Carrier 48SX024-060 manual

Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERA TIONS .................1 - 9 General ......................................1 RECEIVING AND INST ALLA TION ........... 10-22 Step 1 — Check Equipment ..................1 0 • IDENTIFY UNIT • INSPECT SHIPMENT Step 2 — Provide Unit Support ..............1 0 • ROOF [...]

REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct panel ............................. 0 Unit top ........................... 3 6 (914) Side opposite ducts ..................... 3 6 (914) Compressor access ..................... 3 6 (914) (Except for NEC requirements) REQ’D CLEARANCES T O COMBUSTIBLE MA T’L. in. (mm) Maximum extension of overhangs [...]

REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct panel ............................. 0 Unit top ........................... 3 6 (914) Side opposite ducts ..................... 3 6 (914) Compressor access ..................... 3 6 (914) (Except for NEC requirements) REQ’D CLEARANCES T O COMBUSTIBLE MA T’L. in. (mm) Maximum extension of overhangs [...]

REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct panel ............................. 0 Unit top ........................... 3 6 (914) Side opposite ducts ..................... 3 6 (914) Compressor access ..................... 3 6 (914) (Except for NEC requirements) REQ’D CLEARANCES T O COMBUSTIBLE MA T’L. in. (mm) Maximum extension of overhangs [...]

REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct panel ............................. 0 Unit top ........................... 3 6 (914) Side opposite ducts ..................... 3 6 (914) Compressor access ..................... 3 6 (914) (Except for NEC requirements) REQ’D CLEARANCES T O COMBUSTIBLE MA T’L. in. (mm) Maximum extension of overhangs [...]

REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct panel ............................. 0 Unit top ........................... 3 6 (914) Side opposite ducts ..................... 3 6 (914) Compressor access ..................... 3 6 (914) (Except for NEC requirements) REQ’D CLEARANCES T O COMBUSTIBLE MA T’L. in. (mm) Maximum extension of overhangs [...]

REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct panel ........................... 0 Unit top ......................... 3 6 (914) Side opposite ducts .................... 3 6 (914) Compressor access .................... 3 6 (914) (Except for NEC requirements) REQ’D CLEARANCES T O COMBUSTIBLE MA T’L. in. (mm) Maximum extension of overhangs ......[...]

REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct panel ............................. 0 Unit top ........................... 3 6 (914) Side opposite ducts ..................... 3 6 (914) Compressor access ..................... 3 6 (914) (Except for NEC requirements) REQ’D CLEARANCES T O COMBUSTIBLE MA T’L. in. (mm) Maximum extension of overhangs [...]

REQ’D CLEARANCES FOR SERVICING. in. (mm) Duct panel ............................. 0 Unit top ........................... 3 6 (914) Side opposite ducts ..................... 3 6 (914) Compressor access ..................... 3 6 (914) (Except for NEC requirements) REQ’D CLEARANCES T O COMBUSTIBLE MA T’L. in. (mm) Maximum extension of overhangs [...]

RECEIVING AND INST ALLA TION Step 1 — Check Equipment IDENTIFY UNIT — The unit model number and serial num- ber are stamped on unit identification plate. Check this information against shipping papers and job data. INSPECT SHIPMENT — Inspect for shipping damage while unit is still on shipping pallet. If unit appears to be damaged or is torn [...]

P ART NUMBER ‘ ‘A ’ ’ FLA T CURB CPRFCURB001A00 8 9 [203] CPRFCURB002A00 1 1 9 [279] CPRFCURB003A00 14 9 [356] NOTES: 1. Roof curb must be set up for unit being installed. 2. Seal strip must be applied as required for unit being installed. 3. Dimensions in [ ] are in millimeters. 4. Roof curb is made of 16 gage steel. 5. Attach ductwork to [...]

UNITS WITHOUT BASE RAIL — If accessory rigging brackets are to be used for rigging, install them as follows: Secure screws and paint protectors solidly against unit basepan to hold lifting brackets in position. Never use lifting brackets when the temperature is be- low −10 F. Never exceed 200 lbs per bracket of lifting force. Never use lifting [...]

UNITS WITH OPTIONAL BASE RAIL — Lifting holes are provided in optional base rail as shown in Fig. 13. Op- erating weights are shown in T ables 1 and 2. Refer to rig- ging instructions on unit. Protective wood support must be removed from unit be- fore unit is mounted to curb. Remove 4 screws that secure support above rigging holes in rails. Slide[...]

T able 1 — Physical Data — Unit 48SS UNIT SIZE 48SS 018040 024040 024060 030040 030060 030080 036060 036080 036100 036120 NOMINAL CAP ACITY (ton) 1 1 ⁄ 2 22 2 1 ⁄ 2 2 1 ⁄ 2 2 1 ⁄ 2 3333 OPERA TING WEIGHT (lb) Without Base Rail 272 303 315 320 332 332 336 336 348 348 With Optional Base Rail 296 327 339 344 356 356 360 360 372 372 COMPRES[...]

T able 2 — Physical Data — Unit 48SX UNIT SIZE 48SX 024040 024060 030040 030060 030080 036060 036080 036100 036120 NOMINAL CAP ACITY (ton) 22 2 1 ⁄ 2 2 1 ⁄ 2 2 1 ⁄ 2 3333 OPERA TING WEIGHT (lb) Without Base Rail 333 345 336 348 348 366 366 378 378 With Optional Base Rail 357 369 360 372 372 390 390 402 402 COMPRESSORS Scroll Quantity 1 RE[...]

(T ext continued from page 13) Unstable operation may occur when the gas valve and manifold assembly are forced out of position while connecting improperly-routed rigid gas piping to the gas valve. Use a backup wrench when making con- nection to avoid strain on, or distortion of, the gas control piping. If a flexible conductor is required or allow[...]

T able 3 — Maximum Gas Flow Capacity* NOMINAL IRON PIPE, SIZE (in.) INTERNAL DIAMETER (in.) LENGTH OF PIPE, FT† 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1 ⁄ 2 .622 175 120 97 82 73 66 61 57 53 50 44 40 — — 3 ⁄ 4 .824 360 250 200 170 151 138 125 1 18 1 10 103 93 84 77 72 1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 1[...]

Adhere to the following criteria when selecting, sizing, and installing the duct system: 1. Units are shipped with all 4 duct openings covered. Re- move appropriate panels for intended installation. 2. Select and size ductwork, supply-air registers, and return-air grilles according to American Society of Heating, Refrigeration and Air Conditioning [...]

T able 4A — Electrical Data — Unit 48SS UNIT SIZE 48SS V -PH-Hz VOL T AGE RANGE COMPRESSOR OUTDOOR-F AN MOTOR INDOOR-F AN MOTOR POWER SUPPL Y A W G6 0C MIN WIRE SIZE MAX WIRE LENGTH (ft) Min Max RLA LRA FLA FLA MCA MOCP* 018 208/230-1-60 187 253 8.3 45.0 0.7 1.8 12.9 15 14 75 024 208/230-1-60 187 253 12.4 61.0 0.7 2.0 18.2 30 12 80 030 208/230-[...]

T able 4B — Electrical Data — Unit 48SX UNIT SIZE 48SX V -PH-Hz VOL T AGE RANGE COMPRESSOR OUTDOOR-F AN MOTOR INDOOR-F AN MOTOR POWER SUPPL Y A W G6 0C MIN WIRE SIZE MAX WIRE LENGTH (ft) Min Max RLA LRA FLA FLA MCA MOCP* 024 208/230-1-60 187 253 12.9 62.5 1.4 2.0 19.5 30 12 75 030 208/230-1-60 187 253 15.0 76.0 1.4 2.6 22.8 30 10 100 036 208/23[...]

Alternate Power Entry 1. Remove knockouts in fixed compressor panel located on duct panel side of unit. 2. Route high-voltage leads into high-voltage terminal box. 3. Connect ground wire to green-yellow wire using field- supplied splice. 4. Connect power wires to unit high-voltage leads. 5. On 3-phase units, locate blue wire projecting from com- [...]

HEA T ANTICIP A TOR SETTING — The room thermostat heat anticipator must be properly adjusted to ensure proper heating performance. Set the heat anticipator , using an am- meter between the W and R terminals to determine the exact required setting. NOTE: For thermostat selection purposes, use 0.18 amp for the approximate required setting. Failure [...]

a. Before lighting the unit for the first time, perform the following: If the gas supply pipe was not purged be- fore connecting the unit, it will be full of air . It is rec- ommended that the ground joint union be loosened, and the supply line be allowed to purge until the odor of gas is detected. Never purge gas lines into a com- bustion chamber[...]

T able 5 — Rated Gas Inputs at Indicated Manifold Pressures UNIT 48SS,SX NUMBER OF ORIFICES GAS SUPPL Y PRESSURE (in. wg) MANIFOLD PRESSURE (in. wg) NA TURAL GAS PROP ANE* Natural Propane Orifice Drill Size Heating Input (Btuh)† Orifice Drill Size Heating Input (Btuh)† Min Max Min Max Natural Propane 018040, 024040, 030040 1 4.0 13.0 4.0 13[...]

Measure Manifold Pressure (Propane Units) — The main burner orifices on a propane gas unit are sized for the unit rated input when the manifold pressure reading matches the level specified in T able 5. Proceed as follows to adjust gas input on a propane gas unit: 1. T urn of f gas to unit. 2. Remove pipe plug on manifold (see Fig. 24), then con[...]

HEA TING SEQUENCE OF OPERA TION — See Fig. 26-33 and unit wiring label. On a call for heating, terminal ‘ ‘W’ ’ of the thermostat is energized, starting the induced-draft motor . When the hall- ef fect sensor on the induced-draft motor senses that it has reached the required speed, the burner sequence begins. This function is performed by[...]

LEGEND AW G — American Wire Gage BR — Blower Relay C— Contactor CAP — Capacitor CH — Crankcase Heater COMP — Compressor Motor CR — Combustion Relay EQUIP — Equipment FL — Fuse Link FS — Flame Sensor FU — Fuse GND — Ground GVR — Gas V alve Relay HS — Hall Effect Sensor HV TRAN — High-V oltage T ransformer I— Ignitor I[...]

LEGEND AW G — American Wire Gage BR — Blower Relay C— Contactor CAP — Capacitor CH — Crankcase Heater COMP — Compressor Motor CR — Combustion Relay EQUIP — Equipment FL — Fuse Link FS — Flame Sensor FU — Fuse GND — Ground GVR — Gas V alve Relay HS — Hall Effect Sensor HV TRAN — High-V oltage T ransformer I— Ignitor I[...]

LEGEND AW G — American Wire Gage BR — Blower Relay C— Contactor CAP — Capacitor CH — Crankcase Heater COMP — Compressor Motor CR — Combustion Relay EQUIP — Equipment FS — Flame Sensor FU — Fuse GND — Ground GVR — Gas V alve Relay HS — Hall Effect Sensor HV TRAN — High-V oltage T ransformer I— Ignitor IDM — Induced-Dr[...]

LEGEND AW G — American Wire Gage BR — Blower Relay C— Contactor CAP — Capacitor COMP — Compressor Motor CR — Combustion Relay DT — Discharge Thermostat EQUIP — Equipment FL — Fuse Link FS — Flame Sensor FU — Fuse GND — Ground GVR — Gas V alve Relay HS — Hall Effect Sensor HV TRAN — High-V oltage T ransformer I— Ignit[...]

LEGEND AW G — American Wire Gage BR — Blower Relay C— Contactor CAP — Capacitor COMP — Compressor Motor CR — Combustion Relay EQUIP — Equipment FL — Fuse Link FS — Flame Sensor FU — Fuse GND — Ground GVR — Gas V alve Relay HS — Hall Effect Sensor HV TRAN — High-V oltage T ransformer I— Ignitor ICM — Integrated Contro[...]

LEGEND AW G — American Wire Gage BR — Blower Relay C— Contactor CAP — Capacitor COMP — Compressor Motor CR — Combustion Relay EQUIP — Equipment FL — Fuse Link FS — Flame Sensor FU — Fuse GND — Ground GVR — Gas V alve Relay HS — Hall Effect Sensor HV TRAN — High-V oltage T ransformer I— Ignitor IDM — Induced-Draft Mot[...]

LEGEND AW G — American Wire Gage BR — Blower Relay C— Contactor CAP — Capacitor COMP — Compressor Motor CR — Combustion Relay EQUIP — Equipment FL — Fuse Link FS — Flame Sensor FU — Fuse GND — Ground GVR — Gas V alve Relay HS — Hall Effect Sensor HV TRAN — High-V oltage T ransformer I— Ignitor ICM — Integrated Contro[...]

LEGEND AW G — American Wire Gage BR — Blower Relay C— Contactor CAP — Capacitor COMP — Compressor Motor CR — Combustion Relay EQUIP — Equipment FS — Flame Sensor FU — Fuse GND — Ground GVR — Gas V alve Relay HS — Hall Effect Sensor HV TRAN — High-V oltage T ransformer I— Ignitor IDM — Induced-Draft Motor IFM — Indoor[...]

CHECKING AND ADJUSTING REFRIGERANT CHARGE — The refrigerant system is fully char ged with R-22 refrig- erant, tested, and factory-sealed. NOTE: Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R-22 charge. A superheat charging label is attached to the inside of the compressor access door .[...]

For Integrated Control Motors (ICM) — T o configure the 48SX unit, move the 5 Easy Select board wires to the terminals which control the airflow . Refer to the Easy Select interface board (Fig. 22) located next to the terminals and to Fig. 30 and 32. Perform the following steps for basic system configuration. AUX HEA T RANGE (VIO) — The air?[...]

T able 8C — Superheat Charging T able, 48SS030 TEMP (F) AIR ENT COND EV AP AIR — CFM 1000 Evap Air — Ewb (F) 54 56 58 60 62 64 66 68 70 72 74 76 65 SPH 14.2 15.1 16.1 17.1 19.2 21.3 23.3 24.7 25.9 27.2 27.8 28.5 70 SPH 13.6 14.1 14.6 15.0 17.1 19.2 21.3 22.8 24.2 25.7 26.3 26.9 75 SPH 13.0 13.0 13.0 13.0 15.1 17.2 19.2 20.9 22.6 24.2 24.8 25.[...]

T able 8F — Superheat Charging T able, 48SS048 (Carrier Scroll Compressor) TEMP (F) AIR ENT COND EV AP AIR — CFM 1600 Evap Air — Ewb (F) 54 56 58 60 62 64 66 68 70 72 74 76 65 SPH 15.5 15.5 15.6 15.6 17.6 19.6 21.6 22.8 24.0 25.2 25.2 25.3 70 SPH 1 1.7 1 1.8 1 1.8 1 1.8 13.9 16.0 18.0 20.1 22.2 24.3 24.3 24.3 75 SPH 8.0 8.0 8.0 8.0 10.2 12.3 [...]

T able 9A — Superheat Charging T able, 48SX024 TEMP (F) AIR ENT COND EV AP AIR — CFM 800 Evap Air — Ewb (F) 54 56 58 60 62 64 66 68 70 72 74 76 65 SPH 22.1 22.1 22.8 23.2 25.3 27.4 29.5 29.8 30.2 30.5 31.3 32.1 70 SPH 18.5 18.9 19.3 19.6 22.2 24.8 27.5 28.3 29.1 30.0 30.0 30.0 75 SPH 15.0 15.4 15.7 16.1 19.2 22.3 25.4 26.7 28.1 29.4 28.7 28.0[...]

T able 9D — Superheat Charging T able, 48SX042 TEMP (F) AIR ENT COND EV AP AIR — CFM 1400 Evap Air — Ewb (F) 54 56 58 60 62 64 66 68 70 72 74 76 65 SPH 23.9 23.9 23.9 23.9 24.4 24.9 25.5 25.8 26.1 26.5 25.6 24.7 70 SPH 21.9 21.9 21.9 21.9 22.4 22.9 23.4 23.7 24.1 24.5 24.0 23.5 75 SPH 19.8 19.8 19.8 19.8 20.3 20.8 21.3 21.7 22.0 22.4 22.4 22.[...]

T able 10 — Required Suction-T ube T emperature (F)* SUPERHEA T TEMP (F) SUCTION PRESSURE A T SERVICE PORT (psig) 61.5 64.2 67.1 70.0 73.0 76.0 79.2 82.4 85.7 0 35 37 39 41 43 45 47 49 51 2 37 39 41 43 45 47 49 51 53 4 39 41 43 45 47 49 51 53 55 6 41 43 45 47 49 51 53 55 57 8 43 45 47 49 51 53 55 57 59 10 45 47 49 51 53 55 57 59 61 12 47 49 51 53[...]

T able 12 — Dry-Coil Air Delivery* — Downflow Discharge at 230 and 460 V — Unit 48SS (Deduct 10% from Cfm and W atts for 208 V Operation) UNIT 48SS MOTOR SPEED AIR DELIVER Y EXTERNAL ST A TIC PRESSURE (in. wg) 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 018 Low W atts † 295 251 223 201 176 149 124 † † † Cfm † 821 817 753 665 536 34[...]

T able 14 — Dry-Coil Air Delivery* — Downflow Discharge at 230 and 460 V — Unit 48SX (Deduct 10% from Cfm and W atts for 208 V Operation) UNIT 48SX MOTOR SPEED AIR DELIVER Y EXTERNAL ST A TIC PRESSURE (in. wg) 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 024, 030 Low W atts 280 275 265 255 250 245 240 †††† C f m 8 2 0 8 1 0 7 5 5 7 0 [...]

T able 17 — Wet Coil Pressure Drop UNIT SIZE AIRFLOW (cfm) PRESSURE DROP (in. wg) 018* 600 0.069 700 0.082 800 0.102 900 0.1 16 024 600 0.039 700 0.058 800 0.075 900 0.088 030 900 0.088 1000 0.095 1200 0.123 036 1000 0.068 1200 0.088 1400 0.108 1600 0.123 042 1000 0.048 1200 0.069 1400 0.088 1600 0.102 048 1400 0.068 1600 0.075 1800 0.088 060 170[...]

Air Filter Never operate the unit without a suitable air filter in the return-air duct system. Always replace the filter with the same dimensional size and type as originally installed. See Tables 1 and 2 for recommended filter sizes. Inspect air filter(s) at least once each month and replace (throwaway-type) or clean (cleanable-type) at least [...]

Combustion-Air Blower — Clean periodically to as- sure proper airflow and heating ef f iciency . Inspect blower wheel every fall and periodically during heating season. For the first heating season, inspect blower wheel bimonthly to determine proper cleaning frequency . T o inspect blower wheel, remove draft hood assembly . Shine a flashlight [...]

Condenser Coil, Evaporator Coil, and Conden- sate Drain Pan — Inspect the condenser coil, evapo- rator coil, and condensate drain pan at least once each year . Proper inspection and cleaning requires the removal of the unit top. See Unit T op Removal section on page 45. The coils are easily cleaned when dry; therefore, inspect and clean the coils[...]

TROUBLESHOOTING Cooling SYMPTOM CAUSE REMEDY Compressor and condenser fan will not start. Power failure Call power company . Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker . Defective thermostat, contactor , transformer, or control relay Replace component. Insuff icient line voltage Determine cause and correct. Incorrec[...]

Cooling (cont) SYMPTOM CAUSE REMEDY Integrated control motor (units 48SX048,060 208/230 v) IFM does not run. Blower wheel not secured to shaft Properly tighten blower wheel to shaft. Insuff icient voltage at motor Determine cause and correct. Power connectors not properly seated Connectors should snap easily; do not force. Integrated control motor [...]

LED T roubleshooting — Error Code SYMPTOM CAUSE REMEDY Hardware failure. (LED OFF) Loss of power to control module (IGC). Check 5 amp fuse on IGC, power to unit, 24-v circuit breaker , and transformer. Units without a 24-v circuit breaker have an internal overload in the 24-v trans- former . If the overload trips, allow 10 minutes for au- tomatic[...]

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ST ART -UP CHECKLIST (Remove and Store in Job File) I. PRELIMINAR Y INFORMA TION MODEL NO.: DA TE: SERIAL NO.: TECHNICIAN: II. PRE-ST ART -UP (insert checkmark in box as each item is completed) M VERIFY THA T ALL P ACKING MA TERIALS HA VE BEEN REMOVED FROM UNIT M VERIFY THA T CONDENSA TE CONNECTION IS INST ALLED PER INST ALLA TION INSTRUCTIONS M CH[...]