Carrier 50VL-A User Manual

50VL---A
Performancet 14 SEER Single---Packaged Air Conditioner
System with Puron® (R ---410A) Refrigerant
Single and Three Phase
2 --- 5 N o m i n a l To n s ( S i z e s 2 4 --- 6 0 )

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--10.................

Check Equipment 2..................................

Identify Unit 2....................................

Inspect Shipment 2.................................

Provide Unit Support 2...............................

Roof Curb 2......................................

Slab Mount 2.....................................

Provide Clearances 7.................................

Field Fabricate Ductwork 7............................

Rig and Place Unit 7.................................

Inspection 7......................................

Rigging/Lifting of Unit 7............................

Connect Condensate Drain 8...........................

Install Duct Connections 8.............................

Configuring Units for Downflow (Vertical) Discharge 8....

Install Electrical Connections 9.........................

High--Voltage Connections 9.........................

Special Procedures for 208v Operation 10...............

Control Voltage Connections 10.......................

Standard Connection 10.............................

Transformer Protection 10...........................

PRE--START--UP 12...................................

START--UP 12--14.....................................

Check for Refrigerant Leaks 12.........................

Start--Up Adjustments 12..............................

Checking Cooling Control Operation 12................

Checking and Adjusting Refrigerant Charge 12...........

Indoor Airflow and Airflow Adjustments 13.............

Continuous Fan Operation 14........................

Cooling Sequence of Operation 14.....................

MAINTENANCE 24--2 6................................

Air Filter 24......................................

Indoor Blower and Motor 24.........................

Outdoor Coil, Indoor Coil, and Condensate Drain Pan 25...

Outdoor Fan 25...................................

Electrical Controls and Wiring 25.....................

Refrigerant Circuit 26...............................

Evaporator Airflow 26..............................

Puron Items 26....................................

TROUBLESHOOTING 27..............................

START--UP CHECKLIST 27............................

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. Use quenching cloth for brazing operations.
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 Electrical Code (NEC) NFPA 70.
In Canada refer to the current editions of the 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
manuals, be alert to the potential for personal injury. Understand
these signal words; DANGER, WARNING, and CAUTION. These
words are used with the safety--alert symbol. DANGER identifies
the most serious hazards which will result in severe personal injury
or death. WARNING signifies hazards which could result in
personal injury or death. CAUTION is used to identify unsafe
practices which may result in minor personal injury or product and
property damage. NOTE is used to highlight suggestions which

will result in enhanced installation, reliability, or operation.

SAFETY CONSIDERATIONS

A09033

Fig. 1 -- Unit 50VL --A

.

1

!

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal
injury or death.

Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be
more than one disconnect switch. Turn of f accessory heater
power switch if applicable.

!

WARNING

PERSONAL INJURY AND ENVIRONMENTAL
HAZARD

Failure to relieve system pressure could result in personal
injury and/or death.

1. Relieve pressure and recover all refrigerant before

50VL -- A

servicing existing equipment, and before final unit disposal.
Use all service ports and open all flow--control devices,
including solenoid valves.

2. Federal regulations require that you do not vent
refrigerant into the atmosphere. Recover during system
repair or final unit disposal.

!

CUT HAZARD

Failure to follow this caution may result in personal injury.

When removing access panels (see Fig. 17) or performing
maintenance functions inside your unit, be aware of sharp
sheet metal parts and screws. Although special care is taken
to reduce sharp edges to a minimum, be extremely careful
when handling parts or reaching into the unit.

CAUTION

INTRODUCTION

The 50VL --A packaged air conditioner is fully self--contained and
designed for outdoor installation (See Fig.1 ). See Fig. 2 and 3 for
unit dimensions. All unit sizes have discharge openings for both
horizontal and downflow configurations, and are factory shipped
with all downflow duct openings covered. The unit may be
installed either on a rooftop or on a ground--level cement slab. (See
Fig. 4 for roof curb dimensions.)

RECEIVING AND INSTALLATION

Step 1 — Check Equipment

IDENTIFY UNIT

The unit model number and serial number are printed on the unit
informative plate. Check this information against shipping papers.

INSPECT SHIPMENT

Inspect for shipping damage before removing packaging materials.
If unit appears to be damaged or is torn loose from its anchorage,
have it examined by transportation inspectors before removal.
Forward claim papers directly to transportation company.
Manufacturer is not responsible for any damage incurred in transit.
Check all items against shipping list. Immediately notify the
nearest equipment distribution office if any item is missing. To
prevent loss or damage, leave all parts in original packages until
installation.

If the unit is to be mounted on a curb in a downflow application,
review Step 7 to determine which method is to be used to remove
the downflow panels before rigging and lifting into place. The
panel removal process may require the unit to be on the ground.

Step 2 — Provide Unit Support

IMPORTANT: The unit must be secured to the curb by installing

screws through the bottom of the curb flange and into the unit base
rails. When installing large base units onto the common curb, the
screws must be installed before allowing the full weight of the unit
to rest on the curb. A minimum of six screws are required for large
base units. Failure to secure unit properly could result in an
unstable unit. See Warning near Rigging/Lifting information and
accessory curb instructions for more details.

For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate if required.

ROOF CURB

Install accessory roof curb in accordance with instructions shipped
with curb (See Fig. 4). Install insulation, cant strips, roofing, and
flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is
critical for a water tight seal. Install gasketing material supplied
with the roof curb. Improperly applied gasketing also can result in
air leaks and poor unit performance.
Curb should be level to within 1/4 in. (6.35 mm) (See Fig 6). This
is necessary for unit drain to function properly. Refer to accessory
roof curb installation instructions for additional information as
required.

Installation on older “G” series roof curbs.

Two accessory kits are available to aid in installing a new “G”
series unit on an old “G” roof curb.

1. Accessory kit number CPADCURB001A00, (small chassis)
and accessory kit number CPADCURB002A00, (large
chassis) includes roof curb adapter and gaskets for the
perimeter seal and duct openings. No additional
modifications to the curb are required when using this kit.

2. An alternative to the adapter curb is to modify the existing
curb by removing the outer horizontal flange and use
accessory kit number CPGSKTKIT001A00 which includes
spacer blocks (for easy alignment to existing curb) and
gaskets for the perimeter seal and duct openings. This kit is
used when existing curb is modified by removing outer
horizontal flange.

!

UNIT/STRUCTURAL DAMAGE HAZARD

Failure to follow this caution may result in property
damage.

Ensure there is sufficient clearance for saw blade when
cutting the outer horizontal flange of the roof curb so there
is no damage to the roof or flashing.

SLAB MOUNT

Place the unit on a solid, level concrete pad that is a minimum of 4
in. (102 mm) thick with 2 in. (51 mm) above grade. The slab
should extend approximately 2 in. (51 mm) beyond the casing on
all 4 sides of the unit (See Fig. 7). Do not secure the unit to the slab
except when required by local codes.

CAUTION

2

50VL -- A

Fig. 2 -- 50VL--A24--36 Unit Dimensions

3

A09462

50VL -- A

Fig. 3 -- 50VL--A42--60 Unit Dimensions

4

A09463

HVAC unit
base rails

Anchor screw

Flashing field
supplied

Roofing material
field supplied

Cant strip
field supplied

HVAC unit
basepan

Sealing
Gasket

Roofcurb

Wood nailer*

Roofcurb*

Insulation
(field supplied)

B

G

C

F

A

H

D

Dashed lines show cross support
location for large basepan units.

E

A09413

50VL -- A

*Provided with roofcurb

ROOF CURB DETAIL

SMALL/COMMON CURB

A09090

B

C

G

A

F

H

E

SUPPLY

AIR

RETURN

AIR

SMALL
BASE
UNIT

LARGE
BASE
UNIT

D

UNIT PLACEMENT ON

LARGE CURB

A09415

COMMON CURB

SMALL OR LARGE BASE UNIT

A09094

UNIT
SIZE

Small

or

Large

CATALOG

NUMBER

CPRFCURB010A00

CPRFCURB011A00

CPRFCURB012A00

Large

CPRFCURB013A00

* Part Numbers CPRCURB010A00 and CPRCURB011A00 can be used on both small an d large basepan units. T he cross supports must be located based on
whether the unit is a small basepan or a large basepan.
NOTES:

1. Roof curb must be set up for unit being installed.

2. Seal strip must be applied, as required, to unit being installed.

3. Roof curb is made of 16 --gauge steel.

4. Attach ductwork to curb (flanges of duct rest on curb).

5. Insulated panels: 1--in. (25.4 mm) thick fiberglass 1 lb. density.

A

IN.

(mm)

11

(279)

14

(356)

11

(279)

14

(356)

B

(small/common

base)

IN. (mm)*

10 (254)

14 (356)

B

(large base)

IN. (mm)*

14 (356)

C

IN.

(mm)

16

(406)

D

IN.

(mm)

47.8

(1214)

E

IN.

(mm)

32.4

(822)

43.9

(1116)

F

IN.

(mm)

2.7

(69)

G

IN. (mm)HIN. (mm)

30.6 (778)

46.1 (1170)

42.2 (1072)

Fig. 4 -- Roof Curb Dimensions

5

A09414

CAUTION - NOTICE TO RIGGERS
PRUDENCE - AVIS AUX MANIPULATEUR

PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION.

Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition

ACCESS PANELS MUST BE IN PLACE WHEN RIGGING.

DUCTS

MINIMUM HEIGHT: 36" (914.4 mm)
HAUTEUR MINIMUM

50VL -- A

SEE DETAIL A
VOIR DÉTAIL A

SMALL CABINET LARGE CABINET

Unit*

Rigging

Weight

* For 460 volt units, add 14 lb (6.35 kg) to the rigging weight.
NOTE: See dimensional drawing for corner weighs.

24 30 36

lb kg lb kg lb kg lb kg lb kg lb kg

295 134 307 139 365 166

UNIT HEIGHT
HAUTEUR D'UNITÉ

DETAIL A

VOIR DÉTAIL A

Unit*

Rigging

Weight

421 191 439 199 467 212

Fig. 5 -- 50VL--A Unit Suggested Rigging

SEAL STRIP MUST BE IN
PLACE BEFORE PLACING
UNIT ON ROOF CURB

42 48 60

BANDE SCELLANT DOIT ÊTRE
EN PLACE AVANT DE PLACER
L'UNITÉ SUR LA BASE DE TOIT

50CY502286 2.0

A09051

6

Step 3 — Provide Clearances

A

The required minimum service clearances are shown in Fig. 2 and

3. Adequate ventilation and outdoor air must be provided. The
outdoor fan draws air through the outdoor coil and discharges it
through the top fan grille. Be sure that the fan discharge does not
recirculate to the outdoor coil. Do not locate the unit in either a
corner or under an overhead obstruction. The minimum clearance
under a partial overhang (such as a normal house overhang) is 48
in. (1219 mm) above the unit top. The maximum horizontal
extension of a partial overhang must not exceed 48 in. (1219 mm)
IMPORTANT: Do not restrict outdoor airflow. An air restriction
at either the outdoor--air inlet or the fan discharge may be
detrimental to compressor life.
Do not place the unit where water, ice, or snow from an overhang
or roof will damage or flood the unit. Do not install the unit on
carpeting or other combustible materials. Slab--mounted units
should be at least 4 in. (102 mm) above the highest expected water
and runoff levels. Do not use unit if it has been under water.

Step 4 — Field--Fabricate Ductwork

Secure all ducts to roof curb and building structure on vertical
discharge units. Do not connect ductwork to unit. For horizontal
applications, unit is provided with flanges on the horizontal
openings. All ductwork should be secured to the flanges. Insulate
and weatherproof all external ductwork, joints, and roof openings
with counter flashing and mastic in accordance with applicable
codes.
Ducts passing through an unconditioned space must be insulated
and covered with a vapor barrier. If a plenum return is used on a
vertical unit, the return should be ducted through the roof deck to
comply with applicable fire codes. See unit rating plate for any
required clearances around ductwork. Cabinet return--air static
shall not exceed --.25 IN. W .C.

Step 5 — Rig and Place Unit

Rigging and handling of this equipment can be hazardous for
many reasons due to the installation location (roofs, elevated
structures, etc.).
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached to the equipment,
and any other safety precautions that might apply.
Training for operators of the lifting equipment should include, but
not be limited to, the following:

1. Application of the lifter to the load, and adjustment of the
lifts to adapt to various sizes or kinds of loads.

2. Instruction in any special operation or precaution.

3. Condition of the load as it relates to operation of the lifting
kit, such as balance, temperature, etc.

Follow all applicable safety codes. Wear safety shoes and work
gloves.

INSPECTION

Prior to initial use, and at monthly intervals, all rigging shackles,
clevis pins, and straps should be visually inspected for any damage,
evidence of wear, structural deformation, or cracks. Particular
attention should be paid to excessive wear at hoist hooking points
and load support areas. Materials showing any kind of wear in
these areas must not be used and should be discarded.

!

WARNING

UNIT FALLING HAZARD

Failure to follow this warning could result in personal
injury or death.

Never stand beneath rigged units or lift over people.

1. Leave top shipping skid on the unit for use as a spreader bar
to prevent the rigging straps from damaging the unit. If the
skid is not available, use a spreader bar of sufficient length
to protect the unit from damage.

!

WARNING

PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personal

When straps are taut, the clevis should be a minimum of 36
in. (914 mm) above the unit top cover.

Rigging/Lifting of Unit (See Fig. 5)

!

WARNING

UNIT FALLING HAZARD

Failure to follow this warning could result in personal
injury or death.

Large base units must be secured to common curb before
allowing full weight of unit to rest on curb. Install screws
through curb into unit base rails while rigging crane is still
supporting unit.

Lifting holes are provided in base rails as shown.

1. Attach shackles, clevis pins, and straps to the base rails of
the unit. Be sure materials are rated to hold the weight of the
unit (See Fig. 5).

2. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unit is lifted level
with the ground.

After the unit is placed on the roof curb or mounting pad, remove
the top skid.

50VL -- A

OPTIONAL

RETURN

AIR

C

MAXIMUM ALLOWABLE

B

A-B

(6.35)

1/4

Fig. 6 -- Unit Leveling Tolerances

DIFFERENCE in. (mm)

1/4

B-C

(6.35)

A-C

1/4

(6.35)

A07925

(50.8mm)

7

2˝

OPENING

EVAP. COIL COND. COIL

Fig. 7 -- Slab Mounting Detail

OPTIONAL

SUPPLY

AIR

OPENING

A07926

Step 6 — Connect Condensate Drain

NOTE: When installing condensate drain connection be sure to

comply with local codes and restrictions.

Model 50VL-- A disposes of condensate water through a 3/4 in.
NPT fitting which exits through the base on the evaporator coil
access side. See Fig. 2 and 3 for location.

Condensate water can be drained directly onto the roof in rooftop
installations (where permitted) or onto a gravel apron in ground
level installations. Install a field-- supplied 2--in. (51 mm)
condensate trap at end of condensate connection to ensure proper
drainage. Make sure that the outlet of the trap is at least 1 in. (25
mm) lower than the drain pan condensate connection to prevent the
pan from overflowing (See Fig. 8). When using a gravel apron,
make sure it slopes away from the unit.

Connect a drain tube using a minimum of 3/4 -- in. PVC or 3/4 --in.
copper pipe (all field--supplied) at the outlet end of the 2-- in. (51
mm) trap. Do not undersize the tube. Pitch the drain tube
downward at a slope of at least 1 -- in. (25 mm) for every 10 ft (3.1
m) of horizontal run. Be sure to check the drain tube for leaks.
Prime trap at the beginning of the cooling season start--up.

50VL -- A

TRAP
OUTLET

1-in. (25 mm) min.

2-in. (51 mm) min.

Fig. 8 -- Condensate Trap

Step 7 — Install Duct Connections

The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
non--residence type air conditioning and ventilating systems,
NFPA 90A or residence type, NFPA 90B and/or local codes and
ordinances.

Select and size ductwork, supply--air registers, and return air grilles
according to ASHRAE (American Society of Heating,
Refrigeration, and Air Conditioning Engineers) recommendations.
The unit has duct flanges on the supply-- and return--air openings
on the side of the unit.

When designing and installing ductwork, consider the following:

1. All units should have field--supplied filters or accessory
filter rack installed in the return--air side of the unit.
Recommended sizes for filters are shown in Table 1.

2. Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.

IMPORTANT: Use flexible connectors between ductwork and
unit to prevent transmission of vibration. Use suitable gaskets to
ensure weather--tight and airtight seal. When electric heat is
installed, use fireproof canvas (or similar heat resistant material)
connector between ductwork and unit discharge connection. If
flexible duct is used, insert a sheet metal sleeve inside duct. Heat
resistant duct connector (or sheet metal sleeve) must extend 24--in.
(610 mm) from electric heater element.

3. Size ductwork for cooling air quantity (cfm). The minimum
air quantity for proper electric heater operation is listed in
Table 2. Heater limit switches may trip at air quantities
below those recommended.

4. Seal, insulate, and weatherproof all external ductwork. Seal,
insulate and cover with a vapor barrier all ductwork passing
through conditioned spaces. Follow latest Sheet Metal and

A09052

Air Conditioning Contractors National Association
(SMACNA) and Air Conditioning Contractors Association
(ACCA) minimum installation standards for residential
heating and air conditioning systems.

5. Secure all ducts to building structure. Flash, weatherproof,
and vibration--isolate duct openings in wall or roof
according to good construction practices.

CONFIGURING UNITS FOR DOWNFLOW
(VERTICAL)

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal
injury or death.

Before performing service or maintenance operations on the
system, turn off main power to unit and install lockout tag.

1. Open all electrical disconnects and install lockout tag before
starting any service work.

2. Remove horizontal (metal) ductcovers to access vertical
(downflow) discharge duct knockouts in unit basepan. (See
Fig. 9.)

To remove downflow return and supply knockout covers, break
front and right side connecting tabs with a screwdriver and
hammer. Push cover down to break rear and left side tabs.

NOTE: These panels are held in place with tabs similar to an
electrical knockout. Reinstall horizontal duct covers (Fig. 9)
shipped on unit from factory. Insure openings are air and
watertight.

NOTE: The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
nonresidence--type air conditioning and ventilating systems, NFPA
90A or residence--type, NFPA 90B; and/or local codes and
ordinances.

Adhere to the following criteria when selecting, sizing, and
installing the duct system:

1. Units are shipped for side shot installation.

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. Use 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 weather--tight and airtight seal.

4. All units must have field --supplied filters or accessory filter
rack installed in the return--air side of the unit.
Recommended sizes for filters are shown in Table 1.

5. Size all ductwork for maximum required airflow (either
heating or cooling) for unit being installed. Avoid abrupt
duct size increases or decreases or performance may be
affected.

6. Adequately insulate and weatherproof all ductwork located
outdoors. Insulate ducts passing through unconditioned
space, and use vapor barrier in accordance with latest issue
of Sheet Metal and Air Conditioning Contractors National
Association (SMACNA) and Air Conditioning Contractors
of America (ACCA) minimum installation standards for
heating and air conditioning systems. Secure all ducts to
building structure.

7. Flash, weatherproof, and vibration--isolate all openings in
building structure in accordance with local codes and good
building practices.

DISCHARGE

!

WARNING

8

Horizontal Duct Covers

Basepan
Downflow
(Vertical)
Supply
Knockout

Fig. 9 -- Supply and Return Duct Opening

Step 8 — Install Electrical Connections

!

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal
injury or death.

The unit cabinet must have an uninterrupted, unbroken
electrical ground to minimize the possibility of personal
injury if an electrical fault should occur. This ground may
consist of an electrical wire connected to the unit ground
screw in the control compartment, or conduit approved for
electrical ground when installed in accordance with NFPA
70 (NEC) (latest edition) (in Canada, Canadian Electrical
Code CSA C22.1) and local electrical codes.

A09076

Basepan
Downflow
(Vertical)
Return
Knockout

A09093

!

UNIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the
unit being installed.

1. Make all electrical connections in accordance with
NFPA 70 (NEC) (latest edition) and local electrical codes
governing such wiring. In Canada, all electrical
connections must be in accordance with CSA standard
C22.1 Canadian Electrical Code Part 1 and applicable
local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between
field--supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.

3. Be sure that high--voltage power to unit is within
operating voltage range indicated on unit rating plate. On
3--phase units, ensure phases are balanced within 2
percent. Consult local power company for correction of
improper voltage and/or phase imbalance.

4. Do not damage internal components when drilling
through any panel to mount electrical hardware, conduit,
etc.

CAUTION

HIGH--VOLTAGE CONNECTIONS

The unit must have a separate electrical service with a
field--supplied, waterproof disconnect switch mounted at, or within
sight from the unit. Refer to the unit rating plate, NEC and local
codes for maximum fuse/circuit breaker size and minimum circuit
amps (ampacity) for wire sizing.

The field--supplied disconnect may be mounted on the unit over
the high--voltage inlet hole when the standard power and
low--voltage entry points are used. See Fig. 2 and 3 for acceptable
location.

See unit wiring label (Fig. 12, 13 and 14) and Fig. 10 for reference
when making high voltage connections. Proceed as follows to
complete the high--voltage connections to the unit.

Single phase units:

1. Run the high-- voltage (L1, L2) and ground lead into the
control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the line side
of the contactor.

4. Connect field L1 to black wire on connection 11 of the
compressor contactor.

50VL -- A

9