Carrier SINGLE PACKAGE ROOFTOP UNITS 48PG20-28 manual

Manufa cturer res erves the right to discon tinue, or chang e at any time , specificat ions or designs witho ut notic e and wit hout inc urring obligati ons. PC 111 Catalog No. 534-80211 Prin ted in U.S .A. Form 48PG-1 0SI Pg 1 9-05 Repla ces: New Book 1 4 Ta b 1 a 6 a Installation, Star t-Up and Ser vice Instructions CONTENTS Page SAFETY CONSIDERA[...]

2 INST ALLA TION Step 1 — Pro vide Unit Support RO O F CUR B — Assemble or install accessory roof curb in accordance with instructions shipped with this accessory . See Fig. 1. Install insulation, cant strips, roofing, and counter fl ash- ing as shown. Ductwork can be installed to roof c urb before unit is set in pla ce. Ductw ork must be atta [...]

3 Fig. 1 — Roof Curb Details[...]

4 NOTES: 1. Add 150 lb (68 kg) for domestic crating. 2. See label for unit location on roof curb. DOES NOT INCLUDE ERV ( ENERGY RECOVERY VENTILA TOR) OPTION. UNIT SIZE MAX WEIGHT (LB) * CENTER OF GRA VITY ( IN.) X Y Z 66.5 66.5 70.5 36.7 31.4 37.0 37.0 31.8 35.2 3825 4075 4300 PG20 PG24 PG28 Fig. 3 — Rigging Details SHIPPING RAILS Fig. 2 — Ship[...]

5 Fig. 4 — Base Unit Dime nsions[...]

6 Table 1 — Ph ysical D ata LEG END *Alumin um e vaporator coi l/aluminum cond enser coil. UNIT 48PG 20 24 28 VO LTA G E 208/230 and 460 575 208/230 and 460 575 208/230 and 460 575 NOMINAL CAP ACITY (T ons) 18 18 20 20 25 25 OPERA TING WEIGHT (lb) 48 Ser ies ( Low Heat ) Al/A l* 2480 2480 2588 2588 2 773 2773 COMPRESSOR Fully Her metic Scroll Qua[...]

7 Table 2 — Fan Motor and Drive Data — Vertical Supply/Return 48PG 20 24 28 208/230 an d 460 575 208/230 an d 460 575 208/230 an d 460 575 LO W RANGE Motor H p 3 . 7 5 3 . 7 555 Motor N ominal R pm 1750 1750 1750 17 50 1750 1750 Maxi mum Cont inuous Bhp 4.26 5.75 4. 26 5.75 5.75 5.75 Maxi mu m Contin uous W atts 3174 4290 3174 42 90 4290 4290 M[...]

8 Table 3 — Fan M otor and Drive Data — Horizontal Supply/Return 48PG 2 0 24 28 208/230 a nd 46 0 575 2 08/23 0 and 46 0 575 208/ 230 an d 460 57 5 LO W RANGE Mot or Hp ———— 5 5 Mot or Nomin al Rpm — — — — 1750 1750 Maximu m Continu ous B hp ———— 5 . 7 5 5 . 7 5 Maximum Con tinuo us W atts — — — — 4290 4290 Moto [...]

9 Step 4 — Field F abricate Ductw ork — On verti cal units, secure all ducts to roof curb and building structure. Do not connect ductwork to unit. For horizontal appli cations, field- supplied flanges should be attached to horizontal dischar g e openings and all ductwork secured to the flanges. Insulate and weatherproof all externa l ductwork, [...]

10 Step 6 — Instal l Flue Hood and Inlet Hood — Flue hood (smaller hood), inlet hood (larger hood), and screens are shipped inside t he unit in the fan sect ion. T o install, remove the heat panel. The flue hood is attac hed to the heat section panel from the outside using the screws provided. See Fig. 10. The inlet hood is installed by inserti[...]

11 Size gas-supply piping for 0.5-in. wg maximum pressure drop. Do not use supply pipe smaller than unit gas connec tion. Step 9 — Make Electrical Connections FIELD POWE R SUPPL Y — Uni t is fa cto ry wi re d fo r vol t- age shown on unit namepl ate. Be sure to check for correct voltage. When installing units, provide disconnect per N EC (Natio[...]

12 Set heat anticipator settings as follows: Settings may be changed slightly to provide a greater degree of comfort for a particu lar installation. Step 10 — Instal l Outdoor Air Hood — Pe r- form t he following procedure to install the outdoor -ai r hood on units equipped with an ec onomizer , two-position damper, or manual outdoor air dampe [...]

13 Table 4A — Electrical Data (Units Without Optional Powered Convenience Outlet) See Legend and Notes on page 15. UNIT SIZE 48HG NOMINAL V O LTA G E (3 Ph, 60 H z) VO LTA G E RANGE COMPRESSOR OFM IFM PO WER EXHAUST COMBUSTION FA N M O TO R POWER SUPPL Y* PO WER SUP PL Y UNITS WITH OPTIONAL HACR BREAKER DISCONNECT SIZE No. 1 No. 2 No. 3 Min Max R[...]

14 Table 4B — Electrical Data (Units With Optional Powered Convenience Outlet) UNIT SIZE 48HG NOMINAL V O LTA G E (3 Ph, 60 Hz ) V O LTAG E RANGE COMPRESSOR OFM IFM PO WER EXHAUST COMBUSTION FA N M O T O R PO WER SUPPL Y * POWER SUPPL Y UNITS W ITH OPTIONAL HA CR BREAKER DISCONNECT SIZE No. 1 No. 2 No. 3 Min Ma x RLA LRA RLA LRA RLA LRA Qty Hp FL[...]

15 LEGEND AND NO TES FOR T ABLES 4A AND 4B LEGEND *Fuse or HACR circuit breaker . NO TES: 1. In co mpliance with NEC requirements for mul timotor and com- bination load equipment (ref e r to NEC Ar ticles 430 and 440), the ov ercurren t protectiv e device f or the unit shall be fuse or HA CR breaker . Canadian units m a y be fuse or circuit breaker[...]

16 Step 11 — P osition Optional P ower Exhaust or Baro m etric Relief Damper Hood — The optional power exhaust or barometric re lief dampers are shi pped assembled and tilted back into the unit for shipping. Brackets and extra screws are shipped in shrink wrap around the dampers. 1. Remove 9 scre ws holding e ach damper assembly i n place. See [...]

17 Fig. 21 — Power Exhaust or B arometric Relief Damper Mounting Details Fig. 22 — Bracket and Hood Positioning[...]

18 PRE-ST ART -UP Proceed as follows to inspect and prepare the unit for initial start-up: 1. Remove all acces s panels. 2. Read and follow instructions on all W ARNING , CAU- TION, and INFORMA TION lab els attached to, or shipped with, the unit. 3. Make the following inspections: a. Insp ect for shipping and handlin g damages such as broken lines,[...]

19 Condenser Fans and Motors — Cond enser fans and motors are factory set. Refer to Condenser -Fan Adjustment section (page 49) as r equired. Retur n-Ai r Fil ters — Check that correct fi lters are in- stalled in filter tracks (see T able 1). Do not ope rate unit without return-air filters. NOTE: For units w ith 4-in. filter option, units are s[...]

20 Table 6 — Fan Performance — 48PGE20 — Vertical Supply/ Return Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (A) Low Range: 68 5-939 r pm, 4.26 bhp (2 08/230 an d 460-v), 75 1-954 r pm, 5.75 bhp (5 75-v) (B) M id-Low R ange: 94 9-120 6 r pm, 5.7 5 bhp (C) M id-Hi gh Range: 94 1-1176[...]

21 Table 7 — Fan Performance — 48PGF20 — Vertical S upply/Return Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (A) Low Range: 68 5-939 r pm, 4.26 bhp (2 08/230 an d 460-v), 75 1-954 r pm, 5.75 bhp (5 75-v) (B) M id-Low R ange: 94 9-120 6 r pm, 5.7 5 bhp (C) M id-Hi gh Range: 94 1-1176[...]

22 Table 8 — Fan Performance — 48PGD24 — Vertical Supply/Retu r n Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (A) Low Range: 68 5-939 r pm, 4.26 bhp (2 08/230 an d 460-v), 75 1-954 r pm, 5.75 bhp (5 75-v) (B) M id-Low R ange: 94 9-120 6 r pm, 5.7 5 bhp (C) M id-Hi gh Range: 94 1-117[...]

23 Table 9 — Fan Performance — 48PGE24 — Vertical Supply/ Return Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (A) Low Range: 68 5-939 r pm, 4.26 bhp (2 08/230 an d 460-v), 75 1-954 r pm, 5.75 bhp (5 75-v) (B) M id-Low R ange: 94 9-120 6 r pm, 5.7 5 bhp (C) M id-Hi gh Range: 94 1-1176[...]

24 Table 10 — Fan Performance — 48PGF24 Vertical Supply/Retur n Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (A) Low Range: 68 5-939 r pm, 4.26 bhp (2 08/230 an d 460-v), 75 1-954 r pm, 5.75 bhp (5 75-v) (B) M id-Low R ange: 94 9-120 6 r pm, 5.7 5 bhp (C) M id-Hi gh Range: 94 1-1176 r [...]

25 Table 11 — Fan Performance — 48PGD28 — Vertical Supply/Return Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (A) Low Range: 68 7-873 r pm, 5.75 bhp (B) M id-Low R ange: 80 5-100 7 r pm, 5.7 5 bhp (C) M id-Hi gh Range: 94 1-1176 r pm, 8. 63 bhp (D) High Rang e: 1014- 1297 rp m, 11.50[...]

26 Table 12 — Fan Performance — 48PGE28 — Ver tical Supply/Return Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (A) Low Range: 68 7-873 r pm, 5.75 bhp (B) M id-Low R ange: 80 5-100 7 r pm, 5.7 5 bhp (C) M id-Hi gh Range: 94 1-1176 r pm, 8. 63 bhp (D) High Rang e: 1014-1 297 r pm, 11. [...]

27 Table 13 — Fan Perform ance — 48 PGF28 — V ertical S upply/Ret urn U nits LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (A) Low Range: 68 7-873 r pm, 5.75 bhp (B) M id-Low R ange: 80 5-100 7 r pm, 5.7 5 bhp (C) M id-Hi gh Range: 94 1-1176 r pm, 8. 63 bhp (D) High Rang e: 1014- 1297 rp m,[...]

28 Table 14 — Fan Performance — 48PGD20 — Horizontal Supply and Return Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (E) Low Range: Not Used (F) M id-Low Ran ge: 896- 1227 rp m, 4.26 bhp (20 8/230 and 46 0-v), 873 -1108 r pm, 5.75 bhp (5 75-v) (G) M id-High Ran ge: 11 13-141 4 r pm, 5[...]

29 Table 15 — Fan Performance — 48PGE20 — Horizontal Supply and Return Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (E) Low Range: Not Used (F) M id-Low Ran ge: 896- 1227 rp m, 4.26 bhp (20 8/230 and 46 0-v), 873 -1108 r pm, 5.75 bhp (5 75-v) (G) M id-High Ran ge: 11 13-141 4 r pm, 5[...]

30 Table 16 — Fan Performance — 48PGF20 — Horiz ontal Supply and Retur n Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (E) Low Range: Not Used (F) M id-Low Ran ge: 896- 1227 rp m, 4.26 bhp (20 8/230 and 46 0-v), 873 -1108 r pm, 5.75 bhp (5 75-v) (G) M id-High Ran ge: 11 13-141 4 r pm,[...]

31 Table 17 — Fan Performance — 48PGD24 — Horizontal Supply and Return Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (E) Low Range: Not Used (F) M id-Low Ran ge: 896- 1227 rp m, 4.26 bhp (20 8/230 and 46 0-v), 873 -1108 r pm, 5.75 bhp (5 75-v) (G) M id-High Ran ge: 11 13-141 4 r pm, 5[...]

32 Table 18 — Fan Performance — 48PGE24 — Horizontal Supply and Return Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (E) Low Range: Not Used (F) M id-Low Ran ge: 896- 1227 rp m, 4.26 bhp (20 8/230 and 46 0-v), 873 -1108 r pm, 5.75 bhp (5 75-v) (G) M id-High Ran ge: 11 13-141 4 r pm, 5[...]

33 Table 19 — Fan Performance — 48PGF24 — Horiz ontal Supply and Retur n Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (E) Low Range: Not Used (F) M id-Low Ran ge: 896- 1227 rp m, 4.26 bhp (20 8/230 and 46 0-v), 873 -1108 r pm, 5.75 bhp (5 75-v) (G) M id-High Ran ge: 11 13-141 4 r pm,[...]

34 Table 20 — Fan Performance — 48PGD28 — Horizontal Supply and Return Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (E) Low Range: 68 7-873 r pm, 5. 75 bhp (F) M id-Low Ran ge: 80 5-1007 r p m, 5.7 5 bhp (G) M id-High R ange: 94 1-1176 r pm, 8.63 bh p (H) High Rang e: 1014-1 297 r pm[...]

35 Table 21 — Fan Performance — 48PGE28 — Horizontal Supply and Return Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (E) Low Range: 68 7-873 r pm, 5. 75 bhp (F) M id-Low Ran ge: 80 5-1007 r p m, 5.7 5 bhp (G) M id-High R ange: 94 1-1176 r pm, 8.63 bh p (H) High Rang e: 1014- 1297 rp m[...]

36 Table 22 — Fan Performance — 48PGF28 — Horiz ontal Supply and Retur n Units LEGEN D Boldface ind icates field-supplied m otor/drive required. NO TES: 1. M otor dr ive ranges: (E) Low Range: 68 7-873 r pm, 5. 75 bhp (F) M id-Low Ran ge: 80 5-1007 r p m, 5.7 5 bhp (G) M id-High R ange: 94 1-1176 r pm, 8.63 bh p (H) High Rang e: 1014-1 297 r [...]

37 Table 23 — P ower Exh aust Fa n Perfo rmance — 4 8PG20-28 LEGEND ESP — External Static Pressure Table 24 — O peration Air Quan tity Limits *7000 cfm m inimum re comme nded above 1.0 i n. wg exter nal st atic pre ssure. Table 25 — Evaporator Fan Motor Specifications AIRFLO W (Cfm) LO W SPEED MEDIUM SPEED HIGH SPEED 208 V 230,46 0,575V 2[...]

38 Table 25 — Evaporator Fan Motor Specificat ions (cont) NO TES: 1. Ext ensive motor a nd elect rical te sting en sures th at the m otors can b e uti- lized with c onfiden ce up to the maximum appl ied bh p , watts, and a mps. Using the fan motor up to the maxi mum ratings shown w ill not result in nui- sance tripping o r premature motor failure[...]

39 Table 26 — Acc essory/F IOP Stat ic Press ure (in. w g)* — 48 PG20-2 8 LEGEN D *The sta tic pressu re must be add ed to th e external stati c pressure. Th e sum a nd the evaporator enteri ng-ai r cfm should then be u sed in con j uncti on with the Fan P erforman ce tables to deter- mine blower r pm and watts. Table 27 — Fan Rpm at Motor Pu[...]

40 Table 28 — EconoM i$e r IV Sens or Usage *CRENTDIF004A00 and CR TE M PSN002A00 accessories are used on m any diff erent base uni ts. As such, th ese kits may con tain parts that will not b e needed f or installati on. †33ZCSENCO2 is an accessor y CO 2 sensor . **33ZCAS PCO2 is an accessory aspirat o r bo x required fo r duct- mounted applica[...]

41 Differen tial Dry Bulb Control — For differential dry bul b control the standard outdoo r dry bulb sensor i s used in conjunc- tion with an additional accessory dry bul b sensor (part number CR TEMPSN002A 00). The accessory sensor must be mounted in the return airstream. W iring is provided in the EconoMi$e r IV wiring harness. See Fig. 26. In[...]

42 CONTROL CURVE A B C D CONTROL POINT APPROX. °F (°C) A T 50% RH 73 (23) 70 (21) 67 (19) 63 (17) 1 2 1 4 1 6 1 8 2 0 2 2 2 4 26 28 30 32 3 4 3 6 3 8 40 42 4 4 46 9 0 1 0 0 80 70 60 50 4 0 3 0 20 1 0 E NT HA LP Y — B TU P E R PO U N D DR Y A IR 85 (29) 90 (32) 95 (35) 100 (38) 105 (41) 11 0 (43) 35 (2) 35 (2) 40 (4) 40 (4) 105 (41) 11 0 (43) 45[...]

43 Minimum P osition Contro l — There is a mi nimum damper position potentiometer on the EconoMi $er IV controller . See Fig. 28. The m inimum damper position maintai ns the mini- mum airflow into the building during the occupied period. When using demand ventilation, the minimum dampe r position represents the minimum ventilation position for VO[...]

44 3. Use the Up/Down button to s elect the preset number . See T able 29. 4. Press Enter to lock i n the selection. 5. Press Mode to exit a nd resume normal operat ion. The custom settings of the CO 2 sensor can be changed a ny- time after the sensor is energized. Follow the steps below to change the non-standard settings: 1. Press Clear and Mode [...]

45 When ignition occurs the IGC board will continue to moni- tor the condition of the rollout and limit switches, the hal l effect sensor , as well as the flame sensor . If the unit is controlled through a room thermostat set for fan auto., 45 seconds after ignition occurs, the indoor-fan motor will be ener gized (and t he outdoor-air dampers will [...]

46 SER VICE Clea ning — Inspect unit interior at beginning of each heat- ing and cooling season and as operating conditio ns require. Re- move unit top panel and/o r side panels for access to unit inter ior . COIL MAINTENANCE AND CLEANING RECOMMEN- DA T I O N — Rout ine cleaning of coi l surfaces is essential to maintain proper operation of the[...]

47 5. Thoroughly apply T ot aline® environmentally sound coil cleaner solution to al l coil surfaces including finned area, tube sheets and coil headers. 6. Hold garden sprayer nozzl e close to finned area s and ap- ply cleaner with a vert ical, up-and-down motion. A voi d spraying in horizontal pattern to minimize potential for fin d amage. 7. En[...]

48 F AN S H A F T BE A R IN GS — Lubri cate bearings at least e v- ery 6 months with suitable bearing grease. T ypical lubrican ts are given below: *Preferred lubricant because it contains rus t and o xidation inhibitors . F AN MOTOR BEARINGS — F an mot or bea rin gs ar e o f the permanently lubricated type. No field lu brication is required. N[...]

49 Table 30 — Belt Tension Adjustment Condenser -Fan Adjustment (F ig. 35) 1. Shut off unit power supply . 2. Remove condenser-fan assembly (grille, mot or, motor cover , an d fan) and loosen fan hub setscrew s. 3. Adjust fan height as shown in Fig. 35. 4. T ighten se tscrews and replace condenser-fan assembly . 5. T urn on pow er to unit. V erif[...]

50 Refrigerant Charge — Am ount of refrigerant charge is listed on unit nameplate. Refer to Carrier G T AC II; Module 5; Charging, Recovery , Recycling, and Reclamat ion section for charging methods and procedures. Unit panel s must be in place when unit is operating during charging procedure. Puron® (R-410A) refrigerant cylinders c ontain a dip[...]

51 4. Set main ga s valve to ON position. 5. Set thermostat at setting t o call for heat. 6. Remove screw cap covering regulator adj ustment screw (see Fig. 40). 7. T urn adjustment screw clockwi se to increase pressure or counterclockwise t o decrease pressure. 8. Once desired p ressure is established, s et unit s etting for no call for heat, turn[...]

52 Table 32 — Altitude Compensation* NA TURAL GAS *As the height above sea le vel increases, there is less oxygen per cubic f oot of air . Therefore, heat input rate should be reduced at higher altitudes. Includes a 4 % input reduction per each 1000 ft. †Orifices avai lable through the local Carrier dealer . PROP ANE GAS *As the height above se[...]

53 Fig. 42 — T ypical Low V oltage Control Sc hematic[...]

54 Fig. 43 — T ypical P ower S ch emat ic[...]

55 Fig. 44 — T ypical Component Arrangement — 48PG20,24[...]

56 Fig. 45 — T ypical Component Arrangement — 4 8PG28 THER M OST A T/IGC M AR K INGS BM — Blower M otor C— Co mmon CM — Inducer M otor CS — Centrifugal Switch G— Fa n IFO — Indoor F an On L1 — Line 1 R— Thermostat Po wer RT — Po wer Supp l y SS — Speed Sensor W— Thermostat Heat W1 — 1st Stage of He ating W2 — 2nd Stage[...]

57 TROUBLESHOO TING Unit T roubleshoot ing — Refer to T ables 33-35 and Fig. 46. Table 33 — Co oling Servi ce Analysi s LEGEND TXV — Ther mostatic Expansion V alve PRO BLEM CA USE REMED Y Compressor a nd Condenser Fan W il l No t Sta r t. P ower f ailure. Call pow er company . Fuse b lown or circuit break er tripped. Replace fu se or reset ci[...]

58 T a b l e3 4—G a sH e a t i n gS e r v i c eA n a l y s i s PRO BLEM CA USE REMED Y Burners Will Not Ignite. M isal igned spark electrode s. Check flame ign ition and sen sor electrod e positioning. Ad j ust a s needed . No gas at main bu r ners. Chec k gas line for a ir ; purge as necessary . After purging gas line of air , allow gas to dissi[...]

59 Fig. 46 — IGC Control (Heating and Cooling) LEGEND NO TE: Ther mostat Fan Switch in the “A UTO” position. IDM — Induced-Draft M otor IGC — Integrated Gas Unit C ontroller[...]

60 Table 35 — IGC Board LED Alarm Codes LEGEND NO TES: 1. There is a 3-sec ond pause bet ween alarm code displa ys. 2. If more than one alarm code exists, al l applicable alarm codes will be displa yed in nume rical sequence . 3. Alarm codes on the IGC will be lost i f power t o t he unit is inter r upted. EconoMi$er IV T roubleshoot ing E C O N [...]

61 DCV (Demand Controlled V entilation) AND POWER EXHAUST — T o ch ec k DCV a nd Po wer E xh au st: 1. Make sure EconoMi$er IV preparation procedure has been performed. 2. Ensure terminals AQ and AQ1 are open. The LED for both DCV and Exhaust shoul d be of f. The actuator should be fully closed. 3. Connect a 9-v battery to A Q (positive node) and[...]

Manufa cturer reser ves the right to discon tinue, or change at any time, specificat ions or designs w ithout not ice and without incurrin g obligations. PC 111 Catalog No. 534-80211 Prin ted in U.S .A. Form 48P G-10SI Pg 62 9-05 Repla ces: New Book 1 4 Ta b 1 a 6 a Copyright 2 005 Car rier Cor poration[...]

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Manufa cturer reser ves the right to discon tinue, or change at any time, specificat ions or designs w ithout not ice and without incurrin g obligations. PC 111 Catalog No. 534-80211 Prin ted in U.S .A. Form 48PG-1 0SI Pg CL-1 9-05 Repl aces: New Book 1 4 Ta b 1 a 6 a Copyright 2 005 Car rier Cor poration - ------------- ----------- ----------- ---[...]