Carrier 48GX060090300, 48GX048115300, 48GX048090300, 48GX042090300, 48GX042060300 Installation Guide

...

HFATUNG & COOLING

Single Packaged Gas Heating/

%isdt_ v_v_carrier.corn

Installation, Start-Up, and Operating

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

48GS, 48GX

Electric Cooling Units

NOTE: Read the entire instruction manual before starting the installation

TABLE OF CONTENTS

SAFETY C ONSIDERATI(INS 1 INTRODE CTION 2

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(ONFIGURING UNITS FOR DO\}_TLOW (VERTI-

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

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

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

SPECIAL PROCEDURES FOR 208°V OPERATION ._ 13

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

< HE(KING AND ADJUSTING REFRIGERANT

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

INDOOR AIRFLOW AND AIRFLOW ADJUST-

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

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

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

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

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

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

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

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

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

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

CONDENSER COIL, EVAPORATOR (OIL, AND

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

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

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

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

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

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

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

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

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

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

NOTE TO INSTALLER Before the installatiom READ THESE INSTRU(TIONS CAREFELLY AND (OMPLETELY. Also,

make sure the User's Manual and Replacement Guide are left with the unit after installation. The furnace is NOT to be used for

temporary heating of buildings or structures under construction.

A99338

Fig. 1--Unit 48GS and 48GX

(Low NO× Model Available)

SAFETY CONSIDERATIONS

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

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

PC 101 Catalog No 534-80128 Printed in U.S.A Form 48GS.GX-6SI Pg 1 11-02 Replaces: 48GS.GX-5SI

Untrained personnel can perfbrm basic maintenance functions of

cleaning coils and filters. All other operations should be perfbrmed

by tlained service personnel When working on air-conditioning

equipmenL observe precautions in the literature, tags, and labels attached to the unit, and other safety precautions that may apply.

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

quenching cloth for unbrazing operations. Have fire extinguisher available ibr all brazing operations.

Improper installation, adjustment, aheration, service, mainte- nancQ or use can cause carbon monoxide poisoning, fire, or an explosion which can result in personal injury or unit damage. Consuh a qualified installer, service agency, or gas supplier for information or assistance. The qualified installer or agency must use only factory-authorized kits or accessories

when modifying this product

Beibre peribrming service or maintenance operations on mail mrn off gas supply to unit. Then mrn off unit main power switch and install lockout tag. Elecn'ical shock or explosion could cause serious inju_ or death.

Recognize safety infbrmation This is the safety-alert symbolz_ When you see this symbol in instructions or manuals, be alert to the potential _br personal injory.

Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safcV-alert symboh

DANGER identifies the most serious hazards which will result in

serious injury or death. WARNING signifies a hazard which could

result in serious inju V or death. CAUTION is used to identii_, unsafe practices which would result in minor personal injury or

product and property damage. NOTE is used to highlight sugges- tions which will result in enhanced installation, reliability, or

operation. These instructions cover minimuna requirements and confbrm to

existing national standards and safety codes. In some instances,

these instructions exceed certain local codes and ordinances,

especially those that may not have kept up with changing residen- tial construction practices. We require these instructions as a minimum ibr a saf_ installation.

INTRODUCTION

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

combination Category- I gas heating/electric cooling units designed

ibr outdoor installation (See Fig. 2 and 3 for unit dimensions). All unit sizes have return and discharge openings ibr both horizontal

and downflow configurations, and are ii_ctory shipped with all

downflow duct openings covered. Units may be installed either on

a rooftop, a cement slab, or directly on the ground if local codes permit (See Fig. 4 for roof curb dimensions).

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

dedicated Low NOxunits designed fbr California installations.

These models meet the California maximum oxides of nitrogen

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

shipped from the factory and must be installed in California Air

Quality Management Districts where a Low NO× rule exists.

RECEBVING AND INSTALLATION

Step 1--CHECK EQUIPMENT

IDENTIFY UNIT

The unit model number and serial nunfber are stamped on unit

identification plate. Check this information against shipping papers

and job data. Verit}' unit voltage and amperage requirements listed on unit rating plate agree with power supply provided to unit

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

If unit appears to be damaged or is torn loose t'rom its anchorage, have it examined by transportation inspectors before removal

Forward claim papers directly to transportation company Manu- facturer is not responsible for any damage incurred in transit

Check all items against shipping list Immediately notify the nearest distributor if any item is missing.

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

INSTALLATION

1. Remove unit from shipping carton Leave top shipping skid on the unit as a spreader bar to prevent the rigging straps from

damaging the unit. If the wood skid is not available, use a spreader bar of sufficient length to protect unit t_-om damage.

2. Position the tiffing bracket assembly around the base of the unit. Be sure the strap does not twist

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

4. Thread liking bracket strapping around bottom perimeter of unit as follows:

a Open lever of tension buckle (ratchet type) b. Feed strapping throngh tension buckle as shown in Fig 7A. c Pull strapping through tension buckle unit taut. d. Snap lever down to lock strap in tension buckle To release

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

5. Tighten the tension buckle until it is taut Lifting brackets must be secure in the rigging holds

6. Attach field=supplied clevis or hook of sufficient strength to hole in the liking bracket (See Fig. 7B).

7. Attach the 2 safkty straps directly to the clevis or hook at the 4 rigging brackets. DO NOT attach the safkty straps to the lifting brackets (See Fig. 7B).

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

9. Lift unit. When unit is directly over the roof curb, remove the 2 safety straps. Lower the equipment onto the roof curb.

Step 2--PROVIDE UNiT SUPPORT

ROOF CLRB Install accessory roof curb in accordance with instructions shipped

with curb (See Fig. 4 for roof curb dimensions). Install insulation, cant strips, roofing, and flashing Ductwork must be attached to

curb

IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasketing material supplied with the roof curb. Improperly applied gasketing can also result in air leaks and poor unit perfbrmance.

Cm:b should be level to within 1/4 in. This is necessa_' for unit drain to Nnction properly. Refkr to accessory roof curb installation instructions for additional information as required.

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

4 in. thick with 2 in. above grade. The slab should be flush on the compressor end of the unit (to allow condensate &ain installation) and should extend 2 in. on the three remaining sides of the unit (See Fig. 6). Do not secure the unit to the slab e:vcept when required by local codes.

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

OPU 6

t '

i N

ZS4 "" 5q } _ 5 :

86 I _ _ j

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

, : _C,_494_ 0_i t:¸

249 ;

i,, s1

550 5 ?49 6

IN _;i }9 8_]

REAR ViEW

REQUIRED CLEARANCE TO COMBUSTIBLE MATL

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

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

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

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

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

NEC. REQUIRED CLEARANCES,

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

UNIT AND UNGROUNDED SURFACES. POWER ENTRY SIDE 3800 [914 0] UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

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

LEGEND CO Centerof OravRy

COND Condensor EVAP Evap@ator

NEC National E[ectnca[Code REQ'D Reqused

NOTE:Dimensions are in in [mm]

INCHES [mm]

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

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

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

(EXCEPT FOR NEC REQUIREMENTS)

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

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

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

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

WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE

INCHES [mm]

UNIT

48GS018040 48GS024040/080 48GS030040/080

48GS038060/090 48GS042060/090 48GX624040/060 48GX036040/060

48GX036066/090

ELECTRICAL CHARACTERISTICS

208/230-1-60 208/230-1-60

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

208/230-1-60

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

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

UNIT WEIGHT

Ib T kg

249.0 113.2

280.0 127.3

320.0 145.1

355.0 161.4

290.0 131.5

313.0 142.0

321.0 145.6

UNIT HEIGHT IN. ([VIM)

,,A,_

35.02 (889.5)

37.02 (940.3)

35.02 (889.5)

37.02 (940.3)

39.02 (991.1)

35.02 (889.5)

20.0 (508.0)

22.5 (571.5)

21.5 (546.1)

22.5 (571.5)

21.5 (546.1)

22.0 (558.8)

CENTER OF GRAVITY

IN.(MM)

140 (3556) 130 (3302)

1375 (349.3)

140 (355.6) 135 (342.9)

145 (3683) 153 (3874)

153 (387.4)

COOO55

15.0(3810)

15.0(3810) 150 (3810)

130 (3302) 130 (3302)

16.0 (4064) 176 (4470)

165 (4191)

70 4 [2 77] i

[33£1

3558 {1411]

_3427 _ 3558

[!3 49] [14 Oi]

SUPPLY

402 o [15 83]

i E_AP COIL

[1177

{a 631

88 3 [3 46] [13831 [13 62] [13831

REAR VIEW

REQUIRED CLEARANCE TO COMBUSTIBLE MATE

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

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

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

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

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

NEC. REQUIRED CLEARANCES,

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

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE 3600 [914.0] UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

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

k_- 10906

[42 943

INCHES [mini

INCHES [mm]

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

47 OO] [4 54]

C01L

4066 [1601]

[16 O!]

TOP VIEW

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

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

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

(EXCEPT FOR NEC REQUIREMENTS)

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

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

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

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

WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE.

LEGEND

CG - Center of Gravity COND - Condensor

EVAP- Evaporator NEC - National Electrical Code

REQ'D - Required

INCHES [mm]

L._ It231

[44 22]

LEFT SIDEVIEW

UNiT

48G8048090/115/130 48GS0600901115/130

48GX042060/090

48GX048090/115/190 48GX060090f115/130

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

i \ o

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

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

ELECTRICAL CHARACTERISTICS

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

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

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

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

CONTROLEN/RY

[.8 1 V I

FRONTVIEW RIGHTSIDEVIEW

UNIT WEIGNT

Ib kg

415 1886 450 2045 382 1733

421 1910 468 2123

UNIT HEIGHT IN. (MM)

"A"

38.98 (990.2)

42.98 (1091.1)

23.0 (584.2)

21.5 (546.1)

23.5 (596.9)

CENTER OF GRAVITY

X 22 (5585) 22 (5585)

IN.(MM}

Y Z

16 (406.4) 17 (432 0)

16 (406.4) 17 (4320) 163 (412.8) 166 (4216) 166 (422.1) 180 (4572)

163 (412.8) 176 (4470)

iA_

000056

RoofCurb for Small Cabinet

Note A: When uNt mounting screw is used,

retah3er bracket must also be used.

Roof Curb for Large Cabinet

Note A: When unit mounting screw is used,

retainer bracket must also be used.

R/A

-'-_- Gasket around_

Suppolt

Long

SL pport

iBXC}

UNiT S_ZE

48GS018o042 48GX024-036

48GS048o060 48GX042-060

NOTES:

1. Roof curb must be set up for unit beh_ginstalled

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

3. Dimensions in ( ) are in millimeters

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

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

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

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

8. Dimensions are in inches

9. When unit mounting screw is used (see Note A), a retainer bracket must be used as well This bracket must also be used when required by code for hurricane or seismic conditions. This bracket is available through Micrometl.

-->

GROL ND MOL_T

The unit may be installed either on a slab or placed directly on the ground if local codes permit. Place the unit on level ground

prepared with gravel _br condensate discharge.

Step 3--FIELD FABRICATI= DUCTWORK Secure all ducts to roof curb and building strecture on vertical

discharge uriits Do t_nt connect duct_oHc to z_nit. For horizontal

ODS CATALOG NUMBER

CPRFCURB006A00 CPRFCURB007A00 CPRFCURB008A00

CPRFCURB009A00

Fig. 4--Roof Curb Dimensions

IN. {NM)

8 (203)

14 (356)

8 (203)

14 (356)

insulated deck pan

applications, unit is provided with flanges on d_e horizontal openings Installation of flexible duct connector is recommended to prevent tlansmission of vibration and/or noise to stl_acture. All ductwork should be secured to the flanges. Insulate and weather° proof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes

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

Gasket around

IN.(MM)

11(279)

11(279) 16 3/16 (411) 16 3/16 (411)

duct

outer edge \

RN.(MM)

161/2 (419)

161/2 (419) 17 3/8 (441) 17 3/8 (441)

S/A

IN. (t_M)

2G3/4 (730)

28-3/4 (730) 40-1/4 (1022) 40-1/4 (1022)

C00076

4 x 3

CORNER #

1 47.3 53.2 53.2 59.7 675 789 85.5 55.1 2 44.8 50.4 50.4 56.5 639 747 81.0 52.2 3 77.2 86.8 86.8 97.3 1101 128.7 1395 89.9

4 79.7 89.6 89.6 106.5 1136 132.8 1440 92.8

TOTAL WEIGHT 249 280 280 320 355 415 450 290

018 024 030 036 042 048 060 024

48GS

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

C00070

48G×

030 036 042 048 060

595 61.0 72.6 800 88.9 563 57.8 68.8 758 84.2 970 99.5 1184 130.5 145.1

1002 102.7 1222 134.7 149.8

313 321 382 421 468

DIJCTS

2 F_

(50.8mn

EVAR COND.

COIL COIL

C99014

Fig. 6--Slab Mounting Details

HANDHOLD

C99067

Fig. 7A--Threading BoR for RiggBng

If a plemma return is used o,1 a vertical unit, the return should be

ducted through the roof'deck to comply with applicable i_re codex

A n_inimum clearance is not required around ductwork_ Cabinet return=air static shall not exceed -25 in. wg.

SEAL STRIP MI _ST BE _N

PLAOE

BASEPAN SLOT (BELOW RIGGtNG HOLDS} BEFORE RIGGING

0t8 024

030 036 042 048

050

024 030 036 042

048 050

MAX,MUM WE,GNT [ A [ B

tb kg in. mm in. mm

271 302

302 342 377 437

472

312 335 343 404

443 490

UNIT 48G8

123.2 20.0 508.0 14.0 355.6

137.3 22.5 571.5 13.0 330.2

137.8 21.5 546.1 13.75 349.3

155.1 22.5 571.5 14.0 355.6

171.4 21.5 546.1 13.5 342.9

198.6 22.0 558.5 17.0 432.0

214.5 22.0 558.5 17.0 432.0 UNIT 48GX

142 22.0 558.5 14.50 368.3 152 22.0 558.5 15.30 388.6 156 22.0 558.5 15.30 388.6 183 23.0 584.2 16.3 414.0

201 21.5 546.1 16.3 414.0 222 23.5 596.9 16.3 414.3

SRZE

PLACE BEFORE PLACING _JN_T ON RO©F CURB

C99015

Fig. 7B--Suggested Rigging

Step 4--PROVIDE CLEARANCES

The required minimum operating and service clearances are shm_n in Fig 2 and 3 Adequate combustion, ventilation and condmlser air must be provided in accordance with section 53, Air fbr

Table 1--Physical Data--UnR 48GS

UNIT SBZE 48GS

NOMINAL CAPACBTY (ton) OPERATING WEIGHT (_b.)

COMPRESSORS

Quantity

REFRmGERANT (R-22)

Quantity (_b.)

REFRIGERANT METERING DEVICE

Orifice ID (in.)

CONDENSER CORL

Rows...Finslin.

Face Area (sq ft)

CONDENSER FAN

NominN Cfm Diameter (in.)

Motor Hp (Rpm)

EVAPORATOR COBL

Rows...Fins/in.

Face Area (sq ft)

EVAPORATOR BLOWER

Nomina_ Airflow (Cfm)

Size ({n.)

Notor BP (Rpm}

FURNACE SECTION*

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

Natural Gas

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

Propane Gas

RETURN-ABR FILTERS (in.)?

Throwaway

* Based on altitude of 0 to 2000 ft

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

fi/minute for throwaway type or 450 if/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 in. wg

018040 024040

1½ 2

249 280

024060

280

030040

2½

280

030080 036060

2½ 3

280 320

038080

320

042060

3½

355

042090

3½

355

Reciprocating

AcutroF M Device

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

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

6 I n 9.1 9.1 10.9 9.1 9.1

2000 1

1/8 (825) 1

2...15 I 2...I5 2...15 3...15 4...15 4...15 " _ ' 3.1 3.1 3.1 3.1 3.1.J _ ,

600 I 800 1000 1200 1400 1400

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

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

.O34

1...17

9.1

2400

1/8 (825)

2...15

3.1

8OO

10 x 10

1/4 (1075)

2400

1/8 (825)

2400

1/8 (825)

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

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

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

.034 .032

1...17 1...17

9.1 10.9

2400 3000

22 22

1/8 (825) ¼ (1100)

2...15 3...15

3.1 3.1

1000 1200

10 x 10 11 x 10

lg (1075) 1/2 (I075)

2...38 2...38

2...46 2...46

20 X 20 20 X 24

3000

¼ (1100)

3000

¼ (1100)

3000

¼(1100)

(ombustion and Ventilation, of the National Fuel Gas <ode ANSI (American National Standards Institute) Z2231 or applicable

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

7.3, or 7.4 or CaniCGA. (Canadian Gas Association) B149 Installation Codes or applicable provisions of local building code.

Do not restrict condenser airflow. An air restriction at either the outdoor-air inlet or the £m discharge can be detrimental to

compressor tiff.

The condenser £m pulls air through the condenser coil and discharges it through the top cover Be sure that the fan discharge

does not recirculate to the condenser coil Do not locate the unit in either a comer or under an overhead obstruction. The minin-mm

clearance under a pmlial overhang (such as a nomml house overhang) is 48-im above the unit top. The nmximnm horizontal extension of a partial overhang must not exceed 48-in_

Do not place the unit where water, ice, or snow flora an overhang or roof will damage or flood the unit. Do not install the unit on carpeting, tile, or other combustible materials. The unit nmy be installed on wood flooring or on (;lass A, B, or ( roof covering

materials.

Step 5--RIG AND PLACE UNW

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

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

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

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

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

riggi<g a_d mo_,i_tg operaff(ms.The unit must be level within 14" for proper condensate drainage; therefore, the ground°level pad or accessory roof curb must be level before setting the unit in place. When a field°fi_bricated support is used, be sure that the support is level and properly supports the unit. Lifting point should be directly over the center of gravity for the unit.

Step g--CONNECT CONDENSATE DRAIN NOTE: When installing condensate &ain connection be sure to

comply with local codes and restrictions. Models 48GS and 48GX dispose of condensate water through a

3/4 in. NPT fitting which exits through the compressor access panel (See Fig. 2 and 3 for location).

Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in ground- level installations. Install a field°supplied condensate trap at end of condensate connection to ensure proper drainage Make sure that the outlet of the trap is at least 1 in. lower than the drain pan condensate connection to prevent the pan fl'om overflowing (See Fig 8) Prime the trap with water When using a gravel apron, make sure it slopes away fl'om the unit

If the installation requires draining the condensate water away from the unit, install a 2=ira trap at the condensate connection to ensure proper &ainage (See Fig. 8). Make sure that the outlet of the trap is at least 1 in. lower than the drainpan condensate connection. This prevents the pan tiom overflowing.

Prime the trap with water. Connect a &ain tube using a mininmna of 3/4-in. PVC or 3/4-in. copper pipe (all field=supplied) at the outlet end of the 2=ira trap. Do not undersize the robe. Pitch the

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

UNiT SIZE 48GS

NOMINAL CAPACITY (ton)

OPERATING WEIGHT (lb.)

COMPRESSORS

Quantity

REFRIGERANT {R=22)

Quantity (lb.)

REFRIGERANT METERING DEVICE

Orifice ID (in.)

CONDENSER COIL

Rows...Fins/im

Face Area {sq ft)

CONDENSER FAN

Nominal Cfm

Diameter (in.)

Motor Hp (Rpm)

EVAPORATOR COIL

Rows...Finsiim

Face Area (sq ft)

EVAPORATOR BLOWER

Nominal Airflow (Cfm)

Size (in.)

Motor Bp (Rpm)

FURNACE SECTION*

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

Natural Gas

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

Propane Gas

RETURN-AIR FILTERS {in.)?

Throwaway

* Based on altitude of 0 to 2000 ft

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

ft/minate for throwaway type or 450 if/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 in wg

048090 048115 060 t 18 060130

4 4 5 5

415 415 450 450

048130 0$0090

4 5

415 450

Scroll Reciprocating

1 1

6.0 6.0 8.0 8.0

6.0 8.0 Acutrol Device

.032 .032 .030 .030

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

12.3 12.3 12.3 12.3

3600 3600 3600 3600

22 22 22 22

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

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

4.7 4.7 4.7 4.7

1600 1600 2000 2000

11X10 11X 10 11X10 11X10

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

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

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

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

.032 .030

1...17 2...17

12.3 12.3

3600 3600

22 22

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

3...15 4._15

4.7 4.7

1600 2000

11 X 10 11 X 10

3/4 (1075) 1.0 (I075)

3...31 3...38

3...41 3...46

24 X 30 24 X 30

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

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

TRAP OUTLET

1" min.

2" rain.

C00009

Fig. 8--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 (See Fig. 3i).

NOTE: Dedicated low NO x models MUST be installed in Call= fomia Air Quality Management Districts where a Low NO× rote

exists,

These models meet the California maximmn oxides of nitrogen (NOx) emissions requirements of 40 nanogramsdoule or less as shipped from the fhctory,

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

The venting system is designed to ensure proper venting. The flue hood assembly must be installed as indicated in this

section of the unit installation insm/ctions,

Install the flue hood as fbllows:

1, This installation must confot_n with local building codes and

with the National Fuel Gas (?ode (NFGC), ANSI Z223 1 (in ( anada., CANiCGA B 149,1, and B 149 2) or NFPA (National Fire Protection Association) latest revision Refer to Provin= cial and local plumbing or wastewater codes and other applicable local codes,

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

compartment) Place vent cap assembly over flue panel, Orient screw holes in vent cap with holes in the flue panel

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

the right side and the tet_ side of the hood.

Step 8--INSTALL GAS PIPING

)"he gas supply pipe enters the unit through the access hole provided, The gas connection to the unit is made to the 1/2=in, FPT gas inlet on the manual shutoff or gas valve.

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

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

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

local utility for recommendations concerning existing lines. Size gas supply piping for 0,5 in, wg maximum pressure drop, _\2_*er _¢se pipe smaHe/' than the ].lL_:in+ FflY gax m/et up tile zmit ,?aX

ICt]1'C.

For natural gas applications, the gas pressure at unit gas connection must not be less than 4.0 in. wg or greater than 13 in. wg while the

TaNe 2--Physicam Data--Unit 48GX

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

NOMINAL CAPACITY (ton) 2 2 2"½ 2_½ 3 3 3½ 3½ OPERATING WEIGHT (lb.) 290 290 313 313 321 321 382 382

COMPRESSORS Scroll

Quantity 1

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

Quantity (_b.)

RBFRBGERANT METERBNG DEVICE

Orifice ID (in.}

CONDENSER COBL

Rows...Fins/in.

Face Area (sq ft}

CONDENSER FAN

Nominal Cfm

Diameter (in.)

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

EVAPORATOR COIL

Rows...Fins/in.

Face Area (sq ft}

EVAPORATOR BLOWER

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

Size (in.)

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

FURNACE SECTION*

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

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

* Based on altitude of Oto 2000 ft

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

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

NaturN Gas

Propane Gas

Throwaway

.034 .034 .030 .030 .032 .032 .034 .034

1._17 1._17 1_.17 1...17 2...I7 2...17 2...17 2._17

10.8 10.8 12.7 12.7 9.1 9.1 12.3 12.3

2350 2350 2350 2350 2350 2350 3300 3300

22 22 22 22 22 22 22 22

3...15 3_.15 3._15 3._15 3._15 3...15 3_.15 3_.15

3.1 3.1 3.1 3.1 3.7 3.7 4.7 4.7

800 800 1000 1000 1200 1200 1400 1400

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

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

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

An 1/8-in. NPT plugged tapping, accessible fbr test gage conneco tiom must be installed immediately upstream of the gas supply connection to the gas valve.

When installing the gas supply line, obsel_'e local codes pertaining to gas pipe installations. Ref)r to the NFGC ANSI Z223J-1988

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

the absence of local building codes, adhere to the fbltowing

pertinent recommendations:

1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in. in ever?" 15 ft to prevent traps. Grade all horizontal runs downward to risers. Use risers to connect to heating section

and to meter.

2. Protect all segments of piping system against physical and thermal damage. Support all piping with appropriate straps, hangers, etc. Use a mininmm of one hanger eve N- 6 ft. For pipe sizes larger d_an 1/2 in., fbltow recommendations of

national codes.

3. Apply joint compound (pipe dope) sparingly and only to male threads of joint when making pipe connections. Use only pipe

dope that is resistant to action of liquefied petroleum gases as specified by local and/or national codes. :\;ever zz.se 7;e_7ot_

tope.

4. Install sediment trap in riser leading to heating section (See Fig. 9). This &ip leg Nnctions as a trap fbr dirt and

condensate.

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

gas supply pipe within 6 ff of heating section.

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

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

national plumbing and gas codes before connecting piping to unit,

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

Unstable operation may occur when the gas valve and manifbld assembly are forced out of position while connect- ing improperlyorouted rigid gas piping to the gas valve. Use a baclcup wrench when making connection to avoid stlain on, or distortion of, the gas contIol piping.

If a flexible conductor is required or allowed by the authority having jurisdictiom black iron pipe shall be installed at the gas valve and shall extend a nlinirnurn of 2 in. outside the unit

casing.

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

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

NOMINAL CAPACBTY (ton) 4 4 4 5 5 5

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

COMPRESSORS Scrolt

Quantity 1

REFRmGERANT {R=22}

REFRIGERANT METERING OEVICE Acutrol Device

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

CONDENSER CORL

Rows...Finstin.

Face Area {sq ft}

CONDENSER FAN

Nominal Cfm

Diameter (in.)

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

EVAPORATOR COIL

Rows...Finslin.

Face Area {sq ft}

EVAPORATOR BLOWER

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

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

Motor Bp (Rpm)

FURNACE SECTION*

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

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

Based on altitude of 0 to 2000 ft

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

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

Natural Gas

Propane Gas

Throwaway

2...17 2._17 2._17 2...17 2_.17 2._17

12.3 12.3 12.3 16.4 16.4 16.4

3300 3300 3300 3300 3300 3300

22 22 22 22 22 22

4...15 4...15 4...15 4...15 4...15 4...15

4.7 4.7 4.7 4.7 4.7 4.7

1600 1600 1600 1750 1750 1750

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

Table 3--Maximum Gas Flow Capacity*

NOMINAL

IRON PIPE,

SIZE

(IN.}

11/4

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

Fire Protection Association NFPA 54. 1 This length includes an ordinary number of fittings

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

leaks. Never purge gas line into combustion charuber. Failure to follow this warning could result in an explosion causing serious injury or death.

8. Check %r gas leaks at the field-installed and factow-installed gas lines after all piping connections have been completed

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

codes and/or regulations)

Step g--INSTALL DUCT CONNECTmONS The unit has duct flanges on the supply- and return-air openings on

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

ductwork connects to the roof cm'b (See Fig 2 and 3 for connections sizes and locations)

iNTERNAL LENGTH OF PIPE, FT¢ DIAMETER

(BN.} 10 20 30 40 50 60 70 80 90 100 125 150 175 200 .622 175 120 97 82 73 66 61 57 53 50 44 40 -- --

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

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

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

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

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

Be%re per%rming service or maintenance operations on the system, mrn off main power to unit. Electrical shock could cause serious injury or death.

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

work_

2. Remove return duct cover located on duct panel by breaking connecting tabs with screw&iver and a hammer (See Fig. 10A

& 10B).

3. To remove supply duct cover, break flout and right side connecting tabs with a screwdriver and a hammer. Push touver down to break rear and left side tabs (See Fig. 10A & 10B)

OUT

--:u

TEE

3"MIN

__!_1

_.._ NIPPLE

CAP

C99020

Fig. 9--Sediment Trap

SUPPLY RETURN DUCT DUCT OPENING OPENING

C99011

Fig. 10A SupNy and Return Duct Opening

4. If unit duct_xork is to be attached to x ertical opening flanges on the unit composite base (jackstand applications only), do so

at this time,

Collect ALL screws that v, ere removed. Do not lea_e screws on rooftop as pem_anent damage to the roof may occur

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

perimeter of the vertical return°air opening be secured to the unit base with aluminum tape. Applicable local codes may require aluminum tape to prevent exposed fiberglass

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

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

7. After completing unit conversion, perform all safety checks and power up unit.

NOTE: The design and installation of the duct system must be in accordance with the standards of the NFPA fbr installation of

nonresidence-type air conditioning and ventilating systems, NFPA 90A or residence-type, NFPA 90B; and/or local codes and

ordinances.

DUCT COVERS REMOVED

C99012

Fig. lOB--Vertical Duct Cover Removed

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

1 Lnits are shipped for horizontal duct installation (by removing

&ct covers)

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

grilles according to American Society of Heating, Refiigera- tion and Air (onditioning Engineers (ASHRAE) recommen=

dations

3 Lse flexible transition between rigid dnctwork and unit to

prevent transmission of" vibration. The transition may be screwed or bolted to duct ['langes. Lse suitable gaskets to

ensure weathertight and airtight seal.

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

rack installed in the return-air side of the unit. Recommended sizes fbr filters are shown in Tables 1 and 2.

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

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

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

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