Carrier SINGLE PACKAGE ROOFTOP UNITS 48PG20-28 Installation And Service Instructions Manual

Download

Page 1

48PG20-28

Single Package Rooftop Units

Electric Cooling/Gas Heating with

Electromechanical Controls and PURON® (R-410A) Refrigerant

Installation, Start-Up and Service Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS ..........................1,2

INSTALLATION ......................................2-17

Step 1 — Provide Unit Support .........................2

• ROOF CURB

• ALTERNATE UNIT SUPPORT

• SLAB MOUNT

Step 2 — Remove Shipping Rails .......................2

Step 3 — Rig and Place Unit ............................2

• POSITIONING

• ROOF MOUNT

• INSTALLATION ONTO CURB

Step 4 — Field Fabricate Ductwork .....................9

Step 5 — Make Unit Duct Connections..................9

• VERTICAL CONFIGURATION

• HORIZONTAL APPLICATIONS

Step 6 — Install Flue Hood and Inlet Hood ............ 10

Step 7 — Trap Condensate Drain ..................... 10

Step 8 — Install Gas Piping ........................... 10

Step 9 — Make Electrical Connections.................11

• FIELD POWER SUPPLY

• FIELD CONTROL WIRING

Step 10 — Install Outdoor-Air Hood................... 12

• MANUAL DAMPER ASSEMBLY

Step 11 — Position Optional Power

Exhaust or Barometric Relief Damper Hood ......... 16

Step 12 — Non-Fused Disconnect .................... 16

Step 13 — Install All Accessories..................... 16

PRE-START-UP ....................................... 18

START-UP...........................................18-45

Unit Preparation ...................................... 18

Compressor Mounting................................ 18

Refrigerant Service Ports ............................. 18

Crankcase Heater(s) .................................. 18

Compressor Rotation................................. 18

Internal Wiring........................................ 18

Subcooler Heat Exchanger (SHX) ..................... 18

Evaporator Fan ....................................... 18

Condenser Fans and Motors.......................... 19

Return-Air Filters ..................................... 19

Outdoor-Air Inlet Screens............................. 19

Gas Heat.............................................. 19

Optional EconoMi$er IV............................... 39

Operating Sequence .................................. 44

SERVICE............................................46-57

Cleaning .............................................. 46

Lubrication ........................................... 47

Manual Outdoor Air Damper .......................... 48

Economizer Adjustment .............................. 48

Evaporator Fan Service and Replacement ............ 48

Evaporator Fan Performance Adjustment............. 48

Evaporator Fan Belt Tension Adjustment ............. 48

Condenser Fan Adjustment........................... 49

Verify Sensor Performance ........................... 49

Economizer Operation During Power Failure.......... 49

Evacuation ........................................... 49

Refrigerant Charge ................................... 50

Gas Valve Adjustment ................................ 50

High Altitude.......................................... 51

Main Burners ......................................... 51

Filter Drier ............................................ 52

Protective Devices.................................... 52

Relief Devices ........................................ 52

Control Circuit, 24-V .................................. 52

Page

Replacement Parts.................................... 52

Diagnostic LEDs ...................................... 52

TROUBLESHOOTING .............................. 57-61

Unit Troubleshooting.................................. 57

EconoMi$er IV Troubleshooting....................... 60

Phase Loss Protection ................................ 61

UNIT START-UP CHECKLIST ........................CL-1

SAFETY CONSIDERATIONS

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

Untrained personnel can perform the basic maintenance functions of cleaning coils and filters and replacing 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 extinguishers available for all brazing operations.

Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury.

Puron (R-410A) refrigerant systems operate at higher pressures than standard R-22 systems. Do not use R-22 service equipment or components on Puron refrigerant equipment. If service equipment is not rated for Puron refrigerant, equipment damage or personal injury may result.

1. Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal injury, or loss of life. Refer to the User’s Information Manual provided with this unit for more details.

2. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

What to do if you smell gas:

1. DO NOT try to light any appliance.

2. DO NOT touch any electrical switch, or use any phone in your building.

3. IMMEDIATELY call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

4. If you cannot reach your gas supplier, call the fire department.

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

Book 1 4 Ta b 1 a 6 a

PC 111 Catalog No. 534-80211 Printed in U.S.A. Form 48PG-10SI Pg 1 9-05 Replaces: New

Page 2

Disconnect gas piping from unit when pressure testing at pressure greater than 0.5 psig. Pressures greater than

0.5 psig will cause gas valve damage resulting in hazardous condition. If gas valve is subjected to pressure greater than

0.5 psig, it must be replaced before use. When pressure testing field-supplied gas piping at pressures of 0.5 psig or less, a unit connected to such piping must be isolated by closing the manual gas valve(s).

IMPORTANT: Units have high ambient operating limits. If limits are exceeded, the units will automatically lock the compressor out of operation. Manual reset will be required to restart the compressor.

INSTALLATION

Step 1 — Provide Unit Support

ROOF CURB — Assemble or install accessory roof curb in accordance with instructions shipped with this accessory. See Fig. 1. Install insulation, cant strips, roofing, and counter flashing as shown. Ductwork can be installed to roof curb before unit is set in place. Ductwork must be attached to curb and not to the unit. Curb must be level. This is necessary to permit unit drain to function properly. Unit leveling tolerance is ±

/16in. per linear ft in any direction. Refer to Accessory Roof Curb Installation Instructions for additional information as required. When accessory roof curb is used, unit may be installed on class A, B, or C roof covering material. Carrier roof curb accessories are for flat roofs or slab mounting.

IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket with the roof curb as shown in Fig. 1. Improperly applied gasket can also result in air leaks and poor unit performance. Do not slide unit to position on roof curb.

ALTERNATE UNIT SUPPORT — When a curb cannot be used, install unit on a noncombustible surface. Support unit with sleepers, using unit curb support area. If sleepers cannot be used, support long sides of unit with a minimum of 3 equally spaced 4-in. x 4-in. pads on each side.

SLAB MOUNT (Horizontal Units Only) — Provide a level concrete slab that extends a minimum of 6 in. beyond unit cabinet. Install a gravel apron in front of condenser coil air inlet to prevent grass and foliage from obstructing airflow.

NOTE: Horizontal units may be installed on a roof curb if required.

Step 2 — Remove Shipping Rails — Remove ship-

ping rails prior to lowering unit onto roof curb. See Fig. 2. The rails are attached to the unit at both the return end and condenser end. Remove the screws from both ends of each rail. Be careful not to drop the rails onto any surface that could be damaged. Discard the rails. It is important to replace the screws into the unit to avoid any air or water leakage.

Step 3 — Rig and Place Unit — Inspect unit for trans-

portation damage. See Tables 1-3 for physical data. File any claim with transportation agency.

All panels must be in place when rigging. Unit is not designed for handling by fork truck. Damage to unit may result.

Do not drop unit; keep upright. Use spreader bars over unit to prevent sling or cable damage. Rollers may be used to move unit across a roof. Level by using unit frame as a reference; leveling tolerance is ± Fig. 3 for additional information. Unit rigging weight is shown in Fig. 3.

Four lifting holes are provided in the unit base rails as shown in Fig. 3. Refer to rigging instructions on unit.

POSITIONING — Maintain clearance, per Fig. 4, around and above unit to provide minimum distance from combustible materials, proper airflow, and service access.

Do not install unit in an indoor location. Do not locate air inlets near exhaust vents or other sources of contaminated air. For proper unit operation, adequate combustion and ventilation air must be provided in accordance with Section 5.3 (Air for Combustion and Ventilation) of the National Fuel Gas Code, ANSI Z223.1 (American National Standards Institute).

Although unit is weatherproof, guard against water from higher level runoff and overhangs.

Locate mechanical draft system flue assembly at least 4 ft from any opening through which combustion products could enter the building, and at least 4 ft from any adjacent building (or per local codes). When unit is located adjacent to public walkways, flue assembly must be at least 7 ft above grade.

ROOF MOUNT — Check building codes for weight distribution requirements. Unit operating weight is shown in Table 1.

INSTALLATION ONTO CURB — The 48PG units are designed to fit on either the accessory full perimeter curb. Correct placement of the unit onto the curb is critical to operating performance. To aid in correct positioning, ing holes have been added to the unit base rails. When placing the unit, these holes should line up with the roof curb edge as shown in Fig. 5 and 6, to assure proper duct opening alignment. For placement on the roof curb, use the alignment holes located approximately 2-in. from the end of the base rail on the return end of the unit. See labels on the side of the unit for more details.

Do not slide unit to position it when it is sitting on the curb. Curb gasketing material may be damaged and leaks may result.

/16in. per linear ft in any direction. See

/8-in. diameter locat-

Do not allow the shipping rail to drop on the roof surface. Damage to the roof surface may result.

Page 3

Fig. 1 — Roof Curb Details

Page 4

SHIPPING RAILS

Fig. 2 — Shipping Rail Removal

MAX

UNIT SIZE

PG20

PG24

PG28

DOES NOT INCLUDE ERV ( ENERGY RECOVERY VENTILATOR) OPTION.

WEIGHT

CENTER OF GRAVITY ( IN.)

(LB) *

3825

4075

4300

66.5

70.5

36.7 31.4

37.0

31.8

37.0

35.2

NOTES:

1. Add 150 lb (68 kg) for domestic crating.

2. See label for unit location on roof curb.

Fig. 3 — Rigging Details

Page 5

Fig. 4 — Base Unit Dimensions

Page 6

Table 1 — Physical Data

UNIT 48PG 20 24 28 VO LTAGE 208/230 and 460 575 208/230 and 460 575 208/230 and 460 575 NOMINAL CAPACITY (Tons) 18 18 20 20 25 25 OPERATING WEIGHT (lb)

48 Series (Low Heat) Al/Al* 2480 2480 2588 2588 2773 2773

COMPRESSOR Fully Hermetic Scroll

Quantity 222233 Number of Refrigerant Circuits 222222 Oil (ounces) Comp A1, A2, B1 85, NA, 85 85, NA, 85 85, NA, 85 85, NA, 85 85, 85, 85 85, 85, 85

REFRIGERANT TYPE Puron® Refrigerant (R-410A)

Expansion Device TXV TXV TXV TXV TXV TXV Change Type Operating Charge (lb)

Circuit A 25.3 25.3 35.7 35.7 49.3 49.3 Circuit B 25.3 25.3 33.5 33.5 24.3 24.3

REFRIGERANT SUBCOOLER

Heat Exch anger Size B15Hx26x26 B15Hx26x26 B15Hx26x26 B15Hx26x26 B15Hx26x36 B15Hx26x36 Expansion Device TXV TXV TXV TXV TXV TXV

CONDENSER COIL Enhanced Copper Tubes, Aluminum Lanced Fins

Rows...Fins/inch 2...17 2...17 3...17 3...17 3...17 3...17 Quantity 223333 Length of Tube Sheets (in.) 80.3 80.3 80.3 80.3 80.3 80.3 Width (in.) 60 60 60 60 60 60 Total Face area (sq. ft) 33.46 33.46 33.46 33.46 33.46 33.46

CONDENSER FAN Propeller

Nominal Cfm (Total, all fans) 14,000 14,000 21,000 21,000 21,000 21,000 Quantity...Diameter (in.) 4...22 4...22 6...22 6...22 6...22 6...22 Motor Hp...Rpm Watts input (Total) 1400 1400 2100 2100 2100 2100

EVAPORATOR COIL Enhanced Copper Tubes, Face Split, Aluminum Double-Wavy Fins

Rows...Fins/inch 4...15 4...15 4...15 4...15 4...15 4...15 Length of Tube Sheets (in.) 69.4 69.4 69.4 69.4 69.4 69.4 Width (in.) 48 48 48 48 60 60 Total Face area (sq ft) 23.13 23.13 23.13 23.13 28.92 28.92

EVAPORATOR FAN Centrifugal, Belt Type

Quantity...Size (in.) 2...15 x 11 2...15 x 11 2...15 x 11 2...15 x 11 2...15 x 11 2...15 x 11 Typ e D riv e Belt Belt Belt Belt Belt Belt Nominal Cfm 7000 7000 8000 8000 10,000 10,000 Motor Bearing Type Ball Ball Ball Ball Ball Ball Maximum Allowable Fan Rpm 1400 1400 1400 1400 1400 1400

FURNACE SECTION

Rollout Switch Cutout Temp (F) Vertical 225 225 225 225 225 225

Burner Orifice Diameter (in. ...drill size) 0.136...29 0.136...29 0.136...29 0.136...29 0.136...29 0.136...29

Gas Natural Natural Natural Natural Natural Natural Thermostat Heat Anticipator Setting

Stage 1 (amps) 0.98 0.98 0.98 0.98 0.98 0.98 Stage 2 (amps) 0.44 0.44 0.44 0.44 0.44 0.44

Gas Input (Btuh) HIGH HEAT Stage 1 317,000 317,000 317,000 317,000 317,000 317,000

Efficiency (Steady State) % Vertical 82 82 82 82 82 82 Temperature Rise Range 25-55 25-55 25-55 25-55 25-55 25-55 Gas Input (Btuh) MEDIUM HEAT Stage 1 281,000 281,000 281,000 281,000 281,000 281,000

Efficiency (Steady State) % Vertical 81 81 81 81 81 81 Temperature Rise Range 25-55 25-55 25-55 25-55 25-55 25-55 Gas Input (Btuh) LOW HEAT Stage 1 199,000 199,000 199,000 199,000 199,000 199,000

Efficiency (Steady State) % Vertical 82 82 82 82 82 82 Temperature Rise Range 15-45 15-45 15-45 15-45 15-45 15-45 Manifold Pr essure

Natural Gas (in. wg) Vertical 3.00 3.00 3.00 3.00 3.00 3.00

Natural Gas (in. wg) Horizontal 2.95 2.95 2.95 2.95 2.95 2.95 Gas Valve Quantity 111111 Gas Valve Pressure Range (in. wg) 5.5-13.0 5.5-13.0 5.5-13.0 5.5-13.0 5.5-13.0 5.5-13.0

Min-Max Allowable (psig) .235-.469 .235-.469 .235-.469 .235-.469 .235-.469 .235-.469 Field Gas Connection Size (in...FPT)

HIGH-PRESSURE SWITCHES (psig)

Cutout 630±10 630±10 630±10 630±10 630±10 630±10 Reset (Auto) 505±20 505±20 505±20 505±20 505±20 505±20

OUTDOOR AIR INLET SCREENS

Quantity...Size (in.) 3...20 x 25 3...20 x 25 3...20 x 25 3...20 x 25 3...20 x 25 3...20 x 25

RETURN-AIR FILTERS

Quantity...Size (in.) 9...16 x 25 x 2 9...16 x 25 x 2 9...16 x 25 x 2 9...16 x 25 x 2 9...20 x 25 x 2 9...20 x 25 x 2

Stage 2 400,000 400,000 400,000 400,000 400,000 400,000

Stage 2 365,000 365,000 365,000 365,000 365,000 365,000

Stage 2 250,000 250,000 250,000 250,000 250,000 250,000

LEGEND

TXV — Thermostatic Expansion Valve

*Aluminum evaporator coil/aluminum condenser coil.

/4...1100

Page 7

Table 2 — Fan Motor and Drive Data — Vertical Supply/Return

48PG

LOW RANGE

Motor Hp 3.753.7555 Motor Nominal Rpm 1750 1750 1750 1750 1750 1750 Maximum Continuous Bhp 4.26 5.75 4.26 5.75 5.75 5.75 Maximum Continuous Watts 3174 4290 3174 4290 4290 4290 Motor Frame Size 56HZ S184T 56HZ S184T S184T S184T Motor Shaft Diameter (in.) Fan Rpm Range 685-939 751-954 685-939 751-954 687-873 687-873 Motor Pulley Min. Pitch Diameter (in.) 2.7 3.7 2.7 3.7 3.7 3.7 Motor Pulley Max. Pitch Diameter (in.) 3.7 4.7 3.7 4.7 4.7 4.7 Blower Pulley Pitch Diameter (in.) 6.8 8.6 6.8 8.6 9.4 9.4 Blower Pulley Shaft Diameter (in.) 1 Blower Pulley Type FixedFixedFixedFixedFixedFixed Pulley Center Line Distance (in.) 11.293-13.544 9.81-13.055 11.293-13.544 9.81-13.055 9.81-13.055 9.81-13.055 Belt, Quantity...Type...Length (in.) 1...BX38...39.8 1...BX40...41.8 1...BX38...39.8 1...BX40...41.8 1...BX41...42.8 1...BX41...42.8 Speed Change Per Turn — Moveable Pulley (rpm) 42 34 42 34 31 31 Moveable Pulley Maximum Full Turns 666666 Factory Speed Setting (rpm) 812 853 812 853 780 780

MID-LOW RANGE

Motor Hp 555555 Motor Nominal Rpm 1750 1750 1750 1750 1750 1750 Maximum Continuous Bhp 5.75 5.75 5.75 5.75 5.75 5.75 Maximum Continuous Watts 4290 4290 4290 4290 4290 4290 Motor Frame Size S184T S184T S184T S184T S184T S184T Motor Shaft Diameter (in.) 1 Fan Rpm Range 949-1206 949-1206 949-1206 949-1206 805-1007 805-1007 Motor Pulley Min. Pitch Diameter (in.) 3.7 3.7 3.7 3.7 4.8 4.8 Motor Pulley Max. Pitch Diameter (in.) 4.7 4.7 4.7 4.7 6 6 Blower Pulley Pitch Diameter (in.) 6.8 6.8 6.8 6.8 10.4 10.4 Blower Pulley Shaft Diameter (in.) 1 Blower Pulley Type FixedFixedFixedFixedFixedFixed Pulley Center Line Distance (in.) 9.81-13.055 9.81-13.055 9.81-13.055 9.81-13.055 9.81-13.055 9.81-13.055 Belt, Quantity...Type...Length (in.) 1...BX38...39.8 1...BX38...39.8 1...BX38...39.8 1...BX38...39.8 1...BX45...46.8 1...BX45...46.8 Speed Change Per Turn — Moveable Pulley (rpm) 43 43 43 43 34 34 Moveable Pulley Maximum Full Turns 666666 Factory Speed Setting (rpm) 1078 1078 1178 1078 906 906

MID-HIGH RANGE

Motor Hp 7.5 7.5 7.5 7.5 7.5 7.5 Motor Nominal Rpm 1750 1750 1750 1750 1750 1750 Maximum Continuous Bhp 8.63 8.63 8.63 8.63 8.63 8.63 Maximum Continuous Watts 6434 6434 6434 6434 6434 6434 Motor Frame Size S213T S213T S213T S213T S213T S213T Motor Shaft Diameter (in.) 1 Fan Rpm Range 941-1176 941-1176 941-1176 941-1176 941-1176 941-1176 Motor Pulley Min. Pitch Diameter (in.) 4.8 4.8 4.8 4.8 4.8 4.8 Motor Pulley Max. Pitch Diameter (in.) 6.0 6.0 6.0 6.0 6.0 6.0 Blower Pulley Pitch Diameter (in.) 8.9 8.9 8.9 8.9 8.9 8.9 Blower Pulley Shaft Diameter (in.) 1 Blower Pulley Type FixedFixedFixedFixedFixedFixed Pulley Center Line Distance (in.) 9.025-12.179 9.025-12.179 9.025-12.179 9.025-12.179 9.025-12.179 9.025-12.179 Belt, Quantity...Type...Length (in.) 1...BX42...43.8 1...BX42...43.8 1...BX42...43.8 1...BX42...43.8 1...BX42...43.8 1...BX42...43.8 Speed Change Per Turn —

Moveable Pulley (rpm) Moveable Pulley Maximum Full Turns 666666 Factory Speed Setting (rpm) 1059 1059 1059 1059 1059 1059

HIGH RANGE

Motor Hp 10 10 10 10 10 10 Motor Nominal Rpm 1750 1750 1750 1750 1750 1750 Maximum Continuous Bhp 11.50 11.50 11.50 11.50 11.50 11.50 Maximum Continuous Watts 8579 8579 8579 8579 8579 8579 Motor Frame Size S215T S215T S215T S215T S215T S215T Motor Shaft Diameter (in.) 1 Fan Rpm Range 1014-1297 1014-1297 1014-1297 1014-1297 1014-1297 1014-1297 Motor Pulley Min. Pitch Diameter (in.) 4.3 4.3 4.3 4.3 4.3 4.3 Motor Pulley Max. Pitch Diameter (in.) 5.5 5.5 5.5 5.5 5.5 5.5 Blower Pulley Pitch Diameter (in.) 7.4 7.4 7.4 7.4 7.4 7.4 Blower Pulley Shaft Diameter (in.) 1 Blower Pulley Type FixedFixedFixedFixedFixedFixed Pulley Center Line Distance (in.) 9.025-12.179 9.025-12.179 9.025-12.179 9.025-12.179 9.025-12.179 9.025-12.179 Belt, Quantity...Type...Length (in.) 2...BX38...39.8 2...BX38...39.8 2...BX38...39.8 2...BX38...39.8 2...BX38..39.8 2...BX38...39.8 Speed Change Per Turn — Moveable Pulley (rpm) 47 47 47 47 47 47 Moveable Pulley Maximum Full Turns 666666 Factory Speed Setting (rpm) 1156 1156 1156 1156 1156 1156

208/230 and 460 575 208/230 and 460 575 208/230 and 460 575

20 24 28

13/

11/

13/

11/

13/

11/

13/

11/

13/

11/

13/

11/

13/

39 39 39 39 39 39

13/

Page 8

Table 3 — Fan Motor and Drive Data — Horizontal Supply/Return

48PG

LOW RANGE

Motor Hp ———— 5 5 Motor Nominal Rpm — — — — 1750 1750 Maximum Continuous Bhp ————5.755.75 Maximum Continuous Watts — — — — 4290 4290 Motor Frame Size — — — — S184T S184T Motor Shaft Diameter (in.) ————1 Fan Rpm Range — — — — 687-873 687-873 Motor Pulley Min. Pitch Diameter (in.) ————3.73.7 Motor Pulley Max. Pitch Diameter (in.) ————4.74.7 Blower Pulley Pitch Diameter (in.) ————9.49.4 Blower Pulley Shaft Diameter (in.) ————1 Blower Pulley Type ————FixedFixed Pulley Center Line Distance (in.) — — — — 9.81-13.055 9.81-13.055 Belt, Quantity...Type...Length (in.) — — — — 1...BX41...42.8 1...BX41...42.8 Speed Change Per Turn —

Moveable Pulley (rpm) Moveable Pulley Maximum Full Turns ———— 6 6 Factory Speed Setting (rpm) ————780780

MID-LOW RANGE

Motor Hp 3.753.75 5 5 Motor Nominal Rpm 1750 1750 1750 1750 1750 1750 Maximum Continuous Bhp 4.26 5.75 4.26 5.75 5.75 5.75 Maximum Continuous Watts 3174 4290 3174 4290 4290 4290 Motor Frame Size 56HZ S184T 56HZ S184T S184T S184T Motor Shaft Diameter (in.) Fan Rpm Range 896-1227 873-1108 896-1227 873-1108 805-1007 805-1007 Motor Pulley Min. Pitch Diameter (in.) 2.7 3.7 2.7 3.7 4.8 4.8 Motor Pulley Max. Pitch Diameter (in.) 3.7 4.7 3.7 4.7 6.0 6.0 Blower Pulley Pitch Diameter (in.) 5.2 7.4 5.2 7.4 10.4 10.4 Blower Pulley Shaft Diameter (in.) 1 Blower Pulley Type Fixed Fixed Fixed Fixed Fixed Fixed Pulley Center Line Distance (in.) 11.293-13.544 9.81-13.055 11.293-13.544 9.81-13.055 9.81-13.055 9.81-13.055 Belt, Quantity...Type...Length (in.) 1...BX35...36.8 1...BX38...39.8 1...BX35...36.8 1...BX38...39.8 1...BX45...46.8 1...BX45...46.8 Speed Change Per Turn —

Moveable Pulley (rpm) Moveable Pulley Maximum Full Turns 666666 Factory Speed Setting (rpm) 1062 991 1062 991 906 906

MID-HIGH RANGE

Motor Hp 55557.57.5 Motor Nominal Rpm 1750 1750 1750 1750 1750 1750 Maximum Continuous Bhp 5.75 5.75 5.75 5.75 8.63 8.63 Maximum Continuous Watts 4290 4290 4290 4290 6434 6434 Motor Frame Size S184T S184T S184T S184T S213T S213T Motor Shaft Diameter (in.) 1 Fan Rpm Range 1113-1414 1113-1414 1113-1414 1113-1414 941-1176 941-1176 Motor Pulley Min. Pitch Diameter (in.) 3.7 3.7 3.7 3.7 4.8 4.8 Motor Pulley Max. Pitch Diameter (in.) 4.7 4.7 4.7 4.7 6.0 6.0 Blower Pulley Pitch Diameter (in.) 5.8 5.8 5.8 5.8 8.9 8.9 Blower Pulley Shaft Diameter (in.) 1 Blower Pulley Type Fixed Fixed Fixed Fixed Fixed Fixed Pulley Center Line Distance (in.) 9.81-13.055 9.81-13.055 9.81-13.055 9.81-13.055 9.025-12.179 9.025-12.179 Belt, Quantity...Type...Length (in.) 1...BX35...36.8 1...BX35...36.8 1...BX35...36.8 1...BX35...36.8 1...BX42...43.8 1...BX42...43.8 Speed Change Per Turn —

Moveable Pulley (rpm) Moveable Pulley Maximum Full Turns 666666 Factory Speed Setting (rpm) 1264 1264 1264 1264 1059 1059

HIGH RANGE

Motor Hp 7.5 7.5 7.5 7.5 10 10 Motor Nominal Rpm 1750 1750 1750 1750 1750 1750 Maximum Continuous Bhp 8.63 8.63 8.63 8.63 11.50 11.50 Maximum Continuous Watts 6434 6434 6434 6434 8579 8579 Motor Frame Size S213T S213T S213T S213T S215T S215T Motor Shaft Diameter (in.) 1 Fan Rpm Range 1096-1339 1096-1339 1096-1339 1096-1339 1014-1297 1014-1297 Motor Pulley Min. Pitch Diameter (in.) 5.4 5.4 5.4 5.4 4.3 4.3 Motor Pulley Max. Pitch Diameter (in.) 6.6 6.6 6.6 6.6 5.5 5.5 Blower Pulley Pitch Diameter (in.) 8.6 8.6 8.6 8.6 7.4 7.4 Blower Pulley Shaft Diameter (in.) 1 Blower Pulley Type Fixed Fixed Fixed Fixed Fixed Fixed Pulley Center Line Distance (in.) 9.025-12.179 9.025-12.179 9.025-12.179 9.025-12.179 9.025-12.179 9.025-12.179 Belt, Quantity...Type...Length (in.) 1...BX42...43.8 1...BX42...43.8 1...BX42...43.8 1...BX42...43.8 1...BX38...39.8 1...BX38...39.8 Speed Change Per Turn —

Moveable Pulley (rpm) Moveable Pulley Maximum Full Turns 666666 Factory Speed Setting (rpm) 1218 1218 1218 1218 1156 1156

208/230 and 460 575 208/230 and 460 575 208/230 and 460 575

20 24 28

13/

11/

————3131

11/

13/

11/

13/

11/

13/

11/

55 39 55 39 34 34

11/

13/

11/

13/

11/

13/

50 50 50 50 39 39

13/

41 41 41 41 47 47

Page 9

(IN BASE RAIL)

EDGE FLANGE

ALIGNMENT HOLES FOR

CURB-BOTH

SIDES

ALIGNMENT

HOLE

ALIGNMENT

HOLE SHOULD

LINE UP WITH

ROOF CURB

EDGE FLANGE

Fig. 5 — Alignment Hole Details

RETURN

OPENING

CURB RETURN OPENING

ROOF CURB

SUPPLY

OPENING

CURB SUPPLY OPENING

Fig. 6 — Alignment Hole Location

For vertical supply and return units, tools or parts could drop into ductwork and cause an injury. 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.

HORIZONTAL APPLICATIONS — Horizontal units are shipped with outer panels that allow for side by side horizontal duct connections. If specified during ordering, the unit will be shipped with the vertical duct openings blocked off from the factory, ready for side supply installation. If the horizontal supply/return option was not specified at time of ordering the unit, a field-installed accessory kit is required to convert the vertical unit into a horizontal supply configuration.

Installation of the duct block-off covers should be completed prior to placing the unit unless sufficient side clearance is available. A minimum of 66 in. is required between the unit and any obstruction to install the duct block-off covers. Side supply duct dimensions and locations are shown on Fig. 4. Install ductwork to horizontal duct flange connections on side of unit.

ECONOMIZER

Step 4 — Field Fabricate Ductwork — On vertical

units, secure all ducts to roof curb and building structure. Do not connect ductwork to unit. For horizontal applications, field-

supplied flanges should be attached to horizontal discharge openings and all ductwork secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes.

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 ducted through the roof deck to comply with applicable fire codes.

A minimum clearance is not required around ductwork. Cabinet return-air static shall not exceed –0.35 in. wg with economizer or 0.45 in. wg without economizer.

These units are designed for a minimum continuous returnair temperature in heating of 50 F (dry bulb), or an intermittent operation down to 45 F (dry bulb), such as when used with a night set-back thermostat.

To operate at lower return-air temperatures, a field-supplied outdoor-air temperature control must be used to initiate both stages of heat when the temperature is below 45 F. Indoor comfort may be compromised when these lower air temperatures are used with insufficient heating temperature rise.

Step 5 — Make Unit Duct Connections

VERTICAL CONFIGURATION — Unit is shipped for vertical supply and return duct connections. Ductwork openings are shown in Fig. 1 and 4. Duct connections for vertical configuration are shown in Fig. 7. Field-fabricated concentric ductwork may be connected as shown in Fig. 8 and 9. The unit is designed to attach the ductwork to the roof curb. Do not attach duct directly to the unit.

SEE NOTE

AIR

NOTE: Do not drill in this area; damage to basepan may result in water leak.

SEE NOTE

HEAT EXCHANGER

AIR

OUT

Fig. 7 — Air Distribution — Vertical Supply/Return

ECONOMIZER

HEAT

AIR OUT

SEE NOTE

EXCHANGER

SEE NOTE

AIR OUT

NOTE: Do not drill in this area; damage to basepan may result in water leak.

AIR IN

Fig. 8 — Air Distribution — Concentric Duct

Page 10

NOTE: Dimensions A, A′,B,andB′ are obtained from field-supplied ceiling diffuser.

Shaded areas indicate block-off pans.

Fig. 9 — Concentric Duct Details

Step 6 — Install Flue Hood and Inlet Hood —

Flue hood (smaller hood), inlet hood (larger hood), and screens are shipped inside the unit in the fan section. To install, remove the heat panel. The flue hood is attached to the heat section panel from the outside using the screws provided. See Fig. 10.

The inlet hood is installed by inserting the hood through the back of the heat panel. Attach the hood by inserting the screws provided through the clearance holes in the heat panel and into the intake hood.

Install the screens into both hoods using the screws and retaining nuts provided with the unit.

Attach the cover of the observation hole on the intake hood and then replace the heat panel onto the unit to complete the installation.

NOTE: When properly installed, the flue hood will line up with the combustion fan housing. See Fig. 11.

Step 7 — Trap Condensate Drain — See Fig. 12

for drain location. One3/4-in. half coupling is provided outside unit evaporator section for condensate drain connection. A trap at least 4-in. deep must be used. See Fig. 13.

All units must have an external trap for condensate drainage. Install a trap at least 4 in. deep and protect against freezeup. If drain line is installed downstream from the external trap, pitch the line away from the unit at 1 in. per 10 ft of run. Do not use a pipe size smaller than the unit connection.

Step 8 — Install Gas Piping — Unit is equipped for

use with natural gas. Refer to local building codes, or in the absence of local codes, to ANSI Z223.1-latest year and addendum Z223.1A-latest year entitled NFGC. In Canada, installation must be in accordance with the CAN1.B149.1 and CAN1.B149.2 installation codes for gas burning appliances.

Support gas piping. For example, a have one field-fabricated support beam every 8 ft. Therefore, an 18-ft long gas pipe would have a minimum of 3 support beams.

Install field-supplied manual gas shutoff valve with a NPT pressure tap for test gage connection at unit. The pressure tap is located on the gas manifold, adjacent to the gas valve. Field gas piping must include sediment trap and union. See Fig. 14.

/4-in. gas pipe must

/8-in.

FLUE HOOD

INLET HOOD

Fig. 10 — Flue and Inlet Hood Locations

COMBUSTION FAN HOUSING

HEAT EXCHANGER SECTION

INDUCED-DRAFT MOTOR

MAIN BURNER SECTION

Fig. 11 — Combustion Fan Housing Location

Page 11

Do not pressure test gas supply while connected to unit. Always disconnect union before servicing.

IMPORTANT: Natural gas pressure at unit gas connection must not be less than 5.5 in. wg or greater than 13.0 in. wg.

Size gas-supply piping for 0.5-in. wg maximum pressure

drop. Do not use supply pipe smaller than unit gas connection.

Fig. 12 — Condensate Drain Details

Step 9 — Make Electrical Connections

FIELD POWER SUPPLY — Unit is factory wired for voltage shown on unit nameplate. Be sure to check for correct voltage.

When installing units, provide disconnect per NEC (National Electrical Code) of adequate size (MOCP [Maximum Overcurrent protection] of unit is on the informative plate). See Tables 4A and 4B. All field wiring must comply with NEC and local codes. Size wire based on MCA (Minimum Circuit Amps) on the unit informative plate. See Fig. 15 for power wiring connection to the unit power terminal block and equipment ground.

Route power and ground lines through control box end panel or unit basepan (see Fig. 4) to connections as shown on unit wiring diagram and Fig. 15.

The correct power phasing is critical to the operation of the scroll compressors. An incorrect phasing will result in compressor shutdown on thermal overload and possible damage to compressor. Should this occur, power phase correction must be made to the incoming power.

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 electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with NEC, ANSI/NFPA (American National Standards Institute/National Fire Protection Association), latest edition, and local electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning could result in the installer being liable for personal injury of others.

NOTE: Trap should be deep enough to offset maximum unit static difference. A 4-in. trap is recommended.

Fig. 13 — Condensate Drain Piping Details

Field wiring must conform to temperature limitations for type “T” wire. All field wiring must comply with NEC and local requirements.

Operating voltage to compressor must be within voltage range indicated on unit nameplate. On 3-phase units, voltages between phases must be balanced within 2%.

Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components.

FIELD CONTROL WIRING — Unit can be controlled with either a Carrier-approved accessory thermostat. Install thermostat according to the installation instructions included with accessory. Locate thermostat assembly on a solid interior wall in the conditioned space to sense average temperature.

Route thermostat cable or equivalent single leads of colored wire from subbase terminals through conduit into unit to lowvoltage connections as shown on unit label wiring diagram and in Fig. 16.

NOTE: For wire runs up to 50 ft, use no. 18 AWG (American Wire Gage) insulated wire (35 C minimum). For 50 to 75 ft, use no. 16 AWG insulated wire (35 C minimum). For over 75 ft, use no. 14 AWG insulated wire (35 C Minimum). All wire larger than no. 18 AWG cannot be directly connected at the thermostat and will require a junction box and splice at the thermostat.

Fig. 14 — Field Gas Piping

Page 12

LEGEND

EQUIP — Equipment GND — Ground NEC — National Electrical Code TB — Terminal Board

NOTE: The maximum wire size for TB1 is 2/0.

Fig. 15 — Field Power Wiring Connections

THERMOSTAT ASSEMBLY

REMOVABLE JUMPER

TB2J11

Y1 Y2

W1 W2 G C

W1 W2 G C X

Fig. 16 — Field Control Thermostat Wiring

Set heat anticipator settings as follows:

VO LTAGE

All 0.98 0.44

STAGE 1

(W1) ON

STAGE 1 AND 2

(W1 AND W2) ON

Settings may be changed slightly to provide a greater degree

of comfort for a particular installation.

Step 10 — Install Outdoor Air Hood — Per-

form the following procedure to install the outdoor-air hood on units equipped with an economizer, two-position damper, or manual outdoor air damper:

1. Remove blank panel from return end of unit (hood section). Save the screws. See Fig. 17 for shipping location of components.

2. Hood sides are fastened to sides of outdoor air opening. Remove the hood sides and save the screws (3 each side).

3. Remove the bracket holding the bottom half of the hood in the shipping position. Remove the hood bottom half and filters (or manual dampers on units so equipped) from outdoor section.

NOTE: On units without economizers, the components are attached to the unit basepan. To access the components, remove the panel below the outdoor air intake section.

4. Remove inner filter track from shipping position in outdoor section. Position inner filter track so the track is

facing outward from the unit. Install the filter track with 4 screws provided.

5. Apply seal strip (provided) to back flange of both hood sides where hood side connects to the unit back panel. See Fig. 18.

6. Apply seal strip (provided) to top flange of both hood sides where hood sides connect to the hood top panels. See Fig. 18.

7. Install hood sides to the back panels using the screws from Step 2. The sloped flanges point outward. The drip edges of the side panels should face outward as well. The filter guides to the hood sides. The flanges of the filter guides should face inward to hold the filters in place. See Fig. 18.

8. Apply seal strip along the entire length of the bottom flange of the hood top. See Fig. 18.

9. Install the bottom part of the hood top using 4 screws provided. See Fig. 18.

10. Remove the packaging from filters (3) and install into the filter tracks. Slide the filters to the sides then place the last filter into the center of the filter track.

NOTE: For units with manual dampers, replace the end filters with the manual dampers. Install the filter in the center between the manual dampers.

11. Install the filter retainer track along the bottom edge of the outdoor air hood using 4 screws provided. See Fig. 18.

12. Install top section of the outdoor air hood using 9 screws provided. See Fig. 18. See Fig. 19 for a picture of the assembled outdoor air hood.

NOTE: For filter removal, remove the four screws holding the filter retainer. The filters can then be removed, cleaned, or replaced. Install the filters by reversing the procedure.

MANUAL DAMPER ASSEMBLY — For units equipped with manual dampers, the assembly process is similar to the outdoor air hood for units with economizers. There are two slide dampers shipped with the unit to allow for manual setting of the outside air volume. When assembling the hood, place one of the manual slide dampers in each of the end positions and the remaining filter in the center position. The manual dampers can then be moved to the appropriate position and then locked into place using the screws mounted in the adjustment slots. See Fig. 20.

HOOD TOP (TOP HALF)

HOOD SIDE

RETURN AIR SECTION

HOOD SIDE

HOOD TOP (BOTTOM HALF)

Fig. 17 — Outdoor-Air Hood Component

Shipping Location

Page 13

Table 4A — Electrical Data (Units Without Optional Powered Convenience Outlet)

UNIT

NOMINAL

SIZE

VO LTAGE

48HG

(3 Ph, 60 Hz)

208/230 187 253 28.2 208 28.2 208 — — 4 0.25 1.5

208/230 187 253 32.1 240 32.1 240 — — 6 0.25 1.5

208/230 187 253 28.2 208 28.2 208 28.2 208 6 0.25 1.5

See Legend and Notes on page 15.

VO LTAGE

RANGE

Min Max RLA LRA RLA LRA RLA LRA Qty Hp

460 414 506 15.4 104 15.4 104 — — 4 0.25 0.7

575 518 633 12.8 83 12.8 83 — — 4 0.25 0.7

460 414 506 15.4 110 15.4 110 — — 6 0.25 0.7

575 518 633 12.8 88 12.8 88 — — 6 0.25 0.7

460 414 506 15.4 104 15.4 104 15.4 104 6 0.25 0.7

575 518 633 12.8 83 12.8 83 12.8 83 6 0.25 0.7

COMPRESSOR

No. 1 No. 2 No. 3

OFM IFM

FLA

Hp FLA Qty Hp

(ea)

3.7 10.6/ 9.6

5 16.7/15.2

7.5 24.2/22

10 30.8/28

3.7 4.8

57.6

7.5 11

10 14

56.1

7.5 9

10 11

3.7 10.6/ 9.6

5 16.7/15.2

7.5 24.2/22

10 30.8/28

3.7 4.8

57.6

7.5 11

10 14

56.1

7.5 9

10 11

5 16.7/15.2

7.5 24.2/22

10 30.8/28

57.6

7.5 11

10 14

56.1

7.5 9

10 11

POWER

EXHAUST

—— —

2 1 5.9 92/ 91 100/100 92/ 92 100/100 98/ 96

— — — 86/ 85 100/100 86/ 86 100/100 91/ 89

2 1 5.9 98/ 96 100/100 98/ 98 100/100 105/103

— — — 94/ 91 100/100 94/ 94 100/100 100/ 97

2 1 5.9 105/103 125/125 105/105 125/125 113/111

— — — 101/ 97 125/100 101/101 125/125 107/104

2 1 5.9 113/109 125/125 113/113 125/125 121/118

—— —

213.1 48 60 48 60 51

—— — 45 60 45 60 47

213.1 51 60 51 60 55

—— — 48 60 48 60 51

213.1 55 60 55 60 58

—— — 51 60 51 60 55

213.1 58 60 58 60 62

—— —

212.4 43 50 43 50 45

—— — 41 50 41 50 43

212.4 45 50 45 50 49

—— — 43 50 43 50 45

212.4 47 60 47 60 51

—— —

2 1 5.9 104/103 125/125 104/104 125/125 110/109

— — — 98/ 96 100/100 98/ 98 100/100 103/102

2 1 5.9 110/108 125/125 110/110 125/125 117/115

— — — 105/103 125/125 105/105 125/125 112/109

2 1 5.9 117/115 125/125 117/117 125/125 126/123

— — — 112/109 125/125 112/112 125/125 120/116

2 1 5.9 124/121 150/150 124/124 150/150 133/130

—— —

213.1 50 60 50 60 53

—— — 46 60 46 60 49

213.1 53 60 53 60 56

—— — 50 60 50 60 53

213.1 56 60 56 60 60

—— — 53 60 53 60 56

213.1 59 60 59 60 63

—— —

212.4 44 50 44 50 47

—— — 42 50 42 50 45

212.4 47 50 47 50 50

—— — 44 50 44 50 47

212.4 49 60 49 60 52

—— —

2 1 5.9 129/128 150/150 129/129 150/150 140/139

— — — 125/123 150/150 125/125 150/150 135/133

2 1 5.9 137/134 150/150 137/137 150/150 149/147

— — — 132/129 150/150 132/132 150/150 143/140

2 1 5.9 144/140 150/150 144/144 150/150 157/153

—— —

213.1 68 80 68 80 74

—— — 65 80 65 80 71

213.1 71 80 71 80 78

—— — 68 80 68 80 74

213.1 74 80 74 80 81

—— —

212.4 57 60 57 60 62

—— — 55 60 55 60 59

212.4 60 60 60 60 65

—— — 57 60 57 60 62

212.4 62 70 62 70 67

FLA (ea)

COMBUSTION

FAN MO TOR

FLA MCA MOCP MCA MOCP FLA

0.5

0.3

0.24

0.5

0.3

0.24

0.5

0.3

0.24

POWER

SUPPLY*

80/ 79 100/100 80/ 80 100/100 84/ 83

42 50 42 50 44

38 50 38 50 40

92/ 91 100/100 92/ 92 100/100 96/ 95

44 50 44 50 46

39 50 39 50 41

117/116 125/125 117/117 125/125 127/125

62 70 62 70 67

52 60 52 60 56

POWER SUPPLY

UNITS WITH

OPTIONAL HACR

BREAKER

DISCONNECT

SIZE

Page 14

Table 4B — Electrical Data (Units With Optional Powered Convenience Outlet)

UNIT

NOMINAL

SIZE

VO LTAGE

48HG

(3 Ph, 60 Hz)

208/230 187 253 28.2 208 28.2 208 — — 4 0.25 1.5

208/230 187 253 32.1 240 32.1 240 — — 6 0.25 1.5

208/230 187 253 28.2 208 28.2 208 28.2 208 6 0.25 1.5

VO LTAGE

RANGE

Min Max RLA LRA RLA LRA RLA LRA Qty Hp

460 414 506 15.4 104 15.4 104 — — 4 0.25 0.7

575 518 633 12.8 83 12.8 83 — — 4 0.25 0.7

460 414 506 15.4 110 15.4 110 — — 6 0.25 0.7

575 518 633 12.8 88 12.8 88 — — 6 0.25 0.7

460 414 506 15.4 104 15.4 104 15.4 104 6 0.25 0.7

575 518 633 12.8 83 12.8 83 12.8 83 6 0.25 0.7

COMPRESSOR

No. 1 No. 2 No. 3

OFM IFM

FLA

Hp FLA Qty Hp

(ea)

3.7 10.6/ 9.6

5 16.7/15.2

7.5 24.2 /22

10 30.8/28

3.7 4.8

57.6

7.5 11

10 14

56.1

7.5 9

10 11

3.7 10.6/ 9.6

5 16.7/15.2

7.5 24.2 /22

10 30.8/28

3.7 4.8

57.6

7.5 11

10 14

56.1

7.5 9

10 11

5 16.7/15.2

7.5 24.2 /22

10 30.8/28

57.6

7.5 11

10 14

56.1

7.5 9

10 11

POWER

EXHAUST

—— —

2 1 5.9 97/ 96 100/100 97/ 97 100/100 103/102

— — — 91/ 90 100/100 91/ 91 100/100 97/ 95

2 1 5.9 103/101 125/125 103/103 125/125 110/109

— — — 99/ 96 100/100 99/ 99 100/100 105/103

2 1 5.9 110/108 125/125 110/110 125/125 119/116

— — — 106/102 125/125 106/106 125/125 113/110

2 1 5.9 118/114 125/125 118/118 125/125 127/123

—— —

213.1 51 60 51 60 55

—— — 48 60 48 60 51

213.1 54 60 54 60 58

—— — 51 60 51 60 55

213.1 58 60 58 60 62

—— — 54 60 54 60 58

213.1 61 70 61 70 65

—— —

212.4 46 50 46 50 49

—— — 44 50 44 50 46

212.4 48 60 48 60 52

—— — 46 50 46 50 49

212.4 50 60 50 60 54

—— —

2 1 5.9 109/108 125/125 109/109 125/125 116/115

— — — 103/101 125/125 103/103 125/125 109/107

2 1 5.9 115/113 125/125 115/115 125/125 123/121

— — — 110/108 125/125 110/110 125/125 118/115

2 1 5.9 122/120 150/150 122/122 150/150 131/129

— — — 117/114 125/125 117/117 125/125 125/122

2 1 5.9 129/126 150/150 129/129 150/150 139/136

—— —

213.1 53 60 53 60 56

—— — 49 60 49 60 52

213.1 56 60 56 60 60

—— — 53 60 53 60 56

213.1 59 60 59 60 63

—— — 56 60 56 60 60

213.1 62 70 62 70 67

—— —

212.4 47 50 47 50 50

—— — 45 50 45 50 48

212.4 50 60 50 60 54

—— — 47 50 47 50 50

212.4 52 60 52 60 56

—— —

2 1 5.9 134/133 150/150 134/134 150/150 146/144

— — — 130/128 150/150 130/130 150/150 141/139

2 1 5.9 142/139 150/150 142/142 150/150 155/152

— — — 137/134 150/150 137/137 150/150 149/146

2 1 5.9 149/145 175/150 149/149 175/175 162/159

—— —

213.1 71 80 71 80 77

—— — 68 80 68 80 74

213.1 74 80 74 80 81

—— — 71 80 71 80 78

213.1 77 90 77 90 85

—— —

212.4 60 60 60 60 65

—— — 58 60 58 60 63

212.4 63 70 63 70 68

—— — 60 60 60 60 65

212.4 65 70 65 70 71

FLA (ea)

COMBUSTION

FAN M OTO R

FLA MCA MOCP MCA MOCP FLA

0.5

0.3

0.24

0.5

0.3

0.24

0.5

0.3

0.24

POWER

SUPPLY*

85/ 84 100/100 85/ 85 100/100 90/ 89

45 60 45 60 48

41 50 41 50 43

97/ 96 100/100 97/ 97 100/100 102/101

47 60 47 60 49

42 50 42 50 45

122/121 150/125 122/122 150/150 133/131

65 80 65 80 70

55 60 55 60 59

POWER SUPPLY

UNITS WITH

OPTIONAL HACR

BREAKER

DISCONNECT

SIZE

Page 15

LEGEND AND NOTES FOR TABLES 4A AND 4B

LEGEND

FLA — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration IFM — Indoor (Evaporator) Fan Motor LRA — Locked Rotor Amps MCA — Minimum Circuit Amps MOCP — Maximum Overcurrent Protection NEC — National Electrical Code OFM — Outdoor (Condenser) Fan Motor RLA — Rated Load Amps

*Fuse or HACR circuit breaker.

NOTES:

1. In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker. Canadian units may be fuse or circuit breaker.

2. Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply voltage is greater than 2%.

the percent voltage imbalance.

% Voltage Imbalance

= 100 x

max voltage deviation from average voltage

Use the following formula to determine

average voltage

EXAMPLE: Supply voltage is 460-3-60.

AB = 452 v BC = 464 v AC = 455 v

Average Voltage=

452 + 464 + 455

1371

= 457

Determine maximum deviation from average voltage.

(AB) 457 - 452 = 5v (BC) 464 - 457 = 7v

(AC) 457 - 455 = 2v Maximum deviation is 7 v. Determine percent voltage imbalance.

% Voltage Imbalance = 100 x

= 1.53%

457

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

IMPORTANT: If the supply voltage phase imbalance is more

than 2%, contact the local electric utility company immediately.

3. The convenience outlet full load amps (FLA) are 5, 3, and 3 for 208/230, 460, 575-V units, respectively.

TOP HOOD SECTION

SEAL STRIP LOCATION

BOTTOM HOOD SECTION

FILTER RETAINER

MANUAL DAMPER (IF EQUIPPED)

NOTE: Units with manual damper only use one filter.

Fig. 18 — Outdoor-Air Hood Details

FILTER GUIDE

HOOD SIDE

FILTER

ADD SEAL STRIP

INNER FILTER TRACK

FILTER GUIDE

HOOD SIDE

ADD SEAL STRIP

UNIT BACK PANEL

ADD SEAL STRIP

Page 16

Fig. 19 — Outdoor-Air Hood Assembled

LOCKING SCREW

MOVEABLE DAMPER

AIR FILTER POSITION

MOVEABLE DAMPER

Fig. 20 — Manual Damper Details

Step 11 — Position Optional Power Exhaust or Barometric Relief Damper Hood —

power exhaust or barometric relief dampers are shipped assembled and tilted back into the unit for shipping. Brackets and extra screws are shipped in shrink wrap around the dampers.

1. Remove 9 screws holding each damper assembly in place. See Fig. 21. Each damper assembly is secured with 3 screws on each side and 3 screws along the bottom. Save screws.

The optional

2. Pivot the damper assembly outward until top edge of the damper assembly rests against the inside wall of unit.

3. Secure each damper assembly to unit with 6 screws across top (3 screws provided) and bottom (3 screws from Step 1) of damper.

4. With screws saved from Step 1, install brackets on each side of damper assembly. See Fig. 22.

5. Remove tape from damper blades.

Step 12 — Non-Fused Disconnect — The handle

for the factory-installed non-fused disconnect is shipped inside the unit to prevent the handle from damage during shipping. Follow these steps to complete installation of the handle.

BESUREPOWERISSHUTOFFTOTHEUNITFROM THE BUILDING POWER SUPPLY. Electrical shock could cause personal injury.

1. Open the control box access door.

2. Remove the small cover plate located on the unit corner post near the control section.

3. Remove the inner control box cover. The handle and shaft are located in a plastic bag at the bottom of the control box.

4. Insert the square shaft into the disconnect with the pins vertical. On the 100-amp disconnect, the shaft is keyed into the disconnect and can only be installed one way (with the pins vertical).

5. Insert the handle through the corner post and onto the shaft with the handle positioned so that “OFF” is on top.

6. Rotate the handle to the “ON” position to lock the pins into the handle.

7. From the inside of the corner post, attach the handle mounting screws to the handle. Slide the shaft fully into the handle and tighten the set screw(s) on the disconnect to lock the shaft. Tighten the screws that attach the handle to the corner post.

8. Rotate the handle back to the “OFF” position.

9. Replace all panels and doors. Power can now be turned back on to the unit.

Step 13 — Install All Accessories — After all of

the factory-installed options have been adjusted, install all field-installed accessories. Refer to the accessory installation instructions included with each accessory. Consult the Carrier Price Pages for accessory package numbers for particular applications.

Be careful when tilting blower assembly. Hoods and blowers are heavy and can cause injury if dropped.

Page 17

Fig. 21 — Power Exhaust or Barometric Relief Damper Mounting Details

Fig. 22 — Bracket and Hood Positioning

Page 18

PRE-START-UP

Failure to observe the following warnings could result in serious personal injury.

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

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

3. Do not remove the compressor terminal cover until all electrical sources are disconnected.

4. Relieve all pressure from the system before touching or disturbing anything inside the compressor terminal box if refrigerant leak is suspected around the compressor terminals.

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

6. Do not use torch to remove any component. The system contains oil and refrigerant under pressure. To remove a component, wear protective goggles and proceed as follows: a. Shut off gas and then electrical power to the unit.

Install lockout tag.

b. Relieve all pressure from the system using both

high-pressure and low-pressure ports.

c. Cut the component connection tubing with a tubing

cutter, and remove the component from the unit.

d. Carefully unsweat the remaining tubing stubs when

necessary. Oil can ignite when exposed to torch flame.

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 WARNING, CAU-

TION, and INFORMATION labels attached to, or shipped with, the unit.

3. Make the following inspections:

a. Inspect for shipping and handling damages such as

broken lines, loose parts, or disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections

and on unit base. Detecting oil generally indicates a refrigerant leak. Leak-test all refrigerant tubing connections using an electronic leak detector, halide torch, or liquid-soap solution.

c. Inspect all field-wiring and factory-wiring connec-

tions. Be sure that connections are completed and tight.

d. Inspect coil fins. If damaged during shipping and

handling, carefully straighten the fins with a fin comb.

4. Verify the following conditions:

a. Make sure that condenser fan blade is correctly

positioned in the fan orifice. See Condenser-Fan

Adjustment section on page 49 for more details. b. Make sure that air filter(s) is in place. c. Make sure that condensate drain trap is filled with

water to ensure proper drainage. d. Make sure that all tools and miscellaneous loose parts

have been removed.

START-UP

Use the following information and Start-Up Checklist on

page CL-1 to check out unit PRIOR to start-up.

Unit Preparation — Check that unit has been installed in

accordance with these installation instructions and all applicable codes.

Compressor Mounting — Compressors are internally

spring mounted. Do not loosen or remove compressor holddown bolts.

Refrigerant Service Ports — Each independent re-

frigerant system has a total of 3 Schrader-type service gage ports per circuit. One port is located on the suction line, one on the compressor discharge line, and one on the liquid line. Be sure that caps on the ports are tight.

Crankcase Heater(s) — Crankcase heaters are ener-

gized as long as there is power to the unit and the compressor is not operating.

IMPORTANT: Unit power must be on for 24 hours prior to start-up. Otherwise, damage to compressor may result.

Compressor Rotation — On 3-phase units, it is impor-

tant to be certain the scroll compressor is rotating in the proper direction. To determine whether or not compressor is rotating in the proper direction:

1. Connect service gages to suction and discharge pressure fittings.

2. Energize the compressor.

3. The suction pressure should drop and the discharge pressure should rise, as is normal on any start-up.

If the suction pressure does not drop and the discharge pres-

sure does not rise to normal levels:

1. Note that the evaporator fan is probably also rotating in the wrong direction.

2. Turn off power to the unit and install lockout tag.

3. Reverse any two of the unit power leads.

4. Turn on power to the unit.

The suction and discharge pressure levels should now move

to their normal start-up levels. NOTE: When the compressor is rotating in the wrong direc-

tion, the unit makes an elevated level of noise and does not provide heating or cooling.

Compressor damage will occur if rotation is not immediately corrected.

Internal Wiring — Check all electrical connections in

unit control boxes; tighten as required.

Subcooler Heat Exchanger (SHX) — The subcool-

er heat exchanger adds approximately 10 to 15° F of subcooling to the system. Check all valves and TXV (thermostatic expansion valve).

Evaporator Fan — Fan belt and variable pulleys are

factory-installed. See Tables 5-23 for fan performance data. Be sure that fans rotate in the proper direction. See Table 24 for air quantity limits. See Table 25 for evaporator fan motor specifications. See Table 26 for accessory/FIOP static pressure. See Table 27 for fan rpm at various motor pulley settings. To alter fan performance, see Evaporator Fan Performance Adjustment sectiononpage48.

Page 19

Condenser Fans and Motors — Condenser fans and

motors are factory set. Refer to Condenser-Fan Adjustment section (page 49) as required.

Return-Air Filters — Check that correct filters are in-

stalled in filter tracks (see Table 1). Do not operate unit without return-air filters.

NOTE: For units with 4-in. filter option, units are shipped with standard 2-in. filters. To install 4-in. filters, the filter spacers must be removed.

Outdoor-Air Inlet Screens — Outdoor-air inlet screens

must be in place before operating unit.

Gas Heat — Verify gas pressures before turning on heat as

follows:

1. Turn off field-supplied manual gas stop, located external to unit.

2. Connect pressure gage to supply gas tap, located on fieldsupplied manual shutoff valve (see Fig. 14).

Table 5 — Fan Performance — 48PGD20 Vertical Supply/Return Units

3. Connect pressure gage to manifold pressure tap.

4. Turn on field-supplied manual gas stop. Temporarily install the jumper wire between “R” and “W1” on TB2. Set thermostat to HEAT and raise set point until heat comes on.

5. After the unit has run for several minutes, verify the supply gas pressure is between 5.5 in. wg to 13.0 in. wg, and the manifold pressure is 2.95 in. wg on horizontal discharge applications and 3.00 on vertical discharge applications. If manifold pressure must be adjusted, refer to Gas Valve Adjustment section.

NOTE: Supply gas pressure must not exceed 13.0 in. wg.

6. Set thermostat to OFF.

7. Remove jumper wire if the unit will be operating under thermostat mode.

8. Return thermostat to desired set point.

AIRFLOW

(Cfm)

5000 590 1.47 663 1.74 727 2.01 786 2.26 840 2.52 5500 633 1.82 703 2.11 764 2.40 820 2.67 872 2.94 6000 677 2.21 744 2.53 803 2.84 857 3.13 907 3.42 6500 722 2.67 786 3.01 842 3.33 894 3.64 942 3.95 7000 767 3.17 828 3.53 883 3.88 933 4.21 979 4.53 7500 813 3.74 871 4.12 924 4.48 972 4.83 1017 5.18 8000 859 4.36 915 4.77 966 5.15 1012 5.52 1056 5.88 8500 906 5.05 959 5.47 1008 5.87 1053 6.26 1096 6.64 9000 952 5.81 1004 6.25 1051 6.67 1095 7.07 1136 7.47

AIRFLOW

(Cfm)

5000 891 2.77 940 3.02 987 3.27 1032 3.52 1076 3.77 5500 921 3.21 968 3.48 1014 3.74 1057 4.01 1099 4.27 6000 954 3.70 999 3.99 1042 4.27 1084 4.55 1125 4.83 6500 988 4.25 1032 4.55 1073 4.85 1114 5.14 1153 5.44 7000 1024 4.85 1066 5.17 1106 5.48 1145 5.79 1183 6.10 7500 1060 5.51 1101 5.84 1140 6.17 1178 6.50 1215 6.82 8000 1098 6.23 1138 6.58 1176 6.92 1213 7.26 1249 7.60 8500 1137 7.01 1175 7.38 1212 7.74 1248 8.09 1283 8.45 9000 1176 7.86 1214 8.24 1250 8.61 1285 8.99 1319 9.36

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

(A) Low Range: 685-939 rpm, 4.26 bhp (208/230 and 460-v), 751-954 rpm, 5.75 bhp (575-v) (B) Mid-Low Range: 949-1206 rpm, 5.75 bhp (C) Mid-High Range: 941-1176 r pm, 8.63 bhp (D) High Range: 1014-1297 rpm, 11.50 bhp

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 20

Table 6 — Fan Performance — 48PGE20 — Vertical Supply/Return Units

AIRFLOW

(Cfm)

5000 607 1.53 677 1.80 740 2.06 797 2.31 850 2.57 5500 652 1.90 719 2.19 779 2.47 833 2.74 884 3.01 6000 699 2.32 763 2.63 819 2.93 872 3.22 921 3.50 6500 746 2.79 807 3.12 861 3.44 911 3.75 958 4.05 7000 794 3.33 851 3.68 904 4.02 952 4.34 998 4.66 7500 842 3.93 897 4.30 947 4.65 994 5.00 1038 5.33 8000 891 4.59 943 4.98 991 5.35 1036 5.71 1079 6.07 8500 940 5.32 990 5.72 1036 6.11 1080 6.49 1121 6.87 9000 990 6.12 1037 6.54 1082 6.95 1124 7.35 1163 7.73

AIRFLOW

(Cfm)

5000 900 2.82 949 3.06 995 3.31 1040 3.56 1083 3.81 5500 933 3.27 979 3.54 1023 3.80 1066 4.06 1108 4.33 6000 967 3.79 1011 4.07 1054 4.35 1095 4.62 1135 4.90 6500 1003 4.35 1046 4.65 1087 4.94 1127 5.24 1165 5.53 7000 1041 4.98 1082 5.29 1122 5.60 1160 5.91 1197 6.22 7500 1079 5.67 1119 5.99 1158 6.32 1195 6.64 1231 6.96 8000 1119 6.42 1158 6.76 1195 7.10 1231 7.44 1267 7.78 8500 1160 7.23 1198 7.59 1234 7.95 1269 8.30 1303 8.65 9000 1202 8.12 1238 8.49 1273 8.87 1308 9.23 1341 9.60

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSUSRE (in. wg)

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 21

Table 7 — Fan Performance — 48PGF20 — Vertical Supply/Return Units

AIRFLOW

(Cfm)

AIRFLOW

(Cfm)

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

B C

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 22

Table 8 — Fan Performance — 48PGD24 — Vertical Supply/Return Units

AIRFLOW

(Cfm)

5,500 633 1.82 703 2.11 764 2.40 820 2.67 872 2.94 6,000 677 2.21 744 2.53 803 2.84 857 3.13 907 3.42 6,500 722 2.67 786 3.01 842 3.33 894 3.64 942 3.95 7,000 767 3.17 828 3.53 883 3.88 933 4.21 979 4.53 7,500 813 3.74 871 4.12 924 4.48 972 4.83 1017 5.18 8,000 859 4.36 915 4.77 966 5.15 1012 5.52 1056 5.88 8,500 906 5.05 959 5.47 1008 5.87 1053 6.26 1096 6.64 9,000 952 5.81 1004 6.25 1051 6.67 1095 7.07 1136 7.47 9,500 999 6.63 1049 7.09 1094 7.53 1137 7.95 1177 8.36

10,000 1047 7.53 1094 8.00 1138 8.46 1180 8.90 1219 9.33

AIRFLOW

(Cfm)

5,500 921 3.21 968 3.48 1014 3.74 1057 4.01 1099 4.27 6,000 954 3.70 999 3.99 1042 4.27 1084 4.55 1125 4.83 6,500 988 4.25 1032 4.55 1073 4.85 1114 5.14 1153 5.44 7,000 1024 4.85 1066 5.17 1106 5.48 1145 5.79 1183 6.10 7,500 1060 5.51 1101 5.84 1140 6.17 1178 6.50 1215 6.82 8,000 1098 6.23 1138 6.58 1176 6.92 1213 7.26 1249 7.60 8,500 1137 7.01 1175 7.38 1212 7.74 1248 8.09 1283 8.45 9,000 1176 7.86 1214 8.24 1250 8.61 1285 8.99 1319 9.36 9,500 1216 8.77 1253 9.17 1288 9.56 1322 9.95 1355 10.33

10,000 1256 9.75 1292 10.16 1327 10.57 1360 10.98 1393 11.38

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 23

Table 9 — Fan Performance — 48PGE24 — Vertical Supply/Return Units

AIRFLOW

(Cfm)

5,500 652 1.90 719 2.19 779 2.47 833 2.74 884 3.01 6,000 699 2.32 763 2.63 819 2.93 872 3.22 921 3.50 6,500 746 2.79 807 3.12 861 3.44 911 3.75 958 4.05 7,000 794 3.33 851 3.68 904 4.02 952 4.34 998 4.66 7,500 842 3.93 897 4.30 947 4.65 994 5.00 1038 5.33 8,000 891 4.59 943 4.98 991 5.35 1036 5.71 1079 6.07 8,500 940 5.32 990 5.72 1036 6.11 1080 6.49 1121 6.87 9,000 990 6.12 1037 6.54 1082 6.95 1124 7.35 1163 7.73 9,500 1039 7.00 1085 7.43 1128 7.85 1168 8.27 1207 8.67

10,000 1089 7.95 1133 8.40 1174 8.83 1213 9.26 1251 9.69

AIRFLOW

(Cfm)

5,500 933 3.27 979 3.54 1023 3.80 1066 4.06 1108 4.33 6,000 967 3.79 1011 4.07 1054 4.35 1095 4.62 1135 4.90 6,500 1003 4.35 1046 4.65 1087 4.94 1127 5.24 1165 5.53 7,000 1041 4.98 1082 5.29 1122 5.60 1160 5.91 1197 6.22 7,500 1079 5.67 1119 5.99 1158 6.32 1195 6.64 1231 6.96 8,000 1119 6.42 1158 6.76 1195 7.10 1231 7.44 1267 7.78 8,500 1160 7.23 1198 7.59 1234 7.95 1269 8.30 1303 8.65 9,000 1202 8.12 1238 8.49 1273 8.87 1308 9.23 1341 9.60 9,500 1244 9.07 1279 9.46 1314 9.85 1347 10.24 1379 10.62

10,000 1287 10.10 1321 10.51 1355 10.91 1387 11.31 ——

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 24

Table 10 — Fan Performance — 48PGF24 Vertical Supply/Return Units

AIRFLOW

(Cfm)

10,000 1089 7.95 1133 8.40 1174 8.83 1213 9.26 1251 9.69

AIRFLOW

(Cfm)

10,000 1287 10.10 1321 10.51 1355 10.91 1387 11.31 ——

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 25

Table 11 — Fan Performance — 48PGD28 — Vertical Supply/Return Units

AIRFLOW

(Cfm)

6,500 750 2.28 806 2.62 854 2.93 898 3.25 943 3.59 7,000 797 2.78 853 3.17 899 3.50 941 3.84 982 4.18 7,500 845 3.34 900 3.78 945 4.15 985 4.51 1024 4.87 8,000 892 3.97 948 4.48 991 4.88 1030 5.26 1067 5.64 8,500 939 4.68 995 5.25 1038 5.69 1076 6.10 1112 6.50 9,000 986 5.46 1042 6.10 1085 6.59 1122 7.04 1157 7.46

9,500 1033 6.32 1090 7.04 1132 7.59 1169 8.07 1203 8.52 10,000 1079 7.26 1137 8.07 1180 8.67 1216 9.19 1249 9.68 10,500 1126 8.28 1184 9.20 1227 9.86 1263 10.43 1296 10.95 11,000 1172 9.40 1232 10.42 1274 11.15 1310 11.76 1342 12.33 11,500 1219 10.61 1279 11.74 1322 12.54 1357 13.21 —— 12,000 1265 11.91 1326 13.17 —————— 12,500 1311 13.32 ————————

AIRFLOW

(Cfm)

6,500 988 3.97 1035 4.40 1082 4.87 1130 5.39 1177 5.95

7,000 1024 4.56 1066 4.98 1109 5.43 1153 5.94 1197 6.48

7,500 1063 5.25 1101 5.66 1141 6.10 1181 6.59 1222 7.12

8,000 1104 6.03 1140 6.44 1176 6.88 1213 7.36 1251 7.87

8,500 1146 6.91 1180 7.33 1214 7.77 1249 8.24 1283 8.74

9,000 1190 7.89 1222 8.32 1255 8.77 1287 9.24 1319 9.74

9,500 1235 8.97 1266 9.42 1296 9.88 1327 10.36 1357 10.86 10,000 1280 10.16 1310 10.63 1340 11.10 1369 11.59 1398 12.09 10,500 1326 11.45 1355 11.95 1384 12.44 ———— 11,000 1372 12.86 ———————— 11,500 —————————— 12,000 —————————— 12,500 ——————————

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

(A) Low Range: 687-873 rpm, 5.75 bhp (B) Mid-Low Range: 805-1007 rpm, 5.75 bhp (C) Mid-High Range: 941-1176 r pm, 8.63 bhp (D) High Range: 1014-1297 rpm, 11.50 bhp

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 26

Table 12 — Fan Performance — 48PGE28 — Vertical Supply/Return Units

AIRFLOW

(Cfm)

6,500 775 2.43 825 2.75 871 3.05 915 3.37 959 3.72 7,000 826 2.98 875 3.22 918 3.58 959 3.98 1000 4.34 7,500 878 3.60 925 3.89 966 4.28 1005 4.69 1043 5.05 8,000 929 4.31 975 4.73 1015 5.11 1052 5.48 1088 5.86 8,500 981 5.11 1026 5.56 1064 5.97 1100 6.37 1134 6.76 9,000 1033 6.00 1076 6.49 1114 6.94 1148 7.36 1181 7.77

9,500 1085 6.98 1128 7.53 1164 8.00 1198 8.45 1229 8.89 10,000 1137 8.08 1179 8.66 1214 9.18 1247 9.65 1278 10.12 10,500 1190 9.28 1230 9.91 1265 10.46 1297 10.97 1327 11.47 11,000 1242 10.60 1282 11.28 1316 11.86 1347 12.41 1376 12.93 11,500 1294 12.04 1333 12.76 1367 13.39 ———— 12,000 1347 13.60 ———————— 12,500 ——————————

AIRFLOW

(Cfm)

6,500 1004 4.11 1050 4.55 1098 5.04 1145 5.57 1192 6.14

7,000 1041 4.73 1083 5.15 1126 5.62 1170 6.14 1214 6.70

7,500 1081 5.44 1120 5.86 1159 6.32 1199 6.82 1240 7.36

8,000 1124 6.26 1160 6.68 1196 7.13 1233 7.62 1270 8.15

8,500 1168 7.17 1202 7.60 1235 8.06 1269 8.54 1304 9.05

9,000 1214 8.20 1245 8.64 1277 9.10 1309 9.58 1341 10.09

9,500 1260 9.33 1290 9.79 1320 10.25 1351 10.74 1381 11.25 10,000 1308 10.58 1337 11.05 1365 11.53 1394 12.03 —— 10,500 1356 11.95 1384 12.44 —————— 11,000 —————————— 11,500 —————————— 12,000 —————————— 12,500 ——————————

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

(A) Low Range: 687-873 rpm, 5.75 bhp (B) Mid-Low Range: 805-1007 rpm, 5.75 bhp (C) Mid-High Range: 941-1176 r pm, 8.63 bhp (D) High Range: 1014-1297 rpm, 11.50 bhp

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 27

Table 13 — Fan Performance — 48PGF28 — Vertical Supply/Return Units

AIRFLOW

(Cfm)

AIRFLOW

(Cfm)

6,500 1004 4.11 1050 4.55 1098 5.04 1145 5.57 1192 6.14

7,000 1041 4.73 1083 5.15 1126 5.62 1170 6.14 1214 6.70

7,500 1081 5.44 1120 5.86 1159 6.32 1199 6.82 1240 7.36

8,000 1124 6.26 1160 6.68 1196 7.13 1233 7.62 1270 8.15

8,500 1168 7.17 1202 7.60 1235 8.06 1269 8.54 1304 9.05

9,000 1214 8.20 1245 8.64 1277 9.10 1309 9.58 1341 10.09

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

(A) Low Range: 687-873 rpm, 5.75 bhp (B) Mid-Low Range: 805-1007 rpm, 5.75 bhp (C) Mid-High Range: 941-1176 r pm, 8.63 bhp (D) High Range: 1014-1297 rpm, 11.50 bhp

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 28

Table 14 — Fan Performance — 48PGD20 — Horizontal Supply and Return Units

AIRFLOW

(Cfm)

5000 862 2.65 917 2.93 969 3.21 1019 3.17 1066 3.52 5500 937 3.26 988 3.56 1036 3.53 1083 3.90 1127 4.28 6000 1013 3.58 1060 3.96 1105 4.35 1149 4.75 1191 5.16 6500 1089 4.48 1133 4.89 1175 5.31 1216 5.73 1256 6.17 7000 1166 5.52 1207 5.96 1247 6.41 1285 6.86 1323 7.32 7500 1243 6.71 1282 7.18 1319 7.66 1355 8.14 1391 8.63 8000 1320 8.07 1356 8.57 1392 9.08 ——— — 8500 1398 9.60 ——————— — 9000 ————————— —

AIRFLOW

(Cfm)

5000 1112 3.88 1156 4.25 1199 4.63 1240 5.02 1280 5.42 5500 1171 4.67 1212 5.06 1253 5.47 1292 5.88 1331 6.30 6000 1232 5.57 1271 6.00 1310 6.43 1348 6.87 1384 7.31 6500 1295 6.61 1333 7.06 1369 7.52 ———— 7000 1360 7.80 1396 8.27 —————— 7500 —————————— 8000 —————————— 8500 —————————— 9000 ——————————

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

(E) Low Range: Not Used (F) Mid-Low Range: 896-1227 rpm, 4.26 bhp (208/230 and 460-v), 873-1108 r pm, 5.75 bhp (575-v) (G) Mid-High Range: 1113-1414 rpm, 5.75 bhp (H) High Range: 1096-1339 rpm, 8.63 bhp

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.8 1.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

G H

Page 29

Table 15 — Fan Performance — 48PGE20 — Horizontal Supply and Return Units

AIRFLOW

(Cfm)

5000 875 2.74 931 3.04 984 3.34 1035 3.33 1083 3.69 5500 952 3.38 1003 3.32 1053 3.70 1100 4.09 1145 4.49 6000 1029 3.74 1077 4.15 1123 4.56 1167 4.98 1210 5.41 6500 1106 4.67 1151 5.11 1194 5.56 1236 6.01 1276 6.47 7000 1184 5.75 1226 6.23 1266 6.71 1306 7.19 1344 7.68 7500 1262 7.00 1302 7.50 1340 8.01 1377 8.53 —— 8000 1341 8.41 1378 8.95 —————— 8500 —-————————— 9000 —-—————————

AIRFLOW

(Cfm)

5000 1130 4.07 1174 4.45 1218 4.84 1259 5.23 1300 5.63 5500 1189 4.90 1232 5.31 1273 5.72 1313 6.15 1352 6.58 6000 1251 5.85 1292 6.29 1331 6.74 1369 7.19 —— 6500 1315 6.94 13547.4113917.89 ———— 7000 1381 8.18 ———————— 7500 —————————— 8000 —————————— 8500 —————————— 9000 ——————————

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

G H

F G

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

G H

Page 30

Table 16 — Fan Performance — 48PGF20 — Horizontal Supply and Return Units

AIRFLOW

(Cfm)

5000 875 2.74 931 3.04 984 3.34 1035 3.33 1083 3.69 5500 952 3.38 1003 3.32 1053 3.70 1100 4.09 1145 4.49 6000 1029 3.74 1077 4.15 1123 4.56 1167 4.98 1210 5.41 6500 1106 4.67 1151 5.11 1194 5.56 1236 6.01 1276 6.47 7000 1184 5.75 1226 6.23 1266 6.71 1306 7.19 1344 7.68 7500 1262 7.00 1302 7.50 1340 8.01 1377 8.53 —— 8000 1341 8.41 1378 8.95 —————— 8500 —————————— 9000 ——————————

AIRFLOW

(Cfm)

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

F G

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 31

Table 17 — Fan Performance — 48PGD24 — Horizontal Supply and Return Units

AIRFLOW

(Cfm)

5,500 937 3.26 988 3.56 1036 3.53 1083 3.90 1127 4.28

6,000 1013 3.58 1060 3.96 1105 4.35 1149 4.75 1191 5.16

6,500 1089 4.48 1133 4.89 1175 5.31 1216 5.73 1256 6.17

7,000 1166 5.52 1207 5.96 1247 6.41 1285 6.86 1323 7.32

7,500 1243 6.71 1282 7.18 1319 7.66 1355 8.14 1391 8.63

8,000 1320 8.07 13568.5713929.08 ————

8,500 1398 9.60 ————————

9,000 ——————————

9,500 —————————— 10,000 ——————————

AIRFLOW

(Cfm)

5,500 1171 4.67 1212 5.06 1253 5.47 1292 5.88 1331 6.30

6,000 1232 5.57 1271 6.00 1310 6.43 1348 6.87 1384 7.31

6,500 1295 6.61 1333 7.06 1369 7.52 ————

7,000 1360 7.80 1396 8.27 ——————

7,500 ——————————

8,000 ——————————

8,500 ——————————

9,000 ——————————

9,500 —————————— 10,000 ——————————

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

G H

Page 32

Table 18 — Fan Performance — 48PGE24 — Horizontal Supply and Return Units

AIRFLOW

(Cfm)

5,500 952 3.38 1003 3.32 1053 3.70 1100 4.09 1145 4.49 6,000 1029 3.74 1077 4.15 1123 4.56 1167 4.98 1210 5.41 6,500 1106 4.67 1151 5.11 1194 5.56 1236 6.01 1276 6.47 7,000 1184 5.75 1226 6.23 1266 6.71 1306 7.19 1344 7.68 7,500 1262 7.00 1302 7.50 1340 8.01 1377 8.53 —— 8,000 1341 8.41 1378 8.95 —————— 8,500 —————————— 9,000 —————————— 9,500 ——————————

10,000 ——————————

AIRFLOW

(Cfm)

5,500 1189 4.90 1232 5.31 1273 5.72 1313 6.15 1352 6.58 6,000 1251 5.85 1292 6.29 1331 6.74 1369 7.19 —— 6,500 1315 6.94 13547.4113917.89 ———— 7,000 1381 8.18 ———————— 7,500 —————————— 8,000 —————————— 8,500 —————————— 9,000 —————————— 9,500 ——————————

10,000 ——————————

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

G H

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 33

Table 19 — Fan Performance — 48PGF24 — Horizontal Supply and Return Units

AIRFLOW

(Cfm)

5,500 952 3.38 1003 3.32 1053 3.70 1100 4.09 1145 4.49

6,000 1029 3.74 1077 4.15 1123 4.56 1167 4.98 1210 5.41

6,500 1106 4.67 1151 5.11 1194 5.56 1236 6.01 1276 6.47

7,000 1184 5.75 1226 6.23 1266 6.71 1306 7.19 1344 7.68

7,500 1262 7.00 1302 7.50 1340 8.01 1377 8.53 ——

8,000 1341 8.41 1378 8.95 ——————

8,500 ——————————

9,000 ——————————

9,500 —————————— 10,000 ——————————

AIRFLOW

(Cfm)

5,500 1189 4.90 1232 5.31 1273 5.72 1313 6.15 1352 6.58

6,000 1251 5.85 1292 6.29 1331 6.74 1369 7.19 ——

6,500 1315 6.94 13547.4113917.89 ————

7,000 1381 8.18 ————————

7,500 ——————————

8,000 ——————————

8,500 ——————————

9,000 ——————————

9,500 —————————— 10,000 ——————————

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

G H

Page 34

Table 20 — Fan Performance — 48PGD28 — Horizontal Supply and Return Units

AIRFLOW

(Cfm)

6,500 786 2.50 819 2.70 857 2.96 899 3.25 943 3.59 7,000 842 3.09 871 3.30 905 3.55 943 3.85 983 4.19 7,500 898 3.77 925 3.99 955 4.24 989 4.54 1026 4.88 8,000 955 4.55 979 4.77 1007 5.03 1037 5.33 1070 5.67 8,500 1012 5.42 1034 5.65 1059 5.92 1087 6.22 1117 6.56 9,000 1069 6.41 1090 6.65 1113 6.92 1138 7.23 1165 7.57

9,500 1127 7.51 1146 7.76 1167 8.04 1190 8.35 1215 8.69 10,000 1184 8.74 1202 8.99 1221 9.28 1243 9.59 1266 9.93 10,500 1242 10.09 1258 10.35 1276 10.64 1296 10.96 1318 11.31 11,000 1299 11.58 1315 11.85 1332 12.15 1350 12.47 1370 12.82 11,500 1357 13.20 1372 13.48 1388 13.79 ———— 12,000 —————————— 12,500 ——————————

AIRFLOW

(Cfm)

6,500 988 3.97 1035 4.39 1082 4.87 1129 5.39 1177 5.95

7,000 1024 4.57 1066 4.98 1109 5.43 1153 5.93 1197 6.48

7,500 1063 5.25 1102 5.66 1141 6.11 1181 6.59 1221 7.11

8,000 1105 6.04 1140 6.45 1176 6.89 1213 7.36 1250 7.87

8,500 1149 6.94 1181 7.34 1215 7.78 1249 8.25 1283 8.74

9,000 1194 7.94 1225 8.35 1256 8.79 1287 9.25 1319 9.74

9,500 1242 9.07 1270 9.47 1298 9.91 1328 10.37 1358 10.87 10,000 1290 10.31 1316 10.72 1343 11.16 1370 11.62 1399 12.11 10,500 1340 11.69 1364 12.10 1389 12.54 ———— 11,000 1391 13.20 ———————— 11,500 —————————— 12,000 —————————— 12,500 ——————————

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

(E) Low Range: 687-873 rpm, 5.75 bhp (F) Mid-Low Range: 805-1007 rpm, 5.75 bhp (G) Mid-High Range: 941-1176 rpm, 8.63 bhp (H) High Range: 1014-1297 rpm, 11.50 bhp

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 35

Table 21 — Fan Performance — 48PGE28 — Horizontal Supply and Return Units

AIRFLOW

(Cfm)

6,500 799 2.58 833 2.79 872 3.05 914 3.36 958 3.71 7,000 856 3.19 887 3.41 921 3.67 958 3.98 999 4.33 7,500 913 3.89 941 4.12 972 4.39 1006 4.69 1042 5.04 8,000 971 4.69 996 4.93 1024 5.20 1055 5.51 1088 5.86 8,500 1029 5.60 1052 5.85 1078 6.12 1106 6.44 1136 6.78 9,000 1087 6.62 1108 6.87 1132 7.16 1158 7.47 1185 7.82

9,500 1145 7.75 1165 8.02 1187 8.31 1211 8.63 1236 8.99 10,000 1203 9.01 1222 9.29 1243 9.59 1265 9.92 1288 10.28 10,500 1261 10.40 1279 10.69 1299 11.00 1319 11.34 1341 11.70 11,000 1320 11.93 1337 12.23 1355 12.55 1374 12.89 1394 13.26 11,500 1378 13.61 ———————— 12,000 —————————— 12,500 ——————————

AIRFLOW

(Cfm)

6,500 1005 4.12 1052 4.57 1100 5.06 1148 5.60 1195 6.17

7,000 1041 4.72 1084 5.16 1128 5.64 1172 6.17 1217 6.74

7,500 1080 5.43 1119 5.86 1160 6.33 1201 6.84 1242 7.40

8,000 1122 6.24 1158 6.66 1195 7.13 1233 7.63 1272 8.17

8,500 1167 7.16 1200 7.58 1234 8.04 1269 8.53 1304 9.06

9,000 1214 8.21 1244 8.62 1275 9.07 1308 9.56 1340 10.08

9,500 1262 9.37 1290 9.78 1319 10.23 1349 10.71 1379 11.23 10,000 1312 10.66 1338 11.08 1365 11.52 1392 12.00 —— 10,500 1363 12.09 1387 12.51 —————— 11,000 —————————— 11,500 —————————— 12,000 —————————— 12,500 ——————————

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

(E) Low Range: 687-873 rpm, 5.75 bhp (F) Mid-Low Range: 805-1007 rpm, 5.75 bhp (G) Mid-High Range: 941-1176 rpm, 8.63 bhp (H) High Range: 1014-1297 rpm, 11.50 bhp

All other rpms require field-supplied motor or drive.

2. See page 36 for general fan performance notes.

LEGEND

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

Page 36

Table 22 — Fan Performance — 48PGF28 — Horizontal Supply and Return Units

AIRFLOW

(Cfm)

0.20.40.60.81.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

AIRFLOW

(Cfm)

6,500 1005 4.12 1052 4.57 1100 5.06 1148 5.60 1195 6.17

7,000 1041 4.72 1084 5.16 1128 5.64 1172 6.17 1217 6.74

7,500 1080 5.43 1119 5.86 1160 6.33 1201 6.84 1242 7.40

8,000 1122 6.24 1158 6.66 1195 7.13 1233 7.63 1272 8.17

8,500 1167 7.16 1200 7.58 1234 8.04 1269 8.53 1304 9.06

9,000 1214 8.21 1244 8.62 1275 9.07 1308 9.56 1340 10.08

Bhp — Brake Horsepower Input to Fan

Boldface indicates field-supplied motor/drive required.

NOTES:

1. Motor drive ranges:

(E) Low Range: 687-873 rpm, 5.75 bhp (F) Mid-Low Range: 805-1007 rpm, 5.75 bhp (G) Mid-High Range: 941-1176 rpm, 8.63 bhp (H) High Range: 1014-1297 rpm, 11.50 bhp

All other rpms require field-supplied motor or drive.

2. See below for general fan performance notes.

LEGEND

1.21.41.61.82.0

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

GENERAL NOTES FOR FAN PERFORMANCE DATA TABLES

1. Static pressure losses (i.e., economizer, electric heat, etc.) must be added to external static pressure before entering Fan Performance table.

2. Interpolation is permissible. Do not extrapolate.

3. Fan performance is based on wet coils, clean filters, and casing losses. See Accessory/FIOP Static Pressure information on page 39.

4. Extensive motor and drive testing on these units ensures that the full horsepower range of the motor can be utilized with confidence. Using the fan motors up to the bhp rating shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.

5. Use of a field-supplied motor may affect wire size. Recalculate the unit power supply MCA and MOCP if required. Contact the local Carrier representative for details.

6. Use the following formula to calculate Input Watts: Input Watts = Bhp x (746/motor eff.)

Page 37

Table 23 — Power Exhaust Fan Performance — 48PG20-28

AIRFLOW

(Cfm)

3250 0.32 1.41 1580 0.70 1.49 1670 — — — — — — — — — — — — 3350 0.23 1.44 1610 0.63 1.52 1700 0.60 1.51 1690 0.82 1.62 1810 — — — — — — 3450 0.17 1.46 1635 0.59 1.55 1730 0.55 1.54 1720 0.78 1.64 1840 — — — — — — 3550 0.13 1.47 1645 0.56 1.56 1745 0.49 1.56 1750 0.73 1.67 1870 — — — — — — 3650 0.09 1.49 1665 0.53 1.58 1765 0.43 1.59 1780 0.68 1.70 1900 — — — — — — 3750 — — — 0.51 1.60 1790 0.39 1.62 1815 0.64 1.72 1930 — — — — — — 3850 — — — 0.48 1.62 1810 0.33 1.64 1835 0.59 1.74 1950 0.60 1.85 2070 0.73 1.99 2230 3950 — — — 0.45 1.64 1835 0.27 1.66 1860 0.54 1.76 1975 0.56 1.87 2095 0.69 2.01 2255 4050 — — — 0.40 1.67 1865 0.22 1.68 1885 0.49 1.79 2000 0.51 1.89 2120 0.65 2.04 2280 4250 — — — — — — 0.17 1.74 1945 0.40 1.84 2060 0.41 1.92 2145 0.56 2.06 2310 4450 — — — — — — 0.00 1.79 2005 0.30 1.89 2115 0.31 1.97 2205 0.47 2.12 2370 4650 — — — — — — — — — 0.22 1.94 2170 0.20 2.04 2280 0.37 2.19 2450 4850 — — — — — — — — — 0.16 1.98 2215 0.11 2.09 2335 0.30 2.24 2505 5050 — — — — — — — — — 0.12 2.02 2260 0.04 2.13 2385 0.23 2.28 2555 5250 ———————————————0.172.332610 5450 ———————————————0.122.382665 5650 ———————————————0.072.402690 5850 ———————————————0.042.422710

ESP — External Static Pressure

ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts

LEGEND

LOW SPEED MEDIUM SPEED HIGH SPEED

208 V 230,460,575V 208 V 230,460,575V 208 V 230,460,575V

Table 24 — Operation Air Quantity Limits

48PG

Minimum Cfm Maximum Cfm Minimum Cfm Minimum Cfm Minimum Cfm Minimum Cfm

20 5000 9,000

24 5500 10,000

28 6500 12,000

*7000 cfm minimum recommended above 1.0 in. wg external static pressure.

COOLING

GAS HEAT

High Heat (8 Cell) 5522 5522 5522 4920

Medium Heat (8 Cell) 4977 4977 4480 4480

Low Heat (5 Cell) 4218 4218 4218 3796

High Heat (8 Cell) 5522 5522 5522 4920

Medium Heat (8 Cell) 4977 4977 4480 4480

Low Heat (5 Cell) 4218 4218 4218 3796

High Heat (8 Cell) 5522 5470* 5522 4920*

Medium Heat (8 Cell) 4977 4977* 4480 4480*

Low Heat (5 Cell) 4218 4218 4218 3796

HEATING (NAT. GAS, VERTICAL)

HEATING

(NAT. GAS,

HORIZONTAL)

HEATING (PROPANE, VERTICAL)

HEATING

(PROPANE,

HORIZONTAL)

Table 25 — Evaporator Fan Motor Specifications

48PG DRIVE ORIENTATION MOTOR P/N NOMINAL HP VOLTAGE MAX WATTS EFFICIENCY % MAX BHP MAX BkW MAX AMPS

Low Vertical

Mid-Low Vertical

Mid-High Vertical

High Vertical

Low Horizontal

Mid-Low Horizontal

Mid-High Horizontal

High Horizontal

HD60FK651 3.7 208 3698 85.8 4.25 3.17 10.6 HD60FK651 3.7 230 3698 85.8 4.25 3.17 9.6 HD60FK651 3.7 460 3698 85.8 4.25 3.17 4.8 HD60FK575 5 575 4900 87.5 5.75 4.29 6.1 HD60FK653 5 208 4900 87.5 5.75 4.29 16.7 HD60FK653 5 230 4900 87.5 5.75 4.29 15.2 HD60FK653 5 460 4900 87.5 5.75 4.29 7.6 HD60FK575 5 575 4900 87.5 5.75 4.29 6.1 HD62FK652 7.5 208 7267 88.5 8.63 6.43 24.2 HD62FK652 7.5 230 7267 88.5 8.63 6.43 22 HD62FK652 7.5 460 7267 88.5 8.63 6.43 11 HD62FK576 7.5 575 7267 88.5 8.63 6.43 9 HD64FK651 10 208 9582 89.5 11.5 8.58 30.8 HD64FK651 10 230 9582 89.5 11.5 8.58 28 HD64FK651 10 460 9582 89.5 11.5 8.58 14 HD64FK575 10 575 9582 89.5 11.5 8.58 11

N/A N/A 208 N/A N/A N/A N/A N/A N/A N/A 230 N/A N/A N/A N/A N/A N/A N/A 460 N/A N/A N/A N/A N/A

Page 38

Table 25 — Evaporator Fan Motor Specifications (cont)

48PG DRIVE ORIENTATION MOTOR P/N NOMINAL HP VOLTAGE MAX WATTS EFFICIENCY % MAX BHP MAX BkW MAX AMPS

Low Vertical

Mid-Low Vertical

Mid-High Vertical

High Vertical

Low Horizontal

Mid-Low Horizontal

Mid-High Horizontal

High Horizontal

Low Vertical

Mid-Low Vertical

Mid-High Vertical

High Vertical

Low Horizontal

Mid-Low Horizontal

Mid-High Horizontal

High Horizontal

NOTES:

1. Extensive motor and electrical testing ensures that the motors can be utilized with confidence up to the maximum applied bhp, watts, and amps. Using the fan motor up to the maximum ratings shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.

N/A N/A 208 N/A N/A N/A N/A N/A N/A N/A 230 N/A N/A N/A N/A N/A N/A N/A 460 N/A N/A N/A N/A N/A

N/A N/A 575 N/A N/A N/A N/A N/A HD60FK651 3.7 208 3698 85.8 4.25 3.17 10.6 HD60FK651 3.7 230 3698 85.8 4.25 3.17 9.6 HD60FK651 3.7 460 3698 85.8 4.25 3.17 4.8 HD60FK575 5 575 4900 87.5 5.75 4.29 6.1 HD60FK653 5 208 4900 87.5 5.75 4.29 16.7 HD60FK653 5 230 4900 87.5 5.75 4.29 15.2 HD60FK653 5 460 4900 87.5 5.75 4.29 7.6 HD60FK575 5 575 4900 87.5 5.75 4.29 6.1 HD62FK652 7.5 208 7267 88.5 8.63 6.43 24.2 HD62FK652 7.5 230 7267 88.5 8.63 6.43 22 HD62FK652 7.5 460 7267 88.5 8.63 6.43 11 HD62FK576 7.5 575 7267 88.5 8.63 6.43 9 HD60FK653 5 208 4900 87.5 5.75 4.29 16.7 HD60FK653 5 230 4900 87.5 5.75 4.29 15.2 HD60FK653 5 460 4900 87.5 5.75 4.29 7.6 HD60FK575 5 575 4900 87.5 5.75 4.29 6.1 HD60FK653 5 208 4900 87.5 5.75 4.29 16.7 HD60FK653 5 230 4900 87.5 5.75 4.29 15.2 HD60FK653 5 460 4900 87.5 5.75 4.29 7.6 HD60FK575 5 575 4900 87.5 5.75 4.29 6.1 HD62FK652 7.5 208 7267 88.5 8.63 6.43 24.2 HD62FK652 7.5 230 7267 88.5 8.63 6.43 22 HD62FK652 7.5 460 7267 88.5 8.63 6.43 11 HD62FK576 7.5 575 7267 88.5 8.63 6.43 9 HD64FK651 10 208 9582 89.5 11.5 8.58 30.8 HD64FK651 10 230 9582 89.5 11.5 8.58 28 HD64FK651 10 460 9582 89.5 11.5 8.58 14 HD64FK575 10 575 9582 89.5 11.5 8.58 11 HD60FK653 5 208 4900 87.5 5.75 4.29 16.7 HD60FK653 5 230 4900 87.5 5.75 4.29 15.2 HD60FK653 5 460 4900 87.5 5.75 4.29 7.6 HD60FK575 5 575 4900 87.5 5.75 4.29 6.1 HD60FK653 5 208 4900 87.5 5.75 4.29 16.7 HD60FK653 5 230 4900 87.5 5.75 4.29 15.2 HD60FK653 5 460 4900 87.5 5.75 4.29 7.6 HD60FK575 5 575 4900 87.5 5.75 4.29 6.1 HD62FK652 7.5 208 7267 88.5 8.63 6.43 24.2 HD62FK652 7.5 230 7267 88.5 8.63 6.43 22 HD62FK652 7.5 460 7267 88.5 8.63 6.43 11 HD62FK576 7.5 575 7267 88.5 8.63 6.43 9 HD64FK651 10 208 9582 89.5 11.5 8.58 30.8 HD64FK651 10 230 9582 89.5 11.5 8.58 28 HD64FK651 10 460 9582 89.5 11.5 8.58 14 HD64FK575 10 575 9582 89.5 11.5 8.58 11

2. All indoor-fan motors 5 hp and larger meet the minimum efficiency requirements as established by the Energy Policy Act of 1992 (EPACT) effective October 24, 1997.

Page 39

Table 26 — Accessory/FIOP Static Pressure (in. wg)* — 48PG20-28

COMPONENT

Economizer 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10

4,000 4,500 5,000 5,500 6,000 6,500 7,000 7,500 8,000

CFM

COMPONENT

Economizer 0.11 0.12 0.13 0.15 0.16 0.17 0.19 0.20

FIOP — Factory-Installed Option

*The static pressure must be added to the external static pressure. The sum and the evaporator

entering-air cfm should then be used in conjunction with the Fan Performance tables to determine blower rpm and watts.

8,500 9,000 9,500 10,000 10,500 11,000 11,500 12,000

LEGEND

CFM

Table 27 — Fan Rpm at Motor Pulley Settings*

UNIT

48PG

20 and 24

(230 and 460 volt)

20 and 24

(575 volt)

(all voltages)

LEGEND *Approximate fan rpm shown.

n/a — not available

DRIVE

Low 685 706 727 749 770 791 812 833 854 876 897 918 939

Mid-Low 949 970 992 1013 1035 1056 1078 1099 1120 1142 1163 1185 1206

Mid-High 941 961 980 1000 1019 1039 1059 1078 1098 1117 1137 1156 1176

High 1014 1038 1061 1085 1108 1132 1156 1179 1203 1226 1250 1273 1297 Low n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a

Mid-Low 896 924 951 979 1006 1034 1062 1089 1117 1144 1172 1199 1227

Mid-High 1113 1138 1163 1188 1213 1238 1264 1289 1314 1339 1364 1389 1414

High 1096 1116 1137 1157 1177 1197 1218 1238 1258 1278 1299 1319 1339 Low 751 768 785 802 819 836 853 869 886 903 920 937 954

Mid-Low 949 970 992 1013 1035 1056 1078 1099 1120 1142 1163 1185 1206

Mid-High 941 961 980 1000 1019 1039 1059 1078 1098 1117 1137 1156 1176

High 1014 1038 1061 1085 1108 1132 1156 1179 1203 1226 1250 1273 1297 Low n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a

Mid-Low 873 893 912 932 951 971 991 1010 1030 1049 1069 1088 1108

Mid-High 1113 1138 1163 1188 1213 1238 1264 1289 1314 1339 1364 1389 1414

High 1096 1116 1137 1157 1177 1197 1218 1238 1258 1278 1299 1319 1339 Low 687 703 718 734 749 765 780 796 811 827 842 858 873

Mid-Low 805 822 839 856 872 889 906 923 940 957 973 990 1007

Mid-High 941 961 980 1000 1019 1039 1059 1078 1098 1117 1137 1156 1176

High 1014 1038 1061 1085 1108 1132 1156 1179 1203 1226 1250 1273 1297 Low 687 703 718 734 749 765 780 796 811 827 842 858 873

Mid-Low 805 822 839 856 872 889 906 923 940 957 973 990 1007

Mid-High 941 961 980 1000 1019 1039 1059 1078 1098 1117 1137 1156 1176

High 1014 1038 1061 1085 1108 1132 1156 1179 1203 1226 1250 1273 1297

111/

MOTOR PULLEY TURNS OPEN

221/

NOTE: Factory pulley speed setting is at 3 turns open.

331/

441/

551/

Optional EconoMi$er IV — See Fig. 23 for EconoMi$er

IV component locations. The optional EconoMi$er IV comes from the factory fully wired and assembled. No field wiring or assembly is required for standard outdoor dry bulb changeover operation. Field wiring of accessory sensors is required for different operational modes.

ECONOMI$ER IV STANDARD SENSORS Outdoor Air Temperature (OAT) Sensor

temperature sensor is a 10 to 20 mA device used to measure the outdoor-air temperature. The outdoor-air temperature is used to determine when the EconoMi$er IV can be used for free cooling. The sensor is factory-installed on the EconoMi$er IV in the outdoor airstream. See Fig. 24. The operating range of temperature measurement is 40 to 100 F.

Mixed-Air Temperature (MAT) Sensor temperature sensor is a 3 K thermistor located at the outlet of the indoor fan. See Fig. 24. This sensor is factory installed. The operating range of temperature measurement is 0° to 158 F.

The temperature sensor is a short probe with blue wires

running to it. Outdoor Air Lockout Sensor

equipped with an ambient temperature lockout switch located in the outdoor airstream which is used to lock out the compressors below a 42 F ambient temperature.

— The Economi$er IV is

— The outdoor air

— The mixed-air

ECONOMI$ER IV CONTROLLER WIRING AND OPERATIONAL MODES — Determine the EconoMi$er IV control mode before set up of the control. Some modes of operation may require different sensors. Refer to Table 28. The EconoMi$er IV is supplied from the factory with a mixed-air temperature sensor and an outdoor air temperature sensor. This allows for operation of the EconoMi$er IV with outdoor air dry bulb changeover control. Additional accessories can be added to allow for different types of changeover control and operation of the EconoMi$er IV and unit.

Outdoor Dry Bulb Changeover

— The standard controller is shipped from the factory configured for outdoor dry bulb changeover control. The outdoor air and mixed-air temperature sensors are included as standard. For this control mode, the outdoor temperature is compared to an adjustable set point selected on the control. If the outdoor-air temperature is above the set point, the EconoMi$er IV will adjust the outdoor-air dampers to minimum position. If the outdoor-air temperature is below the set point, the position of the outdoor-air dampers will be controlled to provided free cooling using outdoor air. When in this mode, the LED next to the free cooling set point potentiometer will be on. The changeover temperature set point is controlled by the free cooling set point potentiometer located on the control. The scale on the potentiometer is A, B, C, and D. See Fig. 25 for the corresponding temperature changeover values.

Page 40

DAMPER ASSEMBLY

WIRE HARNESS

DAMPER ACTUATOR

PL7

ECONOMIZER BLOCK OFF

INDOOR AIR ENTHALPY

Fig. 23 — EconoMi$er IV Component Locations (Exploded View)

MAT LOCATION

OAT LOCATION

Fig. 24 — Sensor Locations (OAT and MAT)

OUTSIDE AIR ENTHALPY

WIRE TIES

LED ON

LED OFF

DEGREES FAHRENHEIT

LED ON

LED OFF

LED ON

LED OFF

Fig. 25 — Temperature Changeover Set Points

LED ON

LED OFF

100

Table 28 — EconoMi$er IV Sensor Usage

APPLICATION

Outdoor Air Dry Bulb None. The outdoor air dry bulb sensor is factory installed. CRTEMPSN002A00*

Differential Dry Bulb CRTEMPSN002A00* (2) CRTEMPSN002A00*

Single Enthalpy HH57AC078 None. The single enthalpy sensor is factory installed.

Differential Enthalpy

for DCV Control using a

Wall-Mounted CO

for DCV Control using a

Duct-Mounted CO

*CRENTDIF004A00 and CRTEMPSN002A00 accessories are used on many different base units. As such, these kits may contain parts that will not be

needed for installation.

†33ZCSENCO2 is an accessory CO

**33ZCASPCO2 is an accessory aspirator box required for duct-mounted applications.

††CRCBDIOX005A00 is an accessory that contains both 33ZCSENCO2 and 33ZCASPCO2 accessories.

Sensor

ECONOMI$ER IV WITH OUTDOOR AIR

33ZCSENCO2†

and

33ZCASPCO2**

sensor.

DRY BULB SENSOR

ECONOMI$ER IV WITH SINGLE

ENTHALPY SENSOR

Accessories Required Accessories Required

HH57AC078

and

CRENTDIF004A00*

33ZCSENCO2 33ZCSENCO2

CRCBDIOX005A00††

33ZCSENCO2†

and

33ZCASPCO2**

CRCBDIOX005A00††

Page 41

Differential Dry Bulb Control

— For differential dry bulb control the standard outdoor dry bulb sensor is used in conjunction with an additional accessory dry bulb sensor (part number CRTEMPSN002A00). The accessory sensor must be mounted in the return airstream. Wiring is provided in the EconoMi$er IV wiring harness. See Fig. 26.

In this mode of operation, the outdoor-air temperature is compared to the return-air temperature and the lower temperature airstream is used for cooling. When using this mode of changeover control, turn the enthalpy set point potentiometer fully clockwise to the D setting.

Outdoor Enthalpy Changeover

— For enthalpy control, accessory enthalpy sensor (part number HH57AC078) is required. Replace the standard outdoor dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location. When the outdoor air enthalpy rises above the outdoor enthalpy changeover set point, the outdoor-air damper moves to its minimum position. The outdoor enthalpy changeover set point is set with the outdoor enthalpy set point potentiometer on the EconoMi$er IV controller. The set points are A, B, C, and D. See Fig. 27. The factory-installed 620-ohm jumper must be in place across terminals S

and + on the EconoMi$er IV control-

ler. See Fig. 26. Differential Enthalpy Control

— For differential enthalpy control, the EconoMi$er IV controller uses two enthalpy sensors (HH57AC078 and CRENTDIF004A00), one in the outside air and one in the return air duct. The EconoMi$er IV controller compares the outdoor air enthalpy to the return air enthalpy to determine EconoMi$er IV use. The controller selects the lower enthalpy air (return or outdoor) for cooling. For example, when the outdoor air has a lower enthalpy than the return air, the EconoMi$er IV opens to bring in outdoor air for free cooling.

Replace the standard outside air dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location. Mount the return air enthalpy sensor in the return air duct. Wiring is provided in the EconoMi$er IV wiring harness. See Fig. 26. The outdoor enthalpy changeover set point is set with the outdoor enthalpy set point potentiometer on the EconoMi$er IV controller. When using this mode of changeover control, turn the enthalpy setpoint potentiometer fully clockwise to the D setting. See Fig. 28.

Indoor Air Quality (IAQ) Sensor Input

— The IAQ input can be used for demand control ventilation control based on the level of CO

measured in the space or return air duct.

Mount the optional IAQ sensor according to manufacturer specifications. The IAQ sensor should be wired to the AQ and AQ1 terminals of the controller. Adjust the DCV (demand controlled ventilation) potentiometers to correspond to the DCV voltage output of the indoor air quality sensor at the user-determined set point. See Fig. 29.

If a separate field-supplied transformer is used to power the IAQ sensor, the sensor must not be grounded or the EconoMi$er IV control board will be damaged.

Exhaust Set Point Adjustment

— The exhaust set point will determine when the exhaust fan runs based on damper position (if accessory power exhaust is installed). The set point is modified with the Exhaust Fan Set Point (EXH SET) potentiometer. See Fig. 28. The set point represents the damper position above which the exhaust fans will be turned on. When there is a call for exhaust, the EconoMi$er IV controller provides a 45 ± 15 second delay before exhaust fan activation to allow the dampers to open. This delay allows the damper to reach the appropriate position to avoid unnecessary fan overload.

Fig. 26 — EconoMi$er IV Wiring

Page 42

CONTROL

CURVE

A B C D

CONTROL POINT

APPROX. °F (°C)

AT 50% RH

73 (23) 70 (21) 67 (19) 63 (17)

LPY

(4)

(2)

—

(29)90(32)95(35)

Y A

(16)

(13)

(10)

(7)

(21)

(18)

(27)

(24)

TIVE HUM

RELA

100 (38)

IDITY

105

110

(41)

(43)

)

(

(2)

(4)

(7)

(10)

(13)

(16)

(18)

(21)

(24)

(27)

APPROXIMATE DRY BULB TEMPERATURE— °F (°C)

Fig. 27 — Enthalpy Changeover Set Points

6000

5000

4000

3000

2000

1000

RANGE CONFIGURATION (ppm)

HIGH LIMIT

(29)90(32)95(35)

CO SENSOR MAX RANGE SETTING

105 (41)

110

(43)

100 (38)

CURVE

2345678

DAMPER VOLTAGE FOR MAX VENTILATION RATE

800 ppm 900 ppm 1000 ppm 1100 ppm

Fig. 28 — EconoMi$er IV Controller Potentiometer

and LED Locations

Fig. 29 — CO

Sensor Maximum Range Setting

Page 43

Minimum Position Control

— There is a minimum damper position potentiometer on the EconoMi$er IV controller. See Fig. 28. The minimum damper position maintains the minimum airflow into the building during the occupied period.

When using demand ventilation, the minimum damper position represents the minimum ventilation position for VOC (volatile organic compounds) ventilation requirements. The maximum demand ventilation position is used for fully occupied ventilation.

When demand ventilation control is not being used, the minimum position potentimeter should be used to set the occupied ventilation position. The maximum demand ventilation position should be turned fully clockwise.

Adjust the minimum position potentiometer to allow the minimum amount of outdoor air, as required by local codes, to enter the building. Make minimum position adjustments with at least 10° F temperature difference between the outdoor and return-air temperatures. To determine the minimum position setting, perform the following procedure:

1. Calculate the appropriate mixed air temperature using the following formula:

xOA)+(TRxRA)=T

TO= Outdoor-Air Temperature OA = Percent of Outdoor Air T

= Return-Air Temperature

RA = Percent of Return Air T

= Mixed-Air Temperature

As an example, if local codes require 10% outdoor air during occupied conditions, outdoor-air temperature is 60 F, and return-air temperature is 75 F.

(60 x .10) + (75 x .90) = 73.5 F

2. Disconnect the mixed air sensor from terminals T and T1.

3. Ensure that the factory-installed jumper is in place across terminals P and P1. If remote damper positioning is being used, make sure that the terminals are wired according to Fig. 26 and that the minimum position potentiometer is turned fully clockwise.

4. Connect 24 vac across terminals TR and TR1.

5. Carefully adjust the minimum position potentiometer until the measured mixed air temperature matches the calculated value.

6. Reconnect the mixed air sensor to terminals T and T1.

Remote control of the EconoMi$er IV damper is desirable when requiring additional temporary ventilation. If a field-supplied remote potentiometer (Honeywell part number S963B1128) is wired to the EconoMi$er IV controller, the minimum position of the damper can be controlled from a remote location.

To control the minimum damper position remotely, remove the factory-installed jumper on the P and P1 terminals on the EconoMi$er IV controller. Wire the field-supplied potentiometer to the P and P1 terminals on the EconoMi$er IV controller. See Fig. 26.

Damper Movement ceives initial power, it can take the damper up to 2

— When the EconoMi$er IV board re-

/2minutes before it begins to position itself. After the initial positioning, subsequent changes to damper position will take up to 30 seconds to initiate. Damper movement from full open to full closed (or vice versa) takes 2

Thermostats

— The EconoMi$er IV control works with con-

/2minutes.

ventional thermostats that have a Y1 (cool stage 1), Y2 (cool stage 2), W1 (heat stage 1), W2 (heat stage 2), and G (fan). The EconoMi$er IV control does not support space temperature sensors like the T55 or T56. Connections are made at the thermostat terminal connection board located in the main control box.

Demand Control Ventilation

— When using the EconoMi$er IV for demand control ventilation, there are some equipment selection criteria which should be considered. When selecting the heat capacity and cool capacity of the equipment, the maximum ventilation rate must be evaluated for design conditions. The maximum damper position must be calculated to provide the desired fresh air.

Typically the maximum ventilation rate will be about 5 to 10% more than the typical cfm required per person, using normal outside air design criteria.

A proportional anticipatory strategy should be taken with the following conditions: a zone with a large area, varied occupancy, and equipment that cannot exceed the required ventilation rate at design conditions. Exceeding the required ventilation rate means the equipment can condition air at a maximum ventilation rate that is greater than the required ventilation rate for maximum occupancy. A proportionalanticipatory strategy will cause the fresh air supplied to increase as the room CO

level increases even though the CO

set point has not been reached. By the time the CO2level reaches the set point, the damper will be at maximum ventilation and should maintain the set point.

In order to have the CO

sensor control the economizer

damper in this manner, first determine the damper voltage output for minimum or base ventilation. Base ventilation is the ventilation required to remove contaminants during unoccupied periods. The following equation may be used to determine the percent of outside-air entering the building for a given damper position. For best results there should be at least a 10 degree difference in outside and return-air temperatures.

xOA)+(TRxRA)=T

TO= Outdoor-Air Temperature OA = Percent of Outdoor Air T

= Return-Air Temperature

RA = Percent of Return Air T

= Mixed-Air Temperature

Once base ventilation has been determined, set the minimum damper position potentiometer to the correct position.

The same equation can be used to determine the occupied or maximum ventilation rate to the building. For example, an output of 3.6 volts to the actuator provides a base ventilation rate of 5% and an output of 6.7 volts provides the maximum ventilation rate of 20% (or base plus 15 cfm per person). Use Fig. 29 to determine the maximum setting of the CO

sensor.

For example, a 1100 ppm set point relates to a 15 cfm per person design. Use the 1100 ppm curve on Fig. 29 to find the point when the CO

sensor output will be 6.7 volts. Line up the

point on the graph with the left side of the chart to determine that the range configuration for the CO

sensor should be 1800

ppm. The EconoMi$er IV controller will output the 6.7 volts from the CO

sensor to the actuator when the CO2concentra-

tion in the space is at 1100 ppm. The DCV set point may be left at 2 volts since the CO

sensor voltage will be ignored by the

EconoMi$er IV controller until it rises above the 3.6 volt setting of the minimum position potentiometer.

Once the fully occupied damper position has been determined, set the maximum damper demand control ventilation potentiometer to this position. Do not set to the maximum position as this can result in over-ventilation to the space and potential high-humidity levels.

Sensor Configuration —TheCO2sensor has preset

standard voltage settings that can be selected anytime after the sensor is powered up. See Table 29.

Use setting 1 or 2 for Carrier equipment. See Table 29.

1. Press Clear and Mode buttons. Hold at least 5 seconds until the sensor enters the Edit mode.

2. Press Mode twice. The STDSET Menu will appear.

Page 44

3. Use the Up/Down button to select the preset number. See Table 29.

4. Press Enter to lock in the selection.

5. Press Mode to exit and resume normal operation.

The custom settings of the CO

sensor can be changed any-

time after the sensor is energized. Follow the steps below to change the non-standard settings:

1. Press Clear and Mode buttons. Hold at least 5 seconds until the sensor enters the Edit mode.

2. Press Mode twice. The STDSET Menu will appear.

3. Use the Up/Down button to toggle to the NONSTD menu and press Enter.

4. Use the Up/Down button to toggle through each of the nine variables, starting with Altitude, until the desired setting is reached.

5. Press Mode to move through the variables.

6. Press Enter to lock in the selection, then press Mode to continue to the next variable.

Dehumidification of Fresh Air with DCV Control

— Information from ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) indicates that the largest humidity load on any zone is the fresh air introduced. For some applications, a device such as a 62AQ energy recovery unit is added to reduce the moisture content of the fresh air being brought into the building when the enthalpy is high. In most cases, the normal heating and cooling processes are more than adequate to remove the humidity loads for most commercial applications.

This makes the control of the of the dehumidification device simple when using the enthalpy or differential enthalpy sensor. The enthalpy sensor or differential enthalpy sensor is installed on the equipment to determine economizer operation. The high enthalpy signal from the enthalpy sensor or differential enthalpy sensor can be used to turn on the outdoor air moisture removal device any time fresh air is required for the space.

The energy recovery device should be sized for maximum latent and sensible conditioning at maximum ventilation on a design day. A calculation for leaving-air temperature on a low ambient, low ventilation day should also be done to determine the mixed-air temperature of the return and pre-conditioned

outside air. The design should produce an air temperature somewhat near room conditions to prevent reheat of the air mixture. The energy recovery device should be interlocked with the heat to turn off the device when in the heat mode.

Operating Sequence

COOLING, UNITS WITHOUT ECONOMIZER — When the thermostat calls for one stage of cooling, Y1 and G are energized. The indoor-fan contactor (IFC) and compressor contactor(s) (C.A1 and C.B1 on three-compressor units or C.A1 only on two-compressor units), and outdoor-fan contactors (OFC1 and OFC2 when outdoor temperature is above LTS setting) are energized and the indoor-fan motor, compressor(s) (A1 and B1 on three compressor units or A1 only on twocompressor units), and outdoor fans controlled by OFC1 are started. If the outdoor temperature is above the setting of the low temperature switch, the outdoor fans controlled by OFC2 are also started.

If more cooling is required, the thermostat will call for a second stage of cooling, energizing Y2. This will allow relay CR1 to energize, which in turn energizes the compressor contactor (C.C1 on three-compressor units or C.B1 on two-compressor units). The second stage compressor (C1 on three-compressor units or B1 on two-compressor units is then started.

HEATING, UNITS WITHOUT ECONOMIZER NOTE: The 48PG20-28 units have 2 stages of heat.

When the thermostat calls for heating, power is sent to W on the IGC (integrated gas unit controller) board. An LED (light-emitting diode) on the IGC board will be on during normal operation. A check is made to ensure that the rollout switch and limit switch are closed and the induced-draft motor is running. The induced-draft motor is then energized, and when speed is proven with the hall effect sensor on the motor, the ignition activation period begins. The burners will ignite within 5 seconds.

If the burners do not light, there is a 22-second delay before another 5-second attempt. If the burners still do not light, this sequence is repeated for 15 minutes. After the 15 minutes have elapsed, if the burners still have not lit, heating is locked out. To reset the control, break 24-v power to the thermostat.

Table 29 — CO

SETTING EQUIPMENT OUTPUT

Interface w/Standard

2 Proportional Any

Building Control System

3 Exponential Any

5 Proportional 20

Economizer

6 Exponential 15

7 Exponential 20

8 Health & Safety Proportional —

Parking/Air Intakes/

Loading Docks

LEGEND

PPM —PartsPerMillion

Proportional Any

Proportional 15

Proportional —

Sensor Standard Settings

VENTILATION

RATE

(cfm/Person)

ANALOG

OUTPUT

0-10V

4-20 mA

2-10V

7-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

CONTROL RANGE

(ppm)

0-2000 1000 50

0-2000 1100 50

0-1100 1100 50

0- 900 900 50

0-1100 1100 50

0- 900 900 50

0-9999 5000 500

0-2000 700 50

OPTIONAL

RELAY SETPOINT

(ppm)

RELAY

HYSTERESIS

(ppm)

Page 45

When ignition occurs the IGC board will continue to monitor the condition of the rollout and limit switches, the hall effect sensor, as well as the flame sensor. If the unit is controlled through a room thermostat set for fan auto., 45 seconds after ignition occurs, the indoor-fan motor will be energized (and the outdoor-air dampers will open to their minimum position). If for some reason the overtemperature limit opens prior to the start of the indoor fan blower, on the next attempt, the 45-second delay will be shortened to 5 seconds less than the time from initiation of heat to when the limit tripped. Gas will not be interrupted to the burners and heating will continue. Once modified, the fan on delay will not change back to 45 seconds unless power is reset to the control.

When additional heat is required, W2 closes and initiates power to the second stage of the main gas valve. When the thermostat is satisfied, W1 and W2 open and the gas valve closes, interrupting the flow of gas to the main burners. If the call for W1 lasted less than 1 minute, the heating cycle will not terminate until 1 minute after W1 became active. If the unit is controlled through a room thermostat set for fan auto., the indoor-fan motor will continue to operate for an additional 45 seconds then stop (and the outdoor-air dampers will close). If the overtemperature limit opens after the indoor motor is stopped within 10 minutes of W1 becoming inactive, on the next cycle the time will be extended by 15 seconds. The maximum delay is 3 minutes. Once modified, the fan off delay will not change back to 45 seconds unless power is reset to the control.

A LED indicator is provided on the IGC to monitor operation. The IGC is located by removing the side panel and viewing the IGC through the view port located in the control box access panel. During normal operation, the LED is continuously on. For information on troubleshooting refer to page 57.

COOLING, UNITS WITH ECONOMI$ER IV — When free cooling is not available, the compressors will be controlled by the zone thermostat. When free cooling is available, the outdoor-air damper is modulated by the EconoMi$er IV control to provide a 50 to 55 F mixed-air temperature into the zone. As the mixed-air temperature fluctuates above 55 or below 50 F, the dampers will be modulated (open or close) to bring the mixed air temperature back within control.

If mechanical cooling is utilized with free cooling, the outdoor-air damper will maintain its current position at the time the compressor is started. If the increase in cooling capacity causes the mixed-air temperature to drop below 45 F, then the outdoor-air damper position will be decreased to the minimum position. If the mixed-air temperature continues to fall, the outdoor-air damper will close. Control returns to normal once the mixed-air temperature rises above 48 F.

If optional power exhaust is installed, as the outdoor-air damper opens and closes, the power exhaust fans will be energized and deenergized.

If field-installed accessory CO

sensors are connected to the

EconoMi$er IV control, a demand controlled ventilation strategy will begin to operate. As the CO above the CO

set point, the minimum position of the damper

will be increased proportionally. As the CO

level in the zone increases

level decreases

because of the increase in fresh air, the outdoor-air damper will be proportionally closed.

For EconoMi$er IV operation, there must be a thermostat call for the fan (G). This will move the damper to its minimum position.

When the EconoMi$er IV control is in the occupied mode and a call for cooling exists (Y1 on the thermostat), the control will first check for indoor fan operation. If the fan is not on, then cooling will not be activated. If the fan is on, then the control will open the EconoMi$er IV damper to the minimum position.

On the initial power to the EconoMi$er IV control, it will

take the damper up to 2

/2minutes before it begins to position itself. Any change in damper position will take up to 30 seconds to initiate. Damper movement from full closed to full open (or vice versa) will take between 1

/2and 21/2minutes.

If free cooling can be used as determined from the appropriate changeover command (switch, dry bulb, enthalpy curve, differential dry bulb, or differential enthalpy), then the control will modulate the dampers open to maintain the mixed-air temperature set point at 50 to 55 F.

If there is a further demand for cooling (cooling second stage — Y2 is energized), then the control will bring on compressor stage 1 to maintain the mixed-air temperature set point. The EconoMi$er IV damper will be open at maximum position. EconoMi$er IV operation is limited to a single compressor.

HEATING, UNITS WITH ECONOMI$ER IV — When the room temperature calls for heat, the heating controls are energized as described in the Heating, Units Without Economizer section. The IFM is energized and the EconoMi$er IV damper modulates to the minimum position. When the thermostat is satisfied and W1 and W2 are deenergized, the IFM continues to run, and the economizer damper modulates to the minimum position.

SUBCOOLER HEAT EXCHANGER (SHX) — The purpose of the subcooler heat exchanger (SHX) and the subcooler TXV is to increase the capacity of the evaporator by sending subcooled liquid refrigerant into the evaporator. Normally, the condenser subcools the liquid refrigerant by approximately 10 F. The SHX adds another 10 F to 15 F degrees of subcooling before the refrigerant reaches the evaporator. This allows the refrigerant to absorb more heat from the mixed air, thereby providing more cooling capacity.

The subcooler functions by taking a small percentage of the high pressure, low temperature liquid refrigerant which exits the condenser and converting it into a low pressure, low temperature gas. This is accomplished by using the subcooler TXV. The gas is then routed through a reverse-flow heat exchanger (SHX), which transfers heat from the remaining liquid refrigerant in the liquid line to the reverse flow gas refrigerant. The moderate temperature gas is then sent to the compressor to complete the loop and the cooler liquid refrigerant continues its normal path to the main TXV and the evaporator. See Fig. 30.

COMPRESSOR

COND

SUBCOOLER HX

SUBCOOLER TXV

EVAP

MAIN TXV

Fig. 30 — Subcooler Operation

Page 46

SERVICE

Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury.

Puron® (R-410A) refrigerant systems operate at higher pressures than standard R-22 systems. Do not use R-22 service equipment or components on Puron refrigerant equipment. If service equipment is not rated for Puron refrigerant, equipment damage or personal injury may result.

2. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

What to do if you smell gas:

1. DO NOT try to light any appliance.

2. DO NOT touch any electrical switch, or use any phone in your building.

3. IMMEDIATELY call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

4. If you cannot reach your gas supplier, call the fire department.

This will make cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse.

Periodic Clean Water Rinse

— A periodic clean water rinse is very beneficial for coils that are applied in coastal or industrial environments. However, it is very important that the water rinse is made with very low velocity water stream to avoid damaging the fin edges. Monthly cleaning as described below is recommended.

Routine Cleaning of Coil Surfaces

— Monthly cleaning with Totaline® environmentally sound coil cleaner is essential to extend the life of coils. This cleaner is available from Carrier Replacement parts division as part number P902-0301 for a one gallon container, and part number P902-0305 for a 5 gallon container. It is recommended that all coils, including standard aluminum, pre-coated, copper/copper or E-coated coils be cleaned with the Totaline environmentally sound coil cleaner as described below. Coil cleaning should be part of the unit’s regularly scheduled maintenance procedures to ensure long life of the coil. Failure to clean the coils may result in reduced durability in the environment.

Avoid the use of:

• coil brighteners

• acid cleaning prior to painting

• high pressure washers

• poor quality water for cleaning

Totaline environmentally sound coil cleaner is non-flammable, hypoallergenic, nonbacterial, and a USDA accepted biodegradable agent that will not harm the coil or surrounding components such as electrical wiring, painted metal surfaces, or insulation. Use of non-recommended coil cleaners is strongly discouraged since coil and unit durability could be affected.

Totaline Environmentally Sound Coil Cleaner Application Equipment

/2gallon garden sprayer

•2

• water rinse with low velocity spray nozzle

Disconnect gas piping from unit when pressure testing at pressure greater than 0.5 psig. Pressures greater than

0.5 psig will cause gas valve damage resulting in hazardous condition. If gas valve is subjected to pressure greater than

Cleaning —

Inspect unit interior at beginning of each heating and cooling season and as operating conditions require. Remove unit top panel and/or side panels for access to unit interior.

COIL MAINTENANCE AND CLEANING RECOMMENDATION — Routine cleaning of coil surfaces is essential to maintain proper operation of the unit. Elimination of contamination and removal of harmful residues will greatly increase the life of the coil and extend the life of the unit. The following maintenance and cleaning procedures are recommended as part of the routine maintenance activities to extend the life of the coil.

Remove Surface Loaded Fibers

— Surface loaded fibers or dirt should be removed with a vacuum cleaner. If a vacuum cleaner is not available, a soft non-metallic bristle brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges can be easily bent over and damage to the coating of a protected coil) if the tool is applied across the fins.

NOTE: Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil.

Harsh chemicals, household bleach or acid or basic cleaners should not be used to clean outdoor or indoor coils of any kind. These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion at the fin/tube interface where dissimilar materials are in contact. If there is dirt below the surface of the coil, use the Totaline environmentally sound coil cleaner as described above.

High velocity water from a pressure washer, garden hose, or compressed air should never be used to clean a coil. The force of the water or air jet will bend the fin edges and increase airside pressure drop. Reduced unit performance or nuisance unit shutdown may occur.

Totaline Environmentally Sound Coil Cleaner Application Instructions

1. Proper eye protection such as safety glasses is recommended during mixing and application.

2. Remove all surface loaded fibers and dirt with a vacuum cleaner as described above.

3. Thoroughly wet finned surfaces with clean water and a low velocity garden hose, being careful not to bend fins.

4. Mix Totaline environmentally sound coil cleaner in a

/2gallon garden sprayer according to the instructions included with the cleaner. The optimum solution temperature is 100 F.

NOTE: Do NOT USE

water in excess of 130 F, as the enzy-

matic activity will be destroyed.

Page 47

5. Thoroughly apply Totaline® environmentally sound coil cleaner solution to all coil surfaces including finned area, tube sheets and coil headers.

6. Hold garden sprayer nozzle close to finned areas and apply cleaner with a vertical, up-and-down motion. Avoid spraying in horizontal pattern to minimize potential for fin damage.

7. Ensure cleaner thoroughly penetrates deep into finned areas.

8. Interior and exterior finned areas must be thoroughly cleaned.

9. Finned surfaces should remain wet with cleaning solution for 10 minutes.

10. Ensure surfaces are not allowed to dry before rinsing. Reapplying cleaner as needed to ensure 10-minute saturation is achieved.

11. Thoroughly rinse all surfaces with low velocity clean water using downward rinsing motion of water spray nozzle. Protect fins from damage from the spray nozzle.

CONDENSATE DRAIN — Check and clean each year at the start of the cooling season. In winter, keep drains and traps dry. An access panel is located above the condensate connection to allow easy clean out of the condensate pan. The first time the panel is removed, the insulation behind the access panel will need to be cut away. Carefully cut the insulation with a knife or blade on three sides so the insulation can be folded out of the way during cleaning. Be careful not to damage components behind the insulation while cutting. Once cleaning is completed, fold the insulation back into place and secure the access panel in the original position.

FILTERS — Clean or replace at start of each heating and cooling season, or more often if operating conditions require. Refer to Table 1 for type and size.

OUTDOOR-AIR INLET SCREENS — Clean screens with steam or hot water and a mild detergent. Do not use throwaway filters in place of screens. See Table 2 for quantity and size.

MAIN BURNER — At the beginning of each heating season, inspect for deterioration or blockage due to corrosion or other causes. Observe the main burner flames. Refer to Main Burners section on page 51.

FLUE GAS PASSAGEWAYS — The flue collector box and heat exchanger cells may be inspected by removing heat section access panel (Fig. 4), flue box cover, and main burner assembly (Fig. 31). Refer to Main Burners section on page 51 for burner removal sequence. If cleaning is required, clean tubes with a wire brush.

Use caution with ceramic heat exchanger baffles. When installing retaining clip, be sure the center leg of the clip extends inward toward baffle. See Fig. 32.

COMBUSTION-AIR BLOWER — Clean periodically to assure proper airflow and heating efficiency. Inspect blower wheel every fall and periodically during heating season. For the first heating season, inspect blower wheel bi-monthly to determine proper cleaning frequency.

To inspect blower wheel, remove heat section panel. Using an inspection mirror and flashlight, look into the flue exhaust duct to inspect the wheel. If cleaning is required, remove motor and wheel assembly by removing the screws holding the flue box cover to the flue box. See Fig. 31. Remove the screws holding the inducer housing to the inlet plate. The wheel can then be removed from the motor shaft and cleaned with a detergent or solvent. Replace the wheel onto the motor shaft in the correct position and reassemble the flue cover onto the flue box.

Lubrication

COMPRESSORS — Each compressor is charged with the correct amount of oil at the factory.

The compressor is in a Puron® refrigerant system and uses a polyolester (POE) oil. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Avoid exposure of the oil to the atmosphere. Damage to components could result.

Polyolester (POE) compressor lubricants are known to cause long term damage to some synthetic roofing materials. Exposure, even if immediately cleaned up, may cause roofing materials to become brittle (leading to cracking) within a year. When performing any service which may risk exposure of compressor oil to the roof, take appropriate precautions to protect roofing. Procedures which risk oil leakage include compressor replacement, repairing refrigerant leaks, and replacing refrigerant components. To prepare rooftop:

1. Cover extended roof work area with an impermeable plastic dropcloth or tarp. Make sure a 10 x 10 area around the work area is covered.

2. Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run-offs. Towel will also protect dropcloth from tears caused by tools or components.

3. Place terrycloth shop towel inside the unit directly under components to be serviced to prevent spills through the bottom of the unit.

4. Perform the required service.

5. Remove and dispose of any oil contaminated material per local codes.

HEAT EXCHANGER SECTION

IGC BOARD (HIDDEN)

MAIN BURNER SECTION

IGC — Integrated Gas

Fig. 31 — Typical Gas Heating Section

COMBUSTION FAN HOUSING

INDUCED DRAFT MOTOR

MAIN GAS VALV E

Controller

CERAMIC BAFFLE

CLIP

NOTE: One baffle and clip will be in each upper tube of the heat exchanger.

Fig. 32 — Removing Heat Exchanger Ceramic

Baffles and Clips

Page 48

FAN SHAFT BEARINGS — Lubricate bearings at least every 6 months with suitable bearing grease. Typical lubricants are given below:

MANUFACTURER LUBRICANT

Texaco Regal AFB-2*

Mobil Mobilplex EP No. 1

Sunoco Prestige 42

Texaco Multifak 2

*Preferred lubricant because it contains rust and oxidation inhibitors.

FAN MOTOR BEARINGS — Fan motor bearings are of the permanently lubricated type. No field lubrication is required. No lubrication of the condenser or evaporator motors are required.

Manual Outdoor Air Damper — If manual outdoor

air damper blade adjustment is required, refer to Step 10 — Install Outdoor Air Hood section on page 12.

Economizer Adjustment — If economizer adjustment

is required, refer to Optional EconoMi$er IV section on page 39.

Evaporator Fan Service and Replacement — The

48PG units feature a slide-out fan deck for easy servicing of the indoor-fan motor, pulleys, belt, and bearings. To service components in this section, perform the following procedure:

1. Turn off unit power.

2. Open the fan section access panel.

3. Remove three no. 10 screws at front of slide-out fan deck. Save screws. See Fig. 33.

4. Disconnect the limit switch wires located on the right side of the fan deck. Other wires do not need to be disconnected.

5. Fan deck can now be slid out to access serviceable components.

DO NOT SLIDE FAN DECK OUT PAST THE STOP BRACKET. If further access is required, the fan deck must be supported. Make sure plugs and wiring are not pinched between fan housing and unit center post. Damage to unit may result.

To align fan and motor pulleys:

1. Loosen fan pulley setscrews.

2. Slide fan pulley along fan shaft.

3. Make angular alignment by loosening motor from mounting plate.

Evaporator Fan Belt Tension Adjustment — To

adjust belt tension:

1. Turn off unit power.

2. Slide out fan deck to service position as shown in Evaporator Fan Service and Replacement section above.

3. Loosen fan motor bolts.

4. Move motor mounting plate to adjust to proper belt tension. See Table 30. Motor adjuster bolts may be used to tighten belts. See Fig. 33.

5. Check for proper belt alignment. Adjust if necessary.

6. Tighten motor mounting plate bolts to lock motor in proper position.

7. Return fan deck back into operating position.

8. Restore power to unit.

MOTOR

FAN PULLEY

LIMIT SWITCH QUICK CONNECT

Fig. 33 — Evaporator-Fan Motor Adjustment

PULLEY (HIDDEN)

MOTOR

MOUNTING BASE

SLIDE-OUT FAN DECK

6. To replace fan deck to operating position, slide fan deck back into the unit. Secure with the three no. 10 screws removedinStep3.

7. Re-attach electrical plugs and wires.

8. Close fan section access door.

9. Restore power to unit.

Evaporator Fan Performance Adjustment (Fig. 33 and 34) —

for speed shown in Table 27. To change fan speeds:

1. Shut off unit power supply.

2. Loosen nuts on the 4 carriage bolts in the mounting base. Using adjusting bolts and plate, slide motor and remove belt.

3. Loosen movable-pulley flange setscrew (see Fig. 34).

4. Screw movable flange toward fixed flange to increase speed and away from fixed flange to decrease speed. Increasing fan speed increases load on motor. Do not exceed maximum speed specified in Table 27. See Table 24 for air quantity limits.

5. Set movable flange at nearest keyway of pulley hub and tighten setscrew. (See Table 27 for speed change for each full turn of pulley flange.)

6. Replace and tighten belts (see Evaporator Fan Belt Tension Adjustment section below).

7. Restore power to unit.

Fan motor pulleys are factory set

Fig. 34 — Evaporator-Fan Alignment

and Adjustment

Page 49

48PG VOLTAGE

230 4.8 5.1 5.6 4.5 NA 4.7 5.0 5.5 460 4.8 5.1 5.6 4.5 NA 4.7 5.0 5.5 575 5.3 5.1 5.6 4.5 NA 5.2 5.0 5.5 230 4.8 5.1 5.6 4.5 NA 4.7 5.0 5.5 460 4.8 5.1 5.6 4.5 NA 4.7 5.0 5.5 575 5.3 5.1 5.6 4.5 NA 5.2 5.0 5.5 230 4.5 5.4 5.9 4.5 4.5 5.4 5.9 4.5 460 4.5 5.4 5.9 4.5 4.5 5.4 5.9 4.5 575 4.5 5.4 5.9 4.5 4.5 5.4 5.9 4.5

Table 30 — Belt Tension Adjustment

BELT TENSION (lb)

Unit Model Number Position 10

A,J B,K C,L D,M E,N F,P G,Q H,R

Condenser-Fan Adjustment (Fig. 35)

1. Shut off unit power supply.

2. Remove condenser-fan assembly (grille, motor, motor cover, and fan) and loosen fan hub setscrews.

3. Adjust fan height as shown in Fig. 35.

4. Tighten setscrews and replace condenser-fan assembly.

5. Turn on power to unit.

Fig. 35 — Condenser-Fan Adjustment

Verify Sensor Performance — Using an ohmmeter

and a thermometer, compare measured temperature to the resistance shown in Table 31.

Table 31 — Sensor Temperature/Resistance Values

TEMPERATURE (F) RESISTANCE (ohms)

–58 200,250 –40 100,680 –22 53,010

–4 29,091 14 16,590 32 9,795 50 5,970 68 3,747 77 3,000

86 2,416 104 1,597 122 1,080 140 746 158 525 176 376 185 321 194 274 212 203 230 153 248 116 257 102 266 89 284 70 302 55

Evacuation — Proper evacuation of the system will re-

move noncondensables and ensure a tight, dry system before charging. Evacuate from both high and low side ports. Never use the system compressor as a vacuum pump. Refrigerant tubes and indoor coil should be evacuated to 500 microns. Always break a vacuum with dry nitrogen. The two possible methods are the deep vacuum method and the triple evacuation method

DEEP VACUUM METHOD — The deep vacuum method requires a vacuum pump capable of pulling a minimum vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth. The deep vacuum method is the most positive way of assuring a system is free of air and liquid water. (See Fig. 36.)

TRIPLE EVACUATION METHOD — The triple evacuation method should only be used when vacuum pump is capable of pumping down to 28 in. of mercury and system does not contain any liquid water. Proceed as follows:

1. Pump system down to 28 in. of mercury and allow pump to continue operating for an additional 15 minutes.

2. Close service valves and shut off vacuum pump.

3. Connect a nitrogen cylinder and regulator to system and open until system pressure is 2 psig.

4. Close service valve and allow system to stand for 1 hr. During this time, dry nitrogen will be able to diffuse throughout the system, absorbing moisture.

5. Repeat this procedure. System will then contain minimal amounts of contaminants and water vapor.

5000

4500

4000

3500

3000

2500

MICRONS

2000

1500

1000

500

MINUTES

Fig. 36 — Deep Vacuum Graph

LEAK IN SYSTEM

VACUUM TIGHT TOO WET

TIGHT DRY SYSTEM

Economizer Operation During Power Failure —

ure, dampers will return to fully closed position until power is restored. Do not manually operate damper motor.

Dampers have a spring return. In event of power fail-

Page 50

Refrigerant Charge — Amount of refrigerant charge is

listed on unit nameplate. Refer to Carrier GTAC II; Module 5; Charging, Recovery, Recycling, and Reclamation section for charging methods and procedures. Unit panels must be in place when unit is operating during charging procedure.

Puron® (R-410A) refrigerant cylinders contain a dip tube which allows liquid refrigerant to flow from the cylinder in an upright position. Charge units with cylinder in the upright position and a commercial type metering device in the manifold hose.

This system uses Puron refrigerant which has higher pressures than R-22 and other refrigerants. No other refrigerant may be used in this system. Gage set, hoses, and recovery system must be designed to handle Puron refrigerant. If unsure about equipment, consult the equipment manufacturer.

NOTE: Do not use recycled refrigerant as it may contain contaminants.

NO CHARGE — Use standard evacuating techniques. After evacuating system, weigh in the specified amount of refrigerant (refer to unit nameplate).

LOW CHARGE COOLING — Using cooling charging chart (see Fig. 37-39), add or remove refrigerant until conditions of the chart are met. An accurate pressure gage and temperaturesensing device are required. Charging is accomplished by ensuring the proper amount of liquid subcooling. Measure liquid linepressure at the liquidline service valve using pressure gage. Connect temperature sensing device to the liquid line near the liquid line service valve and insulate it so that outdoor ambient temperature does not affect reading.

TO USE THE COOLING CHARGING CHART — Use the above temperature and pressure readings, and find the intersection point on the cooling charging chart. If intersection point on chart is above line, add refrigerant. If intersection point on chart is below line, carefully recover some of the charge. Recheck suction pressure as charge is adjusted.

NOTE: Indoor-air cfm must be within normal operating range of unit. All outdoor fans must be operating.

The TXV (thermostatic expansion valve) is set to maintain between 10 and 15 degrees of superheat at the compressors. The valves are factory set and cannot be adjusted. Do not use a TXV designed for use with R-22 refrigerant.

PURON REFRIGERANT — Puron refrigerant operates at 50 to 70 percent higher pressures than R-22. Be sure that servicing

Fig. 37 — Charging Chart — 48PG20

Fig. 38 — Charging Chart — 48PG24

Fig. 39 — Charging Chart — 48PG28

equipment and replacement components are designed to operate with Puron refrigerant. Do not mix with components that have been used with other refrigerants. Puron refrigerant, as with other HFCs, is only compatible with POE oils.

Recovery cylinder service pressure rating must be 400 psig. Puron systems should be charged with liquid refrigerant. Use a commercial-type metering device in the manifold hose. Manifold sets should be 750 psig high-side and 200 psig low-side with 520 psig low-side retard. Use hoses with 750 psig service pressure rating. Leak detectors should be designed to detect HFC refrigerant.

Gas Valve Adjustment

NATURAL GAS — The gas valve opens and closes in response to the thermostat or limit control.

When power is supplied to valve terminals W2 (High Fire) and C1, the main valve opens to its preset position.

The regular factory setting is stamped on the valve body. The setting is 3.00 in. wg for vertical supply/discharge units. The setting is 2.95 in. wg for horizontal supply/discharge units.

To adjust regulator:

1. Set unit at setting for no call for heat.

2. Turn main gas valve to OFF position.

3. Remove pressure tap connection. Install a suitable pressuremeasuring device.

/8-in. pipe plug from manifold or gas valve

Page 51

4. Set main gas valve to ON position.

5. Set thermostat at setting to call for heat.

6. Remove screw cap covering regulator adjustment screw (see Fig. 40).

7. Turn adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.

8. Once desired pressure is established, set unit setting for no call for heat, turn off main gas valve, remove pressure-measuring device, and replace

/8-in. pipe

plug and screw cap.

High Altitude — For high altitude applications greater

than 2000 ft the heat input rate should be reduced. The higher the altitude is above sea level, the less oxygen is in the air. See Table 32 for orifice sizing. A high altitude kit is available to convert unit for altitudes up to 7,000 ft.

Main Burners — For all applications, main burners are

factory set and should require no adjustment. MAIN BURNER REMOVAL

1. Shut off (field-supplied) manual main gas valve.

2. Shut off power to unit.

3. Remove gas section access panel.

4. Disconnect gas piping from gas valve inlet.

5. Remove wires from gas valve.

6. Remove wires from rollout switch.

7. Remove sensor wire and ignitor cable from IGC board.

8. Remove 2 screws securing manifold bracket to basepan.

9. Remove 2 screws that hold the burner assembly to vestibule plate.

10. Lift burner/manifold assembly out of unit.

2 LEADS, #18 WIRE 1/32 INSULATION, 600V. MAX., 105°C

INLET PRESSURE TAP (PLUGGED) 1/8 - 27 N.P.T. THDS.

W-1

OFF

RECEPTACLE TERMINAL

REGULATOR ADJUSTMENT SCREW (REMOVE COVER)

D-1

D-2

PILOT

ADJ.

W-2

OUTLET PRESSURE TAP (PLUGGED) 1/8-27 N.P.T. THDS.

RECEPTACLE AND TAB COMBINATION TERMINAL

PILOT CONNECTION FOR 1/4” O.D. TUBING (PLUGGED)

Fig. 40 — Gas Valve

CLEANING AND ADJUSTMENT

1. Remove burner rack from unit as described in Main Burner Removal section above.

2. Inspect burners, and if dirty, remove burners from rack.

3. Using a soft brush, clean burners and crossover port as required.

4. Adjust spark gap. See Fig. 41.

5. Reinstall burners on rack.

6. Reinstall burner rack as described above.

SEE DETAIL “C”

Fig. 41 — Spark Gap Adjustment

Page 52

Table 32 — Altitude Compensation*

NATURAL GAS

ELEVATION

(ft)

0-1,999 29 30 29 29

2,000 29 30 29 29 3,000 30 31 30 30 4,000 30 31 30 30 5,000 30 31 30 30 6,000 30 31 30 30 7,000 31 32 31 31 8,000 31 32 31 31 9,000 31 32 31 31

10,000 32 33 32 32

*As the height above sea level increases, there is less oxygen per cubic foot of air. Therefore, heat input

rate should be reduced at higher altitudes. Includes a 4% input reduction per each 1000 ft.

†Orifices available through the local Carrier dealer.

ELEVATION

(ft)

0-1,999 35 38 35 35

2,000 36 39 36 36 3,000 36 39 36 36 4,000 37 40 37 37 5,000 37 40 37 37 6,000 38 41 38 38 7,000 39 42 39 39 8,000 40 43 40 40 9,000 41 44 41 41

10,000 42 45 42 42

*As the height above sea level increases, there is less oxygen per cubic foot of air. Therefore, heat input

ate should be reduced at higher altitudes. Includes a 4% input reduction per each 1000 ft.

†Orifices available through the local Carrier dealer.

Low Heat Medium Heat High Heat (6 Cell) High Heat (8 Cell)

NATURAL GAS ORIFICE SIZE†

PROPANE GAS

PROPANE GAS ORIFICE SIZE†

Filter Drier — Replace whenever refrigerant system is ex-

posed to atmosphere. Only use factory specified liquid-line filter driers with working pressures no less than 650 psig. Do not install a suction-line filter drier in liquid line. A liquid-line filter drier designed for use with Puron® refrigerant is required for each circuit.

Protective Devices

COMPRESSOR PROTECTION Overcurrent

protection. Overtemperature

to protect it against excessively high discharge gas temperatures. High-Pressure Switch

compressor will shut down and the compressor lockout (CLO) device will energize to block further compressor operation. The high-pressure switch will reset automatically as the refrigerant pressure drops below its reset level. The CLO will remain energized until manually reset or cooling demand is removed.

Low-Pressure Switch the compressor will shut down and the compressor lockout (CLO) device will energize to block further compressor operation. The low-pressure switch will reset automatically as the refrigerant pressure rises above its reset level. The CLO will remain energized until manually reset or cooling demand is removed.

Freeze Protection Switch evaporator coil section to provide protection against continued unit operation with a frosted evaporator surface. If the freeze protection switch opens, the compressor on this circuit will shut down and the compressor lockout (CLO) device will energize to block further compressor operation. The freeze protection switch will reset as the evaporator tube temperature rises above its reset level. The CLO will remain energized until manually reset or cooling demand is removed.

— Each compressor has internal line break motor

— Each compressor has an internal protector

— If the high-pressure switch opens, the

— If the low-pressure switch opens,

— This switch is installed on each

Compressor Lockout (CLO) Device

— The CLO prevents automatic recycling of the compressor as safety controls reset. If the high-pressure switch, low-pressure switch or freeze protection switch opens, the CLO device will energize to block further compressor operation. To reset the CLO (after all safety switches have reset), either open the thermostat to remove the cooling demand signal (and then re-close) or cycle the control power in the unit.

EVAPORATOR FAN MOTOR PROTECTION — A manual reset, calibrated trip, magnetic circuit breaker protects against overcurrent. Do not bypass connections or increase the size of the breaker to correct trouble. Determine the cause and correct it before resetting the breaker.

CONDENSER-FAN MOTOR PROTECTION — Each condenser-fan motor is internally protected against overtemperature.

Fuses are also located in the control box and feed power to the condenser fan motors. Always replace blown fuses with the correct size fuse as indicated on the unit fuse label.

Relief Devices — All units have relief devices to protect

against damage from excessive pressures (i.e., fire). These devices protect the high and low side and are located at the suction line service port. Protect joint during brazing operations near joint.

Control Circuit, 24-V — Each control circuit is pro-

tected against overcurrent by a 3.2 amp circuit breaker. Breaker can be reset. If it trips, determine cause of trouble before resetting. See Fig. 42-45 for schematics.

Replacement Parts — A complete list of replacement

parts may be obtained from any Carrier distributor upon request.

Diagnostic LEDs — The IGC control board has a LED

for diagnostic purposes. See Unit Troubleshooting section on page 57 for more information.

Page 53

Fig. 42 — Typical Low Voltage Control Schematic

Page 54

Fig. 43 — Typical Power Schematic

Page 55

Fig. 44 — Typical Component Arrangement — 48PG20,24

Page 56

LEGEND FOR FIG. 42-45

LPS — Low-Pressure Switch

---A — Circuit A

LS — Limit Switch

AUX — Auxiliary Contact

OAS — Outdoor-Air Sensor

OFC — Outdoor-Fan Contactor

AL — Ambient Limit

---B — Circuit B

OFM — Outdoor-Fan Motor

C—Compressor Contactor

Te r m i na l B l o c k

Terminal (Unmarked)

Te r m i na l ( Marked)

Factory Wiring

Field Wiring

To Indicate Common Potential

Only. Not to Represent Wiring.

To Indicate FIOP or Accessory

PEC — Power Exhaust Contactor

PEM — Power Exhaust Motor

PL — Plug

PLP — Phase Loss Protection

QC — Quick Connect

QT — Quadruple Terminal

RAS — Return Air Sensor

RS — Rollout Switch

SAT — Supply-Air Temperature

TB — Ter m i n a l B l o ck

TRAN — Transformer

TXV — Thermostatic Expansion Valve

W/AT — With Auxiliary Trip

and Refrigeration

CAP — Capacitor

CB — Compressor Circuit Breaker

CCH — Crankcase Heater

CLO — Compressor Lockout

COMP — Compressor

CT BRK — Circuit Breaker

CR — Control Relay

DU — Dummy Terminal

ECB — Economizer Control Board

FCS — Fan Cycling Switch

FIOP — Factory-Installed Option

FPT — Freeze Protection Thermostat

FS — Flame Sensor

FU — Fuse

GND — Ground

GV — Gas Valve

HACR — Heating, Air Conditioning,

HERM — Her metic

HPS — High-Pressure Switch

I—Ignitor

IAQ — Indoor Air Quality

IDM — Induced-Draft Motor

IDR — Induced Draft Relay

IFC — Indoor-Fan Contactor

IFCB — Indoor Fan Circuit Breaker

IFM — Indoor-Fan Motor

IGC — Integrated Gas Controller

LOR — Lockout Relay

THERMOSTAT/IGC MARKINGS

Fig. 45 — Typical Component Arrangement — 48PG28

field modifications or additions must be in compliance with all applicable

codes.

protected against primary single-phase conditions.

NOTES:

1. Factory wiring is in accordance with the National Electrical Codes. Any

BM — Blower Motor

C—Common

CM — Inducer Motor

CS — Centrifugal Switch

G—Fan

IFO — Indoor Fan On

L1 — Line 1

R—Thermostat Power

RT — Power Supply

SS — Speed Sensor

overload and safety devices. Before replacing CLO, check these devices.

2. Use 75° C min wire for field power supply. Use copper wires for all units.

3. All circuit breakers “Must Trip Amps” are equal to or less than 156% RLA.

4. Compressor and fan motors are thermally protected. Three-phase motors

5. The CLO locks out the compressor to prevent short cycling on compressor

W—Thermostat Heat

W1 — 1st Stage of Heating

W2 — 2nd Stage of Heating

X—Alarm Output

Y1 — 1st Stage of Cooling

Y2 — 2nd Stage of Cooling

Page 57

TROUBLESHOOTING

Unit Troubleshooting —

Refer to Tables 33-35 and

Fig. 46.

Table 33 — Cooling Service Analysis

PROBLEM CAUSE REMEDY

Compressor and Condenser Fan Will Not Start.

Compressor Will Not Start but Condenser Fan Runs.

Compressor Cycles (other than normally satisfying thermostat).

Compressor Operates continuously.

Excessive Head Pressure. Dirty air filter. Replace filter.

Head Pressure Too Low. Low refrigerant charge. Check for leaks, repair, and recharge.

Excessive Suction Pressure. High heat load. Check for source and eliminate.

Suction Pressure Too Low. Dirty air filter. Replace filter.

LEGEND

TXV — Thermostatic Expansion Valve

Power failure. Call power company. Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Defective thermostat, contactor, transformer, or control

relay. Insufficient line voltage. Determine cause and correct. Incorrect or faulty wiring. Check wiring diagram and rewire correctly. Thermostat setting too high. Lower thermostat setting below room temperature. Faulty wiring or loose connections in compressor

circuit. Compressor motor burned out, seized, or internal

overload open. Defective overload. Determine cause and replace. Compressor locked out Determine cause for safety trip and reset lockout. One leg of 3-phase power dead. Replace fuse or reset circuit breaker.

Refrigerant overcharge or undercharge. Recover refrigerant, evacuate system, and recharge to

Defective compressor. Replace and determine cause. Insufficient line voltage. Determine cause and correct. Blocked condenser. Determine cause and correct. Defective overload. Determine cause and replace. Defective thermostat. Replace thermostat. Faulty condenser-fan motor. Replace. Restriction in refrigerant system. Locate restriction and remove. Dirty air filter. Replace filter. Unit undersized for load. Decrease load or increase unit size. Thermostat set too low. Reset thermostat. Low refrigerant charge. Locate leak, repair, and recharge. Air in system. Recover refrigerant, evacuate system, and recharge. Condenser coil dirty or restricted. Clean coil or remove restriction.

Dirty condenser coil. Clean coil. Refrigerant overcharged. Recover excess refrigerant. Faulty TXV. 1. Check TXV bulb mounting and secure tightly to suction line.

Air in system. Recover refrigerant, evacuate system, and recharge. Condenser air restricted or air short-cycling. Determine cause and correct.

Restriction in liquid tube. Remove restriction.

Faulty TXV. 1. Check TXV bulb mounting and secure tightly to suction line.

Refrigerant overcharged. Recover excess refrigerant.

Low refrigerant charge. Check for leaks, repair, and recharge. Metering device or low side restricted. Remove source of restriction. Faulty TXV. 1. Check TXV bulb mounting and secure tightly to suction line.

Insufficient evaporator airflow. Increase air quantity. Check filter and replace if necessary. Temperature too low in conditioned area. Reset thermostat. Field-installed filter drier restricted. Replace.

Replace component.

Check wiring and repair or replace.

Determine cause. Replace compressor.

Determine cause.

nameplate.

2. Replace TXV if stuck open or closed.

Page 58

Table34—GasHeatingServiceAnalysis

PROBLEM CAUSE REMEDY

Burners Will Not Ignite. Misaligned spark electrodes. Check flame ignition and sensor electrode positioning.

No gas at main burners. Check gas line for air; purge as necessary. After purging gas

Water in gas line. Drain water and install drip leg to trap water. No power to furnace. Check power supply, fuses, wiring, and circuit breaker. No 24 v power supply to control circuit. Check transformer. Transformers with internal overcurrent pro-

Miswired or loose connections. Check all wiring and wire nut connections. Burned-out heat anticipator in thermostat. Replace thermostat. Broken thermostat wires. Run continuity check. Replace wires if necessary.

Inadequate Heating. Dirty air filter. Clean or replace filter as necessary.

Gas input to unit too low. Check gas pressure at manifold. Clock gas meter for input.

Unit undersized for application. Replace with proper unit or add additional unit. Restricted airflow. Clean filter, replace filter, or remove any restrictions. Blower speed too low. Install alternate motor, if applicable, or adjust pulley to increase

Limit switch cycles main burners. Check rotation of blower, thermostat heat anticipator settings,

Too much outdoor air. Adjust minimum position.

Poor Flame Characteristics. Incomplete combustion (lack of combustion air)

Burners Will Not Turn Off. Unit is locked into Heating mode for a one minute

results in: Aldehyde odors, CO, sooting flame, or floating

flame.

minimum.

Adjust as needed.

line of air, allow gas to dissipate for at least 5 minutes before attempting to relight unit.

Check gas valve.

tection require a cool-down period before resetting. Check 24-v circuit breaker; reset if necessary.

If too low, increase manifold pressure or replace with correct orifices.

fan speed.

and temperature rise of unit. Adjust as needed.

Check economizer operation. Check all screws around flue outlets and burner compartment.

Tighten as necessary. Cracked heat exchanger. Replace heat exchanger. Overfired unit — reduce input, change orifices, or adjust gas

line or manifold pressure. Check vent for restriction. Clean as necessary. Check orifice to burner alignment. Wait until mandatory one minute time period has elapsed or

power to unit.

Page 59

LEGEND

IDM — Induced-Draft Motor IGC — Integrated Gas Unit Controller

NOTE: Thermostat Fan Switch in the “AUTO” position.

Fig. 46 — IGC Control (Heating and Cooling)

Page 60

Table 35 — IGC Board LED Alarm Codes

LED

FLASH

CODE

On Normal Operation — — — Off Hardware Failure No gas heating. — Loss of power to the IGC. Check 5 amp fuse on IGC,

1 Flash Indoor Fan On/Off Delay

2 Flashes Limit Switch Fault Gas valve and igniter Off.

3 Flashes Flame Sense Fault Indoor fan and inducer On. Flame sense normal.

4 Flashes Four Consecutive Limit

5 Flashes Ignition Fault No gas heating. Heat call (W) Off.

6 Flashes Induced Draft Motor Fault If heat off: no gas heating.

7 Flashes Rollout Switch Lockout Gas valve and igniter Off.

8 Flashes Internal Control Lockout No gas heating. Power reset. IGC has sensed internal hardware or software error. If

9 Flashes Temporary Software Lockout No gas heating. 1 hour auto reset, or

IGC — Integrated Gas Unit Control LED — Light-Emitting Diode

DESCRIPTION

Modified

Switch Fault

LEGEND NOTES:

ACTION TAKEN BY

CONTROL

5 seconds subtracted from On delay. 5 seconds added to Off delay (3 min max).

Indoor fan and inducer On.

No gas heating. Heat call (W) Off.

If heat on: gas valve Off and inducer On.

Indoor fan and inducer On.

RESET METHOD PROBABLE CAUSE

Power reset. High temperature limit switch opens during heat

Limit switch closed, or heat call (W) Off.

Power reset for LED reset.

Inducer sense normal, or heat call (W) Off.

Power reset. Rollout switch has opened. Check gas valve opera-

power reset.

1. There is a 3-second pause between alarm code displays.

2. If more than one alarm code exists, all applicable alarm codes will be

displayed in numerical sequence.

3. Alarm codes on the IGC will be lost if power to the unit is interrupted.

power to unit, 24V circuit breaker, transformer, and wiring to the IGC.

exchanger warm-up period before fan-on delay expires. High temperature limit switch opens within 10 minutes of heat call (W) Off. See Limit Switch Fault.

High temperature limit switch is open. Check the operation of the indoor (evaporator) fan motor. Ensure that the supply-air temperature rise is within the range on the unit nameplate. Check wiring and limit switch operation.

The IGC sensed a flame when the gas valve should be closed. Check wiring, flame sensor, and gas valve operation.

4 consecutive limit switch faults within a single call for heat. See Limit Switch Fault.

Unit unsuccessfully attempted ignition for 15 minutes. Check igniter and flame sensor electrode spacing, gaps, etc. Check flame sense and igniter wiring. Check gas valve operation and gas supply.

Inducer sense On when heat call Off, or inducer sense Off when heat call On. Check wiring, voltage, and operation of IGC motor. Check speed sensor wiring to IGC.

tion. Check induced-draft blower wheel is properly secured to motor shaft.

fault is not cleared by resetting 24 v power, replace the IGC.

Electrical interference is disrupting the IGC software.

EconoMi$er IV Troubleshooting

ECONOMI$ER IV PREPARATION — This procedure is used to prepare the EconoMi$er IV for troubleshooting. No troubleshooting or testing is done by performing the following procedure.

NOTE: This procedure requires a 9-v battery, 1.2 kilo-ohm resistor, and a 5.6 kilo-ohm resistor which are not supplied with the EconoMi$er IV.

IMPORTANT: Be sure to record the positions of all potentiometers before starting troubleshooting.

1. Disconnect power at TR and TR1. All LEDs should be off. Exhaust fan contacts should be open.

2. Disconnect device at P and P1.

3. Jumper P to P1.

4. Disconnect wires at T and T1. Place 5.6 kilo-ohm resistor across T and T1.

5. Jumper TR to 1.

6. Jumper TR to N.

7. If connected, remove sensor from terminals S Connect 1.2 kilo-ohm 4074EJM checkout resistor across terminals S

8. Put 620-ohm resistor across terminals S

and +.

9. Set minimum position, DCV set point, and exhaust potentiometers fully CCW (counterclockwise).

and +.

10. Set DCV maximum position potentiometer fully CW (clockwise).

11. Set enthalpy potentiometer to D.

12. Apply power (24 vac) to terminals TR and TR1.

DIFFERENTIAL ENTHALPY — To check differential enthalpy:

1. Make sure EconoMi$er IV preparation procedure has been performed.

2. Place 620-ohm resistor across S

3. Place 1.2 kilo-ohm resistor across S

and +.

and +. The Free

Cool LED should be lit.

4. Remove 620-ohm resistor across S

and +. The Free

Cool LED should turn off.

5. Return EconoMi$er IV settings and wiring to normal after completing troubleshooting.

SINGLE ENTHALPY — To check single enthalpy:

1. Make sure EconoMi$er IV preparation procedure has been performed.

2. Set the enthalpy potentiometer to A (fully CCW). The Free Cool LED should be lit.

3. Set the enthalpy potentiometer to D (fully CW). The Free Cool LED should turn off.

4. Return EconoMi$er IV settings and wiring to normal after completing troubleshooting.

Page 61

DCV (Demand Controlled Ventilation) AND POWER EXHAUST — To check DCV and Power Exhaust:

1. Make sure EconoMi$er IV preparation procedure has been performed.

2. Ensure terminals AQ and AQ1 are open. The LED for both DCV and Exhaust should be off. The actuator should be fully closed.

3. Connect a 9-v battery to AQ (positive node) and AQ1 (negative node). The LED for both DCV and Exhaust should turn on. The actuator should drive to between 90 and 95% open.

4. Turn the Exhaust potentiometer CW until the Exhaust LED turns off. The LED should turn off when the potentiometer is approximately 90%. The actuator should remain in position.

5. Turn the DCV set point potentiometer CW until the DCV LED turns off. The DCV LED should turn off when the potentiometer is approximately 9 v. The actuator should drive fully closed.

6. Turn the DCV and Exhaust potentiometers CCW until the Exhaust LED turns on. The exhaust contacts will close 30 to 120 seconds after the Exhaust LED turns on.

7. Return EconoMi$er IV settings and wiring to normal after completing troubleshooting.

DCV MINIMUM AND MAXIMUM POSITION — To check the DCV minimum and maximum position:

1. Make sure EconoMi$er IV preparation procedure has been performed.

2. Connect a 9-v battery to AQ (positive node) and AQ1 (negative node). The DCV LED should turn on. The actuator should drive to between 90 and 95% open.

3. Turn the DCV Maximum Position potentiometer to midpoint. The actuator should drive to between 20 and 80% open.

4. Turn the DCV Maximum Position potentiometer to fully CCW. The actuator should drive fully closed.

5. Turn the Minimum Position potentiometer to midpoint. The actuator should drive to between 20 and 80% open.

6. Turn the Minimum Position Potentiometer fully CW. The actuator should drive fully open.

7. Remove the jumper from TR and N. The actuator should drive fully closed.

8. Return EconoMi$er IV settings and wiring to normal after completing troubleshooting.

MIXED-AIR INPUT — To check mixed-air input:

1. Make sure EconoMi$er IV preparation procedure has been performed.

2. Set the Enthalpy potentiometer to A. The Free Cool LED turns on. The actuator should drive to between 20 and 80% open.

3. Remove the 5.6 kilo-ohm resistor and jumper T to T1. The actuator should drive fully open.

4. Remove the jumper across T and T1. The actuator should drive fully closed.

5. Return EconoMi$er IV settings and wiring to normal after completing troubleshooting.

ECONOMI$ER IV TROUBLESHOOTING COMPLETION — This procedure is used to return the EconoMi$er IV to operation. No troubleshooting or testing is done by performing the following procedure.

1. Disconnect power at TR and TR1.

2. Set enthalpy potentiometer to previous setting.

3. Set DCV maximum position potentiometer to previous setting.

4. Set minimum position, DCV set point, and exhaust potentiometers to previous settings.

5. Remove 620-ohm resistor from terminals S

and +.

6. Remove 1.2 kilo-ohm checkout resistor from terminals S

and +. If used, reconnect sensor from terminals SOand

7. Remove jumper from TR to N.

8. Remove jumper from TR to 1.

9. Remove 5.6 kilo-ohm resistor from T and T1. Reconnect wires at T and T1.

10. Remove jumper from P to P1. Reconnect device at P and P1.

11. Apply power (24 vac) to terminals TR and TR1.

Phase Loss Protection — The phase loss protection

option will monitor the three-phase electrical system to provide phase reversal and phase loss protection.

PHASE REVERSAL PROTECTION — If the control senses an incorrect phase relationship, the relay (K1) will be deenergized (opening its contact). If the phase relationship is correct, the relay will be energized. The control has a selfbypass function after a pre-set time. If the control determines that the three phases stay in a correct relationship for 10 consecutive minutes, the relay will stay energized regardless of the phase sequence of three inputs as long as 24-vac control voltage is applied. This self-bypass function will be reset if all three phases are restored in a phase loss event.

PHASE LOSS PROTECTION — If the reverse rotation board senses any one of the three phase inputs has no AC voltage, the relay will be deenergized (opening its contact). This protection is always active as long as 24-vac control voltage is applied, and is not affected by the self bypass function of the phase sequence monitoring function. However, in the event of phase loss, the relay will be re-energized only if all three phases are restored and the three phases are in the correct sequence.

A red LED is provided to indicate the function of the board.

See the table below.

LED STATUS FUNCTION

On Continuously Relay contact closed (normal operation).

Blinking

Off 24 vac control power not present (off).

Relay contact open (phase loss or phase reversal has occurred) — No power will be supplied to the control system.

Page 62

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

Book 1 4 Ta b 1 a 6 a

PC 111 Catalog No. 534-80211 Printed in U.S.A. Form 48PG-10SI Pg 62 9-05 Replaces: New

Page 63

Page 64

UNIT START-UP CHECKLIST

MODEL NO.:___________________________________________ SERIAL NO.:______________________________________________

DATE:_________________________________________________ TECHNICIAN: ____________________________________________

I. PRE-START-UP:



VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT



VERIFY INSTALLATION OF OUTDOOR AIR HOOD



VERIFY INSTALLATION OF FLUE EXHAUST AND INLET HOOD



VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS



VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT



VERIFY GAS PRESSURE TO UNIT GAS VALVE IS WITHIN SPECIFIED RANGE



CHECK GAS PIPING FOR LEAKS



CHECK THAT INDOOR-AIR FILTERS ARE CLEAN AND IN PLACE



CHECK THAT OUTDOOR AIR INLET SCREENS ARE IN PLACE



VERIFY THAT UNIT IS LEVEL



CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE, AND VERIFY SETSCREW

IS TIGHT



VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED



VERIFY THAT SCROLL COMPRESSORS ARE ROTATING IN THE CORRECT DIRECTION



VERIFY INSTALLATION OF THERMOSTAT



VERIFY THAT CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR AT LEAST 24 HOURS

II. START-UP

ELECTRICAL

SUPPLY VOLTAGE L1-L2 L2-L3 L3-L1

COMPRESSOR AMPS — COMPRESSOR A1 L1 L2 L3

— COMPRESSOR A2 L1 L2 L3 — COMPRESSOR B1 L1 L2 L3

SUPPLY FAN AMPS L1 L2 L3

TEMPERATURES

OUTDOOR-AIR TEMPERATURE F DB (Dry Bulb) RETURN-AIR TEMPERATURE F DB COOLING SUPPLY AIR F GAS HEAT SUPPLY AIR F

PRESSURES

GAS INLET PRESSURE IN. WG GAS MANIFOLD PRESSURE STAGE NO. 1 IN. WG STAGE NO. 2 IN. WG REFRIGERANT SUCTION CIRCUIT A PSIG

CIRCUIT B PSIG

REFRIGERANT DISCHARGE CIRCUIT A PSIG

CIRCUIT B PSIG

FWB(WetBulb)

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE



VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGE 50

GENERAL



ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS

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

Book 1 4 Ta b 1 a 6 a

PC 111 Catalog No. 534-80211 Printed in U.S.A. Form 48PG-10SI Pg CL-1 9-05 Replaces: New

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

Carrier SINGLE PACKAGE ROOFTOP UNITS 48PG20-28 Installation And Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual