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Carrier 48VL-A User Manual

Carrier 48VL-A
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1
48VL---A
Performancet 14 SEER Single---Packaged Air
Conditioner and Gas Furnace 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--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

Table of Contents

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Carrier 48VL-A Specifications

General IconGeneral
RefrigerantR-410A
TypeAir Conditioner
Compressor TypeScroll Compressor
Indoor Unit Dimensions (L x W x H)Varies by model
Outdoor Unit Dimensions (L x W x H)Varies by model
Weight (Indoor Unit)Varies by model
Weight (Outdoor Unit)Varies by model
Power Supply208/230V, 1-phase, 60Hz
HSPF RatingNot Applicable

Summary

SAFETY CONSIDERATIONS

INTRODUCTION

RECEIVING AND INSTALLATION

Check Equipment

Verify unit model, serial number, and shipping papers.

Identify Unit

Locate and check the unit's information plate for model and serial numbers.

Inspect Shipment

Check for shipping damage before removing packaging materials.

Provide Unit Support

Install unit support, considering hurricane tie-downs and roof curbs.

Roof Curb

Install accessory roof curb, ensuring it is level for proper drain function.

Slab Mount

Place unit on a solid, level pad at least 2 inches above grade.

Field Fabricate Ductwork

Secure all ductwork to the unit flanges and building structure.

Provide Clearances

Ensure adequate clearances for combustion, ventilation, and condenser air.

Rigging/Lifting of Unit

Handle and install equipment using trained personnel and proper lifting techniques.

Connect Condensate Drain

Install a 3/4-in. NPT fitting and a 2-in. condensate trap with proper pitch.

Install Gas Piping

Connect gas supply line to the unit's gas valve, following codes.

Install Duct Connections

Connect ductwork to unit flanges for supply and return air openings.

Configuring Units for Downflow (Vertical) Discharge

Remove horizontal duct covers to access vertical discharge duct knockouts.

Install Electrical Connections

Make electrical connections following NEC and local codes, using copper wire.

High-Voltage Connections

Connect high-voltage power leads using copper wire and a waterproof disconnect switch.

Special Procedures for 208-V Operation

Adjust transformer for 208-V operation by moving a wire to the correct terminal.

Control Voltage Connections

Use appropriate gauge wires for thermostat connections based on distance.

Standard Connection

Route low-voltage thermostat leads and make connections in the splice box.

Heat Anticipator Setting

Adjust thermostat heat anticipator for proper heating performance.

Transformer Protection

Check for blown fuses if overload or short is present in the transformer circuit.

PRE-START-UP

START-UP

Check for Refrigerant Leaks

Locate and repair refrigerant leaks, recover charge, and evacuate system.

Start-Up Heating & Make Adjustments

Follow lighting instructions and ensure burner alignment for heating.

Check Gas Input

Check gas input and manifold pressure, adjusting if necessary per altitude.

Adjust Gas Input

Measure manifold pressure and adjust gas input using the adjustment screw.

Check Burner Flame

Observe burner flames for light blue color and proper appearance.

Normal Operation

Monitor the IGC LED for normal operation or error codes.

Airflow and Temperature Rise

Ensure heating operation within the stamped temperature-rise range.

Heating Sequence of Operation

Understand the sequence from thermostat call to fan shutoff.

Limit Switches

Understand the function of limit switches in breaking the control circuit.

Rollout Switch

Recognize the rollout switch function to close the gas valve.

Start-Up Cooling & Make Adjustments

Follow pre-start-up procedures before starting cooling operations.

Checking Cooling Control Operation

Verify proper operation of cooling controls, including fan and compressor.

Checking & Adjusting Refrigerant Charge

Inspect and adjust refrigerant charge based on system pressures and temperatures.

Indoor Airflow and Airflow Adjustments

Select and adjust fan speeds for optimal heating and cooling airflow.

Cooling Sequence of Operation

Understand the sequence of operation for cooling mode.

MAINTENANCE

Air Filter

Inspect and clean or replace air filters monthly.

Indoor Blower and Motor

Clean accumulated dirt and grease from the blower motor and wheel annually.

Induced Draft (combustion air) Blower Assembly

Clean the induced-draft blower assembly periodically for proper airflow.

Flue Gas Passageways

Inspect the flue collector box and heat exchanger surfaces.

Limit Switch

Locate the limit switch on the fan partition for inspection.

Burner Ignition

Understand the direct spark ignition system and IGC module.

Main Burners

Inspect main burners for deterioration or blockage at the start of each heating season.

Outdoor Coil, Indoor Coil, and Condensate Drain Pan

Inspect and clean coils and drain pan annually.

Outdoor Fan

Keep the condenser fan free from obstructions for proper cooling.

Electrical Controls and Wiring

Check electrical controls and wiring annually for tightness and proper operation.

Refrigerant Circuit

Annually inspect refrigerant tubing connections and unit base for oil.

Gas Input

Check gas input if improper heating performance is suspected.

Evaporator Airflow

Check evaporator airflow if improper performance is suspected.

Puron Items

Understand Puron refrigerant properties, metering devices, and pressure switches.

Compressor Oil

Use correct POE oil for the Copeland scroll compressor and handle with care.

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