Table of Contents
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Step 1 - Provide Unit Support . . . . . . . . . . . . . . . 1
• ROOF CURB
Step 2 - Field Fabricate Ductwork . . . . . . . . . . . . 2
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 4 - Rig and Place Unit . . . . . . . . . . . . . . . . . . 2
Step 5 - Install Flue Hood . . . . . . . . . . . . . . . . . . . 8
Step 6 - Install Gas Piping . . . . . . . . . . . . . . . . . . . 8
Step 7 - Make Electrical Connections . . . . . . . . 8
• FIELD POWER SUPPLY
• HEAT ANTICIPATOR SETTINGS
• MANUAL OUTDOOR-AIR DAMPER
Step 9 - Adjust Evaporator-Fan Speed . . . . . . 16
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,24
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-30
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 31-36
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . CL-1
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment
can be hazardous due to system pressure and electrical com-
ponents. 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 per-
sonnel. When working on air-conditioning equipment, ob-
serve precautions 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 ex-
tinguishers 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.
Book 1 4
PC 111
Tab
1a 6a
Single-Package Rooftop Heating/Cooling Units
Installation, Start-Up and
Service Instructions
Page
Catalog No. 564-934
Printed in U.S.A.
Disconnect gas piping from unit when leak
testing at pressure greater than
sures greater than
valve damage resulting in hazardous con-
dition. If gas valve is subjected to pres-
sure greater than
before use. When pressure testing field-
supplied gas piping at pressures of
or less, a unit connected to such piping must
be isolated by manually closing the gas
valve(s).
Before performing service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury.
INSTALLATION
Unit is shipped in the vertical discharge configuration. To
convert to horizontal configuration, remove screws from side
duct opening covers and remove covers. Using the same screws,
install covers on vertical duct openings with the insulation-
side down. Seals around duct openings must be tight. See
Fig. 1.
Step 1 - Provide Unit Support
ROOF CURB - Assemble and install accessory roof curb
in accordance with instructions shipped with curb. See
Fig. 2. Install insulation, cant strips, roofing felt, and counter
flashing as shown. Ductwork must be attached to curb. If
gas is to be routed through the curb, attach the accessory
thru-the-curb service connection plate to the roof curb in ac-
cordance with the accessory installation instructions. Con-
nection plate must be installed before unit is set in roof curb.
IMPORTANT: The gasketing of the unit to the roof
curb is critical for a watertight seal. Install gasket sup-
plied with the roof curb as shown in Fig. 2. Improp-
erly applied gasket can also result in air leaks and poor
unit performance.
Curb should be level. Unit leveling tolerances are shown
in Fig. 3. This is necessary for unit drain to function prop-
erly. Refer to Accessory Roof Curb Installation Instructions
for additional information as required.
Form 48TJ-13SI
Pg 1
48TJD008-014
48TJE008-014
48TJF008-012
1
⁄
psig. Pres-
2
1
⁄
psig will cause gas
2
1
⁄
psig, it must be replaced
2
1
⁄
psig
2
9-96
Replaces: 48TJ-10SI
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Table of Contents
Related Manuals for Carrier 48TJD008-014
Summary of Contents for Carrier 48TJD008-014
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Page 1: Table Of Contents
Fig. 3. This is necessary for unit drain to function prop- erly. Refer to Accessory Roof Curb Installation Instructions for additional information as required. Printed in U.S.A. Form 48TJ-13SI 48TJD008-014 48TJE008-014 48TJF008-012 Disconnect gas piping from unit when leak testing at pressure greater than ⁄... -
Page 2: Slab Mount
SLAB MOUNT (Horizontal Units Only) — Provide a level concrete slab that extends a minimum of 6 in. beyond unit cabinet. 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. - Page 3 UNIT SIZE ‘‘B’’ ‘‘C’’ 48TJ 008-014 2 -8 ⁄ [827] 1 -10 ⁄ [583] ‘‘E’’ POWER ‘‘D’’ ALT DRAIN HOLE CONNECTION ⁄ ⁄ ⁄ [45] ⁄ ⁄ Fig. 2 — Roof Curb Details CONNECTOR CONTROL ACCESSORY CONNECTION PACKAGE CRBTMPWR00A100 ⁄ (THRU-THE-BOTTOM) CRBTMPWR00A200 ⁄...
- Page 4 MAXIMUM ALLOWABLE DIFFERENCE (in.) Fig. 3 — Unit Leveling Tolerances NOTE: Drain plug is shown in factory-installed position. Fig. 4 — Condensate Drain Pan NOTES: 1. Dimension in ( ) is in millimeters. 2. Hook rigging shackles through holes in base rail as shown in detail ‘‘A.’’ Holes in base rails are centered around the unit center of gravity.
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Page 5: Physical Data
UNIT SIZE 48TJ NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Unit Al/Al* Al/Cu* Cu/Cu* Durablade Economizer PARBLADE Economizer Roof Curb COMPRESSOR Quantity Oil (oz) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1 Circuit 2 CONDENSER COIL Rows...Fins/in. Total Face Area (sq ft) CONDENSER FAN Nominal Cfm Quantity...Diameter (in.) - Page 6 UNIT SIZE 48TJ FURNACE SECTION Rollout Switch Cutout Temp (F) Burner Orifice Diameter (in..drill size) Natural Gas Liquid Propane Pilot Orifice Diameter (Quantity) in..drill size Natural Gas Liquid Propane Thermostat Heat Anticipator Setting (amps) 208/230 v Stage 1 Stage 2 460 v Stage 1 Stage 2...
- Page 7 STANDARD CORNER CORNER CORNER UNIT WEIGHT WEIGHT WEIGHT UNIT WEIGHT 48TJ D/E/F008 239 109 280 127 1-2 D/E/F009 242 110 284 129 3-3 D/E/F012 1035 225 102 285 129 333 151 2-5 D/E014 1050 228 103 289 131 338 153 1-2 CORNER WEIGHT ‘‘H’’...
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Page 8: Positioning Step 5 - Install Flue Hood
Refer to Fig. 7 for drilling holes in basepan. FIELD CONTROL WIRING — Install a Carrier-approved accessory thermostat assembly according to installation in- structions included with the accessory. Locate thermostat as-... - Page 9 Route thermostat cable or equivalent single leads of col- ored wire from subbase terminals to low-voltage connec- tions on unit (shown in Fig. 11) as described in Steps 1 - 4 below. 1. If unit is mounted on roof curb and accessory thru-the- curb service plate connection is used, route wire through connection plate.
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Page 10: Field Control Wiring
LEGEND AHA — Adjustable Heat Anticipator — Cooling Compensator — Thermostat-Cooling — Thermostat-Heating Field Wiring Factory Wiring Fig. 11 — Low-Voltage Connections Fig. 10 — Power Wiring Connections UNIT CONNECTION BOARD RACEWAY Fig. 12 — Field Control Wiring Raceway LEGEND —... -
Page 11: Step 8 - Adjust Factory-Installed Options
(evaporator) fan status, filter status, and indoor-air quality. The Apollo control is designed to work with Carrier TEMP and VVT systems. The thermostat must be wired to the Apollo control before starting the unit. -
Page 12: Optional Durablade Economizer
Fig. 17 — Position Setting 9. Remove and save screws currently on sides of hood. Insert screens. Secure screens to hood using the screws. See Fig. 16. 10. Replace filter access panel. Ensure filter access panel slides along the tracks and is securely engaged. OPTIONAL DURABLADE ECONOMIZER —... - Page 13 Fig. 19 — Outdoor-Air Hood Details Fig. 20 — Vertical Discharge Block-Off Plate (Sizes 120,150 only) ECONOMIZER ECONOMIZER CONTROL BOARD PLUG Fig. 21 — Durablade Economizer Installed in Unit ECONOMIZER CONTROL BOARD POSITION SETTING BRACKET Fig. 22 — Horizontal Durablade Economizer Installation (90 Degree Rotation) Fig.
- Page 14 Example: Given — Negative Pressure ..... . . 0.1 in. wg Outdoor Airflow ......1100 cfm Determine —...
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Page 15: Optional Parablade Economizer
Fig. 28 — Durablade Economizer Barometric Relief Damper Characteristics OPTIONAL PARABLADE ECONOMIZER — The op- tional PARABLADE economizer hood assembly is pack- aged and shipped in the filter section. Damper blades and control boards are installed at the factory and the econo- mizer is shipped in the vertical discharge position. -
Page 16: Step 9 - Adjust Evaporator-Fan Speed
CONTROL POINT CONTROL F (C) (APPROX) CURVE AT 50% RH 73 [23] 70 [21] 67 [19] 63 [17] RH — Relative Humidity Fig. 30 — Enthalpy Settings for PARABLADE Economizer Fig. 31 — Panels Reinstalled on Unit Fig. 32 — Outdoor-Air Hood Installed on Unit Fig. - Page 17 Fig. 34 — Typical Belt-Drive Motor Mounting for Sizes 008,009 Fig. 35 — Typical Belt-Drive Motor Mounting for Sizes 012,014 Table 3 — Fan Rpm at Motor Pulley Settings* UNIT 48TJ ⁄ 008† 008** 009† 012† 012†† 1085 1060 1035 014†...
- Page 18 48TJD/TJE/TJF008,009 48TJD/TJE/TJF012 (Std) 48TJD/TJE/TJF012 (Alt) 48TJD/TJE014 (Std) 48TJD/TJE014 (Alt) NOTE: Convert watts to bhp using the following formula: watts input x motor efficiency bhp = Table 5 — Economizer Static Pressure Drop (in. wg) UNIT 48TJ Durablade Economizer PARABLADE Economizer UNIT EVAPORATOR- 48TJ...
- Page 19 Unit warranty will not be affected. 7. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 8. Interpolation is permissible. Do not extrapolate. EXTERNAL STATIC PRESSURE (in. wg) 1.21...
- Page 20 Unit war- ranty will not be affected. 7. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 8. Interpolation is permissible. Do not extrapolate. EXTERNAL STATIC PRESSURE (in. wg) 902 2.06...
- Page 21 Unit warranty will not be affected. 7. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 8. Interpolation is permissible. Do not extrapolate. EXTERNAL STATIC PRESSURE (in. wg) 1.17...
- Page 22 Unit war- ranty will not be affected. 7. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 8. Interpolation is permissible. Do not extrapolate. EXTERNAL STATIC PRESSURE (in. wg) 869 1.89...
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Page 23: Start-Up
START-UP Unit Preparation — Make sure that unit has been in- stalled in accordance with these installation instructions and applicable codes. Make sure that Start-Up Checklist has been completed and filled out. Return-Air Filters — Make sure correct filters are in- stalled in filter tracks (see Table 1). - Page 24 Table 15 — Altitude Compensation* 125,000, 180,000, AND 224,000 BTUH NOMINAL INPUT ELEVATION Natural Liquid (Ft) Propane Orifice Orifice Size† Size† 0-2,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 *As the height above sea level increases, there is less oxygen per cubic foot of air.
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Page 25: 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 each heating and cooling season and as operating conditions require. EVAPORATOR COIL — Clean coil as required. Inspect coil at beginning of heating and cooling seasons. - Page 26 Amount of refrigerant charge is listed on unit nameplate (also refer to Table 1). Refer to Carrier GTAC 2-5 Charging, Recovery, Recycling, and Rec- lamation training manual and the following procedures. Unit panels must be in place when unit is operating dur- ing charging procedure.
- Page 27 Fig. 42 — Cooling Charging Chart; 48TJ009 Fig. 43 — Cooling Charging Chart; 48TJ012...
- Page 28 Flue Gas Passageways — To inspect the flue col- lector box and upper areas of the heat exchanger: 1. Remove the combustion blower wheel and motor assem- bly according to directions in Combustion-Air Blower sec- tion below. 2. Remove the flue cover to inspect the heat exchanger. 3.
- Page 29 6. Reinstall burner rack as described in Removal and Re- placement of Gas Train section, this page. Replacement Parts — A complete list of replace- ment parts may be obtained from any Carrier distributor upon request. Fig. 45 — Burner Section Details Fig. 46 — Burner Tray Details...
- Page 30 125,000 BTUH INPUT 48TJD008,009 120,000-180,000 BTUH INPUT 48TJD012, 48TJE008,009 180,000-224,000 BTUH INPUT 200,000-250,000 BTUH INPUT 48TJD014; 48TJE012 48TJF008,009 48TJE014; 48TJF012 NOTE: Dimensions in ( ) are millimeters. Fig. 47 — Spark Gap Adjustment...
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Page 31: Troubleshooting
PROBLEM Hardware failure. Loss of power to control module (IGC). (LED OFF) Limit switch fault. High temperature limit switch is open. (LED 2 flashes) Flame sense fault. The IGC sensed flame that should not be present. (LED 3 flashes) 4 consecutive limit Inadequate airflow to unit. - Page 32 Table 18 — Durablade Economizer Troubleshooting PROBLEM Damper does not Indoor (evaporator) fan is off. open. 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 33 Table 19 — PARABLADE Economizer Service Troubleshooting PROBLEM Damper does not Evaporator fan not on. open. No power to economizer motor. Economizer motor failure. Economizer opera- Economizer control module tion limited to mini- failure. mum position. Damper does not No power to economizer. close.
- Page 34 Table 20 — Cooling Service Troubleshooting PROBLEM Compressor and Power failure. condenser fan Fuse blown or circuit breaker tripped. will not start. Defective thermostat, contactor, transformer, or control relay. Insufficient line voltage. Incorrect or faulty wiring. Thermostat setting too high. Compressor will not start Faulty wiring or loose connections in compressor circuit.
- Page 35 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.
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Page 36: Typical Wiring Schematic And Component Arrangement
Fig. 48 — Typical Wiring Schematic and Component Arrangement... - Page 38 Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4 PC 111 Catalog No. 564-934 Printed in U.S.A. Form 48TJ-13SI Pg 38 9-96...
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Page 40: Start-Up Checklist
VERIFY REFRIGERANT CHARGE USING CHARGING TABLES VERIFY THAT 3-PHASE SCROLL COMPRESSOR ROTATING IN CORRECT DIRECTION (48TJ014 ONLY) Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.