Carrier 48TC 04 Series Installations- und Benutzerhandbuch

Service and Maintenance Instructions

48TC**04 --- 16

Nominal 3 to 15 Tons

with Puron(R---410A) Refrigerant

TABLE OF CONTENTS

SAFETY CONSIDERATIONS 1....................

UNIT ARRANGEMENT AND ACCESS 3...........

ROUTINE MAINTENANCE 3.....................

SUPPLY FAN (BLOWER) SECTION 6..............

STAGED AIR VOLUME CONTROL (SAV) -- 2 SPEED

FAN WITH VARIABLE FREQUENCY

DRIVE (VFD) 7.................................

ADDITIONAL VARIABLE FREQUENCY DRIVE

(VFD) INSTALLATION AND TROUBLESHOOTING. 8

SUPPLY FAN MOTOR 8..........................

COOLING 10...................................

EVAPORATOR COIL METERING DEVICES 13......

PURONR(R--410A) REFRIGERANT 16.............

COOLING CHARGING CHARTS 21................

COMPRESSOR 34...............................

CONVENIENCE OUTLETS 36....................

SMOKE DETECTORS 37.........................

SENSOR AND CONTROLLER TESTS 41...........

INDICATORS 43................................

PROTECTIVE DEVICES 44.......................

GAS HEATING SYSTEM 45......................

PREMIERLINKCONTROL 62...................

RTU--OPEN CONTROL SYSTEM 62................

SENSORY/ACCESSORY INSTALLATION 63........

HUMIDI--MIZER ADAPTIVE DEHUMIDIFICATION

SYSTEM 64....................................

ECONOMIZER SYSTEMS 78.....................

PRE--START--UP 87..............................

START--UP, GENERAL 87........................

START--UP, PREMIERLINKCONTROLS 90.......

START--UP, RTU--OPEN CONTROLS 90............

FASTENER TORQUE VALUES 90.................

APPENDIX I. PHYSICAL DATA 91................

APPENDIX II. FAN PERFORMANCE 97............

APPENDIX III. WIRING DIAGRAMS 111...........

APPENDIX IV. MOTORMASTER SENSOR

LOCATIONS 149................................

UNIT START-UP CHECKLIST 151.................

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment

can be hazardous due to system pressure and electrical

components. Only trained and qualified service personnel

should install, repair, or service air-conditioning

equipment. Untrained personnel can perform the basic

maintenance functions of replacing filters. Trained service

personnel should perform all other operations.

When working on air-conditioning equipment, observe

precautions in the literature, tags and labels attached to

the unit, and other safety precautions that can 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.

Follow all safety codes. Wear safety glasses and work

gloves. Use quenching cloth for brazing operations. Have

fire extinguisher available. Read these instructions

thoroughly and follow all warnings or cautions attached to

the unit. Consult local building codes and National

Electrical Code (NEC) for special requirements.

Recognize safety information. This is the safety--ALERT

symbol . When you see this symbol on the unit and in

instructions or manuals, be aware of the potential for

physical injury hazards.

Understand the signal words DANGER,WARNING,and

CAUTION. These words are used with the

safety--ALERT symbol. DANGER indicates a hazardous

situation which, if not avoided, will result in death or

severe personal injury. WARNING indicates a hazardous

situation which, if not avoided, could result in death or

personal injury. CAUTION indicates a hazardous

situation which, if not avoided, could result in minor to

moderate injury or product and property damage.

NOTICE is used to address practices not related to

physical injury. NOTE is used to highlight suggestions

which will result in enhanced installation, reliability, or

operation.

IMPORTANT:Lockout/Tagout is a term used when

electrical power switches are physically locked

preventing power to the unit. A placard is placed on

the power switch alerting service personnel that the

power is disconnected.

CUT HAZARD

Failure to follow this caution can result in personal

injury.

Sheet metal parts can have sharp edges or burrs. Use

care and wear appropriate protective clothing, safety

glasses and gloves when handling parts and servicing

air conditioning units.

CAUTION

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal

injury or death.

Before performing service or maintenance operations

on unit, LOCK--OUT/TAGOUT the main power

switch to unit. Electrical shock and rotating equipment

could cause severe injury.

!WARNING

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal

injury or death.

Units with convenience outlet circuits can use

multiple disconnects. Check convenience outlet for

power status before opening unit for service. Locate

the disconnect switch and lock it in the open position

it. LOCK--OUT/TAGOUT this switch to notify others.

!WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personal

injury, death and/or equipment damage.

Puron (R--410A) refrigerant systems operate at higher

pressures than standard R--22 systems. Do not use

R--22 service equipment or components on Puron

refrigerant equipment.

!WARNING

UNIT DAMAGE HAZARD

Failure to follow this caution may result in reduced

unit performance or unit shutdown.

High velocity water from a pressure washer, 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.

CAUTION

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal

injury, death and/or property damage.

Disconnect gas piping from unit when pressure testing

at pressure greater than 0.5 psig. Pressures greater

than 0.5 psig will cause gas valve damage resulting in

hazardous 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).

!WARNING

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal

injury, death and/or property damage.

Never use air or gases containing oxygen for leak

testing or for operating refrigerant compressors.

Pressurized mixtures of air or gases containing oxygen

can lead to an explosion.

!WARNING

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal

injury, death and/or property damage.

Never use non--certified refrigerants in this product.

Non--certified refrigerants could contain contaminates

that could lead to unsafe operating conditions. Use

ONLY refrigerants that conform to AHRI Standard

700.

!WARNING

48TC

UNIT ARRANGEMENT AND ACCESS

General

Fig. 1 and Fig. 2 show the general unit arrangement and

access locations.

OUTDOOR-AIR OPENING

AND INDOOR COIL

ACCESS PANEL

COMPRESSOR

ACCESS PANEL

(04 - 07 only)

FILTER ACCESS

PANEL

C08449

Fig. 1 -- Typical Access Panel Locations

BLOWER

ACCESS

PANEL

FLUE

OPENING

CONTROL

BOX

COMPRESSOR

(08-12 only)

C08450

Fig. 2 -- Blower Access Panel Location

ROUTINE MAINTENANCE

The following items should be part of a routine

maintenance program and should to be checked every

month until a specific schedule for each can be identified

for this installation:

Quarterly Inspection (& 30 days after initial start)

SReplace return air filter

SClean outdoor hood inlet filters

SCheck belt tension

SCheck belt condition

SCheck pulley alignment

SCheck fan shaft bearing locking collar tightness

SCheck condenser coil for cleanliness

SCheck condensate drain

Seasonal Maintenance

The following items should be checked at the beginning

of each season (or more often if local conditions and

usage patterns dictate):

Air Conditioning

SEnsure condenser fan motor mounting bolts are tight

SEnsure compressor mounting bolts are tight

SCondenser fan blade positioning

SInspect control box for cleanliness and wiring condition

SEnsure wire terminal are tight

SCheck refrigerant charge level

SClean evaporator coil

SCheck evaporator blower motor amperage

Heating

SEnsure heat exchanger flue passageways are clean

SInspect gas burner condition

SCheck gas manifold pressure

SHeating temperature rise

Economizer or Outside Air Damper

SInspect condition of inlet filters

SCheck damper travel (economizer)

SCheck gear and dampers for debris and dirt

Air Filters and Screens

Each unit is equipped with return air filters. If the unit has

an economizer, it will also have an outside air screen. If a

manual outside air damper is added, an inlet air screen

will also be present.

All filters and screens will need to be periodically cleaned

or replaced.

Return Air Filters

Return air filters are a disposable fiberglass media type.

Access to the filters is through the small lift--out panel

located on the rear side of the unit, above the

evaporator/return air access panel. See Fig. 1.

48TC

PERSONAL INJURY HAZARD

Failure to follow this caution may result in premature

wear and damage to equipment.

Dirt and debris can collect on heat exchangers and

coils and can cause excessive current used resulting in

motor failure.

CAUTION

IMPORTANT: DO NOT OPERATE THE UNIT

WITHOUT THESE FILTERS!

Removing the Return Air Filters:

1. Grasp the bottom flange of the upper panel.

2. Lift up and swing the bottom out until the panel dis-

engages and pulls out.

3. Reach inside and remove the filters from the filter

rack.

4. Replace these filters, as required, with filters of

same size and media type.

Reinstalling the Access Panel:

1. Slide the top of the panel up under the unit’s top

panel.

2. Slide the bottom flange into the side channels.

3. Push the bottom flange down until it contacts the top

of the lower panel (or economizer top).

Outside Air Hood

Outside air hood inlet screens are permanent aluminum

mesh--type filters. Check screens for cleanliness. Remove

the screens when cleaning is required. Clean by washing

with hot low--pressure water and soft detergent. Replace

all screens before restarting the unit. Observe the flow

direction arrows on the side of each filter frame when

installing.

Economizer Inlet Air Screen

This air screen is retained by filter clips under the top

edge of the hood. See Fig. 3.

CLEANABLE

ALUMINUM

SCREEN

HOOD

FILTER

CLIP

OUTSIDE

AIR

BAROMETRIC

RELIEF

DIVIDER

17 1/4”

(438 mm)

C06027

Fig. 3 -- Inlet Air Screen Installation

Remove the screen by opening the filter clips. Re--install

the filter by placing the screen in its track, then closing

the filter clips.

Manual Outside Air Hood Screen

This inlet screen is secured by a retainer angle across the

top edge of the hood. See Fig. 4.

Remove the screen by loosening the screws in the top

retainer and sliding the retainer up until the filter can be

removed. Reinstall by placing the frame in its track,

rotating the retainer back down and tightening all screws.

C07156

Fig. 4 -- Screens Installed on Outdoor--Air Hood

(Sizes 7--1/2 to 15 Tons Shown)

48TC

MODEL NOMENCLATURE

Coil Options For Round Tube/Plate Fin Condenser Coil Models Only (outdoor-

indoor-hailguard)

A = Al/Cu - Al/Cu

B = Precoat Al/Cu - Al/Cu

C = E-coat Al/Cu - Al/Cu

D = E-coat Al/Cu - E-coat Al/Cu

E = Cu/Cu - Al/Cu

F = Cu/Cu - Cu/Cu

M = Al/Cu - Al/Cu – Louvered Hail Guards

N = Precoat Al/Cu - Al/Cu – Louvered Hail Guards

P = E-coat Al/Cu - Al/Cu – Louvered Hail Guards

Q = E-coat Al/Cu - E-coat Al/Cu – Louvered Hail Guards

R = Cu/Cu - Al/Cu – Louvered Hail Guards

S = Cu/Cu - Cu/Cu – Louvered Hail Guards

Coil Options For All Aluminum – Novation Condenser Coil Models Only

(outdoor-indoor-hailguard)

G = Al/Al – Al/Cu

H = Al/Al – Cu/Cu

J = Al/Al – E-coat Al/Cu

K = E-coat Al/Al – Al/Cu

L = E-coat Al/Al – E-coat Al/Cu

T = Al/Al – Al/Cu, Louvered Hail Guards

U = Al/Al – Cu/Cu, Louvered Hail Guards

V = Al/Al – E-coat Al/Cu, Louvered Hail Guards

W = E-coat Al/Al – Al/Cu, Louvered Hail Guards

X = E-coat Al/Al – E-coat Al/Cu, Louvered Hail Guards

4 8 T C D A 0 4 A 1 A 5 - 0 A 0 A 0

Unit Heat Type

48 – Gas Heat

Packaged

Rooftop

Series/Model

TC – Standard Efficiency

Heat Size

D – Low heat

E – Medium Heat

F – High Heat

L – Low NO

, Low Heat

M – Low NO

, Medium Heat

N – Low NO

, High Heat

S – Stainless Steel, Low Heat

R – Stainless Steel, Medium Heat

T – Stainless Steel, High Heat

Refrig. Systems Options

A - Standard One Stage Cooling Models

B – Standard One Stage Cooling Models

with Humidi-MiZer (04-07 models only)

D – Two Stage Cooling Models 08-16

E – Two Stage Cooling Models 08-16

with Al/Cu condenser Coils and

with Humidi-MiZer

Cooling Tons

04 - 3 ton 08 – 7.5 ton 16 – 15 Tons

05 - 4 ton 09 – 8.5 ton

06 - 5 ton 12 – 10 ton

07 - 6 ton 14 – 12.5 ton

Packaging and Seismic Compliant

0 = Standard

1 = LTL

3 = CA Seismic Compliant

4 = LTL and CA Seismic Compliant Label

Electrical Options

A = None

C = Non-Fused Disconnect

D = Thru-The-Base Connections

F = Non-Fused Disconnect and Thru-The-Base Connections

G = 2-Speed Indoor Fan (VFD) Controller

J = 2 Speed Fan Controller (VFD) and Non-Fused Disconnect

K = 2 Speed Fan Controller (VFD) and Thru-The Base Connections

M = 2 Speed Fan Controller (VFD) with Non-Fused Disconnect and

Thru-The Base Connections

Service Options

0 = None

1 = Unpowered Convenience Outlet

2 = Powered Convenience Outlet

3 = Hinged Panels

4 = Hinged Panels, Unpowered Convenience Outlet

5 = Hinged Panels, Powered Convenience Outlet

Intake / Exhaust Options

A = None

B = Temperature Economizer w/ Barometric Relief

F = Enthalpy Economizer w/ Barometric Relief

K = 2-Position Damper

U = Temp Ultra Low Leak Economizer w/Baro Relief

W = Enthalpy Ultra Low Leak Econo w/Baro Relief

Base unit controls

0 = Electromechanical Controls. Can be used with W7212 EconoMi$er IV

(factory or field installed)

1 = PremierLink Controller

2 = RTU Open Multi-Protocol Controller

6 = Electromechanical Controls. Can be used with W7220 EconoMi$er X

(factory or field installed)

Sensor Options

A = None

B = RA Smoke Detector

C = SA Smoke Detector

D = RA + SA Smoke Detector

E = CO2 Sensor

F = RA Smoke Detector and CO2 Sensor

G = SA Smoke Detector and CO2 Sensor

H = RA + SA Smoke Detector and CO2 Sensor

Indoor Fan Options

1 = Standard Static Option

2 = Medium Static Option

3 = High Static Option

C = High Static Option w/ High Effy Motor (Size 16 Only)

Design Revision

Factory Assigned

Voltage

1 = 575/3/60 5 = 208-230/3/60

3 = 208-230/1/60 6 = 460/3/60

123456789101112131415161718

Note: On single phase (-3 voltage code) models, the following

are not available as a factory installed option:

- Humidi-Mizer

- Coated Coils or Cu Fin Coils

- Louvered Hail Guards

- Economizer or 2 Position Damper

- Powered 115 Volt Convenience Outlet

Not all possible options can be displayed above.

C13211B

48TC

SUPPLY FAN (BLOWER) SECTION

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could cause personal

injury or death.

Before performing service or maintenance operations

on the fan system, shut off all unit power and

lock--out the unit disconnect switch. Place tag on

switch to notify others maintenance is being done.

Do not reach into the fan section with power still

applied to unit.

!WARNING

Supply Fan (Belt--Drive)

The supply fan system consists of a forward--curved

centrifugal blower wheel on a solid shaft with two

concentric type bearings, one on each side of the blower

housing. A fixed--pitch driven pulley is attached to the fan

shaft and an adjustable--pitch driver pulley is on the

motor. The pulleys are connected using a “V” type belt.

See Fig. 5.

BLOWER PULLEY

V-BELT

MOTOR

PULLEY

MOTOR

MOTOR MOUNTING

PLATE

MOUNTING

BOLTS (4)

C11504

Fig. 5 -- Belt Drive Motor Mounting

Belt

Check the belt condition and tension quarterly.

BROWNING BELT

TENSION CHECKER

STRAIGHTEDGE

1/2”

(1.3 cm)

BELT

DEFLECTION

C12093

Fig. 6 -- Checking Blower Motor Belt Tension

Changing Fan Speed:

1. Shut off unit power supply.

2. Loosen belt by loosening fan motor mounting nuts.

See Fig. 5.

3. Loosen movable pulley flange setscrew. See Fig. 7.

4. Screw movable flange toward fixed flange to in-

crease speed and away from fixed flange to decrease

speed. Increasing fan speed increases load on motor.

Do not exceed maximum speed specified.

5. Set movable flange at nearest keyway of pulley hub

and tighten setscrew to torque specifications.

Align fan and motor pulleys:

1. Loosen fan pulley setscrews.

2. Slide fan pulley along fan shaft. Make angular align-

ment by loosening motor from mounting.

3. Tighten fan pulley setscrews and motor mounting

bolts to torque specifications.

4. Recheck belt tension.

Inspect the belt for signs of cracking, fraying or glazing

along the inside surfaces. Check belt tension by using a

spring--force tool such as Browning’s “Belt Tension

Checker” (p/n: 1302546 or equivalent tool). Tension

should be 6--lbs at a ⅝--in. (1.6cm) deflection when

measured at the centerline of the belt span. This point is at

the center of the belt when measuring the distance

between the motor shaft and the blower shaft. See Fig. 6.

1. Place a straightedge along the belt between the two

pulleys.

2. Set the tension checker to the desired tension. Place

the large O--ring at that point.

3. Press the tension checker downward on the belt until

the large O--ring is at the bottom of the straightedge.

4. Adjust the belt tension as needed.

NOTE: Without the spring--tension tool, place a straight

edge across the belt surface at the pulleys, then deflect the

belt at mid--span using one finger to a ½--in. deflection.

Adjust belt tension by loosening the motor mounting plate

front bolts and rear bolt and sliding the plate toward the

fan (to reduce tension) or away from fan (to increase

tension). Ensure the blower shaft and the motor shaft are

parallel to each other (pulleys aligned). Tighten all bolts

securely when finished.

Replacing the belt:

1. Use a belt with same section type or similar size. Do

not substitute a “FHP” type belt. When installing the

new belt, do not use a tool (screwdriver or pry--bar)

to force the belt over the pulley flanges, this will

stress the belt and cause a reduction in belt life.

2. Loosen the motor mounting plate front bolts and rear

bolts.

3. Push the motor and its mounting plate towards the

blower housing as close as possible to reduce the

center distance between fan shaft and motor shaft.

4. Remove the belt by gently lifting the old belt over

one of the pulleys.

48TC

5. Install the new belt by gently sliding the belt over

both pulleys and then sliding the motor and plate

away from the fan housing until proper tension is

achieved.

6. Check the alignment of the pulleys, adjust if neces-

sary.

7. Tighten all bolts.

8. Check the tension after a few hours of runtime and

re--adjust as required.

Adjustable--Pitch Pulley on Motor

The motor pulley is an adjustable--pitch type that allows a

servicer to implement changes in the fan wheel speed to

match as--installed ductwork systems. The pulley consists

of a fixed flange side that faces the motor (secured to the

motor shaft) and a movable flange side that can be rotated

around the fixed flange side that increases or reduces the

pitch diameter of this driver pulley. See Fig. 7.

As the pitch diameter is changed by adjusting the position

of the movable flange, the centerline on this pulley shifts

laterally (along the motor shaft). This creates a

requirement for a realignment of the pulleys after any

adjustment of the movable flange. Also reset the belt

tension after each realignment.

Check the condition of the motor pulley for signs of wear.

Glazing of the belt contact surfaces and erosion on these

surfaces are signs of improper belt tension and/or belt

slippage. Pulley replacement can be necessary.

STRAIGHT EDGE

MUST BE PARALLEL

WITH BELT

SETSCREWS

MOTOR AND

FANSHAFTS

MUST BE

PARALLEL

FIXED FLANGE

MOVABLE

FLANGE

SINGLE - GROOVE

FAN PULLEY

MOTOR PULLEY

C07075

Fig. 7 -- Supply--Fan Pulley Adjustment

Bearings

This fan system uses bearings featuring concentric split

locking collars. The collars are tightened through a cap

screw bridging the split portion of the collar. The cap

screw has a Torx T25 socket head. To tighten the locking

collar: Hold the locking collar tightly against the inner

race of the bearing and torque the cap screw to 55--60

in--lb (6.2--6.8 Nm). See Fig. 8.

LOCKING COLLAR

T-25 TORX SOCKET

HEAD CAP SCREW

C11505

Fig. 8 -- Tightening Locking Collar

STAGED AIR VOLUME CONTROL (SAV) --

2 SPEED FAN WITH VARIABLE

FREQUENCY DRIVE (VFD)

Staged Air Volume (SAV) Indoor Fan Speed

System

The Staged Air Volume (SAV) system utilizes a fan speed

control board and Variable Frequency Drive (VFD) to

automatically adjust the indoor fan motor speed in

sequence with the unit’s ventilation, cooling and heating

operation. Per ASHRAE 90.1 2010standard section

6.4.3.10.b, during the first stage of cooling operation the

SAV system will adjust the fan motor to provide

two--thirds (2/3) of the design airflow rate for the unit.

When the call for the second stage of cooling is required,

the SAV system will allow the design airflow rate for the

unit established (100%). During the heating mode, the

SAV system will allow total design airflow rate (100%)

operation. During ventilation mode, the SAV system will

operate the fan motor at 2/3 speed.

Identifying Factory Option

This supplement only applies to units that meet the

criteria detailed in Table 1. If the unit does not meet that

criteria, discard this document.

Table 1 – Model--Size / VFD option Indicator

Model / Sizes Position in

Model Number

VFD FIOP

Indicator

48TC / 08---30 17 G, J

Unit Installation with SAV Option

Refer to the base unit installation instructions for standard

required operating and service clearances.

NOTICE: The remote VFD keypad is a field--installed

option. It is not included as part of the factory--installed

VFD option. See Figs. 9, 10 and 11 for locations of the

Variable Frequency Drive (VFD) as mounted on the

various 48TC models.

48TC

See “Variable Frequency Drive (VFD) Installation, Setup

and Troubleshooting Supplement” for wiring schematics

and performance charts and configuration.

VARIABLE

FREQUENCY

DRIVE (VFD)

C11528

Fig. 9 -- VFD Location for 48TC 08 -- 09 Units

VARIABLE

FREQUENCY

DRIVE (VFD)

C11529

Fig. 10 -- VFD Location for 48TC 12--14 Units

VARIABLE

FREQUENCY

DRIVE (VFD)

C11530

Fig. 11 -- VFD Location for 48TC 16 Unit

Additional Variable Frequency Drive (VFD)

Installation and Troubleshooting

Additional installation, wiring and troubleshooting

information for the Variable Frequency Drive can be

found in the following manual: “Variable Frequency

Drive (VFD) Installation, Setup and Troubleshooting

Supplement.” Have a copy of this manual on hand at

start--up.

SUPPLY FAN MOTOR

Replacing the Motor

When replacing the motor, also replace the external--tooth

lock washer (star washer) under the motor mounting base;

this is part of the motor grounding system. Ensure the

teeth on the lock washer are in contact with the motor’s

painted base. Tighten motor mounting bolts to 120 12

in--lbs.

BLOWER PULLEY

V-BELT

MOTOR

PULLEY

MOTOR

MOTOR MOUNTING

PLATE

MOUNTING

BOLTS (4)

C11504

Fig. 12 -- Replacing Belt Driven Motor

Use the following steps to replace the belt--driven motor.

1. Turn off all electrical power to the unit. Use

approved lockout/tagout procedures on all electrical

power sources.

2. Remove cover on motor connection box.

3. Disconnect all electrical leads to the motor.

4. Loosen four mounting plate bolts.

5. Move motor assembly toward blower assembly.

6. Remove V--belt from blower pulley and motor

pulley.

7. Remove four bolts, four flat washers, four lock

washers and four nuts attaching the motor mounting

plate to the unit. Discard all lock washers.

8. Remove motor and motor mounting plate from unit.

9. Remove four bolts, four flat washers, four lock

washers and one external--tooth lock washer

attaching motor to the motor mounting plate. Discard

all lock washers and external--tooth lock washer.

10. Lift motor from motor mounting plate and set aside.

11. Slide motor mounting band from old motor.

12. Slide motor mounting band onto new motor and set

motor onto the motor mounting plate.

48TC

13. Inspect variable pitch pulley on old motor for cracks

and wear.

14. Remove variable pitch pulley from old motor and

attach it to the new motor. Secure the pulley to the

motor by tightening the setscrew to the motor shaft.

15. Insert four bolts and flat washers through holes in

the motor mounting band into holes on the motor

mounting plate.

16. On one bolt, place a new external--tooth lock washer

between the motor and motor mounting plate.

17. Ensure the teeth of the external--tooth lock washer

make contact with the painted base of the motor.

This washer is essential for properly grounding

motor.

18. Install four new lock washers and four nuts on the

bolts on the bottom of the motor mounting plate.

19. Do Not tighten the mounting bolts at this time.

20. Install four bolts, four flat washers, four new lock

washers and four nuts attaching the motor assembly

to the unit.

21. Do Not tighten the mounting bolts at this time.

22. Install motor drive V--belt to motor pulley and

blower wheel pulley. See CAUTION below.

23. Align the motor pulley and blower wheel pulley

using a straight edge. See Fig. 7.

24. Adjust the V--belt tension using adjustment tool. See

Fig. 13.

BROWNING BELT

TENSION CHECKER

STRAIGHTEDGE

1/2”

(1.3 cm)

BELT

DEFLECTION

C12093

Fig. 13 -- Adjusting V--belt Tension

25. Tighten four bolts securing motor to motor mounting

plate. Torque four bolts to 120 12 in--lbs (14 1.4

Nm).

26. Tighten four bolts securing motor mounting plate to

unit. Torque four bolts to 120 12 in--lbs (14 1.4

Nm).

27. Remove cover on new motor connection box.

28. Re--connect all electrical leads to the motor and

replace the connection box cover.

29. Re--connect all electrical power to the unit. Remove

lockout tags on all electrical power sources.

30. Start unit and allow to run for a designated period.

31. Shut off unit and make any necessary adjustments to

the V--belt tension or the motor and blower wheel

pulley alignment.

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution can result in premature

wear and damage to equipment.

Do not use a screwdriver or a pry bar to place the new

V--belt in the pulley groove. This can cause stress on

the V--belt and the pulley resulting in premature wear

on the V--belt and damage to the pulley.

CAUTION

Changing Fan Wheel Speed by Changing Pulleys

The horsepower rating of the belt is primarily dictated by

the pitch diameter of the smaller pulley in the drive

system (typically the motor pulley in these units). Do not

install a replacement motor pulley with a smaller pitch

diameter than provided on the original factory pulley.

Change fan wheel speed by changing the fixed fan pulley

(larger pitch diameter to reduce wheel speed, smaller

pitch diameter to increase wheel speed) or select a new

system with both pulleys and matching belt(s).

Before changing pulleys to increase fan wheel speed,

check the fan performance at the target speed and airflow

rate to determine new motor loading (bhp). Use the fan

performance tables or use the Packaged Rooftop Builder

software program. Confirm that the motor in this unit is

capable of operating at the new operating condition. Fan

shaft loading increases dramatically as wheel speed is

increased.

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution can result in equipment

damage.

Drive packages cannot be changed in the field. For

example: a standard drive cannot be changed to a high

static drive. This type of change will alter the unit’s

certification and could require heavier wiring to

support the higher amperage draw of the drive

package.

CAUTION

To reduce vibration, replace the motor’s adjustable pitch

pulley with a fixed pitch pulley (after the final airflow

balance adjustment). This will reduce the amount of

vibration generated by the motor/belt--drive system.

To determine variable pitch pulley diameter perform the

following calculation:

1. Determine full open and full closed pulley diameter.

2. Subtract the full open diameter from the full closed

diameter.

3. Divide that number by the number of pulley turns

open from full closed

This number is the change in pitch datum per turn

open.

48TC

EXAMPLE

--Pulley dimensions 2.9 to 3.9 (full close to full open)

-- 3 . 9 -- 2 . 9 = 1

--1 divided by 5 (turns from full close to full open)

--0.2 change in pulley diameter per turn open

--2.9 + 0.2 = 3.1--in pulley diameter when pulley closed

one turn from full open

COOLING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personal

injury, death and/or equipment damage.

This system uses PuronRrefrigerant which has

higher pressures than R--22 and other refrigerants. No

other refrigerant can be used in this system. Gauge

set, hoses, and recovery system must be designed to

handle Puron refrigerant. If unsure about equipment,

consult the equipment manufacturer.

!WARNING

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in death,

serious personal injury and/or property damage.

Never use non--certified refrigerants in this product.

Non--certified refrigerants could contain contaminates

that could lead to unsafe operating conditions. Use

ONLY refrigerants that conform to AHRI Standard

700.

!WARNING

Condenser Coils Size D08--D14

All 48TC units are available with Round Tube/Plate Fin

(RTPF) coil construction. 48TC units with size

designations D08, D12 and D14 are also available with

optional all--aluminum Novation coil construction. Check

position 11 on the unit’s infomative data plate for coil

construction code, then refer to Model Nomenclature on

page 5 to confirm this unit’s coil construction type.

Novation (MCHX) Condenser Coil

The condenser coil uses new NOVATIONHeat

Exchanger Technology or Microchannel Heat Exchanger.

Coil (MCHX). This is an all--aluminum construction with

louvered fins over single--depth crosstubes. The crosstubes

have multiple small passages (microchannels) through

which the refrigerant passes from header to header on

each end. Tubes and fins are made of aluminum.

Connection tube joints are made of copper. The coil can

be one--row or two--row. Two--row coils are spaced apart

to assist in cleaning. See Fig. 14.

Routine Cleaning of NOVATION Condenser Coil

Surfaces

DO NOT clean the NOVATION condenser coil with

chemicals. ONLY water is approved as the cleaning

solution. Only clean potable water is authorized for

cleaning NOVATION condensers. Carefully remove any

foreign objects or debris attached to the coil face or

trapped within the mounting frame and brackets. Using a

high pressure water sprayer, purge any soap or industrial

cleaners from hose and/or dilution tank prior to wetting

the coil.

EXPLOSION HAZARD

Failure to follow this warning could

result in death, serious personal injury,

and/or property damage.

Never use air or gases containing

oxygen for leak testing or operating

refrigerant compressors. Pressurized

mixtures of air or gases containing

oxygen can lead to an explosion.

!WARNING

TUBES

FINS

MANIFOLD

MICROCHANNELS

C07273B

Fig. 14 -- Novation (Microchannel) Coil

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution can result in equipment

damage.

DO NOT use Totalineenvironmentally sound coil

cleaner on the aluminum NOVATION condenser.

Damage to the coil can occur. Only clean potable

water is authorized for cleaning.

CAUTION

48TC

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