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Carrier G Series Installation Instructions Manual
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Carrier G Series Installation Instructions Manual

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PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx
14 SEER Single-Packaged Air Conditioner and Gas Furnace System
with R-410A Refrigerant
Single Phase 2-5 Nominal Tons (Sizes 24-60)
Three Phase 3-5 Nominal Tons (Sizes 36-60)
IMPORTANT: Effective January 1, 2015, all split system and packaged
air conditioners must be installed pursuant to applicable regional
efficiency standards issued by the Department of Energy.
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

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Receiving and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pre-start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Start-up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fig. 1 - Unit PGD4, PGS4, WPG4

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.
Installation Instructions
A170030
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
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.
WARNING
!
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury and/or
death.
Carbon Monoxide (CO) is a colorless, odorless, and tasteless poisonous
gas that can be fatal when inhaled. Follow all installation, maintenance,
and service instructions. See additional information below regarding
the installation of a CO Alarm.
Most states in the USA and jurisdictions in Canada have laws that
require the use of Carbon Monoxide (CO) alarms with fuel burning
products. Examples of fuel burning products are furnaces, boilers, space
heaters, generators, water heaters, stoves/ranges, clothes dryers,
fireplaces, incinerators, automobiles, and other internal combustion
engines. Even if there are no laws in your jurisdiction requiring a CO
Alarm, it's highly recommended that whenever any fuel burning product
is used in or around the home or business that the dwelling be equipped
with a CO Alarm(s). The Consumer Product Safety Commission
recommends the use of CO Alarm(s). The CO Alarm(s) must be
installed, operated, and maintained according to the CO Alarm
manufacturer's instructions. For more information about Carbon
Monoxide, local laws, or to purchase a CO Alarm only, please visit the
following website
https://www.kidde.com
!
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 off accessory heater power switch if applicable.
CAUTION
. When

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Summary of Contents for Carrier G Series

  • Page 1: Table Of Contents

    PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx 14 SEER Single-Packaged Air Conditioner and Gas Furnace System with R-410A Refrigerant Single Phase 2-5 Nominal Tons (Sizes 24-60) Three Phase 3-5 Nominal Tons (Sizes 36-60) Installation Instructions IMPORTANT: Effective January 1, 2015, all split system and packaged In Canada refer to the current editions of the National Standards of air conditioners must be installed pursuant to applicable regional...

  • Page 2: Introduction

    PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Roof Curb CAUTION Install accessory roof curb in accordance with instructions shipped with curb (See Fig. 7). Install insulation, cant strips, roofing, and flashing. FIRE, EXPLOSION, ELECTRICAL SHOCK AND Ductwork must be attached to curb.
  • Page 3 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Ducts passing through an unconditioned space must be insulated and 3. Condition of the load as it relates to operation of the lifting kit, such covered with a vapor barrier. as balance, temperature, etc.
  • Page 4 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions A200169 Fig. 3 – PGD4 24-36 Unit Dimensions Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 5 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions A200158 Fig. 4 – WPG4 24-36 Unit Dimensions Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 6 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions A200162 Fig. 5 – PGD4 42-60 Unit Dimensions Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 7 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions A220030 Fig. 6 – WPG4 42-60 Unit Dimensions Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 8 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Dashed lines show cross support location for large basepan units. HVAC unit HVAC unit basepan base rails Sealing Gasket Roofcurb Anchor screw Wood nailer* Flashing field supplied Roofcurb* Insulation...
  • Page 9 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions CAUTION - NOTICE TO RIGGERS PRUDENCE - AVIS AUX MANIPULATEUR ACCESS PANELS MUST BE IN PLACE WHEN RIGGING. PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION. Use top skid as spreader bar.
  • Page 10 Table 1 – Physical Data Unit Size 24040 24060 30040 30060 36060 42060 42090 48090 60090 NOMINAL CAPACITY (ton) 2-1/2 2-1/2 3-1/2 3-1/2 SHIPPING WEIGHT lb. SHIPPING WEIGHT (kg) COMPRESSOR / QUANTITY Rotary / 1 Scroll / 1 REFRIGERANT (R-410A) Quantity lb.
  • Page 11 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Table 2 – Maximum Gas Flow Capacity † Length of Pipe ft (m) Nominal Internal Iron Pipe Diameter Size (in.) (in.) (12) (15) (18) (21) (24) (27) (30) (38)
  • Page 12 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Use a minimum of one hanger every 6 ft (1.8 m). For pipe sizes WARNING larger than 1/2 in., follow recommendations of national codes. 3. Apply joint compound (pipe dope) sparingly and only to male FIRE OR EXPLOSION HAZARD threads of joint when making pipe connections.
  • Page 13 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions screwdriver and hammer. Push cover down to break rear and left 6. Adequately insulate and weatherproof all ductwork located side tabs. These plastic knockouts are held in place with tabs outdoors.
  • Page 14 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions NOTE: Field supplied disconnect switch box should be positioned so Locate six (seven for 3-phase) 18-gage wires leaving control box. These that it does not cover up any of the unit gas combustion supply air low-voltage connection leads can be identified by the colors red, green, louvers.

  • Page 15: Pre-Start-Up

    PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Pre-start-up a. Make sure gas line is free of air. Before lighting the unit for the first time, perform the following with the gas valve in the OFF WARNING position: NOTE: If the gas supply pipe was not purged before connecting the...
  • Page 16 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Table 3 – Altitude Derate Multiplier for U.S.A. Derate Multiplier † Altitude ft Percent of Derate ‡ Factor 0-2000 1.00 (0-610) *. In Canada see Canadian Altitude Adjustment. †.
  • Page 17 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions If larger adjustments are required, change main burner orifices following 4. 87.8 x 1050 = 92,190 Btuh input the recommendations of national and local codes. If the desired gas input is 89,000 Btuh, only a minor change in the NOTE: All other appliances that use the same meter must be turned off manifold pressure is required.
  • Page 18 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions CONNECTION WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING SCHEMATIC 208/230-1-60 IF USED CONT CAP 1 FIELD SUPPLY SEE NOTE 8 POWER EQUIP GND UNIT ONLY MAXIMUM WIRE GRN/YEL...
  • Page 19 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions LADDER WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING USE COPPER CONDUCTORS ONLY LEGEND FIELD SUPPLY EQUIP GND 208/230 VAC. 60 HZ. 1PH C;21 FIELD SPLICE CONT COMPRESSOR CONTACTOR...
  • Page 20 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions CONNECTION WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING SCHEMATIC 208/230-3-60 IF USED CONT CAP 1 FIELD SUPPLY SEE NOTE 8 POWER COMP EQUIP GND GRN/YEL UNIT ONLY MAXIMUM WIRE...
  • Page 21 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions LADDER WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING USE COPPER CONDUCTORS ONLY LEGEND FIELD SUPPLY EQUIP GND 208/230 VAC. 60 HZ. 3PH EQUIP EQUIPMENT FIELD SPLICE C;21...
  • Page 22 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Normal Operation Table 6 – LED Indications An LED (light-emitting diode) indicator is provided on the integrated Status Code LED Indication gas unit controller (IGC) to monitor operation. The IGC is located by Normal Operation removing the control access panel (see Fig.
  • Page 23 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions is more than 2°F (1.1°C) lower than required liquid line WARNING temperature. NOTE: If the problem causing the inaccurate readings is a refrigerant EXPLOSION HAZARD leak, refer to the Check for Refrigerant Leaks section. Failure to follow this warning could result in Indoor Airflow and Airflow Adjustments death, serious personal injury, and/or property...
  • Page 24 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Dehumidification Cooling Fan Speed Set-up: 2-Pin Terminal IMPORTANT: Dehumidification control must open control circuit on humidity rise above set point. Use of the dehumidification cooling fan speed requires use of either a 24 VAC dehumidistat or a thermostat which includes control of a 24 VAC dehumidistat connection.
  • Page 25 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Table 8 – Cooling Charging Chart Superheat charging table is derived from optimum performance point. (95°F [35°C] outdoor ambient and (80°F [27°C] dry bulb; 67°F [19°C] wet bulb indoor condition.) Where a dash(--) appears do not attempt to check charge or charge unit under these conditions using the superheat method.
  • Page 26 Table 9 – Dry Coil Air Delivery - Horizontal and Downflow Discharge Sizes 24-60 208/230VAC - 1 & 3 Phase ESP (in. W.C.) Heating Rise Allowable Unit Size Motor Speed °F (°C) Functions 0.09 0.10 0.10 0.11 † Blue Alternate Heating Gas Heat Rise (°F) Gas Heat Rise (°C) Heating...
  • Page 27 Table 9 – Dry Coil Air Delivery - Horizontal and Downflow Discharge Sizes 24-60 208/230VAC - 1 & 3 Phase (Continued) Heating Rise Allowable ESP (in. W.C.) Unit Size Motor Speed °F (°C) Functions 0.09 0.10 0.10 0.11 † Blue Gas Heat Rise (°F) Gas Heat Rise (°C) 0.14...
  • Page 28 Table 9 – Dry Coil Air Delivery - Horizontal and Downflow Discharge Sizes 24-60 208/230VAC - 1 & 3 Phase (Continued) Heating Rise Allowable ESP (in. W.C.) Unit Size Motor Speed °F (°C) Functions 1001 0.13 0.13 0.14 0.14 0.15 0.16 0.17 0.18...
  • Page 29 Table 9 – Dry Coil Air Delivery - Horizontal and Downflow Discharge Sizes 24-60 208/230VAC - 1 & 3 Phase (Continued) Heating Rise Allowable ESP (in. W.C.) Unit Size Motor Speed °F (°C) Functions 0.09 0.10 0.10 0.11 0.12 0.12 0.13 0.14 0.14...

  • Page 30: Maintenance

    PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Table 12 – Filter Pressure Drop Table (IN. W.C.) Cooling Standard CFM (SCFM) Filter Size in. (mm) Tons 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 600-1400 CFM 2.0, 12x20x1+12x20x1...
  • Page 31 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions a. Ensure proper reassembly by marking wheel orientation. If lockout occurs, unit may be reset by either momentarily interrupting b. Lift wheel from housing. When handling and/or cleaning blower power supply to unit or by turning selector switch to OFF position at the wheel, be sure not to disturb balance weights (clips) on blower thermostat.
  • Page 32 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions done by removing the screws from the front cover of the burner box and losing the screws on each side of the top cover to allow easy removal of baffle from the burner box.
  • Page 33 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions FAN GRILLE MOTOR MOTOR SHAFT A08505 MAX DISTANCE BETWEEN TOP OF FAN GRILLE AND BOTTOM OF FAN BLADE “A” Size Fig. 26 – Fan Blade Position Electrical Controls and Wiring R-410A Items Inspect and check the electrical controls and wiring annually.

  • Page 34: Troubleshooting

    PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions off, if possible, for most troubleshooting techniques. Refrigerants Exposure, even if immediately cleaned up, may cause embrittlement present additional safety hazards. (leading to cracking) to occur in one year or more. When performing any service that may risk exposure of compressor oil to the roof, take WARNING appropriate precautions to protect roofing.
  • Page 35 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Table 13 – Troubleshooting Chart SYMPTOM CAUSE REMEDY Power failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective contactor, transformer, or high-pressure, Replace component loss-of-charge or low-pressure switch Compressor and condenser fan will not start.
  • Page 36 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Table 14 – Troubleshooting Guide–Heating SYMPTOM CAUSE REMEDY Water in gas line Drain. Install drip leg. No power to furnace Check power supply fuses, wiring or circuit breaker. Check transformer.
  • Page 37 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions Start-Up Checklist (Remove and Store in Job Files) I. PRELIMINARY INFORMATION MODEL NO.: ____________________________________________ SERIAL NO.: ____________________________________________ DATE: __________________________________________________ TECHNICIAN: ___________________________________________ II. PRESTART-UP (Insert check mark in box as each item is completed) (¦...
  • Page 38 PGD4, PGS4, Series G, H WPG4 Series D, H Ultra Low NOx: Installation Instructions © 2021 Carrier. All rights reserved. Edition Date: 12/21 Catalog No: PGD4-S4-WPG4-ULN-03SI A Carrier Company Replaces: 46201200501 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

This manual is also suitable for:

H wpg4 seriesPgd4Pgs4H ultra low no series