Carrier COMFORTLINK 48P2 User's Manual
Contents
1. Fig 1 Heat Section Details LIMIT SWITCH NO 1 FLUE OUTLET SECTION 2 et GAS VALVE FLUE FLUE OUTLET OUTLET SECTION 3 SECTION 1 GAS VALVE GAS VALVE LIMIT SWITCH NO 2 NOTE High heat consists of sections 1 3 Low heat consists of sections 1 and 2 only 055 100 SIZES HIGH HEAT Fig 1 Heat Section Details cont 10 Using the scrolling marquee enable the unit to run using the following procedure a Push the ESCAPE key unit a blank display screen is shown b Push the w key until the SERVICE TEST LED is lit c Push the ENTER key The display will show STOP d Push the ENTER key again The NO YES display will flash e Push the A or key to toggle the display to NO and then push ENTER The unit will return to normal operation and exit SERVICE TEST mode 11 To test the operation of the gas section use the scrolling marquee Service Test routine to energize the gas outputs and to tum on the gas Refer to the unit Controls Start Up Operation Service and Troubleshooting literature for more information 12 For normal operation make sure that units with a conven tional thermostat are set to heating control temperature On VAV variable air volume and constant volume units with a space temperature sensor make sure that the set points are at the normal heat set points WARNING If the main burners fail to light or the blower fails2. All units have filter tracks into which the filters slide Remove the filters by pulling outward from the track See Fig 4 for filter access door location Note the direction of flow arrows on the filter frame If you have difficulty in locating your air filter in the return air duct system or if you have questions concerning proper filter maintenance contact your dealer for instructions Table 1 Indoor Air Filter Data UNIT SIZE 48P2 P3 FILTER TYPE QUANT roles P4 P5 in Disposable Fiberglass Standard or Medium Effi 8 20 x 2 XS ciency 30 Pleated Optional 77 030 050 90 Bag Optional with High 6 20 x 24 x 22 Velocity Pre Filters 20 x 20 x 22 16 x 20 x2 20 X 24x 2 Disposable Fiberglass Standard or Medium Effi 45 55 x 52 X ciency 30 Pleated Optional 055 070 90 Bag Optional with High 6 24 x 24 x 22 Velocity Pre Filters 6 24 x 20 x 22 6 24 x 24 x 2 6 20 x 24 x 2 Disposable Fiberglass Standard or Medium Effi 1155025005 075 ciency 30 Pleated Optional i High Efficiency 65 Pleated 12 20 x 25 x 2 Optional 12 20 x 20 x 2 Disposable Fiberglass 12 20x25x2 Standard or Medium Effi o 090 100 ciency 30 Pleated Optional 12 202 20 e High Efficiency 65 Pleated 12 20 x 25x 2 Optional 12 20 x 20 x 2 See base unit Installation Instructions if field supplied or optional factory supplied filters are used When replacing filte
3. All maintenance should be handled by skilled experienced personnel Your dealer can help you establish a standard procedure For your safety keep the gas heating area clear and free of combustible materials gasoline and other flammable liquids and vapors To ensure proper functioning of the unit flow of combus tion and ventilating air must not be obstructed from reaching the gas heating area Clearance of at least 4 ft on all sides is required ROUTINE MAINTENANCE AND CARE FOR THE EQUIPMENT OWNER Before proceeding with those things you might want to maintain yourself please carefully consider the following WARNING TURN OFF GAS SUPPLY AND THEN ELECTRI CAL POWER TO YOUR UNIT BEFORE SERVIC ING OR PERFORMING MAINTENANCE Do not turn off electrical power to this unit without first turning off the gas supply When removing access panels or performing mainte nance functions inside your unit be aware of sharp sheet metal parts and screws Although special care has been taken to reduce sharp edges inside the unit be extremely careful when handling parts or reaching into the unit Failure to follow these procedures can result in serious fire or personal injury Air Filters Air filters should be checked at least every 3 or 4 weeks and changed or cleaned whenever they become dirty Table 1 indicates the correct filter size for your unit Open the hinged filter access door to replace or inspect the filters
4. call the fire department the control box at the compressor end of the unit Installation and service must be per a Push the ESCAPE key unit a blank display screen formed by a qualified installer service is shown agency Orne gas SUPPLEN b Push the fy key until the SERVICE TEST LED is lit c Push the ENTER key The display will show If you do not follow these instructions exactly a fire or explosion may result causing property damage injury or loss of life WARNING STOP Improper installation adjustment alteration ser d kar ENTER key again The NO YES display vice or maintenance can cause injury or property ee damage Refer to this manual For assistance or e Push the LA Or D key to toggle the display to additional information consult a qualified installer YES and then push ENTER The unit will be service agency or the gas supplier locked off from heating cooling or any operation The controls will still function and the display will still operate WARNING 2 Close the field installed manual gas shutoff valve Before performing recommended maintenance be sure 3 Turn off the electrical power to the unit using the optional main power switch to unit is turned off and lockout tag is disconnect or the field installed disconnect and lock off installed Electrical shock could cause personal injury using proper lockout and tag out procedures 4 Open the burner section hinged access door Your combina
5. 48P2 P3 P4 P5030 100 Gas Heating Electric Cooling Units with COMFORTLINK Controls User s Information Manual NOTE TO INSTALLER TO LIGHT UNIT This manual should be left with the equipment owner A DANGER Do not turn off the electrical power to unit without first turning off the gas supply Before attempting to start the gas heating section familiarize yourself with all the procedures that must be followed Never attempt to manually light the burners on the unit with a match lighter or any other flame If the electric sparking device fails to light the burners refer to the shutdown procedures then call your dealer as soon as possible WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier See Fig 1 for location of gas valve s Refer to Fig 2 while from a neighbor s phone Follow the proceeding with the following steps gas supplier s instructions 1 Turn off the unit demand for cooling or heating by using e If you cannot reach your gas sup the scrolling marquee The scrolling marquee is located in plier
6. Belts Periodically check the condition of fan wheels and housings and belt tension When service is neces sary call your dealer Evaporator Fan Motor Condenser Fan Motor and Combustion Fan Motor Lubrication is not recommended Bearings will not require lubrication for at least 5 years of normal operation After 5 years motor life can be extended by having the motors serviced at an authorized motor service shop Fan Shaft Bearings Charge fittings annually with Shell Alvania No 2 or equivalent grease Evaporator and Condenser Coils Cleaning of the coils should only be done by qualified service personnel Contact your dealer for the required maintenance as needed Condensate Drain The drain pan and condensate drain line should be checked and cleaned at the same time the cooling coils are checked by your dealer Compressors All compressors are factory shipped with a normal charge of the correct type refrigeration grade oil in them and should rarely require additional oil The service technician must be certain the proper oil level is maintained in the compressor when it is installed and running Condenser Fan WARNING Do not poke sticks screwdrivers or any other object into revolving fan blades Severe bodily injury may result The fan must be kept free of all obstructions to ensure prop er cooling Contact your dealer for any required service Electrical Controls and Wiring Electrical contro
7. ed correctly so that a proper seal is maintained Contact your dealer for the required period ic maintenance LOCK OUT TAG STEP 3 STEP 5 MAIN OFF STEP 7 Fig 3 To Shut Unit Off POWER EXHAUST ACCESS DOOR ACCESS GAS SECTION CONTROL TYP BOTH SIDES DOORS ACCESS DOOR BOX POWER FILTER AIR GAS EXHAUST ACCESS HOODS BURNERS OPTION DOOR 48P2 P3 P4 P5030 035 SIZE 030 SHOWN ACCESS E DOORS GAS SECTION ile TYP BOTH SIDES ACCESS DOOR POWER FILTER EXHAUST Sea Sd OPTION 48P2 P3 P4 P5040 070 SIZE 060 SHOWN ACCESS ACCESS DOOR Rs GAS SECTION CONTROL TYP BOTH SIDES ACCESS DOOR BOX a EDS E EE ESA ES ZOA EURO Se SR NOT el D a Na PAS LY LY LY gt P Se Vs dr O AE ey Wi Y o e Fi Km la a a IN B AR pe 0 Ss EN TO Td NA fo e ac pd E Se PAW Ate Sy 0 O yy E x Ol POWER FILTER AIR GAS EX ACCESS SREE DOOR HOODS BURNERS 48P2 P3 P4 P5075 100 Fig 4 Door Locations Fan and
8. ig 4 and 5 for location of access panel and proper flame appearance 5 Inspection and if required cleaning of the condenser and evaporator coils 6 Inspection and if required cleaning of the evaporator drain pan 7 Inspection cleaning and lubrication of blower wheel housing and motor 8 Inspection of all supply air and return air ducts for leaks obstructions and insulation integrity Any problems found should be resolved at this time 9 Inspection of the unit base to ensure that no cracks gaps etc exist which may cause a hazardous condition 10 Inspection of the unit casing for signs of deterioration 11 Inspection of all electrical wiring and components to assure proper connection 12 Inspection for leaks in the refrigerant circuit Pressure check to determine appropriate refrigerant charge 13 Operational check of the unit to determine working con ditions Repair or adjustment should be made at this time 14 Your servicing dealer may offer an economical service contract that covers seasonal inspections Ask for further details Complete Service Instructions can be found in the base unit Controls Start Up Operation Service and Troubleshooting literature Copyright 2009 Carrier Corporation BEFORE YOU CALL FOR SERVICE CHECK FOR SEVERAL EASILY SOLVED PROBLEMS If insufficient heat or cooling is suspected Check for sufficient airflow Check the air filters for dirt Check for blocked return ai
9. ll show STOP d Push the ENTER key again The NO YES display will flash e Push the LA or D key to toggle the display to YES and then push ENTER The unit will be locked off from heating cooling or any operation The controls will still function and the display will still operate 2 Close the field installed manual gas shutoff valve 3 Turn off the electrical power to the unit using the optional disconnect or the field installed disconnect and lock off using proper lockout and tag out procedures 4 Open the burner section hinged access door 5 Move the switch on the gas valves to the OFF position and wait 5 minutes before doing any service in the section or on the piping 6 Close the burner section hinged access door 7 Ifunit is being shut down because of a malfunction call your dealer as soon as possible If unit is being shut down because the heating season has ended restore electrical power to the unit and reset the scrolling marquee to Run mode to ensure operation of the cooling system during the cooling season IMPORTANT Should overheating occur or the gas supply fail to shut off shut off the manual gas valve to the unit before shutting off the electrical supply Do not use this unit if any part has been under water Imme diately call a qualified service technician to inspect the unit and to replace any part of the control system and gas control that has been under water MAINTAINING YOUR UNIT
10. ls are difficult to check without proper instrumentation therefore if there are any discrepancies in the operating cycle contact your dealer and request service Refrigerant Circuit The refrigerant circuit is difficult to check for leaks without the proper equipment therefore if inadequate cooling is suspected contact your dealer for service Combustion Area and Vent System The com bustion area and vent system should be visually inspected be fore each heating season The normal accumulation of dirt soot rust and scale can result in loss of efficiency and improp er performance if allowed to build up Accumulation on the burner crossover tube can result in the burners firing out of normal time sequence This delayed ignition is characterized by an especially loud sound CAUTION If your unit makes any unusual or especially loud noises during heating shut down the heating section and call your dealer See Fig 1 and 4 and proceed as follows to inspect the com bustion area and power venting system of your unit 1 Turn off gas supply and then electrical power to your unit 2 Open gas section access door 3 Using a flashlight carefully inspect the burner areas for dirt soot rust or scale CAUTION If dirt soot rust or scale accumulations are found call your dealer and do not operate your heating section 4 When you have completed your inspection follow the start up procedures in this ma
11. nual to restore your unit to operation 5 Observe unit heating operation and watch the burner flame core to see if it is bright blue If you observe a sus pected malfunction or if the burner flame cores are not bright blue call your dealer See Fig 5 NOTE Burner flame cores that have a mixture of orange yellow or red flames together with the blue may not be burning gas efficiently Your dealer may have to adjust the air gas mixture 6 Replace gas section access panel Unit Panels and Doors After performing any main tenance or service on the unit be sure all panels and doors are securely fastened in place to prevent rain from entering unit cabinet and to prevent disruption of the correct unit airflow pattern BURNER FLAME TIP FLAME CORE Fig 5 Proper Flame Appearance REGULAR DEALER MAINTENANCE In addition to the type of routine maintenance you might be willing to perform your unit should be inspected regularly by a properly trained service technician An inspection preferably each year but at least every other year should include the following 1 Inspection of all flue product passages including the burners heat exchanger flue collector box and vent pipe 2 Inspection of all combustion air and ventilation air pas sages and openings 3 Close inspection of all gas pipes leading to and inside your unit 4 Adjustment of the air gas mixture if the burner flames are not bright blue See F
12. r or supply air grilles Be sure they are open and unobstructed Be sure heating and cooling set points are correct If these checks do not reveal the cause call your servicing dealer If your unit is not operating at all check the following list for easy solutions Check to be sure that heating temperature set point is set above the indoor temperature during the heating season or that cooling temperature set point is below the indoor temperature during the cooling season Be sure the unit on off switch is in the ON position and not in the OFF position Be sure unit has been programmed with the appropriate time schedules and desired operating set points Is the electrical supply switch ON Are any fuses blown or have any of the circuit breakers tripped During the heating season check the manual shutoff valve Is this lever parallel with the pipe indicating that the valve is open Or is the lever at a right angle indicating that the valve is closed If closed has the gas been shut off for safety reasons Otherwise you may open the valve and follow the start up procedures listed in this manual NOTE Before proceeding with the next check turn OFF the electrical power supply to the unit Open the control access door During the heating season check the control switch on the gas valve It is in the ON position If it is not be sure it has not been turned off for the purpose of safety Follow the start up procedu
13. res in this manual If your unit still fails to operate call your servicing dealer for troubleshooting and repairs Specify the model and serial numbers of your unit Record them in this manual in the space provided If the dealer knows exactly which unit you have he may be able to offer suggestions over the phone or save valu able time through knowledgeable preparation for the service call IN CASE OF TROUBLE If after performing the above unit performance is unsatis factory shut off the unit and call your dealer Dealer s Name Telephone No Unit Model Unit Serial Number Unit Address Bus Number Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53480054 01 Printed in U S A Form 48P 1SO Pg 8 4 09 Replaces New
14. rs always use the same type and size originally supplied When replacing your unit filters always use the same size and type of filter that was originally supplied by the installer Units with outdoor air capability have a cleanable filter for the outdoor air This filter should be checked annually and cleaned as necessary Remove by removing screws in outdoor air filter retainer and sliding filters out of the unit WARNING Never operate your unit without filters in place Failure to heed this warning may result in damage to the blower motor and or compressor An accumulation of dust and lint on internal parts of your unit can cause loss of efficiency and in some cases fire O Run Status Service Test O Temperature O Pressures O Setpoints Onn O Outputs SS O Operating Modes Alarms STEP 1 HINGES ne STEP 6 2 2 a a I Heat Exchanger To ensure dependable and efficient heating operation the heat exchanger should be checked by a qualified maintenance person before each heating season and cleaned when necessary This checkout should not be attempt ed by anyone not having the required expertise and equipment to do the job properly Checking and or cleaning the heat exchanger involves removing the gas controls assembly and the flue collector box cover and when completed reinstalling the gas controls assembly for proper operation Also the flue collector box cover must be replac
15. tion heating cooling rooftop unit is equipped 5 Move the switch on the gas valves to the OFF position with an automatic direct spark ignition system and induced and wait 5 minutes draft power combustion blower NOTE If this is the first installation of the unit the gas flue hoods must be installed before operating unit These A WARNING must be installed for the unit to run properly 6 Move the switch on the gas valves to the ON position Burners will light automatically Do not attempt to light by 7 Close the burner section hinged access door hand personal injury may result 8 Turn on the electrical supply to the units 9 Open the field installed manual gas valve Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53480054 01 Printed in U S A Form 48P 1SO Pg 1 4 09 Replaces New LIMIT SWITCH NO 2 FLUE OUTLET SECTION 2 GAS VALVE FLUE OUTLET SECTION 1 GAS VALVE NOTE High heat consists of sections 1 and 2 Low heat consists of section 1 only 030 050 SIZES LIMIT SWITCH NO 1 FLUE FLUE OUTLET OUTLET SECTION 2 SECTION 1 GAS VALVE J GAS VALVE LIMIT SWITCH NO 2 or NOTE High heat consists of sections 1 3 Low heat consists of sections 1 and 2 only 055 100 SIZES LOW HEAT
16. to start shut down gas heating section and call your dealer for ser vice Failure to follow these requirements could result in serious personal injury O Run Status O Service Test Temperature Pressures O Operating Modes Alarms STEP 1 LOCK OUT TAG STEP 3 HINGES HINGES a STEP 6 STEP 7 MAIN O Run Status Service Test O Temperature Pressures O onte Simons O Operating Modes Alarms OFF STEP 8 STEP 9 STEP 10 Fig 2 To Light Unit 3 TO SHUT UNIT OFF WARNING 1 Do not turn off the electrical power to unit without first turning off the gas supply 2 Never attempt to manually light the main burners on unit with a match lighter or any other flame If the electric sparking device fails to light the main burners refer to the following shutdown procedures Call your dealer as soon as possible Failure to follow these procedures can result in serious fire or personal injury See Fig 1 for location of gas valve s Refer to Fig 3 while proceeding with the following steps 1 Turn off the unit demand for cooling or heating by using the scrolling marquee The scrolling marquee is located in the control box at the compressor end of the unit a Push the ESCAPE key unit a blank display screen is shown b Push the rw key until the SERVICE TEST LED is lit c Push the ENTER key The display wi
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