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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Page Count: 36

HFATUNG & COOLING

48GS, 48GX

Single Packaged Gas Heating/

Electric Cooling Units

%isdt_ v_v_carrier.corn

Installation, Start-Up, and Operating

48GS Sizes 018-060, 48GX Sizes 024-060

NOTE: Read the entire instruction manual before starting the

installation

TABLE OF CONTENTS

SAFETY C ONSIDERATI(INS 1

INTRODE CTION 2

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

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

IDENTIFY EJNIT ................................................................ 2

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

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

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

ROOF (LRB ....................................................................... 2

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

GROL_D MOL_T ............................................................ 5

FIELD FABRICATE DUCTW()RK ........................................ 5

PROVIDE CLEARAN( ES ...................................................... 6

RIG AND PLA(E ENIT ......................................................... 7

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

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

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

INSTALL DUCT ( ONNE( TIONS ...................................... 10

(ONFIGURING UNITS FOR DO\}_TLOW (VERTI-

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

INSTALL ELECTRICAL ( ONNE(TIONS ......................... 12

HIGH-V()LTAGE CONNECTIONS ................................ 12

SPECIAL PROCEDURES FOR 208°V OPERATION ._ 13

CONTROL VOLTAGE CONNECTIONS ....................... 13

HEAT ANTICIPATOR SETTING ................................... 13

TRAN SFORMER PR()TECTION .................................... 13

PRE-START-E P .......................................................................... 15

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

(HECK FOR REFRIGERANT LEAKS ............................... 15

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

CHE(K HEATING CONTROL ....................................... 16

CHECK GAS INPUT ........................................................ !6

ADJUST GAS INPET ...................................................... 16

CHECK BURNER FLAME .............................................. 20

AIRFLOW AND TEMPERATURE RISE ....................... 20

HEATING SEQUEN(E OF OPERATION ..................... 20

LIMIT SWITCHES ........................................................... 20

AE XILIARY LIMIT SWITCH (ROLLOE T) .................. 21

START°E P COOLING AND MAKE ADJUSTMENTS ...... 21

CHECKING COOLING CONTROL OPERATION ....... 2!

< HE(KING AND ADJUSTING REFRIGERANT

CHARGE ........................................................................... 21

INDOOR AIRFLOW AND AIRFLOW ADJUST-

MENTS .............................................................................. 22

COOLING SEQE ENCE OF OPERATION ..................... 22

MAINTENANCE ......................................................................... 22

AIR FILTER ...................................................................... 25

EVAPORATOR BLOWER AND MOT()R ..................... 25

FLEE GAS PASSAGEWAYS ......................................... 27

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

LIMIT SWIT(H ................................................................ 28

BURNER IGNITION ........................................................ 28

MAIN BE RNERS ............................................................. 28

CONDENSER COIL, EVAPORATOR (OIL, AND

CONDENSATE DRAIN PAN .......................................... 29

CONDENSER FAN .......................................................... 29

ELECTRICAL CONTROLS AND WIRING .................. 30

REFRIGERANT CIRCUIT ............................................... 30

GAS INPUT ...................................................................... 30

EVAPORATOR AIRFLOW ............................................. 30

METERING DEVICE A(UTROL DEVICE ............. 30

LIQUID LINE STRAINER .............................................. 30

TROE BLESHOOTING ............................................................... 30

START-UP CHEf KLIST ............................................................ 30

NOTE TO INSTALLER Before the installatiom READ THESE

INSTRU(TIONS CAREFELLY AND (OMPLETELY. Also,

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

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

temporary heating of buildings or structures under construction.

A99338

Fig. 1--Unit 48GS and 48GX

(Low NO× Model Available)

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be

hazardous due to system pressure and ebctrical components Only

trained and qualified personnel should install, repair, or service

air-conditioning equipment.

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

PC 101 Catalog No 534-80128 Printed in U.S.A Form 48GS.GX-6SI Pg 1 11-02 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 precautions in the literature, tags, and labels

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

Follow all safe V codes. Wear safety glasses and work gloves. Use

quenching cloth for unbrazing operations. Have fire extinguisher

available ibr all brazing operations.

Improper installation, adjustment, aheration, service, mainte-

nancQ or use can cause carbon monoxide poisoning, fire, or

an explosion which can result in personal injury or unit

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

supplier for information or assistance. The qualified installer

or agency must use only factory-authorized kits or accessories

when modifying this product

Beibre peribrming service or maintenance operations on mail

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

switch and install lockout tag. Elecn'ical shock or explosion

could cause serious inju_ or death.

Recognize safety infbrmation This is the safety-alert symbolz_

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

the potential _br personal injory.

Understand the signal words 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 signifies a hazard which could

result in serious inju V or death. CAUTION is used to identii_,

unsafe practices which would result in minor personal injury or

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

tions which will result in enhanced installation, reliability, or

operation.

These instructions cover minimuna requirements and confbrm to

existing national standards and safety codes. In some instances,

these instructions exceed certain local codes and ordinances,

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

tial construction practices. We require these instructions as a

minimum ibr a saf_ installation.

INTRODUCTION

The 48GS and 48GX units (See Fig. 1) are fu!ly self_containe&

combination Category- I gas heating/electric cooling units designed

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

unit sizes have return and discharge openings ibr both horizontal

and downflow configurations, and are ii_ctory shipped with all

downflow duct openings covered. Units may be installed either on

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

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

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

dedicated Low NOxunits designed fbr California installations.

These models meet the California maximum oxides of nitrogen

(NOx) emissions requirements of 40 nanograms joule or less as

shipped from the factory and must be installed in California Air

Quality Management Districts where a Low NO× rule exists.

RECEBVING AND INSTALLATION

Step 1--CHECK EQUIPMENT

IDENTIFY UNIT

The unit model number and serial nunfber are stamped on unit

identification plate. Check this information against shipping papers

and job data. Verit}' unit voltage and amperage requirements listed

on unit rating plate agree with power supply provided to unit

INSPECT SHIPMENT

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

If unit appears to be damaged or is torn loose t'rom its anchorage,

have it examined by transportation inspectors before removal

Forward claim papers directly to transportation company Manu-

facturer is not responsible for any damage incurred in transit

Check all items against shipping list Immediately notify the

nearest distributor if any item is missing.

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

until installation.

INSTALLATION

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

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

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

spreader bar of sufficient length to protect unit t_-om damage.

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

unit. Be sure the strap does not twist

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

in the composite pan.

4. Thread liking bracket strapping around bottom perimeter of

unit as follows:

a Open lever of tension buckle (ratchet type)

b. Feed strapping throngh tension buckle as shown in Fig 7A.

c Pull strapping through tension buckle unit taut.

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

strapping, squeeze safkty latch, Ilk lever, and pull webbing

outward

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

must be secure in the rigging holds

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

hole in the liking bracket (See Fig. 7B).

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

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

lifting brackets (See Fig. 7B).

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

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

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

Step 2--PROVIDE UNiT SUPPORT

ROOF CLRB

Install accessory roof curb in accordance with instructions shipped

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

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

curb

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

for a watertight seal. Install gasketing material supplied with the

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

and poor unit perfbrmance.

Cm:b should be level to within 1/4 in. This is necessa_' for unit

drain to Nnction properly. Refkr to accessory roof curb installation

instructions for additional information as required.

SLAB MOUNT

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

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

compressor end of the unit (to allow condensate &ain installation)

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

(See Fig. 6). Do not secure the unit to the slab e:vcept when

required by local codes.

(t CD,[ [_H [ GJ I _1,

ZS4 "" 5q } _ 5 :

[_9 K,] [ [2, _o] _ [o oo] i

86 I _ _ j

, : _C,_494_ 0_i t:¸

OPU 6

t '

i N

249 ;

i,, s1 550 5 ?49 6

IN _;i }9 8_]

REAR ViEW

REQUIRED CLEARANCE TO COMBUSTIBLE MATL INCHES [mm]

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

DUCT SIDE OF UNIT ......................................................................... 200 [508]

SIDE OPPOSITE DUCTS ................................................................ 14.00 [355 8]

BOTTOM OF UNIT ............................................................................. 050 [127]

ELECTRIC HEAT PANEL ................................................................. 3600 [914 4]

NEC. REQUIRED CLEARANCES,

INCHES [mm]

BETWEEN UNITS, POWER ENTRY SIDE .................................... 42.00 [1086 8]

UNIT AND UNGROUNDED SURFACES. POWER ENTRY SIDE 3800 [914 0]

UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES POWER ENTRY SIDE ......................... 4200 [1066 8]

LEGEND

CO Center of OravRy

COND Condensor

EVAP Evap@ator

NEC National E[ectnca[Code

REQ'D Reqused

NOTE:Dimensionsare in in [mm]

REQUIRED CLEARANCE FOR OPERATION AND SERVICING INCHES [mm]

EVAR COIL ACCESS SIDE ............................................................ 36.00 [914 0]

POWER ENTRY SIDE .................................................................... 3600 [914 0]

(EXCEPT FOR NEC REQUIREMENTS)

UNIT TOP ....................................................................................... 48.00 [1219 2]

SIDE OPPOSITE DUCTS .............................................................. 36.00 [914 0]

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

*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 1200 [304 8] FROM

WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE

UNIT

48GS018040

48GS024040/080

48GS030040/080

48GS038060/090

48GS042060/090

48GX624040/060

48GX036040/060

48GX036066/090

ELECTRICAL CHARACTERISTICS

208/230-1-60

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

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

208/230-1-60

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

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

UNIT WEIGHT

Ib Tkg

249.0 113.2

280.0 127.3

320.0 145.1

355.0 161.4

290.0 131.5

313.0 142.0

321.0 145.6

UNIT HEIGHT IN. ([VIM)

,,A,_

35.02 (889.5)

37.02 (940.3)

35.02 (889.5)

37.02 (940.3)

39.02 (991.1)

35.02 (889.5)

20.0 (508.0)

22.5 (571.5)

21.5 (546.1)

22.5 (571.5)

21.5 (546.1)

22.0 (558.8)

Fig. 2--48GS018-042 and 48GX024-036 Unit Dimensions

CENTER OF GRAVITY

IN.(MM)

140 (3556)

130 (3302)

1375 (349.3)

140 (355.6)

135 (342.9)

145 (3683)

153 (3874)

153 (387.4)

COOO55

15.0(3810)

150 (3810)

130 (3302)

16.0 (4064)

176 (4470)

165 (4191)

[33£1

70 4

[2 77] i

402 o

[15 83]

[1177

{a 631

88 3

[3 46] [13831 [13 62] [13831

REAR VIEW

REQUIRED CLEARANCE TO COMBUSTIBLE MATE

INCHES [mini

TOP OF UNIT ................................................................................... 14,00 [355 6]

DUCT SIDE OF UNIT ......................................................................... 2.00 [50.8]

SIDE OPPOSITE DUCTS ................................................................ 14,00 [355 6]

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

FLUE PANEL .................................................................................... 36,00 [914 4]

NEC. REQUIRED CLEARANCES,

INCHES [mm]

BETWEEN UNITS, POWER ENTRY SIDE .................................... 4200 [1066.6]

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

UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES, POWER ENTRY SIDE ......................... 4200 [1066 8]

[16 O!]

i E_AP COIL

k_- 10906

[42 943

L._ It231

[44 22]

LEFT SIDEVIEW

UNiT

48G8048090/115/130

48GS0600901115/130

48GX042060/090

48GX048090/115/190

48GX060090f115/130

3558

{1411] _3427 _ 3558

[!3 49] [14 Oi]

SUPPLY

4066

[1601]

TOP VIEW

C01L

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

INCHES [mm]

EVAR COIL ACCESS SIDE ............................................................ 3600 [914 0]

POWER ENTRY SIDE .................................................................... 3600 [914 0]

(EXCEPT FOR NEC REQUIREMENTS)

UNIT TOP ....................................................................................... 4800 [1219.2]

SIDE OPPOSITE DUCTS .............................................................. 3600 [914 0]

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

*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 1200 [304 8] FROM

WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE.

LEGEND

CG - Center of Gravity

COND - Condensor

EVAP- Evaporator

NEC - National Electrical Code

REQ'D - Required

1939 _'< _ !15 4 NOTE:Dimensionsare in in, [ram]

47 OO] [4 54]

....... ,,OO/ i? L[4iR) " i...........

"....................... 12 i [O 881 OlA I@lE ' ..............

CONTROLEN/RY

[.8 1 VIiA_

i \ o

[ 68] MPRESSOR,BLOtlER 6AS S{CTION FLUE FLOOD fY _4] 7[O 50] N P T

329 O & Et CTR CAt £;¢[SS PANEl 528 GAS ENTRY 5 O

FRONTVIEW RIGHTSIDEVIEW 000056

ELECTRICAL CHARACTERISTICS

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

208/230-1-60, 208/230-%60, 460-3%0

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

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

UNIT WEIGNT

Ib kg

415 1886

450 2045

382 1733

421 1910

468 2123

UNIT HEIGHT IN. (MM)

"A"

38.98 (990.2)

42.98 (1091.1)

22 (5585)

23.0 (584.2)

21.5 (546.1)

23.5 (596.9)

Fig. 3--48G8048-060 and 48GX042-060 Unit Dimensions

CENTER OF GRAVITY

IN.(MM}

Y Z

16 (406.4) 17 (432 0)

16 (406.4) 17 (4320)

163 (412.8) 166 (4216)

166 (422.1) 180 (4572)

163 (412.8) 176 (4470)

RoofCurb for Small Cabinet

Note A: When uNt mounting screw is used,

retah3er bracket must also be used.

Roof Curb for Large Cabinet

Note A: When unit mounting screw is used,

retainer bracket must also be used.

-->

R/A

-'-_- Gasket around_

duct

S/A

Long

SL pport

Suppolt

insulated

deck pan Gasket around

outer edge \ \,

iBXC}

C00076

UNiT S_ZE

48GS018o042 48GX024-036

48GS048o060 48GX042-060

NOTES:

1. Roof curb must be set up for unit beh_ginstalled

ODS CATALOG NUMBER

CPRFCURB006A00

CPRFCURB007A00

CPRFCURB008A00

CPRFCURB009A00

IN. {NM)

8 (203)

14 (356)

8 (203)

14 (356)

IN.(MM)

11(279)

16 3/16 (411)

RN.(MM)

161/2 (419)

17 3/8 (441)

IN. (t_M)

2G3/4 (730)

28-3/4 (730)

40-1/4 (1022)

2. Seal strip must be applied, as required, to unit being installed.

3. Dimensions in ( ) are in millimeters

4. Roof curb is made of 16-gage steel.

5. Table lists only the dimensions, per part number, that have changed

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

7. InsuIated panels: 1-in. thick fiberglass 1 Ib density.

8. Dimensions are in inches

9. 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 or

seismic conditions. This bracket is available through Micrometl.

Fig. 4--Roof Curb Dimensions

GROL ND MOL_T

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

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

prepared with gravel _br condensate discharge.

Step 3--FIELD FABRICATI= DUCTWORK

Secure all ducts to roof curb and building strecture on vertical

discharge uriits Do t_nt connect duct_oHc to z_nit. For horizontal

applications, unit is provided with flanges on d_e horizontal

openings Installation of flexible duct connector is recommended

to prevent tlansmission of vibration and/or noise to stl_acture. All

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

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

flashing and mastic in accordance with applicable codes

Ducts passing through an unconditioned space must be insulated

and covered with a vapor barrier.

4 x 3

C00070

48GS

CORNER # 018 024 030 036 042 048 060 024

1 47.3 53.2 53.2 59.7 675 789 85.5 55.1

2 44.8 50.4 50.4 56.5 639 747 81.0 52.2

3 77.2 86.8 86.8 97.3 1101 128.7 1395 89.9

4 79.7 89.6 89.6 106.5 1136 132.8 1440 92.8

TOTAL WEIGHT 249 280 280 320 355 415 450 290

48G×

030 036 042 048 060

595 61.0 72.6 800 88.9

563 57.8 68.8 758 84.2

970 99.5 1184 130.5 145.1

1002 102.7 1222 134.7 149.8

313 321 382 421 468

Fig. 8--48GS and 48GX Unit Corner We{ghts

2 F_

(50.8mn

EVAR COND.

COIL COIL

Fig. 6--Slab Mounting Details

C99014

HANDHOLD

Fig. 7A--Threading BoR for RiggBng

C99067

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.

PLAOE

BASEPAN SLOT (BELOW RIGGtNG HOLDS}

BEFORE RIGGING

SRZE

0t8

024

030

036

042

048

050

024

030

036

042

048

050

DIJCTS

SEAL STRIP MI _ST BE _N

PLACE BEFORE PLACING

_JN_T ON RO©F CURB

C99015

MAX,MUM WE,GNT [ A [ B

tb kg in. mm in. mm

271

302

342

377

437

472

312

335

343

404

443

490

UNIT 48G8

123.2 20.0 508.0 14.0 355.6

137.3 22.5 571.5 13.0 330.2

137.8 21.5 546.1 13.75 349.3

155.1 22.5 571.5 14.0 355.6

171.4 21.5 546.1 13.5 342.9

198.6 22.0 558.5 17.0 432.0

214.5 22.0 558.5 17.0 432.0

UNIT 48GX

142 22.0 558.5 14.50 368.3

152 22.0 558.5 15.30 388.6

156 22.0 558.5 15.30 388.6

183 23.0 584.2 16.3 414.0

201 21.5 546.1 16.3 414.0

222 23.5 596.9 16.3 414.3

Fig. 7B--Suggested Rigging

Step 4--PROVIDE 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 Data--UnR 48GS

UNIT SBZE 48GS

NOMINAL CAPACBTY (ton)

OPERATING WEIGHT (_b.)

COMPRESSORS

Quantity

REFRmGERANT (R-22)

Quantity (_b.)

REFRIGERANT METERING DEVICE

Orifice ID (in.)

CONDENSER CORL

Rows...Finslin.

Face Area (sq ft)

CONDENSER FAN

NominN Cfm

Diameter (in.)

Motor Hp (Rpm)

EVAPORATOR COBL

Rows...Fins/in.

Face Area (sq ft)

EVAPORATOR BLOWER

Nomina_ Airflow (Cfm)

Size ({n.)

Notor BP (Rpm}

FURNACE SECTION*

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

Natural Gas

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

Propane Gas

RETURN-ABR FILTERS (in.)?

Throwaway

* Based on altitude of 0 to 2000 ft

018040 024040

1½ 2

249 280

024060

280

030040

2½

280

038080

320

042060

3½

355

042090

3½

355

.034 I .034 .034 .032 .034 .034

1 17 [ 1._17 1_17 1._17 1_.17 1._17

6 I n 9.1 9.1 10.9 9.1 9.1

2400

1/8 (825)

2000 1

1/8 (825) 1

030080 036060

2½ 3

280 320

Reciprocating

AcutroF M Device

.034 .032

1...17 1...17

9.1 10.9

2400 3000

22 22

1/8 (825) ¼ (1100)

2...15 3...15

3.1 3.1

1000 1200

10 x 10 11 x 10

lg (1075) 1/2 (I075)

2...38 2...38

2...46 2...46

20 X 20 20 X 24

3000

¼ (1100)

2400

1/8 (825)

3000

¼ (1100)

.O34

1...17

9.1

2400

1/8 (825)

2...15

3.1

8OO

10 x 10

1/4 (1075)

3000

¼(1100)

2...15 I 2...I5 2...15 3...15 4...15 4...15

" _ ' 3.1 3.1 3.1 3.1 3.1.J _ ,

600 I 800 1000 1200 1400 1400

10x10 I 10x10 10x10 11x10 11x10 11x10

1/4 (87511 1/4 (I075) 1/4 (1075) 1/2 (1075) 3/4 (1075) 3/4 (1075)

2...45 I 2...45 2...38 2...45 3...38 2...38 3...38

2...50 I 2...50 2...46 2...50 3...46 2...46 3...46

20x20 I 20x20 20X20 20x20 20X24 20x24 20x24

? 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, of the National Fuel Gas <ode ANSI

(American National Standards Institute) Z2231 or applicable

provisions of local building code In Canada, _bllow sections 7.2,

7.3, or 7.4 or CaniCGA. (Canadian Gas Association) B149

Installation Codes or applicable provisions of local building code.

Do not restrict condenser airflow. An air restriction at either

the outdoor-air inlet or the £m discharge can be detrimental to

compressor tiff.

The condenser £m pulls air through the condenser coil and

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

does not recirculate to the condenser coil Do not locate the unit in

either a comer or under an overhead obstruction. The minin-mm

clearance under a pmlial overhang (such as a nomml house

overhang) is 48-im above the unit top. The nmximnm horizontal

extension of a partial overhang must not exceed 48-in_

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

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

carpeting, tile, or other combustible materials. The unit nmy be

installed on wood flooring or on (;lass A, B, or ( roof covering

materials.

Step 5--RIG AND PLACE UNW

When installing the unit on a rooftop, be sure the roof will

support the additional _eight

Use spreader bars or crate top when rigging the uniL The units

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

operating weight. L'xe e:v::'eme ca_ltio_v to prea,e_vt damage whe_

mu_ ing the _mit. Unit m_¢stremain in an upH@tpo,sition dHring a//

riggi<g a_d mo_,i_tg operaff(ms.The unit must be level within 14"

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

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

When a field°fi_bricated support is used, be sure that the support is

level and properly supports the unit. Lifting point should be

directly over the center of gravity for the unit.

Step g--CONNECT CONDENSATE DRAIN

NOTE: When installing condensate &ain connection be sure to

comply with local codes and restrictions.

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

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

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

Condensate water can be drained directly onto the roof in rooftop

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

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

condensate connection to ensure proper drainage Make sure that

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

condensate connection to prevent the pan fl'om overflowing (See

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

make sure it slopes away fl'om the unit

If the installation requires draining the condensate water away

from the unit, install a 2=ira trap at the condensate connection to

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

the trap is at least 1 in. lower than the drainpan condensate

connection. This prevents the pan tiom overflowing.

Prime the trap with water. Connect a &ain tube using a mininmna

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

outlet end of the 2=ira trap. Do not undersize the robe. Pitch the

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

UNiT SIZE 48GS

NOMINAL CAPACITY (ton)

OPERATING WEIGHT (lb.)

COMPRESSORS

Quantity

REFRIGERANT {R=22)

Quantity (lb.)

REFRIGERANT METERING DEVICE

Orifice ID (in.)

CONDENSER COIL

Rows...Fins/im

Face Area {sq ft)

CONDENSER FAN

Nominal Cfm

Diameter (in.)

Motor Hp (Rpm)

EVAPORATOR COIL

Rows...Finsiim

Face Area (sq ft)

EVAPORATOR BLOWER

Nominal Airflow (Cfm)

Size (in.)

Motor Bp (Rpm)

FURNACE SECTION*

Burner Orifice No. {Qty...DrSI Size)

Natural Gas

Burner Orifice No. {Qty...DrSI Size)

Propane Gas

RETURN-AIR FILTERS {in.)?

Throwaway

* Based on altitude of 0 to 2000 ft

048090 048115 060 t 18 060130

4 4 5 5

415 415 450 450

Scroll Reciprocating

1 1

6.0 6.0 8.0 8.0

.032 .032 .030 .030

1._17 1._17 2._17 2._17

12.3 12.3 12.3 12.3

3600 3600 3600 3600

22 22 22 22

'/_ (1100) 1/_(1100) '/_ (1100) '/_ (1100)

3...15 3...15 4._15 4...15

4.7 4.7 4.7 4.7

1600 1600 2000 2000

11X10 11X 10 11X10 11X10

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

3._38 3...33 3_.33 3_.31

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

24 X 30 24 X 30 24 X 30 24 X 30

048130 0$0090

4 5

415 450

6.0 8.0

Acutrol Device

.032 .030

1...17 2...17

12.3 12.3

3600 3600

22 22

1/_(1100) '/_ (1100)

3...15 4._15

4.7 4.7

1600 2000

11 X 10 11 X 10

3/4 (1075) 1.0 (I075)

3...31 3...38

3...41 3...46

24 X 30 24 X 30

1 Reqaired filter sizes shown are based on the larger of the AR[ (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300

ft/minate 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

drain robe downward at a slope of at least 1-in. %r every 10 ft of

horizontal run, Be sure to check the drain robe for leaks,

1" min.

TRAP

OUTLET

2" rain.

Fig. 8--Condensate Trap

C00009

Step 7--INSTALL FLUE HOOD

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

indoor blower compartment Remove the service access panel to

locate the assembly (See Fig. 3i).

NOTE: Dedicated low NO x models MUST be installed in Call=

fomia Air Quality Management Districts where a Low NO× rote

exists,

These models meet the California maximmn oxides of nitrogen

(NOx) emissions requirements of 40 nanogramsdoule or less as

shipped from the fhctory,

NOTE: Low NO x requirements apply only to natural gas instal-

lations,

The venting system is designed to ensure proper venting. The

flue hood assembly must be installed as indicated in this

section of the unit installation insm/ctions,

Install the flue hood as fbllows:

1, This installation must confot_n with local building codes and

with the National Fuel Gas (?ode (NFGC), ANSI Z223 1 (in

( anada., CANiCGA B 149,1, and B 149 2) or NFPA (National

Fire Protection Association) latest revision Refer to Provin=

cial and local plumbing or wastewater codes and other

applicable local codes,

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

compartment) Place vent cap assembly over flue panel, Orient

screw holes in vent cap with holes in the flue panel

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

the right side and the tet_ side of the hood.

Step 8--INSTALL GAS PIPING

)"he gas supply pipe enters the unit through the access hole

provided, The gas connection to the unit is made to the 1/2=in, FPT

gas inlet on the manual shutoff or gas valve.

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

Table 3 and the NFGC for gas pipe sizing. Do _ot zlse cast-iros_

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

local utility for recommendations concerning existing lines. Size

gas supply piping for 0,5 in, wg maximum pressure drop, _\2_*er

_¢se pipe smaHe/' than the ].lL_:in+ FflY gax m/et up tile zmit ,?aX

ICt]1'C.

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

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

TaNe 2--Physicam Data--Unit 48GX

UNiT BBZE 48GX 024040 024000 030040 030000 030060 036090 042060 042090

NOMINAL CAPACITY (ton) 2 2 2"½ 2_½ 3 3 3½ 3½

OPERATING WEIGHT (lb.) 290 290 313 313 321 321 382 382

COMPRESSORS Scroll

Quantity 1

REFRmGERANT (R-22) 3.7 3.7 4.4 4.4 5.2 5.2 6.4 6.4

Quantity (_b.)

RBFRBGERANT METERBNG DEVICE .034 .034 .030 .030 .032 .032 .034 .034

Orifice ID (in.}

CONDENSER COBL 1._17 1._17 1_.17 1...17 2...I7 2...17 2...17 2._17

Rows...Fins/in. 10.8 10.8 12.7 12.7 9.1 9.1 12.3 12.3

Face Area (sq ft}

CONDENSER FAN 2350 2350 2350 2350 2350 2350 3300 3300

Nominal Cfm 22 22 22 22 22 22 22 22

Diameter (in.)

Motor Bp (Rpm) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825)

EVAPORATOR COIL 3...15 3_.15 3._15 3._15 3._15 3...15 3_.15 3_.15

Rows...Fins/in. 3.1 3.1 3.1 3.1 3.7 3.7 4.7 4.7

Face Area (sq ft}

EVAPORATOR BLOWER 800 800 1000 1000 1200 1200 1400 1400

Nominal Airflow (Cfm) 10X10 10X10 10X10 10X10 11X10 11X10 11X10 11X10

Size (in.)

Motor Hp {Rpm) 1/4 (1075) 1/4 (1075) 1/4 (1075) 1/4 (1075) 1/2 (1075) 1/2 (1075) 3/4 (1075) 3/4 (1075)

FURNACE SECTION*

Burner Orifice No. (Qty...DriH Size) 2...44 2_.38 2_.44 2...38 2...38 3...38 2...38 3_.38

NaturN Gas 2...50 2...46 2...50 2...46 2...46 3...46 2...46 3...46

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

Propane Gas

R_:TURN-ABR FBLTERS (Jn.)t 20 X 20 20 X 20 20 X 20 20 X 20 20 X 24 20 X 24 24 X 30 24 X 30

Throwaway

* Based on altitude of Oto 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

if/minute for high-capacity type Air filter pressure drop for non-standard fitters must not exceed 008 in wg.

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

not be less than 7.0 in wg oi" greater than 13 in wg at the unit

connection

An 1/8-in. NPT plugged tapping, accessible fbr test gage conneco

tiom must be installed immediately upstream of the gas supply

connection to the gas valve.

When installing the gas supply line, obsel_'e local codes pertaining

to gas pipe installations. Ref)r to the NFGC ANSI Z223J-1988

NFPA latest edition (in Canada, (ANiCGA B 14% 1, (2)-M86). In

the absence of local building codes, adhere to the fbltowing

pertinent recommendations:

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

ever?" 15 ft to prevent traps. Grade all horizontal runs

downward to risers. Use risers to connect to heating section

and to meter.

2. Protect all segments of piping system against physical and

thermal damage. Support all piping with appropriate straps,

hangers, etc. Use a mininmm of one hanger eve N- 6ft. For

pipe sizes larger d_an 1/2 in., fbltow recommendations of

national codes.

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

threads of joint when making pipe connections. Use only pipe

dope that is resistant to action of liquefied petroleum gases as

specified by local and/or national codes. :\;ever zz.se 7;e_7ot_

tope.

4. Install sediment trap in riser leading to heating section (See

Fig. 9). This &ip leg Nnctions as a trap fbr dirt and

condensate.

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

gas supply pipe within 6 ff of heating section.

6. Install groundojoint union close to heating section between

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

? Pressure-test all gas piping in accordance witla local and

national plumbing and gas codes before connecting piping to

unit,

NOTI::: Pressure test the gas supply system qfter the gas supply

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

disconnected f?om the gas valve during the testing of the piping

systems when test pressure is in excess of 0.5 psig. Pressure test

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

psig. The unit heating section must be isolated fi'om the gas piping

system by closing the external main manual shutoff valve and

slightly opening the ground-joint union.

Unstable operation may occur when the gas valve and

manifbld assembly are forced out of position while connect-

ing improperlyorouted rigid gas piping to the gas valve. Use

a baclcup wrench when making connection to avoid stlain on,

or distortion of, the gas contIol piping.

If a flexible conductor is required or allowed by the authority

having jurisdictiom black iron pipe shall be installed at the

gas valve and shall extend a nlinirnurn of 2in. outside the unit

casing.

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

UNiT BBZE 48G× 048090 048115 048130 0g0090 060115 060130

NOMINAL CAPACBTY (ton) 4 4 4 5 5 5

OPERATING WEIGHT (_b.) 421 421 421 468 468 468

COMPRESSORS Scrolt

Quantity 1

REFRmGERANT {R=22}

REFRIGERANT METERING OEVICE Acutrol Device

Orifice ID (in.) .034 .034 .034 .032 .032 .032

CONDENSER CORL 2...17 2._17 2._17 2...17 2_.17 2._17

Rows...Finstin. 12.3 12.3 12.3 16.4 16.4 16.4

Face Area {sq ft}

CONDENSER FAN 3300 3300 3300 3300 3300 3300

Nominal Cfm 22 22 22 22 22 22

Diameter (in.)

Motor Hp (Rpm) _A(1100) _¼(1100) _¼(1100) _A(1100) _A (1100) _A(1100)

EVAPORATOR COIL 4...15 4...15 4...15 4...15 4...15 4...15

Rows...Finslin. 4.7 4.7 4.7 4.7 4.7 4.7

Face Area {sq ft}

EVAPORATOR BLOWER 1600 1600 1600 1750 1750 1750

Nomina_ Airflow (Cfm} 11 X 10 11 X 10 11 X 10 11 X 10 11 X 10 11 X 10

Size ({n.} 3/4 (1075) 3/4 (1075) 3/4 (1075) 1.0 (I075) 1.0 (1075) 1.0 (1075)

Motor Bp (Rpm)

FURNACE SECTION*

Burner Orifice No. (Qty...DriH Size) 3._38 3...33 3...31 3...38 3_.33 3_.31

Natural Gas 3...46 3...42 3...41 3...46 3...42 3...41

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

Propane Gas

RETURN-AIR FILTERS (in.)'( 24 X 30 24 X 30 24 X 30 24 X 30 24 X 30 24 X 30

Throwaway

Based on altitude of 0 to 2000 ft

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

ft/minute for high-capacity type Air filter pressure drop for non-standard filters must not exceed 008 in. wg.

Table 3--Maximum Gas Flow Capacity*

NOMINAL

IRON PIPE,

SIZE

(IN.}

11/4

iNTERNAL LENGTH OF PIPE, FT¢

DIAMETER

(BN.} 10 20 30 40 50 60 70 80 90 100 125 150 175 200

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

.624 360 250 200 170 151 138 125 118 110 103 93 84 77 72

1.049 660 465 375 320 285 260 240 220 205 195 175 160 145 135

1.380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280

1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430

Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 05-in wg (based on a 0.60 specific gravity gas). Refer to Tabte C-4, National

Fire Protection Association NFPA 54.

1 This length includes an ordinary number of fittings

Never use a match or other open flame when checking %r gas

leaks. Never purge gas line into combustion charuber. Failure

to follow this warning could result in an explosion causing

serious injury or death.

8. Check %r gas leaks at the field-installed and factow-installed

gas lines after all piping connections have been completed

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

codes and/or regulations)

Step g--INSTALL DUCT CONNECTmONS

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

the side and bottom o_["the unit, For downshot applications, the

ductwork connects to the roof cm'b (See Fig 2 and 3 for

connections sizes and locations)

CONFIGURING UNITS FOR DOV_q',rFLOW (VERTI(AL) DIS-

( HARGE

Be%re per%rming service or maintenance operations on the

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

cause serious injury or death.

1. Open all electrical disconnects be%re starting any service

work_

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

connecting tabs with screw&iver and a hammer (See Fig. 10A

& 10B).

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

connecting tabs with a screwdriver and a hammer. Push touver

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

OUT

3"MIN

__!_1

--:u

TEE

_.._ NIPPLE

CAP

Fig. 9--Sediment Trap

C99020

SUPPLY RETURN

DUCT DUCT

OPENING OPENING C99011

Fig. 10A SupNy and Return Duct Opening

4. If unit duct_xork is to be attached to x ertical opening flanges

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

at this time,

Collect ALL screws that v, ere removed. Do not lea_e screws

on rooftop as pem_anent damage to the roof may occur

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

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

unit base with aluminum tape. Applicable local codes may

require aluminum tape to prevent exposed fiberglass

6. Cover both horizontal duct openings with the duct covers fl'om

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

watertight.

7. After completing unit conversion, perform all safety checks

and power up unit.

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

accordance with the standards of the NFPA fbr installation of

nonresidence-type air conditioning and ventilating systems, NFPA

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

ordinances.

DUCT COVERS REMOVED

C99012

Fig. lOB--Vertical Duct Cover Removed

Adhere to the following criteria when selecting, sizing_ and

installing the duct system:

1Lnits are shipped for horizontal duct installation (by removing

&ct covers)

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

grilles according to American Society of Heating, Refiigera-

tion and Air (onditioning Engineers (ASHRAE) recommen=

dations

3Lse flexible transition between rigid dnctwork and unit to

prevent transmission of" vibration. The transition may be

screwed or bolted to duct ['langes. Lse suitable gaskets to

ensure weathertight and airtight seal.

4 All units must have field-supplied filters or accessory filter

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

sizes fbr filters are shown in Tables 1 and 2.

5. Size all dnctwork for naaximnm required airflow (either

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

size increases or decreases or perfimnance may be affected.

6. Adequately insulate and weatherproof all ductwork located

outdoors. Insulate ducts passing through unconditioned space,

and use vapor barrier in accordance with latest issue of Sheet

Metal and Air Conditioning Contractors National Association

(SMA(NA) and Air Conditioning Contractors of America

(AC(A) mininmm installation standards for heating and air

conditioning systems. Secure all dtlcts to building structure.

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

building structure in accordance with local codes and good

building practices.

UNIT

SBZE

48GS

018

824

O3O

836

042

048

OGO

V-PH-HZ

208/230-1-60

208/230-3-60

208/230-1-60

208/230-3-60

460-3-60

208/230-1-60

208/230-3-60

460-3-60

208/230-1-60

208/230-3-60

460-3-60

208/230-1-60

208/230-3-60

460-3-60

VOLTAGE

RANGE

Table 4--Electrical Data--Unit 48GS

COMPRESSOR OUTDOOR FAN INDOOR FAN

MOTOR MOTOR

FLA

1.8

2.0

3.6

1.9

3.8

2.0

3.8

2.0

6.2

3.2

Max RLA

253 9.0

253 12.8

253 14.4

253 12.6

253 13.0

253 9.0

506 4.5

253 18.6

253 10.7

506 5.3

253 25.3

253 13.5

506 6.7

253 28.9

253 18.6

506 8.5

Min

187

414

187

414

197

187

414

187

414

LRA

45.0

61.0

73.0

68.0

81.0

78.0

40.0

105.0

85.0

42.0

131.0

108.0

47.5

147.0

125.0

66.5

FLA

0.8

1.6

0.9

1.6

0.9

1.6

0.9

1.6

0.9

POWER SUPPLY

Max Fuse or

MCA Ckt Bkr

13.9 20

18.8 30

20.8 30

13.2 20

24.0 35

16.5 25

8.4 15

27.5 45

18.8 25

9.5 15

37.0 60

22.3 35

11.3 15

43.9 60

31.1 45

14.7 20

Step 10--INSTALL ELECTRICAL CONNECTIONS

The unit cabinet must have an unimetTupted, unbroken

electrical ground to minimize the possibility of serious injury

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

an electrical wire connected to the unit ground lug in the

control compartment, or conduit approved for electrical

ground when installed in accordance with NEC (National

Electlical Code) ANSIiNFPA (latest edition) and local elec-

trical codes. In Canada, fi_llow Canadian Electrical Code

CSA (Canadian Standards Association) (22.1 and local

electrical codes. Failure to adhere to this warning could result

in serious injm?- or death.

Failure to %tlow these precautions could result in damage to

the unit being installed:

1 Make all electrical connections in accordance with NEC

ANSINFPA (latest edition) and local electrical codes

governing such wiring In Canada, all electrical connec-

tions must be in accordance with CSA standard C22.1

Canadian Electrical (?ode Part 1 and applicable local

codes RefBr to unit wiring diagram.

2 Use only copper conductor fbr connections between

field-supplied electrical disconnect switch and unit. DO

NOT USE ALUMINUM WIRE

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

voltage range indicated on unit rating plate

4 Do not damage internal components when drilling through

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

3-phase units, ensure phases are balanced within 2percenL

Consult local power company fbr correction of improper

voltage an&or phase imbalance

HIGH-VOLTAGE CONNECTIONS

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

supplied, waterproof, disconnect switch mounted at, or within

sight fi'om, the unit Refer to the unit rating plate fbr maximum

Nseicircuit breaker size and minimum circuit amps (ampacity) for

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

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

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

tow-voltage entIy points are used (See Fig. 2and 3 fbr acceptable

location).

See unit wiring label and Fig. 11 fbr refhrence when making high

voltage connections. Proceed as follows to complete the high-

voltage connections to the unit.

HIGH VOLTAGE /

POWER LEADS .<_o_

(SEE UNITWIRING_

LABEL) _:_

CONTROLBOX

LOW-VOLTAGE _

POWER LEADS_

(SEE UNIT

WIRING LABEL)

GND

'O"

SPLICE BOX

_ POWER

4Z::S JsuPPLY

FIELD-SUPPLED

FUSED DISCONNECT

VV_TLV_)_ @

YELLYL_ Q)

REDIRZ_> @

BRN!_ O" C)

THERMOSTAT

(TYPICAL)

C99018

Fig. 11--High= and Control=Voltage Connections

Single phase units:

1. Run the high-voltage (LI_ L2) and ground leads into the

control box.

2. Connect ground lead to chassis ground connection.

3. Connect L! to pressure tug connection 11 of the compressor

contactor,

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

contactor.

Three-phase units:

1. Run the high-voltage (L!, L2, L3) and ground leads into the

control box.

LEGEND

FLA -- Full Load Amps

LRA -- Locked Rotor Amps

MCA -- Minimum Circuit Amps

MOCP -- Maximum Overcurrent Protection

RLA -- Rated Load Amps

CKT BKR -- Circuit Breaker

NOTES:

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 volt-

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

the percentage of 'voltage imbalance.

% Voltage imbalance

= 100 x max voltage deviation from average voltage

average voltage

EXAMPLE: Suppty voltage is 460-3-60.

A B C AB = 452 v

BC = 464 v

AC = 455 v

Average Voltage = 452 + 464 + 455

_ 1371

= 457

Determine maximum deviation from average 'voltage.

(AB) 457 452=5v

(BC) 464 457=7v

(AC) 457 455=2v

Maximum deviation is 7 v.

Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x --

457

: 1.53%

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

maximum allowable 2%.

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 wires connected to the lines side

of the contactor

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

compressor contactor

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

compressor contactor

6. (onnect field wire L3 to Blue wire flora compressor

SPE(IAL PRO(EDURES FOR 208-V OPERATION

iii_ iiiiiiiiiii_,

Be_bre making any wiring changes, make sure the gas supply

is switched off first. Thet_ switch off the power st_pply to the

unit and install tockot_t tag. Electrical shock can cause serious

injury or death.

CONTROL VOLTAGE CONNE( TIONS

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

problems may result.

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

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

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

more than 100 ft flora the unit (as measured along fl_e control

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

minimmn) wires.

Standard ( onnection

Remove knockout hole located in the flue panel adjacent to the

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

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

grommet in the knockout opening. Provide a drip loop before

running wire through panel.

Rtm the low-voltage leads fiom the thermostat, through the inlet

hole, and into unit tow-voltage splice box.

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

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

brown, and white (See Fig. 1 i). Ensure the leads are long enough

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

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

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

cut wires, so that _hey do not interI:_re with operation of unit.

HEAT ANTICIPATOR SETTING

The room thermostat heat anticipator must be properly adjusted to

ensure proper heating performance. Set the heat anticipator, using

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

required setting.

NOT_:: For thermostat selection purposes, use 0.18 amp for fl-le

approximate required setting. Failure to make a proper heat

anticipator adjustment will result in improper operation, discom-

fort to the occupants of the conditioned space, and inefficient

energy utilization; however, the required setting may be changed

slightly to provide a greater degree of comfort for a particular

installation.

TRANSFORMER PROTE( TION

The tra_,_former is of fl_e energy-limiting type. It is set to

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

UNIT

SBZE

48GX

O24

030

036

O42

O48

OGO

V-PN-NZ

208/230-1-80

208/230-1-60

208/230-3-80

208/230-1-60

208/230-3-80

460-3-60

208/230-1-80

208/230-3-80

460-3-80

208/230-1-60

208/230-3-80

480-3-60

208/230-1-80

208/230-3-60

460-3-80

VOLTAGE

RANGE

Tab{e 5--Electrical Data--Unit 48GX

COMPRESSOR OUTDOOR FAN INDOOR FAN

MOTOR MOTOR

FLA

2.0

2.1

3.6

1.9

4.1

2.0

4.1

1.9

6.2

3.2

Max RLA

253 10.9

253 13.5

253 9.0

253 16.7

253 11.2

506 5.4

253 17.9

253 12.4

506 6.I

253 23.4

253 13.0

506 6.4

253 28.8

253 17.3

506 9.0

Min

187

414

187

414

187

414

187

414

LRA

54.0

73.0

63.0

97.0

75.0

37.5

104.0

88.0

44.0

126.0

93.0

46.5

169.0

123.0

62.0

FLA

0.9

0.8

0.9

1.6

1.8

0.9

1.5

0.9

1.6

1.8

0.9

POWER SUPPLY

Max Fuse or

MCA Ckt Bkr

16.5 25

19.8 30

14.2 20

25.3 40

18.4 25

9.6 15

28.1 45

21.2 30

10.5 15

34.9 45

21.9 30

10.8 15

43.8 60

29.4 45

15.4 20

LEGEND Q

FLA -- Full Load Amps

LRA -- Locked RotorAmps C US

MCA -- Minimum CircuitAmps

MOCP -- Maximum Overcurrent Protection

RLA -- Rated Load Amps

CKT BKR -- Circuit Breaker

NOTES:

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 volt-

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

the percentage of voltage imbalance.

% Voltage imbalance

= 100 x max voltage deviation fr

average voltage

EXAMPLE: Supply 'voltage is 460-3-60.

A B C AB = 452 v

BC = 464 v

AC = 455 v

Average Voltage = 452 + 464 + 455

1371

= 457

Determine maximum deviation from average 'voltage.

(AB) 457 452=5v

(BC) 464 457=7v

(AC) 457 455=2v

Maximum deviation is 7 v.

Determine percent of voltage imbalance.

% Voltage imbalance = 100 x --

457

= 1.53%

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

maximum allowable 2%.

IMPORTANT: tf the suppty voltage phase imbalance is_

more than 2%, contact your local electric utility company I

immediately.

Tab{e 5--Legend

PREoSTARToUP

Failure to obselwe the %llowing warnings could result in

serious injury:

I Follow recognized safhty practices and wear protective

goggles when checking or se_'icing reffigeiant system

2 Do not operate compressor or provide any electric power to

onit unless compressor tem_inal cover is in place and

secured.

3. Do not remove compressor terminal cover until all electli=

cal sources are disconnected.

4. Relieve and recover all refrigerant fi'om system before

touching or disturbing anything inside terminal box if

ret'rigerant leak is suspected around compressor terminals.

5. Never attempt to repair soldered connection while refrig=

erant system is under pressure.

6. Do not use torch to remove any component. System

contains oil and refrigerant under pressure. To remove a

component, wear protective goggles and proceed as fbl=

lows:

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

b. Relieve and recover all refrigerant fi'om system using

both high= and low=pressure ports.

c. Cut component connecting tubing with robing cutter and

remove component fi'om unit.

d. Carefully unsweat remaining tubing stubs when neces=

sary. Oil can ignite when exposed to torch flame.

Proceed as %llows to inspect and prepare the unit %r initial

startup:

1. Remove access panel

2. Read and follow instluctions on all WARNING, (AUTION,

and IN'FORMATION labels attached to, or shipped with, unit

3. Make the following inspections:

a Inspect for shipping and handling damages such as broken

lines, loose parts, disconnected wires, etc.

b. Inspect fbr oil at all refrigerant robing connections and on

unit base Detecting oil generally indicates a refrigerant

leak.

c Leak test all refrigerant robing connections using electronic

leak detector, halide torch, or liquid=soap solution If a

refrigerant leak is detected, see the Checkii_r Rc/i'ige_'c,t_t

Leal_s section.

d. Inspect all field= and fhctoo'=wiring connections. Be sure

that connections are completed and tight.

e. Ensure wires do not contact refrigerant robing or sharp

sheet metal edges.

f\ Inspect coil fins. If damaged during shipping and handling,

carefully straighten fins with a fin comb.

4. Veri/) the fbllowing conditions:

Do not purge gas supply into the con£bustion chamber Do not

use a match or other open flame to check for gas leaks

Failure to follow this warning could result in an explosion

causing serious injury or death.

a. Make sure gas line is fi'ee of air. Be%re lighting the unit %r

the first time, perfbrm the fbllowing with the gas valve in

the "OFF" position:

If the gas supply pipe was not purged before connecting

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

ground joint union be loosened, and the supply line be

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

purge gas lines into a combustion chamber Immediately

upon detection of gas odor, retighten the union Allow 5

minutes to elapse_ then light unit.

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

in fbn orifice. Leading edge of condenser=tim blade should

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

c. Ensure fan hub is 1/8 in. maximum fi'om motor housing

(See Fig. 12).

MOTOR _. .... , FAN GRILLE

1/8"MAX BETWEEN _J "'-

MOTORAND FAN HUB MOTOR SHAFT C99009

Fig. 12--Fan Blade Clearance

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

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

ensure proper drainage.

£ Make sure that all tools and miscellaneous loose parts have

been removed.

MANIFOLD PIPE PLUG

C99019

Fig. 13--Burner Assembly

STAR%UP

Step I--CHECK FOR REFRIGERANT LEAKS

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

charge the unit:

1. Locate leak and make sure that refi'igerant system pressure has

been relieved and reclaimed Ii'om both high= and low-pressure

porls.

2. Repair leak fbllowing Refiigerant Service procedures.

NOTE[: Install a filter drier whenever the system has been opened

for repair.

3 Add a small charge of R-22 refi'igerant vapor to system and

leak-test unit.

BURNER FLAME

_Z NIFOLD

C99021

Fig. 14--Monoport Burner

4. Recover refi'igerant from ret'rigerant system and evacuate to

500 microns if additional leaks are not found

5. (barge unit with R-22 ret'rigerant, using a volumetric°

charging cylinder or accurate scale R@_' to _lnit _'atmg plate

fin" _'eq_li_'ed cha_'.ge_ Be sure to add extra ref?igerant to

compensate for internal volume of filter &ier.

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

MENTS

section bel\_re starting the unit

Do not jumper any safety devices when operating the unit

Make sure that burner orifices are properly aligned. Unstable

operation may occur when the burner orifices in the manifold are

misaligned

Follow the lighting instructions on the heating section operation

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

heating section.

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

gas piping has been checked fbr leaks.

(HECK HEATING CONTROL

Start and check the unit fbr proper heating control operation as

fbllows (see fl/rnace lighting instructions located inside burner or

blower access panel):

1. Place room thermostat SYSTEM switch in the HEAT position

and d'*e fan switch is placed in AUTO position.

2. Set the heating temperature control of the thermostat above

ro on'l temperature

3. The induced-&aft motor will start.

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

sec. If the burners do not tighk there is a 22-sec. delay bel\_re

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

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

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

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

5. The evaporator fan will mrn on 45 sec. after fl_e flame has

been established. The evaporator fan will mm off45 sec. after

the thermostat has been satisfied.

(HECK GAS INPUT

Check gas input and manifbld pressure aker unit start=up (See

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

* 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.

These units are designed to consume the rated gas inputs

using fl-_e fixed orifices at specified manifold pressures as

shown in Table 6 DO NOT REDRILL THE ORIFICES

UNDER ANY CIRCUMSTAN(ES.

ADJUST GAS INPUT

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

at fl_e meter or by measuring the manifbld pressure Measuring the

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

manifold pressure must he measured to determine the input of

propane gas units

Measure Gas Flow (Natural Gas Units)

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

mani_bld pressure. The manifold pressure must be maintained

between 3.4 and 3.6 in. wg.

If target adjustments are required,

change main burner orifices following

the recommendations of national

and local codes

NOTI=: All other appliances that use the same meter must be

turned off when gas flow is measured at the meter

Proceed as follows:

1. Turn off gas supply to unit.

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

manometer. Turn on gas supply to unit.

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

revolution

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

seconds in one hour).

5. 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

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)

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:

1. 32 sec. to complete one revolution.

2. 3600+32 112.5

3. 1125 x 1 1125 t't-_of gas flowihr

4. 1125 x 1050 118,125 Btuh input

If the desired gas input is i 15,000 Bmh, only a minor change in the

manifold pressure is required

Observe manifold pressure and proceed as follows to adjust gas

input:

1. Remove cover screw over regulator adjustment screw on gas

valve.

FIELD

SUPPLY

EQUIP GND

POWER

SCHEMATIC

208/230-1-60

COOLING FAN LOGIC

G G

ENERGfZED DEENERGIZED

HEATINGFANLOGIC

ENERGIZED DE ENERGIZED

_OFF

HEAT

_HEAT

OAUTO

FIELD-THERMOSTAT

i I

I I

I I r

I [i I.

W43 BLK

CAP 2

COMMON-- i i

¢/15YEL PRIMARY

TRAN1

SECONDARY

24V

W13 BLK

24V SPLICE BOX

W19 WHT

_W20GRN

Z_ w21 RED

W39 RED J2

IGC

o .........

OFM

MG\/

FLAF_ESEN

YEL_ I

0 O BRN_

--W41 GRN-YEL

W32 BAN

W48 BAN

COMP

GROUNDED

TRU STANDOFF

IFM

IDM

W46 BAN

GRN-YEL_

W30BRN

UNIT COMPONENT ARRANGEMENT

OUTDOOR FAN []

SECTIDN

COblPRESSOR INDOOR FAN F_

SECTION SECTION

CAP2

COfIP

c s

R _ ...............

LARGE CHASSIS LOC

EQUIP

_lcAP; ji_,

GASSECTION

DISCONNECT

PERNEC

LEGEND

AHA - Adjustable Heat NEC -NationN Electrical

Anticipator Code

BR - Blower Relay OFM - Outdoor-Fan Motor

C - Contactor QT -Quadruple TerminN

CAP - Capacitor RS -RoJiout Switch

CQMP - Compressor Motor SEN - Sensor

CR - Combustion Relay SW - Switch

CS - Centrifugal Switch TRAN - Transformer

EQUIP- Equipment

FS -Flame Sensor _ Field Splice

FU - Fuse

GND - Ground _ Terminal (Marked)

GV - Gas VaNe

GVR - GasVNve Relay _ Terminal(Unmarked)

HS - Hat] Effect Sensor

HV - High Voltage _ Splice

TRAN - Transformer

I - Ignitor _ Splice (Marked)

IDM - Induced-Draft Motor -- Factory Wiring

IFC - Indoor-Fan Contactor -- -- -Field Control Wiring

IFM - Indoor-Fan Motor

IGC - Integrated Gas Unit _ _ =Field Power Wiring

Controller .... Accessory or

L1 - Line Optional Wiring

LS - Limit Switch To indicate Common

LS1 - Limit Switch Potential Only, Not

MGV - Main GasVa]ve to Represent 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 Wiring Diagram, Units 48GS and 48GX

2. ]-urn regulator adjustment screw clockwise to increase gas decrease input Manifold pIessure must be between 3.4 and

input_ or turn regulator adjustment screw counterclockwise to 3,6 in, wg. Unsa/_ operation of the unit may result if maul/bid

COOL NG FAN LOGIC:

0 T T_30

G G

ENERGIZED DE ENERGIZED

HEATING FAN LOGIC

0 45 T T30

WBR WBR

ENERGIZED DE ENERGIZED

TRANI

O__ W13 BLK-

COMMON------

J l_l

--o OAUTO

FIELD-THERMOSTAT

__ __ z_

W59YEL

-- W64 YEL--

W15YEL

SECONDARY

24V

W56 BLU

IFM

IDM

I 24V SPLICE BOX

W19WHT

W20 GRN

W21 RED

UNIT COMPONENT ARRANGEMENT

OUTDOORFAN F_

SECTION

EQUIP

GND

EED' o SSO E

_ _ ,_

_cAP3 j! -

COMP

GASSECTION

DISCONNECT

PERNED

--W39 RED J2 1 _

IGC --L

F/_:> --I

__./<32:} SAF

@ -- __

, i

Y ' Q_'_* /o

_2J qF]

GROUNDED

TRUSTANDOFF

FLAMESEN

-W4I GRN-YEL

-- W32 BRN

W46 BRN

W46BRN--

W30 BRN

LEGEND

AHA - Adjustable Heat NEC -National Electrical

Anticipator Code

BR - Blower Relay OFM - Outdoor-Fan Motor

C - Contactor QT - QuadrupleTerminal

CAP - Capacitor RS - Rollout Switch

COMP - Compressor Motor SEN - Sensor

CR - Combustion Relay SW - Switch

CS - Centrifugal Switch TRAN - Transformer

EQUIP- Equipment

FS - Flame Sensor _ Field Splice

FU - Fuse

GND - Ground O Terminal (Marked)

GV - Gas Valve

GVR - GasValve Relay O Terminal (Unmarked)

HS - Hall Effect Sensor

HV - High Voltage _ Splice

TRAN - Transformer

I - ignitor <[_)@ Splice (Marked)

IDM - Induced-Draft Motor -- FactoryWiring

IFC - Indoor-Fan Contactor -- -- - Field Control Wiring

IFM - Indoor-Fan Motor

iGC - integrated Gas Unit -- -- - Field Power Wiring

Controller .... Accessory or

L1 - Line Optional Wiring

LS - Limit Switch To indicate Common

LS1 - Limit Switch Potential Only, Not

MGV - Main Gas Valve toRepresentWiring

NOTES:

1Fany 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

Fig. 16--2081230-3-60 Wiring Diagram, Units 48GS and 48GX

C00058

OFM

COMP

COOLING FAN LOGIC

0 T T+30

G G

ENERGIZED DE ENERGIZED

HEATING FAN LOGC

0 45 T T÷30

W BR W BR

ENERGLZED DE ENER®JZED

° AUTO

FIELD-THERMOSTAT

COMMON------

TRAN1

-W13 BLK

1 24V SPLICE BOX

i --

I I ---WSWNT

-W20 GRN

i i r

..... W21 RED

--I I

_q i

i __

UNIT COMPONENT ARRANGEMENT

OUTDOOR FAN []

SECTION

COMPRESSOR INDOORFAN F_

SECTON SECTION L2_

COMP

EQUIP

FROMCONPl_Ap31 11(

OLo

GASSECTION

DISCONNECT

PEREC

IFM

IDM

4_SECONDARY]

24V

W39 RED

IGC

; F -_,j

!-]

5 AMF

_z- -- 't0

BLU_--1

to MGV

-IF] --W35 GRA

, W34 BRN

FLAMESEN

--O O--- BRN--_

-W41 GRN-YEL

-- W32 BRN

_W46 BRN

W46BRN--

GROUNDED

TRUSTANDOFF

W30BRN-

LEGEND

AHA - Adjustable Heat NBC - National Electrical

Anticipator Code

BR - Blower Relay OFM - OutdooFFan Motor

C - Contactor QT - Quadruple Terminal

CAP - Capacitor RS - Rollout Switch

COMP- Compressor Motor SEN - Sensor

CR - Combustion Relay SW - Switch

CS - Centrifugal Switch TRAN - Transformer

EQUIP- Equipment

FS - Flame Sensor FieldSplice

FU - Fuse

GND - Ground (_D Terminal (Marked)

GV - Gas \/alve

GVR - GasValve Relay O Terminal (Unmarked)

HS - Hall Effect Sensor

HV - High Voltage _ Splice

TRAN - Transformer

I - Ignitor _ Splice (Marked)

IDM - Induced-Draft Motor -- FactoryWiring

IFC - Indoor-Fan Contactor -- -- - FieldControl Wiring

IFM - Indoor-Fan Motor

IGC - Integrated Gas Unit _ _ - Field Power Wiring

Controller .... Accessory or

LI - Line Optional Wiring

LS - Limit Switch _ To Indicate Common

LS1 - Limit Switch Potential Only, Not

MGV - Main GasValve to Represent Wiring

NOTES:

1If 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

Fig. 17480-3-60 Wiring Diagram, Units 48GS and 48GX

C00059

Table 6--Heating inputs

HEATING

iNPUT

(BTUH)*

NUMBER

ORIFICES

40,000 2

G0,000 2

90,000 3

115,000 3

130,000 3

Min

4.0

GAS SUPPLY PRESSURE

(IN, WG}

Natural Propanet

Min

4.0

Max

13.0

Natural

3.5

Max

13.0

MANIFOLD

PRESSURE

(IN, WG)

Propane¢

3.5

3.4

3.7

3.5

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 1000 fl above sea level

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

may result

Unsafe operation of the unit may result if mani%ld pressure

is outside this range Serious injury ,death or unit damage

may result

3. Replace cover screw cap on gas valve

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 Pressure (Propane Units)

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

unit rated input when the manifold pressure reading matches the

level specified in Table 6.

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

1. Turn off gas to unit.

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

Fig. 13).

3. Turn on gas to unit.

4. Remove cover screw over regulator adjustment screw on gas

valve.

5. Adjust regulator adjustment screw to the correct manifold

pressure, as specified in Table 6. Turn adjusting screw

clockwise to increase mani_bld pressure, or turn adjusting

screw counterclockwise to decrease mani_bld pressure.

6. Replace cover screw.

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

Replace pipe plug on gas valvQ then turn on gas to unit. (hock

£_r leaks.

CHECK B[ RNER FLAME

With burner access panel removed, observe the unit heating

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

soft in appearance, and that the flames are approximately d-_esame

fbr each burner Propane will have blue flame with yellow tips

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

burner removal.

AIRFLOW AND TEMPERATL RE RISE

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

heating operation within the temperature=rise range stamped on the

unit rating plate

Table 7 shows the approved temperature rise range _br each

heating input, and the air delivery cfirt at rations temperature rises

The heating operation airflow must produce a temperature rise that

_511s within the approved range.

Refkr to/nduo*' Ai_3flon at_d Ai(f!on, Ac!j_zstme_v_:_ section to adjust

heating airflow when required.

HEATING SEQUENCE OF OPERATION

(See Fig. 15-17 and unit wiring label)

On a call fPr beating, terminal "W" of the thermostat is energized,

starting the indtlced=draft motor. When ff*e hall=effect sensor on

the induced=draft motor senses that it has reached d-_e required

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

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

energized 45 sec after flame is established. When the thermostat

is satisfied and "W" is deenergized, the burners stop firing and the

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

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

board to monitor operation. The control board is located by

removing the burner access panel. During normal operation, the

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

Table 8--LED Indications

ERROR CODE

Norma_ Operation

Hardware Failure

Fan OntOff Belay Modified

Limit Switch Fault

Flame Sense FauR

Four Consecutive Limit Switch Faults

Ignition Lockout Fault

induced-Draft Motor Fault

RoHout Switch FauR

Internal Control Fault

Temporary lock-out (1 hr)

NOTES:

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

LED INDICATION

Off

1 Flash

2 Flashes

3 Flashes

4 Flashes

5 Flashes

6 Flashes

7 Flashes

8 Flashes

9 Flashes

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

displayed in numerical sequence

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

LIMIT SWITCHES

Normally closed limit switch (LS) completes the control circuit

through the thermostat R circuiL Should the leaving=air tempera°

rare rise above the maximum allowable temperature, the limit

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

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

flow to the burners and pilot. The blower motor continues to 1tin

until LS resets.

When the air temperature at the limit switch drops to the

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

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

cycles and the unit returns to normal heating operation.

Table 7--Air Delivery {Cfm) at indicated Temperature Rise and Rated Heating input

HEATING

INPUT

(BTUH) 20 25 30

40,000 1500 1200 1000

60,000 2250 1800 1500

90,000 -- -- 2250

115,000 -- -- --

130,000 -- -- --

857

1286

1929

2464

2786

TEMPERATURE R_SB °F

40 45 50

750 667 600

1125 1000 900

1688 1500 1350

2156 1917 1725

2438 2167 1950

545

818

1227

1568

1773

5OO

75O

1125

1438

1625

692

1038

1327

1500

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

964

1232

AL XILIARY LIMIT SWITCH (ROLLOL T)

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

event of flame rollout The switch is located above the main

burners. When the temperature at the auxilia_" switch reaches the

maximum allowable temperature, the R contlol circuit tlips,

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

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

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

FAULT (ODE 7.

Step a--START-UP COOUNG AND MAKE ADJUST-

MENTS

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

section before starting the unit

Do not jumper any safety devices when operating the unit.

Do riot operate the compressor when the outdoor temperature

is below 40cT (unless accessory tow=ambient kit is installed).

Do riot rapid-cycle the compressor. Allow 5 minutes between

"on" cycles to prevent compressor damage.

(HE(KING (OOLING (ONTROL OPERATION

Start and check the unit for proper cooling controi operation as

follows:

1. Place room thermostat SYSTEM switch in OFF position

Observe that blower motor starts when FAN switch is placed

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

AUTO. position

2. Place SYSTEM switch in (COL position and FAN switch in

AUTO. position. Set cooling control below room temperature

Observe that compressor, condenser fm_, and evaporator

blower motors start. Observe that cooling cycle shuts down

when control setting is satisfied. The evaporator fhn will

continue to rnn for 30 sec.

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

SYSTEM and FAN switches in AUTO. positions. Observe

that unit operates in Heating mode when temperature control

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

operates in (ooling mode when temperature control is set to

"call fbr cooling" (below room temperature)

IMPORTANT: Three-phase, scroll compressor units

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

These units must be checked to ensure proper compressor

3-phase power lead orientation If not corrected within 5

minutes, the internal protector shuts off the compressor.

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

cot_'ect rotation. When taming backwards, scroll compres-

sors emit elevated noise levels, and the difference between

compressor suction and discharge pressures may be &a-

matically lower than normal.

CHE(KING AND ADJUSTING REFRIGERANT (HARGE

The refrigerant system is fidly charged with R-22 refi'igerant,

tested, and fitctow-sealed,

NOTE: A({iustment of d'le ref?ige*ant charge is not required

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

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

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

rare at given suction line pressures and outdoor ambient tempera-

tures

An accurate superheat, thermocouple- or d-iermistor-type ther-

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

when using the superheat charging method for evaluating the unit

charge. Do nut u,se7nerc_z_?' or .small diaT-O_e t,s_ermomete_'s

/_ecaz_se they are l_ot adeqzeate jot thi.s 07)e o/" mea.s_zrement.

When evaluating d_e refi'igerant charge, an indicated adjust°

ment to d_e specified factory charge must always 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 smwice fittings,

2 [sing hoses with valve core depressors, attach tow- and

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

fittings, respectively,

3 Start unit in Cooling mode and let unit run until system

pressures stabilize,

4 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),

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

NOTE: If the problem causing the inaccurate readings is a

refrigerant leak, refer to the Cheek_br R@'igeras_t Leaks section

INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS

For cooling operation, the recommended airflow is 350 to 450

cIi*n fPr each 12,000 Btuh of rated cooling capacity. For

heating operation, the airflo_ must produce a temperature rise

that falls within the range stamped on the unit rating plate

Table 7 shows the temperature rise at various airflow rates Tables

11 and 13 show both heating and cooling airflows at various

external static pressures. Refer to these tables to determine the

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

wet coil pressure &up).

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

fi'ee fi'om obstrnctions, and adjusted properly

Be%re changing blower speed, shut off gas supply. Lhen

disconnect electrical power to the unit and install lockout tag.

Electrical shock or explosion can cause serious injury or

death.

Airflow can be changed by changing the lead connections of the

blower motor.

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

iactory wired ibr tow speed operation. Unit 48GS030 is factoQ'

wired for medium speed

All 4gGX units are factory wired fbr tow speed and may need to

be wired for medium or high speed in the field.

For 208/230V

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

Table 9=Color Coding for 2081230=V Motor Leads

3=SPEED 2-SPEED

Naek = high speed black = high speed

blue = medium speed

red = low speed red = low speed

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

For color coding on the 460=v GE motor teads, see Table 10.

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,sispart:,'. To select high speed on 460-v GE motors, separate

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

3-SPEED 2=SPEED

black = high speed black = high speed

violet = jumper blue = jumper

orange = medium speed

red = low speed red = tow speed

the black (female quick connect QC fi'om the jumper lead

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

Ii_,s_date the imnl_er to redid eonlaet _itll a'/_3c,Sla,s,sispargx.

COOLING SEQUENCE OF OPERATION

With the room them?ostat SYSTEM switch in the COOL position

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

of operation is as follows:

1. When the room temperature rises to a point that is slightly

above the cooling control setting of t!-_e them?ostat, the

thermostat completes the circuit between _hermostat terminal

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

thermostat:

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

and complete the circuit through compressor motor (COMP)

to condenser (outdoor) t5n motor (OFM). Both motors start

instantly.

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

and complete the circuit through evaporator blower (indoor)

_hn motor (IFM),

NOTE: (:)nee the compressor has started and then stopped, it

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

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

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

thermostat At tl-_is point, the thermostat "breaks" tl-_e circuit

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

circuits deenergize contactor coil (. The condenser and compres-

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

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

cooling" fiom the room thermostat.

MAINTENANCE

To ensure continuing high per_brmance and to minimize the

possibility of premature equipment failure, periodic maintenance

must be per_brmed on this equipment This combination

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

a qualified stun'ice person. To troubleshoot cooling or heating of

units, refer to Tables 16 18.

NOTE: Consult your local dealer about the availability of a

l'naintenance contract

The ability to properly per%m_ maintenance on this equip=

ment requires certain expertise, mechanical skills, tools, and

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

perform any maintenance on this equipment other than those

procedures recommended in the User's Manual. FAILURE

TO HEED THIS WARNING (OULD RESULT IN SERI=

OUS INJURY AND POSSIBLE DAMAGE TO THIS

EQUIPMENT.

Table 11--Dry Col! Air Delivery* - Horizontal Downflow Discharge -

Unit 48GS018°060 (Deduct 10 percent for 208 Volts)

230 AND 460 VOLT

Motor External Static Pressure (in. wg)

Unit Speed 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Watts 227 212 196 177 165 153 .....

Low Cfm 1082 1016 929 796 668 428 .....

Watts ...........

0t8 Med Cfm ...........

Watts 287 275 266 253 242 234 226 ....

High Cfm 1270 1179 1054 932 780 633 372 ....

Watts 280 275 270 267 264 262 260 ....

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

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

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

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

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

Watts 280 275 270 267 264 262 260 ....

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

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

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

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

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

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

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

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

036 Med Cfm 1720 1630 1538 1439 1346 1267 1167 1126 1018 858 781

Watts 810 800 790 782 766 742 723 709 688 661 627

High Cfm 1800 1745 1660 1600 1547 1465 1360 1270 1163 967 876

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

Low Cfm -- 1454 1387 1326 1275 1204 1142 1081 995 918 --

Watts -- 886 855 825 795 778 765 750 735 718 700

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

Watts -- -- -- 1000 950 925 910 890 875 855 833

High Cfm -- -- -- 1551 1488 1424 1360 1296 1233 1148 1071

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

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

Watts -- 853 836 821 807 782 756 730 699 667 640

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

Watts -- 979 959 943 927 897 868 838 802 766 730

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

Watts 1033 949 864 836 822 808 772 737 705 674 642

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

Watts 1084 1054 1024 994 971 955 928 897 867 835 803

0$0 Med Cfm 2318 2248 2179 2110 2058 2000 1932 1885 1829 1740 1638

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

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

* Air delivery values are without air filter and are for dry coil (See Table 14-48GS Wet Coil Pressure Drop).

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

UNiT SI£E

018,024, 030

036

042, 048, 060

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

CFM

FILTER $1Z _= 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300

20 X 20 X 1 0.05 0.07 0.08 0.10 0.12 0.13 0.14 0.15

20X24X1 0.09 0.10 0.11 0.13 0.14 0.15 0.16

24X30X 1 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18

Table13--Dn]Coil Air Delivery* -Horizontam and Downflow Discharge-

Unit 48GX024=000 (Deduct 10 percent for 208 Volts)

Unit

O24

030

036

O42

O48

050

230 AND 450 VOLT

Motor External Static Pressure (in. wg)

Speed 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Watts 281 282 281 278 276 ......

Low Cfm 899 828 757 691 619 ......

Watts -- -- -- 375 370 363 357 352 -- -- --

Med Cfm -- -- -- 969 897 824 744 649 -- -- --

Watts ..... 468 457 444 431 423 --

High Cfm ..... 994 913 826 730 620 --

Watts 246 244 243 241 .......

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

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

Med Cfm 1233 1170 1109 1038 953 855 754 ....

Watts .... 441 432 421 410 400 -- --

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

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

Low Cfm -- 1463 1406 1344 1273 1188 1091 983 -- -- --

Watts -- -- 514 501 487 47I 455 438 422 -- --

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

Watts -- -- -- 646 636 626 614 602 589 -- --

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

Watts 643 625 614 605 593 574 549 518 485 454 --

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

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

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

Watts ....... 790 766 742 713

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

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

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

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

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

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

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

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

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

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

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

Watts -- -- 960 949 920 883 845 812 783 753 --

High Cfm -- -- 2497 2224 2075 1986 1915 1831 1721 1588 --

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

NOTE: Deduct field-supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure availabb for ducth_g

Failure to %ltow these warnings could result in serious injury:

1 First, mrn offgas supply to the uniL Yhe_ turn offelectlical

power to the unit and install lockout tag befbre perfbrming

any maintenance or service on the unit_

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

with any mechanical equipment, personal injury can result

fi'om sharp edges_ etc.

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

with, the unit.

4. Should overheating occur or the gas supply fhil to shut of 7,

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

shut off electrical supply and install lockout tag.

Errors made when reconnecting wires may cause improper

and dangerous operation. Label all wires prior to disconnec=

tion when servicing.

The n_ininmm maintenance requirements fbr this equipment are as

follows:

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

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

30 40 50 60 70 80 90

SUCTION L]NE TEMPERATURE ("F)

I I I I I I I

4 10 IB 21 27 32

SUCT]ON LINE TEMPERATURE (_C)

Fig. 18--Cooling Charging Chart, 48GS018 U_ °46

30 40 50 50 70

SUCTION L]NE TEMPERATURE (_F)

I I I I I

4 10 18 21

SUCTION LINE TEMPERATURE (_C)

_ OUTDOOR TEMP

_ _F _ C

/15 46

-K_los <

_ ss ss

,_ 85 29

75 24

55 13

80 90

I I

27 32

Chart, 48GS024 U_ °42

30 40 SO 80 70 80 90

SUCTION LINE TEMPERATURE (_F)

I I I I I I I

4 10 16 21 27 32

SUCTION LINE TEMPERATURE ("C) C00043

Fig. 20--Cooling Charg{ng Chart, 48G8030 Units

4. Check electlical connections fbr tighmess and controls tbr

proper operation each heating and cooling season, Service

when necessa_-

5. Ensure wires are not contacting refrigerant robes or sharp

sheet metal edges.

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

Clean and adjust when necessary.

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

30 40 50 SO 70 80 90

SUCTION LINE TEMPERATURE {'F)

I I I I I I I

4 10 1B 21 27 32

SUCTION LINE TEMPERATURE (_C)

Fig. 21--Cooling Charging Chart, 48GS036 U[_i_S044

AIR FILTER

Never operate the unit without a suitable air tilter in the

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

dimensional size and type as originally installed (See Tables

1 and 2 %r recommended filter sizes).

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

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

each heating and cooling season or whenever the filter(s) becomes

clogged with dust and/or lint.

EVAPORATOR BLOWER AND MOTOR

NOT_:: Ail motors are permanently lubricated. Do not attempt to

lubricate these motors.

30 40 50 60 70

SUCTION LINE TEMPERATURE (_F)

I I I I I

-1 4 10 16 21

SUCTION LINE TEMPERATURE (:C)

Fig 23--CooHn_

}L TDOOR TEMP

F C

115 46

105 41

95 35

85 29

75 24

65 18

55 13

45 7

80 90

I I

27 32

C00047

48G8048 UnRs

SUCTION LINE TEMPERATURE IF

-1 4 10 16 21 27 32

SUCTION LINE TEMPERATURE (:C) C00048

Fig. 24--Cooling Charging Chart, 48GS060 Units

For longer life, operating economy, and continuing efficiency,

clean accumulated dirt and grease flora the blower wheel and

motor annually.

Befbre cleaning the blower motor and wheel, disconnect gas

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

Failure to adhere to this warning could cause serious injm T or

death.

(leaning the Blower Motor and Wheel

1, Remove and disassemble blower asserubly as %llows:

a, Remove unit access panel

b, Disconnect motor lead flora blower relay (BM) Discon=

nect yellow toad ['rom terminal L2 of the contactor

SUCTION LINE TEMPERATURE

Fig. 25--Cooling Charging Chart, 48GX024 UQ_0;049

c. On a/l units, remove blower assembly flora unit. Remove

screws securing blower to blower partition and slide

assembly out. Be care£hl not to tear insulation in blower

compartmenL

d. Ensure proper reassen£bly by marking blower wheel and

motor in relation _o blower housing before disassembly.

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

Remove screws that secure motor mount brackets m

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

2. Remove and clean blower wheel as %llows:

a. Ensure proper reassembly by marking wheel orientation.

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

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

on blower wheel vanes.

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

brush. Remove lint and/or dirt accumulations from wheel

(030) 60HZ CHARGING CHART

SUCTION LINE TEMPERATURE

26--Coolin{ 48GX0a0

(036) 60HZ CHARGING CHART

SUCTION UNE TEMPERATURE IF

-1 4 10 16 21 27 32

SUCTION LINE TEMPERATURE (C)

Fig. 27--Coolinc 48GX036 U_9c_°51

SUCTION LINE TEMPERATURE

-1 4 10 16 21 27 32

SUCTION LINE TEMPERATURE (:C) C00052

Fig. 28--Cooling ChargBng Chart, 48GX042 Units

and housing with vacuum cleaner, using soft brllsh attach°

ment. Remove grease and oil with mild solvent

d, Reassemble wheel into housing.

eReassemble motor into housing Be sure setscrews are

tightened on motor shak flats and not on round part of

shaft.

£ Reinstall unit access panel.

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

proper blower rotation and motor speeds during heating and

cooling cycles.

FLI_E GAS PASSAGEWAYS

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

exchanger:

1. Remove the combustion blower wheel and motor assembly

according to directions in the d'oml_.stiut_-.ti_' Blo_ e_' section

SUCTION LINE TEMPERATURE

-1 4 10 16 21 27 32

SUCTION LINE TEMPERATURE (C)

Fig. 29--Cooling Charging Chart, 48GX048 U_i_ °53

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

collector box cover (See Fig. 31 34).

3 Remove the 12 screws holding the flue collector box cover

(See Fig 33 34) to the heat exchanger assembly. Inspect the

heat exchangers.

4. (lean all surfitces, as required, using a wire brush.

COMBUSTION=AIR 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 bi-

monthly to determine proper cleaning frequency

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:

1 Remove unit access panel (See Fig. 32).

TaNe 14_48GS Wet Coit Pressure Drop

UNIT SiZE

48GS

018

024

030

036

042

048

060

AIRFLOW

(CFM)

500

600

7OO

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1900

2000

2100

PRESSURE DROP

(iN. WG)

0.049

0.070

0.095

0.077

0.100

0.127

0.065

0.080

0.097

0.084

0.100

0.177

0.103

0.120

0.138

0.088

0.100

0.113

0.108

0.120

0.132

Table 16--48GX Wet Coil Pressure Drop

UNIT SIZE

48GX

024

030

oa6

042

048

060

AIRFLOW

(CFM)

7OO

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1900

2000

2100

PRESSURE DROP

(IN. WG)

0.0535

0.067

0.123

0.0687

0.083

0.150

0.084

0.100

0.177

0.099

0.177

0.204

0.199

0.137

0.156

0.108

0.120

0.132

2, Remove the 7 screws that attach induced-drafl motor monnt-

ing plate to blower housing (See Fig 33)

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

housing (See Fig. 33). Clean the blower wheel. If additional

cleaning is required, continue with Steps 4 and 5.

4. To remove blower, remove 2 setscrews

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

that hold blower housing to mounting plate

6. To reinstall, reverse the procedure outlined above.

(060) 60HZ CHARGING CHART

SUCTION LINE TEMPERATURE (C C00054

Fig. 30--Cooling Charging Chart, 48GX060 Units

INDUCED DRAFT MOTOR MOUNT

VENT HOOD

iN SHIPPING

LOCATION

A /

FLUE

ROLLOUT

SWITCH

COLLECTOR BLO'WER BURNER MOUNTING

BOX HOUSING RACK SCREW C99022

Fig. 31--Blower Housing and Flue Collector Box

BL RNER IGNITION

Unit is equipped with a direct spark ignition 100 percent tockont

system. Ignition modtlle is located in the control box. Module

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

diagram for LED interpretation.

If lockout occurs, unit may be reset by either momentarily

interrupting power supply to unit or by turning selector switch to

OFF position at the thermostat

MAIN BURNERS

At the beginning of each heating season, inspect for deterioration

or blockage due to corrosion or other causes Obsma'e the main

burner flames and adjust, if necessary.

LIMIT SWITCH

Remove unit access panel Limit switch is located on the blower

partition

FRONT

ACCESS PANEL

Fig. 32--UNt Access Panel

C99091

HOUSING

2 SETSCREWS

(HIDDEN)

C99085

Fig. 33--Remova! of Motor and Blower Wheel

When servicing gas train, do not hit or plug orifice spuds.

Removal of Gas Train

To remove the gas train for servicing:

l. Shut of'["main gas valve.

2. Shut off power to unit and install lockout tag

3. Remove unit access panel (See Fig. 32)

4. Disconnect gas piping at unit gas valve

5. Remove wires connected to gas valve Mark each wire

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

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

the unit base (See Fig. 31)

8. Slide the burner rack out of the unit (See Fig 31 and 34)

C99086

Fig. 34--Burner Rack Removed

9 To reinstall, reverse the procedure outlined above

CONDENSER COIL, EVAPORATOR (OIL, AND

CONDENSATE DRAIN PAN

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.

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

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

CONDENSER FAN"

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,

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

cover,

2. Tuna motor/grille assembly upside down or* top cover to

expose the fan blade,

3.Inspectthefanblades%r cracks or bends

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

fun off the motor shaft.

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

away fi'om the motor end 11/8 in. of motor shaft will be

visible. See Fig. 12).

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

when tightening.

7. Replace grille.

ELECTRICAL (ONTROLS AND WIRING

Inspect and check the electrical controls and wiring annually. Be

sz_re to 1urn rfl tke gas .s_lp?/y, and then tke eleetr/ea/ pot_ er ;o the

_znif.

Remove access panel to locate all the electrical controls and

wiring. (heck al! electrical connections for tightness. Tighten all

screw connections. If any smoky or burned connections are

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

wire end and reassemble the connection properly and securely.

After inspecting the electrical controls and wiring, replace the

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

heating cycle arid one complete cooling cycle to ensure proper

operation. If discrepancies are observed in either or both operating

cycles, or if a suspected malfimction has occmTed, check each

electrical component with the proper electrical instrumentation.

Refer to the unit wiring label when making these checkouts.

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

in this publication as an aid in determining proper control

operation

REFRIGERANT CIRCUIT

Annually inspect all refi'igerant robing connections and the unit

base tbr oil accumulations. Detecting oil generally indicates a

refrigerant leak.

System urider pressure Relieve pressure arid recover al!

refrigerant before system repair or final unit disposal to avoid

serious injury or death. Use all service ports and open nil

flow=control devices, including solenoid vah'es.

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

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

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

detected, refer to the ('l_ecl;/br R@'igerat_f LeaI;s section.

If no refrigerant leaks are fbund and tow cooling performance is

suspected, refer to the ('becking and.4d]z_sfhg R@'/gerant (']ia_'ge

section.

GAS INPUT

The gas input does not require checking unless improper heating

performance is suspected. Ifa problem exists, refer to the Start-5})

section

EVAPORATOR AIRFLOW

The heating and/or cooling airflow does not require checking

unless improper perfbrmance is suspected. Ira pro/_/em exists, /:,e

.s_lre llIat all s_lp/)- a_'ld retail'n-airgrilles are olden and fi'eefi'om

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

system airflow.

METERING DEVKE A(UTROL DEVI(E

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

to the evaporator coil

LIQUID LINE STRAINER

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

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

device.

TROUBLESNOOTNG

Use the Zl'o_lblc'skoofin_ Ch_ides (See Tables 1(_18) if problems

occur with these urks.

START-UP ¢HECKUST

Use the ,;;tar/{,_ (']_ee]dist to ensure proper start-up procedures are

followed.

SYMPTOM

Compressor and condenser fan

will not start=

Compressor will not

start but condenser

fan runs.

Table 16--Troubleshooting Guide--Cooling

CAUSE

Power Failure

Fuse blown or circuit breaker tripped

Defective thermostat, contactor, transformer, or control relay

Insufficient line voltage

Incorrect or faulty wiring

Thermostat setting too high

Faulty wiring or loose connections in compressor circuit

Compressor motor burned out, seized, or internal

overload open

Defective run/start capadtor, overload, start relay

One leg of 3-phase power dead

Three-phase scroll compressor

(48GS048 and 48GX030=060 only}

makes excessive noise, and there may Scroll compressor is rotating in the wrong direction

be a low pressure differential.

Compressor cycles (other than

normally satisfying thermostat).

Compressor operates continuously.

Excessive head pressure,

Head pressure tOO lOW,

Excessive suction pressure,

Suction pressure too low=

Refrigerant overcharge or undercharge

Defective compressor

Insufficient line voltage

Blocked condenser

Defective run/start capacitor, ovedoad or start relay

Defective thermostat

Faulty condenser-fan motor or capacitor

Restriction in refrigerant system

Dirty air filter

Unit undersized for load

Thermostat set too low

Low reMgerant charge

Leaking valves in compressor

Air in system

Condenser soil dirty or restricted

Dirty air filter

Dirty condenser coil

Refrigerant overcharged

Air in system

Condenser air restricted or air short-cycling

Low refrigerant charge

Compressor valves leaking

Restriction in Hquid tube

High heat load

Compressor valves leaking

RsMgerant overcharged

Dirty air filter

Low refrigerant charge

Metering device or low side restricted

Insufficient evaporator airflow

Temperature too low in conditioned area

Outdoor ambient below 40°F

Field-installed filter-drier restricted

REMEDY

Call power company

Replace fuse or reset circuit breaker

Replace component

Determine cause and correct

Check wiring diagram and rewire correctly

Lower thermostat setting below room temperature.

Check wiring and repair or replace.

Determine cause

Replace compressor.

Determine cause and replace.

Replace fuse or reset circuit breaker

Determine cause.

Correct the direction of rotation by reversing the

3-phase power leads to the unit Shut down unit

to allow pressures to equalize.

Recover refrigerant, evacuate system, and recharge to

capacities shown on nameplate

Replace and determine cause

Determine cause and correct

Determine cause and replace.

Replace thermostat.

Replace.

Locate restriction and remove

Replace filter.

Decrease load or increase unit size

Reset thermostat

Locate leak, repair, and recharge

Replace compressor.

Recover refrigerant, evacuate system, and recharge

Clean coil or remove restriction.

Replace filter.

Clean coil.

Recover excess refrigerant

Recover refrigerant, evacuate system, and recharge

Determine cause and correct

Check for leaks, repair, and recharge.

Replace compressor.

Remove restriction.

Check for source and eliminate.

Replace compressor.

Recover excess refrigerant

Replace Filter.

Check for leaks, repair, and recharge.

Remove source of restriction.

increase air quantity Check filter -- replace if necessary

Reset thermostat

install low-ambient kit.

Replace.

Table 17--Troubleshooting Guide-Heating

SYMPTOM CAUSE REMEDY

Water in gas line Drain. Install drip leg.

No power to furnace Check power supply fuses, wiring, or circuit breaker

Check transformer.

No 24-v power supply to contro{ circuit NOTE: Some transformers have internal overcurrent

protection that requires a cool-down period to reset.

Miswired or loose connections Check all wiring and wirenut connections

Burned-out heat anticipator in Replace thermostat.

Burners will not ignite, thermostat

Broken thermostat wire Run continuity check Replace wire if necessary

Check flame ignition and sense electrode positioning

Misaligned spark electrodes Adjust as necessary.

1Check gas line for air Purge as necessary

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

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

2 Check gas valve.

Dirty air filter Clean or replace filter as necessary.

Check gas pressure at manifold match with that on

Gas input to furnace too low unit nameplate

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

inadequate heating. Restricted airflow Clean or replace filter Remove any restriction.

Use faster speed tap if available, or install alternate

Blower speed too low motor.

Check rotation of blower, thermostat heat anticipator settings,

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

1Tighten all screws around burner compartment

Incomplete combustion results in: 2 Cracked heat exchanger Replace.

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

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

4 Check burner alignment

Table18--TroubleshootingGuide-LEDErrorCodes

SYMPTOM CAUSE REMEDY

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

Hardware failure, transformer Units without a 24-v circuit breaker have an internal

Less of power to control module (IGC)*. overload in the 24-v transformer. If the overload trips, allow 10 rain-

(LED OFF) utes

for automatic reset.

High limit switch opens during heat

Fan ON/OFF delay modified exchanger warm-up period before fan-on Ensure unit is fired on rate: ensure temperature rise is correct.

delay expires. Ensure units external static pressure is within application guidelines

(LED/FLASH) Limit switch opens within three minutes

after blower-off delay timing in Heating mode.

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

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

on the unit nameplate.

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

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

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

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

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

(LED 5 flashes) 15 minutes, that flame sense and ignition wires are properly terminated. Verify

that unit is obtaining proper amount of gas.

Check for proper voltage. If motor is operating, check the speed

Indueed_draft motor fault. IGC does not sense that induced-draft sensor plug/IGC Terminal J2 connection Proper connection:

PIN 1-- White

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

PIN 3 -- Black

Rollout switch will automatical{y reset, but IGC* will continue to Iock-

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

(LED 7 flashes} Rollout switch has opened. blower wheel is properly secured to motor shaft. Reset unit at unit

disconnect

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

(LED 8 flashes) software or hardware

Reset 24-v. to control board or turn thermostat off,

Temporary software lock out. Electrical interference then on again Fault will automatically

(LED g flashes) impeding ]GC software reset itself in one (1) hour

* 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 analysis.

LEGEND

IGC -- Integrated Gas Unit Controller

LED -- Light-Emitting Diode

START-UPCHECKLIST

(RemoveandStoreinJob File)

LPRELIMINARY 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

]NDOOR (EVAPORATOR) FAN AMPS

L2-L3 L3-LI

L2 L3

TEMPERATURES

OUTDOOR (CONDENSER) AIR TEMPERATURE: DB

RETURN=AIR TEMPERATURE: DB WB

COOLING SUPPLY AIR: DB WB

GAS HEAT SUPPLY AIR:

PRESSURES

GAS INLET PRESSURE IN. WG

GAS MANIFOLD PRESSURE IN. WG

REFRIGERANT SUCTION PSIG

REFRIGERANT DISCHARGE PSIG

SUCTION LINE TEMP*

DISCHARGE LINE TEMPt

VERIFY REFRIGERANT CHARGE USING CHARGING TABLES

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

DIRECTION.

* Measured at s_mtion inlet to compressor

+ Measured at Iicp_id line leaving condenser

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

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