Carrier K Series Installation Instructions Manual

PGR5 Series K: Installation Instructions
PGR5 Series K
15.2+ SEER2 2-Stage Packaged Air Conditioner and Gas Furnace System
with R-410A Refrigerant
Single and Three Phase
2-5 Nominal Tons (Sizes 24-60)
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

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Receiving and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Identify Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspect Shipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Slab Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rigging/Lifting of Unit (See
Configuring Units for Downflow (Vertical) Discharge . . . . . . 11
High-Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Special Procedures for 208-v Operation . . . . . . . . . . . . . . . . . . 13
Control Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Standard Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Heat Anticipator Setting (Electro-Mechanical Thermostats only)14
Transformer Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pre-Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Check Heating Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Check Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjust Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Check Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Airflow and Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . . . 25
Heating Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . 25
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Rollout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Checking Cooling Control Operation . . . . . . . . . . . . . . . . . . . . 25
Checking and Adjusting Refrigerant Charge . . . . . . . . . . . . . . 26
Indoor Airflow and Airflow Adjustments . . . . . . . . . . . . . . . . 26
Cooling Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . 27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Indoor Blower and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Induced Draft (combustion air) Blower Assembly. . . . . . . . . . 54
Flue Gas Passageways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Burner Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Main Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Outdoor Coil, Indoor Coil, and Condensate Drain Pan . . . . . . 55
Outdoor Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Electrical Controls and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 56
Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
Installation Instructions
Fig. 6) . . . . . . . . . . . . . . . . . . . . . . 4
Gas Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Evaporator Airflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
R-410A Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Metering Device (Thermostatic Expansion Valve ) . . . . . . . . . 57
Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Loss of Charge Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
High-Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Copeland Scroll Compressor R-410A Refrigerant). . . . . . . . . 57
Refrigerant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Start-up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fig. 1 - Unit PGR5(Low NOx Model Available)

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
you see this symbol on the unit and in instructions or manuals, be alert to
the potential for personal injury. Understand these signal words:
1
A09033
. When