Operating instructions

ManualsBrandsCal Flame ManualsHeating SystemFPT-1100

48GS, 48GX

Single Packaged Gas Heating/

Electric Cooling Units

Installation, Start-Up, and Operating Instructions

48GS Sizes 018-060, 48GX Sizes 024-060

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

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

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

GROUND MOUNT ............................................................5

FIELD FABRICATE DUCTWORK........................................5

PROVIDE CLEARANCES......................................................6

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 ...13

CONTROL VOLTAGE CONNECTIONS.......................13

HEAT ANTICIPATOR SETTING...................................13

TRANSFORMER PROTECTION....................................13

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

START-UP...................................................................................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..............................................20

AIRFLOW AND TEMPERATURE RISE.......................20

HEATING SEQUENCE OF OPERATION.....................20

LIMIT SWITCHES...........................................................20

AUXILIARY LIMIT SWITCH (ROLLOUT)..................21

START-UP COOLING AND MAKE ADJUSTMENTS......21

CHECKING COOLING CONTROL OPERATION .......21

CHECKING AND ADJUSTING REFRIGERANT

CHARGE...........................................................................21

INDOOR AIRFLOW AND AIRFLOW ADJUST-

MENTS..............................................................................22

COOLING SEQUENCE OF OPERATION.....................22

MAINTENANCE.........................................................................22

AIR FILTER......................................................................25

EVAPORATOR BLOWER AND MOTOR.....................25

FLUE GAS PASSAGEWAYS .........................................27

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

LIMIT SWITCH................................................................28

BURNER IGNITION........................................................28

MAIN BURNERS.............................................................28

CONDENSER COIL, EVAPORATOR COIL, AND

CONDENSATE DRAIN PAN..........................................29

CONDENSER FAN ..........................................................29

ELECTRICAL CONTROLS AND WIRING ..................30

REFRIGERANT CIRCUIT...............................................30

GAS INPUT ......................................................................30

EVAPORATOR AIRFLOW.............................................30

METERING DEVICE — ACUTROL DEVICE .............30

LIQUID LINE STRAINER ..............................................30

TROUBLESHOOTING ...............................................................30

START-UP CHECKLIST............................................................30

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 heating 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.

Fig. 1—Unit 48GS and 48GX

(Low NO

Model Available)

A99338

Visit www.carrier.com

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

Book 1 4

Tab 1a 6a

PC 101 Catalog No. 534–80121 Printed in U.S.A. Form 48GS,GX-5SI Pg 1 7-02 Replaces: 48GS,GX-4SI

Summary of content (36 pages)

PAGE 1
48GS, 48GX Single Packaged Gas Heating/ Electric Cooling Units Visit www.carrier.com Installation, Start-Up, and Operating Instructions 48GS Sizes 018-060, 48GX Sizes 024-060 NOTE: Read the entire instruction manual before starting the installation. TABLE OF CONTENTS SAFETY CONSIDERATIONS .....................................................1 INTRODUCTION ..........................................................................2 RECEIVING AND INSTALLATION ..........................................
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Untrained personnel can perform basic maintenance functions of cleaning coils and filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags, and labels attached to the unit, and other safety precautions that may apply. and job data. Verify unit voltage and amperage requirements listed on unit rating plate agree with power supply provided to unit.
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REQUIRED CLEARANCE TO COMBUSTIBLE MATL. REQUIRED CLEARANCE FOR OPERATION AND SERVICING INCHES [mm] TOP OF UNIT...................................................................................14.00 [355.6] DUCT SIDE OF UNIT.........................................................................2.00 [50.8] SIDE OPPOSITE DUCTS ................................................................14.00 [355.6] BOTTOM OF UNIT .............................................................................0.50 [12.
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REQUIRED CLEARANCE TO COMBUSTIBLE MATL. REQUIRED CLEARANCE FOR OPERATION AND SERVICING INCHES [mm] TOP OF UNIT...................................................................................14.00 [355.6] DUCT SIDE OF UNIT.........................................................................2.00 [50.8] SIDE OPPOSITE DUCTS ................................................................14.00 [355.6] BOTTOM OF UNIT .............................................................................0.50 [12.
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HVAC unit base HVAC unit base Screw (NOTE A) Screw (NOTE A) Gasketing inner flange* *Gasketing outer flange Gasketing inner flange* *Gasketing outer flange Wood nailer* Flashing field supplied Wood nailer* Flashing field supplied Roofcurb* Insulation (field supplied) Roofing material field supplied Roofing material field supplied Duct work field supplied Cant strip field supplied Roofcurb* Insulation (field supplied) Duct work field supplied Cant strip field supplied Roof Roof *Provided
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1 2 y 4 3 x C00070 48GS CORNER # 48GX 018 024 030 036 042 048 060 024 030 036 042 048 060 1 47.3 53.2 53.2 59.7 67.5 78.9 85.5 55.1 59.5 61.0 72.6 80.0 88.9 2 44.8 50.4 50.4 56.5 63.9 74.7 81.0 52.2 56.3 57.8 68.8 75.8 84.2 3 77.2 86.8 86.8 97.3 110.1 128.7 139.5 89.9 97.0 99.5 118.4 130.5 145.1 4 79.7 89.6 89.6 106.5 113.6 132.8 144.0 92.8 100.2 102.7 122.2 134.7 149.
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Table 1—Physical Data—Unit 48GS UNIT SIZE 48GS NOMINAL CAPACITY (ton) OPERATING WEIGHT (lb.) COMPRESSORS Quantity REFRIGERANT (R-22) Quantity (lb.) REFRIGERANT METERING DEVICE Orifice ID (in.) 018040 1½ 249 024040 2 280 024060 2 280 030040 2½ 280 2.6 3.5 3.5 3.65 .034 .034 .034 .034 030060 036060 2½ 3 280 320 Reciprocating 1 3.65 4.4 036090 3 320 042060 3½ 355 042090 3½ 355 4.4 5.7 5.7 Acutrol™ Device .034 .032 .032 .034 .034 CONDENSER COIL 1...17 1...17 1...17 1...17 1...17 1...17 1..
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Table 1—Physical Data—Unit 48GS (Continued) UNIT SIZE 48GS NOMINAL CAPACITY (ton) OPERATING WEIGHT (lb.) COMPRESSORS Quantity REFRIGERANT (R-22) Quantity (lb.) 048090 4 415 048115 4 415 Scroll 1 048130 4 415 060090 5 450 060115 5 450 Reciprocating 1 060130 5 450 6.0 6.0 6.0 8.0 8.0 8.0 .032 .032 Acutrol Device .032 .030 .030 .030 1...17 12.3 1...17 12.3 1...17 12.3 2...17 12.3 2...17 12.3 2...17 12.
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Table 2—Physical Data—Unit 48GX UNIT SIZE 48GX NOMINAL CAPACITY (ton) 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 Cfm 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...Drill Size) Natural Gas Burner Orifice No. (Qty...
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Table 2—Physical Data—Unit 48GX (Continued) UNIT SIZE 48GX NOMINAL CAPACITY (ton) OPERATING WEIGHT (lb.) COMPRESSORS Quantity REFRIGERANT (R-22) Quantity (lb.) 048090 4 421 048115 4 421 048130 4 421 060090 5 468 060115 5 468 060130 5 468 Scroll 1 8.3 8.3 8.3 8.1 8.1 8.1 .034 .034 Acutrol Device .034 .032 .032 .032 2...17 12.3 2...17 12.3 2...17 12.3 2...17 16.4 2...17 16.4 2...17 16.
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IN TEE OUT NIPPLE CAP C99020 Fig. 9—Sediment Trap DUCT COVERS REMOVED C99012 Fig. 10B—Vertical Duct Cover Removed SUPPLY DUCT OPENING Adhere to the following criteria when selecting, sizing, and installing the duct system: 1. Units are shipped for horizontal duct installation (by removing duct covers). 2. Select and size ductwork, supply-air registers, and return-air grilles according to American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) recommendations. 3.
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Table 4—Electrical Data—Unit 48GS UNIT SIZE 48GS 018 024 030 036 042 048 060 V-PH-HZ 208/230–1–60 208/230–1–60 208/230–1–60 208/230–3–60 208/230–1–60 208/230–3–60 460–3–60 208/230–1–60 208/230–3–60 460–3–60 208/230–1–60 208/230–3–60 460–3–60 208/230–1–60 208/230–3–60 460–3–60 VOLTAGE RANGE COMPRESSOR OUTDOOR FAN MOTOR INDOOR FAN MOTOR POWER SUPPLY Min Max RLA LRA FLA FLA MCA 187 187 187 187 187 187 414 187 187 414 197 187 414 187 187 414 253 253 253 253 253 253 506 253 253 506 253 253 506
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EXAMPLE: Supply voltage is 460-3-60. AB = 452 v BC = 464 v AC = 455 v LEGEND FLA — Full Load Amps LRA — Locked Rotor Amps MCA — Minimum Circuit Amps MOCP — Maximum Overcurrent Protection RLA — Rated Load Amps CKT BKR — Circuit Breaker 452 + 464 + 455 3 1371 = 3 = 457 ® Average Voltage = NOTES: 1.
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Table 5—Electrical Data—Unit 48GX UNIT SIZE 48GX 024 030 036 042 048 060 V-PH-HZ 208/230–1–60 208/230–1–60 208/230–3–60 208/230–1–60 208/230–3–60 460–3–60 208/230–1–60 208/230–3–60 460–3–60 208/230–1–60 208/230–3–60 460–3–60 208/230–1–60 208/230–3–60 460–3–60 VOLTAGE RANGE COMPRESSOR INDOOR FAN MOTOR POWER SUPPLY Min Max RLA LRA FLA FLA MCA 187 187 187 187 187 414 187 187 414 187 187 414 187 187 414 253 253 253 253 253 506 253 253 506 253 253 506 253 253 506 10.3 13.5 9.0 16.7 11.2 5.
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PRE-START-UP ground joint 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. Immediately upon detection of gas odor, retighten the union. Allow 5 minutes to elapse, then light unit. Failure to observe the following warnings could result in serious injury: 1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system. 2.
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BURNER FLAME • The rated gas inputs shown in Table 6 are for altitudes from sea level to 2000 ft above sea level. These inputs are based on natural gas with a heating value of 1050 Btu/ft3 at 0.65 specific gravity, or propane gas with a heating value of 2500 Btu/ft3 at 1.5 specific gravity. • For elevations above 2000 ft, reduce input 4 percent for each 1000 ft above sea level.
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W43 BLK C FIELD SUPPLY BLK W6 YEL 11 21 13 23 CAP 2 1 BRN H YEL ST EQUIP_GND POWER W59 BLU T T+30 G DE-ENERGIZED PRIMARY 230V 230 TRAN1 HEATING FAN LOGIC 0 45 W BR ENERGIZED 200 SECONDARY 24V 24V T T+30 W BR DE-ENERGIZED W13 BLK 24V SPLICE BOX RH OFF HEAT AUTO COOL AHA THI YEL QT W46 BRN L2 J2 L2 L2 IFC W G R YI TCI COOL CR BR FAN LOGIC SEE NOTE #5 5 AMP FU RT RS BLU RS BLU LS V10 LS V10 CS YEL 1 SAFETY LOGIC RS 3 V10 1 GVR W35 GRA GV FS YEL FLA
PAGE 18
21 11 W54 BLK SUPPLY W55 YEL BLK W43 BLK C FIELD 23 13 POWER OFM YEL 1 CAP 2 W6 YEL 1 BRN QT L1 W8 BLK (060 ONLY) C L2 W7 YEL R L3 EQUIP_GND W56 BLU (SEE NOTE #4) COMP S RED YEL W14 BLK COOLING FAN LOGIC T T+30 G DE-ENERGIZED 0 G ENERGIZED COM PRIMARY 230V 230 TRAN1 HEATING FAN LOGIC 0 45 W BR ENERGIZED 200 24V T T+30 W BR DE-ENERGIZED SECONDARY 24V IFM BRN QT V10 W24 YEL W50 V10 W15 YEL BRN/WHT OR YEL CAP 1 W44 RED W59 YEL W64 YEL YEL IDM CAP 3 BRN QT GRN
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21 11 W54 BLK SUPPLY W55 YEL 23 13 CAP 2 W6 YEL 1 BRN QT L1 W8 BLK C L2 EQUIP_GND W7 YEL R L3 (060 ONLY) W56 BLU (SEE NOTE #4) W14 BLK COOLING FAN LOGIC T T+30 G DE-ENERGIZED PRIMARY 460V COM W61 YEL YEL RED W63 YEL W64 YEL YEL CAP 1 BRN QT 460 24V T T+30 W BR DE-ENERGIZED SECONDARY 24V IFM V10 TRAN1 HEATING FAN LOGIC COMP S W59 RED W50 V10 W15 YEL 0 45 W BR ENERGIZED OFM YEL 1 POWER 0 G ENERGIZED BLK W43 BLK C FIELD YEL IDM CAP 3 BRN QT GRN-YEL W46 BRN
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Table 6—Heating Inputs HEATING INPUT (BTUH)* NUMBER OF ORIFICES 40,000 60,000 90,000 115,000 130,000 2 2 3 3 3 Min 4.0 4.0 4.0 4.0 4.0 GAS SUPPLY PRESSURE (IN. WG) Natural Propane† Max Min 13.0 4.0 13.0 4.0 13.0 4.0 13.0 4.0 13.0 4.0 MANIFOLD PRESSURE (IN. WG) Max 13.0 13.0 13.0 13.0 13.0 Natural 3.5 3.5 3.5 3.5 3.5 Propane† 3.5 3.5 3.4 3.7 3.5 * When a unit is converted to propane, different size orifices must be used. See separate, natural-to-propane conversion kit instructions.
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Table 7—Air Delivery (Cfm) at Indicated Temperature Rise and Rated Heating Input HEATING INPUT (BTUH) 40,000 60,000 90,000 115,000 130,000 TEMPERATURE RISE °F 20 25 30 35 40 45 50 55 60 65 70 1500 2250 — — — 1200 1800 — — — 1000 1500 2250 — — 857 1286 1929 2464 2786 750 1125 1688 2156 2438 667 1000 1500 1917 2167 600 900 1350 1725 1950 545 818 1227 1568 1773 500 750 1125 1438 1625 — 692 1038 1327 1500 — — 964 1232 — NOTE: Dashed areas do not fall within the approved temperature rise r
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6. Compare actual suction-tube temperature with desired suction-tube temperature. Using a tolerance of ± 3°F, add refrigerant if actual temperature is more than 3°F higher than proper suction-tube temperature, or remove refrigerant if actual temperature is more than 3°F lower than required suction-tube temperature.
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Table 11—Dry Coil Air Delivery* – Horizontal Downflow Discharge – Unit 48GS018-060 (Deduct 10 percent for 208 Volts) Unit Motor Speed Low 018 Med High Low 024 Med High Low 030 Med High Low 036 Med High Low 042 Med High Low 048 Med High Low 060 Med High Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm 0.
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Table 13—Dry Coil Air Delivery* – Horizontal and Downflow Discharge – Unit 48GX024-060 (Deduct 10 percent for 208 Volts) Unit Motor Speed Low 024 Med High Low 030 Med High Low 036 Med High Low 042 Med High Low 048 Med High Low 060 Med High Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm Watts Cfm 0.
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C00046 C00042 Fig. 18—Cooling Charging Chart, 48GS018 Units Fig. 19—Cooling Charging Chart, 48GS024 Units C00043 C00044 Fig. 21—Cooling Charging Chart, 48GS036 Units Fig. 20—Cooling Charging Chart, 48GS030 Units AIR FILTER 4. Check electrical connections for tightness and controls for proper operation each heating and cooling season. Service when necessary. 5. Ensure wires are not contacting refrigerant tubes or sharp sheet metal edges. 6.
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C00045 OUTDOOR TEMP °F °C 689 100 620 551 483 414 SUCTION LINE PRESSURE (PSIG) SUCTION LINE PRESSURE (KILOPASCALS) 758 110 90 414 345 50 276 40 46 41 35 29 24 18 13 7 50 207 30 30 40 50 60 70 SUCTION LINE TEMPERATURE (°F) 80 90 -1 4 10 16 21 SUCTION LINE TEMPERATURE (°C) 27 32 7 30 40 50 60 70 SUCTION LINE TEMPERATURE (°F) 80 90 -1 4 10 16 21 SUCTION LINE TEMPERATURE (°C) 27 32 (024) 60HZ CHARGING CHART 60 40 45 60 689 100 70 276 18 13 70 345 C00048 620 551
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483 414 345 46 41 95 35 85 75 65 55 45 29 24 18 13 7 90 80 70 60 50 276 40 207 30 620 551 483 414 345 13 45 7 60 50 40 207 30 90 -1 4 10 16 21 SUCTION LINE TEMPERATURE (°C) 27 32 -1 4 10 16 21 SUCTION LINE TEMPERATURE (°C) 27 32 C00051 Fig.
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Table 14—48GS Wet Coil Pressure Drop 024 030 036 042 048 060 OUTDOOR TEMP °F °C 689 100 PRESSURE DROP (IN. WG) 0.049 0.070 0.095 0.077 0.100 0.127 0.065 0.080 0.097 0.084 0.100 0.177 0.103 0.120 0.138 0.088 0.100 0.113 0.108 0.120 0.
PAGE 29
FRONT ACCESS PANEL C99091 Fig. 32—Unit Access Panel C99086 Fig. 34—Burner Rack Removed 9. To reinstall, reverse the procedure outlined above. BLOWER HOUSING CONDENSER COIL, EVAPORATOR COIL, AND CONDENSATE DRAIN PAN Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year or more often if necessary. The coils are easily cleaned when dry; therefore, inspect and clean the coils either before or after each cooling season.
PAGE 30
3. Inspect the fan blades for cracks or bends. halide torch, or liquid-soap solution. If a refrigerant leak is detected, refer to the Check for Refrigerant Leaks section. 4. If fan needs to be removed, loosen the setscrew and slide the fan off the motor shaft. If no refrigerant leaks are found and low cooling performance is suspected, refer to the Checking and Adjusting Refrigerant Charge section. 5. When replacing fan blade, position blade so the hub is 1/8 in. away from the motor end (1/8 in.
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Table 16—Troubleshooting Guide—Cooling SYMPTOM Compressor and condenser fan will not start. Compressor will not start but condenser fan runs. CAUSE REMEDY Power Failure Call power company. Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker. Defective thermostat, contactor, transformer, or control relay Replace component. Insufficient line voltage Determine cause and correct. Incorrect or faulty wiring Check wiring diagram and rewire correctly.
PAGE 32
Table 17—Troubleshooting Guide–Heating SYMPTOM Burners will not ignite. Inadequate heating. Poor flame characteristics. CAUSE REMEDY Water in gas line Drain. Install drip leg. No power to furnace Check power supply fuses, wiring, or circuit breaker. No 24-v power supply to control circuit Check transformer. NOTE: Some transformers have internal overcurrent protection that requires a cool-down period to reset.
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Table 18—Troubleshooting Guide–LED Error Codes SYMPTOM CAUSE REMEDY Hardware failure. (LED OFF) Loss of power to control module (IGC)*. Check 5-amp fuse on IGC*, power to unit, 24–v circuit breaker, and transformer. Units without a 24–v circuit breaker have an internal overload in the 24–v transformer. If the overload trips, allow 10 minutes for automatic reset. Fan ON/OFF delay modified (LED/FLASH) High limit switch opens during heat exchanger warm-up period before fan-on delay expires.
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START-UP CHECKLIST (Remove and Store in Job File) I. PRELIMINARY INFORMATION MODEL NO: ............................................................................................................................................................. SERIAL NO: .............................................................................................................................................................. DATE: ...........................................................................................
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PAGE 36
Form No. 48GS,GX-5SI Replaces: 48GS,GX-4SI Page 36 7/02 Copyright 2002 Carrier Corp. Catalog No.