Carrier 48Tj016 028 Users Manual

CARRIER Package Units(both units combined) Manual L0606341 CARRIER Package Units(both units combined) Owner's Manual, CARRIER Package Units(both units combined) installation guides

2015-01-24

: Carrier Carrier-48Tj016-028-Users-Manual-310808 carrier-48tj016-028-users-manual-310808 carrier pdf

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48TJ016-028
Single-Package Rooftop Units
Electric Cooling/Gas Heating

Installation, Start-Up and
Service Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS ......................
l
INSTALLATION ................................
2-31
Step 1 -- Provide Unit Support ...................
2
• ROOF CURB
• ALTERNATE UNIT SUPPORT
Step 2 -- Rig and Place Unit .....................
2
• POSITIONING
• ROOF MOUNT
Step 3 -- Field Fabricate Ductwork ...............
9
Step 4 -- Make Unit Duct Connections ...........
9
Step 5 -- Install Flue Hood and Wind Baffle ...... 9
Step 6 -- Trap Condensate Drain .................
9
Step 7 -- Orifice Change ........................
10
Step 8 -- Install Gas Piping .....................
11
Step 9 -- Make Electrical Connections ..........
11
• FIELD POWER SUPPLY
• FIELD CONTROL WIRING
• OPTIONAL NON-FUSED DISCONNECT
• OPTIONAL CONVENIENCE OUTLET
Step 10 -- Make Outdoor-Air Inlet Adjustments.. 14
Step 11 -- Install Outdoor-Air Hood .............
14
Step 12- Install All Accessories
...............
15
• MOTORMASTER® I CONTROL INSTALLATION
• MOTORMASTER V CONTROL INSTALLATION
Step 13- Adjust Factory-Installed Options ..... 17
• PREMIERLINK TM CONTROL
• ENTHALPY SWITCH/RECEIVER
• OUTDOOR ENTHALPY CONTROL
• DIFFERENTIALENTHALPY
CONTROL
• ENTHALPY SENSORS AND CONTROL
• OPTIONAL ECONOMI$ERIV AND
ECONOMI$ER2
• ECONOMI$ERIV STANDARD SENSORS
• ECONOMI$ERIV CONTROL MODES
Step 14 -- Install Humidistat for
Optional MoistureMi$er TM Package ............
29
START-UP ....................................
31-38
SERVICE .....................................
39-47
TROUBLESHOOTING .........................
48-52
INDEX ...........................................
53
START-UP CHECKLIST ........................
CL-I
SAFETY

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 extinguishers available for all brazing operations.

Before perforlning service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury.

1. Improper inst_dlation, adjustment, alteration, service,
or maintenance can cause property &image, personal
injury, or loss of life. Refer to the User's Information
Manual provided with this unit for more details.
2. Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance.
What to do if you smell gas:
I. DO NOT Uy to light any appliance.
2. DO NOT touch any electrical switch, or use any
phone in your building.
3. IMMEDIATELY call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
4.

czfll the fire

Disconnect gas piping hom unit when pressure testing at
pressure greater than 0.5 psig. Pressures greater than
0.5 psig will cause gas valve damage resulting in haz_udous
condition. If gas valve is subjected to pressure greater than
0.5 psig, it must be replaced before use. When pressure
testing field-supplied gas piping at pressures of 0.5 psig or
less, a unit connected to such piping must be isolated by
closing the manual gas valve(s).

CONSIDERATIONS
its. If limits are exceeded, the units will automatically
lock the compressor out of operation. Manu_d reset will
IMPORTANT: Units have high ambient operating limbe required to restgu-tthe compressor.

Installation and selwicing of air-conditioning equipment can
be hazardous due to system pressure and electric_d components. Only trained and qualified service personnel should install, repaiL or service ai>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 ai>conditioning equipment, observe
Manufacturer

If you cannot reach your gas supplier,
department.

reserves the right to discontinue, or change at any time, specifications
Catalog No. 04-53480009-01

Printed in U,S.A,

or designs

Form 48TJ-22SI

without notice and without incurring obligations.
Pg 1

3-06

Replaces:

48TJ-21SI

I
]

INSTALLATION

Step 2 --

Inspect unit for transportation dmnage. If &_mage is found,
file claim with transportation agency.

Step 1 --

Provide

Unit Support

ROOF CURB -- Assemble and install accessory roof curb or
horizont_d a&tpter roof curb in accordance with instructions
shipped with this accessory. See Fig. 1 and 2. Install insulation,
cant strips, roofing, and counter flashing as shown. Ductwork
can be installed to roof curb or horizontal adapter roof curb before unit is set in place. Curb or a&tpter roof curb should be
level. This is necessary to permit unit drain to function properly. Unit leveling tolerance is + l/l(_ in. per linear fl in any direction. Refer to Accessory Roof Curb or Horizontal A&_pter
Roof Curb Installation Instructions for additional information
as required. When accessory roof curb or horizontal adapter
roof curb is used, unit may be installed on class A, B, or C roof
covering material.
IMPORTANT: The gasketing of the unit to the roof curb
or adapter roof curb is critical for a watertight se_d.
Inst_fll gasket with the roof curb or adapter as shown in
Fig. 2. Improperly applied gasket can _dso result in air
leaks and poor unit performance.
ALTERNATE UNIT SUPPORT -- When the curb or adapter
cannot be used, install unit on a noncombustible
surface. Support unit with sleepers, using unit curb support area. If sleepers
cannot be used, support long sides of unit with a minimum of 3
equally spaced 4-in. x 4-in. pads on each side.

Rig and Place Unit --

Do not diop unit;

keep upright. Use spreader bras over unit to prevent sling or
cable &image. Rollers may be used to move unit across a roof.
Level by using unit frame as a refelence; leveling tolerance is
_+1/1_in. per linear fl in any direction. See Fig. 3 for additiomfl
information. Unit operating weight is shown in Table 1.
Four lifting holes are provided in ends of unit base rails as
shown in Fig. 3. Refer to rigging instructions on unit.
POSITIONINGMaintain
clearance, per Fig. 4 and 5,
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 contmninated
all: For proper unit operation, adequate combustion and ventilation air must be provided in accordance with Section 5.3 (Air
for Combustion and Ventilation) of the National Fuel Gas
Code, ANSI Z223.1 (American National Stan&_rds Institute).
Although unit is weatherproof,
higher level runoff and overhangs.

guard against

water from

Ix)cate mechanical diaft system flue assembly at least 4 ft
from any opening through which combustion products could
enter the building, and at least 4 ft from any adjacent building.
When unit is located adjacent to public walkways, flue assembly must be at least 7 ft above grade.
ROOF MOUNT-bution requirements.
Table 1.

Check building codes for weight distriUnit operating weight is shown in
hlstructions

continued

on page 9.

25% VENT AIR//

ECONOMIZER
HOOD

BLOCK-OFFJ___
PAN

i
I

A,R

OUT

HORIZONTALSUPPLY/
CURB

TRANSITION

DUCT

(CRRFCURB013A00)

FULLY INSULATED
SUPPLY PLENUM

14-3/4_

1 1/2 # DENSITY,
STICK PINNED & GLUED

NOTE: CRRFCURB013A00
is a fully factory preassembled horizontal adapter and includes an insulated transition duct. The pressure drop through the adapter curb is negligible.
For horizontal return applications: The power exhaust and barometric relief dampers must be installed in the return air duct.

12" WIDE STANDING-SEAM PANELS
ACCESSORY
PACKAGE NO.
CRRFCURB013A00

Fig. 1 -- Horizontal Supply/Return

CURB
HEIGHT
1'-11"
(584

Adapter Installation

DESCRIPTION
Pre-Assembled, Roof Curb,
Horizontal Adapter

PKG. NO. REF.

DESCRIPTION

HEIGHT

CRRFCURBOIOAO0

1"- 2" (305)

Standard Curb 14" High

CRRFCURBO11AO0

2'- CURB
0" (610)

Standard Curb for Units Requiring

CRRFCURBO12AO0

2'- 0" (610)

Side Supply and Return Curb for High Installation

High Installation

S'-I0

I/2"

PLAN

VIEW

NO-E5_
1, ROOF
CURB ACCESSORY
IS SHIPPED
DISASSEMBLED.
2. IN5ULATED
PANEL5_
1_ THICK
NEOPRENE
COATED
I-I/2 LS DENSITY
3. DIMEN51ON5
iN ( ) ARE
IN MILLIMETER5,
4. I:zZ_>DIRECTiON
OF AIR FLOW
5, ROOFCURB=
IS GA_
(VAO3-SS)
5TL,
6. A 90 DEGREE
ELBOW
MUST
BE
INBTALLEO
ON THE SUPPLY
DUCT
WORK
BELOW
THE UNIT
DIgCHARGE
FOR UNITS
EQUIPPED
WITH
ELECTRIC
HEATERS.

--OUTLINEGPUN,T

ROOF

CURB

NOTE_

iBOHPRi
5UPPL
IBECT.
G'
(REF

SUPPLY

OPENING
CURB

2 3/1S _
(1SSS)
OPENING)

TO
PREVENT
BUILD-UP

SECTION,

UNIT

5'-9"
(1753)

THE
THE

HAZARD
DRAIN
CAN

OF
PAN

ONL

STAGNANT
OF
THE

i
AND
= CSMPRES50R

SHOWN.

1
A_

)R
KEEP
POWER
_-o-s
(132)

THIS

AREA

(GAS

ENTRY

CLEAR
FOR

CONDENSER

FOR
GAS

(310)

DUCT

ENSi

AND
FIR

D ROOFTOPS)

END
COMPRESSOR

B_L

3/s"

DIMEN51ON5

ATTACH

ROOF

(degPees

ond

ir/chetO

CURB

(578)

UNIT LEVELING
_Fro_ edge OF uniL

////_

TOLERANCES
to horizonLaL,

_NAIL

GASKET

HEIGHT
FROM TABLE

(Sl)

_
COUNTER
(FIELD

NOM, 514"
X
(S2)
X (102)
TYP.
4 PLCS
O'

WATER
INDOOR

PITCHED

ROOFING
FELT
(FIELD
SUPPLIED)

DUCT

1
(44)

(FIELD

j
FLASHING
SUPPLIED)

SUPPLIED)

CANT
(FIELD

5TRP
SUPPLIED)

(75)

UNIT

(FIELD SUPPLIED)
ROOFING MATERIAL

OPENINGS

O'-S
(421)
RETURN _
5'-7
1116"
(1703A

SUPPLY
_*_q(14s7I"-6 _ ,
_0"_2
I/2
(CRRFCURBOI2AO0
ONLY)
(64)

(CRRFCURSOI2AO0

AIR

RETUR i_ AIR

ONLY)
SECTION

Fig. 2 -- Roof Curb Details

A-A

OPTIONAL
=SIDE
SUPPLY

(FIELD

SUPPLIED)

I0'-0"
(3048)

,SPREADERBARS

"DETAIL

3'-7 112"

(t t 05)
_

_RIGGINGHOOK
UNIT BASE RAIL

SEE
"DETAIL

NOTES:
1. Dimensions in ( ) are in millimeters.
2. Refer to Fig. 4 and 5 for unit operating weights.
3. Remove boards at ends of unit and runners prior to rigging,
4. Rig by inserting hooks into unit base rails as shown. Use corner post from packaging
damage, Use bumper boards for spreader bars on all units.
5. Weights do not include optional economizer, Add 90 Ib (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.

UNIT
48TJ

DIMENSIONS

MAXIMUM
SHIPPING
WEIGHT

R-in.

Ft-in.

016

1775

805

6-111_

2121

3-5

1041

020

1875

850

6-111_

2121

3-3

024

1985

900

6-111_

2121

3-2

985

028

2135

988

6-111_

2121

3-2

985

Fig. 3 -- Rigging Details

991

to protect coil from

UNIT

STD UNIT
WEIGHT
Ib

ECONOMIZER
WEIGHT
Ib

CORNER
A
Ib

CORNER
B

CORNER
C
Ib

48TJD,
TJF016

1650

748

423

192

386

175

403

183

48TJD,
TJF020

1800

816

432

196

410

186

461

209

CORNER
D

DIM A

DIM B

DIM C

ft-in,

if-in,

ft-in,

438

199

3-5

1041

3-5

1041

1-10

559

472

214

3-3

991

3-7

1092

1-8

508

NOTES:
1. Refer to print for roof curb accessory dimensions.
2. Dimensions in ( ) are in millimeters.
3. _
4. E_

Center of Gravity.
Direction of airflow.

5. Ductwork to be attached to accessory roof curb only.
6. Minimum clearance:
• Rear: T-O" (2134) for coil removal. This dimension can be reduced to
4'-0" (1219) if conditions permit coil removal from the top.
• 4'-0" (1219) to combustible surfaces, all four sides (includes between
units).
• Left side: 4'-0" (1219) for proper condenser coil airflow.
• Front: 4'-0" (1219) for control box access.
• Right side: 4'-0" (1219) for proper operation of damper and power
exhaust if so equipped.
• Top: 6'-0" (1829) to assure proper condenser fan operation.
• Bottom: 14" (356) to combustible surfaces (when not using curb).
• Control box side: 3'-0" (914) to ungrounded surfaces, non-combustible.
• Control box side: 3"-6" (1067) to block or concrete walls, or other
grounded surfaces.
• Local codes or jurisdiction may prevail.
7. With the exception of clearance for the condenser coil and the damper/
power exhaust as stated in Note #6, a removable fence or barricade
requires no clearance.
8. Dimensions are from outside of corner post. Allow 0'-s/l_" (8) on each side
for top cover drip edge.

_0"11
CORNER CS

3" S
iT6)

0
B

3 //8"_
t791

3/8"

OIA

CONCENTRIC

K.O.

(35)
TOP

LEFT

_5/I_CORNER

(3031

r[LTERS
ACCESSFAR S]OE

SIDE

3 9
(lt43}

VIEW

Z-Z

BAROMETRIC RELIEF/POWER
(ACCESSORY ONLY)

iS1)
FRONT

SECTION

Fig. 4-

Base Unit Dimensions; 48TJ016,020

A+A

EXHAUST

UNIT

BTD UNIT
WEIGHT
Ib

ECONOMIZER
WEIGHT
Ib

CORNER
A
Ib

CORNER
B
Ib

CORNER
C
Ib

48TJD,
TJF024

1850

839

443

201

406

184

476

216

48TJ D,
TJF028

2000

907

471

214

428

194

526

239

CORNER
D

DIM A

DIM B

DIM C

ft-in,

mm ft-in,

ft-in,

525

238

3-2

965

3-5

1041

1-8

508

574

260

3-2

965

3-8

1041

1-8

508

NOTES:
1. Refer to print for roof curb accessory dimensions.
2. Dimensions in ( ) are in millimeters•
3. _

TYPICAL

4 CORNERS

Center of Gravity.

4. E_
Direction of airflow•
5. Ductwork to be attached to accessory roof curb only.
6. Minimum clearance:
• Rear: 7'-0" (2134) for coil removal• This dimension can be reduced to
4'-0" (1219) if conditions permit coil removal from the top.
• 4'-0" (1219) to combustible surfaces, all four sides (includes between
units).
• Left side: 4'-0" (1219) for proper condenser coil airflow.
• Front: 4'-0" (1219) for control box access•
• Right side: 4'-0" (1219) for proper operation of damper and power
exhaust if so equipped.
• Top: 6"-0" (1829) to assure proper condenser fan operation•
• Bottom: 14" (356) to combustible surfaces (when not using curb).
• Control box side: 3'-0 _"(914) to ungrounded surfaces, non-combustible.
• Control box side: 3'-6" (1067) to block or concrete walls, or other
grounded surfaces•
• Local codes or jurisdiction may prevail•
7. With the exception of clearance for the condenser coil and the damper/
power exhaust as stated in Note #6, a removable fence or barricade
requires no clearance•
8. Dimensions are from outside of corner post. Allow O'-S/16" (8) on each
side for top cover drip edge.

1
OIA

I-_o, 11 lJ,,o
13031

L£rT
3'11
t12002

HOLE

COHRER
6

(20Z)_

trg2

SIDE

1/4'

( 51 I

SECTION

Fig. 5 -- Base Unit Dimensions; 48TJ024,028

A-A

Table 1 -- Physical Data
016D/F

UNIT 48TJ

208/230, 460 v I
15
1650
90
200

NOMINAL CAPACITY (tons)
OPERATING WEIGHT (Ib)
Economizer
Roof Curb
COMPRESSOR
Quantity,.,Model
(Ckt 1, Ckt 2)
Number of Refrigerant
Circuits
Oil (oz) (Ckt 1, Ckt 2)
Stages of Capacity Control (%)
REFRIGERANT TYPE
Expansion Device
Operating Charge (Ib-oz)

10-5

COIL

20
1850
90
200

25
2000
90
200

1...SM120,
1 ._SM110
2
110,110
52/48

1...SM161,
1 _.SM120
2
112, 110
56/44

11-5

2...17
21.7

16-3 I

21-0

14-8

3_.15
I
3...15
21.7
21.7
Propeller Type
10,400
9300
13,700
3...22
3..,22
2...30
V2...1050
V2._1050
1 ..,1075
1100
1100
3400
Cross-Hatched 3/8-in. Copper Tubes, Aluminum
Copper Plate Fins, Face Split

Rows...Fins/in.
Total Face Area (sq ft)
EVAPORATOR FAN
Quantity...Size (in.)
Type Drive
Nominal Cfm
Motor Hp
Motor Nominal Rpm

Low-Medium
High Static

Motor Bearing Type
Maximum Allowable Rpm
Motor Pulley Pitch Diameter
Min/Max (in.)
Nominal Motor Shaft Diameter (in.)
Fan Pulley Pitch Diameter (in,)
Nominal Fan Shaft Diameter
Belt, Quantity...Type...Length

17.5
2...17

Maximum Continuous Bhp
Motor Frame Size
Nominal Rpm High/Low
Fan r/s Range

(in,)
(in.)

Pulley Center Line Distance (in.)
Speed Change per Full Turn of
Movable Pulley Flange (rpm)
Movable Pulley Maximum Full Turns
From Closed Position
Factory Speed
Factory Speed Setting (rpm)
at Pulled/lin.t

Static

Low-Medium
High Static

Static

Low-Medium
High Static

Static

Low-Medium
High Static

Static

Low-Medium
High Static

Static

Low-Medium
High Static

Static

2,..10 x 10
Belt
6000
3.7
1725

2,.,10 x 10
Belt
6000
3,0
1725

4.25

3,45

56H

891-1179
1227-1550
Ball
1550
3.1/4.1
3.7/4.7
7/8
6.0
5.2
13/16
1 ,..BX_,42
1 ,..BX_,42
13.5-15.5
48
55

1159-1429

5
3.5
1035
1389
13/16

LEGEND
---

18
1800
90
200

15-4

Cross-Hatched 3/8-in. Copper Tubes, Aluminum Lanced,
Aluminum Pre-Coated, or Copper Plate Fins

Rows...Fins/in.
Total
Face Area (sq ft)
CONDENSER FAN
Nominal Cfm
Quantity,..Diameter
(in.)
Motor Hp...Rpm
Watts Input (Total)
EVAPORATOR COIL

Bhp
TXV

028D/F

10-13 I 15-2I

Fan Shaft Diameter

024D/F

Scroll
1 ...SM120,
1_.SR*782AE
2
110, 72
60/40
R-22
TXV

2_.SR*942AE
2
90, 90
50/50

c,rcu,t,*
Circuit

CONDENSER

020D/F
575 v

Brake Horsepower
Thermostatic Expansion Valve

*Circuit 1 uses the lower portion of condenser coil and lower portion of evaporator coils; and Circuit 2 uses the upper portion of both coils.
tRollout switch is manual reset.

Ball
1550
4.3/5,3
7&
6,4
13/16
1,..BX..,45
13.5-15.5
44

5
3.5
1296
-13/16

17.5
17.5
3...15
I
3_.15
Centrifugal Type
2...12 x 12
2...12 x 12
Belt
Belt
7200
8000
5
7.5
1745
1745
8.7 [208/230,575
5.90
9.5 [460 v]
184T
213T
910-1095
1069-1287
Ball
1550
4.9/5.9
4.9/5.9
1V8
9,4
8,0
17/16

1.-BX,..50
1.-BX-.48
13.3-14.8
37
34
5
3.5
1002
1178
17/16

4...15
21.7
12,500
2...30
1 .,.1075
3400

Lanced or

17.5
4_.15
2._12x12
Belt
10,000
10
1740
10.2 [208/230, 575 v]
11,8 [460 v]
215T

1002-1225
1193-1458
Ball
1550
5,4/6,6
5,4/6,6
13/8
9.4
7.9
17/16
1-.BX-.54
1 ...BX-.50
14.6-15,4
37
44

1066-1283
1332-1550
Ball
1550
4,9/5.9
4,9/5.9
lS/s
8.0
6,4
17/16
2..,BX,..50
2..,BX,..47
14.6-15,4
36
45

5
3.5
1120
1328

5
3.5
1182
1470

17/16

**The 48TJ028 units requires 2-in. industrial-grade filters capable of handling
face velocities of up to 625 ft/min (such as American Air Filter no. 5700 or
equivalent).
NOTE: The 48TJ016-028
on the suction side.

units have a low-pressure

switch (standard)

located

Table 1 -- Physical Data (cont)
UNIT 48TJ
FURNACE SECTION
Rollout Switch Cutout Temp (F)t
Burner Orifice Diameter (in....drill size)
Natural Gas
Thermostat Heat Anticipator Setting (amps)
208/230, 575
Stage 1
Stage 2
460 v
Stage 1
Stage 2
Gas Input
Stage 1
Stage 2
Efficiency (Steady State) (%)
Temperature Rise Range
Manifold Pressure (in. wg)
Natural Gas
Gas Valve Quantity
Field Gas Connection Size (in.-FPT)
HIGH-PRESSURE
SWITCH (psig)
Cutout
Reset (Auto)
LOW-PRESSURE SWITCH (psig)
Cutout
Reset (Auto)
FREEZE PROTECTION THERMOSTAT
Opens
Closes
OUTDOOR-AIR
INLET SCREENS
Quantity...Size (in.)

016D/F

O20D/F

024D/F

028D/F

190

0.1285-.30/0.136-.29

0.1285.-30/0.136-.29

0.98
0.44
0.80
0.44
172,000/225,000
230,000/300,000
81
15-45/20-50

3/4

---

206,000/270,000
275,000/360,000
81
15-45/20-50

3.3
1
3/4

0.1285_.30/0.136...29

0.98
0.44
0.80
0.44
206,000/270,000
275,000/360,000
81
15-45/20-50
3.3
1
3/4

426
32O
27
44
(F)
3O-+5
45-+5
Cleanable
2...20 x 25 x 1
1...20 x 20 x 1
Throwaway**
4_.20 x 20 x 2
4...16 x 20 x 2
V2 Hp, 208/230-460

LEGEND
Bhp
TXV

0.98
0.44
0.80
0.44
206,000/270,000
275,000/360,000
81
15-45/20-50

3.3
1
3/4

3.3
1

RETURN-AIR FILTERS
Quantity.,.Size
(in.)
POWER EXHAUST

0.1285.-30/0.136-.29

0.98
0.44
0.80
0.44

Brake Horsepower
Thermostatic Expansion Valve

*Circuit 1 uses the lower portion of condenser coil and lower portion of evaporator coils; and Circuit 2 uses the upper portion of both coils.
tRollout switch is manual reset.

v Motor Direct Drive, Propeller-Fan

(Factory-Wired

for 460 v)

**The 48TJ028 units requires 2-in. industrial-grade
filters capable of handling
face velocities of up to 625 ft/min (such as American Air Filter no. 5700 or
equivalent).
NOTE: The 48TJ016-028
on the suction side.

units have a low-pressure

switch (standard)

located

Step 3 --

Field Fabricate Ductwork -- Secure all
ducts to building structure. Use flexible duct connectors between unit and ducts as required. 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
sulated and covered with a vapor barrie];

Step 4 --

space must be in-

and

roof

CUlb

Install Flue Hood and Wind

Unit

basepans.

HEAT

Baffle --

Flue hood and wind baffle are shipped secured under main
control box. To install, secure flue hood to access panel. See
Fig. 9. 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. 10.

Step 6 -- Trap Condensate

Make Unit Duct Connections

is shipped for thru-the-bottonl duct connections. Ductwork
openings are shown in Fig. 1, 4, and 5. Duct connections are
shown in Fig. 6. Field-fabricated
concentric ductwork may be
connected as shown in Fig. 7 and 8. Attach all ductwork to roof
curb

Step 5 --

Drain -- See Fig,

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 3/4-in. diameter pipe nipple, coupled to standard 3/4-in. diameter elbows, provide a
straight path down through hole in unit base rails (see Fig. 12).
A trap at least 4-in. deep must be used.

I'-O1

24"MIN.
SEE NOTE

BAFFLE
[_AIR
OUT

NOTE: Do not drill in this area; damage to basepan may result in
water leak.
Fig. 6 -- Air

Distribution

NOTE: Dimensions A, A', and B' are obtained from field-supplied
ceiling diffuser.
Shaded area indicates block-off panels.
Fig. 8-

Concentric

Duct Details

-- Thru-the-Bottom

,.ii

\
J

\
N

WIND
BAFFLE

\
\
\

FLUE
SEE NOTE

HOOD

NOTE

COMBUSTION
FAN HOUSING
(INSIDE)

AIR OUT

AIR IN

AIR OUT

NOTE: Do not drill in this area; damage to basepan may result in
water leak.
Fig. 7 -- Concentric

[l
[l
[
[
[
[
[
[
[

Duct

WIND BAFFLE
MOUNTING HOLES

Air Distribution

Fig. 9 -- Flue Hood Location

INDUCED
MOTOR

Step 7 -- Orifice Change -- This unit is factory assembled for heating operation using natund gas at an elevation

DRAFT

from sea level to 2000 ft. This unit uses orifice type
LH32RFnnn, where "nnn" indicates the orifice size based on
drill size diameter in thousands of an inch.
HIGH ELEVATION (Above 2000 ft) -- Use accessory high
altitude kit when inst_dling this unit at an elewttion of 2000 to
7000 ft. For elevations above 7000 ft, refer to Table 2 to identify the correct orifice size for the elevation. See Table 3 for the
number of orifices requiled for each unit size. Purchase these
orifices from your local Carrier dealel: Follow instructions in
accessory Installation Instructions to install the correct orifices.
Table

2 -- Altitude

ELEVATION (ft)

COMBUSTION
FAN HOUSING

Fig. 10-

MAIN BURNER
SECTION

Combustion

0-1,999
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,000

HEAT EXCHANGER
SECTION

Fan Housing Location

Compensation*
NATURAL

GAS ORIFICE]-

Low Heat
30
30
31
31
31
31
32
32
33
35

High Heat
29
29
30
30
30
30
31
31
31
32

*As the height above sea level increases, there is less oxygen per
cubic foot of air. Therefore, heat input rate should be reduced at
higher altitudes. Includes a 4% input reduction per each 1000 ft.
1-Orifices available through your Carrier dealer.

Table 3 -- Orifice Quantity
UNIT

3/4" FPT DRAIN
CONNECTION

ORIFICE QUANTITY

48TJD016

48TJD020,
48TJD024,
48TJD028,
48TJF016

48TJF020,
48TJF024,
48TJF028

CONVERSION
TO LP (Liquid Propane) GAS -- Use accessory LP gas conversion kit when converting this 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 elewttion. See Table 3 for the number of orifices
required for each unit size. Purchase these orifices from your
loc_fl Carrier dealel: Follow instructions in accessory Installation Instructions to inst_dl the correct orifices.

1-3/8"
DRAIN HOLE

Fig. 11 -- Condensate Drain Details
(48TJ016 Shown)

Table 4 -- LP Gas Conversion*
ELEVATION (ft)
0-1,999
2,000
3,000
4,000
5,000
6,000
7,000
8,000
0,000
10,000

3/4 -IN. FPT
DRAIN CONNECTION

____.

(FIELD-SUPPLIED)NIPPLE

(HALF CO_--

BASE RAIL _@_

8 1/2-1N. (FIELD ....
SUPPLIED) NIPPLE

Fig. 12-

Condensate

LP GAS ORIFICE]"
36
37
38
38
39
40
41
41
42
43

Drain Piping Details

Tlansformer no. 1 is wired for 230-v unit. If 208/230-v unit
is to be run with 208-v power supply, the transformer must be
rewired as follows:

Step 8 --

Install Gas Piping -- Unit is equipped for
use with natured gas. Installation must conform with loc_d
building codes or. in the absence of loc_d codes, with the
National Fuel Gas Code, ANSI Z223.1.

1. Remove

Install field-supplied manu_d gas shutoff valve with a lh-in.
NPT pressme tap for test gage connection at unit. Field gas piping must include sediment trap and union. See Fig. 13.

Do not pressure test gas supply while connected to unit.
Always disconnect union before servicing. Exceeding
maximum manifold pressure may cause explosion and
injury.

FIELD CONTROL WIRING -- Install a Carrier-approved
accessory thermostat assembly according to installation instructions included with accessory. Ix)cate thermostat assembly
on a solid interior wall in the conditioned space to sense average temperature.

FT'I
GAS

Route thermostat
cable or equivalent
single leads of
colored wire from subbase termimds through conduit in unit to
low-voltage connections as shown on unit label wiring diagram
and in Fig. 15.

PRESSURE TAP
(1/8" NPT PLUG)

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 directly connected at
the thermostat and will require a junction box and splice at the
thermostat.

Recap both wires.

Unit failure as a result of operation on improper line voltage
or excessive phase imbalance constitutes abuse and may cause
&Lmage to electrical components.

MANUAL SHUTOFF

UNIT

Operating voltage to compressor
must be within voltage
range indicated on unit nameplate. On 3-phase units, voltages
between phases must be balanced within 2%.

Size gas-supply piping for 0.5-in. wg maximum pressure
drop. Do not use supply pipe sm_dler than unit gas connection.

Remove cap from orange (230 v) spliced wire.
Replace orange wire with led wire.

Be certain unused wires ale capped. Failure to do so may
&_mage the transformers.

tion must not be less than 5.5 in. wg or greater than
IMPORTANT:
Natural gas pressure at unit gas connec13.5 in. wg.

(FIELD SUPPLIED)
_ _

cap fiom red (208 v) wire.

2.
3.

•---- SEDIMENTTRAP

Set heat anticipator settings as follows:

Fig. 13 -- Field Gas Piping
Step 9 --

Make Electrical

Connections

wiring

must

comply

with

NEC

and

0.98
0.80

0.44
0.44

Settings may be changed slightly to provide a greater degree
of comfort for a particuku installation.

FIELD POWER SUPPLYUnit is factory wiled for voltage shown on nameplate.
When inst_dling units, provide a disconnect per NEC (National Electrical Code) of adequate size (Table 5).
All field
requirements.

VO LTAG E
208/230,575
460

----1

TBI
II

local

FIELD

i_II

III

=U.l
z

II_

POWER

[

Route power ground lines through control box end panel or
unit basepan (see Fig. 4 and 5) to connections as shown on unit
wiring diagram and Fig. 14.

i _

.......

I _

SUP_PLY

I-IN

The correct power phasing is critical in the operation of the
scroll compressol,s. An incorrect phasing will cause the
compressor to rotate in the wrong direction. This may lead
to premature compressor failure.

EQUIP

I
..............

EQUIP
GND
NEC
TB

The unit must be electrically grounded in accor&mce with
local codes and NEC ANSI/NFPA 70 (National Fire Protection Association)
to protect against fire and electric
shock.

GND

]

-----

LEGEND
Equipment
Ground
National Electrical Code
Terminal Block

NOTE: The maximum wire size for TB1 is 2/0.
Fig. 14-

Field wiring must confirm to temperature limitations for
type "T" wire. All field wiring must comply with NEC and local requirements.
11

Field

Power

Wiring

Connections

OPTIONAL NON-FUSED
DISCONNECT
-- On units with
the optiomfl non-fused disconnect, incoming power will be
wired into the disconnect switch. Refer to Fig. 16 for wiring
for 100 and 200 amp disconnect
switches. Units with an
MOCP under 100 will use the 100 amp disconnect switch.
Units with an MOCP over 100 will use the 200 amp disconnect switch. Refer to the applicable disconnect wMng diagram.

THERMOSTAT

Lu
cc

To prevent breakage during shipping, the disconnect handle
and shaft are shipped and packaged inside the unit control box.
Install the disconnect handle before unit operation. To install
the handle and shaft, perform the following procedure:
1. Open the control box door and remove the handle and
shaft from shipping location.
2. Ix_osen the Allen bolt located on the disconnect switch.
The bolt is located on the square hole and is used to hold
the shaft in place. The shaft cannot be inserted until the
Allen bolt is moved.
3.

Tighten the Allen bolt to lock the shaft into position.
Close the control box dool:

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.

Turn the handle to the OFF position and close the dool:
The handle should fit over the end of the shaft when the
door is closed.

The handle must be in the OFF position to open the control box dool:

z
a_

cc
o

o
_

_,
m

cc
m
Z

Fig. 15 -- Field Control Thermostat Wiring

UNIT
lO0

BLK,

WIRING
YEL.

6T3

4T2

2T1

LOAD

3L2

1L1 LINE

BLU.
I

AMP

[ NON_:EPDOWDEIRsCONNE_T

_--

Insert the disconnect shaft into the squae hole on the disconnect switch. The end of the shaft is specially cut and
the shaft can only be inserted in the correct orientation.

4.
5.

q
m

ASSEMBLY

OA:

;_ ;__T2E
j
FIELD

POWER SUPPLY

UNIT
200

BLK.

AMP

5L3

WIRING
YEL.

BLU,

4--+--t--- '

[ NON FUSED DISCONNECT

__i

FIELD

_i_
POWER

Lli E j
SUPPLY

NOTE: The disconnect takes the place of TB-1 as shown on the unit wiring
diagram label and the component arrangement label.

Fig. 16-

OPTIONAL
CONVENIENCE
OUTLET-On units with
optiomfl convenience
outlet, a 115-v GFI (ground fault interrupt) convenience outlet receptacle is provided for field wiring.
Field wiring should be run through the 7Is-in. knockout provided in the basepan near the return air opening.

Optional

Non-Fused

Disconnect

Wiring

Table 5 -- Electrical Data
NOMINAL
VOLTAGE

UNIT
48TJ

(3Ph,

60Hz)

208/230

016
(15 Tons)

RLA

LRA

RLA

LRA

FLA(ea)

190

0.5

1.7

3.7

460

414

508

13.5

0.5

0.8

3.7

4.8

575

518

632

10.2

0.5

0.8

3.0

3.9

187

253

237

184

0.5

1.7

5.0

15.8/15.8

460

414

508

16.2

130

10.2

0.5

0.8

5.0

7.9

575

518

632

12.7

0.5

0.8

5.0

6.0

187

253

460

414

508

575

518

46O

10.5/11.0

237

29.5

237

6.6

7.5

16.2

130

14.1

130

3.3

7.5

13.0

632

12.7

11.3

3.4

7.5

10.0

187

253

47.5

265

237

6.6

10.0

414

508

22.9

145

16.2

130

3.3

10.0

518

632

17.9

102

12.7

3.4

25.0/25.0

28.0/28.0

COMBUSTION
FAN MOTOR

10.0

13.0

POWER
SUPPLY

LRA

FLA

MCA

MOCP*

4.6

18.8

0.57
0.57

74/74
79/79

90/90
100/100

2.3

6.0

0.30
0.30

38
40

50
50

2.1

4.8

0.57
0.57

30
32

35
40

4.6

18.8

0.87
0.57

88/88
90/90

110/110
110/110

2.3

6.0

0,30
0.30

41
43

80
50

2.1

4.8

0,87
0.57

33
35

45
45

4.6

18.8

0.57
0.57

109/109
114/114

125/125
125/125

2.3

6.0

0.30
0.30

54
56

70
70

2.1

4.8

0.57
0.57

44
46

80
50

0.87
0.57

134/134
138/138

178/175
175/175

4.6

18.8

0,30

2.3

6.0

0.30
0.57

68
55

90
70

2.1

4.8

0.57

14.6

Example: Supply voltage is 460-3-60.

Full Load Amps
Heating, Air Conditioning and Refrigeration
Indoor (Evaporator) Fan Motor
Locked Rotor Amps
Minimum Circuit Amps
Maximum Overcurrent Protection
National Electrical Code
Outdoor (Condenser) Fan Motor
Rated Load Amps

AB = 452 v
BC = 464 v
482 + 464 + 488
3

Average Voltage
AC = 455 v

1371
=--

*Fuse or HACR circuit breaker.
Determine
(AB) 487
(BC) 464
(AC) 487
Maximum

cCt os

= 457
maximum deviation from average voltage.
- 482 = 8 v
- 487 = 7 v
- 488 = 2 v
deviation is 7 v.

Determine

percent of voltage imbalance.
7
% Voltage Imbalance = 100 x
487

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.
2. Unbalanced 3-Phase Supply Voltage
Never operate a motor where, a phase imbalance in supply voltage is
o
greater than 2_,
Use the following formula to determine the percent of voltage imbalance,
% Voltage Imbalance
= 100 x

FLA

25.6

LEGEND
----------

FLA

190

575

FLA
HACR
IFM
LRA
MCA
MOCP
NEC
OFM
RLA

POWER
EXHAUST

IFM

25.6

208/230

028
(28 Tons)

Max

OFM

253

208/230

O24
(20 Tons)

Min

COMPRESSOR
No. 1
No, 2

187

208/230

020
(18 Tons)

VOLTAGE
RANGE

= 1.53%
This amount of phase imbalance
allowable 2%.

max voltage deviation from average voltage
average voltage

is satisfactory

as it is below the maximum

2%,
contact your Iflocal
utility company
immediately.is more than
IMPORTANT:
the electric
supply voltage
phase imbalance

Step 10 -ments

Make

Outdoor-Air

Inlet

AdjustOUTDOOR-AIR
HOOD AND
MOUNTING BRACKETS

MANUAL OUTDOOR-AIR
DAMPER -- All units (except
those equipped with a factory-inst_dled economizer)
have a
manual outdoor-air &tmper to provide ventilation ail:
Damper can be preset to admit up to 25% outdoor air into
return-tdr compartment. To adjust, loosen secunng screws and
move &tmper to desired setting, then retighten screws to secure
dmnper (see Fig. 17).
25% ADJUSTABLE
AIR DAMPER

F[_ER
PACKAGEAN[
HOOD
COMPONENTS

ol
/I

÷I

BASE
UNIT

RETURN-AIRFILTE}
ACCESS PANEL

Fig. 18-

Outdoor-Air

Hood Component Location

PANEL

SECURING

SCREWS

Fig. 17 -- Standard 25% Outdoor-Air
Section Details
UPPER
RETAINER

Step 11 -- Install Outdoor-Air

IMPORTANT:
If the unit is equipped with the optional
EconoMiSerIV.
move the outdoor air temperature sensor
prior to installing the outdoor air hood. See the Optional
EconoMiSerIV and EconoMiSer2 section for more details.

SEAL;

Fig. 19-

The outdoor- air hood is common to 25% air ventilation and
economizel: If EconoMiSerIV
is used, all electrical connections have been made and adjusted at the factoly. Assemble
and install hood in the field.

4.
5.

7.
8.

Seal

Strip

Location

BAFFLE

NOTE: The hood top panel, upper and lower filter retainel_,
hood drain pan, baffle (size 024 and 028), and filter support
bracket me secured opposite the condenser end of the unit. The
screens, hood side panels, remaining section of tilter support
bracket, seal strip, and hmdware are in a package located
inside the return-air filter access panel (Fig. 18).
1. Attach seal strip to upper filter retainer. See Fig. 19.
2.

PAN

Hood

\
LOWER

FILTER

RETAINER

Assemble hood top panel, side panels, upper filter retainel: and dnun pan (see Fig. 20).
Secure lower filter rettuner and support bracket to unit.
See Fig. 20. Leave screws loose on size 024 and 028
units.
Slide bafile (size 024 and 028) behind lower filter retainer
and tighten screws.
Ix_osen 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 inlet opening.
Match notches in hood top panel to unit top panel screws.
|nsert hood flange between top panel fange and unit.
Tighten screws.
Hold hood side panel flanges flat against unit, and install
screws removed in Step 5.

HOOD SIDE
PANELS (2)
BAFFLE
. (024 TO
028 ONLY)

LOWER
FILTER
RETAINER
FILTER SUPPORT
BRACKET

Insert outdoor-air inlet screens and spacer in channel created by lower filter retainer and filter support bracket.

HOOD DRAIN PAN
UPPER FILTER RETAINER

Fig. 20 -- Outdoor-Air
14

Hood

Details

Step 12 -- Install All Accessories--

Install all

Install Motormaster
[ Controls -- Only one Motormaster
I
control is required per unit. The Motormaster I control must be
used in conjunction with the Accessory 0 ° F Ix_w Ambient Kit
(purchased separately). The Motormaster [ device controls outdoor fan no. 1 while outdoor fans no. 2 and 3 are sequenced off
by the Accessory 0 ° F Low Ambient Kit.
Accessoiw 0 ° F Din' Ambient Kit -- Inst_dl the Accessory 0° F
Ix_w Ambient Kit per instruction supplied with accessory.
Sensor Assembly -- Install the sensor assembly in the location
shown in Fig. 25_
Motor MountTo ensure proper fan height, replace the existing motor mount with the new motor mount provided with
accessory.
Tran._fiwmer (460 and 575-v Units On@) -- On 460 and 575-v
units, a transhmner
is required. The transformer is provided
with the accessory and must be field-installed.
Motormaswr I Control -- Recommended
mounting location is
on the inside of the panel to the left of the control box. The
control should be mounted on the inside of the panel, vertically, with leads protruding from bottom of extrusion.

field-installed accessories. Refer to the accessoly installation
instructions included with each accessory.
MOTORMASTER®
I
CONTROL
INSTALLATION
(48TJ016,020
UNITS)
Install Field-Fabricated
Wind Baffles -- Wind baffles must
be field-fabricated for all units to ensure proper cooling cycle
operation at low ambient temperatures. See Fig. 21 for baffle
details. Use 20-gage,
galvanized
sheet metal, or similar
conosion-resistant
metal for baffles. Use field-supplied screws
to attach baffles to unit. Screws should be 1/4-in. diameter and
5/8-in. long. Drill required screw holes for mounting baffles.

To avoid dmnage to the refiigemnt coils and electric_d components, use recommended
screw sizes only. Use care
when drilling holes.

_Oo
_:tOo
°
_:toO°
_:to
°
_o°
_:_o
°

_o°
_o°
_o
_o
_o
_o
_o
_o

) MIN

BAFFLE TOP VIEW

1" (25) MIN--_

78.12" -+0.125"
0984 -+3)
I

10" (254)

_..]--" _¥p)
-'

40"
1016
_10"

+"--

\
3/4"(19)0-¥P)--'_

ffYP)

""-'--I

_"_

15" (381)
1_

-4i----,i

SENSOR
LOCATION

(254)

(TYP)

"1" (25) MIN

_$o
°
_o°
_o°
_:to
°
€:to°
_o°
_1_o
o°
_:_o
°

BAFFLE FRONT VIEW

NOTE: Dimensions

_o
_o
SENSOR
LOCATION

_o
_o
_o

in ( ) are in mm.

_o°
_oOO
°

Fig. 21 -- Wind Baffle Details

HAIRPIN

END

48TJ016

_o°
HAIRPIN

END

48TJ020

NOTE: All sensors are located on the eighth hairpin up from the
bottom.

Fig. 22 -- Motormaster

I Sensor Locations

MOTORMASTER®
V
CONTROL
INSTALLATION
(48TJ024,028
UNITS)
Install Field-Fabricated
Wind Baflles -- Wind baflles must
be field-fabricated for all units to ensure proper cooling cycle
operation at low ambient temperatures. See Fig. 21 for baflle
details. Use 20-gage, galvanized sheet metal, or similar corrosion-resistant metal for baffles. Use field-supplied screws to attach baffles to unit. Screws should be l/4-in, diameter and
5/8-in. long. Drill required screw holes for mounting baffles.

FROM FUSE BLOCK

10 o---1
>-

1.2

1.3

o
o

To avoid dmnage to the refligerant coils and electrical components, use lecommended
screw sizes only. Use cme
when &'illing holes.

B
13B

Install Motormaster
V Controls
-The Motormaster
V
(MMV) control is a motor speed control device which adjusts
condenser fan motor speed in response to declining liquid lefrigerant pressure. A properly applied Motormaster V control
extends the operating range of air-conditioning
systems and
permits operation at lower outdoor ambient temperatures.
The minimum
operate are:

mnbient temperatures

Unit
40

ooo
o

at which the unit will
TO MOTOR(S)

TEMPERATURE
Standard

o
TO PRESSURE
TRANSDUCER

OPERATING

Unit with
Low Ambient
25

Kit

Fig. 23 -- Motormaster

LIMITS -- F°
I

Unit with

MMV -20
Control

V Control

Table 6 -- Motormaster V Control Package Usage
To operate down to the ambient
temperatures
listed,
Motormaster V controls (Fig. 23) must be added. Field-fabricated and installed wind baffles gue _dso required for _dl units (see
Fig. 21). The Motormaster V control permits operation of the
unit to an ambient temperature of-20 IF.The control regulates the
speed of 3-phase fan motors that gue compatible with the control.
These motors me factory installed.

ITEM DESCRIPTION
48TJ024,028
UNIT

V control

per instructions

CRLOWAMB015A00

460
VOLTAGE
575

CR LOWAMB016A00

Table 7 -- Applicable

See Table 6 for the Motormaster V control accessory package usage. Table 7 shows applicable voltages and motors.
Replacement of motor or fan blade IS NOT REQUIRED
ON
CURRENT
PRODUCTION
UNITS since the control is
compatible with the factory-installed
fan motors. Only field
wiring control is required.
Inst_dl the Motormaster
with accessory.

208/230

VOLTAGE
208/230-3-60
480-3-60
575-3-60

supplied

CRLOWAMB017A00

Voltages

and Motors

COMPATIBLE MOTOR
HD52AK654
HD52AK654
HD52GE576

Step 13 --Adjust

Factory-Installed

Options

into the fan section, down along the back side of the fan, and
_dong the fan deck over to the supply-air opening.
The SAT probe is wire-tied to the supply-air opening (on the
horizontal opening end) in its shipping position. Remove the
sensor for installation. Re-position the sensor in the flange of
the supply-air opening or in the supply air duct (as required by
local codes). Drill or punch a l/2-in, hole in the flange or duct.
Use two field-supplied, self-drilling screws to secme the sensor
probe in a horizontal orientation.

PREMIERLINK
TM CONTROL
-- The PrelnierLink controller is available as a special order from the facto U and is compatible with the Ctmier Comfort Network® (CCN) system.
This control is designed to allow usel_ the access and ability to
change factoly-defined
settings, thus expanding the function of
the standard unit control board. Carrier's diagnostic stan&ud
tier display tools such as Navigator r_'_ device or Scrolling
Marquee can be used with the PremierLink controller.
The PremierLink controller (see Fig. 24) requires the use of
a C;urier electronic themiostat or a CCN connection for time
broadcast to initiate its internal timeclock. This is necessmy for
broadcast of time of day functions (occupied/unoccupied).
No
sensors are supplied with the field-mounted PremierLink control. The factou-installed
PremierLink control includes only
the supply-tfir temperature (SAT) sensor and the outdoor air
temperature (OAT) sensor as standmd. An indoor air quality
(CO2) sensor can be added as tin option. Refer to Table 8 for
sensor usage. Refer to Fig. 25 for PremierLink controller wiring. The PremierLink control may be mounted in the control
panel or an men below the control panel.

NOTE: The sensor must be mounted in the dischmge airstream
downstream of the cooling coil and any heating devices. Be
sure the probe tip does not come in contact with any of the unit
or heat surfaces.
Outdoor Air Temperature
(OAT) Sensor -- When the unit is
supplied with a factoly-mounted
PremierLink
control, the
outdoor-air temperature sensor (OAT) is factory-supplied
and
wired.
Install the Indoor Air Quality (CO2) Sensor -optional indoor air quality (CO2) sensor according
turer specifications.

A sepmate field-supplied
transformer
must be used to
power the CO2 sensoc
Wire the CO2 sensor to the COM and IAQI terminals of J5
on the PremierLink controflec Refer to the PremierLink Installation, Start-up, and Configuration
Instructions
for detailed
wiring and configuration information.

NOTE: PremierLink controller version 1.3 and later is shipped
in Sensor mode. If used with a thermostat, the PremierLink
controller must be configured to Thermostat mode.
Install the Supply Air Temperature
(SAT) Sensor -- When
the unit is supplied with a factou-mounted
PremierLink control, the supply-air temperature (SAT) sensor (33ZCSENSAT)
is factory-supplied
and wired. The wiring is muted from the
PlemierLink control over the control box, through a grommet,

HVACSENSOR INPUTS
SPACE TEMP

SET POINT _
SUPPLY AIR TEMP

0
[TT_

Nil

TEMP

]1il

INDOOR

AIR QUALITY

ETa'

OUTDOOR

AIR QUALITY

OUTDOOR

DUAL MODE SENSOR (STAT)

...........................

t"1

Mount the
to manufac-

Rm Numt_e 33CSP_lEML_

i 2;_1_

PremlerZ_nk

.....

[

]Jr_

.....
_,___._!.,.
a_

TH:I
COMP SAFETY (Y1) "J_
FIRE SHUTDOWN

SUPPLY PAN STATUS (Wl) "'_[1
NOT USED (W2) ""I"13

ENTHALPY

H ; I

(Y2) _

STATUS (ENTH)

i ]
• I

_o_

/.._]__ttol

I._o'1 I<,<>,<,_/" \
/
CCN/LEN
PORT

t
NAVIGATOR
PORT

L_I..,,..'It
4 20MA/
ECONOMIZER

' SASP + 5 and economizer
position > 80%,
economizer will go to minimum position for 3 minutes or
until SAT > 68 IF.
First stage of mechanical cooling will be energized.
Integrator resets.
Economizer
opens again and controls to current SASP
after stage one on for 90 seconds.
With YI and Y2 energized
economizer
maintains
an
SASP = SATLO2 + 3.
If SAT > SASP + 5 and economizer
position >80%,
economizer will go to minimum position for 3 minutes or
until SAT > 68 E
If compressor
one is on then second stage of mechanical
cooling will be energized. Otherwise the first stage will
be energized.
Integrator resets.
Economizer
opens again and controls
to SASP after
stage one on for 90 seconds.
Routine

•
•

3 (OAT > 68)

Economizer
is opened 100%.
Compressors
1 and 2 are cycled based on YI and Y2
using minimum on and off times and watching the supply air temperature
as compared
to SATLOI
and
SATLO2 set points.

If optiomd power exhaust is installed, as the outdoor-air
&tmper opens and closes, the power exhaust fans will be energized and deenergized.
If field-installed accessory CO2 sensors me connected to the
PremierLink
control, a PlD-controlled
demand ventilation
strategy will begin to operate. As the CO2 level in the zone
increases above the CO2 set point, the minimum position of the
&_mper will be increased proportionally.
As the COz level
decreases because of the increase in fresh air, the outdoor-air
&tmper will be proportionally closed.
HEATING, UNITS WITH ECONOMISER2,
PREMIERLINK
CONTROL AND A THERMOSTAT -- When the thermostat
calls for heating, terminal Wl is energized. The PremierLink
control will move the economizer damper to the minimum
position if there is a call for G and closed if there is a call for
WI without G In order to prevent thermostat from short cycling, the unit is locked into the heating mode for at least
10 minutes when WI is energized. The induced-di'aft motor is
then energized and the burner ignition sequence begins.

The PremierLink control will use the following information
determine if free cooling is available:
Indoor fan has been on for at least 30 seconds.
The SPT. SAT. and OAT inputs must have valid readings.
OAT must be less than 75 F.
OAT must be less than Sir[ '.
Enthalpy must be LOW (may be jumpered if an enthalpy
sensor not available).
• Economizer
position is NOT forced.
to
•
•
•
•
•

On units equipped for two stages of heat, when additional
heat is needed, W2 is energized and the high-fire solenoid on
the main gas valve (MGV) is energized. When the thermostat
is satisfied and WI is deenergized,
the IFM stops after a
45-second time-off delay unless G is still maintained.

Pre-cooling occurs when the is no call fi_m the thermostat
except G Pre-cooling is defined as the economizer modulates
to provide 70 F supply air

COOLING,
UNITS WITH ECONOMISER2,
PREMIERLINK CONTROL
AND A ROOM SENSOR -- When free
cooling is not available, the compressors will be controlled by
the PremierLink controller using a PID Enor reduction calculation as indicated by Fig. 46.

When free cooling is available the PremierLink control will
control the compressors and economizer to provide a supplyair tempemtme determined to meet the YI and Y2 c_dls from
the thermostat using the following three routines. The three
control routines are based on OAT.

The PremierLink controller will use the following information to determine if free cooling is available:
• Indoor fan has been on for at least 30 seconds.
• The SPT. SAT. and OAT inputs must have valid readings.
• OAT must be less than 75 E
• OAT must be less than SPT.
• Enthalpy
must be LOW (may be jumpered
if and
enthalpy sensor is not available).
• Economizer
position is NOT forced.

The 3 routines ;ue based on OAT where:
SASP = Supply Air Set Point
Cooling Ix_ckout Set Point

PID = Proportional Integral
Routine 1 (OAT < DXCTLO)
YI energized
(SATLOI + 3).
Y2 energized
(SATLO2 + 3).

•
•
•

•

If free cooling can be used as determined from the appropriate changeover command (switch, diy bulb, enthalpy curve,
differential dry bulb, or differential enthalpy), a call for cooling
(YI closes at the thermostat) will cause the control to modulate
the &tmpeLs open to maintain the supply air temperature set
point at 50 to 55 E
As the supply-air temperature diops below the set point
range of 50 to 55 E the control will modulate the outdoor-air
dampers closed to maintain the proper supply-air temperature.
HEATING, UNITS WITH ECONOMISERIV
-- When the
room thermostat calls for heat, the heating controls are energized as described in the Heating, Units Without Economizer
section. When the indoor fan is energized, the economizer
damper moves to the minimum position. When the indoor fan
is off. the economizer dmnper is fully closed.
COOLING.
UNITS WITH ECONOMISER2,
PREMIERLINK TM CONTROL AND A THERMOSTAT
-- When free
cooling is not available, the compressoLs will be controlled by
the PremierLink control in response to the YI and Y2 inputs
from the thermostat.

= Dilect Expansion

•

Damper movement from full closed to lifll open (or vice
veLsa) will take between 11/2and 21/: minutes.

DXCTLO

Routine 2 (DXCTLO
•

economizer

maintains

SASP

economizer

maintains

SASP

When free cooling is available, the outdoor-air damper is
positioned through the use of a Proportional
Integral (PID)
control process to provide a calculated supply-air temperature
37

intothezone.
Thesupply
airwillmaintain
thespace
temperaturebetween
theheating
andcooling
setpoints
asindicated
in
Fig.47.
ThePremierLink
TM will integrate
the compressol_ stages
with the economizer based on similar logic as the three routines
listed 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.

If Heating PID STAGES=2
•
•

•
•
•
•
•
•

HEAT STAGES=I
HEAT STAGES=2

(75% capacity) will energize HSI
(100% capacity) will energize HS2

In order to prevent short cycling, the unit is locked into the
Heating mode forat least 10 minutes when HSI is deenergized.
When HSI is energized the induced-di'aft
motor is then
energized and the burner ignition sequence begins. On units
equipped for two stages of heat, when additional heat is needed, HS2 is energized and the high-fire solenoid on the main gas
valve (MGV) is energized. When the space condition is satisfied and HSI is deenergized the IFM stops after a 45-second
time-off delay unless in the occupied mode. The fan will run
continuously
in the occupied mode as lequired by nafiomd
energy and fiesh air standards.

The high space set point is used for DX (direct expansion)
cooling control, while the economizer space set point is a
c:dculated value between the heating and cooling set points.
The economizer set point will always be at least one degree
below the cooling set point, allowing for a smooth transition
from mechanical
cooling with economizer
assist, back to
economizer
cooling as the cooling set point is achieved.
The compressors
may be used for initkd cooling then the
PremierLink controller will modulate the economizer using an
enor reduction calculation
to hold the space temperature
between the heating and cooling set points. See Fig. 47.
conditions

If the PremierLink controller detemfines that heat stages are
required, the economizer dalnper will be moved to minimum
position if occupied and closed if unoccupied.
Staging should be as follows:

When outdoor-air temperature conditions require the economizer to close for a compressor stage-up sequence, the economizer control integrator is reset to zero after the stage-up sequence is completed. This prevents the supply-tOT temperature
from &'opping too quickly and creating a freeze condition that
would make the compressor turn off prematurely.

The controller uses the following
economizer cooling:

If all of the above conditions m'e met, the number of heat
stages is c_dculated; otherwise the required number of heat
stages will be set to 0.

TEMPERATURE

CONTROL

to determine
w

Enthalpyis
Low
SAT reading is available
OAT reading is available
SPT reading is available
OAT < SPT
Economizer
Position is NOT forced

75,

•_ 73
w

72 ...............................................

""" SET POINT

TEMPERATURE

_- 70
W

o
694
cO

If any of the above conditions me not met, the economizer
submaster reference (ECSR) is set to maximum limit and the
dmnper moves to minimum position. The operating sequence
is complete. The ECSR is recalculated every 30 seconds.

68J
TIME

NOTE: PremierLink control performs smart staging of 2 stages of DX
cooling and up to 3 stages of heat.

If an optional power exhaust is inst:dled, as the outdoor-air
dmnper opens and closes, the power exhaust fans will be
energized and deenergized.

Fig. 46 -- DX Cooling Temperature
Control Example

If field-installed
accessory CO2 sensors are connected to
the PlemierLink control, a PID-controlled
demand ventilation
strategy will begin to operate. As the CO2 level in the zone
increases above the CO2 set point, the minimum position of the
dmnper will be increased proportionally.
As the CO2 level
decreases because of the increase in fresh all: the outdoor-air
dalnper will be proportionally closed.
HEATING. UNIT WITH ECONOMI$ER2,
PREMIERLINK
CONTROL AND A ROOM SENSOR -- Every 40 seconds
the controller will calculate the required heat stages (maximum
of 3) to maintain supply air temperature (SAT) if the following
qualifying conditions are met:
• Indoor fan has been on for at least 30 seconds.
• COOL mode is not active.
• OCCUPIED,
TEMRCOMPENSATED
START or HEAT
mode is active.
• SAT reading is available.
• Fire shutdown mode is not active.

TEMPERATURE

W
QZ

QZ
W
Q_
W
W

73
741_

......... _

71 t

704 ........
69

CONTROL

/j
_

....................................

------ COOL SETPOINT

X_"_H%_,_-_'-

..........................

TEMPERATURE

-- - HEAT

TIME

Fig. 47 -- Economizer
Temperature
Control Example

SETPOINT

SERVICE

aluminum,
pro-coated, copper/copper
or E-coated coils be
cleaned with the Totaline environmentally
sound coil cleaner
as described below. Coil cleaning should be part of the unit's
reguhuty scheduled maintenance procedures to ensure long life
of the coil. Failure to clean the coils may result in reduced durability in the environment.
Avoid the use of:
• Coil brighteners
• Acid cleaning prior to painting
• High pressure washers
• Poor quality water for cleaning

Before performing service or maintenance operations on
unit, turn off main power switch to unit and install lockout
tag on disconnect switch. Electrical shock could cause personal injury.

Cleaning-

Inspect unit interior at beginning
of each
heating and cooling season and as operating conditions require
(see Fig. 48). Remove unit top panel and/or side panels for access to unit interioc

Totaline environmentally
sound coil cleaner is non-flammable, hypoallergenic, nonbacterial, and a USDA accepted biodegradable agent that will not harm the coil or surrounding components such as electrical wiring, painted metal surfaces, or insulation. Use of non-recommended
coil cleaners is strongly
discouraged since coil and unit durability could be affected.

COIL MAINTENANCE
AND CLEANING
RECOMMENDATION -- Routine cleaning of coil surfaces is essential to
maintain proper operation of the unit. Elimination of contmnination and remowd of harmful residues will greatly increase
the life of the coil and extend the life of the unit. The following
maintenance and cleaning procedures are recommended as part
of the routine maintenance activities to extend the life of the
coil.
INDUCED DRAFT
MOTOR

INTEGRATED GAS
UNIT CONTROLLER
(HIDDEN)

VIEW
PORT

Totaline Environmentally
Sound
Equipment
• 21/2 gallon garden sprayer
• Water rinse with low velocity

Coil

Cleaner

Al)l)lRz_tion

spray nozzle

CONTROL BOX
ACCESS PANEL

Harsh chemicals, household bleach or acid or basic cleaners should not be used to clean outdoor or indoor coils of
any kind. These cleaners can be very difficult to rinse out
of the coil and can accelerate corrosion at the fin/tube interface where dissimilar materials are in contact. If there is
dirt below the surface of the coil, use the Totaline environmentally sound coil cleaner as described above.

ilGC
FAULT

High velocity water fi'om a pressure washeL garden hose,
or compressed air should never be used to clean a coil. The
force of the water or air jet will bend the fin edges and
increase airside pressure drop. Reduced unit performance
or nuisance unit shutdown may occm:

\
COMBUSTION
FAN HOUSING

MAIN BURNER
SECTION

FLUE BOX
COVER

Totaline Environmentally
Instructions

MAIN GAS
VALVE

Sound

Coil

Cleaner

Al)l)fi{zaion

1. Proper eye protection such as safety glasses is recommended during mixing and application.
2. Remove all surface loaded fibers and dirt with a vacuum
cleaner as described above.

Fig. 48 -- Typical Gas Heating Section
Remove Surface Loaded Fibers -- Surface loaded fibers or
dirt should be removed with a vacuum cleanel: If a vacuum
cleaner is not available, a soft non-metallic bristle brush may
be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily &_maged (fin edges
can be easily bent over graddamage to the coating of a protected coil) if the tool is applied across the fins.
NOTE: Use of a water stream, such as a garden hose, against a
surface loaded coil will drive the fibers and diri into the coil.
This will make cleaning efforts morn difficult. Surface loaded
fibeL'smust be completely removed prior to using low velocity
clean water nnse.

3. Thoroughly wet finned surfaces with clean water and a
low velocity garden hose, being careful not to bend fins.
4. Mix Totaline environmentally sound coil cleaner in a
2V2 gallon gmden sprayer according to the instructions
included with the cleanel: The optimum solution temperature is 100E
NOTE: Do NOT USE water in excess of 130 F. as the enzymatic activity will be destroyed.
5. Thoroughly apply Totaline environmentally sound coil
cleaner solution to all coil surfaces including finned area,
tube sheets and coil headers.

Periodic Clean Water Rinse --A periodic clean water rinse is
veU beneficial for coils that am applied in coastal or industrial
environments. HoweveL it is very important that the water
rinse is made with veq low velocity water stream to avoid
damaging the fin edges. Monthly cleaning as described below
is recommended.

6. Hold garden sprayer nozzle close to finned areas and apply cleaner with a vertical, up-and-down motion. Avoid
spraying in horizontal pattern to minimize potential for
fin damage.
7. Ensure cleaner thoroughly penetrates deep into finned
gueas.
8. Interior and exterior finned meas must be thoroughly
cleaned.

Routine Cleaning of Coil Surfaces -- Monthly cleaning with
Totaline® environmentally sound coil cleaner is essential to
extend the life of coils. This cleaner is available from Cmrier
Replacement parts division as part number P902-0301 for a
one gallon containel; and pmt number lX)02-0305 for a 5 gallon
containel: It is recommended that all coils, including stan&trd

9. Finned surfaces should remain wet with cleaning solution
for 10 minutes.
39

10.

Lubrication

Ensure surfaces are not allowed to &y before rinsing.
Reapplying cleaner as needed to ensure 10-minute saturation is achieved.

COMPRESSORSEach compressor
is ch_uged with the
correct amount of oil at the factory. Conventional white oil
(Sontext 200LT) is used. White oil is compatible with 3GS oil,
and 3GS oil may be used if the addition of oil is required. See
compressor nameplate for origimd oil charge. A complete rech_uge should be four ounces less than the origimd oil charge.
When a compressor is exchanged in the field it is possible that
a major portion of the oil from the replaced compressor may
still be in the system. While this will not affect the reliability of
the replacement compressor, the extra oil will add rotor drag
and increase power usage. To remove this excess oil, an access
valve may be added to the lower portion of the suction line at
the inlet of the compressol: The compressor should then be mn
for 10 minutes, shut down, and the access valve opened until
no oil flows. This should be repeated twice to make sure the
proper oil level has been achieved.

11. Thoroughly
rinse _dl surfaces with low velocity clean
water using downward
rinsing motion of water spray
nozzle. Protect tins from &_mage from the spray nozzle.
CONDENSATE
DRAINCheck and clean each year at
sttut of cooling season. In wintel, keep &ains and traps dry.
During periods of low outdoor temperatures, add anti-freeze
solution to the drain to prevent freeze up. Follow _dl precautions on anti-freeze labeling.
FILTERS -- Clean or replace at start of each heating and cooling season, or more often if operating conditions require. Refer
to Table 1 for type and size.
OUTDOOR-AIR
INLET SCREENS -- Clean screens with
steam or hot water and a mild detergent. Do not use throwaway
filteL's in place of screens. See Table 1 for quantity and size.

FAN SHAFT BEARINGS
-- For size 016 units, bearings are
permanently
lubricated. No field lubrication is required. For
size 020-028 units, lubricate bearings at least every 6 months
with suitable bearing grease. Extended grease line is provided
for far side fan bearing (opposite drive side). Typical lubricants
are given below:

MAIN BURNER -- At the beginning of each heating season,
inspect for deterioration or blockage due to corrosion or other
causes. Observe the main burner flames. Refer to Main BurneLs section on 43.
FLUE GAS PASSAGEWAYS
-- The flue collector box and
heat exchanger cells may be inspected by removing heat exchanger access panel (see Fig. 4 and 5), flue box cover, and
main burner assembly. Refer to Main Burners section on
page 43 for burner removal sequence. If cleaning is required,
remove heat exchanger baffles and clean tubes with a wire
brush.

MANUFACTURER

LUBRICANT

Texaco
Mobil
Sunoco
Texaco
*Preferred

Use caution with ceramic heat exchanger baffles. When inst_dling retaining clip, be sure the center leg of the clip extends
inward toward baffle. See Fig. 49.

Regal AFB-2*
Mobilplex EP No. 1
Prestige 42
Multifak 2

lubricant because it contains rust and oxidation inhibitors.

CONDENSER
AND
EVAPORATOR-FAN
MOTOR
BEARINGS
-- The condenser-fan and evaporator-fan motors
have permanently
sealed bearings, so no field lubrication is
necessaq.

CERAMIC
BAFFLE

Evaporator

(Fig. 50-52)

-shown in Table 1.

Fan

Performance

Adjustment

Fan motor pulleys are factory set for speed

To change fan speeds:
1. Shut off unit power supply.

CLIP_

/
HEAT EXCHANGER
TUBES

NOTE: One baffle and clip will be in each upper tube of the heat
exchanger.

Fig. 49 -- Removing Heat Exchanger Ceramic
Baffles and Clips

COMBUSTION-AIR
BLOWER -- Clean periodically to assure proper airflow and heating efficiency. Inspect blower
wheel evely fall and periodically during heating season. For the
fiLst heating season, inspect blower wheel bi-monthly to determine proper cleaning frequency.

Size 016 Only: Loosen belt by loosening carriage
nuts holding motor mount assembly to fan scroll
side plates (A and B).

Size 020-028 Only: Loosen nuts on the 2 carriage
bolts in the motor mounting base. Install jacking
bolt and plate under motor base (bolt and plate are
shipped in installer's packet). Using bolt and plate,
raise motor to top of slide and remove belt. Secure
motor in this position by tightening the nuts on the
carriage bolts.

Loosen movable-pulley

Screw movable flange toward fixed flange to increase
speed and away from fixed flange to decrease speed. Increasing fan speed increases load on motor Do not exceed maximum speed specified in Table 1.

flange setscrew (see Fig. 50).

See Table 20 for air quantity limits.

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 combustion
fan housing. The motor and wheel assembly will slide up and
out of the fan housing. Remove the blower wheel from the motor shaft and clean with a detergent or solvent. Replace motor
and wheel assembly.

Set movable flange at netuest keyway of pulley hub and
tighten setscrew. (See Table 1 for speed change for each
full turn of pulley flange.)

Replace and tighten belts. See Belt Tension Adjustment
section on page 42.

To align fan and motor pulleys:
1. Loosen fan pulley setscrews.

Slide fan pulley _dong fan shaft.

Make angular alignment
mounting plate.

loosening

motor

from

Evaporator
48TJ016

UNITS

Fan Service

and Replacement

(See Fig. 51 )

MOTOR
PULLEY

NOTE: To lemove belts only. follow Steps 1-6.
1. Remove filter and supply-air section panels.
2. Remove unit top panel.
3. Loosen carriage nuts A and B holding motor mount
assembly to fan scroll side plates.
4. Loosen screw C.
5. Rotate motor mount assembly (with motor attached) as
far as possible away from evaporator coil.
6. Remove belt.
7. Rotate motor mount assembly back past original position
toward evaporator coil.
8. Remove motor mounting nuts D and E (both sides).
9. Lift motor up through top of unit.
10. Reverse above procedure to leinstall motol:
11. Check and adjust belt tension as necessary.

UNIT TOP PANEL
D

MOTOR

FAN
PULLEY

48TJ020-028 UNITS (See Fig. 52) -- The 48TJ020-028 units
use a fan motor mounting system that features a slide-out
motor mounting plate. To replace or service the motor, slide
out the bracket.
1. Remove the evaporator-fan
access panel and the heating control access panel.
2. Remove the center post (located between the evaporator
fan and heating control access panels) and all screws
securing it.
3. Loosen nuts on the 2 carriage bolts in the motor mounting
base.
4.

5.
6.
7.
8.

FAN SCROLL
SIDE PLATES

Using jacking bolt under motor base, raise motor to top of
slide and remove belt. Secure motor in this position by
tightening the nuts on the cturiage bolts.
Remove the belt drive.

DRAIN
CONNECTION

Fig. 51 -- 48TJ016 Evaporator-Fan
Motor Adjustment

Remove jacking bolt and tapped jacking bolt plate.
Remove the 2 screws that secure the motor mounting
plate to the motor support channel.
Remove the 3 screws from the end of the motor support
channel that interfere with the motor slide path.
FAN PULLEY_

SECOND BELT
ON 10 HP MOTOR
ONLY

BELT,

STRAIGHTEDGE
PARALLEL
WITH BELT

PULLEY

MUST
MOTOR

PULLEY

SLIDING MOTOR
PLATE

ENSURE PROPER
CLEARANCE BETWEEN
BELT(_ AND FAN
.SUPPORT NOTCH

MOTOR
PLATE

MOVABLE
FLANGES

PULLEY
\

MOTOR AND FAN
SHAFTS MUST BE
PARALLEL

\
-JACKING
MOTOR SUPPORT
CHANNEL

JACKING

BOLT

NOTE: A 31/2-in. bolt and threaded plate are included in the
installer's packet. They should be added to the motor support channel below the motor mounting plate to aid in raising the motor. The
plate part number is 50DP503842. The adjustment bolt is 3/8-16 x
13/4 in. LG.

FIXED FLANGE
SINGLE-GROOVE

Fig. 52 -- 48TJ020-028 Evaporator-Fan
Motor Section
Fig. 50 -- Evaporator-Fan

PLATE

SETSCREWS

Pulley and Adjustment
41

9.
10.

Slide out the motor and motor mounting plate.
Disconnect wiring connections and remove the 4 mounting bolts.
11. Remove the motol:
12. To inst;dl the new motor, revel.se Steps 1-11.

Belt Tension

Adjustment

GTAC II; Module 5; Charging,
Recovery. Recycling,
and
Reclamation
section for chguging methods and procedures.
Unit panels must be in place when unit is operating during
chguging procedure.
NOTE: Do not use recycled
contaminants.

To adjust belt tension:

3.
4.

Move motor mounting plate up or down for proper
belt tension (1/2 in. deflection with one finger).
Size 020-028 Units:

Adjustment

48TJ01 (7,020 UNITS (Fig. 53)
1. Shut off unit power supply.
2. Remove access panel(s) closest to the fan to be adjusted.
3. Ix)osen fan hub setscrews.
4.

Adjust fan height on shaft using a strtdghtedge
across the fan orifice.

5.
6.

Tighten setscrews and replace panel(s).
Turn on unit powec

48TJ024,028

UNITS

placed

NOTE: Indoor-air cfm must be within normal operating
of unit. All outdoor fans must be operating.

MOISTUREMISER
TM SYSTEM
CHARGING
-- The system charge for units with the MoistureMiSer
option is greater
than that of the standard unit _done. The chtuge for units with
this option is indicated on the unit nameplate &awing. To
chm:ge systems using the MoistureMiSer
dehumidification
package, fully evacuate, recover, and re-chtuge the system to
the nameplate
specified charge level. To check or adjust
refrigerant charge on systems using the MoistureMiSer
dehumidification
package, charge per the standard subcooling
chtuts. The subcooler MUST be deenergized to use the chalging chmts. The charts reference a liquid pressure (psig) and
temperature at a point between the condenser coil and the subcooler coil. A tap is provided on the unit to measure liquid
pressure entering the subcooler (leaving the condenser).

Tighten setscrews and replace rubber hubcap to prevent
hub from rusting to motor shaft.
Fill hub recess with permagum if robber hubcap is
missing.

Power Failure

-- Dampers have a spring return. In event
of power failme, dampers will return to fully closed position
until power is restored. Do not manual@ ol)eraw economizer
mo_ol_

Refrigerant Charge
listed on unit nameplate

-- Amount of refligerant chmge is
and in Table 1. Refer to Carrier

range

The TXV (thermostatic expansion valve) is set to maintain
between 15 and 20 degrees of supefl]eat at the compressors.
The valves are factory set and should not require re-adjustment.

(Fig. 54)

1. Shut off unit power supply.
2. Remove fan top-grille assembly and loosen fan hub
screws.
3. Adjust fan heigN on unit, using a straightedge placed
across the Nn orifice.
4.

contain

LOW CHARGE
COOLING -- Using cooling charging chart
(see Fig. 55), add or remove refrigerant until conditions of the
chart are met. Note that ch_uging ch_ut is different from those
nominally used. An accurate pressure gage and temperaturesensing device is required. Charging is accomplished by ensuring the proper amount of liquid sub-cooling. Measure liquid
line pressure at the liquid line service valve using pressure
gage. Connect temperature
sensing device to the liquid line
ne;u 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 intersection point on the cooling charging chin1. If intersection point
on chart is above line, add refrigerant. If intel.section point on
chtut is below line, carefully recover some of the charge.
Recheck suction pressure as charge is adjusted.

Turn motor jacking bolt to move motor mounting
plate up or down for propel belt tension (3/8 in.
deflection at midspan with one finger [9 lb force]).
Tighten nuts.
Adjust bolts and nut on mounting plate to secure motor in
fixed position.

Condenser-Fan

as it may

NO CHARGE -- Use standard evacuating techniques. After
ewtcuating system, weigh in the specified amount of refrigerant (refer to Table 1).

1. Loosen fan motor bolts.
2. a Size 016 Units:

refrigerant

BOTH CIRCUITS
ALL OUTDOOR FANS MUST BE OPERATING

=....
N

_140,

_12°1 I I 'Abd_HAR'G'E'I_AB'Ot/&
CORV'E
Illll

Fan Adjustment,

llllll

48TJ016,020

LU 60

III I I III I IJZI"I4Eb6&&
&.'ARGE
,FBELow
CURVE

IIIIIIIL/IIII

III1 11 III

RAIN
SHIELD
50

100

150

200

LIQUID PRESSURE

Fig. 55-

NOTE: Dimensions are in inches.
Fig. 54 -- Condenser-Fan

soolillilillilili ililli I
IIIIIIIIIIIIII
IIII1 t"
0111
11111
IIIIIIIIJ,
Z'I I
lili i lili iliiJZlilii I

NOTE: Dimensions are in inches.
Fig. 53 -- Condenser

lllllllll

Adjustment,

48TJ024,028
42

Cooling

250

300

350

AT LIQUID VALVE (PSIG)

Charging

Chart

400

Protective

Gas Valve Adjustment
NATURAL GASThe gas valve ()pens and closes
sponse to the thermostat or limit control.
When power is supplied to valve terminals
m;dn v_dve opens to its preset position.
The regular
(3.3 in. wg).

factory setting

To adjust regulator:
1. Set thermostat
2.
3.

4.
5.
6.
7.
8.

is stamped

COMPRESSOR

in re-

on the v;dve body

at setting for no call for heat.

Turn main gas valve to OFF position.
Remove l/s-in, pipe plug from manifold or gas v;dve
pressure tap connection.
Install a suitable pressuremeasuring device.
Set main gas valve to ON position.
Set thennostat at setting to call for heat.

Crankcase Heater -- Only the 48TJ028 unit and units with
optional
MoistureMiSer TM dehumidification
system
are
equipped with a 70-watt crankcase heater to prevent absorption
of liquid refrigerant by oil in the crankcase when the compressor is idle. The crankcase heater is energized whenever there is
a main power to the unit and the compressor is not energized.

Remove screw cap covering regulator adjustment sclew
(see Fig. 56).
Turn adjustment screw clockwise to increase pressure or
counterclockwise
to decrease pressure.
Once desired pressure is established, set thermostat setting for no call for heat, turn off main gas valve, remove
pressure-measuring
device, and replace I/s-in. pipe plug
and screw cap.

Fig. 56 -- Gas Valve
burners

are

1. Shut off (field-supplied) manual main gas v;dve.
2. Shut off power to unit.
3. Remove unit control box access panel, burner section access panel, and center post (see Fig. 4 and 5).
4. Disconnect gas piping from gas valve inlet.
5. Remove wires from gas valve.
6. Remove wires from rollout switch.
7.
8.
9.

Remove sensor wire and ignitor cable from [GC board.
Remove 2 screws securing manifold bracket to basepan.
Remove 2 screws that hold the burner support plate
flange to the vestibule plate.
10. Lift burner assembly out of unit.
CLEANING
AND ADJUSTMENT
1. Remove burner
Burner Removal
2.
3.

rack from unit as described
section above.

Relief Devices

-- All units have relief devices to protect
against damage from excessive pressures (i.e., fire). These
devices protect the high and low side.

Control

Circuit, 24-7--This
control circuit is protected against overcurrent
by a 3.2 amp circuit breakec
Bre;_ker can be reset. If it trips, determine cause of trouble
before resetting. See Fig. 58 and 59 for typical wiring diagram
and component ;urangement.

in Main

Inspect burners, and if dirty, remove burners fiom rack.
Using a soft brush, clean burners and crossover port as
required.

4.
5.

Adjust spark gap. See Fig. 57.
Reinst_dl burners on rack.

Reinstall burner rock as described

Filter Drier-

Replace
exposed to atmosphere.

whenever

energize the crankcase heaters for 24 houLs before stmtIMPORTANT:
After a prolonged shutdown or servicing,
ing the compressors.

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,
the cooling lockout (CLO) will lock the compressors off. To
reset, manually move the thermostat setting.
EVAPORATOR-FAN
MOTOR PROTECTION
-- A manual reset, calibrated trip, magnetic circuit bleaker protects
against overcurrent. Do not bypass connections or increase the
size of the breaker to correct trouble. Determine the cause and
correct it before resetting the breakel:
CONDENSER-FAN
MOTOR
PROTECTION
-- Each
condenser-fan
motor
is internally
protected
against
overtemperature.
HIGH-PRESSURE
AND LOW-PRESSURE
SWITCHES
-If either switch trips, or if the compressor overtemperature
switch activates, that refrigerant circuit will be automatically
locked out by the CLO. To reset, manually move the thermostat setting.
FREEZE PROTECTION
THERMOSTAT
(FPT) -- An FPT
is located on the top and bottom of the evaporator coil. They
detect frost build-up and turn off the compressol: allowing the
coil to clem: Once the frost has melted, the compressor can be
reenergized by resetting the compressor lockout.

REGULATOR
..-----"ADJUSTMENT
SCREW
(REMOVE
COVER)

-- For all applications, main
factory set and should require no adjustment.
MAIN BURNER REMOVAL

Replacement Parts
parts may
request.

be obtained

Diagnostic
above.
refrigerant

system

PROTECTION

Phase Protection
-- On 48TJ016 and 020 units, the phase
monitor relay (PMR) will monitor the sequence of the 3-phase
electric_d system to provide phase reversal protection. The
PMR will also monitor the 3-phase voltage inputs to provide
phase loss protection for the 3-phase device.
Overcurrent -- Each compressor has internal line break motor
protection, except the circuit no. 1 on the 48TJ028 units. Compressor no. 1 on the 48TJ028 unit uses an electronic module,
located with the compressor junction box, to provide motor
protection. This electronic module monitors winding and dischtuge temperatures. If these temperatures reach the trip values, the module interrupts the control line and causes the
compressor to switch off.

DI and C2, the

Main Burners

Devices

IGC Control

has LEDs for diagnostic
section on page 48.

-- A complete list of replacement
from any Carrier distributor upon

LEDs--

purposes.

The

IGC

bom'd

Refer to Troubleshooting

I
I

Optional

Hinged Access Doors --When the optional
service package is ordered or the if the hinged access doors
option is ordered, the unit will be provided with external and
internal hinged access dool_ to facilitate service.

Two internal access doors are provided inside the filter/
drive access dool: The filter access door (on the left) is secured
by 2 small 1/4 turn latches with folding bail-type handles. This
door must be opened prior to opening the drive access dool:
The &ive access door is shipped with 2 sheet metal screws
holding the door closed. Upon initial opening of the dooL these
screws may be removed and discarded. The door is then held
shut by the filter access door, which closes over it.

Four external hinged access doors are provided. All extern;d
doors _ue provided with 2 large 1/4 turn latches with folding
bail-type handles. (Compressor access doors have one latch.) A
single door is provided for filter and drive 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 dool: Two doors are provided for access to the compressor compartment.

SEE
"C"

I
I

•

@ @

I
I

48TJD016

,@
I
I

o(_o

48TJD020-028

AND 48TJF016

o_o
@

48TJ F020-028

SPARK GAP .120" TO .140"

DETAIL "C"
Fig. 57 -- Spark

Gap
44

Adjustment

_RK

IAP

.181"

SCHEMATIC

CAP_

CAP2gff__

gg£

OrMZ

o_
IFC

A_TO

ORN_.._

4
I
I
I

,<]
D

......

[

12® -

y_4t

J®

._
_

....

,
ore

GROUNOZO
?_RU STAWO0_

-k_:,
°AUTO

IELD

THERMOSTAT
.......

"X_,'_

___t_tu

K |

O_C,p,wr_P"

TO _CONO"IZ_R O_IIO"/_CC_SSOR_

gCONOI_IZER

OPTIOR/aCCZSSO_y

L _ _o,,-<_o. /
RD

PL1-12

Fig. 58 -- Typical Wiring Schematic (48TJ016, 208/230-V Shown)
45

COMPONENT ARRANGEMENT
CONTROL

BOX

LEO
®@@

IG¢

1©

GAS

SECTION

II--_LK
BtK

•II..
Iii
ii__
IIII
OFMI , 2,3
_Lt,R

2v
[_pt p_

o_,

--I

I II.=,

_Ov

_x_

[ .........
80AeO

_1011

[]_"

,IOli
,1Oll
,IOll

PL_

Fig. 59 -- Typical Component

Arrangement (48TJ016 Unit Shown)

LEGEND AND NOTES FOR FIG. 58 AND 59
LEGEND
AHA
-BKR W/AT -C
-CAP
-CB
-CC
-CLO
--

Adjustable, Heat Anticipator
Breaks with Amp Turns
Contactor, Compressor
Capacitor
Circuit Breaker
Cooling Compensator
Compressor Lockout

SN
TB
TC
TH
TRAN

COMP
DM
DU
EQUIP
FPT

------

Compressor Motor
Damper Motor
Dummy Terminal
Equipment
Freeze Protection Thermostat

FU
GND
HPS
IAQ
IDM
IFM
IGC
L
LED
LPS
LS
MGV
NEC
OAT

---------------

Fuse
Ground
High-Pressure Switch
Indoor Air Quality Sensor
Induced-Draft Motor
Indoor-Fan Motor
Integrated Gas Unit Controller
Light
Light Emitting Diode
Low-Pressure Switch
Limit Switch
Main Gas Valve
National Electrical Code
Outdoor Air Temperature Sensor

OCCUP
OFC

---

Occupancy Sensor
Outdoor-Fan Contactor

RAT Accessory

OFM
PL
PMR
QT
RAT
RS

-------

Outdoor-Fan Motor
Plug Assembly
Phase Monitor Relay
Quadruple Terminal
Return Air Temperature
Rollout Switch

Low Ambient Lockout Switch

------

Sensor
Terminal Block
Thermostat Cooling
Thermostat Heating
Transformer
Terminal (Marked)

O
_

Terminal (Unmarked)
Terminal Block

•

Splice
Factory Wiring

_ m--

Field Control Wiring
Accessory or Optional Wiring

......m_

To indicate common potential only;
not to represent wiring.

_
_

Economizer

Motor

Remote POT Field Accessory
OAT Sensor

Disch Air Sensor
Sensor

Sensor

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. TRAN1 is wired for 230-v operation. If unit is 208 v, disconnect the black wires from the ORN TRAN
wire and reconnect to the RED TRAN wire. Apply wirenuts to wires.
4. CB1,2 Must Trip Amps are equal to or less than 156% FLA. IFCB 140%.
5. The CLO locks out the compressor to prevent short cycling on compressor overload and safety devices;
before replacing CLO check these devices.
6. Jumpers are omitted when unit is equipped with economizer.
7. Number(s) indicates the line location of used contacts. A bracket over (2) numbers signifies a single
pole, double throw contact. An underlined number signifies a normally closed contact. Plain (no line)
number signifies a normally open contact.
8. Remove jumper between RC and RH.
9. 620 Ohm, 1 watt, 5% resistor should be removed only when using differential enthalpy or dry bulb.
10. If a separate field-supplied 24 v transformer is used for the IAQ sensor power supply, it cannot have the
secondary of the transformer grounded.
11. OAT sensor is shipped inside unit and must be relocated in the field for proper operation.
12. 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.

TROUBLESHOOTING

Unit Troubleshooting-

Refer to Tables

27-29

should turn on. The actuator should &ive 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. Tile actuator should
drive fully closed.
6. Turn the DCV and Exhaust potentiometers
CCW until
the Exhaust LED turns on. The exhaust contacts will
close 30 to 120 seconds after the Exhaust LED turns on.
7. Return EconoMi$erIV
settings and wiring to normal
after completing troubleshooting.
DCV MINIMUM AND MAXIMUM POSITION -- To check
the DCV minimum and maximum position:

and

Fig. 60.

EconoMi$erlV

Troubleshooting--

See Table 30

for EconoMi$erlV
logic.
A limctional view of the EconoMiSerlV is shown in Fig. 61.
Typic_d settings, sensor ranges, and jumper positions ale also
shown. An EconoMiSerIV simulator program is available from
Ctuder to help with EconoMi$erIV training and troubleshooting.
ECONOMISERIV
PREPARATION
-- This procedure
is
used to prepare the EconoMiSerIV
for troubleshooting.
No
troubleshooting or testing is done by performing the following
procedure.
NOTE: This procedure requires a 9-v battery, 1.2 kilo-ohm
resistol, and a 5.6 kilo-ohln resistor which are not supplied
with the EconoMiSerlV.

1. Make sure EconoMiSerIV
preparation
procedure
has
been perforlned.
2. Connect a 9-v battery to AQ (positive node) and AQI
(negative node). The DCV LED should turn on. The
actuator should drive to between 90 and 95% open.
3. Turn the DCV Maximum Position potentiometer to midpoint. The actuator should drive to between 20 and 80%
open.
4. Turn the DCV Maximum Position potentiometer to lidly
CCW. The actuator should drive fully closed.
5. Turn the Minimum Position potentiometer
to midpoint.
The actuator should drive to between 20 and 80% open.
6. Turn the Minimum Position Potentiometer lully CW. The
actuator should drive fully open.
7. Remove the jumper from TR and N. The actuator should
drive fully closed.
8. Return EconoMiSerIV
settings and wiring to norm¢fl
after completing troubleshooting.

[ tiometers
IMPORTANT:
before Be
starting
sure totroubleshooting.
record the positions of aH poten- ]
1. Disconnect power at TR and TRI. All LEDs should be
off. Exhaust fan contacts should be open.
2. Disconnect device at P and PI.
3.
4.

Jumper P to PI.
Disconnect wires at T and TI. Place 5.6 kilo-ohm resistor
across T and TI.

5.
6.
7.

Jumper TR to 1.
Jumper TR to N.
If connected, remove sensor from termimds So and +.
Connect 1.2 kilo-ohm 4074EJM checkout resistor across
terminals So and +.
8. Put 620-ohm resistor across terminals SR and +.
9. Set minimum position, DCV set point, and exhaust
potentiometers fully CCW (counteMockwise).
10. Set DCV maximum
position potentiometer
fully CW
(clockwise).
11. Set enthalpy potentiometer to D.
12. Apply power (24 vac) to terminals TR and TRI.
DIFFERENTIAL
ENTHALPY-To check
differential
enthalpy:
1. Make sure EconoMiSerIV
prep_uation procedure has
been performed.
2. Place 620-ohm resistor across So and +.
3. Place 1.2 kilo-ohm resistor across SR and +. The Free
Cool LED should be lit.
4. Remove 620-ohm resistor across So and +. Tile Free
Cool LED should turn off.
5. Return EconoMiSerIV
settings and wiring to normal
after completing troubleshooting.
SINGLE ENTHALPY
-- To check single enthalpy:
1. Make sure EconoMiSerIV
prepmation
procedure has
been performed.
2. Set the enthalpy potentiometer
to A (fully CCW). The
Free Cool LED should be lit.

SUPPLY-AIR [NPUT -- To check supply-air input:
1. Make sure EconoMiSerIV
preparation
procedure
has
been performed.
2. Set the Enthalpy potentiometer to A. The Free Cool LED
turns on. The actuator should drive to between 20 and
80% open.
3. Remove the 5.6 kilo-ohm lesistor and jumper T to TI.
The actuator should drive fidly open.
4. Remove the jumper across T and TI. The actuator should
drive fully closed.
5. Return EconoMiSerlV
settings and wiring to normal
after completing troubleshooting.
ECONOMISER
IV TROUBLESHOOTING
COMPLETION -- Tiffs procedure is used to return the EconoMiSerIV
to operation. No troubleshooting or testing is done by performing the following procedure.
1. Disconnect power at TR and TRI.
2. Set enthalpy potentiometer to previous setting.
3. Set DCV maximum position potentiometer
to previous
setting.
4. Set minimum position, DCV set point, and exhaust
potentiometers to previous settings.
5. Remove 620-ohm resistor fix_m terminals SR and +.
6. Remove 1.2 kilo-ohln checkout resistor from terminals So
and +. If used, reconnect sensor fix_m terminals So and +.
7. Remove jumper from TR to N.
8. Remove jumper from TR to 1.
9. Remove 5.6 kilo-ohm resistor from T and TI. Reconnect
wires at T and TI.
10. Remove jumper from P to PI. Reconnect device at P and
PI.
11. Apply power (24 vac) to termimds TR and TRI.

Set the enth_flpy potentiometer to D (fully CW). The Free
Cool LED should turn off.
4. Return EconoMiSerlV
settings and wiring to normal
after completing troubleshooting.
DCV (Demand
Controlled
Ventilation)
AND POWER
EXHAUST -- To check DCV and Power Exhaust:
1. Make sure EconoMiSerIV
prepmation
procedure has
been performed.
2. Ensure terminals AQ and AQI _ue open. The LED for
both DCV and Exhaust should be off. The actuator
should be fldly closed.
3. Connect a 9-v battery to AQ (positive node) and AQI
(negative node). The LED for both DCV and Exhaust
48

Table 27 -- Cooling
PROBLEM

CAUSE

Compressor
and
Condenser Fan
Will Not Start.

REMEDY

Power failure.
Fuse blown or circuit breaker tripped.
Defective thermostat,
relay.
Insufficient

Compressor
Will Not
Start but Condenser Fan
Runs.

Compressor
Cycles
(other than normally
satisfying thermostat).

Call power company.
Replace fuse or reset circuit breaker.

contactor, transformer,

line voltage.

Excessive
Pressure.

Head

Determine cause and correct.
Check wiring diagram and rewire correctly.
Lower thermostat setting below room temperature.

setting too high.

Three phase power incorrectly connected (sizes 016 and
020 only). Indicated by flashing red LED on Phase Monitor Relay (PMR) board (see Control Box Component
Arrangement for location).

Correct field power phasing.

Faulty wiring or loose connections in compressor circuit.
Compressor motor burned out, seized, or internal overload open.

Check wiring and repair or replace.
Determine cause. Replace compressor.

Defective overload.

Determine cause and replace.

Compressor

Determine cause for safety trip and reset lockout.

locked out

One leg of 3-phase power dead.

Replace fuse or reset circuit breaker.
Determine cause.

Refrigerant

Defective compressor.

Recover refrigerant, evacuate system, and recharge
to nameplate.
Replace and determine cause.

Insufficient line voltage.
Blocked condenser.

Determine cause and correct.
Determine cause and correct.

Defective overload.

Determine cause and replace.

overcharge or undercharge.

Excessive
Pressure.

Suction
Low.

Too Low.

Suction

Pressure

Too

Replace thermostat.
motor.

Replace.

Restriction in refrigerant system.

Locate restriction and remove.

Dirty air filter.
Unit undersized for load.

Replace filter.
Decrease load or increase unit size.

Thermostat

Reset thermostat.

set too low.

Low refrigerant charge.

Locate leak, repair, and recharge.

Air in system.

Recover refrigerant,

Condenser coil dirty or restricted.

Clean coil or remove restriction.

Dirty air filter.
Dirty condenser

Replace filter.
Clean coil.

Refrigerant

Head Pressure

coil.

overcharged.

evacuate system, and recharge.

Recover excess refrigerant.

Faulty TXV.

1. Check TXV bulb mounting and secure tightly to
suction line.
2. Replace TXV if stuck open or closed.

Air in system.

Recover refrigerant,

Condenser air restricted or air short-cycling.

Determine cause and correct.

Low refrigerant charge.

Check for leaks, repair, and recharge.

Restriction in liquid tube.

Remove restriction.

High heat load.
Faulty TXV.

Check for source and eliminate.
1. Check TXV bulb mounting and secure tightly to
suction line.
2. Replace TXV if stuck open or closed.

Refrigerant

Recover excess refrigerant.

overcharged.

evacuate system, and recharge.

Dirty air filter.
Low refrigerant charge.

Replace filter.
Check for leaks, repair, and recharge.

Metering device or low side restricted.

Remove source of restriction.

Faulty TXV.

1. Check TXV bulb mounting and secure tightly to
suction line.
2. Replace TXV if stuck open or closed.

Insufficient evaporator airflow.

Increase air quantity. Check filter and replace if
necessary.

Temperature too low in conditioned
Field-installed

area.

Reset thermostat.

filter drier restricted,

Replace.

LEGEND
TXV -- Thermostatic

Replace component.

Thermostat

Faulty condenser-fan
Operates

or control

Incorrect or faulty wiring.

Defective thermostat.

Compressor
continuously.

Service Analysis

Expansion Valve

Table 28 -- Heating Service Analysis
PROBLEM
Burners Will Not
Ignite.

CAUSE

REMEDY

Misaligned spark electrodes.

Check flame ignition and sensor electrode positioning.
Adjust as needed.

No gas at main burners.

Check gas line for air; purge as necessary. After purging
gas line of air, allow gas to dissipate for at least 5 minutes before attempting to relight unit.
Check gas valve.

Inadequate

Heating,

Water in gas line.

Drain water and install drip leg to trap water.

No power to furnace.
No 24 v power supply to control circuit.

Check power supply, fuses, wiring, and circuit breaker.
Check transformer. Transformers with internal overcurrent protection require a cool-down period before
resetting. Check 24-v circuit breaker; reset if necessary.

Miswired or loose connections.

Check all wiring and wire nut connections.

Burned-out heat anticipator
Broken thermostat wires.

Replace thermostat.

in thermostat.

Run continuity check. Replace wires if necessary.

Dirty air filter.

Clean or replace filter as necessary.

Gas input to unit too low.

Check gas pressure at manifold. Check gas meter for
input. If too low, increase manifold pressure or replace
with correct orifices.

Unit undersized for application.
Restricted airflow.

Poor Flame
Characteristics.

Replace with proper unit or add additional unit.
Clean filter, replace filter, or remove any restrictions.

Blower speed too low.

Install alternate motor, if applicable, or adjust pulley to
increase fan speed.

Limit switch cycles main burners.

Check rotation of blower, thermostat heat anticipator settings, and temperature rise of unit. Adjust as needed.

Too much outdoor air.

Adjust minimum position.

Incomplete combustion
results in:

(lack of combustion

Check economizer operation.
Check all screws around flue outlets and burner compartment. Tighten as necessary.

air)

Aldehyde odors, CO, sooting flame, or floating flame.

Cracked heat exchanger.
Overtired unit -- reduce input, change orifices, or adjust
gas line or manifold pressure.
Check vent for restriction. Clean as necessary.
Check orifice to burner alignment.

Burners Will Not Turn
Off.

Unit is locked into Heating mode for a one minute
minimum.

Table 29 -- MoistureMi$er
PROBLEM
Subcooler

Will Not Energize

Dehumidification

Will Not Deenergize

Service Analysis

CAUSE

REMEDY

Liquid line three-way valve will not operate.

Low System Capacity

Subcooler

No power to subcooler control transformer.
No power from subcooler control transformer
liquid line three-way valve.

Subcooler

Wait until mandatory one-minute time period has
elapsed or cycle power to unit.

Liquid line three-way valve will not close.
Low refrigerant charge or frosted coil.

Check power source. Ensure all wire connections
are tight.
to

1. Fuse open; check
2. Subcooler control
Cycle unit off and
to reset. Replace
3. Transformer bad;

fuse. Ensure continuity of wiring.
low-pressure switch open.
allow low-pressure switch
switch if it will not close.
check transformer.

1. Solenoid coil defective; replace.
2. Solenoid valve stuck closed; replace.
Valve is stuck open; replace.
1. Check charge amount. See system charging
section.
2. Evaporator coil frosted; check and replace
subcooler control low-pressure switch if necessary.

I_-INDO(:W_FANI)EI.AY
(HEATING)

2 _S

J___

--_

OFF

4 FI.ASI'E8 - LIW_ SWITCH
CYCLED 4 TIMES ON SINGLE
CALL FOR HEAT

(No _

wth_

15 _)

6 FI.ASHES- iNDUCED DRAFT
MOTOR FAULT
(NOsigr_ frem f_'_ _ !_t
8enm:,r
forB0 mKx_,es)

STeEr
I_TELY
OU113OOR
FAN MOTOR

I. I

, ,FOR iNDOOR FAN

I
I
I

7 _ ROLLCtrr- OPtENING
8_MICH OF

SOFTWARE

2. DEFECTIVE _V TRANS.
& BROKB_ V_IRE
, BLOWN 5 AMP FUSE

& NO POWB_ TO U_T

HEATING

'Wl' FROM BASE CONTROL
BOARD
ON IGC - 1 MINUTE LOCK-ON

ENERGIZES

'W'

RELAY ON _C B EN_

I
I
I

COOLING DEMAND

IGC BOARD

-SWRCH
OFmNING OF LIMff

3 _S
- _
81_813f1
IN_CATES FLAME WITH
CLOSED C:':':':':':':':':_
VALVE

YES

OUIDOOR F/M_ STOP
IMMEDIATELY

t,
EE--CT
8EN8OR SENDS
CORRECT
TO
'J f ON_L
K3C
_ _ B_N.o
ATCO_-CT
_ 81GNAL(AT
L_EA-_
_0.P_,

FAULT

9 FLASHES
LOCKOUT
- SOFTWARE
F LIMIT swrrcH AND ROLLOUT
9A,TI'CH ARE CLOSED, IGC _
LOGIC _
INITIATIE IGNITION
SEQUENCE

_I"ES

10,000 Vt3LT 8PN_K FO_ 5

VALVE FOR 5 SEONOS
_3c SAFEW LO_C OPENS GAS

OFF GAS VALVE AND sPARK
;GC SAFELY LOGIC WILL SHUT

Yes

H_S BEEN R_

D_J_ TO _

81/_TCH

_FrER_OONI_(O_LESS.:T_ETI_e
TRIPS)
tGC _MLL B_ERGIZE BLOWISR RELAY

SUBTRACT 5 S_CONDS (OR
5 _:CONDS)
FROM
_DOOR F_ ON TIME DE_AY

LEGEND

IGC -- Integrated Gas Unit Controller
NOTE: Thermostat
Fan Switch in the "AUTO"
position.

_,, s_.._Er_
(DELAY _

LO_C
_._rs OFF
_ VALVE

BY 5 880OND8 FOR ESE;H UMfr 8w_roH TRP
45 SECOND
MAXIMUMBLOWER
DELAY: SHUTOFF
3 MINLrlEs)DELAY

Fig. 60 -- IGC Control (Heating and Cooling)

I
I

Table 30 -- EconoMi$erlV

Input/Output

Logic

INPUTS
Demand Control
Ventilation (DCV)
Below set
(DCV LED Off)

Above set
(DCV LED On)

OUTPUTS

Enthalpy*
Outdoor

N Terminalt

Compressor
Return

Stage
1

High
(Free Cooling LED Off)

Low

On
On

On
Off

On
On

On
Off

Off

Low
(Free Cooling LED On)

High

On
On

On
Off

Off

On
On

High
(Free Cooling LED Off)

Low

Low
(Free Cooling LED On)

High

*For single enthalpy control, the module compares
enthalpy to the ABCD set point.
tPower at N terminal determines Occupied/Unoccupied
24 vac (Occupied), no power (Unoccupied).
**Modulation is based on the supply air sensor signal.
1-tModulation is based on the DCV signal.

Stage
2

Occupied

Unoccupied
Dam )er

Minimum position

Closed

Off
Off

Modulating** (between rain.
position and full-open)

Modulating** (between
closed and full-open)

Off

Minimum position

Closed

On
Off

On
On

On
Off

Modulating1-1- (between min.
position and DCV maximum)

Off

Modulatingtl(between
closed and DCV
maximum)

On
On

On
Off

Off
Off

Modulating***

Modulatingtl-t

Off

outdoor

***Modulation is based on the greater of DCV and supply air sensor
signals, between minimum position and either maximum position
(DCV) or fully open (supply air signal).
ttl-Modulation
is based on the greater of DCV and supply air sensor signals, between closed and either maximum position (DCV)
or fully open (supply air signal).

setting:

Fig. 61 -- EconoMiSerlV Functional View

INDEX
Altitude compensation
lO
Burner spark gap
44
Carrier Comfort Network@
Changeover set points
26
Charging chart, ret_igerant
Clearance
5, 6
CO2 sensor
Configuration
28
Settings
27, 29
Combustion blower wheel
Compressor
Lubrication
40
Mounting
31
Rotation
31
Concentric duct
Condensate drain
Cleaning
Location
Condenser

17
42

40
9, 10
coil
7

Cleaning
39
Condenser fan
7
Adjustment
42
Control circuit
Wiring
11
Convenience outlet
12
Crankcase heater
.31,43
Demand control ventilation
Dehumidification
29
Dimensions
3-6
Ductwork
9
EconoMiSerlV
23-29
Control mode
25

28'

Controller wiring
24
Demand ventilation control
Dry bulb changeover
25
Enthalpy sensor
26
Troubleshooting
4& .52
Usage
25
Wiring
24
EconoMi$er2
23, 24
Electrical connections
l]
Electrical data
13
Enthalpy changeover
Error codes
51

set points

Evaporator coil
7
Cleaning
39
Evaporator fan motor
Lubrication
40
Motor data
36
Mounting
41
Performance
32-34
Pulley adjustnlent
41
Pulley setting
7, 35
Speed
7
Filter
Cleaning
40
Size
8
Filter drier
43
Flue collector box

Flue gas passageways
40
Flue hood
9
Freeze protection thermostat
Gas connection
8

Gas input
8
Gas piping
11
Gas pressure
1, & 11
Heat anticipator settings
8, 11
High-pressure switch
8, 43
Hinged access doors
44
Horizontal adapter roof curb
2
Humidistat
29
Indoor air quality sensor
Integrated gas controller
Error codes
51

MoistureMiSer TM
dehumidification
29-31,3.5,42, 50
Motormaster@ I control
15
Motormaster V control 16
Mounting
Compressor
.31
Unit 2
Natnral gas 8,43
Non-fused disconnect
12
Operating limits 16
Operating sequence
36-38
Cooling
36
EconoMi$erlV
36, 37
EconoMi$er2 with
PremierLink TM control
37, 38'
Heating 36, 37
Outdoor air hocKt 14
Outdoor air temperature sensor 17,25
Outdoor air inlet screens
Cleaning
40
Dimensions
8
Physical data Z 8
Power supply
11
Wiring 11
PmmierLink controls
17-20
Pressure, drop
Economizer
35
MoistureMi$er
35
Pressure switches
High pressure 8
Low pressure
8
Refrigerant
Charge Z 42
Type 7
Refrigerant selwice ports 31
Replacement parts 43
Return air filter &36
Return air temperature sensor 26
Rigging unit 2, 4
Roof curb
Assembly
2
Dimensions
2, 3
Leveling tolerances 2, 3
Weight 7
Safety considerations
1
Ser_,ice .39-47
Start-up 31-38
Start-up checklist
CL-]
Supply-air temperature sensor
17, 25
Thermostat
12
Troubleshooting
48-.52
Weight
Corner .5,,5
EconoMi$erlV
5-7
Maximum
4
Unit 5-7
Wind baffle 15, 16
Wiring
EconoMiSerlV
24
EconoMi$er2
24
Humidistat 30
Non-fused disconnect
12
Power connections
l]
PremierLink
18,20
Thermostat
12
Unit 4.5,4'5

17
51

Liquid propane
10
Ix_w-pressure switch
8, 43
Main burners
40, 43
Manual outdoor air damper

SERVICE

Packaged Service Training programs tue an excellent
discussed in this manual, including:

TRAINING

way to increase your knowledge

• Unit Familiarization

• Maintenance

• [nstallation

• Opel_ting

Overview

A large selection of pl_duct, theory, and skills programs are available,
and materials. All include video and/or slides, plus companion book.

of the equipment

Sequence
using popular video-based

formats

Classroom
Service Training which includes "hands-on"
experience with the products in our labs can
mean increased confidence that really pays dividends in faster troubleshooting and fewer c_fllbacks. Course
descriptions and schedules tue in our catalog.
CALL
] Packaged

FOR FREE

CATALOG

Selvice Training

[

1-800-644-5544
] Classroom

Service Training

Copyright 2008 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications
Catalog No. 04-53480009-01

Printed in U.S.A.

or designs

Form 48TJ-22SI

without notice and without incurring obligations.
Pg 54

3-06

Replaces: 48TJ-21SI

START-UP

CHECKLIST

MODEL NO.:

SERIAL NO.:

DATE:

TECHNICIAN:

PRE-START-UP
[] VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
[] VERIFY INSTALLATION OF INDOOR FAN MOTOR ADJUSTMENT BOLT AND PLATE (48TJ020-028 ONLY)
[] VERIFY INSTALLATION OF OUTDOOR-AIR HOOD
[] VERIFY INSTALLATION OF FLUE HOOD AND WIND BAFFLE
[] VERIFY THAT CONDENSATE CONNECTION

IS INSTALLED PER INSTRUCTIONS

[] VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT
[] CHECK GAS PIPING FOR LEAKS
[] CHECK THAT FILTERS AND SCREENS ARE CLEAN AND IN PLACE
[] VERIFY THAT UNIT IS LEVEL
LU

[] CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE, AND VERIFY SETSCREW
IS TIGHT

z
c_

[] VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED

I--

[] VERIFY THAT SCROLL COMPRESSOR IS ROTATING IN THE CORRECT DIRECTION

[] VERIFY THAT CRANKCASE HEATER HAS BEEN ENERGIZED FOR 24 HOURS (SIZE 028 AND UNITS WITH
MOISTUREMISER T:'IDEHUMIDIFICATION SYSTEM ONLY)

o,
<
Io

START-UP
ELECTRICAL
SUPPLY VOLTAGE
COMPRESSOR

AMPS

LI-L2

L2-L3

L3-LI

COMPRESSOR NO. 1

COMPRESSOR NO. 2

SUPPLY FAN AMPS

EXHAUST FAN AMPS

TEMPERATURES
OUTDOOR-AIR TEMPERATURE
RETURN-AIR TEMPERATURE

F DB (Dry-Bulb)
F DB

COOLING SUPPLY AIR

GAS HEAT SUPPLY AIR

F WB (Wet-Bulb)

z
rm
LU

Ic_

PRESSURES

o,
GAS INLET PRESSURE
GAS MANIFOLD PRESSURE
REFRIGERANT SUCTION
REFRIGERANT DISCHARGE
[]

VERIFY

REFRIGERANT

<
I-

IN. WG
STAGE NO. 1

IN. WG

CIRCUIT

NO. 1

PSIG

CIRCUIT

NO. 1

PSIG

CHARGE

USING

CHARGING

CHART

STAGE NO. 2
CIRCUIT NO. 2
CIRCUIT NO. 2

IN. WG
PSIG
PSIG

ON PAGE 42.

GENERAL
[] ECONOMIZERMINIMUM VENT AND CHANGEOVERSETFINGS TO JOB REQUIREMENTS

Copyright 2006 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications
Book

1 14

Tab

1a 16a

Catalog No. 04-53480009-01

Printed in U.S.A.

or designs without notice and without incurring obligations.

Form 48TJ-22SI

Pg CL-1

3-06

Replaces: 48TJ-21Sl

Source Exif Data:
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Carrier 48Tj016 028 Users Manual

CARRIER Package Units(both units combined) Manual L0606341 CARRIER Package Units(both units combined) Owner's Manual, CARRIER Package Units(both units combined) installation guides

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