Carrier 48KHA User Manual

0 (0)

Carrier Corporation • Syracuse. N Y 13221

Note to Installer: After installation, leave these instructions, Owner’s Manual and Parts Replacement Guide with equipment owner.

Packaged Heating/Cooling Units

CONTENTS

SAFETY CONSIDERATIONS

GENERAL .........................................................

INSTALLATION.................................................

Step 1 — Rig and Place Unit

...........................

• ROOFTOP INSTALLATION

• GROUND LEVEL INSTALLATION

• CLEARANCES

• CONDENSATE DISPOSAL

• VENTING

Step 2 — Make Gas Piping Connections Step 3 — Make Duct Connections

Step 4 — Make Wiring Connections ...

..................

• HIGH-VOLTAGE CONNECTIONS

• SPECIAL PROCEDURES FOR 208-V OPERATION

• LOW-VOLTAGE CONNECTIONS

• HEAT ANTICIPATOR SETTING

START-UP

SERVICE............................................................

TROUBLESHOOTING CHARTS

.........................................................

......................

Page

. 1

. 1,2

. 2-9

. 2

9-18 18-21 22,23

Use care in handling, rigging and setting bulky equipment.

Observe precautions in these instructions and on equipment tags, stickers and labels.

SAFETY CONSIDERATIONS

NOTE: Installation of this unit must conform to the guidelines presented in these Installation Instruc tions. Read and beeome familiar with this publica tion before starting installation.

Only trained, qualified installers and service mechanics should install, start-up and service this equipment. Consult the Owner’s Manual for routine maintenance. All other operations should be per formed by trained service personnel.

• Follow all safety codes.

• Wear safety glasses and work gloves.

Fig. 1 — Model 48KHA.KLA

GENERAL

Models 48KHA,KLA packaged gas/ electric units

(Fig. 1) are design certified in accordance with

ANSI Z21.47-1983, ARI Standard 210-81 and ARl Standard 270-84. The units are design certified by the American Gas Association (AGA) for use with natural or propane gases with appropriate eontrols and orifices. See Table 1 for heating input ratings.

Models 48KHA,KLA units are fully self-contained, combination gas-heating/electric-cooling units designed for outdoor installation on either a rooftop or ground-level slab.

These units are equipped with an energy-saving automatic, intermittent, electric spark ignition system that does not have a continuously burning pilot. All units are manufactured with natural gas controls.

Form 48KH,KL-9SI

Table 1 — Perferjpiance Data

MODEL 48-

KLA118310BE KLA124310BE 23,800

KHA024310BF KLA130310BE

KHA030310BF KLA136310BE

KLA036510CE

KLA036610CE KHA136310BE КНА036510СЕ KHA036310BF KHA036510CF

KLA142310BE KLA042510CE KHA042310BF KHA042510CF 42,000

KLA148310BE KLA048510CE

KLA048610CE 49,000 80,000 KHA048310BF KHA048510CF

KLA160310BE KHA060310BF

*Rated in accordance with U S Government DOE test procedures and/or

ARI Standard 210-81

tSound rating per ARI 270-84

^The capacity ratings of single-phase units are in accordance with U S

Government DOE test procedures and/or AGA certification require ments For 3-phase units, the efficiency rating is a product thermal efficiency rating determined under continuous operating conditions, independent of any installed system

COOLING

CAPACITY

(Btuh)*

17,800

24,000 29,600 40,000

29,600 36,000

36,000 36,000 60,000 36,000 100,000 36,000 36,000 36,000

42,000 42,000 42,000

49,000 49,000

49,000 125,000 97,000 49,000 125,000

60,000 100,0001: 60,000 1 50,0001

RATED

HEATING

INPUT (Btuh)

40,000 40,000

75,000 58,000

75,000 58,000 60,000

60,000 45,000

100,000 125,000 97,000 1 25,000

60,000 47,000 78

60,000 45,000 125,000 97,000 125,000

80,000 80,000 60,000

OUTPUT

CAPACITY

(Btuh)

32,000 32,000

32,000

47,000

45,000 79,000 75,000 80

93,750

93,750 63,000

60,000

93,750

79,000$

11 6,0001

ARIt SOUND RATING

(Bels)

7.8

7 8

8.0

7 8

7.8

8 0

8.0

7 8 7 8

7.8 8 4t

8 41 8 41 8 41

8.41

8 41 8 41

handle an airflow of350 to 450 cfm per each 12,000

Btuh of rated coaling capacity. See Table 8 for cool

ing and heating airflow requirements. NOTE: When installing any accessory item, see

Installation Instructions packaged with accessory.

Units with number 1 in the 4th digit location of model number in Table 1 meet California oxides of nitrogen (NOx) maximum emission requirements.

Units are factory charged with R-22 refrigerant. To install; connect gas supply, air ducts, high- and low-voltage wiring and condensate drain, and install

a field-supplied air filter in the return-air ductwork.

All units can be connected into existing duct

systems that are properly sized and designed to

SPREADER BARS:

(2)2x4"xUNIT LENGTH PLUS lO" WITH

DEEP 90° NOTCHES EA(iH END

(2) ¿iiAxUNIT WIDTH WITH 1^

DEEP 90° NOTCHES

EACH END

LOCATE CHAINS THROUGH HOLES IN BASE CHANNELS

2 — 48KHA.KLA Suggested Rigging

TWO OR THREE BASE CHANNELS ATTACHED TO BOTTOM OF UNIT

SPREADER BARS

CHAIN

Step 1

INSTALLATION

Rig and Place Unit

ROOFTOP INSTALLATION

If installation requires draining the condensate water away from unit, connect a drain tube using a minimum of 7/8-in. OD copper tubing, 3/4-in. galvanized pipe or 7/8-in. plastic pipe.

là

undersize the tube. Pitch drain tube downward at a

Do not

slope at least one in. for every 10 ft of horizontal run. Be sure to check drain tube for leaks.

When installing a Model 48KHA,KLA end dis charge unit with a field-supplied downflow plenum, a field-supplied roof-mounting curb must be in stalled on and flashed into roof before unit installa tion. When installing a Model 48KHA,KLA end discharge unit without a downflow plenum, place

Condensate water can be drained directly onto roof in rooftop installations (where permitted) or onto a gravel apron in ground level installations. When using a gravel apron, make sure it slopes away from the unit.

unit on a level base that provides proper support. On flat roofs be sure unit is located at least 4 in.

TO DRAIN

above highest expected water level on roof to prevent flooding. Consult local codes for additional installation requirements.

GROUND LEVEL INSTALLATION — Place unit on a solid, level concrete pad that is a minimum of 4 in. thick and that extends approximately 2 in. beyond casing on all sides of unit. Do not secure unit to pad except when required by local codes.

CLEARANCES — Required minimum operating and service clearances are shown in Fig. 4 for pro viding adequate combustion, ventilation and con denser air.

VENTING — The vent cap, combustion air shroud and flue assembly are shipped in either the blower or

control compartment. Vent screen is taped to blower

housing. Remove access doors to locate assemblies. See Fig. 4 for door locations.

Condenser fan discharges through top of unit.

Ensure that fan discharge does not recirculate to condenser coil. Do not locate unit in either a corner or under a complete overhead obstruction. Mini mum clearance under a partial overhang (such as a typical house roof overhang) is 3 ft above vent cap.

Maximum horizontal extension of a partial over hang must not exceed 4 feet.

Do not locate unit where water, falling ice or snow from an overhang or roof will damage or flood the unit. Do not locate unit where grass, shrubs or other plants will interfere with the airflow either into or

out of unit. Do not install unit on carpeting, tile or other combustible material other than wood flooring.

CONDENSATE DISPOSAL NOTE: Be sure condensate water disposal methods

comply with local codes, restrictions and practices.

Models 48KHA,KLA dispose of condensate water through a 3/4-in. MPT drain fitting. See Fig. 4 for location.

Install a 3-in. trap at the drain fitting to ensure proper drainage. See Fig. 3. Make sure trap outlet is at least 2 in. lower than unit drain pan connection to prevent pan from overflowing. Prime trap with water.

NOTE: Screw holes in flue assembly and unit top are positioned to ensure proper orientation when installed. Refer to Fig. 5 and install vent cap as

follows;

1. Place combustion air shroud over combustion air opening in unit top, and line up screw holes in shroud with holes in top. Secure shroud to top, using screws with rubber washers (provided).

2. The flue gasket is shipped in the literature as sembly envelope. Place gasket and flue assembly through hole in combustion air shroud, orient screw holes in base of flue assembly with holes in unit top, and secure gasket and flue assembly to unit top, using screws provided.

3. Form flat wire screen (provided) into circular shape around protruding lip of combustion-air shroud and bend wire ends through holes of screen mesh to secure screen in place. Make sure that no sharp edges are left exposed.

4. Place vent cap sleeve inside flue assembly. Orient spring clip of vent cap with slot in assembly. Be sure clip snaps into slot to secure clip onto assembly.

# MPT

PLUGGED ACCESS HOLE ” FOR REFRIGERANT j!lH PRESSURE GAGE HOSES

drain conn

*NOTON MODELS48KLAII8 THROUGH

136¡ KHA024 THROUGH 030.

CONTROLS ACCESS DOOR

BLOWER ACCESS DOOR

* LOW VOLTAGE

INLET

K HIGH VOLTAGEINLET

C> EVAPORATOR AIRFLOW ¿CONDENSER AIRFLOW

■VENT CAP

COMBUSTION AIR INLET BOX

V ^4

NOT ON MODELS

48KLAII8 THROUGH 136;

FPT GAS INLET

KHA024 THROUGH 030

MODEL 48-

KLA118 KLA124

KHA024 KLA130 КНАОЗО KLA136 KLA036

КНА136 кнАОзе KLA142 KLA042 КНА042

Dimensions

(ft-in.)

4- 5%

2- 6% 3- 4% 3- 8% C 3- 2Vb 3- 5Ув D

E 1- 4

1- 4 1-7

4- 5% 5- 5%

3-10У8 4- 6У8

2- 0 2-8

1-4 1- 1У4

F 0- 7У4 0- 8Уе 0- 8Ув

H 1- ЗУ4 1- ЗУ4 1- 8У4 1- 8У4

0-11%

—

0- 1Уз2

0- 1У8

0- 4 Мб N 1-10

MODEL

48-

KLA118 KLA124 83 КНА024 KLA130 КНАОЗО KLA136 KLA036 КНА136 КНА036 KLA142 KLA042^ КНА042 KLA148 KLA048 КНА048 KLA160 КНА060

CORNER WT (Ib)

A В

82 79

81 79

93 90 92 372

93 91 94 98 97 92 98 97 92

122

120 116 117 475

122

120 116 117 475 108 105 102 108

105 102 105 420 113 111 107 130

135 130

135 137 134

139

144

148 155 151

0-10% 0-10%

—

0- 1У8 0- 1% 0- 1У8 0- 6 Мб

2-4 2- 4

С D

'“'ТР

82 94

93 93 380

105 109 440

137

133 535 133

144

138 144

139 148

151

1-10'Уз2

1- 4 1-5

0- 8Мб 0- 8Уб

TOTAL

OPERATING

WT (lb)

320 325 375

375 380

420

535 555 575 605 615

KLA148

KLA048 КНА048 KLA160 КНА060

6- 0% 3- 8%

1- 1У4

0- 8Уе 0-1 1У8

2- ОзУз2

0- 1%

2-4

Weight Data

TOTAL

SHIPPING

WT (lb)

330 335 385 382 385 390 390 485 485 430 430 450 545 545 565 585

VIEW AA

CLEARANCES (ft-in.)

Above flue vent .. ................................... 3-0

Duct side of unit

.............................

................

0-6

Side opposite ducts...................................................... 2-6

Blower access panel side ... ...

..............

2-6

Side opposite blower access panel............................................... 2-6

Bottom of unit

......................

.................... .. .. ....0

NOTE: Provision must be made for fresh ambient air to reach the outdoor coil without recirculation of the air from the outdoor fan discharge

Fig. 4 — Dimensions and Clearances (ft-in.)

Step 2 — Make Gas Piping Connections — A

manual shutoff valve is shipped loose in the burner compartment or blower compartment. Connect one end of a field-supplied 1/2-in. straight nipple to the gas valve inlet. Connect the other end of the nipple to the manual shutoff valve as shown in Fig. 6. The gas supply pipe enters unit through access hole pro vided. See Fig. 4 for location. The gas connection to unit is made to the 1/2-in. FPT gas inlet on manual shutoff. See Fig. 6 for inlet location.

Install a separate gas supply line that runs directly

from meter to heating section. Do not use cast-iron

pipe. Check local utility for recommendations con

cerning existing lines. Choose a supply pipe that is large enough to keep pressure loss as low as prac tical. Never use pipe smaller than the 112-in. FPT

gas inlet on unit manual shutoff.

When installing gas supply line, observe local codes pertaining to gas pipe installations. Refer to National Fuel Gas Code, NFPA 54-1980/ANSI Z223.1-1980 in absence of local building codes. Adhere to following pertinent recommendations:

Control Transformer 9

Compressor Contactor 10

Ground Lug

Dual Run Capacitor 11 (for compressor and 12 condenser fan motor) 13

Gas Valve

1/2-in Nipple 14

Gas Pipe Entrance Hole 15 Gas Inlet 16 Pressure Tap 17

Manual Shutoff Regulator, Adjustment Cover Screw Electronic Control Head Secondary-Air Shield Low-Voltage Pigtail Leads Blower Motor Run Capacitor Heating Relay Cooling Relay Combustion Air Shroud

Fig. 6 — Model 48KLA036 — Side View

(Partial) with Access Doors Removed

1. Avoid low spots in long runs of pipe. Grade all pipe I /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 hangers, etc. Use a minimum of one hanger in every 6 feet. For pipe sizes larger than 1 / 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 speci fied by local and/or national codes. Never use

pipe thread tape.

4. Install a sediment trap in riser leading to the heat ing section. See Fig. 7. This drip leg functions as a trap for dirt and condensate. Install trap where condensate cannot freeze. Install this sediment trap by connecting a piping tee to riser leading to heating section, so that straight-through section of tee is vertical. Then, connect capped nipple

into lower end of tee. Extend capped nipple below level of gas controls.

Fig. 7 — Sediment Trap

Step 3 — Make Duct Connections — Model

48KHA,KLA has duct flanges on the supply-and return-air openings on side of unit. See Fig. 4 for connection sizes and locations.

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

NOTE: The unit manual shutoff valve has a

1/8-in. tapping on the inlet side of this shutoff

for measuring gas input pressure.

6. Install ground-joint union close to heating sec

tion between unit manual shutoff and external

manual main shutoff valve.

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

NOTE: When pressure-testing the gas supply system after the gas supply piping has been con nected to the unit gas valve, the supply piping must be disconnected from the gas valve during any pressure testing of the piping systems at test pressure in excess of 0.5 in. psig. When pressure testing the gas supply piping system at test pres sures equal to or less than 0.5 in. psig, the unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening

ground-joint union.

8. Where permitted by local codes, use an approved corrugated metal tubing gas connector between rigid gas piping and unit manual shutoff.

9. Check for gas leaks at all field-installed and factory-installed gas lines after all piping connec tions have been completed. Use soap-and-water solution (or method specified by local codes and/ or regulations).

Adhere to the following requirements when se

lecting, sizing and installing duct system:

1. Select and size ductwork, supply-air registers and return-air grilles according to ASHRAE recom mendations and as presented in Carrier System

Design Manual, Part 2.

2. Use a 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 a weathertight and airtight seal.

Table 2 — Filter Sizes (Field Supplied),

(Sq In.)*

STANDARD

MODEL 48-

KLA118310BE

KHA024310BF

KLA124310BE

KHA030310BF

KLA130310BE

KHA036310BF KHA036510CE

KHA036510CF KHA136310BE KLA036510CE KLA036610CE KLA136310BE

KHA042310BF

KHA042510CF KLA042510CE KLA142310BE

KHA048310BF

KHA048510CF 768 KLA048510CE KLA048610CE KLA148310BE 768

KHA060310BF KLA160310BE

*Required air filter areas shown are based on the ARI-rated cooling

airflow or the heating airflow at a velocity of 300 fpm depending on whichever value is larger Air filter pressure drop should not exceed 0 08 in wg

DISPOSABLE

TYPE

302 202 454 384 257

480 320 480 320

694 462 576 384 694 462 . 576 384 > 576 384 576 384 576 384

694 462 694 672 448 672 448

768 768 512

768 512

960 640 960

CLEANABLE OR HIGH CAPACITY

TYPE

303

462

512 512

512

640

3. Install external, field-supplied air filter(s) in return-air ductwork where it is easily accessible

for service. Recommended filter sizes are shown in Table 2.

4. Size all ductwork for maximum required airflow (either heating or cooling) for unit beinginstalled. Avoid abrupt duct size increases or decreases.

5. Adequately insulate and weatherproof all duct work located outdoors. Insulate ducts passing through an unconditioned space, and use a vapor barrier in accordance with the latest issue of SMACNA and NESCA minimum installation standards for heating and air conditioning systems. Secure all ducts to building structure.

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

Step 4 — Make Wiring Connections

4. When low-voltage control wires are run in same conduit as high-voltage wires, insulate lowvoltage wires for highest voltage contained within conduit.

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

HIGH-VOLTAGE CONNECTIONS — Unit must have a separate electrical service with a fieldsupplied, waterproof, fused disconnect switch per

NEC mounted near, and within sight from, the unit.

Refer to unit rating plate for maximum fuse size and

minimum circuit amps (ampacity) for wire sizing. Table 3 shows recommended wire sizes and lengths based on rating plate data.

The field-supplied disconnect switch box may be

mounted on unit over the high-voltage inlet hole in control corner panel. See Fig. 4.

1. Make all electrical connections in accordance with National Electrical Code ANSI/NFPA 70-

1984 and local electrical codes governing such

wiring.

2. Use only copper conductor for connections between the field-supplied electrical disconnect switch and the unit. Do not use aluminum or

copper-clad aluminum wire.

3. Ensure that high-voltage power to unit is within

operating voltage range indicated on unit rating plate. On 3-phase units, ensure that phases are

balanced within 2%. Consult local power company for correction of improper voltage and/or phase balance.

Proceed as follows to complete the high-voltage

connections to unit:

1. Connect ground lead to chassis ground connec tion when using a separate ground wire.

2. Run high-voltage leads into unit control box and connect to contactor. See unit wiring label and Fig. 6 and 8.

NOTE: On 3-phase units, connect third high-voltage

lead to brown high-voltage pigtail lead. See unit wiring label and Fig. 8.

SPECIAL PROCEDURES FOR 208-V OPERATION

For operation on 208 volts, disconnect orange

transformer-primary lead from contactor. See unit wiring label and Fig. 6. Remove tape and cover from

terminal on end of red transformer-primary lead. Save cover. Connect red lead to contactor terminal from which orange lead was disconnected.

Table 3 — Electrical Data (60 Hz)

MODEL

48-

KLA118 KLA124 KHA024 KLA130 KHA030 KLA136 KLA036 KLA036 KHA136

KHA036 KHA036 KLA142 KLA042 KHA042 KHA042

KLA148 KLA048 KLA048

KHA048

KLA1 60

KHA060

AWG — American Wire Gage

FLA — Full Load Amps IFM — Indoor Fan Motor LRA “ Locked Rotor Amps MCA — Maximum Circuit Ampacity OFM — Outdoor Fan Motor RLA — Rated Load Amps

SERIES

310BE 208/230-1 310BE 208/230-1 310BF 310BE 310BF 310BE 208/230-1 510CE 610CE 460-3 310BE

310BF

510CE.CF

310BE 510CE 310BF 51 DCF 208/230-3 310BE 510CE 610CE 460-3

310BF 208/230-1 510CF 310BE

310BF

VOLTSPHASE

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

208/230-3

208/230-1 208/230-3

208/230-1 208/230-3 208/230-1

208/230-1 208/230-3 187

208/230-3

230-1 230-1

OPERATING

VOLTAGE*

Max

Min 197 197 197 197 197 197 187 253 414 506

197 187 253

197 187 197 187 197

414 197 253 187 253 207 253 207 253

253 253 253 253 253 253

253

253 253 253

253 253 253 506

COMPR FLA

RLA LRA

8 7 11 7 63 0 1 7 11 7 63 0 13 7 76.0

13.7 76 0 17 6 88 0 4 6 11 5 65 1

5 1 32 8

17 6 88 0 3 8

11.5 65.1 5.6

23.9 95.4 4.1

15 3

23.9 95.4

15.3 82.0 5.0 1.0 25.2

23.7 116.0 4.5 1.9 36.1

14 7 92 0 7 8 2 2

70 23 7

14 7 27 8 130 0 6 2 27 8 130 0

‘Voltage limits between which the unit will operate satisfactorily flf other than 75 C copper wire is used, determine size from unit ampacity and the National

Electrical code Voltage drop of wire must be less than 2% of unit rated voltage Maximum

wire length is for one way along the wiie path from unit to service panel

^Maximum dual element size

IFM

49 0 1 2

3 0 1 0 18 7

3.1 1.0 21.2

2.9 1.0

4 7

1 9 0 6 8 9

82.0 5.6 1.0

3.9 0.8 34.6

46 0

3 3 1 2

116.0 3.7 5 8

92 0

6 5

MCAt

OFM

1 0 13 1 10 9 20 14 1 0 17 4 14 4 25 12

21.0 17.6 30 1 0 27 6 1 0 20 1 17 2 25

08 26 6

1.0 21.0

0.8 34.8

25.8 21.9 35 10

28 4 24 7 35 13 3 11 5 20 14

1.9

35.3 29.3 50 8 111

2.2 26.4

42 9

1 9

1.9

43 2 36 2 60 8 99

MAX

AMPS

15 7 25 12

17.8 30

23 2 40

22 2 40 10

18.1 25 10

28.8 50 8

28.6 50 8 114

21.3 35 10 111

30.1 50

22.7 35 10 104 35 9 60 8

MAX FUSE

SIZE (Amps)t

7.6 15 14 272

MIN WIRE

SIZE (AWG)t

(75C Copper)

10 115 10 116 10 88 10 137

8 108

10 96

MAX

WIRE

LENGTHt

76 89 82

130 113 108

180

100

SINGLE-STAGE HEAT 6 COOL-

MANUAL CHANGEOVER

, Field Low-Voltage Wiring , Field High-Voltage Wiring . Factory Low-Voltage Wiring . Factory High-Voltage Wiring

Fig. 8 — High- and Low-Voltage Connections

SINGLE-STAGE HEAT 8 COOL-

AUTOCHANGEOVER

JUMPER-1

CONTACTOR TERMINALS

FIELD SPLICE^

>- CD

LOW-VOLTAGE

PIGTAIL LEADS

CONTROL BOX

NOTE: For manual changeover applications, use thermostat part no HH01AD042 with subbase part no HH93AZ042; or thermostat part no HH01AD040 with subbase part no. HH93AZ040

For automatic changeover, use thermostat part no HH07AT174 with subbase part no

HH93AZ096; or thermostat part no HH10AD041 with subbase part no HH93AZ041

LiJ

HIGH-VOLTAGE PIGTAIL LEAD

(SEE UNIT WIRING LABEL)

--------

—■

---------

♦OHM^ —

FIELD-SUPPLIED DISCONNECT PER NEC

3-PHASE UNITS ONLY

.POWER

SUPPLY

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