Carrier 48TF004-007 User Manual

48TF004-007 Single-Package Rooftop Heating/Cooling Units

Installation, Start-Up, and

Service Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			1-35
Step 1		— Provide Unit Support . . . . . . . . . . . . . . . .	. . . 1
•	ROOF CURB
•	SLAB MOUNT
Step 2		— Field Fabricate Ductwork . . . . . . . . . . . . .	. . 2
Step 3		— Install External Trap for Condensate
	Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . 2
Step 4		— Rig and Place Unit . . . . . . . . . . . . . . . . . . .	. . 2

•POSITIONING

Step 5	— Install Flue Hood . . . . . . . . . . . . . . . . . . . . . . .	4
Step 6	— Install Gas Piping . . . . . . . . . . . . . . . . . . . . . .	4
Step 7	— Make Electrical Connections . . . . . . . . . . .	8

•FIELD POWER SUPPLY

•FIELD CONTROL WIRING

•HEAT ANTICIPATOR SETTINGS

Step 8 — Make Outdoor-Air Adjustments

and Install Outdoor-Air Hood. . . . . . . . . . . . . . . . . . 11

•MANUAL OUTDOOR-AIR DAMPER

•OPTIONAL DURABLADE ECONOMIZER

•OPTIONAL ECONOMI$ER

Step 9 — Adjust Evaporator-Fan Speed . . . . . . . . .		19
•	DIRECT-DRIVE MOTORS
•	BELT-DRIVE MOTORS

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-38 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-43 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 44-49 START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags and labels attached to the unit, and other safety precautions that apply.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguishers available for all brazing operations.

Disconnect gas piping from unit when leak testing at pressure greater than 1/2 psig. Pressures greater than 1/2 psig will cause gas valve damage resulting in hazardous condition. If gas valve is subjected to pressure greater than 1/2 psig, it must be replaced before use. When pressure testing field-supplied gas piping at pressures of 1/2 psig or less, a unit connected to such piping must be isolated by manually closing the gas valve.

Before performing service or maintenance operations on unit, turn off main power switch to unit and install a lockout tag. Electrical shock could cause personal injury.

INSTALLATION

Unit is shipped in the vertical duct configuration. To convert to horizontal configuration, remove screws from side duct opening covers and remove covers. Using the same screws, install covers on vertical duct openings with the insulation-side down. Seals around duct openings must be tight. See Fig. 1.

Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree with power supply provided.

Step 1 — Provide Unit Support

ROOF CURB — Assemble and install accessory roof curb in accordance with instructions shipped with curb. See Fig. 2. Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb, not to the unit. The accessory thru-the-bottom power and gas connection package must be installed before the unit is set on the roof curb. If fieldinstalled (thru-the-roof curb) gas connections are desired, use factory-supplied 3/4-in. pipe coupling and gas plate assembly to mount the thru-the-roof curb connection to the roof curb. Gas connections and power connections to the unit must be field installed after the unit is installed on the roof curb.

If electric and control wiring is to be routed through the basepan, attach the accessory thru-the-bottom service connections to the basepan in accordance with the accessory installation instructions.

IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket supplied with the roof curb as shown in Fig. 2. Improperly applied gasket can result in air leaks and poor unit performance.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book	1	4	PC 111	Catalog No. 534-80000	Printed in U.S.A.	Form 48TF-1SI	Pg 1	8-00	Replaces: New
Tab	1a	6a

Fig. 1 — Horizontal Conversion Panels

Curb should be level. Unit leveling tolerances are shown in Fig. 3. This is necessary for unit drain to function properly. Refer to Accessory Roof Curb Installation Instructions for additional information as required.

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 — Secure all ducts to roof curb and building structure on vertical ducted units. Do not connect ductwork to unit. For horizontal applications, field-supplied flanges should be attached to horizontal duct openings and all ductwork should be secured to the flanges. 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 insulated and covered with a vapor barrier.

If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes.

A minimum clearance is not required around ductwork. Cabinet return air static shall not exceed –.20 in. wg with EconoMi$er, –.35 in. wg with Durablade economizer, or –.45 in. wg without economizer.

These units are designed for a minimum continuous heating return-air temperature of 50 F (dry bulb), or an intermittent operation down to 45 F (dry bulb), such as when used with a night set-back thermostat.

Step 3 — Install External Trap for Condensate Drain — The unit’s 3/4-in. condensate drain connections are located on the bottom and side of the unit. Unit discharge connections do not determine the use of drain connections; either drain connection can be used with vertical or horizontal applications.

When using the standard side drain connection, make sure the plug (Red) in the alternate bottom connection is tight before installing the unit.

To use the bottom drain connection for a roof curb installation, relocate the factory-installed plug (Red) from the bottom connection to the side connection. See Fig. 4. The piping for the condensate drain and external trap can be completed after the unit is in place.

All units must have an external trap for condensate drainage. Install a trap at least 4-in. deep and protect against freezeup. If drain line is installed downstream from the external trap, pitch the line away from the unit at 1 in. per 10 ft of run. Do not use a pipe size smaller than the unit connection (3/4 in.).

Step 4 — Rig and Place Unit — Inspect unit for transportation damage. File any claim with transportation agency. Keep unit upright and do not drop. Spreader bars are not required if top crating is left on unit. Rollers may be used to move unit across a roof. Level by using unit frame as a reference. See Table 1 and Fig. 5 for additional information.

Lifting holes are provided in base rails as shown in Fig. 6. Refer to rigging instructions on unit.

All panels must be in place when rigging.

POSITIONING — Maintain clearance around and above unit to provide minimum distance from combustible materials, proper airflow, and service access. See Fig. 6. A properly positioned unit will have the following clearances between unit and roof curb: 1/4-in. clearance between roof curb and base rails on each side and duct end of unit; 1/4-in. clearance between roof curb and condenser coil end of unit. (See Fig. 2, section C-C.)

Do not install unit in an indoor location. Do not locate unit air inlets near exhaust vents or other sources of contaminated air.

Be sure that unit is installed such that snow will not block the combustion intake or flue outlet.

2

	ROOF CURB	A	UNIT SIZE
	ACCESSORY
	CRRFCURB001A00	1¢-2²
		[356]
			48TF004-007
	CRRFCURB002A00	2¢-0²
		[610]

NOTES:

1.Roof curb accessory is shipped disassembled.

2.Insulated panels.

3. Dimensions in [ ] are in millimeters.

4.Roof curb, galvanized steel.

5.Attach ductwork to curb (flanges of duct rest on curb).

6.Service clearance: 4 ft on each side.

			D ALT	“E”		“F”	“G”		CONNECTOR
	B	C	DRAIN
				GAS		POWER	CONTROL		PKG. ACCY.
			HOLE
				3	/4²	3/ ² [19] NPT)	1	/2²	CRBTMPWR001A00
						4
	1¢-911/16²	1¢-4²	13/4²	[19] NPT		11/4² [31.7]	[12.7]		CRBTMPWR002A00
				1/2²		3/4² [19] NPT			CRBTMPWR003A00
	[551]	[406]	[44.5]	[12.7] NPT			1/2²
				3	/4²	11/4² [31.7]	[12.7]		CRBTMPWR004A00
				[19] NPT

3

7. Direction of airflow.

8.Connector packages CRBTMPWR001A00 and 002A00 are for thru-the- curb connections. Packages CRBTMPWR003A00 and 004A00 are for thru-the-bottom connections.

Fig. 2 — Roof Curb Dimensions

MAXIMUM ALLOWABLE

DIFFERENCE (in.)

A-B	B-C	A-C
0.5	1.0	1.0

Fig. 3 — Unit Leveling Tolerances

NOTE: Drain plug is shown in factory-installed position.

Fig. 4 — Condensate Drain Connection

Unit may be installed directly on wood flooring or on Class A, B, or C roof-covering material when roof curb is used.

Although unit is weatherproof, guard against water from higher level runoff and overhangs.

Flue vent discharge must have a minimum horizontal clearance of 4 ft from electric and gas meters, gas regulators, and gas relief equipment.

Minimum distance between unit and other electrically live parts is 48 inches.

NOTES:

1. Dimensions in ( ) are in millimeters.

2.Hook rigging shackles through holes in base rail, as shown in detail “A.’ Holes in base rails are centered around the unit center of gravity. Use wooden top skid when rigging to prevent rigging straps from damaging unit.

Flue gas can deteriorate building materials. Orient unit such that flue gas will not affect building materials.

Adequate combustion-air space must be provided for proper operation of this equipment. Be sure that installation complies with all local codes and Section 5.3, Air for Combustion and Ventilation, NFGC (National Fuel Gas Code), and ANSI (American National Standards Institute) Z223.1, and NFPA (National Fire Protection Association) 54 TIA-54-84-1. In Canada, installation must be in accordance with the CAN1-B149 installation codes for gas burning appliances.

After unit is in position, remove rigging skids and shipping materials.

Step 5 — Install Flue Hood — Flue hood is shipped screwed to the basepan beside the burner compartment access panel. Remove from shipping location and using screws provided, install flue hood and screen in location shown in Fig. 7.

Step 6 — Install Gas Piping — Unit is equipped for use with type of gas shown on nameplate. Refer to local building codes, or in the absence of local codes, to ANSI Z223.1 entitled National Fuel Gas Code. In Canada, installation must be in accordance with the CAN1.B149.1 and CAN1.B149.2 installation codes for gas burning appliances.

For natural gas applications, gas pressure at unit gas connection must not be less than 4 in. wg or greater than 13.0 in. wg while unit is operating. On 48TF005,006,007 high heat units, the gas pressure at unit gas connection must not be less than 5 in. wg or greater than 13 in. wg while the unit is operating. For propane applications, the gas pressure must not be less than 5 in. wg or greater than 13 in. wg at the unit connection.

Size gas supply piping for 0.5 in. wg maximum pressure drop. Do not use supply pipe smaller than unit gas connection. Support gas piping as shown in the table in Fig. 8. For example, a 3/4-in. gas pipe must have one field-fabricated support beam every 8 ft. Therefore, an 18-ft long gas pipe would have a minimum of 2 support beams, a 48-ft long pipe would have a minimum of 6 support beams.

See Fig. 8 for typical pipe guide and locations of external manual main shutoff valve.

3.Unit weights do not include economizer. See Table 1 for economizer weights.

All panels must be in place when rigging.

UNIT	MAX WEIGHT		“A”			“B”		“C”
	Lb	Kg	in.		mm	in.	mm	in.	mm
48TFE,TFF,TFM,TFN004	510	231
48TFD,TFE,TFF,TFL,TFM,TFN005	520	236	73.69		1872	37.50	953	33.35	845
48TFD,TFE,TFF,TFL,TFM,TFN006	540	245
48TFD,TFE,TFF007	615	279

Fig. 5 — Rigging Details

4

Table 1 — Physical Data — 48TF004-007

UNIT SIZE 48TF				E/F/M/N004			D/E/F/L/M/N005			D/E/F/L/M/N006			D/E/F007
NOMINAL CAPACITY (tons)				3			4			5			6
OPERATING WEIGHT (lb)
Unit
	Al/Al*			460			470			490			565
	Al/Cu*			465			476			497			576
	Cu/Cu*			468			482			505			587
Economizer
	Durablade			34			34			34			34
	EconoMi$er			47			47			47			47
Roof Curb†				115			115			115			115
COMPRESSOR							Reciprocating						Scroll
Quantity				1			1			1			1
No. Cylinders (per Circuit)				2			2			2			2
Oil (oz)				50			50			50			54
REFRIGERANT TYPE							R-22
Expansion Device							Acutrol™ Metering Device
Operating Charge (lb-oz)
	Circuit 1			4-4			6-6			6-14			9-0
	Circuit 2			—			—			—			—
CONDENSER COIL					Enhanced Copper Tubes, Aluminum Lanced Fins
Rows...Fins/in.				1...17			2...17			2...17			2...17
Total Face Area (sq ft)				8.36			8.36			10.42			10.42
CONDENSER FAN							Propeller Type
Nominal Cfm				3500			4000			4000			4000
Quantity...Diameter (in.)				1...22.0			1...22.0			1...22.0			1...22.0
Motor Hp...Rpm				1/ ...1100			1/ ...1100			1/ ...1100			1/ ...1100
Watts Input (Total)				4			4			4			4
				325			325			325			325
EVAPORATOR COIL					Enhanced Copper Tubes, Aluminum Double-Wavy Fins
Rows...Fins/in.				2...15			2...15			3...15			4...15
Total Face Area (sq ft)				4.17			5.5			5.5			5.5
EVAPORATOR FAN							Centrifugal Type
Quantity...Size (in.)			Std	1...10 x 10			1...10 x 10			1...11 x 10			1...10 x 10
			Alt	1...10 x 10			1...10 x 10			1...10 x 10			—
			High-Static	1...10 x 10			1...10 x 10			1...11 x 10			1...10 x 10
Type Drive			Std	Direct			Direct			Direct			Belt
			Alt	Belt			Belt			Belt			—
Nominal Cfm			High-Static	Belt			Belt			Belt			Belt
				1200			1600			2000			2400
Maximum Continuous Bhp			Std	.34			.75			1.20			2.40
			Alt	1.00			1.00			1.30/2.40**			—
			High-Static	2.40			2.40			2.90			2.90
Motor Frame Size			Std	48			48			48			56
			Alt	48			48			56			—
			High-Static	56			56			56			56
Nominal Rpm High/Low			Std	860/800			1075/970			1075/970			—
			Alt	1620			1620			1725			—
			High-Static	1725			1725			1725			1725
Fan Rpm Range			Std	—			—			—			1070-1460
			Alt	760-1000			835-1185			900-1300			—
Motor Bearing Type			High-Static	1075-1455			1075-1455			1300-1685			1300-1685
				Ball			Ball			Ball			Ball
Maximum Allowable Rpm				2100			2100			2100			2100
Motor Pulley Pitch Diameter Min/Max (in.)			Std	—			—			—			2.8/3.8
			Alt	1.9/2.9			1.9/2.9			2.4/3.4			—
			High-Static	2.8/3.8			2.8/3.8			3.4/4.4			3.4/4.4
Nominal Motor Shaft Diameter (in.)			Std	1/			1/			1/			5/
			Alt	2			2			2			8
				1/			1/			5/			—
				2			2			8			5/8
Fan Pulley Pitch Diameter (in.)			High-Static	5/8			5/8			5/8
			Std	—			—			—			4.5
			Alt	4.5			4.0			4.5			—
			High-Static	4.5			4.5			4.5			4.5
Belt, Quantity...Type...Length (in.)			Std	—			—			—			1...A...40
			Alt	1...A...34			1...A...34			1...A...39			—
			High-Static	1...A...39			1...A...39			1...A...40			1...A...40
Pulley Center Line Distance (in.)			Std	—			—			—			14.7-15.5
			Alt	10.0-12.4			10.0-12.4			14.7-15.5			—
			High-Static	10.0-12.4			10.0-12.4			14.7-15.5			14.7-15.5
Speed Change per Full Turn of			Std	—			—			—			80
	Movable Pulley Flange (rpm)		Alt	48			70			80			—
			High-Static	65			65			60			60
Movable Pulley Maximum Full Turns			Std	—			—			—			5
	From Closed Position		Alt	5			5			5			—
			High-Static	6			6			5			5
Factory Setting			Std	—			—			—			3
			Alt	3			3			3			—
Factory Speed Setting (rpm)			High-Static	31/2			31/2			31/2			31/2
			Std	—			—			—			1225
			Alt	856			975			1060			—
			High-Static	1233			1233			1396			1396
Fan Shaft Diameter at Pulley (in.)				5/			5/			5/			5/
				8			8			8			8
		LEGEND			††Rollout switch lockout is manually reset by interrupting power to unit or
Al	—	Aluminum			resetting thermostat.
					|| Single-phase units have a single-stage gas valve. The heating input values
Bhp	—	Brake Horsepower
					are as follows:
Cu	—	Copper
					48TFF004, 115,000 Btuh
*Evaporator coil fin material/condenser coil fin material. Contact your local					48TFF005, 150,000 Btuh
					48TFF006, 150,000 Btuh
representative for details about coated fins.
†Weight of 14-in. roof curb.					NOTE: High-static motor not available on single-phase units.
**Single phase/three-phase.

5

Table 1 — Physical Data — 48TF004-007 (cont)

UNIT SIZE 48TF			E/F/M/N004	D/E/F/L/M/N005		D/E/F/L/M/N006	D/E/F007
FURNACE SECTION
Rollout Switch Cutout
Temp (F)††			195	195		195	195
Burner Orifice Diameter
(in. ...drill size)
Natural Gas	Std	TFD	—	.113...33		.113...33	.113...33
		TFE	.113...33	.113...33		.113...33	.113...33
		TFF	.113...33	.129...30		.129...30	.129...30
		TFL	—	.102...38		.102...38	—
		TFM	.102...38	.102...38		.102...38	—
		TFN	.102...38	.116...32		.116...32	—
Liquid Propane	Alt	TFD	—	.089...43		.089...43	.089...43
		TFE	.089...43	.089...43		.089...43	.089...43
		TFF	.089...43	.102...38		.102...38	.102...38
		TFL	—	.082...45		.082...45	—
		TFM	.082...45	.082...45		.082...45	—
Thermostat Heat Anticipator		TFN	.082...45	.089...43		.089...43	—
Setting (amps)
208/230 v and 575	Stage 1		.14	.14		.14	.14
	Stage 2		.14	.14		.14	.14
460 v	Stage 1		.14	.14		.14	.14
	Stage 2		.14	.14		.14	.14
Gas Input (Btuh)||	Stage 1	TFD	—	72,000		72,000	72,000
		TFE	72,000	115,000		115,000	115,000
		TFF	82,000	120,000		120,000	120,000
		TFL	—	60,000		60,000	—
		TFM	60,000	90,000		90,000	—
		TFN	90,000	120,000		120,000	—
	Stage 2	TFF	115,000	150,000		150,000	150,000
	(3-phase units)
Efficiency (Steady
State) (%)			80	80		80	80
Temperature Rise Range		TFD	—	25-55		25-55	25-55
		TFE	25-55	35-65		35-65	35-65
		TFF	55-85	50-80		50-80	50-80
		TFL	—	20-50		20-50	—
		TFM	20-50	30-60		30-60	—
Manifold Pressure (in. wg)		TFN	30-60	40-70		40-70	—
Natural Gas	Std		3.5	3.5		3.5	3.5
Liquid Propane	Alt		3.5	3.5		3.5	3.5
Gas Valve Quantity			1	1		1	1
Gas Valve Pressure Range
Psig			0.180-0.487	0.180-0.487		0.180-0.487	0.180-0.487
in. wg			5.0-13.5	5.0-13.5		5.0-13.5	5.0-13.5
Field Gas Connection			1/	1/		1/	1/
Size (in.)
			2	2		2	2
HIGH-PRESSURE SWITCH (psig)
Standard Compressor				450 ± 50			500 ± 50
Internal Relief (Differential)
Cutout				428			428
Reset (Auto.)				320			320
LOSS-OF-CHARGE (LOW-					7 ± 3
PRESSURE SWITCH) (psig)
Cutout
Reset (Auto.)					22 ± 7
FREEZE PROTECTION
THERMOSTAT (F)
Opens					30 ± 5
Closes					45 ± 5
OUTDOOR-AIR INLET SCREENS					Cleanable
Quantity...Size (in.)				1...20 x 24 x 1
RETURN-AIR FILTERS				Throwaway
Quantity...Size (in.)				2...16 x 25 x 2

		LEGEND
Al	—	Aluminum
Bhp	—	Brake Horsepower
Cu	—	Copper

*Evaporator coil fin material/condenser coil fin material. Contact your local representative for details about coated fins.

†Weight of 14-in. roof curb. **Single phase/three-phase.

††Rollout switch lockout is manually reset by interrupting power to unit or resetting thermostat.

||Single-phase units have a single-stage gas valve. The heating input values are as follows:

48TFF004, 115,000 Btuh 48TFF005, 150,000 Btuh 48TFF006, 150,000 Btuh

NOTE: High-static motor not available on single-phase units.

6

7

				STD UNIT				DURABLADE		ECONOMI$ER			(A)			(B)			(C)					(D)		“A”
		UNIT		WEIGHT				ECONOMIZER WEIGHT		WEIGHT		CORNER WEIGHT			CORNER WEIGHT			CORNER WEIGHT					CORNER WEIGHT			PANEL
				Lbs		Kg		Lbs	Kg	Lbs	Kg	Lbs		Kg	Lbs		Kg	Lbs				Kg	Lbs		Kg	LENGTH
	48TFN,TFM,TFF,TFE004			460		209						140		63.5	105		47.6	159		72.1			56		25.4	1¢-103/8² [568.0]
48TFN,TFM,TFL,TFF,TFE,TFD005				470		213		34	15.4	47	21.3	142		64.4	106		48.1	162		73.5			60		27.2	1¢-103/8² [568.0]
48TFN,TFM,TFL,TFF,TFE,TFD006				490		222						150		68.0	115		52.2	160		72.6			65		29.5	1¢-03/8² [315.0]
		48TFF,TFE,TFD007		565		256						165		74.8	136		61.7	200		90.7			64		29.0	1¢-03/8² [315.0]
		CONNECTION SIZES
A		13/8² Dia. [35] Field Power Supply Hole
B		2² Dia. [51] Power Supply Knockout
C		21/2² Dia. [64] Power Supply Knockout
D		7/8² Dia. [22] Field Control Wiring Hole
E		3/4²-14 NPT Condensate Drain
F		1/2²-14 NPT Gas Connection

NOTES:

1. Dimensions in [ ] are in millimeters.

2. Center of Gravity.

3. Direction of Airflow.

4.On vertical discharge units, ductwork to be attached to accessory roof curb only. For horizontal discharge units, field-supplied flanges should be attached to horizontal discharge openings, and all ductwork should be attached to the flanges.

5.Minimum clearance (local codes or jurisdiction may prevail):

a. Between unit, flue side and combustible surfaces, 36 inches.

b. Bottom of unit to combustible surfaces (when not using curb) 1 inch. Bottom of base rail to combustible surfaces (when not using curb) 0 inches.

c.Condenser coil for proper airflow, 36 in. one side, 12 in. the other. The side getting the greater clearance is optional.

d.Overhead, 60 in. to assure proper condenser fan operation.

e.Between units, control box side, 42 in. per NEC (National Electrical Code).

f.Between unit and ungrounded surfaces, control box side, 36 in. per NEC.

g.Between unit and block or concrete walls and other grounded surfaces, control box side, 42 in. per NEC.

h.Horizontal supply and return end, 0 inches.

6.With the exception of the clearance for the condenser coil and combustion side as stated in Note 5a, b, and c, a removable fence or barricade requires no clearance.

7.Units may be installed on combustible floors made from wood or Class A, B, or C roof covering material if set on base rail.

8.The vertical center of gravity is 1¢-6² [457] up from the bottom of the base rail.

BOTTOM POWER CHART,

THESE HOLES REQ’D FOR USE WITH ACCESSORY PACKAGES — CRBTMPWR001A00, 3A00 (1/2², 3/4²)

THREADED

WIRE

REQ’D HOLE

CONDUIT

SIZES

USE

SIZE

(Max.)

1/2²

24 V

7/8² [22.2]

3/4²

Power

11/8² [28.4]

1/2² FPT

Gas

11/4² [31.8]

Fig. 6 — Base Unit Dimensions

Step 7 — Make Electrical Connections

Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code), ANSI/NFPA, latest edition, and local electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning could result in the installer being liable for personal injury of others.

FIELD POWER SUPPLY — All units except 208/230-v units are factory wired for the voltage shown on the nameplate. If the 208/230-v unit is to be connected to a 208-v power supply, the transformer must be rewired by moving the black wire with the 1/4-in. female space connector from the 230-volt connection and moving to the 200-volt 1/4-in. male terminal on the primary side of the transformer.

Refer to unit label diagram for additional information. Pigtails are provided for field wire connections. Use factorysupplied splices or UL (Underwriters’ Laboratories) approved copper/aluminum connector.

When installing units, provide a disconnect per the NEC.

All field wiring must comply with NEC and local requirements.

Install field wiring as follows:

1.Install conduit through side panel openings. For units without electric heat, install conduit between disconnect and control box.

2.Install power lines to terminal connections as shown in Fig. 9.

Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate (see Table 2). On 3-phase units, voltages between phases must be balanced within 2% and the current within 10%. Use the formula shown in the legend for Table 2, Note 2 to determine the percent of voltage imbalance. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty.

FIELD CONTROL WIRING — Install a Carrier-approved accessory thermostat assembly according to installation instructions included with the accessory. Locate thermostat assembly on a solid wall in the conditioned space to sense average temperature in accordance with thermostat installation instructions. Connect thermostat wires to terminal board.

Route thermostat cable or equivalent single leads of colored wire from subbase terminals through connector on unit to lowvoltage connections (shown in Fig. 10).

NOTE: For wire runs up 50 ft, use no. 18 AWG (American Wire Gage) insulated wire (35 C minimum). For 50 to 75 ft, use no. 16 AWG insulated wire (35 C minimum). For over 75 ft, use no. 14 AWG insulated wire (35 C minimum). All wire larger than no. 18 AWG cannot be directly connected to

BLOWER

ACCESS

PANEL

Fig. 7 — Flue Hood Details

LEGEND

NFGC — National Fuel Gas Code *Field supplied.

NOTE: Follow all local codes.

SPACING OF SUPPORTS

STEEL PIPE	X
NOMINAL DIAMETER	DIMENSIONS
(in.)	(feet)
1/	6
2
3/ or 1	8
4
11/ or larger	10
4

Fig. 8 — Gas Piping Guide (With Accessory Thru-the-Curb Service Connections)

the thermostat and will require a junction box and splice at the thermostat.

Pass the control wires through the hole provided in the corner post; then feed wires through the raceway built into the corner post to the 24-v barrier located on the left side of the control box. See Fig. 11. The raceway provides the UL required clearance between highand low-voltage wiring.

HEAT ANTICIPATOR SETTINGS — Set heat anticipator settings at .14 amp for the first stage and .14 amp for secondstage heating, when available.

8

	208/230-1-60	208/230-3-60
		460-3-60
		(SIZE 007 ONLY)

		575-3-60	208/230-3-60
		(SIZE 007 ONLY)	575-3-60, 460-3-60
			(SIZES 004-006)
		LEGEND
C	—	Contactor
COMP —		Compressor
NEC	—	National Electrical Code
TB	—	Terminal Block

Fig. 9 — Power Wiring Connections

RACEWAY LOW VOLTAGE

INTEGRATED GAS UNIT

CONNECTIONS

CONTROLLER (IGC)

	LEGEND
AHA	— Adjustable Heat Anticipator
	Field Wiring
	Factory Wiring

NOTES:
1.	Connect Y2 when unit is equipped with an economizer.	HOLE IN END PANEL (HIDDEN)
2.	Connect W2 when unit is equipped with two stages of heat.
	Fig. 10 — Low-Voltage Connections	Fig. 11 — Field Control Wiring Raceway

9

Table 2 — Electrical Data

UNIT	NOMINAL	IFM	VOLTAGE		COMPRESSOR				OFM		IFM	COMBUSTION	POWER		DISCONNECT
			RANGE			(ea)			(ea)			FAN MOTOR	SUPPLY		SIZE*
48TF	V-Ph-Hz	TYPE									FLA
			Min	Max	RLA		LRA	Qty	Hp	FLA		FLA	MCA	MOCP†	FLA	LRA
	208/230-1-60	Std	187	254	16.2		96.0	1	1/	1.4	3.5	.6	24.5/24.5	30/30	23/23	106/106
		Alt							4		4.9		26.6/26.6	35/35	26/26	111/111
		Std									3.5		17.7/17.7	25/25	17/17	85/85
	208/230-3-60	Alt	187	254	10.2		75.0	1	1/	1.4	4.9	.6	19.1/19.1	25/25	19/19	90/90
									4
		High									5.2		19.4/19.4	25/25	19/19	109/109
004		Std									1.3		7.6	15	7	48/48
	460-3-60	Alt	414	508	4.4		40.0	1	1/	0.8	2.1	.3	8.4	15	8	48/48
									4
		High									2.6		8.9	15	9	57/57
		Std									1.3		6.3	15	7	35
	575-3-60	Alt	518	632	3.7		31.0	1	1/	0.8	2.1	.3	6.9	15	8	37
									4
		High									2.6		7.3	15	7	45
	208/230-1-60	Std	187	254	23.3		118.0	1	1/	1.4	3.5	.6	34.0/34.0	40/40	32/32	129/129
		Alt							4		4.9		35.4/35.4	45/45	34/34	133/133
		Std									3.5		24.2/24.2	30/30	23/23	101/101
	208/230-3-60	Alt	187	254	15.4		90.0	1	1/	1.4	4.9	.6	25.6/25.6	30/30	25/25	105/105
									4
		High									5.2		25.9/25.9	30/30	25/25	124/124
005		Std									1.8		13.0	20	13	51
	460-3-60	Alt	414	508	8.3		45.0	1	1/	0.8	2.1	.3	13.3	20	13	53
									4
		High									2.6		13.8	20	13	62
		Std									1.8		10.1	15	10	41
	575-3-60	Alt	518	632	6.4		36.0	1	1/	0.8	2.1	.3	10.3	15	11	42
									4
		High									2.6		10.7	15	10	50
	208/230-1-60	Std	187	254	28.8		147	1	1/	1.4	5.9	.6	43.3/43.3	60/60	42/42	161/161
		Alt							4		6.6		44.0/44.0	60/60	42/42	184/184
		Std									5.9		27.3/27.3	35/35	29/29	128/128
	208/230-3-60	Alt	187	254	16.3		114	1	1/	1.4	5.2	.6	26.6/26.6	35/35	26/26	148/148
									4
		High									7.5		28.9/28.9	35/35	29/29	174/174
006		Std									3.1		13.2	20	13	72
	460-3-60	Alt	414	508	7.4		64	1	1/	0.8	2.6	.3	12.7	15	12	81
									4
		High									3.4		13.5	20	13	94
		Std									3.1		10.9	15	11	58
	575-3-60	Alt	518	632	6.2		62	1	1/	0.8	3.0	.3	10.5	15	10	66
									4
		High									3.4		12.6	15	11	76
	208/230-3-60	Std	187	254	23.6		146	1	1/	1.4	5.2	.6	30.2/30.2	35/35	29/29	180/180
		High							4		7.5		32.5/32.5	40/40	32/32	205/205
007	460-3-60	Std	414	508	10.6		73	1	1/	0.6	2.6	.3	15.4	20	15	90
		High							4		3.4		16.1	20	16	103
	575-3-60	Std	518	632	8.5		58.4	1	1/	0.6	2.6	.3	12.3	15	13	72
		High							4		3.4		12.9	20	14	82

		LEGEND
FLA	—	Full Load Amps
HACR —		Heating, Air Conditioning and Refrigeration
IFM	—	Indoor (Evaporator) Fan Motor
LRA	—	Locked Rotor Amps
MCA	—	Minimum Circuit Amps
MOCP —		Maximum Overcurrent Protection
NEC	—	National Electrical Code
OFM	—	Outdoor (Condenser) Fan Motor
RLA	—	Rated Load Amps

*Used to determine minimum disconnect per NEC. †Fuse or HACR circuit breaker.

NOTES:

1.In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker. Canadian units may be fuse or circuit breaker.

2.Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine the percent of voltage imbalance.

% Voltage Imbalance

= 100 x

max voltage deviation from average voltage

average voltage

Example: Supply voltage is 460-3-60.

AB = 452 v

BC = 464 v

AC = 455 v

Average Voltage =

452 + 464 + 455

3

=

1371

3

= 457

Determine maximum deviation from average voltage. (AB) 457 – 452 = 5 v

(BC) 464 – 457 = 7 v (AC) 457 – 455 = 2 v

Maximum deviation is 7 v.

Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x

7

457

= 1.53%

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.

10

Step 8 — Make Outdoor-Air Adjustments and Install Outdoor-Air Hood

MANUAL OUTDOOR-AIR DAMPER — The out door-air hood and screen are attached to 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 panel and screws. See Fig. 12.

3.Separate hood and screen from basepan by removing the 4 screws securing them. Save all screws.

4.Replace evaporator coil access panel.

OUTDOOR

AIR OPENING

PANEL

3 SCREWS (SIDE)

5.Place hood on front of outdoor air opening panel. See Fig. 13 for hood details. Secure top of hood with the 4 screws removed in Step 3. See Fig. 14.

6.Remove and save 6 screws (3 on each side) from sides of the manual outdoor-air damper.

7.Align screw holes on hood with screw holes on side of manual outdoor-air damper. See Fig. 13 and 14. Secure hood with 6 screws from Step 6.

8.Adjust minimum position setting of the damper blade by adjusting the manual outdoor-air adjustment screws on the front of the damper blade. See Fig. 12. Slide blade vertically until it is in the appropriate position determined by Fig. 15. Tighten screws.

9.Remove and save screws currently on sides of hood. Insert screen. Secure screen to hood using the screws. See Fig. 14.

	Fig. 14 — Outdoor-Air Damper with
Fig. 12 — Damper Panel with Manual Outdoor-Air	Hood Attached
Damper Installed

Fig. 15 — Position Setting

Fig. 13 — Outdoor-Air Hood Details

11

OPTIONAL DURABLADE ECONOMIZER — The optional economizer hood assembly is packaged and shipped in the filter section. Damper blades and control boards are installed at the factory and the economizer is shipped in the vertical discharge position.

NOTE: Horizontal discharge block-off plate is shipped with the air hood package. If unit is to be used for vertical discharge application, discard this plate.

Assembly:

1.Determine if ventilation air is required in building. If so, determine minimum amount to be supplied by each unit and record quantity of ventilation air needed for use in Step 6.

2.Remove filter access panel by raising panel and swinging panel outward. Panel is now disengaged from track and can be removed. No tools are required to remove filter access panel. Remove outdoor-air opening panel. Save panels and screws. See Fig. 16. Remove optional outdoor-air damper hood package from filter section.

3.Assemble outdoor-air hood top and side plates as shown in Fig. 17. Install seal strips on hood top and sides. Put aside screen retainer and screws for later assembly. Do not attach hood to unit at this time.

4.To convert to horizontal discharge application:

a.Rotate economizer 90 degrees until the economizer motor faces the condenser section (see Fig. 18).

b. Rotate the barometric relief damper hinge 90 degrees. Barometric relief damper should open vertically to operate properly.

c.Install horizontal discharge block-off plate over the opening on the access panel. (Block-off plate MUST be installed before installing hood assembly.) See Fig. 19.

5.Insert economizer plug into economizer harness. Remove tape from barometric relief damper. See Fig. 20.

6.If ventilation air is not required, proceed to Step 7. If ventilation air is required, determine minimum position setting for required airflow. See Fig. 21. Adjust minimum position setting by adjusting the screws on the position setting bracket. Slide bracket until the top screw is in the position determined by Fig. 21. Tighten screws.

7.Remove tape from outdoor-air thermostat (OAT). Fasten OAT to inside of hood using screws and speed clips provided. See Fig. 22. Make sure OAT terminals are positioned up.

8.Replace outdoor-air opening panel using screws from Step 2. Replace filter access panel. Ensure the filter access panel slides along the tracks and is securely engaged.

9.Fasten hood top and side plate assembly (Fig. 17) to outdoor-air opening panel with screws provided.

10.Place knob supplied with economizer on OAT. See Fig. 22. Set for 3° F below indoor room thermostat setting. If accessory enthalpy control (EC) is used in place of OAT, see instructions shipped with EC for installation and adjustment. See Fig. 22.

11.Connect OAT per Fig. 23.

12.Slide outdoor-air inlet screen into screen track on hood side plate. While holding screen in place, fasten screen retainer to hood using screws provided.

NOTE: Refer to Fig. 24 for economizer barometric relief damper characteristics.

Fig. 16 — Typical Access Panel Locations

Fig. 17 — Outdoor-Air Hood Details

ECONOMIZER CONTROL BOARD

BAROMETRIC

RELIEF

DAMPER

ECONOMIZER

PLUG

SHIPPING

SCREW

ECONOMIZER

MOTOR

Fig. 18 — Horizontal Durablade Economizer

Installation

12

BLOCK-OFF PLATE

Fig. 19 — Horizontal Discharge Block-Off Plate

U-SHAPED

ECONOMIZER

HOLE

CONTROL

ECONOMIZER

ECONOMIZER

TOP

(NOT

BOARD

PLUG

MOTOR

SCREW

SHOWN)

WIRING

HARNESS

BAROMETRIC

RELIEF DAMPER

SHIPPING

SCREW

POSITION SETTING

BRACKET

Fig. 20 — Durablade Economizer Installed in Unit

ENTHALPY

CONTROL

REV

B .

OPEN

POSITIONMINIMUM

B

S

C

O

TR

D

S

T

3

1

P

HOOD

T1

4

2

5

P1

T ID

8

CONT

OR

CONT

Y

%

8 RUSH

A

1

IMUH

–

9

AC

UNPOWERED

SHO

C

30 60

70

90

1

AT

ACT

CTS

3

ENTHALPY

60

DAMPER

D

A

5A

TE

2

TR

10

CW

24V

RA

50

TINGS:

ST

AC

55

OUTDOOR

OPEN

B

SETPOINTS

WN

24V

3 .

HIGH

A

1

A

IN

75

CLOSED

DAMPER

mA

RUN,

TR1

CONTROL

F

VDC

1

65 70

.

°

CCW

MIN

IN

ENTHALPY

1

TEMP

–

A

3

1

.

5A

.

T

80

85

REV.

97-3672

EXAMPLE:

Given — Negative Pressure . . . . . . . . . . . . . . . . . . . . . . . 0.2 in. wg Outdoor Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 cfm

Determine — Setting = 5 in.

Fig. 22 — Outdoor-Air Thermostat/

Enthalpy Control Installation

Fig. 21 — Durablade Economizer

Minimum Position Setting

13

LEGEND

OAT — Outdoor-Air Thermostat

NOTE: See unit wiring diagram for details.

Fig. 23 — Wiring Connections for

Outdoor-Air Thermostat

	0.90
	0.80
wg)(in.	0.70
	0.60
DROP
	0.50
PRESSURE
	0.40
	0.30
	0.20
	0.10
	0.00
			100				200		300		400		500		600		700		800
											CFM

Fig. 24 — Durablade Economizer

Barometric Relief Damper Characteristics

OPTIONAL ECONOMI$ER — See Fig. 25 for Ec onoMi$er component locations.

1.To 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 discard. See Fig. 26.

If installing an optional Power Exhaust Assembly, refer to the EconoMi$er Power Exhaust Installation Instructions.

Controller should be mounted in vertical position as shown in Fig. 25.

2.Assemble the hood assembly as follows:

Remove the EconoMi$er hood from its packaging. Remove shipping brackets holding hood package to EconoMi$er. Locate the outdoor-air opening panel. See Fig. 27. Remove hood assembly shipping brackets located on the back (sloped) side of the EconoMi$er assembly. These brackets are used to retain the hood assembly during shipping only.

3.Installs the 1/8 x 3/4-in. seal strip on the exhaust air hood side panels and the bottom bracket. Assemble the exhaust air hood to the outdoor-air opening panel as shown in Fig. 27, using the screws provided. Do not attach hood assembly to unit at this time.

4.Install the 1/8 x 3/4-in. seal strip on the outdoor-air hood top and side panels. Assemble the outdoor-air hood to the outdoor-air opening panel as shown in Fig. 28, using the screws provided. Do not attach hood assembly to the unit

at this time.

	ECONOMI$ER	CONTROLLER
	PLUG
		GEAR-DRIVEN
		DAMPER

OUTDOOR AIR

TEMPERATURE

SENSOR

ACTUATOR

BAROMETRIC RELIEF DAMPERS

Fig. 25 — EconoMi$er Component Locations

OUTDOOR-AIR	FILTER ACCESS
OPENING PANEL	PANEL

Fig. 26 — Typical Access Panel Locations

OUTDOOR AIR

OPENING PANEL EXHAUST AIR HOOD TOP

SCREEN

RETAINER

	EXHAUST AIR
SEAL STRIP	HOOD SIDES

EXHAUST AIR SCREEN

EXHAUST AIR BOTTOM BRACKET

Fig. 27 — Exhaust Air Hood Assembly

14

5.Slide the outdoor-air inlet screens into the screen track on the hood side panels. While holding the screens in place, fasten the screen retainer to the hood using the screws provided. Repeat the process for the barometric exhaust air screen. Do not attach completed (Fig. 29) hood assembly to unit at this time.

6.Slide the EconoMi$er assembly into the rooftop unit. See Fig. 30 and 31.

NOTE: Be sure to engage rear EconoMi$er flange under tabs in return-air opening of the unit base. See Fig. 30.

7.Install the outdoor-air block-off plate, then secure the EconoMi$er with the screws provided. See Fig. 31.

8.Remove and discard the 12-pin jumper plug from the unit wiring harness located in the upper left corner and insert the EconoMi$er plug into the unit wiring harness. Refer to wiring diagram Fig. 32 and 33. Also refer to Fig. 34 if installing an accessory power exhaust.

9.Install the complete hood assembly on the unit and secure using the screws provided.

10.Remove the indoor fan motor access panel. See Fig. 35.

11.Mount the supply-air temperature sensor to the lower left portion of the indoor blower housing with the two (2) screws provided (see Fig. 36). Connect the violet and pink wires to the corresponding connections on the supply-air temperature sensor. Replace the indoor fan motor access panel.

Fig. 29 — Completed Hood Assembly

UNIT FILTER	ECONOMI$ER CLIP
RACK	HVAC UNIT

ECONOMI$ER

UNIT BASE

ECONOMI$ER REAR

FLANGE

Fig. 30 — Rear EconoMi$er Flange Installation

	OUTDOOR AIR	SEAL STRIP
	OPENING
		OUTDOOR AIR
	PANEL	HOOD TOP
		WIRING
		HARNESS
		SCREEN
		RETAINER

SEAL STRIP	OUTDOOR AIR	OUTDOOR
	INLET
	SCREENS	AIR
		BLOCK-OFF
ASSEMBLED		PLATE
EXHAUST HOOD
OUTDOOR AIR
HOOD SIDES
Fig. 28 — Outdoor-Air Hood Assembly		Fig. 31 — EconoMi$er Installed

15

LEGEND

OAT — Outdoor-Air Temperature

RAT — Return-Air Temperature

Fig. 32 — EconoMi$er Wiring

ECONOMI$ER

BROWN

TEMP

CONTROLLER

VIOLET

TEMP

OUTDOOR

OAT

COM

AIR

COM

WHITE

OUT

SENSOR

OAH

RED

PWR

-15 V

BROWN

TEMP

RAT

COM

VIOLET

TEMP

RETURN

WHITE

COM

AIR

RAH

SENSOR

+15 V

RED

OUT

PWR

CO2 SENSOR

CO2 (+)

V+

24

CO2 COM

COM

VAC

DAT

COM

SUPPLY AIR

REM POT

TEMPERATURE SENSOR

COM

PINK

TEMP

LED

VIOLET

TEMP

COM

Fig. 33 — EconoMi$er Sensor Wiring

16