Carrier 50ZHA024-060 User Manual

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Installation, Start-Up and Service 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

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

GROUND MOUNT ............................................................2

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

Place Unit..................................................................................2

Select and Install Ductwork .....................................................2

CONVERTING HORIZONTAL DISCHARGE UNITS TO DOWNFLOW (VERTICAL) DIS-

CHARGE ..................................................................4

Provide for Condensate Disposal .............................................4

Install Electrical Connections...................................................5

HIGH-VOLTAGE CONNECTIONS..................................5

ROUTING POWER LEADS INTO UNIT ........................6

CONNECTING GROUND LEAD TO UNIT GROUND .6

ROUTING CONTROL POWER WIRES ..........................6

ACCESSORY ELECTRIC HEAT WIRING .....................6

PRE-START-UP ............................................................................6

START-UP .....................................................................................7

Check for Refrigerant Leaks ....................................................8

LOCATE AND REPAIR REFRIGERANT LEAKS AND

CHARGE THE UNIT AS FOLLOWS: .............................8

Start-Up Cooling Section and Make Adjustments ..................8

CHECKING COOLING CONTROL OPERATION .........8

Refrigerant Charge....................................................................8

NO CHARGE......................................................................8

LOW CHARGE COOLING ...............................................9

HEATING MODE CHARGE.............................................9

Indoor Airflow and Airflow Adjustments................................9

FOR 208/230-V .................................................................13

Unit Controls...........................................................................13

HIGH-PRESSURE RELIEF VALVE...............................13

LOSS OF CHARGE SWITCH.........................................13

COMPRESSOR OVERLOAD..........................................13

Sequence of Operation............................................................13

FAN OPERATION............................................................13

COOLING..........................................................................14

HEATING..........................................................................14

CONTINUOUS FAN ........................................................14

DEFROST..........................................................................14

ELECTRIC RESISTANCE HEATING............................14

MAINTENANCE.........................................................................15

Air Filter..................................................................................15

Unit Top Removal (Outdoor-Coil Side) ................................15

50ZHA024-060

Packaged Heat Pump Units

A05194

Fig. 1—Unit 50ZHA

Indoor Blower and Motor.......................................................15

Outdoor Coil, Indoor Coil, and Condensate Drain Pan ........16

Outdoor Fan ............................................................................16

Electrical Controls and Wiring...............................................16

Refrigerant Circuit ..................................................................17

Indoor Airflow ........................................................................17

Metering Devices ....................................................................17

Lubrication ..............................................................................17

Liquid Line Strainer................................................................17

High Flow Valves...................................................................17

TROUBLESHOOTING ...............................................................17

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

NOTE TO INSTALLER—Before installation, READ THESE INSTRUCTIONS CAREFULLY AND COMPLETELY. Also, make sure the User’s Manual and Replacement Guide are left with the unit after installation.

SAFETY CONSIDERATIONS

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

Untrained workers can perform basic maintenance functions of cleaning coils and filters. All other operations should be performed by trained service people. When working on air-conditioning equipment, pay attention to precautions in the literature, tags, and labels attached to the unit, and other safety precautions that may apply.

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

Book 1 4 Tab 6 8

PC 101 Printed in U.S.A. Catalog No. 50ZHA-1SI Pg 1 9-05 Replaces: New

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations.

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury, death and/or property damage. Before performing service or maintenance operations on system, turn off main power to unit and install lockout tag. Turn off accessory heater power switch if applicable.

Recognize safety information. This is the safety-alert symbol . 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 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.

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 residential construction practices. We require these instructions as a minimum for a safe installation.

INTRODUCTION

50ZHA heat pump units are fully self-contained and designed for outdoor installation (See Fig. 1). As shown in Fig. 2, units are shipped in a horizontal-discharge configuration for installation on a ground-level slab. All units can be field-converted to downflow discharge configurations for rooftop applications with a fieldsupplied plenum.

RECEIVING AND INSTALLATION

Step 1—Check Equipment

IDENTIFY UNIT

The unit model number and serial number are stamped on the unit identification plate. Check this information against shipping papers. Verify that unit voltage and amperage listed on unit rating plate agree with power supplied for equipment.

INSPECT SHIPMENT

Inspect for shipping damage while unit is still on shipping pallet. If unit appears to be damaged or is torn loose from its securing points, 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 Distributor if any item is missing.

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

Step 2—Provide Unit Support

SLAB MOUNT

Place the unit on a rigid, level surface, suitable to support the unit weight. A concrete pad or a suitable fiberglass mounting pad is recommended. The flat surface should extend approximately 2-in. beyond the unit casing on the 2 sides. The duct connection side and condensate drain connection sides should be flush with the edge of the flat surface.

A 6-in. wide gravel apron should be used around the flat surface to prevent airflow blockage by grass or shrubs. Do not secure the unit to the flat surface except where required by local codes.

The unit should be level to within 1/4 inch. This is necessary for the unit drain to function properly.

GROUND MOUNT

The unit may also be installed directly on the ground if local codes permit. Place unit on level ground prepared with gravel for condensate discharge.

HURRICANE HOLD DOWN

Contact you local distributor for specific hurricane hold down details and PE (Professional Engineer) certification when required.

Step 3—Provide Clearances

The required minimum service clearances and clearances to combustibles are shown in Fig. 2. Adequate ventilation and outdoor coil air must be provided.

The outdoor fan pulls air through the outdoor coil and discharges it through the fan on the top cover. 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 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 inches.

Do not place the unit where water, ice, or snow from an overhang or roof will damage or flood the unit. The unit may be installed on wood flooring or on Class A, B, or C roof covering materials.

OPERATIONAL HAZARD Failure to follow this caution may result in unit component damage. Do not restrict outdoor coil airflow. An air restriction at either the outdoor-air inlet or the fan discharge can be harmful to compressor life.

Step 4—Place Unit

Unit can be moved with the rigging holds provided in the unit base. Refer to Table 2 for operating weights. Use extreme caution to

prevent damage when moving the unit. Unit must remain in an upright position during all moving operations. The unit must be

level with in 1/4” for proper condensate drainage; the ground-level pad must be level before setting the unit in place. When a field-fabricated support is used, be sure that the support is level and that it properly supports the unit.

Step 5—Select and Install Ductwork

The design and installation of the duct system must be in accordance with:

• the standards of the NFPA (National Fire Protection Association) for installation of nonresidence-type air conditioning and ventilating systems

• NFPA90A or residence-type, NFPA90B; and/or local codes and 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.

Use the duct flanges provided on the supply- and return-air openings on the side of the unit. See Fig. 2 for connection sizes and locations. The 14-in. round duct collars are shipped inside the unit attached to the base pan in the indoor blower compartment. They

A05201

Fig. 2—Unit Base Dimensions, 50ZHA024-060

Table 1—Unit Specifications

UNIT ELECTRICAL CHARACTERISTICS

50ZHA024 208/230-1-60 293 133 30.13 (765) 14.0 (356) 19.0 (483) 12.0 (305) 50ZHA030 208/230-1-60 324 147 34.13 (867) 14.0 (356) 19.0 (483) 12.0 (305) 50ZHA036 208/230-1-60 377 171 42.13 (1070) 14.0 (356) 19.0 (438) 19.8 (503) 50ZHA042 208/230-1-60 389 177 42.13 (1070) 14.0 (356) 19.0 (483) 21.9 (556) 50ZHA048 208/230-1-60 384 175 42.13 (1070) 14.0 (356) 19.0 (483) 19.8 (503) 50ZHA060 208/230-1-60 433 197 42.13 (1070) 14.0 (356) 19.0 (483) 21.9 (556)

UNIT WEIGHT

lb kg ″A″ XYZ

UNIT HEIGHT

IN. (MM)

CENTER OF GRAVITY IN. (MM)

are field-installed and must be removed from the indoor blower compartment prior to start-up, even if they are not used for installation.

When designing and installing ductwork, consider the following:

UNIT DAMAGE HAZARD Failure to follw this caution may result in damage to unit components. When connecting ductwork to units, do not drill deeper than 3/4 inch in shaded area shown in Fig. 3 or coil may be damaged.

• All units should have field-supplied filters installed in the return-air side of the unit. Recommended sizes for filters are shown in Table 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 weathertight and airtight seal. When electric heat is installed, use fire proof canvas (or similar heat resistant material) connector between ductwork and unit discharge connection. If flexible duct is used, insert a sheet metal sleeve inside duct. Heat resistant duct connector (or sheet metal sleeve) must extend 24–in. from the unit discharge connection flange into the ductwork.

• Size ductwork for cooling air quantity (cfm). The minimum air quantity for proper electric heater operation is listed in Table 3. Heater limit switches may trip at air quantities below those recommended.

• Insulate and weatherproof all external ductwork. 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 Contractors Association (ACCA) minimum installation standards for residential heating and air conditioning systems.

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

Figure 4 shows a typical duct system with 50ZHA unit installed.

CONVERTING HORIZONTAL DISCHARGE UNITS TO DOWNFLOW (VERTICAL) DISCHARGE

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Before performing service or maintenance operations on system, turn off main power to unit and install lockout tag. Turn off accessory heater power switch if applicable.

Units are dedicated side supply products. They are not convertible to vertical air supply. A field-supplied plenum must be used to convert to vertical air discharge.

Step 6—Provide for Condensate Disposal

NOTE: Be sure that condensate-water disposal methods comply

with local codes, restrictions, and practices.

Unit removes condensate through a 1 3/64-in. ID hole (using 3/4-in. OD piping or tubing) which is located at the end of the unit. See Fig. 2 for location of condensate connection.

19.17

3.92

Fig. 3—Area Not to Be Drilled More Than 3/4-in.

Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in groundlevel installations. Install a field-supplied condensate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. lower than the drain-pan condensate connection to prevent the pan from overflowing. 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 using a 3/4-in. OD tubing or pipe. (See Fig. 5 and 6.) 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. Prime the trap with water. Connect a drain tube using a minimum of 3/4-in. PVC, 3/4-in. CPVC, or 3/4-in. copper pipe (all field supplied). Do not undersize the tube. Pitch the drain tube downward at a slope of at least 1 in. for every 10 ft of horizontal run. Be sure to check the drain tube for leaks. Prime trap at the beginning of the cooling season start-up. Allowable glues for condensate trap connection are: Standard ABS, CPVC, or PVC cement.

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Table 2—Physical Data

UNIT 50ZHA 024 030 036 042 048 060

OPERATING WEIGHT (lbs) 293 324 377 389 384 433

COMPRESSOR TYPE Scroll Ultra Tech Scroll

15.8

4.9 Direct Drive

R-22

Propeller

Round

14 14

2...21

15.8

3200

1/4 (1100)

4...17

6.1

1400

11x9

3/4 (1050)

2...21

13.3

3200

1/4 (1100)

4...17

4.9

1600

11x10

1 (1050)

2...21

15.8

3300

1/2 (1100)

4...17

6.1

1875

11x10

1 (1050)

REFRIGERANT Charge (lb)

REFRIGERANT METERING DEVICE

*Required filter sizes shown are based on the ARI (Air Conditioning and Refrigeration Institute) rated airflow at a velocity of 300 ft/min for throwaway type or 450 ft/min

for high capacity type. Recommended filters are 1-in. thick.

Orifice ID (in.)

Orifice OD (in.) .049 .057 .059 .063 .070 .073

CONDENSER COIL

Rows...Fins/in.

Face Area (sq. ft.)

CONDENSER FAN

Nominal Cfm

Diameter (in.)

Motor HP (RPM)

EVAPORATOR COIL

Face Area (sq. ft.)

Evaporator Blower

Nominal Airflow (CFM)

Size (in.)

Motor HP (RPM)

CONNECTING DUCT SIZES

Supply Air (in.) Return Air (in.)

Return-Air Filters (in.)*

Throwaway

7.5 10.3 10.3 11.9 11.4 13.3 Accurater TXV

.067 .067 .082 .086 — —

Copper Tubes, Aluminum Plate Fins

2...21

11.1

2600

1/8 (825)

3...17

4.3

800

10x8

1/2 (1050)

24x24 24x24 24x24 24x30 30x30 30x30

2...21

12.7

2600

1/8 (825)

3...17

4.9

1000

10x8

1/2 (1050)

2...21

3200

1/4 (1100)

Copper Tubes, Aluminum Plate Fins

4...17

1200

11x9

3/4 (1050)

Step 7—Install Electrical Connections

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. 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 in the control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code), ANSI (American National Standards Institute)/NFPA (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes.

UNIT DAMAGE HAZARD Failure to follow these precautions may result in damage to the unit being installed:

1. Make all electrical connections in accordance with NEC ANSI/NFPA (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 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. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are run in same conduit as high-voltage wires.

5. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc. Consult local power company for correction of improper voltage.

HIGH-VOLTAGE CONNECTIONS

The unit must have a separate electrical service with a fieldsupplied, 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 6 for electrical data.

The field-supplied disconnect may be mounted on the unit over the high-voltage inlet hole. (See Fig. 2.)

INDOOR THERMOSTAT

RETURN AIR

TOP COVER

Power Wiring

Control Wiring

Condenser Airflow

Evaporator Airflow

POWER AND LOW-VOLTAGE ENTRY

COMPOSITE RUST-PROOF BASEPAN

CONDENSATE DRAIN CONNECTION

*Separate disconnect per NEC (National Electrical Code) required for electric heater when singlepoint conection is not used.

FROM POWER SOURCE

DISCONNECT PER NEC* (UNIT AND ELECTRIC HEATER)

C00008

Fig. 4—Typical installation

1” (25mm) MIN.

TRAP OUTLET

2” (50mm) MIN.

C99013

Fig. 5—Condensate Trap (Using Tubing)

TRAP OUTLET

1" min.

2" min.

C00009

Fig. 6—PVC Condensate Trap

Table 3—Minimum Airflow for Safe Electric Heater

Operation (CFM)

SIZE 024 030 036 042 048 060

Cfm 600 750 900 1050 1200 1500

UNIT DAMAGE HAZARD Failure to follow this caution may result in unit component damage. Operation of unit on improper line voltage constitutes abuse and may cause unit damage that could affect warranty.

ROUTING POWER LEADS INTO UNIT

Use only copper wire between disconnect and unit. The highvoltage leads should be in a conduit until they enter the unit; conduit termination at the unit must be watertight. Run the high-voltage leads through the hole on the control box side of the unit (see Fig. 7 for location). When the leads are inside the unit, run leads to the control box (Fig. 8). For single-phase units, connect leads to the black and yellow wires (see Fig. 9).

CONNECTING GROUND LEAD TO UNIT GROUND

Refer to Fig. 8 and 9. Connect the ground lead to the chassis using the unit ground in the control box.

ROUTING CONTROL POWER WIRES

Form a drip-loop with the thermostat leads before routing them into the unit. Route the thermostat leads through grommeted hole provided in unit into unit control box (See Fig. 7). Connect thermostat leads and unit power leads as shown in Fig. 9, 10A & 10B.

Route thermostat wires through grommet providing a drip-loop at the panel. Connect low-voltage leads to the thermostat as shown in Fig. 10A & 10B.

The unit transformer supplies 24-v power for complete system including accessory electrical heater. Transformer is factory wired for 230-v operation.

ACCESSORY ELECTRIC HEAT WIRING

Refer to accessory electric heat installation instructions for information on installing accessory electric heat. Accessory electric heat wiring is shown in Fig. 11A, 11B, & 11C.

PRE-START-UP

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD Failure to observe the following warnings could result in serious injury, death and/or property damage:

1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.

2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured.

3. Do not remove compressor terminal cover until all electrical sources are disconnected and lockout tag is installed.

4. Relieve all pressure from both high- and low-pressure sides of the system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals. Use accepted methods to recover refrigerant.

5. Never attempt to repair soldered connection while refrigerant system is under pressure.

6. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective goggles and proceed as follows: a. Shut off electrical power to unit and install lockout tag. b. Relieve all refrigerant from system using both high- and

low-pressure ports. Use accepted methods to recover refrigerant.

c. Cut component connecting tubing with tubing cutter and

remove component from unit.

d. Carefully unsweat remaining tubing stubs when neces-

sary. Oil can ignite when exposed to torch flame.

Use the Start-Up Checklist supplied at the end of this book and proceed as follows to inspect and prepare the unit for initial start-up:

1. Remove all access panels.

2. Read and follow instructions on all DANGER, WARNING, CAUTION, and INFORMATION labels attached to, or shipped with unit.

Make the following inspections:

a. Inspect for shipping and handling damages such as broken

lines, loose parts, disconnected wires, etc.

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