User`s manual

ManualsBrandsCal Flame ManualsHeating SystemFPT-1100

HFATUNG & COOLING

48GS, 48GX

Single Packaged Gas Heating/

Electric Cooling Units

%isdt_ v_v_carrier.corn

Installation, Start-Up, and Operating

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

NOTE: Read the entire instruction manual before starting the

installation

TABLE OF CONTENTS

SAFETY C ONSIDERATI(INS 1

INTRODE CTION 2

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

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

IDENTIFY EJNIT ................................................................ 2

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

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

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

ROOF (LRB ....................................................................... 2

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

GROL_D MOL_T ............................................................ 5

FIELD FABRICATE DUCTW()RK ........................................ 5

PROVIDE CLEARAN( ES ...................................................... 6

RIG AND PLA(E ENIT ......................................................... 7

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

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

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

INSTALL DUCT ( ONNE( TIONS ...................................... 10

(ONFIGURING UNITS FOR DO\}_TLOW (VERTI-

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

INSTALL ELECTRICAL ( ONNE(TIONS ......................... 12

HIGH-V()LTAGE CONNECTIONS ................................ 12

SPECIAL PROCEDURES FOR 208°V OPERATION ._ 13

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

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

TRAN SFORMER PR()TECTION .................................... 13

PRE-START-E P .......................................................................... 15

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

(HECK FOR REFRIGERANT LEAKS ............................... 15

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

CHE(K HEATING CONTROL ....................................... 16

CHECK GAS INPUT ........................................................ !6

ADJUST GAS INPET ...................................................... 16

CHECK BURNER FLAME .............................................. 20

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

HEATING SEQUEN(E OF OPERATION ..................... 20

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

AE XILIARY LIMIT SWITCH (ROLLOE T) .................. 21

START°E P COOLING AND MAKE ADJUSTMENTS ...... 21

CHECKING COOLING CONTROL OPERATION ....... 2!

< HE(KING AND ADJUSTING REFRIGERANT

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

INDOOR AIRFLOW AND AIRFLOW ADJUST-

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

COOLING SEQE ENCE OF OPERATION ..................... 22

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

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

EVAPORATOR BLOWER AND MOT()R ..................... 25

FLEE GAS PASSAGEWAYS ......................................... 27

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

LIMIT SWIT(H ................................................................ 28

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

MAIN BE RNERS ............................................................. 28

CONDENSER COIL, EVAPORATOR (OIL, AND

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

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

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

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

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

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

METERING DEVICE A(UTROL DEVICE ............. 30

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

TROE BLESHOOTING ............................................................... 30

START-UP CHEf KLIST ............................................................ 30

NOTE TO INSTALLER Before the installatiom READ THESE

INSTRU(TIONS CAREFELLY AND (OMPLETELY. 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.

A99338

Fig. 1--Unit 48GS and 48GX

(Low NO× Model Available)

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be

hazardous due to system pressure and ebctrical 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 oNigations.

PC 101 Catalog No 534-80128 Printed in U.S.A Form 48GS.GX-6SI Pg 1 11-02 Replaces: 48GS.GX-5SI

Summary of content (36 pages)

PAGE 1
48GS, 48GX Packaged Gas Heating/ Electric Cooling Units Single HFATUNG & COOLING %isdt_ v_v_carrier.corn Installation, Start-Up, and Operating 48GS Sizes 018-060, 48GX Sizes 024-060 NOTE: Read installation the entire instruction before starting OF CONTENTS MAIN 1 CTION RECEIVING AND INSTALLATION .......................................... CHECK EQUIPMENT ............................................................. IDENTIFY EJNIT ................................................................
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Untrained personnel can perfbrm basic maintenance functions of cleaning coils and filters. All other operations should be perfbrmed by tlained service personnel When working on air-conditioning equipmenL observe attached precautions to the unit, Follow and other safety all safe V codes.
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ZS4 86 I (t CD,[ [_H [ GJ I "" [_9 K,] i[ _ j _ 5q } _ 5 : [2, _o] _ [o oo] i _1, , : _C,_494_ 0_i t:¸ OPU 6 t' i N 249 550 5 IN _;i ; i,, s1 ?49 6 }9 8_] REAR ViEW REQUIRED CLEARANCE TO COMBUSTIBLE MATL REQUIRED CLEARANCE TOP OF UNIT ................................................................................... DUCT SIDE OF UNIT ......................................................................... SIDE OPPOSITE DUCTS .................................................
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_3427 _ [!3 49] 3558 {1411] 3558 [14 Oi] [33£1 SUPPLY 70 [2 4 77] i [16 4066 [1601] O!] 402 o [15 83] i E_AP COIL [1177 {a C01L 631 i 88 3 [3 46] [13831 [13 62] TOP VIEW [13831 REAR VIEW REQUIRED CLEARANCE TO COMBUSTIBLE MATE REQUIRED INCHES 14,00 2.00 14,00 0.50 36,00 TOP OF UNIT ................................................................................... DUCT SIDE OF UNIT ......................................................................... SIDE OPPOSITE DUCTS .........
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RoofCurb for Small Cabinet Roof Note A: When uNt mounting screw is used, retah3er bracket must also be used. Curb for Large Cabinet Note A: When unit mounting screw is used, retainer bracket must also be used. R/A S/A /\ -'-_- Gasket around_ duct \ \ insulated deck pan Suppolt \ Gasket around outer edge \ \, Long SL pport iBXC} C00076 UNiT S_ZE 48GS018o042 ODS CATALOG 48GX024-036 48GS048o060 48GX042-060 NUMBER A IN. {NM) B IN.(MM) C RN. (MM) D IN.
PAGE 6
Y 4 x 3 C00070 48GS CORNER TOTAL 48G× # 018 024 030 036 1 47.3 53.2 53.2 59.7 2 44.8 50.4 50.4 56.5 639 3 77.2 86.8 86.8 97.3 1101 4 79.7 89.6 89.6 106.5 1136 WEIGHT 249 280 280 320 Fig. 8--48GS 042 675 355 048 060 024 030 036 042 048 060 789 85.5 55.1 595 61.0 72.6 800 88.9 747 81.0 52.2 563 57.8 68.8 758 84.2 128.7 1395 89.9 970 99.5 1184 130.5 145.1 132.8 1440 92.8 1002 102.7 1222 134.7 149.
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Table 1--Physical UNIT SBZE 48GS NOMINAL Data--UnR 48GS 024040 024060 030040 030080 036060 038080 042060 1½ 2 2 2½ 2½ 3 3 3½ 3½ 249 280 280 280 280 320 320 355 355 018040 CAPACBTY (ton) OPERATING WEIGHT COMPRESSORS Quantity (_b.) 042090 Reciprocating 1 REFRmGERANT (R-22) Quantity (_b.) REFRIGERANT METERING Orifice AcutroF M Device DEVICE .034 ID (in.) I .O34 .034 .034 .034 .032 .032 .034 .034 1...17 9.1 1._17 9.1 1_17 9.1 1...17 9.1 1...17 10.9 1._17 10.
PAGE 8
Table 1--Physical UNiT SIZE 48GS NOMINAL CAPACITY OPERATING WEIGHT COMPRESSORS Quantity 048130 (ton) 4 4 4 5 5 5 (lb.) 415 415 415 450 450 450 0$0090 060 t 18 Scroll 1 METERING Orifice 48GS (Continued) 048115 REFRIGERANT {R=22) Quantity (lb.) REFRIGERANT Data--Unit 048090 Reciprocating 1 8.0 8.0 8.0 6.0 6.0 6.0 .032 .032 .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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TaNe 2--Physicam Data--Unit UNiT BBZE 48GX NOMINAL 024040 CAPACITY 2 2 2"½ 2_½ 290 290 313 313 030060 036090 042060 042090 3 3 3½ 3½ 321 321 382 382 Scroll 1 Orifice ID (in.} CONDENSER COBL Rows...Fins/in. Face Area (sq ft} CONDENSER FAN Nominal Cfm Diameter (in.) Motor Bp (Rpm) 3.7 3.7 4.4 4.4 5.2 5.2 6.4 6.4 .034 .034 .030 .030 .032 .032 .034 .034 1._17 10.8 1._17 10.8 1_.17 12.7 1...17 12.7 2...I7 9.1 2...17 9.1 2...17 12.3 2._17 12.
PAGE 10
Table 2--Physical UNiT BBZE 48G× NOMINAL Data--Unit 048090 CAPACBTY (ton) OPERATING WEIGHT COMPRESSORS Quantity (_b.) 48GX (Continued) 048115 048130 0g0090 060115 060130 4 4 4 5 5 5 421 421 421 468 468 468 Scrolt 1 REFRmGERANT {R=22} REFRIGERANT METERING Orifice OEVICE Acutrol Device ID (in.) CONDENSER CORL Rows...Finstin. Face Area {sq ft} CONDENSER FAN Nominal Cfm Diameter (in.) Motor Hp (Rpm) .034 .034 .034 .032 .032 .032 2...17 12.3 2._17 12.3 2._17 12.3 2...
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IN --:u TEE OUT _.._ I NIPPLE 3"MIN __!_1 CAP C99020 Fig. 9--Sediment Trap DUCT COVERS REMOVED C99012 Fig.
PAGE 12
Table 4--Electrical UNIT SBZE 48GS VOLTAGE RANGE V-PH-HZ Data--Unit COMPRESSOR Min Max 48GS OUTDOOR FAN MOTOR INDOOR FAN MOTOR FLA MCA Max Fuse or Ckt Bkr RLA LRA FLA POWER SUPPLY 018 208/230-1-60 187 253 9.0 45.0 0.8 1.8 13.9 20 824 208/230-1-60 187 253 12.8 61.0 0.8 2.0 18.8 30 208/230-1-60 187 253 14.4 73.0 0.8 2.0 20.8 30 208/230-3-60 187 253 12.6 68.0 0.8 2.0 13.2 20 208/230-1-60 187 253 13.0 81.0 1.6 3.6 24.0 35 208/230-3-60 187 253 9.
PAGE 13
EXAMPLE: Suppty voltage is 460-3-60. A B C AB = 452 v LEGEND AC = 455 v FLA -- Full Load Amps LRA -- Locked Rotor Amps MCA -- Minimum Circuit Amps MOCP -- Maximum Overcurrent Protection RLA -- Rated Load Amps CKT BKR -- Circuit Breaker Average Voltage = 452 + 464 + 455 3 BC = 464 v _ 1371 3 = 457 NOTES: Determine maximum deviation from average 'voltage. (AB) 457 452=5v (BC) 464 457=7v (AC) 457 455=2v Maximum deviation is 7 v. 1.
PAGE 14
Tab{e 5--Electrical UNIT SBZE 48GX O24 030 036 O42 O48 OGO VOLTAGE RANGE V-PN-NZ Data--Unit COMPRESSOR 48GX OUTDOOR FAN MOTOR INDOOR FAN MOTOR POWER SUPPLY Min Max RLA LRA FLA FLA MCA Max Fuse or Ckt Bkr 208/230-1-80 187 253 10.9 54.0 0.9 2.0 16.5 25 208/230-1-60 187 253 13.5 73.0 0.8 2.1 19.8 30 208/230-3-80 187 253 9.0 63.0 0.8 2.1 14.2 20 208/230-1-60 187 253 16.7 97.0 0.8 3.6 25.3 40 208/230-3-80 187 253 11.2 75.0 0.8 3.6 18.
PAGE 15
PREoSTARToUP 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 Failure to obselwe serious injury: I the Follow recognized goggles when %llowing safhty checking 2 Do not operate practices or se_'icing compressor onit unless secured. warnings tem_inal 6. Do system not to repair soldered pressure.
PAGE 16
BURNER FLAME _Z * The rated gas inputs shown in Table 6 are %r altitudes fiom sea 1eve1 to 2000 ft above sea tevel. These inputs are based on natural gas with a heating value of 1050 Bmift 3 at 0.65 specific gravity, or propane gas with a heating value of 2500 Bmifl 3 at 15 specific gravity. * For elevations above 2000 if, reduce input 4 percent fbr each 1000 ft above sea level.
PAGE 17
W43 BLK FIELD OFM CAP 2 SUPPLY EQUIP GND POWER COMP SCHEMATIC 208/230-1-60 IFM ¢/15YEL COOLING FAN QT PRIMARY LOGIC IDM +3 G G ENERGfZED DEENERGIZED TRAN1 HEATINGFANLOGIC SECONDARY 24V ENERGIZED DE W46 BAN ENERGIZED CR i I I _OFF HEAT W13 BLK 24V SPLICE BOX BR W39 RED IGC J2 W19 WHT I I _W20GRN I I r I [i I. Z_ w21 RED _HEAT OAUTO MG\/ FLAF_ESEN YEL_ I o .........
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W56 BLU W59YEL W64 YEL-- -- IFM W15YEL COOL NG 0 G ENERGIZED FAN LOGIC: F o T T_30 G DE ENERGIZED HEATING FAN 0 45 W BR ENERGIZED IDM g TRANI LOGIC SECONDARY 24V T T30 W BR DE ENERGIZED W46BRN-- OR RC O__ RH I I W13 BLK24V SPLICE BOX BR --W39 RED IGC J2 - @ 1_ - L W19WHT W20 GRN J l_l / _:> F __.
PAGE 19
OFM COMP IFM COOLING FAN LOGIC IDM 0 T T+30 G G ENERGIZED DE ENERGIZED HEATING FAN TRAN1 LOGC 4_SECONDARY] 0 45 T T÷30 W BR W BR ENERGLZED DE ENER®JZED W46BRN-- 24V OR RC -W13 (7 1 24V i BLK SPLICE BOX BR -- I I i i W39 RED IGC J_ ---WSWNT r .....
PAGE 20
Table 6--Heating GAS SUPPLY HEATING iNPUT (BTUH)* NUMBER OF ORIFICES inputs PRESSURE MANIFOLD PRESSURE (IN, WG} Natural (IN, WG) Propanet Min Max Min Max Natural 40,000 2 4.0 13.0 4.0 13.0 3.5 Propane¢ 3.5 G0,000 2 4.0 13.0 4.0 13.0 3.5 3.5 90,000 3 4.0 13.0 4.0 13.0 3.5 3.4 115,000 3 4.0 13.0 4.0 13.0 3.5 3.7 3 4.0 13.0 4.0 13.0 3.5 3.5 130,000 When a unit is converted to propane, different size orifices must be used.
PAGE 21
Table 7--Air Delivery {Cfm) at indicated Temperature Rise and Rated Heating input HEATING INPUT (BTUH) 20 25 30 35 40 45 50 55 6O 40,000 1500 1200 1000 857 750 667 600 545 5OO 60,000 2250 1800 1500 1286 1125 1000 900 818 75O 692 1688 1500 1350 1227 1125 1038 964 1232 TEMPERATURE R_SB °F 65 7O 90,000 -- -- 2250 1929 115,000 -- -- -- 2464 2156 1917 1725 1568 1438 1327 130,000 -- -- -- 2786 2438 2167 1950 1773 1625 1500 NOTE: Dashed areas
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6.
PAGE 23
Table 11--Dry Col! Air Delivery* - Horizontal Downflow Discharge Unit 48GS018°060 (Deduct 10 percent for 208 Volts) - 230 AND 460 VOLT Unit Motor Speed Low 0t8 Low Med High Low 030 Med High Low 036 Med High Low 042 Med High Low 048 Med High Low 0$0 0.2 0.3 Watts 227 212 196 177 165 153 ..... Cfm 1082 1016 929 796 668 428 ..... Med High 0.7 0.8 0.9 1.0 ........... Cfm High 024 0.1 Watts Med External Static Pressure (in. wg) 0.4 0.5 0.6 0.0 ...........
PAGE 24
Table13--Dn] Coil Air Delivery* - Horizontam and Downflow DischargeUnit 48GX024=000 (Deduct 10 percent for 208 Volts) 230 AND 450 VOLT Motor Speed Unit Low O24 Med High Low 030 Med High Low 036 Med High Low O42 Med Low O48 Med High Low 050 0.1 0.2 0.3 Watts 281 282 281 278 276 Med High to %ltow power 828 757 691 619 ...... -- -- 375 370 363 357 352 -- -- -- Cfm -- -- -- 969 897 824 744 649 -- -- -- 468 994 457 913 444 826 431 730 423 620 --- ....
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_ OUTDOOR _ _F -K_los _ 30 40 I 50 70 TEMPERATURE ("F) I I IB 21 SUCT]ON LINE TEMPERATURE Fig.
PAGE 26
}L TDOOR TEMP F 30 40 50 SUCTION I 4 SUCTION I -1 60 LINE TEMPERATURE I I 10 16 LINE TEMPERATURE C 115 46 105 41 95 85 75 35 29 24 65 55 18 13 45 7 70 80 90 (_F) I 21 (:C) I 27 I 32 C00047 48G8048 UnRs Fig 23--CooHn_ -1 SUCTION LINE TEMPERATURE IF 4 SUCTION 10 16 LINE TEMPERATURE 21 (:C) Fig. 24--Cooling For longer life, clean accumulated motor annually. operating dirt Charging 32 SUCTION and continuing flora LINE TEMPERATURE C00048 Fig.
PAGE 27
(030) 60HZ CHARGING CHART (036) 60HZ CHARGING -1 SUCTION LINE TEMPERATURE 48GX0a0 26--Coolin{ -1 SUCTION LINE TEMPERATURE 4 SUCTION 10 16 LINE TEMPERATURE Fig. 28--Cooling and housing ment. grease d, Reassemble wheel e Reassemble motor tightened shaft. £ Reinstall 3. Restore proper 32 cleaner, shak using soft brllsh attach° 2.
PAGE 28
TaNe 14_48GS Wet Coit Pressure Drop UNIT SiZE 48GS AIRFLOW (CFM) 500 (iN. WG) 0.049 018 600 0.070 7OO 0.095 7OO 0.077 800 0.100 900 0.127 900 0.065 1000 0.080 1100 0.097 1100 0.084 1200 0.100 1300 0.177 1300 0.103 1400 0.120 1500 0.138 1500 0.088 1600 0.100 1700 0.113 1900 0.108 2000 0.120 2100 0.132 024 030 036 042 048 060 PRESSURE (060) 60HZ CHARGING CHART DROP SUCTION LINE TEMPERATURE C00054 Fig.
PAGE 29
FRONT ACCESS PANEL C99091 Fig. 32--UNt Access Panel C99086 Fig. 34--Burner Rack Removed 9 To reinstall, reverse the procedure outlined above HOUSING CONDENSER COIL, EVAPORATOR CONDENSATE DRAIN PAN (OIL, AND Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year or more often if"necessa W The coils are easily cleaned when du; therefbre, inspect and clean the coils either befbre or after each cooling season.
PAGE 30
3.Inspect thefanblades %r cracks 4. If fire needs to be removed, fun off the motor shaft. 5. When replacing away fi'om visible. position end 11/8 in. of motor shaft will be engages the flat area on the motor The gas input (ONTROLS controls and wiring annually. Remove controls (heck screw noticed, wire to locate al! electrical connections. all the connections If any disassemble does not require is suspected.
PAGE 31
Table 16--Troubleshooting SYMPTOM Guide--Cooling CAUSE REMEDY Power Failure Call power company Fuse blown or circuit breaker tripped Compressor and condenser will not start= Defective thermostat, fan Insufficient contactor, Replace fuse or reset circuit breaker transformer, or control relay Incorrect or faulty wiring Thermostat fan runs.
PAGE 32
Table 17--Troubleshooting SYMPTOM REMEDY Water in gas line Drain. Install drip leg. No power to furnace Check power supply fuses, wiring, or circuit breaker Check transformer. NOTE: Some transformers have internal overcurrent protection that requires a cool-down period to reset. No 24-v power supply to contro{ circuit Burners will not ignite, Miswired or loose connections Check all wiring and wirenut connections Burned-out thermostat Replace thermostat.
PAGE 33
Table18--TroubleshootingGuide-LEDError Codes SYMPTOM CAUSE REMEDY Check 5-amp fuse on IGC*, power to unit, 24-v circuit breaker, and Hardware failure, Less of power to control module (IGC)*. (LED OFF) transformer Units without a 24-v overload in the 24-v transformer. utes for automatic reset. circuit breaker have an internal If the overload trips, allow 10 rain- High limit switch opens during heat Fan ON/OFF delay modified exchanger warm-up period before fan-on delay expires.
PAGE 34
START-UPCHECKLIST (RemoveandStore in Job File) L PRELIMINARY INFORMATION MODEL NO: ............................................................................................................................................................. SERIAL NO: .............................................................................................................................................................. DATE: .............................................................................................
PAGE 35
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FormNo.48GS,GX-6SI Replaces: 48GS,GX-5SIPage36 11/02 Copyright 2002Carrier Corp. Catalog No.