Carrier 48GP030060300 User Manual CENTRAL PACKAGE Manuals And Guides L0410008

CARRIER Package Units(both units combined) Manual L0410008 CARRIER Package Units(both units combined) Owner's Manual, CARRIER Package Units(both units combined) installation guides

User Manual: Carrier 48GP030060300 48GP030060300 CARRIER CENTRAL PACKAGE - Manuals and Guides View the owners manual for your CARRIER CENTRAL PACKAGE #48GP030060300. Home:Heating & Cooling Parts:Carrier Parts:Carrier CENTRAL PACKAGE Manual

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48GP, 48GPN
Single Package Gas Heating/Electric Cooling Units
With Puron® (R-410A) Refrigerant

HEATING & COOUNG

Visit www.carrier.cmn

Installation, Start-Up, and Operating Instructions
48GP, 48GPN Sizes 024-060
NOTE:
Read
installation.

the

entire

instruction

manual

before

starting

the

Index

Page

SAFETY

CONSIDERATIONS

.....................................................

RULES FOR SAFE INSTALLATION
RECEIVING
AND INSTALLATION

1

AND OPERATION....
..........................................

1-2
2

CHECK EQUIPMENT
..................................................................
PROVIDE
UNIT SUPPORT .........................................................
Roof

2
2

Curb ............................................................................

Slab Mount

2

..........................................................................

Ground Mount
FIELD FABRICATE

2

.....................................................................
DUCTWORK
.............................................

2
2

PROVIDE

CLEARANCES

RIG AND
CONNECT

PLACE UNIT .......................................................
3, 6-7
CONDENSATE
DRAIN ...........................................
7

INSTALL

FLUE

INSTALL

GAS

INSTALL
INSTALL

DUCT CONNECTIONS
.......................................
ELECTRICAL
CONNECTIONS
.........................

HOOD

2-3

...............................................................

PIPING

High-Voltage
Special

........................................................

7

.............................................................

Connections

Procedures

7-8
8, 10
11-13

................................................

for 208-V

Operation

11

..........................

11

Control Voltage Connections
............................................
Standard Connection ..........................................................

12
12

Heat Anticpator
Setting .....................................................
Transformer
Protection ......................................................

13
13

PRE-START-UP
START-UP

..........................................................................
....................................................................

REFRIGERANT

SYSTEM

START-UP
NOTE
THESE

22-26

..........................................................

Before
CAREFULLY

of buildings

31

the installation,
READ
AND COMPLETELY.

Also, make sure the User's Manual and Replacement
left with the unit after installation,
the furnace is NOT
heating

27
28-30

............................................................

TO INSTALLER
INSTRUCTIONS

for temporary
tion.

26

GUIDE ....................................................
..........................................................

CHECKLIST

or structures

Guide are
to be used

under

construc-

SAFETY CONSIDERATIONS
Installation
hazardous
trained

and

and qualified

air-conditioning
Untrained

equipment

and electrical

personnel

should

equipment,
attached

can perform

smwice personnel.
observe
to the unit,

all safety

quenching

cloth

repair,

basic maintenance

When

precautions

Only

codes.

Wear safety

for unbrazing

glasses

tags

and labels

that may apply.

and work gloves.
Have

Use

fire extinguisher

operations.

reserves the right
PC 101

precautions

operations.

of

be performed

on air-conditioning

in the literature,

to discontinue,

Catalog No

534-755

AND OPERATION

FR |','1,_I;1: I l_e
Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, fire, or
an explosion which can result in serious injury or unit
damage. Consult a qualified installer, service agency, or gas
supplier for information or assistance. The qualified installer
or agency must use only factory-authorized kits or accessories
when modifying this product.
Understand the signal words
DANGER, WARNING,
and
CAUTION. DANGER identifies the most serious hazards which
will result in severe serious injury or death. WARNING indicates
a condition that could result in serious injury or death. CAUTION
is used to identify unsafe practices which would result in minor or
moderate injury or product and property damage.
The power supply (volts, phase, and hertz) must correspond to that
specified on unit rating plate.

or smwice

functions

should

working

and other safety

lbr all brazing

Manufacturer

can be

components.

install,

coils and filters. All other operations

by trained

available

of air-conditioning
pressure

equipment.

personnel

cleaning

Follow

servicing

due to system

RULES FOR SAFE INSTALLATION

13-22

MAINTENANCE

48GP

13

..............................................................................

QUICK REFERENCE
TROUBLESHOOTING

C99088

Fig. 1--Unit

The electrical supply provided by the utility must be sufficient to
handle load imposed by this unit.
This installation must conform with local building codes and with
NEC (National Electrical Code) and NFPA 70, NFPA 54 ANSI
Z223.1 latest revision, and NFGC (National Fuel Gas (;ode). Refer
to provincial and local plumbing or waste water codes and other
applicable local codes.
Approved for outdoor installation on wood flooring or on class A,
B or C roof covering materials.

or change at any time, specifications
Printed in US.A.

Form

or designs
48GP-1SI

without notice and without incurring obligations.
Pg 1

3-00

Replaces:

New

Before performing

service

or maintenance

turn off gas supply

then unit main

shock

could

or explosion

cause

operations

power

serious

on unit,

switch.

iniury

Electrical

or death.

2,
MAXIMUM
ALLOWABLE
DIFFERENCE
(in.)

r:l ['_IliilI0]/l
Puron

(R-410A)

standard

systems

R-22 systems.

components

is rated
The

contained,

combination

units

designed

48GP

All

with all downflow
either

on

sizes

local

Fig.

1)

are

Fig. 2--Unit

fully

have

discharge

slab,

codes).

See

cooling

openings

for both

and are factory

covered.

cement

self-

See Fig. 6 and 7 for unit

configurations,

shipped

Units may be installed

or directly
Figs.

on the ground

4 and

5 for

roof

(if
curb

GROL_D

MOUNT

or placed
unit

on level

Step

3--Field

Secure

all ducts

discharge
applications,

less

as

shipped

fi'om

the

California
Air Quality
rule exists.

factory

and

Management

MUST

Districts

be

where

or

installed

l--Check

IDENTIFY

against

unit

papers

is still on shipping
loose

ficom its

inspectors

incurred

Check

all

nearest

Carrier

ROOF

CURB

instructions
roof

curb

flashing.

or damage,

Unit
Install

or is tom

dimensions.

Install

by

transportation

papers

directly

roof

notify

flanges

ductwork,

on

the

horizontal

to the flanges.

joints,

Insulate

and roof openings

in accordance

with

applicable

an unconditioned

If a plenum

return

through

space

must be insulated

barrier.

is used on a vertical

unit, the return

the roof deck to comply with applicable
clearance

static

is not required

shall not exceed

around

should

be

fire codes.

ductwork.

Cabinet

-.25 in. wg.

RETURN iUPl_
'
_11'1
\

_\i

IIIII
IIIII OPENING
IIIII
IIIII
IIIII

'

"
iH

SUPPLY

III
OPENING 111
111
111
111

IIIII
IIIII
IIIII

III
III
III

the
EVAR COIL

in original

Install

with

4 and 5 and Table

1 for

cant strips,

roofing,

and

to curb.

of the unit to the roof curb is critical
gasketing

applied

properly.

material

gasketing

supplied

can also result

with the
in air leaks

MOUNT
flush

1/4 inch. This is necessm T for unit

Refer to accessory

for additional

that is a minimum

COND

information

Place

C99014

&din installation)

level concrete

with 2 in. above

compressor

end

and should
by local

codes.

Step

4_Provide

The required

Clearances

minimum

operating

in Fig. 6 and 7. Adequate

and service

combustion,

clearances

ventilation,

are shown

and condenser

air must be provided,
in accordance
with section 5.3, Air for
Combustion
and Ventilation,
of the National Fuel Gas Code ANSI
(American

National

tions

7.2,

7.3 or 7.4

Standards

B149

Installation

Institute)

or CaniCGA

Codes),

Z223.1

[Canadian

or applicable

(in Canada,
Gas

provisions

sec-

Association]
of local build-

ing code.

grade.

of the
extend

¥!I [_:.llli_0]/1

(see Fig. 2).

unit

pad

The slab
(to allow

Do not restrict

condenser

the outdoor-air

inlet or the fan discharge

compressor

airflow.

An air restriction

at either

can be detrimental

to

life.

2 in. on the three

sides of the unit. See Fig. 3. Do not secure the unit to the
when required

Mounting Details

roof curb installation

as required

the unit on a solid,

of 4 in. thick
on the

COIL

packages

curb in accordance

insulation,

be level to within

drain to function

slab eycept

through

to

unit perfomlanee.

condensate

with

be secnred

and mastic

with a vapor

for any

Immediately

See Figs.

must be attached

seal.

remaining

passing

if any item is missing.

all parts

accessory

for a watertight

be

flashing

on vertical

Support

with curb.

roof curb. Improperly

instructions

all external

Fig. 3_lab

The gasketing

should

while unit

list.
office

leave

IMPORTANT:

SLAB

damage

is not responsible

shipping

shipped

Curb should

is provided
should

structure

dz¢ctworlc to unit. For horizontal

number

to be damaged
claim

Manufacturer

against

Ductwork

and poor

and building

this infomlation

it examined

Forward

Air Conditioning

To prevent loss
until installation.
2--Provide

dis-

in transit.

items

Step

have

removal.

company.

for shipping

If unit appears

anchorage,

and serial

Check

for condensate

data.

Inspect

pallet.

before

transportation
damage

and job

SHIPMENT

number

plate.

Place the

Ductwork
curb

and covered

return-air

The unit model

shipping

counter

A minimum

on unit identification

INSPECT

Ducts

ducted

Equipment

L_'IT

are stamped

gravel

on a slab

pemfit.

in

a Low NOx

RECEIVING AND INSTALLATION
Step

with

to roof

All ductwork

codes.

joule

with

units. Do not connect

o f nitrogen

of 40 nanogrmns

either

if local codes

prepared

Fabricate

and weathelproof

requirement

on the ground

ground

C99065

Leveling Tolerances

The unit may be installed

directly

48GPN units are dedicated Low NOx units designed for California
installations.
These models meet the California
maximum
oxides
emissions

1/4

charge.

openings.

(NOx)

A-C

1/4

or

service

I gas heating/electric

duct openings

a rooftop,

permitted
by
dimensions.

(see

installation.

and downflow

equipment
Ensure

B-C

1/4

than

(R-410A).

Category

unit

pressures

equipment.

units

for outdoor

dimensions.
horizontal

(R-410A)

for Puron

GENERAL

at higher

Do not use R-22 service

on Puron

equipment

operate

A-B

The condenser
it through

pulls

air through

the top cover.

the condenser

coil and discharges

Be sure that the fan discharge

does not

J

44 5,16

SUPPORT B

(2)

END

ViEW

(INSULATED)

A99320

Fig. 4_Roof Curb Dimensions
Top View

SIDE

PAN EL__,
BASE

SUPPORT

...... 0.75

R'B(S)

_/

I_i if'

BOTTOM

(o,Ot pFL%"')NG
............1L[
CANT
(FIELD

STR

P
.......

_

I
4.0"
1

SUPPLY

NA'LER
......

SUPPLIBD_

PAN

JINSULATION

..........

(FIELD

SUPPLIED)

ROOFING
MATERIAL
(FIELD
SUPPLIED)

A99340

Fig. 5--Roof Curb Dimensions
Side View
UNIT SIZE

ODS ORDER

NUMBER

A
IN, [MM]

B
IN, [MM]

C
IN, [MM]

D
IN, [MM]
28 3/4 [730]

CPRFCURB006A00

8 [203]

11 27/32 [301]

30 5/8 [778]

ROOF

CPRFCURB007A00

14 [356]

11 27/32 [301]

30 5/8 [778]

28 3/4 [730]

CURB

CPRFCURB008A00

8 [203]

15 27/32 [402]

42 1/8 [1070]

40 1/4 [1022]

C PRFCURB009A00

14 [356]

15 27/32 [402]

42 1/8 [1070]

40 1/4 [1022]

48GP024-036

48GP042-060

Notes:
1. Roof curb must be set up for unit being installed
2. Seal strip must be applied as required to unit being installed
3. Dimensions in [ ] are in millimeters.
4. Roof curb is made of 16 gage steel.
5. Table Iists only the dimensions per part number that have changed.
6. Attach ductwork to curb (flanges of duct rest on curb)
7. Insulated panels: 1-in. thick fiberglass 1 lb. density
8. Dimensions are in inches

Table 1--Roof
recirculate

to the condenser

coil. Do not locate

comer

or under

an overhead

under

a partial

overhang

48-in.

above the unit top. The maximum

partial

overhang

Do not place
or roof will
carpeting,

obstmction.
(such

as a normal

nmst not exceed

the unit where water,
damage

or flood

tile, or other

installed on wood
materials.

flooring

house

horizontal

a

Step

is

Rigging
reasons

clearance

overhang)
extension

of a

48 inches.
ice, or snow

the unit.

combustible

the unit in either

The minimum

The

the unit on
unit may be

or on Class A, B, or C roof

covering

5--Rig

and

Place

Unit

and handling of this equipment
due to the installation
location

can be hazardous
for many
(roofs, elevated stmctures,

etc.).
Only

fFom an overhang

Do not install
materials.

Curb Dimensions

trained,

should

handle

When

working

literature,

qualified

Training

with

on tags,

and any other

operators

and ground

support

staff

this equipment.

this equipment,

stickers

observe

and labels

safety precautions

for operations

NOT be limited

crane

and install

that might

of the lifting

to the following:

precautions

attached

equipment

in the

to the equipment,

apply.
should include,

but

E_39]

T

SUPPLY
OUCT
OPENING

4020
E1585]

805
[516]

i
y

COND

_1177
I

[463]

153 5
[694]

NON SENT

1
893
[348]

_
249 6
[983]

[21

67]

[983]

EVAP

COIL

TOP VIEW

REAR VIEW
REQ'D CLEARANCES

FOR OPERATION

AND SERVICING

Evaporator coil access side ..................
Power entry side (except for NEC requirements)
Unit top ..........................
Side opposite ducts
.....................
Duct panel
........................

in. (mm)

REQ'D CLEARANCES

36 (914)
36 (914)
48 (1219)
36 (914)
12 (304.8)*

.........

*Minimum distances: If unit is placed Iess than 12 in. (3048
system, then the system performance may be compromised.

mm) from wall

NEC REQ'D CLEARANCES.
Between
Unit and
Unit and
surfaces,

LEGEND
CG - Center of Gravity
COND - Condenser
EVAP - Evaporator
NEC - National Electrical Code
REQ'D - Required
Note: Dimensions are in in (mm)

44]

FIELD ENTRY
SERVICE PORTS

MAT'L

in. (mm)
14 (355.6)
2 (50.8)
14 (355.6)
0.50 (12.7)
36 (914.4)

in (mm)

units, power entry side
..............
ungrounded surfaces, power entry side .........
block or concrete walls and other grounded
control box side
.................

42 (1066.8)
36 (914)
42 (1066.8)

11939
[4TOO]

_7985
[31

TO COMBUSTIBLE

Top of unit .........................
Duct side of unit .......................
Side opposite ducts .....................
Bottom of unit .......................
Flue panel .........................

t

\
[091]

\

250

]
o

S?O_S
162_,_61

42 l
[168]

190 [075] NPT

22 O _)P

4562
[119_]

_OMPRESSOR
& ELECTRICAL

BLOWER

GAS SECTION

347

2

[O50]
GAS ENTRY

FLUE HOOR

ACCESS PANEL

[1285]
1226 3
[_828]

[285]
_8310
[52

NPT
50
[0R0]

62]

LEFT SIDEVIEW

RIGHTSIDE VIEW

FRONT VIEW

C99017
UNIT

ELECTRICAL
CHARACTERISTICS

UNIT

UNIT WEIGHT
lb.

kg.

CENTER OF GRAVITY
IN. [MM]

HEIGHT

IN. [MM]
"k"

48GP024040/060

208/230-1-60

290.0

1315

3702

[940

48GP030040/060

208/230-1-60,
208/230-3-60

313.0

1420

3902

321.0

1456

3502

Y

X

Z

22.0

[5588]

145 [368.3]

16.0

[9911]

22.0

[5588]

153

[387.4]

17.614470]

[8895]

22.0

[5588]

153

[387.4]

16.5

3]

[4064]

208/230-1-60,

48GP036060/090

208/230-3-60,
460-3-60

Fig. 6--48GP024-036
4

Unit Dimensions

[4191]

860
[3 39]

t
4066
[16 01]

I

T

T

4020
[15 832

Y
EVAP

TOP VIEW

[348]

REAR VIEW
REQUIRED CLEARANCE FOR OPERATION AND SERVICING

REQUIRED CLEARANCE TO COMBUSTIBLE MATE
in. [mm]
3600 [914 6]
3600 [914 O]

EVAR COIL ACCESS SIDE ..............................................................
POWER ENTRY SIDE ......................................................................
(EXCEPT FOR NEC REQUIREMENTS)
UNIT TOP .........................................................................................
SIDE OPPOSITE DUCTS ................................................................
DUCT PANEL ...................................................................................

3600 [914.0]
3600 [914.0]
1200 [304 8] *

TOP OF UNIT ...................................................................................
DUCT SIDE OF UNIT .........................................................................
SIDE OPPOSITE DUCTS ................................................................
BOTTOM OF UNIT .............................................................................
ELECTRIC HEAT PANEL .................................................................

in
14.00
2.00
14.00
0.50
36.00

[mm]
[355.6]
[508]
[355.6]
[12.7]
[914.4]

NEC.REQUIREDCLEARANCES.
*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 12.00 [304.8] FROM
WALL SYSTEM, THEN SYSTEM PERFORMANCE
MAYBE COMPROMISE

BETWEEN
UNIT AND
UNiT AND
GROUNDED

SURFACES,

POWER

ENTRY

SIDE .........................

42.00

1193 9
[4700]

1090 6
[42 94]
FIELO

MILLIMETERS
[IN]
UNITS,
POWER
ENTRY
SIDE ....................................
4200
[1066.8]
UNGROUNDED
SURFACES,
POWER
ENTRY
SiDE .3600
[914.0]
BLOCK
OR CONCRETE
WALLS
AND OTHER

t

ENTRY_

SERVICE PORI

mHmmmmmH!
39

I

1.3

,/
I
190 [073]
NPT
x 22 0 [0 87] #P

427
[168]
329 0
[1295]

/
_OMPRE360R
5LOWER GAS SECTION
ELECTRICAL ACCESS PANEL

12263
[48 28]

[285]

1424

[561]

[4422]

FRONT VIEW

LEFT SIDE VIEW

RIGHT SIDE VIEW
C99074

UNIT

ELECTRICAL
CHARACTERISTICS

UNIT

WEIGHT

UNIT

CENTER OF GRAVITY
IN. [MM]

HEIGHT

IN, [MM]
"A"

X

Y

Z

Ib

kg

382

173.3

38.98

[990.2]

23.0

[584

2]

163

[412.8]

16.6

[421

6]

421

191.0

38.98

[990.2]

21.5

[546

1]

166

[422.1]

18.0

[457

2]

468

212.3

[1091.7]

23.5

[596

9]

163 [412.8]

17.6

[447

O]

208/230-1-60

48GP042060/090

208/230-3-60
460-3-60
208/230-1-60

48GP048090/115/130

208/230-3-60
460-3-60
208/230-1-60,

48GP060090/115/130

208/230-3-60,

4298

460-3-60

Fig. 7--48GP042-060

Unit Dimensions

[1066.8]

i. Application

of the lifter to the load and adjustment

if any, that adapts

it to various

2. Instruction

in any special

3. Condition

of the

of the lifts,

5. Attach

sizes or kinds of loads.

operation

safety straps directly

or clevis
brackets.

clip.

Do not

to the field supplied

attach

the safety

lifting kit, such
Follow

as balance,

all applicable

safety

required

for operation

temperature,

codes.

straps

to the lifting

or precaution.
6. Use the top of the unit as a spreader

load itself,

rigging

straps

Wear

of the

straps from damaging

etc.

use a spreader

safety

shoes

bar to prevent

the rigging

the unit. If the wood top is not available,

bar of sufficient

length

to not damage

the unit.

and work

gloves.

o
•
Ir!] L,TV"I:I.1J
R[.

Never

exceed

Accessory

200 lbs. per bracket
lifting

kit

Packaged
units which
molded hand holds.
Never

stand beneath

unit

INSPECTION
rigging
damage,
hooking

points

units

with

base

injury

serious

of gravity

or death.

to initial use, and at monthly
should

should
in these

Small

pan with

or lift over people.

cause

be visually

structural
be paid

and load support

any kind of wear
discarded.

a composite

over the center

of wear,

attention

force.

used

be directly

and straps

evidence

Particular

lifting

to be

DETAIL
A
SCALE
025O

could

Prior

brackets

have
rigged

Lifting point should
for the unit.
A &opped

is only

intervals,

inspected

deformation,
to excessive

areas. Brackets

areas nmst

or
wear

all

lbr any
cracks.
at hoist

or straps showing

not be used

and should

C99066

be

Fig. 8--Lifting

Point

INSTALLATION:
i.

Position
unit.

the lifting

Leave

spreader
2. Place

the top

bracket

assembly

shipping

skid

around
on the

the base of the
unit

to act as a

bar. Be sure the strap does not twist.
each

handholds

of the

four

in the composite

(4) metal

lifting

brackets

into

the
HOOK

pan.

3. Tighten the ratchet strap until tight. Lifting
secure in the handholds.

brackets

should be

4. Attach the clevis or hook of sufficient strength to hole in the
lifting bracket as shown in Fig. 8.

FEED

II_N_,-

C99067

Belt

Threading

i. Open lever

Instructions:
of tension

2. Feed webbing
3. Pull webbing
4. Snap

lever

5. To release,
outward

through
through

buckle
tension
tension

down to lock strap
squeeze

safety

Fig. 9--Belt

buckle
buckle

as shown
until taught

in tension

latch,

lift lever

Threading

buckle
and pull webbing

914-1371
DUCTS
(36'i54")

\
B

t_7_557,)

/

J

SEAL STRIP MUST BE IN
PLACE BEFORE PLACING
UNIT ON ROOF CURB

12263

PLACE

RIGGING

STRAPS

BASEPAN SLOT (BELOW
BEFORE RIGGING

HANDHOLDS)

C99015
UNIT 48GP

MAXIMUM

Size

tb

024

312

030

335

036

WEIGHT

A
mm

in

mm

5585

14.5

3883

22.0
22.0

5585

15.3

3886

5585

15.3

3886

183

23.0

5842

18.3

4140

443

201

21.5

5461

18.3

4140

490

222

23.5

5969

18.3

4143

kg
142

in.
22.0

343

152
156

042

404

048
060

Fig. lO--Suggested

Step 6--Connect
NOTE:

Condensate

When installing

comply

with

The 48GP units dispose

water

installations

(where

through

directly

a field-supplied

the outlet

of the trap

is at least

1 in. lower

condensate

connection

to prevent

the pan from

the trap with
away

If the installation

install

ensure

&ainage.

proper

the trap

is at least

connection

to prevent

with water. Connect
or 3/4 -in. copper
2-in.

trap.

Do

See Fig.

locate

blower

is shipped

compartment.

screwed

Remove

to the coil panel in the

the service

access

panel to

the assembly.

Dedicated

low NOx

48GP

models

MIST

be installed

in Califor-

water.

When

in ground-

Make

sure that

than the drain

pan

overflowing.

See

using

nitrogen

draining

the

a gravel

1 in. lower

than the

the pan from

NOTE:
lations.

undersize

the

tube.

Low NOx

drain

water

pan

the trap

of 3/4 -in. PVC
the

Install

system

i.

the flue hood

gas instal-

is designed

to ensure proper

venting.

The

in this

as follows:

This installation

must

with the National

conform

Canada,

drain

Fire Protection

Association)

cial

plumbing

tube

CANiCGA

and

local

applicable

flue hood

screw holes

TRAP
OUTLET

3. Secure
the right

ANSI

codes

and

Z223.1

(in

B 149.1, and B 149.2) or NFPA
latest

(National

revision.

Refer

to Provin-

water

codes

and

or waste

from shipping

location

Place vent cap assembly
in vent cap with holes

flue hood

other

(inside

the blower

over flue panel.

Orient

in the flue panel.

to flue panel by inserting

a single

screw

on

side and the left side of the hood.

Step 8--Install
C99013

(NFGC),

local codes.

compartment).

1" MtN.

with local building

Fuel Gas Code

end of the

2. Remove

Trap

or

of

condensate

Prime

apply only to natural

flue hood assembly
must be installed
as indicated
section of the unit installation
instructions.

to

downward at a slope of at least one in. for every 10 ft of horizontal
run. Be sure to check the drain robe for leaks. 12

Fig. 11--Condensate

of 40 nanograms.joule

¥:I [q:lw_l[0]/l

away

connection

at the outlet
Pitch

requirement

requirements

apron,

sure that the outlet

overflowing.

pipe (all field-supplied)

emissions

from the _aetory.

The venting
condensate

a 2-in. trap at the condensate
See Fig. 11. Make

(NOx)

less as shipped

NOx rule
oxides of

trap at end of

drainage.

a drain robe using a minimum

not

The flue hood assembly

from the unit.

requires

from the unit,

proper

apron

condensate

to ensure

sure it slopes

panel.

onto the roof in rooftop

or onto a gravel

connection

make

a 3/4 in. NPT

access

Flue Hood

nia Air Quality Management
Districts where a Low
exists. These models
meet the California
maximum

permitted)
Install

water

condensate

Fig. 11. Prime

be sure to

indoor

the compressor

can be drained

level installations.

drain connection

of condensate

Rigging

Step 7--Install

and restrictions.

fitting which exits through
6 and 7 for location.
Condensate

Drain

condensate

local codes

B

Gas Piping

The gas supply pipe enters the unit through the access hole
provided. The gas connection to the unit is made to the 1/2-in. FPT
gas inlet on the manual shutoff or gas valve.

Install

a gas supply

line that runs to the heating

Table 4 and the NFGC
pipe. It is recommended
local utility

for recommendations

gas supply

piping

use pipe smaller
valve.
For natural

concerning

for 0.5 in. wg maximum
than

the

1/2-in.

gas applications,

FPT

is operating.

the gas pressure

For propane

A 1/8-in. NPT plugged
nmst be installed

Refer

to

tapping

immediately

lines.
drop.

Size
Never

on the unit

gas

NOTE:

The

the gas pressure

less than 0.5 psig,
the gas piping
valve

must

for test gage connection
of the gas supply

by closing

opening

Unstable

operation

manifold

assembly

installing

Refer

54 latest

edition

(in Canada,

edition).

In the absence
pertinent

i. Avoid
every

ing improperly

line, observe
to the NFGC

of local

ANSI

must be isolated
main mannal

Use risers

all segments

codes,

Support

hangers,

etc. Use

a minimum

pipe sizes larger
national codes.

than

compound

Grade

system

all piping
i/2

all

to connect

of piping

damage.

NFPA

B149.2

latest

adhere

to the

union.

occur

when

the

to heating

rigid gas piping

when snaking

against

follow

(pipe dope)

physical
every

and
straps,

and

connectUse

to avoid strain

on,

piping.

sparingly

If a flexible conductor is required or allowed by the authority
having jurisdiction, black iron pipe shall be installed at the
gas valve and shall extend a minimum of 2 in. outside the unit
casing.

¥_ kU/'_W
:I: I I:[_
Never use a snatch

or other open flame

leaks. Never purge

gas line into combustion

to follow
serious

of

8. Check

and only to male

pipe connections.

this warning

injury

could

result

when checking

in an explosion

aRer all piping

Use

and water

soap

codes

Use only pipe

petroleum
gases as
Never use Teflon

for gas leaks at the field-installed

gas lines

Step

and.or

connections

solution

(or method

9--Install

Duct

6. Install ground-joint
unit manual shutoff
all

plumbing

union close
and external

gas

main

piping

valve

in

before

with

connection

local

and

of piping

UNITS

Before

performing

system,

FOR DOV_rNFLOW

service

tuna off main
serious

i. Open
work.

injury

return

connecting

connecting
down

disconnects

supply

duct

DIS-

require

that

with

accessory

watertight.

break

front

any service

by breaking
(Fig.

13).

and right

and a hammer.

side

Push louver

14).

to vertical

damage

the basepan
return-air

aluminum

opening

flanges

tape.

duct

Applicable
exposed

duct openings
cover

kit.

to the roof may occur.
insulation

opening

tape to prevent

6. Cover both horizontal
the

cover,

as permanent

of the vertical
aluminum

could

(iackstand applications
only), do so at this
screws that were removed.
Do not leave

5. It is recommended
basepan

on duct panel
and a hammer

is to be attached

screws on rooftop

on the

shock

starting

rear and leR side tabs (Fig.

on the unit basepan
time. Collect ALL

C99020

before

duct cover located

4. If unit ductwork

Trap

operations

to unit. Electrical

tabs with a screwdriver

to break

perimeter

or maintenance

power

tabs with screwdriver

3. To remove

Fig. 12_Sediment

(VERTICAL)

or death.

all electrical

2. Remove

CAP

See Fig. 6 and 7 for

¥_ kU/'_W
=I: IIT[_

cause

NIPPLE

by local

The unit has duct flanges on the supply- and retnrn-air openings on
the side and bottom of the unit. For downshot
applications
the

to heating section between
manual main shutoff valve.

in accordance

and gas codes

shutoff

section.

completed.

Connections

CONFIGURING
CHARGE

manual

6 It. of heating

been
specified

regulations).

5. Install

external,

causing

and factory-installed
have

ductwork
can be connected
to the roof curb.
connection
sizes and locations.

pipe within

Failure

or death

4. Install sediment trap in riser leading to heating section per Fig.
12. This drip leg functions as a trap for dirt and condensate.
an accessible,

for gas

chamber.

6 It. For

recommendations

tape.

national
to unit.

valve

while

to the gas valve.

connection

of, the gas control

runs
section

with appropriate

dope that is resistant to action of liquefied
specified by local and/or national codes.

7. Pressure-test

gas

out of position

1.4 in. in

horizontal

of one hanger
in.,

of joint when snaking

gas supply

from
shutoff

pertaining

Z223.1,

B149.1,

building

traps.

thermal

threads

local codes

CANiCGA

It. to prevent

3. Apply joint

section

the ground-ioint

may

routed

wrench

or distortion

recommendations:

downward
to risers.
and to meter.
2. Protect

the gas

connec-

low spots in long runs of pipe. Grade all pipe
15

from

¥!I [q:.IlriiI°]/1

the gas supply

to gas pipe installations.

following

be disconnected

the external

are forced

tion to the gas valve.
When

must

the unit heating

system

and slightly

a backup

upstream

piping

¥:I [_0l/l

than 13 in. wg at the unit

accessible

supply

valve during the testing of the piping systems when test pressure is
in excess of 0.5 psig (13.8 WC). If the test pressure is equal to or

at unit gas connection

than 13 in. wg while the

applications,

not be less than 7.0 in. wg or greater
connection.

existing
pressure

gas inlet

must not be less than 4.0 in. wg or greater
unit

section.

for gas pipe sizing. Do not use cast-iron
that a black iron pipe is used. check the

around

be secured
local

codes

the

to the
may

fiberglass.

with the duct covers from

Ensure

opening

is air-and

Table 2--Physical
UNit

SIZE 48GP

NOMINAL

024060

030040

030060

036060

036090

042060

042090

(ton)

2

2

2 1/2

2 1/2

3

3

3 1/2

3 1/2

(Ib)

290

290

313

313

321

321

382

382

CAPACITY

OPERATING WEIGHT
COMPRESSORS
Quantity
REFRIGERANT
Quantity

Data -- Unit 48GP -- 024040-042090

024040

ScroH
1

(R-410A)
(Ib)

50

5.0

5.5

55

69

69

9.0

9.0

REFRIGERANT METERING DEVICE
Orifice ID (in,)
AccuRater_
Piston

.057

.057

057

057

085

.085

.070

070

CONDENSER COIL
Rows...Fins/in.
Face Area (sq ft)

1/17
10.9

1/17
10.9

1/17
127

1/17
127

2/17
91

2/17
91

2/17
12.3

2/17
123

2350
22
1/8 (825)

2350
22
1/8 (825)

2350
22
1/8 (825)

2350
22
1/8 (825)

2350
22
1/8 (825)

2350
22
1/8 (825)

2350
22
1/8 (825)

2350
22
1/8 (825)

3/15
37

3/15
3.7

3/15
3.7

3/15
37

3/15
37

3/15
37

3/15
4.7

3/15
4.7

800
10x10
1/4

800
10x10
1/4

800
10×10
1/4

1000
10x10
1/4

1200
10x10
1/2

1200
10x10
1/2

1400
11x10
3/4

1400
11×10
3/4

2..44
2..50

2..38
2..46

2.38
2. 46

3.38
3. 46

2.38
2 .46

3..38
3..48

CONDENSER FAN
Nominal CFM
Diameter (in.)
Motor Hp (RPM)
EVAPORATOR
COIL
Rows...Fins/in.
Face Area (sq ft)
EVAPORATOR
BLOWER
Nominal

Airflow (CFM)
Size (in.)
Motor HP

FURNACE
Burner

SECTION*

Orifice No. (Qty...Drill
Natural Gas
Orifice No. (Qty...Drill
Propane Gas

Burner

Size)
Size)

HIGH-PRESSURE
SWITCH
Cutout
Reset (Auto.)
LOSS-OF-C

2.38
2 .46

(psig)

HARGE/LOW-PRESSU
(Liquid Line) (psig)
Cutout
Reset

2.44
2. 50

810 _+15
420 +_25

RE SWITCH
20 +_5
45 +_10

(Auto.)

RETURN-AiR
FILTERS
,o)T.rowaway
20×24×1
I 28×
24×1
I 28×
24xlI 20×
24xlI 20×24×1
I 20×24×1
I 24×30×1
I 24×
30×1
Table 3--Physical
UNIT SIZE 48GP
NOMINAL

048115

048130

060090

060115

(ton)

4

4

4

5

5

5

(Ib)

421

421

421

468

468

468

CAPACITY

OPERATING

Data -- Unit 48GP -- 048090-060130

048090

WEIGHT

COMPRESSORS
Quantity

Scrotl
1

REFRIGERANT
(R-410A)
Quantity (Ib)
REFRIGERANT
METERING DEVICE
Orifice ID (in,)
Accurater_
Piston
CONDENSER COIL
Rows...Fins/in.
Face Area (sq ft)
CONDENSER
FAN
Nominal Cfm
Diameter (in.)
Motor Hp (RPM)
EVAPORATOR
COIL
Rows...Fins/in.
Face Area (sq ft)
EVAPORATOR

BLOWER

Nominal Airflow (Cfm)
Size (in,)
Motor HP
FURNACE
Burner
Burner

9.5

9.5

95

10.0

10.0

100

.073

073

073

.086

.088

088

2/17
12.3

2/17
123

2/17
123

2/17
16.4

2/17
16.4

2/17
164

3300
22

3300
22

3300
22

3300
22

3300
22

3300
22

1/4 (1100)

1/4 (1100)

1/4 (1100)

1/4 (1100)

1/4 (1100)

1/4 (1100)

4/15
47

4/15
4.7

4/15
4.7

4/15
47

4/15
47

4/15
4.7

1600
11 x 10
3/4

1600
11 x 10
3/4

1600
11 x 10
3/4

1750
11 x 10
1O

1750
11 x 10
10

1750
11 x 10
1.0

3..31
3..41

3..38
3..48

SECTION*

Orifice No. (Qty...Driil
Natural Gas
Orifice No. (Qty...Drill
Propane Gas

HIGH-PRESSURE
SWITCH
Cutout
Reset (Auto.)
LOSS-OF-CHARGE/LOW-PRESSU
(Liquid Line) (psig)
Cutout
Reset (Auto.)
RETURN-AIR

060130

FILTERS

Size)
Size)

3.38
3.46

3.33
3.42

(psig)

3.33
3.42

3.31
3.41

810 _+15
420 +_25

RE SWITCH

(in.)Throwaway

20 _+5
45 +_10
24x

30x1

I
I

24x

30x1

I
I

24x

30xl

I
I

24x

30xl

I
I

24x

30x1

I
I

24x

30x1

Table 4--Maximum

Gas Flow Capacity*
LENGTH

NOMINAL

IRON PIPE SIZE (IN.)

INTERNAL

DIAMETER

(IN,)

OF PIPE, FTt

10

20

30

40

50

60

70

80

90

100

125

150

622

175

120

87

82

73

66

61

57

53

50

44

40

3/4

824

360

250

200

170

151

138

125

118

110

103

93

84

77

72

1

1048

680

465

375

320

285

260

240

220

205

185

175

160

145

135

1 1/4

1 380

1400

950

770

600

580

530

490

460

430

400

360

325

300

280

1 1/2

1610

2100

1460

1180

890

900

810

750

690

650

620

550

500

460

430

1/2

175

200

*Capacity of pipe in cu ft. of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0 5-in. wg (based on a 0.60 specific gravity gas) Refer to Table C-4, National
Fire Protection Association NFPA 54
1-This length includes an ordinary

7. After

completing

and power

number of fittings.

unit conversion,

perform

all safety

checks

up unit.

NOTE:
The design and installation
of the duct system must be in
accordance
with the standards
of the NFPA for installation
of
nonresidence-type
90A

or

air conditioning

residence-type,

residence-type,

NFPA

90B;

90B;

and.or

TO THE FOLLOWING

ADHERE

ING, SIZING,
i. Units

AND

according

transition

prevent

transmission

screwed

or bolted

ensure

weather

NFPA

codes

and

and ordinances.

CRITERIA

WHEN

THE DUCT

supply-air

to American

tion and Air Conditioning
dations.
flexible

local

SELECT-

SYSTEM:

for side shot installation.

and size ductwork,

grilles

systems,

and.or

local codes

INSTALLING

are shipped

2. Select

3. Use

and ventilating

NFPA

registers,

Society

Engineers

between

tight

rigid

flanges.

and airtight

Refrigera-

(ASHRAE)

of vibration.
to duct

and return-air

of Heating,

recommen-

ductwork

and unit

The

transition

Use

suitable

°/

to

may

be

gaskets

to

all

heating

ductwork

size increases
6. Adequately
outdoors.

insulate
Insulate

required

or performance

and weatherproof

ducts passing

barrier

through

in accordance

and Air Conditioning

RETURN
DUCT
OPENING
C99089

for unit being installed.

or decreases

and use vapor
Metal

for maxinmm

or cooling)

I

seal.

Fig. 13--Supply

4. All units must have field-supplied
filters or accessory
filter
rack installed in the return-air
side of the unit. Recommended
sizes for filters are shown in Tables 2 and 3.
5. Size

I

SUPPLY
DUCT
OPENING

airflow
Avoid

(either

abrupt

duct

may be affected.
all ductwork

located

unconditioned

space,

with latest

Contractors

and Return Duct Opening

issue of Sheet

National

Association

(SMACNA)
and Air Conditioning
Contractors
of America
(ACCA) minimum
installation
standards
for heating and air
conditioning

systems.

Secure

all ducts

to building

7. Flash, weatherproof,
and vibration-isolate
building
structure
in accordance
with local
building

structure.

all openings
in
codes and good

practices.

VERTICAL

DUCT

COVERS
C99012

Fig. 14_Vertical

10

Duct Cover Removed

Step lO--Install

Electrical Connections

The field-supplied

¥_ t','l'JI d ='ll_d
The

unit

electrical

cabinet

must

ground

if an electrical

have

to minimize

fault should

an electrical

wire

an

uninten'upted,

the possibility

occur.

connected

This ground

to the unit

control

compartment,

or

ground

when

in accordance

installed

conduit

70 (latest

Canadian

Electrical

[Canadian

Code CSA

as an electrical
could result

grozmd.

in serious

voltage

lug in the

voltage

electrical

Single

NEC

edition)

(National

i.

(in Canada,

Standards

to adhere

to follow

to this warning

or death.

these precantions

could result

ANSI_FPA

70 (latest

edition)

and local

governing
such wiring. In Canada,
tions must be in accordance
with
Canadian
codes.
2. Use

Electrical

Refer
only

Code

to unit wiring
copper

3. Be sure that high-voltage
voltage

range

indicated

4. Do not damage
any panel

Part

to mount

for

electrical

power

switch

and/or

phase

imbalance

HIGH-VOLTAGE

CONNECTIONS

separate

service

disconnect

electrical

switch mounted

to the unit rating plate
minimum
electrical

circuit
data.

with

amps (ampacity)

to the unit.

ground

DO

The

unit

a field-supplied,

for wire sizing.

L2)

and

ground

leads

into

the

lead to chassis

ground

connection.

23 of the compressor

phase

units:

Run the high-voltage
control box.

6. Connect

ground

field

(LI,

L2, L3) and ground

lead to chassis
and yellow
L1

to black

ground

into the

connection.

wires connected
wire

leads

on

to the lines side

connection

I1

of the

contactor.

field wire L2 to yellow

wire on connection

13 of the

contactor.
field wire L3 to Blue wire from compressor.

PROCEDURES

FOR 208-V

OPERATION

through
etc.

Make sure that the gas supply thet_ the power supply to the
unit is switched OFF before making any wiring changes.
Electrical shock or explosion could cause serious i11iury or
death.

5).
must

have

a

water-proof,

sight from the unit. Refer

fuse/circuit

(L1,

lug connection

5. Connect

within 2%.
of improper

to Table

high

the high-

4. Connect L2 to pressure
contactor.

compressor

operating

when drilling

(refer

when making

to complete

11 of the compressor

SPECIAL

conduit,

as follows

lug connection

4. Connect

plate.

hardware,

on the

units:

3. Locate the black
of the contactor.

between

to unit is within

at, or within

for maxilnum

connections
phase

compressor

components

electrical

Proceed

2. Connect

local

and unit.

5. On 3-phase units, ensure phases are balanced
Consult local power company
for con'ection
voltage

codes

applicable

connections

disconnect
WIRE.

on unit rating

internal

with NEC

all electrical
connecCSA standard (722.1

1 and

and Fig. 16 lbr reference

Run the high-voltage
control box.

Three

to

diagram.

conductor

field-supplied
electrical
NOT USE ALUMINUM

in damage

in accordance

box may be mounted

3. Connect L1 to pressure
contactor.

i.

the unit being installed:
1. Make all electrical connections

label

connections.

2. Connect

r:l [ "ffz_iilI*]2
Failure

switch

Associa-

codes. Do t_ot z¢se gas pip6_g

Failure

injury

of

for

with

Code) ANSI/NFPA
and local electrical

ground

See unit wiring

injury

may consist

approved

Electrical

tion] C22.1)

unbroken

of serious

disconnect

unit over the high-voltage
inlet hole when the standard power and
low-voltage
entry points are used. See Fig. 6 and 7 for acceptable
location.

breaker

With disconnect

size and

See Table

(3/16 in.) terminal

5 for

transformer

11

switch

open, move

marked

to primary

yellow

230 to terminal

voltage

wire l}om transformer
marked

of 208 vac.

200. This retaps

Table 5--Electrical
UNIT
SIZE

VOLTAGE
RANGE

V-PH-HZ

48GP
024

Data -- 48GP

OUTDOOR

COMPRESSOR

FAN MOTOR

INDOOR

FAN

MOTOR

POWER

SUPPLY

Min

Max

RLA

LRA

FLA

FLA

MCA

208/230-1-60

187

253

13.5

61.0

08

2.0

19.7

30

208/230-1-60

187

253

14.7

73.0

08

2.1

21.3

35

208/230-3-60

187

253

9.6

63.0

08

2.1

14.9

20

208/230-1-60

187

253

15.4

83.0

08

3.6

23.7

35

208/230-3-60

187

253

12.2

77.0

08

3.6

19.7

30

414

506

5.1

35.0

08

1.9

9.1

15

208/230-1-60

187

253

18.6

105.0

16

4.1

29.0

45

208/230-3-60

187

253

13.5

77.0

16

4.1

22.6

35

414

506

6.3

39.9

09

2.0

10.8

15

208/230-1-60

187

253

20.5

109.0

16

4.1

31.3

50

208/230-3-60

187

253

14.7

91.0

16

4.1

24.1

35

414

506

6.5

46.9

09

2.0

11.0

15

208/230-1-60

187

253

27.6

158.0

16

6.2

42.3

60

208/230-3-60

187

253

18.1

137.0

16

6.2

30.4

45

414

506

9.9

62.9

09

3.2

15.4

20

MOCP*

030

036

460-3-60

042

460-3-60

048

460-3-60

060

460-3-60

EXAMPLE: Supply voltage is 469-3-60.
a B C
AB = 452 v
FLA
LRA
MCA
MOCP
RLA

------

Full Load Amps
Locked RotorAmps
Minimum Circuit Amps
Maximum Overcurrent Protection
Rated Load Amps

LEGEND

C@

AC = 455 v

US

Average Voltage =
BC = 464 v

452

+ 464

+

455

3
1371
3

= 457

NOTES:
1. In compliance with NEC (National Electrical Code) requirements
for multimotor and combination toad equipment (refer to NEC
Articles 430 and 440), the overcurrent protective device for the
unit shall be Power Supply fuse. The CGA (Canadian Gas
Association) units may be fuse or circuit breaker.
2. Minimum wire size is based on 60 C copper wire. If other than
60 C wire is used, or if length exceeds wire length in table,
determine size from NEC.
3. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine
the percentage of voltage imbalance.

Determine maximum deviation from average voltage.
(AB) 457 452 = 5 v
(BC) 464 457 = 7 v
(AC) 457 455 = 2 v
Maximum deviation is 7 v.
Determine percent of voltage imbalance.
7
% Voltage Imbalance = 100 x -457
= 153%
This amount of phase imbalance is satisfactory
maximum allowable 2%.

% Voltage imbalance
= 100 x

max voltage deviation from average voltage
average voltage

as it is below the

IMPORTANT: If the supply voltage phase imbalance
is
more than 2%, contact your local electric utility company
immediately.
C99024

Fig. 15--Electrical

Data Legend

CONTROL VOLTAGE CONNECTIONS
NOTE:
control
Use

P

Do not use any type of power-stealing
problems

no.

thermostat.

may result.

18 American

Wire

Gage

(AWG)

color-coded,

to make the control voltage connections
and the unit. If the thermostat
is located

more

the unit

i00

ft from

voltage wires), use
minimum)
wires.
STANDARD

and 7. Remove

adjacent

Locate

a drip loop before

grommet

leads

running

fl:om the

five 18-gage

wires leaving

leads can be identified

side of control

into the low-voltage
box).

Stripped

-

-

i_

o- - £]_POWER

insulated

(35 C

CONTROL

BOX

hole located

panel.

GRN(G)

LOW-VOLTAGE
POWER
LEADS-

packet
opening.

the inlet

_1 Q

"-RED_'R'Z

(SEE UNiT
WIRING LABEL)

panel.
through

"L

--YELLY
L 1:_

See Fig. 6

installer's

control

SUPPLY

FIELD-SUPPLIED
FUSED DISCONNECT

GND

THERMOSTAT

®
@

SPLICE

I

(TYPICAL)

BOX

C99018

box.
box. These

Fig. 16--High-

low-voltage

and Control-Voltage

Connections

by the colors red, green, yellow,

and white. (See Fig. 16.) Ensure

to be routed

-

- :I

the control

in the knockout

wire through

splice

along

knockout
access

fl:om the thermostat,

and into unit low-voltage

connection
brown,

Remove

to the control

the rubber

the low-voltage

hole,

color-coded,

with unit) and install grommet

Provide
Run

16 AWG

CONNECTION

in the flue panel
(included

no.

(as measured

-

insulated

(35 C minimum)
wires
between
the thermostat
than

HIGH VOLTAGE
|
POWER LEADS

{UNMARKED1

,
(jI_PLICE
(NARKED_
FACTORY WINING
FIELD CONTROL WIRING
--FIELD POWER WIRIMG
---- ACCESSORY OR OMTIONAL
WIRING
TO IN_ IEATE COMMON
y
POTENTIAL ONL:
NOT TO REPRESENT WINING

I

BR
C
CAP

° AUTO

SECTION

DISCONNECT
PER NEC

BRN

To

nB(

COMM
CR
EOUIP

BLOWER RELAY
_0#NT ACTOR
CAPACITOR
_
COMiRESSOR
MOTOR
COMBUSTION RELAY
EQUIPMENT

FL
FU
ORb
GVN
HPS
HS
HV TRAN
I
IGC
IBM
IFM
LPS
LS

FLAME SENSOR
FUSE
GROUND
GAS VALVE RELA
_
,, SWITCH
HIGH _RESSU_E
HALL EFFECT SENSOR
HIGH VOLTAGE TRANSFORMER
IGNITOR
INTERORATED GAS UNIT
CONTROLLER
INDUCED ORAFT _OTON
INDOOR FAN MOTOR
LOW PRESSURE SWITCH
LIMIT
SWITCH

MGV
OFM
OT
RS
TRAN

WAIN GAS VALVE
Oi_TDOOR: FAN MOTOR
QUADRUPLE
TERMINAL
ROLLOUT SWITCH
TRANSFORMER

I
NOTES:
IIF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED,
IT MUST BE REPLACER WITH T_PE 90 NEGREE R WIRE OR
ITS
EODIVALENT
R SEE PRICE PAGES FOR THERMOSTAT ANN SbBNASES
]USE
75 DEGREE COP?ER CONDUCTORS FOR FIELD INSTALLATION
4 ON ALL UNITS FOR G E MOTORS WIRE AS FOLLOWS
FOR NIGH SPEED CONNECT TO NLK AND YEL
FOR MEN SPEED CONNECT TO ORN AND YEL & SPLICE TOGETHER BLK A_D VIO
FOR LOW SPEED CONNECT TO RED ANN YEL & SPLICE TOGETHER NLK AND VIO
SON MODELS @MOPe24 036 HAS LSI AND LS2 WIRED IN SERIES
ON MODELS _NGPO42 Q60 HAS LSI ONLY

J
ON
FIELD

THERMOSTAT

C99078

Fig 22460-3-60

Wiring Diagram

superheat

charging

method

for evaluating

the unit charge.

use mercw 3"or small dial-o_e
thermometers
adequate for this O'pe of measurement.
IMPORTANT:
cated

When

adjustment

very minimal.

evaluating

to the specified

If a substantial

REFRIGERANT
is listed

on

Service
Unit

the unit

panels

charging

nameplate.

be

is indicated,

The amount

Manual,

must

must

Refer

in place

when

be

as insuf-

of rel}igerant

is

ating system,
system

Use standard

evacuating

in the specified

Refi'igeration

COOLING:

Charging

conditions
different

Charts

of the

Measure

operating

wired

during

After

of refrigerant

chart

the units to correct

are met.

reqnired.

gage

Connect

Vary

Note

used.

superheat

pressure

outdoor

(Figs. 23-28).

from type normally

Accurate

and

ambient
charts

on charging

operating

conditions.

sensing

devices

gage to the service

To change

port

motor

are

are based

temperature

red

using
until the

charging

air CFM

must

be within

the normal

ambient

CHARGING

temperature

the chart
NOTF::

INDOOR

what

problem

refrigerant
leak,
this docmnent.

CHARTS:

and read the suction

to determine
If the

the suction

causing

refer to Check

AIRFLOW

cfin

AND

operation,

for each

heating

12,000

operation,

that falls within

Take

pressure

speed

are

on the

the

change

the speed,

motor

speed.

chassis

parts.

For 460-v
l'ollows:

Refer

being

the lead connections

should

black = high speed
---

speed

red = low speed

of the blower

motor

the blower

(BM),

relay

BM for single-phase

remove

Insulate

and replace
the removed

GE Motors

The

readings
Leaks

is a

section

speed

in

ADJUSTMENTS

the recommended
Btuh

of rated

the range

stamped

tables

cooling

must produce

is 350 to 450

airflows

to avoid

leads

separate

For

to the BR. Insulate

rise

parts.

air-flow

plate.

rates.
external

the airflow

Table
static
for the

installed.

20

motor

(BR)

coded

as

the black
quick

= high

speed.

wire.

the jumper

fan motor

with

The

speed

motor

Insulate

speeds

the lead
lead

is

black must

removed

lead et_d to

To select high speed

on 460-v GE

female

connect

= low

remove

and replace

BM. For low and medium

to the jumper

lead male

motor (BM),

relay

with chassis parts.

motors,

_ith

= jumper

red

avoid contact
jumper

contact

are color

blue

be connected

capacity.

at various

to determine

to terminal

is
To

2-SPEED

blower

a temperature

on the unit rating

rise at various

and cooling

to these

airflow

attached

wire

units.

with lead for desired blower

black

lead fi'om the blower
desired

the fan

This

and 3-phase

lead

motor

the speed of the blower

l'or the

remove

(BR).

orange = medium
red = low
To change

as follows:

2-SPEED

violet = jumper

be.

of the

in the field.

leads are color-coded

a-SPEED

to

or

wired for low speed and may need to be

leg lead fi'om

operating

gage.

inaccurate

AIRFLOW

7 shows the temperature
Refer

= low

to the

shock

or death.

by changing

The motor

to terminal

the outdoor

temperature

for Refi'igerant

the airflow

9 shows both heating
pressures.

injury

or high speed

the speed

attached

P':I["%-lliilI'l/l
For cooling

serious

black = high

COOLING

are open,

power

Electrical

black = high speed
blue = medium speed

of the unit.

TO USE

system

for medium

evacu(refer to

refrigerant

that

Charts

for the various

the pressure

Indoor

cause

electrical

speed.

3-SPEED

suction line. Mount the temperature
sensing device on the suction
line and insulate it so that the outdoor ambient does not effect the
reading.

could

blower

All 48GP units are factory

techniques.

amount

grilles

properly.

thet_ disconnect

changing

For 208/230-v

weigh

CHARGE

Cooling

Table

before

data plate).

LOW

range

off gas supply

unit

Airflow can be changed
blower motor.

charge

procedures.

NO CHARGE:

Shut

explosion

section.
unit

and return-air

and adjusted

an indialways

such

to Can'ier

Rel}igerants

Be sure that all supply-

l'ree fi'om obstructions,

an abnomaal

in the cooling system,
coil or both coils.

CHARGE

Techniques

charge,

factory

charge

NOTI=:

Do not

they are not

the refi'igerant

adjustment

condition
exists somewhere
ficient airflow across either

because

quick

connect

(QC)

(QC)

and connect

to avoid

cot_tact

from

the black

_ith

the
lead

at_3" chassis

(O24}

(030} 60 HZ OHARGINGCHART
FOR USE WITH U_ITS USING R4 _0A REFRIGERANT
125

52 I

115

461

1241

18._

1172

170 ZZZZZZZZZZZZZZZZZZZZZ

OUTDOOR
F TEMPC

Z

ZZZZZZZZZZZZZZZZZZZZZ
Ca"
a_ 1/03
o
o

105

411

75

241

65

181

55

Isl

, 1/03

1034

965

® i0_

_

_
_

_
_

965

125

52

i05
115

41
46

85

29

75

24

160
0

zzzzzzzzzzzzzzzzzzzzz

_

150zzzzzzzzzzzzzzzzz_
zzzzzzzzzzzzzzzzz_zz,_
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_

zzzzzzzzzzzzz._£z_-:2

0

ZZZZZZZZZZZZZZZZ_,_

_

z6s

_8

896

8

ZZ

55

13

827

758

2OO

3OO

7I

11

7OO

800
SUCTION LNE TEMPERATURE (OEG F)

"

,"

io

",

_"

7I

11

I
I
4I
10
16
SUCT ON LINE TE_dPERATURE (DEG C}

SUCTION UNE TEMPERATURE (DEG C)

I
21

2I7

C99079

Fig. 23--Cooling

Charging

Cha_,

48GP024

Units

C99080

Fig. 24--Cooling

Charging

Chart, 48GP030

Units

(O36}

:_ 1103
O
_
Z

1034

_

965

_

896

105

41 I

75

24 I

65

181

55

ISl

8
_

_27

758

2OO

3OO

7I

11

7O0

I

I

,o
I

",

800

2"

SUCTION UNE TEMPER_URE

7I

4I

11

(DEC F}

i'o

i_

SUCTION LINE TEMPER_URE

'1

2'

(OEG O)

C99081

Fig. 25 -- Cooling Charging

Chart, 48GP036

C99082

Units

Fig. 26--Cooling

125

52 I

115

461

85

29 I

1241

180ZZZZZZZZZZZZZZZZZZZZ

1172

170 ZZZZZZZZZZZZZZZZZZZZZ

;_ I103

:_ 1103
o

o

1054

75

965

_

896

0
_

_27

_os4

24 I

65

181

55

isl

45

u_

7 I

896

_27
75a

758

690
20o

3o0

70o

7

Units

800

_
_
I_

Z

Z_25
115
I05

52
46
4

o

_

s5

ZZZZZZZZZZZZZZZZZZZZZ
15o

_ _ £

13o

_ _

_

_

_2Ozzzzzzzzzzz_z_ZZ_Z

29
24

Z
Z

ZZZZZZZZZZZZZZZZ]_
ZZZZZZZZZZZZZZZZ_'Z_

Z

_

i/0

_ _

I%00

soo

'

7

_6

OU_y,,OpO
R
F
C

Z

160
6

_
_
w

Chart, 48GP042

{060} 60 HZ CHARGING CHART
FO_ USE W_THUNITS USING R4 0A _SFR GERANT

{048}

_

Charging

'_

40o
500
6oo
suc ION LIN_TEM_ERATUNE (DEC F)

'

4

110

I_

0

;_

80 0

_'_

SUCTION LINE TEMPERATURE (DEG C)

C99083

Fig. 27--Cooling

Charging

Chart, 48GP048

Units

C99084

Fig. 28--Cooling

21

Charging

Chart, 48GP060

Units

Table 9--Wet

Coil Air Delivery* -- Horizontal and Downflow
Unit 48GP024-060 (Deduct 10% for 208 Volts)

Discharge

230 AND 460 VOLT
Unit
48GP

Motor
Speed
Low

024

Medium

0.0

01

02

0.3

External
0.4

Watts

279

282

280

277

276

Cfm

882

801

738

604
367

361

356

351

Cfm

-

936

868

797

719

626

-

Watts

-

-

-

463

452

439

428

-

-

956

878

794

702

-

243

244

242

885

842

786

....

353

339

333

330

326

320

Cfm

1195

1134

1070

997

911

818

-

443

436

426

416

406

397

Cfm

-

1230

1145

1061

977

888

786

Watts

490

463

446

432

418

403

389

378

-

Cfm

1431

1398

1347

1281

1205

1118

1024

921

-

Watts

513

501

488

474

459

443

428

-

Cfm

1491

1426

1351

1267

1175

1077

976

-

Watts

-

645

636

627

616

605

593

583
936

-

1484

1410

1330

1243

1147

1044

Watts

634

618

608

598

583

562

534

502

473

454

457

Cfm

1669

1599

1545

1498

1448

1391

1326

1257

1189

1132

1101

Watts

-

733

704

672

638

604

574

550

536

Cfm

-

1746

1688

1630

1566

1492

1399

1279

1120

Watts

-

-

-

797

773

751

727

696

Cfm

-

-

-

1727

1632

1537

1423

1308

-

Watts

591

578

573

568

559

544

524

500

Cfm

1554

1523

1496

1467

1432

1387

1332

1269

-

Watts

755

737

719

699

678

653

627

602

579

562

556

Cfm

1834

1802

1758

1706

1648

1585

1520

1455

1392

1332

1276

Medium

Watts

-

890

858

828

801

777

756

734

709

Cfm

-

1943

1870

1793

1711

1624

1531

1433

1329

High
Low

060

Medium

Watts

589

576

569

566

559

541

499

Cfm

1946

1891

1836

1779

1718

1651

1577

Watts

750

733

715

695

673

648

623

598

577

Cfm

2189

2097

2021

1952

1883

1809

1727

1635

1530

Watts

879

850

821

795

772

750

728

701

Cfm

2337

2159

2050

1974

1905

1824

1722

1597

High

*Air delivery values are without air filter.
Note: Deduct field-supplied air filter pressure

drop to obtain external static pressure available

COOLING SEQUENCE OF OPERATION
With the room
thermostat S_ STEM switch in the COOL position and the FAN
switch in the AUTO. position, the cooling sequence of operation is
as follows:
When
the

the

room

temperature

rises

cooling

control

setting

completes

the circuit

between

and

G.

These

completed

to a point

of

the

coil

(C) (through

(through

unit

wire

G)

open

contacts

Y)

wire
the

is slightly
the

terminal

through

unit

across

that

thermostat,

thermostat

circuits

contactor

the
and

24-v

normally

complete
denser
The

the

circuit

(outdoor)

through

fan

set of normally

complete

of

motor

of

open

the circuit

contactor

compressor
(OFM).

contacts

motor

Both

circuits

evaporator

waiting

should

Once
not

be

the

compressor

has

started

again

until

started

start
relay

5 minutes

and

close

setting

motor

stops.

The

for the next "call

coil

motors
unit

C and
stop. After

relay

is in a "standby"

for cooling"

coil

BR.

a 30-second

The
delay,

condition,

from the room thermostat.

To ensure continuing high performance, and to minimize the
possibility of premature equipment failure, periodic maintenance
must be performed on this equipment.
This combination
heating cooling unit should be inspected at least once each year by
a qualified service person. To troubleshoot heating or cooling of
units, refer to tables at the back of the book.

and

to coninstantly.

BR close

(indoor)

then

have

drops
of the

control

MAINTENANCE

and

fan motor

(IFM).
NOTE:

contactor

and compressor

the blower

Y

transformer

(COMP)

blower

de-energize

condenser

connect

(C)

motors

of energized

through

until the room temperature
the cooling

relay coil (BR)

blower

secondary

energized

"on"
below

room thermostat.
At this point, the thermostat
"breaks"
the circuit
between thermostat
terminal R to terminals Y and G. These open

thermostat

thermostat

cycle remains

to a point that is slightly

above

R to terminals

for ducting

The cooling

(TRAN).
The

-

-

High

048

-

Watts

Low

Low

10

....

Cfm

Cfm

Medium

-

Watts

High

042

-

Watts

09

-

373

Medium

036

0.8

674

High
Low

0.7

-

-

Cfm

Medium

030

(in. wg)
06

Watts

High
Low

Static Pressure
05

has

stopped,

NOTE TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.

it

elapsed.

22

For

longer

The ability to properly perform maintenance on this equipment reqnires certain expertise, mechanical skills, tools, and
equipment. If you do not possess these, do not attempt to
perform any maintenance on this equipment other than those
procedures recommended in the User's Manual. FAILURE
TO HEED THIS WARNING COULD RESULT IN SERIOUS INJURY AND POSSIBLE DAMAGE TO THIS
EQUIPMENT.

Turn

1. Turn off gas supply,
unit belbre
unit.

performing

any maintenance

caution

when removing

any mechanical

fi'om sharp edges,

equipment,

the blower

Remove

to the

or service

on the

panels

serious

and parts.

injury

overheating

As

and dangerous

either

d. Ensure

on, or in contact

occur, or the gas supply
main

manual

fail to shut ofl;

gas valve

supply.

i.

operation.

air

may

all wires

requirements

each

month.

drain

pan,

cause

proper

indoor

coil,

cooling

season

*'or cleanliness.

3. Inspect

blower

motor

each
For

improper

bimonthly
4. Check
proper

injury or

as t`ollows:

relay (BR). Disconnect

L2 of the contactor.

blower

assembly

fi'om unit.

to

blower

Be careful

not

to tear insulation

l`or this equipment

are as

Clean

when

Clean

or

when

replace

to determine

partition

Remove
and

slide

in blower

electrical

connections

operation

each

inspect

ment.

cleaning

and

Clean

and

cooling

tightened
shaft.

when

f. Reinstall

wheel

3. Restore
controls

season.

housing

and motor
wheel

reassembly

blower

wheel

and

bet`ore disassembly.

wheel to motor shaft,
mount brackets to housmount

out of housing.

as follows:

by marking
When

with vacuum

Remove

e. Reassemble

frequency.

for tightness

heating

each

and check

blower

by marking

to blower

wheel

handling

orientation.

and.or

balance

cleaning

weights

(clips)

c. Remove
caked-on
dirt from wheel and housing
with a
brush. Remove lint and/or dirt accumulations
from wheel

necessary.

season.

season,

proper

drain

lbr cleanliness

and cooling

heating

reassembly

blower wheel, be sure not to disturb
on blower wheel vanes.

prior to disconnec-

and condensate

and wheel

heating
first

terminal

from housing.

d. Reassemble

2. Inspect

lubrication

lead fi'om blower

and clean blower

b. Lift wheel

necessary.

necessary.

and wheel.

panel.

ing, and slide motor

wires

Label

filter(s)

assembly

setscrew(s)
that secures
screws that secure motor

and housing

Inspect

when

proper

a. Ensure

reconnecting

maintenance

out.

motor

could cause serious

blower

in relation

e. Loosen
remove

to the unit,

servicing.

The mininmm
l`ollows:

and

and tag electrical

the blower

blower

remove

securing

assembly

can result

V:I[_'12

tion when

motor

lead from

screws

2. Remove

when

efficiency,
wheel

and wheel:

unit access

yellow

motor

then shut off the electrical

made

continuing
the blower

compartment.
combustible

shut off the external

Errors

motor

and disassemble

a. Remove

etc.

3. Never place anything
with, the unit.
4. Should

power

and
fi'om

then disconnect
cleaning

to this warning

c. On all units,

2. Use extreme
with

injury

to adhere

b. Disconnect

then turn off electrical

economy,
and grease

off the gas supply,

Failure
death.

i.
in serious

dirt

power to the unit before

¥_ i','l:_l fl: IR[_
could result

operating

r!] |','I:_ il:l IT[=a

To clean

Failure to follow these warnings
or death:

life,

clean accumulated
motor annually.

grease

cleaner,

wheel

into housing.

motor

into housing.

on motor

shaft

unit access

panel.

electrical

power,

Be

attach-

sure setscrew(s)

flats and not

on round

are

part

of

then gas supply to unit. Start unit and

check l'or proper blower rotation
heating and cooling cycles.

for

using soft brush

and oil with mild solvent.

and motor

speeds

during

Smwice

necessary.

5. Cheek

and inspect

Clean and adjust
6. Check

heating
when

flue hood

section

bel`ore each heating

_- ....

season.

necessary.

and remove

any obstructions

if necessary.

AIR FILTER
IMPORTANT:
in the return-air

Never

operate

the unit without

a suitable

air filter

duct

system.

Always

the filter

with

replace

stone dimensional
size and type as originally
2 and 3 l`or recommended
filter sizes.
Inspect

air

filter(s)

at

least

once

each

(throwaway-type)
or clean (cleanable-type)
each heating and cooling season or whenever
clogged

installed.

month

the

See Tables

and

replace

at least twice during
the filter(s) becomes

o

I

with dust and lint.

EVAPORATOR

BLOWER

NOTE: All motors
these motors.

I

l
C99090

Fig. 29--Unit

AND MOTOR

are pre-lubrieated.

Do not attempt

to lubricate

FLUE

GAS

box and upper

23

PASSAGEWAYS

Access

Panel

To inspect

areas of the heat exchanger:

the flue

collector

INDUCED

DRAFT

MOTOR

2. Remove

MOUNT

the 7 screws

ing plate

to blower

3. Slide the motor

that attach

housing

induced-draft

motor

and blower

wheel

assembly

out of the blower

housing

(See Fig. 31). Clean

the blower

wheeh

cleaning

is required,

with Steps

4 and 5.

4. To remove

blower,

5. To remove

motor

mount-

(See Fig. 30).

continue
remove

2 setscrews

If additional

(See Fig. 31).

n

o_

and cooling

that hold blower
6. To reinstall,

housing

reverse

fan assembly,

to mounting

the procedure

remove

4 screws

plate.

outlined

above.

_D

LIMIT

SWITCH

located

on the blower

BURNER

/

/

--at7

A

IN SHIPPING
LOCATION

COLLECTOR
BOX

7

/

VENTHOO(
FLUE/

ignition

BURNER
RACK

If

MOUNTING
SCREW

i. Remove
according
below.
2. Remove

(Fig.

blower

to directions

the 3 screws

collector
3. Remove

Housing and Flue Collector Box

the combustion

box cover

wheel

and motor

in Combustion-Air

holding

the blower

Unit

lockout

occurs,

panel.

is equipped

system.

unit

MAIN

BURNERS

assembly

inspect

for deterioration

section

causes.

Observe

Blower

housing

lockout

access

Ignition

Limit

switch

with

module

is

a direct

spark

is located

in the

a self-diagnostic
LED.
for LED interpretations.

may

be

reset

inten'upting
power supply to unit,
OFF position at the thermostat.

C99022

Fig. 30--Blower

IGNITION
100%

unit

partition.

control
box. Module
contains
servicing,
refer to label diagram

ROLLOUT
SWITCH

BLOWER
HOUSING

Remove

At the beginning

either

momentarily

selector

of each

or blockage

the main burner

by

or turning

During

switch

heating

due to corrosion

flames

and adjust

to

season,
or other

if necessary.

to the flue

(see Fig. 30).

the 12 screws

30) to the heat

holding
exchanger

the flue collector
assembly.

Inspect

box cover

REMOVAL

the heat

OF GAS TRAIN

exchangers.
4. Clean

all surfaces

as required,

using

the wire brush.
@

BLOWER
HOUSING

®

2 SETSCREWS
{HIDDEN)
/

C99086
i

Fig. 32--Burner

C99085

Fig. 31--Removal

of Motor and Blower Wheel

i. Shut off manual
2. Shut off power

COMBUSTION-AIR BLOWER
Clean periodically to assure
proper airflow and heating efficiency. Inspect blower wheel every
fi_ll and periodically during heating season. For the first heating
season, inspect blower wheel bimonthly to determine proper
cleaning frequency.

3. Remove

unit

4. Disconnect

To inspect blower wheel, remove draft hood assembly. Shine a
flashlight into opening to inspect wheeh If cleaning is required,
remove motor and wheel as follows:
i. Remove unit access panel (See Fig. 29).

to unit.
access

panel

gas piping
wires

6. Remove

ignitor

7. Remove

the mounting

(See Fig. 29).

at unit

connected

gas valve.

to gas valve.

and sensor

wires

screw

Mark

each wire.

at the ignitor

that attaches

module.

the burner

rack to

(See Fig. 30).

8. Slide the burner

24

gas valve.

5. Remove

the basepan

Rack Removed

rack out of the unit (See Figs.

30 and 32).

9. Toreinstall,
reverse
theprocedure
outlined
above.

NOTE:

CONDENSER
COIL,EVAPORATOR
COIL,ANDCONDENSATE
DRAIN
PAN Inspect
thecondenser
coil,evaporator
coil,
andcondensate
drainpanatleastonce
each
year.
Thecoilsareeasily
cleaned
whendry;therefore,
inspect
andclean
thecoilseither
before
oraftereach
cooling
season.
Remove
all
obstructions,
including
weeds
andshrubs,
thatinterfere
withthe
airflow
through
thecondenser
coil.
Straighten
bentfinswithafin comb.
If coated
withdirtorlint,
cleanthecoilswitha vacuum
cleaner,
usingthesoftbrush
attachment.
Becareful
nottobendthefins.If coated
withoilor
grease,
cleanthecoilswithamilddetergent-and-water
solution.
Rinse
coilswithclear
water,
usingagarden
hose.
Becarefid
notto
splash
water
onmotors,
insulation,
wiring,
orairfilter(s).
Forbest
results,
spray
condenser
coilfinsfrominside
tooutside
theunit.
Onunitswithanouterandinnercondenser
coil,besure
toclean
between
thecoils.Besure
toflushalldirtanddebris
fromtheunit
base.
Inspect
thedrainpanandcondensate
drainlinewheninspecting
thecoils.
Clean
thedrain
panandcondensate
drain
byremoving
all
foreign
matter
fromthepan.Flushthepananddraintubewith
clear
water.
Donotsplash
water
ontheinsulation,
motor,
wiring,
or airfilter(s).If thedraintubeis restricted,
clearit witha
"plumbers
snake"or similarprobedevice.
Ensure
thatthe
auxiliary
drainportabove
thedraintubeisalsoclear.

Refer to the heating

in this publication
operation.
REFRIGERANT
nections

FAN

leak-test

Keep

the condenser

unit.

cooling
Damage

i. Remove
cover.
2. Turn

fan free

operation.

halide

torch,

detected,

place

articles

to ensure

holding

to Checking

section

grille

and motor

does

assembly

upside

3. Inspect

the tan blades

4. If tan needs

to be removed,

tim off the motor
5. When

replacing

in. away

for cracks

down

on

top

cover

to

return-air

is clean.

Airflow
airflow.

Adjustments

METERING

from

the setscrew

and slide the

fan blade,

position

that setscrew

when

line.
SWITCHES

vices

into

wired

7. Replace

CONTROLS

the electrical
gas supply,
Remove

controls

AND WIRING

and wiring

annually.

and then the electrical

access
Check

panel

to locate

all electrical

screw connections.
noticed, disassemble
wire

the flat area on the motor

shaft

grille.

ELECTRICAL

wiring.

engages

po_er
all

end and reassemble

and check

circuit.

the

electrical

against

leads
switch.

inspecting

access

panel.

heating

cycle

operation.
cycles,
electrical

the

electrical

Start the unit,

troubleshooting

unless

exists.

If switch

charge

so that

without

breaking

in the

are
the

To check
i.

and securely.

controls

and one complete

If discrepancies

or if a suspected
component

with

Refer to the unit wiring

and

cooling

wiring,

at least
cycle

replace

gages

line and
events

If system

as

etc. It

pressure

is

to unit.

are

You should

attached
certain

Never

for

all system

open

system

with dry nitrogen.
The

line

high-pressure

and protects

It opens

against

switch

is lo-

excessive

con-

at 610 psig.

may be caused by a dirty condenser

or condenser

this device

that a problem

and recover

0 psi.

have con-

to refrigeration

to remove

remove
read

SWITCH

discharge

coil, flfiled tim

air recirculation.

switch:

Turn off gas and then all power
leads

to unit.

on switch.

3. Apply
tinuity

proper

ohmmeter

leads

on a good

switch.

COPELAND

SCROLL

has occun'ed,

ANT

compressor

electrical

by such

coil, dirty filters,

switch.

switches

vacuum

malfunction
the proper

across

must be removed,

in either or both operating

label when making

(AIR CONDI-

on the liquid

you are reasonably

are observed

check

(R-

the

one complete

to ensure

for the Puron

caused

indoor

specifically

R-22 pressure

SWITCH

it is not advisable

pressure

coil pressure.

or burned
connections
clean all the parts, restrip

and obsel_'e

these

pressure,

motor,

are

off

in the

on switch.

on a good

2. Disconnect
After

leads

ohmmeter

High pressure

and

are present

systems.

is located

across

de-

shut

switch:

Because

all

properly

low airflow

under

Tighten

They

switches

pressures

and

system

are protective

as replacements

low suction

the

This meter-

voltage).

(R-410A)

This switch

and that the

in the brass hex-body

on a pressure drop at about 20 psig.
this, switch should be closed.

denser
controls

for tightness.

the connection

pressure

is
and

Airflow

to check

switches

(low

Turn off gas and then all power

cated

20

air-

supply-

obstructions,

high or low pressures

These

ONLY)

all

PISTON

Pressure

with Puron

cooling

refer to Indoor

on page

circuit

if abnormally

HIGH-PRESSURE

to the unit.

connections

If any smokey
the connection,

Inspect

Be sure to turn qff'Ne

is

Charge

performance

that

and is contained

control

to operate

and/or

be sure

OF CHARGE/LOW-PRESSURE

system

tightening.

is

performance

improper

ACCURATOR_:

PRESSURE

NOTI=:

shaft will be

visible).
6. Ensure

section

in the liquid

tinuity

blade so that the hub is 1/8

end (1/8 in. of motor

leak

on page 13.

Refrigerant

heating

unless

necessary,

is a fixed orifice

3. Apply

the motor

The
exists,

When

DEVICE

ing device

2. Disconnect

shaft.

section

and low cooling

g141les are open and free flvm

air filter

i.

If a refi'igerant
Leaks

and Adjusting

checking

If a problem

To check

or bends.

loosen

are found

require

loss of charge,

the fan blade.

leak-detector,

AIRFLOW

not

suspected.

opens
above

motor/grille

is suspected,

an electronic

on page 20.

EVAPORATOR

TIONER

to top

con-

Detect-

using
solution.

leaks

refer

tubing

annually.

leak.

for Refrigerant

suspected,

protects

condenser

all refrigerant

control

performance

liquid-soap

If no refrigerant

LOSS

on top of the

to unit may result.

6 screws

expose

or

refer to Check

of operation

proper

cooling

tubing

switches
must not be used
410A) air conditioner.

from all obstructions

Never

sequence

determining

a refi'igerant

or if low

all refi'igerant

refrigeration

Y:I[ "_a!liilI'12

in

Inspect

indicates

If oil is detected

flow

cooling

aid

CIRCUIT

ing oil generally

designed

proper

andor

an

and the unit base for oil accumulations

compressor

CONDENSER

as

each

instrumentation.

designed

these checkouts.

cannot

25

The
to

operate

be interchanged.

across

switch.

COMPRESSOR
used
with

in this

Puron

You should

(PURON
product

(R-410A)

have con-

REFRIGERis specifically

refrigerant

and

Thecompressor
isanelectrical
(aswellasmechanical)
device.
Exercise
extreme
caution
when
working
nearcompressors.
Power
should
beshutoff,if possible,
formosttroubleshooting
techniqnes.
Refrigerants
present
additional
safety
hazards.

SERVICING

Exposure,
ment

r'!_ |','1-'I ;I: IIR_
Wear

safety

glasses

and gloves

Failure to follow this warning
or death.

when

SYSTEMS

even if immediately

(leading

performing
handling

can cause

dures

injury,

take

the interaction
compressor
more

tolerant

of stresses

starts.

device

and an

designed
port

has

differential

by debris,

is equipped

pressure

the system

scroll.

or discharge

relief

The

valves,

liquid
The

backwards

pressure

scroll

slugging,

the

The

to protect

against

extreme

high

pressure,

the

range

between

550

and

psi

Copeland

is the only oil allowed

scroll

compressor

uses

Mobil

3MA

625

uses

operating

No other
hoses,
Puron.

pressures

system

If you are unsure

Failure

to use

replacement

Puron

consult

nmst

refrigerant

POE

which

oil.

through

LIQUID

has

be

designed

servicing

may result

Gage

system

to handle

manufi_cmrer.
equipment

in property

or

damage

contaminants

or

cylinders

hygroscopic,

clip tube,

and CFC
exposure

refrigerants.

it absorbs
water

Take

valve.

oil to
Proce-

limited

to,

replacing
switch,

me-

PROCEDURE:

shop

towel

inside

by tools
unit

innnediately

and prevent

openings

or components.

lubricant

under
run-offs

in the base pan.

required

service.

water
as other

all necessary

readily.

POE

oils designed
precautions

oils

FILTER

of any oil contaminated

DRIER
with

material

per

The filter drier is specifically

Puron.

Use

only

When removing

fiaetory-authorized

whenever

the refrigerant

a filter drier, use a tubing

cutter

to cut the &ier fi'om the system. Do not unsweat
a filter drier
from the system. Heat fi'om unsweating
will release moisture
and

COMPRESSOR
OIL
The compressor
in this system uses a
polyolester
(POE) oil, Mobil 3MA POE. This oil is extremely
as nmch

pressure

to be serviced

is opened.

PURON

15 times

not
leaks,

drier,

Filter drier nmst be replaced

fi'om &ier into

(R-410A)

information

absorb

cloth

to operate

components.

set,

injury.

meaning

are

or reversing

PRECAUTIONARY

the louvered

LINE

designed

and other refrigerants.

in this system.

the equipment

compatible

components

but

roofing.

refi'igerant

such as filter

5. Remove
and dispose
local codes.

than R-22

may be used

recovery

include,

repairing

When

for oil recharge.

Puron(P_ (R-410A)

refi'igerant

and

terry

4. Perform

system

leakage

embrittle-

of compressor

to protect

drop cloth fi'om tears caused

3. Place

r:l ["_lliiI'l/l
higher

ROOF

protect

REFRIGERANT

This

precautions

coil, accumulator,

component(s)

This

oil

components

device,

up, may cause

in one year or more.

2. Cover area in front of the unit service panel with a terry cloth
shop towel to absorb lubricant spills and prevent run-offs, and

is a safety

pressure.

The

MA-

i. Cover extended roof working area with an impermeable
polyethylene (plastic) drip cloth or tarp. Cover an approximate
i0 x 10 ft. area.

anti-rotational
port

risk

cleaned

that may risk exposure

replacement,

SYNTHETIC

and

and replaces

relief

SYNTHETIC

and it is

protector.
an operating

tering

by

with an anti-rotational

port.

the scroll from mining

for a cycle

device,

caused

internal

throughout

and an orbiting
suction

The compressor

device prevents

relief

refrigerant

of a stationary
has no dynamic

flooded

need

pumps

WITH

to occur

appropriate

which

compressor
refrigerant

The scroll compressor

to cracking)

any service

the roof,

refrigerants.

a fire, serious

ON ROOFS

TERIALS
POE (polyolester)
compressor
lubricants are known
to cause long term damage to some synthetic roofing materials.

from

can

for HCFC

plate
contain

cylinder
charge

REFRIGERANT
and charging

to avoid

26

CHARGING

chart.

Some

a dip tube to allow

in upright
Puron

a commercial
metering
into suction-line.

of the oil to the atmosphere.

system.

position.

liquid

with cylinder

device

in manitbld

refrigerant

refrigerant

For cylinders

units

Refer to unit

R-410A

equipped

to flow
with a

in upright position

and

hose. Charge refiigerant

AIR CONDITIONER
Puron refrigerant
to operate

operates

at 50%-70%

higher

Puron

•

Puron refrigerant
cylinders manufactured
position. Cylinders
manufactured
March
to flow.

refrigerant

Recovery
Puron

(R-410A)--QUICK

REFERENCE

Be sure that servicing

equipment

GUIDE

and replacement

components

are designed

are rose colored.

service

should

sets should

Use hoses

pressure

be charged

should

be designed

as with other HFCs,

Vacuum

pumps

Do not install

specified

Wrap

filter

Do not use an R-22
Never

open system

When

system

Always

replace

Obsmwe

to atmosphere

filter

Puron

type metering

with 520 psig

low-side

device

in the manifold

retard.

HFC refrigerant.
with POE oils.

from oil.
with rated

working

pressures

no less than 600 psig.

Do not expose
plastics

valves

oil to atmosphere.

and roofing

materials.

with wet cloth when brazing.
on every unit.

TXV.
while

it is under

for service,

drier after opening

break
system

a vacuum.

vacuum

with dry nitrogen

for service.

into the atmosphere.

all warnings,

Do not leave

or DOT BW400.

rating.

drier is required

must be opened

Do not vent Puron

4BA400

Use a commercial

and 200 psig low-side

filter &iers

to certain

and service

liquid-line

refrigerant.

to detect

moisture

rapidly.

damage

all filter driers

A Puron

must be 400 psig, DOT

filter drier in liquid-line.

moisture

POE oils may cause

pressure

liquid-line

a suction-line

POE oils absorb

rating

with liquid

is only compatible

will not remove

use factory

prior to March 1, 1999, have a clip tube that allows liquid to flow out of cylinder in upright
1, 1999 and later DO NOT have a dip tube and MUST be positioned
upside down to allow liquid

be 750 psig high-side

with 750 psig selwice

detectors

Puron,

cylinders

cylinder

systems

Manilbld

Only

PURON®
than R-22.

with Puron.

•

Leak

WITH
pressures

cautions,
suction

and bold text.

line driers

in place

for more than 72 hours.

27

and replace

filter

driers.

hose.

Table lO--Troubleshooting
SYMPTOM

-- Cooling

CAUSE

REMEDY

Power failure

Call power company.

Fuse blown or circuit breaker tripped

Replace fuse or reset circuit breaker.

Defective thermostat, contactor, transformer, control relay, high pressure, or loss of charge switch
Compressor

and condenser

fan will not start.

Insufficient

line vottage

Incorrect or faulty wiring
Thermostat

Compressor

will not start but condenser
runs.

fan

Compressor
Defective

Lower thermostat

in compressor

motor burned out, seized, or internal
overload open

run/start capacitor, ovedoad,

start relay

One leg of 3-phase power dead
Three-phase scroll compressor makes excessive noise, and there may be a low pressure
differential.

Scrotl compressor

Refrigerant

is rotating in the wrong direction

overcharge

or undercharge

Defective compressor
Insufficient
Compressor

cycles (other than normally satisfying thermostat).

line voltage

Blocked condenser
Defective run/start capacitor, overload or start
relay
Defective thermostat
Faulty condenser-fan
Restriction

system

Dirty air filter
Unit undersized for toad

Compressor

set too Iow

Low refrigerant

operates continuously.

charge

Leaking valves in compressor

coit dirty or restricted
Dirty air filter

Dirty condenser
Excessive

head

Refrigerant

pressure.

coil

overcharged

air restricted
Low refrigerant

Head pressure too low.

Compressor
Restriction

or air short-cycling
charge

valves leaking
in liquid tube

suction

pressure.

Compressor
Refrigerant

valves leaking
overcharged

Dirty air filter
Low refrigerant

too low.

Insufficient

charge

evaporator

airflow

Temperature too tow in conditioned area
Outdoor ambient below 40 F
Field-installed

Determine

filter-drier

28

cause and replace.

Replace fuse or reset circuit breaker. Determine
cause.
Correct the direction of rotation by reversing the
3-phase power Ieads to the unit. Shut down unit
to allow pressures to equalize
Recover refrigerant, evacuate system, and recharge to capacities shown on nameplate
Replace and determine cause.
Determine cause and correct
Determine

cause and correct

Determine

cause and replace.

Replace thermostat
Replace.
Locate restriction and remove

Decrease

Replace fitter.
load or increase

unit size

Reset thermostat.
Locate leak, repair, and recharge
Replace compressor
evacuate
charge.

system,

and re-

Ctean coit or remove restriction
Replace fitter.
Clean coil
Recover excess

Determine

refrigerant.

evacuate system,
charge.
cause and correct

and re-

Check for leaks, repair and recharge
Replace compressor
Remove restriction

RepIace compressor
Recover excess

refrigerant.

Replace filter.

Metering device or low side restricted
Suction pressure

cause. Replace compressor

Check for source and eliminate

High heat load
Excessive

Determine

Recover refrigerant,

Air in system
Condenser

Check wiring and repair or repIace.

Recover refrigerant,

Air in system
Condenser

setting below room temperature

motor or capacitor

in refrigerant

Thermostat

cause and correct

Check wiring diagram and rewire correctly.

setting too high

Faulty wiring or loose connections
circuit

Replace component
Determine

restricted

Check for leaks, repair and recharge
Remove source of restriction.
Increase air quantity. Check filter -necessary.
Reset thermostat.
Install low-ambient
Replace

kit.

replace

if

Table 11--Troubleshooting
SYMPTOM

-- Heating

CAUSE

REMEDY

Water in gas line

Drain

No power to furnace
Miswired or loose connections
Burned-out

heat anticipator

Broken thermostat
Burners will not ignite.
Misaligned

spark electrodes

No gas at main burners

Dirty air flIter

Inadequate

heating

Restricted

for application
airflow

Limit switch cycles main burners

characteristics

check

Replace wire if necessary.

Check flame ignition and sense electrode
tioning. Adjust as necessary

posi-

1. Check gas line for air. Purge as necessary
NOTE: After purging gas line of air, wait at least
5 minutes for any gas to dissipate before attempting to light unit
2. Check gas valve

check gas pressure at manifold Match with that
on unit nameplate
Replace with proper unit or add additional
Clean or replace filter

Blower speed too Iow

Poor flame,

Replace thermostat.
Rue continuity

Clean or replace fitter as necessary

Gas input to furnace too tow
Unit undersized

Check alt wiring and wirenut connections

in thermostat
wire

Install drip leg

Check power suppty fuses, wiring, or circuit
breaker.

Incomplete combustion results in: Aldehyde
odors, carbon monoxide, sooting flame, floating
flame

29

unit

Remove any restriction.

Use faster speed tap if avaiIabie,
nate motor

or install alter-

Check rotation of blower, thermostat heat anticipator settings, and temperature rise of unit. Adjust as necessary.
1 Tighten all screws around burner compartments.
2 Cracked heat exchanger. Replace
3 Unit overfired Reduce input (change orifices
or adjust gas line or manifold pressure)
4 Check burner alignment

Table 12--LED

Troubleshooting-Error

SYMPTOM

Hardware failure.
(LED OFF)

REMEDY

Loss of power to control modute (tGC)

High limit switch opens during heat exchanger
warm-up period before fan-on deIay expires
Fan ON/OFF

delay modified.

(LED/FLASH)

Limit switch opens within three minutes after
blower-off delay timing in Heating mode

Limit switch fault. (LED 2 flashes)

High temperature

Flame sense fault. (LED 3 flashes)
4 consecutive

ignition

limit switch
flashes)

lockout,

Induce-draft

motor

Rollout switch

Internal
Internal

faults.

limit switch is open

The IGC sensed flame that should not be present

Inadequate airflow to unit

(LED 5 flashes)

Unit unsuccessfully

attempted
utes

fault. (LED 9 flashes)

any

be replaced,

electrical

that may

for additional
LEGEND

Refer to Heating
troubleshooting

IGC

Integrated

LED

Light-Emitting

Ensure unit's external static pressure is within
application guidelines.
Check operation of indoor (evaporator) fan motor.
Ensure that the supply-air temperature rise is in
accordance with the range on the unit nameplate.
Reset unit

if probtem persists,
board.

replace control

Check ignitor and flame sensor electrode spacing, gaps, etc Ensure that flame sensor and ignition wires are properly terminated. Verify that unit
is obtaining proper amount of gas
Check for proper voltage If motor is operating,
check the speed sensor plug/IGC Terminal J2
connection Proper connection:
PiN I - White,
PIN 2 - Red,
PIN 3 - Btack
Rollout switch witl automatically reset, but IGC
wilt continue to lockout unit. check gas valve operation, ensure that induced-draft btower wheel is
propedy secured to motor shaft Reset unit at
unit disconnect

if error code is not cteared by resetting unit
power, reptace the IGC.

yourself

be present

Troubleshooting

rise

Microprocessor has sensed an error in it's redundant software comparison

to

before

handling
new control board, the IGC is sensitive to static
electricity
and may be damaged
if the necessary
precautions
are not taken.
IMPORTANT:

Ensure unit is fired on rate and temperature
is correct.

if error code is not cleared by resetting unit
power, replace the IGC.

be sure to ground

charge

on IGC, power to unit, 24-v
transformer. Units without a
have an internal overload in
ft the overload trips, allow
for automatic reset.

has sensed an error in the software or hardware

Microprocessor

r.,_[_,];3
dissipate

motor is

RolIout switch has opened

control fault. (LED 8 flashes)

If the IGC must

ignition for 15 min-

IGC does not sense that induced-draft
operating

fault. (LED 6 flashes)

Check 5 amp fuse
circuit breaker, and
24-v circuit breaker
the 24-v transformer
20 minutes

Check operation of indoor (evaporator) fan motor
and that supply-air temperature rise agrees with
range on unit nameplate information.

(LED 4

fault. (LED 7 flashes)

software

Code

CAUSE

(:hart

analysis.

Gas Unit Controller
Diode

30

START-UP CHECKLIST
(Remove and Store in Job File)
I. PRELIMINARY
MODEL

INFORMATION

SERIAL NO.:

NO.:

TECHNICIAN:

DATE:

II. PRE-START-[

P (Insert

checkmark

in box as each item is completed)

( ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
( ) VERIFY THAT CONDENSATE
( ) CHECK ALL ELECTRICAL

CONNECTION

CONNECTIONS

IS INSTALLED

PER INSTALLATION

AND TERMINALS

FOR TIGHTNESS

INSTRUCTIONS

( ) CHECK GAS PIPING FOR LEAKS
( ) CHECK THAT INDOOR (EVAPORATOR)
( ) VERIFY THAT LE';IT INSTALLATION

AIR FILTER IS CLEAN AND IN PLACE

IS LEVEL

( ) CHECK FAN" WHEEL, AND PROPELLER

FOR LOCATION

IN HOUSING/ORIFICE

AND SETSCREW

IlL START-UP
ELECTRICAL
SUPPLY VOLTAGE L1-L2
COMPRESSOR

AMPS LI

INDOOR (EVAPORATOR)
TEMPERAT[

L2-L3

L3-L1

L2

L3

FAN AMPS

RES
DB

OUTDOOR (CONDENSER) AIR TEMPERATURE
RETURN-AIR TEMPERATURE
DB
COOLING SUPPLY AIR

DB

WB
WB

GAS HEAT SUPPLY AIR
PRESSURES
GAS INLET PRESSURE
GAS MANIFOLD

IN. WG

PRESSURE

REFRIGERANT

SUCTION

REFRIGERANT

DISCHARGE

( ) VERIFY

REFRIGERANT

( ) VERIFY

THAT

IN. WG
PSIG SUCTION LINE TEMP*
PSIG DISCHARGE
CHARGE

THREE-PHASE

USING

SCROLL

CHARGING
COMPRESSOR

TEMPt

CHARTS
IS ROTATING

* Measured at suction inletto compressor
1 Measured at liquid line leaving condenser.

31

IN CORRECT

DIRECTION.

TIGHTNESS

Copyright

2000 CARRIER

Manufacturer
Book_ 1_ 4
Tab 16al 8a

Corp. • 7310 W. Morris St • indianapolis,

reserves the right to discontinue,
PC 101

Catalog

No

534-755

IN 46231

48gplsi

or change at any time, specifications
Printed in U.S.A.

Form

or designs
48GP-1SI

without notice and without incurring
Pg 32

3-00

obligations.
Replaces:

New



---

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