Carrier 48PG20---28 Specifications

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Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 111 Catalog No. 534-80211 Printed in U.S.A. Form 48PG-10SI Pg 1 9-05 Replaces: New
Book 1 4
Tab 1 a 6 a
Installation, Start-Up and Service Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS ..........................1,2
INSTALLATION ......................................2-17
Step 1 — Provide Unit Support .........................2
ROOF CURB
ALTERNATE UNIT SUPPORT
SLAB MOUNT
Step 2 — Remove Shipping Rails .......................2
Step 3 — Rig and Place Unit ............................2
POSITIONING
ROOF MOUNT
INSTALLATION ONTO CURB
Step 4 — Field Fabricate Ductwork .....................9
Step 5 — Make Unit Duct Connections..................9
VERTICAL CONFIGURATION
HORIZONTAL APPLICATIONS
Step 6 — Install Flue Hood and Inlet Hood ............ 10
Step 7 — Trap Condensate Drain ..................... 10
Step 8 — Install Gas Piping ........................... 10
Step 9 — Make Electrical Connections.................11
FIELD POWER SUPPLY
FIELD CONTROL WIRING
Step 10 — Install Outdoor-Air Hood................... 12
MANUAL DAMPER ASSEMBLY
Step 11 — Position Optional Power
Exhaust or Barometric Relief Damper Hood ......... 16
Step 12 — Non-Fused Disconnect .................... 16
Step 13 — Install All Accessories ..................... 16
PRE-START-UP ....................................... 18
START-UP...........................................18-45
Unit Preparation ...................................... 18
Compressor Mounting................................ 18
Refrigerant Service Ports ............................. 18
Crankcase Heater(s) .................................. 18
Compressor Rotation................................. 18
Internal Wiring........................................ 18
Subcooler Heat Exchanger (SHX)..................... 18
Evaporator Fan ....................................... 18
Condenser Fans and Motors.......................... 19
Return-Air Filters ..................................... 19
Outdoor-Air Inlet Screens............................. 19
Gas Heat.............................................. 19
Optional EconoMi$er IV............................... 39
Operating Sequence .................................. 44
SERVICE............................................46-57
Cleaning .............................................. 46
Lubrication ........................................... 47
Manual Outdoor Air Damper .......................... 48
Economizer Adjustment .............................. 48
Evaporator Fan Service and Replacement ............ 48
Evaporator Fan Performance Adjustment ............. 48
Evaporator Fan Belt Tension Adjustment ............. 48
Condenser Fan Adjustment........................... 49
Verify Sensor Performance ........................... 49
Economizer Operation During Power Failure.......... 49
Evacuation ........................................... 49
Refrigerant Charge ................................... 50
Gas Valve Adjustment ................................ 50
High Altitude.......................................... 51
Main Burners ......................................... 51
Filter Drier ............................................ 52
Protective Devices.................................... 52
Relief Devices ........................................ 52
Page
Control Circuit, 24-V .................................. 52
Replacement Parts.................................... 52
Diagnostic LEDs ...................................... 52
TROUBLESHOOTING .............................. 57-61
Unit Troubleshooting.................................. 57
EconoMi$er IV Troubleshooting....................... 60
Phase Loss Protection ................................ 61
UNIT START-UP CHECKLIST ........................CL-1
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical compo-
nents. Only trained and qualified service personnel should
install, repair, or service air-conditioning equipment.
Untrained personnel can perform the basic maintenance
functions of cleaning coils and filters and replacing filters. All
other operations should be performed by trained service per-
sonnel. 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.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations. Have
fire extinguishers available for all brazing operations.
Before performing service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury.
Puron (R-410A) refrigerant systems operate at higher pres-
sures than standard R-22 systems. Do not use R-22 service
equipment or components on Puron refrigerant equipment.
If service equipment is not rated for Puron refrigerant,
equipment damage or personal injury may result.
1. Improper installation, adjustment, alteration, service,
or maintenance can cause property damage, personal
injury, or loss of life. Refer to the Users Information
Manual provided with this unit for more details.
2. 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:
1. DO NOT try to light any appliance.
2. DO NOT touch any electrical switch, or use any
phone in your building.
3. IMMEDIATELY call your gas supplier from a neigh-
bors phone. Follow the gas suppliers instructions.
4. If you cannot reach your gas supplier, call the fire
department.
48PG20-28
Single Package Rooftop Units
Electric Cooling/Gas Heating with
Electromechanical Controls and PURON® (R-410A) Refrigerant
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1 2 ... 64

Summary of Contents

Page 1 - Single Package Rooftop Units

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.PC 1

Page 2 - Step 1 — Provide Unit Support

10Step 6 — Install Flue Hood and Inlet Hood —Flue hood (smaller hood), inlet hood (larger hood), and screensare shipped inside the unit in the fan sec

Page 3 - Fig. 1 — Roof Curb Details

11Size gas-supply piping for 0.5-in. wg maximum pressuredrop. Do not use supply pipe smaller than unit gas connection.Step 9 — Make Electrical Connect

Page 4 - Fig. 3 — Rigging Details

12Set heat anticipator settings as follows:Settings may be changed slightly to provide a greater degreeof comfort for a particular installation.Step 1

Page 5 - Fig. 4 — Base Unit Dimensions

13Table 4A — Electrical Data (Units Without Optional Powered Convenience Outlet)See Legend and Notes on page 15.UNITSIZE48HGNOMINALVOLTAGE(3 Ph, 60 Hz

Page 6 - Table 1 — Physical Data

14Table 4B — Electrical Data (Units With Optional Powered Convenience Outlet)UNITSIZE48HGNOMINALVOLTAGE(3 Ph, 60 Hz)VOLTAGERANGECOMPRESSOROFM IFMPOWER

Page 7

15LEGEND AND NOTES FOR TABLES 4A AND 4BLEGEND*Fuse or HACR circuit breaker.NOTES:1. In compliance with NEC requirements for multimotor and com-binatio

Page 8

16Step 11 — Position Optional Power Exhaust orBarometric Relief Damper Hood —The optionalpower exhaust or barometric relief dampers are shippedassembl

Page 9

17Fig. 21 — Power Exhaust or Barometric Relief Damper Mounting DetailsFig. 22 — Bracket and Hood Positioning

Page 10 - INLET HOOD

18PRE-START-UPProceed as follows to inspect and prepare the unit for initialstart-up:1. Remove all access panels.2. Read and follow instructions on al

Page 11

19Condenser Fans and Motors — Condenser fans andmotors are factory set. Refer to Condenser-Fan Adjustmentsection (page 49) as required.Return-Air Filt

Page 12

2INSTALLATIONStep 1 — Provide Unit SupportROOF CURB — Assemble or install accessory roof curb inaccordance with instructions shipped with this accesso

Page 13

20Table 6 — Fan Performance — 48PGE20 — Vertical Supply/Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor drive

Page 14

21Table 7 — Fan Performance — 48PGF20 — Vertical Supply/Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor drive

Page 15

22Table 8 — Fan Performance — 48PGD24 — Vertical Supply/Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor drive

Page 16 - LOCKING SCREW

23Table 9 — Fan Performance — 48PGE24 — Vertical Supply/Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor drive

Page 17

24Table 10 — Fan Performance — 48PGF24 Vertical Supply/Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor drive r

Page 18

25Table 11 — Fan Performance — 48PGD28 — Vertical Supply/Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor drive

Page 19

26Table 12 — Fan Performance — 48PGE28 — Vertical Supply/Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor drive

Page 20

27Table 13 — Fan Performance — 48PGF28 — Vertical Supply/Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor drive

Page 21

28Table 14 — Fan Performance — 48PGD20 — Horizontal Supply and Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor

Page 22

29Table 15 — Fan Performance — 48PGE20 — Horizontal Supply and Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor

Page 23

3Fig. 1 — Roof Curb Details

Page 24

30Table 16 — Fan Performance — 48PGF20 — Horizontal Supply and Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor

Page 25

31Table 17 — Fan Performance — 48PGD24 — Horizontal Supply and Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor

Page 26

32Table 18 — Fan Performance — 48PGE24 — Horizontal Supply and Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor

Page 27

33Table 19 — Fan Performance — 48PGF24 — Horizontal Supply and Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor

Page 28

34Table 20 — Fan Performance — 48PGD28 — Horizontal Supply and Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor

Page 29

35Table 21 — Fan Performance — 48PGE28 — Horizontal Supply and Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor

Page 30

36Table 22 — Fan Performance — 48PGF28 — Horizontal Supply and Return UnitsLEGENDBoldface indicates field-supplied motor/drive required.NOTES:1. Motor

Page 31

37Table 23 — Power Exhaust Fan Performance — 48PG20-28LEGENDESP — External Static PressureTable 24 — Operation Air Quantity Limits*7000 cfm minimum re

Page 32

38Table 25 — Evaporator Fan Motor Specifications (cont)NOTES:1. Extensive motor and electrical testing ensures that the motors can be uti-lized with c

Page 33

39Table 26 — Accessory/FIOP Static Pressure (in. wg)* — 48PG20-28LEGEND*The static pressure must be added to the external static pressure. The sum and

Page 34

4NOTES:1. Add 150 lb (68 kg) for domestic crating.2. See label for unit location on roof curb.DOES NOT INCLUDE ERV ( ENERGY RECOVERY VENTILATOR) OPTIO

Page 35

40Table 28 — EconoMi$er IV Sensor Usage*CRENTDIF004A00 and CRTEMPSN002A00 accessories are used on many different base units. As such, these kits may c

Page 36

41Differential Dry Bulb Control— For differential dry bulbcontrol the standard outdoor dry bulb sensor is used in conjunc-tion with an additional acce

Page 37

42CONTROLCURVEABCDCONTROL POINTAPPROX. °F (°C)AT 50% RH73 (23)70 (21)67 (19)63 (17)12 14 16 18 20 22 24 26 28

Page 38

43Minimum Position Control— There is a minimum damperposition potentiometer on the EconoMi$er IV controller. SeeFig. 28. The minimum damper position m

Page 39

443. Use the Up/Down button to select the preset number. SeeTable 29.4. Press Enter to lock in the selection.5. Press Mode to exit and resume normal o

Page 40 - OAT LOCATION

45When ignition occurs the IGC board will continue to moni-tor the condition of the rollout and limit switches, the hall effectsensor, as well as the

Page 41

46SERVICECleaning —Inspect unit interior at beginning of each heat-ing and cooling season and as operating conditions require. Re-move unit top panel

Page 42 - 1100 ppm

475. Thoroughly apply Totaline® environmentally sound coilcleaner solution to all coil surfaces including finned area,tube sheets and coil headers.6.

Page 43

48FAN SHAFT BEARINGS — Lubricate bearings at least ev-ery 6 months with suitable bearing grease. Typical lubricantsare given below:*Preferred lubrican

Page 44 - Operating Sequence

49Table 30 — Belt Tension AdjustmentCondenser-Fan Adjustment (Fig. 35)1. Shut off unit power supply.2. Remove condenser-fan assembly (grille, motor, m

Page 45

5Fig. 4 — Base Unit Dimensions

Page 46 - Cleaning —

50Refrigerant Charge — Amount of refrigerant charge islisted on unit nameplate. Refer to Carrier GTAC II; Module 5;Charging, Recovery, Recycling, and

Page 47 - Controller

514. Set main gas valve to ON position.5. Set thermostat at setting to call for heat.6. Remove screw cap covering regulator adjustment screw(see Fig.

Page 48

52Table 32 — Altitude Compensation*NATURAL GAS*As the height above sea level increases, there is less oxygen per cubic foot of air. Therefore, heat in

Page 49

53Fig. 42 — Typical Low Voltage Control Schematic

Page 50 - Gas Valve Adjustment

54Fig. 43 — Typical Power Schematic

Page 51 - SEE DETAIL “C”

55Fig. 44 — Typical Component Arrangement — 48PG20,24

Page 52 - PROPANE GAS

56Fig. 45 — Typical Component Arrangement — 48PG28THERMOSTAT/IGC MARKINGSBM — Blower MotorC—CommonCM — Inducer MotorCS — Centrifugal SwitchG—FanIFO —

Page 53

57TROUBLESHOOTINGUnit Troubleshooting —Refer to Tables 33-35 andFig. 46.Table 33 — Cooling Service AnalysisLEGENDTXV — Thermostatic Expansion ValvePRO

Page 54

58Table34—GasHeatingServiceAnalysisPROBLEM CAUSE REMEDYBurners Will Not Ignite. Misaligned spark electrodes. Check flame ignition and sensor electrode

Page 55

59Fig. 46 — IGC Control (Heating and Cooling)LEGENDNOTE: Thermostat Fan Switch in the“AUTO” position.IDM — Induced-Draft MotorIGC — Integrated Gas Uni

Page 56 - LEGEND FOR FIG. 42-45

6Table 1 — Physical DataLEGEND*Aluminum evaporator coil/aluminum condenser coil.UNIT 48PG 20 24 28VOLTAGE 208/230 and 460 575 208/230 and 460 575 208/

Page 57 - Unit Troubleshooting —

60Table 35 — IGC Board LED Alarm CodesLEGEND NOTES:1. There is a 3-second pause between alarm code displays.2. If more than one alarm code exists, all

Page 58

61DCV (Demand Controlled Ventilation) AND POWEREXHAUST — To check DCV and Power Exhaust:1. Make sure EconoMi$er IV preparation procedure hasbeen perfo

Page 59 - IDM — Induced-Draft Motor

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.PC 1

Page 61

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.PC 1

Page 62 - Tab 1 a 6 a

7Table 2 — Fan Motor and Drive Data — Vertical Supply/Return48PG20 24 28208/230 and 460 575 208/230 and 460 575 208/230 and 460 575LOW RANGEMotor Hp 3

Page 63

8Table 3 — Fan Motor and Drive Data — Horizontal Supply/Return48PG20 24 28208/230 and 460 575 208/230 and 460 575 208/230 and 460 575LOW RANGEMotor Hp

Page 64 - II. START-UP

9Step 4 — Field Fabricate Ductwork — On verticalunits, secure all ducts to roof curb and building structure. Donot connect ductwork to unit. For horiz

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