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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . 1-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEIVING AND INSTALLATION . . . . . . . . . . . 7-14
Step 1 - Check Equipment . . . . . . . . . . . . . . . .
Step 2 - Provide Unit Support . . . . . . . . . . . . . . 7
Step 3 - Field Fabricate Ductwork . . . . . . . . . .
Step 4 - Provide Clearances . . . . . . . . . . . . . . .
Step 5 - Rig and Place Unit . . . . . . . . . . . . . . . .
Step 6 - Connect Condensate Drain . . . . . . . .
Step 7 - Install Flue Hood . . . . . . . . . . . . . . . . .
Step 8 - Install Gas Piping . . . . . . . . . . . . . . . . .
Step 9 - Install Duct Connections . . . . . . . . . . 10
Step 10 - Install Electrical Connections . . . . . 12
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-25
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-29
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 30-32
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . CL-1
NOTE TO INSTALLER - READ THESE INSTRUC-
TIONS CAREFULLY AND COMPLETELY before install-
ing this unit (Fig. 1). Also, make sure the User's Manual and
Replacement Guide are left with the unit after installation.
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment
can be hazardous due to system pressure and electrical com-
ponents. Only trained and qualified personnel should
install, repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance func-
tions 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, and other safety
precautions that may apply.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 111
Tab
5a 5a
Installation, Start-Up and
Service Instructions
Page
Catalog No. 534-722
Printed in U.S.A.
Dual Fuel Heat Pump Units
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire ex-
tinguisher available for all brazing operations.
Understand the signal words - DANGER, WARNING,
1
and CAUTION. Danger identifies the most serious hazards
which will result in severe personal injury or death. Warning
7
indicates a condition that could result in personal injury. Cau-
tion is used to identify unsafe practices which would result
in minor personal injury or product property damage.
Improper installation, adjustment, alteration, service, main-
7
tenance, or use can cause carbon monoxide poisoning,
fire, or an explosion which can result in personal injury
7
or unit damage. Consult a qualified installer, service agency,
7
or gas supplier for information or assistance. The quali-
fied installer or agency must use only factory-authorized
kits or accessories when modifying this product.
8
8
8
Before performing service or maintenance operations on
unit, turn off gas supply then unit main power switch.
Electrical shock could cause personal injury.
General -
The 48HX units (see Fig. 1) are fully self-
contained, combination electric heat pump units with
gas-fired back-up heat. The units are designed for outdoor
installation. See Fig. 2-5 for unit dimensions. All unit sizes
have discharge openings for both horizontal and down-
flow configurations, and are factory shipped with all 4 duct
openings covered. Units may be installed either on a rooftop
or a ground-level cement slab. See Fig. 6 for roof curb
dimensions.
Fig. 1 - Typical 48HX Unit Shown with Optional
Form 48HX-3SI
48HX030-060
Base Rail
Pg 1
9-98
Replaces: 48HX-2SI
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Summary of Contents for Carrier 48HX030-060
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Page 1: Table Of Contents
48HX030-060 Dual Fuel Heat Pump Units Installation, Start-Up and Service Instructions Follow all safety codes. Wear safety glasses and work gloves. CONTENTS Use quenching cloth for unbrazing operations. Have fire ex- Page tinguisher available for all brazing operations. SAFETY CONSIDERATIONS ....1-6 Understand the signal words —... - Page 2 REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct Panel ........0 Unit Top .
- Page 3 REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct Panel ....... 0 Unit Top .
- Page 4 REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct Panel ........0 Unit Top .
- Page 5 REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct Panel ........0 Unit Top .
- Page 6 PART NUMBER ‘‘A’’ CPRFCURB001A00 8 [203] FLAT CPRFCURB002A00 11 [279] CPRFCURB003A00 14 [356] NOTES: 1. Roof curb must be set up for unit being installed. 2. Seal strip must be applied as required for unit being installed. 3. Dimensions in [ ] are in millimeters. 4.
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Page 7: Receiving And Installation
Check all items against shipping list. Immediately notify Fig. 7 — Unit Leveling Tolerances the nearest Carrier Air Conditioning office if any item is missing. To prevent loss or damage, leave all parts in original pack- discharge openings. -
Page 8: Units Without Base Rail
Use extreme caution to prevent damage when moving the unit. Unit must remain in an upright position during all rig- ging and moving operations. The unit must be level for proper condensate drainage; therefore, the ground-level pad or accessory roof curb must be level before setting the unit in place. - Page 9 NOTICE TO RIGGERS Hook rigging shackles through holes in lifting brackets, as shown in Details ‘‘A’’ and ‘‘C.’’ Lifting brackets to be centered around the unit All panels must be in place when rigging. center of gravity. Use wooden top skid when rigging, to prevent rig- ging straps from damaging unit.
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Page 10: Step 9 - Install Duct Connections
Fig. 10 — Condensate Trap 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 unit is operating. For propane applica- tions, the gas pressure must not be less than 4.0 in. wg or greater than 13 in. - Page 11 7. If unit ductwork is to be attached to vertical opening 10. After completing unit conversion, perform all safety checks flanges on the unit basepan (jackstand applications only), and power up unit. do so at this time. NOTE: The design and installation of the duct system must 8.
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Page 12: Step 10 - Install Electrical Connections
Table 2 — Maximum Gas Flow Capacity* NOMINAL LENGTH OF PIPE, FT† INTERNAL IRON PIPE, DIAMETER SIZE (in.) (in.) ⁄ .622 — — ⁄ .824 1.049 ⁄ 1.380 1400 ⁄ 1.610 2100 1460 1180 *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). - Page 13 Power Entry 1. Remove knockouts in fixed compressor panel located on duct panel side of unit. 2. Route high-voltage leads into high-voltage terminal box. 3. Connect ground wire to green-yellow wire using field- supplied splice. 4. Connect power wires to unit high-voltage leads. 5.
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Page 14: Special Procedures For 208-Voperation
SPECIAL PROCEDURES FOR 208-V OPERATION Make sure that the gas supply then the power supply to the unit is switched OFF before making any wiring changes. Electrical shock can cause personal injury or death. 1. Disconnect the red transformer-primary lead from the con- tactor. -
Page 15: Pre-Start-Up
a. Before lighting the unit for the first time, perform the PRE-START-UP following: If the gas supply pipe was not purged be- fore connecting the unit, it will be full of air. It is rec- ommended that the ground joint union be loosened, and the supply line be allowed to purge until the odor Failure to observe the following warnings could result of gas is detected. - Page 16 of 2500 Btu/ft at 1.5 specific gravity. For elevations above Start Up Heating Section and Make 2000 ft, reduce input 4% for each 1000 ft above sea level. Adjustments When the gas supply being used has a different heating value or specific gravity, refer to national and local codes, or con- tact your distributor to determine the required orifice size.
- Page 17 If the desired gas input is 80,000 Btuh, only a minor change in the manifold pressure is required. Observe manifold pressure and proceed as follows to ad- just gas input: 1. Remove cover screw over regulator adjustment screw on gas valve. 2.
- Page 18 Table 5 — Air Delivery (Cfm) at Indicated Temperature Rise and Rated Heating Input HEATING TEMPERATURE RISE °F INPUT (Btuh) 40,000 1389 1111 — — — — — — 56,000 1944 1556 1296 1111 — — — — — 80,000 2778 2222 1852...
- Page 19 Table 6A — Superheat Charging Table, 48HX030 INDOOR AIR — 1000 CFM TEMP (F) OUTDOOR Indoor Air — Ewb (F) ENTERING AIR 12.5 19.6 26.6 26.9 27.2 27.5 26.5 25.4 10.5 17.5 24.5 24.8 25.1 25.4 25.1 24.8 15.5 22.5 22.8 23.1 23.4...
- Page 20 Table 6D — Superheat Charging Table, 48HX060 INDOOR AIR — 1800 CFM TEMP (F) OUTDOOR Indoor Air — Ewb (F) ENTERING AIR 21.0 21.0 21.0 21.0 22.8 24.7 26.5 27.8 29.1 30.4 29.5 28.6 16.5 16.5 16.5 16.5 18.8 21.1 23.5 25.2 27.0...
- Page 21 Table 8 — Dry-Coil Air Delivery* — Horizontal and Downflow Discharge at 230 and 460 V — Size 030,036 (Deduct 10% from Cfm and Watts for 208 V Operation) EXTERNAL STATIC PRESSURE (in. wg) UNIT MOTOR 48HX SPEED DELIVERY Watts †...
- Page 22 Table 11 — Dry-Coil Air Delivery* Cooling and Heat Conversely, if the local cost of electricity is low or the Pump Heating; Sizes 048,060; Horizontal and local cost of gas is high, it is cost effective to switch to gas- Vertical Discharge for Integrated Control fired heating at a colder outdoor temperature.
- Page 23 satisfied, contacts open, deenergizing contactor and relay; coil (BR) (through unit wire G) across the 24-v secondary of motors and gas heater deenergize. The IFM may be con- transformer (TRAN). trolled by a time-delay relay that keeps the fan on for NOTE: The blower relay coil (BR) is used on non-ICM 30 seconds.
- Page 24 OUTDOOR COIL INDOOR COIL Check Valves Open Closed STRAINER Open Closed LEGEND LCS — Loss of Charge Switch Acutrol™ Metering Device Check Valve (Arrow indicates direction of flow) HEATING CYCLE 1. Hot gas from compressor flows through the 4-way valve and is 3.
- Page 25 OUTDOOR COIL INDOOR COIL Check Valves Closed STRAINER Open Closed Open LEGEND LCS — Loss of Charge Switch Acutrol™ Metering Device Check Valve (Arrow indicates direction of flow) COOLING CYCLE 1. Hot gas from compressor flows through the 4-way valve and is 3.
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Page 26: Maintenance
Inspect air filter(s) at least once each month and replace MAINTENANCE (throwaway-type) or clean (cleanable-type) at least twice dur- To ensure continuing high performance, and to minimize ing each heating and cooling season or whenever the the possibility of premature equipment failure, periodic main- filter(s) becomes clogged with dust and lint. - Page 27 c. Use a good grade of SAE (Society of Automotive En- gineers) 20 nondetergent motor oil and put one tea- spoon ( ⁄ oz. or 16 to 25 drops) in each oil port. d. Allow time for oil to be absorbed by each bearing, then wipe excess oil from motor housing.
- Page 28 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).
- Page 29 leak-detector, halide torch, or liquid-soap solution. If a Electrical Controls and Wiring — Inspect and check refrigerant leak is detected, refer to Check for Refrigerant the electrical controls and wiring annually. Be sure to turn Leaks section on page 15. off the gas supply, and then the electrical power to the unit.
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Page 30: Troubleshooting
TROUBLESHOOTING Cooling and Heating SYMPTOM CAUSE REMEDY Compressor and out- OAT set above outdoor ambient temperature Lower OAT setting. door fan will not start. Power failure Call power company. Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker. Defective thermostat, contactor, transformer, Replace component. - Page 31 Cooling and Heating (cont) SYMPTOM CAUSE REMEDY Excessive suction (Cool) High heat load Check for source and eliminate. pressure. Reversing valve hung up or leaking internally Replace valve. Refrigerant overcharged Recover excess refrigerant. Suction pressure too (Cool) Dirty air filter Replace filter.
- Page 32 LED Troubleshooting — Error Code SYMPTOM CAUSE REMEDY Hardware failure. Loss of power to control module Check 5 amp fuse on IGC, power to unit, 24-v circuit (LED OFF) (IGC). 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 minutes for automatic reset.
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Page 34: Book 1 4 Pc 111 Catalog No. 534-722 Printed In U.s.a
Copyright 1998 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4 PC 111 Catalog No. 534-722 Printed in U.S.A. Form 48HX-3SI Pg 34 9-98... -
Page 36: Start-Up Checklist
VERIFY REFRIGERANT CHARGE USING CHARGING TABLES VERIFY THAT 3-PHASE SCROLL COMPRESSOR IS ROTATING IN CORRECT DIRECTION Copyright 1998 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.