Carrier 48DJ, Installation, Start-Up And Service Instructions Manual

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Installation, Start-Up and
Service Instructions
CONTENTS
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY CONSIDERATIONS
. . . . . . . . . . . . . . . . . . . 2
INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Rigging and Unit Placement
. . . . . . . . . . . . . . . . . . 2
Roof Curb
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Roof Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Slab Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Field-Fabricated Ductwork . . . . . . . . . . . . . . . . . . . . 6
Condensate Drains
. . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install Outdoor Hoods
. . . . . . . . . . . . . . . . . . . . . . . 10
• UNIT SIZES 034 AND 044
• UNIT SIZES 054-074
Outdoor-Air Inlet Adjustments
. . . . . . . . . . . . . . . 10
• MANUAL OUTDOOR-AIR DAMPER
• ECONOMIZER SETTINGS
Field Wire Routing . . . . . . . . . . . . . . . . . . . . . . . . . . 17
• UNIT SIZES 034 AND 044
• UNIT SIZES 054-074
Field Electrical Connections
. . . . . . . . . . . . . . . . . 17
• POWER WIRING
• CONTROL WIRING
Gas Piping (48 Series Units Only)
. . . . . . . . . . . . 36
Installing Flue/Inlet Hoods (48 Series Units
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
• UNIT SIZES 034 AND 044
• UNIT SIZES 054-074
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-41
Unit Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Compressor Mounting
. . . . . . . . . . . . . . . . . . . . . . . 38
Evaporator-Fan Shipping Brackets
. . . . . . . . . . . 38
• UNIT SIZES 034 AND 044
• UNIT SIZES 054-074
Internal Wiring
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Refrigerant Service Valves . . . . . . . . . . . . . . . . . . . 38
Crankcase Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Gas Manifold Pressure (48 Series
Units Only)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Unit Voltage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Leak Test and Dehydration
. . . . . . . . . . . . . . . . . . 39
Evaporator-Fan Belts, Pulleys, and Sheaves
. . 39
Condenser Fans and Motors
. . . . . . . . . . . . . . . . . 40
Return-Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Economizer Inlet Screens . . . . . . . . . . . . . . . . . . . 40
Economizer Dampers . . . . . . . . . . . . . . . . . . . . . . . 40
25% Outdoor-Air Damper . . . . . . . . . . . . . . . . . . . . 40
Initial Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,42
General
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operating Sequences
. . . . . . . . . . . . . . . . . . . . . . . 41
• COOLING, UNITS WITHOUT ECONOMIZER
• HEATING, UNITS WITHOUT ECONOMIZER
Page
• COOLING, UNITS WITH ECONOMIZER
• HEATING, UNITS WITH ECONOMIZER
• VENTILATION AIR CIRCULATION (Continuous Fan)
• AUTOMATIC CHANGEOVER USING AUTOMATIC
CHANGEOVER THERMOSTAT
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . 42
SERVICE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-53
Service Access
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
• COMPRESSORS
• LIQUID SERVICE VALVES, FILTER DRIERS, AND
SIGHT GLASSES
• EVAPORATOR-FAN MOTORS, PULLEYS, AND
BELTS
• POWER EXHAUST MOTORS, PULLEYS, AND
BELTS
• UNIT CONTROL BOX
• GAS HEAT SECTION (48 Series Units Only)
• MAIN AND PILOT BURNERS (48 Series Units Only)
• FLUE GAS PASSAGEWAYS (48 Series Units Only)
• COMBUSTION AIR BLOWER (48 Series Units Only)
• ECONOMIZER DAMPER MOTOR
• ELECTRIC HEATER CONTROL BOX (50 Series
Units Only)
• HEATER BOX (50 Series Units Only)
• 25% OUTDOOR-AIR DAMPER
• MODULATING POWER EXHAUST DAMPER
MOTOR
• RETURN-AIR FILTERS
• CONDENSER FANS AND FAN MOTORS
• INLET GUIDE VANE MOTOR
Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Lubrication
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
• COMPRESSORS
• FAN SHAFT BEARINGS
• INLET GUIDE VANE BEARINGS (Units With
Optional Inlet Guide Vanes)
• FAN MOTOR BEARINGS
• DOOR HINGES
Adjustments
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
• EVAPORATOR FAN AND POWER EXHAUST
MOTOR PLATE
• MODULATING POWER EXHAUST DIFFERENTIAL
PRESSURE SWITCH
• INLET GUIDE VANE DIFFERENTIAL PRESSURE
SWITCH (Units With Optional Inlet Guide Vanes and
Static Pressure Control)
• BELT INSTALLATION AND TENSIONING
• PULLEY ALIGNMENT
• INSTALLING ALTERNATE MOTOR PULLEY
(Evaporator Fan Only)
• CONDENSER FAN ADJUSTMENT
• 25% OUTDOOR-AIR DAMPER
• REFRIGERANT CHARGE
• PILOT LIGHT OFF (48 Series Units Only)
48DJ,DK,NP034-074
50DJ,DK,DW,DY,NB,NP034-074
Single Package Heating and Cooling Units
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 1
Tab 1a 1b
PC 111 Catalog No. 564-818 Printed in U.S.A. Form 48/50D,N-9SI Pg 1 3-96 Replaces: 48DJ,DK-3SI;
48/50NB,NP-1SI; 50DJ,DK-9SI