Carrier 48KH User's Manual
Contents
1. Adhere to the following requirements when selec ting sizing and installing duct system 1 Select and size ductwork supply air registers and return air grilles according to ASHRAE recom mendations and as presented in Carrier System Design Manual Part 2 System airflow must be within range of temperature rise and external static pressure shown on unit AGA rating plate i i i 1 i i H 2 Use a 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 a weather tight and airtight seal Table 2 Filter Sizes Field Supplied Size Sq In STANDARD CLEANABLE OR MODEL 48 DISPOSABLE HIGH CAPACITY MCN TYPE TYPE bed KLO18300BE 300 1 487 KLO24300BE 400 257 KH024300BE 400 260 KLO30300BE 522 339 __ KH030300BE 522 339 KLO36300BE 576 374 KLO36500CE 576 374 KLO36600CE 576 374 KH036300BE l 583 379 KH036300BF i 722 451 KHO36500CE 576 374 KH036500CF 694 451 KLO42300BE 4 109727 437 N KLO42500CE 672 437 KH042300BE 672 437 _ KH042500CE 672 437 KLO48300BE 768 499 KLO48500CE 768 499 KLO48600CE 768 499 KH048300BE BF 768 499 KHO48500CE CF 768 d 499 KLO60300BE 950 618 KHO60300BE BF 950 618 Recommended air filter areas shown are based on either the ARI rated cooling airflow or the heating airftow at a velocity of 300 fpm depending2. M eo AGERE t M M ECORI Check air gap between electrode tip and pilot burner Gap should be as shown in Fig 11 Readjust as necessary Clean moisture or dirt accumulation on n electrode _ ceramic with cloth a abii redes EU m o con worsen sua Cracked ceramic replace pilot electrode assembly Check for loose or broken wiring at and between spark generator and electrode Replace wire or tighten con nection as necessary Check fuses or circuit breaker to ensure voltage to unit Check 24 volt input to Spark generator If you read 24 volts and above steps have been completed replace spark generator Realign electrode tip away from main bi burner but main tain spark gap to pilot burner lt See gt Fig 11 p Clean pilot c orifice Check f for vc voltage t to terminals no 3 and 5 of g gas valve Check to see if pilot valve is opening Check for lo loose or broken wiring connections If no deficiency is found replace gas valve Ges cae c senescit reer His net Drain install water trap M Check lt power supply fuses wiring or circuit breaker uamiascameg d Check transformer replace if necessary Check all wiring e and wirenut connections _ Clean pilot orifice Replace pilot Replace thermostat LE G mean me a ok comets ARUBA Check to see if
3. Faulty condenser fan motor or Replace D Se capacitor CURE Rm NEN i are Restriction in refrigerant system Locate restriction and remove Compressor operates Dirty air filter Replace filter ie ae ae CE continuously _ Unit undersized for load m Decrease load d or increase 1 unit s size HER odes _ Thermostat set too low _ f _ Res Reset thermostat ete at ee eae Low refrigerant charge Locate leak repair and recharge Replace compressor _ Leaking v valves in compressor set t rt r ma m o r M Air in system Blow refrigerant evacuate system and recharge eosin wer p S Clean coil or remove restriction imao ma m oean CRY mae NS OMEN AF UREN RRL KAISHO ARERR RW SAN fh PM OER SE TAA RL MARNE SESA Replace filter Condenser coil dirty or restricted p nmeek Excessive head pressure Dirty a air filter Dirty con condenser coil Clean coil Refrigerant overcharged Purge excess refrigerant Air in system li NA Blow refrigerant evacuate system and recharge Condenser air restricted or air short cycling devises eei vias amanenna aranana E on e me wes ar Head pressure too low Low refrigerant charge Determine cause and correct men anon RHENUS TEIN RN HRC SAUER Check for leaks rej repair and recharge Compressor valves leaking m re it nae epee m
4. KH042 80 000 BARGE IC AS ESSA 12820 1235 1182 1134 1089 1048 1010 975 94 E 1134 1089 1048 1010 975 942 911 KLO48 80 000 1134 1089 1048 1010 975 942 911 KHo4s 100 000 1417 1362 1310 12631 1218 1177 1138 1102 ud ums m KHO48BF CF 125 000 MEX MB SN ZO 1842 1770 1703 1641 1584 1530 1480 1433 1389 1347 1308 1272 1237 1204 KLo60 100 000 1417 1362 1310 1263 1218 1177 1138 1102 Prem die 2e KHO60 120 000 1701 1634 1572 1515 1462 1412 1366 1323 1282 1244 1208 1174 1142 1111 KHOGOBF 150 000 5 2211 2124 2044 1970 1901 1836 1776 1720 1667 1617 1570 ee 1484 1444 ne DRE E ecd uy uoa admi sites died mnn ow be nto om mass cae EH NOTE Shaded areas of the table fall below the approved temperature rise range of the unit Dashed areas of the table fall beyond the air delivery capability of the unit within the operating voltage range for all voltage options for each size unit Capacity Temperature Rise 1 08 x cfm Single phase units Temperature rise for 3 phase units may be different due to blower motor performance For 3 phase units use 12 NOTE 4 SCHEMATIC DIAGRAM GOWER Li mnam mm m5 mm m a n D S S EN E E O O E OD A N E D D A E S S E
5. Number One Air Conditioning Maker Division of Carrier Corporation Carrier Parkway Syracuse N Y 13221 Combination Heating Cooling Units Note to Installer After installation leave these instructions Owner s Manual and Parts Replacement Guide with equipment owner INDEX Page SAFETY CONSIDERATIONS l GENERAL uie AoriIR Vb ak oed 1 2 INSTALLATION eese 2 9 Step 1 Rig and Place Unit 2 e ROOFTOP INSTALLATION e GROUND LEVEL INSTALLATION CLEARANCES CONDENSATE DISPOSAL e VENTING Step 2 Make Gas Piping Connections 5 Step 3 Make Duct Connections 6 Step 4 Make Wiring Connections 7 e HIGH VOLTAGE CONNECTIONS e SPECIAL PROCEDURES FOR 208 V OPERATION e LOW VOLTAGE CONNECTIONS HEAT ANTICIPATOR SETTING START UP usns exer sus seers 9 18 SERVICE ouo sx UEX ena AMEEREA VER 18 21 TROUBLESHOOTING CHARTS 22 23 SAFETY CONSIDERATIONS NOTE Installation of this unit must conform to the guidelines presented in these Installation Instruc tions Read and become familiar with this publica tion before starting installation Carrier Corporation 1982 Only trained qualified installers and service mechanics should install start up and service this equipment Consult the Owner s Manual for routine maintenance All other operations should be per formed by trained service personnel Follow all safe
6. 1160 1150 1150 1140 1130 1110 1395 1395 1800 1788 1768 1738 1766 1668 1628 15881 2050 2018 11970 KLO48 1790 1770 1745 1715 1680 1646 1605 1565 2020 1975 1930 2165 2110 2055 2600 1940 1880 1815 1755 2278 2226 2160 2 2110 2060 2005 1950 1890 1835 1775 1710 i 1 1480 1460 1470 1450 7995 1950 1895 1960 1910 1730 1665 1600 1690 1630 1960 1820 1845 1770 onara 013867 1350 1370 1340 17751 17106 1735 1670 See next page for applicable notes b 14 Table 6 Model 48KH KL Air Delivery cfm at Indicated External Static Pressure and Voltage Cont EXTERNAL STATIC PRESSURE E in wg UNIT BLOWER D METER LL vise 2 hte ad NEU PHASE 60 He sited 04 os os o7 os joo 01102 T 195 1400 1385 1365 1340 1305 11730 1720 1395 1380 1355 1330 1290 11728 1710 1665 1625 1586 1 1530 1476 11970 1945 1648 1600 1550 1500 1440 1950 1920 1795 1750 1700 1645 1590 12178 2130 1765 1715 1665 1615 156C 12130 2085 1700 1678 Ies ss 1685 1660 1625 1585 1910 1878 1825 1775 1889 1840 4 1790 41735 2085 2030 1970 11905 2035 1980 1920 11855 Low i i 208 KHO48 230 3 Med mammenn eR ins MN mnm i srt ai t is c m i i 41985 1585 1580 1560 1530 1495 _ Cool i i 1585
7. 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 proper electrical instru mentation Refer to unit wiring label when making these checkouts NOTE Refer to heating and or cooling sequence of operation in this publication asanaidindetermining proper control operation l Lt 8 o d al amp l Fig 11 Position of Electrode to Pilot 21 Refrigerant Circuit Annually inspect all refrig erant tubing connections and unit base for oil accu mulations Presence of oil generally indicates a refrigerant leak If oil is detected or if low cooling performance is suspected leak test all refrigerant tubing using an electronic leak detector halide torch or liquid soap solution If a refrigerant leak is detected see Unit Preparation Refrigerant Leaks If no refrigerant leaks are found and low cooling performance is suspected see Cooling Section Start up and Adjustments Checking and Adjusting Refrigerant Charge section Gas Input Gas input does not require checking unless improper heating performance is suspected If a problem exists refer to Heating Section Start up and Adjustments section Evaporator Airflow Heating and or cooling airflow does not require checking unless improper performance is suspected If a problem exists be sure all supply and return air grilles are o
8. table compare desired superheat temperature with suction low side operating pressure psig to determine proper suction tube temperature 7 Compare actual suction tube temperature with proper suction tube temperature Using a tol erance of 5 F add refrigerant ifactual tempera ture is more than 5 F higher than proper suction tube temperature or remove refrigerant if actual temperature is more than5 F lower than required suction tube temperature NOTE If the problem causing inaccurate readings is a refrigerant leak see Unit Preparation Refrig erant Leaks section of these instructions INDOOR AIRFLOW AND ADJUSTMENTS Models 48KH KL end discharge units have direct drive blower motors All motors are factory connected to deliver proper heating and cooling air flows at normal external static pressures except for some 208 v applications Table 5 shows heating airflow at various tempera ture rises Table 6 shows both heating and cooling airflows at various external static pressures for Models 48KH KL direct drive units Refer to these tables to determine airflow for system being in stalled See Table7 for rated cooling and heating airflows NOTE Be sure all supply and return air grilles are open free from obstructions and adjusted properly NOTE When operating the 208 230 volt 3 phase version of Models 48KH048 48KL060 and 48KH 060 at 208 volts lead connections of blower motor must be changed as indi
9. 155 1575 1550 1515 1475 KLOG0 230 1 epos opns NE eei teeuimeshzi M j2975 2280 2185 2095 2000 ol x t g Sa a h 12270 2186 2100 2016 1930 pu EM uer 1880 1875 1860 1825 1770 ds 1865 1840 1790 1725 2130 2075 2015 1955 1890 KHOEO ME RN 2075 2025 1965 1900 1835 2260 2180 2095 2010 2175 2100 2020 1945 2345 12255 p M IN E RE ERREUR RE Air delivery values are without air filter Deduct field supplied air filter pressure drop to NOTE Do not operate iss unit at a cooling airflow that is less than 350 fpm per each obtain external static pressure available for ducting 12 000 Btuh of rated cooling capacity Indoor coil icing may occur at airflows below this tHeating airflow values are with a dry coil Cooling airflow values are with a wet coil These airflow values are at the factory heating and cooling blower motor speed setting ini A dash indicates portions of the table that are beyond the blower motor capability or that are not applicable thermostat simultaneously energizes pilot valve stops and burner flames go out Gas flow thru pilot part of gas valve and pilot igniter Energized pilot gas valve also stops and pilot flame goes out a it ilot pas Valys permis gas to Howto pilot Time delay heat relay de energizes however there NOTE Pilot gas valve is
10. CAUSE REMEDY _ uU Compressor and con Power failure Call power i company denser fan will not start Fuse blown or circuit breaker Replace fuse or reset circuit breaker tripped ARCEM Defective thermostat contactor Replace component i transformer or control rol relay A e a a ee Insufficient line ne voltage Determine cause and correct 7 Incorrect or r faulty wiring Check wiring diagram and rewire re correctly Thermostat setting too high Lower thermostat se setting 1g below W room n temperature _ Compressor will not start Faulty wiring or loose connections Check wiring and repair or replace but condenser fan runs in compressor circuit AN N Compressor motor burned out Determine cause Replace compressor j Seized or internal overload open l l ES i Defective run start capacitor Determine cause and replace overload start relay j One leg of 3 phase power dead Determine cause Replace fuse or reset circuit breaker Compressor cycles other Refrigerant overcharge or Blow refrigerant evacuate system and recharge to than normally satisfying undercharge nameplate MEE thermostat Defective compressor Determine cause replace Insufficient line voltage Determine cause gt and correct sta cere alfa i Blocked condenser Determine cause and correct TERR pcs capacitor Determine cause and replace EM 7 overload or start relay Fe TEAS E TES Defective thermostat Replace thermostat
11. Replace compressor Remove restriction we on won Aten ALONSO EIS Restriction in 1 liquid tube Excessive suction pressure High heat load r P th RE Check for source and eliminate i me m M _ Compressor valves leaking Replace cc compressor Refrigerant overcharged _ Purge e excess refrigerant Dirtya air filter Replace filter Low refrigerant charge Check for leaks r repair and d recharge Metering device or low side restricted a onec epu emos cma e rr P paa rasa came ete Suction pressure too low Nx D a Remove s source of restriction e namme r mm c M Hn Increase air quantity Check filter replace if necessary Reset thermostat Temperature too low in condi tioned area Outdoor ambient b below 55 Fo a Insufficient evaporator airflow Install accessory low ambient kit Field installed filter drier i Replace l restricted 23 af For replacement items use Carrier Specified Parts Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Form 48KH KL 1SI New PrintedinUSA 11 82 PC 101 CatalogNo 534 843
12. a D a e j SUPPLY Lo ma am am me amm m m RED RY NOTE C c ve EQUIP GND c BRN 7 CAP za 4 e YEL RED PEK N ORN QT ST nM BLK ORN ond BLK 7 IFR YEL YEL q Bk FMC NOTE 6 COOLING HEATING BLK BRN Hcr RED VIO ju A RED SY ORN ait T PRI J BLK TRAN CONTROL CENTER I SINGLE STAGE HEAT amp SINGLE STAGE COOL R Cx YEL S GRN BRN GRN GRN DISCONNECT I 5 4 3 p NEC lj 7 H ls i iso q Ps lt r 2 Lae POWER mam mam um uum O D DDD ek WIRING ee GND re C C FIELD 2 EPA PI LL bee ate CONTROL a ee WIRING B uid TRAN Transformer NOTES Capacitor Bl Wire Sleeve COMP Compressor l 1 Use copper conductors only GV Gas Valve O Component Connection Unmarked 2 Compressor and fan motors thermally protected IFM Indoor Fan Motor Component Connection Marked 3 Transformer pigtails red 208 v orange 230 v insulate IFMC Indoor Fan Motor Capacitor u unused lead IFR Indoor Fan Relay Cooling Field Wiring IFSS Indoor Fan Safety Switch eS Field Ground Wiring 4 Neutral for 240 416 v system for Canada only LS Limit Switch mmm Field P Wiri 5 If any of the original wire furnished must be replaced OFM Outdoor Fan Motor z l Midi iic it should be replaced with wire of the same type or A PI Pilot Igniter ER Field Splice its equivalent PS Pressure Switch Q Junction 6 Fan motor pigtails r
13. and unit divider panel 4 Make following inspections a Inspect for shipping and handling damages such as broken lines loose parts disconnected wires etc b Inspect for oil at all refrigerant tubing connec tions and on unit base The presence of oil generally indicates a refrigerant leak Leak test all refrigerant tubing connections using electronic leak detector halide torch or liquid soap solution If refrigerant leak is detected see Refrigerant Leaks in next part of this section c Inspect all field and factory wiring connec tions Be sure connections are completed and tight d Inspect coil fins If damaged during shipping and handling carefully straighten fins with a fin comb 5 Verify the following conditions a Make sure gas supply has been purged and all gas piping has been checked for leaks b Make sure outdoor fan blade is correctly posi tioned in fan orifice B ades should clear fan motor by no more than 1 4 inch c Make sure air filter s is in place d Make sure condensate drain pan is filled with water to ensure proper drainage e Make sure all tools and miscellaneous loose parts have been removed 6 Replace all access panels Unit is now ready for initial start up REFRIGERANT LEAKS Proceed as follows to repair a refrigerant leak and to charge the unit 1 Locate leak and ensure that refrigerant system pressure has been relieved 2 Repair leak following accepted prac
14. ie eot hn 0 6 platelet tts nier olus RU Elson Sede Rara Side opposite squirts sch reo nde a RE ROLE E I 2 6 piti g ons Blower access panel side 05 eme 2 6 n i ite blower access panel sssessrsresrereress 2 A 1455 8 45 8 5 5 6 8 6 0 3 8 pai uM 0 B 2 6 3 4 3 4 3 8 3 8 5 8 3 8 5 8 ie f Cc 3 2 1 8 3 5 1 8 3 10 1 8 4 6 1 8 NOTE Provision must be made for fresh ambient air to reach the D 1 4 1 7 2 0 2 8 outdoor coil without recirculation of the air from the outdoor fan E ga iA 121 174 1 1 1 4 1 1 174 discharge F O 7 1 4 O 8 7 8 O 8 7 8 O 8 7 8 G 0 11 0 10 0 10 0 10 1 2 H 1 3 1 4 1 3 1 4 1 8 1 4 1 8 1 4 J 1 10 5 8 2 0 11 16 K 0 1 3 32 0 1 ida ZA 0 1 3 8 O 1 3 8 Weight Data ARMES 4 OPERATING SHIPPING D C A Bic p WT Ib WT Ib 82 79 78 81 320 330 KLO24 T 83 81 79 82 325 335 KHO24 96 94 91 94 375 385 KLO30 97 93 91 94 375 385 KHO30 97 93 90 92 372 385 KLO36 98 97 92 93 380 390 KHO36 122 120 116 117 475 485 KLO42 108 105 102 105 420 430 KHO42 113 111 107 109 440 450 A B KLO48 130 135 1137 133 535 545 KHO48 134 139 144 138 555 565 KLO60 148 144 139 144 575 585 KHO60 155 151 148 151 605 615 disse ses sees E bte rmn pea EE i sonne nitet etitm aas oe quens put tte tito TIS 1 Fig 4 Dimensions and Clearances ft in o COMBUSTION AIR SHR
15. unit rating plate for maximum fuse size and minimum circuit amps ampacity for wire sizing Table 3 shows recommended wire sizes and lengths based on rating plate data The field supplied disconnect switch box may be mounted on unit over the high voltage inlet hole in control corner panel See Fig 4 Proceed as follows to complete the high voltage connections to unit 1 Connect ground lead to chassis ground connec tion when using a separate ground wire 2 Run high voltage leads into unit control box and connect to contactor See unit wiring label and Fig 6 and 8 NOTE On 3 phase units connect third high voltage lead to brown high voltage pigtail lead See unit wiring label and Fig 8 SPECIAL PROCEDURES FOR 208 V OPERATION For operation on 208 volts disconnect orange transformer primary lead from contactor See unit wiring label and Fig 6 Remove tape and cover from terminal on end of red transformer primary lead Save cover Connect red lead to contactor terminal from which orange lead was disconnected Sa y Seam ot cn cp CASSIS OTOL SH 10e _ Table 3 Electrical Data 60 Hz Meere qi S C iota ERE U MINIMUM d MINIMUM MAX WIRE MODEL SERIES V PH POEMES SEINE FOR WIRE WIRE SIZE AWG LENGTH x P 60 or 75 C Copper ft klore 3008E 208 230 1 5 MEME MER _KLO24 300BE 208 230 1 172 KHO24
16. 0 655 635 610 585 CAE 208 Cool 690 670 650 30 605 580 SEOSO 230 1 Heat 1325 1270 1210 1150 1090 1020 Cool 1270 1220 1165 1110 1045 Heat 1125 1070 1015 955 208 Cool 1085 1035 985 925 KHO30 230 1 asats ae tec cona s a Es Heat 1225 1165 1105 1040 Cool 1175 1120 1065 1005 PETS stimme deem ena animse v LR cad i Heat 950 945 940 930 208 Coo 945 940 935 925 910 890 230 1 a Heat 1570 1500 1425 1355 1280 1200 a Coolt 1475 1410 1345 1275 1205 1140 irae k Heat 1165 11287 1100 1078 10401 998 830113657 71348 208 ow Coo 1155 1110 1085 1050 1015 960 855 11345 1320 i nea Magus vieni oe ea coo t LL EE oo ow Im eU ERE o 230 3 High Heat 1525 1415 1375 1330 1280 1220 1135 1620 1580 gni Coolt 1475 1370 1325 1280 1225 1155 1045 1560 1520 puis Doce ict 1185 1175 1160 1165 1155 1 ee a 1535 1500 d SE l1485 l1450 Heat 1280 1215 1190 13160 7 71 4810 11480 Coolt 1265 1195 1165 1130 44475 1440 Heat 1825 1630 1540 1425 11908711845 Cool 1735 1515 1410 1270 bo 14790 Heat 1275 j 1240 1220 1195 1135 1100 1505 Coolt 1270 1225 1205 117
17. 25 KLO48300BE 1600 020 925 KLO48500CE 1600 0 20 925 KLO48600CE 1690 0 20 925 KH048300BE 1600 O 20 1155 KH048300BF 1600 0 20 1445 KHO48500CE 1600 0 20 1155 KHO48500CF 1600 0 20 1445 KL060300BE 1980 0 20 1155 KH060300BE 1980 O 20 1155 0 20 KH060300BF 1980 Rated in accordance with ARI Standard 210 81 See Make Wiring Connections Special Procedures for 208 v Operation section for proper procedures to insulate an unused electrical lead When installing a 208 or 230 v direct drive unit that is factory connected for heating and cooling speeds that are not the same and same speed for both heating and cooling is required for a particular application connect appropriate color coded lead to terminal2 of cooling relay and connect a field supplied jumper between heat relay and terminal 2 of cooling relay Be sure to properly insulate unused motor lead s CONTROLS All compressors have the following internal protection controls High Pressure Relief Valve This valve opens when pressure differential between low and high side becomes excessive Compressor Overload This overload interrupts power to compressor when either current or internal temperature becomes excessive and automatically resets when internal temperature drops to a safe level This overload may require up to 60 minutes or longer to reset therefore if internal overload is suspected of being open disconnect electrical power to unit and ch
18. 300BE 208 230 1 185 KLO30 300BE 208 2301 198 KHO3O0 300BE 208 2301 Doa 300BE 208 230 1 243 KLO36 500CE 208 230 3 174 600CE __ 460 3 AS 300BE BF 208 230 1 233 i dado je 208 230 3 183 300BE 208 230 1 28 8 KLO42 SoocE 208 230 8 187 249 3008E 208 230 1 286 eon SOOCE 208 230 3 187 213 _300BE 208 2301 t KLO48 500CE 208 230 3 24 8 j 9900E 1 3009 A D 300BE BF 208 230 1 29 3 iind BOOCE CF 208 230 3 _ 228 KLO60 300BE 230 1 E 6 155 100 f KHO60 _300BE BF L 230 1 362 6 81 150 120 t weemenr ec dece a cei x e d Wire sizes are based on 60 or 75 copper wire at 86 F 30 C ambient temperature and the minimum ampacity If other than 60 or 75 C copper wire is used if the ambient temperature is above 86 F 30 C or if the voltage drop of the wire exceeds 296 of the total rated voltage determine the wire size from the minimum SINGLE STAGE HEAT amp COOL MANUAL CHANGEOVER ampacity shown and the National Electrical Code Wire lengths shown are measured one way along the wire path between the unit and service panel TData in parentheses are based on 60 C copper wire Data in brackets are based on 75 C copper wire SINGLE STAGE HEAT amp COOL AUTOCHANGEOVER JUMPER 7 exu CONTACTOR TERMINALS FIELD SPLICE SEE UNIT WIRING LABEL POWER POWER SUPPLY SUPPLY D gt LOW VOLTAGE b LOW VOLTAGE PIGTAIL LEADS PIGTAIL LEAD
19. 5 1110 1075 1490 Heat 1625 16 51 1848 1500 1455 1350 11285 1845 Cool 1590 1490 1445 1395 1306 1245 11770 1855 1785 1715 1740 1675 1610 820 795 760 815 790 750 Heati i 2035 Cool 1915 Heat 855 Cool 855 Do mede met Heat 1700 1570 1475 1645 1545 1570 1495 2130 12070 148C 11410 1995 1940 1875 1035 1030 1495 1425 1355 1770 Coolt 1635 1440 1378 1305 1695 Heat 970 Cool 965 ES Heat 2040 Cool 1950 g 935 310 880 835 786 1190 940 930 905 870 820 765 1190 1785 1715 1640 0 1886 1 1486 2 1705 1635 1555 1465 5 1380 2030 Heat 1410 1255 1175 1580 Cool 1390 1215 1120 Ea 1535 230 1 BE Heat 1690 15251 1450 ST 2 2x 11776 igh Coolt 1535 1465 1390 E Ze 11705 KH042 Mette ne M ren ere Heatt 1400 1395 1385 1365 1895 1246 1176 5 1650 1305 Cool 1395 1385 1370 1345 1260 1208 1145 1630 1250 1655 1615 b 1505 1440 1 1376 1455 1615 1570 1455 1390 1320 1550 1470 1360 TES T1920 1845 1770 1628 1550 ev Lom cub opes 1790 1725 1150 1150 1150 1150 1150 1145 1135 1115 11395 1395 1395 211385 1370 11358 1330 1300 1180 1150
20. OUD ASSEMBLED Fig 5 Vent Cap Assembly Step 2 Make Gas Piping Connections The gas supply pipe enters unit thru access hole provided See Fig 4 for location The gas connection to unit is made to the 1 2 in FPT gas inlet on gas valve See Fig 6 for inlet location Install a separate gas supply line that runs directly from meter to heating section Do not use cast iron pipe Check local utility for recommendations con cerning existing lines Choose a supply pipe that is large enough to keep pressure lossaslow as practical Never use pipe smaller than the 1 2 in FPT gas inlet on gas valve When installing gas supply line observe local codes pertaining to gas pipe installations Refer to National Fuel Gas Code ANSIZ223 1 1980 or NFPA 54 1980 in absence of local building codes Adhere to following pertinent recommendations 1 Avoid low spots in long runs of pipe Grade all pipe 1 4 in in every 15 ft to prevent traps Grade all horizontal runs downward to risers Use risers to connect to heating section and to meter 2 Support all piping with appropriate hangers etc Use a minimum of one hanger inevery 6 feet For pipe sizes larger than 1 2in follow recom mendations of national codes oe OC ao 1 Control Transformer 11 Pilot Tube 2 Compressor Contactor 12 Model 646A X Gas 3 Ground Lug Valve 4 Dual Run Capacitor 13 Pressure TapPipePlug for compressor and 14 Gas Va
21. Route blower motor leads into control compartment and reconnect all blower motor leads to proper termination points in unit control box Replace panels 5 Restore electrical power then gas supply to unit Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles Heating Section Ensure dependable and effi cient heating operation by inspecting heating section before each heating season and cleaning when neces sary Proceed as follows 1 Turn off gas supply then disconnect electrical power to unit 2 Inspect and clean heating section a Remove control access door b Remove unit top following procedures under Top Removal c Remove secondary air shield flue baffles pilot and burners Flue baffles may be re moved after partial loosening of collector front panel Inspect and clean all of these com ponents Be sure to remove any residue that may have collected on a component d Clean flue ways with brush and or vacuum and inspect heat exchanger for leaks and cracks e Inspect indoor air passages in unit for cleanli ness and check tightness of screws and parts f Replace all components removed in step c and replace unit top 3 Restore electrical power then gas supply to unit Start heating cycle and adjust burner air shutters See Heating Section Start up and Adjustments Adjusting Burner Air Shutters 20 ef 4 Inspect gas control area for gas leaks
22. S CONTROL BOX FIELD SUPPLIED FIELD SUPPLIED EE HIGH VOLTAGE DISCONNECT PER NEC HIGH VOLTAGE DISCONNECT P PIGTAIL LEAD CONTACTOR TERMINALS PIGTAIL LEAD 3 PHASE SEE UNIT WIRING LABEL UNITS ONLY 3 PHASE UNITS ONLY Ec Field Low Voltage Wiring aes i ei mium Field High Voltage Wiring Factory Low Voltage Wiring Factory High Voltage Wiring NOTE For manual changeover applications use thermostat part no HHO1ADO42 with subbase part no HH93AZ042 or thermostat part no HHO1ADO40 with subbase part no HH93AZ040 For automatic changeover use thermostat part no HHO7AT174 with subbase part no HH93AZO96 or thermostat part no HH10ADO41 with subbase part no HH93AZ041 Fig 8 High and Low Voltage Connections eS B Using cover removed from red lead insulate loose terminal on orange lead Wrap cover with electrical tape so that metal terminal cannot be seen NOTE For some 48K H K L units the factory wired blower motor speed connections may require changing for 208 v operation to ensure adequate air flow at the rated external static pressure See unit wiring label Insulate all unused motor leads follow ing same procedures described for transformer leads LOW VOLTAGE CONNECTIONS Use a suit able room thermostat as specified on unit wiring label Locate room thermostat on an inside wall in space to be conditioned where it will not be subjected to either a cooling or heating source or direct exposure to sunlight Mount ther
23. S MAR MANIFOLD NATURAL GAS LP Propane GAS PRESSURE ad PA al tina Heating _ in wg Orifice B mai aar Orifice out P N P N Natural ry uP LP Prop Btuh _ Btuh 3 5 i 105 5 LH32D8205 40 000 LH32DB201 40 00 000 3 B 10 5 LH32DB205 60 000 A 60 000 35 10 5 1H32DB200 LH32DB201 80 000 7 35 105 LH32DB200 LH32DB201 vo 100 000 35 105 LH32D8207 Not Available 35 1 10 5 1LH32DB200 120 000 LH32DB 120 000 Not Available For altitudes above 2000 feet reduce input rating 4 for each 1000 feet above sea level 35 105 LH32D8207 180 000 CA After air shutter adjustments have been com pleted observe that flames on each burner are light blue and soft in appearance and that flames are same height along entire length of each burner See Fig 9 MACE i opio OUTER MANTLE OUTER CONE BURNER MANIFOLD Fig 9 Burner Flames BLOWER HEAT RELAY OPERATION Heat ing relay see Fig 6 and unit wiring diagram is located in the control box and adjusts to permit either longer or shorter OFF cycles The ON cycle automatically adjusts as OFF cycle changes Adjust ing lever on relay is factory set at center position to provide optimum performance for most installa tions On unusual installations or where line voltage is considerably above or below rated voltage an increase or decrease may be required for length of time blower remains on To in
24. a solenoid consisting of a Isa built in delay before heat relay contacts open and PICK and a HOLD coil Both coils must be ener blower continues to move air across heat exchanger gized to open pilot gas valve but only HOLD coil to help optimize heating efficiency When heat relay must be energized to keep valve open contacts open circuit to blower motor breaks and motor stops Unit is in a standby condition waiting for next call for heat from thermostat LIMIT AND PRESSURESWITCHES Furnace Energized pilot igniter sends ahigh voltage charge to pilot electrode part of pilot Pilot electrode pro duces a spark that ignites pilot Flame sensing monometal switch in pilot proves presence of pilot flame Approximately 40 to 60 seconds after pilot limit switch see Fig 10 closes gas valve if leaving flame is established normally closed contacts of air temperature exceeds KOE pilot open and normally open contacts close Normally closed limit switch completes control Switching of pilot contacts de energizes pilot igniter circuit thru pigtail lead W to gas valve 5 F See and PICK coil of pilot solenoid HOLD coil of Fig 10 Should leaving air temperature riseto 175 F pilot solenoid is still energized therefore pilot gas switch opens and W control circuit breaks Any valve remains open and pilot remains lit interruption in W control circuit instantly closes gas valve and stops gas flow to burners and pilot Blower motor continues to r
25. al other than wood flooring CONDENSATE DISPOSAL NOTE Be sure condensate water disposal methods comply with local codes restrictions and practices Models 48KH KL dispose of condensate water thru a 3 4 in MPT drain fitting See Fig 4 for location Install a 3 in trap at the drain fitting to ensure proper drainage See Fig 3 Make sure trap outlet is at least 2 in lower than unit drain pan connection to prevent pan from overflowing Prime trap with water If installation requires draining the condensate water away from unit connect a drain tube using a minimum of 7 8 in OD copper tubing 3 4 in galvanized pipe or 7 8 in plastic pipe Do not undersize the tube Pitch drain tube downward at a slope at least in for every 10 ft of horizontal run Be sure to check drain tube for leaks Condensate water can be drained directly onto roof in rooftop installations where permitted or onto a gravel apron in ground level installations When using a gravel apron make sure it slopes away from the unit Fig 3 Condensate Trap VENTING The vent cap combustion air shroud and flue assembly are shipped ineither the blower or control compartment Vent screen is taped to blower housing Remove access doors to locate assemblies See Fig 4 for door locations AA NOTE Screw holes in flue assembly and unit top are positioned to ensure proper orientation when installed Refer to Fig 5 and install vent cap as follow
26. ate at high speed until outdoor temperature drops to 61 4 F At 61 F or lower fan motor operates at low speed and permits cooling operation down to 40 F Cooling cycle remains on until room temperature drops to a point slightly below cooling control set ting of room thermostat At this point thermostat cooling bulb tilts and breaks circuit betweenthermo stat terminal R to terminals Y and G These open circuits de energize contactor coil and relay coil Condenser compressor and blower motors stop Unit is in a standby condition waiting for next call for cooling from room thermostat 18 e SERVICE To ensure continuing high performance and to minimize possibility of premature equipment failure periodic maintenance must be performed on this equipment This combination heating cooling unit should be inspected at least once each year by a qualified service person NOTE TO EQUIPMENT OWNER Consult your local dealer about the availability of a maintenance contract The minimum maintenance requirements for this equipment are as follows l Inspect air filter s each month Clean or replace when necessary 2 Inspect cooling coil drain pan and condensate drain each cooling season for cleanliness Clean when necessary 3 Inspect blower motor and wheel for cleanliness and check lubrication each heating and cooling season Service when necessary 4 Check electrical connections for tightness and controls for proper
27. cated on unit wiring label to ensure proper airflow Heating and or cooling airflow of 208 230 v direct drive blower motors can be changed by changing the lead connections of blower motor Motor leads are color coded as follows black high speed blue medium speed red low speed NOTE Some direct drive blower motors do not have lead for medium speed Factory connections and available optional connections are shown in Table 6 For all units motor lead connected to heat relay determines heating speed and resulting airflow and motor lead connected to cooling relay determines the cooling speed and resulting airflow See unit wiring label To change heating and or cooling speed connect appropriate color coded lead to appropriate relay Be sure to properly insulate any unused motor lead 17 Table 7 Rated Cooling and Heating Airflows pt PER NF ar e RATED EXTERNAL RATED COOLING STATIC HEATING MODEL 48 AIRFLOW PRESSURE AIRFLOW l i cfm in wg cfm KLO18300BE 600 010 555 KL024300BE 825 0 10 555 KH024300BE 825 0 10 835 KL030300BE 1088 O15 465 KH030300BE 1088 0 15 835 KLO36300BE 1200 0 15 835 KLO36500CE 1200 015 835 KLO36600CE 1200 015 835 KH036300BE 1215 0 15 1155 KH036300BF 1215 0 15 1445 KH036500CE 1215 015 1155 KH036500CF 1200 015 1445 KLO42300BE 1400 015 695 KL042500CE 1400 015 695 KH042300BE 1400 015 925 KH042500CE 1400 015 9
28. correct R 22 charge for best performance is charge that results in a suction gas superheat of 5 F at compressor inlet when unit is operating at ARI rating conditions of 95 F db outdoor and 80 F db 67 F wb indoor A superheat charging label is attached to outside of compressor access door Label includes a Field Superheat Charging Table and a Required Suction Tube F temperature chart An accurate superheat thermocouple or thermistor type thermometer a sling psychrometer and a gage manifold are required when using super heat charging method for evaluating unit charge Do not use mercury or small dial type thermometers because they are not adequate for this type of measurement Proceed as follows 1 Remove caps from low and high pressure service fittings 2 Using hoses with valve core depressors attach low and high pressure gage hoses to low and high pressure service fittings respectively 3 Start unit in cooling mode and let unit run until system pressures stabilize 4 Measure and record the following a Outdoor ambient air temperature F db b Evaporator inlet air temperature F wb c Suction tube temperature F at low side service fitting d Suction low side pressure psig 5 Using Field Superheat Charging Table compare outdoor air temperature F db with evaporator inlet air temperature F wb to determine desired system operating superheat temperature 6 Using Required Suction Tube F
29. crease blower opera tion time move adjusting lever toward right hand position To decrease blower operation time move lever toward left hand position AIRFLOW AND TEMPERATURE RISE The heating section of each size of unit is designed and approved for heating operation within temperature rise range stamped on unit rating plate Table5 shows approved temperature rise range for each unit and air delivery cfm at various tem perature rises Heating operation airflow must pro duce a temperature rise that falls withintheapproved range Refer to CoolingSectionStart upand Adjust ments Indoor Airflow and Airflow Adjustments to adjust heating airflow when required HEATING SEQUENCE OF OPERATION The following sequence of operation pertains to all 208 230 volt 3 phase units however the sequence of operation of single phase and 460 volt units is very similar Refer to the wiring diagram in Fig 10 NOTE Althoughactualunit wiring may vary slightly from that shown in Fig 10 sequence of operation will not be affected With room thermostat selector switch at HEAT position and FAN switch at AUTO position heat ing sequence of operation is as follows Models 48KH KL have an intermittent electric spark ignition system without a standing flame When manual control valve is opened gas flows to solenoid valve chamber of gas valve Unitis nowina standby condition and ready for a call for heat from room thermostat When room t
30. d condensate drain by removing all foreign matter from pan Flush pan and drain tube with clear water Do not splash water on insulation motor wiring or air filter s If drain tube is restricted clear it with a plumber s snake or similar probe device The bottom of drain tube has a 1 8 in diameter hole This hole is located in the portion of the drain tube that runs thru drain pan Clean this hole witha stiff wire that has a 3 8 in long 90 degree bend Condenser Fan Inspect fan blades for cracks or bends each year Ensure that blades clear the motor by exactly 1 4 inch If blade assembly has slipped down motor shaft adjust fan position on motor shaft by loosen ing setscrew s then moving blade assembly up Be sure setscrew s is on flat s of shaft before tightening Electrical Controls and Wiring Inspect and check electrical controls and wiring annually Be sure to turn off gas supply and then electrical power to unit Remove control blower and compressor com partment access panels to locate all electrical con trols and wiring Check all electrical connections for tightness Tighten all screw connections If any smoky or burned connections are noticed dis assemble the connection clean all parts restrip wire end and reassemble connection properly and securely After inspecting electrical controls and wiring replace all panels Start unit and observe atleast one complete heating cycle and one complete cooling
31. e Observe that after built in time delays the pilot automatically lights burners light and blower motor starts Observe that burners and pilot are extinguished and that after a built in delay blower motor stops when heating control setting of thermostat is satisfied GAS INPUT The rated gas inputs shown in Table 4 are for alti tudes from sea level up to 2000 ft above sea level These inputs are based on natural gas with a heating value of 1050 Btu cu ft at 0 65 specific gravity or LP propane gas with a heating value of 2500 Btu cu ft at 1 5 specific gravity For elevations above 2000 ft reduce input 4 for each 1000 ft above sea level When gas supply being used has a different heating value or specific gravity refer to Carrier training manuals national and local codes or contact your Carrier distributor or dealer to determine required orifice size ADJUSTING GAS INPUT The gas input to unit is determined by measuring the gas flow at the meter or by measuring the manifold pressure Measuring the gas flow at the meter is recommended for natural gas units Manifold pressure must be measured to determine the input of LP propane gas units Measuring Gas Flow at Meter Method Natural Gas Units Minor adjustment can be made by changing manifold pressure Manifold pressure must be maintained between 3 2 and 3 8 in wg If larger adjustments are required change main burner orifices following recommendations of natio
32. e to increase gas input or turn regulator adjustment screw counterclockwise to decrease input Mani fold pressure must be between 3 2 and 3 8 in wg UNSAFE OPERATION OF THE UNIT MAY RESULT IF MANIFOLD PRESSURE IS OUTSIDE THIS RANGE 3 Replace vented seal cap on gas valve 4 Turn off gas supply to unit Remove manometer from pressure tap Replace pipe plug on gas valve Turn on gas to unit Check for leaks Measuring Manifold Pressure LP Propane Gas Units The main burner orifices on a propane gas unit are sized for the unit rated input when manifold pressure is 10 5 in wg Proceed as follows to adjust gas input on an LP propane gas unit 1 Turn off gas to unit 2 Remove pipe plug on gas valve outlet identified as PRESS TAP then connect manometer at this point 3 Turn on gas to unit 4 Remove vented seal cap over REG ADJ screw on gas valve 5 Adjust regulator adjustment screw for a manifold pressure reading of 10 5 in wg Turn adjusting screw clockwise to increase manifold pressure or turn adjusting screw counterclockwise to de crease manifold pressure 6 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 ADJUSTING BURNER AIR SHUTTERS After burners have operated at full input for at least 10 minutes adjust primary air to each burner to ensure optimum heating performance Make these adjustments when unit is bein
33. eck circuit thru overload with an ohm meter or continuity tester COOLING SEQUENCE OF OPERATION The following sequence of operation pertains to all 208 230 volt 3 phase units however sequence of opera tion of single phase and 460 volt units is very similar Refer to wiring diagram in Fig 10 NOTE Although actual unit wiring may vary slightly from that shown in Fig 10 sequence of operation will not be affected With room thermostat selector switch in the COOL position and fan switch in AUTO position cooling sequence of operation is as follows When room temperature rises to a point slightly above cooling control setting of thermostat thermo stat cooling bulb tilts and completes circuit between thermostat terminal R to terminals Y and G These completed circuits thru the thermostat connect contactor coil thru unit wire Y and relay coil thru unit wire G across the 24 volt secondary of transformer The 2 sets of normally open contacts of energized contactor 2D close and complete circuit thru com pressor motor 3F and condenser fan motor 3DI Both motors start instantly The set of normally open contacts of energized relay closes and completes circuit thru evaporator blower motor Blower motor starts instantly NOTE Three phase units are equipped with a 2 speed condenser fan motor and a temperature actuated switch Fan motor operates at high speed when outdoor temperature rises to 75 3 F and continues to oper
34. ed low black high insulate un QT Quadruple Terminal used lead ST Start Thermistor Junction Thermostat to Subbase TDR Time Delay Relay Adjustable Heating Alternate Start Thermistor Wiring 7 Pressure switch furnished with propane units only Fig 10 Typical Wiring Diagram 48KH030300 shown 13 Table 6 Model 48KH KL Air Delivery cfm at Indicated External Static Pressure and Voltage Axesor Menem ann Memmius UM ee ma ewe o ee HAN MR m unns e nues seen o HM de sR Ha a Ete HH nian nunt FF REET Gat TC TT ONO SRO T ELE ncn PX MUR EERE EXTERNAL STATIC PRESSURE in wg UNIT BLOWER MODEL vorrs MOTOR con 208v au 230V or 460V doo en 0 PHASE 60 Hz SPEED i 2 0 pa 08 oo o1 02 os o4 Tos os T 565 510 805 765 725 675 625 i n 535 480 720 680 635 585 kids ose rei NEAR abe 230 1 610 555 570 520 700 l 725 675 620 KLO24 20g wre fens zur i 230 1 820 760 700 790 730 668 835 780 ac dn a5 gis 780 71 920 880 84 208 835 800 765 890 860 NOLS 023993 Rea 11125 11076 11030 980 936 880 1118 1068 1018 868 818 1 Cool 1080 1035 990 950 900 855 1075 1030 980 An eov uu ie Hmmm om eo Nertoowesguesae dem eee oe pras eae esce EI E Heatt 700 68
35. ed tapping that is accessible for test gage connection imme diately upstream from gas supply connection to heating section and downstream from main manual shutoff valve 6 Install ground joint union close to heating sec tion between gas valve and external manual main shutoff valve 7 Pressure test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit NOTE When pressure testing the gas supply system after the gas supply piping has been con nected to the unit gas valve the supply piping must be disconnected from the gas valve during any pressure testing of the piping systems at test pressure in excess of 0 5 in wg When pressure testing the gas supply piping system at test pres sures equal to or less than 0 5 in wg the unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening ground joint union 8 Where permitted by local codes use an approved corrugated metal tubing gas connector between rigid gas piping and gas valve UMEN Check for gas leaks at all field installed and factory installed gas lines after all piping connec tions have been completed Use soap and water solution or method specified by local codes and or regulations et Step 3 Make Duct Connections Model 48K H KL has duct flanges onthe supply and return air openings on side of unit See Fig 4
36. emperature drops to a point slightly below heating control setting of room thermostat the thermostat heating bulb tilts and completes cir cuit between thermostat terminals R and W This completed circuit between R and W thru the room Table 5 Air Delivery cfm at Indicated Temperature Rise and Rated Heating Input RAG MAREE De o von f MP ove om Heating EP WEN LU coul MDC MODEL 9 input Btuh 35 37 39 41 43 51 53 55 57 59 61 63 65 ez 69 71 73 75 T T kois 40000 794 751 712 678 646 567 545 E 487 471 456 441 427 veles d er KLOo24 40 00 794 751 712 678 646 567 45 x KHO24 60 000 1180 1126 TO68 1016 969 850 817 786 758 731 706 KLO30 40 000 EXPORTERS S a eae eens eee 567 545 524 505 487 471 455 eal har T J KHO30 60 000 1790 1126 1068 1016 969 850 817 786 758 ms eee pues pee emm SI a KL036 60 000 ecl 1126 1068 1016 969 8501 817 786 758 731 706 683 KHO36 100 000 1781 1694 161 1417 1362 1310 1263 1218 1177 1138 1102 1068 1036 1006 573 9511 926 KHO36BF CF 125 000 _ CR 1842 1770 1703 16411 1584 1530 1480 1433 1 1389 1347 1308 1272 1237 1204 Kto42 60 000 Re 860 B17 786 758 731 706 683 661 641 622 604 587 571 556
37. er company for correction of improper voltage and or phase balance 4 When low voltage control wires are run in same conduit as high voltage wires insulate low voltage wires for highest voltage contained within conduit 5 Do not damage internal components when drill ing thru any panel to mount electrical hardware conduit etc 6 Make sure service conductors used between elec trical service panel and field supplied electrical disconnect switch do not have a current capacity less than the copper wire specified and do not create a total voltage drop in excess of 206 of rated voltage of the unit when compressor is operating NOTE When using aluminum conductor from elec trical service to disconnect switch where local codes permit use of aluminum wire make connections in accordance with National Electrical Code Prepare all aluminum wire immediately before installation by brush scratching the wire then coating the wire with a corrosion inhibitor such as Pentrox A Be sure entire connection is completely covered to pre vent an electrochemical reaction that will cause con nection to fail very quickly Do not reduce effective size of wire by cutting off strands to fit wire into a connector Always use properly sized connectors HIGH VOLTAGE CONNECTIONS Unit must have a separate electrical service with a field supplied waterproof fused disconnect switch per NEC mounted near and within sight from the unit Refer to
38. g installed and during routine maintenance inspections at beginning of each heating season Be sure each burner is clean and free of deposits before adjusting primary air Primary air to each burner is regulated by burner air shutter on each burner See Fig 9 for location of burner air shutter With all burners operating adjust primary air to each burner as follows 1 Loosen locking screw that secures air shutter in place on burner then partially close air shutter until a slight yellow tip appears on top of burner flames 2 Open air shutter very slowly until yellow tip just disappears then secure air shutter in place with locking screw 3 Repeat steps 1 and 2 for each burner Table 4 Rated Gas Inputs at Indicated Manifold Pressures Wee senem quy SMASH umm emm seen a msequi ua en unseres sra GAS SUPPLY Capanema ammeessa TURES en I RAN y aeee wae ee a EU PRESSURE in wg ORIFICES Natural T LP Propane n Max Min Max KL018 024 0300 2 50 b xh 6 110 T3071 3 KHO24 030 PEN e KLO36 042 3 50 1136 110 130 KH042 KLO048 4 50 113 6 410 130 KH036 048 ae Tait db duas KLO60 5 50 1361 110 130 KHO36BF CF f y PE KHOA8BF CF 5 501136 110 130 KHOGOBE 6 136 110 7 13 0 KHO60BE 6 50 I KHOGOBF i UB so 136 110 Based on altitudes from sea level up to 2000 feet above sea level Mee o caes stone m ans ARRAN M DNO PM Mia emo AACA OENORO R
39. lve Outlet 15 Gas Manifold 16 Gas Burner condenser fan motor 5 Low Voltage Pigtail Leads 17 Burner Air Shutter 6 Compressor Control 18 Secondary Air Shield Compartment Divider 19 Blower Housing Panel 20 Evaporator Motor Run 7 Igniter Module Capacitor 8 Manual ON OFF 21 Blower Control Com Knob partment Divider 9 Gas Valve Inlet Panel 10 Pipe Plug LP 22 Heating Relay Propane unit pres 23 Cooling Relay sure switch mounts here Fig 6 Model 48KLO36 Side View Partial with Access Door Removed 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 speci fied by local and or national codes Never use pipe thread tape 4 Install a sediment trap in riser leading to the heat ing section See Fig 7 Thisdriplegfunctionsasa trap for dirt and condensate Install trap where condensate cannot freeze Install this sediment trap by connecting a piping tee to riser leading to heating section so that straight thru section of tee is vertical Then connect capped nipple into lower end of tee Extend capped nipple below level of gas controls TEE La NIPPLE CAP Fig 7 Sediment Trap 5 Install an accessible external manual shutoff valve in gas supply pipe within 6 ft of heating section Install a 1 8 in NPT plugg
40. main gas valve is opening Look for loose or broken wiring connections If no deficiency is found _ replace valve assembly ERI continuity ch check to locate break C AA enses amissus cnm Som or replace fi filter as necessary Check gas pressure at manifold Clock gas meter for input If too low increase manifold pressure or replace with correct orifices Mo Replace with proper unit or add additional unit Clean or replace filter or re remove e any restriction deem naransan Use faster speed tap or instali optional blower Dirty air filters clean or replace Registers closed re restricted ductwork open or remove restriction Ed rPr AI Check heat anticipator setting c on thermostat readjust Air shutters on burners closed adjust 1 to soft blue flame senec Check all screws around flue outlets and burner com partment tighten artis HER R Lack of Combustion air r See Installation section Cracked heat exchanger replace Overfired furnace reduce input or change orifices E E Miles QD ense Check orifice to burner alignment rr 1 seni einai m A TROUBLESHOOTING CHART Table 9 Cooling Service Analysis Chart a amice M MM MY ies SYMPTOM l l PROBABLE
41. mostat 4 to 5 ft above floor Use no 18 AWG color coded insulated 35 C minimum wires to make low voltage connections between thermostat and unit Ifthermostat is located more than 100 ft from unit as measured along the low voltage wires use no 16 AWG color coded insulated 35 C minimum wires A grommeted low voltage inlet hole is located in the panel adjacent to control access panel See Fig 4 Run low voltage leads from thermostat thru inlet hole and to low voltage flagged pigtail leads that run thrua hole in bottom of unit control box See Fig 6 Connect thermostat leads to pigtail leads as shown in Fig 8 HEAT ANTICIPATOR SETTING Room thermostat heat anticipator must be properly ad justed to ensure proper heating performance Set heat anticipator using ammeter to determine exact required setting NOTE For thermostat selection purposes use 0 85 amps for approximate required setting Failure to make a proper heat anticipator adjust ment will result in improper operation discomfort to occupants of conditioned space and inefficient energy use however required setting may be changed slightly to provide a greater degree of com fort for a particular installation START UP Unit Preparation Follow recognized safety practices and wear pro tective goggles when checking or servicing refrig erant system 2 Do not operate compressor or provide any elec tric power to unit unless compressor terminal co
42. nal and local codes NOTE All other appliances that use the same meter must be turned off when gas flow is measured at meter Proceed as follows l Turn off gas supply to unit 2 Remove pipe plug on gas valve outlet identified as PRESS TAP then connect water 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 of seconds in hour 5 Multiply result of step4 by the number of cu ft shown for one revolution of test dial to obtain cu ft of gas flow per hour 6 Multiply result of step 5 by Btu heating value of gas to obtain total measured input in Btuh Com pare this value with heating input shown in Table 4 Consult local gas supplier if the heating value of gas is not known Example Assume that the size of test dial is cu ft one revolution takes 30 seconds and the heating value of the gas is 1050 Btu percu ft then proceed as follows a 30 seconds to complete one revolution b 30 divided into 3600 equals 120 c 120 times one equals 120 cu ft of gas flow per hour d 120 times 1050 equals 126 000 Btuh input If the desired gas input is 125 000 Btuh only a minor change in the manifold pressure is required Observe manifold pressure and proceed as follows to adjust gas Input I Remove vented seal cap over REG ADJ screw on gas valve 2 Turn regulator adjustment screw clockwis
43. on whichever value is larger Air filter pressure drop should not exceed O 08 in wg for unit to produce the rated cooling performance e 3 Install external field supplied air filter s in return air ductwork where it is easily accessible for service Recommended filter sizes are shown in Table 2 4 Size all ductwork for maximum required airflow either heating or cooling for unit being installed Avoid abrupt duct size increases or decreases 5 Adequately insulate and weatherproof all duct work located outdoors Insulate ducts passing thru an unconditioned space and use a vapor barrier in accordance with the latest issue of SMACNA and NESCA minimum installation standards for heating and air conditioning systems Secure all ducts to building structure 6 Flash weatherproof and vibration isolate all openings in building structure in accordance with local codes and good building practices Step 4 Make Wiring Connections l Make all electrical connections in accordance with National Electrical Code ANSI NFPA 70 1981 and local electrical codes governing such wiring 2 Use only copper conductor for connections between the field supplied electrical disconnect switch and the unit Do not use aluminum or copper clad aluminum wire 3 Ensure that high voltage power to unit is within operating voltage range indicated on unit rating plate On 3 phase units ensure that phases are balanced within 2 Consult local pow
44. operation each heating and cooling season Service when necessary 5 Check and inspect heating section before each heating season Clean and adjust when necessary Top Removal weet epee se eee NOTE When performing maintenance or service procedures that require removal of unit top be sure to perform all routine maintenance procedures that require top removal including inspection of heat exchanger area coil inspection and cleaning and condensate drain pan inspection and cleaning When performing maintenance and service pro cedures that require unit top removal refer to following top removal procedures 1 Turn off gas supply then disconnect electric power to unit 2 Remove vent cap and combustion air assemblies Do not damage gasket Refer to Venting section and reverse assembly procedures shown 3 Remove all screws that secure unit top including screws around 4 sides and those on top that screw into internal divider panels Save all screws 4 Tape all side panels at each seam near unit top Use tape strips that are at least 5 in long to pre vent sides from falling when top is removed 5 Carefully lift top from unit Set top on edge and ensure that it is supported by unit side that is opposite duct or plenum side Use extreme care to prevent damage to the seal that isolates heat exchanger and flue products or the fan blades motor and insulation 6 Carefully replace and secure unit top
45. pen and free from obstructions and air filter is clean When necessary refer to Cooling Section Start up and Adjustments Indoor Airflow and Airflow Adjust ments section to check system airflow TROUBLESHOOTING CHART Table 8 Heating Service Analysis Chart SYMPTOM Pilot will not light No spark at electrode 2 EE i H i i i i be ra H i ta 1 Spark shorting out to main burner No gas s at pilot burner C Burners will not ignite Water in gas line No power to furnace No 24 volt power supply to control circuit Pilot burning improperly sharp blue flame BM Burned out heat anticipator in thermostat No gas at main burners Broken thermostat wire Dirty air filter Gas input to furnace too low 5 Miswired or loose connections Dirty pilot yellow flame Ll Inadequate heating Unit undersized for application Restricted airflow Blower speed too low Limit switch cycles main burners PP ee ee eee E Incomplete combustion results in Aldehyde odors CO sooting flame floating flame t M Cimino Mise UU i eee oh MM AgNO Mes YA RMR ni Moe d mem Poor flame characteristics f Check v vent for restriction clean as required lua ER e sse navman aici marenana SAONE GRADOS meinte SRE Mita 22 e PROBABLE CAUSE d REMEDY E ead epee see el Nd m
46. r wheel and motor in relation to blower housing before disassembly e Loosen setscrew s thatsecures wheel to motor shaft remove screws that secure motor mount brackets to housing and slide motor and motor mount out of housing 2 Lubricate motor a Thoroughly clean all accumulations of dirt or grease from motor housing b Remove dust caps or plugs from oil ports located at each end of motor c Use a good grade of SAE 20 nondetergent motor oil and put one teaspoon 5 cc 3 16 oz or 16 to 25 drops in each oil port d Allow time for oil to be absorbed by each bearing then wipe excess oil from motor housing e Replace dust caps or plugs in oil ports 3 Remove and clean blower wheel a Ensure proper reassembly by marking wheel orientation and cutoff plate location b Remove screws holding cutoff plate and remove plate from housing c Lift wheel from housing When handling and or cleaning blower wheel be sure not to disturb balance weights clips on blower wheel vanes d Remove caked on dirt from wheel and hous ing with a brush Remove lint and or dirt accumulation from wheel and housing with vacuum cleaner using soft brush attachment Remove grease and oil with mild solvent e Reassemble wheel and cutoff plate into housing f Reassemble motor into housing Be sure set screws are tightened on motor shaft flats and not on round part of shaft 4 Reinstall blower assembly into unit
47. roof mounting curb must be installed on and flashed into roof before unit installation When installing a Model 48KH KL end discharge unit without a downflow plenum place unit on a level base that provides proper support On flat roofs be sure unit is located at least 4 in above highest ex pected water level on roof to prevent flooding Consult local codes for additional installation requirements GROUND LEVEL INSTALLATION Place unit on a solid level concrete pad that is a minimum of 4 in thick and that extends approximately 2 in beyond casing on all sides of unit Do not secure unit to pad except when required by local codes CLEARANCES Required minimum operating and service clearances are shown in Fig 4 for pro viding adequate combustion ventilation and con denser air Condenser fan discharges thru top of unit Ensure that fan discharge does not recirculate to condenser coil Do not locate unit in either a corner or under a complete overhead obstruction Minimumclearance under a partial overhang suchasa typical house roof overhang is 3 ft above vent cap Maximum hori zontal extension of a partial overhang must not exceed 4 feet Do not locate unit where water falling ice or snow from an overhang or roof will damage or flood the unit Do not locate unit where grass shrubs or other plants will interfere with the airflow either into or out of unit Do not install unit on carpeting tile or other combustible materi
48. rtified by the American Gas Association AGA for use with natural or LP propane gases with appropriate controls and orifices See Table for heating input ratings Models 48KH KL units are fully self contained combination gas heating electric cooling units designed for outdoor installa tion on either a rooftop or ground level slab These units are equipped with an energy saving automatic intermittent electric spark ignition id 2LAEUNIT LENGTH PRUSIO WITH SPREADER BARS system that does not have a continuously burning L DEEP 90 NOTCHES EACH END pilot All units are manufactured with natural gas y 2 24 UNIT WIDTH WITH IS Guan controls aca ela adic Units are factory charged with R 22 refrigerant To install connect gas supply air ducts high and low voltage wiring and condensate drain and install a field supplied air filter in the return air ductwork All units can be connected into existing duct systems that are properly sized and designed to handle an airflow of 350 to 450 cfm per each 12 000 Btuh of rated cooling capacity See Table 7 for cool ing and heating airflow requirements LOCATE CHAINS THRU HOLES IN BASE NOTE When installing any accessory item see ANNEES NS o TO Installation Instructions packaged with accessory SOTTOMIOR UNIT Fig 2 48KH KL Suggested Rigging ROOFTOP INSTALLATION When installing a Model 48K H KL end discharge unit with a field supplied downflow plenum a field supplied
49. s 1 Place combustion air shroud over combustion air opening in unit top and line up screw holes in shroud with holes in top Secure shroud to top using screws with rubber washers provided 2 Place gasket and flue assembly thru hole in com bustion air shroud orient screw holes in base of flue assembly with holes in unit top and secure gasket and flue assembly to unit top using screws provided 3 Form flat wire screen provided into circular shape around protruding lip of combustion air shroud and bend wire ends thru holes of screen mesh to secure screen in place Make sure that no sharp edges are left exposed 4 Place vent cap sleeve inside flue assembly Orient spring clip of vent cap with slot in assembly Be sure clip snaps into slot to secure clip onto assembly A PLUGGED ACCESS HOLE e RUTRUM ue i 3 F 8 CONTROLS ACCESS DOOR VENT CAP dl COMPR ACCESS DOOR REMOVABLE COMBUSTION AIR INLET BOX PANEL BLOWER ACCESS DOOR MXN 2 LOW VOLTAGE INLET ES ee 8 i FORK LIFT NN SLOTS M o UNDERNEATH 3 j 8 i 2 MPT o d NOT ON MODELS 48KLOI8 THRU 036 KHO24 THRU 030 3 33 gt EVAPORATOR AIRFLOW ED CONDENSER AIRFLOW E NOT ON MODELS Voss THRU 4 DRAIN CONN 036 KHO24 THRU KH024 036 KLO48 CLEARANCES ft in MopEL4s KL078 KLO3O klosz Ono Above HUS EAN E Sod Red 3 0 KLO36 KHO42 KHO60 Duct side of unit Baator
50. tices NOTE Install a filter drier whenever system has been opened for repair 3 Add a small charge of R 22 refrigerant vapor to system and leak test unit 4 Evacuate refrigerant system if additional leaks are not found 5 Charge unit with R 22 refrigerant using a volumetric charging cylinder such as Dial a Charge or accurate scale Refer to unit rating plate for required charge Be sure to add extra re frigerant to compensate for internal volume of filter drier NOTE See Cooling Section Start Up and Adjust ments Checking and Adjusting Refrigerant Charge Heating Section Start Up and Adjustments Do not jumper any safety devices when operating unit Ensure that burner orifices are properly aligned Unstable operation may occur when the burner orifices in the manifold are misaligned To ensure correct burner orifice alignment check orifice angle with a machinist s protractor or other suitable device The orifice angle must be from horizontal to 3 degrees down as measured from unit base Follow instructions on heating section operation label located in unit near the gas valve or in Owner s Manual to start the heating section ef CHECKING HEATING CONTROL OPERA TION Start and check unit for proper heating control operation as follows Place room thermostat selector switch in HEAT position and fan switch in AUTO position Set heating temperature control of thermostat above room temperatur
51. to unit using screws removed in step3 when maintenance and or service procedures are concluded Be sure to use original screws that have rubber washers to seal out water when securing top to internal divider panels 7 Reinstall vent cap and combustion air assem blies Refer to Venting section 19 Air Filter Inspect field supplied air filter s at least once each month and replace disposable type or clean cleanable type at least twice during each heating and cooling season or whenever the filter s becomes clogged with dust and lint Evaporator Blower Wheel and Motor For longer life operating economy and continuing effi ciency clean accumulated dirt and grease from blower wheel and motor annually Lubricate motor every 5 years if motor is used intermittently thermostat FAN switch in AUTO position or every 2 years if motor is used continu ously thermostat FAN switch in ON position Clean and lubricate blower motor and wheel as follows 1 Remove and disassemble blower assembly a Remove blower and control access panels b Refer to unit wiring label and disconnect blower motor leads from their termination points in unit control box Be sure to mark wiring label appropriately if lead terminations were not previously marked Pull leads into blower compartment c Remove blower assembly from unit Be careful not to tear insulation in blower compartment d Ensure proper reassembly by marking blowe
52. ty codes Wear safety glasses and work gloves Use care in handling rigging and setting bulky equipment Observe precautions in these instructions and on equipment tags stickers and labels Fig 1 Model 48KH KL GENERAL Models 48KH KL packaged gas electric units see Fig 1 have been designed and tested in accord ance with ANSIZ21 47b 1982 ARI Standard Form 48KH KL 1SI Au ocn Table 1 Performance Data ee ee ie MEC NOMINAL RATED ARI MODEL48 COOLING BUT SOUND SIZE RATING PRI NP ty ceed ced aos OMAN E tp leet KL018300BE 018 40000 80 KLO24300BE 024 40 000 82 KH024300BE 024 60000 80 KLO303O00BE 030 40 000 82 KH030300BE amp 030 0j 60000 82 KLO36300BE 036 60 000 80 KLO36500CE 036 60 000 80 KLO36600CE 036 60 000 80 KH036300BE 036 100 000 80 KH036300BF 036 125 000 80 KHO36500CE 036 100 000 80 _ KHO36500CF 036 125 000 80 KLO42300BE 042 60 000 82 KLO42500CE 042 60 000 82 KH042300BE 042 80 000 82 KH042500CE 042 _ 80000 82 KLO48300BE 048 80 000 84 KLO48500CE 048 80000 84 KLO48600CE 048 80000 84 KHO48300BE 048 100 000 84 KHO48300BF 048 125 000 84 KHO48500CE 048 100 000 8 4 KH048500CF 048 3125000 84 KLO60300BE 060 100000 82 KHO60300BE 060 120000 82 KH060300BF 060 150000 82 Sound rating per ARI 270 82 210 81 and ARI Standard 270 82 The units are de sign ce
53. un until time delay sequence of heat relay is completed When air temperature at limit switch drops to the low temperature setting of limit switch switch Switching of pilot contacts also completes low closes and completes W control circuit Electric voltage circuit to time delay heat relay and terminal spark ignition system cycles and unit returns to no of gas valve After approximately 10 seconds normal heating operation heat motor operated gas valve opens and permits gas to flow to burners where gas is ignited by pilot Ignited burners heat the heat exchanger Pressure switch see Fig 10 isrequired only when unit operates on LP propane gas BLOWER SAFETY SWITCH Blower safety switch is a temperature actuated switch connected parallel with contacts of heat relay Function of switch is to activate blower should gas valve fail to After built in time delay normally open relay contacts of energized heat relay close and circuit to blower motor is completed Blower motor starts Heating cycle remains on until room temperature close when thermostat 1s satisfied Safety switch is rises to a point that is slightly above heating control mounted on blower divider panel When tempera setting of room thermostat At this point thermostat ture at safety switch reaches approximately 175 F heating bulb tilts and breaks circuit betweenthermo switch closes to start blower Switch opens when stat terminals R and W Gas flow thru gas val
54. using a soap and water solution 5 Replace control access panel Pilot Inspect the pilot and clean when necessary at beginning of each heating season Remove accu mulation of soot and carbon from only the outside of the pilot The pilot flame must be high enough to properly touch flame sensing element and to light burners Condenser Coil Evaporator Coil and Con denser Drain Pan Inspect condenser coil evap orator coil and condensate drain pan at least once each year Proper inspection and cleaning requires removal of unit top See Top Removal section Coils are easily cleaned when dry therefore in spect and clean coils either before or after each cooling season Remove all obstructions including weeds and shrubs that interfere with airflow thru condenser coil Straighten bent fins witha fin comb If coated with dirt or lint clean coils with a vacuum cleaner using soft brush attachment Be careful not to bend fins If coated with oil or grease clean coils with 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 of unit On units with an outer and inner condenser coil be sure to clean between coils Be sure to flush all dirt and debris from unit base Inspect drain pan and condensate drain line when inspecting the coils Clean drain pan an
55. ve temperature at switch drops to approximately 1 16 F 15 Cooling Section Start Up and Adjustments CHECKING COOLING CONTROL OPERA TION Start and check unit for proper cooling control operation as follows 1 Place room thermostat selector switch in OFF position Observe that blower motor starts when fan switch is placed in ON position and shuts off when fan switch is placed in AUTO position 2 Place selector switch in COOL position and fan switch in AUTO position Set cooling control below room temperature Observe that compres sor 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 selector and fan switches in AUTO position Observe that unit operates in heating mode when temperature control is set to call for heating above room temperature and operates in cooling mode when temperature con trol is set to call for cooling below room temperature CHECKING AND ADJUSTING REFRIG ERANT CHARGE Refrigerant system is fully charged with R 22 refrigerant tested and factory sealed For most applications factory charge is the correct amount for best performance however this charge may require a slight adjustment to attain rated performance NOTE Adjustment of refrigerant charge is not re quired unless unit is suspected of not having proper R 22 charge For all applications
56. ver is in place and secured 3 Do not remove compressor terminal cover until all electrical sources have been disconnected 4 Relieve all pressure from system before touching or disturbing anything inside terminal box if a refrigerant leak is suspected around compressor terminals 5 Never attempt to repair a soldered connection while refrigerant system is under pressure 6 Do not use a torch to remove any component System contains oil and refrigerant under pres sure To remove a component wear protective goggles and proceed as follows a Shut off gas supply first and then electrical power to unit b Relieve all pressure from system c Use tubing cutter to cut tubing that connects component and remove component from unit d Carefully unsweat remaining tubing stubs when necessary Oil can ignite when exposed to torch flame PRE START UP PROCEDURES Proceed as follows to inspect and prepare unit for initial start up l Remove all access panels 2 Read and follow instructions on all WARNING CAUTION and INFORMATION labels at tached to or shipped with the unit such as blower rotation labels etc 3 Remove these shipping components on the fol lowing sizes of Models 48KH KL a 030 and 036 sizes remove styrofoam block wedged between header and unit side panel b 048 size remove shipping clamps that hold compressor to unit base c 060 size remove styrofoam block wedged between compressor
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