Carrier 48EZ-N-A User Manual

0 (0)

48EZ(N) ---A Comfort t 13 SEER Single --- Packaged HYBRID HEATr Dual Fuel System with Puron® (R ---410A) Refrigerant Single and Three Phase 2 --- 5 N o m i n a l To n s ( S i z e s 2 4 --- 6 0 )

Installation Instructions

NOTE: Read the entire instruction manual before starting the installation.

NOTE: Installer: Make sure the Owner’s Manual and Service Instructions are left with the unit after installation.

TABLE OF CONTENTS

PAGE

SAFETY CONSIDERATIONS 1--2.......................

INTRODUCTION 2...................................

RECEIVING AND INSTALLATION 2--13.................

Check Equipment 2..................................

Identify Unit 2....................................

Inspect Shipment 2.................................

Provide Unit Support 2...............................

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

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

Field Fabricate Ductwork 6............................

Provide Clearances 6.................................

Rig and Place Unit 6.................................

Connect Condensate Drain 7...........................

Install Flue Hood 7...................................

Install Gas Piping 7..................................

Install Duct Connections 9.............................

Configuring Units for Downflow (Vertical)

Discharge 9......................................

Install Electrical Connections 12........................

High--Voltage Connections 12........................

Special Procedures for 208--V Operation 12..............

Control Voltage Connections 13.......................

Balance Point Setting Thermidistat or Hybrid Heat

Thermostat 13....................................

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

P R E -- S T A R T -- U P 1 3 -- 1 4................................

START--UP 14--17.....................................

Check for Refrigerant Leaks 14.........................

Unit Sequence of Operation 14.........................

Start--Up Heating and Make Adjustments 14...............

Checking Heating Control 14.........................

Check Gas Input 15................................

Adjust Gas Input 15................................

Check Burner Flame 16.............................

Start--Up Cooling and Make Adjustments 16...............

Checking Cooling Control Operation 16................

Checking and Adjusting Refrigerant 17.................

Indoor Airflow and Airflow Adjustments 17.............

MAINTENANCE 32--38................................

Air Filter 32........................................

Indoor Blower and Motor 32...........................

Flue Gas Passageways 33..............................

Limit Switch 33.....................................

Burner Ignition 33...................................

Main Burners 33....................................

Outdoor Coil, Indoor Coil, & Condensate Drain Pan 33......

Outdoor Fan 34.....................................

Electrical Controls and Wiring 34.......................

Refrigerant Circuit 34.................................

Gas Input 35........................................

Indoor Airflow 35...................................

Check Defrost Thermostat 35...........................

PuronR Items 35....................................

TROUBLESHOOTING 38..............................

START--UP CHECKLIST 38............................

Installation and servicing of this equipment can be hazardous due to mechanical and electrical components. Only trained and qualified personnel should install, repair, or service this equipment.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on this equipment, observe precautions in the literature, on tags, and on labels attached to or shipped with the unit and other safety precautions that may apply.

Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes, the current editions of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code (NEC) NFPA 70.

In Canada refer to the current editions of the National Standards of Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane Installation codes, and Canadian Electrical Code CSA C22.1.

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 these 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 hazards which could result in personal injury or death. CAUTION is used to identify unsafe practic-

A09034

Fig. 1 -- Unit 48EZ-- A

SAFETY CONSIDERATIONS

es 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 result in personal injury or death.

Before installing or servicing system, always turn off main power to system and install lockout tag. There may be more than one disconnect switch. Turn off accessory heater power switch if applicable.

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD

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

48EZ --A

A qualified installer or agency must use only factory--authorized kits or accessories when modifying this product.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

When removing access panels (see Fig. 18) or performing maintenance functions inside your unit, be aware of sharp sheet metal parts and screws. Although special care is taken to reduce sharp edges to a minimum, be extremely careful when handling parts or reaching into the unit.

INTRODUCTION

The 48EZ--A unit (see Fig. 1) is a fully self--contained, combination Category I gas heating/electric heating and cooling unit designed for outdoor installation (See Fig. 2 and 3 for unit dimensions). All unit sizes have return and discharge openings for both horizontal and downflow configurations, and are factory shipped with all downflow duct openings covered. Units may be installed either on a rooftop, or on a cement slab (See Fig. 4 for roof curb dimensions).

In gas heating mode, this unit is designed for a minimum continuous return--air temperature of 55_F(13_C) db and a maximum continuous return--air temperature of 80_F(27_C) db. Failure to follow these return--air temperature limits may affect reliability of heat exchangers, motors, and other components.

Models with an N in the fifth position of the model number are dedicated Low NOx units designed for 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 or any other regions in North America where a Low NOx rule exists.

RECEIVING AND INSTALLATION

Step 1 — Check Equipment

IDENTIFY UNIT The unit model number and serial number are stamped on the unit

information plate. Check this information against shipping papers. INSPECT SHIPMENT

Inspect for shipping damage before removing packaging materials. If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before removal.

Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit. Check all items against shipping list. Immediately notify the nearest equipment distribution office if any item is missing. To prevent loss or damage, leave all parts in original packages until installation.

If the unit is to be mounted on a curb in a downflow application, review Step 9 to determine which method is to be used to remove the downflow panels before rigging and lifting into place. The panel removal process may require the unit to be on the ground.

Step 2 — Provide Unit Support

For hurricane tie downs, contact distributor for details and PE (Professional Engineering) Certificate if required.

ROOF CURB

Install accessory roof curb in accordance with instructions shipped with curb (See Fig. 4). 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 water tight seal. Install gasketing material supplied with the roof curb. Improperly applied gasketing also can result in air leaks and poor unit performance.

Curb should be level to within 1/4 in. (6 mm). This is necessary for unit drain to function properly. Refer to accessory roof curb installation instructions for additional information as required.

Installation on older “G” series roof curbs.

Two accessory kits are available to aid in installing a new “G” series unit on an old “G” roof curb.

1. Accessory kit number CPADCURB001A00, (small chassis) and accessory kit number CPADCURB002A00, (large chassis) includes roof curb adapter and gaskets for the perimeter seal and duct openings. No additional modifications to the curb are required when using this kit.

2. An alternative to the adapter curb is to modify the existing curb by removing the outer horizontal flange and use accessory kit number CPGSKTKIT001A00 which includes spacer blocks (for easy alignment to existing curb) and gaskets for the perimeter seal and duct openings. This kit is used when existing curb is modified by removing outer horizontal flange.

CAUTION

UNIT/STRUCTURAL DAMAGE HAZARD

Failure to follow this caution may result in property damage.

Ensure there is sufficient clearance for saw blade when cutting the outer horizontal flange of the roof curb so there is no damage to the roof or flashing.

SLAB MOUNT

Place the unit on a solid, level concrete pad that is a minimum of 4 in. (102 mm) thick with 2 in. (51 mm) above grade. The slab should be flush on the compressor end of the unit (to allow condensate drain installation) and should extend 2 in. (51 mm) on the three remaining sides of the unit. Do not secure the unit to the slab except when required by local codes.

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

48EZ --A

Fig. 2 -- 48EZ--A24 --36 Unit Dimensions

A09450

48EZ --A

Fig. 3 -- 48EZ--A42 --60 Unit Dimensions

A09451

HVAC unit base rails

Anchor screw

Flashing field supplied

Roofing material field supplied

Cant strip field supplied

HVAC unit basepan

Sealing Gasket

Roofcurb

Wood nailer*

Roofcurb*

Insulation (field supplied)

*Provided with roofcurb

ROOF CURB DETAIL

SMALL CURB

A09090

A09418

48EZ --A

LARGE CURB

UNIT SIZE

Small

Large

NOTES:

1. Roof curb must be set up for unit being installed.

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

3. Roof curb is made of 16 --gauge steel.

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

5. Insulated panels: 1 --in. (25.4 mm) thick fiberglass 1 lb. density.

CATALOG

NUMBER

CPRFCURB010A00 11 (279) CPRFCURB011A00 14 (356) CPRFCURB012A00 11 (279) CPRFCURB013A00 14 (356)

IMPORTANT: Do not install large base pan HYBRID HEAT units onto the small base pan (common curb). The center of gravity on a large base pan HYBRID HEAT unit could overhang the curb causing an unsafe condition. Before installing any large base pan unit onto the common

IN. (mm)BIN. (mm)*

10 (254)

14 (356)

Fig. 4 -- Roof Curb Dimensions

A09415

A09419

IN. (mm)DIN. (mm)EIN. (mm)FIN. (mm)GIN. (mm)HIN. (mm)

16 (406)

47.8

(1214)

32.4 (822)

43.9

(1116)

2.7 (69)

30.6 (778)

46.1 (1170)

42.2 (1072)

curb, check the “Y” distance in the product literature dimensional drawing to ensure that “Y” is greater than 14 in. (356 mm). Do not install any large base pan unit onto the common curb with a “Y” dimension (center of gravity) less than 14 in. (356 mm).

CAUTION - NOTICE TO RIGGERS PRUDENCE - AVIS AUX MANIPULATEUR

ACCESS PANELS MUST BE IN PLACE WHEN RIGGING.

PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION.

Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition

DUCTS

MINIMUM HEIGHT: 36" (914.4 mm) HAUTEUR MINIMUM

SEE DETAIL A VOIR DÉTAIL A

48EZ --A

RIGGING WEIGHTS (SMALL CABINET) RIGGING WEIGHTS ( LARGE CABINET)

Unit

Rigging

Weight

NOTE: See dimensional drawing for corner weights.

24 30 36

lb kg lb kg lb kg lb kg lb kg lb kg

359 163 373 169 379 172

Step 3 — Field Fabricate Ductwork

Secure all ducts to roof curb and building structure on vertical discharge units. Do not connect ductwork to unit. For horizontal applications, unit is provided with flanges on the horizontal openings. All ductwork should be secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes.

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.

See unit rating plate for any required clearances around ductwork. Cabinet return--air static shall not exceed --.25 IN. W.C.

Step 4 — Provide Clearances

The required minimum operating and service clearances are shown in Fig. 2 and 3.

IMPORTANT: Do not restrict outdoor airflow. An air restriction at either the outdoor--air inlet or the fan discharge may be detrimental to compressor life.

The condenser fan pulls air through the condenser coil and discharges it through the top grille. Be sure that the fan discharge does not recirculate to the condenser coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48--in. (1219 mm) above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48--in. (1219 mm).

Do not place the unit where water, ice, or snow from an overhang or roof will damage or flood the unit. Do not install the unit on carpeting or other combustible materials. The unit may be installed on Class A, B, or C roof covering materials. Slab mounted units should be at least 4--in. (102 mm) above the highest expected water and runoff levels. Do not use unit if it has been under water.

UNIT HEIGHT HAUTEUR D'UNITÉ

DETAIL A

VOIR DÉTAIL A

Unit

Rigging

Weight

42 48 60

461 209 482 219 507 230

Fig. 5 -- 48EZ--A Suggested Rigging

Step 5 — Rig and Place Unit

PERSONAL INJURY OR PROPERTY DAMAGE HAZARD

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

When installing the unit on a rooftop, be sure the roof will support the additional weight.

Rigging and handling of this equipment can be hazardous for many reasons due to the installation location (roofs, elevated structures, etc.).

Only trained, qualified crane operators and ground support staff should handle and install this equipment.

When working with this equipment, observe precautions in the literature, on tags, stickers, and labels attached to the equipment, and any other safety precautions that might apply.

Training for operators of the lifting equipment should include, but not be limited to, the following:

1. Application of the lifter to the load, and adjustment of the lifts to adapt to various sizes or kinds of loads.

2. Instruction in any special operation or precaution.

3. Condition of the load as it relates to operation of the lifting kit, such as balance, temperature, etc.

Follow all applicable safety codes. W ear safety shoes and work gloves.

Inspection

Prior to initial use, and at monthly intervals, all rigging shackles, clevis pins, and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular attention should be paid to excessive wear at hoist

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

BANDE SCELLANT DOIT ÊTRE EN PLACE AVANT DE PLACER L'UNITÉ SUR LA BASE DE TOIT

50CY502286 2.0

WARNING

A09051

hooking points and load support areas. Materials showing any kind of wear in these areas must not be used and should be discarded.

WARNING

UNIT FALLING HAZARD

Failure to follow this warning could result in personal injury or death.

Never stand beneath rigged units or lift over people.

WARNING

PROPERTY DAMAGE HAZARD

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

When straps are taut, the clevis should be a minimum of 36 in. (914 mm) above the unit top cover.

Rigging/Lifting of Unit (See Fig. 5)

Lifting holes are provided in base rails as shown in Fig. 2 and 3.

1. Leave top shipping skid on the unit for use as a spreader bar to prevent the rigging straps from damaging the unit. If the skid is not available, use a spreader bar of sufficient length to protect the unit from damage.

2. Attach shackles, clevis pins, and straps to the base rails of the unit. Be sure materials are rated to hold the weight of the unit (See Fig. 5).

3. Attach a clevis of sufficient strength in the middle of the straps. Adjust the clevis location to ensure unit is lifted level with the ground.

After the unit is placed on the roof curb or mounting pad, remove the top skid.

Step 6 — Connect Condensate Drain

NOTE: When installing condensate drain connection be sure to

comply with local codes and restrictions.

Model 48EZ--A disposes 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. (25 mm) lower than the drain--pan condensate connection to prevent the pan from overflowing (See Fig. 6). Prime the trap with water. When using a gravel apron, make sure it slopes away from the unit.

If the installation requires draining the condensate water away from the unit, install a 2 -- in. (51 mm) trap at the condensate connection to ensure proper drainage (See Fig. 6). Make sure that the outlet of the trap is at least 1 in. (25 mm) lower than the drain--pan condensate connection. This prevents the pan from overflowing.

Prime the trap with water. Connect a drain tube -- using a minimum of 3/4-- in. PVC or 3/4--in. copper pipe (all field--supplied) -- at the outlet end of the 2--in. (51 mm) trap. Do not undersize the tube. Pitch the drain tube downward at a slope of at least 1-- in. (25 mm) for every 10 ft (3 m) of horizontal run. Be sure to check the drain tube for leaks.

TRAP OUTLET

1-in. (25 mm) min.

2-in. (51 mm) min.

A09052

Fig. 6 -- Condensate Trap

Step 7 — Install Flue Hood

The flue assembly is secured and shipped in the return air duct. Remove duct cover to locate the assembly (See Fig. 8).

NOTE: Dedicated low NOx models MUST be installed in California Air Quality Management Districts where a Low NOx rule exists.

These models meet the California maximum oxides of nitrogen (NOx) emissions requirements of 40 nanograms/joule or less as shipped from the factory.

NOTE: Low NOx requirements apply only to natural gas installations.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

The venting system is designed to ensure proper venting. The flue hood assembly must be installed as indicted in this section of the unit installation instructions.

Install the flue hood as follows:

1. This installation must conform with local building codes and with the National Fuel Gas Code (NFGC) NFPA 54 / ANSI Z223.1, (in Canada, CAN/CGA B149.1, and B149.2) latest revision. Refer to Provincial and local plumbing or wastewater codes and other applicable local codes.

2. Remove flue hood from shipping location (inside the return section of the blower compartment-- see Fig. 8). Remove the return duct cover to locate the flue hood. Place flue hood assembly over flue panel. Orient screw holes in flue hood with holes in the flue panel.

3. Secure flue hood to flue panel by inserting a single screw on the top flange and the bottom flange of the hood.

Step 8 — Install Gas Piping

The gas supply pipe enters the unit through the access hole provided. The gas connection to the unit is made to the 1/2--in. (12.7 mm) FPT gas inlet on the gas valve.

Install a gas supply line that runs to the heating section. Refer to Table 2 and the NFGC for gas pipe sizing. Do not use cast--iron pipe. It is recommended that a black iron pipe is used. Check the local utility for recommendations concerning existing lines. Size gas supply piping for 0.5 IN. W.C. maximum pressure drop. Never use pipe smaller than the 1/2--in. (12.7 mm) FPT gas inlet on the unit gas valve.

For natural gas applications, the gas pressure at unit gas connection must not be less than 4.0 IN. W.C. or greater than 13 IN. W.C. while the unit is operating. For propane applications, the gas pressure must not be less than 11.0 IN. W .C. or greater than 13 IN. W.C. at the unit connection.

48EZ --A

A 1/8--in. (3.2 mm) NPT plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the gas valve.

When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to the NFGC NFPA 54/ANSI Z223.1 latest edition (in Canada, CAN/CGA B149.1).

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.

2. When flexible connectors are used, the maximum length shall not exceed 36 in. (915 mm).

3. When lever handle type manual equipment shutoff valves are used, they shall be T --handle valves.

4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.

In the absence of local building codes, adhere to the following pertinent recommendations:

1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in. (6.35 mm) for every 15 ft (4.6 m) of length to prevent traps. Grade all horizontal runs downward to risers. Use risers to connect to heating section and to meter.

48EZ --A

2. Protect all segments of piping system against physical and thermal damage. Support all piping with appropriate straps, hangers, etc. Use a minimum of one hanger every 6 ft (1.8 m). For pipe sizes larger than 1/2 in., (12.7 mm) follow 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 liquedfied petroleum gases as specified by local and/or national codes. Never use Teflon tape.

4. Install sediment trap in riser leading to heating section (See Fig. 7). This drip leg functions as a trap for dirt and condensate.

5. Install an accessible, external, manual main shutoff valve in gas supply pipe within 6 ft (1.8 m) of heating section.

6. Install ground--joint union close to heating section between unit manual shutoff and external manual main shut--off valve.

7. Pressure test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit.

NOTE: Pressure test the gas supply system after the gas supply piping is connected to the gas valve. The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0.5 psig. Pressure test the gas supply piping system at pressures equal to or less than 0.5 psig. The unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the ground-- joint union.

WARNING

FIRE OR EXPLOSION HAZARD

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

--Connect gas pipe to unit using a backup wrench to avoid damaging gas controls.

--Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

--Use proper length of pipe to avoid stress on gas control manifold.

--If a flexible connector is required or allowed by authority having jurisdiction, black iron pipe shall be installed at furnace gas valve and extend a minimum of 2 in. (51 mm) outside furnace casing.

--If codes allow a flexible connector, always use a new connector. Do not use a connector which has previously serviced another gas appliance.

8. Check for gas leaks at the field--installed and factory--installed gas lines after all piping connections have been completed. Use a commercially available soap solution made specifically for the detection of leaks (or method specified by local codes and/or regulations).

TEE

OUT

NIPPLE

CAP

C99020

Fig. 7 -- Sediment Trap

Step 9 — Install Duct Connections

The unit has duct flanges on the supply-- and return--air openings on the side and bottom of the unit. For downshot applications, the ductwork connects to the roof curb (See Fig. 2 and 3 for connection sizes and locations).

Configuring Units for Downflow (Vertical) Discharge

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Before installing or servicing system, always turn off main power to system and install lockout tag. There may be more than one disconnect switch.

1. Open all electrical disconnects before starting any service work.

2. Remove horizontal (metal) duct covers to access vertical (downflow) discharge duct knockouts in unit basepan. (See Fig. 8.)

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property damage.

Collect ALL screws that were removed. Do not leave screws on rooftop as permanent damage to the roof may occur.

WARNING

CAUTION

3. Use flexible transition between rigid ductwork and unit to prevent transmission of vibration. The transition may be screwed or bolted to duct flanges. Use suitable gaskets to ensure weather tight and airtight seal.

4. All units must have field--supplied filters or accessory filter rack installed in the return--air side of the unit. Recommended sizes for filters are shown in Table 1.

5. Size all ductwork for maximum required airflow (either heating or cooling) for unit being installed. Avoid abrupt duct size increases or decreases or performance may be affected.

6. Adequately insulate and weatherproof all ductwork located outdoors. Insulate ducts passing through unconditioned space, and use vapor barrier in accordance with latest issue of Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors of America (ACCA) minimum installation standards for heating and air conditioning systems. Secure all ducts to building structure.

7. Flash, weatherproof, and vibration--isolate all openings in building structure in accordance with local codes and good building practices.

48EZ --A

To remove downflow return and supply knockout covers, break front and right side connecting tabs with a screwdriver and hammer. Push cover down to break rear and left side tabs.

NOTE: These panels are held in place with tabs similar to an electrical knockout. Reinstall horizontal duct covers (Fig. 8) shipped on unit from factory. Insure openings are air and watertight.

NOTE: The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidence--type air conditioning and ventilating systems, NFPA 90A or residence--type, NFPA 90B; and/or local codes and ordinances.

Adhere to the following criteria when selecting, sizing, and installing the duct system:

1. Units are shipped for horizontal duct installation (by removing duct covers).

2. Select and size ductwork, supply--air registers, and return--air grilles according to American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) recommendations.

Horizontal Duct Covers

Basepan Downflow (Vertical) Supply Knockout

Fig. 8 -- Supply and Return Duct Opening

Basepan Downflow (Vertical) Return Knockout

A09061

A09060

Table 1 – Physical Data -- Unit 48EZ -- A

UNIT SIZE 48EZ ---A 24040 24060 30040 30060 36060 36090 42060 42090

NOMINAL C APACITY --- ton 2 2 2 --- 1 / 2 2 --- 1 / 2 3 3 3 --- 1 / 2 3 --- 1 / 2

SHIPPING WEIGHT ---lb.

COMPRESSORS Scroll

Quantity 1

REFRIGERANT (R --- 410A)

Quantity --- lb

REFRIGERANT METERING

Nominal Cooling Airflow---(CFM)

48EZ --A

Natural Gas Qty...Drill Size (Factory Installed)

*Based on altitude of 0 to 2000 ft (0 ---610 m). {Required filter sizes shown are based on the larger of the AHRI (Air Conditioning, Heating and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 ft/minute for high ---capacity type. Air filter pressure drop for non ---standard filters must not exceed 0.08 IN. W.C. } If using accessory filter rack refer to filter rack installation instructions for correct filter size and quantity.

Propane GasQty...Drill Size

HIGH --- PRESSURE SWITCH

LOW---PRESSURE SWITCH

RETURN--- AIR FILTERS † }

DEVICE

OUTDOOR ORIFICE

in. (qty)

(mm)

OUTDOOR COIL

Rows...Fins/in. F a c e A r e a --- s q f t OUTDOOR FAN

Nominal Cfm Diameter--- in.

Motor Hp (Rpm)

INDOOR COIL

Rows...Fins/in. F a c e A r e a --- s q f t

INDOOR BLOWER

S i z e --- i n .

M o t o r --- h p

FURNACE SECTION*

Burner Orifice

( p s i g ) C u t --- o u t

Reset (Auto)

L O S S --- O F --- C H A R G E /

(Liquid Line) (psig)

C u t --- o u t

Reset (auto)

Throwaway (in.)

(kg)

(mm)

359 163

8.3

3.8

0.032 (2)

2...21

11.9

2000

610

1/5 (810)

3...17

3.7

800

10x10

254x254

1/2

2...44

2...55

20x20x1

508x508x25

.81

359 163

8.3

3.8

2...21

11.9

2000

610

1/5 (810)

3...17

3.7

800

10x10

254x254

1/2

2...38

2...53

373 169

10.2

4.6

0.035 (2)

2...21

11.9

2700

610

1/5 (810)

3...17

3.7

1000

10x10

254x254

1/2

2...44

2...55

20x24x1

508x610x25

373 169

10.2

4.6

I n do o r --- T X V, O u t door --- A cc u r a t e r

.89

2...21

11.9

2700

610

1/5 (810)

3...17

3.7

1000

10x10

254x254

1/2

2...38

2...53

650 +/---15 420 +/---25

2 0 + / --- 5

45 +/---10

379 172

7.9

3.6

2...21

11.9

2700

610

1/5 (810)

3...17

3.7

1200

11x10

279x254

3/4

2...38

2...53

0.037 (2) .94

379 172

7.9

3.6

2...21

11.9

2700

610

1/5 (810)

3...17

3.7

1200

11x10

279x254

3/4

3...38

3...53

610x762x25

1/5 (810)

279x254

24x30x1

461 209

10.0

4.5

0.038 (Left)

0.040(Right)

2...21

13.6

3100

660

3...17

4.7

1400

11x10

3/4

2...38

2...53

.97/1.02

461 209

10.0

4.5

2...21

13.6

3100

660

1/5 (810)

3...17

4.7

1400

11x10

279x254

3/4

3...38

3...53

Table 1 -- Physical Data -- Unit 48EZ --A (Cont’d)

NUMBER

MANIFOLD

PRES

SURE

ORIFICES

UNIT SIZE 48EZ ---A 48090 48115 48130 60090 60115 60130

NOMINAL C APACITY --- ton 4 4 4 5 5 5

OPERATING WEIGHT --- lb

COMPRESSORS Scroll

Quantity 1

REFRIGERANT (R --- 410A)

Quantity --- lb

REFRIGERANT METERING DEVICE TXV

OUTDOOR ORIFICE ---in. (qty)

OUTDOOR COIL

Rows...Fins --- in. F a c e A r e a --- s q f t

OUTDOOR FAN

Nominal Cfm Diameter--- in.

M o t o r H p --- R p m

INDOOR COIL Rows...Fins --- in. F a c e A r e a --- s q f t

INDOOR BLOWER

Nominal Cooling Airflow---(CFM)

Natural Gas Qty...Drill Size (Factory Installed)

velocity of 300 ft/minute for high ---capacity type. Air filter pressure drop for non ---standard filters must not exceed 0.08 IN. W.C. } If using accessory filter rack refer to filter rack installation instructions for correct filter size and quantity.

Propane GasQty...Drill Size

HIGH --- PRESSURE SWITCH (psig) Cut --- out

LOW---PRESSURE SWITCH

S i z e --- i n .

M o t o r --- h p

FURNACE SECTION*

Burner Orifice

Reset (Auto)

L O S S --- O F --- C H A R G E /

(Liquid Line) (psig)

C u t --- o u t

Reset (auto)

RETURN--- AIR FILTERS †

Throwaway (in.)

(mm)

(kg)

(kg )

(mm)

482 219

2...21

13.6

3100

660

1/5 (810)

3...17

4.7

1600

11x10

279x254

1.0

3...38

3...53

482 219

9.6

4.4

0.046 (2)

1.2

2...21

13.6

3100

660

1/5 (810)

3...17

4.7

1600

11x10

279x254

1.0

3...33

3...51

482 219

2...21

13.6

3100

660

1/5 (810)

3...17

4.7

1600

11x10

279x254

1.0

3...31

3...49 650 +/---15 420 +/---25

2 0 + / --- 5

45 +/---10

24x36x1

(610x914x25)

507 230

2...21

17.5

3500

660

1/5 (810)

3...17

5.7

1850

11x10

279x254

1.0

3...38

3...53

507 230

12.3

5.6

0.052 (2)

1.3

2...21

17.5

3500

660

1/5 (810)

3...17

5.7

1850

11x10

279x254

1.0

3...33

3...51

507 230

2...21

17.5

3500

660

1/5 (810)

3...17

5.7

1850

11x10

279x254

1.0

3...31

3...49

Table 2 – Maximum Gas Flow Capacity*

NOMINAL

IRON PIPE,

SIZE (IN.)

1/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 — — 3/4 .824 360 250 200 170 151 138 125 118 110 103 93 84 77 72

1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 1 --- 1 / 4 1.380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280 1 --- 1 / 2 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 0.5---IN. W.C. (based on a 0.60 specific gravity gas). Refer toTable2 and National Fire Protection Association NFPA 54/ANSI Z223.1. † This length includes an ordinary number of fittings.

INTERNAL

DIAMETER

(IN.)

(3.1)20(6.1)30(9.1)40(12.2)50(15.2)60(18.3)70(21.3)80(24.4)90(27.4)

LENGTH OF PIPE, FT† (m)

100

(30.5)

125

(38.1)

150

(46.0)

175

(53.3)

48EZ --A

200

(61.0)

Table 3 – Heating Inputs

HEATING INPUT

(BTUH)

GAS SUPPL Y PRESSURE (IN. W.C.)

Natural{ Propane*{

Min Max Min Max Natural{ Propane*†

40,000 2 4.0 13.0 11.0 13.0 3.2∼3.8 10.0∼11.0 60,000 2 4.0 13.0 11.0 13.0 3.2∼3.8 10.0∼11.0

90,000 3 4.0 13.0 11.0 13.0 3.2∼3.8 10.0∼11.0 115,000 3 4.0 13.0 11.0 13.0 3.2∼3.8 10.0∼11.0 130,000 3 4.0 13.0 11.0 13.0 3.2∼3.8 10.0∼11.0

*When a unit is converted to propane, different size or ifices must be used. See separate, natural --- to ---propane conver sion kit instructions.

{Based on altitudes from sea level to 2000 ft (610 m) above sea level. In U.S.A. for al titudes above 2000 ft (610 m), reduce input rating 4 percent for each addi-

tional 1000 ft (305 m) above sea level. In Canada, from 2000 ft (610 m) above sea level to 4500 ft (1372 m) above sea level, dera te the unit 10 percent.

MANIFOLD PRESSURE

(IN. W.C.)

Step 10 — Install Electrical Connections

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

The unit cabinet must have an uninterrupted, unbroken electrical ground. This ground may consist of an electrical wire connected to the unit ground screw in the control compartment,or conduitapproved for electrical ground when installed in accordance with NEC, NFPA 70 National Fire Protection Association (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes.

UNIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the unit being installed.

48EZ --A

1. Make all electrical connections in accordance with NEC NFPA 70 (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between field--supplied electrical disconnect switch and unit. DO NOT USE ALUMINUM WIRE.

3. Be sure that high-- voltage power to unit is within operating voltage range indicated on unit rating plate. On 3--phase units, ensure phases are balanced within 2 percent. Consult local power company for correction of improper voltage and/or phase imbalance.

4. Insulate low--voltage wires for highest voltage contained within conduit when low-- voltage control wires are in same conduit as high-- voltage wires.

5. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc.

High--Voltage Connections

When routing power leads into unit, use only copper wire between disconnect and unit. The high voltage leads should be in a conduit until they enter the duct panel; conduit termination at the duct panel must be watertight.

The unit must have a separate electrical service with a field--supplied, waterproof disconnect switch mounted at, or within sight from, the unit. Refer to the unit rating plate, NEC and local codes for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing.

The field--supplied disconnect switch box may be mounted on the unit over the high--voltage inlet hole when the standard power and low--voltage entry points are used (See Fig. 2 and 3 for acceptable location).

NOTE: Field supplied disconnect switch box should be positioned so that it does not cover up any of the unit gas combustion supply air louvers.

See unit wiring label (Fig. 14 and 15) and Fig. 9 for reference when making high voltage connections. Proceed as follows to complete the high--voltage connections to the unit.

Single phase units:

1. Run the high--voltage (L1, L2) and ground lead into the control box.

2. Connect ground lead to chassis ground connection.

WARNING

CAUTION

HIGH VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL)

CONTROL BOX

LOW-VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL)

EQUIP GR

SPLICE BOX

FIELD-SUPPLIED FUSED DISCONNECT

WHT(W1)

YEL(Y)

GRN(G)

RED(R)

BRN(C)

ORN(O)

BLU (DH)

GRA (Y2)

3-Phase Only

POWER SUPPLY

THERMOSTAT (TYPICAL)

Fig. 9 -- High and Control--Voltage Connections

3. Locate the black and yellow wires connected to the line side of the contactor.

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

5.ConnectfieldwireL2toyellowwireonconnection23of the compressor contactor.

Three--phase units:

1. Run the high--voltage (L1, L2, L3) and ground lead into the control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the line side of the contactor.

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

5.ConnectfieldwireL3toyellowwireonconnection13of the compressor contactor.

6. Connect field wire L2 to blue wire from compressor.

Special Procedures for 208--V Operation

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Make sure thepowersupply to the unit isswitchedOFFbefore making any wiring changes.Tag the disconnect switch with a suitable warning label. With disconnect switch open, move black wire from transformer (3/16 in.) terminal marked 230 to terminal marked 200. This retaps transformer to primary voltage of 208 vac.

WARNING

ELECTRICAL SHOCK AND EXPLOSION HAZARD

Failure to follow this warning could result in personal injury or death.

Beforemaking any wiringchanges, make sure thegassupply is switched off first. Then switch off the power supply to the unit and install lockout tag.

A09067

Control Voltage Connections

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 (30.5 m) from the unit (as measured along the control voltage wires), use no. 16 AWG color--coded, insulated (35_C minimum) wires.

Locate the seven (eight on 3-- phase) low voltage thermostat leads in 24 volt splice box. See Fig. 9 for connection diagram. Run the low--voltage leads from the thermostat, through the control wiring inlet hole grommet (Fig. 2 and 3), and into the low--voltage splice box. Provide a drip loop before running wires through panel. Secure and strain relief all wires so that they do not interfere with operation of unit. A gray wire is standard on 3--phase unit for connection to an economizer.

Balance Point Setting--Thermidistat or Hybrid Thermostat

BALANCE POINT TEMPERATURE--The “balance point” temperature is a setting which affects the operation of the heating mode. This is a field-- selected input temperature (range 5 to 55_F) (--15to12_C) where the Thermidistat or dual fuel thermostat will monitor outdoor air temperature and decide whether to enable or disable the heat pump. If the outdoor temperature is above the “balance point”, the heat pump will energize first to try to satisfy the indoor temperature demand. If the heat pump does not make a sufficient improvement within a reasonable time period (i.e. 15 minutes), then the gas furnace will come on to satisfy the indoor temperature demand. If the outdoor temperature is below the “balance point”, the heat pump will not be allowed to operate (i.e. locked out), and the gas furnace will be used to satisfy the indoor temperature. There are three separate concepts which are related to selecting the final “balance point” temperature. Read each of the following carefully to determine the best “balance point” in a hybrid installation:

1. Capacity Balance Temperature: This is a point where the heat pump cannot provide sufficient capacity to keep up with the indoor temperature demand because of declining outdoor temperature. At or below this point, the furnace is needed to maintain proper indoor temperature.

2. Economic Balance Temperature: Above this point, the heat pump is the most cost efficient to operate, and below this point the furnace is the most cost efficient to operate. This can be somewhat complicated to determine and it involves knowing the cost of gas and electricity, as well as the efficiency of the furnace and heat pump. For the most economical operation, the heat pump should operate above this temperature (assuming it has sufficient capacity) and the furnace should operate below this temperature.

3. Comfort Balance Temperature: When the heat pump is operating below this point, the indoor supply air feels uncomfortable (i.e. too cool). This is purely subjective and will depend on the homeowner’s idea of comfort. Below this temperature the gas furnace should operate in order to satisfy the desire for indoor comfort.

Transformer Protection

The transformer is of the energy--limiting type. It is set to withstand a 30--sec. overload or shorted secondary condition. If an overload or short is present, correct overload condition and check for blown fuse on gas control board or Interface Fan Board. Replace fuse as required with correct size and rating.

PRE--START--UP

WARNING

FIRE,EXPLOSION, ELECTRICAL SHOCK HAZARD

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

1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.

2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured.

3. Do not remove compressor terminal cover until all electrical sources are disconnected and tagged.

4. Relieve and recover all refrigerant from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals.

5. Never attempt to repair soldered connection while refrigerant 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 follows:

a. Shut off electrical power to unit and install lockout

tag.

b. Relieve and reclaim all refrigerant from system

using both high-- and low--pressure ports.

c. Cut component connecting tubing with tubing

cutter and remove component from unit.

d. Carefully unsweat remaining tubing stubs when

necessary. Oil can ignite when exposed to torch flame.

Proceed as follows to inspect and prepare the unit for initial start--up:

1. Remove access panels (see Fig. 18).

2. Read and follow instructions on all WARNING, CAUTION, and INFORMATION 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 for oil at all refrigerant tubing connections and

on unit base. Detecting oil generally indicates a refrigerant leak.

c. Leak test all refrigerant tubing connections using

electronic leak detector, halide torch, or liquid--soap solution. If a refrigerant leak is detected, see the Check for Refrigerant Leaks section.

d. Inspect all field-- and factory--wiring connections. Be

sure that connections are completed and tight.

e. Ensure wires do not touch refrigerant tubing or sharp

sheet metal edges.

f. Inspect coil fins. If damaged during shipping and

handling, carefully straighten fins with a fin comb.

WARNING

FIRE, EXPLOSION HAZARD

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

Do not purge gas supplyintothecombustion chamber.Do not use a match or other open flame to check for gas leaks. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

48EZ --A

+ 28 hidden pages