CARRIER Package Units(both Units Combined) Manual L0604537

48GS L0604537

User Manual: CARRIER CARRIER Package Units(both units combined) Manual CARRIER Package Units(both units combined) Owner's Manual, CARRIER Package Units(both units combined) installation guides

Open the PDF directly: View PDF .
Page Count: 32

HEATING & COOLING

48GS, 48GX

3-Phase Single-Packaged Gas Heating/

Electric Cooling Units

Visit www.carrier.com

Installation, Start-Up, and Operating Instructions

48GS Sizes 030-060, 48GX Sizes 030-060

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS ..................................................... 1

INTRODUCTION .......................................................................... 2

RECEIVING AND INSTALLATION .......................................... 2

CHECK EQUIPMENT ............................................................. 2

IDENTIFY UNIT ................................................................ 2

INSPECT SHIPMENT ........................................................ 2

INSTALLATION ................................................................ 2

PROVIDE uNrr SUPPORT .................................................... 2

ROOF CURB ....................................................................... 2

SLAB MOUNT ................................................................... 2

GROUND MOUNT ............................................................ 6

FIELD FABRICATE DUCTWORK ........................................ 6

PROVIDE CLEARANCES ...................................................... 7

RIG AND PLACE UNIT ......................................................... 7

CONNECT CONDENSATE DRAIN ...................................... 7

INSTALL FLUE HOOD .......................................................... 8

INSTALL GAS PIPING ........................................................... 8

INSTALL DUCT CONNECTIONS ...................................... 10

CONFIGURING UNITS FOR DOWNFLOW (VERTI-

CAL) DISCHARGE .......................................................... 10

INSTALL ELECTRICAL CONNECTIONS ......................... 12

HIGH-VOLTAGE CONNECTIONS ................................ 12

SPECIAL PROCEDURES FOR 208-V OPERATION ...12

CONTROL VOLTAGE CONNECTIONS ....................... 12

HEAT ANTICIPATOR SETTING ................................... 12

TRANSFORMER PROTECTION .................................... 15

PRE-START-UP .......................................................................... 15

START-HE ................................................................................... 15

CHECK FOR REFRIGERANT LEAKS ............................... 15

START-UP HEATING AND MAKE ADJUSTMENTS......16

CHECK HEATING CONTROL ....................................... 16

CHECK GAS INPUT ........................................................ 16

ADJUST GAS INPUT ...................................................... 16

CHECK BURNER FLAME .............................................. 19

AIRFLOW AND TEMPERATURE RISE ....................... 19

HEATING SEQUENCE OF OPERATION ..................... 19

LIMIT SWITCHES ........................................................... 19

AUXILIARY LIMIT SWITCH (ROLLOUT) .................. 19

START-UP COOLING AND MAKE ADJUSTMENTS......20

CHECKING COOLING CONTROL OPERATION .......20

CHECKING AND ADJUSTING REFRIGERANT

CHARGE ........................................................................... 20

INDOOR AIRFLOW AND AIRFLOW ADJUST-

MENTS .............................................................................. 21

COOLING SEQUENCE OF OPERATION ..................... 21

MAINTENANCE ......................................................................... 21

AIR FILTER ...................................................................... 24

EVAPORATOR BLOWER AND MOTOR ..................... 24

FLUE GAS PASSAGEWAYS ......................................... 26

A99338

Fig. 1--Unit 48GS and 48GX

COMBUSTION-AIR BLOWER ....................................... 27

LIMIT SWITCH ................................................................ 27

BURNER IGNITION ........................................................ 27

MAIN BURNERS ............................................................. 27

CONDENSER COIL, EVAPORATOR COIL, AND

CONDENSATE DRAIN PAN .......................................... 27

CONDENSER FAN .......................................................... 28

ELECTRICAL CONTROLS AND WIRING .................. 28

REFRIGERANT CIRCUIT ............................................... 28

GAS INPUT ...................................................................... 28

EVAPORATOR AIRFLOW ............................................. 28

METERING DEVICE -- ACUTROL DEVICE ............. 28

LIQUID LINE STRAINER .............................................. 28

TROUBLESHOOTING ............................................................... 28

START-UP CHECKLIST ............................................................ 28

NOTE TO INSTALLER-- Before the installation, READ THESE

INSTRUCTIONS CAREFULLY AND COMPLETELY. Also,

make sure the User's Manual and Replacement Guide are left with

the unit after installation. The furnace is NOT to be used for

temporary beating of buildings or structures under construction.

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be

hazardous due to system pressure and electrical components. Only

trained and qualified personnel should install repair, or service

air-conditioning equipment.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring otiligations.

PC 101 Printed ir_U.S.A. Catalog NO. 48GS,GX-TSI Pg 1 2-06 Replaces: New

Untrained personnel can perform basic maintenance functions of

cleaning coils and filters. All other operations should be performed

by trained service personnel. When working on air-conditioning

equipment, observe precautions in the literature, tags, and labels

attached to the unit, and other safety precautions that may apply.

Follow all safety codes. Wear safety gla.gses and work gloves. Use

quenching cloth for unbrazing operations. Have fire extinguisher

available for all brazing operations.

Improper installation, adjustment, alteration, service, mainte-

nance, or u_ can cause carbon monoxide poisoning, fire, or

an explosion which can result in personal injury or unit

damage. Consult a qualified installer, service agency, or gas

supplier for information or assistance. The qualified installer

or agency must use only factory-authorized kits or accessories

when modifying this product.

Before performing service or maintenance operations on unit,

turn off gas supply to unit. Then turn off unit main power

switch and install lockout tag. Electrical shock or explosion

could cause serious injury or death.

Recognize safety information. This is the safety-alert symbolzf x .

When you see this symbol in instructions or manuals, be alert to

the potential for personal injury.

Understand the signal words DANGER, WARNING, CAUTION,

and NOTE. These words are used with the safety-alert symbol.

DANGER identifies the most serious hazards which will result in

serious injury or death. WARNING signifies a hazard which could

result in serious injury or death. CAUTION is used to identify

unsafe practices which would result in minor personal injury or

product and property damage. NOTE is used to highlight sugges-

tions which will result in enhanced installation, reliability, or

operation.

These instructions cover minimum requirements and conform to

existing national standards and safety codes. In some instances,

these instructions exceed certain local codes and ordinances,

especially those that may not have kept up with changing residen-

tial construction practices. We require these instructions as a

minimum for a safe installation.

INTRODUCTION

The 48GS and 48GX units (See Fig. 1) are fully self-contained,

combination Category I gas heating/electric cooling units designec[

for outdoor installation (See Fig. 2 and 3 for unit dimensions). All

unit sizes have return and discharge openings for both horizontal

and downffuw configurations, and are factory shipped with all

downflow duct openings covered. Units may be installed either on

a rooftop, a cement slab, or directly on the ground if local codes

permit (See Fig. 4 for roof curb dimensions).

Models with an N in the fifth position of the model number are

dedicated Low NO x units designed for California installation.

These models meet the California maximum oxides of nitrogen

(NO,) emissions requirements of 40 nanograms/joule or less as

shipped from the factory and must be installed in California Air

Quality Management Districts where a Low NO_ rule exists.

RECEIVING AND INSTALLATION

Step I_HECK EQUIPMENT

IDENTIFY UN1T

The unit model number and serial number are stamped on unit

identification plate. Check this information against shipping papers

and job data. Verify unit voltage and amperage requirements listed

on unit rating plate agree with power supply provided to unit.

INSPECT SIUPMENT

Inspect for shipping damage while unit is still on shipping pallet.

If unit appears to be damaged or is torn loose from its anchorage,

have it examined by transportation inspectors before removal.

Forward claim papers directly to transportation company. Manu-

facturer is not responsible for any damage incurred in transit.

Check all items against shipping list. Immediately notify the

nearest distributor if any item is missing.

To prevent loss or damage, leave all parts in original packages

until installation.

INSTALLATION

1. Remove unit from shipping carton. Leave top shipping skid on

the unit as a spreader bar to prevent the rigging straps from

damaging the unit. If the wood skid is not available, use a

spreader bar of sufficient length to protect unit from damage.

2. Position the lifting bracket assembly around the base of the

unit. Be sure the strap does not twist.

3. Place each of the 4 metal lifting brackets into the rigging holds

in the composite pan.

4. Thread lifting bracket strapping around bottom perimeter of

unit as follows:

a. Open lever of tension buckle (ratchet type).

b. Feed strapping through tension buckle as shown in Fig. 7.

c. Pull strapping through tension buckle unit taut.

d. Snap lever down to lock strap in tension buckle. To relea._e

strapping, squeeze safety latch, lift lever, and pull webbing

outward.

5. Tighten the tension buckle until it is taut. Lifting brackets

must be secure in the rigging holds.

6. Attach field-supplied clevis or hook of sufficient strength to

hole in the lifting bracket (See Fig. 7).

7. Attach the 2 safety straps directly to the clevis or hook at the

4 rigging brackets. DO NOT attach the safety straps to the

lifting brackets (See Fig. 7).

8. Position lifting point directly over the unit's center of gravity.

9. Lift unit. When unit is directly over the roof curb, remove the

2 safety straps. Lower the equipment onto the roof curb.

Step 2--PROVIDE UNIT SUPPORT

ROOF CURB

Install accessory roof curb in accordance with instructions shipped

with curb (See Fig. 4 for roof curb dimensions). Install insulation,

cant strips, roofing, and flashing. Ductwork must be attached to

curb.

IMPORTANT: The ga,sketing of the unit to the roof curb is critical

for a watertight seal. Install ga.sheting material supplied with the

roof curb. Improperly applied gasketing can also result in air leaks

and poor unit performance.

Curb should be level to within I/4 in. This is necessary for unit

drain to function properly. Refer to accessory roof curb installation

instructions for additional information as required.

SLAB MOUNT

Place the unit on a solid, level concrete pad that is aminimum of

4 in. thick with 2 in. above grade. The slab should be flush on the

compressor end of the unit (to allow condensate drain installation)

and .should extend 2 in. on the three remaining sides of the unit

(See Fig. 6). Do not secure the unit to the slab except when

required by local codes.

eLocKorrP_.[Lr_ _e O'NL_

'"11111

_11111111 III

suPeL_

ae 3 --

REAR

REQUIRED CLEARANCETO COMBUSTIBLE MATL. INCHES [ram]

TOP OF UNIT ................................................................................... 14.00 [355¸6

DUCT SIDE OF UNIT ................................................................ 2.00 [508]

SIDE OPPOSPTE DUCTS ............................................................... 14.00 (355 6]

BOTTOM OF UN T 0 50 12

ELECTR C HEAT PANEL" i_ iiiii_i.iii.i , , i :'i"i "" " "36"00 [914714]

NEC.REQUIREDCLEARANCES. INCHES [mm

BETWEEN UNITS, pOWER ENTRY S DE .............................. 4200 [1066.8

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE .36.00 [914 O]

UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES, POWER ENTRY S_DE ......................... 42,00 [1066 8]

LEGEND

CG -Center of Gravity

COND Condensor

EVAP - Evaporator

NEC - National Bectrical Code

9EQ'D +Required

NOTE: Dimensions are In If] [mm]

TOP VIEW

REQUIRED CLEARANCE FOROPERATION AND SERVICING

INCHES [mini

EVAP COIL ACCESS SIDE ....................................................... 36.00 [9140 1

POWER ENTRY SIDE ....................................................... 36¸00 [914.0 I

(EXCEPT FOR NEC REQUIREMENTS)

UNIT TOP ............................................................................. 48 00 [1219.2]

SIDE OPPOSITE DUCTS .............................................................. 36¸00 [914 O]

DUCT PANEL ...................................................................... 12 00 [304.8] *

+MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 12.00 [304.8] FROM

WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE.

-- 7+e m --

t+c+4)

8_Le

LEFT SIDE VIEW

_ _1_1

' +illllllllllll +

, !lllllllllllllllll

'/_- "_Gr_'_""1 " '

E_tRIC_L _¢¢ESS p_N[L

FRONTVIEW

+'+'+p+_,_++++++;

__ _ 14 1 k

\ ....... l

i;'+"++,-- --

RIGHT SIDE VIEW

UNIT

48GS030040/060

48GS036OR0i090

48GS042060/090

48GX030040/060

48GX036060/090

ELECTRICAL CHARACTERISTICS UNIT WEIGHT UNIT HEIGHT IN. (MM)

"A"

Ib kg

208/230-34_0 280.0 127.3 35.02 (5893)

208/230-3_0, 460-3-50 320.0 145.1 37.02 (940.3)

208/230_34_0, 460-3-60 355.0 161.4 35.0_ (889.5)

208/230-3-60 313.0 142.0 39,02 (991,1)

208/230-3-60, 460-3-60 321.0 145.6 35.02 (989.5)

CENTER OF GRAVITY

IN. (MM)

X Y

21.5 (546.1) 13,75 (349,3)

22.5 (571.5) 14.0 (355.6)

21.5 (546.1) 13.5 (342.9)

22,0 (558,8) 15.3 (987.4)

22.0 (558.8) 15.3 (387.4)

Fig. 2_8GS030-042 and 48GX030-036 Unit Dimensions

C0(X)55

15.0 (381.0)

13.0 (330.2)

17.6 (447.0)

16.5 (419.1)

{4 t_:

SUPPL_ D[TU_M

0P_WING 0pEWIN_

! i i

_ 3 TOP VIEW

REAR VIEW

REQUIRED CLEARANCETO COMmJSTIBLE MAll. REI_IIRB) CLEARANCEFOROPERATION AND SERVICING

INCHES tmm] INCHES [mm]

TOP OF UNIT ................................................................................ 14.00 355.6 EVAR COIL ACCESS SIDE ............................................................ 36.00 [914.0]

DUCT SIDE OF UNIT ........................................................................ 2.00 _50.8 POWER ENTRY SIDE .................................................................. 36.00 [914.0}

SIDE OPPOSITE DUCTS ................................................................ 14.0'3 [355.6 (EXCEPT FOR NEE REQUIREMENTS)

BO'[TOM OFUNIT...: ........................................................................ 0.50 12.7] SIDE OPPOSITE DUCTS ............................................................ 36.001914.0]1

ELECTRIC HEAT PANEL ................................................................ 36.C_ [914.4] UNIT TOp ....................................................................................... 48.00 1219.2 I

DUCT PANEL ............................................................................... 12.00 [304.8] *

NEE. REQUIRED CLEARANCES. INCHES [mm] *MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 12.00 [304.8] FROM

BETWEEN UNITS, pOWER ENTRY SIDE .................................... 4200 [1066.8] WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE.

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE ,3600 [914.0]

UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES POWER ENTRY SIDE ......................... 4200 [1066.8]

LEGEND

CG - Center of Gravity

COND Condensor

EVAP Evaporator

NEE National Electrical Code

REQ'D Required

FRONTVIEW

Hs _ NOTE:Dimensions =e in in [mini

_ _ io _e] DI_ WOE[

.......... llllIllllllllllll

_- ..... \ m

\,,,,, [.......r ..

[5._II

RIGIIT _DE VIEW

UNIT

48GS04809Q/115il 30

48GS060090H 15/130

48GX042060/090

48GX048090/115il 30

48GX060090/115/1 30

ELECTRICAL CHARACTERISTICS UNIT WEIGHT UNIT HEIGHT IN. (MM)

Ib kg

208/230-3-60, 460-3-60 415 188.6 38.98 (990.2)

208./230-3-60, 460-3-60 450 204.5 38.98 (990.2)

208/230-3-60, 460-3-60 382 173.3 38.98 (990.2)

208/230-3-60, 460-3-60 421 191.0 38.98 (999.2)

208/230-3-60, 460-3-60 468 212.3 42.98 (1091.1)

22 (558.5)

23.0 (584.2)

21.5 (545.1)

23.5 (596.9)

CENTER OF GRAVITY

IN. (MM)

15 (406.4)

16 (406.4)

16.3 (412,8)

16.6 (422.1)

15.3 (412.8)

C00056

17 (432.0)

17 (432._

16.6 (421.6)

18.0 (457.2)

17.6 (447.0)

Fig. 3_48GS048-060 and 48GX042-060 Unit Dimensions

VACunit

! _ii!_i_ iiiii!i!i!_i

__Screw _.g

nailer*

FIasSuk__piefdSt_do _nf_ii_i

II_11 _H"Insusttion(field

field supplied --

Du_

_l_ R_f_fieldsupplied

Roof Curb for Small Cabinet

Note A:When unit mounting screw is used

retainer bracket must also be used.

Roof Curb for Large Cabinet

Note A:When unit mounting screw is used

retainer bracket must also be used.

UNIT SIZE

48GS030-042 48GX030-036

48GS048-060 48GX042-060

\R/A

Insulated

deckpan

Gasket around

duct

Gasket around

outer edge _

\/S/A

C00076

ODS CATALOG NUMBER

CPRFCURB006A0O

CPRFCURB007AOO

CPRFCURB008A00

CPRFCURB009A00

NOTES:

1. Roof curb must be set up for unit being installed.

2. Seal etdp 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 I sts only he d mensions, per part number that have changed.

6. Attach ductwork to curb flanges of duct rest on curb.

7. nsuated panals: 1-in. hickfibergass b density.

8. Dimensions are in inches.

IN.(MM)

8(203)

14 (356)

8(203)

14 (356)

IN. (MM)

11(279)

163/16 (411)

IN. (MM)

161/2 (419)

17 3/8 (441)

17 3/9 (441)

IN. (MM)

29-3/4 (730)

28-3/4 (730)

40-1/4 (1022)

9. Wl_en unit mounting screw is used (see Note A), a retainer bracket must be used as well. This bracket must also be used when required by code for hurricane or

seismic conditions. This bracket is available through Micrometl.

Fig. 4---Roof Curb Dimensions

COO070

48GS 48GX

CORNER #030 036 042 048 060 030 036 042 048 060

1 53.2 59.7 67.5 78.9 85.5 59.5 61.O 72.6 80.0 88.9

2 50.4 56.5 63,9 74.7 81,0 56,3 57.8 68.8 75,8 84.2

3 86.8 97.3 110.1 128.7 139.5 97.0 99,5 118.4 130.5 145.1

4 89.6 106.5 113.6 132.8 144.0 100.2 102,7 122.2 134.7 149.8

TOTAL WEIGHT 250 320 355 415 450 313 321 382 421 465

Fig. 5_48GS and 48GX Unit Corner Weights

DETAIL A

SEE DETAIL AJ

J MINIMUMHEIGHT: _"

C99014

EVAR COND.

COIL COIL

Fig. 6_Slab Mounting Details

GROUND MOUNT

The unit may be installed either on a slab or placed directly on the

ground if local codes permit. Place the unit on level ground

prepared with gravel for condensate di_harge.

Step 3---FIELD FABRICATE DUC'FWORK

SIZE I""X'MU 'WE'k HTI 'n l in

UNIT 48GS

A05179

mrn

Secure all ducts to roof curb and building structure on vertical

discharge units. Do not connect ductwork to uniL For horizontal

applications, unit is provided with flanges on the horizontal

openings. Installation of flexible duct connector is recommended

to prevent transmission of vibration and/or noise to structure. All

Fig, 7--Suggested Rigging

030 302 137.3 21.5 546.1 13,75 349.3

036 342 155.1 22.5 571.5 14,0 355.6

042 377 171.4 21.5 546.1 13.5 342.9

048 437 198.6 22.0 556.5 17.0 432.0

060 472 214.5 22.0 558,5 17.0 432.0

UNIT 48GX

030 335 152 22.0 558.5 15.30 388.6

036 343 156 22.0 558.5 16.30 388.6

042 404 183 23.0 584,2 16.3 414,0

048 443 201 21.5 546.1 16.3 414.0

060 490 222 23.5 596.9 16.3 414.3

UNIT SIZE 48GS

NOMINAL CAPACITY (ton)

OPERATING WEIGHT (lb.)

COMPRESSORS

Quantity

REFRIGERANT (R-22)

Quantity (lb.)

REFRIGERANT METERING DEVICE

Orifice ID (in.)

CONDENSER COIL

Rows...Fins/in.

Face Area (sq ft)

CONDENSER FAN

Nominal Clm

Diameter (in.)

Motor Hp (Rpm)

EVAPORATOR COIL

Rows...Fins/in.

Face Area ($q ft)

EVAPORATOR BLOWER

Nominal Airflow (C/m)

Size (in.)

Motor HP (Rpm)

FURNACE SECTION*

Burner Orifice No. (Qty...Orill Size)

Natural Gas

Burner Orifice No. (Qty.-Drill Size)

Propane Gas

RETURN-AIR FILTERS (in.)t

Throwaway

• Basedonaltitudeof 0 to 2000 It.

Table 1--Physical Data--Unit 48GS

030040 030060 042060

2½ 2½ 3½

280 280 355

042090

31/2

355

3.65 3,65 5.7 I 5.7

.034

1...17

9.1

2400

1/8 (625)

2...15

3.1

1000

10 x 10

1/4(1075)

2...45

2...50

.O34

1...17

9.1

2400

1/8 (825)

2._15

3.1

1000

10 x 10

1/4 (1075)

2...38

2-.46

20 X20

036060 036690

3 3

320 320

Reciprocating

I4.4 4.4

Acutrol TM Device

.032 ,032

1...17 1...17

10.9 10.9

3000 3000

22 22

_A(1100) ,_i (1100)

3._15 3...15

3.1 3.1

1200 1200

11 x 10 11 x 10

1/2 (1075) 1/2 (1075)

2...38 3_,38

2...46 3...46

20 X 24 20 X 24

.O34

1...17

9.1

3000

_A (1100)

4...15

3.1

1400

11 x 10

3/4 (1076)

2...3_

2...46

20 x 24

20 x 20

.O34

1...17

9.1

3000

(11oo)

4...15

3.1

1400

11 x10

3/4 (1075)

3...38

3...46

20 X24

i" Required filter sizes shown are based on the larger of the AR] (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating ain'low velocity of 300

if]minute for throwaway type or 450 ft]rninute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 in. wg.

ductwork should be secured to the flanges. Insulate and weather-

proof all external ductwork, joints, and roof openings with counter

flashing and mastic in accordance with applicable codes.

Ducts passing through an unconditioned space must be insulated

and covered with a vapor barrier.

If a plenum return is used on a vertical unit, the return should be

ducted through the roof deck to comply with applicable fire codes.

A minimum clearance is not required around ductwork. Cabinet

return-air static shall not exceed -.25 in. wg.

Step 4--PROVIDE CLEARANCES

The required minimum operating and service clearances are shown

in Fig. 2 and 3. Adequate combustion, ventilation 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 Standards Institute) Z223.1 or applicable

provisions of local building code. In Canada, follow sections 7.2,

7.3, or 7.4 or Can/CGA. (Canadian Gas Association) B149

Installation Codes or applicable provisions of local building code.

compressor life.

The condenser fan pulls air through the condenser coil and

discharges it through the top cover. Be sure that the fan discharge

does not recirculate to the condenser coll. Do not locate the unit in

either a corner or under an overhead obstruction. The minimum

clearance under a partial overhang (such as a normal house

overhang) is 48-in. above the unit top. The maximum horizontal

extension of a partial overhang must not exceed 48-in..

Do not place the unit where water, ice, or snow from an overhang

or roof will damage or flood the unit. Do not install die unit on

carpeting, tile, or other combustible materialS. The unit may be

installed on wood flooring or on Class A, B, or C roof covering

materials.

Step 5--RIG AND PLACE UNIT

support the additional weight.

Use spreader bars or crate top when rigging the unit. The units

must be rigged for lifting (See Fig. 6). Refer to Table 1 and 2 for

operating weight. Use extreme caution to prevent damage when

moving the unit. Unit must remain in an upright position during all

rigging and moving operatiottv.The unit must be level within 1/4"'

for proper condensate drainage; therefore, the ground-level pad or

accessory roof curb must be level before setting die unit in place.

When a field-fabricated support is used, be sure that the support is

level and properly supports die unit. Lifting point should be

directly over the center of gravity for the unit.

Step 6--CONNECT CONDENSATE DRAIN

NOTE: When installing condensate drain connection be sure to

comply with local codes and restrictions.

Models 48GS and 48GX dispose of condensate water through a

3/4 in. NPT fitting which exits through the compressor access

panel (See Fig. 2 and 3 for location).

Condensate water can be drained directly onto the roof in rooftop

installations (where permitted) or onto a gravel apron in ground-

level installations. Install a field-supplied condensate trap at end of

condensate connection to ensure proper drainage. Make sure that

UNIT SIZE 48GS

NOMINAL CAPACITY (ton)

OPERATING WEIGHT (lb.)

COMPRESSORS

Quantity

REFRIGERANT (R-22)

Quantity (lb.)

REFRIGERANT METERING DEVICE

Orifice ID (in.)

CONDENSER COIL

Rows.- Fins/in.

Face Area (sq ft)

CONDENSER FAN

Nominal Cfm

Diameter (in.)

Motor Hp (Rpm)

EVAPORATOR COIL

Rows._Fins/in.

Face Area (sq It)

EVAPORATOR BLOWER

Nominal Airflow (Cfm)

Size (in.)

Motor Hp (Rpm)

FURNACE SECTION*

Burner Orifice No. (Qty._Drill Size)

Natural Gas

Burner Orifice No. (Qty...Drill Size)

Propane Gas

RETURN-AIR FILTERS (in.)t

Throwaway

* Basedon altitudeof0 to 2000 ft.

Table 1--Physical Data--Unit 48GS (Continued)

048090 048115 048130 060090

444 5

415

6.0

.O32

1...17

12,3

3600

1A(11o0)

3...15

4.7

1600

11 xlO

3/4 (1075)

3...38

3.,.46

24X30

415 415 450

Scroll

I 6.0 ! 6.0 8.0

Acutrol Device

.032 .032 ,030

1,,,17 1..,17 2...17

12.3 12.3 12.3

3600 3600 3600

22 22 22

!4 (1100) 1,4(1100) 1,4(1100)

3...15 3...15 4...15

4.7 4.7 4.7

1600 1600 2000

11X10 11X10 11X10

314 (1075) 3/4 (1075) 1.0 (1075)

3.-33 3...31 3...38

3...42 3...41 3...46

24X30 24X30 24X30

060115 060130

450 450

Reciprocating

I g° I 60

,030

2-,17

12.3

3600

1,4(1100)

4...15

4.7

2000

11 X 10

1.0 (1075)

3,,,33

3...42

24 X 30

.030

2...17

12.3

36OO

t4 (110o)

4...15

4.7

2000

11 X10

1.0(1075)

3...31

3...41

24 X 30

tRequired filter sizes shown are based on the larger of the ARI Air Conditioning and Refrigeration Institute) rated cooling airflow or the hea ing a rf ow ve oclty o 300

Wrn nste or throwaway type or 450 if/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 in. wg,

the oudet of the trap is at least 1 in. lower than the drain pan

condensate connection to prevent the pan from overflowing (See

Fig. 8). Prime the trap with water. When using a gravel apron,

make sure it slopes away from the unit.

If the installation requires draining the condensate water away

from the unit, install a 2-in. trap at the condensate connection to

ensure proper drainage (See Fig. 8). Make sure that the outlet of

the trap is at hi&st 1 in. lower than the drainpan condensate

connection. This prevents the pan from overflowing.

Prime the trap with water. Connect a drain tube -using a minimum

of 3/4-in. PVC or 314-in. copper pipe (all field-supplied) - at the

outlet end of the 2-in. trap. Do not undersize the tube. Pitch the

drain tube downward at a slope of at least 1-in. for every 10 R of

horizontal run. Be sure to check the drain tube for leaks.

i q

Fig. 8--Condensate Trap

TRAP

OUTLET

2" rain.

C00009

Step 7--INSTALL FLUE HOOD

The flue hood assembly is shipped screwed to the coil panel in the

indoor blower compartment. Remove the service access panel to

locate the assembly (See Fig. 27).

NOTE: Dedicated low NO_ models MUST be installed in Cali-

fornia Air quahty Management Districts where a Low NO_ rule

exists.

These models meet the California maximum oxides of nitrogen

(NO,) emissions requirements of 40 nanograms/joule or less as

shipped from the factory.

NOTE: Low NO. requirements ap-ply only to natural gas instal-

lations.

Install the flue hood as follows:

1. This ir_tallation must conform with local building codes and

with the National Fuel Gas Code (NFGC), ANSI Z223.1 (in

Canada, CAN/CGA B149.1, and B149.2) or NFPA (National

Fire Protection Association) latest revision. Refer to Provin-

cial and local plumbing or wastewa_r codes and other

applicable local codes.

2. Remove flue hood from shipping location (inside the blower

compartment). Place vent cap assembly over flue panel. Orient

screw holes in vent cap with holes in the flue panel.

3. Secure flue hood to flue panel by inserting a single screw on

the right side and the left side of the hood.

Step 8---INSTALL GAS PIPING

The gas supply pipe enters the unit through the access hole

provided. The gas connection to the unit is made to the 1/2-in. FPT

gas inlet on the manual shutoff or gas valve.

Table 2--Physical Data--Unit 48GX

UNIT SIZE 48GX

NOMINAL CAPACITY (ton)

OPERATING WEIGHT (lb.)

COMPRESSORS

Quantity

REFRIGERANT (R-22)

Quantity (lb.)

REFRIGERANT METERING DEVICE

Orifice ID (in.)

CONDENSER COIL

Rows.-Fins/in.

Face Area (sq ft)

CONDENSER FAN

Nominal Ctm

Diameter (in.)

Motor Hp (Rpm)

EVAPORATOR COIL

Rows...Fins/in.

Face Area (sq ft)

EVAPORATOR BLOWER

Nominal Airflow (Cfm)

Size (in.)

Motor Hp (Rpm)

FURNACE SECTION*

Burner Orifice No. (Qty.-Drill Size)

Natural Gas

Burner Orifice No. (Qty...Dri0 Size)

Propane Gas

RETURN-AIR FILTERS (in.)t

Throwaway

• Based on altitude of 0 to2000 ft.

030040

2½

313

030060

2½

313

036060

321

_6060

_roll

042060 042090

3½ 3½

382 382

4.4 4.4 5.2 5.2 6.4 6.4

.030 .030 .032 .032 .034 .034

1...17 1...17 2...17 2...17 2...17 2...17

12.7 12.7 9.1 9.1 12.3 12.3

2350 2350 2350 2350 3300 3300

22 22 22 22 22 22

1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825)

3...15 3...15 3...15 3...15 3...15 3...15

3.1 3.1 3.7 3.7 4.7 4.7

1006

lOX10

1/4 (1075)

2...38

2...46

20 X 20

106O

10x10

1/4 (1075)

1200

11 X 10

1/2 (1075)

2,,,38

2...46

20 X 24

2...44

2,,.50

1200

11X10

1/2 (1075)

3,,,38

3,,,46

20 X 2420 X 20

1400

11X 10

3/4 (1075)

2..,38

2..,46

24 X 30

1400

11X 10

3/4 (1075)

3...38

3...46

24 X 30

fRequired filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow orthe heating airflow velocityof 300

if]minute for high-capacity type. Air riser pressure drop for non-standard filters must not exceed 0.08 in. wg.

Install a gas supply line that runs to the heating section. Refer to

Table 3 and the NFGC for gas pipe sizing. Do not use cast-iron

pipe. It is recommended that a black iron pipe is used. Check the

local utility for recommendations concerning existing tines. Size

gas supply piping for 0.5 in. wg maximum pressure drop. Never

use pipe smaller than the 1/2-in. FPT gas ial_'t on the unit gas

valve.

For natural gas applications, the gas pressure at unit gas connection

must not be less than 4.0 in. wg or greater than 13 in. wg while the

unit is operating. For propane applications, the gas pressure must

not be less than 7.0 in. wg or greater than 13 in. wg at the unit

connection.

An l/8-in. NPT plugged tapping, accessible for test gage connec-

tion, must be installed immediately upstream of the gas supply

connection to the gas valve.

When installing the gas supply fine, observe local codes pertaining

to gas pipe installations. Refer to the NFGC ANSI Z223.1-1988

NFPA latest edition (in Canada, CAN/CGA B149.1, (2)-M86). In

the absence of local building codes, adhere to the following

pertinent recommendations:

1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in. in

every 15 ft to prevent traps. Grade all horizontal runs

downward to risers. Use risers to connect to heating section

and to meter.

2. Protect all segments of piping system against physical and

thermal damage. Support all piping with appropriate straps,

bangers, etc. Use a minimum of one hanger every 6 ft. For

pipe sizes larger than l/2 in., follow recommendations of

national codes.

3. Apply joint compound (pipe dope) sparingly and only to male

threads of jc;mt when making pipe connections. Use only pipe

dope that is resistant to action of liquefied petroleum gases as

specified by local and/or national codes. Never use Teflon

tape.

Install sediment trap in riser leading to heating _ction (See

Fig. 9). This drip leg functions a.s a trap for dirt and

condensate.

5. Install an accessible, external, manual main shutoff valve in

gas supply pipe within 6 ft of heating section.

6. Install ground-joint union close to heating section between

unit manual shutoff and external manual main shut-off valve.

7. Pressure-test all gas piping in accordance with local and

national plumbing and gas codes before connecting piping to

unit.

NOTE: Pressure test the gas supply system after the gas supply

piping is connected to the gas valve. The supply piping must be

disconnected from the gas valve during the testing of the piping

systero_s when test pressure is in excess of 0.5 palg. Pressure test

the gas supply piping system at pressures equal to or less than 0.5

psig. The unit heating section must be isolated from the gas piping

system by closing the external main manual shutoff valve and

slightly opening the ground-joint union.

Wl E_

Unstable operation may occur when the gas valve and

manifold assembly are forced out of position while connect-

ing improperly-routed rigid ga_s piping to the gas valve. Use

a backup wrench when making connection to avoid strain on,

or distortion of, the ga._ control piping.

UNIT SIZE 48GX

NOMINAL CAPACITY (ton)

OPERATING WEIGHT (lb.)

COMPRESSORS

Quantity

REFRIGERANT (R-22)

Quantity (lb.)

REFRIGERANT METERING DEVICE

Orifice ID (in.)

CONDENSER COIL

Rows...Fins/in.

Face Area (sq ft)

CONDENSER FAN

Nominal Cfm

Diameter (in,)

Motor Hp (Rpm)

EVAPORATOR COIL

Rows,,.Finslin.

Face Area (sq ft)

EVAPORATOR BLOWER

Nominal Airflow (Cfm)

Size (in.)

Motor Hp (Rpm)

FURNACE SECTION*

Burner Orifice No. (Qty...Drill Size)

Natural Gas

Burner Orifice No. (Qty...Drill Size)

Propane Gas

RETURN-AIR FILTERS (in.)t

Throwaway

• Basedonaltitude of 0 to 2000 ft.

Table 2--Physical Data--Unit 48GX (Continued)

048090 048115 048130 060090

421

060115 060130

5 5

468 468

8.3 I 3.1 8.1

.O34

2...17

12.3

33O0

¼(1100)

4...15

4.7

1600

11X 10

3/4 (1075)

3,..38

3..,46

445

421 421 468

Scroll

I 03 I83 r 81

Acutml Device

.034 .034 ,032

2...17 2...17 2...17

12.3 12.3 16.4

3300 3300 3300

22 22 22

_A(1100) _A(1100) ¼ (1100)

4...15 4...15 4...15

4.7 4.7 4.7

1600 1600 1750

11X10 11X10 11X10

3/4 (1075) 3/4 (1076) 1,0 (1075)

3...33 3,,.31 3.-38

3...42 3...41 3...46

24X30 24X30 24X3024 X30

.032

2-.17

16,4

3300

1A (1100)

' 4...15

4.7

1750

11X 10

1.0 (1075)

3.,.33

3...42

24 X 30

.O32

2...17

16.4

3300

(1100)

4...15

4.7

1750

11 X 10

1.0 (1075)

3...31

3,,.41

24 X 30

_"Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300

if/minute for high-capacity type. Air tilter pressure drop for non-standard filters must not exceed 0.08 in. wg.

Table 3_Maximum Gas Flow Capacity*

NOMINAL

IRON PIPE,

SIZE

(IN.)

11A

INTERNAL LENGTH OF PIPE, FTt

DIAMETER

(IN.) 10 20 30 40 50 60 70 80 90 100 126 150

.622 175 120 97 82 73 66 61 57 53 50 44 40

,824 360 250 200 170 151 138 125 118 110 103 93 I 84 77

1.049 680 465 375 320 285 260 240 220 205 195 175 i160 145

1.380 1400 950 770 600 580 530 490 460 430 400 360 I325 300

1,610 2100 1460 1180 990 900 810 750 690 650 620 550 i500 460

__apacity_fpipeincu__fgasperhrf_rgaspressure_f__5psig_r_ess_Pressuredr_p____5-in_wg basedona0.60speci cg a',,itygas) Ree oTabeC_l

Fire Protection Association NFPA 54.

f This length includes an ordinary number of fittings.

175 200

135

230

430

National

casing.

Step 9--INSTALL DUCT CONNECTIONS

The unit has duct flanges on the supply- and return-air openings on

the side and bottom of the unit. For downshot applications, the

ductwork connects to the roof curb (See Fig. 2 and 3 for

connections sizes and locations).

CONFIGURING UNITS FOR DOWNFLOW (VERTICAL) DIS-

CHARGE

serious injury or death.

8. Check for gas leaks at the field-installed and factory-installed

gas lines after all piping connections have been completed.

Use soap-and-water solution (or method specified by local

codes and/or regulations).

cause serious injury or death.

1. Open all electrical disconnects before starting any service

work.

3"MIN

C99020

Fig. 9_Sediment Trap

2. Remove return duct cover located on duct panel by breaking

connecting tabs with screwdriver and a hammer (See Fig. 10A

& 10B).

3. To remove supply duct cover, break front and tight side

connecting tabs with a screwdriver and a hammer. Push louver

down to break rear and left side tabs (See Fig. 10A & 10B).

4. If unit ductwork is to be attached to veztical opening flanges

on the unit composite base (jackstand applications only), do so

at this time.

5. It is recommended that the unit base insulation around the

perimeter of the vertical return-air opening be secured to the

unit base with aluminum tape. Applicable local codes may

require aluminum tape to prevent exposed fiberglass.

6. Cover both horizontal duct openings with the duct covers from

the accessory duct cover kit. Ensure opening is air- and

watertight.

- t

,=T---

SUPPLY RETURN

DUCT DUCT

OPENING OPENING

C99011

Fig. 10A Supply and Return Duct Opening

DUCTCOVERSREMOVED

C99012

Fig. 10B--Vertical Duct Cover Removed

7. After completing unit conversion, perform all safety checks

and power up unit.

NOTre: The design and installation of the duct system must be in

accordance with the standards of the NFPA for installation of

nonresidence-type air conditioning and ventilating systems, NFPA

90A or residence-type, NFPA 90B; and/or local codes and

ordinances.

Adhere to the following criteria when selecting, sizing, and

installing the duct system:

1. Units are shipped for horizontal duct installation (by removing

duct covers).

2. Select and size ductwork, supply-air registers, and return-air

grilles according to American Society of Heating, Refrigera-

tion and Air Conditioning Engineers (ASHRAE) recommen-

dadons.

Use flexible transition between rigid ductwork and unit to

prevent transmission of vibration. The transition may be

screwed or bolted to duct flanges. Use suitable gaskets to

ensure weathertight and airtight seal.

All units must have field-supplied filters or accessory fdter

rack installed in the return-air side of the unit. Recommended

sizes for filters are shown in Tables 1 and 2.

Size all ductwork for maximum required airflow (either

heating or cooling) for unit being installed. Avoid abrupt duet

size increases or decreases or performance may be affected.

Adequately insulate and weatherproof all ductwork located

outdoors. Insulate ducts passing through unconditioned space,

and use vapor barrier in accordance with latest issue of Sheet

Metal and Air Conditioning Contractors National Association

(SMACNA) and Air Conditioning Contractors of America

(ACCA) minimum installation standards for heating and air

conditioning systems. Secure all ducts to building structure.

Flasli, weatherproof, and vibration-isolate all openings in

building structure in accordance with local codes and good

building practices.

Step 10--INSTALL ELECTRICAL CONNECTIONS

r._l LI"/_-'1,'I I",[_

The unit cabinet must have an uninterrupted, unbroken

electrical ground to minimize the possibility of serious injury

if an electrical fault should occur. This ground may consist of

an electrical rare connected to the unit ground lug in the

control compartment, or conduit approved for electrical

ground when installed in accordance with NEC (National

Electrical Code) ANSI/NFPA (latest edition) and local elec-

trical codes. In Canada, follow Canadian Electrical Code

CSA (Canadian Standards Association) C22.1 and local

electrical codes. Failure to adhere to this warning could re.cull

in serious injury or death.

Failure to follow these precautions could result in damage to

the unit being installed:

1. Make all electrical connections in accordance with NEC

ANSI/NFPA (latest edition) and local electrical codes

governing such wiring. In Canada, all electrical connec-

tions must be in accordance with CSA standard C22.1

Canadian Electrical Code Part 1 and applicable local

codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between

field-supplied electrical disconnect switch and unit. DO

NOT USE ALUMINUM WIRE.

3. Be sure that high-voltage power to unit is within operating

voltage range indicated on unit rating plate.

4. Do not damage internal components when drilling through

any panel to mount electrical hardware, conduit, etc. On

3-phase units, ensure phases are balanced within 2 percent.

Consult local power company for correction of improper

voltage and/or phase imbalance.

r!_kvl:1:]_llTI

HIGH-VOLTAGE CONNECTIONS

The unit must have a separate electrical service with a field-

supplied, waterproof, disconnect switch mounted at, or within

sight from, the unit. Refer to the unit rating plate for maximum

fllse/circdit breaker size and minimum circuit amps (ampacity) for

wire sizing (See Tables 4 and 5 for electrical data).

The lleld-supplied disconnect switch box may be mounted on the

unit over the high-voltage inlet hole when the standard power and

low-voltage entry points are used (See Fig. 2 and 3 for acceptable

location).

See unit wiring label and Fig. 11 for reference when making high

voltage connections. Proceed as follows to complete the high-

voltage connections to the unit.

I. Run the high-voltage (LI, L2, L3) and ground leads into the

control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the lines side

of the contactor.

4. Connect field L1 to black wire on connection 11 of the

compressor contactor.

5. Connect field wire L2 to yellow wire on connection 13 of the

compressor contactor.

6. Connect field wire L3 to Blue wire from compressor.

HIGH VOLTAGE r- - -

POWER LEADS l_ _o-

(SEE UNIT WIRING

LABEL)

GND

CONTROL BOX

LOW-VOLTAGE _i

POWER LEADS_

(SEE UNIT

WIRING LABEL)

SPLICE BOX

FIELD-SUPPLIED

FUSED DISCONNECT

_GRN_(G_) _yEpIRc_A_O_TAT

C99018

Fig. 11--High- and Control-Voltage connections

SPECIAL PROCEDURES FOR 208-V OPERATION

Before making any wiring changes, make sure the gas supply

is switched off first. Then switch off the power supply to the

unit and install lockout tag. Electrical shock can cause serious

Injury or death.

CONTROL VOLTAGE CONNECTIONS

Do not use any type of power-stealing thermostat. Unit control

problems may result.

Use no. 18 American Wire Gage (AWG) color-coded, insulated

(35 C minimum) wires to make the control voltage connections

between the thermostat and the unit. If the thermostat is located

more than 100 ft from the unit (as measured along the control

voltage wires), use no. 16 AWG color-coded, insulated (35 C

minimum) wires.

Standard Connection

Remove knockout hole located in the flue panel adjacent to the

control access panel (See Fig. 2 and 3). Remove the rubber

grommet from the installer's packet (included with unit) and install

grommet in the knockout opening. Provide a drip loop before

running wire through panel.

Run the low-voltage leads from the thermostat, through the inlet

hole, and into unit low-voltage splice box.

Locate five 18-gage wires leaving control box. These low-voltage

connection leads can be identified by the colors red, green, yellow,

brown, and white (See Fig. 11). Ensure the leads are long enough

to be routed into the low-voltage splice box (located below fight

side of control box). Route leads through hole in bottom of control

box and make low-voltage connections (See Fig. 11). Secure all

cut wires, so that they do not interfere with operation of unit.

HEAT ANTICIPATOR SETTING

The room thermostat heat anticipator must be properly adjusted to

ensure proper heating performance. Set the heat anticipator, using

an ammeter between the W and R terminals to determine the exact

required _tdng.

NOTE: For thermostat selection purposes, use 0.18 amp for the

approximate required setting. Failure to make a proper heat

anticipator adjustment will result in improper operation, discom-

fort to the occupants of the conditioned space, and inefficient

energy utilization; however, the required setting may be changed

slightly to provide a greater degree of comfort for a particular

installation.

UNIT

SIZE

46GS

030

O36

042

O48

O60

Table 4--Electrical Data--Unit 48GS

V-PH-HZ

VOLTAGE COMPRESSOR

RANGE

Min Max RLA LRA

OUTDOOR FAN

MOTOR INDOOR FAN

MOTOR POWER SUPPLY

208/230-3-S0 187 253 12.6

208/230-3--60 187 253 9.0

460-3-60 414 506 4.5

208/230-3-60 187 253 10.7

460-3-60 414 506 5.3

208/2_0 187 253 13.5

460-3-60 414 506 6.7

208/230-3-60 187 253 18.6

460-3-60 414 506 8,5

FLA

68.0 0.8

78.0 1.6

40.0 0.9

85.0 1.6

42.0 0.9

108.0 1.6

47.5 0.9

125.0 1.6

66.5 0.9

FLA MCA Max Fuse or

Ckt Bkr

2.0 13.2 20

3,6 16,5 25

1.9 8.4 15

3.8 18.8 25

2.0 9.5 15

3.8 22.3 35

2.0 11.3 15

6.2 31.1 45

3.2 14.7 20

MCA Minimum Circuit Amps _"

MOCP Maximum Overcurrent Protection

RLA -- Rated Load Amps

CKT BKR -- Circuit Breaker

NOTES:

1. In compliance with NEC (National Electrical Code) requirements

for multimotor and combination load equipment (refer to NEC

Articles 436 and 440), the overcurrent protective device for the

unit shall be Power Supply fuse. Canadian units may be

fuse or circuit breaker.

2. Minimum wire size is based on 60 C copper wire. If other than

60 C wire is used, or if length exceeds wire length in table,

determine size from NEC.

3. Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply volt-

age is greater than 2%. Use the following formula to determine

the percentage of voltage imbalance.

% Voltage imbalance

= 100 x max voltage deviation from average voita_le

average voltage

EXAMPLE: Supply voltage is 460-3-60.

AS C AB = 452 v

BC = 464 v

AC = 455 v

Average Voltage = 452 + 464 + 455

= 1371

= 457

Determine maximum deviation from average voltage.

(AB) 457 452=5v

(BC) 464 457=7v

(AC) 457 455=2v

Maximum deviation is 7 v.

Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x 7

457

-- 1.53%

This amount of phase imbalance is satisfactoryas it is below the

maximum allowable 2%.

IIMPORTANT: If the supply voltage phase imbalance is

immediately,morethan 2%, contact your local electric utility company

Table 5_Electrical Data_nit 48GX

UNIT

SIZE

48GX

030

036

042

O48

O60

V-PH-HZ

VOLTAGE

RANGE COMPRESSOR OUTDOOR FAN

MOTOR

FLA

INDOOR FAN

MOTOR

Min Max RLA LRA

288/230_3_0 187 253 9.0 63.0

2O6/23_0 187 253 11.2 75.0

460-3-50 414 506 5.4 37.5

208/230-3-60 187 253 12,4 88,0

460-3_0 414 506 6,1 44.0

208/230-3_0 187 253 13.0 93,0

460-3-60 414 506 6.4 46.5

208/230-3-60 187 253 17.3 123.0

460-3_$0 414 506 9.0 62,0

0.8

0,9

1.6

0.9

1.5

0.9

1.6

0,9

POWER SUPPLY

Max Fuse or

FLA MCA Ckt Bkr

2.1 14.2 20

3.6 18.4 25

1.9 9.6 15

4.1 21.2 30

2.0 10.5 15

4.1 21.9 30

1.9 10.8 15

6.2 29.4 45

3.2 15.4 20

LEGEND

FLA -- Full Load Amps

LRA -- Locked Rotor Amps C US

MCA -- Minimum CircuitAmps

MOCP -- Maximum Ovemurrent Protection

RLA -- Rated Load Amps

CKT BKR -- Circuit Breaker

NOTES:

1. In compliance with NEC (National ElectricalCode) requirements

for muitimotor and combination load equipment (refer to NEC

Articles 430 and 440), the overcurrent prote_ive device for the

unit shall be Power Supply fuse. Canadian units may be

fuse or circuit breaker.

2. Minimum wire size is based on 60 C copper wire. If other than

60 Cwire 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 imba/ance in supply volt=

age is greater than 2%. Use the following formula to determine

the percentage of voltage imbalance.

% Voltage imbalance

=tOO x max voltage deviation from average voltage

average voltage

EXAMPLE: Supply voltage is 460-3-60,

A e c AB =452 v

BC =464 v

AC = 455 v

Average Voltage = 452 + 464 + 455

= 1371

= 457

Determine maximum deviation from average voltage.

(AB) 457 452=5v

(BC) 464 457=7v

(AC) 457 455=2v

Maximum deviation is 7 v.

Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x --

457

= 1.53%

This amount of phase imbalance is satisfactoryas it is below the

maximum allowable 2%.

IMPORTANT:olf the supply voltage phase imbalance is

itmnOmredlhataer_y2%, contact your local electric utility company

C99024

Table 5_Legend

TRANSFORMER PROTECTION

The transformer is of the energy-limiting type. It is set to

withstand a 30°sec. overload or shorted secondary condition.

PPdE-START-UP

Failure to observe the following warnings could result in

serious injury:

1. Follow recognized safety practices and wear protective

goggles when checking or servicing refrigerant system.

2. Do not operate compressor or provide any electric power to

unit unless compressor terminal cover is in place and

secured.

3. Do not remove compressor terminal cover until all electri-

cal sources are disconnected.

4. Relieve and recover all refrigerant from system before

touching or disturbing anything inside terminal box ff

refrigerant leak is suspected around compressor terminals.

5. Never attempt to repair soldered connection while refrig-

erant system is under pressure.

6. Do not use torch to remove any componenL System

contains oil and refrigerant under pressure. To remove a

component, wear protective goggles and proceed as fol-

lows:

a. Shut off gas supply and then electrical power to unit.

b. Relieve and recover all refrigerant from system using

both high- and low-pressure ports.

c. Cut component connecting tubing with tubing cutter and

remove component from unit.

d. Carefully unsweat remaining tubing stubs when neces-

sary. Oil can ignite when exposed to torch flame.

Proceed as follows to inspect and prepare the unit for initial

startup:

1. Remove access panel.

2. Read and follow instructions on all WARNING, CAUTION,

and INFORMATION labels attached to, or shipped with, unit.

3. Make the following inspections:

a. Inspect for shipping and handling damages such as broken

lines, loose parle, disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections and on

unit base. Detecting oil generally indicates a refrigerant

leak.

c. Leak test all refrigerant tubing connections using electronic

leak detector, halide torch, or liquid-soap solution. If a

refrigerant leak is detected, see the Check for Refrigerant

Leaks section.

d. Inspect all field- and factery-wirlng connections. Be sure

that connections are completed and tight.

e. Ensure wires do not contact refrigerant tubing or sharp

sheet metal edges.

f. Inspect coil f'ms. If damaged during shipping and handling,

carefully straighten fins with a i'm comb.

4. Verify the following conditions:

a. Make sure gas line is free of air. Before lighting the unit for

the first time, perform the following with the gas valve in

the "OFF" position:

If the gas supply pipe was not purged before connecting

the unit, it will be full of air. It is recommended that the

ground joint union be loosened, and the supply line be

allowed to purge until the odor of gas is detected. Never

purge gas lines into a combustion chamber. Immediately

upon detection of gas odor, retighten the union. Allow 5

minutes to elapse, then light unit.

b. Make sure that condenser-fan blade is correctly positioned

in fan orifice. Leading edge of condenser-fan blade should

be 1/2 in. maximum from fan orifice ventari.

c. Ensure fan hub is 1/8 in. maximum from motor housing

(See Fig. 12).

MOTORAND FANHUB MOTORSHAFT C99009

Fig. 12--Fan Blade Clearance

MANIFOLD

Fig. 13_Burner Assembly

d. Make sure that air falter(s) is in place.

PIPE PLUG

C99019

e. Make sure that condensate drain trap is filled with water to

ensure proper drainage.

f. Make sure that all tools and miscellaneous loose parts have

been removed.

START-UP

Step I_CHECK FOR REFRIGERANT LEAKS

Proceed as follows to locate and repair a refrigerant leak and to

charge the unit:

1. Locate leak and make sure that refrigerant system pressure has

been relieved and reclaimed from beth high- and low-pressure

por_.

2. Repair leak following Refrigerant Service procedures.

BURNER FLAME

BURNER

_IANIFOL D

C99021

Fig. 14_Monoport Burner

NOTE: Install a f-alterdrier whenever the system has been opened

for repair.

3. Add a small charge of R-22 refrigerant vapor to system and

leak-test unit.

4. Recover refrigerant from refrigerant system and evacuate to

500 microns if additional leaks are not found.

5. Charge unit with R-22 refrigerant, using a volumetric-

charging cylinder or accurate scale. Refer to unit rating plate

for required charge. Be sure to add extra refrigerant to

compensate for internal volume of falter drier.

Step 2--START-UP HEATING AND MAKE ADJUST-

MENTS

Do not jumper any safety devices when operating the unit.

Make sure that burner OFLfices are properly aligned. Unstable

operation may occur when the burner orifices in the manifold are

misaligned.

Follow the fighting instructions on the heating section operation

label (located inside the burner or blower access door) to start the

heating section.

NOTE: Make sum that gas supply has been purged, and that all

gas piping has been checked for leaks.

CHECK HEATING CONTROL

Start and check the unit for proper heating control operation as

follows (see furnace fighting instructions located inside burner or

blower access panel):

1. Place room thermostat SYSTEM switch in the HEAT position

and the fan switch is placed in ALrrO. position.

2. Set the heating temperature control of the thermostat above

room temperature.

3. The induced-draft motor will start.

4. After a call for heating, the main burner should light within 5

see. If the burners do not fight, there is a 22-see. delay before

another 5-sec. try. If the burners still do not light, this

sequence is repeated. If the burners do not light within 15

minutes from the initial call for heat, there is a lockout. To

reset the control, break the 24-v power to W.

5. The evaporator fan will turn on 45 sec. after the flame has

been established. The evaporator fan will turn off 45 sec. after

the thermostat has been satisfied.

CHECK GAS INPUT

Check gas input and manifold pressure after unit start-up (See

Table 6). If adjustment is required proceed as follows:

•The rated gas inputs shown in Table 6 are for altitudes from sea

level to 2000 fit above sea level. These inputs are based on

natural gas with a heating value of 1050 Btu/ft 3 at 0.65 specific

gravity, or propane gas with a heating value of 2500 Btu/ft 3 at

1.5 specific gravity.

• For elevations above 2000 ft, reduce input 4 percent for each

1000 ft above sea level

• When the ga.s supply being used has a different heating value or

specific gravity, refer to national and local codes, or contact

your distributor to determine the required orifice size.

ADJUST GAS INPUT

The gas input to the unit is determined by measuring the gas flow

at the meter or by measuring the manifold pressure. Measuring the

gas flow at the meter is recommended for natural gas units. The

manifold pressure must be measured to determine the input of

propane ga_s units.

Measure Gas Flow (Natural Gas Units)

Minor adjustment to the gas flow can be made by changing the

manifold pressure. The manifold pressure must be maintained

between 3.4 and 3.6 in. wg.

If larger adjustments are required,

change main burner orifices following

the recommendations of national

and local codes.

NOTE: All other appliances that use the same meter must be

turned off when gas flow is measured at the meter.

Proceed as follows:

1. Turn off gas supply to unit.

2. Remove pipe plug on manifold (See Fig. 13) and connect

manometer. Turn on gas supply to unit.

3. Record number of seconds for gas meter test dial to make one

revolution.

4. Divide number of seconds in Step 3 into 3600 (number of

seconds in one hour).

5. Multiply result of Step 4 by the number of cu fitshown for one

revolution of test dial to obtain cuft of gas flow per hour.

6. Multiply result of Step 5 by Btu heating value of gas to obtain

total measured input in Btuh. Compare this value with heating

input shown in Table 6 (Consult the local gas supplier if the

heating value of gas is not known).

EXAMPLE: Assume that the size of test dial ks I cuft. one

revolution takes 32 sec., and the heating value of the gas is 1050

Btu/ft 3. Proceed as follows:

1. 32 sec. to complete one revolution.

2. 3600+ 32= 112.5.

3. 112.5 x 1 =112.5 ft3 of gas flow/hr.

4. 112.5 x 1050 = 118,125 Btuh input.

If the desired gas input is 115,000 Btuh, only a minor change in the

manifold pressure is required.

Observe manifold pressure and proceed as follows to adjust gas

input:

FIELD

SUPPLY

POWER

W4.3 BLK

OFM

10ONLY)

EQUIP GMG

COOLINGFANLOGIC

T+30

G G

ENERGIZED DEFNERGIZED

HEAtiNGFANLOGIC

o 45 • T+3O

W BR WBR

ENERGIZED DE B_ERG[ZED

OFF

HEAT B

I THI AHA

_HEAT

OAUTO

_CCO TCl YI

FAN G

FIELD=THERMOSTAT

COMMON --

TRAN1

UNIT COMPONENT ARRANGEMENT

OLFDCORFAN []

SEGTION

EQUll

G_D

COMPRESSORINBOORFAN [_ CO_TROLBOX

SECTION _ECTION _

24V

CQMp L_PLICE_)

" [BN

_ASSECTIOf_

COMP

W15YEL

DISCONNECT

PER NEC

W56 BLU-

[SEE NOTE #4)_

W59YEL--

W64YEL--

IFM

IDM

W46 BRN--

W30 BRN-

LEGEND

AHA - Adjustable Heat NEC -National Electrical

Anticipator Code

BR - Blower Relay ORe - Outdoor-Fan Motor

C - Contactor QT - QuabrupleTerminel

CAP -Capacitor RS - Rollout Switch

COMP- Compressor Motor SEN - Sensor

CR - Combustion Relay SW - Switch

CS - Centrifugal Switch TRAN - Transformer

EQUIP- Equipment

FS - Flame Sensor _ Reid Splice

FU - Fuse

GND - Ground _Terminal(Marked)

GV -Gas Valve

GVR - Gas Valve Relay OTerminal (Unmarked)

HS - Hall Effect Sensor

HV - High Voltage _ Splice

TRAN - Transformer

]- Ignitor _Splice (Marked)

IDM -inducab-Oraft Motor -- FactoryWidng

IFC - In.or-Fan Co_tactor -- -- - I_eld Contro_ Wiring

IFM - Indoor-Fan Motor

IGC - Integrated Gas Unff -- -- - Reid Power Wiring

Controller .... Accessory or

L1 - Line Ol_ional Wiring

LS - Limit Switch _To Indicate Common

LS1 - Limi_ Switch Potential Oely, Not

MGV - Main Gas Velve toRedrcsentWiring

NOTES:

1. If any of the odginel wires furniabed are reol_ced, thay must be

replaced with type 90 degree Cwire or its equivalent.

2. Seepricopagesforthermostatandsubbases.

3. Use 75 degree C copper conductors for field installation.

4. For high speed IFM, dis_3nnect RED wire from IGC terminal BM

and connect BLK w_re from IFM, For medium speed, disconnect

RED wire from IGC terminal BM and connect BLU wire from IFM.

Fig. 15_208/230-3-60 Wiring Diagram, Units 48GS and 48GX

C00058

F,ELO c I

E ,P_QMO--'/// l

W45 BLK BLK

CAP 2 YEL

W5 YEL BRN

WO BLK L__

(060ONLY)% L3- \ N, /coMP

W56 BLU

COGUNG FAN LOGIC

(SEE NOTE #4)

wB,YEL

- -W64 YEL CAP 1

--W15YEL PRIMARY Q BR

--W14 BLK 460V Vl0

/_,_i _ I_BRN

_GRN YEk

G G

ENERGIZED D_NW_IGIZED

HEATING WOI L(3GIC

ENERG_I_t _-ENERGtZED

OFF -_ _

_HEAT II

°_LrrO II

_TCI ",'1 I I

--1 II

I II

I I!

FIELO'THERMOSTAT I

COMMON ill

UNIT COMPONENT ARRANGEMSNT

OUTDOOR FAN []

SECTION

EQUIF

GND

_,OMPRESN)R rNNXIRFAN _ _BOLBOX

SEC17ON SECTION _

24V

°0 []

_ASSECTION

--W13 BLK--

124V SPUCE

Wl 9WHT

W20 GRN

W21 RED

DISCONNECT

pERNEC

IFM

MGV

--W35 GRA_

FLt_E SEN

--VEL--O

IDM

W46 BRN--

--W39 REDIGC _]_

'- .......... _ --Wa2BRN-- m

W33 YEL

W30 BRN"

LEGEND

AHA - Adjustable Heat NEC -National Bectdcal

Anticipator Code

BR - Blower Relay OFM - Outdoor-Fan Motor

C - Contactor QT - QuedrupleTerminal

CAP - Capacitor RS - Rollout Switch

COMP- Compressor Motor SEN - Sensor

CR - Combustion Relay SW -Switch

CS - Cen_'ffugaJ Switch TRAN - Transformer

EQUIP- Equipment

FS l Rame Sensor _Field Splice

FU -Fuse

GND - Ground _ Terminal (Marked)

GV lGas Valve

GVR - Gas Valve Relay C) Terminal (Unmarked)

HS - Hall Effect Sensor

HV - High VoRage • Splice

TRAN - Transformer

IlIgnitor _ Splice(Marked)

IDM -Inducod-Draft Motor -- FactoryWidng

IFC -ladoor-Fan Contactor -- -- - Reid Con_rolWiring

IFM - Indoor-Fan Motor

IGC -Integrated Gas Unit -- -- - Field PowerW_ring

Controller .... Accessory or

L1 - Line Op5onal Widng

LS - Limit Switch -- TO Indicate Common

LS1 - Limit Switch Potential Only, Not

MGV - MelnGasValve teRepresentW_ring

NOTES:

1. ff any of the original wires furnished ara replaced, they must be

replaced with type 90 degree C wire or Its equivalent

2. See price pages fo_thermostat and subbase_

3. Use 75 degree Ccopper conductors for field installation.

.For high speed IFM, disconnect RED win_ from IGC terminal BM

and connect BLK wlre from IFM. For medium speed, disconnect

RED wire from IQC terminal BM and cennect BLU wire from IFM.

Fig. 16_460-3-60 Wiring Diagram, Units 48GS and 48GX

C00059

Table 6_Heating Inputs

HEATING

INPUT

(BTUH)*

NUMBER

ORIFICES

40,000 2

60,000 2

90,000 3

115,000 3

130,000 3

Min

4.0

GAS SUPPLY PRESSURE

(IN. WG)

Natural Propanel"

Max Min

13,0 4.0

13.0 4.0

Max

13.0

13,0

13.0

MANIFOLD

PRESSURE

(IN. WG)

Natural Propane,"

3.5 3.5

3.5 3.4

3.5 3.7

3.5 3.5

•When a unit is converted to propane, different size orifices must be used. See separate, natural4o-propene conversion kit instructions.

f Based on altitudes from sea level to 2000 It above sea level. For altitudes above 2000 It, reduce input rating 4percent for each additional 1000 It above sea level.

in Canada, from 2000 It above sea level to 4500 It above sea lev_, derato the unit 10 percent.

1. Remove cover screw over regulator adjustment screw on gas

valve.

2. Turn regulator adjustment screw clockv4se to increase gas

input, or turn regulator adjustment screw counterclockwise to

decrease input. Manifold pressure must be between 3.4 and

3.6 in. wg. Unsafe operation of the unit may result if manifold

pressure is outside this range. Personal injury or unit damage

may result.

3. Replace cover screw cap on gas valve.

4. Turn off gas supply to unit. Remove manometer from pressure

tap and replace pipe plug on gas valve. Turn on gas to unit and

check for leaks.

Measure Manifold Pressure (Propane Units)

The main burner orifices on a propane gas unit are sized for the

unit rated input when the manifold pressure reading matches the

level specified in Table 6.

Proceed as follows to adjust gas input on a propane gas unit:

1. Turn off gas to unit.

2. Remove pipe plug on manifold and connect manometer (See

Fig. 13).

3. Turn on gas to unit.

4. Remove cover screw over regulator adjustment screw on gas

Valve.

5. Adjust regulator adjustment screw to the correct manifold

pressure, as specified in Table 6. Turn adjusting screw

clockwise to increase manifold pressure, or turn adjusting

screw counterclockwise to decrease manifold pressure.

6. Replace cover screw.

7. Turn off gas to unit. Remove manometer from pressure tap.

Replace pipe plug on gas valve, then turn on gas to unit. Check

for leaks.

CHECK BURNER FLAME

With burner access panel removed, observe the unit heating

operation. Watch the burner flames to see if they are light blue and

soR in appearance, and that the flames are approximately the same

for each burner. Propane will have blue flame with yellow tips

(See Fig. 14). Refer to the Maintenance section for information on

burner removal.

AIRFLOW AND TEMPERATURE RISE

The heating section for each size unit is designed and approved for

hearing operation within the temperature-rise range stamped on the

unit rating plate.

Table 7 shows the approved temperature rise range for each

heating input, and the air delivery cfm at various temperature rises.

The heating operation airflow must produce a temperature rise that

fails within the approved range.

Refer to Indoor Airflow and Airflow Adjustrnents section to adjust

heating airflow when required.

HEATING SEQUENCE OF OPERATION

(See Fig. 15-16 and unit wiring label).

On a call for hearing, terminal "W" of the thermostat is energized,

starting the induced-draft motor. When die hall-effect sensor on

the induced-draft motor senses that it has reached the required

speed, the burner sequence begins. This function is performed by

the integrated gas control (IGC). The evaporator-fan motor is

energized 45 sec. afar flame is established. When the thermostat

is satisfied and "W" is deenergized, the burners stop f-wing and the

evaporator-fan motor shuts off after a 45-sec. time-off delay.

An LED (light-emitting diode) indicator is provided on the control

board to monitor operation. The control board is located by

removing the burner access panel. During normal operation, the

LED is continuously on (See Table 8 for error codes).

LIMIT SWITCHES

Normally closed limit switch (LS) completes the control circuit

through the thermostat R circuit. Should the leaving-air tempera-

ture rise above the maximum allowable temperature, the limit

switch opens and the R control circuit "breaks." Any interruption

in the R control circuit instantly closes the gas valve and stops gas

flow to the burners and pilot. The blower motor continues to run

until LS resets.

When die air temperature at the limit switch drops to the

low-temperature setting of the limit switch, the switch closes and

completes the R control circuit. The electric-spark ignition system

cycles and the unit returns to normal beating operation.

AUXILIARY LIMIT SWITCH (ROLLOUT)

The function of the switch is to close the main gas valve in the

event of flame rollout. The switch is loca_d above die main

burners. When the temperature at the auxiliary switch reaches the

maximum allowable temperature, the R control circuit trips,

closing the gas valve and stopping gas flow to the burners. The

indoor (evaporator) fan motor (IFM) and induced draft motor

continue to man until switch is reset. The IGC LED will display

FAULT CODE 7.

HEATING

INPUT

(BTUH)

40,000

60,000

90,000

115,000

130,000

Table 7--Air Delivery (Cfm) at Indicated Temperature Rise and Rated Heating Input

TEMPERATURE RISE °F

20 25 30 35 40 45 50 55 60 65 70

1500 1200 1000 857 750 667 600 545 500 -- --

2250 1800 1500 1286 1125 1000 900 818 750 692 --

-- -- 2250 1929 1688 1500 1350 1227 1125 1038 964

-- -- -- 2464 2156 1917 1725 1568 1438 1327 1232

-- -- -- 2786 2438 2167 1950 1773 1625 1506 --

NOTE: Dashed areas do not fall within the approved temperature _se range of the unit.

Table 8--LED Indications

ERROR CODE LED INDICATION

Normal Operation On

Hardware Failure Off

Fan On/Off Delay Modified 1 Flash

Limit Switch Fault 2 Flashes

Flame Sense Fault 3 Flashes

Four Consecutive Limit Switch Faults 4 Flashes

Ignition Lockout Fault 5 Flashes

Induced-Draft Motor Fault 6 Flashes

Rollout Switch Fault 7 Flashes

Internal Control Fault 8 Flashes

Temporary lock-out (1 hr) 9 Flashes

NOTES:

1. There is a 3-sec. pause between error code displays.

2. If more than one error code exists, all applicable error codes will be

displayed in numerical sequence

3. This chart is on the wiring diagram located inside the burner access panel,

Step 3--START-UP COOLING AND MAKE ADJUST-

MENTS

Ir!_[,,,Y±'Ti]id[,,]_'I

Complete the required procedures given in the Pre-Start-Up

section before starting the unit.

Do not jumper any safety devices when operating the unit.

Do not operate the compressor when the outdoor temperature

is below 40OF (unless accessory low-ambient kit is installed).

Do not rapid-cycle the compressor. Allow 5 minutes between

"on" cycles to prevent compressor damage.

CHECKING COOLING CONTROL OPERATION

Start and check the unit for proper cooling control operation as

follows:

I. Place room thermostat SYSTEM switch in OFF position.

Observe that blower motor starts when FAN switch is placed

in ON position and shuts down when FAN switch is placed in

AUTO. position.

2. Place SYSTEM switch in COOL position and FAN switch in

AUTO. position. Set cooling control below room temperature.

Observe that compressor, condenser fan, and evaporator

blower motors start. Observe that cooling cycle shuts down

when control setting is satisfied. The evaporator fan will

continue to run for 30 see.

3. When using an auto-changeover room thermostat, place both

SYSTEM and FAN switches in AUTO. positions. Observe

that unit operates in Heating mode when temperature control

is set to "call for heating" (above room temperature) and

operates in Cooling mode when temperature control is set to

"call for cooling" (below room temperature).

IMPORTANT: Three-phase, scroll compressor units

(48GS048 and 48GX030-060) are direction-oriented.

These units must be checked to ensure proper compressor

3-phase power lead orientation. If not corrected within 5

minutes, the internal protector shuts off the compressor.

The 3-phase power leads to the unit must be reversed to

correct rotation. When turning backwards, _roll compres-

sors emit elevated noise levels, and the difference between

compressor suction and discharge pressures may be dra-

matically lower than normal.

CHECKING AND ADJUSTING REFRIGERANT CHARGE

The refrigerant system is fully charged with R-22 refrigerant,

tested, and factory-sealed.

NOTE: Adjustment of the refrigerant charge is not required

unless the unit is suspected of not having the proper R-22 charge.

A superheat charging chart is attached to the outside of the service

access panel. The chart includes the required suction line tempera-

ture at given suction line pressures and outdoor ambient tempera-

tures.

An accurate superheat, thermocouple- or thermistor-type ther-

mometer, a sling psychrometer, and a gauge manifold are required

when using the superheat charging method for evaluating the unit

charge. Do not use mercury or small dial-type thermometers

beca_ve they are not adequate for this _pe of measurernent.

When evaluating the refrigerant charge, an indicated adjust-

ment to the specified factory charge must always be very

minimal. If a substantial adjustment is indicated, an abnormal

condition exists somewhere in the cooling system, such as

insufficient airflow across either coil or both coiLs.

Proceed as follows:

1. Remove caps from low- and high-pressure service fittings.

2. Using hoses with valve core depressors, attach low- and

high-pressure gauge hoses to low- and high-pressure service

fittings, respectively.

3. Start unit in Cooling mode and let unit ran until system

pressures stabilize.

4. Measure and record the following:

a. Outdoor ambient-air temperature (°F db).

b. Evaporator iniet-air temperature (°F wb).

c. Suction-tube temperature (°F) at low-side service fitting.

d. Suction (low-side) pressure (psig).

5. Using "Conling Charging Charts," compare outdoor-air tem-

perature (°F db) with the suction line pressure (psig) to

determinedesiredsystemoperatingsuctionlinetemperature

(SeeFig.17-26).

6.Compareactualsuction-tubetemperaturewithdesired

suction-tubetemperature.Usingatoleranceof -+3°F,add

refrigerantif actualtemperatureismorethan 3°F higher than

proper suction-tube temperature, or remove refrigerant if

actual temperature is more than 3°F lower than required

suction-tabe temperature.

NOTE: If the problem causing the inaccurate readings is a

refrigerant leak, refer to the Check for Refrigerant Leaks section.

INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS

Table 10-Color Coding for 460-V GE Motor Leads

3-SPEED 2-SPEED

black = high speed black = high speed

violet = jumper blue = jumper

orange = medium speed

red = low speed red = low speed

chassis parts. To select high speed on 460-v GE motors, separate

the black (female quick connect - QC - from the jumper lead

(male quick connect - QC) and connect the black lead to the BR.

lr_*ulate the jumper to avoid contact with any chassis parts.

Table 7 shows the temperature rise at various airflow rates. Tables

11 and 13 show both heating and cooling airflows at various

external static pressures. Refer to these tables to determine the

airflow for the system being installed (See Tables 14 and 15 for

wet coil pressure drop).

NOTE: Be sure that all supply- and return-air grilles are open,

free from obstructions, and adjusted properly.

Before changing blower speed, shut off gas supply. Then

disconnect electrical power to the unit and install lockout tag.

Electrical shock or explosion can cause serious injury or

death.

Airflow can be changed by changing the lead connections of the

blower motor.

Unit 48GS two- or three-speed motors (except size 030) are

factory wired for low speed operation. Unit 48GS030 is factory

wired for medium speed.

All 48GX units are factory wired for low speed and may need to

be wired for medium or high speed in the field.

For 208/230V

For color coding on the 208/230V motor leads, see Table 9.

Table 9-Color Coding for 208/230-V Motor Leads

3-SPEED 2-SPEED

black =high speed black =high speed

blue = medium speed

red = low speed red - low speed

To change the speed of the blower motor (BM), remove the fan

motor speed leg lead from the blower relay (BR). This wire is

attached to terminal BM of the integrated gas control (IGC) beard

for 3-phase units. To change the speed, remove and replace with

lead for desired blower motor speed. Insulate the removed lead to

avoid contact with chassis parts.

For 460-V GE Motors

For color coding on the 460-v GE motor leads, see Table 10.

To change the speed of the blower motor (BM), remove fan motor

speed lead from the blower relay (BR) and replace with the lead

for the desired blower motor speed. The motor speed lead is

attached to terminal BM of the integrated gas control (IGC) board.

For low and medium speeds, black must be connected to the

jumper wire. Insulate removed lead end to avoid contact with

COOLING SEQUENCE OF OPERATION

With the room thermostat SYSTEM switch in the COOL position

and the FAN switch in the AUTO position, the cooling sequence

of operation is as follows:

l. When the room temperature rkses to a point that is slightly

above the cooling control setting of the thermostat, the

thermostat completes the circuit between thermostat terminal

R to terminals Y and G. These completed circuits through the

thermostat:

2. The normally open contacts of energized contactor (C) close

and complete the circuit through compressor motor (COMP)

to condenser (outdoor) fan motor (OFM). Both motors start

instantly.

3. The set of normally open contacts of energized relay BM close

and complete the circuit through evaporator blower (indoor)

fan motor (IFM).

NOTE: Once the compressor has started and then stopped, it

should not be started again until 5 minutes have elapsed. The

cooling cycle remains "on" until the room temperature drops to a

point that is sfightly below the cooling control setting of the room

thermostat. At this point, the thermostat "breaks" the circuit

between thermostat terminal R to terminals Y and G. These open

circuits deenergize contactor coil C. The condenser and compres-

sor motors stop. After a 30-sec. delay, the blower motor stops. The

uhit is in a "standby" condition, waiting for the next "call for

cooling" from the room thermostat.

MAINTENANCE

To ensure continuing high performance and to minimize the

possibility of premature equipment failure, periodic maintenance

must be performed on this equipment. Tiffs combination

heating/cooling unit should be inspected at least once each year by

a qualified service person. To troubleshoot cooling or heating of

units, refer to Tables 16-18.

NOTE: Consult your local dealer about the availability of a

maintenance contract.

The ability to properly perform maintenance on this equip-

ment requires certain expertise, mechanical skills, tools, and

equipment. If you do not possess these, do not attempt to

perform any maintenance on this equipment other than those

procedures recommended in the User's Manual. FAILURE

TO HEED THIS WARNING COULD RESULT IN SERI-

OUS INJURY AND POSSIBLE DAMAGE TO THIS

EQUIPMENT.

Table 11--Dry Coil Air Delivery* - Horizontal Downflow Discharge -

Unit 48GS030-060 (Deduct 10 percent for 208 Volts)

230 AND 460 VOLT

Unit M_or E_ernalSt_ic P_ssure (in. wg)

Speed 0,O 0.1 0,2 0.3 0,4 0.5 0,6 0.7 0.8 0.9 1.0

WaHs 260 275 270 267 264 252 260 -- -- --

Low Cfm 950 880 825 750 670 580 400 ....

WaHs 380 375 365 360 355 350 344 335 312 -- --

030 Med Cfm 1220 1150 1090 1025 970 860 760 620 450 -- --

WaRs 485 475 470 460 455 445 437 430 415 385 --

High Cfm 1475 1440 1350 1275 1200 1125 1025 925 750 400 --

WaUs 576 566 556 538 512 497 481 466 450 435 --

Low Cfm 1430 1403 1365 1263 1157 1068 973 900 827 704 --

Watts 680 671 660 624 604 620 602 558 534 512 496

036 Med Cfm 1720 1630 1538 1439 1346 1267 1167 1126 1018 958 781

Watts 810 800 790 762 766 742 723 709 688 661 627

High Cfm 1800 1745 1660 1600 1547 1465 1360 1276 1163 967 876

Wa6s -- 675 660 650 640 630 620 610 595 580 --

Low Cfm -- 1454 1387 1326 1275 1204 1142 1061 995 918 --

WaRs -- 866 655 825 795 778 765 750 735 718 700

042 Med Cfm -- 1515 1458 1406 1350 1285 1224 1163 1091 1013 932

High WaRs -- -- -- 1000 950 925 910 890 875 855 833

Cfm -- -- -- 1551 1488 1424 1360 1296 1233 1146 1071

WaRs -- 727 712 700 688 666 644 622 595 569 --

Low cfm - 1678 1639 1600 1561 1500 1440 1379 1289 1198 -

wars -853 836 621 807 762 756 730 699 667 640

048 Med Cfm -- 1914 1870 1825 1780 1711 1642 1573 1470 1367 1270

High WaRs -- 979 959 943 927 697 868 838 802 766 736

Cfm -- 2150 2100 2050 2000 1922 1845 1767 1600 1535 1419

Watts 1033 949 864 836 822 608 772 737 705 674 642

Low Cfrn 2105 2057 2009 1943 1909 1876 1823 1770 1698 1627 1531

WaRs 1084 1054 1024 994 971 055 928 997 867 635 803

060 Med CfTn 2318 2248 2179 2110 2058 2000 1932 1885 1829 1740 1638

Watts -- -- 1184 1152 1120 1102 1084 1056 1029 997 965

High Cfm -- -- 2349 2278 2207 2124 2041 2000 1960 1853 1745

* Air delivery values are without air filter and are for dry coil (See Table 14_8GS Wet Coil Pressure Drop).

NOTE: Deduct field-supplied air filter pressure drop and wet coil pressure drop to obtain exlemal static pressure available for ducting.

Table 12--Filter Pressure Drop (In. wg)

UNITSIZE RLTER SIZE CFM

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 22(;0 2300

030 20 X 20 X 1 0,05 0.07 0.08 0,10 0.12 0.13 0,14 0.15

036 20 X 24 X 1 ....... 0.09 0.10 0,11 0.13 0.14 0.15 0.16

042, 648, 060 24 X 30 X 1 0.07 0.08 0.09 0.10 0.11 0.12 0,13 0.14 0.15 0.16 0,17 0,18

Failure to follow these warnings could result in serious injury:

I. FirsL turn off gas supply to the unit. Then turn off electrical

power to the unit and install lockout tag before performing

any maintenance or service on the unit.

2. Use extreme caution when removing panels and parts. As

with any mechanical equipment, personal injury can result

from sharp edges, etc.

3. Never place anything combustible either on, or in contact

with, the unit.

4. Should overheating occur or the gas supply fail to shut off,

turn off external main manual gas valve to the unit. Then

shut off electrical supply and install lockout tag.

tion when servicing.

The minimum maintenance requirements for this equipment are as

follows:

1. Inspect air filter(s) each month. Clean or replace when

necessary. Certain geographical locations may require more

frequent inspections.

2. Inspect indoor coil, outdoor coil, drain pan, and condensate

drain each cooling season for cleanliness. Clean at least once

per healing /cooling season or more often if needed.

Table 13--Dry Coil Air Delivery* - Horizontal and Downflow Discharge -

Unit 48GX030-060 (Deduct 10 percent for 208 Volts)

230 AND 466 VOLT

Unit Motor E_ernal Static Pressure (in. wg)

Speed 0,0 0.1 0.2 6.3 0.4 0.8 0.6 0,7 0.8 0,9 1.0

WaRs 246 244 243 241 .......

Low Cfm 982 860 808 736 .......

WaRs 343 339 336 332 328 322 317 ....

030 Med Cfm 1233 1179 1109 1038 953 855 754 ....

WaRs .... 441 432 421 410 400 -- --

High Cfm .... 1202 1111 1021 929 826 -- --

WaRs -- 470 458 445 430 415 399 384 -- -- --

Low Cfrn -- 1463 1406 1344 1273 1186 1091 983 -- -- --

WaRs -- -- 614 501 487 471 455 438 422 -- --

036 Med Cfm -- -- 1497 1428 1348 1255 1152 1042 929 -- --

WaRs -- -- -- 646 636 626 614 662 589 -- --

High Cfm -- -- -- 1491 1412 1325 1228 1120 1003 -- --

Low WaRs 643 625 614 605 593 574 549 518 486 454 --

Cfm 1626 1614 1579 1532 1478 1421 1361 1295 1218 1120 --

WaRs .... 726 695 661 625 591 561 540

042 Med Cfm .... 1731 1672 1610 1541 1456 1345 1193

WaRs ....... 790 766 742 713

High Cfm ....... 1699 1602 1494 1367

WaRs 614 588 577 572 566 556 539 517 491 -- --

Low Cfm 1591 1549 1518 1490 1460 1421 1372 1312 1242 -- --

WaRs 778 756 738 719 699 676 650 623 596 572 555

048 Med Cfm 1854 1837 1804 1759 1705 1643 1577 1508 1440 1375 1315

WaRs .... 896 862 829 800 775 752 728

High Cfm .... 1956 1879 1797 1709 1615 1514 1406

WaRs 834 813 782 746 712 680 652 626 -- -- --

LOW Cfm 2016 1955 1898 1840 1781 1717 1646 1566 -- -- --

WaRs 941 889 851 822 797 772 745 714 679 639 --

060 Med Cfm 2379 2233 2124 2038 1964 1892 1814 1727 1626 1511 --

WaRs -- -- 960 949 920 863 845 812 783 753 --

High Cfm -- -- 2497 2224 2076 1986 1915 1831 1721 1588 --

* Air delivery values are without air filter and are for dry coil (See Table 15-48GX Wet Coil Pressure Drop table),

NOTE: Deduct field-supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting.

40 50 50 70 80 90

SUCT]ON LINE TEMPERATURE ('F)

I 4 1I0 116 217

5UC7_0_, LINE T£HpERATURE ('C) C00043

Fig. 17--Cooling Charging Chart, 48GS030 Units

751 I1C

lOO

90-

'50 -

30 40 5'0 50

SUCTIONLINE TEHPERATURE(-F]

I I

4 i_O 16

SUCTIONLINE TEMPERATURE(.C]

Fig. 18--Cooling Charging Chart, 48GS036 U_ e44

Fig.19---CoolingChargingChad,48GS042U_ °4s

÷_ iii I

ii=i

75_ 110 i !

68= 100-

_v i _' 105 41

.95 :t5

m _ 65 18

LU _ _ J_'_ L,,,,_

_ _ o70 _.TI _"_' ' .-

i, !i

_7_,o11

30 40 50 60 70 80 90

SUCTIONUNETEMPERATUREI°Fq

IIII=I I

-1 410 16 21 27 32

SUCTION LINE TEMPERATURE (°C)

Fig. 20--Cooling Charging Chart, 48GS048 Unl_ls°47

689 100-

q_l _8o-

_£1 i#)

_LU

40-

2o713o

Ililll

IIr- I_45 73

,==,,_._- .._, , I I

; ii'_

!111 I_-'_ !

-i

i i '

40 50 60 70 80 gO

SUCTION UNE TEMPERATURE I_F)

III II

4 10 16 21 27 32

SUCTION LINE TEMPERATURE (°C)

Fig. 21--Cooling Charging Chart, 48GS060 U_ m

3. Inspect blower motor and wheel for cleanliness at the begin-

ning of each heating and cooling season. Clean when neces-

sary. For first heating and cooling sem_on, inspect blower

wheel hi-monthly to determine proper cleaning frequency.

4. Check electrical connections for dghtness and controls for

proper operation each heating and cooling season. Service

when necessary.

5. Ensure wires are not contacting refrigerant tubes or sharp

sheet metal edges.

6. Check and inspect heating section before each heating season.

Clean and adjust when necessary.

7. Check flue hood and remove any obstructions, if necessary.

AIR FILTER

Inspect air filter(s) at least once each month and replace

(throwaway-type) or clean (cleanable-type) at least twice during

each heating and cooling season or whenever the f-alter(s) becomes

clogged with dust and/or lint.

EVAPORATOR BLOWER AND MOTOR

NOTE: All motors are permanently lubricated. Do not attempt to

lubricate these motors.

2761 40

i _71 30

(0301 60HZ CHARGING CHART r_

40 50 60 70 8_0 90

SUCTION LINETEMPERATURE (_F}

_1 4 10 16 21 27 32

SUCTION LINETEMPERATURE (_C)

Fig. 22--Cooling Charging Chart, 48GX030 Un_l_°46

68E 100

<_'62C 90-

°- ,

_ 551 _

g _6o !

_48E 70

cu _ _

_41, =" i

o 6o !

-_so!

27[ 40

(042) 60HZ CHARGING CHART 0_ ]_=

_F ,C

-1 4 10 16 21 27 312I

SUCTION LINE TEMPERATURE ("C) IC00052

Fig. 24---Cooling Charging Chart, 48GX042 Units

For longer life, operating economy, and continuing efficiency,

clean accumulated dirt and grease from the blower wheel and

motor annually.

Before cleaning the blower motor and wheel, disconnect gas

supply. Then turn off and tag electrical power to the unit.

Failure to adhere to this warning could cause serious injury or

death.

Cleaning the Blower Motor and Wheel

1. Remove and disassemble blower assembly as follows:

a. Remove unit access panel.

b. Disconnect motor lead from blower relay (BM). Discon-

nect yellow lead from temainal L2 of the contactor.

(036) 60HZ CHARGING CHART _J_

4o so 6o _o

sucnoNLI_ETEMPERATUREII°_ I

-1 4 10 16 21 27 32

SUCTION LINE TEMPERA31JRE (°C)

Fig. 23---Cooling Charging Chart, 48GX036 U_ °51

68_

i _62I

q551

_ 41"

_ a4_

271

2O;

(048) 60HZ CHARGING CHART

100

90-

_7o

o_z6o_

30 40 50 60 70 80 90

SIUCTION LINE TEMPE P,ATU RE I(°F)

I I '

-1 4t0 16 21 27 32

SUCTION UNETEMPERATURE I°C)

Fig. 25--Cooling Charging Chart, 48GX048 Units°°53

c. On all units, remove blower assembly from unit. Remove

screws securing blower to blower partition and slide

assembly out. Be careful not to tear insulation in blower

compartment.

d. Ensure proper reassembly by marking blower wheel and

motor in relation to blower housing before disassembly.

e. Loosen setscrew(s) that secures wheel to motor shall

Remove screws that secure motor mount brackets to

housing, and slide motor and motor mount out of housing.

Remove and clean blower wheel as follows:

a. Ensure proper reassembly by marking wheel orientation.

b. Lift wheel from housing. When handling and/or cleaning

blower wheel, be sure not to disturb balance weights (clips)

on blower wheel vanes.

Table 14_8GS Wet Coil Pressure Drop

UNIT SIZE AIRFLOW PRESSURE DROP

48GS (CFM) (IN. WG)

900 0.065

030 1000 0.080

1100 0.097

1100 0.084

036 1200 0.100

1300 0.177

1300 0.103

042 1400 0.120

1500 0.138

1500 0.088

048 1600 0.100

1700 0.113

1900 0.108

060 2000 0.120

2100 0.132

Table 1,5_48GX Wet Coil Pressure Drop

UNIT SIZE AIRFLOW PRESSURE DROP

48GX (CFM) (IN. WG)

900 0.0687

030 1000 0.083

1100 0.150

1100 0.084

036 1200 0.100

1300 0,177

1300 0.099

042 1400 0.177

1500 0.204

1500 0.199

048 1600 0.137

1700 0,156

1900 0.108

060 2000 0,120

2100 0.132

(060) 60HZ CHARGING CHART _RT

= _ I I 105

_620 904 ;_,_ L_ '2, 85

_,_ _1 75

,F "L, I _ IV 45

==_o_ ,i-"

"i. 'k

_41_ z60d

30 40 50 60 70 80 90

SU_TION LIN ETEMPERATURE I°Ft

IIII

4 10 16 21

SUCTION UNE TEMPERATURE (_C)

27 32

Fig. 2_Cooling Charging Chart, 48GX060 Units

INDUCED DRAFT MOTOR MOUNT

ROLLOUT

SWITCH

COLLECTOR BLOWER BURNER MOUNTING

BOX HOUSING RACK SCREW

C99022

Fig. 27--Blower Housing and Flue Collector Box

FRONT

ACCESS PANEL

Fig. 28_Unit Access Panel

C99091

c. Remove caked-on dirt from wheel and housing with a

brush. Remove lint and/or dirt accumulations from wheel

and housing with vacuum cleaner, using soft brash attach-

ment. Remove grease and oil with mild solvent.

d. Reassemble wheel into housing.

e. Reassemble motor into housing. Be sure setscrews are

tightened on motor shaft fiats and not on round part of

shaft.

f. Reinstall unit access panel

3. Restore electrical power to unit. Start unit and check for

proper blower rotation and motor speeds during heating and

cooling cycles.

FLUE GAS PASSAGEWAYS

To inspect the flue collector box and upper areas of the heat

exchanger:

1. Remove the combustion blower wheel and motor assembly

according to directions in the Combustion-Air Blower section.

HOUSING

2 SETSCREWS

(HIDDEN)

C99085

Fig. 29---Removal of Motor and Blower Wheel

C99086

Fig. 30_Burner Rack Removed

2. Remove the 3 screws holding die blower housing to die flue

collector box cover (See Fig. 27-30).

3. Remove the 12 screws holding the flue collector box cover

(See Fig. 29-30) to die heat exchanger assembly. Inspect the

beat exchangers.

4. Clean all surfaces, as required, using a wire brush.

COMBUSTION-AIR BLOWER

Clean periodically to assure proper airflow and heating efficiency.

Inspect blower wheel every fall and periodicaily during the heating

season. For the first heating sea.son, inspect blower wheel bi-

monthly to determine proper cleaning frequency.

To inspect blower wheel, remove draft hood assembly. Shine a

flashlight into opening to inspect wheel. If cleaning is required,

remove motor and wheel as follows:

1. Remove unit access panel (See Fig. 28).

2. Remove the 7 screws that attach induced-draft motor mount-

ing plate to blower housing (See Fig. 29).

3. Slide the motor and blower wheel a._sembly out of the blower

housing (See Fig. 29). Clean the blower wheel. If additional

cleaning is required, continue with Steps 4 and 5.

4. To remove blower, remove 2 setscrews.

5. To remove motor and cooling fan assembly, remove 4 screws

that hold blower housing to mounting plate.

6. To reinstall, reverse the procedure outlined above.

LIMIT SWITCH

Remove unit access panel. Limit switch is located on the blower

partition.

BURNER IGNITION

Unit is equipped with a direct spark ignition 100 percent lockout

system. Ignition module is located in die control box. Module

contains a self-diagnostic LED. During servicing, refer to label

diagram for LED interpretation.

If lockout occurs, unit may be reset by either momentarily

interrupting power supply to unit or by turning selector switch to

OFF position at die thermostat.

MAIN BURNERS

At the beginning of each heating season, irtspect for deterioration

or blockage due to corrosion or other causes. Observe the main

burner flames and adjust, if necessary.

Removal of Gas Train

To remove die gas train for servicing:

1. Shut off main gas valve.

2. Shut off power to unit and install lockout tag.

3. Remove unit access panel (See Fig. 28).

4. Disconnect gas piping at unit gas valve.

5. Remove wires connected to gas valve. Mark each wire.

6. Remove ignitor and sensor wires at the ignitor module.

7. Remove the mounting screw that attaches the burner rack to

the unit base (See Fig. 27).

8. Slide die burner rack out of the unit (See Fig. 27 and 30).

9. To reinstall, reverse die procedure outlined above.

CONDENSER COIL, EVAPORATOR COIL, AND

CONDENSATE DRAIN PAN

Inspect the condenser coil, evaporator coil, and condensate drain

pan at least once each year or more often if necessary.

The coils are easily cleaned when dry; therefore, inspect and clean

the coils either before or after each cooling season. Remove all

obstructions, including weeds and shrubs, that interfere with die

airflow through the condenser coil.

Straighten bent fins with a fin comb. If coated with dirt or lint,

clean the coils with a vacuum cleaner, using die so_ brush

attachment. Be careful not to bend die fins. If coated with oil or

grease, clean the coils with a mild detergent-and-water solution.

Rinse coils with clear water, using a garden bose. Re careful not to

splash water on motors, insulation, wiring, or air l-alter(s). For best

results, spray condenser coil fins from inside to outside die unit.

On units with an outer and inner condenser coil, be sure to clean

between the coils. Be sure to flush ail dirt and debris from the unit

base.

Inspectthedrainpanandcondensatedrainlinewheninspecting

thecoils.Cleanthedrainpanandcondensatedrainbyremovingall

foreignmatterfromthepan.Flushthepananddraintubewith

clearwater.Donotsplashwaterontheinsulation,motor,wiring,

orairfilter(s).If thedraintubeis restricted,clearit witha

"plumberssnake"orsimilarprobedevice.Ensurethattheauxiliary

drainportabovethedraintubeisalsoclear

CONDENSER FAN

NOTE: Refer to the heating and/or cooling sequence of operation

in this publication as an aid in determining proper control

operation

_GERANT CIRCUIT

Annually inspect all refrigerant tubing connections and the unit

base for oil accumulations. Detecting oil generally indicates a

refrigerant leak.

l. Remove 6 screws holding condenser grille and motor to top

cover.

2. Turn motor/grille a_s_mbly upside down on top cover to

expose the fan blade.

3. Inspect the fan blades for cracks or bends.

4. If fan needs to be removed, loosen the setscrew and slide the

fan off the motor shaft.

5. When replacing fan blade, position blade so the hub is 1/8 in.

away from the motor end (l/8 ha. of motor shaft will be

visible. See Fig. 12).

6. ErL_ure that setscrew engages the flat area on the motor shaft

when tightening.

7. Replace grille.

ELECTRICAL CONTROLS AND WIRING

Irmpect and check the electrical controls and wiring annually. Be

sure to turn off the gas supply, and then the electrical power to the

uniL

Remove access panel to locate all the electrical controls and

wiring. Check all electrical connections for tightness. Tighten all

screw connections. If any smoky or burned connections are

noticed, disassemble the connection, clean all the parts, restrip the

wire end and reassemble the connection properly and securely.

After inspecting the electrical controls and wiring, replace the

access panel. Start the unit, and observe at least one complete

heating cycle and one complete cooling cycle to ensure proper

operation. If discrepancies are observed in either or both operating

cycles, or if a suspected malfunction has occurred, check each

electrical component with the proper electrical instrumentation.

Refer to the unit wiring label when making these checkouts.

If oil is detected or if low cooling performance is suspected,

leak-test all refrigerant tubing using an electronic leak-detector,

halide torch, or liquid-soap solution. If a refrigerant leak is

detected, refer to the Check for Refrigerant Leaks section.

If no refrigerant leaks are found and low cooling performance is

suspected, refer to the Checking and Adjusting Refrigerant Charge

section.

GAS INPUT

The gas input does not require checking unless improper heating

performance is suspected. If a problem exists, refer to the Start-Up

section.

EVAPORATOR AIRFLOW

The heating and/or cooling airflow does not require checking

unless improper performance is suspected- lfa problem exists, be

sure that all supply- and return-air grilles are open and free from

obstructiomr, and that the air filter is clearL When necessary, refer

to the Indoor Airflow andAirflow Adjustments section to check the

system airflow.

METERING DEVICE -- ACUTROL DEVICE

This metering device is a fixed orifice and is located in the header

to the evaporator coil.

LIQUID LINE STRAINER

The liquid line strainer (to protect metering device) is made of wire

mesh and located ha the liquid line on the inlet side of the metering

device.

TROUBLESHOOTING

Use the Troubleshooting Guides (See Tables 16-18) if problems

occur with these units.

START-UP CHECKLIST

Use the Start-Up Checklist to ensure proper start-up procedures are

followed.

SYMPTOM

Compressor and condenser fan

will not start.

Compressor will not

start but condenser

fan runs,

Three-phase scroll compressor

(48GS048 and 48GX030-060 only)

makes excessive noise, and there may

be alow pressure dilferentiat.

Compressor cycles (other than

normally satisfying thermostat).

Compressor operates oonUnuously,

Excessive head pressure.

Head pressure too low.

Excessive suction pressure.

Suction pressure too low.

Table 16_Troubleshooting Guide_Cooling

CAUSE

Power Failure

Fuse blown or circuit breaker tdppad

Defective thermostat, contactor, transformer, or control relay

Insufficient line voltage

Incorrect or faulty widng

Thermostat setting too high

Faulty widng or loose connections in compressor circuit

Compressor motor burned out, seized, or internal

ovedoad open

Defective run/start capacitor, overload, start relay

One leg of 3-phase power dead

Scroll compressor is rotsting in the wrong direction

Refrigerant overcharge or undercharge

Defective compressor

insufficient line voltage

Blocked condenser

Defective _n/start capacitor, ovedoad or start relay

Defective thermostat

Faulty condenser-fan motor or capacitor

Restriction in refitgerant system

Dirty air filter

Unit undersized for load

Thermostat set too low

Low refrigerant charge

Leaking valves in compressor

Air in system

Condenser coil dirty or restricted

Dirty air filter

Dirty condenser COil

Refrigerant overcharged

Air in system

Condenser air restricted or air short_ysiing

Low refrigerant charge

Compressor valves leaking

Restriction in liquid tube

High heat load

Compressor valves leaking

Refrigerant overcharged

Dirty air filter

Low refitgerant charge

Mefedng device or low side restdcted

Insufficient evaporator airflow

Temperature too low in conditioned area

Outdoor ambient below 40°F

Fistd-instailed filter-alder restricted

REMEDY

Call power company.

Replace fuse or reset cimuit breaker.

Replace component.

Determine cause and correct.

Check widng diagram and rewire correctly.

Lower thermostat setting below room temperature.

Check wiring and repair or replace.

Determine cause

Replace compressor.

Determine cause and replace.

Replace fuse or reset circuit breaker.

Determine cause.

Correct the direction of rotation by reversing the

3-phase power leads to the unit. Shut down unit

to allow pressures to equat_ze.

Recover refrigerant, evacuate system, and recharge to

capacities shown on nameplate.

Replace and determine cause.

Determine cause and correct.

Determine cause and replace.

Replace thermostat.

Replace.

Locate restriction and remove.

Replace filter.

Decrease load or increase unit size.

Reset thermostat.

Locate leak, repair, and recharge.

Replace compressor.

Recover refrigerant, evacuate system, and recharge.

Clean coil or remove restdction.

Replace filter.

Clean coil.

Recover excess refrigerant.

Recover refdgerant, evacuate system, and recharge.

Determine cause and correct.

Check for leaks, repair, and recharge.

Replace compressor.

Remove restriction.

Check for source and eliminate.

Replace compressor.

Recover excess refrigerant.

Replace Filter.

Check for leaks, repair, and recharge.

Remove source of restdction.

Increase air quantity. Check filter -- replace if necessary.

Reset thermostat.

install low-ambient kit.

Replace.

Table 17--Troubleshooting Guide-Heating

SYMPTOM CAUSE REMEDY

Water in gas line Drain. Install drip htg.

No power to f_mace Check power supply fuses, widng, or circuit breaker,

Check transformer,

No 24-v power supply to control circuit NOTE: Some transformers have internal overcurrerd

protection that requires accol_lown period to reset.

Miswirod or loose connections Check all widng and wirenut connections

Burned-out heat anticipator in Replace thermostat.

Burners will not ignite, thermostat

Broken thermostat wire Run continuity check, Replace wire if necessary.

Check flame ignition and sense electrode positioning.

Mlaaligned spark electrodes Adjust as necessary.

1.Check gas line for air. Purge as necessary.

NOTE: After purging gas line of air, wait at least 5 minutes for any

No gas at main burners gas to dissipate before attempting to light unit.

2. Check gas valve.

Dirty air filter Clean or replace filter as necessary.

Check gas pressure at manifold match with that on

Gas input to fumace too low unit nameplate.

Unit undersized for application Replace with proper unit or add additional unit.

inadequate heaUng. Restricted airflow Clean or replace rifler. Remove any restriction.

Use faster speed tap if available, or install aflemate

Blower speed too low motor.

Check rotation of blower, thermostat heat anticipator settings,

Limit switch cycles main burners temperature rise of unit. Adjust as necessary.

1.Tighten all screws around burner compartment.

Incomplete combustion results in: 2. Cracked heat exchanger. Replace.

Poor flame characteristics. Aldehyde odors, carbon monoxide, sooting 3. Unit oven3red. Reduce input (change orifices or

flame, floating flame adjust gas line or manifold pressure).

4. Check burner alignment,

Table 18---Troubleshooting Guide-LED Error Codes

SYMPTOM CAUSE REMEDY

Check 5-amp fuse on IGC*, power to unit, 24-v circuit breaker, and

Hardware failure, transformer. Units without a24-v circuit breaker have an internal

(LED OFF) Loss of power to control module (IGC)'. overload in the 24-v transformer. If the ovedoad tdps, ariow 10 min-

utes

for automatic reset.

High limit switch opens during heat

exchanger warm-up period before fan-on Ensure unit is fired on rate; ensure temperature rise is correct.

Fan ON/OFF delay modified delay expires.

{LED/FLASH) Limit switch opens within three minutes Ensure unWs exfamai static pressure is within application guidelines.

after blower_ff delay timing in Heating mode.

Draft switch faults. Check the operation of the indoor (evaporator) fan motor. Ensure

(LED 2 flashes) High tempemtore limit switch is open. that the supply-air temperature rise is in accordance with the range

on the unit nameplate.

Flame sense fault. The IGC* sensed flame that should not be

(LED 3 flashes) present. Reset unit. If problem persists, replace central board.

4 consecutive limit switch faults. Check operation of indoor (evaporator) fan motor and that supply-air

(LED 4 flashes) Inadequate airflow to unit temperature rise agrees with range on unfl nameplate information.

Ignition lockout. Unit unsuccessfully attempted ignition for Check ignitor and flame sensor electrode spacing, gaps, etc. Ensure

(LED 5 flashes) 15 minutes, that flame sense and ignflion 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:

Induced-draft motor fault. IGC does not sense that ioduced-draft PIN 1 White

(LED 6 flashes) motor is operating.* PIN 2 -- Red

PIN 3 -- Black.

Roliout switch will automatic.aflyreset, but IGC* will continue to iock-

Roflout switch fault, out unit. Check gas valve operation. Ensure that induced-draft

(LED 7 flashes) Roltout switch has opened, blower wheel is properly secured to motor shaft. Reset unit at unit

disconnect.

Rofiout control fault. Microprocessor has sensed an error in the if error code is not cleared by resetting unit power, replace the IGC*.

(LED 8 flashes) software or hardware.

Temporary software lock out. Electrical interference Reset 24-v. to control board or tom thermostat off,

then on again. Fault will automatically

(LED 9 flashes) impeding IGC software reset itsefl in one (1) hour.

* WARNING i_. : If the IGC must be replaced, be sure to ground yourself to dissipate any electrical charge that may be present before handling new control board. The

IGC is sens"I_ to static electflaity and may he damaged if the necessary precautions are not taken.

IMPORTANT: Refer to Table 17--Troubleshoofing Guide-q-leating for additional troubleshooting analysis.

LEGEND

tP=re----_tegrated Gas Unit Controller

LED -- Light*Emfltiog Diode

START-UP CHECKLIST

(Remove and Store in Job File)

I. PRELIMINARY INFORMATION

MODEL NO: .............................................................................................................................................................

SERIAL NO: ..............................................................................................................................................................

DATE: ........................................................................................................................................................................

TECHNICIAN: ...........................................................................................................................................................

JOB LOCATION: ...........................................................................................................................................................

H. PRE-START-UP (insert checkmark in box as each item is completed)

VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT

__ VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS

CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS

CHECK GAS PIPING FOR LEAKS

-- CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE

VERIFY THAT UNIT INSTALLATION IS LEVEL

__ CHECK FAN WHEEL PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW TIGHTNESS

HI. START-UP

ELECTRICAL

SUPPLY VOLTAGE L!-L2 L2-L3 ____

COMPRESSOR AMPS L1 L2

INDOOR (EVAPORATOR) FAN AMPS

L3-L1

TEMPERATURES

OUTDOOR (CONDENSER) AIR TEMPERATURE: DB

RETURN-AIR TEMPERATURE: DB WB

COOLING SUPPLY AIR: DB WB

GAS HEAT SUPPLY AIR:

PRESSURES

GAS INLET PRESSURE IN. WG

GAS MANIFOLD PRESSURE IN. WG

REFRIGERANT SUCTION . PSIG

REFRIGERANT DISCHARGE PSIG

SUCTION LINE TEMP*

DISCHARGE LINE TEMPt

__ VERIFY REFRIGERANT CHARGE USING CHARGING TABLES

__ VERIFY THAT 3-PHASE SCROLL COMPRESSOR (48GS048 and 48GX030-060) IS ROTATING IN CORRECT

DIRECTION.

*Me_asured at suction inlet to compP..ssor

t Measured at liquid line leaving condenser

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 101 Printed in U.S.A. Catalog No, 48GS,GX+TSI Pg 32 2-06 Replaces: New

CARRIER Package Units(both Units Combined) Manual L0604537

48GS L0604537

Navigation menu

Versions of this User Manual:

Views

Navigation