Carrier WeatherExpert 48LC Installation Instructions Manual
48LC
WeatherExpertRSeries
Single Package Rooftop
Gas Heat/Electric Cooling Unit
with Puronr (R ---410A) Refrigerant
Sizes: 14, 17, 20, 24, 26
Installation Instructions
NOTE: Read the entire instruction manual before starting
the installation.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS 2....................
Rated Indoor Airflow (cfm) 4.....................
INSTALLATION 15..............................
Jobsite Survey 15...............................
Step 1 -- Plan for Unit Location 15.................
Roof Mount 15..............................
Step 2 -- Plan for Sequence of Unit Installation 15.....
Curb--Mounted Installation 15..................
Pad--Mounted Installation 15...................
Frame--Mounted Installation 15.................
Step 3 -- Inspect Unit 15..........................
Step 4 -- Provide Unit Support 16..................
Roof Curb Mount 16.........................
Slab Mount (Horizontal Units Only) 16..........
Alternate Unit Support
(In Lieu of Curb or Slab Mount) 16.............
Step 5 -- Field Fabricate Ductwork 20...............
Step 6 -- Rig and Place Unit 20....................
Positioning on Curb 21.......................
Step 7 -- Horizontal Duct Connection 21............
Step 8 -- Install Outside Air Hood — Factory Option 21..
Step 9 -- Install Flue Hood and Combustion Air Hood 22.
Step 10 -- Install Gas Piping 23....................
Gas Supply Line 23..........................
Factory--Option Thru--Base Connections 24.......
Step 11 -- Install External Condensate Trap and Line 25..
Step 12 -- Make Electrical Connections 25...........
Field Power Supply 25........................
Units Without Factory--Installed
Non--Fused Disconnect or HACR 32.............
Units With Factory--Installed
Non--Fused Disconnect or HACR 32.............
All Units 33................................
Convenience Outlets 33.......................
HACR 34..................................
Factory--Option Thru--Base Connections 35......
Units Without Thru --Base Connections 35........
Field Control Wiring 35.......................
Thermostat 35...............................
Unit Without Thru--Base Conversion Kit 35.......
Heat Anticipator Settings 36...................
Transformer Connection
for 208--v Power Supply 36.....................
RTU Open Controller (Factory--Installed Option) 36...
SystemVut Controller (Factory--Installed Option) 36..
Humidi--MiZer
Humidi--MiZer System -- Space RH Controller 37..
Integrated Staging Control (ISC) Board 38...........
ISC Board — Sequence of Operation 38...........
General 38.................................
Ventilation 38...............................
Cooling 39.................................
Humidi--MiZer System (Optional) 39............
Economizer (Optional) 39.....................
Low Ambient Cooling Operation
Down to 40_F(4_C) 40.......................
Heating 40.................................
EconoMi$er
Unit Installation 41..........................
Enthalpy Sensor Relocation 41.................
W7220 Economizer Controller 41................
User Interface 41............................
Keypad 41.................................
Menu Structure 42.............................
Connections and Applications 46.................
W7220 Economizer Module Wiring 46..........
Economizer Controlled Configurations 47..........
Enthalpy Changeover Control 47...............
Enthalpy Settings 47.........................
Demand Controlled Ventilation 49..............
Economizer Occupancy Control 50..............
R
System Control Connections 37....
R
X (Factory--Installed Option) 41.......
Hardware 51.................................
Actuators 51................................
Supply Air Temperature Sensor 51..............
Outside Air Temperature Sensor 51.............
Enthalpy Control Sensor Configuration 51........
Operating Sequences 52........................
Staged Air Volume (3--Speed) Fan Motor 52......
W7220 Economizer Control 52.................
Base Unit Controls 52........................
R
Cooling, Unit With EconoMi$er
Without CO
Heating With EconoMi$er X 54.................
Demand Controlled Ventilation 55..............
Setup and Configuration 55.....................
Initial Menu Display 55.......................
Time--out and Screensaver 55..................
Checkout 55.................................
Status 56...................................
Calibration of Sensors 56......................
Resetting All Defaults 56......................
Troubleshooting 56............................
Power Up Delay 56..........................
Power Loss (Outage or Brownout) 56............
Alarms 56..................................
Clearing Alarms 56..........................
Control Set Point and Configuration Log 59........
Staged Air Volume (SAVt)
with Variable Frequency Drive 62..................
Multi--Speed VFD Display Kit
(Field--Installed Accessory) 63....................
Connecting the Keypad to the VFD 63.............
Program the VFD for 3 Discrete
Indoor Fan Speeds 64..........................
Smoke Detectors 80...........................
Return Air Sensor Tube Installation 80...........
Smoke Detector Test Magnet 80................
Additional Application Data 80.................
Step 13 -- Install Accessories 80...................
Step 14 -- Check Belt Tension 81...................
UNIT START--UP CHECKLIST 83..................
Sensor 52.......................
2
X
product. Refer to the individual instructions packaged with
the kits or accessories when installing.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloths for brazing operations and
have a fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions attached to
the unit. Consult local building codes and appropriate
national electrical codes (in USA, ANSI/NFPA 70,
National Electrical Code (NEC); in Canada, CSA C22.1)
for special requirements.
It is important to recognize safety information. This is the
safety--alert symbol
unit and in instructions or manuals, be alert to the
potential for personal injury.
Understand the signal words DANGER, WARNING,
CAUTION, and NOTE. These words are used with the
safety--alert symbol. DANGER identifies the most serious
hazards which will result in seve re personal injury or
death. WARNING signifies hazards which could result in
personal injury or death. CAUTION is used to identify
unsafe practices, which may result in minor personal
injury or product and property damage. NOTE is used to
highlight suggestions which will result in enhanced
installation, reliability, or operation.
!
FIRE, EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury or death.
Disconnect gas piping from unit when leak testing at
pressure greater than 0.5 psig (3450 Pa). Pressures
greater than 0.5 psig (3450 Pa) will cause gas valve
damage resulting in hazardous condition. If gas valve is
subjected to pressure greater than 0.5 psig (3450 Pa), it
must be replaced before use. When pressure testing
field--supplied gas piping at pressures of 0.5 psig
(3450 Pa) or less, a unit connected to such piping must
be isolated by closing the manual gas valve.
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Inlet pressure tab set screw must be tightened and
NPT pipe plug must be installed to prevent gas leaks.
!
. When you see this symbol on the
WARNING
WARNING
1
/8in.
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical
shock or other conditions which may cause personal injury
or property damage. Consult a qualified installer, service
agency, or your distributor or branch for information or
assistance. The qualified installer or agency must use
factory--authorized kits or accessories when modifying this
518
GAS VALVE
INLET PRESSURE
TAP SET SCREW
2
!
WARNING
!
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Manifold pressure tap set screw must be tightened and
1
/8in. NPT pipe plug must be installed to prevent gas
leak.
MANIFOLD PRESSURE
TAP SET SCREW
MANIFOLD
GAS VALVE
!
WARNING
CARBON--MONOXIDE POISONING HAZARD
Failure to follow instructions could result in severe
personal injury or death due to carbon--monoxide
poisoning, if combustion products infiltrate into the
building.
Check that all openings in the outside wall around the
vent (and air intake) pipe(s) are sealed to prevent
infiltration of c om bustion products into the building.
Check that furnace vent (and air intake) terminal(s)
are not obstructed in any way during all seasons.
!
WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could cause personal
injury, death and/or equipment damage.
Puronr (R--410A) refrige rant systems operate at
higher pressures than standard R--22 systems. Do not
use R--22 service equipment or components on Puron
refrigerant equipment.
!
WARNING
PERSONAL INJURY AND ENVIRONMENTAL
HAZARD
Failure to follow this warning could cause personal
injury or death.
Relieve pre ssure and recover all refrigerant before
system repair or final unit disposal.
Ware safety glasses and gloves when handling
refrigerants. Keep torches and other ignition sources
away from refrigerants and oils.
!
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal
injury.
Sheet metal parts may have sharp edges or burrs. Use
care and wear appropriate protective clothing, safety
glasses and gloves when handling parts and servicing
air conditioning equipment.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could cause personal
injury or death.
Before performing service or maintenance operations
on unit, always turn off main power switch to unit and
install lock(s) and lockout tag(s). Unit ma y have more
than one power switch.
3
518
Rated Indoor Airflow (cfm)
The table to the right lists the rated indoor airflow used
for the AHRI efficiency rating for the units covered in this
document.
Model Number Full Load Airflow (cfm)
48LC**14 4375
48LC**17 4875
48LC**20 5690
48LC**24 6500
48LC**26 7500
Position:
Example:
1234567891011 12 13 14 15 16
48LCD0 24A1A5 -0A0A0
Unit Heat Type
48 - Gas Heat Packaged Rooftop
Model Series - WeatherExpert
®
LC - Ultra High Efficiency
Heat Options
D = Low Gas Heat
E = Medium Gas Heat
F = High Gas Heat
S = Low Heat w/ Stainless Steel Exchanger
R = Medium Heat w/ Stainless Steel Exchanger
T = High Heat w/ Stainless Steel Exchanger
Refrig. Systems Options
0 = Three stage cooling capacity control with TXV
A = Three stage cooling capacity control with TXV
and Humidi-MiZer
®
system
Cooling Tons
14 - 12.5 ton
17 - 15 ton
20 - 17.5 ton
24 - 20 ton
26 - 23 ton
Sens or Options
A = None
B = RA Smoke Detector
C = SA Smoke Detector
D = RA + SA Smoke Detector
E = CO
2
F = RA Smoke Detector and CO
G = SA Smoke Detector and CO
H = RA + SA Smoke Detector and CO
2
2
2
Indoor Fan Motor Options
1 = Standard Static / Vertical Supply, Return Air Flow
2 = Medium Static / Vertical Supply, Return Air Flow
3 = High Static / Vertical Supply, Return Air Flow
4 = Ultra High Static / Vertical Supply, Return Air Flow
5 = Standard Static / Horizontal Supply, Return Air Flow
6 = Medium Static / Horizontal Supply, Return Air Flow
7 = High Static / Horizontal Supply, Return Air Flow
8 = Ultra High Static / Horizontal Supply, Return Air Flow
17
18
Packaging
0 = Standard
1 = LTL
Electrical Options
A = None
B = HACR Circuit Breaker
C = Non-Fused Disconnect
Service Options
0 = None
1 = Unpowered Convenience Outlet
2 = Powered Convenience Outlet
3 = Hinged Panels
4 = Hinged Panels and
Unpowered Convenience Outlet
5 = Hinged Panels and
Powered Convenience Outlet
Intake / Exhaust Options
A = None
B = Temperature Standard Leak Economizer with
Barometric Relief
C = Temperature Standard Leak Economizer with
Centrifugal Power Exhaust - Vertical Only
E = Enthalpy Standard Leak Economizer with
Barometric Relief
F = Enthalpy Standard Leak Economizer with
Centrifugal Power Exhaust - Vertical Only
N = Temperature Ultra Low Leak Economizer with
Barometric Relief
P = Temperature Ultra Low Leak Economizer
with Centrifugal Power Exhaust - Vertical Only
R = Enthalpy Ultra Low Leak Economizer with
Barometric Relief
S = Enthalpy Ultra Low Leak Economizer with
Centrifugal Power Exhaust - Vertical Only
Base Unit Controls
0 = Electro-mechanical Controls
1 = RTU Open Multi-Protocol Controller
4 = SystemVu™ Controller
Design Revision
- = Factory Design Revision
Coil Options: Fin/Tube (Condenser- Evaporator - Hail Guard)
A = Al/Cu - Al/Cu
B = Precoat Al/Cu - Al/Cu
C = E-coat Al/Cu - Al/Cu
D = E-coat Al/Cu - E-coat Al/Cu
E = Cu/Cu - Al/Cu
F = Cu/Cu - Cu/Cu
M = Al/Cu -Al/Cu — Louvered Hail Guard
N = Precoat Al/Cu - Al/Cu — Louvered Hail Guard
P = E-coat Al/Cu - Al/Cu — Louvered Hail Guard
Q = E-coat Al/Cu - E-coat Al/Cu — Louvered Hail Guard
R = Cu/Cu - Al/Cu — Louvered Hail Guard
S = Cu/Cu - Cu/Cu — Louvered Hail Guard
Fig. 1 -- 48LC 14--26 Model Number Nomenclature (Example)
Voltage
1 = 575/3/60
5 = 208-230/3/60
6 = 460/3/60
a48--- 9335
4
Fig. 2 -- Unit Dimensional Drawing – 14 Size Unit, Sheet 1 of 3
C13057
5
Fig.2(cont)--UnitDimensionalDrawing–14SizeUnit,Sheet2of3
C13058
6
Fig.2(cont)--UnitDimensionalDrawing–14SizeUnit,Sheet3of3
C13059
7
Fig. 3 -- Unit Dimensional Drawing – 17 and 20 Size Units, Sheet 1 of 3
C13032
8
Fig. 3 (cont) -- Unit Dimensional Drawing – 17 and 20 Size Units, Sheet 2 of 3
C13033
9
Fig. 3 (cont) -- Unit Dimensional Drawing – 17 and 20 Size Units, Sheet 3 of 3
C13034
10
Fig. 4 -- Unit Dimensional Drawing – 24 and 26 Size Units, Sheet 1 of 3
C14106
11
Fig. 4 (cont) -- Unit Dimensional Drawing – 24 and 26 Size Units, Sheet 2 of 3
C14107
12
Fig. 4 (cont) -- Unit Dimensional Drawing – 24 and 26 Size Units, Sheet 3 of 3
C14108
13
C
D
B
LOCATION DIMENSION CONDITION
A 36-- -in (914 mm) • Recommended clearance for air flow and service
B 42--- in (1067 mm) • Recommended clearance for air flow and service
• No Convenience Outlet
18-- -in (457 mm)
36-- -in (914 mm)
C
42-- -in (1067 mm)
96-- -in (2438 mm)
D 42--- in (1067 mm) • Recommended clearance for service.
NOTE: Unit not designed to have overhead obstruction. Contact Application Engineering for guidance on any application planning
overhead obstruction or for vertical clearances.
•NoEconomizer
• No field--- installed disconnect on economizer hood side (Factory --- installed disconnect installed).
• Convenience Outlet installed.
• Vertical surface behind servicer is electrically non ---conductive (e.g.: wood, fiberglass).
• Convenience Outlet installed.
• Vertical surface behind servicer is electrically conductive (e.g.: metal, masonry).
• Economizer and/or Power Exhaust installed.
• Check for sources of flue products with 10 feet (3 meters) of economizer fresh air intake.
A
Fig. 5 -- Service Clearance Dimensional Drawing
C12384
48LC**
Base Unit 1853 (842.3) 2095 (952.3) 2201 (1000.7) 2347 (1067.0) 2492 (1132.6)
Economizer 246 (112) 246 (112) 246 (112) 246 (112) 246 (112)
Powered Outlet 35 (16) 35 (16) 35 (16) 35 (16) 35 (16)
Curb
14--- in/356 mm 240 (109) 240 (109) 255 (116) 255 (116) 273 (124)
24--- in/610 mm 340 (154) 340 (154) 355 (161) 355 (161) 355 (161)
14 17 20 24 26
Table 1 – Operating Weights
UNIT LB (KG)
14
INSTALLATION
Jobsite Survey
Complete the following checks before installation.
1. Consult local building codes and the NEC (National
Electrical Code) ANSI/NFPA 70 for special installation requirements.
2. Determine unit location (from project plans) or select
unit location.
3. Check for possible overhead obstructions which may
interfere with unit lifting or rigging.
Step 1 — Plan for Unit Location
Select a location for the unit and its support system (curb or
other) that provides for the minimum clearances required for
safety. This includes the clearance to combustible surfaces,
unit performance and service access below, around and
above unit as specified in unit drawings. See Fig. 5.
NOTE: Consider also the effect of adjacent units.
Be sure that the unit is installed such that snow will not
block the combustion air intake or flute outlet.
Unit may be installed directly on wood floo rin g or on Class
A, B, or C roof--covering material when roof curb is used.
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 pro vid ed in accord an ce with S ection
5.3 (Air for Combustion and Ventilation) of the National
Fuel Gas Code, ANSI Z223.1 (American National Standards
Institute) and NFPA (National Fire Protection Association)
54 TIA----54----84----1. In Canada, installation must be in
accordance with the CAN1----B149 installation codes for gas
burning appliances.
Although unit is weatherproof, avoid locations that permit
water from higher level runoff and overhangs to fall onto the
unit.
Locate mechanical draft system flue assembly at least 4 ft
(1.2 m) from any opening through which combustion
products could enter the building, and at least 4 ft (1.2 m)
from any adjacent building (or per local code). Locate the
flue assembly at least 10 ft (3.05 m) from an adjacent
unit’s fresh air intake hood if within 3 ft (0.91 m) of same
elevation (or per local code). When unit is located
adjacent t o public walkways, flue assembly must be at
least 7 ft (2.1 m) above grade.
Select a unit mounting system that provides adequate
height to allow installation of condensate trap per
requirements. Refer to Step 11 — Install External
Condensate Trap and Line for required trap dimensions.
Roof Mount —
Check building codes for weight distribution
requirements. Unit operating weight i s shown in Table 1.
Step 2 — Plan for Sequence of Unit Installation
The support method used for this unit will dictate different
sequences for the steps of unit installation. For example, on
curb--mounted units, some accessories must be installed on
the unit before the unit is placed on the curb. Review the
following for recommended sequences for installation steps.
Curb--mounted installation —
Install curb
Install field--fabricated ductwork inside curb
Install thru-- base service connection fittings (affects
curb and unit)
Rig and place unit
Remove top skid
Install outside air hood
Install smoke detector tube
Install combustion air hood
Install flue hood
Install gas piping
Install condensate line trap and piping
Make electrical connections
Install other accessories
Pad--mounted installation —
Prepare pad and unit supports
Rig and place unit
Remove duct covers and top skid
Install smoke detector return air sensor tube
Install field--fabricated ductwork at unit duct openings
Install outside air hood
Install combustion air hood
Install flue hood
Install gas piping
Install condensate line trap and piping
Make electrical connections
Install other accessories
Frame--mounted installation —
Frame--mounted applications generally follow the
sequence for a curb installation. Adapt as required to
suit specific installation plan.
Step 3 — Inspect unit
Inspect unit for transportation damage. File any claim
with transportation agency.
Confirm before i nstallation of unit that voltage, amperage
and circuit protection requirements listed on unit data
plate agree with power supply provided.
On units with hinged panel option, check to be sure all
latches are tight and in closed position.
Locate the carton containing the outside air hood parts; see
Fig. 7 and 13. Do not remove carton until unit has been
rigged and located in final position.
15
Step 4 — Provide Unit Support
A
Roof Curb Mount —
Accessory roof curb details and dimensions are shown in
Fig. 8, 9 and 10. Assemble and install accessory roof curb in
accordance with instructions shipped with the curb.
NOTE: The gasketing of the unit to the roof curb is critical
for a watertight seal. Install gasket supplied with the roof
curb as shown in Fig. 8, 9 and 10. Improperly applied
gasket can also result in air leaks and poor unit performance.
Curb should be level. This is necessary for unit drain to
function properly. Unit leveling tolerances are shown in
Fig. 6. Refer to Accessory Roof Curb Installation
Instructions for additional information as required.
C
A
B
Fig. 6 -- Unit Leveling Tolerances
Install insulation, cant strips, roofing fe lt, and counter
flashing as shown. Ductwork must be attached to curb and
not to the unit. Thru--the--base power connection must be
installed before the unit is set on the roof curb. If
field--i nstalled thru--the--roof curb gas connections are
desired, remove knockout in basepan located in the gas
section; see Fig. 7 for location. Gas connections and
power connections to the unit must be field--installed after
the unit is installed on the roof curb.
MAXIMUM ALLOWABLE
DIFFERENCE IN. (MM)
A-B
0.25” (6)
B-C
0.5” (12)
A-C
0.5” (12)
C10628
box area of access panel; see Fig. 2, 3, or 4 for basepan
knockout loc ations for location. Attach the service
connections to the basepan.
Hood Carton Location
(rear access panel)
Control Box
ccess Panel
Filter and
Indoor Coil
Access Panel
Indoor Blower
Access Panel
Gas Heat
Access Panel
Compressor
(each side)
C11154
Fig. 7 -- Typical Access Panel and Compr es s o r Locations
Slab Mount (Horizontal Units Only) —
Provide a level concrete slab that extends a minimum of
6–in. (150 mm) beyond unit cabinet. Install a gravel apron
in front of condenser c oil air inlet to prevent grass and
foliage from obstructing airflow.
NOTE: Horizontal units may be installed on a roof curb
if required.
Alternate Unit Support (In Lieu of Curb or Slab
Mount) —
A non--combustible sleeper rail can be used in the unit
curb support area. If sleeper rails cannot be used, support
the long sides of the unit with a minimum of 4 equally
spaced 4--in. x 4--in. (102 mm x 102 mm) pads on each
side. Locate pads so that they support the rail s. Make sure
to avoid the fork openings.
If electric and control wiring is to be routed through the
basepan, remove knockouts in basepan located in control
16
C13054
Fig. 8 -- Roof Curb Details – 14 Size Unit
17
Fig. 9 -- Roof Curb Details – 17 and 20 Size Units
C13055
18
Fig. 10 -- Roof Curb Details – 24 and 26 Size Units
C13056
19
Step 5 — Field Fabricate Ductwork
Cabinet return-air static pressure (a negative condition)
shall not exceed 0.5 in. wg (87 Pa) with economizer or
without economizer.
For vertical ducted applications, secure all ducts to roof curb
and building structure. Do not connect ductwork to unit.
Fabricate supply ductwork so that the cross sectional
dimensions are equal to or greater than the unit supply
duct opening dimensions for the first 18 in. (458 mm) of
duct length from the unit basepan.
Step 6 — Rig and Place Unit
Keep unit upright and do not drop. Spreader bars are not
required if top crating is left on unit. Rollers may be used
to move unit across a roof. Level by using unit frame as a
reference. See Table 1 (on page 14) and Fig. 11 (below)
for additional information.
Lifting holes are provided in base rails as shown in
Fig. 11. Refe r to riggi ng instructions on unit .
!
CAUTION
Insulate and weatherproof all external ductwork, joints,
and roof openings with counter flashing and mastic in
accordance with applicable codes.
Ducts passing through unconditioned spaces 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.
!
CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in damage
to roofing materials.
Membrane roofs can be cut by sharp sheet metal
edges. Be careful when placing any sheet metal parts
on such roof.
"914-1371"
(36"-54")
"B"
SEE DETAIL A
UNIT DAMAGE HAZARD
Failure to follow this caution may result in
equipment damage.
All panels must be in place when rigging. Unit is not
designed for handling by fork truck when packaging
is removed.
Before setting the unit onto the curb, recheck gasketing on
curb.
PLACE ALL SEAL STRIP
IN PLACE BEFORE PLACING
UNIT ON ROOF CURB.
DUCT END
DETAIL A
"A"
UNIT
48LC**14 2135 970 127.8 3249 59.1 1501 52.3 1328
48LC**17 2377 1080 141.5 3595 65.5 1664 60.3 1532
48LC**20 2483 1129 141.5 3595 65.5 1664 60.3 1532
48LC**24 2629 1195 157.8 4007 72.8 1849 60.3 1532
48LC**26 2774 1261 157.8 4007 7208 1849 60.3 1532
NOTES:
1. Dimensions in ( ) are inches.
2. Hook rigging shackles through holes in base rail, as shown in detail “A .” Holes in b ase rails are centered around the unit center of
gravity. Use wooden top to prevent rigging straps from damaging unit.
MAX WEIGHT
LB KG IN MM IN MM IN MM
"C"
C09107
DIMENSIONS
A B C
Fig. 11 -- Rigging Details
20
PositioningonCurb—
r
Position unit on roof curb so that the following clearances
are maintained:
curb and the base rail inside the right and left,
1
/4in. (6 mm) clearance between the roof
1
/2in.
(12 mm) clearance between the roof curb and the base rail
inside the front and back. This will result in the distance
between the roof curb and the base rail inside on the
condenser end of the unit being approximat ely equal to
Details A and B in Fig. 8, 9 and 10.
Do not attempt to slide unit on curb after unit is set. Doing
so will result in damage to the roof curb seal.
Although unit is weatherproof, guard against water from
higher level runoff and ove rhangs.
Flue vent dischar ge must have a minimum horizontal
clearance of 48 in. (1220 mm) from electric and gas meters,
gas regulators, and gas relief equipment. Minimum distance
between unit and other electrically live parts is 48 inches
(1220 mm).
Flue gas can deteriorate building materials. Orient unit such
that flue gas will not affect building materials . Locate
mechanical draft system flue assembly at least 48 in.
(1220 mm) from an adjacent building or combustible
material.
Field--supplied(3/4--inch) flanges should be attached to
horizontal duct openings (see Fig. 12) and all ductwork
should be secured to the flanges. Insulate and weatherproof
all external ductwork, joints, and roof or building openings
with counter flashing and mastic in accordance with
applicable codes.
Step 8 — Install Outside Air Hood — Factory
Option
The outside air hood for factory--option economizer is
shipped in knock--down form and requires field assembly.
The panel for the hood top is shipped on the end of the
unit (see Fig. 13). The remaining parts for the hood
assembly (including side panels, filters and tracks) are
shippedinacartonthatissecuredtotherearoftheblower
assembly. Access the carton location through rear panel
(see Fig. 14).
Hood Top
Shipping
Position
After unit is in position, remove rigging skids and
shipping materials.
Step 7 — Horizontal Duct Connection
Refer to Fig. 2, 3 and 4 for locations and sizes of the
horizontal duct connections. Note that there are two different
return air duct connection locations – one for unit without an
economizer (on back side of unit) and a different one for
unit equipped with an economizer (on left end, under the
economizer hood). The supply air duct connection is on the
back side. See Fig. 12 for top view depicting typical
horizontal duct arrangements.
C09134
Fig. 13 -- Hood Top – Shipping Position
To remove the hood parts package:
1. Remove the back blower access panel.
2. Locate and cut the strap, being careful to not damage
any wiring.
3. Carefully lift the hood package carton through the
back blower access opening.
See Fig. 15 for identification of the various parts of the
hood assembly.
Hood
Package
Horizontal
Supply Air
Supply
Location Back Back Left end
H e i g h t --- I n . ( m m ) 157/8(402) 493/8(1253) 183/8(467)
W i d t h --- i n . ( m m ) 293/4(756) 233/8(593) 615/8(1564)
Return Air Duct
Return without
Economizer
Fig. 12 -- Horizontal Duct Opening Dimensions
without
Economizer
Return Air Duct
with Economize
Return with
Economizer
C10626
C09133
Fig. 14 -- Hood Package – Shipping Location
21
To assemble the outside air hood:
A
1. Remove hood top panel from shipping position on
unit end.
2. Install four angles to the upper end panel using the
screws provided.
3. Apply seal strip to mating flanges on the side plates
of the hood (see Fig. 15).
pply Seal Strips
to the back of
these flanges
2
Seal Strips
5
Apply Seal Strip
to the front of
this flange
6
Apply Seal Strips
to the back of
these surfaces
7
4
Item # Description Qty
1 Angles 4
2 Side Plates 2
3 Hood 1
4 Outdoor Air Screens 4
5 Side Filter Supports 2
6 Side Drip Angles 2
7 Top Diverters 2
4
1
3
7
4
Apply Seal Strip
to the back of
this flange
Apply Seal Strip
to the front of
this flange
4
C09079
Fig. 15 -- Hood Part Identification and Seal Strip
Application Areas
Step 9 — Install Flue Hood and Combustion Air
Hood
The flue hood is shipped screwed to the fan deck inside
the burner compartment. Remove the burner access panel
and then rem ove the flue hood from i ts shipping location.
Using the screws provided, install flue hood in the
location shown in Fig. 17.
The combustion air hood is attache d to the back of the
burner access panel. Remove the two screws securing the
hood to the back of the burner access panel. Using the two
2
5
6
screws, re--attach the hood to the front of the burner
access panel as shown in Fig. 17.
4. Secure side plates to panel using the screws provided.
5. Apply seal strip to mating flange of the hood (see
Fig. 15).
Combustion
Air Hood
Flue Hood
C10744
Fig. 17 -- Flue Hood and Combustion Air Hood Details
6. Secure top flange using screws provided in kit.
7. Install outdoor air screens by sliding them into the
channel formed by the four angles install ed in step 2.
Make sure that the screens extend across the entire
length of the hood.
8. Install side filter supports using the screws provided.
9. Install side drip angles using the screws provided.
10. Run a continuous length of seal strip across the hood
covering the engagement holes in the lower hood.
11. Install top diverter using the screws provided.
12. On units with barometric relief, remove screws at bottom of relief damper. Do not discard damper door.
C09090
Fig. 16 -- Hood Assembly – Completed
22
Step 10 — Install Gas Piping
Installation of the gas piping must be in accordance with
local building codes and with applicable national codes.
In U.S.A., refer to NFPA 54/ANSI Z223.1 National Fuel
Gas Code (NFGC). In Canada, installation must be
accordance with the CAN/CSA B149.1 a nd CAN/CSA
B149.2 installation codes for gas burning appliances.
This unit is factory equipped for use with Natural Gas fuel
at elevations up to 2000 ft (610 m) above sea level. Unit
may be field converted for operation at elevations above
2000 ft (610 m) and/or for use with liquefied petroleum
fuel. See accessory kit installation instructions regarding
these accessories.
NOTE: Furnace gas input rate on rating plate is for
installation up to 2000 ft (610 m) above sea level. In
U.S.A. the input rating for altitudes above 2000 ft (610 m)
must be derated by 4% for each 1000 ft (305 m) above sea
level.
For natural gas applications, gas pressure at unit gas
connection must not be less than 5 in. wg (1246 Pa) or
greater than 13 in. wg (3240 Pa) while the unit is
operating. For liquified petroleum applications, the gas
pressure must not be less than 11 in. wg (2740 Pa) or
greater than 13 in. wg (3240 Pa) at the unit connection.
T able 2 – Typical
Item Qty Description
1 1 90 Deg Street Elbow
2 1 5 Inch Long Nipple
3 1 Ground--- Joint Union
4 1 3 Inch Long Nipple
5 1 90 Deg Elbow
6 1 12 Inch Long Nipple
7 1 90 Deg Elbow
8 1 3 Inch Long Nipple
9 1 TEE
10 1 4 Inch Long Nipple (Sediment Trap)
11 1 Cap
12 1 31/2Inch Long Nipple
13 1 NIBCO* Ball Valve (GB30)
14 1 8 Inch Long Nipple
15 1 90 D eg Elbow
3
/4--in. NPT Field Supplied Piping Parts
Pipe gas supply into 90 degree elbow item 15 (see Table 2)
through the hole in the unit basepan.
For typical3/4inch NPT field supplied fittings required
for NON Thru--Base gas supply starting from the unit gas
valve, omit items 14 and 15 from Table 2 and pipe gas
supply into TEE. See Fig. 19.
4
6
5
3
2
1
Gas Supply Line —
The gas supply pipe enters the unit adjacent to the burner
access panel on the front side of the unit, through the
grommeted hole. The gas connection to the unit is made
3
to the
Table 2 lists typical
/4in. FPT gas inlet port on the unit ga s valve.
3
/4inch NPT (National Pipe Thread)
field supplied pipe fittings required for Thru--Base gas
supply, starting from the unit gas valve (see Fig. 18).
4
6
7
8
9
10
11
12
5
13
14
3
2
1
15
7
8
9
12
13
10
11
C101006
Fig. 19 -- Gas Supply Line Piping
Table 3 – Natural Gas Supply Line Pressure Ranges
UNIT MODEL UNIT SIZE MIN MAX
48LC** 14, 17, 20, 24, 26
5.0 in. wg
(1246 Pa)
13.0 in. wg
(3240 Pa)
Table 4 – Liquid Propane Supply Line Pressure Ranges
UNIT MODEL UNIT SIZE MIN MAX
48LC** 14, 17, 20, 24, 26
11.0 in. wg
(2740 Pa)
13.0 in. wg
(3240 Pa)
Fig. 18 -- Gas Supply Line Piping with Thru--Base
C10999
Manifold pressure is factory--adjusted for natural gas (NG)
fuel use. Adjust as required to obtain best flame
characteristics.
Table 5 – Natural Gas Manifold Pressure Ranges
UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE
48LC** 14, 17, 20, 24, 26
* NIBCO is a registered trademark of NIBCO Inc.
23
3.0 in. wg
(747 Pa)
2.0 in. Wg
(498 Pa)
Manifold pressure for liquid propane (LP) fuel must be
R
adjusted to specified range. Follow instructions in the
accessory kit to make initial readjustment.
Table 6 – Liquid Propane Manifold Pressure Ranges
UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE
48LC** 14, 17, 20, 24, 26
48LCS* 14 only
!
CAUTION
11.0 in. wg
(2740 Pa)
9.8 in. wg
(2441 Pa)
7.3 in. Wg
(1818 Pa)
6.5 in. Wg
(1619 Pa)
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in damage
to equipment.
When connecting the gas li ne to the unit gas valve,
the installer MUST use a backup wrench to prevent
damage to the valve.
Install a gas supply line that runs to the unit heating
section. Refer to the NFPA 54/NFGC or equivalent code
for gas pipe sizing data. Do not use a pipe smaller than the
size specified. Siz e the gas supply line to allow for a
maximum pressure drop of 0.5--in. wg (124 Pa) between
gas regulator source and unit gas valve connection when
unit is operating at high--fire flow rate.
The gas supply line can approach the unit in two ways:
horizontally from outside the unit (across the roof), or
through unit basepan. Observe clearance to gas line
components per Fig. 20.
X
9” MINIMUM CLEARANCE
BASE UNIT
BASE RAIL
FOR PANEL REMOVAL
MANUAL GAS
SHUTOFF VALVE
48” MINIMUM
ROOF
CURB
NFGC – National Fuel Gas Code
Field supplied.
*
NOTE: Follow all local codes.
STEEL PIPE
NOMINAL DIAMETER
(in.)
1
/
2
3
/
or 1
4
1
1
/
or larger
4
LEGEND
GAS
REGULATOR
*
DRIP LEG
PER NFGC
FABRICATED
SPACINGOFSUPPORTS
X DIMENSION
(ft)
6
8
10
*
*
FIELD-
SUPPORT
FROM
GAS
METE
*
C11121
Fig. 20 -- Gas Piping Guide
Factory--Option Thru--Base Connections —
Electrical Connections: Knockouts are located in the
control box area. Remove the appropriate size knockout
for high voltage connection. Use the field supplied
connector depe nding on wiring or conduit being utilized.
7
Remove the
/8--in. (22mm) knockout and appropriate
connector for low voltage wiring. If non--unit powered
7
convenience outlet is being utilized, remove the
/8-- i n .
(22mm) knockout and utilize appropriate connector for
115 volt line. See “Step 12 — Make Electrical
Connections” for details.
Gas Connections: Remove the knockout in the base pan
3
and route
/4--in. gas line up through the opening. Install an
elbow and route gas line through opening in panel after first
removing plastic bushing. Install a gas shut off followed by a
drip leg and ground--joint union. Route gas line into gas
section through the grommet (Part #: KA56SL112) at the gas
inlet and into the gas valve. See Fig. 18 and Table 2. If a
regulator is installed, it must be located 4 feet (1.22 meters)
from the flue outlet.
Some municipal codes require that the manual shutoff
valve be located upstream of the sediment trap. See
Fig. 19 for typical piping arrangements for gas piping that
has been routed through the sidewall of the base pan.
When installing the gas supply line, observe local codes
pertaining to gas pipe installations. Refer to the NFPA
54/ANSI Z 223. 1 NFGC latest edition (in Canada,
CAN/CSA B149.1). In the absence of local building codes,
adhere to the following pertinent recommendations:
1. Avoid low spots in long runs of pipe. Grade all pipe
1
/4--in. in every 15 ft (7 mm in every 5 m) to prevent
traps. Grade all horizontal runs downward to risers.
Use risers to connect to heating section and to meter.
2. Protect all segments of piping system against physical
and thermal damage. Support all piping with appropriate straps, hangers, etc. Use a minimum of one
hanger every 6 ft (1.8 m). For pipe sizes larger than
1
/2--in., follow recommendations of national codes.
3. Apply joint compound (pipe dope) sparingly and only
to male threads of joint when making pi pe
connections. Use only pipe dope that is resistant to
action of liquefied petroleum gases as specified by
local and/or national codes. If using PTFE (Teflon*)
tape, ensure the material is Double Density type and
is labeled for use on gas lines. Apply tape per
manufacturer’s instructions.
4. Pressure--test all gas piping in accordance with local
and national plumbing and gas codes before connecting piping to unit.
NOTE: Pressure test the gas supply system after the gas
supply piping is connected to the gas valve. The supply
piping must be disconnected from the gas valve during the
testing of the piping systems when test pressure is in
excess of 0.5 psig (3450 Pa). Pressure test the gas supply
piping system at pressures equal to or less than 0.5 psig
(3450 Pa). The unit heating section must be isolated from
the gas piping system by closing the external ma in manual
shutoff valve and slightly opening the ground--joint union.
Check for gas leaks at the field--installed and
factory--installed gas lines after all piping connections
have been completed. Use soap--and--water solution (or
method specified by local codes and/or regulations).
* Teflon is a registered trademark of DuPont.
24
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
S Connect gas pipe to unit using a backup wrench to
avoid damaging gas controls.
S Never purge a gas line into a combustion chamber.
S Never test for gas leaks with an open flame. Use a
commercially available soap solution made
specifically for the detection of leaks to check all
connections.
S Use proper length of pipe to avoid stress on gas
control manifold.
The piping for the condensate drain and external trap can
be completed after the unit is in place. Hand tighten
fittings to the drain pan fitting. Provide adequate support
for the drain line. Failure to do so can result in damage to
the drain pan. See Fig. 23.
MINIMUM PITCH
1” (25mm) PER
10’ (3m) OF LINE
TO ROOF
DRAIN
BASE RAIL
OPEN
VENT
3˝ (76mm)
MIN
SEE NOTE
NOTE: If orifice hole appears damaged or it is suspected to
have been redrilled, check orifice hole with a numbered drill
bit of correct size. Never redrill an orif ice. A bur r--free and
squarely aligned orifice hole is essential for proper flame
characteristics.
BURNER
ORIFICE
A93059
Fig. 21 -- Orifice Hole
Step 11 — Install External Condensate Tr ap and
Line
The unit has one3/4-in. condensate drain connection on the
end of the condensate pan (see Fig. 22). See Fig. 2, 3 and 4,
item “E”, in the view labeled “BACK (HORIZONTAL
DISCH A RG E) ” (located on sh eet 2 of 3 of each figure) for
the location of the condensate drain connection.
ROOF
DRAIN PLUG
NOTE: Trap should be deep enough to offset maximum unit static
difference. A 4” (102mm) trap is recommended.
CURB
C11291
Fig. 23 -- Condensate Drain Piping Details
All units must have an external trap for condensate
drainage. Install a trap at least 4-in. (102 mm) dee p and
protect against freeze-up. If drain line is installed
downstream from the external trap, pitch the line away
from the unit at 1-in. per 10 ft (25 mm in 3 m) of run. Do
not use a pipe size smaller than the unit connection
3
/4-in.).
(
Step 12 — Make Electrical Connections
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Do not use gas piping as an electrical ground. 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 (National
Electrical Code); ANSI/NFPA 70, latest edition (in
Canada, Canadian Electrical Code CSA [Canadian
Standards Association] C22.1), and local electrical
codes.
CONDENSATE
DRAIN
CONNECTION
Fig. 22 -- Condensate Drain Pan Connection
C10729
NOTE: Field--supplied wiring shall conform with the
limitations of minimum 63_F(33_C) rise.
Field Power Supply —
If equipped with optional Powered Convenience Outlet:
The power source leads to the convenience outlet’s
transformer primary are not factory connected. Installer
must connect these leads according to required operation
of the convenience out let. If an always--energized
convenience outlet operation is desire d, connect the
source leads to the line side of the uni t--mounted
25
disconnect. (Check with local codes to ensure this method
is acceptable in your area.) If a de--energize via unit
disconnect switch operation of the convenienc e outlet is
desired, connect the source leads to the load side of the
unit disconnect. On a unit without a unit--mounted
disconnect or HACR, connect the source leads to the
terminal block with unit field power leads. See Fig. 24.
BLK
YEL
BLU
LOAD
SIDE
LINE
SIDE
SEE
DETAIL
A
L1
L2
L3
A
DETAIL
CONTROL BOX
C11181
Fig. 24 -- Location of TB1
Field power wires are connected to the unit at line--side
pressure lugs on the terminal block (see wiring diagram
label for control box component arrangement) or at
factory--installed option non--fused disconnect switch or
HACR breaker. Use copper conductors only.
NOTE: Make field power connections directly to line
connection pressure lugs only.
!
WARNING
FIRE HAZARD
Failure to follow this warning could result in
intermittent operation or unsatisfactory performance.
Do not connect aluminum wire between disconnect
switch and air conditioning unit. Use only copper
wire.(SeeFig.25.)
ELECTRIC
DISCONNECT
SWITCH
COPPER
WIRE ONLY
ALUMINUM
WIRE
A93033
Fig. 25 -- Disconnect Switch and Unit
26
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