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48JZ(N) 024-060

Single Packaged Gas Heating/Electric Heat Pump

Umts With Puron® (R-410A) Refrlqerant

Visit www.camer.eom

Installation, Start-Up, and Operating Instructions

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

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

INTRODUCTION .......................................................................... 2

RECEIVING AND INSTALLATION .......................................... 2

CHECK EQUIPMENT ............................................................. 2

IDENTIFY UNIT ................................................................ 2

INSPECT SHIPMENT ........................................................ 2

PROVIDE UNIT SUPPORT .................................................... 2

ROOF CURB ....................................................................... 2

SLAB MOUNT ................................................................... 2

GROUND MOUNT ............................................................ 2

FIELD FABRICATE DUCTWORK ........................................ 3

PROVIDE CLEARANCES ...................................................... 4

RIG AND PLACE UNIT ......................................................... 6

CONNECT CONDENSATE DRAIN ...................................... 6

INSTALL FLUE HOOD .......................................................... 6

INSTALL GAS PIPING ........................................................... 7

INSTALL DUCT CONNECTIONS ........................................ 9

CONFIGURING UNITS FOR DOWNFLOW (VERTI-

CAL) DISCHARGE ............................................................ 9

INSTALL ELECTRICAL CONNECTIONS ......................... I0

HIGH-VOLTAGE CONNECTIONS ................................ 10

SPECIAL PROCEDURES FOR 208-V OPERATION ...11

CONTROL VOLTAGE CONNECTIONS ....................... 11

HEAT ANTICIPATOR SETTING ................................... 11

TRANSFORMER PROTECTION .................................... 11

PRE-START-UP .......................................................................... 12

START-UP ................................................................................... 13

CHECK FOR REFRIGERANT LEAKS ............................... 13

START-UP HEAT AND MAKE ADJUSTMENTS ............. 13

CHECK HEATING CONTROL ....................................... 13

HEATING SEQUENCE OF OPERATION-HEAT

PUMP ................................................................................. 18

HEATING SEQUENCE OF OPERATION-GAS

HEAT ................................................................................. 18

START-UP COOLING AND MAKE ADJUSTMENTS....., 19

COOLING SEQUENCE OF OPERATION ..................... 19

CHECKING COOLING CONTROL OPERATION (NON-

ICM UNITS) ...................................................................... 19

MAINTENANCE ......................................................................... 20

AIR FILTER ...................................................................... 22

INDOOR BLOWER AND MOTOR ................................ 22

FLUE GAS PASSAGEWAYS ......................................... 24

COMBUSTION-AIR BLOWER ....................................... 24

LIMIT SWITCH ................................................................ 25

BURNER IGNITION ........................................................ 25

MAIN BURNERS ............................................................. 25

OUTDOOR COIL, INDOOR COIL, AND

CONDENSATE DRAIN ................................................... 25

OUTDOOR FAN ............................................................... 25

ELECTRICAL CONTROLS AND WIRING .................. 25

HEAT PUMP SYSTEM ITEMS ...................................... 26

REFRIGERANT CIRCUIT ............................................... 27

GAS INPUT ...................................................................... 27

INDOOR AIRFLOW ........................................................ 27

PURON® SYSTEM ITEMS ............................................ 27

TROUBLESHOOTING ............................................................... 28

START-UP CHECKLIST ............................................................ 28

NOTE TO INSTALLER-- Before the installation, READ THESE

INSTRUCTIONS CAREFULLY AND COMPLETELY. Also,

make sure the User's Manual and Replacement Guide are left with

the unit after installation. The furnace is NOT to be used for

temporary beating of buildings or structures under construction.

C99O88

Fig. 1--Untt 48JZ

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be

hazardous due to system pressure and electrical components, Only

trained and qualified personnel should install, repair, or service

alr-eooditioning equipment.

Untrained personnel can perform basic maintenance functions of

cleaning coils and filters. All other operations should be performed

by trained service personnel. When working on air-conditioning

equipment, observe precautions in the literature, tags, and labels

attached to the unit, 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 extinguisher

available for all brazing operations.

Manufacturer reserves the right to discontinue, or change at any time, speciflcatiotls or designs without notice and without Incurring obligations.

PC 101 Catalog NO, 534--80083 Printed in U.S,A, Form 48JZ-1SI Pg 1 10-01 ReplaCeS: New

Summary of content (36 pages)

PAGE 1
48JZ(N) 024-060 Single Packaged Gas Heating/Electric Heat Pump Umts With Puron® (R-410A) Refrlqerant Visit www.camer.eom Installation, Start-Up, and Operating Instructions NOTE: Read installation. the entire instruction TABLE SAFETY before starting the OF CONTENTS CONSIDERATIONS INTRODUCTION manual ..................................................... .......................................................................... 1 2 RECEIVING AND INSTALLATION .....................................
PAGE 2
Ensure electrical power supply provided for unit matches requirements listed on the unit rating plate. Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, fire, or an explosion which can result in serious injury, death or unit INSPE, CT SHIPMENT Inspect for shipping damage while unit is still on shipping pallet. If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before removal.
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[)$_] IZliI] 1583_ REAR VIEW TOP VIEW REQ'D CLEARANCES FOR OPERATION AND SERVICING. in. (mm) REQ'D CLEARANCES TO COMBUSTIBLE Evaporator coil access side .................. Power entry side (except lot NEC requirements) ......... Unit top .......................... S de opposite ducs ..................... Duct panel ........................ Top of unit ......................... Duct side of unit ....................... Side opposite ducts ..................... Bottom 0t unit .......................
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HgHHHHmH SU_pLf oueT Op[Mty_ loz._ I15_) I R[TURN 0U¢1 O_EliH5 i I (4 53) +s 3 1_ 4+) 11]|]_ (l]|il TOP VIEW [l_.|3J REARVIEW REQUIREDCLEARANCETO COMBUSTIBLEMATL, REQUIRED CLEARANCEFOR OPERATIONAND SERVICING in. ram] EV_. CO,L AOCSSS mOB .............................................................. 36.00, 1914.0TOP OF UNIT ................................................................................... POWER ENTRY SiDE ......................................................................
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Roof Curb for Small Roof Curb Cabinet for Larga Cabinet Note A: When unit mounting screw is used, retainer bracket must also be used. Note A: When unit mounting screw is used, retainer bracket must alsO be used. \ R/A \/ /\ S/A \ "'-"Gasket around_ duct Insulated Gasket around deck pan outer edge \ \ C00076 UNIT SIZE 48JZ024-036 48JZ042-060 B IN, (MM) 11(279) A IN.
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1 2 H Y © 4 3 x C00070 CORNER WEIGHTS (SMALL CABINET) N 036 321 N 52 60.5 61.0 ,¢t 88 49 121 57.3 95.0 108.2 57.8 99.5 102.7 024 _10 Comer Weight 1 Comer Weight 2 Corner Weight 3 Corner Weight 4 I I =o 1:= o CORNER WEIGHTS (LARGE CABINET) Unit 042 048 030 ,_P4 Unit Totn) W_inht 380 409 5O4 Comer Weight 1 83 108 105 Comer Weight 2 Comer Weight 3 Comer Weight 4 52 115 130 48 125 128 76 130 193 ,q o 060 Total Weight Fig. 5--48JZ Corner Weights -..
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Table UNIT SIZE 48JZ NOMINAL CAPACITY (ton) OPERATING WEIGHT (lb.) COMPRESSORS Quantity REFRIGERANT (R-410A) Quantity (Lb.) REFRIGERANT METERING DEVICE Orifice ID (In,) AccuRater Piston • Orifice OD (in.) OUTDOOR COIL Rows...Flns/In. Face Area (sq ft) OUTDOOR FAN Nominal Cfm Dlameter (in.) Motor HP (Rpm) iNDOOR COIL Rows..Fins/in. Face Area (sq ft) INDOOR BLOWER (Standard PSC Motor) Nominal Airflow (Cfm) Size (in.) Motor (HP) FURNACE SECTION* Burner Odfice No. (Qty...
PAGE 8
Table 1--Physical Data---Unit 48JZ (Continued) UNIT SIZE 48JZ NOMINAL CAPACITY (ton) OPERATING WEIGHT (lb.) COMPRESSORS Quantity REFRIGERANT (R-410A) Quantity (lb.) REFRIGERANT METERING DEVICE Orifice ID (In.) AccuRater 048090 4 048115 4 048130 4 060090 5 060115 5 060130 5 409 409 409 504 504 804 10.6 12.4 12.4 12.4 Scroll 1 Orifice OD (In.) OUTDOOR COIL Rows...Flns_l n. Face Area (sq ft) OUTDOOR FAN Nominal Cfm Diameter (in.) Motor HP (Rpm) INDOOR COIL Rows...Flns/In.
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[N 3. Use a screwdriver and hammer to remove the panels in the bottom of the unit base (See Fig. 9 & 10). ..=====,......" .._ . CAP C99020 Fig. 8--Sediment Trap =---= Unstable operation may occur when the gas valve and manifold assembly are forced out of position while connecting improperly-routed rigid gas piping to the gas valve.
PAGE 10
7. After completing unit conversion, and power up unit. perform all safety checks NOTEt The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of the unit being installed: I. Make all electrical connections in accordance with NEC ANSI/NFPA 70 (latest edition) and local electrical codes nonresidence-type air conditioning and ventilating systems, NFPA 90A or residence-type, NFPA 90B; and/or local codes and ordinances.
PAGE 11
Table3---ElectrlcaIData_Unlt48JZ UNIT SIZE 48JZ VOLTAGE RANGE V-PH-HZ COMPRESSOR INDOOR FAN MOTOR OUTDOORFAN MOTOR Min Max RLA LRA FLA POWER SUPPLY FLA MCA MAX FUSE OR CKT BKR 2.0 2.1 19.8 22.9 30 35 4.1 4.1 4.1 26.8 21.0 33.0 40 30 50 24.3 32.3 24.1 35 50 35 024 208/230-1-60 187 253 13.5 61.0 0.9 030 208/230-1-60 187 263 15.9 73.0 0.9 208/230-1-60 187 253 16.9 83.0 1.6 208/230-.3--60 187 253 12.2 77.0 1.6 208/230-1-60 187 263 22.4 105.0 0.
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EXAMPLE: Supply voltage is 230-3-60. A B C AB=232V FLA LRA MCA CKT BKR RLA --- Full Load Amps Locked Rotor Am s Minimum Circuit Amps Circuit Breaker Rated Load Amps LmENO 'PO --- ,, @ AC = 225 v US _lp Average Voltage = 232 + 227 + 225 3 BG = 227 v = 68._4 3 = 228 NOTES: 1. In compliance with NEC (National Electrical Code) requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be Power Supply fuse.
PAGE 13
BURNER FLAME • FAN GRILLE 1/8" (3•175mml MAX BETWEEN MOTOR AND FAN HUB MOTOR SHAFT C99009 _/_ABURNIR Fig. 12--Fan f. Make sure that all tools and miscellaneous been removed. loose parts have 5. Compressors are internally spring mounted. remove compressor bold-down bolts. Do not loosen or C_2I Fig. 14--Monoport 6. Each unit has 2 schrader-type ports, one low-side located on the suction line. and one high-side located on the compressor discharge line. Be sure that caps on these ports are tight. 7.
PAGE 14
SCHEMATIC 2081230-I-60 SUPPLY P_[R tomlclnm _ o w "--WSI _ 8L LK HP$ _3 9RII- _,3o _ozl uN,It -pNx _[_Tn_ _a tC_n_ UNIT COMPON[NT O_lo00ltal 11¢I1_ ARRANGtMENT [] [_IP. $[¢11_1 $[¢TI_ I ¢G_II_ 601 L- 3r__1 .... DIP SWITCH SETTINGS __I° it_ ,----, ....
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EraOSl 8oa_o R (oe_ _ _ [-----_54 8L_)--W53 W5 _ 6LU 8RJ BLK Hp$ 43 BRN-- 3iZ) UNIT COHPON[NT s[¢l_oN °_TOOO_rAI ARRANGE_EN! [] (o,u r _., GUD DiP iKr_ml_ SWITCH SETTINGS i_ w_t_s .... --i _ Iru I m c_ "-'a _ mlts: I _r _, w _ NI_II_ ,1_1 r_lls_| _ _K(o, SCOIIII[_I P[I I[¢ c I I --,-_,-,- ;- _1@ ,(_ 48JZ500002 1,.° L4J Fig.
PAGE 16
SCHEMATIC 2081230-I-60 II[LD m _PLt I _'OW(R i m DiP SWITCH SETTINGS ÷ [_,_ 14eJ_500004 Fig.
PAGE 17
Table 5--Heating HEATING INPUT (BTUH)* Inputs GAS SUPPLY PRESSURE (IN. WG) Natural Propanet NUMBER OF ORIFICES MANIFOLD PRESSURE (IN. WG) Min Max Min Max Natural Propane1* 40,000 2 4.0 13.0 4.0 13.0 3.5 3.5 60,000 2 4.0 13.0 4.0 13.0 3.5 3.5 90,000 3 4.0 13.0 4.0 13.0 3.5 3.4 115,000 3 4.0 13.0 4.0 13.0 3.5 • 3.7 130,000 3 4.0 13.0 4.0 13.0 3.5 3.5 f When a and is converted to propane, different size orifices must be used, See s_ _arate.
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Table 6--Air Delivery (CFM) at Indicated Temperature Rise and Rated Heating Input HEATING INPUT (BTUH) TEMPERATURE RiSE =F 20 25 30 35 40 45 50 56 60 65 70 40,000 1500 1200 1000 857 750 667 600 545 500 -- -- 60,000 90,000 115_000 2250 --- 1800 --- 1500 2250 -- 1286 1929 2464 1125 1668 2156 1000 1500 1917 900 1350 1725 818 1227 1568 750 1125 1438 692 1038 1327 -964 1232 130,000 -- -- -- 2786 2438 2167 1950 1773 1625 1500 -- NOTE: Cashed areas do not fall
PAGE 19
Step 3_START-UP MENTS COOLING COMPRESSOR AND MAKE ADJUST- On 3-phase ROTATION units with scroll compressors, it is important to be certain compressor is rotation in the proper direction, To determine whether or not compressor is rotating in the proper direction: 1. Connect fittings. Complete the required procedures given in the Pre-Sturt-Up section before starting the unit. Do not jumper any safety devices when operating the unit.
PAGE 20
OUTDOOR CC4L INDOOR COIL LCS Meledng Posilton LEGEND HPS - High Pressure Switch LCS - Loss of Charge Switch z_: AccurateP Metering Device ] Arrow indicates direction of flow C_ Fig. 18--Typical EXAMPLE: IFig. 20) Outdoor Temperature.....85 Heat Pump Operation, Table F Suction Pressure......145 psig Suction Temperature should be...70 F (Suction Temperature may vary +/- 3°1::) 4.
PAGE 21
INDOOR COIL C:3 LCS OLff!).OOR Ci BypaSs Position LEGEND HPS - High Pressure Switch LCS - LOSSof Charge Switch _; Accurate(" Metering Device ] Arrow indicates direction of flow C00096 Fig. 19---Typical Heat Pump Operation, Cooling Mode Table 9---Filter Pressure Drop (In. wg) FILTERSIZE 500 600 700 800 900 1000 1100 1200 1300 20X20X1 20 X 24 X 1 OmO50.07 .... 0.08 0.10 0.12 0.13 O.O9 0.10 0.14 0.11 0.15 0.13 ........... 0114 0115 0c9M0,10 0.16 24X30Xl ....... 0107 0.
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Table 10---Wet Coil Air Delivery* - Horizontal and Downflow Discharge Unit 48JZ024-060 (Deduct 10 percent for 208 Volts) 230 VOLT Unit 0.0 0.1 0.2 0.3 External 0,4 Wa_s 279 282 280 277 276 Motor Speed Low 024 Med High Low 030 Med High Low 036 Med High Low 042 Med Low 046 Med High Low 060 Med High (in. wg) 0.6 0.7 0.8 0.9 1,0 ...... Cfm 582 801 738 674 604 Wa_s -- -- -- 373 367 361 356 351 -- -- -- Cfm -- -- -- 936 868 797 719 626 -- -- ......
PAGE 23
(030) 60 Hz CCOUNG CHARGING CHART For Use with Units Using R410a Rel;lger_nt (042) 60 Hz COOLING CHARGING CHART For use with units using R41 Ca Refrigerant I _LlttF4_Q otno0_ i F t25 C 52 it5 106 46 41 35 35 35 I F C 115 46 K 15 24 ¢5 R zl K 58 7 gJGrcwU_ rBe_t _ _ C00083 Fig. 21--Cooling Charging Chart, 48JZ030 C00085 Units Fig.
PAGE 24
F C 12S Q I IS II IS 7 FRONT ACCESS PANEL C99091 Fig. 27--Unit Access Panel G_7 Fig. 25---Cooling Charging Chart, 48JZ060 Units BLOWER HOUSING INDUCED DRAFT MOTOR MOUNT 2 SETSCREWS (HIDDEN) LLOUT VENT HOOD IN SHIPPING LOCATION FLUE /' COLLECTOR BOX SWITCH BLOWER HOUSING BURNER RACK MOUNTING SCREW C99085 C99022 Fig. 26---Blower Housing and Flue Collector Fig. 28---Removal Box 3. Remove e. Reassemble motor into housing.
PAGE 25
6. Remove ignitor and sensor wires at the ignitor module. 7. Remove the mounting screw that attaches the burner rack to the unit base (See Fig. 28). 8. Slide the burner rack out of the unit (See Fig. 26 and 29). 9. To reinstall, reverse the procedure OUTDOOR COIL, INDOOR CONDENSATE DRAIN outlined above. COIL, AND Inspect the Outdoor coil. Indoor coil.
PAGE 26
7, m "11 .-I O i o Speedup Pins Fig. 30--Defrost Control Board heating cycle and one complete operation. If discrepancies cycles, or if a suspected cooling cycle to ensure proper field-selectable time period (DIP switch 1 and 2 on the board) between defrost cycles of 30, 60, 90, or 120 minutes (factory set at 30 minutes). are observed in either or both operating malfunction has occurred, check each electrical component with the proper electrical instrumentation.
PAGE 27
3. Restart unit in Heating mode, allowing outdoor coil. frost to accumulate GASINPUT on The gas input does not require checking unless improper heating performance is suspected. If a problem exists, refer to the Start-Up section. 4. After a few minutes in Heating mode, liquid line temperature should drop below closing proximately 30°F). NOTE: Unit will remain point of defrost thermostat (ap- INDOOR in defrost until reopens at approximately 80°F coil temperature remainder of defrost cycle time.
PAGE 28
Exposure, even if immediately cleaned up, may cause embrittlement (leading to cracking) to occur in one year or more. When Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils. Failure to tollow this warning can cause a fire, serious injury, or death. performing any service that may risk exposure of compressor oil to the roof. take appropriate precautions to protect roofing.
PAGE 29
HEAT PUMP WITH PURON--QUICK REFERENCE GUIDE Puron refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing equipment and replacement components are designed to operate with Puron. Puron refrigerant cylinders are rose colored. • Puron refrigerant cylinders manufactured prior to March 1, 1999, have a dip tube that allows liquid to flow out of cylinder in upright position.
PAGE 30
Table 11--Troubleshooting Power Fuse Compressor and outdoor tan will not start. REMEDY Call power company. Failure blown or cimutt DetectNe breaker thermostat, insufficient Incorrect translormer, or cordtol setting or loose connect tons in compressor burned Detecttve capaettor, runi_tatt leg of 3-phase power out.
PAGE 31
Table 12--Troubleshooting SYMPTOM Water No 24-v to tUrdaCe power Misowited Burned*out thermostat will not ignite. Broken to conttot circuit heat anticipator spark Drain. Install drip leg. Check power Check translormer. _upp]y fuses, wiring, or circuit breake_ NOTE: Some transformers have Ioternal over-current protection that require_ a coot-down perv3d to reset. or loose connections No gas at main Poor flame characteristics. supp;y thermostat Misaligned Inadequate heating.
PAGE 32
Table 13--Troubleshooting SYMPTOM He.ware failure. (LED OFF) Fan OWOFF delay (LED 1 FLASH) Limit switch 2 flashes) REMEDY Check 5-amp fuse on IGC*, power to urdt. 24-v circuit breaker, and transformer. Units without a 24_/circuit breaker have an internal ovehoad in the 24-v transformer. If the overlOad tdps, al_w 10 minutes for automatk_reset. LosS of power to control module (]GC)*. modified High Jim[t switch opens duhog heat exchanger warm-up panod before fan-on delay expires.
PAGE 33
START-UP (Remove I. PRELIMINARY CHECKLIST and Store in Job File) INFORMATION MODEL NO: ............................................................................................................................................................. SERIAL NO: .............................................................................................................................................................. DATE: .......................................................................................
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Copyright 2001 CARRIER Corp. ° 7310 W. Morris St. • indianapolis, IN 46231 Manufacturer reserves the right to discontinue, PC 101 Catalog No. 534-80083 48JZlsi or change at any time, specifications or designs without notice and without incurring obligations. Printed in U.S.A.