Carrier RGV036 Installation Instructions Manual
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Carrier RGV036 Installation Instructions Manual

Carrier RGV036 Installation Instructions Manual

Single package rooftop gas heating/electric cooling unit with r-410a refrigerant
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . 1
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rated Indoor Airflow . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 1 - Plan for Unit Location . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 3 - Inspect Unit . . . . . . . . . . . . . . . . . . . . . 8
Step 4 - Provide Unit Support . . . . . . . . . . . . . 8
• ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR
Step 6 - Rig and Place Unit . . . . . . . . . . . . . . 10
Ductwork (When Required) . . . . . . . . . . . . . 11
HOOD PACKAGE REMOVAL AND SETUP (FACTO-
RY OPTION)
Step 10 - Install Flue Hood . . . . . . . . . . . . . . 13
Step 11 - Install Gas Piping . . . . . . . . . . . . . . 13
Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DISCONNECT
RGV036-072
Single Package Rooftop
Gas Heating/Electric Cooling Unit
with R-410A Refrigerant
Installation Instructions
Page
RGV-036-072-01SI
Integrated Gas Controller . . . . . . . . . . . . . . . . 26
X (Factory Option) . . . . . . . . . . . 28
®
2
Controller Options . . . . . . . . . . . . . . . . . . . . . . 41
Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . 41
®
Step 15 - Install Accessories . . . . . . . . . . . . 43
Step 16 - Fan Speed Set Up . . . . . . . . . . . . . 44
START-UP CHECKLIST. . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical
components. Only trained and qualified service personnel
should install, repair, or service air-conditioning equipment.
Untrained personnel can perform 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,
observe precautions in the literature, tags and labels
attached to the unit, and other safety precautions that may
apply.
Follow all safety codes, including ANSI (American National
Standards Institute) Z223.1. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations. Have
fire extinguisher available for all brazing operations.
It is important to recognize safety information. This is the
safety-alert symbol
. When you see this symbol on the
unit and in instructions or manuals, be alert to the potential
for personal injury.
10-22

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Summary of Contents for Carrier RGV036

  • Page 1: Table Of Contents

    RGV036-072 Single Package Rooftop Gas Heating/Electric Cooling Unit with R-410A Refrigerant Installation Instructions • HOT GAS RE-HEAT CONTROL CONNECTIONS CONTENTS • TYPICAL UNIT WIRING DIAGRAMS Page Integrated Gas Controller ....26 SAFETY CONSIDERATIONS .
  • Page 2 Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the CAUTION safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. PERSONAL INJURY HAZARD WARNING signifies hazards which could result in personal injury or death.

  • Page 3: Model Number Nomenclature And

    1/8 in. NPT pipe plug must be installed to prevent gas efficiency rating for the units covered in this document. leaks. Table 1 — Rated Indoor Airflow MODEL NUMBER RATED INDOOR AIRFLOW (cfm) RGV036/037 1050 RGV048/049 1500 RGV060 2000 RGV061...
  • Page 4 The following are not available as factory-installed options for models with this voltage code: coated or copper fin coils, economizers and two-position damper, powered convenience outlet, Hot Gas Re-Heat. Hot Gas Re-Heat system includes Low Ambient controller. Fig. 1 — RGV036-072 Model Number Nomenclature RGV-036-072-01SI Specifications subject to change without notice.
  • Page 5 For dimensions and drawings,036 also applies to 037; 048 also applies to 049; 060 also applies to 061. Fig. 2 — Unit Dimensional Drawing...
  • Page 6 For dimensions and drawings,036 also applies to 037; 048 also applies to 049; 060 also applies to 061. Fig. 2 — Unit Dimensional Drawing (cont)
  • Page 7 For dimensions and drawings,036 also applies to 037; 048 also applies to 049; 060 also applies to 061. Fig. 2 — Unit Dimensional Drawing (cont)

  • Page 8: Installation

    INSTALLATION Step 2 — Plan for Sequence of Unit Installation Jobsite Survey The support method used for this unit will dictate different Complete the following checks before installation. sequences for the steps of unit installation. For example, on 1. Consult local building codes and the NEC (National curb-mounted units, some accessories must be installed on Electrical Code) ANSI/NFPA 70 for special installa- the unit before the unit is placed on the curb.
  • Page 9 ROOF CURB NOTES: POWER WIRING CONTROL WIRING ACCESSORY CONVENIENCE CONNECTOR PKG. ACC. GAS CONNECTION TYPE GAS FITTING ACCESSORY # 1. ROOFCURB ACCESSORY IS SHIPPED DISASSEMBLED. FITTING FITTING OUTLET WIRING CONNECTOR 2. INSULATED PANELS: 25.4 [1"] THK. POLYURETHANE FOAM, 44.5 [1-3/4] # DENSITY. 14"...

  • Page 10: Slab Mount (Horizontal Units Only)

    NOTE: The gasketing of the unit to the roof curb is critical Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in for a watertight seal. Install gasket supplied with the roof accordance with applicable codes. curb as shown in Fig.

  • Page 11: Step 7 - Convert To Horizontal And Connect

    2. Hook rigging shackles through holes in base rail, as shown in Detail A. Holes in base rails are centered around the unit center of gravity. Use wooden top to prevent rigging straps from damaging unit. DIMENSIONS MAXIMUM WEIGHT UNIT RGV036/037 74.5 1890 37.6 33.5 RGV048/049 74.5...

  • Page 12: Step 8 - Install Outside Air Hood

    Screws Filter Access Panel Compressor Duct Covers Access Panel Sheet Metal Outdoor-Air Opening and Face Up Indoor Coil Access Panel Fig. 9 — Typical Access Panel Locations Basepan Hood Parts Fig. 8 — Horizontal Duct Panels In Place Step 8 — Install Outside Air Hood Plastic Tie Wrap ECONOMIZER AND TWO-POSITION DAMPER HOOD Qty (2)

  • Page 13: Step 9 - Units With Hinged Panels Only

    7. Replace the filter access panel. Compressor Door Outdoor Coil Panel Latch Fig. 14 — Compressor Door Latch Location Panel Step 10 — Install Flue Hood Caulk Here Flue hood is shipped screwed to the basepan beside the Indoor Indoor burner compartment access panel.

  • Page 14: Factory Option Thru-Base Connections

    X DIMENSION (ft) NOTE(S): 3/4 or 1 Low Fire, 1.7 in. wg (423 Pa), applies to the following 3-phase voltage units only: RGV036*E and RGV048/060/072*F. 1-1/4 or larger Table 6 — Liquid Propane Manifold Pressure Ranges Fig. 16 — Gas Piping Guide...
  • Page 15 between the “L” bracket and the connector plate assembly). NOTE: Take care not to damage the gasket, as it is reused in the following step. 3. Place the gasket over the embossed area in the basepan, aligning the holes in the gasket to the holes in the basepan.
  • Page 16 When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to the NFPA 54/ANSI Z223.1 NFGC latest edition (in Canada, CAN/CSA B149.1). In the absence of local building codes, adhere to 9" (229 mm) Minimum the following pertinent recommendations: •...

  • Page 17: Step 12 - Install External Condensate Trap And

    Minimum Pitch 1 in. (25 mm) Per Base Rail 10 ft. (3m) of Line 3 in. (76 mm) Open Vent See Note To Roof Drain Burner Roof Orifice Curb Drain Plug NOTE: Trap should be deep enough to offset maximum unit static difference.

  • Page 18: Units With Factory-Installed Non-Fused

    2. Remove 3 cap head screws that secure the NFD enclo- sure front cover — 2 on the face of the cover and 1 on WARNING the left side cover. See Fig. 29. FIRE HAZARD 3. Remove the front cover of the NFD enclosure. Failure to follow this warning could result in personal 4.

  • Page 19: Units Without Factory-Installed Non-Fused Disconnect

    UNITS WITHOUT FACTORY-INSTALLED NON-FUSED CONVENIENCE OUTLETS DISCONNECT When installing units, provide a disconnect switch per WARNING NEC (National Electrical Code) of adequate size. Disconnect sizing data is provided on the unit informative ELECTRICAL OPERATION HAZARD plate. Locate on unit cabinet or within sight of the unit per Failure to follow this warning could result in personal national or local codes.

  • Page 20: Factory-Option Thru-Base Connections (Electrical Connections)

    provide service power to the unit when the unit disconnect switch is open. Other connection methods will result in the WARNING convenience outlet circuit being de-energized when the unit disconnect switch is open. See Fig. 33. ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death.

  • Page 21: Units Without Thru-Base Connections (Electrical Connections)

    Check tightness of connector lock nuts before connecting electrical conduits. Typical Unit Field-supplied and field-installed liquid tight conduit connec- Thermostat Control tors and conduit may be attached to the connectors on the Connections Board basepan. Pull correctly rated high voltage and low voltage through appropriate conduits.

  • Page 22: Heat Anticipator Settings

    HEAT ANTICIPATOR SETTINGS Unit Control Set heat anticipator settings at 0.14 amp for the first stage Board and 0.14 amp for second-stage heating, when available. HOT GAS RE-HEAT CONTROL CONNECTIONS Hot Gas Re-Heat Space RH Controller NOTE: The Hot Gas Re-Heat system is a factory-installed option.
  • Page 23 Fig. 38 — Typical RGV036-060 Control Wiring Diagram with Electromechanical and W7212, 208/230V-3-60 Unit Shown...
  • Page 24 Fig. 39 — Typical RGV072 Control Wiring Diagram with Electromechanical and W7220, 208/230V-3-60 Unit Shown...
  • Page 25 Fig. 40 — Typical RGV036-072 Power Wiring Diagram, 208/230V Unit Shown RGV-036-072-01SI Specifications subject to change without notice.

  • Page 26: Integrated Gas Controller

    Integrated Gas Controller When the thermostat calls for heating, power is sent to W on the Integrated Gas Controller (IGC) board. An LED (light This unit contains an Integrated Gas Controller (IGC) board. emitting diode) on the IGC board turns on and remains on The IGC control board uses a flue gas pressure switch that during normal operation.
  • Page 27 UNIT CONTROL BOARD Fig. 43 — Typical IGC Control Wiring Diagram Table 7 — IGC Board LED Alarm Codes a,b,c LED FLASH ACTION TAKEN BY DESCRIPTION RESET METHOD PROBABLE CAUSE CODE CONTROL Normal Operation — — — Hardware Failure No gas heating. Loss of power to the IGC.

  • Page 28: Economi$Er ® X (Factory Option)

    EconoMi$er X (Factory Option) ® User Interface Provides status for normal operation, setup parameters, The EconoMi$er X system is an expandable economizer checkout tests, and alarm and error conditions with a 2-line control system, which includes a W7220 economizer mod- 16 character LCD display and 4 button keypad.

  • Page 29: Economizer Module Wiring Details

    Exception of display operation down to –4°F (–20°C) with Table 8 — Economizer Module — Left Hand Terminal full recovery at –4°F (–20°C) from exposure to –40°F Blocks (–40°C) Storage Temperature LABEL TYPE DESCRIPTION –40 to 150°F (–40 to 65°C) Top Left Terminal Block Shipping Temperature 20k NTC...

  • Page 30: Co 2 Sensor Wiring

    Sensor (Hot) Black Yellow Analog Brown – Orange Green Switch Label Power Supply. Provide Disconnect Means and Overload Protection As Required. Fig. 47 — CO Sensor Wiring Switches INTERFACE OVERVIEW This section describes how to use the EconoMi$er user in- ®...

  • Page 31: Setup And Configuration

    To use the keypad when working with Setpoints, System IMPORTANT: Table 12 illustrates the complete hierarchy. and Advanced Settings, Checkout tests and Alarms: Your menu parameters may be different depending on 1. Navigate to the desired menu. your configuration. 2. Press the (Enter) button to display the first item in For example, if you do not have a DCV (CO ) sensor, then...
  • Page 32 Table 12 — W7220 Menu Structure PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT FIRST STAGE COOLING DEMAND (Y1–IN) ECONO AVAIL YES/NO YES = economizing available; the system can use outside air for free cooling when required. FIRST STAGE COOLING RELAY OUTPUT ECONOMIZING YES/NO YES = outside air being used for 1 stage cooling.
  • Page 33 Table 12 — W7220 Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT MECH COOL ON Displays stage of mechanical cooling that is active. 0, 1, or 2 HEAT STAGES ON Displays the stage of heat pump heating that is active. STATUS SUPPLY FAN SPEED (cont)
  • Page 34 Table 12 — W7220 Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT Exhaust fan set point for single-speed units. Based on OA Damper EXH1 SET 0 to 100% position to activate power exhaust. EXHAUST FAN 1 SETPOINT AT LOW SPEED on 2 speed or EXH1 L SET 0 to 100% 3 speed with 1 heat and 2 cool.
  • Page 35 Table 12 — W7220 Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT COOLING STAGE 3 DELAY 0 min, 5 min, Delay after stage 2 cool has been active. Turns on second stage of 15 min, then cooling when economizer is first stage and mechanical cooling is STG3 DLY 2.0h...
  • Page 36 Table 12 — W7220 Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT DISCHARGE AIR S-BUS SENSOR ERROR DA SYLK T ERR — — Discharge air sensor has failed or become disconnected — check wiring and then replace sensor if the alarm continues. OUTSIDE AIR TEMPERATURE SENSOR ERROR OA SENS T ERR —...

  • Page 37: Enthalpy Settings

    ENTHALPY SETTINGS and OA dew point are all below the selected boundary, the economizer sets the economizing mode to YES, When the OA temperature, enthalpy and dew point are economizing is available. below the respective set points, the Outdoor Air can be When all of the OA conditions are above the selected used for economizing.

  • Page 38: Standard Or Single-Speed Fan Operation

    STANDARD OR SINGLE-SPEED FAN OPERATION The W7220 controller will control a standard 1-speed unit when configured for FAN TYPE = 1 SPEED. Refer to Table 14 for economizer operation. Table 14 — Economizer Operation — FAN TYPE = 1SPEED INPUTS OUTPUTS Demand Damper Position...

  • Page 39: Speed Fan Operation

    2 SPEED FAN OPERATION The 2-speed fan delay is available when the system is programmed for 2-speed fan (in the System Setup menu NOTE: 2-Speed Fan operation applies to RGV072 mod- item). The 2-speed fan delay is defaulted to 5 minutes els only.

  • Page 40: 2Sp H/C (2-Speed Heat/Cool) Fan Operation (Single Phase Units Only)

    2SP H/C (2-SPEED HEAT/COOL) FAN OPERATION On single phase RGV 036/037 to 048/049 ton units, if re- duced the heating fan speed is lower than the cooling (SINGLE PHASE UNITS ONLY) speed and the economizer FAN TYPE needs to be set to The W7220 controller does not actually control the fan 2SP H/C (2-speed Heat/Cool).

  • Page 41: Checkout

    CHECKOUT Inspect all wiring connections at the economizer module’s CAUTION terminals, and verify compliance with the installation wiring diagrams. For checkout, review the Status of each config- EQUIPMENT DAMAGE HAZARD ured parameter and perform the Checkout tests. Failure to follow this caution may result in equipment NOTE: For information about menu navigation and use of damage.
  • Page 42 3. Screw the sensor and detector plate into its operating position using screws from Step 1. See Fig. 51, Step 3. 4. Connect the flexible tube on the sampling inlet to the Return Air Smoke Detetor sampling tube on the basepan. (As Shipped) Additional Application Data Refer to the application data document “Factory Installed...

  • Page 43: Step 14 - Adjust Factory-Installed Options

    Step 14 — Adjust Factory-Installed Options Step 15 — Install Accessories Available accessories include: SMOKE DETECTORS • Roof curb Smoke detector(s) will be connected at the Unit Control • Thru-base connection kit (must be installed before Board (UCB), at terminals marked “Smoke Shutdown.” De- tach the jumper covering the Smoke Shutdown terminals on unit is set on roof curb) the UCB and then attach the wiring harness from the smoke...

  • Page 44: Step 16 - Fan Speed Set Up

    Step 16 — Fan Speed Set Up UNITS WITH ELECTROMECHANICAL CONTROLS The fan speed set up controls are located on the lower sec- tion of the Unit Control Board (UCB). See Fig. 53 for the lo- cation on 3-phase voltage units or Fig. 54 for the location on single phase voltage units.
  • Page 45 ESP in. wg Factory Setting: Calculator 9.0 V 1500 Field Setting: 1625 Record field setting here 10.0 1750 1875 2000 Switch Range: 2125 2250 4.1 - 7.5 2375 6.9 - 8.7 2500 7.7 - 10.0 Field Accessories: Economizer * Overlap in A, B, C switch range designed for maximum field adjustment potential.
  • Page 46 © 2022 Carrier Lewisburg, TN 37091 USA Replaces: 52501150101 RGV-036-072-01SI Specifications are subject to change without notice.

  • Page 47: Start-Up Checklist

    START-UP CHECKLIST FOR RGV036-072 SINGLE PACKAGE ROOFTOP GAS HEATING/ELECTRIC COOLING UNIT (Remove and use for job file) NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sections of this Installation Instruction document.
  • Page 48 (Y/N) _____ 9. Open humidistat input compressor and outdoor fan stop; LSV and DSV solenoids de-energized. (Y/N) _____ 10. Restore set points for thermostat and humidistat. (Y/N) _____ © 2022 Carrier Lewisburg, TN 37091 USA Replaces: 52501150101 RGV-036-072-01SI CL-2 Specifications are subject to change without notice.

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