Carrier 50PG03-07 User Manual

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50PG03---07 Single Package Rooftop Units Electric Cooling with PURONR (R ---410A)

Refrigerant and COMFORTLinkt Controls

Installation Instructions

IMPORTANT: This installation instruction contains basic unit installation information including installation of field control devices. For information on unit start--up, service, and operation, refer to the unit Controls, Start-- Up, Operation, Service, and Troubleshooting Instructions also enclosed in the unit literature packet.

TABLE OF CONTENTS

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

INSTALLATION 4....................................

Step 1 -- Provide unit Support 4.........................

Step 2 -- Rig and Place Unit 4...........................

Step 3 -- Field Fabricate Ductwork 7......................

Step 4 -- Make Unit Duct Connections 7...................

Step 5 -- Install External Trap for Condensate Drain 7........

Step 6 -- Make Electrical Connections 8................... Step 7 -- Install Outdoor Air Hoods (Units With

Economizer 22...............................

Step 8 -- Install All Accessories 22.......................

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair, or service air-conditioning equipment.

Untrained personnel can perform the basic maintenance functions of cleaning coils and filters and replacing filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags and labels attached to the unit, and other safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work gloves. Recognize safety information. This is the safety--alert symbol

When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could cause personal injury or death.

Before performing service or maintenance operations on unit, turn off main power switch to unit and install lockout tag.

WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personal injury, death and/or equipment damage.

Puron (R--410a) refrigerant systems operate at higher pressures than standard R--22 systems. Do not use R--22 service equipment or components on Puron refrigerant equipment.

WARNING

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

1. Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal

injury, or loss of life. Refer to the User’s Information

Manual provided with this unit for more details.

2. Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any other

appliance.

IMPORTANT: Units have high ambient operating limits. If limits are exceeded, the units will automatically lock the compressor out of operation. Manual reset will be required to restart the compressor.

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50PG03--07

Fig. 1 -- Roof Curb Details

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50PG03--07

Fig. 2 -- Base Unit Dimensions

INSTALLATION

Step 1 — Provide Unit Support

Roof Curb

Assemble or install accessory roof curb in accordance with instructions shipped with this accessory. (See Fig. 1.) Install insulation, cant strips, roofing, and counter flashing as shown. Ductwork can be installed to roof curb before unit is set in place. Ductwork must be attached to curb and not to the unit. Curb must be level. This is necessary to permit unit drain to function properly. Unit leveling tolerance is  1/16--in. per linear ft in any direction. Refer to Accessory Roof Curb Installation Instructions for additional information as required. When accessory roof curb is used, unit may be installed on class A, B, or C roof covering material. Carrier roof curb accessories are for flat roofs or slab mounting.

IMPORTANT: The gasketing of theunit to the roof curb is critical for a watertight seal. Install gasket with the roof curb as shown in Fig. 1. Improperly applied gasket can also result in air leaks and poor unit performance. Do not slide unit to position on roof curb.

Alternate Unit Support

50PG03--07

When a curb cannot be used, install unit on a noncombustible surface. Support unit with sleepers, using unit curb support area. If sleepers cannot beused, support long sides of unit with a minimum of 3 equally spaced 4--in. x 4--in. pads on each side.

Step 2 — Rig and Place Unit

Inspect unit for transportation damage. See Table 1 for physical data. File any claim with transportation agency.

CAUTION

PERSONAL INJURY AND PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in damage to roof. All panels must be in place when rigging. Unit is not

designed for handling by fork truck.

Do not drop unit; keep upright. Use spreader bars over unit to prevent sling or cable damage. Rollers may be used to move unit across a roof. Level by using unit rail as a reference; leveling tolerance is ± 1/16--in. per linear ft in any direction. See Fig. 3 for additional information. Unit rigging weight is shown in Fig. 3.

Rigging holes are provided in the unit base rails as shown in Fig. 3. Refer to rigging instructions on unit.

Positioning

Maintain clearance, per Fig. 2, around and above unit to provide minimum distance from combustible materials, proper airflow, and service access. See Fig. 4 for location of access panels.

Do not install unit in an indoor location. Do not locate air inlets near exhaust vents or other sources of contaminated air.

Although unit is weatherproof, guard against water from higher level runoff and overhangs.

After unit is in position, remove crating and polyethylene sheet.

Roof Mount

Check building codes for weight distribution requirements. Unit operating weight is shown in Table 1.

Installation Onto Curb

The 50PG units are designed to fit on the accessory full perimeter curb. In either case, correct placement of the unit onto the curb is critical to operating performance. To aid in correct positioning, place unit on roof curb to maintain 1/4--in. gap between the inside of rail and roof curb on long sides and a 1/2--in. gap between the inside of rail and roof curb on both duct and condenser ends. Refer to Fig. 1 and 3, to assure proper duct opening alignment.

NOTE: Before positioning unit onto curb, refer to Step 5 -- Install External Trap for Condensate Drain section concerning bottom drain connection plug.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage.

Do not slide unit to position when it is sitting on the curb. Curb gasketing material may be damaged and leaks may result.

Slab Mount (Horizontal Units Only)

Provide a level concrete slab that extends a minimum of 6--in. beyond unit cabinet. Install a gravel apron in front of condenser--coil air inlet to prevent grass and foliage from obstructing airflow.

NOTE: Horizontal units may be installed on a roof curb if required.

CAU OTI

ACCESS PANEL MUST BE IN PLACE WHEN RIGGING.

Hook rigging shackles through holes in base rail, as shown in Detail A. Holes in base rails are centered around the unit center of gravity. Use wooden top skid, when rigging, to prevent rigging straps from damaging unit.

A B C D E MAX. WEIGHT

UNIT SIZE

in. mm in. mm in. mm in. mm in. mm lb kg

03-07 77.9 1978 36-54 914-1371 44.8 1139 42.0 1067 23.5 597 1156 52

N- NOTICE TO R GGERS:I

Fig. 3 -- 50PG Rigging Label

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Table 1 – Physical Data

BASE UNIT 50PG 03 04 05 06 07 NOMINAL CAPACITY (Tons) OPERATING WEIGHT (lb)

Unit* Economizer

Vert ical Horizontal

Humidi-MiZer™ Adaptive Dehumidification

System

Roof Curb

14-in. 24-in.

COMPRESSOR

Quantity Oil Type Number of Refrigerant Circuits Oil (o z )

REFRIGERANT TYPE

Expansion Device Operating Charge (lb) — Standard Unit Operating Charge (lb) — Unit with

Humidi-MiZer System CONDENSER COIL

Condenser A (Outer)

Rows...Fins/in. Face A rea (s q ft)

Condenser B (Inner)

Rows...Fins/in. Face A rea (s q ft)

Humidi-MiZer Coil

Rows...Fins/in. Face A rea (s q ft)

CONDENSER FAN

Quantity…Diameter (in.) Nominal Cfm (Total, all fans) Motor Hp

Nominal Rpm — High Speed

Nominal Rpm — Low Speed

EVAPORATOR COIL

Rows…Fins/in. Face A rea (s q ft)

* See Legend on next page.

2 3 4 5 6

704 704 775 829 874

40 40 40 40 40 50 50 50 50 50

22 31 27 26

122 122 122 122 122 184 184 184 184 184

Fully Hermetic Scroll

1 1 1 1 1

Copeland 3MA

1 1 1 1 1

38 42 42 66 56

R-410A (Puron® Refrigerant)

TXV TXV TXV TXV TXV

7.3 9.0 15.7 16.6 19.0

11.75 13.50 25.00 22.00 22.70

Enhanced Copper Tubes, Aluminum Lanced Fins

1…17 1…17 2…17 2…17 2…17

12.6 12.6 12.6 12.6 12.6

— 1…17 2…17 2…17 2…17 — 12.6 12.6 12.6 12.6

1...17 1...17 1...17 1...17 1...17

6.4 6.4 9.3 9.3 9.3 Propeller

1…24 1…24 1…24 1…24 1…24

3500 3500 3500 4500 4500

825 825 825 1100 1100

300 300 300 300 300

Enhanced Copper Tubes, Aluminum Double-Wavy Fins, Face Split

2…15 2…15 2…15 3…15 4…15

9.3 9.3 9.3 9.3 9.3

50PG03--07

BASE UNIT 50PG (co nt) 03 04 05 06 07 EVAPORATOR FAN

Quantity…Size (in.) Low

Ty pe D ri ve Low

Nominal Cfm Maximum Continuous Bhp Low

Motor Nominal Rpm Motor Frame Size Low

Fan Rp m Range Low

Motor Bearing Type Maximum Fan Rpm Motor Pulley Pitch Diameter Range (in.) Low

Fan Pulley Pitch Diameter (in.) Low

Nominal Motor Shaft Diameter (in.) Low

Belt...PitchLength(in.)

Belt…Ty pe Low

50PG03--07

Pulley Center L ine Distance Min. (in.) Low

Pulley Center Line Distance Max. (in.) Low

Speed Change per Full Turn of

Movable Pulley Flange (rpm)

Movable Pulley Maximum Full

Turns from Closed Position

FactoryPulleySetting(rpm) Low

Fan Shaft Diameter at Pulley (in.)

HIGH-PRESSURE SWITCH (psig)

Cutout Reset (Auto.)

RETURN-AIR FILTERS

Quantity…Size (in.)

LEGEND TXV --- Thermostatic Expansion Valve * Aluminum evaporator coil/aluminum condenser coil. { Single phase/three phase.

Table 1 — Physical Data (cont)

High

Low

High

High Low High Low High

High

1...12 x 9

1...12 x 9 Belt Belt 800 1200 1600 2000 2400

0.85

1620 1620 1620 1725 1725

48Y 48Y

482-736

656-1001

Ball Ball Ball Ball Ball

2000 2000 2000 2000 2000

1.9-2.9

6.8

5.0

49.3 49.3 49.3 49.3 49.3

49.3 AX AX

16.2

20.2

48 65

5 482 656

660 ± 10 660 ± 10 660 ± 10 660 ± 10 660 ± 10 505 ± 20 505 ± 20 505 ± 20 505 ± 20 505 ± 20

4…16 x 20 x 2 4…16 x 20 x 2 4…16 x 20 x 2 4…16 x 20 x 2 4…16 x 20 x 2

1...12 x 9 1...12 x 9 1...12 x 9 1...12 x 9

Centrifugal Type, Belt Drive

1...12 x 9 1...12 x 9 1...12 x 9 1...12 x 9 Belt Belt Belt Belt Belt Belt Belt Belt

0.85 0.85 0.85/2.40† 2.40

0.85 1.60/2.40† 1.60/2.40† 3.10

48Y 48Y 56Y 56Y 48Y 56Y 56Y 56Y

482-736 596-910 690-978 796-1128

796-1128 828-1173 929-1261 1150-1438

1.9-2.9 1.9-2.9 2.4-3.4 2.4-3.4

2.4-3.4 2.4-3.4 2.8-3.8 4.0-5.0

6.8 5.5 6.0 5.2

5.2 5.0 5.2 6.0

49.3 49.3 49.3 52.3 AX AX AX AX AX AX AX AX

16.2 16.2 16.2 16.2

20.2 20.2 20.2 20.2

48 59 58 66 62 69 66 58

5 5 5 5

5 5 5 5 482 596 690 796 796 828 929 1150

Throwaway

Step 3 — Field Fabricate Ductwork

On vertical units, secure all ducts to roof curb and building structure. Do not connect ductwork to unit. For horizontal applications, field--supplied flanges should be attached to horizontal discharge openings and all ductwork secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes.

Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier.

If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes.

A minimum clearance is not required around ductwork. Cabinet return--air static pressure (a negative condition) shall not exceed

0.35--in. wg with economizer or 0.45--in. wg without economizer.

Step 4 — Make Unit Duct Connections

Vertical Supply/Return Configuration

Unit is shipped in vertical supply/return configuration. Ductwork openings are shown in Fig. 1 and 3. Attach the ductwork to the roof curb. Do not attach duct directly to the unit.

WARNING

PERSONAL INJURY HAZARD

Failure to follow this warning could result in personal injury.

For vertical supply and return units, tools or parts could drop into ductwork and cause an injury. Install a 90--degree turn in the return ductwork between the unit and the conditioned space. If a 90--degree elbow cannot be installed, then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space.

Horizontal Supply/Return Applications

Unit can be field--converted from vertical supply/return to horizontal supply/return. Remove all screws securing horizontal

CONTROL BOX AND COMPRESSOR

ELECTRICAL

OPTIONS PANEL

duct covers to duct panel. Save panels. Install duct covers in the vertical duct openings in the basepan with the insulation side up. Covers will drop into openings and can be secured using field--supplied self--tapping screws. Ductwork can be attached to duct flanges provided on unit. When securing ductwork to unit, do not drill in area below bead or above top edge of duct opening.

Step 5 — Install External Trap for Condensate Drain

The unit’s 3/4--in. condensate drain connections are located on the bottom and side of the unit. If the down drain is used, drill a minimum of a 5/8-in. diameter hole but not larger than a diameter hole through the drain pan. A dimple of 2 mm in diameter and 1.5 mm deep will be provided in the drain pan to help locate the drill bit and to start the hole. Do not cut through the PVC pipe threads. Unit discharge connections do not determine the use of drain connections; either drain connection can be used with vertical or horizontal applications. See Fig. 2 for locations.

When using the standard side drain connection, make sure the plug (red) in the alternate bottom connection is tight before installing the unit. (See Fig. 5.)

To use the bottom drain connection for a roof curb installation, relocate the factory--installed plug (red) from the bottom connection to the side connection. A 1/2--in. socket extension can be used to remove the plug. (See Fig. 5.) The piping for the condensate drain and external trap can be completed after the unit is in place.

All units must have an external trap for condensate drainage. Install a trap at least 4--in. deep and protect against freezeup. If drain line is installed downstream from the external trap, pitch the line away from the unit at 1--in. per 10 ft of run. Do not use a pipe size smaller than the unit connection (3/4--in.). (See Fig. 6 and 7.)

The 50PG units are provided with a removable condensate pan for ease of cleaning. It is recommended that a union be placed between the unit and condensate drainage to ease the removal of the pan during servicing. Adequate clearance should be allowed if removal of condensate pan is required. Allow 54--in. between condensate pan access panel and any obstruction for complete removal.

INDOOR MOTOR ACCESS DOOR

/4-in.

50PG03--07

OUTDOOR AIR SCREEN (HIDDEN)

ECONOMIZER HOOD

BAROMETRIC RELIEF DAMPER HOOD

BASEPAN CONNECTIONS

ACCESS PANEL

Fig. 4 -- Panel and Filter Locations

FILTER ACCESS DOOR

ELECTRIC HEAT ACCESS DOOR

CONDENSER COIL

ACCESS PANEL

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