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Carrier 48A020 060 Installation Instructions PDF
en
Summary of Content for Carrier 48A020 060 Installation Instructions PDF
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480230-01 Printed in U.S.A. Form 48A-20SI Pg 1 3-19 Replaces: 48A-18SI
Installation Instructions CONTENTS
Page SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . 1 ACOUSTICAL CONSIDERATIONS . . . . . . . . . . . . . . . . 3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Acoustic Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Step 1 Provide Unit Support . . . . . . . . . . . . . . . . . . . 4 ROOF CURB ALTERNATE UNIT SUPPORT Step 2 Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . 4 POSITIONING ROOF MOUNT Step 3 Field Fabricate Ductwork . . . . . . . . . . . . . . 21 Step 4 Make Unit Duct Connections . . . . . . . . . . 21 48A2, A3, A6, A7 UNITS 48A4, A5, A8, A9 UNITS Step 5 Install Flue Hood . . . . . . . . . . . . . . . . . . . . . . 22 48A020-050 UNITS 48A060 UNITS Step 6 Trap Condensate Drain. . . . . . . . . . . . . . . . 22 Step 7 Install Gas Piping . . . . . . . . . . . . . . . . . . . . . 23 OPTIONAL STAGED GAS UNITS Step 8 Install Supply-Air Thermistors (Staged and Modulating Gas Units Only) . . . . . 23 Step 9 Make Electrical Connections . . . . . . . . . . 24 POWER WIRING FIELD POWER SUPPLY FIELD CONTROL WIRING Step 10 Make Outdoor-Air Inlet
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ECONOMIZER AND FIXED OUTDOOR
AIR DAMPER Step 11 Position Power Exhaust/Barometric
Relief Damper Hood . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Step 12 Route VAV Static Pressure Sensors . 31 VAV DUCT PRESSURE TRANSDUCER VAV BUILDING PRESSURE TRANSDUCER Step 13 Install All Accessories . . . . . . . . . . . . . . . 31 FIELD-FABRICATED WIND BAFFLES Step 14 Perform Field Modifications . . . . . . . . . . 33 DUCTWORK BACnet Communication Option Wiring . . . . . . . . . 33 WIRING THE UPC OPEN CONTROLLER TO THE
MS/TP NETWORK MS/TP WIRING RECOMMENDATIONS
SAFETY CONSIDERATIONS Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical compo- nents. Only trained and qualified service personnel should in- stall, repair, or service air-conditioning equipment.
Untrained personnel can perform the basic maintenance functions of cleaning coils and filters and replacing filters. All other operations should be performed by trained service
personnel. When working on air-conditioning equipment, ob- serve precautions in the literature, tags, and labels attached to the unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguishers available for all brazing operations.
WARNING
Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury.
WARNING Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal injury, or loss of life. Refer to the Users Information Manual pro- vided with this unit for more details. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
What to do if you smell gas: 1. DO NOT try to light any appliance. 2. DO NOT touch any electrical switch, or use any
phone in your building. 3. IMMEDIATELY call your gas supplier from a neigh-
bors phone. Follow the gas suppliers instructions. 4. If you cannot reach your gas supplier, call the fire
department.
WARNING
DO NOT USE TORCH to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective gloves and gog- gles and proceed as follows: a. Shut off electrical power to unit. b. Recover refrigerant to relieve all pressure from sys-
tem using both high-pressure and low pressure ports. c. Traces of vapor should be displaced with nitrogen
and the work area should be well ventilated. Refrig- erant in contact with an open flame produces toxic gases.
d. Cut component connection tubing with tubing cutter and remove component from unit. Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when nec- essary. Oil can ignite when exposed to torch flame.
Failure to follow these procedures may result in personal injury or death.
WeatherMaker
48A020-060 Single Package Gas Heating/Electric Cooling
Rooftop Units with ComfortLink Controls and Puron Refrigerant (R-410A)
2
CAUTION
DO NOT re-use compressor oil or any oil that has been exposed to the atmosphere. Dispose of oil per local codes and regulations. DO NOT leave refrigerant system open to air any longer than the actual time required to service the equipment. Seal circuits being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be com- pleted. Failure to follow these procedures may result in dam- age to equipment.
WARNING
Disconnect gas piping from unit when pressure testing at pres- sure greater than 0.5 psig. Pressures greater than 0.5 psig will cause gas valve damage resulting in hazardous condition. If gas valve is subjected to pressure greater than 0.5 psig, it must be replaced before use. When pressure testing field-supplied gas piping at pressures of 0.5 psig or less, a unit connected to such piping must be isolated by closing the manual gas valve(s).
WARNING
CARBON-MONOXIDE POISONING HAZARD Failure to follow instructions could result in severe personal injury or death due to carbon-monoxide poisoning, if com- bustion products infiltrate into the building. Check that all openings in the outside wall around the vent (and air intake) pipe(s) are sealed to prevent infiltration of combustion products into the building. Check that furnace vent (and air intake) terminal(s) are not obstructed in any way during all seasons.
AVERTISSEMENT
RISQUE DINTOXICATION AU MONOXYDE DE CARBONE Si ces directives ne sont pas suivies, cela peut entraner des blessures graves ou une intoxication au monoxyde de carbone pouvant causer la mort, si des produits de combustion sinfiltrent dans le btiment. Vrifier que toutes les ouvertures pratiques dans le mur extrieur autour du ou des tuyaux dvent (et de la prise dair) sont scelles de manire empcher linfiltration de produits de combustion dans le btiment. Veiller ce que la ou les sorties de lvent de lappareil de chauffage (et la prise dair) ne soient, en aucune faon, obstrues, quelle que soit la saison.
WARNING
UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause personal injury, death and/or equipment damage. Puron (R-410A) refrigerant systems operate at higher pres- sures than standard R-22 systems. Do not use R-22 service equipment or components on Puron refrigerant equipment.
WARNING
FIRE HAZARD Failure to follow this warning could result in personal inju- ry, death, and/or property damage. Inlet pressure tap set screw must be tightened and 1/8-in. NPT pipe plug must be installed to prevent gas leaks.
WARNING
FIRE HAZARD Failure to follow this warning could result in personal inju- ry, death, and/or property damage. Manifold pressure tap set screw must be tightened and 1/8-in. NPT pipe plug must be installed to prevent gas leaks.
WARNING
If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, per- sonal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch; do not use any
phone in your building. Immediately call your gas supplier from a neighbors
phone. Follow the gas suppliers instructions. If you cannot reach your gas supplier, call the fire
department. Installation and service must be performed by a qualified installer, service agency or the gas supplier.
GAS VALVE
INLET PRESSURE TAP SET SCREW
MANIFOLD
GAS VALVE
MANIFOLD PRESSURE TAP SET SCREW
3
ACOUSTICAL CONSIDERATIONS In order to minimize sound transmitted to the space, please
conform to the following recommendations (see Fig. 1):
Location Avoid locating the unit above sound-sensitive areas.
Instead, locate the unit above restrooms, storage areas, corridors, or other noise-tolerant areas.
Avoid mounting the unit in the middle of large roof expanses between vertical supports. This will minimize the phenomenon known as roof bounce.
Install the units close to vertical roof supports (columns or load bearing walls).
Locate the units at least 25 ft away from critical areas. If this is not possible, the ductwork and ceiling structure should be acoustically treated.
Consider the use of vibration isolators or an acoustic curb.
Ductwork Utilize flexible connectors between the unit and the sup-
ply and return ducts. Supply and return air main trunk ducts should be located
over hallways and/or public areas. Provide trailing edge turning vanes in ductwork elbows
and tees to reduce air turbulence. Make the ductwork as stiff as possible. Use round duct wherever possible because it is less noisy. Seal all penetrations around ductwork entering the space. Make sure that ceiling and wall contractors do not attach
hangers or supports to ductwork. Provide as smooth and gradual transition as possible when
connecting the rooftop unit discharge to the supply duct. If a ceiling plenum return is utilized, provide a return
elbow or tee to eliminate line-of-sight noise to the space. Face the entrance of the return duct away from other adjacent units.
Acoustic Insulation Provide acoustic interior lining for first 20 ft of supply
and return duct or until the first elbow is encountered. The elbow prevents line-of-sight transmission in the sup- ply and return ducts.
Install a double layer of 2-in. low density quilted fiberglass acoustical pad with a 1/8-in. barium-loaded vinyl facing on top of the roof deck before building insulation and roofing installation occur. Place the material inside the curb and for 4 to 8 ft beyond the unit perimeter, dependent upon unit size (larger units require a wider apron outside the curb). Openings in the pad should only be large enough for the supply and return ducts. An alternate approach is to use two layers of gypsum board with staggered seams in addition to the acoustical pad.
AVERTISSEMENT
RISQUE DINCENDIE OU DEXPLOSION Si les consignes de scurit ne sont pas suivies la lettre, cela peut entraner la mort, de graves blessures ou des dommages matriels. Ne pas entreposer ni utiliser dessence ni autres vapeurs ou liquides inflammables proximit de cet appareil ou de tout autre appareil. QUE FAIRE SI UNE ODEUR DE GAZ EST DTECTE Ne mettre en marche aucun appareil. Ne toucher aucun interrupteur lectrique; ne pas
utiliser de tlphone dans le btiment. Quitter le btiment immdiatement. Appeler immdiatement le fournisseur de gaz en
utilisant le tlphone dun voisin. Suivre les instructions du fournisseur de gaz.
Si le fournisseur de gaz nest pas accessible, appeler le service dincendie.
Linstallation et lentretien doivent tre effectus par un installateur ou une entreprise dentretien qualifi, ou le fournisseur de gaz.
FLEXIBLE CONNECTORS SUPPLY AND RETURN
VIBRATION ISOLATORS IN ROOF CURB
INTAKE PLENUM
SUPPLY FAN
DISCHARGE PLENUM
COMPRESSOR/ CONDENSING SECTION ALL ROOF
PENETRATIONS SHOULD BE SEALED AIR TIGHT
ROUND DUCT CONTROLS RUMBLE BEST
SUPPLY AND RETURN DUCTS LINED WITH ACOUSTICAL DUCT LINER
Fig. 1 Acoustical Considerations
4
INSTALLATION
Installation of this furnace at altitudes above 2000 ft (610 m) shall be made in accordance with the Listed High Altitude Conversion Kit available with this furnace. L'installation de ce gnrateur de chaleur des altitudes suprieures 2000 pi (610 m) doit tre effectue conform- ment aux instructions accompagnant la trousse de conversion pour haute altitude fournie avec cet appareil.
Step 1 Provide Unit Support
ROOF CURB For vertical discharge units, assemble or install accessory roof curb in accordance with instructions shipped with this accessory. See Fig. 2-4. Install insulation, cant strips, roofing, and counter flashing as shown. Ductwork can be installed to roof curb before unit is set in place. Curb should be level. This is neces- sary to permit unit drain to function properly. Unit leveling toler- ance is shown in Fig. 2-4. Refer to Accessory Roof Curb Installa- tion Instructions for additional information as required. When ac- cessory roof curb is used, unit may be installed on class A, B, or C roof covering material.
ALTERNATE UNIT SUPPORT When the preferred curb or slab mount cannot be used, support unit with sleepers on perime- ter, using unit curb support area. If sleepers cannot be used, sup- port long sides of unit (refer to Fig. 5-13) with a minimum number of 4-in. x 4-in. pads spaced as follows: 48A20-035 units require 3 pads on each side; 48A040-050 units require 4 pads on each side; 48A060 units require 6 pads on each side. Unit may sag if support- ed by corners only.
Step 2 Rig and Place Unit Inspect unit for trans- portation damage. See Tables 1-6 for physical data and specifica- tions. File any claim with transportation agency. Do not drop unit; keep upright. Use spreader bars over unit to pre- vent sling or cable damage. This unit must be handled with a crane and cannot be handled by a fork truck. Level by using unit frame as a reference; leveling tolerance is shown in Fig. 2-4. See Fig. 14 for additional information. Unit operating weight is shown in Table 2. NOTE: On retrofit jobs, ductwork may be attached to the old unit instead of a roof curb. Be careful not to damage ductwork when removing old unit. Attach existing ductwork to roof curb instead of unit. Four lifting lugs are provided on the unit base rails as shown in Fig. 5-13. Refer to rigging instructions on unit. POSITIONING Maintain clearance, per Fig. 5-13, around and above unit to provide minimum distance from combustible mate- rials, proper airflow, and service access. Do not install unit in an indoor location. Do not locate unit air inlets near exhaust vents or other sources of contaminated air. For proper unit operation, adequate combustion and ventilation air must be provided in accordance with Section 5.3 (Air for Com- bustion and Ventilation) of the National Fuel Gas Code, ANSI Z223.1 (American National Standards Institute). Although unit is weatherproof, guard against water from higher level runoff and overhangs. Locate mechanical draft system flue assembly at least 4 ft from any opening through which combustion products could enter the building, and at least 4 ft from any adjacent building. When unit is located adjacent to public walkways, flue assembly must be at least 7 ft above grade. ROOF MOUNT Check building codes for weight distribu- tion requirements. See Fig. 14. Unit operating weight is shown in Table 2.
CAUTION
Ensure clearances are in accordance with local installation codes, the requirements of the gas supplier and the manu- facturer's installation Instructions.
ATTENTION
Assurez-vous que les dgagements sont conformes aux codes d'installation locaux, aux exigences du fournisseur de gaz et aux instructions d'installation du fabricant.
CAUTION
1. All panels must be in place when rigging or damage to unit may occur.
2. Unit is not designed for handling by fork truck. Damage to unit may occur.
IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket with the roof curb as shown in Fig. 2-4. Improperly applied gasket can also result in air leaks and poor unit performance.
Instructions continued on page 21.
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13 .8
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0. 75
N PT
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3. 50
N PT
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9]
24 [6
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24 [6
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15 .5
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15 .9
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8. 60
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1 41
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7. 50
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19 .0
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30 .1
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7 8.
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22 .7
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1 "[2
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[8 75
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24 .4
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8. 05
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16 2.
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8.
V A
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R
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G S
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V A
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B LE
F O
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1. 5"
D U
C T
FL A
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TT A
C H
M E
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U N
IT S
IZ E
O P
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A TI
N G
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A V
IT Y
C
O R
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R W
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H T
(L B
) A
B LB
S FT
/IN FT
/IN 1
2 3
4 48
A 2/
A 3/
A 6/
A 7
(D ,M
,S ) 0
60 83
86 14
- 9
5/ 8"
3 - 5
1 /4
" 19
09 16
93 22
43 25
41
48 A
2/ A
3/ A
6/ A
7 (E
,N ,T
) 0 60
86 26
14 -
2 3/
8" 3
- 3 1
/4 "
21 59
17 45
21 00
26 22
48 A
4/ A
5/ A
7/ A
8 (D
,M ,S
) 0 60
84 26
14 -
1 5/
8" 3
- 9 1
/4 "
17 63
20 72
22 59
23 33
48 A
4/ A
5/ A
7/ A
8 (E
,N ,T
) 0 60
86 76
13 -
7 1/
4" 3
- 7 1
/4 "
20 00
21 26
21 34
24 17
50 A
2/ A
3/ A
6/ A
7 06
0 83
11 15
- 5"
3 - 7
3 /8
" 17
10 16
63 24
33 25
04
50 A
4/ A
5/ A
7/ A
8 06
0 85
26 14
- 8
1/ 2"
3 - 1
1 1/
8" 16
13 20
78 24
84 23
51
B A
S E
U N
IT W
E IG
H TS
(S E
E N
O TE
7 )
LB (K
g)
06 0
48 A
2D /A
3D /A
6D /A
7D 70
66 (3
20 5)
48 A
2E /A
3E /A
6E /A
7E 73
06 (3
31 4)
48 A
4D /A
5D /A
8D /A
9D 71
06 (3
22 3)
48 A
4E /A
5E /A
8E /A
9E 73
56 (3
33 7)
50 A
2/ A
3/ A
6E /A
7E 68
26 (3
09 6)
50 A
4/ A
5/ A
8E /A
9E 70
41 (3
19 4)
O P
TI O
N S
/ A
C C
E S
S O
R IE
S (S
E E
N O
TE 7
)
B A
R O
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TR IC
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LI E
F 45
0 (2
04 )
N O
N M
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. P O
W E
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X H
A U
S T
67 5
(3 06
)
M O
D . P
O W
E R
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H A
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T 72
5 (3
29 )
E LE
C TR
IC H
E A
T 16
5 (7
5)
C U
T U
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FI N
C O
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C O
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(1 2)
C U
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F IN
C O
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C O
IL 67
7 (3
07 )
C V
M O
TO R
W E
IG H
TS LB
(K g)
V A
V M
O TO
R W
E IG
H TS
LB (K
g) (S
E E
N O
TE 8
)
H IG
H E
FF C
'Y IF
M P
R E
M IU
M E
FF C
'Y IF
M H
IG H
E FF
C 'Y
IF M
P R
E M
IU M
E FF
C 'Y
IF M
25 H
P (1
8. 65
k W
) 23
0/ 46
0 24
0 (1
09 )
30 9
(1 40
) 37
5 (1
70 )
44 4
(2 01
) 57
5 24
0 (1
09 )
31 9
(1 45
) 37
5 (1
70 )
45 4
(2 06
)
30 H
P (2
2. 38
k W
) 23
0/ 46
0 28
3 (1
28 )
35 5
(1 61
) 41
8 (1
90 )
49 0
(2 22
) 57
5 28
3 (1
28 )
35 9
(1 63
) 41
8 (1
90 )
49 4
(2 24
)
40 H
P (2
9. 84
k W
) 23
0/ 46
0 37
2 (1
69 )
41 5
(1 88
) 50
7 (2
30 )
55 0
(2 49
) 57
5 37
2 (1
69 )
41 0
(1 86
) 50
7 (2
30 )
54 5
(2 47
)
U N
IT S
IZ E
O P
E R
A TI
N G
W E
IG H
T C
E N
TE R
O F
G R
A V
IT Y
C O
R N
E R
W E
IG H
T (k
g) A
B K
G M
M M
M 1
2 3
4 48
A 2/
A 3/
A 6/
A 7
(D ,M
,S ) 0
60 38
04 45
11 10
49 86
6 76
8 10
17 11
53
48 A
2/ A
3/ A
6/ A
7 (E
,N ,T
) 0 60
39 13
43 29
99 6
97 9
79 2
95 3
11 89
48 A
4/ A
5/ A
7/ A
8 (D
,M ,S
) 0 60
38 22
43 09
11 49
80 0
94 0
10 24
10 58
48 A
4/ A
5/ A
7/ A
8 (E
,N ,T
) 0 60
39 36
41 47
10 97
90 7
96 4
96 8
10 96
50 A
2/ A
3/ A
6/ A
7 06
0 37
70 46
98 11
02 77
6 75
5 11
04 11
36
50 A
4/ A
5/ A
7/ A
8 06
0 38
68 44
84 11
96 73
2 94
2 11
27 10
66
12
43
O FM
#4 O
FM #2
O FM
#3 O
FM #1
E C
O N
O M
IZ E
R S
ID E
:
6 '-0
" [ 18
29 ] (
FO R
T U
B E
C O
N D
E N
S E
R C
O IL
S )
8
'-0 " [
24 38
] ( FO
R R
E M
O V
A L
O F
M C
H X
C O
N D
E N
S E
R C
O IL
S )
17
Table 1 Physical Data 48A Units
LEGEND * Sizes 020 to 027: Circuit 1 uses the lower portion of condenser coil, Circuit 2 uses the upper portion. Sizes 030 and 035: Circuit 1 uses the upper portion of condenser coil, Circuit 2 uses the lower portion. Sizes 040 and 050: Circuit 1 uses the left condenser coil, Circuit 2 the right. Size 060: Circuit A uses the two MCHX coils near the bulkhead, Circuit B uses the two MCHX coils near the control box.
Rollout switch is manual reset.
UNIT 48A 020D/E 025D/E 027D/E 030D/E NOMINAL CAPACITY (tons) 20 25 27 30
BASE UNIT See Unit Weights Table OPERATING WEIGHT (lb) COMPRESSOR Quantity ... Type (Ckt 1/Ckt 2) 2 ... ZP67/1ZP91 2 ... ZP91/1ZP91 2 ... ZP91/1ZP91 2ZP72, 2ZP72 Number of Refrigerant Circuits 2 2 2 2 Oil Precharged Precharged Precharged Precharged
REFRIGERANT R-410A Operating Charge (lb), Ckt 1/Ckt 2 RTPF Coils 26.2/18.8 30.2/15.2 32.8/16.5 30.5/34.3 MCHX Coils 14.9/11.8 16.5/11.0 16.5/11.0 15.1/15.3 MCHX Coils with Humidi-MiZer Coil 22.1/11.8 23.7/11.0 23.7/11.0 15.1/22.5
MCHX CONDENSER* Quantity 1 1 1 1 Total Face Area (sq ft) 32.9 32.9 32.9 32.9
RTPF CONDENSER Quantity 1 1 1 1 Rows...Fins/in. 2...15 3...15 3...15 4...15 Total Face Area (sq ft) 33.3 33.3 33.3 33.3
CONDENSER FAN Propeller Type Nominal Cfm 19,500 19,500 19,500 19,500 Quantity... Diameter (in.) 2 ... 30 2 ... 30 2 ... 30 2 ... 30 Motor Hp 1 1 1 1
EVAPORATOR COIL Cross-Hatched Copper Tubes, Aluminum Plate Fins with Intertwined Circuits Tube Size (in.) 3/8 3/8 3/8 3/8 Rows ... Fins/in. 3 ... 15 4 ... 14 4 ... 15 4 ... 15 Total Face Area (sq ft) 31.7 31.7 31.7 31.7
HUMIDI-MIZER COIL Quantity 1 1 1 1 Face Area (sq ft) 14.4 14.4 14.4 14.4
EVAPORATOR FAN Centrifugal Type Quantity ... Size (in.) 2 ... 20 X 15 2 ... 20 X 15 2 ... 20 X 15 2 ... 20 X 15 Type Drive Belt Belt Belt Belt Nominal Cfm 8,000 10,000 11,000 12,000 Motor Hp 5 10 15 5 10 15 10 15 20 10 15 20 Motor Frame Size 184T 215T 254T 184T 215T 254T 215T 254T 256T 215T 254T 256T Motor Bearing Type Ball Ball Ball Ball Maximum Allowable Rpm 1200 1200 1200 1200 Motor Pulley Pitch Diameter 4.8 4.4 5.7 5.2 6.1 5.5 4.4 4.9 5.9 4.4 5.7 5.9 Nominal Motor Shaft Diameter (in.) 11/8 13/8 15/8 11/8 13/8 15/8 13/8 15/8 15/8 13/8 15/8 15/8 Fan Pulley Pitch Diameter (in.) 12.4 8.6 9.1 12.4 11.1 8.7 9.4 8.1 8.7 9.0 9.1 8.7 Nominal Fan Shaft Diameter (in.) 115/16 115/16 115/16 115/16 Belt Quantity 1 2 2 1 1 2 2 2 2 2 2 2 Belt Type BX56 BX50 5VX530 BX56 5VX570 5VX530 BX50 5VX500 5VX530 BX50 5VX530 5VX530 Belt Length (in.) 56 63 53 56 57 53 50 50 53 50 53 53 Pulley Center Line Distance (in.) 16.0-18.7 15.6-18.4 15.0-17.9 15.6-18.4 15.6-
18.4 15.0- 17.9
15.6- 18.4 15.0-17.9 15.0-17.9 15.6-18.4 15.0-17.9 15.0-17.9
Factory Speed Setting (rpm) 717 924 1096 773 962 1106 848 1059 1187 856 1096 1187
FURNACE SECTION Supply Line Pressure Range 5.0-in. wg min/13.5-in. wg max. Rollout Switch Cutout Temp (F) 225 225 225 225 Burner Orifice Diameter (in. ...drill size) Natural Gas Std .111 ... 34 .111 ... 34 .111 ... 34 .111 ... 34 Liquid Propane Alt .089 ... 43 .089 ... 43 .089 ... 43 .089 ... 43 Thermostat Heat Anticipator Setting Stage 1 (amps) 0.1 0.1 0.1 0.1 Stage 2 (amps) 0.1 0.1 0.1 0.1 Gas Input (Btuh) Stage 1 (Low Heat/High Heat) 262,500/394,000 262,500/394,000 262,500/394,000 262,500/394,000
Stage 2 (Low Heat/High Heat) 350,000/525,000 350,000/525,000 350,000/525,000 350,000/525,000
Efficiency (Steady State) (%) 81 81 81 81 Temperature Rise Range (F) 15-45/35-65 15-45/35-65 15-45/35-65 15-45/35-65 Manifold Pressure (in. wg) Natural Gas Std 3.5 3.5 3.5 3.5 Liquid Propane Alt 3.5 3.5 3.5 3.5 Gas Valve Quantity 2 2 2 2
HIGH-PRESSURE SWITCH (psig) Cutout 650 650 650 650 Reset (Auto.) 500 500 500 500
MIXED-AIR FILTERS Quantity ... Size (in.) Standard 10 ... 20 x 24 x 2 10 ... 20 x 24 x 2 10 ... 20 x 24 x 2 10 ... 20 x 24 x 2 Pleated 5 ... 20 x 20 x 4
5 ... 20 x 24 x 4 5 ... 20 x 20 x 4 5 ... 20 x 24 x 4
5 ... 20 x 20 x 4 5 ... 20 x 24 x 4
5 ... 20 x 20 x 4 5 ... 20 x 24 x 4
OUTDOOR-AIR FILTERS Quantity...Size (in.) 8...16 x 25 x 2
4...20 x 25 x 2
POWER EXHAUST Direct Drive, Single-Phase Motors (Factory-Wired for High Speed Operation), Forward-Curved Fan Wheels with Backdraft Dampers on Each Fan Housing
Motor, Quantity...Hp 4...1 Fan, Diameter...Width (in.) 11 x 10
Al Aluminum Cu Copper MCHX Microchannel Heat Exchanger RTPF Round Tube Plate Fin
18
Table 1 Physical Data 48A Units (cont)
LEGEND * Sizes 020 to 027: Circuit 1 uses the lower portion of condenser coil, Circuit 2 uses the upper portion. Sizes 030 and 035: Circuit 1 uses the upper portion of condenser coil, Circuit 2 uses the lower portion. Sizes 040 and 050: Circuit 1 uses the left condenser coil, Circuit 2 the right. Size 060: Circuit A uses the two MCHX coils near the bulkhead, Circuit B uses the two MCHX coils near the control box.
Rollout switch is manual reset.
UNIT 48A 035D/E 040D/E 050D/E 060D/E NOMINAL CAPACITY (tons) 35 40 50 60
BASE UNIT See Unit Weights Table OPERATING WEIGHT (lb) COMPRESSOR Quantity ... Type (Ckt 1/Ckt 2) 2 ... ZP67/2...ZP104 2...ZP104/2...ZP104 2ZP122/2ZP122 2ZP154/2ZP154 Number of Refrigerant Circuits 2 2 2 2 Oil Precharged Precharged Precharged Precharged
REFRIGERANT R-410A Operating Charge (lb), Ckt 1/Ckt 2 RTPF Coils 28.7/44.0 44.0/44.0 56.3/57.3 78.5/82.0 MCHX Coils 17.9/26.0 23.0/23.5 27.0/28.0 36.6/37.8 MCHX Coils with Humidi-MiZer Coil 17.9/31.5 23.0/30.5 26.5/34.5 36.6/47.6
MCHX CONDENSER* Quantity 1 2 2 4 Total Face Area (sq ft) 32.9 65.8 65.8 105.2
RTPF CONDENSER Quantity 1 2 2 2 Rows...Fins/in. 4...15 3...15 4...15 6...30 Total Face Area (sq ft) 33.3 66.7 66.7 100.0
CONDENSER FAN Propeller Type Nominal Cfm 19,500 32,000 35,000 40,000
Quantity... Diameter (in.) 2 ... 30 4 ... 30 4 ... 30 4...30.5(MCHX), 6...30(RTPF)
Motor Hp 1 1 1 1
EVAPORATOR COIL Cross-Hatched Copper Tubes, Aluminum Plate Fins with Intertwined Circuits Tube Size (in.) 1/2 1/2 1/2 1/2 Rows ... Fins/in. 6 ... 16 4 ... 17 6 ... 16 4...17 Total Face Area (sq ft) 31.3 31.3 31.3 48.1
HUMIDI-MIZER COIL Quantity 1 1 1 1 Face Area (sq ft) 14.4 14.4 14.4 14.1
EVAPORATOR FAN Centrifugal Type Quantity ... Size (in.) 2 ... 20 X 15 2 ... 20 X 15 2 ... 20 X 15 3 ... 20 X 15 Type Drive Belt Belt Belt Belt Nominal Cfm 14,000 16,000 18,000 24,000 Motor Hp 15 20 25 15 20 25 20 25 30 25 30 40 Motor Frame Size 254T 256T 284T 254T 256T 284T 256T 284T 286T 284T 286T 324T Motor Bearing Type Ball Ball Ball Ball Maximum Allowable Rpm 1300 1300 1300 1200 Motor Pulley Pitch Diameter (in.) 5.1 5.7 6.2 5.3 5.7 7.5 5.7 6.2 6.7 5.3 5.9 6.5 Nominal Motor Shaft Diameter (in.) 15/8 15/8 17/8 15/8 15/8 17/8 15/8 17/8 17/8 17/8 17/8 21/8 Fan Pulley Pitch Diameter (in.) 8.7 8.7 8.7 9.5 9.5 11.1 9.5 9.5 9.5 9.1 9.5 9.5 Nominal Fan Shaft Diameter (in.) 115/16 115/16 115/16 115/16 Belt Quantity 2 2 2 2 2 2 2 2 2 3 3 3 Belt Type 5VX500 5VX530 5VX550 5VX530 5VX550 5VX590 5VX550 5VX570 5VX570 5VX530 5VX550 5VX570 Belt Length (in.) 50 53 55 53 55 59 55 57 57 53 55 57
Pulley Center Line Distance (in.) 15.0- 17.9
15.0- 17.9
15.0- 17.9
15.0- 17.9
15.0- 17.9
14.6- 17.6
15.0- 17.9
14.6- 17.6
14.6- 17.6
15.2- 17.5
14.7- 17.2
14.2- 17.0
Factory Speed Setting (rpm) 1025 1147 1247 976 1050 1182 1050 1142 1234 1019 1087 1197
FURNACE SECTION Supply Line Pressure Range 5.0-in. wg min/13.5-in. wg max. Rollout Switch Cutout Temp (F) 225 225 225 225 Burner Orifice Diameter (in ...drill size)
Natural Gas Std .111 ... 34 (low)/.120 ... 31 (high) .120 ... 31 .120 ... 31 .120...31
Liquid Propane Alt .089 ... 43 .096 ... 41 .096 ... 41 .096...41 Thermostat Heat Anticipator Setting Stage 1 (amps) 0.1 0.24 0.1 0.1 Stage 2 (amps) 0.1 0.13 0.1 0.1 Gas Input (Btuh) Stage 1 (Low Heat/High Heat) 262,500/600,000 300,000/600,000 300,000/600,000 582,000/873,000
Stage 2 (Low Heat/High Heat) 350,000/800,000 400,000/800,000 400,000/800,000 776,000/1,164,000
Efficiency (Steady State) (%) 81 81 81 81 Temperature Rise Range (F) 15-45/30-60 10-40/30-60 10-40/30-60 10-40/30-60 Manifold Pressure (in. wg) Natural Gas Std 3.5 3.5 3.5 3.3 Liquid Propane Alt 3.5 3.5 3.5 3.3 Gas Valve Quantity 2 2 2 3
HIGH-PRESSURE SWITCH (psig) Cutout 650 650 650 650 Reset (Auto.) 500 500 500 500
MIXED-AIR FILTERS Quantity ... Size (in.) Standard 10 ... 20 x 24 x 2 10 ... 20 x 24 x 2 10 ... 20 x 24 x 2 16...20 x 24 x 2
8...20 x 20 x 4 8...20 x 24 x 4
Pleated 5 ... 20 x 20 x 4 5 ... 20 x 24 x 4
5 ... 20 x 20 x 4 5 ... 20 x 24 x 4
5 ... 20 x 20 x 4 5 ... 20 x 24 x 4
OUTDOOR-AIR FILTERS
Quantity...Size (in.) 8...16 x 25 x 2 4...20 x 25 x 2
8...16 x 25 x 2 4...20 x 25 x 2
8...16 x 25 x 2 4...20 x 25 x 2
12...16 x 25 x 2 6...20 x 25 x 2
POWER EXHAUST Direct Drive, Single-Phase Motors (Factory-Wired for High Speed Operation), Forward-Curved Fan Wheels with Backdraft Dampers on Each Fan Housing
Motor, Quantity...Hp 4...1 11 x 10
4...1 11 x 10
4...1 11 x 10
6...1 11 x 10 Fan, Diameter...Width (in.)
Al Aluminum Cu Copper MCHX Microchannel Heat Exchanger RTPF Round Tube Plate Fin
19
F ig
. 1 4
R
ig g
in g
In fo
rm at
io n
N O
TE :
A dd
3 12
lb s
(1 42
k g)
fo r e
xp or
t c ra
tin g.
(0 27
-0 35
u ni
ts )
A dd
3 46
lb s
(1 57
k g)
fo r e
xp or
t c ra
tin g.
(0 40
-0 50
u ni
ts )
A dd
5 88
lb s
(2 66
k g)
fo r e
xp or
t c ra
tin g.
(0 60
u ni
ts )
A dd
th e
w ei
gh ts
s ho
w n
be lo
w fo
r r ou
nd tu
be p
la te
fi n
co ils
50 EJ
50 03
05 R
EV 2
.0
U ni
t S iz
e ---
--- ---
- 02
7 03
0- 03
5 04
0 05
0 06
0 C
op pe
r T ub
e/ A
lu m
in um
F in
C on
d C
oi l
10 5
lb s
(4 8
kg )
16 0
lb s
(7 2
kg )
19 2
lb s
(8 7
kg )
31 7
lb s
(1 44
k g)
26 lb
s (1
2 kg
) C
op pe
r T ub
e/ C
op pe
r F in
C on
d. C
oi l
26 8
lb s
(1 22
k g)
37 7
lb s
(1 71
k g)
51 8
lb s
(2 35
k g)
75 1
lb s
(3 41
k g)
67 7
lb s
(3 07
k g)
Th e w
eig ht
dis trib
uti on
an d c
en ter
of gr
av ity
inf orm
ati on
ar e r
ep res
en tat
ive of
a sta
nd ard
un it a
nd in
clu de
th e i
mp ac
t o f fa
cto ry
ins tal
led ec
on om
ize r, l
arg es
t IF M
mo tor
& VF
D, mo
du lat
ing po
we r e
xh au
st (bo
th fac
tor y in
sta lled
an d f
ield in
sta lled
op tio
ns ), a
nd el
ec tric
he at
(on 50
A o nly
).
LB S
48 54
49 44
50 24
49 32
49 84
50 64
48 34
49 24
50 04
49 12
49 64
50 44
51 21
53 26
54 86
53 14
53 66
55 26
55 59
57 64
59 24
57 52
58 04
59 64
57 44
59 49
61 09
59 37
59 89
61 49
83 11
83 86
86 26
85 26
84 26
86 76
K G
S 22
02 22
43 22
79 22
37 22
61 22
97 21
93 22
33 22
70 22
28 22
52 22
88 23
23 24
16 24
89 24
11 24
34 25
07 25
21 26
14 26
87 26
09 26
33 27
05 26
06 26
99 27
71 26
93 27
17 27
89 37
70 38
04 39
13 38
68 38
22 39
36
IN C
H ES
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
87 .7
87
.7
16 1.
7 16
1. 7
16 1.
7 16
1. 7
16 1.
7 16
1. 7
M M
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
22 27
41 06
41 06
41 06
41 06
41 06
41 06
IN C
H ES
97 .2
96 .1
95 .6
93 .6
92
.7
92 .3
95
.2 94
.0 93
.6 91
.6
90 .6
90
.3
95 .9
94
.8
94 .2
92
.7
91 .7
91
.3
12 1.
8 12
0. 3
11 8.
8 11
6. 5
11 5.
1 11
3. 9
11 9.
5 11
8. 1
11 6.
6 11
4. 3
11 2.
9 11
1. 7
18 4.
9 17
7. 6
17 0.
4 17
6. 5
16 9.
6 16
3. 3
M M
24 69
24 41
24 28
23 79
23 54
23 44
24 17
23 89
23 76
23 27
23 02
22 93
24 36
24 08
23 94
23 54
23 29
23 18
30 94
30 56
30 18
29 58
29 24
28 93
30 35
29 99
29 62
29 04
28 68
28 37
46 98
45 11
43 29
44 84
43 09
41 47
IN C
H ES
44 .1
43 .7
43 .4
48 .4
48 .0
47 .7
44 .4
44 .0
43 .7
48 .8
48 .3
48 .0
41 .4
41 .0
40 .7
45 .7
45 .3
44 .9 41 41 41 45 .4
44 .9
44 .6 42 41 41 45 .5
45 .1
44 .7 43 41 39 47 .1
45 .2
43 .2
M M
11 20
11 10
11 02
12 30
12 20
12 11
11 28
11 18
11 10
12 38
12 28
12 19
10 53
10 42
10 35
11 62
11 51
11 41
10 52
10 41
10 33
11 52
11 42
11 32
10 59
10 48
10 40
11 56
11 45
11 35
11 02
10 49
99 6
11 96
11 49
10 97
50 A
2/ A
3/ A
6/ A
7 02
7 48
A 2/
A 3/
A 6/
A 7D
0 27
48 A
2/ A
3/ A
6/ A
7E 0
27 50
A 4/
A 5/
A 8/
A 9
02 7
48 A
4/ A
5/ A
8/ A
9D 0
27 48
A 4/
A 5/
A 8/
A 9E
0 27
50 A
2/ A
3/ A
6/ A
7 03
0 48
A 2/
A 3/
A 6/
A 7D
0 30
48 A
2/ A
3/ A
6/ A
7E 0
30 50
A 4/
A 5/
A 8/
A 9
03 0
48 A
4/ A
5/ A
8/ A
9D 0
30 48
A 4/
A 5/
A 8/
A 9E
0 30
50 A
2/ A
3/ A
6/ A
7 03
5 48
A 2/
A 3/
A 6/
A 7D
0 35
48 A
2/ A
3/ A
6/ A
7E 0
35 50
A 4/
A 5/
A 8/
A 9
03 5
48 A
4/ A
5/ A
8/ A
9D 0
35 48
A 4/
A 5/
A 8/
A 9E
0 35
50 A
2/ A
3/ A
6/ A
7 04
0 48
A 2/
A 3/
A 6/
A 7D
0 40
48 A
2/ A
3/ A
6/ A
7E 0
40 50
A 4/
A 5/
A 8/
A 9
04 0
48 A
4/ A
5/ A
8/ A
9D 0
40 48
A 4/
A 5/
A 8/
A 9E
0 40
50 A
2/ A
3/ A
6/ A
7 05
0 48
A 2/
A 3/
A 6/
A 7D
0 50
48 A
2/ A
3/ A
6/ A
7E 0
50 50
A 4/
A 5/
A 8/
A 9
05 0
48 A
4/ A
5/ A
8/ A
9D 0
50 48
A 4/
A 5/
A 8/
A 9E
0 50
50 A
2/ A
3/ A
6/ A
7 06
0 48
A 2/
A 3/
A 6/
A 7D
0 60
48 A
2/ A
3/ A
6/ A
7E 0
60 50
A 4/
A 5/
A 8/
A 9
06 0
48 A
4/ A
5/ A
8/ A
9D 0
60 48
A 4/
A 5/
A 8/
A 9E
0 60
M O
D EL
B C
W EI
G H
T A
20
Table 2 Unit Operating Weights* (lb)
Table 3 Option and Accessory Weights (lb)
Table 4 Constant Volume Fan Motor Weights (lb)
Table 5 Variable Air Volume / Staged Air Volume Fan Motor Weights (lb)
LEGEND AND NOTES FOR TABLES 2-5
LEGEND *Outdoor-air hoods and filters included in base unit weights; indoor- fan motors are NOT included. NOTES: 1. Base unit weight includes OA hoods (economizer or outdoor air
damper); does not include an indoor-fan motor. ADD indoor motor, FIOPs and accessories for TOTAL operating weight.
2. VAV/SAV motor weights include the indoor motor and the VFD, optional VFD bypass, VFD transducer, and associated wiring.
UNIT SIZE 020 025 027 030 035 040 050 060 48A2D,A3D,A6D,A7D 3825 3961 3961 3992 4340 4770 4914 7066 48A2E,A3E,A6E,A7E 3905 4041 4041 4072 4500 4930 5074 7306 48A4D,A5D,A8D,A9D 3865 4001 4001 4032 4380 4810 4954 7106 48A4E,A5E,A8E,A9E 3945 4081 4081 4112 4540 4970 5114 7356
UNIT SIZE 020 025 027 030 035 040 050 060 OPTIONS/ACCESSORIES (WEIGHT ADDERS) (lb)
Barometric Relief 300 300 300 300 300 300 300 450 Non-Modulating Power Exhaust 450 450 450 450 450 450 450 675 Modulating Power Exhaust 500 500 500 500 500 500 500 725 Electric Heat 110 110 110 110 110 110 110 165 Cu Tube/Aluminum Fin Condenser Coil 100 100 100 150 150 187 317 26 Cu Tube/Cu Fin Condenser Coil 263 263 263 370 370 512 751 677
OA Hood Crate/Packaging (Less Hoods Weight)
45 45 45 45 45 45 45 45 (Packaging Only)
Outdoor Air Hoods/Filters (included with unit) 170 170 170 170 170 170 170 255 Hail Guards 73 73 73 73 73 146 146 219 Roof Curb (14-in.) 365 365 365 365 365 410 410 540 Double Wall 275 275 275 275 275 275 275 375 Humidi-MiZer Coil 150 150 150 150 150 180 180 195
MOTOR HP UNIT VOLTAGE PREMIUM
EFFICIENCY IFM
5 HP 230/460 80
380 75 575 80
10 HP 230/460 126
380 120 575 126
15 HP 230/460 217
380 155 575 217
20 HP 230/460 250
380 185 575 250
25 HP 230/460 309
380 225 575 309
30 HP 230/460 303
380 283 575 303
40 HP 230/460 551
380 601 575 551
MOTOR HP UNIT VOLTAGE PREMIUM
EFFICIENCY IFM
5 HP 230/460 138
380 133 575 149
10 HP 230/460 195
380 198 575 195
15 HP 230/460 316
380 254 575 319
20 HP 230/460 385
380 320 575 357
25 HP 230/460 444
380 360 575 454
30 HP 230/460 338
380 318 575 342
40 HP 230/460 686
380 736 575 686
Cu Copper FIOP Factory-Installed Option HP Horsepower IFM Indoor-Fan Motor OA Outdoor Air SAV Staged Air Volume VAV Variable Air Volume VFD Variable Frequency Drive
21
Table 6 Evaporator Fan Motor Data
NOTES: 1. Motor shaft speed is 1750 rpm. The fan shaft diameter is 115/16 inches. 2. All indoor fan motors meet the minimum efficiency requirements as established
by the Energy Policy Act of 1992 (EPACT), effective October 24, 1997.
Step 3 Field Fabricate Ductwork Secure all ducts to building structure. Use flexible duct connectors between unit and ducts as required. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes. NOTE: Due to width of the horizontal supply and return ductwork, provisions should be made for servicing of the outdoor air filters (i.e., catwalk over ductwork).
Ducts passing through an unconditioned space must be insulat- ed and covered with a vapor barrier. Outlet grilles must not lie di- rectly below unit discharge. The return duct must have a 90-de- gree elbow before opening into the building space if the unit is equipped with power exhaust.
To attach ductwork to roof curb, insert duct approximately 10 to 11 in. up into roof curb. Connect ductwork to 14-gage roof curb material with sheet metal screws driven from inside the duct.
Follow AMCA (Air Movement and Control Association) guidelines relating to ductwork connections to the unit. These guidelines recommend a minimum 21/2 equivalent duct diame- ters of straight duct connected to supply air inlet and outlet openings before any transitions, fittings, dampers, etc. Failure to adhere to these guidelines may result in system effects which can impact the units ability to achieve published perfor- mance.
Step 4 Make Unit Duct Connections 48A2, A3, A6, AND A7 UNITS Unit is shipped for thru-the- bottom duct connections. Field-fabricated ductwork should be attached to the roof curb. Supply and return duct dimensions are shown in Fig. 5, 6, 9, and 12. Air distribution is shown in
Fig. 15. Refer to installation instructions shipped with roof curb for more information.
48A4, A5, A8, AND A9 UNITS Remove shipping covers from supply and return air openings. Attach field-supplied ductwork to unit. Connect to the unit with a single duct for all sup- ply openings and with a single duct for all return openings. Split- ting of the airflow into branch ducts should not be done at the unit. Sufficient duct length should be used prior to branching to ensure the air temperatures are well mixed within the ductwork. See Fig. 7, 8, 10, and 11 for duct opening dimensions. Secure all ducts to building structure. Air distribution is shown in Fig. 16. Verify the Outdoor Air Temperature (OAT) and Return Air Temperature (RAT) sensors as outlined in Fig. 17 can measure the OAT and RAT temperature sensors in the corresponding air streams. Relo- cate the sensor locations if needed. Install accessory barometric relief or power exhaust in the field- fabricated return ductwork. Refer to Step 11 Position Power Exhaust/Barometric Relief Damper Hood section on page 30 for more information.
UNIT SIZE 48A
MOTOR HP
MOTOR SHAFT DIA.
(in.)
FAN SHAFT SPEED (RPM)
MOTOR SHEAVE
(P/N)
MOTOR SHEAVE
PITCH DIAMETER
(in.)
BUSHING DIAMETER
(in.)
FAN SHEAVE
(P/N)
FAN SHEAVE
PITCH DIAMETER
(in.)
BUSHING DIAMETER
(in.)
BELT (QUANTITY)
(P/N)
BELT TENSION
(lb at .25 in.)
020 5 1.125 717 BK55 4.8 NONE - 1.125 1B5V124 12.4 B - 1.9375 BX56 8
10 1.375 924 2BK50 4.4 NONE - 1.375 2B5V86 8.6 B - 1.9375 (2) BX50 8 15 1.625 1096 2B5V56 5.7 B - 1.625 2B5V90 9.1 B - 1.9375 (2) 5VX530 9
025 5 1.125 773 BK55 5.2 NONE - 1.125 1B5V124 12.4 B - 1.9375 BX56 8
10 1.375 962 1B5V60 6.1 H - 1.375 1B5V110 11.1 B - 1.9375 5VX570 11 15 1.625 1106 2B5V54 5.5 B - 1.625 2B5V86 8.7 B - 1.9375 (2) 5VX530 9
027 10 1.375 848 2BK50 4.4 NONE - 1.375 2B5V94 9.4 B - 1.9375 (2) BX50 8 15 1.625 1059 2B5V56 4.9 B - 1.625 2B5V90 8.1 B - 1.9375 (2) 5VX530 10 20 1.625 1187 2B5V58 5.9 B - 1.625 2B5V86 8.7 B - 1.9375 (2) 5VX530 11
030 10 1.375 856 2BK50 4.4 H - 1.375 2B5V94 9.0 B - 1.9375 (2) BX50 8 15 1.625 1096 2B5V56 5.7 B - 1.625 2B5V90 9.1 B - 1.9375 (2) 5VX530 9 20 1.625 1187 2B5V58 5.9 B - 1.625 2B5V86 8.7 B - 1.9375 (2) 5VX530 11
035 15 1.625 1025 2B5V50 5.1 B - 1.625 2B5V86 8.7 B - 1.9375 (2) 5VX500 9 20 1.625 1147 2B5V56 5.7 B - 1.625 2B5V86 8.7 B - 1.9375 (2) 5VX530 10 25 1.875 1247 2B5V62 6.2 B - 1.875 2B5V86 8.7 B - 1.9375 (2) 5VX530 11
040 15 1.625 976 2B5V52 5.3 B - 1.625 2B5V94 9.5 B - 1.9375 (2) 5VX530 10 20 1.625 1050 2B5V56 5.7 B - 1.625 2B5V94 9.5 B - 1.9375 (2) 5VX550 11 25 1.875 1182 2B5V74 7.5 B - 1.875 2B5V110 11.1 B - 1.9375 (2) 5VX590 11
050 20 1.625 1050 2B5V56 5.7 B - 1.625 2B5V94 9.5 B - 1.9375 (2) 5VX550 10 25 1.875 1142 2B5V62 6.2 B - 1.875 2B5V94 9.5 B - 1.9375 (2) 5VX570 11 30 1.875 1234 2B5V66 6.7 B - 1.875 2B5V94 9.5 B - 1.9375 (2) 5VX570 13
060 25 1.875 1019 3B5V52 5.3 B - 1.875 3B5V90 9.1 B - 1.9375 (3) 5VX530 12 30 1.875 1086 3B5V58 5.9 B - 1.875 3B5V94 9.5 B - 1.9375 (3) 5VX550 12 40 2.125 1197 3B5V64 6.5 B - 2.125 3B5V94 9.5 B - 1.9375 (3) 5VX570 14
WARNING
For vertical supply and return units, tools or parts could drop into ductwork and cause an injury. Install a 90-degree elbow turn in the supply and return ductwork between the unit and the conditioned space. If a 90-degree elbow cannot be installed, then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space.
Fig. 15 Air Distribution Thru-the-Bottom
a48-8241
22
Fig. 17 Outdoor Air and Return Air Sensors Location
Step 5 Install Flue Hood 48A2020-050 UNITS Flue hood is shipped inside gas sec- tion of unit. To install, secure flue hood to access panel. See Fig. 18. 48A2060 UNITS Flue hood and wind baffle are shipped inside gas section of unit. To install, secure flue hood to access panel. Install the two pieces of the wind baffle over the flue hood. See Fig. 19. NOTE: When properly installed, flue hood will line up with combustion fan housing. See Fig. 20.
Step 6 Trap Condensate Drain See Fig. 5-12 for drain location. Condensate drain is open to atmosphere and must be trapped. Install a trapped drain at the drain location. One 1-in. female coupling is provided inside the unit evapora- tor section for condensate drain connection. A trap at least 4 in. deep must be used. See Fig. 21. Trap must be installed to pre- vent freeze-up. Condensate pans are sloped so that water will completely drain from the condensate pan to comply with indoor air quality guidelines. The condensate drain pans are not insulated.
Fig. 16 Air Distribution Thru-the-Side
a48-8242
Fig. 18 Flue Hood Location (48A020-050 Units)
a48-3712
Fig. 19 Flue Hood Location (48A2,A3,A4,A5060 Units)
a48-4076
FLUE HOOD
GAS SECTION ACCESS PANEL
WIND BAFFLE
TOP VIEW SIDE VIEW
Fig. 20 Combustion Fan Housing Location (48A020-050 Shown)
a48-3823
23
Step 7 Install Gas Piping Unit is equipped for use with natural gas. Installation must conform with local building codes or, in the absence of local codes, with the Na- tional Fuel Gas Code, ANSI Z223.1. Install manual gas shutoff valve with a 1/8-in. NPT pressure tap for test gage connection at unit. Field gas piping must include sediment trap and union. See Fig. 22. A 1/8-in. NPT is also located on the gas manifold adjacent to the gas valve.
Size gas-supply piping for 0.5-in. wg maximum pressure drop. Do not use supply pipe smaller than unit gas connection. OPTIONAL STAGED GAS UNITS See Table 7 for staged gas information. Staging pattern is selected during controls start-up. For complete information and service instructions for staged gas control units, see Controls, Start-Up, Operation, Service and Troubleshooting literature.
Table 7 48A Series Staged Gas Control
Step 8 Install Supply-Air Thermistors (Staged and Modulating Gas Units Only) Supply-air thermistors are a field-installed, factory-provided component. Three supply-air thermistors are shipped with staged and modulating gas units inside the unit control box. Thermistor wires must be connected to the SGC (staged gas controller) in the unit control box. See Table 8. The supply-air thermistors should be located in the supply duct with the fol- lowing criteria: downstream of the heat exchanger cells equally spaced as far as possible from the heat
exchanger cells a duct location where none of the supply air thermistors
are within sight of the heat exchanger cells a duct location with good mixed supply air portion of the
unit.
Table 8 SGC Thermistor Designations
SGC Staged Gas Controller
WARNING
Do not pressure test gas supply while connected to unit. Always disconnect union before servicing. Personal injury or damage to unit may occur.
IMPORTANT: Natural gas pressure at unit gas connection must not be less than 5 in. wg or greater than 13.5 in. wg.
Fig. 21 Condensate Drain Trap Piping Details (Typical Roof Curb or Slab Mount Shown)
a48-3714
NUMBER OF STAGES
MODEL NUMBER POSITION HEAT SIZE
5 6,7,8
5 STAGES
S
020 025 027 030 035 040 050
Low
T 035 040 050
High
7 STAGES T
020 025 027 030
High
9 STAGES T 060 High 11 STAGES S 060 Low
Fig. 22 Field Gas Piping
a48-2524
THERMISTOR PIN
CONNECTION POINT
FUNCTION AND LOCATION PART NO.
Thermistors
SAT1 J8 1,2 (SGC) Supply-Air Thermistor (SAT) Inserted into supply section underneath the gas heat section (factory-provided, field-installed)
HH79NZ034 SAT2 J8 3,4 (SGC) Supply-Air Thermistor (SAT) Inserted into supply section underneath the
gas heat section (factory-provided, field-installed)
SAT3 J8 5,6 (SGC) Supply-Air Thermistor (SAT) Inserted into supply section underneath the gas heat section (factory-provided, field-installed)
LIMTTEMP J8 15,16 (SGC)
Limit Switch Thermistor (LIMTTEMP) Inserted next to the lower limit switch (factory-installed)
24
Step 9 Make Electrical Connections POWER WIRING Units are factory wired for the voltage shown on the unit nameplate. Provide a unit safety disconnect switch in the main power supply to each unit (see Fig. 23). Select switch size and mounting loca- tion in accordance with applicable local codes or National Electri- cal Code (NEC). If combining the functions of safety disconnect with maximum overcurrent protection (MOCP) fuses (fused dis- connect), coordinate safety switch size with MOCP size data as marked on unit informative plate. Unit may be equipped with optional factory-installed non-fused disconnect switch (see Fig. 23). Provide maximum overcurrent protection devices (fuses or HACR breakers, per local codes) in branch circuit wiring remote from unit. Observe requirements of NEC Article 440. Install service switch upstream of remote fuses if required. The main power terminal block is suitable for use with aluminum or copper wire. See Fig. 23. Units have circuit breakers for com- pressors, fan motors, and control circuit. The unit must be electri- cally grounded in accordance with local codes or, in absence of local codes, with NEC, ANSI C1-latest year. FIELD POWER SUPPLY Unit is factory wired for voltage shown on unit nameplate. Field wiring can be brought into the unit from bottom (through basepan and roof curb) or through side of unit (corner post next to control box). A 31/2-in. NPT coupling for field power wiring and a 3/4-in. NPT coupling for 24-v control wiring are provided in basepan. In the side post, there are two 21/2-in. (sizes 020-035) or 3-in. (sizes 040-060) knockouts for the field power wiring. See Fig. 5-12. If control wiring is to be brought in through side of unit, a 7/8-in. diameter hole is provided in the condenser side post next to the control box. Do not route control wiring in the same conduit as power wiring. If disconnect box is mounted to corner post, be careful not to drill or screw into the condenser coil.
Routing Through Bottom of Unit If wiring is brought in through bottom of unit, use field-supplied watertight conduit to route power wiring through the 31/2-in. diameter hole provided in the unit basepan. Install conduit connector in unit basepan as shown in Fig. 5-12. Route power and ground lines through connector to terminal con- nections in unit control box as shown on unit wiring diagram and Fig. 23. Use strain relief going into control box through 35/8-in. diameter hole provided. After wires are in unit control box, connect to power terminal block (see Power Wiring section). Low-voltage wiring must be run in watertight conduit from the basepan to control box and through 7/8-in. diameter hole provided in bottom of unit control box. Field-supplied strain relief must be used going into the box. After wiring is in control box, make con- nections to proper terminals on terminal blocks (see Field Control Wiring section).
Routing Through Side of Unit Route power wiring in field- supplied watertight conduit into unit through 21/2-in. (sizes 020- 035) or 3-in. (sizes 040-060) hole. Use field-supplied strain relief going into control box through 358- in. diameter hole provided. After wires are in unit control box, connect to power terminal block (see Power Wiring section). Bring low-voltage control wiring through the 7/8-in. diameter hole provided in the condenser section side post. Use strain relief going into 7/8-in. diameter hole in bottom of unit control box. After wiring is in control box, make connection to proper termi- nals on terminal blocks (see Field Control Wiring section).
Affix crankcase heater sticker (located in the installers packet) to unit disconnect switch. Voltage to compressor terminals during compressor operation must be within the voltage range indicated on the unit nameplate. Phases must be balanced within 2%. Use the following formula to determine the percent of voltage imbalance.
% Voltage Imbalance:
Example: Supply voltage is 230-3-60
Determine maximum deviation from average voltage. (AB) 227-224 = 3 v (BC) 231-227 = 4 v (AC) 227-226 = 1 v Maximum deviation is 4 v. Determine percent of voltage imbalance.
LEGEND GND Ground NEC National Electrical Code TB Terminal Block
Fig. 23 Field Power Wiring Connections
a48-6977
F IE
LD S
U P
P LI
E D
D IS
C O
N N
E C
T P
E R
N E
C
FIELD
POWER
SUPPLY
11 21
22
2313
12
TB1
EQUIP GND
F IE
LD P
O W
E R
W IR
IN G
11 21
22
2313
12
GND
OPTIONAL FACTORY-INSTALLED
DISCONNECT
FIELD-INSTALLED DISCONNECT
FACTORY-INSTALLED DISCONNECT
IMPORTANT: The VAV (variable air volume) units use vari- able frequency drives, which generate and can radiate radio frequency energy. If units are not installed and used in accor- dance with these instructions, they may cause radio interfer- ence. They have been tested and found to comply with limits of a Class A computing device pursuant to International Stan- dard in North American EN 61000-2/3, which are designed to provide reasonable protection against such interference when operated in a commercial environment.
WARNING
The unit must be electrically grounded in accordance with local codes and NEC ANSI/NFPA 70 (National Fire Protec- tion Association). Personal injury may result.
= 100 x max voltage deviation from average voltage
average voltage
AB = 224 v
BC = 231 v
AC = 226 v
Average Voltage = (224 + 231 + 226)
= 681
= 227 3 3
A B C
MOTOR
25
This amount of phase imbalance is satisfactory as it is below the maxi- mum allowable 2%.
NOTE: Check all factory and field electrical connections for tightness.
Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause dam- age to electrical components. On 208/230-v units, transformers 1-5 are wired for 230-v. If 208/ 230-v unit is to be run with 208-v power supply, the transformers must be rewired as follows: For transformer 1 move the black wire connected to terminal H2 and connect it to terminal H3. For transformers 2-4, used for the 24-volt control circuits, connect as follows: 1. Remove cap from red (208 v) wire. 2. Remove cap from spliced orange (230 v) wire. Disconnect
orange wire from black unit power wire. 3. Cap orange wire. 4. Splice red wire and black unit power wire. Cap wires.
If the unit is equipped with the optional convenience outlet con- nect the yellow wire to H2 on transformer 5.
FIELD CONTROL WIRING The 48A Series units support a large number of control options that can impact the field control wiring. The control options that the unit can provide relate to the follow- ing parameters: CV (constant volume), VAV (variable air volume), SAV
(staged air volume), VVT (variable volume variable tem- perature) or Carrier TEMP system control operation.
Standalone with a thermostat (CV) or with a space sensor (CV and VAV)
Network application with CCN (Carrier Comfort Net- work) or other networks
Demand controlled ventilation with CO2 sensor Economizer and economizer with changeover control Staged gas heat Building and duct static pressure control Fire shutdown and smoke control Diagnostics and monitoring
For constant volume applications a thermostat (T-Stat) or space temperature sensor (SPT) will be required.
T-STAT (Conventional Thermostat) Unit can be controlled with a Carrier-approved accessory electro-mechanical or electron- ic thermostat that has two stages of cooling, two stages of heating control, and an output for indoor fan control. It may also include time of day scheduling or use the scheduling routines built into the ComfortLink controls. Install thermostat according to the installation instructions included with accessory thermostat and the unit wiring diagrams. Locate thermostat assembly on a solid interior wall in the condi- tioned space to sense average temperature. Route thermostat cable or equivalent single leads of colored wire from subbase terminals through conduit into unit to low-voltage connection in the main control box. For thermostat TB4 connec- tions see Fig. 24. NOTE: For wire runs up to 50 ft, use no. 18 AWG (American Wire Gage) insulated wire (35C minimum). For 50 to 75 ft, use no. 16 AWG insulated wire (35C minimum). For over
75 ft, use no. 14 AWG insulated wire (35C Minimum). Wire larger than no. 18 AWG cannot be directly connected at the thermostat and will require a junction box and splice at the thermostat. Set heat anticipator settings as follows:
Settings may be changed slightly to provide a greater degree of comfort for a particular installation.
Staged Gas Control Option Thermistors If the unit is equipped with the staged gas heat option, supply-air thermistors must be installed. Three supply-air thermistors are shipped with staged gas units and are inside the heating section. The supply-air thermistors should be located in the supply duct with the follow- ing criteria: Downstream of the heat exchanger cells Equally spaced as far as possible from the heat exchanger cells In a duct location where none of the supply-air thermistors
are within sight of the heat exchanger cells In a duct location with good mixed supply-air portion of the unit.
SPT (Space Temperature Sensor) For constant volume appli- cations the ComfortLink controls can also be used with T55 and T56 space temperature sensors that use a 10K thermistor. The T56 sensor also has the capability for a configurable temperature set point offset. For variable air volume applications only the T55 sensor can be used. Install sensor according to the installation instructions included with accessory sensor. Locate sensor assembly on a solid interior wall in the conditioned space to sense average temperature. Run wiring to the space sensor as shown in Fig. 25. Note that when the remote sensor is used, the red jumper wires provided must be connected from TB4 terminal 4 to 5 and TB4 terminal 5 to 1. Both the T55 and T56 sensors have a CCN communications port and this should be wired to the CCN Communications TB3 board if it is desired to have access to the CCN system through the sen- sor. If more than one T55 sensor is being used and averaged, sen- sors must be wired in multiples of 4 or 9 as shown in Fig. 26.
% Voltage Imbalance= 100x 4
= 1.78% 227
IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.
IMPORTANT: BE CERTAIN UNUSED WIRES ARE CAPPED. Failure to do so may damage the transformers.
48A SIZE STAGE 1 (W1) ON
STAGE 2 (W1 AND W2) ON
020-050 0.24 0.13 060 0.36 0.13
TB4
Fig. 24 Field Control Thermostat Wiring
a48-8243
R Y1 Y2 W1 W2 G C X
R Y1 Y2 W1 W2 G C X
FIELD-SUPPLIED THERMOSTAT
LIGHT
RC
1 2 3 4 5 6 7 8
Fig. 25 Space Temperature Sensor Wiring
a48-6854
T1 T2
1
2 4
3 5
6
7
8
9
10
11
12
13
14
15
16
TH C SN
T56 SPTT55 SPT
UNIT TB5
26
T58 Communicating Thermostat Carrier also has a fully communicating thermostat which, if used, will be wired to the CCN communication connections on TB3 as described in the Car- rier Comfort Network Interface section below.
Carrier Comfort Network Interface The rooftop units can be connected to the CCN system. The communication bus wiring is supplied and installed in the field. Wiring consists of shielded, 3- conductor cable with drain wire. The system elements are connect- ed to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it, the negative pins must be wired to the negative pins, and the signal pins must be wired to signal ground pins. Wiring connec- tions for CCN system should be made at the TB3 terminal block using the screw terminals. The TB3 board also contains an RJ14 CCN plug that can be used to connect a field service computer or other CCN device temporarily. There is also an RJ14 LEN (local equipment network) connection that is used to connect a Naviga- tor device or download software. Conductors and drain wire must be 20 AWG minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon1, or polyethylene. An aluminum/polyes- ter 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of 20C to 60C (4F to 140F) is required. Table 9 lists cables that meet the requirements.
Table 9 CCN Connection Approved Shield Cable
Table 10 Color Code Recommendations
If a cable with a different color scheme is selected, a similar color code should be adopted for the entire network. At each system element, the shields of the communication bus cables must be tied together. If the communication bus is entirely within one building, the resulting continuous shield must be connected to a ground at one point only. If the communication bus cable exits from one building and enters another, the shields must be connected to grounds at the lightning suppressor in each building where the cable enters or exits the building (one point per building only). To connect the unit to the network: 1. Turn off power to the control box.
NOTE: Use T55 sensor only.
Fig. 26 Space Temperature Averaging Wiring
a48-6855
3
4
RED
BLK
TB5
3
4
TB5
SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 4
SENSOR 1 SENSOR 2 SENSOR 3
SENSOR 4 SENSOR 5 SENSOR 6
SENSOR 7 SENSOR 8 SENSOR 9
SPACE TEMPERATURE AVERAGING (4 SENSOR APPLICATION)
SPACE TEMPERATURE AVERAGING (9 SENSOR APPLICATION)
1. Teflon is a registered trademark of DuPont.
MANUFACTURER CABLE PART NO. Alpha 2413 or 5463 American A22503 Belden 8772 Columbia 02525
IMPORTANT: When connecting to CCN communication bus to system elements, use color coding system for the entire network to simplify installation and checkout. See Table 10.
SIGNAL TYPE CCN BUS CONDUCTOR INSULATION COLOR
CCN PLUG PIN NO.
Positive (+) RED 1 Ground WHITE 2
Negative () BLACK 3
27
2. Cut the CCN wire and strip the ends of the red (+), white (ground), and black () conductors. (If a different network color scheme is used, substitute appropriate colors.)
3. Remove the 3-pin male plug from the base control board in the main control box, and connect the wires as follows: a. Insert and secure the red (+) wire to terminal 1 of the
3-pin plug. b. Insert and secure the white (ground) wire to terminal
2 of the 3-pin plug. c. Insert and secure the black () wire to terminal 3 of
the 3-pin plug. 4. Insert the plug into the existing 3-pin mating connector on
the base module in the main control box.
VAV Units with Heat For variable air volume units that will use heat, the variable air volume terminals should be interlocked with the unit at TB5 terminals 1 and 2.
Demand Controlled Ventilation The unit can be equipped with a CO2 sensor for use in demand ventilation. This can be facto- ry supplied and will be mounted in the return duct. It can also be field supplied and mounted in the return duct or in the space. Con- nect the field-installed 4 to 20 mA sensor to TB5 terminals 6 and 7. Do not remove the factory-installed 182-ohm resistor. If an outdoor air quality sensor is used then it should be wired to terminal 11 and 12 on TB6. This will require the use of the optional controls expansion module.
Remote IAQ Override If the control is being used with a non- Carrier building management system, it supports the use of the re- mote IAQ override switch. This should be connected to TB6 ter- minal 13 and 14. Use of this will require the optional controls ex- pansion module.
Remote Economizer Position Control The ComfortLink con- trols will normally control the position of the economizer, but it can also support field control of the economizer position through a 4 to 20 mA signal. If this is used it should be connected to TB5 terminal 6 and 7. If the signal is a 4 to 20 mA signal then leave the 182-ohm resistor in place.
Remote Economizer Enable If the control is being used with other building management systems and the system will control the enabling and disabling of the economizer free cooling, this switch input can be connected to TB6 terminals 1 and 2. Note that the controls also support integrated economizer changeover using outdoor dry bulb, differential dry bulb, outdoor enthalpy, and dif- ferential enthalpy.
Remote Occupancy Switch For interface to other building management systems, the control also supports a switch input for remote occupancy signals. This wiring should be connected to ter- minal TB6 terminal 1 and 3.
Remote Economizer Minimum Position Control If the Com- fortLink controller is controlling the economizer, but a remote mini- mum position is required, then an external 100K potentiometer can be connected to TB5 terminal 6 and 7. Remove the factory-in- stalled 182-ohm resistor.
Smoke Sensor Interface The ComfortLink controller includes an optional factory-installed return air smoke detector. Remote alarm circuits can be wired to TB5 terminal 8 and 9.
Fire Shutdown and Smoke Control The control supports in- terface to fire and smoke control systems and allows for the fol- lowing system overrides from remote switch inputs.
Fire Shutdown Connect to TB5 terminals 10 and 11. Smoke Pressurization Connect to TB5 terminals 12
and 13. This requires the use of the optional controls expansion module.
Smoke Evacuation Connect to TB5 terminals 12 and 14. This requires the use of the optional controls expansion module.
Smoke Purge Connect to TB5 terminals 12 and 15. This requires the use of the optional controls expansion module.
Demand Limiting The control can also be used with demand limiting control from remote building management systems. If a two-stage system is going to be used with redline limiting where the machine is not allowed to increase load and load shed where the load is decreased to a configurable limit in capacity then these can be connected to TB6 terminals 4 and 5, and 5 and 6. This requires use of the controls expansion module.
Step 10 Make Outdoor-Air Inlet Adjustments ECONOMIZER AND FIXED OUTDOOR AIR DAMPER Hoods are used on all units with economizer or adjustable self-closing fixed outdoor air damper. NOTE: If accessory power exhaust or barometric relief packages are being added to the unit, install power exhaust or barometric relief before installing economizer hoods.
Economizer Hood Assembly The economizer hood is shipped in a package secured to the outside of the unit. The hood assemblies must be field assembled. The 48A4,A5,A8,A9 units are side supply and side return. The return duct limits access to economizer filters from below. The 48A020-050 units have two hoods on every unit. The 48A060 units have 3 hoods on every unit. NOTE: Before assembly of the economizer hood, check along the outer edges of the economizer assembly for any seal strip protrud- ing past the flanges. Trim the excess seal strip so that it is flush with the economizer assembly flanges. Perform the following procedure to assemble the economizer hood. 1. Apply black seal strip (provided) to outside top-edge of hood
sides. Wrap seal strip over edge to cover top flange (2 hood sides per hood assembly). Make sure seal strip covers screw holes. See Fig. 27.
2. Add gray foam strip (provided) to cross members on bottom tray. See Fig. 28.
3. Assemble hood sides, top, and cross member with gasket- ed screws provided. See Fig. 29.
4. Attach speed clips (provided) to hood top. Engagement section of the clip faces inside hood. See Fig. 30.
5. Apply black seal strip (provided) to mounting flanges of hood sides being sure to cover mounting holes. See Fig. 31.
6. Apply black seal strip (provided) to back of hood top mount- ing flange. Seal strip of hood top mounting flange must press tightly against seal strip of hood side mounting flanges. See Fig. 31.
7. Attach gray foam strip (provided) to block-off baffle on out- er face of flange. See Fig. 32.
8. Remove the screws on each end and along top of the outdoor air opening of unit. Set hood assembly in place and attach to unit using gasketed screws. See Fig. 33.
9. Locate and mount block-off baffle using 3 screws. See Fig. 34.
10. Assemble bottom filter tracks side by side with the mounting angle together. The filter track assemblies must be installed with the flange and mounting angle pointing down. See Fig. 35-37.
11. Attach speed clips (provided) to hood side panels. Engage- ment section of clip faces up and towards the outside of the hood side panels. Attach mounting angles to hood with gas- keted screws provided. See Fig. 38. NOTE: Be sure the filters are installed with the airflow in the correct direction.
28
12. Attach filter track under the hood assembly. See Fig. 39. 13. Attach black seal strip (provided) to filter cover. Seal strip
should be applied centered over the holes of the one flange, making sure to fully cover holes and center over the other large flange. See Fig. 40.
14. Slide two 20 x 25-in. filters into cross members of hood as- sembly. Attach filter cover over filters with screws and speed clips provided. See Fig. 41.
TOP FLANGE
BLACK SEAL STRIP
HOOD SIDE
Fig. 27 Adding Seal Strip to Top of Hood Sides
GRAY FOAM STRIP
CROSS MEMBER
Fig. 28 Adding Foam Strip to Cross Member
HOOD SIDE
CROSS MEMBER HOOD
SIDE
HOOD TOP
Fig. 29 Economizer Hood Assembly
Fig. 30 Top Hood with Speed Clips
TOP HOOD
SIDE HOOD
CROSSMEMBER
SEAL STRIP
Fig. 31 Adding Seal Strip to Hood Top and Side Hoods
BLOCKOFF BAFFLE
GRAY FOAM STRIP
Fig. 32 Adding Foam Strip to Block-Off Baffle
Fig. 33 Removing Screws from the Outdoor Air Opening of Unit
29
BLOCK-OFF BAFFLE
Fig. 34 Mounting Block-Off Baffle to the Unit
Fig. 35 Correctly Assembled Bottom Filter Assembly, Sizes 020-035 Only
FILTER ASSEMBLY
MOUNTING ANGLE FASTENED TO BOTTOM OF FILTER ASSEMBLY
FLANGE POINTING DOWN
FILTER ASSEMBLY
MOUNTING ANGLE FASTENED TO BOTTOM OF FILTER ASSEMBLY
FLANGE POINTING DOWN
Fig. 36 Correctly Assembled Bottom Filter Assembly, Sizes 040-060 Only
Fig. 37 Flange and Mounting Angle Pointing Down
FILTER TRACK
MOUNTING ANGLE
SPEED CLIPS
Fig. 38 Bottom Filters Installed with Flange Pointing Down
FLANGE POINTING DOWN MOUNTING
ANGLE
Fig. 39 Bottom Filters Installed with Flange Pointing Down
Fig. 40 Attaching Seal Strip to Filter Cover
BLACK SEAL STRIP (CENTERED)
FILTER COVER
FILTER COVER
FILTERS
Fig. 41 Slide Two Filters
30
Step 11 Position Power Exhaust/Barometric Relief Damper Hood All units are shipped with the hoods folded inside the unit in a shipping position. For 48A2,A3,A6,A7 units the hood must be tilted out once the unit is installed. On 48A4,A5,A8,A9 units (designed for horizontal supply and return), the assemblies will have to be relocated to the return ductwork. See Fig. 42 for dimensions and details. All electrical connections have been made and adjusted at the factory. The power exhaust blowers and barometric relief dampers are shipped assembled and tilted back into the unit for shipping. Brackets and extra screws are shipped in shrink wrap around the dampers. If ordered, each unit will have 4 (48A020- 050 units) or 6 (48A060 units) power exhaust blowers and motors or barometric relief dampers. 1. Remove 9 screws holding each damper assembly in
place. See Fig. 43. Each damper assembly is secured with
3 screws on each side and 3 screws along the bottom. Save screws.
2. Pivot each damper assembly outward until edges of damper assembly rest against inside wall of unit.
3. Secure each damper assembly to unit with 6 screws across top (3 screws provided) and bottom (3 screws from Step 1) of damper.
4. With screws saved from Step 1, install brackets on each side of damper assembly.
5. Remove tape from damper blades.
CAUTION
Be careful when tilting blower assembly. Hoods and blow- ers are heavy and can cause injury if dropped.
Fig. 42 Power Exhaust Relocated to Side Return Duct (for CRPWREXH033A00, 034A00, 035A00, and 036A00)
42.56
42 MIN.
S/A
R/ A
ECONOMIZER HOOD
ECONOMIZER HOOD
J BO X
PLENUM RA TED CABLE (FIELD SUPPLIED )
12.94 (UNI T
OPENING)
END #2
END #1
AL TERNA TE LOCA TIO N (END)
23.28 TY P
42.62 TYP
LOCA TIO N BAROMETRIC RELIEF OR POWER EXHAUST SIDE #2
23.28
SIDE #1
42.62
J BO X
R/ A S/A
NOTES: 1. Unless otherwise specified, all dimensions are to outside of part. 2. Dimensions are in inches. 3. On 48A4,A5,A8,A9 units, accessory barometric relief or power exhaust must be mounted in the field-supplied return ductwork.
Fig. 43 Barometric Relief Damper and Power Exhaust Mounting Details (for CRPWREXH033A00, 034A00, 035A00, and 036A00)
a48-3808
31
Step 12 Route VAV Static Pressure Sensors VAV DUCT PRESSURE TRANSDUCER The VAV duct pressure transducer (VAV inverter pressure transducer) is locat- ed behind the filter access door on the lower inner panel. See Fig. 44. A section of field-supplied 1/4-in. plastic tubing must be run from the high pressure tap on the differential pressure switch and connected to a field-supplied tap in the supply-air duct. The tap is usually located 2/3 of the way out on the main supply duct. Remove plug button in panel to route tubing. VAV BUILDING PRESSURE TRANSDUCER The VAV building pressure transducer (modulating power ex- haust pressure transducer) is located behind the filter ac- cess door on the lower inner panel. See Fig. 44. A section of field-supplied 1/4-in. plastic tubing must be run from the high pressure tap on the differential pressure switch to the conditioned space. The pressure tube must be terminated in the conditioned space where a constant pressure is re- quired. This location is usually in an entrance lobby so that the building exterior doors will open and close properly. Remove plug button in panel to route tubing. The low pressure tap is factory-routed to the atmosphere. For a positive-pressure building, route the high tap to building air and low tap to atmosphere. For a negative-pressure building, route the high tap to atmosphere and the low tap to building air.
Step 13 Install All Accessories After all the factory-installed options have been adjusted, install all field-in- stalled accessories. Refer to the accessory installation instruc- tions included with each accessory. The 48A Series units have a large number of factory-installed options which were previously available only as accessories. Some of the available options can also be installed in the field if needed. In most cases the units have been pre-wired so that the accessories can be easily installed. Instructions are shipped with each accessory. Configuration of the controls for these accessories as well as the factory-installed options can be found in the Controls, Start-up, Operation, Service and Trou- bleshooting book. The following is a list of some of the com- mon accessories:
Thermostats and space temperature sensors LP (liquid propane) conversion kit Accessory barometric relief damper Accessory power exhaust Non-modulating to modulating power exhaust Condenser coil hail guards Outdoor humidity sensor (used for economizer enthalpy
changeover) Return air humidity sensors (used for economizer differ-
ential enthalpy changeover, factory-installed with Humidi-MiZer option)
Return air smoke detector Controls expansion module (used for interface to building
management systems, not typically needed on system with the Carrier Comfort Network [CCN] system)
Plugged filter sensor Motormaster V low ambient head pressure control
FIELD-FABRICATED WIND BAFFLES
In areas with prevailing winds of more than 5 mph and where temperatures drop below 32F, wind baffles must be field fab- ricated to ensure proper cooling cycle operation at low-ambi- ent temperatures with Motormaster V controls. Baffles are not needed on size 060 units with MCHX (microchannel heat exchangers). See Fig. 45 for baffle details. Use 20-gage galva- nized sheet metal, or similar corrosion-resistant material for the baffles. Use field-supplied screws to attach baffles to unit. Screws should be 1/4-in. diameter or larger. Screws should not be more than 1/2 inch in length. Drill required screw holes for mounting baffles.
IMPORTANT: Carrier recommends the installation of field-fabricated wind baffles on all vertically oriented condenser coils when operating in environments with prevailing winds of more than 5 mph and where tem- peratures drop below 32F. See the Motormaster accessory installation guide for instructions.
WARNING
To avoid the possibility of electrical shock, open all discon- nects before installing or servicing this accessory.
CAUTION
To avoid damage to refrigerant coils, electrical compo- nents, and wiring use extreme care when drilling screw holes and screwing in fasteners.
Fig. 44 Pressure Transducer Locations
a48-6976AUXILIARY CONTROL BOX
PRESSURE TRANSDUCERS (INSIDE OF PANEL)
32
Fig. 45 Wind Baffle Details
NOTE: 48A060 units with MCHX do not require baffles.
LEGEND MCHX Microchannel Heat Exchanger RTPF Round Tube Plate Fin Heat Exchanger
UNIT SIZE 48A QUANTITY
DIMENSION A in. mm
020-035 1 78.125 0.125 1984 3 036-050 2 78.125 0.125 1984 3
060 2 118 0.125 2997 3
SIZES 020-035
SIZES 036-050 AND 060 RTPF
33
Step 14 Perform Field Modifications DUCTWORK
Bottom Return Units (48A2,A3,A6,A7) Field-Modified for Side Return The 48A2,A3,A6,A7 units with bottom return air connections may be field-modified to accommodate side re- turn air connections.
Conversion to horizontal return requires that the bottom return openings of the unit must be sealed with airtight panels capable of supporting the weight of a person. The return ductwork con- nection locations on the side of the unit are higher than normal (31 in. high). Unit-mounted power exhaust or barometric relief cannot be used because return air ductwork will cover the power exhaust or barometric relief installation locations. Power exhaust or barometric relief may be installed in the return air ductwork. To convert the unit, perform the following: 1. Seal the bottom return openings of the unit with airtight
panels capable of supporting the weight of a person. 2. Remove the panels located below the economizer
outdoor-air dampers. These openings will be used for the return-air ductwork. There are 2 panels on 48A2,A3,A6,A7020-050 units. There are 3 panels on 48A2,A3,A6,A7060 units. These openings are nor- mally used for power exhaust or barometric relief.
3. Run the return air ductwork up to the openings. One sin- gle duct is recommended to connect to the unit over the return air openings. See Fig. 46. The return duct must in- corporate a minimum 3/4-in. flange for connection to the unit cabinet. The unit does not have duct flanges for this conversion.
Side Supply and Return Units (48A4,A5,A8,A9) with Field- Installed Power Exhaust in Return Duct Space must be available in the return duct to mount the power exhaust fan (gravity relief) modules. Dimensions and suggested locations are shown in Fig. 46. These instructions are a guideline and not a comprehensive procedure. The design contractor must pro- vide some design initiative. The wiring harness that is provided with the power exhaust accessory is not long enough for the fan modules to be mounted in the return air duct. Field-supplied wiring must be spliced into the harness. Use a junction box at each splice. The wiring may be run in the return duct, or externally in conduit. A service access panel will be needed near each power exhaust fan.
BACnet1 Communication Option Wiring WIRING THE UPC OPEN CONTROLLER TO THE MS/TP NETWORK The UPC Open controller communicates us- ing BACnet on an MS/TP network segment communications at 9600 bps, 19.2 kbps, 38.4 kbps, or 76.8 kbps. Wire the controllers on an MS/TP network segment in a daisy- chain configuration. Wire specifications for the cable are 22 AWG (American Wire Gage) or 24 AWG, low-capacitance, twisted, stranded, shielded copper wire. The maximum length is 2000 ft. Install a BT485 terminator on the first and last controller on a network segment to add bias and prevent signal distortions due to echoing. See Fig. 47-49. To wire the UPC Open controller to the BAS network: 1. Pull the screw terminal connector from the controllers
BAS Port. 2. Check the communications wiring for shorts and
grounds. 3. Connect the communications wiring to the BAS ports
screw terminals labeled Net +, Net -, and Shield. NOTE: Use the same polarity throughout the network segment. 4. Insert the power screw terminal connector into the UPC
Open controllers power terminals if they are not current- ly connected.
5. Verify communication with the network by viewing a module status report. To perform a module status report using the BACview2 keypad/display unit, press and hold the FN key, then press the . key.
To install a BT485 terminator, push the BT485 terminator on to the BT485 connector located near the BACnet connector. NOTE: The BT485 terminator has no polarity associated with it. To order a BT485 terminator, consult Commercial Products i-Vu Open Control System Master Prices. MS/TP WIRING RECOMMENDATIONS Recommen- dations are shown in Tables 11 and 12. The wire jacket and UL temperature rating specifications list two acceptable al- ternatives. The Halar3 specification has a higher tempera- ture rating and a tougher outer jacket than the SmokeGard4
specification, and it is appropriate for use in applications where the user is concerned about abrasion. The Halar jack- et is also less likely to crack in extremely low temperatures. NOTE: Use the specified type of wire and cable for maximum signal integrity.
IMPORTANT: The following section is a guideline and not a comprehensive procedure to field-modify the units. The installing contractor must provide some design initiative. Field conversion is complex and is not recommended.
1. BACnet is a registered trademark of ASHRAE (American Society of Heating, Refrigerating, and Air-Conditioning Engineers).
2. BACview is a registered trademark of Automated Logic Corporation. 3. Halar is a registered trademark of Solvay Plastics. 4. SmokeGard is a trademark of AlphaGary-Mexichem Corp.
34
Table 11 Open System Wiring Specifications and Recommended Vendors
LEGEND
WIRING SPECIFICATIONS RECOMMENDED VENDORS AND PART NUMBERS
WIRE TYPE DESCRIPTION CONNECT AIR INTERNATIONAL BELDEN RMCORP
CONTRACTORS WIRE AND
CABLE
MS/TP NETWORK (RS-485)
22 AWG, single twisted shielded pair, low capacitance, CL2P, TC foam FEP, plenum rated. See MS/TP Installation Guide for specifications.
W221P-22227 25160PV CLP0520LC
24 AWG, single twisted shielded pair, low capacitance, CL2P, TC foam FEP, plenum rated. See MS/TP Installation Guide for specifications.
W241P-2000F 82841 25120-OR
RNET 4 conductor, unshielded, CMP, 18 AWG, plenum rated. W184C-2099BLB 6302UE 21450 CLP0442
Fig. 46 Side Return Air Conversion a48-8371
31.25 INSIDE
RA
97.78 (027-050), 150.47 (060) INSIDE DIMENSION
AWG American Wire Gage CL2P Class 2 Plenum Cable CMP Communications Plenum Rated FEP Fluorinated Ethylene Polymer TC Tinned Copper
35
Table 12 MS/TP Wiring Recommendations
LEGEND
SPECIFICATION RECOMMMENDATION CABLE Single twisted pair, low capacitance, CL2P, 22 AWG (7x30), TC foam FEP, plenum rated cable
CONDUCTOR 22 or 24 AWG stranded copper (tin plated) INSULATION Foamed FEP 0.015 in. (0.381 mm) wall 0.060 in. (1.524 mm) O.D.
COLOR CODE Black/White TWIST LAY 2 in. (50.8 mm) lay on pair 6 twists/foot (20 twists/meter) nominal SHIELDING Aluminum/Mylar shield with 24 AWG TC drain wire
JACKET SmokeGard Jacket (SmokeGard PVC) 0.021 in. (0.5334 mm) wall 0.175 in. (4.445 mm) O.D. Halar Jacket (E-CTFE) 0.010 in. (0.254 mm) wall 0.144 in. (3.6576 mm) O.D.
DC RESISTANCE 15.2 Ohms/1000 feet (50 Ohms/km) nominal CAPACITANCE 12.5 pF/ft (41 pF/meter) nominal conductor to conductor
CHARACTERISTIC IMPEDANCE 100 Ohms nominal WEIGHT 12 lb/1000 feet (17.9 kg/km)
UL TEMPERATURE RATING SmokeGard 167F (75C) Halar -40 to 302F (-40 to 150C)
VOLTAGE 300 Vac, power limited LISTING UL: NEC CL2P, or better
AWG American Wire Gage CL2P Class 2 Plenum Cable DC Direct Current FEP Fluorinated Ethylene Polymer NEC National Electrical Code O.D. Outside Diameter TC Tinned Copper UL Underwriters Laboratories
Fig. 47 UPC Open Controller
876
5 4 321
09
876
5 4 321
09
BACNET BAUD RATE DIP SWITCHES
ADDRESS ROTARY SWITCHES
POWER LED
RUN LED
ERROR LED
BACNET CONNECTION (BAS PORT)
BT485 TERMINATOR
Tx2 LED
Rx2 LED
Tx1 LED
Rx1 LED
EIA-485 JUMPERS
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480230-01 Printed in U.S.A. Form 48A-20SI Pg 36 3-19 Replaces: 48A-18SI
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