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Carrier 48TJD008-014 manual

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Table of contents for the manual

  • Page 1

    Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERA TIONS ...................1 INST ALLA TION ............................. 1-22 Step 1 — Provide Unit Support ...............1 • ROOF CURB • SLAB MOUNT Step 2 — Field Fabricate Ductwork ............2 Step 3 — Install External T rap for Condensate Drain ...........[...]

  • Page 2

    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. Step 2 — Field Fabricate Ductwork — Sec[...]

  • Page 3

    UNIT SIZE ‘‘ A’’ ROOF CURB 48TJ ACCESSOR Y 008-014 1 8 -2 9 [356] CRRFCURB003A00 2 8 -0 9 [610] CRRFCURB004A00 UNIT SIZE 48TJ ‘ ‘B’ ’ ‘ ‘C’ ’ ‘ ‘D’ ’ AL T DRAIN HOLE ‘ ‘E’ ’ GAS POWER CONNECTION CONTROL CONNECTION CONNECTOR ACCESSOR Y P ACKAGE 008-014 2 8 -8 7 ⁄ 16 9 [827] 1 8 -10 15 ⁄ 16 9 [583] 1 3 ⁄ [...]

  • Page 4

    Locate mechanical draft system flue assembly at least 48 in. from any opening through which combustion prod- ucts could enter the building, and at least 48 in. from an ad- jacent building or combustible material. When unit is located adjacent to public walkways, flue assembly must be at least 7 ft above grade. Flue vent discharge must have a mini[...]

  • Page 5

    T able 1 — Physical Data UNIT SIZE 48TJ 008D/E/F 009D/E/F 012D/E/F 014D/E NOMINAL CAP ACITY (tons) 7 1 ⁄ 2 8 1 ⁄ 2 10 12 1 ⁄ 2 OPERA TING WEIGHT (lb) Unit Al/Al* 870 880 1035 1050 Al/Cu* 881 896 1057 1077 Cu/Cu* 893 907 1080 1 100 Durablade Economizer 44 44 44 44 P ARBLADE Economizer 62 62 62 62 Roof Curb 143 143 143 143 COMPRESSOR Reciproc[...]

  • Page 6

    T able 1 — Physical Data (cont) UNIT SIZE 48TJ 008D/E/F 009D/E/F 012D/E/F 014D/E FURNACE SECTION Rollout Switch Cutout T emp (F) 195 195 195 195 Burner Orifice Diameter (in. ...drill size) Natural Gas Std .120...31 .120...31 .120...31/.120...31/.129...30 .120...31/.129...30 Liquid Propane Alt .096...41 .096...41 .096...41/.096...41/.102...38 .09[...]

  • Page 7

    UNIT 48TJ ST ANDARD UNIT WEIGHT CORNER WEIGHT (A) CORNER WEIGHT (B) CORNER WEIGHT (C) CORNER WEIGHT (D) ‘‘H’ ’ ‘ ‘J’’ ‘‘K’ ’ ‘‘L ’’ Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg ft-in. mm ft-in. mm ft-in. mm ft-in. mm D/E/F008 870 395 189 86 161 73 239 109 280 127 1-2 7 ⁄ 8 378 3-5 5 ⁄ 16 1050 2-9 11 ⁄ 16 856 2- 2 7 ⁄ 16 672[...]

  • Page 8

    Step 5 — Install Flue Hood — Flue hood is shipped screwed to the burner compartment access panel. Remove from shipping location and, using screws provided, install flue hood and screen in location shown in Fig. 8. Step 6 — Install Gas Piping — Unit is equipped for use with type of gas shown on nameplate. Refer to local build- ing codes, or[...]

  • 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. 1 1) as described in Step s1-4 below . 1. If unit is mounted on roof curb and accessory thru-the- curb service plate connection is used, route wire through connection plate. 2. Pass control wires through the[...]

  • Page 10

    Fig. 10 — Power Wiring Connections LEGEND C— Contactor COMPS — Compressors IFC — Indoor (Evaporator) Fan Contactor NEC — National Electrical Code TB — T erminal Block T erminal Block Connection Splice Connection (Factory Supplied) Field Wiring Factory Wiring LEGEND AHA — Adjustable Heat Anticipator CC — Cooling Compensator TC — Th[...]

  • 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 VVT t systems. The thermostat must be wired to the Apollo contr[...]

  • Page 12

    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 — The op- tional economizer hood assembly is packaged and shipped in the filter se[...]

  • Page 13

    Fig. 19 — Outdoor-Air Hood Details Fig. 20 — V ertical Discharge Block-Off Plate (Sizes 120,150 only) ECONOMIZER CONTROL BOARD ECONOMIZER PLUG ECONOMIZER M OTOR TO P SCREW Fig. 21 — Durablade Economizer Installed in Unit ECONOMIZER CONTROL BOARD ECONOMIZER MO TOR POSITION SETTING BRACKET Fig. 22 — Horizontal Durablade Economizer Installatio[...]

  • Page 14

    Example: Given — Negative Pressure ....................... 0 . 1 i n . w g Outdoor Airflow ........................ 1 1 0 0 c f m Determine — Setting = 6 9 Fig. 24 — Durablade Economizer Damper Minimum Position Setting 4 3 2 1 0 5 6 7 8 9 Fig. 25 — Durablade Economizer Minimum Position Damper Setting MINIMUM POSITION OPEN 3 1 T P P1 T1 4 2[...]

  • Page 15

    OPTIONAL P ARABLADE ECONOMIZER — The op- tional P ARABLADE 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. NOTE: Horizontal discharge block-of f plate is shipped with the air hood package. Th[...]

  • Page 16

    Step 9 — Adjust Evaporator-Fan Speed — Ad- just evaporator-fan speed to meet jobsite conditions. T able 3 shows fan rpm at motor pulley settings, T able 4 shows motor ef f iciencies and T able 5 gives accessory static pressure drops. T able 6 shows motor performance. Refer to T ables 7-14 to determine fan speed settings. Fan motor pul- leys are[...]

  • Page 17

    T able 3 — Fan Rpm at Motor Pulley Settings* UNIT 48TJ MOTOR PULLEY TURNS OPEN 0 1 ⁄ 2 11 1 ⁄ 2 22 1 ⁄ 2 33 1 ⁄ 2 44 1 ⁄ 2 55 1 ⁄ 2 6 008† 840 815 790 765 740 715 690 665 640 615 590 — — 008** 935 910 885 860 835 810 785 760 735 710 685 — — 009† 935 910 885 860 835 810 785 760 735 710 685 — — 012† 935 910 885 860 835[...]

  • Page 18

    T able 4 — Evaporator-Fan Motor Eff iciency MOTOR EFFICIENCY (%) 48TJD/TJE/TJF008,009 80 48TJD/TJE/TJF012 (Std) 80 48TJD/TJE/TJF012 (Alt) 83 48TJD/TJE014 (Std) 85 48TJD/TJE014 (Alt) 87 NOTE: Convert watts to bhp using the following formula: watts input x motor eff iciency bhp = 746 T able 5 — Economizer Static Pressure Drop (in. wg) UNIT 48TJ C[...]

  • Page 19

    T able 7 — Fan Performance, 48TJ008 — V ertical Discharge Units AIRFLOW (Cfm) EXTERNAL ST A TIC PRESSURE (in. wg) 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 2200 506 0.52 586 0.72 656 0.95 718 1.18 776 1.43 838 1.78 898 2.21 935 2.58 2250 514 0.55 593 0.76 662 0.99 724 1.22 781 1.78 841 1.81 [...]

  • Page 20

    T able 9 — Fan Performance, 48TJ012 — V ertical Discharge Units AIRFLOW (Cfm) EXTERNAL ST A TIC PRESSURE (in. wg) 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 3000 592 0.76 661 0.93 722 1.09 779 1.26 829 1.42 880 1.58 924 1.73 970 1.89 1019 2.00 1066 2.30 3100 607 0.83 6[...]

  • Page 21

    T able 1 1 — Fan Performance, 48TJ008 — Horizontal Discharge Units AIRFLOW (Cfm) EXTERNAL ST A TIC PRESSURE (in. wg) 0.2 0.4 0.6 0.8 0.9 1.0 1.2 1.4 1.6 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 2200 499 0.50 580 0.70 652 0.94 717 1.17 748 1.30 779 1.43 839 1.78 905 2.21 951 2.57 2250 507 0.53 586 0.73 658 0.97 722[...]

  • Page 22

    T able 13 — Fan Performance, 48TJ012 — Horizontal Discharge Units AIRFLOW (Cfm) EXTERNAL ST A TIC PRESSURE (in. wg) 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp 3000 552 0.68 632 0.87 701 1.05 761 1.22 816 1.36 871 1.54 918 1.67 967 1.89 1010 2.09 1063 2.46 3100 565 0.74[...]

  • Page 23

    ST ART -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 T able 1). Do not operate unit with- out retu[...]

  • Page 24

    T able 15 — Altitude Compensation* ELEV A TION (Ft) 125,000, 180,000, AND 224,000 BTUH NOMINAL INPUT 250,000 BTUH NOMINAL INPUT Natural Gas Orifice Size† Liquid Propane Orifice Size† Natural Gas Orifice Size† Liquid Propane Orifice Size† 0-2,000 31 41 30 38 2,000 32 42 30 39 3,000 32 42 31 40 4,000 32 42 32 41 5,000 33 43 33 42 6,000 [...]

  • Page 25

    SERVICE When servicing unit, shut of f 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. EV APORA TOR COIL — Clean coil as required. Inspect coil at beginning of heating and cooling seasons. 1[...]

  • Page 26

    Condenser-Fan Adjustment (Fig. 40) 1. Shut of f unit power supply . 2. Remove condenser -fan assembly (grille, motor , motor cover, and fan) and loosen fan hub setscrews. 3. Adjust fan height as shown in Fig. 40. 4. T ighten setscrews and replace condenser-fan assembly . Manual Outdoor-Air Damper — If outdoor-air damper blade is required, see Man[...]

  • Page 27

    Fig. 42 — Cooling Charging Chart; 48TJ009 Fig. 43 — Cooling Charging Chart; 48TJ012 27[...]

  • Page 28

    Flue Gas Passageways — T o 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. Clean all surfaces as required using a wire brush. Combustion[...]

  • Page 29

    REMOV AL AND REPLACEMENT OF GAS TRAIN (Fig. 45 and 46) 1. Shut of f manual gas valve. 2. Shut of f power to unit. 3. Slide out burner section side panel (not shown). 4. Disconnect gas piping at unit gas valve. 5. Remove wires connected to gas valve. Mark each wire. 6. Remove wires from ignitor and sensor wires at the Inte- grated Gas Unit Controlle[...]

  • Page 30

    NOTE: Dimensions in ( ) are millimeters. Fig. 47 — Spark Gap Adjustment 125,000 BTUH INPUT 48TJD008,009 120,000-180,000 BTUH INPUT 48TJD012, 48TJE008,009 48TJD014; 48TJE012 48TJF008,009 48TJE014; 48TJF012 180,000-224,000 BTUH INPUT 200,000-250,000 BTUH INPUT 30[...]

  • Page 31

    TROUBLESHOOTING T able 17 — LED Error Code Service Analysis PROBLEM CAUSE REMEDY Hardware failure. (LED OFF) Loss of power to control module (IGC). Check 5-amp fuse on IGC, power to unit, 24-v circuit breaker , and transformer . Units without a 24-v circuit breaker have an internal overload in the 24-v trans- former . If the overload trips, allow[...]

  • Page 32

    T able 18 — Durablade Economizer T roubleshooting PROBLEM CAUSE REMEDY Damper does not open. Indoor (evaporator) fan is off. 1. Check to ensure that 24 vac is present at terminal C1 on the IFC or that 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). If 24 vac is not present, che[...]

  • Page 33

    T able 19 — P ARABLADE Economizer Service T roubleshooting PROBLEM CAUSE REMEDY Damper does not open. Evaporator fan not on. Check wiring between G on connection board and indoor (evaporator) fan contactor . No power to economizer motor . 1. Disconnect power at TR and TR1. Disconnect jumper across P and P1. 2. Connect jumper across TR and 1. 3. C[...]

  • Page 34

    T able 20 — Cooling Service T roubleshooting PROBLEM CAUSE REMEDY Compressor and condenser fan will not start. Power failure. Call power company . Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker . Defective thermostat, contactor , transformer , or control relay . Replace component. Insuff icient line voltage. Determin[...]

  • Page 35

    T able 21 — Heating Service T roubleshooting 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[...]

  • Page 36

    Fig. 48 — T ypical Wiring Schematic and Component Arrangement 36[...]

  • Page 37

    [...]

  • 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 Ta b 1 a 6 a PC 1 1 1 Catalog No. 564-934 Printed in U.S.A. Form 48TJ-13SI Pg 38 9-96 Replaces: 48TJ-10SI[...]

  • Page 39

    [...]

  • Page 40

    ST ART -UP CHECKLIST (Remove and Store in Job File) I. PRELIMINAR Y INFORMA TION MODEL NO.: DA TE: SERIAL NO.: TECHNICIAN: II. PRE-ST ART -UP (insert checkmark in box as each item is completed) M VERIFY THA T ALL P ACKING MA TERIALS HA VE BEEN REMOVED FROM UNIT M REMOVE SHIPPING TIE DOWN BANDS ON COMPRESSOR (SIZE 014 ONL Y) PER INST ALLA TION INSTR[...]