matthews main post office - iron horse...

Matthews Main Post Office

HVAC Installation and Repair Project

The following report includes: submittal documents, project summary, product sales info, efficiency data,

product catalog link, before and after pictures, and commissioning reports. The intent of this report is to

provide a brief synopsis of the project, along with important technical and operational information.

11/15/2011 Matthews, North Carolina

Matthews Main Post Office HVAC Installation and Repair Project

Matthews, North Carolina

Table of Contents:

Table of Contents: ........................................................................................................................... 2

Project Summary: ........................................................................................................................... 3

Site Photos: ...................................................................................................................................... 4

Before and After Photos: ................................................................................................................ 5

Efficiency Data with Catalog Link: ............................................................................................... 7

Commissioning Worksheet: ........................................................................................................... 8

Product Summary: ........................................................................................................................ 10

Submittal Data: ............................................................................................................................. 12

Corporate Office:

P.O. Box 73026

Richmond, VA 23235

(919) 682- 2200

(804) 323-4455

(804) 267-1893 fax

www.ironhorsemechanical.net



Project Summary:

Two 7 ½-TON York Gas Pack Rooftop Units (RTU-1B and RTU-2B) were replaced

with Carrier 48HC High Efficiency Packaged Gas/Electric Rooftop Units. The new

units have following features and benefits:

Medium gas heat

High efficiency, 12.0 EER

Dual circuit

Downflow configuration

7 1/2 ton nominal cooling capacity

208-230v-3ph

Vertical economizer with barometric relief (factory installed)

Curb adapter (field installed)

Powered convenience outlet, GFCI (factory installed)

Additional product information is provided in the Product Summary and Submittal

Data sections of this report.

This project also provided for certain temporary and permanent repairs to RTU-

1A, RTU-1B, RTU-2A, RTU-2B, RTU-3, RTU-3B, RTU-4A, RTU-5, RTU-6A, RTU-7A,

and RTU-8. Further details of the installation and repair work are provided in the

work scope section of the JOC Contract and our project proposal.



Site Photos:

Matthews Main Post Office

301 E. John St.

Matthews, NC 28105-7957



Before Pictures:

Before Picture RTU 1B

York Gas Pack Rooftop Unit

Model #D4CG090N13025A

Serial #NNGM158971

Before Picture RTU 2B

York Gas Pack Rooftop Units

Model #D4CG090N13025A

Serial #NBHM015773



After Pictures:

After Picture RTU 1B

Carrier Gas Pack Rooftop Units

Model #48HCED08A2A5A0B2A0

Serial #4411G50399

After Picture RTU 2B

Carrier Gas Pack Rooftop Units

Model #48HCED08A2A5A0B2A0

Serial #4411G50400



Matthews Main Office Efficiency Data:

A product catalog is available using the following link: http://www.docs.hvacpartners.com/idc/groups/public/documents/techlit/48hc-08pd.pdf

N= New O= Old

QTY Serial Number Make & Model Number

Cooling

Capacity

Tons

Cooling

Capacity

MBH

Cooling

EER

Cooling

SEER/IEER

/IPLV

Heating

Input

MBH/

Stage 1

Heating

Input

MBH/

Stage 2

Heating

Output

MBH/

Stage 1

Heating

Output

MBH/

Stage 2

Heating

AFUE%

Heating

Steady State

Efficiency%

Ref. Age Economizer

(Yes/No)

N 1 4411G50399 Carrier 48HCED082A5-

0B2A0 7.5 89 12.00 13.00 120 180 98 148 N/A 82% R410A 2011 Yes

N 1 4411G50400 Carrier 48HCED082A5-

0B2A0 7.5 89 12.00 13.00 120 180 98 148 N/A 82% R410A 2011 Yes

O 1 NNGM158977 York D4CG090N13025A 7.5 R22 1998

O 1 NBHM015773 York D4CG090N13025A 7.5 R22 1998

http://www.docs.hvacpartners.com/idc/groups/public/documents/techlit/48hc-08pd.pdf



Commissioning Worksheets:

EQUIPMENT STARTUP CHECKLIST/COMMISSIONING REPORT

Job Name Matthews Main Office Date(s) of Installation November 15, 2011

Outside Temp and Weather Conditions 67°

Lead Technician: Jim Whinnie Additional Technician(s): Jerry Burden

PRE START-UP TASKS UNIT #

1 UNIT #

2

Make/Model # of new unit

Carrier 48HCED08A2A5A0B2A0 Carrier 48HCED08A2A5A0B2A0

Serial # of new unit

4411G50399 4411G50400

Before starting changeout, verify correct voltage and phase of new equip.

Voltage Phase 208/230 3

Voltage Phase 208/230 3

Verify Installation and Ops Manuals are present and being strictly followed.

Completed Completed

Check electrical conn. for tightness - ohm out high voltage wiring to verify insulation

Completed Completed

Check blower wheel tightness and alignment. Verify pulley alignment and belt tightness.

Completed Completed

Check unit for level.

Completed Completed

Verify the condensate lines is the correct size and installed per mfgr specs.

Completed Completed

Verhify the curb/curb adapter is sealed properly and water tight.

Completed Completed

Verify the unit is properly grounded and secured.

Completed Completed

Check that the unit has filters installed with no gaps between.

Completed Completed

START-UP TASKS UNIT # 1

UNIT # 2

Verify proper rotation Completed Completed

Supply voltage (L1-L2) 213 213



Actual compressor amps #1 L1: 10.9 L2: 11.1 L3:11.1 L1: 10.8 L2: 10.9 L3: 11.0

Actual compressor amps #2 L1: 10.8 L2: 10.9 L3:10.9 L1: 10.7 L2: 10.8 L3: 10.9

Compressor rated Amps #1 13.6 13.6

Compressor rated Amps #2 13.6 13.6

Actual fan amps Cond #1 1.1 1.0

Actual fan amps Cond #2 1.0 1.0

Rated fan amps Cond #1 1.5 1.9

Rated fan amps Cond #2 1.5 1.5



START-UP TASKS (Cont.)

UNIT # 1

UNIT # 2

Actual fan amps Evap 4.0 5.2

Rated fan amps Evap 5.2 4.0

Pressures 1 Suct 1

140 Disch 1

270 Suct 1

139 Disch 1

268

Pressures 2 Suct 2

135 Disch 2

265 Suct 2

139 Disch 2

268

Temperatures Ret Air

72 Sup Air

50 Ret Air

72 Sup Air

50

Temp differential across coil (fully loaded) 22° 22°

Superheat 1 At Coil

16° At Compressor

17° At Coil

16° At Compressor

17°

Superheat 2 At Coil

17° At Compressor

19° At Coil

17° At Compressor

19°

T-Stat properly mounted and verified for proper and accurate operation? Completed Completed

Unit tested under full load conditions in heating and cooling modes? Completed Completed

Verify unit is balanced Completed

Completed

Label new unit and make ready for final inspection Completed Completed

Clean job site and remove all materials and debris Completed Completed

Turnover to Postmaster or OIC (manuals, training, etc.) Completed Completed



Product Summary:

48HC WEATHERMASTER®

Single-Package Rooftop High Efficiency Gas Heating/Electric Cooling Units 3 to 25 Nominal Tons

48HC WEATHERMASTER® rooftop unit were designed by customers for customers. With a gauge plug, centralized control center, plug & play accessory board, "no-strip screw" collars, and handled access panels, we’ve made the unit easy to install, easy to maintain, and easy to use. Units are pre-wired and pre-charged with environmentally sound Puron® (R-410A) refrigerant at the factory. The units are factory tested in both heating and cooling modes.

Performance Features

Puron® (R-410A) HFC refrigerant

ASHRAE 90.1 and Energy Star compliant

Single-stage capacity control (sizes 04 to 07)

Two-stage cooling capacity control (sizes 08 to 28)

SEERs up to 15.6

EERs up to 12.2

IEERs up to 13.0

Exclusive non-corrosive composite condensate pan in accordance with ASHRAE 62 Standard, sloping design; side or center drain

Gas efficiencies up to 82%

Induced draft combustion

Single and multi-state heating

Pre-painted exterior panels and primer-coated interior panels tested to 500 hours salt spray protection

TXV refrigerant metering device on each circuit with removable power element

Fully insulated cabinet

Enhanced copper tube and aluminum fin designed condenser and evaporator coils. Special coated coils also available

Exclusive IGC solid-state control for on-board diagnostics with LED error code designation, burner control logic and energy saving indoor fan motor delay

Dedicated 3-5 ton "Low NOx" models available that meet California Air Quality Management NOx requirement of 40 nangram/joule or ess. Low NOx models include stainless steel heat exchangers.

Stanadrd cooling operating range up to 125 °F (52°C) and down to 35°F (-2°C). Low ambient controllers can bring cooling operation down to -20°F (-29°C)

Rated in accordance with ARI Standards 210/240 (sizes 04 to 06 ) and 340/360 (sizes 07 to 28)

Designed in accordance with Underwriters’ Laboratories Standard 1995

Listed by UL and UL, Canada, or ETL



Maintenance Features

Access panels with easy grip handles

Innovative , easy starting, no-strip screw feature on unit access panels

Two-inch disposable return air filters

Tool-less filter access door

Optional hinged access panels also available

Belt drive evaporator-fan motor and pulley combinations available on all three phase models to meet any application

Electric Drive x13 (5 speed/torque) motor on 04 to 06 models

New terminal board facilitating simple safety circuit troubleshooting and simplified control box arrangement

Installation Features

Field convertible from vertical to horizontal airflow for slab mounting (sizes 04 to 14)

Provisions for thru-the-bottom power entry capability as standard

Single point gas and electric connections

Full perimeter base rail with built-in rigging adapters and fork truck slots

Dedicated vertical and horizontal airflow models available (factory option on size 17 to 28 units)

Reliability Features

Scroll compressors with internal line-break overload protection

24-volt control circuit protected with resettable circuit breaker

Permanently lubricated evaporator-fan motor

Totally enclosed condenser motors with permanently lubricated bearings

Low pressure and high-pressure switch protection

Exclusive IGC anti-cycle protection for gas heat operation

Solid-state electronic direct spark ignition system

Flame roll-out safety protector

Liquid line filter drier as standard

Standard Limited Warranty

10 years parts only heat exchanger - aluminized

15 years parts only heat exchanger - stainless steel

5 years parts only compressor

One year parts only on all other parts

Extended warranty packages available



SUBMITTAL

Project

MATTHEWS MAIN OFFICE



RTU-1 AND RTU-2 3 Unit Report 4 Certified Drawing 5 Performance Summary 7 Unit Feature Sheet 10



RTU-1 AND RTU-2

Tag Cover Sheet Unit Report

Certified Drawing Performance Report

Unit Feature Sheet



Part Number Description Quantity

48HCED08A2A5-0B2A0 Rooftop Unit 2

Base Unit Medium Static Option - Belt Drive Al/Cu - Al/Cu Powered Convenience Outlet Standard Packaging Electromechanical control, Temperature economizer with barometric

relief

Unit Parameters

Unit Model: 48HCED08A2A5-0B2A0 Unit Size: 08 (7.5 Tons) Volts-Phase-Hertz: 208-3-60 Heating Type: Gas

Duct Cfg: Vertical Supply / Vertical Return

Medium Heat Two stage cooling models

Dimensions (ft. in.) & Weight (lb.) ***

Unit Length: 7' 4.125''

Unit Width: 4' 11.5''

Unit Height: 4' 1.375'' *** Weights and Dimensions are approximate. Weight does not include roof

curbs, unit packaging, field installed accessories or factory installed options. Approximate dimensions are provided primarily for shipping purposes. For exact dimensions and weights, refer to appropriate product data catalog.

Total Operating Weight: 1065 lb

Unit Configuration

Medium Static Option - Belt Drive Al/Cu - Al/Cu Electro-mechanical controls Temperature Economizer w/ Barometric Relief Powered Convenience Outlet Standard Packaging

Warranty Information

1-Year parts 5-Year compressor parts 10-Year heat exchanger - Aluminized

No optional warranties were selected.

NOTE: Please see Warranty Catalog 500-089 for explanation of policies and ordering methods.

Ordering Information



48HC-A01 41

48HC-008 49

48HC-009 49

111531 3?

15 1

1351

2 DIA KNOC"OOT

314 (511 DIA ESS

118 111I CIA

NSATE

12 "-14 "-14

" 1511

fOR ITH KlTS:

01 • CRBT ,0 - CRBT

01 - BWPAH CRBT 08,09 -

1 118"

1

11" 041 J /4"

118" 18. 314"

1001 & 002 PWVIDES 3/4 " FPT T RU FL/l.NGE SIZE: 2"

NOTES:

1. DIMEiSIOiS ARE IN INCHES, DIMENSIONS IN I 1 ARE IN 1LlliETERS

1 CEN1ER OF GRAVITY

3 . DJRECTJON OF A1R FLOW

UNIT j

' H

40-J/S --- ., 110151

ECOIIOillER HOOD

IO PTl ONAU

10-3/i 1527 I

.RETU

.RN

..

FILTER ACC ESS PIINEL !TOOL-LESSI

INDOOR COIL ACCESS PIINEL

..

CONDENSER COll

t

AIR

40+3/8 .. I1011]

SUPPL'f

AIR

_1

1 3/4 ' 144.4 1

THRU-THE-BASE CHART IFIOPl FOR "TH RU -THE-BAS EPAN" FACTOR!OPTIO N, FIHJNGS FOR ONL T I. Y. !1 AR E PROVIDED. "

FOR BELOLISTED MODELS, A FIELD SUPPLIED I 12" ADAPTER IS REQUIRED BETWEEN BA SE PAN FITT ING MD GAS VALVE: 46HCD, E, S, R-0 J 48HCD,S·08 48f+!:D,S - 09

'"

N TROL BOX

CONDENSER COI L

CO ACCESS PAiEL

OPTIONAL9 il INDOOR BLOWER

OPTIONAL FACTORY

I NSTALLED CONVENIENCE

OUTLET

J FACTCH!

INSTALLED DISCONNECT

ACCESS

F [_ fAHDLE

Ow

UTSIDE

3·314 r-

-..

HAN OLE---n IT 00 "L='J' I 'L='J' 00·

1-51B- L l -3/!!

(OSJ >-------- 5!·112 ------1 11510I



IT

I

. LBS.

-A01 I6 318 34 61 19 718 I 5051

915 419 9 156 .1 41 518 11081] 34 1

915 10 190 9 34 1 /8

LBS . "·

* STAN DA R D U W mG HT 1S W ITH LOW GA S HE AT AND Wl!HOU T PACK AGI NG. FOR OTHER OPHONS AH D AC C ESSORI ES, R EFER TO TH E P ROD UCT DATA C WLOG

COR NE R A

COR NER D

CORNE R 8

COR NER C

·- . ..

CJ ••• 1 C.

= n = NEW 48HC 08-12 SINGLE ZONE ELECTRICAL L:::::::j L:::::::j 00·



Part Number:48HCED08A2A5-0B2A0

ARI EER: 12.00 IEER: 13.0

Base Unit Dimensions

Unit Length: 88.1 in Unit Width: 59.5 in Unit Height: 49.4 in

Operating Weight

Base Unit Weight: 925 lb Medium Heat: 15 lb Medium Static Option - Belt Drive: 15 lb Temperature Economizer w/ Barometric Relief: 75 lb Powered Convenience Outlet: 35 lb

Total Operating Weight: 1065 lb

Unit Voltage-Phase-Hertz: 208-3-60 Air Discharge: Vertical Fan Drive Type: Belt

Actual Airflow: 3000 CFM Site Altitude: 0 ft

Cooling Performance

Condenser Entering Air DB: 95.0 F Evaporator Entering Air DB: 80.0 F Evaporator Entering Air WB: 67.0 F Entering Air Enthalpy: 31.44 BTU/lb Evaporator Leaving Air DB: 57.7 F Evaporator Leaving Air WB: 57.2 F Evaporator Leaving Air Enthalpy: 24.53 BTU/lb Gross Cooling Capacity: 93.30 MBH Gross Sensible Capacity: 72.19 MBH Compressor Power Input: 6.24 kW Coil Bypass Factor: 0.198

Heating Performance

Heating Airflow: 3000 CFM Entering Air Temp: 70.0 F Leaving Air Temp: 115.7 F Gas Input Capacity: 120.0 / 180.0 MBH Gas Heating Capacity: 148.00 MBH Temperature Rise: 45.7 F NOTE: Second Stage

Supply Fan

External Static Pressure: 0.50 in wg Options / Accessories Static Pressure

EconoMi$erIV / EconoMi$er2: 0.11 in wg Total External Static: 0.61 in wg Fan RPM: 759 Fan Power: 1.17 BHP NOTE: Selected IFM RPM Range: 690 - 936

Electrical Data

Minimum Voltage: 187 Maximum Voltage: 253



Compressor #1 RLA: 13.6 Compressor #1 LRA: 83



Compressor #2 RLA: 13.6 Compressor #2 LRA: 83 Outdoor Fan Motor Qty: 2 Outdoor Fan FLA (ea): 1.5 Indoor Fan Motor Type: MED Indoor Fan Motor FLA: 5.2 Combustion Fan Motor FLA (ea): 0.48 Power Supply MCA: 43.6 Power Supply MOCP (Fuse or HACR): 50 Min. Unit Disconnect FLA: 46 Min. Unit Disconnect LRA: 207 Electrical Convenience Outlet: Yes NOTE: Convenience outlet must be field connected to the line/load side of the unit disconnect per local code.

Acoustics

Sound Power Levels, db re 10E-12 Watts

Discharge Inlet Outdoor

63 Hz 96.6 93.8 90.6 125 Hz 90.7 84.0 84.3 250 Hz 75.1 67.8 80.2 500 Hz 68.9 63.9 79.3

1000 Hz 64.0 61.2 77.1 2000 Hz 62.1 56.3 72.2 4000 Hz 64.8 55.6 67.4 8000 Hz 65.1 55.0 63.7

A-Weighted 77.7 72.1 82.0

Advanced Acoustics

Detailed Acoustics Information

Advanced Accoustics Parameters

1. Unit height above ground: 30.0 ft 2. Horizontal distance from unit to receiver: 50.0 ft 3. Receiver height above ground: 5.7 ft 4. Height of obstruction: 0.0 ft 5. Horizontal distance from obstruction to receiver: 0.0 ft 6. Horizontal distance from unit to obstruction: 0.0 ft

Octave Band Center Frequency, Hz 63 125 250 500 1k 2k 4k 8k Overall

1. Sound Power Levels at Unit's Acoustic Center, Lw 90.6 84.3 80.2 79.3 77.1 72.2 67.4 63.7 92.3 Lw

2. A-Weighted Sound Power Levels at Unit's Acoustic Center, LwA 64.4 68.2 71.6 76.1 77.1 73.4 68.4 62.6 81.7 LwA

3. Sound Pressure Levels at Specific Distance from Unit, Lp 58.2 51.9 47.8 46.9 44.7 39.8 35.0 31.3 59.9 Lp

4. A-Weighted Sound Pressure Levels at Specific Distance from Unit, LpA 58.2 51.9 47.8 46.9 44.7 39.8 35.0 31.3 59.9 LpA

Calculation methods used in this program are patterned after the ASHRAE Guide; other ASHRAE Publications and the AHRI Acoustical Standards. While a very significant effort has been made to insure the technical accuracy of this program, it is assumed that the user is knowledgeable in the art of system sound estimation and is aware of the tolerances involved in real world acoustical estimation. This program makes certain assumptions as to the dominant sound sources and sound paths which may not always be



appropriate to the real system being estimated. Because of this, no assurances can be offered that this software will always generate an accurate sound prediction from user supplied input data. If in doubt about the estimation of expected sound levels in a space, an Acoustical Engineer or a person with sound prediction expertise should be consulted.



Sta

tic P

ressu

re (

in. w

g.)

2.0

FanCurve

1200RPM

1.8 1100RPM

1.6

1.4

1000RPM

1.2 900RPM

3.70BHP

1.0 SC

800RPM

0.8

0.6

700RPM

600RPM

3.00BHP

RP

0.4 500RPM

0.2

0.0

400RPM

0.50BHP

0.75BHP

1.00BHP

1.50BHP

2.00BHP

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

Airflow(CFM-thousands) RPM=759BHP=1.17MaximumRPM=1084MaximumHP=3.70

Note:Pleasecontactapplicationengineeringforselectionsoutsidetheshadedregion. SC-SystemCurve RP-RatedPoint



Unit Feature Sheet for RTU-1 AND RTU-2 Project MATTHEVVS MAIN OFFICE

Preoared Bv:

10/11/2011

0355PM

e WeatherMaster· - 48HC

PACKAGED ROOFTOP GAS HEATING/ELECTRIC COOLING UNI TS

3,4,5,6,7.5,8.5,10 and12.5 TONS

--

Optional Louvered Hail Gua rd Shown

PUron.

STANDARD FEATURES INCLUDE: • Puron® (R-41O.A.)HFC refrigerant charged • ASHRAE 90.1compliant and Energy Sfar qualified • Scroll compressors with internalline break and overload

protection • Single-stage cooling capadty controlon all04-07 models • Two-stage coolingcapac1ty controlon 08-14models. • SEER's up to 15.6.EER's up to 13.0 and lEER's up to 13.0 • TXV meteringdevice on each independent circu • 04-06 models use X-13 (5 Speed/Torque)Direct Drive Motor

standard • Belt drive f an and pulley combinations - allthree phasemodels • Exc1us1ve non-corrosiVe compose condensate pan1n

accordance wh ASHRA.E Standard 62,slopingdesign,side or center dram

• Standard coolingoperationto 125•F (52.C)to 35•F (2•C) • Units use high pertormance copper tubeI aluminumiln

condenser andevaporator coils • Pre-painted exterior panels and primer-coated interior panels

testedto 500 hours salt spray protection • Fully insulated cabinet • Exclusive IGC solid-state controlf or on-boarddiagnostics with

LED error code designationburner controllogic andenergy saving indoor f an motor delav

• LowNOx models that meet California Air Quality Management • Induced draft gas heat combustion design • Redundant gas valves with up to two stages of heating • Low pressure and high pressure switch protected.

MAINTENANCE FEATURES: • Accesspanels with e.asy grip handles .



WEATHERMASTER SERIES

WeatherMaster (48HC) units are high efficiency, single packaged gas heating,electriccoolinguns that are pre-wired and charged with Puron:l> (R-410)refngerant. They are f acto I)' tested in both heating and cooling modes, and rated in accordance wh AHRIStandards 210/240 (04-06 sizes) and 340/360 (07-14sizes). WeatherMaster units are designed in accordance with UL Standard 1995, and listed by the UndeiWriters'Laboratories.

Ullofd.... TU ......IIdic.llllloll

............ IN

...

Certified to ISO 9001



• lnnovat1ve easy startng,no-stnp screws on unit access panels • Two-inch disposable returnairtmers andTooless fmer access • Newterminalboardf acilitatingsimple safety circu

troubleshooting andsimplifiedcontrolbox arrangement • Exclusive IGC solid-state controlf or on-boarddiagnostics with

LED error code designation,burner controllogic and energy sav1ng1ndoorf an motor delay.

INSTALLATIONFEATURES: • Thru-the-bottom power entry capability • S1ngle po nt gas andelectnc connect1ons • Fullperimeter base railwith built-in rigging adapters andf ork slots • Convertiblefrom verticalto horizontalairtlowf or slabmounting

STANDARD PARTS WARRANTY: • 10-year heat exchanger-15-year stainless steeloption • 5-year compressor • 1-year parts • Many optionalupgrades also available

OPTIONS INCLUDE BUT ARE NOTLIMITED TO: • Premierlink'" andMultiProtocolDirect OigalControls (DOC) Supply and ReturnAir Smoke Detectors,highstatic motors • Louveredcondenser coilguards andcoilcoating options

Economizer,disconnect and convenience outlefoptions • Stainless Steelheatexchanger (standard with Low Nox) • Hinged access panels • Humidi-MiZer dehumidificationsystemon 04 to 12 models.

matthews main post office - iron horse...

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