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.

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)

• 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. 208/230-3-60

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

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

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.

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

4 x

CORNER WEIGHTS (SMALL CABINET)

1:=

-..)

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

C00070

CORNER WEIGHTS (LARGE CABINET)

,¢t

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

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

1/8 (825)

8.9

0.061

0.040(2)

2...17

10.3

2300

1/8 (825)

Scrofl

9.3

0.067

0.040 (2)

2..17

10.3

2800

1/4 (1100)

4...15

3.7

610 +/- 15 420 +/- 25

20 +/- 5

45 +/- 10

20x20 1i20.0xti20x24x1120x24xfi20x24x1!24x30xli24x30xl

036090

321

9.3

0.067

o.o4o(2)

2...17

10.3

28O0

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

1/6 (825)

9.5

0.073

0.038 (2)

2...17

13.5

2500

1/8 (1100)

3...15

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:

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.

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.

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

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 1/4 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.

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.

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