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

Catalog No. 004-816

Printed in U.S.A.

Form 48TF-C1SI

Pg 1

1-01

Replaces: New

Book 1

4

Tab

1a 6a

Installation, Start-Up and

Service Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS

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

INSTALLATION

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-33

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 Connection

 . . . . . . . . . . . . 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 ECONOMI$ER

Step 9 — Adjust Evaporator-Fan Speed

 . . . . . . . . . 20

START-UP

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  34-36

SERVICE

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  36-41

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . .  42-46

START-UP CHECKLIST

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

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can

be hazardous due to system pressure and electrical compo-
nents. 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 personnel.
When working on air-conditioning equipment, observe precau-
tions 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 extinguishers available for all brazing operations.

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 insula-
tion 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. In-
stall insulation, cant strips, roofing felt, and counter flashing as
shown.  Ductwork must be attached to curb. If gas, electric
power or control power is to be routed through the curb, attach
the accessory thru-the-curb service connection plates to the
roof curb in accordance with the accessory installation instruc-
tions. Connection plates must be installed before unit is set in
roof curb.

Curb should be level. Unit leveling tolerances are shown in

Fig. 3. This is necessary for unit drain to function properly. Re-
fer to Accessory Roof Curb Installation Instructions for addi-
tional information as required.

Disconnect gas piping from unit when leak test-
ing at pressure greater than 3.4 kPa (

1

/

2

 psig).

Pressures greater than 3.4 kPa (

1

/

2

 psig) will

cause gas valve damage resulting in hazardous
condition. If gas valve is ever subjected to pres-
sure greater than 3.4 kPa (

1

/

2

 

psig), it must be

replaced before use. When pressure testing
field-supplied gas piping at pressures of 3.4 kPa
(

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.

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

48TFD008-014

48TFE008-014

48TFF008,012

Single-Package Rooftop Heating/Cooling Units

50 Hz

Summary of Contents for 48TFD008

Page 1: ...ischarge 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 insu...

Page 2: ...ori zontal applications When using the standard side drain connection make sure the plug Red in the alternate bottom connection is tight before installing the unit To use the bottom drain connection f...

Page 3: ...ated panels 1 in 25 thick polyurethane foam 13 4 lb density 3 Dimensions in are in millimeters 4 Roof curb 16 gage steel 5 Attach ductwork to curb flanges of duct rest on curb 6 Service clearance 4 ft...

Page 4: ...equate 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 Nati...

Page 5: ...102 127 Nominal Motor Shaft Diameter mm 16 16 22 Fan Pulley Pitch Diameter mm 178 178 203 Nominal Fan Shaft Diameter mm 25 25 25 Belt Quantity Type Length mm 1 A 1245 1 A 1245 1 A 1346 Pulley Center...

Page 6: ...ter in 5 8 5 8 7 8 Fan Pulley Pitch Diameter in 7 0 7 0 8 0 Nominal Fan Shaft Diameter in Belt Quantity Type Length in 1 A 49 1 A 49 1 A 53 Pulley Center Line Distance in 16 75 19 25 15 85 17 50 15 85...

Page 7: ...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 dis charge openings...

Page 8: ...may cause damage to electrical compo nents Such operation would invalidate any applicable Carrier warranty NOTE If field installed thru the bottom connections are used refer to the accessory installa...

Page 9: ...ing 4 Connect thermostat wires to screw terminals on low voltage connection board HEAT ANTICIPATOR SETTINGS Set heat anticipator settings at 14 amp for the first stage and 20 amp for second stage heat...

Page 10: ...Contactor IFC Indoor Evaporator Fan Contactor NEC National Electrical Code U S A Standard Splice Connection Factory Supplied Equipment Ground Field Wiring Factory Wiring Fig 10 Low Voltage Connection...

Page 11: ...evaporator coil access panel using screws from Step 2 5 Place hood on front of evaporator coil access panel See Fig 14 for hood details Secure top of hood with the screws removed in Step 3 See Fig 15...

Page 12: ...hould 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 assem bly See Fig...

Page 13: ...ONOMIZER MOTOR POSITION SETTING BRACKET BLOCK OFF PLATE Fig 18 Outdoor Air Hood Details Fig 19 Vertical Discharge Block Off Plate 48TF012 014 Units Only Fig 20 Durablade Economizer Installed in Unit F...

Page 14: ...NTS CCW CONTACTS SHOWN IN HIGH ENTHALPY RUSH AT 24VAC 3 mA MIN AT 11 VDC CONTACT RATINGS 1 5A RUN 3 5A IN OR UNPOWERED STATE 1 2 3 TR TR1 24V AC ENTHALPY CONTROL ENTHALPY CONTROL HOOD Example Given Ne...

Page 15: ...panel as shown in Fig 30 using the screws provided Do not attach hood assembly to unit at this time 4 Install the 3 mm x 22 mm 1 8 x 7 8 in seal strip on the outdoor air hood top and side panels Assem...

Page 16: ...to wiring diagram Fig 36 and 37 Also refer to Fig 38 if installing an accessory power exhaust 10 Install the complete hood assembly on the unit and secure using the screws provided 11 Remove the indoo...

Page 17: ...ETURN AIR SENSOR VIOLET WHITE RED OAT COM OAH 15 V RAT COM RAH 15 V ECONOMI ER CONTROLLER PINK TEMP TEMP VIOLET SUPPLY AIR TEMPERATURE SENSOR V 24 COM VAC SENSOR CO2 COM DAT COM REM POT COM LED COM CO...

Page 18: ...EEN YELLOW 3 2 1 5 8 6 9 B A 7 4 LT BLUE BLACK BROWN C1 BLUE FAN 2 FAN 1 BLACK BLACK BLACK R1 24 VAC R2 24 VAC BLACK BLUE 1 2 3 BROWN ORANGE 3 PIN CONNECTOR PLUG YELLOW RED YEL H1 BLU GRAY H4 SECONDAR...

Page 19: ...ndoor fan must be on to set the ventilation air Either put the thermostat in the continuous fan mode or jumper the R and G terminals at the rooftop unit connection board 2 Locate the minimum position...

Page 20: ...ize 008 Slide motor mounting plate away from fan scroll for proper belt tension 13 mm 1 2 in deflection with 3 6 to 4 5 kg 8 to 10 lbs of force and tighten mounting nuts See Fig 42 Sizes 012 014 Slide...

Page 21: ...2 30 12 00 UNIT 48TF MOTOR PULLEY TURNS OPEN 0 1 2 1 11 2 2 21 2 3 31 2 4 41 2 5 008 700 681 660 639 618 597 576 555 534 513 492 012 779 760 739 718 697 676 655 634 613 592 571 014 900 883 865 843 825...

Page 22: ...11 1 0 85 12 1 1 02 13 1 1 26 1450 10 1 0 68 11 3 0 86 12 3 1 09 13 2 1 29 1500 10 4 0 78 11 5 0 96 12 6 1 18 13 5 1 38 1550 10 7 0 81 11 8 1 06 12 8 1 25 13 7 1 48 1600 11 0 0 90 12 0 1 10 13 0 1 35...

Page 23: ...5 1 08 13 3 1 22 14 2 1 36 15 0 1 52 1850 11 7 1 00 12 7 1 15 13 6 1 31 14 4 1 44 15 2 1 60 1900 12 0 1 08 12 9 1 23 13 8 1 40 14 6 1 53 15 4 1 70 1950 12 2 1 16 13 2 1 31 14 1 1 49 14 8 1 63 15 6 1 7...

Page 24: ...4 2 16 16 2 2 38 17 0 2 60 17 7 2 79 18 5 2 99 2500 15 7 2 28 16 5 2 52 17 3 2 75 18 0 2 95 18 7 3 13 2550 15 9 2 43 16 8 2 65 17 5 2 90 18 2 3 10 18 0 3 29 2600 16 2 2 58 17 1 2 81 17 8 3 05 18 5 3...

Page 25: ...450 10 0 0 67 11 2 0 88 12 2 1 07 13 2 1 27 13 6 1 40 1500 10 2 0 74 11 4 0 94 12 4 1 15 13 4 1 36 13 8 1 48 1550 10 5 0 80 11 7 1 02 12 7 1 23 13 6 1 44 14 0 1 56 1600 10 8 0 88 11 9 1 09 12 9 1 32 1...

Page 26: ...12 8 1 14 13 7 1 30 14 6 1 47 1850 10 8 0 92 11 9 1 04 13 0 1 21 13 9 1 39 14 8 1 55 1900 11 1 1 00 12 1 1 14 13 2 1 29 14 1 1 47 15 0 1 64 1950 11 3 1 09 12 3 1 22 13 4 1 38 14 3 1 55 15 2 1 72 2000...

Page 27: ...7 4 2 64 2450 14 1 1 84 15 1 2 10 16 0 2 31 16 8 2 56 17 6 2 77 2500 14 4 1 95 15 4 2 22 16 2 2 44 17 1 2 69 17 8 2 90 2550 14 7 2 07 15 6 2 34 16 5 2 56 17 3 2 83 18 1 3 05 2600 14 9 2 18 15 8 2 47 1...

Page 28: ...00 706 1 25 764 1 52 2700 582 0 83 655 1 08 719 1 34 776 1 61 2800 598 0 90 670 1 17 732 1 43 789 1 71 2900 614 0 98 684 1 25 745 1 53 802 1 81 3000 630 1 07 699 1 35 759 1 63 815 1 92 3100 646 1 16...

Page 29: ...1 33 760 1 54 814 1 75 863 1 92 912 2 14 3800 715 1 43 774 1 64 828 1 86 875 2 04 924 2 26 3900 731 1 54 787 1 74 843 1 98 888 2 16 936 2 30 4000 747 1 65 801 1 85 857 2 10 902 2 30 948 2 51 4100 763...

Page 30: ...3 3 61 1097 3 88 4900 926 2 93 977 3 24 1024 3 54 1068 3 80 1111 4 06 5000 942 3 11 993 3 41 1039 3 73 1080 3 90 1126 4 25 5100 959 3 29 1009 3 60 1055 3 92 1097 4 19 1139 4 46 5200 976 3 47 1025 3 78...

Page 31: ...00 588 0 86 662 1 13 723 1 38 782 1 66 809 1 82 2900 604 0 94 676 1 21 737 1 48 794 1 76 821 1 92 3000 620 1 02 690 1 30 750 1 58 806 1 86 832 2 02 3100 636 1 11 704 1 39 764 1 69 818 1 97 844 2 13 32...

Page 32: ...7 3800 662 1 33 726 1 51 789 1 72 846 1 95 897 2 18 3900 677 1 44 738 1 61 801 1 82 857 2 06 908 2 29 4000 692 1 55 750 1 73 813 1 94 868 2 17 918 2 40 4100 707 1 67 762 1 84 825 2 05 878 2 28 929 2 5...

Page 33: ...3 65 1073 3 94 5100 882 2 79 938 3 17 990 3 46 1040 3 82 1085 4 12 5200 896 2 95 952 3 33 1003 3 63 1053 4 00 1098 4 30 5300 911 3 11 967 3 50 1017 3 80 1066 4 18 1111 4 50 5400 926 3 27 981 3 68 103...

Page 34: ...unit charge Refer to Refrigerant Charge section page 37 Unit must operate a minimum of 15 minutes before adjusting charge Reset thermostat at a position above room temperature Compressor and outdoor...

Page 35: ...is cooling If the thermo stat calls for a second stage of cooling by energizing Y2 com pressor contactor no 2 C2 is energized and compressor no 2 starts When the thermostat is satisfied C1 and C2 are...

Page 36: ...and 2 are deen ergized Re asserting Y2 will start compressor no 1 and after a 20 minute interstage delay compressor no 2 5 If compressor no 1 is energized and the thermostat is sat isfied compressor n...

Page 37: ...ystem weigh in the specified amount of refriger ant refer to Tables 1A and 1B LOW CHARGE COOLING Using the Cooling Charging Charts Fig 49 51 vary refrigerant until the conditions of the appropriate ch...

Page 38: ...38 Fig 49 Cooling Charging Charts 48TF008 Units Fig 50 Cooling Charging Charts 48TF012 Units...

Page 39: ...n the control box Fig 11 Module contains a self diagnostic LED light emitting diode A single LED on the IGC provides a visual display of operational or sequential problems when the power supply is int...

Page 40: ...he unit Fig 53 9 To reinstall reverse the procedure outlined above CLEANING AND ADJUSTMENT 1 Remove burner rack from unit as described in Removal and Replacement of Gas Train section on this page 2 In...

Page 41: ...rk Gap Adjustment 48TFD008 31 4 21 1 kW INPUT 107 000 72 000 BTUH 48TFE008 48TFD012 50 4 31 9 kW INPUT 172 000 109 000 BTUH 48TFD014 48TFE012 48TFF008 59 8 39 8 kW INPUT 204 000 136 000 BTUH 48TFE014...

Page 42: ...n wires are properly termi nated Verify that unit is obtaining proper amount of gas Induced draft motor fault LED 6 flashes IGC does not sense that induced draft motor is operating Check for proper vo...

Page 43: ...tes continuously Dirty air filter Replace filter Unit undersized for load Decrease load or increase unit size Thermostat set too low Reset thermostat Low refrigerant charge Locate leak repair and rech...

Page 44: ...Fan On terminal Check whether 24 vac is present at PL6 1 red wire and or PL6 3 black wire If 24 vac is not present check wiring see unit label diagram Check proper thermostat connection to G on the co...

Page 45: ...ings and the economizer control board wiring are correct check to ensure that the 24 vac terminal of the SAT has 24 vac white wire If OAT EC and control board are functioning and wired properly and no...

Page 46: ...ressure Switch LS Limit Switch MGV Main Gas Valve MTR Motor OAT Outdoor Air Thermostat OFM Outdoor Fan Motor P Plug PL Plug Assembly QT Quadruple Terminal R Relay RS Rollout Switch SAT Supply Air Ther...

Page 47: ......

Page 48: ...BRACKETS PER INSTALLATION INSTRUCTIONS VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS CHECK GAS PIPING FOR LE...

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