Carrier TJF004 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. 534-774 Prin ted in U.S.A. Form 4 8TJ-18 SI Pg 1 10-00 Replace s: 48T J-16SI Book 1 4 Ta b 1 a 6 a Installation, Star t-Up and Ser v ice Instr u ctions CONTENTS Pa ge SAF[...]

2 Curb should be level. Unit leveling tolerances are shown in Fig. 3. This is nece ssary for unit drain to func tion properly . Re- fer to Accessory Roof Curb Installation In structions for addi- tional information as required. SLAB MOUNT (Horizontal Units On ly) — Pr ovi de a le vel concrete slab that extends a minimum of 6 i n. beyond unit cab-[...]

3 TO ENSURE AIRTIGHT CONNECTION PLACE UNIT AS CLOSE TO END AS POSSIBLE. TO ENSURE AIRTIGHT CONNECTION PLACE UNIT AS CLOSE TO END AS POSSIBLE. Fig. 2 — Roof Curb Dimensions ROOF CURB A CCESSOR Y ‘‘ A ’ ’ UNIT SIZE 48TJ CRRFCURB001A00 1 ′ -2 ″ [356] 004-0 07 CRRFCURB002A00 2 ′ -0 ″ [610] NO TES: 1. Roof curb accessor y is sh ipped d[...]

4 PO S IT I O N I N G — Maintain cle arance around and above unit to provide minimum distance from combustible materials, proper airflow , and service access. See Fig. 6. A properly posi- tioned unit will have the following clearances betwe en unit and roof curb: 1 / 4 -in. clearance betw een roof curb and base rai ls on each side and duct end of[...]

5 Step 7 — Make Electrical Connections DISC ON NEC T B OX L OCA TI ON — The field-supplied dis- connect box may be mounted on the unit’ s end panel or on the corner post. Mount disconnect box on the left side of the rating plate when mounting on th e unit’ s end panel. Do not mount t he disconnect box over the uni t rating plate. When mount[...]

6 Table 1 — P hysical D ata LEGEND *Evaporator coi l fin ma ter ial/conde nser c oil fin mater ial. Contact your local repres entative for details about coated fi ns. †Weight of 14-in . roof curb. **Singl e phase/th ree-ph ase. ††Rollou t switch locko ut is manua lly reset by interr upting power to unit or resettin g ther most at. NO TES: 1[...]

7 Table 1 — Physical data (cont) LEGEND *Evaporator coi l fin ma ter ial/conde nser c oil fin m ater ial. C ontact your l ocal repres entative for details about coated fi ns. †Weight of 14-in . roof curb. **Singl e phase/th ree-p hase. ††Rollou t switch lockout is manually reset by interr uptin g power to unit or resettin g ther most at. NO[...]

8 UNIT 48TJ ST A NDARD UNIT WEIGHT DURABLADE ECONOMIZER WEIGHT ECONOMI$ER WEIGHT CORNER WEIGHT (A) CORNER WEIGHT (B) CORNER WEIGHT (C) CORNER WEIGHT (D) Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg L b Kg E/F004 460 20 9 34 15.4 47 21.3 140 63.5 105 47.6 159 72.1 56 25.4 D/E/F005 470 213 3 4 15.4 47 21.3 142 64.4 106 48.1 162 73.5 60 27.2 D/E/F006 490 222 3[...]

9 V oltage to compressor termi nals during operation must be within voltage range indicated on unit nameplate (see T able 2). On 3-phase units, voltages betw een phases must be balanc ed within 2% and the current within 10%. U se the formula shown in the legend for T able 2, Note 2 to determine the percent of voltage imbalance. Opera tion on improp[...]

10 LEGEND Fig. 11 — Power Wiring Connections C— Contactor COMP — Compr essor NEC — National Electrical Code TB — T er minal Block Fig. 12 — Low-Voltage Connections LEG END AHA — Adjust able Heat Anticipator Field Wiring F acto ry W iring 208/230-1 -60 208/230-3-6 0 460-3-60 (SIZE 007 O NL Y) 208/230-3-6 0 575- 3-60, 460-3 -60 (SIZES 0[...]

11 Table 2 — E lectrical Data LEGEND *Used to determine minimum disconn ect per NEC. † Fus e or H ACR circ uit brea ker . NO TES: 1. In complianc e with NEC re quirements f or multimotor and combinati on load equipme nt (ref er to NEC Articles 430 and 440) , the ov ercurrent protec tiv e de vice for t he unit sha ll be fuse or HACR brea ker . C[...]

12 Step 8 — Make Outdoor -Air Adjustments and Install Outdoor -Air Hood MANUAL OUTDOOR-AIR DAMPER — Th e ou t door-air hood and screen are attached t o the basepan at the bottom of the unit for shipping. Assembly: 1. Determine quantity of ventilation required for building. Record amount for use in Step 8. 2. Remove and save outdoor air opening [...]

13 OP TIONAL DUR ABLADE ECONOMIZER — T h e o pt io n- al econom izer hood asse mbly is pac kaged a nd shipped in the fil- ter se ction. Damp er blad es and cont rol boa rds are in stalled at the factor y and the econo mizer i s shipped in the v ertica l disch arge position. NOTE: Horizontal discharge block-off plate is shipped with the air hood p[...]

14 ECONOMIZER CONTROL BOARD ECONOMIZER PLUG ECONOMIZER M OTO R TO P SCREW BAROMETRIC RELIEF D AMPER WIRING HARNESS POSITION SETTING BRACKET U-SHAPED HOLE (NO T SHOWN) SHIPPING SCREW 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[...]

15 OP TIONAL ECO NOMI$ER — See Fig . 26 fo r Ec onoMi$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. 27. If installing an optional Power Exhaust Assem[...]

16 5. Slid e th e out door-a ir i nlet s creens into the scree n t rack o n the hood side panels. While holding the scre ens in pl ace, fasten the screen r etainer to the hood usi ng the screws provided. Repeat the process for t he barometric exhaust air screen. Do not attach completed (Fig. 30) hood as- semb ly to un it a t this ti me. 6. Slide th[...]

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$ER CONTROLLER PINK TEMP TEMP VIOLET SUPPL Y AIR TEMPERA TURE SENSOR V+ 24 COM V AC SENSOR CO 2 (+) COM DA T COM REM POT COM LED COM CO 2 CO 2 LEG END Fig. 33 — EconoMi$er W[...]

18 4-PIN CONNECTOR PLUG L1 L2 GREEN 1 1 22 33 44 GND 230 V AC 1 PHASE GREEN/ YELLOW 3 2 1 5 8 6 9 B A 7 4 L T . BLUE BLACK BROWN C1 BLUE GREEN/ YELLOW 3 2 1 5 8 6 9 B A 7 4 L T . BLUE BLACK BROWN C1 BLUE F AN 2 F AN 1 BLACK BLACK BLACK R1 24 V AC R2 24 V AC BLACK BLUE 1 2 3 BROWN ORANGE 3-PIN CONNECTOR PLUG YELLOW RED YEL H1 BLU GRA Y H4 SECONDARY [...]

19 CO 2 Control Set Up — If a CO 2 sensor is not being used, proceed to th e ne xt section. I f a CO 2 sensor is being used, per- form the following: 1. Determine the val ue at whi ch you want the minimum position of the dampers to begin opening to allow a greater amount of outdoor air to enter . The range is 800 to 1,400 ppm. 2. Loca te the CO 2[...]

20 Step 9 — A djus t Evapor ator-Fan Sp eed — Ad- just evaporator-fan rpm to me et jobsite conditions. T able 5 shows fan rpm at motor pulley settings. T able 6 shows motor performance. See T able 7 for Accessory/FIO P Static Pressure. Refer to T ables 8-29 to determine fan speed settings. DI R E C T -D R I V E M O TO R S — The evaporat or-fa[...]

21 Table 5 — Fan Rpm at Motor Pulley Settings* *Appro ximate f an r pm show n. † Indic ates a lternate mot or a nd driv e packa ge. **Indic ates high- s tatic moto r and dr iv e pac kage. †† Indic ates st andard motor a nd drive pac kage. Table 6 — Motor Da ta LEGEND BHP — Brak e Horsepo wer *Extens iv e motor and elect rical testing on[...]

22 Table 8 — Fan Performanc e 48TJ004 — Vertic al Dischar ge Units, Standar d Motor LEGE ND NO TES: 1. V alues include losses f or filters, unit casing, and wet co ils. S ee T able 7 f or accessory/FIOP static pre ssure inf ormation. 2. Extensiv e motor an d electrical testing on the se uni ts ensures that the ful l rang e of the mo tor can be [...]

23 Table 10 — Fan Per formance 48TJ004 — Vertica l Discharge Units, High-Stat ic Motor LEGE ND *Motor driv e range is 1075 to 1455 r pm. All othe r rpms require a fie ld- supp lie d dr ive. NO TES: 1. Boldface indica tes fi eld- supp li ed dr ive is requi red. 2. V alues include losses f or filters, unit casing, and wet co ils. S ee T able 7 f [...]

24 Table 12 — Fan Performance 48TJ005 — Vertical D ischarge Units, Alternate Moto r LEG END *Motor d rive range i s 835 to 1185 r pm. All other r pms r equire a field-sup plied drive. NO TES: 1. Boldface indicates field -supplied drive is required. 2. ind icates field -suppli ed moto r and drive are require d. 3. V alues include losses for filt[...]

25 Table 14 — Fan Perfo rmance 48 TJ006 — V ertical D ischarge Units, Standard Moto r LEGE ND NO TES: 1. V alues include losses f or filters, unit casing, and wet co ils. S ee T able 7 f or accessory/FIOP static pre ssure inf ormation. 2. Extensiv e motor and electrical testing on the se uni ts ensures that the ful l rang e of the mo tor can be[...]

26 Table 16 — Fan Per formance 48TJ006 — Vertica l Discharge Units, High-Stat ic Motor LEGE ND *Motor driv e range is 1300 to 1685 r pm. All othe r rpms require a fie ld- supp lie d dr ive. NO TES: 1. Boldface indica tes fi eld- supp li ed dr ive is requi red. 2. indica tes field -suppli ed motor and driv e are require d. 3. V alues include los[...]

27 Table 17 — Fan Perfo rmance 48 TJ007 — V ertical D ischarge Units, Standard Moto r LEGE ND *Motor driv e range is 1070 to 1460 r pm. All othe r rpms require a fie ld- supp lie d dr ive. NO TES: 1. Boldface indica tes fi eld- supp li ed dr ive is requi red. 2. indicat es fiel d-supplied motor a nd drive are required. 3. V alues include losses[...]

28 Table 18 — Fan Per formance 48TJ007 — Vertica l Discharge Units, High-Stat ic Motor LEGE ND *Motor driv e range is 1300 to 1685 r pm. All othe r rpms require a fie ld- supp lie d dr ive. NO TES: 1. Boldface indica tes fi eld- supp li ed dr ive is requi red. 2. indicat es fiel d-supplied motor a nd drive are required. 3. V alues include losse[...]

29 Table 19 — Fan Performance 48TJ004 — Horizontal Discharge Units, Standard Motor LEGE ND NO TES: 1. V alues include losses f or filters, unit casing, and wet co ils. S ee T able 7 f or accessory/FIOP static pre ssure inf ormation. 2. Extensiv e motor and electrical testing on the se uni ts ensures that the ful l rang e of the mo tor can be ut[...]

30 Table 21 — Fan Perfo rmance 48TJ0 04 — Horizontal Di scharg e Units, Hig h-Static M otor LEGEN D *Motor driv e range is 1075 to 1455 r pm. All othe r rpms require a fie ld- supp lie d dr ive. NO TES: 1. Boldface indica tes fi eld- supp li ed dr ive is requi red. 2. V alues include losses f or filters, unit casing, and wet co ils. S ee T able[...]

31 Table 22 — Fan Performance 48TJ005 — Horizontal Discharge Units, Standard Motor LEGE ND NO TES: 1. V alues include losses f or filters, unit casing, and wet co ils. S ee T able 7 f or accessory/FIOP static pre ssure inf ormation. 2. Extensiv e motor and electrical testing on the se uni ts ensures that the ful l rang e of the mo tor can be ut[...]

32 Table 24 — Fan Perfo rmance 48TJ0 05 — Horizontal Di scharg e Units, Hig h-Static M otor LEGEN D *Motor driv e range is 1075 to 1455 r pm. All othe r rpms require a fie ld- supp lie d dr ive. NO TES: 1. Boldface indica tes fi eld- supp li ed dr ive is requi red. 2. V alues include losses f or filters, unit casing, and wet co ils. S ee T able[...]

33 Table 26 — Fan Performance 48TJ006 — Horizon tal Discha rge U nits, Altern ate Motor LEGE ND *Motor d rive r ange is 900 to 1300 rpm. All other r pms require a field- supp lie d dr ive. NO TES: 1. Boldface indica tes fi eld- supp li ed dr ive is requi red. 2. indicat es fiel d-supplied motor a nd drive are required. 3. V alues include losses[...]

34 Table 27 — Fan Perfo rmance 48TJ0 06 — Horizontal Di scharg e Units, Hig h-Static M otor LEGE ND *Motor driv e range is 1300 to 1685 r pm. All othe r rpms require a fie ld- supp lie d dr ive. NO TES: 1. Boldface indica tes fi eld- supp li ed dr ive is requi red. 2. indicat es fiel d-supplied motor a nd drive are required. 3. V alues include [...]

35 Table 28 — Fan Performance 48TJ007 — Horizontal Discharge Units, Standard Motor LEGE ND *Motor driv e range is 1070 to 1460 r pm. All othe r rpms require a fie ld- supp lie d dr ive. NO TES: 1. Boldface indica tes fi eld- supp li ed dr ive is requi red. 2. indicat es fiel d-supplied motor a nd drive are required. 3. V alues include losses f [...]

36 Table 29 — Fan Perfo rmance 48TJ0 07 — Horizontal Di scharg e Units, Hig h-Static M otor LEGE ND *Motor driv e range is 1300 to 1685 r pm. All othe r rpms require a fie ld- supp lie d dr ive. NO TES: 1. Boldface indica tes fi eld- supp li ed dr ive is requi red. 2. indicat es fiel d-supplied motor a nd drive are required. 3. V alues include [...]

37 ST ART - UP Unit Preparation — Make sure that unit has been in- stalled in acc ordance with thes e installat ion instructions and applicable codes. Return-Air Filters — M ake sure correct filters are i n- stalled in filter tracks. See T able 1. Do not opera te unit without return-air filte rs. Compressor Mounting — Compressors are internal[...]

38 Heating 1. Purge gas supply line of air by opening union ahead of gas valve. If gas odor is detected, tighten uni on and wait 5 minutes before proceeding. 2. T urn on electrical supply and open manual gas valve. 3. Set system switch selector at HEA T position and fan switch at AUT O. or ON position. S et heating temperature lever above room temp[...]

39 Safety Relief — A soft solder joi nt at the suc tion s ervice Schrader port provides pres sure relief under abnormal tempera- ture and pressure condi tions (i. e., fire in building). U s e backup wrench wh en tightening fl are cap. High Flo w V alves — Located on the compressor hot gas and suction tubes are High Flow V alves. Large black pla[...]

40 SER VICE Cleaning — Inspect unit interior at the begi nning of heat- ing and cooling season and as operating conditions require. EV APOR A T OR CO IL 1. T urn unit powe r of f and tag dis conn ect. Remove evapora- tor coil access panel. 2. If economizer is installed, remove economizer by discon- necting 12-pin Molex plug and removing ec onomiz[...]

41 Lubricati on COM P RES S OR S — Each com pressor is ch arged wit h the correct amount of oil at the factory . F AN - M O TO R B EA R I NG S — Fan-m otor bearings a re of the permanently lubricated type. No further lubrication is re- quired . No lubrication of condenser or evaporator fan motors is required. Manual Outdoor -Air Damper — If o[...]

42 Fig. 49 — Cooling Charging Chart, 48TJ004 Fig. 50 — Cooling Cha rging Chart, 48TJ005 Fig. 51 — Cooling Charging Char t, 48TJ006 Fig. 52 — Cooling Charging Chart, 48TJ007[...]

43 Combust i on-Air Blo wer — Clean periodically to as- sure proper airflow and hea ting efficiency . Inspect blower wheel every fall a nd periodically during heat ing season. For the first heating season, inspect blower w heel bimonthly to deter- mine proper cleaning frequency . T o access burner section, slide the sliding burner partition out o[...]

44 Fig. 54 — Burner Tray De tails Fig. 55 — Spark Adjus tment LO W HEA T 48TJE0 04, 48T JD005-0 07 — 74, 000 BTUH INPUT MEDIUM ANDHIGH HEA T 48TJ E005 -0 07, 48 TJF 004 — 115,00 0 BTUH INPUT 48TJF 005-007 — 150,000 B TUH INP UT[...]

45 TROUBLESHOO TING Table 32 — LED Error Code Service Analysis LEGEND Table 33 — Heatin g Servic e Analysis SYMPT OM CA USE REMED Y Hardware fa ilure . (LED OFF) Loss of po wer t o control modu le (IGC). Check 5 amp fuse on IGC, power to unit, 24-v circui t break er , and transf or mer . Units without a 24- v circuit bre aker hav e an internal [...]

46 Table 34 — Cooling Se rvice Ana lysis PROBLEM C A USE REMED Y Compressor and condenser fan will n ot start. P ower f ailure. Call power compan y . Fuse blown or circuit breaker tripped. Replace fuse or reset circ uit breaker . Def e ctiv e thermos tat, contactor , transf orm er , or control rela y . Replace component. Insufficient line voltage[...]

47 Table 35 — Durablade Economizer Troubleshooting PROBLEM C A U SE REMED Y Damper does not open . Indoor (ev aporator) fan is off. 1. Check to ensure that 24 vac is present at terminal C1 on the IFC or that 24 v ac is present at the IFO term inal. Chec k whether 24 v ac is present at PL6-1 (red wire) and/or PL6-3 (black wire). If 24 v ac is not [...]

48 Table 36 — EconoMi$er Troubleshooting LEGEND PL — Plug PROBLEM POT ENT IAL CA USE REMED Y Damper Does Not Open Indoor ( Evaporator) F an is Off Check to ensure tha t 24 vac is p resent at T er minal C1 (Com mon Po wer) on the IF C (Indo or [E vaporator] Fan Contactor) or that 24 vac is pre sent at the IFO ( Indoor [Evaporator] Fan On) ter mi[...]

49 Fig. 56 — Typical Wiring Diagram and Component Arrangement[...]

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 Cata log No . 534-7 74 Printed in U .S. A. F orm 48TJ-1 8SI Pg 50 10-00 R epla ces: 48TJ- 16SI Book 1 4 Ta b 1 a 6 a Copyright 20 00 Car rier Cor po ration LEGEND FOR FIG. 56 — TY P[...]

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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. 534-774 Print ed in U.S.A. Form 48 TJ-18SI P g CL-1 10-00 Replaces: 4 8TJ-16 SI Book 1 4 Ta b 1 a 6 a Copyright 20 00 Car rier Cor po ration - - - - - - - - - - - - - - - [...]