48ZG,ZN030-105
48ZT,ZW,Z6,Z8075-105
Gas Heating/Electric Cooling Units
with COMFORTLINK™ Controls
User’s Information Manual
NOTE TO INSTALLER:
TO LIGHT UNIT
This manual should be left with the equipment owner.
1. Do not turn off the electrical power to unit without
first turning off the gas supply.
2. Before attempting to start the gas heating section,
familiarize yourself with all the procedures that must
be followed.
WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or loss of life.
— Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
3. Never attempt to manually light the unit with a match,
lighter, or any other flame. If the electric sparking de-
vice fails to light the burners, refer to the shutdown
procedures, then call your dealer as soon as possible.
If you do not follow these instructions exactly, a fire or
explosion may result, causing property damage, injury, or
loss of life.
• Do not touch any electrical switch;
do not use any phone in your
building.
• Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.
See Fig. 1 for location of gas valve(s). Refer to Fig. 2 while
proceeding with the following steps.
1. Turn off the unit demand for cooling or heating by using
the scrolling marquee. The scrolling marquee is located in
the control box at the compressor end of the unit.
• If you cannot reach your gas sup-
plier, call the fire department.
ESCAPE
a. Push the
is shown.
key unit a blank display screen
— Installation and service must be per-
formed by a qualified installer, service
agency or the gas supplier.
b. Push the
lit.
key until the SERVICE TEST LED is
ENTER
c. Push the
STOP.
key. The display will show
key again. The NO/YES display
key to toggle the display to
ENTER
d. Push the
will flash.
Improper installation, adjustment, alteration, service, or
maintenance can cause injury or property damage. Refer to
this manual. For assistance or additional information, con-
sult a qualified installer, service agency, or the gas supplier.
e. Push the
or
ENTER
YES and then push
. The unit will be
locked off from heating, cooling or any operation.
The controls will still function and the display will
still operate.
2. Close the field-installed manual gas shutoff valve.
Before performing recommended maintenance, be sure
main power switch to unit is turned off. Electrical shock
could cause personal injury.
3. Turn off the electrical power to the unit using the optional
disconnect or the field-installed disconnect and lock off
using proper lockout and tag-out procedures.
Your combination heating/cooling rooftop unit is equipped
with an automatic direct spark ignition system and induced-
draft power combustion blower.
4. Open the burner section hinged access door.
5. Move the switch on the gas valves to the OFF position
and wait 5 minutes.
NOTE: If this is the first installation of the unit, the gas
flue hoods must be installed before operating unit. These
must be installed for the unit to run properly.
Do not attempt to light by hand; personal injury may result.
6. Move the switch on the gas valves to the ON position.
7. Close the burner section hinged access door.
8. Turn on the electrical supply to the units.
9. Open the field-installed manual gas valve.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480045-01 Printed in U.S.A. Form 48Z-5SO Pg 1 7-07 Replaces: 48Z-3SO
Book 1
Tab 1a
MAIN
MODE
Run Status
Service Test
Temperature
ON
Pressures
Setpoints
Inputs
Alarm Status
Outputs
Configuration
Time Clock
Operating Modes
Alarms
ESCAPE ENTER
OFF
STEP 1
STEP 2
LOCK-OUT
G
TA
STEP 3
a48-8297
STEP 5
STEP 4
a48-8298
STEP 6
STEP 7
MODE
Run Status
Service Test
Temperature
Pressures
Setpoints
Inputs
Alarm Status
Outputs
Configuration
Time Clock
Operating Modes
Alarms
ESCAPE ENTER
STEP 8
STEP 9
STEP 10
Fig. 2 — To Light Unit
3
For your safety, keep the gas heating area clear and free of
combustible materials, gasoline, and other flammable liquids
and vapors.
TO SHUT UNIT OFF
To ensure proper functioning of the unit, flow of combus-
tion and ventilating air must not be obstructed from reaching
the gas heating area. Clearance of at least 4 ft on all sides is
required.
Do not turn off the electrical power to unit without first
turning off the gas supply.
Never attempt to manually light the main burners on a unit
with a match, lighter, or any other flame.
ROUTINE MAINTENANCE AND CARE
FOR THE EQUIPMENT OWNER
If the electric sparking device fails to light the main burn-
ers, refer to the following shut off procedure, then call your
dealer as soon as possible.
Failure to follow these procedures can result in serious fire
or personal injury.
Before proceeding with those things you might want to
maintain yourself, please carefully consider the following:
See Fig. 1 for location of gas valve(s). Refer to Fig. 3 while
proceeding with the following steps.
1. Turn off the unit demand for cooling or heating by using
the scrolling marquee. The scrolling marquee is located in
the control box at the compressor end of the unit.
1. TURN OFF GAS SUPPLY FIRST AND THEN
ELECTRICAL POWER TO YOUR UNIT BEFORE
SERVICING OR PERFORMING MAINTENANCE.
2. Do not turn off electrical power to this unit without
first turning off the gas supply.
3. When opening access doors or performing mainte-
nance functions inside your unit, be aware of sharp
sheet metal parts and screws. Although special care
has been taken to reduce sharp edges to a minimum,
be extremely careful when handling parts or reaching
into the unit.
ESCAPE
a. Push the
is shown.
key unit a blank display screen
b. Push the
lit.
key until the SERVICE TEST LED is
ENTER
c. Push the
STOP.
key. The display will show
key again. The NO/YES display
key to toggle the display to
Failure to follow these procedures can result in serious fire
or personal injury.
ENTER
d. Push the
will flash.
e. Push the
or
Air Filters — Air filters should be checked at least every
3 or 4 weeks and changed or cleaned whenever they become
dirty. Table 1 indicates the correct filter size for your unit. Open
the hinged filter access door to replace or inspect the filters. All
units have filter tracks into which the filters slide. Remove the
filters by pulling outward from the track. See Fig. 4 for filter
access door location. Note the direction of flow arrows on the
filter frame.
ENTER
YES and then push
. The unit will be
locked off from heating, cooling or any operation.
The controls will still function and the display will
still operate.
2. Close the field-installed manual gas shutoff valve.
3. Turn off the electrical power to the unit using the optional
disconnect or the field-installed disconnect and lock off
using proper lockout and tag-out procedures.
If you have difficulty in locating your air filter in the return-
air duct system, or if you have questions concerning proper
filter maintenance, contact your dealer for instructions.
4. Open the burner section hinged access door.
Table 1 — Indoor-Air Filter Data*
5. Move the switch on the gas valves to the OFF position
and wait 5 minutes before doing any service in the section
or on the piping.
6. Close the burner section hinged access door.
7. If unit is being shut down because of a malfunction, call
your dealer as soon as possible.
UNIT SIZE
48Z
QUANTITY...Size
(in.)
FILTER TYPE
Disposable Fiberglass
(Standard) or Medium Effi-
ciency 30% Pleated (Optional)
8...20 x 25 x 2,
8...20 x 20 x 2
030-050
055-070
90% Bag (Optional) with High- 6...20 x 24 x 22,
Velocity Pre-Filters
6...20 x 20 x 22,
12...16 x 20 x 2,
3...20 x 24 x 2
If unit is being shut down because the heating season has
ended, restore electrical power to the unit and reset the
scrolling marquee to Run mode to ensure operation of the
cooling system during the cooling season.
Disposable Fiberglass
(Standard) or Medium Effi-
ciency 30% Pleated (Optional)
12...20 x 25 x 2,
12...20 x 25 x 2
IMPORTANT: Should overheating occur or the gas supply
fail to shut off, shut off the manual gas valve to the unit
before shutting off the electrical supply.
90% Bag (Optional) with High- 6...24 x 20 x 22,
Velocity Pre-Filters
6...24 x 24 x 22,
6...20 x 24 x 2,
6...24 x 24 x 2
Do not use this unit if any part has been under water. Imme-
diately call a qualified service technician to inspect the unit and
to replace any part of the control system and gas control that
has been under water.
Disposable Fiberglass
12...20 x 25 x 2,
12...20 x 20 x 2
(Standard) or Medium Effi-
ciency 30% Pleated (Optional)
075
High Efficiency 65% Pleated
(Optional)
12...20 x 25 x 2,
12...20 x 20 x 2
Disposable Fiberglass
MAINTAINING YOUR UNIT
12...20 x 25 x 2,
12...20 x 20 x 2
(Standard) or Medium Effi-
ciency 30% Pleated (Optional)
090,105
All maintenance should be handled by skilled, experienced
personnel. Your dealer can help you establish a standard
procedure.
High Efficiency 65% Pleated
(Optional)
*See base unit Installation Instructions if field-supplied or optional
factory-supplied filters are used. When replacing filters, always use
the same type and size originally supplied.
12...20 x 25 x 2,
12...20 x 20 x 2
4
When replacing your unit filters, always use the same size
and type of filter that was originally supplied by the installer.
Units with outdoor air capability have a cleanable filter for
the outdoor air. This filter should be checked annually and
cleaned as necessary. Remove by removing screws in outdoor-
air filter retainer and sliding filters out of the unit.
Heat Exchanger — To ensure dependable and efficient
heating operation, the heat exchanger should be checked by a
qualified maintenance person before each heating season, and
cleaned when necessary. This checkout should not be attempt-
ed by anyone not having the required expertise and equipment
to do the job properly. Checking and/or cleaning the heat
exchanger involves removing the gas controls assembly and
the flue collector box cover and, when completed, reinstalling
the gas controls assembly for proper operation. Also, the flue
collector box cover must be replaced correctly so that a proper
seal is maintained. Contact your dealer for the required period-
ic maintenance.
Never operate your unit without filters in place. Failure to
heed this warning may result in damage to the blower
motor and/or compressor. An accumulation of dust and lint
on internal parts of your unit can cause loss of efficiency
and, in some cases, fire.
MAIN
MODE
Run Status
Service Test
Temperature
ON
Pressures
Setpoints
Alarm Status
Inputs
Outputs
Configuration
Time Clock
Operating Modes
Alarms
ESCAPE ENTER
OFF
STEP 1
STEP 2
LOCK-OUT
G
TA
STEP 3
STEP 5
STEP 4
STEP 7
STEP 6
Fig. 3 — To Shut Unit Off
5
SIZES 030-050 (040 SHOWN)
SIZES 055-070
POWER EXHAUST VFD
(NEAR SIDE)
POWER EXHAUST
CONTROL BOX
(FAR SIDE)
ACCESS DOOR
ACCESS DOOR
(FAR SIDE ONLY)
FLUE OUTLETS
(FAR SIDE)
(NEAR SIDE ONLY)
ACCESS DOOR
(BOTH SIDES)
ACCESS DOOR
(FAR SIDE ONLY)
CONTROL BOX
GAS SECTION
ACCESS DOOR
(FAR SIDE)
POWER EXHAUST ACCESS DOOR
(BOTH SIDES)
ACCESS DOOR
(BOTH SIDES)
FILTER
ACCESS
SIZES 075-105
Fig. 4 — Door Locations (48Z Series Units)
6
See Fig. 1 and 5 and proceed as follows to inspect the com-
bustion area and power-venting system of your unit.
1. Turn off gas supply and then electrical power to your unit.
2. Open gas section access door.
3. Using a flashlight, carefully inspect the burner areas for
dirt, soot, rust, or scale.
Fan and Belts — Periodically check the condition of fan
wheels and housings and belt tension. When service is neces-
sary, call your dealer.
Evaporator-Fan Motor, Condenser-Fan Motor
and Combustion-Fan Motor — Lubrication is not
recommended. Bearings will not require lubrication for at least
5 years of normal operation. After 5 years, motor life can be
extended by having the motors serviced at an authorized motor
service shop.
If dirt, soot, rust, or scale accumulations are found, call
your dealer and do not operate your heating section.
Bodily injury or unit damage may result.
Fan Shaft Bearings — Charge fittings annually with
Shell Alvania No. 2 or equivalent grease.
Evaporator and Condenser Coils — Cleaning of the
coils should only be done by qualified service personnel.
Contact your dealer for the required maintenance as needed.
4. When you have completed your inspection, follow the
start-up procedures in this manual to restore your unit to
operation.
5. Observe unit heating operation, and watch the burner
flame core to see if it is bright blue. If you observe a sus-
pected malfunction, or if the burner flame cores are not
bright blue, call your dealer. See Fig. 6.
Condensate Drain — The drain pan and condensate
drain line should be checked and cleaned at the same time the
cooling coils are checked by your dealer.
Compressors — All compressors are factory shipped
with a normal charge of the correct type refrigeration grade oil
in them and should rarely require additional oil. The service
technician must be certain the proper oil level is maintained in
the compressor when it is installed and running.
NOTE: Burner flame cores that have a mixture of orange,
yellow, or red flames together with the blue may not be
burning gas efficiently. Your dealer may have to adjust
the air/gas mixture.
6. Replace gas section access panel.
Condenser Fan
Unit Panels and Doors — After performing any main-
tenance or service on the unit, be sure all panels and doors are
securely fastened in place to prevent rain from entering
unit cabinet and to prevent disruption of the correct unit airflow
pattern.
Do not poke sticks, screwdrivers, or any other object into
revolving fan blades. Severe bodily injury may result.
The fan must be kept free of all obstructions to ensure prop-
er cooling. Contact your dealer for any required service.
Electrical Controls and Wiring — Electrical controls
are difficult to check without proper instrumentation; therefore,
if there are any discrepancies in the operating cycle, contact
your dealer and request service.
Refrigerant Circuit — The refrigerant circuit is difficult
to check for leaks without the proper equipment; therefore,
if inadequate cooling is suspected, contact your dealer for
service.
Fig. 5 — Typical Location of Access Panel
Combustion Area and Vent System — The com-
bustion area and vent system should be visually inspected be-
fore each heating season. The normal accumulation of dirt,
soot, rust, and scale can result in loss of efficiency and improp-
er performance if allowed to build up. Accumulation on the
burner crossover tube can result in the burners firing out of nor-
mal time sequence. This delayed ignition is characterized by an
especially loud sound.
If your unit makes an unusual or especially loud noise
when the main burners are lit, shut down the heating
section and call your dealer. Bodily injury or unit damage
may result.
Fig. 6 — Proper Flame Appearance
7
REGULAR DEALER MAINTENANCE
BEFORE YOU CALL FOR SERVICE, CHECK
FOR SEVERAL EASILY SOLVED PROBLEMS
In addition to the type of routine maintenance you might be
willing to perform, your unit should be inspected regularly by a
properly trained service technician. An inspection (preferably
each year, but at least every other year) should include the
following:
1. Inspection of all flue product passages — including the
burners, heat exchanger, flue collector box, and vent pipe.
If insufficient heat or cooling is suspected:
(
) Check for sufficient airflow. Check the air filters for dirt.
Check for blocked return-air or supply-air grilles. Be sure they
are open and unobstructed. Be sure heating and cooling set
points are correct. If these checks do not reveal the cause, call
your servicing dealer.
2. Inspection of all combustion-air and ventilation-air pas-
sages and openings.
3. Close inspection of all gas pipes leading to and inside
your unit.
4. Adjustment of the air/gas mixture if the burner flames are
not bright blue. (See Fig. 5 and 6 for location of access
panel and proper flame appearance.)
5. Inspection, and if required, cleaning of the condenser and
evaporator coils.
If your unit is not operating at all, check the following list for
easy solutions:
(
) Check to be sure that heating temperature set point is set
above the indoor temperature during the heating season, or that
cooling temperature set point is below the indoor temperature
during the cooling season. Be sure the unit on/off switch is in
the ON position and not in the OFF position. Be sure unit has
been programmed with the appropriate time schedules and
desired operating set points.
(
) Is the electrical supply switch ON? Are any fuses blown,
or have any of the circuit breakers tripped?
) During the heating season, check the manual shutoff
6. Inspection, and if required, cleaning of the evaporator
drain pan.
7. Inspection, cleaning, and lubrication of blower wheel
housing and motor.
8. Inspection of all supply-air and return-air ducts for leaks,
obstructions, and insulation integrity. Any problems
found should be resolved at this time.
9. Inspection of the unit base to ensure that no cracks, gaps,
etc., exist which may cause a hazardous condition.
(
valve. Is this lever parallel with the pipe, indicating that the
valve is open? Or is the lever at a right angle, indicating that
the valve is closed? If closed, has the gas been shut off for
safety reasons? Otherwise, you may open the valve and follow
the start-up procedures listed in this manual.
NOTE: Before proceeding with the next check, turn OFF the
electrical power supply to the unit. Open the control access
door.
10. Inspection of the unit casing for signs of deterioration.
11. Inspection of all electrical wiring and components to
assure proper connection.
12. Inspection for leaks in the refrigerant circuit. Pressure-
check to determine appropriate refrigerant charge.
(
) During the heating season, check the control switch on
the gas valve. It is in the ON position? If it is not, be sure it has
not been turned off for the purpose of safety. Follow the start-
up procedures in this manual.
(
) If your unit still fails to operate, call your servicing dealer
13. Operational check of the unit to determine working con-
ditions. Repair or adjustment should be made at this time.
14. Your servicing dealer may offer an economical service
contract that covers seasonal inspections. Ask for further
details.
Complete Service Instructions can be found in the base unit
Controls, Start-Up, Operation, Service and Troubleshooting
literature.
for troubleshooting and repairs. Specify the model and serial
numbers of your unit. (Record them in this manual in the space
provided.) If the dealer knows exactly which unit you have, he
may be able to offer suggestions over the phone, or save valu-
able time through knowledgeable preparation for the service
call.
IN CASE OF TROUBLE
If, after performing the above, unit performance is unsatis-
factory, shut off the unit and call your dealer.
Dealer’s Name _____________________________________
Telephone No. _____________________________________
Unit Model ________________________________________
Unit Serial Number _________________________________
Unit Address ______________________________________
Bus Number _______________________________________
Copyright 2007 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480045-01 Printed in U.S.A. Form 48Z-5SO Pg 8 7-07 Replaces: 48Z-3SO
Book 1
Tab 1a
|