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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)_ _Wl6 BO× CONTROL SECTIO EOUI P GD POWER YEL W9 SCHEMATIC 208/250 I 60 IFM WI5 YEL-- Wl COOLING N G ENERGIZED i T M DE QT i T+45 BR ENERGIZE _} I I I W19 Writ W20 GRN J I _ _ I E3ISPLICE (MARKED} FACTOR_ WIRING FIELD CONTROL MIRING --i FIELD POMER MIRING Ill ACCESSORY OR OPTIONAL WIRING /-()D WRl RED _) I [_ /i BLU_ I T TCI J? / SEENOTE L t _BB_ YI I I AUTO I ' _SL,S IF{IS} vlo f/ LSRA _Cg_ v,o_oCO I I J SECTION DISCONNECT PER NEE --TO INDICATE COMMON POTENTIAL ONLY NOT TO REPRESENT WINING BR 8LOMER C 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 1241 18._ 1172 170 ZZZZZZZZZZZZZZZZZZZZZ OUTDOOR F TEMPC Z ZZZZZZZZZZZZZZZZZZZZZ Ca" a_ 1/03 o o 105 411 75 241 65 181 55 Isl , 1/03 1034 965 ® i0_ _ _ _ _ _ 965 125 52 i05 115 41 46 85 29 75 24 160 0 zzzzzzzzzzzzzzzzzzzzz _ 150zzzzzzzzzzzzzzzzz_ zzzzzzzzzzzzzzzzz_zz,_ _40 _ _ _ zzzzzzzzzzzzz._£z_-:2 0 ZZZZZZZZZZZZZZZZ_,_ _ z6s _8 896 8 ZZ 55 13 827 758 2OO 3OO 7I 11 7OO 800 SUCTION LNE TEMPERATURE (OEG F) " ," io ", _" 7I 11 I I 4I 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 _ 965 _ 896 105 41 I 75 24 I 65 181 55 ISl 8 _ _27 758 2OO 3OO 7I 11 7O0 I I ,o I ", 800 2" SUCTION UNE TEMPER_URE 7I 4I 11 (DEC F} 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 o 1054 75 965 _ 896 0 _ _27 _os4 24 I 65 181 55 isl 45 u_ 7 I 896 _27 75a 758 690 20o 3o0 70o 7 Units 800 _ _ I_ Z Z_25 115 I05 52 46 4 o _ s5 ZZZZZZZZZZZZZZZZZZZZZ 15o _ _ £ 13o _ _ _ _ _2Ozzzzzzzzzzz_z_ZZ_Z 29 24 Z Z ZZZZZZZZZZZZZZZZ]_ ZZZZZZZZZZZZZZZZ_'Z_ Z _ i/0 _ _ I%00 soo ' 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
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