Carrier 48TJD008-014 User Manual

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Installation, Start-Up and
Service Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS ...................1
INSTALLATION .............................1-22
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 ...................8
Step 6 Install Gas Piping ...................8
Step 7 Make Electrical Connections ........8
FIELD POWER SUPPLY
FIELD CONTROL WIRING
HEAT ANTICIPATOR SETTINGS
Step 8 Adjust Factory-Installed Options ...11
APOLLO CONTROL
MANUAL OUTDOOR-AIR DAMPER
OPTIONAL DURABLADE ECONOMIZER
OPTIONAL PARABLADE ECONOMIZER
Step 9 Adjust Evaporator-Fan Speed ......16
START-UP .................................23,24
SERVICE ..................................25-30
TROUBLESHOOTING ......................31-36
START-UP CHECKLIST .................... CL-1
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment
can be hazardous due to system pressure and electrical com-
ponents. Only trained and qualified service personnel should
install, 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 per-
sonnel. When working on air-conditioning equipment, ob-
serve precautions in the literature, tags and labels attached
to the unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire ex-
tinguishers available for all brazing operations.
Disconnect gas piping from unit when leak
testing at pressure greater than
1
2
psig. Pres-
sures greater than
1
2
psig will cause gas
valve damage resulting in hazardous con-
dition. If gas valve is subjected to pres-
sure 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(s).
Before performing service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury.
INSTALLATION
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
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. If
gas is to be routed through the curb, attach the accessory
thru-the-curb service connection plate to the roof curb in ac-
cordance with the accessory installation instructions. Con-
nection plate must be installed before unit is set in roof curb.
IMPORTANT: The gasketing of the unit to the roof
curb is critical for a watertight seal. Install gasket sup-
plied with the roof curb as shown in Fig. 2. Improp-
erly applied gasket can also result in air leaks and poor
unit performance.
Curb should be level. Unit leveling tolerances are shown
in Fig. 3. This is necessary for unit drain to function prop-
erly. Refer to Accessory Roof Curb Installation Instructions
for additional information as required.
48TJD008-014
48TJE008-014
48TJF008-012
Single-Package Rooftop Heating/Cooling Units
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 1a 6a
PC 111 Catalog No. 564-934 Printed in U.S.A. Form 48TJ-13SI Pg 1 9-96 Replaces: 48TJ-10SI
Page view 0
1 2 3 4 5 6 ... 39 40

Summary of Contents

Page 1 - Service Instructions

Installation, Start-Up andService InstructionsCONTENTSPageSAFETY CONSIDERATIONS ...1INSTALLATION ...1-22Step

Page 2

Fig. 10 — Power Wiring ConnectionsLEGENDC—ContactorCOMPS — CompressorsIFC — Indoor (Evaporator) FanContactorNEC — National Electrical CodeTB — Termina

Page 3 - Fig. 2 — Roof Curb Details

Step 8 — Adjust Factory-Installed OptionsAPOLLO CONTROL — The optional Apollo control is usedto actively monitor all modes of operation as well as ind

Page 4 - maximum unit static

9. Remove and save screws currently on sides of hood.Insert screens. Secure screens to hood using the screws.See Fig. 16.10. Replace filter access pane

Page 5 - Table 1 — Physical Data

Fig. 19 — Outdoor-Air Hood DetailsFig. 20 — Vertical Discharge Block-Off Plate(Sizes 120,150 only)ECONOMIZERCONTROL BOARDECONOMIZERPLUGECONOMIZERMOTOR

Page 6

Example:Given —Negative Pressure ...0.1in.wgOutdoor Airflow ...1100cfmDetermine —Setting = 69Fig. 24 — Durabla

Page 7 - Fig. 7 — Base Unit Dimensions

OPTIONAL PARABLADE ECONOMIZER — The op-tional PARABLADE economizer hood assembly is pack-aged and shipped in the filter section. Damper blades andcontr

Page 8 - SPACING OF SUPPORTS

Step 9 — Adjust Evaporator-Fan Speed — Ad-just evaporator-fan speed to meet jobsite conditions.Table 3 shows fan rpm at motor pulley settings, Table 4

Page 9

Table 3 — Fan Rpm at Motor Pulley Settings*UNIT48TJMOTOR PULLEY TURNS OPEN01⁄2111⁄2221⁄2331⁄2441⁄2551⁄26008† 840 815 790 765 740 715 690 665 640 615 5

Page 10

Table 4 — Evaporator-Fan Motor EfficiencyMOTOR EFFICIENCY (%)48TJD/TJE/TJF008,009 8048TJD/TJE/TJF012 (Std) 8048TJD/TJE/TJF012 (Alt) 8348TJD/TJE014 (St

Page 11

Table 7 — Fan Performance, 48TJ008 — Vertical Discharge UnitsAIRFLOW(Cfm)EXTERNAL STATIC PRESSURE (in. wg)0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6Rpm Bhp Rpm B

Page 12 - FILTER ACCESS

SLAB MOUNT (Horizontal Units Only) — Provide a levelconcrete slab that extends a minimum of 6 in. beyond unitcabinet. Install a gravel apron in front

Page 13 - BLOCK-OFF PLATE

Table 9 — Fan Performance, 48TJ012 — Vertical Discharge UnitsAIRFLOW(Cfm)EXTERNAL STATIC PRESSURE (in. wg)0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0Rpm B

Page 14 - POSITION

Table 11 — Fan Performance, 48TJ008 — Horizontal Discharge UnitsAIRFLOW(Cfm)EXTERNAL STATIC PRESSURE (in. wg)0.2 0.4 0.6 0.8 0.9 1.0 1.2 1.4 1.6Rpm Bh

Page 15

Table 13 — Fan Performance, 48TJ012 — Horizontal Discharge UnitsAIRFLOW(Cfm)EXTERNAL STATIC PRESSURE (in. wg)0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0Rp

Page 16 - RH — Relative Humidity

START-UPUnit Preparation —Make sure that unit has been in-stalled in accordance with these installation instructions andapplicable codes. Make sure th

Page 17 - PLATE NUTS

Table 15 — Altitude Compensation*ELEVATION(Ft)125,000, 180,000, AND224,000 BTUHNOMINAL INPUT250,000 BTUHNOMINAL INPUTNaturalGasOrificeSize†LiquidPropan

Page 18 - Table 6 — Motor Data

SERVICEWhen servicing unit, shut off all electrical power to unitto avoid shock hazard or injury from rotating parts.Cleaning — Inspect unit interior

Page 19

Condenser-Fan Adjustment (Fig. 40)1. Shut off unit power supply.2. Remove condenser-fan assembly (grille, motor, motor cover,and fan) and loosen fan h

Page 20

Fig. 42 — Cooling Charging Chart; 48TJ009Fig. 43 — Cooling Charging Chart; 48TJ01227

Page 21

Flue Gas Passageways — To inspect the flue col-lector box and upper areas of the heat exchanger:1. Remove the combustion blower wheel and motor assem-b

Page 22

REMOVAL AND REPLACEMENT OF GAS TRAIN(Fig. 45 and 46)1. Shut off manual gas valve.2. Shut off power to unit.3. Slide out burner section side panel (not

Page 23

UNIT SIZE‘‘A’’ROOF CURB48TJ ACCESSORY008-01418-29 [356] CRRFCURB003A0028-09 [610] CRRFCURB004A00UNIT SIZE48TJ‘‘B’’ ‘‘C’’ ‘‘D’’ ALT DRAIN HOLE‘‘E’’GASP

Page 24 - Operating Sequence

NOTE: Dimensions in ( ) are millimeters.Fig. 47 — Spark Gap Adjustment125,000 BTUH INPUT48TJD008,009120,000-180,000 BTUH INPUT48TJD012, 48TJE008,00948

Page 25 - Lubrication

TROUBLESHOOTINGTable 17 — LED Error Code Service AnalysisPROBLEM CAUSE REMEDYHardware failure.(LED OFF)Loss of power to control module (IGC). Check 5-

Page 26 - 460 V and 575 V 3.50

Table 18 — Durablade Economizer TroubleshootingPROBLEM CAUSE REMEDYDamper does notopen.Indoor (evaporator) fan is off. 1. Check to ensure that 24 vac

Page 27

Table 19 — PARABLADE Economizer Service TroubleshootingPROBLEM CAUSE REMEDYDamper does notopen.Evaporator fan not on. Check wiring between G on connec

Page 28

Table 20 — Cooling Service TroubleshootingPROBLEM CAUSE REMEDYCompressor andcondenser fanwill not start.Power failure. Call power company.Fuse blown o

Page 29

Table 21 — Heating Service TroubleshootingPROBLEM CAUSE REMEDYBurners will notignite.Misaligned spark electrodes. Check flame ignition and sensor elect

Page 30

Fig. 48 — Typical Wiring Schematic and Component Arrangement36

Page 32

Copyright 1996 Carrier CorporationManufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and w

Page 34

Locate mechanical draft system flue assembly at least48 in. from any opening through which combustion prod-ucts could enter the building, and at least

Page 35 - LEGEND AND NOTES FOR FIG. 48

START-UP CHECKLIST(Remove and Store in Job File)I. PRELIMINARY INFORMATIONMODEL NO.:DATE:SERIAL NO.:TECHNICIAN:II. PRE-START-UP (insert checkmark in b

Page 36

Table 1 — Physical DataUNIT SIZE 48TJ 008D/E/F 009D/E/F 012D/E/F 014D/ENOMINAL CAPACITY (tons) 71⁄281⁄210 121⁄2OPERATING WEIGHT (lb)UnitAl/Al* 870 880

Page 37

Table 1 — Physical Data (cont)UNIT SIZE 48TJ 008D/E/F 009D/E/F 012D/E/F 014D/EFURNACE SECTIONRollout Switch CutoutTemp (F) 195 195 195 195Burner Orific

Page 38 - Tab 1a 6a

UNIT48TJSTANDARDUNITWEIGHTCORNERWEIGHT(A)CORNERWEIGHT(B)CORNERWEIGHT(C)CORNERWEIGHT(D)‘‘H’’ ‘‘J’’ ‘‘K’’ ‘‘L’’Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg ft-in. mm f

Page 39

Step 5 — Install Flue Hood — Flue hood is shippedscrewed to the burner compartment access panel. Removefrom shipping location and, using screws provid

Page 40 - III. START-UP

Route thermostat cable or equivalent single leads of col-ored wire from subbase terminals to low-voltage connec-tions on unit (shown in Fig. 11) as de

Related models: 48TJF008-012

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