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Installation, Start-Up, and Operating Instructions

1. GROUNDED SURFACES POWER ENTRY SIDE 42 00 1066 8 LEGEND CG Center of Gravity COND Condensor EVAP Evaporator NEC National Electrical Code REQ D Required 1193 9 ar 115 4 NOTE Dimensions in in mm r 1230 07 141 001 TN L un T FR 28 6 1 13 DIA K O z POWER ENTRY 22 2 10 88 DIA HOLE CONTROL ENTRY B A 506 1 0 P HS 258 7 10 191 19 0 015 NPT COMPRESSOR BLOWER GAS SECTION 12 7 0 50 N P T x 22 0 0 87 DP 329 0 amp ELECTRICAL ACCESS PANEL 52 8 Li GAS ENTRY 5 0 E oa 2 081 10 201 be 1123 1 2 851 48 281 5 44 22 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW 00056 CENTER OF GRAVITY UNIT WEIGHT UNIT ELECTRICAL CHARACTERISTICS UNIT HEID IN MM IN MM Ib kg X Y Z 48GS048090 115 130 208 230 3 60 460 3 60 415 188 6 38 98 990 2 22 558 5 16 406 4 17 432 0 48GS060090 115 130 208 230 3 60 460 3 60 450 204 5 38 98 990 2 22 558 5 16 406 4 17 432 0 48GX042060 090 208 230 3 60 460 3 60 382 173 3 38 98 990 2 23 0 584 2 16 3 412 8 16 6 421 6 48GX048090 115 130 208 230 3 60 460 3 60 421 191 0 38 98 990 2 21 5 546 1 16 6 422 1 18 0 457 2 48GX060090 1 15 130 208 230 3 60 460 3 60 468 212 3 42 98 1091 1 23 5 596 9 16 3 412 8 17 6 447 0 Fig 3 48GS048 060 and 48GX042 060 Unit Dimensions 4
2. Screw un NOTE 1 Gasketing outer flange WD ES IE ES Flashing field supplied Roofing material field supplied Cant strip field supplied Gasketing inner flange H Wood nailer Roofcurb Insulation field supplied 7 Duct wo rk field supplied Provided with roofcurb Roof Curb for Small Cabinet Note A When unit mounting screw is used retainer bracket must also be used Supply opening Bx C NOTE Gasketing outer flange Flashing field supplied Roofing mateial field supplied Cant strip field supplied Screw gn Gask eting inner flange Wood nailer Roofcurb Insulation field supplied Duct wo rk field supplied Roof Curb for Provided with roofcurb Large Cabinet Note A When unit mounting screw is used retainer bracket must also be used Tf R A S A Gasket around duct Insulated Gasket around insulate deck pan outer edge leck pan Long Return opening BXC C00076 UNIT SIZE ODS CATALOG NUMBER B IN IN IN IN CPRFCURBOO6A00 8 203 11 279 161 2 419 28 3 4 730 48GS030 042 48GX030 036 CPRFCURBO007A00 14 356 11
3. UNIT SIZE 48GX 048090 048115 048130 060090 060115 060130 NOMINAL CAPACITY ton 4 4 4 5 5 5 OPERATING WEIGHT Ib 421 421 421 468 468 468 COMPRESSORS Scroll Quantity 1 REFRIGERANT R 22 Quantity Ib 8 3 8 3 8 3 8 1 8 1 8 1 REFRIGERANT METERING DEVICE Acutrol Device Orifice ID in 034 034 034 032 032 032 v E 2 17 2 17 2 17 2 17 2 17 2 17 Face Area sq ft 12 3 12 3 12 3 16 4 16 4 16 4 3300 3300 3300 3300 3300 3300 Diameter 22 22 22 22 22 22 Motor Hp Rpm 1100 74 1100 74 1100 1100 74 1100 74 1100 Bici 4 15 4 15 4 15 4 15 4 15 4 15 Face Area sq fi 4 7 4 7 4 7 4 7 4 7 4 7 Sioa 1600 1600 1600 1750 1750 1750 Size 11 X 10 11 X 10 11 X 10 11 X 10 11 X 10 11 X 10 Motor Hp Rpm 3 4 1075 3 4 1075 3 4 1075 1 0 1075 1 0 1075 1 0 1075 FURNACE SECTION Burner Orifice No Qty Drill Size 3 38 3 33 3 31 3 38 3 33 3 31 Gas 3 46 3 42 3 41 3 46 3 42 3 41 Burner Orifice No Qty Drill Size Propane Gas RETURN AIR FILTERS in t Throwaway 24 X 30 24 X 30 24 X 30 24 X 30 24 X 30 24 X 30 Based on altitude of O to 2000 ft T Required filter sizes shown are based on the larger of the ARI Air Conditioning and Refrigeration Institute rated cooling airflow or the heating airflow velocity of 300 ft minute for high capacity type Air filter pressure drop for non standard filters must not exceed 0 08 in w
4. Excessive head pressure Air in system Recover refrigerant evacuate system and recharge Condenser coil dirty or restricted Clean coil or remove restriction Dirty air filter Replace filter Dirty condenser coil Clean coil Refrigerant overcharged Recover excess refrigerant Air in system Recover refrigerant evacuate system and recharge Condenser air restricted or air short cycling Determine cause and correct Head pressure too low Excessive suction pressure Low refrigerant charge Check for leaks repair and recharge Compressor valves leaking Replace compressor Restriction in liquid tube High heat load Remove restriction Check for source and eliminate Compressor valves leaking Replace compressor Refrigerant overcharged Recover excess refrigerant Suction pressure too low Dirty air filter Replace Filter Low refrigerant charge Check for leaks repair and recharge Metering device or low side restricted Remove source of restriction Insufficient evaporator airflow Increase air quantity Check filter replace if necessary Temperature too low in conditioned area Reset thermostat Outdoor ambient below 40 F Install low ambient kit Field installed filter drier restricted 29 Replace SYMPTOM Table 17 Troubleshooting Guide Heating CAUSE REMEDY Water in gas lin
5. tr z 2 zi n zi z z 2 414 260 45 7 2 414 260 a _ l z z o 2 2 345 50 345 250 2 2 7 no 276 40 276 40 207 30 207 30 30 40 50 60 70 80 90 30 40 50 60 70 80 90 SUCTION LINE TEMPERATURE F SUCTION LINE TEMPERATURE F 1 4 10 16 21 27 32 1 4 10 16 21 27 32 SUCTION LINE TEMPERATURE C SUCTION LINE TEMPERATURE C C00052 90053 Fig 24 Cooling Charging Chart 48GX042 Units Fig 25 Cooling Charging Chart 48GX048 Units For longer life operating economy and continuing efficiency c On all units remove blower assembly from unit Remove clean accumulated dirt and grease from the blower wheel and screws securing blower to blower partition and slide motor annually assembly out Be careful not to tear insulation in blower compartment A WARNING d Ensure proper reassembly by marking blower wheel and motor in relation to blower housing before disassembly Before cleaning the blower motor and wheel disconnect gas supply Then turn off and tag electrical power to the unit e Loosen setscrew s that secures wheel to motor shaft Failure to adhere to this warning could cause serious injury or Remove screws that secure motor mount brackets to death housing and slide motor and motor mount out of housing Cleaning the Blower Motor and Wheel 2 Remove and clean blower wheel as follows 1 Remove and disassemble blower assembly as follows a Ensure proper reassembly by marking wheel or
6. 105 4 amp 89 100 821 30 95 35 o 5 115 46 o lt 0 2 a 85 29 5 a 105 41 S S 620 u90 95 35 2552 BO B 5 85 29 zx E 75 24 B 75 24 a 65 18 2 is 65 18 m 483 amp 10 9 2 amp 80 55 18 D 483 a 55 13 ul ul ul oc z 45 T 2 4 5 n 1 w EG 483 270 Z 414 250 6 f 2 o Z 5 418 E 348 so 9 414 60 n o 27g 40 345 50 30 276 40 30 40 50 60 70 80 30 30 40 50 60 70 80 90 SUCTION LINE TEMPERATURE F SUCTION LINE TEMPERATURE F 4 10 16 21 27 32 E 4 10 16 21 27 32 SUCTION LINE TEMPERATURE CO SUCTION LINE TEMPERATURE 00045 00047 Fig 19 Cooling Charging Chart 4865042 Units Fig 20 Cooling Charging Chart 48GS048 Units OUTDOOR TEMP 689 100 115 46 _ 105 41 95 35 620 90 85 29 b 75 24 2 3 65 18 amp e 55 13 2 551 45 7 REF 6 483 170 Qo fu 8 Z 414260 JO o gt 345 50 2 no 276 40 207 30 30 40 50 60 70 80 90 SUCTION LINE TEMPERATURE CF E 4 10 16 21 27 32 SUCTION LINE TEMPERATURE C 00048 Fig 21 Cooling Charging Chart 48GS060 Units Inspect blower motor and wheel for cleanliness at the begin AIR FILTER ning of each heating and cooling season Clean when neces sary For first heating and cooling season inspect blower CAUTION wheel bi monthly to determine proper cleaning frequency Never operate the unit without a suitable air filter in the Check el
7. c W43 BLK BLK FIELD W54 BLK 1 YEL OFM SUPPLY CAP 2 W55YEL H23 We BRN POWER Q NS W8 BLK Ho ZZ DNA EQUIP GND W7 YEL R COMP 060 ONLY e amp L3 reves W56 BLU S SEE NOTE 4 W61 YEL YEL RED W63 YEL r YEL IFM W64 YEL CAP 1 ar I BRN PRIMARY COOLING FAN LOGIC W14 BLK Cor 460 V10 0 T 0 9 YEL IDM ENERGIZED DE ENERGIZED TRAN T S CAP 3 1 2 BRN HEATING FAN LOGIC QT SECONDARY 1 GRNYEL 0 45 T 30 24V c W46 BRN W BR w BR ENERGIZED DE ENERGIZED n H W13 BLK uk BM 24V SPLICE BOX BR W39 RED 2 IGC a 1 W19 WHT OD 4 woo GRN 5 AMP RHL RT W21 RED RS BLU m X88 BLU G 3 C REH vio T a E 15 v10 moe MGV M om Vis pts rit iH W35 GRA 1 Toc Lan W34 BRN ae FLAME SEN G9 Y amp o o NUN l 3 O BRN W41 GRN YEL GRN YEL _ FIELD THERMOSTAT Or W32 BRN 46 BRN W32 BRN l N HS GROUNDED TRU STANDOFF W33 YEL W30 BRN COMMON W30 BRN LEGEND Adjustable Heat NEC National Electrical Anticipator Code UNIT COMPONENT ARRANGEMENT BR Blower Relay Outdoor Fan Motor FAN OFM Contactor QT Quadruple Terminal CAP Capacitor RS Rollout Switch COMP Compr
8. HEATING amp COOLING 48GS 48GX 3 Phase Single Packaged Gas Heating Electric Cooling Units Visit www carrier com Installation Start Up and Operating Instructions 48GS Sizes 030 060 48GX Sizes 030 060 NOTE Read the entire instruction manual before starting the installation TABLE OF CONTENTS SAFETY CONSIDERATIONS eene inrer rtt 1 INTRODUCTION 2 RECEIVING AND INSTALLATION eee 2 CHECK EQUIPMENT ttti tr torte rara n etna 2 IDENTIFY UNIT tte 2 INSPECT SHIPMENT reote ep eae buts 2 INSTALLATION scito ttn ter rr trus 2 PROVIDE UNIT SUPPORT irre tonto reete 2 ROOF CURBS nime 2 SLAB MOUNT e n ee n gage tae een 2 GROUND MOUNT ois sicscsostsstesisscesssesssedeassssesseseoseaveonessaabed 6 FIELD FABRICATE DUCTWORK nnn 6 PROVIDE CLEBEARANCGDBS treten 7 RIG AND PLACE UNIT trn rere 7 CONNECT CONDENSATE 7 INSTALL FLUE HOOD 5 need 8 INSTALL GAS PIPING eet cher rr re rro xOx co sese 8 INSTALL DUCT CONNECTIONS 10 CONFIGURING UNITS FOR DOWNFLOW VERTI CAL DISCHARGE tete nein 10 INSTALL ELECTRICAL CONNECTIONS 12 HIGH VOLTAGE CONNECTIONS 12 SPECIAL PROCEDURES FOR 208 V OPERA
9. sor motors stop After a 30 sec delay the blower motor stops The unit is in a standby condition waiting for the next call for cooling from the room thermostat MAINTENANCE To ensure continuing high performance and to minimize the possibility of premature equipment failure periodic maintenance must be performed on this equipment This combination heating cooling unit should be inspected at least once each year by a qualified service person To troubleshoot cooling or heating of units refer to Tables 16 18 NOTE Consult your local dealer about the availability of a maintenance contract WARNING The ability to properly perform maintenance on this equip ment requires certain expertise mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User s Manual FAILURE TO HEED THIS WARNING COULD RESULT IN SERI OUS INJURY AND POSSIBLE DAMAGE TO THIS EQUIPMENT Table 11 Dry Coil Air Delivery Horizontal Downflow Discharge Unit 48GS030 060 Deduct 10 percent for 208 Volts 230 AND 460 VOLT Unit Motor External Static Pressure in wg Speed 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 Tem Watts 280 275 270 267 264 262 260 95
10. 1184 1152 1120 1102 1084 1056 1029 997 965 Cfm 2349 2278 2207 2124 2041 2000 1960 1853 1745 Air delivery values are without air filter and are for dry coil See Table 14 48GS Wet Coil Pressure Drop NOTE Deduct field supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting Table 12 Filter Pressure Drop In wg CFM UNIT SIZE FILTER SIZE 500 600 700 800 2100 2200 2300 030 20 X 20 X 1 0 05 0 07 0 08 0 10 036 20X24X1 042 048 060 24 X 30 X 1 i 0 16 0 17 0 18 CAUTION Errors made when reconnecting wires may cause improper A WARNING Failure to follow these warnings could result in serious injury 1 First turn off gas supply to the unit Then turn off electrical power to the unit and install lockout tag before performing any maintenance or service on the unit Use extreme caution when removing panels and parts As The minimum maintenance requirements for this equipment are as with any mechanical equipment personal injury can result follows from sharp edges etc 1 Inspect air filter s each month Clean or replace when Never place anything combustible either on or in contact necessary Certain geographical locations may require more with the unit frequent inspections Should overheating occur or the gas supply fail to shut off turn o
11. 982 860 808 736 030 Med Watts 343 339 336 332 328 322 317 Cfm 1233 1170 1109 1038 953 855 754 High Watts 441 432 421 410 400 1202 1111 1021 929 826 Watts 470 458 445 430 415 399 384 1463 1406 1344 1273 1188 1091 983 036 Med Watts 514 501 487 471 455 438 422 Cfm 1497 1428 1348 1255 1152 1042 929 High Watts 646 636 626 614 602 589 Cfm 1491 1412 1325 1228 1120 1003 L w Watts 643 605 593 574 549 518 485 454 Cfm 1626 1532 1478 1421 1361 1295 1218 1120 042 Med Watts 726 695 661 625 591 561 540 1731 1672 1610 1541 1456 1345 1193 High Watts 790 766 742 713 1699 1602 1494 1367 Watts 614 572 566 556 539 517 491 1591 1490 1460 1421 1372 1312 1242 048 Med Watts 778 719 699 676 650 623 596 572 555 1854 1759 1705 1643 1577 1508 1440 1375 1315 High Watts 896 862 829 800 11D 752 728 Cfm 1956 1879 1797 1709 1615 1514 1406 Low Watts 834 746 712 680 652 626 2016 1840 1781 1717 1646 1566 060 Med Watts 941 822 797 772 745 714 679 639 2379 2038 1964 1892 1814 1727 1626 1511 High Watts 949 920 883 845 812 783 753 Cfm 2224 2075 1986 1915 1831 1721 1588 Air delivery values are without air filter and are for dry coil See Table 15 48GX Wet Coil Pressure Drop table NOTE Deduct field supplied air filter pressure drop and wet coil pressure drop to obtain external static
12. however the required setting may be changed slightly to provide a greater degree of comfort for a particular installation Table 4 Electrical Data Unit 48GS UNIT EE COMPRESSOR MOTORS POWER SUPPLY SIZE V PH HZ ESS 48GS Min Max RLA LRA FLA FLA MCA 030 208 230 3 60 187 253 12 6 68 0 08 2 0 13 2 20 ose _208 280 8 60 187 253 9 0 78 0 1 6 3 6 16 5 25 460 3 60 414 506 45 40 0 0 9 1 9 84 15 208230 3 60 187 253 107 85 0 1 6 3 8 18 8 25 460 360 414 506 42 0 0 9 20 9 5 15 oag 208230 3 60 187 253 18 5 108 0 1 6 3 8 22 3 35 460 360 414 506 67 47 5 0 9 2 0 11 3 15 208 230 3 60 187 253 18 6 125 0 1 6 6 2 811 45 060 460 3 60 414 506 85 66 5 0 9 82 14 7 20 EXAMPLE Supply voltage is 460 3 60 AB 452 v LEGEND m e BC 464 v FLA Full Load Amps C UL US AC 455 v LRA Locked Rotor Amps MCA Minimum Circuit Amps Average Voltage 3 MOCP Maximum Overcurrent Protection RLA Rated Load Amps _ 1371 CKT BKR Circuit Breaker 3 457 NOTES Determine maximum deviation from average voltage AB 457 452 5v 464 457 7Vv 457 455 2 1 In compliance with NEC National Electrical Code requirements for multimotor and combination load equipment refer to NEC Articles 430 and 440 the overcurrent protective device for the unit shall be Power Supply fuse Canadian u
13. obstructions and that the air filter is clean When necessary refer to the Indoor Airflow and Airflow Adjustments section to check the system airflow METERING DEVICE ACUTROL DEVICE This metering device is a fixed orifice and is located in the header to the evaporator coil LIQUID LINE STRAINER The liquid line strainer to protect metering device is made of wire mesh and located in the liquid line on the inlet side of the metering device TROUBLESHOOTING Use the Troubleshooting Guides See Tables 16 18 if problems occur with these units START UP CHECKLIST Use the Start Up Checklist to ensure proper start up procedures are followed SYMPTOM Table 16 Troubleshooting Guide Cooling CAUSE REMEDY Compressor and condenser fan will not start Compressor will not start but condenser fan runs Power Failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective thermostat contactor transformer or control relay Replace component Insufficient line voltage Determine cause and correct Incorrect or faulty wiring Check wiring diagram and rewire correctly Thermostat setting too high Faulty wiring or loose connections in compressor circuit Lower thermostat setting below room temperature Check wiring and repair or replace Compressor motor burned out seized or internal overload open Determine cause Replace
14. tions which will result in enhanced installation reliability or operation These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with changing residen tial construction practices We require these instructions as a minimum for a safe installation INTRODUCTION The 48GS and 48GX units See Fig 1 are fully self contained combination Category I gas heating electric cooling units designed for outdoor installation See Fig 2 and 3 for unit dimensions All unit sizes have return and discharge openings for both horizontal and downflow configurations and are factory shipped with all downflow duct openings covered Units may be installed either on a rooftop a cement slab or directly on the ground if local codes permit See Fig 4 for roof curb dimensions Models with an N in the fifth position of the model number are dedicated Low NO units designed for California installation These models meet the California maximum oxides of nitrogen NO emissions requirements of 40 nanograms joule or less as shipped from the factory and must be installed in California Air Quality Management Districts where a Low NO rule exists RECEIVING AND INSTALLATION Step 1 CHECK EQUIPMENT IDENTIFY UNIT The unit model number and serial number are stamped on unit identification pla
15. 0 145 6 35 02 889 5 22 0 558 8 15 3 387 4 16 5 419 1 Fig 2 48GS030 042 and 48GX030 036 Unit Dimensions 3 355 8 342 1 355 8 14 011 13 491 14 011 HE a RETURN SUPPLY B y Jess IT optional 406 6 Hl RETURN supply lll 406 6 16 011 AIR AIR illi 16 01 OPENING L OPENING n fl I M 1 Ml 7 iC I COND COIL We Ww 80 5 supply RETURN itl Gin 115 83 OPENING OPENING Y 1 EVAP COIL r Jl 173 5 z225 2 16 831 117 7 14 63 COND COIL pe 948 REAR VIEW REQUIRED CLEARANCE TO COMBUSTIBLE MATL REQUIRED CLEARANCE FOR OPERATION AND SERVICING INCHES mm TOP OF UNIT EVAP COIL ACCESS SIDE 36 00 914 0 DUCT SIDE OF UNIT POWER ENTRY SIDE 36 00 914 0 SIDE OPPOSITE DUC BOTTOM OF UNIT ELECTRIC HEAT PA NEC REQUIRED CLEARANCES INCHES mm BETWEEN UNITS POWER ENTRY 42 00 1066 8 UNIT AND UNGROUNDED SURFACES POWER ENTRY SIDE 36 00 914 0 UNIT AND BLOCK OR CONCRETE WALLS AND OTHER 48 00 1219 2 36 00 914 0 12 00 304 8 MINIMUM DISTANCES IF UNIT IS PLACED LESS THAN 12 00 304 8 FROM WALL SYSTEM THEN SYSTEM PERFORMANCE MAYBE COMPROMISE DUCT PANEL
16. 279 161 2 419 28 3 4 730 CPRFCURBO008A00 8 203 16 3 16 411 17 3 8 441 40 1 4 1022 4 48 48GX042 805938060 80X012 060 CPRFCURB009A00 14 356 16 3 16 411 17 3 8 441 40 1 4 1022 NOTES 1 Roof curb must be set up for unit being installed 2 Seal strip must be applied as required to unit being installed 3 Dimensions in are in millimeters 4 Roof curb is made of 16 gage steel 5 Table lists only the dimensions per part number that have changed 6 Attach ductwork to curb flanges of duct rest on curb 7 Insulated panels 1 in thick fiberglass 1 Ib density 8 Dimensions are in inches 9 Seismic conditions This bracket is available through Micrometl Fig 4 Roof Curb Dimensions When unit mounting screw is used see Note A a retainer bracket must be used as well This bracket must also be used when required by code for hurricane or C00070 CORNER 48GS 48GX 030 036 042 048 060 030 036 042 048 060 1 53 2 59 7 67 5 78 9 85 5 59 5 61 0 72 6 80 0 88 9 2 50 4 56 5 63 9 74 7 81 0 56 3 57 8 68 8 75 8 84 2 3 86 8 97 3 110 1 128 7 139 5 97 0 99 5 118 4 130 5 145 1 4 89 6 106 5 113 6 132 8 144 0 100 2 102 7 122 2 134 7 149 8 TOTAL WEIGHT 280 320 355 415 450 313 321 382 421 468 Fig 5 48GS and 48GX Unit Corner Weights MINIMUM HEIGHT 36 COIL COIL C99014 A05179 Fig 6 Slab Mounting
17. COIL EVAPORATOR COIL AND CONDENSATE DRAIN erre 27 CONDENSER 28 ELECTRICAL CONTROLS AND WIRING 28 REFRIGERANT CIRCUIT eee GAS INPUT nnns EVAPORATOR AIRFLOW METERING DEVICE ACUTROL DEVICE 28 LIQUID LINE STRAINER nnne 28 TROUBLESHOOTING erret ert teneo bere na START UP CHECKLIST NOTE TO INSTALLER Before the installation READ THESE INSTRUCTIONS CAREFULLY AND COMPLETELY Also make sure the User s Manual and Replacement Guide are left with the unit after installation The furnace is NOT to be used for temporary heating of buildings or structures under construction SAFETY CONSIDERATIONS Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical components Only trained and qualified personnel should install repair or service air conditioning equipment Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 101 Tab 1a 6a Printed in U S A Catalog No 48GS GX 7SI Pg 1 2 06 Replaces New Untrained personnel can perform basic maintenance functions of cleaning coils and 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 a
18. Details size MAXIMUM WEIGHT B Ib kg in mm in mm UNIT 48GS GROUND MOUNT 030 302 137 3 21 5 546 1 13 75 349 3 The unit may be installed either on a slab or placed directly on the 036 ME doo COREL M BR LAM Soc ground if local codes permit Place the unit on level ground 042 377 171 4 21 5 546 1 13 5 342 9 prepared with gravel for condensate discharge 048 437 198 6 22 0 558 5 17 0 4320 060 472 214 5 22 0 558 5 17 0 432 0 Step 3 FIELD FABRICATE DUCTWORK UNIT 48GX Secure all ducts to roof curb and building structure on vertical En n 2226 discharge units Do not connect ductwork to unit For horizontal ie UR P 042 404 183 23 0 584 2 16 3 414 0 applications unit is provided with flanges on the horizontal openings Installation of flexible duct connector is recommended S 3E NN 21 215 5461 163 4140 to prevent transmission of vibration and or noise to structure 080 499 ven ae Fig 7 Suggested Rigging Table 1 Physical Data Unit 48GS UNIT SIZE 48GS 030040 030060 036060 036090 042060 042090 NOMINAL CAPACITY ton 2 2 3 3 3 3 OPERATING WEIGHT Ib 280 280 320 320 355 355 COMPRESSORS Reciprocating Quantity 1 REFRIGERANT R 22 Quantity Ib 3 65 3 65 44 44 5 7 5 7 REFRIGERANT METERING DEVICE Acutrol Device Orifice ID in 034 034 032 032 034 034 Rs IS 1 17 1 17 1 17 1 17 Tct Face Area sq ft 9 1 9 1 1
19. Do not leave screws on rooftop as permanent damage to the roof may occur Adhere to the following criteria when selecting sizing and installing the duct system 5 It is recommended that the unit base insulation around the perimeter of the vertical return air opening be secured to the unit base with aluminum tape Applicable local codes may require aluminum tape to prevent exposed fiberglass 2 Select and size ductwork supply air registers and return air grilles according to American Society of Heating Refrigera tion and Air Conditioning Engineers ASHRAE recommen dations 1 Units are shipped for horizontal duct installation by removing duct covers 6 Cover both horizontal duct openings with the duct covers from the accessory duct cover kit Ensure opening is air and watertight 3 Use flexible transition between rigid ductwork and unit to prevent transmission of vibration The transition may be screwed or bolted to duct flanges Use suitable gaskets to ensure weathertight and airtight seal j 4 All units must have field supplied filters or accessory filter rack installed in the return air side of the unit Recommended A sizes for filters are shown in Tables 1 and 2 e 5 Size all ductwork for maximum required airflow either 7 heating or cooling for unit being installed Avoid abrupt duct size increases or decreases or performance may be affected 6 Adequately ins
20. and evaporator blower motors start Observe that cooling cycle shuts down when control setting is satisfied The evaporator fan will continue to run for 30 sec 3 When using an auto changeover room thermostat place both SYSTEM and FAN switches in AUTO positions Observe that unit operates in Heating mode when temperature control is set to call for heating above room temperature and operates in Cooling mode when temperature control is set to call for cooling below room temperature 20 IMPORTANT Three phase scroll compressor units 48GS048 and 48GX030 060 are direction oriented These units must be checked to ensure proper compressor 3 phase power lead orientation If not corrected within 5 minutes the internal protector shuts off the compressor The 3 phase power leads to the unit must be reversed to correct rotation When turning backwards scroll compres sors emit elevated noise levels and the difference between compressor suction and discharge pressures may be dra matically lower than normal CHECKING AND ADJUSTING REFRIGERANT CHARGE The refrigerant system is fully charged with R 22 refrigerant tested and factory sealed NOTE Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R 22 charge A superheat charging chart is attached to the outside of the service access panel The chart includes the required suction line tempera ture at given
21. be installed on wood flooring or on Class A B or C roof covering materials Step 5 RIG AND PLACE UNIT A CAUTION When installing the unit on a rooftop be sure the roof will support the additional weight Use spreader bars or crate top when rigging the unit The units must be rigged for lifting See Fig 6 Refer to Table 1 and 2 for operating weight Use extreme caution to prevent damage when moving the unit Unit must remain in an upright position during all rigging and moving operations The unit must be level within 1 4 for proper condensate drainage therefore the ground level pad or accessory roof curb must be level before setting the unit in place When a field fabricated support is used be sure that the support is level and properly supports the unit Lifting point should be directly over the center of gravity for the unit Step 6 CONNECT CONDENSATE DRAIN NOTE When installing condensate drain connection be sure to comply with local codes and restrictions Models 48GS and 48GX dispose of condensate water through a 3 4 in NPT fitting which exits through the compressor access panel See Fig 2 and 3 for location Condensate water can be drained directly onto the roof in rooftop installations where permitted or onto a gravel apron in ground level installations Install a field supplied condensate trap at end of condensate connection to ensure proper drainage Make sure that Table 1 Physical Data Unit 48G
22. check each electrical component with the proper electrical instrumentation Refer to the unit wiring label when making these checkouts 28 NOTE Refer to the heating and or cooling sequence of operation in this publication as an aid in determining proper control operation REFRIGERANT CIRCUIT Annually inspect all refrigerant tubing connections and the unit base for oil accumulations Detecting oil generally indicates a refrigerant leak A WARNING System under pressure Relieve pressure and recover all refrigerant before system repair or final unit disposal to avoid serious injury or death Use all service ports and open all flow control devices including solenoid valves If oil is detected or if low cooling performance is suspected leak test all refrigerant tubing using an electronic leak detector halide torch or liquid soap solution If a refrigerant leak is detected refer to the Check for Refrigerant Leaks section If no refrigerant leaks are found and low cooling performance is suspected refer to the Checking and Adjusting Refrigerant Charge section GAS INPUT The gas input does not require checking unless improper heating performance is suspected If a problem exists refer to the Start Up section EVAPORATOR AIRFLOW The heating and or cooling airflow does not require checking unless improper performance is suspected f a problem exists be sure that all supply and return air grilles are open and free from
23. death A WARNING Before performing service or maintenance operations on the system turn off main power to unit Electrical shock could cause serious injury or death 8 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 1 Open all electrical disconnects before starting any service work 10 Wess Se TEE OUT NIPPLE CAP C99020 Fig 9 Sediment Trap 2 Remove return duct cover located on duct panel by breaking connecting tabs with screwdriver and a hammer See Fig 10 C99012 amp 10B 3 To remove supply duct cover break front and right side connecting tabs with a screwdriver and a hammer Push louver down to break rear and left side tabs See Fig 10A amp 10B 7 After completing unit conversion perform all safety checks 4 If unit ductwork is to be attached to vertical opening flanges and power up unit on the unit composite base jackstand applications only do so at this time Fig 10B Vertical Duct Cover Removed NOTE The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidence type air conditioning and ventilating systems NFPA A CAUTION 90A or residence type NFPA 90B and or local codes and ordinances Collect ALL screws that were removed
24. or less as shipped from the factory NOTE Low NO requirements ap ply only to natural gas instal lations CAUTION The venting system is designed to ensure proper venting The flue hood assembly must be installed as indicated in this section of the unit installation instructions Install the flue hood as follows 1 This installation must conform with local building codes and with the National Fuel Gas Code NFGC ANSI Z223 1 in Canada CAN CGA B149 1 and B149 2 or NFPA National Fire Protection Association latest revision Refer to Provin cial and local plumbing or wastewater codes and other applicable local codes 2 Remove flue hood from shipping location inside the blower compartment Place vent cap assembly over flue panel Orient screw holes in vent cap with holes in the flue panel 3 Secure flue hood to flue panel by inserting a single screw on the right side and the left side of the hood Step 8 INSTALL GAS PIPING The gas supply pipe enters the unit through the access hole provided The gas connection to the unit is made to the 1 2 in FPT gas inlet on the manual shutoff or gas valve Table 2 Physical Data Unit 48GX UNIT SIZE 48GX 030040 030060 036060 036090 042060 042090 NOMINAL CAPACITY ton 2 2 3 3 3 37 OPERATING WEIGHT 313 313 321 321 382 382 COMPRESSORS Scroll Quantity 1 REFRIGERANT 22 Quantity Ib T4 4
25. pressure available for ducting 758 110 758 110 689 100 OUTDOOR 689 100 OUTDOOR Je 115 46 115 46 z o 85 29 z a gt g 552 eo Be oo yf 7 2 D 65 18 E 55 18 2 z 4e3 70 i E ge vis dor E 414 Z60 fra 5345 50 345 276 40 276 40 30 30 30 40 50 60 70 80 90 30 40 50 50 70 80 90 SUCTION LINE TEMPERATURE F SUCTION LINE TEMPERATURE F 4 10 16 21 27 32 10 16 21 27 32 SUCTION LINE TEMPERATURE C SUCTION LINE TEMPERATURE CO C00043 00044 Fig 17 Cooling Charging Chart 4865030 Units 23 Fig 18 Cooling Charging Chart 48GS036 Units 758 110 758 110 689 100 OUTDOOR TEMP P amp OUTDOOR TEMP 1
26. suction line pressures and outdoor ambient tempera tures An accurate superheat thermocouple or thermistor type ther mometer a sling psychrometer and a gauge manifold are required when using the superheat charging method for evaluating the unit charge Do not use mercury or small dial type thermometers because they are not adequate for this type of measurement CAUTION When evaluating the refrigerant charge an indicated adjust ment to the specified factory charge must always be very minimal If a substantial adjustment is indicated an abnormal condition exists somewhere in the cooling system such as insufficient airflow across either coil or both coils Proceed as follows 1 Remove caps from low and high pressure service fittings 2 Using hoses with valve core depressors attach low and high pressure gauge hoses to low and high pressure service fittings respectively 3 Start unit in Cooling mode and let unit run until system pressures stabilize 4 Measure and record the following a Outdoor ambient air temperature F db b Evaporator inlet air temperature F wb c Suction tube temperature at low side service fitting d Suction low side pressure psig 5 Using Cooling Charging Charts compare outdoor air tem perature F db with the suction line pressure psig to determine desired system operating suction line temperature See Fig 17 26 6 Compare actual suction tube tem
27. 0 50 8 14 00 355 6 0 50 12 7 36 00 914 4 NOTE Dimensions are in in mm POWER ENTRY SIDE EXCEPT FOR NEC REQUIREMENTS UNIT TOP SIDE OPPOSITE DUCTS DUCT PANEL MINIMUM DISTANCES IF UNIT IS PLACED LESS THAN 12 00 304 8 FROM WALL SYSTEM THEN SYSTEM PERFORMANCE MAYBE COMPROMISE 510 3 22 451 DRAIN OUTLET 0 75 N P T RET 16 5 1193 9 116 3 31441 47 001 4 581 FIELD ENTRY RVI PORT f SERVICE PORTS 23 0 ge m 28 6 1 131 DIA i POWER 22 2 0 88 DIA HOLE CONTROL ENTRY x 22 0 DP COMPRESSOR BLOWER GAS SECTION FLUE HOOD A 12 7 10 501 W P T 326 5 amp ELECTRICAL ACCESS PANEL 11 84 L GAS EN i 52 8 m 12 851 1226 3 2 081 831 0 48 281 32 121 HOT LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW 00055 CENTER OF GRAVITY UNIT WEIGHT UNIT ELECTRICAL CHARACTERISTICS us IN MM Ib kg X Y Z 48GS030040 060 208 230 3 60 280 0 127 3 35 02 889 5 21 5 546 1 13 75 349 3 15 0 381 0 48GS036060 090 208 230 3 60 460 3 60 320 0 145 1 37 02 940 3 22 5 571 5 14 0 355 6 13 0 330 2 48GS042060 090 208 230 3 60 460 3 60 355 0 161 4 35 02 889 5 21 5 546 1 13 5 342 9 13 0 330 2 48GX030040 060 208 230 3 60 313 0 142 0 39 02 991 1 22 0 558 8 15 3 387 4 17 6 447 0 48GX036060 090 208 230 3 60 460 3 60 321
28. 0 _90 do M 9 6 65 18 9 8 95 35 amp e 55 13 85 29 551 45 7 9 551 80 75 24 x lt 2 19 65 18 T 2 483 E 70 483 70 55 13 7 n w a T e BH 45 7 z a a 414 560 414 60 zl zi z o 5 2 o 345 50 345 250 be o no 276 40 276 40 207 30 207 30 30 40 50 60 70 80 90 30 40 50 60 70 80 90 SUCTION LINE TEMPERATURE F SUCTION LINE TEMPERATURE F 1 4 10 16 21 27 2 1 4 10 16 21 27 32 SUCTION LINE TEMPERATURE C SUCTION LINE TEMPERATURE C Fig 22 Cooling Charging Chart 48GX030 Units Fig 23 Cooling Charging Chart 48GX036 Units 042 60HZ CHARGING CHART OUTDOOR TEP 048 60HZ CHARGING CHART QUIDBOR TM 689 100 689 100 a 115 46 G 115 46 2620 90 105 41 d 620 90 105 41 9 E 9 6 95 35 2 5 2 5 85 29 a Je 75 24 5 S 75 24 S 551 22 551 lt E a 65 18 ie 65 18 2 55 13 t o tt 0 2 483 70 2 483 70 55 13 QB a
29. 0 880 825 750 670 580 400 030 Med Watts 380 375 365 360 355 350 344 335 312 Cfm 1220 1150 1090 1025 970 860 760 620 450 High Watts 485 475 470 460 455 445 437 430 415 385 1475 1440 1350 1275 1200 1125 1025 925 750 400 Tem Watts 576 566 556 538 512 497 481 466 450 435 Cfm 1430 1403 1365 1263 1157 1068 973 900 827 704 036 Med Watts 680 671 660 624 604 620 602 558 534 512 496 Cfm 1720 1630 1538 1439 1346 1267 1167 1126 1018 858 781 High Watts 810 800 790 782 766 742 723 709 688 661 627 Cfm 1800 1745 1660 1600 1547 1465 1360 1270 1163 967 876 Low Watts 675 660 650 640 630 620 610 595 580 Cfm 1454 1387 1326 1275 1204 1142 1081 995 918 042 Med Watts 886 855 825 795 778 765 750 735 718 700 1515 1458 1406 1350 1285 1224 1163 1091 1013 932 High Watts 1000 950 925 910 890 875 855 833 Cfm 1551 1488 1424 1360 1296 1233 1148 1071 bow Watts 727 712 700 688 666 644 622 595 569 1678 1639 1600 1561 1500 1440 1379 1289 1198 048 Med Watts 853 836 821 807 782 756 730 699 667 640 Cfm 1914 1870 1825 1780 1711 1642 1573 1470 1367 1270 High Watts 979 959 943 927 897 868 838 802 766 730 2150 2100 2050 2000 1922 1845 1767 1600 1535 1419 Low Watts 1033 949 864 836 822 808 772 737 705 674 642 Cfm 2105 2057 2009 1943 1909 1876 1823 1770 1698 1627 1531 060 Med Watts 1084 1054 1024 994 971 955 928 897 867 835 803 Cfm 2318 2248 2179 2110 2058 2000 1932 1885 1829 1740 1638 High Watts
30. 0 9 10 9 9 1 9 1 oon 2400 2400 3000 3000 3000 3000 Diameter in 22 22 22 22 22 22 Motor Hp Rpm 1 8 825 1 8 825 7 1100 1100 14 1100 14 1100 Seas i 2 15 2 15 3 15 3 15 4 15 4 15 m 4 3 1 3 1 3 1 3 1 3 1 3 1 Face Area sq ft ped duy 1000 1000 1200 1200 1400 1400 Size in 10 x 10 10 x 10 11x 10 11x 10 11x 10 11x 10 Motor HP Rpm 1 4 1075 1 4 1075 1 2 1075 1 2 1075 3 4 1075 3 4 1075 FURNACE SECTION Burner Orifice No Qty Drill Size 2 45 2 38 2 38 3 38 2 38 3 38 Natural Gas Burner Orifice No Qty Drill Size 90 Propane Gas RETURN AIR FILTERS in t Throwaway 20 x 20 20 X 20 20 X 24 20 X 24 20 x 24 20 x 24 Based on altitude of to 2000 ft T Required filter sizes shown are based on the larger of the ARI Air Conditioning and Refrigeration Institute rated cooling airflow or the heating airflow velocity of 300 ft minute for throwaway type or 450 ft minute for high capacity type Air filter pressure drop for non standard filters must not exceed 0 08 in wg ductwork should be secured to the flanges Insulate and weather proof 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 compl
31. 3 2 15 4 20 EXAMPLE Supply voltage is 460 3 60 LEGEND EM BC 464 V LRA fae s C US 452 464 455 MCA Minimum Circuit Amps Average Voltage EIE EE MOCP Maximum Overcurrent Protection RLA Rated Load Amps 1371 CKT BKR Circuit Breaker 3 457 NOTES 1 In compliance with NEC National Electrical Code requirements for multimotor and combination load equipment refer to NEC Articles 430 and 440 the overcurrent protective device for the unit shall be Power Supply fuse Canadian units may be fuse or circuit breaker 2 Minimum wire size is based on 60 C copper wire If other than 60 C wire is used or if length exceeds wire length in table determine size from NEC 3 Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance in supply volt age is greater than 2 Use the following formula to determine the percentage of voltage imbalance Voltage imbalance max voltage deviation from average voltage average voltage Determine maximum deviation from average voltage 457 452 5 464 457 7 457 455 2 Maximum deviation is 7 v Determine percent of voltage imbalance 7 Voltage Imbalance 100x 457 1 53 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 your local electric utility company immediately C
32. 32 sec and the heating value of the gas is 1050 Btu ft Proceed as follows 1 32 sec to complete one revolution 2 3600 32 112 5 3 112 5 x 1 2112 5 of gas flow hr 4 112 5 x 1050 118 125 Btuh input If the desired gas input is 115 000 Btuh only a minor change in the manifold pressure is required Observe manifold pressure and proceed as follows to adjust gas input C W43 BLK BLK FIELD mmn m m i W54 BLK 1 YEL OFM SUPPLY CAP 2 1 wssvEL He3 W6 YEL g I BRN POWER L122 060 ONLY W8 BLK AM EQUIP GND W7 YEL R COMP a L3 W56 BLU S SEE NOTE 4 RED YEL W59 YEL BRN WHT IFM W64 YEL e CAP1 OR YEL L BRN W15 YEL PRIMARY T QT 230V COOLING FAN LOGIC W14 BLK o 2 V10 0 T 30 YEL IDM G G gt z CAP3 ENERGIZED DE ENERGIZED TRAN1 x 8 CBAN HEATING FAN LOGIC T SECONDARY S
33. 4 52 5 2 6 4 6 4 REFRIGERANT METERING DEVICE Orifice ID in 030 030 032 032 034 034 Pc E 1 17 1 17 2 17 2 417 2 17 2 17 Face Area sq ft 12 7 12 7 9 1 9 1 12 3 12 3 cepi 2350 2350 2350 2350 3300 3300 Diameter in 22 22 22 22 22 22 Motor Hp Rpm 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 1 8 825 Spee ee 9 15 15 3 2 15 3 15 3 15 3 15 Face Area sq ft 31 3 1 3 7 3 7 4 7 4 7 pede bi ca 1000 1000 1200 1200 1400 1400 Size in 10 X 10 10 X 10 11 X 10 11 X 10 11 X 10 11 X 10 Motor Hp Rpm 1 4 1075 1 4 1075 1 2 1075 1 2 1075 3 4 1075 3 4 1075 FURNACE SECTION Burner Orifice No Qty Drill Size 2 44 2 38 2 38 8 55 588 4 258 Natural Gas Burner Orifice No Qty Drill Size 2 46 2 46 3 46 2 46 3 46 Propane Gas RETURN AIR FILTERS Throwaway 20 X 20 20 X 20 20 X 24 20 X 24 24 X 30 24 X 30 Based on altitude of O to 2000 ft t Required filter sizes shown are based on the larger of the ARI Air Conditioning and Refrigeration Institute rated cooling airflow or the heating airflow velocity of 300 ft minute for high capacity type Air filter pressure drop for non standard filters must not exceed 0 08 in wg Install a gas supply line that runs to the heating section Refer to specified by local and or national codes Never use Teflon Table 3 and the NFGC for gas pipe sizing Do not use cast iron tape pipe It is recommended that a black iron pipe is used Check the 4 local utility
34. 6 To reinstall reverse the procedure outlined above LIMIT SWITCH Remove unit access panel Limit switch is located on the blower partition BURNER IGNITION Unit is equipped with a direct spark ignition 100 percent lockout system Ignition module is located in the control box Module contains a self diagnostic LED During servicing refer to label diagram for LED interpretation If lockout occurs unit may be reset by either momentarily interrupting power supply to unit or by turning selector switch to OFF position at the thermostat MAIN BURNERS At the beginning of each heating season inspect for deterioration or blockage due to corrosion or other causes Observe the main burner flames and adjust if necessary A CAUTION When servicing gas train do not hit or plug orifice spuds Removal of Gas Train To remove the gas train for servicing 1 Shut off main gas valve Shut off power to unit and install lockout tag Remove unit access panel See Fig 28 Disconnect gas piping at unit gas valve Remove wires connected to gas valve Mark each wire Remove ignitor and sensor wires at the ignitor module ROO DD Remove the mounting screw that attaches the burner rack to the unit base See Fig 27 8 Slide the burner rack out of the unit See Fig 27 and 30 9 To reinstall reverse the procedure outlined above CONDENSER COIL EVAPORATOR COIL AND CONDENSATE DRAIN PAN Inspect the condense
35. 99024 Table 5 Legend 14 TRANSFORMER PROTECTION The transformer is of the energy limiting type It is set to withstand a 30 sec overload or shorted secondary condition PRE START UP A WARNING Failure to observe the following warnings could result in serious injury 1 Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system 2 Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured 3 Do not remove compressor terminal cover until all electri cal sources are disconnected 4 Relieve and recover all refrigerant from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals 5 Never attempt to repair soldered connection while refrig erant system is under pressure 6 Do not use torch to remove any component System contains oil and refrigerant under pressure To remove a component wear protective goggles and proceed as fol lows a Shut off gas supply and then electrical power to unit b Relieve and recover all refrigerant from system using both high and low pressure ports c Cut component connecting tubing with tubing cutter and remove component from unit d Carefully unsweat remaining tubing stubs when neces sary Oil can ignite when exposed to torch flame Proceed as follows to inspect and prepare the unit for initial st
36. ATURE DB WB COOLING SUPPLY AIR DB WB GAS HEAT SUPPLY AIR PRESSURES GAS INLET PRESSURE IN WG GAS MANIFOLD PRESSURE IN WG REFRIGERANT SUCTION PSIG REFRIGERANT DISCHARGE PSIG SUCTION LINE TEMP DISCHARGE LINE TEMP VERIFY REFRIGERANT CHARGE USING CHARGING TABLES VERIFY THAT 3 PHASE SCROLL COMPRESSOR 48GS048 and 48GX030 060 IS ROTATING IN CORRECT DIRECTION Measured at suction inlet to compressor Measured at liquid line leaving condenser 31 Copyright 2006 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 1 PC 101 Printed in U S A Catalog No 48GS GX 7SI Pg 32 2 06 Replaces New
37. PERATURE F 1 4 10 16 21 27 32 SUCTION LINE TEMPERATURE C 00054 Fig 26 Cooling Charging Chart 48GX060 Units INDUCED DRAFT MOTOR MOUNT 96000900000000090000 ROLLOUT FLUE SWITCH COLLECTOR BLOWER BURNER MOUNTING BOX HOUSING RACK SCREW C99022 Fig 27 Blower Housing and Flue Collector Box SZ 6 7 ACCESS PANEL 99091 Fig 28 Unit Access Panel c Remove caked on dirt from wheel and housing with a brush Remove lint and or dirt accumulations from wheel and housing with vacuum cleaner using soft brush attach ment Remove grease and oil with mild solvent d Reassemble wheel into housing e Reassemble motor into housing Be sure setscrews are tightened on motor shaft flats and not on round part of shaft f Reinstall unit access panel 3 Restore electrical power to unit Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles FLUE GAS PASSAGEWAYS To inspect the flue collector box and upper areas of the heat exchanger 1 Remove the combustion blower wheel and motor assembly according to directions in the Combustion Air Blower section 26 BLO
38. S Continued UNIT SIZE 48GS 048090 048115 048130 060090 060115 060130 NOMINAL CAPACITY ton 4 4 4 5 5 5 OPERATING WEIGHT Ib 415 415 415 450 450 450 COMPRESSORS Scroll Reciprocating Quantity 1 1 REFRIGERANT R 22 Quantity Ib 6 0 6 0 6 0 8 0 8 0 8 0 REFRIGERANT METERING DEVICE Acutrol Device Orifice ID in 032 032 032 030 030 030 ig E 1 17 Uem r 14 17 2 17 2 17 2 517 Face Area sq ft 12 3 12 3 12 3 12 3 12 3 12 3 TE 3600 3600 3600 3600 3600 3600 Diameter in 22 22 22 22 22 22 Motor Hp Rpm 1100 1100 1100 1100 1100 1100 E 3 15 3 15 3 15 4 15 4 15 4 15 Face Area sq ft 4 7 4 7 4 7 4 7 4 7 an AAA 1600 1600 1600 2000 2000 2000 Size in 11X10 11X10 11 X 10 11 X 10 11 X 10 11 X 10 Motor Hp Rpm 3 4 1075 3 4 1075 3 4 1075 1 0 1075 1 0 1075 1 0 1075 FURNACE SECTION Burner Orifice No Qty Drill Size 3 38 3 33 3 31 T Natural Gas e E Burner Orifice No Qty Drill Size 3 42 3 41 3 46 3 42 3 41 Propane Gas RETURN AIR FILTERS in t Throwaway 24 X 30 24 X 30 24 X 30 24 X 30 24 X 30 24 X 30 Based on altitude of to 2000 ft T Required filter sizes shown are based on the larger of the ARI Air Conditioning and Refrigeration Institute rated cooling airflow or the heating airflow velocity of 300 ft minute for throwaway type or 450 ft minute for high capacity
39. SUPPLY PRESSURE MANIFOLD INPUT Propanet IN WG BTUH ORIFICES Min Max Min Max Natural Propanet 40 000 2 4 0 13 0 4 0 13 0 3 5 3 5 60 000 2 4 0 13 0 4 0 13 0 3 5 3 5 90 000 3 4 0 13 0 4 0 13 0 3 5 3 4 115 000 3 4 0 13 0 4 0 13 0 3 5 3 7 130 000 3 4 0 13 0 4 0 13 0 3 5 3 5 When a unit is converted to propane different size orifices must be used See separate natural to propane conversion kit instructions T Based on altitudes from sea level to 2000 ft above sea level For altitudes above 2000 ft reduce input rating 4 percent for each additional 1000 ft above sea level In Canada from 2000 ft above sea level to 4500 ft above sea level derate the unit 10 percent Remove cover screw over regulator adjustment screw on gas valve 2 Turn regulator adjustment screw clockwise to increase gas input or turn regulator adjustment screw counterclockwise to decrease input Manifold pressure must be between 3 4 and 3 6 in wg Unsafe operation of the unit may result if manifold pressure is outside this range Personal injury or unit damage may result A WARNING Unsafe operation of the unit may result if manifold pressure is outside this range Serious injury death or unit damage may result 3 Replace cover screw cap on gas valve 4 Turn off gas supply to unit Remove manometer from pressure tap and replace pipe plug on gas valve Turn on gas to unit and check for leaks Measure Ma
40. TION 12 CONTROL VOLTAGE CONNECTIONS 12 HEAT ANTICIPATOR SETTING eee 12 TRANSFORMER PROTECTION ee 15 PRESTAR T UP saroia Brat vi dieto Im Do Eo S 15 START UP kesoren 15 CHECK FOR REFRIGERANT 15 START UP HEATING AND MAKE ADJUSTMENTS 16 CHECK HEATING CONTROL cece eee 16 CHECK GAS INPUT ADJUST GAS INPUT CHECK BURNER BLAME trente 19 AIRFLOW AND TEMPERATURE RISE 19 HEATING SEQUENCE OF OPERATION 19 LIMIT SWITCHES 19 AUXILIARY LIMIT SWITCH ROLLOUT 19 START UP COOLING AND MAKE ADJUSTMENTS 20 CHECKING COOLING CONTROL OPERATION 20 CHECKING ADJUSTING REFRIGERANT CHARGE a nn nOD 20 INDOOR AIRFLOW AIRFLOW ADJUST MENTS MY 21 COOLING SEQUENCE OF OPERATION 21 MAINTENANCE 3 232 oni Re theta kite beer eror se ke EY EYED eS 21 AIR PUCTER d 24 EVAPORATOR BLOWER AND 24 FLUE GAS PASSAGEWAYS 26 S44 A99338 Fig 1 Unit 48GS and 48GX COMBUSTION AIR BLOWRER enne 27 LIMIT SWITCH BURNER IGNITION MAIN BURNERS 0I rrr rear ert CONDENSER
41. U ae 24V 24 W46 BRN if s Ww j ENERGIZED DE ENERGIZED CR W13 BLK m 24 SPLICE BOX i xd W39 RED 2 LN IGC x J 2 19 WH 0 21 woo GRN 1 r 5 AMP LN Lom W21 RED BLU BO Does RE vio TCI YI 7 coo 88 vo x MGV veL GVR L 4 KH W34 BRN AUTO FLAME SEN FAN amp L TRAN i EL O O72 Po a i Al o o o o BN ON e ee W41 GRN YEL GRN YEL 3 FIELD THERMOSTAT E qose W32 BRN QN WA46 BRN W32 a S W33 YEL W30 BRN COMMON W30 BRN LEGEND Adjustable Heat NEC National Electrical Anticipator Code UNT COMPONENT ARRANGEMENS BR Blower Relay OFM Outdoor Fan Motor OUTDOOR FAN OFM Contactor QT Quadruple Terminal SECTION CAP Capacitor RS Rollout Switch EQUIP COMP Compressor Motor SEN Sensor m CR Combustion Relay SW Switch COMPRESSOR INDOOR FAN CONTROL BOX CS Centrifugal Switch TRAN Transformer SECTION SECTION LS EQUIP Equipment pan i TRAN FS Flame Sensor Field Splice FU Fuse GND Ground lt Terminal Marked FROM COMP 2 GV Gas Valve 1 capal i GVR Gas Valve Relay Terminal Unmarked Q HS Hall Effect Sensor R HV High Voltage gt CAP 2 IFM IGC TRAN Transformer Ignitor Splice Marked 9 24V IDM Induced Draft Motor Factor
42. UST GAS INPUT The gas input to the unit is determined by measuring the gas flow at the meter or by measuring the manifold pressure Measuring the gas flow at the meter is recommended for natural gas units The manifold pressure must be measured to determine the input of propane gas units Measure Gas Flow Natural Gas Units Minor adjustment to the gas flow can be made by changing the manifold pressure The manifold pressure must be maintained between 3 4 and 3 6 in wg If larger adjustments are required change main burner orifices following the recommendations of national and local codes NOTE other appliances that use the same meter must be turned off when gas flow is measured at the meter Proceed as follows 1 Turn off gas supply to unit 2 Remove pipe plug on manifold See Fig 13 and connect manometer Turn on gas supply to unit 3 Record number of seconds for gas meter test dial to make one revolution 4 Divide number of seconds in Step 3 into 3600 number of seconds in one hour 5 Multiply result of Step 4 by the number of cu ft shown for one revolution of test dial to obtain cu ft of gas flow per hour 6 Multiply result of Step 5 by Btu heating value of gas to obtain total measured input in Btuh Compare this value with heating input shown in Table 6 Consult the local gas supplier if the heating value of gas is not known EXAMPLE Assume that the size of test dial is 1 cu ft one revolution takes
43. WER HOUSING 2 SETSCREWS HIDDEN C99085 Fig 29 Removal of Motor and Blower Wheel v q T TS A SS SS IN yes Sy aly Pe C99086 Fig 30 Burner Rack Removed 2 Remove the 3 screws holding the blower housing to the flue collector box cover See Fig 27 30 3 Remove the 12 screws holding the flue collector box cover See Fig 29 30 to the heat exchanger assembly Inspect the heat exchangers 4 Clean all surfaces as required using a wire brush COMBUSTION AIR BLOWER Clean periodically to assure proper airflow and heating efficiency Inspect blower wheel every fall and periodically during the heating season For the first heating season inspect blower wheel bi monthly to determine proper cleaning frequency To inspect blower wheel remove draft hood assembly Shine a flashlight into opening to inspect wheel If cleaning is required remove motor and wheel as follows 27 1 Remove unit access panel See Fig 28 2 Remove the 7 screws that attach induced draft motor mount ing plate to blower housing See Fig 29 3 Slide the motor and blower wheel assembly out of the blower housing See Fig 29 Clean the blower wheel If additional cleaning is required continue with Steps 4 and 5 4 To remove blower remove 2 setscrews 5 To remove motor and cooling fan assembly remove 4 screws that hold blower housing to mounting plate
44. arts To select high speed on 460 v GE motors separate the black female quick connect QC from the jumper lead male quick connect QC and connect the black lead to the BR Insulate the jumper to avoid contact with any chassis parts COOLING SEQUENCE OF OPERATION With the room thermostat SYSTEM switch in the COOL position and the FAN switch in the AUTO position the cooling sequence of operation is as follows 1 When the room temperature rises to a point that is slightly above the cooling control setting of the thermostat the thermostat completes the circuit between thermostat terminal R to terminals Y and G These completed circuits through the thermostat 2 The normally open contacts of energized contactor C close and complete the circuit through compressor motor COMP to condenser outdoor fan motor OFM Both motors start instantly 3 The set of normally open contacts of energized relay BM close and complete the circuit through evaporator blower indoor fan motor IFM NOTE Once the compressor has started and then stopped it should not be started again until 5 minutes have elapsed The cooling cycle remains until the room temperature drops to a point that is slightly below the cooling control setting of the room thermostat At this point the thermostat breaks the circuit between thermostat terminal R to terminals Y and G These open circuits deenergize contactor coil C The condenser and compres
45. artup 1 Remove access panel 2 Read and follow instructions on all WARNING CAUTION and INFORMATION labels attached to or shipped with unit 3 Make the following inspections a Inspect for shipping and handling damages such as broken lines loose parts disconnected wires etc b Inspect for oil at all refrigerant tubing connections and on unit base Detecting oil generally indicates a refrigerant leak c Leak test all refrigerant tubing connections using electronic leak detector halide torch or liquid soap solution If a refrigerant leak is detected see the Check for Refrigerant Leaks section d Inspect all field and factory wiring connections Be sure that connections are completed and tight e Ensure wires do not contact refrigerant tubing or sharp sheet metal edges f Inspect coil fins If damaged during shipping and handling carefully straighten fins with a fin comb 4 Verify the following conditions CAUTION Do not purge gas supply into the combustion chamber Do not use a match or other open flame to check for gas leaks Failure to follow this warning could result in an explosion causing serious injury or death a Make sure gas line is free of air Before lighting the unit for the first time perform the following with the gas valve in 15 the OFF position If the gas supply pipe was not purged before connecting the unit it will be full of air It is recommended that the groun
46. compressor Defective run start capacitor overload start relay Determine cause and replace One leg of 3 phase power dead Replace fuse or reset circuit breaker Determine cause Three phase scroll compressor 48GS048 and 48GX030 060 only makes excessive noise and there may be a low pressure differential Scroll compressor is rotating in the wrong direction Correct the direction of rotation by reversing the 3 phase power leads to the unit Shut down unit to allow pressures to equalize Compressor cycles other than normally satisfying thermostat Refrigerant overcharge or undercharge Recover refrigerant evacuate system and recharge to capacities shown on nameplate Defective compressor Replace and determine cause Insufficient line voltage Determine cause and correct Blocked condenser Determine cause and correct Defective run start capacitor overload or start relay Determine cause and replace Defective thermostat Replace thermostat Faulty condenser fan motor or capacitor Replace Restriction in refrigerant system Locate restriction and remove Compressor operates continuously Dirty air filter Replace filter Unit undersized for load Thermostat set too low Decrease load or increase unit size Reset thermostat Low refrigerant charge Locate leak repair and recharge Leaking valves in compressor Replace compressor
47. d joint union be loosened and the supply line be allowed to purge until the odor of gas is detected Never purge gas lines into a combustion chamber Immediately upon detection of gas odor retighten the union Allow 5 minutes to elapse then light unit b Make sure that condenser fan blade is correctly positioned in fan orifice Leading edge of condenser fan blade should be 1 2 in maximum from fan orifice venturi c Ensure fan hub is 1 8 in maximum from motor housing See Fig 12 MOTOR FAN GRILLE 1 2 MOTOR SHAFT 1 8 MAX BETWEEN MOTOR AND FAN HUB 99009 Fig 12 Fan Blade Clearance TKK eM SL v MANIFOLD PIPE PLUG C99019 Fig 13 Burner Assembly d Make sure that air filter s is in place e Make sure that condensate drain trap is filled with water to ensure proper drainage f Make sure that all tools and miscellaneous loose parts have been removed START UP Step 1 CHECK FOR REFRIGERANT LEAKS Proceed as follows to locate and repair a refrigerant leak and to charge the unit 1 Locate leak and make sure that refrigerant system pressure has been relieved and reclaimed from both high and low pressure ports 2 Repair leak following Refrigerant Service procedures BURNER FLAME MANIFOLD C99021 Fig 14 Monoport Burner NOTE Install a filter drier whenever the
48. e Drain Install drip leg No power to furnace Check power supply fuses wiring or circuit breaker No 24 v power supply to control circuit Check transformer NOTE Some transformers have internal overcurrent protection that requires a cool down period to reset Miswired or loose connections Check all wiring and wirenut connections Burners will not ignite Burned out heat anticipator in thermostat Replace thermostat Broken thermostat wire Run continuity check Replace wire if necessary Misaligned spark electrodes Check flame ignition and sense electrode positioning Adjust as necessary No gas at main burners 1 Check gas line for air Purge as necessary NOTE After purging gas line of air wait at least 5 minutes for any gas to dissipate before attempting to light unit 2 Check gas valve Dirty air filter Clean or replace filter as necessary Gas input to furnace too low Check gas pressure at manifold match with that on unit nameplate Unit undersized for application Replace with proper unit or add additional unit Inadequate heating Restricted airflow Clean or replace filter Remove any restriction Blower speed too low Use faster speed tap if available or install alternate motor Limit switch cycles main burners Check rotation of blower thermostat heat anticipator settings temperature rise of unit Adjust as necessary Poor
49. ectrical connections for tightness and controls for return air duct system Always replace the filter with the same proper operation each heating and cooling season Service dimensional size and type as originally installed See Tables when necessary 1 and 2 for recommended filter sizes Ensure wires are not contacting refrigerant tubes or sharp Inspect air filter s at least once each month and replace sheet metal edges throwaway type or clean cleanable type at least twice during each heating and cooling season or whenever the filter s becomes clogged with dust and or lint EVAPORATOR BLOWER AND MOTOR NOTE All motors are permanently lubricated Do not attempt to lubricate these motors Check and inspect heating section before each heating season Clean and adjust when necessary Check flue hood and remove any obstructions if necessary 24 030 60HZ CHARGING CHART OUTDOOR TEMP 036 60HZ CHARGING CHART OUTDOOR TEMP 689 100 115 46 689 100 105 41 p 95 35 m 8 8 115 46 85 29 zi z 620 90 85 29 z 62
50. essor Motor SEN Sensor CR Combustion Relay SW Switch COMPRESSOR INDOOR FAN CONTROL BOX CS Centrifugal Switch TRAN Transformer SECTION SECTION EQUIP Equipment TRAN FS Flame Sensor xX Field Splice FU Fuse GND Ground C Terminal Marked GV Gas Valve GVR Gas Valve Relay Terminal Unmarked HS Hall Effect Sensor HV High Voltage Q Splice CAP 2 TRAN Transformer ar Ignitor 5 Splice Marked IDM Induced Draft Motor Factory Wiring COMP Indoor Fan Contactor Field Control Wiring IFM Indoor Fan Motor IGC Integrated Gas Unit Field Power Wiring Controller Accessory or L1 Line Optional Wiring T uu Indicate Common i 1 Potential Only Not R MGV Main Gas Valve to Represent Wiring GAS SECTION NOTES 1 If any of the original wires furnished are replaced they must be DISCONNECT replaced with type 90 degree C wire or its equivalent See price pages for thermostat and subbases Use 75 degree C copper conductors for field installation For high speed IFM disconnect RED wire from IGC terminal BM and connect BLK wire from IFM For medium speed disconnect RED wire from IGC terminal BM and connect BLU wire from IFM C00059 Fig 16 460 3 60 Wiring Diagram Units 48GS and 48GX 18 Table 6 Heating Inputs GAS
51. f Delay Modified 1 Flash Limit Switch Fault 2 Flashes Flame Sense Fault 3 Flashes Four Consecutive Limit Switch Faults 4 Flashes Ignition Lockout Fault 5 Flashes Induced Draft Motor Fault 6 Flashes Rollout Switch Fault 7 Flashes Internal Control Fault 8 Flashes Temporary lock out 1 hr 9 Flashes NOTES 1 There is a 3 sec pause between error code displays 2 If more than one error code exists all applicable error codes will be displayed in numerical sequence 3 This chart is on the wiring diagram located inside the burner access panel Step 3 START UP COOLING AND MAKE ADJUST MENTS CAUTION Complete the required procedures given in the Pre Start Up section before starting the unit Do not jumper any safety devices when operating the unit Do not operate the compressor when the outdoor temperature is below 40 F unless accessory low ambient kit is installed Do not rapid cycle the compressor Allow 5 minutes between on cycles to prevent compressor damage CHECKING COOLING CONTROL OPERATION Start and check the unit for proper cooling control operation as follows 1 Place room thermostat SYSTEM switch in OFF position Observe that blower motor starts when FAN switch is placed in ON position and shuts down when FAN switch is placed in AUTO position 2 Place SYSTEM switch in COOL position and FAN switch in AUTO position Set cooling control below room temperature Observe that compressor condenser fan
52. ff external main manual gas valve to the unit Then shut off electrical supply and install lockout tag and dangerous operation Label all wires prior to disconnec tion when servicing 2 Inspect indoor coil outdoor coil drain pan and condensate drain each cooling season for cleanliness Clean at least once per heating cooling season or more often if needed 22 Table 13 Dry Coil Air Delivery Horizontal and Downflow Discharge Unit 48GX030 060 Deduct 10 percent for 208 Volts 230 AND 460 VOLT Unit Motor External Static Pressure in wg Speed 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 Watts 246 244 243 241 Low
53. flame characteristics SYMPTOM Incomplete combustion results in Aldehyde odors carbon monoxide sooting flame floating flame 1 Tighten all screws around burner compartment 2 Cracked heat exchanger Replace 3 Unit overfired Reduce input change orifices or adjust gas line or manifold pressure 4 Check burner alignment Table 18 Troubleshooting Guide LED Error Codes CAUSE REMEDY Hardware failure LED OFF Loss of power to control module IGC Check 5 amp fuse on IGC power to unit 24 v circuit breaker and transformer Units without a 24 v circuit breaker have an internal overload in the 24 v transformer If the overload trips allow 10 min utes for automatic reset Fan ON OFF delay modified LED FLASH High limit switch opens during heat exchanger warm up period before fan on delay expires Limit switch opens within three minutes after blower off delay timing in Heating mode Ensure unit is fired on rate ensure temperature rise is correct Ensure unit s external static pressure is within application guidelines Limit switch faults LED 2 flashes High temperature limit switch is open Check the operation of the indoor evaporator fan motor Ensure that the supply air temperature rise is in accordance with the range on the unit nameplate Flame sense fault LED 3 flashes 4 consecutive limit switch faults LED 4 flashes Ignition lockout LED 5 f
54. flow to the burners and pilot The blower motor continues to run until LS resets When the air temperature at the limit switch drops to the low temperature setting of the limit switch the switch closes and completes the R control circuit The electric spark ignition system cycles and the unit returns to normal heating operation AUXILIARY LIMIT SWITCH ROLLOUT The function of the switch is to close the main gas valve in the event of flame rollout The switch is located above the main burners When the temperature at the auxiliary switch reaches the maximum allowable temperature the R control circuit trips closing the gas valve and stopping gas flow to the burners The indoor evaporator fan motor IFM and induced draft motor continue to run until switch is reset The LED will display FAULT CODE 7 Table 7 Air Delivery at Indicated Temperature Rise and Rated Heating Input HEATING TEMPERATURE RISE F INPUT BTUH 20 25 30 35 45 50 55 70 40 000 1500 1200 1000 857 750 667 600 545 60 000 2250 1800 1500 1286 1125 1000 900 818 90 000 2250 1929 1688 1500 1350 1227 964 115 000 2464 2156 1917 1725 1568 1232 130 000 2786 2438 2167 1950 1773 NOTE Dashed areas do not fall within the approved temperature rise range of the unit Table 8 LED Indications ERROR CODE LED INDICATION Normal Operation On Hardware Failure Off Fan On Of
55. for recommendations concerning existing lines Size gas supply piping for 0 5 in wg maximum pressure drop Never use pipe smaller than the 1 2 gas inlet on the unit gas valve 5 Install an accessible external manual main shutoff valve in gas supply pipe within 6 ft of heating section Install sediment trap in riser leading to heating section See Fig 9 This drip leg functions as a trap for dirt and condensate For natural gas applications the gas pressure at unit gas connection must not be less than 4 0 in wg or greater than 13 in wg while the 6 Install ground joint union close to heating section between unit is operating For propane applications the gas pressure must unit manual shutoff and external manual main shut off valve not be less than 7 0 in wg or greater than 13 in wg at the unit 7 Pressure test all gas piping in accordance with local and connection national plumbing and gas codes before connecting piping to An 1 8 in NPT plugged tapping accessible for test gage connec unit tion must be installed immediately upstream of the gas supply connection to the gas valve 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 Pressure test the gas supply piping system at pressures equal to or less than 0 5 ps
56. g Table 3 Maximum Gas Flow Capacity NOMINAL INTERNAL LENGTH OF PIPE FT IRON RIPE DIAMETER IN 10 20 30 100 125 150 175 200 622 175 120 97 s 4 o 824 360 250 200 84 77 72 1 1 049 680 465 375 195 175 160 145 135 1 1 380 1400 950 770 400 360 325 300 280 1 1610 2100 1460 1180 620 550 500 460 430 Capacity of pipe in cu ft of gas per hr for gas pressure of 0 5 psig or less Pressure drop of 0 5 in wg based on a 0 60 specific gravity gas Refer to Table C 4 National Fire Protection Association NFPA 54 T This length includes an ordinary number of fittings Step 9 INSTALL DUCT CONNECTIONS The unit has duct flanges on the supply and return air openings on the side and bottom of the unit For downshot applications the ductwork connects to the roof curb See Fig 2 and 3 for connections sizes and locations CAUTION If a flexible conductor is required or allowed by the authority having jurisdiction black iron pipe shall be installed at the gas valve and shall extend a minimum of 2 in outside the unit casing CONFIGURING UNITS FOR DOWNFLOW VERTICAL DIS CHARGE A WARNING Never use a match or other open flame when checking for gas leaks Never purge gas line into combustion chamber Failure to follow this warning could result in an explosion causing serious injury or
57. ientation a Remove unit access panel b Lift wheel from housing When handling and or cleaning blower wheel be sure not to disturb balance weights clips b Disconnect motor lead from blower relay BM Discon on blower wheel vanes nect yellow lead from terminal L2 of the contactor 25 Table 14 48GS Wet Coil Pressure Drop UNIT SIZE AIRFLOW PRESSURE DROP 48GS CFM IN WG 900 0 065 030 1000 0 080 1100 0 097 1100 0 084 036 1200 0 100 1300 0 177 1300 0 103 042 1400 0 120 1500 0 138 1500 0 088 048 1600 0 100 1700 0 113 1900 0 108 060 2000 0 120 2100 0 132 Table 15 48GX Wet Coil Pressure Drop UNIT SIZE AIRFLOW PRESSURE DROP 48GX CFM IN WG 900 0 0687 030 1000 0 083 1100 0 150 1100 0 084 036 1200 0 100 1300 0 177 1300 0 099 042 1400 0 177 1500 0 204 1500 0 199 048 1600 0 137 1700 0 156 1900 0 108 060 2000 0 120 2100 0 132 060 60 2 CHARGING CHART 689 100 115 46 105 41 a 95 35 2 620 90 85 29 75 24 o e amp 65 18 E geo 55 13 y la 45 7 ra N 2 483 70 ou Haz 60 z o gt 345 5o 2 2 276 40 207 30 30 40 50 60 70 80 90 SUCTION LINE TEM
58. ig The unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the ground joint union When installing the gas supply line observe local codes pertaining to gas pipe installations Refer to the NFGC ANSI Z223 1 1988 NFPA latest edition in Canada CAN CGA B149 1 2 M86 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 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 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 pipe connections Use only pipe dope that is resistant to action of liquefied petroleum gases as CAUTION Unstable operation may occur when the gas valve and manifold assembly are forced out of position while connect ing improperly routed rigid gas piping to the gas valve Use backup wrench when making connection to avoid strain on or distortion of the gas control piping Table 2 Physical Data Unit 48GX Continued
59. in Fault will automatically reset itself in one 1 hour If the IGC must be replaced be sure to ground yourself to dissipate any electrical charge that may be present before handling new control board The IGC is sensitive to static electricity and may be damaged if the necessary precautions are not taken IMPORTANT Refer to Table 17 Troubleshooting Guide Heating for additional troubleshooting analysis LEGEND 1GE ntegrated Gas Unit Controller LED Light Emitting Diode 30 START UP CHECKLIST Remove and Store in Job File I PRELIMINARY INFORMATION MODEL racer tee Det SERIAL NO teste te tette P rs cette DATE 2 te a HR GU RED di assets TECHNIGPAN iiti ette ro et tex JOB LOCATION sicot ere II PRE START UP insert checkmark in box as each item is completed VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT ____ VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS ____ CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS CHECK GAS PIPING FOR LEAKS CHECK THAT INDOOR EVAPORATOR AIR FILTER IS CLEAN AND IN PLACE VERIFY THAT UNIT INSTALLATION IS LEVEL CHECK FAN WHEEL PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW TIGHTNESS START UP ELECTRICAL SUPPLY VOLTAGE 11 12 L2 L3 L3 L1 COMPRESSOR AMPS L1 12 L3 COMPRESSOR AMPS L1 L2 L3 INDOOR EVAPORATOR FAN AMPS TEMPERATURES OUTDOOR CONDENSER AIR TEMPERATURE DB RETURN AIR TEMPER
60. input and the air delivery cfm at various temperature rises The heating operation airflow must produce a temperature rise that falls within the approved range Refer to Indoor Airflow and Airflow Adjustments section to adjust heating airflow when required HEATING SEQUENCE OF OPERATION See Fig 15 16 and unit wiring label On a call for heating terminal of the thermostat is energized starting the induced draft motor When the hall effect sensor on the induced draft motor senses that it has reached the required speed the burner sequence begins This function is performed by the integrated gas control IGC The evaporator fan motor is energized 45 sec after flame is established When the thermostat is satisfied and W is deenergized the burners stop firing and the evaporator fan motor shuts off after a 45 sec time off delay An LED light emitting diode indicator is provided on the control board to monitor operation The control board is located by removing the burner access panel During normal operation the LED is continuously on See Table 8 for error codes LIMIT SWITCHES Normally closed limit switch LS completes the control circuit through the thermostat R circuit Should the leaving air tempera ture rise above the maximum allowable temperature the limit switch opens and the R control circuit breaks Any interruption in the R control circuit instantly closes the gas valve and stops gas
61. ions Proceed as follows to complete the high voltage connections to the unit 1 Run the high voltage L1 L2 L3 and ground leads into the control box 2 Connect ground lead to chassis ground connection 3 Locate the black and yellow wires connected to the lines side of the contactor 4 Connect field L1 to black wire on connection 11 of the compressor contactor 5 Connect field wire L2 to yellow wire on connection 13 of the compressor contactor 6 Connect field wire L3 to Blue wire from compressor 12 HIGH VOLTAGE POWER LEADS CL POWER puc WIRING _PSUPPLY FIELD SUPPLIED ako FUSED DISCONNECT CONTROL BOX WHT W141 LYEL Y p THERMOSTAT GRN G LOW VOLTAGE 0 TYPICAL POWER LEADS RED R p SEE UNIT WIRING LABEL BRN C SPLICE BOX C99018 Fig 11 High and Control Voltage Connections SPECIAL PROCEDURES FOR 208 V OPERATION A WARNING Before making any wiring changes make sure the gas supply is switched off first Then switch off the power supply to the unit and install lockout tag Electrical shock can cause serious injury or death CONTROL VOLTAGE CONNECTIONS Do not use any type of power stealing thermostat Unit control problems may result Use no 18 American Wire Gage AWG color coded insulated 35 C minimum wires to make the control voltage connections between the thermostat and the unit If the thermostat is located more than 100 ft from the unit as measured along the contr
62. ions to ensure proper cooling operation Never place articles on top of the unit Damage to unit may result 1 Remove 6 screws holding condenser grille and motor to top cover 2 Turn motor grille assembly upside down on top cover to expose the fan blade 3 Inspect the fan blades for cracks or bends 4 If fan needs to be removed loosen the setscrew and slide the fan off the motor shaft 5 When replacing fan blade position blade so the hub is 1 8 in away from the motor end 1 8 in of motor shaft will be visible See Fig 12 6 Ensure that setscrew engages the flat area on the motor shaft when tightening 7 Replace grille ELECTRICAL CONTROLS AND WIRING Inspect and check the electrical controls and wiring annually Be sure to turn off the gas supply and then the electrical power to the unit Remove access panel to locate all the electrical controls and wiring Check all electrical connections for tightness Tighten all screw connections If any smoky or burned connections are noticed disassemble the connection clean all the parts restrip the wire end and reassemble the connection properly and securely After inspecting the electrical controls and wiring replace the access panel Start the unit and observe at least one complete heating cycle and one complete cooling cycle to ensure proper operation If discrepancies are observed in either or both operating cycles or if a suspected malfunction has occurred
63. lashes The IGC sensed flame that should not be present Inadequate airflow to unit Unit unsuccessfully attempted ignition for 15 minutes Reset unit If problem persists replace control board Check operation of indoor evaporator fan motor and that supply air temperature rise agrees with range on unit nameplate information Check ignitor and flame sensor electrode spacing gaps etc Ensure that flame sense and ignition wires are properly terminated Verify that unit is obtaining proper amount of gas Induced draft motor fault LED 6 flashes IGC does not sense that induced draft motor is operating Check for proper voltage If motor is operating check the speed sensor plug IGC Terminal J2 connection Proper connection PIN 1 White PIN 2 Red PIN 3 Black Rollout switch fault LED 7 flashes Rollout switch has opened Rollout switch will automatically reset but IGC will continue to lock out unit Check gas valve operation Ensure that induced draft blower wheel is properly secured to motor shaft Reset unit at unit disconnect Rollout control fault LED 8 flashes Microprocessor has sensed an error in the software or hardware If error code is not cleared by resetting unit power replace the IGC Temporary software lock out LED 9 flashes WARNING Electrical interference impeding IGC software Reset 24 v to control board or turn thermostat off then on aga
64. nd other safety precautions that may apply Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for unbrazing operations Have fire extinguisher available for all brazing operations A WARNING Improper installation adjustment alteration service mainte nance or use can cause carbon monoxide poisoning fire or an explosion which can result in personal injury or unit damage Consult a qualified installer service agency or gas supplier for information or assistance The qualified installer or agency must use only factory authorized kits or accessories when modifying this product A WARNING Before performing service or maintenance operations on unit turn off gas supply to unit Then turn off unit main power switch and install lockout tag Electrical shock or explosion could cause serious injury or death Recognize safety information This is the safety alert symbol A When you see this symbol in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING CAUTION and NOTE These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in serious injury or death WARNING signifies a hazard which could result in serious injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight sugges
65. nifold Pressure Propane Units The main burner orifices on a propane gas unit are sized for the unit rated input when the manifold pressure reading matches the level specified in Table 6 Proceed as follows to adjust gas input on a propane gas unit 1 Turn off gas to unit 2 Remove pipe plug on manifold and connect manometer See Fig 13 3 Turn on gas to unit 4 Remove cover screw over regulator adjustment screw on gas valve 5 Adjust regulator adjustment screw to the correct manifold pressure as specified in Table 6 Turn adjusting screw clockwise to increase manifold pressure or turn adjusting screw counterclockwise to decrease manifold pressure 6 Replace cover screw 7 Turn off gas to unit Remove manometer from pressure tap Replace pipe plug on gas valve then turn on gas to unit Check for leaks CHECK BURNER FLAME With burner access panel removed observe the unit heating operation Watch the burner flames to see if they are light blue and soft in appearance and that the flames are approximately the same for each burner Propane will have blue flame with yellow tips See Fig 14 Refer to the Maintenance section for information on burner removal 19 AIRFLOW AND TEMPERATURE RISE The heating section for each size unit is designed and approved for heating operation within the temperature rise range stamped on the unit rating plate Table 7 shows the approved temperature rise range for each heating
66. nits may be fuse or circuit breaker Maximum deviation is 7 v 2 Minimum wire size is based on 60 C copper wire If other than g 60 C wire is used or if length exceeds wire length in table Determine percent of voltage imbalance determine size from NEC 6 7 3 Unbalanced 3 Phase Supply Voltage Voltage Imbalance 100 x 457 Never operate a motor where a phase imbalance in supply volt age is greater than 2 Use the following formula to determine 1 5396 the percentage of voltage imbalance i 9 9 This amount of phase imbalance is satisfactory as it is below the Voltage imbalance maximum allowable 2 max voltage deviation from average voltage average voltage IMPORTANT If the supply voltage phase imbalance is more than 296 contact your local electric utility company immediately 13 Table 5 Electrical Data Unit 48GX UNIT NOE COMPRESSOR ee ee POWER SUPPLY Max Fuse or 48GX Min Max RLA LRA FLA FLA MCA Ckt Bkr 030 208 230 3 60 187 253 9 0 63 0 0 8 2 1 14 2 20 036 208 230 3 60 187 253 11 2 75 0 0 8 3 6 18 4 25 460 3 60 414 506 5 4 37 5 0 9 1 9 9 6 15 042 208 230 3 60 187 253 12 4 88 0 1 6 4 1 21 2 30 460 3 60 414 506 6 1 44 0 0 9 2 0 10 5 15 048 208 230 3 60 187 253 13 0 93 0 1 5 4 1 21 9 30 460 3 60 414 506 6 4 46 5 0 9 1 9 10 8 15 060 208 230 3 60 187 253 17 3 123 0 1 6 6 2 29 4 45 460 3 60 414 506 9 0 62 0 0 9
67. ol voltage wires use no 16 AWG color coded insulated 35 C minimum wires Standard Connection Remove knockout hole located in the flue panel adjacent to the control access panel See Fig 2 and 3 Remove the rubber grommet from the installer s packet included with unit and install grommet in the knockout opening Provide a drip loop before running wire through panel Run the low voltage leads from the thermostat through the inlet hole and into unit low voltage splice box Locate five 18 gage wires leaving control box These low voltage connection leads can be identified by the colors red green yellow brown and white See Fig 11 Ensure the leads are long enough to be routed into the low voltage splice box located below right side of control box Route leads through hole in bottom of control box and make low voltage connections See Fig 11 Secure all cut wires so that they do not interfere with operation of unit HEAT ANTICIPATOR SETTING The room thermostat heat anticipator must be properly adjusted to ensure proper heating performance Set the heat anticipator using an ammeter between the W and R terminals to determine the exact required setting NOTE For thermostat selection purposes use 0 18 amp for the approximate required setting Failure to make a proper heat anticipator adjustment will result in improper operation discom fort to the occupants of the conditioned space and inefficient energy utilization
68. or low speed operation Unit 48GS030 is factory wired for medium speed 48GX units are factory wired for low speed and may need to be wired for medium or high speed in the field For 208 230V For color coding on the 208 230V motor leads see Table 9 Table 9 Color Coding for 208 230 V Motor Leads 3 SPEED 2 SPEED black high speed black high speed blue medium speed red low speed red low speed To change the speed of the blower motor BM remove the fan motor speed leg lead from the blower relay BR This wire is attached to terminal BM of the integrated gas control IGC board for 3 phase units To change the speed remove and replace with lead for desired blower motor speed Insulate the removed lead to avoid contact with chassis parts For 460 V GE Motors For color coding on the 460 v GE motor leads see Table 10 To change the speed of the blower motor BM remove fan motor speed lead from the blower relay BR and replace with the lead for the desired blower motor speed The motor speed lead is attached to terminal BM of the integrated gas control IGC board For low and medium speeds black must be connected to the jumper wire Insulate removed lead end to avoid contact with 21 Table 10 Color Coding for 460 V GE Motor Leads 3 SPEED 2 SPEED black high speed black high speed violet jumper blue jumper orange medium speed red low speed red low speed chassis p
69. perature with desired suction tube temperature Using a tolerance of 3 F add refrigerant if actual temperature is more than 3 F higher than proper suction tube temperature or remove refrigerant if actual temperature is more than 3 F lower than required suction tube temperature NOTE If the problem causing the inaccurate readings is a refrigerant leak refer to the Check for Refrigerant Leaks section INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS A CAUTION For cooling operation the recommended airflow is 350 to 450 cfm for each 12 000 Btuh of rated cooling capacity For heating operation the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate Table 7 shows the temperature rise at various airflow rates Tables 11 and 13 show both heating and cooling airflows at various external static pressures Refer to these tables to determine the airflow for the system being installed See Tables 14 and 15 for wet coil pressure drop NOTE Be sure that all supply and return air grilles are open free from obstructions and adjusted properly A WARNING Before changing blower speed shut off gas supply Then disconnect electrical power to the unit and install lockout tag Electrical shock or explosion can cause serious injury or death Airflow can be changed by changing the lead connections of the blower motor Unit 4865 two or three speed motors except size 030 are factory wired f
70. r coil evaporator coil and condensate drain pan at least once each year or more often if necessary The coils are easily cleaned when dry therefore inspect and clean the coils either before or after each cooling season Remove all obstructions including weeds and shrubs that interfere with the airflow through the condenser coil Straighten bent fins with a fin comb If coated with dirt or lint clean the coils with a vacuum cleaner using the soft brush attachment Be careful not to bend the fins If coated with oil or grease clean the coils with a mild detergent and water solution Rinse coils with clear water using a garden hose Be careful not to splash water on motors insulation wiring or air filter s For best results spray condenser coil fins from inside to outside the unit On units with an outer and inner condenser coil be sure to clean between the coils Be sure to flush all dirt and debris from the unit base Inspect the drain pan and condensate drain line when inspecting the coils Clean the drain pan and condensate drain by removing all foreign matter from the pan Flush the pan and drain tube with clear water Do not splash water on the insulation motor wiring or air filter s If the drain tube is restricted clear it with a plumbers snake or similar probe device Ensure that the auxiliary drain port above the drain tube is also clear CONDENSER FAN A CAUTION Keep the condenser fan free from all obstruct
71. raft motor will start 4 After a call for heating the main burner should light within 5 sec If the burners do not light there is a 22 sec delay before another 5 sec try If the burners still do not light this sequence is repeated If the burners do not light within 15 minutes from the initial call for heat there is a lockout To reset the control break the 24 v power to W 5 The evaporator fan will turn on 45 sec after the flame has been established The evaporator fan will turn off 45 sec after the thermostat has been satisfied 16 CHECK GAS INPUT Check gas input and manifold pressure after unit start up See Table 6 If adjustment is required proceed as follows Therated gas inputs shown in Table 6 are for altitudes from sea level to 2000 ft above sea level These inputs are based on natural gas with a heating value of 1050 Btu f at 0 65 specific gravity or propane gas with a heating value of 2500 Btu ft at 1 5 specific gravity For elevations above 2000 ft reduce input 4 percent for each 1000 ft above sea level When the gas supply being used has a different heating value or specific gravity refer to national and local codes or contact your distributor to determine the required orifice size CAUTION These units are designed to consume the rated gas inputs using the fixed orifices at specified manifold pressures as shown in Table 6 DO NOT REDRILL THE ORIFICES UNDER ANY CIRCUMSTANCES ADJ
72. sion buckle To release strapping squeeze safety latch lift lever and pull webbing outward 5 Tighten the tension buckle until it is taut Lifting brackets must be secure in the rigging holds 6 Attach field supplied clevis or hook of sufficient strength to hole in the lifting bracket See Fig 7 7 Attach the 2 safety straps directly to the clevis or hook at the 4 rigging brackets DO NOT attach the safety straps to the lifting brackets See Fig 7 8 Position lifting point directly over the unit s center of gravity 9 Lift unit When unit is directly over the roof curb remove the 2 safety straps Lower the equipment onto the roof curb Step 2 PROVIDE UNIT SUPPORT ROOF CURB Install accessory roof curb in accordance with instructions shipped with curb See Fig 4 for roof curb dimensions Install insulation cant strips roofing and flashing Ductwork must be attached to curb IMPORTANT The gasketing of the unit to the roof curb is critical for a watertight seal Install gasketing material supplied with the roof curb Improperly applied gasketing can also result in air leaks and poor unit performance Curb should be level to within 1 4 in This is necessary for unit drain to function properly Refer to accessory roof curb installation instructions for additional information as required SLAB MOUNT Place the unit on a solid level concrete pad that is a minimum of 4 in thick with 2 in above grade The slab sho
73. system has been opened for repair 3 Add a small charge of R 22 refrigerant vapor to system and leak test unit 4 Recover refrigerant from refrigerant system and evacuate to 500 microns if additional leaks are not found 5 Charge unit with R 22 refrigerant using a volumetric charging cylinder or accurate scale Refer to unit rating plate for required charge Be sure to add extra refrigerant to compensate for internal volume of filter drier Step 2 START UP HEATING AND MAKE ADJUST MENTS CAUTION Complete the required procedures given in the Pre Start Up section before starting the unit Do not jumper any safety devices when operating the unit Make sure that burner orifices are properly aligned Unstable operation may occur when the burner orifices in the manifold are misaligned Follow the lighting instructions on the heating section operation label located inside the burner or blower access door to start the heating section NOTE Make sure that gas supply has been purged and that all gas piping has been checked for leaks CHECK HEATING CONTROL Start and check the unit for proper heating control operation as follows see furnace lighting instructions located inside burner or blower access panel 1 Place room thermostat SYSTEM switch in the HEAT position and the fan switch is placed in AUTO position 2 Set the heating temperature control of the thermostat above room temperature 3 The induced d
74. te Check this information against shipping papers and job data Verify unit voltage and amperage requirements listed on unit rating plate agree with power supply provided to unit INSPECT SHIPMENT Inspect for shipping damage while unit is still on shipping pallet If unit appears to be damaged or is torn loose from its anchorage have it examined by transportation inspectors before removal Forward claim papers directly to transportation company Manu facturer is not responsible for any damage incurred in transit Check all items against shipping list Immediately notify the nearest distributor if any item is missing To prevent loss or damage leave all parts in original packages until installation INSTALLATION 1 Remove unit from shipping carton Leave top shipping skid on the unit as a spreader bar to prevent the rigging straps from damaging the unit If the wood skid is not available use a spreader bar of sufficient length to protect unit from damage 2 Position the lifting bracket assembly around the base of the unit Be sure the strap does not twist 3 Place each of the 4 metal lifting brackets into the rigging holds in the composite pan 4 Thread lifting bracket strapping around bottom perimeter of unit as follows a Open lever of tension buckle ratchet type b Feed strapping through tension buckle as shown in Fig 7 c Pull strapping through tension buckle unit taut d Snap lever down to lock strap in ten
75. type Air filter pressure drop for non standard filters must not exceed 0 08 in wg the outlet of the trap is at least 1 in lower than the drain pan condensate connection to prevent the pan from overflowing See Fig 8 Prime the trap with water When using a gravel apron make sure it slopes away from the unit If the installation requires draining the condensate water away from the unit install a 2 in trap at the condensate connection to ensure proper drainage See Fig 8 Make sure that the outlet of the trap is at least 1 in lower than the drainpan condensate connection This prevents the pan from overflowing Prime the trap with water Connect a drain tube using a minimum of 3 4 in PVC or 3 4 in copper pipe all field supplied at the outlet end of the 2 in trap Do not undersize the tube Pitch the drain tube downward at a slope of at least 1 in for every 10 ft of horizontal run Be sure to check the drain tube for leaks TRAP i OUTLET 2 min C00009 Fig 8 Condensate Trap Step 7 INSTALL FLUE HOOD The flue hood assembly is shipped screwed to the coil panel in the indoor blower compartment Remove the service access panel to locate the assembly See Fig 27 NOTE Dedicated low NO models MUST be installed in Cali fornia Air quality Management Districts where a Low NO rule exists These models meet the California maximum oxides of nitrogen NO emissions requirements of 40 nanograms joule
76. ulate and weatherproof all ductwork located outdoors Insulate ducts passing through unconditioned space and use vapor barrier in accordance with latest issue of Sheet Metal and Air Conditioning Contractors National Association SMACNA and Air Conditioning Contractors of America ACCA minimum installation standards for heating and air fi H conditioning systems Secure all ducts to building structure j 7 Flash weatherproof and vibration isolate all openings in SUPPLY RETURN s DUCT DUCT building structure in accordance with local codes and good OPENING OPENING building practices 99011 Fig 10 Supply and Return Duct Opening 11 Step 10 INSTALL ELECTRICAL CONNECTIONS A WARNING The unit cabinet must have an uninterrupted unbroken electrical ground to minimize the possibility of serious injury if an electrical fault should occur This ground may consist of an electrical wire connected to the unit ground lug in the control compartment or conduit approved for electrical ground when installed in accordance with NEC National Electrical Code ANSI NFPA latest edition and local elec trical codes In Canada follow Canadian Electrical Code CSA Canadian Standards Association C22 1 and local electrical codes Failure to adhere to this warning could result in serious injury or death A CAUTION Failure to follow these precautions could result in damage to the
77. uld be flush on the compressor end of the unit to allow condensate drain installation and should extend 2 in on the three remaining sides of the unit See Fig 6 Do not secure the unit to the slab except when required by local codes BLOCKOFF PANEL ON 018 ONLY 254 0 10 001 SUPPLY 254 0 546 1 10 00 21 501 RETURN 2 181 024 042 ONLY i b 3 T i 406 4 Ill OPENING OPENING 11111 e __ il I D s i Q ET 0 V SUPPLY RETURN RN mm 80 5 15 831 m M 3 171 LL J 018 NOW zz 12 COND COIL EVAP COIL i 3 48 TOP VIEW 249 6 be 550 5 249 6 be 19 831 21 67 19 831 REAR VIEW REQUIRED CLEARANCE TO COMBUSTIBLE MATL REQUIRED CLEARANCE FOR OPERATION AND SERVICING INCHES mm INCHES mm TOP OF UNIT 14 00 355 6 EVAP COIL ACCESS SIDE DUCT SIDE OF UNIT SIDE OPPOSITE DUCTS BOTTOM OF UNIT ELECTRIC HEAT PANEL NEC REQUIRED CLEARANCES INCHES mm BETWEEN UNITS POWER ENTRY 42 00 1066 8 UNIT AND UNGROUNDED SURFACES POWER ENTRY SIDE 36 00 914 0 UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES POWER ENTRY SIDE 42 00 1066 8 LEGEND CG Center of Gravity COND Condensor EVAP Evaporator NEC National Electrical Code REQ D Required 2 0
78. unit being installed 1 Make all electrical connections in accordance with NEC ANSI NFPA latest edition and local electrical codes governing such wiring In Canada all electrical connec tions must be in accordance with CSA standard C22 1 Canadian Electrical Code Part 1 and applicable local codes Refer to unit wiring diagram Use only copper conductor for connections between field supplied electrical disconnect switch and unit DO NOT USE ALUMINUM WIRE Be sure that high voltage power to unit is within operating voltage range indicated on unit rating plate Do not damage internal components when drilling through any panel to mount electrical hardware conduit etc On 3 phase units ensure phases are balanced within 2 percent Consult local power company for correction of improper voltage and or phase imbalance HIGH VOLTAGE CONNECTIONS The unit must have a separate electrical service with a field supplied waterproof disconnect switch mounted at or within sight from the unit Refer to the unit rating plate for maximum fuse circuit breaker size and minimum circuit amps ampacity for wire sizing See Tables 4 and 5 for electrical data The field supplied disconnect switch box may be mounted on the unit over the high voltage inlet hole when the standard power and low voltage entry points are used See Fig 2 and 3 for acceptable location See unit wiring label and Fig 11 for reference when making high voltage connect
79. y Wiring COMP SPLICE BOX IFC Indoor Fan Contactor Field Control Wiring Indoor Fan Motor d ne HS IGC Integrated Gas Unit Field Power Wiring Controller Accessory or L1 Line Optional Wiring Mey 15 Limit Switch To Indicate Common 5 LS1 Limit Switch Potential Only Not R 11 5 MGV Main Gas Valve to Represent Wiring RS GAS SECTION NOTES o 1 If any of the original wires furnished are replaced they must be DISCONNECT replaced with type 90 degree C wire or its equivalent PER NEC See price pages for thermostat and subbases BON Use 75 degree C copper conductors for field installation Forhigh speed IFM disconnect RED wire from IGC terminal BM and connect BLK wire from IFM For medium speed disconnect RED wire from IGC terminal BM and connect BLU wire from IFM C00058 Fig 15 208 230 3 60 Wiring Diagram Units 48GS and 48GX 17
80. y with applicable fire codes A minimum clearance is not required around ductwork Cabinet return air static shall not exceed 25 in wg Step 4 PROVIDE CLEARANCES The required minimum operating and service clearances are shown in Fig 2 and 3 Adequate combustion ventilation and condenser air must be provided in accordance with section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI American National Standards Institute Z223 1 or applicable provisions of local building code In Canada follow sections 7 2 7 3 or 7 4 or Can CGA Canadian Gas Association B149 Installation Codes or applicable provisions of local building code A CAUTION Do not restrict condenser airflow An air restriction at either the outdoor air inlet or the fan discharge can be detrimental to compressor life The condenser fan pulls air through the condenser coil and discharges it through the top cover Be sure that the fan discharge does not recirculate to the condenser coil Do not locate the unit in either a corner or under an overhead obstruction The minimum clearance under a partial overhang such as a normal house overhang is 48 in above the unit top The maximum horizontal extension of a partial overhang must not exceed 48 in Do not place the unit where water ice or snow from an overhang or roof will damage or flood the unit Do not install the unit on carpeting tile or other combustible materials The unit may

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