Carrier 48TJD Series Installation, Start-Up And Service Instructions Manual
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Carrier 48TJD Series Installation, Start-Up And Service Instructions Manual

Carrier 48TJD Series Installation, Start-Up And Service Instructions Manual

Single-package rooftop heating/cooling units
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Installation, Start-Up, and
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Step 1 - Provide Unit Support . . . . . . . . . . . . . . . 1
• ROOF CURB
Step 2 - Field Fabricate Ductwork . . . . . . . . . . . . 2
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 4 - Rig and Place Unit . . . . . . . . . . . . . . . . . . 2
• POSITIONING
Step 5 - Install Flue Hood . . . . . . . . . . . . . . . . . . . 4
Step 6 - Install Gas Piping . . . . . . . . . . . . . . . . . . . 4
• HEAT ANTICIPATOR SETTINGS
• MANUAL OUTDOOR-AIR DAMPER
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27,28
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-33
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 34-40
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 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
Service Instructions
Page
Catalog No. 534-852
Printed in U.S.A.
48TJD/TJE/TJF005-007
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
placed 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 clos-
ing the gas valve.
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, not
to the unit. The accessory thru-the-bottom power connection
package must be installed before the unit is set on the roof
curb. If field installed (through the roof curb) gas connec-
tions are desired, use factory supplied
and gas plate assembly to mount the through the roof curb
connection to the roof curb. Gas connections and power con-
nections to the unit must be field installed after the unit is
installed on the 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 result in air leaks and poor unit
performance.
Form 48TJ-9SI
Pg 1
48TJE/TJF004
1
⁄
psig.
2
1
⁄
psig will cause
2
1
⁄
psig, it must be re-
2
3
⁄
in. pipe coupling
4
8-95
Replaces: 48TJ-3SI

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  • Page 1: Table Of Contents

    48TJE/TJF004 48TJD/TJE/TJF005-007 Single-Package Rooftop Heating/Cooling Units Installation, Start-Up, and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS ....1 Disconnect gas piping from unit when leak testing at pressure greater than ⁄...

  • Page 2: Slab Mount

    Fig. 1 — Horizontal Conversion Panels Curb should be level. Unit leveling tolerances are shown Step 3 — Install External Trap for Condensate in Fig. 3. This is necessary for unit drain to function prop- Drain — The unit’s 3/4-in. condensate drain connections erly.
  • Page 3 CONNECTION SIZES UNIT D ALT CONNECTOR ‘‘E’’ SIZE DRAIN GAS POWER CONTROL PACKAGE 48TJ HOLE ACCESSORY 004-007 1 -9 ⁄ 1 -4 ⁄ ⁄ ⁄ ⁄ CRBTMPWR001A00 [551] [406] [44.5] (Thru-the-Bottom) ROOF CURB UNIT SIZE ‘‘A’’ ACCESSORY 48TJ 1 -2 CRRFCURB001A00 [356] 004-007...

  • Page 4: Step 5 - Install Flue Hood

    POSITIONING — Maintain clearance around and above unit For natural gas applications, gas pressure at unit gas con- to provide minimum distance from combustible materials, nection must not be less than 4 in. wg or greater than proper airflow, and service access. See Fig. 6. A properly 13.0 in.

  • Page 5: Field Power Supply

    Such operation would invalidate any applicable Carrier warranty. FIELD CONTROL WIRING — Install a Carrier-approved accessory thermostat assembly according to installation in- structions included with the accessory. Locate thermostat as-...
  • Page 6 NOTE: Trap should be deep enough to offset maximum unit static difference. A 4-in. trap is recommended. Fig. 4B — External Trap Condensate Drain NOTE: Drain plug is shown in factory-installed position. Fig. 4A — Internal Trap Condensate Drain 3. Unit weights do not include economizer. See Table 1 for econo- NOTES: mizer weights.
  • Page 7 Table 1 — Physical Data BASE UNIT 48 TJE/TJF004 TJD/TJE/TJF005 TJD/TJE/TJF006 TJD/TJE/TJF007 NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Unit Varislide™ Economizer PARABLADE Economizer Roof Curb COMPRESSOR Hermetic (Reciprocating) Quantity Oil (oz) REFRIGERANT TYPE R-22 Operating Charge (lb-oz) 4-11 5-13 CONDENSER COIL Enhanced Copper Tubes, Aluminum Lanced Fins Rows...Fins/in.
  • Page 8 Table 1 — Physical Data (cont) BASE UNIT 48 TJE/TJF004 TJD/TJE/TJF005 TJD/TJE/TJF006 TJD/TJE/TJF007 FURNACE SECTION Rollout Switch Cutout Temp (F)* Burner Orifice Diameter (in..drill size)† Natural Gas .113...33 .113...33/ .113...33/ .113...33/ .113...33/ .113...33/ .113...33/ .129...30 .129...30 .129...30 Liquid Propane** .082...45 .082...45/ .082...45/...
  • Page 9 LEGEND CORNER CORNER CORNER CORNER ECONOMIZER WEIGHT STD. UNIT WEIGHT WEIGHT WEIGHT WEIGHT LED — Light-Emitting Diode WEIGHT UNIT Varislide™ PARABLADE *Indicates horizontal center of gravity. †Indicates vertical center of gravity. 48TJF/TJE004 15.4 19.1 140 63.5 105 47.6 159 72.1 25.4 NOTES: 1.
  • Page 10 CONDENSER COIL TOP COVER CORNER POST END PANEL Fig. 7 — Flue Hood Details Fig. 9 — Conduit Installation LEGEND NFGC — National Fuel Gas Code *Field supplied. NOTE: Follow all local codes. SPACING OF SUPPORTS STEEL PIPE NOMINAL DIMENSIONS DIAMETER (feet) (in.)

  • Page 11: Field Control Wiring

    208/230-1-60 208/230-3-60 460-3-60 (SIZE 007 ONLY) 575-3-60 (SIZE 007 ONLY) 208/230-3-60 575-3-60, 460-3-60 LEGEND (SIZES 004-006) — Contactor COMP — Compressor — National Electrical Code — Terminal Block Fig. 11 — Power Wiring Connections LEGEND AHA — Adjustable Heat Anticipator TH —...
  • Page 12 EXAMPLE: Supply voltage is 460-3-60. IMPORTANT: Optional, alternate evaporator-fan motor and drive AB = 452 v are not available for 48TJ007 units. Contact your local Carrier BC = 464 v representative for more information about field-installed AC = 455 v motors.

  • Page 13: Step 8 - Make Outdoor-Air Adjustments And Install Outdoor-Air Hood

    5. Place hood on front of evaporator coil access panel. See Step 8 — Make Outdoor-Air Adjustments and Fig. 14 for hood details. Secure top of hood with the Install Outdoor-Air Hood 4 screws removed in Step 3. See Fig. 15. MANUAL OUTDOOR-AIR DAMPER —...

  • Page 14: Optional Varislide™ Economizer

    OPTIONAL VARISLIDE ™ ECONOMIZER — The op- 8. Replace outdoor-air opening panel using screws from tional economizer hood assembly is packaged and shipped Step 2. Replace filter access panel. Ensure the filter in the filter section. Damper blades and control boards are access panel slides along the tracks and is securely installed at the factory and the economizer is shipped in the engaged.
  • Page 15 Fig. 20 — Horizontal Discharge Block-Off Plate U-SHAPED HOLE ECONOMIZER (NOT CONTROL ECONOMIZER ECONOMIZER SHOWN) BOARD PLUG MOTOR SCREW WIRING HARNESS BAROMETRIC RELIEF DAMPER POSITION SETTING BRACKET Fig. 21 — Varislide™ Economizer Installed in Unit EXAMPLE: Given — Negative Pressure ....0.2 in. wg Outdoor Air .

  • Page 16: Optional Parablade Economizer

    5. If ventilation air is not required, proceed to Step 6. If ven- tilation air is required, perform the following: a. Make sure the factory-installed jumper is in place across LEGEND terminals P and P1 on the economizer logic module. OAT —...
  • Page 17 6. Determine the enthalpy changeover set point from 8. Fasten hood top and side plate assembly (Fig. 29) to outdoor- Fig. 27. The enthalpy changeover set point should be set air opening panel with screws provided. to return the outdoor-air damper to the minimum position 9.

  • Page 18: Step 9 - Adjust Evaporator-Fan Speed

    unit. If other than factory setting is desired, refer to label diagram for motor reconnection. See Fig. 32 for direct drive motor location. BELT DRIVE MOTORS — Fan motor pulleys are factory set for speed shown in Table 1. See Fig. 33 for belt drive motor location.
  • Page 19 To align fan and motor pulleys: To adjust belt tension: 1. Loosen fan pulley setscrews. 1. Loosen fan motor mounting nuts. 2. Slide fan pulley along fan shaft. 2. Slide motor mounting plate away from fan scroll for proper belt tension ( ⁄...
  • Page 20 1. Boldface indicates a field-supplied drive is required. (See 5. Use of a field-supplied motor may affect wire sizing. Contact Note 6.) Carrier representative to verify. 6. Alternate motor drive range: 760 to 1090. All other rpms require indicates field-supplied motor and drive are required.
  • Page 21 1. Boldface indicates a field-supplied drive is required. (See 5. Use of a field-supplied motor may affect wire sizing. Contact Note 6.) Carrier representative to verify. 6. Alternate motor drive range: 840 to 1185. All other rpms require indicates field-supplied motor and drive are required.
  • Page 22 1. Boldface indicates a field-supplied drive is required. (See 5. Use of a field-supplied motor may affect wire sizing. Contact Note 6.) Carrier representative to verify. 6. Alternate motor drive range: 900 to 1300. All other rpms require indicates field-supplied motor and drive are required.
  • Page 23 1. Boldface indicates a field-supplied drive is required. (See 5. Use of a field-supplied motor may affect wire sizing. Contact Note 6.) Carrier representative to verify. 6. Standard motor drive range: 1070 to 1460. All other rpms require indicates field-supplied motor and drive are required.
  • Page 24 Table 13 — Fan Performance, 48TJE/TJF004 Horizontal Discharge Units; Alternate Motor (Belt) EXTERNAL STATIC PRESSURE (in. wg) AIRFLOW (Cfm) Watts Watts Watts Watts Watts Watts Watts Watts 1000 1100 1005 1200 1038 1300 1012 1061 1400 1027 1071 1500 1014 1056 1097 EXTERNAL STATIC PRESSURE (in.
  • Page 25 1. Boldface indicates a field-supplied drive is required. (See 5. Use of a field-supplied motor may affect wire sizing. Contact Note 6.) Carrier representative to verify. 6. Alternate motor drive range: 840 to 1185. All other rpms require indicates field-supplied motor and drive are required.
  • Page 26 1. Boldface indicates a field-supplied drive is required. (See 5. Use of a field-supplied motor may affect wire sizing. Contact Note 6.) Carrier representative to verify. 6. Alternate motor drive range: 900 to 1300. All other rpms require indicates field-supplied motor and drive are required.

  • Page 27: Start-Up

    *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 28 The evaporator-fan OFF delay can also be modified. Once When the outdoor-air temperature is below the OAT set- the call for heating has ended, there is a 10-minute period ting and the thermostat calls for cooling, the economizer damper during which the modification can occur. If the limit switch moves to the minimum position.

  • Page 29: 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 30 (also refer to Table 1). Refer to Flue Gas Passageways — To inspect the flue col- Carrier GTAC2-5 Charging, Recovery, Recycling, and Rec- lector box and upper areas of the heat exchanger: lamation training manual and the following procedures.
  • Page 31 Fig. 42 — Cooling Charging Chart, 48TJ006 Fig. 40 — Cooling Charging Chart, 48TJ004 Fig. 43 — Cooling Charging Chart, 48TJ007 Fig. 41 — Cooling Charging Chart, 48TJ005...
  • Page 32 If lockout occurs, unit may be reset by interrupting power Replacement Parts — A complete list of replacement supply to unit for at least 5 seconds. parts may be obtained from any Carrier distributor upon Table 20 — LED Error Code Description* request. LED INDICATION...
  • Page 33 Fig. 45 — Burner Tray Details LOW HEAT 48TJE004, 48TJD005-007 — 74,000 BTUH INPUT MEDIUM AND HIGH HEAT 48TJE005-007, 48TJF004 — 115,000 BTUH INPUT 48TJF005-007 — 150,000 BTUH INPUT Fig. 46 — Spark Adjustment...

  • Page 34: Troubleshooting

    TROUBLESHOOTING Table 21 — LED Error Code Service Analysis PROBLEM CAUSE REMEDY Hardware failure. Loss of power to control module (IGC). Check 5 amp fuse on IGC, power to unit, 24-v circuit (LED OFF) breaker, and transformer. Units without a 24-v circuit breaker have an internal overload in the 24-v trans- former.
  • Page 35 Table 22 — Heating Service Analysis PROBLEM CAUSE REMEDY Burners will not ignite. Misaligned spark electrodes. Check flame ignition and sensor electrode positioning. Adjust as needed. No gas at main burners. Check gas line for air, purge as necessary. After purging gas line of air, allow gas to dissipate for at least 5 min- utes before attempting to relight unit.
  • Page 36 Table 23 — Cooling Service Analysis PROBLEM CAUSE REMEDY Compressor and condenser Power failure. Call power company. fan will not start. Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Defective thermostat, contactor, transformer, or Replace component. control relay.
  • Page 37 Table 24 — Varislide™ Economizer Troubleshooting PROBLEM CAUSE REMEDY Damper does not Indoor (evaporator) fan is off. 1. Check to ensure that 24 vac is present at terminal C1 on the IFC or that open. 24 vac is present at the IFO terminal. Check whether 24 vac is present at PL6-1 (red wire) and/or PL6-3 (black wire).
  • Page 38 Table 25 — PARABLADE Economizer Troubleshooting PROBLEM CAUSE REMEDY Damper does not open. Evaporator fan not on. Check wiring between G on connection board and indoor fan contactor. No power to economizer 1. Disconnect power at TR and TR1. Disconnect jumper across P motor.
  • Page 39 LEGEND FOR FIG. 47 — TYPICAL WIRING SCHEMATIC AND COMPONENT ARRANGEMENT IMPORTANT: Refer to unit wiring label for actual unit wiring information. — Adjustable Heat Anticipator — Rollout Switch — Contactor, Compressor — Supply Air Thermostat — Capacitor — Sensor —...
  • Page 40 Fig. 47 — Typical Wiring Diagram and Component Arrangement...
  • Page 42 Copyright 1995 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. 534-852 Printed in U.S.A. Form 48TJ-9SI Pg 42 8-95...

  • Page 44: Start-Up Checklist

    PSIG REFRIGERANT DISCHARGE PSIG VERIFY REFRIGERANT CHARGE USING CHARGING TABLES Copyright 1995 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. 534-852 Printed in U.S.A.

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