Carrier 48TM016 Installation, Start-Up And Service Instructions Manual Download Page 6

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Summary of Contents for 48TM016

Page 1: ... 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...

Page 2: ...intain clearance per Fig 4 6 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 air must be provided in accordance with Section 5 3 Air for Combustio...

Page 3: ...3 Fig 2A Roof Curb Details 48TM016 025 ...

Page 4: ...4 Fig 2B Roof Curb Details 48TM028 ...

Page 5: ...er 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 All panels must be in place when rigging Fig 3 Rigging Details UNIT 48TM MAXIMUM SHIPPING WEIGHT DIMENSIONS A B lb kg ft in mm ft in mm 016 1875 850 6 111 2 2121 4 0 1219 020 1925 873 6 111 2 2121 3 2 9...

Page 6: ...6 Fig 4 Base Unit Dimensions 48TM016 020 ...

Page 7: ...7 Fig 5 Base Unit Dimensions 48TM025 ...

Page 8: ...8 Fig 6 Base Unit Dimensions 48TM028 ...

Page 9: ...ominal Cfm 10 500 10 500 14 200 21 000 Quantity Diameter in 3 22 3 22 2 30 6 22 Motor Hp Rpm 1 2 1050 1 2 1050 1 1075 1 2 1050 Watts Input Total 1100 1100 3400 2200 EVAPORATOR COIL Cross Hatched 3 8 in Copper Tubes Aluminum Lanced or Copper Plate Fins Face Split Rows Fins in 4 15 4 15 4 15 4 15 Total Face Area sq ft 17 5 17 5 17 5 17 5 EVAPORATOR FAN Centrifugal Type Quantity Size in 2 12 x 12 2 1...

Page 10: ...136 29 0 1285 30 0 136 29 0 1285 30 0 136 29 Thermostat Heat Anticipator Setting amps 208 230 575 v Stage 1 0 98 0 98 0 98 0 98 Stage 2 0 44 0 44 0 44 0 44 460 v Stage 1 0 80 0 80 0 80 0 80 Stage 2 0 44 0 44 0 44 0 44 Gas Input Stage 1 172 000 225 000 206 000 270 000 206 000 270 000 206 000 270 000 Stage 2 230 000 300 000 275 000 360 000 275 000 360 000 275 000 360 000 Efficiency Steady State 81 8...

Page 11: ...To install secure flue hood to access panel See Fig 10 The wind baffle is then installed over the flue hood NOTE When properly installed flue hood will line up with combustion fan housing See Fig 11 Step 6 Trap Condensate Drain See Fig 12 for drain location One 3 4 in half coupling is provided inside unit evaporator section for condensate drain connection An 81 2 in x 3 4 in diameter and 2 in x 3 ...

Page 12: ...is unit for use with 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 the elevation See Table 3 for the number of orifices required for each unit size Purchase these orifices from your local Carrier dealer Follow instructions in accessory Installa tion Instructions to install the correct orifices Table 4 LP Gas Conver...

Page 13: ...roved accessory thermostat assembly according to installation in structions included with accessory 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 16 N...

Page 14: ...nd 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 the OFF position the handle will be horizontal 7 Turn ...

Page 15: ... 5 0 75 5 0 6 0 0 57 31 40 2 1 4 8 0 57 34 40 020 208 230 187 253 30 1 225 28 8 195 3 0 5 1 7 5 0 15 8 15 8 0 57 87 87 110 110 4 6 18 8 0 57 92 92 110 110 460 414 508 15 5 114 14 7 95 3 0 5 0 8 5 0 7 9 0 30 44 50 2 3 6 0 0 30 47 60 575 518 632 5 12 1 80 10 7 80 3 0 5 0 75 5 0 6 0 0 57 34 40 2 1 4 8 0 57 36 40 025 208 230 187 253 42 239 33 6 225 2 1 6 6 7 5 25 0 25 0 0 57 124 124 150 150 4 6 18 8 0...

Page 16: ...ain er and drain pan see Fig 21 3 Secure lower filter retainer and support bracket to unit See Fig 21 Leave screws loose on 025 and 028 units 4 Slide baffle sizes 025 and 028 behind lower filter retain er 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 in...

Page 17: ...on size 028 units while outdoor fans no 2 and 3 and 5 and 6 on 028 units are sequenced off by the Accessory 0 F Low Ambient Kit Accessory 0 F Low Ambient Kit Install the accessory 0 F low ambient kit per instruction supplied with accessory Sensor Assembly Install the sensor assembly in the location shown in Fig 23 Motor Mount To ensure proper fan height replace the exist ing motor mount with the n...

Page 18: ...orallunits see Fig 22 The Motormaster V control permits operation of the unit to an ambient temperature of 20 F 29 C The control regulates the speed of 3 phase fan motors that are compatible with the control These motors are factory installed See Table 6 for the Motormaster V control accessory package usage Table 7 shows applicable voltages and motors Replacement of fan motor IS NOT REQUIRED ON CU...

Page 19: ...ature SAT Sensor When the unit is supplied with a factory mounted PremierLink con trol the supply air temperature SAT sensor 33ZCSENSAT is factory 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 the ...

Page 20: ... YEL CMP2 BLU HS1 WHT HS2 PNK ORN HS3 EXH RVS RED PWR CUT FOR DUAL TRANSFORMER EQUIPMENT RELAYS RED TSTAT CONTROL G Y1 Y2 W1 W2 ENTH GRN YEL BLU WHT PNK ORN RED RED RED RED RED RED J4 DISCRETE SWITCH POSITION 0 POSITION 1 1 LEN CCN LOAD FACTORY DEFAULTS ON POWERUP NO ACTION 4 R Y1 Y2 W1 W2 G C X DDC CONTROL TSTAT CONTROL Y1 CMP SAFE FSD Y2 SFS W1 X X C C RMTOCC NOT USED G W2 TB2 C WHT OR BLK FROM ...

Page 21: ...is below 74 5 F The relay output is wired to the unit economizer which will open or close depending on the output of the switch NOTE The enthalpy calculation is done using an average altitude of 1000 ft above sea level Mounting Mount the enthalpy switch receiver in a location where the outdoor air can be sampled such as the outdoor air intake The enthalpy switch receiver is not a NEMA 4 National E...

Page 22: ...thalpy Switch Receiver Dimensions 33CSENTHSW Fig 28 Enthalpy Sensor Dimensions 33CSENTSEN Fig 29 Typical Wiring Schematic Carrier Rooftop Unit with PremierLink Controls Used with Differential Enthalpy Control only ...

Page 23: ...tch receiver To power the enthalpy switch receiver from the econ omizer harness connect power of the enthalpy switch receiver to the red and brown wires 1 and 4 on the economizer harness Connect the LOW Enthalpy terminal on the enthalpy switch receiver to J4 pin 2 of the PremierLink control on the HVAC unit The switch can be powered through the Premier Link control board if desired Wire the 24VAC ...

Page 24: ...return air sensor is wired to the enthalpy controller HH57AC077 The outdoor enthalpy changeover set point is set at the controller To wire the return air enthalpy sensor perform the follow ing see Fig 31 1 Use a 2 conductor 18 or 20 AWG twisted pair cable to connect the return air enthalpy sensor to the enthalpy controller 2 At the enthalpy control remove the factory installed resistor from the SR...

Page 25: ...IV is equipped with an ambient temperature lockout switch located in the outdoor airstream which is used to lockout the compressors below a 42 F ambient temperature See Fig 33 Table 11 Supply Air Sensor Temperature Resistance Values DAMPER STATIC PRESSURE in wg 0 2 0 4 0 6 0 8 1 0 1 2 LEAKAGE cfm 35 53 65 75 90 102 CFM 4500 5000 5400 6000 7200 7500 9000 10 000 11 250 0 040 0 050 0 060 0 070 0 090 ...

Page 26: ... sensor power supply it cannot have the secondary of the transformer grounded 3 For field installed remote minimum position POT remove black wire jumper between P and P1 and set control minimum position POT to the minimum position Fig 36 EconoMi erIV Wiring 4 3 5 2 8 6 7 1 10 11 9 12 PINK BLACK BLUE NOTE 1 NOTE 2 RUN 500 OHM RESISTOR 50HJ540573 ACTUATOR ASSEMBLY RED WHITE ECONOMISER2 PLUG DIRECT D...

Page 27: ... located on the control See Fig 38 The scale on the potentiometer is A B C and D See Fig 39 for the corresponding temperature changeover values Differential Dry Bulb Control For differential dry bulb control the standard outdoor dry bulb sensor is used in conjunc tion with an additional accessory return air sensor part number CRTEMPSN002A00 The accessory sensor must be mounted in the return airstr...

Page 28: ...ion position for VOC volatile organic compound ventilation requirements The maximum demand ventilation position is used for fully occu pied ventilation When demand ventilation control is not being used the minimum position potentiometer should be used to set the oc cupied ventilation position The maximum demand ventilation position should be turned fully clockwise Adjust the minimum position poten...

Page 29: ...ld maintain the set point CONTROL CURVE A B C D CONTROL POINT APPROX F C AT 50 RH 73 23 70 21 67 19 63 17 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 3 4 3 6 3 8 4 0 4 2 4 4 4 6 9 0 1 0 0 8 0 7 0 6 0 5 0 4 0 3 0 20 10 E N T H A L P Y B T U P E R P O U N D D R Y A I R 85 29 90 32 95 35 100 38 105 41 110 43 35 2 35 2 40 4 40 4 105 41 110 43 45 7 45 7 50 10 50 10 55 13 55 13 60 16 60 16 65 18 65 18 7...

Page 30: ... 1 or 2 for Carrier equipment See Table 13 1 Press Clear and Mode buttons Hold at least 5 seconds until the sensor enters the Edit mode 2 Press Mode twice The STDSET Menu will appear 3 Use the Up Down button to select the preset number See Table 13 4 Press Enter to lock in the selection 5 Press Mode to exit and resume normal operation The custom settings of the CO2 sensor can be changed any time a...

Page 31: ...hrough conduit in unit to the low voltage connection on the 2 pole terminal strip TB3 as shown in Fig 44 and Fig 45 See Fig 46 for operational diagram Fig 45 Typical MoistureMi er Dehumidification Package Control Box Fig 44 Typical MoistureMi er Dehumidification Package Humidistat Wiring Schematic 460 V Unit Shown GRN YEL 24V TRAN1 RED BLK YEL ORN A C GRN YEL 24V TRAN3 RED BLK YEL ORN A C YEL BLK ...

Page 32: ...32 Fig 46 MoistureMi er Dehumidification Operation Diagram TXV Thermostatic Expansion Valve ...

Page 33: ...installed See Tables 14 21 for fan performance data Be sure that fans rotate in the proper direction See Table 22 for air quantity limits See Table 23 for static pressure information for accessories and options See Table 24 for fan rpm at various motor pulley settings See Tables 25 and 26 for evaporator fan motor data To alter fan performance see Evaporator Fan Performance Adjustment section on pa...

Page 34: ... 950 3057 3 59 1013 3364 3 95 1072 3675 4 31 1129 3991 4 68 1183 4311 5 06 7200 986 3401 3 99 1047 3717 4 36 1104 4037 4 74 1159 4361 5 11 1211 4689 5 50 7500 1022 3770 4 42 1081 4095 4 80 1136 4423 5 19 1189 4755 5 58 1241 5091 5 97 AIRFLOW cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 2 1 4 1 6 1 8 2 0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 4500 1044 2345 2 75 110...

Page 35: ... 52 1190 4163 4 88 6900 1000 3298 3 87 1059 3603 4 23 1115 3912 4 59 1168 4225 4 96 1220 4543 5 33 7200 1038 3672 4 31 1095 3986 4 67 1149 4303 5 05 1201 4625 5 42 1251 4950 5 81 7500 1077 4072 4 78 1131 4394 5 15 1184 4720 5 54 1234 5050 5 92 AIRFLOW cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 2 1 4 1 6 1 8 2 0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 4500 1060 241...

Page 36: ...236 5 13 4310 1288 5 50 4622 1313 5 68 4780 1337 5 87 4939 6 500 1219 5 29 4450 1270 5 66 4759 1320 6 03 5073 1344 6 22 5232 1368 6 41 5391 7 000 1258 5 88 4942 1307 6 25 5253 1355 6 62 5569 1378 6 81 5729 1402 7 00 5890 7 500 1299 6 52 5480 1346 6 89 5794 1392 7 27 6113 1415 7 46 6273 1437 7 65 6435 8 000 1341 7 21 6065 1387 7 59 6383 1392 7 97 6704 1453 8 16 6866 1475 8 36 7028 8 500 1385 7 97 6...

Page 37: ...6 74 1224 5915 7 02 1272 6154 7 30 1319 6395 7 59 1364 6639 7 88 9 500 1235 6315 7 49 1282 6552 7 77 1327 6791 8 06 1372 7033 8 34 1415 7276 8 63 10 000 1295 6988 8 29 1340 7225 8 57 1383 7465 8 86 1426 7706 9 14 1468 7949 9 43 AIRFLOW cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 2 1 4 1 6 1 8 2 0 Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp Rpm Watts Bhp 6 000 1141 3829 4 54 1196 408...

Page 38: ...29 5609 6 65 1277 5847 6 94 1323 6088 7 22 1368 6331 7 51 9 000 1244 6011 7 13 1290 6247 7 41 1335 6485 7 69 1380 6726 7 98 1423 6968 8 27 9 500 1308 6687 7 93 1352 6924 8 21 1395 7162 8 50 1437 7402 8 78 1479 7644 9 07 10 000 1372 7401 8 78 1414 7638 9 06 1455 7876 9 34 1496 8117 9 63 1535 8358 9 92 AIRFLOW cfm AVAILABLE EXTERNAL STATIC PRESSURE in wg 1 2 1 4 1 6 1 8 2 0 Rpm Watts Bhp Rpm Watts B...

Page 39: ...97 5 766 1314 7 55 6 243 8 500 1117 5 74 4 750 1169 6 28 5 190 1219 6 83 5645 1268 7 40 6 114 1315 7 98 6 597 1361 8 58 7 094 9 000 1177 6 75 5 583 1226 7 31 6 047 1274 7 89 6524 1320 8 48 7 015 1365 9 09 7 520 1410 9 72 8 037 9 500 1237 7 98 6 511 1284 8 46 6 999 1329 9 07 7499 1374 9 69 8 012 1417 10 33 8 538 1459 10 98 9 076 10 000 1297 9 12 7 450 1342 9 74 8 051 1385 10 37 8574 1428 11 02 9 11...

Page 40: ... 24 1997 UNIT 48TM MINIMUM COOLING CFM MINIMUM HEATING CFM MAXIMUM CFM Low Heat High Heat 016 4500 3800 3800 7 500 020 5400 4750 5450 9 000 025 6000 4750 5450 10 000 028 7000 4750 5450 11 250 COMPONENT CFM 4500 5000 5400 6000 7200 7500 9000 10 000 11 250 EconoMi erIV and EconoMi er2 0 040 0 050 0 060 0 070 0 090 0 100 0 110 0 120 0 140 MoistureMi er Dehumidification 0 045 0 048 0 060 0 071 0 103 0...

Page 41: ...es because of the increase in fresh air the outdoor air damper will be proportionally closed Damper position will follow the high er demand condition from DCV mode or free cooling mode Damper movement from full closed to full open or vice versa will take between 11 2 and 21 2 minutes If free cooling can be used as determined from the appropri ate changeover command switch dry bulb enthalpy curve d...

Page 42: ...in Fig 48 The PremierLink will integrate the compressors stages with the economizer based on similar logic as the three routines list ed in the previous section The SASP will float up and down based on the error reduction calculations that compare space temperature and space set point When outdoor air temperature conditions require the econo mizer to close for a compressor stage up sequence the ec...

Page 43: ...nspect blower wheel every fall and periodically during heating season For the first heating season inspect blower wheel bi monthly to deter mine proper cleaning frequency To inspect blower wheel remove heat exchanger access panel Shine a flashlight into opening to inspect wheel If cleaning is required remove motor and wheel assembly by removing screws holding motor mounting plate to top of combust...

Page 44: ...sen fan pulley setscrews 2 Slide fan pulley along fan shaft 3 Make angular alignment by loosening motor from mounting plate Evaporator Fan Service and Replacement The 48TM units use a fan motor mounting system that features a slide out motor mounting plate See Fig 51 To replace or ser vice the motor slide out the bracket 1 Remove the evaporator fan access panel and the heat ing control access pane...

Page 45: ...suring the proper amount of liquid subcooling Measure liquid line pressure at the liquid line service valve using pressure gage Connect temperature sensing device to the liquid line near the liquid line service valve and insulate it so that outdoor ambient temperature does not affect reading TO USE THE COOLING CHARGING CHART Use the above temperature and pressure readings and find the intersec tio...

Page 46: ... heater to prevent absorption of liquid refrigerant by oil in the crankcase when the compressor is idle The crank case heater is energized whenever there is a main power to the unit and the compressor is not energized Compressor Lockout If any of the safeties high pressure low pressure freeze protection thermostat compressor internal thermostat trip or if there is loss of power to the compressors ...

Page 47: ...access One door is provided for control box access The control box access door is interlocked with the non fused disconnect which must be in the OFF position to open the door Two doors are provided on 48TM016 025 units for access to the compressor compartment Two internal access doors are provided inside the filter drive access door The filter access door on the left is secured by 2 small 1 4 turn...

Page 48: ...48 Fig 57 Typical Wiring Schematic 48TM016 020 208 230 V Shown ...

Page 49: ...49 Fig 58 Typical Component Arrangement ...

Page 50: ...AT Sensor Disch Air Sensor RAT Accessory Sensor Low Ambient Lockout Switch LEGEND AND NOTES FOR FIG 57 AND 58 LEGEND NOTES 1 Compressor and or fan motor s thermally protected Three phase motors protected against primary single phasing conditions 2 If any of the original wire furnished must be replaced it must be replaced with Type 90 C or its equivalent 3 Jumpers are omitted when unit is equipped ...

Page 51: ... should turn on The actuator should drive to between 90 and 95 open 4 Turn the Exhaust potentiometer CW until the Exhaust LED turns off The LED should turn off when the potentiometer is approximately 90 The actuator should remain in position 5 Turn the DCV set point potentiometer CW until the DCV LED turns off The DCV LED should turn off when the potentiometer is approximately 9 v The actuator sho...

Page 52: ...ause and replace Defective thermostat Replace thermostat Faulty condenser fan motor Replace Restriction in refrigerant system Locate restriction and remove Compressor Operates 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 recharge Air in system Recover r...

Page 53: ... increase fan speed Limit switch cycles main burners Check rotation of blower thermostat heat anticipator set tings and temperature rise of unit Adjust as needed Too much outdoor air Adjust minimum position Check economizer operation Poor Flame Characteristics Incomplete combustion lack of combustion air results in Aldehyde odors CO sooting flame or floating flame Check all screws around flue outl...

Page 54: ...er maximum position DCV or fully open supply air signal INPUTS OUTPUTS Demand Control Ventilation DCV Enthalpy Y1 Y2 Compressor N Terminal Outdoor Return Stage 1 Stage 2 Occupied Unoccupied Damper Below set DCV LED Off High Free Cooling LED Off Low On On On On Minimum position Closed On Off On Off Off Off Off Off Low Free Cooling LED On High On On On Off Modulating between min position and full op...

Page 55: ...55 Fig 59 IGC Control Heating and Cooling LEGEND IGC Integrated Gas Unit Controller NOTE Thermostat Fan Switch in the AUTO position ...

Page 56: ...56 Fig 60 EconoMi erIV Functional View ...

Page 57: ...pressure switch 10 46 Hinged access doors 47 Horizontal adapter roof curb 2 Humidistat 31 Indoor air quality sensor 19 Integrated gas controller Error codes 55 Liquid propane 10 12 Low pressure switch 10 46 Main burners 43 46 Manual outdoor air damper 16 MoistureMi er dehumidification package 31 32 45 53 MotorMaster I control 17 Motormaster V control 18 Mounting Compressor 33 Unit 2 Natural gas 10...

Page 58: ...ed in this manual including Unit Familiarization Maintenance Installation Overview Operating Sequence A large selection of product theory and skills programs are available using popular video based formats and materials All include video and or slides plus companion book Classroom Service Training which includes hands on experience with the products in our labs can mean increased confidence that r...

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Page 60: ... PLACE VERIFY THAT UNIT IS LEVEL CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND VERIFY SETSCREW IS TIGHT VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED VERIFY THAT SCROLL COMPRESSOR IS ROTATING IN THE CORRECT DIRECTION VERIFY THAT CRANKCASE HEATER HAS BEEN ENERGIZED FOR 24 HOURS START UP ELECTRICAL SUPPLY FAN AMPS EXHAUST FAN AMPS TEMPERATURES OUTDOOR AIR T...

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