Operating instructions

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HEATING & COOLING

48GS, 48GX

3-Phase Single-Packaged Gas Heating/

Electric Cooling Units

Visit www.carrier.com

Installation, Start-Up, and Operating Instructions

48GS Sizes 030-060, 48GX Sizes 030-060

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

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

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

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

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

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

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

INSTALLATION ................................................................ 2

PROVIDE uNrr SUPPORT .................................................... 2

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

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

GROUND MOUNT ............................................................ 6

FIELD FABRICATE DUCTWORK ........................................ 6

PROVIDE CLEARANCES ...................................................... 7

RIG AND PLACE UNIT ......................................................... 7

CONNECT CONDENSATE DRAIN ...................................... 7

INSTALL FLUE HOOD .......................................................... 8

INSTALL GAS PIPING ........................................................... 8

INSTALL DUCT CONNECTIONS ...................................... 10

CONFIGURING UNITS FOR DOWNFLOW (VERTI-

CAL) DISCHARGE .......................................................... 10

INSTALL ELECTRICAL CONNECTIONS ......................... 12

HIGH-VOLTAGE CONNECTIONS ................................ 12

SPECIAL PROCEDURES FOR 208-V OPERATION ...12

CONTROL VOLTAGE CONNECTIONS ....................... 12

HEAT ANTICIPATOR SETTING ................................... 12

TRANSFORMER PROTECTION .................................... 15

PRE-START-UP .......................................................................... 15

START-HE ................................................................................... 15

CHECK FOR REFRIGERANT LEAKS ............................... 15

START-UP HEATING AND MAKE ADJUSTMENTS......16

CHECK HEATING CONTROL ....................................... 16

CHECK GAS INPUT ........................................................ 16

ADJUST GAS INPUT ...................................................... 16

CHECK BURNER FLAME .............................................. 19

AIRFLOW AND TEMPERATURE RISE ....................... 19

HEATING SEQUENCE OF OPERATION ..................... 19

LIMIT SWITCHES ........................................................... 19

AUXILIARY LIMIT SWITCH (ROLLOUT) .................. 19

START-UP COOLING AND MAKE ADJUSTMENTS......20

CHECKING COOLING CONTROL OPERATION .......20

CHECKING AND ADJUSTING REFRIGERANT

CHARGE ........................................................................... 20

INDOOR AIRFLOW AND AIRFLOW ADJUST-

MENTS .............................................................................. 21

COOLING SEQUENCE OF OPERATION ..................... 21

MAINTENANCE ......................................................................... 21

AIR FILTER ...................................................................... 24

EVAPORATOR BLOWER AND MOTOR ..................... 24

FLUE GAS PASSAGEWAYS ......................................... 26

A99338

Fig. 1--Unit 48GS and 48GX

COMBUSTION-AIR BLOWER ....................................... 27

LIMIT SWITCH ................................................................ 27

BURNER IGNITION ........................................................ 27

MAIN BURNERS ............................................................. 27

CONDENSER COIL, EVAPORATOR COIL, AND

CONDENSATE DRAIN PAN .......................................... 27

CONDENSER FAN .......................................................... 28

ELECTRICAL CONTROLS AND WIRING .................. 28

REFRIGERANT CIRCUIT ............................................... 28

GAS INPUT ...................................................................... 28

EVAPORATOR AIRFLOW ............................................. 28

METERING DEVICE -- ACUTROL DEVICE ............. 28

LIQUID LINE STRAINER .............................................. 28

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

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

NOTE TO INSTALLER-- Before the installation, READ THESE

INSTRUCTIONS CAREFULLY AND COMPLETELY. Also,

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

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

temporary beating of buildings or structures under construction.

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be

hazardous due to system pressure and electrical components. Only

trained and qualified personnel should install repair, or service

air-conditioning equipment.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring otiligations.

PC 101 Printed ir_U.S.A. Catalog NO. 48GS,GX-TSI Pg 1 2-06 Replaces: New

Summary of content (32 pages)

PAGE 1
48GS, 48GX 3-Phase Single-Packaged Gas Heating/ Electric Cooling Units HEATING & COOLING Visit www.carrier.com Installation, Start-Up, and Operating Instructions 48GS Sizes 030-060, 48GX Sizes 030-060 NOTE: Read installation. the entire instruction TABLE SAFETY RECEIVING before starting ..................................................... .......................................................................... AND INSTALLATION .......................................... CHECK EQUIPMENT ....
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Untrained cleaning personnel by trained equipment, attached Follow can perform basic maintenance coils and filters. All other operations functions of should be performed service personnel. When working on air-conditioning observe precautions in the literature, tags, and labels to the unit, and other safety precautions that may apply. all safety codes. Wear safety gla.gses and work gloves. Use quenching cloth for unbrazing operations. available for all brazing operations.
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eLocKorrP_.[L r_ _e O'NL_ '"11111 _11111111 III suPeL_ ae 3 -- TOP VIEW REAR REQUIRED CLEARANCE TO COMBUSTIBLE MATL. REQUIRED CLEARANCE FOROPERATION AND SERVICING INCHES TOP OF UNIT ................................................................................... 14.00 DUCT SIDE OF UNIT ................................................................ 2.00 SIDE OPPOSPTE DUCTS ............................................................... 14.00 BOTTOM OF UN T 0 50 ELECTR C HEAT PANEL" i_ iiiii_i.
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SUPPL_ D[TU_M 0P_WING 0pEWIN_ ! i i {4 t_: _ 3 TOP VIEW REAR VIEW REQUIRED CLEARANCE TO COMmJSTIBLE MAll. TOP OF UNIT ................................................................................ DUCT SIDE OF UNIT ........................................................................ SIDE OPPOSITE DUCTS ................................................................ ELECTRIC HEAT PANEL ................................................................ BO'[TOM OFUNIT...: .......................
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VACunit ! _ii!_i_ iiiii!i!i!_i __Screw _.g nailer* _n f_ii_i FIasSuk __ piefdS t_do I I_11 _H" Insusttion(field field supplied -Du_ _l_ _fieldsupplied R_f Roof Curb for Small Cabinet Roof Curb for Note A:When unit mounting screw is used retainer bracket must also be used. Large Cabinet Note A:When unit mounting screw is used retainer bracket must also be used.
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2 Y 4 x 3 COO070 48GS CORNER # 48GX 030 036 042 048 060 030 036 042 048 060 1 53.2 59.7 67.5 78.9 85.5 59.5 61.O 72.6 80.0 88.9 2 50.4 56.5 63,9 74.7 81,0 56,3 57.8 68.8 75,8 84.2 3 86.8 97.3 110.1 128.7 139.5 97.0 99,5 118.4 130.5 145.1 4 89.6 106.5 113.6 132.8 144.0 100.2 102,7 122.2 134.7 149.8 TOTAL WEIGHT 250 320 355 415 450 313 321 382 421 465 Fig.
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Table 1--Physical Data--Unit 48GS UNIT SIZE 48GS 030040 030060 036060 036690 042060 NOMINAL CAPACITY (ton) 2½ 2½ 3 3 3½ OPERATING WEIGHT (lb.) COMPRESSORS Quantity REFRIGERANT (R-22) Quantity (lb.) 280 280 320 320 355 042090 31/2 355 Reciprocating 1 3.65 3,65 I 4.4 4.4 Acutrol REFRIGERANT METERING DEVICE Orifice ID (in.) CONDENSER COIL Rows...Fins/in. Face Area (sq ft) CONDENSER FAN Nominal Clm Diameter (in.) Motor Hp (Rpm) EVAPORATOR COIL Rows...Fins/in.
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Table 1--Physical Data--Unit 48GS (Continued) UNIT SIZE 48GS 048090 048115 048130 060090 NOMINAL CAPACITY (ton) OPERATING WEIGHT (lb.) COMPRESSORS Quantity REFRIGERANT (R-22) Quantity (lb.) 4 415 4 415 4 415 5 450 Scroll 1 6.0 I 6.0 060115 5 060130 5 450 450 Reciprocating 1 ! 6.0 8.0 I g° I 60 Acutrol Device REFRIGERANT METERING DEVICE Orifice ID (in.) CONDENSER COIL Rows.- Fins/in. Face Area (sq ft) CONDENSER FAN Nominal Cfm Diameter (in.) Motor Hp (Rpm) EVAPORATOR COIL Rows.
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Table 2--Physical UNIT SIZE 48GX 030040 030060 NOMINAL CAPACITY (ton) 2½ 313 2½ 313 OPERATING WEIGHT (lb.) COMPRESSORS Quantity REFRIGERANT (R-22) Quantity (lb.) REFRIGERANT METERING DEVICE Orifice ID (in.) CONDENSER COIL Rows.-Fins/in. Face Area (sq ft) CONDENSER FAN Nominal Ctm Diameter (in.) Motor Hp (Rpm) EVAPORATOR COIL Rows...Fins/in. Face Area (sq ft) EVAPORATOR BLOWER Nominal Airflow (Cfm) Size (in.) Motor Hp (Rpm) FURNACE SECTION* Burner Orifice No. (Qty.
PAGE 10
Table 2--Physical UNIT SIZE 48GX NOMINAL CAPACITY (ton) OPERATING WEIGHT (lb.) COMPRESSORS Quantity Data--Unit 48GX (Continued) 048090 4 048115 4 048130 4 060090 5 060115 5 060130 5 421 421 421 468 468 468 3.1 8.1 Scroll 1 REFRIGERANT (R-22) Quantity (lb.) 8.3 REFRIGERANT METERING DEVICE Orifice ID (in.) I 03 I 83 r 81 I Acutml Device CONDENSER COIL Rows...Fins/in. Face Area (sq ft) CONDENSER FAN Nominal Cfm Diameter (in,) Motor Hp (Rpm) EVAPORATOR COIL Rows,,.Finslin.
PAGE 11
IN I 3"MIN I C99020 Fig. 9_Sediment 2. Remove Trap DUCTCOVERSREMOVED return duct cover located on duct panel by breaking connecting & 10B). tabs with screwdriver and a hammer (See Fig. 10A C99012 Fig. 10B--Vertical Duct Cover Removed 3. To remove supply duct cover, break front and tight side connecting tabs with a screwdriver and a hammer. Push louver down to break rear and left side tabs (See Fig. 10A & 10B). 4. If unit ductwork is to be attached on the unit composite at this time.
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Step 10--INSTALL ELECTRICAL CONNECTIONS /_ HIGH VOLTAGE r._l LI"/_ -'1,'I I",[_ r - - - (SEE UNIT WIRING POWER LEADS l_ _oLABEL) The unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of serious injury if an electrical fault should occur.
PAGE 13
Table 4--Electrical UNIT SIZE 46GS 030 O36 042 O48 O60 V-PH-HZ VOLTAGE RANGE COMPRESSOR Data--Unit 48GS OUTDOOR FAN MOTOR INDOOR FAN MOTOR POWER SUPPLY Min Max RLA LRA FLA FLA MCA 208/230-3-S0 187 253 12.6 13.2 187 253 9.0 0.8 1.6 2.0 208/230-3--60 68.0 78.0 Max Fuse or Ckt Bkr 20 460-3-60 414 506 4.5 40.0 0.9 3,6 1.9 16,5 8.4 25 15 208/230-3-60 187 253 10.7 85.0 1.6 3.8 18.8 25 460-3-60 414 506 5.3 42.0 0.9 187 253 13.5 1.6 0.9 2.0 3.8 9.5 22.
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Table 5_Electrical UNIT SIZE 48GX V-PH-HZ 030 036 042 O48 O60 VOLTAGE RANGE Data_nit COMPRESSOR 48GX OUTDOOR FAN MOTOR INDOOR FAN MOTOR POWER SUPPLY RLA LRA FLA FLA MCA 253 9.0 63.0 0.8 2.1 14.2 Max Fuse or Ckt Bkr 20 253 11.2 75.0 0.8 3.6 18.4 25 414 506 5.4 37.5 208/230-3-60 187 253 12,4 88,0 0,9 1.6 1.9 4.1 9.6 21.2 15 30 460-3_0 208/230-3_0 414 187 506 253 6,1 13.0 44.0 93,0 0.9 2.0 10.5 15 1.5 4.1 21.
PAGE 15
TRANSFORMER PROTECTION the "OFF" position: If the gas supply pipe was not purged before connecting the unit, it will be full of air. It is recommended that the The transformer is of the energy-limiting type. It is set to withstand a 30°sec. overload or shorted secondary condition. ground joint PPdE-START-UP union be loosened, and the supply line be allowed to purge until the odor of gas is detected. Never purge gas lines into a combustion chamber.
PAGE 16
CHECK BURNER FLAME Check Table BURNER GAS INPUT gas input and manifold 6). If adjustment D after unit start-up proceed (See as follows: • The rated gas inputs shown in Table 6 are for altitudes from sea level to 2000 fit above sea level. These inputs are based on natural gas with a heating value of 1050 Btu/ft 3 at 0.65 specific gravity, or propane gas with a heating value of 2500 Btu/ft 3 at • For elevations 1000 ft above • When the ga.
PAGE 17
W4.
PAGE 18
F,ELO c I W45 BLK BLK CAP 2 E ,P_QMO --'/// l WO BLK L__ (060ONLY) % L3- \ N, / coMP IFM wB,YEL -W64 YEL --W15YEL --W14 FAN LOGIC BRN W56 BLU (SEE NOTE #4) - COGUNG YEL W5 YEL CAP 1 PRIMARY BLK Q BR 460V Vl0 r IDM G G ENERGIZED D_NW_IGIZED /_,_i _ I_BRN HEATING WOI L(3GIC ENERG_I_t _GRN YEk W46 BRN-- _-ENERGtZED CR --W13 1 RH BLK-- 24V SPUCE BR --W39 IGC RED _]_ Wl 9 WHT W20 GRN OFF -_ _HEAT II ° _LrrO _ i W21 RED _ II TCI ",'1 I I I --1 I MGV II I!
PAGE 19
Table 6_Heating HEATING INPUT (BTUH)* NUMBER OF ORIFICES 40,000 Inputs GAS SUPPLY PRESSURE (IN. WG) Natural MANIFOLD PRESSURE (IN. WG) Propanel" Min Max Min Max 2 4.0 13,0 4.0 13.0 60,000 90,000 2 3 4.0 4.0 13.0 13.0 4.0 4.0 13.0 13,0 115,000 3 4.0 13.0 4.0 130,000 3 4.0 13.0 4.0 Natural 3.5 Propane," 3.5 3.5 3.5 13.0 3.5 3.5 3.4 3.7 13.0 3.5 3.5 • When a unit is converted to propane, different size orifices must be used.
PAGE 20
Table 7--Air Delivery (Cfm) at Indicated Temperature Rise and Rated Heating Input HEATING INPUT (BTUH) 20 25 30 35 40 45 50 55 60 65 70 40,000 1500 1200 1000 857 750 667 600 545 500 -- -- 60,000 2250 1800 1500 1286 1125 1000 900 818 750 692 -- 90,000 -- -- 2250 1929 1688 1500 1350 1227 1125 1038 964 115,000 -- -- -- 2464 2156 1917 1725 1568 1438 1327 1232 -- -- -- 2786 2438 2167 1950 1773 1625 1506 -- TEMPERATURE 130,000 RISE °F NOTE:
PAGE 21
determine desired system operating suction linetemperature (See Fig.17-26). 6.Compare actualsuction-tube temperature with desired suction-tube temperature. Usinga tolerance of -+3°F,add refrigerant if actual temperature ismore than 3°F higher than proper suction-tube temperature, actual temperature is more suction-tabe temperature.
PAGE 22
Table 11--Dry Coil Air Delivery* - Horizontal Downflow Discharge Unit 48GS030-060 (Deduct 10 percent for 208 Volts) 230 AND 460 VOLT Unit M_or Speed 0,O 0.1 0,2 0.3 E_ernalSt_ic 0,4 P_ssure (in. wg) 0.5 0,6 WaHs 260 275 270 267 0.7 0.8 0.9 264 252 260 -- -- -- Cfm WaHs 950 380 880 375 825 365 750 360 670 355 580 350 400 344 ....
PAGE 23
Table 13--Dry Coil Air Delivery* - Horizontal and Downflow Discharge Unit 48GX030-060 (Deduct 10 percent for 208 Volts) 230 AND Unit Motor Speed WaRs 0,0 246 0.1 244 0.2 243 6.3 241 466 VOLT E_ernal Static Pressure 0.4 0.8 ....... (in. wg) 0.6 0,7 .... 0.8 0,9 1.0 Low 030 Med High Low 036 Med High Low 042 Med High Low 048 Med High LOW 060 Med High Cfm 982 860 808 736 WaRs 343 339 336 332 328 ....... 322 317 Cfm 1233 1179 1109 1038 953 855 754 .... WaRs ...
PAGE 24
÷_ 75_ 110 68= 100- _v i i I i i i = i i ! i _' 105 41 95 :t5 65 18 . m _ LU __ _ o70 _ .TI _ J_'_ _"_' i, L,,,,_ !i' .- _7_ ,o11 30 40 50 I 60 70 80 90 I 27 I 32 SUCTION UNETEMPERATURE I°Fq I -1 Fig.19---Cooling ChargingChad,48GS042 U_ °4s I 4 SUCTION I I = 10 16 21 LINE TEMPERATURE (°C) Fig. 20--Cooling Charging Chart, 48GS048 Unl_ls°47 Ililll 689 o i 100- _ q_l _8o_£1 I I r- I _ ,==,,_._- ..
PAGE 25
(0301 60HZ CHARGING CHART (036) 60HZ CHARGING CHART r_ _J_ 46 41 35 15 _5 95 29 24 18 13 B5 7 75 85 55 45 I 2761 40 L i _71 30 40 50 60 SUCTION LINETEMPERATURE _1 4 10 16 SUCTION LINETEMPERATURE Fig. 22--Cooling 27 32 4o so 6o _o 8o sucnoNLI_E TEMPERATUREII°_ 21 -1 °- 4 10 16 21 SUCTION LINE TEMPERA31JRE (°C) (_C) CHART 0_ _F 27 I 32 Fig.
PAGE 26
Table 14_8GS INDUCED DRAFT MOTOR MOUNT Wet Coil Pressure Drop UNIT SIZE 48GS AIRFLOW (CFM) PRESSURE DROP (IN. WG) 030 900 1000 0.065 0.080 1100 0.097 1100 0.084 1200 1300 0.100 0.177 1300 0.103 1400 0.120 1500 1500 0.138 0.088 1600 0.100 1700 1900 0.113 0.108 2000 0.120 2100 0.132 036 042 048 060 ROLLOUT SWITCH COLLECTOR BOX BLOWER HOUSING BURNER RACK MOUNTING SCREW C99022 Fig.
PAGE 27
1. Remove unit access 2. Remove the 7 screws that attach induced-draft panel (See Fig. 28). ing plate to blower housing HOUSING motor mount- (See Fig. 29). 3. Slide the motor and blower wheel a._sembly out of the blower housing (See Fig. 29). Clean the blower wheel. If additional cleaning is required, 4. To remove blower, continue remove with Steps 4 and 5. 2 setscrews. 5. To remove motor and cooling fan assembly, remove that hold blower housing to mounting plate. 6.
PAGE 28
Inspect thedrainpanandcondensate drain linewhen inspecting thecoils. Clean thedrain panand condensate drain byremoving all foreign matter fromthepan. Flush thepananddraintubewith clear water. Donotsplash water ontheinsulation, motor, wiring, or airfilter(s). If thedraintubeis restricted, clearit witha "plumbers snake" orsimilar probe device.
PAGE 29
Table 16_Troubleshooting SYMPTOM Compressor and condenser will not start. fan Compressor will not start but condenser fan runs, Three-phase scroll compressor (48GS048 and 48GX030-060 only) makes excessive be a low pressure noise, and dilferentiat. Guide_Cooling CAUSE there may REMEDY Power Failure Call power company. Fuse blown or circuit breaker tdppad Replace fuse or reset cimuit breaker. Defective thermostat, contactor, transformer, or control relay Replace component.
PAGE 30
Table 17--Troubleshooting SYMPTOM REMEDY Water in gas line Drain. Install drip htg. No power to f_mace Check power supply fuses, widng, or circuit breaker, Check transformer, NOTE: Some transformers have internal overcurrerd protection that requires a ccol_lown period to reset. No 24-v power supply to control circuit Burners will not ignite, inadequate Guide-Heating CAUSE heaUng. Poor flame characteristics.
PAGE 31
START-UP CHECKLIST (Remove and Store in Job File) I. PRELIMINARY INFORMATION MODEL NO: ............................................................................................................................................................. SERIAL NO: .............................................................................................................................................................. DATE: .........................................................................................
PAGE 32
Copyright 2006 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 Manufacturer reserves the right to discontinue, or change at any time, specifications PC 101 Printed in U.S.A. Catalog No, 48GS,GX+TSI or designs without notice and without incurring obligations.