Carrier RGV036 G Series Installation Instructions Manual

Single package rooftop ultra low nox 14 ng/j gas heating/electric cooling unit with r-410a refrigerant

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Ultra Low NOx (14 ng/J) Gas Heating/Electric Cooling Unit

CONTENTS

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . 1

MODEL NUMBER NOMENCLATURE AND

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Rated Indoor Airflow . . . . . . . . . . . . . . . . . . . . . 3

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 1 — Plan for Unit Location . . . . . . . . . . . . 8

• ROOF MOUNT

Step 2 — Plan for Sequence of Unit

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

• CURB-MOUNTED INSTALLATION

• PAD-MOUNTED INSTALLATION

• FRAME-MOUNTED INSTALLATION

Step 3 — Inspect Unit . . . . . . . . . . . . . . . . . . . . . 8

Step 4 — Provide Unit Support . . . . . . . . . . . . . 8

• ROOF CURB MOUNT

• SLAB MOUNT (HORIZONTAL UNITS ONLY)

• ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR

SLAB MOUNT)

Step 5 — Field Fabricate Ductwork . . . . . . . . . 10

Step 6 — Rig and Place Unit . . . . . . . . . . . . . . 10

• POSITIONING ON CURB

Step 7 — Convert to Horizontal and Connect

Ductwork (When Required) . . . . . . . . . . . . . 11

Step 8 — Install Outside Air Hood . . . . . . . . . 12

• ECONOMIZER AND TWO-POSITION DAMPER

HOOD PACKAGE REMOVAL AND SETUP

(FACTORY OPTION)

• ECONOMIZER AND TWO-POSITION HOOD

Step 9 — Units with Hinged Panels Only . . . . 13

Step 10 — Install Flue Hood . . . . . . . . . . . . . . 13

Step 11 — Install Gas Piping . . . . . . . . . . . . . . 13

• FACTORY OPTION THRU-BASE CONNECTIONS

(GAS CONNECTIONS)

Step 12 — Install External Condensate Trap and

Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Step 13 — Make Electrical Connections . . . . . 17

• FIELD POWER SUPPLY

• UNITS WITH FACTORY-INSTALLED NON-FUSED

DISCONNECT

• UNITS WITHOUT FACTORY-INSTALLED

NON-FUSED DISCONNECT

• ALL UNITS

• CONVENIENCE OUTLETS

• FACTORY-OPTION THRU-BASE CONNECTIONS

(ELECTRICAL CONNECTIONS)

• UNITS WITHOUT THRU-BASE CONNECTIONS

(ELECTRICAL CONNECTIONS)

• FIELD CONTROL WIRING

• THERMOSTAT

• HEAT ANTICIPATOR SETTINGS

RGV036-061*G

Single Package Rooftop

with R-410A Refrigerant

Installation Instructions

Page

RGVG-036-061-02SI

• HOT GAS RE-HEAT CONTROL CONNECTIONS

• TYPICAL UNIT WIRING DIAGRAMS

Integrated Gas Controller . . . . . . . . . . . . . . . . 27

EconoMi$er X (Factory Option) . . . . . . . . . . . . 31

• SYSTEM COMPONENTS

• SPECIFICATIONS

• INPUTS

• OUTPUTS

• ENVIRONMENTAL

• ECONOMIZER MODULE WIRING DETAILS

• S-BUS SENSOR WIRING

• CO

SENSOR WIRING

• INTERFACE OVERVIEW

• SETUP AND CONFIGURATION

• TIME-OUT AND SCREENSAVER

• ENTHALPY SETTINGS

• STANDARD OR SINGLE SPEED FAN OPERATION

• 2 SPEED FAN OPERATION

• 2SP H/C (2 SPEED HEAT/COOL) FAN OPERATION

(SINGLE PHASE UNITS ONLY)

• 3 SPEED FAN OPERATION

• CHECKOUT

• TROUBLESHOOTING

Controller Options . . . . . . . . . . . . . . . . . . . . . . 44

• LOW AMBIENT

Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . 45

Step 14 — Adjust Factory-Installed Options . 46

• SMOKE DETECTORS

• ECONOMI$ER IV OCCUPANCY SWITCH

Step 15 — Install Accessories . . . . . . . . . . . . 46

Step 16 — Fan Speed Set Up . . . . . . . . . . . . . 47

• UNITS WITH ELECTRO-MECHANICAL CONTROLS

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.

3-23

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Summary of Contents for Carrier RGV036 G Series

Page 1 RGV036-061*G Single Package Rooftop Ultra Low NOx (14 ng/J) Gas Heating/Electric Cooling Unit with R-410A Refrigerant Installation Instructions CONTENTS Page • HOT GAS RE-HEAT CONTROL CONNECTIONS • TYPICAL UNIT WIRING DIAGRAMS SAFETY CONSIDERATIONS ....1 Integrated Gas Controller .
Page 2 It is important to recognize safety information. This is the safety-alert symbol . When you see this symbol on the WARNING unit and in instructions or manuals, be alert to the potential for personal injury. CARBON-MONOXIDE POISONING HAZARD Understand the signal words DANGER, WARNING, Failure to follow instructions could result in severe CAUTION, and NOTE.
Page 3 WARNING CAUTION FIRE HAZARD UNIT OPERATION HAZARD Failure to follow this warning could result in severe per- Do not detach the burner box from the heat exchanger sonal injury and/or property damage. panel. If the burner box must be replaced, refer to the Service and Maintenance Instructions for the unit.
Page 4 MODEL SERIES Position Number R = Rooftop G = Gas Heat / Electric Cooling Type V = 14 SEER (036-060) Standard Efficiency 036 = 36,000 BTUH = 3 Tons 037 = 36,000 BTUH = 3 Tons SEER2¹ Nominal 048 = 48,000 BTUH = 4 Tons 049 = 48,000 BTUH = 4 Tons SEER2¹...
Page 5 Fig. 2 — Unit Dimensional Drawing...
Page 6 Fig. 2 — Unit Dimensional Drawing (cont)
Page 7 Fig. 2 — Unit Dimensional Drawing (cont)
Page 8 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 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 accor- for a watertight seal. Install gasket supplied with the roof dance with applicable codes. curb as shown in Fig.
Page 11 Place all seal strips in place before "B" placing unit 36-54 in. Required Detail "A" on roof curb (914-1371 mm) Spreader Bars Duct End "C" Side "A" See Detail "A" NOTE(S): 1. SPREADER BARS ARE REQUIRED. Top damage will occur if spreader bars are not used. 2.
Page 12 Filter Access Panel Screws 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 2. Swing out indoor coil access panel and insert the hood sides under the panel (hood top). Use the screws pro- vided to attach the hood sides to the hood top. Use screws provided to attach the hood sides to the unit. See Fig.
Page 14 The gas supply pipe enters the unit at the burner access FACTORY OPTION THRU-BASE CONNECTIONS panel on the front side of the unit, through the long slot at (GAS CONNECTIONS) the bottom of the access panel. The gas connection to the This service connection kit consists of a 1/2 in.
Page 15 washer head screws and the gasket (located between the “L” bracket and the connector plate assembly). 9" (229 mm) Minimum 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 Thru-Curb Adapter Union basepan, aligning the holes in the gasket to the holes...
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 the following pertinent recommendations: •...
Page 17 Step 12 — Install External Condensate Trap and Step 13 — Make Electrical Connections Line The unit has one 3/4-in. condensate drain connection on WARNING the end of the condensate pan and an alternate connection on the bottom. See Fig. 24. Unit airflow configuration does Failure to follow this warning could result in personal not determine which drain connection to use.
Page 18 9. Install the handle on to the painted cover horizontally Units Without Non-Fused Disconnect Option with the red arrow pointing to the left. 10. Secure the handle to the painted cover with (2) screws and lock washers supplied. 11. Engaging the shaft into the handle socket, re-install (3) hex screws on the NFD enclosure.
Page 19 All units except 208/230v units are factory wired for the volt- Convenience age shown on the nameplate. If the 208/230v unit is to be Outlet GFCI connected to a 208v power supply, the control transformer PWD-CO Fuse must be rewired by moving the black wire with the 1/4-in. fe- Switch male spade connector from the 230v connection and mov- ing it to the 200v 1/4-in.
Page 20 4. Mount the weatherproof cover to the backing plate as shown in Fig. 32. 5. Remove two slot fillers in the bottom of the cover to per- mit service tool cords to exit the cover. 6. Check for full closing and latching. GFCI Receptacle Cover —...
Page 21 field cut in the main control box bottom on the left side so Thermostat Wiring, Units Without Thru-Base the 24-v control connections can be made. Connect the Connection Kit control power conduit to the unit control box at this hole. Pass the thermostat control wires through the hole provided in the corner post;...
Page 22 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 Control Wiring Diagram, Electro-Mechanical with W7212 (RGV036-061*G/H 208/230-3-60 Unit Shown)
Page 24 Fig. 39 — Typical Control Wiring Diagram, Electro-Mechanical with W7220 (RGV036-061*G/H 208/230-3-60 Unit Shown)
Page 25 Fig. 40 — Typical RGV036-061*G/H Power Wiring Diagram, 208/230-3-60 Unit Shown RGVG-036-061-02SI Specifications subject to change without notice.
Page 26 Fig. 41 — Typical RGV036-061*G/H Power Wiring Diagram for 460-3-60 Electro-Mechanical Units Shown RGVG-036-061-02SI Specifications subject to change without notice.
Page 27 Integrated Gas Controller the pressure switch is open. If the check was successful, the induced draft motor is energized. When the pressure in This unit contains an Integrated Gas Controller (IGC) board. the heat exchanger is low enough to close the pressure The IGC control board uses a flue gas pressure switch that switch, the ignition activation period begins.
Page 28 Spade Connect Ignitor Redundant Gas Valve Relay Status LED Overcurrent Fuse Protection Fig. 43 — IGC Board Component Layout UNIT CONTROL BOARD Fig. 44 — Typical IGC Control Wiring Diagram RGVG-036-061-02SI Specifications subject to change without notice.
Page 29 Table 5 — IGC Board LED Alarm Codes a,b,c FLASH SYMPTOM CAUSE REMEDY CODE Normal Operation — — Check 5-amp fuse on the ICG, power to unit, 24V circuit breaker, and Loss of power to control module transformer. Units without a 24V circuit breaker have an internal overload in No Power or Hardware Failure (IGC) the 24V transformer.
Page 30 Pre-purge: Induced draft motor Ignition: Gas valve and Call for heat: starts and runs for 30 seconds at igniter energize for 2 W terminal is energized ignition speed, Speed 1 seconds Rectification: Flame sensor activates for 2 seconds after Gas valve and igniter ignition period de-energerized Is flame...
Page 31 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 four button keypad.
Page 32 ENVIRONMENTAL Table 6 — Economizer Module — Left Hand Terminal Blocks Operating Temperature –40°F to 150°F (–40°C to 65°C). LABEL TYPE DESCRIPTION Exception of display operation down to –4°F (–20°C) with Top Left Terminal Block full recovery at –4°F (–20°C) from exposure to –40°F 20k NTC Mixed Air Temperature Sensor (Polarity (–40°C)
Page 33 Sensor (Hot) Black Yellow Analog Brown – Orange Green SWITCH LABEL Power Supply. Provide Disconnect Means and Overload Protection As Required. Fig. 49 — CO Sensor Wiring SWITCHES INTERFACE OVERVIEW This section describes how to use the EconoMi$er X user ®...
Page 34 To use the keypad when working with Setpoints System and IMPORTANT: Table 10 illustrates the complete hierarchy. 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 35 Table 10 — 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 36 Table 10 — 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 37 Table 10 — 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 3 EXH1 L SET 0 to 100% speed with 1 heat and 2 cool.
Page 38 Table 10 — 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 39 Table 10 — 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 then replace sensor if the alarm continues. OUTSIDE AIR TEMPERATURE SENSOR ERROR OA SENS T ERR —...
Page 40 ENTHALPY SETTINGS OA dew point are all below the selected boundary, the economizer sets the economizing mode to YES, economiz- When the OA temperature, enthalpy and dew point are be- ing is available. low the respective setpoints, the Outdoor Air can be used When all of the OA conditions are above the selected for economizing.
Page 41 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 12 for economizer operation. Table 12 — Economizer Operation - FAN TYPE = 1SPEED INPUTS OUTPUTS Demand...
Page 42 2 SPEED FAN OPERATION The 2 speed fan delay is available when the system is pro- grammed for 2 speed fan (in the System Setup menu item). The W7220 controller has the capability to work with a sys- The 2 speed fan delay is defaulted to 5 minutes and can be tem using a 2-speed supply fan.
Page 43 2SP H/C (2 SPEED HEAT/COOL) FAN OPERATION On single phase RGV037/049/061*G/H units, if reduced the heating fan speed is lower than the cooling speed and the (SINGLE PHASE UNITS ONLY) economizer FAN TYPE needs to be set to 2SP H/C The W7220 controller does not actually control the fan (2 speed Heat/Cool).
Page 44 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 45 Smoke Detectors Additional Application Data Refer to the application data document “Factory Installed Smoke detectors are available as factory-installed options Smoke Detectors for Small and Medium Rooftop Units 2 to on RGV036-061*G/H models. Smoke detectors may be 25 Tons” for discussions on additional control features of specified for supply air only, for return air without or with these smoke detectors including multiple unit coordination.
Page 46 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- unit is set on roof curb) tach the jumper covering the Smoke Shutdown terminals on the UCB and then attach the wiring harness from the smoke...
Page 47 Step 16 — Fan Speed Set Up UNITS WITH ELECTRO-MECHANICAL CONTROLS The fan speed set up controls are located on the lower sec- tion of the Unit Control Board (UCB). See Fig. 55 for the lo- cation on 3 phase voltage units or Fig. 56 for the location on single phase voltage units.
Page 48 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 50 © 2023 Carrier Lewisburg, TN 37091 USA Replaces: RGVG-036-060-01SI RGVG-036-061-02SI Specifications are subject to change without notice.
Page 51 START-UP CHECKLIST FOR RGV036-061*G/H 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 sec- tions of this Installation Instruction document.
Page 52 8. Open W1 restore unit to dehumid mode (Y/N) _____ 9. Open humidistat input compressor and outdoor fan stop; LSV and DSV solenoids de-energized (Y/N) _____ 10. Restore setpoints for thermostat and humidistat (Y/N) _____ © 2023 Carrier Lewisburg, TN 37091 USA Replaces: RGVG-036-060-01SI...

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