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Installation, Start-Up and Service Instructions

1. 758 110 OUTDOOR TEMP E 86 125 52 589 100 E 115 46 2105 41 621 30 95 35 o 2 fs CL LESS 29 5 E t 5 2 552 CE E gt A 65 18 c 13 5 gt c c 2 483 670 L 45 7 n 1 1 Z 414 260 S 5 5 5345 50 D wo 276 40 30 30 40 50 50 70 80 90 SUCTION LINE TEMPERATURE 4 10 16 21 27 32 SUCTION LINE TEMPERATURE Fig 18 Cooling Charging Chart 48GS018 Units 758 110 689 100 OUTDOOR TEMP z 621 30 115 45 8 105 41 amp o 95 35 2552 85 29 x 5 75 2 65 18 483 70 9 55 13 5 Z 414 250 2 5 5 ud S 345 50 276 40 30 30 40 50 50 70 80 90 SUCTION LINE TEMPERATURE CF 4 10 16 21 27 32 SUCTION LINE TEMPERATURE Fig 19 Cooling Charging Chart 48GS024 Units 23 758 110 689 1 00 115 46 4621 105 4 g 5 95 35 a
2. COMMON WI3 BLK 24V SPLICE BOX UNIT COMPONENT ARRANGEMENT INDOOR FAN SECTION W43 BLK BLK OUTDOOR FAN YEL OFM SECTION COMPRESSOR SECTION COMP RED YEL BRN WHT IFM WI6 YEL OR YEL WIS YEL PRIMARY 230V SEE NOTE 5 m 9 v NOTES FLAME SEN YEL o i Bon GROUNDED THRU STANDOFF W33 YEL Fig 15 208 230 1 60 Wiring Diagram Unit 48GS and 48GX LEGEND Adjustable Heat Anticipator QT Blower Relay RS Contactor ST ompressor Motor Combustion Relay LA Equipment ame Sensor Elam lt gt Ground O Gas Valve Relay Hall Effect Sensor High Voltage Transformer Ignitor Induced Draft Motor Indoor Fan Motor Integrated Gas Unit Controller Limit Switch Main Gas Valve National Electrical Code Outdoor Fan Motor DISCONNECT PER NEC Quadruple Terminal Rollout Switch Thermistor Sensor Transformer Field Splice Terminal Marked Terminal Unmarked Splice Splice Marked Factory Wiring Field Control Wiring Field Power Wiring Accessory or Optional Wiring To Indicate Common Potential Only Not to Represent Wiring 1 If any of the original wires furnished are replaced it must be replaced with type 90 degree C wire or its equivalent See price pages for thermostat and subbases Use 75 degree C copper conductors for field installation For high
3. Suction pressure too low Dirty air filter Dirty condenser coil Refrigerant overcharged Air in system Condenser air restricted or air short cycling Low refrigerant charge Compressor valves leaking Restriction in liquid tube High heat load Replace filter Clean coil Recover excess refrigerant Recover refrigerant evacuate system and recharge Determine cause and correct Check for leaks repair and recharge Replace compressor Remove restriction Check for source and eliminate Compressor valves leaking Refrigerant overcharged Dirty air filter Low refrigerant charge Metering device or low side restricted Insufficient evaporator airflow Temperature too low in conditioned area Outdoor ambient below 40 F Field installed filter drier restricted 33 Replace compressor Recover excess refrigerant Replace filter Check for leaks repair and recharge Remove source of restriction Increase air quantity Check filter replace if necessary Reset thermostat Install low ambient kit Replace Heating SYMPTOM CAUSE REMEDY Burners will not ignite Water in gas line Drain Install drip leg No power to furnace Check power supply fuses wiring or circuit breaker No 24 v power supply to control Check transformer circuit NOTE Some transformers have internal overcurrent protection that requires a cool down period to reset Miswired or loose connections Check all wiring and wirenut con
4. To remove motor and cooling fan assembly remove 4 screws that hold blower housing to mounting plate To reinstall reverse the procedure outlined above Limit Switch Remove unit access panel Limit switch is located on the blower partition BLOWER HOUSING 2 SETSCREWS HIDDEN Fig 33 Removal of Motor and Blower Wheel Burner Ignition Unit is equipped with a direct spark ignition 100 lockout system Ignition module is lo cated in the control box Module contains a self diagnostic LED During servicing refer to label diagram for LED interpretation If lockout occurs unit may be reset by either momentarily interrupting power supply to unit or turning selector switch to OFF position at the thermostat Main Burners At the beginning of each heating sea son inspect for deterioration or blockage due to corrosion or other causes Observe the main burner flames and adjust if necessary A CAUTION When servicing gas train do not hit or plug orifice spuds REMOVAL OF GAS TRAIN Shut off manual gas valve Shut off power to unit Remove unit access panel See Fig 32 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 31
5. 1 1 si 3 1727 1 528 1 si 2 28 Table 11 48GS Wet Coil Pressure Drop UNIT SIZE PRESSURE DROP 48GS cfm in wg 0 049 018 ___600 0 070 0 095 700 0 077 99 0 127 900 0 065 030 0 080 0 097 0 084 036 0 100 0 177 0 103 042 0 120 1500 0 138 048 0 100 0 113 1900 0 108 0132 Table 11B 48GX Wet Coil Pressure Drop UNIT SIZE PRESSURE DROP 48GX cfm in wg 700 0 0535 024 0 067 800 0 123 900 0 0687 030 0 083 0 150 0 084 036 0 100 0 177 0 099 042 1400 0 177 0 199 048 0 137 0 156 0 108 060 0 120 0 132 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 ther mostat 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 complete the circuit through compressor motor COMP to condenser outdoor fan motor OFM Both motors start instantly The set of normally open contacts of energized relay BR close and complete the circuit through ev
6. 46340 414 506 61 440 09 20 105 15 30 1 45 048 212 30 45 36 414 506 58 440 09 20 102 15 43 8 60 060 208 230 3 60 187 253 17 3 123 0 1 6 6 2 29 4 45 LEGEND FLA Full Load Amps HACR Heating Air Conditioning U and Refrigeration LRA Locked Rotor Amps C L US MCA Minimum Circuit Amps MOCP Maximum Overcurrent Protection RLA Rated Load Amps Fuse or HACR Breaker NOTES 1 In compliance with NEC National Electrical Code requirements for multimotor and combination load equipment refer to NEC Articles 430 and 440 the overcurrent protective device for the unit shall be fuse or HACR breaker The CGA Canadian Gas Association units may be fuse or circuit breaker 2 Minimum wire size is based on 60 C copper wire If other than 60 C wire is used or if length exceeds wire length in table determine size from NEC 3 Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance in supply volt age is greater than 2 Use the following formula to determine the percentage of voltage imbalance 96 Voltage imbalance 100x max voltage deviation from average voltage average voltage 13 EXAMPLE Supply voltage is 460 3 60 AB 452 v BC 464 v AC 455 v Average Voltage 482 54541455 2 2971 3 457 Determine maximum deviation from average voltage 457 452 5 v BC 464 457 7 v AC 457 455 2 v Maximum deviat
7. Rows Fins in 3 15 Face Area sq ft 4 7 EVAPORATOR BLOWER Nominal Airflow Cfm 800 1400 1400 Size in 10 x 10 11 x 10 11 x 10 Motor Hp Va FURNACE SECTION Burner Orifice No Qty Drill Size 3 38 Natural Gas m Burner Orifice No Qty Drill Size 3 46 Propane Gas di B ZA RETURN AIR FILTERS in f Throwaway 20 x 20 20 x 20 20 x 20 20 x 20 20 x 24 20 x 24 24 x 30 24 x 30 UNIT SIZE 48GX NOMINAL CAPACITY ton OPERATING WEIGHT Ib COMPRESSORS Quantity REFRIGERANT R 22 Quantity Ib REFRIGERANT METERING DEVICE Orifice ID in CONDENSER COIL Rows Fins in Face Area sq ft CONDENSER FAN Nominal Cfm Diameter in Motor Hp Rpm EVAPORATOR COIL Rows Fins in Face Area sq ft EVAPORATOR BLOWER Nominal Airflow Cfm Size in Motor Hp FURNACE SECTION Burner Orifice No Qty Drill Size Natural Gas Burner Orifice No Qty Drill Size Propane Gas RETURN AIR FILTERS in f Throwaway Based on altitude of 0 to 2000 feet TRequired filter sizes shown are based and Refrigeration Institute rated coolin 048090 048115 048130 060090 060115 060130 5 5 f 5 421 421 421 468 468 468 Scrol a za Acutrol Device 034 034 032 032 032 2 17 2 17 2 17 2 17 12 3 16 4 16 4 16 4 8300 3300 3300 3300 22 A 1100 100 A 100 A 100 4 15 4 15 4 15 47 47 1750 1750 1750 11x10 11x10 11x10 1 0 1 0 1 0 3 31
8. 6 Multiply result of Step 5 by Btu heating value of gas to Observe manifold pressure and proceed as follows to ad just gas input 1 Remove cover screw over regulator adjustment screw on obtain total measured input in Btuh Compare this value valve with heating input shown in Table 6 Consult the local 2 Turn regulator adjustment screw clockwise to increase gas gas supplier if the heating value of gas is not known input or turn regulator adjustment screw counterclock wise to decrease input Manifold pressure must be be EXAMPLE Assume that the size of test dial is 1 cu ft one tween 3 4 and 3 6 in wg revolution takes 32 seconds and the heating value of the gas is 1050 Btu ft Proceed as follows 4 WARNING 1 32 seconds to complete one revolution Unsafe operation of the unit may result if manifold 2 3600 32 112 5 pressure is outside this range Personal injury or unit damage may result 3 112 5 x 1 112 5 f of gas flow hr 4 112 5 x 1050 118 125 Btuh input Ifthe desired gas input is 115 000 Btuh only a minor change in the manifold pressure is required Replace cover screw cap on gas valve 4 Turn off gas supply to unit Remove manometer from pres sure tap and replace pipe plug on gas valve Turn on gas to unit and check for leaks 16 Measure Manifold Pressure Propa
9. place 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 NOTE Refer to the heating and or cooling sequence of op eration 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 Detecting oil generally indicates a refrigerant leak If oil is detected or if low cooling performance is sus pected leak test all refrigerant tubing using an electronic leak detector halide torch or liquid soap solution If a refriger ant leak is detected refer to Check for Refrigerant Leaks section on page 15 If no refrigerant leaks are found and low cooling perfor mance is suspected refer to Checking and Adjusting Refrig erant Charge section on page 22 Gas Input The gas input does not require checking unless improper heating performance is suspected If a prob lem exists refer to Start Up section on page 15 Evaporator Airflow The heating and or cooling air flow does not require checking unless improper perform ance is suspected f a problem exists be sure that all suppl
10. 49 14 011 ss Ir RETURN SUPPLY n EE it OPTIONAL OPTIONAL 406 6 RETURN SUPPLY 406 6 Ded WN opening opening Le Hi 2 NONE m ill 222 NENNEN i z ill 2 SA ceu Ji SAM n s e E jem ple ee OPENING OPENING Y i EVAP COIL PE 113 5 pzszzzzzzzEzzzzzczzz 2 6 83 117 7 4 63 COND COIL P X ih 7 REAR VIEW REQ D CLEARANCES FOR OPERATION AND SERVICING in mm REQ D CLEARANCES TO COMBUSTIBLE MAT L in mm Evaporatorcoilaccessside 36 914 TOD OF UNI 5525565 Me we 14 355 6 Power entry side except for NEC requirements 36 914 Duct side 505 a ek OR ee 2 50 8 Unt OD uu o o9 Rom moe Roo o x JE JR 48 1219 Side opposite ducts 14 355 6 Side opposite ducts 36 914 Boom OF UME su a Eom Roe ohm 0 50 12 7 Ductpehel 4 xc x kom whom eoe m 12 304 8 Flug RO ob or we we 36 914 4 Minimum distances If unit is placed less than 12 in 304 8 mm from wall NEC REQ D CLEARANCES in mm system then the systemi performance may be compromised Between units power entry side 42 1066 8 Unit and ungrounded surfaces power entry side 36 914 Un
11. 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 A CAUTION Keep the condenser fan free from all obstructions to en sure 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 W in away from the motor end in of motor shaft will be visible See Fig 12 6 Ensure that setscrew engages the flat area on the motor shaft when tightening 7 Replace grille Electrical Controls and Wiring Inspect and check the electrical controls and wiring annually Be sure to turn off the gas supply and then the electrical power to the unit Remove access panel to locate all the electrical controls and wiring Check all electrical connections for tightness 32 Tighten all screw connections If any smoky or burned con nections 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 re
12. VIEW e 249 6 h 550 5 e 249 6 9 83 21 67 9 83 REAR VIEW REQ D CLEARANCES FOR OPERATION AND SERVICING in mm REQ D CLEARANCES TO COMBUSTIBLE MAT L in mm Evaporator coilaccessside 36 914 TOD e uoce eoo he Be lk oe o Sam e 14 355 6 Power entry side except for NEC requirements 36 914 Duct side of Unit lt gt socos 9 ooo RR a 50 8 D so C NG ob ag ey D 48 1219 Side opposite ducis 14 355 6 Side opposite ducts 36 914 Bottom of Unit uu ea s oko oom ER Roo oe RR 0 50 12 7 Duct panel uo we des ode sa 12 304 8 Flue panel 6 xn xo 9 ox UC ow o 36 914 4 Minimum distances If unit is placed less than 12 in 304 8 mm from wall NEC REQ D CLEARANCES in mm system then the system performance may be compromised Between units power entry side units power entry side 42 1066 8 Unit and ungrounded surfaces power entry side 36 914 Unit and block or concrete walls and other grounded surfaces control box side 42 1066 8 ELECTRICAL UNIT WEIGHT UNIT HEIGHT CENTER OF GRAVITY CHARACTERISTICS mm kg 2 48GS018040 208 230 1 60 249 0 113 2 35 02 889 5 15 0 381 0 48GS024040 060 208 230 1 60 280 0 127 3 35 02 889 5 15 0 381 0 48GS030040 060 208 230 1 60 208 230 3 60 280 0 127 3 35
13. according to directions in Combustion Air Blower sec tion below Remove the 3 screws holding the blower housing to the flue collector box cover see Fig 31 Remove the 12 screws holding the flue collector box cover Fig 31 to the heat exchanger assembly Inspect the heat exchangers Clean all surfaces as required using the wire brush INDUCED DRAFT MOTOR MOUNT VENT HOOD FLUE IN SHIPPING LOCATION BOX MOUNTING SCREW COLLECTOR BLOWER BURNER HOUSING RACK Fig 31 Blower Housing and Flue Collector Box Combustion Air Blower Clean periodically to as sure 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 hood assembly Shine a flashlight into opening to inspect wheel If cleaning is re quired remove motor and wheel as follows 1 2 3 4 5 6 Remove unit access panel See Fig 32 Remove the 7 screws that attach induced draft motor mount ing plate to blower housing See Fig 31 Slide the motor and blower wheel assembly out of the blower housing See Fig 33 Clean the blower wheel If additional cleaning is required continue with Steps 4 and 5 To remove blower remove 2 setscrews See Fig 33
14. and 3 phase units To change the speed remove and replace with lead for desired blower motor speed Insulate the re moved lead to avoid contact with chassis parts For 460 v GE Motors The motor leads are color coded as follows 3 SPEED black high violet jumper orange medium red low To change the speed of the blower motor BM remove fan motor speed lead from the blower relay BR and re place 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
15. being installed in California Air Quality Management Districts which require NO emissions of 40 nanograms joule or less a field installed low NO kit must be field installed For 40 000 and 60 000 Btuh input models use kit part number CPLOWNOX002A00 This kit contains two NO reduction baffles and one conversion label For 90 000 115 000 and 130 000 Btuh input models use kit part number CPLOWNOX003A00 This kit contains three NO reduc tion baffles and one conversion label A CAUTION The venting system is designed to ensure proper vent ing The flue hood assembly must be installed as indi cated 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 Provincial and local plumbing or wastewater codes and other applicable local codes 2 Remove flue hood from shipping location inside the blower compartment Place vent cap assembly over flue panel Orient screw holes in vent cap with holes in the flue panel 3 Secure flue hood to flue panel by inserting a single screw on the right side and the left side of the hood 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 th
16. condition 14 PRE START UP A WARNING Failure to observe the following warnings could result in serious personal injury 1 Follow recognized safety practices and wear protec tive goggles and gloves 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 electrical sources are disconnected Relieve and recover all refrigerant from system be fore touching or disturbing anything inside terminal box if refrigerant leak is suspected around compres sor terminals Never attempt to repair soldered connection while re frigerant system is under pressure Do not use torch to remove any component System contains oil and refrigerant under pressure To re move component wear protective goggles and gloves Proceed as follows Shut off gas supply and then electrical power to unit Relieve and recover all refrigerant from system using both high and low pressure ports Cut component connecting tubing with tubing cut ter and remove component from unit Carefully unsweat remaining tubing stubs when necessary Oil can ignite when exposed to torch flame Proceed as follows to inspect and prepare the unit for ini tial start up 1 Remove access panel 2 Read and follow instructions on all WARNING CAU TION and INFORMATION labels atta
17. insulated and covered with a vapor barrier If a plenum return is used on a vertical unit the return should be ducted through the roof deck to comply with applicable fire codes A minimum clearance is not required around ductwork Cabinet return air static shall not exceed 25 in wg Step 4 Provide Clearances The required min imum operating and service clearances are shown in Fig 2 and 3 Adequate combustion ventilation and con denser air must be provided in accordance with section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI American National Standards Institute Z223 1 in Canada sections 7 2 7 3 or 7 4 or Can CGA Canadian Gas Association B149 Installation Codes or applicable pro visions of local building code A 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 dis charge does not recirculate to the condenser coil Do not lo cate the unit in either a corner or under an overhead obstruc tion 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 where water ice or snow from an overhang or roof
18. is 350 to 450 cfm for each 12 000 Btuh of rated cooling capacity For heating operation the airflow must pro duce a temperature rise that falls within the range stamped on the unit rating plate 22 Table 7 shows the temperature rise at various airflow rates Tables 9 and 10 shows both heating and cooling airflows at various external static pressures Refer to these tables to determine the airflow for the system being installed See Tables 11A and 11B for wet coil pressure drop NOTE Be sure that all supply and return air grilles are open free from obstructions and adjusted properly A WARNING Shut off gas supply then disconnect electrical power to the unit before changing blower speed Electrical shock can cause personal injury or death Airflow can be changed by changing the lead connections of the blower motor Unit 48GS two or three speed motors except size 030 are factory wired for low speed operation Unit 48GS030 is factory wired for medium speed All 48GX units are factory wired for low speed and may need to be wired for medium or high speed in the field For 208 230 v Motors 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 IGC terminal BM for single phase
19. switch in COOL position and FAN switch in AUTO position Set cooling control below room tem perature Observe that compressor condenser fan and evap orator 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 tem perature control is set to for heating above room temperature and operates in Cooling mode when tem perature control is set to for cooling below room temperature IMPORTANT Three phase scroll compressor units 48GS048 and 48GX030 060 are direction oriented These units must be checked to ensure proper com pressor 3 phase power lead orientation If not cor rected within 5 minutes the internal protector will shut off the compressor 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 com pressor suction and discharge pressures may be dramatically lower than normal Text continued on page 22 61 FIELD SUPPLY EQUIP GND POWER a SCHEMATIC 208 230 1 60 COOLING FAN LOGIC 0 6 ENERGIZED T T 30 DE ENERGIZED HEATING FAN LOGIC 0 45 W BR ENERGIZED T 45 BR DE ENERGIZED
20. the approved temperature rise range for each heating input and the air delivery cfm at various tempera ture rises The heating operation airflow must produce a tem perature rise that falls within the approved range Refer to Indoor Airflow and Airflow Adjustments section on page 22 to adjust heating airflow when required Table 7 Air Delivery Cfm at Indicated Temperature Rise and Rated Heating Input TEMPERATURE RISE F 20 25 30 40 4 so 55 65 70 40000 1500 1200 0 97 7m e 999 54 5 00 2280 1800 1o00 o0 7o 90 000 2250 1929 1688 1500 1350 1227 1125 1038 964 730 000 e 267 1950 193 16 350 NOTE Dashed areas do not fall within the approved temperature rise range of the unit 17 HEATING SEQUENCE OF OPERATION See Fig 15 17 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 thermostat is satisfied and W is deenergized the burners stop firing and the evaporator fan motor shuts off after a 45 second time o
21. unit For downshot applications the ductwork connects to the roof curb See Fig 2 and 3 for connection sizes and locations CONFIGURING UNITS FOR DOWNFLOW VERTI CAL DISCHARGE A WARNING Before performing service or maintenance operations on the system turn off main power to unit or electrical shock could result 10 1 Open all electrical disconnects before starting any serv ice work 2 Remove return duct cover located on duct panel by break ing connecting tabs with screwdriver and a hammer Fig 9 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 10 4 If unit ductwork is to be attached to vertical opening flanges on the unit basepan jackstand applications only do so at this time 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 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 instal lation of nonresidence type air conditioning and ven
22. wiring changes Electrical shock can cause personal injury or death With disconnect switch open move yellow wire from trans former 3 6 in terminal marked 230 to terminal marked 200 This retaps transformer to primary voltage of 208 vac Table 4 Electrical Data Unit 48GS UNIT VOLTAGE OUTDOOR FAN INDOOR FAN SUPPLY FUSE OR size V PH Hz RANGE COMPRESSOR MOTO MOTOR HACR BRKR Due mer ra f 1 MOCP 018 20525010 187 258 901 450 450 060 208 230 3 60 125 0 460 3 60 se ss ses LEGEND FLA Full Load Amps HACR Heating Air Conditioning U and Refrigeration L LRA Locked Rotor Amps C US MCA Minimum Circuit Amps MOCP Maximum Overcurrent Protection RLA Rated Load Amps 208 230 1 60 187 12 8 61 0 30 030 208 230 1 60 187 14 4 73 0 8 2 0 20 8 30 20 35 036 25 46036 414 506 58 400 09 19 101 15 45 042 25 460360 414 506 53 420 09 20 95 15 60 048 35 400260 414 506 67 478 59 20 15 6 2 o9 Fuse or HACR Breaker NOTES 1 In compliance with NEC National Electrical Code requirements for multimotor and combination load equipment refer to NEC Articles 430 and 440 the overcurrent protective device for the unit shall be fuse or HACR breaker The CGA Canadian Gas Association units may be fuse or circuit breaker Minimum wire size is based on 60
23. 0 3 60 460 3 60 382 8422 38 98 990 2 23 0 584 2 16 3 412 8 16 6 421 6 48GX048090 115 130 208 230 1 60 208 230 3 60 460 3 60 421 9282 38 98 990 2 21 5 546 1 16 6 422 1 18 0 457 2 48GX060090 115 130 208 230 1 60 208 230 3 60 460 3 60 1031 7 42 98 1091 7 23 5 596 9 16 3 412 8 17 6 447 0 Fig 3 48GS048 060 and 48GX042 060 Unit Dimensions RECEIVING AND INSTALLATION Step 1 Check Equipment IDENTIFY UNIT The unit model number and serial num ber 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 trans portation 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 pack ages until installation Step 2 Provide Unit Support ROOF CURB Install accessory roof curb in accordance with instructions shipped with curb See Fig 4 for roof curb dimensions Install insulation cant strips roofing and flash ing Ductwork must be attached to curb IMPORTANT The gask
24. 02 889 5 15 0 381 0 48GS036060 090 208 230 1 60 208 230 3 60 460 3 60 314 0 142 7 35 02 889 5 13 0 330 2 48GS042060 090 208 230 1 60 208 230 3 60 460 3 60 355 0 161 4 35 02 889 5 13 0 330 2 48GX024040 060 208 230 1 60 290 0 639 3 35 02 889 5 16 0 406 4 48GX030040 060 208 230 1 60 208 230 3 60 313 0 690 0 39 02 991 1 17 6 447 0 48GX036060 090 208 230 1 60 208 230 3 60 460 3 60 321 0 707 7 35 02 889 5 16 5 419 1 UT 003 7 ner FIELD ENTRY SERVICE PORTS 28 6 1 13 DIA K 0 POWER ENTRY 22 2 0 88 DIA HOLE CONTROL ENTRY 123 0 4 84 456 2 17 961 347 2 313 8 12 351 13 671 59g 8 22 DRAIN OUTLET 42 19 0 0 75 N P T x 22 0 DP t OMPRESSOR BLOWER GAS SECTION FLUE HOOD 46 8 12 1 0 50 N P T 326 5 amp ELECTRICAL ACCESS PANEL 1 84 GAS ENTRY 12 85 5 0 12 4 52 8 es 0 20 2 85 1226 3 12 08 48 281 be 831 0 122 2 32 721 4 81 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW LEGEND CG Center of Gravity COND Condenser EVAP Evaporator _ NEC National Electrical Code REQ D Required NOTE Dimensions are in mm in Fig 2 48GS018 042 and 48GX024 036 Unit Dimensions 355 8 342 7 355 8 14 01 13
25. 3 3 12 3 12 3 12 3 CONDENSER FAN Nominal Cfm 3600 3800 a Diameter in 22 22 Motor Hp Rpm V4 1100 Va 1100 Va 4100 EVAPORATOR COIL Rows Fins in 3 15 3 15 3 15 4 15 4 15 22 Face Area sq ft 4 7 4 7 4 7 4 7 4 7 EVAPORATOR BLOWER Nominal Airflow Cfm Size in Motor Hp FURNACE SECTION Burner Orifice No Qty Drill Size 3 31 Natural Gas di Burner Orifice No Qty Drill Size 3 41 Propane Gas RETURN AIR FILTERS in f Throwaway 24x30 24x30 24x30 24x30 24x30 24X30 Based on altitude of 0 to 2000 feet TRequired filter sizes shown are based on the larger of the ARI Air Conditioning and Refrigeration Institute rated cooling airflow or the heating airflow velocity of 300 ft min for throwaway type or 450 ft min for high capacity type Air filter pressure drop for non standard filters must not exceed 0 08 in wg 1600 2000 2000 2000 11x10 11x10 11x10 11x10 1 0 1 0 1 0 Table 2 Physical Data Unit 48GX UNIT SIZE 48GX 024040 024060 030040 030060 036060 036090 042060 042090 NOMINAL CAPACITY ton Em OPERATING WEIGHT Ib 313 321 382 COMPRESSORS Scroll Quantity 1 REFRIGERANT R 22 Quantity Ib 3 4 3 4 4 4 4 4 5 2 5 2 6 4 6 4 REFRIGERANT METERING DEVICE Orifice ID in 034 034 030 034 CONDENSER COIL Rows Fins in 2 17 Face Area sq ft 12 3 CONDENSER FAN Nominal Cfm 3300 Diameter in 22 Motor Hp Rpm 1 1100 EVAPORATOR COIL
26. 3 41 24x30 24x30 24x30 24x30 24x30 24 X 30 on the larger of the ARI Air Conditioning g airflow or the heating airflow velocity of 300 ft min for throwaway type or 450 ft min for high capacity type Air filter pressure drop for non standard filters must not exceed 0 08 in wg Text continued from page 7 A CAUTION Unstable operation may occur when the gas valve and manifold assembly are forced out of position while connecting improperly routed rigid gas piping to the gas valve Use a backup wrench when making con nection to avoid strain on or distortion of the gas control piping A 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 mini mum of 2 in outside the unit casing A WARNING Never use a match or other open flame when check ing for gas leaks Never purge gas line into com bustion chamber Failure to follow this warning could result in an explosion causing personal 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 speci fied by local codes and or regulations IN TEE OUT NIPPLE CAP Fig 8 Sediment Trap Step 9 Install Duct Connections The unit has duct flanges on the supply and return air openings on the side and bottom of the
27. 4 262 260 950 825 750 670 580 40 630 Watts 380 375 365 360 355 350 344 335 312 Cim 1220 1150 1090 1025 970 860 760 620 450 High Watts 45 45 401 455 4s 40 451 385 1475 1440 1350 1 1200 1125 1025 Ewa se se sr ose mr er im iue rss T ere 390 er oni m Watts 680 671 660 624 604 620 602 558 534 512 496 781 Watts 810 800 790 782 766 742 723 709 688 661 627 Cim 1800 1745 1660 1600 1547 1465 1360 1270 1163 967 876 Watts 675 660 650 640 630 620 610 595 580 Cim 1454 1387 1326 1275 1204 1142 1081 995 918 042 Watts 886 855 82 795 778 765 750 735 718 700 Cim 1515 1458 1406 1350 1285 1224 1163 1091 1013 932 Watts 1000 950 925 910 890 875 855 833 Cim 1551 1488 1424 1360 1296 1233 1148 1071 wats rie me 0 oes oe sej we 52 cim 169 1600 1961 1800 1440 1379 1269 198 wat 640 979 959 943 927 897 868 838 802 766 730 JE IE IE Z Watts 1033 949 864 836 822 808 772 737 705 6
28. 48 422 Ctm 1497 1428 1348 1255 1152 1042 929 Wats 646 636 626 614 602 589 High Cfm O 1412 1325 1228 1120 1003 ce ws fees se se se wes Lem 1628 1614 1879 3592 r ami dasi as aie nar 042 1 1 a es 540 Cim 1731 1672 1610 1541 1456 1345 1193 ee 713 em l 1699 1602 1494 1367 Watts 614 588 577 572 566 556 539 517 491 Cim 1591 1549 1518 1490 1460 1421 1372 1312 1242 di Watts 778 78 736 79 S09 676 850 62 59 5 2 555 1315 78 728 Cim 1956 1879 1797 1709 1615 1514 1406 ae mu ss 7m 7e mle sm sx cim 206 1995 188 1840 1781 177 1846 196 _ o ea 845 si2 783 759 Fem delivery values are without air filter and are for dry coil See Table 11B Wet Coil Pressure Drop table NOTE Deduct field supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting 060 atts 851 714 2253 2124 oss 1
29. 48GS018 060 48GX024 060 Single Package Gas Heating Electric Cooling Units Installation Start Up and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS 1 3 General 1 RECEIVING AND INSTALLATION 4 14 Step 1 Check Equipment 4 IDENTIFY UNIT INSPECT SHIPMENT Step 2 Provide Unit Support 4 ROOF CURB SLAB MOUNT GROUND MOUNT Step 3 Field Fabricate Ductwork 4 Step 4 Provide Clearances 4 Step 5 Rig and Place Unit 4 Step 6 Connect Condensate Drain 7 Step 7 Install Flue Hood 7 Step 8 Install Gas Piping 7 Step 9 Install Duct Connections 10 CONFIGURING UNITS FOR DOWNFLOW VERTICAL DISCHARGE Step 10 Install Electrical Connections 11 HIGH VOLTAGE CONNECTIONS SPECIAL PROCEDURES FOR 208 V OPERATION CONTROL VOLTAGE CONNECTIONS HEAT ANTICIPATOR SETTING TRANSFORMER PROTECTION PRE START UP 14 15 START UP 15 29 MAINTENANCE 29 32 TROUBLESHOOTING 33 34 START UP CHECKLIST CL 1 NOTE TO INSTALLER Before the installation READ THESE INSTRUCTIONS CAREFULLY AND COM PLETELY Also make sure the User s Manual and
30. 74 642 Cim 2105 2057 2009 1943 1909 1876 1823 1770 1698 1627 1531 060 Watts 1084 1054 1024 994 971 955 928 897 867 835 803 1638 Watts 1184 1152 1120 1102 1084 1056 1029 997 965 Ctm 2849 2278 2207 2124 2041 2000 1960 1853 1745 Air delivery values are without air filter and are for dry coil See Table 11A Wet Coil Pressure Drop table NOTE Deduct field supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting 27 Table 10 Dry Coil Air Delivery Horizontal and Downflow Discharge Unit 48GX024 060 Deduct 10 for 208 Volts 230 AND 460 VOLT Unit Motor External Static Pressure in wg ii Seed or oz o4 os oe 07 os 99 1 0 NEK ENE NE ENE NE NE NEON 899 828 757 691 619 ose See 024 468 457 444 431 423 994 913 826 730 620 Low 036 me e ab E ER M RC MES UE Watts m 432 421 410 400 ee SE Watts 470 458 445 430 415 399 384 Ctm 1463 1406 1344 1273 1188 1091 983 056 wats 54 so 487 471 455
31. C copper wire If other than 60 C wire is used or if length exceeds wire length in table determine size from NEC Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance in supply volt age is greater than 2 Use the following formula to determine the percentage of voltage imbalance 96 Voltage imbalance 100 max voltage deviation from average voltage average voltage 12 60 45 20 EXAMPLE Supply voltage is 460 3 60 AB 452 v eae BC 464 v AC 455 v Average Voltage 48214841150 1371 3 457 Determine maximum deviation from average voltage AB 457 452 5v BC 464 457 7 v AC 457 455 2 v Maximum deviation is 7 v Determine percent of voltage imbalance Voltage Imbalance 100 x ME 457 1 53 This amount of phase imbalance is satisfactory as it is below the maximum allowable 2 IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately Table 5 Electrical Data Unit 48GX WNT venas RANGE COMPRESSOR POWER RGR 48GX Mi Mex HLA LRA MCA MOCP 024 208230160 187 263 103 560 08 20 187 25 20230160 187 253 135 730 os 21 198 30 208 230 3 60 187 253 9 0 63 0 0 8 2 1 14 2 20 oss 208230360 187 253 12 750 os 36 184 25 46340 414 506 54 375 os 19 96 15 28 1 45 042 212 30
32. CAP2 We YEL oy ES POWER m ee W8 BLK EQUIP_GND i veL COMP 060 ig TES W56 BLU YEL RED YEL IFM ee PRIMARY 460V COOLING FAN LOGIC 10 i 30 YEL IDM ENERGIZED DE ENERGIZED TRANI HEATING FAN LOGIC E GRN YEL 0 45 jT T 30 W BR BR ENERGIZED DE ENERGIZED Vl3 BLK 24V SPLICE BOX SECONDARY 24V W46 BRN W34 ae FLAME oy EL o een GRN YEL GRN YEL GROUNDED THRU STANDOFF W33 YEL OUTDOOR FAN SECTION COMPRESSOR SECTION COMP E 5 R INDOOR FAN SECTION GAS UJE B DISCONNECT PER NEC with type 90 degree C wire or its equivalent 2 See price pages for thermostat and subbases Fig 17 460 3 60 Wiring Diagram Unit 48GS and 48GX LEGEND AHA Adjustable Heat Anticipator NEC National Electrical Code BR Blower Relay OFM Outdoor Fan Motor Contactor QT Quadruple Terminal CAP Capacitor RS Rollout Switch COMP Compressor Motor SEN Sensor CR Combustion Relay SW Switch EG IP Centrifugal Switch TRAN Transformer Equipment FS Fusible Link ZA Field Splice FU Fuse GND Ground lt gt Terminal Marked GV Gas Valve GVR Gas Valve Relay O Terminal Unmarked HS Hall Effect Sensor Splice HV High Voltage Ignitor lt gt Splice Marked IDM Induced Draft Motor Factory W
33. E TEMPERATURE C Fig 25 Cooling Charging Chart Fig 27 Cooling Charging Chart 48GX024 Units 48GX036 Units 030 GOHZ CHARGING CHART SUCTION LINE TEMPERATURE C SUCTION LENE TEMPERATURE C Fig 26 Cooling Charging Chart Fig 28 Cooling Charging Chart 48GX030 Units 48GX042 Units 25 019 5 46 2 SUCTION LINE TEMPERATURE C Fig 29 Cooling Charging Chart 48GX048 Units 26 0 69 10 50 SUCTION LINE TEMPERATURE F 4 16 16 i 32 SUCTION LINE TEMPERATURE C 0 Fig 30 Cooling Charging Chart 48GX060 Units Table 9 Dry Coil Air Delivery Horizontal and Downflow Discharge Unit 48GS018 060 Deduct 10 for 208 Volts 230 AND 460 VOLT Unit Motor External Static Pressure in wg 3803 01 02 03 04 05 06 07 os 09 10 oe RET eee Cim 1082 1016 929 796 668 428 was mm me ar mE m9 1 3 Cim 201 49 1054 Ss 7e 65 32 p 024 om oem Cim 1220 1150 1090 1025 970 860 760 620 450 Watts 485 475 470 460 455 445 437 430 415 385 Ew e pe pee pes m pue pxs Z Watts 280 275 270 267 26
34. Printed in U S A Tab 1aj6a Form 48GS GX 1SI Pg 34 1 99 Replaces 48GS 1SI START UP CHECKLIST Remove and Store in Job File PRELIMINARY INFORMATION MODEL NO DATE SERIAL TECHNICIAN 1 PRE START UP insert checkmark in box as each item is completed CHECK GAS PIPING FOR LEAKS VERIFY THAT UNIT INSTALLATION IS LEVEL 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 THAT INDOOR EVAPORATOR AIR FILTER IS CLEAN AND IN PLACE CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW CUT ALONG DOTTED LINE TIGHTNESS START UP ELECTRICAL SUPPLY VOLTAGE L1 L2 L2 L3 L3 L1 COMPRESSOR AMPS 1 L2 L3 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 TEMP VERIFY REFRIGERANT CHARGE USING CHARGING TABLES VERIFY THAT 3 PHASE SCROLL COMPRESSOR 48GS048 AND 48GX030 060 IS ROTATING IN CORRECT DIRECTION Measured at suction inlet to compressor TMeasured at liquid line leaving condenser Copyrig
35. 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 func tion of the switch is to close the main gas valve in the event of flame rollout The switch is located above the main burn ers When the temperature at the auxiliary switch reaches the maximum allowable temperature the R control circuit trips closing the gas valve and stopping gas flow to the burn ers 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 Start Up Cooling Section and Make Adjustments 4 CAUTION Complete the required procedures given in the Pre Start Up section on page 14 before starting the unit Do not jumper any safety devices when operating the unit Do not operate the compressor when the outdoor tem perature is below 40 F unless accessory low ambient kit is installed Do not rapid cycle the compressor Allow 5 minutes be tween 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
36. Replace ment Guide are left with the unit after installation The fur nace is NOT to be used for temporary heating of buildings or structures under construction SAFETY CONSIDERATIONS Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical com ponents Only trained and qualified personnel should install repair or service air conditioning equipment Untrained personnel can perform basic maintenance func tions of cleaning coils and filters All other operations should be performed by trained service personnel When working on air conditioning equipment observe precautions in the literature tags and labels attached to the unit and other safety precautions that may apply Fig 1 Unit 48GS and 48GX Shown with Accessory Wire Grille Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for unbrazing operations Have fire extinguisher available for all brazing operations A WARNING Improper installation adjustment alteration service main tenance or use can cause carbon monoxide poisoning fire or an explosion which can result in personal injury or unit damage Consult a qualified installer service agency or gas supplier for information or assistance The quali fied installer or agency must use only factory authorized kits or accessories when modifying this product A WARNING Before performing service or maintenance operatio
37. Slide the burner rack out of the unit See Fig 31 and 34 9 To reinstall reverse the procedure outlined above Fig 34 Burner Rack Removed Condenser Coil Evaporator Coil and Conden sate Drain Pan Inspect the condenser coil evapo rator 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 sea son 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 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 in specting 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
38. aporator blower in door fan motor IFM 29 NOTE Once the compressor has started and then has stopped it should not be started again until 5 minutes have elapsed The cooling cycle remains until the room tempera ture drops to point that is slightly below the cooling control setting of the room thermostat At this point the thermostat breaks the circuit between thermostat terminal to ter minals Y and G These open circuits deenergize 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 main tenance must be performed on this equipment This combi nation heating cooling unit should be inspected at least once each year by a qualified service person To troubleshoot heat ing 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 maintenance on this equipment requires certain expertise mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equip ment other than those procedures recommended in the U
39. ata Unit 48GS UNIT SIZE 48GS 018040 024040 024060 030040 030060 036060 036090 042060 042090 NOMINAL CAPACITY ton Su OPERATING WEIGHT Ib 355 355 COMPRESSORS Reciprocating Quantity 1 REFRIGERANT R 22 Quantity Ib 2 6 3 5 3 5 3 65 3 65 3 75 3 75 5 7 5 7 REFRIGERANT METERING DEVICE TE Devico Orifice ID in 034 CONDENSER COIL Rows Fins in 17 17 17 17 1 17 Face Area sq ft E 1 1 Hi 1 p 1 9 1 CONDENSER FAN Nominal Cfm Diameter in Motor Hp Rpm EVAPORATOR COIL Rows Fins in Face Area sq ft EVAPORATOR BLOWER Nominal Airflow Cfm 600 800 800 1000 1000 1200 1200 1400 1400 Size in 10x10 10x 10 10x10 10x 10 10x10 11x10 11x10 11x10 11x10 Motor Hp Va Va Va Va Va Ve Ve 34 94 FURNACE SECTION Burner Orifice No Qty Drill Size Natural Gas 5 2 38 3 38 Burner Orifice No Qty Drill Size Propane Gas 2 46 3 46 RETURN AIR FILTERS in t Throwaway 20 x 20 20x 20 20x20 20x20 20x20 20x 24 20 x 24 20 x 24 20 x 24 UNIT SIZE 48GS 048090 048115 048130 060090 060115 060130 NOMINAL CAPACITY ton p ee 5 5 5 OPERATING WEIGHT Ib 415 415 450 450 450 COMPRESSORS Scroll Reciprocating Quantity 1 1 REFRIGERANT R 22 Quantity Ib 6 0 6 0 REFRIGERANT METERING DEVICE Acutrol Device Orifice ID in 032 032 032 030 CONDENSER COIL Rows Fins in 1 17 1 17 17 2 17 2 17 2 17 Face Area sq ft 12 3 12
40. ched to or shipped with unit 3 Make the following inspections a Inspect for shipping and handling damages such as bro ken lines loose parts disconnected wires etc b Inspect for oil at all refrigerant tubing connections and on unit base Detecting oil generally indicates a re frigerant leak c Leak test all refrigerant tubing connections using elec tronic leak detector halide torch or liquid soap solu tion If a refrigerant leak is detected see Check for Refrigerant Leaks section on page 15 d Inspect all field and factory wiring connections Be sure that connections are completed and tight e Inspect coil fins If damaged during shipping and han dling carefully straighten fins with a fin comb 4 Verify the following conditions A CAUTION Do not purge gas supply into the combustion cham ber 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 personal 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 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 Im mediately upon detection of gas odor retighten the union Allow 5 mi
41. ding structure 7 Flash weatherproof and vibration isolate all openings in building structure in accordance with local codes and good building practices Table 3 Maximum Gas Flow Capacity NOMINAL INTERNAL LENGTH OF PIPE FTf DIAMETER in ENE SEVE NE eee 125 200 Ye __ 622 175 120 97 82 81 2 824 250 200 170 118 110 103 93 77 72 1 1380 1400 950 770 600 580 530 490 460 430 400 325 300 280 1 1610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 Capacity of pipe in cu ft of gas per hr for gas pressure of 0 5 psig or less Pressure drop of 0 5 in wg based on a 0 60 specific gravity gas Refer to Table C 4 National Fire Protection Association NFPA 54 TThis length includes an ordinary number of fittings Step 10 Install Electrical Connections A WARNING The unit cabinet must have an uninterrupted unbroken electrical ground to minimize the possibility of personal 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 con duit approved for electrical ground when installed in accordance with NEC National Electrical Code ANSI NFPA latest edition in Canada Canadian Electrical Code CSA Canadian Standards Associat
42. drip loop before running wire through panel Run the low voltage leads from the thermostat through the inlet hole and into unit low voltage splice box Locate five 18 gage wires leaving control box These low voltage connection leads can be identified by the colors red green yellow brown and white See Fig 11 Ensure the leads are long enough to be routed into the low voltage splice box located below right side of control box Stripped yel low wire is located in connection box Route leads through hole in bottom of control box and make low voltage con nections as shown in Fig 11 Secure all cut wires so that they do not interfere with operation of unit HEAT ANTICIPATOR SETTING The room thermostat heat anticipator must be properly adjusted to ensure proper heating performance Set the heat anticipator using an am meter 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 discomfort to the occupants of the conditioned space and inefficient energy utilization how ever 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
43. e 2 in gas inlet on the manual shutoff or gas valve Install a gas supply line that runs to the heating section Refer to Table 3 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 con cerning existing lines Size gas supply piping for 0 5 in wg maximum pressure drop Never use pipe smaller than the 4 2 in gas inlet on the unit gas valve For natural gas applications the gas pressure at unit gas connection must not be less than 4 0 in wg or greater than 13 in wg while the unit is operating For propane applica tions the gas pressure must not be less than 4 0 in wg or greater than 13 in wg at the unit connection An in NPT plugged tapping accessible for test gage connection must be installed immediately upstream of the gas supply connection 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 1988 NFPA latest edition in Canada CAN CGA B149 1 2 M86 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 VA inch in every 15 ft to prevent traps Grade all hori zontal 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 Sup
44. e contactor c On all units remove blower assembly from unit Re move 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 housing and slide motor and motor mount out of housing Remove and clean blower wheel as follows a Ensure proper orientation b Lift wheel from housing When handling and or clean ing 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 at tachment Remove grease and oil with mild solvent d Reassemble wheel into housing reassembly by marking wheel 30 e Reassemble motor into housing Be sure setscrews are tightened on motor shaft flats and not on round part of shaft f Reinstall unit access panel Restore electrical power then gas supply to unit Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles Flue Gas Passageways To inspect the flue col lector box and upper areas of the heat exchanger Remove the combustion blower wheel and motor assem bly
45. eting of the unit to the roof curb is critical for a watertight seal Install gasket ing material supplied with the roof curb Improperly applied gasketing can also result in air leaks and poor unit performance Curb should be level to within 4 inch This is necessary for unit drain to function properly Refer to accessory roof curb installation instructions for additional information as required 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 5 Do not secure the unit to the slab except when required by local codes GROUND MOUNT The unit may be installed either on a slab or placed directly on the ground if local codes permit Place the unit on level ground prepared with gravel for con densate discharge 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 hori zontal applications unit is provided with flanges on the hori zontal 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
46. ff 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 NOTES 1 There is a 3 second pause between error code displays 2 lf more than one error code exists all applicable error codes will be displayed in numerical sequence 3 This chart is on the wiring diagram located inside the burner access panel LIMIT SWITCHES Normally closed limit switch LS completes the control circuit through the thermostat R cir cuit Should the leaving air temperature rise above the maxi mum allowable temperature the limit switch opens and the control circuit breaks Any interruption in con trol 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
47. ft above sea level In Canada from 2000 ft above sea level to 4500 ft above sea level derate the unit 10 ADJUST GAS INPUT The gas input to the unit is determined by measuring the gas flow at the meter or by o measuring the manifold pressure Measuring the gas flow at the meter is recommended for natural gas units The mani fold pressure must be measured to determine the input of 0 propane gas units 5 Measure Gas Flow Natural Gas Units Minor adjust NY 5 ment to the gas flow can be made by changing the man ifold pressure The manifold pressure must be maintained 9 between 3 4 and 3 6 in wg If larger adjustments quired change main burner orifices following the recom mendations of national and local codes NOTE All other appliances that use the same meter must be 3 i turned off when gas flow is measured at the meter E Proceed as follows f 1 Turn off gas supply to unit 5 2 Remove pipe plug manifold see Fig 13 then connect manometer at this point Turn on gas to unit 3 Record number of seconds for gas meter test dial to make one revolution 4 Divide number of seconds in Step 3 into 3600 number MANIFOLD PIPE PLUG of seconds in one hour Fig 13 Burner Assembly 5 Multiply result 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
48. ged Attach ductwork to curb flanges of duct rest on curb Insulated panels 1 in thick fiberglass 1 Ib density Dimensions are in inches 46 3 16 44 5 16 K z Hh L SUPPORT B 13 16 A SUPPORT A gt END VIEW DECK PAN INSULATED SIDE PANEL gt BASE PAN 3 9 BOTTOM SUPPLY SUPPORT RIB S SEAL STRIP FACTORY SUPPLIED COUNTER FLASHING NAILER FIELD SUPPLIED ROOFING FELT FIELD SUPPLIED INSULATION FIELD SUPPLIED FIELD SUPPLIED ROOFING MATERIAL FIELD SUPPLIED FULL PERIMETER CURB Fig 4 Roof Curb Dimensions 914 1371 36 54 DUCTS SEAL STRIP MUST BE IN PLACE BEFORE PLACING UNIT ON ROOF CURB PLACE RIGGING STRAPS IN BASEPAN SLOT BELOW HANDHOLDS BEFORE RIGGING Size mm i m mm i 018 355 6 024 330 2 030 349 3 036 355 6 042 342 9 048 437 198 6 17 0 432 0 060 472 214 5 17 0 432 0 MAXIMUM UNIT 48GX WEIGHT in mm jin 312 688 0 220 558 5 145 335 738 7 22 0 558 5 15 3 7564 220 5585 890 9 230 5842 8 69 215 5461 10805 235 5969 Fig 6 Suggested Rigging Step 6 Connect Condensate Drain NOTE When installing condensate drain connection be sure to comply with local codes and restrictions Models 48GS and GX dispose of condensate water through 34 in NPT fitting which exits through
49. gt 45 7 483 70 j 414 550 yt z i 5 S z 94142 x 5345 50 29 2 I gt k 276 40 345 50 39 276 40 HH 30 40 50 50 70 80 90 3 n B na 1 js ni sa a SUCTION LINE TEMPERATURE F 4 10 18 21 27 32 1 1 1 4 10 16 21 21 32 SUCTION LINE TEMPERATURE C SUCTION LINE TEMPERATURE C Fig 22 Cooling Charging Chart 48GS042 Units Fig 23 Cooling Charging Chart 48GS048 Units 689 100 OUTDOOR TEMP F 115 46 105 41 620 90 85 35 METAK 15 24 65 18 25 55 13 2 45 555 5 80 2 5 e H 483 5 2 gt A a 414 Z 60 z z a 2 2345 2 50 e 2 v SUCTION LINE TEMPERATURE 207 30 30 40 50 60 70 80 90 SUCTION LINE TEMPERATURE F J 14 4 10 16 21 27 32 Fig 24 Cooling Charging Chart 48GS060 Units 24 SUCTION LINE TEMPERATURE C SUCTION LIN
50. ht 1999 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 111 Catalog No 534 732 Printed in U S A Form 48GS GX 1SI Pg CL 1 1 99 Replaces 48GS 1SI Tab 1aj6a CUT ALONG DOTTED LINE
51. ion C22 1 and local electrical codes Do not use gas piping as an elec trical ground Failure to adhere to this warning could result in personal injury or death A CAUTION Failure to follow these precautions could result dam age to the unit being installed SUPPLY RETURN 1 Make all electrical connections in accordance with NEC DUCT DUCT ANSI NFPA latest edition and local electrical codes gov OPENING OFENING erning such wiring In Canada all electrical connections Fig 9 Supply and Return Duct Openings must be in accordance with CSA standard C22 1 Cana dian 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 oper ating 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 Tables 4 and 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 b
52. ion is 7 v Determine percent of voltage imbalance Voltage Imbalance 100 x Bos 457 1 53 This amount of phase imbalance is satisfactory as it is below the maximum allowable 296 IMPORTANT If the supply voltage phase imbalance is more than 296 contact your local electric utility company immediately ee HIGH VOLTAGE POWER LEAD SEE UNIT WIRING LABEL ETT 2 FIELD SUPPLIED dil FUSED DISCONNECT CONTROL BOX WHT W1 p 2 THERMOSTAT GRN G LOW VOLTAGE m TYPICAL POWER LEADS FaR p SEE UNIT WIRING LABEL BRN C SPLICE BOX LEGEND Field Control Voltage Wiring eee Field High Voltage Wiring NOTE Use blue wire for 3 phase units only Fig 11 High and Control Voltage Connections CONTROL VOLTAGE CONNECTIONS NOTE Do not use any type of power stealing thermostat Unit control problems may result Use no 18 American Wire Gage AWG color coded in sulated 35 C minimum wires to make the control volt age connections between the thermostat and the unit If the thermostat is located more than 100 ft from the unit as mea sured along the control voltage wires use no 16 AWG color coded insulated 35 C minimum wires Standard Connection Remove knockout hole located in the flue panel adjacent to the control access panel See Fig 2 and 3 Remove the rubber grommet from the install er s packet included with unit and install grommet in the knockout opening Provide a
53. iri IFC Indoor Fan Contactor SCIOIY MMII IFM Indoor Fan Motor Field Control Wiring IGC Integrated Gas Unit Controller Field Power Wiring te i Switch Accessory or Optional Wiring LS1 Limit Switch Indicate Common Potential MGV Main Gas Valve Only Not to Represent Wiring 3 Use 75 degree C copper conductors for field installation 4 For high speed IFM disconnect RED wire from IGC terminal BM and con nect BLK wire from IFM For medium speed disconnect RED wire from IGC terminal BM and connect BLU wire from IFM 21 CHECKING AND ADJUSTING REFRIGERANT CHARGE The refrigerant system is fully charged with R 22 refrig erant tested and factory sealed NOTE Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R 22 charge A superheat charging chart is attached to the outside of the service access panel The chart includes the required suc tion line temperature at given suction line pressures and out door ambient temperatures An accurate superheat thermocouple or thermistor type thermometer and a gage manifold are required when using the superheat charging method for evaluating the unit charge Do not use mercury or small dial type thermometers be cause they are not adequate for this type of measurement A CAUTION When evaluating the refrigerant charge an indicated ad justment to the specified factory charge must a
54. it and block or concrete walls and other grounded surfaces control box side 42 1066 8 LEGEND CG Center of Gravity COND Condenser EVAP Evaporator NEC National Electrical Code REG D Required NOTE Dimensions are in mm in lu 1090 6 i TINTE 4 FIELD ENTRY 1 SERVICE PORT 0 911 2 TE z 28 6 1 131 DIA K O POWER ENTRY 22 2 0 88 DIA HOLE CONTROL ENTRY 3 123 0 4 84 4 eS sl 820 2 toc E 19 331 xr BEDA HU its T T T T T DRAIN OUTLET 42 1 19 0 0 75 N P T 4 1 68 COMPRESSOR BLOWER GAS SECTION mee ti JT 12 1 0 50 N P T x 22 0 0 87 DP 329 0 amp ELECTRICAL ACCESS PANEL Li GAS ENTRY 12539 02 08 EE He 142 4 1123 1 1565 48 28 5 61 44 22 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW ELECTRICAL UNIT WEIGHT UNIT HEIGHT CENTER OF GRAVITY UNIT in mm in mm CHARACTERISTICS ib kg 48GS048090 115 130 208 230 1 60 208 230 3 60 460 3 60 188 6 38 98 990 2 22 558 5 16 406 4 17 432 0 48GS060090 115 130 208 230 1 60 208 230 3 60 460 3 60 204 5 38 98 990 2 22 558 5 16 4064 17 432 0 48GX042060 090 208 230 1 60 208 23
55. justments CAUTION Complete the reguired procedures given in Pre Start Up section on page 14 before starting the unit Do not jumper any safety devices when operating the unit Make sure that burner orifices are properly aligned Un stable operation may occur when the burner orifices in the manifold are misaligned Follow the lighting instructions on the heating section operation label located inside the burner or blower access door to start the heating section NOTE Make sure that gas supply has been purged and that all gas piping has been checked for leaks CHECK HEATING CONTROL Start and check the unit for proper heating control operation as follows See furnace lighting instructions located inside burner or blower access panel 1 Place the room thermostat SYSTEM switch in the HEAT position and the fan switch in the AUTO position 2 Set the heating temperature control of the thermostat above room temperature 3 The induced draft motor will start 4 After a call for heating the main burner should light with in 5 seconds If the burners do not light there is a 22 second delay before another 5 second try If the burn ers still do not light this seguence is repeated If the burn ers 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 e
56. lways be very minimal If a substantial adjustment is indicated an abnormal condition exists somewhere in the cooling system such as insufficient airflow across either coil or both coils Proceed as follows Remove caps from low and high pressure 1 4 in Schrader service fittings 2 Using hoses with valve core depressors attach low and high pressure gage hoses to low and high pressure serv ice fittings respectively 3 Start unit in Cooling mode and let unit run until system pressures stabilize 4 Measure and record the following a Outdoor ambient air temperature F db b Suction tube temperature F at low side service fitting c Suction low side pressure psig 5 Using Cooling Charging Charts compare outdoor air temperature F db with the suction line pressure psig to determine desired system operating suction line tem perature See Fig 18 30 6 Compare actual suction tube temperature with desired suction tube temperature Using a tolerance of 3 F add refrigerant if actual temperature is more than 3 F higher than proper suction tube temperature or remove refrig erant if actual temperature is more than 3 F lower than required suction tube temperature NOTE If the problem causing the inaccurate readings is a refrigerant leak refer to Check for Refrigerant Leaks sec tion on page 15 INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS A CAUTION For cooling operation the recommended airflow
57. mp o 85 29 552 3 75 24 pos yO 65 18 a a P 483 70 2 5 7 x 414 zgo pra 5 S 5 345 50 276 40 30 30 40 50 60 20 80 90 SUCTION LINE TEMPERATURE F 4 10 16 21 27 32 SUCTION LINE TEMPERATURE Fig 20 Cooling Charging Chart 48GS030 Units 758 110 689 100 QUTDOOR TEMP 115 46 a 621 90 108 4 5 5 95 35 85 29 5 JS SES 4 na 75 2 B a 65 18 to D 483 70 55 13 45 y 414 260 2 m S 5 5 457 o 345 50 276 40 30 30 40 50 60 70 80 90 SUCTION LINE TEMPERATURE F 10 16 21 27 32 SUCTION LINE TEMPERATURE C Fig 21 Cooling Charging Chart 48GS036 Units 758 10 158 110 OUTDOOR TEMP Fe a OUTDOOR TEMP 689 100 eF c 689 100 j 115 46 115 46 521 90 2 5 e 56200 90 95 35 x D 85 2 2 2 85 29 5 IS E WE HH m oM 552 _ S 79 2 65 18 2 a v 551 5 80 55 13 n 65 18 udo 2 483 45 T 2 483 270 55 13 a v 2
58. ne Units The main burner orifices on a propane gas unit are sized for the unit rated input when the manifold pressure reading matches the level specified in Table 6 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 13 then con nect manometer at this point 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 mani fold 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 re moved observe the unit heating operation Watch the burner flames to see if they are light blue and soft in appearance and that the flames are approximately the same for each burner Propane will have blue flame with yellow tips See Fig 14 Refer to Maintenance section for information on burner removal BURNER FLAME Fig 14 Monoport Burners AIRFLOW AND TEMPERATURE RISE The heating sec tion 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
59. nections 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 positioning 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 attempting 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 or add additional unit Restricted airflow Clean or replace filter Remove any restriction Blower speed too low Use faster speed tap if available or install alternate motor Limit switch cycles main burners Check rotation of blower thermostat heat anticipator settings tem perature rise of unit Adjust as necessary Poor flame characteristics Incomplete combustion results in Aldehyde odors carbon monoxide sooting flame floating flame 1 Tighten all screws around burner compartment 2 Cracked heat exchanger Replace 3 Unit overfired Reduce input change orifices or adjust gas line or manifold pressure 4 Check burner alignment LED Troubleshooting Error Code SYMPTOM REMEDY Hardware failu
60. nnections for tightness and controls for proper operation each heating and cooling season Serv ice when necessary Check and inspect heating section before each heating sea son Clean and adjust when necessary Check flue hood and remove any obstructions if necessary Air Filter A CAUTION 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 and 2 for recommended filter sizes Inspect air filter s at least once each month and replace throwaway type or clean cleanable type at least twice dur ing each heating and cooling season or whenever the filter s becomes clogged with dust and lint Evaporator Blower and Motor NOTE All motors are prelubricated Do not attempt to lu bricate these motors For longer life operating economy and continuing effi ciency clean accumulated dirt and grease from the blower wheel and motor annually 4 WARNING Turn off the gas supply then disconnect and tag elec trical power to the unit before cleaning the blower mo tor and wheel Failure to adhere to this warning could cause personal injury or death To clean the blower motor and wheel Remove and disassemble blower assembly as follows a Remove unit access panel b Disconnect motor lead from blower relay BR Disconnect yellow lead from terminal L2 of th
61. ns on unit turn off gas supply then unit main power switch Electrical shock could cause personal injury General The 48GS GX units see Fig 1 are fully self contained combination Category I gas heating electric cooling units designed for outdoor installation See Fig 2 and 3 pages 2 and 3 for unit dimensions All unit sizes have return and discharge openings for both horizontal and down flow configurations and are factory shipped with all down flow duct openings covered Units may be installed either on a rooftop a cement slab or directly on the ground if per mitted by local codes See Fig 4 for roof curb dimensions Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 534 732 1 4 PC 111 Tab 1 Printed U S A Form 48GS GX 1SI Pg 1 1 99 Replaces 48GS 1SI 254 0 546 1 254 0 10 001 21 501 10 001 86 1 3 39 BLOCKOFF PANEL ON 018 ONLY Pe Lora 70 12 581 024 042 ONLY i SUPPL AIR 11 3 406 4 OPENING NOPENING qu 16 001 il Fd BLA 402 0 SUPPLY RETURN ir nim M 4 Y COND COIL da ________ 018 15353 COND COIL 88 3 COIL 3 48 TOP
62. nutes to elapse then light unit b Make sure that condenser fan blade is correctly posi tioned in fan orifice Leading edge of condenser fan blade should be 2 in maximum from fan orifice c Ensure fan hub is in max from motor housing see Fig 12 d Make sure that air filter s is in place e Make sure that condensate drain trap is filled with wa ter 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 Fig 12 Fan Blade Clearance START UP Check for Refrigerant Leaks Proceed as follows to locate and repair a refrigerant leak and to charge the unit 1 Locate leak and make sure that refrigerant system pres sure has been relieved and refrigerant recovered from both high and low pressure ports 2 Repair leak following standard Refrigerant Service procedures NOTE Install a filter drier whenever the system has been opened for repair 3 Add a small charge of R 22 refrigerant vapor to system and leak test unit 4 Evacuate and recover refrigerant from refrigerant system if additional leaks are not found 5 Charge unit with R 22 refrigerant using a volumetric charging cylinder or accurate scale Refer to unit rating plate for required charge Be sure to add extra refrigerant to compensate for internal volume of filter drier 15 Start Up Heating Section and Make Ad
63. port all piping with appropriate straps hangers etc Use a minimum of one hanger every 6 ft For pipe sizes larger than in follow recommendations of national codes 3 Apply joint compound pipe dope sparingly and only to male threads of joint when making pipe connections Use only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and or national codes Never use Teflon tape 4 Install sediment trap in riser leading to heating section per Fig 8 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 be tween unit manual shutoff and external manual main shut off valve 7 Pressure test all gas piping in accordance with local and national plumbing and gas codes before connecting pip ing to unit NOTE Pressure test the gas supply system after the gas supply piping is connected to the gas valve The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0 5 psig 13 8 WC Pressure test the gas sup ply piping system at pressures equal to or less than 0 5 psig The unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the ground joint union Table 1 Physical D
64. re Loss of power to control module IGC LED OFF Fan ON OFF delay modified LED High limit switch opens during heat FLASH exchanger warm up period before fan on delay expires Limit switch opens within three minutes af ter blower off delay timing in Heating mode Limit switch fault High temperature limit switch is open LED 2 flashes Check 5 amp fuse on IGC power to unit 24 v circuit breaker and transformer Units without a 24 v circuit breaker have an internal overload in the 24 v transformer If the overload trips allow 10 min utes for automatic reset Ensure unit is fired on rate and temperature rise is correct Ensure unit s external static pressure is within application guidelines Check the operation of the indoor evaporator fan motor Ensure that the supply air temperature rise is in accordance with the range on the unit nameplate Flame sense fault The IGC sensed flame that should not be Reset unit If problem persists replace control board LED 3 flashes present Ignition lockout Unit unsuccessfully attempted ignition for Check ignitor and flame sensor electrode spacing gaps etc Ensure LED 5 flashes 15 minutes that flame sense and ignition wires are properly terminated Verify that unit is obtaining proper amount of gas Induced draft motor fault IGC does not sense that induced draft mo Check for proper voltage If motor is operating check the speed LED 6 flashes tor is operating
65. reaker size and minimum circuit amps ampacity for wire sizing See Tables 4 and 5 for electrical data The field supplied disconnect switch box may be mounted on the unit over the high voltage inlet hole when the standard power and low voltage entry points are used See Fig 2 and 3 for acceptable location See unit wiring label and Fig 11 for reference when mak ing high voltage connections Proceed as follows to com plete the high voltage connections to the unit Fig 10 Vertical Duct Cover Removed 11 Single phase units 1 2 3 4 Run the high voltage L1 L2 and ground leads into the control box Connect ground lead to chassis ground connection Connect L1 to pressure lug connection 11 of the com pressor contactor Connect L2 to pressure lug connection 23 of the com pressor contactor Three phase units 1 2 3 Run the high voltage L1 L2 L3 and ground leads into the control box Connect ground lead to chassis ground connection Locate the black and yellow wires connected to the lines side of the contactor Connect field L1 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
66. sensor plug IGC Terminal J2 connection Proper connection PIN 1 White PIN 2 Red PIN 3 Black Rollout switch fault Rollout switch has opened LED 7 flashes Internal control fault Microprocessor has sensed an error in the LED 8 flashes software or hardware A WARNING If the IGC must be replaced be sure to ground yourself to dis sipate any electrical charge that may be present before han dling new control board The IGC is sensitive to static electricity and may be damaged if the necessary precautions are not taken Copyright 1999 Carrier Corporation 4 consecutive limit switch faults Inadequate airflow to unit Check operation of indoor evaporator fan motor and that supply air LED 4 flashes temperature rise agrees with range on unit nameplate information Rollout switch will automatically reset but IGC will continue to lock out unit Check gas valve operation Ensure that induced draft blower wheel is properly secured to motor shaft Reset unit at unit disconnect If error code is not cleared by resetting unit power replace the IGC IMPORTANT Refer to Heating troubleshooting chart for addi tional troubleshooting analysis LEGEND IGC Integrated Gas Unit Controller LED Light Emitting Diode Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 1 4 PC 111 Catalog No 534 732
67. ser s Manual FAILURE TO HEED THIS WARN ING COULD RESULT IN SERIOUS PERSONAL INJURY AND POSSIBLE DAMAGE TO THIS EQUIPMENT A WARNING Failure to follow these warnings could result in serious personal injury 1 Turn off gas supply then turn off electrical power to the unit before performing any maintenance or serv ice on the unit Use extreme caution when removing panels and parts As with any mechanical equipment personal injury can result from sharp edges etc Never place anything combustible either on or in con tact 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 A CAUTION Errors made when reconnecting wires may cause im proper and dangerous operation Label all wires prior to disconnection when servicing The minimum maintenance requirements for this equip ment are as follows 1 Inspect air filter s each month Clean or replace when necessary Certain geographical locations may require more frequent inspections 2 Inspect indoor coil outdoor coil drain pan and conden sate drain each cooling season for cleanliness Clean when necessary 3 Inspect blower motor and wheel for cleanliness each heat ing and cooling season Clean when necessary For first heating and cooling season inspect blower wheel bi monthly to determine proper cleaning frequency Check electrical co
68. speed IFM disconnect RED wire from IGC terminal BM and connect BLK wire from IFM For medium speed disconnect RED wire from IGC terminal BM and connect BLU wire from IFM 5 Models 48GS018 042 and 48GX024 036 have LS1 and LS2 wired in series Models 48GS048 060 and 48GX042 060 have LS1 only FIELD 4 Rm W54 BLK SUPPLY 55 YEL POWER 4 EQUIP_GND B C W43 BLK LK YEL OFM Fe H6 1 7 BRN Lie 060 ONLY W8 BLK L2 W7 YEL COMP L3 W56 BLU SEE NOTE 4 D RED YEL W59 YEL WI6 YEL BRN WHT OR YEL oT Wi5 YEL PRIMARY 230V 14 BLK 200 236 COOLING FAN LOGIC i T 30 ENERGIZED DE ENERGI ED TRANI HEATING FAN LOGIC _ GRN YEL 45 T 1430 W46 BRN W BR BR ENERGIZED DE ENERGIZED Yl3 BLK 24V SPLICE BOX MGV W34 sti BRN 3 GRN YEL FIELD THERMOSTAT XQ W32 BRN THRU STANDOFF 30 BRN KRU A zel W33 YEL COMMON W30 BRN LEGEND AHA Adjustable Heat Anticipator NEC National Electrical Code UNIT COMPONENT ARRANGEMENT BR Blower Relay OFM Outdoor Fan Motor OUTDOOR TAN Contactor QT Quadruple Terminal Capacitor RS Rollout Switch COMP Compressor Motor SEN Sensor CR Combustion Rela
69. t line voltage REMEDY Call power company Replace fuse or reset circuit breaker Replace component Determine cause and correct Check wiring diagram and rewire correctly Lower thermostat setting below room temperature Check wiring and repair or replace Determine cause Replace compressor Determine cause and replace Replace fuse or reset circuit breaker Determine cause Correct the direction of rotation by reversing the 3 phase power leads to the unit Shut down unit to allow pressures to equalize Recover refrigerant evacuate system and recharge to capacities shown on nameplate Replace and determine cause Determine cause and correct Blocked condenser Defective run start capacitor overload or start relay Defective thermostat Determine cause and correct Determine cause and replace Replace thermostat Faulty condenser fan motor or capacitor Restriction in refrigerant system Dirty air filter Unit undersized for load Thermostat set too low Low refrigerant charge Leaking valves in compressor Air in system Condenser coil dirty or restricted Replace Locate restriction and remove Replace filter Decrease load or increase unit size Reset thermostat Locate leak repair and recharge Replace compressor Recover refrigerant evacuate system and recharge Clean coil or remove restriction Excessive head pressure Head pressure too low Excessive suction pressure
70. the compressor ac cess panel See Fig 2 and 3 for location Condensate water can be drained directly onto the roof in rooftop installations where permitted or onto a gravel apron in ground level installations Install a field supplied conden sate trap at end of condensate connection to ensure proper drainage Make sure that the outlet of the trap is at least 1 in lower than the drain pan condensate connection to pre vent the pan from overflowing See Fig 7 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 con nection to ensure proper drainage See Fig 7 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 mini mum of 74 in PVC or 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 1 MIN TRAP OUTLET 2 MIN Fig 7 Condensate 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 For units
71. tilating 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 selecting sizing and installing the duct system 1 Units are shipped for horizontal duct installation 2 Select and size ductwork supply air registers and return air grilles according to American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE recommendations 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 weathertight and airtight seal 4 All units must have field supplied filters or accessory fil ter rack installed in the return air side of the unit Rec ommended sizes for filters are shown in Tables 1 and 2 5 Size all ductwork for maximum required airflow either heating or cooling for unit being installed Avoid abrupt duct size increases or decreases or performance may be affected 6 Adequately insulate and weatherproof all ductwork located outdoors Insulate ducts passing through uncon ditioned 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 sys tems Secure all ducts to buil
72. vaporator fan will turn off 45 seconds after the thermostat has been satisfied CHECK GAS INPUT Check gas input and manifold pres sure after unit start up See Table 6 If adjustment is reguired 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 or propane gas with a heating value of 2500 Btu ft at 1 5 specific gravity For elevations above 2000 ft reduce input 4 for each 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 CAUTION These units are designed to consume the rated gas in puts using the fixed orifices at specified manifold pres sures as shown in Table 6 DO NOT REDRILL THE ORIFICES UNDER ANY CIRCUMSTANCES Table 6 Heating Inputs GAS SUPPLY PRESSURE HEATING NUMBER in wg PRESSURE ee 4 0 13 0 4 0 13 0 3 5 4 0 0 MANIFOLD Propanet 115 000 130 000 3 When a unit is converted to propane different size orifices must be used See separate natural to propane conversion kit instructions TBased on altitudes from sea level to 2000 ft above sea level For altitudes above 2000 ft reduce input rating 4 for each additional 1000
73. 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 A CAUTION When installing the unit on a rooftop be sure the roof will support the additional weight Use spreader bars or crate top when rigging the unit The units must be rigged for lifting as shown in Fig 6 Refer to Table 1 and 2 for operating weight Use extreme caution to prevent damage when moving the unit Unit must remain in an upright position during all rigging and moving opera tions The unit must be level for proper condensate drain age therefore the ground level pad or accessory roof curb must be level before setting the unit in place When a field fabricated support is used be sure that the support is level and properly supports the unit C D 48GS018 042 CPRFCURBOO6A00 8 203 112742 301 30 778 2834 730 FLAT 48GX024 036 CPRFCURBO007A00 14 356 11272 301 30 778 2834 730 CURB 48GS048 060 CPRFCURBO08A00 8 203 1527 2 402 4218 1070 4014 1022 48GX042 060 CPRFCURBOO9A00 14 356 152752 402 421 1070 40 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 chan
74. y Switch COMPRESSOR INDOOR FAN Centrifugal Switch TRAN Transformer SECTION Equipment FS Fusible Link Z Field Splice FU Fuse GND Ground lt gt Terminal Marked GV Gas Valve GVR Gas Valve Relay O Terminal Unmarked HS Hall Effect Sensor e Splice HV High Voltage Ignitor gt Splice Marked IDM Induced Draft Motor Factory Wirin IFC Indoor Fan Contactor o 9 Indoor Fan Motor Field Control Wiring IGC Integrated Gas Unit Controller Field Power Wiring Es Switch Accessory or Optional Wiring 151 Limit Switch Indicate Common Potential MGV Main Gas Valve Only Not to Represent Wiring NOTES O 1 If any of the original wires furnished are replaced they must be replaced with type 90 de GAS SECTION gree C wire or its equivalent See price pages for thermostat and subbases Use 75 degree C copper conductors for field installation For high speed IFM disconnect RED wire from IGC terminal BM and connect BLK wire from IFM For medium speed disconnect RED wire from IGC terminal BM and connect BLU wire from IFM Fig 16 208 230 3 60 Wiring Diagram Unit 48GS and 48GX DISCONNECT PER NEC Ron 20 NOTES 1 If any of the original wires furnished are replaced they must be replaced c W43 BLK FIELD SUPPLY
75. y 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 22 to check the system airflow Metering Device Acutrol Device This me tering device is a fixed orifice and is located in the header to the evaporator coil Liquid Line Strainer The liquid line strainer to pro tect metering device is made of wire mesh and located in the liquid line on the inlet side of the metering device SYMPTOM Compressor and con denser fan will not start Compressor will not start but condenser fan runs Three phase scroll compressor 48GS048 and 48GX030 060 only makes excessive noise and there may be a low pressure differential Compressor cycles other than normally satisfying thermostat Compressor operates continuously TROUBLESHOOTING Cooling CAUSE Power failure Fuse blown or circuit breaker tripped Defective thermostat contactor transformer or control relay Insufficient line voltage Incorrect or faulty wiring Thermostat setting too high Faulty wiring or loose connections in compressor circuit Compressor motor burned out seized or internal overload open Defective run start capacitor overload start relay One leg of 3 phase power dead Scroll compressor is rotating in the wrong direction Refrigerant overcharge or undercharge Defective compressor Insufficien

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