Carrier 48TJ016-028 User Manual

Single-Package Rooftop Units

Electric Cooling/Gas Heating

Installation, Start-Up and

Service Instructions

48TJ016-028

CONTENTS

Page

SAFETY CONSIDERATIONS............................................I

INSTALLATION.............................................................2-31

Step 1 — Provide Unit Support............................................2

• ROOF CURB

• ALTERNATE UNIT SUPPORT Step 2 —- Rig and Place Unit

• POSITIONING

• ROOF MOUNT

Step 3 — Field Fabricate Ductwork.....................................9

Step 4 — Make Unit Duct Connections Step 5 — Install Flue Hood and Wind Baffle

Step 6 — Trap Condensate Drain........................................9

Step 7 — Orifice Change Step 8 — Install Gas Piping Step 9 — Make Electrical Connections

• FIELD POWER SUPPLY

• FIELD CONTROL WIRING

• OPTIONAL NON-FUSED DISCONNECT

• OPTIONAL CONVENIENCE OUTLET

Step 10 — Make Outdoor-Air Inlet Adjustments,. 14 Step 11 — Install Outdoor-Air Hood

Step 12 — Install All Accessories.......................................15

MOTORMASTER® I CONTROL INSTALLATION MOTORMASTER V CONTROL INSTALLATION

Step 13 — Adjust Factory-Installed Options

PREMIERLINKTM CONTROL ENTHALPY SWITCH/RECEIVER OUTDOOR ENTHALPY CONTROL DIFFERENTIAL ENTHALPY CONTROL ENTHALPY SENSORS AND CONTROL OPTIONAL ECONOMISERIV AND

ECONOMI$ER2

ECONOMI$ERIV STANDARD SENSORS ECONOMI$ERIV CONTROL MODES

Step 14 — Install Humidlstat for

Optional MoistureMISer’'“ Package

START-UP......................................................................31-38

SERVICE........................................................................39-47

TROUBLESHOOTING

INDEX...................................................................................53

START-UP CHECKLIST..............................................CL 1

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11 11

48 52

precautions in the literature, tags and labels attached to the unit, and other safety precautions that may apply.

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

A WARNING

Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injuiy.

A WARNING

1. Improper instiillation, adjustment, alteration, service, or maintenance can cause properfy ckimage, personal injuiy, or loss of life. Refer to the User's Information Manual provided with this unit for more details.

2, Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of tliis or any otlier appliance.

What to do if you smell gas:

1. DO NOT tiy to light any appliance.

2. DO NOT touch any electrical switch, or use any phone in your building,

3. IMMEDIATELY call your gas supplier from a neigh bor’s phone. Follow the gas supplier’s instmctions.

4. If you cannot reach your gas supplier, cttll the fire deparfment.

A WARNING

Disconnect gas piping from unit when pressure testing at pressure greater than 0.5 psig. Pressures greater than

0.5 psig will cause gas valve damage resulting in haziu'dous condition. If gas valve is subjected to pressure greater than

0.5 psig, it must be replaced before use. When pressure testing field-supplied gas piping at pressures of 0.5 psig or less, a unit connected to such piping must be isolated by closing the manual gas valve(s).

SAFETY CONSIDERATIONS

Installation and seiTicing of air-conditioning equipment can be hazardous due to system pressure and electrictil compo nents, Only triiined and qualified service personnel should in stall, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance func tions 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

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

Book 1 |4

Tab lajca

Catalog No. 04-53480009-01 Printed in U.S.A. Form 48TJ-22SI Pg 1 3-06 Replaces: 48TJ-21SI

IMPORTANT: Units have high ambient operating lim its. If limits are exceeded, the units will automatically lock the compressor out of operation. Manuiil reset will be required to restiuf the compressor.

INSTALLATION

Inspect unit for transportation danage. If cktmage is found,

file claim with transportation agency.

Step 1 — Provide Unit Support

ROOF CURB — Assemble and install accessoiy roof curb or horizontiil adapter roof cuifi in accordance witli instinctions shipped with this accessoiy. See Fig. 1 and 2. Install insulation, cant strips, roofing, and counter flashing as shown. Ductwork can be installed to roof curb or horizontal adapter roof curb be fore unit is set in place. Curb or adapter roof curb should be level. Tills is necessaiy to permit unit drain to function proper ly. Unit leveling tolerance is ± Vu, in. per linear ft in any direc tion. Refer to Accessoiy Roof Curb or Horizontal Adapter Roof Curb Installation Instmctions for additional information as required. When accessoiy roof curb or horizontal adapter roof curb is used, unit may be installed on class A, B, or C roof covering material.

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

ALTERNATE UNIT SUPPORT ^ When the curb or adapter cannot be used, install unit on a noncombustible surface. Sup port unit with sleepers, using unit curb support area. If sleepers cannot be used, support long sides of unit with a minimum of 3 equally spaced 4-in. x 4-in. pads on each side.

Step 2 — Rig and Place Unit — Do not di'op unit; keep upright. Use spreader biu's over unit to prevent sling or cable diimage. Rollers may be used to move unit across a roof. Level by using unit frame as a reference; leveling tolerance is ±V](i in. per linear ft in any direction. See Fig. 3 for additional information. Unit operating weight is shown in Table 1.

Four lifting holes are provided in ends of unit base rails as

shown in Fig. 3. Refer to rigging instmctions on unit. POSITIONING — Maintain clearance, per Fig. 4 and 5,

around and above unit to provide minimum distance from combustible materials, proper airflow, and service access.

Do not install unit in an indoor location. Do not locate unit air inlets near exhaust vents or other sources of contaminated air. For proper unit operation, adequate combustion and venti lation ail' must be provided in accordance with Section 5.3 (Air for Combustion and Ventilation) of the National Fuel Gas Code, ANSI Z223.1 (American National Standards Institute).

Although unit is weatlierproof, guard against water from higher level mnoff and overhangs.

Locate mechanical di'aft system flue assembly at least 4 ft from any opening through which combustion products could enter the building, and at least 4 ft from any adjacent building. When unit is located adjacent to public walkways, flue assem bly must be at least 7 ft above grade.

ROOF MOUNT — Check building codes for weight distri bution requirements. Unit operating weight is shown in Table 1.

Instructions continued cm page 9.

NOTE: CRRFCURB013A00 is a fuliy factory prsassembied hori zontal adapter and includes an insulated transition duct. The pres sure drop through the adapter curb is negligible.

For horizontal return applications; The power exhaust and baro

metric relief dampers must be installed in the return air duct.

Fig. 1 — Horizontal Supply/Return Adapter Installation

ACCESSORY

PACKAGE NO.

CRRFCURB013AOO

CURB

HEIGHT

(584)

DESCRIPTION

Pre-Assembled, Roof Curb,

Horizontal Adapter

PKG. NO. REF.

CURB

HEIGHT

DESCRIPTION

CRRFCURB010A00 2" (305) Standard Curb 14" High CRRFCURB011A00 2'- 0"(610) Standard Curb for Units Requiring High Installation CRRFCURB012A00 2'- 0"(610) Side Supply and Return Curb for High Installation

NOTES:

K ROOF CURB ACCESSORY 15 SHIPPED D15AS5EHBLED.

2. INSULATED PANELS: 1* THICK NEOPRENE COATED 1-1/2 LB DENSITY

3. DIMENSIONS IN C ) ARE IN MILLIMETERS.

4. c=i> direction of AIR FLOW

5. ROOFCURB: 16 GA. CVA03-56) STL. S. A 30 DEGREE ELBOW MUST BE INSTALLED ON THE SUPPLY DUCT

WORK BELOW THE UNIT DISCHARGE FOR UNITS EQUIPPED WITH ELECTRIC HEATERS.

NOTE; TO PREVENT THE HAZARD OF STAGNANT WATER BUllD-UP IN THE DRAIN PAN OF THE INDOOP SECTION, UNIT CAN ONLY BE PITCHED AS SHOWN.

....

UNIT

ALL .26 .45 .28 .43

CONDENSER

AND

COMPRESSOR

END

DIMENSIONS (degrees ond inches)

DEG. IN. DEG. IN.

UNIT LEVELING TOLERANCES

-nom edge oF unit to horizcntoL.

A-

NOM. 5/4 K

(323 X (1023

TYP. 4 PLC5

COUNTER FLASHING;

CRRFCURB012A00'0NLY) 0

<CRRFCURB012AOO ONLY)

(FIELD SUPPLIED)

•ROOFING FELT (FIELD SUPPLIED)

■CANT STRIP

(FIELD SUPPLIED)

ROOFING MATERIAL

(FIELD SUPPLIED)

Fig. 2 — Roof Curb Details

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 rails as shown. Use corner post from packaging to protect coil from

damage. Use bumper boards for spreader bars on all units.

5. Weights do not include optional economizer. Add 90 lb (41 kg) for economizer weight.

6. Weights given are for aluminum evaporator and condenser coil plate fins.

A CAUTION

All panels must be in place when rigging.

UNIT 48TJ

016 1775 805 020 1875 850 6-11 Vg 2121 3-3 991 024 1985 900 028 2135 968 6-11 Vg 2121 3-2 965

MAXIMUM

SHIPPING WEIGHT

lb kg Ft-in. mm Ft-in. mm

6-11V2

6-11 Vg

DIMENSIONS

A B

2121 3-5 1041

2121 3-2 965

Fig. 3 — Rigging Detaiis

HP m PLCS

0 ' ■ 3 T3S“^ Í

1993 I

STD UNIT

WEIGHT

UNIT

48TJD,

1650 748 90 41 423 192 386 175 403 183 438 199 3-5 1041 3-5 1041 1-10 559

TJF016

48TJD,

1800 816 90 41 432 196 410 186 461 209 472 214 3-3 991 3-7 1092 1-8 508

TJF020

ECONOMIZER

WEIGHT

CORNERACORNERBCORNERCCORNER

NOTES:

1. Refer to print for roof curb accessory dimensions.

2. Dimensions in ( ) are in miiiimeters.

o Direction of airflow.

5. Ductwork to be attached to accessory roof curb only.

6. Minimum clearance:

• Rear: 7'-0" (2134) for coil removal. This dimension can be reduced to

4'-0" (1219) if conditions permit coil removal from the top.

• 4'-0" (1219) to combustible surfaces, all four sides (includes between

units).

• Left side; 4'-0" (1219) for proper condenser coil airflow.

• Front: 4'-0" (1219) for control box access.

• Right side: 4'-0" (1219) for proper operation of damper and power

exhaust if so equipped.

• Top: 6'-0" (1829) to assure proper condenser fan operation.

• Bottom: 14" (356) to combustible surfaces (when not using curb).

• Control box side; 3'-0" (914) to ungrounded surfaces, non-combustible.

• Control box side: 3'-6" (1067) to block or concrete walls, or other

grounded surfaces.

• Local codes or jurisdiction may prevail.

7. With the exception of clearance for the condenser coil and the damper/ power exhaust as stated in Note #6, a removable fence or barricade requires no clearance.

8. Dimensions are from outside of corner post. Allow O'-s/ie" (8) on each side for top cover drip edge.

Center of Gravity,

DIMA DIM B DIM C

ft-in. mm ft-in. mm ft-in. mm

Fig. 4— Base Unit Dimensions; 48TJ016,020

SECTION A-A

TTP (41 PLCS^

0'-3 ?/8'

1 3/8* 8iA. 08AIM HOLE

STD UNIT

WEIGHT

UNIT

48TJD,

1850 839 90 41 443 201 406 184 476 216 525 238 3-2 965 3-5 1041 1-8 508

TJF024 48TJD,

2000 907 90 41 471 214 428 194 526 239 574 260 3-2 965 3-5 1041 1-8 508

TJF028

ECONOMIZER

WEIGHT

CORNERACORNERBCORNERCCORNER

NOTES:

1. Refer to print for roof curb accessory dimensions.

2, Dimensions in ( ) are in millimeters. 3^ Center of Gravity.

5. Ductwork to be attached to accessory roof curb only.

6. Minimum clearance:

• Rear: 7'-0" (2134) for coil removal. This dimension can be reduced to

4'-0" (1219) if conditions permit coil removal from the top.

• 4'-0" (1219) to combustible surfaces, all four sides (includes between

units). ' Left side: 4'-0" (1219) for proper condenser coil airflow. ' Front: 4'-0" (1219) for control box access.

• Right side: 4'-0" (1219) for proper operation of damper and power

exhaust if so equipped.

• Top: 6'-0" (1829) to assure proper condenser fan operation. ' Bottom: 14" (356) to combustible surfaces (when not using curb). ' Control box side: 3'-0" (914) to ungrounded surfaces, non-combustible.

• Control box side: 3'-6" (1067) to block or concrete walls, or other

grounded surfaces.

• Local codes or jurisdiction may prevail.

7. With the exception of clearance for the condenser coil and the damper/ power exhaust as stated in Note #6, a removable fence or barricade requires no clearance.

8. Dimensions are from outside of corner post. Allow O'-^/ie" (8) on each side for top cover drip edge.

Direction of airflow.

DIMA DIM B DIMC

ft-in. mm ft-in. mm tt-in. mm

Fig. 5 — Base Unit Dimensions; 48TJ024,028

SECTfON A-A

Table 1 — Physical Data

UNIT 48TJ

208/230, 460 V 1 575 V NOMINAL CAPACITY (tons) 15 18 20 25 OPERATING WEIGHT (lb)

Economizer Roof Curb

COMPRESSOR

Quantity...Model (Ckt 1, Ckt 2) Number of Refrigerant Circuits

Oi!(oz)(Ckt1,Ckt 2) Stages of Capacity Controi (%)

REFRiGERANTTYPE

Expansion Device Operating Charge (Ib-oz) Circuit 1* Circuit 2

CONDENSER COIL

Rows...Fins/in.

Total Face Area (sq ft)

CONDENSER FAN

Nominal Cfm Quantity...Diameter (in.) Motor Hp...Rpm

Watts Input (Total)

EVAPORATOR COIL

Rows...Fins/in.

Total Face Area (sq ft)

EVAPORATOR FAM Centrifugal Type

Quantity...Size (in.) 2...10 X 10 2...10 X 10 2...12X 12 2...12 X 12 2...12X 12

Type Drive Belt Belt Belt Belt Belt

Nominal Cfm 6000 6000 7200 8000 10,000 Motor Hp 3.7 3.0 5 7.5 10 Motor Nominal Rpm 1725 1725 1745 1745 1740

Maximum Continuous Bhp 4.25 3.45 5.90 Motor Frame Size 56H 56H 184T 213T 215T

Nominal Rpm High/Low Fan r/s Range Low-Medium Static 891-1179 1159-1429 910-1095 1002-1225 1066-1283

Motor Bearing Type Ball Ball Ball Ball Ball Maximum Allowable Rpm 1550 1550 1550 1550 1550 Motor Pulley Pitch Diameter Low-Medium Static 3.1/4.1 4.3/5,3 4.9/5.9 5.4/6.6 4,9/5.9

Min/Max (in.) High Static 3.7/4.7 Nomina! Motor Shaft Diameter (in.) Fan Pulley Pitch Diameter (in.) Low-Medium Static 6.0 6.4 9.4 9.4 8.0

Nominal Fan Shaft Diameter (in.) Belt, Quantity..,Type...Length (in.) Low-Medium Static 1...BX...42 1...BX...45 1...BX...50 1...BX...54 2...BX...50

Pulley Center Line Distance (in.) 13.5-15,5 13.5-15,5 13.3-14.8 14.6-15.4 14,6-15.4 Speed Change per Full Turn of Low-Medium Static 48 44 37 37 36

Movable Pulley Flange (rpm) Movable Pulley Maximum Full Turns

From Closed Position 5 5 5 5 5 Factory Speed 3.5 3,5 3.5 3.5 3.5 Factory Speed Setting (rpm) Low-Medium Static 1035 1296 1002 1120 1182

Fan Shaft Diameter at Pulley (in.)

LEGEND

Bhp ™ Brake Horsepower

TXV — Thermostatic Expansion Valve

Xircuit 1 uses the lower portion of condenser coil and lower portion of evap

orator coils; and Circuit 2 uses the upper portion of both coils.

fRollout switch is manual reset.

High Static 1227-1550

High Static 5.2

High Static 1...BX...42

High Static 55

High Static 1389

016D/F

1650

200

2...SR’'942AE 2

90, 90

50/50

10-13 1 15-2 1 16-3 1 21-0

10-5 1 11-5 1 14-8 1 15-4

Cross-Hatched %-in. Copper Tubes, Aluminum Lanced,

2.,.17 1 3...15 1 3...15 I 4.,,15

21.7 1 21.7 1 21.7 1 21.7

10,400

3.. .22

f/2..,1050

1100

2...17 I 3...15 I 3...15 I

17.5 17.5 17.5

— — — — —

% Vh

1"/,6 13/16 1"/16 1"/i6

1"/i6 13/16 1^16 1 Vi 6 1 Vi6

Aluminum Pre-Coated, or Copper Plate Fins

Cross-Hatched ^/a-in. Copper Tubes, Aluminum Lanced or

—

"'"'The 48TJ028 units requires 2-in. industrial-grade filters capable of handling

face velocities of up to 625 ft/min {such as American Air Filter no. 5700 or equivalent).

NOTE: The 48TJ016-028 units have a low-pressure switch (standard) located

on the suction side.

020D/F 024D/F 028D/F

1B00

200

Scr

1...SM120,

1...SRV82AE 2

110, 72

60/40

R-22 TXV

Propelle

9300

3...22

'/г...1050

1100

Copper Plate Fins, Face Split

1069-1287 1193-1458 1332-1550

4.9/5.9 5.4/6.6 4,9/5.9 1'/8 1% 13/8

8.0 7.9 6.4

1...BX...48 1..,BX,..50 2..,BX,..47

34 44 45

1178 1328 1470

1850

3ll

200

1.. .5M120,

1.. .5M110 2

110,110

52/48

r Type

13,700

2,,.30

1..,1075

3400

8.7 [208/230, 575 v]

9.5 [460 v[

1.. .5M161,

1.. .5M120

10.2 [208/230, 575 v[

11.8 [460 v]

2000

200

112, 110

56/44

12,500

2...30

1.,.1075

3400

4...15

17.5

1Vi6

Table 1 — Physical Data (cent)

FURNACE SECTION

Rollout Switch Cutout Temp (F)+ 190 190 190 190

Burner Orifice Diameter (in....drill size)

Natural Gas 0.1285...30/0.136...29 0.1285...30/0.136...29 0.1285...30/0.136...29 0.1285...30/0.136...29

Thermostat Heat Anticipator Setting (amps)

208/230, 575 Stage 1 0.98 0.98 0.98 0.98

460 V stage 1 0.80 0.80 0.80 0,80 Gas Input Stage 1 172,000/225,000 206,000/270,000 206,000/270,000 206,000/270,000 Efficiency (Steady State) {%) 81 81 81 81

Temperature Rise Range Manifold Pressure (in. wg)

Natural Gas 3.3 3.3 3.3 3.3 Gas Valve Quantity 1 1 1 1 Field Gas Connection Size (in .-FPT)

HIGH-PRESSURE SWITCH (psig)

Cutout Reset (Auto)

LOW-PRESSURE SWITCH (psig)

Cutout Reset (Auto)

FREEZE PROTECTION THERMOSTAT (F)

Opens Closes

OUTDOOR-AIR INLET SCREENS

Quantity...Size (in.)

RETURN-AIR FILTERS

Quantity...Size (in.)

POWER EXHAUST V2 Hp, 208/230-460 V Motor Direct Drive, Propeller-Fan (Factory-Wired for 460 v)

Bhp ™ Brake Horsepower TXV — Thermostatic Expansion Valve

'Circuit 1 uses the lower portion of condenser coil and lower portion of evap

orator coils; and Circuit 2 uses the upper portion of both coils.

fRollout switch is manual reset.

UNIT 48TJ 016D/F 020D/F 024D/F 028D/F

Stage 2 0.44 0.44 0.44 0,44 Stage 2 0.44 0.44 0.44 0,44 Stage 2 230,000/300,000 275,000/360,000 275,000/360,000 275,000/360,000

15-45/20-50 15-45/20-50 15-45/20-50 15-45/20-50

3/4 3/4 3/4 3/4

__________________

LEGEND

**The 48TJ028 units requires 2-in. industrial-grade filters capable of handling

face velocities of up to 625 ft/min (such as American Air Filter no, 5700 or equivalent).

NOTE: The 48TJ016-028 units have a low-pressure switch (standard) located on the suction side.

426 320

27 44

30 ±5 45 ±5

Cleanable

2.. .20x25x 1

1.. .20x 20 x1 Throwaway*’'

4.. .20x20x2

4.. .16x20x2

step 3 — Field Fabricate Ductwork — Secure all

ducts to building stnjcture. Use flexible duct connectors be tween unit and ducts as required. Insulate and weatlierproof 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

sulated and covered with a vapor barrier.

Step 4 — Make Unit Duct Connections — Unit

is shipped for thra-the-bottom duct connections. Ductwork openings are shown in Fig. 1, 4, and 5. Duct connections are shown in Fig. 6. Field-fabricated concentric ductwork may be connected as shown in Fig. 7 and 8. Attach all ductwork to roof curb and roof cuit) basepans.

Step 5 — Install Flue Hood and Wind Baffle —

Flue hood and wind baffle are shipped secured under main control box. To install, secure flue hood to access panel. See Fig. 9. The wind baffle is then installed over the flue hood.

NOTE: When properly installed, flue hood will line up with combustion tan housing. See Fig. 10.

Step 6 — Trap Condensate Drain — See Fig. 11

for drain location. One ^4-in. half coupling is provided inside

unit evaporator section for condensate drain connection. An

S'A-in. X ^4-in. diameter and 2-in. x diameter pipe nip ple, coupled to standard V4-in. diameter elbows, provide a straight path down through hole in unit base rtiils (see Fig. 12).

A trap at least 4-in. deep must be used.

NOTE: Do not drill in this area; damage to basepan may result in

water leak.

Fig. 6 — Air Distribution — Thru-the-Bottom

NOTE: Dimensions A, A', and B' are obtained trom field-supplied ceiling diffuser.

I r| Shaded area indicates block-off panels.

Fig. 8 — Concentric Duct Details

AIR OUT AIR IN

NOTE: Do not drill in this area; damage to basepan may result in

water leak.

AIR OUT

Fig. 7 — Concentric Duct Air Distribution

INDUCED DRAFT MOTOR

Step 7 — Orifice Change — This unit is factoiy as

sembled for heating operation using natural gas at an elevation from sea level to 2000 ft. Tliis unit uses orifice type LH32RFnnn, where “nnn” indicates the orifice size based on drill size diameter in thousands of an inch.

HIGH ELEVATION (Above 2000 ft) — Use accessoiy high altitude kit when installing tliis unit at an elevation of 2000 to 7000 ft. For elevations above 7000 ft, refer to Table 2 to identi fy the correct orifice size for fhe elevafion. See Table 3 for the number of orifices required for each unit size. Purchase these orifices from your local Carrier dealer. Follow instmctions in accessoiy Installation Instmctions to install the correct orifices.

Table 2 — Altitude Compensation*

COMBUSTION MAIN BURNER HEAT EXCHANGER FAN HOUSING SECTION SECTION

Pig -|o — Combustion Fan Housing Location

Fig. 11 — Condensate Drain Details

(48TJ016 Shown)

ELEVATION (ft)

0-1,999 30 29

2,000 30 29 3,000 31 30 4,000 31 30 5,000 31 30 6,000 31 30 7,000 32 31 8,000 32 31 9,000 33 31

10,000 35 32

*As the height above sea level Increases, there is less oxygen per

cubic foot of air. Therefore, heat input rate should be reduced at higher altitudes. Includes a 4% input reduction per each 1000 ft.

fOrifices available through your Carrier dealer.

NATURAL GAS ORIFICEf

Low Heat High Heat

Table 3 — Orifice Quantity

UNIT ORIFICE QUANTITY

48TJD016 5 48TJD020,

48TJD024, 48TJD028, 48TJF016

48TJF020, 48TJF024, 48TJF028

CONVERSION TO LP (Liquid Propane) GAS -- Use acces soiy LP gas conversion kit when converting this unit for use witli LP fuel usage for elevations up to 7000 ft. For elevations above 7000 ft, refer to Table 4 to identify the correct orifice size for tlie elevation. See Table 3 for the number of orifices required for each unit size. Purchase these orifices from your loctil Carrier dealer. Follow instmctions in accessoiy Installa tion Instmctions to install the correct orifices.

Table 4 — LP Gas Conversion*

Fig. 12 — Condensate Drain Piping Details

ELEVATION (ft)

0-1,999 36

2,000 37 3,000 38 4,000 38 5,000 39 6,000 40 7,000 41 8,000 41 9,000 42

10,000 43

*As the height above sea level increases, there is less oxygen per

cubic foot of air. Therefore, heat input rate should be reduced at higher altitudes. Includes a 4% input reduction per each 1000 ft.

fOrifices available through your Carrier dealer.

LP GAS ORIFICEf

step 8 — Install Gas Piping — Unit is equipped for

use with natui'iil gas. Installation must conform with local building codes or. in the absence of lociil codes, with the National Fuel Gas Code. ANSI Z22.3.1.

Install field-supplied manual gas shutoff valve with a Vs-in. NPT pressure tap for test gage connection at unit. Field gas pip ing must include sediment trap and union. See Fig. 1.1.

Transformer no. 1 is wired for 230-v unit. If 208/230-v unit

is to be nan with 208-v power supply, the transformer must be

rewired as follows:

1. Remove cap from red (208 v) wire,

2. Remove cap from orange (230 v) spliced wire.

3. Replace orange wire with red wire.

4. Recap both wires.

A WARNING

Do not pressure test gas supply while connected to unit. Always disconnect union before servicing. Exceeding maximum manifold pressure may cause explosion and injuiy.

IMPORTANT: Natural gas pressure at unit gas connec

tion must not be less than 5.5 in. wg or greater than

1.3.5 in. wg.

Size gas-supply piping for 0.5-in. wg maximum pressure drop. Do not use supply pipe smiillei' than unit gas connection.

MANUAL SHUTOFF

step 9 — Make Electrical Connections

FIELD POWER SUPPLY — Unit is factoiy wired for volt age shown on nameplate.

When instiilling units, provide a disconnect per NEC (Na

tional Electrical Code) of adequate size (Table 5).

All field wiring must comply with NEC and local requirements.

Route power ground lines through control box end panel or unit basepan (see Fig. 4 and 5) to connections as shown on unit wiring diagram and Fig. 14.

A CAUTION

Be certain unused wires are capped. Failure to do so may damage the transformers.

Operating voltage to compressor must be within voltage range indicated on unit nameplate. On 3-phase units, voltages between phases must be balanced within 2%.

Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components.

FIELD CONTROL WIRING — Install a Carrier-approved accessoiy thermostat assembly according to installation in-

stmctions included with accessoiy. Locate thermostat assembly on a solid interior wall in the conditioned space to sense aver age temperature.

Route thermostat cable or equivalent single leads of

colored wire from subbase terminals through conduit in unit to

low-voltage connections as shown on unit label wiring diagram and in Fig. 15.

NOTE: For wire nans up to 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 at tlae thermostat and will require a junction box and splice at the tliermostat.

Set heat anticipator settings as follows:

VOLTAGE W1 W2

208/230,575 0.98 0.44

460 0,80 0.44

Settings may be changed slightly to provide a greater degree

of comfort for a particulai' installation.

A CAUTION

Tlie correct power phasing is critical in the operation of the scroll compressor. An incorrect phasing will cause the compressor to rotate in the wrong direction. This may lead to premature compressor failure.

A WARNING

Tlie unit must be electrically grounded in accordance with local codes and NEC ANSl/NFPA 70 (National Fire Pro tection Association) to protect against fire and electric shock.

Field wiring must confirm to temperature limitations for type “T’ wire. All field wiring must comply with NEC and lo cal requirements.

LEGEND

EQUIP — Equipment GND — Ground NEC — National Electrical Code TB — Terminal Block

NOTE: The maximum wire size for TB1 is 2/0.

Fig. 14 — Field Power Wiring Connections

OPTIONAL NON-FUSED DISCONNECT — On units with the optional 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. Refer to the applicable disconnect wiring diagram.

To prevent breakage during shipping, the disconnect handle and shaft aie shipped and packaged inside the unit control box. Install the disconnect handle before unit operation. To install the handle and shaft, perform the following procedure:

1. Open the control box door and remove the handle and shaft from shipping location.

2. Loosen the Allen bolt located on the disconnect switch. Tlie bolt is located on the square hole and is used to hold the shaft in place. Tlie shaft cannot be inserted until the Allen bolt is moved.

3. Insert the disconnect shaft into the sqiuu'e hole on the dis connect switch. The end of the shaft is specially cut and the shaft can only be inserted in the correct orientation.

4. Tighten the Allen bolt to lock the shaft into position.

5. Close the control box door.

6. Attach the handle to the external access door with the two screws provided. When the handle is in the ON position, the handle will be vertical. When the handle is in tlie OFF position, the handle will be horizontal.

7. Turn tlie handle to the OFF position and close the door. Tlie handle should fit over the end of the shaft when the door is closed.

8. The handle must be in the OFF position to open the con trol box door.

OPTIONAL CONVENIENCE OUTLET--On units with optiontil convenience outlet, a 115-v GFI (ground fault interrttpt) convenience outlet receptacle is provided tor field wiring. Field wiring should be nm through the Vs-in. knockout pro vided in the basepan near the return air opening.

THERMOSTAT ASSEMBLY

Fig. 15 — Field Control Thermostat Wiring

6T3 4T2 2Tl LOAD

#11®

■ “È

PI P

5L3 3L2 1L1 LINE

□ □ □

'^N N N

OHO

2 4 E

NOTE: The disconnect takes the place of TB-1 as shown on the unit wiring diagram label and the component arrangement label.

Fig. 16 — Optional Non-Fused Disconnect Wiring

Table 5 — Electrical Data

UNIT 48TJ

016

(15 Tons)

020

(18 Tons)

024

(20 Tons)

028

(25 Tons)

FLA — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration

!FH/l ~ 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

'Fuse or HACR circuit breaker.

NOTES:

1. In compliance with NEC requirements for multimofor and combinafion load equipmenf (refer fo 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 volt

age imbalance. % Voltage Imbalance

too X

NOMINAL

VOLTAGE

(3 Ph, 60 Hz)

208/230 187 253 25.6 190 25.6 190 3 0.5 1.7 3.7 10.5/11.0

460 414 508 13.5 95 13.5 95 3 0.5 0.8 3.7 4.8

575 5f8 632 10.2 75 10.2 75 3 0.5 0.8 3.0 3.9

208/230 187 253 33 237 23 184 3 0.5 1.7 5.0 15,8/15.8

460 414 508 16.2 130 10.2 90 3 0.5 0.8 5.0 7.9

575 518 632 12.7 85 9 73 3 0.5 0.8 5.0 6,0

208/230 187 253 33 237 29.5 237 2 1 6.6 7.5 25.0/25.0

460 414 508 16.2 130 14.1 130 2 1 3.3 7.5 13.0

575 518 632 12.7 85 11.3 85 2 1 3.4 7.5 10.0

208/230 187 253 47.5 265 33 237 2 1 6.6 10.0 28.0/28.0

460 414 508 22.9 145 16.2 130 2 1 3.3 10.0 14.6

575 518 632 17.9 102 12.7 85 2 1 3.4 10.0 13.0

LEGEND

max voltage deviation from average voltage

VOLTAGE

RANGE

Min Max RLA LRA RLA LRA Qty

average voltage

COMPRESSOR

No. 1 No. 2

OFM IFM

FLA (ea)

Example: Supply voltage is 460-3-60.

ABC

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 = f 00 x

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.

POWER

EXHAUST

COMBUSTION

FAN MOTOR

POWER

SUPPLY

FLA FLA LRA FLA MCA MOCP*

4,6 18.8 0.57 79/79 100/100

2.3 6.0 0.30 40 50

— — 0.57 30 35

2.1 4.8 0.57 32 40

— — 0.57 85/85 110/110

4.6 18.8 0.57 90/90 110/110 — — 0.30 41 50

2,3 6.0 0,30 43 50

— —

2,1 4.8 0.57 35 45

0.57 74/74 90/90

0.30 38 50

0.57 33 45

— — 0.57 109/109 125/125

4,6 18.8 0.57 114/114 125/125

— —

2,3 6.0 0.30 56 70

2.1 4.8 0.57 46 50

—

4.6 18.8 0.57 138/138 175/175

— —

2.3 6.0 0.30 68 90

— — 0.57 55 70

2,1 4.8 0.57 57 70

AB = 452 V BC = 464 V AC = 455 V

Average Voltage ;

= t .53%

0.30 54 70

0.57

0.57 134/134 175/175

0.30 66 80

452 + 464 + 455

f37f

= 457

457

step 10 — Make Outdoor-Air Inlet Adjust ments

MANUAL OUTDOOR-AIR DAMPER ^ All units (except those equipped with a factoiy-instiilled economizer) have a manual outdoor-air damper to provide ventilation air.

Damper can be preset to admit up to 25% outdoor air into return-£iir compartment. To adjust, loosen securing screws and move damper to desired setting, tlien retighten screws to secure diunper (see Fig. 17).

25% ADJUSTABLE AIR DAMPER

SECURING SCREWS

Fig. 17

Standard 25% Outdoor-Air

Section Details

Step 11 — Install Outdoor-Air Hood

Fig. 18 — Outdoor-Air Hood Component Location

HOOD DRAIN PAN

IMPORTANT: If the unit is equipped with the optional EconoMi$eiTV, move the outdoor air temperature sensor prior to installing the outdoor air hood. See the Optional EconoMi$eiTV and EconoMi$er2 section for more details.

Tlie outdoor- air hood is common to 25% air ventilation and economizer. If EconoMi$erIV is used, all electrical connec tions have been made and adjusted at the factory. Assemble and install hood in the field.

NOTE: Tlie hood top panel, upper and lower filter rettdners, hood drain pan, baffle (size 024 and 028), and filter support bracket iu'e secured opposite the condenser end of the unit. The screens, hood side panels, remaining section of filter support bracket, seal strip, and hai'dware are in a package located inside the return-air filter access panel (Fig. 18).

1. Attach seal strip to upper filter retainer. See Fig. 19.

2. Assemble hood top panel, side panels, upper filter retain er, and drain pan (see Fig. 20).

.2. Secure lower filter retainer and support bracket to unit.

See Fig. 20. Leave screws loose on size 024 and 028 units.

4. Slide baffle (size 024 and 028) behind lower filter retainer and tighten screws.

5. Loosen sheet metal screws for top panel of base unit located above outdoor-air inlet opening, and remove screws for hood side panels located on the sides of the outdoor-air inlet opening.

6. Match notches in hood top panel to unit top panel screws. Insert hood flange between top panel flange and unit. Tighten screws.

7. Hold hood side panel flanges flat against unit, and instiill screws removed in Step 5.

8. Inseit outdooi'-air inlet screens and spacer in channel cre ated by lower filter retainer and filter support bracket.

BAFFLE

step 12 — Install All Accessories— install all

field-installed accessories. Refer to the accessoiy installation instructions included with each accessoiy.

MOTORMASTER® I CONTROL INSTALLATION (48TJ0I6,020 UNITS)

Install Field-Fabricated Wind Baffles — Wind baffles must be field-fabricated for all units to ensure proper cooling cycle operation at low ambient temperatures. See Fig. 21 for baffle detiiils. Use 20-gage, galvanized sheet metal, or similar coiTosion-resistant metal for baffles. Use field-supplied screws to attach baffles to unit. Screws should be V4-in. diameter and 5/8-in. long. Drill required screw holes for mounting baffles.

A CAUTION

To avoid diunage to the refrigerant coils and electrical com ponents, use recommended screw sizes only. Use care when drilling holes.

NOTE: Dimensions in ( ) are in mm.

Fig. 21 — Wind Baffle Details

Install Motormaster I Controls — Only one Motormaster I control is required per unit. Tlie Motormaster I control must be used in conjunction with the Accessoiy 0° F Low Ambient Kit

(purchased separately). Tlie Motonnaster I device controls out door fan no. I while outdoor fans no. 2 and ."5 are sequenced off by the Accessoiy 0° F Low Ambient Kit. Accessory 0° F Low Ambient Kit — Instiill the Accessoiy 0° F Low Ambient Kit per instmction supplied with accessoiy.

Sensor Assembly — Install the sensor assembly in the location

shown in Fig. 22. Motor Mount — To ensure proper fan height, replace the exist

ing motor mount with the new motor mount provided with accessoiy.

Transformer (460 and 575-v Units Only) — On 460 and 575-v units, a transfonner is required. The transformer is provided with the accessoiy and must be field-installed.

Motormaster I Control — Recommended mounting location is on the inside of the panel to the left of the control box. The control should be mounted on the inside of the panel, verti cally, with leads protniding from bottom of extinsion.

îî°o

0 0

cp o

0 0

cp o

îi°°

cp 0

(b 0

cp 0

0 0

G) o

d) o

G) o cp o

® 0

d> 0

<p 0

îî ° 0

d> 0

(p 0

Î0 0

(p 0

cp 0 t p 0 cp o

SENSOR LOCATION

cp o

è 0

G) 0

0 0

G) o

cb 0

îi°°

0 0

îi“°

G) o

îi°°

cp 0

îî°o

<p 0

G) 0

SENSOR LOCATION

HAiRPIN END

NOTE: All sensors are located on the eighth hairpin up from the bottom.

48TJ016

----------

HAIRPIN END

ïh-

cp o

ih"

il»

cp 0

il»

cp 0

il»

cp o

il"

il»

tp 0

il»

cp 0

il»

cp 0

il»

cp 0

il»

cp 0

il»

cp 0

il»

cp o

il»

cp o

il»

tp 0

il»

cp 0

il»

48TJ020

Fig. 22 — Motormaster I Sensor Locations

MOTORMASTER® V CONTROL INSTALLATION (48TJ024,028 UNITS)

Install Lield-Fabricated Wind Baffles — Wind baffles must be field-fabricated for all units to ensure proper cooling cycle operation at low ambient temperatures. See Fig. 21 for baffle details. Use 20-gage, galvanized sheet metal, or similar coito- sion-resistant metal for baffles. Use field-supplied screws to at tach baffles to unit. Screws should be ‘A-in. diameter and 5/s-in. long. Drill required screw holes for mounting baffles.

A 0j|^||Y|Q||

To avoid dmnage to the refrigerant coils and electrical com ponents, use recommended screw sizes only. Use cru'e when diilling holes.

Install Motormaster V Controls — Tlie Motormaster V (MMV) control is a motor speed control device which adjusts condenser fan motor speed in response to declining liquid re frigerant pressure. A properly applied Motormaster V control extends the operating range of air-conditioning systems and permits operation at lower outdoor ambient temperatures.

Tlie minimum iunbient temperatures at which the unit will

operate are:

TEMPERATURE OPERATING LIMÌTS — F°

standard Unit with Unit with

Unit Low Ambient Kit MMV Control

40 25 -20

To operate down to the ambient temperatures listed, Motomiaster V controls (Fig. 23) must be added. Field-fabricat ed and installed wind baffles iu'e also required for iill units (see Fig. 21). The Motormaster V control permits operation of the unit to an ambient temperature of-20 F. Tlie control regulates the speed of 3-phase fan motors that aie compatible with the control. Tliese motors are factoiy installed.

See Table 6 for the Motormaster V control accessoiy pack age usage. Table 7 shows applicable voltages and motors. Replacement of motor or fan blade IS NOT REQUIRED ON CURRENT PRODUCTION UNITS since the control is compatible with the factoiy-installed fan motors. Only field wiring control is required

Install the Motormaster V control per instiuctions supplied with accessoiy.

FR<3M FUSE BLOCK

Ó O Ò O Ó

TO PRESSURE^ TRANSDUCER

U L3

12 13Ai

I n io/-\

256

IflrtDfVÌÓnrTnhDnrvnfìDITri

/;n 7Î Î3 B-

O Q O O O

C E [3

TO MOTOR(S)

Fig. 23

Table 6 — Motormaster V Control Package Usage

UNIT VOLTAGE ITEM DESCRIPTION

48TJ024,028 460 CRLOWAÌVIB016A00

Table 7 — Applicable Voltages and Motors

VOLTAGE COMPATIBLE MOTOR

208/230-3-60 HD52AK654

460-3-60 HD52AK654 575-3-60 HD52GE576

Motormaster V Control

208/230 CRLOWAIVIB015A00

575 CRLOWAW1B017A00

step 13 — Adjust Factory-Installed Options

PREMIERLINKTM CONTROL — The PremierLink control ler is available as a special order from the factoiy and is com patible with the CiU'rier Comfort Network® (CCN) system. This control is designed to allow usere the access and ability to change factoiy-defmed settings, thus expanding the function of the standard unit control board. Carrier’s diagnostic standard tier display tools such as Navigator''^' device or Scrolling Marquee can be used witli the PremierLink controller.

Tire PremierLink controller (see Fig. 24) requires the use of a Cai'rier electronic themnostat or a CCN connection for time broadcast to initiate its internal timeclock. This is necessaiy for broadcast of time of day functions (occupied/unoccupied). No sensors are supplied with the field-mounted PremierLink con trol. The factoiy-installed PremierLink conti'ol includes only the supply-air temperature (SAT) sensor and the outdoor air temperature (OAT) sensor as standiu'd. An indoor air quality (CO2) sensor can be added as an option. Refer to Table 8 for sensor usage. Refer to Fig. 25 for PremierLink controller wir ing. The PremierLink control may be mounted in the control panel or an area below the control panel.

NOTE: PremierLink controller version 1.3 and later is shipped in Sensor mode. If used with a thermostat, the PremierLink controller must be configured to Thermostat mode.

Install the Supply Air Temperature (SAT) Sensor — When the unit is supplied with a factoiy-mounted PremierLink con trol, the supply-air temperature (SAT) sensor (33ZCSENSAT) is factoiy-supplied and wired. The wiring is routed from the PremierLink control over the control box, through a grommet.

into the fan section, down along the back side of the fan, and

along the fan deck over to the supply-air opening.

The SAT probe is wire-tied to tire supply-air opening (on the

horizontal opening end) in its shipping position. Remove the

sensor for installation. Re-position the sensor in the flange of

tire supply-air opening or in the supply air duct (as required by

local codes). Drill or punch a ‘/2-in. hole in the flange or duct.

Use two field-supplied, self-drilling screws to secure the sensor

probe in a horizontal orientation.

NOTE: The sensor must be mounted in tire dischiu'ge airstream downstream of the cooling coil and any heating devices. Be

sure the probe tip does not come in contact with any of the unit

or heat surfaces. Outdoor Air Temperature (OAT) Sensor — When the unit is

supplied with a factoiy-mounted PremierLink control, the outdoor-air temperature sensor (OAT) is factoiy-supplied and wired.

Install the Indoor Air Quality (CQt) Sensor — Mount the optional indoor air quality (CO2) sensor according to manufac turer specificiitions.

A sepiii'ate field-supplied transformer must be used to

power the CO2 sensor.

Wire the CO2 sensor to tlie COM and lAQI terminals of J5

on the PremierLink controller. Refer to the PremierLink Instal

lation, Start-up, and Configuration Instnictions for detailed wiring and configuration information.

HVAC SENSOR INPUTS

SPACE TEMP

SET POINT ^

SUPPLY AIR TEMP

OUTDOOR TEMP

INDOOR AIR QUALITY

OUTDOOR AIR QUALITY

DUAL MODE SENSOR (STAT)

REMOTE OCCUPANCY (Q)

COMP SAFETY (Y1) ^

FIRE SHUTDOWN (Y2) ^

SUPPLY FAN STATUS (W1)

NOT USED (W2) ^

ENTHALPY STATUS (ENTH)

CCN/LEN

PORT

NAVIGATOR

PORT

4-2OMA INDOOR COMPR HEAT EXHAUST

ECONOMIZER FAN MOTOR 1&2 LOW/HIGH RVS VALVE

-------------------------------

Fig. 24 — PremierLink Controller

X f M N N

OUTPUTS--------------------------------------------•-

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