Carrier TJF005-007, 48TJD, TJE, TJF004, 48TJE User Manual

Single-Package Rooftop Heating/Cooling Units

Installation, Start-Up and

Service Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS INSTALLATION

Step 1 — Provide Unit Support

•ROOF CURB

• SLAB MOUNT

Step 2 — Field Fabricate Ductwork Step 3 — Install External Trap for

Condensate Drain

Step 4 — Rig and Place Unit

• POSITIONING

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

• DISCONNECT BOX LOCATION

• FIELD POWER SUPPLY

• FIELD CONTROL WIRING

• HEA T ANTICIPATOR SETTINGS

Step 8 — Make Outdoor-Air Adjustment and

Install Outdoor-Air Hood

• MANUAL OUTDOOR-AIR DAMPER

• OPTIONAL DURABLADE ECONOMIZER

• OPTIONAL ECONOMI$ER

Step 9 — Adjust Evaporator-Fan Speed

• DIRECT-DRIVE MOTORS

• BELT-DRIVE MOTORS

START-UP SERVICE TROUBLESHOOTING START-UP CHECKLIST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-39

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-44

. . . . . . . . . . . . . . . . . . . . . . . . . 45-50

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 li terature, ta gs and label s attached t o the uni t, 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.

Ensure voltage listed on unit data plate agrees with electrical supply provided for the unit.

. . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . 5

. . . . . . . . . . . . . . . . . . . . . . 12

. . . . . . . . . 20

. . . . . . . . . . . . . . . . . . . . . . . .CL-1

48TJE,TJF004

48TJD,TJE,TJF005-007

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

pressure testing field-supplied gas piping at pressures of 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 lockout tag. Electrical shock could cause personal injury.

Unit is shipped in the vertical discharge 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.

Step 1 — Provide Unit Support

ROO F CU R B — Assemble and instal l acces sory roof curb in accordance with instructions shipped with curb. See Fig. 2. Install insulation, cant strips, roofing felt, and counter flashing as

Ductwork must be attached to curb, not to the unit. The

shown.

accessory thru-the-bottom power and gas connection package must be installed before the unit is set on the roof curb.

installed (thru-the-roof curb) gas connections are desired, use factory-supplied 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 th e 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 also r esult in air or water leaks and

poor unit performance.

must

psig, it

be replaced before use. When

/2 psig or less, a unit connected to

INSTALLATION

If field-

/4 in. pipe coupling and gas plate assembly to

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

Book 1 4 Ta b 1 a 6 a

PC 111 Catalog No. 534-774 Printed in U.S.A. Form 48TJ-18SI Pg 1 10-00 Replaces: 48TJ-16SI

Fig. 1 — Horizontal Conversion Panels

(Viewed from Duct End)

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 —

ducts to roof curb and building structure on vertical units.

not connect ductwork to unit.

supplied flanges should be attached to horizontal discharge 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 –.30 in. wg with EconoMi$er, or –.35 in. wg with Durablade Economizer, or –.45 in. wg without economizer.

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

For horizontal applications, field-

Secure all

Step 3 — Install External Trap for Condensate Drain —

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 ve rtical or horiz ontal 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 drai n 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 fr eezeup. 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 (

Step 4 — Rig and Place Unit —

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 and lifting.

The unit’s 3/4-in. condensate drain connections are

/4 in.).

Inspect unit for

‘‘B’’ ‘‘C’’

1′-9

/16″

[551]

1′-4″ [406]

‘‘D’’ ALT

DRAIN HOLE

13/4″

[44.5]

‘‘E’’ Gas

″

[19] NPT

″

[12.7] NPT

/4″

[19] NPT

“F”

Powe r

/4″

[19] NPT

″

[31.7]

″

[19] NPT

11/4″

[31.7]

“G”

Control

/2″

[12.7] NPT

CONNECTOR

PKG ACY

CRBTMPWR001A00

CRBTMPWR002A00

CRBTMPWR003A00

CRBTMPWR004A00

ROOF CURB

ACCESSORY

CRRFCURB001A00

CRRFCURB002A00

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′ on each side.

‘‘A’’

1′-2″ [356]

2′-0″ [610]

UNIT SIZE

48TJ

004-007

7. Direction of airflow.

8. Connector packages CRBTMPWR001A00 and 2A00 are for thru-the-curb type. Packages CRBTMPWR003A00 and 4A00 are for the thruthe-bottom type connections.

TO ENSURE AIRTIGHT CONNECTION PLACE UNIT AS CLOSE TO END AS POSSIBLE.

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

CONDENSATE PAN (SIDE VIEW)

DRAIN PLUG

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

Fig. 4 — Internal Trap Condensate Drain

POS ITION ING — Maintain cleara nce 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:

/4-in. clearance between roof curb and ba se 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 within 10 ft of exhaust vents or other sources of contaminated air or as local codes require.

Be sure that unit is installed so that snow will not block the

combustion intake or flue outlet.

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.

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 burner compartment access panel. Remove from shipping location and using screws provided, install flue hood and screen in location shown in Fig. 7.

For units size 004-006 being installed in California Air Quality Management Districts, which require NOx emissions of 40 nanograms/joule or less, a field-installed low NOx kit must be used.

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 48TJ005,006,007 high heat units, the gas pressure at unit gas connection must not be less than 5 in. wg or greater t han 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 sully piping for 0.5 in. wg maximum pressure drop. Do not use supply pipe small than unit gas connection. Support gas piping as shown in the table in Fig. 8. For example, a

/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.

NOTES:

1. Dimension in ( ) is 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.

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

All panels must be in place when rigging.

Fig. 5 — Rigging Details

UNIT

48TJE,TJF004 48TJD,TJE,TJF005 48TJD,TJE,TJF006 48TJD,TJE,TJF007

MAX

WEIGHT

lb kg in. mm in. mm in. mm

510 231 520 236 540 245 615 279

73.69 1872 37.50 953 33.35 847

DIMENSIONS

‘‘A’’ ‘‘B’’ ‘‘C’’

Step 7 — Make Electrical Connections

Unit cabinet must have an uninterrupted, unbroken elect rical 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

Do not use gas piping as an electrical ground.

codes. ure to follow this warning could result in the installer being liable for personal injury of others.

DISCONNECT BOX LOCATION — The field-supplied disconnect 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 the unit’s end panel.

disconnect box over the unit rating plate.

Do not mount the

When mounting disconnect box on corner post, secure disconnect box to corner post and condenser coil top cover. See Fig. 7.

A disconnect box mounting space is available when an optional or accessory condenser coil grille is used. Mount the disconnect on the sheet metal provided with t he condenser coil grille. The sheet metal is loc ated adjacent to the corner post on the left side of the power wiring access panel.

Fail-

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, t he transformer

must

be rewired by disconnecting the black wire from the 230-v terminal wire on the transformer and connecting it to the 200-v red terminal of the transformer.

Refer to unit label diagram for additional information. Wiring leads are provided for field service. Use copper conductors only when splice connectors are used.

When installing units, provide a disconnect per NEC.

All field wiring must comply with NEC and local requirements. In Canada, electrical connections must be in accordance with CSA (Canadian Standards Association) C22.1 Canadian Electrical Code Part One.

Install field wiring as follows:

1. Connect ground lead to chassis ground connection when using separate ground ties.

2. Install conduit between disconnect and side panel. Insert conduit through power supply knockout opening. See Fig. 9.

3. Connect power lines to power wiring leads.

4. Pigtails are provided for field power connections and are located inside the burner access panel. See Fig. 10 and 11. Use factory-supplied splices or Underwriters’ Laboratories (UL) approved copper connector .

Table 1 — Physical Data

UNIT SIZE 48TJ E/F004 D/E/F005 D/E/F006 D/E/F007 NOMINAL CAPACITY (tons) 3456 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

Quantity 1111 No. Cylinders (per Circuit) 2222 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 Watts Input (Total) 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

Typ e Dri v e St d Direct Direct Direct Belt

Nominal Cfm 1200 1600 2000 2400 Maximum Continuous Bhp Std .34 .75 1.20 2.40

Motor Frame Size Std 48 48 48 56

Nominal Rpm High/Low Std 860/800 1075/970 1075/970 —

Fan Rpm Range Std — — — 1070-1460

Motor Bearing Type Ball Ball Ball Ball Maximum Allowable Rpm 2100 2100 2100 2100 Motor Pulley Pitch Diameter Min/Max (in.) Std — — — 2.8/3.8

Nominal Motor Shaft Diameter (in.) Std

Fan Pulley Pitch Diameter (in.) Std ———4.5

Belt, Quantity...Type...Length (in.) Std — — — 1...A...40

Pulley Center Line Distance (in.) Std — — — 14.7-15.5

Speed Change per Full Turn of Std ———80

Movable Pulley Flange (rpm) Alt 48 70 80 —

Movable Pulley Maximum Full Turns Std ——— 5

From Closed Position Alt 555—

Factory Setting Std ——— 3

Factory Speed Setting (rpm) Std ———1225

Fan Shaft Diameter at Pulley (in.)

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

Alt Belt Belt Belt — High-Static Belt Belt Belt Belt

Alt 1.00 1.00 1.30/2.40** — High-Static 2.40 2.40 2.90 2.90

Alt 48 48 56 — High-Static 56 56 56 56

Alt 1620 1620 1725 — High-Static 1725 1725 1725 1725

Alt 760-1000 835-1185 900-1300 — High-Static 1075-1455 1075-1455 1300-1685 1300-1685

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

Alt High-Static

Alt 4.5 4.0 4.5 — High-Static 4.5 4.5 4.5 4.5

Alt 1...A...34 1...A...34 1...A...39 — High-Static 1...A...39 1...A...39 1...A...40 1...A...40

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

High-Static 65 65 60 60

High-Static 6655

Alt 333— High-Static 3

Alt 856 975 1060 — High-Static 1233 1233 1396 1396

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.

/4...1100

31/

2 2 8

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

resetting thermostat.

NOTES:

1. The 48TJ004-007 units have a loss-of-charge (low pressure) switch located in the liquid line.

2. High-static motor not available on single-phase units.

/4...1100

31/

2 8 8

Scroll

/4...1100

—

31/

Table 1 — Physical data (cont)

UNIT SIZE 48TJ E/F004 D/E/F005 D/E/F006 D/E/F007 FURNACE SECTION

Rollout Switch Cutout Temp (F)†† 195 195 195 195 Burner Orifice Diameter

(in. ...drill size)

Natural Gas Std .113...33 .113...33/.113...33/.129...30 .113...33/.113...33/.129...30 .113...33/.113...33/.129...30

Liquid Propane Alt .089...43 .089...43/.089...43/.102...38 .089...43/.089...43/.102...38 .089...43/.089...43/.102...38 Thermostat Heat Anticipator Setting (amps)

208/230 v and 575 Stage 1 .14 .14 .14 .14

460 v Stage 1 .14 .14 .14 .14

Stage 2 .14 .14 .14 .14

Gas Input (Btuh) Stage 1 74,000/82,000 74,000/115,000/120,000 74,000/115,000/120,000 74,000/115,000/120,000

Efficiency (Steady State) (%) 80 80 80 80 Temperature Rise Range 25-55/55-85 25-55/35-65/50-80 25-55/35-65/50-80 25-55/35-65/50-80 Manifold Pressure (in. wg)

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 11 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 Size (in.)

HIGH-PRESSURE SWITCH (psig)

Standard Compressor 450 ± 50 500 ± 50 Internal Relief (Differential) Cutout 428 428 Reset (Auto.) 320 320

LOSS-OF-CHARGE (LOW 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.

Stage 2 .14 .14 .14 .14

Stage 2 —/115,000 —/—/150,000 —/—/150,000 —/—/150,000

7 ± 3

**Single phase/three-phase. ††Rollout switch lockout is manually reset by interrupting power to unit or

resetting thermostat.

NOTES:

1. The 48TJ004-007 units have a loss-of-charge (low-pressure) switch located in the liquid line.

2. High-static motor not available on single-phase units.

STANDARD

UNIT 48TJ

E/F004 D/E/F005 D/E/F006 D/E/F007

A B C

NOTES:

1. Dimensions in [ ] are in millimeters.

UNIT

WEIGHT

Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg

460 209 34 15.4 47 21.3 140 63.5 105 47.6 159 72.1 56 25.4 470 213 34 15.4 47 21.3 142 64.4 106 48.1 162 73.5 60 27.2 490 222 34 15.4 47 21.3 150 68.0 115 52.2 160 72.6 65 29.5 565 256 34 15.4 47 21.3 165 74.8 136 61.7 200 90.7 64 29.0

CONNECTION SIZES

11/

Dia [27] Field Power Supply Hole

″″″″

-14 NPT Condensate Drain

″″″″

-14 NPT Gas Connection

″″″″

DURABLADE

ECONOMIZER

WEIGHT

ECONOMI$ER

WEIGHT

CORNER

WEIGHT

(A)

CORNER

WEIGHT

(B)

CORNER

WEIGHT

(C)

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. 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 notes 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 ver tical ce nter of gravity is 1′-6″ [457] up from the bottom of the base rail.

CORNER WEIGHT

(D)

BOTTOM POWER CHART, THESE HOLES REQUIRED FOR

USE WITH ACCESSORY PACKAGES — CRBTMPWR001A00,

(POWER AND CONTROL) AND CRBTMPWR003A00

(POWER, CONTROL, AND GAS)

THREADED

CONDUIT SIZE

″″″″

FPT

WIRE

USE

24 V

Powe r 11/

Gas 11/

HOLE SIZES (MAX.)

REQURED

[22.2]

″″″″

[28.4]

″″″″

[31.8]

″

″ ″

Fig. 6 — Base Unit Dimensions

CONDENSER COIL TOP COVER

CORNER POST

INTAKE LOUVERS

FLUE HOOD

Fig. 7 — Flue Hood Details

END PANEL

Fig. 9 — Conduit Installation

LEGEND

NFGC —

*Field supplied. NOTE: Follow all local codes.

National Fuel Gas Code

SPACING OF SUPPORTS

STEEL PIPE

NOMINAL

DIAMETER

(in.)

or 1

or larger

DIMENSIONS

(feet)

6 8

Fig. 8 — Gas Piping Guide (With Accessory

Thru-the-Curb Service Connections)

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 CONTR OL 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. 12).

LEGEND

IGC — LED —

Integrated Gas Unit Controller Light-Emitting Diode

Fig. 10 — Component Location

NOTE: For wire runs 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 directl y connected to the thermostat and will require a junction box and splice at the thermostat.

Feed control wires through the raceway located between the condenser coil top cover and burner side panel. See Fig. 10. Connect control wires to corresponding screw terminals, the low-voltage connections located inside low-voltage access panel. See Fig. 12 for connections. The low-voltage connections provide the UL required clearance between high- and 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.

208/230-1-60

208/230-3-60

460-3-60

(SIZE 007 ONLY)

LEGEND

C— COMP — NEC — TB —

Contactor Compressor National Electrical Code Terminal Block

575-3-60

(SIZE 007 ONLY)

208/230-3-60

575-3-60, 460-3-60

(SIZES 004-006)

Fig. 11 — Power Wiring Connections

LEGEND

AHA —

Adjustable Heat Anticipator Field Wiring Factory Wiring

Fig. 12 — Low-Voltage Connections

Table 2 — Electrical Data

UNIT 48TF

NOMINAL

V-P h- Hz

208/230-1-60

VOLTAGE

IFM

TYPE

RANGE

Min Max RLA LRA Qty Hp FLA MCA MOCP† FLA LRA

Std

187 254 16.2 96.0 1

Alt 4.9 26.6/26.6 35/35 26/26 111/111

COMPRESSOR

(ea)

Std

208/230-3-60

187 254 10.2 75.0 1

Alt 4.9 19.1/19.1 25/25 19/19 90/90

High 5.2 19.4/19.4 25/25 19/19 109/109

004

460-3-60

Std

414 508 4.4 40.0 1

Alt 2.1 8.4 15 8 48/48

High 2.6 8.9 15 9 57/57

Std

575-3-60

518 632 3.7 31.0 1

Alt 2.1 6.9 15 8 37

High 2.6 7.3 15 7 45

208/230-1-60

Std

187 254 23.3 118.0 1

Alt 4.9 35.4/35.4 45/45 34/34 133/133

Std

208/230-3-60

187 254 15.4 90.0 1

Alt 4.9 25.6/25.6 30/30 25/25 105/105

High 5.2 25.9/25.9 30/30 25/25 124/124

005

460-3-60

Std

414 508 8.3 45.0 1

Alt 2.1 13.3 20 13 53

High 2.6 13.8 20 13 62

Std

575-3-60

518 632 6.4 36.0 1

Alt 2.1 10.3 15 11 42

High 2.6 10.7 15 10 50

208/230-1-60

Std

187 254 28.8 147.0 1

Alt 6.6 44.0/44.0 60/60 42/42 184/184

Std

208/230-3-60

Alt 5.2 26.6/26.6 35/35 26/26 148/148

187 254 16.3 114.0 1

High 7.5 28.9/28.9 35/35 29/29 174/174

006

460-3-60

Std

414 508 7.4 64.0 1

Alt 2.6 12.7 15 12 81

High 3.4 13.5 20 13 94

Std

575-3-60

Alt 3.0 10.5 15 10 66

518 632 6.2 62.0 1

High 3.4 12.6 15 11 76

Std

187 254 23.6 146.0 1

High 7.5 32.5/32.5 40/40 32/32 205/205

Std

414 508 10.6 73.0 1

High 3.4 16.1 20 16 103

Std

518 632 8.5 58.4 1

High 3.4 12.9 20 14 82

007

208/230-3-60

460-3-60

575-3-60

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.

Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply voltage is greater than 2%.

of voltage imbalance.

Use the following formula to determine the percent

% Voltage Imbalance

= 100 x

max voltage deviation from average voltage

average voltage

OFM

(ea)

/41.4

/40.8

/41.4

/40.8

/41.4

/40.8

/41.4

/40.6

IFM

FLA

3.5

COMBUSTION

FAN MOTOR

FLA

POWER

SUPPLY

24.5/24.5 30/30 23/23 106/106

17.7/17.7 25/25 17/17 85/85

DISCONNECT

SIZE*

1.3

7.6 15 7 48/48

1.3

6.3 15 7 35

3.5

34.0/34.0 40/40 32/32 129/129

24.2/24.2 30/30 23/23 101/101

1.8

13.0 20 13 51

1.8

10.1 15 10 41

5.9

43.3/43.3 60/60 42/42 161/161

27.3/27.3 35/35 29/29 128/128

3.1

13.2 20 13 72

3.1

10.9 15 11 58

5.2

2.6

30.2/30.2 35/35 29/29 180/180

15.4 20 15 90

12.3 15 13 72

Example: Supply voltage is 460-3-60.

AB = 452 v BC = 464 v AC = 455 v

Average Voltage =

Determine maximum deviation from average voltage.

(AB) 457 – 452 = 5 v (BC) 464 – 457 = 7 v (AC) 457 – 455 = 2 v

452 + 464 + 455

1371

= 457

Maximum deviation is 7 v.

Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x

457

= 1.53%

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

IMPORTANT:

than 2%, contact your local electric utility company immediately.

If the supply voltage phase imbalance is more

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

MANUAL OUTDOOR-AIR DAMPER — The outdoor-air hood and screen are attached to the base pan 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. 13.

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

4. Replace outdoor air opening panel.

OUTDOOR AIR OPENING PANEL

3 SCREWS (SIDE)

5. Place hood on front of outdoor air opening panel. See Fig. 14 for hood details. Secure top of hood with the 4 screws removed in Step 3. See Fig. 15.

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. 14 and 15. Secure hood with 6 screws from Step 6.

8. Adjust minimum position setting of the damper bl ade by adjusting the manual outdoor-air adjustment screws on the front of the damper blade. See Fig. 13. Slide blade vertically until it is in the appropriate position determined by Fig. 16. Tighten screws.

9. Remove and save screws currently on sides of hood. Insert screen. Secure screen to hood using the screws. See Fig. 15.

Fig. 13 — Damper Panel with Manual Outdoor-Air

Damper Installed

Fig. 15 — Outdoor-Air Damper with

Hood Attached

Fig. 14 — Outdoor-Air Hood Details

Fig. 16 — Position Setting

OPTIONAL DURABLADE ECONOMIZER — The option-

ECONOMIZER CONTROL BOARD

BAROMETRIC RELIEF DAMPER

ECONOMIZER PLUG

ECONOMIZER MOTOR

SHIPPING SCREW

Fig. 18 — Outdoor-Air Hood Details

Fig. 19 — Horizontal Durablade

Economizer Installation

Fig. 17 — Typical Access Panel Locations

al economizer hood assembly is packaged and shipped in the filter section. Dampe r blades an d cont rol boa rds are ins talled at th e factory and the ec onomizer is shipped in the vertical di scharge 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.

NOTE: Be sure to engage Durablade economizer flange under tabs in return-air opening of the unit base.

Assembly:

1. Determine if ventilation air is re quired in building. If so, determine the minimum amount to be supplied by ea ch 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. 17. Remove optional economizer and outdoor-air damper hood package from filter section.

3. Assemble outdoor-air hood top and side plates as shown in Fig. 18. Install seal strips on hood top and sides. Put aside screen retainer and screws for later assembly.

not attach hood to unit at this time.

4. To convert to horizontal discharge application:

a. Rotate economizer 90 degrees until the econo-

mizer motor faces the condenser section (see Fig. 19).

b. Re move screws and t ape fr om da mper t hen r otate

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. 20. Remove 12-pin blue and yellow wire jumper plug and store.

5. Insert economizer plug into economizer harness. Remove tape from barometric relief damper. See Fig. 21. Remove shipping screw (see Fig. 19).

6. If ventilation air is not required, proceed to Step 7. If ventilation air is required, determine the minimum position setting for required airflow. See Fig. 22. 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. 22. Tighten screws.

7. Remove tape from outdoor-air thermostat (OAT). Fasten OAT to inside of hood using screws and speed c lips provided. See Fig. 23. Make sure OAT terminals are positioned up.

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

9. Fasten hood top and side plate assembly (Fig. 18) to outdoor-air opening panel with screws provided.

10. Place knob supplied with economizer on OAT. See Fig. 23. Set OAT 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. 23.

11. Connect OAT per Fig. 24.

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

NOTE: Refer to Fig. 25 for economizer barometric relief damper characteristics.

BLOCK-OFF PLATE

Fig. 20 — Horizontal Discharge Block-Off Plate

U-SHAPED HOLE (NOT SHOWN)

ECONOMIZER CONTROL BOARD

ECONOMIZER PLUG

WIRING HARNESS

BAROMETRIC RELIEF DAMPER

SHIPPING SCREW

ECONOMIZER MOTOR

POSITION SETTING BRACKET

TOP SCREW

Fig. 21 — Durablade Economizer Installed in Unit

ENTHALPY CONTROL

HOOD

TOP

OUTSIDE AIR SCREEN

OPEN

OUTDOOR TEMP

OAT (TERMINALS ARE UP)

UNIT

V .

POSITION

MINIMUM

CONT

OR UNPOWERED ST

ACT RA

CTS SHO

DAMPER

OPEN

CLOSED

4 V

–SETPOINTS

TINGS: 1.5A

N IN H

3 m

IGH ENTHALPY

RUN, 3.5A IN

–CCW

IN. A

DAMPER

T 1

1 VDC

-3

ENTHALPY CONTROL

2 4 V A C

TR1

Example:

Given — Negative Pressure. . . . . . . . . . . . . . . . . . . . . . . 0.2 in. wg

Outdoor Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 cfm

Determine — Setting = 5 in.

Fig. 22 — Durablade Economizer

Minimum Position Setting

Fig. 23 — Outdoor-Air Thermostat/

Enthalpy Control Installation

LEGEND

OUTDOOR AIR OPENING PANEL

SEAL STRIP

EXHAUST AIR SCREEN

EXHAUST AIR HOOD TOP

SCREEN RETAINER

EXHAUST AIR HOOD SIDES

EXHAUST AIR BOTTOM BRACKET

Fig. 28 — Exhaust Air Hood Assembly

OUTDOOR-AIR OPENING PANEL

FILTER ACCESS PANEL

Fig. 27 — Typical Access Panel Locations

BAROMETRIC RELIEF DAMPERS

CONTROLLER

ECONOMI$ER PLUG

GEAR-DRIVEN DAMPER

OUTDOOR AIR TEMPERATURE SENSOR

ACTUATOR

Fig. 26 — EconoMi$er Component Locations

OAT —

NOTE: See unit wiring diagram for details.

Outdoor-Air Thermostat

Fig. 24 — Wiring Connections for

Outdoor-Air Thermostat

0.90

0.80

0.70

0.60

0.50

0.40

0.30

PRESSURE DROP (in. wg)

0.20

0.10

0.00

200 300 400

100

CFM

Fig. 25 — Durablade Economizer

Barometric Relief Damper Characteristics

OPTIONAL ECONOMI$ER — See Fig. 26 for EconoMi$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. 27.

If installing an optional Power Exhaust Assembly, refer to

EconoMi$er Power Exhaust Installation Instructions

the Controller should be mounted in vertical position as

shown in Fig. 26.

2. Assemble the hood assembly as follows: Remove the EconoMi$er hood from its packaging.

Remove shipping brackets holding hood package to EconoMi$er. Locate the outdoor-air opening panel. See Fig. 28. Remove hood assembly shipping brackets located on the back (sloped) side of the EconoMi$er assembly. These brackets are used to retain the hood assembly during shipping only .

3. Install the

/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. 28, using the screws provided.

assembly to unit at this time.

4. Instal l the top and side panels. Assemble the outdoor-air hood to the outdoor-air opening panel as shown in Fig. 29, using the screws provided.

at this time.

/8 x 3/4-in. seal strip on the outdoor-air hood

Do not attach hood assembly to the unit

500 600

700

Do not attach hood

800

5. Slide the outdoor-air inlet screens into the screen track on

WIRING HARNESS

OUTDOOR AIR BLOCK-OFF PLATE

Fig. 32 — EconoMi$er Installed

Fig. 31 — Rear EconoMi$er Flange Installation

Fig. 30 — Completed Hood Assembly

the hood side panels. While holding the screens in pl ace, 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. 30) hood as-

sembly to unit a t this ti me.

6. Slide the EconoMi$er assembly into the rooftop unit. See Fig. 31 and 32.

NOTE: Be sure to engage rear EconoMi$er flange under tabs in return-air opening of the unit base. See Fig. 31.

7. Install the outdoor-air block-off plate, then secure the EconoMi$er with the screws provided. See Fig. 32.

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 diagrams Fig. 33 and 34. Also refer to Fig. 35 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. 36.

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. 37). Connect the vi olet and pink wires to the corresponding connections on the supply-air temperature sensor. Replace the indoor fan motor access panel.

UNIT FILTER RACK

UNIT BASE

ECONOMI$ER CLIP HVAC UNIT

ECONOMI$ER

ECONOMI$ER REAR FLANGE

OUTDOOR AIR OPENING PANEL

ASSEMBLED EXHAUST HOOD

Fig. 29 — Outdoor-Air Hood Assembly

SEAL STRIP

OUTDOOR AIR HOOD SIDES

OUTDOOR AIR HOOD TOP

SCREEN RETAINER

OUTDOOR AIR INLET SCREENS

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