Carrier 48TF004-007 Installation, Start-Up And Service Instructions Manual
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Carrier 48TF004-007 Installation, Start-Up And Service Instructions Manual

Carrier 48TF004-007 Installation, Start-Up And Service Instructions Manual

Single-package rooftop heating/cooling units
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CONTENTS

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Step 1 — Provide Unit Support . . . . . . . . . . . . . . . . . . . 1
• ROOF CURB
• SLAB MOUNT
Step 2 — Field Fabricate Ductwork . . . . . . . . . . . . . . . 2
Step 3 — Install External Trap for Condensate
Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 4 — Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . 2
•
POSITIONING
Step 5 — Install Flue Hood . . . . . . . . . . . . . . . . . . . . . . . 4
Step 6 — Install Gas Piping . . . . . . . . . . . . . . . . . . . . . . 4
Step 7 — Make Electrical Connections . . . . . . . . . . . 8
• FIELD POWER SUPPLY
• FIELD CONTROL WIRING
• HEAT ANTICIPATOR SETTINGS
Step 8 — Make Outdoor-Air Adjustments
and Install Outdoor-Air Hood. . . . . . . . . . . . . . . . . . 11
• MANUAL OUTDOOR-AIR DAMPER
• OPTIONAL DURABLADE ECONOMIZER
• OPTIONAL ECONOMI$ER
Step 9 — Adjust Evaporator-Fan Speed . . . . . . . . . 19
• DIRECT-DRIVE MOTORS
• BELT-DRIVE MOTORS
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-38
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-43
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . 44-49
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 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.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 111
Book 1
4
Tab
1a 6a
Installation, Start-Up, and
Service Instructions
Page
Catalog No. 534-80000
Printed in U.S.A.
Single-Package Rooftop
Heating/Cooling Units
Disconnect gas piping from unit when leak
testing at pressure greater than
Pressures greater than
gas valve damage resulting in hazardous
condition. If gas valve is subjected to pres-
sure greater than
replaced before use. When pressure testing
field-supplied gas piping at pressures of
1
/
psig or less, a unit connected to such
2
piping must be isolated by manually closing
the gas valve.
Before performing service or maintenance operations on
unit, turn off main power switch to unit and install a lock-
out tag. Electrical shock could cause personal injury.

INSTALLATION

Unit is shipped in the vertical duct configuration. To convert
to horizontal configuration, remove screws from side duct
opening covers and remove covers. Using the same screws, in-
stall covers on vertical duct openings with the insulation-side
down. Seals around duct openings must be tight. See Fig. 1.
Confirm before installation of unit that voltage, amperage
and circuit protection requirements listed on unit data plate
agree with power supply provided.
Step 1 — Provide Unit Support
Roof Curb — Assemble and install accessory roof curb in
accordance with instructions shipped with curb. See Fig. 2. In-
stall insulation, cant strips, roofing felt, and counter flashing as
shown. Ductwork must be attached to curb, not to the unit. The
accessory thru-the-bottom power and gas connection package
must be installed before the unit is set on the roof curb. If field-
installed (thru-the-roof curb) gas connections are desired, use
3
factory-supplied
/
-in. pipe coupling and gas plate assembly to
4
mount the thru-the-roof curb connection to the roof curb. Gas
connections and power connections to the unit must be field in-
stalled after the unit is installed on the roof curb.
If electric and control wiring is to be routed through the
basepan, attach the accessory thru-the-bottom service connec-
tions to the basepan in accordance with the accessory installa-
tion instructions.
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. 2. Improperly
applied gasket can result in air leaks and poor unit
performance.
Form 48TF-1SI
48TF004-007
1
/
psig.
2
1
/
psig will cause
2
1
/
psig, it must be
2
Pg 1
8-00
Replaces: New

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Summary of Contents for Carrier 48TF004-007

  • Page 1 Install gasket supplied with the roof curb as shown in Fig. 2. Improperly applied gasket can result in air leaks and poor unit performance. Printed in U.S.A. Form 48TF-1SI 48TF004-007 psig. psig will cause psig, it must be Pg 1 8-00...

  • Page 2: Installation

    Curb should be level. Unit leveling tolerances are shown in Fig. 3. 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.
  • Page 3 1 -2 3. Dimensions in [ ] are in millimeters. CRRFCURB001A00 [356] 4. Roof curb, galvanized steel. 48TF004-007 5. Attach ductwork to curb (flanges of duct rest on curb). 2 -0 CRRFCURB002A00 6. Service clearance: 4 ft on each side.

  • Page 4: Step 6 — Install Gas Piping

    MAXIMUM ALLOWABLE DIFFERENCE (in.) Fig. 3 — Unit Leveling Tolerances NOTE: Drain plug is shown in factory-installed position. Fig. 4 — Condensate Drain Connection Unit may be installed directly on wood flooring or on Class A, B, or C roof-covering material when roof curb is used. Although unit is weatherproof, guard against water from higher level runoff and overhangs.
  • Page 5 Copper *Evaporator coil fin material/condenser coil fin material. Contact your local representative for details about coated fins. †Weight of 14-in. roof curb. **Single phase/three-phase. Table 1 — Physical Data — 48TF004-007 E/F/M/N004 D/E/F/L/M/N005 Reciprocating — Enhanced Copper Tubes, Aluminum Lanced Fins 1...17...
  • Page 6 Table 1 — Physical Data — 48TF004-007 (cont) UNIT SIZE 48TF FURNACE SECTION Rollout Switch Cutout Temp (F)†† Burner Orifice Diameter (in..drill size) Natural Gas Liquid Propane Thermostat Heat Anticipator Setting (amps) 208/230 v and 575 Stage 1 Stage 2...

  • Page 7: Tf004

    STD UNIT DURABLADE WEIGHT ECONOMIZER WEIGHT UNIT 48TFN,TFM,TFF,TFE004 48TFN,TFM,TFL,TFF,TFE,TFD005 48TFN,TFM,TFL,TFF,TFE,TFD006 48TFF,TFE,TFD007 CONNECTION SIZES Dia. [35] Field Power Supply Hole 2 Dia. [51] Power Supply Knockout Dia. [64] Power Supply Knockout Dia. [22] Field Control Wiring Hole -14 NPT Condensate Drain -14 NPT Gas Connection NOTES: 1.

  • Page 8: Step 7 — Make Electrical Connections

    Such operation would invalidate any applicable Carrier warranty. FIELD CONTROL WIRING — Install a Carrier-approved accessory thermostat assembly according to installation instructions included with the accessory. Locate thermostat as-...
  • Page 9 208/230-1-60 575-3-60 (SIZE 007 ONLY) LEGEND — Contactor COMP — Compressor — National Electrical Code — Terminal Block LEGEND — Adjustable Heat Anticipator Field Wiring Factory Wiring NOTES: 1. Connect Y2 when unit is equipped with an economizer. 2. Connect W2 when unit is equipped with two stages of heat. Fig.
  • Page 10 VOLTAGE COMPRESSOR UNIT NOMINAL RANGE 48TF V-Ph-Hz TYPE 208/230-1-60 208/230-3-60 High 460-3-60 High 575-3-60 High 208/230-1-60 208/230-3-60 High 460-3-60 High 575-3-60 High 208/230-1-60 208/230-3-60 High 460-3-60 High 575-3-60 High 208/230-3-60 High 460-3-60 High 575-3-60 High LEGEND — Full Load Amps HACR —...

  • Page 11: And Install Outdoor-Air Hood

    Step 8 — Make Outdoor-Air Adjustments and Install Outdoor-Air Hood MANUAL OUTDOOR-AIR DAMPER — The outdoor-air hood and screen are attached to the basepan at the bottom of the unit for shipping. Assembly: 1. Determine quantity of ventilation required for building. Record amount for use in Step 8.
  • Page 12 OPTIONAL DURABLADE ECONOMIZER — The tional economizer hood assembly is packaged and shipped in the filter section. Damper blades and control boards are in- stalled at the factory and the economizer is shipped in the verti- cal discharge position. NOTE: Horizontal discharge block-off plate is shipped with the air hood package.
  • Page 13 BLOCK-OFF PLATE Fig. 19 — Horizontal Discharge Block-Off Plate ECONOMIZER U-SHAPED CONTROL ECONOMIZER ECONOMIZER HOLE (NOT BOARD PLUG MOTOR SHOWN) WIRING HARNESS BAROMETRIC RELIEF DAMPER SHIPPING SCREW Fig. 20 — Durablade Economizer Installed in Unit EXAMPLE: Given — Negative Pressure ..... . . 0.2 in. wg Outdoor Air .
  • Page 14 LEGEND OAT — Outdoor-Air Thermostat NOTE: See unit wiring diagram for details. Fig. 23 — Wiring Connections for Outdoor-Air Thermostat 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 Fig. 24 — Durablade Economizer Barometric Relief Damper Characteristics OPTIONAL ECONOMI$ER — See Fig. 25 for EconoMi$er component locations.
  • Page 15 5. Slide the outdoor-air inlet screens into the screen track on the hood side panels. While holding the screens in place, fasten the screen retainer to the hood using the screws provided. Repeat the process for the barometric exhaust air screen. Do not attach completed (Fig. 29) hood as- sembly to unit at this time.
  • Page 16 LEGEND — Outdoor-Air Temperature — Return-Air Temperature ECONOMI$ER CONTROLLER -15 V +15 V REM POT Fig. 32 — EconoMi$er Wiring BROWN TEMP VIOLET TEMP OUTDOOR SENSOR WHITE BROWN TEMP VIOLET RETURN TEMP WHITE SENSOR SENSOR SUPPLY AIR TEMPERATURE SENSOR PINK TEMP VIOLET TEMP...
  • Page 17 TO FUSED DISCONNECT GRAY RED YEL BLU GRAY X2 X3 SECONDARY SECONDARY 230VAC 230VAC COMPRESSOR 1 CONTACTOR 230VAC 4-PIN CONNECTOR 2 x 4 IN. PLUG HANDY BOX BLACK L1 BLUE GREEN GND 230 VAC GREEN 1 PHASE Fig. 34 — Wiring Diagram for Power Exhaust System Fig.
  • Page 18 SUPPLY AIR TEMPERATURE SENSOR MOUNTING LOCATION SUPPLY AIR TEMPERATURE SENSOR Fig. 36 — 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 — just evaporator-fan rpm to meet jobsite conditions. Table 5 shows fan rpm at motor pulley settings. Table 6 shows motor performance. See Table 7 for Accessory/FIOP Static Pressure. Refer to Tables 8-29 to determine fan speed settings. DIRECT-DRIVE MOTORS —...
  • Page 20 Using your fan motors up to the horsepower ratings shown in this table will not result in nuisance tripping or premature motor failure. Unit war- ranty will not be affected. †Single phase/three-phase. Table 7 — Accessory/FIOP Static Pressure* (in. wg) — 48TF004-007 COMPONENT Durablade Economizer EconoMi$er LEGEND FIOP —...
  • Page 21 Unit warranty will not be affected. See Table 6 — Motor Data for additional information. 3. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. External Static Pressure (in. wg) Watts Watts 0.22...
  • Page 22 See Table 6 — Motor Data for addi- tional information. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. 5. Interpolation is permissible. Do not extrapolate. 230, 460, 575 V Watts 0.74...
  • Page 23 Unit warranty will not be affected. See Table 6 — Motor Data for additional information. 5. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. 6. Interpolation is permissible. Do not extrapolate. External Static Pressure (in. wg)
  • Page 24 Unit warranty will not be affected. See Table 6 — Motor Data for Additional information. 3. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. External Static Pressure (in. wg) Watts Watts 0.56...
  • Page 25 See Table 6 — Motor Data for addi- tional information. 5. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. 6. Interpolation is permissible. Do not extrapolate. Watts Watts 1084 0.85...
  • Page 26 See Table 6 — Motor Data for addi- tional information. 5. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. 6. Interpolation is permissible. Do not extrapolate. Watts Watts 0.97...
  • Page 27 See Table 6 — Motor Data for addi- tional information. 5. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. 6. Interpolation is permissible. Do not extrapolate. Watts Watts 1248 1.20...
  • Page 28 Unit warranty will not be affected. See Table 6 — Motor Data for Additional information. 3. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. External Static Pressure (in. wg) Watts Watts 0.12...
  • Page 29 Unit war- ranty will not be affected. See Table 6 — Motor Data for additional information. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. 5. Interpolation is permissible. Do not extrapolate. Watts Watts 0.36...
  • Page 30 Unit warranty will not be affected. See Table 6 — Motor Data for Additional information. 3. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. External Static Pressure (in. wg) 0.29 761 0.34...
  • Page 31 See Table 6 — Motor Data for additional information. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. 5. Interpolation is permissible. Do not extrapolate. Medium Speed 208 V...
  • Page 32 Unit warranty will not be affected. See Table 6 — Motor Data for additional information. 5. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. 6. Interpolation is permissible. Do not extrapolate. Watts Watts 0.67...
  • Page 33 See Table 6 — Motor Data for addi- tional information. 5. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. 6. Interpolation is permissible. Do not extrapolate. Watts Watts 0.83...
  • Page 34 Unit war- ranty will not be affected. See Table 6 — Motor Data for additional information. 5. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. 6. Interpolation is permissible. Do not extrapolate. Watts Watts 1.05...
  • Page 35 See Table 6 — Motor Data for addi- tional information. 5. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative for details. 6. Interpolation is permissible. Do not extrapolate. Watts Watts 1.14...
  • Page 36 *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 Carrier distributor. Heating 1. Purge gas supply line of air by opening union ahead of gas valve.
  • Page 37 If the limit switch trips at the start of the heating cycle dur- ing the evaporator ON delay, the time period of the ON delay for the next cycle will be 5 seconds less than the time at which the switch tripped. (Example: If the limit switch trips at 30 sec- onds, the evaporator-fan ON delay for the next cycle will occur at 25 seconds.) To prevent short-cycling, a 5-second reduction will only occur if a minimum of 10 minutes has elapsed since...
  • Page 38 HEATING, UNITS WITH ECONOMIZER — When the thermostat calls for heating, terminal W1 is energized. To pre- vent thermostat short-cycling, the unit is locked into the Heat- ing mode for at least 1 minute when W1 is energized. The induced-draft motor is energized and the burner ignition se- quence begins.
  • Page 39 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 40 3 TON UNIT CHARGING CHART SUCTION LINE TEMPERATURE (DEG. C) Fig. 46 — Cooling Charging Chart, 48TF004 4 TON UNIT CHARGING CHART SUCTION LINE TEMPERATURE (DEG. C) SUCTION LINE TEMPERATURE (DEG. F) Fig. 47 — Cooling Charging Chart, 48TF005 SUCTION LINE TEMPERATURE (DEG. F) OUTDOOR TEMP OUTDOOR...
  • Page 41 5 TON UNIT CHARGING CHART Fig. 48 — Cooling Charging Chart, 48TF006 6 TON UNIT (60 Hz) CHARGING CHART Fig. 49 — Cooling Charging Chart, 48TF007 SUCTION LINE TEMPERATURE (DEG. C) SUCTION LINE TEMPERATURE (DEG. F) SUCTION LINE TEMPERATURE (DEG. C) SUCTION LINE TEMPERATURE (DEG.
  • Page 42 5. Reinstall burners on rack. 6. Reinstall burner rack as described in Removal and Re- placement of Gas Train section, above. Replacement Parts — A complete list of replacement parts may be obtained from any Carrier distributor upon request. INDUCED- DRAFT MOTOR...
  • Page 43 Fig. 51 — Burner Tray Details LOW HEAT 48TFE004, 48TFD005-007 — 74,000 BTUH INPUT 48TFM004, 48TFL005-006 — 60,000 BTUH INPUT MEDIUM AND HIGH HEAT 48TFE005-007, 48TFF004 — 115,000 BTUH INPUT 48TFF005-007 — 150,000 BTUH INPUT 48TFN004, 48TFM005-006 — 90,000 BTUH INPUT 48TFN005-006 —...

  • Page 44: Troubleshooting

    Table 32 — LED Error Code Service Analysis PROBLEM Hardware failure. Loss of power to control module (IGC). (LED OFF) Limit switch fault. High temperature limit switch is open. (LED 2 flashes) The IGC sensed flame that should not be Flame sense fault.
  • Page 45 PROBLEM Compressor and condenser fan Power failure. will not start. Fuse blown or circuit breaker tripped. Defective thermostat, contactor, transformer, or control relay. Insufficient line voltage. Incorrect or faulty wiring. Thermostat setting too high. Compressor will not start but Faulty wiring or loose connections in compressor condenser fan runs.
  • Page 46 Table 35 — Durablade Economizer Troubleshooting PROBLEM CAUSE Damper does not open. Indoor (evaporator) fan is off. No power to economizer motor. Economizer motor failure. Economizer operation OAT or EC set too high. limited to minimum position. Verify economizer control board is correctly wired and works properly.
  • Page 47 PROBLEM CAUSE Damper does not open. Indoor (evaporator) fan is Off. No power to EconoMi$er controller. No power to G terminal. Controller fault. Thermostat fault. Actuator fault. EconoMi$er operation Minimum position set incorrectly. Verify that the MIN POS (%) is set greater than zero. Adjust MIN POS (%) to limited to minimum position.
  • Page 48 Fig. 53 — Typical Wiring Diagram and Component Arrangement...
  • Page 49 LEGEND FOR FIG. 53 — TYPICAL WIRING SCHEMATIC AND COMPONENT ARRANGEMENT IMPORTANT: Refer to unit wiring label for actual unit wiring information. — Adjustable Heat Anticipator — Contactor, Compressor — Capacitor — Cooling Compensator COMP — Compressor Motor — Diode —...
  • Page 50 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. 534-80000 Printed in U.S.A. Form 48TF-1SI Pg 50 8-00 Replaces: New...
  • Page 52 VERIFY REFRIGERANT CHARGE USING CHARGING TABLES VERIFY THAT 3-PHASE SCROLL COMPRESSOR IS ROTATING IN CORRECT DIRECTION (48TF007 ONLY) Copyright 2000 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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