International comfort products RGS036 Series, RGS048 Series, RGS060 Series, RGS072 Series Installation Instructions Manual
INSTALLATION INSTRUCTIONS
R--410A Single--Package Rooftop Gas Heating /
Electric Cooling
RGS036--072
NOTE: Read the entire instruction manual before starting
the installation
TABLE OF CONTENTS
SAFETY CONSIDERATIONS 2....................
Rated Indoor Airflow (cfm) 3.....................
INSTALLATION 6...............................
Jobsite Survey 6................................
Step 1 -- Plan for Unit Location 6..................
Roof Mount 7...............................
Step 2 -- Plan for Sequence of Unit Installation 7......
Curb--Mount Installation 7.....................
Pad--Mount Installation 7......................
Frame--Mount Installation 7....................
Step 3 -- Inspect Unit 7...........................
Step 4 -- Provide Unit Support 8...................
Roof Curb Mount 8..........................
Slab Mount (Horizontal Units Only) 8...........
Alternate Unit Support
(In Lieu of Curb or Slab Mount) 8..............
Step 5 -- Field Fabricate Ductwork 10...............
Step 6 -- Rig and Place Unit 10....................
Positioning on Curb 11.......................
Step 7 -- Convert to Horizontal & Connect Ductwork 11.
Step 8 -- Install Outside Air Hood 11...............
Economizer and Two Position Damper Hood
Package Removal and Setup — Factory Option 11.
Economizer Hood and Two--Position Hood 12.....
Step 9 -- Install Flue Hood 12.....................
Step 10 -- Install Gas Piping 12....................
Factory--Option Thru--Base Connections
(Gas Connections) 13.........................
Step 11 -- Install External Condensate Trap and Line 15..
Step 12 -- Make Electrical Connections 16...........
Field Power Supply 16........................
Units with Factory--Installed
Non--Fused Disconnect 16.....................
Units without Factory--Installed
Non--Fused Disconnect 17.....................
All Units 17................................
Convenience Outlets 18.......................
Factory--Option Thru--Base Connections
(Electrical Connections) 18....................
Units without Thru--Base Connections 18.........
Field Control Wiring 19.......................
Thermostat 19...............................
Unit without Thru--Base Connection Kit 19.......
Heat Anticipator Settings 19...................
EconoMi$er X (Factory--Installed Option) 19.......
Hot Gas Re--Heat Control Connections 20..........
Hot Gas Re--Heat -- Space RH Controller 20......
Smoke Detectors 22...........................
Step 13 -- Adjust Factory--Installed Options 25........
Step 14 -- Install Accessories 25...................
START--UP CHECKLIST 27.......................
Specifications are subject to change without notice.
509 01 3522 00 03/2015
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 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.
. When you see this symbol on the
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could cause personal
injury or death.
Before performing service or maintenance operations
on unit, turn off main power switch to unit and install
lock(s) and lockout tag(s). Ensure electrical service to
rooftop unit agrees with voltage and amperage listed
on the unit rating plate. Unit may have more than one
power switch.
!
WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could cause personal
injury, death and/or equipment damage.
R--410A refrigerant systems operate at higher
pressures than standard R--22 systems. Do not use
R--22 service equipment or components on R--410A
refrigerant equipment.
Understand the signal words DANGER, WARNING,
CAUTION, and NOTE. These words are used with the
safety--alert symbol. DANGER identifies the most serious
hazards which will result in severe personal injury or
death. WARNING signifies 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.
!
WARNING
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.
!
WARNING
PERSONAL INJURY AND ENVIRONMENTAL
HAZARD
Failure to follow this warning could cause personal
injury or death.
Relieve pressure and recover all refrigerant before
system repair or final unit disposal.
Wear safety glasses and gloves when handling
refrigerants. Keep torches and other ignition sources
away from refrigerants and oils.
!
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.
CAUTION
2 509 01 3522 00
Specifications are subject to change without notice.
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)
RGS036 1275
RGS048 1400
RGS060 1800
RGS072 2200
MODEL NOMENCLATURE
MODEL SERIES RGS0 3 6HDAA0AAA
Position Number
R = Rooftop
12345678910111213
14
G = Gas/Electric
S = Standard ASHRAE 90.1-2010 Efficiency
036 = 3 Tons
048 = 4 Tons
060 = 5 Tons
072 = 6 Tons
K = 208/230−1−60
H = 208/230−3−60
L = 460−3−60
S = 575−3−60
D = Low Heat S = Low Heat, Stainless Steel Heat Exchanger
E = Medium Heat R = Medium Heat, Stainless Steel Heat Exchanger
F = High Heat T = High Heat, Stainless Steel Heat Exchanger
L = Low Heat, Low NO
M = Medium Heat, Low NO
N = High Heat, Low NO
A = Belt Drive, Standard Static Motor
B = Belt Drive, High Static Motor
C = Belt Drive, Medium Static Motor
X = Direct Drive, Standard Static (3, 4, and 5 ton models only)
A = None
B = Economizer w/Baro−relief, OA Temp sensor
E = Economizer w/Baro−relief + CO
H = Economizer w/Baro−relief, enthalpy sensor
L = Economizer w/Baro−relief + CO
U = Temp Ultra Low Leak Economizer w/Baro−relief
W = Enthalpy Ultra Low Leak Economizer w/Baro−relief
P = 2−Position damper
x
x
x
Sensor, OA Temp sensor
2
Sensor, enthalpy sensor
2
Type
Efficiency
Nominal Cooling Capacity
Voltage
Heating Capacity
Motor Option (Indoor Fan)
Outdoor Air Options / Control
0A = No Options
AT = Non−powered 115v C.O.
4B = Non−Fused Disconnect
BR = Supply Air Smoke Detector
AA = Easy Access Hinged Panels Factory Installed Options
A = Aluminum / Copper Cond & Evap Coil
B = Precoat Alum/Copper Cond with Alum / Copper Evap (3 phase only)
C = E−Coated Alum/Copper Cond with Alum / Copper Evap (3 phase only)
D = E−Coated Alum / Copper Cond & Evap (3 phase only)
E = Copper/Copper Cond & Alum/Copper Evap (3 phase only)
F = Copper/Copper Cond & Evap (3 phase only) Condenser / Evaporator Coil Configuration
A = Standard Single Speed Indoor Fan Motor. For W7212 Controls
B = Standard Single Speed Indoor Fan Motor. For W7220 Controls Motor Type Option
NOTE: Factory installed options are NOT available on single phase models. This includes economizers and 2 position dampers.
1
Combinations of FIOPS are available.
509 01 3522 00 3
1
C150163
Specifications are subject to change without notice.
Fig. 1 -- Unit Dimensional Drawing
C150164
4 509 01 3522 00
Specifications are subject to change without notice.
Fig. 1 -- Unit Dimensional Drawing (cont.)
C150165
509 01 3522 00 5
Specifications are subject to change without notice.
C
D
B
A
LOCATION DIMENSION CONDITION
48---in (1219 mm)
A
B
C
D
NOTE: Unit not designed to have overhead obstruction. Contact Application Engineering for guidance on any application
18---in (457 mm)
18---in (457) mm
12---in (305 mm)
42---in (1067 mm)
36---in (914 mm)
Special
36---in (914 mm)
18---in (457 mm)
48---in (1219 mm)
42---in (1067 mm)
36---in (914 mm
Special
planning overhead obstruction or for vertical clearances.
Unit disconnect is mounted on panel
No disconnect, convenience outlet option
Recommended service clearance
Minimum clearance
Surface behind servicer is grounded (e.g., metal, masonry wall)
Surface behind servicer is electrically non--- conductive (e.g., wood, fiberglass)
Check sources of flue products within 10 --- ft of unit fresh air intake hood
Side condensate drain is used
Minimum clearance
No flue discharge accessory installed, surface is combustible material
Surface behind servicer is grounded (e.g., metal, masonry wall, another unit)
Surface behind servicer is electrically non--- conductive (e.g., wood, fiberglass)
Check for adjacent units or building fresh air intakes within 10--- ft of this unit’s flue outlet
Fig. 2 -- Service Clearance Dimensional Drawing
C08337
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. 2.
NOTE: Consider also the effect of adjacent units.
6 509 01 3522 00
Be sure that unit is installed such that snow will not block
the combustion intake or flue outlet.
Unit may be installed directly on wood flooring 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 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) 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.
Specifications are subject to change without notice.
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 to 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 is 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 accessory thru--base service connection package
(affects curb and unit) (refer to accessory installation
instructions for details)
Prepare bottom condensate drain connection to suit
planned condensate line routing (refer to Step 11 for
details)
Rig and place unit
Install outdoor 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
Check and tighten the bottom condensate drain
connection plug
Rig and place unit
Convert unit to side duct connection arrangement
Install field--fabricated ductwork at unit duct openings
Install outdoor 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 installation of unit that voltage, amperage
and circuit protection requirements listed on unit data
plate agree with power supply provided.
Table 1 – Operating Weights
RGS
Base Unit 483 (219) 537 (244) 569 (258) 652 (296)
Economizer
Vertical 50 (23) 50 (23) 50 (23) 50 (23)
Horizontal 80 (36) 80 (36) 80 (36) 80 (36)
Hot Gas Re ---Heat System N/A N/A N/A 41 (15)
Cu Fins 25 (11) 43 (20) 56 (25) 73 (33)
Unpowered Outlet 32 (15) 32 (15) 32 (15) 32 (15)
Curb
14---in/356 mm 110 (50) 110 (50) 110 (50) 110 (50)
24---in/610 mm 145 (66) 145 (66) 145 (66) 145 (66)
036 048 060 072
UNITS LB (KG)
509 01 3522 00 7
Specifications are subject to change without notice.
Step 4 — Provide Unit Support
Roof Curb Mount —
Accessory roof curb details and dimensions are shown in
Fig. 4. 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. 4. 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 show in
Fig. 3. Refer to Accessory Roof Curb Installation
Instructions for additional information as required.
MAXIMUM ALLOWABLE
DIFFERENCE IN. (MM)
A-B
0.5” (13)
Fig. 3 -- Unit Leveling Tolerances
B-C
1.0” (25)
A-C
1.0” (25)
C06110
Install insulation, cant strips, roofing felt, and counter
flashing as shown. Ductwork must be attached to curb and
not to the unit. The accessory thru--the--base power and
gas connection package must be installed before the unit
is set on the roof curb. If field--installed thru--the--roof
curb gas connections are desired, use factory--supplied
1
/2--in. pipe coupling and gas plate assembly to mount the
thru--the--roof curb connection to the roof curb. Gas
connections and power connections to the unit must be
field installed after the unit is installed on the roof curb.
If electric and control wiring is to be routed through the
basepan, attach the accessory thru--the--base service
connections to the basepan in accordance with the
accessory installation instructions.
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 coil 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
(InLieuofCurborSlabMount)—
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 3 equally spaced 4--in. x
4--in. (102 mm x 102 mm) pads on each side.
8 509 01 3522 00
Specifications are subject to change without notice.
1-3/4"
[44.4]
(004-007)
B
ACCESSORY CONVENIENCE
OUTLET WIRING CONNECTOR
FITTING
1/2" [12.7] NPT 1/2" [12.7] NPT
CONTROL WIRING
FITTING
3/4" [19] NPT
POWER WIRING
1/2" [12.7] NPTCRRFCURB002A01
THRU THE CURB
CRBTMPWR003A01 THRU THE BOTTOM
CRBTMPWR001A01 3/4" [19] NPT
CONNECTOR PKG. ACC. GAS CONNECTION TYPE GAS FITTING
1-3/4"
[44.5]
11 3/4"[298.5] WIDE
INSULATED DECK PANELS
1.00"
[25.4]
"A"
SEE NOTE #2
2-3/8"
[61]
1' 4-13/16"
[427] INSIDE
8 9/16"[217.5] WIDE
INSULATED DECK PANEL
GAS SERVICE PLATE
THRU THE CURB
1-3/4"
[44.4]
E-E
SCALE 0.250
SECTION
DRILL HOLE
2" [50.8] @
ASSEMBLY (IF
REQUIRED)
(SEE NOTE #8)
RETURN AIR
1-3/4"
[44.5]
SUPPLY AIR
[1711.3]
5' 7-3/8"
"A"
NAIL (FIELD SUPPLIED)
TYPICAL (4) SIDES
UNIT
[944.6]
3'-1 3/16"
SEE VIEW "B"
ROOFING FELT
COUNTER FLASHING
(FIELD SUPPLIED)
7/16"
[11]
CURB ASY, ROOF
THIS DOCUMENT AND THE INFORMATION CONTAINED THEREIN
IS PROPRIETARY TO CARRIER CORPORATION AND SHALL NOT
BE USED OR DISCLOSED TO OTHERS, IN WHOLE OR IN PART,
WITHOUT THE WRITTEN AUTHORIZATION OF CARRIER CORPORATION.
1041738
TOLERANCES ON:
AUTHORIZATION NUMBER TITLE
DIMENSIONS ARE IN INCHES
----
UNLESS OTHERWISE SPECIFIED
1 DEC 2 DEC 3 DEC ANG
PRODUCTION
CERTIFIED DRAWING
---
MATERIAL
DRAWING RELEASE LEVEL:
THIRD ANGLE
PROJECTION
ROOFING MATERIAL
(FIELD SUPPLIED)
CANT STRIP
(FIELD SUPPLIED)
(FIELD SUPPLIED)
RIGID INSULATION
SHEET 5 OF 5
48TC400427
SIZE DRAWING NUMBER REV
D
-
-
-
DRAFTER CHECKER
ENGINEERING MANUFACTURING
-
MMC 06/17/11 - -
-
T-005, Y-002
WEIGHT:
- PURCH - N/A MMC
ENGINEERING REQUIREMENTS
SURFACE FINISH MFG/PURCH MODEL (INTERNAL USE ONLY) NEXT DRAWING SCALE DISTRIBUTION
ECN NO.APP'DCHK'DBYDATEREVISION RECORDREV
1067898--MMC04/22/13
(FIELD SUPPLIED)
NOTES:
1. ROOFCURB ACCESSORY IS SHIPPED DISASSEMBLED.
2. INSULATED PANELS: 25.4 [1"] THK. POLYURETHANE FOAM, 44.5 [1-3/4] # DENSITY.
3. DIMENSIONS IN [ ] ARE IN MILLIMETERS.
4. ROOFCURB: 18 GAGE STEEL.
5. ATTACH DUCTWORK TO CURB. (FLANGES OF DUCT REST ON CURB).
6. SERVICE CLEARANCE 4 FEET ON EACH SIDE.
7. DIRECTION OF AIR FLOW.
8. CONNECTOR PACKAGE CRBTMPWR001A01 IS FOR THRU-THE-CURB GAS TYPE
PACKAGE CRBTMPWR003A01 IS FOR THRU-THE-BOTTOM TYPE GAS CONNECTIONS.
A
14"
ROOF CURB
ACCESSORY #
CRRFCURB001A01
[356]
24"
[610]
11.96"
5.42"
[303.8]
[137.7]
21.74"
[552.2]
VIEW "B"
CORNER DETAIL
70.87"
[1800.2]
32.19"
[817.6]
E
E
RETURN AIR
4.96"
[126.0]
OPENING
1/3/4"[44.5]
15.19"
[385.8]
21.84"
3.00"
[554.7]
[76.2]
16.03"
[407.2]
SUPPLY AIR
OPENING
14.00"
[355.6]
Fig. 4 -- Roof Curb Details
DUCT
GASKET
(FIELD SUPPLIED)
(SUPPLIED WITH CURB)
13.78"
[350.0]
3.00"
[76.2]
40.69"
[1033.5]
20.41"
[518.3]
1.75"
[44.5]
OVERALL DIM. 5'-7 3/8" WAS 5'-7 7/8; 18GA
MATERIAL WA 16 GA.; NAIL FIELD SUPPLIED WAS
WITH CURB
A
SUPPLY AIR RETURN AIR
1/4"
[7.0]
[115.5]
4 9/16"
C13310
509 01 3522 00 9
Specifications are subject to change without notice.
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