Carrier 48GH User Manual

Carrier Parkway • Syracuse NY 13221
Combination Heating/Cooling Units
MOTE TO INSTALLER: THESE INSTRUCTIONS SHOULD BE
LEFT WITH THE EQUIPMENT OWNER.
INDEX
Page
SAFETY CONSIDERATIONS INTRODUCTION
GENERAL INSTALLATION
..................................................
............................................................
................................................
Step 1 — Rig and Place Unit .............................. 2
..............................
2-8
2
• ROOFTOP INSTALLATION
• GROUND LEVEL INSTALLATION
• CLEARANCES
• CONDENSATE DISPOSAL
• VENTING
Step 2—Make Gas Piping Connections... 5
PLUGGED ACCESS HOLE FOR REFRIGERANT . raSS-K PRESSURE GAGE HOSES
Page
Step 3 — Make Duct Connections ..................... 5
Step 4 — Make Wiring Connections ... 6-8
• HIGH-VOLTAGE CONNECTIONS
• SPECIAL PROCEDURES FOR 208-V OPERATION
• LOW-VOLTAGE CONNECTIONS
• HEAT ANTICIPATOR SETTING
START-UP .........................................................8-16
OPERATING SEQUENCE
SERVICE .........................................................17-20
TROUBLESHOOTING CHARTS
CONTROLS ACCESS DOOR
BLOWER ACCESS DOOR
I
LOW VOLTAGE-
INLET
K HIGH VOLTAGE INLET
..............................
......................
•VENT CAP
COMBUSTION AIR INLET BOX
16,17
21,22
# MPT
DRAIN CONN
© Carrier Corporation 1982
EVAPORATOR AIRFLOW
o
*NOT ON MODELS 48GL0I8 THRU
036; GH024 THRU 030
48GH.GL REQUIRED CLEARANCES (ft-in )
Above flue vent 3-0 Duct side of unit 0-6 Side opposite ducts 2-6 Blower access panel side 2-6 Side opposite blower access panel 2-6 Bottom of unit 0
NOTE Provision must be made for fresh ambient air to reach the outdoor coil without recirculation of the air from the outdoor fan discharge
CONDENSER AIRFLOW
Fig. 1 — Dimensions
NOT ON MODELS 48GL0I8 THRU 036;
GH024 THRU 030
Form 48GH.GL-5SI
ge
16
17
20 22
lOX
a
)36;
O

SAFETY CONSIDERATIONS

Installation, start-up and servicing of this equip ment can be hazardous due to system pressures, electrical components and equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics should install, start-up and service this equipment.
Consult the Owner’s Manual for routine main tenance. All other operations should be performed by trained service personnel.
When working on the equipment, observe pre cautions in the literature, tags, stickers and labels attached to the equipment and any other safety precautions that apply.
• Follow all safety codes.
• Wear safety glasses and work gloves.
• Use care in handling, rigging and setting bulky equipment.
WARNING; Do Hot discosaect electric power to this appliance wiiliout Htst mrnirfg oft the gas
supply. Be sure power to ©quipmeot is shut off before perforuiiug maintenance (»r service.

INTRODUCTION

Models 48GH/GL Packaged Gas/Electric Units are fully self-contained, combination gas-heating/ electric-cooling units designed for outdoor installa tion either on a rooftop or ground-level slab. See
Fig. 1.
These units are equipped with an energy-saving automatic intermittent electric spark ignition system that does not have a continuously-burning pilot.
Also included is the Time Guard II circuit for added compressor protection. All units are manufactured with natural gas controls.
Models 48GH/GL are AG A design-certified with 2 input ratings. See Table 1. All units are manu factured for operation at the minimum rating. For
operation at the maximum ratings, optional burner orifices must be field installed. See Table 3.
These units are factory charged with R-22 refrig
erant. To install: connect gas supply, air ducts, high-
and low-voltage wiring, condensate drain, and install a field-supplied air filter in the return-air ductwork.
All units can be connected into existing duct
systems that are properly sized and designed to
handle an airflow of 350 to 450 cfm per each 12,000
Btuh of rated cooling capacity. See Tables 1 and 4
for cooling and heating airflow requirements.
NOTE: When installing any accessory item, see
Installation Instructions packaged with the
accessory.
IMPORTANT —
READ BEFORE INSTALLING
L This insiaUation must conform with all
applicable local and national codes.
2. Power .supply (volts, hertz and phase) must correspond to that specified on unit rating
plate.
3- Elecíríeal supply provided by utility mast be
sufikient to handle load imposed by this unit.
4. Refer to the 4SGH / GL dimensionai drawing for locations of gas inlet, elearical inlets, condensate drain, duct connections, and required clearances before setting unit in
place.
5. Locate the nnit where the vent cap will be a minimum of 4 ft from openable windows or
doors.
6. This installation must conform with local building codes and with the National Fuel
Gas code ANSÍ Z223.1-1980.

GENERAL

Models 48GH/GL Packaged Gas/Electric Units have been designed and tested in accordance with ANSI Z21.47-1978, ARI Standard 210-79 and ARI Standard 270-75. The appliance design is certified by the American Gas Association (AGA) for use with natural or LP (propane) gases with appropriate components and orifices.
INSTALLATION
Step 1 — Rig and Place Unit
CAUTION: W'hen rigging unit to be lifted, use spreader bars to protect top and sides. Models 4^GH/GL must he rigged for lifting as shown in Fig, 2. Use extreme caution to prevent damage when moving unit.
SPREADER BARS:
(2)2x4xUNIT LENGTH PLUS IO"WITH
if DEEP 90° NOTCHES EACH END
(2) 2x4xUNIT WIDTH WITH 1^’
DEEP 90° NOTCHES
EACH END
PACKAGED UNIT-
LOCATE CHAINS THRU HOLES IN BASE CHANNELS
Fig. 2 — 48GH/GL Suggested Rigging
USE SPREADER BARS TO PROTECT UNIT
CHAIN
TWO OR THREE BASE CHANNELS ATTACHED TO
BOTTOM OF UNIT
5SI
Unit must remain in an upright position during all rigging and moving operations. Unit must be level for proper condensate drainage; therefore, ground­level pad or field-supplied mounting curb must be level before setting unit in place.
ROOFTOP INSTALLATION
CAUllONt When ìnstaHjjig «mt <m a rooftop, be sure rooi wiU soppori. ibe additional weight.
Refer to Produot Data Digest to obtain total
weight and comer weight infonrnation.
When installing a Model 48GH/GL end­discharge unit with a field-supplied downflow plenum, a field-supplied roof-mounting curb must be installed on and flashed into roof before unit
installation.
When installing a Model 48GH/GL end-
discharge unit without a downflow plenum, place
unit on a level base that provides proper support. On flat roofs be sure that unit is located at least 4 in. above highest expected water level on roof to pre vent flooding. Consult local codes for additional installation requirements.
GROUND-LEVEL INSTALLATION - Place unit on a solid, level concrete pad that is a minimum of 4 in. thick and that extends approximately 2 in. beyond casing on all 4 sides of unit. Do not secure unit to pad except when required by local codes.
CLEARANCES — The required minimum oper
ating and service clearances are shown in Fig. 1.
CAUTION: Douot resïîicî ccsdenser air^ow:.
An air restriction at either outdoor-air inlet (the
entire surface of the outdoor coil) or fan dis
charge can he detfinaeniai to compressor hfe.
Condenser Ian discharges thru top of unit. En sure that fan discharge does not recirculate to condenser coil. Do not locate unit in either a corner or under a complete overhead obstruction. Mini mum clearance under a partial overhang (such as a normal house roof overhang) is 3 ft above vent cap.
Do not locate unit where water, falling ice or snow from an overhang or roof will damage or flood the unit. Do not locate unit where grass, shrubs, or other plants will interfere with airflow either into or out of unit.
CONDENSATE DISPOSAE NOTE. Ensure that condensate-water disposal
methods comply with local codes, restrictions and practices.
Models 48GH/GL dispose of condensate water thru a 3/4-in. MPT drain fitting. See Fig. 1 for location.
Install a 3-in. trap at drain fitting to ensure proper drainage. See Fig. 3. Make sure trap outlet is at least 2 in. lower than unit drain pan connection to prevent pan from overflowing. Prime trap with water.
If the installation requires draining condensate
water away from the unit, connect a drain tube using a minimum of 7/8-in. OD copper tubing.
3/
no
at ru
ro on
W
aw
FRC
VI du
CO
lo(
St£ tO|
bl(
MODEL 48 SERIES 320 320 DIMENSIONS |ft-in.)
FIELD-SUPPLIED FILTER
SIZE (sq. in.)* Standard Disposable Type Cleanable- or
High-Capacity Type
OPERATING WT (lb) SHIPPING WT (lb)
HEATING INPUTS (Btuh)
COOLING AIRFLOW (Cfm) 600 EXTERNAL STATIC
PRESSURE (in. wg)
A 4-5-578 B C 3-2­D 1 -4 E 1 -4 F G 0- 11 H
K 0-1-
Min Max
GL018 GL024
2-6-3/8
1/8
0-7-
1/4
1-0-5/8
3/32
289 396 188 257
320 330 335
40,000 50,000
0 10
^Recommended, field-supplied air filter areas shown are based on either cooling airflow at a velocity of 300 ft per
minute or heating airflow at a temperature of 60 F. depending on whichever value is larger Air filter pressure drop should not exceed 0 08 in wg for unit to produce rated cooling performance
fWhen Models 48GH024 or GH036 are installed for operation at minimum rated heating input, recommended
minimum air filter area Is the smaller sq in figure shown for each type of filter Larger figures shown are mini-
325
40,000 50,000
825
0 10
GH024 GL030
320
396/433t 257/281t
375 375 385
60,000 40,000
75,000 50,000
825 0 10
320/330
*
1088 0 15
522 339
385
GH030
320/330 320/330
4-5-5/8 3-4-3/8 3-5-1/8
1 -7
1-1 1/4
0-8-7/8
0-10
1-5-5/8
3/8
0-1
522 576 339 374 374 374
375 380 385 390
60,000 60,000 75,000 75,000
1088 ^ 1200
0 15 0 15
GL036
520/530 1 620/630
576 576
380 390
60,000 60,000 75,000
1200 1200 0 15 0 15
Table 1 — Installation
GH036
320/330 520/5
380 475 390 485
100,000
75,000
1 25,000
583/722f 379/469t
1215
0 15
583/72
379/461
100,00 125,00
475 485
1215 0 15
h(
tAI
or
3/4-in. galvanized pipe,“ or 7/€-in. plastic pipe. Do not undersize the tube. Pitch drain tube downward
at a slope of at least 1 in. in every 10 ft of horizontal run. Be sure to check drain tube for leaks.
Condensate water can be drained directly onto roof in rooftop installations (where permitted) or onto a gravel apron in ground-level installations.
When using a gravel apron, make sure it slopes
away from unit.
TO DRAIN
Fig. 3 — Condensate Trap
VENTING — The vent cap and combustion-air duct assemblies are shipped in either the blower or control compartment. Remove access doors to locate assemblies. See Fig. 1 for door locations. Vent stack extension is shipped either in air hole in unit top or fastened to back of the control box or in blower compartment.
CAUTION: Venting system is designed to en sure proper venting. Vent cap assembly must be installed as indicated in this section of installa tion Instructions.

allation Data

036
520/530
583/722t 379/469t
475 420 420 485 430 430
100,000 125,000
1215 0 15 0 15 0 15
672 672 672 437 437
60,000 75,000
1400
GL042
5- 5-5/8 3- 8-5/8
3-10-1/8
2-
0
1- 1 -1/4
0- 8-7/8
0-10 1- 6-1/4 1-10-5/8
0- 1
-3/8
520
60,000 75,000
1400
GH042
... “0^
672 768
437 437 440
450
80,000 80,000
100,000 100,000
1400 1400 0 15
440 450
0 15
GL048
320 520
499 499 535
545
80,000
100,000
1600 1600
0 20
80,000
100,000
768
535 545
0 20
620
768 499
535 545
80,000
100,000
1600 0 20
6- 0-3/8 3- 8-5/8 4- 6-1/8
2- 8
-1/4
1- 1
0- 8-7/8
0-10-1/2
1- 3-1/4
2-0-11/16
-3/8
0- 1
GH048
320
768 768 499 499
555 555 565 565
100,000 125,000
1600 1600 0 20 0 20 0 20 0 20
520
100,000 1 25,000
GL060
320/330 320/330
6- 0-3/8 3- 8-5/8 4- 6-1/8
1- 1-1/4 0- 8-7/8
0-10-1/2
1- 6-1/4
2-0-11/16
0- 1-3/8
951
618
575
585 615
100,000 120,000
1 25,000
1981 1981
150,000
GH060
2- 8
951 618
605
mum recommended filter areas when these units have been field converted for operation at maximum rated heating input
JAH units have a minimum and maximum AGA-certified rated heating input and are manufactured with burner
orifices for heating operation at minimum rating Units may not be derated below this minimum rating
IP
NOTE: Screw holes in vent stack extension and unit top are positioned to ensure proper orientation when installed.
Refer to Fig. 4 and install vent cap as follows:
1. Place combustion-air duct over combustion-air opening in unit top, and line up screw holes in duct with holes in top. Secure duct to top using screws with rubber washers (provided).
2. Place gasket and vent stack extension thru hole in combustion-air duct, orient screw holes in base of vent stack extension with holes in unit top, and secure gasket and vent stack extension to unit top using screws provided.
3. Form flat wire screen (provided) into circular shape around protruding lip of combustion-air duct, and bend wire ends thru holes of screen mesh to secure screen in place. Make sure that no sharp edges are left exposed.
4. Place vent cap sleeve inside vent stack extension. Orient spring clip of vent cap with slot in extension. Be sure that clip snaps into slot to secure clip onto extension.
Step 2 — Make Gas Piping Connections — The
gas supply pipe enters unit thru access hole pro vided. See Fig. 1 for location. The gas connection to unit is made to the 1/2-in. FPT gas inlet on gas valve.
Install a separate gas supply line that runs directly from meter to heating section. Do not use cast-iron or galvanized pipe. Check local utility for recommendations concerning existing lines. Choose a supply pipe that is large enough to keep pressure loss as low as practical. Never use pipe .smaller than
the 112-in. FPT gas inlet on gas valve.
When installing gas supply line, observe local codes pertaining to gas pipe installations. Refer to National Fuel Gas Code ANSI Z223.1-1980 in absence of local building codes. Adhere to pertinent recommendations.
1. Avoid low spots in long runs of pipe. Grade all pipe 1 / 4-in. in every 15 ft to prevent traps. Grade all horizontal runs downward to risers. Use risers; to connect to heating section and to meter.
2. Support all piping with appropriate hangers, etc. Use a minimum of one hanger in every 6 feet. For pipe sizes larger than 1/2 in., follow recom mendations of national codes.
3. Apply joint compounds (pipe dope) sparingly and only to male threads of joint when making pipe connections. Use only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and/ or national codes.
Never use Teflon tape.
4. Install a sediment trap in riser leading to the
heating section. This drip leg functions as a trap for dirt and condensate. Install trap where con densate cannot freeze. Install this sediment trap by connecting a piping tee to riser leading to
heating section so that straight-thru section of tee is vertical. See Fig. 5. Then, connect capped nipple into lower end of tee. Extend capped nipple below level of gas controls.
5. Install an accessible, external, manual shutoff valve in gas supply pipe within 6 ft of heating section. Install a 1/8-in. NET plugged tapping that is accessible for test-gage connection
immediately upstream of gas supply connection
to heating section.
6. Install ground-joint union close to heating
section between gas valve and external manual shutoff valve.
CAUTION: Unstable operaiion may occur, particuiarly under htgh-wind conditions^ when gas valve and manifold assembly are forced out of piKiltion while connecting improperly routed
rigid gas piping to gas vaive. Use a backup wrench when making connection to avoid strain on, or distortion of, gas control piping.
7. Use flexible gas pipe to make connection between
rigid gas piping and gas valve where permitted by local codes. Flexible pipe ensures proper alignment between manifold orifices and burner.
WARNING; Never use a match or other open flame when checking for gas ieaks„
8. Check for gas leaks at all field-insialled and
factory-installed gas lines after all piping connec tions have been completed. Use soap-and-water solution (or method specified by local codes and/or regulations).
Step 3 — Make Duct Connections — Model
48GH/GL has duct flanges on the supply- and
return-air openings on side of unit. See Fig. 1 for
connection sizes and locations.
W'ARNÌNG: The dc-sign and instailation of duct
system must be in accordance with staodardsof
National Fire PTotectson Associatkm for Instailatiou of nonresidence-type mr condì­tioning and ventiiatmg sysieras, NFPA No. 90; or residence-type, NFP.ÀNo, 90S; and/or local codes and ordinances.
Table 2 — Electrical Data
OPER
MODEL
48
GL018 GL024 GH024 GL030 GH030
GL036
GH036
GL042
GH042
GL048
GH048 GL060
GH060
AWG —American Wire Gage
MCA —Minimum Circuit Ampacity
*Maximum Dual Element Size. tUse only copper wire for field connections to unit. Wire size is
based on 60 C or 75 C copper conductor at 86 F (30 C) ambient temperature and ampacity shown in table If other than 60 C or
SERIES
320 320
320 320/330 208-230-1 320/330
320/330 520/530 620/630
320/330 520/530
320
520
320
520
320
520 620
320
520 320/330 320/330 230-1
V-PH
208-230-1 208-230-1 208-230-1
208-230-1 208-230-1
208/230-3
460-3
208-230-1
208/230-3
208-230-1
208/230-3 187 253 21 9
208-230-1 197 253
208/230-3 187 253 21.3
230-1 207 253
208/230-3 187 253
460-3 414 506 230-1
208/230-3 187 253
230-1
VOLTAGE
RANGE
Min Max
197 197 197 197 197
197 187
414 506 9 1
197 187
197 253 26.4
207 253
207 253 43.4 207 253
253 253 160 253 17 3 253 19 3 253
253 25 0 253 18 6
253 24.8 253 19 5
TOTAL
AMPS
11 4
19.1
26 2
30 3 26 6
11.7
29 5
24 6
43 7
MAX BRANCH CIRCUIT FUSE
SIZE (Amps)*
20 13.8 30 30 20 7 10 112 35 23 4 10 100 35
45 30.0 r 10 77 35 21 9 10 121 15 108
45 29 8 35 22.8 10 116
50 31 8 8
40 25.8 50 31 6 8 117
40 25.2 10 60 36 3 8 107
45 30 8 8 135
20 60 35.5 8 110
45 28 8 10 60 52 3 6 60
75 C copper conductor is used, if ambient temperature is above 86F, or if voltage drop of the wire exceeds 2% of total rated voltage of the unit, determine wire size from ampacity shown and National Electrical Code (NEC). Wire lengths shown are measured one way along wire path between unit and service panel for minimum voltage drop.
MCA
194 12
23 2
135 14 169
52 6 j 6
MIN
WIRE SIZE
(AWG)t
14
10
14 10 78
10 103
MAX WIRE
LENGTH
(ft)t
67 76
101
218
117
106
92 116 116
Adhere to the following criteria when selecting,
sizing, and installing duct system:
1. Select and size ductwork, supply-air registers and return-air grilles according to Carrier Sys tem Design Manual, Part 2. System airflow must he within range of temperature rise and external static pressure shown on unit AGA rating plate.
CAUTION; When duci-sj'stem fastening boks are being drilled into side of Model 4M}HfCL instead of the unit ductnanges, use extreme care
to avoid puncturing coil or coil tubes.
2. Use a flexible transition between rigid ductwork
and unit to prevent transmission of vibration. The transition may be screwed or bolted to duct flanges. Use suitable gaskets to ensure a weather and airtight seal.
3. Install an external, field-supplied air filter(s) in return-air ductwork where it is easily accessible for service. Recommended filter sizes are shown in Table 1.
4. Size all ductwork for maximum required airflow (either heating or cooling) for unit being in
stalled. Avoid abrupt duct size increases or decreases.
5. Adequately insulate and weatherproof all duct work located outdoors. Insulate ducts passing
thru an unconditioned space, and use a vapor barrier in accordance with latest issue of SMACNA and NESCA minimum installation standards for heating and air conditioning
systems. Secure all ducts to building structure.
6. Flash, weatherproof and vibration-isolate all openings in building structure in accordance with local codes and good building practices.

Step 4 — Make Wiring Connections

WARNING: Umt cabinet must have an un~ intemipted. unbroken electrical ground to minimize the possibility of personal injury' if an electrical fault should occur. Ibis ground may consist of electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with National Electrical Code and local electrical codes. Do not use gas piping
as an electrical ground. A failure to follow this
warning could result in the installer being liable for the personal injury' of others.
CAUI ION: A failure lo follow' these precau tions could result in damage to unit being
installed:
1. Make all electrical connections in accordance with National Electrical Code and local elec trical codes governing such wiring.
2. Use only copper conductor for connections between field-supplied electrical disconnect switch and the unit. Do not use aluminum or
copper-clad aluminum wire.
3. Ensure that high-voltage power to unit is within
operating voltage range indicated on unit rating plate. On 3-phase units, ensure that phases are
balanced within 2%. Consult the local power company for correction of improper voltage and/or phase imbalance.
4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are run in same conduit as high­voltage wires.
5. Do not damage internal components when
drilling thru any panel to mount electrical hardware, conduit, etc.
6. Make sure that service conductors used between
the electrical service panel and field-supplied electrical disconnect switch do not have a current capacity less than the copper wire specified, and do not create a total voltage drop in excess of 2% of rated voltage of the unit.
NOTE: When using aluminum conductor from electrical service to disconnect switch (where local codes permit use of aluminum wire), make the connections in accordance with National Electrical
Code. Prepare all aluminum wire immediately be fore installation by “brush-scratching” the wire,
then coating the wire with a corrosion inhibitor
(such as Pentrox A). Be sure that entire connection
is completely covered to prevent an electrochemical
reaction that will cause the connection to fail very
quickly. Do not reduce effective size of wire by
cutting off strands to fit wire into a connector.
Always use properly sized connectors. HIGH-VOLTAGE CONNECTIONS ^ Unit must
have a separate electrical service with a field­supplied, waterproof, fused disconnect switch per NEC mounted at, or within sight from, the unit.
Refer to unit rating plate for maximum fuse size and minimum circuit amps (ampacity) for wire sizing.
Table 2 shows recommended wire sizes and lengths based on rating plate data.
The field-supplied disconnect switch box may be mounted on unit over the high-voltage inlet hole in control corner panel. See Fig. 1.
WARNING: Label part no, A-74I9ÍB, whickis shipped loose in bag of parts, must be affixed to the disconnect switch, box. This iabei states;
“DO NOT DISCONNECT THE ELEC TRICAL POW'ER TO THIS APPLIANCE WITHOUT FIRST TURNING OFF THE GAS SUPPLY ”
1 — Control Transformer 2 — Compressor Contactor 3 — Ground Lug 4 — Dual Run Capacitor
(for compressor and condenser fan motor)
5 — Low-Voltage Pigtail
Leads
6 — Compressor/Control
Compartment Divider
Panel 7 — Igniter Module 8 — Manual On/Off Knob 9 — Gas Valve Inlet
10 — Pipe Plug —
LP (Propane) unit
pressure switch
mounts here
Fig. 6 — Model 48GL036 — Side View (Partial) with Access Doors Removed
11 — Pilot Tube 12 - Model 646A-X
Gas Valve 13 — Pressure Tap Pipe Plug 14 — Gas Valve Outlet 15 — Gas Manifold 16 — Gas Burner 17 — Burner Air Shutter 18 — Secondary-Air Shield 19 — Blower Housing 20 — Evaporator Motor
Run Capacitor 21 — Blower/Control
Compartment Divider
Panel 22 — Heating Relay 23 — Cooling Relay
Proceed as follows to complete the high-voltage
connections to unit:
1. Connect ground lead to chassis ground connec tion when using a separate ground wire.
2. Run high-voltage leads with field-supplied conduit into unit control box and connect to contactor. See unit wiring label, and Fig. 6 and 7.
NOTE: On 3-phase units, connect third high-voltage lead to brown high-voltage pigtail lead. See unit wiring label and Fig. 7.
SPECIAL PROCEDURES FOR 208-V
OPERATION
WARNING; Make stire that power supply to «iut k switched OFF before ruakipg any wiring changes.
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