Carrier 48GS018040300 User Manual CENTRAL PACKAGE Manuals And Guides L0410010
CARRIER Package Units(both units combined) Manual L0410010 CARRIER Package Units(both units combined) Owner's Manual, CARRIER Package Units(both units combined) installation guides
User Manual: Carrier 48GS018040300 48GS018040300 CARRIER CENTRAL PACKAGE - Manuals and Guides View the owners manual for your CARRIER CENTRAL PACKAGE #48GS018040300. Home:Heating & Cooling Parts:Carrier Parts:Carrier CENTRAL PACKAGE Manual
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48GS, 48GX Packaged Gas Heating/ Electric Cooling Units Single HFATUNG & COOLING %isdt_ v_v_carrier.corn Installation, Start-Up, and Operating 48GS Sizes 018-060, 48GX Sizes 024-060 NOTE: Read installation the entire instruction before starting OF CONTENTS MAIN 1 CTION RECEIVING AND INSTALLATION .......................................... CHECK EQUIPMENT ............................................................. IDENTIFY EJNIT ................................................................ INSPECT SHIPMENT ........................................................ INSTALLATION ................................................................ PROVIDE SWIT(H BURNER C ONSIDERATI(INS INTRODE COMBUSTION-AIR the LIMIT TABLE SAFETY manual IGNITION BE RNERS CONDENSER 29 ELECTRICAL CONTROLS 30 ............................................... 30 2 2 GAS INPUT ...................................................................... EVAPORATOR AIRFLOW ............................................. 30 30 2 METERING LIQUID 2 TROE BLESHOOTING CLEARAN( CONNECT FLUE INSTALL GAS INSTALL DUCT ...................................... .......................................................... TIONS UNITS 8 FOR DO\}_TLOW FOR SETTING PR()TECTION HEATING AND CHE(K HEATING CONTROL CHECK GAS CHECK INPET 13 .................................... 13 AND 15 ............................... ADJUSTMENTS 15 ...... 16 ....................................... 16 !6 16 .............................................. TEMPERATURE construction. 15 ...................................................... FLAME under 13 INPUT ........................................................ BURNER AIRFLOW MAKE or structures Also, ._ 13 P .......................................................................... START°UP THESE 12 OPERATION ................................... LEAKS of buildings READ (OMPLETELY. 10 12 ................................................................................... FOR REFRIGERANT heating AND (VERTI- ....................... CONNECTIONS Before the installatiom CAREFELLY 10 ................................ 208°V TO INSTALLER temporary 8 ...................................... CONNECTIONS VOLTAGE GAS 30 make sure the User's Manual and Replacement Guide are left with the unit after installation. The furnace is NOT to be used for ANTICIPATOR ADJUST 30 KLIST ............................................................ 7 DRAIN CONTROL (HECK 30 INSTRU(TIONS PROCEDURES START-UP .............................................. ............................................................... NOTE SPECIAL PRE-START-E ............. 30 7 ( ONNE( TRAN SFORMER STRAINER DEVICE 6 CAL) DISCHARGE .......................................................... INSTALL ELECTRICAL ( ONNE(TIONS ......................... HEAT CHEf A(UTROL .................. ......................................................... HOOD HIGH-V()LTAGE LINE WIRING 5 PIPING ........................................................... (ONFIGURING START-UP CIRCUIT AND 29 ES ...................................................... ENIT CONDENSATE INSTALL 5 PAN .......................................... DEVICE 2 PROVIDE DRAIN REFRIGERANT ................................................................... RIG AND PLA(E 28 AND 2 2 ....................................................................... ........................................ (OIL, FAN .......................................................... (LRB DUCTW()RK EVAPORATOR CONDENSER MOUNT FABRICATE 28 ............................................................. CONDENSATE SLAB FIELD 28 2 ROOF ............................................................ 27 2 SUPPORT. MOL_T ....................................... ........................................................ COIL, UNIT GROL_D ................................................... BLOWER ................................................................ 20 RISE ....................... 20 HEATING SEQUEN(E OF OPERATION ..................... LIMIT SWITCHES ........................................................... 20 20 AE XILIARY LIMIT SWITCH (ROLLOE T) .................. 21 START°E P COOLING AND MAKE ADJUSTMENTS ...... 21 CHECKING COOLING CONTROL < HE(KING AND ADJUSTING CHARGE ....... 2! AIRFLOW AND AIRFLOW SEQE ENCE MAINTENANCE AIR FILTER OF OPERATION 22 ..................... SAFETY 22 ......................................................................... 22 Installation ...................................................................... 25 hazardous 25 27 trained EVAPORATOR BLOWER AND MOT()R ..................... FLEE GAS PASSAGEWAYS ......................................... Manufacturer Fig. 1--Unit 48GS and 48GX (Low NO× Model Available) 21 ADJUST- .............................................................................. COOLING A99338 REFRIGERANT ........................................................................... INDOOR MENTS OPERATION reserves PC 101 the right to discontinue, Catalog No 534-80128 or change and servicing Form of air-conditioning due to system pressure and qualified air-conditioning at any time, specifications Printed in U.S.A CONSIDERATIONS or designs 48GS.GX-6SI personnel equipment and ebctrical should install, can be components repair, Only or service equipment. without notice Pg 1 and without 11-02 incurring oNigations. Replaces: 48GS.GX-5SI Untrained personnel can perfbrm basic maintenance functions of cleaning coils and filters. All other operations should be perfbrmed by tlained service personnel When working on air-conditioning equipmenL observe attached precautions to the unit, Follow and other safety all safe V codes. quenching cloth available nancQ installation, which can Consuh supplier for information when aheration, monoxide result a qualified service, in personal installer, for shipping If unit appears have or assistance. or unit agency, The qualified and amperage agree with power damage it examined claim directly for any damage all items against distributor if any item is missing. shipping installer switch could and install cause Recognize When lockout serious safety Understand the signal shock the unit. the tiffing in the composite symbolz_ or manuals, a be alert to injory. DANGER, WARNING, CAUTION, and NOTE. These words are used with the safcV-alert symboh DANGER identifies the most serious hazards which will result in serious injury or death. WARNING result in serious unsafe practices product tions a hazard will damage. result NOTE is used in enhanced to highlight installation, length bracket existing these cover national minimuna standards instructions and safety exceed certain codes. local or and confbrm In some codes and to assembly combination Category- ibr outdoor installation unit sizes have return and downflow units units designed (See Fig. 2 and 3 for unit dimensions). and discharge configurations, duct openings a rooftop, a cement openings ibr both horizontal and are ii_ctory covered. All shipped with all Units may be installed either on slab, or directly on the ground if local codes (See Fig. 4 for roof curb dimensions). Models with an N in the fifth position dedicated Low NOxunits These models (NOx) emissions shipped from Quality meet requirements the factory Management 1--CHECK IDENTIFY The unit designed maximum where AND nmnber are installations. oxides of 40 nanograms and must Districts of the model fbr California the California RECEBVING Step cooling be installed of nitrogen joule or less as in California Air a Low NO× rule exists. identification plate. Check and serial nunfber this information are stamped against the base of the into the rigging holds buckle around bottom (ratchet type) perimeter tension buckle as shown buckle unit taut. to lock strap in tension squeeze the tension must be secure safkty latch, Ilk lever, buckle until in the rigging 6. Attach field=supplied 7. Attach clevis bracket buckle of in Fig 7A. To release and pull webbing it is taut Lifting brackets holds shipping or hook brackets. lifting brackets 8. Position DO NOT point directly straps. Lower 2--PROVIDE ROOF CLRB Install accessory to the clevis or hook attach the safkty straps over the unit's When unit is directly 2 safety strips, to at the to the UNiT the onto the roof curb. SUPPORT roof curb in accordance roofing, center of gravity. over the roof curb, remove the equipment with instructions with curb (See Fig. 4 for roof curb dimensions). cant strength (See Fig. 7B). liking 9. Lift unit. of sufficient (See Fig. 7B). the 2 safkty straps directly 4 rigging and flashing Install Ductwork must shipped insulation, be attached to curb IMPORTANT: The gasketing for a watertight seal. Install roof curb. Improperly of the unit to the roof curb is critical gasketing applied material gasketing supplied with the can also result in air leaks and poor unit perfbrmance. Cm:b should be level to within drain to Nnction instructions SLAB properly. for additional 1/4 in. This is necessa_' Refkr to accessory information for unit roof curb installation as required. MOUNT 4 in. thick with 2 in. above EQUIPMENT number around tension Place the unit on a solid, INSTALLATION UNIT model use a not twist throngh Step Fig. 1) are fu!ly self_containe& I gas heating/electric downflow permit (See available, through Pull strapping 5. Tighten instances, INTRODUCTION and 48GX packages unit t_-om damage. c strapping, outward ordinances, especially those that may not have kept up with changing residential construction practices. We require these instructions as a minimum ibr a saf_ installation. The 48GS the sugges- reliability, requirements skid is not b. Feed strapping hole in the liking instructions in original to protect strapping of tension d. Snap lever down operation. These notify pan. Open lever which could inju V or death. CAUTION is used to identii_, which would result in minor personal injury or and property which signifies Manu- in transit Immediately 3. Place each of the 4 metal lifting brackets power or explosion This is the safety-alert words incurred all parts If the wood bar of sufficient 4. Thread liking bracket unit as follows: in instructions removal on mail main or death. infbrmation _br personal operations mrn off unit tag. Elecn'ical inju_ you see this symbol the potential Then before company 1. Remove unit from shipping carton Leave top shipping skid on the unit as a spreader bar to prevent the rigging straps from kits or accessories or maintenance pallet. INSTALLATION or gas damaging to unit. list leave unit. Be sure the strap does service inspectors to transportation nearest 2. Position peribrming listed to unit is still on shipping Check this product mrn off gas supply provided or is torn loose t'rom its anchorage, by transportation papers is not responsible spreader Beibre requirements supply while unit to be damaged To prevent loss or damage, until installation. fire, or injury service plate SHIPMENT Forward mainte- poisoning, must use only factory-authorized modifying Use fire extinguisher Inspect facturer adjustment, damage. or agency Have operations. or use can cause carbon an explosion INSPECT that may apply. and work gloves. operations. on unit rating tags, and labels precautions Wear safety glasses for unbrazing ibr all brazing Improper in the literature, and job data. Verit}' unit voltage level concrete grade. compressor end of the unit (to allow and should extend on unit (See Fig. 6). Do papers required condensate 2 in. on the three not by local codes. secure the pad that is a minimum The slab should unit remaining to the of be flush on the &ain installation) sides slab of the unit e:vcept when ZS4 86 I (t CD,[ [_H [ GJ I "" [_9 K,] i[ _ j _ 5q } _ 5 : [2, _o] _ [o oo] i _1, , : _C,_494_ 0_i t:¸ OPU 6 t' i N 249 550 5 IN _;i ; i,, s1 ?49 6 }9 8_] REAR ViEW REQUIRED CLEARANCE TO COMBUSTIBLE MATL REQUIRED CLEARANCE TOP OF UNIT ................................................................................... DUCT SIDE OF UNIT ......................................................................... SIDE OPPOSITE DUCTS ................................................................ BOTTOM OF UNIT ............................................................................. ELECTRIC HEAT PANEL ................................................................. INCHES 14.00 200 14.00 050 3600 [mm] [355 6] [508] [355 8] [127] [914 4] FOR OPERATION AND SERVICING INCHES [mm] 36.00 [914 0] 3600 [914 0] EVAR COIL ACCESS SIDE ............................................................ POWER ENTRY SIDE .................................................................... (EXCEPT FOR NEC REQUIREMENTS) UNIT TOP ....................................................................................... SIDE OPPOSITE DUCTS .............................................................. DUCT PANEL ................................................................................. 48.00 [1219 2] 36.00 [914 0] 1200 [304 8] * NEC. REQUIRED CLEARANCES, INCHES BETWEEN UNITS, POWER ENTRY SIDE .................................... 42.00 UNIT AND UNGROUNDED SURFACES. POWER ENTRY SIDE 3800 UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES POWER ENTRY SIDE ......................... 4200 [mm] [1086 8] [914 0] *MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 1200 [304 8] FROM WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE [1066 8] LEGEND CO Center of OravRy COND Condensor EVAP Evap@ator NEC National E[ectnca[Code REQ'D Reqused NOTE: Dimensions are in in [mm] COOO55 UNIT ELECTRICAL 48GS018040 48GS024040/080 48GS030040/080 CHARACTERISTICS UNIT WEIGHT 208/230-1-60 Ib 249.0 208/230-1-60 208/230-1-60, 208/230-3-60 T CENTER UNIT HEIGHT IN. ([VIM) ,,A,_ X kg 113.2 35.02 (889.5) 20.0 (508.0) 280.0 127.3 35.02 (889.5) 22.5 280.0 127.3 35.02 (889.5) 21.5 OF GRAVITY IN.(MM) Y 140 (3556) (571.5) 130 (3302) (546.1) 1375 (349.3) Z 15.0(3810) 15.0(3810) 150 (3810) 48GS038060/090 208/230-1-60, 208/230-3-60, 460-3-60 320.0 145.1 37.02 (940.3) 22.5 (571.5) 140 (355.6) 130 (3302) 48GS042060/090 208/230-1-60, 208/230-3-60, 460-3-60 355.0 161.4 35.02 (889.5) 21.5 (546.1) 135 (342.9) 130 (3302) 290.0 131.5 37.02 (940.3) 22.0 (558.8) 145 (3683) 16.0 (4064) 313.0 142.0 39.02 (991.1) 22.0 (558.8) 153 (3874) 176 (4470) 321.0 145.6 35.02 (889.5) 22.0 (558.8) 153 (387.4) 165 (4191) 48GX624040/060 48GX036040/060 48GX036066/090 208/230-1-60 208/230-1-60, 208/230-1-60, 208/230-3-60 208/230-3-60,460-3-60 Fig. 2--48GS018-042 and 48GX024-036 Unit Dimensions _3427 _ [!3 49] 3558 {1411] 3558 [14 Oi] [33£1 SUPPLY 70 [2 4 77] i [16 4066 [1601] O!] 402 o [15 83] i E_AP COIL [1177 {a C01L 631 i 88 3 [3 46] [13831 [13 62] TOP VIEW [13831 REAR VIEW REQUIRED CLEARANCE TO COMBUSTIBLE MATE REQUIRED INCHES 14,00 2.00 14,00 0.50 36,00 TOP OF UNIT ................................................................................... DUCT SIDE OF UNIT ......................................................................... SIDE OPPOSITE DUCTS ................................................................ BOTTOM OF UNIT ............................................................................. FLUE PANEL .................................................................................... [mini [355 6] [50.8] [355 6] [12.7] [914 4] CLEARANCE FOR OPERATION AND SERVICING EVAR COIL ACCESS SIDE ............................................................ POWER ENTRY SIDE .................................................................... INCHES 3600 3600 [mm] [914 0] [914 0] (EXCEPT FOR NEC REQUIREMENTS) UNIT TOP ....................................................................................... SIDE OPPOSITE DUCTS .............................................................. 4800 3600 [1219.2] [914 0] DUCT 1200 [304 PANEL ................................................................................. 8] NEC. REQUIRED CLEARANCES, INCHES BETWEEN UNITS, POWER ENTRY SIDE .................................... 4200 UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE 3600 UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES, POWER ENTRY SIDE ......................... 4200 *MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 1200 [304 8] FROM WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE. [mm] [1066.6] [914.0] [1066 8] LEGEND CG - Center of Gravity COND - Condensor EVAP- Evaporator NEC - National Electrical Code REQ'D - Required k_- 1939 10906 [42 943 47 _'< _ OO] , ....... " NOTE:Dimensionsare in in, [ram] 4 ,OO/ i? i " \ MPRESSOR, BLOtlER 6AS S{CTION & Et CTR CAt £;¢[SS PANEl ........... ' .............. [.8 1 i [ 68] 329 O L[4iR) 12 i [O 881 OlA I@lE CONTROLEN/RY ....................... A_ L._ !15 [4 54] V I i o FLUE FLOOD fY _4] 528 7 [O 50] N P T GAS ENTRY 5 O It231 [44 22] LEFT SIDEVIEW UNiT FRONTVIEW ELECTRICAL CHARACTERISTICS UNIT WEIGNT RIGHTSIDE VIEW 000056 CENTER OF GRAVITY IN.(MM} UNIT HEIGHT IN. (MM) "A" X Y Z 16 (406.4) 17 (432 0) Ib kg 48G8048090/115/130 208-230/1/60, 208/230-3-60, 460-%60 415 1886 38.98 (990.2) 48GS0600901115/130 208/230-1-60, 208/230-%60, 460-3%0 450 2045 38.98 (990.2) 16 (406.4) 17 (4320) 48GX042060/090 208/230-1-60, 208/230-3-60, 460-3-60 382 1733 38.98 (990.2) 23.0 (584.2) 163 (412.8) 166 (4216) 48GX048090/115/190 208/230-1-60, 208/230-%60, 460-3-60 421 1910 (990.2) 21.5 (546.1) 166 (422.1) 180 (4572) 48GX060090f115/130 208/230-1-60, 208/230-%60, 460-3-60 468 2123 (1091.1) 23.5 (596.9) 163 (412.8) 176 (4470) Fig. 3--48G8048-060 38.98 42.98 and 48GX042-060 22 (5585) 22 (5585) Unit Dimensions * RoofCurb for Small Cabinet Roof Note A: When uNt mounting screw is used, retah3er bracket must also be used. Curb for Large Cabinet Note A: When unit mounting screw is used, retainer bracket must also be used. R/A S/A /\ -'-_- Gasket around_ duct \ \ insulated deck pan Suppolt \ Gasket around outer edge \ \, Long SL pport iBXC} C00076 UNiT S_ZE 48GS018o042 ODS CATALOG 48GX024-036 48GS048o060 48GX042-060 NUMBER A IN. {NM) B IN.(MM) C RN. (MM) D IN. (t_M) 2G3/4 (730) CPRFCURB006A00 8 (203) 11(279) 161/2 (419) CPRFCURB007A00 14 (356) 11(279) 161/2 (419) 28-3/4 (730) CPRFCURB008A00 8 (203) 16 3/16 (411) 17 3/8 (441) 40-1/4 (1022) CPRFCURB009A00 14 (356) 16 3/16 (411) 17 3/8 (441) 40-1/4 (1022) NOTES: 1. Roof curb must be set up for unit beh_ginstalled 2. 3. 4. 5. 6. 7. 8. 9. Seal strip must be applied, as required, to unit being installed. Dimensions in ( ) are in millimeters Roof curb is made of 16-gage steel. Table lists only the dimensions, per part number, that have changed Attach ductwork to curb (flanges of duct rest on curb) InsuIated panels: 1-in. thick fiberglass 1 Ib density. Dimensions are in inches When unit mounting screw is used (see Note A), a retainer bracket must be used as well This bracket must also be used when required by code for hurricane seismic conditions. This bracket is available through Micrometl. Fig. 4--Roof --> GROL ND MOL_T ground if local prepared Curb Dimensions applications, The unit may be installed codes with gravel either permit. on a slab or placed Place _br condensate the unit directly on level on the ground discharge. openings unit 3--FIELD Secure discharge all ducts uriits FABRICATI= to roof DUCTWORK curb and building Do t_nt connect duct_oHc tlansmission ductwork should strecture on vertical Ducts passing and covered ductwork, flanges joints, and/or barrier. d_e horizontal is recommended noise to stl_acture. Insulate and roof openings with applicable an unconditioned a vapor on duct connector to the flanges. in accordance through with of vibration be secured and mastic with of flexible to prevent flashing to z_nit. For horizontal is provided Installation proof all external Step or space All and weather° with counter codes must be insulated Y 4 x 3 C00070 48GS CORNER TOTAL 48G× # 018 024 030 036 1 47.3 53.2 53.2 59.7 2 44.8 50.4 50.4 56.5 639 3 77.2 86.8 86.8 97.3 1101 4 79.7 89.6 89.6 106.5 1136 WEIGHT 249 280 280 320 Fig. 8--48GS 042 675 355 048 060 024 030 036 042 048 060 789 85.5 55.1 595 61.0 72.6 800 88.9 747 81.0 52.2 563 57.8 68.8 758 84.2 128.7 1395 89.9 970 99.5 1184 130.5 145.1 132.8 1440 92.8 1002 102.7 1222 134.7 149.8 415 450 290 313 382 421 468 321 and 48GX Unit Corner We{ghts DIJCTS PLAOE SEAL STRIP MI _ST BE _N PLACE BEFORE PLACING _JN_T ON RO©F CURB BASEPAN BEFORE 2 F_ SLOT (BELOW RIGGtNG HOLDS} RIGGING (50.8mn C99015 SRZE EVAR COIL tb COND. COIL J Mounting WE,GNT [ A kg in. [ B mm in. mm UNIT 48G8 C99014 Fig. 6--Slab MAX,MUM Details HANDHOLD / 0t8 271 123.2 20.0 508.0 14.0 355.6 024 302 137.3 22.5 571.5 13.0 330.2 030 302 137.8 21.5 546.1 13.75 349.3 036 342 155.1 22.5 571.5 14.0 355.6 042 377 171.4 21.5 546.1 13.5 342.9 048 437 198.6 22.0 558.5 17.0 432.0 050 472 214.5 22.0 558.5 17.0 432.0 UNIT 48GX C99067 Fig. 7A--Threading 024 312 142 22.0 558.5 14.50 368.3 030 335 152 22.0 558.5 15.30 388.6 036 343 156 22.0 558.5 15.30 388.6 042 404 183 23.0 584.2 16.3 414.0 048 443 201 21.5 546.1 16.3 414.0 050 490 222 23.5 596.9 16.3 414.3 BoR for RiggBng If a plemma return is used o,1 a vertical unit, the return should be ducted through the roof'deck to comply with applicable i_re codex A n_inimum clearance is not required around ductwork_ Cabinet return=air static shall not exceed -25 in. wg. Fig. 7B--Suggested Step 4--PROVIDE Rigging CLEARANCES The required minimum operating and service clearances are shm_n in Fig 2 and 3 Adequate combustion, ventilation and condmlser air must be provided in accordance with section 53, Air fbr Table 1--Physical UNIT SBZE 48GS NOMINAL Data--UnR 48GS 024040 024060 030040 030080 036060 038080 042060 1½ 2 2 2½ 2½ 3 3 3½ 3½ 249 280 280 280 280 320 320 355 355 018040 CAPACBTY (ton) OPERATING WEIGHT COMPRESSORS Quantity (_b.) 042090 Reciprocating 1 REFRmGERANT (R-22) Quantity (_b.) REFRIGERANT METERING Orifice AcutroF M Device DEVICE .034 ID (in.) I .O34 .034 .034 .034 .032 .032 .034 .034 1...17 9.1 1._17 9.1 1_17 9.1 1...17 9.1 1...17 10.9 1._17 10.9 1_.17 9.1 1._17 9.1 2400 22 2400 22 2400 22 2400 22 3000 22 3000 22 3000 22 3000 22 1/8 (825) 1/8 (825) 1/8 (825) ¼ (1100) ¼ (1100) ¼(1100) 2...I5 3.1 2...15 3.1 2...15 3.1 3...15 3.1 3...15 3.1 4...15 3.1 4...15 3.1 800 10x10 1/4 (I075) 1000 10x10 1/4 (1075) 1000 10 x 10 lg (1075) 1200 11 x 10 1/2 (I075) 1200 11x10 1/2 (1075) 1400 11x10 3/4 (1075) 1400 11x10 3/4 (1075) 2...45 2...50 2...38 2...46 2...45 2...50 2...38 2...46 2...38 2...46 3...38 3...46 2...38 2...46 3...38 3...46 20x20 20X20 20 X 20 20 X 24 u CONDENSER CORL Rows...Finslin. Face Area (sq ft) CONDENSER FAN NominN Cfm Diameter (in.) Motor Hp (Rpm) EVAPORATOR COBL Rows...Fins/in. 1 [ n u 2000 1 1/8 (825) 1 1/8 (825) ¼ (1100) u 2...15 " __ .J Face Area (sq ft) EVAPORATOR BLOWER I ', 2...15 3.1 u 600 I 8OO 10x10 I 10 x 10 1/4 (87511 1/4 (1075) Nomina_ Airflow (Cfm) Size ({n.) Notor BP (Rpm} FURNACE SECTION* u Burner Orifice No. (Qty...Drill Natural Gas Size) Burner Orifice No. (Qty...Drilt Propane Gas Size) RETURN-ABR FILTERS Throwaway 17 6 I 2...45 2...50 I I u (in.)? 20x20 I 20x20 20X24 20x24 20x24 * Based on altitude of 0 to 2000 ft ? Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 fi/minute for throwaway type or 450 if/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 in. wg (ombustion and Ventilation, (American National of the National Standards provisions of local building 7.3, or 7.4 or CaniCGA. Installation Codes condenser provisions airflow. condenser £m pulls air through discharges it through the top cover does not recirculate to the condenser either a comer clearance or under under overhang) is 48-im extension of a partial Do not place or roof will carpeting, damage or flood tile, or other 5--RIG AND (such condenser coil as a nomml ice, or snow riggi@ BRN!_ O" C) fbr power THERMOSTAT YELLYL_ Q) codes applicable @ VV_TLV_)_ NEC diagram. electrical phase with electrical 1 and on unit rating internal CONTROLBOX all electrical connecCSA standard C22.1 disconnect WIRE 3 Be sure that high-voltage 4 Do not damage Part conductor field-supplied electrical NOT USE ALUMINUM to 'O" and (?ode in damage in accordance edition) RefBr to unit wiring voltage POWER _:_ could result could result governing such wiring In Canada, tions must be in accordance with Use high high- injm?- or death. the unit being installed: 1 Make all electrical connections 2 the (SEE UNITWIRING_ GND codes when making to complete to the unit. mm Failure and (See Fig. 2 and 3 fbr acceptable (National Electrical Association) on the power electrical and local Canadian to adhere of connections. NEC edition) are used label and Fig. 11 fbr refhrence voltage for with (latest Standards codes. in serious conduit See unit wiring injury may consist ground box may be mounted location). unbroken of serious entIy points switch inlet hole when the standard phase and Control=Voltage units: 1. Run the high-voltage control box. etc. On 2 percenL of improper Connections (LI_ L2) lead to chassis and ground ground leads into the 2. Connect ground connection. 3. Connect L! to pressure tug connection 11 of the compressor 4. Connect L2 to pressure contactor. tug connection 23 of the compressor contactor, HIGH-VOLTAGE The unit supplied, sight must CONNECTIONS have a separate waterproof, fi'om, the unit disconnect Refer Nseicircuit breaker wire (See Tables sizing electrical switch service mounted to the unit rating size and minimum circuit 4 and 5 for electrical with a field- at, or within plate fbr maximum amps (ampacity) Three-phase for units: 1. Run the high-voltage control box. data). 12 (L!, L2, L3) and ground leads into the EXAMPLE: Suppty voltage is 460-3-60. A B C AB = 452 v LEGEND AC = 455 v FLA -- Full Load Amps LRA -- Locked Rotor Amps MCA -- Minimum Circuit Amps MOCP -- Maximum Overcurrent Protection RLA -- Rated Load Amps CKT BKR -- Circuit Breaker Average Voltage = 452 + 464 + 455 3 BC = 464 v _ 1371 3 = 457 NOTES: Determine maximum deviation from average 'voltage. (AB) 457 452=5v (BC) 464 457=7v (AC) 457 455=2v Maximum deviation is 7 v. 1. tn compliance with NEC (National Electrical Code) requirements for muttimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be Power Supply fuse. Canadian units may be fuse or circuit breaker. 2. Minimum wire size is based on 60 C copper wire. If other than 60 C wire is used, or if length exceeds wire length in table, determine size from NEC. 3. Unbalanced 3-Phase Supply 'Voltage Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine the percentage of 'voltage imbalance. Determine percent of voltage imbalance. 7 % Voltage Imbalance = 100 x -457 : 1.53% This amount of phase imbalance maximum allowable 2%. % Voltage imbalance = 100 x max voltage deviation from average voltage average voltage is satisfactory as it is below the IMPORTANT: tf the supply 'voltage phase imbalance is more than 2%, contact your local electric utility company immediately. c99024 Table4_Legend 2. Connect ground lead to chassis ground connection 3. Locate the black and yellow of the contactor wires connected 4. Connect wire field compressor 5. (onnect L1 to black SPE(IAL on connection wire on connection wire L3 to Blue wire PRO(EDURES FOR flora compressor 208-V OPERATION changes, off first. Thet_ switch make off the power Do not VOLTAGE TIONS Unit control may result. no. 18 American Wire Gage (AWG) color-coded, insulated (35 C minimum) wires between the thermostat to make the control voltage connections and the unit. If the thermostat is located more the unit than voltage 100 ft flora wires), minimmn) no. (as measured 16 AWG knockout access hole located panel (See in the flue panel Fig. 2 and grommet fi'om the installer's packet grommet in the knockout opening. wire through Rtm the low-voltage leads five 18-gage connection brown, (35 C adjacent to the (included Remove the rubber with unit) and install Provide fiom the thermostat, splice wires leaving leads can be identified and white to be routed 3). a drip loop before panel. hole, and into unit tow-voltage Locate fl_e control insulated ( onnection Remove running along color-coded, wires. Standard control use the inlet box. control box. These low-voltage by the colors red, green, yellow, (See Fig. 1 i). Ensure into the low-voltage through the leads are long enough splice box (located below Fig 11) all of unit. SETTING heat anticipator required setting. NOT_:: For thermostat selection required adjustment setting. must be properly purposes, Failure will result right 13 a greater TRANSFORMER PROTE( The is tra_,_former withstand thermostat thermostat slightly to provide installation. st_pply to the shock can cause serious use any type of power-stealing problems Use CONNE( of control Secure adjusted to a 30-sec. of in improper degree a proper operation, heat discom- space, and inefficient setting may be changed of comfort for a particular TION fl_e energy-limiting overload use 0.18 amp for fl-le to make fort to the occupants of the conditioned energy utilization; however, the required sure the gas supply or death. CONTROL ANTICIPATOR anticipator N any wiring hole in bottom (See so that _hey do not interI:_re with operation approximate iiiiiiiiiii_, unit and install tockot_t tag. Electrical injury connections ensure proper heating performance. Set the heat anticipator, using an ammeter between the W and R terminals to determine the exact 13 of the iii_ is switched leads through tow-voltage HEAT 11 of the contactor Be_bre making box). Route box and make The room field wire L2 to yellow field side of control cut wires, contactor compressor 6. (onnect to the lines side or shorted type. secondary It is condition. set to Tab{e 5--Electrical UNIT SBZE 48GX O24 030 036 O42 O48 OGO VOLTAGE RANGE V-PN-NZ Data--Unit COMPRESSOR 48GX OUTDOOR FAN MOTOR INDOOR FAN MOTOR POWER SUPPLY Min Max RLA LRA FLA FLA MCA Max Fuse or Ckt Bkr 208/230-1-80 187 253 10.9 54.0 0.9 2.0 16.5 25 208/230-1-60 187 253 13.5 73.0 0.8 2.1 19.8 30 208/230-3-80 187 253 9.0 63.0 0.8 2.1 14.2 20 208/230-1-60 187 253 16.7 97.0 0.8 3.6 25.3 40 208/230-3-80 187 253 11.2 75.0 0.8 3.6 18.4 25 460-3-60 414 506 5.4 37.5 0.9 1.9 9.6 15 208/230-1-80 187 253 17.9 104.0 1.6 4.1 28.1 45 208/230-3-80 187 253 12.4 88.0 1.8 4.1 21.2 30 460-3-80 414 506 6.I 44.0 0.9 2.0 10.5 15 208/230-1-60 187 253 23.4 126.0 1.5 4.1 34.9 45 208/230-3-80 187 253 13.0 93.0 1.5 4.1 21.9 30 480-3-60 414 506 6.4 46.5 0.9 1.9 10.8 15 208/230-1-80 187 253 28.8 169.0 1.6 6.2 43.8 60 208/230-3-60 187 253 17.3 123.0 1.8 6.2 29.4 45 460-3-80 414 506 9.0 62.0 0.9 3.2 15.4 20 EXAMPLE: Supply 'voltage is 460-3-60. A B C AB = 452 v FLA -- Full Load Amps LRA -- LockedLEGEND RotorAmps MCA -- Minimum CircuitAmps MOCP -- Maximum Overcurrent RLA -- Rated Load Amps CKT BKR -- Circuit Breaker AC = 455 v C Q US Average Voltage = BC = 464 v Protection 3 1371 3 = 457 NOTES: Determine maximum deviation from average 'voltage. (AB) 457 452=5v (BC) 464 457=7v (AC) 457 455=2v Maximum deviation is 7 v. 1. tn compliance with NEC (National Electrical Code) requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be Power Supply fuse. Canadian units may be fuse or circuit breaker. 2. Minimum wire size is based on 60 C copper wire. tf 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 int_balance in supply voltage is greater than 2%. Use the following formula to determine the percentage of voltage imbalance. Determine percent of voltage imbalance. 7 % Voltage imbalance = 100 x -457 = 1.53% This amount of phase imbalance maximum allowable 2%. % Voltage imbalance = 100 x 452 + 464 + 455 max voltage deviation fr average voltage is satisfactory as it is below the 1 IMPORTANT: tf the suppty voltage phase imbalance is_ more than 2%, contact your local electric utility company I immediately. Tab{e 5--Legend 14 PREoSTARToUP ground joint union be loosened, and the supply line be allowed to purge until the odor of gas is detected. Never purge gas lines into a combustion chamber Immediately Failure to obselwe serious injury: I the Follow recognized goggles when %llowing safhty checking 2 Do not operate practices or se_'icing compressor onit unless secured. warnings tem_inal 6. Do system not to repair soldered pressure. torch to remove use contains oil and refrigerant component, lows: wear b. Relieve c. Cut component c. Ensure as %llows 1. Remove access box when System To remove and proceed power fi'om fan hub is 1/8 in. maximum tubing and positioned fi'om motor housing 12). stubs prepare , FAN GRILLE "'MOTOR SHAFT C99009 Fig. 12--Fan using cutter when d. Make and sure that air filter(s) is in place. drain trap is filled £ Make sure that all tools and miscellaneous been removed. neces= unit Blade Clearance e. Make sure that condensate ensure proper drainage. flame. the .... as fbl= system to torch _. 1/8" MAX BETWEEN _J MOTORAND FAN HUB a to unit. with robing exposed to inspect blade is correctly refrig= component. tubing remaining 5 if fi'om unit. unsweat sary. Oil can ignite Proceed to and ports. connecting Allow terminals. while pressure. all refrigerant component d. Carefully any and then electrical and recover remove sure that condenser-fan the union unit. before terminal connection goggles both high= and low=pressure system compressor under protective a. Shut off gas supply inside around is under then light in fbn orifice. Leading edge of condenser=tim blade should be 1/2 in. maximum from fan orifice venmri. MOTOR fi'om anything leak is suspected attempt erant power is in place b. Make of gas odor, retighten to elapse_ cover until all electli= all refrigerant or disturbing ret'rigerant 5. Never system detection minutes (See Fig. and recover touching protective any electric upon in and wear cover 3. Do not remove compressor terminal cal sources are disconnected. 4. Relieve result reffigeiant or provide compressor could with water to loose parts have %r initial startup: 2. Read panel and follow instluctions and IN'FORMATION 3. Make the following a Inspect lines, b. Inspect parts, and handling fbr oil at all refrigerant robing connections Detecting detector, oil generally halide indicates robing connections torch, or wires sheet metal f\ Inspect do not solution contact If a Rc/i'ige_'c,t_t connections. Be sure and tight. refrigerant robing or sharp MANIFOLD C99019 straighten the fbllowing during shipping and handling, Fig. 13--Burner fins with a fin comb. I--CHECK Proceed Do not purge gas supply use or other Failure to follow causing serious a. Make into the con£bustion open flame this warning injury could chamber to check result Do not for gas the fbllowing FOR as follows REFRIGERANT to locate and repair LEAKS a refrigerant 1. Locate leak and make sure that refi'igerant leaks been relieved in an explosion leak and to the unit: and reclaimed system pressure has Ii'om both high= and low-pressure porls. sure gas line is fi'ee of air. Be%re the "OFF" charge or death. the first time, perfbrm Assembly STAR%UP conditions: Step a match PIPE PLUG edges. coil fins. If damaged carefully using electronic see the Checkii_r are completed and on a refrigerant liquid=soap all field= and fhctoo'=wiring that connections e. Ensure such as broken etc. refrigerant leak is detected, Leal_s section. 4. Veri/) damages wires, c Leak test all refrigerant d. Inspect with, unit disconnected unit base leak. leak (AUTION, to, or shipped inspections: for shipping loose on all WARNING, labels attached lighting 2. Repair the unit %r NOTE[: with the gas valve in leak fbllowing Install Refiigerant a filter drier whenever Service procedures. the system has been opened for repair. position: If the gas supply pipe was not purged before connecting the unit, it will be full of air. It is recommended that the 3 15 Add a small charge leak-test unit. of R-22 refi'igerant vapor to system and BURNER FLAME _Z * The rated gas inputs shown in Table 6 are %r altitudes fiom sea 1eve1 to 2000 ft above sea tevel. These inputs are based on natural gas with a heating value of 1050 Bmift 3 at 0.65 specific gravity, or propane gas with a heating value of 2500 Bmifl 3 at 15 specific gravity. * For elevations above 2000 if, reduce input 4 percent fbr each 1000 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. NIFOLD These C99021 Fig. 14--Monoport 4. Recover refi'igerant from 500 microns if additional 5. (barge unit charging with cylinder R-22 ret'rigerant, or accurate fin" _'eq_li_'ed cha_'.ge_ Be compensate for internal Step 2--START-UP MENTS Burner ret'rigerant system and evacuate leaks are not found scale sure add extra &ier. AND gas flow manifold to propane Measure ADJUST- Minor bel\_re starting Make sure operation that burner devices orifices may occur when when operating are properly the burner heating section. NOTE: Make gas piping in the manifold are (HECK Start checked HEATING and check the unit (see fl/rnace has been purged, Gas Flow (Natural blower access heating instructions control located operation inside 2. Set the heating SYSTEM is placed temperature The manifold between 3.4 and 3.6 in. wg. If target adjustments can be made pressure must by changing be the maintained are required, orifices following of national codes as burner 5. Muhiply result of Step 4 by the numbe* ofcu fl shown _br one revolution of test dial to obtain cuff of gas flow pc* hour or panel): and d'*e fan switch pressure. 4. Divide number of seconds in Step 3 into 3600 (number of seconds in one hour). fbr proper 1. Place room thermostat Gas Units) to the gas flow 3. Record number of seconds for gas meter test dial to make one revolution and that all fbr leaks. lighting the for natural gas units. The to determine the input of 2. Remove pipe plug on manifold (See Fig. 13) and connect manometer. Turn on gas supply to unit. CONTROL fbllows the gas flow Measuring 1. Turn off gas supply to unit. on the heating section operation or blower access door) to start the sure that gas supply has been pressure NOTI=: All other appliances that use the same meter must be turned off when gas flow is measured at the meter Proceed as follows: Unstable misaligned Follow the lighting instructions label (located inside the burner inputs the unit aligned. orifices gas by measuring the manifbld at the meter is recommended pressure must he measured change main burner the recommendations the unit any safety or by measuring adjusm_ent and local Do not jumper the rated gas units mani_bld section to consume GAS INPUT at fl_e meter ref?igerant MAKE are designed The gas input to the unit is detem_ined a volumetric° of filter HEATING ADJUST to R@_' to _lnit _'atmg plate to volume using units using fl-_e fixed orifices at specified manifold pressures as shown in Table 6 DO NOT REDRILL THE ORIFICES UNDER ANY CIRCUMSTAN(ES. switch in the HEAT in AUTO control 6. Muhiply result of Step 5 by Bm 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 supplie* if the heating value of gas is not known) position position. of the thermostat above ro on'l temperature 3. The induced-&aft 4. After motor a call for heating, sec. If the burners another sequence minutes 5-sec. If the is repeated. from burners break fan will should light within is a 22-sec. still If fl_e burners the initial reset the control, 5. The evaporator the main burner do not tighk there try. call for heat, do not light, light within 15 is a lockout. To do not there the 24-v power mrn on 45 sec. 5 delay bel\_re 1. 32 sec. to complete one revolution. this 2. 3600+32 3. 1125 x 1 to W. after 112.5 1125 t't-_of gas flowihr 4. 1125 x 1050 fl_e flame been established. The evaporator fan will mm off45 the thermostat has been satisfied. (HECK EXAMPLE: Assume d'mt the size of test dial is 1 cuft, one revolution takes 32 sec, and the heating value of the gas is 1050 Btuift 3. Proceed as follows: will start. has 118,125 Btuh input If the desired gas input is i 15,000 Bmh, only a minor change in the manifold pressure is required sec. after Observe manifold pressure and proceed as follows to adjust gas input: GAS INPUT Check gas input and manifbld pressure aker unit start=up (See Table 6). If adjustment is required proceed as fbllows: 1. Remove cover screw over regulator adjustment screw on gas valve. 16 W43 BLK FIELD OFM CAP 2 SUPPLY EQUIP GND POWER COMP SCHEMATIC 208/230-1-60 IFM ¢/15YEL COOLING FAN QT PRIMARY LOGIC IDM +3 G G ENERGfZED DEENERGIZED TRAN1 HEATINGFANLOGIC SECONDARY 24V ENERGIZED DE W46 BAN ENERGIZED CR i I I _OFF HEAT W13 BLK 24V SPLICE BOX BR W39 RED IGC J2 W19 WHT I I _W20GRN I I r I [i I. Z_ w21 RED _HEAT OAUTO MG\/ FLAF_ESEN YEL_ I o ......... ON 0 --W41 FIELD-THERMOSTAT O BRN_ GRN-YEL W32 BAN W48 BAN GRN-YEL_ GROUNDED TRU STANDOFF COMMON-- UNIT COMPONENT i i W30BRN DISCONNECT PER NEC ARRANGEMENT LEGEND SECTIDN OUTDOOR FAN AHA - Adjustable Heat Anticipator BR - Blower Relay C - Contactor CAP - Capacitor CQMP - Compressor Motor CR - Combustion Relay CS - Centrifugal Switch EQUIPEquipment FS - Flame Sensor FU - Fuse GND - Ground GV - Gas VaNe GVR - GasVNve Relay HS - Hat] Effect Sensor HV - High Voltage TRAN - Transformer I - Ignitor IDM - Induced-Draft Motor IFC - Indoor-Fan Contactor IFM - Indoor-Fan Motor IGC - Integrated Gas Unit Controller L1 - Line LS - Limit Switch [] EQUIP COblPRESSOR INDOOR SECTION SECTION FAN F_ _lcAP; ji_, m o" CAP 2 COfIP c s R _ LARGE CHASSIS ............... LOC GASSECTION LS1 MGV NEC - OFM QT RS SEN SW TRAN - _ NationN Electrical Code Outdoor-Fan Motor Quadruple TerminN RoJiout Switch Sensor Switch Transformer Field Splice _ Terminal (Marked) _ Terminal(Unmarked) _ Splice _ -- Splice (Marked) Factory Wiring -- -- - _ .... _ = Field Power Wiring Accessory or Optional Wiring To indicate Common Potential Only, Not to Represent Wiring - Limit Switch - Main GasVa]ve Field Control Wiring NOTES: 1 If any of the original wires rum shed are replaced, they must be replaced with type 90 degree C wire or its equivalent¸ 2 See pdce pages for thermostat and subbases 3 Use 75 degree C copper conductors for field installation 4 For high speed IFM, disconnect RED wire from IGC terminal BM and connect BLK wire from IFM For medium speed, disconnect RED wire from IGC terminal BM and connect BLU wire from IFM C00057 Fig. 15--208/230-1-60 2. ]-urn regulator adjustment input_ or turn regulator screw adjustment clockwise screw Wiring to increase gas counterclockwise to Diagram, Units 48GS and 48GX decrease input Manifold 3,6 in, wg. Unsa/_ 17 operation pIessure must be between 3.4 and of the unit may result if maul/bid W56 BLU W59YEL W64 YEL-- -- IFM W15YEL COOL NG 0 G ENERGIZED FAN LOGIC: F o T T_30 G DE ENERGIZED HEATING FAN 0 45 W BR ENERGIZED IDM g TRANI LOGIC SECONDARY 24V T T30 W BR DE ENERGIZED W46BRN-- OR RC O__ RH I I W13 BLK24V SPLICE BOX BR --W39 RED IGC J2 - @ 1_ - L W19WHT W20 GRN J l_l / _:> F __./<32:} SAF W21 RED , --o OAUTO @ -- __ @ -- __ i Y --I ' Q_'_* /o _2J qF] FLAMESEN ON -W4I GRN-YEL -- W32 BRN FIELD-THERMOSTAT 2 __ __ W46 BRN GROUNDED TRUSTANDOFF z_ W30 BRN COMMON-----LEGEND UNIT COMPONENT OUTDOOR FAN SECTION F_ EQUIP GND EED' o SSO E j! - _cAP3 _ _ ,_ COMP C AHA - BR C CAP COMP CR CS EQUIPFS FU GND - Adjustable Heat Anticipator Blower Relay Contactor Capacitor Compressor Motor Combustion Relay Centrifugal Switch Equipment Flame Sensor Fuse Ground GV GVR HS HV TRAN I - Gas Valve GasValve Relay Hall Effect Sensor High Voltage Transformer ignitor IDM IFC IFM iGC - L1 LS - Induced-Draft Motor Indoor-Fan Contactor Indoor-Fan Motor integrated Gas Unit Controller Line Limit Switch LS1 MGV - Limit Switch Main Gas Valve ARRANGEMENT S NEC - OFM QT RS SEN SW TRAN - _ National Electrical Code Outdoor-Fan Motor QuadrupleTerminal Rollout Switch Sensor Switch Transformer Field Splice O Terminal (Marked) O Terminal (Unmarked) _ Splice <[_)@ Splice -- (Marked) FactoryWiring -- -- - Field Control -.... -- - Field Power Wiring Accessory or Optional Wiring To indicate Common Potential Only, Not toRepresentWiring Wiring NOTES: 1 F any of the odgina] wires furnished are replaced, they must be replaced with type 90 degree C wire or its equivalent. 2 See price pages for thermostat and subbases 3. Use 75 degree C copper conductors for field installation 4 For high speed IFM, disconnect RED wire from IGC terminal BM and connect BLK wire from IFM For medium speed, disconnect RED wire from IGC terminal BM and connect BLU wire from IFM GASSECTION DISCONNECT PER NED C00058 Fig. 16--2081230-3-60 Wiring Diagram, 18 Units 48GS and 48GX OFM COMP IFM COOLING FAN LOGIC IDM 0 T T+30 G G ENERGIZED DE ENERGIZED HEATING FAN TRAN1 LOGC 4_SECONDARY] 0 45 T T÷30 W BR W BR ENERGLZED DE ENER®JZED W46BRN-- 24V OR RC -W13 (7 1 24V i BLK SPLICE BOX BR -- I I i i W39 RED IGC J_ ---WSWNT r ..... -W20 GRN ; 5 AMF F -_,j W21 RED BLU_--1 r ° AUTO _z- -- 't0 to MGV --I I I ,R -IF] --W35 GRA , W34 BRN FLAMESEN _q i --O ON i i i i FIELD-THERMOSTAT !-] __ O--- -W41 BRN--_ GRN-YEL -- W32 BRN _W46 BRN GROUNDED TRUSTANDOFF COMMON------ W30 BRNLEGEND AHA - BR C CAP COMPCR CS EQUIPFS FU GND GV GVR HS HV TRAN I - IDM IFC IFM IGC - LI LS LS1 MGV - UNIT COMPONENT ARRANGEMENT SECTION OUTDOOR FAN [] EQUIP COMPRESSOR INDOORFAN SECTON SECTION F_ L2_ FROMCONPl_Ap31 11( OLo COMP C S R GASSECTION DISCONNECT PER EC - Adjustable Heat Anticipator Blower Relay Contactor Capacitor Compressor Motor Combustion Relay Centrifugal Switch Equipment Flame Sensor Fuse Ground Gas \/alve GasValve Relay Hall Effect Sensor High Voltage Transformer Ignitor NBC - OFM QT RS SEN SW TRAN - Induced-Draft Motor Indoor-Fan Contactor Indoor-Fan Motor Integrated Gas Unit Controller Line Limit Switch Limit Switch Main GasValve -- National Electrical Code OutdooFFan Motor Quadruple Terminal Rollout Switch Sensor Switch Transformer FieldSplice (_D Terminal (Marked) O Terminal _ (Unmarked) Splice _ Splice (Marked) FactoryWiring -- -- - FieldControl Wiring _ .... _ - Field Power Wiring Accessory or Optional Wiring To Indicate Common Potential Only, Not to Represent Wiring _ NOTES: 1 If any of the original wires furnished are replaced, they must be replaced with type 90 degree C wire or its equivalent 2 See price pages for thermostat and subbases 3 Use 75 degree C copper conductors fo_ field installation 4 For high speed IFM, disconnect RED wire from IGC terminal BM and connect BLK wire from IFM. For medium speed, disconnect RED wire from IGC terminal BM and connect BLU wire from IFM C00059 Fig. 17480-3-60 Wiring Diagram, 19 Units 48GS and 48GX Table 6--Heating GAS SUPPLY HEATING iNPUT (BTUH)* NUMBER OF ORIFICES inputs PRESSURE MANIFOLD PRESSURE (IN, WG} Natural (IN, WG) Propanet Min Max Min Max Natural 40,000 2 4.0 13.0 4.0 13.0 3.5 Propane¢ 3.5 G0,000 2 4.0 13.0 4.0 13.0 3.5 3.5 90,000 3 4.0 13.0 4.0 13.0 3.5 3.4 115,000 3 4.0 13.0 4.0 13.0 3.5 3.7 3 4.0 13.0 4.0 13.0 3.5 3.5 130,000 When a unit is converted to propane, different size orifices must be used. See separate, naturaMo-propane conversion kit instructions 1 Based on altitudes from sea level to 2000 fL above sea level. For altitudes above 2000 fL, reduce input rating 4 percent for each additional In Canada, from 2000 ft above sea level to 4500 ft above sea level, derate the unit 10 percent pressure is outside this range. Personal injury or unit damage Refkr may result to/nduo*' heating HEATING Unsafe operation is outside of the unit may result this range Serious injury if mani%ld , death Ai_3flon at_d Ai(f!on, airflow when SEQUENCE On a call fPr beating, or unit damage starting may result 3. Replace cover screw cap on gas valve speed, the 4. Turn offgas supply to mail Remove manometer fi'om pressure tap and replace pipe plug on gas valve. Turn on gas to unit and check _br leaks. Measure Manifbld The main burner unit input rated (Propane orifices on a propane in Table as follows gas unit pressure are sized reading 6. gas input on a propane 5. Adjust screw regulator pressure, as clockwise screw and connect over regulator adjustment specified in to increase cover is continuously manometer (See or turn mani_bld Remove manometer With B[ RNER burner operation. fbr each burner panel removed, flames will have (See Fig. 14). Refer to the Ji_d_te_a_ce burner removal. AIRFLOW AND The heating section heating operation unit rating Table heating TEMPERATL pressure. tap. the the unit observe are approximately blue flame section the temperature=rise approved operation _511s within the approved Indications Fan OntOff Belay Modified Limit Switch Fault 1 Flash Off 2 Flashes FauR Limit 3 Flashes Switch Faults 4 Flashes 5 Flashes 6 Flashes RoHout Switch FauR 7 Flashes Internal Fault 8 Flashes Control lock-out 9 Flashes (1 hr) NOTES: 1. There is a 3-sec pause between error code displays. heating with d-_esame yellow tips for information on LIMIT temperature airflow closed through rare and approved range stamped for rise range a temperature When rises the air tow-temperature rise that completes range. cycles 2O (LS) R circuiL the maximum circuit flow to the burners until LS resets. _br each temperature above switch opens and the R control in the R control on the limit the thermostat rise switch cfirt at rations must produce SWITCHES Normally RE RISE input, and the air delivery The heating by the On Temporary plate 7 shows located operation, codes). Ignition Lockout Fault induced-Draft Motor Fault adjusting from pressure for each size unit is designed within 8 for error is to see if they are light blue and and that the flames Propane board normal 2. If more than one error code exists, all applicable error codes will be displayed in numerical sequence 3. This chart is on the wiring diagram located inside the burner access panel the burner soft in appearance, control During delay. on the control LED INDICATION Four Consecutive screw FLAME access Watch The panel. on (See Table Flame Sense Replace pipe plug on gas valvQ then turn on gas to unit. (hock £_r leaks. CHECK is provided ERROR CODE manifold adjusting pressure, to decrease screw on gas to the correct 6. Turn stop firing and the Norma_ Operation Hardware Failure screw. 7. Turn off gas to unit. access is the thermostat gas unit: adjustment screw Table mani_bld counterclockwise 6. Replace operation. by motor a 45=sec. time-off indicator on is perfbm_ed When the burners off after diode) the burner 3. Turn on gas to unit. cover shuts sensor d-_e required evaporator=fan is established. is deenergized, motor to monitor Fig. 13). 4. Remove valve. after flame Table 8--LED pipe plug on manifold it has reached The and "W" 1. Turn off gas to unit. 2. Remove that This function is satisfied LED to adjust senses is energized, ff*e hall=effect (IGC). 45 sec removing of the thermostat When begins. energized board the "W" motor. control An LED (light=emitting for the matches label) sequence gas evaporator-tim Units) when the manifold level specified Proceed Pressure terminal motor the burner integrated to adjust OF OPERATION the indtlced=draft the induced=draft Ac!j_zstme_v_:_ section required. (See Fig. 15-17 and unit wiring pressure 1000 fl above sea level instantly temperature setting the R control allowable temperature, "breaks." the limit Any interruption at the motor limit of the limit switch, and the unit returns circuit tempera° closes the gas valve and stops gas The blower circuit. the control the leaving=air circuit and pilot. completes Should switch heating to 1tin drops to the the switch The electric=spark to normal continues closes ignition operation. and system Table 7--Air Delivery {Cfm) at indicated Temperature Rise and Rated Heating input HEATING INPUT (BTUH) 20 25 30 35 40 45 50 55 6O 40,000 1500 1200 1000 857 750 667 600 545 5OO 60,000 2250 1800 1500 1286 1125 1000 900 818 75O 692 1688 1500 1350 1227 1125 1038 964 1232 TEMPERATURE R_SB °F 65 7O 90,000 -- -- 2250 1929 115,000 -- -- -- 2464 2156 1917 1725 1568 1438 1327 130,000 -- -- -- 2786 2438 2167 1950 1773 1625 1500 NOTE: Dashed areas do not fall within the approved temperature AL XILIARY LIMIT SWITCH (ROLLOL T) The function of the switch is to close the main event of flame rollout The switch is located burners. When maximum the temperature allowable closing the gas valve indoor (evaporator) continue FAULT at the auxilia_" temperature, the and stopping gas flow fin to run until (ODE 7. motor switch Step a--START-UP MENTS R (IFM) is reset. gas valve in d-ie above the main switch reaches contlol and AND These tlips, to the burners. induced IMPORTANT: (48GS048 arid the circuit draft The IGC LED COOUNG rise range of the unit. The motor The 3-phase Do not jumper any safety Do riot operate the compressor is below 40cT (unless Do riot rapid-cycle "on" cycles (HE(KING ADJUST- compressor 1. Place The tow=ambient Allow the unit. unless kit is installed). suction access OPERATION for proper cooling controi operation thermostat that blower SYSTEM motor switch starts in OFF when FAN switch and shuts down when FAN switch as within AUTO. position. Observe that blower switch in (COL Set cooling control compressor, motors start. position AND ADJUSTING system A({iustment be reversed charging panel. charged may be &a- R-22 suction An superheat, accurate is attached refi'igerant, Do nut to the outside of the service suction and outdoor or and a gauge charging fm_, and that cooling when control setting is satisfied. continue to rnn for 30 sec. The method u,se7nerc_z_?' or .small line tempera- ambient cycle shuts d-iermistor-type manifold for evaluating diaT-O_e is set to "call operates in Heating for heating" in (ooling fbr cooling" mode (above when When ment down mode when temperature (below room temperature) control evaluating d_e refi'igerant to d_e specified factory charge, charge an indicated must always adjust° be ve_- minimal. If a substantial adjustment is indicated, an abnot_nai condition exists somewhere in the cooling system, such as insufi[icient airflow across either coil or both coils. Proceed as follows: 1, Remove caps fiom tow- and high-pressure control temperature) the unit t,s_ermomete_'s N fhn will temperature room ther- are required in 3. When using an auto=changeover room thermostat, place both SYSTEM and FAN switches in AUTO. positions. Observe that unit operates tempera- /_ecaz_se they are l_ot adeqzeate jot thi.s 07)e o/" mea.s_zrement. evaporator evaporator required R-22 charge. thermocouple- a sling psychrometer, is not the proper the required line pressures charge. charge of not having chart when using the superheat switch to (HARGE with d'le ref?ige*ant The chart includes position in pressures REFRIGERANT is fidly of rare at given tures below room temperature condenser Observe and FAN 5 off the compressor. position 2. Place SYSTEM "call and discharge is placed is placed shuts compressor corrected to dte unit must than normal. the unit is suspected A superheat between damage. (ONTROL leads proper If not and fitctow-sealed, NOTE: temperature 5 minutes to ensure protector lower refrigerant mometer, in ON position AUTO. when operating when the outdoor compressor the unit room Observe devices accessory (OOLING in the Pro-Start-Up tested, the compressor. to prevent Start and check follows: given power compressor units direction-oriented. cot_'ect rotation. When taming backwards, scroll compressors emit elevated noise levels, and the difference between CHE(KING procedures the unit scroll are lead orientation the internal matically Complete the required section before starting must be checked power minutes, will display MAKE units 3-phase Three-phase, 48GX030-060) arid smwice fittings, 2 [sing hoses with valve core depressors, attach tow- and high-pressure gauge hoses to low- and high-pressure service fittings, respectively, is set to 3 Start unit in Cooling pressures stabilize, 4 mode and let unit run until system Measm'e and record the following: a Outdoor ambient-air temperature (C>Fdb), b Evaporator inlet-air tempe*ante (°F wb), c Suction-tube temperature (°F) at tow-side service fitting d Suction (low-side) pressure (psig), 5 Lsing "Cooling Charging Charts," compare outdoor-air ten> perature (°F db) with the suction line pressure (psig) to determine desired system operating suction line temperature (See Fig, 18 30), 2i 6. (ompare actual suction=robe temperature with desired suction-robe temperature [sing a tolerance of" + 3°F, add refiigerant if"actual temperature is more than 3C>Fhighe* than proper suction=tube temperature, or remove rel'rigerant if actual ternperatme is more than 3C>Flower than required suction-tube temperature TaNe 10-Color Coding for 460-V GE Motor Leads 3-SPEED 2=SPEED black = high speed black = high speed violet orange = jumper = medium red = low speed NOTE: If the problem causing the inaccurate readings is a refrigerant leak, refer to the Cheek_br R@'igeras_t Leaks section the black INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS (male (female quick quick connect COOLING operation, cIi*n fPr each heating 12,000 operation, that falls within Table 7 shows Btuh of rated the airflo_ the range 13 show external static both stamped for the system wet coil pressure being installed rise of operation is as follows: airflow rates airflows tables 1. When Tables (See Tables 14 and 15 for 2. The normally grilles are open, speed, disconnect electrical power Electrical death. shock explosion or Airflow can be changed blower motor. shut off gas supply. by changing cause to condenser (outdoor) serious tag. NOTE: or should not cooling cycle remains injury the lead connections of the thermostat circuits Table 9=Color 9. 'on" Both (() the close (COMP) motors start the room have R to terminals stopped, drops to a of the room "breaks" tl-_e circuit Y and G. These the blower waiting it The setting coil (. The condenser condition, (indoor) elapsed. temperature control a 30=sec. delay, fiom the room blower and then 5 minutes the thermostat contactor relay BM close evaporator has started until tem_inal stop. After ensure open and compres- motor for the next stops. The "call _br thermostat. continuing possibility of premature must per_brmed be a qualified units, black = high speed high per_brmance equipment on unit should stun'ice person. refer to Tables 16 NOTE: Consult your l'naintenance contract speed red = low speed through motor of energized until tl-_is point, heating/cooling 2-SPEED Naek = high speed blue = medium (OFM). the terminal MAINTENANCE Coding for 2081230=V Motor Leads 3=SPEED t5n motor through again is in a "standby" To see Table At deenergize For 208/230V leads, compressor below the cooling thermostat sor motors unit motor _hermostat of energized open contacts be started point that is slightly speed on the 208/230V between through (:)nee the compressor cooling" coding that is slightly contactor contacts sequence t!-_e them?ostat, open the circuit All 4gGX units are factory wired fbr tow speed and may need to be wired for medium or high speed in the field. For color of circuits and complete the circuit _hn motor (IFM), Unit 48GS two- or three=speed motors (except size 030) are iactory wired ibr tow speed operation. Unit 48GS030 is factoQ' for medium the cooling Y and G. These completed and complete between wired in the COOL position to a point setting the circuit 3. The set of normally Lhen to the unit and install lockout can lead instantly. 1 blower rises control completes R to terminals thermostat: the the jumper _itll a'/_3 c,Sla,s,sispargx. position, temperature cooling thermostat at various to determine the fi'om the black lead to the BR switch in the AUTO. the room above eonlaet SYSTEM a temperature plate QC OF OPERATION them?ostat switch &up). changing SEQUENCE With the room and the FAN NOTE: Be sure that all supply- and return-air fi'ee fi'om obstrnctions, and adjusted properly Be%re to redid For cooling to these connect capacity. on the unit rating and Refer is 350 to 450 cooling rise at various heating pressures. airflow must produce the temperature 11 and airflow the recommended red = tow speed QC) and connect Ii_,s_date the imnl_er For cooling blue = jumper speed this and to minimize the failure, periodic maintenance equipment This combination be inspected at least once each year by To troubleshoot cooling or heating of 18. local dealer about the availability of red = low speed To change the speed of the blower motor (BM), remove the ihn motor speed leg lead fi'om the blower relay (BR). This wire is attached to terminal BM of the integrated gas control (IG() board _br single- and 3=phase traits. To change the speed, remove and replace with lead for desired blower motor speed. Inszdate the removed lead lo avoid contact u,ith cha,ssi,spartx. For 460=V GE Motors The ability to properly ment requires equipment. perform any maintenance To change the speed of the blower motor (BM), remove fan motor speed lead from t!_e blower relay (BR) and replace with the lead _br the desired blower motor speed. The motor speed lead is attached to terminal BM of the integrated gas control (IGC) board For low and mediunl speeds, black must be connected to the jmalper wire i.s_d.te removed lead e_d to redid cu_tact nith eha,s,sis part:,'. To select high speed on 460-v GE motors, separate 22 maintenance mechanical possess these, AND POSSIBLE on this equip= skills, do not on this equipment recommended in the User's THIS WARNING (OULD INJURY EQUIPMENT. For color coding on the 460=v GE motor teads, see Table 10. per%m_ expertise, If you do not procedures TO HEED OUS certain tools, and attempt to other than those Manual. RESULT DAMAGE FAILURE IN SERI= TO THIS a Table 11--Dry Col! Air Delivery* - Horizontal Downflow Discharge Unit 48GS018°060 (Deduct 10 percent for 208 Volts) - 230 AND 460 VOLT Unit Motor Speed Low 0t8 Low Med High Low 030 Med High Low 036 Med High Low 042 Med High Low 048 Med High Low 0$0 0.2 0.3 Watts 227 212 196 177 165 153 ..... Cfm 1082 1016 929 796 668 428 ..... Med High 0.7 0.8 0.9 1.0 ........... Cfm High 024 0.1 Watts Med External Static Pressure (in. wg) 0.4 0.5 0.6 0.0 ........... Watts Cfm 287 1270 275 1179 266 1054 253 932 242 780 234 633 226 372 .... .... Watts 280 275 270 267 264 262 260 .... Cfm 950 880 825 750 670 580 400 .... Watts 380 375 365 360 355 350 344 335 312 -- -- Cfm 1220 1150 1090 1025 970 860 760 620 450 -- -- Watts Cfm 485 1475 475 1440 470 1350 460 1275 455 1200 445 1125 437 1025 430 925 415 750 385 400 --- Watts 280 275 270 267 264 262 260 .... Cfm 950 880 825 750 670 580 400 .... Watts 380 375 365 360 355 350 344 335 312 -- -- Cfm 1220 1150 1090 1025 970 860 760 620 450 -- -- Watts Cfm 485 1475 475 1440 470 1350 460 1275 455 1200 445 1125 437 1025 430 925 415 750 385 400 ---- Watts 576 566 556 538 512 497 481 466 450 435 Cfm 1430 1403 1365 1263 1157 1068 973 900 827 704 -- Watts 680 671 660 624 604 620 602 558 534 512 496 Cfm 1720 1630 1538 1439 1346 1267 1167 1126 1018 858 781 Watts Cfm 810 1800 800 1745 790 1660 782 1600 766 1547 742 1465 723 1360 709 1270 688 1163 661 967 627 876 Watts -- 675 660 650 640 630 620 610 595 580 -- Cfm -- 1454 1387 1326 1275 1204 1142 1081 995 918 -- Watts -- 886 855 825 795 778 765 750 735 718 700 Cfm -- 1515 1458 1406 1350 1285 1224 1163 1091 1013 932 Watts Cfm --- --- --- 1000 1551 950 1488 925 1424 910 1360 890 1296 875 1233 855 1148 833 1071 Watts -- 727 712 700 688 666 644 622 595 569 -- Cfm -- 1678 1639 1600 1561 1500 1440 1379 1289 1198 -- Watts -- 853 836 821 807 782 756 730 699 667 640 Cfm -- 1914 1870 1825 1780 1711 1642 1573 1470 1367 1270 Watts Cfm --- 979 2150 959 2100 943 2050 927 2000 897 1922 868 1845 838 1767 802 1600 766 1535 730 1419 Watts 1033 949 864 836 822 808 772 737 705 674 642 Cfm 2105 2057 2009 1943 1909 1876 1823 1770 1698 1627 1531 Watts 1084 1054 1024 994 971 955 928 897 867 835 803 Cfm 2318 2248 2179 2110 2058 2000 1932 1885 1829 1740 1638 Watts Cfm --- --- 1184 2349 1152 2278 1120 2207 1102 2124 1084 2041 1056 2000 1029 1960 997 1853 965 1745 * Air delivery values are without air filter and are for dry coil (See Table 14-48GS NOTE: Deduct field-supplied Wet Coil Pressure Drop). air filter pressure drop and wet coil pressure drop to obtain external static pressure available Table 12--Filter UNiT SI£E FILTER $1Z _= 018,024, 030 036 20 X 20 X 1 042, 048, 060 24X30X 20X24X1 Pressure for ducting Drop (in. wg) CFM 500 600 700 800 900 1000 1100 1200 0.05 0.07 0.08 0.10 0.12 0.13 0.14 0.15 0.09 0.10 0.11 1 23 1300 1400 1500 0.13 0.14 0.15 0.16 0.07 0.08 0.09 0.10 1600 1700 1800 1900 2000 2100 2200 2300 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 Table13--Dn] Coil Air Delivery* - Horizontam and Downflow DischargeUnit 48GX024=000 (Deduct 10 percent for 208 Volts) 230 AND 450 VOLT Motor Speed Unit Low O24 Med High Low 030 Med High Low 036 Med High Low O42 Med Low O48 Med High Low 050 0.1 0.2 0.3 Watts 281 282 281 278 276 Med High to %ltow power 828 757 691 619 ...... -- -- 375 370 363 357 352 -- -- -- Cfm -- -- -- 969 897 824 744 649 -- -- -- 468 994 457 913 444 826 431 730 423 620 --- .... Watts Cfm ..... ..... Watts 246 244 243 241 Cfm 982 860 808 736 ....... Watts 343 339 336 332 328 322 317 Cfm 1233 1170 1109 1038 953 855 754 .... Watts Cfm .... .... 441 1202 432 1111 421 1021 410 929 400 826 --- --- Watts -- 470 458 445 430 415 399 384 -- -- -- Cfm -- 1463 1406 1344 1273 1188 1091 983 -- -- -- Watts -- -- 514 501 487 47I 455 438 422 -- -- Cfm -- -- 1497 1428 1348 1255 1152 1042 929 -- -- Watts Cfm --- --- --- 646 1491 636 1412 626 1325 614 1228 602 1120 589 1003 --- ---- ....... Watts 643 625 614 605 593 574 549 518 485 454 Cfm 1626 1614 1579 1532 1478 1421 1361 1295 1218 1120 -- Watts .... 726 695 661 625 591 561 540 Cfm .... 1731 1672 1610 1541 1456 1345 1193 790 1699 766 1602 742 1494 713 1367 -- ....... ....... Watts 614 588 577 572 566 556 539 517 491 -- Cfm 1591 1549 1518 1490 1460 1421 1372 1312 1242 -- -- Watts 778 756 738 719 699 676 650 623 596 572 555 Cfm 1854 1837 1804 1759 1705 1643 1577 1508 1440 1375 1315 Watts Cfm .... .... 896 1956 862 1879 829 1797 800 1709 775 1615 752 1514 728 1406 Watts 834 813 782 746 712 680 652 626 -- -- -- Cfm 2016 1955 1898 1840 1781 1717 1646 1566 -- -- -- Watts 941 889 851 822 797 772 745 714 679 639 -- Cfm 2379 2233 2124 2038 1964 1892 1814 1727 1626 1511 -- Watts Cfm --- --- 960 2497 949 2224 920 2075 883 1986 845 1915 812 1831 783 1721 753 1588 --- Wet Coil Pressure Drop table) air filter pressure drop and wet coil pressure drop to obtain external static pressure availabb could result in serious injury: Errors supply to the uniL Yhe_ turn offelectlical to the unit and install lockout 2. Use extreme or service caution tag befbre equipment, panels perfbrming personal and parts. injury overheating turn off external shut off electrical combustible occur main gas valve can result and install lockout Label wires may cause all wires prior improper to disconnec= fbr this equipment are as 1, Inspect air filter(s) each month (lean or replace when necessaw Certain geographical locations may require more fi'equent inspections, 2, Inspect indoor coil, outdoor coil, drain pan, and condensate &ain each cooling season for cleanliness, (lean at least once per heating cooling season or more often if'needed fhil to shut of 7, to the unit. reconnecting operation. The n_ininmm maintenance requirements follows: As on, or in contact or the gas supply manual supply either when for ducth_g tion when servicing. fi'om sharp edges_ etc. 3. Never place anything with, the unit. made and dangerous on the unit_ when removing with any mechanical 4. Should 1.0 -- these warnings any maintenance 0.9 899 NOTE: Deduct field-supplied 1 First, mrn offgas 0.8 Cfm * Air delivery values are without air filter and are for dry coil (See Table 15-48GX Failure 0.7 ...... Watts Watts Cfm High External Static Pressure (in. wg) 0.4 0.5 0.6 0.0 The_ tag. 3, Inspect blower motor and wheel fbr cleanliness at the begin= ning of" each heating and cooling season Clean when neces= saW Fo* fit:st heating and cooling season, inspect blower wheel bi-monthly to determine proper cleaning frequency 24 _ OUTDOOR _ _F -K_los _ 30 40 I 50 70 TEMPERATURE ("F) I I IB 21 SUCT]ON LINE TEMPERATURE Fig. 18--Cooling 30 60 SUCTION L]NE I I 4 10 Charging 40 SUCTION I 80 90 30 I 27 I 32 I (_C) SO 80 LINE TEMPERATURE 70 I 10 I 16 SUCTION LINE TEMPERATURE TEMPERATURE _ /15 ,_ 50 70 TEMPERATURE (_F) I I 18 21 °46 C 46 < ss 85 29 75 ss 24 55 13 80 90 I 27 I 32 (_C) Chart, 48GS024 U_ 80 90 30 I 27 I 32 I 40 50 SO 70 SUCTION LINE TEMPERATURE {'F) I I I I 4 10 1B 21 SUCTION LINE TEMPERATURE (_C) (_F) I 21 50 L]NE I 10 SUCTION LINE Chart, 48GS018 U_ I 4 40 SUCTION I 4 TEMP ("C) 80 90 I 27 I 32 °42 C00043 Fig. 20--Cooling Charg{ng 4. Check electlical connections proper operation each when 5. Ensure wires and cooling and controls tbr season, Service robes or sharp Charging Chart, U[_i_S 044 48GS036 AIR FILTER are not contacting refrigerant Never edges. and inspect Clean and adjust 7. Check fbr tighmess heating Fig. 21--Cooling necessa_- sheet metal 6. Check Chart, 48G8030 Units flue hood operate return-air heating when section before each heating season. any obstructions, without Always a suitable replace if necessary. Inspect air filter(s) (throwaway=type) at or clean least NOT_:: lubricate 25 BLOWER installed each (cleanable=type) each heating and cooling season clogged with dust and/or lint. EVAPORATOR once air tilter Ail motors are permanently these motors. (See Tables month and at least twice or whenever AND in the the filter with the same dimensional size and type as originally 1 and 2 %r recommended filter sizes). necessary. and remove the unit duct system. the filter(s) replace during becomes MOTOR lubricated. Do not attempt to }L TDOOR TEMP F 30 40 50 SUCTION I 4 SUCTION I -1 60 LINE TEMPERATURE I I 10 16 LINE TEMPERATURE C 115 46 105 41 95 85 75 35 29 24 65 55 18 13 45 7 70 80 90 (_F) I 21 (:C) I 27 I 32 C00047 48G8048 UnRs Fig 23--CooHn_ -1 SUCTION LINE TEMPERATURE IF 4 SUCTION 10 16 LINE TEMPERATURE 21 (:C) Fig. 24--Cooling For longer life, clean accumulated motor annually. operating dirt Charging 32 SUCTION and continuing flora LINE TEMPERATURE C00048 Fig. 25--Cooling Chart, 48GS060 Units economy, and grease 27 c. On a/l units, efficiency, the blower wheel Charging and screws remove securing assembly out. Chart, blower blower assembly to Be care£hl UQ_0;049 48GX024 flora unit. Remove blower partition and not to tear insulation slide in blower compartmenL d. Ensure proper motor Befbre supply. Failure death. cleaning the blower motor and wheel, Then turn off and tag electrical to adhere to this warning could disconnect power gas e. Loosen Remove to the unit cause serious injm T or housing, 2. Remove (leaning the Blower Motor and Wheel a. Ensure 1, Remove and disassemble blower asserubly as %llows: reassen£bly in relation by marking _o blower housing and slide motor and clean blower proper reassembly from housing. and motor wheel and mount out of housing. as %llows: by marking When wheel handling blower wheel, be sure not to disturb on blower wheel vanes. b, Disconnect motor lead flora blower relay (BM) Discon= nect yellow toad ['rom terminal L2 of the contactor wheel disassembly. setscrew(s) that secures wheel to motor shaft. screws that secure motor mount brackets m b. Lif_ wheel a, Remove unit access panel blower before balance orientation. and/or weights cleaning (clips) c. Remove caked-on dirt from wheel and housing with a brush. Remove lint and/or dirt accumulations from wheel 26 (030) 60HZ CHARGING CHART (036) 60HZ CHARGING -1 SUCTION LINE TEMPERATURE 48GX0a0 26--Coolin{ -1 SUCTION LINE TEMPERATURE 4 SUCTION 10 16 LINE TEMPERATURE Fig. 28--Cooling and housing ment. grease d, Reassemble wheel e Reassemble motor tightened shaft. £ Reinstall 3. Restore proper 32 cleaner, shak using soft brllsh attach° 2. Remove solvent Be sure flats and not setscrews on round part blower rotation and motor Start unit speeds and during check heating PASSAGEWAYS To inspect the flue collector box and upper areas according the combustion to directions blower wheel and motor in the d'oml_.stiut_-.ti_' Charging Remove the holding 21 (C) 27 32 Chart, 48GX048 U_i_ °53 the blower housing to the flue (See Fig. 31 34). 12 screws holding the flue 33 34) to the heat exchanger collector assembly. box cover Inspect the all surfitces, as required, using a wire brush. BLOWER Clean periodically to assu*e proper airflow and heating efficiency. Inspect blower wheel eve*y fall and periodically during the heating season. For the first heating season, inspect blower wheel bimonthly to determine proper cleaning frequency and To inspect blower wheel, remove drak hood assembly Shine a flashlight into opening to inspect wheel If cleaning is required, remove motor and wheel as _bllows: of the heat exchanger: 1. Remove 10 16 LINE TEMPERATURE for cycles. FLI_E GAS LINE TEMPERATURE 4 SUCTION box cover COMBUSTION=AIR to uniL 32 heat exchangers. of panel. power SUCTION the 3 screws (See Fig are 27 48GX036 U_9c_°51 collector 4. (lean unit access 21 (C) Fig. 29--Cooling 3 housing IF 10 16 LINE TEMPERATURE C00052 and oil with mild into UNE TEMPERATURE 4 SUCTION -1 into housing. on motor electrical cooling 27 SUCTION Fig. 27--Coolinc ChargBng Chart, 48GX042 Units with vacuum Remove 21 (:C) CHART assembly 1 Remove unit access panel (See Fig. 32). Blo_ e_' section 27 TaNe 14_48GS Wet Coit Pressure Drop UNIT SiZE 48GS AIRFLOW (CFM) 500 (iN. WG) 0.049 018 600 0.070 7OO 0.095 7OO 0.077 800 0.100 900 0.127 900 0.065 1000 0.080 1100 0.097 1100 0.084 1200 0.100 1300 0.177 1300 0.103 1400 0.120 1500 0.138 1500 0.088 1600 0.100 1700 0.113 1900 0.108 2000 0.120 2100 0.132 024 030 036 042 048 060 PRESSURE (060) 60HZ CHARGING CHART DROP SUCTION LINE TEMPERATURE C00054 Fig. 30--Cooling Charging Chart, 48GX060 Units INDUCED Table 16--48GX Wet Coil Pressure AIRFLOW (CFM) 7OO PRESSURE DROP (IN. WG) 0.0535 024 800 0.067 oa6 042 048 060 2, Remove the 7 screws ing plate to blower 3. Slide the motor 900 0.123 900 0.0687 1000 0.083 1100 0.150 1100 0.084 1200 0.100 1300 0.177 1300 0.099 1400 0.177 1500 0.204 1500 0.199 1600 0.137 1700 0.156 1900 0.108 2000 0.120 BL RNER 2100 0.132 Unit is equipped with a direct system. modtlle that attach housing and blower induced-drafl (See Fig wheel motor (See Fig. 33). Clean the blower cleaning is required, with Steps 4 and 5. 4. To remove blower, remove Fig. 31--Blower monnt- outlined ROLLOUT SWITCH BURNER MOUNTING RACK SCREW C99022 a self'diagnostic for LED interpretation. lockout occurs, unit interrupting power supply burner LIMIT SWITCH Remove unit access panel Limit switch is located on the blower partition 28 and spark Flue ignition is located diagram MAIN 4 screws Housing contains Collector Box 100 percent tockont LED. may in the control During be to unit reset servicing, by refer either or by turning box. Module to label momentarily selector switch to at the thermostat BURNERS or blockage above. the procedure Ignition At the beginning 6. To reinstall, / IGNITION OFF position 2 setscrews remove A FLUE COLLECTOR BLO'WER BOX HOUSING VENT HOOD iN SHIPPING LOCATION If additional 5. To remove motor and cooling fan assembly, that hold blower housing to mounting plate reverse // out of the blower wheel. MOUNT t / If housing continue MOTOR CO 33) assembly DRAFT Drop UNIT SIZE 48GX 030 (C flames of each heating due to corrosion and adjust, season, or other if necessary. inspect causes for deterioration Obsma'e the main FRONT ACCESS PANEL C99091 Fig. 32--UNt Access Panel C99086 Fig. 34--Burner Rack Removed 9 To reinstall, reverse the procedure outlined above HOUSING CONDENSER COIL, EVAPORATOR CONDENSATE DRAIN PAN (OIL, AND Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year or more often if"necessa W The coils are easily cleaned when du; therefbre, inspect and clean the coils either befbre or after each cooling season. Remove all obstructions, including weeds and shn/bs, that interfc, e with the airflow through the condenser coil. 2 SETSCREWS Straighten bent fins with a fin comb If coated with dirt or tint, clean the coils with a vacuum cleaner, using the soft brush attachment. Be carefhl not to bend the fins If coated wit}* oil or grease, clean the coils with a mild detergent-and=water solution. Rinse coils with clear water, using a garden hose. Be careflfl not to splash water on motors, insulation, wiring, or ai* filter(s) For best resuhs, spray condenser coil fins f?om inside to outside the unit. On units with an outer and inner condenser coil, be sure to clean between the coils Be sure to f'lush all dirt and debris from the unit base (HIDDEN) C99085 Fig. 33--Remova! of Motor and Blower Wheel Inspect the drain pan and condensate drain line when inspecting the coils. Clean the drain par* and condensate drain by removing all foreign matter from d*e pan Flush the pan and drain robe with clear water Do not splash water on the insulation, motor, wiring, or air fiher(s)_ If the drain tube is restricted, clear it with a "plumbers snake" or similar probe device. Ensure that the auxiliary drain port above the &ain robe is also clear When servicing gas train, do not hit or plug orifice spuds. Removal of Gas Train To remove the gas train for servicing: CONDENSER l. Shut of'["main gas valve. FAN" 2. Shut off power to unit and install lockout tag 3. Remove unit access panel (See Fig. 32) 4. Disconnect 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, 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. 1. Remove cover, 7. Remove the mounting screw that attaches the burner rack to the unit base (See Fig. 31) 2. Tuna 8. Slide the burner rack out of the unit (See Fig 31 and 34) expose 29 6 screws motor/grille holding assembly the fan blade, condenser grille and motor upside down or* top to top cover to 3.Inspect thefanblades %r cracks 4. If fire needs to be removed, fun off the motor shaft. 5. When replacing away fi'om visible. position end 11/8 in. of motor shaft will be engages the flat area on the motor The gas input (ONTROLS controls and wiring annually. Remove controls (heck screw noticed, wire to locate al! electrical connections. all the connections If any disassemble does not require is suspected. smoky burned clean the connection and Tighten heating all the parts, restfip and/or improper inspecting access panel. heating cycle operation. cycles, the electrical Start the unit, electrical controls If discrepancies component cooling wiring, at least cycle in either the proper Refkr to the heating and/or in this publication aid an performance R@'/gerant is (']ia_'ge checking unless problem exists, airflow does improper heating refer to the Start-5}) cooling a_'ld retail'n-air grilles cooling in not require Ira pro/_/em checking exists, /:,e are olden and fi'eefi'om the system airflow. A(UTROL DEVI(E the This metering device is a fixed orifice and is located in the header to the evaporator coil proper or both operating electrical making is suspected. check LIQUID LINE STRAINER each instrumentation. The liquid line strainer (to protect metering device) is made of wire mesh and located in the liquid line on the inlet side of the metering device. these checkouts. sequence determining of operation proper control TROUBLESNOOTNG REFRIGERANT CIRCUIT Annually inspect all refi'igerant base oil accumulations. tbr and tow cooling and.4d]z_sfhg ob.strz¢ctio_.s, and tkat tlie air filter is clean. When necessary, refer to the Indoor .4i(flo_v at_d A i_;f](n_ A@¢stmet_s section to check the operation refrigerant is are one complete has occmTed, label when replace to ensure malfimction NOTE: as leak LeaI;s section. and securely. are observed with to the unit wiring and and observe arid one complete or if a suspected Refer Ifa perfbrmance METERING DEVKE After a refi'igerant AIRFLOW .s_lre llIat all s_lp/)- all connections properly The unless for tightness. or the connection, end and reassemble electrical EVAPORATOR Be pot_ er ;o the panel If R@'igerat_f AND WIRING the electrical sz_re to 1urn rfl tke gas .s_lp?/y, and then tke eleetr/ea/ _znif. access solmion leaks are fbund refer to the ('becking performance section and check liquid-soap shaft grille. ELECTRICAL wiring. suspected, section. blade so the hub is 1/8 in. tightening. 7. Replace or refer to the ('l_ecl;/br GAS INPUT that setscrew when torch., detected, and slide the See Fig. 12). 6. Ensure Inspect halide the setscrew If no refrigerant tim blade, the motor or bends loosen robing Detecting connections Use the Zl'o_lblc'skoofin_ occur with these urks. and the unit oil generally indicates START-UP Use the ,;;tar/{,_ followed. System urider pressure refrigerant before system Relieve pressure arid recover al! repair or final unit disposal to avoid serious Use injury or death. devices, including all service solenoid If oil is detected or if low cooling leak-test all refi'igerant robing using ports and open nil vah'es. perfbrmance an electronic 1(_18) if problems a leak. flow=control Ch_ides (See Tables is suspected, leak=detector, 3O ¢HECKUST (']_ee]dist to ensure proper start-up procedures are Table 16--Troubleshooting SYMPTOM Guide--Cooling CAUSE REMEDY Power Failure Call power company Fuse blown or circuit breaker tripped Compressor and condenser will not start= Defective thermostat, fan Insufficient contactor, Replace fuse or reset circuit breaker transformer, or control relay Incorrect or faulty wiring Thermostat fan runs. setting too high Lower thermostat may normally cycles satisfying (other than Determine Scroll compressor overload, start relay is rotating in the wrong direction overcharge or undercharge Replace and determine Determine cause and correct Determine cause and correct Determine cause and replace. line voltage Blocked condenser Thermostat continuously. ovedoad or start relay motor or capacitor in refrigerant pressure, Replace filter. Decrease load or increase unit size for load Reset thermostat charge Locate leak, repair, and recharge Leaking valves in compressor Replace compressor. Air in system Recover Condenser Clean coil or remove restriction. soil dirty or restricted Refrigerant Condenser overcharged Recover excess air restricted Low refrigerant lOW, Compressor Restriction pressure, or air short-cycling charge Remove system, Compressor Replace compressor. Insufficient valves leaking overcharged Recover excess refrigerant Replace Filter. charge evaporator Check for leaks, repair, and recharge. Remove source of restriction. airflow Temperature too low in conditioned Outdoor ambient below 40°F Field-installed and recharge restriction. Check for source and eliminate. Metering device or low side restricted too low= refrigerant Recover refrigerant, evacuate Determine cause and correct Replace compressor. in Hquid tube Low refrigerant and recharge Check for leaks, repair, and recharge. valves leaking Dirty air filter pressure system, High heat load RsMgerant Suction refrigerant, evacuate Replace filter. Clean coil. coil Air in system tOO Replace. Locate restriction and remove system set too low Low reMgerant Dirty condenser suction cause Replace thermostat. Dirty air filter Excessive and recharge to thermostat). operates pressure Recover refrigerant, evacuate system, capacities shown on nameplate Insufficient Dirty air filter Unit undersized Head Correct the direction of rotation by reversing the 3-phase power leads to the unit Shut down unit to allow pressures to equalize. Defective compressor Restriction head cause and replace. Replace fuse or reset circuit breaker Determine cause. power dead Faulty condenser-fan Excessive setting below room temperature. Check wiring and repair or replace. Defective run/start capadtor, Defective run/start capacitor, Defective thermostat Compressor circuit Determine cause Replace compressor. Refrigerant Compressor in compressor Compressor motor burned out, seized, or internal overload open One leg of 3-phase Three-phase scroll compressor (48GS048 and 48GX030=060 only} makes excessive noise, and there be a low pressure differential. cause and correct Check wiring diagram and rewire correctly Faulty wiring or loose connections Compressor will not start but condenser Replace component Determine line voltage filter-drier area increase air quantity Reset thermostat install low-ambient restricted Replace. 31 Check filter -- replace if necessary kit. Table 17--Troubleshooting SYMPTOM REMEDY Water in gas line Drain. Install drip leg. No power to furnace Check power supply fuses, wiring, or circuit breaker Check transformer. NOTE: Some transformers have internal overcurrent protection that requires a cool-down period to reset. No 24-v power supply to contro{ circuit Burners will not ignite, Miswired or loose connections Check all wiring and wirenut connections Burned-out thermostat Replace thermostat. heat anticipator Broken thermostat Misaligned inadequate heating. Poor flame characteristics. Guide-Heating CAUSE in wire Run continuity check Replace wire if necessary Check flame ignition and sense electrode Adjust as necessary. spark electrodes No gas at main burners 1 Check NOTE: gas to 2 Check Dirty air filter Clean or replace filter as necessary. Gas input to furnace too low Check gas pressure at manifold unit nameplate Unit undersized Replace with proper unit or add additional for application positioning gas line for air Purge as necessary After purging gas line of air, wait at least 5 minutes for any dissipate before attempting to light unit gas valve. match with that on unit. Restricted airflow Clean or replace filter Blower speed too low Use faster speed tap if available, or install alternate motor. Limit switch cycles main burners Check rotation of blower, thermostat heat anticipator temperature rise of unit Adjust as necessary. Incomplete combustion results in: Aldehyde odors, carbon monoxide, flame, floating flame 1 Tighten all screws around burner compartment 2 Cracked heat exchanger Replace. 3 Unit overtired. Reduce input (change orifices or adjust gas line or manifold pressure). 4 Check burner alignment sooting 32 Remove any restriction. settings, Table18--TroubleshootingGuide-LEDError Codes SYMPTOM CAUSE REMEDY Check 5-amp fuse on IGC*, power to unit, 24-v circuit breaker, and Hardware failure, Less of power to control module (IGC)*. (LED OFF) transformer Units without a 24-v overload in the 24-v transformer. utes for automatic reset. circuit breaker have an internal If the overload trips, allow 10 rain- High limit switch opens during heat Fan ON/OFF delay modified exchanger warm-up period before fan-on delay expires. Limit switch opens within three minutes (LED/FLASH) Ensure unit is fired on rate: ensure temperature rise is correct. Ensure units external static pressure is within application guidelines after blower-off delay timing in Heating mode. Limit switch faults. (LED 2 flashes) High temperature Flame sense fault. (LED 3 flashes) The IGC _ sensed flame that should not be present. Reset unit. If problem persists, Inadequate airflow to unit Check operation of indoor (evaporator) fan motor and that supply-air temperature rise agrees with range on unit nameplate information 4 consecutive limit (LED 4 flashes) switch Check the operation of the indoor (evaporator) fan motor. Ensure that the supply-air temperature rise is in accordance with the range on the unit nameplate. limit switch is open. faults. Ignition lockout. (LED 5 flashes) Unit unsuccessfully 15 minutes, attempted ignition for Indueed_draft IGC does not sense that induced-draft Check ignitor and flame sensor electrode spacing, gaps, etc Ensure that flame sense and ignition wires are properly terminated. Verify that unit is obtaining proper amount of gas. Check for proper voltage. motor fault. (LED 6 flashes) sensor plug/IGC PIN 1-- White PIN 2 -- Red PIN 3 -- Black motor is operating* Rollout switch has opened. Rollout control (LED 8 flashes) Microprocessor has sensed an error in the software or hardware Temporary software lock out. (LED g flashes) check the speed Proper connection: If error code is not cleared by resetting unit power, replace the IGC*. Reset 24-v. to control board or turn thermostat then on again Fault will automatically reset itself in one (1) hour Electrical interference impeding If motor is operating, Terminal J2 connection Rollout switch will automatical{y reset, but IGC* will continue to Iockout unit Check gas valve operation. Ensure that induced-draft blower wheel is properly secured to motor shaft. Reset unit at unit disconnect Rollout switch fault, (LED 7 flashes} fault. replace control board. ]GC software off, * WARNING/_ X : 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 sensibve to static electricity and may be damaged if the necessary precautions are not taken IMPORTANT: Refer to Table 17--Troubleshooting Guide--Heating for additional troubleshooting LEGEND IGC -- Integrated Gas Unit Controller LED -- Light-Emitting Diode 33 analysis. START-UPCHECKLIST (RemoveandStore in Job File) L PRELIMINARY INFORMATION MODEL NO: ............................................................................................................................................................. SERIAL NO: .............................................................................................................................................................. DATE: ........................................................................................................................................................................ TECHNICIAN: ........................................................................................................................................................... JOB LOCATION: ........................................................................................................................................................... II. PRE-START-UP (insert checkmark in box as each item is completed) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS CHECK GAS PIPING FOR LEAKS CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PEACE VERIFY THAT UNIT INSTALLATION IS LEVEL CHECK FAN WHEEL PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW TIGHTNESS IIL START-UP ELE( TRI(AL SUPPLY VOLTAGE LI-L2 COMPRESSOR AMPS L1 COMPRESSOR AMPS L1 ]NDOOR (EVAPORATOR) L2-L3 L3-LI L2 L3 L2 L3 FAN AMPS TEMPERATURES 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 VERIFY REFRIGERANT DB WB WB IN. WG IN. WG PSIG PSIG SUCTION LINE TEMP* DISCHARGE LINE TEMPt CHARGE USING CHARGING TABLES VERIFY THAT 3-PHASE SCROLL COMPRESSOR DIRECTION. * Measured at s_mtion inlet to compressor + Measured at Iicp_id line leaving condenser (48GS048 and 48GX030-060) 34 IS ROTATING IN CORRECT 35 FormNo.48GS,GX-6SI Replaces: 48GS,GX-5SIPage36 11/02 Copyright 2002Carrier Corp. Catalog No.534-80128
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