Carrier Performance 48VGUK Installation Instructions Manual
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Carrier Performance 48VGUK Installation Instructions Manual

15.2+ seer2 ultra low nox 2-stage packaged air conditioner and single stage gas furnace system with puron r-410a refrigerant single and three phase 2-5 nominal tons sizes 24-60
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48VGUK
Performance™ 15.2+ SEER2 Ultra Low NOx 2-Stage
Packaged Air Conditioner and Single Stage Gas
Furnace System with Puron® (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
High-Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Special Procedures for 208-v Operation . . . . . . . . . . . . . . . . . . 13
Control Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Standard Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transformer Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pre-Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Check Heating Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Check Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjust Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Airflow and Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . . . 22
Phase Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Burner Thermal Switch (Ultra Low NOx) . . . . . . . . . . . . . . . . 22
Checking Cooling Control Operation . . . . . . . . . . . . . . . . . . . . 22
Checking and Adjusting Refrigerant Charge . . . . . . . . . . . . . . 23
Indoor Airflow and Airflow Adjustments . . . . . . . . . . . . . . . . 23
Cooling Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . 24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Indoor Blower and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Flue Gas Passageways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Burner Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
38
Installation Instructions
6) . . . . . . . . . . . . . . . . . . . . . . 4
Outdoor Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electrical Controls and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 39
Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Gas Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Evaporator Airflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Puron (R-410A) Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Loss of Charge Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
High-Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Refrigerant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Start-up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fig. 1 - Unit 48VG Ultra Low NOx
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.
21.)

Safety Considerations

A09033

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Summary of Contents for Carrier Performance 48VGUK

  • Page 1: Table Of Contents

    48VGUK Performance™ 15.2+ SEER2 Ultra Low NOx 2-Stage Packaged Air Conditioner and Single Stage Gas Furnace System with Puron® (R-410A) Refrigerant Single and Three Phase 2-5 Nominal Tons (Sizes 24-60) Installation Instructions IMPORTANT: Effective January 1, 2015, all split system and packaged Outdoor Coil, Indoor Coil, and Condensate Drain Pan .

  • Page 2: Introduction

    48VGUK: Installation Instructions In Canada refer to the current editions of the National Standards of CAUTION Canada CAN/CSA-B149.1 and .2 Natural Gas and Propane Installation codes, and Canadian Electrical Code CSA C22.1 FIRE, EXPLOSION, ELECTRICAL SHOCK AND Recognize safety information. This is the safety-alert symbol .

  • Page 3: Receiving And Installation

    48VGUK: Installation Instructions Receiving and Installation Step 1 – Check Equipment OPTIONAL OPTIONAL Identify Unit RETURN SUPPLY The unit model number and serial number are stamped on the unit OPENING OPENING information plate. Check this information against shipping papers. Inspect Shipment Inspect for shipping damage before removing packaging materials.

  • Page 4: Inspection

    48VGUK: Installation Instructions available, use a spreader bar of sufficient length to protect the unit WARNING from damage. 2. Attach shackles, clevis pins, and straps to the base rails of the unit. PERSONAL INJURY OR PROPERTY DAMAGE Be sure materials are rated to hold the weight of the unit (See HAZARD Fig.
  • Page 5 48VGUK: Installation Instructions A230027 Fig. 3 – 24-30 Unit Dimensions Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 6 48VGUK: Installation Instructions A230028 Fig. 4 – 36-60 Unit Dimensions Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 7 48VGUK: Installation Instructions SMALL/COMMON CURB SMALL SUPPLY BASE UNIT LARGE BASE RETURN UNIT UNIT PLACEMENT ON COMMON CURB SMALL OR LARGE BASE UNIT LARGE CURB A180216 B (small / common UNIT CATALOG B (large base) base) SIZE NUMBER IN. (mm)* IN.
  • Page 8 48VGUK: 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. / Utiliser la palette du haut comme barre de répartition DUCTS MINIMUM HEIGHT: 36"...
  • Page 9 48VGUK: Installation Instructions Table 1 – Physical Data UNIT SIZE 24040 24060 36060 48090 60090 NOMINAL CAPACITY (ton) SHIPPING WEIGHT lb. SHIPPING WEIGHT (kg) COMPRESSORS Scroll l Quantity REFRIGERANT (R-410A) Quantity lb. 7.05 7.05 10.8 12.1 Quantity (kg) REFRIGERANT METERING DEVICE OUTDOOR COIL Rows...Fins/in.
  • Page 10 48VGUK: Installation Instructions Step 6 – Connect Condensate Drain Step 8 – Install Gas Piping NOTE: When installing condensate drain connection be sure to comply The gas supply pipe enters the unit through the access hole provided. with local codes and restrictions. The gas connection to the unit is made to the 1/2-in.

  • Page 11: Configuring Units For Downflow (Vertical) Discharge

    48VGUK: 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) (46) (53) (61) .622 — — .824 1.049 1-1/4 1.380 1400...
  • Page 12 48VGUK: Installation Instructions CAUTION PROPERTY DAMAGE HAZARD Basepan Failure to follow this caution may result in property damage. Downflow (Vertical) Basepan Collect ALL screws that were removed. Do not leave screws on rooftop Supply Downflow as permanent damage to the roof may occur. Knockout (Vertical) Return...

  • Page 13: High-Voltage Connections

    48VGUK: Installation Instructions 2. Connect ground lead to chassis ground connection. CAUTION 3. Locate the black and yellow wires connected to the line side of the contactor (if equipped). UNIT COMPONENT DAMAGE HAZARD 4. Connect field L1 to black wire from connection 11 of the Failure to follow this caution may result in damage to the unit being compressor contactor.

  • Page 14: Heat Anticipator Setting (Electro-Mechanical Thermostats Only)14

    48VGUK: Installation Instructions Pre-Start-up HIGH VOLTAGE POWER LEADS (SEE UNIT WIRING WARNING LABEL) POWER 3-PHASE SHOWN SUPPLY 1-PHASE USES ENVIRONMENTAL, FIRE, EXPLOSION, ELECTRICAL TWO POWER LEADS SHOCK HAZARD EQUIP GR FIELD-SUPPLIED Failure to follow this warning could result in personal injury or death. FUSED DISCONNECT Follow recognized safety practices and wear protective goggles CONTROL BOX...

  • Page 15: Start-Up

    48VGUK: Installation Instructions 4. Verify the following conditions: Follow the lighting instructions on the heating section operation label a. Make sure gas line is free of air. Before lighting the unit for the (located on the inside of the control access panel) to start the heating first time, perform the following with the gas valve in the OFF section.

  • Page 16: Check Gas Input

    48VGUK: Installation Instructions 5. The evaporator fan will turn on 30 sec. after the flame has been established. The evaporator fan will turn off 90 sec. after the thermostat has been satisfied. Please note that the integrated gas unit controller (IGC) has the capability to automatically reduce the evaporator “ON”...
  • Page 17 48VGUK: Installation Instructions Table 4 – High Altitude Compensation, Natural Gas - Single and Three Phase Models Rated Heating Input (Btu/hr), Natural Gas at Installation Altitude Above Sea Level, U.S.A. Nameplate Input (Btu/hr) 0 to 2000 ft (0-610 m) 45,000 45,000 60,000 60,000...
  • Page 18 48VGUK: Installation Instructions A230036 Fig. 15 – 208/230-1-60 Connection Wiring Diagram Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 19 48VGUK: Installation Instructions A230037 Fig. 16 – 208/230-1-60 Ladder Wiring Diagram Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 20 48VGUK: Installation Instructions A230038 Fig. 17 – 208/230-3-60 Connection Wiring Diagram Gas Inputs 40, 60, 90 KBtu/hr Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 21 48VGUK: Installation Instructions A230039 Fig. 18 – 208/230-3-60 Ladder Wiring Diagram Gas Inputs 40, 60, 90 KBtu/hr Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

  • Page 22: Normal Operation

    48VGUK: Installation Instructions Normal Operation Table 7 – 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 removing the control access panel (see Fig.

  • Page 23: Checking And Adjusting Refrigerant Charge

    48VGUK: Installation Instructions Indoor Airflow and Airflow Adjustments IMPORTANT: Three-phase, scroll compressors are direction oriented. Unit must be checked to ensure proper compressor 3-phase power lead CAUTION orientation. If not corrected within 5 minutes, the internal protector will shut off the compressor. The 3-phase power leads to the unit must be reversed to correct rotation.

  • Page 24: Cooling Sequence Of Operation

    48VGUK: Installation Instructions Table 11 to find lower speed/airflows available at that total static 2-Pin Terminal pressure. All airflows not shaded in Table 11 are acceptable for Dehum speed. The speed chosen must provide airflow of between 320 CFM per ton of cooling and rated airflow.
  • Page 25 48VGUK: Installation Instructions Table 8 – Subcooling Charging Chart A230122 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 26 Table 9 – Dry Coil Air Delivery** - Horizontal and Downflow Discharge Sizes 24-60 208/230 VAC - 1,3 Phase Heating Rise Motor ESP (in. W.C.) Unit Size Allowable Functions Motor Speed Selection Speed SW2-5 SW2-6 Continuous Fan* SW1-7 SW1-8 Dehumidification Low SW1-3 SW1-4 Low Stage Cooling...
  • Page 27 Table 9 – Dry Coil Air Delivery** - Horizontal and Downflow Discharge Sizes 24-60 208/230 VAC - 1,3 Phase (Continued) Heating Rise Motor ESP (in. W.C.) Unit Size Allowable Functions Motor Speed Selection Speed SW1-5 SW1-6 Dehumidification High SW1-1 SW1-2 High Stage Cooling 0.15 0.15...
  • Page 28 Table 9 – Dry Coil Air Delivery** - Horizontal and Downflow Discharge Sizes 24-60 208/230 VAC - 1,3 Phase (Continued) Heating Rise Motor ESP (in. W.C.) Unit Size Allowable Functions Motor Speed Selection Speed SW2-5 SW2-6 Continuous Fan* SW1-7 SW1-8 Dehumidification Low SW1-3 SW1-4...
  • Page 29 Table 9 – Dry Coil Air Delivery** - Horizontal and Downflow Discharge Sizes 24-60 208/230 VAC - 1,3 Phase (Continued) Heating Rise Motor ESP (in. W.C.) Unit Size Allowable Functions Motor Speed Selection Speed SW1-5 SW1-6 Dehumidification High 1122 1064 1003 SW1-1 SW1-2...
  • Page 30 Table 9 – Dry Coil Air Delivery** - Horizontal and Downflow Discharge Sizes 24-60 208/230 VAC - 1,3 Phase (Continued) Heating Rise Motor ESP (in. W.C.) Unit Size Allowable Functions Motor Speed Selection Speed SW2-5 SW2-6 Continuous Fan* SW1-7 SW1-8 Dehumidification Low SW1-3 SW1-4...
  • Page 31 Table 9 – Dry Coil Air Delivery** - Horizontal and Downflow Discharge Sizes 24-60 208/230 VAC - 1,3 Phase (Continued) Heating Rise Motor ESP (in. W.C.) Unit Size Allowable Functions Motor Speed Selection Speed SW1-5 SW1-6 Dehumidification High 1190 1134 1085 1025 SW1-1...
  • Page 32 Table 9 – Dry Coil Air Delivery** - Horizontal and Downflow Discharge Sizes 24-60 208/230 VAC - 1,3 Phase (Continued) Heating Rise Motor ESP (in. W.C.) Unit Size Allowable Functions Motor Speed Selection Speed SW2-5 SW2-6 Continuous Fan* SW1-7 SW1-8 Dehumidification Low SW1-3 SW1-4...
  • Page 33 Table 9 – Dry Coil Air Delivery** - Horizontal and Downflow Discharge Sizes 24-60 208/230 VAC - 1,3 Phase (Continued) Heating Rise Motor ESP (in. W.C.) Unit Size Allowable Functions Motor Speed Selection Speed SW1-5 SW1-6 Dehumidification High 1383 1339 1296 1254 1209...
  • Page 34 Table 9 – Dry Coil Air Delivery** - Horizontal and Downflow Discharge Sizes 24-60 208/230 VAC - 1,3 Phase (Continued) Heating Rise Motor ESP (in. W.C.) Unit Size Allowable Functions Motor Speed Selection Speed SW2-5 SW2-6 Continuous Fan* SW1-7 SW1-8 Dehumidification Low SW1-3 SW1-4...
  • Page 35 Table 9 – Dry Coil Air Delivery** - Horizontal and Downflow Discharge Sizes 24-60 208/230 VAC - 1,3 Phase (Continued) Heating Rise Motor ESP (in. W.C.) Unit Size Allowable Functions Motor Speed Selection Speed SW1-5 SW1-6 Dehumidification High 1383 1339 1296 1254 1209...
  • Page 36 Table 10 – Wet Coil Pressure Drop (IN. W.C.) Unit Standard CFM (SCFM) Size 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 0.02 0.03 0.04 0.04 0.05 0.06 0.03 0.04 0.05 0.05 0.06 0.07 0.08 0.08 0.09 0.10...

  • Page 37: Maintenance

    48VGUK: Installation Instructions Maintenance 6. Check and inspect heating section before each heating season. Clean and adjust when necessary. To ensure continuing high performance and to minimize the possibility 7. Check flue hood and remove any obstructions, if necessary. of premature equipment failure, periodic maintenance must be Air Filter performed on this equipment.

  • Page 38: Flue Gas Passageways

    48VGUK: Installation Instructions To inspect blower wheel: NOTE: For Ultra Low NOx The combined flame sensor/sparker is located on the right side of the burner box (See Fig. 20). The flame 1. Shut off power to the unit and close the manual shut off valve on sensor/sparker is accessible for service by removing the cover in the the gas supply line to the unit.

  • Page 39: Outdoor Coil, Indoor Coil, And Condensate Drain Pan

    48VGUK: Installation Instructions Outdoor Coil, Indoor Coil, and Condensate Drain Pan Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year. BLOWER The coils are easily cleaned when dry; therefore, inspect and clean the HOUSING coils either before or after each cooling season.

  • Page 40: Refrigerant Circuit

    48VGUK: Installation Instructions FAN GRILLE MOTOR MOTOR SHAFT A08505 MAX DISTANCE BETWEEN TOP OF FAN GRILLE AND BOTTOM OF FAN BLADE “A” Size Fig. 24 – Fan Blade Position Refrigerant Circuit pressure switches must not be used as replacements for the Puron (R-410A) system.

  • Page 41: Refrigerant System

    48VGUK: Installation Instructions Synthetic Roof Precautionary Procedure WARNING 1. Cover extended roof working area with an impermeable polyethylene (plastic) drip cloth or tarp. Cover an approximate 10 FIRE/EXPLOSION HAZARD X 10 ft. (3.1 m X 3.1 m) area. Failure to follow this warning could result in personal injury or death 2.
  • Page 42 48VGUK: 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. Insufficient line voltage Determine cause and correct Incorrect or faulty wiring...
  • Page 43 48VGUK: 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. No 24-v power supply to control circuit NOTE: Some transformers have internal over-current protection that requires a cool-down period to reset.
  • Page 44 Access My Learning Center with your HVACpartners credentials at www.mlctraining.com. Please contact us a mylearning@carrier.com with questions. © 2023 Carrier. All rights reserved. Edition Date: 02/23 Catalog No: 48VG-ULN-06SI Replaces:48VG-ULN-05SI Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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