Home

Installation, Start-Up, and Operating Instructions

1. Air delivery values are without air filter and for dry coil See Table 10 48SD Wet Coil Pressure Drop table and Table 8 Filter Pressure Drop Factory shipped heating cooling speed NA Not allowed for heating speed Note Deduct field supplied air filter pressure drop and wet coil pressure drop to abtain external static pressure available for ducting d Reassemble wheel into housing e Reassemble motor into housing Be sure setscrews are tightened on motor shaft flats and not on round part of shaft f Reinstall unit access panel 3 Restore electrical power to unit Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles FLUE GAS PASSAGEWAYS To inspect the flue collector box and upper areas of the heat exchanger Remove the combustion blower wheel and motor assembly according to directions in the Combustion Air Blower section 2 Remove the 3 screws holding the blower housing to the flue collector box cover See Fig 16 19 3 Remove the 12 screws holding the flue collector box cover See Fig 18 19 to the heat exchanger assembly Inspect the heat exchangers 4 Clean all surfaces as required using a wire brush INDUCED DRAFT COMBUSTION AIR BLOWER Clean periodically to assure proper airflow and heating efficiency Inspect blower wheel every fall and periodically during the heating season For the first heating season inspect b
2. 24 ELECTRICAL CONTROLS AND WIRING 24 REFRIGERANT CIRCUIT GAS INPUT EVAPORATOR AIRFLOW METERING DEVICE 24 LIQUID LINE STRAINER incitis 24 TROUBLESHOOTING sara niim timet START UP CHECKLIST NOTE TO INSTALLER Before the installation READ THESE INSTRUCTIONS CAREFULLY AND COMPLETELY Also make sure the User s Manual and Replacement Guide are left with the unit after installation The furnace is NOT to be used for temporary heating of buildings or structures under construction SAFETY CONSIDERATIONS Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical components Only trained and qualified personnel should install repair or service air conditioning equipment Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 101 Tab 1a 6a Printed in U S A Catalog 4850 15 Pg 1 8 05 Replaces New Untrained personnel can perform basic maintenance functions of cleaning coils and 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
3. Based on altitude of 0 to 2000 ft T Required filter sizes shown are based on the larger of the ARI Air Conditioning and Refrigeration Institute rated cooling airflow or the heating airflow velocity of 300 ft minute for high capacity type Air filter pressure drop for non standard filters must not exceed 0 08 in wg 7 3 or 7 4 or Can CGA Canadian Gas Association B149 Installation Codes or applicable provisions of local building code Step 5 RIG AND PLACE UNIT CAUTION PROPERTY DAMAGE HAZARD CAUTION OPERATIONAL HAZARD Failure to follow this caution may result in unit component Failure to follow this caution may result in property damage When installing the unit on a rooftop be sure the roof will support the additional weight damage Do not restrict condenser airflow An air restriction at either the outdoor air inlet or the fan discharge can be detrimental to compressor life Use spreader bars or crate top when rigging the unit The units must be rigged for lifting See Fig 7 Refer to Table 1 for operating weight Use extreme caution to prevent damage when The condenser fan pulls air through the condenser coil and discharges it through the top cover Be sure that the fan discharge does not recirculate to the condenser coil Do not locate the unit in either a corner or under an overhead obstruction The minimum clearance under a partial overhang such as a normal house overhang is 48 in above t
4. e E Wood nailer Flashing field supplied Flashing field supplied Roofcurb La Roofcurb Insulation field 171 supplied Duct wo rk field supplied Insulation field supplied Roofing materal Roofing material field supplied field supplied Duct wo rk field supplied Cant strip Cant strip field supplied field supplied N Provided with roofcurb Provided with roofcurb Roof Curb for Small Cabinet Roof Curb for Large Cabinet Note A When unit mounting screw is used Note A When unit mounting screw is used retainer bracket must also be used retainer bracket must also be used Tf R A S A Gasket around duct P dd Insulated Gasket around deck pan outer edge Insulated deck pan Long Support t Return opening BXC A05165 A B D E F G UNIT SIZE ODS CATALOG NUMBER IN IN MM IN MM IN MM IN MM IN MM A8SD024 030 __CPRFCURBOO6A00 8 203 11 279 161 2 419 28 3 4 730 30 3 8 771 44 5 16 1126 45 15 16 1167 CPRFCURBO007A00 14 356 11 279 161 2 419 28 3 4 730 30 3 8 771 44 5 16 1126 45 15 16 1167 4850036 06 __CPRECURB008A00 8 203 16 3 16 411 17 3 8 441
5. 1466 1437 1387 1330 1264 1183 1093 Heating Rise F 29 30 31 31 32 34 36 38 41 Watts 741 715 694 669 645 610 573 544 48SD N 042060 25 55 Medium CFM 1738 1698 1653 1604 1538 1457 1362 1271 Heating Rise F 26 27 27 28 29 31 33 35 Watts 798 772 738 700 High CFM 1720 1648 1540 1414 Heating Rise F 26 27 29 32 20 Table 9 Dry Coil Air Delivery Horizontal and Downflow Discharge Unit 48SD024 060 Deduct 10 percent for 208 Volts UNIT HEATING RISE RANGE F MOTOR SPEED EXTERNAL STATIC 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 Watts 625 606 586 571 550 534 509 483 457 Low CFM 1539 1496 1466 1437 1387 1330 1264 1183 1093 Heating Rise F 44 45 46 47 49 51 53 57 62 Watts 715 694 669 645 610 573 544 48SD N 042090 40 70 Medium CFM 1698 1653 1604 1538 1457 1362 1271 Heating Rise F 40 41 42 44 46 50 53 Watts 772 738 700 High CFM 1648 1540 1414 Heating Rise F 41 44 48 Watts 627 617 607 584 567 548 528 503 Low CFM 1550 1530 1493 1461 1414 1361 1320 1250 Heating Rise F 44 44 45 46 48 50 51 54 Watts 771 755 734 711 690 665 639 607 572 48SD N 048090 25 55 Med
6. 5 yg 91 T L Nya an 4 Nu92T AuVQNO23S NUg8 34 1 1 WOI 34 qm 403 318 f LIA A aug 49 AUNTS al 134 0 134 LIM 1HM NU8 310N 339 13 Bp 870 ONY 9 14 YOSSIYdNOD mE 019 66M 134 LLM 88M 2 Nua 1 W3O 134 134 wg KINO SLINN 8 0 9 0 20 41103 09 1 0 2 80c JILVWN3H2S YIMOd AlddfiS X18 118 HOD 01313 05125 208 230 1 60 Wiring Diagram Units 48 0 Fig 15 14 Table 4 Heating Inputs GAS SUPPLY PRESSURE MANIFOLD INPUT OF Natural Propanet IN WG BTUH ORIFICES Natural Propanet 40 000 2 4 0 13 0 4 0 13 0 3 5 3 5 60 000 2 4 0 13 0 4 0 13 0 3 5 3 5 90 000 3 4 0 13 0 4 0 13 0 3 5 3 4 115 000 3 4 0 13 0 4 0 13 0 3 5 3 7 130 000 3 4 0 13 0 4 0 13 0 3 5 3 5 When a unit is converted to propane different size orifices must be used See separate natural to propane conversion kit instructions T Based on altitudes from sea level to 2000 ft above sea level For altitudes above 2000 ft reduce input rating 4 percent for each additional 1000 ft above sea level In Canada from 2000 ft above sea level to 4500 ft above sea level derate the unit 10 percent Step 2 START UP H
7. CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death The venting system is designed to ensure proper venting The flue hood assembly must be installed as indicated in this section of the unit installation instructions Install the flue hood as follows 1 This installation must conform with local building codes and with the National Fuel Gas Code NFGC ANSI Z223 1 in Canada CAN CGA 149 1 and B149 2 NFPA National Fire Protection Association latest revision Refer to Provin cial and local plumbing or wastewater codes and other applicable local codes 2 Remove flue hood from shipping location inside the blower compartment Place vent cap assembly over flue panel Orient screw holes in vent cap with holes in the flue panel 3 Secure flue hood to flue panel by inserting a single screw on the right side and the left side of the hood Table 2 Maximum Gas Flow Capacity NOMINAL INTERNAL LENGTH OF PIPE FTt IRON RIPE DIAMETER ig IN 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1 2 622 175 120 97 82 73 61 57 53 50 44 40 3 4 824 360 250 200 170 151 138 125 118 110 103 93 77 72 1 1 049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 1 1 4 1 380 1400 950 770 600 580 530 490 460 430 400
8. HEATING amp COOLING 48SD Single Packaged Gas Heating Electric Cooling Units Visit www carrier com Installation Start Up and Operating Instructions Size 024 060 NOTE Read the entire instruction manual before starting the installation TABLE OF CONTENTS SAFETY CONSIDERATIONS eene inrer rtt 1 INTRODUYCTION 7 rtt 2 RECEIVING AND INSTALLATION eee 2 CHECK EQUIPMENT aicssscssescssssssisssssssssossssenssnssassanssnsonsossoasves 2 IDENTIFY UNIT tte 2 INSPECT 5 2 INSTALLATION ttn e trenes 2 PROVIDE UNIT SUPPORT enceinte rere 2 ROOF CURB errien ar EH ED n imer ERE 2 GROUND MOUNT 4 SLAB MOUNT Van 4 FIELD FABRICATE DUCTWORK nnn 6 PROVIDE CLEARANCES 7 RIG AND PLACE trt ren 7 CONNECT CONDENSATE 7 INSTALE BE UB HOOD erede 8 INSTALL GAS PIPING eet cher rr ren rox sese 9 INSTALL DUCT CONNECTIONS 10 CONFIGURING UNITS FOR DOWNFLOW VERTI CAL DISCHARGE tete terne 10 INSTALL ELECTRICAL CONNECTIONS 11 HIGH VOLTAGE CONNECTIONS 11 SPECIAL PROCEDURES FOR 208 V OPERATION 12 CONTROL VOLTAGE CONNECTIONS 12 HEAT A
9. On a call for heating terminal of the thermostat is energized starting the induced draft motor When the hall effect sensor on the induced draft motor senses that it has reached the required speed the burner sequence begins This function is performed by the integrated gas control IGC The indoor evaporator fan motor is energized 45 sec after flame is established When the thermostat is satisfied and is de energized the burners stop firing and the indoor evaporator fan motor shuts off after a 45 sec time off delay An LED light emitting diode indicator is provided on the control board to monitor operation The control board is located by removing the burner access panel During normal operation the LED is continuously on See Table 5 for error codes Table 5 LED Indications ERROR CODE LED INDICATION Normal Operation On Hardware Failure Off Fan On Off Delay Modified 1 Flash Limit Switch Fault 2 Flashes Flame Sense Fault 3 Flashes Four Consecutive Limit Switch Faults 4 Flashes Ignition Lockout Fault 5 Flashes Induced Draft Motor Fault 6 Flashes Rollout Switch Fault 7 Flashes Internal Control Fault 8 Flashes Temporary lock out 1 hr 9 Flashes NOTES 1 There is a 3 sec pause between error code displays 2 If more than one error code exists all applicable error codes will be displayed in numerical sequence 3 This chart is on the wiring diagram located inside the
10. 360 325 300 280 1 1 2 1 610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 Capacity of pipe in cu ft of gas per hr for gas pressure of 0 5 psig or less Pressure drop of 0 5 in wg based on a 0 60 specific gravity gas Refer to Table C 4 National Fire Protection Association NFPA 54 T This length includes an ordinary number of fittings Step 8 INSTALL GAS PIPING The gas supply pipe enters the unit through the access hole provided The gas connection to the unit is made to the 1 2 in FPT gas inlet on the manual shutoff or gas valve Install a gas supply line that runs to the heating section Refer to Table 2 and the NFGC for gas pipe sizing Do not use cast iron pipe It is recommended that a black iron pipe is used Check the local utility for recommendations concerning existing lines Size gas supply piping for 0 5 in wg maximum pressure drop Never use pipe smaller than the 1 2 in FPT gas inlet on the unit gas valve For natural gas applications the gas pressure at unit gas connection must not be less than 4 0 in wg or greater than 13 in wg while the unit is operating For propane applications the gas pressure must not be less than 7 0 in wg or greater than 13 in wg at the unit connection An 1 8 in NPT plugged tapping accessible for test gage connec tion must be installed immediately upstream of the gas supply connection to the gas
11. 550 5 249 6 9 83 21 67 9 83 REAR VIEW CLEARANCE TO COMBUSTIBLE MATL Refer to Maximum Operating Clearances TOP OF UNIT DUCT SIDE OF UNIT SIDE OPPOSITE DUC BOTTOM OF UNIT NEC REQUIRED CLEARANCES BETWEEN UNITS POWER ENTRY SIDE 546 1 254 0 21 501 10 001 E 042 ONLY NAL riae 16 001 018 COND COIL NON BENT INCHES mm INCHES mm 42 00 1066 8 UNIT AND UNGROUNDED SURFACES POWER ENTRY SIDE 36 00 914 0 UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES POWER ENTRY SIDE LEGEND CG Center of Gravity COND Condensor EVAP Evaporator NEC National Electrical Code REQ D Required NOTE Dimensions are in in mm EM 198 5 e amp Q FIELD ENTRY SERVICE PORTS 42 00 1066 8 COND COIL EVAP COIL TOP VIEW REQUIRED CLEARANCE FOR OPERATION AND SERVICING EVAP COIL ACCESS SIDE POWER ENTRY SIDE EXCEPT FOR UNIT TOP SIDE OPPO DUCT PANEL MINIMUM DISTANCES IF UNIT IS PLACED LESS THAN 12 00 304 8 FROM WALL SYSTEM THEN SYSTEM PERFORMANCE MAYBE COMPROMISE INCHES mm 36 00 914 0 42 00 1066 8 48 00 1219 2 36 00 914 0 31 44 1193 9 47 001 28 6 1 13 DIA K 0 POWER ENTRY 22 2 0 88 DIA HOLE CONTROL ENTRY 12 7 0 50 N
12. Clean or replace filter as necessary Gas input to furnace too low Check gas pressure at manifold match with that on unit nameplate Unit undersized for application Replace with proper unit or add additional unit Restricted airflow Clean or replace filter Remove any restriction Blower speed too low Use faster speed tap if available or install alternate motor Limit switch cycles main burners Check rotation of blower thermostat heat anticipator settings temperature rise of unit Adjust as necessary Poor flame characteristics Incomplete combustion results in Aldehyde odors carbon monoxide sooting flame floating flame 26 1 Tighten all screws around burner compartment 2 Cracked heat exchanger Replace 3 Unit overfired Reduce input change orifices or adjust gas line or manifold pressure 4 Check burner alignment 5 Inspect heat exchanger for blockage Clean as necessary SYMPTOM Table 13 Troubleshooting Guide LED Error Codes CAUSE REMEDY Hardware failure LED OFF Loss of power to control module IGC Check 5 amp fuse on IGC power to unit 24 v circuit breaker and transformer Units without a 24 v circuit breaker have an internal overload in the 24 v transformer If the overload trips allow 10 min utes for automatic reset Fan ON OFF delay modified LED FLASH High limit switch opens during heat exchanger warm up period before
13. See Table 3 for electrical data The field supplied disconnect switch box may be mounted on the unit over the high voltage inlet hole when the standard power and low voltage entry points are used See Fig 2 and 3 for acceptable location See unit wiring label and Fig 11 for reference when making high voltage connections Proceed as follows to complete the high voltage connections to the unit are EIS HIGH VOLTAGE POWER LEADS 49977 7 SEE UNIT WIRING PONER LABEL a FIELD SUPPLIED a FUSED DISCONNECT CONTROL BOX WHT W1 p LYEL Y p THERMOSTAT GRN G LOW VOLTAGE TYPICAL POWER LEADS RED R SEE UNIT WIRING LABEL BRN C SPLICE BOX m Fig 11 High and Control Voltage Connections Single phase units 1 Run the high voltage L1 L2 and ground leads into the control box 2 Connect ground lead to chassis ground connection 3 Connect L1 to pressure lug connection 11 of the compressor contactor 4 Connect L2 to pressure lug connection 23 of the compressor contactor Table 3 Electrical Data Unit 48SD UNIT ANGES COMPRESSOR n n MIR POWER SUPPLY SIZE V PH HZ 48SD Min Max RLA LRA FLA FLA MCA 024 208 230 1 60 187 253 10 9 54 0 09 20 16 5 16 5 20 20 030 208 230 1 60 187 253 140 72 5 0 9 20 20 4 20 4 25 25 036 208 230 1 60 187 253 16 0 88 0 0 9 34 24 0 24 0 30 30 042 208 230 1 60 187 253 18 4 104 0 09 44 28 0 28 0 35 35 048 208
14. compare outdoor air tem perature F db with the suction line pressure psig to determine desired system operating suction line temperature See Table 7 6 Compare actual suction tube temperature with desired suction tube temperature Using a tolerance of 3 F add refrigerant if actual temperature is more than 3 F higher than proper suction tube temperature or remove refrigerant if actual temperature is more than 3 F lower than required suction tube temperature NOTE If the problem causing the inaccurate readings is a refrigerant leak refer to the Check for Refrigerant Leaks section INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS A CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in unit damage For cooling operation the recommended airflow is 350 to 450 cfm for each 12 000 Btuh of rated cooling capacity For heating operation the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate Table 9 shows the temperature rise at various airflow rates Table 9 shows both heating and cooling airflows at various external static pressures Refer to these tables to determine the airflow for the system being installed See Table 10 for wet coil pressure drop NOTE Be sure that all supply and return air grilles are open free from obstructions and adjusted properly A WARNING FIRE EXPLOSION AND ELECTRICAL SHOCK HAZ ARD Failure to follow this warning
15. 0 50 12 7 NEC REQUIRED CLEARANCES INCHES mm BETWEEN UNITS POWER ENTRY SIDE 42 00 1066 8 UNIT AND UNGROUNDED SURFACES POWER ENTRY SIDE 36 00 914 0 UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES POWER ENTRY SIDE 42 00 1066 8 E EXCEPT FOR NEC REQUIREMENTS UNIT TOP SIDE OPPOSITE DUCTS DUCT PANEL 48 00 1219 2 36 00 914 0 12 00 304 8 MINIMUM DISTANCES IF UNIT IS PLACED LESS THAN 12 00 304 8 FROM WALL SYSTEM THEN SYSTEM PERFORMANCE MAYBE COMPROMISE LEGEND CG Center of Gravity COND Condensor EVAP Evaporator NEC National Electrical Code REQ D Required je 15 4 NOTE Dimensions are in in mm 11 1090 6 142 94 FIELD ENTRY 23 0 4 SERVICE PORT 0 911 4 54 28 6 1 13 DIA K 0 POWER ENTRY 22 2 0 88 DIA HOLE CONTROL ENTRY 620 2 24 42 12 951 12 4 2 85 1226 3 j 7 d 42 1 46 8 11 68 OMPRESSOR BLOWER GAS SECTION 1 84 12 7 10 501 N P T 329 0 amp ELECTRICAL ACCESS PANEL GAS ENTRY FLUE HOOD 5 0 0 201 44 22 1123 1 48 281 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW A05142 CENTER OF GRAVITY UNIT ELECTRICAL CHARACTERISTICS UNIT WEIGHT UNIT IN IN MM Ib kg X Y 7 48SD036060 090 208 230
16. 1 60 433 0 196 0 42 98 1092 0 21 0 533 0 20 5 520 0 16 6 422 0 48SD042060 090 208 230 1 60 460 0 209 0 46 98 1193 0 21 0 533 0 20 5 520 0 17 1 434 0 48SD048090 115 130 208 230 1 60 480 0 218 0 46 98 1193 0 21 0 533 0 20 0 508 0 17 4 442 0 48SD060090 115 130 208 230 1 60 492 0 223 0 46 98 1193 0 21 0 533 0 20 0 508 0 17 6 447 0 Fig 3 48SD036 Curb should be level to within 1 4 in This is necessary for unit drain to function properly Refer to accessory roof curb installation instructions for additional information as required GROUND MOUNT The unit may be installed either on a slab or placed directly on the ground if local codes permit Place the unit on level ground prepared with gravel for condensate discharge 060 Unit Dimensions SLAB MOUNT Place the unit on a solid level concrete pad that is a minimum of 4 in thick with 2 in above grade The slab should be flush on the compressor end of the unit to allow condensate drain installation and should extend 2 in on the three remaining sides of the unit See Fig 6 Do not secure the unit to the slab except when required by local codes VACunit base Gask eting inner flange Screw NOTE A Screw NOTE A Gasketing inner flange f Gasketing Gasketing outer flange outer flange qu W Wood nailer
17. 40 1 4 1022 41 15 16 1065 44 7 16 1129 46 1 16 1169 CPRFCURBO09A00 14 356 16 3 16 411 17 3 8 441 40 1 4 1022 41 15 16 1065 44 7 16 1129 46 1 16 1169 NOTES Roof curb must be set up for unit being installed Seal strip must be applied as required to unit being installed Dimensions in are in millimeters Roof curb is made of 16 gage steel Table lists only the dimensions per part number that have changed Attach ductwork to curb flanges of duct rest on curb Insulated panels 1 in thick fiberglass 1 Ib density Dimensions are in inches When unit mounting screw is used see Note A a retainer bracket must be used as well This bracket must also be used when required by code for hurricane or Seismic conditions This bracket is available through Micrometl Fig 4 Roof Curb Dimensions 5 0 00 C00070 48SD 024 030 036 042 048 060 1 69 74 87 93 97 99 2 53 57 68 72 74 76 3 83 88 104 111 116 119 4 138 147 174 184 193 198 TOTAL WEIGHT 343 366 433 460 480 492 Fig 5 48SD Unit Corner Weights in Pounds C99014 Fig 6 Slab Mounting Details Step 3 FIELD FABRICATE DUCTWORK Secure all ducts to roof curb and building structure on vertical discharge units Do not connect ductwork to unit For horizontal applications unit is provided with flanges on the horizontal openi
18. CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in component damage and cause flame impingement of burners and heat exchangers When servicing gas train do not hit or plug orifice spuds Removal of Gas Train To remove the gas train for servicing 1 Shut off main gas valve Shut off power to unit and install lockout tag Remove unit access panel See Fig 17 Disconnect gas piping at unit gas valve Remove wires connected to gas valve Mark each wire Remove ignitor and sensor wires at the ignitor module t ROO P Remove the mounting screw that attaches the burner rack to the unit base See Fig 16 8 Slide the burner rack out of the unit See Fig 16 and 19 9 To reinstall reverse the procedure outlined above CONDENSER COIL EVAPORATOR COIL AND CONDENSATE DRAIN PAN Inspect the condenser coil evaporator coil and condensate drain pan at least once each year or more often if necessary The coils are easily cleaned when dry therefore inspect and clean the coils either before or after each cooling season Remove all obstructions including weeds and shrubs that interfere with the airflow through the condenser coil Straighten bent fins with a fin comb If coated with dirt or lint clean the coils with a vacuum cleaner using the soft brush Table 10 48SD Wet Coil Pressure Drop UNIT SIZE
19. Heating Rise F 32 33 34 36 37 39 40 42 Watts 1012 993 981 963 948 927 904 886 High CFM 2184 2109 2036 1963 1886 1812 1729 1647 Heating Rise F 31 32 33 34 36 37 39 41 Watts 786 769 754 736 722 705 684 658 Low CFM 2027 1960 1901 1821 1759 1693 1616 1513 Heating Rise F 43 44 45 47 49 51 53 57 Watts 873 849 833 815 798 782 763 748 48SD N 060115 35 65 Medium CFM 2095 2026 1962 1887 1817 1748 1679 1583 Heating Rise F 41 43 44 46 47 49 51 54 Watts 1012 993 981 963 948 927 904 886 High CFM 2184 2109 2036 1963 1886 1812 1729 1647 m Heating Rise F 39 41 42 44 46 48 50 52 21 Table 9 Dry Coil Air Delivery Horizontal and Downflow Discharge Unit 48SD024 060 Deduct 10 percent for 208 Volts EXTERNAL STATIC PRESSURE WC UNIT HEATING RISE RANGE F MOTOR SPEED 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 Watts 769 754 736 722 705 684 658 CFM 1960 1901 1821 1759 1693 1616 1513 Heating Rise F 50 51 54 55 58 60 64 Watts 849 833 815 798 782 763 748 48SD N 060130 40 70 CFM 2026 1962 1887 1817 1748 1679 1588 Heating Rise F 48 50 52 54 56 58 62 Watts 993 981 963 948 927 904 886 CFM 2109 2036 1963 1886 1812 1729 1647 Heating Rise F 46 48 50 52 54 56 59
20. P T 12 00 304 8 CHEESE ER enn wm 1226 3 2 08 ure 831 0 48 28 122 2 32 721 4 81 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW A05166 CENTER OF GRAVITY UNIT WEIGHT UNIT ELECTRICAL CHARACTERISTICS c IN MM IN MM Ib kg X Y 7 4850024040 060 208 230 1 60 343 0 156 0 39 02 991 0 20 0 508 0 19 3 490 0 17 6 447 0 4850030040 060 208 230 1 60 366 0 166 0 41 02 1042 0 20 0 508 0 14 0 356 0 13 0 330 0 Fig 2 48SD024 030 Unit Dimensions 3 355 8 355 8 p 14 01 14 01 86 0 3 391 RETURN SUPPLY n ___ _ ________ p o OPTIONAL optional 406 6 RETURN supply 1 406 6 16 01 AIR AIR 16 01 OPENING OPENING Tm B a COND COIL T 80 5 4636 SUPPL RETURN 115 831 OPENING OPENING Y ll M EVAP COIL S Jl 173 5 Ezzzzzz 2 6 83 4 63 OND COIL MX T TOP VIEW REAR VIEW REQUIRED CLEARANCE TO COMBUSTIBLE MATL REQUIRED CLEARANCE FOR OPERATION AND SERVICING INCHES mm Refer to Maximum Operating Clearances INCHES mm EVAP COIL ACCESS SIDE 36 00 914 0 TOP OF UNIT 14 00 355 6 POWER ENTRY SID 42 00 1066 8 DUCT SIDE OF UNIT 2 00 50 8 SIDE OPPOSITE DUCTS 14 00 355 6 BOTTOM OF UNIT 2
21. Unit 48SD Continued UNIT SIZE 48SD 048090 048115 048130 060090 060115 060130 NOMINAL CAPACITY ton 4 4 4 5 5 5 OPERATING WEIGHT Ib 480 480 480 492 492 492 COMPRESSORS Scroll Quantity 1 REFRIGERANT R 22 Quantity Ib 12 3 12 3 12 3 12 0 12 0 12 0 REFRIGERANT METERING DEVICE Accurater Orifice ID in 088 088 088 101 101 101 2 21 2 21 2 21 2 21 2 21 2 21 Face Area sq ft 19 4 19 4 19 4 19 4 19 4 19 4 ee 3300 3300 3300 3300 3300 3300 Diameter 22 22 22 22 22 22 Motor Hp Rpm 1100 1100 14 1100 1100 1100 1100 Bici 4 15 4 15 4 15 4 15 4 15 4 15 Face Area sq fl 4 7 4 7 4 7 4 7 4 7 4 7 1600 1600 1600 1750 1750 1750 Size in 11 X 10 11 X 10 11 X 10 11 X 10 11 X 10 11 X 10 Motor Hp Rpm 1 2 1075 1 2 1075 1 2 1075 1 0 1040 1 0 1040 1 0 1040 FURNACE SECTION Burner Orifice No Qty Drill Size 3 38 3 33 3 31 3 38 3 33 3 31 Natural Gas 3 46 3 42 3 41 3 46 3 42 3 41 Burner Orifice No Qty Drill Size Propane Gas RETURN AIR FILTERS in t 24 X 36 X 1 Throwaway Based on altitude of 0 to 2000 ft T Required filter sizes shown are based on the larger of the ARI Air Conditioning and Refrigeration Institute rated cooling airflow or the heating airflow velocity of 300 ft minute for high capacity type Air filter pressure drop for non standard f
22. Wear safety glasses and work gloves Use quenching cloth for unbrazing operations Have fire extinguisher available for all brazing operations A WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CAR BON MONOXIDE POISONING HAZARD Improper installation adjustment alteration service mainte nance or use can cause carbon monoxide poisoning fire or an explosion which can result in personal injury or unit damage Consult a qualified installer service agency or gas supplier for information or assistance The qualified installer or agency must use only factory authorized kits or accessories when modifying this product A WARNING FIRE EXPLOSION AND ELECTRICAL SHOCK HAZ ARD Failure to follow this warning could result in personal injury death and or property damage Before performing service or maintenance operations on unit turn off gas supply to unit Then turn off unit main power switch and install lockout tag Electrical shock or explosion could cause serious injury or death Recognize safety information This is the safety alert symbol A When you see this symbol in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING CAUTION and NOTE These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in serious injury or death WARNING signifies a hazard which could result in serious injury or death CAUTION
23. could result in personal injury death and or property damage Before changing blower speed shut off gas supply Then disconnect electrical power to the unit and install lockout tag Airflow can be changed by changing the lead connections of the indoor evaporator fan motor All 48SD units are factory wired for low speed except sizes 030 and 048 which are wired for medium speed For 208 230V For color coding on the 208 230V motor leads see Table 6 Table 6 Color Coding for 208 230 V Motor Leads BLACK HIGH SPEED Blue medium speed Red low speed To change the speed of the indoor evaporator fan motor remove the fan motor speed leg lead from the blower relay BR This wire is attached to terminal BM of the integrated gas control IGC board for single phase units To change the speed remove and replace with lead for desired blower motor speed nsulate the removed lead to avoid contact with chassis parts COOLING SEQUENCE OF OPERATION With the room thermostat SYSTEM switch in the COOL position and the FAN switch in the AUTO position the cooling sequence of operation is as follows 1 When the room temperature rises to a point that is slightly above the cooling control setting of the thermostat the thermostat completes the circuit between thermostat terminal R to terminals Y and G These completed circuits through the thermostat 2 The normally open contacts of energized contactor C close and complete the c
24. must be measured to determine the input of propane gas units Measure Gas Flow Natural Gas Units Minor adjustment to the gas flow can be made by changing the manifold pressure The manifold pressure must be maintained between 3 4 and 3 6 in wg If larger adjustments are required change main burner orifices following the recommendations of national and local codes NOTE All other appliances that use the same meter must be turned off when gas flow is measured at the meter NOTE Make sure that gas supply has been purged and that all gas piping has been checked for leaks CHECK HEATING CONTROL Start and check the unit for proper heating control operation as follows see furnace lighting instructions located inside burner or blower access panel 1 Place room thermostat SYSTEM switch in the HEAT position and the fan switch is placed in AUTO position Set the heating temperature control of the thermostat above room temperature 3 The induced draft motor will start Proceed as follows 4 After a call for heating the main burner should light within 5 sec If the burners do not light there is a 22 sec delay before 1 Turn off gas supply to unit another 5 sec try If the burners still do not light this 2 Remove pipe plug on manifold See Fig 13 and connect sequence is repeated If the burners do not light within 15 manometer Turn on gas supply to unit minutes from the initial call for heat there is a lockout To 3 R
25. revolution 3600 32 112 5 3 112 5 x 1 2112 5 f of gas flow hr 4 112 5 x 1050 118 125 Btuh input If the desired gas input is 115 000 Btuh only a minor change in the manifold pressure is required Observe manifold pressure and proceed as follows to adjust gas input Remove cover screw over regulator adjustment screw on gas valve 2 Turn regulator adjustment screw clockwise to increase gas input or turn regulator adjustment screw counterclockwise to decrease input Manifold pressure must be between 3 4 and 3 6 in wg Unsafe operation of the unit may result if manifold pressure is outside this range Personal injury or unit damage may result A WARNING FIRE AND UNIT DAMAGE HAZARD Failure to follow this warning couild result in personal injury death and or property damage Unsafe operation of the unit may result if manifold pressure is outside this range Serious injury death or unit damage may result 3 Replace cover screw cap on gas valve 4 Turn off gas supply to unit Remove manometer from pressure tap and replace pipe plug on gas valve Turn on gas to unit and check for leaks Measure Manifold Pressure Propane Units The main burner orifices on a propane gas unit are sized for the unit rated input when the manifold pressure reading matches the level specified in Table 4 Proceed as follows to adjust gas input on a propane gas unit 1 Turn off gas to unit 2 Remove pipe plug on manif
26. units with an outer and inner condenser coil be sure to clean between the coils Be sure to flush all dirt and debris from the unit base Inspect the drain pan and condensate drain line when inspecting the coils Clean the drain pan and condensate drain by removing all foreign matter from the pan Flush the pan and drain tube with clear water Do not splash water on the insulation motor wiring or air filter s If the drain tube is restricted clear it with a plumbers snake or similar probe device Ensure that the auxiliary drain port above the drain tube is also clear CONDENSER FAN CAUTION OPERATIONAL HAZARD Failure to follow this caution may result in unit component damage Keep the condenser fan free from all obstructions to ensure proper cooling operation Never place articles on top of the unit Damage to unit may result 1 Remove 6 screws holding condenser grille and motor to top cover 2 Turn motor grille assembly upside down on top cover to expose the fan blade 3 Inspect the fan blades for cracks or bends 4 If fan needs to be removed loosen the setscrew and slide the fan off the motor shaft 5 When replacing fan blade position blade so the hub is 1 8 in away from the motor end 1 8 in of motor shaft will be visible See Fig 12 6 Ensure that setscrew engages the flat area on the motor shaft when tightening 7 Replace grille ELECTRICAL CONTROLS AND WIRING Inspect and check the elect
27. valve When installing the gas supply line observe local codes pertaining to gas pipe installations Refer to the NFGC ANSI Z223 1 1988 NFPA latest edition in Canada CAN CGA B149 1 2 86 In the absence of local building codes adhere to the following pertinent recommendations 1 Avoid low spots in long runs of pipe Grade all pipe 1 4 in in every 15 ft to prevent traps Grade all horizontal runs downward to risers Use risers to connect to heating section and to meter 2 Protect all segments of piping system against physical and thermal damage Support all piping with appropriate straps hangers etc Use a minimum of one hanger every 6 ft For pipe sizes larger than 1 2 in follow recommendations of national codes 3 Apply joint compound pipe dope sparingly and only to male threads of joint when making pipe connections Use only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and or national codes Never use Teflon tape 4 Install sediment trap in riser leading to heating section See Fig 9 This drip leg functions as a trap for dirt and condensate TEE T NIPPLE a iim CAP C99020 Fig 9 Sediment Trap 5 Install an accessible external manual main shutoff valve in gas supply pipe within 6 ft of heating section 6 Install ground joint union close to heating section between unit manual shutoff and external manual main shut off valve 7 Pressure tes
28. 230 1 60 187 253 18 3 109 0 15 44 28 5 28 5 35 35 060 208 230 1 60 187 253 250 148 0 15 62 39 0 39 0 50 50 LEGEND FLA Full Load Amps C UL US LRA Locked Rotor Amps MCA Minimum Circuit Amps MOCP Maximum Overcurrent Protection RLA Rated Load Amps NOTES 1 In compliance with NEC National Electrical Code requirements for multimotor and combination load equipment refer to NEC Articles 430 and 440 the overcurrent protective device for the unit shall be Power Supply fuse The CGA Canadian Gas Association units may be fuse or circuit breaker 2 Minimum wire size is based on 60 C copper wire If other than 60 C wire is used or if length exceeds wire length in table determine size from NEC C99024 Table 3 Legend SPECIAL PROCEDURES FOR 208 V OPERATION A WARNING FIRE EXPLOSION AND ELECTRICAL SHOCK HAZ ARD Failure to follow this warning could result in personal injury death and or property damage Before making any wiring changes make sure the gas supply is switched off first Then switch off the power supply to the unit and install lockout tag CONTROL VOLTAGE CONNECTIONS Do not use any type of power stealing thermostat Unit control problems may result Use no 18 American Wire Gage AWG color coded insulated 35 C minimum wires to make the control voltage connections between the thermostat and the unit If the thermostat is located more than 100 ft
29. 32 34 37 40 Watts 411 405 398 390 379 357 357 48SD N 030040 20 50 Medium CFM 1195 1155 1100 1028 957 868 769 Heating Rise F 25 26 27 29 31 35 39 Watts 477 467 447 435 High CFM 1185 1088 970 853 Heating Rise F 25 28 31 35 Watts 311 309 304 301 Low CFM 935 885 820 757 Heating Rise F 48 51 55 59 Watts 411 405 398 390 379 357 357 48SD N 030060 35 65 Medium CFM 1195 1155 1100 1028 957 868 769 Heating Rise F 38 39 41 44 47 52 59 Watts 477 467 447 435 High CFM 1185 1088 970 853 Heating Rise F 38 41 46 53 Watts 437 433 424 417 403 391 379 362 Low CFM 1353 1318 1283 1235 1187 1123 1059 975 Heating Rise F 33 34 35 36 38 40 42 46 Watts 531 516 496 478 459 435 48SD N 036060 25 55 Medium CFM 1489 1437 1362 1289 1208 1099 Heating Rise F 30 31 33 35 37 41 Watts 629 602 High CFM 1470 1357 Heating Rise F 31 33 Watts 437 433 424 417 403 391 379 362 Low CFM 1353 1318 1283 1235 1187 1123 1059 975 Heating Rise F 50 51 53 55 57 60 64 69 Watts 531 516 496 478 459 435 48SD N 036090 40 70 Medium CFM 1489 1437 1362 1289 1208 1099 Heating Rise F 45 47 50 52 56 61 Watts 629 602 High CFM 1470 1357 Heating Rise F 46 50 Watts 625 606 586 571 550 534 509 483 457 Low CFM 1539 1496
30. EATING AND MAKE ADJUST MENTS When the gas supply being used has a different heating value or specific gravity refer to national and local codes or contact your distributor to determine the required orifice size CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in component damage due to flame impingement of burners and heat exchangers Do Not redrill an orifice Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flame If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in improper unit operation Complete the required procedures given in the Pre Start Up section before starting the unit Do not jumper any safety devices when operating the unit Make sure that burner orifices are properly aligned Unstable operation may occur when the burner orifices in the manifold are misaligned ADJUST GAS INPUT Follow the lighting instructions on the heating section operation label located inside the burner or blower access door to start the The gas input to the unit is determined by measuring the gas flow heating section at the meter or by measuring the manifold pressure Measuring the gas flow at the meter is recommended for natural gas units The manifold pressure
31. NTICIPATOR SETTING eee 12 TRANSFORMER PROTECTION ee 12 PRESTAR T UP saoi 12 START UP E EAE 13 CHECK FOR REFRIGERANT LEAKS 13 START UP HEATING AND MAKE ADJUSTMENTS 15 CHECK HEATING CONTROL eee 15 CHECK GAS INPUT ADJUST GAS INPUT CHECK BURNER FLAME 16 AIRFLOW AND TEMPERATURE 16 HEATING SEQUENCE OF OPERATION 16 LIMIT SWITCHES 16 ROLLOUT SWITCH ensure 16 START UP COOLING AND MAKE ADJUSTMENTS 17 CHECKING COOLING CONTROL OPERATION 17 CHECKING AND ADJUSTING REFRIGERANT CHARGE aea ah nen nee av 17 INDOOR AIRFLOW AND AIRFLOW ADJUST MENTS M 17 COOLING SEQUENCE OF OPERATION 18 nie eet einen Y eror ves be sey HEADS 18 AIR d 18 EVAPORATOR BLOWER AND MOTOR 18 FLUE GAS PASSAGEWAYS 22 S44 A99338 Fig 1 Unit 48SD Low NO Model Available COMBUSTION AIR 22 LIMIT SWITCH BURNER IGNITION MAIN CONDENSER COIL EVAPORATOR COIL AND CONDENSATE DRAIN PAN 22 CONDENSER
32. OLIMS 1001108 9010 pes 10 3015102 5 010 8000110 W40 DE SV9 AR HOLIMS LIMIT 1 ONIUIM 1N3S3Hd3H 01 LON YOLOW YOOONT nil CAINO 191143104 YOLOW 13 80 032101 NOI NOWNOD 31V210NI 01 8311081802 SNIUIM LINN SY9 031V89831NI 291 WNOI1dO AYOSS3D9 3011591 ONTYIM YIMOd 01313 UINYOASNVYL HOIH ONINIM 108109 01313 WOSN3S 193333 SH ONIYIM AYOLIVI Av138 3ATVA 579 YA 0392 VW 321145 ano 32114 3514 ni 0 40 3 IWV14 54 TWNINYIL CO 321145 03147 JIN 34 03931 193 02510 1123 SY9 501 SISSWHD 39897 5 410 H 24V 15 1135 N01123S i TOULNOD 3000 1 5055399002 1011235 430 8000110 1N3439NV4UV LNANOdWOD LINN 050 NO n18 9 21 134 LLM 9 ZIM nua OLM JJOONVIS NYHL 03041039 028 9 9 81M NYG 01M OE NOWWO2 1 150483 1 07313 0 734 NaS 3Wv14 vag A9W 251 197 n18 ng 038 M G ILON 335 201 27 01 034 ELM im X08 301145 Av
33. Rollout switch fault LED 7 flashes Rollout switch has opened Rollout switch will automatically reset but IGC will continue to lock out unit Check gas valve operation Ensure that induced draft blower wheel is properly secured to motor shaft Inspect Heat Ex changer Reset unit at unit disconnect Internal control fault LED 8 flashes Microprocessor has sensed an error in the software or hardware If error code is not cleared by resetting unit power replace the IGC Temporary software lock out LED 9 flashes Electrical interference impeding IGC software Reset 24 v to control board or turn thermostat off then on again Fault will automatically reset itself in one 1 hour WARNING If the IGC must be replaced be sure to ground yourself to dissipate any electrical charge that may be present before handling new control board The IGC is sensitive to static electricity and may be damaged if the necessary precautions are not taken IMPORTANT Refer to Table 12 Troubleshooting Guide Heating for additional troubleshooting analysis LEGEND IGC Integrated Gas Unit Controller LED Light Emitting Diode 277 START UP CHECKLIST Remove and Store in Job File I PRELIMINARY INFORMATION MODEL corir e teg SERIAL INO dedans pde diee DATE TECHNICIAN JOB LOCATION 3 8 eme eem II PRE START UP insert checkmark in box
34. STANDARD CFM S C F M 48SD 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 024 030 037 044 053 063 030 037 044 053 063 072 081 105 036 038 044 051 059 065 072 080 042 044 051 059 065 072 080 088 095 105 048 044 050 053 059 066 072 077 086 060 079 087 095 102 113 123 IGNITION MODULE INDUCED uis i MOTOR MOUNT E BLOWER HOUSING all Fig 16 Blower Housing and Flue Collector Box FLUE COLLECTOR BOX NS Wee M SS 24 SS SS BLOWER HOUSING RACK SCREW Fig 17 Unit Access Panel SWITCH BURNER MOUNTING A05119 2 SETSCREWS HIDDEN C99085 Fig 18 Removal of Motor and Blower Wheel SUR e C99091 23 2 ST OF 0 Fig 19 Burner Rack Removed C99086 attachment Be careful not to bend the fins If coated with oil or grease clean the coils with a mild detergent and water solution Rinse coils with clear water using a garden hose Be careful not to splash water on motors insulation wiring or air filter s For best results spray condenser coil fins from inside to outside the unit On
35. X 30X 1 UNIT SIZE FILTER SIZE For longer life operating economy and continuing efficiency c On all units remove blower assembly from unit Remove clean accumulated dirt and grease from the blower wheel and Screws securing blower to blower partition and slide motor annually assembly out Be careful not to tear insulation in blower compartment A WARNING d Ensure proper reassembly by marking blower wheel and motor in relation to blower housing before disassembly FIRE EXPLOSION AND ELECTRICAL SHOCK HAZ ARD e Loosen setscrew s that secures wheel to motor shaft Remove screws that secure motor mount brackets to housing and slide motor and motor mount out of housing Failure to follow this warning could result in personal injury death and or property damage Before cleaning the blower motor and wheel disconnect gas supply Then turn off and tag electrical power to the unit a Ensure proper reassembly by marking wheel orientation b Lift wheel from housing When handling and or cleaning blower wheel be sure not to disturb balance weights clips 1 Remove and disassemble blower assembly as follows on blower wheel vanes 2 Remove and clean blower wheel as follows Cleaning the Blower Motor and Wheel a Remove unit access panel c Remove caked on dirt from wheel and housing with a brush Remove lint and or dirt accumulations from whee
36. air Before lighting the unit for the first time perform the following with the gas valve in the OFF position If the gas supply pipe was not purged before connecting the unit it will be full of air It is recommended that the ground joint union be loosened and the supply line be allowed to purge until the odor of gas is detected Never purge gas lines into a combustion chamber Immediately upon detection of gas odor retighten the union Allow 5 minutes to elapse then light unit b Make sure that condenser fan blade is correctly positioned in fan orifice Leading edge of condenser fan blade should be 1 2 in maximum from fan orifice venturi c Ensure fan hub is 1 8 in maximum from motor housing See Fig 12 MOTOR FAN GRILLE 12 MOTOR SHAFT 1 8 MAX BETWEEN MOTOR AND FAN HUB C99009 Fig 12 Fan Blade Clearance d Make sure that air filter s is in place e Make sure that condensate drain trap is filled with water to ensure proper drainage f Make sure that all tools and miscellaneous loose parts have been removed 13 MANIFOLD PIPE PLUG C99019 Fig 13 Burner Assembly BURNER FLAME MANIFOLD C99021 Fig 14 Monoport Burner START UP Step 1 CHECK FOR REFRIGERANT LEAKS Proceed as follows to locate and repair a refrigerant leak and to charge the unit 1 Locat
37. 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 CHECK GAS PIPING FOR LEAKS CHECK THAT INDOOR EVAPORATOR AIR FILTER IS CLEAN AND IN PLACE VERIFY THAT UNIT INSTALLATION IS LEVEL CHECK FAN WHEEL PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW TIGHTNESS START UP ELECTRICAL SUPPLY VOLTAGE 11 12 COMPRESSOR AMPS L1 COMPRESSOR AMPS L1 INDOOR EVAPORATOR FAN AMPS TEMPERATURES OUTDOOR CONDENSER AIR TEMPERATURE DB RETURN AIR TEMPERATURE DB WB COOLING SUPPLY AIR DB WB GAS HEAT SUPPLY AIR PRESSURES GAS INLET PRESSURE IN WG GAS MANIFOLD PRESSURE IN WG REFRIGERANT SUCTION PSIG REFRIGERANT DISCHARGE PSIG SUCTION LINE TEMP DISCHARGE LINE TEMP VERIFY REFRIGERANT CHARGE USING CHARGING TABLES Measured at suction inlet to compressor Measured at liquid line leaving condenser Copyright 2005 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 114 101 Printed in U S A Catalog No 48SD 1SI Pg 28 8 05 Replaces New Tab 1a
38. burner access panel LIMIT SWITCHES Normally closed limit switch LS completes the control circuit through the thermostat R circuit Should the leaving air tempera ture rise above the maximum allowable temperature the limit switch opens and the R control circuit breaks Any interruption in the R control circuit instantly closes the gas valve and stops gas flow to the burners and pilot The blower motor continues to run until LS resets When the air temperature at the limit switch drops to the low temperature setting of the limit switch the switch closes and completes the R control circuit The electric spark ignition system cycles and the unit returns to normal heating operation ROLLOUT SWITCH The function of the rollout switch is to close the main gas valve in the event of flame rollout The switch is located above the main burners When the temperature at the rollout switch reaches the maximum allowable temperature the R control circuit trips closing the gas valve and stopping gas flow to the burners The indoor evaporator fan motor IFM and induced draft motor continue to run until switch is reset The IGC LED will display FAULT CODE 7 Step 3 START UP COOLING AND MAKE ADJUST MENTS CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in unit and or property damage Complete the required procedures given in the Pre Start Up section before starting the unit Do not jumper any saf
39. ck for gas leaks at the field installed and factory installed gas lines after all piping connections have been completed Use soap and water solution or method specified by local codes and or regulations Step 9 INSTALL DUCT CONNECTIONS The unit has duct flanges on the supply and return air openings on the side and bottom of the unit For downshot applications the ductwork connects to the roof curb See Fig 2 and 3 for connections sizes and locations CONFIGURING UNITS FOR DOWNFLOW VERTICAL DIS CHARGE A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before performing service or maintenance operations on the system turn off main power to unit 1 Open all electrical disconnects before starting any service work 2 Remove return duct cover located on duct panel by breaking connecting tabs with screwdriver and a hammer See Fig 10A amp 10B 3 To remove supply duct cover break front and right side connecting tabs with a screwdriver and a hammer Push louver down to break rear and left side tabs See Fig 10A amp 10B 4 If unit ductwork is to be attached to vertical opening flanges on the unit composite base jackstand applications only do so at this time SUPPLY RETURN VENT HOOD DUCT DUCT SHIPPING OPENING OPENING LOCATION A05143 Fig 10A Supply and Retur
40. e leak and make sure that refrigerant system pressure has been relieved and reclaimed from both high and low pressure ports 2 Repair leak following Refrigerant Service procedures NOTE Install a filter drier whenever the system has been opened for repair 3 Add a small charge of R 22 refrigerant vapor to system and leak test unit 4 Recover refrigerant from refrigerant system and evacuate to 500 microns if additional leaks are not found 5 Charge unit with R 22 refrigerant using a volumetric charging cylinder or accurate scale Refer to unit rating plate for required charge Be sure to add extra refrigerant to compensate for internal volume of filter drier AINO 151 SYH 090 9 00S8h S1300N NO 7531835 NI 0331 ZSI ONY 157 060 0058 S1300N lt Wil JYIM 18 123NNO2 ONY 291 3uIM 038 123NNODSIQ 033dS WNIGIW 803 3UIM 123NNOO ANY W8 29I MOuj 3UIM 038 1 3NNOOSIQ Mi4I 0339 HOIH 804 NOTLVTIVISNI 01313 803 SYOLINGNOD 434402 338930 SL ASN SASVGGNS ONY LVLSOWNYIHL 803 53974 32144 335 2 IN31VAIfO3 5 11 30 341 2 338930 06 HLIM Q32v1d34 38 1 11 0331938 3uv 0 S3UIM TVNIOIUO JHL JO ANY 3171 153100 0321903N3 30 032190383 ug ug Srl 1 S o s 21901 9NI1V3H 0321983N3 30 037198303 9 5 0 1 0 ______ 21901 9NI 1002 IN3NdINO 41103 4Y138 NOTLSNGNOD a2 H
41. eaks repair and recharge Remove source of restriction Insufficient evaporator airflow Increase air quantity Check filter replace if necessary Temperature too low in conditioned area Reset thermostat Outdoor ambient below 40 F Install low ambient kit Field installed filter drier restricted 25 Replace SYMPTOM Table 12 Troubleshooting Guide Heating CAUSE REMEDY Burners will not ignite Water in gas line Drain Install drip leg No power to furnace Check power supply fuses wiring or circuit breaker No 24 v power supply to control circuit Check transformer Check fuse on ignition control NOTE Some transformers have internal overcurrent protection that requires a cool down period to reset Miswired or loose connections Check all wiring and wirenut connections Burned out heat anticipator in thermostat Replace thermostat Broken thermostat wire Run continuity check Replace wire if necessary Misaligned spark electrodes No gas at main burners Check flame ignition and sense electrode positioning Adjust as necessary 1 Check gas line for air Purge as necessary NOTE After purging gas line of air wait at least 5 minutes for any gas to dissipate before attempting to light unit 2 Check gas valve Turn gas valve switch to ON Make sure wires properly connected to gas valve Inadequate heating Dirty air filter
42. ecord number of seconds for gas meter test dial to make one reset the control break the 24 v power to W revolution 5 The evaporator fan will turn on 45 sec after the flame has 4 Divide number of seconds in Step 3 into 3600 number of been established The evaporator fan will turn off 45 sec after seconds in one hour the thermostat has been 5 Multiply result of Step 4 by the number of cu ft shown for one CHECK GAS INPUT revolution of test dial to obtain cu ft of gas flow per hour Check gas input and manifold pressure after unit start up See 6 Multiply result of Step 5 by Btu heating value of gas to obtain Table 4 If adjustment is required proceed as follows The rated gas inputs shown in Table 4 are for altitudes from sea level to 2000 ft above sea level These inputs are based on natural gas with a heating value of 1050 Btu ft at 0 65 specific gravity or propane gas with a heating value of 2500 Btu ft at 1 5 specific gravity For elevations above 2000 ft reduce input 4 percent for each 1000 ft above sea level For example at 2001 ft a 1296 total derate is required total measured input in Btuh Compare this value with heating input shown in Table 4 Consult the local gas supplier if the heating value of gas is not known EXAMPLE Assume that the size of test dial is 1 cu ft one revolution takes 32 sec and the heating value of the gas is 1050 Proceed as follows 1 2 15 32 sec to complete one
43. ety devices when operating the unit Do not operate the compressor when the outdoor temperature is below 40 F unless accessory low ambient kit is installed Do not rapid cycle the compressor Allow 5 minutes between cycles to prevent compressor damage CHECKING COOLING CONTROL OPERATION Start and check the unit for proper cooling control operation as follows 1 Place room thermostat SYSTEM switch in OFF position Observe that blower motor starts when FAN switch is placed in ON position and shuts down when FAN switch is placed in AUTO position 2 Place SYSTEM switch in COOL position and FAN switch in AUTO position Set cooling control below room temperature Observe that compressor condenser fan and evaporator blower motors start Observe that cooling cycle shuts down when control setting is satisfied The evaporator fan will continue to run for 30 sec 3 When using an auto changeover room thermostat place both SYSTEM and FAN switches in AUTO positions Observe that unit operates in Heating mode when temperature control is set to call for heating above room temperature and operates in Cooling mode when temperature control is set to call for cooling below room temperature CHECKING AND ADJUSTING REFRIGERANT CHARGE The refrigerant system is fully charged with R 22 refrigerant tested and factory sealed NOTE Adjustment of the refrigerant charge is not required unless the unit is suspected of not ha
44. f the conditioned space and inefficient energy utilization however the required setting may be changed slightly to provide a greater degree of comfort for a particular installation TRANSFORMER PROTECTION The transformer is of the energy limiting type It is set to withstand a 30 sec overload or shorted secondary condition PRE START UP A WARNING FIRE EXPLOSION AND ELECTRICAL SHOCK HAZ ARD Failure to follow this warning could result in personal injury death and or property damage 1 Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system 2 Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured 3 Do not remove compressor terminal cover until all electri cal sources are disconnected 4 Relieve and recover all refrigerant from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals 5 Never attempt to repair soldered connection while refrig erant system is under pressure 6 Do not use torch to remove any component System contains oil and refrigerant under pressure To remove a component wear protective goggles and proceed as fol lows a Shut off gas supply and then electrical power to unit b Relieve and recover all refrigerant from system using both high and low pressure ports c Cut component connecting tubing wit
45. fan on delay expires Limit switch opens within three minutes after blower off delay timing in Heating mode Ensure unit is fired on rate ensure temperature rise is correct Ensure unit s external static pressure is within application guidelines Limit switch faults LED 2 flashes High temperature limit switch is open Check the operation of the indoor evaporator fan motor Ensure that the supply air temperature rise is in accordance with the range on the unit nameplate Clean or replace filters Flame sense fault LED 3 flashes The IGC sensed flame that should not be present Reset unit If problem persists replace control board 4 consecutive limit switch faults LED 4 flashes Inadequate airflow to unit Check operation of indoor evaporator fan motor and that supply air temperature rise agrees with range on unit nameplate information Ignition lockout LED 5 flashes Unit unsuccessfully attempted ignition for 15 minutes Check ignitor and flame sensor electrode spacing gaps etc Ensure that flame sense and ignition wires are properly terminated Verify that unit is obtaining proper amount of gas Induced draft motor fault LED 6 flashes IGC does not sense that induced draft motor is operating Check for proper voltage If motor is operating check the speed sensor plug IGC Terminal J2 connection Proper connection PIN 1 White PIN 2 Red PIN 3 Black
46. from the unit as measured along the control voltage wires use no 16 AWG color coded insulated 35 C minimum wires Standard Connection Remove knockout hole located in the flue panel adjacent to the control access panel See Fig 2 and 3 Remove the rubber grommet from the installer s packet included with unit and install grommet in the knockout opening Provide a drip loop before running wire through panel Run the low voltage leads from the thermostat through the inlet hole and into unit low voltage splice box Locate five 18 gage wires leaving control box These low voltage connection leads can be identified by the colors red green yellow brown and white See Fig 11 Ensure the leads are long enough to be routed into the low voltage splice box located below right side of control box Route leads through hole in bottom of control box and make low voltage connections See Fig 11 Secure all cut wires so that they do not interfere with operation of unit HEAT ANTICIPATOR SETTING The room thermostat heat anticipator must be properly adjusted to ensure proper heating performance Set the heat anticipator using an ammeter between the W and R terminals to determine the exact required setting NOTE For thermostat selection purposes use 0 18 amp for the approximate required setting Failure to make a proper heat anticipator adjustment will result in improper operation discom fort to the occupants o
47. h tubing cutter and remove component from unit d Carefully unsweat remaining tubing stubs when neces sary Oil can ignite when exposed to torch flame Proceed as follows to inspect and prepare the unit for initial startup 1 Remove access panel 2 Read and follow instructions on all WARNING CAUTION and INFORMATION labels attached to or shipped with unit 3 Make the following inspections a Inspect for shipping and handling damages such as broken lines loose parts disconnected wires etc b Inspect for oil at all refrigerant tubing connections and on unit base Detecting oil generally indicates a refrigerant leak c Leak test all refrigerant tubing connections using electronic leak detector halide torch or liquid soap solution If a refrigerant leak is detected see the Check for Refrigerant Leaks section d Inspect all field and factory wiring connections Be sure that connections are completed and tight e Ensure wires do not contact refrigerant tubing or sharp sheet metal edges f Inspect coil fins If damaged during shipping and handling carefully straighten fins with a fin comb 4 Verify the following conditions A WARNING FIRE EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Do not purge gas supply into the combustion chamber Do not use a match or other open flame to check for gas leaks a Make sure gas line is free of
48. he unit top The maximum horizontal extension of a partial overhang must not exceed 48 in Do not place the unit where water ice or snow from an overhang or roof will damage or flood the unit Do not install the unit on carpeting tile or other combustible materials The unit may be installed on wood flooring or on Class A B or C roof covering materials moving the unit Unit must remain in an upright position during all rigging and moving operations The unit must be level within 1 4 for proper condensate drainage therefore the ground level pad or accessory roof curb must be level before setting the unit in place When a field fabricated support is used be sure that the support is level and properly supports the unit Lifting point should be directly over the center of gravity for the unit Step 6 CONNECT CONDENSATE DRAIN NOTE When installing condensate drain connection be sure to comply with local codes and restrictions Model 48SD disposes of condensate water through a 3 4 in NPT fitting which exits through the compressor access panel See Fig 2 and 3 for location Condensate water can be drained directly onto the roof in rooftop installations where permitted or onto a gravel apron in ground level installations Install a field supplied condensate trap at end of condensate connection to ensure proper drainage Make sure that the outlet of the trap is at least 1 in lower than the drain pan Table 1 Physical Data
49. ica where a Low NO rule exists RECEIVING AND INSTALLATION Step 1 CHECK EQUIPMENT IDENTIFY UNIT The unit model number and serial number are stamped on unit identification plate Check this information against shipping papers and job data Verify unit voltage and amperage requirements listed on unit rating plate agree with power supply provided to unit INSPECT SHIPMENT Inspect for shipping damage while unit is still on shipping pallet If unit appears to be damaged or is torn loose from its anchorage have it examined by transportation inspectors before removal Forward claim papers directly to transportation company Manu facturer is not responsible for any damage incurred in transit Check all items against shipping list Immediately notify the nearest distributor if any item is missing To prevent loss or damage leave all parts in original packages until installation INSTALLATION 1 Remove unit from shipping carton Leave top shipping skid on the unit as a spreader bar to prevent the rigging straps from damaging the unit If the wood skid is not available use a spreader bar of sufficient length to protect unit from damage 2 Position the lifting bracket assembly around the base of the unit Be sure the strap does not twist 3 Place each of the 4 metal lifting brackets into the rigging holds in the composite pan 4 Thread lifting bracket strapping around bottom perimeter of unit as follows a Open lever of tensio
50. ilters must not exceed 0 08 in wg condensate connection to prevent the pan from overflowing See Fig 8 Prime the trap with water When using a gravel apron make sure it slopes away from the unit If the installation requires draining the condensate water away from the unit install a 2 in trap at the condensate connection to ensure proper drainage See Fig 8 Make sure that the outlet of the trap is at least 1 in lower than the drainpan condensate connection This prevents the pan from overflowing Prime the trap with water Connect a drain tube using a minimum of 3 4 in PVC or 3 4 in copper pipe all field supplied at the outlet end of the 2 in trap Do not undersize the tube Pitch the drain tube downward at a slope of at least 1 in for every 10 ft of horizontal run Be sure to check the drain tube for leaks TRAP OUTLET 1 min 2 min C00009 Fig 8 Condensate Trap Step 7 INSTALL FLUE HOOD The flue assembly is secured and shipped in the return air duct Remove duct cover to locate the assembly See Fig 10A NOTE Dedicated low NO models MUST be installed in Cali fornia Air Quality Management Districts where a Low NO rule exists These models meet the California maximum oxides of nitrogen NO emissions requirements of 40 nanograms joule or less as shipped from the factory NOTE Low NO requirements apply only to natural gas instal lations A WARNING
51. ircuit through compressor motor COMP to condenser outdoor fan motor OFM Both motors start instantly 3 The set of normally open contacts of energized relay BM close and complete the circuit through evaporator blower indoor fan motor IFM NOTE Once the compressor has started and then stopped it should not be started again until 5 minutes have elapsed The cooling cycle remains on until the room temperature drops to a point that is slightly below the cooling control setting of the room thermostat At this point the thermostat breaks the circuit between thermostat terminal R to terminals Y and G These open circuits deenergize contactor coil C The condenser and compres sor motors stop After a 30 sec delay the blower motor stops The unit is in a standby condition waiting for the next call for cooling from the room thermostat MAINTENANCE To ensure continuing high performance and to minimize the possibility of premature equipment failure periodic maintenance must be performed on this equipment This combination heating cooling unit should be inspected at least once each year by a qualified service person To troubleshoot cooling or heating of units refer to Tables 11 13 NOTE Consult your local dealer about the availability of a maintenance contract A WARNING FIRE EXPLOSION ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury death and or property damage The abil
52. is used to identify unsafe practices which may result in minor personal injury or product and property damage NOTE is used to highlight sugges tions which will result in enhanced installation reliability or operation These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with changing residen tial construction practices We require these instructions as a minimum for a safe installation INTRODUCTION The 48SD unit See Fig 1 is fully self contained combination Category I gas heating electric cooling units designed for outdoor installation See Fig 2 and 3 for unit dimensions All unit sizes have return and discharge openings for both horizontal and downflow configurations and are factory shipped with all down flow duct openings covered Units may be installed either on a rooftop a cement slab or directly on the ground if local codes permit See Fig 4 for roof curb dimensions Models with an N in the fifth position of the model number are dedicated Low units designed for California installations These models meet the California maximum oxides of nitrogen NO emissions requirements of 40 nanograms joule or less as shipped from the factory and must be installed in California Air Quality Management Districts or any other regions in North Amer
53. ity to properly perform maintenance on this equip ment requires certain expertise mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User s Manual 18 A WARNING FIRE EXPLOSION ELECTRICAL SHOCK PERSONAL INJURY HAZARD Failure to follow these warnings could result in serious injury 1 First turn off gas supply to the unit Then turn off electrical power to the unit and install lockout tag before performing any maintenance or service on the unit Use extreme caution when removing panels and parts As with any mechanical equipment personal injury can result from sharp edges etc Never place anything combustible either on or in contact with the unit Should overheating occur or the gas supply fail to shut off turn off external main manual gas valve to the unit Then shut off electrical supply and install lockout tag A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in unit damage Errors made when reconnecting wires may cause improper and dangerous operation Label all wires prior to disconnec tion when servicing The minimum maintenance requirements for this equipment are as follows 1 Inspect air filter s each month Clean or replace when necessary Certain geographical locations may require more frequent inspections N Inspect indoor coil outdoo
54. ium CFM 1798 1771 1734 1687 1645 1595 1530 1449 1355 Heating Rise F 38 38 39 40 41 42 44 47 50 Watts 908 887 858 827 804 767 748 High CFM 2000 1944 1876 1811 1735 1647 1555 Heating Rise F 34 35 36 37 39 41 43 Watts 627 617 607 584 567 548 528 Low CFM 1550 1530 1493 1461 1414 1361 1320 Heating Rise F 56 56 58 59 61 63 65 Watts 771 755 734 711 690 665 639 607 572 48SD N 048115 35 65 Medium CFM 1798 1771 1734 1687 1645 1595 1530 1449 1355 Heating Rise F 48 49 50 51 52 54 56 60 64 Watts 908 887 858 827 804 767 748 High CFM 2000 1944 1876 1811 1735 1647 1555 Heating Rise F 43 44 46 48 50 52 55 Watts 627 617 607 584 567 Low CFM 1550 1530 1493 1461 1414 Heating Rise F 63 64 65 67 69 Watts 771 755 734 711 690 665 639 607 48SD N 048130 40 70 Medium CFM 1798 1771 1734 1687 1645 1595 1530 1449 Heating Rise F 54 55 56 58 59 61 64 67 Watts 908 887 858 827 804 767 748 High CFM 2000 1944 1876 1811 1735 1647 1555 Heating Rise F 49 50 52 54 56 59 63 Watts 786 769 754 736 722 705 684 658 Low CFM 2027 1960 1901 1821 1759 1693 1616 1513 Heating Rise F 33 34 36 37 38 40 42 45 Watts 873 849 833 815 798 782 763 748 48SD N 060090 25 55 Medium CFM 2095 1962 1887 1817 1748 1679 1583
55. l and housing with vacuum cleaner using soft brush attach ment Remove grease and oil with mild solvent b Disconnect motor lead from blower relay BM Discon nect yellow lead from terminal L2 of the contactor 19 Table 9 Dry Coil Air Delivery Horizontal and Downflow Discharge Unit 48SD024 060 Deduct 10 percent for 208 Volts UNIT HEATING RISE RANGE F MOTOR SPEED EXTERNAL SIATIC 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 Watts 311 309 304 301 286 Low CFM 935 885 820 757 686 Heating Rise F 32 34 37 40 44 Watts 379 357 357 345 48SD N 024040 20 50 Medium CFM 957 868 769 647 Heating Rise F 31 35 39 46 Watts 447 435 421 High CFM 970 853 712 Heating Rise F 31 35 42 Watts 311 309 304 301 Low CFM 935 885 820 757 Heating Rise F 48 51 55 59 Watts 411 405 398 390 379 357 357 48SD N 024060 35 65 Medium CFM 1195 1155 1100 1028 957 868 769 Heating Rise F 38 39 41 44 47 52 59 Watts 447 435 421 High CFM 970 853 712 Heating Rise F 46 53 63 Watts 311 309 304 301 Low CFM 935 885 820 757 Heating Rise F
56. llow sections 7 2 Table 1 Physical Data Unit 48SD UNIT SIZE 48SD 024040 024060 030040 030060 036060 036090 042060 042090 NOMINAL CAPACITY ton 2 2 2 2 3 3 3 3 OPERATING WEIGHT 343 343 366 366 433 433 460 460 COMPRESSORS Scroll Quantity 1 REFRIGERANT R 22 Quantity Ib 7 8 7 8 8 4 8 4 10 9 10 9 10 9 10 9 REFRIGERANT METERING DEVICE Accurater Orifice ID in 065 065 070 070 080 080 088 088 2 21 2 2 2 21 2 21 2 21 2 21 2 21 2 21 Face Area sq ft 11 9 11 9 13 6 13 6 15 5 15 5 19 4 19 4 2700 2700 2700 2700 2800 2800 2800 2800 22 22 22 22 22 22 22 22 Diameter in Motor Hp Rpm EVAPORATOR COIL 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 ip 3 17 3 17 947 3 17 3 17 3 17 9 47 3 17 Rows Fins in Face Area sq ft 3 7 3 7 3 7 3 7 4 7 4 7 4 7 4 7 EVAPORATOR BLOWER 800 800 1000 1000 1200 1200 1400 1400 Nominal Airflow Cfm Size in Motor Hp Rpm FURNACE SECTION Burner Orifice No Qty Drill Size 10X10 10X10 10X10 10X10 11X10 11X10 11X10 11X10 1 3 1050 1 3 1050 1 3 1050 1 3 1050 1 2 1000 1 2 1000 1 2 1075 1 2 1075 2 44 2 38 2 44 2 38 2 38 3 38 2 38 3 38 Natural Gas Burner Orifice No Qty Drill Size 2590 2 46 290 246 3 46 269 Propane Gas RETURN AIR FILTERS in T 20 X 24 X 1 24 X 86 X 1 Throwaway
57. lower wheel bi monthly to determine proper cleaning frequency To inspect blower wheel remove draft hood assembly Shine a flashlight into opening to inspect wheel If cleaning is required remove motor and wheel as follows 1 Remove unit access panel See Fig 17 2 Remove the 7 screws that attach induced draft motor mount ing plate to blower housing See Fig 18 3 Slide the motor and blower wheel assembly out of the blower housing See Fig 18 Clean the blower wheel If additional cleaning is required continue with Steps 4 and 5 4 To remove blower remove 2 setscrews 5 To remove motor and cooling fan assembly remove 4 screws that hold blower housing to mounting plate 6 To reinstall reverse the procedure outlined above LIMIT SWITCH Remove unit access panel Limit switch is located on the blower partition 22 BURNER IGNITION Unit is equipped with a direct spark ignition 100 percent lockout system Ignition module is located in the control box See Fig 16 Module contains a self diagnostic LED During servicing refer to label diagram for LED interpretation If lockout occurs unit may be reset by either momentarily interrupting power supply to unit or by turning selector switch to OFF position at the thermostat MAIN BURNERS At the beginning of each heating season inspect for deterioration or blockage due to corrosion or other causes Observe the main burner flames and adjust if necessary
58. mostat Faulty condenser fan motor or capacitor Replace Restriction in refrigerant system Locate restriction and remove Compressor operates continuously Excessive head pressure Dirty air filter Replace filter Unit undersized for load Decrease load or increase unit size Thermostat set too low Reset thermostat Low refrigerant charge Locate leak repair and recharge Leaking valves in compressor Replace compressor Air in system Recover refrigerant evacuate system and recharge Condenser coil dirty or restricted Clean coil or remove restriction Dirty air filter Replace filter Dirty condenser coil Clean coil Refrigerant overcharged Recover excess refrigerant Air in system Recover refrigerant evacuate system and recharge Condenser air restricted or air short cycling Determine cause and correct Head pressure too low Low refrigerant charge Check for leaks repair and recharge Compressor valves leaking Replace compressor Restriction in liquid tube Remove restriction Excessive suction pressure High heat load Check for source and eliminate Compressor valves leaking Replace compressor Refrigerant overcharged Recover excess refrigerant Suction pressure too low Dirty air filter Replace Filter Low refrigerant charge Metering device or low side restricted Check for l
59. n Duct Opening C99012 Fig 10B Vertical Duct Cover Removed CAUTION PROPERTY DAMAGE HAZARD Failure to follow this caution may result in property damage Collect ALL screws that were removed Do not leave screws on rooftop as permanent damage to the roof may occur 5 It is recommended that the unit base insulation around the perimeter of the vertical return air opening be secured to the unit base with aluminum tape Applicable local codes may require aluminum tape to prevent exposed fiberglass 6 Cover both horizontal duct openings with the duct covers from the accessory duct cover kit Ensure opening is air and watertight 7 After completing unit conversion perform all safety checks and power up unit NOTE The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of 10 nonresidence type air conditioning and ventilating systems NFPA 90A or residence type NFPA 90B and or local codes and ordinances Adhere to the following criteria when selecting sizing and installing the duct system 1 Units are shipped for horizontal duct installation by removing duct covers 2 Select and size ductwork supply air registers and return air grilles according to American Society of Heating Refrigera tion and Air Conditioning Engineers ASHRAE recommen dations 3 Use flexible transition between rigid ductwork and unit to prevent transmissio
60. n buckle ratchet type b Feed strapping through tension buckle as shown in Fig 7A c Pull strapping through tension buckle unit taut d Snap lever down to lock strap in tension buckle To release strapping squeeze safety latch lift lever and pull webbing outward 5 Tighten the tension buckle until it is taut Lifting brackets must be secure in the rigging holds 6 Attach field supplied clevis or hook of sufficient strength to hole in the lifting bracket See Fig 7B 7 Attach the 2 safety straps directly to the clevis or hook at the 4 rigging brackets DO NOT attach the safety straps to the lifting brackets See Fig 7B 8 Position lifting point directly over the unit s center of gravity 9 Lift unit When unit is directly over the roof curb remove the 2 safety straps Lower the equipment onto the roof curb Step 2 PROVIDE UNIT SUPPORT ROOF CURB Install accessory roof curb in accordance with instructions shipped with curb See Fig 4 for roof curb dimensions Install insulation cant strips roofing and flashing Ductwork must be attached to curb IMPORTANT The gasketing of the unit to the roof curb is critical for a watertight seal Install gasketing material supplied with the roof curb Improperly applied gasketing can also result in air leaks and poor unit performance BLOCKOFF PANEL ON 018 uh SUPPLY RETURN REQUIRED DUCT DUCT OPENING OPENING 249 6 t
61. n of vibration The transition may be screwed or bolted to duct flanges Use suitable gaskets to ensure weathertight and airtight seal 4 All units must have field supplied filters or accessory filter rack installed in the return air side of the unit Recommended sizes for filters are shown in Table 1 5 Size all ductwork for maximum required airflow either heating or cooling for unit being installed Avoid abrupt duct size increases or decreases or performance may be affected 6 Adequately insulate and weatherproof all ductwork located outdoors Insulate ducts passing through unconditioned space and use vapor barrier in accordance with latest issue of Sheet Metal and Air Conditioning Contractors National Association SMACNA and Air Conditioning Contractors of America ACCA minimum installation standards for heating and air conditioning systems Secure all ducts to building structure 7 Flash weatherproof and vibration isolate all openings in building structure in accordance with local codes and good building practices Step 10 INSTALL ELECTRICAL CONNECTIONS A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death The unit cabinet must have an uninterrupted unbroken electrical ground to minimize the possibility of serious injury if an electrical fault should occur This ground may consist of an electrical wire connected to the unit ground lug in the control compartmen
62. ngs Installation of flexible duct connector is recommended to prevent transmission of vibration and or noise to structure All ductwork should be secured to the flanges Insulate and weather proof 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 If a plenum return is used on a vertical unit the return should be ducted through the roof deck to comply with applicable fire codes A minimum clearance is not required around ductwork Cabinet return air static shall not exceed 25 in wg MINIMUM HEIGHT 36 C99015 SIZE MAXIMUM WEIGHT kg in mm in mm UNIT 48SD 024 372 169 20 0 508 0 19 3 490 2 030 395 179 20 0 508 0 14 0 355 6 036 462 210 21 0 533 4 20 5 520 7 042 489 222 21 0 533 4 20 5 520 7 048 509 231 21 0 533 4 20 0 508 0 060 521 236 21 0 583 4 20 0 508 0 Fig 7 Suggested Rigging Step 4 PROVIDE CLEARANCES The required minimum operating and service clearances are shown in Fig 2 and 3 Adequate combustion ventilation and condenser air must be provided in accordance with section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI American National Standards Institute Z223 1 or applicable provisions of local building code In Canada fo
63. not attempt to lubricate these motors Table 7 Cooling Checking Chart Suction Line Temperature F OD Temp Suction Line Pressure PSIG F 52 54 5 S 6 amp cg 70 82 85 89 9 E CEN IC ERES ES RC ES 5 pepe sees eed 5 eT 111 sp 85 0 EN Lm Suction Line Temperature C OD Temp Suction Line Pressure kPa CF 36t 370 387 405 423 442 462 482 502 523 544 566 589 612 636 17 _ 46 ES 316 7 ae 5 oe L4 Wt t 46 pep L9 gt Table 8 Filter Pressure Drop In wg CFM 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 024 030 20 X 20 X 1 0 05 0 07 0 08 0 10 0 12 0 13 0 14 0 15 036 20 X 24 X 1 0 09 0 10 0 11 0 13 0 14 0 15 0 16 042 048 060 24
64. old and connect manometer See Fig 13 3 Turn on gas to unit 4 Remove cover screw over regulator adjustment screw on gas valve 5 Adjust regulator adjustment screw to the correct manifold pressure as specified in Table 4 Turn adjusting screw clockwise to increase manifold pressure or turn adjusting screw counterclockwise to decrease manifold pressure 6 Replace cover screw 7 Turn off gas to unit Remove manometer from pressure tap Replace pipe plug on gas valve then turn on gas to unit Check for leaks CHECK BURNER FLAME With burner access panel removed observe the unit heating operation Watch the burner flames to see if they are light blue and soft in appearance and that the flames are approximately the same for each burner Propane will have blue flame See Fig 14 Refer to the Maintenance section for information on burner removal AIRFLOW AND TEMPERATURE RISE The heating section for each size unit is designed and approved for heating operation within the temperature rise range stamped on the unit rating plate 16 Table 9 shows the approved temperature rise range for each heating input and the air delivery cfm at various temperature rises The heating operation airflow must produce a temperature rise that falls within the approved range Refer to Indoor Airflow and Airflow Adjustments section to adjust heating airflow when required HEATING SEQUENCE OF OPERATION See Fig 15 and unit wiring label
65. or death Use all service ports and open all flow control devices including solenoid valves If oil is detected or if low cooling performance is suspected leak test all refrigerant tubing using an electronic leak detector halide torch or liquid soap solution If a refrigerant leak is detected refer to the Check for Refrigerant Leaks section If no refrigerant leaks are found and low cooling performance is suspected refer to the Checking and Adjusting Refrigerant Charge section GAS INPUT The gas input does not require checking unless improper heating performance is suspected If a problem exists refer to the Start Up section EVAPORATOR AIRFLOW The heating and or cooling airflow does not require checking unless improper performance is suspected f a problem exists be sure that all supply and return air grilles are open and free from obstructions and that the air filter is clean When necessary refer to the Indoor Airflow and Airflow Adjustments section to check the system airflow METERING DEVICE ACCURATER This metering device is a fixed orifice and is located in the distributor assembly to the indoor coil LIQUID LINE STRAINER The liquid line strainer to protect metering device is made of wire mesh and located in the liquid line on the inlet side of the metering device TROUBLESHOOTING Use the Troubleshooting Guides See Tables 11 13 if problems occur with these units START UP CHECKLIST Use the Sta
66. r coil drain pan and condensate drain each cooling season for cleanliness Clean at least once per heating cooling season or more often if needed 3 Inspect indoor evaporator fan motor and wheel for cleanli ness at the beginning of each heating and cooling season Clean when necessary For first heating and cooling season inspect blower wheel bi monthly to determine proper cleaning frequency 4 Check electrical connections for tightness and controls for proper operation each heating and cooling season Service when necessary 5 Ensure wires are not contacting refrigerant tubes or sharp sheet metal edges 6 Check and inspect heating section before each heating season Clean and adjust when necessary 7 Check flue hood and remove any obstructions if necessary AIR FILTER CAUTION UNIT PERFORMANCE AND DAMAGE HAZARD Failure to follow this caution may result in improper unit operation and damage to unit components Never operate the unit without a suitable air filter in the return air duct system Always replace the filter with the same dimensional size and type as originally installed See Table 1 for recommended filter sizes Inspect air filter s at least once each month and replace throwaway type or clean permanent at least twice during each heating and cooling season or whenever the filter s becomes clogged with dust and or lint INDOOR EVAPORATOR MOTOR NOTE All motors are permanently lubricated Do
67. rical controls and wiring annually Be sure to turn off the gas supply and then the electrical power to the unit Remove access panel to locate all the electrical controls and wiring Check all electrical connections for tightness Tighten all screw connections If any smoky or burned connections are noticed disassemble the connection clean all the parts restrip the wire end and reassemble the connection properly and securely After inspecting the electrical controls and wiring replace the access panel Start the unit and observe at least one complete heating cycle and one complete cooling cycle to ensure proper operation If discrepancies are observed in either or both operating 24 cycles or if a suspected malfunction has occurred check each electrical component with the proper electrical instrumentation Refer to the unit wiring label when making these checkouts NOTE Refer to the heating and or cooling sequence of operation in this publication as an aid in determining proper control operation REFRIGERANT CIRCUIT Annually inspect all refrigerant tubing connections and the unit base for oil accumulations Detecting oil generally indicates a refrigerant leak A WARNING FIRE EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage System under pressure Relieve pressure and recover all refrigerant before system repair or final unit disposal to avoid serious injury
68. rt Up Checklist to ensure proper start up procedures are followed SYMPTOM Table 11 Troubleshooting Guide Cooling CAUSE REMEDY Compressor and condenser fan will not start Compressor will not start but condenser fan runs Power Failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective thermostat contactor transformer or control relay Replace component Insufficient line voltage Determine cause and correct Incorrect or faulty wiring Check wiring diagram and rewire correctly Thermostat setting too high Faulty wiring or loose connections in compressor circuit Lower thermostat setting below room temperature Check wiring and repair or replace Compressor motor burned out seized or internal overload open Determine cause Replace compressor Defective run start capacitor overload start relay Determine cause and replace Compressor cycles other than normally satisfying thermostat Refrigerant overcharge or undercharge Recover refrigerant evacuate system and recharge to capacities shown on nameplate Defective compressor Insufficient line voltage Replace and determine cause Determine cause and correct Blocked condenser Determine cause and correct Defective run start capacitor overload or start relay Determine cause and replace Defective thermostat Replace ther
69. t or conduit approved for electrical ground when installed in accordance with NEC National Electrical Code ANSI NFPA latest edition and local elec trical codes In Canada follow Canadian Electrical Code CSA Canadian Standards Association C22 1 and local electrical codes 11 A CAUTION UNIT DAMAGE HAZARD Failure to follow these precautions may result in damage to the unit being installed 1 Make all electrical connections in accordance with NEC ANSI NFPA latest edition and local electrical codes governing such wiring In Canada all electrical connec tions must be in accordance with CSA standard C22 1 Canadian Electrical Code Part 1 and applicable local codes Refer to unit wiring diagram 2 Use only copper conductor for connections between field supplied electrical disconnect switch and unit DO NOT USE ALUMINUM WIRE 3 Be sure that high voltage power to unit is within operating voltage range indicated on unit rating plate 4 Do not damage internal components when drilling through any panel to mount electrical hardware conduit etc Consult local power company for correction of improper voltage and or phase imbalance HIGH VOLTAGE CONNECTIONS The unit must have a separate electrical service with a field supplied waterproof disconnect switch mounted at or within sight from the unit Refer to the unit rating plate for maximum fuse circuit breaker size and minimum circuit amps ampacity for wire sizing
70. t all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit NOTE Pressure test the gas supply system after the gas supply piping is connected to the gas valve The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0 5 psig Pressure test the gas supply piping system at pressures equal to or less than 0 5 psig The unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the ground joint union A WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in fire explosion personal injury death and or property damage Connect gas pipe to unit using a backup wrench to avoid damaging gas controls Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections Use proper length of pipe to avoid stress on gas control manifold If a flexible connector is required or allowed by authority having jurisdiction black iron pipe shall be installed at furnace gas valve and extend a minimum of 2 in outside furnace casing If codes allow a flexible connector always use a new connector Do not use a connector which has previously serviced another gas appliance 8 Che
71. ving the proper R 22 charge A superheat charging chart is attached to the outside of the service access panel The chart includes the required suction line tempera ture at given suction line pressures and outdoor ambient tempera tures An accurate superheat thermocouple or thermistor type ther mometer and a gauge manifold are required when using the superheat charging method for evaluating the unit charge Do not use mercury or small dial type thermometers because they are not adequate for this type of measurement 17 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in unit damage When evaluating the refrigerant charge an indicated adjust ment to the specified factory charge must always be very minimal If a substantial adjustment is indicated an abnormal condition exists somewhere in the cooling system such as insufficient airflow across either coil or both coils Proceed as follows 1 Remove caps from low and high pressure service fittings 2 Using hoses with valve core depressors attach low and high pressure gauge hoses to low and high pressure service fittings respectively 3 Start unit in Cooling mode and let unit run until system pressures stabilize 4 Measure and record the following a Outdoor ambient air temperature F db b Suction tube temperature F at low side service fitting c Suction low side pressure psig 5 Using Cooling Charging Charts

Installation, Start-Up, and Operating Instructions

Contents

Download Pdf Manuals

Related Search

Related Contents