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Carrier 48FC 08-16 Series - User Manual

Carrier 48FC 08-16 Series
124 pages
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Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480332-01 Printed in U.S.A. Form 48FC-8-16-01SM Pg 1 11-23 Replaces: NEW
Service and Maintenance Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 2
UNIT ARRANGEMENT AND ACCESS . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 3
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SUPPLY FAN (BLOWER) SECTION . . . . . . . . . . . . . . 4
Supply Fan (Direct-Drive) . . . . . . . . . . . . . . . . . . . . . . 4
Staged Air Volume . . . . . . . . . . . . . . . . . . . . . . . . . . 13
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Condenser Coil Maintenance and Cleaning
Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . 13
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Evaporator Coil Metering Devices . . . . . . . . . . . . . . 15
THERMOSTATIC EXPANSION VALVE (TXV) . . . . . 15
TXV Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing TXV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Refrigerant System Pressure Access Ports . . . . . . 15
PURON (R-410A) REFRIGERANT . . . . . . . . . . . . . . . 16
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . 16
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replacing Compressor . . . . . . . . . . . . . . . . . . . . . . . 27
Compressor Rotation . . . . . . . . . . . . . . . . . . . . . . . . 27
Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Condenser-Fan Adjustment . . . . . . . . . . . . . . . . . . . 27
Troubleshooting Cooling System . . . . . . . . . . . . . . 28
CONVENIENCE OUTLETS . . . . . . . . . . . . . . . . . . . . 29
Convenience Outlets . . . . . . . . . . . . . . . . . . . . . . . . 29
Installing Weatherproof Cover . . . . . . . . . . . . . . . . . 29
Non-Powered Type . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Unit-Powered Type . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuse on Powered Type . . . . . . . . . . . . . . . . . . . . . . . 30
SMOKE DETECTORS . . . . . . . . . . . . . . . . . . . . . . . . 30
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Smoke Detector Sensor . . . . . . . . . . . . . . . . . . . . . . 30
Smoke Detector Locations . . . . . . . . . . . . . . . . . . . . 31
Completing Installation of Return Air Smoke
Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FIOP Smoke Detector Wiring and Response . . . . . 33
SENSOR AND CONTROLLER TESTS . . . . . . . . . . . 33
Sensor Alarm Test . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Controller Alarm Test . . . . . . . . . . . . . . . . . . . . . . . . 33
Dirty Controller Test . . . . . . . . . . . . . . . . . . . . . . . . .33
Dirty Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Changing the Dirt Sensor Test . . . . . . . . . . . . . . . . .34
Remote Station Test . . . . . . . . . . . . . . . . . . . . . . . . .34
SD-TRK4 Remote Alarm Test Procedure . . . . . . . .34
Remote Test/Reset Station Dirty Sensor Test . . . .34
Dirty Sensor Test Using an SD-TRK4 . . . . . . . . . . .35
Detector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
PROTECTIVE DEVICES . . . . . . . . . . . . . . . . . . . . . . .36
Compressor Protection . . . . . . . . . . . . . . . . . . . . . . .36
Relief Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Control Circuit, 24-V . . . . . . . . . . . . . . . . . . . . . . . . .37
GAS HEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . .38
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Fuel Types and Pressures . . . . . . . . . . . . . . . . . . . .38
Flue Gas Passageways . . . . . . . . . . . . . . . . . . . . . . .39
Combustion-Air Blower . . . . . . . . . . . . . . . . . . . . . . .39
Burners and Igniters . . . . . . . . . . . . . . . . . . . . . . . . .40
Burner Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Orifice Replacement . . . . . . . . . . . . . . . . . . . . . . . . .43
Troubleshooting Heating System . . . . . . . . . . . . . .45
SYSTEMVU CONTROL SYSTEM . . . . . . . . . . . . . . . .47
SystemVu Interface . . . . . . . . . . . . . . . . . . . . . . . . . .47
Additional SystemVu Installation and
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .47
ECONOMIZER SYSTEMS . . . . . . . . . . . . . . . . . . . . .48
EconoMi$er2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
EconoMi$er IV (Field-Installed Accessory) . . . . . . .50
EconoMi$er X (Factory-Installed Option) . . . . . . . .57
PRE-START-UP/START-UP . . . . . . . . . . . . . . . . . . . .68
START-UP, GENERAL . . . . . . . . . . . . . . . . . . . . . . . .69
Unit Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Additional Installation/Inspection . . . . . . . . . . . . . .69
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Return-Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Outdoor-Air Inlet Screens . . . . . . . . . . . . . . . . . . . . .70
Compressor Mounting . . . . . . . . . . . . . . . . . . . . . . .70
Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Refrigerant Service Ports . . . . . . . . . . . . . . . . . . . . .70
Compressor Rotation . . . . . . . . . . . . . . . . . . . . . . . .70
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Main Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Ventilation (Continuous Fan) . . . . . . . . . . . . . . . . . .71
FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . .71
START-UP, SYSTEMVU CONTROLS . . . . . . . . . . . .71
48FC**08-16
Single Package Rooftop Gas Heat/Electric Cooling Unit
with Puron
®
(R-410A) Refrigerant
7.5 to 15 Nominal Tons

Table of Contents

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Carrier 48FC 08-16 Series Specifications

General IconGeneral
BrandCarrier
Model48FC 08-16 Series
CategoryAir Conditioner
LanguageEnglish

Summary

SAFETY CONSIDERATIONS

UNIT OPERATION AND SAFETY HAZARD

Warning regarding system pressure and electrical components.

FIRE, EXPLOSION HAZARD

Warning about handling refrigerants and pressure testing.

WARNING ELECTRICAL OPERATION HAZARD

Warning about electrical hazards and lockout/tagout.

UNIT ARRANGEMENT AND ACCESS

General

Shows general unit arrangement and access locations.

Routine Maintenance

Items for monthly/quarterly checks and seasonal maintenance.

Filters

RETURN AIR FILTERS

Instructions for accessing and replacing disposable filters.

OUTSIDE AIR HOOD

Maintenance for permanent aluminum-mesh screens.

SUPPLY FAN (BLOWER) SECTION

Supply Fan (Direct-Drive)

Details about EcoBlue™ direct drive vane axial fan system.

EVALUATING MOTOR SPEED

SELECTING FAN SPEED

Instructions for setting fan speed via UCB.

Units with Electro-mechanical controls

Fan speed controls located on the Unit Control Board (UCB).

Units with SystemVu controls

SystemVu Interface

Keypad interface for accessing control information and testing.

Additional SystemVu Installation and Troubleshooting

Manual for further installation and troubleshooting info.

TROUBLESHOOTING THE ECM MOTOR

Troubleshooting the motor requires a voltmeter

Steps to troubleshoot ECM motor issues.

Removing the Motor and Fan Assembly

Removing the Motor and Fan Assembly

Procedure for disassembling the fan assembly.

Disassembling Standard;Medium Motor and Fan Assembly

Disassembling Standard;Medium Motor and Fan Assembly

Steps to take apart the fan assembly.

Disassembling High Static Motor and Fan Assembly

Disassembling High Static Motor and Fan Assembly

Steps to take apart the fan assembly.

Reassembly of Standard;Medium Motor and Fan Assembly

Reassembly of Standard;Medium Motor and Fan Assembly

Procedure for reassembling the fan assembly.

Reassembly of High Static Motor and Fan Assembly

Reassembly of High Static Motor and Fan Assembly

Procedure for reassembling the fan assembly.

Reinstalling Motor and Fan Assembly

Reinstalling Motor and Fan Assembly

Steps for installing the fan assembly back into the unit.

COOLING

Condenser Coil Maintenance and Cleaning Recommendation

Routine maintenance and cleaning procedures.

ROUTINE CLEANING OF COIL SURFACES

Use of specific coil cleaner and cleaning steps.

Totaline Environmentally Balanced Coil Cleaner Application Instructions

Evaporator Coil and Metering Devices

Cleaning the Evaporator Coil

Steps to clean the evaporator coil.

THERMOSTATIC EXPANSION VALVE (TXV)

Description of the TXV.

Replacing TXV

Step-by-step guide for replacing a TXV.

PURON (R-410 A) REFRIGERANT

Refrigerant Charge

Instructions for checking and adding refrigerant.

LOW-CHARGE COOLING

Using charts to charge the system for cooling.

USING COOLING CHARGING CHARTS

How to interpret cooling charging charts.

COOLING CHARGING CHARTS

7.5 Ton Entry Tier R-410 A Charging Chart

Chart for charging 7.5 Ton units.

10 Ton Entry Tier R-410 A Charging Chart

Chart for charging 10 Ton units.

15 Ton Entry Tier R-410 A Charging Chart

Chart for charging 15 Ton units.

COMPRESSOR

Compressor Rotation

Procedure to check and correct compressor rotation direction.

Condenser-Fan Adjustment

Steps to adjust fan height and tighten set screws.

PROTECTIVE DEVICES

Compressor Protection

Internal protection for compressor.

MIXED TEMPERATURE SENSOR

Sensor location and function.

HIGH PRESSURE SWITCH

High pressure switch mounted on discharge line.

PROTECTIVE DEVICES

LOW PRESSURE SWITCH

Switch protecting against loss of charge.

EVAPORATOR FREEZE PROTECTION

Temperature switch protecting against coil frosting.

SUPPLY (INDOOR) FAN MOTOR PROTECTION

Safety relay protecting the fan motor.

GAS HEATING SYSTEM

General

Description of the heat exchanger system and safety switches.

Fuel Types and Pressures

Information on gas types and required pressures.

Burners and Igniters

MAIN BURNERS

Inspection of main burners for deterioration or blockage.

REMOVAL AND REPLACEMENT OF GAS TRAIN

REMOVAL AND REPLACEMENT OF GAS TRAIN

Steps to remove and replace the gas train.

REMOVING THE HEAT EXCHANGER

REMOVING THE HEAT EXCHANGER

Steps to remove the heat exchanger from the unit.

GAS VALVE

CHECK UNIT OPERATION AND MAKE NECESSARY ADJUSTMENTS

Steps to adjust gas valve pressure settings.

Burner Ignition

Burner Ignition

System description for direct spark ignition.

SYSTEMVU CONTROL SYSTEM

SystemVu Interface

Keypad interface for accessing control information and testing.

Additional SystemVu Installation and Troubleshooting

Manual for further installation and troubleshooting info.

ECONOMIZER SYSTEMS

EconoMi$er X

Factory-installed economizer system with logic control.

EconoMi$er IV

Field-installed economizer system with logic control.

EconoMi$er2

Economizer system without a control system.

EconoMi$er IV (Field-Installed Accessory)

ECONOMISER IV STANDARD SENSORS

Information on standard sensors used with the EconoMi$er IV.

Outdoor Air Temperature (OAT) Sensor

Outdoor Air Temperature (OAT) Sensor

Measures outdoor air temperature for free cooling.

Supply Air Temperature (SAT) Sensor

Supply Air Temperature (SAT) Sensor

Measures supply air temperature for economizer control.

EconoMi$er IV CONTROL MODES

Outdoor Dry Bulb Changeover

Control mode using outdoor dry bulb temperature.

Outdoor Enthalpy Changeover

Control mode using outdoor air enthalpy.

Differential Enthalpy Control

Control mode comparing outdoor and return air enthalpy.

Indoor Air Quality (IAQ) Sensor Input

Indoor Air Quality (IAQ) Sensor Input

Used for demand controlled ventilation based on CO2 levels.

Demand Controlled Ventilation (DCV)

Demand Controlled Ventilation (DCV)

Using DCV for ventilation requirements.

DCV (DEMAND CONTROLLED VENTILATION) AND POWER EXHAUST

DCV (DEMAND CONTROLLED VENTILATION) AND POWER EXHAUST

Procedure to check DCV and power exhaust.

DCV MINIMUM AND MAXIMUM POSITION

DCV MINIMUM AND MAXIMUM POSITION

Checking DCV minimum and maximum damper positions.

EconoMi$er X (Factory-Installed Option)

PRODUCT DESCRIPTION

Expandable economizer control system with W7220 module.

SYSTEM COMPONENTS

Overview of system components.

Economizer Module

The core module providing economizer control functionality.

SPECIFICATIONS

User Interface

Provides status, parameters, and testing via LCD and keypad.

INPUTS

Section detailing system inputs.

Sensors

Details on required and optional sensors like MA, OA, RA.

S-BUS SENSOR WIRING

S-BUS SENSOR WIRING

Wiring sensors using color-coded terminals.

CO2 SENSOR WIRING

CO2 SENSOR WIRING

Wiring diagram and notes for the CO2 sensor.

INTERFACE OVERVIEW

Keypad and menu navigation

Navigating menus using keypad buttons.

USER INTERFACE

USER INTERFACE

Description of the 2-line LCD and 4-button keypad.

Setup and Configuration

Setup and Configuration

Steps to configure the economizer module for the system.

STATUS

STATUS

Displays current operating status parameters.

SETPOINTS

SETPOINTS

Configuration parameters for economizer operation.

SYSTEM SETUP

SYSTEM SETUP

Options for configuring system parameters.

ADVANCED SETUP

ADVANCED SETUP

Advanced configuration options for the economizer.

CHECKOUT

CHECKOUT

Procedures for testing system components.

ALARMS

ALARMS

Displays active alarms and error conditions.

Enthalpy Settings

Enthalpy Settings

Boundaries for economizing based on enthalpy.

2 Speed Fan Operation

2 Speed Fan Operation

How the W7220 controls OA damper based on fan speed.

PRE-START-UP;START-UP

PRE-START-UP;START-UP

Safety and procedural warnings for start-up.

START-UP, GENERAL

Unit Preparation

Ensuring unit is installed per instructions and codes.

Compressor Rotation

Compressor Rotation

Procedure to determine correct rotation direction.

Cooling

Cooling

Steps to start the unit in cooling mode.

Heating

Heating

Steps to operate the unit in heating mode.

Ventilation (Continuous Fan)

Ventilation (Continuous Fan)

Evaporator fan operates continuously.

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES

Table of torque values for fasteners.

APPENDIX A - MODEL NUMBER NOMENCLATURE

Cooling Tons

Indicates the cooling capacity in tons.

Heat Options

Details heat options and exchanger types.

Intake; Exhaust Options

Specifies economizer and airflow options.

APPENDIX B - PHYSICAL DATA

EVAPORATOR FAN AND MOTOR

Fan and motor specifications.

CONDENSER FAN AND MOTOR

Condenser fan and motor specifications.

APPENDIX C - GAS HEAT DATA

Natural Gas Heat

Gas heat data for natural gas.

Liquid Propane Heat

LP gas heat data.

APPENDIX D - FAN PERFORMANCE

GENERAL FAN PERFORMANCE NOTES

General notes on fan performance data and EPACT regulations.

48 FCFM08 - 7.5 Ton Vertical Supply (rpm - bhp)

48 FCFM08 - 7.5 Ton Vertical Supply (rpm - bhp)

Fan performance data for 7.5 Ton vertical supply (rpm/bhp).

48 FCFM08 - Standard;Medium Static - 7.5 Ton Vertical Supply (rpm - vdc)

48 FCFM08 - Standard;Medium Static - 7.5 Ton Vertical Supply (rpm - vdc)

Fan performance data for 7.5 Ton vertical supply (rpm/vdc).

48 FCFM09 - 8.5 Ton Vertical Supply (rpm - bhp)

48 FCFM09 - 8.5 Ton Vertical Supply (rpm - bhp)

Fan performance data for 8.5 Ton vertical supply (rpm/bhp).

48 FCFM09 - Standard;Medium Static - 8.5 Ton Vertical Supply (rpm - vdc)

48 FCFM09 - Standard;Medium Static - 8.5 Ton Vertical Supply (rpm - vdc)

Fan performance data for 8.5 Ton vertical supply (rpm/vdc).

48 FCFM12 - 10 Ton Vertical Supply (rpm - bhp)

48 FCFM12 - 10 Ton Vertical Supply (rpm - bhp)

Fan performance data for 10 Ton vertical supply (rpm/bhp).

48 FCFM12 - Standard;Medium Static - 10 Ton Vertical Supply (rpm - vdc)

48 FCFM12 - Standard;Medium Static - 10 Ton Vertical Supply (rpm - vdc)

Fan performance data for 10 Ton vertical supply (rpm/vdc).

48 FCFM14 - 12.5 Ton Vertical Supply (rpm - bhp)

48 FCFM14 - 12.5 Ton Vertical Supply (rpm - bhp)

Fan performance data for 12.5 Ton vertical supply (rpm/bhp).

48 FCFM14 - Standard;Medium Static - 12.5 Ton Vertical Supply (rpm - vdc)

48 FCFM14 - Standard;Medium Static - 12.5 Ton Vertical Supply (rpm - vdc)

Fan performance data for 12.5 Ton vertical supply (rpm/vdc).

48 FCFM16 - 15 Ton Vertical Supply (rpm - bhp)

48 FCFM16 - 15 Ton Vertical Supply (rpm - bhp)

Fan performance data for 15 Ton vertical supply (rpm/bhp).

48 FCFM16 - Standard;Medium Static - 15 Ton Vertical Supply (rpm - vdc)

48 FCFM16 - Standard;Medium Static - 15 Ton Vertical Supply (rpm - vdc)

Fan performance data for 15 Ton vertical supply (rpm/vdc).

APPENDIX E - WIRING DIAGRAMS

48 FC*08-16 - Wiring Diagrams - Standard SCCR

Wiring diagrams for standard SCCR units.

48 FC*08-16 - Wiring Diagrams - High SCCR

Wiring diagrams for high SCCR units.

Fig. B - Typical Control Wiring Diagram - 48 FC**08-12 208;230, 460, 575-3-60 Unit with Electro-Mechanical Control and W7220 Economizer - Standard and High SCCR

Fig. H - Typical Power Wiring Diagram - 48 FC**08-12 208;230, 460-3-60 Unit with Electro-Mechanical or W7220 Controllers - Standard SCCR

APPENDIX F - LOW AMBIENT CONTROL SENSOR LOCATION

7.5 Ton Outdoor Circuiting

Sensor location for 7.5 Ton outdoor units.

8.5 Ton to 10.0 Ton Outdoor Circuiting

Sensor location for 8.5-10 Ton outdoor units.

15.0 Ton Outdoor Circuiting

Sensor location for 15 Ton outdoor units.

START-UP CHECKLIST

II. PRE-START-UP

Checklist for verifying unit readiness before start-up.

III. START-UP

Procedures for initial unit start-up.

ELECTRICAL

Steps to check electrical connections and readings.

IV. HUMIDI-MIZER SYSTEM START-UP

STEPS

Steps to start the Humidi-MiZer system in cooling mode.

OBSERVE AND RECORD

Section to record observed pressure and temperature data.

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