Carrier 50CR User Manual

50CR Infinityt Single--Packaged Heat Pump Units With Puron®(R--410A) Refrigerant Sizes 024--060

Installation Instructions

NOTE: Read the entire instruction manual before starting the

installation.

NOTE: Installer: Make sure the Owner’s Manual and Service Instructions are left with the unit after installation.

TABLE OF CONTENTS

Page

SAFETY CONSIDERATIONS 2........................

INTRODUCTION 2..................................

RECEIVING AND INSTALLATION 2--16................

Check Equipment 2.................................

Identify Unit 2...................................

Inspect Shipment 2................................

Provide Unit Support 2..............................

Roof Curb 2.....................................

Slab Mount 2....................................

Ground Mount 2.................................

Provide Clearances 2................................

Rig and Place Unit 7................................

Inspection 7.....................................

Introduction 7....................................

Use of Rigging Bracket 7...........................

Select and Install Ductwork 9..........................

Converting Horizontal Discharge Units to Downflow

(Vertical) Discharge Units 9.........................

Provide for Condensate Disposal 9.....................

Install Electrical Connections 11.......................

High-- Voltage Connections 11.......................

Routing Power Leads Into Unit 11....................

Connecting Ground Lead to Ground Screw 11..........

Routing Control Wires 11..........................

Accessory Installation 16...........................

Special Procedures for 208--v Operation 16.............

PRE--START--UP 17..................................

START--UP 17.......................................

Unit Start--Up 17--23................................

Sequence of Operation 20............................

Check for Refrigerant Leaks 20........................

Start--Up Adjustments 20.............................

Checking Cooling and Heating Control Operation 20.....

Checking and Adjusting Refrigerant Charge 22..........

Refrigerant Charge 22.............................

No Charge 22....................................

Low Charge Cooling 22............................

To Use Cooling Charging Charts 22...................

Indoor Airflow and Airflow Adjustments 22............

Defrost Control 22..................................

Quiet Shift 22....................................

Defrost 22......................................

Emergency Heat/Cool Mode 22........................

A05307

Fig. 1 -- Unit 50CR

MAINTENANCE 24--28...............................

Air Filter 25.......................................

Indoor Blower and Motor 25..........................

Outdoor Coil, Indoor Coil, and Condensate Drain Pan 25....

Outdoor Fan 25....................................

Electrical Controls and Wiring 26......................

Refrigerant Circuit 26................................

Indoor Airflow 26..................................

Metering Devices–TXV & AccuRater

Pressure Switches 26................................

L o s s -- o f -- C h a r g e S w i t c h 2 7...........................

High--Pressure Switch 27.............................

Copeland Scroll Compressor (Puron

Refrigerant System 27...............................

Refrigerant 27...................................

Compressor Oil 27................................

Servicing Systems on Roofs with Synthetic Materials 27...

Liquid--Line Filter Drier 28.........................

Puron (R--410A) Refrigerant Charging 28..............

System Information 28...............................

L o s s -- o f -- C h a r g e S w i t c h 2 8.........................

Check Defrost Thermostat 28........................

TROUBLESHOOTING 28.............................

START--UP CHECKLIST 28...........................

Piston 26..........

Refrigerant) 27.......

SAFETY CONSIDERATIONS

Installation and servicing of this equipment can be hazardous due to mechanical and electrical components. Only trained and qualified personnel should install, repair, or service this equipment.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on this equipment, observe precautions in the literature, on tags, and on labels attached to or shipped with the unit and other safety precautions that may apply.

Follow all safety codes. Installation must be in compliance with local and national building codes. Wear safety glasses, protective clothing, and work gloves. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit.

Recognize safety information. This is the safety--alert symbol Whenyou seethissymbolon the unit andin instructions or manuals, be alert to the potential for personal injury.

50CR

Understand these signal words; DANGER, WARNING, and CAUTION. 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 hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may 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.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Before installing or servicing system, always turn off main power to system. There may be more than one disconnect switch. Turn off accessory heater power switch if applicable.

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in unit component damage.

Puron (R--410A) systems operate at higher pressures than standard R--22 systems. DO NOT use R--22 service equipment or components on Puron (R--410A) equipment. Ensure service equipment is rated for Puron (R--410A).

The 50CR heat pump is fully self--contained and designed for outdoor installation. Standard units are shipped in a horizontal--discharge configuration for installation on a ground-- level slab. Standard units can be converted to downflow (vertical) discharge configurations for rooftop applications.

WARNING

CAUTION

INTRODUCTION

RECEIVING AND INSTALLATION

Step 1—Check Equipment

IDENTIFY UNIT

The unit model number and serial number are printed on the unit informative plate. Check this information against shipping papers.

INSPECT SHIPMENT

Inspect for shipping damage while unit is still on shipping pallet. If unit appears to be damaged or is tornloose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit. Check all items against shipping list. Immediately notify the nearest Carrier Air Conditioning office if any item is missing. To prevent loss or damage, leave all parts in original packages until installation.

Step 2—Provide Unit Support

For hurricane tie downs, contact distributor for details and PE Certificate (Professional Engineering) if required.

ROOF CURB

Install accessory roof curb in accordance with instructions shipped with curb (See Fig. 2). Install insulation, cant strips, roofing, and flashing. Ductwork must be attached to curb.

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

Curb should be level to within 1/4 in. (See Fig. 3). 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 extend approximately 2 in. beyond the casing on all 4 sides ofthe unit (See Fig. 4). Do not secure the unit to the slab except when required by local codes.

GROUND MOUNT

The unit may be installed either on a slab or placed directly on the groundif localcodespermit.Placethe unit on level ground prepared with gravel for condensate discharge.

Step 3—Provide Clearances

The required minimum service clearances are shown in Fig.6 and 7. Adequate ventilation and outdoor air must be provided. The outdoor fan draws air through the outdoor coil and discharges it through the top fan grille. Be sure that the fan discharge does not recirculate to the outdoor coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance undera partialoverhang (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.

IMPORTANT: Do not restrict outdoorairflow. An air restriction at either the outdoor--air inlet or the fan discharge may be detrimental to compressor life.

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 or other combustible materials. Slab--mounted units should be at least 4 in. above the highest expected water and runoff levels. Do not use unit if it has been under water.

HVAC unit

Scre w

(NO TE A)

*Gask eting

outer flange

Flashing field

supplied

Roofing material

field supplied

Cant str ip

field supplied

base

Gask eting

inner flange*

Wood nailer*

Roof curb*

Insulation (field

supplied)

Ductwork

field supplied

HVAC unit

Scre w

(NOTE A)

*Gask eting

outer flange

Flashing field

supplied

Roofing material

field supplied

Cant str ip

field supplied

base

Gask eting

inner flange*

Ductwork

field supplied

Wood nailer*

Roof curb*

Insulation (field

supplied)

*Provided with roof curb

Roof Curb for Small Cabinet

Note A: When unit mounting scre w is used,

Return opening

UNIT SIZE

50CR024--036

50CR042--060

retainer bra cke t must also be used.

(B X C)

ODS CATALOG

NUMBER

CPRFCURB006A00 8 (203) 11 (279) 16--1/2 (419) 28--3/4 (730) 30--3/8 (771) 44--5/16 (1126) 45 --15/16 (1167) CPRFCURB007A00 14 (356) 11 (279) 16 --1/2 (419) 28 --3/4 (730) 30 --3/8 (771) 44--5/16 (1126) 45--15/16 (1167) CPRFCURB008A00 8 (203) 16--3/16 (411) 17 --3/8 (441) 40--1/4 (1022) 41--15/16 (1065) 44 --7/16 (1129) 46--1/16 (1169) CPRFCURB009A00 14 (356) 16--3/16 (411) 17--3/8 (441) 40--1/4 (1022) 41--15/16 (1065) 44--7/16 (1129) 46 --1/16 (1169)

B Typ.

Insulated deck pan

Roof

Supply opening

(B x C)

C Typ.

Short

Support

Long

Support

IN. (MM)BIN. (MM)

IN. (MM)

*Provided with roof curb

Roof Curb for Large Cabinet

Note A: When unit mounting scre w is used,

retainer bra cket must also be used.

R/A

Insulated deck pan

IN. (MM)

Gask et around

duct

Gask et around

outer edge

IN. (MM)

Roof

S/A

IN. (MM)

NOTES:

1. Roof curb must be set up for unit being installed.

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

3. Dimension in ( ) are in millimeters.

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

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

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

7. Insulated panels: 1--in. thick fiberglass 1 lb. density.

8. Dimensions are in inches.

9. When unit mounting screw is used (see Note A), a retainer bracket mu st be u sed as well. This bracket must also be used when required by code f or hur ricaneorseismic conditions. This bracket is available through Micrometl.

Fig. 2 -- Roof Curb Dimensions

50CR

A05308

MAXIMUM ALLOWABLE

DIFFERENCE (in.)

A-B B-C A-C

1/4 1/4 1/4

C99065

Fig. 3 -- Unit Leveling Tolerances

OPTIONAL

RETURN

AIR

50CR

OPENING

EVAP. COIL COND. COIL

OPTIONAL

SUPPLY

AIR

OPENING

C99096

Fig. 4 -- Slab Mounting Detail

A06114

Fig. 5 -- Corner Weights (Lbs.)

CORNER WEIGHTS (SMALL CABINET) CORNER WEIGHTS (LARGE CABINET)

Unit 024 030 036

Unit 042 048 060

Total Weight 349 349 373 Total Weight 438 463 499

Corner Weight 1 70 70 75 Corner Weight 1 88 98 107

Model

Corner Weight 2 54 54 58 Corner Weight 2 68 61 70

50CR

Corner Weight 3 84 84 90 Corner Weight 3 106 127 136

50CR

Model

Corner Weight 4 141 141 150 Corner Weight 4 177 177 186

A05299

50CR

Fig. 6 -- 50CR024--036 Unit Dimensions

A05300

50CR

Fig. 7 -- 50CR042--060 Unit Dimensions

Step 4—Rig and Place Unit

Rigging and handling of this equipment can be hazardous for many reasons due to the installation location (roofs, elevated structures, etc.).

Only trained, qualified crane operators and ground support staff should handle and install this equipment.

When working with this equipment, observe precautions in the literature, on tags, stickers, and labels attached to the equipment, and any other safety precautions that might apply.

Training for operators of the lifting equipment should include, but not be limited to, the following:

1. Application of the lifter to the load, and adjustment of the lifts to adapt to various sizes or kinds of loads.

2. Instruction in any special operation or precaution.

3. Condition of the load as it relates to operation of the lifting kit, such as balance, temperature, etc.

Follow all applicable safety codes. Wear safety shoes and work gloves.

INSPECTION

Prior to initial use, and at monthly intervals, all rigging brackets and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular attention should be paid to excessive wear at hoist hooking points and load support areas. Brackets or straps showing any kind of wear in these areas must not be used and should be discarded.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Before installing or servicing system, always turn off main power to system. There may be more than one disconnect switch. Turn off accessory heater power switch if applicable. Tag disconnect switch with a suitable warning label.

UNIT FALLING HAZARD

Failure to follow this warning could result in personal injury or death.

Never stand beneath rigged units or lift over people.

INTRODUCTION

The lifting/rigging bracket is engineered and designed to be installed only on Small Packaged Products. This bracket is to be used to rig/lift a Small Packaged Product onto roofs or other elevated structures.

PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personal injury/death or property damage.

Rigging brackets for one unit use only. When removing a unit at the end of its useful life, use a new set of brackets.

WARNING

USE OF RIGGING BRACKET

Field Installation of Rigging

1. If applicable, remove unit from shipping carton. Leave top shipping skid on the unit for use asa spreaderbar to prevent the rigging straps from damaging the unit. If the skid is not available, use a spreader bar of sufficient length to protect the unit from damage.

2. Remove 4 screws in unit corner posts.

3. Attach each of the 4 metal rigging brackets under the panel rain lip (See Fig. 8). Use the screws removed in step 2 above to secure the brackets to the unit.

PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personal injury/death or property damage.

Rigging bracket MUST be under the rain lip to provide adequate lifting.

PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personal injury/death or property damage.

Do not strip screws when re-- securing the unit. If a screw is stripped, replacethe stripped one with a larger diameterscrew (included).

Rigging/Lifting of Unit

1. Bend top of brackets down approximately 30 degrees from the corner posts.

2. Attach straps of equal length to the rigging brackets at oppositeends of the unit. Be sure straps are rated to hold the weight of the unit (See Fig. 9).

3. Attach a clevis of sufficient strength in the middle of the straps. Adjust the clevis location to ensure unit is lifted level with the ground.

4. Afterunit is securely in placedetachrigging straps.Remove corner posts, screws, and rigging brackets then reinstall screws.

UNIT FALLING HAZARD

Failure to follow this warning could result in personal injury/death or property damage.

When straps are taut, the clevis should be a minimum of 36 inches above the unit top cover.

After the unit is placed on the roof curb or mounting pad, remove the top crating. On 50CR060 units only, 2 wire ties fastened to the outdoor coils and reversing valve/accumulator assembly must be cut. Remove the left and front louvered panels and corner post to access wire ties. The wire tie to be cut on the left is located approximately 4 in. down the tube sheet. The wire tie to be cut on the right is located approximately 6 in. down the tube sheet.

Bracket

WARNING

50CR

50CR50CR

DETAIL

C03017

Fig. 8 -- Rigging Bracket Under Unit Rain Lip

UNIT SIZE

50CR024 372 169 50CR030 372 169 50CR036 395 179 50CR042 462 210 50CR048 485 220 50CR060 521 236

MAXIMUM SHIPPING WEIGHT

Lb Kg

Fig. 9 -- Suggested Rigging

A06113

Step 5—Select and Install Ductwork

The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of non--residence type air conditioning and ventilating systems, NFPA 90A or residence type, NFPA 90B and/or local codes and ordinances.

Select and size ductwork, supply-- air registers, and return air grilles according to ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) recommendations.

The unit hasduct flangeson the supply-- and return--air openings on the side of the unit.

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal injury or death.

For vertical supply and return units, tools or parts could drop into ductwork, therefore, install a 90 degree turn in the return ductwork between the unit and the conditioned space. If a 90 degree elbow cannot be installed, then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space. Units with electric heaters require 90 degree elbow in supply duct.

When designing and installing ductwork, consider the following:

1. Allunits should havefield--supplied filtersor accessory filter rack installed in the return--air side of the unit. Recommended sizes for filters are shown in Table 1.

2. Avoid abrupt duct size increases and reductions. Abrupt change in duct size adversely affects air performance.

IMPORTANT: Use flexible connectors between ductwork and unit to prevent transmission of vibration. Use suitable gaskets to ensure weather tight and airtight seal. When electric heat is installed, use fireproof canvas (or similar heat resistant material) connector between ductworkand unit discharge connection. If flexibleduct is used, insert a sheet metal sleeve inside duct. Heat resistant duct connector (or sheet metal sleeve) must extend 24--in. from electric heater element.

3. Size ductwork for max cooling air quantity (400 cfm/ton).

4. Seal,insulate, and weatherproof all externalductwork. Seal, insulate and cover with a vapor barrier all ductwork passing through conditioned spaces. Follow latest Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning ContractorsAssociation (ACCA) minimum installation standards for residential heating and air conditioning systems.

5. Secure all ducts to building structure. Flash, weatherproof, and vibration--isolate duct openings in wall or roof according to good construction practices.

WARNING

CONVERTING HORIZONTAL DISCHARGE UNITS TO DOWNFLOW (VERTICAL) DISCHARGE UNITS

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Before installing or servicing system, always turn off main power to system. There may be more than one disconnect switch.Turn off accessory heater power switch if applicable.

1. Open allelectrical disconnects and install lockout tag before starting any service work.

2. Remove side duct covers to access bottom return and supply knockouts.

NOTE: These panels are held in place with tabs similar to an electrical knockout.

3. Use a screwdriver and hammer to remove the panels in the bottom of the composite unit base.

4. Ensure the side duct covers are in place to block off the horizontal air openings (See Fig. 11).

Step 6—Provide for Condensate Disposal

NOTE: Ensure that condensate--water disposal methods comply

with local codes, restrictions, and practices.

Theunits disposeof condensate through a3/4 in.NPT femalefitting that exits on the compressor end of the unit. Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in ground level installations. Install a field--supplied condensate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. lower than the drain--pan condensate connection to preventthe pan fromoverflowing. Primethe trap with water. When using a gravel apron, make sureit slopes away fromthe unit.

If the installation requires draining the condensate water away from the unit, install a field--supplied 2 --in. trap at the condensate connection to ensure proper drainage. Condensate trap is available as an accessory or is field--supplied. Make sure that the outlet of the trap is at least 1 in. lower than the unit drain--pan condensate connection to prevent the pan from overflowing. Connect a drain trough using a minimum of field--supplied 3/4 -- in. PVC or field--supplied 3/4 --in. copper pipe at outlet end of the 2 -- in. trap (See Fig. 12). Do not undersize the tube. Pitch the drain trough downwardat a slopeof at least1 in.for every 10 ft.of horizontal run. Be sure to check the drain trough for leaks. Prime the trap at the beginning of the cooling season start--up.

WARNING

50CR

Table 1—Physical Data -- Unit 50CR

UNIT SIZE 024 030 036 042 048 060

NOMINAL CAPACITY (ton) 2 2--1/2 3 3--1/2 4 5

OPERATING WEIGHT (lb.) 350 350 373 440 463 499

Refrigerant (R-- 410A) Quantity (lb.) 7.5 8 9.5 10.8 11. 5 14.0

REFRIGERANT METERING DEVICE TXV

50CR

HIGH--PRESSURE SWITCH (psig)

LOSS--O F -- CHARGE/LOW--PRESSURE SWITCH

*Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 ft/minute for throw away type o r 450 f t/minute for high-- capacity type. Air filter pressure drop for non--standard filters must not exceed 0.08 in. wg.

Compressor Scroll

ORIFICE OD (in.) 0.035 (2) 0.035 (2) 0.038 (2) 0.038 (2)

OUTDOOR COIL

Rows…Fins/in. 2…21 2…21 2…21 2…21 2…21 2…21

Face Area (sq. ft.) 12.3 12.3 13.6 15.4 17.2 19.4

OUTDOOR FAN

Nominal Cfm 2700 2700 2800 2800 3300 3300

Diameter 22 22 22 22 22 22

Motor HP (RPM) 1/8 (825) 1/8 (825) 1/8 (825) 1/8 (825) 1/4 (1100) 1/4 (1100)

INDOOR COIL

Rows…Fins/in. 3…15 3…15 4…15 3…15 4…15 4…17

Face Area (sq. ft.) 3.7 3.7 3.7 4.7 4.7 5.7

INDOOR BLOWER

Nominal Airflow (Cfm)

Size (in.) 10x10 10x10 11x1 0 11x 1 0 11x 1 0 11x 1 0

Motor HP (RPM) 1/2 1/2 3/4 3/4 3/4 1

Cutout

Reset (Auto)

(Liquid Line) (psig)

Cutout

Reset (Auto)

Return-- Air Filters (in.)*

Throwaway

Comfort Variable based on Comfort Roll back (see User Interface instructions for more information).

Efficiency 700 875 1050 1225 1400 1750

Max 800 1000 1200 1400 1600 2000

20x24x1 20x24x1 24x30x1 24x36x1 24x36x1 24x36x1

0.038 (Left OD Coil)

0.046 (Right OD Coil)

650 ± 15 420 ± 25

20 ± 5

45 ± 10

0.042 (Left OD Coil)

0.052 (Right OD Coil)

TOP COVER

USER INTERFACE

RETURN AIR

FROM POWER SOURCE

DISCONNECT

PER NEC* FROM GAS LINE

*NEC - NATIONAL ELECTRICAL CODE

Fig. 10 -- Typical Installation

A06091

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