Carrier 48TJ016-028 manual

48TJ016-028 Single-Package Rooftop Units Electric Cooling/Gas Heating Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS ...................... l INSTALLATION ................................ 2-31 Step 1 -- Provide Unit Support ................... 2 • ROOF CURB • ALTERNATE UNIT SUPPORT Step 2 -- Rig and Place Un[...]

INSTALLATION Inspect unit for transportation dmnage. If &_mage is found, file claim with transportation agency. Step 1 -- Provide Unit Support ROOF CURB -- Assemble and install accessory roof curb or horizont_d a&tpter roof curb in accordance with instructions shipped with this accessory. See Fig. 1 and 2. Install insulation, cant strips, r[...]

CURB PKG. NO. REF. HEIGHT CRRFCURBOIOAO0 1"- 2" (305) CRRFCURBO11AO0 2'- 0" (610) CRRFCURBO12AO0 2'- 0" (610) DESCRIPTION Standard Curb 14" High Standard Curb for Units Requiring High Installation Side Supply and Return Curb for High Installation S'-I0 I/2" =I PLAN VIEW OF ROOF CURB --OUTLINEGPUN,T i BOH[...]

I0'-0" (3048) ,SPREADER BARS "DETAIL A" _ _RIGGING HOOK 3'-7 112" (t t 05) UNIT BASE RAIL SEE "DETAIL A' NOTES: 1. Dimensions in ( ) are in millimeters. 2. Refer to Fig. 4 and 5 for unit operating weights. 3. Remove boards at ends of unit and runners prior to rigging, 4. Rig by inserting hooks into unit base [...]

STD UNIT ECONOMIZER CORNER CORNER CORNER CORNER UNIT WEIGHT WEIGHT A B C D Ib kg Ib kg Ib kg Ib kg Ib kg Ib kg 48TJD, TJF016 1650 748 90 41 423 192 386 175 403 183 438 199 48TJD, TJF020 1800 816 90 41 432 196 410 186 461 209 472 214 DIM A DIM B DIM C ft-in, mm if-in, mm ft-in, mm 3-5 1041 3-5 1041 1-10 559 3-3 991 3-7 1092 1-8 508 L_ NOTES: 1. Refe[...]

BTD UNIT ECONOMIZER CORNER CORNER CORNER CORNER UNIT WEIGHT WEIGHT A B C D Ib kg Ib kg Ib kg Ib kg Ib kg Ib kg 48TJD, TJF024 1850 839 90 41 443 201 406 184 476 216 525 238 48TJ D, TJF028 2000 907 90 41 471 214 428 194 526 239 574 260 DIM A DIM B DIM C ft-in, mm ft-in, mm ft-in, mm 3-2 965 3-5 1041 1-8 508 3-2 965 3-8 1041 1-8 508 TYPICAL 4 CORNERS [...]

Table 1 -- Physical Data 016D/F UNIT 48TJ 020D/F 024D/F 028D/F 208/230, 460 v I 575 v NOMINAL CAPACITY (tons) 15 18 20 25 OPERATING WEIGHT (Ib) 1650 1800 1850 2000 Economizer 90 90 90 90 Roof Curb 200 200 200 200 COMPRESSOR Scroll 1 ...SM120, 1 ...SM120, 1...SM161, Quantity,.,Model (Ckt 1, Ckt 2) 2_.SR*942AE 1_.SR*782AE 1 ._SM110 1 _.SM120 Number o[...]

Table 1 -- Physical Data (cont) UNIT 48TJ FURNACE SECTION Rollout Switch Cutout Temp (F)t Burner Orifice Diameter (in....drill size) Natural Gas Thermostat Heat Anticipator Setting (amps) 208/230, 575 Stage 1 460 v Gas Input Stage 2 Stage 1 Stage 2 Stage 1 Stage 2 Efficiency (Steady State) (%) Temperature Rise Range Manifold Pressure (in. wg) Natur[...]

Step 3 -- Field Fabricate Ductwork -- Secure all 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- sul[...]

INDUCED DRAFT MOTOR COMBUSTION MAIN BURNER HEAT EXCHANGER FAN HOUSING SECTION SECTION Fig. 10- Combustion Fan Housing Location 3/4" FPT DRAIN 1-3/8" CONNECTION DRAIN HOLE Fig. 11 -- Condensate Drain Details (48TJ016 Shown) 3/4 -IN. FPT DRAIN CONNECTION (HALF CO_-- BASE RAIL _@_ ____. (FIELD-SUPPLIED) NIPPLE 3" 8 1/2-1N. (FIELD .... S[...]

Step 8 -- Install Gas Piping -- Unit is equipped for use with natured gas. Installation must conform with loc_d building codes or. in the absence of loc_d codes, with the National Fuel Gas Code, ANSI Z223.1. Install field-supplied manu_d gas shutoff valve with a lh-in. NPT pressme tap for test gage connection at unit. Field gas pip- ing must includ[...]

OPTIONAL NON-FUSED DISCONNECT -- On units with the optiomfl non-fused disconnect, incoming power will be wired into the disconnect switch. Refer to Fig. 16 for wiring for 100 and 200 amp disconnect switches. Units with an MOCP under 100 will use the 100 amp disconnect switch. Units with an MOCP over 100 will use the 200 amp discon- nect switch. Ref[...]

Table 5 -- Electrical Data UNIT 48TJ 016 (15 Tons) 020 (18 Tons) O24 (20 Tons) 028 (28 Tons) NOMINAL VOLTAGE COMPRESSOR OFM VOLTAGE RANGE No. 1 No, 2 (3Ph, 60Hz) Min Max RLA LRA RLA LRA Q_ Hp FLA(ea) Hp 208/230 460 575 208/230 460 575 208/230 460 575 208/230 46O 575 POWER COMBUSTION IFM EXHAUST FAN MOTOR FLA FLA LRA FLA 187 253 25.6 190 25.6 190 3 [...]

Step 10 -- Make Outdoor-Air Inlet Adjust- ments MANUAL OUTDOOR-AIR DAMPER -- All units (except those equipped with a factory-inst_dled economizer) have a manual outdoor-air &tmper to provide ventilation ail: Damper can be preset to admit up to 25% outdoor air into return-tdr compartment. To adjust, loosen secunng screws and move &tmper to d[...]

Step 12 -- Install All Accessories-- Install all field-installed accessories. Refer to the accessoly installation instructions included with each accessory. MOTORMASTER® I CONTROL INSTALLATION (48TJ016,020 UNITS) Install Field-Fabricated Wind Baffles -- Wind baffles must be field-fabricated for all units to ensure proper cooling cycle operation at[...]

MOTORMASTER® V CONTROL INSTALLATION (48TJ024,028 UNITS) Install Field-Fabricated Wind Baflles -- Wind baflles must be field-fabricated for all units to ensure proper cooling cycle operation at low ambient temperatures. See Fig. 21 for baflle details. Use 20-gage, galvanized sheet metal, or similar corro- sion-resistant metal for baffles. Use field[...]

Step 13 --Adjust Factory-Installed Options PREMIERLINK TM CONTROL -- The PrelnierLink control- ler is available as a special order from the facto U and is com- patible with the Ctmier Comfort Network® (CCN) system. This control is designed to allow usel_ the access and ability to change factoly-defined settings, thus expanding the function of the [...]

SAT GRN WHT BLU _] BLUE (_ BRN (_ BLK BRN i ORN BRN • BRN VlO • VlO [_ BRN OAT PNK RED BRN BLU GRN YEL BLU RED RED RED _Lu RRN BLK COM BRN CO_'_ w• _ BRN COM RED _ COM DDC CONF{OL GRN_ RED _ YEL RED _ BLU RED FT FsD : PremierLink Control (_-- WNT CL01 DDC CONTROL R TSTAT CONTROL CMP SAFE Y1 Y1 FSD Y2 Y2 SFS Wl Wl NOT USED W2 W2 RMTOCC G [...]

Table 8 -- PremierLink TM Sensor Usage OUTDOOR AIR RETURN AIR OUTDOOR AIR RETURN AIR APPLICATION TEMPERATURE SENSOR TEMPERATURE SENSOR ENTHALPY SENSOR ENTHALPY SENSOR Differential Dry Bulb Temperature with Required -- PremierLink* Included -- 33ZCT55SPT -- -- (PremierLink HH79NZ039 or Equivalent requires 4-20 mA Actuator) Single Enthalpy with Requi[...]

Thermistor fSensor Fig. 26 -- Enthalpy SwitchlReceiver Dimensions (33CSENTHSW) Thermistor _ S Humidi_ Sensor I Fig. 27 -- Enthalpy Sensor Dimensions (33CSENTSEN) / o ....... _(OR UNIT GROUND) *Used with Differential Enthalpy Control only, TM Fig. 28 -- Typical Wiring Schematic -- Carrier Rooftop Unit with PremierLink Controls 20[...]

DIFFERENTIAL ENTHALPY CONTROL (Fig. 29) -- Diffemntifd enthalpy control mquiles both fin enthalpy switch/ receiver (33CSENTHSW) and fin enthalpy sensor (33CSENTSEN). The enthalpy switchkeceiver is mounted in the outdoor air inlet and calculates outdoor air enthalpy. Tile enthalpy sensor is mounted in the return airstream and cfflcu- lates the entha[...]

Enthalpy Sensor Jumper Settings -- There me two jumpers. One julnper determines the mode of the enthalpy sensor. The other jumper is not used. To access the jumpers, relnove the 4 screws holding the cover on the enthalpy sensor and then re- move the covel: The factory settings for the jumpers are M3 and OFF. The mode jumper should be set to M3 for [...]

OPTIONAL ECONOMISERIV AND ECONOMISER2 -- See Fig. 32 and 33 for EconoMiSerIV component locations. See Fig. 34 for EconoMi$er2 component locations. NOTE: These instructions are for installing the optional EconoMiSerIV and EconoMiSer2 only. Refer to the accessory EconoMiSerIV or EconoMiSer2 installation instructions when field installing an EconoMi$e[...]

L1 _4 L1 -S - (NOT BSEDI L1-9 m PLI _8 TO MAIN PLI _5 CONTROL /_ I BOX PL1-6 PLI-II 1 PLI*I PLI _R PL1-10 (NOT USED) LEGEND DCV -- Demand Controlled Ventilation IAQ --Indoor Air Quality LALS I Low Temperature Compressor Lookout Switch OAT IOutdoor_Air Temperature POT -- Potentiometer -- ORN (FIE£B ACCESSORY} REMOTE MIN POSITION POT _E_T[ POT (ISS_[...]

ECONOMISERIV STANDARD SENSORS Outdoor Air Temperature (OAT) Sensor -- The outdoor air temperature sensor (HH57AC074) is a 10 to 20 mA device used to measure the outdoor-air temperature. The outdoor-air temperature is used to determine when the EconoMiSerIV can be used for free cooling. The sensor must be field-relocated. See Fig. 32. The operating [...]

19 18 17 16- 15 < E14 13 12 11 lO 9 40 I LED ON -- - LED OFF 45 50 55 _ED ON LED O; _< LED ON-- -- "t,4 I LED OFF { 65 70 75 80 85 90 95 100 DEGREES FAHRENHEIT Fig. 38 -- Outside Air Temperature Changeover Set Points Outdoor Enthalpy Changeover -- For enthalpy control, tic- cessoq enthalpy sensor (part number HH57AC078) is required. Repl[...]

CONTROL CONTROL POINT CURVE APPROX. °F (°C) AT 50% RH A 73 (23) B 70 (21) C 67/19) D 63 (17) 85 90 95 100 105 110 (29) (32) (35) (38) (41) (43) 1 /I XI IX _ 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 (2) (4) (7) (10) (13) (16) (18) (21) (24) (27) (29) (32) (35) (38) (41) (43) APPROXIMATE DRY BULB TEMPERATURE-- °F (°C) Fig. 40 -- Enth[...]

2. Disconnect the supply-air sensor from termimds T and TI. 3. Ensure that file factory-installed jumper is in place across terminals P and PI. If remote damper positioning is being used, make sure that file tenninals are wired according to Fig. 35 and that the minimum position potentiometer is turned fully clockwise. 4. Connect 24 vac across termi[...]

Table 13 -- 002 Sensor Standard Settings ANALOG OUTPUT SETTING 1 2 3 4 5 6 7 8 EQUIPMENT Interface with Standard Building Control System Economizer Health & Safety 9 Parking/Air Intakes/ Loading Docks LEGEND ppm -- Parts Per Million OUTPUT Proportional Proportional Exponential Proportional Proportional Exponential Exponential Proportional Propo[...]

MOISTUREMI$ER _-_YEL- BLK ?-_ BLK_ YEL TRANt 2_4_ GRN-YEL LEGEND CB -- Circuit Breaker LLSV -- Liquid Line Solenoid Valve LPS -- Low-Pressure Switch TB -- Terminal Block TRAN -- Transformer TRAN 24V GRN-YEL TO CRANKCASE 1HEATER CIRCUITS BLK BLK LLSVksv_ _ S-LPS1 CB4 TB3 BLK-- 3.2 AMPS S LPS2 L FACTOR (OR HUMIDISTATIF USED) Fig. 43- Typical Moisture[...]

CONDENSER COiL , SUCTION l DISCHARGE F CCH CRANKCASE HEATER OUTDOOR AiR EVAPORATOR COIL S-LPS J SUB COOLERCONTROL LOW PRESSURESWITCH TXV SUBCOOLER / COIL EQUALIZER LINE INDOOR AIR 3-WAY VALVE TXV -- Thermostatic Expansion Valve Fig. 45 -- MoistureMi$er TM Dehumidification Package Operation Diagram START-UP Use the following information and Start-Up[...]

AIRFLOW (cfm) 4500 4800 5100 5400 5700 6000 6300 6600 6900 7200 7500 Table 14 -- Fan Performance -- 48TJD016 (Low Heat Units) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 0.2 0.4 0,6 0,8 1.0 1.2 Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts 809 1.83 1317 906 1.74 1502 994 1.96 1690 1078 2.18 1882 1156 2.41 2077 [...]

Table 16 -- Fan Performance -- 48TJD028 (Low Heat Units) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) AIRFLOW (cfrn) 0.2 0.4 0.6 0.8 1.0 1.2 Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts 7,000 941 3,35 2769 1002 3.60 3140 1061 4,27 3528 1117 4.76 3934 1171 5.27 4356 1224 5.60 4794 7,500 999 4,05 3346 1057 4.53 3[...]

Table 18 -- Fan Performance- 48TJF020 and 024 (High Heat Units) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) AIRFLOW (cfm) 0.2 0.4 0.6 0.8 1.0 1.2 Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts 5_500 795 2.43 2043 866 2.74 2306 934 3.07 2578 998 3.40 2856 1059 3.74 3142 1117 4.08 3434 6,000 854 2.92 2452 921 3.24[...]

UNIT 48TJ 016 020 024 028 Table 20 -- Air Quantity Limits MINIMUM COOLING CFM 4500 5400 6000 7000 MINIMUM HEATING CFM Low Heat High Heat 3800 3800 4750 5450 4750 5450 4750 5450 MAXIMUM CFM 7,500 9,000 10,000 11,250 Table 21 -- Accessory/FlOP Static Pressure* (in. wg) -- 48TJ016 4500 CFM COMPONENT 5000 6000 7200 7500 Economizer 0.04 0.05 0.07 0.09 0[...]

UNIT UNIT 48TJ VOLTAG E 208/230 016 460 575 208/230 020 460 575 208/230 024 460 575 208/230 028 460 575 LEGEND BHP -- Brake Horsepower BkW -- Brake Kilowatts Table 25 -- Evaporator-Fan Motor Data MAXIMUM MAXIMUM MAXIMUM ACCEPTABLE ACCEPTABLE ACCEPTABLE CONTINUOUS BHP* CONTINUOUS BkW* OPERATING WATTS 4.25 3.17 3,775 4.25 3.17 3,775 3.45 2.59 3,065 5[...]

Above 50 F supply-air temperature, the dmnpers will modu- late from 100% open tothe minimum open position. From 50 F to 45 F supply-air temperature, the &tmpers will maintain atthe minimum open position. Below 45 F the &lmpers will be completely shut. As thesupply-air temperature rises, the dampers will come back open to the minimum open po[...]

into the zone. The supply air will maintain the space tempera- ture between the heating and cooling set points as indicated in Fig. 47. The PremierLink TM will integrate the compressol_ stages with the economizer based on similar logic as the three routines listed in the previous section. The SASP will float up and down based on the error reduction[...]

SERVICE Before performing service or maintenance operations on unit, turn off main power switch to unit and install lockout tag on disconnect switch. Electrical shock could cause per- sonal injury. Cleaning- Inspect unit interior at beginning of each heating and cooling season and as operating conditions require (see Fig. 48). Remove unit top panel[...]

10. Ensure surfaces are not allowed to &y before rinsing. Reapplying cleaner as needed to ensure 10-minute satura- tion is achieved. 11. Thoroughly rinse _dl surfaces with low velocity clean water using downward rinsing motion of water spray nozzle. Protect tins from &_mage from the spray nozzle. CONDENSATE DRAIN- Check and clean each year [...]

Evaporator Fan Service and Replacement 48TJ016 UNITS (See Fig. 51 ) NOTE: To lemove belts only. follow Steps 1-6. 1. Remove filter and supply-air section panels. 2. Remove unit top panel. 3. Loosen carriage nuts A and B holding motor mount assembly to fan scroll side plates. 4. Loosen screw C. 5. Rotate motor mount assembly (with motor attached) as[...]

9. Slide out the motor and motor mounting plate. 10. Disconnect wiring connections and remove the 4 mount- ing bolts. 11. Remove the motol: 12. To inst;dl the new motor, revel.se Steps 1-11. Belt Tension Adjustment -- To adjust belt tension: 1. Loosen fan motor bolts. 2. a Size 016 Units: Move motor mounting plate up or down for proper belt tension[...]

Gas Valve Adjustment NATURAL GAS- The gas valve ()pens and closes in re- sponse to the thermostat or limit control. When power is supplied to valve terminals DI and C2, the m;dn v_dve opens to its preset position. The regular factory setting is stamped on the v;dve body (3.3 in. wg). To adjust regulator: 1. Set thermostat at setting for no call for[...]

Optional Hinged Access Doors --When the optional 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 dool_ to facilitate service. Four external hinged access doors are provided. All extern;d doors _ue provided with 2 large 1/4 turn latches with folding ba[...]

A_TO I I I -k_:, °AUTO SCHEMATIC L_ B _ CAP_ CAP2 gff__ gg£ OrMZ o_ __ __ % -- -- ORN_.._ ,<] D 4 i ...... [ 12 ® - ._ y_4t J® _ .... , GROUNOZO ?_RU STAWO0_ IFC ore IELD THERMOSTAT ....... ___t_tu ! TO _CONO"IZ_R O_IIO"/_CC_SSOR_ "X_,'_ -- O_C,p,wr_P" K | TO gCONOI_IZER OPTIOR/aCCZSSO_y R D PL1-12 L _ _o,,-<_o. /[...]

LEO IG¢ 1 J2 © COMPONENT ARRANGEMENT CONTROL BOX 0 0 ®@@ II--_LK OFMI , 2,3 _Lt,R • II.. Iii i i__ i IIII o_, --I I II.=, GAS SECTION BtK 2v _Ov [_pt p_ _x_ [ ......... 80AeO []_" 0 _1011 ,IOli ,1Oll ,IOll PL_ Fig. 59 -- Typical Component Arrangement (48TJ016 Unit Shown) I 46[...]

LEGEND AND NOTES FOR FIG. 58 AND 59 LEGEND AHA -- Adjustable, Heat Anticipator SN -- Sensor BKR W/AT -- Breaks with Amp Turns TB -- Terminal Block C -- Contactor, Compressor TC -- Thermostat Cooling CAP -- Capacitor TH -- Thermostat Heating CB -- Circuit Breaker TRAN -- Transformer CC -- Cooling Compensator CLO -- Compressor Lockout _ Terminal (Mar[...]

TROUBLESHOOTING Unit Troubleshooting- Refer to Tables 27-29 and Fig. 60. EconoMi$erlV Troubleshooting-- See Table 30 for EconoMi$erlV logic. A limctional view of the EconoMiSerlV is shown in Fig. 61. Typic_d settings, sensor ranges, and jumper positions ale also shown. An EconoMiSerIV simulator program is available from Ctuder to help with EconoMi$[...]

Table 27 -- Cooling Service Analysis PROBLEM CAUSE REMEDY Compressor and Power failure. Call power company. Condenser Fan Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Will Not Start. Defective thermostat, contactor, transformer, or control Replace component. relay. Insufficient line voltage. Determine cause and corr[...]

Table 28 -- Heating Service Analysis PROBLEM CAUSE 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, Dirty air filter. Gas[...]

I_-INDO(:W_FANI)EI.AY J___ (HEATING) 2 _S - OFmNING OF LIMff SWRCH 3 _S - _ 81_813f1 IN_CATES FLAME WITH CLOSED C:':':':':':':':':_ VALVE 4 FI.ASI'E8 - LIW_ SWITCH CYCLED 4 TIMES ON SINGLE CALL FOR HEAT (No _ wth_ 15 _) 6 FI.ASHES - iNDUCED DRAFT MOTOR FAULT (NOsigr_ frem f_'_ _ !_t 8enm:,r for B0 m[...]

Table 30 -- EconoMi$erlV Input/Output Logic Demand Control Ventilation (DCV) Below set (DCV LED Off) Above set (DCV LED On) INPUTS Enthalpy* Compressor Outdoor Return Y1 Y2 Stage Stage 1 2 High Low On On On On (Free Cooling LED Off) On Off On Off Off Off Off Off Low High On On On Off (Free Cooling LED On) On Off Off Off Off Off Off Off High Low On [...]

Altitude compensation lO Burner spark gap 44 Carrier Comfort Network@ 17 Changeover set points 26 Charging chart, ret_igerant 42 Clearance 5, 6 CO2 sensor Configuration 28 Settings 27, 29 Combustion blower wheel 40 Compressor Lubrication 40 Mounting 31 Rotation 31 Concentric duct 9 Condensate drain Cleaning 40 Location 9, 10 Condenser coil 7 Cleani[...]

SERVICE TRAINING Packaged Service Training programs tue an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • [nstallation Overview • Maintenance • Opel_ting Sequence A large selection of pl_duct, theory, and skills programs are available, using popular video-based formats[...]

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START-UP CHECKLIST MODEL NO.: SERIAL NO.: DATE: TECHNICIAN: PRE-START-UP [] VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT [] VERIFY INSTALLATION OF INDOOR FAN MOTOR ADJUSTMENT BOLT AND PLATE (48TJ020-028 ONLY) [] VERIFY INSTALLATION OF OUTDOOR-AIR HOOD [] VERIFY INSTALLATION OF FLUE HOOD AND WIND BAFFLE [] VERIFY THAT CONDENSATE CON[...]