0TJ06-03S Single-Package Rooftop Units Electric Cooling with Electric Heat Option Installation, Start-Up and Service Instructions CONTENTS SAFETY CONSIDERATIONS. INSTALLATION... Step Rig and Place Unit POSITIONING ROOF MOUNT Step Field Fabricate Ductwork. Step 3 Make Unit Duct Connections. Step 4 Trap Condensate Drain Step Make Electrical Connections. FIELD POWER SUPPLY FIELD CONTROL WIRING NON-FUSED DISCONNECT Step 6 Make Outdoor-Air Inlet. MANUAL OUTDOOR-AIR VENT. START-UP. SERVICE...................... TROUBLESHOOTING........... START-UP CHECKLIST Page 6 6 6 6 9 9 6 4 SAFETY CONSIDERATIONS Installation and servicing 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 basic maintenance functions of cleaning coils and filters and replacing filters. All other operations should be performed by trained service personnel When working on air-conditioning equipment, observe 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 un-brazing operations. Have fire extinguishers available for all brazing operations. WARNING Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury. IMPORTANT: Units have high ambient operating limits. If limits are exceeded, the unit will automatically lock the compressor out of operation. Manual reset will be required to restart the compressor. - - Form 0TJSD-04 IOM
INSTALLATION Step Rig and Place Unit Inspect unit for transportation damage. File any claim with transportation agency. Keep unit upright, and do not drop. Use spreader bars over unit to prevent sling or cable damage. Rollers may be used to move unit across a roof Level by using unit frame as a reference; leveling tolerance is± /6 in. per linear ft in any direction. See Fig. for additional information. Unit weight is shown in Table. Four lifting holes are provided in ends of unit base rails as shown in Fig.. Refer to rigging instructions on unit. POSITIONING Provide clearance around and above unit for airflow, safety, and service access. Do not install unit in an indoor location. Do not locate air inlets near exhaust vents or other sources of contaminated air. Although unit is weatherproof, guard against water from higher level runoff and overhangs. ROOF MOUNT Check building codes for weight distribution requirements. Table. Unit Weights & Dimensions. DIMENSIONS MAXIMUM SHIPPING WEIGHT UNIT OTJ A B Lb Kg in. mm in. mm 06 68 73 9-/4 38 4 04 00 733 786 9-/4 38 40 06 04 874 80 96.0 440 39 99 08 03 93 96.0 440 38 96 03 0 000 0-3/64 0 4 04 NOTES:. Dimensions in ( ) are in millimeters.. Remove boards at ends of unit and runners prior to rigging. 3. Rig by inserting hooks into unit base rails as shown. Use corner post from packaging to protect coil from damage. Use bumper boards for spreader bars. 4. Weights given are for aluminum evaporator and condenser coil plate fins. CAUTION All panels must be in place when rigging. IMPORTANT: All units are internally isolated against vibration. If extra isolation required, please see dimensional drawing (page- 3) for corner weights. Fig. Rigging Details - -
Fig.- Base Unit Dimension, 0TJ6-03 - 3 -
Table Physical Data ( Hz) UNIT 0TJ 06 00 04 08 03 NOMINAL CAPACITY (tons) 8 0 8 / OPERATING WEIGHT For Operating Weights see page 3. COMPRESSOR Scroll Quantity...Danfoss Model (Ckt, Ckt )... SM00S..SM0S,..SM00S...SM0S,..SM0S..SM6T,...SM0S..SM6T, Number of Refrigerant Circuits Oil (oz) (Ckt, Ckt ) Stages of Capacity Control (%) REFRIGERANT TYPE Expansion Device Operating Charge (lb-oz) Circuit * Circuit CONDENSER COIL Rows...Fins/in. Total Face Area (sq ft) CONDENSER FAN Nominal Cfm Quantity...Diameter (in.), No. of Blades. Motor Hp...Rpm EVAPORATOR COIL Rows...Fins/in. Total Face Area (sq ft) EVAPORATOR FAN Quantity...Size (in.) Type Drive Nominal Cfm Motor Hp Motor Nominal Rpm Maximum Continuous Bhp Motor Frame Size Fan Rpm Range Fan Pulley Pitch Diameter (in.) Nominal Fan Shaft Diameter (in.) Motor Bearing Type Maximum Allowable Rpm Motor Pulley Pitch Diameter Min/Max (in.) Nominal Motor Shaft Diameter (in.) Belt, Quantity...Type...Length (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 Setting Factory Speed Setting (rpm) 8, 8 0/0-8 -8...6 4.43...7 8.4...6 x 6 Belt 00 74. 84T 690-840.0.9 Ball 00 4.3/. /8... SPA 900 3.8-30 / 76 06,8 /4 06, 06 /4 R- TXV 36, 06 /40 7-0 0-8 4-0 4-0 4-0 6-0 Grooved 3/8-in. Copper Tubes, Aluminium Wavy, Aluminium Pre-Coated, or Copper Plate Fins 3...6 3..6 4...6 4.43 7.44 7.44 Propeller Type 4,00...30 4 40 Grooved 3/8-in. Copper Tubes, LSW or Copper Plate Fins, Face Split 3...7 3...7 4...7 8.4 Centrifugal Type...6 x 6...8 x 8...8 x 8 Belt Belt Belt 6300 8000 8700 7. 7. 74 74 74. 8. 8. 84T 3T 3T 76-90 70-80 80-90 0.0.0.0.9.38.38 Ball Ball Ball 00 400 400 4.3/. 4./.0./.7 /8... SPA 900 3.8-30 / 840 3/8... SPB 0 3.8-0 / 7 3/8... SPB 0 3.8-0 / 8 36, 36 0/0 4-0 4-0 4...6 30.00,000...30 4 40 4...7 3.3...8 x 8 Belt 0,00 0 74 T 80-080.0.38 Ball 400.4/6.8 3/8... SPB 000 3.8-0 / 97 HIGH-PRESSURE SWITCH (psig) Cut-out Reset (Auto) LOW-PRESSURE SWITCH (psig) Cut-out Reset (Auto) FREEZE PROTECTION THERMOSTAT (F) Opens Closes RETURN-AIR FILTERS Quantity...Size (in.) Condenser Motor Efficiency 80% Evaporator Motor Efficiency 87% 46 30 7 44 30 ± 4 ± Aluminium 4...(3. x. ) Aluminium 4..(36. x. ) - 4 -
Table 3 Physical Data (0 Hz) UNIT 0TJ 06 00 04 08 03 NOMINAL CAPACITY (tons) 8 0 8 / OPERATING WEIGHT For Operating Weights see page 3. COMPRESSOR Scroll Quantity...Danfoss Model (Ckt, Ckt ) Number of Refrigerant Circuits Oil (oz) (Ckt, Ckt ) Stages of Capacity Control (%) REFRIGERANT TYPE Expansion Device Operating Charge (lb-oz) Circuit * Circuit CONDENSER COIL Rows...Fins/in. Total Face Area (sq ft) CONDENSER FAN Nominal Cfm Quantity...Diameter (in.) No. of Blades. Motor Hp...Rpm EVAPORATOR COIL Rows...Fins/in. Total Face Area (sq ft) EVAPORATOR FAN Quantity...Size (in.) Type Drive Nominal Cfm Motor Hp Motor Nominal Rpm Maximum Continuous Bhp Motor Frame Size Fan Rpm Range Fan Pulley Pitch Diameter (in.) Nominal Fan Shaft Diameter (in.) Motor Bearing Type Maximum Allowable Rpm Motor Pulley Pitch Diameter Min/Max (in.) Nominal Motor Shaft Diameter (in.) Belt, Quantity...Type...Length (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 Setting Factory Speed Setting (rpm)...sm0s 06, 06 0/0 4-0 4-0...6 4.43...7 8.4...6 x 6 Belt 00 43. 84T 690-840 8 7/8.9 Ball 00 4.3/. /8... SPA 800 3.8-30 / 76..SM0S,..SM0S 06,06 /4...SM6T,..SM0S 36, 06 /40 R- TXV..SM8W,...SM6T 36, 36 /4 7-8 3-0 -0 4-8 4-8 7-0 Grooved 3/8-in. Copper Tubes, Aluminium Wavy, Aluminium Pre-Coated, or Copper Plate Fins 3...6 3...6 4...6 4.43 7.44 7.44 Propeller Type,800...30 4 90 Grooved 3/8-in. Copper Tubes, LSW or Copper Plate Fins, Face Split 3...7 3...7 4...7 8.4 Centrifugal Type...6 x 6...8 x 8...8 x 8 Belt Belt Belt 6300 8000 8700 7. 7. 43 43 43. 8. 8. 84T 3T 3T 76-90 70-80 80-90 7 7/8 9 /7 9 /7.9.38.38 Ball Ball Ball 00 400 400 4.3/. 4./.0./.7 /8... SPA 800 3.8-30 / 840 3/8... SPB 000 3.8-0 / 7 3/8... SPB 000 3.8-0 / 8 4,00...30 6 90..SM8W, 36, 36 0/0-0 -0 4...6 30.00 4...7 3.3...8 x 8 Belt 0,00 0 43 T 830-00 9 /7.38 Ball 400.4/6.8 3/8... SPB 90 3.8-0 / 9 HIGH-PRESSURE SWITCH (psig) Cut-out Reset (Auto) LOW-PRESSURE SWITCH (psig) Cut-out Reset (Auto) FREEZE PROTECTION THERMOSTAT (F) Opens Closes RETURN-AIR FILTERS Quantity...Size (in.) Condenser Motor Efficiency 80% Evaporator Motor Efficiency 87% 46 30 7 44 30 ± 4 ± Aluminium 4...(3. x. ) Aluminium 4..(36. x. ) - -
Step Field Fabricate Ductwork Secure all ducts to building structure. Use flexible duct connectors between unit and ducts as required(a space for. to 3 ft is required in case of repairing or replacing the blower wheel). 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 space must be insulated and covered with a vapor barrier. The 0TJ units with electric heat require a -in. clearance for the first 4 in. of ductwork. Outlet grilles must not lie directly below unit discharge. NOTE: A 90-degree elbow must be provided in the ductwork to comply with UL (Underwriters Laboratories) codes for use with electric heat. Step 3 Make Unit Duct Connections Unit is shipped for side duct connections. Ductwork openings are shown in Fig. 6. Step 4 Trap Condensate Drain See Fig. 3 and 6 for drain location. Plug is provided in drain hole and must be removed when unit is operating. One 3/4-in. half coupling is provided inside unit evaporator section for condensate drain connection. An 8/ in. x 3/4-in. diameter nipple and a -in. x 3/4-in. diameter pipe nipple are coupled to standard 3/4-in. diameter elbows to provide a straight path down through holes in unit base rails (see Fig. ). A trap at least 4-in. deep must be used. Fig. 3 Condensate Drain Details Step Make Electrical Connections FIELD POWER SUPPLY Unit is factory wired for voltage shown on nameplate. When installing units, provide a disconnect, per NEC (National Electrical Code) requirements, of adequate size (Table 4). All field wiring must comply with NEC and local requirements. Route power lines through control box access panel or unit base-pan to connections as shown on unit wiring diagram and Fig. 4. Operating voltage to compressor must be within voltage range indicated on unit nameplate. On 3-phase units, voltages between phases must be balanced within % and the current must be balanced within 0%. CAUTION The correct power phasing is critical in the operation of the scroll compressors. An incorrect phasing will cause the compressor to rotate in the wrong direction. This may lead to premature compressor failure. Use the following formula to determine the percentage of voltage imbalance. Percentage of Voltage Imbalance max voltage deviation from average voltage =00x average voltage EXAMPLE: Supply voltage is 4-3-. AB = 4 v BC = 464 v AC = 4 v Average Voltage = 4+464+4 3 37 = 3 =47 Determine maximum deviation from average (AB) 47 4 = v (BC) 464 47 = 7 v (AC) 47 4 = v Maximum deviation is 7 v. Determine percent voltage imbalance: 7 Percentage of Voltage Imbalance = 00 x 47 =.3 % This amount of phase imbalance is satisfactory as it is below the maximum allowable %. IMPORTANT: If the supply voltage phase imbalance is more than %, contact your local electric utility company immediately. Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. FIELD CONTROL WIRING Install a Carrierapproved accessory thermostat assembly according to the installation instructions included with the accessory. Locate thermostat assembly on a solid wall in the conditioned space to sense average temperature. Route thermostat cable or equivalent single leads of no. 8 AWG (American Wire Gage) colored wire from subbase terminals through conduit in unit to low-voltage connections as shown on unit label wiring diagram and in Fig.. NOTE: For wire runs up to 0 ft, use no. 8 AWG insulated wire (3 C minimum). For 0 to 7 ft, use no. 6 AWG insulated wire (3 C minimum). For over 7 ft, use no. 4 AWG insulated wire (3 C minimum). All wire larger than no. 8 AWG cannot be directly connected to - 6 -
the thermostat and will require a junction box and splice at the thermostat. Set heat anticipator settings as indicated in Table 7. Settings may be changed slightly to provide a greater degree of comfort for a particular installation. Table 4 - TB MAXIMUM WIRE SIZE UNIT 0TJ VOLTAGE 08/30, 380 400 ALL 30 kcmil /0 LEGEND EQUIP Equipment GND Ground kcmil Thousand Circular Mils NEC National Electrical Code TB Terminal Block Fig. 4 Field Power Wiring Connections Fig. Field Control Thermostat Wiring Fig.6 Air Distribution (0TJ06 03) - 7 -
Table -Electrical data 0TJ06-03 NOMINAL VOLTAGE COMPRESSOR POWER OFM IFM ELECTRIC HEAT* VOLTAGE RANGE NO. NO. SUPPLY UNIT (3PH) (Hz) Min Max RLA LRA RLA LRA Qty Hp FLA (ea) Hp FLA TOTAL FLA/STAGE STAGES MCA MOCP kw 6 0 4 8 03 30 380 4 400 30 380 4 400 30 380 4 400 30 380 4 400 30 380 4 400 0 0 0 0 0 87 34 44 3 87 34 44 3 87 34 44 3 87 34 44 3 87 34 44 3 3 48 08 440 3 48 08 440 3 48 08 440 3 48 08 440 3 48 08 440 8.8 4.7. 30..3. 9.6 37.8. 7. 4.8.8 7. 4.8.8 7. 9 3 9 40 4 39 4 67 30 8 98 30 8 98 8.8 4.7. 8.8 4.7. 30..3. 9.6 37.8. 7. 4.8.8 7. 9 3 9 9 3 9 40 4 39 4 67 30 8 98 6.6 3.9 3.3 3.4 6.6 3.9 3.3 3.4 6.6 3.9 3.3 3.4 6.6 3.9 3.3 3.4 6.6 3.9 3.3 3.4 7. 7. 7. 7. 7. 7. 7. 7. 0 0 0 0.8 7.7 6.4 7.6.8 7.7 6.4 7.6 9.4.7 9.7.4 9.4.7 9.7.4 6.8 6. 3.4 6. 7. 8.6 7.6 7. 8.6 7.6 36.7 4.8 36.8 8 36.7 4.8 36.8 8 36.7 4.8 36.8 8 34.6 4.3 7. 34.6 4.3 7. 47 9 3 0 47 9 3 0 47 9 3 0 9 0 47 0 94 0 48 4 0 6 4 69 3 69 6 77 8 74 70 8 0 0 70 30 7 70 8 0 80 7 9 0 90 8 00 LEGEND AND NOTES FOR ELECTRICAL DATA TABLES. LEGEND FLA Full Load Amps HACR Heating, Air Conditioning and Refrigeration IFM Indoor (Evaporator) Fan Motor LRA Locked Rotor Amps MCA Minimum Circuit Amps MOCP Maximum Overcurrent Protection NEC National Electrical Code OFM Outdoor (Condenser) Fan Motor RLA Rated Load Amps *Heater capacity (kw) is based on heater voltage of 08 v, 40 v, 380 v, 480 v, and 0 v. Heaters are rated at 40 v, 480 v, or 0 v. If power distribution voltage to unit varies from rated heater voltage, heater kw will vary accordingly. To determine heater capacity at actual unit voltage, multiply 40 v, 480 v, or 0 v capacity by multipliers found in table on page 4 Product Data. Fuse or HACR circuit breaker. NOTES:. In compliance with NEC requirements for multi-motor and combination load equipment (refer to NEC Articles 430 and 440), the over current protective device for the unit shall be fuse or HACR breaker. The Canadian units may be fuse or circuit breaker.. Unbalanced 3-Phase Supply Voltage Never operate a motor where a phase imbalance in supply voltage is greater than %. Use the following formula to determine the percent of voltage imbalance. % Voltage Imbalance = 00 x maximum deviation from average voltage average voltage EXAMPLE: Supply voltage is 4-3-. AB = 4 v BC = 464 v AC = 4 v Average Voltage= 4 + 464 + 4 3 = 37 3 = 47 Determine maximum deviation from average voltage. (AB) 47 4 = v (BC) 464 47 = 7 v (AC) 47 4 = v Maximum deviation is 7 v. Determine percent voltage imbalance. 7 % Voltage Imbalance = 00 x 47 =.3% This amount of phase imbalance is satisfactory as it is below the maximum allowable %. IMPORTANT: If the supply voltage phase imbalance is more than % contact your local electric Utility company 3. MCA calculation for 0TJ06-03units with electric heaters over 0 kw = (. x IFM amps) + (.00 x heater FLA).. - 8 -
NON-FUSED DISCONNECT On units with the optional non-fused disconnect, incoming power will be wired into the disconnect switch. Refer to Fig. 7 for wiring for 00 and 00 amp disconnect switches. Units with an MOCP under 00 will use the 00 amp disconnect switch. Units with an MOCP over 00 will use the 00 amp disconnect switch. Refer to the applicable disconnect wiring diagram. NOTE: The disconnect takes the place of TB- as shown on the unit wiring diagram label and the component arrangement label. Fig. 7 Optional Non-Fused Disconnect Wiring Step 6 Outdoor-Air Inlet MANUAL OUTDOOR-SIDE VENT. All units have a manual outdoor-side Vent. to provide ventilation air. Side Vent. can admit up to 0% outdoor air into return-air compartment. UNIT 0TJ 06, 00 04, 03 UNIT VOLTAGE kw* STAGE STAGE 08 3 0. 0. 30 30 0. 0. 08 30 0. 0. 30 40 0. 0. Table 6 Heat Anticipator Setting. START-UP Use the following information and Start-Up Checklist on page CL- to check out unit PRIOR to start-up. Unit Preparation Check that unit has been installed in accordance with these installation instructions and all applicable codes. Internal Wiring Check all electrical connections in unit control boxes; tighten as required. Compressor Mounting Compressors are internally spring mounted. Do not loosen or remove compressor hold down bolts. Refrigerant Service Ports Each refrigerant system has a total of 3 Schrader-type service gage ports. One port is located on the suction line, one on the compressor discharge line, and one on the liquid line. In addition Schrader-type valves are located underneath the low-pressure switches. Be sure that caps on the ports are tight. Compressor Rotation It is important to be certain the compressors are rotating in the proper direction. To determine whether or not compressors are rotating in the proper direction:. Connect service gages to suction and discharge pressure fittings.. Energize the compressor. 3. The suction pressure should drop and the discharge pressure should rise, as is normal on any start-up. If the suction pressure does not drop and the discharge pressure does not rise to normal levels:. Note that the evaporator fan is probably also rotating in the wrong direction.. Turn off power to the unit. 3. Reverse any two of the incoming power leads. 4. Turn on power to the compressor. The suction and discharge pressure levels should now move to their normal start-up levels. NOTE: When compressors are rotating in the wrong direction, the unit will have increased noise levels and will not provide heating and cooling. After a few minutes of reverse operation, the scroll compressor internal overload protection will open, which will activate the unit s lockout and requires a manual reset. Reset is accomplished by turning the thermostat on and off. Evaporator Fan Fan belt and variable pulleys are factory installed. Remove tape from the fan pulley. See Table 7 for Air Quantity Limits. See Tables 8- for Fan Performance data. Be sure that fans rotate in the proper direction. See Table 3 for fan rpm at various fan motor pulley settings. To alter fan performance, see Evaporator- Fan Performance Adjustment section, page 7. IMPORTANT: Seal all in and out of Electrical Box to Prevent Moist Air from entering - 9 -
Table 7 Air Quantity Limits UNIT 0TJ MINIMUM CFM / L/s MAXIMUM CFM / L/s 06 4800 / 6 7,00 / 339 00 00 / 96 7,0 / 386 04 00 / 83 0,000 / 479 08 0 / 3067 0,700 / 049 03 800 / 40,00 / 899 Condenser Fans and Motors Fans and motors are factory set. Refer to Condenser-Fan Adjustment section (page 7) as required. Return-Air Filters Check that correct filters are installed in filter tracks. See Table, 3. Do not operate unit without return-air filters. Fig.8-0% Fresh Outdoor-Air Option. - 0 -
Performance data (cont) Table 8-FAN PERFORMANCE 0TJ06 UNIT ENGLISH 0TJ06 AIR AVAILABLE EXTERNAL STATIC PRESSURE(iwg) FLOW 0. 0.4 0.6 0.8 (CFM) RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts 4800 68.6 300 736.8 467 789.0 644 00 70.8 00 77.0 678 807. 86 400 78. 7 777.3 889 8. 86 700 704. 767 7.3 944 799.6 44 84.8 333 00 686. 833 73.4 0 778.7 83.9 4 867 3. 6 6300 7. 00 79.8 89 803 3.0 00 846 3.3 700 888 3. 9 60 74.9 389 788 3. 0 830 3.4 8 87 3.7 30 9 3.9 344 6900 774 3.3 7 8 3. 9 86 3.8 344 89 4. 3367 934 4.3 30 700 80 3.7 306 844 4.0 389 883 4. 3 9 4. 3744 98 4.8 3978 700 836 4. 3444 874 4. 3368 9 4.7 39 948.0 46 0TJ06 AIR AVAILABLE EXTERNAL STATIC PRESSURE(iwg) FLOW..4.6 (CFM) RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts 4800 840. 8 889.4 0 937.7 00 00 86. 044 903.7 33 949.9 4 400 87.8 78 97 3.0 467 96 3. 678 700 890 3. 33 934 3.3 744 00 90 3.4 8 9 3.7 3033 6300 930 3.8 333 60 9 4. 3467 LEGEND Bhp Brake Horsepower FIOP Factory-Installed Option Watts Input Watts to Motor Normal face: refers to the Standard Motor & Drive Package. Bold-Italic face: requires a field supplied drive package. NOTES:. Do not adjust motor rpm such that motor maximum bhp and/or watts is exceeded at the maximum operating cfm.. Static pressure losses must be added to external static pressure before entering Fan Performance table. 3. Interpolation is permissible. Do not extrapolate. 4. Fan performance is based on wet coils, clean filters, and casing losses.. Extensive motor and drive testing on these units ensures that the full horsepower and watts range of the motor can be utilized with confidence. Using your fan motors up to the watts or bhp rating shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected. 6. Use of a field-supplied motor may affect wiring size. Contact your Carrier representative for details 7. Evaporator Motor Efficiency 87%. - -
0TJ00 Table 9-FAN PERFORMANCE 0TJ00 UNIT ENGLISH AIR AVAILABLE EXTERNAL STATIC PRESSURE(iwg) FLOW 0. 0.4 0.6 0.8 (CFM) RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts 00 780.4 96 87.6 44 874.8 344 800 807.7 33 8.9 4 896 3. 633 0 79.8 3 83 3. 33 878 3.3 733 9 3.6 944 6400 779 3.0 444 8 3. 644 864 3.4 86 906 3.7 3078 947 4.0 389 6700 8 3.4 778 8 3.6 989 89 3.9 3 93 4. 3433 97 4.4 3667 7000 844 3.8 344 883 4. 3367 9 4.3 30 9 4.6 3833 998 4.9 4067 7300 877 4.3 36 9 4.6 3789 9 4.9 40 989. 467 70 87 4. 3744 946. 4 98.4 4467 0TJ00 AIR AVAILABLE EXTERNAL STATIC PRESSURE(iwg) FLOW..4 (CFM) RPM Bhp Watts RPM Bhp Watts 00 99 3. 44 963 3.3 700 800 940 3.4 833 983 3.7 3044 0 963 3.8 367 6400 993 4.0 33 LEGEND Bhp Brake Horsepower FIOP Factory-Installed Option Watts Input Watts to Motor Normal face: refers to the Standard Motor & Drive Package. Bold-Italic face: requires a field supplied drive package. NOTES:. Do not adjust motor rpm such that motor maximum bhp and/or watts is exceeded at the maximum operating cfm.. Static pressure losses must be added to external static pressure before entering Fan Performance table. 3. Interpolation is permissible. Do not extrapolate. 4. Fan performance is based on wet coils, clean filters, and casing losses.. Extensive motor and drive testing on these units ensures that the full horsepower and watts range of the motor can be utilized with confidence. Using your fan motors up to the watts or bhp rating shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected. 6. Use of a field-supplied motor may affect wiring size. Contact your Carrier representative for details 7. Evaporator Motor Efficiency 87%. - -
Table 0-FAN PERFORMANCE 0TJ04 UNIT ENGLISH 0TJ04 AIR AVAILABLE EXTERNAL STATIC PRESSURE(iwg) FLOW 0. 0.4 0.6 0.8 (CFM) RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts 00 6400 69.6 78 6800 707 3.0 46 700 683 3.0 74 3.3 767 70 703 3.4 86 74 3.8 3 8000 686 3.6 978 7 3.9 333 76 4. 3489 8400 67 3.7 300 709 4. 336 746 4.4 36 78 4.7 3900 8800 696 4. 300 73 4.6 3778 767 4.9 406 80. 4333 900 687 4.4 3678 7 4.8 396 77. 444 790. 433 84.8 48 90 7.0 444 746.4 4433 779.7 4733 8 6. 033 844 6.4 333 0000 740.6 4667 773 6.0 4967 80 6.4 78 836 6.8 89 867 7. 900 0TJ04 AIR AVAILABLE EXTERNAL STATIC PRESSURE(iwg) FLOW..4.6.8 (CFM) RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts 00 7.6 44 767.9 367 80 3. 0 8 3.4 844 89 3.7 3089 6400 73.9 400 778 3. 633 89 3. 878 8 3.8 3 899 4. 3378 6800 70 3.3 700 79 3.6 944 83 3.9 389 870 4. 3444 908 4. 37 700 764 3.6 30 804 3.9 367 84 4.3 3 880 4.6 3789 97 4.9 4067 70 78 4. 3367 89 4.4 3633 86 4.7 3900 893.0 478 99.4 446 8000 799 4. 376 836 4.9 4033 87. 43 907.6 40 94.9 4889 8400 88.0 478 83.4 446 887.7 4744 9 6. 00 LEGEND Bhp Brake Horsepower FIOP Factory-Installed Option Watts Input Watts to Motor Normal face: refers to the Standard Motor & Drive Package. Bold-Italic face: requires a field supplied drive package. NOTES:. Do not adjust motor rpm such that motor maximum bhp and/or watts is exceeded at the maximum operating cfm.. Static pressure losses must be added to external static pressure before entering Fan Performance table. 3. Interpolation is permissible. Do not extrapolate. 4. Fan performance is based on wet coils, clean filters, and casing losses.. Extensive motor and drive testing on these units ensures that the full horsepower and watts range of the motor can be utilized with confidence. Using your fan motors up to the watts or bhp rating shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected. 6. Use of a field-supplied motor may affect wiring size. Contact your Carrier representative for details 7. Evaporator Motor Efficiency 87%. - 3 -
Table -FAN PERFORMANCE 0TJ08 UNIT ENGLISH 0TJ08 AIR AVAILABLE EXTERNAL STATIC PRESSURE(iwg) FLOW 0. 0.4 0.6 0.8 (CFM) RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts 0 7000 700 8000 788 4.4 3678 800 8. 433 9000 70 4. 3700 74 4.8 3978 77. 46 809. 444 843.9 4844 900 74. 43 774.6 46 807.9 49 839 6.3 87 6.7 0000 776 6.0 000 808 6.4 3 839 6.8 6 864 7. 867 90 7.6 66 000 8 7.0 76 84 7.3 78 87 7.7 6400 90 8. 6733 0TJ08 AIR AVAILABLE EXTERNAL STATIC PRESSURE(iwg) FLOW..4.6.8 (CFM) RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts 0 80 3.4 8 84 3.7 3078 88 4.0 33 90 4.3 389 7000 779 3.6 989 89 3.9 344 88 4. 300 896 4.6 3767 700 80 4. 3444 839 4. 37 876 4.8 3978 93. 46 8000 8 4.8 3944 86. 4 896.4 4 800 80.4 4 884.8 4800 98 6. 00 9000 876 6. 33 909 6.6 444 900 903 7.0 8 LEGEND Bhp Brake Horsepower FIOP Factory-Installed Option Watts Input Watts to Motor Normal face: refers to the Standard Motor & Drive Package. Bold-Italic face: requires a field supplied drive package. NOTES:. Do not adjust motor rpm such that motor maximum bhp and/or watts is exceeded at the maximum operating cfm.. Static pressure losses must be added to external static pressure before entering Fan Performance table. 3. Interpolation is permissible. Do not extrapolate. 4. Fan performance is based on wet coils, clean filters, and casing losses.. Extensive motor and drive testing on these units ensures that the full horsepower and watts range of the motor can be utilized with confidence. Using your fan motors up to the watts or bhp rating shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected. 6. Use of a field-supplied motor may affect wiring size. Contact your Carrier representative for details 7. Evaporator Motor Efficiency 87%. - 4 -
Table -FAN PERFORMANCE 0TJ03 UNIT ENGLISH 0TJ03 AIR AVAILABLE EXTERNAL STATIC PRESSURE(iwg) FLOW 0. 0.4 0.6 0.8 (CFM) RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts 8000 800 9000 900 833 6. 384 0000 830 6.7 779 86 7. 66 000 88 7. 9 88 7.6 647 888 7.9 6884 000 89 7.7 6674 89 8.6 744 888 8. 7384 96 8.9 7733 00 834 8.3 7 863 8.8 78 89 9. 794 99 9.6 834 946 0.0 8686 000 868 9.4 874 89 9.9 847 9 0.3 899 949 0.7 930 976. 9686 00 90 0.6 909 98. 993 94. 9977 980.0 0384 00.4 0779 0TJ03 AIR AVAILABLE EXTERNAL STATIC PRESSURE(iwg) FLOW..4.6.8 (CFM) RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts RPM Bhp Watts 8000 830 4.8 474 866. 446 90. 4767 936.9 070 800 8. 4744 886.8 047 90 6. 349 93 6. 663 9000 840.8 03 873 6. 349 90 6. 663 938 6.9 988 970 7.3 634 900 86 6.6 709 897 7.0 3 98 7.3 63 99 7.7 6698 990 8. 703 0000 89 7.4 644 9 7.8 6779 9 8. 78 98 8.6 7477 0 9.3 808 000 98 8.3 733 947 8.8 793 976 9. 794 004 9.6 740 03 0.0 74 000 94 9.4 80 97 9.8 846 000 0. 8837 08 0.6 909 0. 993 00 974 0. 908 000 0.9 944 07.3 986 03.8 0 000 00.6 008 08. 0477 LEGEND Bhp Brake Horsepower FIOP Factory-Installed Option Watts Input Watts to Motor Normal face: refers to the Standard Motor & Drive Package. Bold-Italic face: requires a field supplied drive package. NOTES:. Do not adjust motor rpm such that motor maximum bhp and/or watts is exceeded at the maximum operating cfm.. Static pressure losses must be added to external static pressure before entering Fan Performance table. 3. Interpolation is permissible. Do not extrapolate. 4. Fan performance is based on wet coils, clean filters, and casing losses.. Extensive motor and drive testing on these units ensures that the full horsepower and watts range of the motor can be utilized with confidence. Using your fan motors up to the watts or bhp rating shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected. 6. Use of a field-supplied motor may affect wiring size. Contact your Carrier representative for details 7. Evaporator Motor Efficiency 87%. - -
Table 3-FAN RPM AT MOTOR PULLEY SETTINGS* ENGLISH Freq. Unit 0TJ MOTOR PULLEY TURNS CLOSE 0 / / / 3 3 / 4 4 / 06 690 70 70 73 70 76 780 79 80 8 840 00 76 780 79 80 8 840 8 870 88 900 9 Hz 04 70 70 730 740 70 7 770 780 790 800 80 08 80 80 830 840 80 8 870 880 890 900 90 03 840 86 890 9 940 96 990 0 040 06 090 06 690 70 70 73 70 76 780 79 80 8 840 00 76 780 79 80 8 840 8 870 88 900 9 0 Hz 04 70 70 730 740 70 7 770 780 790 800 80 08 80 80 830 840 80 8 870 880 890 900 90 03 830 8 880 90 930 9 980 00 030 0 080 *Approximate fan rpm shown. *The standard belt size may not cover all the above range. Other RPMs require a field supplied Drive Package. Base Unit Operation COOLING, UNITS WITHOUT ECONOMI$ER When thermostat calls for cooling, terminals G and Y are energized. The indoor (evaporator) fan contactor (IFC), and compressor contactor no. (C) are energized and evaporator-fan motor, compressor no. and condenser fans start. The condenser-fan motors run continuously while unit is cooling. If the thermostat calls for a second stage of cooling by energizing Y, compressor contactor no. (C) is energized and compressor no. starts. HEATING, UNITS WITHOUT ECONOMI$ER - (If Accessory or Optional Heater is Installed) Upon a call for heating through terminal W, IFC and heater contactor no. (HC) are energized. On units equipped for stages of heat, when additional heat is needed, HC is energized through W. SERVICE Cleaning Inspect unit interior at beginning of each heating and cooling season and as operating conditions require. Remove unit top panel and/or side panels for access to unit interior. EVAPORATOR COIL Clean as required with a commercial coil cleaner. CONDENSER COIL Clean condenser coil annually and as required by location and outdoor-air conditions. Inspect coil monthly clean as required. CONDENSATE DRAIN Check and clean each year at start of cooling season. FILTERS Clean or replace at start of each heating and cooling season, or more often if operating conditions require. Refer to Table &3 for type and size. Lubrication COMPRESSORS Each compressor is charged with the correct amount of oil at the factory. Conventional white oil (Sontext 00LT) 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 original oil charge. A complete recharge should be four ounces less than the original 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 compressor. The compressor should then be run for 0 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. FAN SHAFT BEARINGS The bearings are of the pillow block type and have grease fittings. Lubricate the bearings twice annually. Typical lubricants are given below: Table. 4 Recommended Lubrications. MANUFACTURER Texaco Mobil Sunoco Texaco LUBRICANT Regal AFB-* Mobilplex EP No. Prestige 4 Multifak *Preferred lubricant because it contains rust and oxidation inhibitors. - 6 -
CONDENSER AND EVAPORATOR-FAN MOTOR BEARINGS The condenser and evaporator-fan motors have permanently-sealed bearings, so no field lubrication is necessary. Evaporator Fan Performance Adjustment NOTE: To remove belts only, follow Steps, & 6. Fan motor pulleys are factory set for speed shown in Table. To change fan speeds:. Shut off unit power supply.. Loosen belt by loosening fan motor mounting plate nuts. Slid the Motor and remove belt. 3. Loosen movable-pulley flange setscrew (see Fig. 9). 4. 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 & 3. See Table 8 for air quantity limits.. Set movable flange at nearest keyway of pulley hub and tighten setscrew. (See Table, 3 & 3 for speed change for each full turn of pulley flange.) 6. Replace and tighten belts. See Belt Tension Adjustment section on the next page. To align fan and motor pulleys:. Loosen fan pulley setscrews.. Slide fan pulley along fan shaft. 3. Make angular alignment by loosening motor from mounting plate. Evaporator Fan Service and Replacement. Remove supply-air section panel (The bolts holding the flexible connection to the panel should be removed).. Remove the Control Side panel. 3. Remove the Belt (refer to the previous section for Belt removal). 4. Remove the locking device of the hub & shaft from the both sides, it can be accessed throw the supply panel side.. Pull the shaft gently from the control side, the blower will fall inside the blower housing. 6. Loosen the (lower) first two bolts from each side of the scroll fan housing mid-plate. This can be done from the supply panel side, now the fan can be removed easily from the supply panel side. 7. To assemble the fan, reverse the above procedure. Fig. 9 Evaporator-Fan Pulley Alignment and Adjustment Belt Tension Adjustment To adjust belt tension:. Loosen fan motor bolts.. Adjust belt tension by sliding the motor on the mounting base. 3. Tighten nuts. 4. Adjust bolts and nut on mounting plate to secure motor in fixed position. Condenser-Fan Adjustment - (Fig. 0). Shut off unit power supply.. Remove fan top-grille assembly and loosen fan hub screws. 3. Adjust fan height on unit, using a straightedge placed across the fan orifice. 4. Tighten setscrews and replace rubber hubcap to prevent hub from rusting to motor shaft.. Fill hub recess with permagum if rubber hubcap is missing. - 7 - NOTE: Dimensions are in inches. Fig. 0 Condenser-Fan Adjustment,
Refrigerant Charge Amount of refrigerant charge is listed on unit nameplate and in Table. Refer to Carrier GTAC II; Module ; Charging, Recovery, Recycling, and Reclamation section for charging methods and procedures. Unit panels must be in place when unit is operating during charging procedure. NOTE: Do not use recycled refrigerant as it may contain contaminants. NO CHARGE Use standard evacuating techniques. After evacuating system, weigh in the specified amount of refrigerant (refer to Table ). LOW CHARGE COOLING Using cooling charging chart (see Fig. ), add or remove refrigerant until conditions of the chart are met. Note that charging chart is different from those normally used. An accurate pressure gage and temperature-sensing 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 near the liquid line service valve and insulate it so that outdoor ambient temperature does not affect reading. TO USE THE COOLING CHARGING CHART Use the above temperature and pressure readings, and find the intersection point on the cooling charging chart. If intersection point on chart is above line, add refrigerant. If intersection point on chart is below line, carefully recover some of the charge. Recheck suction pressure as charge is adjusted. NOTE: Indoor-air CFM must be within normal operating range of unit. All outdoor fans must be operating. Fig. Cooling Charging Chart Filter Drier Replace whenever refrigerant system is exposed to atmosphere. Protective Devices COMPRESSOR PROTECTION Over current Each compressor has internal line break motor protection, except the circuit no. on the 0TJ08 unit and both circuits in 0TJ03 witch has an electronic module located with the compressor junction box, to provide motor protection. This electronic module monitors winding and discharge temperatures. If these temperatures reach the trip values, the module interrupts the control line and causes the compressor to switch off. IMPORTANT: After prolonged shutdown or servicing in cold wether, energize the crankcase heaters for 4 hours before starting the compressors. Compressor Lockout If any of the safeties (highpressure, low-pressure, freeze protection thermostat, compressor internal thermostat, external compressor thermal overload) trip, or if there is loss of power to the compressors, the CLO (compressor lockout) will lock the compressors off. To reset, manually move the thermostat setting. Compressor Overload Each compressor contactor has its thermal over load devise. See table. for thermal overload Amps settings. EVAPORATOR FAN MOTOR PROTECTION The Evaporator Fan Contactor has its thermal over load devise. See table. for thermal overload Amps settings. CONDENSER-FAN MOTOR PROTECTION Each Condenser-fan motor is internally protected against over temperature. HIGH- AND LOW-PRESSURE SWITCHES If either switch trips, or if the compressor over temperature 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. It detects frost build-up and turns off the compressor, allowing the coil to clear. Once the frost has melted, the compressor can be reenergized. To reset, manually move the thermostat setting. Relief Devices All units have relief devices to protect against damage from excessive pressures (e.g., fire). These devices protect the high and low side. Control Circuit, 4-V This control circuit is protected against over-current by a 3.-amp circuit breaker. Breaker can be reset. If it trips, determine cause of trouble before resetting. Replacement Parts A complete list of replacement parts may be obtained from any Carrier distributor. - 8 -
Table. Thermal overloads settings. SETTINGS POWER SUPPLY UNIT SIZE V/Ph/Hz INDOOR COMP COMP MOTOR 6.0 3 3 0.0 38 3 30/3/ 4 8.0 4 38 8 8.0 4 3 7.0 6 7.0 8 8 0 7.0 8 380/3/ 4.0 4 8.0 3 4 3 6. 3 3 6 6.0 6 6 0 6.0 7 6 4/3/ 4 9.0 7 8 9.0 6 3 4. 6 6 6 7.0 7 7 0 7.0 7 400/3/0 4 0. 6 8 0. 30 6 3 6.0 30 30 WARNING Thermal overloads settings are factory adjusted; any change for these settings may affect the unit operation and can cause a serious failure. IMPORTANT Field installed thermostat should include time delay between stages to limit the inrush current during the unit starting. - 9 -
Fig.-Typical Wiring Schematic- Hz & 0TJ06-04 0Hz - 0 -
Fig.3-Typical Wiring Schematic- 0TJ08-03 0Hz - -
Fig.4-Typical Wiring Schematic- (Cont.) COMPONENT ARRANGEMENT HZ & SIZES 06-04 0HZ COMPONENT ARRANGEMENT SIZES 08, 03 0HZ - -
Fig.-Typical Wiring Schematic -(Cont.) - 3 -
TROUBLESHOOTING Table 6 Cooling Service Analysis PROBLEM CAUSE REMEDY Compressor and Power failure. Call power company. condenser fan will Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. not start. Defective thermostat, contactor, transformer, or control Replace component. relay. Insufficient line voltage. Determine cause and correct. Incorrect or faulty wiring. Check wiring diagram and rewire correctly. Thermostat setting too high. Lower thermostat setting below room temperature. Compressor will Faulty wiring or loose connections in compressor circuit. Check wiring and repair or replace. not start but Compressor motor burned out, seized, or internal over- Determine cause. Replace compressor. condenser fan runs. load open. Defective overload. Determine cause and replace. Compressor locked out Determine cause for safety trip and reset lockout. One leg of 3-phase power dead. Replace fuse or reset circuit breaker. Determine cause. Compressor cycles (other than normally satisfying thermostat). Compressor operates continuously. Excessive head pressure. Refrigerant overcharge or undercharge. Defective compressor. Insufficient line voltage. Blocked condenser. Defective overload. Defective thermostat. Faulty condenser-fan motor. Restriction in refrigerant system. Dirty air filter. Unit undersized for load. Thermostat set too low. Low refrigerant charge. Air in system. Condenser coil dirty or restricted. Dirty air filter. Dirty condenser coil. Refrigerant overcharged. Faulty TXV. Air in system. Condenser air restricted or air short-cycling. Head pressure too Low refrigerant charge. low. Restriction in liquid tube. Remove restriction. Recover refrigerant, evacuate system, and recharge to nameplate. Replace and determine cause. Determine cause and correct. Determine cause and correct. Determine cause and replace. Replace thermostat. Replace. Locate restriction and remove. Replace filter. Decrease load or increase unit size. Reset thermostat. Locate leak, repair, and recharge. Recover refrigerant, evacuate system, and recharge. Clean coil or remove restriction. Replace filter. Clean coil. Recover excess refrigerant.. Check TXV bulb mounting and secure tightly to suction line.. Replace TXV if stuck open or closed. Recover refrigerant, evacuate system, and recharge. Determine cause and correct. Check for leaks, repair, and recharge. Excessive suction pressure. Suction pressure too low. High heat load. Faulty TXV. Refrigerant overcharged. Dirty air filter. Low refrigerant charge. Metering device or low side restricted. Faulty TXV. Insufficient evaporator airflow. Temperature too low in conditioned area. Field-installed filter drier restricted. Check for source and eliminate.. Check TXV bulb mounting and secure tightly to suction line.. Replace TXV if stuck open or closed. Recover excess refrigerant. Replace filter. Check for leaks, repair, and recharge. Remove source of restriction.. Check TXV bulb mounting and secure tightly to suction line.. Replace TXV if stuck open or closed. Increase air quantity. Check filter and replace if necessary. Reset thermostat. Replace. - 4 -
Notes - -
Notes - 6 -
Notes - 7 -
I. PRELIMINARY INFORMATION MODEL NO.: DATE: START-UP CHECKLIST (Remove and Store in Job File) - 8 - SERIAL NO.: TECHNICIAN: II. PRE-START-UP (insert checkmark in box as each item is completed) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS VERIFY THAT UNIT INSTALLATION IS LEVEL CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS III. START-UP ELECTRICAL SUPPLY VOLTAGE L-L L-L3 L3-L COMPRESSOR - AMPS L L L3 COMPRESSOR - AMPS L L L3 INDOOR FAN AMPS TEMPERATURES OUTDOOR-AIR TEMPERATURE DB RETURN-AIR TEMPERATURE DB WB COOLING SUPPLY AIR PRESSURES REFRIGERANT SUCTION CIR REFRIGERANT DISCHARGE CIR REFRIGERANT SUCTION CIR REFRIGERANT DISCHARGE CIR PSIG PSIG PSIG PSIG VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGES 8. Form 0TJSD-04 IOM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE