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Installation, Start-Up, and Operating Instructions

1. 220660 NYG 7 NOWNOD 541 SdH 18 ale 18 0 41 18 9 13 NYG OSM NYG ZEM gt 15 NAHL SH KINO 151 SYH 090 2 04987 1300N NO 7631835 NI 251 151 5 920 7204987 51300 9PM WOU4 381M N18 LIANNOD 9 291 nud ZEM JAIM QIY 1234802510703145 NNIGIN 04 5 1 1 0731 3 Wil WOUd 181 18 LOINNOD 9 291 3818 4384 LOINNOISIG W4 03385 HOIH 903 7 E 9 TIA NYO TPM D NOILYTIVISNI 07313 803 SYOLINGNOD 834402 338930 SL 35076 aes 3 EZT SASVGGNS IYISOWYJHI 803 520 4 22184 21572 See By INFWAINOI 5 11 o ee Iwi 2 338930 06 3441 HLIM 03271438 38 150 11 03271433 QIHSINYNI SIYIM TWNI9IYO IHL 40 3171 NYG PEM 35 3 aE 19 i 7 253108 71901 M lt 113398 679 GEM Sy 52 1 1103 81103 27901 138 101118002 82 I 1 OIA 21145 1001108 190107 OIA SDH IWYNINYIL 10 HOLOW 8000100 NJO 4YOLIVINOD 2 nig 54 JATWA 579 NIYN AON 118 83078 88 Sy 85 EIN
2. of pipe cu ft of gas per hr for gas pressure of 0 5 psig less Pressure drop of 0 5 in wg based 0 60 specific gravity gas Refer to Table C 4 National Fire Protection Association NFPA 54 tThis length includes an ordinary number of fittings 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 nonresidence type air conditioning and ventilating systems NFPA 90A or residence type NFPA 90B and or local codes and residence type NFPA 90B and or local codes and ordinances ADHERE TO THE FOLLOWING CRITERIA WHEN SELECT ING SIZING AND INSTALLING THE DUCT SYSTEM 1 Units are shipped for side shot installation 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 transmission of vibration The transition may be screwed or bolted to duct flanges Use suitable gaskets to ensure weather tight 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 Tables 2 and 3 5 Size all ductwork for maximum required airflow either
3. eA Er 36 00 914 0 14 00 355 6 POWER ENTRY 36 00 914 0 DUCT SIDE OF UNIT 2 00 50 8 EXCEPT FOR NEC REQUIREMENTS SIDE OPPOSITE DUCTS 14 00 355 6 36 00 914 0 BOTTOM OF UNIT 0 50 12 7 SIDE OPPOSITE DUCTS 36 00 914 0 ELECTRIC HEAT PANEL 36 00 914 4 DUCT PANEL 12 00 304 8 MINIMUM DISTANCES IF UNIT IS PLACED LESS THAN 12 00 304 8 FROM WALL SYSTEM THEN SYSTEM PERFORMANCE MAYBE COMPROMISE NEC REQUIRED CLEARANCES IN BETWEEN UNITS POWER ENTRY SIDE 2 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 42 00 1066 8 47 001 J usa AT hi 1 T F z 28 6 1 131 DIA K O POWER ENTRY CONTROL ENTRY 123 0 53 14 841 506 1 620 2 119 gif 24 42 1 Sari 1 1 AF 1 x 1 DRAIN OUTLET ti 7 19 0 0 75 N P T 1 681 COMPRESSOR BLOWER GAS SECTION 1 84 12 7 0 501 N P T x 22 0 0 87 DP 32
4. 4 Evacuate refrigerant system and reclaim refrigerant if no additional leaks are found 5 Charge unit with R 410a refrigerant using a volumetric charging cylinder or accurate scale Refer to unit rating plate for required charge Table 6 Heating Inputs GAS SUPPLY PRESSURE MANIFOLD PRESSURE HEATING NUMBER IN WG IN WG INPUT OF Naida BTUH ORIFICES Natural Propanet 40 000 2 4 0 13 0 7 0 13 0 3 5 3 5 60 000 2 4 0 13 0 7 0 13 0 3 5 3 5 90 000 3 40 13 0 7 0 13 0 3 5 3 5 115 000 3 4 0 13 0 7 0 13 0 3 5 3 5 130 000 3 4 0 13 0 7 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 on altitudes from sea level to 2000 ft above sea level For altitudes above 2000 ft reduce input rating 4 for each 1000 ft above sea level In Canada from 2000 ft above sea level to 4500 ft above sea level derate the unit 10 START UP HEATING SECTION AND MAKE ADJUSTMENTS IMPORTANT Complete the required procedures given in the Pre Start Up section above 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 NOTE Make sure that gas supply has been purged and that al
5. SEE DETAIL A SPACE IN BRACKET ASSEMBLY 99066 Fig 8 Lifting Point 7 HANDHOLD GY C99067 Belt Threading Instructions 1 Open lever of tension buckle Feed webbing through tension buckle as shown Pull webbing through tension buckle until taught Snap lever down to lock strap in tension buckle A U N To release squeeze safety latch lift lever and pull webbing outward Fig 9 Belt Threading PLACE RIGGING STRAPS IN BASEPAN SLOT BELOW HANDHOLDS BEFORE RIGGING DUCTS SEAL STRIP MUST BE IN PLACE BEFORE PLACING UNIT ON ROOF CURB 99015 UNIT 48GP MAXIMUM WEIGHT A B Size Ib kg in mm in mm 024 312 142 22 0 558 5 14 5 368 3 030 335 152 22 0 558 5 15 3 388 6 036 343 156 22 0 558 5 15 3 388 6 042 404 183 23 0 584 2 16 3 414 0 048 443 201 21 5 546 1 16 3 414 0 060 490 222 23 5 596 9 16 3 414 3 Fig 10 Suggested Rigging Step 6 Connect Condensate Drain NOTE When installing condensate drain connection be sure to comply with local codes and restrictions The 48GP units dispose of condensate water through a 3 4 in NPT fitting which exits through the compressor access panel See Fig 6 and 7 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 p
6. yO Carrier SS HEATING amp COOLING 48GP 48GPN Single Package Gas Heating Electric Cooling Units With Puron R 410A Refrigerant Visit www carrier com Installation Start Up and Operating Instructions 48GP 48GPN Sizes 024 060 NOTE Read the entire instruction manual before starting the installation Index Page SAFETY 5 22 00 1 RULES FOR SAFE INSTALLATION AND OPERATION 1 2 RECEIVING AND 2 2 0 2 gt 2 PROVIDE UNIT 22 0 20200000 0 20 00 00000 2 sess 2 Be in San 2 Ground MOUNE 2 2 FIELD FABRICATE 2 2 0 2 PROVIDE CLEARANCES ccccccccccccsseccssscessecesssecesseeeseeesee 2 3 RIG AND PLAGE 3 6 7 CONNECT CONDENSATE DRAIN 7 INSTALL FLUE HOOD 7 INSTAEL GAS PIPING 000 7 8 INSTALL DUCT CONNECTIONS 22 8 10 INSTALL ELECTRICAL 8 222222 11 13 High Voltage wll Special Procedures for 208 V Operation 11 Control
7. Prior to initial use and at monthly intervals all rigging brackets and straps should be visually inspected for any damage evidence of wear structural deformation or cracks Particular attention should be paid to excessive wear at hoist hooking points and load support areas Brackets or straps showing any kind of wear in these areas must not be used and should be discarded INSTALLATION 1 Position the lifting bracket assembly around the base of the unit Leave the top shipping skid on the unit to act as a spreader bar Be sure the strap does not twist 2 Place each of the four 4 metal lifting brackets into the handholds in the composite pan 3 Tighten the ratchet strap until tight Lifting brackets should be secure in the handholds 4 Attach the clevis or hook of sufficient strength to hole in the lifting bracket as shown in Fig 8 5 Attach safety straps directly to the field supplied rigging straps or clevis clip Do not attach the safety straps to the lifting brackets 6 Use the top of the unit as a spreader bar to prevent the rigging straps from damaging the unit If the wood top is not available use a spreader bar of sufficient length to not damage the unit DETAIL A SCALE 0 250 TIGHTEN STRAPPING SECURELY WITH TENSION BUCKLE INSTALL SAFETY STRAPS RIGGING CLEVIS AT 4 RIGGING BRACKETS PLACE RIGGING BRACKET ASSEMBLY IN 4 HAND HOLES AND INSTALL TIE DOWN STRAP AROUND PERIMETER OF UNIT AND THROUGH
8. except for NEC requirements Unit top Side opposite ducts Duct panel Minimum distances If unit is placed less than 12 in 304 8 mm from wail system then the system performance may be compromised LEGEND CG Center of Gravity COND Condenser EVAP Evaporator NEC National Electrical Code REQ D Required Note Dimensions are in in mm TOP VIEW REQ D CLEARANCES TO COMBUSTIBLE in mm 22 ne bee dod due be amp 14 355 6 UCU Side Be GS AE tk SL ee 2 50 8 Side opposite 14 355 6 o s Soe we 0 50 12 7 Five cok de eee a doe ee 36 914 4 NEC REQ D CLEARANCES in mm Between units power entry side Unit and ungrounded surfaces power entryside 36 914 Unit and block or concrete walls and other grounded surfaces control box side g FIELD ENTRY SERVICE PORTS 23 0 10 91 28 6 1 13 DIA POWER ENTRY 22 2 0 88 DIA HOLE CONTROL ENTRY hy 510 3 122 451 11 86 347 2 12 351 113 671 208 g 3 8 221 42 7 1901 OMPRESSOR BLOWER GAS SECTION FLUE HOOD 46 8 A 32
9. 1000 ft above sea level 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 4 CAUTION These units are designed to consume the rated gas inputs using the fixed orifices at specified manifold pressures as shown in Table 6 DO NOT REDRILL THE ORIFICES UNDER ANY CIRCUMSTANCES 14 ADJUST GAS INPUT The gas input to the unit is determined by measuring the gas flow 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 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 local codes NOTE All other appliances that use the same meter must be turned off when gas flow is measured at the meter Proceed as follows Turn off gas supply to unit 1 Remove pipe plug on manifold see Fig 18 then connect manometer at this point turn on gas to unit 2 Record number of seconds for gas meter test dial to make one revolution 3 Divide number of seconds in Step 3 into 3600 number of seconds on one hour Multiply resul
10. 170 1103 160 150 8 965 140 2 96 gt 130 827 2 120 758 110 690 100 20 0 30 0 40 0 50 0 60 0 70 0 80 0 SUCTION LINE TEMPERATURE DEG F T T T T T T T 7 1 4 10 16 21 27 SUCTION LINE TEMPERATURE DEG C SUCTION LINE PRESSURE KILOPASCALS 030 60 Hz CHARGING CHART OUTDOOR FOR USE WITH UNITS USING R410A REFRIGERANT 1241 180 1172 170 1103 160 1034 150 gt B 8 965 140 w 896 gt 130 27 2 120 758 110 690 100 20 0 30 0 40 0 50 0 60 0 70 0 80 0 SUCTION LINE TEMPERATURE DEG T T T 7 51 4 10 16 21 27 SUCTION LINE TEMPERATURE DEG 99079 Fig 23 Cooling Charging Chart 48GP024 Units SUCTION LINE PRESSURE KILOPASCALS 036 60 Hz CHARGING CHART OUTDOOR TEMP FOR USE WITH UNITS USING R410A REFRIGERANT F 1241 180 1172 170 1103 160 1034 w 150 2 8 965 140 W 896 130 5 9 827 2 120 758 110 100 20 0 30 0 40 0 50 0 60 0 70 0 80 0 SUCTION LINE TEMPERATURE DEG 7 st 4 10 16 21 27 SUCTION LINE TEMPERATURE DEG C 99081 Fig 25 Cooling Charging Chart 48GP036 Units SUCTION LINE PRESSURE KILOPASCALS 048 60 Hz CHARGING CHART OUTDOOR FOR USE WITH UNITS USING R4
11. 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 6 PI EE Se 2 gt RETURN RETU EVAP COIL COND COIL 99014 Fig 3 Slab Mounting Details Step 4 Provide Clearances The required minimum operating and service clearances are shown in Fig 6 and 7 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 2223 1 in Canada sec tions 7 2 7 3 or 7 4 or Can CGA Canadian Gas Association B149 Installation Codes or applicable provisions of local build ing code CAUTION Do not restrict condenser airflow An air restriction at either the outdoor air inlet or the fan discharge can be detrimental to compressor life The condenser pulls air through the condenser coil and discharges it through the top cover Be sure that the fan discharge does not 46 3 16 SS 4 7 8 ae gt gt je SUPPORT B SUPPORT A 2 21 END VIEW A99320 Fig 4 Roof Curb Dimensions Top View SIDE 0 75 BOTTOM SUP
12. NO 1 631835 NI ZSI ONY 157 S H 9 0 720d98 513004 NO S as 1 50 0333 3841 018 1234802 ONY 291 NOYA JUIN 1234802510 03346 WNIOIN 04 134 89 IWD 55 250 WOU4 3818 WIG LOINNOD 9 291 WOT 4384 123 02 10 41 03345 803 7 i 21 NOILVTTVISNI 01311 401 58012040802 834402 338930 5125075 W SASVAGNS ANY IVISONYIHL 803 5194 39184 21522 0 13 54 ro 1003 S LI Nas IAW 14 9 2818 2 338920 06 3441 HLIM 03271418 38 1SAW 11 NYa 032 1428 03 51 804 53814 TWNIS YO FHL 30 31 9 21901 T 253108 2 YY9 SEM NEEN THA ININdINOJ 41003 21501 AY134 NOI 1518902 vi OIA area OIA ST 80552384400 sph YANYOISNVYL 47 HOLIMS 1001104 58 OLV INOJ 7 nig 8 1 10 414013 su 85 80104 8000110 GEO ng 55 038 124 7 509 NIV ONIYIM 1 1 1 418 OL LON HOLIMS sa Wor 18 14 01 YOLON NY4 800081 ni GS ILON 335 S 2 i YOLOW 13 80 4320481 wal _ 62 NYS 02 311081302 01140 YO 18055322 7 LINN 5 9 G3LVYOUILNI 291 83404 01313 LHM 61 YOLIN
13. X C99086 Fig 32 Burner Rack Removed Shut off manual gas valve Shut off power to unit Remove unit access panel See Fig 29 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 Remove the mounting screw that attaches the burner rack to the basepan See Fig 30 8 Slide the burner rack out of the unit See Figs 30 and 32 9 To reinstall reverse the procedure outlined above CONDENSER COIL EVAPORATOR COIL AND CONDEN SATE DRAIN PAN Inspect the condenser coil evaporator coil and condensate drain pan at least once each year 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 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 units with an outer and inner condenser coil
14. 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 re tighten 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 see Fig 17 c Ensure fan hub is 1 8 in max from motor housing 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 MOTOR FAN GRILLE 1 8 MAX BETWEEN MOTOR AND FAN HUB MOTOR SHAFT 99009 Fig 17 Fan Blade Clearance START UP Use the Start Up Checklist supplied at the end of this book and proceed as follows CHECK FOR REFRIGERANT LEAKS Proceed as follows to locate and repair refrigerant leaks and charge the unit 1 Locate leak and make sure that refrigerant system pressure has been relieved and refrigerant recovered from both high and low pressure ports 2 Repair leak following accepted practices NOTE Replace filter drier whenever the system has been opened for repair 3 Check system for leaks using an approved method
15. line and insulate it so that the outdoor ambient does not effect the reading Indoor air CFM must be within the normal operating range of the unit TO USE COOLING CHARGING CHARTS Take the outdoor ambient temperature and read the suction pressure gage Refer to the chart to determine what the suction temperature should be NOTE If the problem causing the inaccurate readings is a refrigerant leak refer to Check for Refrigerant Leaks section in this document INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS 4 CAUTION 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 7 shows the temperature rise at various air flow 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 20 NOTE Be sure that all supply and return air grilles are open free from obstructions and adjusted properly WARNING Shut off gas supply then disconnect electrical power to the unit before changing blower speed Electrical shock or explosion could cause serious injury or death Airflow can be changed by changing the lead connections of the blower motor All 48GP units are factory wired for low speed and may need to be wired for medium or high
16. plumbing or waste water codes and other applicable local codes Approved for outdoor installation on wood flooring or on class A B or C roof covering materials Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 101 Catalog No 534 755 Tab 8 Printed in U S A Form 48GP 1SI Pg 1 3 00 Replaces New A WARNING Before performing service or maintenance operations on unit turn off gas supply then unit main power switch Electrical shock or explosion could cause serious injury or death 4 CAUTION Puron R 410A systems operate at higher pressures than standard R 22 systems Do not use R 22 service equipment or components on Puron R 410A equipment Ensure service equipment is rated for Puron R 410A GENERAL The 48GP units see Fig 1 are fully self contained combination Category I gas heating electric cooling units designed for outdoor installation See Fig 6 and 7 for unit dimensions All unit sizes have discharge openings for both horizontal and downflow configurations and are factory shipped with all downflow duct openings covered Units may be installed either on a rooftop cement slab or directly on the ground if permitted by local codes See Figs 4 and 5 for roof curb dimensions 48GPN units are dedicated Low NOx units designed for California installations These models meet
17. pressure or loss of charge switch Replace component 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 tempera ture Compressor will not start but condenser fan runs Faulty wiring or loose connections in compressor circuit 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 One leg of 3 phase power dead Replace fuse or reset circuit breaker Determine cause Three phase scroll compressor makes exces sive noise and there may be a low pressure differential Scroll compressor is rotating in the wrong direc tion Correct the direction of rotation by reversing the 3 phase power leads to the unit Shut down unit to allow pressures to equalize Compressor cycles other than normally sat isfying thermostat Refrigerant overcharge or undercharge Recover refrigerant evacuate system and re charge 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 c
18. sediment trap in riser leading to heating section per Fig 12 This drip leg functions as a trap for dirt and condensate 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 shutoff valve 7 Pressure test all gas piping in accordance with local and national plumbing and gas codes before connection of piping to unit TEE NIPPLE CAP 99020 Fig 12 Sediment Trap NOTE 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 13 8 If the test pressure is 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 CAUTION Unstable operation may occur when the gas valve and manifold assembly are forced out of position while connect ing improperly routed rigid gas piping to the gas valve Use a backup wrench when making connection to avoid strain on or distortion of the gas control piping CAUTION If a flexible conductor is required or allowed by the authority having jurisdiction black iron pipe shall be installed at the gas valve and shall extend a minimum of 2 in outside the unit casing A WARNING Never
19. 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 DANGER 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 Leak test all refrigerant tubing connections using electronic leak detector halide torch or liquid soap solu tion If a refrigerant leak is detected see Check for Refrigerant Leaks section on page 13 13 c Inspect all field and factory wiring connections Be sure that connections are completed and tight d Inspect coil fins If damaged during shipping and handling carefully straighten fins with a fin comb 4 Verify the following conditions A WARNING Do not purge gas supply into the combustion chamber Do not use a match or other open flame to check for gas leaks Failure to follow this warning could result in an explosion causing serious injury or death a Before lighting the unit for the first time perform the following with the gas valve in the OFF position If the
20. use a match or other open flame when checking for gas leaks Never purge gas line into combustion chamber Failure to follow this warning could result in an explosion causing serious injury or death 8 Check 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 can be connected to the roof curb See Fig 6 and 7 for connection sizes and locations CONFIGURING UNITS FOR DOWNFLOW VERTICAL DIS CHARGE A WARNING Before performing service or maintenance operations on the system turn off main power to unit Electrical shock could cause serious injury or death 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 Fig 13 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 Fig 14 4 If unit ductwork is to be attached to vertical opening flanges on the unit basepan jackstand applications only do so at this time Collect ALL screws that were removed Do not leave screws on ro
21. 10A REFRIGERANT F TEMP 1241 180 125 52 1172 170 115 46 1103 160 1034 w 150 5 2 8 965 140 W 896 130 5 8 827 120 758 110 690 100 20 0 30 0 40 0 50 0 60 0 70 0 80 0 SUCTION LINE TEMPERATURE DEG F T T T T T 7 4 10 16 21 27 SUCTION LINE TEMPERATURE DEG 99083 Fig 27 Cooling Charging Chart 48GP048 Units 21 C99080 Fig 24 Cooling Charging Chart 48GP030 Units SUCTION LINE PRESSURE KILOPASCALS 042 60 Hz CHARGING CHART OUTDOOR FOR USE WITH UNITS USING R410A REFRIGERANT TEMP 1241 180 125 52 115 46 1172 170 105 41 1103 160 1034 150 140 896 130 S SUCTION LINE PRESSURE PSIG 827 120 758 110 690 100 20 0 30 0 40 0 50 0 60 0 70 0 80 0 SUCTION LINE TEMPERATURE DEG F T 74 4 10 16 21 27 SUCTION LINE TEMPERATURE DEG 99082 Fig 26 Cooling Charging Chart 48GP042 Units SUCTION LINE PRESSURE KILOPASCALS 060 60 Hz CHARGING CHART OUTDOOR FOR USE WITH UNITS USING R410A REFRIGERANT 1241 180 1172 170 8 160 8 150 140 896 130 S amp SUCTION LINE PRESSURE PSIG 827 120 758 110 690 100 20 0 30 0 40 0 50 0 60 0 70 0 80 0 SUCTION LINE TEMPERATURE DEG F T T T T T T T 6 1 4 10 16 21 27 SUCTION LINE TEMPERATURE DEG 99084 Fig
22. 12 18 PGM 3000110 01311 2 INIWSJONVYYV INAINOdWOD LINN y18 418 18 weerd 09 097 22 820669 NYG OEM lt 7 NOWNOD 541 SdH nig ols 18 9 18 old y 18 114 NYG OEM NYG ZEM 11048 15 NYHL SH 3 NYG 9M KINO 151 SWH 090 2704987 513004 NO 7531815 GIYIM ZSI ONY ISI SYH 960 204987 1100 NO S NYG ZEM LVLSOWYFHL G791 4 OIA WIG YFHLIOOL 121145 134 038 OL 1238802 41145 MOT 404 13 89 111 89 TPM OIA WIG 3901 121145 134 NYO OL LIINNOD 01195 0384 804 13 WIG OL 121 802 03345 H9IH 803 T NYG 5 401101 SY 3814 580104379 803 SLINM 11 NOLLVTIVISNI 07313 804 58401200802 814402 138930 SL 35072 134 7515 8815 ANY LVLSOWYSHL 801 539 4 12184 33572 NaS 4WV14 INFTVAINOA 5 11 NYG YEM 181 2 318930 06 03971939 38 LSAW 11 032 1438 38 1 51 804 SIYIM IYNI9IYO FHL 30 ANY 34171 253104 2 v49 GEM 3 _ 41103 AY734 NOILSNEWOD 9 D 01A 0 1 YINYOISNV
23. 28 Cooling Charging Chart 48GP060 Units Table 9 Wet Coil Air Delivery Horizontal and Downflow Discharge Unit 48GP024 060 Deduct 10 for 208 Volts 230 AND 460 VOLT Unit Motor External Static Pressure in wg 48GP Speed 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 Watts 279 282 280 277 276 882 801 738 674 604 024 Medium Watts 373 367 361 356 351 936 868 797 719 626 High Watts 463 452 439 428 956 878 794 702 Watts 243 244 242 Low Cfm 885 842 786 030 Mealum Watts 353 339 333 330 326 320 1195 1134 1070 997 911 818 High Watts 443 436 426 416 406 397 1230 1145 1061 977 888 786 cow Watts 490 463 446 432 418 403 389 378 Cfm 1431 1398 1347 1281 1205 1118 1024 921 036 Medium Watts 513 501 488 474 459 443 428 Cfm 1491 1426 1351 1267 1175 1077 976 High Watts 645 636 627 616 605 593 583 Cfm 1484 1410 1330 1243 1147 1044 936 Bw Watts 634 618 608 598 583 562 534 502 473 454 457 Cfm 1669 1599 1545 1498 1448 1391 1326 1257 1189 1132 1101 Watts 733 704 672 638 604 574 550 536 042 Medium Cfm 1746 1688 1630 1566 1492 1399 1279 1120 High Watts 797 773 751 727 696
24. 29 Unit Access Panel FLUE GAS PASSAGEWAYS To inspect the flue collector box and upper areas of the heat exchanger INDUCED DRAFT MOTOR MOUNT Pe e 25 5 i 1 15 5 5 550 505550009605060 ROLLOUT T HOOD FLUE SWITCH IN SHIPPIN LLECTOR BLOWER BURNER MOUNTING 2800 Gay ag HOUSING RACK SCREW 99022 Fig 30 Blower Housing and Flue Collector 1 Remove the combustion blower wheel and motor assembly according to directions in Combustion Air Blower section below 2 Remove the 3 screws holding the blower housing to the flue collector box cover see Fig 30 3 Remove the 12 screws holding the flue collector box cover Fig 30 to the heat exchanger assembly Inspect the heat exchangers 4 Clean all surfaces as required using the wire brush BLOWER HOUSING 2 SETSCREWS HIDDEN 99085 Fig 31 Removal of Motor and Blower Wheel COMBUSTION AIR BLOWER Clean periodically to assure proper airflow and heating efficiency Inspect blower wheel every fall and periodically during heating season For the first heating season inspect blower wheel bimonthly to determine proper cleaning frequency To inspect blower wheel remove draft
25. 3300 22 3300 22 1 4 1100 EVAPORATOR COIL Rows Fins in Face Area sq ft 4 15 4 7 4 15 4 7 4 15 4 7 4 15 4 7 4 15 4 7 4 15 4 7 EVAPORATOR BLOWER Nominal Airflow Cfm Size in Motor HP 1600 11x 10 3 4 1600 11x 10 3 4 1600 11x 10 3 4 1750 11x 10 1 0 11x 10 1750 1750 11x 10 FURNACE SECTION Burner Orifice No Qty Drill Size Natural Gas Burner Orifice No Qty Drill Size Propane Gas HIGH PRESSURE SWITCH psig Cutout Reset Auto 610 15 420 25 LOSS OF CHARGE LOW PRESSURE SWITCH Liquid Line psig Cutout Reset Auto 2045 45 10 RETURN AIR FILTERS in Throwaway 24 x 30x1 24 x 30x1 24 x 30 1 24 x 30x1 24 x 30x1 24 x 30x1 Table 4 Maximum Gas Flow Capacity LENGTH OF PIPE FTt NOMINAL IRON PIPE SIZE IN INTERNAL DIAMETER IN 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1 2 622 175 120 97 82 73 66 61 57 53 50 44 40 3 4 824 360 250 200 170 151 138 125 118 110 103 93 84 77 72 1 1 049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 11 4 1 380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280 1 1 2 1 610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430
26. 5 for electrical data 11 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 6 and 7 for acceptable location See unit wiring label and Fig 16 for reference when making high voltage connections Proceed as follows to complete the high voltage connections to the unit 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 Three phase units 1 Run the high voltage L1 L2 L3 and ground leads into the control box 2 Connect ground lead to chassis ground connection 3 Locate the black and yellow wires connected to the lines side of the contactor 4 Connect 11 to black wire on connection 11 of the compressor contactor 5 Connect field wire L2 to yellow wire on connection 13 of the compressor contactor 6 Connect field wire L3 to Blue wire from compressor SPECIAL PROCEDURES FOR 208 V OPERATION A WARNING Make sure that the gas supply then the power supply to the unit is switched OFF before making any wiring changes Electrical shock or explosion could cause serious injury or death With disconnect switch open move yellow wire from transfo
27. 6 5 ELECTRICAL ACCESS PANEL 84 GAS ENTR ae 12 4 10 201 2 85 1226 3 0 831 0 48 28 122 2 132 721 14 811 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW 99017 ELECTRICAL UNIT HEIGHT CENTER OF GRAVITY UNIT CHARACTERISTICS UNIT WEIGHT IN MM IN MM lb kg X Y 2 48GP024040 060 208 230 1 60 290 0 131 5 37 02 940 3 22 0 558 8 14 5 368 3 16 0 406 4 208 230 1 60 48GP030040 060 2 230 3 60 313 0 142 0 39 02 991 1 22 0 558 8 15 3 387 4 17 6 447 0 208 230 1 60 48GP036060 090 208 230 3 60 321 0 145 6 35 02 889 5 22 0 558 8 15 3 387 4 16 5 419 1 460 3 60 4 Fig 6 48GP024 036 Unit Dimensions 355 8 342 7 355 8 14 01 13 491 14 011 Sa PB RETURN SUPPLY Be 7 n OPTIONAL OPTIONAL 406 6 RETURN M 406 6 116 01 AIR AIR 116 01 OPENING 2A OPENING Mi Ihe oll D 4 21 q COND COIL 5 j 80 5 SUPPLY RETURN WAS 3 17 Duct DUCT m 19 83 OPENING OPENING Y ill EVAP COIL 13 5 EP S Se 7 16 83 OND COIL 113 ag TOP VIEW REAR VIEW REQUIRED CLEARANCE FOR OPERATION AND SERVICING REQUIRED CLEARANCE TO COMBUSTIBLE MATL in mm in mm 65 6
28. 7 v 2 Minimum wire size is based on 60 C copper wire If other than 60 wire is used or if length exceeds wire length in table Determine percent of voltage imbalance determine size from NEC 7 3 Unbalanced 3 Phase Supply Voltage Voltage Imbalance 100 x 457 Never operate a motor where a phase imbalance in supply volt age is greater than 2 Use the following formula to determine 1 53 the percentage of voltage imbalance a This amount of phase imbalance is satisfactory as it is below the Voltage imbalance maximum allowable 2 100x max voltage deviation from average voltage average voltage IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately 99024 Fig 15 Electrical Data Legend CONTROL VOLTAGE CONNECTIONS z 2 HIGH VOLTAGE NOTE Do not use any type of power stealing thermostat Unit POWER LEADS power control problems may result BEL WIRING Bi ee _ _f SUPPLY Use no 18 American Wire Gage AWG color coded insulated 35 minimum wires to make the control voltage connections between the thermostat and the unit If the thermostat is located FIELD SUPPLIED more than 100 ft from the unit as measured along the control GND FUSED DISCONNECT voltage wires use no 16 AWG color coded insulated 35 C CONTROL BOX minimum wires WHT W1 STANDARD CONNECTION Remove knockout hole located _ in
29. 9 0 8 ELECTRICAL ACCESS PANEL 22 GAS ENTRY 6 ee 12 081 00920 be 1123 1 48 281 44 221 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW 99074 ELECTRICAL UNIT HEIGHT CENTER OF GRAVITY UNIT CHARACTERISTICS UNIT WEIGHT IN MM IN MM lb kg A X 2 208 230 1 60 48GP042060 090 208 230 3 60 382 173 3 38 98 990 2 23 0 584 2 16 3 412 8 16 6 421 6 460 3 60 208 230 1 60 48GP048090 115 130 208 230 3 60 421 191 0 38 98 990 2 21 5 546 1 16 6 422 1 18 0 457 2 460 3 60 208 230 1 60 48GP060090 115 130 208 230 3 60 468 212 3 42 98 1091 7 23 5 596 9 16 3 412 8 17 6 447 0 460 3 60 Fig 7 48GP042 060 Unit Dimensions 1 Application of the lifter to the load and adjustment of the lifts if any that adapts it to various sizes or kinds of loads 2 Instruction in any special operation or precaution 3 Condition of the load itself required for operation of the lifting kit such as balance temperature etc Follow all applicable safety codes Wear safety shoes and work gloves WARNING Never exceed 200 165 per bracket lifting force Accessory lifting kit is only to be used with Small Packaged units which have a composite base pan with molded hand holds Never stand beneath rigged units or lift over people Lifting point should be directly over the center of gravity for the unit A dropped unit could cause serious injury or death INSPECTION
30. Cfm 1727 1632 1537 1423 1308 7 Watts 591 578 573 568 559 544 524 500 Cfm 1554 1523 1496 1467 1432 1387 1332 1269 048 Medium Watts 755 737 719 699 678 653 627 602 579 562 556 Cfm 1834 1802 1758 1706 1648 1585 1520 1455 1392 1332 1276 High Watts 890 858 828 801 777 756 734 709 1943 1870 1793 1711 1624 1531 1433 1329 Low Watts 589 576 569 566 559 541 499 1946 1891 1836 1779 1718 1651 1577 Watts 750 733 715 695 673 648 623 598 577 060 Medium Cfm 2189 2097 2021 1952 1883 1809 1727 1635 1530 High Watts 879 850 795 772 750 728 701 Cfm 2337 2159 2050 1974 1905 1824 1722 1597 delivery values are without air filter Note Deduct field supplied air filter pressure drop to obtain external static pressure available for ducting 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 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 connect contactor coil C through unit wire Y and blower relay coil BR through unit wire G across the 24 v secondary of transformer TRAN The normally open contacts of energized contactor C close and compl
31. DI ONIXIM 1081802 07313 UINYOASNVYL JOVLIOA HOTH NYYL AH ONIYIM AYOLIV4 27 291 805835 123443 SH 121145 HOLIMS 38055384 HOTH SdH 21 77 438 6EM JAYA 5000 0100 221745 ANNOYS 321145 Ave ISN nd Ya wna 805835 3HV14 53 121145 4131457 15 lt 82 EREN 321943N3 30 437198383 Site ag M 4g M N 834 11 201 SISSWHD 39891 1 1 vo oar mO OIA OSM 13 Yeh 438 134 99 7 10 21901 9NILYJH nug 21198382 INVOL 0321 983N3 30 4 1 134 0 l 0 21901 N 4 9N11009 OIA 062 3 218 619 Yd 14 2 awe 09 1 062 902 1 gt 21 LWWAHOS 5 TIA 914 410 PE ILON 339 011235 011235 GN 41103 400051 8055 38440 144 1235 2 719 5 01313 INAWFONVYEYY LNINOdWOD LINN wig WIG EPM 17 weibeig 09 2 022 802 12
32. ES 51 ONIYIM 183534434 01 LON ne 58 438 HOLIMS 39155399 MOT 41 1 KINO WWILNILOd 6 310 115 YOON PEN NOKHOD OL TH y 7 1 03204081 WE Te 83110481802 ONT YIM z NYS 020 LINN SY9 QJLYY9YJLN 291 01140 Y0 180551224 7 YOLINOI ONTYIM 83404 01313 IHM GIM YINYOISNYYL JOVLIOA HOTH NYYL AH ONIYIM 1081802 07313 805835 123442 TIYH SH Ta HOLIMS 38055384 SdH ue gD 291 577 SYD 340 eR 03 annoy OND 121145 1 27 3503 nd TWNINYAL ug 08391125 805835 3 13 13 ng 2 CIN 321145 01313 2 are st Wo 01393 82 02719843843 24 417198183 ug ag M JIN Yad v 12318802514 Nya 9PM 5 Ape i AYVONODAS 13 99 17 19 a 21901 N 4 ONT LYSH Nye INVYL 031 lt 198283 30 437198383 5 9 13 PNI S l 0 20 5 21901 9811002 OIA 062 00 3 3168 A0E 10 a AYVWI Ud NYG 1h 13 SIM 134 30 1492 Wil LHM N 8 13 eqs oth 09 l 039 339 JILWWAHOS 5 118 9SM 4 02 J34 LA 41003 21 011235 011235 2 WIG 8M 08 1081102 3 30553390217 INQ 090 1 16 Y4AMOd J34 9M 134 SSM 24 2 11 4 14415 101 1235 130 13
33. IGHTNESS START UP ELECTRICAL SUPPLY VOLTAGE 11 12 L2 L3 L3 L1 COMPRESSOR AMPS 1 L2 L3 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 SUCTION LINE TEMP REFRIGERANT DISCHARGE PSIG DISCHARGE VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS VERIFY THAT THREE PHASE SCROLL COMPRESSOR IS ROTATING IN CORRECT DIRECTION Measured at suction inlet to compressor t Measured at liquid line leaving condenser 31 Copyright 2000 CARRIER Corp 7310 W Morris St Indianapolis 46231 48gp1si Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 100 k PC 101 Catalog No 534 755 Printed in U S A Form 48GP 1SI Pg 32 3 00 Replaces New al
34. NG SEQUENCE OF OPERATION See Fig 20 22 and unit wiring label On a call for heating terminal W 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 evaporator fan motor is energized 45 seconds after flame is established When the thermo stat is satisfied and is de energized the burners stop firing and the evaporator fan motor shuts off after a 45 second 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 8 for error codes Table 8 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 Internal Software Fault 9 Flashes NOTES 1 There is a 3 second 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 cha
35. PLY SUPPORT RIB S SEAL STRIP FACTORY SUPPLIED COUNTER FLASHING NAILER FIELD SUPPLIED ROOFING FELT FIELD SUPPLIED CANT STRIP HELD SUPPLIED FIELD SUPPLIED SU ROOFING MATERIAL FIELD SUPPLIED 99340 Fig 5 Roof Curb Dimensions Side View A B D UNIT SIZE ODS ORDER NUMBER IN IN MM MM IN CPRFCURBOO6A00 8 203 11 27 32 301 30 5 8 778 28 3 4 730 ROOF CPRFCURB007A00 14 356 11 27 32 301 30 5 8 778 28 3 4 730 CURB 008 00 8 203 15 27 32 402 42 1 8 1070 40 1 4 1022 CPRFCURBOO9A00 14 356 15 27 32 402 42 1 8 1070 40 1 4 1022 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 16 density Dimensions are in inches Table 1 Roof Curb Dimensions recirculate to the condenser coil Do not locate the unit in either a comer or under an overhead obstruction The minimum clearance under a partial overhang such as a normal house overhang is 48 in above the unit top The maximum horizontal extension of a partial overhang must not exceed 48 inches Do not place the unit wh
36. Voltage 12 Standard Connection 212 Heat Anticpator Setting 13 Transformer Protection 13 PRE STPART UP AR A 13 STAR 13 22 MAINTENANCE seed T 22 26 REFRIGERANT 6 5 00 26 QUICK REFERENCE 00022 00 000000 27 5 2 2 4 41 20 000000000000000000000 28 30 START UP 8 0 2 0000202 2020 10 000 00 00000000 31 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 construc tion 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 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 precau
37. YL 80551844002 4902 251 A _157 HOLIMS 1001708 58 49 8 114080 00 19 80104 8000100 CE YOLIVINOD 2 nig 579 AVIY 834018 88 58 039 128 HOLIMS LIWII 51 nig PLAS eR YOLOW 13 80 4320081 OL 577 83110818302 ONT G 4ILON 335 020 LINN S 9 QJLYY9YILNI 391 TYNOILdO YO_AYOSSIIIV 7 8011191 ONIYIM 838404 07313 LHM 61M YANYOISNVYL 39 170 HOTH Y 7081802 01313 805835 123443 11VH 225 HOLIMS 39155399 SdH a EE _ 19138 JATVA 5 9 39 0 8 321145 QIY 6EM ANNOY 489 121145 l sia m TAWA ae Madi 321145 QIAYYW 201145 01313 7 al 13931 0371941 1 20 417198181 ug M ud M 238 34 NYG 97M 2 Shil 1 A AUYQNOD3S 10 4 01023 21901 NY3 ONTLV3H oe 037198383 30 43719083943 ta oe 9 9 134 l 0 21901 NY4 9811002 18 71 Ud 19 13 SIM NYa G 14 2 JJA Wil 13 09 09 2 097 13 19M v 3101 339 21 LVWAHOS 5 118 IGM E 090 134 LN GND diNO3 21 011235 NOI LOJIS 2 218 8M 1041802 800081 80551854902 YIMOd Nua 144 EZ l 134 SGM 24 2 10 4 1148405 011235 10 1 12 M18 PGM
38. aintenance 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 FAILURE TO HEED THIS WARNING COULD RESULT IN SERI OUS INJURY AND POSSIBLE DAMAGE TO THIS EQUIPMENT A WARNING Failure to follow these warnings could result in serious injury or death 1 Turn off gas supply then turn off electrical power to the unit before performing any maintenance or service on the unit Use extreme caution when removing panels and parts As with any mechanical equipment serious 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 shut off the external main manual gas valve to the unit then shut off the electrical supply CAUTION 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 2 Inspect indoor coil drain pan and condensate drain each cooling season for cleanliness Clean when necessary 3 Inspect blower motor and wheel for cleanliness and check lubrication each heating and cooling
39. air leaks and poor unit performance Curb should be level to within 1 4 inch This is necessary for unit drain to function properly Refer to accessory roof curb installation instructions for additional information as required see Fig 2 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 3 Do not secure the unit to the slab except when required by local codes MAXIMUM ALLOWABLE DIFFERENCE A B B C A C 1 4 1 4 1 4 Fig 2 Unit Leveling Tolerances 99065 GROUND MOUNT The unit may be installed either a slab or placed directly on the ground if local codes permit Place the unit on level ground prepared with gravel for condensate dis charge 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 openings All ductwork should be secured to the flanges 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
40. ause and replace Defective thermostat Faulty condenser fan motor or capacitor Replace thermostat Replace Restriction in refrigerant system Locate restriction and remove Compressor operates continuously 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 re charge Condenser coil dirty or restricted Clean coil or remove restriction Excessive head pressure Dirty air filter Replace filter Dirty condenser coil Clean coil Refrigerant overcharged Recover excess refrigerant Air in system Recover refrigerant evacuate system and re charge 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 Compressor valves leaking Check for source and eliminate Replace compressor Refrigerant overcharged Recover excess refrigerant Suction pressure too low Dirty air filter Replace filter Low refrige
41. 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 4 CAUTION 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 that the hub is 1 8 in away from the motor end 1 8 in of motor shaft will be visible 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 electrical controls and wiring annually Be sure to turn off the gas supply and then the electrical power to the unit Remove access pan
42. by the interaction of a stationary and an orbiting scroll The scroll compressor has no dynamic suction or discharge valves and it is more tolerant of stresses caused by debris liquid slugging and flooded starts The compressor is equipped with an anti rotational device and an internal pressure relief port The anti rotational device prevents the scroll from turning backwards and replaces the need for a cycle protector The pressure relief port is a safety device designed to protect against extreme high pressure the relief port has an operating range between 550 and 625 psi differential pressure The Copeland scroll compressor uses Mobil 3MA POE oil This is the only oil allowed for oil recharge REFRIGERANT 4 CAUTION This system uses Puron R 410A refrigerant which has higher operating pressures than R 22 and other refrigerants No other refrigerant may be used in this system Gage set hoses and recovery system must be designed to handle Puron If you are unsure consult the equipment manufacturer Failure to use Puron compatible servicing equipment or replacement components may result in property damage or injury COMPRESSOR OIL The compressor in this system uses a polyolester POE oil Mobil 3MA POE This oil is extremely hygroscopic meaning it absorbs water readily POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precautions to avoid exposure of t
43. d sets should be 750 psig high side and 200 psig low side with 520 psig low side retard Use hoses with 750 psig service pressure rating Leak detectors should be designed to detect HFC refrigerant Puron as with other HFCs is only compatible with POE oils Vacuum pumps will not remove moisture from oil Only use factory specified liquid line filter driers with rated working pressures no less than 600 psig Do not install a suction line filter drier in liquid line POE oils absorb moisture rapidly Do not expose oil to atmosphere POE oils may cause damage to certain plastics and roofing materials Wrap all filter driers and service valves with wet cloth when brazing A Puron liquid line filter drier is required on every unit Do not use an R 22 TXV Never open system to atmosphere while it is under a vacuum When system must be opened for service break vacuum with dry nitrogen and replace filter driers Always replace filter drier after opening system for service Do not vent Puron into the atmosphere Observe all warnings cautions and bold text Do not leave Puron suction line driers in place for more than 72 hours 27 SYMPTOM Table 10 Troubleshooting Cooling CAUSE REMEDY Compressor and condenser fan will not start Power failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective thermostat contactor transformer con trol relay high
44. e unit access panel Disconnect motor lead from blower relay BR Disconnect yellow lead from terminal L2 of the contactor c On all units remove blower assembly from unit Remove screws securing blower to blower partition and slide assembly out Be careful not to tear insulation in blower compartment d Ensure proper reassembly by marking blower wheel and motor in relation to blower housing before disassembly e Loosen setscrew s that secures wheel to motor shaft remove screws that secure motor mount brackets to hous ing and slide motor and motor mount out of housing 2 Remove and clean blower wheel as follows 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 on blower wheel vanes c Remove caked on dirt from wheel and housing with a brush Remove lint and or dirt accumulations from wheel and housing with vacuum cleaner using soft brush attach ment Remove grease and oil with mild solvent d Reassemble wheel into housing Reassemble motor into housing Be sure setscrew s tightened on motor shaft flats and not on round part of shaft f Reinstall unit access panel 3 Restore electrical power then gas supply to unit Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles ee Fig
45. ea CEM 800 800 800 1000 1200 1200 1400 1400 Sie in 10x10 10 10 10 10 10x10 10x10 10x10 11 10 11x10 erate 1 4 1 4 1 4 1 4 1 2 1 2 3 4 3 4 FURNACE Burner a ar ean Size 2 44 2 38 2 44 2 38 2 38 3 38 2 38 3 38 atura as Burman ritica Seal Seed 2 50 2 46 2 50 2 46 2 46 3 46 2 46 3 46 Propane Gas HIGH PRESSURE SWITCH psig Cutout F 18 Reset Auto LOSS OF CHARGE LOW PRESSURE SWITCH Liquid Line psig 20 5 Cutout 45 10 Reset Auto RETURN AIR FILTERS in Throwaway 20 x 24xt 20 20x24x1 20x24x1 20x 24x1 20 24x30x1 24x 3051 Table 3 Physical Data Unit 48GP 048090 060130 UNIT SIZE 48GP NOMINAL CAPACITY ton 048090 4 048115 4 048130 4 060090 5 060115 5 060130 5 OPERATING WEIGHT Ib 421 421 421 468 468 468 COMPRESSORS Quantity 5 roll REFRIGERANT R 410A Quantity Ib 9 5 9 5 9 5 10 0 10 0 10 0 REFRIGERANT METERING DEVICE Orifice ID in Accurater Piston 073 073 073 086 086 086 CONDENSER COIL Rows Fins in Face Area sq ft 2 17 12 3 2 17 12 3 2 17 12 3 2 17 16 4 2 17 16 4 2 17 16 4 CONDENSER Nominal Cfm Diameter in Motor Hp RPM 3300 22 1 4 1100 3300 22 1 4 1100 3300 22 1 4 1100 3300 22 1 4 1100 1 4 1100
46. el to locate all the electrical controls and wiring Check all electrical connections for tightness Tighten all screw connections If any smokey 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 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 25 NOTE Refer to the heating and or cooling sequence of operation in this publication as an aid in determining proper control operation REFRIGERANT CIRCUIT Inspect all refrigerant tubing con nections and the unit base for oil accumulations annually Detect ing oil generally indicates a refrigerant leak 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 Check for Refrigerant Leaks section on page 13 If no refrigerant leaks are found and low cooling performance is suspected refer to Checking and Adjusting Refrigerant Charge section o
47. ere 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 Step 5 Rig and Place Unit Rigging and handling of this equipment can be hazardous for many reasons due to the installation location roofs elevated structures etc Only trained qualified crane operators and ground support staff should handle and install this equipment When working with this equipment observe precautions in the literature on tags stickers and labels attached to the equipment and any other safety precautions that might apply Training for operations of the lifting equipment should include but NOT be limited to the following SUPPLY RETURN DUCT DUCT OPENING OPENING 14 631 88 3 3 481 2496 be 550 5 2495 19 831 21 611 19 831 254 0 546 2540 110 001 121 501 110 001 86 1 13 39 SUPPLY 70 6 2 78 asa fi RETURN SUPPLY Ill ALR AIR 406 4 II OPENING OPENING oe il 80 5 COND NON BENT 153 3 1 26 04 COND COIL COIL REQ D CLEARANCES FOR OPERATION AND SERVICING in mm Evaporator coil access side Power entry side
48. es 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 on 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 seconds 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 IMPORTANT Three phase scroll compressor units direction oriented These units must be checked to ensure proper compressor 3 phase power lead orientation If not corrected within 5 minutes the internal protector will shut off the compress
49. ete the circuit through compressor motor COMP to con denser outdoor fan motor OFM Both motors start instantly The set of normally open contacts of energized relay BR close and complete the circuit through evaporator blower indoor fan motor NOTE Once the compressor has started and then has stopped it should not be started again until 5 minutes have elapsed 22 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 de energize contactor coil C and relay coil BR The condenser and compressor motors stop After a 30 second 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 heating or cooling of units refer to tables at the back of the book NOTE TO EQUIPMENT OWNER Consult your local dealer about the availability of a maintenance contract A WARNING The ability to properly perform m
50. f they are light blue and soft in appearance and that the flames are approximately the same for each burner Propane will have blue flame with yellow tips See Fig 19 Refer to Maintenance section for information on burner removal BURNER FLAME MANIFOLD 99021 Fig 19 Monoport Burners 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 Table 7 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 on the following pages to adjust heating airflow when required Table 7 Air Delivery Cfm at Indicated Temperature Rise and Rated Heating Input HEATING INPUT TEMPERATURE RISE F BTUH INPUT 20 25 30 35 40 45 50 55 60 65 70 40 000 1500 1200 1000 857 750 667 600 60 000 2250 1800 1500 1286 1125 1000 900 818 750 692 90 000 2700 2250 1929 1688 1500 1350 1227 1125 1038 964 115 000 2464 2156 1917 1725 1568 1438 1327 130 000 2438 2167 1950 1773 1625 1500 1393 NOTE Dashed areas do not fall within the approved temperature rise range of the unit START UP COOLING SECTION AND MAKE ADJUST HEATI
51. fort to the occupants of 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 second overload or shorted secondary condition PRE START UP A WARNING Failure to observe the following warnings could result in serious injury or death 1 Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured Do not remove compressor terminal cover until all electri cal sources are disconnected Relieve and recover all refrigerant from both high and low pressure sides of system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals Never attempt to repair soldered connection while refrig erant system is under pressure 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 reclaim all refrigerant from system using both high and low pressure ports c Cut component connecting tubing with
52. 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 A 1 8 in NPT plugged tapping accessible for test gage connection must be installed immediately upstream of the gas supply connec tion to the gas valve When installing the gas supply line observe local codes pertaining to gas pipe installations Refer to the NFGC ANSI Z223 1 NFPA 54 latest edition in Canada CAN CGA B149 1 B149 2 latest edition 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
53. he oil to the atmosphere 26 SERVICING SYSTEMS ON ROOFS WITH SYNTHETIC MA TERIALS POE polyolester compressor lubricants are known to cause long term damage to some synthetic roofing materials Exposure even if immediately cleaned up may cause embrittle ment leading to cracking to occur in one year or more When performing any service that may risk exposure of compressor oil to the roof take appropriate precautions to protect roofing Proce dures which risk oil leakage include but are not limited to compressor replacement repairing refrigerant leaks replacing refrigerant components such as filter drier pressure switch me tering device coil accumulator or reversing valve SYNTHETIC ROOF PRECAUTIONARY PROCEDURE 1 Cover extended roof working area with an impermeable polyethylene plastic drip cloth or tarp Cover an approximate 10 x 10 ft area 2 Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run offs and protect drop cloth from tears caused by tools or components 3 Place terry cloth shop towel inside unit immediately under component s to be serviced and prevent lubricant run offs through the louvered openings in the base pan 4 Perform required service 5 Remove and dispose of any oil contaminated material per local codes LIQUID LINE FILTER DRIER The filter drier is specifically designed to operate with Puron Use only factor
54. 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 10 p AON 7 SUPPLY RETURN DUCT DUCT OPENING OPENING 99089 Fig 13 Supply and Return Duct Opening 99012 Fig 14 Vertical Duct Cover Removed Step 10 Install Electrical Connections A WARNING 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 compartment or conduit approved for electrical ground when installed in accordance with NEC National Electrical Code ANSI NFPA 70 latest edition in Canada Canad
55. 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 29 24 2 Remove the 7 screws that attach induced draft motor mount ing plate to blower housing See Fig 30 3 Slide the motor and blower wheel assembly out of the blower housing See Fig 31 Clean the blower wheel If additional cleaning is required continue with Steps 4 and 5 4 To remove blower remove 2 setscrews See Fig 31 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 BURNER IGNITION Unit is equipped with a direct spark ignition 100 lockout system Ignition module is located in the control box Module contains a self diagnostic LED During servicing refer to label diagram for LED interpretations If lockout occurs unit may be reset by either momentarily interrupting power supply to unit or 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 CAUTION When servicing gas train do not hit or plug orifice spuds REMOVAL OF GAS TRAIN Nz
56. ian Electrical Code CSA Canadian Standards Associa tion C22 1 and local electrical codes Do not use gas piping as an electrical ground Failure to adhere to this warning could result in serious injury or death 4 CAUTION Failure to follow these precautions could result in damage to the unit being installed 1 Make all electrical connections in accordance with NEC ANSI NFPA 70 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 5 On 3 phase units ensure phases are balanced within 2 Consult local power company for correction of improper voltage and or phase imbalance refer to Table 5 HIGH VOLTAGE CONNECTIONS The unit must have a separate electrical service with a field supplied water proof 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 See Table
57. l 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 in the AUTO position Set the heating temperature control of the thermostat above room temperature 3 The induced draft motor will start After a call for heating the main burner should light within 5 seconds If the burners do not light there is a 22 second delay before another 5 second try If the burners still do not light this sequence is repeated If the burners do not light within 15 minutes from the initial call for heat there is a lockout To reset the control break the 24 v power to W 5 The evaporator fan will turn on 45 seconds after the flame has been established The evaporator fan will turn off 45 seconds after the thermostat has been satisfied CHECK GAS INPUT Check gas input and manifold pressure after unit start up See Table 6 If adjustment is required proceed as follows The rated gas inputs shown in Table 6 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 propane gas with a heating value of 2500 at 1 5 specific gravity For elevations above 2000 ft reduce input 4 for each
58. me om NY4 8000100 5 ol 01311 INAWFONVYYY LNANOdWOD LINN wg 19 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 IMPORTANT When evaluating the refrigerant charge an indi cated adjustment 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 insuf ficient airflow across either coil or both coils REFRIGERANT CHARGE The amount of refrigerant charge is listed on the unit nameplate Refer to Carrier Refrigeration Service Techniques Manual Refrigerants section Unit panels must be in place when unit is operating during charging procedures NO CHARGE Use standard evacuating techniques After evacu ating system weigh in the specified amount of refrigerant refer to system data plate LOW CHARGE COOLING Measure outdoor ambient using Cooling Charging Charts Figs 23 28 Vary refrigerant until the conditions of the chart are met Note that charging charts are different from type normally used Charts are based on charging the units to correct superheat for the various operating conditions Accurate pressure gage and temperature sensing devices are required Connect the pressure gage to the service port on the suction line Mount the temperature sensing device on the suction
59. n page 20 EVAPORATOR AIRFLOW The heating and or cooling air flow does not require checking unless improper performance is suspected If 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 Indoor Airflow and Airflow Adjustments section on page 20 to check the system airflow METERING PISTON This meter ing device is a fixed orifice and is contained in the brass hex body in the liquid line PRESSURE SWITCHES Pressure switches are protective de vices wired into control circuit low voltage They shut off compressor if abnormally high or low pressures are present in the refrigeration circuit These pressure switches are specifically designed to operate with Puron R 410A systems R 22 pressure switches must not be used as replacements for the Puron R 410A air conditioner LOSS OF CHARGE LOW PRESSURE SWITCH AIR CONDI TIONER ONLY This switch is located on the liquid line and protects against low suction pressures caused by such events as loss of charge low airflow across indoor coil dirty filters etc It opens on a pressure drop at about 20 psig If system pressure is above this switch should be closed To check switch 1 Turn off gas and then all power to unit 2 Disconnect leads on switch 3 Apply ohmmeter leads across switch You should have con tinuity on a good
60. nts apply only to natural gas instal lations 4 CAUTION 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 B149 1 and B149 2 or NFPA National Fire Protection Association latest revision Refer to Provin cial and local plumbing or waste water 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 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 4 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
61. oftop as permanent damage to the roof may occur 5 It is recommended that the basepan insulation around the perimeter of the vertical return air opening be secured to the basepan 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 Table 2 Physical Data Unit 48GP 024040 042090 UNIT SIZE 48GP 024040 024060 030040 030060 036060 036090 042060 042090 NOMINAL CAPACITY ton 2 2 21 2 21 2 3 3 3 1 2 31 2 OPERATING WEIGHT Ib 290 290 313 313 321 321 382 382 COMPRESSORS Scroll Quantity 1 REFRIGERANT R 410A aah ae 5 0 5 0 55 55 6 9 6 9 9 0 9 0 REFRIGERANT METERING DEVICE Orifice ID in 057 057 057 057 065 065 070 070 AccuRater Piston einai COIL 1 17 1 17 1 17 147 2 17 2 17 2 17 2 17 Area ent 10 9 10 9 12 7 127 9 1 9 1 12 3 12 3 STEEL 2350 2350 2350 2350 2350 2350 2350 2350 22 22 22 22 22 22 22 22 Motor Hp RPM 18 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 3 15 3 15 3 15 3 15 3 15 3 15 3 15 3 15 37 37 37 37 37 37 47 47 Face Area sq ft ze Ai
62. ontrol fault LED 8 flashes Microprocessor has sensed an error in the soft ware or hardware If error code is not cleared by resetting unit power replace the IGC Internal software fault LED 9 flashes 4 CAUTION If the IGC must be replaced be sure to ground yourself to dissipate any electrical charge that may be present before Microprocessor has sensed an error in it s redun dant software comparison 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 Heating Troubleshooting Chart for additional troubleshooting analysis LEGEND IGC Integrated Gas Unit Controller LED Light Emitting Diode 30 If error code is not cleared by resetting unit power replace the IGC START UP CHECKLIST Remove and Store in Job File 1 PRELIMINARY INFORMATION MODEL NO SERIAL NO DATE TECHNICIAN 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 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 AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW T
63. or The 3 phase power leads to the unit must be reversed to correct rotation When turning backwards scroll compressors emit el evated noise levels and the difference between compressor suction and discharge pressures may be dramatically lower than normal CHECKING AND ADJUSTING REFRIGERANT CHARGE The refrigerant system is fully charged with R 410A Puron refrigerant and is tested and factory sealed NOTE Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R 410A charge The charging label and the tables shown refer to system temperatures and pressures A refrigerant charging chart label is attached to the outside of the compressor access door The chart includes the required suction line temperature at given suction line pressures and outdoor ambients An accurate superheat thermocouple or thermistor type ther mometer and a gage manifold are required when using the weibeig 09 1 022 802 02 920669 OEM 7 7 NOWWOD 541 SdH 118 ols 118 18 old 18 134 NYG OEM 11008 15 NYHL SH XO wi KINO 151 SYH 090 204987 57300
64. 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 alter nate motor Limit switch cycles main burners Check rotation of blower thermostat heat antici pator settings and temperature rise of unit Ad just as necessary Poor flame characteristics Incomplete combustion results in Aldehyde odors carbon monoxide sooting flame floating flame 29 1 Tighten all screws around burner compart ments 2 Cracked heat exchanger Replace 3 Unit overfired Reduce input change orifices or adjust gas line or manifold pressure 4 Check burner alignment SYMPTOM CAUSE Table 12 LED Troubleshooting Error Code 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 20 minutes for automatic reset Fan ON OFF delay modified LED FLASH High limit switch opens during heat exchanger warm up period before fan on delay expires Ensure unit is fired on rate and temperature rise is correct Limit switch opens within three minutes after blower off delay timing in Heating mode Ensure unit s external static pressure is within application guidelines Limit
65. p 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 unit are sized for the unit rated input when the manifold pressure reading matches the level specified in Table 6 A WARNING If converting to propane gas remove the burner assembly and inspect the heat exchanger tubes If there are V shaped NOx baffles installed in the firing tubes THEY MUST REMOVED Discard the baffles after removal Refer to Maintenance section for information on burner removal Proceed as follows to adjust gas input on a propane gas unit 1 Turn off gas to unit 2 Remove pipe plug on manifold see Fig 18 then connect manometer at this point 15 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 6 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 i
66. rant charge Check for leaks repair and recharge Metering device or low side restricted 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 28 Replace SYMPTOM Table 11 Troubleshooting 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 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 Check flame ignition and sense electrode posi tioning Adjust as necessary No gas at main burners 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 at tempting to light unit 2 Check gas valve Inadequate heating Dirty air filter 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
67. rmer 3 16 in terminal marked 230 to terminal marked 200 This retaps transformer to primary voltage of 208 vac Table 5 Electrical Data 48GP UNIT COMPRESSOR OUTDOOR FAN MOTOR INDOOR FAN MOTOR POWER SUPPLY SIZE 48GP MCR Min RLA LRA FLA FLA MCA MOCP 024 208 230 1 60 187 19 7 30 030 208 230 1 60 187 21 3 35 208 230 3 60 187 14 9 20 208 230 1 60 187 23 7 35 036 208 230 3 60 187 19 7 30 460 3 60 414 9 1 15 208 230 1 60 187 29 0 45 042 208 230 3 60 187 22 6 35 460 3 60 414 10 8 15 208 230 1 60 187 31 3 50 048 208 230 3 60 187 24 1 35 460 3 60 414 11 0 15 208 230 1 60 187 42 3 60 060 208 230 3 60 187 30 4 45 460 3 60 414 15 4 20 EXAMPLE Supply voltage is 460 3 60 AB 452 LEGEND 484 v FLA Full Load Amps US 455 v LRA Locked Rotor Amps _ 462 464 455 Minimum Circuit Amps Average Voltage MOCP Maximum Overcurrent Protection RLA Rated Load Amps 1371 3 NOTES 1 In compliance with NEC National Electrical Code requirements Determine maximum deviation from average voltage for multimotor and combination load equipment refer to NEC 457 452 5 Articles 430 and 440 the overcurrent protective device for the 464 457 7 unit shall be Power Supply fuse The CGA Canadian Gas 457 455 2v Association units may be fuse or circuit breaker Maximum deviation is
68. roper drainage Make sure that the outlet of the trap is at least 1 in lower than the drain pan condensate connection to prevent the pan from overflowing See Fig 11 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 11 Make sure that the outlet of the trap is at least 1 in lower than the drain pan condensate connection to prevent 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 one in for every 10 ft of horizontal run Be sure to check the drain tube for leaks 12 1 MIN TRAP OUTLET 2 MIN C99013 Fig 11 Trap Step 7 Install Flue Hood The flue hood assembly is shipped screwed to the coil panel in the indoor blower compartment Remove the service access panel to locate the assembly Dedicated low NOx 48GP models MUST be installed in Califor nia Air Quality Management Districts where a Low NOx rule exists These models meet the California maximum oxides of nitrogen NOx emissions requirement of 40 nanograms joule or less as shipped from the factory NOTE Low NOx requireme
69. rt is on the wiring diagram located inside the burner access panel LIMIT SWITCHES Normally closed limit switch LS com pletes the control circuit through the thermostat R circuit Should the leaving air temperature 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 When this fault occurs the IGC LED will display FAULT CODE 2 AUXILIARY LIMIT SWITCH ROLLOUT The function of the 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 auxiliary switch reaches the maximum allow able 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 16 MENTS CAUTION Complete the required procedures given in the Pre Start Up section on previous pages before starting the unit Do not jumper any safety devic
70. season Clean when necessary For first heating season inspect blower wheel bimonthly 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 Check and inspect heating section before each heating season Clean and adjust when necessary 6 Check flue hood and remove any obstructions if necessary AIR FILTER IMPORTANT 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 Tables 2 and 3 for recommended filter sizes Inspect air filter s at least once each month and replace throwaway type or clean cleanable type at least twice during each heating and cooling season or whenever the filter s becomes clogged with dust and lint EVAPORATOR BLOWER AND MOTOR NOTE All motors are pre lubricated Do not attempt to lubricate these motors For longer life operating economy and continuing efficiency clean accumulated dirt and grease from the blower wheel and motor annually A WARNING Turn off the gas supply then disconnect and tag electrical power to the unit before cleaning the blower motor and wheel Failure to adhere to this warning could cause serious injury or death To clean the blower motor and wheel 1 Remove and disassemble blower assembly as follows a Remov
71. speed in the field For 208 230 v The motor leads are color coded as follows 3 SPEED 2 SPEED black high speed black high speed blue medium speed red low speed red low speed To change the speed of the blower motor BM remove the fan motor speed leg lead from the blower relay BR This wire is attached to terminal BM for single phase and 3 phase units To change the speed remove and replace with lead for desired blower motor speed Insulate the removed lead to avoid contact with chassis parts For 460 GE Motors The motor leads are color coded as follows 3 SPEED 2 SPEED black high black high violet jumper orange medium red low blue jumper red low To change the speed of the blower motor BM remove fan motor speed lead from the blower relay BR and replace with the lead for the desired blower motor speed The motor speed lead is attached to terminal BM For low and medium speeds black must be connected to the jumper wire Insulate removed lead end to avoid contact with chassis parts To select high speed on 460 v GE motors separate the black female quick connect QC from the jumper lead male quick connect QC and connect the black lead to the BR Insulate the jumper to avoid contact with any chassis parts SUCTION LINE PRESSURE KILOPASCALS 024 60 Hz CHARGING CHART OUTDOOR FOR USE WITH UNITS USING R410A REFRIGERANT TEMP 1241 180 1172
72. switch NOTE Because these switches are attached to refrigeration system under pressure it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists If switch must be removed remove and recover all system charge so that pressure gages read 0 psi Never open system without breaking vacuum with dry nitrogen HIGH PRESSURE SWITCH The high pressure switch is lo cated in the discharge line and protects against excessive con denser coil pressure It opens at 610 psig High pressure may be caused by a dirty condenser coil failed fan motor or condenser air recirculation To check switch 1 Turn off gas and then all power to unit 2 Disconnect leads on switch 3 Apply ohmmeter leads across switch You should have con tinuity on a good switch COPELAND SCROLL COMPRESSOR PURON REFRIGER ANT The compressor used in this product is specifically designed to operate with Puron R 410A refrigerant and cannot be interchanged The compressor is an electrical as well as mechanical device Exercise extreme caution when working near compressors Power should be shut off if possible for most troubleshooting tech niques Refrigerants present additional safety hazards A WARNING Wear safety glasses and gloves when handling refrigerants Failure to follow this warning can cause a fire serious injury or death The scroll compressor pumps refrigerant throughout the system
73. switch fault LED 2 flashes High temperature limit switch is open Check operation of indoor evaporator fan motor Ensure that the supply air temperature rise is in accordance with the range on the unit nameplate 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 min utes Check ignitor and flame sensor electrode spac ing gaps etc Ensure that flame sensor and igni tion wires are properly terminated Verify that unit is obtaining proper amount of gas Induce draft motor fault LED 6 flashes IGC does not sense that induced draft motor is Check for proper voltage If motor is operating check the speed sensor plug IGC Terminal J2 connection Proper connection operating PIN 1 White PIN 2 Red PIN Black Rollout switch fault LED 7 flashes Rollout switch has opened Rollout switch will automatically reset but IGC will continue to lockout unit check gas valve op eration ensure that induced draft blower wheel is properly secured to motor shaft Reset unit at unit disconnect Internal c
74. t of Step 4 by the number of cu ft shown for one revolution of test dial to obtain cu ft of gas flow per hour 5 Multiply result of Step 5 by Btu heating value of gas to obtain total measured input in Btuh Compare this value with heating input shown in Table 6 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 seconds and the heating value of the gas is 1050 Btu ft Proceed as follows 1 32 seconds to complete one revolution 2 3600 32 112 5 3 112 5 x 1 112 5 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 1 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 0 N 2 UF MANIFOLD PIPE PLUG 99019 Fig 18 Assembly WARNING Unsafe operation of the unit may result if manifold pressure is outside this range Serious injury or unit damage may result 3 Replace cover screw ca
75. the California maximum oxides of nitrogen NOx emissions requirement of 40 nanograms joule or less as shipped from the factory and MUST be installed in California Air Quality Management Districts where a Low NOx 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 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 Manufacturer is not responsible for any damage incurred in transit Check all items against shipping list Immediately notify the nearest Carrier Air Conditioning office if any item is missing To prevent loss or damage leave all parts in original packages until installation Step 2 Provide Unit Support ROOF CURB Install accessory roof curb in accordance with instructions shipped with curb See Figs 4 and 5 and Table 1 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
76. the flue panel adjacent to the control access panel See Fig 6 GRN G i 4 LOW VOLTAGE pera and 7 Remove the rubber grommet from the installer s packet BOWER LEADS REDIR p included with unit and install grommet in the knockout opening SEE UNIT BENG Provide a drip loop before running wire through panel WIRING LABEL PRNO Run the low voltage leads from the thermostat through the inlet SPLICE BOX hole and into unit low voltage splice box 99018 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 16 Ensure the leads are long enough to be routed into the low voltage splice box located below right side of control box Stripped yellow wire is located in connection 12 Fig 16 High and Control Voltage Connections box Route leads through hole in bottom of control box and make low voltage connections as shown in Fig 16 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
77. tions that may apply Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for unbrazing operations Have fire extinguisher available for all brazing operations C99088 Fig 1 Unit 48GP RULES FOR SAFE INSTALLATION AND OPERATION A WARNING Improper installation adjustment alteration service mainte nance or use can cause carbon monoxide poisoning fire or an explosion which can result in serious 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 Understand the signal words DANGER WARNING and CAUTION DANGER identifies the most serious hazards which will result in severe serious injury or death WARNING indicates a condition that could result in serious injury or death CAUTION is used to identify unsafe practices which would result in minor or moderate injury or product and property damage The power supply volts phase and hertz must correspond to that specified on unit rating plate The electrical supply provided by the utility must be sufficient to handle load imposed by this unit This installation must conform with local building codes and with NEC National Electrical Code and NFPA 70 NFPA 54 ANSI 7223 1 latest revision and NFGC National Fuel Gas Code Refer to provincial and local
78. y authorized components Filter drier must be replaced whenever the refrigerant system is opened When removing a filter drier use a tubing cutter to cut the drier from the system Do not unsweat a filter drier from the system Heat from unsweating will release moisture and contaminants from drier into system PURON R 410A REFRIGERANT CHARGING Refer to unit information plate and charging chart Some R 410A refrigerant cylinders contain a dip tube to allow liquid refrigerant to flow from cylinder in upright position For cylinders equipped with a dip tube charge Puron units with cylinder in upright position and a commercial metering device in manifold hose Charge refrigerant into suction line AIR CONDITIONER WITH PURON R 410A QUICK REFERENCE GUIDE Puron refrigerant operates at 50 70 higher pressures than R 22 Be sure that servicing equipment and replacement components are designed to operate with Puron Puron refrigerant cylinders are rose colored Puron refrigerant cylinders manufactured prior to March 1 1999 have a dip tube that allows liquid to flow out of cylinder in upright position Cylinders manufactured March 1 1999 and later DO NOT have a dip tube and MUST be positioned upside down to allow liquid to flow Recovery cylinder service pressure rating must be 400 psig DOT 4BA400 or DOT BW400 Puron systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose Manifol

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