Carrier 48TM016-028 manual

Manufa cturer res erves the right to discon tinue, or chang e at any time , specificat ions or designs witho ut notic e and wit hout inc urring obligati ons. Catalog No. 04-5348 0016- 01 Pr inted in U.S.A. Form 48T M-4SI Pg 1 3-06 Replace s: 48T M-3SI Book 1 4 Ta b 1 a 6 a Installation, Star t-Up and Ser vice Instr uct ions CONTENTS Page SAFETY CON[...]

2 INST ALLA TION Inspect unit for transportation dam age. If damage is found, file an y claim with t he tran sporta tio n agenc y . Step 1 — Pro vide Unit Support RO O F CU R B — Assemble and install accessory roof curb or horizontal adapter roof curb in accordance with instructions shipped with this accessory . See Fig. 1-2B. Install insulatio[...]

3 Fig. 2A — Roof Curb Detail s — 48TM016-025[...]

4 Fig. 2B — Roof Curb Details — 48TM028[...]

5 NOT ES: 1. Dimensions in ( ) are in millimeters . 2. Refer to Fig. 4-6 f or unit operating weights. 3. Remove boards at ends of unit and r unners pr ior to r igging. 4. Rig by inser ting hooks into unit base rails as shown. Use cor ner post from packaging to prot ect coil from damage. Use bumper boards f or spreader bars on all units. 5. Weights [...]

6 Fig. 4 — Base Unit Dimen sions — 48T M016,020[...]

7 Fig. 5 — Base Unit Dimensions — 48T M025[...]

8 Fig. 6 — Base Unit Di mensions — 48TM028[...]

9 Table 1 — P hysical D ata LEGEND *The ZRU140KC compressor is a tandem compre ssor , consisting of a ZR72K C (25% to tal capacity) and a ZR68KC (24% total capacity). †Circuit 1 uses the lower portion of the condenser coil and lower p or tion of the ev aporator coils; and Circuit 2 uses t he upper por tion of both coils . **Pulley has 6 turns. [...]

10 Table 1 — Physical Data (cont) LEGEND *The ZRU140KC compressor is a tandem compre ssor , consisting of a ZR72K C (25% to tal capacity) and a Z R68KC (24% t otal capacity). †Circuit 1 uses the lower portion of the condenser coil and lower p or tion of the ev aporator coils; and Circuit 2 uses t he upper por tion of both coils . **Pulley has 6[...]

11 Step 3 — Field F abricate Ductwor k — Secure all ducts to building structure. U se flexible duct c onnectors be- tween unit and ducts as required. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in acc ordance with applicable code s. Ducts passing through an unconditioned space must[...]

12 Step 7 — Orifice Change — This unit i s factory as- sembled for heating operation using natural gas at an elevation from sea level to 2000 ft. This unit uses orifice type LH32RFnnn, where “nnn” indicates the orifice size based on drill size diameter in thousands of an i nch. HIGH ELEV A TION (Above 2000 ft) — Us e ac ce ss o ry h ig h [...]

13 Step 8 — Install Gas Pi ping — Unit is equipped for use with natural ga s. Installation must conform with l ocal building codes or , in the absence of l ocal codes, with t he National Fuel Gas Code, ANSI Z223.1. Install field-supplied m anual gas shutoff valve with a 1 / 8 -in. NP T pressure tap for test gage connection at unit. Fiel d gas p[...]

14 OP TIONAL NON-F USED DISCONNEC T — On unit s with the optional non-fused disconnect, incoming power w ill be wired into the disconnect switch. Refer to Fig. 17 for wiring for 100 and 200 amp disconnect swi tches. Units with an MOCP (maximum overcurrent protect ion) under 100 will use the 100 amp disconnect switch. Units with an MOCP over 100 w[...]

15 Table 5 — E lectrical Data LEGEND *Fuse or HACR ci rcuit br eaker . NO TES: 1. In compliance with NEC r equirements for multimotor and combin ation load equ ipment ( refer to NEC Ar ti cles 430 a nd 440) , the overcurrent p ro- tective de vice for the unit shall be fuse or HA CR breaker . Canadian units m a yb ef u s eo rc i r c u i tb r e a k[...]

16 Step 10 — Make Outdoor -Air Inlet Adjust- ments MANUAL OUTDOOR-AIR DAMPER — All un i ts (ex c ep t those equipped with a fac tory-installed economizer) ha ve a manual outdoor-air damper to provide ventilation air . Damper can be preset to admit up to 25% outdoor air into return-air compar tment. T o adjust, loosen securing screw s and move d[...]

17 Step 12 — Install All Accessori es — After all th e factory-installed opt ions have been adj usted, install all f ield- installed acc essories . Refer to the accessory insta llati on instructions included with each ac cessory . MOTORMASTER® I CONTROL INST ALLA TION (48TM016, 020, and 028) Install Field-Fabricated W ind Baffles — Wind baf [...]

18 MOTORMASTER® V CONTROL INST ALLA TION (48TM025 On ly) Install Field-Fabricated W i nd Baffles — Wind baffles must be field-fabricated for a ll units to ensure prope r cooling cycl e operation at low ambi ent temperatures. See Fig. 22 for baffle details. Use 20-gage, galvanized s heet metal, or similar corrosion-resistant metal for baffles. Us[...]

19 Step 13 — Adjust Factory- Installed Opti ons PRE MIE RL INK ™ CO NTRO L — The Prem ier Lin k cont rol- ler is available as a special order from the factory and is com pati ble wit h the Carr ier Co mfor t Netwo rk® (CC N) sys- tem. This control is designed to allow users the access and abil- ity to change factory-defined settings, thus ex[...]

20 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 25 1 SA T OA T RED WHT RED BLU YEL VIO BRN ORN BRN BLK BRN BLUE ECONO NOT USED RELA YS RED RED RED RED RED RED R Y1 Y2 W1 W2 G C X ORN GRN PNK BRN RED RED RED RED BRN BRN RED BLU ORN PNK WHT BLU YEL GRN R Y1 Y2 W1 W2 G FIELD THERMOST A T* C X WHT X CLO1 R W2 W 9 8 G IGC PL1 PL1 IGC [...]

21 T abl e 8 — P rem ierL ink ™ Se nsor Usa g e *PremierLink control requires supply air temperature sensor 33ZCSENSA T and outdoor air temper ature sensor HH79NZ039 — Included with f ac tory -installed PremierLink control; field-supplied and field-installed with f ield-installed PremierLink control. NO TES: 1. CO 2 Sensors (Optional): 33ZCSE[...]

22 Fig. 27 — Enthalpy Switch/Receiver Dime nsions (33CSENTHSW) Fig. 28 — Enthalpy Sensor Dimensions (33 CSENT SEN) Fig. 29 — Typical Wiring Schematic — Ca rrier Rooftop Unit with PremierLink™ Controls *Used with Differential Enthalp y Control only .[...]

23 DIFFERENTIAL ENTHALPY CONTRO L (Fig. 30) — Differential enthalpy control requires both an enthalpy switch/ receiver (33CSENTHSW) and an e nthalpy sensor (33CSENTSEN). The enthalpy switch/ receiver i s mounted in the outdoor air inlet and calculates outdoor air e nthalpy . The enthalpy sensor is mounted in the return airstream and calcu- lates [...]

24 The mode jumper should be set to M3 for 4 to 20 mA output. The factory test jumper should remain on OFF or the enthalpy sensor will not calculate enthalpy . ENTH ALP Y SENS ORS AN D CONT ROL — T he en t ha lpy control (HH57AC077) is suppl ied as a field-installed accessory to be used w ith the EconoMi$er2 damper control option. The outdoor air[...]

25 Outdoor air leakage is shown in T able 9. Return air pressur e drop is shown in T able 10. T able 9 — O utdoor Air Damper Leakag e T able 10 — Return A ir Pressure Drop (in. wg) ECONOMI$ERIV ST ANDAR D SENSORS Outdoor Air T emperature (OA T) Sensor — The outdoor ai r temperature sensor ( HH57AC074) is a 10 to 2 0 mA device used to measure [...]

26 LEGEND DCV — Demand Controlled V entilation IAQ — In door Air Q uality LALS — Low T emperatur e Comp ressor Loc k out Swi tch OA T — O utdoor-Ai r T emperature PO T — Potentiom eter P otentiome ter Default Settin gs: P ower Exhaust Middle Minimum P os. Fully Closed DCV Max . Mi ddl e DCV Set Middle Enthalpy C S etting NO TES: 1. 620 oh[...]

27 ECONOMI$ERIV CONTROL MOD ES Determine the EconoMi$erIV c ontrol mode before set up of the control. Some modes of operation may requi re different sen- sors. Refer to T able 12. The E cono Mi$e rIV is suppl ied from th e factory with a supply air temper ature sensor , a low temperature compres sor lockout switch, and an out door air tempera ture [...]

28 Outdoor Enthal py Changeover — F or enthalpy control, ac - cessory enthalpy sensor (part number H H57AC078) is required. Replace the standard out door dry bulb temperatur e sensor with the accessory enthalpy sensor in the same mount- ing location. See Fig. 33. When the outdoor air enthalpy rises above the outdoor enthalpy changeover set point,[...]

29 T ypically the maximum ventilation rate will be about 5 to 10% more than the typica l cfm required per person, using normal outside air desi gn criteria. A proportional anticipat ory strategy shoul d be taken wit h the following conditions: a zone with a large area, varied occ u- pancy , and equipment t hat cannot exceed the required ventila - t[...]

30 In order to have the CO 2 sensor control the ec onomizer damper in this manner, first determine the damper voltage out- put for minimum or base ventilation. Base ventilation is the ventilation require d to remove cont aminants duri ng unoccu- pied periods. The following equation may be used to determine the percent of outside-air entering the bu[...]

31 Step 14 — Install Humi distat f or Optional Moisture Mi $er™ P acka ge — Moist ureMi $er dehu- midificati on package ope ration can be c ontrolled by fiel d instal lation of a Carri e r-a pproved hu midistat . T o install t he humidistat p erform t he following pr ocedure: 1. Locate humidis tat on a solid interior wall in the condi- tioned[...]

32 Fig. 46 — Mois tureMi$er™ Dehumidification Operation Diagram TXV — Thermost atic Expansion V alve[...]

33 ST ART - UP Use the following information a nd Start-Up Checklist on page CL-1 to check out unit PRIOR to sta rt-up. Unit Preparation — Check that unit has been installed in accordance with these installation instructions and all applica- ble codes. COMPRESSOR MOUNTING — Com p re sso rs are in ter nal - ly spring mounted. Do not loosen or re[...]

34 Table 14 — Fan Perform ance — 48TMD016 (Low Heat Units) * LEGEND *Standard low-medium static drive range is 873 to 1021 rpm. Alter- nate high-static drive range is 1025 to 1200. Other rpm s require a field-supplied drive. Refer to page 39 for general F an P erformance Data notes. NO TE: Maximum continuous bhp f or the standard motor is 6.13.[...]

35 Table 15 — Fan Pe rformance — 4 8TMF016 ( High Heat Un its)* LEGEND *Standard low-medium static drive range is 873 to 1021 rpm. Alter- nate high-static drive range is 1025 to 1200. Other rpm s require a field-supplied drive. Refer to page 39 for general F an P erformance Data notes. NO TE: Maximum continuous bhp f or the standard motor is 6.[...]

36 Table 16 — Fan Perform ance — 48TMD020 (Low Heat Units) * LEGEN D *Stand ard low-med ium static d rive range i s 910 to 1 095 r pm. Al tern ate high- static dr ive range is 106 9 to 12 87. Oth er r pms re quire a fie ld-supp lied dr ive. Refer to pag e 39 for gen eral Fan P er forman ce Dat a notes. NOTE: Maximum con tinuous b hp is 5.9 0. T[...]

37 Table 18 — Fan Perform ance — 48TMD025 (Low Heat Units) * LEGEND *Standard low-medium static dr iv e range is 1002 to 1151 r pm. Alter- nate high-static drive range is 1193 to 1369. Other rpm s require a field-supplied drive. Refer to page 39 for general F an P erformance Data notes. NO TE: Maximum continuous bhp for the standard motor is 8.[...]

38 Table 19 — Fan Pe rformance — 4 8TMF025 ( High Heat Un its)* LEGEND *Standard low-medium static dr iv e range is 1002 to 1151 r pm. Alter- nate high-static drive range is 1193 to 1369. Other rpm s require a field-supplied drive. Refer to page 39 for general F an P erformance Data notes. NO TE: Maximum continuous bhp for the standard m otor i[...]

39 Table 20 — Fan Perform ance — 48TMD028 (Low Heat Units) * LEGEND *Stand ard low-med ium stat ic dri ve range is 1066 to 1283 r pm. Alter na te high- static dr ive range is 133 2 to 15 50. Oth er r pms re quire a fie ld-supp lied dr ive. Refer to this p age for gen eral Fan P er forman ce Data n otes. NOTE: Maximum co ntinuous b hp is 10. 20 [...]

40 Table 22 — Air Q uantity Limits Table 23 — Accessory /FIOP St atic Pre ssure (in . wg)* — 48TM016-02 8 LEGEND *The static press ure must be added to exter nal static pr essure. The sum and the evaporator enter ing-air cfm sho uld then be used in con j uncti on with the F an Pe rf ormance tab les to determi ne b low er r pm and wa tts . Tab[...]

41 Operating Sequ ence COOLING , UNITS WITHOUT ECONOMIZER — W h e n thermostat calls for c ooling, terminals G an d Y1 are ener gized. The indo or (evap orator) f an contacto r (IFC), compressor c on- tact or no. 1 (C 1) and out door -fan contact or (OFC ) are ener - gized, an d evaporat or -fan moto r , compressor no. 1, a nd both conden ser fan[...]

42 Routin e 3 (OA T > 68) • Econom izer is opened 1 00%. • Compressor s 1 and 2 are cycled based on Y1 and Y2 using minimum on and off times and watching the sup- ply ai r temp er ature as c omp ared t o SA TLO 1 and SA TLO2 set points. If optional power exhaust is installed, as the out door- air damper opens and closes, the power e xhaust f[...]

43 HEA TING , UN IT WITH ECONOMI$ER2, PREM IERLINK CON TRO L AN D A ROO M SE NSO R — Every 40 seconds the contro ller will calc ulate the re quired heat stages (maxi mum of 3) to maintain supply air t emperature (SA T) if the following qualifying conditions are met: • Indoor fan h as been on fo r at least 30 seconds. • COOL mode is not active[...]

44 F A N SH A F T B E A R IN G S — Lubricat e bearings at least every 6 months with suitable bearing grease. Extended grease line is provided for far side fan bearing (opposite drive side). T ypical lubricants are give n below: *Preferred lubricant because it contains r ust and oxidat ion inhibitors. CONDENSER AND EV AP ORA TOR -F AN MOT OR BE A [...]

45 Belt T ension Adjustment — T o adjust belt tension: 1. L oose n fa n mot or bo lts. 2. T urn m otor jacking bolt to move motor mount ing plate up or down for proper belt tension ( 3 / 8 in. deflect ion at midspan with one finger [9 lb force]). 3. Tighten nuts. 4. Adjust bolts and nut on mounting plate to secure motor in fixed position. Condens[...]

46 Gas V alve Adjustment NA TU RA L GA S — The gas valve opens and closes in response to the therm ostat or limi t control. When power is supplied t o valve terminals D1 and C2, the main valve opens to its preset position. The regular factory setting is st amped on the valve body (3.3 in. wg). T o adjust regulator: 1. Set thermost at at setting f[...]

47 Diagnosti c IGC Control LEDs — The IGC board has LEDs for diagnostic purposes. Re fer to T roubleshooting s e c t i o no np a g e5 1 . Optional Hinged Access Doo rs — When the optional service p ackage is o rdered or the if the hing ed access doo rs option is ordered, the unit will be provided with external an d internal hinged access doors [...]

48 Fig. 57 — T ypical Wi ring S chematic (48TM 016,020 — 2 08/230 V S hown)[...]

49 Fig. 58 — T ypical Component Arrangement[...]

50 AHA — Ad j usta ble Heat Anticipator C— Contacto r , C ompressor CAP — Capa citor CB — Circuit Breaker CC — Cooli ng Co mpensator CH — Crankc ase Heater CLO — Compre ssor Lockout COMP — Com pressor Motor CR — Cont rol Relay DM — Damper Mo tor DU — Dumm y T erminal EQUIP — Equipmen t FPT — F reeze Protection Ther m ostat[...]

51 TROUBLESHOO TING Unit T rou bleshootin g — Refer to T ables 27-29 and Fig. 59. EconoMi$erIV T roub leshooting — See T able 30 for EconoMi$er IV logic. A functional view of the EconoMi$erIV is shown in Fig. 60. T ypic al settings, sensor ranges, and jumper positions are also shown. An EconoMi$erIV simulator program is available from Carrier t[...]

52 7. Remove jumper from TR to N. 8. Remove jumper from TR to 1. 9. Remove 5.6 kilo-ohm resistor from T and T1. Rec onnect wires at T a nd T1. 10. Remove jumper from P to P1. R econnect device at P and P1. 1 1. Apply powe r (24 vac) to terminals TR and TR1. Table 27 — Cooling Se rvice Analysi s LEGEND TXV — Ther mostatic Expansion V alve PROBLE[...]

53 Table 28 — Heating Servic e Analysis LEGEND GR — Ground Table 29 — MoistureM i$er™ Deh umidificat ion Subcool er Service Analysis PROBLEM CAUSE REME D Y Burners Will Not Ignit e. Misaligned spark electrodes. Check flame ignition and sensor electrode positioning. Ad j ust as needed. No gas at main burners. Check gas line f or air ; purge [...]

54 Table 30 — EconoMi$erIV Input/Output Logic *For single enthalpy control, the module compares outdoor enthalpy to the ABCD set point. †P ower at N term inal determ ines Occupied/Unoccupied setting: 24 vac (Occupied), no power (Unoccupied). **Modulation is based on the supply air sensor signal. ††Modulation is based on the DCV signal. ***M[...]

55 Fig. 59 — IGC Control (Heating and Cooling) LEGEND IGC — Integrated Gas Unit Controller NO TE: Thermostat F an Switch in the “A UT O” position.[...]

56 Fig. 60 — EconoMi$erIV Functional View[...]

57 INDEX Air quali ty lim its 40 Altitude com pensati on 12 Burn er sect ion 12 Burn er sp ark g ap 47 Carrier Comfort Network® 19 Char ging chart, re frigera nt 45 Clea ranc e 6-8 CO 2 sensor Configuration 30 Settings 29, 30 Combustion blower wheel 43 Compre ssor Lockout 25, 46 Lubrication 43 Mounting 33 Rotation 33 Concentric duct 11 Condensate [...]

Manufa cturer reser ves the right to discon tinue, or change at any time, specificat ions or designs w ithout not ice and without incurrin g obligations. Catalog No. 04-5348 0016- 01 P rin ted in U.S.A. For m 48TM- 4SI Pg 58 3-06 Replaces: 4 8TM-3 SI Book 1 4 Ta b 1 a 6 a Copyright 2 006 Car rier Cor poration SER VICE TRAINING Packaged Service T ra[...]

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Manufa cturer reser ves the right to discon tinue, or change at any time, specificat ions or designs w ithout not ice and without incurrin g obligations. Catalog No. 04-5348001 6-01 Pr inted i n U .S.A. Form 48TM-4SI Pg CL-1 3-06 Replace s: 48TM-3 SI Book 1 4 Ta b 1 a 6 a Copyright 2 006 Car rier Cor poration - ------------- ----------- -----------[...]