Carrier 48GP (N) 024-060 Operating instructions

48GP, 48GPN
Single Package Gas Heating/Electric Cooling Units
With Puron® (R-410A) Refrigerant
HEATING & COOUNG
Visit www.carrier.cmn
Installation, Start-Up, and Operating Instructions
48GP, 48GPN Sizes 024-060
NOTE:
Read
installation.
the
entire
instruction
manual
before
starting
the
Index
Page
SAFETY
CONSIDERATIONS
.....................................................
RULES FOR SAFE INSTALLATION
RECEIVING
AND INSTALLATION
1
AND OPERATION....
..........................................
1-2
2
CHECK EQUIPMENT
..................................................................
PROVIDE
UNIT SUPPORT .........................................................
Roof
2
2
Curb ............................................................................
Slab Mount
2
..........................................................................
Ground Mount
FIELD FABRICATE
2
.....................................................................
DUCTWORK
.............................................
2
2
PROVIDE
CLEARANCES
RIG AND
CONNECT
PLACE UNIT .......................................................
3, 6-7
CONDENSATE
DRAIN ...........................................
7
INSTALL
FLUE
INSTALL
GAS
INSTALL
INSTALL
DUCT CONNECTIONS
.......................................
ELECTRICAL
CONNECTIONS
.........................
HOOD
2-3
...............................................................
PIPING
High-Voltage
Special
........................................................
7
.............................................................
Connections
Procedures
7-8
8, 10
11-13
................................................
for 208-V
Operation
11
..........................
11
Control Voltage Connections
............................................
Standard Connection ..........................................................
12
12
Heat Anticpator
Setting .....................................................
Transformer
Protection ......................................................
13
13
PRE-START-UP
START-UP
..........................................................................
....................................................................
REFRIGERANT
SYSTEM
START-UP
NOTE
THESE
22-26
..........................................................
Before
CAREFULLY
of buildings
31
the installation,
READ
AND COMPLETELY.
Also, make sure the User's Manual and Replacement
left with the unit after installation,
the furnace is NOT
heating
27
28-30
............................................................
TO INSTALLER
INSTRUCTIONS
for temporary
tion.
26
GUIDE ....................................................
..........................................................
CHECKLIST
or structures
Guide are
to be used
under
construc-
SAFETY CONSIDERATIONS
Installation
hazardous
trained
and
and qualified
air-conditioning
Untrained
equipment
and electrical
personnel
should
equipment,
attached
can perform
smwice personnel.
observe
to the unit,
all safety
quenching
cloth
repair,
basic maintenance
When
precautions
Only
codes.
Wear safety
for unbrazing
glasses
tags
and labels
that may apply.
and work gloves.
Have
Use
fire extinguisher
operations.
reserves the right
PC 101
precautions
operations.
of
be performed
on air-conditioning
in the literature,
to discontinue,
Catalog No
534-755
AND OPERATION
FR |','1,_I;1: I l_e
Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, fire, or
an explosion which can result in serious injury or unit
damage. Consult a qualified installer, service agency, or gas
supplier for information or assistance. The qualified installer
or agency must use only factory-authorized kits or accessories
when modifying this product.
Understand the signal words
DANGER, WARNING,
and
CAUTION. DANGER identifies the most serious hazards which
will result in severe serious injury or death. WARNING indicates
a condition that could result in serious injury or death. CAUTION
is used to identify unsafe practices which would result in minor or
moderate injury or product and property damage.
The power supply (volts, phase, and hertz) must correspond to that
specified on unit rating plate.
or smwice
functions
should
working
and other safety
lbr all brazing
Manufacturer
can be
components.
install,
coils and filters. All other operations
by trained
available
of air-conditioning
pressure
equipment.
personnel
cleaning
Follow
servicing
due to system
RULES FOR SAFE INSTALLATION
13-22
MAINTENANCE
48GP
13
..............................................................................
QUICK REFERENCE
TROUBLESHOOTING
C99088
Fig. 1--Unit
The electrical supply provided by the utility must be sufficient to
handle load imposed by this unit.
This installation must conform with local building codes and with
NEC (National Electrical Code) and NFPA 70, NFPA 54 ANSI
Z223.1 latest revision, and NFGC (National Fuel Gas (;ode). Refer
to provincial and local plumbing or waste water codes and other
applicable local codes.
Approved for outdoor installation on wood flooring or on class A,
B or C roof covering materials.
or change at any time, specifications
Printed in US.A.
Form
or designs
48GP-1SI
without notice and without incurring obligations.
Pg 1
3-00
Replaces:
New
Before performing
service
or maintenance
turn off gas supply
then unit main
shock
could
or explosion
cause
operations
power
serious
on unit,
switch.
iniury
Electrical
or death.
2,
MAXIMUM
ALLOWABLE
DIFFERENCE
(in.)
r:l ['_IliilI0]/l
Puron
(R-410A)
standard
systems
R-22 systems.
components
is rated
The
contained,
combination
units
designed
48GP
All
with all downflow
either
on
sizes
local
Fig.
1)
are
Fig. 2--Unit
fully
have
discharge
slab,
codes).
See
cooling
openings
for both
and are factory
covered.
cement
self-
See Fig. 6 and 7 for unit
configurations,
shipped
Units may be installed
or directly
Figs.
on the ground
4 and
5 for
roof
(if
curb
GROL_D
MOUNT
or placed
unit
on level
Step
3--Field
Secure
all ducts
discharge
applications,
less
as
shipped
fi'om
the
California
Air Quality
rule exists.
factory
and
Management
MUST
Districts
be
where
or
installed
l--Check
IDENTIFY
against
unit
papers
is still on shipping
loose
ficom its
inspectors
incurred
Check
all
nearest
Carrier
ROOF
CURB
instructions
roof
curb
flashing.
or damage,
Unit
Install
or is tom
dimensions.
Install
by
transportation
papers
directly
roof
notify
flanges
ductwork,
on
the
horizontal
to the flanges.
joints,
Insulate
and roof openings
in accordance
with
applicable
an unconditioned
If a plenum
return
through
space
must be insulated
barrier.
is used on a vertical
unit, the return
the roof deck to comply with applicable
clearance
static
is not required
shall not exceed
around
should
be
fire codes.
ductwork.
Cabinet
-.25 in. wg.
RETURN iUPl_
'
_11'1
\
_\i
IIIII
IIIII OPENING
IIIII
IIIII
IIIII
'
"
iH
SUPPLY
III
OPENING 111
111
111
111
IIIII
IIIII
IIIII
III
III
III
the
EVAR COIL
in original
Install
with
4 and 5 and Table
1 for
cant strips,
roofing,
and
to curb.
of the unit to the roof curb is critical
gasketing
applied
properly.
material
gasketing
supplied
can also result
with the
in air leaks
MOUNT
flush
1/4 inch. This is necessm T for unit
Refer to accessory
for additional
that is a minimum
COND
information
Place
C99014
&din installation)
level concrete
with 2 in. above
compressor
end
and should
by local
codes.
Step
4_Provide
The required
Clearances
minimum
operating
in Fig. 6 and 7. Adequate
and service
combustion,
clearances
ventilation,
are shown
and condenser
air must be provided,
in accordance
with section 5.3, Air for
Combustion
and Ventilation,
of the National Fuel Gas Code ANSI
(American
National
tions
7.2,
7.3 or 7.4
Standards
B149
Installation
Institute)
or CaniCGA
Codes),
Z223.1
[Canadian
or applicable
(in Canada,
Gas
provisions
sec-
Association]
of local build-
ing code.
grade.
of the
extend
¥!I [_:.llli_0]/1
(see Fig. 2).
unit
pad
The slab
(to allow
Do not restrict
condenser
the outdoor-air
inlet or the fan discharge
compressor
airflow.
An air restriction
at either
can be detrimental
to
life.
2 in. on the three
sides of the unit. See Fig. 3. Do not secure the unit to the
when required
Mounting Details
roof curb installation
as required
the unit on a solid,
of 4 in. thick
on the
COIL
packages
curb in accordance
insulation,
be level to within
drain to function
slab eycept
through
to
unit perfomlanee.
condensate
with
be secnred
and mastic
with a vapor
for any
Immediately
See Figs.
must be attached
seal.
remaining
passing
if any item is missing.
all parts
accessory
for a watertight
be
flashing
on vertical
Support
with curb.
roof curb. Improperly
instructions
all external
Fig. 3_lab
The gasketing
should
while unit
list.
office
leave
IMPORTANT:
SLAB
damage
is not responsible
shipping
shipped
Curb should
is provided
should
structure
dz¢ctworlc to unit. For horizontal
number
to be damaged
claim
Manufacturer
against
Ductwork
and poor
and building
this infomlation
it examined
Forward
Air Conditioning
To prevent loss
until installation.
2--Provide
dis-
in transit.
items
Step
have
removal.
company.
for shipping
If unit appears
anchorage,
and serial
Check
for condensate
data.
Inspect
pallet.
before
transportation
damage
and job
SHIPMENT
number
plate.
Place the
Ductwork
curb
and covered
return-air
The unit model
shipping
counter
A minimum
on unit identification
INSPECT
Ducts
ducted
Equipment
L_'IT
are stamped
gravel
on a slab
pemfit.
in
a Low NOx
RECEIVING AND INSTALLATION
Step
with
to roof
All ductwork
codes.
joule
with
units. Do not connect
o f nitrogen
of 40 nanogrmns
either
if local codes
prepared
Fabricate
and weathelproof
requirement
on the ground
ground
C99065
Leveling Tolerances
The unit may be installed
directly
48GPN units are dedicated Low NOx units designed for California
installations.
These models meet the California
maximum
oxides
emissions
1/4
charge.
openings.
(NOx)
A-C
1/4
or
service
I gas heating/electric
duct openings
a rooftop,
permitted
by
dimensions.
(see
installation.
and downflow
equipment
Ensure
B-C
1/4
than
(R-410A).
Category
unit
pressures
equipment.
units
for outdoor
dimensions.
horizontal
(R-410A)
for Puron
GENERAL
at higher
Do not use R-22 service
on Puron
equipment
operate
A-B
The condenser
it through
pulls
air through
the top cover.
the condenser
coil and discharges
Be sure that the fan discharge
does not
J
44 5,16
SUPPORT B
(2)
END
ViEW
(INSULATED)
A99320
Fig. 4_Roof Curb Dimensions
Top View
SIDE
PAN EL__,
BASE
SUPPORT
...... 0.75
R'B(S)
_/
I_i if'
BOTTOM
(o,Ot pFL%"')NG
............1L[
CANT
(FIELD
STR
P
.......
_
I
4.0"
1
SUPPLY
NA'LER
......
SUPPLIBD_
PAN
JINSULATION
..........
(FIELD
SUPPLIED)
ROOFING
MATERIAL
(FIELD
SUPPLIED)
A99340
Fig. 5--Roof Curb Dimensions
Side View
UNIT SIZE
ODS ORDER
NUMBER
A
IN, [MM]
B
IN, [MM]
C
IN, [MM]
D
IN, [MM]
28 3/4 [730]
CPRFCURB006A00
8 [203]
11 27/32 [301]
30 5/8 [778]
ROOF
CPRFCURB007A00
14 [356]
11 27/32 [301]
30 5/8 [778]
28 3/4 [730]
CURB
CPRFCURB008A00
8 [203]
15 27/32 [402]
42 1/8 [1070]
40 1/4 [1022]
C PRFCURB009A00
14 [356]
15 27/32 [402]
42 1/8 [1070]
40 1/4 [1022]
48GP024-036
48GP042-060
Notes:
1. Roof curb must be set up for unit being installed
2. Seal strip must be applied as required to unit being installed
3. Dimensions in [ ] are in millimeters.
4. Roof curb is made of 16 gage steel.
5. Table Iists only the dimensions per part number that have changed.
6. Attach ductwork to curb (flanges of duct rest on curb)
7. Insulated panels: 1-in. thick fiberglass 1 lb. density
8. Dimensions are in inches
Table 1--Roof
recirculate
to the condenser
coil. Do not locate
comer
or under
an overhead
under
a partial
overhang
48-in.
above the unit top. The maximum
partial
overhang
Do not place
or roof will
carpeting,
obstmction.
(such
as a normal
nmst not exceed
the unit where water,
damage
or flood
tile, or other
installed on wood
materials.
flooring
house
horizontal
a
Step
is
Rigging
reasons
clearance
overhang)
extension
of a
48 inches.
ice, or snow
the unit.
combustible
the unit in either
The minimum
The
the unit on
unit may be
or on Class A, B, or C roof
covering
5--Rig
and
Place
Unit
and handling of this equipment
due to the installation
location
can be hazardous
for many
(roofs, elevated stmctures,
etc.).
Only
fFom an overhang
Do not install
materials.
Curb Dimensions
trained,
should
handle
When
working
literature,
qualified
Training
with
on tags,
and any other
operators
and ground
support
staff
this equipment.
this equipment,
stickers
observe
and labels
safety precautions
for operations
NOT be limited
crane
and install
that might
of the lifting
to the following:
precautions
attached
equipment
in the
to the equipment,
apply.
should include,
but
E_39]
T
SUPPLY
OUCT
OPENING
4020
E1585]
805
[516]
i
y
COND
_1177
I
[463]
153 5
[694]
NON SENT
1
893
[348]
_
249 6
[983]
[21
67]
[983]
EVAP
COIL
TOP VIEW
REAR VIEW
REQ'D CLEARANCES
FOR OPERATION
AND SERVICING
Evaporator coil access side ..................
Power entry side (except for NEC requirements)
Unit top ..........................
Side opposite ducts
.....................
Duct panel
........................
in. (mm)
REQ'D CLEARANCES
36 (914)
36 (914)
48 (1219)
36 (914)
12 (304.8)*
.........
*Minimum distances: If unit is placed Iess than 12 in. (3048
system, then the system performance may be compromised.
mm) from wall
NEC REQ'D CLEARANCES.
Between
Unit and
Unit and
surfaces,
LEGEND
CG - Center of Gravity
COND - Condenser
EVAP - Evaporator
NEC - National Electrical Code
REQ'D - Required
Note: Dimensions are in in (mm)
44]
FIELD ENTRY
SERVICE PORTS
MAT'L
in. (mm)
14 (355.6)
2 (50.8)
14 (355.6)
0.50 (12.7)
36 (914.4)
in (mm)
units, power entry side
..............
ungrounded surfaces, power entry side .........
block or concrete walls and other grounded
control box side
.................
42 (1066.8)
36 (914)
42 (1066.8)
11939
[4TOO]
_7985
[31
TO COMBUSTIBLE
Top of unit .........................
Duct side of unit .......................
Side opposite ducts .....................
Bottom of unit .......................
Flue panel .........................
t
\
[091]
\
250
]
o
S?O_S
162_,_61
42 l
[168]
190 [075] NPT
22 O _)P
4562
[119_]
_OMPRESSOR
& ELECTRICAL
BLOWER
GAS SECTION
347
2
[O50]
GAS ENTRY
FLUE HOOR
ACCESS PANEL
[1285]
1226 3
[_828]
[285]
_8310
[52
NPT
50
[0R0]
62]
LEFT SIDEVIEW
RIGHTSIDE VIEW
FRONT VIEW
C99017
UNIT
ELECTRICAL
CHARACTERISTICS
UNIT
UNIT WEIGHT
lb.
kg.
CENTER OF GRAVITY
IN. [MM]
HEIGHT
IN. [MM]
"k"
48GP024040/060
208/230-1-60
290.0
1315
3702
[940
48GP030040/060
208/230-1-60,
208/230-3-60
313.0
1420
3902
321.0
1456
3502
Y
X
Z
22.0
[5588]
145 [368.3]
16.0
[9911]
22.0
[5588]
153
[387.4]
17.614470]
[8895]
22.0
[5588]
153
[387.4]
16.5
3]
[4064]
208/230-1-60,
48GP036060/090
208/230-3-60,
460-3-60
Fig. 6--48GP024-036
4
Unit Dimensions
[4191]
860
[3 39]
t
4066
[16 01]
I
T
T
4020
[15 832
Y
EVAP
TOP VIEW
[348]
REAR VIEW
REQUIRED CLEARANCE FOR OPERATION AND SERVICING
REQUIRED CLEARANCE TO COMBUSTIBLE MATE
in. [mm]
3600 [914 6]
3600 [914 O]
EVAR COIL ACCESS SIDE ..............................................................
POWER ENTRY SIDE ......................................................................
(EXCEPT FOR NEC REQUIREMENTS)
UNIT TOP .........................................................................................
SIDE OPPOSITE DUCTS ................................................................
DUCT PANEL ...................................................................................
3600 [914.0]
3600 [914.0]
1200 [304 8] *
TOP OF UNIT ...................................................................................
DUCT SIDE OF UNIT .........................................................................
SIDE OPPOSITE DUCTS ................................................................
BOTTOM OF UNIT .............................................................................
ELECTRIC HEAT PANEL .................................................................
in
14.00
2.00
14.00
0.50
36.00
[mm]
[355.6]
[508]
[355.6]
[12.7]
[914.4]
NEC.REQUIREDCLEARANCES.
*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 12.00 [304.8] FROM
WALL SYSTEM, THEN SYSTEM PERFORMANCE
MAYBE COMPROMISE
BETWEEN
UNIT AND
UNiT AND
GROUNDED
SURFACES,
POWER
ENTRY
SIDE .........................
42.00
1193 9
[4700]
1090 6
[42 94]
FIELO
MILLIMETERS
[IN]
UNITS,
POWER
ENTRY
SIDE ....................................
4200
[1066.8]
UNGROUNDED
SURFACES,
POWER
ENTRY
SiDE .3600
[914.0]
BLOCK
OR CONCRETE
WALLS
AND OTHER
t
ENTRY_
SERVICE PORI
mHmmmmmH!
39
I
1.3
,/
I
190 [073]
NPT
x 22 0 [0 87] #P
427
[168]
329 0
[1295]
/
_OMPRE360R
5LOWER GAS SECTION
ELECTRICAL ACCESS PANEL
12263
[48 28]
[285]
1424
[561]
[4422]
FRONT VIEW
LEFT SIDE VIEW
RIGHT SIDE VIEW
C99074
UNIT
ELECTRICAL
CHARACTERISTICS
UNIT
WEIGHT
UNIT
CENTER OF GRAVITY
IN. [MM]
HEIGHT
IN, [MM]
"A"
X
Y
Z
Ib
kg
382
173.3
38.98
[990.2]
23.0
[584
2]
163
[412.8]
16.6
[421
6]
421
191.0
38.98
[990.2]
21.5
[546
1]
166
[422.1]
18.0
[457
2]
468
212.3
[1091.7]
23.5
[596
9]
163 [412.8]
17.6
[447
O]
208/230-1-60
48GP042060/090
208/230-3-60
460-3-60
208/230-1-60
48GP048090/115/130
208/230-3-60
460-3-60
208/230-1-60,
48GP060090/115/130
208/230-3-60,
4298
460-3-60
Fig. 7--48GP042-060
Unit Dimensions
[1066.8]
i. Application
of the lifter to the load and adjustment
if any, that adapts
it to various
2. Instruction
in any special
3. Condition
of the
of the lifts,
5. Attach
sizes or kinds of loads.
operation
safety straps directly
or clevis
brackets.
clip.
Do not
to the field supplied
attach
the safety
lifting kit, such
Follow
as balance,
all applicable
safety
required
for operation
temperature,
codes.
straps
to the lifting
or precaution.
6. Use the top of the unit as a spreader
load itself,
rigging
straps
Wear
of the
straps from damaging
etc.
use a spreader
safety
shoes
bar to prevent
the rigging
the unit. If the wood top is not available,
bar of sufficient
length
to not damage
the unit.
and work
gloves.
o
•
Ir!] L,TV"I:I.1J
R[.
Never
exceed
Accessory
200 lbs. per bracket
lifting
kit
Packaged
units which
molded hand holds.
Never
stand beneath
unit
INSPECTION
rigging
damage,
hooking
points
units
with
base
injury
serious
of gravity
or death.
to initial use, and at monthly
should
should
in these
Small
pan with
or lift over people.
cause
be visually
structural
be paid
and load support
any kind of wear
discarded.
a composite
over the center
of wear,
attention
force.
used
be directly
and straps
evidence
Particular
lifting
to be
DETAIL
A
SCALE
025O
could
Prior
brackets
have
rigged
Lifting point should
for the unit.
A &opped
is only
intervals,
inspected
deformation,
to excessive
areas. Brackets
areas nmst
or
wear
all
lbr any
cracks.
at hoist
or straps showing
not be used
and should
C99066
be
Fig. 8--Lifting
Point
INSTALLATION:
i.
Position
unit.
the lifting
Leave
spreader
2. Place
the top
bracket
assembly
shipping
skid
around
on the
the base of the
unit
to act as a
bar. Be sure the strap does not twist.
each
handholds
of the
four
in the composite
(4) metal
lifting
brackets
into
the
HOOK
pan.
3. Tighten the ratchet strap until tight. Lifting
secure in the handholds.
brackets
should be
4. Attach the clevis or hook of sufficient strength to hole in the
lifting bracket as shown in Fig. 8.
FEED
II_N_,-
C99067
Belt
Threading
i. Open lever
Instructions:
of tension
2. Feed webbing
3. Pull webbing
4. Snap
lever
5. To release,
outward
through
through
buckle
tension
tension
down to lock strap
squeeze
safety
Fig. 9--Belt
buckle
buckle
as shown
until taught
in tension
latch,
lift lever
Threading
buckle
and pull webbing
914-1371
DUCTS
(36'i54")
\
B
t_7_557,)
/
J
SEAL STRIP MUST BE IN
PLACE BEFORE PLACING
UNIT ON ROOF CURB
12263
PLACE
RIGGING
STRAPS
BASEPAN SLOT (BELOW
BEFORE RIGGING
HANDHOLDS)
C99015
UNIT 48GP
MAXIMUM
Size
tb
024
312
030
335
036
WEIGHT
A
mm
in
mm
5585
14.5
3883
22.0
22.0
5585
15.3
3886
5585
15.3
3886
183
23.0
5842
18.3
4140
443
201
21.5
5461
18.3
4140
490
222
23.5
5969
18.3
4143
kg
142
in.
22.0
343
152
156
042
404
048
060
Fig. lO--Suggested
Step 6--Connect
NOTE:
Condensate
When installing
comply
with
The 48GP units dispose
water
installations
(where
through
directly
a field-supplied
the outlet
of the trap
is at least
1 in. lower
condensate
connection
to prevent
the pan from
the trap with
away
If the installation
install
ensure
&ainage.
proper
the trap
is at least
connection
to prevent
with water. Connect
or 3/4 -in. copper
2-in.
trap.
Do
See Fig.
locate
blower
is shipped
compartment.
screwed
Remove
to the coil panel in the
the service
access
panel to
the assembly.
Dedicated
low NOx
48GP
models
MIST
be installed
in Califor-
water.
When
in ground-
Make
sure that
than the drain
pan
overflowing.
See
using
nitrogen
draining
the
a gravel
1 in. lower
than the
the pan from
NOTE:
lations.
undersize
the
tube.
Low NOx
drain
water
pan
the trap
of 3/4 -in. PVC
the
Install
system
i.
the flue hood
gas instal-
is designed
to ensure proper
venting.
The
in this
as follows:
This installation
must
with the National
conform
Canada,
drain
Fire Protection
Association)
cial
plumbing
tube
CANiCGA
and
local
applicable
flue hood
screw holes
TRAP
OUTLET
3. Secure
the right
ANSI
codes
and
Z223.1
(in
B 149.1, and B 149.2) or NFPA
latest
(National
revision.
Refer
to Provin-
water
codes
and
or waste
from shipping
location
Place vent cap assembly
in vent cap with holes
flue hood
other
(inside
the blower
over flue panel.
Orient
in the flue panel.
to flue panel by inserting
a single
screw
on
side and the left side of the hood.
Step 8--Install
C99013
(NFGC),
local codes.
compartment).
1" MtN.
with local building
Fuel Gas Code
end of the
2. Remove
Trap
or
of
condensate
Prime
apply only to natural
flue hood assembly
must be installed
as indicated
section of the unit installation
instructions.
to
downward at a slope of at least one in. for every 10 ft of horizontal
run. Be sure to check the drain robe for leaks. 12
Fig. 11--Condensate
of 40 nanograms.joule
¥:I [q:lw_l[0]/l
away
connection
at the outlet
Pitch
requirement
requirements
apron,
sure that the outlet
overflowing.
pipe (all field-supplied)
emissions
from the _aetory.
The venting
condensate
a 2-in. trap at the condensate
See Fig. 11. Make
(NOx)
less as shipped
NOx rule
oxides of
trap at end of
drainage.
a drain robe using a minimum
not
The flue hood assembly
from the unit.
requires
from the unit,
proper
apron
condensate
to ensure
sure it slopes
panel.
onto the roof in rooftop
or onto a gravel
connection
make
a 3/4 in. NPT
access
Flue Hood
nia Air Quality Management
Districts where a Low
exists. These models
meet the California
maximum
permitted)
Install
water
condensate
Fig. 11. Prime
be sure to
indoor
the compressor
can be drained
level installations.
drain connection
of condensate
Rigging
Step 7--Install
and restrictions.
fitting which exits through
6 and 7 for location.
Condensate
Drain
condensate
local codes
B
Gas Piping
The gas supply pipe enters the unit through the access hole
provided. The gas connection to the unit is made to the 1/2-in. FPT
gas inlet on the manual shutoff or gas valve.
Install
a gas supply
line that runs to the heating
Table 4 and the NFGC
pipe. It is recommended
local utility
for recommendations
gas supply
piping
use pipe smaller
valve.
For natural
concerning
for 0.5 in. wg maximum
than
the
1/2-in.
gas applications,
FPT
is operating.
the gas pressure
For propane
A 1/8-in. NPT plugged
nmst be installed
Refer
to
tapping
immediately
lines.
drop.
Size
Never
on the unit
gas
NOTE:
The
the gas pressure
less than 0.5 psig,
the gas piping
valve
must
for test gage connection
of the gas supply
by closing
opening
Unstable
operation
manifold
assembly
installing
Refer
54 latest
edition
(in Canada,
edition).
In the absence
pertinent
i. Avoid
every
ing improperly
line, observe
to the NFGC
of local
ANSI
must be isolated
main mannal
Use risers
all segments
codes,
Support
hangers,
etc. Use
a minimum
pipe sizes larger
national codes.
than
compound
Grade
system
all piping
i/2
all
to connect
of piping
damage.
NFPA
B149.2
latest
adhere
to the
union.
occur
when
the
to heating
rigid gas piping
when snaking
against
follow
(pipe dope)
physical
every
and
straps,
and
connectUse
to avoid strain
on,
piping.
sparingly
If a flexible conductor is required or allowed by the authority
having jurisdiction, black iron pipe shall be installed at the
gas valve and shall extend a minimum of 2 in. outside the unit
casing.
¥_ kU/'_W
:I: I I:[_
Never use a snatch
or other open flame
leaks. Never purge
gas line into combustion
to follow
serious
of
8. Check
and only to male
pipe connections.
this warning
injury
could
result
when checking
in an explosion
aRer all piping
Use
and water
soap
codes
Use only pipe
petroleum
gases as
Never use Teflon
for gas leaks at the field-installed
gas lines
Step
and.or
connections
solution
(or method
9--Install
Duct
6. Install ground-joint
unit manual shutoff
all
plumbing
union close
and external
gas
main
piping
valve
in
before
with
connection
local
and
of piping
UNITS
Before
performing
system,
FOR DOV_rNFLOW
service
tuna off main
serious
i. Open
work.
injury
return
connecting
connecting
down
disconnects
supply
duct
DIS-
require
that
with
accessory
watertight.
break
front
any service
by breaking
(Fig.
13).
and right
and a hammer.
side
Push louver
14).
to vertical
damage
the basepan
return-air
aluminum
opening
flanges
tape.
duct
Applicable
exposed
duct openings
cover
kit.
to the roof may occur.
insulation
opening
tape to prevent
6. Cover both horizontal
the
cover,
as permanent
of the vertical
aluminum
could
(iackstand applications
only), do so at this
screws that were removed.
Do not leave
5. It is recommended
basepan
on duct panel
and a hammer
is to be attached
screws on rooftop
on the
shock
starting
rear and leR side tabs (Fig.
on the unit basepan
time. Collect ALL
C99020
before
duct cover located
4. If unit ductwork
Trap
operations
to unit. Electrical
tabs with a screwdriver
to break
perimeter
or maintenance
power
tabs with screwdriver
3. To remove
Fig. 12_Sediment
(VERTICAL)
or death.
all electrical
2. Remove
CAP
See Fig. 6 and 7 for
¥_ kU/'_W
=I: IIT[_
cause
NIPPLE
by local
The unit has duct flanges on the supply- and retnrn-air openings on
the side and bottom of the unit. For downshot
applications
the
to heating section between
manual main shutoff valve.
in accordance
and gas codes
shutoff
section.
completed.
Connections
CONFIGURING
CHARGE
manual
6 It. of heating
been
specified
regulations).
5. Install
external,
causing
and factory-installed
have
ductwork
can be connected
to the roof curb.
connection
sizes and locations.
pipe within
Failure
or death
4. Install sediment trap in riser leading to heating section per Fig.
12. This drip leg functions as a trap for dirt and condensate.
an accessible,
for gas
chamber.
6 It. For
recommendations
tape.
national
to unit.
valve
while
to the gas valve.
connection
of, the gas control
runs
section
with appropriate
dope that is resistant to action of liquefied
specified by local and/or national codes.
7. Pressure-test
gas
out of position
1.4 in. in
horizontal
of one hanger
in.,
of joint when snaking
gas supply
from
shutoff
pertaining
Z223.1,
B149.1,
building
traps.
thermal
threads
local codes
CANiCGA
It. to prevent
3. Apply joint
section
the ground-ioint
may
routed
wrench
or distortion
recommendations:
downward
to risers.
and to meter.
2. Protect
the gas
connec-
low spots in long runs of pipe. Grade all pipe
15
from
¥!I [q:.IlriiI°]/1
the gas supply
to gas pipe installations.
following
be disconnected
the external
are forced
tion to the gas valve.
When
must
the unit heating
system
and slightly
a backup
upstream
piping
¥:I [_0l/l
than 13 in. wg at the unit
accessible
supply
valve during the testing of the piping systems when test pressure is
in excess of 0.5 psig (13.8 WC). If the test pressure is equal to or
at unit gas connection
than 13 in. wg while the
applications,
not be less than 7.0 in. wg or greater
connection.
existing
pressure
gas inlet
must not be less than 4.0 in. wg or greater
unit
section.
for gas pipe sizing. Do not use cast-iron
that a black iron pipe is used. check the
around
be secured
local
codes
the
to the
may
fiberglass.
with the duct covers from
Ensure
opening
is air-and
Table 2--Physical
UNit
SIZE 48GP
NOMINAL
024060
030040
030060
036060
036090
042060
042090
(ton)
2
2
2 1/2
2 1/2
3
3
3 1/2
3 1/2
(Ib)
290
290
313
313
321
321
382
382
CAPACITY
OPERATING WEIGHT
COMPRESSORS
Quantity
REFRIGERANT
Quantity
Data -- Unit 48GP -- 024040-042090
024040
ScroH
1
(R-410A)
(Ib)
50
5.0
5.5
55
69
69
9.0
9.0
REFRIGERANT METERING DEVICE
Orifice ID (in,)
AccuRater_
Piston
.057
.057
057
057
085
.085
.070
070
CONDENSER COIL
Rows...Fins/in.
Face Area (sq ft)
1/17
10.9
1/17
10.9
1/17
127
1/17
127
2/17
91
2/17
91
2/17
12.3
2/17
123
2350
22
1/8 (825)
2350
22
1/8 (825)
2350
22
1/8 (825)
2350
22
1/8 (825)
2350
22
1/8 (825)
2350
22
1/8 (825)
2350
22
1/8 (825)
2350
22
1/8 (825)
3/15
37
3/15
3.7
3/15
3.7
3/15
37
3/15
37
3/15
37
3/15
4.7
3/15
4.7
800
10x10
1/4
800
10x10
1/4
800
10×10
1/4
1000
10x10
1/4
1200
10x10
1/2
1200
10x10
1/2
1400
11x10
3/4
1400
11×10
3/4
2..44
2..50
2..38
2..46
2.38
2. 46
3.38
3. 46
2.38
2 .46
3..38
3..48
CONDENSER FAN
Nominal CFM
Diameter (in.)
Motor Hp (RPM)
EVAPORATOR
COIL
Rows...Fins/in.
Face Area (sq ft)
EVAPORATOR
BLOWER
Nominal
Airflow (CFM)
Size (in.)
Motor HP
FURNACE
Burner
SECTION*
Orifice No. (Qty...Drill
Natural Gas
Orifice No. (Qty...Drill
Propane Gas
Burner
Size)
Size)
HIGH-PRESSURE
SWITCH
Cutout
Reset (Auto.)
LOSS-OF-C
2.38
2 .46
(psig)
HARGE/LOW-PRESSU
(Liquid Line) (psig)
Cutout
Reset
2.44
2. 50
810 _+15
420 +_25
RE SWITCH
20 +_5
45 +_10
(Auto.)
RETURN-AiR
FILTERS
,o)T.rowaway
20×24×1
I 28×
24×1
I 28×
24xlI 20×
24xlI 20×24×1
I 20×24×1
I 24×30×1
I 24×
30×1
Table 3--Physical
UNIT SIZE 48GP
NOMINAL
048115
048130
060090
060115
(ton)
4
4
4
5
5
5
(Ib)
421
421
421
468
468
468
CAPACITY
OPERATING
Data -- Unit 48GP -- 048090-060130
048090
WEIGHT
COMPRESSORS
Quantity
Scrotl
1
REFRIGERANT
(R-410A)
Quantity (Ib)
REFRIGERANT
METERING DEVICE
Orifice ID (in,)
Accurater_
Piston
CONDENSER COIL
Rows...Fins/in.
Face Area (sq ft)
CONDENSER
FAN
Nominal Cfm
Diameter (in.)
Motor Hp (RPM)
EVAPORATOR
COIL
Rows...Fins/in.
Face Area (sq ft)
EVAPORATOR
BLOWER
Nominal Airflow (Cfm)
Size (in,)
Motor HP
FURNACE
Burner
Burner
9.5
9.5
95
10.0
10.0
100
.073
073
073
.086
.088
088
2/17
12.3
2/17
123
2/17
123
2/17
16.4
2/17
16.4
2/17
164
3300
22
3300
22
3300
22
3300
22
3300
22
3300
22
1/4 (1100)
1/4 (1100)
1/4 (1100)
1/4 (1100)
1/4 (1100)
1/4 (1100)
4/15
47
4/15
4.7
4/15
4.7
4/15
47
4/15
47
4/15
4.7
1600
11 x 10
3/4
1600
11 x 10
3/4
1600
11 x 10
3/4
1750
11 x 10
1O
1750
11 x 10
10
1750
11 x 10
1.0
3..31
3..41
3..38
3..48
SECTION*
Orifice No. (Qty...Driil
Natural Gas
Orifice No. (Qty...Drill
Propane Gas
HIGH-PRESSURE
SWITCH
Cutout
Reset (Auto.)
LOSS-OF-CHARGE/LOW-PRESSU
(Liquid Line) (psig)
Cutout
Reset (Auto.)
RETURN-AIR
060130
FILTERS
Size)
Size)
3.38
3.46
3.33
3.42
(psig)
3.33
3.42
3.31
3.41
810 _+15
420 +_25
RE SWITCH
(in.)Throwaway
20 _+5
45 +_10
24x
30x1
I
I
24x
30x1
I
I
24x
30xl
I
I
24x
30xl
I
I
24x
30x1
I
I
24x
30x1
Table 4--Maximum
Gas Flow Capacity*
LENGTH
NOMINAL
IRON PIPE SIZE (IN.)
INTERNAL
DIAMETER
(IN,)
OF PIPE, FTt
10
20
30
40
50
60
70
80
90
100
125
150
622
175
120
87
82
73
66
61
57
53
50
44
40
3/4
824
360
250
200
170
151
138
125
118
110
103
93
84
77
72
1
1048
680
465
375
320
285
260
240
220
205
185
175
160
145
135
1 1/4
1 380
1400
950
770
600
580
530
490
460
430
400
360
325
300
280
1 1/2
1610
2100
1460
1180
890
900
810
750
690
650
620
550
500
460
430
1/2
175
200
*Capacity of pipe in cu ft. of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0 5-in. wg (based on a 0.60 specific gravity gas) Refer to Table C-4, National
Fire Protection Association NFPA 54
1-This length includes an ordinary
7. After
completing
and power
number of fittings.
unit conversion,
perform
all safety
checks
up unit.
NOTE:
The design and installation
of the duct system must be in
accordance
with the standards
of the NFPA for installation
of
nonresidence-type
90A
or
air conditioning
residence-type,
residence-type,
NFPA
90B;
90B;
and.or
TO THE FOLLOWING
ADHERE
ING, SIZING,
i. Units
AND
according
transition
prevent
transmission
screwed
or bolted
ensure
weather
NFPA
codes
and
and ordinances.
CRITERIA
WHEN
THE DUCT
supply-air
to American
tion and Air Conditioning
dations.
flexible
local
SELECT-
SYSTEM:
for side shot installation.
and size ductwork,
grilles
systems,
and.or
local codes
INSTALLING
are shipped
2. Select
3. Use
and ventilating
NFPA
registers,
Society
Engineers
between
tight
rigid
flanges.
and airtight
Refrigera-
(ASHRAE)
of vibration.
to duct
and return-air
of Heating,
recommen-
ductwork
and unit
The
transition
Use
suitable
°/
to
may
be
gaskets
to
all
heating
ductwork
size increases
6. Adequately
outdoors.
insulate
Insulate
required
or performance
and weatherproof
ducts passing
barrier
through
in accordance
and Air Conditioning
RETURN
DUCT
OPENING
C99089
for unit being installed.
or decreases
and use vapor
Metal
for maxinmm
or cooling)
I
seal.
Fig. 13--Supply
4. All units must have field-supplied
filters or accessory
filter
rack installed in the return-air
side of the unit. Recommended
sizes for filters are shown in Tables 2 and 3.
5. Size
I
SUPPLY
DUCT
OPENING
airflow
Avoid
(either
abrupt
duct
may be affected.
all ductwork
located
unconditioned
space,
with latest
Contractors
and Return Duct Opening
issue of Sheet
National
Association
(SMACNA)
and Air Conditioning
Contractors
of America
(ACCA) minimum
installation
standards
for heating and air
conditioning
systems.
Secure
all ducts
to building
7. Flash, weatherproof,
and vibration-isolate
building
structure
in accordance
with local
building
structure.
all openings
in
codes and good
practices.
VERTICAL
DUCT
COVERS
C99012
Fig. 14_Vertical
10
Duct Cover Removed
Step lO--Install
Electrical Connections
The field-supplied
¥_ t','l'JI d ='ll_d
The
unit
electrical
cabinet
must
ground
if an electrical
have
to minimize
fault should
an electrical
wire
an
uninten'upted,
the possibility
occur.
connected
This ground
to the unit
control
compartment,
or
ground
when
in accordance
installed
conduit
70 (latest
Canadian
Electrical
[Canadian
Code CSA
as an electrical
could result
grozmd.
in serious
voltage
lug in the
voltage
electrical
Single
NEC
edition)
(National
i.
(in Canada,
Standards
to adhere
to follow
to this warning
or death.
these precantions
could result
ANSI_FPA
70 (latest
edition)
and local
governing
such wiring. In Canada,
tions must be in accordance
with
Canadian
codes.
2. Use
Electrical
Refer
only
Code
to unit wiring
copper
3. Be sure that high-voltage
voltage
range
indicated
4. Do not damage
any panel
Part
to mount
for
electrical
power
switch
and/or
phase
imbalance
HIGH-VOLTAGE
CONNECTIONS
separate
service
disconnect
electrical
switch mounted
to the unit rating plate
minimum
electrical
circuit
data.
with
amps (ampacity)
to the unit.
ground
DO
The
unit
a field-supplied,
for wire sizing.
L2)
and
ground
leads
into
the
lead to chassis
ground
connection.
23 of the compressor
phase
units:
Run the high-voltage
control box.
6. Connect
ground
field
(LI,
L2, L3) and ground
lead to chassis
and yellow
L1
to black
ground
into the
connection.
wires connected
wire
leads
on
to the lines side
connection
I1
of the
contactor.
field wire L2 to yellow
wire on connection
13 of the
contactor.
field wire L3 to Blue wire from compressor.
PROCEDURES
FOR 208-V
OPERATION
through
etc.
Make sure that the gas supply thet_ the power supply to the
unit is switched OFF before making any wiring changes.
Electrical shock or explosion could cause serious i11iury or
death.
5).
must
have
a
water-proof,
sight from the unit. Refer
fuse/circuit
(L1,
lug connection
5. Connect
within 2%.
of improper
to Table
high
the high-
4. Connect L2 to pressure
contactor.
compressor
operating
when drilling
(refer
when making
to complete
11 of the compressor
SPECIAL
conduit,
as follows
lug connection
4. Connect
plate.
hardware,
on the
units:
3. Locate the black
of the contactor.
between
to unit is within
at, or within
for maxilnum
connections
phase
compressor
components
electrical
Proceed
2. Connect
local
and unit.
5. On 3-phase units, ensure phases are balanced
Consult local power company
for con'ection
voltage
codes
applicable
connections
disconnect
WIRE.
on unit rating
internal
with NEC
all electrical
connecCSA standard (722.1
1 and
and Fig. 16 lbr reference
Run the high-voltage
control box.
Three
to
diagram.
conductor
field-supplied
electrical
NOT USE ALUMINUM
in damage
in accordance
box may be mounted
3. Connect L1 to pressure
contactor.
i.
the unit being installed:
1. Make all electrical connections
label
connections.
2. Connect
r:l [ "ffz_iilI*]2
Failure
switch
Associa-
codes. Do t_ot z¢se gas pip6_g
Failure
injury
of
for
with
Code) ANSI/NFPA
and local electrical
ground
See unit wiring
injury
may consist
approved
Electrical
tion] C22.1)
unbroken
of serious
disconnect
unit over the high-voltage
inlet hole when the standard power and
low-voltage
entry points are used. See Fig. 6 and 7 for acceptable
location.
breaker
With disconnect
size and
See Table
(3/16 in.) terminal
5 for
transformer
11
switch
open, move
marked
to primary
yellow
230 to terminal
voltage
wire l}om transformer
marked
of 208 vac.
200. This retaps
Table 5--Electrical
UNIT
SIZE
VOLTAGE
RANGE
V-PH-HZ
48GP
024
Data -- 48GP
OUTDOOR
COMPRESSOR
FAN MOTOR
INDOOR
FAN
MOTOR
POWER
SUPPLY
Min
Max
RLA
LRA
FLA
FLA
MCA
208/230-1-60
187
253
13.5
61.0
08
2.0
19.7
30
208/230-1-60
187
253
14.7
73.0
08
2.1
21.3
35
208/230-3-60
187
253
9.6
63.0
08
2.1
14.9
20
208/230-1-60
187
253
15.4
83.0
08
3.6
23.7
35
208/230-3-60
187
253
12.2
77.0
08
3.6
19.7
30
414
506
5.1
35.0
08
1.9
9.1
15
208/230-1-60
187
253
18.6
105.0
16
4.1
29.0
45
208/230-3-60
187
253
13.5
77.0
16
4.1
22.6
35
414
506
6.3
39.9
09
2.0
10.8
15
208/230-1-60
187
253
20.5
109.0
16
4.1
31.3
50
208/230-3-60
187
253
14.7
91.0
16
4.1
24.1
35
414
506
6.5
46.9
09
2.0
11.0
15
208/230-1-60
187
253
27.6
158.0
16
6.2
42.3
60
208/230-3-60
187
253
18.1
137.0
16
6.2
30.4
45
414
506
9.9
62.9
09
3.2
15.4
20
MOCP*
030
036
460-3-60
042
460-3-60
048
460-3-60
060
460-3-60
EXAMPLE: Supply voltage is 469-3-60.
a B C
AB = 452 v
FLA
LRA
MCA
MOCP
RLA
------
Full Load Amps
Locked RotorAmps
Minimum Circuit Amps
Maximum Overcurrent Protection
Rated Load Amps
LEGEND
C@
AC = 455 v
US
Average Voltage =
BC = 464 v
452
+ 464
+
455
3
1371
3
= 457
NOTES:
1. In compliance with NEC (National Electrical Code) requirements
for multimotor and combination toad equipment (refer to NEC
Articles 430 and 440), the overcurrent protective device for the
unit shall be Power Supply fuse. The CGA (Canadian Gas
Association) units may be fuse or circuit breaker.
2. Minimum wire size is based on 60 C copper wire. If other than
60 C wire is used, or if length exceeds wire length in table,
determine size from NEC.
3. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine
the percentage of voltage imbalance.
Determine maximum deviation from average voltage.
(AB) 457 452 = 5 v
(BC) 464 457 = 7 v
(AC) 457 455 = 2 v
Maximum deviation is 7 v.
Determine percent of voltage imbalance.
7
% Voltage Imbalance = 100 x -457
= 153%
This amount of phase imbalance is satisfactory
maximum allowable 2%.
% Voltage imbalance
= 100 x
max voltage deviation from average voltage
average voltage
as it is below the
IMPORTANT: If the supply voltage phase imbalance
is
more than 2%, contact your local electric utility company
immediately.
C99024
Fig. 15--Electrical
Data Legend
CONTROL VOLTAGE CONNECTIONS
NOTE:
control
Use
P
Do not use any type of power-stealing
problems
no.
thermostat.
may result.
18 American
Wire
Gage
(AWG)
color-coded,
to make the control voltage connections
and the unit. If the thermostat
is located
more
the unit
i00
ft from
voltage wires), use
minimum)
wires.
STANDARD
and 7. Remove
adjacent
Locate
a drip loop before
grommet
leads
running
fl:om the
five 18-gage
wires leaving
leads can be identified
side of control
into the low-voltage
box).
Stripped
-
-
i_
o- - £]_POWER
insulated
(35 C
CONTROL
BOX
hole located
panel.
GRN(G)
LOW-VOLTAGE
POWER
LEADS-
packet
opening.
the inlet
_1 Q
"-RED_'R'Z
(SEE UNiT
WIRING LABEL)
panel.
through
"L
--YELLY
L 1:_
See Fig. 6
installer's
control
SUPPLY
FIELD-SUPPLIED
FUSED DISCONNECT
GND
THERMOSTAT
®
@
SPLICE
I
(TYPICAL)
BOX
C99018
box.
box. These
Fig. 16--High-
low-voltage
and Control-Voltage
Connections
by the colors red, green, yellow,
and white. (See Fig. 16.) Ensure
to be routed
-
- :I
the control
in the knockout
wire through
splice
along
knockout
access
fl:om the thermostat,
and into unit low-voltage
connection
brown,
Remove
to the control
the rubber
the low-voltage
hole,
color-coded,
with unit) and install grommet
Provide
Run
16 AWG
CONNECTION
in the flue panel
(included
no.
(as measured
-
insulated
(35 C minimum)
wires
between
the thermostat
than
HIGH VOLTAGE
|
POWER LEADS
<o(SEE UNIT WIRING|
LABEL)
_-
Unit
the leads are long enough
splice box (located
yellow
wire is located
below
right
in connection
box. Route
leads through
low-voltage
connections
hole in bottom
as shown
so that they do not interfere
12
of control
box and make
in Fig. 16. Secure all cut wires,
with operation
of unit.
HEATANTICIPATOR
SETTINGTheroomthemlostat
heat
anticipator
mustbeproperly
adjusted
toensure
proper
heating
performance.
Settheheatanticipator,
using
anammeter
between
theWandRtemlinals
todetermine
theexact
required
setting.
NOTE:
For thermostat
approximate
Failure
to make
improper
a proper
heat anticipator
discomfort
space,
and inefficient
setting
may
shorted
adjustment
utilization;
slightly
for a particular
4. Verify
will result
straighten
the following
the required
a greater
degree
of
The
transformer
overload
a. Before
or
Failure
to observe
serious
injury
the
following
union
safety
wamings
practices
or servicing
compressor
around
and recover
terminal
in
attempt
refrigerant
system.
any electric
soldered
oil and refrigerant
wear
be loosened,
b. Make
power
to
is in place
from
both
touching
box if refi'igerant
to repair
and
high-
sure that condenser-fan
c. Ensure
connecting
pressure.
purge
upon
to purge
gas lines into
detection
5 minutes
of gas
to elapse,
then
Leading
and
blade is con'ectly
edge of condenser-_an
from fan orifice
fan hub is 1/8 in. max from
motor
housing.
is in place.
e. Make
sure that condensate
&ain trap is filled
proper
should
(see Fig. 17).
sure that air filter(s)
ensure
positioned
blade
with water to
&ainage.
f. Make sure that all tools and miscellaneous
been removed.
loose parts have
refrig-
component.
goggles
the
If the
the unit,
line be allowed
d. Make
MOTOR
any
Allow
perlbrln
position:
that the ground joint
Never
hnmediately
the union.
be 1/2 in. maxinmm
leak is suspected
while
time,
before
and the supply
chamber,
in fan orifice.
or disturbing
connection
under
protective
first
light unit.
terminals.
erant system is under pressure.
6. Do not use torch to remove
component,
lows:
pipe was not purged
a combustion
cover until all electri-
all refrigerant
inside terminal
contains
result
protective
cover
sides of system before
compressor
5. Never
could
and wear
or provide
compressor
for the
until the odor of gas is detected.
3. Do not remove compressor
terminal
cal sources are disconnected.
anything
the unit
odor, re-tighten
checking
2. Do not operate
low-pressure
and handling,
with the gas valve in the "OFF"
it will be fidl of air. It is recommended
or death:
recognized
4. Relieve
shipping
conditions:
lighting
following
¥_ L'Jl:l;tlllX_
unit unless
secured.
during
fins with a fin comb.
is of the
a 30-second
condition.
when
Be sure
Do not purge gas supplyintothe combustion chamber. Do not
use a match or other open flame to check Ibr gas leaks.
Failure to follow this waming could result in an explosion
causing serious injury or death.
gas supply
goggles
connections.
and tight.
Ig_|','l'_l fill IX_
in
PRE-START-UP
1. Follow
and factory-wiring
are completed
coil fins. If damaged
carefully
installation.
type. It is set to withstand
secondary
d. Inspect
of the conditioned
however,
to provide
PROTECTION
energy-limiting
use 0.18 amp for the
to the occupants
energy
be changed
TRANSFORMER
purposes,
all field-
that connections
setting.
operation,
comfort
selection
required
c. Inspect
_
FAN
GRILLE
System
To remove
and proceed
a
as fol-
a. Shut off gas supply and then electrical power to unit.
b. Relieve
and reclaim all refrigerant
l}om system using
both high-
and low-pressure
c. Cut component
remove
component
d. CarefMly
as
unsweat
follows
robing with tubing
1/8" MAX BETWEEN
MOTOR
AND FAN HUB
cutter and
remaining
when
to inspect
tubing
exposed
and
stubs
prepare
Fig. 17--Fan
when neces-
to torch
the
flame.
unit
access
Use the Start-Up
for initial
panel.
and follow
CAUTION,
shipped
instructions
and
on all DANGER,
INFORMATION
labels
as follows:
CHECK
FOR
attached
to,
i.
and repair
lines,
or
been relieved
parts,
LEAKS
leaks
Proceed
and charge
and
as follows
to
the unit:
and refrigerant
recovered
system pressure
from
both high-
has
and
ports.
inspections:
lbr shipping
loose
refrigerant
at the end of this book,
Locate leak and make sure that refrigerant
2. Repair
a. Inspect
supplied
WARNING,
with, unit.
the following
Blade Clearance
REFRIGERANT
low-pressure
3. Make
Checklist
proceed
locate
2. Read
SHAFT
START-UP
startup:
i. Remove
MOTOR
C99009
l_'om unit.
sary. Oil can ignite
Proceed
ports.
connecting
and handling
disconnected
damages
wires,
leak following
accepted
practices.
such as broken
NOTI=:
etc.
Replace
filter drier whenever
the system has been opened
for repair.
b. Inspect
unit
leak.
for oil at all refrigerant
base.
Leak
electronic
tion.
Detecting
If
Refrigerant
test
all
refrigerant
leak detector,
a refrigerant
Leaks
tubing
oil generally
tubing
halide
leak
section
connections
indicates
torch,
connections
using
or liquid-soap
solu-
is detected,
on page
and on
3. Check
a refrigerant
see
Check
system
4. Evacuate
additional
for
5. Charge
13.
charging
unit
with
cylinder
for required
13
for leaks using
refiigerant
system
leaks are found.
an approved
method.
and
refi'igerant
reclaim
R-410a
refrigerant,
or accurate
scale.
cha_'ge.
R@r
using
if no
a volumetric-
to unit rating
plate
Table 6--Heating
HEATING
INPUT
(BTUH)*
Inputs
GAS SUPPLY PRESSURE
(IN. WG)
NUMBER
OF
ORIFICES
MANIFOLD
PRESSURE
(IN. WG)
Natural
PropaneT
Max
Natural
Propane'i"
40,000
2
40
130
70
130
3.5
35
60,000
2
40
130
70
130
3.5
35
90,000
3
40
130
70
130
3.5
35
115,000
3
40
130
70
130
3.5
35
130,000
3
40
130
70
130
3.5
35
*When a unit is converted
to propane,
different
Min
Max
Min
size orifices must be used. See separate
naturaI-to-propane
conversion
kit instructions
1-Based on aItitudes from sea level to 2000 ft. above sea levet. For altitudes above 2000 ft., reduce input rating 4% for each 1000 ft above sea Ievel. in Canada,
2000 ft above sea level to 4500 ft above sea Ievel, derate the unit 10%
START
UP HEATING
IMPORTANT:
Complete
Pre-Start-Up
section
Do not jumper
Make
sure
operation
SECTION
the
above
burner
required
before
any safety
that
AND MAKE
given
are properly
the burner
ADJUST
in the
the unit.
Unstable
in the manifold
Make
gas piping
sure that gas supply
has been
CHECK
checked
HEATING
heating
instructions
control
located
operation
inside
and the FAN
2. Set the heating
burner
access
switch
in the AUTO
the unit
(see fumace
or blower
temperature
for
NOTE:
lighting
panel.):
in the HEAT
Turn
4. After
motor
a call for heating,
seconds.
above
before
another
5-second
this sequence is repeated.
minutes from the initial
reset the control,
5. The evaporator
break
should
light within
there is a 22-second
try. If the burners
CHECK
GAS
INPU_Check
after unit start-up
as follows:
The rated
shown
level to 2000 ft. above
gas with a heating
5. Multiply
gas with
gravity.
For elevations
in Table
6 are for altitudes
sea level. These
a heating
value,
or contact
value
above
sea level.
heating
local codes,
orifice size.
heating
inputs are based
of 2500
2000
When
or specific
ft., reduce
gravity,
sea
input
refer
used
4.
units
are designed
using the fixed
shown in Table
UNDER
to consume
in Step
the size
be
18) then
connect
test dial to make one
3 into
3600
(number
of
of cu. ft. shown
for
cu. ft. of gas flow per hour.
value of gas to obtain
this value with heating
the local gas supplier
if the
of test dial
is 1 cu. ft., one
value
of the gas is
one revolution.
112.5
112.5 ft 3 of gas flow&r.
118,125
Btuh input.
gas input is 115,000
pressure
is required.
and
Observe
manifold
pressure
Btuh, only a minor
and proceed
change
in the
as follows
to adjust
adjustment
screw
gas
input:
2. Turn
gas inputs
cover
regulator
screw over regulator
adjustment
input, or turn regulator
orifices at specified
manifold
pressures
as
6. DO NOT REDRILL
THE ORIFICES
ANY CIRC[
that
to complete
112.5 x 1050
i. Remove
valve.
the rated
Fig.
for gas meter
6. (Consult
manifold
P':I['_:lliiI0]11
These
Assume
If the desired
the required
must
of gas is not known.)
has a
to national
to determine
(see
of Step 5 by Btu heating
in Table
3. 112.5 x 1
or
4% for each
being
meter
orifices
at the meter.
input in Btuh. Compare
2. 3600+32
on natural
gravity,
use the same
revolution
takes 32 seconds, and the heating
1050 Btuift 3. Proceed as follows:
Btuift 3 at 1.5 specific
the gas supply
your distributor
from
main bumer
codes.
of Step 4 by the number
value
EXAMPLE:
proceed
pressure.
3.4 and 3.6 in.
local
of test dial to obtain
result
input shown
pressure
is required,
value of 1050 Btuift 3 at 0.65 specific
propane
different
6.) If adjustment
result
total measured
and manifold
adjustment
turn on gas to unit.
of seconds
one revolution
after the flame has
between
change
on manifold
at this point,
i. 32 seconds
gas inputs
ft. above
gas input
(See Table
pipe plug
4. Multiply
been established.
The evaporator
fan will turn off 45 seconds
after the thermostat
has been satisfied.
to
to unit.
light,
to W.
fan will mm on 45 seconds
that
Minor
the manifold
of national
3. Divide number
of seconds
seconds on one hour).
If the burners do not light within 15
call for heat, there is a lockout. To
the 24-v power
are required,
delay
still do not
5
Gas Units)
must be maintained
appliances
2. Record number
revolution.
do not light,
for
be measured
as follows:
manometer
will start.
is recommended
must
by changing
gas flow is measured
off gas supply
i. Remove
of the thermostat
the main burner
If the bumers
other
by
the manifold
gas units.
the recommendations
off when
Proceed
position
position.
control
pressure
All
turned
pressure
(Natural
wg. If larger adjustments
temperature.
3. The induced-&aft
i000
GAS FLOW
following
as follows.
SYSTEM
switch
and that all
Start and check
manifold
to the gas flow can be made
for leaks.
CONTROL
Place room thermostat
rooln
has been purged,
The
the input of propane
MEASURE
are
or by measuring
the gas flow at the meter
units.
The manifold
NOTE:
i.
gas
determine
misaligned.
proper
Measuring
natural
gas input to the unit is determined
the gas flow at the meter
pressure.
aligned.
orifices
GAS INPU_The
measuring
the unit.
when operating
orifices
may occur when
procedures
starting
devices
ADJUSTMENTS
from
decrease
input.
3.6 in. wg.
MSTANCES.
14
screw
adjustment
Manifold
pressure
clockwise
on gas
to increase
gas
screw counterclockwise
to
must
be between
3.4 and
3. Turn on gas to unit.
4. Remove
valve.
cover
screw over regulator
5. Adjust
regulator
adjustment
pressure,
as
clockwise
to increase
screw
specified
6. Replace
7. Turn
cover
screw
in
Table
manifold
counterclockwise
PIPE
C99019
Fig. 18--Burner
or turn
manometer
screw
adjusting
pressure.
BURNER
FLAME
With burner
operation.
the same for each
Assembly
from pressure
tap.
then turn on gas to unit. check
Watch
access
panel
the burner
burner.
removed,
flames
to see
and that the flames
Propane
flame with yellow tips. (See Fig. 19). Refer
for information
on burner removal.
PLUG
manifold
adjusting
manifold
if they are light blue and soft in appearance,
MANIFOLD
on gas
screw.
the unit heating
approximately
screw
correct
Turn
pressure,
Replace pipe plug on gas valve,
for leaks.
observe
to the
6.
to decrease
off gas to unit. Remove
CHECK
adjustment
will
are
have blue
to Maintenance
section
BURNER FLAME
F_ WI_'I ;h" !R[fl_
Unsafe
operation
is outside
result.
3. Replace
this
cover
4. Turn offgas
of the unit may result
range.
Serious
screw
supply
il_iury
if manifold
or unit
to unit. Remove
MANIFOLD
The main
burner
BURNER
may
cap on gas valve.
manometer
tap and replace pipe plug on gas valve.
check for leaks.
MEASURE
pressure
damage
MANIFOLD
PRESSURE
orifices
(PROPANE
on a propane
unit rated input when the manifold
level specified
in Table 6.
from pressure
Turn on gas to unit and
UNITS)
unit are sized
pressure
reading
for the
matches
the
C99021
Fig. 19--Monoport
lr_ i','l:_hh' !Rl:fl_
If converting
inspect
to propane
the heat
exchanger
baffles
installed
REMOVED.
Discard
robes.
in the
the baffles
Refer
gas, remove
firing
the burner
If there
tubes,
assembly
are V-shaped
THEY
AIRFLOW
and
NOx
MUST
BE
after removal.
to Maintenance
section
information
on
burner
removal.
Proceed
as follows
to adjust
gas input on a propane
the temperature
Table
7 shows
i.
Turn off gas to unit.
manometer
pipe
plug
on manifold
(see Fig.
18) then
connect
at this point.
15
rise range
falls within
the approved
to Indoor
pages
Airflow
to adjust
stamped
temperature
input, and the air delivery
airflow
RISE
and approved
approved
operation
Refer
gas unit:
the
The heating
following
2. Remove
TEMPERATURE
within
heating
for
AND
for each size unit is designed
Burners
The heating
for heating
on the unit rating
rise
cfin at various
must produce
section
operation
range
temperature
a temperature
plate.
for each
rises.
rise that
range.
and Airflow
heating
Adjustments
airflow
section
when required.
on the
Table 7--Air
HEATING
INPUT
(BTUH)
INPUT
Delivery (Cfm) at Indicated Temperature
TEMPERATURE
40
20
25
30
40,000
1500
1200
1000
857
60,000
2250
1800
1500
1286
90,000
--
2700
2250
1929
115,000
--
--
--
2464
130,000
....
temperature
HEATING
SEQUENCE
See Fig. 20-22
unit wiring
label.
starting
the induced-draft
speed, the burner
the
terminal
the induced-draft
integrated
energized
"W" of the thermostat
motor.
When
gas control
45 seconds
(IGC).
after flame
The
and "W" is de-energized,
fan motor
to monitor
LED
diode)
667
600
--
--
1000
900
818
750
692
1688
1500
1350
1227
1125
1038
2156
1917
1725
1568
1438
1327
2438
2167
1950
1773
1625
1500
access
is continuously
When
motor
Complete
section
is
the thermodelay.
The
control
board
is located
by
During
normal
operation,
the
"on" cycles
CHECKING
8 for error codes.
check
any safety
given
starting
devices
when
the compressor.
COOLING
CONTROL
room
AUTO
On
cooling
thermostat
that blower
in ON position
LED INDICATION
Observe
3 Flashes
blower
4 Flashes
when control
setting is satisfied.
continue to run for 30 seconds.
7 Flashes
Internal
Control Fault
8 Flashes
Internal
Software Fault
9 Flashes
AUTO
6 Flashes
3. When
that
using
cooling"
(below
com-
compressor
Should
5 minutes,
SWITCHES_onnally
leaving-air
"breaks".
closed
circuit
through
temperature
temperature,
the
limit
rise
switch
Any interruption
limit
switch
the thennostat
above
opens
the
air
the maximum
and
in the R control
low-temperature
completes
temperature
setting
the R control
at the
the
R control
circuit
LIMIT
switch
drops
the switch
circuit.
spark ignition
The electric
to normal
the IGC LED
AUXILIARY
limit
heating
will display
SWITCH
FAULT
(ROLLOUT)
When
turning
evated noise
The
at the anxiliary
able temperature,
and stopping
motor
is reset.
switch
the R control
gas flow to the burners.
(IFM) and induced
draft motor
The IGC LED will
reaches
circuit
display
trips,
The indoor
continue
FAULT
NOTE:
this
2.
function
of
and
in
evaporator
cycle
shuts
evaporator
room thermostat,
positions.
control
down
fan
will
place
both
Observe
that
control
is set
and operates
in
is set to "call
for
compressor
lead orientation.
unit
must
If not con'ected
within
is tully
The
to con'ect
compressors
between
AD,RTSTING
compressor.
reversed
emit
compressor
may be &amatically
system
are
proper
be
scroll
units
to ensure
will shut offthe
backwards,
and is tested
to run until
Adjustment
el-
suction
lower
than normal.
REFRIGERANT
CHARGE
charged
and factory
the unit
charge.
The charging
A refrigerant
compressor
allow-
with R-410A
(Puron)
sealed.
switch
An
7.
16
label
charging
access
accurate
mometer,
the
is suspected
refrigerant
of not
charge
having
and the tables
the
shown
is not
required
proper
R-410A
refer to system
and pressures.
line temperature
ambients..
fan
of
unless
temperatures
the gas valve
(evaporator)
CODE
The
switch
system
the maximum
closing
AND
The refrigerant
the switch is to close the main gas valve in the event of flame
rollout. The switch is located above the main bumers. When the
temperature
CHECKING
fan,
in AUTO
levels, and the difference
pressures
refrigerant,
in
room temperature.
cooling
scroll
to the
and discharge
the
is placed
and FAN
must be checked
protector
rotation.
to
switch
room temperature)
units
power
closes
When
CODE
3-phase
the internal
circuit
The
position.
temperature).
These
leads
closes and
operation.
room
power
and pilot.
that
temperature
Three-phase,
3-phase
instantly
and
switch is placed
mode when temperature
(above
when
direction-oriented.
allowable
of the limit switch,
and the unit returns
_ault occurs,
(LS)
R circuit.
the gas valve and stops gas flow to the burners
blower motor continues to run until LS resets.
cycles
in Heating
mode
LIMIT
the control
Start
in OFF
below
condenser
Observe
an auto-changeover
Cooling
IMPORTANT:
When
start.
and FAN" switches
unit operates
error code displays
between
as follows:
FAN
position
control
compressor,
to "call for heating"
pause between
in COOL
Set cooling
motors
2 If more than one error code exists, all applicable error codes wilt be
displayed in numerical sequence.
3 This chart is on the wiring diagram located insidethe burner access
panel
pletes
switch
position.
SYSTEM
NOTES:
switch
and shuts down when FAN
2 Flashes
Rollout Switch Fault
5 minutes
starts when
Flame Sense Fault
5 Flashes
the unit.
position.
2. Place SYSTEM
Ignition Lockout Fault
Induced-Draft
Motor Fault
the unit.
operation
SYSTEM
motor
off
is a 3-second
AD,RTST-
OPERATION
control
1 Flash
1 There
MAKE
damage.
Fan On/Off Delay Modified
Limit Switch Fault
Limit Switch Faults
1393
operating
Allow
compressor
Failure
Four Consecutive
964
in the Pre-Start-Up
before
to prevent
the unit for proper
Observe
Normal Operation
the
AND
procedures
pages
Do not rapid-cycle
on the control
i. Place
Hardware
70
Do not operate the compressor
when the outdoor temperature
is below 40 ° F (unless accessory low-mnbient
kit is installed).
stop firing and
time-off
is provided
CODE
SECTION
the required
on previous
Do not jumper
Table 8 LED Indications
ERROR
65
on
panel.
on. See Table
60
START UP COOLING
MENTS
and
sensor
fan
the burners
indicator
operation.
the burner
evaporator
shuts off after a 45-second
An LED (light-emitting
55
is energized,
the hall-effect
is established.
stat is satisfied
removing
750
1125
motor senses that it has reached the required
sequence begins. This function is perfomled
by
the evaporator
board
50
rise range of the unit.
NOTE: Dashed areas do not fall within the approved
On a call for heating,
RISE °F
45
35
OF OPERATION
Rise and Rated Heating Input
a gage
label is attached
The chart
at given
superheat,
and
chart
door.
includes
suction
line
thermocouplemanifold
are
to the outside
the required
pressures
of the
suction
and
outdoor
or thermistor-type
required
when
using
therthe
UNIT COMPONENT ARRANGEMENT
FIELD
OFM
SECTION
OUTDOOR FAN
U
SUPPLY
EQUIP
GND !
COMPRESSOR
_
_
_1 [[
COMP
(SEE NOTE #4)_
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BO×
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SECTIO
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I
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INDICATE COMMON
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ONLY
NOT TO REPRESENT
WINING
BR
8LOMER
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CAP
COMP
CONTACTOR
CAPACITOR
COMPRESSOR
CR
EOMIP
COMDUSTION
EQMIPMENT
RELAY
FS
FLAME SENSOR
FU
FUSE
GND
GROUND
GVR
GAS VALVE RELAY
HPS
HIGH PRESSURE SNITCH
HS
HNLL EFFECT SENSOR
HV TRAN HIGH VOLTAGE TRANSFORMER
I
IGNITOR
IGC
INTERGRATED GAS MNIT
CONTROLLER
IDM
INDUCED DRAFT MOTOR
IFM
INDOOR FAN _OTOR
LPS
LOW PRESSNRE SMITCH
LS
LIMIT SMITCH
MGV
MAIN GAS VALVE
OFM
OUTDOOR FAN MOTOR
_
THAN
QNADRUPLERoLLOUT
SWITcHTERMINAL
TRANSFORMER
MOTOR
RELAY
NOTES:
IIF
ANY OF THE ORIGINAL WIRES FURNISHER ARE REPLACER,
IT MUST RE REPLACED WITH TYPE 90 DEGREE C WIRE OR
ITS EODIVALENT
2SEE PRICE PAGES FOR THERMOSTAT AND SUNNASES
5USE T5 DEGREE COPPER CONDUCTORSFOR FIELD INSTALLATION¸
4FOR HIGH SPEED IF_,DISCONNECT NED
WIRE FROM IGC;D_ AND CONNECT NLH NINE FNO_ IFM
FOR MEDIUM NPEEO,DISGONNECT RED WINE
FRO_ IgC:RN AN8 CONNECT RLU MINE FROM IFM
50N MODELS 48GPOR4 056 HAS LSI AND LS2 IN SERIES¸
ON MODELS 48GP042 O_D HAS LSI ONLY¸
wON
Jl
FIELD
mB(
LEGEND
W59 REDBR
--
0
aiii ........
LARGE CHASSIS LOCATION
_FIELI)
SPLICE
O
TEN_INAL
{MARKEI))
o TERMINAL (UNMARKED1
0
SNLICE
BLI_
24V SPLICE BOX
,
GAS
TEL
CR
WI3
FI
AHA
_GRN
W46 BRN
RH
COOLJ. TH I
_
N
FAR LOGIC
OFF
_COOL
E
P_ MAR_
Gs
RCS
k
I
80X
FAN LOGIC
T
T+5D
G
DE ENERGIZED
HEATING
i
i
D N5
W DR
ENERGIZED
BLK
Z4V
[SPLICE
COMP
THERMOSTAT
_
W41 GRN YEL--GR
W32 8RN
_W46 BRN
%_,
2
_L
YEL_BLK_-_BLK_
LUg.
GRO NDED
z_BL
YEL_
/_X_i_/_
_
W'_q
n R
_WSO RN
W30 BR
COMMOb--
C99076
Fig. 20--208/230-1-60
Wiring
Diagram
UNIT
OFM
COMPONENT
ARRANGEMENT
OUTDOORFAN
ECTIO
EQUIP
GND i
ONLY) COMPRESSOR
CONTROL
BOX
!
SECTION
COMP
NON_OMP
_ T rl,_
GAPBII _
@
CO_*P
COOLING
O
G
ENERGIZED
HEATING
ii
0 45
W BR
ENERGIZED
FAN
IGC
E@
O_
I_#ICE
BOX
LOGIC
c
IBM
T
%30
g
DE ENERGIZED
s
R
GAS
_GRN YEL
FAN LOGIC
I
i
T
T+45
W
BR
DE ENERGIZED
nD@
SECTION
01SCO
NECT
:_ER NEE
W46 BRN
LEGEND
_FIELD
SRLIBE
O TERMINAL (MARKED/
o TERMINAL (NNMARKEB}
0
SPLICE
<IISPLICE
(MARKED)
FACTORY WINING
II
ii-
I
FIELD CONTROL WIRING
FIELD POWER WINING
ACCESSORY OR OPTIONAL
WIRING
TO INDICATE _OMMON
POTENTIAL ONLY:
NOT TO REPRESENT WIRING
BR
BLOWER RELAY
C
_0_NTACTOM
CAP
COMM
CR
EQUIP
CAPACITOR
COMPRESSOR MOTOR
COMBUSTION RELAY
EQUIPMENT
FL
FU
GND
GVR
NPS
HS
HV TRAM
I
IGC
IDM
IFM
LPS
Lq
MGV
OFM
OT
RS
TRAN
FLAME SENSOR
FUSE
GBONNB
GAS VALVE RELAY
HIGH PRESSURE SWITBN
HALL EFFECT SENSOR
HIGH VOLTAGE TRANSFORMER
IGNITOR
INTERGRATED GAS UNIT
CONTROLLER
INDUCED BNAFT MOTOR
o
INDOOR FAN MOTO_
LOW RRESSUBE SWITCH
LI_IT
SWITCH
MAIN GAS VALVE
OUTDOOR^ FAN MOTOR
QUADRUPLE TERMINAL
ROLLOUT S W ITCH
TRANSFORMER
'
NOTES:
IIF
ANY OF TNE ORIGINAL WIRES FURNISHED ARE REPLACED,
IT MUST BE REPLACD WITH TYPE 90 DEGREEC WIRE OR
ITS EQUIVALENT
2 SEE PRICE PAGES FOR THERMOSTAT AND SBBBASES
5USE Y5 BEBREE COPRER ¢OROUBTORS FOR FIELD INSTALLATION
4FOR HIGH SPEED IFM,OISDONNKT
REO
WIRE FROM IBG;BM ANB CONNECT BLK WIRE FROM IEM
FOR NDIUN SPEED,BISCONNEGT RE_ WIRE
F_OM IGD;BN AND CONNECT BLU WIRE FROM IFM
5 ON MOBELS 4BBPOR_ 036 HAS LSI ARB LSR IN SERIES
ON MOBELS 4BBPO42 DBD HAS LSI ONLY
C99077
Fig. 21--208/230-3-60
Wiring
Diagram
W43 BLK
UNIT COMPONENT ARRANGEMENT
OUTDOOR FAN
SECTION
OFM
OT CAP_
W6
COMPRESSOR
W8
CONTROL
SECTION
80X
EQUIP
GND
L
/
__I
COMP
(060 ONLY)_L
W56 BLU
5
:ROM COMP
_CAPSI
_
,
I_
I
(SEE NOTE @4)_
@
16C0_
RNg
COMP
COOLING
FAN
ISPLICE
E@
LOGIC
C
O
G
ENERGIZED
T
O
DE
HEATI
T+SO
OT
I
i
T
T+45
W
BR
DE ENERGIZED
zGRN
S
R
ENERGIZED
G FAN LOGIC
I
i
O 45
W BR
ENENGIZEO
BOX
YEL
W46
iGAS
_FIELD
O
o
II
SPLICE
TERMINAL
TERMINAL
S_LICE
(MARKED>
{UNMARKED1
,
(jI_PLICE
(NARKED_
FACTORY WINING
FIELD CONTROL WIRING
--FIELD POWER WIRIMG
---- ACCESSORY OR OMTIONAL
WIRING
TO IN_ IEATE COMMON
y
POTENTIAL ONL:
NOT TO REPRESENT WINING
I
BR
C
CAP
° AUTO
SECTION
DISCONNECT
PER NEC
BRN
To
nB(
COMM
CR
EOUIP
BLOWER RELAY
_0#NT ACTOR
CAPACITOR
_
COMiRESSOR
MOTOR
COMBUSTION RELAY
EQUIPMENT
FL
FU
ORb
GVN
HPS
HS
HV TRAN
I
IGC
IBM
IFM
LPS
LS
FLAME SENSOR
FUSE
GROUND
GAS VALVE RELA
_
,, SWITCH
HIGH _RESSU_E
HALL EFFECT SENSOR
HIGH VOLTAGE TRANSFORMER
IGNITOR
INTERORATED GAS UNIT
CONTROLLER
INDUCED ORAFT _OTON
INDOOR FAN MOTOR
LOW PRESSURE SWITCH
LIMIT
SWITCH
MGV
OFM
OT
RS
TRAN
WAIN GAS VALVE
Oi_TDOOR: FAN MOTOR
QUADRUPLE
TERMINAL
ROLLOUT SWITCH
TRANSFORMER
I
NOTES:
IIF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED,
IT MUST BE REPLACER WITH T_PE 90 NEGREE R WIRE OR
ITS
EODIVALENT
R SEE PRICE PAGES FOR THERMOSTAT ANN SbBNASES
]USE
75 DEGREE COP?ER CONDUCTORS FOR FIELD INSTALLATION
4 ON ALL UNITS FOR G E MOTORS WIRE AS FOLLOWS
FOR NIGH SPEED CONNECT TO NLK AND YEL
FOR MEN SPEED CONNECT TO ORN AND YEL & SPLICE TOGETHER BLK A_D VIO
FOR LOW SPEED CONNECT TO RED ANN YEL & SPLICE TOGETHER NLK AND VIO
SON MODELS @MOPe24 036 HAS LSI AND LS2 WIRED IN SERIES
ON MODELS _NGPO42 Q60 HAS LSI ONLY
J
ON
FIELD
THERMOSTAT
C99078
Fig 22460-3-60
Wiring Diagram
superheat
charging
method
for evaluating
the unit charge.
use mercw 3"or small dial-o_e
thermometers
adequate for this O'pe of measurement.
IMPORTANT:
cated
When
adjustment
very minimal.
evaluating
to the specified
If a substantial
REFRIGERANT
is listed
on
Service
Unit
the unit
panels
charging
nameplate.
be
is indicated,
The amount
Manual,
must
must
Refer
in place
when
be
as insuf-
of rel}igerant
is
ating system,
system
Use standard
evacuating
in the specified
Refi'igeration
COOLING:
Charging
conditions
different
Charts
of the
Measure
operating
wired
during
After
of refrigerant
chart
the units to correct
are met.
reqnired.
gage
Connect
Vary
Note
used.
superheat
pressure
outdoor
(Figs. 23-28).
from type normally
Accurate
and
ambient
charts
on charging
operating
conditions.
sensing
devices
gage to the service
To change
port
motor
are
are based
temperature
red
using
until the
charging
air CFM
must
be within
the normal
ambient
CHARGING
temperature
the chart
NOTF::
INDOOR
what
problem
refrigerant
leak,
this docmnent.
CHARTS:
and read the suction
to determine
If the
the suction
causing
refer to Check
AIRFLOW
cfin
AND
operation,
for each
heating
12,000
operation,
that falls within
Take
pressure
speed
are
on the
the
change
the speed,
motor
speed.
chassis
parts.
For 460-v
l'ollows:
Refer
being
the lead connections
should
black = high speed
---
speed
red = low speed
of the blower
motor
the blower
(BM),
relay
BM for single-phase
remove
Insulate
and replace
the removed
GE Motors
The
readings
Leaks
is a
section
speed
in
ADJUSTMENTS
the recommended
Btuh
of rated
the range
stamped
tables
cooling
must produce
is 350 to 450
airflows
to avoid
leads
separate
For
to the BR. Insulate
rise
parts.
air-flow
plate.
rates.
external
the airflow
Table
static
for the
installed.
20
motor
(BR)
coded
as
the black
quick
= high
speed.
wire.
the jumper
fan motor
with
The
speed
motor
Insulate
speeds
the lead
lead
is
black must
removed
lead et_d to
To select high speed
on 460-v GE
female
connect
= low
remove
and replace
BM. For low and medium
to the jumper
lead male
motor (BM),
relay
with chassis parts.
motors,
_ith
= jumper
red
avoid contact
jumper
contact
are color
blue
be connected
capacity.
at various
to determine
to terminal
is
To
2-SPEED
blower
a temperature
on the unit rating
rise at various
and cooling
to these
airflow
attached
wire
units.
with lead for desired blower
black
lead fi'om the blower
desired
the fan
This
and 3-phase
lead
motor
the speed of the blower
l'or the
remove
(BR).
orange = medium
red = low
To change
as follows:
2-SPEED
violet = jumper
be.
of the
in the field.
leads are color-coded
a-SPEED
to
or
wired for low speed and may need to be
leg lead fi'om
operating
gage.
inaccurate
AIRFLOW
7 shows the temperature
Refer
= low
to the
shock
or death.
by changing
The motor
to terminal
the outdoor
temperature
for Refi'igerant
the airflow
9 shows both heating
pressures.
injury
or high speed
the speed
attached
P':I["%-lliilI'l/l
For cooling
serious
black = high
COOLING
are open,
power
Electrical
black = high speed
blue = medium speed
of the unit.
TO USE
system
for medium
evacu(refer to
refrigerant
that
Charts
for the various
the pressure
Indoor
cause
electrical
speed.
3-SPEED
suction line. Mount the temperature
sensing device on the suction
line and insulate it so that the outdoor ambient does not effect the
reading.
could
blower
All 48GP units are factory
techniques.
amount
grilles
properly.
thet_ disconnect
changing
For 208/230-v
weigh
CHARGE
Cooling
Table
before
data plate).
LOW
range
off gas supply
unit
Airflow can be changed
blower motor.
charge
procedures.
NO CHARGE:
Shut
explosion
section.
unit
and return-air
and adjusted
an indialways
such
to Can'ier
Rel}igerants
Be sure that all supply-
l'ree fi'om obstructions,
an abnomaal
in the cooling system,
coil or both coils.
CHARGE
Techniques
charge,
factory
charge
NOTI=:
Do not
they are not
the refi'igerant
adjustment
condition
exists somewhere
ficient airflow across either
because
quick
connect
(QC)
(QC)
and connect
to avoid
cot_tact
from
the black
_ith
the
lead
at_3" chassis
(O24}
(030} 60 HZ OHARGINGCHART
FOR USE WITH U_ITS USING R4 _0A REFRIGERANT
125
52 I
115
461
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10
16
SUCT ON LINE TE_dPERATURE (DEG C}
SUCTION UNE TEMPERATURE (DEG C)
I
21
2I7
C99079
Fig. 23--Cooling
Charging
Cha_,
48GP024
Units
C99080
Fig. 24--Cooling
Charging
Chart, 48GP030
Units
(O36}
:_ 1103
O
_
Z
1034
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965
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896
105
41 I
75
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SUCTION UNE TEMPER_URE
7I
4I
11
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i'o
i_
SUCTION LINE TEMPER_URE
'1
2'
(OEG O)
C99081
Fig. 25 -- Cooling Charging
Chart, 48GP036
C99082
Units
Fig. 26--Cooling
125
52 I
115
461
85
29 I
1241
180ZZZZZZZZZZZZZZZZZZZZ
1172
170 ZZZZZZZZZZZZZZZZZZZZZ
;_ I103
:_ 1103
o
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1054
75
965
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24 I
65
181
55
isl
45
u_
7 I
896
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75a
758
690
20o
3o0
70o
7
Units
800
_
_
I_
Z
Z_25
115
I05
52
46
4
o
_
s5
ZZZZZZZZZZZZZZZZZZZZZ
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_ _ £
13o
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_
_
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29
24
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soo
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7
_6
OU_y,,OpO
R
F
C
Z
160
6
_
_
w
Chart, 48GP042
{060} 60 HZ CHARGING CHART
FO_ USE W_THUNITS USING R4 0A _SFR GERANT
{048}
_
Charging
'_
40o
500
6oo
suc ION LIN_TEM_ERATUNE (DEC F)
'
4
110
I_
0
;_
80 0
_'_
SUCTION LINE TEMPERATURE (DEG C)
C99083
Fig. 27--Cooling
Charging
Chart, 48GP048
Units
C99084
Fig. 28--Cooling
21
Charging
Chart, 48GP060
Units
Table 9--Wet
Coil Air Delivery* -- Horizontal and Downflow
Unit 48GP024-060 (Deduct 10% for 208 Volts)
Discharge
230 AND 460 VOLT
Unit
48GP
Motor
Speed
Low
024
Medium
0.0
01
02
0.3
External
0.4
Watts
279
282
280
277
276
Cfm
882
801
738
604
367
361
356
351
Cfm
-
936
868
797
719
626
-
Watts
-
-
-
463
452
439
428
-
-
956
878
794
702
-
243
244
242
885
842
786
....
353
339
333
330
326
320
Cfm
1195
1134
1070
997
911
818
-
443
436
426
416
406
397
Cfm
-
1230
1145
1061
977
888
786
Watts
490
463
446
432
418
403
389
378
-
Cfm
1431
1398
1347
1281
1205
1118
1024
921
-
Watts
513
501
488
474
459
443
428
-
Cfm
1491
1426
1351
1267
1175
1077
976
-
Watts
-
645
636
627
616
605
593
583
936
-
1484
1410
1330
1243
1147
1044
Watts
634
618
608
598
583
562
534
502
473
454
457
Cfm
1669
1599
1545
1498
1448
1391
1326
1257
1189
1132
1101
Watts
-
733
704
672
638
604
574
550
536
Cfm
-
1746
1688
1630
1566
1492
1399
1279
1120
Watts
-
-
-
797
773
751
727
696
Cfm
-
-
-
1727
1632
1537
1423
1308
-
Watts
591
578
573
568
559
544
524
500
Cfm
1554
1523
1496
1467
1432
1387
1332
1269
-
Watts
755
737
719
699
678
653
627
602
579
562
556
Cfm
1834
1802
1758
1706
1648
1585
1520
1455
1392
1332
1276
Medium
Watts
-
890
858
828
801
777
756
734
709
Cfm
-
1943
1870
1793
1711
1624
1531
1433
1329
High
Low
060
Medium
Watts
589
576
569
566
559
541
499
Cfm
1946
1891
1836
1779
1718
1651
1577
Watts
750
733
715
695
673
648
623
598
577
Cfm
2189
2097
2021
1952
1883
1809
1727
1635
1530
Watts
879
850
821
795
772
750
728
701
Cfm
2337
2159
2050
1974
1905
1824
1722
1597
High
*Air delivery values are without air filter.
Note: Deduct field-supplied air filter pressure
drop to obtain external static pressure available
COOLING SEQUENCE OF OPERATION
With the room
thermostat S_ STEM switch in the COOL position and the FAN
switch in the AUTO. position, the cooling sequence of operation is
as follows:
When
the
the
room
temperature
rises
cooling
control
setting
completes
the circuit
between
and
G.
These
completed
to a point
of
the
coil
(C) (through
(through
unit
wire
G)
open
contacts
Y)
wire
the
is slightly
the
terminal
through
unit
across
that
thermostat,
thermostat
circuits
contactor
the
and
24-v
normally
complete
denser
The
the
circuit
(outdoor)
through
fan
set of normally
complete
of
motor
of
open
the circuit
contactor
compressor
(OFM).
contacts
motor
Both
circuits
evaporator
waiting
should
Once
not
be
the
compressor
has
started
again
until
started
start
relay
5 minutes
and
close
setting
motor
stops.
The
for the next "call
coil
motors
unit
C and
stop. After
relay
is in a "standby"
for cooling"
coil
BR.
a 30-second
The
delay,
condition,
from the room thermostat.
To ensure continuing high performance, and to minimize the
possibility of premature equipment failure, periodic maintenance
must be performed on this equipment.
This combination
heating cooling unit should be inspected at least once each year by
a qualified service person. To troubleshoot heating or cooling of
units, refer to tables at the back of the book.
and
to coninstantly.
BR close
(indoor)
then
have
drops
of the
control
MAINTENANCE
and
fan motor
(IFM).
NOTE:
contactor
and compressor
the blower
Y
transformer
(COMP)
blower
de-energize
condenser
connect
(C)
motors
of energized
through
until the room temperature
the cooling
relay coil (BR)
blower
secondary
energized
"on"
below
room thermostat.
At this point, the thermostat
"breaks"
the circuit
between thermostat
terminal R to terminals Y and G. These open
thermostat
thermostat
cycle remains
to a point that is slightly
above
R to terminals
for ducting
The cooling
(TRAN).
The
-
-
High
048
-
Watts
Low
Low
10
....
Cfm
Cfm
Medium
-
Watts
High
042
-
Watts
09
-
373
Medium
036
0.8
674
High
Low
0.7
-
-
Cfm
Medium
030
(in. wg)
06
Watts
High
Low
Static Pressure
05
has
stopped,
NOTE TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.
it
elapsed.
22
For
longer
The ability to properly perform maintenance on this equipment reqnires certain expertise, mechanical skills, tools, and
equipment. If you do not possess these, do not attempt to
perform any maintenance on this equipment other than those
procedures recommended in the User's Manual. FAILURE
TO HEED THIS WARNING COULD RESULT IN SERIOUS INJURY AND POSSIBLE DAMAGE TO THIS
EQUIPMENT.
Turn
1. Turn off gas supply,
unit belbre
unit.
performing
any maintenance
caution
when removing
any mechanical
fi'om sharp edges,
equipment,
the blower
Remove
to the
or service
on the
panels
serious
and parts.
injury
overheating
As
and dangerous
either
d. Ensure
on, or in contact
occur, or the gas supply
main
manual
fail to shut ofl;
gas valve
supply.
i.
operation.
air
may
all wires
requirements
each
month.
drain
pan,
cause
proper
indoor
coil,
cooling
season
*'or cleanliness.
3. Inspect
blower
motor
each
For
improper
bimonthly
4. Check
proper
injury or
as t`ollows:
relay (BR). Disconnect
L2 of the contactor.
blower
assembly
fi'om unit.
to
blower
Be careful
not
to tear insulation
l`or this equipment
are as
Clean
when
Clean
or
when
replace
to determine
partition
Remove
and
slide
in blower
electrical
connections
operation
each
inspect
ment.
cleaning
and
Clean
and
cooling
tightened
shaft.
when
f. Reinstall
wheel
3. Restore
controls
season.
housing
and motor
wheel
reassembly
blower
wheel
and
bet`ore disassembly.
wheel to motor shaft,
mount brackets to housmount
out of housing.
as follows:
by marking
When
with vacuum
Remove
e. Reassemble
frequency.
for tightness
heating
each
and check
blower
by marking
to blower
wheel
handling
orientation.
and.or
balance
cleaning
weights
(clips)
c. Remove
caked-on
dirt from wheel and housing
with a
brush. Remove lint and/or dirt accumulations
from wheel
necessary.
season.
season,
proper
drain
lbr cleanliness
and cooling
heating
reassembly
blower wheel, be sure not to disturb
on blower wheel vanes.
prior to disconnec-
and condensate
and wheel
heating
first
terminal
from housing.
d. Reassemble
2. Inspect
lubrication
lead fi'om blower
and clean blower
b. Lift wheel
necessary.
necessary.
and wheel.
panel.
ing, and slide motor
wires
Label
filter(s)
assembly
setscrew(s)
that secures
screws that secure motor
and housing
Inspect
when
proper
a. Ensure
reconnecting
maintenance
out.
motor
could cause serious
blower
in relation
e. Loosen
remove
to the unit,
servicing.
The mininmm
l`ollows:
and
and tag electrical
the blower
blower
remove
securing
assembly
can result
V:I[_'12
tion when
motor
lead from
screws
2. Remove
when
efficiency,
wheel
and wheel:
unit access
yellow
motor
then shut off the electrical
made
continuing
the blower
compartment.
combustible
shut off the external
Errors
motor
and disassemble
a. Remove
etc.
3. Never place anything
with, the unit.
4. Should
power
and
fi'om
then disconnect
cleaning
to this warning
c. On all units,
2. Use extreme
with
injury
to adhere
b. Disconnect
then turn off electrical
economy,
and grease
off the gas supply,
Failure
death.
i.
in serious
dirt
power to the unit before
¥_ i','l:_l fl: IR[_
could result
operating
r!] |','I:_ il:l IT[=a
To clean
Failure to follow these warnings
or death:
life,
clean accumulated
motor annually.
grease
cleaner,
wheel
into housing.
motor
into housing.
on motor
shaft
unit access
panel.
electrical
power,
Be
attach-
sure setscrew(s)
flats and not
on round
are
part
of
then gas supply to unit. Start unit and
check l'or proper blower rotation
heating and cooling cycles.
for
using soft brush
and oil with mild solvent.
and motor
speeds
during
Smwice
necessary.
5. Cheek
and inspect
Clean and adjust
6. Check
heating
when
flue hood
section
bel`ore each heating
_- ....
season.
necessary.
and remove
any obstructions
if necessary.
AIR FILTER
IMPORTANT:
in the return-air
Never
operate
the unit without
a suitable
air filter
duct
system.
Always
the filter
with
replace
stone dimensional
size and type as originally
2 and 3 l`or recommended
filter sizes.
Inspect
air
filter(s)
at
least
once
each
(throwaway-type)
or clean (cleanable-type)
each heating and cooling season or whenever
clogged
installed.
month
the
See Tables
and
replace
at least twice during
the filter(s) becomes
o
I
with dust and lint.
EVAPORATOR
BLOWER
NOTE: All motors
these motors.
I
l
C99090
Fig. 29--Unit
AND MOTOR
are pre-lubrieated.
Do not attempt
to lubricate
FLUE
GAS
box and upper
23
PASSAGEWAYS
Access
Panel
To inspect
areas of the heat exchanger:
the flue
collector
INDUCED
DRAFT
MOTOR
2. Remove
MOUNT
the 7 screws
ing plate
to blower
3. Slide the motor
that attach
housing
induced-draft
motor
and blower
wheel
assembly
out of the blower
housing
(See Fig. 31). Clean
the blower
wheeh
cleaning
is required,
with Steps
4 and 5.
4. To remove
blower,
5. To remove
motor
mount-
(See Fig. 30).
continue
remove
2 setscrews
If additional
(See Fig. 31).
n
o_
and cooling
that hold blower
6. To reinstall,
housing
reverse
fan assembly,
to mounting
the procedure
remove
4 screws
plate.
outlined
above.
_D
LIMIT
SWITCH
located
on the blower
BURNER
/
/
--at7
A
IN SHIPPING
LOCATION
COLLECTOR
BOX
7
/
VENTHOO(
FLUE/
ignition
BURNER
RACK
If
MOUNTING
SCREW
i. Remove
according
below.
2. Remove
(Fig.
blower
to directions
the 3 screws
collector
3. Remove
Housing and Flue Collector Box
the combustion
box cover
wheel
and motor
in Combustion-Air
holding
the blower
Unit
lockout
occurs,
panel.
is equipped
system.
unit
MAIN
BURNERS
assembly
inspect
for deterioration
section
causes.
Observe
Blower
housing
lockout
access
Ignition
Limit
switch
with
module
is
a direct
spark
is located
in the
a self-diagnostic
LED.
for LED interpretations.
may
be
reset
inten'upting
power supply to unit,
OFF position at the thermostat.
C99022
Fig. 30--Blower
IGNITION
100%
unit
partition.
control
box. Module
contains
servicing,
refer to label diagram
ROLLOUT
SWITCH
BLOWER
HOUSING
Remove
At the beginning
either
momentarily
selector
of each
or blockage
the main burner
by
or turning
During
switch
heating
due to corrosion
flames
and adjust
to
season,
or other
if necessary.
to the flue
(see Fig. 30).
the 12 screws
30) to the heat
holding
exchanger
the flue collector
assembly.
Inspect
box cover
REMOVAL
the heat
OF GAS TRAIN
exchangers.
4. Clean
all surfaces
as required,
using
the wire brush.
@
BLOWER
HOUSING
®
2 SETSCREWS
{HIDDEN)
/
C99086
i
Fig. 32--Burner
C99085
Fig. 31--Removal
of Motor and Blower Wheel
i. Shut off manual
2. Shut off power
COMBUSTION-AIR BLOWER
Clean periodically to assure
proper airflow and heating efficiency. Inspect blower wheel every
fi_ll and periodically during heating season. For the first heating
season, inspect blower wheel bimonthly to determine proper
cleaning frequency.
3. Remove
unit
4. Disconnect
To inspect blower wheel, remove draft hood assembly. Shine a
flashlight into opening to inspect wheeh If cleaning is required,
remove motor and wheel as follows:
i. Remove unit access panel (See Fig. 29).
to unit.
access
panel
gas piping
wires
6. Remove
ignitor
7. Remove
the mounting
(See Fig. 29).
at unit
connected
gas valve.
to gas valve.
and sensor
wires
screw
Mark
each wire.
at the ignitor
that attaches
module.
the burner
rack to
(See Fig. 30).
8. Slide the burner
24
gas valve.
5. Remove
the basepan
Rack Removed
rack out of the unit (See Figs.
30 and 32).
9. Toreinstall,
reverse
theprocedure
outlined
above.
NOTE:
CONDENSER
COIL,EVAPORATOR
COIL,ANDCONDENSATE
DRAIN
PAN Inspect
thecondenser
coil,evaporator
coil,
andcondensate
drainpanatleastonce
each
year.
Thecoilsareeasily
cleaned
whendry;therefore,
inspect
andclean
thecoilseither
before
oraftereach
cooling
season.
Remove
all
obstructions,
including
weeds
andshrubs,
thatinterfere
withthe
airflow
through
thecondenser
coil.
Straighten
bentfinswithafin comb.
If coated
withdirtorlint,
cleanthecoilswitha vacuum
cleaner,
usingthesoftbrush
attachment.
Becareful
nottobendthefins.If coated
withoilor
grease,
cleanthecoilswithamilddetergent-and-water
solution.
Rinse
coilswithclear
water,
usingagarden
hose.
Becarefid
notto
splash
water
onmotors,
insulation,
wiring,
orairfilter(s).
Forbest
results,
spray
condenser
coilfinsfrominside
tooutside
theunit.
Onunitswithanouterandinnercondenser
coil,besure
toclean
between
thecoils.Besure
toflushalldirtanddebris
fromtheunit
base.
Inspect
thedrainpanandcondensate
drainlinewheninspecting
thecoils.
Clean
thedrain
panandcondensate
drain
byremoving
all
foreign
matter
fromthepan.Flushthepananddraintubewith
clear
water.
Donotsplash
water
ontheinsulation,
motor,
wiring,
or airfilter(s).If thedraintubeis restricted,
clearit witha
"plumbers
snake"or similarprobedevice.
Ensure
thatthe
auxiliary
drainportabove
thedraintubeisalsoclear.
Refer to the heating
in this publication
operation.
REFRIGERANT
nections
FAN
leak-test
Keep
the condenser
unit.
cooling
Damage
i. Remove
cover.
2. Turn
fan free
operation.
halide
torch,
detected,
place
articles
to ensure
holding
to Checking
section
grille
and motor
does
assembly
upside
3. Inspect
the tan blades
4. If tan needs
to be removed,
tim off the motor
5. When
replacing
in. away
for cracks
down
on
top
cover
to
return-air
is clean.
Airflow
airflow.
Adjustments
METERING
from
the setscrew
and slide the
fan blade,
position
that setscrew
when
line.
SWITCHES
vices
into
wired
7. Replace
CONTROLS
the electrical
gas supply,
Remove
controls
AND WIRING
and wiring
annually.
and then the electrical
access
Check
panel
to locate
all electrical
screw connections.
noticed, disassemble
wire
the flat area on the motor
shaft
grille.
ELECTRICAL
wiring.
engages
po_er
all
end and reassemble
and check
circuit.
the
electrical
against
leads
switch.
inspecting
access
panel.
heating
cycle
operation.
cycles,
electrical
the
electrical
Start the unit,
troubleshooting
unless
exists.
If switch
charge
so that
without
breaking
in the
are
the
To check
i.
and securely.
controls
and one complete
If discrepancies
or if a suspected
component
with
Refer to the unit wiring
and
cooling
wiring,
at least
cycle
replace
gages
line and
events
If system
as
etc. It
pressure
is
to unit.
are
You should
attached
certain
Never
for
all system
open
system
with dry nitrogen.
The
line
high-pressure
and protects
It opens
against
switch
is lo-
excessive
con-
at 610 psig.
may be caused by a dirty condenser
or condenser
this device
that a problem
and recover
0 psi.
have con-
to refrigeration
to remove
remove
read
SWITCH
discharge
coil, flfiled tim
air recirculation.
switch:
Turn off gas and then all power
leads
to unit.
on switch.
3. Apply
tinuity
proper
ohmmeter
leads
on a good
switch.
COPELAND
SCROLL
has occun'ed,
ANT
compressor
electrical
by such
coil, dirty filters,
switch.
switches
vacuum
malfunction
the proper
across
must be removed,
in either or both operating
label when making
(AIR CONDI-
on the liquid
you are reasonably
are observed
check
(R-
the
one complete
to ensure
for the Puron
caused
indoor
specifically
R-22 pressure
SWITCH
it is not advisable
pressure
coil pressure.
or burned
connections
clean all the parts, restrip
and obsel_'e
these
pressure,
motor,
are
off
in the
on switch.
on a good
2. Disconnect
After
leads
ohmmeter
High pressure
and
are present
systems.
is located
across
de-
shut
switch:
Because
all
properly
low airflow
under
Tighten
They
switches
pressures
and
system
are protective
as replacements
low suction
the
This meter-
voltage).
(R-410A)
This switch
and that the
in the brass hex-body
on a pressure drop at about 20 psig.
this, switch should be closed.
denser
controls
for tightness.
the connection
pressure
is
and
Airflow
to check
switches
(low
Turn off gas and then all power
cated
20
air-
supply-
obstructions,
high or low pressures
These
ONLY)
all
PISTON
Pressure
with Puron
cooling
refer to Indoor
on page
circuit
if abnormally
HIGH-PRESSURE
to the unit.
connections
If any smokey
the connection,
Inspect
Be sure to turn qff'Ne
is
Charge
performance
that
and is contained
control
to operate
and/or
be sure
OF CHARGE/LOW-PRESSURE
system
tightening.
is
performance
improper
ACCURATOR_:
PRESSURE
NOTI=:
shaft will be
visible).
6. Ensure
section
in the liquid
tinuity
blade so that the hub is 1/8
end (1/8 in. of motor
leak
on page 13.
Refrigerant
heating
unless
necessary,
is a fixed orifice
3. Apply
the motor
The
exists,
When
DEVICE
ing device
2. Disconnect
shaft.
section
and low cooling
g141les are open and free flvm
air filter
i.
If a refi'igerant
Leaks
and Adjusting
checking
If a problem
To check
or bends.
loosen
are found
require
loss of charge,
the fan blade.
leak-detector,
AIRFLOW
not
suspected.
opens
above
motor/grille
is suspected,
an electronic
on page 20.
EVAPORATOR
TIONER
to top
con-
Detect-
using
solution.
leaks
refer
tubing
annually.
leak.
for Refrigerant
suspected,
protects
condenser
all refrigerant
control
performance
liquid-soap
If no refrigerant
LOSS
on top of the
to unit may result.
6 screws
expose
or
refer to Check
of operation
proper
cooling
tubing
switches
must not be used
410A) air conditioner.
from all obstructions
Never
sequence
determining
a refi'igerant
or if low
all refi'igerant
refrigeration
Y:I[ "_a!liilI'12
in
Inspect
indicates
If oil is detected
flow
cooling
aid
CIRCUIT
ing oil generally
designed
proper
andor
an
and the unit base for oil accumulations
compressor
CONDENSER
as
each
instrumentation.
designed
these checkouts.
cannot
25
The
to
operate
be interchanged.
across
switch.
COMPRESSOR
used
with
in this
Puron
You should
(PURON
product
(R-410A)
have con-
REFRIGERis specifically
refrigerant
and
Thecompressor
isanelectrical
(aswellasmechanical)
device.
Exercise
extreme
caution
when
working
nearcompressors.
Power
should
beshutoff,if possible,
formosttroubleshooting
techniqnes.
Refrigerants
present
additional
safety
hazards.
SERVICING
Exposure,
ment
r'!_ |','1-'I ;I: IIR_
Wear
safety
glasses
and gloves
Failure to follow this warning
or death.
when
SYSTEMS
even if immediately
(leading
performing
handling
can cause
dures
injury,
take
the interaction
compressor
more
tolerant
of stresses
starts.
device
and an
designed
port
has
differential
by debris,
is equipped
pressure
the system
scroll.
or discharge
relief
The
valves,
liquid
The
backwards
pressure
scroll
slugging,
the
The
to protect
against
extreme
high
pressure,
the
range
between
550
and
psi
Copeland
is the only oil allowed
scroll
compressor
uses
Mobil
3MA
625
uses
operating
No other
hoses,
Puron.
pressures
system
If you are unsure
Failure
to use
replacement
Puron
consult
nmst
refrigerant
POE
which
oil.
through
LIQUID
has
be
designed
servicing
may result
Gage
system
to handle
manufi_cmrer.
equipment
in property
or
damage
contaminants
or
cylinders
hygroscopic,
clip tube,
and CFC
exposure
refrigerants.
it absorbs
water
Take
valve.
oil to
Proce-
limited
to,
replacing
switch,
me-
PROCEDURE:
shop
towel
inside
by tools
unit
innnediately
and prevent
openings
or components.
lubricant
under
run-offs
in the base pan.
required
service.
water
as other
all necessary
readily.
POE
oils designed
precautions
oils
FILTER
of any oil contaminated
DRIER
with
material
per
The filter drier is specifically
Puron.
Use
only
When removing
fiaetory-authorized
whenever
the refrigerant
a filter drier, use a tubing
cutter
to cut the &ier fi'om the system. Do not unsweat
a filter drier
from the system. Heat fi'om unsweating
will release moisture
and
COMPRESSOR
OIL
The compressor
in this system uses a
polyolester
(POE) oil, Mobil 3MA POE. This oil is extremely
as nmch
pressure
to be serviced
is opened.
PURON
15 times
not
leaks,
drier,
Filter drier nmst be replaced
fi'om &ier into
(R-410A)
information
absorb
cloth
to operate
components.
set,
injury.
meaning
are
or reversing
PRECAUTIONARY
the louvered
LINE
designed
and other refrigerants.
in this system.
the equipment
compatible
components
but
roofing.
refi'igerant
such as filter
5. Remove
and dispose
local codes.
than R-22
may be used
recovery
include,
repairing
When
for oil recharge.
Puron(P_ (R-410A)
refi'igerant
and
terry
4. Perform
system
leakage
embrittle-
of compressor
to protect
drop cloth fi'om tears caused
3. Place
r:l ["_lliiI'l/l
higher
ROOF
protect
REFRIGERANT
This
precautions
coil, accumulator,
component(s)
This
oil
components
device,
up, may cause
in one year or more.
2. Cover area in front of the unit service panel with a terry cloth
shop towel to absorb lubricant spills and prevent run-offs, and
is a safety
pressure.
The
MA-
i. Cover extended roof working area with an impermeable
polyethylene (plastic) drip cloth or tarp. Cover an approximate
i0 x 10 ft. area.
anti-rotational
port
risk
cleaned
that may risk exposure
replacement,
SYNTHETIC
and
and replaces
relief
SYNTHETIC
and it is
protector.
an operating
tering
by
with an anti-rotational
port.
the scroll from mining
for a cycle
device,
caused
internal
throughout
and an orbiting
suction
The compressor
device prevents
relief
refrigerant
of a stationary
has no dynamic
flooded
need
pumps
WITH
to occur
appropriate
which
compressor
refrigerant
The scroll compressor
to cracking)
any service
the roof,
refrigerants.
a fire, serious
ON ROOFS
TERIALS
POE (polyolester)
compressor
lubricants are known
to cause long term damage to some synthetic roofing materials.
from
can
for HCFC
plate
contain
cylinder
charge
REFRIGERANT
and charging
to avoid
26
CHARGING
chart.
Some
a dip tube to allow
in upright
Puron
a commercial
metering
into suction-line.
of the oil to the atmosphere.
system.
position.
liquid
with cylinder
device
in manitbld
refrigerant
refrigerant
For cylinders
units
Refer to unit
R-410A
equipped
to flow
with a
in upright position
and
hose. Charge refiigerant
AIR CONDITIONER
Puron refrigerant
to operate
operates
at 50%-70%
higher
Puron
•
Puron refrigerant
cylinders manufactured
position. Cylinders
manufactured
March
to flow.
refrigerant
Recovery
Puron
(R-410A)--QUICK
REFERENCE
Be sure that servicing
equipment
GUIDE
and replacement
components
are designed
are rose colored.
service
should
sets should
Use hoses
pressure
be charged
should
be designed
as with other HFCs,
Vacuum
pumps
Do not install
specified
Wrap
filter
Do not use an R-22
Never
open system
When
system
Always
replace
Obsmwe
to atmosphere
filter
Puron
type metering
with 520 psig
low-side
device
in the manifold
retard.
HFC refrigerant.
with POE oils.
from oil.
with rated
working
pressures
no less than 600 psig.
Do not expose
plastics
valves
oil to atmosphere.
and roofing
materials.
with wet cloth when brazing.
on every unit.
TXV.
while
it is under
for service,
drier after opening
break
system
a vacuum.
vacuum
with dry nitrogen
for service.
into the atmosphere.
all warnings,
Do not leave
or DOT BW400.
rating.
drier is required
must be opened
Do not vent Puron
4BA400
Use a commercial
and 200 psig low-side
filter &iers
to certain
and service
liquid-line
refrigerant.
to detect
moisture
rapidly.
damage
all filter driers
A Puron
must be 400 psig, DOT
filter drier in liquid-line.
moisture
POE oils may cause
pressure
liquid-line
a suction-line
POE oils absorb
rating
with liquid
is only compatible
will not remove
use factory
prior to March 1, 1999, have a clip tube that allows liquid to flow out of cylinder in upright
1, 1999 and later DO NOT have a dip tube and MUST be positioned
upside down to allow liquid
be 750 psig high-side
with 750 psig selwice
detectors
Puron,
cylinders
cylinder
systems
Manilbld
Only
PURON®
than R-22.
with Puron.
•
Leak
WITH
pressures
cautions,
suction
and bold text.
line driers
in place
for more than 72 hours.
27
and replace
filter
driers.
hose.
Table lO--Troubleshooting
SYMPTOM
-- Cooling
CAUSE
REMEDY
Power failure
Call power company.
Fuse blown or circuit breaker tripped
Replace fuse or reset circuit breaker.
Defective thermostat, contactor, transformer, control relay, high pressure, or loss of charge switch
Compressor
and condenser
fan will not start.
Insufficient
line vottage
Incorrect or faulty wiring
Thermostat
Compressor
will not start but condenser
runs.
fan
Compressor
Defective
Lower thermostat
in compressor
motor burned out, seized, or internal
overload open
run/start capacitor, ovedoad,
start relay
One leg of 3-phase power dead
Three-phase scroll compressor makes excessive noise, and there may be a low pressure
differential.
Scrotl compressor
Refrigerant
is rotating in the wrong direction
overcharge
or undercharge
Defective compressor
Insufficient
Compressor
cycles (other than normally satisfying thermostat).
line voltage
Blocked condenser
Defective run/start capacitor, overload or start
relay
Defective thermostat
Faulty condenser-fan
Restriction
system
Dirty air filter
Unit undersized for toad
Compressor
set too Iow
Low refrigerant
operates continuously.
charge
Leaking valves in compressor
coit dirty or restricted
Dirty air filter
Dirty condenser
Excessive
head
Refrigerant
pressure.
coil
overcharged
air restricted
Low refrigerant
Head pressure too low.
Compressor
Restriction
or air short-cycling
charge
valves leaking
in liquid tube
suction
pressure.
Compressor
Refrigerant
valves leaking
overcharged
Dirty air filter
Low refrigerant
too low.
Insufficient
charge
evaporator
airflow
Temperature too tow in conditioned area
Outdoor ambient below 40 F
Field-installed
Determine
filter-drier
28
cause and replace.
Replace fuse or reset circuit breaker. Determine
cause.
Correct the direction of rotation by reversing the
3-phase power Ieads to the unit. Shut down unit
to allow pressures to equalize
Recover refrigerant, evacuate system, and recharge to capacities shown on nameplate
Replace and determine cause.
Determine cause and correct
Determine
cause and correct
Determine
cause and replace.
Replace thermostat
Replace.
Locate restriction and remove
Decrease
Replace fitter.
load or increase
unit size
Reset thermostat.
Locate leak, repair, and recharge
Replace compressor
evacuate
charge.
system,
and re-
Ctean coit or remove restriction
Replace fitter.
Clean coil
Recover excess
Determine
refrigerant.
evacuate system,
charge.
cause and correct
and re-
Check for leaks, repair and recharge
Replace compressor
Remove restriction
RepIace compressor
Recover excess
refrigerant.
Replace filter.
Metering device or low side restricted
Suction pressure
cause. Replace compressor
Check for source and eliminate
High heat load
Excessive
Determine
Recover refrigerant,
Air in system
Condenser
Check wiring and repair or repIace.
Recover refrigerant,
Air in system
Condenser
setting below room temperature
motor or capacitor
in refrigerant
Thermostat
cause and correct
Check wiring diagram and rewire correctly.
setting too high
Faulty wiring or loose connections
circuit
Replace component
Determine
restricted
Check for leaks, repair and recharge
Remove source of restriction.
Increase air quantity. Check filter -necessary.
Reset thermostat.
Install low-ambient
Replace
kit.
replace
if
Table 11--Troubleshooting
SYMPTOM
-- Heating
CAUSE
REMEDY
Water in gas line
Drain
No power to furnace
Miswired or loose connections
Burned-out
heat anticipator
Broken thermostat
Burners will not ignite.
Misaligned
spark electrodes
No gas at main burners
Dirty air flIter
Inadequate
heating
Restricted
for application
airflow
Limit switch cycles main burners
characteristics
check
Replace wire if necessary.
Check flame ignition and sense electrode
tioning. Adjust as necessary
posi-
1. Check gas line for air. Purge as necessary
NOTE: After purging gas line of air, wait at least
5 minutes for any gas to dissipate before attempting to light unit
2. Check gas valve
check gas pressure at manifold Match with that
on unit nameplate
Replace with proper unit or add additional
Clean or replace filter
Blower speed too Iow
Poor flame,
Replace thermostat.
Rue continuity
Clean or replace fitter as necessary
Gas input to furnace too tow
Unit undersized
Check alt wiring and wirenut connections
in thermostat
wire
Install drip leg
Check power suppty fuses, wiring, or circuit
breaker.
Incomplete combustion results in: Aldehyde
odors, carbon monoxide, sooting flame, floating
flame
29
unit
Remove any restriction.
Use faster speed tap if avaiIabie,
nate motor
or install alter-
Check rotation of blower, thermostat heat anticipator settings, and temperature rise of unit. Adjust as necessary.
1 Tighten all screws around burner compartments.
2 Cracked heat exchanger. Replace
3 Unit overfired Reduce input (change orifices
or adjust gas line or manifold pressure)
4 Check burner alignment
Table 12--LED
Troubleshooting-Error
SYMPTOM
Hardware failure.
(LED OFF)
REMEDY
Loss of power to control modute (tGC)
High limit switch opens during heat exchanger
warm-up period before fan-on deIay expires
Fan ON/OFF
delay modified.
(LED/FLASH)
Limit switch opens within three minutes after
blower-off delay timing in Heating mode
Limit switch fault. (LED 2 flashes)
High temperature
Flame sense fault. (LED 3 flashes)
4 consecutive
ignition
limit switch
flashes)
lockout,
Induce-draft
motor
Rollout switch
Internal
Internal
faults.
limit switch is open
The IGC sensed flame that should not be present
Inadequate airflow to unit
(LED 5 flashes)
Unit unsuccessfully
attempted
utes
fault. (LED 9 flashes)
any
be replaced,
electrical
that may
for additional
LEGEND
Refer to Heating
troubleshooting
IGC
Integrated
LED
Light-Emitting
Ensure unit's external static pressure is within
application guidelines.
Check operation of indoor (evaporator) fan motor.
Ensure that the supply-air temperature rise is in
accordance with the range on the unit nameplate.
Reset unit
if probtem persists,
board.
replace control
Check ignitor and flame sensor electrode spacing, gaps, etc Ensure that flame sensor and ignition wires are properly terminated. Verify that unit
is obtaining proper amount of gas
Check for proper voltage If motor is operating,
check the speed sensor plug/IGC Terminal J2
connection Proper connection:
PiN I - White,
PIN 2 - Red,
PIN 3 - Btack
Rollout switch witl automatically reset, but IGC
wilt continue to lockout unit. check gas valve operation, ensure that induced-draft btower wheel is
propedy secured to motor shaft Reset unit at
unit disconnect
if error code is not cteared by resetting unit
power, reptace the IGC.
yourself
be present
Troubleshooting
rise
Microprocessor has sensed an error in it's redundant software comparison
to
before
handling
new control board, the IGC is sensitive to static
electricity
and may be damaged
if the necessary
precautions
are not taken.
IMPORTANT:
Ensure unit is fired on rate and temperature
is correct.
if error code is not cleared by resetting unit
power, replace the IGC.
be sure to ground
charge
on IGC, power to unit, 24-v
transformer. Units without a
have an internal overload in
ft the overload trips, allow
for automatic reset.
has sensed an error in the software or hardware
Microprocessor
r.,_[_,];3
dissipate
motor is
RolIout switch has opened
control fault. (LED 8 flashes)
If the IGC must
ignition for 15 min-
IGC does not sense that induced-draft
operating
fault. (LED 6 flashes)
Check 5 amp fuse
circuit breaker, and
24-v circuit breaker
the 24-v transformer
20 minutes
Check operation of indoor (evaporator) fan motor
and that supply-air temperature rise agrees with
range on unit nameplate information.
(LED 4
fault. (LED 7 flashes)
software
Code
CAUSE
(:hart
analysis.
Gas Unit Controller
Diode
30
START-UP CHECKLIST
(Remove and Store in Job File)
I. PRELIMINARY
MODEL
INFORMATION
SERIAL NO.:
NO.:
TECHNICIAN:
DATE:
II. PRE-START-[
P (Insert
checkmark
in box as each item is completed)
( ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
( ) VERIFY THAT CONDENSATE
( ) CHECK ALL ELECTRICAL
CONNECTION
CONNECTIONS
IS INSTALLED
PER INSTALLATION
AND TERMINALS
FOR TIGHTNESS
INSTRUCTIONS
( ) CHECK GAS PIPING FOR LEAKS
( ) CHECK THAT INDOOR (EVAPORATOR)
( ) VERIFY THAT LE';IT INSTALLATION
AIR FILTER IS CLEAN AND IN PLACE
IS LEVEL
( ) CHECK FAN" WHEEL, AND PROPELLER
FOR LOCATION
IN HOUSING/ORIFICE
AND SETSCREW
IlL START-UP
ELECTRICAL
SUPPLY VOLTAGE L1-L2
COMPRESSOR
AMPS LI
INDOOR (EVAPORATOR)
TEMPERAT[
L2-L3
L3-L1
L2
L3
FAN AMPS
RES
DB
OUTDOOR (CONDENSER) AIR TEMPERATURE
RETURN-AIR TEMPERATURE
DB
COOLING SUPPLY AIR
DB
WB
WB
GAS HEAT SUPPLY AIR
PRESSURES
GAS INLET PRESSURE
GAS MANIFOLD
IN. WG
PRESSURE
REFRIGERANT
SUCTION
REFRIGERANT
DISCHARGE
( ) VERIFY
REFRIGERANT
( ) VERIFY
THAT
IN. WG
PSIG SUCTION LINE TEMP*
PSIG DISCHARGE
CHARGE
THREE-PHASE
USING
SCROLL
CHARGING
COMPRESSOR
TEMPt
CHARTS
IS ROTATING
* Measured at suction inletto compressor
1 Measured at liquid line leaving condenser.
31
IN CORRECT
DIRECTION.
TIGHTNESS
Copyright
2000 CARRIER
Manufacturer
Book_ 1_ 4
Tab 16al 8a
Corp. • 7310 W. Morris St • indianapolis,
reserves the right to discontinue,
PC 101
Catalog
No
534-755
IN 46231
48gplsi
or change at any time, specifications
Printed in U.S.A.
Form
or designs
48GP-1SI
without notice and without incurring
Pg 32
3-00
obligations.
Replaces:
New