Carrier 48JZ060130300, 48JZ060115300, 48JZ048115300, 48JZ048090300, 48JZ036090300 Installation Guide
...
48JZ(N) 024-060
Single Packaged Gas Heating/Electric Heat Pump
Umts With Puron® (R-410A) Refrlqerant
Visit www.camer.eom
Installation, Start-Up, and Operating Instructions
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS ..................................................... 1
INTRODUCTION .......................................................................... 2
RECEIVING AND INSTALLATION .......................................... 2
CHECK EQUIPMENT ............................................................. 2
IDENTIFY UNIT ................................................................ 2
INSPECT SHIPMENT ........................................................ 2
PROVIDE UNIT SUPPORT .................................................... 2
ROOF CURB ....................................................................... 2
SLAB MOUNT ................................................................... 2
GROUND MOUNT ............................................................ 2
FIELD FABRICATE DUCTWORK ........................................ 3
PROVIDE CLEARANCES ...................................................... 4
RIG AND PLACE UNIT ......................................................... 6
CONNECT CONDENSATE DRAIN ...................................... 6
INSTALL FLUE HOOD .......................................................... 6
INSTALL GAS PIPING ........................................................... 7
INSTALL DUCT CONNECTIONS ........................................ 9
CONFIGURING UNITS FOR DOWNFLOW (VERTI-
CAL) DISCHARGE ............................................................ 9
INSTALL ELECTRICAL CONNECTIONS ......................... I0
HIGH-VOLTAGE CONNECTIONS ................................ 10
SPECIAL PROCEDURES FOR 208-V OPERATION ...11
CONTROL VOLTAGE CONNECTIONS ....................... 11
HEAT ANTICIPATOR SETTING ................................... 11
TRANSFORMER PROTECTION .................................... 11
PRE-START-UP .......................................................................... 12
START-UP ................................................................................... 13
CHECK FOR REFRIGERANT LEAKS ............................... 13
START-UP HEAT AND MAKE ADJUSTMENTS ............. 13
CHECK HEATING CONTROL ....................................... 13
HEATING SEQUENCE OF OPERATION-HEAT
PUMP ................................................................................. 18
HEATING SEQUENCE OF OPERATION-GAS
HEAT ................................................................................. 18
START-UP COOLING AND MAKE ADJUSTMENTS....., 19
COOLING SEQUENCE OF OPERATION ..................... 19
CHECKING COOLING CONTROL OPERATION (NON-
ICM UNITS) ...................................................................... 19
MAINTENANCE ......................................................................... 20
AIR FILTER ...................................................................... 22
INDOOR BLOWER AND MOTOR ................................ 22
FLUE GAS PASSAGEWAYS ......................................... 24
COMBUSTION-AIR BLOWER ....................................... 24
LIMIT SWITCH ................................................................ 25
BURNER IGNITION ........................................................ 25
MAIN BURNERS ............................................................. 25
OUTDOOR COIL, INDOOR COIL, AND
CONDENSATE DRAIN ................................................... 25
OUTDOOR FAN ............................................................... 25
ELECTRICAL CONTROLS AND WIRING .................. 25
HEAT PUMP SYSTEM ITEMS ...................................... 26
REFRIGERANT CIRCUIT ............................................... 27
GAS INPUT ...................................................................... 27
INDOOR AIRFLOW ........................................................ 27
PURON® SYSTEM ITEMS ............................................ 27
TROUBLESHOOTING ............................................................... 28
START-UP CHECKLIST ............................................................ 28
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 beating of buildings or structures under construction.
C99O88
Fig. 1--Untt 48JZ
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 service
alr-eooditioning equipment.
Untrained personnel can perform basic maintenance functions of
cleaning coils and filters. All other operations should be performed
by trained service personnel. When working on air-conditioning
equipment, observe precautions in the literature, tags, and labels
attached to the unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves. Use
quenching cloth for unbrazing operations. Have fire extinguisher
available for all brazing operations.
Manufacturer reserves the right to discontinue, or change at any time, speciflcatiotls or designs without notice and without Incurring obligations.
PC 101 Catalog NO, 534--80083 Printedin U.S,A, Form 48JZ-1SI Pg 1 10-01 ReplaCeS: New
Improper installation, adjustment, alteration, service, mainte-
nance, or use can cause carbon monoxide poisoning, fire, or
an explosion which can result in serious injury, death 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.
gl.3_
tum off gas supply to unit. Then turn off unit main power
switch and install lock-out tag, Electrical shock or explosion
I Before performing service or maintenance operations on unit,
could cause serious injury or death.
Recognize safety information. This is the sat_ty-alert symbolAN.
When you see this symbol in instructions or manuals, be alert to
the potential for personal injury.
Understand the signal words DANGER, WARNING, CAUTION,
and NOTE. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies a hazard
which could result in personal injury or death, CAUTION is used
to identify unsafe practices which would 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.
These instructions cover minimum requirements and conform 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 for a safe installation.
INTRODUCTION
The 48JZ unit (See Fig, 1) is a fully self-contained, combination
electric heat pump unit with gas-firod back-up heat 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 down-
flow duct openings covered. Units may he 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 (available on single phase
only) of the model number are dedicated Low NOx units designed
for California installations.
NOTE: Low NOx requirements apply only to natural gas instal-
lations.
These models meet the California maximum oxides of nitrogen
(NOx) emissions requirements of 40 nanograms/jouIe or less as
shipped from the factory and must be installed in California Air
Quality Management Districts where a Low NOx rule exists.
NOTE: In order for this unit to run as designed, you must install
with either Carrier's Thermidistat TM control or Dual fuel thermo-
stat. We recommend the Thermidlstat TM control if using variable
speed blower motors.
RECEIVING AND INSTALLATION
Step 1--CHECK EQUIPMENT
IDENTIFY UNIT
The unit model number and serial number are stamped on unit
identification / rating plate. Check this information against ship-
ping papers and job data.
Ensure electrical power supply provided for unit matches the
requirements listed on the unit rating plate.
INSPE, CT SHIPMENT
Inspect for shipping damage while unit is still on shipping pallet.
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. 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.
Step 2--PROVIDE UNIT SUPPORT
ROOF CURB
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, Duetwork must be attached to
curb.
IMPORTANT: The gasketing of the unit to the roof curb is critical
for a watertight seal. Install gasketthg material supplied with the
roof curb. Improperly applied gasketing can also result in air leaks
and poor unit performance.
Curb should be level to within 1/4 in. This is necessary for unit
drain to function properly. Refer 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 drain installation)
and should extend 2 in. on the three remaining sides of the unit. Do
not secure the unit to the slab except when required by local codes.
GROUND MOUNT
DUCTS
12k_3
PL_3E RIGGING STRAPS IN
BASEPAN SLOT (B_LC'_ RIGGING 1.1(_05)
BEFORE P,_*GIi*K3
UNIT MAXIMUM WEIGHT A B
SEAL STRIp MUST BE IN
pLACE B_FORE pLACING
UNIT ON ROOF CURB
4 zl,h Iommln,ore
UNIT 48JZ
024
030
036
042
048
060
The unit may be installed either on a slab or placed directly on the
ground if local codes permit. Plane the unit on level ground
prepared with gravel for condensate discharge.
2
332 151 22.0 558.5 14.50 368.3
346 157 22.0 558.5 15.30 388.6
343 156 22.0 558.5 15.30 388.6
402 182 23.0 584.2 16.3 414.0
431 195 21.5 546.1 16.3 414.0
526 239 23.5 596.9 16.3 414.3
Fig. if--Suggested Rigging
C99015
[)$_] IZliI] 1583_
REARVIEW
TOP VIEW
REQ'D CLEARANCES FOR OPERATION AND SERVICING. in. (mm)
Evaporator coil access side .................. 36 (914)
Power entry side (except lot NEC requirements) ......... 36 (914)
Unit top .......................... 48 (1219
S de opposite ducs ..................... 36 914
Duct panel ........................ 12 (304.8)"
*Minimum distances: If unit is placed less than 12 in. (304.8 ram) from wall
system, then the system pedormance may be compromised.
LEGEND
CG - Center of Gravity
CONC _ CondenSer
EVAP - Evaporator
NEG - National EleCtriCalCode
REQ'D - Required
Note: Dimensions are in in. (mrn)
A
• Z? ! DP
REQ'D CLEARANCES TO COMBUSTIBLE MATL. in. (mm)
Top of unit ......................... 14 (395.6)
Duct side of unit ....................... 2 (50.8)
Side opposite ducts ..................... 14 (355.6)
Bottom 0t unit ....................... 0.50 (12.7)
Flue panel ......................... 36 (914.4)
NEC REQ*C CLEARANCES. in. (mrn)
Between units, power entry side .............. 42 1066.8)
Unt and ungrounded sudaces, power entry side ......... 35 {914
Unit and blOCkor conctele wails and other grounded
surfaces, contrel pox side ................. 42 (1066.8)
831.0
r_ 721
LEFT SIDE ViEW
UNIT
48JZ024-040
48JZ030-040/060
48JZ836_060/090
ELECTRICAL CHARACTERISTICS
208/230-1-60
208/230-1-60
208/230-1-60. 208/230-3-60
FRONTV_EW
UNIT WEIGHT UNIT HEIGHT
Ib kg "A"
310,0 141,0 35.02 (889,5)
324.0 147,0 37.02 (940,3)
321,0 145,6 37.62 (940.3)
Fig. 2--48JZ024-036 Unit Dimensions
Step 3--FIELD FABRICATE DUCTWORK
Secure all ducts to roof curb and building structure on vertical
discharge units. Do /lot connect ductwork to unit. For horizontal
applications, unit is provided with flanges on the horizontal
openings. All ductwork should be secured to the flanges. Insulate
and weatherproof all external ductwork, joints, and roof openings
with counter flashing and mastic in accordance with applicable
codes.
tl2.1
I_$_)
RIGHTSIDEVIEWC99017
CENTER OF GRAVITY
IN. (MM)
X Y Z
22.0 (558.8) 14.5 (368.3) 16.0 (406.4)
22.0 (558,8) 15,3 (387.4) 17.6 (447,0)
22.0 (558,8) 15.3 (387.4) 16,5 (419,1)
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
ductod through the roof deck to comply with applicable fire codes.
A minimum clearance is not requin_d around ductwork. Cabinet
return-air static shall not exceed -.25 in. wg.
iN. (MM)
HgHHHHmH
I
loz._
I15_)
SU_pLf R[TURN
oueT 0U¢1
Op[Mty_ O_EliH5
i I
(4 53)
+s 3
1_ 4+) 11]|]_ (l]|il [l_.|3J
REARVIEW
REQUIRED CLEARANCEFOR OPERATIONAND SERVICING
EV_.CO,LAOCSSSmOB..............................................................36.00,1914.0
POWER ENTRY SiDE ...................................................................... 36.00 t91+.o!
(EXCEPTPORNECREOUmEMENTSl
UNITTOP.........................................................................................36.00[ I$14.0
SIDEOPPOSITE DUCTS ................................................................ 36,00 g14.0
DUCT PANEL ................................................................................... 12+001304.81 "
"MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 12.C0 [304,8] FROM
WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE+
in. ram]
TOP VIEW
REQUIREDCLEARANCETO COMBUSTIBLEMATL,
TOP OF UNIT ................................................................................... 14.00 355.6]
DUCT SIDE OF UNIT ......................................................................... 2.00 50.6
SIDE OPPOSITE DUCTS ................................................................ 14.00 355.6]
BOTTOM OF UNIT ............................................................................. 0.50 12.7
FLUE PANEL .................................................................................... 36.00 914.4
NED, REQUIRED CLEARANCES.
B_TN EEN UNITS, POWER ENTRY SIDE .................................... 42.00 It 066.8
UNIT AND UNGROUNDED SURFACES, POWER ENTRY S DE ._36.00 9 4.0
UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE ......................... 42.00 11066.8]
Z81
in. mm]
MILLIMETERS [IN.]
IOZO]
IIZ_.I
144.22J
LEFT SIDE VIEW FRONT VIEW
UNIT
48JZ042-060/090
48JZ048-0901115/130
48JZ060-O95/115/130
ELECTRICAL CHARACTERISTICS
208/230-1-60, 208123C_3-60 380 172 40.98 (1040.9)
205/230-1-60, 208/230-3-60 409 186 40.98 (1040.9)
205/230-1-60+ 205/230-3o60 504 229 42.96 (1091,1)
UNIT WEIGHT
ib kg
UNIT HEIGHT
IN. (MM)
X Y Z
23.0 (584.2) 16,3 (412.8) 16.6 (421,6)
21,5 (946.1) 16.6 (422+1) 16.0 (457.2)
23.5 (596,9) 16.3 (412.8) 17.6 (447.0)
RIGHTSIDE VIEW
CENTER OF GRAVITY
IN. (MM)
C99074
Fig. 3--48JZ042-060 Unit Dimensions
Step 4--PROVIDE CLEARANCES 7.3, or 7.4 or Can/CGA. (Canadian Gas Association) B149
The required minimum operating and service clearances are shown Installation Codes or applicable provisions of local building code.
in Fig. 2 and 3. Adequate combustion, ventilation and outdoor coil
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 or applicable
provisions of local building code. In Canada, follow sections 7.2,
Roof Curb for Small Cabinet
Note A: When unit mounting screw is used,
retainer bracket must alsObe used.
Roof Curb for Larga Cabinet
Note A: When unit mounting screw is used,
retainer bracket must alsobe used.
\
R/A
"'-"Gasket around_
\
Insulated Gasket around
deck pan outer edge \
UNIT SIZE ODS CATALOG NUMBER
48JZ024-036
48JZ042-060
NOTES:
1. Roof curb must be set up for unit beinlnginstalled.
2, Seal strip must be applied, as require, to unit being installed,
3. Dimensions in ( ) are in millimeters.
4, Roof curb is made ol 16-gage steel,
5. Table lists only the dimensions, per part number, that have changed.
6. Attach ductwork to curb (flanges ol duct rest on curb).
7. Insulated panels: 1-in, thick fiberg{ass 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 bracl_et is available through Micromed.
--)
Do not restrict outdoor coil airflow. An air restriction at either
the outdoor-air inlet or the fan discharge can be detrimental to
compressor life.
The outdoor tan pulls air through the outdoor coil and discharges
it through the top cover. Be sure that the fan discharge does not
recirculate to the outdoor coil. Do not locate the unit in either a
CPRFCURB006A00
CPRFCURB007A00
CPRFCURB008A00
CPRFCURBO09A00
Fig. 4---Roof Curb Dimensions
A
IN. (MM)
8 (203)
14 (356)
8 (203)
14 (356)
corner or under an overhead obstruction. 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 must not exceed 48-in.,
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, tile. or other combustible materials. The unit may be
installed on wood flooring or on Class A. B. or C roof covering
materials.
B
IN, (MM)
11(279)
11(279)
163/16 (411)
163/16 (411)
duct
\
C D
IN, (MM) IN, (MM)
16 1/2 (419) 28 3/4 (730)
16 1/2 (419) 28 3/4 (730)
17 3/8 (441) 40 1/4 (1022)
17 3/8 (441) 40 1/4 (1022)
\/
S/A
/\
C00076
1 2
Y
©
4 x
CORNER WEIGHTS (SMALL CABINET)
N
=o
1:=
o
-..)
Step 5---RIG AND PLACE UNIT
When installing the unit on a rooftop, be sure the roof will
support the additional weight.
Use spreader bars or crate top when rigging the unit. The units
must be rigged for lifting (See Fig. 6). Refer to Table 1 for
operating weight. Use extreme caution to prevent damage when
moving the unit. Unit must remain in an upright position during all
rigging and moving operations.The unit must be level 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-fabricated 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 6---CONNECT CONDENSATE DRAIN
NOTE: When installing condensate drain connection be sure to
comply with local codes and restrictions.
Model 4gJZ 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 I in. lower than the drain condensate
connection to prevent the drain from overflowing (See Fig. 7).
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 drainage (See Fig. 7). Make sure that the outlet of
the trap is at least 1 in. lower than the drain condensate connection,
This prevents the drain from overt]owing.
Unit 024 I 030
Totn) W_inht _10 I ,_P4
Comer Weight 1 52 60.5
Comer Weight 2 88 57.3
Corner Weight 3 49 95.0
Corner Weight 4 121 108.2
Fig. 5--48JZ Corner Weights
036
321
61.0
57.8
99.5
102.7
H
3
C00070
CORNER WEIGHTS (LARGE CABINET)
N
,q
,¢t
o
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-supplled) - 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 l-in. for every 10 ft of
horizontal run. Be sure to check the drain tube for leaks.
1" (25mm) MIN.
Unit 042 048
Total Weight 380 409
Comer Weight 1 83 108
Comer Weight 2 52 48
Comer Weight 3 115 125
Comer Weight 4 130 128
Fig. 7--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.
Install the flue hood as follows:
1. This installation must conform with local building codes and
with the National Fuel Gas Code (NFGC), ANSI Z223.1 (in
Canada, CAN/CGA B149.1, and B149.2) 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
060
5O4
105
76
130
193
C99013
2"(50mm) MIN.
Table 1--Physical Data---Unit 48JZ
UNIT SIZE 48JZ
NOMINAL CAPACITY (ton)
OPERATING WEIGHT (lb.)
COMPRESSORS
Quantity
REFRIGERANT (R-410A)
Quantity (Lb.)
REFRIGERANT METERING DEVICE
Burner Odfice No. (Qty...Ddll Size)
Burner Orifice No. (Qty,..Ddfl Size)
HIGH-PRESSURE SWITCH (psig)
• BaSedonaltitudeof 0 to 2000 ft.
t Required filter sizes shown are based on the larger ot the ARI Air Conditioning and Refrigeration InstLtute)rated coolingaidlow or the heating aLdLowvelocity of 300
if/minute for high-capacity type. Air tLiterpressure drop tot non-standard filters must nol exceed 0.08 n, wg.
Orifice ID (In,)
AccuRater Piston
Orifice OD (in.)
OUTDOOR COIL
Rows...Flns/In.
Face Area (sq ft)
OUTDOOR FAN
Nominal Cfm
Dlameter (in.)
Motor HP (Rpm)
iNDOOR COIL
Rows..Fins/in.
Face Area (sq ft)
INDOOR BLOWER
(Standard PSC Motor)
Nominal Airflow (Cfm)
Size (in.)
Motor (HP)
FURNACE SECTION*
Natural Gas
Propane Gas
Cut-out
Reset (Auto)
LOSS-OF-CHARGE /
LOW-PRESSURE SWITCH
(Liquid Line) (pslg)
Cut-out
Reset (auto)
RETURN-AIR FILTERS (tn.)t
Throwaway
024040 030040 030060 036060
2 2-112 2-1/2 3
310 324 324 321
7.0
0.061
0,032 (2)
2...17
6.5
2350
22
1/8 (825)
3...15 3...15 3...15 4...15 3...15
3.7 3.7 3.7 3.7 4.7
800 1000 1000 1200 1200 1400 1400
10X10 10X10 10X10 10X10 10X10 11X10 11X10
1/4 1/4 114 1/2 1/2 1/2 1/2
2...44 2...44 2...36 2...38 3...38 2...38 3...38
2...50 2...50 2...46 2.-46 3..,46 2...46 3...46
8.9
0.061
0.040 (2)
2...17
10.3
2350
22
1/8 (825)
8.9
0.061
0.040(2)
2...17
10.3
2300
22
1/8 (825)
Scrofl
1
9.3
0.067
0.040 (2)
2..17
10.3
2800
22
1/4 (1100)
4...15
3.7
610 +/- 15
420 +/- 25
20 +/- 5
45 +/- 10
20x20 1i20.0xti20x24x1120x24xfi20x24x1!24x30xli24x30xl
036090
3
321
9.3
0.067
o.o4o(2)
2...17
10.3
28O0
22
1/4 (1100)
042060 042090
3-1/2 3-1/2
380 380
9.5
0.073
0.038(2)
2...17
13.5
2500
22
1/6 (825)
9.5
0.073
0.038 (2)
2...17
13.5
2500
1/8 (1100)
3...15
22
4.7
screw holes in vent cap with holes in the flue panel.
3. Secure fine hood to flue panel by insetting a single screw on
the right side and the left side of the hood.
Step g--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 l/2-in. FPT
gas inlet on the manual shutoff or gas valve.
Install a gas supply line that tans 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. wg maximum pressure drop. Never
ltse pipe smaller than tile l/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.
An I/8-in. NPT plugged tapping, accessible for test gage connec-
tion. 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. RetEr to the NFGC ANSI Z223.1 NFPA
54 latest edition (in Canada, CAN/CGA B 149.1, latest edition). 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. in
every 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 minimum of one hanger every 6 ft. 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 making 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. (S¢€
Fig. 8). This drip leg functions as a trap for dirt and
condensate.
Table 1--Physical Data---Unit 48JZ (Continued)
UNIT SIZE 48JZ
NOMINAL CAPACITY (ton)
OPERATING WEIGHT (lb.)
COMPRESSORS
Quantity
REFRIGERANT (R-410A)
REFRIGERANT METERING DEVICE
Burner Orifice No. (Qty..Drill Size)
Burner Orifice No. (Qty...Drgl Size)
HIGH-PRESSURE SWITCH (psig)
• Basedonaltitudeof0 to 2000 ft.
t Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated coolingaidlow or the heafing airflow velocity of 300
ft/minute for higfi-capacity type. Air filter pressure drop for non-staedard tilters must not exceed 0.08 in. wg.
Quantity (lb.)
Orifice ID (In.)
AccuRater
Orifice OD (In.)
OUTDOOR COIL
Rows...Flns_l n.
Face Area (sq ft)
OUTDOOR FAN
Nominal Cfm
Diameter (in.)
Motor HP (Rpm)
INDOOR COIL
Rows...Flns/In.
Face Area (sq ft)
iNDOOR BLOWER
(Standard PSC Motor)
Nominal Airflow (Cfm)
Size (in.)
Motor (HP)
FURNACE SECTION"
Natural Gas
Propane Gas
Cut-out
Reset (Auto)
LOSS-OF-CHARGE /
LOW-PRESSURE SWITCH
(Uquld Line) (psig)
Cut-out
Reset (auto)
RETURN-AIR FILTERS (in.)1"
Throwaway
048090 048115 048130 060090 060115 060130
4 4 4 5 5 5
409 409 409 504 504 804
Scroll
1
10.6 10.6 I 10.6 12.4 12.4 12.4
0.076 0.076 0.076 0.088 0.088 0.088
0.046 (2) 0.046 (2) 0.046 (2) 0.052 (2) 0.052 (2) 0.05_ (2)
2...17 2...17 2...17 2..17 2...17 2...17
13.5 13.5 13.5 15.4 15.4 15.4
3300 3300 3300 3300 3300 3300
22 22 22 22 22 22
1/4 (1100) 1/4 (1100) 1/4 (1100) 1/4 (1100) 1/4 (1100) 1/4 (1100)
4...15 4...15 4...15 4...15 4.,15 4._15
4.7 4.7 4.7 5.7 5.7 5.7
1600 1600 t 600 t750 1750 1750
11 X10 11X10 11Xt0 11X10 11 X 10 11 X 10
112 112 1/2 1.0 1.0 1.0
3...38 3...33 3...31 3...38 3...33 3..31
3...46 3...42 3...41 3...46 3...42 3...41
610 +/- 15
420 +/- 25
20+/- 5
45 +/" 10
24x30Xl124x30x1124x30x1124x30xt!24x30x1124x30xt
Table 2--Maximum Gas Flow Capacity*
NOMINAL
IRON PIPE,
SIZE
0N.)
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 psigor less. Pressure drop of 0.5-in. wg (based on a 0.60 specificgravity gas). Refer to Table, National
Fire Protection Association NFPA 54.
_" This length includes an ordinary number of fittings.
5. Install an accessible, external, manual main shutoff valve in
gas supply pipe within 6 ft 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.
INTERNAL LENGTH OF PIPE, FTt
DIAMETER
(IN.) 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
.824 360 250 200 170 151 138 125 118 110 103 93 84 77 72
1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135
1.380 1400 950 770 800 580 530 490 480 430 400 360 325 300 280
1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430
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.
[N 3. Use a screwdriver and hammer to remove the panels in the
. CAP
Fig. 8--Sediment Trap
bottom of the unit base (See Fig. 9 & 10).
..=====,......" .._
C99020
=---= ,
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 on the square neck of the inlet side of the
gas valve when making connection to avoid strain on, or
i distortion of, the gas control piping.
Never use a match 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 after 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 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
connections sizes and locations).
CONFIGURING UNITS FOR DOWNFLOW (VERTICAL) DIS-
CHARGE
SUPPLY RETURN
DUCT DUCT
OPENING OPENING
C99011
Fig. 9_Supply and Return Duct Opening
DUCT COVERS REMOVED
C99012
Fig. 10--Vertical Duct Cover Removed
4. If unit ductwork is to be attached to vertical opening flanges
on the unit base (jackstand applications only), do so at this
time.
Before performing service or maintenance operations on the
system, turn off main power to unit and install lock-out tag.
Electrical shock could cause serious injury or death.
1. Open all electrical disconnects before starting any service
work.
2. Remove horizontalductcoversto access bottom returnand
supplyknockoutpanels.
5. It is recommended that the base insulation around the perim-
eter of the vertical return-air opening be secured to the base
with aluminum tape. Applicable local codes may require
aluminum tape to prevent exposed fiberglass.
6. Cover both horizontal duct openings with the provided duct
covers. Ensure opening is air- and watertight.
7. After completing unit conversion, perform all safety checks
and power up unit.
NOTEt 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:
I. 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, Refrigera-
tion and Air Conditioning Engineers (ASHRAE) recommen-
dations.
3. 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.
4. 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.
5. 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 weathertight and airtight seal.
6. 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.
7. Hash, weatherproof, and vibration-isolate all openings in
building structure in accordance with local codes and good
building practices.
Step 10--INSTALL ELECTRICAL CONNECTIONS
The unit cabinet must have an uninterrupted, unbroken
electrical ground to minimize the possibility of personal
injury if an electrical fault should occur. This ground may
consist of an electrical wire connected to the unit ground lug
in the control compartment, or conduit approved for electrical
ground when installed in accordance with NEC (National
Electrical Code) ANSI/NFPA 70 (latest edition) and local
electrical codes. In Canada, follow Canadian Electrical Code
CSA (Canadian Standards Association) C22.1 and local
electrical codes. Failure to adhere to this warning could result
in serious injury or death.
the unit being installed:
I. Make all electrical connections in accordance with NEC
ANSI/NFPA 70 (latest edition) and local electrical codes
governing such wiring. In Canada, all electrical connec-
tions must be in accordance with CSA standard C22.1
Canadian Electrical Code Part l 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.
4. Do not damage internal components when drilling through
any panel to mount electrical hardware, conduit, etc. On
3-phase units, ensure phases are balanced within 2 percent.
Consult local power company for correction of improper
voltage and/or phase imbalance.
HIGH-VOLTAGE CONNECTIONS
The unit must have a separate electrical service with a field-
supplied, waterproof, disconnect switch mounted at, or within
sight from, the unit. Refer to the unit rating plate for maximum
fuse!circuit breaker size and minimum circuit amps (ampacity) for
wire sizing. (See Table 3 for electrical data.)
The field-supplied disconnect switch box may be mounted on the
unit over the high-voltage inlet hole when the standard power and
low-voltage entry points are used (See Fig. 2 and 3 for acceptable
location).
See unit wiring label and Fig. 11 for reference when making high
voltage connections. Proceed as follows to complete the high-
voltage connections to the unit.
LABEL) . •
CONTROL BOX
LOW-VOLTAGE /
POWER LEADS" , O-
(SEE UNIT
WIRING LABEL) i O-
fi:i:(SEE UNIT WIRING
/_ I=m
GND
FIELD-SUPPLIED
FUSED DISCONNECT
tO-
io.-
i
io-
'-NL°LD-
®
SPLICE BOX
FIELD CONTROL - VOLTAGE WIRING
FIELD HIGH - VOLTAGE WIRING
Fig. 11--High- and Control-Voltage Connections
Single phase units:
i. Run the high-voltage (LI, L2) and ground leads into the
control box.
2. Connect ground lead to chassis ground connection.
l0
C01110
UNIT
SIZE
48JZ
024
030
036
042
048
060
Table3---ElectrlcaIData_Unlt48JZ
VOLTAGE
V-PH-HZ
208/230-1-60 187 253 13.5 61.0 0.9
208/230-1-60 187 263 15.9 73.0 0.9
208/230-1-60 187 253 16.9 83.0 1.6
208/230-.3--60 187 253 12.2 77.0 1.6
208/230-1-60 187 263 22.4 105.0 0.9
208/230-3-60 187 253 15.4 88.0 0.9
208/230-1-60 187 253 21.3 109.0 1.6
208/230-3-60 187 263 14.7 91.0 1.6
208/230--1-60 187 253 27.6 158.0 1.5
208/230-3-60 187 253 19.2 137.0 1.5
RANGE
Min Max
COMPRESSOR OUTDOORFAN
MOTOR
RLA LRA FLA
INDOOR FAN
MOTOR POWER SUPPLY
MAX FUSE
FLA MCA OR CKT BKR
2.0 19.8 30
2.1 22.9 35
4.1 26.8 40
4.1 21.0 30
4.1 33.0 50
4.1 24.3 35
4.1 32.3 50
4.1 24.1 35
6.2 42.2 60
6.2 31.7 40
3. Locate the black and yellow wires connected to the line side
of the contactor.
4. Connect LI to black wire on connection 11 of the compressor
contactor.
5. Connect L2 to yellow wire on connection 23 of the compres-
sor contactor.
Three-phase units:
1. Run the high-voltage (LI. L2, L3) and ground leads into the
control box.
2. Connect ground lead to chassis ground connection.
3. Locate the black and yellow wires connected to the lines side
of the contactor.
4. Connect field LI to black wire on connection 11 of the
compressor contactor.
5. Connect field wire L2 to yellow wire on connection 13 of the
compressor contactor.
6. Connect field wire L3 to Blue wire from compressor.
SPECIAL PROCEDURES FOR 208-V OPERATION
CONTROL VOLTAGE CONNECTIONS
NOTE: This unit must be installed with either a Thermidistat TM
or Dual fuel thermostat for proper system operation.
Do not ttse any type of power-stealing thermostat (no Common
"C" comtectiott at Slat). 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 from the unit (as measured along the control
voltage wires), use no. 16 AWG color-coded, insulated (35 C
minimum) wires.
Dual fuel thermostat or Thermidistat '_t control is required for
proper operation of the dual fuel heat pump unit. Be sure to follow
the instructions supplied with the thermostat and control.
Standard Connection
Remove knockout hole located in the flue panel adjacent to the
control access panel (See Fig. 2 and 3). Remove the rubber
grommet from the installer's packet (included with unit) and install
grommet in the knockout opening. Provide a ddp loop befure
running wire through panel.
Run the low-voltage leads from the thermostat, through the inlet
hole, and into unit low-voltage splice box.
Locate five 18-gage wires leaving control box, These low-voltage
connection leads can be identified by the colors red, green, yellow.
brown, and white (See Fig. 11). Ensure the leads are long enough
to be routed into the low-voltage splice box (located below right
side of control box). Stripped yellow wire is located in connection
box. Route leads through hole in bottom of control box and make
low-voltage connections (See Fig. 11). Secure all cut wires, so that
they do not interfere with operation of unit.
HEAT ANTICIPATOR SETTING
The room thermostat heat anticipator must be properly adjusted to
ensure proper heating performance. Set the heat anticipator, using
an ammeter between the W and R terminals to determine the exact
required setting,
NOTE: For thermostat selection purposes, use 0.18 amp for the
approximate required setting. Failure to make a proper heat
anticipator adjustment will result in improper operation, discom-
fort to the occupants of the conditioned space, and inefficient
energy utilization; however, the required setting may be changed
slightly to provide a greater degree of comfort for a particular
installation.
TRANSFORMER PROTECTION
The transformer is of the energy-limiting type. It is set to
withstand a 30-see. overload or shorted secondary condition.
11
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