installation, Start-Up and Service instructions
Contents
1. 758 110 758 110 OUTDOOR TEMP OUTDOOR TEMP F 5 689 100 ga ng 689 100 15 46 115 46 Se Se 2621 90 pape 2621 90 g 5 5 85 29 a 85 29 3552 80 2652 80 aes ee ei a 75 4 SR es 18 HA a 65 18 55 13 H 55 13 i 483 70 B 483 70 SEN Wc ba 45 7 Bi riu c 2 c n a W a iei x 2414 260 2414 260 ex 5 S9 5 S Leg ul D uU G345 50 5345 50 Jl N 278 40 278 40 30 30 60 70 80 90 40 50 60 70 80 90 PERATURE cr suet ON LINE TEMPERATURE cA 16 21 27 32 4 10 16 21 27 32 PERATURE COJ SUCTION LINE TEMPERATURE C C00017 C00019 Fig 17 Cooling Charging Chart 50ZP036 Units Fig 19 Cooling Charging Chart 50ZP048 Units2. 758 110 758 110 OUTDOOR TEMP 689 100 FOSC 689 100 OUTDOOR TEMP 115 46 125 52 8 621 30 E 5621 90 d 2 95 55 95 35 lt lt z NAME 5 2 amp s iM 2552 80 552 80 2 Z uP ep aa S d 75 24 u 55 13 w 65 18 S c SN amp 70 45 7 p 483 amp 70 55 13 JE Eo 6 7 84 4 Z 414 260 Z 414 260 f X Z IS 5 g I 5 34 50 53 345 50 iu n 276 40 276 40 30 30 60 70 80 90 40 50 50 70 80 90 PERATURE SUCTION LINE TEMPERATURE F 16 21 27 32 4 10 16 2 27 32 PERATURE CO SUCTION LI PERATURE CC C00018 C00020 Fig 18 Cooling Charging Chart 50ZP042 Units Fig 20 Cooling Charging Chart 50ZP060 Units 1 Inspect air filter s each month Clean or replace when necessary Inspect indoor coil outdoor coil drain pan and condensate drain each cooling season for cleanliness Clean when neces sary 3 Inspect blower motor and wheel for cleanliness each cooling season Clean when necessary For first heating season inspect blower wheel bimonthly to determine proper cleaning frequency 4 Check electrical connections for tightness and controls for proper operation each cooling season Service when neces sary 5 Check the drain channel in the top cover periodically for blockage leaves insects Clean as needed A WARNING Failure to follow these warnings could re
3. emmmer DISCONNECT 88 8 dd EL RN YEL INDOOR FAN BLOWER HOUSING ELECTRIC HEAT IACCESSOR 2 amp 060 CAP1 IFM CAP 24 POWER ENTRY PER NEC 036 042 8 060 OVERLOAD PROTECTOR ALL EXCEPT 048 IEN mo BRN EEN 048 GRN Wiem FI MEE E 24V SPLICE BOX 038 042 8 060 ee BRN TOR B OR IFR 3 COM TRAN WH Ta BRN 24V SPLICE BOX SEE ACCESSORY HEATER LABEL FOR CONTROL WIRING LEGEND FIELD SPLICE MARKED WIRE TERMINAL MARKED TERMINAL UNMARKED TERMINAL BLOCK eh Beef o 6 SPLICE SPLICE MARKED FACTORY WIRING FIELD CONTROL WIRING FIELD POWER WIRING C ACCESSORY OR OPTIONAL WIRING TO INDICATE COMMON POTENTIAL ONLY NOT TO REPRESENT WIRING Proceed mem EH em H NOTES 1 IF ANY OF THE ORIGINAL WIRE FURNISHED MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 90 C WIRE OR ITS EQUIVALENT 2 SEE PRICE PAGES FOR THERMOSTAT AND SUBBASE PART NUMBERS CONNECT IONS BRN mem 55 6 09099869989 mmm eessen emm mmer mm eume DAS onnenn BRN TDR 3 OR IFR 3 CONTACTOR COMPRESSOR CAPACITOR COMPRESSOR MOTOR EGUIPMENT FUSE LINK FUSE GROUND HEATER RELAY STRIP HEAT INDOOR FAN MOTOR INDOOR FAN RELAY INTERNAL PROTECTOR OUTDOOR FAN MOTOR QUADRUPLE TERMINAL SLOW BLOW FUSE TERMINAL BLOCK TIME DEL
4. E I En GRN S EUM UNIT CONTROL BOX THERMOSTAT AND SUBBASE r C00013 Fig 14 Control Connections on charging the units to the correct superheat for the various operating conditions Accurate pressure gauge and temperature sensing device are required To measure suction pressure perform the following l Connect the pressure gauge to the service port on the suction line Mount the temperature sensing device on the suction line and insulate it so that outdoor ambient temperature does not affect the reading Indoor air cfm must be within the normal oper ating range of the unit TO USE COOLING CHARGING CHARTS 1 Take the outdoor ambient temperature and read the suction pressure gauge Refer to appropriate chart to determine what the suction temperature should be 3 Tf suction temperature is high add refrigerant If suction temperature is low carefully recover some of the charge 4 Recheck the suction pressure as charge is adjusted EXAMPLE Fig 17 Outdoor Temperature 85 F Suction Pressure 80 psig Suction Temperature should be 70 F Suction Temperature may vary x5 F If Chargemaster charging device is used temperature and pressure readings must be accomplished using the charging chart Step 4 Indoor Airflow and Airflow Adjustments 4 CAUTION For cooling operation the recommended airflow is 35
5. Replace fuse or reset circuit breaker Determine cause Recover refrigerant evacuate system and re charge to capacities shown on nameplate Replace and determine cause One leg of 3 phase power dead Refrigerant overcharge or undercharge Defective compressor Determine cause and correct Determine cause and correct Insufficient line voltage Blocked condenser Defective run start capacitor overload or start relay Defective thermostat Determine cause and replace Replace thermostat Replace Locate restriction and remove Replace filter Faulty condenser fan motor or capacitor Restriction in refrigerant system Compressor operates continuously Excessive head pressure Dirty air filter Unit undersized for load Thermostat set too low Low refrigerant charge Leaking valves in compressor Decrease load or increase unit size Reset thermostat Locate leak repair and recharge Replace compressor Recover refrigerant evacuate system and re charge Clean coil or remove restriction Replace filter Clean coil Recover excess refrigerant Recover refrigerant evacuate system and re charge Determine cause and correct Air in system Condenser coil dirty or restricted Dirty air filter Dirty condenser coil Refrigerant overcharged Air in system Condenser air restricted or air short cycling Head pressure too low Excessive suction pressure Suction pressure too low Check
6. 0 07 0 09 0 14 0 12 036 0 04 FILTER CFM SIZE SIZE 0 06 50ZP IN 1500 1600 1700 1800 a EE 2100 2200 2300 0 08 036 042 24x 24 0 14 015 0 09 048 060 24 x 30 0 10 0 15 0 16 0 18 0 07 0 08 0 09 Table 7 Accessory Electric Heat Pressure Drop 0 07 in wg 0 08 2 00 0 09 HEATER KW 5 20 2300 0 10 042 048 CFM 1400 1600 060 600 800 1000 1200 0 06 0 08 0 10 1800 2000 2200 0 25 Step 5 Condenser Fan 2 Remove condenser fan assembly grille motor motor cover A CAUTION and fan by removing screws and flipping assembly onto unit top cover Keep the condenser fan free from all obstructions to ensure proper cooling operation Never place articles on top of the 3 Loosen fan hub setscrews unit Damage to unit may result 4 Adjust fan height as shown in Fig 21 g g 1 Shut off unit power supply 5 Tighten setscrews 17 6 Replace condenser fan assembly Step 6 Electrical Controls and Wiring Inspect and check the electrical controls and wiring annually Be sure to turn off the electrical power to the unit Remove the top panel to locate all the electrical controls and wiring Check all electrical connections for tightness Tighten all screw connections If any smoky or burned connections are noticed disassemble the connection clean all the parts restrip the
7. Be sure to flush all dirt and debris from the unit base Inspect the drain pan and condensate drain line when inspecting the coils Clean the drain pan and condensate drain by removing all foreign matter from the pan Flush the pan and drain tube with clear water Do not splash water on the insulation motor wiring or air filter s If the drain tube is restricted clear it with a plumbers snake auxiliary drain port above the drain tube is also clear or similar probe device Ensure that the Table 4 Dry Coil Air Delivery Horizontal Discharge Deduct 10 percent for 208 Volt Operation 230 AND 460 VOLT External Static in wg 0 6 Unit Motor Speed Air Delivery 0 3 F 0 7 zu Ce L t 420 Lus um we xw xs Dx T 1204 1120 1008 a 51 1 65 roer oao ara res a Ce f ess f ero f srs f seo f sos f aes fao 1450 1297 190 va 411 378 350 SE CS EN Er m 1126 m Ces 464 270 38 220 Sh 6 8 EN gt 943 m 720 Tm 1618 1510 421 309 187 EE cm 1 98 159 1727 1652 565 149 818 782 696 632 2000 ss 718 625 446 810 680 580 480 1018 1000 835 790 650 2102 2025 m s 855 752 468 1038 1001 840 800 691 2202 1008 828 750 700 2200 27 son i 889 820 729 EH 1021 924 860 819 ee 08 252 Table 5 Wet Coil Pressure Drop UNIT SIZE AIRFLOW PRESSURE DROP 50ZP CFM IN WG
8. Face Area sq ft 3 1 3 9 4 3 4 9 EVAPORATOR FAN MOTOR Direct Drive Blower Motor Size in 10x8 10x9 10x9 10 x 10 Nominal Cfm 1200 1400 1600 1850 Rpm Range 800 1050 800 1050 1000 1100 950 1100 Number of Speeds 3 3 2 3 2 Factory Speed Setting Low Med Low Low Motor Hp 1 2 1 2 3 4 1 CONNECTING DUCT SIZES Round Square Supply Air in 14 13 9 x 13 9 Return Air in 14 13 9 x 27 8 FIELD SUPPLIED RETURN AIR FILTERT Throwaway in 24 x 24 24 x 24 24 x 30 24 x 30 460 v motors are 2 speed or 3 speed TRequired filter sizes shown are based on the ARI Air Conditioning and Refrigeration Institute rated airflow at a velocity of 300 ft min for throwaway type or 450 ft min for high capacity type Recommended filters are 1 in thick condensate connection to prevent the pan from overflowing See Fig 9 and 10 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 using a 3 4 in OD tubing or pipe See Fig 9 and 10 Make sure that the outlet of the trap is at least in lower than the unit drain pan condensate connection to prevent the pan from overflowing Prime the trap with water Connect a drain tube using a minimum of 3 A in PVC 3 4 in CPVC or 3 4 in copper pipe all field supplied Do not undersize the tube Pitch the drain tube downward at a slope of at least 1 in for every 10 ft of horizo
9. HEATING FIELD POWER WIRING TRANSFORMER ACCESSORY OR OPTIONAL WIRING GRN YEL TO INDICATE COMMON TERMINAL MARKED bel POTENTIAL ONLY CCESSORY NOT TO REPRESENT WIRING NOTES 1 IF ANY OF THE ORIGINAL WIRE FURNISHED CAPI WITH TYPE 90 C WIRE OR ITS EQUIVALENT GUIP GND EME CAR SEE PRICE PAGES FOR THERMOSTAT AND SUBBASE PART NUMBERS CONNECTION BOX ACCESSORY ONLY SINGLE POINT MUST BE REPLACED IT MUST BE REPLACED SET HEAT ANTICIPATOR AT 6 ELECTRIC HEAT 24 SPLICE K EQUIP GND BOX USE 75 C COPPER CONDUCTORS ONLY FAN SEQUENCE FOR TDR Se oe i NS rop HIGH SPEED IFM DISCONNECT BLU WIRE FROM TOR 3 AND CONNECT BLK JPR pL 3 WIRE FROM IFM FOR MEDIUM SPEED 4 DISCONNECT BLU WIRE FROM TDR 3 e Ft orscowetr 24V POWER ENTRY BND CONNEC CORN MIRE SE ROM IEMs ENERGIZED DE ENERG1ZED PER NEC IS0 P003 JA 06024 Fig 16B Wiring Diagram 460 3 60 14
10. When the need for heating is satisfied the heater and IFM are deenergized Table 3 Electrical Data 50ZP VOLTAGE UNIT 50ZP RANGE COMPRESSOR OFM IFM ELECTRIC HEAT SINGLE POINT POWER SUPPLY DISCONNECT SIZE SIZE FLA FLA 3 4 FUSE OR MIN MAX RLA LRA Nominal KW FLA MCA HACR BKR MOCP FLA LRA J 15 4 154 10 4 12 0 16 5 18 5 SEH 20 8 24 1 29 6 33 6 59 25 31 3 36 1 42 6 48 6 41 7 48 1 55 6 63 6 17 9 17 9 8 5 0 17 9 18 5 1 5 2 8 i 1 29 6 33 6 S 1 42 6 48 6 60 70 55 6 63 6 80 90 036 208 230 3 60 187 254 8 9 64 5 1 5 2 8 74 042 208 230 3 60 83 21 1 21 1 25 25 21 1 21 1 25 25 27 5 27 5 8 5 0 27 5 27 5 1 4 5 8 1 33 3 37 3 131 46 3 52 3 59 3 67 3 208 230 3 60 060 12 6 70 12 6 71 0 7 2 6 18 3 71 25 8 71 33 3 71 460 3 60 187 048 208 230 3 60 187 187 414 109 73 123 73 1 42 5 10 8 24 1 31 3 35 3 35 60 87 EI 3 36 1 44 3 50 4 45 60 7 48 1 57 4 65 4 60 701 16 3 114 74 6 amp 4 254 254 254 508 See legend following Electrical Data charts EXAMPLE Supply voltage is 460 3 60 AB 452 v LEGEND LL BC 464 v FLA Full Load Amps UL AC 455 v GC Locked Rotor Amps C US Average Voltage 452 464 455 Minimum Circuit Amps MOCP Maximum Overcurrent Protection 8 RLA Rated Load Amps 1371 CKT BKR Circuit Breaker 3 457 NOTES 1 In compliance wit
11. the potential for personal injury Understand the signal words DANGER WARNING CAUTION and NOTE These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies a hazard which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight suggestions Which will result in enhanced installation reliability or operation These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with changing residen tial construction practices We require these instructions as a minimum for a safe installation INTRODUCTION 50ZP cooling units are fully self contained and designed for outdoor installation See Fig 1 As shown in Fig 2 4 units are shipped in a horizontal discharge configuration for installation on a ground level slab Al units can be field converted to downflow discharge configurations for rooftop applications with a field supplied plenum RECEIVING AND INSTALLATION Step 1 Check Equipment IDENTIFY UNIT The unit model number and serial number are stamped on the unit identification plate Check this information against shipping pa pers IN
12. 00 508 0 20 00 241 3 9 50 Fig 2 Unit Base Dimensions 50ZP0036 3 REQUIRED CLEARANCE TO COMBUSTIBLE MATL TOP OF UNIT DUCT SIDE OF UN 0 SIDE OPPOSITE DU 0 BOTTOM OF UNIT 0 NEC REQUIRED CLEARANCES INCHES BETWEEN UNITS POWER ENTRY SIDE 42 UNIT AND UNGROUNDED SURFACES POWER ENTRY SIDE 36 00 UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES POWER ENTRY SIDE 42 00 2 lt REQUIRED CLEARANCE FOR OPERATION AND SERVICING CONDENSER COIL ACCESS SIDE POWER ENTRY GIDE 40 00 EXCEPT FOR NEC REQUIREMENTS UNIT TOP centes 48 00 SIDE OPPOSITE DUCTS 30 00 LEGEND NEC National Electrical Code NOTES removable fence or barricade requires no clearance 2 Dimensions are in inches Dimensions in are in millimeters COMPRESSOR PANEL FIELD ENTRY TO SERVICE PORTS 549 0 21 61 19 61 RIGHT SIDE VIEW 1 0 x 12 7 DEEP LEFT SIDE VIEW 26 772 1 05401 FRONT VIEW mm 1066 8 914 0 1066 8 2 m 30 00 762 0 762 o 1219 2 762 0 1 Clearances must be maintained to prevent recirculation of air frorn outdoor fan discharge with the exception of the condenser coil 36 00 in 914 0 mm 600003 UNIT ELECTRICAL CHARACTERISTICS ONT na x ENTER E EE N 2 502 042 2
13. Electrical Connection 2 Read and follow instructions on all DANGER WARNING CAUTION and INFORMATION labels attached to or shipped with unit Make the following inspections Inspect for shipping and handling damages such as broken lines loose parts disconnected wires etc COMPRESSOR CONTACTOR TRANSFORMER ELECTRIC GROUND INDOOR OUTDOOR FAN MOTOR HIGH HEATER LUG FAN AND COMPRESSOR VOLTAGE FUSES RELAY START CAPACITOR LEADS 4 Fig 12 Control Box Wiring Inspect for oil at all refrigerant tubing connections and on unit base Detecting oil generally indicates a refrigerant leak Leak test all refrigerant tubing connections using electronic leak detector or liquid soap solution If a refrig erant leak is detected see following Check for Refrigerant Leaks section Inspect all field and factory wiring connections Be sure that connections are completed and tight d Inspect coil fins If damaged during shipping and handling carefully straighten fins with a fin comb 3 Verify the following conditions a Make sure that outdoor fan blade is correctly positioned in fan orifice Top edge of blade should be 3 125 in down from condenser outlet grille See Condenser Fan section Refer to the Table of Contents for page number b Make sure that air filter is in place c Make sure that condensate drain pan and trap are filled with water to ensure proper drainage d Make sure that all to
14. for leaks repair and recharge Replace compressor Remove restriction Check for source and eliminate 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 Low refrigerant charge Compressor valves leaking Restriction in liquid tube High heat load 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 19 START UP CHECKLIST REMOVE AND STORE IN JOB FILE L PRELIMINARY INFORMATION Technician ll PRE START UP 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 ___ Verify that unit installation is level Check fan wheel propeller for location in housing and setscrew tightness lil START UP Supply Voltage L1 L2 L2 L3 L3 L1 Compressor Amps L1 2 13 Indoor Evaporator Fan Amps TEMPERATURE Outdoor Condenser Air Temperature D I Return Air Temperature DB W
15. grilles are open and free from obstructions and that the air filter is clean When necessary refer to Indoor Airflow and Airflow Adjustments section to check the system airflow See Table of Contents for page number Step 9 Metering Devices Refrigerant metering devices are fixed orifices and are located in the inlet header to the evaporator coil Step 10 Liquid Line Strainer The liquid line strainer to protect metering device is made of wire mesh and is located in the liquid line on the inlet side of the metering device Table 8 Troubleshooting Cooling SYMPTOM REMEDY Call power company CAUSE Power Failure Compressor and condenser fan will not start Compressor will not start but condenser fan runs Compressor cycles other than normally satisfying thermostat Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective thermostat contractor transformer or control relay Insufficient line voltage Incorrect or faulty wiring Replace component Determine cause and correct Check wiring diagram and rewire correctly Lower thermostat setting below room tempera Thermostat setting too high ture Faulty wiring or loose connections in compressor Check wiring and repair or replace circuit Compressor motor burned out seized or internal overload open Defective run start capacitor overload start relay Determine cause Replace compressor Determine cause and replace
16. npe rn eripere reiten 8 ACCESSORY ELECTRIC HEAT WIRING 8 Evaporator AlITIOW RGA eeepc orte 8 SPECIAL PROCEDURES FOR 208 V OPERATION 8 Metering Devices I EE 8 PRE START UP Liquid Eine Stainere uite rentem o eterteetetetus 8 START UP Hee Peed ee Check for Refrigerant Leaks trends 9 START UP CHECKLIST 8 LOCATE AND REPAIR REFRIGERANT LEAKS AND NOTE TO INSTALLER Before installation READ THESE CHARGE THE UNIT AS 011 0 5 9 INSTRUCTIONS CAREFULLY AND COMPLETELY Also Start Up Cooling Section and Make Adjustments 10 make sure the User s Manual and Replacement Guide are left with CHECKING COOLING CONTROL OPERATION 10 the unit after installation R fnserant Charger cc os ees reece eerte eege EE 10 NO CHARGE tee d RM rer 10 LOWCHARGE COOLINQG eene 10 TO USE COOLING CHARGING CHARTS 10 SAFETY CONSIDERATIONS Indoor Airflow and Airflow Adjustments 10 Installation and servicing of air conditioning equipment can be FOR Gg EINEN sees tete BC 11 hazardous due to system pressure and electrical components Only FOR 460 V MOTORS 11 trained and qualified workers should install repair or service Unity Controls beienee 11 air conditioning equipment HIGH PRESSURE RELIEF 11 Untraine
17. oil with a mild solvent c Reassemble blower into housing Place upper orifice ring on blower to judge location of the blower wheel Blower wheel should be approximately 0 2 in below bottom of orifice ring when centered correctly Be sure setscrews are tightened on motor and are not on round part of shaft d Set upper orifice ring in place with 3 screws removed in step 1 e Replace top access panel Step 4 Condenser Coil Evaporator Coil and Conden sate Drain Pan Inspect the condenser coil evaporator coil and condensate drain pan at least once each year requires the removal of the unit top See Unit Top Removal section above Proper inspection and cleaning The coils are easily cleaned when dry therefore inspect and clean the coils either before or after each cooling season Remove all obstructions including weeds and shrubs that interfere with the airflow through the condenser coil Straighten bent fins with a fin comb If coated with dirt or lint clean the coils with a vacuum cleaner using a 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
18. that require unit top removal Refer to the following top removal procedures 1 Remove 7 screws on unit top cover surface Save all screws 2 Remove 2 screws on unit top cover flange Save all screws 3 Lift top from unit carefully Set top on edge and make sure that top is supported by unit side that is opposite duct or plenum side 4 Carefully replace and secure unit top to unit using screws removed in steps 1 and 2 when maintenance and or service procedures are completed 16 Step 3 Evaporator Blower and Motor For longer life operating economy and continuing efficiency clean accumulated dirt and grease from the blower wheel and motor annually Disconnect and tag electrical power to the unit before cleaning the blower wheel Failure to adhere to this warning could cause serious injury or death To clean the blower wheel 1 Access the blower assembly as follows a Remove top access panel b Remove 3 screws that hold blower orifice ring to blower housing Save screws c Loosen setscrew s which secure wheel to motor shaft NW Remove and clean blower wheel as follows a Lift wheel from housing When handling and or cleaning blower wheel be sure not to disturb balance weights clips on blower wheel vanes b 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 a soft brush attachment Remove grease and
19. wire end and reassemble the connection properly and securely 00021 Fig 21 Condenser Fan Adjustment Alter inspecting the electrical controls and wiring replace all the panels Start the unit and observe at least one complete cooling cycle to ensure proper operation If discrepancies are observed in operating cycle or if a suspected malfunction has occurred check each electrical component with the proper electrical instrumenta tion Refer to the unit wiring label when making these checkouts NOTE Refer to the Sequence of Operation section as an aid in determining proper control operation See Table of Contents for page number 18 Step 7 Refrigerant Circuit Inspect all refrigerant tubing connections and the unit base for oil accumulations annually Detecting oil generally indicates a refrig erant leak If oil is detected or if low cooling performance is suspected leak test all refrigerant tubing using an electronic leak detector or liquid soap solution If a refrigerant leak is detected refer to Check for Refrigerant Leaks section See Table of Contents for page number If no refrigerant leaks are found and low cooling performance is suspected refer to Refrigerant Charge See Table of Contents for page number Step 8 Evaporator Airflow The cooling airflow does not require checking unless improper performance is suspected f a problem exists be sure that all supply and return air
20. 0 to 450 cfm per each 12 000 Btuh of rated cooling capacity Table 4 shows dry coil air delivery for horizontal discharge units Tables 5 7 show pressure drops NOTE Be sure that all supply and return air grilles are open free from obstructions and adjusted properly A WARNING Disconnect electrical power to the unit before changing blower speed Electrical shock can cause injury or death Airflow can be changed by changing the lead connections of the blower motor Units 50ZP036 048 and 060 blower motors are factory wired for low speed operation Units 50ZP042 are factory wired for medium speed operation YIO STEP 2 Wi SL e Wi eg WEE CSTEPIL 222 i 1d BLK CONTACTOR 2 i UNIT POWER 7 WIRING FUSE BLOCK CONTACTOR 1 Fig 15 Accessory Electric Heater Wiring FOR 208 230 V The motor leads are color coded as follows 3 SPEED black high speed blue medium speed red low speed 2 SPEED black high speed red low speed To change the speed of the blower motor BM remove the fan motor speed leg lead from the indoor evaporator fan relay IFR and replace with lead for desired blower motor speed nsulate the removed lead to avoid contact with chassis parts FOR 460 V MOTORS The motor leads are color coded as follows 3 SPEED 060 ONLY 2 SPEED black high speed black to purple yellow line orange medium speed purple to black blue lo
21. 08 230 3 60 355 6 14 00 508 0 20 00 304 8 12 00 50ZP048 208 230 3 60 355 6 14 00 508 0 20 00 304 8 12 00 Fig 3 Unit Base Dimensions 50ZP042 048 4 DIMENSIONS IN ARE IN INCHES REQUIRED CLEARANCE TO COMBUSTIBLE MATL INCHES mm 117 6 ei 35 353 7 TOP OF UNIT 0 4 53 13 891 2 111 DUCT SIDE OF UNIT SIDE OPPOSITE DUCTS BOTTOM OF UNIT NEC REQUIRED CLEARANCES INCHES mm BETWEEN UNITS POWER ENTRY 42 00 1066 8 UNIT AND UNGROUNDED SURFACES POWEH ENTRY SIDE 36 00 914 0 UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES POWER ENTRY SIDE 42 00 1066 8 T i REQUIRED CLEARANCE FOR OPERATION AND SERVICING 706 0 INCHES 21 80 CONDENSER COIL ACCESS SIDE NTRY SIDE 5 13 881 lt s t 30 00 762 0 S E 138 3 P 1 LEGEND run 9 a e 4 e e i n NEC National Electrical Code 88 9 NOTES REAR VIEW 3 50 1 Clearances must be maintained to prevent recirculation of air from outdoor fan discharge with the exception of the condenser coil 36 00 in 914 0 mm removable fence or barricade requires no clearance 29850 2 Dimensions are in inches Dimensions in are in millimeters 50 981 BOTTOM O
22. 50ZP036 060 3 Phase Single Packaged Air Conditioners HEATING amp COOLING Visit www carrier com Installation Start Up and Service Instructions NOTE Read the entire instruction manual before starting the installation TABLE OF CONTENTS SAFETY CONSIDERATIONS sees 1 E 5 cm INTRODUCTION urn esa aco EE 2 E zEERL S RECEIVING AND INSTALLATION seen 2 ES Bess Check Equipment ed sek H E ER ZEE juipmen ES 3 EE IDEN TIE UN E 2 ES S 22 2 2 INSPECT SHIPMENT GE 2 S zd Provide Unit Support neret t 2 ES E E SLAB MOUN Eege eatin ee 2 S Ze Provide Clearances 202 ASN y EE F Y S Bees Place Unit Ls x S SS Select and Install Ductwork oo cece esceseesensensereaniee 2 SS INSTALL FLANGES FOR DUCTWORK CONNEC TIONS 50ZP060 ONLY 2 CONVERTING HORIZONTAL DISCHARGE UNITS TO up DOWNFLOW VERTICAL DISCHARGE 6 Fig 1 Unit 50ZP Provide for Condensate Disposal sess 6 install Electtical Connectionsetgsveearod e ee EEN 7 Evaporator Blower and Motor 6 HIGH VOLTAGE CONNECTIONS 7 Condenser Coil Evaporator Coil and Condensate Drain Pan 16 ROUTING POWER LEADS INTO UNIT s 11111111 8 Eer T CONNECTING GROUND LEAD TO UNIT GROUND 8 Electrical Controls and Wing sete rre 8 ROUTING CONTROL POWER WIRES s g Refrigerant CAITGUIL iu nenne
23. AY RELAY THERMOSTAT HEAT ING TRANSFORMER FAN SEQUENCE FOR TDR 3 55 HEAT ANTICIPATOR AT 6 4 USE 75 C COPPER CONDUCTORS ONLY TOR 1 3 ENERGIZED GE 30 5 DE ENERGI ZED Fig 16A Wiring Diagram 208 230 3 60 13 TOVA ASTONAS A A06023 SCHEMATIC 460 3 60 Eun GND BEK MAXIMUM WIRE SIZE 2 AWG aa BLK BLK YEL K13 Fave BLU YEL USED WITH Ce ACCESSORY ELECTRIC HEAT Li OPTION ONLY USED WITH HEATER OPTIONS j POWER Ife 5 10 15 amp 20 KW OVERLOAD PROTECTOR SUPPLY L3 MAXIMUM WIRE SIZE 2 AWG RED BLK RIC BLU ATIC YEL BRN ko BRN QT Cap GRN YEL TRANI BRN proces ai CBRN RED THERMOSTAT SUB BASE COM TRAN WHT i i i A em 2A r ICE 5EE ACCESSORY HEATER LABEL FOR CONTROL WIRING VIO men 56 pr S 598 EE v gae CONNECT IONS 10 0 KW AND ABOVE 1 955 5 m SEE NOTE 2 24V ae LEGEND FIELD SPLICE CONTACTOR COMPRESSOR ENT ARRANGEMENT CAPACITOR MARKED WIRE COMPRESSOR MOTOR P EQUIPMENT FUSE LINK TERMINAL UNMARKED GROUND HEATER RELAY STRIP HEAT T A BLOCK INDOOR FAN MOTOR SPLICE INTERNAL PROTECTOR INDOOR FAN OUTDOOR FAN MOTOR SPLICE MARKED BLOWER HOUSING QUADRUPLE TERMINAL a FACTORY WIRING TERMINAL BLOCK TIME DELAY RELAY BRN GRN YEL i T FIELD CONTROL WIRING
24. B Cooling Supply Air DB WB PRESSURES Refrigerant Suction psig Suction Line Temp Refrigerant Discharge psig Discharge Tempt Verify Refrigerant charge using charging tables ___ Verify that 3 phase scroll compressor B0GL030 060 is rotating in correct direction Measured at suction inlet to compressor T1Measured at liquid line leaving condenser Copyright 2006 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 101 Printed in U S A Catalog No 50ZP 5Sl Pg 20 2 06 Replaces New Tab 6a 8a
25. F UNIT SIDE OPPOSITE DUCTS BOTTOM OF UNIT NEC REQUIRED CLEARANCES INCHES mm 0 INCHES mm BETWEEN UNITS POWER ENTRY SIDE 42 00 1066 8 UNIT AND UNGROUNDED SURFACES PO 36 00 914 0 UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES POWER ENTRY SIDE 42 00 1066 8 REQUIRED CLEARANCE FOR OPERATION AND SERVICING INCHES mm CONDENSER COIL ACCESS SIDE 30 00 762 0 POWER ENTRY SIDE 30 00 762 0 EXCEPT FOR NEC REQUIREMENTS 48 00 1219 2 UNIT TOP SIDE OPPOSITE DUCTS 30 00 762 0 LEGEND NEC National Electrical Code NOTES 1 Clearances must be maintained to prevent recirculation of air from outdoor fan discharge with the exception of the condenser coil 36 00 in 914 0 mm A removable fence or barricade requires no clearance 2 Dimensions are in inches Dimensions in are in millimeters OD BOX AND EVAP COH COMPRESSOR PANEL 69 0 549 0 2 72 21 61 FIELD ENTRY TO 5 2 88 s SERVICE PORTS POWER ENTRY LOW VOLTAGE ENTRY i 30 6 1 201 498 ee 63 2 LEFT SIDE VIEW FRONT VIEW tien 26 772 0 x 12 7 DEEP ELECTRICAL CHARACTERISTICS 1 05401 RIGHT SIDE VIEW C00156 UNIT WEIGHT CENTER OF GRAVITY IN ib kg X Y 2 50ZP036 208 230 3 60 250 355 6 14
26. F UNIT EVAP COIL g kt rs Tl T1 i ho Tes j COND COIL Y 812 5 hite 31 99 1T 1 PRI BOTTOM OF UNIT J atom CONTROL BOX AND EVAP COIL ACCESS PANEL 564 64 5489 0 2 121 21 611 COMPRESSOR PANEL FIELD amp NTRY TO SERVICENPORTS 44 5 DIA 22 20 DIA 15 31 0 88 51 E 751 8 29 60 s LEFT SIDE VIEW FRONT VIEW 1 20 498 1 25 ti 19 61 de 7 151 7 RIGHT SIDE VIEW ELECTRICAL CHARACTERISTICS 5 kg X x 208 230 3 60 460 3 60 355 6 14 00 508 0 20 00 Fig 4 Unit Base Dimensions 50ZP060 5 C00158 UNIT WEIGHT CENTER OF GRAVITY IN 50ZP060 355 6 14 00 4 Install 2 hand formed flanges onto return air opening in holes provided to form a rectangle around the return air opening 5 Install remaining 2 hand formed flanges around discharge air opening in holes provided 6 Ductwork can now be attached to flanges When designing and installing ductwork consider the following 4 CAUTION When connecting ductwork to units do not drill deeper than 3 4 inch in shaded area shown in Fig 7 or coil may be damaged All units should have field supplied filters installed in the return air side of the unit Recommended sizes for filters are shown in Table 1 Avoid abrupt duct size increases and reductions Abrupt change in duct size adversely affects air performance IMPORTANT Use flexible con
27. SPECT SHIPMENT Inspect for shipping damage while unit is still on shipping pallet If unit appears to be damaged or is torn loose from its securing points have it examined by transportation inspectors before removal Forward claim papers directly to transportation company Manufacturer is not responsible for any damage incurred in transit Check all items against shipping list Immediately notify the nearest Carrier Air Conditioning office if any item is missing To prevent loss or damage leave all parts in original packages until installation Step 2 Provide Unit Support SLAB MOUNT Place the unit on a rigid level surface suitable to support the unit weight The flat surface should extend approximately 2 in beyond he unit casing on the 2 sides The duct connection side and he flat surface A concrete pad or a suitable fiberglass mounting pad is recommended A 6 in wide gravel apron should be used around the flat surface to prevent airflow blockage by grass or shrubs Do not secure the unit o the flat surface except where required by local codes The unit should be level to within 1 4 inch This is necessary for he unit drain to function properly condensate drain connection sides should be flush with the edge of Step 3 Provide Clearances The required minimum service clearances and clearances to combustibles are shown in Fig 2 4 Adequate ventilation and condenser air must be provided The condenser fan pulls air throug
28. ansformer is factory wired for 230 v operation If supply voltage is 208 v rewire transformer primary as described in the Special Procedures for 208 v Opera on section below ACCESSORY ELECTRIC HEAT WIRING Refer to accessory electric heat installation instructions for infor mation on installing accessory electric heat Accessory electric heat wiring is shown in Fig 15 SPECIAL PROCEDURES FOR 208 V OPERATION A WARNING Make sure that the power supply to the unit is switched OFF before making any wiring changes Electrical shock can cause serious injury or death 1 Remove wirenut from connection of ORG wire to BLK wire Disconnect the ORG transformer primary lead from the BLK wire Save wirenut See unit wiring label Remove the wirenut from the terminal on the end of the RED transformer primary lead 3 Save the wirenut 4 Connect the RED lead to the BLK wire from which the ORG lead was disconnected Insulate with wirenut from Step 1 5 Using the wirenut removed from the RED lead insulate the loose terminal on the ORG lead 6 Wrap the wirenuts with electrical tape so that the metal terminals cannot be seen Indoor blower motor speeds may need to be changed for 208 v operation Refer to Indoor Airflow and Airflow Adjustments section See Table of Contents for page number PRE START UP A WARNING Failure to observe the following warnings could result in serious injury or death 1 Follow rec
29. d workers can perform basic maintenance functions of COMPRESSOR 11 cleaning coils and filters All other operations should be performed Sequence EE 11 by trained service people When working on air conditioning FAN OPERATION un 11 equipment pay attention to precautions in the literature tags and COOEING 5988 ve 11 labels attached to the unit and other safety precautions that may HEATING tete nea eae oi PROP PEPPER EBENE 11 apply VERRECHNEN 12 Follow all safety codes Wear safety glasses and work gloves Use AID HE 16 quenching cloth for unbrazing operations Have fire extinguisher Unit Top Removal Condenser Coil Side 16 available for all brazing operations Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 101 Printed in U S A Catalog No 50ZP 5SI Pg 1 2 06 Replaces New Tab 6a 8a A WARNING Before performing service or maintenance operations on system turn off main power to unit Turn off accessory heater power switch if applicable Electrical shock can cause serious injury or death Recognize safety information This is the safety alert symbol A When you see this symbol in instructions or manuals be alert to
30. e dedicated side supply products They are not convertible to vertical air supply A field supplied plenum must be used to convert to vertical air discharge Step 6 Provide for Condensate Disposal NOTE Be sure that condensate water disposal methods comply with local codes restrictions and practices Unit removes condensate through a 1 3 64 in ID hole which is located at the end of the unit See Fig condensate connection 2 4 for location of SS 06667 Fig 7 Area Not to Be Drilled More Than 3 4 in Condensate water can be drained directly onto the roof in rooftop installations where permitted or onto a gravel apron in ground level installations Install a field supplied condensate trap at end of condensate connection to ensure proper drainage Make sure that the outlet of the trap is at least in lower than the drain pan Table 1 Physical Data UNIT 50ZP 036 042 048 060 OPERATING WEIGHT ibs 250 297 310 350 COMPRESSOR TYPE Reciprocating REFRIGERANT Charge Ib 47 44 61 75 REFRIGERANT METERING DEVICE Acutrol Device CONDENSER COIL Copper Tubes Aluminum Plate Fins Rows Fins in 2 17 1 17 2 17 2 17 Face Area sq ft 6 2 11 1 6 6 10 7 CONDENSER FAN MOTOR CFM Propeller 2600 2600 2800 Nominal Rpm 1100 1100 1100 Motor Hp 1 4 1 4 1 4 Diameter in 20 20 20 EVAPORATOR COIL Copper Tubes Aluminum Plate Fins Rows Fins in 3 15 3 15 3 15 4 15
31. essor 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 Place SYSTEM switch in COOL position and FAN switch in AUTO position Set cooling control below room temperature Observe that compressor condenser fan and evaporator blower motors start Observe that cooling cycle shuts down when control setting is satisfied 3 When using an automatic changeover room thermostat place both SYSTEM and FAN switches in AUTO positions Observe that unit operates in Cooling mode when temperature control is set to call for cooling below room temperature Step 3 Refrigerant Charge Amount of refrigerant charge is listed on unit nameplate also refer to Table 1 Refer to Carrier Refrigerant Service Techniques Manual Refrigerant section Unit panels must be in place when unit is operating during charging procedure NO CHARGE Use standard evacuating techniques After evacuating system weigh in the specified amount of refrigerant Refer to Table 1 LOW CHARGE COOLING Use Cooling Charging Charts Fig 17 20 Vary refrigerant until the conditions of the appropriate chart are met Note that charging charts are different from the type normally used Charts are based 10
32. f premature equipment failure periodic maintenance must be performed on this equipment This cooling unit should be inspected at least once each year by a qualified service person To troubleshoot cooling of units refer to Troubleshooting chart in procedures recommended in the User s Manual FAILURE back OF book TO HEED THIS WARNING COULD RESULT IN SERI NOTE TO EQUIPMENT OWNER Consult your local dealer OUS INJURY DEATH OR DAMAGE TO THIS EQUIP about the availability of a maintenance contract MENT The minimum maintenance requirements for this equipment are as follows 12 MAXIMUM WIRE SIZE 2 AWG USED WITH ACCESSORY ELECTRIC HEAT OPTION ONLY USED WITH HEATER OPTIONS 5 10 amp 15 KW MAXIMUM WIRE SIZE 2 AWG SEE ELECTRIC HEAT SCHEMATIC USED WITH ACCESSORY ELECTRIC HEAT OPTION ONLY USED WITH HEATER OPTIONS 20 KW ONLY MAXIMUM WIRE SIZE 2 0 AWG T EQUIP GND FIELD mamen KE SUPPLY 6 5 j Dee 01 lt e AEN 4 SUPPLY SCHEMATIC 208 230 3 60 036 048 amp 050 TOR 036 042 8 060 QT CAPI SEE NOTE 2 WHT i Fi A ATT mea VIO 10 0 KW AND ABOVE 24V SPLICE BOX P cxi ur ans 86 86 5 8598 ARRANGEMENT SINGLE POINT CONNECTION BOX ACCESSORY ONLY ELECTRIC HEAT EQUIP GND 036 04 CAP2 OFM CAP
33. h NEC National Electrical Code requirements Determine maximum deviation from average voltage for multimotor and combination load equipment refer to NEC AB 457 452 5 Articles 430 and 440 the overcurrent protective device for the BC 464 45727v unit shall be Power Supply fuse Canadian units may be AC 457 455 2v fuse or circuit breaker Maximurn deviation is 7 v 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 percent of voltage imbalance determine size from NEC e 7 3 Unbalanced 3 Phase Supply Voltage Voltage Imbalance 100 x 257 Never operate a motor where a phase imbalance in supply volt age is greater than 2 Use the following formula to determine 1 5395 the percentage of voltage imbalance P g 9 This amount of phase imbalance is satisfactory as it is below the Voltage imbalance maximum allowable 2 100 max voltage deviation from average voltage average voltage IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately MAINTENANCE A WARNING The ability to properly perform maintenance on this equip ment requires certain expertise mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those To ensure continuing high performance and to reduce the possi bility o
34. h the condenser coil and discharges it through the fan on the top cover Be sure that the fan discharge does not recirculate to the condenser coil Do not locate the unit in either a corner or under an overhead obstruction The minimum clearance under a partial overhang such as normal house overhang is 48 in above the unit top The maximum horizontal extension of a partial overhang must not exceed 48 inches A CAUTION Do not restrict condenser airflow An air restriction at either the outdoor air inlet or the fan discharge can be harmful to compressor life Do not place the unit where water ice or snow from an overhang or roof will damage or flood the unit The unit may be installed on wood flooring or on Class A B or C roof covering materials Step 4 Place Unit Unit can be moved with the handholds provided in the unit basepan Refer to Table for operating weights Use extreme caution to prevent damage when moving the unit Unit must remain in an upright position during all moving operations The unit must be level for proper condensate drainage the ground level pad must be level before setting the unit in place When a field fabricated support is used be sure that the support is level and that it properly supports the unit Step 5 Select and install Ductwork The design and installation of the duct system must be in accordance with standards of the NFPA National Fire Protection Associa tion for in
35. n the EAN switch is set to AUTO the thermostat deenergizes he IFR provided there is not a call for cooling The contacts open and the IFM is deenergized The IFM will be energized only when here is a call for cooling or if the unit is equipped with accessory electric heat the indoor fan motor will also run while the acces sory electric heat is energized NOTE 50ZP060 unit is equipped with a time delay relay On this unit the indoor fan remains on for 30 seconds after G or Y is deenergized COOLING On a call for cooling the compressor contactor C and the IFR are energized through the Y and G terminals of the thermostat On units with a compressor time delay relay there is a 5 minute 45 sec delay between compressor starts Energizing the compressor contactor supplies power to the compressor and the outdoor condenser fan motor OFM Energizing the IFR provides power to the IFM When the need for cooling has been satisfied the OFM compres sor and IFM FAN on AUTO are deenergized If the unit is equipped with a 30 second delay the indoor fan will remain energized for 30 seconds after the compressor is deenergized 060 unit only HEATING If accessory electric heaters are installed on a call for heat the thermostat energized the W relay which energizes the electric heaters The IFR is energized which starts the indoor fan motor If the heaters are staged W2 is energized when the second stage of heating is required
36. nectors between ductwork and unit to prevent transmission of vibration Use suitable gaskets to ensure weathertight and airtight seal Size ductwork for cooling air quantity efm The minimum air quantity for proper electric heater operation is listed in Table 2 Heater limit switches may trip at air quantities below those recommended e Insulate and weatherproof all external ductwork Insulate and cover with a vapor barrier all ductwork passing through conditioned spaces Follow latest Sheet Metal and Air Condi tioning Contractors National Association SMACNA and Air Conditioning Contractors Association ACCA minimum in stallation standards for residential heating and air conditioning systems e Secure all ducts to building structure Flash weatherproof and vibration isolate duct openings in wall or roof according to good construction practices Figure 8 shows a typical duct system with 50ZP unit installed FLANGE ATTACHED C00005 Fig 5 Shipping Location of Duct Flanges Size 060 Only FIVE PIECES OF DUCT HERE FOR SHIPMENT 6 C00006 Fig 6 Flanges Installed on 50ZP060 Units CONVERTING HORIZONTAL DISCHARGE UNITS TO DOWNFLOW VERTICAL DISCHARGE Before performing service or maintenance operations on system turn off main power to unit Turn off accessory heater power switch if applicable Electrical shock can cause serious injury or death Units ar
37. ntal run Be sure to check the drain tube for leaks Prime trap at the beginning of the cooling season start up Allowable glues for condensate trap connection are Standard ABS CPVC or PVC cement Step 7 Iinstall Electrical Connections 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 in the control compartment or conduit approved for electrical ground when installed in accordance with NEC National Electrical Code ANSI American National Standards Institute VNFPA latest edition in Canada Canadian Elec trical Code CSA C22 1 and local electrical codes Failure to adhere to this warning could result in serious injury or death CAUTION Failure to follow these precautions could result in damage to the unit being installed 1 Make all electrical connections in accordance with NEC ANSI NFPA latest edition and local electrical codes governing such wiring In Canada all electrical connec tions must be in accordance with CSA standard C22 1 Canadian Electrical Code Part and applicable local codes Refer to unit wiring diagram Use only copper conductor for connections between field supplied electrical disconnect switch and unit DO NOT USE ALUMINUM WIRE Be sure that high voltage power to unit is within operating v
38. ognized safety practices and wear protective goggles when checking or servicing refrigerant system 2 Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured Do not remove compressor terminal cover until all electri cal sources are disconnected Relieve all pressure from both high and low pressure sides of the system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around com pressor terminals Use accepted methods to recover refrig erant Never attempt to repair soldered connection while refrig erant system is under pressure Do not use torch to remove any component System contains oil and refrigerant under pressure To remove component wear protective goggles and proceed as fol lows Shut off electrical power to unit b Relieve all refrigerant from system using both high and low pressure ports Use accepted methods to recover refrigerant c Cut component connecting tubing with tubing cutter and remove component from unit d Carefully unsweat remaining tubing stubs when neces sary Oil can ignite when exposed to torch flame Use the Start Up Checklist supplied at the end of this book and proceed as follows to inspect and prepare the unit for initial start up 1 Remove all access panels HIGH VOLTAGE LOW VOLTAGE POWER WIRING WIRING ENTRY ENTRY HOLE HOLE C00010 Fig 11 Unit
39. ols and miscellaneous loose parts have been removed START UP Use the Start Up Checklist supplied at the end of this book and proceed as follows Step 1 Check for Refrigerant Leaks LOCATE AND REPAIR REFRIGERANT LEAKS AND CHARGE THE UNIT AS FOLLOWS 1 Using both high and low pressure ports locate leaks and reclaim remaining refrigerant to relieve system pressure 2 Repair leak following accepted practices NOTE Install a filter drier whenever the system has been opened for repair 3 Check system for leaks using an approved method UNIT GROUND GROUND eg LEAD A SINGLE PHASE Il R Bk 3 EE TODISGONNECT PERNEC LL gt PER NEC i p dee BLU Fig 13 Line Power Connections SE 4 Evacuate refrigerant system and reclaim refrigerant if no additional leaks are found 5 Charge unit with R 22 refrigerant using 8 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 field installed filter drier Step 2 Start Up Cooling Section and Make Adjustments A CAUTION Complete the required procedures given in the Pre Start Up section this page before starting the unit Do not jumper any safety devices when operating the unit Do not operate the compressor when the outdoor temperature is below 40 F Do not rapid cycle the compressor Allow 5 minutes between on cycles to prevent compr
40. oltage range indicated on unit rating plate Insulate low voltage wires for highest voltage contained within conduit when low voltage control wires are run in same conduit as high voltage wires Do not damage internal components when drilling through any panel to mount electrical hardware conduit etc On all 3 phase units ensure phases are balanced within 2 percent Consult local power company for correction of improper voltage and or phase imbalance HIGH VOLTAGE CONNECTIONS The unit must have a separate electrical service with a field supplied waterproof disconnect switch mounted at or within sight from the unit Refer to the unit rating plate for maximum fuse circuit breaker size and minimum circuit amps ampacity for wire sizing See Table 3 for electrical data The field supplied disconnect may be mounted on the unit over the high voltage inlet hole See Fig 2 4 INDOOR afz THERMOSTAT ges UNIT AND COMPOSITE RUST PROOF BASEPAN CONDENSATE Control Wiring DRAIN CONNECTION Condenser Arten Separate disconnect per NEC Electrical Code required for electric heater when single L Evaporator Alrflow point conection Is not used 00008 C00008 Fig 8 Typical installation 1 25mm MIN Y TRAP OUTLET Y 2 50mm MIN C99013 Fig 9 Condensate Trap Using Tubing TRAP i OUTLET 1 min 2 min 600009 Fig 10 Condensa
41. stallation of nonresidence type air conditioning and ventilating systems e NFPA90A or residence type NFPA90B and or local codes and residence type NFPA 90B and or local codes and ordinances Select and size ductwork supply air registers and return air grilles according to ASHRAE American Society of Heating Refrigera on and Air Conditioning Engineers recommendations Use the duct flanges provided on the supply and return air openings on the side of the unit See Fig 2 4 for connection sizes and locations The 14 in round duct collars size 036 048 units are shipped inside the unit attached to the indoor blower They are field installed and must be removed from the indoor cavity prior to start up even if they are not used for installation INSTALL FLANGES FOR DUCTWORK CONNECTIONS 502 060 ONLY The 50 060 units are shipped with flanges which must be field installed on the unit To install unit flanges l Five pieces of flange are shipped on the return air opening of the unit Remove the flanges from the shipping position See Fig 5 Screws are field supplied One piece of flange is used as it is shipped straight Bend the other 4 pieces at right angles 3 Install the straight flange on the right side of the return air opening in holes provided See Fig 6 Flanges should stick out from unit to allow for connection of ductwork REQUIRED CLEARANCE TO COMBUSTIBLE MATL TOP OF UNIT DUCT SIDE O
42. sult in serious injury or death 1 Turn off electrical power to the unit before performing any maintenance or service on the unit Use extreme caution when removing panels and parts As with any mechanical equipment personal injury can result from sharp edges etc Never place anything combustible either on or in contact with the unit Step 1 Air Filter Never operate the unit without a suitable air filter in the return air duct system Always replace the filter with the same dimensional size and type as originally installed See Table 1 for recommended filter sizes Inspect air filter s at least once each month and replace throwaway type or clean cleanable type at least twice during each cooling season or whenever the filters become clogged with dust and lint Replace filters with the same dimensional size and type as originally provided when necessary Step 2 Unit Top Removal Condenser Coil Side NOTE When performing maintenance or service procedures that require removal of the unit top be sure to perform all of the routine maintenance procedures that require top removal including coil inspection and cleaning and condensate drain pan inspection and cleaning WARNING Disconnect and tag electrical power to the unit before removing top Failure to adhere to this warning could cause serious injury or death Only qualified service personnel should perform maintenance and service procedures
43. te Trap Using PVC Piping Table 2 Minimum Airflow for Safe Electric Heater Operation CFM SIZE 036 060 1200 1750 A CAUTION Operation of unit on improper line voltage constitutes abuse and may cause unit damage that could affect warranty ROUTING POWER LEADS INTO UNIT Use only copper wire between disconnect and unit The high voltage leads should be in a conduit until they enter the unit DISCONNECT PER NEC ELECTRIC HEATER conduit termination at the unit must be watertight Run the high voltage leads through the hole on the control box side of the unit see Fig 11 for location When the leads are inside the unit run leads to the control box see Fig 12 On 3 phase units connect the leads to the black yellow and blue wires see Fig 13 CONNECTING GROUND LEAD TO UNIT GROUND Refer to Fig 12 and 13 Connect the ground lead to the chassis using the unit ground lug in the control box ROUTING CONTROL POWER WIRES Form a drip loop with the thermostat leads before routing them into the unit Route the thermostat leads through grommeted hole provided in unit into unit control box See Fig 11 Connect thermostat leads to unit control power leads as shown in Fig 14 Route thermostat wires through grommet providing a drip loop at the panel Connect low voltage leads to the thermostat as shown in Fig 14 The unit transformer supplies 24 v power for complete system including accessory electrical heater Tr
44. w speed red line To change the speed of the blower motor BM from low speed to high speed remove the red lead from the indoor fan relay AIFR Insulate the red lead to avoid contact with any chassis parts Separate the black lead from the purple lead Connect the black lead to the IFR Insulate the purple lead to avoid contact with any chassis parts Step 5 Unit Controls All compressors have the following internal protection controls HIGH PRESSURE RELIEF VALVE This valve opens when the pressure differential between the low and high side becomes excessive COMPRESSOR OVERLOAD This overload interrupts power to the compressor when either the current or internal temperature become excessive and automati cally resets when the internal temperature drops to a safe level This overload may require up to 60 minutes or longer to reset therefore if the internal overload is suspected of being open 11 disconnect the electrical power to the unit and check the circuit through the overload with an ohmmeter or continuity tester Step 6 Sequence of Operation FAN OPERATION The FAN switch on the thermostat controls indoor fan operation When the FAN switch is placed in the ON position the IER indoor fan relay is energized through the G terminal on the hermostat The normally open contacts close which then provide power to the indoor evaporator fan motor IFM The IFM will run continuously when the FAN switch is set to ON Whe
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