toolis 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 forvarious functions that expedite system checks and testing.

Carrier requires the use of the B&B485CARLP9A PortPowered RS232 to RS485 Converter for proper operation.NOTE: The B&B485CARLP9A Port Powered RS232 toRS485 is available through:B&B Electronics1500 Boyce Memorial DriveP.O. Box 1040Ottawa, IL 61350

Refer to the ComfortID Test and Balance Tool SoftwareInstallation and Operation Instructions (Carrier publication no.533-360) for additional information.

HF23BJ042Made in Switzerlandby Belimo Automation

LR 92800

NEMA 2

Class 2 Supply

LISTED94D5TENP IND &REG. EQUIP.

24VAC/DC50/60 Hz3VA 2W

5K

WIP

yel blu ora blk red wht

COM

1 2 3

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

0 1

J4

RH/IAQ

GND

SECFLOW

+10V

DMPPOS

GND

TESTGND

+24VSPT

GND

SAT

T56

GND

PAT

N/A

J3J1

SR

VC

24V

AC +

G-

HIG

H

Part Number: 33ZCFANTRM

S/N:

Bus#:

Element#:

Unit#:

J6

CC

WC

OM

CW

HE

AT

124

VA

CH

EA

T2

ZONE Controller®

®

C US

LOW

1 6

31

+

G-

J2A

CC

N LEN

J2B

+

G-

11

13

3

2

15 16

FAN ACFAN

24VACN/A

HEAT3

J7J6

11

23

CWCOMCCW

J8S

EC

DM

P13

CCNCOMMUNICATIONCONNECTOR

RED (+)

WHITE (GND)

BLACK (–)

CCN

Fig. 27 — CCN Terminations at Zone Controller

21

Table 11 — Troubleshooting Guide For ComfortID™ Terminal Controls

VVT® CONTROLS

GeneralDIRECT DRIVE HIGH TORQUE ACTUATOR — Thedirect-drive high torque actuator is used in VVT (variablevolume and variable temperature) systems for changing thedamper position. The actuator is factory-installed on the termi-nal damper and is controlled by a zone controller or a monitorthermostat. The thermostat calculates how much heating orcooling is required to each zone in the VVT system. The actua-tor receives the commands from its controlling device andmoves its damper to change the amount of heated or condi-tioned air that is sent to its zone.

If the 35E unit is equipped with electric heat, only power tothe electric heater must be supplied. If the unit does not have anelectric heater, then a field-supplied dedicated 24 vac/Class IIpower source must be installed and wired to the VVT control-ler. Refer to Table 12 for the minimum VA requirement and tothe wire label diagram for power connections.RELAY PACKAGE — The relay package is factory-suppliedas required depending on the control package ordered.

The relay pack output harness is connected to the outputconnector on the relay pack. The pigtail is routed through thegrommet the bottom of actuator.

For hot water heat applications, connect the white wire fromthe relay pack output harness to the field-supplied two-positionwater valve. See the unit wiring diagram for more information.ADDITIONAL SENSOR INSTALLATION — Additional sen-sors are required for certain control sequences. A pressuretransducer is factory supplied, wired, piped, and installed in-side the control box for units with pressure independent con-trols. Follow the installation instructions provided with eachsensor.NOTE: Pressure sensor is NOT installed inside the actuatorhousing. There is no clearance available for the pressure trans-ducer inside the actuator.THERMOSTATS — Thermostats are sold separately and arenot provided as part of any VVT control package. Refer to thespecific control publication for thermostat operation.

Thermostat Placement — Begin the thermostat instal-lation by determining where the device will be located. In mostcases, this will be pre-determined by the building plans.

The thermostat should be located on an interior wall, about5 ft from the floor. The device should be located away from di-rect sunlight, drafts, or interior heat sources which may influ-ence temperature readings.

The device may also be mounted in a remote location withthe 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 horizontallymay be used instead of cutting the hole.

2. Remove the cover from the thermostat/controller. Care-fully remove the circuit board from the backplate of thethermostat/controller. Line up the backplate with the holein the wall. Push the protruding part of the backplate intothe hole. Pull the thermostat/controller wires out throughthe backplate.

3. Attach backplate to wall with screws provided.

Wiring Requirements — The wiring requirements forthe 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 fromthermostat to thermostat in daisy-chain configuration. (Refer toTable 12 for specific control package requirements.)

Table 12 — Minimum VA Requirements

PROBLEM CAUSE CORRECTIVE ACTIONMeasured Airflow Does Not AgreeWith Display Value.

Terminal airflow not calibrated or airflowsensor not calibrated.Wrong terminal inlet size.

Perform damper/transducer and zone calibration.

Check and correct terminal inlet size if necessary.

Supply Air Temperature (SAT)Displays 0.0°. Terminal Not EquippedWith Heat or Field Installed.

No heat type configured or ducted heat notconfigured.

For terminals without heat, the SAT sensor isnot used. If required, configure Heat Type = 2and Ducted Heat = YES.

Baseboard Perimeter Heat DoesNot Work.

No heat type configured. Configure Heat Type. If modulating baseboard,then Ducted Heat must equal YES and sensorHH79NZ078 must be affixed to measure leaving watertemperature.

Modulating Baseboard Hot WaterHeat Does Not Control Properly.

Improperly configured. Readjust the following service configuration parameters:Heat Start Value = 110 FMaximum Duct Temperature = 180 FP Gain = 20I Gain = 1.3

Electric Reheat Does Not Operate. No power to heater.Airflow too low or high temperature limittripped.

Check fuses and disconnect.Verify airflow exceeds 500 fpm. Adjust Reheat CFM Limit ifrequired to operate below 120 F discharge with all stagesoperating.

Hot Water Reheat Does Not Operate. No hot water available.Water valve wired wrong or not functioning.

Repair as required.Check wiring and correct if necessary. Retest watervalve operation.

Excessive Air Noise. Airflow limits not set properly.Excessive system static pressure.Diffusers too small.

Check and readjust maximum airflow limits.Check system static pressure. Reduce pressure if required.Replace with proper size.

Unit Will Not Provide ModulatingDamper Control During Air SourceHeating/Warm-Up Mode.

Primary air temperature sensor notinstalled and no Linkage Master is used(PAT sensor required for control package4140 and 4145, cooling only, stand-aloneoperation).

Install PAT sensor and configure as a Linkage Masterwith a system size of 1 zone.

CONTROL SEQ NO. MIN VA REQUIREMENT8200 308201 Factory Supplied (75)8202 408206 358207 Factory Supplied (75)8208 458209 308210 35

22

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

Wiring Connections

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. 29and 30.

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 theterminal block should be away from the wall. Push theterminal block into the track until about 1/2 in. is leftprotruding.

4. Align the ribbon cable from the thermostat/controller cir-cuit board with the ribbon connector on the terminalboard and push gently to connect.

5. Push the terminal board fully into backplate until the latchclicks into place.

6. Place the foam backing on the circuit board. Slide the cir-cuit board under the back plate securing bars. DO NOTCREASE RIBBON CABLE.

7. Align thermostat board with alignment pin. Gently pulldown on the thermostat latch and press firmly until thecircuit board snaps into place.

8. If optional locking thermostat cover is purchased, insertlocking clip on the inside of the thermostat cover. Pushfirmly into place.

9. Insert tabs on thermostat cover into top slots on the back-plate. Press firmly on the bottom of the thermostat coverto snap cover into lace.NOTE: If the optional locking thermostat cover was in-stalled, the key must be inserted into the locking device toremove front cover.

Electric shock can cause injury or death. Ensure power tothe HVAC unit has been disconnected before wiring.

ACTUATORCOVER

COVERSCREW(HIDDEN)

GROMMET

WIRINGHARNESSES

MOUNTINGBRACKET

COVERSCREW

KMC

3 PIN TEMPERATURESENSOR CONNECTOR

5 PIN T-STATCONNECTOR

THRU HOLEFOR TEMP.SENSOR

(2) 3 PIN POWERCONNECTOR

8 PIN RELAYCONNECTOR

ACTUATORSHIPPED ATCLOSEDPOSITON

10 PIN ANALOGCONNECTION

(2) 5/16-18SET SCREWS

COVER REMOVEDWITH COVER

Fig. 28 — High Torque Actuator

1 3/4”

1 3/4”

Fig. 29 — Mounting Hole Dimensions

23

VVT® Control Configuration/Testing — CarrierVVT controls require a field-supplied VVT thermostat for thespecific application based on the control package ordered. Thethermostat is factory-supplied with default configuration. Thisallows pressure dependent cooling only terminals to operate ina stand-alone mode, during the construction phase. The install-er is required to configure the terminal, system and userspecific parameters. All programming can be done at thethermostat without the use of a PC. Terminal parameters in-clude inlet area (pressure independent), airflow limits (pressureindependent), minimum or maximum damper position adjust-ments, and damper position factor (reheat applications).

System parameters such as system type (pressure dependent orindependent), and controller address along with user parame-ters such as occupancy and set point schedules, must be enteredbefore final checkout and commissioning.

For more information and details regarding specific controlconfiguration parameters and programming procedures, referto the Carrier Comfort Network® system Variable Volume andTemperature (VVT) Product Data literature and the configura-tion instructions provided with the thermostat.

Refer to the specific control sequence (35E-82XX) for de-tailed operational information. This information should be usedto test and commission the control.

Control Start-UpGENERAL — Air volume delivery to the conditioned spaceis controlled by the modulating of the primary air damper andthe sequencing of the air source supply fan. The VVT control-ler positions the damper by way of an actuator and turns thefan on and off through relay contactors.PRIMARY SYSTEM CHECK

1. Check that all controls, control box, and ductwork havebeen properly installed and set according to installationinstructions and job requirements.

2. Check that final filters have been installed in the air-handling apparatus. Dust and debris can adversely affectsystem 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 pip-ing 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 full-

open position.

Fig. 30 — Wiring Connections

Fig. 31 — Terminal Board Installation

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 24 3-06 Replaces: 35E-1SI

Copyright 2006 Carrier Corporation

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