Carrier 48VL-A, Installation Instructions Manual

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1
48VL---A
Performance
t
14 SEER Single---Packaged Air
Conditioner and Gas Furnace System with Puron
®
(R---410A) Refrigerant
Single and Three Phase
2---5 Nominal Tons (Sizes 24---60)
Installation Instructions
NOTE : Read the entire instruction manual before starting the
installation.
NOTE : Installer: Make sure the Owner’s Manual and Service
Instructions are left with the unit after installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 1--2 . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEIVING AND INSTALLATION 2--12 . . . . . . . . . . . . . . . . .
Check Equipment 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identify Unit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspect Shipment 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Provide Unit Support 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Roof Curb 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slab Mount 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field Fabricate Ductwork 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Provide Clearances 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rig and Place Unit 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rigging/Lifting of Unit 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connect Condensate Drain 9 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Flue Hood 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Gas Piping 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Duct Connections 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring Units for Downflow (Vertical)
Discharge 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Electrical Connections 11 . . . . . . . . . . . . . . . . . . . . . . . .
High--Voltage Connections 11 . . . . . . . . . . . . . . . . . . . . . . . .
Special Procedures for 208--V Operation 12 . . . . . . . . . . . . . .
Control Voltage Connections 12 . . . . . . . . . . . . . . . . . . . . . . .
Standard Connection 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Anticipator Setting 12 . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer Protection 12 . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRE--START--UP 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
START--UP 13--24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check for Refrigerant Leaks 13 . . . . . . . . . . . . . . . . . . . . . . . . .
Start--Up Heating & Make Adjustments 14 . . . . . . . . . . . . . . . .
Check Heating Control 14 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Gas Input 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Gas Input 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Burner Flame 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Airflow and Temperature Rise 22 . . . . . . . . . . . . . . . . . . . . . .
Heating Sequence of Operation 22 . . . . . . . . . . . . . . . . . . . . .
Limit Switches 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rollout Switch 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start--Up Cooling & Make Adjustments 22 . . . . . . . . . . . . . . . .
Checking Cooling Control Operation 22 . . . . . . . . . . . . . . . .
Checking & Adjusting Refrigerant Charge 22 . . . . . . . . . . . .
Indoor Airflow and Airflow Adjustments 23 . . . . . . . . . . . . .
Cooling Sequence of Operation 24 . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 48--51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indoor Blower and Motor 48 . . . . . . . . . . . . . . . . . . . . . . . . .
A09033
Fig. 1 -- Unit 48VL--A
(Low NOx Model Available)
Induced Draft (Combustion Air) Blower 49 . . . . . . . . . . . . . .
Flue Gas Passageways 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner Ignition 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Burners 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Gas Train 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outdoor Coil, Indoor Coil, & Condensate Drain Pan 49 . . . .
Outdoor Fan 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Controls and Wiring 50 . . . . . . . . . . . . . . . . . . . . .
Refrigerant Circuit 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Input 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Airflow 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Puron Items 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
START--UP CHECKLIST 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit. consult local
building codes, the current editions of the National Fuel Gas Code
(NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code
(NEC) NFPA 70.
In Canada refer to the current editions of the National Standards of
Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane
Installation codes, and Canadian Electrical Code CSA C22.1
Recognize safety information. This is the safety--alert symbol
.
When you see this symbol on the unit and in instructions or manu-
als, be alert to the potential for personal injury. Understand these