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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HEATING & COOUNG

48GP, 48GPN

Single Package Gas Heating/Electric Cooling Units

With Puron® (R-410A) Refrigerant

Visit www.carrier.cmn

Installation, Start-Up, and Operating Instructions

48GP, 48GPN Sizes 024-060

NOTE: Read the entire instruction manual before starting the

installation.

Index Page

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

RULES FOR SAFE INSTALLATION AND OPERATION.... 1-2

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

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

PROVIDE UNIT SUPPORT ......................................................... 2

Roof Curb ............................................................................ 2

Slab Mount .......................................................................... 2

Ground Mount ..................................................................... 2

FIELD FABRICATE DUCTWORK ............................................. 2

PROVIDE CLEARANCES ........................................................ 2-3

RIG AND PLACE UNIT ....................................................... 3, 6-7

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

INSTALL FLUE HOOD ............................................................... 7

INSTALL GAS PIPING ............................................................. 7-8

INSTALL DUCT CONNECTIONS ....................................... 8, 10

INSTALL ELECTRICAL CONNECTIONS ......................... 11-13

High-Voltage Connections ................................................ 11

Special Procedures for 208-V Operation .......................... 11

Control Voltage Connections ............................................ 12

Standard Connection .......................................................... 12

Heat Anticpator Setting ..................................................... 13

Transformer Protection ...................................................... 13

PRE-START-UP .......................................................................... 13

START-UP .............................................................................. 13-22

MAINTENANCE .................................................................... 22-26

REFRIGERANT SYSTEM .......................................................... 26

QUICK REFERENCE GUIDE .................................................... 27

TROUBLESHOOTING .......................................................... 28-30

START-UP CHECKLIST ............................................................ 31

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 heating of buildings or structures under construc-

tion.

FR|','1,_I;1:Il_e

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 smwice

air-conditioning equipment.

Untrained personnel can perform basic maintenance functions of

cleaning coils and filters. All other operations should be performed

by trained smwice 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 glasses and work gloves. Use

quenching cloth for unbrazing operations. Have fire extinguisher

available lbr all brazing operations.

Fig. 1--Unit 48GP C99088

RULES FOR SAFE INSTALLATION AND OPERATION

Improper installation, adjustment, alteration, service, mainte-

nance, 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.

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.

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

PC 101 Catalog No 534-755 Printed in US.A. Form 48GP-1SI Pg 1 3-00 Replaces: New

Before performing service or maintenance operations on unit,

turn off gas supply then unit main power switch. Electrical

shock or explosion could cause serious iniury or death.

r:l ['_IliilI0]/l

Puron (R-410A) systems operate at higher pressures than

standard R-22 systems. Do not use R-22 service equipment or

components on Puron (R-410A) equipment. Ensure service

equipment is rated for Puron (R-410A).

GENERAL The 48GP units (see Fig. 1) are fully self-

contained, combination Category I gas heating/electric cooling

units designed for outdoor installation. See Fig. 6 and 7 for unit

dimensions. All unit sizes have discharge openings for both

horizontal and downflow configurations, and are factory shipped

with all downflow duct openings covered. Units may be installed

either on a rooftop, cement slab, or directly on the ground (if

permitted by local codes). See Figs. 4 and 5 for roof curb

dimensions.

48GPN units are dedicated Low NOx units designed for California

installations. These models meet the California maximum oxides

o f nitrogen (NOx) emissions requirement of 40 nanogrmns joule or

less as shipped fi'om the factory and MUST be installed in

California Air Quality Management Districts where a Low NOx

rule exists.

RECEIVING AND INSTALLATION

Step l--Check Equipment

IDENTIFY L_'IT The unit model number and serial number

are stamped on unit identification plate. Check this infomlation

against shipping papers and job data.

INSPECT SHIPMENT Inspect for shipping damage while unit

is still on shipping pallet. If unit appears to be damaged or is tom

loose ficom its anchorage, have it examined by transportation

inspectors before removal. Forward claim papers directly to

transportation company. Manufacturer is not responsible for any

damage incurred in transit.

Check all items against shipping list. Immediately notify the

nearest Carrier Air Conditioning office if any item is missing.

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

until installation.

MAXIMUM ALLOWABLE

DIFFERENCE (in.)

A-B B-C A-C

1/4 1/4 1/4

C99065

Fig. 2--Unit Leveling Tolerances

GROL_D MOUNT The unit may be installed either on a slab

or placed directly on the ground if local codes pemfit. Place the

unit on level ground prepared with gravel for condensate dis-

charge.

Step 3--Field Fabricate Ductwork

Secure all ducts to roof curb and building structure on vertical

discharge units. Do not connect dz¢ctworlc to unit. For horizontal

applications, unit is provided with flanges on the horizontal

openings. All ductwork should be secnred to the flanges. Insulate

and weathelproof 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.

RETURN ' ' SUPPLY "

_11'1 iUPl_ \ _\i iH

IIIII III

IIIII OPENING OPENING 111

IIIII 111

IIIII III

EVAR COIL COND COIL

Fig. 3_lab Mounting Details

C99014

Step 2--Provide Unit Support

ROOF CURB Install accessory roof curb in accordance with

instructions shipped with curb. See Figs. 4 and 5 and Table 1 for

roof curb dimensions. Install insulation, cant strips, roofing, and

flashing. Ductwork must be attached to curb.

IMPORTANT: The gasketing of the unit to the roof curb is critical

for a watertight seal. Install gasketing material supplied with the

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

and poor unit perfomlanee.

Curb should be level to within 1/4 inch. This is necessm T for unit

drain to function properly. Refer to accessory roof curb installation

instructions for additional information as required (see Fig. 2).

SLAB MOUNT Place the unit on a solid, level concrete pad

that is a minimum of 4 in. thick with 2in. above grade. The slab

should be flush on the compressor end of the unit (to allow

condensate &din installation) and should extend 2in. on the three

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

slab eycept when required by local codes.

Step 4_Provide Clearances

The required minimum operating and service clearances are shown

in Fig. 6 and 7. 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 (in Canada, sec-

tions 7.2, 7.3 or 7.4 or CaniCGA [Canadian Gas Association]

B149 Installation Codes), or applicable provisions of local build-

ing code.

¥!I [_:.llli_0]/1

Do not restrict condenser airflow. An air restriction at either

the outdoor-air inlet or the fan discharge can be detrimental to

compressor life.

The condenser pulls air through the condenser coil and discharges

it through the top cover. Be sure that the fan discharge does not

J 44 5,16

SUPPORT B

(2)

(INSULATED)

Fig. 4_Roof Curb Dimensions

Top View

SIDE PAN EL__,

0.75 1

BASE PAN I

4.0"

SUPPORT R'B(S) ...... _/ I_i if' BOTTOM SUPPLY

(o,Ot pFL%"')NG............1L[ NA'LER

CANT STR P ...... JINSULATION

(FIELD SUPPLIBD_ ....... _ .......... (FIELD SUPPLIED)

ROOFING MATERIAL

(FIELD SUPPLIED)

Fig. 5--Roof Curb Dimensions

Side View

END ViEW

A99320

A99340

ABC D

UNIT SIZE ODS ORDER NUMBER IN, [MM] IN, [MM] IN, [MM] IN, [MM]

CPRFCURB006A00 8 [203] 11 27/32 [301] 30 5/8 [778] 28 3/4 [730]

48GP024-036

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]

48GP042-060 CPRFCURB009A00 14 [356] 15 27/32 [402] 42 1/8 [1070] 40 1/4 [1022]

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 Curb Dimensions

recirculate to the condenser coil. Do not locate the unit in either a

comer or under an overhead obstmction. 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 nmst not exceed 48 inches.

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

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

Rigging and handling of this equipment can be hazardous for many

reasons due to the installation location (roofs, elevated stmctures,

etc.).

Only trained, qualified crane operators and ground support staff

should handle and install this equipment.

When working with this equipment, observe precautions in the

literature, on tags, stickers and labels attached to the equipment,

and any other safety precautions that might apply.

Training for operations of the lifting equipment should include, but

NOT be limited to the following:

E_39]

4020

E1585]

_1177

[463]

SUPPLY

OUCT

OPENING

893 _

[348]

249 6

[983]

[21 67] [983]

REAR VIEW

y COND

I NON SENT

EVAP COIL TOP VIEW

805

[516]

153 5

[694]

REQ'D CLEARANCES FOR OPERATION AND SERVICING in. (mm)

Evaporator coil access side .................. 36 (914)

Power entry side (except for NEC requirements) ......... 36 (914)

Unit top .......................... 48 (1219)

Side opposite ducts ..................... 36 (914)

Duct panel ........................ 12 (304.8)*

*Minimum distances: If unit is placed Iess than 12 in. (3048 mm) from wall

system, then the system performance may be compromised.

LEGEND

CG - Center of Gravity

COND - Condenser

EVAP - Evaporator

NEC - National Electrical Code

REQ'D - Required

Note: Dimensions are in in (mm)

REQ'D CLEARANCES TO COMBUSTIBLE MAT'L in. (mm)

Top of unit ......................... 14 (355.6)

Duct side of unit ....................... 2 (50.8)

Side opposite ducts ..................... 14 (355.6)

Bottom of unit ....................... 0.50 (12.7)

Flue panel ......................... 36 (914.4)

NEC REQ'D CLEARANCES. in (mm)

Between units, power entry side .............. 42 (1066.8)

Unit and ungrounded surfaces, power entry side ......... 36 (914)

Unit and block or concrete walls and other grounded

surfaces, control box side ................. 42 (1066.8)

_7985

[31 44]

FIELD ENTRY

SERVICE PORTS \\

250 ]

[091]

S?O_S

162_,_61

11939

[4TOO]

4562

[119_] 347 2

190 [075] NPT

22 O _)P

_8310

[52 62]

LEFT SIDEVIEW

UNIT

48GP024040/060

48GP030040/060

48GP036060/090

42 l

[168]

[1285]

[285]

ELECTRICAL

CHARACTERISTICS

_OMPRESSOR BLOWER GAS SECTION

& ELECTRICAL ACCESS PANEL

1226 3

[_828]

FRONT VIEW

FLUE HOOR

UNIT HEIGHT

IN. [MM]

"k"

3702 [940 3]

UNIT WEIGHT

lb. kg.

290.0 1315

313.0 1420

321.0 1456

RIGHTSIDEVIEW

C99017

Fig. 6--48GP024-036 Unit Dimensions

X Z

208/230-1-60 22.0 [5588] 16.0 [4064]

208/230-1-60, 3902 [9911] 22.0 [5588] 153 [387.4] 17.614470]

208/230-3-60

208/230-1-60,

208/230-3-60, 3502 [8895] 22.0 [5588] 153 [387.4] 16.5 [4191]

460-3-60

[O50] NPT

GAS ENTRY

[0R0]

CENTER OF GRAVITY

IN. [MM]

145 [368.3]

860

[3 39]

4020

[15 832

[348]

[16 01]

EVAP

TOP VIEW

4066

REAR VIEW

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

in. [mm]

EVAR COIL ACCESS SIDE .............................................................. 3600 [914 6]

POWER ENTRY SIDE ...................................................................... 3600 [914 O]

(EXCEPT FOR NEC REQUIREMENTS)

UNIT TOP ......................................................................................... 3600 [914.0]

SIDE OPPOSITE DUCTS ................................................................ 3600 [914.0]

DUCT PANEL ................................................................................... 1200 [304 8] *

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

WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE

1090 6

[42 94]

FIELO ENTRY_

SERVICE PORI

427

190 [073] NPT [168]

x 22 0 [0 87] #P 329 0

[1295]

[4422]

LEFT SIDE VIEW

[285]

1193 9

[4700]

REQUIRED CLEARANCE TO COMBUSTIBLE MATE

in [mm]

TOP OF UNIT ................................................................................... 14.00 [355.6]

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

SIDE OPPOSITE DUCTS ................................................................ 14.00 [355.6]

BOTTOM OF UNIT ............................................................................. 0.50 [12.7]

ELECTRIC HEAT PANEL ................................................................. 36.00 [914.4]

NEC.REQUIREDCLEARANCES.

MILLIMETERS [IN]

BETWEEN UNITS, POWER ENTRY SIDE .................................... 4200 [1066.8]

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SiDE .3600 [914.0]

UNiT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES, POWER ENTRY SIDE ......................... 42.00 [1066.8]

mHmmmmmH!

_OMPRE360R 5LOWER GAS SECTION

ELECTRICAL ACCESS PANEL

12263

[48 28]

FRONT VIEW

39 I

1.3

1424

[561]

RIGHT SIDE VIEW

UNIT

48GP042060/090

48GP048090/115/130

48GP060090/115/130

ELECTRICAL

CHARACTERISTICS

208/230-1-60

208/230-3-60

460-3-60

208/230-1-60

208/230-3-60

460-3-60

208/230-1-60,

208/230-3-60,

460-3-60

UNIT WEIGHT

Ib kg

382 173.3

421 191.0

468 212.3

UNIT HEIGHT

IN, [MM]

"A"

38.98 [990.2]

4298 [1091.7]

CENTER OF GRAVITY

IN. [MM]

23.0 [584 2]

21.5 [546 1]

23.5 [596 9]

C99074

Y Z

163 [412.8] 16.6 [421 6]

166 [422.1] 18.0 [457 2]

163 [412.8] 17.6 [447 O]

Fig. 7--48GP042-060 Unit Dimensions

i. Application of the lifter to the load and adjustment of the lifts,

if any, that adapts it to various sizes or kinds of loads.

2. Instruction in any special operation or precaution.

3. Condition of the load itself, required for operation of the

lifting kit, such as balance, temperature, etc.

Follow all applicable safety codes. Wear safety shoes and work

gloves.

TV" o •

Ir!] L, I:I.1J R[.

Never exceed 200 lbs. per bracket lifting force.

Accessory lifting kit is only to be used with Small

Packaged units which have a composite base pan with

molded hand holds.

Never stand beneath rigged units or lift over people.

Lifting point should be directly over the center of gravity

for the unit.

A &opped unit could cause serious injury or death.

INSPECTION Prior to initial use, and at monthly intervals, all

rigging brackets and straps should be visually inspected lbr any

damage, evidence of wear, structural deformation, or cracks.

Particular attention should be paid to excessive wear at hoist

hooking points and load support areas. Brackets or straps showing

any kind of wear in these areas nmst not be used and should be

discarded.

INSTALLATION:

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

unit. Leave the top shipping skid on the unit to act as a

spreader bar. Be sure the strap does not twist.

2. Place each of the four (4) metal lifting brackets into the

handholds in the composite pan.

3. Tighten the ratchet strap until tight. Lifting brackets should be

secure in the handholds.

4. Attach the clevis or hook of sufficient strength to hole in the

lifting bracket as shown in Fig. 8.

5. Attach safety straps directly to the field supplied rigging straps

or clevis clip. Do not attach the safety straps to the lifting

brackets.

6. Use the top of the unit as a spreader bar to prevent the rigging

straps from damaging the unit. If the wood top is not available,

use a spreader bar of sufficient length to not damage the unit.

DETAIL A

SCALE 025O

Fig. 8--Lifting Point

C99066

HOOK

FEED II_N_,-

C99067

Belt Threading Instructions:

i. Open lever of tension buckle

2. Feed webbing through tension buckle as shown

3. Pull webbing through tension buckle until taught

4. Snap lever down to lock strap in tension buckle

5. To release, squeeze safety latch, lift lever and pull webbing

outward

Fig. 9--Belt Threading

914-1371

(36'i54")

t_7_557,)

12263

PLACE RIGGING STRAPS

BASEPAN SLOT (BELOW HANDHOLDS)

BEFORE RIGGING

DUCTS

SEAL STRIP MUST BE IN

PLACE BEFORE PLACING

UNIT ON ROOF CURB

C99015

UNIT 48GP MAXIMUM WEIGHT A B

Size tb mm in mm

024 312 5585 14.5 3883

030 335 5585 15.3 3886

036 343 5585 15.3 3886

042 404 5842 18.3 4140

048 443 5461 18.3 4140

060 490 5969 18.3 4143

kg in.

142 22.0

152 22.0

156 22.0

183 23.0

201 21.5

222 23.5

Fig. lO--Suggested Rigging

Step 6--Connect Condensate Drain

NOTE: When installing condensate drain connection be sure to

comply with local codes and restrictions.

The 48GP units dispose of condensate water through a 3/4 in. NPT

fitting which exits through the compressor access panel. See Fig.

6 and 7 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

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

condensate connection to prevent the pan from overflowing. See

Fig. 11. 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 &ainage. See Fig. 11. Make sure that the outlet of

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

connection to prevent the pan from overflowing. Prime the trap

with water. Connect a drain robe using a minimum of 3/4 -in. PVC

or 3/4 -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 one in. for every 10 ft of horizontal

run. Be sure to check the drain robe for leaks. 12

¥:I [q:lw_l[0]/l

1" MtN.

TRAP

OUTLET

C99013

Fig. 11--Condensate Trap

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.

Dedicated low NOx 48GP models MIST be installed in Califor-

nia Air Quality Management Districts where a Low NOx rule

exists. These models meet the California maximum oxides of

nitrogen (NOx) emissions requirement of 40 nanograms.joule or

less as shipped from the _aetory.

NOTE: Low NOx requirements apply only to natural gas instal-

lations.

The venting system is designed to ensure proper venting. The

flue hood assembly must be installed as indicated in this

section of the unit installation instructions.

Install the flue hood as follows:

i. This installation must conform with local building codes and

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

Canada, CANiCGA B 149.1, and B 149.2) or NFPA (National

Fire Protection Association) latest revision. Refer to Provin-

cial and local plumbing or waste water 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.

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

Table 4 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 lines. Size

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

use pipe smaller than the 1/2-in. FPT gas inlet 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.

A 1/8-in. NPT plugged tapping accessible for test gage connection

nmst be installed immediately upstream of the gas supply connec-

tion to the gas valve.

When installing the gas supply line, observe local codes pertaining

to gas pipe installations. Refer to the NFGC ANSI Z223.1, NFPA

54 latest edition (in Canada, CANiCGA B149.1, B149.2 latest

edition). In the absence of local building codes, adhere to the

following pertinent recommendations:

i. Avoid low spots in long runs of pipe. Grade all pipe 1.4 in. in

every 15 It. 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,

hangers, etc. Use a minimum of one hanger every 6 It. For

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

national codes.

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

threads of joint when snaking 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.

4. Install sediment trap in riser leading to heating section per Fig.

12. This drip leg functions as a trap for dirt and condensate.

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

gas supply pipe within 6 It. of heating section.

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

unit manual shutoff and external manual main shutoff valve.

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

national plumbing and gas codes before connection of piping

to unit.

¥:I [_0l/l

¥!I [q:.IlriiI°]/1

¥_ kU/'_W:I: II:[_

¥_ kU/'_W=I: IIT[_

NIPPLE

CAP

Fig. 12_Sediment Trap

C99020

NOTE: The supply piping must be disconnected from the gas

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

less than 0.5 psig, the unit heating section must be isolated from

the gas piping system by closing the external main mannal shutoff

valve and slightly opening the ground-ioint union.

Unstable operation may occur when the gas valve and

manifold assembly are forced out of position while connect-

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

a backup wrench when snaking connection to avoid strain on,

or distortion of, the gas control piping.

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 2in. outside the unit

casing.

Never use a snatch or other open flame when checking for gas

leaks. Never purge gas line into combustion chamber. Failure

to follow this warning could result in an explosion causing

serious injury or death

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

gas lines aRer all piping connections have been completed.

Use soap and water solution (or method specified by local

codes and.or regulations).

Step 9--Install Duct Connections

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

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

ductwork can be connected to the roof curb. See Fig. 6 and 7 for

connection sizes and locations.

CONFIGURING UNITS FOR DOV_rNFLOW (VERTICAL) DIS-

CHARGE

Before performing service or maintenance operations on the

system, tuna off main power to unit. Electrical shock could

cause serious injury or death.

i. Open all electrical disconnects before starting any service

work.

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

connecting tabs with screwdriver and a hammer (Fig. 13).

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

connecting tabs with a screwdriver and a hammer. Push louver

down to break rear and leR side tabs (Fig. 14).

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

on the unit basepan (iackstand applications only), do so at this

time. Collect ALL screws that were removed. Do not leave

screws on rooftop as permanent damage to the roof may occur.

5. It is recommended that the basepan insulation around the

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

basepan 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.

Table 2--Physical Data -- Unit 48GP -- 024040-042090

UNit SIZE 48GP 024040 024060 030040 030060 036060 036090 042060 042090

NOMINAL CAPACITY (ton) 2 2 2 1/2 2 1/2 3 3 3 1/2 3 1/2

OPERATING WEIGHT (Ib) 290 290 313 313 321 321 382 382

COMPRESSORS ScroH

Quantity 1

REFRIGERANT (R-410A) 50 5.0 5.5 55 69 69 9.0 9.0

Quantity (Ib)

REFRIGERANT METERING DEVICE

Orifice ID (in,) .057 .057 057 057 085 .085 .070 070

AccuRater_ Piston

CONDENSER COIL 1/17 1/17 1/17 1/17 2/17 2/17 2/17 2/17

Rows...Fins/in. 10.9 10.9 127 127 91 91 12.3 123

Face Area (sq ft)

CONDENSER FAN 2350 2350 2350 2350 2350 2350 2350 2350

Nominal CFM 22 22 22 22 22 22 22 22

Diameter (in.) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825)

Motor Hp (RPM)

EVAPORATOR COIL 3/15 3/15 3/15 3/15 3/15 3/15 3/15 3/15

Rows...Fins/in. 37 3.7 3.7 37 37 37 4.7 4.7

Face Area (sq ft)

EVAPORATOR BLOWER 800 800 800 1000 1200 1200 1400 1400

Nominal Airflow (CFM) 10x10 10x10 10×10 10x10 10x10 10x10 11x10 11×10

Size (in.) 1/4 1/4 1/4 1/4 1/2 1/2 3/4 3/4

Motor HP

FURNACE SECTION*

Burner Orifice No. (Qty...Drill Size) 2.44 2.38 2..44 2..38 2.38 3.38 2.38 3..38

Natural Gas 2. 50 2 .46 2..50 2..46 2. 46 3. 46 2 .46 3..48

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

Propane Gas

HIGH-PRESSURE SWITCH (psig) 810 _+15

Cutout 420 +_25

Reset (Auto.)

LOSS-OF-C HARGE/LOW-PRESSU RE SWITCH

(Liquid Line) (psig) 20 +_5

Cutout 45 +_10

Reset (Auto.)

RETURN-AiRFILTERS ,o)T.rowaway20×24×1I 28×24×1I 28×24xlI 20×24xlI 20×24×1I 20×24×1I 24×30×1I 24×30×1

Table 3--Physical Data -- Unit 48GP -- 048090-060130

UNIT SIZE 48GP 048090 048115 048130 060090 060115 060130

NOMINAL CAPACITY (ton) 4 4 4 5 5 5

OPERATING WEIGHT (Ib) 421 421 421 468 468 468

COMPRESSORS Scrotl

Quantity 1

REFRIGERANT (R-410A) 9.5 9.5 95 10.0 10.0 100

Quantity (Ib)

REFRIGERANT METERING DEVICE

Orifice ID (in,) .073 073 073 .086 .088 088

Accurater_ Piston

CONDENSER COIL 2/17 2/17 2/17 2/17 2/17 2/17

Rows...Fins/in. 12.3 123 123 16.4 16.4 164

Face Area (sq ft)

CONDENSER FAN 3300 3300 3300 3300 3300 3300

Nominal Cfm 22 22 22 22 22 22

Diameter (in.)

Motor Hp (RPM) 1/4 (1100) 1/4 (1100) 1/4 (1100) 1/4 (1100) 1/4 (1100) 1/4 (1100)

EVAPORATOR COIL 4/15 4/15 4/15 4/15 4/15 4/15

Rows...Fins/in. 47 4.7 4.7 47 47 4.7

Face Area (sq ft)

EVAPORATOR BLOWER 1600 1600 1600 1750 1750 1750

Nominal Airflow (Cfm) 11 x 10 11 x 10 11 x 10 11 x 10 11 x 10 11 x 10

Size (in,) 3/4 3/4 3/4 1O 10 1.0

Motor HP

FURNACE SECTION*

Burner Orifice No. (Qty...Driil Size) 3.38 3.33 3..31 3..38 3.33 3.31

Natural Gas 3.46 3.42 3..41 3..48 3.42 3.41

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

Propane Gas

HIGH-PRESSURE SWITCH (psig) 810 _+15

Cutout 420 +_25

Reset (Auto.)

LOSS-OF-CHARGE/LOW-PRESSU RE SWITCH

(Liquid Line) (psig) 20 _+5

Cutout 45 +_10

Reset (Auto.)

RETURN-AIR FILTERS (in.)Throwaway 24x 30x1 I 24x 30x1 I 24x 30xl I 24x 30xl I 24x 30x1 I 24x 30x1

II III

NOMINAL IRON PIPE SIZE (IN.)

1/2

3/4

1 1/4

1 1/2

Table 4--Maximum Gas Flow Capacity*

LENGTH OF PIPE, FTt

INTERNAL DIAMETER (IN,) 10 20 30 40 50 60 70 80 90 100 125 150 175 200

622 175 120 87 82 73 66 61 57 53 50 44 40

824 360 250 200 170 151 138 125 118 110 103 93 84 77 72

1048 680 465 375 320 285 260 240 220 205 185 175 160 145 135

1380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280

1610 2100 1460 1180 890 900 810 750 690 650 620 550 500 460 430

*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 number of fittings.

7. After completing unit conversion, perform all safety checks

and power 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 air conditioning and ventilating systems, NFPA

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

residence-type, NFPA 90B; and.or local codes and ordinances.

ADHERE TO THE FOLLOWING CRITERIA WHEN SELECT-

ING, SIZING, AND INSTALLING THE DUCT SYSTEM:

i. Units are shipped for side shot installation.

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-

dations.

3. 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 weather tight and airtight seal.

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 2and 3.

5. Size all ductwork for maxinmm required airflow (either

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

size increases or decreases or performance may be affected.

6. 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.

7. Flash, weatherproof, and vibration-isolate all openings in

building structure in accordance with local codes and good

building practices.

°/ I I

SUPPLY RETURN

DUCT DUCT

OPENING OPENING

C99089

Fig. 13--Supply and Return Duct Opening

VERTICAL DUCT COVERS

C99012

Fig. 14_Vertical Duct Cover Removed

Step lO--Install Electrical Connections

¥_ t','l'JI d='ll_d

The unit cabinet must have an uninten'upted, unbroken

electrical ground to minimize the possibility of serious injury

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

an electrical wire 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 70 (latest edition) (in Canada,

Canadian Electrical Code CSA [Canadian Standards Associa-

tion] C22.1) and local electrical codes. Do t_ot z¢se gas pip6_g

as an electrical grozmd. Failure to adhere to this warning

could result in serious injury or death.

r:l [ "ffz_iilI*]2

Failure to follow these precantions could result in damage to

the unit being installed:

1. Make all electrical connections in accordance with NEC

ANSI_FPA 70 (latest edition) and local electrical codes

governing such wiring. In Canada, all electrical connec-

tions must be in accordance with CSA standard (722.1

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.

5. On 3-phase units, ensure phases are balanced within 2%.

Consult local power company for con'ection of improper

voltage and/or phase imbalance (refer to Table 5).

HIGH-VOLTAGE CONNECTIONS The unit must have a

separate electrical service with a field-supplied, water-proof,

disconnect switch mounted at, or within sight from the unit. Refer

to the unit rating plate for maxilnum fuse/circuit breaker size and

minimum circuit amps (ampacity) for wire sizing. See Table 5 for

electrical data.

The field-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. 6 and 7 for acceptable

location.

See unit wiring label and Fig. 16 lbr reference when making high

voltage connections. Proceed as follows to complete the high-

voltage connections to the unit.

Single phase units:

i. Run the high-voltage (L1, L2) and ground leads into the

control box.

2. Connect ground lead to chassis ground connection.

3. Connect L1 to pressure lug connection 11 of the compressor

contactor.

4. Connect L2 to pressure lug connection 23 of the compressor

contactor.

Three phase units:

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 I1 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.

SPECIAL PROCEDURES FOR 208-V OPERATION

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.

With disconnect switch open, move yellow wire l}om transformer

(3/16 in.) terminal marked 230 to terminal marked 200. This retaps

transformer to primary voltage of 208 vac.

UNIT

SIZE 48GP

024

030

036

042

048

060

V-PH-HZ

208/230-1-60

208/230-3-60

208/230-1-60

208/230-3-60

460-3-60

208/230-1-60

208/230-3-60

460-3-60

208/230-1-60

208/230-3-60

460-3-60

208/230-1-60

208/230-3-60

460-3-60

VOLTAGE

RANGE

Min Max

187 253

414 506

187 253

414 506

187 253

414 506

187 253

414 506

Table 5--Electrical Data -- 48GP

COMPRESSOR

RLA LRA

13.5 61.0

14.7 73.0

9.6 63.0

15.4 83.0

12.2 77.0

5.1 35.0

18.6 105.0

13.5 77.0

6.3 39.9

20.5 109.0

14.7 91.0

6.5 46.9

27.6 158.0

18.1 137.0

9.9 62.9

OUTDOOR FAN MOTOR

FLA

INDOOR FAN MOTOR

FLA

2.0

2.1

3.6

1.9

4.1

2.0

4.1

2.0

6.2

3.2

POWER SUPPLY

MCA MOCP*

19.7 30

21.3 35

14.9 20

23.7 35

19.7 30

9.1 15

29.0 45

22.6 35

10.8 15

31.3 50

24.1 35

11.0 15

42.3 60

30.4 45

15.4 20

LEGEND C@US

FLA -- Full Load Amps

LRA -- Locked RotorAmps

MCA -- Minimum Circuit Amps

MOCP -- Maximum Overcurrent Protection

RLA -- Rated Load Amps

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 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 voltage

average voltage

EXAMPLE: Supply voltage is 469-3-60.

a B 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 = 5 v

(BC) 464 457 = 7 v

(AC) 457 455 = 2 v

Maximum deviation is 7 v.

Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x --

457

=153%

This amount of phase imbalance is satisfactory as it is below the

maximum allowable 2%.

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: 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 i00 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. 6

and 7. Remove the rubber grommet fl:om 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 fl:om 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. 16.) Ensure the leads are long enough

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

side of control box). Stripped yellow wire is located in connection

HIGH VOLTAGE |

POWER LEADS <o- - -

(SEE UNIT WIRING|

LABEL) _- --

GND

CONTROL BOX

LOW-VOLTAGE

POWER LEADS-

(SEE UNiT

WIRING LABEL)

SPLICE BOX

i_ o- -£]_POWER

-:I SUPPLY

FIELD-SUPPLIED

FUSED DISCONNECT

--YELLYL1:_

GRN(G) _1 QTHERMOSTAT

@I (TYPICAL)

"-RED_'R'Z ®

C99018

Fig. 16--High- and Control-Voltage Connections

box. Route leads through hole in bottom of control box and make

low-voltage connections as shown in Fig. 16. Secure all cut wires,

so that they do not interfere with operation of unit.

HEATANTICIPATORSETTINGTheroomthemlostatheat

anticipatormustbeproperlyadjustedtoensureproperheating

performance.Settheheatanticipator,usinganammeterbetween

theWandRtemlinalstodeterminetheexactrequiredsetting.

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, discomfort 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.

TRANSFORMER PROTECTION The transformer is of the

energy-limiting type. It is set to withstand a 30-second overload or

shorted secondary condition.

PRE-START-UP

Ig_|','l'_l fill IX_

¥_ L'Jl:l;tlllX_

Failure to observe the following wamings could result in

serious injury or death:

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 both high- and

low-pressure sides of system before touching or disturbing

anything inside terminal box if refi'igerant 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 component. 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 reclaim all refrigerant l}om system using

both high- and low-pressure ports.

c. Cut component connecting robing with tubing cutter and

remove component l_'om unit.

d. CarefMly 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:

i. Remove access panel.

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

CAUTION, and INFORMATION labels attached to, or

shipped with, unit.

3. Make the following inspections:

a. Inspect lbr shipping and handling damages such as broken

lines, loose parts, disconnected wires, etc.

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

unit base. Detecting oil generally indicates a refrigerant

leak. Leak test all refrigerant tubing connections using

electronic leak detector, halide torch, or liquid-soap solu-

tion. If a refrigerant leak is detected, see Check for

Refrigerant Leaks section on page 13.

c. Inspect all field- and factory-wiring connections. Be sure

that connections are completed and tight.

d. Inspect coil fins. If damaged during shipping and handling,

carefully straighten fins with a fin comb.

4. Verify the following conditions:

Do not purge gas supplyintothe combustion chamber. Do not

use a match or other open flame to check Ibr gas leaks.

Failure to follow this waming could result in an explosion

causing serious injury or death.

a. Before lighting the unit for the first time, perlbrln 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 fidl 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, hnmediately upon detection of gas

odor, re-tighten the union. Allow 5 minutes to elapse, then

light unit.

b. Make sure that condenser-fan blade is con'ectly positioned

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

be 1/2 in. maxinmm from fan orifice (see Fig. 17).

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

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

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

ensure proper &ainage.

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

been removed.

MOTOR _ FAN GRILLE

1/8" MAX BETWEEN

MOTOR AND FAN HUB MOTOR SHAFT

C99009

Fig. 17--Fan Blade Clearance

START-UP

Use the Start-Up Checklist supplied at the end of this book, and

proceed as follows:

CHECK FOR REFRIGERANT LEAKS Proceed as follows to

locate and repair refrigerant leaks and charge the unit:

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

been relieved and refrigerant recovered from both high- and

low-pressure ports.

2. Repair leak following accepted practices.

NOTI=: Replace filter drier whenever the system has been opened

for repair.

3. Check system for leaks using an approved method.

4. Evacuate refiigerant system and reclaim refi'igerant if no

additional leaks are found.

5. Charge unit with R-410a refrigerant, using a volumetric-

charging cylinder or accurate scale. R@r to unit rating plate

for required cha_'ge.

HEATING

INPUT

(BTUH)*

NUMBER

ORIFICES

Table 6--Heating Inputs

40,000 2

60,000 2

90,000 3

115,000 3

130,000 3

Min

GAS SUPPLY PRESSURE

(IN. WG)

Natural

Max

130

PropaneT

Min

Max

130

MANIFOLD PRESSURE

Natural

3.5

(IN. WG)

Propane'i"

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

1-Based on aItitudes from sea level to 2000 ft. above sea levet. For altitudes above 2000 ft., reduce input rating 4% for each 1000 ft above sea Ievel. in Canada, from

2000 ft above sea level to 4500 ft above sea Ievel, derate the unit 10%

START UP HEATING SECTION AND MAKE ADJUSTMENTS

IMPORTANT: Complete the required procedures given in the

Pre-Start-Up section above before starting the unit.

Do not jumper any safety devices when operating the unit.

Make sure that burner orifices are properly aligned. Unstable

operation may occur when the burner orifices in the manifold are

misaligned.

NOTE: Make sure 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 fumace lighting

instructions located inside burner or blower access panel.):

i. Place room thermostat SYSTEM switch in the HEAT position

and the FAN switch in the AUTO position.

2. Set the heating temperature control of the thermostat above

rooln temperature.

3. The induced-&aft motor will start.

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

seconds. If the bumers do not light, there is a 22-second delay

before another 5-second 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 mm on 45 seconds after the flame has

been established. The evaporator fan will turn off 45 seconds

after the thermostat has been satisfied.

CHECK GAS INPU_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 ft. above sea level. These inputs are based on natural

gas with a heating value of 1050 Btuift 3 at 0.65 specific gravity, or

propane gas with a heating value of 2500 Btuift 3 at 1.5 specific

gravity. For elevations above 2000 ft., reduce input 4% for each

i000 ft. above sea level. When the gas 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.

P':I['_:lliiI0]11

These units are designed to consume the rated gas inputs

using the fixed orifices at specified manifold pressures as

shown in Table 6. DO NOT REDRILL THE ORIFICES

UNDER ANY CIRC[ MSTANCES.

ADJUST GAS INPU_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 gas 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 bumer orifices

following the recommendations of national 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:

Turn off gas supply to unit.

i. Remove pipe plug on manifold (see Fig. 18) then connect

manometer at this point, turn on gas to unit.

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

revolution.

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

seconds on one hour).

4. Multiply result of Step 4 by the number of cu. ft. shown for

one revolution of test dial to obtain cu. ft. of gas flow per hour.

5. 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 is 1 cu. ft., one

revolution takes 32 seconds, and the heating value of the gas is

1050 Btuift 3. Proceed as follows:

i. 32 seconds to complete one revolution.

2. 3600+32 112.5

3. 112.5 x 1 112.5 ft 3 of gas flow&r.

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:

i. Remove cover screw over regulator adjustment screw on gas

valve.

2. Turn regulator adjustment screw clockwise 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.

MANIFOLD PIPE PLUG

Fig. 18--Burner Assembly

C99019

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 soft in appearance, and that the flames are

approximately the same for each burner. Propane will have blue

flame with yellow tips. (See Fig. 19). Refer to Maintenance section

for information on burner removal.

BURNER FLAME

F_ WI_'I ;h" !R[fl_

Unsafe operation of the unit may result if manifold pressure

is outside this range. Serious il_iury or unit damage may

result.

3. Replace cover screw cap on gas valve.

4. Turn offgas 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 unit are sized for the

unit rated input when the manifold pressure reading matches the

level specified in Table 6.

lr_ i','l:_hh' !Rl:fl_

If converting to propane gas, remove the burner assembly and

inspect the heat exchanger robes. If there are V-shaped NOx

baffles installed in the firing tubes, THEY MUST BE

REMOVED.

Discard the baffles after removal.

Refer to Maintenance section for information on burner

removal.

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

i. Turn off gas to unit.

2. Remove pipe plug on manifold (see Fig. 18) then connect

manometer at this point.

BURNER

MANIFOLD

C99021

Fig. 19--Monoport Burners

AIRFLOW AND TEMPERATURE RISE The heating section

for each size unit is designed and approved for heating 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 cfin at various temperature rises.

The heating operation airflow must produce a temperature rise that

falls within the approved range.

Refer to Indoor Airflow and Airflow Adjustments section on the

following pages to adjust heating airflow when required.

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

HEATING

INPUT

(BTUH)

INPUT 20 25 30 35

40,000 1500 1200 1000 857

60,000 2250 1800 1500 1286

90,000 -- 2700 2250 1929

115,000 -- -- -- 2464

130,000 ....

NOTE: Dashed areas do not fall within the approved temperature rise range

TEMPERATURE RISE °F

40 45 50 55 60

750 667 600 -- --

1125 1000 900 818 750

1688 1500 1350 1227 1125

2156 1917 1725 1568 1438

2438 2167 1950 1773 1625

65 70

692

1038 964

1327

1500 1393

of the unit.

HEATING SEQUENCE OF OPERATION See Fig. 20-22 and

unit wiring label.

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

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

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

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

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

energized 45 seconds after flame is established. When the thermo-

stat is satisfied and "W" is de-energized, the burners stop firing and

the evaporator fan motor shuts off after a 45-second 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.

Table 8 LED Indications

ERROR CODE

Normal Operation

Hardware Failure

Fan On/Off Delay Modified

Limit Switch Fault

Flame Sense Fault

Four Consecutive Limit Switch Faults

Ignition Lockout Fault

Induced-Draft Motor Fault

Rollout Switch Fault

Internal Control Fault

Internal Software Fault

NOTES:

1There is a 3-second pause between error code displays

LED INDICATION

off

1 Flash

2 Flashes

3 Flashes

4 Flashes

5 Flashes

6 Flashes

7 Flashes

8 Flashes

9 Flashes

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

displayed in numerical sequence.

3 This chart ison the wiring diagram located insidethe burner access

panel

LIMIT SWITCHES_onnally closed limit switch (LS) com-

pletes the control circuit through the thennostat R circuit. Should

the leaving-air temperature 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 the 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 heating operation. When this

_ault occurs, the IGC LED will display FAULT CODE 2.

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 located above the main bumers. When the

temperature at the anxiliary switch reaches the maximum allow-

able 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 run until switch

is reset. The IGC LED will display FAULT CODE 7.

START UP COOLING SECTION AND MAKE AD,RTST-

MENTS

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

section on previous pages 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 40 ° F (unless accessory low-mnbient 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 seconds.

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 are

direction-oriented. These units must be checked to ensure proper

compressor 3-phase power lead orientation. If not con'ected within

5 minutes, the internal protector will shut offthe compressor. The

3-phase power leads to the unit must be reversed to con'ect

rotation. When turning backwards, scroll compressors emit el-

evated noise levels, and the difference between compressor suction

and discharge pressures may be &amatically lower than normal.

CHECKING AND AD,RTSTING REFRIGERANT CHARGE

The refrigerant system is tully charged with R-410A (Puron)

refrigerant, and is tested and factory sealed.

NOTE: Adjustment of the refrigerant charge is not required

unless the unit is suspected of not having the proper R-410A

charge. The charging label and the tables shown refer to system

temperatures and pressures.

A refrigerant charging chart label is attached to the outside of the

compressor access door. The chart includes the required suction

line temperature at given suction line pressures and outdoor

ambients..

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

mometer, and a gage manifold are required when using the

FIELD

SUPPLY

OFM

EOUI P GD

POWER

SCHEMATIC

208/250 I 60

COOLING FAN LOGIC

N T T+5D

G G

ENERGIZED DE ENERGIZED

HEATING FAR LOGIC

i i i i

D N5 T T+45

W DR M BR

ENERGIZED DE ENERGIZE _}

RCS

OFF

0I COOLJ. TH I AHA

aiii ........

_COOL TCI YI

AUTO

wON

FIELD THERMOSTAT

COMMOb--

24V SPLICE BOX

I I I

J L t

I I

I J

(SEE NOTE #4)_

_Wl6 YEL

WI5 YEL--

Wl BLK P_ MAR_

WI3 BLI_

COMP

IFM

QT _GRN TEL

W46 BRN

-- W59 REDBR J? _ I

W19 Writ _ /-()D

W20 GRN

/ SEENOTE

WRl RED _) I [_ BLU_ /i

T ' _SL,S f/LSRA

_BB_ IF{IS} vlo _Cg_ v,o_oCO

Jl _ W41 GRN YEL--GR YEL_

%_, W32 8RN

_W46 BRN

2 GRO NDED /_X_i_/_ W'_q n R

_L YEL_BLK_-_BLK_ LUg. z_BL _ _WSO RN

W30 BR

UNIT COMPONENT ARRANGEMENT

OUTDOOR FAN U

SECTION

EQUIP

GND !

COMPRESSOR CONTROL BO×

SECTIO _ _ _1 [[

Z4V

COMP [SPLICE 80X

Gs _

N mB(

GAS SECTION

DISCONNECT

LARGE CHASSIS LOCATION PER NEE

LEGEND

_FIELI) SPLICE FS FLAME SENSOR

O TEN_INAL {MARKEI)) FU FUSE

oTERMINAL (UNMARKED1 GND GROUND

0 SNLICE GVR GAS VALVE RELAY

HPS HIGH PRESSURE SNITCH

E3ISPLICE (MARKED} HS HNLL EFFECT SENSOR

FACTOR_ WIRING HV TRAN HIGH VOLTAGE TRANSFORMER

FIELD CONTROL MIRING I IGNITOR

--i FIELD POMER MIRING IGC INTERGRATED GAS MNIT

Ill ACCESSORY OR OPTIONAL CONTROLLER

WIRING IDM INDUCED DRAFT MOTOR

IFM INDOOR FAN _OTOR

--TO INDICATE COMMON LPS LOW PRESSNRE SMITCH

POTENTIAL ONLY LS LIMIT SMITCH

NOT TO REPRESENT WINING MGV MAIN GAS VALVE

BR 8LOMER RELAY OFM OUTDOOR FAN MOTOR

C CONTACTOR _ QNADRUPLERoLLOUTSWITcHTERMINAL

CAP CAPACITOR THAN TRANSFORMER

COMP COMPRESSOR MOTOR

CR COMDUSTION RELAY

EOMIP EQMIPMENT

NOTES:

IIF ANY OF THE ORIGINAL WIRES FURNISHER ARE REPLACER,

IT MUST RE REPLACED WITH TYPE 90 DEGREE C WIRE OR

ITS EODIVALENT

2SEE PRICE PAGES FOR THERMOSTAT AND SUNNASES

5USE T5 DEGREE COPPER CONDUCTORSFOR FIELD INSTALLATION¸

4FOR HIGH SPEED IF_,DISCONNECT NED

WIRE FROM IGC;D_ AND CONNECT NLH NINE FNO_ IFM

FOR MEDIUM NPEEO,DISGONNECT RED WINE

FRO_ IgC:RN AN8 CONNECT RLU MINE FROM IFM

50N MODELS 48GPOR4 056 HAS LSI AND LS2 IN SERIES¸

ON MODELS 48GP042 O_D HAS LSI ONLY¸

Fig. 20--208/230-1-60 Wiring Diagram

C99076

COOLING FAN LOGIC

OT %30

G g

ENERGIZED DE ENERGIZED

HEATING FAN LOGIC

ii I i

0 45 T T+45

W BR W BR

ENERGIZED DE ENERGIZED

OFM

ONLY)

COMP

IBM

_GRN YEL

W46 BRN

UNIT COMPONENT ARRANGEMENT

OUTDOORFAN

ECTIO

COMPRESSOR

SECTION

CO_*P

EQUIP

GND i

CONTROL BOX !

NON_OMP_ T rl,_

GAPBII _

@ IGC O_

I_#ICEBOX

nD@

GAS SECTION

01SCO NECT

:_ER NEE

LEGEND

_FIELD SRLIBE

O TERMINAL (MARKED/ FL FLAME SENSOR

o TERMINAL (NNMARKEB} FU FUSE

0 SPLICE GND GBONNB

<IISPLICE (MARKED) GVR GAS VALVE RELAY

NPS HIGH PRESSURE SWITBN

FACTORY WINING HS HALL EFFECT SENSOR

FIELD CONTROL WIRING HV TRAM HIGH VOLTAGE TRANSFORMER

II FIELD POWER WINING I IGNITOR

ii- ACCESSORY OR OPTIONAL IGC INTERGRATED GAS UNIT

WIRING CONTROLLER

IDM INDUCED BNAFT MOTOR

I TO INDICATE _OMMON o

IFM INDOOR FAN MOTO_

POTENTIAL ONLY: LPS LOW RRESSUBE SWITCH

NOT TO REPRESENT WIRING L q LI_IT SWITCH

BR BLOWER RELAY MGV MAIN GAS VALVE

C _0_NTACTOM OFM OUTDOOR^ FAN MOTOR

OT QUADRUPLE TERMINAL

CAP CAPACITOR R R W

S OLLOUT S ITCH

COMM COMPRESSOR MOTOR TRAN TRANSFORMER

CR COMBUSTION RELAY '

EQUIP EQUIPMENT

NOTES:

IIF ANY OF TNE ORIGINAL WIRES FURNISHED ARE REPLACED,

IT MUST BE REPLACD WITH TYPE 90 DEGREEC WIRE OR

ITS EQUIVALENT

2 SEE PRICE PAGES FOR THERMOSTATAND SBBBASES

5USE Y5 BEBREE COPRER ¢OROUBTORS FOR FIELD INSTALLATION

4FOR HIGH SPEED IFM,OISDONNKT REO

WIRE FROM IBG;BM ANB CONNECT BLK WIRE FROM IEM

FOR NDIUN SPEED,BISCONNEGT RE_ WIRE

F_OM IGD;BN AND CONNECT BLU WIRE FROM IFM

5 ON MOBELS 4BBPOR_ 036 HAS LSI ARB LSR IN SERIES

ON MOBELS 4BBPO42 DBD HAS LSI ONLY

Fig. 21--208/230-3-60 Wiring Diagram

C99077

COOLING FAN LOGIC

O T T+SO

G O

ENERGIZED DE ENERGIZED

HEATI G FAN LOGIC

I i I i

O 45 T T+45

W BR W BR

ENENGIZEO DE ENERGIZED

° AUTO

FIELD THERMOSTAT

W43 BLK

OT CAP_

(060 ONLY)_L 5

W56 BLU

(SEE NOTE @4)_

OT zGRN YEL

W46 BRN

OFM

COMP

UNIT COMPONENT ARRANGEMENT

OUTDOOR FAN

SECTION

EQUIP

GND L

COMPRESSOR CONTROL 80X /

SECTION __I

:ROM COMP _ , I_

_CAPSI I

@ 16C0_

RNg

COMP ISPLICE BOX

R nB(

iGAS SECTION

DISCONNECT

PER NEC

_FIELD SPLICE

O TERMINAL (MARKED> FL FLAME SENSOR

o TERMINAL {UNMARKED1 FU FUSE

II S_LICE ORb GROUND

, GVN GAS VALVE RELA

(jI_PLICE (NARKED_ _ ,,

HPS HIGH _RESSU_E SWITCH

FACTORY WINING HS HALL EFFECT SENSOR

FIELD CONTROL WIRING HV TRAN HIGH VOLTAGE TRANSFORMER

--- FIELD POWER WIRIMG I IGNITOR

---- ACCESSORY OR OMTIONAL IGC INTERORATED GAS UNIT

WIRING CONTROLLER

IBM INDUCED ORAFT _OTON

I TO IN_ IEATE COMMON

y IFM INDOOR FAN MOTOR

POTENTIAL ONL: LPS LOW PRESSURE SWITCH

NOT TO REPRESENT WINING LS LIMIT SWITCH

BR BLOWER RELAY MGV WAIN GAS VALVE

C _0#NTACTOR OFM Oi_TDOOR: FAN MOTOR

OT QUADRUPLE TERMINAL

CAP CAPACITOR_ RS ROLLOUT SWITCH

COMM COMiRESSOR MOTOR TRAN TRANSFORMER

CR COMBUSTION RELAY

EOUIP EQUIPMENT

NOTES:

IIF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED,

IT MUST BE REPLACER WITH T_PE 90 NEGREE R WIRE OR

ITS EODIVALENT

RSEE 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

Fig 22460-3-60 Wiring Diagram

C99078

superheat charging method for evaluating the unit charge. Do not

use mercw 3"or small dial-o_e thermometers because they are not

adequate for this O'pe of measurement.

IMPORTANT: When evaluating the refi'igerant charge, an indi-

cated adjustment to the specified factory charge must always be

very minimal. If a substantial adjustment is indicated, an abnomaal

condition exists somewhere in the cooling system, such as insuf-

ficient airflow across either coil or both coils.

REFRIGERANT CHARGE The amount of rel}igerant charge

is listed on the unit nameplate. Refer to Can'ier Refi'igeration

Service Techniques Manual, Rel}igerants section.

Unit panels must be in place when unit is operating during

charging procedures.

NO CHARGE: Use standard evacuating techniques. After evacu-

ating system, weigh in the specified amount of refrigerant (refer to

system data plate).

LOW CHARGE COOLING: Measure outdoor ambient using

Cooling Charging Charts (Figs. 23-28). Vary refrigerant until the

conditions of the chart are met. Note that charging charts are

different from type normally used. Charts are based on charging

the units to correct superheat for the various operating conditions.

Accurate pressure gage and temperature sensing devices are

reqnired. Connect the pressure gage to the service port on the

suction line. Mount the temperature sensing device on the suction

line and insulate it so that the outdoor ambient does not effect the

reading. Indoor air CFM must be within the normal operating

range of the unit.

TO USE COOLING CHARGING CHARTS: Take the outdoor

ambient temperature and read the suction pressure gage. Refer to

the chart to determine what the suction temperature should be.

NOTF:: If the problem causing the inaccurate readings is a

refrigerant leak, refer to Check for Refi'igerant Leaks section in

this docmnent.

INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS

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

For cooling operation, the recommended airflow is 350 to 450

cfin for each 12,000 Btuh of rated cooling capacity. For

heating operation, the airflow must produce a temperature rise

that falls within the range stamped on the unit rating plate.

Table 7 shows the temperature rise at various air-flow rates. Table

9 shows both heating and cooling airflows at various external static

pressures. Refer to these tables to determine the airflow for the

system being installed.

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

l'ree fi'om obstructions, and adjusted properly.

Shut off gas supply thet_ disconnect electrical power to the

unit before changing blower speed. Electrical shock or

explosion could cause serious injury or death.

Airflow can be changed by changing the lead connections of the

blower motor.

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

wired for medium or high speed in the field.

For 208/230-v The motor leads are color-coded as follows:

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 fi'om the blower relay (BR). This wire is

attached to terminal BM for single-phase and 3-phase units. To

change the speed, remove and replace with lead for desired blower

motor speed. Insulate the removed lead to avoid contact _ith

chassis parts.

For 460-v GE Motors The motor leads are color coded as

l'ollows:

a-SPEED

black = high

violet = jumper

orange = medium

red = low

2-SPEED

black = high

blue = jumper

red = low

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

speed lead fi'om the blower relay (BR) and replace with the lead

l'or the desired blower motor speed. The motor speed lead is

attached to terminal BM. For low and medium speeds black must

be connected to the jumper wire. Insulate removed lead et_d to

avoid contact with 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. Insulate the jumper to avoid cot_tact _ith at_3" chassis

parts.

Ca"

a_ 1/03

o 1034

965

896

8827

758

(O24}

2OO 3OO 7OO 800

I 117 " ," io ", _"

SUCTION UNE TEMPERATURE (DEG C)

125 52I

115 461

105 411

75 241

65 181

55 Isl

(030} 60 HZ OHARGINGCHART OUTDOOR

FOR USE WITH U_ITS USING R4 _0A REFRIGERANT FTEMPC

1241 18._

1172 170 ZZZZZZZZZZZZZZZZZZZZZ Z

ZZZZZZZZZZZZZZZZZZZZZ 125 52

, 115 46

1/03 160 i05 41

0 zzzzzzzzzzzzzzzzzzzzz _

® i0_ _ 150zzzzzzzzzzzzzzzzz_ 85 29

_ _ zzzzzzzzzzzzzzzzz_zz,_ 75 24

_ 965 _ _40 _ _ _

_ zzzzzzzzzzzzz._£z_-:2 z6s _8

0 ZZZZZZZZZZZZZZZZ_,_ ZZ 55 13

SUCTION LNE TEMPERATURE (OEG F)

I 11 I I I I I7

7 4 10 16 21 2

SUCT ON LINE TE_dPERATURE (DEG C}

:_ 1103

_ 1034

_ 965

_ 896

_ _27

758

C99079

Fig. 23--Cooling Charging Cha_, 48GP024 Units

(O36}

105 41 I

75 24 I

65 181

55 ISl

2OO 3OO 7O0 800

I 11 I I I7 ,o ", 2"

C99080

Fig. 24--Cooling Charging Chart, 48GP030 Units

SUCTION UNE TEMPER_URE (DEC F}

I 11 I7 4 i'o i_ '1 2'

SUCTION LINE TEMPER_URE (OEG O)

C99082

Fig. 26--Cooling Charging Chart, 48GP042 Units

C99081

Fig. 25 -- Cooling Charging Chart, 48GP036 Units

:_ 1103

_ 1054

_ 965

_ 896

_ _27

758

{048}

20o 3o0 70o 800

7 _6

125 52 I

115 461

85 29 I

75 24 I

65 181

55 isl

45 7 I

{060} 60 HZ CHARGING CHART OU_y,,OpOR

FO_ USE W_THUNITS USING R4 0A _SFR GERANT F C

1241 180ZZZZZZZZZZZZZZZZZZZZ Z Z

1172 170 ZZZZZZZZZZZZZZZZZZZZZ Z_25 52

115 46

I05 4

;_ I103 160

6 ZZZZZZZZZZZZZZZZZZZZZ s5

o _os4 _ 15o _ _ £ Z29

_ ZZZZZZZZZZZZZZZZ]_ Z 24

_I_ ZZZZZZZZZZZZZZZZ_'Z_

u_ 896 13o _ _ _ Z

o _

_27 _ _2Ozzzzzzzzzzz_z_ZZ_Z _

75a i/0 _ _

690 I%00 soo 40o 500 6oo

suc ION LIN_TEM_ERATUNE (DEC F) 0 80 0

' '_ ' I_ ;_ _'_7 4 110

SUCTION LINE TEMPERATURE (DEG C)

C99083

Fig. 27--Cooling Charging Chart, 48GP048 Units C99084

Fig. 28--Cooling Charging Chart, 48GP060 Units

Unit

48GP

024

030

036

042

048

060

Table 9--Wet Coil Air Delivery* -- Horizontal and Downflow Discharge

Unit 48GP024-060 (Deduct 10% for 208 Volts)

230 AND 460 VOLT

Motor External Static Pressure (in. wg)

Speed 0.0 01 02 0.3 0.4 05 06 0.7 0.8

Watts 279 282 280 277 276 - -

Low Cfm 882 801 738 674 604 - -

Watts - 373 367 361 356 351 -

Medium Cfm - 936 868 797 719 626 -

Watts - - - 463 452 439 428

High Cfm - - - 956 878 794 702

Watts 243 244 242 ....

Low Cfm 885 842 786 ....

Watts 353 339 333 330 326 320 -

Medium Cfm 1195 1134 1070 997 911 818 -

Watts - 443 436 426 416 406 397

High Cfm - 1230 1145 1061 977 888 786

Watts 490 463 446 432 418 403 389 378 -

Low Cfm 1431 1398 1347 1281 1205 1118 1024 921 -

Watts 513 501 488 474 459 443 428 -

Medium Cfm 1491 1426 1351 1267 1175 1077 976 -

Watts - 645 636 627 616 605 593 583

High Cfm - 1484 1410 1330 1243 1147 1044 936

Watts 634 618 608 598 583 562 534 502 473

Low Cfm 1669 1599 1545 1498 1448 1391 1326 1257 1189

Watts - 733 704 672 638 604 574

Medium Cfm - 1746 1688 1630 1566 1492 1399

Watts - - - 797 773 751

High Cfm - - - 1727 1632 1537

Watts 591 578 573 568 559 544 524 500 -

Low Cfm 1554 1523 1496 1467 1432 1387 1332 1269 -

Watts 755 737 719 699 678 653 627 602 579

Medium Cfm 1834 1802 1758 1706 1648 1585 1520 1455 1392

Watts - 890 858 828 801 777 756

High Cfm - 1943 1870 1793 1711 1624 1531

Watts 589 576 569 566 559 541 499

Low Cfm 1946 1891 1836 1779 1718 1651 1577

Watts 750 733 715 695 673 648 623 598 577

Medium Cfm 2189 2097 2021 1952 1883 1809 1727 1635 1530

Watts 879 850 821 795 772 750 728 701

High Cfm 2337 2159 2050 1974 1905 1824 1722 1597

09 10

454 457

1132 1101

550 536

1279 1120

727 696

1423 1308

562 556

1332 1276

734 709

1433 1329

*Air delivery values are without air filter.

Note: Deduct field-supplied air filter pressure drop to obtain external static pressure available for ducting

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 room temperature rises 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 connect

contactor coil (C) (through unit wire Y) and blower relay coil (BR)

(through unit wire G) across the 24-v secondary of transformer

(TRAN).

The normally open contacts of energized contactor (C) close and

complete the circuit through compressor motor (COMP) to con-

denser (outdoor) fan motor (OFM). Both motors start instantly.

The set of normally open contacts of energized relay BR close and

complete the circuit through evaporator blower (indoor) fan motor

(IFM).

NOTE: Once the compressor has started and then has 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 slightly 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 de-energize contactor coil C and relay coil BR. The

condenser and compressor motors stop. After a 30-second delay,

the blower motor stops. The unit 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. 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.

NOTE TO EQUIPMENT OWNER: Consult your local dealer

about the availability of a maintenance contract.

The ability to properly perform maintenance on this equip-

ment 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 SERI-

OUS INJURY AND POSSIBLE DAMAGE TO THIS

EQUIPMENT.

For longer life, operating economy, and continuing efficiency,

clean accumulated dirt and grease fi'om the blower wheel and

motor annually.

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

Turn off the gas supply, then disconnect and tag electrical

power to the unit before cleaning the blower motor and wheel.

Failure to adhere to this warning could cause serious injury or

death.

¥_ i','l:_l fl: IR[_

Failure to follow these warnings could result in serious injury

or death:

1. Turn off gas supply, then turn off electrical power to the

unit belbre performing any maintenance or service on the

unit.

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

with any mechanical equipment, serious injury can result

fi'om 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 ofl;

shut off the external main manual gas valve to the unit,

then shut off the electrical supply.

V:I[_'12

Errors made when reconnecting wires may cause improper

and dangerous operation. Label all wires prior to disconnec-

tion when servicing.

The mininmm maintenance requirements l`or this equipment are as

l`ollows:

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

necessary.

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

cooling season *'or cleanliness. Clean when necessary.

3. Inspect blower motor and wheel lbr cleanliness and check

lubrication each heating and cooling season. Clean when

necessary. For first heating season, inspect blower wheel

bimonthly to determine proper cleaning frequency.

4. Check electrical connections for tightness and controls for

proper operation each heating and cooling season. Smwice

when necessary.

5. Cheek and inspect heating section bel`ore each heating season.

Clean and adjust when necessary.

6. Check flue hood and remove any obstructions if necessary.

AIR FILTER

IMPORTANT: Never operate the unit without a suitable air filter

in the return-air duct system. Always replace the filter with the

stone dimensional size and type as originally installed. See Tables

2and 3 l`or recommended filter sizes.

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 filter(s) becomes

clogged with dust and lint.

EVAPORATOR BLOWER AND MOTOR

To clean the blower motor and wheel:

i. Remove and disassemble blower assembly as t`ollows:

a. Remove unit access panel.

b. Disconnect motor lead fi'om blower relay (BR). Disconnect

yellow lead from terminal L2 of the contactor.

c. On all units, remove blower assembly fi'om 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 bet`ore disassembly.

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

remove screws that secure motor mount brackets to hous-

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

2. 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.

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 brush attach-

ment. Remove grease and oil with mild solvent.

d. Reassemble wheel into housing.

e. Reassemble motor into housing. Be sure setscrew(s) are

tightened on motor shaft flats and not on round part of

shaft.

f. Reinstall unit access panel.

3. Restore electrical power, then gas supply to unit. Start unit and

check l'or proper blower rotation and motor speeds during

heating and cooling cycles.

_- ....

IIl

Fig. 29--Unit Access Panel

C99090

NOTE: All motors are pre-lubrieated. Do not attempt to lubricate

these motors.

FLUE GAS PASSAGEWAYS To inspect the flue collector

box and upper areas of the heat exchanger:

INDUCED DRAFT MOTOR MOUNT

/ --at7

/ A

VENTHOO(FLUE/

ROLLOUT

SWITCH

IN SHIPPING COLLECTOR BLOWER BURNER MOUNTING

LOCATION BOX HOUSING RACK SCREW

C99022

Fig. 30--Blower Housing and Flue Collector Box

i. Remove the combustion blower wheel and motor assembly

according to directions in Combustion-Air Blower section

below.

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

collector box cover (see Fig. 30).

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

(Fig. 30) to the heat exchanger assembly. Inspect the heat

exchangers.

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

BLOWER

HOUSING

2 SETSCREWS

{HIDDEN)

C99085

Fig. 31--Removal of Motor and Blower Wheel

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.

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).

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

ing plate to blower housing (See Fig. 30).

3. Slide the motor and blower wheel assembly out of the blower

housing (See Fig. 31). Clean the blower wheeh If additional

cleaning is required, continue with Steps 4 and 5.

4. To remove blower, remove 2setscrews (See Fig. 31).

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% lockout system. Ignition module is located in the

control box. Module contains a self-diagnostic LED. During

servicing, refer to label diagram for LED interpretations.

If lockout occurs, unit may be reset by either momentarily

inten'upting power supply to unit, or turning selector switch to

OFF position at the thermostat.

MAIN BURNERS At the beginning of each heating season,

inspect for deterioration or blockage due to corrosion or other

causes. Observe the main burner flames and adjust if necessary.

REMOVAL OF GAS TRAIN

C99086

Fig. 32--Burner Rack Removed

i. Shut off manual gas valve.

2. Shut off power to unit.

3. Remove unit access panel (See Fig. 29).

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 basepan (See Fig. 30).

8. Slide the burner rack out of the unit (See Figs. 30 and 32).

9. Toreinstall,reversetheprocedureoutlinedabove.

CONDENSERCOIL,EVAPORATORCOIL,ANDCONDEN-

SATEDRAINPAN Inspectthecondensercoil,evaporatorcoil,

andcondensatedrainpanatleastonceeachyear.

Thecoilsareeasilycleanedwhendry;therefore,inspectandclean

thecoilseitherbeforeoraftereachcoolingseason.Removeall

obstructions,includingweedsandshrubs,thatinterferewiththe

airflowthroughthecondensercoil.

Straightenbentfinswithafincomb.If coatedwithdirtorlint,

cleanthecoilswitha vacuumcleaner,usingthesoftbrush

attachment.Becarefulnottobendthefins.If coatedwithoilor

grease,cleanthecoilswithamilddetergent-and-watersolution.

Rinsecoilswithclearwater,usingagardenhose.Becarefidnotto

splashwateronmotors,insulation,wiring,orairfilter(s).Forbest

results,spraycondensercoilfinsfrominsidetooutsidetheunit.

Onunitswithanouterandinnercondensercoil,besuretoclean

betweenthecoils.Besuretoflushalldirtanddebrisfromtheunit

base.

Inspectthedrainpanandcondensatedrainlinewheninspecting

thecoils.Cleanthedrainpanandcondensatedrainbyremovingall

foreignmatterfromthepan.Flushthepananddraintubewith

clearwater.Donotsplashwaterontheinsulation,motor,wiring,

orairfilter(s).If thedraintubeisrestricted,clearit witha

"plumberssnake"or similarprobedevice.Ensurethatthe

auxiliarydrainportabovethedraintubeisalsoclear.

CONDENSER FAN

Y:I[ "_a!liilI'12

Keep the condenser fan free from all obstructions to ensure

proper cooling operation. Never place articles on top of the

unit. Damage to unit may result.

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

cover.

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

expose the fan blade.

3. Inspect the tan blades for cracks or bends.

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

tim off the motor shaft.

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

in. away from the motor end (1/8 in. of motor shaft will be

visible).

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

when tightening.

7. Replace grille.

ELECTRICAL CONTROLS AND WIRING Inspect and check

the electrical controls and wiring annually. Be sure to turn qff'Ne

gas supply, and then the electrical po_er to the unit.

Remove access panel to locate all the electrical controls and

wiring. Check all electrical connections for tightness. Tighten all

screw connections. If any smokey 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 obsel_'e 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 occun'ed, check each

electrical component with the proper electrical instrumentation.

Refer to the unit wiring label when making these checkouts.

NOTE: Refer to the heating andor cooling sequence of operation

in this publication as an aid in determining proper control

operation.

REFRIGERANT CIRCUIT Inspect all refrigerant tubing con-

nections and the unit base for oil accumulations annually. Detect-

ing oil generally indicates a refi'igerant leak.

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

leak-test all refi'igerant tubing using an electronic leak-detector,

halide torch, or liquid-soap solution. If a refi'igerant leak is

detected, refer to Check for Refrigerant Leaks section on page 13.

If no refrigerant leaks are found and low cooling performance is

suspected, refer to Checking and Adjusting Refrigerant Charge

section on page 20.

EVAPORATOR AIRFLOW The heating and/or cooling air-

flow does not require checking unless improper performance is

suspected. If a problem exists, be sure that all supply- and

return-air g141les are open and free flvm obstructions, and that the

air filter is clean. When necessary, refer to Indoor Airflow and

Airflow Adjustments section on page 20 to check the system

airflow.

METERING DEVICE ACCURATOR_: PISTON This meter-

ing device is a fixed orifice and is contained in the brass hex-body

in the liquid line.

PRESSURE SWITCHES Pressure switches are protective de-

vices wired into control circuit (low voltage). They shut off

compressor if abnormally high or low pressures are present in the

refrigeration circuit. These pressure switches are specifically

designed to operate with Puron (R-410A) systems. R-22 pressure

switches must not be used as replacements for the Puron (R-

410A) air conditioner.

LOSS OF CHARGE/LOW-PRESSURE SWITCH (AIR CONDI-

TIONER ONLY) This switch is located on the liquid line and

protects against low suction pressures caused by such events as

loss of charge, low airflow across indoor coil, dirty filters, etc. It

opens on a pressure drop at about 20 psig. If system pressure is

above this, switch should be closed.

To check switch:

i. Turn off gas and then all power to unit.

2. Disconnect leads on switch.

3. Apply ohmmeter leads across switch. You should have con-

tinuity on a good switch.

NOTI=: Because these switches are attached to refrigeration

system under pressure, it is not advisable to remove this device for

troubleshooting unless you are reasonably certain that a problem

exists. If switch must be removed, remove and recover all system

charge so that pressure gages read 0 psi. Never open system

without breaking vacuum with dry nitrogen.

HIGH-PRESSURE SWITCH The high-pressure switch is lo-

cated in the discharge line and protects against excessive con-

denser coil pressure. It opens at 610 psig.

High pressure may be caused by a dirty condenser coil, flfiled tim

motor, or condenser air recirculation.

To check switch:

i. Turn off gas and then all power to unit.

2. Disconnect leads on switch.

3. Apply ohmmeter leads across switch. You should have con-

tinuity on a good switch.

COPELAND SCROLL COMPRESSOR (PURON REFRIGER-

ANT The compressor used in this product is specifically

designed to operate with Puron (R-410A) refrigerant and

cannot be interchanged.

Thecompressorisanelectrical(aswellasmechanical)device.

Exerciseextremecautionwhenworkingnearcompressors.Power

shouldbeshutoff,if possible,formosttroubleshootingtech-

niqnes.Refrigerantspresentadditionalsafetyhazards.

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

Wear safety glasses and gloves when handling refrigerants.

Failure to follow this warning can cause a fire, serious injury,

or death.

The scroll compressor pumps refrigerant throughout the system by

the interaction of a stationary and an orbiting scroll. The scroll

compressor has no dynamic suction or discharge valves, and it is

more tolerant of stresses caused by debris, liquid slugging, and

flooded starts. The compressor is equipped with an anti-rotational

device and an internal pressure relief port. The anti-rotational

device prevents the scroll from mining backwards and replaces the

need for a cycle protector. The pressure relief port is a safety

device, designed to protect against extreme high pressure, the

relief port has an operating range between 550 and 625 psi

differential pressure.

The Copeland scroll compressor uses Mobil 3MA POE oil.

This is the only oil allowed for oil recharge.

REFRIGERANT

r:l ["_lliiI'l/l

This system uses Puron(P_ (R-410A) refrigerant which has

higher operating pressures than R-22 and other refrigerants.

No other refi'igerant may be used in this system. Gage set,

hoses, and recovery system nmst be designed to handle

Puron. If you are unsure consult the equipment manufi_cmrer.

Failure to use Puron compatible servicing equipment or

replacement components may result in property damage or

injury.

COMPRESSOR OIL The compressor in this system uses a

polyolester (POE) oil, Mobil 3MA POE. This oil is extremely

hygroscopic, meaning it absorbs water readily. POE oils can

absorb 15 times as nmch water as other oils designed for HCFC

and CFC refrigerants. Take all necessary precautions to avoid

exposure of the oil to the atmosphere.

SERVICING SYSTEMS ON ROOFS WITH SYNTHETIC MA-

TERIALS POE (polyolester) compressor lubricants are known

to cause long term damage to some synthetic roofing materials.

Exposure, even if immediately cleaned up, may cause embrittle-

ment (leading to cracking) to occur in one year or more. When

performing any service that may risk exposure of compressor oil to

the roof, take appropriate precautions to protect roofing. Proce-

dures which risk oil leakage include, but are not limited to,

compressor replacement, repairing refi'igerant leaks, replacing

refrigerant components such as filter drier, pressure switch, me-

tering device, coil, accumulator, or reversing valve.

SYNTHETIC ROOF PRECAUTIONARY PROCEDURE:

i. Cover extended roof working area with an impermeable

polyethylene (plastic) drip cloth or tarp. Cover an approximate

i0 x 10 ft. area.

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

protect drop cloth fi'om tears caused by tools or components.

3. Place terry cloth shop towel inside unit innnediately under

component(s) to be serviced and prevent lubricant run-offs

through the louvered openings in the base pan.

4. Perform required service.

5. Remove and dispose of any oil contaminated material per

local codes.

LIQUID LINE FILTER DRIER The filter drier is specifically

designed to operate with Puron. Use only fiaetory-authorized

components. Filter drier nmst be replaced whenever the refrigerant

system is opened. When removing 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

contaminants fi'om &ier into system.

PURON (R-410A) REFRIGERANT CHARGING Refer to unit

information plate and charging chart. Some R-410A refrigerant

cylinders contain adip tube to allow liquid refrigerant to flow

from cylinder in upright position. For cylinders equipped with a

clip tube, charge Puron units with cylinder in upright position and

acommercial metering device in manitbld hose. Charge refiigerant

into suction-line.

AIR CONDITIONER WITH PURON® (R-410A)--QUICK REFERENCE GUIDE

Puron refrigerant operates at 50%-70% higher pressures than R-22. Be sure that servicing equipment and replacement components are designed

to operate with Puron.

• Puron refrigerant cylinders are rose colored.

• Puron refrigerant cylinders manufactured prior to March 1, 1999, have a clip tube that allows liquid to flow out of cylinder in upright

position. Cylinders manufactured March 1, 1999 and later DO NOT have a dip tube and MUST be positioned upside down to allow liquid

to flow.

Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.

Puron systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose.

Manilbld sets should be 750 psig high-side and 200 psig low-side with 520 psig low-side retard.

Use hoses with 750 psig selwice pressure rating.

Leak detectors should be designed to detect HFC refrigerant.

Puron, as with other HFCs, is only compatible with POE oils.

Vacuum pumps will not remove moisture from oil.

Only use factory specified liquid-line filter &iers with rated working pressures no less than 600 psig.

Do not install a suction-line filter drier in liquid-line.

POE oils absorb moisture rapidly. Do not expose oil to atmosphere.

POE oils may cause damage to certain plastics and roofing materials.

Wrap all filter driers and service valves with wet cloth when brazing.

A Puron liquid-line filter drier is required on every unit.

Do not use an R-22 TXV.

Never open system to atmosphere while it is under a vacuum.

When system must be opened for service, break vacuum with dry nitrogen and replace filter driers.

Always replace filter drier after opening system for service.

Do not vent Puron into the atmosphere.

Obsmwe all warnings, cautions, and bold text.

Do not leave Puron suction line driers in place for more than 72 hours.

SYMPTOM

Compressor and condenser fan will not start.

Compressor will not start but condenser fan

runs.

Table lO--Troubleshooting -- Cooling

CAUSE

Power failure

Fuse blown or circuit breaker tripped

Defective thermostat, contactor, transformer, con-

trol relay, high pressure, or loss of charge switch

Insufficient line vottage

Incorrect or faulty wiring

Thermostat setting too high

Faulty wiring or loose connections in compressor

circuit

Compressor motor burned out, seized, or internal

overload open

Defective run/start capacitor, ovedoad, start relay

One leg of 3-phase power dead

Three-phase scroll compressor makes exces- Scrotl compressor is rotating in the wrong direc-

sive noise, and there may be a low pressure tion

differential.

Compressor cycles (other than normally sat-

isfying thermostat).

Compressor operates continuously.

Excessive head pressure.

Head pressure too low.

Excessive suction pressure.

Suction pressure too low.

Refrigerant overcharge or undercharge

Defective compressor

Insufficient line voltage

Blocked condenser

Defective run/start capacitor, overload or start

relay

Defective thermostat

Faulty condenser-fan motor or capacitor

Restriction in refrigerant system

Dirty air filter

Unit undersized for toad

Thermostat set too Iow

Low refrigerant charge

Leaking valves in compressor

Air in system

Condenser coit dirty or restricted

Dirty air filter

Dirty condenser coil

Refrigerant overcharged

Air in system

Condenser air restricted or air short-cycling

Low refrigerant charge

Compressor valves leaking

Restriction in liquid tube

High heat load

Compressor valves leaking

Refrigerant overcharged

Dirty air filter

Low refrigerant charge

Metering device or low side restricted

Insufficient evaporator airflow

Temperature too tow in conditioned area

Outdoor ambient below 40 F

Field-installed filter-drier restricted

REMEDY

Call power company.

Replace fuse or reset circuit breaker.

Replace component

Determine cause and correct

Check wiring diagram and rewire correctly.

Lower thermostat setting below room tempera-

ture

Check wiring and repair or repIace.

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 Ieads to the unit. Shut down unit

to allow pressures to equalize

Recover refrigerant, evacuate system, and re-

charge 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 fitter.

Decrease load or increase unit size

Reset thermostat.

Locate leak, repair, and recharge

Replace compressor

Recover refrigerant, evacuate system, and re-

charge.

Ctean coit or remove restriction

Replace fitter.

Clean coil

Recover excess refrigerant.

Recover refrigerant, evacuate system, and re-

charge.

Determine cause and correct

Check for leaks, repair and recharge

Replace compressor

Remove restriction

Check for source and eliminate

RepIace compressor

Recover excess refrigerant.

Replace filter.

Check for leaks, repair and recharge

Remove source of restriction.

Increase air quantity. Check filter -- replace if

necessary.

Reset thermostat.

Install low-ambient kit.

Replace

Table 11--Troubleshooting -- Heating

CAUSE

Water in gas line

No power to furnace

Miswired or loose connections

Burned-out heat anticipator in thermostat

Broken thermostat wire

Misaligned spark electrodes

SYMPTOM

Burners will not ignite.

Inadequate heating

Poor flame, characteristics

No gas at main burners

Dirty air flIter

Gas input to furnace too tow

Unit undersized for application

Restricted airflow

Blower speed too Iow

Limit switch cycles main burners

Incomplete combustion results in: Aldehyde

odors, carbon monoxide, sooting flame, floating

flame

REMEDY

Drain Install drip leg

Check power suppty fuses, wiring, or circuit

breaker.

Check alt wiring and wirenut connections

Replace thermostat.

Rue continuity check Replace wire if necessary.

Check flame ignition and sense electrode posi-

tioning. 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 gas to dissipate before at-

tempting to light unit

2. Check gas valve

Clean or replace fitter as necessary

check gas pressure at manifold Match with that

on unit nameplate

Replace with proper unit or add additional unit

Clean or replace filter Remove any restriction.

Use faster speed tap if avaiIabie, or install alter-

nate motor

Check rotation of blower, thermostat heat antici-

pator settings, and temperature rise of unit. Ad-

just as necessary.

1 Tighten all screws around burner compart-

ments.

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 Code

SYMPTOM CAUSE

Hardware failure.

(LED OFF) Loss of power to control modute (tGC)

Fan ON/OFF delay modified. (LED/FLASH)

High limit switch opens during heat exchanger

warm-up period before fan-on deIay expires

Limit switch opens within three minutes after

blower-off delay timing in Heating mode

Limit switch fault. (LED 2flashes) High temperature limit switch is open

Flame sense fault. (LED 3flashes) The IGC sensed flame that should not be present

4 consecutive limit switch faults. (LED 4

flashes) Inadequate airflow to unit

ignition lockout, (LED 5 flashes) Unit unsuccessfully attempted ignition for 15 min-

utes

IGC does not sense that induced-draft motor is

Induce-draft motor fault. (LED 6 flashes) operating

Rollout switch fault. (LED 7 flashes) RolIout switch has opened

Internal control fault. (LED 8 flashes) Microprocessor has sensed an error in the soft-

ware or hardware

Internal software fault. (LED 9flashes) Microprocessor has sensed an error in it's redun-

dant software comparison

REMEDY

Check 5 amp fuse on IGC, power to unit, 24-v

circuit breaker, and transformer. Units without a

24-v circuit breaker have an internal overload in

the 24-v transformer ft the overload trips, allow

20 minutes for automatic reset.

Ensure unit is fired on rate and temperature rise

is correct.

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, replace control

board.

Check operation of indoor (evaporator) fan motor

and that supply-air temperature rise agrees with

range on unit nameplate information.

Check ignitor and flame sensor electrode spac-

ing, gaps, etc Ensure that flame sensor and igni-

tion 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 op-

eration, ensure that induced-draft btower wheel is

propedy secured to motor shaft Reset unit at

unit disconnect

if error code is not cleared by resetting unit

power, replace the IGC.

if error code is not cteared by resetting unit

power, reptace the IGC.

r.,_[_,];3

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 sensitive to static

electricity and may be damaged if the necessary precautions

are not taken.

IMPORTANT: Refer to Heating Troubleshooting (:hart

for additional troubleshooting analysis.

LEGEND

IGC Integrated Gas Unit Controller

LED Light-Emitting Diode

I. PRELIMINARY INFORMATION

MODEL NO.:

DATE:

START-UP CHECKLIST

(Remove and Store in Job File)

SERIAL NO.:

TECHNICIAN:

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 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 LE';IT INSTALLATION IS LEVEL

( ) CHECK FAN" WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS

IlL START-UP

ELECTRICAL

SUPPLY VOLTAGE L1-L2 L2-L3

COMPRESSOR AMPS LI L2

INDOOR (EVAPORATOR) FAN AMPS

TEMPERAT[ RES

OUTDOOR (CONDENSER) AIR TEMPERATURE

RETURN-AIR TEMPERATURE DB

COOLING SUPPLY AIR DB

GAS HEAT SUPPLY AIR

PRESSURES

GAS INLET PRESSURE

GAS MANIFOLD PRESSURE

REFRIGERANT SUCTION

REFRIGERANT DISCHARGE

L3-L1

IN. WG

PSIG SUCTION LINE TEMP*

PSIG DISCHARGE TEMPt

( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS

( ) VERIFY THAT THREE-PHASE SCROLL COMPRESSOR IS ROTATING IN CORRECT DIRECTION.

* Measured at suction inletto compressor

1 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.

Book_ 1_ 4 PC 101 Catalog No 534-755 Printed in U.S.A. Form 48GP-1SI Pg 32 3-00 Replaces: New

Tab 16al 8a

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

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