Carrier 48HJD005-007 Installation, Start-Up And Service Instructions Manual

(low nox) single-package rooftop heating/cooling

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CONTENTS

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Step 1 — Provide Unit Support . . . . . . . . . . . . . . . . . . . 1

• ROOF CURB

• SLAB MOUNT

Step 2 — Field Fabricate Ductwork . . . . . . . . . . . . . . . 3

Step 3 — Install External Trap for

Condensate Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 4 — Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . 3

• POSITIONING

Step 5 — Install Flue Hood . . . . . . . . . . . . . . . . . . . . . . . 4

Step 6 — Install Gas Piping . . . . . . . . . . . . . . . . . . . . . . 4

Step 7 — Make Electrical Connections . . . . . . . . . . . 4

• FIELD POWER SUPPLY

• FIELD CONTROL WIRING

• HEAT ANTICIPATOR SETTINGS

Step 8 — Adjust Factory-Installed Options . . . . . . . 8

• MOISTUREMISER DEHUMIDIFCATION

PACKAGE

• APOLLO CONTROL

• DISCONNECT SWITCH

• OPTIONAL DURABLADE ECONOMIZER

• OPTIONAL ECONOMI$ER

Step 9 — Adjust Evaporator-Fan Speed . . . . . . . . . 19

• BELT-DRIVE MOTORS

Pre-Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-32

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-38

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . 39-45

Start-Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can

be hazardous due to system pressure and electrical compo-

nents. Only trained and qualified service personnel should

install, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance func-

tions of cleaning coils and filters and replacing filters. All other

operations should be performed by trained service personnel.

When working on air-conditioning equipment, observe precau-

tions in the literature, tags and labels attached to the unit, and

other safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work

gloves. Use quenching cloth for unbrazing operations. Have

fire extinguishers available for all brazing operations.

Before performing service or maintenance operations on

unit, turn off main power switch to unit and install lockout

tag. Ensure electrical service to rooftop unit agrees with

voltage and amperage listed on the unit rating plate. Elec-

trical shock could cause personal injury.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 111

Book 1

Tab

1a 6a

48HJL/HJM/HJN/HJG/HJH/HJK004-006 (LOW NO

Single-Package Rooftop Heating/Cooling

Installation, Start-Up and

Service Instructions

Page

Catalog No. 534-767

Printed in U.S.A.

48HJD005-007, 48HJE/HJF004-007

Disconnect gas piping from unit when leak

testing at pressure greater than

sures greater than

damage resulting in hazardous condition. If

gas valve is subjected to pressure greater than

psig, it must be replaced before use. When

pressure testing field-supplied gas piping at

pressures of

to such piping must be isolated by manually

closing the gas valve(s).

INSTALLATION

Unit is shipped in the vertical discharge configuration. To

convert to horizontal discharge application, remove duct open-

ing covers. Using the same screws, install covers on duct open-

ings in basepan of unit with insulation-side down. Seals around

openings must be tight.

NOTE: Any combination of supply and return ducting is per-

missible, i.e., vertical supply combined with horizontal return.

Step 1 — Provide Unit Support

ROOF CURB — Assemble and install accessory roof curb in

accordance with instructions shipped with curb. See Fig. 1. In-

stall insulation, cant strips, roofing felt, and counter flashing as

shown. Ductwork must be attached to curb, not to the unit.

If electric control power or gas service is to be routed through

the basepan, attach the accessory thru-the-bottom service con-

nections to the basepan in accordance with the accessory instal-

lation instructions. Connections must be installed before unit is

set on roof curb.

IMPORTANT: The gasketing of the unit to the roof curb

is critical for a watertight seal. Install gasket supplied

with the roof curb as shown in Fig. 1. Improperly

applied gasket can result in air leaks and poor unit

performance.

Curb should be level. Unit leveling tolerances are shown in

Fig. 2. This is necessary for unit drain to function properly. Re-

fer to Accessory Roof Curb Installation Instructions for addi-

tional information as required.

SLAB MOUNT (Horizontal Units Only) — Provide a level

concrete slab that extends a minimum of 6 in. beyond unit cab-

inet. Install a gravel apron in front of condenser-coil air inlet to

prevent grass and foliage from obstructing airflow.

NOTE: Horizontal units may be installed on a roof curb if

required.

Form 48HJ-18SI

psig. Pres-

psig will cause gas valve

psig or less, a unit connected

Pg 1

9-00

Replaces: 48HJ-17SI

)

Table of Contents

Troubleshooting

Summary of Contents for Carrier 48HJD005-007

Page 1 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. PC 111 Catalog No. 534-767 Book 1 1a 6a 48HJD005-007, 48HJE/HJF004-007 Single-Package Rooftop Heating/Cooling Page Disconnect gas piping from unit when leak testing at pressure greater than sures greater than damage resulting in hazardous condition.
Page 3: Installation
MAXIMUM ALLOWABLE DIFFERENCE (in.) Fig. 2 — Unit Leveling Tolerances Step 2 — Field Fabricate Ductwork — ducts to roof curb and building structure on vertical discharge units. Do not connect ductwork to unit. For horizontal applica- tions, field-supplied isolation flanges should be attached to hor- izontal discharge openings and all ductwork should be secured to the flanges.
Page 4: Step 5 — Install Flue Hood
NOTES: 1. Place unit on curb as close as possible to the duct end. 2. Dimension in ( ) is in millimeters. 3. Hook rigging shackles through holes in base rail as shown in detail ‘‘A.’’ Holes in base rails are centered around the unit cen- ter of gravity.
Page 5 2...15 *Single phase/three phase. †Indicates automatic reset. **48HJD005-007 and 48HJE004 (72,000 Btuh heat input) units have 2 burners. 48HJE005-007 and 48HJF004 (115,000 Btuh heat input) units and 48HJF005- 007 (150,000 Btuh Heat input) units have 3 burners. ††An LP kit is available as an accessory.
Page 6 2...16 x 25 x 2 *Single phase/three phase. †Indicates automatic reset. **48HJD005-007 and 48HJE004 (72,000 Btuh heat input) units have 2 burners. 48HJE005-007 and 48HJF004 (115,000 Btuh heat input) units and 48HJF005- 007 (150,000 Btuh Heat input) units have 3 burners.
Page 7 STANDARD DURABLADE ECONOMI$ER UNIT ECONOMIZER UNIT WEIGHT WEIGHT WEIGHT 48HJ 15.4 21.3 15.4 21.3 15.4 21.3 15.4 21.3 CONNECTION SIZES ″ ″ ″ ″ Dia [35] Field Power Supply Hole 2″ ″ ″ ″ Dia [51] Power Supply Knockout ″ ″ ″ ″ Dia [44] Charging Port Hole ″...
Page 8: Step 8 — Adjust Factory-Installed Options
APOLLO CONTROL — The optional Apollo control is used to actively monitor all modes of operation as well as indoor (evaporator) fan status, filter status, and indoor-air quality. The Apollo control is designed to work with Carrier TEMP and ® systems.
Page 9 LEGEND AHA — Adjustable Heat Anticipator — Cooling Compensator — Thermostat-Cooling — Thermostat-Heating Field Wiring Factory Wiring NOTE: Connect Y2 when unit is equipped with an integrated economizer. Fig. 9 — Low-Voltage Connections With or Without Economizer Fig. 8 — Power Wiring Connections RACEWAY HOLE IN END PANEL (HIDDEN) Fig.
Page 10 Table 2A — 48HJ Electrical Data Standard Motor (Units Without Electrical Convenience Outlet) VOLTAGE NOMINAL UNIT RANGE VOLTAGE 48HJ (V-Ph-Hz) 208/230-1-60 208/230-3-60 (3 Tons) 460-3-60 575-3-60 208/230-1-60 208/230-3-60 (4 Tons) 460-3-60 575-3-60 208/230-1-60 208/230-3-60 (5 Tons) 460-3-60 575-3-60 208/230-3-60 460-3-60 (6 Tons) 575-3-60 Table 2B —...
Page 11 Table 2C — 48HJ High-Static Motor Units Without Electrical Convenience Outlet VOLTAGE NOMINAL UNIT RANGE VOLTAGE 48HJ (V-Ph-Hz) Min Max 208/230-3-60 187 460-3-60 575-3-60 208/230-3-60 187 460-3-60 575-3-60 208/230-3-60 187 460-3-60 575-3-60 208/230-3-60 187 460-3-60 575-3-60 Table 2D — 48HJ High-Static Motor Units With Electrical Convenience Outlet VOLTAGE NOMINAL UNIT...
Page 12 OPTIONAL DURABLADE ECONOMIZER — The option- al economizer hood assembly is packaged and shipped in the filter section. Damper blades and control boards are installed at the factory and the economizer is shipped in the vertical dis- charge position. NOTE: Horizontal discharge block-off plate is shipped with the air hood package.
Page 13 9. Replace outdoor-air opening panel using screws from Step 2. Replace filter access panel. Ensure the filter ac- cess panel slides along the tracks and is securely engaged. 10. Fasten hood top and side plate assembly (Fig. 14) to outdoor-air opening panel with screws provided. 11.
Page 14 U-SHAPED HOLE (NOT SHOWN) ECONOMIZER PLUG WIRING HARNESS Fig. 18 — Typical Durablade Economizer and Wiring Harness Example: Given — Negative Pressure ......0.1 in. wg Outdoor Airflow .
Page 15 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 Fig. 22 — Durablade Economizer Barometric Relief Damper Characteristics OPTIONAL ECONOMI$ER — See Fig. 23 for EconoMi$er component locations. 1. To remove the existing unit filter access panel, raise the panel and swing the bottom outward.
Page 16 OUTDOOR AIR SEAL STRIP OPENING PANEL SEAL STRIP ASSEMBLED EXHAUST HOOD OUTDOOR AIR HOOD SIDES Fig. 26 — Outdoor-Air Hood Assembly Fig. 27 — Completed Hood Assembly LEGEND OAT — Outdoor-Air Thermostat UNIT FILTER OUTDOOR AIR RACK HOOD TOP SCREEN RETAINER UNIT BASE OUTDOOR AIR...
Page 17 ECONOMI$ER BROWN TEMP CONTROLLER VIOLET TEMP OUTDOOR SENSOR WHITE -15 V BROWN TEMP VIOLET RETURN TEMP WHITE SENSOR +15 V SENSOR SUPPLY AIR TEMPERATURE SENSOR REM POT PINK TEMP VIOLET TEMP Fig. 31 — EconoMi$er Sensor Wiring POWER EXHAUST SYSTEM (HIGH VOLTAGE) TO FUSED DISCONNECT GRAY...
Page 18 SUPPLY AIR TEMPERATURE SENSOR MOUNTING LOCATION SUPPLY AIR TEMPERATURE SENSOR Fig. 34 — Supply-Air Sensor Placement Control Setup — If a CO sensor is not being used, pro- ceed to the next section. If a CO sensor is being used, perform the following: 1.
Page 19: Step 9 — Adjust Evaporator-Fan Speed
Step 9 — Adjust Evaporator-Fan Speed — just evaporator-fan speed to meet jobsite conditions. Tables 5A and 5B show fan rpm at motor pulley settings. Tables 6 and 7 show maximum amp draw of belt-drive motor. Table 8 shows motor nominal horsepower for evaporator-fan motors.
Page 20 Table 5A — 48HJ Fan Rpm at Motor Pulley Setting With Standard Motor STANDARD MOTOR* UNIT 48HJ 1090 1055 1185 1150 1460 1425 (single-phase) 006 (3-phase) 1585 1540 and 007 *Approximate fan rpm shown (standard motor/drive). Table 5B — 48HJ Fan Rpm at Motor Pulley Setting With High Static Motor HIGH-STATIC MOTOR UNIT 48HJ...
Page 21 Unit warranty will not be affected. See Evaporator-Fan Motor Data tables on page 20 for additional information. 5. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 6. Interpolation is permissible. Do not extrapolate.
Page 22 Unit warranty will not be affected. See Evapora- tor-Fan Motor Data tables on page 20 for additional information. 6. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 7. Interpolation is permissible. Do not extrapolate.
Page 23 Unit warranty will not be affected. See Evaporator-Fan Motor Data tables on page 20 for additional information. 6. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 7. Interpolation is permissible. Do not extrapolate.
Page 24 Unit warranty will not be affected. See Evaporator-Fan Motor Data tables on page 20 for additional infor- mation. 6. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 7. Interpolation is permissible. Do not extrapolate.
Page 25 Unit warranty will not be affected. See Evaporator- Fan Motor Data tables on page 20 for additional information. 5. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 6. Interpolation is permissible. Do not extrapolate.
Page 26 Unit warranty will not be affected. See Evaporator- Fan Motor Data tables on page 20 for additional information. 6. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 7. Interpolation is permissible. Do not extrapolate.
Page 27 Unit warranty will not be affected. See Evaporator-Fan Motor Data tables on page 20 for additional information. 6. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 7. Interpolation is permissible. Do not extrapolate.
Page 28 Unit warranty will not be affected. See Evaporator- Fan Motor Data tables on page 20 for additional information. 6. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 7. Interpolation is permissible. Do not extrapolate.
Page 29: Pre-Start-Up
PRE-START-UP Failure to observe the following warnings could result in serious personal injury: 1. Follow recognized safety practices and wear protec- tive goggles when checking or servicing refrigerant system. 2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured.
Page 30 *As the height above sea level increases, there is less oxygen per cubic foot of air. Therefore, heat input rate should be reduced at higher altitudes. †Orifices available through your local Carrier distributor. Heating 1. Purge gas supply line of air by opening union ahead of the gas valve.
Page 31 HEATING, UNITS WITHOUT ECONOMIZER — When the thermostat calls for heating, terminal W1 is energized. The induced-draft motor is energized and the burner ignition se- quence begins. The indoor (evaporator) fan motor (IFM) is en- ergized 45 seconds after a flame is ignited. When additional heat is needed, W2 is energized and the high-fire solenoid on the main gas valve (MGV) is energized.
Page 32 Fig. 39 — MoistureMiser Option Operation...
Page 33: Service
SERVICE When servicing unit, shut off all electrical power to unit to avoid shock hazard or injury from rotating parts. Cleaning — Inspect unit interior at the beginning of heat- ing and cooling season and as operating conditions require. EVAPORATOR COIL 1.
Page 34 45 F. No adjustments are necessary. Refrigerant Charge — Amount of refrigerant charge is listed on unit nameplate (also refer to Table 1). Refer to Carrier GTAC2-5 Charging, Recovery, Recycling, and Reclamation training manual and the following procedures. Unit panels must be in place when unit is operating during charging procedure.
Page 35 Fig. 46 — Cooling Charging Chart, Standard 48HJ006 Fig. 47 — Cooling Charging Chart, Standard 48HJ007 TO USE COOLING CHARGING CHART, STANDARD UNIT — Take the outdoor ambient temperature and read the suction pressure gage. Refer to charts to determine what suction temperature should be.
Page 36 CONDENSER FAN MUST BE OPERATING CONDENSER FAN MUST BE OPERATING Fig. 48 — Cooling Charging Chart, 48HJ004 with Fig. 50 — Cooling Charging Chart, 48HJ006 with Optional MoistureMiser Dehumidification Package Optional MoistureMiser Dehumidification Package CONDENSER FAN MUST BE OPERATING CONDENSER FAN MUST BE OPERATING Fig.
Page 37 5. Reinstall burners on rack. 6. Reinstall burner rack as described above. Replacement Parts — A complete list of replace- ment parts may be obtained from any Carrier distributor upon request. Refer to Fig. 55 for a typical unit wiring schematic. ROLLOUT...
Page 38 LOW HEAT 48HJE004, 48HJD005-007 — 72,000 BTUH INPUT MEDIUM AND HIGH HEAT 48HJE005-007, 48HJF004 — 115,000 BTUH INPUT 48HJF005-007 — 150,000 BTUH INPUT Fig. 54 — Spark Gap Adjustment...
Page 39: Troubleshooting
Table 30 — LED Error Code Service Analysis SYMPTOM Hardware failure. Loss of power to control module (IGC). (LED OFF) Fan ON/OFF delay modified High limit switch opens during heat (LED/FLASH) exchanger warm-up period before fan-on delay expires. Limit switch opens within three minutes after blower-off delay timing in Heating mode.
Page 40 PROBLEM Burners will not Misaligned spark electrodes. ignite. No gas at main burners. Water in gas line. No power to furnace. No 24 v power supply to control circuit. Miswired or loose connections. Burned-out heat anticipator in thermostat. Broken thermostat wires. Inadequate heating.
Page 41 Table 33 — EconoMi$er Flash Code Identification FLASH CODE CAUSE Constant On Normal operation Constant Off No power Continuous CONFIG button pushed and held Flash between 3 and 9 seconds Flash One Control board fault Flash Two Thermostat fault (i.e., Y2 without Y1) Actuator fault Flash Three Flash Four...
Page 42 Table 35 — MoistureMiser Dehumidification Subcooler Service Analysis PROBLEM Subcooler will not energize. No power to control transformer from evaporator-fan motor. No power from control transformer to liquid line solenoid valve Liquid line solenoid valve will not operate. Subcooler will not deenergize. Liquid line solenoid valve will not open.
Page 43 PROBLEM Compressor and condenser fan will not start. Compressor will not start but condenser fan runs. Compressor cycles (other than normally satisfying thermostat). Compressor operates continuously. Excessive head pressure. Head pressure too low. Excessive suction pressure. Suction pressure too low. Evaporator fan will not shut off.
Page 45 LEGEND AND NOTES FOR FIG. 55 — Adjustable Heat Anticipator — Contactor, Compressor — Capacitor — Cooling Compensator — Compressor Lockout COMP — Compressor Motor — Diode — Enthalpy Control ECON — Economizer — Emergency Power Supply EQUIP — Equipment —...
Page 46 Copyright 2000 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 PC 111 Catalog No. 534-767 Printed in U.S.A. Form 48HJ-18SI Pg 46 9-00 Replaces: 48HJ-17SI...
Page 48 VERIFY REFRIGERANT CHARGE USING CHARGING TABLES VERIFY THAT 3-PHASE SCROLL COMPRESSOR ROTATING IN CORRECT DIRECTION Copyright 2000 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book PC 111 Catalog No.

Carrier 48HJD005-007 Installation, Start-Up And Service Instructions Manual

Quick Links

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Troubleshooting

Related Manuals for Carrier 48HJD005-007

Summary of Contents for Carrier 48HJD005-007

Page 3: Installation

Page 4: Step 5 — Install Flue Hood

Page 8: Step 8 — Adjust Factory-Installed Options

Page 19: Step 9 — Adjust Evaporator-Fan Speed

Page 29: Pre-Start-Up

Page 33: Service

Page 39: Troubleshooting

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