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48AZ/UZ Packaged Rooftop Cooling/ Heat Pump and Gas Heating Units

Installation, operation and maintenance instructions

Contents stARt-UP CHeCK LIst .............................................................................................................................................................. 4 Physical data ...................................................................................................................................................................................... 6 Dimensions, mm................................................................................................................................................................................ 8 Fan performance (standard) .......................................................................................................................................................... 13 Fan performance (optional drive - high static pressure 1) ......................................................................................................... 14 Fan performance (optional drive - high static pressure 2) ......................................................................................................... 15 Fan performance (optional drive - high static pressure 3) ......................................................................................................... 16 Electrical data ................................................................................................................................................................................. 17 Recommended wire sections ......................................................................................................................................................... 18 sAFetY ConsIDeRAtIons................................................................................................................................................... 18 InstALLAtIon ........................................................................................................................................................................... 18 Siting the unit .................................................................................................................................................................................. 18 Unit base frame............................................................................................................................................................................... 19 Sensor connection and location .................................................................................................................................................... 20 Ductwork ......................................................................................................................................................................................... 21 Condensate and rainwater drainage............................................................................................................................................. 21 eLeCtRICAL ConneCtIons ............................................................................................................................................... 21 Inserting line power leads into unit .............................................................................................................................................. 22 Thermostat connection .................................................................................................................................................................. 22 Necessary checks/precautions before start-up ............................................................................................................................ 22 VeRIFICAtIon oF tHe ReFRIgeRAnt CHARge ...................................................................................................... 22 Refrigerant guidelines .................................................................................................................................................................... 23 Recharging liquid refrigerant ........................................................................................................................................................ 23 Undercharge.................................................................................................................................................................................... 23 Characteristics of R-407C .............................................................................................................................................................. 23 stARt-UP (CooLIng).............................................................................................................................................................. 24 Initial checks.................................................................................................................................................................................... 24 ReFRIgeRAnt sYstem DesCRIPtIon ........................................................................................................................... 24 ComPRessoR RePLACement ........................................................................................................................................... 25 Description of unit protection devices ......................................................................................................................................... 25 High pressurestat ............................................................................................................................................................................ 25 Operating limits .............................................................................................................................................................................. 25 gAs HeAtIng ............................................................................................................................................................................. 25 Introduction..................................................................................................................................................................................... 25 PReLImInARY CHeCKs BeFoRe stARt-UP.................................................................................................................. 26 Gas connection ............................................................................................................................................................................... 27 Operating limits ............................................................................................................................................................................. 27 Installation of flue outlet terminal guard and wind baffle ......................................................................................................... 27 CommIssIonIng ...................................................................................................................................................................... 28 Checks to be carried out before starting up the gas burner ...................................................................................................... 28 Required equipment list for start-up............................................................................................................................................ 28 PRessURe ADjUstments on tHe HIgH-Low RegULAtIng VALVe .............................................................. 29 gAs ConVeRsIon InstRUCtIons ................................................................................................................................... 30 Sequence .......................................................................................................................................................................................... 30 gAs FIRe-UP seqUenCe ....................................................................................................................................................... 31 seRVICe AnD mAIntenAnCe ............................................................................................................................................ 32 Temperature limit switches ........................................................................................................................................................... 33 Main burners ................................................................................................................................................................................... 34 Integrated gas unit controller (IGC) ............................................................................................................................................ 35 gAs BURneR tRoUBLesHootIng .................................................................................................................................. 36

settIng UP tHe PRo-DIALog PLUs ContRoL ........................................................................................................ 39 Local interface general features.................................................................................................................................................... 39 Unit start/stop control .................................................................................................................................................................... 41 Menus .......................................................................................................................................................................................... 42 oPtIons AnD ACCessoRIes ............................................................................................................................................... 42 geneRAL mAIntenAnCe.................................................................................................................................................... 43 seRVICe ........................................................................................................................................................................................ 43 Indoor fan air adjustment .............................................................................................................................................................. 43 Lubrication ...................................................................................................................................................................................... 44 Condenser coil ................................................................................................................................................................................ 44 mAIntenAnCe PRogRAmme............................................................................................................................................ 45 Maintenance instructions............................................................................................................................................................... 45 Maintenance schedule .................................................................................................................................................................... 45 Description of the maintenance operations ................................................................................................................................ 45 Servicing recommendations .......................................................................................................................................................... 46 FInAL ReCommenDAtIons ................................................................................................................................................ 46 tRoUBLesHootIng CHARt ............................................................................................................................................... 47

IMPORTANT: The appliance must be installed in accordance with local safety codes and regulations and is intended for outdoor use only. Please read the manufacturer's instructions carefully before starting this unit. CAUTION: Before installation, check that the local distribution conditions, type of gas and available pressure, and the power supply and adjustments of the appliance are correct.

the drawings in this document are for illustrative purposes only and is not part of any offer for sale or contract. 3

START-UP CHECK LIST


Equipment sold by: ..................................................................................................................... Installed by: ................................................................................................................................. Site address: ................................................................................................................... Contract No: ........................................................................ Contract No: ........................................................................ Start up date: .................................................................

Equipment type and serial No: 48AZ/UZ ....................................................................................................................................................................................

eLeCtRICAL DAtA: Supply voltage Ph 1: ........................... Volts Ph 2: .................... Volts Ph 3: ................... Volts

Nominal voltage: ...................................................... Volts Current draw Ph 1: ................................ Amperes Control circuit voltage: ................................ Volts

% network voltage: ............................................................./..... Ph 2: ................................... Amperes Ph 3: ...................................... Amperes

Control circuit fuse: ............................................................................................ Amperes

Main circuit breaker rating: ...........................................................................................................................................................................................................

CooLIng UnIt PHYsICAL DAtA: Condenser: Entering air temp.: ...................................................... Leaving air temp.: ...................................................... Pressure drop (air): .................................................... Discharge air pressure: ............................................ Fan motor input:
o

Evaporator: C C Entering air temp.: ....................................................... Leaving air temp.: ....................................................... Pressure drop (air): ...................................................... Discharge air pressure: ............................................... Fan motor input: Ph. 1: ................................... Ph. 2: ................................... Ph. 3: ...................................
o

C C

kPa Pa

kPa Pa Volts Volts Volts

Ph. 1: ................................. Volts Ph. 2: ................................. Volts Ph. 3: ................................. Volts

sAFetY DeVICe settIng: High pressure switch: Low pressure switch: Step controller: cut-out: ................................................... kPa cut-out: ................................................... kPa cut-out 1st step: ....................................... oC cut-out 2nd step: ..................................... oC cut-in: ............................................................... kPa cut-in: ............................................................... kPa cut-in 1st step: ................................................. oC cut-in 2nd step: .......................................:....... oC

Oil level: ........................................................................................................................................................................................................................................... Oil visible in sight glass? .............................................................................................................................................................................................................. ACCessoRIes

START-UP CHECK LIST (continued)


gAs BURneR no. 1 Size .................................... Pipe size ............................. Line pressure ..................... mbar Check burner pressure Min. rate ........................... mbar Max. rate ............................. mbar Pressure cut-out, air flow pressure switch .................................... Pa Motor current ....................... A Flue temp. .............................. C CO2 ....................................... % CO ppm ................................... % Serial No. ................................. Gas type g................................ gAs BURneR no. 2 Size .................................... Pipe size ............................. Line pressure .................. mbar Check burner pressure Min. rate ......................... mbar Max. rate ............................. mbar Serial No. ................................. Gas type g................................

Pressure cut-out, air flow pressure switch .................................... Pa Motor current ....................... A CO2 ...................................... % Flue temp. ................................ C CO ppm ................................... %

Commissioning engineer (name): .................................................................... Customer agreement (name): ........................................................................... Remarks:

Date: ............................................................................................................. Date: ............................................................................................................

note: Complete this start-up list at the time of installation

Physical data
48AZ Nominal cooling capacity* Operating weight Refrigerant charge Circuit A/B Compressor Quantity, circuit A/B Oil charge (each) Control type Indoor coil Face area Rows ... fin spacing Outdoor coil Face area Rows ... fin spacing Indoor fan Air flow Fan speed Nominal power input Nominal static pressure (dry/wet coil) Outdoor fan Quantity Air flow Fan speed (high/low speed) Nominal power input (each) Air filter Quantity Width x height Thickness kW kg kg l m2 mm m2 mm l/s r/s kW Pa l/s r/s kW mm mm 016 020 024 43 54.1 70 745 920 1060 R-407C 11.6/6.2/7.1 9.4/9.9 Scroll Hermetic Scroll 1/1/1 1/1 6.6 4 4 Pro-Dialog Plus Copper tubes, aluminium fins 1.71 1.71 1.71 3 ... 1.7 3 ... 1.81 4 ... 1.7 Copper tubes, aluminium fins 2.05 1.93 2.78 4 ... 1.7 4 ... 1.7 4 ... 1.7 One, centrifugal 2528 3444 3472 15.25 18.28 18.77 2.2 4 5.5 146 159 149 Axial Flying Bird fans with rotating shroud 1 2 2 6100 6600 10600 15.6/7.8 11.5/5.8 15.6/7.8 1.8 0.75 1.8 G4 6 6 6 595 x 495 595 x 495 595 x 495 50 50 50 028 78.1 1070 9.4/9.9 Scroll 1/1 6.6 1.71 4 ... 1.7 2.78 4 ... 1.7 3944 18.77 5.5 149 2 10600 15.6/7.8 1.8 6 595 x 495 50 034 99.5 1545 14.6/14.6 Hermetic 1/1 7.6 2.56 3 ... 1.7 5.20 3 ... 1.81 5550 13.62 7.5 146 2 13000 15.6/7.8 1.8 9 595 x 495 50 028 77 85 1080 9.4/9.9 Scroll 1/1 6.6 1.71 4 ... 1.7 2.78 4 ... 1.7 3944 18.77 5.5 149 2 10600 15.6/7.8 1.8 6 595 x 495 50 040 116.1 1595 18.0/18.0 Hermetic 1/1 7.6 2.56 4 ... 1.7 5.20 3 ... 1.81 5550 14.30 7.5 165 2 12500 15.6/7.8 1.8 9 595 x 495 50

48UZ 016 020 024 Nominal cooling capacity* kW 41 52 68.5 Nominal heating capacity** kW 45 56,7 79 Operating weight kg 755 930 1070 Refrigerant charge R-407C Circuit A /B kg 11.8/6.5/7.4 9.4/9.9 Compressor Scroll Hermetic Scroll Quantity, circuit A/B 1/1/1 1/1 Oil charge (each) l 6.6 4 4 Control type Pro-Dialog Plus Indoor coil Copper tubes, aluminium fins 1.71 1.71 1.71 Face area m2 Rows ... fin spacing mm 3 ... 1.7 3 ... 1.81 4 ... 1.7 Outdoor coil Copper tubes, aluminium fins 2.05 1.93 2.78 Face area m2 Rows ... fin spacing mm 3 ... 1.7 4 ... 1.7 4 ... 1.7 Indoor fan One, centrifugal Air flow l/s 2528 3444 3472 Fan speed r/s 15.25 18.28 18.77 Nominal power input kW 2.2 4 5.5 Nominal static pressure (dry/wet coil) Pa 146 159 149 Outdoor fan Axial Flying Bird fans with rotating shroud Quantity 1 2 2 Air flow l/s 6100 6600 10600 Fan speed (high/low speed) r/s 15.6/7.8 11.5/5.8 15.6/7.8 Nominal power input (each) kW 1.8 0.75 1.8 Air filter G4 Quantity 6 6 6 Width x height mm 595 x 495 595 x 495 595 x 495 Thickness mm 50 50 50 * Nominal Eurovent conditions: outdoor air dry bulb temperature of 35C, indoor air wet bulb temperature of 19C. ** Nominal Eurovent conditions: outdoor air wet bulb temperature of 6C, indoor air dry bulb temperature of 20C.

Physical data (continued)


Heating modules Natural gas heating Net heat input (min./max.) Heat output (min./max.) Natural gas (G20) rate* Natural gas (G25) rate Natural gas (G25.1) rate Injectors Quantity Size Propane gas heating Net heat input (min./max.) Heat output (min./max.) Propane gas (G31) rate* 5 cells kW kW l/s m3/h l/s m3/h l/s m3/h mm kW kW kg/h m3/h 35.4/52.6 30.8/46.8 1.04/1.55 3.74/5.57 1.21/1.80 4.36/6.47 1.21/1.79 4.34/6.46 5 3.26 -/59.1 -/53.2 -/4.59 -/2.42 6 cells 48.6/69.4 41.8/61.8 1.43/2.04 5.14/7.34 1.66/2.37 5.98/8.54 1.66/2.37 5.97/8.53 6 3.45 -/71.0 -/63.9 -/5.51 -/2.90 7 cells 56.7/81.0 49.9/72.9 1.67/2.38 6.00/8.57 1.94/2.77 6.98/9.97 1.66/2.77 5.97/9.96 7 3.45 -/82.8 -/74.5 -/6.43 -/3.39 7 1.9 80 0.22 Rp 3/4 F 5 + 5 cells 35.4/105.2 30.8/93.6 1.04/3.09 3.74/11.13 1.21/3.60 4.36/12.95 1.21/3.59 4.34/12.94 10 3.26 59.1 /118.2 52.6/105.2 4.59/9.18 2.42/4.83 10 1.9 135 0.44 Rp 3/4 F 6 + 6 cells 48.6/138.8 42.8/125.0 1.43/4.08 5.14/14.7 1.66/4.74 5.98/17.08 1.66/4.74 5.97/17.07 12 3.45 71.0/142.0 63.9/127.8 5.51/11.03 2.90/5.81 12 1.9 150 0.44 Rp 3/4 F 7 + 7 cells 56.7/162.0 50.5/147.4 1.67/4.76 6.00/17.14 1.94/5.54 6.97/19.94 1.93/5.54 6.96/19.93 14 3.45 82.8/165.6 75.3/150.7 6.43/12.86 3.39/6.77 14 1.9 165 0.44 Rp 3/4 F

Injectors Quantity 5 6 Size mm 1.9 1.9 Weight** kg 65 73 Power input (400 V-3 ph-50 Hz)** kW 0.22 0.22 Gas connection in Rp 3/4 F Rp 3/4 F * (Hi) Natural gas G20 net calorific value 34.02 MJ/m3 @ 15C, 1013.25 mbar (Hi) Natural gas G25 net calorific value 29.25 MJ/m3 @ 15C, 1013.25 mbar (Hi) Natural gas G25.1 net calorific value 29.3 MJ/m3 @ 15C, 1013.25 mbar (Hi) Propane gas G31 net calorific value 46.34 MJ/kg @ 15C, 1013.25 mbar (Hi) Propane gas G31 net calorific value 88.0 MJ/m3 @ 15C, 1013.25 mbar ** Weight and power input values are valid for the heating modules.

Dimensions, mm 48AZ/UZ 016

Electrical box access panel Main disconnect switch Filter access panel

Right side view

Left side view

Rear view
(1) Optional air return duct connection (2) Optional power exhaust connection (1) + (2) Alternative air return duct connection. In this case power exhaust option is not used.

- -A- Control wiring inlet 38

Front view

Water connections 64

Gas connections 29

Power wiring inlet 64

When designing an installation, always use up-to-date drawings, available from your local Carrier office.

48AZ/UZ 020

Electrical box access panel Main disconnect switch Filter access panel

Right side view

Left side view

Rear view

- -A- Control wiring inlet 38

Front view

Water connections 64

(1) Optional air return duct connection (2) Optional power exhaust connection (1) + (2) Alternative air return duct connection. In this case power exhaust option is not used.

Gas connections 29

Power wiring inlet 64

When designing an installation, always use up-to-date drawings, available from your local Carrier office.

48AZ/UZ 024-028

Electrical box access panel Main disconnect switch Filter access panel

Right side view

Left side view

Rear view
Control wiring inlet 38

Front view
Water connections 64

(1) Optional air return duct connection (2) Optional power exhaust connection (1) + (2) Alternative air return duct connection. In this case power exhaust option is not used.
Power wiring inlet 64

Gas connections 29

- -A- -

When designing an installation, always use up-to-date drawings, available from your local Carrier office.

10

48AZ 034-040

Electrical box access panel Main disconnect switch Filter access panel

Right side view

Left side view

Rear view
Control wiring inlet 38

Front view
Water connections 64 Gas connections 29

Power wiring inlet 64

(1) Optional air return duct connection (2) Optional power exhaust connection (1) + (2) Alternative air return duct connection. In this case power exhaust option is not used.

When designing an installation, always use up-to-date drawings, available from your local Carrier office.

11

Fig. 1 - Service area, mm

2000`*

Clearances required * A minimum 2000 mm clearance must be left in front of the gas module side.

Fig. 2 - Centre of gravity (approx.)


48AZ 016 020 XG* mm 1573 1573 YG* mm 911 1133 ZG* mm 590 553 * Measured from point 4 48UZ 016 XG* mm 1583 YG* mm 911 ZG* mm 590 * Measured from point 4 020 1583 1133 553 024 1551 1125 553 028 1630 1114 624 024 1561 1125 553 034 2500 1100 1090 028 1640 1114 624 040 2530 1100 1090

Fig. 3 - Weight distribution, kg (approx.)


48AZ 1 2 3 4 5 6 48UZ 1 2 3 4 5 6 016 79 73 167 104 125 200 016 79 75 170 104 127 203 020 122 140 212 117 132 199 020 122 142 215 117 134 202 024 119 156 264 112 155 252 024 119 158 267 112 157 255 028 121 158 265 114 157 254 028 121 160 268 114 159 257

NOTE: The units have mounting holes in the lower section, to be used by the installer, if required. 48AZ 1 2 3 4 5 6 7 8 034 125 156 261 230 125 156 261 230 040 133 162 265 236 133 162 265 236

12

Fan performance (standard) 48AZ/UZ 016


Motor pulley position Pa kW 1 turn open Pa 15.72 r/s kW 2 turns open Pa 15.25 r/s kW 3 turns open Pa 14.78 r/s kW 4 turns open Pa 14.32 r/s kW Factory setting Pa 15.25 r/s kW Closed 16.20 r/s Standard motor: 2.2 kW Air flow, l/s 2022 2222 229 209 1.43 1.60 212 192 1.35 1.52 196 176 1.28 1.44 181 159 1.21 1.36 165 143 1.14 1.29 196 176 1.28 1.44 2361 195 1.72 178 1.64 161 1.56 144 1.48 128 1.40 161 1.56 2528 181 1.89 163 1.80 146 1.71 128 1.63 111 1.55 146 1.71 2916 159 2.30 139 2.19 120 2.10 101 2.00 82 1.90 120 2.10 3033 128 2.43 108 2.33 88 2.22 68 2.12 49 2.02 88 2.22

48AZ/UZ 020
Motor pulley position Closed 19.22 r/s Pa kW 1 turn open Pa 18.75 r/s kW 2 turns open Pa 18.28 r/s kW 3 turns open Pa 17.82 r/s kW 4 turns open Pa 17.37 r/s kW Factory setting Pa 18.28 r/s kW Air flow, l/s 2611 2777 324 310 2.64 2.85 304 289 2.52 2.73 284 269 2.42 2.62 265 250 2.31 2.50 246 230 2.21 2.40 284 269 2.42 2.62 3055 276 3.23 255 3.10 234 2.98 214 2.85 193 2.74 234 2.98 3444 204 3.82 181 3.68 159 3.54 137 3.40 114 3.27 159 3.54 3611 180 4.08 156 3.94 133 3.79 110 3.65 87 3.51 133 3.79 3944 111 4.66 85 4.50 61 4.33 35 4.18 10 4.02 61 4.33

Standard motor: 4 kW

48AZ/UZ 024
Motor pulley position Closed 20.23 r/s Pa kW 1 turn open Pa 19.75 r/s kW 2 turns open Pa 19.25 r/s kW 3 turns open Pa 18.77 r/s kW 4 turns open Pa 18.28 r/s kW Factory setting Pa 18.77 r/s kW Air flow, l/s 2777 3055 287 265 3.12 3.52 265 243 2.98 3.37 243 220 2.86 3.24 221 198 2.74 3.10 200 176 2.61 2.97 221 198 2.74 3.10 3472 222 4.19 198 4.03 174 3.87 149 3.72 126 3.58 149 3.72 3611 204 4.43 179 4.26 155 4.10 130 3.94 105 3.79 130 3.94 3888 158 4.93 131 4.75 105 4.57 79 4.41 53 4.24 79 4.41 4166 83 5.47 55 5.28 28 5.08 -

48AZ/UZ 028
Motor pulley position Pa kW 1 turn open Pa 19.75 r/s kW 2 turns open Pa 19.25 r/s kW 3 turns open Pa 18.77 r/s kW 4 turns open Pa 18.28 r/s kW Factory setting Pa 18.77 r/s kW Closed 20.23 r/s Standard motor: 5.5 kW Air flow, l/s 3138 3333 320 304 3.64 3.96 297 281 3.50 3.80 274 257 3.36 3.65 251 233 3.22 3.51 229 210 3.08 3.36 251 233 3.22 3.51 3611 276 4.43 251 4.26 226 4.10 201 3.94 177 3.79 201 3.94 3944 228 5.04 202 4.86 176 4.68 149 4.51 122 4.33 149 4.51 4166 192 5.47 164 5.28 137 5.08 108 4.90 81 4.72 108 4.90 4750 42 6.71 10 6.49 -

Standard motor: 5.5 kW

48AZ 034
Motor pulley position Pa kW 1 turn open Pa 13.95 r/s kW 2 turns open Pa 13.62 r/s kW 3 turns open Pa 13.27 r/s kW 4 turns open Pa 12.92 r/s kW Factory setting Pa 13.62 r/s kW Closed 14.30 r/s Standard motor: 7.5 kW Legend: Pa - External static pressure kW - Fan power input Higher than the nominal motor power Air flow. l/s 5000 5277 249 229 5.72 6.16 222 203 5.50 5.91 197 177 5.27 5.68 172 150 5.05 5.45 147 125 4.84 5.22 197 177 5.27 5.68 5550 200 6.59 173 6.34 146 6.09 119 5.85 93 5.62 146 6.09 5695 175 6.84 148 6.58 120 6.33 93 6.08 66 5.83 120 6.33 5833 149 7.07 120 6.81 93 6.55 65 6.29 38 6.04 93 6.55 6111 107 7.57 79 7.28 50 7.01 22 6.74 50 7.01

48AZ 040
Motor pulley position Closed 14.30 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 5000 5277 215 197 5.72 6.16 188 171 5.50 5.91 163 145 5.27 5.68 138 118 5.05 5.45 113 93 4.84 5.22 215 197 5.72 6.16 5550 165 6.59 138 6.34 111 6.09 84 5.85 58 5.62 165 6.59 5695 139 6.84 111 6.58 84 6.33 56 6.08 30 5.83 139 6.84 5833 108 7.07 80 6.81 52 6.55 25 6.29 108 7.07 6111 49 7.57 21 7.28 49 7.57

Factory setting 14.30 r/s

4 turns open 12.92 r/s

3 turns open 13.27 r/s

2 turns open 13.62 r/s

1 turn open 13.95 r/s

Standard motor: 7.5 kW

13

Fan performance (optional drive - high static pressure 1) 48AZ/UZ 016


Motor pulley position Closed 19.98 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 2022 2222 378 359 2.16 2.37 353 335 2.03 2.24 329 311 1.91 2.11 306 287 1.79 1.99 283 264 1.69 1.87 2361 348 2.53 323 2.39 299 2.25 275 2.13 252 2.01 2528 336 2.73 311 2.59 287 2.45 262 2.32 239 2.19 2916 323 3.24 297 3.08 271 2.93 246 3 221 2.64 3033 296 3.41 269 3.25 243 3.09 217 2.94 191 2.78

48AZ/UZ 020
Motor pulley position Closed 19.07 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 2611 2777 512 498 3.44 3.66 486 472 3.29 3.51 460 447 3.15 3.36 435 422 3.01 3.22 411 397 2.88 3.08 3055 467 4.06 441 3.90 416 3.75 390 3.59 366 3.44 3444 404 4.69 378 4.51 351 4.34 325 4.17 300 4.00 3611 385 4.97 358 4.79 331 4.60 305 4.43 279 4.26 3944 329 5.58 302 5.38 274 5.18 247 4.99 220 4.80

1 turn open 19.40 r/s

2 turns open 18.83 r/s

3 turns open 18.25 r/s

4 turns open 17.67 r/s

4 turns open 17.40 r/s

3 turns open 17.82 r/s

2 turns open 18.23 r/s

1 turn open 18.65 r/s

Standard motor: 3 kW

Standard motor: 5.5 kW

48AZ/UZ 024
Motor pulley position Closed 19.07 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 2777 3055 430 409 3.66 4.06 404 383 3.51 3.90 378 358 3.36 3.75 353 332 3.22 3.59 329 308 3.08 3.44 3472 373 4.74 346 4.56 320 4.38 293 4.21 268 4.05 3611 358 4.97 331 4.79 304 4.60 278 4.43 252 4.26 3888 319 5.47 291 5.27 264 5.08 237 4.89 210 4.71 4166 256 6.00 227 5.79 199 5.59 171 5.38 143 5.19

48AZ/UZ 028
Motor pulley position Closed 19.15 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 3138 3333 470 457 4.23 4.54 441 428 4.04 4.34 412 399 3.86 4.15 384 370 3.69 3.97 356 342 3.52 3.79 3611 435 5.01 404 4.80 375 4.60 345 4.40 316 4.22 3944 377 5.95 344 5.72 313 5.50 282 5.27 251 5.06 4166 371 6.04 338 5.81 307 5.58 276 5.35 245 5.14 4750 250 7.28 216 7.00 181 6.74 147 6.48 114 6.23

1 turn open 18.65 r/s

2 turns open 18.23 r/s 3 turns open 17.82 r/s 4 turns open 17.40 r/s

1 turn open 18.68 r/s

2 turns open 18.23 r/s

3 turns open 17.77 r/s

4 turns open 17.30 r/s

Standard motor: 5.5 kW

Standard motor: 5.5 kW

48AZ 034
Motor pulley position Closed 15.32 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 5000 5277 328 310 6.43 6.90 298 280 6.17 6.62 270 251 5.91 6.36 242 222 5.66 6.09 214 194 5.42 5.83 5550 283 7.39 252 7.09 223 6.80 193 6.53 164 6.26 5695 259 7.65 228 7.34 198 7.05 168 6.77 138 6.49 5833 233 7.90 202 7.59 171 7.30 141 7.00 111 6.72 6111 194 8.43 163 8.11 131 7.80 100 7.49 69 7.19

48AZ 040
Motor pulley position Closed 15.88 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 5000 5277 339 324 6.84 7.34 311 296 6.59 7.07 284 268 6.34 6.80 257 240 6.10 6.55 230 213 5.86 6.30 5550 295 7.84 266 7.56 237 7.29 209 7.01 182 6.75 5695 270 8.12 241 7.83 212 7.54 183 7.26 155 7.00 5833 241 8.39 212 8.09 183 7.79 154 7.51 125 7.24 6111 186 8.93 156 8.63 126 8.32 96 8.02 67 7.74

1 turn open 14.95 r/s

2 turns open 14.58 r/s 3 turns open 14.22 r/s 4 turns open 13.83 r/s

1 turn open 15.55 r/s

2 turns open 15.20 r/s

3 turns open 14.85 r/s

4 turns open 14.50 r/s

Standard motor: 7.5 kW Legend: Pa - External static pressure kW - Fan power input Higher than the nominal motor power Note: The factory setting for the motor pulley position is "Closed".

Standard motor: 7.5 kW

14

Fan performance (optional drive - high static pressure 2) 48AZ/UZ 016


Motor pulley position Closed 21.53 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 2022 2222 492 474 2.55 2.84 466 448 2.43 2.71 441 421 2.32 2.60 416 396 2.22 2.48 392 371 2.11 2.37 2361 461 3.05 434 2.92 407 2.80 381 2.67 355 2.56 2528 446 3.33 418 3.19 391 3.06 364 2.93 337 2.80 2916 421 4.02 391 3.86 362 3.71 333 4 304 3.41 3033 388 4.24 358 4.07 328 3.92 298 3.76 269 3.61

48AZ/UZ 020
Motor pulley position Closed 20.23 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 2611 2777 588 574 3.88 4.12 555 542 3.69 3.92 524 510 3.51 3.73 493 479 3.33 3.55 463 449 3.16 3.38 3055 544 4.55 512 4.34 480 4.14 448 3.95 418 3.76 3444 482 5.22 449 4.99 417 4.77 385 4.56 354 4.35 3611 464 5.52 430 5.28 398 5.06 365 4.84 334 4.62 3944 411 6.16 376 5.91 342 5.67 309 5.43 277 5.19

1 turn open 21.00 r/s

2 turns open 20.48 r/s 3 turns open 19.97 r/s 4 turns open 19.45 r/s

1 turn open 19.75 r/s 2 turns open 19.25 r/s 3 turns open 18.77 r/s 4 turns open 18.28 r/s

Standard motor: 4 kW

Standard motor: 5.5 kW

48AZ/UZ 024
Motor pulley position Closed 20.23 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 2777 3055 506 486 4.12 4.55 473 454 3.92 4.34 442 422 3.73 4.14 411 390 3.55 3.95 381 360 3.38 3.76 3472 451 5.27 418 5.04 385 4.82 353 4.61 322 4.40 3611 437 5.52 403 5.28 370 5.06 338 4.84 307 4.62 3888 400 6.05 366 5.80 332 5.56 299 5.33 267 5.10 4166 338 6.62 303 6.36 269 6.10 235 5.85 201 5.61

48AZ/UZ 028
Motor pulley position Closed 20.23 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 3138 3333 541 529 4.67 5.01 508 496 4.46 4.79 476 464 4.26 4.57 445 432 4.06 4.36 415 401 3.87 4.17 3611 508 5.50 474 5.27 441 5.05 409 4.83 378 4.61 3944 473 6.16 439 5.90 405 5.66 372 5.42 339 5.19 4166 447 6.61 412 6.35 378 6.09 343 5.84 310 5.60 4750 332 7.91 294 7.62 258 7.33 221 7.04 185 6.76

4 turns open 18.28 r/s

3 turns open 18.77 r/s

1 turn open 19.75 r/s 2 turns open 19.25 r/s

1 turn open 19.75 r/s 2 turns open 19.25 r/s 3 turns open 18.77 r/s 4 turns open 18.28 r/s

Standard motor: 5.5 kW

Standard motor: 7.5 kW

48AZ 034
Motor pulley position Closed 15.95 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 5000 5277 444 429 6.99 7.47 414 398 6.72 7.19 384 368 6.46 6.92 355 337 6.21 6.65 325 308 5.96 6.39 5550 404 7.97 372 7.68 341 7.39 311 7.12 280 6.85 5695 381 8.24 349 7.94 318 7.65 287 7.37 256 7.09 5833 357 8.51 324 8.20 292 7.91 261 7.61 231 7.32 6111 320 9.06 287 8.74 255 8.42 223 8.12 191 7.82

48AZ 040
Motor pulley position Closed 16.02 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 5000 5277 416 403 7.04 7.53 376 362 6.69 7.15 336 321 6.34 6.79 297 281 6.00 6.44 259 242 5.68 6.11 5550 375 8.03 333 7.64 292 7.26 251 6.90 211 6.54 5695 351 8.30 309 7.90 266 7.52 225 7.14 185 6.77 5833 323 8.57 280 8.16 237 7.77 196 7.38 155 7.01 6111 269 9.13 225 8.69 182 8.28 139 7.88 98 7.48

1 turn open 15.60 r/s

2 turns open 15.25 r/s 3 turns open 14.90 r/s 4 turns open 14.55 r/s

1 turn open 15.55 r/s

2 turns open 15.08 r/s

3 turns open 14.62 r/s

4 turns open 14.15 r/s

Standard motor: 2 x 4 kW Legend: Pa - External static pressure (standard filters, dry coil) kW - Fan power input Higher than the nominal motor power Note: The factory setting for the motor pulley position is "Closed".

Standard motor: 2 x 4 kW

15

Fan performance (optional drive - high static pressure 3) 48AZ/UZ 016


Motor pulley position Closed 23.92 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 2022 2222 618 602 3.13 3.45 580 564 2.95 3.27 543 526 2.78 3.09 508 490 2.62 2.92 473 454 2.46 2.75 2361 591 3.70 552 3.50 514 3.31 477 3.13 441 2.96 2528 579 4.01 539 3.81 501 3.60 463 3.41 425 3.23 2916 562 4.79 520 4.56 479 4.33 439 4.11 399 3.90 3033 532 5.04 490 4.80 448 4.56 406 4.34 366 4.12

48AZ/UZ 020
Motor pulley position Closed 22.48 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 2611 2777 746 732 4.82 5.08 710 697 4.60 4.86 675 661 4.38 4.64 640 627 4.17 4.43 607 593 3.98 4.23 3055 703 5.58 667 5.34 631 5.10 597 4.88 563 4.66 3444 643 6.33 606 6.07 571 5.82 536 5.58 502 5.34 3611 625 6.66 589 6.40 553 6.15 518 5.89 483 5.65 3944 575 7.40 538 7.11 501 6.84 465 6.57 430 6.31

1 turn open 23.22 r/s

2 turns open 22.53 r/s

1 turn open 22.00 r/s

3 turns open 21.83 r/s

2 turns open 21.50 r/s

4 turns open 21.13 r/s

3 turns open 21.02 r/s

4 turns open 20.53 r/s

Standard motor: 5.5 kW

Standard motor: 7.5 kW

48AZ/UZ 024
Motor pulley position Closed 22.48 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 2777 3055 664 645 5.08 5.58 628 609 4.86 5.34 593 573 4.64 5.10 559 539 4.43 4.88 525 505 4.23 4.66 3472 611 6.38 575 6.12 539 5.87 504 5.63 470 5.39 3611 598 6.66 561 6.40 526 6.15 490 5.89 456 5.65 3888 563 7.27 527 6.99 490 6.71 455 6.45 420 6.19 4166 505 7.92 467 7.62 430 7.33 394 7.04 358 6.77

48AZ/UZ 028
Motor pulley position Closed 21.45 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 3138 3333 625 614 5.22 5.57 589 577 4.98 5.32 553 541 4.75 5.08 518 506 4.52 4.85 484 471 4.31 4.62 3611 593 6.12 556 5.85 520 5.59 484 5.34 449 5.10 3944 560 6.81 522 6.53 485 6.25 449 5.98 413 5.72 4166 535 7.29 497 6.99 459 6.71 422 6.43 386 6.15 4750 426 8.69 385 8.36 345 8.02 306 7.71 266 7.40

1 turn open 22.00 r/s

2 turns open 21.50 r/s

1 turn open 20.93 r/s

3 turns open 21.02 r/s

2 turns open 20.42 r/s

4 turns open 20.53 r/s

3 turns open 19.90 r/s

4 turns open 19.37 r/s

Standard motor: 7.5 kW

Standard motor: 7.5 kW

48AZ 034
Motor pulley position Closed 17.02 r/s 1 turn open 16.65 r/s 2 turns open 16.28 r/s 3 turns open 15.92 r/s 4 turns open 15.53 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 5000 5277 542 528 7.85 8.38 508 493 7.54 8.07 474 459 7.25 7.75 441 426 6.96 7.44 409 393 6.68 7.15 5550 505 8.92 470 8.58 435 8.26 401 7.94 367 7.63 5695 483 9.21 447 8.87 413 8.54 378 8.21 344 7.89 5833 459 9.50 424 9.15 388 8.81 354 8.48 319 8.16 6111 425 10.10 389 9.73 352 9.38 317 9.03 282 8.69

48AZ 040
Motor pulley position Closed 17.17 r/s Pa kW Pa kW Pa kW Pa kW Pa kW Air flow, l/s 5000 5277 521 509 7.97 8.50 483 470 7.62 8.14 445 432 7.29 7.79 408 394 6.97 7.44 371 357 6.65 7.11 5550 482 9.05 443 8.67 404 8.30 366 7.94 328 7.60 5695 460 9.34 420 8.96 381 8.58 342 8.22 304 7.86 5833 432 9.63 392 9.24 353 8.85 314 8.48 275 8.12 6111 381 10.23 340 9.82 299 9.43 259 9.04 221 8.65

1 turn open 16.75 r/s

2 turns open 16.33 r/s

3 turns open 15.92 r/s

4 turns open 15.50 r/s

Standard motor: 2 x 5.5 kW Legend: Pa - External static pressure kW - Fan power input Higher than the nominal motor power Note: The factory setting for the motor pulley position is Closed.

Standard motor: 2 x 5.5 kW

16

Electrical data
48AZ Nominal supply Voltage range Nominal power input* Effective power input* Nominal current drawn* Effective current drawn* Maximum power input*** Maximum current drawn*** Starting current V-ph-Hz V kW kW A A kW A A 016 400-3-50 360-440 17.49 16.14 36.30 33.50 20.63 42.78 182 020 360-440 27.08 25.16 49.33 45.84 30.07 54.75 133 024 360-440 31.85 29.85 56.23 52.70 37.56 66.29 184.3 028 360-440 37.11 34.74 72.47 67.85 44.39 86.68 216 034 360-440 45.70 42.37 79.70 73.90 50.75 88.50 315 028 360-440 35.41 36.37 33.04 34.00 67.85 68.62 63.31 64.15 42.28 44.26 81.01 83.51 216 040 360-440 54.10 50.81 92.80 87.15 60.10 103.10 340

48UZ 016 020 024 Nominal supply V-ph-Hz 400-3-50 Voltage range V 360-440 360-440 360-440 Nominal power input Cooling* kW 17.01 26.12 31.76 Heating** kW 16.77 21.91 33.54 Effective power input Cooling* kW 15.66 24.20 29.76 Heating** kW 15.42 19.99 31.54 Nominal current drawn Cooling* A 35.09 46.76 56.23 Heating** A 34.54 42.00 58.02 Effective current drawn Cooling* A 32.31 43.32 52.69 Heating** A 31.76 38.32 54.56 Maximum power input Cooling*** kW 20.03 28.97 37.41 Heating**** kW 19.21 25.85 36.06 Maximum current drawn Cooling*** kW 41.32 51.86 66.23 Heating**** kW 39.57 49.55 62.38 Starting current A 182 133 184.3 * Nominal Eurovent conditions: outdoor air dry bulb temperature of 35oC, indoor air wet bulb temperature of 19oC. o ** Nominal Eurovent conditions: outdoor air wet bulb temperature of 6 C, indoor air dry bulb temperature of 20oC. *** Based on an outdoor air dry bulb temperature of 46oC. **** Based on an outdoor air wet bulb temperature of 18oC and an indoor air dry bulb temperature of 27C. Standard units (without options and accessories).

Electrical data notes: 48AZ/UZ units have a single power connection point located at the main switch. The control box includes the following standard features: a main disconnect switch, starter and motor protection devices for each compressor, fans and electrical heater option the control devices Field connections: All connections to the system and the electrical installations must be in full accordance with all applicable local codes. The Carrier 48AZ/UZ units are designed and built to ensure conformance with these codes. The recommendations of European standard EN 60204-1 (machine safety - electrical machine components - part 1: general regulations - corresponds to IEC 60204-1) are specifically taken into account, when designing the electrical equipment.

1.

2. 3. 4. 5. 6.

NOTES: Generally the recommendations of IEC 60364 are accepted as compliance with the requirements of the installation directives. Conformance with EN 60204 is the best means of ensuring compliance with the Machines Directive 1.5.1. Annex B of EN 60204-1 describes the electrical characteristics used for the operation of the machines.

The operating environment is specified below: a. Environment* - Environment as classified in EN 60721 (corresponds to IEC 60721): - outdoor installation (IP24) - ambient temperature range: -10C to +46C - altitude: 2000 m b. Competence of personnel, class BA4 (trained personnel - IEC 60364) Power supply frequency variation: 2 Hz. The neutral (N) conductor must not be connected directly to the unit (if necessary use a transformer). Overcurrent protection of the power supply conductors is not provided with the unit. The factory-installed disconnect switch(es)/circuit breaker(s) is (are) of a type suitable for power interruption in accordance with EN 60947. The units are designed for connection to TN networks (IEC 60364). For IT networks the earth connection must not be at the network earth. Provide a local earth, consult competent local organisations to complete the electrical installation.

Caution: If particular aspects of an actual installation do not conform to the conditions described above, or if there are other conditions which should be considered, always contact your local Carrier representative.

17

Recommended wire sections Wire sizing is the responsibility of the installer, and depends on the characteristics and regulations applicable to each installation site. The following is only to be used as a guideline, and does not make Carrier in any way liable. After wire sizing has been completed, using the certified dimensional drawing, the installer must ensure easy connection and define any modifications necessary on site. The connections provided as standard for the field-supplied power entry cables to the general disconnect/isolator switch are designed for the number and type of wires, listed in the table below. The calculations are based on the maximum machine current (see electrical data tables) and the standard installation practises, in accordance with IEC 60364, table 52C. The calculation is based on PVC Cu. A maximum ambient temperature of 46C has been taken into consideration.

WARNING: Before performing service or maintenance operations on the unit, isolate the gas supply and turn off the main power switch to the unit. Electrical shock could cause personal injury. This unit is designed for ducted installation (indoor air discharge). If ducts are not used the installer must place a protection grille in the discharge. Only for use when repairing Original Spare Parts. For repairs, special attention must be paid to the correct installation of the spare parts. The parts must always be installed in their original position. During unit operation, some of the refrigerant circuit elements could reach a temperature in excess of 70C so only trained or qualified personnel should access areas protected by access panels. This unit should not be installed in an explosive atmosphere. The unit can operate in normal radioelectric atmospheres in residential, commercial and light industrial installations. For other applications, please consult Carrier. INSTALLATION Inspect shipment. Inspect the unit. If it is damaged, or if the shipment is incomplete, immediately file a claim with the shipping company. Check that the local power supply agrees with the specification on the unit nameplate.

IMPORTANT: Before connection of the main power cables (L1 - L2 - L3) on the terminal block, it is imperative to check the correct order of the 3 phases before proceeding to the connection on the main disconnect/isolator switch.
FLA

The given wire length limits the voltage drop to < 5% (length L in metres - see table below).
Cable type PVC Cu PVC Cu PVC Cu PVC Cu PVC Cu PVC Cu PVC Cu PVC Cu L (mm) 65 80 95 115 130 160 175 195

S min. (mm2) by phase 36.0 1x6 50.0 1 x 10 66.0 1 x 16 84.0 1 x 25 104.0 1 x 35 123.0 1 x 50 155.0 1 x 70 192.0 1 x 95 FLA Full load current, A

Siting the unit Check the following points: The location must be able to support the unit operating weight (see Physical data table). Allow sufficient space for servicing and air flow around the unit (see dimensional drawings). Select a location free of dust or foreign matter which may cause coil clogging. Consult all applicable rules and standards which govern the installation of air conditioning equipment. Vibration absorbers should be provided throughout the installation to prevent noise transmission. Rigging Use a hoisting chain with a minimum length of 5 m and a suitable rigging hook to lift the unit (see Fig. 4). To prevent damage while in transit, do not remove the protective panel materials until it is at its final location. Never roll or tip the unit more than 15. IMPORTANT: Make sure that all unit panels are fixed in place before moving. Raise and set down the unit carefully.

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, start-up or service air conditioning equipment. All operations (other than those stated in the User Instruction booklet) 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 a quenching cloth for unbrazing operations.

18

Fig. 4 - Rigging 48AZ/UZ 016-020


3500 mm

Due to the size and weight of the units the base frame must be on some kind of support which fulfils the following requirements: The surface area must be sufficient for distributing the unit weight over the building structure. Sufficient drainholes should be provided to avoid the accumulation of rainwater. The unit should be firmly fixed to the floor. The structure should be capable of supporting the unit weight during installation and operation. The standard unit leaves the factory with the air discharge and return flanges in the lower section (see Fig. 6) and the corresponding holes in the support (see Fig. 5) must be made. Fig. 5 - Hole for ducts (standard unit)

48AZ/UZ 024-028 AIR IN


3500 mm

AIR OUT

48AZ 034-040

3500 mm

48AZ/UZ 016-028 48AZ 034-040

a 285 287

b c 1745 154 1745 156

d e 2115 208 3572 210

f g 1700 276 1700 278

h i j k 500 418.5 418.5 101 1005 423 650 120

Mount the parts, marked * in the position shown in Fig. 6 before the unit is placed on the support. Fig. 6 - Unit air inlet and outlet

Air out

Unit base frame This appliance is for connection to a ducted air system only. It shall not be used without ductwork connected to the air out or discharge side of the appliance. It is possible to provide fresh air to the appliance inlet air side without the use of duct work via an optional kit containing a louvre system, and protective hood and grilles. Consult the appliance supplier or distributor for more information.

Air in

19

Air inlet and outlet flange parts should be mounted as shown in Fig. 7 (b) before the unit is placed on the support. Fig. 7 - View A-A of Fig. 6 (a)
Air inlet

Fig. 10 - Front discharge and return

Air inlet

(b)

Min. 500 Min.500 mm mm

See note Air outlet


Air outlet

See note

Roof slab field-supplied

See note Roof slab See note field-supplied

Fig. 8 - Standard discharge and return

Roof slab

Roof slab

It is necessary to use adequate sealants and joints to ensure correct fitting and watertightness between the ducts and the support so that air and moisture do not enter the building. WARNING: Do not drill any holes in the indoor coil area as this might damage the condensate drain pan. IMPORTANT: The unit should be correctly levelled to avoid drainage problems.

Roof slab

Roof slab

See note Air inlet


Air inlet

See note

See note Air outlet Air outlet

Sensor connection and location Outdoor temperature sensor, space temperature sensor and supply temperature sensor are provided in the control box together with their connectors. Please refer to the wiring diagrams for the required connection and correct cable diameters. Criteria for selecting sensor locations will vary with system and building specifics. Recommended sensor locations are shown in Fig. 11. 1. Outdoor temperature sensor 2. Space (ambient) temperature sensor 3. Supply temperature sensor (2*) if the space temperature sensor is used in a duct, the space temperature sensor must be selected as same type of supply temperature sensor. Fig. 11 - Sensor location

See note

NOTE: Do not drill in this area as damage to basepan and refrigerant lines may result in water leakage.

Alternatively, the return air can enter through the rear section (see Fig. 9). In this case, remove the panel and place it on the lower section. Fig. 9 - Return air through unit rear

Air inlet
Roof See note slab See note

Air inlet

Min. Min.500 mm 500 mm

Roof slab field-supplied

field-supplied

See note Air outlet


Air outlet

See note

Roof slab Roof slab

Roof slab

The unit air discharge and return can be effected through the side (Fig. 10). In this case, the optional roof curb must be used after placing the panel covering the return area in the lower section.
Air inlet Air outlet

20

Ductwork The ductwork dimensions should be determined in accordance with the air flow to be carried, and the available static pressure of the unit. The different air flows and static pressures which each unit can supply, are shown in the fan performance tables. It is recommended to observe the following considerations: Whatever type of ductwork is used, it should not be made of materials which are flammable, or which give off toxic gases in the event of a fire. The internal surfaces should be smooth, and not contaminate the air which passes through. It is recommended to use sheet metal ducts which are adequately insulated to avoid condensation and thermal leakage. At the points where the ducts join the unit, it is recommended to use flexible connections which absorb vibrations, prevent noise inside the ductwork and allow access to the unit. Bends near the unit outlet should be avoided as much as possible. If unavoidable, they should be as slight as possible, and internal deflectors should be used when the duct has large dimensions. NOTE: All duct sizing and design work should be carried out by qualified technicians. Condensate and rainwater drainage The units incorporate drillholes in the base near the outdoor coils to drain rainwater and condensation. The indoor heat exchanger area incorporates a condensate pan with an outside drain pipe diameter of 23 mm, and a 35 mm diameter drillhole must be made in the support (see Fig. 12). Fig. 12 - Condensate drain details
Drain pipe 23 mm outside diameter (OD)

Fig. 13 - Condensate drain pipe details


Drain pipe 23 mm outside diameter

Field-supplied

ELECTRICAL CONNECTIONS WARNING: To prevent electrical shock or equipment damage, make sure disconnects are open before electrical connections are made. If this action is not taken, personal injury may occur. Field wiring must comply with all applicable codes. Take special care when making the earth connection. Voltage to the unit must be within 10% of the voltage and 10% of the current indicated on the nameplate. Contact your local power company for correction of an incorrect line voltage. Check the voltage before selecting supply wiring fuses and controls. WARNING: Operation of the unit with an improper supply voltage or excessive phase imbalance constitutes abuse which will invalidate the Carrier warranty. If the phase imbalance exceeds 2% for voltage, or 10% for current, contact your local electricity supply source at once and ensure that the chiller is not switched on until corrective measures have been taken. IMPORTANT: To ensure the correct unit power supply (cable entry, conductor cross section, protection devices etc.), consult the electrical data table, the wiring diagram supplied with the unit and the applicable standards concerning the installation of air conditioning equipment. Never operate a unit if the voltage imbalance exceeds 2%. The following formula must be used to determine the percentage of voltage imbalance. Voltage imbalance % = Largest deviation from average voltage Average voltage

Drillhole 35 mm outside diameter (OD)

A drain pipe for evacuating condensate must be incorporated taking into account the following recommendations: Use galvanized steel, copper or plastic piping. Do not use ordinary garden hose material. If a rigid material has been used for the drain pipe, it is necessary to provide an elastic coupling in the drainage line to absorb possible vibrations. It is recommended to incorporate a trap of the appropriate dimensions (see Fig. 13). The drain pipe should always be below the connection itself, and should slope to facilitate drainage.

21

example: Nominal supply: 400-3-50 AB = BC = AC = 404 V 399 V 394 V 404 + 399 + 394 3

Necessary checks/precautions before start-up


Motor

Average voltage =

= 399 = 400 V

Determine maximum deviation from average voltage: AB = BC = AC = 404 - 400 = 4 400 - 399 = 1 400 - 394 = 6

Largest deviation is 6 volts. Percentage voltage imbalance is therefore: 6 x 100 = 1.5% 400 This is less than the permissible 2% and is therefore acceptable. CAUTION: The installer must install protection devices, as required by the applicable legislation. Inserting line power leads into unit Install air-tight duct conduits in the front panel knock-outs. Route all wires through the conduits to terminal blocks in the control box. Use copper, copper-clad aluminium or aluminium wire for power supply. Thermostat connection Thermostat/unit connection must be via a loom (wire cross section depends on the cable length) manufactured in accordance with the wiring diagram accompanying the unit. Follow the instructions supplied with the control for thermostat assembly and handling. The general rules below should be taken into account: Voltage at 24 V AC Standard outlet (service C, R, G, Y1/W2,Y1, Y/Y2, O/ W2, W/W1) Outlet O is active on cooling NOTE 1: The thermostat cables should be separate from any 230 V or 400 V cable.

Ensure that all electrical connections are properly tightened. Ensure that the unit is level and well-supported. Check the condition of the ductwork in case damage has occurred during installation. The air filter should be clean and in place. All the panels should be fitted and firmly secured with the corresponding screws. Make sure that there is sufficient space for servicing and maintenance purposes. Check the drain connections. Ensure that there are no refrigerant leaks. Confirm that the electrical power source agrees with the unit nameplate rating. Make sure that compressors float freely on the mounting springs.

WARNING: The compressors are mounted on vibration isolators. Do not loosen or remove the support mounting bolts. Check for proper fan rotation.

VERIFICATION OF THE REFRIGERANT CHARGE CAUTION: The 48AZ/UZ units are supplied with a precise refrigerant charge (see Physical Data table). To verify the correct system charge prodeed as follows: Set unit to cooling mode. Ensure that no bubbles appear in the sight glass, when operating the unit at full load for a while, at a saturated condensing temperature of between 52 and 54C. If necessary cover a section of the coil surface to obtain this condensing temperature. Under these conditions the apparent subcooling which is equal to the saturated condensing temperature (1 - on the saturated dew point curve) minus the liquid refrigerant temperature (3) ahead of the expansion device must be between 8 and 10C. This corresponds to an actual subcooling temperature of between 3 and 5 K at the condenser outlet, depending on the unit type. Actual subcooling is equal the saturated liquid temperature (2 - on the saturated bubble point curve) minus the liquid refrigerant temperature (3) ahead of the expansion device. Use the pressure tap supplied on the liquid piping to charge refrigerant and to find out the pressure of the liquid refrigerant. If the subcooling value is not correct, i.e. lower than the specified values, a leak detection test must be carried out on the unit, as it no longer contains its original charge. WARNING: To ensure proper operation of 48AZ/UZ units there must be at least 8 K of subcooling as the liquid refrigerant enters the expansion valve. The 48AZ/UZ units use refrigerant. For your information, we are reproducing here some extracts from the official publication dealing with the design, installation, operation and maintenance of air conditioning and refrigeration systems and the training of people involved in these activities, agreed by the air conditioning and refrigeration industry.

22

Refrigerant guidelines Refrigeration installations must be inspected and maintained regularly and rigorously by specialists. Their activities must be overseen and checked by properly trained people. To minimise discharge to the atmosphere, refrigerants and lubricating oil must be transferred using methods which reduce leaks and losses to a minimum and with materials that are suitable for the products. Leaks must be repaired immediately. All units are equipped with connections on the suction and liquid line, which permit the connection of refrigerant recovery valves. If the residual pressure is too low to make the transfer alone, a purpose-built refrigerant recovery unit must be used. Compressor lubricating oil contains refrigerant. Any oil drained from a system during maintenance must therefore be handled and stored accordingly. Refrigerant under pressure must never be discharged to the atmosphere. If the refrigerant circuit is opened, plug all openings if the operation takes up to one day, or charge the circuit with nitrogen for longer operations. Apparent and actual subcooling

Recharging liquid refrigerant CAUTION: 48AZ/UZ units are charged with liquid HFC-407C refrigerant. This non-azeotropic refrigerant blend consists of 23% R-32, 25% of R-125 and 52% R-134a, and is characterised by the fact that at the time of the change in state the temperature of the liquid/vapour mixture is not constant, as with azeotropic refrigerants. All checks must be pressure tests, and the appropriate pressure/temperature ratio table must be used to determine the corresponding saturated temperatures (saturated bubble point curve or saturated dew point curve). Leak detection is especially important for units charged with refrigerant R-407C. Depending on whether the leak occurs in the liquid or in the vapour phase, the proportion of the different components in the remaining liquid is not the same. NOTE: Regularly carry out leak checks and immediately repair any leak found. If there is a leak in the plate heat exchanger, this part must be replaced. Undercharge If there is not enough refrigerant in the system, this is indicated by gas bubbles in the moisture sight glass in the cooling mode.
1

5 3 2

If the undercharge is significant, large bubbles appear in the moisture sight glass, and the suction pressure drops. The compressor suction superheat is also high. The machine must be recharged after the leak has been repaired. Find the leak and completely drain the system with a refrigerant recovery unit. Carry out the repair, leak test and then recharge the system. IMPORTANT: After the leak has been repaired, the circuit must be tested, without exceeding the maximum low-side operating pressure shown on the unit name plate. The refrigerant must always be recharged in the liquid phase into the liquid line. The refrigerant cylinder must always contain at least 10% of its initial charge. For the refrigerant quantity per circuit, refer to the data on the unit name plate. Characteristics of R-407C See the table on the next page. Saturated bubble point temperatures (bubble point curve) Saturated dew point temperatures (dew point curve)

Pressure

L+V

Enthalpy Legend 1 Saturated condensing temperature at the dew point 2 Saturated liquid temperature at the bubble point 3 Liquid refrigerant temperature 4 Saturation curve at the dew point 5 Saturation curbe at the bubble point 6 Isotherms 7 Apparent subcooling (1 - 3) 8 Real subcooling (2 - 3) L Liquid L + V Liquid + vapour V Vapour

23

Characteristics of R-407C
Bar (relative) 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 4.25 4.5 4.75 5 5.25 5.5 5.75 6 6.25 6.5 6.75 7 7.25 7.5 7.75 8 8.25 8.5 8.75 9 9.25 9.5 9.75 10 10.25 Saturated bubble point temp. , C -28.55 -25.66 -23.01 -20.57 -18.28 -16.14 -14.12 -12.21 -10.4 -8.67 -7.01 -5.43 -3.9 -2.44 -1.02 0.34 1.66 2.94 4.19 5.4 6.57 7.71 8.83 9.92 10.98 12.02 13.03 14.02 14.99 15.94 16.88 17.79 18.69 19.57 20.43 21.28 22.12 22.94 Saturated dew point temp., C -21.72 -18.88 -16.29 -13.88 -11.65 -9.55 -7.57 -5.7 -3.93 -2.23 -0.61 0.93 2.42 3.85 5.23 6.57 7.86 9.11 10.33 11.5 12.65 13.76 14.85 15.91 16.94 17.95 18.94 19.9 20.85 21.77 22.68 23.57 24.44 25.29 26.13 26.96 27.77 28.56 Bar (relative) 10.5 10.75 11 11.25 11.5 11.75 12 12.25 12.5 12.75 13 13.25 13.5 13.75 14 14.25 14.5 14.75 15 15.25 15.5 15.75 16 16.25 16.5 16.75 17 17.25 17.5 17.75 18 18.25 18.5 18.75 19 19.25 19.5 19.75 Saturated bubble point temp., C 23.74 24.54 25.32 26.09 26.85 27.6 28.34 29.06 29.78 30.49 31.18 31.87 32.55 33.22 33.89 34.54 35.19 35.83 36.46 37.08 37.7 38.31 38.92 39.52 40.11 40.69 41.27 41.85 42.41 42.98 43.53 44.09 44.63 45.17 45.71 46.24 46.77 47.29 Saturated dew point temp., C 29.35 30.12 30.87 31.62 32.35 33.08 33.79 34.5 35.19 35.87 36.55 37.21 37.87 38.51 39.16 39.79 40.41 41.03 41.64 42.24 42.84 43.42 44.01 44.58 45.15 45.71 46.27 46.82 47.37 47.91 48.44 48.97 49.5 50.02 50.53 51.04 51.55 52.05 Bar (relative) 20 20.25 20.5 20.75 21 21.25 21.5 21.75 22 22.25 22.5 22.75 23 23.25 23.5 23.75 24 24.25 24.5 24.75 25 25.25 25.5 25.75 26 26.25 26.5 26.75 27 27.25 27.5 27.75 28 28.25 28.5 28.75 29 29.25 Saturated bubble point temp., C 47.81 48.32 48.83 49.34 49.84 50.34 50.83 51.32 51.8 52.28 52.76 53.24 53.71 54.17 54.64 55.1 55.55 56.01 56.46 56.9 57.35 57.79 58.23 58.66 59.09 59.52 59.95 60.37 60.79 61.21 61.63 62.04 62.45 62.86 63.27 63.67 64.07 64.47 Saturated dew point temp., C 52.55 53.04 53.53 54.01 54.49 54.96 55.43 55.9 56.36 56.82 57.28 57.73 58.18 58.62 59.07 59.5 59.94 60.37 60.8 61.22 61.65 62.07 62.48 62.9 63.31 63.71 64.12 64.52 64.92 65.31 65.71 66.1 66.49 66.87 67.26 67.64 68.02 68.39

START-UP (COOLING) Actual start-up should only be done under the supervision of a qualified refrigeration mechanic. Initial checks With the unit in operation, ensure that the values shown on the high and low pressure gauges are within the normal limits. It is advisable to simulate unit shutdown due to high and low pressure, in order to make sure that the high pressure switch works properly. To do so, proceed as follows: High pressure shutdown (cooling cycle): Completely cover the outdoor air inlet, or disconnect the outdoor fan and motor. The unit should stop at a pressure of 29 bar. Low pressure shutdown (cooling cycle): Cover the indoor air inlet, or disconnect the indoor fan and motor. Observe the low pressure gauge. The unit should stop at a pressure of 0.55 bar. Check that the motor and compressor consumptions are approximately the same as those shown on the unit nameplate. Consumption data is also given in the Electrical data table.

REFRIGERANT SYSTEM DESCRIPTION The refrigerant circuit incorporates the following primary elements: Refrigerant-air heat exchanger: made of high quality copper tubes and pretreated aluminium fins. Refrigerant lines: made completely of high quality copper. Bi-flow expansion valve Compressors: scroll compressors for 48AZ/UZ 016, 024, 028 and hermetic compressors for 48AZ/UZ 020 and 48AZ 034-040. Filter drier and obus type access valve. safety elements: high, low pressure transducer and high pressure switch. All units include the R-407C refrigerant charge necessary for correct operation.

24

COMPRESSOR REPLACEMENT When an internal fault occurs, the compressor must be replaced. This must be done as detailed below: Disconnect the unit from the electrical supply. Remove the panels. Remove the gas from the refrigerant circuit using recovery equipment to avoid harming the atmosphere. Electrically disconnect the compressor and/or remove the crankcase heater. Unbraze or unscrew the suction and discharge lines, taking care not to damage the rest of the components. Remove the fastenings. Replace the compressor, ensuring that it contains sufficient oil. Braze or screw in the lines. Connect the compressor according to the wiring diagram. Evacuate the compressor. Fill in the refrigerant charge indicated on the nameplate. NOTE: This operation must be done by a qualified technician. Description of unit protection devices The unit includes the following compressor protection devices: Internal protector for 48AZ/UZ 016-028. External protector for 48AZ 034-040. Outdoor fan motor thermomagnetic switch. Indoor fan motor thermomagnetic switch. High pressurestat This protects the unit against excessive condensing pressure. The high pressurestat has factory-fixed nonadjustable settings. To check, see section Initial checks.
High pressure Min. Max. -0.9 29 -20 68 29 32 Low pressure Min. Max. -0.9 25 -20 62 -

GAS HEATING IMPORTANT: Inadequate installation, adjustment, information, servicing or maintenance can cause damage, injury to staff or loss of life. Any unauthorized modifications or adjustments to the appliance are likely to invalidate the certification, any warranty or guarantee and may also infringe on current statutory requirements. Petrol, or other inflammable, fume-emitting products and liquids of any other application must not be stored or use in the vicinity of units. After removing panels from the unit, keep them in a safe place to prevent them dropping from the roof. Introduction The gas heating system is designed to be used as an alternative to the hot water coil or electric heating options. The rooftop unit is available with three gas heating modules with two-step heating for natural gas and one-step heating for LPG in 48AZ/UZ 016-028 series rooftop units. In 48AZ 034-040 series rooftop units, two of same modules are working in series with three-step heating for natural gas and two-step heating for LPG. tubular, dimpled gas heat exchanger The tubular, dimpled gas heat exchangers optimize the heat transfer for improved efficiency. The tubular design permits hot gases to make multiple passes across the path of the supply air. The dimpled design creates a turbulent gas flow to maximize the heating efficiency. The extra thick AlumagardTM heat exchanger coating provides corrosion resistance and ensures long life on the heat exchanger. modular burner compartment The burner assembly consists of series of injectors. The gas-air mixture, prepared in the burners, enables excellent combustion within the heat exchanger tubes. The direct-spark ignition system saves operating expense when compared to pilot igniton systems. No crossover tube is required, therefore no sooting or pilot fouling problems can occur. Induced draft combustion system The unsightly appearance of flue stacks is eliminated and the effects of wind on heating operations are diminished by the induced draft combustion system. The inducer fan draws hot combustion gas through the heat exchanger at the optimum rate for most effective heat transfer. The heat exchanger operates under negative pressure, preventing flue gas leakage into the indoor supply air for improved efficiency. Integrated gas unit controller (IgC) All ignition components are contained in the compact IGC which is easily accessible for servicing. The ignition control board with CE mark, provides built-in diagnostic capability. Two LEDs (light-emitting diodes) simplify troubleshooting by providing visual fault notification and system status confirmation. This LED fault notification system reduces service personnel troubleshooting time and minimizes service costs. 25

PS TS Pressure switch cut-out pressure Test pressure, unit leak test

bar C bar bar

WARNING: Alteration of factory settings other than the design setpoint, without manufacturer's authorisation, may void the warranty. Operating limits These units have been designed to operate within the following limits: Cooling operation
Zone Indoor Maximum Minimum Air temperature Dry bulb Wet bulb +35C +21C Dry bulb Outdoor +46C -10C Wet bulb -

Heat pump operation


Zone Indoor Maximum Minimum Air temperature Dry bulb Wet bulb +27C Dry bulb Outdoor +22C -10C Wet bulb +16C -

Fig. 14 - Tubular, dimpled gas heat exchanger

PRELIMINARY CHECKS BEFORE START-UP NOTES: Any work on the gas system must be carried out by qualified personnel. This unit must be installed in accordance with local safety codes and regulations and can only be used in a well ventilated area. Please read the manufacturers instructions carefully before starting a unit. Prior to dispatch, the rooftop unit was operated and tested at the factory. Gas type, power supply, adjustment and settings of the unit have been factory set and sealed and are indicated on the data plate. Before commissioning a unit with gas burner, it is mandatory to ensure that the gas distribution system (type of gas, available pressure) is compatible with the gas type, power supply, adjustment and settings of the unit. Check access and clearance around the unit (refer to Fig. 1) Make sure one can move freely around the unit. A minimum 2 m clearance must be left in front of the gas module side. Combustion air inlet and burnt gas exhausts must not be obstructed in any way. WARNING: This appliance is suitable only for operation using the gas as stated on the identification warning label. For appliances supplied as double category appliances, i.e. for those countries using gas categories II2H3P, II2Er3P, II2E3P and II2Hs3P, it is possible to convert from natural gas to propane or vice versa. Consult your local distributor or appliance manufacturer for further information. They will advise if conversion is suitable and will supply you with the correct conversion kit and suitable conversion instructions for your appliance. WARNING: Only original manufacturers parts shall be used. Failure to fit original manufacturers parts will invalidate any warranty or guarantee and may contravene the approval and certification of this appliance. Any gas conversion operation shall be carried out only by qualified and authorized personnel. It is the responsibility of the authorized person to ensure the correct and safe operation of the appliance following any gas conversion procedure. The appliance must be re-commissioned following any gas conversion procedure in accordance with the gas conversion instructions.

Fig. 15 - Modular burner compartment

Fig. 16 - Induced draft combustion system

26

Gas connection Gas fired rooftop units are designed to operate on either natural gas (G20)/(G25)/(G25.1) or propane gas (G31). The gas supply to a rooftop gas unit must be realized according to gas safety installation and use regulations and local safety codes and rules. The diameter of the pipework connected to each rooftop must never be smaller than the diameter of the connection on the rooftop unit. Make sure that a shut-off isolation valve has been installed before each rooftop. The isolation valve must be connected to the main gas inlet supply pipe as close as possible to the appliance. For safety and accessibility reasons the isolation valve must not be fitted within the appliance gas valve compartment. Make sure that the gas service includes a filter and has been tested and purged in accordance with prescribed practice prior to commissioning and taking the appliance into service. Gas service pipes shall not be routed through any heated or fresh air ducts. Supply network pipe sizing: female threaded connection: ISO 7 Rp 3/4.

Fig. 17 - Flue outlet terminal guard and wind baffle location for 48AZ/UZ 016-028

Operating limits Air flow limits are the minimum and maximum values given in the fan performance tables. The minimum allowable ambient (outdoor air) temperature is -15C. The maximum allowable ambient (outdoor air) temperature is 60C.

Fig. 18 - Flue outlet terminal guard and wind baffle location for 48AZ 034-040

Installation of flue outlet terminal guard and wind baffle The flue outlet terminal guard and wind baffle are shipped secured under main control box. To install, secure the flue terminal guard to the access panel. See Fig. 17. The wind baffle is then installed over the flue terminal guard. There are two flue terminal guards and wind baffles for 48AZ 034-040 units. See Fig. 18.

27

COMMISSIONING Checks to be carried out before starting up the gas burner NOTE: Access is required to the gas valve compartment only for commissioning checks. This requires the use of the special key tool supplied with the unit. Upon completion of any work the key tool shall not be left with the user so as to discourage inappropriate or unauthorized access. Required equipment list for start-up An accurate manometer from 0 to 3500 Pa (0 to 350 mbar): 0.1% full scale Flexible PVC or similar tubing Suitable gas leak detection fluid 8 mm wrench 3.5 mm screwdriver

The following recommendations refer specifically to gas operation: 1. Check that the gas used is the right type for the unit to be used. 2. Check that there is a shut-off isolation valve fitted at the gas inlet of the unit. 3. Isolate the appliance from the electrical mains supply and turn off the gas supply to the appliance at the isolation valve. 4. The whole of the gas service installation including the meter must be inspected, tested for soundness and purged in accordance with appropriate requirements. NOTE: The soundness of the gas burner pipework has been checked prior to leaving the factory. However during installation, connections may have been loosened. Check the soundness of the appliance pipework using a suitable gas leak detection solution. If any leaks are found they must be rectified immediately. CAUTION: Never use a flame for checking gas soundness. 5. To check the gas supply pressure locate the pressure test point on the inlet side of the gas valve(s). Loosen, but do not remove the screw within the test point and connect a suitable pressure gauge. Turn on the gas and electrical supplies. Check that the gas inlet pressure is at least as indicated on the appliance identification data label (e.g. for 2H - G20 - 20 mbar). Operate the appliance via the Pro-Dialog control at the maximum rate. Refer to the start-up procedures in the Setting up Pro-Dialog control section. Increase the set temperature (room setpoint temperature) to a temperature higher than the actual room temperature. Re-check that the appliance inlet pressure is as indicated on the appliance identification data label. If the inlet pressure is not as required, check supply pipework for adequacy or contact your gas supplier.

10. Turn off the appliance. Remove the pressure gauge and retighten the test point screw. Check for gas tightness at the test point using a suitable leak detection solution. 11. To check the appliance burner pressures locate the burner pressure test point on the outlet side of the gas valve(s). Loosen, but do not remove the screw within the test point and connect a suitable pressure gauge. 12. The appliance gas valve(s) is factory set and sealed at the correct settings for the gas type concerned according to the appliance data indication label and should not require adjustment. If adjustment is necessary, perhaps due to using G25 or G25.1 natural gases, then carry out the following procedure. 13. Again operate the appliance as detailed in point 8. Check that the maximum rate burner pressure is as stated on the data badge for the type of gas being supplied. If adjustment of the maximum rate is necessary refer to Pressure adjustments on the high-low regulating valve section. 14. To check the minimum rate burner pressure, disconnect one of the low voltage leads from the electrical highlow regulator to initiate operation at the minimum rate. If adjustment of the maximum rate is necessary refer to Pressure adjustments on the high-low regulating valve section. IMPORTANT: Following any adjustment procedure of the gas valve settings, the tamperproof cap must again be sealed. A suitable method is to apply a spot of durable paint as indicated in Fig. 19. 15. After checking of the burner pressures, turn the appliance off, remove the test equipment and retighten the pressure test point screw. Check for gas tightness at the test point following the restart of the appliance. 16. Before leaving the installation, instruct and demonstrate the safe and efficient operation of the appliance to the user. Guide the user through the user instructions and also leave these installation instructions in their care, stressing that they will be required for future reference. Advise the user that continued safe and efficient use is dependent on regular servicing. Recommend that the gas circuit be serviced at least annually.

6. 7. 8.

9.

28

PRESSURE ADjUSTMENTS ON THE HIGH-LOW REGULATING VALVE IMPORTANT: The appliances burner pressure settings are factory set and sealed according to the country of destination. Check and adjust if necessary the valve inlet pressure to 20.0 mbar (G20) or 25.0 mbar for (G25) or (G25.1) or 37.0 or 50.0 mbar for propane (G31) after gas burner ignition. Before commencing an adjustment connect a manometer to the burner pressure test point on the gas valve. Lever off the cover cap as indicated. The maximum high pressure setting must be adjusted first after which the minimum low rate setting can be adjusted. Any adjustment of the maximum setting influences the minimum rate setting. Do not adjust maximum or minimum settings above or below the pressure stated on the data plate or in table 1. Fig. 19 - Gas valve adjustment details
A B C Tamperproof Tamperproof paint spot

Adjusting maximum pressure Energise the high-low regulator, set the gas control in operation (light burner) and wait until an outlet pressure is recorded on the pressure gauge. Use an 8 mm wrench to turn the adjustment screw for the maximum pressure setting, clockwise to increase, counter clockwise to decrease the pressure until the desired maximum pressure is obtained. Check the maximum pressure several times. Adjusting minimum pressure Disconnect the electrical connection of the high-low regulator. Set the gas control in operation and wait until an outlet pressure is recorded on the pressure gauge. Use a 3,5 mm screwdriver to turn the adjustment screw for the minimum pressure setting, clockwise to increase, counter clockwise to decrease pressure until the desired minimum pressure is obtained. Check the minimum pressure several times. Before commencing an adjustment, connect a manometer to the burner pressure test point. Table 1 - Pressure setting for each type of gas
Category Supply pressure 20.0 1 25.0 1 25.0 1 37.0/ 50.0 1.9 G20 G25 G25.1 G31 Low heat injection 2.8 0.2 4.2 0.2 4.8 0.2 25.5 0.5 High heat Injection 5.8 0.2 8.5 0.2 9.5 0.2 25.5 0.5

paint spot

D 65

32 32

Legend: A Cap A Cap B Adjustment screw for max. pressure setting B Adjustment screw for maximum pressure setting C Adjustment screw for min. pressure setting C Adjustment screw for minimum pressure setting D 6.3 MM. AMP terminals D 6.3 mmE AMP terminals Earth terminal E Earth terminal F M5 pressure feedback connection F M5 pressure feedback connection

29

GAS CONVERSION INSTRUCTIONS WARNING: Only original manufacturers parts shall be used. Failure to fit original manufacturers parts will invalidate any warranty or guarantee and may contravene the approval and certification of this appliance. Any gas conversion operation shall be carried out only by qualified and authorized personnel. It is the responsibility of the authorized person to ensure the correct and safe operation of the appliance following any gas conversion procedure. The appliance must be re-commissioned following any gas conversion procedure in accordance with these instructions. For conversion from a natural gas appliance to a propane appliance or a propane appliance to a natural gas appliance it will be necessary to obtain the correct conversion kit for your appliance. Refer to the list below and and ensure the correct part number for the appliance has been supplied. Propane Kit A (Part no. 57080020710) - for model 48AZ/UZ 016150 - containing 5 off 1.90 mm injectors, a replacement gas type indicating sticker for the additional appliance data label. Propane Kit B (Part no. 57080020720) - for models 48AZ/UZ 016160/48AZ/UZ 020160/48AZ/UZ 024160/48AZ/UZ 028160 - containing 6 off 1.90 mm injectors, a replacement gas type indicating sticker for the additional appliance data label. Propane Kit C (Part no. 57080020730) - for models 48AZ/UZ 020170/48AZ/UZ 024170/48AZ/UZ 028170 - containing 7 off 1.90 mm injectors, a replacement gas type indicating sticker for the additional appliance data label. Propane Kit D (Part no. 57080020740) - for model 48AZ 034255/48AZ 040255 - containing 10 off 1.90 mm injectors, a replacement gas type indicating sticker for the additional appliance data label. Propane Kit e (Part no. 57080020750) - for model 48AZ 034266/48AZ 040266 - containing 12 off 1.90 mm injectors, a replacement gas type indicating sticker for the additional appliance data label. Propane Kit F (Part no. 57080020760) - for model 48AZ 034277/48AZ 040277 - containing 14 off 1.90 mm injectors, a replacement gas type indicating sticker for the additional appliance data label. natural gas Kit A (Part no. 57080020711) - for model 48AZ/ UZ 016150 - containing 5 off 3.26 mm injectors, a replacement gas type indicating sticker for the additional appliance data label. natural gas Kit B (Part no. 57080020721) - for models 48AZ/ UZ 016160/48AZ/UZ 020160/48AZ/UZ 024160/ 48AZ/UZ 028160 - containing 6 off 3.45 mm injectors, a replacement gas type indicating sticker for the additional appliance data label.

natural gas Kit C (Part no. 57080020731) - for models 48AZ/ UZ020170/48AZ/UZ024170/48AZ/UZ028170 - containing 7 off 3.45 mm injectors, a replacement gas type indicating sticker for the additional appliance data label. natural gas Kit D (Part no. 57080020741) - for model 48AZ 034255/48AZ 040255 - containing 10 off 3.26 mm injectors, a replacement gas type indicating sticker for the additional appliance data label. natural gas Kit e (Part no. 57080020751) - for model 48AZ 034266/48AZ 040266 - containing 12 off 3.45 mm injectors, a replacement gas type indicating sticker for the additional appliance data label. natural gas Kit F (Part no. 57080020761) - for model 48AZ 034277/48AZ 040277 - containing 14 off 3.45 mm injectors, a replacement gas type indicating sticker for the additional appliance data label. Sequence 1. Isolate the appliance from the electrical mains supply and turn off the gas supply to the appliance at the isolation valve. 2. Remove the flue outlet terminal guard(s) and wind baffle(s) from the compartment panel. 3. Remove the compartment cover to gain access to the burner assembly. 4. Remove the 2 screws securing the flame rollout switch to the No. 4 burner for a natural gas appliance and No. 3 burner for a propane appliance and save. 5. Remove each individual burner tube component to gain access to the injectors. Ensure that the outer burners return to the original position when re-assembling. 6. Remove the injectors using a suitable 14 mm wrench. 7. Replace the injectors with the new injectors ensuring that the injector is tightened. 8. Refit the burner tubes and reattach the flame rollout switch to burner No. 3 for propane conversion or burner No. 4 for natural gas conversion using same screws. See Fig. 20 for rollout switch relocation in case of propane conversion. 9. Replace the compartment cover and the flue outlet guard(s) and wind baffle(s). Ensure any seals are intact and correctly positioned. Replace damaged seals if necessary. 10. Commission the appliance in accordance with the Commissioning section in this manual. Fig. 20 - Rollout switch relocation for propane conversion ROLLOUT SWITCH
Rollout switch (bracket assembly
(BRACKET) ASSEMBLY

#5

#4

#3

#2

#1

Screws

SCREWS

Burner No. 1

BURNER #1

30

GAS FIRE-UP SEqUENCE


START: POWER ON Ignition control main power ON Control self-diagnostic check. Is the control operating correctly? Yes No PERMANENT LOCKOUT MODE Diagnostic LEDs will indicate lockout mode due to circuit board self-check failure or incorrect wiring to circuit board FLAME SENSE WITHOUT GAS VALVE LOCKOUT MODE CAB power on Diagnostic LEDs will indicate lockout mode due to flame sense without gas valve Does flame sense signal indicate no flame present?

Control automatically resets and clears all lockout conditions Flame Sense monitored continuously. Does Flame Sense signal indicate no flame present? Yes Rollout and limit switch monitored continuously. Is rollout and limit switch closed? Yes No

Yes

No

No

Yes

Diagnostic LEDs indicate normal operation Has first stage heat contact closed, initiating a call for heat? No Yes

ROLL-OUT/LIMIT SWITCH OPEN LOCKOUT MODE Gas valve power off CAB power off Diagnostic LEDs will indicate rollout/limit switch failure Is rollout and limit switch closed?

No

CALL FOR HEAT Diagnostic LEDs indicate control is in heating mode

PRESSURE SWITCH FAILURE LOCKOUT MODE CAB power off Diagnostic LEDs will indicate a CAB pressure switch failure Yes Has the CAB pressure switch opened?

No

Combustion Air Blower (CAB) pressure switch No monitored continuously during the heating cycle. Is the CAB pressure switch open? CAB pressure switch is powered on Yes Yes

Has the CAB pressure switch closed within 2.5 minutes? Yes 15 second pre-purge

Yes No

5-MINUTE PRESSURE SWITCH WATCH GUARD MODE Gas valve power off CAB power off Diagnostic LEDs will indicate CAB pressure switch failure Is 5-minute time period complete?

No

Ignition trial (7 seconds) (Start ignition spark. Open main gas valve) Indoor air blower is powered on 45 seconds after main gas valve is powered on Flame sensed? Yes No

1-HOUR WATCH GUARD MODE Gas valve power off CAB power off Diagnostic LEDs will indicate control is in watch guard mode due to an ignition failure or an open limit switch Yes Is 60-minute time period complete?

No

10 second flame stabilization FFRT = 1.5 seconds Flame sensed? Yes No

No

FAILED IGNITION TRIAL OR FLAME LOSS DURING FLAME STABILIZATION PERIOD Gas valve power off CAB remains on Does the total combined number of failed ignition trials and Yes flame loss during flame stabilization = 5? FLAME LOSS AFTER FLAME ESTABLISHED Gas valve power off CAB remains on Total loss of flame incidents after flame established = 5?

FLAME ESTABLISHED FFRT = 0.8 seconds Failed ignition trial/flame loss during stabilization Counter reset to 0 Flame sensed? Yes No

No

Yes

CAB pressure switch monitored continuously during the heating cycle Is pressure switch closed? No Yes No Heat demand satisfied? Yes Gas valve power off

High limit switch monitored continuously through heating cycle Is high limit switch closed? Yes

HIGH LIMIT SWITCH OPEN Gas valve power off CAB power off Diagnostic LEDs will indicate high limit switch open HIGH LIMIT SWITCH 3-MINUTE TIME-OUT Yes Has the high limit switch been open for more than 3 minutes? Yes No Has the high limit switch closed? No PRESSURE SWITCH OPEN Gas valve power off

No

CAB continues for a 5-second post-purge following a satisfied thermostat demand When heat demand is satisfied, indoor air blower continues to run

Has the CAB pressure switch Yes Has the CAB pressure switch Yes closed? reclosed more than 4 times? No No Has the CAB pressure switch Yes been open longer than 2.5 minutes? No

31

SERVICE AND MAINTENANCE WARNING: Before performing service or maintenance operations on the unit, turn off the main power switch to the unit. Weatherproof covers are required under wet conditions. Electrical shock could cause personal injury. IMPORTANT: During any service or maintenance operation, if parts are evidently faulty or damaged they shall be replaced. Only original manufacturers parts shall be used as detailed in the spare parts list. Failure to fit original manufacturers parts will invalidate any warranty or guarantee and may contravene the approval and certification of this appliance. Following any operation on the appliance which has necessitated removal and replacement of any parts, the appliance shall be recommissioned in accordance with the Commissioning section of these instructions. Cleaning Inspect unit interior at beginning of each heating and cooling season and as operating conditions require. Remove unit side panels for access to unit interior. main burner At the beginning of each heating season, inspect for deterioration or blockage due to corrosion or other causes. Observe the main burner flames. Refer to the Main burners section. Flue gas passageways The flue collector box and heat exchanger cells may be inspected by removing the heat exchanger access panel, flue box cover, and main burner assembly (Fig. 25). Refer to the Main burners section for the burner removal sequence. If cleaning is required, remove the heat exchanger baffles and clean the tubes with a wire brush. Use caution with the ceramic heat exchanger baffles. When installing a retaining clip, be sure the centre leg of the clip extends inward towards the baffle. See Fig. 21. NOTE: One baffle and clip will be in each upper tube of the heat exchanger. Fig. 21 - Removing heat exchanger ceramic baffles and clips
Ceramic CERAMIC baffles BAFFLE Clips CLIP

Combustion air blower Clean periodically to assure proper air flow and heating efficiency. Inspect the blower wheel every autumn and periodically during the heating season. For the first heating season, inspect the blower wheel bi-monthly to determine the proper cleaning frequency. To inspect the blower wheel, remove the heat exchanger access panel. Shine a flashlight into the opening to inspect the wheel. If cleaning is required, remove the motor and wheel assembly by removing the screws holding the motor mounting plate to the top of the combustion fan housing (Fig. 22). The motor and wheel assembly will slide up and out of the fan housing. Remove the blower wheel from the motor shaft and clean with a detergent or solvent. Replace the motor and wheel assembly. Fig. 22 - Typical gas heating section for 48AZ/UZ 016-028
Induced draft motor Pressure switch Combustion fan housing Integrated gas unit controller

Rollout switch

Main burner section

Flue box cover

Main gas valve

Gas pressure switch

In unit sizes 48AZ 034-040 two of same modules are working in series and all the components of gas heating section are doubled.

Heat exchanger tubes HEAT EXCHANGER TUBES

32

Temperature limit switches There is one limit switch (LS) and one high limit switch (HLS) in 48AZ/UZ 016-028 units and two limit switches (LS1, LS2) and two high limit switches (HLS1, HLS2) in 48AZ 034-040 units which are all manually reset. Fig. 23 - Temperature limit switches
48AZ 016-028 B LS VIEW A

HLS

VIEW B

HLS1

LS1

LS2

DETAIL Z

48AZ 034-040

HLS2

33

Main burners For all applications, the main burners are factory set and should require no adjustment. main burner removal 1. Shut off the (field-supplied) manual main gas valve. 2. Shut off power to the unit. 3. Open the unit control box access panel, remove the burner section access panel and centre post. 4. Disconnect the gas piping from the gas valve inlet. 5. Remove the wires from the gas valve. 6. Remove the wires from the rollout switch. 7. Remove the sensor wire and ignitor cable from the IGC board. 8. Remove the two screws securing the manifold bracket to the basepan. 9. Remove the two screws that hold the burner support plate flange to the vestibule plate. 10. Lift the burner assembly out of the unit.

Cleaning and adjustment 1. Remove the burner rack from the unit as described in the Main burner removal section above. 2. Inspect the burners, and if dirty, remove burners from the rack. 3. Using a soft brush, clean the burners and crossover port as required. 4. Adjust the spark gap. See Fig. 24. 5. Reinstall the burners on the rack. 6. Reinstall the burner rack as described above.

Fig. 24 - Main burner details


1 2 3 4 5

Z 5 CELLS

VIEW C

VIEW B 6 CELLS

B
1 2 3 4 5 6 7

B 7 CELLS

VIEW A

3.1 7+

0.3

5-

0.1

4.57-6.35

4.57- 6.35

Z DETAIL

SECTION B-B

SECTION A-A

34

Integrated gas unit controller (IGC) All ignition components are contained in the compact IGC which is easily accessible for servicing. At start-up, the control runs a self diagnostic check. Diagnostic LEDs will indicate Lockout mode after a circuit board self-check or incorrect wiring to the circuit board. In 48AZ 034-040 series units, each module has its own ignition board. In the first heating stage, the first module is fired. At the second heating stage, the second module is fired and at the third heating stage, high heat of both modules is running. If there is a call for heating, the operating sequence is as follows:

Combustion air blower is powered on Pre-purge starts for 15 seconds Ignition spark starts for 7 seconds Main gas valve opens Flame is sensed by ionization

If a fault of any kind occurs during the ignition or operating cycles, the controller detects the fault, and diagnostic LEDs will indicate the mode of failure.

Diagnostic button JP1

DIAG #1

DIAG #2

Two green LED lights are to be clearly marked as DIAG #1 and DIAG #2. The diagnostic signals for failure modes are as follows:
Safety circuit High limit switch (manual reset) open Pressure switch open 5-minute Watchguard Pressure switch failed to close Burners failed to ignite Flame sensed without valve energised Rollout switch or limit switch (manual reset) open Circuit board failure or control is wired incorrectly Power on Monitored during Heating demand only Heating demand only Heating demand only All times All times All times All times Action Gas valve off Combustion air blower off Gas valve off Combustion air blower off Gas valve off Combustion air blower off Gas valve off Combustion air blower off Gas valve off Combustion air blower off Gas valve off Combustion air blower off Control waiting for a heating signal from the thermostat. An increased flash rate indicates a call for heat DIAG #1 Flash Off Alternate flash Flash On On Simultaneous flash DIAG #2 On Flash Alternate flash Off Flash On Simultaneous flash

35

Lockout The safety shut-down condition of the system, such that a restart can only be accomplished by removing power, shorting the on-board jumper (JP1) momentarily, and restoring power once again. During the Lockout condition, the combustion blower will be OFF and the diagnostic will signal Lockout mode. The high limit switch and limit switch must be reset manually by pressing reset buttons of switches during their faults. Control will hold the last failure code in memory for a minimum of 1 minute following interruption of main power to the control. To retrieve the last failure code, a diagnostic button provided on the circuit board must be pressed. When this button is pressed and held, the diagnostic LED lights will signal the last failure code held in memory. To clear the memory of the stored failure code, remove the main power and short the jumper JP1 for 5 seconds.

GAS BURNER TROUBLESHOOTING Check that the gas isolation shut-off valves are open. Check the gas pressure at the inlet of the gas valves. Adjust the set points to prioritise the burner. Increase the value of the room temperature set point to a temperature higher than actual room temperature.

Burners will not ignite

Symptoms

Misaligned spark electrodes No gas at main burners

Cause

Remedy

Check flame ignition and sensor electrode positioning. Adjust as needed. Check gas line for air; purge as necessary. After purging the gas line of air, allow the gas to dissipate for at least 5 minutes before attempting to relight the unit. Check the gas valve. Drain water and install drip leg to trap water. Check power supply, fuses, wiring, and circuit breaker. Check transformer. Check 24-V circuit breaker; reset if necessary. Check all wiring and wire nut connections. Clean or replace filter as necessary. Check gas pressure at manifold. Clock gas meter for input. If too low, increase manifold pressure or replace with correct orifices. Replace with proper unit or add additional unit. Clean filter, replace filter, or remove any restrictions. Install alternate motor, if applicable, or adjust pulley to increase fan speed. Check rotation of blower, temperature settings, and temperature rise of unit. Adjust as needed. Adjust minimum position. Check economizer operation. Check all screws around flue outlets and burner compartment. Tighten as necessary. Cracked heat exchanger. Overfired unit - reduce input, change orifices, or adjust gas line or manifold pressure. Check vent for restriction. Clean as necessary. Check orifice to burner alignment.

Inadequate heating

Water in gas line No power to unit No 24 V power supply to control circuit Miswired or loose connections Dirty air filter Gas input to unit too low Unit undersized for application Restricted air flow Blower speed too low Limit switch cycles main burners Too much outdoor air

Poor flame characteristics

Incomplete combustion (lack of combustion air) results in aldehyde odours, CO, sooting flame, or floating flame

IMPORTANT: Following any operation on the appliance which has necessitated removal and replacement of any parts, the appliance shall be recommissioned in accordance with the Commissioning section of these instructions.

36

HEAT STAGE 1 SUPPLY FAN CONTACT

HEAT STAGE 2
.

BRWN
. .

24 V AC BLU
.
.

PRESSURE SWITCH

GAS VALVE

P
-GV
2 1

BRWN
.

BLK

-PS GPS
.

GRY
.

CONTACT
P
3
R L2 TB1 G W Y C

RED

HI LIMIT SWITCH

ROLLOUT SWITCH

-HLS

BL WR
.

IGB

CMB HTG ACC

BRWN

-ROS

A1 -R1
.

BRWN
L1

A2
11

-R1 12
ACC

14

LIMIT SWITCH

-LS

GND

0V

COOL ACB LOW

RED

24 V AC
.

HOT

ACB FLAME T1 HEAT ACB

GRY
.

GRY
24 V AC

Schematic of gas control for 48AZ/UZ 016-028

0V 24 V AC

-FU2 3,5 A

-IG
PROBE

-FP

FLAME

SPARK

37

BRWN BLU
. . . .

BRWN BLU
.

BLK

BRWN

PRESSURE SWITCH
GAS VALVE

GAS VALVE
-PS1
2 1

PRESSURE SWITCH

P
.

P
-GV1

-PS2 GRY
. .

BRWN

BLK

-GV2

ROLLOUT SWITCH
6 5 4
.

ROLLOUT SWITCH BRWN


.

-ROS2
.

BL WR CMB HTG ACC

A1 -ROS1
7

-LS2

LIMIT SWITCH

LIMIT SWITCH

-LS1

0V 24 V AC

-FU2 6,3 A

FLAME

PROBE

FLAME

Schematic of gas control for 48AZ 034-040

SPARK

-FP 2

-FP 1

PROBE

38
HEAT STAGE 1
.

HEAT STAGE 2 SUPPLY FAN CONTACT

HEAT STAGE 3

GRY
.

P
RED
.

GPS2
3

P
GPS1
G W Y TB1 C R

RED
L2

HI LIMIT SWITCH
C L2

W Y TB1

HI LIMIT SWITCH

-HLS2

IGB2
-R2 BRWN
.

-HLS1

IGB1

BRWN -R1
.

BL WR CMB HTG ACC

A1 BRWN
L1
.

A2 11 -R2 12
GND

A2
11

L1 ACC

ACC

-R1 12 14

14

0V
.

GND

208
RED
.

RED
HOT

308

24 V AC
T1
.

HOT

GRY
.

GRY

209
GRY

FLAME

309

FLAME 24 V AC

24 V AC

COOL ACB LOW ACB HEAT ACB

T1

COOL ACB LOW ACB HEAT ACB

-IG 2

-IG 1 SPARK

SETTING UP THE PRO-DIALOG PLUS CONTROL Local interface general features I - standard - small human interface general features

the interface It gives access to all Pro-Dialog Plus data and operating functions. It consists of: A two-digit display showing the number of the item selected. A four-digit display showing the contents of the item selected. 5 buttons and 1 alarm LED for unit start/stop, menu selection, menu item selection and value adjustment, and alarm annunciation.
MAIN INTERFACE Button Name Menu Up arrow Down arrow Enter Start/stop

Description Permits the selection of a main menu. Permits scrolling through the menu items (in the two-digit display). If the modification mode is active this button authorises increase of the value of any parameter. Permits scrolling through the menu items (in the two-digit display). If the modification mode is active this button authorises decrease of the value of any parameter. Gives access to the modification mode, validates a modification or displays expanded item description. Authorises start or stop of the unit in local mode or modification of its operating type.

LEDs LED

INDICATION WHEN LIT Red LED: - Lit: Circuit A, B or unit shut down by alarm - Flashing: Circuit A, B or unit running with alarm present

39

II - optional - enhanced human interface general features


MAIN INTERFACE SUMMARY INTERFACE MAIN INTERFACE SUMMARY INTERFACE

SINGLE-CIRCUIT COOLING UNIT INTERFACE MENU BLOCK MENU BLOCK

DUAL-CIRCUIT COOLING UNIT INTERFACE

The local interface enables a number of operating parameters to be displayed and modified. The interface consists of two distinct parts: the main interface (left hand section) and the summary interface (right hand section).

main interface It gives access to all Pro-Dialog Plus data and operating functions. It consists of: A two-digit display showing the number of the item selected. A four-digit display showing the contents of the item selected. LEDs and buttons for unit start/stop, menu selection, menu item selection and value adjustment.

MAIN INTERFACE BUTTON NAME Menu Up arrow Down arrow Enter Start/stop DESCRIPTION Permits the selection of a main menu. Each main menu is represented by an icon. The icon is lit if active. Permits scrolling through the menu items (in the two-digit display). If the modification mode is active this button authorises increase of the value of any parameter. Permits scrolling through the menu items (in the two-digit display). If the modification mode is active this button authorises decrease of the value of any parameter. Gives access to the modification mode, validates a modification or displays expanded item description. Authorises start or stop of the unit in local mode or modification of its operating type.

MAIN INTERFACE MENU LEDS LED NAME INFORMATION menu TEMPERATURES menu
kPa

DESCRIPTION Displays the general operating parameters for the unit. Displays the unit operating temperatures. Displays the unit operating pressures. Displays the unit setpoints and enables them to be modified. Displays the status of the unit digital and analogue inputs. Displays the status of the unit outputs and enables them to be tested. Displays the unit configuration and enables it to be modified. Displays active alarms. Displays the history of the alarms. Displays the operating times and number of starts for the unit and the compressors.

PRESSURES menu SETPOINTS menu INPUTS menu OUTPUTS/TESTS menu CONFIGURATIONS menu ALARMS menu ALARMS HISTORY menu OPERATING LOG menu

40

The summary interface (right hand section) includes a mimic diagram of the unit, together with push-buttons and LEDs. It gives quick access to the main operating parameters of the unit.
SUMMARY INTERFACE LEDS LED INDICATION WHEN LIT Green LED: The unit is authorised to start or is already running

the following operating types can be selected using the start/stop button:
OPERATING TYPES 4-DIGIT DISPLAY LOFF L-On L-Sc* DESCRIPTION Local Off. The unit is halted in local mode. Local On. The unit is in local control mode and is authorised to start. Local On - timer control. The unit is in local control mode. It is authorised to start if the period is occupied. If the timer program for unit operation is unoccupied, the unit remains shut down until the perod becomes occupied. CCN. The unit is controlled by CCN commands. Remote. The unit is controlled by remote control contacts. (This operating type shall be selected when using the Room-mate comfort controller option.) Remote by thermostat. The unit is comtrolled via external contacts by a thermostat.

Red LED: - Lit: circuit A or unit shut down by alarm - Flashing: circuit A or unit running with alarm present Red LED: - Lit: circuit B or unit shut down by alarm - Flashing: circuit B or unit running with alarm present Red LED: Optional air flow detection. Green LED: The indoor fan is running.

CCN* rEM* tStA *

Yellow LEDs: From top to bottom - start/stop status of compressor A1 or B1. Flashing LED indicates that the circuit is in the protection or defrost mode (A or B). Green LED: The unit operates in heating mode. Green LED: The unit operates in cooling mode. SUMMARY INTERFACE PUSH BUTTONS BUTTON DISPLAY Blue button: supply air temperature, return air temperature in C Gray button: outdoor air temperature in C Control point (setpoint + reset) in C Press 1: circuit A/B discharge pressure in kPa Press 2: circuit A/B saturated condensing temperature in C Press 1: circuit A/B suction pressure in kPa Press 2: circuit A/B saturated suction temperature in C Press 1: compressor A1/B1 operating hours in h/10 or h/100

Displayed if the configuration requires it.

stopping the unit in local mode The unit can be stopped in local mode at any time by pressing the Start/Stop button.
TO STOP THE UNIT BUTTON ACTION Press the Start/Stop button for less than 4 seconds (one short press is enough). If the button is released, the unit stops without the need for further action.

2-DIGIT DISPLAY C

4-DIGIT DISPLAY LOFF

LOFF

starting unit and selecting an operating type The unit can be started in local mode, or unit operating type can be changed at any time using the Start/Stop button. In the example that follows, the unit is stopped (LOFF) and the user wants to start the unit in local mode.
CHANGING THE OPERATING TYPE BUTTON ACTION Continually press the operating type selection button for more than 4 seconds. Hold down the Start/Stop button. The available operating types are displayed one by one until the button is released. 2-DIGIT DISPLAY C 4-DIGIT DISPLAY LOFF L-ON L-Sc

Unit start/stop control Description The unit start/stop can be controlled by one of the following methods: Locally on the actual unit (Local operating type) By remote control with the aid of user contacts (remote operating type) By CCN control with the aid of the CCN (CCN operating type) The main interface includes a Start/Stop button which can be used to stop or start the unit in the local operating type or to select the remote or CCN operating type. The available operating types are described in the following table.

Release the Start/Stop button if the operating type you want is displayed (in this example L-On). "C" flashes in the 2-digit display to show that the controller is awaiting confirmation. Press the Enter button to confirm the operating type selected (in this example: LOn). "t" is displayed in the 2-digit display to indicate the operating type selected. If the Enter button is not pressed soon enough the controller will cancel the change and continue to use the previous operating type.

rEM L-On

L-On

41

Menus selecting a menu The MENU button authorises you to select a menu from the 10 main menus that are available. Each time you press this button one of the 10 LEDs lights up in turn alongside each of the icons representing a main menu. The active menu is the one against which the LED is lit. If a menu is empty then its LED is not lit. To scroll quickly through the menus, hold the MENU button down. selecting a menu item The up and down Arrow buttons let you scroll through the menu items. Menu item numbers are displayed in the two-digit display. The item number increases or decreases every time you press the up or down Arrow button. The menu items that are not in use or incompatible with the configuration are not displayed. The value or status associated with the active item is displayed in the four-digit display. To scroll quickly through the items, hold the up or down Arrow button down. The following example shows how to access item 3 in the Pressures menu.
SELECTING A MENU ITEM OPERATION Press the MENU button until the PRESSURE menu appears on the LCD. If the optional interface is used, the LED marked PRESSURE lights up. Press one of the Arrow buttons until the two-digit display shows 3 (item number 3). PRESS BUTTON MENU LED* ITEM NUMBER 2-DIGIT DISPLAY 0
kPa

OPTIONS AND ACCESSORIES


Economizer enthalpic control Economizer thermostatic control Crankcase heater Economizer hood with sliding panel Manual outdoor air damper Propane gas option Front discharge roof curb Vertical roof curb Vertical roof curb with air ventilation (French ERP regulation) Adjustable longitudinal roof curb, vertical discharge Adjustable transverse roof curb, vertical discharge Air return fan Air return fan with damper actuator Power exhaust Barometric exhaust Dirty filter alarm G4 efficiency 50 mm thick filters, fire class M1 F6 efficiency 50 mm thick filters, fire class M1 F7 efficiency 50 mm thick filters, fire class M1 G4 + F6 efficiency 50 mm thick filters, fire class M1 G4 + F7 efficiency 50 mm thick filters, fire class M1 F6 + F7 efficiency 50 mm thick filters, fire class M1 High static pressure transmission - HS1 High static pressure transmission - HS2 High static pressure transmission - HS3 Fire thermostat Smoke detector Smoke detector with DAD (French ERP regulation) Air flow detector Stainless steel drain pan Pre-coated blue-fin coils Additional space temperature sensor IAQ CO2 indoor air quality sensor Room-mate comfort controller Free contact terminal Pro-Dialog+ user interface JBus communication gateway LonWorks communication gateway Programmable thermostat TSTAT Non-programmable thermostat TSTAT Option Accessory x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

0 1

kPa

2 3

* Optional interface

modifying the value of a parameter/access to a sub-menu Press the Enter button for more than 2 seconds to enter the modification mode or to select a sub-menu. This lets you correct the value of an item or select a sub-menu with the aid of the up and down Arrow buttons (if you are authorised to overwrite the item concerned). When modification mode is activated, the LED of the main menu to which the item belongs flashes in the menu block, if the optional interface is used. Once the required value is obtained, press the Enter button again to validate the change or to access the sub-menu. The LED for the menu to which the item belongs then stops flashing, indicating that modification mode no longer applies. In modification mode, the value to be modified increases or decreases in steps of 0.1 every time you press the Arrow buttons. Holding one of these buttons down increases the rate of increase or decrease.

42

GENERAL MAINTENANCE ATTENTION: Before starting any servicing or maintenance operation on the unit, make sure that the power supply has been disconnected. A current discharge could cause personal injury. In order to obtain maximum performance from the unit special attention should be paid to the following points: electrical connections: The supply voltage should be within the limits permitted by the compressor. Ensure that no faulty contacts exist in the terminal blocks, contactor boards, etc. Make sure that all the electrical connections are properly tightened, and that all the electrical components (contactors, relays, etc) are firmly secured to the corresponding rails. Pay special attention to the condition of the connecting cables between the control elements and the electrical box, and to that of the unit power supply cable. They should not be twisted and there should be no slits or notches in the insulation. Check the starting and running consumptions are within the limits specified in the corresponding technical information. Drainage: Frequently check that the drain is not obstructed, and that the condensate pan is clean and level. Inlet filter: This should be cleaned periodically. The frequency depends on the purity of the entering air. The filter may be cleaned with a household vacuum cleaner, or by immersing it in water. Refrigerant circuit: Ensure that there is no leakage of refrigerant or oil from the compressor. Check that the high and low side operating pressures are normal. Make sure that the coils are not dirty. If necessary an optional filter may be placed at the outdoor air inlet. Check for unusual compressor noise. Controls: Check the operation of all the relays, high and low pressurestats, etc.

To align fan and motor pulleys: 1. Loosen fan pulley setscrews. Slide fan pulley along the pulley shaft and align with the motor using a ruler, making sure that it is parallel to the belt. 2. Tighten the fan pulley setscrews. To adjust the belt tension, loosen the motor mounting plate bolts and slide the motor mounting plate until the belts are tensioned as shown in Fig. 25. Fan and motor pulleys can be aligned as shown in Fig. 26. If the unit is equipped with adjustable pulleys, the pulley ratio and operating point can be adjusted by loosening the setscrew, arranging the moving part of the pulley to the appropriate position and then fixing the setscrew. See fan performance tables for adjustments. Fig. 25 - Fan speed adjustment 48AZ/UZ 016 standard - Hs1 - Hs2 - Hs3 48AZ/UZ 020/024 standard - Hs1 - Hs2 48AZ/UZ 028 standard - Hs1

SERVICE Indoor fan air adjustment The drive is factory set in accordance with the fan performance tables. When indoor pressure and air flow requirements differ from nominal ratings, the motor pulley can be adjusted for different available static pressure values (see fan performance tables). To change the fan speed: 1. Move the motor along its track in order to remove the belt. 2. Loosen the pulley setscrews 2 and rotate as necessary. 3. Tighten the setscrews 2. 4. Replace the belt(s) in the channel of the pulley. 5. Tighten the belt(s), using the tension screw nut and washer. See maintenance section and Fig. 25. 48AZ 034-040 standard - Hs1 - Hs2 - Hs3

Legend 1 Motor plate 2 Motor pulley 3 Setscrew 4 Motor 5 Belt 6 Tensioning screw 7 Fan pulley 8 Fan scroll

43

48AZ/UZ 020-028 - Hs3

Lubrication Both the motors and the fans have factory lubricated and sealed bearings, and need no further lubrication. The compressor has its own oil supply and oil should not be added unless a leak has occurred. Condenser coil We recommend, that finned coils are inspected regularly to check the degree of fouling. This depends on the environment where the unit is installed, and will be worse in urban and industrial installations and near trees that shed their leaves. For coil cleaning proceed as follows: Remove fibres and dust collected on the condenser face with a soft brush (or vacuum cleaner). Clean the coil with the appropriate cleaning agents.

Legend 1 Motor plate 2 Motor pulley 3 Setscrew 4 Motor 5 Belt 6 Tensioning screw 7 Fan pulley 8 Fan scroll

With pressurised cleaning methods care should be taken not to damage the coil fins. The spraying of the coil must be done: in the direction of the fins in the opposite direction of the air flow direction with a large diffuser (25-30) at a distance of 300 mm. It is not necessary to rinse the coil, as the products used are pH neutral. To ensure that the coil is perfectly clean, we recommend rinsing with a low water flow rate. The pH value of the water used should be between 7 and 8. WARNING: Never use pressurized water without a large diffusor. Concentrated and/or rotating water jets are strictly forbidden. Correct and frequent cleaning (approximately every three months) will prevent 2/3 of the corrosion problems. Never use a fluid with a temperature above 45C to clean the air heat exchangers.

Fig. 26 - To align fan and motor pulleys

1 2 3 4 5+7 6

Fixed flange Setscrew Movable flange Straight-edge must be parallel with belt Motor and fan shafts must be parallel Pulleys

44

MAINTENANCE PROGRAMME All maintenance operations must be carried out by technicians who have been trained on Carrier products, observing all Carrier quality and safety standards. Maintenance instructions During the unit operating life the service checks and tests must be carried out in accordance with applicable national regulations. If there are no similar criteria in local regulations, the informa-tion on checks during operation in annex C of standard EN 378-2 can be used. External visual checks: annex A and B of standard EN 378-2. Corrosion checks: annex D of standard EN 378-2. These controls must be carried out: After an intervention that is likely to affect the resistance or a change in use or change of high-pressure refrigerant, or after a shut down of more than two years. Components that do not comply, must be changed. Test pressures above the respective component design pressure must not be applied (annex B and D). After repair or significant modifications or significant system or component extension (annex B). After re-installation at another site (annexes A, B and D). After repair following a refrigerant leak (annex D). The frequency of refrigerant leak detection can vary from once per year for systems with less than 1% leak rate per year to once a day for systems with a leak rate of 35% per year or more. The frequency is in proportion with the leak rate. NOTE 1: High leak rates are not acceptable. The necessary steps must be taken to eliminate any leak detected. NOTE 2: Fixed refrigerant detectors are not leak detectors, as they cannot locate the leak. Maintenance schedule Regular maintenance is indispensable to optimise the operating life and reliability of the equipment. Maintenance operations must be carried out in accordance with the schedules below: service A B C Frequency Weekly Monthly Annually

Description of the maintenance operations The equipment is supplied with polyolester oil (POE). Only use oil approved by Carrier. service A Full-load operating test Verify the following values: compressor high-pressure side discharge pressure compressor low-pressure side suction pressure charge visible in the sight glass Verify the alarm status service B Carrier out the operations listed under Service A. Refrigerant circuit Verify the air heat exchanger cleanliness status and clean it at least once a year, or more often if the equipment environment is especially demanding. To clean the equipment, follow the Carrier recommendations. Among other things, this ensures that the unit performances can be guaranteed. Full-load operating test. In addition to the operations described under Service A, check the following values: compressor discharge pressure compressor oil level actual liquid subcooling overheating at the expansion device. Verify the charge status by checking the colour indicator of the sight glass. If the colour has turned to yellow, change the charge and replace the filter drier after carrying out a leak test of the circuit. electrical checks Check the tightening of the electric connections, contactors, disconnect switch and transformer. Check the status of the contactors, fuses and capacitators, as required. Carry out a quick test (refer to the manual for the Rooftop Pro-Dialog Plus control). mechanical checks Verify that nothing impedes the rotation of the fan impeller of the air heat exchanger.

IMPORTANT: Before each equipment maintenance operation please ensure that: the unit is in the OFF position it is impossible for the unit to restart automatically during maintenance.

45

service C Carry out the operations listed under Service B. Refrigerant circuit Check the leak-tightness of the circuit and ensure that there is no piping damage. Carry out an oil contamination test. If acid, water or metallic particles are present replace the oil in the circuit. Verify the tightening of the thermostatic mechanism of the expansion device. Full-load operating test. In addition to the checks carried out under Service B, validate the values of the heat exchanger inlet and outlet tightening. Check the operation of the high-pressure and lowpressure switches. Replace them if there is a fault. Check the fouling of the filter drier (by checking the temperature difference in the copper piping). Replace it if necessary. electrical checks Check the status of the electrical cables and their insulation. Carry out an operating test of the electric evaporator heaters, compressor crankcase heater, piping and expansion device, as required. Check the phase/earth insulation of the compressors and fans. Check the compressor and fan winding status. mechanical checks Check the tightening of the indoor and outdoor fan, compressor and control box fixing bolts. Check that no water has penetrated into the control box. All metallic parts of the unit (chassis, casing panels, control boxes, heat exchangers etc.) are protected against corrosion by a coating of powder or liquid paint. To prevent the risk of blistering corrosion that can appear when moisture penetrates under the protective coatings, it is necessary to carry out periodic checks of the coating (paint) condition.

Servicing recommendations Before replacing any of the elements in the cooling circuit, ensure that the entire refrigerant charge is removed from both the high and low pressure sides of the unit. The control elements of the cooling system are highly sensitive. If they need to be replaced, care should be taken not to overheat them with blowlamps whilst soldering. A damp cloth should be wrapped around the component to be soldered, and the flame directed away from the component body. Silver alloy soldering rods should always be used. If the total unit gas charge has to be replaced, the quantity should be as given on the nameplate and the unit should be properly evacuated beforehand. During unit operation all panels should be in place, including the electrical box access panel. If it is necessary to cut the lines of the refrigerant circuit, tube cutters should always be used and never tools which produce burrs. All refrigerant circuit tubing should be of copper, specially made for refrigeration purposes.

FINAL RECOMMENDATIONS The unit you have purchased has undergone strict quality control procedures before leaving the factory. All components, including the control systems and electrical equipment, etc., are certified by our Quality Control Department, and tested under the harshest possible operating conditions in our laboratories. However, after leaving the factory, it is possible that one or more of these elements may be damaged due to causes beyond our control. In such an event, the user should not work on any of the internal components, or subject the unit to operating conditions which are not specified in this manual, since serious damage may result and the guarantee would be invalidated. Repair and maintenance work should always be left to the installer. All recommendations concerning unit installation are intended to be as a guideline. The installer should carry out the installation according to the design conditions and should comply with all applicable regulations for air conditioning and refrigeration installations. NOTE: The manufacturer does not accept responsibility for any malfunctions resulting from misuse of the equipment.

46

TROUBLESHOOTING CHART A list of possible faults, as well as the probable cause and suggested solutions is shown in the table below. In the event of a unit malfunction it is recommended to disconnect the power supply and ascertain the cause. Troubleshooting chart
Symptoms Unit does not start Cause No power supply Main switch open Low line voltage A protection has tripped Contactor stuck open Seized compressor Defective compressor contactor Defective compressor Refrigerant losses Defective low pressure transducer Refrigerant losses Indoor fan does not operate Cooling unit Defective high pressurestat Blocked filter drier Outdoor fan does not operate Heat pump unit Defective high pressurestat Outdoor fan does not operate Piping vibration Noisy compressor Badly fitting panels Leak in system Defective drainage connections Remedy Connect power supply Close main unit disconnect switch Check voltage and remedy the deficiency Reset Check and if necessary replace contactor Check and if necessary replace compressor Check and if necessary replace contactor Check and if necessary replace compressor Check and add the necessary quantity Check and if necessary replace low pressure transducer Check and add the necessary quantity Check fan motor Check and if necessary replace pressurestat Check and if necessary replace filter Check fan motor Replace pressurestat Check fan motor Support piping Check and change if necessary Install correctly Repair leak Check and tighten if necessary

Unit starts and stops frequently Unit continuously cuts out at low pressure Unit continuously cuts out at high pressure

Abnormal system noise Compressor loses oil Water loss

IMPORTANT: Following any operation on the appliance which has necessitated removal and replacement of any parts, the appliance shall be recommissioned in accordance with the commissioning section of these instructions.

47

Order No. 14816-20, 08.2010. Supersedes order No.: 14816-20, 10.2007. Manufacturer reserves the right to change any product specifications without notice.

Manufactured by: Alarko-Carrier, Gebze, Turkey Printed in the Netherlands

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