Carrier 48TFD008-014 Installation And Service Instructions Manual

Single-package rooftop heating/cooling units 50 hz

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CONTENTS

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

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

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 . . . . . . . . . . . . . . . . . . . . . . . 8

Step 6 — Install Gas Piping . . . . . . . . . . . . . . . . . . . . . . 8

Step 7 — Make Electrical Connection . . . . . . . . . . . . 8

• FIELD POWER SUPPLY

• FIELD CONTROL WIRING

• HEAT ANTICIPATOR SETTINGS

Step 8 — Adjust Factory-Installed Options . . . . . . 11

• APOLLO CONTROL

• MANUAL OUTDOOR-AIR DAMPER

• OPTIONAL DURABLADE ECONOMIZER

• OPTIONAL ECONOMI$ER

Step 9 — Adjust Evaporator-Fan Speed . . . . . . . . . 20

Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-36

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-41

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . 42-46

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.

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

Catalog No. 004-816

Book 1

Tab

1a 6a

Single-Package Rooftop Heating/Cooling Units

Installation, Start-Up and

Service Instructions

Page

Printed in U.S.A.

Disconnect gas piping from unit when leak test-

ing at pressure greater than 3.4 kPa (

Pressures greater than 3.4 kPa (

cause gas valve damage resulting in hazardous

condition. If gas valve is ever subjected to pres-

sure greater than 3.4 kPa (

replaced before use. When pressure testing

field-supplied gas piping at pressures of 3.4 kPa

(

psig) 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 insula-

tion 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. In-

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

shown. Ductwork must be attached to curb. If gas, electric

power or control power is to be routed through the curb, attach

the accessory thru-the-curb service connection plates to the

roof curb in accordance with the accessory installation instruc-

tions. Connection plates 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 supplied

with the roof curb as shown in Fig. 2. Improperly

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 properly. Re-

fer to Accessory Roof Curb Installation Instructions for addi-

tional information as required.

Form 48TF-C1SI

Pg 1

48TFD008-014

48TFE008-014

48TFF008,012

50 Hz

psig).

psig) will

psig), it must be

1-01

Replaces: New

Table of Contents

Troubleshooting

Summary of Contents for Carrier CARRIER 48TFD008-014

Page 1 Installation, Start-Up and Service Instructions CONTENTS SAFETY CONSIDERATIONS ..... . 1 INSTALLATION ....... . 1-33 Step 1 —...
Page 2: Step 2 — Field Fabricate Ductwork
SLAB MOUNT (Horizontal Units Only) — Provide a level concrete slab that extends a minimum of 152 mm (6 in.) beyond unit cabinet. Install a gravel apron in front of con- denser coil air inlet to prevent grass and foliage from obstruct- ing airflow.
Page 3: Roof Curb Details
CONNECTOR PKG. ACCY. CRBTMPWR001A00 CRBTMPWR002A00 ″ ″ 2′-8 1′-10 CRBTMPWR003A00 [827] [583] CRBTMPWR004A00 D ALT DRAIN POWER CONTROL HOLE ″ [19] NPT ″ ″ ″ [31.7] [19] NPT [12.7] ″ ″ ″ [19] NPT [44.5] ″ [12.7] NPT ″ [12.7] ″...
Page 4: Installation
Although unit is weatherproof, guard against water from higher level runoff and overhangs. Position unit on roof curb so that the following clearances are maintained: 7 mm ( -in.) clearance between roof curb and base rails on each side and duct end of unit; 84 mm (3 clearance between roof curb and condenser coil end of unit.
Page 5 UNIT SIZE 48TF Low Heat (D), Medium Heat (E), High Heat (F) NOMINAL CAPACITY (kW) OPERATING WEIGHT (kg) Unit Durablade Economizer EconoMi$er Roof Curb* COMPRESSOR TYPE Quantity Oil (ml) REFRIGERANT TYPE Operating Charge (kg) Circuit 1 Circuit 2 CONDENSER COIL Rows...Fins/m Total Face Area (sq m) CONDENSER FAN...
Page 6 UNIT SIZE 48TF Low Heat (D), Medium Heat (E), High Heat (F) NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Unit Durablade Economizer EconoMi$er Roof Curb* COMPRESSOR TYPE Quantity Oil (oz) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1 Circuit 2 CONDENSER COIL Rows...Fins/in.
Page 7 DURABLADE STANDARD ECONOMI$ER ECONOMIZER UNIT UNIT WEIGHT WEIGHT WEIGHT 48TF D/E/F008 D/E/F012 1035 D/E014 1050 NOTES: 1. Dimensions in [ ] are in millimeters. Center of gravity. Direction of airflow. 4. On vertical discharge units, ductwork to be attached to accessory roof curb only.
Page 8: Step 5 — Install Flue Hood
Note 2 to determine the percentage of voltage imbalance. Op- eration on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical compo- nents. Such operation would invalidate any applicable Carrier warranty. NOTE: If field-installed thru-the-bottom connections are used, refer to the accessory installation instructions for power wiring.
Page 9 VOLTAGE NOMINAL UNIT RANGE VOLTAGE 48TF (50 Hz) (3 phase) (3 phase) (3 phase) LEGEND — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration — Indoor (Evaporator) Fan Motor — Locked Rotor Amps — Minimum Circuit Amps MOCP — Maximum Overcurrent Protection —...
Page 10 LEGEND AHA — Adjustable Heat Anticipator — Cooling Compensator Field Wiring Factory Wiring Fig. 10 — Low-Voltage Connections Fig. 9 — Power Wiring Connections UNIT LOW VOLTAGE CONNECTION BOARD RACEWAY Fig. 11 — Field Control Wiring Raceway and Compressor Location LEGEND —...
Page 11: 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 12 OUTDOOR AIRFLOW (cfm x 100) OUTDOOR AIRFLOW (L/s) Fig. 16 — Position Setting OPTIONAL DURABLADE ECONOMIZER — The option- al economizer hood assembly is packaged and shipped in the fil- ter section. Damper blades and control boards are installed at the factory and the economizer is shipped in the vertical discharge position.
Page 13 Fig. 18 — Outdoor-Air Hood Details Fig. 19 — Vertical Discharge Block-Off Plate (48TF012, 014 Units Only) ECONOMIZER ECONOMIZER CONTROL BOARD PLUG SHIPPING SCREW Fig. 20 — Durablade Economizer Installed in Unit ECONOMIZER CONTROL BOARD POSITION SETTING BRACKET Fig. 21 — Horizontal Durablade Economizer Installation (90 Degree Rotation) Fig.
Page 14: Tfd008
Example: Given — Negative Pressure ......25 Pa (0.1 in. wg) Outdoor Airflow ......520 L/s (1100 cfm) Determine —...
Page 15 Fig. 26 — Wiring Connections for Outdoor-Air Thermostat 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 Fig. 27 — Durablade Economizer Barometric Relief Damper Characteristics OPTIONAL ECONOMI$ER — See Fig. 28 for EconoMi$er component locations. 1. To remove the existing unit filter access panel, raise the panel and swing the bottom outward.
Page 16 OUTDOOR AIR SEAL STRIP OPENING PANEL SEAL STRIP ASSEMBLED EXHAUST HOOD OUTDOOR AIR HOOD SIDES Fig. 31 — Outdoor Air Hood Assembly Fig. 32 — Completed Hood Assembly 5. Slide the outdoor air inlet screens into the screen track on the hood side panels.
Page 17 LEGEND OAT — Outdoor-Air Thermostat ECONOMI$ER CONTROLLER +15 V +15 V REM POT Fig. 36 — 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 Fig.
Page 18 TO FUSED DISCONNECT RED YEL BLU GRAY X2 X3 SECONDARY 230VAC 4-PIN CONNECTOR 2 x 4 IN. PLUG HANDY BOX BLACK L1 BLUE GREEN GND 230 VAC GREEN 1 PHASE Fig. 38 — Wiring Diagram for Power Exhaust System SUPPLY AIR TEMPERATURE SENSOR MOUNTING...
Page 19 Control Set Up — 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. Determine the value at which you want the minimum position of the dampers to begin opening to allow a great- er amount of outdoor air to enter.
Page 20: Step 9 — Adjust Evaporator-Fan Speed
Step 9 — Adjust Evaporator-Fan Speed — just evaporator-fan speed to meet jobsite requirement. Table 6 shows motor performance. Tables 7 and 8 show fan rpm at motor pulley settings, Table 9 shows motor efficiencies and Tables 10 and 11 give accessory static pressure drops. Re- fer to Tables 12-23 to determine fan speed settings.
Page 21 Table 7 — Fan R/s at Motor Pulley Settings (SI) UNIT 48TF 11.70 11.35 13.00 12.65 15.00 14.70 Table 8 — Fan Rpm at Motor Pulley Settings (English) UNIT 48TF Table 9 — Evaporator-Fan Motor Efficiency MOTOR EFFICIENCY (%) 48TF D/E/F008 D/E/F012 D/E014...
Page 22 2.78 — 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. 5. Standard drive range is 8.2 to 11.7 r/s. All other speeds require a field-supplied drive. 6. Maximum continuous BkW is 1.79. Extensive motor and electri- cal testing on these units ensures that the full range of the motor can be utilized with confidence.
Page 23 3. Values include losses for filters, unit casing, and wet coils. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. EXTERNAL STATIC PRESSURE (Pa) 10.9 0.67 12.0...
Page 24 3. Values include losses for filters, unit casing, and wet coils. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. EXTERNAL STATIC PRESSURE (Pa) 13.5 1.27 14.4...
Page 25 3. Values include losses for filters, unit casing, and wet coils. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. EXTERNAL STATIC PRESSURE (Pa) 0.49 10.7 0.66...
Page 26 3. Values include losses for filters, unit casing, and wet coils. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. EXTERNAL STATIC PRESSURE (Pa) 10.5 0.63 11.6...
Page 27 3. Values include losses for filters, unit casing, and wet coils. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. EXTERNAL STATIC PRESSURE (Pa) 12.7 1.14 13.7...
Page 28 3. Values include losses for filters, unit casing, and wet coils. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. EXTERNAL STATIC PRESSURE (in. wg) 0.72 0.76...
Page 29 3. Values include losses for filters, unit casing, and wet coils. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. EXTERNAL STATIC PRESSURE (in. wg) 0.93 1.09...
Page 30 3. Values include losses for filters, unit casing, and wet coils. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. EXTERNAL STATIC PRESSURE (in. wg) 1.58 1.79...
Page 31 3. Values include losses for filters, unit casing, and wet coils. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. EXTERNAL STATIC PRESSURE (in. wg) 0.70 0.94...
Page 32 3. Values include losses for filters, unit casing, and wet coils. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. EXTERNAL STATIC PRESSURE (in. wg) 0.87 1.05...
Page 33 3. Values include losses for filters, unit casing, and wet coils. 4. Use of a field-supplied motor may affect wire sizing. Contact your Carrier representative to verify. EXTERNAL STATIC PRESSURE (in. wg) 1.43 1.65...
Page 34 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, located on back page of this booklet, has been completed and filled out. Return-Air Filters — Make sure correct filters are in- stalled in filter tracks (see Tables 1A and 1B).
Page 35 5. After a call for heating, the main burners should light within 5 seconds. If the burners do not light, then there is a 22-second delay before another 5-second ignition try. If the burners still do not light, the time delay is repeated. If the burners do not light within 15 minutes, there is a lockout.
Page 36 If the outdoor air alone cannot satisfy the cooling require- ments of the conditioned space, economizer cooling is integrat- ed with mechanical cooling, providing second-stage cooling. Compressor no. 1 and the condenser fan will be energized and the position of the economizer damper will be determined by the supply-air temperature.
Page 37 Amount of refrigerant charge is listed on unit nameplate (also refer to Tables 1A and 1B). Refer to Carrier GTAC 2-5 Charging, Recovery, recycling, and recla- mation training manual and the following procedures. Unit panels must be in place when unit is operating during charging procedure.
Page 38 Fig. 49 — Cooling Charging Charts, 48TF008 Units Fig. 50 — Cooling Charging Charts, 48TF012 Units...
Page 39 CIRCUIT NO. 1 Fig. 51 — Cooling Charging Chart; 48TF014 Units Flue Gas Passageways — To inspect the flue collec- tor 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 section below.
Page 40 5. Reinstall burners on rack. 6. Reinstall burner rack as described in Removal and Re- placement of Gas Train section. Replacement Parts — A complete list of replacement parts may be obtained from any Carrier distributor upon request. INDUCED- DRAFT MOTOR...
Page 41 NOTE: Dimensions in ( ) are millimeters. 31.4/21.1 kW INPUT (107,000/72,000 BTUH) 50.4/31.9 kW INPUT/ (172,000/109,000 BTUH) Fig. 54 — Spark Gap Adjustment 48TFD008 48TFE008, 48TFD012 48TFD014, 48TFE012, 48TFF008 59.8/39.8 kW INPUT (204,000/136,000 BTUH) 48TFE014, 48TFF012 65.6/43.9 kW INPUT (224,000/150,000 BTUH)
Page 42: Troubleshooting
Table 26 — 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 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. Compressor no.
Page 44 Table 28 — Heating Service Troubleshooting 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.
Page 45 Table 30 — Durablade Economizer Troubleshooting PROBLEM CAUSE Damper does not Indoor (evaporator) fan is off. open. No power to economizer motor. Economizer motor failure. Economizer OAT or EC set too high. operation limited to minimum position. Verify economizer control board is correctly wired and works properly.
Page 46 Copyright 2001 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. 004-816 1a 6a Fig. 55 — Typical Unit Wiring Schematic Printed in U.S.A.
Page 48 VERIFY REFRIGERANT CHARGE USING CHARGING TABLES VERIFY THAT 3-PHASE SCROLL COMPRESSOR ROTATING IN CORRECT DIRECTION (014 ONLY) Copyright 2001 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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Carrier 48TFD008-014 Installation And Service Instructions Manual

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

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

Troubleshooting

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