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Installation, Start-Up and Service Instructions
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . .1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Step 1 - Provide Unit Support . . . . . . . . . . . . . . . . . . . . .2
• ALTERNATE UNIT SUPPORT
Step 2 - Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . . .2
• POSITIONING
Step 3 - Field Fabricate Ductwork . . . . . . . . . . . . . . .11
Step 4 - Make Unit Duct Connections . . . . . . . . . . .11
Step 5 - Install Flue Hood and Wind Baffle . . . . . .11
Step 6 - Trap Condensate Drain . . . . . . . . . . . . . . . . .11
Step 7 - Orifice Change . . . . . . . . . . . . . . . . . . . . . . . . . .12
Step 8 - Install Gas Piping . . . . . . . . . . . . . . . . . . . . . . .13
Step 9 - Make Electrical Connections . . . . . . . . . . .13
• OPTIONAL NON-FUSED DISCONNECT
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Step 11 - Install Outdoor-Air Hood . . . . . . . . . . . . . .16
Step 12 - Install All Accessories . . . . . . . . . . . . . . . 17
• MOTORMASTER V CONTROL INSTALLATION
Step 13 - Adjust Factory-Installed Options . . . . . 19
• PREMIERLINK™ CONTROL
Optional MoistureMi$er™ Package. . . . . . . . . . . . 31
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-43
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-50
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 51-56
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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 in-
stall, repair, or service air-conditioning equipment.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480016-01
Book 1
4
Tab
1a 6a
Single-Package Rooftop Units
Electric Cooling/Gas Heating
Untrained personnel can perform basic maintenance func-
tions of cleaning coils and filters and replacing filters. All other
Page
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. Electrical shock
could cause personal injury.
1. Improper installation, adjustment, alteration, service,
or maintenance can cause property damage, personal
injury, or loss of life. Refer to the User's Information
Manual provided with this unit for more details.
2. Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance.
What to do if you smell gas:
1. DO NOT try to light any appliance.
2. DO NOT touch any electrical switch, or use any
phone in your building.
3. IMMEDIATELY call your gas supplier from a neigh-
bor's phone. Follow the gas supplier's instructions.
4. If you cannot reach your gas supplier, call the fire
department.
Disconnect gas piping from unit when pressure testing at
pressure greater than 0.5 psig. Pressures greater than
0.5 psig will cause gas valve damage resulting in hazardous
condition. If gas valve is subjected to pressure greater than
0.5 psig, it must be replaced before use. When pressure
testing field-supplied gas piping at pressures of 0.5 psig or
less, a unit connected to such piping must be isolated by
closing the manual gas valve(s).
IMPORTANT: Units have high ambient operating limits. If
limits are exceeded, the units will automatically lock the
compressor out of operation. Manual reset will be required
to restart the compressor.
Printed in U.S.A.
Form 48TM-4SI
48TM016-028
Pg 1
3-06
Replaces: 48TM-3SI
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Summary of Contents for Carrier 48TM016-028
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Page 1: Table Of Contents
IMPORTANT: Units have high ambient operating limits. If limits are exceeded, the units will automatically lock the compressor out of operation. Manual reset will be required to restart the compressor. Printed in U.S.A. Form 48TM-4SI 48TM016-028 Pg 1 3-06 Replaces: 48TM-3SI... -
Page 2: Installation
INSTALLATION Inspect unit for transportation damage. If damage is found, file any claim with the transportation agency. Step 1 — Provide Unit Support ROOF CURB — Assemble and install accessory roof curb or horizontal adapter roof curb in accordance with instructions shipped with this accessory. - Page 5 NOTES: 1. Dimensions in ( ) are in millimeters. 2. Refer to Fig. 4-6 for unit operating weights. 3. Remove boards at ends of unit and runners prior to rigging. 4. Rig by inserting hooks into unit base rails as shown. Use corner post from packaging to protect coil from damage.
- Page 9 ¶The 48TM028 unit requires 2-in. industrial-grade filters capable of handling face velocities up to 625 ft/min (such as American Air Filter no. 5700 or equivalent). NOTE: The 48TM016-028 units have a low-pressure switch (standard) located on the suction side. Table 1 — Physical Data...
- Page 10 ¶The 48TM028 unit requires 2-in. industrial-grade filters capable of handling face velocities up to 625 ft/min (such as American Air Filter no. 5700 or equivalent). NOTE: The 48TM016-028 units have a low-pressure switch (standard) located on the suction side. Table 1 — Physical Data (cont)
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Page 11: Step 3 - Field Fabricate Ductwork
Step 3 — Field Fabricate Ductwork — ducts to building structure. Use flexible duct connectors be- tween unit and ducts as required. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes. Ducts passing through an unconditioned space must be in- sulated and covered with a vapor barrier. -
Page 12: Step 7 - Orifice Change
See Table 3 for the number of orifices required for each unit size. Purchase these orifices from your local Carrier dealer. Follow instructions in accessory Installation Instructions to install the correct orifices. -
Page 13: Step 8 - Install Gas Piping
Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. FIELD CONTROL WIRING — Install a Carrier-approved accessory thermostat assembly according to installation in- structions included with accessory. Locate thermostat assembly on a solid interior wall in the conditioned space to sense aver- age temperature. -
Page 14: Optional Convenience Outlet
OPTIONAL NON-FUSED DISCONNECT — On units with the optional non-fused disconnect, incoming power will be wired into the disconnect switch. Refer to Fig. 17 for wiring for 100 and 200 amp disconnect switches. Units with an MOCP (maximum overcurrent protection) under 100 will use the 100 amp disconnect switch. - Page 15 COMPRESSOR VOLTAGE NOMINAL UNIT RANGE VOLTAGE No. 1 48TM (3 Ph, 60 Hz) Max RLA LRA RLA LRA RLA LRA Qty Hp FLA (ea) 208/230 32.1 195 16.4 208/230 30.1 225 15.5 114 632.5 12.1 208/230 19.2 125 13.8 80.0 208/230 187.2 20.7 156 20.7 156...
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Page 16: Step 10 - Make Outdoor-Air Inlet
Step 10 — Make Outdoor-Air Inlet Adjust- ments MANUAL OUTDOOR-AIR DAMPER — All units (except those equipped with a factory-installed economizer) have a manual outdoor-air damper to provide ventilation air. Damper can be preset to admit up to 25% outdoor air into return-air compartment. -
Page 17: Step 12 - Install All Accessories
Step 12 — Install All Accessories — factory-installed options have been adjusted, install all field- installed accessories. Refer to the accessory installation instructions included with each accessory. MOTORMASTER® CONTROL (48TM016,020, and 028) Install Field-Fabricated Wind Baffles — Wind baffles must be field-fabricated for all units to ensure proper cooling cycle operation at low ambient temperatures. - Page 18 TO PRESSURE TRANSDUCER Fig. 24 — Motormaster® V Control Unit with MMV Control Table 6 — Motormaster V Control Package Usage –20 (–29) UNIT 48TM016-028 Table 7 — Applicable Voltages and Motors VOLTAGE 208/230-3-60 460-3-60 575-3-60 FROM FUSE BLOCK 12 13A...
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Page 19: Step 13 - Adjust Factory-Installed Options
Scrolling Marquee can be used with the PremierLink controller. The PremierLink controller (see Fig. 25) requires the use of a Carrier electronic thermostat or a CCN connection for time broadcast to initiate its internal timeclock. This is necessary for broadcast of time of day functions (occupied/unoccupied). No sensors are supplied with the field-mounted PremierLink control. -
Page 21: Enthalpy Switch/Receiver
-in. TEK screws. Insert the screws through the holes in the sides of the enthalpy switch/receiver. Wiring — Carrier recommends the use of 18 to 22 AWG (American Wire Gage) twisted pair or shielded cable for all wiring. All connections must be made with connectors. - Page 22 Fig. 27 — Enthalpy Switch/Receiver Dimensions Fig. 28 — Enthalpy Sensor Dimensions (33CSENTHSW) (33CSENTSEN) *Used with Differential Enthalpy Control only. Fig. 29 — Typical Wiring Schematic — Carrier Rooftop Unit with PremierLink™ Controls...
- Page 23 -in. TEK screws. Insert the screws through the holes in the sides of the enthalpy sensor. Wiring — Carrier recommends the use of 18 to 22 AWG twisted pair or shielded cable for all wiring. All connections must be made with -in.
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Page 24: Differential Enthalpy Control
Connect the GRAY/RED wire to J4-1 on Premier- Link controller and to terminal (2) on enthalpy sensor. NOTE: If installing in a Carrier rooftop, use the two gray wires provided from the control section to the economizer to connect PremierLink controller to terminals 2 and 3 on enthalpy sensor. -
Page 25: Economi$Eriv Standard Sensors
Outdoor air leakage is shown in Table 9. Return air pressure drop is shown in Table 10. Table 9 — Outdoor Air Damper Leakage DAMPER STATIC PRESSURE (in. wg) LEAKAGE (cfm) Table 10 — Return Air Pressure Drop (in. wg) 4500 5000 5400 6000 7200 7500 9000 10,000 11,250 0.040 0.050 0.060 0.070 0.090 0.100 0.110 0.120 OUTDOOR AIR... - Page 26 LEGEND Potentiometer Default Settings: Power Exhaust DCV — Demand Controlled Ventilation Minimum Pos. IAQ — Indoor Air Quality DCV Max. LALS — Low Temperature Compressor DCV Set Lockout Switch Enthalpy OAT — Outdoor-Air Temperature POT — Potentiometer NOTE 1 NOTE 2 50HJ540573 ACTUATOR ASSEMBLY...
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Page 27: Economi$Eriv Control Modes
ECONOMI$ERIV CONTROL MODES IMPORTANT: The optional EconoMi$er2 does not include a controller. The EconoMi$er2 is operated by a 4 to 20 mA signal from an existing field-supplied controller (such as PremierLink™ control). See Fig. 37 for wiring information. Determine the EconoMi$erIV control mode before set up of the control. - Page 28 Outdoor Enthalpy Changeover — For enthalpy control, ac- cessory enthalpy sensor (part number HH57AC078) is required. Replace the standard outdoor dry bulb temperature sensor with the accessory enthalpy sensor in the same mount- ing location. See Fig. 33. When the outdoor air enthalpy rises above the outdoor enthalpy changeover set point, the outdoor- air damper moves to its minimum position.
- Page 29 Typically the maximum ventilation rate will be about 5 to 10% more than the typical cfm required per person, using normal outside air design criteria. A proportional anticipatory strategy should be taken with the following conditions: a zone with a large area, varied occu- pancy, and equipment that cannot exceed the required ventila- tion rate at design conditions.
- Page 30 See Table 13. Use setting 1 or 2 for Carrier equipment. See Table 13. 1. Press Clear and Mode buttons. Hold at least 5 seconds until the sensor enters the Edit mode.
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Page 31: Step 14 - Install Humidistat For Optional Moisturemi$Er™ Package
Step 14 — Install Humidistat for Optional MoistureMi$er™ Package — midification package operation can be controlled by field installation of a Carrier-approved humidistat. To install the humidistat perform the following procedure: 1. Locate humidistat on a solid interior wall in the condi- tioned space. - Page 32 — Thermostatic Expansion Valve Fig. 46 — MoistureMi$er™ Dehumidification Operation Diagram...
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Page 33: Start-Up
START-UP Use the following information and Start-Up Checklist on page CL-1 to check out unit PRIOR to start-up. Unit Preparation — Check that unit has been installed in accordance with these installation instructions and all applica- ble codes. COMPRESSOR MOUNTING — Compressors are internal- ly spring mounted. - Page 34 Table 14 — Fan Performance — 48TMD016 (Low Heat Units)* AIRFLOW (cfm) Watts 4500 1307 1.53 4800 1384 1.62 5100 1465 1.72 5700 1911 2.24 6000 2164 2.54 6300 2439 2.86 6600 2737 3.21 6900 3057 3.59 1013 7200 3401 3.99 1047 7500...
- Page 35 Table 15 — Fan Performance — 48TMF016 (High Heat Units)* AIRFLOW (cfm) Watts 4500 1307 1.53 4800 1384 1.62 5100 1571 1.84 5700 2054 2.41 6000 2329 2.73 6300 2628 3.08 6600 2951 3.46 1023 6900 1000 3298 3.87 1059 7200 1038 3672...
- Page 36 Table 16 — Fan Performance — 48TMD020 (Low Heat Units)* AIRFLOW (cfm) Watts 5,500 2.27 1908 2.58 6,000 2.72 2287 3.04 6,500 3.22 2710 3.55 7,000 3.78 3177 4.11 7,500 4.39 3690 1038 4.73 8,000 1038 5.06 4251 1093 5.40 8,500 1096 5.78...
- Page 37 Table 18 — Fan Performance — 48TMD025 (Low Heat Units)* AIRFLOW (cfm) Watts 6,000 2607 3.09 6,500 3030 3.59 7,000 3488 4.14 1001 7,500 3982 4.72 1055 8,000 1056 4512 5.35 1111 8,500 1116 5077 6.02 1167 9,000 1175 5678 6.74 1224 9,500...
- Page 38 Table 19 — Fan Performance — 48TMF025 (High Heat Units)* AIRFLOW (cfm) Watts 6,000 2752 3.26 6,500 3201 3.80 7,000 3687 4.37 1049 7,500 1054 4211 5.00 1109 8,000 1117 4773 5.66 1168 8,500 1180 5373 6.37 1229 9,000 1244 6011 7.13 1290...
- Page 39 Using fan motors up to the watts or bhp rating shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected. 5. Use of a field-supplied motor may affect wire size. Contact your Carrier representative for details. Watts...
- Page 40 UNIT 48TM Table 23 — Accessory/FIOP Static Pressure (in. wg)* — 48TM016-028 COMPONENT EconoMi$erIV and EconoMi$er2 MoistureMi$er™ Dehumidification LEGEND FIOP — Factory-Installed Option *The static pressure must be added to external static pressure. The sum and the evaporator entering-air cfm should then be used in conjunction with the Fan Performance tables to determine blower rpm and watts.
- Page 41 Operating Sequence COOLING, UNITS WITHOUT ECONOMIZER — When thermostat calls for cooling, terminals G and Y1 are energized. The indoor (evaporator) fan contactor (IFC), compressor con- tactor no. 1 (C1) and outdoor-fan contactor (OFC) are ener- gized, and evaporator-fan motor, compressor no. 1, and both condenser fans start.
- Page 42 Routine 3 (OAT > 68) • Economizer is opened 100%. • Compressors 1 and 2 are cycled based on Y1 and Y2 using minimum on and off times and watching the sup- ply air temperature as compared to SATLO1 and SATLO2 set points.
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Page 43: Service
HEATING, UNIT WITH ECONOMI$ER2, PREMIERLINK CONTROL AND A ROOM SENSOR — Every 40 seconds the controller will calculate the required heat stages (maximum of 3) to maintain supply air temperature (SAT) if the following qualifying conditions are met: • Indoor fan has been on for at least 30 seconds. •... - Page 44 FAN SHAFT BEARINGS — Lubricate bearings at least every 6 months with suitable bearing grease. Extended grease line is provided for far side fan bearing (opposite drive side). Typical lubricants are given below: MANUFACTURER Texaco Mobil Mobilplex EP No. 1 Sunoco Texaco *Preferred lubricant because it contains rust and oxidation inhibitors.
- Page 45 Fig. 53 — Condenser-Fan Adjustment, 48TM025 Refrigerant Charge — listed on unit nameplate and in Table 1. Refer to Carrier GTAC II; Module 5; Charging, Recovery, Recycling, and Reclama- tion section for charging methods and procedures. Unit in. deflection at panels must be in place when unit is operating during charging procedure.
- Page 46 Breaker can be reset. If it trips, determine cause of trouble before resetting. See Fig. 57 and 58 for typical wiring diagrams. Replacement Parts — parts may be obtained from any Carrier distributor upon request. Replace whenever refrigerant system is All units have relief devices to protect...
- Page 47 Diagnostic IGC Control LEDs — has LEDs for diagnostic purposes. Refer to Troubleshooting section on page 51. Optional Hinged Access Doors — service package is ordered or the if the hinged access doors option is ordered, the unit will be provided with external and internal hinged access doors to facilitate service.
- Page 48 Fig. 57 — Typical Wiring Schematic (48TM016,020 — 208/230 V Shown)
- Page 49 Fig. 58 — Typical Component Arrangement...
- Page 50 LEGEND AND NOTES FOR FIG. 57 AND 58 — Adjustable Heat Anticipator — Contactor, Compressor — Capacitor — Circuit Breaker — Cooling Compensator — Crankcase Heater — Compressor Lockout COMP — Compressor Motor — Control Relay — Damper Motor — Dummy Terminal EQUIP —...
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Page 51: Troubleshooting
A functional view of the EconoMi$erIV is shown in Fig. 60. Typical settings, sensor ranges, and jumper positions are also shown. An EconoMi$erIV simulator program is available from Carrier to help with EconoMi$erIV training and troubleshooting. ECONOMI$ERIV PREPARATION — This procedure is used to prepare the EconoMi$erIV for troubleshooting. - Page 52 7. Remove jumper from TR to N. 8. Remove jumper from TR to 1. 9. Remove 5.6 kilo-ohm resistor from T and T1. Reconnect wires at T and T1. PROBLEM Compressor and Power failure. Condenser Fan Fuse blown or circuit breaker tripped. Will Not Start.
- Page 53 PROBLEM Burners Will Not Misaligned spark electrodes. Ignite. No gas at main burners. Water in gas line. No power to furnace. No 24 v power supply to control circuit. Miswired or loose connections. Burned-out heat anticipator in thermostat. Broken thermostat wires. Inadequate Heating.
- Page 54 Table 30 — EconoMi$erIV Input/Output Logic INPUTS Enthalpy* Demand Control Ventilation (DCV) Outdoor Below set High (DCV LED Off) (Free Cooling LED Off) (Free Cooling LED On) Above set High (DCV LED On) (Free Cooling LED Off) (Free Cooling LED On) *For single enthalpy control, the module compares outdoor enthalpy to the ABCD set point.
- Page 55 LEGEND IGC — Integrated Gas Unit Controller NOTE: Thermostat Fan Switch in the “AUTO” position. Fig. 59 — IGC Control (Heating and Cooling)
- Page 56 Fig. 60 — EconoMi$erIV Functional View...
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Page 57: Index
Air quality limits Altitude compensation Burner section Burner spark gap Carrier Comfort Network® Charging chart, refrigerant Clearance sensor Configuration Settings 29, 30 Combustion blower wheel Compressor Lockout 25, 46 Lubrication Mounting Rotation Concentric duct Condensate drain Cleaning Location 11, 12... - Page 58 Course descriptions and schedules are in our catalog. [ ] Packaged Service Training Copyright 2006 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 Catalog No.
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Page 60: Start-Up Checklist
VERIFY REFRIGERANT CHARGE USING CHARGING CHART ON PAGE 45. GENERAL ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS Copyright 2006 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book Catalog No.