Carrier 48HJD005-007 manual

Manufactu rer reser ves the rig ht to dis continue , or chan ge at a ny time, spec ificat ions or des igns without notice an d withou t inc urring obligations. PC 111 Catalo g No. 534-767 Prin ted in U.S.A. Form 4 8HJ-18S I Pg 1 9-00 Replaces: 48H J-17SI Book 1 4 Ta b 1 a 6 a Installation, Star t-Up and Ser v ice Instr u ctions CONTENTS Page SAFETY[...]

2 ROOF CURB A CCESSOR Y “A” UNIT SIZE 48/50HJ CRRFCURB001A00 1 ′ -2 ″ [356] 004-007 CRRFCURB002A00 2 ′ -0 ″ [610] NO TES: 1. Roof curb access or y is shipp ed disa ssemb led. 2. Insula ted panels. 3. Dimensions in [ ] are in millimeters. 4. Roof cu rb: gal vanized steel. 5. Attach ductwor k to curb ( flanges of duct rest on curb ). UNIT[...]

3 Step 2 — Field Fabr icate D uctw ork — Secure all ducts to roof curb and building structure on vertical discharge units. D o not connect ductwork to unit. For horizontal applica- tions, field-supplied isolation flanges should be attached to hor- izontal discharge openings and all ductwork should be sec ured to the flanges. Insulate and weathe[...]

4 Step 5 — Install Flue Hood — Flue hood is shipped screwed to th e burner compart ment acce ss panel. Rem ove from shipping location and, using screws provided, install flue hood in location shown in Fig. 5 and 6. For units being installed in Ca lifornia Air Quality Manage - ment Districts which require NO x emissions of 40 nanogram s/ joule o[...]

5 Table 1 — P hysical D ata LEGEND *Single phase/three phase. †Indicates automatic reset. **48HJD005-007 and 48HJE004 (72,000 Btuh heat input) units have 2 burners. 48HJE005-007 and 48HJF004 (115,000 Btuh heat input) units and 48HJF005- 007 (150,000 Btuh Heat input) units have 3 b ur ners. ††An LP kit is availab le as an accessor y . ||Thre[...]

6 Tab le 1 — Physi cal Dat a (co nt) LEGEND *Single phase/three phase. †Indicates automatic reset. **48HJD005-007 and 48HJE004 (72,000 Btuh heat input) units have 2 burners. 48HJE005-007 and 48HJF004 (115,000 Btuh heat input) units and 48HJF005- 007 (150,000 Btuh Heat input) units have 3 b ur ners. ††An LP kit is availab le as an accessor y[...]

7 UNIT 48HJ ST ANDARD UNIT WEIGHT DURABLADE ECONOMIZER WEIGHT ECONOMI$ER WEIGHT CORNER WEIGHT (A) CORNER WEIGHT (B) COR NER WEIGHT (C) CORNER WEIG HT (D) Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg 004 530 240 34 15.4 47 21.3 127 57.6 122 55.3 138 62 .6 143 64.9 005 540 245 34 15.4 47 21.3 129 58.5 124 56.2 141 64 .0 146 66.2 006 560 254 34 15.4 47 2[...]

8 Install conduit through side panel openings indicated in Fig. 5. Route power lines through connector to terminal con- nections as shown in Fig. 8. V oltage to compressor termi nals during operation must be within voltage range indicated on unit namepl ate (also see T ables 2A-2D). On 3-phase units, voltage s between phases must be balanced within[...]

9 RACEW A Y LOW V OL T AGE CONNECTIONS INTEGRA TED GAS UNIT CONTROLLER (IGC) HOLE IN END P ANEL (HIDDEN) Fig. 8 — Power Wiring Connections LEG END C— Contactor COMPS — Compressor s EQUIP — Equipment GND — Ground IFC — Indoor (Evaporator) F an Contactor NEC — National Electrical Code TB — T erminal B lock Fig. 9 — Low-Voltage Conne[...]

10 Table 2A — 48HJ Electrical Data Standard Motor (Units Without Electrical Convenience Outlet) Table 2B — 48HJ E lectrica l Data Standar d Motor ( Units W ith El ectrical C onvenien ce Ou tlet) LEGEND *Used to determine minimum disconnect per NEC. † Fuse or HACR circuit breaker . NO TES: 1. In compliance with NEC requirem ents f or multimoto[...]

11 Table 2C — 4 8HJ High -Static M otor Units W ithout E lectrica l Convenie nce Outlet Table 2D — 48HJ High-Static Motor Units With Electrical Convenience Outlet LEGEND *Used to determine minimum disconnect per NEC. † Fuse or HACR circuit breaker . NO TES: 1. In compliance with NEC requirem ents f or multimotor and combi- nation load equipme[...]

12 OP TIONAL DURABLA DE ECON OMIZER — The option- al economizer hood assembly is packaged and shipped in the filter section. Damper blade s and control boards are installed at the factory and the econom izer is shipped in the vert ical dis- charge position. NOTE: Horizontal discharge block-off plate is shipped with the air hood package. If unit i[...]

13 9. Replace outdoor-air opening panel using screws from Step 2. R eplace fi lter acce ss panel. Ens ure the filter ac - cess panel slides along the tracks and is secur ely engaged. 10. Fasten hood top and side plate assembly (Fig. 14) t o outdoor-air opening panel with screws provided. 1 1. Place knob supplied w ith economizer on OA T . See Fig. [...]

14 U-SHAPED HOLE (NOT SHOWN) ECONOMIZER PLUG WIRING HARNESS 4 3 2 1 0 5 6 7 8 9 UNIT TOP OA T (TERMINALS ARE UP) OUTSIDE AIR SCREEN MINIMUM POSITION OPEN 3 1 T P P1 T1 4 2 5 S S O D C TR B RE V . B 1 9 8 8 1 8 A % H U M I D I T Y 90 70 60 30 10 D C B A 60 65 70 7 5 55 50 85 8 0 DAMPER DAMPER CLOSED OPEN OUTDOOR TEMP . ° F R E V . 9 7-36 72 CW – [...]

15 OP TIONAL ECO NOMI$ER — See Fig . 23 fo r Ec onoMi$er component locations. 1. T o remove the existing unit filter access panel, raise the panel and swing the bottom outward. The panel is now disengaged from the track and can be removed. Remove the indoor coil access panel and di scard. See Fig. 24. If installing an optional Power Exhaust Assem[...]

16 SEAL STRIP SEAL STRIP OUTDOOR AIR HOOD TOP SCREEN RET AINER OUTDOOR AIR INLET SCREENS OUTDOOR AIR HOOD SIDES ASSEMBLED EXHAUST HOOD OUTDOOR AIR OPENING P ANEL ECONOMIZER ECONOMIZER REAR FLANGE UNIT BASE UNIT FIL TER RACK ECONOMIZER CLIP HV AC UNIT WIRING HARNESS OUTDOOR AIR BLOCK-OFF PLA TE Fig. 26 — Outdoor-Air Hood Assembly Fig. 27 — Compl[...]

17 OUTDOOR AIR SENSOR TEMP TEMP COM OUT PWR BROWN VIOLET WHITE RED BROWN TEMP TEMP COM OUT PWR RETURN AIR SENSOR VIOLET WHITE RED OA T COM OAH -15 V RA T COM RAH +15 V ECONOMI$ER CONTROLLER PINK TEMP TEMP VIOLET SUPPL Y AIR TEMPERA TURE SENSOR V+ 24 COM V AC SENSOR CO 2 (+) COM DA T COM REM POT COM LED COM CO 2 CO 2 CONTROL BOX/BURNER ACCESS P ANEL[...]

18 CO 2 C ontrol Setu p — If a CO 2 sensor is not being used, pro- ceed to t he next sect ion. If a CO 2 sensor is being used, perform the following: 1. Determine the value at which you want the minimum po- sition of the dampers to begin opening to allow a greater amount of outdoor air to enter . The range i s 800 to 1,400 ppm. 2. Loca te the CO [...]

19 Step 9 — A dju st Evapor ator-Fan Sp eed — Ad- just evaporator-fan speed to meet jobsite condi tions. T ables 5A and 5B show fan rpm at motor pulley settings. T ables 6 and 7 show maximum amp draw of belt-drive motor . T able 8 shows motor nominal horsepower for eva porator-fan motors. Refer to T ables 8-25 for performance data. See T ables [...]

20 Table 5A — 48HJ Fan Rpm at Motor Pulley Setting With Standard Motor *Approx imate fan rpm s hown (standard motor/drive). Table 5B — 48HJ Fan Rpm at Motor Pulley Setting With High Static Motor Table 6 — Evaporator-Fa n Motor Data — Standar d Motor LEGEND Bhp — Brake Hor sepower *Extensive motor and electrical testing on these units ensu[...]

21 Table 8 — Motor Nominal Horsepower Table 9 — Outdoor Sound Power (Total Unit) LEG END Table 10 — 48HJ004 Fan Perf ormance — Ve rtical Disc harge Units W ith Standar d Motor Table 11 — 48HJ004 Fan Performance — Verti cal Discha rge Uni ts With Hi gh-Stati c Motor LEGEND AND NOTES FOR T ABLES 10 AND 11 LEGEND NO TES: 1. Boldface indica[...]

22 Table 12 — 48HJ005 Fan Perf ormance — Ve rtical Disc harge Units W ith Standar d Motor Table 13 — 48HJ005 Fan Performance — Ver tical Disch arge Uni ts With Hi gh-Stati c Motor LEGEND AND NOTES FOR T ABLES 12 AND 13 LEGEND NO TES: 1. Boldface indica tes fie ld-s upp lied driv e requi red. (See Note 3.) 2. indicates field -supplied moto r[...]

23 Table 14 — 48HJ006 Fan Perf ormance — Ve rtical Disc harge Units W ith Standar d Motor Single-Phase Un its 3-Phase Units Table 15 — 48HJ006 Fan Performance — Verti cal Discha rge Uni ts With Hi gh-Stati c Motor LEGEND AND NOTES FOR T ABLES 14 AND 15 L EGEND NO TES: 1. Boldface indica tes fie ld-s upp lied driv e requ ired. (See Note 3.) [...]

24 Table 16 — 48HJ007 Fan Perf ormance — Ve rtical Disc harge Units W ith Standar d Motor Table 17 — 48HJ007 Fan Performance — Ver tical Disch arge Uni ts With Hi gh-Stati c Motor LEGEND AND NOTES FOR T ABLES 16 AND 17 LEGEND NO TES: 1. Boldface indica tes fie ld-s upp lied driv e requ ired. (See Note 3.) 2. indicates field -supplied moto r[...]

25 Tab le 1 8 — 4 8HJ004 Fan Perf ormance — Horizontal Discharge Units With Standard Motor Table 19 — 48HJ004 Fan Performance — Horizont al Discha rge Units With Hig h-Static M otor LEGEND AND NOTES FOR T ABLES 18 AND 19 LEGEND NO TES: 1. Boldface indica tes fie ld-s upp lied driv e requ ired. (See Note 3.) 2. Motor dri ve range is 760 to 1[...]

26 Tab le 2 0 — 4 8HJ005 Fan Performance — Horizontal Discharge Units With Standa rd Motor Table 21 — 48HJ00 5 Fan Per formance — Horizo ntal Disc harge Units With H igh-St atic Motor LEGEND AND NOTES FOR T ABLES 20 AND 21 LEGEND NO TES: 1. Boldface indica tes fie ld-s upp lied driv e requ ired. (See Note 3.) 2. indicate s field-su pplied m[...]

27 Tab le 2 2 — 4 8HJ006 Fan Perf ormance — Horizontal Discharge Units With Standard Motor Single-Phase Un its 3-Phase Units Table 23 — 48HJ006 Fan Performance — Horiz ontal Disc harge Units With Hig h-Static M otor LEGEND AND NOTES FOR T ABLES 22 AND 23 LEGEND NO TES: 1. Boldface indica tes fie ld-s upp lied driv e requ ired. (See Note 3.)[...]

28 Tab le 2 4 — 4 8HJ007 Fan Performance — Horizontal Discharge Units With Standa rd Motor Table 25 — 48HJ00 7 Fan Per formance — Horizo ntal Disc harge Units With H igh-St atic Motor LEGEND AND NOTES FOR T ABLES 24 AND 25 LEGEND NO TES: 1. Boldface indica tes fie ld-s upp lied driv e requ ired. (See Note 3.) 2. indicate s field-su pplied m[...]

29 PRE-ST ART -UP Proceed as foll ows to inspect and prepare the unit for initial start-up: 1. Remove all ac cess panels. 2. Read and follow instructions on all W ARNING, CAU- TION, and INF ORMA TION labels at tached to, or shipped with, unit. 3. Make the following inspec tions: a. Inspect for shipping and handling damages such as broken lines, loo[...]

30 NOTE: When the compre ssor is rotating in the wr ong direc- tion, the unit will make an elevated level of noise and will not provide cooling. Cooling — Set space thermostat to OFF position. T o start unit, turn on main power supply . Set system selector switch at COOL position and fan s witch at AUT O. position. Adjust ther- mostat to a settin[...]

31 HEA TING, UN ITS WIT HOUT ECON OMIZER — Wh e n the thermostat cal ls for heat ing, termina l W1 is energized. The induced-draft motor is e nergized and the burner ignition se- quence begins. The indoor (evaporator) fan mot or (IFM) is en- ergized 45 seconds after a flame is ignited. When a dditional heat is needed, W2 is energized and the high[...]

32 Fig. 39 — Moi stureMiser Opti on Operat ion[...]

33 SER VICE Cleaning — Inspect unit interior at the begi nning of heat- ing and cooling season and as operating conditions require. EV APORA T OR COI L 1. T urn unit power of f, tag disconnect. Remo ve evaporator coil access panel. 2. If economizer or two-position damper is installed, re - move economizer by disconnecting Mole x plug and re- movi[...]

34 Condenser -Fan Adjustme nt (Fig. 43) — Shut off unit power supply . Remove condenser-fan assembly (grille, motor , motor cover , and fan) and loosen f an hub setscrews. Adjust fan height as shown in Fig. 43. Tighten setscrews and replace condenser-f an assembly . Economizer Adjustment — Refer to Optional Econo- mizer sections on pages 12 and[...]

35 TO USE COOLING CHARGING CHAR T , ST ANDARD UN I T — T ake the outdoor ambient temperature and read the suction pressure gage. Ref er to charts to dete rmine what suction temperature should be. If suction temperature is high, add refrigerant. If suction tempera ture is low , ca refully recover some of the charge. Recheck the suction pressure as[...]

36 Fig. 48 — Cooling Charging Chart, 48HJ004 with Optional MoistureMiser Dehumidification Pac kage Fig. 49 — Cooling Charging Chart, 48HJ005 with Optiona l Moistur eMiser Deh umidific ation Pa ckage Fig. 50 — Cooling Charging Chart, 4 8HJ006 with Optional MoistureMis er Dehumidifica tion Package Fig. 51 — Cooli ng Chargin g Chart, 48 HJ007 [...]

37 Burner Igniti on — Unit is equipped with a direct spark ignition 100% lockout system. Integrated Gas Unit Controller (IGC) is located in the control box (Fig . 10). A single LED on the IGC provides a visual display of op e rational or sequential problems when the power supply is uninterrupted. The LED can be observed through the viewport. When[...]

38 Fig. 54 — Spar k Gap Adjus tment LO W H EA T 48HJE004, 48H JD005 -007 — 72,000 BTUH INPUT MEDIUM AND HIG H HEA T 48HJE00 5-007, 4 8HJF00 4 — 115,0 00 B TUH INP UT 48HJF005 -007 — 150,000 BTUH INPUT[...]

39 TROUBLESHOO TING Refer to T ables 30-36 for troubleshooting details. Table 30 — LED Error Code Service Analysis LEGEND SYMPTOM CA USE REMED Y Har dware fa ilure. (LED OF F) Loss of power to control module (IGC). Check 5 amp fuse on IGC , power to unit, 24-v circuit break er, and transf or mer. Units without a 24-v circuit breaker ha ve an inte[...]

40 Table 31 — Heatin g Servic e Analysis Table 32 — Durab lade Ec onomi zer Serv ice An alysis LEGE ND PROBLEM C A US E RE MED Y Burners wil l not ignit e . Misaligned spark electrodes. Check flame ignition and sensor electrode positioning. Adjust as needed. No gas at main b urner s. Chec k gas line for air purge as necessar y . After purging g[...]

41 Ta b l e 3 3 — EconoMi$er Flash Code Identification T ab le 34 — EconoMi$er T roubleshooting LEGEND FLASH CODE CA USE A C TION T AKEN BY E CONOMI$ER Constant On Nor mal operation Norm al operation. Constant Off No power No operation. Continu ous Flash CONFIG but ton pushed and held between 3 and 9 sec onds Outdoor air damper is stroked fully[...]

42 Table 35 — MoistureMiser Dehumidification Subcooler Service Analysis PROBLEM CA USE REME D Y Subcoole r will not ener gize . No power to control transformer from ev aporator-fan motor . Check po wer source and e vaporator-f an rela y . Ensure all wire connections are tight. No power f rom control transf or mer to liquid line solenoid valv e 1.[...]

43 Table 36 — Cooling Se rvice A nalysis PROBLEM C A USE REMED Y Compressor and condenser fan will n ot start. P ower f ailure. Call power company . Fuse blown or circuit breaker tripped. Replace fuse or reset circ uit breaker . Def ectiv e thermos tat, contactor , transf o rm er , or control rela y . Replace component. Insufficient line voltage [...]

44 Fig. 55 — Typic al Wiring Schematic and Component Arra ngement (208/230 3-Phas e Unit Sh own)[...]

45 LEGEND AND NO TES FOR FIG. 55 AHA — Adjustable Heat Anticipator C — Contactor , Compress or CAP — Capacitor CC — Cooling Compensator CLO — Compresso r Lock out COMP — Compresso r Motor D — Diode EC — Enthalpy Control ECON — Economizer EPS — Emergenc y P ow er Supp ly EQUIP — Equipm ent ER — Economizer Relay FPT — F reez[...]

Manufactu rer reser ves the rig ht to dis continue , or chan ge at a ny time, spec ificati ons or des igns without notice an d wit hout inc urring obligations. PC 111 Catalog No. 534-767 Prin ted in U.S.A. Form 4 8HJ-18S I Pg 46 9-00 Repla ces: 48 HJ-17S I Book 1 4 Ta b 1 a 6 a Copyright 20 00 Car rier Cor po ration[...]

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Manufactu rer reser ves the rig ht to dis continue , or chan ge at a ny time, spec ificati ons or des igns without notice an d wit hout inc urring obligations. PC 111 Catalog No. 534-767 Print ed in U.S.A. Form 48HJ -18SI Pg CL -1 9 -00 Repl aces: 48HJ-17 SI Book 1 4 Ta b 1 a 6 a Copyright 20 00 Car rier Cor po ration - - - - - - - - - - - - - - - [...]