Carrier 48GP060130300, 48GP060115300, 48GP060090310, 48GP060090300, 48GP048130300 Installation Guide
...
48GP, 48GPN
Single Package Gas Heating/Electric Cooling Units
HEATING & COOUNG
Visit www.carrier.cmn
With Puron® (R-410A) Refrigerant
Installation, Start-Up, and Operating Instructions
48GP, 48GPN Sizes 024-060
NOTE: Read the entire instruction manual before starting the
installation.
Index Page
SAFETY CONSIDERATIONS ..................................................... 1
RULES FOR SAFE INSTALLATION AND OPERATION.... 1-2
RECEIVING AND INSTALLATION .......................................... 2
CHECK EQUIPMENT .................................................................. 2
PROVIDE UNIT SUPPORT ......................................................... 2
Roof Curb ............................................................................ 2
Slab Mount .......................................................................... 2
Ground Mount ..................................................................... 2
FIELD FABRICATE DUCTWORK ............................................. 2
PROVIDE CLEARANCES ........................................................ 2-3
RIG AND PLACE UNIT ....................................................... 3, 6-7
CONNECT CONDENSATE DRAIN ........................................... 7
INSTALL FLUE HOOD ............................................................... 7
INSTALL GAS PIPING ............................................................. 7-8
INSTALL DUCT CONNECTIONS ....................................... 8, 10
INSTALL ELECTRICAL CONNECTIONS ......................... 11-13
High-Voltage Connections ................................................ 11
Special Procedures for 208-V Operation .......................... 11
Control Voltage Connections ............................................ 12
Standard Connection .......................................................... 12
Heat Anticpator Setting ..................................................... 13
Transformer Protection ...................................................... 13
PRE-START-UP .......................................................................... 13
START-UP .............................................................................. 13-22
MAINTENANCE .................................................................... 22-26
REFRIGERANT SYSTEM .......................................................... 26
QUICK REFERENCE GUIDE .................................................... 27
TROUBLESHOOTING .......................................................... 28-30
START-UP CHECKLIST ............................................................ 31
NOTE TO INSTALLER Before the installation, READ
THESE INSTRUCTIONS CAREFULLY AND COMPLETELY.
Also, make sure the User's Manual and Replacement Guide are
left with the unit after installation, the furnace is NOT to be used
for temporary heating of buildings or structures under construc-
tion.
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can be
hazardous due to system pressure and electrical components. Only
trained and qualified personnel should install, repair, or smwice
air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of
cleaning coils and filters. All other operations should be performed
by trained smwice personnel. When working on air-conditioning
equipment, observe precautions in the literature, tags and labels
attached to the unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves. Use
quenching cloth for unbrazing operations. Have fire extinguisher
available lbr all brazing operations.
RULES FOR SAFE INSTALLATION AND OPERATION
Improper installation, adjustment, alteration, service, mainte-
nance, or use can cause carbon monoxide poisoning, fire, or
an explosion which can result in serious injury or unit
damage. Consult a qualified installer, service agency, or gas
supplier for information or assistance. The qualified installer
or agency must use only factory-authorized kits or accessories
when modifying this product.
Understand the signal words DANGER, WARNING, and
CAUTION. DANGER identifies the most serious hazards which
will result in severe serious injury or death. WARNING indicates
a condition that could result in serious injury or death. CAUTION
is used to identify unsafe practices which would result in minor or
moderate injury or product and property damage.
The power supply (volts, phase, and hertz) must correspond to that
specified on unit rating plate.
The electrical supply provided by the utility must be sufficient to
handle load imposed by this unit.
This installation must conform with local building codes and with
NEC (National Electrical Code) and NFPA 70, NFPA 54 ANSI
Z223.1 latest revision, and NFGC (National Fuel Gas (;ode). Refer
to provincial and local plumbing or waste water codes and other
applicable local codes.
Approved for outdoor installation on wood flooring or on class A,
B or C roof covering materials.
Fig. 1--Unit 48GP
FR|','1,_I;1:Il_e
C99088
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 101 Catalog No 534-755 Printed in US.A. Form 48GP-1SI Pg 1 3-00 Replaces: New
Before performing service or maintenance operations on unit,
turn off gas supply then unit main power switch. Electrical
shock or explosion could cause serious iniury or death.
r:l ['_IliilI0]/l
Puron (R-410A) systems operate at higher pressures than
standard R-22 systems. Do not use R-22 service equipment or
components on Puron (R-410A) equipment. Ensure service
equipment is rated for Puron (R-410A).
GENERAL The 48GP units (see Fig. 1) are fully self-
contained, combination Category I gas heating/electric cooling
units designed for outdoor installation. See Fig. 6 and 7 for unit
dimensions. All unit sizes have discharge openings for both
horizontal and downflow configurations, and are factory shipped
with all downflow duct openings covered. Units may be installed
either on a rooftop, cement slab, or directly on the ground (if
permitted by local codes). See Figs. 4 and 5 for roof curb
dimensions.
48GPN units are dedicated Low NOx units designed for California
installations. These models meet the California maximum oxides
o f nitrogen (NOx) emissions requirement of 40 nanogrmns joule or
less as shipped fi'om the factory and MUST be installed in
California Air Quality Management Districts where a Low NOx
rule exists.
RECEIVING AND INSTALLATION
Step l--Check Equipment
IDENTIFY L_'IT The unit model number and serial number
are stamped on unit identification plate. Check this infomlation
against shipping papers and job data.
INSPECT SHIPMENT Inspect for shipping damage while unit
is still on shipping pallet. If unit appears to be damaged or is tom
loose ficom its anchorage, have it examined by transportation
inspectors before removal. Forward claim papers directly to
transportation company. Manufacturer is not responsible for any
damage incurred in transit.
Check all items against shipping list. Immediately notify the
nearest Carrier Air Conditioning office if any item is missing.
To prevent loss or damage, leave all parts in original packages
until installation.
2,
MAXIMUM ALLOWABLE
DIFFERENCE (in.)
A-B B-C A-C
1/4 1/4 1/4
Fig. 2--Unit Leveling Tolerances
C99065
GROL_D MOUNT The unit may be installed either on a slab
or placed directly on the ground if local codes pemfit. Place the
unit on level ground prepared with gravel for condensate dis-
charge.
Step 3--Field Fabricate Ductwork
Secure all ducts to roof curb and building structure on vertical
discharge units. Do not connect dz¢ctworlc to unit. For horizontal
applications, unit is provided with flanges on the horizontal
openings. All ductwork should be secnred to the flanges. Insulate
and weathelproof all external ductwork, joints, and roof openings
with counter flashing and mastic in accordance with applicable
codes.
Ducts passing through an unconditioned space must be insulated
and covered with a vapor barrier.
If a plenum return is used on a vertical unit, the return should be
ducted through the roof deck to comply with applicable fire codes.
A minimum clearance is not required around ductwork. Cabinet
return-air static shall not exceed -.25 in. wg.
RETURN ' ' SUPPLY "
_11'1 iUPl_ \ _\i iH
IIIII III
IIIII OPENING OPENING111
IIIII 111
IIIII 111
IIIII 111
IIIII III
IIIII III
IIIII III
EVAR COIL COND COIL
C99014
Fig. 3_lab Mounting Details
Step 2--Provide Unit Support
ROOF CURB Install accessory roof curb in accordance with
instructions shipped with curb. See Figs. 4 and 5 and Table 1 for
roof curb dimensions. Install insulation, cant strips, roofing, and
flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is critical
for a watertight seal. Install gasketing material supplied with the
roof curb. Improperly applied gasketing can also result in air leaks
and poor unit perfomlanee.
Curb should be level to within 1/4 inch. This is necessm T for unit
drain to function properly. Refer to accessory roof curb installation
instructions for additional information as required (see Fig. 2).
SLAB MOUNT Place the unit on a solid, level concrete pad
that is a minimum of 4 in. thick with 2 in. above grade. The slab
should be flush on the compressor end of the unit (to allow
condensate &din installation) and should extend 2 in. on the three
remaining sides of the unit. See Fig. 3. Do not secure the unit to the
slab eycept when required by local codes.
Step 4_Provide Clearances
The required minimum operating and service clearances are shown
in Fig. 6 and 7. Adequate combustion, ventilation, and condenser
air must be provided, in accordance with section 5.3, Air for
Combustion and Ventilation, of the National Fuel Gas Code ANSI
(American National Standards Institute) Z223.1 (in Canada, sec-
tions 7.2, 7.3 or 7.4 or CaniCGA [Canadian Gas Association]
B149 Installation Codes), or applicable provisions of local build-
ing code.
¥!I [_:.llli_0]/1
Do not restrict condenser airflow. An air restriction at either
the outdoor-air inlet or the fan discharge can be detrimental to
compressor life.
The condenser pulls air through the condenser coil and discharges
it through the top cover. Be sure that the fan discharge does not
J 44 5,16
SUPPORTB
(INSULATED)
Fig. 4_Roof Curb Dimensions
Top View
(2)
END ViEW
A99320
SIDE PAN EL__,
SUPPORT R'B(S) ...... _/ I_i if' BOTTOM SUPPLY
0.75 1
BASE PAN I
4.0"
(o,Ot pFL%"')NG............1L[ NA'LER
CANT STR P ...... JINSULATION
(FIELD SUPPLIBD_ ....... _ .......... (FIELD SUPPLIED)
ROOFING MATERIAL
(FIELD SUPPLIED)
Fig. 5--Roof Curb Dimensions
UNIT SIZE ODS ORDER NUMBER
ROOF CPRFCURB007A00 14 [356] 11 27/32 [301] 30 5/8 [778] 28 3/4 [730]
CURB CPRFCURB008A00 8 [203] 15 27/32 [402] 42 1/8 [1070] 40 1/4 [1022]
Notes:
1. Roof curb must be set up for unit being installed
2. Seal strip must be applied as required to unit being installed
3. Dimensions in [ ] are in millimeters.
4. Roof curb is made of 16 gage steel.
5. Table Iists only the dimensions per part number that have changed.
6. Attach ductwork to curb (flanges of duct rest on curb)
7. Insulated panels: 1-in. thick fiberglass 1lb. density
8. Dimensions are in inches
48GP024-036
48GP042-060
CPRFCURB006A00 8 [203] 11 27/32 [301] 30 5/8 [778] 28 3/4 [730]
CPRFCURB009A00 14 [356] 15 27/32 [402] 42 1/8 [1070] 40 1/4 [1022]
Side View
A B C D
IN, [MM] IN, [MM] IN, [MM] IN, [MM]
A99340
Table 1--Roof Curb Dimensions
recirculate to the condenser coil. Do not locate the unit in either a
comer or under an overhead obstmction. The minimum clearance
under a partial overhang (such as a normal house overhang) is
48-in. above the unit top. The maximum horizontal extension of a
partial overhang nmst not exceed 48 inches.
Do not place the unit where water, ice, or snow fFom an overhang
or roof will damage or flood the unit. Do not install the unit on
carpeting, tile, or other combustible materials. The unit may be
installed on wood flooring or on Class A, B, or C roof covering
materials.
Step 5--Rig and Place Unit
Rigging and handling of this equipment can be hazardous for many
reasons due to the installation location (roofs, elevated stmctures,
etc.).
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers and labels attached to the equipment,
and any other safety precautions that might apply.
Training for operations of the lifting equipment should include, but
NOT be limited to the following:
E_39]
4020
E1585]
T
SUPPLY
OUCT
OPENING
i
_1177
[463]
893 _
[348]
REQ'D CLEARANCES FOR OPERATION AND SERVICING in. (mm)
Evaporator coil access side .................. 36 (914)
Power entry side (except for NEC requirements) ......... 36 (914)
Unit top .......................... 48 (1219)
Side opposite ducts ..................... 36 (914)
Duct panel ........................ 12 (304.8)*
*Minimum distances: If unit is placed Iess than 12 in. (3048 mm) from wall
system, then the system performance may be compromised.
LEGEND
CG - Center of Gravity
COND - Condenser
EVAP - Evaporator
NEC - National Electrical Code
REQ'D - Required
Note: Dimensions are in in (mm)
_7985
249 6
[983]
[31 44]
FIELD ENTRY
SERVICE PORTS \
[21 67] [983]
REAR VIEW
\
[091]
t
y COND
I NON SENT
11939
[4TOO]
805
[516]
EVAP COIL
TOP VIEW
REQ'D CLEARANCES TO COMBUSTIBLE MAT'L in. (mm)
Top of unit ......................... 14 (355.6)
Duct side of unit ....................... 2 (50.8)
Side opposite ducts ..................... 14 (355.6)
Bottom of unit ....................... 0.50 (12.7)
Flue panel ......................... 36 (914.4)
NEC REQ'D CLEARANCES. in (mm)
Between units, power entry side .............. 42 (1066.8)
Unit and ungrounded surfaces, power entry side ......... 36 (914)
Unit and block or concrete walls and other grounded
surfaces, control box side ................. 42 (1066.8)
153 5
[694]
1
190 [075] NPT
22 O _)P
_8310
LEFT SIDEVIEW
UNIT
48GP024040/060
48GP030040/060
48GP036060/090
[52 62]
250 ]
S?O_S
162_,_61
42 l
[168]
[1285]
[285]
_OMPRESSOR BLOWER GAS SECTION
& ELECTRICAL ACCESS PANEL
1226 3
[_828]
4562
[119_] 347 2
FLUE HOOR
FRONT VIEW
ELECTRICAL
CHARACTERISTICS
UNIT WEIGHT
lb. kg.
208/230-1-60 22.0 [5588] 16.0 [4064]
208/230-1-60, 3902 [9911] 22.0 [5588] 153 [387.4] 17.614470]
208/230-3-60
208/230-1-60,
208/230-3-60, 3502 [8895] 22.0 [5588] 153 [387.4] 16.5 [4191]
460-3-60
290.0 1315
313.0 1420
321.0 1456
UNIT HEIGHT
IN. [MM]
"k"
3702 [940 3]
CENTER OF GRAVITY
X Z
o
GAS ENTRY
RIGHTSIDEVIEW
IN. [MM]
Y
145 [368.3]
[O50] NPT
Fig. 6--48GP024-036 Unit Dimensions
4
50
[0R0]
C99017
860
[3 39]
[16 01]
T
4020
[15 832
[348]
T
Y
EVAP
REAR VIEW
REQUIRED CLEARANCE FOR OPERATION AND SERVICING
EVAR COIL ACCESS SIDE .............................................................. 3600 [914 6]
POWER ENTRY SIDE ...................................................................... 3600 [914 O]
(EXCEPT FOR NEC REQUIREMENTS)
UNIT TOP ......................................................................................... 3600 [914.0]
SIDE OPPOSITE DUCTS ................................................................ 3600 [914.0]
DUCT PANEL ................................................................................... 1200 [304 8] *
*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 12.00 [304.8] FROM
WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE
1090 6
[42 94]
FIELO ENTRY_
SERVICE PORI
in. [mm]
1193 9
[4700]
t
t
4066
I
TOP VIEW
REQUIRED CLEARANCE TO COMBUSTIBLE MATE
TOP OF UNIT ................................................................................... 14.00 [355.6]
DUCT SIDE OF UNIT ......................................................................... 2.00 [508]
SIDE OPPOSITE DUCTS ................................................................ 14.00 [355.6]
BOTTOM OF UNIT ............................................................................. 0.50 [12.7]
ELECTRIC HEAT PANEL ................................................................. 36.00 [914.4]
NEC.REQUIREDCLEARANCES.
BETWEEN UNITS, POWER ENTRY SIDE .................................... 4200 [1066.8]
UNIT AND UNGROUNDED SURFACES, POWER ENTRY SiDE .3600 [914.0]
UNiT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE ......................... 42.00 [1066.8]
MILLIMETERS [IN]
in [mm]
I
190 [073] NPT [168]
x 22 0 [0 87] #P 329 0
[4422]
LEFT SIDE VIEW
UNIT
48GP042060/090
48GP048090/115/130
48GP060090/115/130
ELECTRICAL
CHARACTERISTICS
208/230-1-60
208/230-3-60
460-3-60
208/230-1-60
208/230-3-60
460-3-60
208/230-1-60,
208/230-3-60,
460-3-60
mHmmmmmH!
,/
427
[1295]
[285]
Fig. 7--48GP042-060 Unit Dimensions
/
_OMPRE360R 5LOWER GAS SECTION
ELECTRICAL ACCESS PANEL
12263
[48 28]
FRONT VIEW
UNIT WEIGHT
Ib kg
382 173.3
421 191.0
468 212.3
UNIT HEIGHT
IN, [MM]
38.98 [990.2]
38.98 [990.2]
4298 [1091.7]
"A"
X
23.0 [584 2]
21.5 [546 1]
23.5 [596 9]
39 I
1.3
1424
[561]
CENTER OF GRAVITY
IN. [MM]
Y Z
163 [412.8] 16.6 [421 6]
166 [422.1] 18.0 [457 2]
163 [412.8] 17.6 [447 O]
RIGHT SIDE VIEW
C99074
i. Application of the lifter to the load and adjustment of the lifts,
if any, that adapts it to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.
3. Condition of the load itself, required for operation of the
lifting kit, such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work
gloves.
TV" o •
Ir!] L, I:I.1J R[.
Never exceed 200 lbs. per bracket lifting force.
Accessory lifting kit is only to be used with Small
Packaged units which have a composite base pan with
molded hand holds.
Never stand beneath rigged units or lift over people.
Lifting point should be directly over the center of gravity
for the unit.
A &opped unit could cause serious injury or death.
INSPECTION Prior to initial use, and at monthly intervals, all
rigging brackets and straps should be visually inspected lbr any
damage, evidence of wear, structural deformation, or cracks.
Particular attention should be paid to excessive wear at hoist
hooking points and load support areas. Brackets or straps showing
any kind of wear in these areas nmst not be used and should be
discarded.
INSTALLATION:
5. Attach safety straps directly to the field supplied rigging straps
or clevis clip. Do not attach the safety straps to the lifting
brackets.
6. Use the top of the unit as a spreader bar to prevent the rigging
straps from damaging the unit. If the wood top is not available,
use a spreader bar of sufficient length to not damage the unit.
DETAIL A
SCALE 025O
C99066
Fig. 8--Lifting Point
i. Position the lifting bracket assembly around the base of the
unit. Leave the top shipping skid on the unit to act as a
spreader bar. Be sure the strap does not twist.
2. Place each of the four (4) metal lifting brackets into the
handholds in the composite pan.
3. Tighten the ratchet strap until tight. Lifting brackets should be
secure in the handholds.
4. Attach the clevis or hook of sufficient strength to hole in the
lifting bracket as shown in Fig. 8.
HOOK
FEED II_N_,-
C99067
Belt Threading Instructions:
i. Open lever of tension buckle
2. Feed webbing through tension buckle as shown
3. Pull webbing through tension buckle until taught
4. Snap lever down to lock strap in tension buckle
5. To release, squeeze safety latch, lift lever and pull webbing
outward
Fig. 9--Belt Threading
914-1371
(36'i54")
\
B
DUCTS
t_7_557,)
J
12263
PLACE RIGGING STRAPS
BASEPAN SLOT (BELOW HANDHOLDS)
BEFORE RIGGING
UNIT 48GP MAXIMUM WEIGHT A B
Size tb mm in mm
024 312 5585 14.5 3883
030 335 5585 15.3 3886
036 343 5585 15.3 3886
042 404 5842 18.3 4140
048 443 5461 18.3 4140
060 490 5969 18.3 4143
kg in.
142 22.0
152 22.0
156 22.0
183 23.0
201 21.5
222 23.5
SEAL STRIP MUST BE IN
PLACE BEFORE PLACING
UNIT ON ROOF CURB
/
Fig. lO--Suggested Rigging
Step 6--Connect Condensate Drain
NOTE: When installing condensate drain connection be sure to
comply with local codes and restrictions.
The 48GP units dispose of condensate water through a 3/4 in. NPT
fitting which exits through the compressor access panel. See Fig.
6 and 7 for location.
Condensate water can be drained directly onto the roof in rooftop
installations (where permitted) or onto a gravel apron in ground-
level installations. Install a field-supplied condensate trap at end of
condensate connection to ensure proper drainage. Make sure that
the outlet of the trap is at least 1 in. lower than the drain pan
condensate connection to prevent the pan from overflowing. See
Fig. 11. Prime the trap with water. When using a gravel apron,
make sure it slopes away from the unit.
If the installation requires draining the condensate water away
from the unit, install a 2-in. trap at the condensate connection to
ensure proper &ainage. See Fig. 11. Make sure that the outlet of
the trap is at least 1 in. lower than the drain pan condensate
connection to prevent the pan from overflowing. Prime the trap
with water. Connect a drain robe using a minimum of 3/4 -in. PVC
or 3/4 -in. copper pipe (all field-supplied) at the outlet end of the
2-in. trap. Do not undersize the tube. Pitch the drain tube
downward at a slope of at least one in. for every 10 ft of horizontal
run. Be sure to check the drain robe for leaks. 12
1" MtN.
TRAP
OUTLET
C99013
Fig. 11--Condensate Trap
Step 7--Install Flue Hood
The flue hood assembly is shipped screwed to the coil panel in the
indoor blower compartment. Remove the service access panel to
locate the assembly.
Dedicated low NOx 48GP models MIST be installed in Califor-
nia Air Quality Management Districts where a Low NOx rule
exists. These models meet the California maximum oxides of
nitrogen (NOx) emissions requirement of 40 nanograms.joule or
less as shipped from the _aetory.
NOTE: Low NOx requirements apply only to natural gas instal-
lations.
¥:I [q:lw_l[0]/l
The venting system is designed to ensure proper venting. The
flue hood assembly must be installed as indicated in this
section of the unit installation instructions.
Install the flue hood as follows:
i. This installation must conform with local building codes and
with the National Fuel Gas Code (NFGC), ANSI Z223.1 (in
Canada, CANiCGA B 149.1, and B 149.2) or NFPA (National
Fire Protection Association) latest revision. Refer to Provin-
cial and local plumbing or waste water codes and other
applicable local codes.
2. Remove flue hood from shipping location (inside the blower
compartment). Place vent cap assembly over flue panel. Orient
screw holes in vent cap with holes in the flue panel.
3. Secure flue hood to flue panel by inserting a single screw on
the right side and the left side of the hood.
Step 8--Install Gas Piping
The gas supply pipe enters the unit through the access hole
provided. The gas connection to the unit is made to the 1/2-in. FPT
gas inlet on the manual shutoff or gas valve.
C99015
Install a gas supply line that runs to the heating section. Refer to
Table 4 and the NFGC for gas pipe sizing. Do not use cast-iron
pipe. It is recommended that a black iron pipe is used. check the
local utility for recommendations concerning existing lines. Size
gas supply piping for 0.5 in. wg maximum pressure drop. Never
use pipe smaller than the 1/2-in. FPT gas inlet on the unit gas
valve.
For natural gas applications, the gas pressure at unit gas connection
must not be less than 4.0 in. wg or greater than 13 in. wg while the
unit is operating. For propane applications, the gas pressure must
not be less than 7.0 in. wg or greater than 13 in. wg at the unit
connection.
A 1/8-in. NPT plugged tapping accessible for test gage connection
nmst be installed immediately upstream of the gas supply connec-
tion to the gas valve.
When installing the gas supply line, observe local codes pertaining
to gas pipe installations. Refer to the NFGC ANSI Z223.1, NFPA
54 latest edition (in Canada, CANiCGA B149.1, B149.2 latest
edition). In the absence of local building codes, adhere to the
following pertinent recommendations:
i. Avoid low spots in long runs of pipe. Grade all pipe 1.4 in. in
every 15 It. to prevent traps. Grade all horizontal runs
downward to risers. Use risers to connect to heating section
and to meter.
2. Protect all segments of piping system against physical and
thermal damage. Support all piping with appropriate straps,
hangers, etc. Use a minimum of one hanger every 6 It. For
pipe sizes larger than i/2 in., follow recommendations of
national codes.
3. Apply joint compound (pipe dope) sparingly and only to male
threads of joint when snaking pipe connections. Use only pipe
dope that is resistant to action of liquefied petroleum gases as
specified by local and/or national codes. Never use Teflon
tape.
4. Install sediment trap in riser leading to heating section per Fig.
12. This drip leg functions as a trap for dirt and condensate.
5. Install an accessible, external, manual main shutoff valve in
gas supply pipe within 6 It. of heating section.
6. Install ground-joint union close to heating section between
unit manual shutoff and external manual main shutoff valve.
7. Pressure-test all gas piping in accordance with local and
national plumbing and gas codes before connection of piping
to unit.
NOTE: The supply piping must be disconnected from the gas
valve during the testing of the piping systems when test pressure is
in excess of 0.5 psig (13.8 WC). If the test pressure is equal to or
less than 0.5 psig, the unit heating section must be isolated from
the gas piping system by closing the external main mannal shutoff
valve and slightly opening the ground-ioint union.
¥:I [_0l/l
Unstable operation may occur when the gas valve and
manifold assembly are forced out of position while connect-
ing improperly routed rigid gas piping to the gas valve. Use
a backup wrench when snaking connection to avoid strain on,
or distortion of, the gas control piping.
¥!I [q:.IlriiI°]/1
If a flexible conductor is required or allowed by the authority
having jurisdiction, black iron pipe shall be installed at the
gas valve and shall extend a minimum of 2 in. outside the unit
casing.
¥_ kU/'_W:I: I I:[_
Never use a snatch or other open flame when checking for gas
leaks. Never purge gas line into combustion chamber. Failure
to follow this warning could result in an explosion causing
serious injury or death
8. Check for gas leaks at the field-installed and factory-installed
gas lines aRer all piping connections have been completed.
Use soap and water solution (or method specified by local
codes and.or regulations).
Step 9--Install Duct Connections
The unit has duct flanges on the supply- and retnrn-air openings on
the side and bottom of the unit. For downshot applications the
ductwork can be connected to the roof curb. See Fig. 6 and 7 for
connection sizes and locations.
CONFIGURING UNITS FOR DOV_rNFLOW (VERTICAL) DIS-
CHARGE
¥_ kU/'_W=I:IIT[_
Before performing service or maintenance operations on the
system, tuna off main power to unit. Electrical shock could
cause serious injury or death.
NIPPLE
CAP
Fig. 12_Sediment Trap
C99020
i. Open all electrical disconnects before starting any service
work.
2. Remove return duct cover located on duct panel by breaking
connecting tabs with screwdriver and a hammer (Fig. 13).
3. To remove supply duct cover, break front and right side
connecting tabs with a screwdriver and a hammer. Push louver
down to break rear and leR side tabs (Fig. 14).
4. If unit ductwork is to be attached to vertical opening flanges
on the unit basepan (iackstand applications only), do so at this
time. Collect ALL screws that were removed. Do not leave
screws on rooftop as permanent damage to the roof may occur.
5. It is recommended that the basepan insulation around the
perimeter of the vertical return-air opening be secured to the
basepan with aluminum tape. Applicable local codes may
require aluminum tape to prevent exposed fiberglass.
6. Cover both horizontal duct openings with the duct covers from
the accessory duct cover kit. Ensure opening is air-and
watertight.
Table 2--Physical Data -- Unit 48GP -- 024040-042090
UNit SIZE 48GP 024040 024060 030040 030060 036060 036090 042060 042090
NOMINAL CAPACITY (ton) 2 2 2 1/2 2 1/2 3 3 3 1/2 3 1/2
OPERATING WEIGHT (Ib) 290 290 313 313 321 321 382 382
COMPRESSORS ScroH
Quantity 1
REFRIGERANT (R-410A) 50 5.0 5.5 55 69 69 9.0 9.0
Quantity (Ib)
REFRIGERANT METERING DEVICE
Burner Orifice No. (Qty...Drill Size) 2.44 2.38 2..44 2..38 2.38 3.38 2.38 3..38
Burner Orifice No. (Qty...Drill Size)
HIGH-PRESSURE SWITCH (psig) 810 _+15
LOSS-OF-C HARGE/LOW-PRESSU RE SWITCH
Orifice ID (in,) .057 .057 057 057 085 .085 .070 070
AccuRater_ Piston
CONDENSER COIL
Rows...Fins/in.
Face Area (sq ft)
CONDENSER FAN
Nominal CFM
Diameter (in.) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825)
Motor Hp (RPM)
EVAPORATOR COIL
Rows...Fins/in.
Face Area (sq ft)
EVAPORATOR BLOWER
Nominal Airflow (CFM) 10x10 10x10 10×10 10x10 10x10 10x10 11x10 11×10
Size (in.) 1/4 1/4 1/4 1/4 1/2 1/2 3/4 3/4
Motor HP
FURNACE SECTION*
Natural Gas
Propane Gas
Cutout 420 +_25
Reset (Auto.)
(Liquid Line) (psig) 20 +_5
Cutout 45 +_10
Reset (Auto.)
1/17 1/17 1/17 1/17 2/17 2/17 2/17 2/17
10.9 10.9 127 127 91 91 12.3 123
2350 2350 2350 2350 2350 2350 2350 2350
22 22 22 22 22 22 22 22
3/15 3/15 3/15 3/15 3/15 3/15 3/15 3/15
37 3.7 3.7 37 37 37 4.7 4.7
800 800 800 1000 1200 1200 1400 1400
2. 50 2 .46 2..50 2..46 2. 46 3. 46 2 .46 3..48
RETURN-AiRFILTERS ,o)T.rowaway20×24×1I 28×24×1I 28×24xlI 20×24xlI 20×24×1I20×24×1I24×30×1I 24×30×1
Table 3--Physical Data -- Unit 48GP -- 048090-060130
UNIT SIZE 48GP 048090 048115 048130 060090 060115 060130
NOMINAL CAPACITY (ton) 4 4 4 5 5 5
OPERATING WEIGHT (Ib) 421 421 421 468 468 468
COMPRESSORS Scrotl
Quantity 1
REFRIGERANT (R-410A) 9.5 9.5 95 10.0 10.0 100
REFRIGERANT METERING DEVICE
Burner Orifice No. (Qty...Driil Size) 3.38 3.33 3..31 3..38 3.33 3.31
Burner Orifice No. (Qty...Drill Size)
HIGH-PRESSURE SWITCH (psig) 810 _+15
LOSS-OF-CHARGE/LOW-PRESSU RE SWITCH
RETURN-AIR FILTERS (in.)Throwaway 24x 30x1 I 24x 30x1 I 24x 30xl I 24x 30xl I 24x 30x1 I 24x 30x1
Quantity (Ib)
Orifice ID (in,) .073 073 073 .086 .088 088
Accurater_ Piston
CONDENSER COIL
Rows...Fins/in.
Face Area (sq ft)
CONDENSER FAN
Nominal Cfm
Diameter (in.)
Motor Hp (RPM) 1/4 (1100) 1/4 (1100) 1/4 (1100) 1/4 (1100) 1/4 (1100) 1/4 (1100)
EVAPORATOR COIL
Rows...Fins/in.
Face Area (sq ft)
EVAPORATOR BLOWER
Nominal Airflow (Cfm) 11 x 10 11 x 10 11 x 10 11 x 10 11 x 10 11 x 10
Size (in,) 3/4 3/4 3/4 1O 10 1.0
Motor HP
FURNACE SECTION*
Natural Gas
Propane Gas
Cutout 420 +_25
Reset (Auto.)
(Liquid Line) (psig) 20 _+5
Cutout 45 +_10
Reset (Auto.)
2/17 2/17 2/17 2/17 2/17 2/17
12.3 123 123 16.4 16.4 164
3300 3300 3300 3300 3300 3300
22 22 22 22 22 22
4/15 4/15 4/15 4/15 4/15 4/15
47 4.7 4.7 47 47 4.7
1600 1600 1600 1750 1750 1750
3.46 3.42 3..41 3..48 3.42 3.41
I I I I I
Table 4--Maximum Gas Flow Capacity*
NOMINAL IRON PIPE SIZE (IN.)
1/2
3/4
1
1 1/4
1 1/2
*Capacity of pipe in cu ft. of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0 5-in. wg (based on a 0.60 specific gravity gas) Refer to Table C-4, National
Fire Protection Association NFPA 54
1-This length includes an ordinary number of fittings.
INTERNAL DIAMETER (IN,)
622 175 120 87 82 73 66 61 57 53 50 44 40
824 360 250 200 170 151 138 125 118 110 103 93 84 77 72
1048 680 465 375 320 285 260 240 220 205 185 175 160 145 135
1380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280
1610 2100 1460 1180 890 900 810 750 690 650 620 550 500 460 430
10 20 30 40 50 60 70 80 90 100 125 150 175 200
7. After completing unit conversion, perform all safety checks
and power up unit.
NOTE: The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
nonresidence-type air conditioning and ventilating systems, NFPA
90A or residence-type, NFPA 90B; and.or local codes and
residence-type, NFPA 90B; and.or local codes and ordinances.
ADHERE TO THE FOLLOWING CRITERIA WHEN SELECT-
ING, SIZING, AND INSTALLING THE DUCT SYSTEM:
i. Units are shipped for side shot installation.
2. Select and size ductwork, supply-air registers, and return-air
grilles according to American Society of Heating, Refrigera-
tion and Air Conditioning Engineers (ASHRAE) recommen-
dations.
3. Use flexible transition between rigid ductwork and unit to
prevent transmission of vibration. The transition may be
screwed or bolted to duct flanges. Use suitable gaskets to
SUPPLY RETURN
DUCT DUCT
OPENING OPENING
ensure weather tight and airtight seal.
4. All units must have field-supplied filters or accessory filter
Fig. 13--Supply and Return Duct Opening
rack installed in the return-air side of the unit. Recommended
sizes for filters are shown in Tables 2 and 3.
5. Size all ductwork for maxinmm required airflow (either
heating or cooling) for unit being installed. Avoid abrupt duct
size increases or decreases or performance may be affected.
6. Adequately insulate and weatherproof all ductwork located
outdoors. Insulate ducts passing through unconditioned space,
and use vapor barrier in accordance with latest issue of Sheet
Metal and Air Conditioning Contractors National Association
(SMACNA) and Air Conditioning Contractors of America
(ACCA) minimum installation standards for heating and air
conditioning systems. Secure all ducts to building structure.
7. Flash, weatherproof, and vibration-isolate all openings in
building structure in accordance with local codes and good
building practices.
LENGTH OF PIPE, FTt
°/ I I
C99089
10
VERTICAL DUCT COVERS
C99012
Fig. 14_Vertical Duct Cover Removed
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